ATV Arctic Cat 2002. Service Manual - part 10

98

3

8. Remove the rear rack/fender assembly (see

Section 8).

9. Remove the hardware securing the air cleaner

housing to the frame.

55

10. Disconnect the crankcase vent hose from the air

cleaner housing.

56

11. Remove the clamps securing the air intake hose to

the carburetor; then remove the air cleaner

housing.

12. Remove the hardware securing the cooling duct

assembly to the frame; then remove the cooling

duct shroud from the V-belt cover.

/9?

/9

13. Remove the hardware securing both footrests to

the frame and front fender.

?6

14. Loosen the clamp securing the carburetor to the

intake. 

15. Route the carburetor assembly up and away from

the engine.

16. Remove the E-clip securing the shift rod to the

engine shift arm.

/96

17. Remove the lock nut (B) securing the shift rod to

the shift lever arm; then remove the shift rod.

RepairPro Service Manual

9?

/94

18. Remove the torx-head screws securing the exhaust

pipe shroud; then remove the shroud.

567

19. Remove the four (two on each side) torx-head

screws securing the inner front fenders to the

frame and footrests.

„

  ,   &  "  

"@""

 "

"A!!$

20. Remove the hardware securing the exhaust pipe to

the muffler, frame, and engine; then remove the

exhaust pipe.

21. Remove the two coolant/oil hoses from the engine.

Route the hoses out of the way.

„

    85       

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!"$

22. Remove the hardware securing the front and rear

driveshafts.

565

566

„

  ,  "       

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23. On the right side, cut the cable ties securing the

wiring harness to the frame.

568

24. Remove the positive cable from the starter motor

and route it out of the way.

25. Remove the speedometer cable from the

speedometer gear housing.

99

3

56?

26. Disconnect the top connector at the CDI unit.

569

27. Disconnect the stator-to-rectifier/regulator con-

nector.

587

28. Remove the temperature sensor wire(s) from the

engine.

„

    85    !

$

/964

58

29. Remove the two cap screws securing the front

upper engine mount to the frame.

/99

30. Remove the cap screw and flange nut securing the

upper engine bracket to the engine; then remove

the bracket.

31. Remove the spark plug wire from the spark plug.

32. Remove the shift indicator connector from the

main wiring harness.

33. Remove the cap screw securing the engine ground

wire to the engine.

34. Remove the three engine mounting through-bolts.

Account for a washer on the upper bolt and a

spacer on the lower front bolt.

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586

588

35. Remove the caps screws securing the two upper

rear engine mounts to the frame.

36. Slightly raise the front of the engine; then remove

the front driveshaft coupler from the engine.

58?

37. Remove the torx-head screws securing the clutch

plenum to the engine; then remove the plenum and

account for a gasket.

589

38. Remove the engine from the right side by moving

the engine forward while raising the engine in the

rear and rotating the engine counterclockwise. The

engine will come out the right side of the frame.

Top-Side Components

(375)

„

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;$

„

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Removing Top-Side 

Components

A. Valve Cover
B. Cylinder Head

„

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7

3

1. Remove the cap screws securing the two tappet

covers. Remove the two tappet covers. Account

for the O-rings.

-)64

„

  3!     

" &!!$

2. Remove the 12 valve cover cap screws. Note the

rubber washers on the four top-side cap screws;

remove the valve cover. Note the orientation of the

cylinder head plug and remove it. Note the

location of the two alignment pins.

-)6

-)54

3. Loosen the cap screw on the end of the cam chain

tensioner; then remove the two Allen-head screws

securing the cam chain tensioner assembly.

Remove the tensioner assembly and gasket.

-)45

-)54

4. Remove the cam chain tensioner pivot cap screw

and washer.

-)5

5. Bend the washer tabs and remove the two cap

screws securing the sprocket to the camshaft.

RepairPro Service Manual

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-)6

-)8

6. Using an awl, rotate the C-ring in its groove until

it is out of the cylinder head; then remove the

C-ring.

„

         ! 

$

-)

7. Noting the timing marks for installing purposes,

drop the sprocket off the camshaft. While holding

the cam chain, slide the sprocket and camshaft out

of the cylinder head. Account for an alignment

pin.

„

  (!   "  & 

!

$

-)

8. Remove the cam chain tensioner by lifting it from

the chain cavity; then remove the two lower nuts

securing the cylinder head to the cylinder, one in

front and one in rear.

-)9

9. Remove the four cylinder head cap screws and

washers. Note that the two cap screws on the right

side of the cylinder head nearest the cam sprocket

are longer than the two cap screws on the left

(spark plug) side. 

-)68

10. Remove the cylinder head from the cylinder,

remove the gasket, and account for two alignment

pins.

7

3

-)6

11. Remove the cam chain guide.

-)8

C. Cylinder
D. Piston

„

  %!    !  

!!$

12. Remove the two nuts securing the right side of the

cylinder to the right-side crankcase half. Account

for the washers.

-)6

13. Lift the cylinder off the crankcase taking care not

to allow the piston to drop against the crankcase.

Account for the gasket and two alignment pins.

-)4

14. Using an awl, remove one piston-pin circlip. Take

care not to drop it into the crankcase.

 

AT THIS POINT

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! $

! CAUTION

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!$

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-)

15. Using Piston-Pin Puller (p/n 0644-328), remove

the piston pin. Account for the opposite-side

circlip. Remove the piston.

„

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!!!$

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A. Starting with the top ring, slide one end of the

ring out of the ring-groove.

B. Remove each ring by working it toward the

dome of the piston while rotating it out of the

groove.

! CAUTION

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 AT THIS POINT

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! $

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75

3

Left-Side Components

(375)

„

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!$

;$

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Removing Left-Side 

Components

A. Recoil Starter
B. Starter Cup
C. Cover/Stator Assembly

1. Remove the four recoil starter cover cap screws.

Remove the recoil starter assembly noting the

location of the single washer. Note the condition

of the recoil cover gasket. Replace if damaged.

 2. Remove the nut and lock washer securing the

starter cup to the crankshaft; then remove the

starter cup. Account for the O-ring inside the cup.

-)7

-)74

3. Lay the engine/transmission on its right side.

Remove the 14 left-side cover-to-crankcase

mounting cap screws noting the location of the

long cap screw with the washer near the middle of

the left-side cover. Keep the different-lengthed 6

mm cap screws in order for installing purposes.

-)?6

4. Using Side Case Puller (p/n 0644-262) and the

6 mm adapter, remove the left-side cover w/stator

assembly. Note the condition of the gasket.

Replace if necessary. Account for the two

alignment pins and the position of the shifter

bracket for installing  purposes.

 AT THIS POINT

 " &  ! ! &

  &  ! &  

&$.,%2,

 $

 AT THIS POINT

 "     %"

(%! $

RepairPro Service Manual

76

-)??

„

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D. Magneto Rotor
E. Starter Motor

„

  %! 4   !  

!!$

5. Remove the magneto rotor nut.

-)94

6. Install Magneto Rotor Remover Adapter (p/n

0444-075).

-)65

7. Using Magneto Rotor Remover (p/n 0444-075),

break the rotor assembly loose from the

crankshaft. Remove the remover, the adapter, the

rotor, and the ring gear. Account for the key.

-)6?

-)69

78

3

-)87

  8. Remove the starter idler gear (No. 1) and starter

idler gear (No. 2).

-)75

9. Remove the gear shift shaft assembly and washer

from the left-side crankcase. Note the positions of

the alignment marks and washer for installing

purposes.

-)9

10. Remove the shift detent cam. Note position of

spacer for installing purposes.

-)7?6

11.  Remove the cam follower assembly.

-)786

-)

12. Remove the spacer from the driveshaft noting the

direction of the stepped side for installing

purposes.

RepairPro Service Manual

7?

-)4

13.  Remove two starter motor cap screws.

-)78?

14. Remove starter motor by tapping lightly with a

mallet.

-)788

15. Using an impact screwdriver, remove the three

Phillips-head screws holding the crankshaft

bearing retainer. Remove the crankshaft bearing

retainer.

-)

Right-Side Components

(375)

„

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 &!

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!$

;$

„

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79

3

Removing Right-Side 

Components

A. V-Belt Cover
B. Driven Clutch
C. Clutch Cover

1. If the engine is still in the frame, turn the gas tank

valve to the OFF position and lay the ATV on its

side. Remove the cap screws securing the

right-side V-belt cover to the clutch cover.

Remove the cover. Note the locations of the long

cap screws and rubber washer and the two wire

forms. Account for the gasket and for two

alignment pins.

-)76

-)78

2.

         

  

-)7

3.

       

        

 

-)75

-)74

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-)76

4

 

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5. Remove the fixed drive face.

-)794

6.

         

  

-)76?

7.

        

         

 

-)79

8. Remove the cap screws holding the clutch cover

onto the right-side crankcase half. Note the

positions of the different-lengthed cap screws for

installing purposes

-)8

9. Using a rubber mallet, loosen

   

then pull it away from the right-side crankcase

half. Account for two alignment pins and gasket.

3

-)5

D. Gear Position Switch
E. Centrifugal Clutch Assembly
F. Oil Pump Drive Gear 
G. Oil Pump Driven Gear

„

  %! 9   !  

!!$

-)78

10.

e cap screws h

  

   

.

-)74

11. Remove the gear position indicator switch.

Account for two contact pins and two springs.

-)747

-)74

12. Remove the one-way sprag clutch noting the

direction of the green dot or the stamp tag

OUTSIDE for installing purposes.

-)?6

13. Remove the left-hand threaded nut holding the

centrifugal clutch assembly.

! CAUTION

       "  @ 

DE$

RepairPro Service Manual

-)74

-)76

14. Remove the oil pump drive gear cap screw.

-)7?

15. Remove oil pump drive gear. Account for the pin.

-)78

16. Remove the snap ring holding the oil pump driven

gear.

-)79

17. Remove oil pump driven gear. Account for the pin.

-)77

18. Remove the cam chain.