ATV Arctic Cat 2002. Service Manual

4-11

3. Inspect gas tank valve, tank cap, and tank for

leaks, holes, and damaged threads.

4. Inspect the gas gauge for proper operation.

INSTALLING

1. Place the gas tank into position on the frame; then

install the torx-head screws. Tighten securely.

2. Connect the fuel hose from the carburetor; then

secure hose to cables and hoses with a cable tie.

3. Install the air-intake snorkel (250/300) or the air

cleaner housing cover (375/400/500).

4. Install the vent hose; then fill the gas tank with

gasoline.

5. Turn the gas tank valve to the ON position and

inspect for leakage.

6. Install the seat.

Gas Tank Valve

The ATV has a valve incorporated into the bottom of

the gas tank. There are three positions: ON, RES, and

OFF.

ATV-1098

In the OFF position, the valve will not allow gasoline

to flow to the carburetor. In the ON position (the nor-

mal operating position), gasoline will flow from the

tank to the carburetor. In this position 2.46 l (0.65 U.S.

gal.) will remain in the tank as a reserve quantity.

Moving the valve to the RES position will allow the

operator to use the remaining gasoline in the tank.

When turning the valve to any of the three positions,

be sure the indicator is pointed directly at the position

desired.

REMOVING/INSPECTING

1. Remove the gas hose from the valve by releasing

the spring clamp.

2. Remove the two nuts securing the valve; then

remove the valve. Account for the gasket.

3. Inspect the gasket and valve/tank mating surfaces

for damage or deterioration.

4. Inspect for and remove any obstructions in the

valve.

INSTALLING

1. Place the valve and gasket into position on the

tank and secure with the nuts. Tighten to 0.1 kg-m

(1 ft-lb).

2. Install the gas hose onto the valve with the spring

clamp.

Gas/Vent Hoses

Replace the gas hose every two years. Damage from

aging may not always be visible. Do not bend or

obstruct the routing of the carburetor vent hose. Make

certain that the vent hose is securely connected to the

carburetor and the opposite end is always open.

! WARNING

Drain the gas tank prior to this procedure.

RepairPro Service Manual

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4-13

ATV-0106

Oil Pump

NOTE: Whenever internal engine components

wear excessively or break and whenever oil is con-
taminated, the oil pump should be disassembled,
cleaned and inspected, and serviced as necessary.

0733-752

0732-310

250/300

KEY

1. Engine Oil Pump
2. Driven Gear
3. Pin
4. Circlip
5. Cap Screw
6. Strainer
7. Cap Screw
8. Cap
9. O-Ring

10. Cap Screw
11. Drain Plug
12. Gasket
13. Filter
14. Filter O-Ring
15. Cap
16. Check Plug
17. Gasket
18. Cap O-Ring
19. Spring
20. Stud Bolt
21. Stud Bolt
22. Nut

250/300

KEY

1. Engine Oil Pump
2. Driven Gear
3. Pin
4. Washer
5. Circlip
6. Cap Screw
7. Strainer
8. Cap Screw
9. Cap

10. O-Ring
11. Bolt
12. Filter
13. Drain Plug
14. Gasket
15. Oil Relief Valve Assy
16. Oil Filter Union

400/500
(Manual Transmission)

RepairPro Service Manual

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4-14

0735-615

REMOVING/DISASSEMBLING

1. Remove the oil pump from the engine (see

Right-Side Components in Section 3).

2. Remove the Phillips-head screw on the back side

of the pump and separate the pump housing and

cover. Note the position of the inner and outer

rotors and alignment pin for assembly.

3. Remove oil pump components.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all oil-pump components.

2. Inspect the rotors for scoring and gouges.

3. Inspect the alignment pin for damage.

4. Inspect the pump housing and cover for cracks or

damage.

ASSEMBLING/INSTALLING

1. Place the rotors into the pump housing making

sure the alignment pin is in the groove of the rotor.

2. Place the cover onto the pump housing.

3. Secure the pump with the Phillips-head screw

coated with red Loctite #271.

4. Install the oil pump into the engine (see Right-Side

Components in Section 3).

Testing Oil Pump

Pressure

NOTE: The engine must be warmed up to operat-

ing temperature for this test.

1. Connect the Arctic Cat Engine Tachometer (p/n

0644-275) to the engine.

2. Connect the Oil Pressure Gauge (p/n 0444-039) to

the oil filter drain plug.

NOTE: Some oil seepage may occur when

installing the oil pressure gauge. Wipe up oil resi-
due with a cloth.

3. Start the engine and run at the specified RPM.

4. The oil pressure gauge must read as specified.

NOTE: If the oil pressure is lower than specified,

check for an oil leak, damaged oil seal, or a defec-
tive oil pump.

NOTE: If the oil pressure is higher than speci-

fied, check for too heavy engine oil weight (see
Section 2), clogged oil passage, clogged oil filter,
or improper installation of the oil filter.

KEY

1. Engine Oil Pump
2. Driven Gear
3. Pin
4. Washer
5. Circlip
6. Cap Screw
7. Strainer
8. Cap Screw
9. Cap

10. O-Ring
11. Cap Screw
12. Filter
13. Drain Plug
14. Gasket
15. Oil Relief Valve Assy
16. Oil Filter Union

375/500
(Automatic Transmission)

250/300

OIL PRESSURE @ 3000 RPM

0.7-2.8 kg/cm²

(10-40 psi)

Oil Temperature - 60°C (140°F)

375

OIL PRESSURE @ 3000 RPM

1.53-3.57 kg/cm²

(21.7-50.8 psi)

Oil Temperature - 60°C (140°F)

400/500 (Manual Transmission)

OIL PRESSURE @ 3000 RPM

1.3-1.7 kg/cm²

(18-24 psi)

Oil Temperature - 60°C (140°F)

500 (Automatic Transmission)

OIL PRESSURE @ 3000 RPM

1.9-2.5 kg/cm²

(27-36 psi)

Oil Temperature - 60°C (140°F)

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4-15

Oil Cooler

(250/300/375)

0733-727

REMOVING

NOTE: It is not necessary to drain the engine oil

for this procedure.

1. Remove the input and output hoses from the

fittings on the cooler.

2. Remove the torx-head screws securing the oil

cooler to the frame. Account for grommets,

collars, and washers.

AL651D

3. Remove the oil cooler from the frame.

INSTALLING

1. Place the collar into position in the frame.

2. Secure the cooler to the frame with the torx-head

screws, washers, collars, and spacers.

AL651D

3. Install the hoses onto their respective fittings and

secure with the clamps.

! CAUTION

Elevate and secure the hoses to avoid oil
spillage.

KEY

1. Oil Cooler
2. Grommet
3. Cap Screw
4. Washer
5. Collar
6. Hose Clamp
7. Hose (Output)
8. Hose (Input)
9. Cap Screw

10. O-Ring
11. Fitting (Angled)
12. Fitting

RepairPro Service Manual

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4-16

Liquid Cooling System

(400/500)

0735-912

0735-528

KEY

1. Radiator Screen
2. Wire Clamp
3. Cap Screw
4. Grommet
5. Collar
6. Hose
7. Radiator Cap
8. Radiator Assy
9. Hose Clamp

10. Radiator
11. Hose Clamp
12. Coolant Hose
13. Fan Blade
14. Fan Motor
15. Machine Screw
16. Coolant Hose
17. Coolant Hose
18. Machine Screw
19. Washer
20. Fender Panel
21. Thumb Screw
22. Speed Nut
23. Nut
24. Washer
25. Stem Bushing
26. Machine Screw
27. Cable Tie
28. Fan Shroud
29. Fender Panel
30. Flange Nut

400/500
(Manual Transmission)

KEY

1. Radiator Screen
2. Wire Clamp
3. Cap Screw
4. Grommet
5. Collar
6. Vent Hose
7. Radiator Cap
8. Radiator Assy
9. Radiator

10. Clamp
11. Coolant Hose
12. Fan Blade
13. Fan Motor
14. Machine Screw
15. Coolant Hose
16. Coolant Hose
17. Washer
18. Fan Shroud
19. Thumb Screw
20. Speed Nut
21. Nut
22. Washer
23. Stem Bushing
24. Machine Screw
25. Cable Tie
26. Cable Tie
27. Flange Nut

500
(Automatic Transmission)

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4-17

The cooling system capacity is approximately 2.9 L (3

U.S. qt). The cooling system should be inspected daily

for leakage and damage. Also, the coolant level should

be checked periodically.

When filling the cooling system, use premixed Arctic

Cat Antifreeze (p/n 0638-395). While the cooling sys-

tem is being filled, air pockets may develop; therefore,

run the engine for five minutes after the initial fill, shut

the engine off, and then fill the cooling system to the

bottom of the stand pipe in the radiator neck.

AN604D

Radiator

0732-411

REMOVING

1. Drain the coolant at the engine.

2. Remove the front rack (see Section 8).

3. Remove the front bumper and grille assembly (see

Section 8).

4. Remove the upper and lower coolant hoses.

5. Remove the two cap screws and nuts securing the

radiator to the frame.

6. Disconnect the fan wiring from the main wiring

harness; then remove the radiator/fan assembly

and account for the two grommets with collar

inserts.

7. Remove the fan/fan shroud assembly from the

radiator.

CC863

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Flush the radiator with water to remove any

contaminants.

2. Inspect the radiator for leaks and damage.

3. Inspect all hoses for cracks and deterioration.

4. Inspect all fasteners and grommets for damage or

wear.

INSTALLING

1. Position the fan/fan shroud assembly on the

radiator; then secure with existing hardware.

2. Place the radiator with grommets and collar inserts

into position on the frame; then install the two cap

screws and nuts. Tighten securely.

3. Install the upper and lower coolant hoses; then

secure with hose clamps.

! CAUTION

After operating the ATV for the initial 5-10
minutes, stop the engine, allow the engine to
cool down, and check the coolant level. Add
coolant as necessary.

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4-18

AF734D

4. Install the front bumper and grille assembly (see

Section 8).

5. Install the front rack (see Section 8).

6. Fill the cooling system (2.9 L or 3 U.S. qt) with

antifreeze. Check for leakage.

7. Connect the fan wiring to the main wiring harness.

Hoses/Thermostat

REMOVING

1. Drain the coolant from the cooling system.

2. Remove the hose clamps securing the lower

coolant hose to the water pump housing and to the

radiator; then remove the lower hose.

CC334D

3. Remove the clamps securing the upper coolant

hose to the thermostat housing and to the radiator;

then remove the upper hose.

CC335D

4. Remove the clamps securing the crossover coolant

hose to the water pump and to the engine water

inlet.

5. Remove the two cap screws securing the

thermostat housing to the cylinder head. Account

for an O-ring and a thermostat.

INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect the thermostat for corrosion, wear, or

spring damage.

2. Using the following procedure, inspect the

thermostat for proper operation.

A. Suspend the thermostat in a container filled

with water.

B. Heat the water and monitor the temperature

with a thermometer.

C. The thermostat should start to open at

48.5-51.5°C (119.3-124°F).

D. If the thermostat does not open, it must be

replaced.

3. Inspect all coolant hoses, connections, and clamps

for deterioration, cracks, and wear.

NOTE: All coolant hoses and clamps should be

replaced every four years or 4000 miles.

INSTALLING

1. Place the thermostat and O-ring into the

thermostat housing; then secure the thermostat

housing to the cylinder head with the two cap

screws.

2. Install the crossover coolant hose onto the water

pump and engine water inlet. Secure with the two

hose clamps.

3. Slide the upper hose onto the thermostat housing

and radiator. Secure with the two hose clamps.

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4-19

4. Install the lower coolant hose onto the water pump

housing and radiator. Secure with the two hose

clamps.

5. Fill the cooling system (2.9 L or 3 U.S. qt) with

antifreeze. Check for leakage.

Fan

REMOVING

1. Remove the radiator (see Radiator in this section).

2. Remove the fan assembly from the radiator.

CC862

INSTALLING

1. Position the fan assembly on the radiator; then

secure with existing hardware.

NOTE: The fan wiring must be in the upper-right

position.

2. Install the radiator (see Radiator in this section).

Servicing Water Pump

(400/500 - Manual Transmission)

REMOVING/DISASSEMBLING

0732-311

1. Drain the coolant.

2. Remove the three cap screws securing the water

pump case. Note the position of the long cap screw

and account for the O-ring.

3. Remove the impeller cap screw, washer, and

gasket.

4. Remove the mechanical seal using this procedure.

A. Tap the tip of a small sheet metal screw into the

inner-metal edge of the seal.

B. Grip the screw with a pair of vise-grip pliers

and pull the seal out. Account for the pump

drive seal.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all pump components in solvent.

2. Inspect the mechanical seal and pump drive seal

for damage.

NOTE: If the mechanical seal and/or pump drive

seal are damaged, they must be replaced as a set.

3. Inspect the impeller for corrosion or damage.

KEY

1. Case
2. Cap Screw
3. Gasket
4. O-Ring
5. Cap Screw
6. Cap Screw
7. Joint
8. Shaft w/Bearing
9. Pin

10. Pump Drive Seal
11. Mechanical Seal
12. Impeller
13. Cap Screw
14. Washer
15. Gasket

RepairPro Service Manual

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4-20

ASSEMBLING/INSTALLING

NOTE: Treat seals and O-rings with clean anti-

freeze for initial lubrication.

1. Press the mechanical seal with pump drive seal

into the impeller by hand.

2. Install the mechanical seal assembly onto the

water pump shaft and secure with the cap screw,

washer, and gasket. Tighten the cap screw

securely.

3. Place the water pump case into position and secure

with the three cap screws. Note the position of the

long cap screw from removal.

4. Fill the cooling system (2.9 l or 3 U.S. qt) with

antifreeze.

NOTE: While the cooling system is being filled,

air pockets may develop; therefore, run the engine
for five minutes after the initial fill, shut the engine
off, and then fill the cooling system.

5. Check the entire cooling system for leakage.

Servicing Water Pump

(500 - Automatic Transmission)

NOTE: When servicing the water pump, it will be

necessary to install a new Oil Seal (p/n 3402-465)
and a new Mechanical Seal/Ceramic Seal Assem-
bly (p/n 3402-360).

735-616A

KEY

1. Water Pump Assy
2. Bolt
3. Gasket
4. O-Ring
5. Impeller/Shaft
6. Mechanical Seal/Ceramic Seal Assy
7. Oil Seal
8. Bearing
9. E-Ring

10. O-Ring
11. Screw
12. Cap Screw

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4-21

REMOVING

1. Remove the radiator cap; then remove the water

pump drain plug and drain the coolant.

CC789

2. Drain the oil from the engine/transmission.

3. Remove the four torx-head cap screws securing

the front and rear fenders to the footrest; then

remove the four cap screws securing the footrest to

the frame. Remove the footrest.

4. From inside the left-front wheel-well, remove the

two torx-head cap screws securing the fender to

the frame.

CC788A

5. Compress the tabs on the coolant hose clamps and

slide the clamps away from the hose ends

approximately 51 mm (2 in.); then remove both

hoses from the water pump.

CC784

6. Using an impact driver, loosen but do not remove

the two Phillips-head water pump cover screws.

CC785A

7. Remove the two cap screws securing the water

pump to the engine; then remove the water pump.

CC786A

DISASSEMBLING

1. Finish removing the two Phillips-head cap screws

securing the cover to the bearing housing; then

remove the cover. Account for the O-ring.

2. Remove the E-ring securing the impeller/shaft to

the bearing housing; then remove the

impeller/shaft.

CC781

3. Using Seal Removal Tool (p/n 0644-072), remove

the mechanical seal and the oil seal from the

bearing housing.

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4-22

CC772

4. Using a small screwdriver, pry up and remove the

ceramic seal from the impeller/shaft; then remove

the seal seat.

CC773

CC775

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all oil-pump components in cleaning

solvent.

2. Inspect the impeller/shaft for corrosion or damage.

ASSEMBLING

1. Place the new oil seal into the bearing housing;

then using a seal driver, gently tap the seal down

until it is fully seated.

CC778

2. Place the new mechanical seal into the bearing

housing; then tap it down until it is fully seated.

NOTE: A large deep-well socket can be used to

drive the seal down evenly.

3. Using the protective cloth provided, slide the new

ceramic seal (red markings down) and seal seat

onto the impeller/shaft. Touch the assembly

ONLY with the protective cloth provided.

CC776

4. Install the impeller/shaft assembly into the bearing

housing; then secure with the E-ring.

CC781

! CAUTION

If the protective cloth is not used and the
seal/seat assembly is touched, permanent
damage to the assembly will occur and
replacement will be necessary.

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4-23

NOTE: Make sure the E-ring is fully seated and

the impeller rotates freely.

5. While holding the bearing housing assembly in

position on the engine, slowly rotate the impeller

until the impeller/shaft engages properly with its

slot in the driven shaft.

NOTE: The bearing housing will be flush with the

engine when the two shafts are properly engaged.

6. With the bearing housing assembly in position on

the engine, place the cover (with O-ring installed)

into position on the housing; then loosely secure

with the two Phillips-head cap screws.

INSTALLING

1. Secure the water pump to the engine with the two

cap screws tightened securely; then tighten the two

Phillips-head cap screws securely.

CC786A

CC785A

2. Connect the two coolant hoses to the water pump

and secure with the clamps.

CC784

3. From inside the left-front wheel-well, secure the

fender to the frame with the two torx-head cap

screws. Tighten securely.

CC788A

4. Place the footrest into position on the frame and

loosely secure with four cap screws; then secure

the front and rear fenders to the footrest with the

four torx-head cap screws. Tighten the four

torx-head cap screws securely; then tighten the

two 8 mm cap screws to 2.8 kg-m (20 ft-lb) and

the two 10 mm cap screws to 5.5 kg-m (40 ft-lb).

5. Fill the engine/transmission with the proper

amount of recommended oil.

6. Fill the cooling system with the proper amount of

recommended coolant.

AN604D

! CAUTION

Failure to properly engage the two shafts could
cause serious engine damage.

RepairPro Service Manual

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5-2

Specifications

250

IGNITION

Ignition Timing

5° BTDC below 1800 RPM
35° BTDC above 3800 RPM

Spark Plug Type

NGK DR7EA

Spark Plug Gap

0.6-0.7 mm
(0.024-0.028 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.1-0.5 ohm

(terminal to ground)

5200-7800 ohms

(high tension - plug cap
removed - to ground)

MAGNETO

Magneto Coil Resistance

(trigger)

(charging)

80-150 ohms (black/yellow

to green/white)

0.1-1.0 ohm

(yellow to yellow)

Magneto Output (approx) 220W @ 5000 RPM

300

IGNITION

Ignition Timing

5° BTDC @ 1800 RPM
30° BTDC @ 3800 RPM

Spark Plug Type

NGK DR7EA

Spark Plug Gap

0.6-0.7 mm
(0.024-0.028 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.1-0.5 ohm

(terminal to ground)

5200-7800 ohms

(high tension - plug cap
removed - to ground)

MAGNETO

Magneto Coil Resistance

(trigger)

(charging)

80-150 ohms (black/yellow

to green/white)

0.1-1.0 ohm

(yellow to yellow)

Magneto Output (approx) 220W @ 5000 RPM

375

IGNITION

Ignition Timing

10° BTDC @ 3000 RPM

Spark Plug Type

NGK CR7E

Spark Plug Gap

0.7-0.8 mm
(0.028-0.032 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.05-0.5 ohm

(terminal to ground)

4000-9000 ohms

(high tension - plug cap
removed - to ground)

MAGNETO

Magneto Coil Resistance

(trigger)

(source/charge)

(charging)

130-250 ohms

(green to blue)

0.03-1.2 ohms

(yellow to white)

0.1-1.0 ohm

(black to black)

Magneto Output (approx) 220W @ 5000 RPM

400

IGNITION

Ignition Timing

10° BTDC @ 1500 RPM

Spark Plug Type

NGK CR6E

Spark Plug Gap

0.7-0.8 mm
(0.028-0.032 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.1-1.0 ohm

(terminal to ground)

4500-10,000 ohms

(high tension - plug cap
removed - to ground)

MAGNETO

Magneto Coil Resistance

(trigger)

(source/charge)

(charging)

150-300 ohms

(green to blue)

0.05-1.0 ohm

(yellow to white)

0.1-1.0 ohm

(black to black)

Magneto Output (approx) 325W @ 5000 RPM

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ATV Arctic Cat 2002. Service Manual - part 17