Snowmobile Arctic Cat (2004 year). Manual - part 35

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ASSEMBLING

0733-277

1. Install the circlip into the groove of the fan case.

A911

2. Press a bearing into the fan case until it is seated

against the circlip.

3. From the opposite side of the fan case, install the

spacer and press the remaining bearing into the fan
case until it is seated.

„

NOTE: The spacer is positioned between the two

fan-case bearings.

4. Insert the fan with shaft through the fan bearings.

5. Install the key into the shaft.

6. Slide the inner pulley half, required shim(s), fan

belt, and outer pulley half onto the shaft.

A913

7. Using the fan spanner wrench, secure the pulley

with a washer, lock washer, and nut. Tighten the
nut to 2.5-4 kg-m (18-29 ft-lb).

INSTALLING FAN

1. Place the fan case assembly on the engine; then

secure with flange nuts and cap screws. Tighten
the flange nuts to 1.8-2.2 kg-m (13-16 ft-lb).
Tighten the cap screws to 0.4-0.7 kg-m (3-5 ft-lb).

2. Place the new fan belt into position on the upper

pulley.

3. Place the fan drive pulley onto the fan belt and

align one of its holes with one of the mounting
holes in the flywheel; then start a cap screw into
the aligned holes and finger-tighten.

4. Rotate the fan drive pulley clockwise while

observing the other two holes in the pulley. When
they align with the two holes in the flywheel, start
the remaining two mounting cap screws.

5. Tighten the three cap screws only to position the

fan drive pulley on the flywheel; then remove the
three cap screws and install the recoil starter
pulley. Apply red Loctite #271 to the threads of
the three cap screws and install them into the
flywheel. Tighten the three cap screws evenly to
0.8-1.2 kg-m (6-9 ft-lb).

6. Check the fan belt tension. Adjust as necessary.

7. Install the fan cover and secure with six screws.

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

8. Install the recoil starter. Secure with four cap

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

REPLACING FAN BELT

1. Remove the fan cover and the recoil starter.

 2. Remove the three cap screws securing the recoil

starter pulley and the fan drive pulley to the
flywheel.

3. Remove the fan drive pulley and fan belt from the

engine.

4. Place the new fan belt into position on the upper

pulley.

KEY

1. Drive Pulley
2. Belt
3. Fan
4. Key
5. Bearing
6. Spacer
7. Circlip
8. Pulley Half
9. Shim

10. Washer
11. Lock Washer
12. Nut
13. Shaft
14. Cap Screw
15. Fan Assy

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5. Place the fan drive pulley onto the fan belt and

align one of its holes with one of the mounting
holes in the flywheel; then start a cap screw into
the aligned hole and finger-tighten.

6. Rotate the fan drive pulley clockwise while

observing the other two holes in the pulley. When
they align with the two holes in the flywheel, start
the remaining two cap screws.

7. Tighten the three cap screws only to position the

fan drive pulley on the flywheel; then remove the
three cap screws and install the recoil starter
pulley. Apply red Loctite #271 to the threads of
the three cap screws and install into the flywheel.
Tighten the three cap screws evenly to 0.8-
1.2 kg-m (6-9 ft-lb).

AB040

„

NOTE: With the new belt installed, check fan belt

tension (see Checking Belt Tension).

8. Install the fan cover. Tighten the screws to 1.1 kg-

m (8 ft-lb). Install the recoil starter. Tighten the
cap screws to 1.1 kg-m (8 ft-lb).

CHECKING BELT TENSION

1. Remove the fan cover.

AB075

2. Squeeze the belt at midspan and observe the belt

deflection. The maximum belt deflection on either
side must not exceed 6 mm (1/4 in.). If the
deflection is not within specifications, adjust the
belt tension.

B075

3. Install the fan cover. Tighten the screws to 1.1 kg-

m (8 ft-lb).

ADJUSTING BELT TENSION

1.  Remove the fan cover.

2. Using the fan spanner wrench, remove the nut,

lock washer, and washer securing the pulley
halves.

3. Slide the outer pulley half off the shaft and

account for any shim(s).

4. Add or remove shim(s) to attain correct belt

tension.

„

NOTE: To increase belt tension, remove shim(s);

to decrease belt tension, install shim(s).

5. Install the fan belt and the outer pulley half on the

shaft and, using the fan spanner wrench, secure
pulley with a washer, lock washer, and nut.
Tighten to 2.5-4 kg-m (18-29 ft-lb).

6. Recheck belt tension; adjust if necessary.

7. Install fan cover. Tighten the screws to 1.1 kg-m

(8 ft-lb).

Repairing

Water Pump

(Standard Models)

„

NOTE: A bleed hole is located at the bottom of

the water pump housing. If there are any signs of
coolant leakage from the bleed hole, the water
pump seals must be replaced. When servicing the
water pump, use Water Pump Bearing and Seal Kit
(p/n 0644-084).

1. Remove the expansion chamber from the engine

compartment.

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2. Attach a long piece of fuel hose to the engine

coolant drain valve (located on the front lower half
of the crankcase). Route the fuel hose outside the
engine compartment and into a container. Open
the drain valve and remove the filler cap. Once the
coolant stops flowing, remove the hose and tighten
the drain valve.

3. Remove the coolant hose from the water pump

cover.

4. Remove the screws securing the water pump

cover; then remove the cover and account for the
O-ring seal.

AN180

5. Loosen the throttle body/carburetor flange clamps;

then remove the throttle body/carburetors.

6. Remove the mounting hardware securing the

engine to the front-end assembly. Remove the
hose from the thermostat housing and tip the
engine forward.

7. Remove either lower union cap screw securing the

lower check valve assembly. Remove the two
screws securing the oil-injection pump and pull
the oil pump from the engine. Leave the pump
hose and cable attached.

8. Remove the cap screw securing the impeller.

AN233

9. Remove the impeller from the shaft. 

„

NOTE: If the impeller won’t slide off the shaft,

start the cap screw into the shaft and tap on the
cap screw driving the shaft back out of the impel-
ler.

AN232

10. Remove the oil-injection pump retainer and shaft

from the opposite side of the crankcase. Account
for the thrust washer located between the retainer
and shaft flange.

AN231

11. Using the long seal driver, drive the water pump

seal from the crankcase.

AN250

12. Using a pair of snap ring pliers, remove the snap

ring securing the inner seal in the crankcase.

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AN249

13. Using the hooked end of the long seal driver, pull

the inner seal free of the crankcase.

ASSEMBLING

1. Wipe the seal area clean using a clean rag.

AN248

2. Position the inner seal onto the seal driver (spring

side towards the crankshaft). Gently tap into
position.

AN259

3. Using a small screwdriver, apply a light coat of

grease to the inner seal lips.

AN262

4. Using a pair of snap ring pliers, install the snap

ring securing the inner seal in the crankcase.

AN249

5. 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.

AN261

6. Apply a light coat of grease to the sealing surface

of the oil-injection pump driveshaft; then install
Oil Seal Installation Tool (p/n 0644-219) at the
end of the shaft. Twist the shaft as it is pushed
through the oil and water pump seals; then remove
the tool. Position the shim on the oil pump end of
the shaft.