ATV Arctic Cat 2002. Service Manual - part 11

 

  Index      Manuals     ATV Arctic Cat 2002. Service Manual

 

Search            copyright infringement  

 

 

 

 

 

 

 

 

Content      ..     9      10      11      12     ..

 

 

ATV Arctic Cat 2002. Service Manual - part 11

 

 

3

-)5

H. Oil Pump/Oil Strainer

„

 %!?! 

!!$

19. Remove three Phillips-head screws holding the oil

pump and remove the oil pump. Account for two

alignment pins.

-)767

20. Remove the four cap screws securing the oil

strainer cover; then remove the Phillips-head

screws securing the oil strainer. Account for

O-rings.

„

       

!!$

-)78

Center Crankcase 

Components

(375)

„

 ! 

#$!

1"!!%(%

1%!!$

„

 /& !  "

 &!

 "&

!$

;$

 AT THIS POINT

 "  !  %"

1%! $

 AT THIS POINT

 "    %" 1%

! $

 AT THIS POINT

 "   ! &

!%!."$

RepairPro Service Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

4

Separating Crankcase 

Halves

1. Remove the left-side and right-side cap screws

securing the crankcase halves noting the position

of the different-sized cap screws for joining

purposes.

-)776

-)7

2

   !  "#!  

$# %&&&%%'(  

 

Account for

two alignment pins

?69

„

 !# 

!

!

"$

-)

Disassembling 

Crankcase Half

1. Remove the secondary (4x4 models) and primary

driveshaft assemblies. Account for the bearing

alignment C-ring on the bearing boss next to the

pinion gear.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

5

3

-)8

„

 4A4 

!&!$

2. Remove the reverse idler gear, spacer, and sleeve.

Account for the washers.

-)5

?87

3. Remove the driveshaft.

-)6

4. Remove the shift fork shaft and the outer shift

fork.

-)8

5. Remove snap ring and gear from the output side of

the gear cluster. Remove the gear cluster and the

inner shift fork together. Account for snap ring,

gear, and washer.

-)?

6. Noting the position of the two holes on the end,

remove the shift cam assembly. Account for inner

and outer washers.

RepairPro Service Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

6

-)9

7. Remove the counterbalance gear. Account for the

key and inner and outer thrust washers.

8. Remove the counterbalance shaft.

-)74

-)77

9.

  !  "#!  

$# %&&&%%'( 

.

-)7

10. Remove the secondary drive gear/secondary

driven gear retaining nut. From inside the

crankcase using a rubber mallet, drive out the

output shaft assembly. Account for the output

shaft, a shim, a washer, and the nut.

-)

Assembling Crankcase 

Half

„

 / &!

$

„

  ,  !   " 

!!$

! CAUTION

)  "   ! 

 &   & &$ , 

" !

         

$

 AT THIS POINT

 "   &  %"

! $

-------------------------------------------------------------------------------------------------------------------------------------------------------------

8

3

 1. Install the output shaft into the crankcase making

sure the two gears, shim, washer, and nut are in the

correct order.

-)99

-)789

 2. Apply red Loctite #271 to the threads of the output

shaft. Install and tighten the nut to 10 kg-m (72

ft-lb). Using a punch, peen the nut.

-)

 3. Apply a liberal amount of oil to the crankshaft

bearing. Using a propane torch, heat the bearing

until the oil begins to smoke; then slide the

crankshaft assembly into place.

-)4

„

 , ! 

 

$

 4. Rotate the crankshaft so the counterweight is

toward the rear of the engine. Install the

counterbalance shaft.

-)74

 5. Keeping the counterbalance gear timing mark

aligned with the the one on the crankshaft gear,

install the large thrust washer, key,  counterbalance

gear, and second large thrust washer. 

-)7

6. Keeping the two holes facing up, install the shift

cam and inner and outer washers.

RepairPro Service Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

?

-)9

7. Align the inner shift fork with the gear cluster and

with the inner washer in place, install the gear

cluster and inner shift fork. While holding the gear

cluster in place, install the washer, gear, and snap

ring.

-)7

-)9?

8. Install the outer shift fork and the shift fork shaft.

-)8

9. Install the input driveshaft.

-)6

?87

10. Install the washer, spacer, sleeve, reverse idler

gear, and washer.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

9

3

-)58

11. Install the secondary (4x4 models) and primary

driveshaft assemblies. Account for the bearing

alignment C-ring on the bearing boss next to the

pinion gear. 

„

    4A4     

!&!$

-)6

Joining Crankcase 

Halves

 1. Verify that the two alignment pins are in place and

that both case halves are clean and grease free.

Apply Three Bond Sealant (p/n 0636-070) to the

mating surfaces. Place the right-side half onto the

left-side half.

-)6

 2. Using a plastic mallet, lightly tap the case halves

together until cap screws can be installed.

 3. From the right side, install the crankcase cap

screws noting the location of the different-sized

cap screws; then tighten only until snug.

„

  1       

 

!$

-)77?

 4. From the left side, install the remaining crankcase

cap screws; then tighten only until snug.

„

  1       

 

!$

RepairPro Service Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

7

?8

 5. In a crisscross/case-to-case pattern, tighten the 8

mm cap screws until the halves are correctly

joined; then tighten to 2-2.4 kg-m (14.5-17 ft-lb).

„

  1       

 $

 6. In a crisscross/case-to-case pattern, tighten the 6

mm cap screws to 0.9-1.3 kg-m (6.5-9.5 ft-lb).

„

  1       

 $

Installing Right-Side 

Components

A. Oil Strainer/Oil Pump

1. Place the oil strainer and new O-ring into position

beneath the crankcase. Tighten the Phillips-head

screws (coated with red Loctite #271) securely.

-)8

2. Noting the directional arrow from removing, place

the strainer cover into position on the crankcase

making sure the O-ring is properly installed and

secure with the four cap screws; then tighten the

oil drain plug to 2.2 kg-m (16 ft-lb).

-)7?

3. Place two alignment pins and the oil pump into

position on the crankcase and secure with the

Phillips-head screws coated with blue Loctite

#243. Tighten to 1 kg-m (7 ft-lb).

-)767

 

AT THIS POINT

!!

!,1%!

, (% !  

,!%!$

! CAUTION

 $

-------------------------------------------------------------------------------------------------------------------------------------------------------------

3

4. Place the pin into position on the oil pump shaft,

install the oil pump driven gear making sure the

recessed side of the gear is directed inward, and

secure with the snap ring.

-)77

-)79

5. Install the cam chain.

„

 3!"

 $

6. Place the pin into position, install the oil pump

drive gear, and tighten the cap screw (coated with

red Loctite #271) securely.

-)78

-)7?

7. Install the centrifugal clutch assembly and

left-hand threaded nut. Tighten securely.

„

 

 $

-)76

-)74

! CAUTION

        @ 

DE$

RepairPro Service Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

 8. Install the one-way sprag clutch making sure that

the green dot or the stamp tag OUTSIDE is facing

out.

-)?6

9. Install gear position indicator switch contact pins

and springs  into the end of the shift cam.

-)74

10. Install gear position indicator switch making sure

the O-ring is well-oiled and properly positioned.

Tighten cap screws securely.

-)747

B. Clutch Cover
C. Fixed Drive Face
D. Movable Drive Face

„

  %! 7   !  

!!$

11. Install two alignment pins and place the clutch

cover gasket into position. Install the clutch cover.

-)5

12. Tighten the clutch cover cap screws securely.

-)8

13. Install the air intake plate. Apply red Loctite #271

to the threads of the three Phillips-head cap

screws; then install and tighten securely.

-)4

-------------------------------------------------------------------------------------------------------------------------------------------------------------

3

14. Place the driven clutch assembly into position and

secure with the nut (threads coated with red

Loctite #271). Tighten to 10.4-11.8 kg-m (75-85

ft-lb).

-)76?

-)9

15. Slide the fixed drive face assembly onto the front

shaft.

16. Spread the faces of the driven clutch by pushing

the inner face toward the engine while turning it

counterclockwise; then when the faces are

separated, insert a wedge (approximately 3/8 in.

thick) between the faces. Release the inner face.

-)47

17. Place the V-belt into position on the driven clutch 

and over the front shaft.

-)4

„

 ' !

$

18. Making sure the eight movable drive face rollers

are in position, pinch the V-belt together near its

center and slide the spacer and movable drive face

onto the shaft. Coat the threads of the nut with red

Loctite #271 and secure the movable drive face.

Tighten the nut to 10.4-11.8 kg-m (75-85 ft-lb).

-)?

-)7

„

 ! "

 "$

19. Rotate the V-belt and drive assemblies until the

V-belt is flush with the top of the driven clutch.

RepairPro Service Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

4

20. Install two alignment pins and place the V-belt

cover gasket into position on the clutch cover.

Install the V-belt cover noting the position of the

long cap screws and rubber washer and two wire

forms. In a crisscross pattern, tighten cap screws to

1.1 kg-m (8 ft-lb).  

-)76

Installing Left-Side 

Components

A. Starter Idler Gears
B. Magneto Rotor

1. Place the crankshaft bearing retainer into position.

Apply red Loctite #271 to the three Phillips-head

screws. Install and tighten the three Phillips-head

screws securely.

-)

2. Install the starter motor and tighten the two cap

screws securely. 

3. Install the driveshaft spacer making sure the

stepped side is to the inside.

-)4

4. Install the shift detent cam making sure the spacer

is properly positioned.

-)7?6

5. Install the cam follower assembly.

-)

6. Install the gear shift shaft assembly and washer

making sure to align the alignment marks.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

5

3

-)9

7. Install starter idler gear (No. 1) and starter idler

gear  (No. 2).

-)75

8. Place the key into its notch; then slide the magneto

rotor (with the ring gear in place) over the

crankshaft. Tighten the nut to 16 kg-m (116 ft-lb).

-)94

C. Cover
D. Recoil Starter

9. Install two alignment pins and place the left-side

cover gasket into position. Install the left-side

cover. Noting the different-lengthed 6 mm cap

screws, the position of the shifter bracket, and the

location of the long cap screw with the washer,

tighten cap screws in a crisscross pattern to 0.9-1.3

kg-m (6.5-9.5 ft-lb).

-)?6

10. Install the starter cup making sure that the O-ring

is in place inside the starter cup. Tighten the nut

w/lock washer to 3.5 kg-m (25 ft-lb). 

-)74

RepairPro Service Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

6

-)7

11. Place the gasket, recoil starter assembly, and cover

into position on the left-side cover making sure the

single washer is properly positioned; then install

and tighten the four cap screws to 0.8 kg-m (6

ft-lb).

Installing Top-Side 

Components

A. Piston
B. Cylinder

„

 ,!"

C$

A. Install a thin oil ring, corrugated oil ring, and

thin oil ring in the bottom groove of the piston.

Stagger the gaps of the upper and lower thin

rings.

-)7

„

  &

$

-)4

1. Install the piston on the connecting rod making

sure there is a circlip on each side and the open

end of the circlip faces upwards.

„

   !      

!$

-)

2. Place the two alignment pins into position. Place

the cylinder gasket into position; then place a

piston holder (or suitable substitute) beneath the

piston skirt and square the piston in respect to the

crankcase.

-)44

! CAUTION

,!!

!

!$

! CAUTION

,    !  

$

-------------------------------------------------------------------------------------------------------------------------------------------------------------

8

3

3. Lubricate the inside wall of the cylinder; then

using a ring compressor or the fingers, compress

the rings and slide the cylinder over the piston.

Route the cam chain up through the cylinder cam

chain housing; then remove the piston holder and

seat the cylinder firmly on the crankcase.

-)45

 4. Loosely install the two nuts with washers which

secure the cylinder to the right-side crankcase half.

„

    &  

 !9$

-)6

C. Cylinder Head
D. Valve Cover

„

  %! 4   !  

!!$

5. While keeping tension on the cam chain, place the

front cam chain guide into the cylinder.

-)49

6. Place the head gasket into position on the cylinder.

Place the alignment pins into position; then place

the head assembly into position on the cylinder

making sure the cam chain is routed through the

chain cavity. 

-)48

-)6

! CAUTION

&&$)

 &     ! 

& &&$

! CAUTION

          

 $

! CAUTION

3!       "

 $

RepairPro Service Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------

?

7. Install the four cylinder head cap screws with

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. Tighten only until snug.

-)87

8. Install the two lower nuts securing the cylinder

head to the cylinder, one in front and one in rear.

-)9

9. In a crisscross pattern, tighten the four cylinder

head cap screws to 3.8 kg-m (27.5 ft-lb). Tighten

the two lower cylinder head nuts to 2.5 kg-m (18

ft-lb) and the cylinder-to-crankcase nuts to 1.1

kg-m (8 ft-lb).

10. With the timing inspection plug removed and the

cam chain held tight, rotate the crankshaft until the

piston is at top-dead-center.

11. With the alignment pin installed in the camshaft,

loosely place the cam sprocket (with the recessed

side facing the camshaft lobes) onto the camshaft

and place it into position with the cam chain over

the sprocket.

-)59

12. While holding the cam chain sprocket to the side,

install the rear cam chain tensioner guide into the

cylinder head. Install the pivot cap screw and

washer.

-)5

13. Place the C-ring into position in its groove in the

cylinder head.

-)

„

    !     

 ;

&$

-------------------------------------------------------------------------------------------------------------------------------------------------------------

 

 

 

 

 

 

 

Content      ..     9      10      11      12     ..