Snowmobile Arctic Cat (2008 year). Manual - part 46

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2

CM175

„NOTE: On the 800 cc to install the remaining cap
screws, the spark plugs must be removed.

41. Start and finger-tighten the remaining cap screws

being very careful not to move the cylinder head;

then tighten the cap screws in two steps to 25 ft-lb

using the appropriate pattern shown.

0742-200

0742-199

„NOTE: At this point on the 800 cc, install the
spark plugs and on both models, tighten the spark
plugs to specifications; then on the 800 cc, install
the knock sensor with the lock plate, tighten the
sensor securely, and bend the lock plate tabs up.

42. With the raised edge of the valve aligned with the

channel of the cylinder, slide the APV assemblies

into position in the cylinders; then secure with cap

screws (coated with blue Loctite #243). Tighten to

8 ft-lb.

CM204

„NOTE: At this point, pressure test the engine
(see Section 3).

43. Secure the stator plate to the crankcase with the

Allen-head cap screws (coated with blue Loctite

#243) and tightened to 8 ft-lb.

44. Route the stator harness through the opening in the

crankcase; then secure the stator to the stator plate

with the Allen-head cap screws (coated with blue

Loctite #243). Tighten to 8 ft-lb.

CM143A

45. Secure the upper ignition timing sensor with cap

screws (coated with blue Loctite #243). Tighten

securely; then install the wiring grommet into the

notch of the crankcase.

CM176A

800 cc

1000 cc

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46. Secure the lower ignition timing sensor with two

cap screws (A) (coated with blue Loctite #243).

Tighten securely; then install the grommet. With

the stator harness properly positioned, install the

plate and cap screw (B) (coated with blue Loctite

#243). Tighten to 8 ft-lb.

CM177A

47. Install the key in the crankshaft. 

48. Place the starter pulley in position on the flywheel;

then loosely secure the starter pulley with three

cap screws (coated with blue Loctite #243). While

holding the starter pulley, slide the flywheel onto

the crankshaft making sure the keyways match.

CM180

„NOTE: Before installing the flywheel, be sure to
wipe the crankshaft and flywheel tapers clean
using a clean towel.

49. Apply red Loctite #271 to the threads of the fly-

wheel cap screw; then finger-tighten with a large

flat washer. DO NOT TIGHTEN AT THIS TIME.

FC080

50. Secure the starter pulley while using the spanner

wrench and tighten the three cap screws (from step

46) evenly to 18 ft-lb.

FC081

51. Using the spanner wrench, tighten the flywheel

cap screw (from step 47) to 50 ft-lb.

„NOTE: On the 1000 cc with alignment pins in
place, install the magneto case on the crankcase
accounting for the different-sized cap screws and
the alignment pins. Tighten cap screws to 8 ft-lb.

CM144A

52. Install the coolant inlet hose to the cylinder head

and water pump; then tighten the hose clamps

securely.

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2

CM181

Installing Engine

1. Install the MAG-side engine mounting bracket to

the engine with cap screws (coated with blue Loc-

tite #243). Tighten to 30 ft-lb.

CM182A

2. Install the front lower engine mounting bracket to

the engine with cap screws (coated with blue Loc-

tite #243). Tighten to 30 ft-lb.

CM200A

3. Place the engine in position in the chassis; then

install the cap screw and lock nut (A) and (B)

securing the MAG-side engine mounting bracket

and the front lower engine mounting bracket to the

chassis. DO NOT TIGHTEN AT THIS TIME.

742-203B

4. Attach the water pump coolant hose to the front

heat exchanger. Secure with the hose clamp.

CM135A

5. Raise the PTO-side of the engine and support the

engine in this position. Connect the coolant tank

hose to the bottom left outlet on the engine and

secure with the hose clamp.

CM136A

6. With the torque bumper positioned against the

gear case, install PTO-side engine mounting

bracket to the engine with cap screws (coated with

blue Loctite #243) and to the chassis with lock

nuts. DO NOT TIGHTEN AT THIS TIME.

7. From step 6, tighten the PTO-side mounting

bracket-to-engine cap screws (D) (coated with

blue Loctite #243) to 24 ft-lb; then tighten the lock

nuts (C) securing the mounting bracket to the

chassis (from step 6) to 20 ft-lb.

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 8. Tighten the MAG-side engine mounting bracket-

to-chassis cap screw and lock nut (A) (from step 3)

to 20 ft-lb and the front lower mounting bracket

cap screw and lock nut (B) (from step 3) to 30 ft-lb.

9. Connect all electrical wiring harness plug-ins

making sure all wiring and coolant hoses are

routed properly as noted in removing; then install

the wiring harness wrap.

„NOTE: Use cable ties to secure the wiring har-
nesses as necessary.

10. Place the recoil starter into position and secure the

starter with five cap screws (coated with blue Loc-

tite #243). Tighten (in a crisscross pattern) to 8 ft-lb.

CM137

11. Tighten the spark plugs to specifications; then

connect the plug wires and on the 800 cc, the

knock sensor plug-in.

CM130A

12. If removed, connect the oil-injection control rod to

the oil-injection pump and secure.

CM028A

13. Route the oil-supply hose through the hole in the

chassis with the rubber grommet and to the oil

pump. Secure with the clamp.

CM131B

„NOTE: After securing the oil-supply hose to the
oil pump, remove the bleed screw to allow any air
in the hose/pump to be released.

CM184A

„NOTE: Confirm that the two coolant hoses which
run to the throttle bodies are accessible to connect
and that the fuel line and oil pump linkage are
accessible.