Snowmobile Arctic Cat (2008 year). Manual - part 32

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2

Removing Engine

„NOTE: Prior to starting the removing procedure,
disconnect the hood harness and the air intake
connector from the air silencer; then remove the
cables and pins securing the hood to the front end
and remove the hood.

1. Remove all springs, hair pin clip, and tab washer

securing the expansion chamber and resonator;

then remove these components from the engine

compartment.

2. Remove the left-side and right-side access panels

and remove the belt guard.

3. Using a ½-in. 12-point socket, remove the cap

screw and lock washer securing the drive clutch to

the crankshaft.

4. Using Drive Clutch Puller and an impact wrench

or a breaker bar and Drive Clutch Spanner

Wrench, tighten the puller. If the drive clutch will

not release, sharply strike the head of the puller.

Repeat this step until the clutch releases. Remove

the drive clutch and drive belt.

CM205

5. Remove the cap screw from the driven pulley and

slide the driven pulley off the gear case input shaft.

Account for alignment washers (if applicable).

CM206

„NOTE: If the driven pulley is tight on the driven
shaft, pull the driven pulley off using the Driven
Pulley Puller.

„NOTE: Steps 6-8 are for the 600 cc engine. For
the 500 cc engine, proceed to step 9.

6. Loosen the two lock nuts securing the servomotor

and cover; then remove the cover. Using a small

needle-nose pliers, remove the cable holder.

CM207A

CM208

7. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

down and out of the servomotor.

CM123A

8. Slide each cable drum out of the slot of the servo-

motor actuator.

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CM124A

9. Drain the engine coolant (see Liquid Cooling Sys-

tem - Section 3).

10. Disconnect the ignition harness from the ECU;

then remove the torx-head screw securing the air

silencer to the front end. Remove the silencer.

CM026A

11. Pull the air silencer boot forward enough to gain

access to the throttle body/carburetor assembly.

CM027

12. Loosen the flange clamps securing the throttle

body assembly to the flange; then move the throt-

tle body assembly forward to allow room to dis-

connect the oil injection cable/control rod from the

oil-injection pump.

CM028A

13. Loosen the clamps securing the coolant hoses con-

nected to the cylinders beneath the exhaust ports

and the PTO-side throttle body; then remove the

vent tube from the top of the cylinder head.

CM030A

14. Move the throttle body assembly to one side out of

the way to a secure position.

„NOTE: With the throttle body assembly out of the
way, disconnect the oil hose from the oil pump;
then plug the oil hose.

CM029A

15. Remove the recoil starter and secure it up and out

of the way in the engine compartment.

16. Remove the cap screws securing the left side of

the steering support to the chassis; then remove the

rear cap screw securing the side-plate brace to the

chassis.

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2

CM209A

17. Remove the front cap screws securing the side-

plate brace to the chassis and remove the brace. 

CM210A

18. Remove the cap screw (A) and lock nuts (B)

securing the left-side engine mounting bracket to

the engine and chassis. Remove the bracket.

742-240A

742-238A

19. Loosen the cap screw/lock nut (C) securing the

right-side engine mounting bracket to the front

end.

20. On the 600 cc, remove the cap screw and lock nut

(D) securing the engine bracket to the front lower

mounting bracket.

21. Disconnect all electrical wires from the engine.

„NOTE: For installing purposes, note the routing
of the harnesses and the location of cable ties.

22. Disconnect the lower coolant hose; then move the

engine toward the left and up to allow enough

room to remove the remaining coolant hose.

MS382D

CM034C

„NOTE: If equipped with electric start, loosen the
two set screws securing the flex-drive shaft to the
pinion drive.

„NOTE: Inspect the engine to ensure all wires,
hoses, and cables have been removed.

23. Lift the engine out of the engine compartment.

24. Remove the exhaust manifold from the engine.

Account for flange nuts and gaskets.

25. Remove the clamp securing the coolant supply

hose from the cylinder head to the water pump.

Then remove the hose from the engine.

500 cc

600 cc

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Disassembling Engine

1. Using the spanner wrench to secure the flywheel,

remove the flywheel cap screw and flat washer;

then remove the three starter pulley cap screws

and remove the pulley.

FC014

FC015

2. Install Flywheel Pulley Insert onto the end of the

crankshaft.

FC016

3. Using Flywheel Puller or suitable substitute,

remove the flywheel from the crankshaft by tight-

ening the puller bolt, striking the head of the puller

bolt with a hammer, and tightening again. Repeat

this procedure until the flywheel is free. Account

for the key.

CM013

„NOTE: To ensure the cleanliness of the flywheel
magnets, place the flywheel (with the magnets fac-
ing upward) on a clean bench.

4. Remove the ignition timing sensor.

FC022

5. Remove the Allen-head cap screws securing the

stator to the stator plate. Move the stator to the

side to access the Phillips-head cap screw securing

the stator lead wire; then remove the cap screw.

! CAUTION

To prevent damage to the crankshaft, do not thread
puller bolts more than 1/2 in. into the flywheel. Dam-
age to the coils may result.