ATV Arctic Cat 2002. Service Manual - part 12

9

3

14. With the alignment pin installed in the camshaft

and the cam lobes directed down (toward the

piston), place the camshaft in position and verify

that the timing mark on the magneto is visible

through the inspection plug and that the timing

marks on the camshaft sprocket are parallel with

the valve cover mating surface.

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15. Apply red Loctite #271 to the cap screws; then

install the cap screws and tab washer to the

camshaft sprocket. Tighten cap screws to 1.5 kg-m

(11 ft-lb).

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16. When the camshaft assembly is seated, ensure the

following.

A. Piston still at top-dead-center.

B. Camshaft lobes directed down (toward the

piston).

C. Camshaft alignment marks parallel to the valve

cover mating surface.

D. Recessed side of the sprocket directed toward

the cam lobes.

E. Camshaft alignment pin and sprocket

alignment hole (smallest) are aligned.

17. Install the cylinder head plug with the open end

facing the camshaft.

18. Remove the cap screw from the end of the chain

tensioner. Account for the plunger, spring, and

O-ring.

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19. Depress the spring-loaded lock and push the

plunger into the tensioner.

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RepairPro Service Manual

7

20. Place the cam chain tensioner assembly and gasket

into the cylinder making sure the ratchet side is

facing toward the top of the cylinder and secure

with the two Allen-head screws.

-)54

21. Install the cap screw and  spring into the end of the

cam chain tensioner. Tighten securely.

-)45

22. Rotate the crankshaft until the first cap screw

securing the sprocket to the camshaft can be

installed; then install the cap screw. Do not tighten

at this time.

23. Rotate the crankshaft until the second cap screw

securing the sprocket to the camshaft can be

installed; then install the cap screw. Do not tighten

at this time.

-)6

-)8

24. Tighten the cap screws (from steps 22 and 23) to

1.15 kg-m (8.5 ft-lb). Bend the washer tabs to

secure the cap screws.

25. Loosen the adjuster screw jam nuts; then loosen

the adjuster screws on the rocker arms in the valve

cover.

26. Apply a thin coat of Three Bond Sealant (p/n

0636-070) to the mating surface of the valve

cover; then place the valve cover into position.

Note that the two alignment pins are properly

positioned.

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27. Install the four top-side cap screws with rubber

washers; then install the remaining cap screws.

Tighten only until snug.

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28. In a crisscross pattern starting from the center and

working outward, tighten the cap screws (from

step 27) to 1 kg-m (7 ft-lb).

29. Adjust valve/tappet clearance using the following

procedure.

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A. Turn the engine over until the piston reaches

top-dead-center on the compression stroke.

B. Place the valve adjuster onto the jam nut

securing the tappet adjuster screw; then rotate

the valve adjuster dial clockwise until the end is

seated in the tappet adjuster screw.

C. While holding the valve adjuster dial in place,

use the valve adjuster handle and loosen the

jam nut; then rotate the tappet adjuster screw

clockwise until friction is felt.

-)64

D. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

E. While holding the valve adjuster handle in

place, rotate the valve adjuster dial

counterclockwise until proper valve/tappet

clearance is attained.

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F. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

30. Place the two tappet covers with O-rings into

position; then install and tighten the cap screws

securely.

-)64

31. Install the spark plug and tighten to 1.7 kg-m (12

ft-lb); then install the timing inspection plug.

Top-Side Components

(500 Automatic)

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Removing Top-Side 

Components

A. Valve Cover
B. Cylinder Head

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1. Remove the two tappet covers.

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RepairPro Service Manual

2. Remove the 12 cap screws securing the valve

cover to the head; account for the four rubber

washers on the top side cap screws. Remove the

valve cover. Account for and note the orientation

of the cylinder head plug. Note the location of two

alignment pins.

77)

84)

8)

3. Loosen the cap screw on the end of the tensioner;

then remove the two Allen-head cap screws

securing the tensioner adjuster assembly and

remove the assembly. Account for a gasket.

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77)

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4. Remove the cap screw securing the chain

tensioner (account for a washer); then remove the

tensioner.

74)

3

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

it is out of the cylinder head; then remove the

C-ring.

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6. Bend the washer tabs and remove the two cap

screws securing the sprocket to the camshaft; then

drop the sprocket off the camshaft. While holding

the chain, slide the sprocket and camshaft out of

the cylinder head.

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7. Remove the five nuts securing the cylinder head to

the cylinder; then remove the four cylinder head

cap screws with copper washers (note location of

the different-sized cap screws and nuts).

78)

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76)

8. Remove the cylinder head from the cylinder,

remove the gasket, and account for two alignment

pins.

RepairPro Service Manual

4

77)

9. Remove the cam chain guide.

7)

C. Cylinder
D. Piston

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10. Loosen the clamp securing the coolant hose to the

union; then detach the hose.

11. Remove the two nuts securing the cylinder to the

crankcase.

7)

12. 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.

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13. Using an awl, remove one piston-pin circlip.

7)

14. Using the Piston-Pin Puller (p/n 0644-328),

remove the piston pin. Account for the

opposite-side circlip. Remove the piston.

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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.

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RepairPro Service Manual

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Left-Side Components

(500 Automatic)

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Removing Left-Side 

Components

A. Recoil Starter
B. Water Pump
C. Cover
D. Magneto Rotor

1. Remove the four cap screws securing the recoil

starter assembly to the left-side cover; then

remove the recoil starter. Account for the gasket.

65

2. Remove the flange nut securing the starter cup to

the crankshaft; then remove the starter cup.

Account for the O-ring inside the cup.

3. Using a cold chisel, scribe a mark showing the

relative position of the shift arm to the shift arm

shaft to aid in installing; then remove the shift

arm.

6

4. Remove the two cap screws securing the

speedometer gear housing; then remove the

housing. Account for the gasket.

65

5. Loosen the clamps securing the coolant hose to the

water pump; then remove the crossover tube from

the cylinder head. Account for an O-ring.

67

6. Remove the two cap screws securing the water

pump to the engine; then remove the water pump.

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7. Remove the 13 cap screws securing the left-side

cover to the crankcase noting the location of the

different-sized cap screws for installing purposes.

66

8. Using Side Case Puller (p/n 0644-262), remove

the side cover. Account for a gasket and two

alignment pins.

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69

9. Remove the nut securing the magneto rotor to the

crankshaft; then install the magneto rotor puller

adapter.

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10. Using Magneto Rotor Remover Set (p/n

0444-075), remove the magneto rotor assembly

from the crankshaft. Account for the key; then

remove the starter clutch gear assembly and

washer.

6

64

11. Remove the two starter gears from the crankcase

noting the direction of the beveled side of the

gears for installing purposes; then remove the two

starter gear shafts.

66

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RepairPro Service Manual

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68

12. Remove the snap ring securing the water pump

driven gear; then remove the gear noting the

direction of the sides of the gear for installing

purposes. Account for the driven gear alignment

pin.

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13. Remove the snap ring securing the water pump

drive gear; then remove the gear noting the

direction of the sides of the gear for installing

purposes. Account for the drive gear alignment

pin.

64

Right-Side Components

(500 Automatic)

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Removing Right-Side 

Components

1. Remove the cap screws securing the V-belt cover

noting the location of the different-lengthed cap

screws for installing purposes; then using a rubber

mallet, gently tap on the cover tabs to loosen the

cover.

5?7

2. Remove the nut securing the movable drive face;

then remove the face. Account for a spacer.

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3. Remove the V-belt.

4. Remove the nut securing the fixed driven

assembly; then remove the assembly.

5?5

5. Remove the fixed drive face.

6. Using an impact driver, remove the Phillips-head

screws securing the air intake plate; then remove

the plate cushion.

5?8

597

7. Remove the cap screws securing the clutch cover.

Note the location of the different-lengthed cap

screws for installing purposes. Using a rubber

mallet, carefully remove the cover. Account for

two alignment pins.

59

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RepairPro Service Manual

47

677

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8. Remove the one-way clutch (D) from the clutch

housing. Note the location of the green alignment

dot (or the word OUTSIDE) for installing

purposes.

9. Using a hydraulic press, remove the clutch

housing assembly from the clutch cover. Account

for the left fixed drive spacer and an O-ring inside

the fixed drive spacer.

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10. Remove the two Allen-head screws securing the

shift indicator sending unit; then remove the unit.

Account for two neutral contact pins and two

springs.

67

67

11. Remove the nut (left-hand threads) securing the

clutch shoe assembly (C). Account for a washer.

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12. Remove the cap screw securing the oil pump drive

gear (B). Account for a cap screw, washer, pin, and

spacer.

676

13. Using an impact driver, remove the Allen-head

screws securing the final drive carrier bearing

housing (E); then remove the housing and account

for two alignment pins.

14. Remove the snap ring securing the oil pump

driven gear (A); then remove the gear noting the

direction of the sides of the gear for installing

purposes. Account for a pin and a washer.

RepairPro Service Manual

4

15. Using an impact driver, remove the three

Phillips-head screws securing the oil pump; then

remove the pump.

6

Center Crankcase 

Components

(500 Automatic)

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Separating Crankcase 

Halves

1. Remove the two shift cam stoppers from the top of

the crankcase.

66

2. Remove the right-side cap screws securing the

crankcase halves. Note the location of the

different-lengthed cap screws.

664

3. Remove the left-side cap screws securing the

crankcase halves. Note the location of the

different-lengthed cap screws.

66

4. Using the Crankcase Separator/Crankshaft

Remover (p/n 0444-009) and tapping lightly with

a rubber mallet, separate the crankcase halves.

Account for two alignment pins.

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Disassembling 

Crankcase Half

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1. Remove the secondary driven shaft assembly (A)

noting the location of the bearing locating pins.

Account for the bearing C-ring.

666

RepairPro Service Manual

44

668

2. Remove the reverse idler gear assembly (F).

Account for all washers, shaft, bushing, and the

gear.

66?

3. Remove the shift shaft (H); then remove the two

forks taking note of the direction of the tabs on the

forks for assembling purposes.

4. Remove the gear shift shaft (G) noting the location

of the two holes on the end of the shaft. Account

for two washers.

68

5. Remove the countershaft assembly (D). Account

for a washer on each end of the countershaft.

684

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6. Using a rubber mallet, tap on the crankcase to

remove the driveshaft.

685

7. Note the alignment dots on the crank balancer

assembly (B) gear and crankshaft (C) gear for

assembling purposes; then slide the crank balancer

gear off the crank balancer. Account for the key in

the keyway.

686

8. Remove the crank balancer.

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