Snowmobile Arctic Cat (2004 year). Manual - part 57

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2. Remove the screws and lock washers securing the

fuel pump; then from the top of the fuel pump,
remove the cap, thick packing, diaphragm, thin
rubber packing, valve section, thin rubber packing,
diaphragm, and thick packing.

3. Push the grommets out of valve section; then

remove the valve from each grommet.

NOTE: Be sure all fuel pump components are

clean and the fittings are tight.

4. Place a valve onto each grommet; then push each

valve with grommet into the valve section of the
fuel pump.

5. In sequence on the bottom of the fuel pump, place

a thick packing, diaphragm, thin rubber packing,
valve section, thin rubber packing, diaphragm,
thick rubber packing, and cap.

NOTE: Make sure the scribed line made during

disassembly is aligned and the tabs on the two
lower packings align with the tabs on the bottom
and valve section of the pump.

6. Secure the fuel pump with the screws and lock

washers. Tighten securely.

SERVICING

1. Scribe a line across the fuel pump sections.

2. Remove the Phillips-head screws and lock

washers securing the fuel pump sections; then
from the top of the fuel pump, remove the cap,
gasket, diaphragm, gasket, valve section, gasket,
diaphragm, and gasket.

NOTE: Be sure all fuel pump components are

clean and the fittings are tight.

3. Push the grommets out of the valve section; then

remove the valve from each grommet.

4. Place a valve onto each grommet; then push each

valve with grommet into the valve section of the
fuel pump.

5. In sequence on the bottom of the fuel pump, place

a gasket, diaphragm, gasket, valve section, gasket,
diaphragm, gasket, and cap.

NOTE: Make sure the scribed line made during

disassembly is aligned and the tabs on the two
upper gaskets align.

6. Secure the fuel pump with the Phillips-head

screws and lock washers. Tighten securely.

Air-Intake Silencer

(One-Piece Style)

The air-intake silencer is a specially designed compo-
nent used to silence the incoming fresh air and also to
catch the fuel that “spits back” out of the carburetors.
The carburetors are calibrated with the air-intake
silencer in position; therefore, the engine must never
be run with the air-intake silencer removed.

CLEANING AND INSPECTING

1. Check for holes or cracks in the silencer.

2. Periodically clean the silencer by blowing fresh air

through it.

Air-Intake Silencer

(Cover/Tool Tray Style)

The air-intake silencer is a specially designed compo-
nent used to silence the incoming fresh air and also to
catch the fuel that “spits back” out of the throttle body/
carburetors. The throttle body/carburetors are cali-
brated with the air-intake silencer in position; there-
fore, the engine must never be run with the air-intake
silencer removed.

CLEANING AND INSPECTING

1. Check for holes or cracks in the silencer.

2. Periodically clean the silencer by removing the

cover/tool tray assembly and vacuuming the
interior of the silencer.

Air-Intake Silencer

(“Laydown” Engine Style)

REMOVING

1. Remove the two hood pins securing the hood to

the front end; then carefully move the hood back
allowing it to rest against the handlebar.

2. Using a #20 torx-bit, remove the three screws

securing the air silencer to the front bumper
assembly. Account for the position of the hood
screen.

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NOTE: On the 600/700 cc, it is necessary to first

remove the two screws securing the ECU to the air
silencer.

CLEANING AND INSPECTING

1. Check for holes or cracks in the silencer.

2. Periodically clean the silencer by blowing fresh air

through it.

INSTALLING

1. Position the hood screen to the front bumper

assembly; then install the air silencer into the front
end.

2. Secure the air silencer with the three screws.

NOTE: On the 600/700 cc, secure the ECU to the

air silencer with the two screws.

Gas Tank/Seat

Assembly

NOTE: Determine which style gas tank/seat

assembly is being removed and installed and use
the specific sub-section accordingly.

REMOVING (Standard EFI Models)

NOTE: If applicable, remove the backrest and

rack (see Section 7).

1. Remove the console (see Section 7).

2. Remove the two cap screws, washers, and lock

nuts (located in the rear compartment) securing the
seat to the tunnel.

3. Remove the vent hose from the gas tank.

4. Disconnect the wiring harness from the fuel pump.

5. Label the fuel hoses “supply” and “return”; then

remove the hoses from the fuel pump.

6. Raise the rear of the seat high enough to

disconnect the taillight wiring harness; then
remove the seat.

INSTALLING (Standard EFI Models)

1. Place the seat in position on the tunnel; then

connect the taillight wiring harness.

2. Connect the vent hose to the gas tank.

3. Connect the fuel supply and return hoses to the

fuel pump. Secure with clamps.

NOTE: The fuel hoses must be connected to

their respective fittings and tightened securely or
leakage will result.

4. Attach the wiring harness to the fuel pump.

5. Secure the seat to the tunnel with two screws,

washers, and lock nuts.

6. Install the console (see Section 7).

NOTE: If applicable, install the backrest and rack

(see Section 7).

REMOVING (Standard Carbureted
Models)

NOTE: If applicable, remove the backrest and

rack (see Section 7).

1. Remove the two lock nuts and washers (located in

the rear tool compartment) securing the seat to the
tunnel.

2. Remove the hose from the gas tank shut-off valve.

Plug the hose to prevent drainage.

3. Remove the screws securing the console; then

remove the console.

AL142D

4. Slide the gas tank/seat assembly rearward; then

remove the vent hose from the gas tank fitting.
Disconnect the taillight wiring harness and
remove.

5. Drain all gasoline from the tank; then (if

necessary) remove the tank outlet assembly and
vent fitting.

! WARNING

Whenever any maintenance is performed on the
fuel system, there should be no welding, smoking,
open flames, etc., in the area.

! CAUTION

Since the fuel supply hose may be under
pressure, remove it slowly to release the
pressure. Place an absorbent towel around the
connection to absorb fuel.

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INSTALLING (Standard Carbureted
Models)

1. If removed, apply teflon tape to the threads of the

tank outlet fitting and vent fitting; then thread each
into the tank.

2. Slide the gas tank/seat assembly into position.

Install the vent hose on the vent fitting and connect
the gas hose to the shut-off valve.

3. Place the gas tank/seat assembly into position,

connect the taillight harness, and secure with lock
nuts and washers.

4. Install and secure the console.

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

position.

6. Inspect the entire fuel system for leaks.

NOTE: If applicable, install the backrest and rack

(see Section 7).

REMOVING (AWS VI Models)

NOTE: On Sabercat models, unhook the hold-

down straps and remove the storage compart-
ment; then trip the seat latches and remove the
seat.

1. From inside the rear storage compartment, remove

the nut and washer securing the seat assembly to
the tunnel; then remove the seat assembly.

FC228

2. Remove the console. Account for all mounting

hardware.

FC227

3. Drain the gasoline from the gas tank.

4. Remove the two lock nuts and two torx-head cap

screws with nuts securing the steering post support
bracket.

FC203

NOTE: Account for the plastic steering post

mounting block.

5. Remove the nine lock nuts securing the gas tank to

the tunnel and footrests; then remove the four torx-
head screws securing the side belly pans to the gas
tank. Account for all mounting hardware.

! CAUTION

Check the vent and gas hoses to be sure they are
not kinked or making contact with the driven
shaft.

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FC229

FC230

6. Remove the gasline hose from the lower right-side

corner of the gas tank; then remove the gas tank
assembly.

FC231

INSTALLING (AWS VI Models)

1. Place the gas tank into postion and secure the

gasline hose.

FC231

2. Secure the side belly pans to the gas tank with the

four torx-head screws; then secure the gas tank to
the tunnel and footrests with the nine lock nuts.

FC230

FC229

3. Making sure the plastic steering post mounting

block is correctly positioned, secure the steering
post support bracket with the two torx-head cap
screws with nuts and the two lock nuts.

FC203

4. Install the console using existing mounting

hardware.

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