Snowmobile Arctic Cat (2004 year). Manual - part 36

3-7

3

AN231

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

retainer.

AN088D

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

Make sure the pump shaft and oil pump align.
Secure with two screws and washers. Tighten the
two screws to 0.7 kg-m (5 ft-lb).

AP143

9. Place the lower check valve into position; then

secure with the gaskets and union cap screw.
Tighten securely.

10. Place the impeller into position and secure with a

cap screw and washer. Be sure the rubber side of
the washer is directed towards 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).

AN178

11. Apply sealant to the crankcase seam; then install

the alignment pins into the crankcase (if removed).

AN179

12. Position the O-ring into the water pump cover;

then install the cover. Secure with the screws.
Tighten to 1.1 kg-m (8 ft-lb).

AN180

13. Set the engine down into position and secure to the

front-end assembly. Tighten to specifications.

14. Connect the coolant hose to the water pump cover

and secure with the clamp.

15. Install the throttle body/carburetors and secure

with clamps.

16. Install the expansion chamber and secure with

springs.

„

NOTE: When installing the springs, the long

hook portion of the spring must be attached to the
exhaust manifold or premature spring failure will
result.

3-8

17. Install the thermostat hose and fill the cooling

system with antifreeze.  Start and run the engine.
Check for leaks and recheck the cooling system to
make sure it has been properly filled.

Repairing Water Pump 

(“Laydown” Engine Models)

„

NOTE: The engine must be removed for this pro-

cedure.

„

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 screws securing the water pump

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

FC118

2. 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.

3. Remove the cap screw securing the impeller.

Account for the rubber washer behind the cap
screw.

FC119

4. Remove the impeller from the shaft.

FC120

„

NOTE: If the impeller will not 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.

FC121

5. 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.

FC122

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

mechanical seal from the crankcase.

3-9

3

FC123

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

ring securing the inner seal in the crankcase.

FC124

8. 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.

FC125

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

side towards the crankshaft). Gently tap into
position.

FC126A

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

grease to the inner seal lips.

FC127

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

ring securing the inner seal in the crankcase.

FC128

5. Using the seal driver, carefully install the outer

water pump mechanical seal. Gently tap the seal
down into position until it seats itself against its
flange.

3-10

FC129

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.

FC122

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

retainer.

FC130A

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

Make sure the pump shaft and oil pump align.
Secure with two screws. Tighten the two screws to
0.7 kg-m (5 ft-lb).

FC131A

9. Place the lower check valve into position; then

secure with the gaskets and union cap screw.
Tighten securely.

10. Place the impeller into position and secure with a

cap screw and washer. Be sure the rubber side of
the washer is directed towards 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).

FC132

11. Apply sealant to the crankcase seam; then install

the alignment pins into the crankcase (if removed).

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.