Snowmobile Arctic Cat (2002 year). Manual - part 27

2-91

2

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 to 1.1 kg-m (8 ft-lb).

22. Secure the intake flanges, reed valve assemblies,

and gaskets with cap screws. Tighten to 0.8-

1.2 kg-m (6-9 ft-lb).

23. Place the cylinder base gasket into position on the

crankcase.

24. 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

25. 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.

AN100

AQ059

26. Place each piston over the connecting rod so the

arrow (or indicator dot) on each piston will point

toward the exhaust port; then secure with an oiled

piston pin.

„

NOTE: The arrow (or indicator dot) is found

either up inside the piston or on the dome top.

AN101

27. Install the new circlips so the open end is directed

either up or down.

! CAUTION

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

2-92

B324D

28. 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.

29. 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.

AN105D

30. Secure each cylinder by installing the four nuts,

washers, and lock washers. DO NOT TIGHTEN

AT THIS TIME.

„

NOTE: The cylinders will be tightened at the

same time as the exhaust manifold is installed to
assure proper cylinder to exhaust manifold align-
ment.

31. Install the oil-injection hoses and secure with the

clamps; then place the lower check-valve

assembly into position and secure with the gaskets

and union cap screw. Tighten securely.

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

cylinder making sure they are correctly positioned

in the grooves.

AN110D

33. Place new O-rings onto each of the head cap

screws. Place four of these cap screws into the

cylinder head. Thread the spark plugs 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 cap screws

being very careful not to move the cylinder head.

ONLY FINGER-TIGHTEN AT THIS TIME.

34. 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.

0733-524

35. Place the thermostat, gasket, and cap into position. 

36. Secure the cap with three cap screws tightened to

0.7-1 kg-m (5-7 ft-lb).

37. Apply a thin coat of high-temperature silicone

sealant to each exhaust port; then install the

exhaust gaskets with the metal sides facing out.

38. 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).

! CAUTION

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

500/600 cc

2-93

2

39. Tighten the spark plugs to 2.5-2.8 kg-m (18-

20 ft-lb); then secure the cylinders by tightening

the cylinder base nuts to 4-6 kg-m (29-43.5 ft-lb)

in three steps using the pattern shown. Pressure

test the engine (see Section 3).

725-318B

40. Secure the ignition timing sensor with screws

coated with blue Loctite #242.

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

crankcase; then apply blue Loctite #242 to the four

screws and tighten to 1.1 kg-m (8 ft-lb).

42. Secure the stator to the stator plate with the Allen-

head cap screws coated with blue Loctite #242 and

tightened to 1.1 kg-m (8 ft-lb); then install the

stator wires with a grommet into the crankcase.

AN413D

43. Install the key in the crankshaft. 

44. Slide the flywheel onto the crankshaft making sure

the keyways match.

„

NOTE: Before installing the flywheel, be sure to

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

45. Apply red Loctite #271 to the threads of the

flywheel nut; then finger-tighten with a large flat

washer, lock washer, and the nut. DO NOT

TIGHTEN AT THIS TIME.

AN120D

46. Place the starter pulley in position; then loosely

secure the starter pulley with three cap screws

(coated with red Loctite #271) 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).

AN121D

47. Using the spanner wrench, tighten the flywheel

nut to 7-9 kg-m (50.5-65 ft-lb).

48. Place the engine mounting brackets into position

on the crankcase and secure with the cap screws.

Tighten to 2.4 kg-m (17 ft-lb).

49. Slide the APV assemblies into position in the

cylinders making sure that on the 500 cc, the

grooved sides are down; then slide the valve

keepers into position and secure with cap screws

(coated with blue Loctite #242). Tighten to 0.9-

1.3 kg-m (6.5-9.5 ft-lb) on the 500 cc and to

1.1 kg-m (8 ft-lb) on the 600 cc.

„

NOTE: The following illustrations are the 500 cc.

Other models may vary slightly.

2-94

AP149

AP120

50. Slide the valve covers into position and secure

with existing nuts. Tighten to 0.9-1.3 kg-m (6.5-

9.5 ft-lb).

Assembling Engine

(800 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.

„

NOTE: Do steps 1-5 only if the water pump has

been disassembled.

1. Apply a thin coat of grease to the inner seal lips of

the water pump seal.

2. Using the seal driver, position the inner water

pump shaft seal onto the seal driver and gently tap

the seal down into position.

„

NOTE: Grease must be applied to the lips of the

inner seal before installation.

AN070D

„

NOTE: The seal must be installed with its spring

side towards the crankshaft.

3. 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.

AN072D

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

of the oil-injection pump/water 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.

! 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.