Snowmobile Arctic Cat (2007 year). Instruction - part 29

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 29

 

 

2-101

2

ZJ018A

12. Connect the harness plug-ins to the ignition

coils (A) and camshaft sensor (B); then route the

main harness to the proper connector locations

and secure with cable ties as noted during

removing.

ZJ094A

13. Install the close-off cover to the front end with

the two cap screws (A) noting that the mounting

tab (B) is installed with the right-side cap screw.

Tighten cap screws securely.

ZJ020A

14. Connect the air temperature sensor harness

plug-in to the sensor on the air silencer; then

with the screws of the flange clamps directed

properly as noted during removing, install the

air silencer to the chassis with the two torx-head

cap screws (do not tighten at this time). At this

point, secure the flange clamps to the throttle

body.

ZJ015A

ZJ013A

„ NOTE: Before installing the air silencer, make
sure the gasline vent hose is routed over the
silencer.

„ NOTE: It is advisable to install the air intake
silencer at an angle positioning it to the PTO-side
throttle body first; then working it back and forth
and with an angle tool, sliding the mag-side air
silencer  boot onto the throttle body. Once in place
and secured, carefully inspect that the boots are
properly seated to the throttle bodies.

15. Install the breather hose connecting the air

intake silencer to the separator tank.

! CAUTION

Make sure the harness is routed away from the
exhaust or any moving parts.

2-102

ZJ096B

16. Install the gas tank to its porper position; then

secure the tank with the seat support assembly

and install the six torx-head cap screws. Tighten

securely.

ZJ010A

17. Install the gasline hose onto the tank and press

down on the connector until it snaps into place;

then install the vent hose to the outlet and secure

with the hose clamp.

ZJ012B

18. Connect the fuel pump four-wire connectors

(A); then connect the harness plug-in (B) to the

chassis control unit. 

ZJ011C

19. With the harness connected, install the air pres-

sure sensor to the bracket on the right-side upper

frame; then install the MAP sensor onto the left-

side upper frame.

20. Install the four cap screws securing the steering

support plate to the steering support (B); then

install the four cap screws securing the upper

bearing bracket to the upper support plate (A).

ZJ009B

ZJ097B

„ NOTE: At this time, securely tighten the two torx-
head cap screws (from step 14) securing the air
silencer to the steering support.

! CAUTION

Prior to continuing the installing procedure, make
sure the gasline hose is properly and securely
“snapped” onto the gas tank.

! CAUTION

Assure that the wiring harness is properly routed
and the cable ties are properly located as noted dur-
ing disassembling.

2-103

2

21. Place the resonator into position in the chassis

and install the two springs securing the resona-

tor to the chassis; then secure the resonator to

the upper frame with the hairpin clip. Install the

exhaust pipe and secure to the manifold and res-

onator with six springs.

22. Connect the harness plug-in for the exhaust tem-

perature sensor.

„ NOTE: Before installing the drive clutch, be sure
to wipe both the crankshaft taper and clutch
mounting taper clean using a clean towel.

23. Place the drive clutch into position on the the

crankshaft and secure with the cap screw and

lock washer. Tighten to specifications.

„ NOTE: To aid in proper tightening of the drive
clutch cap screw, apply oil to the threads of the
cap screw prior to installing.

ZJ294

„ NOTE: Apply a coat of Anti-Seize Thread Com-
pound (p/n 0678-146) to the splines of the input
shaft.

24. Install the driven pulley on the gear case input

shaft making sure the alignment washers are in

place.

25. Secure the driven pulley with components and

hardware as noted in removing. Tighten to spec-

ifications.

ZJ250A

26. Check drive clutch/driven pulley alignment.

27. Install the drive belt (so the part number can be

read).

28. Install the front/rear upper side panels; then

secure the panels with the five torx-head cap

screws for each side.

741-744A

29. Install the handlebar close-off panel; then secure

the panel with the two torx-head cap screws.

Position the console assembly on the headlight

support bracket; then connect the main hood

harness. Secure the console with the two torx-

head cap screws.

30. Install the battery; then secure with the hold-

down plate. Connect the positive cable and then

the negative cable.

31. With all coolant hoses secure, add engine cool-

ant.

! CAUTION

When installing the drive clutch, do not tighten the
clutch cap screw with any kind of impact tool.
Tighten cap screw using a hand torque wrench only.
Failure to do so could result in stationary sheave
damage.

! CAUTION

It is critical that the two 1.5 mm (0.060 in.) washers
are in place on the input shaft when installing the
driven pulley.

! WARNING

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

2-104

32. Install the hood; then install the side access pan-

els and secure with existing mounting hardware.

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

cap from the oil reservoir and add the recom-

mended amount of oil using the following pro-

cedure.

A. Pour 2.9 l (3 U.S. qt) of the recommended

engine oil into the oil reservoir.

B. Open the air bleed bolt located on the oil

pump (beneath the coolant tank) to purge air

from the oil hose.

ZJ004A

„ NOTE: When air can no longer be heard purging
from oil pump bleed, tighten the bleed bolt to 1.05
kg-m (7.5 ft-lb).

C. Without starting the engine, place the handle-

bar emergency stop switch to the RUN posi-

tion and the ignition switch to the ON

position. The Oil Pressure Warning Light

should illuminate.

D. If the warning light illuminates (from step C),

start the engine. The warning light should go

out within five seconds. If it does, proceed to

step E.

„ NOTE: If the warning light does not go out, shut
the engine off immediately and repeat step B; then
place the ignition switch to the ON position and
repeat step D.

E. Shut the engine off and pour the remaining

amount (0.9 1 or 1 U.S. qt) of recommended

oil into the oil reservoir; then proceed to

check engine oil level.

F. Start the engine and allow it to warm up for

5-10 minutes.

G. Shut the engine off; then remove the oil level

stick from the oil reservoir. Wipe the stick

clean.

H. Insert the oil level stick into the oil reservoir

without threading it in and remove. Read the

oil level shown on the stick. The oil level

should be near the middle of or on the high

end of the NORMAL range on the stick.

0741-490

! CAUTION

After running the engine to the proper operating
temperature, shut the engine off; then open the
hood and access panels and inspect for any signs of
coolant, gasoline, or oil leakage.

 

 

 

 

 

 

 

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