Snowmobile Arctic Cat (2004 year). Manual - part 40

3-23

3

AP165

4. One at a time, slide each of the exhaust valve/

valve guide assemblies through the retaining plate
and onto the pin in the valve stopper.

AP162

„

NOTE: The single center mounting hole on the

retaining plate should be up.

5. Slide the valve assembly into the proper cylinder.

AP154

6. Secure the valve assembly to the cylinder with

three Allen-head cap screws (coated with blue
Loctite #242). Tighten to 1.1 kg-m (8 ft-lb).

AP153

7. Slide the valve cover onto the studs on the engine.

Secure with four nuts. Tighten securely.

AP119

8. Perform steps 6-10 in the appropriate Cable

Adjustment in this sub-section.

Removing/Disassembling
(800/900 cc)

„

NOTE: To avoid a parts mix-up, it is recom-

mended that only one valve assembly at a time be
removed from the engine.

1. Remove the valve assembly from the engine (see

Section 2).

AP121

2. Remove the retaining screw securing the exhaust

valve to the valve stopper.

3-24

AP123

3. Hold the valve stopper securely and pull the cable

back and up until it clears the top of the stopper;
then slowly release the cable and remove it from
the valve stopper.

AP125

Cleaning and Inspecting

1. Remove all carbon deposits with solvent and a soft

abrasive such as a Scotch-Brite pad.

2. Inspect all parts for nicks, burrs, or other signs of

unusual wear.

Assembling/Installing
(800/900 cc)

AP124A

1. Slide the return spring over the end of the

actuating cable.

„

NOTE: Make sure that the small cable end spring

stays in place at the end of the cable.

2. Place the valve stopper on the cable and slide it

down until the cable end is inside the stopper.

AP125

3. Slide the exhaust valve through the retaining plate

and insert it into the valve stopper. Secure with the
retaining screw. Tighten to 0.6 kg-m (4 ft-lb).

AP123

4. Slide the valve assembly into the proper cylinder.

AP121

„

NOTE: The flat side of the retaining plate must

be down.

5. Secure the valve assembly to the cylinder with two

Allen-head cap screws (coated with blue Loctite
#242). Tighten to 0.9-1.3 kg-m (6.5-9.5 ft-lb).

3-25

3

AP120

6. Place the valve cover with the gasket into position

on the engine. Secure with four cap screws.
Tighten to 0.9-1.3 kg-m (6.5-9.5 ft-lb).

AP119

7. Perform steps 6-10 in the appropriate Cable

Adjustment in this sub-section.

Removing/Disassembling                       
(“Laydown” Engine Models)

„

NOTE: To avoid a parts mix-up, it is recom-

mended that only one valve assembly at a time be
removed from the engine.

1. Remove the valve assembly from the engine.

FC115

2. Remove the retaining screw securing the exhaust

valve to the valve stopper.

FC112

3. Hold the valve stopper securely and pull the cable

back and up until it clears the top of the stopper;
then slowly release the cable and remove it from
the valve stopper.

FC113

Cleaning and Inspecting

1. Remove all carbon deposits with solvent and a soft

abrasive such as a Scotch-Brite pad.

2. Inspect all parts for nicks, burrs, or other signs of

unusual wear.

Replacing Oil Seal

1. Carefully pry the seal up from beneath taking care

not to damage the valve plate.

FC116

2. Install the new seal using an appropriate-sized seal

driving tool.

3-26

FC117

Assembling/Installing

FC111A

1. Slide the return spring over the end of the

actuating cable.

FC114

„

NOTE: Make sure that the small cable end spring

stays in place at the end of the cable.

2. With the cover gasket properly positioned, place

the valve stopper on the cable end and slide it
down until the cable end is inside the stopper.

FC113

3. With the valve plate gasket properly positioned,

slide the exhaust valve through the valve plate and
insert it into the valve stopper. Secure with the
retaining screw. Tighten to 0.6 kg-m (4 ft-lb).

FC112

„

NOTE: Note that the exhaust valve gaskets are

directional and must be installed correctly.

4. Slide the valve assembly into the proper cylinder.

FC115

! CAUTION

The long side of the exhaust valve must be
facing toward the cylinder head or severe engine
damage may occur.