ATV Arctic Cat 2002. Service Manual - part 13

45

3

68?

9. Remove the snap ring securing the water pump

driven gear shaft.

689

10. Using a hydraulic press, remove the crankshaft

assembly.

„

 +!"!!"

$

6?7

11. Remove the cap screws securing the oil strainer

cap; then remove the cap. Account for the cap

O-ring.

6?

12. Using an impact driver, remove the two screws

securing the oil strainer; then remove the strainer.

6?

13. To remove the assembly, remove the nut securing

the secondary drive gear and secondary driven

gear; then from the inside of the crankcase using a

rubber mallet, remove the output shaft assembly.

Account for the output shaft, two gears, a shim, a

washer, and the nut.

6?

! CAUTION

)  "   ! 

 &   & &$ , 

" !

         

$

RepairPro Service Manual

46

6?6

Assembling Crankcase 

Half

1. Install the output shaft assembly into the crankcase

making sure the two gears, shim, washer, and nut

are properly sequenced.

6?6

„

  "&"

!$

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

shaft; then secure with the nut. Tighten nut to 10

kg-m (72 ft-lb); then using a punch, peen the nut.

6?8

3. Apply a liberal amount of engine 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.

6??

6?9

„

 , ! 

 

$

697

4. Install the crank balancer.

48

3

68?

„

  ,    &    

 &

@

;

  &$

5. Place the key into the crank balancer keyway; then

install the crank balancer gear making sure the

alignment dots on the crank balancer gear and the

crankshaft gear align.

686

6. Place a washer on each end of the countershaft

assembly; then install the assembly.

684

7. Install the driveshaft.

685

8. Place a washer on each end of the gear shift shaft;

then install the shaft assembly making sure the two

holes on the end of the shaft are positioned

vertically.

68

9. Insert the two shift forks into the sliding dogs

noting the direction of the tabs from

disassembling; then install the shift fork shaft.

„

 - !

&!!&

$

669

10. Install the reverse idler gear assembly noting the

positioning of the two washers, gear, bushing, and

shaft.

RepairPro Service Manual

4?

66?

11. Install the front and rear secondary driven shaft

assemblies into the left side of the crankcase

making sure the bearing locating pins are facing

upward and the bearing C-ring is fully seated in

the crankcase.

666

668

12. Place the oil strainer into position; then secure

with the two screws.

6?

13. Place the oil strainer cap into position making sure

the O-ring is in position; then secure the cap with

cap screws. Tighten securely.

6?

Joining Crankcase 

Halves

1. Apply High-Temp Sealant (p/n 0636-069) to the

left-side mating surface.

69

2. Lightly oil all bearings and grease all shafts in the

right-side crankcase.

49

3

694

696

3. Using a propane torch, heat the right-side

crankshaft bearing until the oil begins to smoke;

then join the two crankcase halves.

695

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

together until cap screws can be installed.

5. From the right side, install the 8 mm cap screws;

then tighten only until snug.

„

  1       

 $

6. From the left side, install the remaining 8 mm cap

screws (two inside the case); then tighten only

until snug.

„

  1       

 $

7. From the left side, install the eight case half 6 mm

cap screws; then tighten only until snug.

„

  1       

 $

8. From the right side, install the 6 mm cap screws;

then tighten only until snug.

„

  1       

 $

9. 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).

698

„

  1       

 $

10. 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       

 $

11. Using a liberal amount of grease, assemble the

shift cam stoppers; then install them into the top of

the engine.

„

 !

!!!

 $

66

RepairPro Service Manual

57

Installing Right-Side 

Components

1. Install the shift indicator sending unit making sure

the two neutral contact pins and the two springs

are properly positioned. Tighten the Allen-head

screws securely.

67

2. Install the secondary shaft bearing housing making

sure the two alignment pins are properly

positioned. Tighten the Allen-head screws

securely.

8

3. Install the oil pump onto the engine; then tighten

the Phillips-head screws securely.

6

4. Install the oil pump drive gear spacer onto the

crank balancer shaft. Grease the pin and insert it

into the shaft; then install the drive gear making

sure the raised side of the gear is facing toward the

inside. Secure the gear with the cap screw (threads

coated with red Loctite #271) and the washer.

Tighten the cap screw to 5 kg-m (36 ft-lb).

8

5. Grease the driven gear pin and insert it into the oil

pump shaft; then install the driven gear (noting the

direction of the sides of the gear from removing).

Secure with a snap ring.

679

„

 B&

"" 

$

 AT THIS POINT

!!

!,1%!

, (% !   ,

!%!$

5

3

6. Install the clutch shoe assembly and secure with

the washer (with the flat side facing the assembly

as noted in removing) and the nut (threads coated

with red Loctite #271). Tighten to 13 kg-m (94

ft-lb).

674

7. Lightly grease the clutch housing seal; then insert

the left fixed drive spacer.

598

595

8. Install the clutch cover alignment pins into the

crankcase, apply oil to the cover gasket, and install

the gasket onto the crankcase.

9. Apply grease to the outer edges of the clutch

housing; then from inside the clutch cover, install

the clutch housing into the cover using a rubber

mallet.

10. Install the one-way clutch onto the clutch shoe

assembly.

59

11. Place the clutch cover/clutch housing assembly

into position on the crankcase; then secure with

the cap screws making sure the different-lengthed

cap screws are in their proper location. Tighten to

1.1 kg-m (8 ft-lb).

12. Place the air intake plate cushion into position;

then install the air intake plate. Tighten the

Phillips-head screws (threads treated with a small

amount of red Loctite #271) securely.

5?9

! CAUTION

        

  &   

$

! CAUTION

B&

<   +%,)=   & 

)%%.B$

RepairPro Service Manual

5

5?6

13. Place the fixed driven assembly into position and

secure with the nut. Tighten to 10.4-11.8 kg-m

(75-85 ft-lb).

86

14. Slide the fixed drive face onto the shaft.

15. 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.

549

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

and over the front shaft.

557

„

 ' !

$

17. Pinch the V-belt together near its center and slide

the spacer and movable drive face onto the shaft.

Secure the drive face with a nut (threads coated

with red Loctite #271). Tighten the nut to

10.4-11.8 kg-m (75-85 ft-lb).

55

„

 ! "

 "$

18. Rotate the V-belt and clutches until the V-belt is

flush with the top of the driven clutch.

19. Place the V-belt cover gasket into position; then

install the cover and secure with the cap screws

making sure the different-lengthed cap screws are

in their proper location. Tighten the cap screws to

1.1 kg-m (8 ft-lb).

86

5

3

Installing Left-Side 

Components

„

  2   !   

!"#"

 &!"!$

1. Install the water pump drive gear alignment pin

and the drive gear (with the flat side of the gear

facing outward as noted in removing); then secure

with the snap ring.

64

„

 !! 

$

2. Install the water pump driven gear alignment pin

and the driven gear (with the beveled side of the

gear facing outward as noted in removing); then

secure with the snap ring.

?45

„

 !! 

$

„

 "

!!$

3. Install the two starter gear shafts; then install the

two starter gears (with the beveled side of the

intermediate gear facing inward as noted in

removing).

66

4. In order on the crankshaft, install a washer, ring

gear, key, and the magneto rotor. Secure with the

nut (threads coated with red Loctite #271). Tighten

to 16 kg-m (116 ft-lb).

5. Lubricate the magneto cover gasket with fresh

engine oil; then place it into position on the two

dowel pins.

69

6. Install the magneto cover and secure with existing

hardware. Tighten to 1.1 kg-m (8 ft-lb).

7. Place the speedometer gear housing and gasket

into position and secure with the two cap screws.

Tighten securely.

879

! CAUTION

-   !   !

! &$

RepairPro Service Manual

54

8. Place the water pump into position and secure with

two cap screws. Tighten securely.

6

9. Install the crossover tube on the water pump and

cylinder head making sure the O-ring is properly

positioned.

69

67

10. Install the shift arm on the shift arm shaft making

sure the scribed marks (from removing) are

aligned. Tighten securely.

11. Place the starter cup into position on the

crankshaft making sure a new, lubricated O-ring is

inside the cup. Tighten the flange nut to 3.5 kg-m

(25 ft-lb).

87

12. Place the gasket and recoil starter assembly into

position on the left-side cover; then tighten four

cap screws to 0.8 kg-m (6 ft-lb).

Installing Top-Side 

Components

A. Piston
B. Cylinder

787

„

  ,  !  " 

C$

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

thin oil ring in the bottom groove of the piston. 

30

$ &

$ %>

$ 

4$ &*

5$ 2

6$ B.+

8$ !%

?$ 1

55

3

'7?5

B. Stagger the gaps of the upper and lower thin

rings.

„

  &

$

'74

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.

„

   !      

!$

7)

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.

75)

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.

74)

4. Loosely install the two nuts which secure the

cylinder to the crankcase.

! CAUTION

,!!

!

!$

! CAUTION

,    !  

$

! CAUTION

&&$)

 &     ! 

& &&$

RepairPro Service Manual

56

„

    &  

 !7$

7)

5. Install the coolant hose onto the crankcase union

and tighten the clamp.

C. Cylinder Head
D. Valve Cover

7844

„

  %! 5   !  

!!$

6. Place the chain guide into the cylinder.

7)

7. 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.

30

$ &.&

$ '"*

$ !

4$ 2

5$ !%

6$ !%

8$ &.*

?$ 2

9$ !%

7$ !%

$ &.%>

$ &.%>

$ %>

4$ !%

5$ !%

6$ 

8$ 

?$ *

9$ .*

7$ %!2

$ ,!!

$ 1

$ !%

4$ &.2

5$ ,2!&

6$ 1

8$ !%

?$ !

9$ !%

7$ 

$ B!%&

$ "

$ "%

4$ 

! CAUTION

          

 $

58

3

77)

65)

8. Install the four cylinder head cap screws with

copper washers (note the locations of the

different-lengthed cap screws). Tighten only until

snug.

8)

9. Loosely install the five cylinder head nuts.

10. In a crisscross pattern, tighten the four cylinder

head cap screws to 3.8 kg-m (27.5 ft-lb); then

tighten the 8 mm nut to 2.5 kg-m (18 ft-lb). Using

a crisscross pattern, tighten the 6 mm nuts to 1.1

kg-m (8 ft-lb). Tighten the two cylinder-to-

crankcase nuts securely.

11. With the timing inspection plug removed and the

chain held tight, rotate the crankshaft until the

piston is at top-dead-center.

12. With the alignment pin installed in the camshaft,

loosely place the cam sprocket (with the recessed

side facing the cam shaft lobes) onto the camshaft.

At this point, do not “seat” the sprocket onto the

shaft.

878>

„

    !     

 ;

&$

13. With the cam lobes directed down (toward the

piston), maneuver the camshaft/sprocket assembly

through the chain and towards its seating position;

then loop the chain over the sprocket.

75)

„

 !

$& !

"""$,

&

! 

 !!$

68)

RepairPro Service Manual

5?

14. Seat the cam sprocket onto the camshaft making

sure the alignment pin in the camshaft aligns with

the smallest hole in the sprocket; then place the

camshaft/sprocket assembly onto the cylinder

ensuring the following.

6?)

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.

15. Place the tab-washer onto the sprocket making

sure it covers the pin in the alignment hole.

'78

87)

16. Install the first cap screw (coated with red Loctite

#271) securing the sprocket and tab-washer to the

cam shaft. Tighten only until snug.

69)

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

cylinder.

7)

18. Install the cylinder head plug in the cylinder head

with the open end facing upward and toward the

inside.

! CAUTION

,& "

 !&!$

! CAUTION

         

&"

 !$ ,   !  

"$

! CAUTION

 !    !    !

!$

59

3

84)

19. Place the chain tensioner into position and secure

with the cap screw and washer.

74)

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

tensioner; then using a flat-blade screwdriver,

rotate the adjuster screw inside the tensioner

clockwise until the screw bottoms.

79)

„

 ; 

;

$; 

!$

21. Place the chain tensioner adjuster assembly and

gasket into position on the cylinder and secure

with the two Allen-head cap screws.

7)

77)

22. Using a flat-blade screwdriver, rotate the adjuster

screw inside the tensioner counterclockwise until

all tension is released; then install the cap screw

into the end of the chain tensioner.

79)

779)

RepairPro Service Manual

67

23. Rotate the crankshaft until the second cap screw

securing the sprocket to the camshaft can be

installed; then install the cap screw (coated with

red Loctite #271) and tighten to 1.5 kg-m (11

ft-lb). Bend the tab to secure the cap screw.

24. Rotate the crankshaft until the first cap screw

securing the sprocket to the camshaft can be

addressed; then tighten to 1.5 kg-m (11 ft-lb).

Bend the tab to secure the cap screw.

25. Loosen the four adjuster screw jam nuts; then

loosen the four adjuster screws on the rocker arms

in the valve cover.

5?)

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

0636-070) to the mating surfaces of the cylinder

head and valve cover.

85)

27. Place the valve cover into position.

„

    !    

;"!$

28. Install the four top side cap screws with rubber

washers; then install the remaining cap screws.

Tighten only until snug.

77)

29. In a crisscross pattern starting from the center and

working outward, tighten the cap screws securely.

30. Adjust valve/tappet clearance using the following

procedure.

„

  + '"  ; <!#

744478?=!$

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.

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.

„

  1   !!! %!

!!""#!!$

„

 1"";

!""#!! &

7$75<7$77$=!$

F. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

31. Place the two tappet covers into position making

sure the proper cap screws are with the proper

cover. Tighten the cap screws securely.