Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 41

2-150

FS205A

B. Loosen the two set screws securing the flex-

drive shaft to the pinion driveshaft.

FS206A

C. Remove the cap screws and lock nuts securing

the starter motor brackets to the chassis and to

the upper frame. Remove the starter motor.

FS207A

FS208A

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

tem - Section 3).

17. 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.

18. 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 control rod from the oil-injection pump.

FS209A

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

19. Loosen the clamps securing the two coolant hoses

connected to the MAG-side and PTO-side throttle

body; then remove the vent tube from the top of

the cylinder head.

„NOTE: On the 1000 cc, remove the coolant
bypass hoses from the cylinders.

20. 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.

! 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.

2-151

2

FS213A

21. Remove the cap screws securing the recoil starter;

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

FS210

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

disconnect the two-wire plug-in for the coolant

temperature sensor (located below the lower

MAG-side ignition coil).

FS211A

„NOTE: On the 800 cc at the coolant filler neck
bracket, disconnect the knock sensor wiring con-
nector and slide the wiring out of the cable tie.

FS212A

23. Remove the harness wrap and disconnect all igni-

tion/main harness connectors; then secure the

main harness out of the way.

FS181

„NOTE: Remove the cable ties securing the cool-
ant hose, gasline hose, and on the LXR, battery
cables together.

FS214A

24. 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.

25. 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.

2-152

FS182A

FS183A

26. Remove the exhaust manifold from the engine.

Account for flange nuts and gaskets.

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

cap screw (B) securing the PTO-side engine

mounting bracket to the chassis.

742-201A

742-213A

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

side bracket to the engine; then remove the

bracket. Account for the torque bumper.

29. Remove the four cap screws (D) securing the

engine/pinion bracket to the engine; then remove

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

mounting bracket to the chassis.

„NOTE: At this point, loosen the clamp securing
the coolant hose to the thermostat housing; then
remove the hose.

FS217A

30. Using the appropriate illustration after step 27,

remove the two cap screws (F) securing the MAG-

side engine mounting bracket to the engine.

31. Prior to removing the engine, tip it back far

enough to allow access to the engine/pinion

bracket (A); then secure the bracket forward with a

suitable tie-down (B).

FS215A

800 cc

1000 cc

2-153

2

FS218A

32. Carefully work the engine out the MAG-side of

the engine compartment.

FS186

33. After the engine has been removed, remove the

clamps securing the coolant supply hoses to the

engine; then remove the hoses.

FS216

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

Disassembling Engine

„NOTE: When disassembling top-side compo-
nents, mark MAG-side and PTO-side components
for assembling purposes.

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.

CM138

CM139

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

the end of the crankshaft.

FC016

! CAUTION

When removing the engine, take care not to damage
the oil pump or the APV cables.