Snowmobile Arctic Cat (2004 year). Manual - part 30

2-107

2

AB073

8. Place the expansion chamber and grafoil gasket

into position and secure with springs.

AB105D

9. Place the engine mount shims into position

between the torque bumper and engine mounting
bracket; then tighten the torque bumper jam nut.

10. Place the drive clutch into position on the

crankshaft; then install the lock washer and bolt.
Tighten the clutch bolt to 6.9-7.6 kg-m (50-
55 ft-lb).

AF477D

„

NOTE: Apply a coat of Anti-Seize Thread Com-

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

11. Install the driven pulley and alignment washers.

Secure with a cap screw and washer tightened to
2.6-3.3 kg-m (19-24 ft-lb).

SC013D

„

NOTE: At this point, check drive clutch/driven

pulley alignment (see Section 8).

12. Install the drive belt and secure the belt guard.

Install the plug in the belly pan.

„

NOTE: If equipped with electric start, connect

the battery.

13. Turn the gas tank shut-off valve to the OPEN

position.

14. Check the ignition timing.

15. Place the rear of the snowmobile up on a shielded

safety stand. Start engine and allow to warm up.
Adjust engine idle to 1500 RPM and check all
safety switches for proper operation.

16. Test drive the snowmobile; then tighten the clutch

bolt to 7.6 kg-m (55 ft-lb).

AF477D

! CAUTION

If the engine had a major overhaul or if any major
part was replaced, proper engine break-in
procedures must be followed.

2-108

Installing Engine

(Standard L/C Models)

1. Place the engine into the engine compartment;

then place the coolant supply hose on the water
pump (coolant tank on the 800/900 cc) and secure
with the clamp.

2. 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).

3. Adjust the torque bumper to allow a clearance

between the engine and the torque bumper of
1.78 mm (0.070 in.); then secure the adjustment by
tightening the jam nuts.

AN610D

4. On the 600 cc, secure the hood cable and ground

wire to the magneto case with the machine screw
tightened to 1.1 kg-m (8 ft-lb).

5. On the 550 cc, attach the hood cable to the exhaust

manifold and the ground wires to the magneto
case.

6. Secure the rear ground wires to the magneto case

with the machine screw tightened to 1.1 kg-m
(8 ft-lb).

7. Place the coolant return hose into position on the

thermostat housing and secure with the clamp.

8. Place the recoil starter into position and secure the

starter with four cap screws and lock washers.
Tighten to 1 kg-m (7 ft-lb).

9. Connect all electrical wires.

„

NOTE: Use cable ties to secure the wiring har-

nesses as necessary.

10. Connect the oil-injection cable/control rod to the

oil-injection pump and secure; then connect the
oil-supply hose to the pump and secure with the
clamp. Bleed the oil-injection system (see
Section 4).

AN392D

11. On carbureted models, connect the impulse hose

to the crankcase.

AN385D

12. Place the carburetors/throttle bodies into position

and secure with the flange clamps. Synchronize
the oil-injection system (see Section 4).

„

NOTE: On the 800/900 cc, install the air-intake

silencer; then place the CDI unit into position and
close the cover.

13. Place the expansion chamber and grafoil gaskets

into position and secure to the exhaust manifold,
front end, and resonator with the springs.

AN378D

„

NOTE: When installing the three exhaust mani-

fold springs, the long hook portion of the spring
must be attached to the exhaust manifold or pre-
mature spring failure will result.

„

NOTE: Before installing the drive clutch, be sure

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

2-109

2

14. Place the drive clutch into position on the

crankshaft and secure with the cap screw and lock
washer. Tighten to 6.9-7.6 kg-m (50-55 ft-lb).

AN381D

„

NOTE: Apply a coat of Anti-Seize Thread Com-

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

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

alignment washers. Secure with a cap screw and
washer. Tighten to 2.6-3.3 kg-m (19-24 ft-lb).

AF120D

SC013D

16. Check drive clutch/driven pulley alignment (see

Section 8).

17. Install the drive belt. Check belt deflection. Secure

the belt guard.

AN379D

18. Fill the cooling system (see Section 3).

19. On models equipped w/electric start, connect the

positive cable to the starter motor; then secure
with the washers and nut making sure the cable is
directed toward the PTO-side of the engine. Secure
the positive cable with a long cable tie.

20. On models equipped w/electric start, connect the

cables to the battery making sure to connect the
positive cable first.

„

NOTE: Steps 21 through 25 are for APV

equipped engines.

21. Slide the cable drums into the servomotor

actuator; then place the cable housings into
position in the servomotor. Secure the cable
housings with the holder.

AP118C

AP117

2-110

22. Position the tab (on the bottom of the servomotor

mounting plate) into the slot in the air-intake
silencer; then secure the mounting plate to the
silencer with a screw.

AP127

23. Place the servomotor with cover into position on

the mounting plate; then secure with two cap
screws.

AP116A

24. Check APV cable adjustment. See Arctic Power

Valve (APV) System in Section 3.

25. Connect the two APV drain hoses making sure

they are not in contact with hot or moving parts.

AP128A

26. If applicable, turn the gas tank shut-off valve to the

OPEN position.

27. Start engine and verify ignition timing.

28. Test drive or run the snowmobile and recheck the

coolant level after 5-6 minutes. Tighten the drive
clutch cap screw to 7.6 kg-m (55 ft-lb).

Installing Engine 

         

(500/600/700 cc 

“Laydown”

Engine Models)

1. Place the engine into the engine compartment and

position it so the magneto case is resting on the
right-front torque bumper; then attach the water
pump coolant hose to the front heat exchanger.
Secure with the hose clamp.

FC047

„

NOTE: If equipped with electric start, insert the

flex-drive shaft into the pinion drive and secure
with the two set screws.

2. Place the engine into the mounting position; then

from the left side, tip the engine forward, raise the
left side of the engine, and allow the chassis to
support the engine in this position. Connect the
coolant tank hose to the bottom left outlet on the
engine in this position. Connect the coolant tank
hose to the bottom left outlet on the engine and
secure with the hose clamp.

FC012

! CAUTION

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.