Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 38

2-138

FC133A

„NOTE: It is important to not get sealant into the
breather hole in the crankcase. If sealant gets into
the hole, carefully remove before proceeding.

FC072B

FC072A

„NOTE: Sealant is only required on the crankcase
seam.

21. Position the O-ring into the water pump cover;

then install the cover. Secure with six screws; then

using the pattern shown, tighten to specifications.

FC134

0742-304

22. Noting the alignment dots, install the thermostat

housing with thermostat. Tighten the existing

hardware securely.

FC078A

FC073

23. Secure the intake flanges, reed valve assemblies,

and gaskets with cap screws. Tighten to specifica-

tions.

2-139

2

24. Install the dowel pins into the crankcase; then

place the cylinder base gasket into position on the

crankcase.

25. Install the piston rings on each piston so the letter

on the top (inclined surface) of each ring faces the

dome of the piston.

726-306A

26. Apply oil to the connecting-rod small end bear-

ings; then install the small-end bearings. Install a

washer on each side of the connecting rod.

FC075

„NOTE: The shoulder side of the washer must
seat to the needle bearing.

27. Place each piston over the connecting rod so the

indicator dot on each piston will point toward the

intake/exhaust ports; then secure with an oiled pis-

ton pin.

„NOTE: The indicator dot is found on the piston
dome top.

FC079A

28. Install the new circlips so the open end is directed

either up or down.

B324D

29. Rotate each piston ring until the ring ends are

properly positioned on either side of the ring

keeper; then apply oil to the piston assemblies and

cylinder bores. Remove the rubber bands from the

connecting rods.

30. In turn on each cylinder, place a piston holder (or

suitable substitute) beneath the piston skirt and

square the piston in respect to the crankcase; then

using a ring compressor or the fingers, compress

the rings and slide the cylinder over the piston.

Remove the piston holder and seat the cylinder

firmly onto the crankcase.

„NOTE: The cylinders should slide on easily. DO
NOT force the cylinders on.

! CAUTION

Incorrect installation of the piston rings will result in
engine damage.

! CAUTION

Make sure the circlips are firmly seated and the open
end is directed either up or down before continuing
with assembly.

2-140

FC076

31. On the 500 cc, secure each cylinder by installing

the eight nuts. DO NOT TIGHTEN AT THIS

TIME.

32. On the 600 cc, secure each cylinder by installing

the four nuts and four cap screws. DO NOT

TIGHTEN AT THIS TIME.

33. Install the oil-injection hoses and secure with the

clamps; then place the lower check-valve assem-

bly into position and secure with the gaskets and

union cap screw. Tighten securely.

34. Secure the cylinders (from steps 31-32) by tighten-

ing the cylinder base nuts (and cap screws on the

600 cc) to specifications in three steps using the

appropriate pattern shown; then tighten the spark

plugs to specifications.

0738-206

0738-220

35. Install the two cylinder O-rings on the top of each

cylinder making sure they are correctly positioned

in the grooves.

FC077

36. Place new O-rings onto each of the head cap

screws. Place four of these cap screws into the cyl-

inder head. Thread the spark plugs in part way;

then while holding the head above the cylinder,

carefully start and finger-tighten all four cap

screws while observing the cylinder O-rings to

make sure they remain in position. Slowly place

the head into position on top of the O-rings. Start

and finger-tighten the remaining cap screws being

very careful not to move the cylinder head.

37. From step 36 in two steps, tighten the 8 mm cap

screws to specifications using the appropriate pat-

tern shown.

0738-204

„NOTE: On the 500 cc after tightening the 8 mm
cap screws, tighten the two remaining 6 mm cap
screws to specifications.

0738-205

500 cc

600 cc

500 cc

600 cc

2-141

2

38. On the 600 cc, slide the APV assemblies into posi-

tion in the cylinders; then slide the valve keepers

into position and secure with cap screws (coated

with blue Loctite #243). Tighten to specifications.

FC025

FC024

„NOTE: At this point, pressure test the engine
(see section 3).

39. On the 600 cc, install the magneto case on the

crankcase accounting for the different-sized cap

screws and the alignment pins. Tighten cap screws

to specifications.

FC019

FC020

40. Secure the ignition timing sensor with screws

coated with blue Loctite #243. Tighten to specifi-

cations.

41. Secure the stator plate to the crankcase with the

Allen-head cap screws coated with blue Loctite

#243 and tightened to specifications; then install

the stator assembly with wires and a grommet into

the crankcase and secure with the Allen-head

screws (coated with blue Loctite #243). Tighten to

specifications.

FC018

42. Install the key in the crankshaft. 

43. Thread two puller bolts into the flywheel; then

slide the flywheel onto the crankshaft making sure

the keyways match. Remove the puller bolts.

„NOTE: Before installing the flywheel, be sure to
wipe the crankshaft and flywheel tapers clean
using a clean towel.

44. Apply red Loctite #271 to the threads of the fly-

wheel cap screw; then finger-tighten with a large

flat washer. DO NOT TIGHTEN AT THIS TIME.

! CAUTION

The long side of the exhaust valve must be facing
toward the cylinder head or severe engine damage
may occur.