Snowmobile Arctic Cat (2008 year). Manual - part 52

2-146

FC071

„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 the 6 mm cap screws to 8 ft-lb and the ten

10 mm cap screws to 31 ft-lb using the appropriate

pattern shown.

0738-201

„NOTE: On the 500 cc after tightening the crank-
case, turn the engine right side up and tighten the
four MAG-housing cap screws in a crisscross pat-
tern to 16 ft-lb.

738-202A

„NOTE: On the 500 cc, secure the connecting rods
with rubber bands on the cylinder studs. On the
600 cc, secure the connecting rods with rubber
hoses.

15. With a new O-ring in place, install the oil-injection

pump retainer.

FC082

16. With a new O-ring in place, install the oil-injection

pump making sure the pump shaft slot and pump

driven gear shaft align. Secure with two screws

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

screws to 8 ft-lb.

„NOTE: For assembling purposes, apply a light
coat of oil to the O-rings before installing.

17. Position the ceramic/rubber seal retainer and seal

into the back side of the water pump impeller with

the ceramic face of the seal directed out.

CM168

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.

500 cc

600 cc

! 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.

2-147

2

CM169

19. Place the impeller into position and secure with a

cap screw and washer. Be sure the rubber side of

the washer is lubricated with a light coat of grease

and directed toward the impeller. Apply blue Loc-

tite #243 to the threads of the cap screw and

tighten to 8 ft-lb.

„NOTE: For assembling purposes, it is advisable
to lubricate the rubber side of the washer before
installing.

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

„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; then

using the pattern shown, tighten to 8 ft-lb.

„NOTE: Lubricating the O-ring with a light coat of
grease will help keep the O-ring in place.

FC134

! CAUTION

If the rubber side of the washer is not positioned
toward the impeller, a coolant leak will result.

2-148

0742-304

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 in a criss-

cross pattern to 8 ft-lb.

24. Install the dowel pins into the crankcase; then

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 bear-

ings; then install the small-end bearings. Install a

washer on each side of the connecting rod.

FC075

„NOTE: The shoulder side of the washer must
seat to the needle bearing.

27. Place each piston over the connecting rod so the

indicator dot on each piston will point toward the

intake/exhaust ports; then secure with an oiled pis-

ton pin.

„NOTE: The indicator dot is found on the piston
dome top.

FC079A

! CAUTION

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

2-149

2

28. Install the new circlips so the open end is directed

either up or down.

B324D

„NOTE: To aid in the circlip installation, it is advis-
able to install the circlip to the inside of the piston
before installing the connecting rod.

29. Rotate each piston ring until the ring ends are

properly positioned on either side of the ring

keeper; then apply oil to the piston assemblies and

cylinder bores. Remove the rubber bands from the

connecting rods.

30. In turn on each cylinder, place a piston holder (or

suitable substitute) beneath the piston skirt and

square the piston in respect to the crankcase; then

using a ring compressor or the fingers, compress

the rings and slide the cylinder over the piston.

Remove the piston holder and seat the cylinder

firmly onto the crankcase.

„NOTE: The cylinders should slide on easily. DO
NOT force the cylinders on.

FC076

31. On the 500 cc, secure each cylinder by installing

the eight nuts. DO NOT TIGHTEN AT THIS

TIME.

32. On the 600 cc, secure each cylinder by installing

the four nuts and four cap screws. DO NOT

TIGHTEN AT THIS TIME.

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

clamps; then place the lower check-valve assem-

bly into position and secure with the gaskets and

union cap screw. Tighten securely.

34. Secure the cylinders (from steps 31-32) by tighten-

ing the cylinder base nuts (and cap screws on the

600 cc) to 42 ft-lb in three steps using the appro-

priate pattern shown; then tighten the spark plugs

to 19 ft-lb.

0742-746

0738-220

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

cylinder making sure they are correctly positioned

in the grooves.

FC077

„NOTE: Lubricating the O-ring with a light coat of
grease will help keep the O-ring in place.

! CAUTION

Make sure the circlips are firmly seated and the open
end is directed either up or down before continuing
with assembly.

500 cc

600 cc