Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 75

 

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Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 75

 

 

5-30

AI043

11. Carefully place the starter case and armature

assembly into the commutator cap. Again, check

to make sure the scribed marks of these two com-

ponents are aligned. With the case flat on the

assembly tool, slowly pull the tool from the starter

motor. The case should then drop into place.

AI044

12. Apply red Loctite #271 to the threads of the two

through-bolts; then install and secure the bolts.

Tighten to 1-1.4 kg-m (7-10 ft-lb).

„NOTE: The starter shouldn’t be picked up until
the two through-bolts have been secured. Spring
pressure from the brush springs will push the
commutator cap off the case.

DISASSEMBLING PINION

1. Remove the dust cap from the end of the pinion

drive by first pulling straight out and then twisting

the dust cap to the side.

2. Place a 11 mm or a 7/16 in. socket over the end of

the pinion shaft and tap the socket gently with a

hammer.

„NOTE: This procedure will dislodge the snap-ring
retainer and expose the snap ring.

3. Using a side cutter, diagonal cutter, or suitable pli-

ers, remove and discard the snap ring.

4. Remove the snap-ring retainer (note end-for-end

orientation), pinion spring, spring retainer, and

pinion gear. Retain all components.

CLEANING AND INSPECTING 
PINION

„NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Using parts-cleaning solvent, wash grease from

the pinion gear. Dry with compressed air.

2. Inspect the pinion gear for wear. If the gear is

worn or chipped, replace the pinion assembly.

3. Inspect the inner gear and housing. If the gear

shows any signs of wear, replace the pinion assem-

bly.

4. Inspect the inner housing for tightness and cracks.

If the housing shows any signs of being loose or

cracked, replace the pinion assembly.

5. Inspect the pinion return spring for wear. If the

spring shows any worn areas, replace the spring.

ASSEMBLING/INSTALLING PINION

1. Slide the pinion gear, spring retainer, pinion

spring, and snap-ring retainer (note end-for-end

orientation) onto the shaft in their original posi-

tions.

2. Place new snap ring over the end of the pinion

shaft; then slide the snap ring over the shaft. Using

a 11 mm or 7/16 in. socket and a hammer, gently

tap the snap ring into the groove on the shaft.

3. Slide the dust cover over the pinion assembly

being careful not to dislodge the grease. Firmly

push the dust cover until it snaps into its retaining

groove.

TESTING STARTER MOTOR

„NOTE: Before installing the starter motor, per-
form test to ensure proper operation using the fol-
lowing procedure.

1. Attach a black jumper cable to a good ground on

the starter.

2. Attach the opposite end of the black jumper cable

to the negative post of a good 12V battery.

3. Attach the red jumper cable to the positive post of

the battery.

! WARNING

When using compressed air to dry components,
always wear safety glasses.

5

5-31

4. Holding the starter firmly down on a work bench,

touch the red jumper cable to the positive cable

stud of the starter.

„NOTE: Starter motor must instantly spin at a high
RPM. The pinion must snap out against the stopper.
If the motor does not spin, remove the red cable
immediately. Check the battery condition and all
connections. If everything checks out satisfactorily
and the starter does not spin, disassemble the
motor and check for pinched or broken wires.

INSTALLING (370 cc Model)

1. Place the starter motor into the bracket; then

secure with existing hardware. Tighten to 1.7-2.1

kg-m (12-15 ft-lb).

2. Attach the red positive cable to the positive stud

terminal and secure with a nut and washers. While

tightening the nut, hold the cable in position so it

is parallel with the starter.

3. Secure the positive cable to the starter motor with

a long cable tie.

4. Connect the cable to the positive post of the bat-

tery; then connect the negative cable to the nega-

tive post.

5. Install the drive clutch.

6. Install the expansion chamber.

INSTALLING (570 cc Model)

1. Install the flex-drive shaft onto the starter motor

and secure with the two Allen-head screws.

2. Place the starter motor into the bracket assembly;

then secure with existing hardware. Tighten to 2.4

kg-m (17 ft-lb).

3. Attach the red positive cable to the positive stud

terminal and secure with a nut and washers. While

tightening the nut, hold the cable in position so it

is parallel with the starter.

INSTALLING (500/600 LXR cc 
Models)

1. Place the mounting bracket to the starter motor;

then secure with existing hardware. Tighten

securely.

2. Place the flex-drive shaft into position on the pin-

ion driveshaft so the set screws are aligned with

the flat-side of the pinion driveshaft.

3. Place the mounting bracket/starter motor into posi-

tion and secure to the chassis with the lock nuts.

4. Attach the battery cables to the starter motor and

secure with nuts.

5. Connect the battery cables (positive cable first) to

the battery.

INSTALLING 

(800/1000 cc LXR Models)

1. Install the mounting bracket to the starter motor;

then secure with existing hardware. Tighten

securely.

2. Place the flex-drive shaft into position on the pin-

ion driveshaft so the set screws are aligned with

the flat-side of the pinion driveshaft.

FS204

3. Place the starter motor with brackets into position

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.

4. Place the positive and negative cables on the

starter motor; then secure with the lock nuts.

Tighten securely.

! WARNING

Be sure to keep clear of the pinion gear area as it will
spin at a high RPM when the red cable is touched to
the positive stud. Personal injury may result if con-
tact is made with a spinning pinion.

! CAUTION

Check the cable installation to make sure it isn’t
near any moving parts or against any sharp edges.

! CAUTION

Check the cable installation to make sure it isn’t
near any moving parts or against any sharp edges.

5-32

FS205A

5. Connect the battery cables (positive cable first) to

the battery.

6. Install and secure the resonator and the expansion

chamber.

„NOTE: To finalize the installing procedure, the air
silencer must be installed. Proceed to the appro-
priate Air-Intake Silencer sub-section in Section 4.

Troubleshooting 

Electric Start

Ignition Timing

„NOTE: Ignition timing can be checked and/or ver-
ified on all snowmobile engines.

CHECKING (All Models)

1. Connect a timing light to the MAG-side spark plug

lead.

2. Using a shielded safety stand, raise the rear of the

snowmobile off the floor and start the engine.

Gradually increase the engine speed to the speci-

fied RPM; the pointer should align with the proper

timing mark on the flywheel.

3. If timing is not correct, adjust the ignition timing.

ADJUSTING (370 cc)

1. Remove the recoil starter, starter pulley, and fly-

wheel.

2. Loosen the two screws securing the stator plate

and rotate the stator plate in the proper direction to

attain correct timing.

„NOTE: Rotate the stator plate clockwise to retard
the timing or counterclockwise to advance the tim-
ing. The stamped marks on the stator plate at the
upper socket-head cap screw mounting hole can
be used for timing.

3. Tighten the screws securing the stator plate.

4. Install the flywheel, starter pulley, and recoil

starter.

5. Recheck timing for accuracy and adjust if neces-

sary.

Ignition Timing 

Specifications

(Table of Contents)

370 cc.................................................................... 5-33
500 cc.................................................................... 5-33
570 cc.................................................................... 5-34
600 cc.................................................................... 5-34
800 cc.................................................................... 5-35
1000 cc (Crossfire/F-Series) ................................. 5-35
1000 cc (M-Series)................................................ 5-36

Problem: Hot or Smoking Wires

Condition

Remedy

1.  System wired incor-

rectly

1. Check wiring against wir-

ing diagram

Problem: Starter Does Not Turn Over

Condition

Remedy

1. Battery discharged

2. Connection loose

3. Grounding improper

4. Fuse blown - not

installed

1. Check/charge the battery

2. Check tightness of all

connections

3. Check round connections

4. Check - replace fuse

5

5-33

370 cc

„NOTE: For 6000 RPM timing purposes on the 370
cc, use a dial indicator and scribe a mark on the
flywheel for 13° BTDC.

Ignition Timing - Engine Warm
BTDC - 18°/2000 RPM - 2.012 mm (0.079
in.)
BTDC - 13°/6000 RPM - 1.056 mm (0.042
in.)
Adjustable

738-950A

500 cc

Ignition Timing - Engine Warm
BTDC - 12°/2000 RPM - 0.867 mm (0.034
in.)
Not Adjustable

0742-218

 

 

 

 

 

 

 

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