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Snowmobile Arctic Cat (2002 year). Manual - part 32

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AQ066

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

oil-injection pump driveshaft. Lubricate the shaft

and install into the crankcase.

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

install the O-ring and slide the adapter into

position on the oil-injection pump driveshaft.

26. 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.

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

crankcase; then apply blue Loctite #242 to the four

screws and secure.

28. Place the water pump housing into position on the

crankcase. Make sure the two O-ring seals on the

backside are in their proper position.

AQ068

29. Install the water pump impeller. Apply blue

Loctite #242 to the threads of the impeller cap

screw; then install the washer and cap screw.

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

NOTE: The rubber side of the washer must be

toward the impeller.

AQ069

30. Install the alignment pins in the water pump cover

and apply a low-temperature grease to the cover

O-ring seal.

AQ070

31. Place the water pump cover into position and

secure.

32. Install the stator plate with the notch for the wiring

harness in the 10 o’clock position; then secure.

33. Install the stator; then route the wiring harness

through the stator plate and crankcase housing and

install the rubber grommet.

34. Apply blue Loctite #242 to the threads of the three

Allen-head cap screws and secure the stator to the

stator plate.

AQ073

NOTE: Wipe the flywheel and crankshaft taper

with a clean cloth to remove any foreign material.

! CAUTION

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

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35. 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

flywheel cap screw.

AQ074

36. Install the starter pulley and secure with three cap

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

37. Tighten the flywheel cap screw to 4-6 kg-m (29-

43.5 ft-lb).

38. 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).

AQ076

39. 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

40. Cap the MAG-side impulse fitting. Secure with a

clamp.

41. Install the spark plugs. Tighten to 2.5-2.8 kg-m

(18-20 ft-lb); then pressure test the engine (see

Section 3).

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NOTES

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Assembly Schematics

Table of Contents

Listed in the table below are symbols indicating spe-

cial instructions and other important information nec-

essary for proper servicing. Please note the definition

for each symbol. These symbols are used throughout

this two-volume set.

KEY-TSKA

SYMBOL

DESCRIPTION

Torque control required

242 - apply blue Loctite #242 (p/n 1639-815)
243 - apply blue Loctite #243 (p/n 1639-413)
270 - apply green Loctite #270 (p/n 1639-817)
271 - apply red Loctite #271 (p/n 1639-820)
609 - apply green Loctite #609 (p/n 1639-821)

Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)
Lubricate with Arctic Cat Extreme 50:1 Injection Oil (p/n 0639-112)

Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)

3B - Three Bond Sealant (p/n 0636-070)
HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)

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