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Snowmobile Arctic Cat (2002 year). Instruction - part 5

2-3

7. Disconnect the fuel hose from the carburetor.

NOTE: Be prepared to wipe up any fuel spillage.

8. Pull the recoil starter rope out approximately 60

cm (24 in.); then tie a slip-knot in the starter rope

below the console and allow the rope to slowly

retract against the starter case.

9. Remove the knot at the handle and remove the

handle; then thread the rope through the bushing in

the console.

10. At this point, scribe a line at the front of the engine

and measure the distance between the crankshaft

and the driveshaft. Record the measurement for

installing purposes.

A048

11. Lay the snowmobile on its side.

NOTE: A piece of cardboard should be used to

protect the finish.

12. Using a flat-blade screwdriver, remove the four

belly pan plugs covering the engine mounting cap

screws; then remove the cap screws. Account for

eight washers and four lock nuts.

A049

NOTE: The front center plug is to access the oil

drain plug.

13. Place the snowmobile in the upright position; then

on the left-hand side of the engine, remove the

three cap screws securing the engine and brake

bracket to the front end.

A050A

14. Remove the engine from the engine compartment.

Removing Engine

(Twin F/C Models)

NOTE: If equipped with electric start, disconnect

the battery.

1. Turn the gas tank shut-off valve to the CLOSED

position.

2. Open the belt guard.

3. Remove the drive belt; then remove the plug from

the belly pan.

NOTE: Before installing the clutch puller, apply

oil to the threads of the puller and a small amount
of grease to the tip of the puller.

4. Remove the bolt and lock washers securing the

drive clutch to the crankshaft; then using the Drive

Clutch Puller (p/n 0644-207) and an impact

wrench or a breaker bar and Drive Clutch Spanner

Wrench (p/n 0644-136), tighten the puller. If the

drive clutch will not release, sharply strike the

head of the puller with a hammer. Repeat this

procedure until the clutch releases.

! WARNING

Whenever any maintenance or inspection is made
on a fuel system when there may be fuel leakage,
there should be no welding, smoking, open flames,
etc., in the area.

2-4

AF472D

AF476D

5. Remove the clutch from the engine compartment.

6. Remove the cap screw and washer securing the

driven pulley; then slide the pulley off the driven

shaft. Account for and note the position of any

alignment washers.

NOTE: If the driven pulley will not slide off the

driven shaft, use the Driven Pulley Puller (p/n
0744-023) for removal.

SC013D

7. Remove the torque bumper. Account for any

engine mount shims.

AF473D

8. Remove the springs securing the expansion

chamber to the exhaust manifold and resonator;

then remove expansion chamber.

AC067

9. Remove the cap screws and lock washers securing

the recoil starter; then remove the starter. Leave it

in the engine compartment.

AB082

10. Disconnect the four-prong main wiring harness

connector and the CDI unit wiring harness.

11. Disconnect the impulse hose from the crankcase.

12. Disconnect the spark plug caps.

13. Loosen the carburetor flange clamp(s). Remove

the carburetor(s) from the intake flange(s) and

carburetor boot(s). Place the carburetor(s) to the

side in an upright position.

2-5

NOTE: If equipped with electric start, remove the

lock nuts and washers securing the starter motor
to the engine mounting bracket and remove the
starter motor.

14. Disconnect the oil-injection cable from the oil-

injection pump. Account for the E-clip and

washer; then disconnect the oil supply hose from

the pump and plug the hose to prevent leakage.

AB081

NOTE: If equipped with electric start, remove the

two lock nuts and washers securing the starter
motor bracket; then remove the three remaining
cap screws, washers, and lock washers securing
the star ter motor bracket and ground cable .
Remove the starter motor bracket.

15. Remove the cap screws securing the engine to the

front end. Account for washers, cap screws, and

lock nuts.

AL201D

16. Lift the engine out of the engine compartment.

17. Remove the cap screws, washers, and lock

washers securing the engine mounting brackets to

the engine; then remove the brackets.

Removing Engine

(500/600/800 cc Twin Models)

NOTE: Some engines are equipped with Arctic

Power Valves (APV). Closely observe the NOTE:
introducing this important information.

NOTE: If applicable, disconnect the battery

cables.

1. Turn the gas tank shut-off valve to the CLOSED

position.

2. Remove all springs securing the expansion

chamber(s) and remove the expansion chamber(s)

from the engine compartment.

3. Open the belt guard; then remove the drive belt.

4. Remove the plug from the belly pan. Using a ½-in.

12-point socket, remove the cap screw and lock

washer securing the drive clutch to the crankshaft;

then using Clutch Puller (p/n 0644-207) and an

impact wrench or a breaker bar and Spanner

Wrench (p/n 0644-136), tighten the puller. If the

drive clutch will not release, sharply strike the

head of the puller. Repeat this step until the clutch

releases. Remove the drive clutch. If applicable,

account for the two sleeves.

AN380D

5. Remove the cap screw and washer securing the

driven pulley; then slide the driven pulley off the

driven shaft. Account for a key, stub shaft, and

alignment washers.

AF120D

2-6

NOTE: If the driven pulley is tight on the driven

shaft, pull the driven pulley off using the Driven
Pulley Puller (p/n 0744-023).

NOTE: Steps 6 through 12 are for APV equipped

engines.

6. Remove the two cap screws securing the

servomotor cover.

AP116A

7. Using a small screwdriver, pry off the cable

retaining cover.

AP117A

8. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

out of the holder.

AP118A

9. Pull the cable up and out of the cable housing

holder; then slide each cable drum to the left and

out of the servomotor actuator.

AP118B

10. Remove the screw securing the servomotor

mounting plate to the air-intake silencer; then pull

the mounting plate forward and up to remove it

from the silencer. Lay the mounting plate aside out

of the way.

AP127

11. Lift the silencer cover and remove the CDI unit;

then lay the unit aside out of the way.

12. Remove the two APV drain hoses and route them

out of the way.

AP128A

13. If applicable, remove the machine screw and

washer securing the mounting plate (for the

ignition coil and fuel pump) to the air-intake

silencer.

14. Remove the screws securing the air-intake

silencer; then move the silencer forward and out of

the engine compartment.

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