Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 46

 

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Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 46

 

 

2-170

0742-199

„NOTE: At this point on the 800 cc, install the
spark plugs; then on both models, tighten the
spark plugs to specifications.

„NOTE: At this point on the 800 cc, install the
knock sensor with the lock plate, tighten the sen-
sor securely, and bend the lock plate tabs up.

40. With the raised edge of the valve aligned with the

channel of the cylinder, slide the APV assemblies

into position in the cylinders; then secure with cap

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

specifications.

CM204

„NOTE: At this point, pressure test the engine
(see Section 3).

41. Secure the stator plate to the crankcase with the

Allen-head cap screws (coated with blue Loctite

#243) and tightened to specifications.

42. Route the stator harness through the opening in the

crankcase; then secure the stator to the stator plate

with the Allen-head cap screws (coated with blue

Loctite #243). Tighten to specifications.

CM143A

43. Secure the upper ignition timing sensor with cap

screws (coated with blue Loctite #243). Tighten

securely; then install the wiring grommet into the

notch of the crankcase.

CM176A

44. Secure the lower ignition timing sensor with two

cap screws (A) (coated with blue Loctite #243).

Tighten securely; then install the grommet. With

the stator harness properly positioned, install the

plate and cap screw (B) (coated with blue Loctite

#243). Tighten securely.

CM177A

45. Install the key in the crankshaft. 

46. Place the starter pulley in position on the flywheel;

then loosely secure the starter pulley with three

cap screws (coated with red Loctite #243). While

holding the starter pulley, slide the flywheel onto

the crankshaft making sure the keyways match.

1000 cc

2-171

2

CM180

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

47. 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

48. Secure the starter pulley while using the spanner

wrench and tighten the three cap screws (from step

46) evenly to specifications.

FC081

49. Using the spanner wrench, tighten the flywheel

cap screw (from step 47) to specifications.

„NOTE: On the 1000 cc with alignment pins in
place, install the magneto case on the crankcase
with the cap screws. Tighten cap screws to specifi-
cations.

CM144A

50. Install the coolant inlet hose to the cylinder head

and water pump; then tighten the hose clamps

securely.

CM181

Installing Engine

1. Install the throttle body hose (A), inlet hose (B),

and the front heat exchanger hose (C) to the

engine; then secure with the hose clamps.

FS187B

„NOTE: At this time if the coolant temperature
sensor was removed, install the sensor and
tighten securely.

2-172

2. Place the engine into the engine compartment

from the MAG-side; then tip the engine forward

and support the engine in this position.

FS186

3. Install the MAG-side engine mounting bracket to

the engine with the two cap screws (F) (coated

with blue Loctite #243). Tighten to specifications.

742-201A

742-213A

4. Position the engine to the chassis mounts; then

install cap screw (E) securing the MAG-side

mounting bracket to the chassis. Tighten cap screw

to specifications.

5. Release the tie-down securing the engine/pin-

ion bracket in the forward position; then posi-

tion the engine to the bracket and secure with

four cap screws (D) (coated with green Loctite

#609). Tighten to specifications.

„NOTE: At this point prior to installing the PTO-
side engine mounting bracket, install the coolant
hose to the thermostat housing and secure with
the clamp.

FS217A

6. Position the torque bumper against the gear case;

then install the PTO-side engine mounting bracket.

„NOTE: Prior to installing the bracket, assure that
the U-nut clip is centered in position.

FS195A

7. Using the appropriate illustration following step 3,

install the cap screw and lock nut (A) and the

lower cap screw (B) securing the PTO-side bracket

to the chassis; then install the four cap screws (C)

(coated with blue Loctite #243) securing the

bracket to the engine. Tighten all mounting hard-

ware to specifications.

! CAUTION

When installing the engine, take care not to damage
the oil pump or the APV cables.

800 cc

1000 cc

! CAUTION

Position the hose clamp screw so it is directed to the
12 o’clock position of the thermostat housing to
avoid contacting the chassis.

2-173

2

8. Connect the coolant hose to the outlet of the front

heat exchanger and secure with the hose clamp.

FS196A

9. Route the ignition harness and the coolant temper-

ature sensor two-wire connector between the cool-

ant tank hose and the chassis; then secure the

ignition harness to the coolant hose with a cable tie

in the position as noted in removing. 

FS197

„NOTE: Prior to connecting the harness, it is
advisable to clean all plug-ins with contact cleaner.

10. Connect all ignition/main harness plug-ins and the

two-wire connector; then install the harness wrap.

FS181

11. Place the recoil starter into position and secure the

starter with six cap screws. In a crisscross pattern,

tighten to specifications.

FS210

12. On the LXR, install the starter motor using the fol-

lowing sequence:

A. Place the flex-drive shaft into position on the

pinion driveshaft so the set screws are aligned

with the flat-side of the pinion driveshaft.

FS204

B. Place the starter motor with bracket into posi-

tion on the chassis and upper frame; then secure

with the cap screws and lock nuts. Tighten

securely.

„NOTE: For installing purposes, it may be neces-
sary to loosen the lock nut securing the bracket to
the starter motor.

C. Place the positive and negative cables on the

starter motor; then secure with the lock nuts.

Tighten securely.

FS205A

 

 

 

 

 

 

 

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