Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 25

2-86

22. Check drive clutch/driven pulley alignment (see

Section 8).

MS390

23. Install the drive belt. Check belt deflection. Secure

the belt guard.

24. With the air silencer properly positioned on the

throttle body assembly, secure the silencer with

the torx-head cap screw.

CM026A

25. Install the resonator and secure with three springs;

then place the expansion chamber and grafoil gas-

kets into position and secure to the exhaust mani-

fold and resonator with the springs.

„NOTE: When installing the three exhaust mani-
fold springs, the long hook portion of the spring
must be attached to the exhaust manifold or pre-
mature spring failure will result.

26. Place the hood into position on the front end and

secure with the two pins and the cables.

27. Connect the ignition harness and the hood harness;

then connect the air intake connector.

CM038

28. Start the engine and warm up to operating temper-

ature; then verify that all components are function-

ing properly and that coolant is circulating through

the cooling system properly.

29. Allow the engine to cool; then check the coolant

level and add coolant as necessary. Verify the

tightening torque of the drive clutch.

Engine - 

Crossfire 800/1000 - 

M-Series 800/1000

This engine servicing sub-section has been organized

to show a progression for the complete servicing of the

Arctic Cat 800 cc/1000 cc (Crossfire/M-Series)

engines. For consistency purposes, this sub-section

shows a complete and thorough progression; however,

for efficiency it may be preferable to remove the

engine as a complete assembly, to remove and disas-

semble only those components which need to be

addressed, and to service only those components.

Also, some components may vary from model to

model. The technician should use discretion and sound

judgment.

„NOTE: Critical torque specifications can be
found on pages 14-17 of this section.

! CAUTION

After running the engine to the proper operating tem-
perature, shut the engine off; then open the hood
and access panels and inspect for any signs of cool-
ant, gasoline, or oil leakage.

! CAUTION

Never run the engine with the hood harness discon-
nected or damage to the electrical system will result.

! CAUTION

If the engine had a major overhaul or if any major
component was replaced, proper engine break-in
procedures must be followed. If the proper engine
break-in procedures are not followed, severe engine
damage may result.

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2

„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 .............................................................. 2-87
Disassembling....................................................... 2-90
Servicing Top-Side Components........................... 2-95
Cleaning and Inspecting ..................................... 2-101
Measuring Critical Components.......................... 2-104
Assembling.......................................................... 2-107
Installing .............................................................. 2-115

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,
remove the hood, and remove the left-side and
right-side access panels.

1. Remove all springs and the hairpin clip securing

the expansion chamber and resonator; then remove

these components from the engine compartment.

2. Remove the belt guard; then remove the drive belt

(see Section 8).

3. On the 800 cc using a 1/2-in. 12-point socket,

remove the cap screw and lock washer securing

the drive clutch to the crankshaft.

4. On the 1000 cc using Drive Clutch Bolt Tool (p/n

0644-281), remove the cap screw and high-collar

washer securing the drive clutch to the crankshaft.

5. Using Clutch Puller (p/n 0644-207) - 800 cc or (p/

n 0644-446) - 1000 cc 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.

6. Remove the cap screw from the driven pulley and

slide the driven pulley off the gear case input shaft.

Account for alignment washers.

CM125A

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

7. Remove 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

8. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

down and out of the servomotor.

2-88

CM128A

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

motor actuator.

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

tem - Section 3).

11. 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

12. Pull the air silencer boot forward enough to gain

access to the throttle body assembly.

CM027

13. 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 control rod from the oil-

injection pump.

CM129A

14. Remove the spark plug wires from the spark plugs;

then on the 800 cc, disconnect the knock sensor

connector.

CM130A

15. Loosen the clamps securing the coolant hoses con-

nected to the throttle bodies; then remove the vent

tube from the top of the cylinder head.

CM131A

„NOTE: On the 1000 cc, remove the coolant by-
pass hoses from the cylinders.

16. 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.

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2

CM029A

17. Remove the recoil starter from the engine. Secure

it out of the way in the engine compartment.

CM137

18. Remove the wiring harness wrap; then disconnect

the ignition/main harness connectors and the tem-

perature sensor connector. Secure the harness out

of the way.

CM134

19. Disconnect the lower coolant hose from the front

heat exchanger; then remove the remaining cool-

ant hose from the thermostat outlet.

CM135A

CM136A

20. Remove the cap screws and lock nuts securing the

steering support and the side-plate brace to the

chassis. 

CM132A

CM133A