Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 26

 

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Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 26

 

 

2-90

21. Remove the lock nuts (A) and (B) from the cap

screws of the MAG-side engine mounting bracket

and the front lower engine mounting bracket (do

not remove the cap screws at this time).

742-203B

22. Remove the lock nuts (C) securing the PTO-side

engine mounting bracket to the chassis.

23. Remove the cap screws (D) securing the PTO-side

engine mounting bracket to the engine.

24. Remove the PTO-side engine mounting bracket;

then remove the cap screws (A) and (B) from step

21.

25. Lift the engine out of the engine compartment.

26. Remove the exhaust manifold and engine mount-

ing brackets from the engine. Account for nuts and

gaskets.

27. Remove the clamp securing the coolant supply

hose from the cylinder head to the water pump.

Then remove the hose from the engine.

CM181

Disassembling Engine

„NOTE: When disassembling top-side compo-
nents, mark MAG-side and PTO-side components
for assembling purposes.

1. Using the spanner wrench to secure the flywheel,

remove the flywheel cap screw and washer; then

remove the three starter pulley cap screws and

remove the pulley.

CM138

CM139

2. Install Flywheel Pulley Insert (p/n 0644-179) onto

the end of the crankshaft.

FC016

2-91

2

3. Using Flywheel Puller (p/n 0744-040) or suitable

substitute, remove the flywheel from the crank-

shaft by tightening the puller bolt, striking the

head of the puller bolt with a hammer, and tighten-

ing again. Repeat this procedure until the flywheel

is free. Account for the key.

CM140

„NOTE: To ensure the cleanliness of the flywheel
magnets, place the flywheel (with the magnets fac-
ing upward) on a clean bench.

„NOTE: On the 1000 cc, remove the Allen-head
cap screws securing the magneto case to the
crankcase. Account for the alignment pins.

CM144A

4. Remove the cap screw securing the ground wire to

the crankcase.

CM142A

5. Remove the Allen-head cap screw (A) securing

the stator lead wire plate to the crankcase; then

remove the Allen-head cap screws (B) securing

the timing sensors, remove the sensors, and

account for the harness grommets.

CM141C

6. Remove the Allen-head cap screws securing the

stator to the stator plate. Route the stator lead wire

out of the crankcase; then remove the stator

assembly.

CM143A

7. Remove the cap screws securing the stator plate to

the engine; then remove the plate.

! CAUTION

To prevent damage to the crankshaft, do not thread
puller bolts more than 12.7 mm (1/2 in.) into the fly-
wheel. Damage to the coils may result.

2-92

CM145D

„NOTE: For assembling purposes, note that the
indentation (A) of the stator plate is aligned with
the harness opening (B) in the crankcase.

CM145C

„NOTE: The stator plate screws had Loctite
applied to the threads during assembly. Using an
impact driver, apply a sharp blow to the head of
each screw to break the Loctite loose before
removal.

8. Remove the cap screws securing the APV assem-

blies to the cylinders; then remove the APV

assemblies and set them aside.

„NOTE: For assembling purposes, note that the
APV exhaust valves and gaskets are directional.

CM146A

CM147

9. Remove the spark plugs.

„NOTE: On the 800 cc at this point, remove the
knock sensor and lock plate from the cylinder
head by bending the lock plate tabs down and
unthreading the sensor.

10. Remove the cap screws with O-rings securing the

cylinder head; then separate from the cylinders.

Account for the O-rings.

„NOTE: When removing the cylinders, place the
engine on its intake flanges on a drain tray to allow
residual coolant to drain from the cylinder/crank-
case water jacket.

11. Remove the four nuts and four cap screws secur-

ing the cylinders to the crankcase; then using a soft

hammer, gently tap the cylinders and remove from

the crankcase by lifting them straight up off their

studs. Account for gasket(s) and alignment pins.

CM148

12. Remove the PTO-side piston-pin circlip from the

PTO-side piston; then remove the MAG-side pis-

ton-pin circlip from the MAG-side piston.

! CAUTION

When removing a cylinder, be sure to support the
piston to prevent damage to the crankcase and pis-
ton.

2-93

2

CM149

13. Using Piston Pin Puller (p/n 0644-328), remove

the piston pins from both pistons.

„NOTE: For proper assembly, keep all MAG-side
components and all PTO-side components sepa-
rated. Assemble them on their proper sides.

CM150

14. Lift the pistons clear of the connecting rods and

remove the small-end connecting-rod bearings

(account for two washers); then remove the piston

rings. Keep each piston with its rings; keep each

piston pin and bearing together as a set.

CM151

„NOTE: Place a suitable length of rubber hose
around the connecting rods. This will prevent the
connecting rods from damaging the crankcase.

15. Remove the oil hoses from the intake flanges; then

remove the intake flanges and reed valve assem-

blies.

CM152

16. Remove the lower union cap screw securing the

lower check valve assembly to the crankcase; then

remove the two screws securing the oil-injection

pump to the crankcase. Remove the pump,

retainer, and O-ring and account for the two gas-

kets from the lower union.

CM153A

CM154A

17. Remove the four cap screws securing the thermo-

stat cap; then remove the cap, gasket, and thermo-

stat.

! CAUTION

DO NOT use any type of punch to drive the piston
pin free of the piston; damage may result. Use a pis-
ton-pin puller only.

 

 

 

 

 

 

 

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