Snowmobile Arctic Cat (2004 year). Manual - part 26

2-91

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

cylinder making sure they are correctly positioned
in the grooves.

AN110D

33. Place new O-rings onto each of the head cap

screws. Place four of these cap screws into the
cylinder head. Thread the spark plugs 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 cap screws
being very careful not to move the cylinder head.
ONLY FINGER-TIGHTEN AT THIS TIME.

34. 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.

0733-524

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

36. Secure the cap with three cap screws tightened to

0.7-1 kg-m (5-7 ft-lb).

37. Apply a thin coat of high-temperature silicone

sealant to each exhaust port; then install the
exhaust gaskets with the metal sides facing out.

38. 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).

39. Tighten the spark plugs to 2.5-2.8 kg-m (18-

20 ft-lb); then secure the cylinders by tightening
the cylinder base nuts to 4-6 kg-m (29-43.5 ft-lb)
in three steps using the pattern shown. Pressure
test the engine (see Section 3).

725-318B

40. Secure the ignition timing sensor with screws

coated with blue Loctite #242.

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

crankcase; then apply blue Loctite #242 to the four
screws and tighten to 1.1 kg-m (8 ft-lb).

42. Secure the stator to the stator plate with the Allen-

head cap screws coated with blue Loctite #242 and
tightened to 1.1 kg-m (8 ft-lb); then install the
stator wires with a grommet into the crankcase.

AN413D

43. Install the key in the crankshaft.

44. Slide the flywheel onto the crankshaft making sure

the keyways match.

NOTE: Before installing the flywheel, be sure to

wipe the crankshaft and flywheel tapers clean
using a clean towel.

45. Apply red Loctite #271 to the threads of the

flywheel nut; then finger-tighten with a large flat
washer, lock washer, and the nut. DO NOT
TIGHTEN AT THIS TIME.

2-92

AN120D

46. Place the starter pulley in position; then loosely

secure the starter pulley with three cap screws
(coated with red Loctite #271) and lock washers.
Secure the pulley while using the spanner wrench
and tighten the three cap screws evenly to 0.7-
1 kg-m (5-7 ft-lb).

AN121D

47. Using the spanner wrench, tighten the flywheel

nut to 7-9 kg-m (50.5-65 ft-lb).

48. Place the engine mounting brackets into position

on the crankcase and secure with the cap screws.
Tighten to 2.4 kg-m (17 ft-lb).

49. Slide the APV assemblies into position in the

cylinders; then slide the valve keepers into
position and secure with cap screws (coated with
blue Loctite #242). Tighten to 1.1 kg-m (8 ft-lb).

NOTE: The following two photographs are for

clarity purposes only. This model may var y
slightly.

AP154

AP153

50. Slide the valve covers into position and secure

with existing nuts. Tighten to 0.9-1.3 kg-m (6.5-
9.5 ft-lb).

Assembling Engine

(800/900 cc Models)

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.

NOTE: Do steps 1-5 only if the water pump has

been disassembled.

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.

2-93

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. Set the top half of the crankcase upside down on

the work bench with a 4 in. block of wood under
each end.

7. Install the C-ring in the upper crankcase half.

Install the four bearing retaining pins in the
crankcase bearing areas.

AJ095

8. Using Arctic Cat 50:1 Injection Oil, lubricate the

crankshaft bearings and slide them onto the
crankshaft.

AP150B

9. 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 crankcase.

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

seal.

10. Apply Arctic Cat 50:1 Injection Oil to all of the

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

NOTE: Check all bearings by trying to rotate

them to make sure they are being held in position
by the retaining pin. Each bearing must drop onto
the retaining pin.

! 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.

! CAUTION

The retaining pin holes on both bearings must be
positioned toward the center of the crankshaft.

! CAUTION

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

2-94

AJ097

11. Rotate the crankshaft center seal rings so the end

gaps of the two large rings are 180° apart, one end
gap being positioned downward and the other
upward; then seat the crankshaft.

AP151

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

0636-069) to the lower crankcase sealing surface.

AQ127

13. Assemble the crankcase halves.

14. Install the crankcase cap screws securing the

crankcase halves making sure the proper-sized cap
screws (on 900 cc models) are in the proper holes.
Tighten in three steps the 10 mm cap screws to
4.8-5.4 kg-m (35-39 ft-lb) on the 800 cc models,
the 10 mm cap screws to 2.4-4.8 kg-m (30-35 ft-
lb) on the 900 cc models, and the 6 mm cap screws
to 0.8-1.2 kg-m (6-9 ft-lb) using the pattern
shown.

AJ101

736-280A

NOTE: On 800 cc models after assembling the

crankcase halves, install the magneto case .
Tighten to 1.8-2.2 kg-m (13-16 ft-lb).

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

retainer.

AN088D

! CAUTION

Check to make sure the two crankcase half
dowel pins are in position at opposite corners of
the lower case half.

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