Snowmobile Arctic Cat (2002 year). Manual - part 23

2-75

2

AB040

31. Place an exhaust manifold gasket on each exhaust

port making sure the metal side of the gasket faces

the cylinder. Slide the exhaust-side cooling shroud

onto the exhaust port studs; then place the upper

cooling shroud into position and secure the

shrouds with 14 cap screws noting the location of

the longer cap screws from disassembling. Tighten

to 0.4-0.7 kg-m (3-5 ft-lb). Connect the spark-plug

caps.

AB012

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

0636-069) to the exhaust-manifold gasket; then

place a gasket on each exhaust port making sure

the metal side of each gasket faces away from the

cylinder. Install the exhaust manifold, lock

washers, and nuts and tighten to 1.8-2.2 kg-m (13-

16 ft-lb).

Assembling Engine

(550 cc Models)

„

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

ommended when assembling the engine.

„

NOTE: When the use of a lubricant is indicated,

use Arctic Cat 50:1 Injection Oil. 

1. Using the water pump bearing and seal driver,

position the inner water pump shaft seal onto the

seal driver and gently tap the seal down into

position.

„

NOTE: Apply grease to the lips of the inner seal

before installation.

AN070

„

NOTE: The seal must be installed with its spring

side towards the crankshaft.

2. Using a small screwdriver, apply a thin coat of

grease to the inner seal lips.

3. Using a pair of snap ring pliers, install the snap

ring securing the inner seal in the crankcase.

4. Using the seal driver, carefully install the outer

water pump seal. Gently tap the seal down into

position until it seats itself against its flange.

AN072

5. Apply a thin coat of grease to the sealing surface

of the oil-injection pump driveshaft; then place the

Oil Seal Installation Tool (p/n 0644-219) at the

end of the shaft. Twist the driveshaft clockwise as

it is pushed through the oil and water pump seals;

then remove the tool. Position the shim on the oil-

injection pump end of the driveshaft.

6. Position the upper crankcase half upside-down on

two wooden blocks; then install the C-ring, the

four bearing retaining pins, and two crankcase

dowel pins.

! CAUTION

Be very careful not to damage the seals when
installing the oil pump driveshaft. Be certain to
use the seal installation tool. Twist the driveshaft
clockwise as it enters the seal area and while it is
being pushed through the seals.

2-76

7. Place the PTO-side crankshaft bearing into

position making sure the bearing retaining pin hole

is positioned inward.

„

NOTE: The bearing retaining pin hole is the hole

that doesn't go entirely through the bearing case.

AN078

8. Lubricate the inner lips of the crankshaft oil seals

with grease; then slide the seals onto the

crankshaft making sure the spring side of each seal

faces the center of the crankshaft.

„

NOTE: There is a MAG-side seal and a PTO-side

seal.

9. Apply oil to the crankshaft bearings; then install

the crankshaft into the upper crankcase half. Be

sure the alignment hole in each bearing is

positioned over its respective dowel pin in the

crankcase; then seat the crankshaft.

„

NOTE: To check the bearing for proper position,

place the point of a sharp tool into the dimple
found in the bearing race. Strike the tool with the
palm of the hand in either direction. If the bearing
moves, it isn't positioned correctly and must be
rotated until it drops onto the retaining pin.

10. Position the two center seal rings with their end

gaps 180° apart (up on one and down on the

other).

AN083

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

0636-069) to the entire bottom half of the

crankcase sealing surface.

AQ127

„

NOTE: Use only High-Temp Sealant (p/n 0636-

069) to seal the crankcase halves.

12. Assemble the crankcase halves making sure that

the crankshaft gear and oil-injection pump

driveshaft gears mesh. Rotate the crankshaft one

full turn to align the crankshaft gear and pump

driveshaft.

13. Install the 14 crankcase cap screws securing the

crankcase halves making sure the cap screws are

in the proper-sized holes. Tighten in three steps the

8 mm cap screws to 1.8-2.8 kg-m (13-20 ft-lb) and

the 6 mm cap screws to 0.8-1.2 kg-m (6-9 ft-lb)

using the pattern shown.

0728-137

! CAUTION

If the bearings are not properly seated during
assembly, the crankcase halves will not seal
tightly and engine damage will result.

2-77

2

„

NOTE: Secure the connecting rods with rubber

bands on the cylinder studs.

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

retainer.

AN088

15. Install the O-ring/gasket and the oil-injection

pump making sure the pump shaft and pump align.

Secure with two screws and washers. Tighten the

two screws to 0.7 kg-m (5 ft-lb).

16. Position the rubber seal retainer and seal into the

back side of the water pump impeller.

„

NOTE: The lined or marked side of the porcelain

seal must face the rubber retainer.

17. Using both thumbs, press the seal into position

making sure its marked side is positioned towards

the rubber seal cup.

18. 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).

AN094

20. Apply sealant to the crankcase seam; then install

the alignment pins into the crankcase.

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 securely.

22. Place the cylinder base gaskets into position on the

crankcase.

„

NOTE: Be sure to spray a thin coat of Copper

Coat Gasket Sealant (p/n 0636-092) onto the gas-
ket if it is being reused.

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

on the top (inclined surface) of each ring faces the

dome of the piston.

! CAUTION

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

! CAUTION

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

2-78

726-306A

24. 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.

25. Place each piston over the connecting rod so the

arrow on each piston will point toward the exhaust

port; then secure with an oiled piston pin.

„

NOTE: The arrow is found either up inside the

piston or on the dome top.

AN101

26. Install the circlips so the open end is directed

either up or down.

AN102

27. 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.

„

NOTE: If the intake flanges were removed from

the cylinders, install them prior to installing the
cylinders. Tighten the nuts to 1.8-2.2 kg-m (13-16
ft-lb). 

28. 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.

AN105

29. Secure each cylinder by installing the four nuts,

washers, and lock washers. DO NOT TIGHTEN

AT THIS TIME.

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

0636-069) to each exhaust port; then install the

two exhaust gaskets with the metal sides facing

out.

! CAUTION

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

! CAUTION

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