Snowmobile Arctic Cat (2004 year). Manual - part 22

2-75

8. Lubricate the inner lips of the crankshaft oil seals

with grease; then slide the seals onto the
crankshaft making sure the spring side of each seal
faces the center of the crankshaft.

NOTE: There is a MAG-side seal and a PTO-side

seal.

9. Apply oil to the crankshaft bearings; then install

the crankshaft into the upper crankcase half. Be
sure the alignment hole in each bearing is
positioned over its respective dowel pin in the
crankcase; then seat the crankshaft.

NOTE: To check the bearing for proper position,

place the point of a sharp tool into the dimple
found in the bearing race. Strike the tool with the
palm of the hand in either direction. If the bearing
moves, it isn't positioned correctly and must be
rotated until it drops onto the retaining pin.

10. Position the two center seal rings with their end

gaps 180° apart (up on one and down on the
other).

AN083

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

0636-069) to the entire bottom half of the
crankcase sealing surface.

AQ127

NOTE: Use only High-Temp Sealant (p/n 0636-

069) to seal the crankcase halves.

12. Assemble the crankcase halves making sure that

the crankshaft gear and oil-injection pump
driveshaft gears mesh. Rotate the crankshaft one
full turn to align the crankshaft gear and pump
driveshaft.

13. Install the 14 crankcase cap screws securing the

crankcase halves making sure the cap screws are
in the proper-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.

0728-137

NOTE: Secure the connecting rods with rubber

bands on the cylinder studs.

14. Install the oil-injection pump retainer O-ring and

retainer.

AN088

15. Install the O-ring/gasket and the oil-injection

pump making sure the pump shaft and pump align.
Secure with two screws and washers. Tighten the
two screws to 0.7 kg-m (5 ft-lb).

16. Position the rubber seal retainer and seal into the

back side of the water pump impeller.

! CAUTION

If the bearings are not properly seated during
assembly, the crankcase halves will not seal
tightly and engine damage will result.

! CAUTION

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

2-76

NOTE: The lined or marked side of the porcelain

seal must face the rubber retainer.

17. Using both thumbs, press the seal into position

making sure its marked side is positioned towards
the rubber seal cup.

18. Apply a thin coat of grease to the seal outer

surface.

19. Place the impeller into position and secure with a

cap screw and washer. Be sure the rubber side of
the washer is directed toward the impeller. Apply
blue Loctite #242 to the threads of the cap screw
and tighten to 0.8-1.2 kg-m (6-9 ft-lb).

AN094

20. Apply sealant to the crankcase seam; then install

the alignment pins into the crankcase.

AN095

NOTE: Sealant is only required on the crankcase

seam.

21. Position the O-ring into the water pump cover;

then install the cover. Secure with five screws.
Tighten securely.

22. Place the cylinder base gaskets into position on the

crankcase.

NOTE: Be sure to spray a thin coat of Copper

Coat Gasket Sealant (p/n 0636-092) onto the gas-
ket if it is being reused.

23. 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

24. Apply oil to the connecting-rod small end

bearings; then install the small-end bearings.
Install a washer on each side of the connecting
rod.

25. Place each piston over the connecting rod so the

arrow on each piston will point toward the exhaust
port; then secure with an oiled piston pin.

NOTE: The arrow is found either up inside the

piston or on the dome top.

AN101

26. Install the circlips so the open end is directed

either up or down.

! CAUTION

The rubber side of the washer (which secures
the impeller) must be positioned toward the
impeller. If installed incorrectly, a coolant leak
will result.

! CAUTION

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

2-77

AN102

27. Rotate each piston ring until the ring ends are

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

NOTE: If the intake flanges were removed from

the cylinders, install them prior to installing the
cylinders. Tighten the nuts to 1.8-2.2 kg-m (13-16
ft-lb).

28. In turn on each cylinder, 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.

NOTE: The cylinders should slide on easily. DO

NOT force the cylinders on.

AN105

29. Secure each cylinder by installing the four nuts,

washers, and lock washers. DO NOT TIGHTEN
AT THIS TIME.

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

0636-069) to each exhaust port; then install the
two exhaust gaskets with the metal sides facing
out.

AN106

31. Install the exhaust manifold and secure with four

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

AN107

32. With the exhaust manifold tightened, secure the

cylinders by tightening the cylinder base nuts to 4-
6 kg-m (29-43.5 ft-lb). Tighten the nuts in three
steps using the pattern shown.

725-318B

33. Install the two oil-injection hoses and secure with

the clamps.

! CAUTION

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

2-78

AN111

34. Install the two cylinder O-rings on the top of each

cylinder making sure they are correctly positioned
in the grooves.

AN110

35. Place new O-rings onto each of the twelve head

cap screws. Place four of these cap screws into one
of the cylinder heads. Thread the spark plug in part
way; then while holding the head above the
cylinder, carefully start all four cap screws while
observing the cylinder O-rings to make sure they
remain in position. Slowly place the head into
position on top of the O-rings. Start the remaining
two cap screws being very careful not to move the
cylinder head. Repeat the same procedure on the
remaining head. ONLY FINGER-TIGHTEN AT
THIS TIME.

36. Apply a thin coat of sealant to the two thermostat

housing gaskets. Place the gaskets and housing
into position and secure with four cap screws and
washers. Tighten the four cap screws in a
crisscross pattern to 0.7-1 kg-m (5-7 ft-lb).

NOTE: The thermostat housing cap screws must

be tightened before tightening the cap screws
securing the head. This will allow the gasket sur-
faces of the head to align with the housing and
prevent any coolant leakage.

AN113

37. Tighten the cap screws securing the head in three

steps to 1.8-2.8 kg-m (13-20 ft-lb) using the
pattern shown. Pressure test the engine (see
Section 3).

0728-138

38. Place the thermostat, gasket, and cap into position.

Secure the cap with three cap screws tightened to
0.7-1 kg-m (5-7 ft-lb).

39. Place the PTO-end plate into position on the

crankcase; then apply blue Loctite #242 to the
screws and tighten securely.

40. Place the stator plate into position over the

crankshaft end.

41. Install the lock washers and washers on the Allen-

head cap screws; then apply blue Loctite #242 to
the threads of the stator plate Allen-head cap
screws and install. DO NOT TIGHTEN AT THIS
TIME.

42. Align the stator plate with the alignment mark

made during disassembly. Tighten both stator plate
screws securely.

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