Snowmobile Arctic Cat (2004 year). Manual - part 17

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2

AN326D

32. Using the hooked end of the tool, pry the seal ring

from the backside of the water pump impeller.

AN327D

Disassembling Engine 

(500/600/700 cc 

“Laydown”

Engine Models)

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.

FC014

FC015

2. Install Flywheel Pulley Insert (p/n 0644-179) onto

the end of the crankshaft.

FC016

3. Using 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.

FC017

! CAUTION

To prevent damage to the crankshaft, the puller
must bottom on the insert 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.

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„

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 ignition timing sensor.

FC022

5. Remove the Allen-head cap screws securing the

stator to the stator plate. Move the stator to the
side to access the Phillips-head cap screw securing
the stator lead wire; then remove the cap screw.

FC018

6. On the 600/700 cc, remove the Allen-head cap

screws securing the magneto case to the
crankcase. Account for four alignment pins.

„

NOTE: Note the different-sized cap screws for

assembling purposes.

FC019

FC020

7. Remove the stator plate from the engine.

FC021

FC065

„

 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.

8. Remove the cap screws securing the APV

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

„

 NOTE: Note that the APV exhaust valves and

gaskets are directional for assembling purposes.

„

 NOTE: The following photographs are for clarity

purposes only. The models may vary slightly.

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2

FC023

FC024

FC025

9. Remove the spark plugs.

10. Remove the cap screws with O-rings securing the

cylinder head; then separate from the cylinders.
Account for the O-rings.

11. Remove the oil-injection hose from each cylinder

and the crankcase nozzle.

FC026

„

NOTE: When removing the cylinders, place the

engine on its intake flanges on a drain tray to allow
residual coolant to drain from the cylinder/crank-
case water jacket.

12. On the 500 cc, remove the eight nuts securing the

cylinders to the crankcase; then using a rubber
hammer, gently tap the cylinders and remove from
the crankcase by lifting them straight up off their
studs. Account for gasket(s) and any alignment
pins.

13. On the 600/700 cc, remove the four nuts and four

bolts securing the cylinders to the crankcase; then
using a rubber hammer, gently tap the cylinders
and remove from the crankcase by lifting them
straight up off their studs. Account for gasket(s)
and any alignment pins.

FC067

 ! CAUTION

When removing a cylinder, be sure to support
the piston to prevent damage to the crankcase
and piston.

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FC027

14. Remove the PTO-side piston-pin circlip from the

PTO-side piston; then remove the MAG-side
piston-pin circlip from the MAG-side piston.

FC028

15. Using Piston Pin Puller (p/n 0644-328), remove

the piston pins from both pistons.

„

NOTE: For proper assembly, keep all MAG-side

components and all PTO-side components sepa-
rated. Assemble them on their proper sides.

FC029

16. Lift the pistons clear of the connecting rods and

remove the small-end connecting-rod bearings
(account for two washers); then remove the piston
rings. Keep each piston with its rings; keep each
piston pin and bearing together as a set.

AN317D

„

NOTE: Place rubber bands over the connecting

rods and around the cylinder studs. This will pre-
vent the connecting rods from damaging the
crankcase.

17. Remove the intake flanges and reed valve

assemblies.

FC030

18. Remove the three cap screws securing the

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

FC032

! CAUTION

DO NOT use any type of punch to drive the
piston pin free of the piston; damage may result.
Use a piston-pin puller only.