Snowmobile Arctic Cat (2002 year). Manual - part 24

2-79

2

AN106

31. 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).

AN107

32. With the exhaust manifold tightened, secure the

cylinders by tightening the cylinder base nuts to 4-

6 kg-m (29-43.5 ft-lb). Tighten the nuts in three

steps using the pattern shown.

725-318B

33. Install the two oil-injection hoses and secure with

the clamps.

AN111

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

cylinder making sure they are correctly positioned

in the grooves.

AN110

35. Place new O-rings onto each of the twelve head

cap screws. Place four of these cap screws into one

of the cylinder heads. Thread the spark plug 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

two cap screws being very careful not to move the

cylinder head. Repeat the same procedure on the

remaining head. ONLY FINGER-TIGHTEN AT

THIS TIME.

36. 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 sur-
faces of the head to align with the housing and
prevent any coolant leakage.

2-80

AN113

37. Tighten the cap screws securing the head in three

steps to 1.8-2.8 kg-m (13-20 ft-lb) using the

pattern shown. Pressure test the engine (see

Section 3).

0728-138

38. 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).

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

crankcase; then apply blue Loctite #242 to the

screws and tighten securely.

40. Place the stator plate into position over the

crankshaft end.

41. Install the lock washers and washers on the Allen-

head cap screws; then apply blue Loctite #242 to

the threads of the stator plate Allen-head cap

screws and install. DO NOT TIGHTEN AT THIS

TIME.

42. Align the stator plate with the alignment mark

made during disassembly. Tighten both stator plate

screws securely.

AN118

„

NOTE: Before installing the flywheel, be sure to

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

43. Install the key in the crankshaft and slide the

flywheel onto the crankshaft making sure the

keyways match; then finger-tighten the flywheel

nut with large flat washer and lock washer. Apply

red Loctite #271 to the threads of the flywheel nut.

44. Install the starter pulley; then secure the starter

pulley with three cap screws 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).

AN121

45. Using the spanner wrench, tighten the flywheel

nut to 7-9 kg-m (50.5-65 ft-lb).

AN122

46. Install the spark plugs and tighten to 2.5-2.8 kg-m

(18-20 ft-lb). Connect the spark plug caps.

2-81

2

47. Place the engine mounting brackets into position

on the crankcase and secure with the cap screws.

Tighten to 2.8-3.5 kg-m (20-25 ft-lb).

Assembling Engine

 

(570 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. Place the upper crankcase half (with its bottom

side up) on two blocks of wood.

2. Lightly grease the inner lips of the crankshaft

seals; then slide them onto the crankshaft.

3. 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 dowel pin. 

„

NOTE: Make sure the crankshaft center C-ring

(integral with the center seal) is properly posi-
tioned in the groove of the upper crankcase half.

4. Install the four crankcase dowel pins.

5. Evenly apply a thin coat of Three Bond Sealant (p/n

0636-070) to the entire bottom half crankcase

sealing surface. 

„

NOTE: Use only Three Bond Sealant (p/n 0636-

070) to seal the crankcase halves.

MD0203

6. Install crankcase lower half. Install eight 8 mm

and four 6 mm cap screws. 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.

737-027A

MD0212

„

NOTE: Check the reed valve on each cylinder for

cracking or fraying around the edges. Make sure
they are closing completely.

„

NOTE: To inspect a reed valve assembly, remove

the two Phillips-head screws securing the reed
valve and reed valve stopper to the block; then
remove the reed valve and stopper.

! CAUTION

To prevent damage to the crankshaft, crankshaft
bearings, or seals, make sure to always lift the
crankshaft from both ends.

! CAUTION

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

2-82

MD0088

„

NOTE: Apply blue Loctite #242 on the Phillips-

head screws when assembling.

„

NOTE: Make sure the angled corner on the reed

valve align with the angled corner on the reed
valve stopper.

MD0213

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

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

dome of the piston.

726-306A

„

NOTE: If the existing rings will not be replaced

with new rings, note the location and top side of
each ring for proper installation. When replacing
with new rings, replace as a complete set only.
When replacing rings note notches in ring ends
which correspond with locating pins in ring
grooves on intake side of the piston. This prevents
the rings from turning on the piston when assem-
bled.

MD0208

MD0272

! CAUTION

Do not over-tighten the Phillips-head screws
when installing the reed valves and reed valve
stoppers.

! CAUTION

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