Snowmobile Arctic Cat (2004 year). Manual - part 38

3-15

0738-584

0738-622

KEY

1. Heat Exchanger
2. Hose
3. Clamp
4. Heat Exchanger
5. Insert
6. Heat Exchanger
7. Rivet
8. Rivet
9. Hose

10. Hose
11. Clamp
12. Cable Tie
13. Hose
14. T-Fitting
15. Clamp
16. Hose
17. Protector
18. Hose
19. Coolant Tank
20. Decal
21. Hose
22. Tank Cap
23. Clamp
24. Hose
25. Cap Screw
26. Bracket
27. Cap Screw
28. Lock Nut
29. Tunnel Protector
30. Clamp

KEY

1. Heat Exchanger
2. Hose
3. Clamp
4. Heat Exchanger
5. Insert
6. Heat Exchanger
7. Rivet
8. Rivet
9. Hose

10. Clamp
11. Hose
12. Hose
13. Hose
14. Coolant Tank
15. Foil Tape
16. Hose
17. Cable Tie
18. Decal
19. Cap
20. Clamp
21. Spacer
22. Cap Screw
23. Rope Guide
24. Lock Nut
25. Cap Screw
26. Tunnel Protector
27. Clamp

3-16

Recoil Starter

REMOVING

1. Tie a slip-knot in the starter rope below the

console and allow the rope to slowly retract
against the starter case.

2. Remove the knot at the handle, remove the handle,

and account for the handle cap; then thread the
rope through the bushing in the console.

3. Remove the cap screws securing the starter

assembly to the magneto case; then remove the
starter assembly.

DISASSEMBLING

1. Secure the recoil starter in a vise.

2. Rotate the roller counterclockwise until the notch

of the roller is near the rope guide in the case.
Guide the rope into the notch and slowly allow the
roller to retract until all recoil spring tension is
released.

B522

3. While exerting downward pressure on the friction

plate, remove the nut and washer or cap screw.

B523

4. Slowly release the plate and lift the plate with

friction spring free of the recoil roller.

5. Remove the friction spring from the plate.

B524

6. Remove the pawl; then remove the return spring.

B525

7. Carefully lift the roller free of the case making

sure the main spring does not accidentally
disengage from the case.

8. Remove the main spring from the case by lifting

the spring end up and out. Hold the remainder of
the spring with thumbs and alternately release
each thumb to allow the spring to gradually release
from the case.

! WARNING

Always wear safety glasses when servicing the
recoil starter.

! WARNING

During the disassembly procedure, continuous
downward pressure must be exerted on the reel so
it does not accidentally disengage and cause
injury.

! WARNING

Care must be taken when allowing the recoil roller
to unwind. Make sure all spring tension is released
before continuing.

! WARNING

Care must be taken when lifting the roller free of the
case.

3-17

NOTE: Do not remove the main spring unless

replacement is necessary. It should be visually
inspected in place to save time.

9. Unwind the rope from the roller, untie the slip-

knot, and remove the rope.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all recoil starter components.

2. Inspect all springs, washers, and pawl for wear or

damage.

3. Inspect the roller and case for cracks or damage.

4. Inspect the center hub for wear, cracks, or damage.

5. Inspect the rope for breaks or fraying.

6. Inspect the main spring for cracks, crystallization,

or abnormal bends.

7. Inspect the handle for damage, cracks, or

deterioration.

ASSEMBLING

732-515A

1. Hook the end of the main spring around the

mounting lug in the case.

2. Insert the main spring into the case; then wind it in

a counterclockwise direction until the complete
spring is installed.

NOTE: The main spring must seat evenly in the

recoil case.

3. Insert the rope through the hole in the roller and tie

a knot in the end; then wrap the rope
counterclockwise around the roller leaving
approximately 50 cm (20 in.) of rope free of the
roller.

4. Apply low-temperature grease to the main spring

and hub.

5. Align the hook in the end of the main spring with

the notch in the roller.

6. Carefully slide the roller over the hub and engage

the spring with the roller.

7. Install the return spring making sure the end is

properly installed in the hole in the roller; then
install the pawl making sure the return spring is
properly preloaded.

B525

8. Slide the end of the rope through the rope guide of

the case; then tie a slip-knot in the rope.

9. Place the friction spring into position on the

friction plate making sure the head of the spring is
opposite the flat of the inner hole. Apply a low-
temperature grease to the plate.

B524

KEY

1. Starter Assy
2. Starter Roller
3. Main Spring
4. Ratchet Set
5. Friction Spring
6. Washer
7. Return Spring
8. Friction Plate

9. Nut

10. Starter Rope
11. Cap Screw
12. Starter Pulley
13. Bolt
14. Decal
15. Pawl

3-18

10. Place the plate into position making sure the flat of

the inner hole is correctly positioned in the hub.
Apply blue Loctite #242 to the threads; then
secure the drive plate with a washer and nut or
with a cap screw. Tighten the nut to 1 kg-m
(7 ft-lb) or tighten the cap screw to 0.8-2.1 kg-m
(6-9 ft-lb).

B526

11. With 50 cm (20 in.) of rope exposed, hook the

rope in the notch of the roller.

12. Rotate the roller four or five turns counter-

clockwise; then release the rope from the notch
and allow the rope to retract.

13. Pull the rope out two or three times to check for

correct tension.

NOTE: Increasing the rotations in step 12 will

increase spring tension.

INSTALLING

1. Place the starter assembly into position against the

magneto case.

2. Secure the starter with cap screws. Tighten to 1

kg-m (7 ft-lb) on the L/C models or to 1.1 kg-m (8
ft-lb) on the F/C models.

NOTE: Before tightening the cap screws, slowly

pull the recoil rope until the pawl engages; then
tighten the cap screws. This will center the recoil
against the magneto case.

3. Thread the rope through the bushing in the

console; then install the handle and secure with a
knot. Seat the cap.

4. Release the slip-knot in the rope.

Arctic Power Valve

(APV) System

NOTE: On carbureted models, the servo will

cycle once each time the engine is started. If the
servo cycles three times and then quits, the cable
lengths are incorrect and must be adjusted.

NOTE: On EFI models, the servo will cycle once

at 7100 RPM. If the servo cycles three times, cable
length adjustment or valve inspection is required.

0735-837

0735-516

APV VALVE POSITION

ENGINE MODEL

ONE STAGE RPM RANGES

Acceleration

APV Cycle RPM

Peak H.P. RPM

500 cc

7250

83-8500

600 cc STD

7000 (Low Alt)

7170 (High Alt)

82-8300

600/700 cc

“Laydown”

7100 (Low Alt)

7200 (High Alt)

78-8000

800 cc

6800 (Low Alt)

6900 (High Alt)

73-7500

900 cc

6850

73-7500

APV CABLE LENGTH (STD)

ENGINE MODEL

CENTER

± 1 mm (0.039 in.)

600 cc

30.1 mm (1.18 in.)

800 cc

38.5 mm (1.51 in.)

900 cc

38.5 mm (1.51 in.)

Content .. 36 37 38 39 ..