Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 18

2-58

MS378

„NOTE: If the driven pulley is tight on the driven
shaft, pull the driven pulley off using the Driven
Pulley Puller (p/n 0644-460).

„NOTE: Steps 6-8 are for the 600 cc engine. For
the 500 cc engine, proceed to step 9.

6. Loosen the two lock nuts securing the servomotor

and cover; then remove the cover. Using a small

needle-nose pliers, remove the servomotor retain-

ing clip and the cable holder.

CM126A

CM127

7. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

down and out of the servomotor.

CM123A

8. Slide each cable drum out of the slot of the servo-

motor actuator.

CM124A

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

tem - Section 3).

10. Disconnect the ignition harness from the ECU;

then remove the torx-head screw securing the air

silencer to the front end. Remove the silencer.

CM026A

11. Pull the air silencer boot forward enough to gain

access to the throttle body/carburetor assembly.

2-59

2

CM027

12. Loosen the flange clamps securing the throttle

body assembly to the flange; then move the throt-

tle body assembly forward to allow room to dis-

connect the oil injection cable/control rod from the

oil-injection pump.

CM028A

13. Loosen the clamps securing the coolant hoses con-

nected to the cylinders beneath the exhaust ports;

then remove the vent tube from the top of the cyl-

inder head.

CM030A

14. 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.

CM029A

15. Remove the recoil starter and secure it up and out

of the way in the engine compartment.

16. Remove the cap screws securing the left side of

the steering support to the chassis.

CM004B

17. Remove the cap screws and lock nuts securing the

side-plate brace to the chassis. 

CM070B

18. Remove the cap screw (A) and lock nuts (B)

securing the left-side engine mounting bracket to

the engine and chassis. Remove the bracket.

2-60

742-240A

742-238A

19. Loosen the cap screw/lock nut (C) securing the

right-side engine mounting bracket to the front

end.

20. On the 600 cc, remove the cap screw and lock nut

(D) securing the engine bracket to the front lower

mounting bracket.

21. Disconnect all electrical wires from the engine.

„NOTE: For installing purposes, note the routing
of the harnesses and the location of cable ties.

22. Disconnect the lower coolant hose; then move the

engine toward the left and up to allow enough

room to remove the remaining coolant hose.

MS382D

CM034C

„NOTE: If equipped with electric start, loosen the
two set screws securing the flex-drive shaft to the
pinion drive.

„NOTE: Inspect the engine to ensure all wires,
hoses, and cables have been removed.

23. Lift the engine out of the engine compartment.

24. Remove the exhaust manifold from the engine.

Account for flange nuts and gaskets.

25. Remove the clamp securing the coolant supply

hose from the cylinder head to the water pump.

Then remove the hose from the engine.

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.

FC014

500 cc

600 cc

2-61

2

FC015

2. Install Flywheel Pulley Insert (p/n 0644-179) onto

the end of the crankshaft.

FC016

3. Using Flywheel Puller (p/n 0744-040) or suitable

substitute, remove the flywheel from the crank-

shaft by tightening the puller bolt, striking the

head of the puller bolt with a hammer, and tighten-

ing again. Repeat this procedure until the flywheel

is free. Account for the key.

CM013

„NOTE: To ensure the cleanliness of the flywheel
magnets, place the flywheel (with the magnets fac-
ing upward) on a clean bench.

4. Remove the ignition timing sensor.

FC022

5. Remove the Allen-head cap screws securing the

stator to the stator plate. Move the stator to the

side to access the Phillips-head cap screw securing

the stator lead wire; then remove the cap screw.

FC018

6. On the 600 cc, remove the Allen-head cap screws

securing the magneto case to the crankcase.

Account for the alignment pins.

„NOTE: Note the different-sized cap screws for
assembling purposes.

FC019

! CAUTION

To prevent damage to the crankshaft, do not thread
puller bolts more than 12.7 mm (1/2 in.) into the fly-
wheel. Damage to the coils may result.