Snowmobile Arctic Cat (2008 year). Manual - part 64

2-194

Problem: Engine Backfires

Condition

Remedy

1. ECU/CCU LED trouble code

2. Throttle/ignition monitor switch adjusted incorrectly

3. Spark plugs fouled — damaged

4. High tension leads/coil shorting

5. ECU/CCU faulty — damaged

6. Fuel mixture lean

7. Oil-injection pump malfunctioning — adjusted incor-

rectly

1. Service — replace problem component

2. Adjust throttle cable tension — service spring

3. Clean — replace spark plugs

4. Service — replace high tension leads/coil

5. Replace ECU/CCU

6. Repair fuel regulator — injector(s)

7. Replace — bleed — adjust oil-injection pump

Problem: Engine Four-Cycles (Floods Excessively)

Condition

Remedy

1. ECU LED trouble code

2. Fuel pressure too high

3. Injector faulty

4. Throttle position sensor faulty

5. Air-intake silencer obstructed

1. Service — replace problem component

2. Replace regulator — hose

3. Replace injector

4. Replace throttle body assembly

5. Remove obstruction

Problem: Engine Stops Suddenly

Condition

Remedy

1. Gas tank empty

2. Spark absent

3. ECU/CCU LED trouble code

4. CDI relay faulty

5. Fuel filter(s) obstructed

6. Fuel pressure low

7. Fuel pump faulty

8. Fuel pump relay faulty

9. Gas tank vent hose obstructed

10. ECU/CCU faulty

11. Fuel hose obstructed — broken — pinched

12. Ignition coil faulty

13. Engine seized

14. Throttle/ignition monitor switch — throttle cable

tension faulty — adjusted incorrectly

1. Fill tank

2. See No Spark at Spark Plugs sub-section

3. Service — replace problem component

4. Replace CDI relay

5. Replace filter(s)

6. Replace regulator — hose

7. Service — replace fuel pump

8. Replace relay

9. Service vent hose

10. Replace ECU/CCU

11. Remove obstruction — repair — replace fuel hose

12. Replace ignition coil

13. Service engine

14. Replace throttle control — adjust throttle cable

Problem: Engine Fails to Stop (Continues to Run, Even with All Switches Off)

Condition

Remedy

1. ECU/CCU shorted to ground

2. Engine wiring harness connections wet

1. Replace ECU/CCU

2. Clean — dry connections

3-1

3

SECTION 3 — 

ENGINE-RELATED ITEMS

TABLE OF

CONTENTS

Engine-Related Items.............................................. 3-2
Axial Fan/Belt (370 cc) ............................................ 3-2
Repairing Water Pump (500/600 cc) ....................... 3-5
Repairing Water Pump (800/1000 cc) ..................... 3-8
Pressure Testing Engine ....................................... 3-12
Liquid Cooling System (500/600/800/1000 cc) ..... 3-12
Cooling System Schematics ................................. 3-15
Recoil Starter (370/500/600 cc) ............................ 3-17
Recoil Starter (570/800/1000 cc) .......................... 3-19
Arctic Power Valve (APV) System ......................... 3-22
Exhaust Controlled Timing (ECT) System ............ 3-28

3-2

Engine-Related Items

„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 servicing the engine-related items.

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

Axial Fan/Belt 

(370 cc)

REMOVING FAN

1. Remove the four cap screws securing the recoil

starter to the fan case.

2. Remove the three cap screws securing the recoil

starter pulley and fan drive pulley to the flywheel;

then remove the recoil starter pulley and fan drive

pulley.

3. Remove the cap screws and flange nuts securing

the fan case assembly to the engine; then remove

the fan case from the engine compartment.

DISASSEMBLING

1. Remove the fan cover; then remove the belt.

2. Using the Fan Spanner Wrench, remove the nut,

lock washer, and washer securing pulley halves.

AB102

3. Slide the outer pulley half, shim(s), fan belt, and

inner pulley half off the shaft and account for the

key and the fan belt.

A908

4. Remove the fan with shaft.

5. Drive the bearings from the fan case and account

for the spacer between the bearings.

A910

„NOTE: A circlip is positioned between the bear-
ings. The bearings must be driven from the center
to the outside of the fan case.

6. Remove the circlip from the fan case.

Description

p/n

Fan Spanner Wrench

0644-340

Water Pump Bearing and Seal Tool Kit

0644-502

Oil Seal Protector Tool

0644-219

Water Pump Bearing and Seal Tool Kit

0644-084

Engine Leak-Down Tester Kit

0644-522

Vacuum Test Pump

0644-131

3-3

3

A911

CLEANING AND INSPECTING

„NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all axial fan components.

2. Inspect the fan case and shaft threaded areas for

damage or stripped threads; then check the shaft

keyway and key for excessive wear.

3. Inspect the fan for broken, bent, or damaged

vanes.

4. Inspect the bearings for smooth rotation.

5. Inspect the pulley halves for cracks, gouges, or

other damage.

6. Inspect the fan belt for cracks, tears, or fraying.

ASSEMBLING

0739-354

1. Install the circlip into the groove of the fan case.

A911

2. Press a bearing into the fan case until it is seated

against the circlip.

3. From the opposite side of the fan case, install the

spacer and press the remaining bearing into the fan

case until it is seated.

„NOTE: The spacer is positioned between the two
fan-case bearings.

4. Insert the fan with shaft through the fan bearings.

5. Install the key into the shaft.

6. Slide the inner pulley half, required shim(s), fan

belt, and outer pulley half onto the shaft.

A913

7. Using the fan spanner wrench, secure the pulley

with a washer, lock washer, and nut. Tighten the

nut to 24 ft-lb.

INSTALLING FAN

1. Place the fan case assembly on the engine; then

secure with flange nuts and cap screws. Tighten

the flange nuts to 14 ft-lb. Tighten the cap screws

to 60 in.-lb.

2. Place the new fan belt into position on the upper

pulley.

3. Place the fan drive pulley onto the fan belt and

align one of its holes with one of the mounting

holes in the flywheel; then start a cap screw into

the aligned holes and finger-tighten.

KEY

1. Drive Pulley

2. Belt

3. Pulley Half

4. Shim

5. Washer

6. Lock Washer

7. Nut

8. Bearing

9. Circlip

10. Spacer

11. Key

12. Fan Assy

13. Shaft

14. Fan

15. Cap Screw