Snowmobile Arctic Cat (2002 year). Instruction - part 7

 

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Snowmobile Arctic Cat (2002 year). Instruction - part 7

 

 

2-11

2

AP118B

13. 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

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

then lay the unit aside out of the way.

15. Remove the two APV drain hoses and route them

out of the way.

AP128A

16. Label the carburetors. Loosen the flange clamp

securing each carburetor to its flange; then remove

the carburetors from the intake flanges. Position

the carburetors to one side in an upright position.

AN614D

17. Disconnect the impulse hose from the crankcase.

18. Loosen the engine torque bumper; then remove the

left-side rear engine nut and washer.

AN610D

19. Disconnect the engine and timing sensor wiring

harnesses from the main wiring harness. Remove

the spark-plug caps from the spark plugs. Remove

the cap screw securing the two ground wires to the

magneto housing cover.

20. Remove the E-clip and washer securing the oil-

injection cable; then disconnect the oil-injection

cable from the oil-injection pump. Disconnect the

oil-supply hose and the oil-output hose from the

pump and plug the hoses to prevent oil drainage.

AN392D

2-12

21. Loosen the clamp securing the coolant supply hose

to the water pump housing; then remove the hose

from the water pump. Loosen the clamp securing

the hose to the thermostat cap; then remove the

hose from the cap.

22. Disconnect the temperature-gauge sender wire.

AJ663

23. Remove the cap screws securing the engine

mounting brackets to the front end. Account for

mounting hardware.

24. Lift the MAG-side of the engine. Remove the four

cap screws and lock washers securing the recoil

starter; then remove the starter from the engine.

Leave it in the engine compartment.

„

NOTE: If applicable, disconnect the solenoid- to-

starter motor cable from the starter motor.

AN012

25. Lift the engine with engine mounting brackets out

of the engine compartment.

26. Remove the mounting brackets from the

crankcase.

Disassembling Engine

Table of Contents

120 cc Model ......................................................... 2-12
370/440 cc Models ................................................ 2-17
550 cc Models ....................................................... 2-20
570 cc Models ....................................................... 2-23
500/600 cc Twin Models ........................................ 2-29
800 cc Models ....................................................... 2-34
600 cc Triple Model ............................................... 2-39
1000 cc Models ..................................................... 2-45

Disassembling Engine

(120 cc Model)

1. Remove the oil drain plug and drain the oil; then

install the oil plug and tighten securely.

GM300D

2. Remove the wing nut securing the air cleaner end

cap to the air cleaner housing.

3. Remove the cap screw and flange nuts securing

the air cleaner housing to the carburetor and

engine.

A002

2-13

2

GF314D

4. Remove the air breather hose from the air cleaner

housing; then remove the air cleaner housing from

the carburetor. Account for the gasket.

A001

GF316D

5. Mark the locations of the springs for assembly;

then disconnect the rod and spring from the

carburetor.

GF208D

6. Slide the carburetor off the mounting studs.

Account for a gasket, insulator block, and a

gasket.

GF318D

7. Remove the recoil starter/fan housing assembly.

GM201D

8. Remove the screws securing the recoil starter

pulley to the flywheel; then remove the nut

securing the flywheel to the crankshaft.

2-14

GM202D

GM203D

9. Using a flywheel puller, remove the flywheel.

GM110D

10. Remove the high tension lead from the spark plug

and two wire forms; then disconnect the ignition

coil wire.

11. Remove the cap screws securing the ignition coil

to the crankcase housing.

GE318D

12. Remove the cylinder head cover.

GM205D

13. Remove the air breather body assembly from the

cylinder head cover. Account for a gasket.

GM206D

14. Remove the screws securing the reed stopper to

the air breather body assembly.

 

 

 

 

 

 

 

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