Snowmobile Arctic Cat (2004 year). Manual - part 28

2-99

2

49. Slide the APV covers into position and secure with

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

50. Position the coolant supply hose on the water

pump and secure with a clamp.

Assembling Engine 

    

(500/600/700 cc 

“Laydown”

Engine 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.

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.

FC035

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.

2-100

FC070A

8. Lubricate the inner lips of the crankshaft oil seals

with grease; then slide the seals (and rubber spacer
on the 600/700 cc) 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.

FC041A

„

 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.

FC071

„

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 three 6 mm cap screws to 0.8-1.2 kg-m

(6-9 ft-lb) and the ten 10 mm cap screws to 4.2-4.8
kg-m (30-35 ft-lb) using the appropriate pattern
shown.

0738-201

! CAUTION

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

500 cc

2-101

2

738-202A

„

NOTE: Secure the connecting rods with rubber

bands on the cylinder studs.

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

retainer.

FC082

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.

FC133A

„

NOTE: It is important to not get sealant into the

breather hole in the crankcase. If sealant gets into
the hole, carefully remove before proceeding.

FC072B

FC072A

! 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.

600/700 cc

! 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.

2-102

„

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 six screws.
Tighten to 1.1 kg-m (8 ft-lb).

FC134

22. Noting the alignment dots, install the thermostat

housing with thermostat. Tighten the existing
hardware securely.

FC078A

FC073

23. Secure the intake flanges, reed valve assemblies,

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

24. Place the cylinder base gasket into position on the

crankcase.

25. 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

26. 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.

FC074

FC075

27. Place each piston over the connecting rod so the

arrow (or indicator dot) on each piston will point
toward the intake/exhaust ports; 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.

!CAUTION

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