Snowmobile Arctic Cat (2002 year). Manual - part 29

2-99

2

AP152

36. Apply a thin coat of silicone sealant to the

crankcase water pump housing sealing surface.

„

NOTE: Sealant is required only on the crankcase

seam.

AN095

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

0636-069) to the water pump cover seal and

position the O-ring into the cover. Carefully place

the cover over the impeller and onto the crankcase.

Secure with six cap screws. Tighten cap screws

evenly to 0.9-1.3 kg-m (6.5-9.5 ft-lb).

38. Install the stator backing plate and secure with

four cap screws. Apply blue Loctite #242 to the

threads of each cap screw before installation.

Tighten securely.

AP133

39. Set the timing sensor into position in the magneto

housing. Apply blue Loctite #242 to the threads of

the two screws and secure the timing sensor to the

housing.

40. Route the stator wiring harness through the rubber

grommet; then place the stator into position and

secure with three screws coated with blue Loctite

#242. Tighten securely.

41. Secure the stator wiring harness to the magneto

housing using the tab plate and screw.

42. Install the key in the crankshaft and slide the

flywheel onto the crankshaft making sure the

keyways align.

AJ128

43. Apply blue Loctite #242 to the threads of the cap

screw; then install the flat washer, lock washer,

and cap screw securing the flywheel. Tighten the

cap screw finger-tight.

44. Place the starter pulley into position on the

flywheel and secure with three cap screws coated

with blue Loctite #242. Tighten the three cap

screws evenly to 0.9-1.3 kg-m (6.5-9.5 ft-lb).

AJ130

45. Using a spanner wrench, tighten the flywheel bolt

to 7.95-8.65 kg-m (57.5-62.5 ft-lb).

2-100

AJ131

46. Place the exhaust manifold into position on the

cylinders; then secure with flange nuts. Tighten to

1.8-2.2 kg-m (13-16 ft-lb).

47. Place the engine mounting brackets into position

on the engine; then secure with cap screws (coated

with blue Loctite #242), lock washers, and flat

washers. Tighten to 2.4 kg-m (17 ft-lb).

48. Slide the APV assemblies into position in the

cylinders making sure the grooved sides are down;

then slide the valve keepers into position and

secure with two cap screws (coated with blue

Loctite #242). Tighten to 0.9-1.3 kg-m (6.5-

9.5 ft-lb).

AP149

AP120

49. Slide the APV covers into position and secure with

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

9.5 ft-lb).

59. Position the coolant supply hose on the water

pump and secure with a clamp.

Assembling Engine

(600 cc Triple Model)

„

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 Kit (p/n

0644-084), position the inner water pump shaft

seal onto the special seal driver and gently tap the

seal down into position.

„

NOTE: The seal must be installed with its spring

side towards the crankshaft.

2. 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 light coat of grease to the sealing surface

of the oil-injection pump driveshaft; then install

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

end of the shaft. Twist the shaft clockwise as it is

pushed through the oil-injection 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 pump driveshaft. Be certain to use
Oil Seal Installation Tool (p/n 0644-219).

2-101

2

AN205

6. Position the upper crankcase half upside-down on

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

six bearing retaining pins.

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.

AN152

8. Lubricate the inner lips of the crankshaft end seals

with grease; then slide the seals onto the

crankshaft making sure the spring side of each seal

faces the bearing on 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 retaining 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.

AN203

10. The sealing rings must be located so none of the

end gaps align. Rotate the rings to “stagger” the

end gaps.

AN083

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

0636-069) to the entire sealing surface of the

bottom half of the crankcase. Install the two dowel

pins into the corners of the crankcase.

AN201

! CAUTION

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

! CAUTION

When installing the crankcase dowel pins, use
the two long dowel pins. The six shorter pins
must be used to align the cylinders.

2-102

12. Place the bottom crankcase half into position and

install the 14 crankcase cap screws (threads coated

with blue Loctite #242). Tighten the cap screws

evenly by hand starting in the center; then tighten

the cap screws in three steps to 1.8-2.8 kg-m (13-

20 ft-lb). Follow the pattern shown.

0731-342

13. Set the engine upright. On the appropriate

crankcase cylinder mounting studs, position two

dowel pins per cylinder. Install the cylinder base

gaskets.

AN197

„

NOTE: The cylinder base gaskets can be reused

if not damaged. When reusing a gasket, coat each
side with Copper Coat Gasket Sealant (p/n 0636-
092).

14. Pre-oil the piston pin bearings and place into

position in the connecting rods; then place a thrust

washer on each end of the bearing. The flat side of

each washer must face outward.

AN194

15. Place the piston over the connecting rod so the

arrow on the piston dome will point towards the

exhaust port of the cylinder; then apply a light coat

of oil to the piston pin and install.

AN193

16. Install the piston rings on the piston with their

tapered side “up.”

17. Secure the piston pin by installing new piston pin

circlips. Install the circlip with the open end up.

18. Apply oil to the piston rings and pistons; then

rotate the rings to correctly position them on either

side of the locating pin in the ring groove. Place a

short piece of wear strip under the piston to keep it

square; then compress the piston rings with one

hand and slide the cylinder down onto the piston.

AN190

19. Align the cylinder exhaust ports using a straight

edge; then secure each cylinder base with four

flanged nuts. In three steps, tighten the nuts to 1.8-

2.8 kg-m (13-20 ft-lb).