Snowmobile Arctic Cat (2004 year). Manual - part 21

2-71

AB092

6. Install the crankcase cap screws making sure the

cap screws are in the corresponding-sized holes.
Tighten in three steps the 8 mm cap screws to 1.8-
2.8 kg-m (13-20 ft-lb) and the 6 mm cap screws to
0.8-1.2 kg-m (6-9 ft-lb) using the pattern shown.

0726-412

NOTE: Secure the connecting rods with rubber

bands on the cylinder studs.

B160

7. Install the piston rings on each piston so the letter

on the top (inclined surface) of each ring faces the
dome of the piston.

726-306A

AC088

8. Apply oil to the connecting-rod small-end

bearings; then install the small-end bearings into
the connecting rods.

NOTE: Apply oil to the piston pin before install-

ing.

9. Place each piston over the connecting rod so the

arrow on the piston dome points toward the
exhaust port; then secure with a piston pin.

NOTE: The arrow is found either up inside the

piston or on the dome top.

10. Install the new circlips so the open end is directed

either down or up.

B324D

! CAUTION

Incorrect installation of the piston rings will
result in engine damage.

2-72

11. Install the cylinder base gaskets onto the crankcase

making sure each gasket aligns with crankcase
transfer passages.

12. Rotate each piston ring until the ring ends are

properly positioned on each side of the ring
keeper; then apply oil to the piston assemblies and
cylinder bores. Remove the rubber bands from the
connecting rods.

726-306B

NOTE: Apply a generous amount of oil to the

surfaces of the pistons, rings, and cylinder bores.

NOTE: Inspect the cylinder-base gasket to

ensure proper positioning.

13. For each piston, place a piston holder (or suitable

substitute) beneath the piston skirt and square the
piston in respect to the crankcase; then using a ring
compressor or the fingers, compress the rings and
slide the cylinder over the piston. Remove the
piston holder and seat the cylinder firmly onto the
crankcase.

A828

14. Place each cylinder head with dowel pins and

gasket into position and install the eight nuts. DO
NOT TIGHTEN AT THIS TIME.

15. Temporarily install the exhaust manifold and

secure with four nuts and lock washers to square
the cylinders. Tighten the manifold nuts to 1.8-
2.2 kg-m (13-16 ft-lb).

16. With the exhaust manifold in place, tighten the

cylinder head nuts in three steps to 1.8-2.8 kg-m
(13-20 ft-lb) using the pattern shown.

0725-318

17. In order, install the gear, shim, gasket, retainer,

gasket, and oil-injection pump. Secure with two
screws, lock washers, and washers. Tighten to
0.7 kg-m (5 ft-lb).

AB078

NOTE: If removed, secure the ignition coil to the

fan case.

18. Align the reference marks made during

disassembly; then secure the stator plate with two
Allen-head cap screws (coated with red Loctite
#271), lock washers, and washers.

NOTE: Before installing the flywheel, wipe the

crankshaft and flywheel taper clean using a clean
cloth.

19. Install the key in the crankshaft and slide the

flywheel onto the crankshaft making sure the
keyways match.

! CAUTION

Make sure circlips are firmly seated and the open
end is directed either down or up before
continuing with assembly.

! CAUTION

Be sure the gear is properly aligned with the slot
of the oil-injection pump shaft. The injection
pump will be damaged if these two components
are not aligned.

2-73

20. Place the fan case into position and secure with

four nuts. Tighten the nuts to 1.8-2.2 kg-m (13-
16 ft-lb).

A814

21. On the 370 cc, apply a thin coat of High-Temp

Sealant (p/n 0636-069) to both sides of the intake
gaskets; then in order, install a gasket (one on each
port), shroud, gasket (one on each port), insulator
(one on each port), gasket (one on each port), and
intake manifold with flange. Secure with nuts
(threads coated with red Loctite #271). Tighten
nuts in three steps to 0.8-1.2 kg-m (6-9 ft-lb).

22. On the 440 cc, apply a thin coat of High-Temp

Sealant (p/n 0636-069) to both sides of the intake
gaskets and the front side of each adapter plate;
then in order, install a gasket (one on each port),
shroud, gasket (one on each port), and adapter
plate (one on each port). Secure with screws
coated with red Loctite #271.

23. Place the intake flanges into position and secure

with nuts (threads coated with red Loctite #271),
lock washers, and washers. Tighten to 1.8-2.2 kg-
m (13-16 ft-lb).

24. Remove the exhaust manifold.

25. Install spark plugs and tighten to 2.5-2.8 kg-m

(18-20 ft-lb).

26. Attach the oil-injection hoses to their fittings.

Secure with clamps.

27. Test the engine for air leaks (see Section 3).

28. Temporarily secure the starter pulley on the

flywheel with three cap screws. Install the
flywheel washer, lock washer, and nut. Apply red
Loctite #271 to the crankshaft threads before
installing the flywheel nut. Using a spanner
wrench to secure the crankshaft, tighten the
flywheel nut to 7-9 kg-m (50.5-65 ft-lb).

AB024

29. Remove the starter pulley. Position the fan belt

drive pulley into the belt. Align the starter pulley
holes with those in the belt pulley. Start one of the
cap screws into the flywheel; then rotate the belt
pulley and starter pulley in a counterclockwise
direction.

30. When the pulley pivots on the cap screw, rock the

pulleys backward or forward until the remaining
cap screw holes align. Install the remaining two
cap screws and tighten evenly to 0.8-1.2 kg-m (6-
9 ft-lb).

NOTE: Apply red Loctite #271 to the threads of

the cap screws before installing.

AB040

31. Place an exhaust manifold gasket on each exhaust

port making sure the metal side of the gasket faces
the cylinder. Slide the exhaust-side cooling shroud
onto the exhaust port studs; then place the upper
cooling shroud into position and secure the
shrouds with 14 cap screws noting the location of
the longer cap screws from disassembling. Tighten
to 0.4-0.7 kg-m (3-5 ft-lb). Connect the spark-plug
caps.

2-74

AB012

32. Apply a thin coat of High-Temp Sealant (p/n

0636-069) to the exhaust-manifold gasket; then
place a gasket on each exhaust port making sure
the metal side of each gasket faces away from the
cylinder. Install the exhaust manifold, lock
washers, and nuts and tighten to 1.8-2.2 kg-m (13-
16 ft-lb).

Assembling Engine

(550 cc Model)

NOTE: The use of new gaskets and seals is rec-

ommended when assembling the engine.

NOTE: When the use of a lubricant is indicated,

use Arctic Cat 50:1 Injection Oil.

1. Using the water pump bearing and seal driver,

position the inner water pump shaft seal onto the
seal driver and gently tap the seal down into
position.

NOTE: Apply grease to the lips of the inner seal

before installation.

AN070

NOTE: The seal must be installed with its spring

side towards the crankshaft.

2. Using a small screwdriver, apply a thin coat of

grease to the inner seal lips.

3. Using a pair of snap ring pliers, install the snap

ring securing the inner seal in the crankcase.

4. Using the seal driver, carefully install the outer

water pump seal. Gently tap the seal down into
position until it seats itself against its flange.

AN072

5. Apply a thin coat of grease to the sealing surface

of the oil-injection pump driveshaft; then place the
Oil Seal Installation Tool (p/n 0644-219) at the
end of the shaft. Twist the driveshaft clockwise as
it is pushed through the oil and water pump seals;
then remove the tool. Position the shim on the oil-
injection pump end of the driveshaft.

6. Position the upper crankcase half upside-down on

two wooden blocks; then install the C-ring, the
four bearing retaining pins, and two crankcase
dowel pins.

7. Place the PTO-side crankshaft bearing into

position making sure the bearing retaining pin hole
is positioned inward.

NOTE: The bearing retaining pin hole is the hole

that doesn't go entirely through the bearing case.

AN078

! CAUTION

Be very careful not to damage the seals when
installing the oil pump driveshaft. Be certain to
use the seal installation tool. Twist the driveshaft
clockwise as it enters the seal area and while it is
being pushed through the seals.

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