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Snowmobile Arctic Cat (2002 year). Manual - part 37

2-131

NOTE: At this point, install the drive chain (see

D r i v e C h a i n a n d S p r o ck e t s s u b - s e c t i o n i n
Section 8).

Installing Engine

(Twin F/C Models)

1. Place each engine mounting bracket onto the

engine. Secure with cap screws, washers, and lock

washers. Tighten to 2.8 kg-m (20 ft-lb).

2. Place the engine assembly into position in the

engine compartment. Secure the engine to the

front end with the cap screws, washers, and lock

nuts. Tighten to 2.8-3.5 kg-m (20-25 ft-lb).

AL201D

AL200D

AL199D

3. Connect the oil-supply hose to the oil-injection

pump; then bleed the system (see Section 4).

NOTE: If equipped with electric start, place the

starter motor bracket on the crankcase and install
the front two and lower rear cap screws, lock
washers, and washers. Place the starter motor into
position and secure with two washers and lock
nuts.

4. Connect the oil-injection cable to the oil-injection

pump control arm and secure the cable mounting

pin with a nylon washer and E-clip.

5. Place the carburetor(s) into position making sure

the boot(s) are properly positioned and secure with

the flange clamp(s).

AH283D

NOTE: At this point, check oil-injection system

synchronization (see Section 4).

6. Connect the impulse hose to the crankcase, the

main wiring harness, the CDI unit wiring harness,

and the spark plug caps.

7. Place the recoil starter into position and secure

with four cap screws and lock washers. Tighten to

1.1 kg-m (8 ft-lb).

NOTE: If equipped with electric start, secure the

battery ground cable with the rear cap screw.

AB073

8. Place the expansion chamber and grafoil gasket

into position and secure with springs.

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AB105D

9. Place the engine mount shims into position

between the torque bumper and engine mounting

bracket; then tighten the torque bumper jam nut.

10. Place the drive clutch into position on the

crankshaft; then install the lock washer and bolt.

Tighten the clutch bolt to 6.9-7.6 kg-m (50-

55 ft-lb).

AF477D

NOTE: Apply a coat of Anti-Seize Thread Com-

pound (p/n 0678-146) to the keyway end of the
driven shaft.

11. Install the driven pulley and alignment washers.

Secure with a cap screw and washer tightened to

2.6-3.3 kg-m (19-24 ft-lb).

SC013D

NOTE: At this point, check drive clutch/driven

pulley alignment (see Section 8).

12. Install the drive belt and secure the belt guard.

Install the plug in the belly pan.

NOTE: If equipped with electric start, connect

the battery.

13. Turn the gas tank shut-off valve to the OPEN

position.

14. Check the ignition timing.

15. Place the rear of the snowmobile up on a safety

stand. Start engine and allow to warm up. Adjust

engine idle to 1500 RPM and check all safety

switches for proper operation.

16. Test drive the snowmobile; then tighten the clutch

bolt to 7.6 kg-m (55 ft-lb).

AF477D

Installing Engine

(Twin L/C Models)

NOTE: Some engines are equipped with Arctic

Power Valves (APV). Closely observe the NOTE:
introducing this important information.

1. Place the engine into the engine compartment;

then place the coolant supply hose on the water

pump (coolant tank on the 800 cc) and secure with

the clamp.

NOTE: On the Wide Track, place the shims in

their proper position on the left rear engine mount
(as noted during removal).

2. On all models except the Wide Track, secure the

right-side front and rear and left-side front engine

mounts to the front end making sure the mounts

are properly positioned. Tighten the cap screws

and nut to 2.8-3.5 kg-m (20-25 ft-lb).

! CAUTION

If the engine had a major overhaul or if any major
part was replaced, proper engine break-in
procedures must be followed.

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NOTE: On the Wide Track tighten the engine

mount cap screws to 7.6 kg-m (55 ft-lb).

3. On all models except the Wide Track, adjust the

torque bumper to allow a clearance between the

engine and the torque bumper of 1.78 mm (0.070

in.); then secure the adjustment by tightening the

jam nuts.

AN610D

4. On the 500/600 cc, secure the hood cable and

ground wire to the magneto case with the machine

screw tightened to 1.1 kg-m (8 ft-lb).

5. On the 550 cc, attach the hood cable to the exhaust

manifold and the ground wires to the magneto

case.

6. Secure the rear ground wires to the magneto case

with the machine screw tightened to 1.1 kg-m

(8 ft-lb).

7. Place the coolant return hose into position on the

thermostat housing and secure with the clamp.

8. Place the recoil starter into position and secure the

starter with four cap screws and lock washers.

Tighten to 1 kg-m (7 ft-lb).

9. Connect all electrical wires.

NOTE: Use cable ties to secure the wiring har-

nesses as necessary.

10. Connect the oil-injection cable/control rod to the

oil-injection pump and secure; then connect the

oil-supply hose to the pump and secure with the

clamp. Bleed the oil-injection system (see

Section 4).

AN392D

11. On carbureted models, connect the impulse hose

to the crankcase.

AN385D

12. Place the carburetors/throttle bodies into position

and secure with the flange clamps. Synchronize

the oil-injection system (see Section 4).

NOTE: On the 800 cc, install the air-intake

silencer; then place the CDI unit into position and
close the cover.

NOTE: On the Wide Track, place the starter

motor and end cap into position and secure with
the lock nuts. Tighten securely.

13. Place the expansion chamber and grafoil gaskets

into position and secure to the exhaust manifold,

front end, and resonator with the springs.

AN378D

2-134

NOTE: When installing the three exhaust mani-

fold springs, the long hook portion of the spring
must be attached to the exhaust manifold or pre-
mature spring failure will result.

NOTE: Before installing the drive clutch, be sure

to wipe both the crankshaft taper and clutch
mounting taper clean using a clean towel.

14. Place the drive clutch into position on the

crankshaft and secure with the cap screw and lock

washer. Tighten to 6.9-7.6 kg-m (50-55 ft-lb).

AN381D

NOTE: On the Wide Track, secure the side panel

to the belly pan with the existing machine screws.

NOTE: Apply a coat of Anti-Seize Thread Com-

pound (p/n 0678-146) to the keyway end of the
driven shaft.

15. Install the driven pulley, key, stub shaft, and

alignment washers. Secure with a cap screw and

washer. Tighten to 2.6-3.3 kg-m (19-24 ft-lb).

AF120D

SC013D

16. Check drive clutch/driven pulley alignment (see

Section 8).

17. Install the drive belt. Check belt deflection. Secure

the belt guard.

AN379D

NOTE: On the Wide Track, secure the belly pan

and bumper to the bumper support tube with a
lock nut; then install the rear belly pan plug.

18. Fill the cooling system (see Section 3).

19. On models equipped w/electric start, connect the

positive cable to the starter motor; then secure

with the washers and nut making sure the cable is

directed toward the PTO-side of the engine. Secure

the positive cable with a long cable tie.

20. On models equipped w/electric start, connect the

cables to the battery making sure to connect the

positive cable first.

NOTE: Steps 21 through 25 are for APV equipped

engines.

21. Slide the cable drums into the servomotor

actuator; then place the cable housings into

position in the servomotor. Secure the cable

housings with the holder.

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