Snowmobile Arctic Cat (2004 year). Manual - part 25

2-87

MD0090

30. Install the intake flange assembly using washers,

lock washers, and nuts. Note the placement of
gaskets, heat deflector, gaskets, insulators, and
flanges. Tighten the nuts (threads coated with red
Loctite #271) to 1.8-2.2 kg-m (13-16 ft-lb).

31. Install the exhaust manifold and gaskets using lock

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

Assembling Engine

(600 cc Standard Engine 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 Synthetic APV 2-Cycle Oil.

1. Apply a thin coat of grease to the inner seal lips of

the water pump seal.

2. Using the seal driver, position the inner water

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

NOTE: Grease must be applied to the lips of the

inner seal before installation.

AN070D

NOTE: The seal must be installed with its spring

side towards the crankshaft.

3. 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.

AN072D

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

of the oil-injection pump/water 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.

AN074

6. Position the upper crankcase half upside-down on

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

! 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.

2-88

AN330D

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.

AN331D

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 dowel pin.

10. Position the two center seal rings with their end

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

AN083D

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 Arctic Cat 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 crankcase cap screws (coated with blue

Loctite #242) securing the crankcase halves.

14. Tighten the 8 mm cap screws to 1.8-2.8 kg-m (13-

20 ft-lb) and the 10 mm cap screws to 4-6 kg-m
(29-43.5 ft-lb) using the pattern shown.

735-670A

! CAUTION

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

2-89

NOTE: Secure the connecting rods with rubber

bands on the cylinder studs.

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

retainer.

AN088D

16. Install the O-ring and the oil-injection pump

making sure the pump shaft slot and pump driven
gear shaft align. Secure with two screws (coated
with blue Loctite #242) and washers. Tighten the
two screws to 0.7 kg-m (5 ft-lb).

17. Position the rubber seal retainer and seal into the

back side of the water pump impeller.

18. Using both thumbs, press the seal into position

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

20. Apply high-temperature sealant to the crankcase/

water pump cover seam; then install the dowel
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 to 1.1 kg-m (8 ft-lb).

22. Secure the intake flanges, reed valve assemblies,

and gaskets with cap screws. Tighten to 0.8-
1.2 kg-m (6-9 ft-lb).

23. Place the cylinder base gasket into position on the

crankcase.

24. 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

25. 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.

! CAUTION

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

! 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.

2-90

AN100

AQ059

26. Place each piston over the connecting rod so the

arrow (or indicator dot) on each piston will point
toward the exhaust port; then secure with an oiled
piston pin.

NOTE: The arrow (or indicator dot) is found

either up inside the piston or on the dome top.

AN101

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

either up or down.

B324D

28. 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.

29. 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.

AN105D

30. Secure each cylinder by installing the four nuts,

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

NOTE: The cylinders will be tightened at the

same time as the exhaust manifold is installed to
assure proper cylinder to exhaust manifold align-
ment.

31. Install the oil-injection hoses and secure with the

clamps; then place the lower check-valve
assembly into position and secure with the gaskets
and union cap screw. Tighten securely.

! CAUTION

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

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