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Snowmobile Arctic Cat (2004 year). Manual - part 46

4-19

5. Secure the mixing body top by tightening the

screw and lock washer making sure the mixing
body top plate is properly positioned.

6. If applicable, connect the safety switch harness to

the main wiring harness.

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

position.

8. Adjust the carburetors (see appropriate Adjusting

Carburetors in this sub-section).

Installing Carburetors

(Standard TM-Style)

1. Prior to installing the carburetors, the carburetor

throttle valves must be checked for
synchronization.

A. With the throttle in the idle position, select a

small drill bit that will just fit under the
cutaway of the fixed throttle valve.

B. Using the same drill bit, check the clearance

under the adjustable throttle valve cutaway. If
clearance is different from the first carburetor
checked, adjust the throttle valve by loosening
the lever ring locking screw; then using an
open-end wrench, rotate the synchronizing nut
in either direction until the clearance is the
same as the first carburetor checked.

0734-445

C. After synchronization has been attained, hold

the synchronizing nut with the open-end
wrench and tighten the lever ring locking
screw.

2. Place the carburetors (with float chamber vent

hoses) in the engine compartment and into the
carburetor boot; then tighten the clamps.

3. Connect the fuel supply hose to the fuel inlet T-

fitting.

4. Connect the throttle cable and choke cables.

5. At this point, there must be free-play gap in the

throttle lever.

733-081C

NOTE: If throttle cable free-play is incorrect, the

throttle safety switch will be activated prematurely
and the engine will not start.

NOTE: If cable free-play must be corrected, uti-

lize the jam nuts on the throttle cable bracket until
no free-play is attained.

6. Place the air-intake silencer into position in the

engine compartment making sure the carburetors
are properly positioned in the boot and secure with
screws.

7. Place the ignition coil/fuel pump mounting plate

into position on the air-intake silencer and secure
with the machine screw and washer.

AN613D

8. Adjust the carburetors (see appropriate Adjusting

Carburetors in this sub-section).

Installing Carburetors

(“Laydown” Engine TM-Style)

1. Prior to installing the carburetors, the carburetor

throttle valves must be checked for
synchronization.

4-20

A. With the throttle in the idle position, select a

small drill bit that will just fit under the
cutaway of the fixed throttle valve.

B. Using the same drill bit, check the clearance

0734-445

C. After synchronization has been attained, hold

the synchronizing nut with the open-end
wrench and tighten the lever ring locking
screw.

2. Connect the coolant hoses to the carburetors and

secure with the clamps.

3. Pry the air silencer boot forward far enough to

allow the carburetor assembly to be placed into
position; then tighten the carburetor flange
clamps, connect the TPS harness, and connect the
throttle cable.

NOTE: Make sure that the coolant drain is tight-

ened and that the drain hose is routed correctly in
the front end.

4. Install the resonator and the expansion chamber.

5. At this point, there must be free-play gap in the

throttle lever.

NOTE: If throttle cable free-play is incorrect, the

throttle safety switch will be activated prematurely
and the engine will not start.

NOTE: If cable free-play must be corrected, uti-

lize the jam nuts on the throttle cable bracket until
free-play is attained.

733-081C

6. Fill the cooling system with coolant.

NOTE: Because the coolant fills slowly into the

engine, it is necessary to wait for 10 minutes after
filling the coolant tank to allow the engine to fill
with coolant.

7. Recheck the coolant level. If the level is low after

10 minutes, repeat step 6.

8. Install the coolant cap to the “first” position.

9. Start the engine. Do not exceed 3000 RPM.

NOTE: After the engine has run for about 3-5

m i n u t e s , t h e r i g h t - s i d e r u n n i n g b o a r d h e a t
exchanger should feel warm to the touch. This is a
sign that the thermostat has opened.

10. Shut off the engine.

11. Tighten the coolant cap to the “second” position.

12. Tip the snowmobile onto the left-hand side (PTO-

side) to allow air to move from the rear heat
exchanger to the coolant tank.

13. Recheck the coolant level. If the coolant level is

low, repeat step 6.

14. Install the coolant cap to the “first” position.

15. Place the snowmobile onto a safety stand.

16. Start the engine and run for 1 to 2 minutes. Do not

exceed 5000 RPM.

17. Monitor the heat exchanger temperature by touch.

18. Shut the engine off for 5 minutes.

19. Start the engine and run for about 3-5 minutes;

then repeat steps 10-18 an additional 2-3 times.

4-21

Adjusting

Carburetor(s)

(VM-Style)

ADJUSTING CHOKE CABLE(S)

1. Be sure the ignition switch key is in the OFF

position and the brake lever lock is set.

2. Loosen the jam nut securing the choke cable

adjuster. Rotate the choke cable adjuster
clockwise until it bottoms against the brass
plunger cap.

3. Slowly rotate the choke cable adjuster

counterclockwise while checking the choke lever
for free-play. As soon as all free-play has been
removed from the end of the lever, stop rotating
the adjuster.

4. With free-play removed from the lever, slowly

rotate the choke cable adjuster once again
clockwise while checking the choke cable lever
for free-play. Adjust until 3 mm (1/8 in.) free-play
between front bottom edge of lever and housing is
attained. Securely tighten the adjuster jam nut.

0732-848

5. On twin carburetor models, repeat steps 3 and 4 on

each carburetor.

NOTE: On twin carburetor models if a carburetor

choke cable is adjusted too tight, the engine will
only operate on 1 cylinder at idle.

ADJUSTING PISTON VALVE(S)

NOTE: On some models, the air-intake silencer

is a one-piece unit, and the silencer boot(s) can be
removed to access the intake bore(s). Remove the
boots; then proceed to step 4.

NOTE: On some models, the air-intake silencer

includes a cover/tool tray assembly and a baffle/
resonator, and the silencer boot cannot be
removed to access the intake bores. Proceed to
step 1.

1. Open the air-intake silencer cover; then remove

the 3 Phillips-head screws securing the cover/tool
tray assembly to the silencer.

2. Tip the cover/tool tray assembly forward and out

of its slots and remove the assembly.

3. Using a large flat-blade screwdriver, remove the

resonator tabs from the air-intake silencer slots
and remove the resonator to access the intake
bores.

NOTE: The resonator can be removed more eas-

ily by removing the back tabs first.

4. Rotate each idle speed screw counterclockwise

until all spring tension is removed.

5. Loosen the jam nut securing each throttle cable

swivel adapter; then rotate the swivel adapter
clockwise until the piston valve bottoms in the
piston valve bore.

6. In turn on each carburetor, place a finger lightly

against the side of the piston valve; then rotate the
carburetor swivel adapter counterclockwise until
slight upward movement of the valve is noted.

7. In turn on each carburetor, place a finger against

either piston valve. Rotate the idle speed screw
clockwise until it contacts the valve.

8. Compress the throttle lever to the full-open

position; then rotate each idle speed screw
clockwise 2 complete turns. Release the throttle
lever.

NOTE: On single carburetor models, the throttle

control is equipped with a 2-wire throttle control
s w i t c h c o n n e c t o r . T h e r e m u s t b e f r e e - p l a y
between the lever and the control housing.

NOTE: On twin carburetor models, the throttle

control is equipped with a 3-prong emergency
stop switch connector. There must be free-play
between the lever and the control housing.

! CAUTION

The air-intake silencer and boots must be in
position whenever the engine is run. If the
silencer is removed and the engine is run, a lean
condition will result. Therefore, DO NOT run the
engine when the air-intake silencer is removed.

4-22

733-081C

NOTE: If cable free-play gap is not correct, rotate

each swivel adapter an equal amount until recom-
mended free-play is achieved. Each piston valve
must be resting against the tip of its idle speed
screw.

NOTE: On twin carburetor models if throttle

cable free-play is incorrect, the carburetor safety
switches will be activated prematurely and the
engine will not start.

9. On some models, install the air-intake silencer

boot(s); on some models, install the baffle/
resonator and the cover/tool tray assembly.

SYNCHRONIZING PISTON VALVES

NOTE: Arctic Cat recommends using the Carbu-

retor Synchronizer (p/n 0644-069). If the carburetor
synchronizer is not available, use the following
procedure.

1. Open the air-intake silencer cover; then remove

the 3 Phillips-head screws securing the cover/tool
tray assembly to the silencer.

2. Tip the cover/tool tray assembly forward and out

of its slots and remove the assembly.

3. Using a large flat-blade screwdriver, remove the

resonator tabs from the air-intake silencer slots
and remove the resonator to access the intake
bores.

NOTE: The resonator can be removed more eas-

ily by removing the back tabs first.

4. Check to make sure the piston valves start to open

at the exact same moment by placing a thumb and
finger against the valves; then lightly compress the
throttle lever.

5. With slight pressure being applied to the throttle

lever, the piston valves should start to open at the
exact same time. Compress and release the throttle
lever several times to assure accurate
determination of piston valve opening.

6. If a piston valve starts to open before another,

rotate the swivel adapter on the valve which is
lifting first clockwise, just enough to synchronize
the valves. Recheck by repeating steps 4-6.

AH096A

7. Tighten the swivel adapter jam nuts securely.

Slide the rubber throttle cable caps down over the
swivel adapters.

AH125

NOTE: There must be free-play in the throttle

lever.

8. After synchronization has been attained, install the

resonator and cover/tool tray assembly.

! WARNING

Be sure to tighten the swivel adapter jam nuts
securely. If a swivel adapter jam nut is not tight-
ened, the adjuster can rotate out of the carburetor
cap causing the piston valve not to return to the
full-closed position.

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