Snowmobile Arctic Cat (2002 year). Manual - part 21

2-67

Assembling Engine

Table of Contents

Assembling Engine

(120 cc Model)

NOTE: The use of new gaskets and seals is rec-

ommended when assembling the engine.

NOTE: When the use of a lubrication is indi-

cated, use a lightweight engine oil.

1. Secure the oil level sensor plate to the crankcase

with the cap screws.

GM126D

2. Install the crankshaft with the connecting rod

journal facing down.

GM124D

3. Note the direction of the arrow on the connecting

rod and the marks on the connecting rod and end

cap made during disassembly.

GM121D

GM120D

4. Coat the cylinder wall, connecting rod bearing

surface, and the crankshaft with lightweight oil;

then compress the piston rings and install the

piston and connecting rod assembly taking care

not to damage the crankshaft with the connecting

rod studs.

NOTE: When installing the piston, rotate the

crankshaft until the piston is at the bottom of the
stroke.

5. Install the connecting rod end cap with the

splasher plate, lock tab, and nuts. Tighten the nuts

to 1.1-1.4 kg-m (8-10 ft-lb).

! CAUTION

The arrow on the connecting rod must face out.

2-68

GM123D

6. Apply lightweight oil to the tappets and camshaft;

then install the tappets and camshaft.

GM217D

GM216D

NOTE: Make sure the timing marks are aligned.

GM215D

7. Install the washer onto the camshaft.

GM214D

8. Place the dowel pins and a gasket into position.

GM213D

9. Secure the crankcase side cover to the crankcase

with the cap screws. Tighten to 0.9-1.2 kg-m (6.5-

9 ft-lb).

GM212D

10. Install the dowel pins and a new gasket; then

secure the head to the cylinder with the cap

screws. Tighten to 2.8 kg-m (20 ft-lb).

2-69

GM210D

11. Apply lightweight oil to the ends of the push rods;

then install the rods.

GM209D

12. Loosely secure the rocker arms to the cylinder

head with the pivots and lock nuts; then place the

piston to the top of the compression stroke, set the

valve clearance to the recommended setting with a

feeler gauge, and while holding the adjustment

nut, tighten the rocker arm lock nuts securely.

Verify valve clearance.

GM208D

13. Secure the reed stopper to the air breather body

assembly with the screws.

GM207D

14. Place the air breather body assembly with gasket

onto the cylinder head cover.

GM206D

15. Install the valve cover with gasket. Tighten to

1.1 kg-m (8 ft-lb).

GM205D

16. Secure the ignition coil to the crankcase housing

with the cap screws.

VALVE CLEARANCE RANGE (Cold)

0.030-0.070 mm

(0.0012-0.0028 in.)

2-70

GE318D

17. Connect the ignition coil wire.

NOTE: The spark plug should be removed and

cleaned or replaced. Adjust gap to specification
and tighten the plug to 2.5-2.8 kg-m (18-20 ft-lb).

18. Connect the high tension lead to the spark plug

and secure with the two wire forms.

19. Install the flywheel and secure with the nut.

Tighten to 6-7 kg-m (43.5-50.5 ft-lb).

GM203D

NOTE: The ignition coil to flywheel air gap must

have a clearance of 0.5 mm (0.020 in.).

20. Secure the recoil starter pulley to the flywheel

with the screws.

GM202D

21. Install the recoil starter/fan housing assembly.

GM201D

22. Install the carburetor (with a gasket, insulator

block, and a gasket) onto the mounting studs.

GF318D

23. Noting the locations of the springs from

disassembly, install the rod and spring onto the

carburetor.

GF208D

24. Install the gasket onto the mounting studs; then

install the air cleaner housing onto the carburetor.

Install the air breather hose onto the air cleaner

housing.

! WARNING

When performing service work on the fuel system,
do not smoke or allow open flames near the snow-
mobile.

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