Snowmobile Arctic Cat (2002 year). Manual - part 6

2-7

2

15. Disconnect the oil-injection cable/control rod from

the oil-injection pump; then disconnect the oil-

supply hose from the pump and plug the hose to

prevent oil drainage.

16. Loosen the flange clamps securing the throttle

body/carburetor to the flange; then remove the

throttle body/carburetor. Place them to one side in

an upright position.

17. On carbureted models, disconnect the impulse

hose from the crankcase.

AN385D

18. Loosen the engine torque bumper and remove the

left rear engine nut and washer.

AN610D

19. Secure the hood with a tie-down strap; then

remove the hood cable.

20. Disconnect all electrical wires from the engine.

21. Remove the recoil starter from the engine. Leave it

in the engine compartment.

„

NOTE: If applicable, disconnect the solenoid-to-

starter motor cable from the starter motor.

22. Loosen the cap screws/lock nuts securing the

engine mounting brackets to the front end.

23. Remove the cap from the coolant drain hose and

route the hose into a suitable container. Remove

the filler cap; then once the coolant stops draining,

install the drain hose cap.

AP126

24. Loosen the clamp securing the supply hose to the

coolant tank and remove the hose. Loosen the

clamp securing the hose to the thermostat cap;

then remove the hose from the cap.

„

NOTE: Inspect the engine to ensure all wires,

hoses, and cables have been removed.

25. Lift the engine with mounting brackets out of the

engine compartment.

26. Remove the cap screws securing the engine

mounting brackets to the crankcase; then remove

the brackets.

27. Remove the exhaust manifold from the engine.

Account for nuts, washers, and gaskets.

28. Remove the clamp securing the coolant supply

hose to the water pump. Then remove the hose

from the pump.

Removing Engine

(550 cc Models)

1. Disconnect the battery cables making sure to

disconnect the negative cable first.

2. Turn the gas tank shut-off valve to the CLOSED

position.

3. Remove the cable tie and positive battery cable

from the starter motor.

4. On the Wide Track, remove the two lock nuts

securing the starter motor to the engine mounting

bracket; then place the starter motor and end cap

off to the side.

5. Remove the springs securing the expansion

chamber to the exhaust manifold, front end, and

resonator. Remove the expansion chamber and

grafoil gasket.

2-8

6. Attach a long piece of fuel hose to the engine

coolant drain (located on the exhaust side of the

engine). Route the hose outside the engine

compartment and into a container. Open the drain

and remove the filler cap. Once the coolant stops

flowing, remove the hose and tighten the drain

valve.

AP058

7. Open the belt guard: then remove the drive belt.

„

NOTE: On the Wide Track, remove the machine

screws securing the side panel to the belly pan;
then remove the side panel. On the Pantera 550
and ZL 550, remove the rubber plug from the belly
pan.

AM115D

8. Using a ½-in. twelve-point socket, remove the bolt

and lock washer securing the drive clutch to the

crankshaft. Using the Clutch Puller (p/n 0644-207)

and an impact wrench or a breaker bar and the

Flywheel Pulley/Spanner Wrench (p/n 0144-310),

tighten the puller. If the drive clutch will not

release, sharply strike the head of the puller.

Repeat this step until the clutch releases. Remove

the drive clutch. If applicable, account for the two

sleeves.

„

NOTE: On the Wide Track, remove the lock nut

securing the belly pan and bumper to the bumper
support tube; then remove the rear plug from the
belly pan.

AF459D

9. Remove the cap screw and washer securing the

driven pulley; then slide the driven pulley off the

driven shaft. Account for a key and alignment

washers.

AF120D

„

NOTE: If the driven pulley is tight on the driven

shaft, pull the driven pulley off using the Driven
Pulley Puller (p/n 0744-023).

10. Loosen the flange clamp securing each carburetor

to its flange; then remove the carburetors. Position

the carburetors to one side in an upright position.

AJ172

11. Disconnect the impulse hose from the crankcase.

12. Remove the cable tie securing the engine and CDI

wiring harnesses to the engine; then disconnect the

main wiring harness from the engine and CDI

wiring harnesses.

2-9

2

13. Remove the spark plug caps and the cable tie

securing the temperature-gauge sender wire; then

disconnect the sender wire.

14. On the Wide Track, remove the ground wire from

the magneto housing.

15. Remove the E-clip and washer securing the oil-

injection cable; then disconnect the oil-injection

cable from the pump. Disconnect the oil-supply

hose from the pump and plug the hose to prevent

oil drainage.

AN009

16. Loosen the clamp securing the supply hose to the

water pump housing; then remove the hose from

the water pump. Loosen the clamp securing the

hose to the thermostat cap; then remove the hose

from the cap.

17. Remove the four cap screws and lock washers

securing the recoil starter; then remove the starter

from the engine. Leave it in the engine

compartment.

„

NOTE: On the Pantera 550, account for the

ground wire.

18. Support the hood; then remove the hood cable

from the exhaust manifold.

19. Remove the mounting hardware securing the

engine to the front end.

„

NOTE: On the Wide Track, account for shims and

note their position on the left rear engine mount
for assembly purposes.

AR321

AN013

20. Lift the engine with mounting brackets out of the

engine compartment.

21. Remove the engine mounting brackets.

Removing Engine

(Triple Models)

„

NOTE: Some engines are equipped with Arctic

Power Valves (APV). Closely observe the NOTE:
introducing this important information.

1. Turn the gas tank shut-off valve to the CLOSED

position.

AL658D

2. Secure the hood with a hold-down strap; then

remove the hood cable.

3. Remove the springs securing the expansion

chambers to the header pipes, the front end, and

the resonator. Remove the expansion chambers

and three grafoil gaskets.

„

NOTE: Number the expansion chambers before

removing to aid in assembly.

! CAUTION

Do not use the starter motor shaft to lift the
engine. Damage may occur.

2-10

4. Remove the cap screws securing the resonator.

Account for and note the location of the engine

ground cable with star washer, washers, bushings,

spacers, and retaining nuts.

5. Attach a long piece of fuel hose to the engine

coolant drain. Route the hose outside the engine

compartment and into a container. Open the drain

valve; then remove the coolant filler cap to vent

the system. Once the coolant stops flowing,

remove the hose and tighten the drain valve.

AQ123

6. Open the belt guard; then remove the drive belt.

7. Remove the plug from the belly pan; then using a

1/2 in. twelve-point socket, remove the bolt and

lock washer securing the drive clutch to the

crankshaft. Using the Drive Clutch Puller (p/n

0644-207) and an impact wrench or a breaker bar

and Spanner Wrench (p/n 0644-136), tighten the

puller. If the drive clutch will not release, sharply

strike the head of the puller. Repeat this step until

the clutch releases. Remove the drive clutch. If

applicable, account for the two sleeves.

AF472D

8. Remove the cap screw securing the driven pulley;

then slide the driven pulley off the driven shaft.

Account for a stub shaft, the location of all

washers, and a key.

„

NOTE: If the driven pulley is tight on the shaft,

pull the driven pulley off using the Driven Pulley
Puller (p/n 0744-023).

„

NOTE: Steps 9 through 15 are for APV equipped

engines.

9. Remove the two cap screws securing the

servomotor cover.

AP116A

10. Using a small screwdriver, pry off the cable

retaining cover.

AP117A

11. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

out of the holder.

AP118A

12. Pull the cable up and out of the cable housing

holder; then slide each cable drum to the left and

out of the servomotor actuator.