Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 39

2-142

FC080

45. Place the starter pulley in position; then loosely

secure the starter pulley with three cap screws

(coated with red Loctite #271). Secure the pulley

while using the spanner wrench and tighten the

three cap screws evenly to specifications.

FC081

46. Using the spanner wrench, tighten the flywheel

cap screw (from step 44) to specifications.

Installing Engine

1. Install the MAG-side engine mounting bracket to

the engine with the two cap screws (coated with

blue Loctite #243). Tighten to specifications.

FS188A

2. Install the front lower engine plate to the engine

with four cap screws (coated with blue Loctite

#243). Tighten to specifications.

FS189A

3. Install the throttle body hose (A), inlet hose (B),

and the front heat exchanger hose (C) to the

engine; then secure with the hose clamps.

FS187B

„NOTE: At this time if the coolant temperature
sensor was removed, install the sensor and
tighten securely.

„NOTE: At this point on the LXR, install the pinion
bracket assembly to the engine with two cap
screws (coated with green Loctite #609). Tighten
to specifications.

FS190A

2-143

2

4. Place the engine into the engine compartment

from the MAG-side; then tip the engine forward

and support the engine in this position. Connect

the coolant hose to the thermostat housing.

FS194A

„NOTE: At this point on the LXR, insert the flex-
drive shaft into the pinion drive and secure with
the two set screws.

FS177A

5. Position the engine to the chassis mounts; then in

order, install cap screw (D) securing the engine

plate to the MAG-side mount, cap screw (E)

securing the MAG-side mounting bracket to the

chassis, and cap screw (D) to the PTO-side mount.

Tighten all mounting cap screws to specifications.

742-205A

6. Position the torque bumper against the gear case;

then install the PTO-side engine mounting bracket.

„NOTE: Prior to installing the bracket, assure that
the U-nut clip is centered in position.

FS195A

7. Using the illustration following step 5, install the

cap screw and lock nut (A) and the lower cap

screw (B) securing the PTO-side bracket to the

chassis; then install the four cap screws (C)

(coated with blue Loctite #243) securing the

bracket to the engine. Tighten all mounting hard-

ware to specifications.

8. Connect the coolant hose to the outlet of the front

heat exchanger and secure with the hose clamp.

FS196A

9. Route the ignition harness and the coolant temper-

ature sensor two-wire connector between the cool-

ant tank and the chassis; then connect all ignition/

main harness plug-ins and the two-wire connector.

! CAUTION

Position the hose clamp screw so it is directed to the
back side of the thermostat housing to avoid con-
tacting the chassis when the engine is lowered and
secured.

2-144

FS197

„NOTE: Prior to connecting the harness, it is
advisable to clean all plug-ins with contact cleaner.

10. Secure the ignition harness to the coolant hose

with a cable tie in the position as noted in remov-

ing; then install the harness wrap.

FS181

11. Place the recoil starter into position and secure the

starter with the cap screws. In a crisscross pattern,

tighten to specifications.

FS180

12. Install the throttle body assembly and secure with

the flange clamps; then connect the oil pump

cable/control rod and the oil hose.

FS178A

FS179A

„NOTE: Check to be sure the mark on the control
arm is aligned with alignment mark on the oil-
injection pump boss in the full-open position. If the
marks are not aligned, adjust synchronization by
loosening the jam nuts on the adjuster. Rotate the
jam nuts/adjuster nut until proper alignment is
attained. Tighten jam nuts.

„ NOTE: When the cable/linkage adjusting nut is
adjusted correctly, the throttle lever will move
approximately 3.2 mm (1/8 in.) before the oil-injec-
tion pump arm begins to move.

13. Remove the oil bleed plug from the oil injection

pump. When oil flows from pump free of air bub-

bles and the hose is full of oil, install the oil bleed

plug and tighten.

„NOTE: It is advisable to place a cloth beneath the
oil-injection pump to contain any oil spilled during
the bleeding process.

14. Connect the throttle body coolant hose to the PTO-

side throttle body and secure with the clamp; then

install the two coolant hoses to the MAG-side and

PTO-side of the crankcase (below the exhaust

ports).

2-145

2

FS198A

FS199A

15. Apply a thin coat of high-temperature silicone

sealant to each exhaust port; then install the

exhaust gaskets.

16. 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 six nuts. Tighten the nuts to specifications.

CM035

17. Route the gasline hose to the throttle body assem-

bly and secure the hose to the fuel rail. Tighten the

clamp securely; then using a cable tie, secure the

hose to the MAG-side engine mounting bracket.

18. Connect the coolant overflow hose to the cylinder

head; then connect the spark plug wires to the

spark plugs.

„NOTE: Steps 19-21 are for the 600 cc engine.

19. Rotate the servomotor clockwise to remove any

slack from the cables.

20. Slide the APV cable drums into the servomotor

actuator; then place the cable housings into posi-

tion in the servomotor. Secure with the cable

holder and the servomotor retaining clip.

FS176

FS175

21. 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.

! CAUTION

When installing the throttle bodies, make sure the
gasline hose is properly routed to avoid premature
wear and/or contact with exhaust components.