Snowmobile Arctic Cat (2008 year). Manual - part 53

2-150

36. Place new O-rings onto each of the head cap

screws. Place four of these cap screws into the cyl-

inder head. Thread the spark plugs in part way;

then while holding the head above the cylinder,

carefully start and finger-tighten all four cap

screws while observing the cylinder O-rings to

make sure they remain in position. Slowly place

the head into position on top of the O-rings. Start

and finger-tighten the remaining cap screws being

very careful not to move the cylinder head.

37. From step 36 in two steps, tighten the 8 mm cap

screws to 19 ft-lb (500 cc) or 25 ft-lb (600 cc)

using the appropriate pattern shown.

0738-204

„NOTE: On the 500 cc after tightening the 8 mm
cap screws, tighten the two remaining 6 mm cap
screws to 6-9 ft-lb.

0738-205

„NOTE: Lubricating the O-ring with a light coat of
grease will help keep them seated in the grooves
of the cylinder.

38. On the 600 cc with the APV gaskets properly posi-

tioned as noted during assembly, slide the APV

assemblies into position in the cylinders; then slide

the valve keepers into position and secure with cap

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

10 ft-lb.

FC025

FC024

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

39. Secure the stator plate to the crankcase with the

Allen-head cap screws coated with blue Loctite

#243 and tightened to 8 ft-lb.

FC021

40. On the 600 cc, install the magneto case on the

crankcase accounting for the different-sized cap

screws and the alignment pins. Tighten cap screws

(coated with blue Loctite #243) to 40 ft-lb.

! CAUTION

The long side of the exhaust valve must be facing
toward the cylinder head or severe engine damage
may occur.

500 cc

600 cc

2-151

2

FC019

FC020

41. Secure the ignition timing sensor with screws

coated with blue Loctite #243. Tighten to 8 ft-lb.

Install the stator assembly with wires and a grom-

met into the crankcase and secure with the Allen-

head screws (coated with blue Loctite #243).

Tighten to 8 ft-lb.

FC018

42. Install the key in the crankshaft. 

43. Thread two puller bolts into the flywheel; then

slide the flywheel onto the crankshaft making sure

the keyways match. Remove the puller bolts.

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

44. 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

45. Place the starter pulley in position; then loosely

secure the starter pulley with three cap screws

(coated with red Loctite #271). Secure the pulley

while using the spanner wrench and tighten the

three cap screws evenly to 8 ft-lb.

FC081

46. Using the spanner wrench, tighten the flywheel

cap screw (from step 44) to 50 ft-lb.

Installing Engine

1. Install the MAG-side engine mounting bracket to

the engine with the two cap screws (coated with

blue Loctite #243). Tighten to 23 ft-lb.

FS188A

2. Install the front lower engine plate to the engine

with four cap screws (coated with blue Loctite

#243). Tighten to 50 ft-lb.

2-152

FS189A

3. Install the throttle body hose (A), inlet hose (B),

and the front heat exchanger hose (C) to the

engine; then secure with the hose clamps.

FS187B

„NOTE: At this time if the coolant temperature
sensor was removed, install the sensor and
tighten securely.

„NOTE: At this point on the LXR, install the pinion
bracket assembly to the engine with two cap
screws (coated with green Loctite #609). Tighten
to specifications.

FS190A

4. Place the engine into the engine compartment

from the MAG-side; then tip the engine forward

and support the engine in this position. Connect

the coolant hose to the thermostat housing.

FS194A

„NOTE: At this point on the LXR, insert the flex-
drive shaft into the pinion drive and secure with
the two set screws.

FS177A

5. Position the engine to the chassis mounts; then in

order, install cap screws (D) securing the engine

plate to the front chassis mounts; then install cap

screw (E) securing the MAG-side mounting

bracket to the chassis, and cap screw (D) to the

PTO-side mount. Tighten the cap screws to 50 ft-

lb.

! CAUTION

Position the hose clamp screw so it is directed to the
back side of the thermostat housing to avoid con-
tacting the chassis when the engine is lowered and
secured.

2-153

2

742-205A

6. Position the torque bumper against the gear case;

then install the PTO-side engine mounting bracket.

„NOTE: Prior to installing the bracket, assure that
the U-nut clip is centered in position.

FS195A

7. Using the illustration following step 5, install the

cap screw and lock nut (A) and the lower cap

screw (B) securing the PTO-side bracket to the

chassis; then install the four cap screws (C)

(coated with blue Loctite #243) securing the

bracket to the engine. Tighten all mounting hard-

ware to 23 ft-lb.

8. Connect the coolant hose to the outlet of the front

heat exchanger and secure with the hose clamp.

FS196A

9. Route the ignition harness and the coolant temper-

ature sensor two-wire connector between the cool-

ant tank and the chassis; then connect all ignition/

main harness plug-ins and the two-wire connector.

FS197

„NOTE: Prior to connecting the harness, it is
advisable to clean all plug-ins with contact cleaner.

10. Secure the ignition harness to the coolant hose

with a cable tie in the position as noted in remov-

ing; then install the harness wrap.

FS181

11. Place the recoil starter into position and secure the

starter with the cap screws. In a crisscross pattern,

tighten to 7 ft-lb.

FS180

12. Connect the oil supply hose (A) to the oil injection

pump; then remove the oil bleed plug (B) from the

oil injection pump. When oil flows from pump

free of air bubbles and the hose is full of oil, install

the oil bleed plug and tighten securely.

„NOTE: It is advisable to place a cloth beneath the
oil-injection pump to contain any oil spilled during
the bleeding process.