Snowmobile Arctic Cat (2000 year). Manual - part 24

20. Install the oil-injection pump retainer taking care to

align the pinion and water pump shafts with their
respective bearings. Press the retainer onto its dowel
pin located in the top half of the crankcase. Install
the screws and tighten to 0.8 - 1.2 kg-m (6-9 ft-lb).
Tighten the screws evenly.

Fig. 2-340

AJ106

21. Place the end plate into position on the crankcase;

then apply blue Loctite #242 to the four screws and
tighten securely.

Fig. 2-341

AJ103

Make sure the slot of the oil-injection pump shaft
is aligned with the shaft in the crankcase before
installing the two oil pump mounting screws. If
not aligned, the oil pump mounting flange will
crack when the screws are tightened.

22. Apply a thin coat of silicone sealant to both sides of

the oil pump gasket. Install the gasket and
oil-injection pump. Secure with two screws and
washers. Tighten the two screws to 0.7 kg-m (5
ft-lb).

The shorter screw must be installed in the top
mounting hole of the oil pump or bearing damage
will result.

Fig. 2-342

AJ107

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

the top or inclined surface of each ring faces the
dome of the piston.

Fig. 2-343

726-306A

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

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

then install the small-end bearings and thrust
washers.

Fig. 2-344

AQ059

25. Place each piston over the connecting rod so the

arrow on each piston will point toward the exhaust
port; then secure with a piston pin.

! CAUTION

2-80

Fig. 2-345

AJ109

NOTE: The arrow is found up inside the piston.

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

either down or up.

Fig. 2-346

AJ110

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

27. Apply a thin coat of Copper Coat Gasket Sealant (p/n

0636-092) to both sides of each cylinder-base gasket
if the gaskets are being reused. If using new gaskets,
it isn’t necessary to apply copper coat. Install the
gasket with the raised portion of the gasket
positioned upward.

Fig. 2-347

AJ111

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.

Fig. 2-348

726-306B

NOTE: If the reed seats were removed, place each

seat with new gasket into position on the cylinder,
apply blue Loctite #242 to the screws, and tighten
securely.

29. Place the reed valve (with the beveled corner

positioned toward the lower right-hand corner) and
stopper into position on the seat; then apply blue
Loctite #242 to the screws and tighten securely.

Fig. 2-349

AQ087

! CAUTION

2-81

30. 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.

Fig. 2-350

AJ112

When installing the cylinders, care must be
taken not to bend or damage the reed stopper.

31. Secure each cylinder by installing the six nuts, four

washers, and lock washers. Tighten the 8 mm
cylinder base nuts to 1.8 - 2.8 kg-m (13-20 ft-lb)
and the 10 mm nuts to 4.0 - 6.0 kg-m (29-43.5 ft-lb).
Tighten all the nuts in three steps using the pattern
shown.

Fig. 2-351

0726-376

32. Place the O-rings into position on the top of each

cylinder.

Fig. 2-352

AJ118

NOTE: If reusing O-rings and they are slightly

stretched, shrink the O-rings by cooling them (in a
refrigerator for example) for a short period of time.

33. Check sealing surface to make sure the surface is

clean; then set the cylinder heads in position. Slide
an O-ring onto each of the 16 cap screws and start
all the head cap screws. DO NOT TIGHTEN AT
THIS TIME.

Fig. 2-353

AJ119

34. Apply a thin coat of High-Temp Sealant (p/n

0636-069) to the two thermostat manifold 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 -
1.0 kg-m (5-7 ft-lb).

NOTE: The thermostat manifold cap screws must

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

35. Tighten the head cap screws in three steps to 1.8 -

2.8 kg-m (13-20 ft-lb) using the pattern shown.

! CAUTION

2-82

Fig. 2-354

AJ121

Fig. 2-355

0727-158

36. Install the oil-injection hose on each cylinder

nozzle and secure with a hose clamp.

37. Test the engine for air leaks (see Section 3).

38. Place the thermostat with gasket and cap into

position. Secure with three cap screws. Tighten to
0.7 - 1.0 kg-m (5-7 ft-lb).

Fig. 2-356

AJ123

39. Apply a thin coat of silicone sealant to the

crankcase water pump housing sealing surface.

Fig. 2-357

AJ115

40. Apply a thin coat of High-Temp Sealant (p/n

0636-069) to the water pump cover seal and
position the O-ring into the cover. Carefully place
the cover over the impeller and onto the crankcase.
Secure with five cap screws. Tighten cap screws
evenly to 0.7 - 1.0 kg-m (5-7 ft-lb).

Fig. 2-358

AJ116

41. Install the trigger coil and secure to the crankcase

using two screws and mounting bracket. Route
wires out through grommet opening in the
crankcase.

42. Install the stator backing plate and secure with four

cap screws. Apply blue Loctite #242 to the threads
of each cap screw before installation.

43. Route the stator wiring harness through the backing

plate and install the rubber grommet around the
harness.

44. Place the stator plate into position and secure with

three screws coated with blue Loctite #242, lock
washers, and washers.

45. Install the key in the crankshaft and slide the

flywheel onto the crankshaft making sure the
keyways align.

2-83

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