Snowmobile Arctic Cat (2007 year). Instruction - part 28

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 28

 

 

2-97

2

739-267B

„ NOTE: By bottoming the sheave adjuster against
the driven shaft, the sheaves at the driven pulley
will spread far enough to allow the installation of
the drive belt.

B. Place the drive belt (so the part number can

be read) between the sheaves of the drive

clutch first; then between the sheaves of the

driven pulley.

C. Using the deflection tool, remove the sheave

adjuster from the end of the driven pulley.

D. Place the shim washers and O-ring (as noted

in removing) onto the sheave adjuster; then

carefully thread the sheave adjuster back into

the driven pulley. Tighten the adjuster

securely using the deflection tool.

E. Close the belt guard; then install the driven

pulley plug.

18. With the two plastic collars, belt guard pin, and

the hairpin clip, secure the belt guard in place.

19. Connect the fuel hose and throttle body heater

hose to the throttle body and secure with the

hose clamps.

20. Connect the fuel hose to the fuel filter and the

throttle body heater hose to the main return

coolant hose.

AO188

„ NOTE: On turbo models, install the intercooler
bracket onto the engine; then tighten the two
flange nuts securely.

21. Install the air silencer bracket to the engine and

secure with the lock nut.

22. Connect the lower drain hose to the outlet at the

bottom of the belly pan.

23. On the non-turbo models, install the air silencer

(see appropriate Servicing Air Silencer in Sec-

tion 3).

AO215

24. Install the throttle cable to the throttle body;

then secure the bracket to the intake plenum.

AO189

25. Secure the throttle body cable bracket to the

intake plenum with the two 6 mm cap screws;

then connect the throttle cable end to the throttle

body.

2-98

26. Install the cable adjuster to the cable bracket,

adjust the cable, and tighten the jam nuts

securely.

27. With the grafoil gasket positioned in the muffler,

install the muffler into the support brackets and

to the exhaust manifold.

28. Using Exhaust Spring Pliers (p/n 0644-391) or

(p/n 0644-397), install the two springs securing

the muffler to the support brackets; then install

the two springs to the exhaust manifold.

AO180

AO267

29. Install the ECU to the bracket in the chassis and

secure with the two #27 torx-head cap screws.

AO184A

30. Connect the main harness connectors in the

chassis.

AO185

31. Install the fuse block making certain the tabs are

locked in place. 

32. If the hood was removed for this procedure,

place the hood into position on the front mounts;

then install the two pivot cap screws and attach

the hood cable with the hairpin clip.

33. On the non-turbo models, connect the speedom-

eter cable to the speedometer and secure the

cable to the hood with cable ties.

MD1422

„ NOTE: Install the cable ties in the original loca-
tions.

34. Connect the two instrument panel electrical con-

nectors near the front of the hood.

! CAUTION

Take care not to damage the windshield when
installing the hood.

2-99

2

MD1419

35. Install the battery and vent hose; then secure

with the hold-down plate. Connect the positive

cable and then the negative cable.

„ NOTE: There is no vent hose on turbo-model
battery.

36. If the engine oil was drained, remove the filler

cap from the engine cover and add the recom-

mended amount of engine oil.

37. With all coolant hoses secure, add the engine

coolant (see Section 3 for proper procedure for

filling the cooling system).

Installing Engine

(1100 cc Z1)

„ NOTE: Engine lift points consist of the four
threaded holes (A) on the front and rear corners of
the cylinder head or on the exhaust manifold (B).

0741-658

„ NOTE: It is advisable to install the engine with
the PTO-side directed upward at an angle to allow
proper clearance for the oil reservoir to be posi-
tioned into the chassis.

1. Using an appropriate engine hoist, carefully

lower the engine into the engine compartment

until the rear mount studs are into the rear

mounts just far enough to hold the engine in

place.

2. Pry the front engine mount forward until the

engine and mount are in proper alignment; then

lower the engine the rest of the way until it is in

place in the chassis.

3. Secure the engine to the chassis with lock nut

(C) and long through-bolt (B) on the front

engine mount; then install the two lock nuts (A)

to the rear engine mounts. Tighten the mounting

hardware to the following torque values:

741-540A

A. Rear mount lock nuts: 4.0-6.1 kg-m (29-44

ft-lb).

B. Through-bolt: 4.2 kg-m (30 ft-lb).

C. Front mount lock nut: 4.2 kg-m (30 ft-lb).

4. Secure the oil reservoir to the chassis with three

cap screws; then tighten securely.

! WARNING

Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery. 

2-100

ZJ021A

„ NOTE: At this point if the oil filter was removed,
install the new oil filter; then tighten to 2.1 kg-m
(15 ft-lb).

5. Install the starter motor cable with cap screws;

then tighten securely.

6. Connect the wiring harness connectors to the

coolant temperature sensor (A) and the oil pres-

sure sensor (B); then install the heat exchanger

coolant hose to the thermostat outlet (C) and oil

cooler hose to the outlet (D) with the clamps.

Tighten securely.

ZJ090B

7. Install the throttle bodies and secure with

clamps; then install the throttle cable to the

throttle bodies.

ZJ103A

8. Install the left-side upper frame to the chassis by

installing the two cap screws and lock nuts (A)

securing the frame to the front end; then install-

ing the remaining cap screw and lock nut (B)

securing the upper frame to the skid plate.

ZJ025A

9. Install the five cap screws and lock nuts secur-

ing the upper frame/support gusset to the steer-

ing support; then secure the headlight support

bracket to the right-side upper frame with the

two cap screws and lock nuts. Tighten all lock

nuts securely.

ZJ024A

„ NOTE: Prior to securing the left-side upper frame
to the steering support, make sure that the ECU
harness is directed below the upper frame.

10. Install the ECU to the left-side upper frame and

secure with the hold-down strap; then install the

MAP sensor to the bracket.

11. Install the coolant/separator tank assembly and

secure to the right-side upper frame with cap

screw, resonator pin, and two lock nuts. Tighten

securely; then install the hoses to the proper

locations on the tank assembly as noted during

removing. Secure with clamps.

„ NOTE: At this time, make sure the coolant hoses
from the coolant tank to the throttle body and
throttle body to the left-side cylinder head are
secured and properly routed.

 

 

 

 

 

 

 

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