Snowmobile Arctic Cat (2002 year). Manual - part 47

3-11

3

Repairing Water Pump

(1000 cc)

REMOVING AND DISASSEMBLING

„

NOTE: A bleed hole is located at the bottom of

the water pump housing. If there is any sign of
coolant leakage from the bleed hole, the water
pump seals must be replaced. When servicing the
water pump, use Water Pump Bearing and Seal Kit
(p/n 0644-084).

AQ104

1. Remove the recoil starter and magneto housing;

then remove the water pump cover.

AQ095

2. Secure the crankshaft using a spanner wrench;

then remove the cap screw securing the impeller.

Remove the impeller from the shaft.

AQ096

3. Slide the center section of the water pump from

the shaft. Inspect both the rear and front seals. If

either appear in poor condition, replacement is

necessary.

AQ112

4. To remove seals, pull the rear seal from the center

section using the puller.

AQ011

5. Using the seal driver, drive the front seal from the

center section.

AQ012

3-12

ASSEMBLING AND INSTALLING

„

NOTE: Shown are the seals and O-rings required

to rebuild the water pump. Clean the center sec-
tion seal area and inspect the center section for
any signs of wear or scoring in the impeller area.

AQ013

1. Using the seal driver, install the front mechanical

seal. Drive the seal down into the center section

until it is firmly seated against its metal flange.

AQ014

2. Using the driver, install the rear seal. The spring

side of the seal must face outward. The seal outer

surface must be flush with the case.

AQ015

3. With the rear seal installed, apply a generous

amount of grease to the seal lips; then install the

O-rings and coat with grease.

AQ016

4. Install the water pump center section on the

crankcase. Install the new impeller sealing ring on

the backside of the impeller.

AQ008

5. Install the impeller and secure with a cap screw

(coated with blue Loctite #242) and flat washer.

The washer has a rubber coated side which must

face the impeller. Tighten the cap screw to 0.8-

1.2 kg-m (6-9 ft-lb). 

6. Install the outer water pump cover and O-ring seal.

Secure the cover with five screws.

AQ005

7. Install the magneto housing and recoil starter.

8. Fill the cooling system with antifreeze. Start and

run the engine. Check for leaks and recheck the

cooling system to make sure it has been properly

filled.

3-13

3

Pressure Testing

Engine

1. Test the engine for air leaks using the following

procedure and Pressure Testing Kit (p/n 0144-

127).

a. Install a plug into each intake-manifold port

and tighten the flange clamps securely.

b. Place a rubber plug and cover on each exhaust

port and secure.

c. Connect the tester pump to an impulse fitting

on the crankcase; then plug any remaining

impulse fittings and pressurize the crankcase to

8 psi and close the valve.

AN128D

d. Monitor the pressure gauge. The pressure must

not drop at a rate of more than 1 psi per minute.

e. If the pressure drops faster than specified,

inspect for an air leak with soapy water or by

completely submerging the pressurized engine

in clean fresh water. Repair as needed.

1. Elevate the front of the snowmobile 30-60 cm (12-

14 in.).

2. Remove the coolant tank cap and check coolant

level. The coolant tank should be filled to the

coolant level line.

3. Install the coolant tank cap; then start the engine.

Run the engine at 3000-3500 RPM until the

bottom heat exchangers become hot to the touch.

Stop the engine and allow the system to cool.

4. Lower the front of the snowmobile and elevate the

rear of the snowmobile 12-14 in. Repeat the

procedures in step 3.

5. Check the coolant level. Add coolant as required

to the coolant tank (coolant tank should be filled to

coolant level line). Repeat procedure until coolant

level stabilizes in the coolant tank.

„

NOTE: If coolant is required, mix coolant for a

temperature of -36°C (-34°F). Follow mixing recom-
mendations of the manufacturer of the coolant.

INSPECTING COOLANT HOSES 

AND CLAMPS

All coolant hoses and connections should be checked

annually for deterioration, cracks, and wear.

All coolant hoses and clamps should be replaced every

four years.

INSPECTING THERMOSTAT

1. Inspect the thermostat for corrosion, wear, or

spring damage.

2. Using the following procedure, inspect the

thermostat for proper operation.

a. Suspend the thermostat in a container filled

with water.

b. Heat the water and monitor the temperature

with a thermometer.

c. The thermostat should open at 50°C (122°F).

Once the thermostat starts to open,

IMMEDIATELY remove the thermostat as it

will lock in the open position if allowed to open

fully.

„

NOTE: The thermostat is of the lock-open type. If

the thermostat is ever allowed to fully open, it will
remain open and replacement will be necessary.

! CAUTION

DO NOT exceed 8 psi pressure or damage to the
seals will result.

! CAUTION

When submerging the engine to test for air leaks,
all external electrical components must be
removed to avoid damage.

! CAUTION

Be sure the cooling system is throughly filled
using the following procedure.

! CAUTION

It is extremely important that the Filling Cooling
System procedure is followed very closely and
the cooling system is properly filled. If the
system isn’t properly filled, piston damage will
occur.

Liquid Cooling 

System

The liquid cooling system consists of heat exchangers,

water pump, and thermostat. The system should be

inspected for leaks or damage whenever an overheating

problem is experienced.

FILLING COOLING SYSTEM

3-14

Cooling System

Schematics

The following schematics are representative of the dif-

ferent styles of 2-stroke cooling systems in the 2002

Arctic Cat snowmobiles. Some components may vary

from model to model; therefore, the technician should

use discretion and sound judgment when servicing a

particular cooling system.

0734-451

0735-951

KEY

1. Coolant Reservoir
2. Spacer
3. Guard
4. Vent Hose
5. Washer
6. Lock Washer
7. Cap Screw
8. Rivet
9. Lock Washer

10. Cap Screw
11. Cap
12. Lock Nut
13. Clamp
14. Hose
15. Hose
16. Heat Exchanger
17. Heat Exchanger
18. Clamp
19. Hose
20. Hose
21. Decal
22. Wire Form Bracket
23. Heat Exchanger
24. Washer
25. Cable Tie
26. Rivet
27. Hose
28. Clamp
29. Cable Tie