Snowmobile Arctic Cat (2007 year). Instruction - part 26

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 26

 

 

2-89

2

27. With a new gasket, install the oil pan and install

the different-lengthed cap screws (as noted in

disassembling). Using the pattern shown,

tighten the cap screws to specifications.

741-584A

„ NOTE: Prior to installing the oil pan, ensure the
oil strainer is cleaned thoroughly.

ZJ078A

„ NOTE: If the oil pan drain plug was removed,
always install a new drain plug Washer (p/n 3307-
101) and a new reservoir Washer (p/n 1670-845).

„ NOTE: Rotate the engine to the upright position;
then, if applicable, remove  the cap screw and
washer securing the pistons in the cylinder.

28. Install the cam chain onto the sprocket on the

crankshaft and route the chain up through the

engine case; then install the front-side cam chain

guide number one making sure that it is seated

properly into the groove in the engine case.

ZJ079A

„ NOTE: Prior to installing the cam chain ten-
sioner, assure that the chain is properly seated to
the gear on the crankshaft.

29. Install the cam chain tensioner; then install the

washers between the engine case and guide/ten-

sioner and secure with two Allen-head cap

screws. Tighten to specifications.

ZJ080

30. Position the pistons at the top-dead-center posi-

tion by rotating the crankshaft until the keyway

on the crankshaft is directed upward and aligned

with the cylinder.

ZJ081A

2-90

31. Install the alignment pins into the top of the

engine; then install the new head gasket.

ZJ102A

32. With the head gasket and dowel pins in place,

install the cylinder head by carefully tilting the

head to the front side of the engine allowing the

cam chain guide to slide into the passage in the

cylinder head; then work the head back and

forth until the head is properly seated to the

engine.

33. Install the flange nuts and cap screws; then

using the pattern shown, tighten in the following

sequence:

A. Cap screws 1-6 initially to 2.5 kg-m (18 ft-lb).

B. Flange nuts 7-8 to 2.5 kg-m (18 ft-lb).

C. Flange nuts 9-10 to 1.4 kg-m (10 ft-lb).

D. Flange nuts 11-12 to 2.5 kg-m (18 ft-lb).

E. Cap screws 13-14 to 1.4 kg-m (10 ft-lb).

F. Cap screws 1-6 finally to 5.9 kg-m (43.5 ft-lb). 

741-617A

34. With a light film of engine-assembly grease

applied to the tappets, install the correct shim

(A) and tappet (B) to each valve of the cylinder

head as noted during disassembling.

ZJ083A

„ NOTE: Prior to installing the camshaft, it is
advisable to apply engine-assembly grease to the
camshaft journals and lobes.

35. With the crankshaft rotated to the top-dead-cen-

ter position, place the cam chain over the

sprocket of the exhaust camshaft.

„ NOTE: The exhaust camshaft must be installed
first.

ZJ084

36. With the timing marks (A) on the face of the

camshaft gear properly aligned, place the cam-

shaft into position on the cylinder head.

741-801A

! CAUTION

Make sure that there are no restrictions in the oil-
port hole of the head gasket or severe engine dam-
age may occur.

2-91

2

37. With the cam chain properly seated to the gears

of the crankshaft and exhaust camshaft, install

the intake camshaft noting that the timing marks

(B) are properly aligned.

„ NOTE: With the camshafts and cam chain in
place, there should be exactly 16 pins from intake
cam mark 3 to exhaust cam mark 2.

741-780A

38. With the camshafts in position and properly

timed, install the camshaft covers along with

cam chain tensioner guide number two; then

using the pattern shown, tighten the twelve cap

screws to specifications.

741-624A

39. Install the cam chain tensioner adjuster by first

compressing the locking clip (A); then by push-

ing in the tensioner shaft until completely com-

pressed.

ZJ085A

40. Install the tensioner and secure with two Allen-

head cap screws; then tighten to specifications.

Install the ball, spring, and tensioner bolt and

tighten to specifications.

ZJ086

41. Install the engine cover alignment pins; then

install the engine cover and secure with four cap

screws and plastic washers. Using the pattern

shown, tighten the cap screws to specifications.

741-580A

42. Install the ignition coils and secure with the cap

screws; then tighten securely.

43. Place the starter gear on the crankshaft; then

with the flywheel key installed in the crankshaft,

install the flywheel with the cap screw. Using

the flywheel holder wrench from Flywheel

Puller Kit (p/n 0644-480), tighten the cap screw

to specifications.

ZJ087

2-92

44. Install the oil scavenge pump alignment pins in

the engine case; then with the inner and outer

seals (A) in place on the pump, install the pump

and secure with the four cap screws (B). Tighten

to specifications.

0742-125

45. With the two pins installed in the engine case,

first install the starter torque limiter (A) and

spacer (B); then install the inner spacer (C),

idler gear (D), and outer spacer (E).

742-002A

46. Install the two alignment pins in the engine for

the magneto cover; then with a new gasket,

install the cover and with the pattern shown,

tighten the 18 cap screws to specifications.

741-583A

„ NOTE: If the water temperature and oil pressure
sensors were removed, install the sensors and
tighten in the following sequence: (A) water tem-
perature sensor to 2.1 kg-m (15 ft-lb) and (B) oil
pressure sensor to 1.4 kg-m (10 ft-lb).

ZJ090A

47. Install a new thermostat; then install the cover

and secure with the two cap screws. Tighten to

specifications.

„ NOTE: Make sure to install the thermostat with
the bypass/check valve directed in the up position.

ZJ091A

48. Install the water hose inlet fitting and secure

with the two cap screws. Tighten to specifica-

tions.

ZJ092

49. Install the two intake flanges; then secure with

the four cap screws. Tighten to specifications.

 

 

 

 

 

 

 

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