Snowmobile Arctic Cat (2000 year). Manual - part 22

Fig. 2-304

0728-137

14. On the 500 cc/600 cc, install the crankcase cap

screws (coated with blue Loctite #242) securing the
crankcase halves. Tighten to 3-4 kg-m (22-29 ft-lb)
using the pattern shown.

Fig. 2-305

0734-050

NOTE: Secure the connecting rods with rubber

bands on the cylinder studs.

15. Install the oil-injection pump retainer O-ring and

retainer.

Fig. 2-306

AN088D

16. Install the O-ring and the oil-injection pump making

sure the pump shaft slot and pump driven gear shaft
align. Secure with two screws (coated with blue
Loctite #242) and washers. Tighten the two screws
to 0.7 kg-m (5 ft-lb).

Be sure the oil-injection pump/water pump
driveshaft is properly aligned with the slot of the
oil-injection pump. The pump will be damaged if
these two components are not aligned.

17. Position the rubber seal retainer and seal into the

back side of the water pump impeller.

18. Using both thumbs, press the seal into position

making sure its marked side is positioned towards
the rubber seal cup; then apply a thin coat of grease
to the seal outer surface.

19. Place the impeller into position and secure with a

cap screw and washer. Be sure the rubber side of the
washer is directed toward the impeller. Apply blue
Loctite #242 to the threads of the cap screw and
tighten to 0.8-1.2 kg-m (6-9 ft-lb).

The rubber side of the washer, which secures the
impeller, must be positioned toward the impeller.
If installed incorrectly, a coolant leak will result.

20. Apply

high-temperature

sealant

the

crankcase/water pump cover seam; then install the
alignment pins into the crankcase.

Fig. 2-307

AN095

NOTE: Sealant is only required on the crankcase

seam.

21. Position the O-ring into the water pump cover; then

install the cover. Secure with five screws. Tighten
to 1.1 kg-m (8 ft-lb).

22. On the 500 cc/600 cc, secure the intake manifolds,

reed block assemblies, and gaskets with cap screws.
Tighten to 1.1 kg-m (8 ft-lb).

23. Place the cylinder base gasket into position on the

crankcase.

500/600 cc

! CAUTION

2-72

24. Install the piston rings on each piston so the letter on

the top (inclined surface) of each ring faces the dome
of the piston.

Fig. 2-308

726-306A

Incorrect installation of the piston rings will
result in engine damage.

25. Apply oil to the connecting-rod small end bearings;

then install the small-end bearings. Install a washer
on each side of the connecting rod.

Fig. 2-309

AN100

Fig. 2-310

AQ059

26. Place each piston over the connecting rod so the

arrow (or indicator dot) on each piston will point
toward the exhaust port; then secure with an oiled
piston pin.

NOTE: The arrow (or indicator dot) is found either

up inside the piston or on the dome top.

Fig. 2-311

AN101

27. Install the new circlips so the open end is directed

either up or down.

Fig. 2-312

B324D

Make sure the circlips are firmly seated and the
open end is directed either up or down before
continuing with assembly.

28. Rotate each piston ring until the ring ends are

properly positioned on either side of the ring keeper;
then apply oil to the piston assemblies and cylinder
bores. Remove the rubber bands from the connecting
rods.

29. In turn on each cylinder, place a piston holder (or

suitable substitute) beneath the piston skirt and
square the piston in respect to the crankcase; then
using a ring compressor or the fingers, compress the
rings and slide the cylinder over the piston. Remove
the piston holder and seat the cylinder firmly onto
the crankcase.

NOTE: The cylinders should slide on easily. DO

NOT force the cylinders on.

! CAUTION

2-73

Fig. 2-313

AN105D

30. Secure each cylinder by installing the four nuts,

washers, and lock washers. DO NOT TIGHTEN AT
THIS TIME.

NOTE: The cylinders will be tightened at the same

time as the exhaust manifold is installed to assure
proper cylinder to exhaust manifold alignment.

31. Install the oil-injection hoses and secure with the

clamps; then place the lower check-valve assembly
into position and secure with the gaskets and union
cap screw. Tighten securely.

32. Install the two cylinder O-rings on the top of each

cylinder making sure they are correctly positioned
in the grooves.

Fig. 2-314

AN110D

33. Place new O-rings onto each of the head cap screws.

Place four of these cap screws into one of the heads
(on the 580 cc) or into the cylinder head (on the 500
cc/600 cc). Thread the spark plugs in part way; then
while holding the head above the cylinder, carefully
start all four cap screws while observing the cylinder
O-rings to make sure they remain in position. Slowly
place the head into position on top of the O-rings.
Start the remaining cap screws being very careful
not

move

the

cylinder

head.

ONLY

FINGER-TIGHTEN AT THIS TIME.

NOTE: On the 580 cc, repeat the same procedure

on the remaining head.

34. On the 580 cc, apply a thin coat of sealant to the two

thermostat housing gaskets. Place the gaskets and
housing into position and secure with four cap
screws and washers. Tighten the four cap screws in
a crisscross pattern to 0.7-1 kg-m (5-7 ft-lb).

NOTE: The thermostat housing cap screws must

be tightened before tightening the cap screws
securing the head. This will allow the gasket
surfaces of the head to align with the housing and
prevent any coolant leakage.

Fig. 2-315

AN146

35. Tighten the cap screws securing the head in three

steps to 1.8-2.8 kg-m (13-20 ft-lb) using the
appropriate pattern shown.

Fig. 2-316

0728-138

Fig. 2-317

0733-524

500/600 cc

2-74

36. Place the thermostat, gasket, and cap into position.

Secure the cap with three cap screws tightened to
0.7-1 kg-m (5-7 ft-lb).

37. Apply a thin coat of high-temperature silicone

sealant to each exhaust port; then install the exhaust
gaskets with the metal sides facing out.

38. Install the exhaust manifold and secure with four

nuts and lock washers. Tighten the four nuts to
1.8-2.2 kg-m (13-16 ft-lb).

39. Tighten the spark plugs to 2.5 kg-m (18 ft-lb); then

secure the cylinders by tightening the cylinder base
nuts to 3-4 kg-m (22-29 ft-lb) in three steps using the
pattern shown. Pressure test the engine (see Section
3).

Fig. 2-318

725-318B

40. On the 500 cc/600 cc, secure the ignition timing

sensor with screws coated with blue Loctite #242.

41. Place the PTO-end plate into position on the

crankcase; then apply blue Loctite #242 to the four
screws and tighten to 1.1 kg-m (8 ft-lb).

NOTE: On the 580 cc, position the stator base over

the crankshaft end; then route the wires through the
magneto housing and install the grommet.

42. On the 580 cc, secure the stator plate to the engine

using the Allen-head cap screws coated with blue
Loctite #242. Tighten to 1.1 kg-m (8 ft-lb).

43. On the 500 cc/600 cc, secure the stator to the stator

plate with the Allen-head cap screws coated with
blue Loctite #242; then install the stator wires with
a grommet into the crankcase.

Fig. 2-319

AN413D

44. On the 500 cc/600 cc, secure the magneto case to the

crankcase using the Allen-head cap screws coated
with blue Loctite #242. Tighten to 2.5 kg-m (18
ft-lb).

45. Install the key in the crankshaft and slide the

flywheel onto the crankshaft making sure the
keyways match.

NOTE: Before installing the flywheel, be sure to

wipe the crankshaft and flywheel tapers clean using
a clean towel.

46. Apply red Loctite #271 to the threads of the flywheel

nut; then finger-tighten with a large flat washer, lock
washer, and the nut. DO NOT TIGHTEN AT THIS
TIME.

Fig. 2-320

AN120D

47. Place the starter pulley in position; then loosely

secure the starter pulley with three cap screws
(coated with red Loctite #271) and lock washers.
Secure the pulley while using the spanner wrench
and tighten the three cap screws evenly to 0.7-1
kg-m (5-7 ft-lb).

2-75

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