Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 17

2-54

MD0264

22. Place the fan and starter pulley into position on the

flywheel. Using Spanner Wrench (p/n 0144-007)

to hold the starter cup, tighten the three cap screws

(coated with green Loctite #609 and Loctite

Primer #7471) to specifications.

MD0280

23. Using Spanner Wrench (p/n 0144-007) to hold the

starter cup, tighten the flywheel cap screw (from

step 21) to specifications.

MD0278

24. Using the six cap screws and the special washers,

install the rear (intake-side) shroud. Tighten the

cap screws to specifications.

MD0277

25. Using the five 6 mm cap screws and the special

washers, install the front (exhaust-side) cooling

shroud and tighten to specifications. Install the

rubber spark plug grommets; then tighten the cap

screws securely.

MD0269

MD0268

26. Install the main fan shroud and recoil starter

assembly. Tighten the eight cap screws to specifi-

cations.

! CAUTION

Do not use green Loctite #609 without also using
Loctite Primer #7471.

! CAUTION

When installing the fan, make sure that the locating
pins on the flywheel align with the indentations in
the fan.

2-55

2

MD0279

MD0291

27. Lubricate the oil-injection pump driveshaft; then

while rotating the driveshaft, install it and the

thrust washer into the lower crankcase half.

„NOTE: Make sure the thrust washer is installed
on the oil injection pump driveshaft when it is
installed.

MD0252

28. Install the oil injection pump driveshaft retainer

and O-ring.

„NOTE: Make sure the O-ring is installed on the oil
injection pump driveshaft retainer when it is
installed.

MD0273

29. Install the oil injection pump aligning the slot on

the oil pump with the flat on the end of the oil

injection pump driveshaft. Tighten the Allen-head

cap screws to specifications.

MD0294

MD0090

30. Install the intake flange assembly using washers,

lock washers, and nuts. Note the placement of gas-

kets with a thin coat of High-Temp Sealant (p/n

0636-069), heat deflector, gaskets, insulators, and

flanges. Tighten the nuts (threads coated with red

Loctite #271) to specifications.

31. Install the exhaust manifold and gaskets with a

thin coat of High-Temp Sealant (p/n 0636-069)

using lock washers and nuts. Tighten the nuts to

specifications.

2-56

Installing Engine

1. Place each engine mounting bracket onto the

engine. Secure with cap screws (coated with blue

Loctite #243), washers, and lock washers. Tighten

to specifications.

2. Place the engine assembly into position in the

engine compartment. Secure the engine to the

front end with the cap screws, washers, and lock

nuts. Tighten to specifications.

570-ENG07A

3. Connect the oil-supply hose to the oil-injection

pump; then bleed the system (see Section 4).

„NOTE: If equipped with electric start, place the
starter motor bracket on the crankcase and install
the front two and lower rear cap screws, lock wash-
ers, and washers. Place the starter motor into posi-
tion and secure with two washers and lock nuts.

4. Connect the oil-injection cable to the oil-injection

pump control arm and secure the cable mounting

pin with a nylon washer and E-clip.

5. Place the carburetors into position making sure the

boots are properly positioned and secure with the

flange clamps.

„NOTE: At this point, check oil-injection system
synchronization (see Section 4).

6. Connect the impulse hose to the crankcase, the

main wiring harness, the CDI unit wiring harness,

and the spark plug caps.

7. Place the recoil starter into position and secure

with four cap screws and lock washers. Tighten to

specifications.

„NOTE: If equipped with electric start, secure the
battery ground cable with the rear cap screw.

8. Place the expansion chamber and grafoil gasket

into position and secure with springs.

AB105D

9. Place the engine mount shims into position

between the torque bumper and engine mounting

bracket; then tighten the torque bumper jam nut.

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

shaft; then install the lock washer and bolt.

Tighten the clutch bolt to specifications.

CM016

„NOTE: Apply a coat of Anti-Seize Thread Com-
pound (p/n 0678-146) to the keyway end of the
driven shaft.

11. Install the driven pulley and alignment washers.

Secure with a cap screw (threads coated with blue

Loctite #243) and washer tightened to 3.3 kg-m

(24 ft-lb).

! CAUTION

When installing the carburetors, make sure the
gasline hoses are properly routed to avoid prema-
ture wear and/or contact with exhaust components.

! CAUTION

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

2-57

2

SC013D

„NOTE: At this point, check drive clutch/driven
pulley alignment (see Section 8).

12. Install the drive belt and secure the belt guard.

Install the plug in the belly pan.

„NOTE: If equipped with electric start, connect the
battery.

13. Turn the gas tank shut-off valve to the OPEN posi-

tion.

14. Check the ignition timing.

15. Place the rear of the snowmobile up on a shielded

safety stand. Start engine and allow to warm up.

Adjust engine idle to 1500 RPM and check all

safety switches for proper operation.

16. Test drive the snowmobile; then tighten the clutch

bolt to specifications.

Engine - 

Crossfire 500/600 - 

M-Series 600

This engine servicing sub-section has been organized

to show a progression for the complete servicing of the

Arctic Cat 500 cc/600 cc (Crossfire/M-Series) engines.

For consistency purposes, this sub-section shows a

complete and thorough progression; however, for effi-

ciency it may be preferable to remove the engine as a

complete assembly, to remove and disassemble only

those components which need to be addressed, and to

service only those components. Also, some compo-

nents may vary from model to model. The technician

should use discretion and sound judgment.

„NOTE: Critical torque specifications can be
found on pages 10-13 of this section.

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

Table of Contents

Removing .............................................................. 2-57
Disassembling ....................................................... 2-60
Servicing Top-Side Components........................... 2-65
Cleaning and Inspecting........................................ 2-70
Measuring Critical Components ............................ 2-73
Assembling............................................................ 2-75
Installing ................................................................ 2-82

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
and remove the hood.

1. Remove all springs securing the expansion cham-

ber and resonator; then remove these components

from the engine compartment.

2. Remove the left-side and right-side access panels

and remove the belt guard; then remove the drive

belt (see Section 8).

3. Using a ½-in. 12-point socket, remove the cap

screw and lock washer securing the drive clutch to

the crankshaft.

FC002A

4. Using Clutch Puller (p/n 0644-207) and an impact

wrench or a breaker bar and Spanner Wrench (p/n

0644-136), 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. If applicable, account for

the two sleeves.

5. Remove the cap screw from the driven pulley and

slide the driven pulley off the gear case input shaft.

Account for alignment washers.

! CAUTION

If the engine had a major overhaul or if any major
part was replaced, proper engine break-in proce-
dures must be followed.