Snowmobile Arctic Cat (2002 year). Manual - part 8

2-15

2

GM207D

15. Remove the lock nuts and pivots securing the

rocker arms to the cylinder head.

GM208D

16. Remove the push rods.

GM209D

17. Remove the cap screws securing the head to the

cylinder; then remove the head and account for a

gasket. Note the location of the dowel pins.

GM210D

GM211D

18. Remove the cap screws securing the crankcase

side cover to the crankcase. Account for dowel

pins and a gasket.

GM212D

GM213D

2-16

19. Remove the washer from camshaft and note the

location of the timing marks on the crankshaft and

camshaft gears.

GM214D

GM215D

20. Remove the camshaft; then remove the tappets.

GM216D

GM217D

21. Rotate the crankshaft until the piston is at the top

of the stroke; then using a chisel, loosen the

connecting rod nut locking tabs.

GM119D

22. Note the direction of the arrow on the connecting

rod and mark the connecting rod and end cap for

reference during installation.

GM121D

GM120D

23. Remove the connecting rod end cap and account

for the splasher plate and lock tab.

2-17

2

GM123D

24. Using two flat blade screwdrivers between the

connecting rod studs and the crankshaft web, push

upward on the piston.

GM122D

25. Remove the crankshaft.

GM124D

26. Remove the cap screws securing the oil level

sensor plate to the crankcase; then remove the

plate.

GM126D

Disassembling Engine

(370/440 cc Models)

1. Remove the four nuts and lock washers securing

the exhaust manifold; then remove the exhaust

manifold. Account for two gaskets.

2. Noting the location of the longer cap screws for

assembly purposes, remove the 14 cap screws,

lock washers, and washers securing the top and

exhaust-side cooling shrouds.

3. Lift the top cooling shroud off the engine and slide

the exhaust-side cooling shroud off the exhaust-

manifold studs. Account for two exhaust-manifold

shroud gaskets.

AB014

4. Disconnect the two oil-injection hoses from their

fittings on the intake manifold (single carburetor)

or on the adapter plates (twin carburetor).

5. A. On the 370 cc, remove the nuts securing the

intake manifold; then remove the manifold with

flange from the engine. Account for two

insulators. Discard the gaskets.

B. On the 440 cc, remove the nuts, lock washers,

and washers securing the intake flanges; then

remove the flanges from the engine. Remove

the screws securing the adapter plates; then

remove the adapter plates. Discard the gaskets.

2-18

6. Remove the intake-manifold cooling shroud from

the engine. Discard the two gaskets.

7. Using Flywheel Spanner Wrench (p/n 0144-007)

to secure the crankshaft, remove the three cap

screws and lock washers securing the starter

pulley to the flywheel. Remove the starter pulley;

then carefully pry the fan belt drive pulley from its

seated position on the flywheel and remove.

AB020

8. Temporarily install the starter pulley on the

flywheel with three cap screws. Using the

flywheel spanner wrench to secure the crankshaft,

loosen and remove the flywheel nut and washers.

AB021

„

NOTE: If an impact wrench is being used, use of

a flywheel spanner wrench will not be necessary.

9. Remove the cap screws securing the starter pulley

to the flywheel and remove the pulley.

10. Remove the flange nuts securing the fan case to

the crankcase; then remove the fan case.

„

NOTE: For further servicing of the axial fan com-

ponents, see section 3.

AB015

11. Install a protective cap onto the end of the

crankshaft.

„

NOTE: A suitable protective cap can be made by

welding a 3 mm (1/8 in.) plate on one side of a
spare flywheel nut.

AB022

12. Using the Flywheel Puller/Spanner Wrench (p/n

0144-310) or suitable equivalent, remove the

flywheel from the crankshaft by tightening the

puller bolt, striking the head of the puller bolt with

a hammer, and tightening again. Repeat procedure

until the flywheel is free. Account for the key in

the end of the crankshaft.

! CAUTION

To prevent damage to the crankshaft, thread a
protective cap onto the crankshaft. The puller
must bottom on the cap and not on the
crankshaft. Also, do not thread puller bolts more
than 12.7 mm (1/2 in.) into the flywheel. Damage
to the coils may result.