Snowmobile Arctic Cat (2004 year). Instruction - part 98

7-56

FC232

Heat Exchanger           

(AWS VI)

REMOVING

„

NOTE: The cooling system must be drained for

this procedure.

1. Remove the three torx-head screws securing the

s n o w f l a p   t o   t h e   b u m p e r ;   t h e n   r e m o v e   t h e
snowflap.

FC232

2. Remove the 10 torx-head screws securing the

bumper to the tunnel.

3.  From inside the rear compartment, remove the nut

and washer securing the seat assembly to the
tunnel; then disconnect the taillight wiring
harness.

FC228

FC233

4. Remove the taillight/bumper assembly from the

tunnel.

FC234

„

NOTE: When removing the right-side belly pan,

the resonator must be removed. When removing
the left-side belly pan, the clutch guard must be
removed.

5. From each side, remove the 10 torx-head screws

securing the side belly pan to the frame.

6. From each side using a 3/16 in. drill bit, drill out

the six rivets securing the side belly pan to the
frame; then remove the belly pan.

7.  Remove the clamps and coolant hoses on each end

of the heat exchanger.

7-57

7

FC242

8.  From beneath the running board using a ball-peen

hammer and a chisel, shear off the rivets securing
the heat exchanger.

FC243

9. From beneath the running board using a punch,

drive out the sheared rivets; then remove the heat
exchanger.

FC244

FC245

INSTALLING

1. Place the heat exchanger into position against the

running board; then on each end of the heat
exchanger, install the coolant hoses and new
clamps. Tighten the clamps securely.

„

NOTE: Installing the coolant hoses and clamps

at this time will aid in holding the heat exchanger
against the running board.

FC246

2. Using an appropriate rivet gun, secure the heat

exchanger to the running board.

FC247

3.  On each side, place the side belly pan into position

on the frame; then secure with the 10 torx-head
screws.

4. On each side using an appropriate rivet gun,

secure the side belly pan with six rivets.

7-58

5. Place the taillight/bumper assembly into position

on the tunnel.

FC234

6. Secure the taillight/bumper assembly to the tunnel

with the 10 torx-head screws.

7.  Connect the taillight wiring harness; then position

the seat assembly onto the tunnel.

FC233

8.  From inside the rear compartment, secure the seat

assembly to the tunnel with the nut and washer.

FC228

9. Secure the snowflap to the bumper with the three

torx-head screws.

FC232

10. Fill the cooling system with the recommended

coolant; then use the following procedure.

„

NOTE: Use a good quality, glycol-based, auto-

motive-type antifreeze. While the cooling system is
being filled, allow enough time for the coolant to
pass through the “weep hole” in the thermostat
and into the system; then fill the tank and run the
engine for five to ten minutes after the initial fill
(until the thermostat opens). Add more coolant if
necessary.

„

NOTE: Because the coolant fills slowly into the

engine, it is necessary to wait for 10 minutes after
filling the coolant tank to allow the engine to fill
with coolant.

11.  Recheck the coolant level. If the level is low after

10 minutes, repeat step 10.

12.  Install the coolant cap to the “first” position.

13.  Start the engine. Do not exceed 3000 RPM.

„

NOTE: After the engine has run for about 3-5

m i n u t e s ,   t h e  r i g h t - s i d e   r u n n i n g   b o a r d  h e a t
exchanger should feel warm to the touch. This is a
sign that the thermostat has opened.

14.  Shut off the engine.

15.  Tighten the coolant cap to the “second” position.

16. Recheck the coolant level. If the coolant level is

low, repeat step 10.

17.  Install the coolant cap to the “first” position.

18. Place the snowmobile onto a safety stand.

19. Start the engine and run for 1 to 2 minutes. Do not

exceed 5000 RPM.

20. Monitor the heat exchanger temperature by touch.

21.  Shut off the engine for 5 minutes.

22. Start the engine and run for about 3-5 minutes;

then repeat steps 14-22 an additional 2-3 times. 

7-59

7

23. Take the snowmobile for a test drive. Do not

exceed 5000 RPM during the test ride. Let the
engine cool down; then recheck the coolant level
and add if necessary.

Air Silencer Assembly

(AWS VI)

REMOVING

0737-994

737-997A

1. Remove the connector clamp securing the intake

connector (hose) to the hood screen.

FC248

2.  Remove the two O-rings from the front mounting

tabs of the hood cover; then carefully close the
hood while supporting the hood cover.

3. Raise the front of the hood cover; then carefully

pull forward on the cover to release the rear cover
locking tabs from the hood.

FC249

FC250

4.  Using a flat-blade screwdriver, carefully pry up (in

multiple locations) on the hood screen to remove it
from the hood cover.

! CAUTION

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

KEY

1. Air Silencer Assy
2. Intake
3. Silencer
4. Intake 

Connector
(Hose)

5. Connector Clamp
6. Self-Tapping 

Screw

7. Hold-Down 

Bracket

8. Self-

Tapping 
Screw 

9. Boot

10. Retaining Clip

KEY

1. Hood Cover Assy
2. O-Ring
3. Decal
4. Hood Cover
5. Decal
6. Decal
7. Foil
8. Decal
9. Hood Screen