Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 34

2-122

18. Loosen the clamps securing the coolant hoses con-

nected to the cylinders beneath the exhaust port

and the throttle body assembly; then remove the

vent tube from the top of the cylinder head.

CM030A

19. 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.

FS179A

20. Remove the cap screws securing the recoil starter;

then secure the recoil starter up and out of the way.

FS180

„NOTE: On the LXR, remove the two set screws
securing the flex-drive shaft to the starter motor;
then remove the flex-drive shaft from the motor.

FS177A

21. Remove the spark plug wires from the plugs; then

disconnect the two-wire plug-in for the coolant

temperature sensor (located below the ignition

coil).

FS193A

22. Remove the harness wrap and disconnect all igni-

tion/main harness connectors; then secure the har-

ness out of the way.

FS181

23. Disconnect the front heat exchanger hose.

„NOTE: Prior to disconnecting the hose, it is
advisable to place an absorbent towel beneath the
hose to collect any coolant from the exchanger.

24. Remove the four cap screws securing the upper

bearing bracket to the upper support plate (account

for the two bracket plates); then secure the steering

post to the headlight support bracket.

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2

FS182A

FS183A

25. Remove the exhaust manifold from the engine.

Account for the flange nuts and gaskets.

26. Remove the cap screw and lock nut (A) and lower

cap screw (B) securing the PTO-side engine

mounting bracket to the chassis.

742-205A

27. Remove the four cap screws (C) securing the PTO-

side bracket to the engine; then remove the

bracket. Account for the torque bumper.

28. Remove the two cap screws (D) securing the front

engine plate to the chassis; then remove the cap

screw (E) securing the MAG-side engine mount-

ing bracket to the chassis.

29. Tip the engine forward and support the engine in a

position to gain access to the clamp securing the

coolant hose to the thermostat housing; then

loosen the clamp and remove the hose.

FS184A

30. With the engine supported in the forward position,

remove the cable tie securing the ignition harness

to the coolant tank/heat exchanger hose; then route

the harness out from behind the hose.

FS185A

31. Remove the engine out the MAG-side of the

engine compartment.

FS186

32. Remove the clamps securing the coolant supply

hoses to the engine; then remove the hoses.

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FS187A

„NOTE: At this point if necessary, remove the
coolant temperature sensor.

33. Remove the two cap screws securing the MAG-

side engine mounting bracket to the engine.

FS188A

34. Remove the four cap screws securing the front

engine plate to the engine.

FS189A

„NOTE: On the LXR, remove the pinion drive
bracket assembly from the engine.

FS190A

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

FC015

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

the end of the crankshaft.

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2

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 four alignment pins.

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

FC019

FC020

7. Remove the stator plate from the engine.

! 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.