Snowmobile Arctic Cat (2004 year). Manual - part 18

2-59

19. Remove the six screws securing the water pump

cover to the crankcase and remove the cover.
Account for the O-ring gasket and the alignment
pins.

20. Remove the cap screw securing the water pump

impeller; then slide the impeller free of the shaft.

21. Remove either lower union cap screw securing the

lower check valve assembly; then remove the two
screws securing the oil-injection pump to the
crankcase. Remove the pump, retainer, and O-ring.

FC031

22. Turn the engine upside down on support blocks

and remove the water temperature sensor switch.

FC033

23. With its bottom side up on two support blocks,

remove the cap screws securing the crankcase
halves.

NOTE: The end bearings are not pressed onto

the crankshaft.

24. Separate the crankcase halves by installing two

crankcase cap screws in opposite corners leaving
the heads approximately 6 mm (1/4 in.) out. Using
a plastic-tipped hammer, tap on each cap screw
head until the case halves separate. Remove the
cap screws.

FC034

25. Lift the bottom half of the crankcase off the top

half.

26. Lift the crankshaft free from the top half of the

crankcase and slide the crankshaft oil seals off the
crankshaft. Account for the C-ring. Remove the
bearing retaining pins and account for the
crankcase dowel pins.

NOTE: On the 600/700 cc, account for the rubber

spacer on the PTO-end of the crankshaft.

27. Remove the oil-injection pump/water pump

driveshaft from the lower crankcase half. Account
for the thrust washer on the outer end of the shaft.

FC035

NOTE: Do not replace the inner seals unless the

water pump shows signs of leaking coolant out of
the small bleed hole in the bottom half of the
crankcase. If a water pump seal is to be replaced,
use the Water Pump Bearing and Seal Kit (p/n
0644-084).

28. Place the crankcase on the bench with the water

pump side down. Using the long seal driver, drive
the mechanical water pump seal from the
crankcase.

! CAUTION

DO NOT drive any tool between halves to
separate the crankcase. Damage to the sealing
surfaces will result.

! CAUTION

Care must be taken to not allow the connecting
rods to drop onto the sealing surface of the
bottom case half.

2-60

FC036

29. Using a pair of snap ring pliers, remove the snap

ring securing the inner seal in the crankcase.

30. Using the hooked end of the tool, pull the inner

seal free of the crankcase.

AN326D

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

from the backside of the water pump impeller.

AN327D

Servicing Top-Side

Components

(500/600/700 cc “

“Laydown”

”

Engine Models)

Many services can be performed without removing the
engine. Some components may vary from model to
model. The technician should use discretion and sound
judgment when removing and installing components.

NOTE: Some photographs used in this sub-sec-

tion are used for clarity purposes only and are not
designed to depict actual conditions.

REMOVING TOP-SIDE COMPONENTS

To access top-side components, use the following
procedure:

1. Remove the expansion chamber and resonator.

2. Using the drain hose, drain the engine coolant out

the exhaust outlet in the belly pan.

3. Remove the four torx-head screws and the three

cap nuts securing the side-plate brace to the
chassis; then remove the exhaust manifold.

FC049

4. Remove the coolant hose and breather hose

connected to the cylinder head.

5. Remove the twelve 10 mm cap screws and two 8

mm cap screws securing the cylinder head; then
remove the cylinder head. Account for the O-
rings.

FC060

2-61

6. Remove the APV's from the cylinder.

FC056

7. Disconnect the two coolant hoses located beneath

the exhaust ports on the cylinders.

FC050A

NOTE: At this point, remove all loose hardware

to avoid any falling down into the chassis.

8. Remove the residual coolant from the cylinder/

crankcase water jacket.

NOTE: After draining the coolant, approximately

1.75 fluid oz of coolant will remain on both the
MAG-side and PTO-side. To remove the residual
coolant, use the following procedure.

a. Using Vacuum Pump (p/n 0644-131), or a suitable

substitute, rig the pump to 3/16 in. outside
diameter hose.

FC058

b. In turn on each fitting of the crankcase, run the

vacuum pump to purge the cylinder/crankcase
water jacket of the residual coolant.

FC057

NOTE: It is critical that all residual coolant is

totally removed from the cylinder/crankcase.

9. On the left-side of the engine, loosen the side

brace and move it up out of the way.

FC059

NOTE: It may be advisable to secure the brace

up out of the way with a strap.

NOTE: At this point, remove all loose hardware

to avoid any falling down into the chassis.

10. Remove the nuts (500 cc) or the cap screws and

nuts (600/700 cc) 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.

2-62

FC061

NOTE: If servicing the MAG-side only, the PTO-

side cylinder must be removed.

FC062

NOTE: When removing the MAG-side piston, the

piston must be at top-dead-center.

FC064

NOTE: For servicing procedures, see Cleaning

and Inspecting Engine and Measuring Critical
Components in this section.

INSTALLING TOP-SIDE COMPONENTS

NOTE: When installing the pistons, make sure to

install the MAG-side piston-pin circlips first; then
install the pistons and secure with the piston pin
and PTO-side piston-pin circlips.

1. Place the cylinders into position on the crankcase

accounting for gasket(s) and any alignment pins.

FC061

FC062

2. Secure the cylinders with existing hardware

tightened to 4-6.1 kg-m (29.4-44.1 ft-lb) using the
appropriate pattern shown.

0738-206

0738-220

3. On the left-side of the engine, place the side brace

into position and secure it with existing hardware.

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