Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 24

 

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Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 24

 

 

2-82

FC020

40. Secure the ignition timing sensor with screws

coated with blue Loctite #243. Tighten to specifi-

cations.

41. Secure the stator plate to the crankcase with the

Allen-head cap screws coated with blue Loctite

#243 and tightened to specifications; then install

the stator assembly with wires and a grommet into

the crankcase and secure with the Allen-head

screws (coated with blue Loctite #243). Tighten to

specifications.

FC018

42. Install the key in the crankshaft. 

43. Thread two puller bolts into the flywheel; then

slide the flywheel onto the crankshaft making sure

the keyways match. Remove the puller bolts.

„NOTE: Before installing the flywheel, be sure to
wipe the crankshaft and flywheel tapers clean
using a clean towel.

44. Apply red Loctite #271 to the threads of the fly-

wheel cap screw; then finger-tighten with a large

flat washer. DO NOT TIGHTEN AT THIS TIME.

FC080

45. Place the starter pulley in position; then loosely

secure the starter pulley with three cap screws

(coated with red Loctite #271). Secure the pulley

while using the spanner wrench and tighten the

three cap screws evenly to specifications.

FC081

46. Using the spanner wrench, tighten the flywheel

cap screw (from step 44) to specifications.

Installing Engine

„NOTE: Prior to installing the engine, secure the
MAG-side mounting bracket and on the 600 cc, the
upper right mounting bracket to the engine with
cap screws (coated with blue Loctite #243) and
tighten to specifications.

1. Place the engine into the engine compartment and

position it so the water pump coolant hose can be

installed to the front heat exchanger. Secure with

the hose clamp.

2-83

2

CM034C

„NOTE: If equipped with electric start, insert the
flex-drive shaft into the pinion drive and secure
with the two set screws.

2. Place the engine into the mounting position; then

from the PTO-side, tip the engine forward, raise

the PTO-side of the engine, and allow the chassis

to support the engine in this position. Connect the

coolant tank hose to the bottom left outlet on the

engine and secure with the hose clamp.

MS382D

3. Connect all electrical wiring making sure all wir-

ing and coolant hoses are routed properly (as noted

in removing); then place the engine into the

mounting position.

„NOTE: Secure the wiring harnesses with cable
ties (as noted in removing).

4. Install the cap screw and nut (C) securing the

MAG-side engine mounting bracket to the side

plate. DO NOT TIGHTEN AT THIS TIME.

742-240A

742-238A

5. Install the PTO-side engine mounting bracket to

the engine with cap screws (A) (coated with blue

Loctite #243) and to the front frame with lock nuts

(B). DO NOT TIGHTEN AT THIS TIME.

6. From step 5, tighten the four mounting bracket

plate-to-engine cap screws (A) to specifications;

then tighten the three lock nuts (B) securing the

engine mounting bracket to the front frame (from

step 5) to specifications.

„NOTE: On the 600 cc, install the cap screw and
lock nut (D) securing the engine mounting bracket
to the front lower mounting bracket.

 7. Tighten the MAG-side engine cap screw and nut

(from step 4) to specifications.

8. Connect the oil-injection cable/control rod to the

oil-injection pump and secure.

CM028A

500 cc

600 cc

2-84

9. Route the oil-supply hose to the pump and secure

with the clamp. Bleed the oil-injection system (see

Section 4).

CM029A

10. Confirm that the two coolant hoses which run

beneath each exhaust port on the cylinders are

accessible to connect and that the fuel line and oil

pump linkage/cable are connected; then place the

throttle bodies into position and secure with the

flange clamps. Synchronize the oil-injection pump

(see Section 4).

FC050A

FC051

11. Install the side-plate brace onto the chassis and

secure with the lock nuts and cap screws. Tighten

securely.

CM070B

12. After securing the brace, secure the steering sup-

port to the chassis. Tighten to 2.8 kg-m (20 ft-lb).

CM004B

13. Apply a thin coat of  high-temperature silicone

sealant to each exhaust port; then install the

exhaust gaskets.

14. Apply a thin coat of high-temperature silicone

sealant to the mating surfaces of the exhaust mani-

fold; then install the exhaust manifold and secure

with the nuts.  Tighten the nuts to specifications.

! CAUTION

Make sure the oil-supply hose is routed properly to
avoid premature wear.

! CAUTION

When installing the throttle bodies, make sure the
gasline hose is properly routed to avoid premature
wear and/or contact with exhaust components.

2-85

2

CM035

15. Fill the cooling system (see Liquid Cooling Sys-

tem in Section 3).

16. Place the recoil starter into position and secure the

starter with the cap screws. Tighten to specifica-

tions.

FC052

„NOTE: Steps 17-19 are for the 600 cc.

17. Slide the APV cable drums into the servomotor

actuator; then place the cable housings into posi-

tion in the servomotor. Secure the cable housings

with the cable retaining cover.

CM124A

18. Place the servomotor cover into position; then

secure with two lock nuts.

CM121A

19. Check APV cable adjustment. See Arctic Power

Valve (APV) System in Section 3.

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

20. Place the drive clutch into position on the crank-

shaft and secure with the cap screw and lock

washer. Tighten to specifications.

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

21. Install the alignment washers; then install the

driven pulley on the gear case input shaft. Tighten

the cap screw to 4.4 kg-m (32 ft-lb).

MS378

! 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 no less than two 1.5 mm (0.060 in.)
washers are in place on the input shaft when install-
ing the driven pulley.

! CAUTION

Do not allow the driven pulley to “float” on the out-
put shaft. Damage to the driven pulley will occur.

 

 

 

 

 

 

 

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