Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 40

2-146

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

shaft and secure with the cap screw and lock

washer. Tighten to specifications.

23. 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).

FS192

24. Check drive clutch/driven pulley alignment (see

Section 8). Install the drive belt. Check belt deflec-

tion. Secure the belt guard.

25. Secure the bearing bracket/steering post assembly

to the upper support plate with the bracket plates

and cap screws (coated with blue Loctite #243).

Tighten the cap screws to 1.1 kg-m (8 ft-lb).

FS182A

„NOTE: When installing the bracket plates, the
wider end of the plate must be directed up.

FS200A

26. Install the air silencer onto the throttle bodies mak-

ing sure the dual intake boot is properly positioned

and seated.

„NOTE: To aid in installing the air silencer, it can
be helpful to remove the air silencer cover and
work the intake boot over the throttle body from
inside the silencer.

FS201A

27. Place the front bumper assembly (with spar pan-

els) into position on the snowmobile; then secure

the front and rear spar panels together with the

torx-head cap screws and lock nuts (A). Tighten

the lock nuts securely.

742-207A

28. Install the body screws and lock nuts (C) from

each side and the self-tapping screws (B) from

each side securing the front bumper assembly to

the chassis. Tighten all hardware securely.

! 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.

2-147

2

29. Connect the air temperature sensor and place the

sensor harness beneath the air-intake duct; then

install the duct into the silencer.

„NOTE: To aid in installing the duct, it can be help-
ful to apply a thin film of WD-40 to the air silencer
seal and to work the duct back and forth until the
sleeve of the duct is properly seated into the
silencer.

30. Secure the air-intake duct to the upper frame with

the cap screw. Tighten securely.

„NOTE: If the ECU was removed to gain access to
the air-intake duct cap screw, install the ECU using
the two lock nuts. Tighten the lock nuts securely;
then connect the harness plug-ins to the ECU.

FS202A

31. Using the illustration following step 27, secure the

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

tube with the three torx-head screws (D). Tighten

the screws securely.

32. Install the seat; then install the machine screw

(threads coated with blue Loctite #243) to the right

side of the seat support.

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

tem in Section 3).

34. Place the rubber exhaust bumper into position on

the air silencer.

FS203A

„NOTE: On the LXR, secure the negative battery
cable to the battery.

35. Install the exhaust resonator and secure to the

upper frame with the tab washer and the hairpin

clip.

36. Place gaskets on the resonator and exhaust mani-

fold; then install the expansion chamber. Secure

the chamber to manifold and upper frame with the

springs.

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

37. Place the console into position on the headlight

support bracket (do not secure the console with the

torx-head screws at this time); then connect the

console/main harness plug-in.

38. Install and close the left-side and right-side access

panels and the hood.

39. 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.

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

level and add coolant as necessary.

41. Verify the tightening torque of the drive clutch.

42. Secure the console to the steering support with the

torx-head screws and tighten the screws securely;

then close the left-side and right-side access panels

and close the hood.

! CAUTION

Make sure to place the sensor harness beneath the
air-intake duct to avoid contact with exhaust compo-
nents.

! CAUTION

It is critical that machine screw is not installed tight
against the seat support. The screw must be loose
enough to be effective as a seat “stop.”

! CAUTION

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

! 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.

2-148

741-722A

Engine - 

F-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 (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 14-17 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 ............................................................ 2-148
Disassembling..................................................... 2-153
Cleaning and Inspecting ..................................... 2-158
Measuring Critical Components.......................... 2-161
Assembling.......................................................... 2-163
Installing .............................................................. 2-171

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.

! 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.

2-149

2

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.

8. Remove the body screws and flange 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).

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. Slide each cable drum back and out of the servo-

motor actuator.

15. On the LXR, remove the starter motor using the

following sequence:

A. Remove the lock nuts securing the negative and

the positive cables to the starter motor.