Snowmobile Arctic Cat (2004 year). Manual - part 11

2-31

2

FC005

8. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings
out of the holder.

FC006A

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

holder; then slide each cable drum back and out of
the servomotor actuator.

FC006B

10. Remove the cap from the coolant drain hose and

route the hose out of the exhaust outlet in the belly
pan into a suitable container. Remove the filler
cap; then once the coolant stops draining, install
the drain hose cap.

AP126

11. Loosen the flange clamps securing the throttle

body/carburetor assembly to the flange; then move
the throttle body/carburetor assembly forward to
allow room to disconnect the oil injection cable/
control rod from the oil-injection pump.

12. On the carbureted models, disconnect the impulse

hose from the crankcase.

FC007A

13. Loosen the clamps securing the coolant hoses

connected to the cylinders beneath the exhaust
ports; then remove the vent tube from the top of
the cylinder head.

FC050A

14. Move the throttle body/carburetor assembly to one

side out of the way to a secure position.

15. Remove the recoil starter and ground wire from

the engine. Leave it in the engine compartment.

2-32

16. Remove the four torx-head screws and the three

cap nuts securing the side-plate brace to the
chassis; then remove the hardware securing the
left-side engine mounting bracket. Remove the
bracket.

FC009

FC010A

17. Loosen the cap screw/lock nut securing the right-

side engine mounting bracket to the front end.

FC011

18. Disconnect all electrical wires from the engine.

19. Disconnect the lower coolant hose; then move the

engine toward the left and up to allow enough
room to remove the remaining coolant hose.

FC012A

FC013A

„

 NOTE: If equipped with electric start, loosen the

two set screws securing the flex-drive shaft to the
pinion drive.

„

 NOTE: Inspect the engine to ensure all wires,

hoses, and cables have been removed.

20. Lift the engine out of the engine compartment.

21. Remove the exhaust manifold from the engine.

Account for nuts, washers, and gaskets.

22. Remove the clamp securing the coolant supply

hose from the cylinder head to the water pump.
Then remove the hose from the engine.

Disassembling Engine

Table of Contents

370/440 cc Models ................................................ 2-33
550 cc Model ......................................................... 2-36
570 cc Models ....................................................... 2-39
600 cc Standard Engine Model ............................. 2-44
800/900 cc Models ................................................ 2-49
500/600/700 cc “Laydown” Engine Models ........... 2-55

2-33

2

Disassembling Engine

(370/440 cc Models)

1. Remove the four nuts and lock washers securing

the exhaust manifold; then remove the exhaust
manifold. Account for two gaskets.

2. Noting the location of the longer cap screws for

assembly purposes, remove the 14 cap screws,
lock washers, and washers securing the top and
exhaust-side cooling shrouds.

3. Lift the top cooling shroud off the engine and slide

the exhaust-side cooling shroud off the exhaust-
manifold studs. Account for two exhaust-manifold
shroud gaskets.

AB014

4. Disconnect the two oil-injection hoses from their

fittings on the intake manifold (single carburetor)
or on the adapter plates (twin carburetor).

5. A. On the 370 cc, remove the nuts securing the

intake manifold; then remove the manifold with
flange from the engine. Account for two
insulators. Discard the gaskets.

B. On the 440 cc, remove the nuts, lock washers,

and washers securing the intake flanges; then
remove the flanges from the engine. Remove
the screws securing the adapter plates; then
remove the adapter plates. Discard the gaskets.

6. Remove the intake-manifold cooling shroud from

the engine. Discard the two gaskets.

7. Using Flywheel Spanner Wrench (p/n 0144-007)

to secure the crankshaft, remove the three cap
screws and lock washers securing the starter
pulley to the flywheel. Remove the starter pulley;
then carefully pry the fan belt drive pulley from its
seated position on the flywheel and remove.

AB020

8. Temporarily install the starter pulley on the

flywheel with three cap screws. Using the
flywheel spanner wrench to secure the crankshaft,
loosen and remove the flywheel nut and washers.

AB021

„

NOTE: If an impact wrench is being used, use of

a flywheel spanner wrench will not be necessary.

9. Remove the cap screws securing the starter pulley

to the flywheel and remove the pulley.

10. Remove the flange nuts securing the fan case to

the crankcase; then remove the fan case.

„

NOTE: For further servicing of the axial fan com-

ponents, see section 3.

AB015

11. Install a protective cap onto the end of the

crankshaft.

2-34

„

NOTE: A suitable protective cap can be made by

welding a 3 mm (1/8 in.) plate on one side of a
spare flywheel nut.

AB022

12. Using the Flywheel Puller/Spanner Wrench (p/n

0144-310) or suitable equivalent, remove the
flywheel from the crankshaft by tightening the
puller bolt, striking the head of the puller bolt with
a hammer, and tightening again. Repeat procedure
until the flywheel is free. Account for the key in
the end of the crankshaft.

AB098

„

NOTE: To ensure the cleanliness of the flywheel

magnets, place the flywheel (with the magnets fac-
ing upward) on a clean bench.

13. Scribe a reference line on the stator plate and

crankcase to aid in assembly; then remove the two
Allen-head cap screws, lock washers, and washers
securing the stator plate.

„

NOTE: The two stator plate Allen-head cap

screws had Loctite applied to the threads during
assembly. Before removing them, apply a sharp
blow to the head of each screw to break the Loctite
loose. If this isn’t done, the screws can be very dif-
ficult to remove.

AB026

14. Remove the stator plate from the engine.

15. Remove the screws, lock washers, and washers

securing the oil-injection pump to the crankcase;
then remove the pump, retainer, shim, and gear.
Account for two gaskets.

AB018

16. Remove the spark plugs.

17. Remove the eight nuts, lock washers, and washers

securing the cylinder heads to the cylinders. Note
the position of the different-sized nuts. Remove
the heads and account for two gaskets and four
dowel pins.

B563

! CAUTION

To prevent damage to the crankshaft, thread a
protective cap onto the crankshaft. The puller
must bottom on the cap and not on the
crankshaft. Also, do not thread puller bolts more
than 12.7 mm (1/2 in.) into the flywheel. Damage
to the coils may result.