Snowmobile Arctic Cat (2004 year). Manual - part 14

2-43

2

MD0094

„

NOTE: The open sides of the piston pin bearing

washers face inward.

MD0251

MD0208

„

NOTE: If the existing rings will not be replaced

with new rings, note the location and top side of
each ring for proper installation. When replacing
with new rings, replace as a complete set only.
When replacing rings note notches in ring ends
which correspond with locating pins in ring
grooves on intake side of the piston. This prevents
the rings from turning on the piston when assem-
bled.

MD0272

MD0271

19. Remove the two Allen-head cap screws securing

the oil-injection pump; then remove the pump.
Account for an O-ring.

MD0090

MD0092

O-Ring

2-44

20. Remove the oil-injection pump driveshaft retainer.

Account for an O-ring.

MD0100

21. Remove the oil-injection pump driveshaft.

Account for a thrust washer.

MD0101

22. Place the crankcase (with its bottom side up) on

two blocks of wood. Remove the 12 cap screws
securing the crankcase halves. Note the position of
the different-sized cap screws.

23. Separate the crankcase halves by installing two of

the cap screws in opposite corners leaving the
heads approximately 6 mm (1/4 in.) out. Using a
plastic mallet, tap on each cap screw until the
crankcase halves separate. Account for four dowel
pins.

MD0283

MD0204

24. Remove the two cap screws; then remove the

crankshaft assembly from the upper crankcase half
making sure to hold both ends of the crankshaft to
keep the bearings and seals from falling off.
Account for bearings and a C-ring.

MD0246

Disassembling Engine

(600 cc Standard Engine Model)

1. Using the spanner wrench to secure the flywheel,

remove the flywheel nut, lock washer, and flat
washer; then remove the three starter pulley cap
screws and remove the pulley.

O-Ring

! CAUTION

To prevent damage to the crankshaft, crankshaft
bearings, or seals, be sure to always lift the
crankshaft from both ends.

2-45

2

AN015

AN407D

2. Install the Crankshaft Protector Cap (p/n 0644-

234) onto the end of the crankshaft.

AN018

AN408D

„

NOTE: A suitable substitute protective cap can

be made by welding a 3 mm (1/8 in.) plate on one
side of a spare flywheel nut.

3. Using the Flywheel Puller/Spanner Wrench (p/n

0144-310) or suitable substitute, remove the
flywheel from the crankshaft by tightening the
puller bolt, striking the head of the puller bolt with
a hammer, and tightening again. Repeat this
procedure until the flywheel is free. Account for
the key.

AR105

AN410D

„

NOTE: To ensure the cleanliness of the flywheel

magnets, place the flywheel (with the magnets fac-
ing upward) on a clean bench.

4. Remove the Allen-head cap screws securing the

stator to the stator plate.

! CAUTION

To prevent damage to the crankshaft, the puller
must bottom on the cap and not on the
crankshaft. Also, do not thread puller bolts more
than 12.7 mm (1/2 in.) into the flywheel. Damage
to the coils may result.

2-46

AP132

5. Remove the Allen-head cap screws securing the

stator plate.

AR106

6. Remove the stator plate from the engine.

AN414D

„

NOTE: The stator plate screws had Loctite

applied to the threads during assembly. Using an
impact driver, apply a sharp blow to the head of
each screw to break the Loctite loose before
removal.

7. Remove the ignition timing sensor.

AR107

AN415D

8. Remove the three cap screws securing the

thermostat cap; then remove the cap, gasket, and
thermostat.

9. Remove the nuts securing the APV covers to the

cylinders; then slide the covers back to expose the
valves.

AP134

10. Remove the cap screws securing the valves to the

cylinders; then remove the APV assemblies and
set them aside.

„

NOTE: The following two photographs are for

clarity purposes only. This mo del may var y
slightly.