Snowmobile Arctic Cat (2008 year). Instruction - part 55

 

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Snowmobile Arctic Cat (2008 year). Instruction - part 55

 

 

2-158

SPECIAL TOOLS

A number of special tools must be available to the

technician when performing service procedures in this

engine section.

„NOTE: Special tools are available from the Arctic
Cat Service Parts Department.

Table of Contents

Removing ............................................................ 2-158
Disassembling..................................................... 2-163
Cleaning and Inspecting ..................................... 2-168
Measuring Critical Components.......................... 2-171
Assembling.......................................................... 2-174
Installing .............................................................. 2-182

Removing Engine

1. Remove the hood and the left-side and right-side

access panels; then remove the torx-head screws

securing the console.

741-722A

2. Lift the rear of the console and disconnect the con-

sole/main harness plug-in; then remove the con-

sole.

3. Remove the hairpin clip and all springs securing

the expansion chamber and resonator; then remove

these components from the engine compartment.

Account for the two exhaust gaskets.

„NOTE: On the LXR, disconnect the negative
cable from the battery.

4. On the standard models, push down on both seat

retainer brackets (located in the rear starage com-

partment) and remove the seat. 

„NOTE: On the LXR and Sno Pro models with the
seat adjusted to its lowest position, remove the
self-tapping screw from the right-side seat adjust-
ment track; then remove the seat.

ZJ100A

5. Remove the torx-head screws securing the handle-

bar close-off panel; then remove the panel.

6. Remove the lock nuts and torx-head cap screws

(A) securing the right-side front and rear spar pan-

els; then remove the torx-head screws (D) securing

the left-side rear spar panel to the gas tank and

support tube.

742-207A

„NOTE: The right-side rear spar panel will remain
secured to the chassis.

7. Remove the cap screw located directly above the

ECU securing the air-silencer duct to the front

upper panel; then disconnect the air temperature

sensor and remove the duct.

„NOTE: To aid in accessing the cap screw, the
ECU may be removed.

Description

p/n

Ball Hone (800 cc)

0644-294

Ball Hone (1000 cc)

0644-531

Drive Clutch Puller

0644-207

Drive Clutch Spanner Wrench

0644-136

Driven Pulley Puller

0644-468

Flywheel Puller

0744-040

Flywheel Pulley Insert

0644-179

Oil Seal Protector Tool

0644-219

Piston Pin Puller

0644-328

Surface Plate

0644-016

V Blocks

0644-022

Water Pump Bearing and Seal Kit

0644-502

2-159

2

8. Remove the body screws and flange nuts (C) from

each side securing the front bumper assembly to

the chassis; then remove the two remaining self-

tapping screws (B) from each side securing the

front bumper assembly. Remove the assembly.

„NOTE: At this point, remove the air-intake silencer
and account for the rubber exhaust bumper.

9. Remove the belt guard; then using a 1/2-in. 12-

point socket (800 cc) or drive clutch bolt tool

(1000 cc), remove the cap screw and lock washer

securing the drive clutch to the crankshaft.

10. Using Drive Clutch Puller and an impact wrench

or a breaker bar and Drive Clutch Spanner

Wrench, tighten the puller. If the drive clutch will

not release, sharply strike the head of the puller.

Repeat this step until the clutch releases. Remove

the drive clutch and the drive belt.

11. Remove the cap screw from the driven pulley and

slide the driven pulley off the gear case input shaft.

Account for alignment washers.

FS192

„NOTE: If the driven pulley is tight on the driven
shaft, pull the driven pulley off using the Driven
Pulley Puller.

12. Using a small needle-nose pliers, remove the ser-

vomotor retaining clip and the cable holder.

FS273A

FS176

13. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

out of the servomotor.

14. Slide each cable drum back and out of the servo-

motor actuator.

15. On the LXR, remove the starter motor using the

following sequence:

A. Remove the lock nuts securing the negative and

the positive cables to the starter motor.

FS205A

B. Loosen the two set screws securing the flex-

drive shaft to the pinion driveshaft.

FS206A

C. Remove the cap screws and lock nuts securing

the starter motor brackets to the chassis and to

the upper frame. Remove the starter motor.

2-160

FS207A

FS208A

16. Drain the engine coolant (see Liquid Cooling Sys-

tem - Section 3).

17. Remove the cable tie securing the gasline supply

hose to the MAG-side engine mounting bracket;

then loosen the clamp and remove the hose from

the throttle body assembly. Plug the end of the

hose and secure it up and out of the way.

„NOTE: Note the routing and securing locations of
the hose for assembling purposes.

18. Loosen the flange clamps securing the throttle

body assembly to the flange; then move the throt-

tle body assembly forward and disconnect the oil

injection control rod from the oil-injection pump.

FS209A

„NOTE: It is advisable to remove the clamps from
the intake flanges to avoid damage during engine
removing.

19. Loosen the clamps securing the two coolant hoses

connected to the MAG-side and PTO-side throttle

body; then remove the vent tube from the top of

the cylinder head.

„NOTE: On the 1000 cc, remove the coolant
bypass hoses from the cylinders.

20. Move the throttle body assembly to one side out of

the way to a secure position.

„NOTE: With the throttle body assembly out of the
way, disconnect the oil hose from the oil pump;
then plug the oil hose.

FS213A

21. Remove the cap screws securing the recoil starter;

then secure the recoil starter up and out of the way.

! CAUTION

The gasline supply hose may be under pressure.
Place an absorbent towel around the connection to
absorb gasoline; then remove the hose slowly to
release the pressure.

2-161

2

FS210

22. Remove the spark plug wires from the plugs; then

disconnect the two-wire plug-in for the coolant

temperature sensor (located below the lower

MAG-side ignition coil).

FS211A

„NOTE: On the 800 cc at the coolant filler neck
bracket, disconnect the knock sensor wiring con-
nector and slide the wiring out of the cable tie.

FS212A

23. Remove the harness wrap and disconnect all igni-

tion/main harness connectors; then secure the

main harness out of the way.

FS181

„NOTE: Remove the cable ties securing the cool-
ant hose, gasline hose, and on the LXR, battery
cables together.

FS214A

24. Disconnect the front heat exchanger hose.

„NOTE: Prior to disconnecting the hose, it is
advisable to place an absorbent towel beneath the
hose to collect any coolant from the exchanger.

25. Remove the four cap screws securing the upper

bearing bracket to the upper support plate (account

for the two bracket plates); then secure the steering

post to the headlight support bracket.

FS182A

 

 

 

 

 

 

 

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