Snowmobile Arctic Cat (2008 year). Manual - part 39

2-93

2

FC052

„NOTE: Steps 19-21 are for the 600 cc.

19. Slide the APV cable drums into the servomotor

actuator; then place the cable housings into posi-

tion in the servomotor. Secure the cable housings

with the cable holder.

CM124A

20. Place the servomotor cover into position; then

secure with two lock nuts.

CM121A

21. Check APV cable adjustment (see Arctic Power

Valve (APV) System in Section 3).

„NOTE: Before installing the drive clutch, be sure
to wipe both the crankshaft taper and clutch
mounting taper clean using a clean towel.

22. Place the drive clutch into position on the crank-

shaft and secure with the cap screw and lock

washer. Tighten to 55 ft-lb.

„NOTE: Before installing the drive clutch, be sure
to wipe both the crankshaft taper and clutch
mounting taper clean using a clean towel.

„NOTE: Apply a coat of Anti-Seize Thread Com-
pound to the end of the input shaft.

23. Install the alignment washers (if applicable); then

install the driven pulley on the gear case input

shaft. Tighten the cap screw to 32 ft-lb.

CM206

24. Check drive clutch/driven pulley alignment (see

Section 6).

MS390

25. Install the drive belt. Check belt deflection. Secure

the belt guard (see Section 6).

26. With the air silencer properly positioned on the

throttle body assembly, secure the silencer with

the torx-head cap screw.

! CAUTION

When installing the drive clutch, do not tighten the
clutch cap screw with any kind of impact tool.
Tighten cap screw using a hand torque wrench only.
Failure to do so could result in stationary sheave
damage.

! CAUTION

Do not allow the driven pulley to “float” on the input
shaft. Damage to the driven pulley will occur.

2-94

CM026A

27. Install the resonator and secure with three springs;

then place the expansion chamber and grafoil gas-

kets into position and secure to the exhaust mani-

fold and resonator with the springs.

„NOTE: When installing the three exhaust mani-
fold springs, the long hook portion of the spring
must be attached to the exhaust manifold or pre-
mature spring failure will result.

28. Place the hood into position on the front end and

secure with the two pins and the cables.

29. Connect the ignition harness and the hood harness;

then connect the air intake connector.

CM038

30. Start the engine and warm up to operating temper-

ature; then verify that all components are function-

ing properly and that coolant is circulating through

the cooling system properly.

31. Allow the engine to cool; then check the coolant

level and add coolant as necessary. Verify the

tightening torque of the drive clutch.

Engine - 

Crossfire 800/1000 - 

M-Series 800/1000

This engine servicing sub-section has been organized to

show a progression for the complete servicing of the

Arctic Cat 800 cc/1000 cc (Crossfire/M-Series) engines.

For consistency purposes, this sub-section shows a com-

plete and thorough progression; however, for efficiency

it may be preferable to remove the engine as a complete

assembly, to remove and disassemble only those compo-

nents which need to be addressed, and to service only

those components. Also, some components may vary

from model to model. The technician should use discre-

tion and sound judgment.

„NOTE: Critical torque specifications can be
found in Section 1 of this manual.

„NOTE: Some illustrations and photographs used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.

SPECIAL TOOLS

A number of special tools must be available to the

technician when performing service procedures in this

engine section.

„NOTE: Special tools are available from the Arctic
Cat Service Parts Department.

! CAUTION

After running the engine to the proper operating tem-
perature, shut the engine off; then open the hood
and access panels and inspect for any signs of cool-
ant, gasoline, or oil leakage.

! CAUTION

Never run the engine with the hood harness discon-
nected or damage to the electrical system will result.

! CAUTION

If the engine had a major overhaul or if any major
component was replaced, proper engine break-in
procedures must be followed (see Section 1). If the
proper engine break-in procedures are not followed,
severe engine damage may result.

Description

p/n

Ball Hone (800 cc)

0644-294

Ball Hone (1000 cc)

0644-531

Drive Clutch Bolt Tool

0644-281

Drive Clutch Puller (800 cc)

0644-207

Drive Clutch Puller (1000 cc)

0644-446

Drive Clutch Spanner Wrench

0644-136

Driven Pulley Puller

0644-468

Flywheel Puller

0744-040

Flywheel Pulley Insert

0644-179

Medium Extractor Nut

0643-074

Oil Seal Protector Tool

0644-219

Piston Pin Puller

0644-328

Surface Plate

0644-016

V Blocks

0644-022

Water Pump Bearing and Seal Kit

0644-502

2-95

2

Table of Contents

Removing .............................................................. 2-95
Disassembling....................................................... 2-98
Servicing Top-Side Components......................... 2-103
Cleaning and Inspecting ..................................... 2-109
Measuring Critical Components.......................... 2-112
Assembling.......................................................... 2-114
Installing .............................................................. 2-123

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,
remove the hood, and remove the left-side and
right-side access panels.

1. Remove all springs and the hairpin clip securing

the expansion chamber and resonator; then remove

these components from the engine compartment.

2. Remove the belt guard; then remove the drive belt

(see Section 6).

3. On the 800 cc using a 1/2-in. 12-point socket,

remove the cap screw and lock washer securing

the drive clutch to the crankshaft.

4. On the 1000 cc using Drive Clutch Bolt Tool,

remove the cap screw and high-collar washer

securing the drive clutch to the crankshaft.

5. 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.

6. Remove the cap screw from the driven pulley and

slide the driven pulley off the gear case input shaft.

Account for alignment washers.

CM125A

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

7. Remove the two lock nuts securing the servomotor

and cover; then remove the cover. Using a small

needle-nose pliers, remove the servomotor retain-

ing clip and the cable holder.

FS273A

CM127

8. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

down and out of the servomotor.

CM128A

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

motor actuator.

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

tem - Section 3).

11. Disconnect the ignition harness from the ECU;

then remove the torx-head screw securing the air

silencer to the front end. Remove the silencer.

2-96

CM026A

12. Pull the air silencer boot forward enough to gain

access to the throttle body assembly.

CM027

13. 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 control rod from the oil-

injection pump.

CM129A

14. Remove the spark plug wires from the spark plugs;

then on the 800 cc, disconnect the knock sensor

connector.

CM130A

15. Loosen the clamps securing the coolant hoses con-

nected to the throttle bodies; then remove the vent

tube from the top of the cylinder head.

CM131A

„NOTE: On the 1000 cc, remove the coolant by-
pass hoses from the cylinders.

16. 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

17. Remove the recoil starter from the engine. Secure

it out of the way in the engine compartment.