Snowmobile Arctic Cat (2000 year). Manual - part 35

3. Place the resonator into position; then secure with

the cap screws, washers, bushings,  spacers,  and
retainer nuts.

NOTE: On models equipped with electric start,

make sure the battery ground cable and star washer
are properly positioned.

4. Connect the temperature-gauge sender wire.

Fig. 2-455

AJ159

5. Place the coolant hoses into position and secure with

the clamps.

6. Connect the cable to the oil-injection pump and

secure with the nylon washer and E-clip; then
connect the oil-supply and oil-output hoses and
secure with the clamp. Bleed the oil-injection pump
(see Section 4).

Fig. 2-456

AN009

7. Connect the impulse hose to the crankcase.

8. Secure the right-side front and rear and left-side

front engine mounts to the front end making sure the
mounts are properly positioned. Tighten the cap
screws and nut to 2.8-3.5 kg-m (20-25 ft-lb).

Fig. 2-457

AN611D

9. Adjust the torque bumper to allow a clearance

between the engine and the torque bumper of 1.78
mm (0.070 in.) on the 1000 cc or 1.5 mm (0.060 in.)
on the 600/800 cc; then secure the adjustment by
tightening the jam nuts.

10. Place the carburetors into position and secure with the

flange clamps. Synchronize the oil-injection pump
(see Section 4).

Fig. 2-458

AN614D

11. Connect the main wiring harness, ignition timing

sensor wiring harness, and the spark-plug caps.
Secure the two brown ground wires to the magneto
housing with a cap screw.

Fig. 2-459

AQ125

2

2-125

12. In order, place the expansion chambers and grafoil

gaskets

into

position.

Secure

the

expansion

chambers to the header pipes and resonator with the
springs. Secure the expansion chambers to the front
end with the long spring.

13. Connect the hood cable to the cable hook; then

secure the hook.

NOTE: Before installing the drive clutch, be sure

to wipe both the crankshaft taper and clutch
mounting taper clean using a clean towel.

14. Place the drive clutch into position on the crankshaft

making sure the two sleeves are properly positioned
(see Section 8) and secure with the clutch bolt and
lock washer. Tighten to 6.9-7.6 kg-m (50-55 ft-lb).
Install the belly pan plug.

Fig. 2-460

AF477D

NOTE: Apply

a

coat

of

Anti-Seize

Thread

Compound (p/n 0678-146) to the keyway end of the
driven shaft.

15. Install the driven pulley, stub shaft, key, and washers

(see Section 8). Secure with a cap screw. Tighten to
2.6-3.3 kg-m (19-24 ft-lb).

Fig. 2-461

SC013D

16. Check  drive clutch/driven pulley alignment  (see

Section 8).

17. Install the drive belt. Check belt deflection (see Section

8). Secure the belt guard.

18. Fill the cooling system (see Section 3); then install

the coolant filler cap.

19. Bleed the oil-injection system (see Section 4).

20. Turn the shut-off valve to the OPEN position.

21. Check ignition timing.

22. Test drive the snowmobile and recheck the coolant

level after 5-10 minutes. Retighten the drive clutch
to 7.6 kg-m (55 ft-lb).

If the engine had a major overhaul or if any major
component

was

replaced,

proper

engine

break-in procedures must be followed. If the
proper engine break-in procedures are not
followed, severe engine damage may result.

! CAUTION

2-126

Troubleshooting

Engine

(Carbureted Models)

Problem: Engine Does Not Start (No Spark at Spark Plugs)

Condition

Remedy

1. Ignition switch malfunctioning—not in RUN position

1. Replace ignition switch—turn switch to RUN position

2. Wiring harness shorting

2. Repair—replace wiring harness

3. Emergency stop switch knob in DOWN position—

malfunctioning

3. Move knob to UP position—replace throttle switch

4. Throttle/ignition monitor switch (TM-style)

adjusted too loose—malfunctioning

4. Adjust (tighten) throttle cable— replace

throttle switch

5. Throttle/ignition monitor switch (VM-style)

adjusted too tight—malfunctioning

5. Adjust (loosen) throttle cable—replace throttle

switch

6. Carburetor safety switches (VM-style)

adjusted incorrectly—malfunctioning

6. Adjust—replace carburetor safety switches

7. Spark plugs fouled—damaged

7. Clean—gap —replace spark plugs

8. Spark-plug caps damaged—leaking—shorting

8. Replace spark-plug caps

9. High tension wires/coil loose—grounded—

faulty

9. Service—replace high tension wires/coil

10. CDI unit faulty

10. Replace CDI unit

11. Charge coil (1) faulty

11. Replace coil

12. Charge coil (2) faulty

12. Replace coil

13. Flywheel magnets weak

13. Replace flywheel

14. Flywheel key sheared

14. Replace key

Problem: Engine Does Not Start (No Fuel at Cylinders)

Condition

Remedy

1. Gas tank empty

1. Fill tank

2. Shut-off valve closed

2. Open shut-off valve

3. Fuel hose broken—pinched

3. Replace—service hose

4. Gas-tank vent—hose obstructed

4. Remove obstruction—replace vent—hose

5. In-line fuel filter obstructed—damaged

5. Remove obstruction—replace in-line fuel filter

6. Fuel pump malfunctioning—faulty

6. Replace—repair—clean fuel pump

7. Impulse hose cracked—broken—pinched—

disconnected

7. Replace—connect impulse hose

8. Carburetors adjusted incorrectly—dirty—

damaged

8. Troubleshoot — clean—replace carburetors

9. Primary compression (crankcase) absent

9. Repair—replace damaged—worn engine components

2

2-127

Problem: Engine Does Not Start (Fuel Does Not Ignite)

Condition

Remedy

1. Carburetor-to-cylinder air leak

1. Replace—service gaskets—intake flanges—

connect oil delivery hose—service intake ports

2. Carburetors adjusted incorrectly—dirty—damaged

2. Troubleshoot—clean—replace carburetors

3. Gasoline contaminated

3. Clean tank—entire fuel system

4. Engine flooded

4. Troubleshoot carburetors—clean—replace air-

intake silencer—clear engine by pulling recoil
several times —install new spark plugs —
try restarting engine

5. Secondary compression (cylinder) low

5. Repair—replace damaged—worn engine

components

6. Choke cable(s) adjusted improperly

6. Check and adjust choke cable(s)

Problem: Engine Does Not Idle

Condition

Remedy

1. Carburetors adjusted incorrectly—dirty—

damaged

1. Troubleshoot—clean—replace carburetors

2. Fuel pump malfunctioning—faulty

2. Replace—repair—clean fuel pump

3. Impulse hose cracked—broken

3. Replace impulse hose

4. Air-intake silencer obstructed—damaged

4. Remove obstruction—replace air-intake silencer

Problem: Engine Loses Power

Condition

Remedy

1. Gas-tank vent—hose obstructed

1. Remove obstruction—replace vent—hose

2. Fuel hose cracked—broken—pinched

2. Replace—service fuel hose

3. In-line fuel filter obstructed—damaged

3. Remove obstruction—replace in-line fuel filter

4. Carburetors adjusted incorrectly—dirty—

damaged—loose

4. Troubleshoot—tighten—clean—

replace carburetors

5. Muffler obstructed—disconnected—damaged

5. Remove obstruction—connect—replace muffler

6. Air-intake silencer obstructed—disconnected—

damaged

6. Remove obstruction—connect—replace air-intake

silencer

7. Exhaust ports carboned

7. Clean exhaust ports

8. Spark plugs fouled—damaged

8. Clean—gap—replace spark plugs

9. High tension wires/coil loose—faulty

9. Service—replace high tension wires/coil

10. Spark-plug caps leaking—shorting

10. Replace spark-plug caps

11. Ignition timing adjusted incorrectly

11. Time ignition

12. Primary and secondary compression low

12. Repair—replace damaged—worn engine

components

13. Charge coil (1) faulty

13. Replace coil

14. Charge coil (2) faulty

14. Replace coil

15. CDI unit faulty

15. Replace CDI unit

16. Oil-injection pump malfunctioning—adjusted

incorrectly

16. Replace—bleed—adjust oil-injection pump

2-128