Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 33

2-118

CM133B

19. Apply a thin coat of  high-temperature silicone

sealant to each exhaust port; then install the

exhaust gaskets.

20. Apply a thin coat of high-temperature silicone

sealant to the mating surfaces of the exhaust mani-

fold; then install the exhaust manifold and secure

with the eight nuts.  Tighten the nuts in a crisscross

pattern to specifications.

21. Slide the APV cable drums into the servomotor

actuator; then place the cable housings into posi-

tion in the servomotor. Secure the cable housings

with the cable holder.

CM127

22. Rotate the servomotor clockwise to remove any

slack from the cables; then install the servomotor

retaining clip.

CM185

23. Place the servomotor cover into position; then

secure with two lock nuts.

CM121A

24. Check APV cable adjustment. See Arctic Power

Valve (APV) System in Section 3.

„NOTE: Before installing the drive clutch, be sure
to wipe both the crankshaft taper and clutch
mounting taper clean using a clean towel.

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

shaft and secure with the cap screw and lock

washer. Tighten to specifications.

„NOTE: On the 1000 cc to aid in proper tightening
of the drive clutch cap screw, apply oil to the
threads of the cap screw prior to installing.

26. Install the alignment washers; then install the

driven pulley on the gear case input shaft. Tighten

the cap screw to 4.4 kg-m (32 ft-lb).

CM125A

27. Check drive clutch/driven pulley alignment (see

Section 8).

! CAUTION

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

! CAUTION

It is critical that no less than two 1.5 mm (0.060 in.)
washers are in place on the input shaft when install-
ing the driven pulley.

2-119

2

MS390

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

the belt guard.

29. Install the resonator and secure with the hairpin

clip and springs; then place the expansion chamber

and grafoil gaskets into position and secure to the

exhaust manifold and resonator with the springs.

„NOTE: When installing the four exhaust manifold
springs, the long hook portion of the spring must
be attached to the exhaust manifold or premature
spring failure will result.

30. Fill the cooling system (see Liquid Cooling Sys-

tem in Section 3).

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

secure with the two pins and the cables.

32. Connect the ignition harness to the ECU and the

hood harness to the main harness; then connect the

air intake connector.

CM038

33. 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.

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

level and add coolant as necessary. Verify the

tightening torque of the drive clutch.

! 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.

2-120

Engine - 

F-Series 500/600

This engine servicing sub-section has been organized

to show a progression for the complete servicing of the

Arctic Cat 500 cc/600 cc (F-Series) engines. For con-

sistency 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 disassemble only those com-

ponents 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 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 ............................................................ 2-120
Disassembling..................................................... 2-124
Cleaning and Inspecting ..................................... 2-129
Measuring Critical Components.......................... 2-132
Assembling.......................................................... 2-135
Installing .............................................................. 2-142

Removing Engine

1. Remove the hood and the left-side and right-side

access panels; then remove the torx-head screws

securing the console.

741-722A

2. Lift the rear of the console and disconnect the con-

sole/main harness plug-in; then remove the con-

sole.

3. Remove the hairpin clip and all springs securing

the expansion chamber and resonator; then remove

these components from the engine compartment.

Account for the two exhaust gaskets.

„NOTE: On the LXR, disconnect the negative
cable from the battery.

4. With the seat adjusted to its lowest position,

remove the self-tapping screw from the right-side

seat adjustment track; then remove the seat.

ZJ100A

5. Remove the torx-head screws securing the handle-

bar close-off panel; then remove the panel.

6. Remove the lock nuts and torx-head cap screws

(A) securing the right-side front and rear spar pan-

els; then remove the torx-head screws (D) securing

the left-side rear spar panel to the gas tank and

support tube.

742-207A

„NOTE: The right-side rear spar panel will remain
secured to the chassis.

7. Remove the cap screw located directly above the

ECU securing the air-silencer duct to the front

upper panel; then disconnect the air temperature

sensor and remove the duct.

„NOTE: To aid in accessing the cap screw, the
ECU may be removed.

2-121

2

8. Remove the body screws and lock nuts (C) from

each side securing the front bumper assembly to

the chassis; then remove the two remaining self-

tapping screws (B) from each side securing the

front bumper assembly. Remove the assembly.

„NOTE: At this point, remove the air-intake
silencer and account for the rubber exhaust
bumper.

9. Remove the belt guard; then using a 1/2-in. 12-

point socket, remove the cap screw and lock

washer securing the drive clutch to the crankshaft.

10. 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 and the drive belt. If

applicable, account for the two sleeves.

11. Remove the cap screw from the driven pulley and

slide the driven pulley off the gear case input shaft.

Account for alignment washers.

FS192

„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 12-14 are for the 600 cc engine. For
the 500 cc engine, proceed to step 15.

12. Using a small needle-nose pliers, remove the ser-

vomotor retaining clip and the cable holder.

FS175

FS176

13. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings

out of the servomotor.

14. Pull the cable down and out of the cable housing

holder; then slide each cable drum back and out of

the servomotor actuator.

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

tem - Section 3).

16. Remove the cable tie securing the gasline supply

hose to the MAG-side engine mounting bracket;

then loosen the clamp and remove the hose from

the throttle body assembly. Plug the end of the

hose and secure it up and out of the way.

„NOTE: Note the routing and securing locations of
the hose for assembling purposes.

17. Loosen the flange clamps securing the throttle

body assembly to the flange; then move the throt-

tle body assembly forward and disconnect the oil

injection cable/control rod from the oil-injection

pump.

FS178A

„NOTE: It is advisable to remove the clamps from
the intake flanges to avoid damage during engine
removing.

! CAUTION

The gasline supply hose may be under pressure.
Place an absorbent towel around the connection to
absorb gasoline; then remove the hose slowly to
release the pressure.