Snowmobile Arctic Cat (2008 year). Manual - part 48

2-130

ZJ100A

5. Remove the torx-head screws securing the handle-

bar close-off panel; then remove the panel.

6. Remove the lock nuts and torx-head cap screws

(A) securing the right-side front and rear spar pan-

els; then remove the torx-head screws (D) securing

the left-side rear spar panel to the gas tank and

support tube.

742-207A

„NOTE: The right-side rear spar panel will remain
secured to the chassis.

7. Remove the cap screw located directly above the

ECU securing the air-silencer duct to the front

upper panel; then disconnect the air temperature

sensor and remove the duct.

„NOTE: To aid in accessing the cap screw, the
ECU may be removed.

8. Remove the body screws and lock nuts (C) from

each side securing the front bumper assembly to

the chassis; then remove the two remaining self-

tapping screws (B) from each side securing the

front bumper assembly. Remove the assembly.

„NOTE: At this point, remove the air-intake silencer
and account for the rubber exhaust bumper.

9. Remove the belt guard; then using a 1/2-in. 12-

point socket, remove the cap screw and lock

washer securing the drive clutch to the crankshaft.

10. 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 the drive belt.

11. Remove the cap screw from the driven pulley and

slide the driven pulley off the gear case input shaft.

Account for alignment washers.

FS192

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

„NOTE: Steps 12-14 are for the 600 cc engine. For
the 500 cc engine, proceed to step 15.

12. Using a small needle-nose pliers, remove the APV

cable holder.

FS176

13. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

out of the servomotor.

14. Pull the cable down and out of the cable housing

holder; then slide each cable drum back and out of

the servomotor actuator.

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

tem - Section 3).

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2

16. Remove the cable tie securing the gasline supply

hose to the MAG-side engine mounting bracket;

then loosen the clamp and remove the hose from

the throttle body assembly. Plug the end of the

hose and secure it up and out of the way.

„NOTE: Note the routing and securing locations of
the hose for assembling purposes.

17. Loosen the flange clamps securing the throttle body

assembly to the flange; then move the throttle body

assembly forward and disconnect the oil injection

cable/control rod from the oil-injection pump.

FS178A

„NOTE: It is advisable to remove the clamps from
the intake flanges to avoid damage during engine
removing.

18. Loosen the clamps securing the coolant hoses con-

nected to the cylinders beneath the exhaust port

and the throttle body assembly; then remove the

vent tube from the top of the cylinder head.

CM030A

19. 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.

FS179A

20. Remove the cap screws securing the recoil starter;

then secure the recoil starter up and out of the way.

FS180

„NOTE: On the LXR, remove the two set screws
securing the flex-drive shaft to the starter motor;
then remove the flex-drive shaft from the motor.

FS177A

21. Remove the spark plug wires from the plugs; then

disconnect the two-wire plug-in for the coolant

temperature sensor (located below the ignition

coil).

! CAUTION

The gasline supply hose may be under pressure.
Place an absorbent towel around the connection to
absorb gasoline; then remove the hose slowly to
release the pressure.

2-132

FS193A

22. Remove the harness wrap and disconnect all igni-

tion/main harness connectors; then secure the har-

ness out of the way.

FS181

23. Disconnect the front heat exchanger hose.

„NOTE: Prior to disconnecting the hose, it is
advisable to place an absorbent towel beneath the
hose to collect any coolant from the exchanger.

24. Remove the four cap screws securing the upper

bearing bracket to the upper support plate (account

for the two bracket plates); then secure the steering

post to the headlight support bracket.

FS182A

FS183A

25. Remove the exhaust manifold from the engine.

Account for the flange nuts and gaskets.

26. Remove the cap screw and lock nut (A) and lower

cap screw (B) securing the PTO-side engine

mounting bracket to the chassis.

742-205A

27. Remove the four cap screws (C) securing the PTO-

side bracket to the engine; then remove the

bracket. Account for the torque bumper.

28. Remove the two cap screws (D) securing the front

engine plate to the chassis; then remove the cap

screw (E) securing the MAG-side engine mount-

ing bracket to the chassis.

29. Tip the engine forward and support the engine in a

position to gain access to the clamp securing the

coolant hose to the thermostat housing; then

loosen the clamp and remove the hose.

FS184A

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2

30. With the engine supported in the forward position,

remove the cable tie securing the ignition harness

to the coolant tank/heat exchanger hose; then route

the harness out from behind the hose.

FS185A

31. Remove the engine out the MAG-side of the

engine compartment.

FS186

32. Remove the clamps securing the coolant supply

hoses to the engine; then remove the hoses.

FS187A

„NOTE: At this point if necessary, remove the
coolant temperature sensor.

33. Remove the two cap screws securing the MAG-

side engine mounting bracket to the engine.

FS188A

34. Remove the four cap screws securing the front

engine plate to the engine.

FS189A

„NOTE: On the LXR, remove the pinion drive
bracket assembly from the engine.

FS190A

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.