Snowmobile Arctic Cat (2008 year). Manual - part 59

2-174

FC046

4. Position the indicator contact point against the

crankshaft at location point C (center). Zero the

indicator and rotate the crankshaft slowly. Note

the amount of crankshaft runout (total indicator

reading).

5. If runout exceeds 0.05 mm (0.002 in.) at any of the

checkpoints, the crankshaft must be either

straightened or replaced.

Assembling Engine

„NOTE: The use of new gaskets and seals is rec-
ommended when assembling the engine.

„NOTE: Before the engine is assembled, clean the
threads of the cap screws and the threaded areas
of the engine where Loctite will be used.

„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.

MS986A

„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.

MS415

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.

MS988

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

of the oil-injection pump/water pump driveshaft;

then place the Oil Seal Protector Tool 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. 

! CAUTION

Be very careful not to damage the seals when
installing the oil pump driveshaft. Be certain to use
the seal protector tool. Twist the driveshaft clock-
wise as it enters the seal area and while it is being
pushed through the seals.

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2

FS191

6. Position the shim on the oil-injection pump end of

the driveshaft.

CM159A

7. Secure the upper crankcase half upside-down on a

suitable support; then install the C-ring (A), the

four bearing retaining pins (B), and the two crank-

case dowel pins (C).

CM165C

8. Place the crankshaft end bearings into position

making sure the bearing retaining pin hole is posi-

tioned inward.

„NOTE: The bearing retaining pin hole is the hole
that does not go entirely through the bearing case.

CM043A

9. Lubricate the inner lips of the crankshaft oil seals

with grease; then slide the seals onto the crank-

shaft making sure the spring side of each seal faces

inward.

10. Apply oil to the crankshaft bearings; then install

the crankshaft into the upper crankcase half. Be

sure the alignment hole in each bearing is posi-

tioned over its respective dowel pin in the crank-

case; then seat the crankshaft.

CM045A

„ 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.

11. Position the two center seal rings with their end

gaps 180° apart (up on one and down on the

other); then apply a thin coat of High-Temp Seal-

ant to the entire bottom half of the crankcase seal-

ing surface.

! CAUTION

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

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CM036A

CM166

„NOTE: Use only Arctic Cat High-Temp Sealant to
seal the crankcase halves.

12. Assemble the crankcase halves making sure that

the crankshaft gear and oil-injection pump drive-

shaft gears mesh. Rotate the crankshaft one full

turn to align the crankshaft gear and pump drive-

shaft.

13. Install the crankcase cap screws securing the

crankcase halves. 

14. Tighten cap screws (1-10) in three steps to 31 ft-lb

using the appropriate pattern shown.

742-198A

742-197A

15. On the 800 cc, tighten cap screw (11) in three steps

to 8 ft-lb; then turn the engine right-side up and

tighten cap screws (12-15) in three steps to 25 ft-

lb.

16. On the 1000 cc, tighten cap screws (11-13) in three

steps to 25 ft-lb; then turn the engine right side up

and tighten cap screw (14) in three steps to 8 ft-lb.

„NOTE: Secure the connecting rods with rubber
hoses.

17. Install the oil-injection pump retainer with a new

O-ring.

FC082

„NOTE: For assembling purposes, lubricate the oil
pump and retainer O-rings with oil before install-
ing.

18. Install the O-ring and the oil-injection pump mak-

ing sure the pump shaft slot (A) and pump driven

gear shaft (B) align. Secure with two screws

(coated with blue Loctite #243). Tighten the two

screws to 8 ft-lb.

800 cc

1000 cc

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2

CM167A

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

clamps; then place the lower union assembly into

position and secure with new washer gaskets and

union cap screw. Tighten to 6 ft-lb.

CM153A

20. Secure the intake flanges, reed valve assemblies,

and gaskets with cap screws; then in a crisscross

pattern, tighten to 8 ft-lb.

21. If removed during disassembly, install the coolant

temperature sensor and tighten securely; then

secure the sensor wire to the sensor with a cable

tie.

CM172

22. Position the ceramic/rubber seal into the back side

of the water pump impeller with the ceramic face

of the seal directed out.

CM168

23. 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.

CM169

24. 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 #243 to the threads of the cap screw

and tighten to 8 ft-lb.

! CAUTION

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

! CAUTION

Assure that a new washer gasket is in place on each
side of the union prior to securing the union cap
screw to the crankcase.