ATV Arctic Cat 2001 Line. Service Manual

Fig. 3-360

CC030D

5. Lay the ATV on its left side; then remove the fifteen

cap screws securing the right-side cover to the
crankcase. Remove the cover. Note the location of
the long cap screw and rubber washer. Account for
the gasket and for two alignment pins.

Fig. 3-361

CC034D

NOTE: The water pump housing does not have to

be removed when removing the right-side cover.

Fig. 3-362

CC068D

NOTE: When removing the right-side cover,

account for the release roller guide that it does not
fall and cause damage.

Fig. 3-363

CC070D

6. Remove the water pump drive joint from the water

pump shaft. Account for the pin.

Fig. 3-364

CC082D

C. Primary Driven Gear
D. Primary Driven Clutch
E. Starter Clutch Housing

NOTE: Steps 1-6 in the preceding sub-section

must precede this procedure.

7. Remove the reverse cam stopper housing and

gasket and account for a stopper and spring.

Fig. 3-365

CC069D

3-74

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

8. Remove the cap screw securing the clutch release

arm and remove the arm; then in a crisscross
pattern, remove the four cap screws securing the
clutch release roller assembly.

NOTE: Scribe a reference mark with a marker on

the arm and shaft to aid in assembly.

Fig. 3-366

CC073D

Fig. 3-367

CC074D

9. Remove the release roller assembly. Account for

four springs.

10. Remove the starter clutch-shoe nut (left-hand

threads) and washer from the driveshaft; then using
a primary clutch shoe remover, remove the clutch
shoe.

Care must be taken when removing the nut; it
has “left-hand” threads.

Fig. 3-368

CC072D

11. Remove the primary drive one-way clutch from the

starter clutch housing. Note the word OUTSIDE
stamped on the clutch for assembly purposes.

Fig. 3-369

CC075D

12. Using the Clutch Sleeve Hub Holder (p/n

0444-007) to hold the clutch sleeve hub, remove the
nut and washer.

Fig. 3-370

CC076D

13. Scribe a line across the primary driven clutch

assembly to aid in assembly.

! CAUTION

3-75

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

Fig. 3-371

CC077D

14. Simultaneously, remove the primary driven clutch

assembly and starter clutch housing from their
respective shafts. Account for the sleeve and
washers.

Fig. 3-372

CC078D

To service clutch components, see Servicing
Right-Side Components in this sub-section.

F. Gear Shift Shaft
G. Oil Pump/Oil Strainer

NOTE: Steps 1-14 in the preceding sub-sections

must precede this procedure.

15. Remove the chain from the crankcase.

Fig. 3-373

CC079D

To service cam chain, see Servicing Right-Side
Components in this sub-section.

16. Remove the nut and washer securing the oil pump

drive gear to the crank balancer shaft; then remove
the gear and account for the pin and the spacer.

Fig. 3-374

CC080D

Fig. 3-375

CC081D

17. Remove the gear shift shaft from the crankcase.

AT THIS POINT

3-76

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

Fig. 3-376

CC085D

18. Release the tension from the gear shift cam stopper

arm spring.

Fig. 3-377

CC086D

19. Remove the cap screw securing the gear shift cam

plate and guide to the gear shift cam; then remove
the cam plate and guide.

Fig. 3-378

CC164D

If servicing of the engine/transmission is due to
a lubrication-related problem, replace the oil
pump.

NOTE: For general servicing, it is advisable to

disassemble, clean, and inspect the oil pump. If any
wear or damage is suspected, replace the oil pump.

20. Remove the circlip securing the oil pump driven

gear; then remove the gear. Account for the pin and
the washer.

Fig. 3-379

CC088D

Fig. 3-380

CC089D

21. Remove the three Phillips-head screws securing the

oil pump; then remove the oil pump.

Fig. 3-381

CC090D

22. Remove the cap screws securing the oil strainer

cap; then remove the cap. Account for the O-ring.

! CAUTION

3-77

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

Fig. 3-382

CC091D

23. Remove the two Phillips-head cap screws securing

the strainer.

Fig. 3-383

CC163D

To service center crankcase components only,
proceed to Separating Crankcase Halves.

Center Crankcase

Components

NOTE: This procedure cannot be done with the

engine/transmission in the frame. Complete
Removing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

Separating

Crankcase Halves

1. Remove the five right-side 6 mm cap screws (one

from inside the case) securing the crankcase halves.
Note the location of the different-lengthed cap screws.

Fig. 3-384

CC530D

2. Remove the seven left-side 6 mm cap screws

securing the crankcase halves. Note the location of
the wiring form. Note the location of the
different-lengthed cap screws.

Fig. 3-385

CC096D

3. Remove the three left-side 8 mm cap screws (two

from inside the case) securing the crankcase halves.
Note the location of the different-lengthed cap screws.

AT THIS POINT

3-78

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

Fig. 3-386

CC097D

4. Remove the three right-side 8 mm cap screws

securing the crankcase halves.

Fig. 3-387

CC098D

5. 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, an O-ring, and a washer.

NOTE: To keep the shaft/gear assemblies intact

for identification, tap the shafts toward the left-side
crankcase half when separating the halves.

Fig. 3-388

CC099D

Fig. 3-389

CC100D

Fig. 3-390

CC101D

Fig. 3-391

CC102D

3-79

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

Disassembling

Crankcase Half

1. Remove the two gear shift fork shafts.

Fig. 3-392

CC104D

2. Remove the reverse shift cam and spacer.

Fig. 3-393

CC103D

3. Disengage four forks from the gear shift cam; then

remove the reverse shifter fork.

Fig. 3-394

CC105D

4. Remove the gear shift cam.

Fig. 3-395

CC106D

5. Remove the three remaining forks noting their

positions for assembling purposes.

To service gear shift forks, see Servicing Center
Crankcase Components in this sub-section.

Fig. 3-396

CC107D

6. Remove the reverse idle shaft. Account for the

bushing, two washers, and the circlip.

Fig. 3-397

CC108D

7. Simultaneously, remove the driveshaft and

countershaft assemblies. Account for the washer on
the countershaft.

AT THIS POINT

3-80

Click Here to Continue

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

Fig. 3-398

CC197D

To service the driveshaft and/or countershaft,
see Servicing Center Crankcase Components in
this sub-section.

NOTE: For efficiency, if the driveshaft and/or

countershaft are not being serviced, it is preferable
to leave them assembled. The technician should use
discretion and sound judgment.

8. Remove the front shaft (4x4) and rear shaft

assemblies. Account for the bearing C-ring.

Fig. 3-399

CC110D

NOTE: Note the alignment marks on the crank

balancer driven gear and balancer drive gear to aid
in assembly.

Fig. 3-400

CC166D

9. Remove the driven gear from the crank balancer.

Account for a key.

Fig. 3-401

CC167D

Fig. 3-402

CC165D

To service the driven gear, see Servicing Center
Crankcase Components in this sub-section.

NOTE: For efficiency, if the driven gear is not

being serviced, it is preferable to leave it assembled.
The technician should use discretion and sound
judgment.

10. Remove the crank balancer.

AT THIS POINT

3-81

Click Here to Go Back

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

Fig. 3-403

CC168D

NOTE: When removing the crank balancer

assembly, rotate the crankshaft counterweight away
from the crank balancer assembly counterweight.

11. Using the Crankcase Separator/Crankshaft

Remover (p/n 0444-009), push the crankshaft
assembly out of the crankcase.

Fig. 3-404

CC115D

To service crankshaft assembly, see Servicing
C e n t e r C r a n k c a s e C om po n e n t s i n t h i s
sub-section.

Do not remove the remaining output shaft
assembly unless absolutely necessary. If the
shaft is removed, the shaft nut must be replaced
w i t h a new o n e a n d t h e s h a f t mu s t b e
re-shimmed.

12. To remove the output shaft, remove the nut, slide

the gear off the shaft (account for a shim or shims),
and drive the shaft out with a plastic mallet (account
for a shim or shims).

Fig. 3-405

CC482D

Assembling

Crankcase Half

NOTE: For ease of assembly, install components

on the left-side crankcase half.

NOTE: If the output shaft was removed, make sure

that the proper shim is installed.

1. To install the output shaft, place the shaft into

position with proper shims, slide the gear onto the
shaft, and secure with a new nut tightened to 10
kg-m (72 ft-lb).

Fig. 3-406

CC117D

AT THIS POINT

! CAUTION

3-82

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

Fig. 3-407

CC116D

2. Using the Crankshaft Installer (p/n 0444-018),

install the crankshaft.

Fig. 3-408

CC151D

3. Install the crank balancer.

Fig. 3-409

CC168D

4. With the key in position, slide the driven gear onto

the crank balancer making sure the timing marks
are aligned.

Fig. 3-410

CC165D

Fig. 3-411

CC167D

Fig. 3-412

CC166D

5. Place the bearing C-ring into position in the

crankcase; then install the front shaft (4x4) and rear
shaft assemblies.

The bearing pins must be positioned into the
crankcase.

! CAUTION

3-83

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

Fig. 3-413

CC110D

6. Simultaneously, install the driveshaft and

countershaft assemblies making sure the washer is
on the countershaft.

Fig. 3-414

CC197D

7. Install the reverse idle shaft with circlip making

sure the oil hole in the shaft is facing downward;
then install a washer, bushing, reverse idle gear, and
a washer.

Fig. 3-415

CC229D

Fig. 3-416

CC231D

8. Place each of the four shift forks into its respective

gear or dog as noted during disassembling; then
install the gear shift cam.

Fig. 3-417

CC107D

Fig. 3-418

CC106D

9. Engage the four forks to the gear shift cam; then

install the reverse shift cam and spacer.

3-84

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

Fig. 3-419

CC105D

Fig. 3-420

CC103D

10. Install the two gear shift fork shafts; then verify that

the two crankcase half alignment pins are in place.

Fig. 3-421

CC104D

NOTE: Prior to joining crankcase halves, turn the

shift cam to ensure all gears shift properly.

Joining Crankcase

Halves

1. Place the O-ring in the left-side crankcase half and

verify that the shim washer is on the idler shaft; then
apply Three Bond Sealant (p/n 0636-070) to the
mating surfaces. Place the right-side half onto the
left-side half.

Fig. 3-422

CC101D

Fig. 3-423

CC102D

Fig. 3-424

CC234D

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

together until cap screws can be installed.

3-85

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