Snowmobile Arctic Cat (2002 year). Manual - part 25

2-83

2

MD0271

8. Lubricate the piston pin bearings and install them

into the connecting rods. 

9.  Install a piston pin bearing washer on each side of

the bearings with the open sides facing the

bearings.

„

NOTE: The open sides of the piston pin bearing

washers must face the bearing.

MD0251

10. Place pistons over the connecting rods with the

arrow (or indicator dot) pointing toward the

exhaust port; then secure with an oiled piston pin.

Install piston pin circlips with the open ends up or

down.

MD0293

MD0248

11. Place the cylinder base gasket into position on the

crankcase making sure the gasket is properly

oriented so the dowel pins will fit through the

holes easily.

„

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.

12. Rotate each piston ring until the ring ends are

properly positioned with the pins in the ring

grooves; then apply oil to the piston assemblies

and cylinder bores. Using a ring compressor or the

fingers, compress the rings and slide the cylinder

over the piston. Seat the cylinder firmly onto the

crankcase. 

„

NOTE: The cylinders should slide on easily. DO

NOT force them on.

MD0229

13. Secure each cylinder by installing the four 6 mm

and eight 8 mm nuts. Tighten the 8 mm nuts to 4-6

kg-m (29-43.5 ft-lb) and the 6 mm nuts to 0.7-1

kg-m (5-7 ft-lb).

! CAUTION

Make sure the circlips are firmly seated in their
grooves and the open ends are pointed up or
down before continuing with assembly.

2-84

MD0086

MD0087

14. Install a new cylinder head gasket and the cylinder

head; then install the eight cap screws and two

nuts with washers. Tighten in three steps to 1.8-2.8

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

MD0232

MD0233

MD0234

MD0259A

15. Install the spark plugs; then tighten to 2.5-2.8 kg-m

(18-20 ft-lb).

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2

MD0235

16. Position the seal retainer plate on the PTO-side;

then install the four cap screws. Tighten the cap

screws to 0.8-1.2 kg-m (6-9 ft-lb).

MD0253

MD0292

17. Install the stator plate and secure with four Allen-

head cap screws. Install the stator plate so the

ignition wire cut-out is in the upper left position.

Lightly coat the four Allen-head cap screws with

red Loctite #271; then tighten them to 0.8-1.2 kg-

m (6-9 ft-lb).

MD0255

18. Place the stator wiring through the hole in the

crankcase; then install the stator. Lightly coat the

three Allen-head cap screws with red Loctite

#271; then tighten them to 0.8-1.2 kg-m (6-9 ft-

lb).

MD0076

MD0274

19. Place the ignition timing sensor wiring through the

hole in the crankcase; then position the ignition

timing sensor and install two Phillips-head cap

screws (coated with red Loctite #271). Tighten the

cap screws securely.

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MD0074

MD0273

20. Install the rubber insulator grommet into the

crankcase.

MD0262

21. Install the key; then install the flywheel and cap

screw. Tighten the cap screw only until snug.

„

NOTE: Do not tighten the flywheel cap screw at

this point. 

MD0264

22. Place the fan and starter pulley into position on the

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

to hold the starter cup, tighten the three cap screws

(coated with green Loctite #609 and Loctite

Primer #7471) to 1.8-2.8 kg-m (13-20 ft-lb).

MD0280

23. Using Spanner Wrench (p/n 0144-007) to hold the

starter cup, tighten the flywheel cap screw (threads

coated with red Loctite #271) to 8.0-8.7 kg-m (58-

63 ft-lb).

! CAUTION

Do not use green Loctite #609 without also using
Loctite Primer #7471.

! CAUTION

When installing the fan, make sure that the
locating pins on the flywheel align with the
indentations in the fan.