Snowmobile Arctic Cat (2002 year). Manual - part 30

2-103

2

0729-585

„

NOTE: If removed, install the exhaust manifolds.

Tighten to 1.8-2.2 kg-m (13-16 ft-lb).

20. Place the cylinder head O-rings into position on

each cylinder.

„

NOTE: If reusing O-rings and they are slightly

stretched, shrink the O-rings by cooling them (in a
refrigerator for example) for a period of time.

21. Being very careful not to move the two O-ring

seals, hold the cylinder head above the cylinder

approximately 1/4 in. and start the cap screws into

the cylinder; then check the O-rings for proper

position and set the head carefully down onto the

cylinder. Finger-tighten the cap screws at this

time.

AN188

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

0636-069) to the three water manifold gaskets.

Place the gaskets and manifold into position and

secure with six cap screws. Using a crisscross

pattern, tighten to 0.7-1 kg-m (5-7 ft-lb).

AN187

23. Tighten the cylinder head cap screws in three steps

using the pattern shown to 2-2.5 kg-m (14.5-

18 ft-lb).

0729-587

24. In turn for each cylinder, install the gasket, reed

valve assembly, and intake flange to the

crankcase; then secure with six cap screws.

Tighten to 0.8-1.2 kg-m (6-9 ft-lb).

AN213

25. Place the thrust washer on the outward end of the

oil-injection pump driveshaft.

26. Apply a light coat of oil to the shaft adapter; then

install the O-ring and slide the adapter into

position on the pump driveshaft.

! CAUTION

Be very careful not to move the cylinder heads
once they are placed on top of the O-rings.

2-104

AN184

27. Being careful to align the slot of the oil-injection

pump shaft with the flat end of the oil-injection

pump driveshaft, install the pump on the crankcase

and secure with two screws.

AN183

28. 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.

AN091

29. Using both thumbs, press the seal into position

making sure its marked side is positioned towards

the rubber retainer.

30. Apply a light coat of grease to the seal outer

surface.

31. 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.

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

screw and tighten to 0.8-1.2 kg-m (6-9 ft-lb).

AN181

33. Apply sealant to the crankcase seam; then install

the dowel pins into the crankcase.

AN179

„

NOTE: Sealant is only required on the crankcase

seam.

34. Position the O-ring into the water pump cover;

then install the cover. Secure with five screws.

Tighten securely.

35. Place the seal protector plate into position on the

crankcase; then apply blue Loctite #242 to the four

screws and secure.

! CAUTION

When installing the oil-injection pump, the pump
driveshaft must align with the pump shaft or
serious damage will result.

! 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.

2-105

2

AJ103

36. Install the stator plate with the large notch for the

wiring harness in the 10 o’clock position; then

secure with two cap screws (threads coated with

blue Loctite #242).

AN170

37. Install the stator; then route the wiring harness

through the crankcase housing and install the

rubber grommet. Apply blue Loctite #242 to the

threads of the three Allen-head cap screws and

secure the stator to the stator plate.

AN171

38. 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.

AN172

39. Secure the timing sensor wiring harness to the

magneto housing using the tab plate and screw.

Apply blue Loctite #242 to the screw threads and

tighten securely.

AN173

„

NOTE: Wipe the flywheel and crankshaft taper

with a clean cloth to remove any foreign material.

40. Install the flywheel key in the crankshaft; then

slide the flywheel onto the crankshaft making sure

the keyways align. Install, but do not tighten, the

flat washer, lock washer, and flywheel nut.

AN174

41. Install the starter pulley and secure with three cap

screws. Tighten to 0.8-1.2 kg-m (6-9 ft-lb).

2-106

AN175

42. Tighten the flywheel nut to 7-9 kg-m (50.5-

65 ft-lb).

AN176

43. Install the magneto case; then apply blue Loctite

#242 to the four Allen-head cap screws and

secure. Tighten to 1.8-2.2 kg-m (13-16 ft-lb).

AN165

44. Install the thermostat with its rubber seal and

thermostat cover. Secure with three cap screws.

Tighten to 0.7-1 kg-m (5-7 ft-lb).

AQ079

45. Slide the valve assembly into the proper cylinder.

AP154

46. Secure the valve assembly to the cylinder with

three Allen-head cap screws (coated with blue

Loctite #242). Tighten to 1.1 kg-m (8 ft-lb).

AP153

47. Slide the valve cover onto the studs on the engine.

Secure with four nuts. Tighten securely.