Snowmobile Arctic Cat (2004 year). Manual - part 44

4-11

4

AH042

11. Separate the starter plunger assembly from the

choke cable by compressing the spring and
removing the plunger from the cable; then remove
the spring. Thread the plunger cap off the cable.

Disassembling

Carburetors

(TM-Style)

AH631DA

„

NOTE: The carburetors do not have to be

removed to change jet needles or main jets; how-
ever, changing throttle valves requires removing
the funnel assemblies. The clearance between the
throttle valve, mixing body, and funnel assembly
(approximately 0.50 mm or 0.020 in.) is normal and
should not be a concern.

AH622DA

„

NOTE: Disassemble the carburetors using this

basic procedure.

1. Loosen the screws (with washers) securing the top

cap to the mixing body; then slide the cap off the
body. Account for the gasket.

AH615D

2. Loosen the screw securing the jet needle retaining

plate; then slide the plate out of the way.

AH616DA

3. Using a pair of needle-nose pliers, remove the jet

needle assembly. Account for the E-clip and
washer.

! CAUTION

If an engine problem has been experienced due
to improper gas/air mixture, verify the carburetor
jetting and E-clip position with the Specification
Chart and Main Jet Chart on the snowmobile for
altitude, temperature, and type of gasoline.

! CAUTION

Do not loosen the lever assembly from the
throttle lever shaft. If the lever assembly is
loosened, the carburetors must be synchronized.

4-12

AH617D

4. Remove the Phillips-head screw and the drain plug

(with O-ring) securing the float chamber to the
mixing body. Remove the chamber and account
for the O-ring.

AH618D

5. Remove the main jet (with washer), pilot jet, and

starter jet.

AH619DA

6. Remove the screws securing the float assembly.

AH620D

7. Remove the float assembly by lifting it up and out

of the mixing body. Account for the O-ring.

AH621D

„

NOTE: It may be necessary to use a spray lubri-

cant such as WD-40 to aid in removing the float
assembly.

8. Remove the Phillips-head screws securing the

funnel assembly to the mixing body.

AH622DA

9. Move the throttle lever to the full-open position;

then remove the funnel assembly. Account for the
gasket.

! CAUTION

To remove the throttle valve, the jet needle must
be removed or damage to the jet needle will
result.

4-13

4

AH623D

10. Move the throttle lever slightly open; then rotate

the throttle valve out of the mixing body.

AH624D

11. While counting the rotations for installing

purposes, rotate the fuel mixture screw clockwise
until lightly seated; then remove the mixture
screw. Account for a rubber washer, washer,
spring, and cap.

AH626D

„

NOTE: In the following step, only one E-clip

needs to be removed to free the throttle valve from
the lever assembly.

12. Remove the E-clip securing the plate to the throttle

valve; then slide the throttle valve to one side and
remove. Account for the plate, washer, clip, and
bushings.

AH627D

AH628D

Cleaning Carburetor

1. Place all metallic components in a wire basket and

submerge in carburetor cleaner.

2. Soak for approximately 30 minutes; then rinse

with fresh parts-cleaning solvent.

3. Wash all non-metallic components with soap and

water. Rinse thoroughly.

4. Dry all components with compressed air only

making sure all holes, orifices, and channels are
unobstructed.

! CAUTION

Do not force a mixture screw when seating.
Forcing a mixture screw may result in damage to
the screw taper and/or mixing body.

! CAUTION

DO NOT place any non-metallic components in
parts-cleaning  solvent or carburetor cleaner
because damage or deterioration will result.

4-14

5. Blow compressed air through all hoses to remove

any obstructions.

Inspecting Carburetor

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the mixing body for cracks, nicks, stripped

threads, and any other imperfections in the casting.

2. Inspect the piston/throttle valve for cracks, score

marks, or imperfections in the casting.

3. On the VM-style, inspect the condition of the

piston valve spring.

4. Inspect the float for perforations or damage.

5. Inspect the gaskets, O-rings, and washers for

distortion, tears, or noticeable damage.

6. When applicable, inspect the tips of the idle speed

screw, jet needle, pilot air screw, needle valve, and
fuel mixture screw for wear, damage, or distortion.

„

NOTE: On the VM-style when inspecting the inlet

needle, inspect the side guides and tip for wear. If
the guides show any sign of wear, replace the inlet
needle.

7. Inspect the pilot jet and main jet for obstructions

or damage.

8. Inspect the starter plunger and seat for wear or

damage.

9. Inspect the carburetor mounting flanges for

damage and tightness.

10. On the TM-style, inspect the throttle shaft seal for

damage and signs of leaking.

Assembling Carburetor

(VM-Style)

1. Install the idle speed screw and spring.

B351

2. Install the pilot air screw and spring. Rotate

clockwise until lightly seated; then turn
counterclockwise the same number of turns as
noted in disassembling for an initial setting.

B350

3. Install the pilot jet.

B352

! WARNING

Always wear safety glasses when drying compo-
nents with compressed air.

! CAUTION

DO NOT use wire or small drill bits to clean
carburetor orifices, holes, or channels. Distorted
or damaged orifices, holes, or channels can
result in poor carburetor operation.

! CAUTION

An air leak between the carburetor and engine
will cause a lean condition and severe engine
damage will result.

! CAUTION

DO NOT force the pilot air screw when seating.
Forcing the screw will result in damage to the
carburetor body.