Snowmobile Arctic Cat (2004 year). Manual - part 24

2-83

2

MD0233

MD0234

0738-291

15. Install the spark plugs; then tighten to 2.5-2.8 kg-m

(18-20 ft-lb).

MD0235

16. Position the seal retainer plate on the PTO-side;

then install the four cap screws. Tighten the cap
screws to 0.8-1.2 kg-m (6-9 ft-lb).

MD0253

MD0292

17.  Install the stator plate and secure with four Allen-

head cap screws. Install the stator plate so the
ignition wire cut-out is in the upper left position.
Lightly coat the four Allen-head cap screws with
red Loctite #271; then tighten them to 0.8-1.2 kg-
m (6-9 ft-lb).

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MD0255

18. Place the stator wiring through the hole in the

crankcase; then install the stator. Lightly coat the
three Allen-head cap screws with red Loctite
#271; then tighten them to 0.8-1.2 kg-m (6-9 ft-
lb).

MD0076

MD0274

19. Place the ignition timing sensor wiring through the

hole in the crankcase; then position the ignition
timing sensor and install two Phillips-head cap
screws (coated with red Loctite #271). Tighten the
cap screws securely.

MD0074

MD0273

20. Install the rubber insulator grommet into the

crankcase.

MD0262

21. Install the key; then install the flywheel and cap

screw. Tighten the cap screw only until snug.

„

NOTE: Do not tighten the flywheel cap screw at

this point. 

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2

MD0264

22. Place the fan and starter pulley into position on the

flywheel. Using Spanner Wrench (p/n 0144-007)
to hold the starter cup, tighten the three cap screws
(coated with green Loctite #609 and Loctite
Primer #7471) to 1.8-2.8 kg-m (13-20 ft-lb).

MD0280

23. Using Spanner Wrench (p/n 0144-007) to hold the

starter cup, tighten the flywheel cap screw (threads
coated with red Loctite #271) to 8.0-8.7 kg-m (58-
63 ft-lb).

MD0278

24. Using the six cap screws and the special washers,

install the rear (intake-side) shroud. Tighten the
cap screws to 0.4-0.7 kg-m (3-5 ft-lb).

MD0277

25. Using the five 6 mm cap screws and the special

washers, install the front (exhaust-side) cooling
shroud and tighten to 0.4-0.7 kg-m (3-5 ft-lb).
Install the rubber spark plug grommets; then
tighten the cap screws securely.

MD0269

! CAUTION

Do not use green Loctite #609 without also using
Loctite Primer #7471.

! CAUTION

When installing the fan, make sure that the
locating pins on the flywheel align with the
indentations in the fan.

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MD0268

26. Install the main fan shroud and recoil starter

assembly. Tighten the eight cap screws to 1.1 kg-m
(8 ft-lb).

                                                              MD0279

MD0291

27. Lubricate the oil-injection pump driveshaft; then

while rotating the driveshaft, install it and the
thrust washer into the lower crankcase half.

„

NOTE: Make sure the thrust washer is installed

on the oil injection pump driveshaft when it is
installed.

MD0252

28. Install the oil injection pump driveshaft retainer

and O-ring.

„

NOTE: Make sure the O-ring is installed on the

oil injection pump driveshaft retainer when it is
installed.

MD0273

29. Install the oil injection pump aligning the slot on

the oil pump with the flat on the end of the oil
injection pump driveshaft. Tighten the Allen-head
cap screws to 0.8-1.2 kg-m (6-9 ft-lb).

MD0294