Snowmobile Arctic Cat (2008 year). Manual - part 38

2-89

2

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-length cap

screws and the alignment pins. Tighten cap screws

(coated with blue Loctite #243) to 40 ft-lb.

FC019

FC020

40. Secure the ignition timing sensor with screws

coated with blue Loctite #243. Tighten to 8 ft-lb.

41. Secure the stator plate to the crankcase with the

Allen-head cap screws coated with blue Loctite

#243 and tightened to 8 ft-lb; 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 8 ft-lb.

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.

2-90

FC080

45. Place the starter pulley in position; then loosely

secure the starter pulley with three cap screws.

Secure the pulley while using the spanner wrench

and tighten the three cap screws evenly to 8 ft-lb.

FC081

46. Using the spanner wrench, tighten the flywheel

cap screw (from step 44) to 50 ft-lb.

47. Install the spark plugs and tighten to 19 ft-lb.

Installing Engine

„NOTE: Prior to installing the engine, secure the
MAG-side mounting bracket and on the 600 cc, the
upper right mounting bracket to the engine with
cap screws (coated with blue Loctite #243) and
tighten to specifications.

1. Place the engine into the engine compartment and

position it so the water pump coolant hose can be

installed to the front heat exchanger. Secure with

the hose clamp.

CM034C

„NOTE: If equipped with electric start, insert the
flex-drive shaft into the pinion drive and secure
with the two set screws.

2. Place the engine into the mounting position; then

from the PTO-side, tip the engine forward, raise

the PTO-side of the engine, and allow the chassis

to support the engine in this position. Connect the

coolant tank hose to the bottom left outlet on the

engine and secure with the hose clamp.

MS382D

3. Connect all electrical wiring making sure all wir-

ing and coolant hoses are routed properly (as noted

in removing); then place the engine into the

mounting position.

„NOTE: Secure the wiring harnesses with cable
ties (as noted in removing).

4. Install the cap screw and nut (C) securing the

MAG-side engine mounting bracket to the side

plate. DO NOT TIGHTEN AT THIS TIME.

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2

742-240A

742-238A

5. Install the PTO-side engine mounting bracket to

the engine with cap screws (coated with blue Loc-

tite #243) (A) and to the front frame with lock nuts

(B). DO NOT TIGHTEN AT THIS TIME.

6. From step 5, tighten the four mounting bracket

plate-to-engine cap screws (coated with blue Loc-

tite #243) (A) to 24 ft-lb; then tighten the three

lock nuts (B) securing the engine mounting

bracket to the front frame (from step 5) to 20 ft-lb.

„NOTE: On the 600 cc, install the cap screw and
lock nut (D) securing the engine mounting bracket
to the front lower mounting bracket.

 7. Tighten the MAG-side engine cap screw (C) and

nut (from step 4) to 20 ft-lb.

8. Connect the oil-injection cable/control rod to the

oil-injection pump and secure.

CM028A

9. Connect the oil supply hoseto the oil injection

pump; then remove the oil bleed plug from the oil

injection pump. When oil flows from pump free of

air bubbles and the hose is full of oil, install the oil

bleed plug and tighten securely.

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

CM029A

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

side throttle body and secure with the clamp; then

with the flange clamps in place, install the throttle

body assembly.

„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.

0742-853

500 cc

600 cc

! CAUTION

Make sure the oil-supply hose is routed properly to
avoid premature wear.

500 cc

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0742-854

„ NOTE: On the 500 cc when the cable adjusting
nut is adjusted correctly, the throttle lever will
move approximately 1/8 in. before the oil-injection
pump control arm begins to move.

11. 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.

12. Install the two coolant hoses to the MAG-side and

PTO-side of the crankcase (below the exhaust

ports) and the overflow hose; then tighten the

coolant hose clamps and the carburetor flange

clamps.

FS271A

13. Apply a thin coat of high-temperature silicone

sealant to each exhaust port; then install the

exhaust gaskets.

14. 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 the nuts. Tighten in a crisscross pattern to 15

ft-lb.

CM035

15. Install the side-plate brace onto the chassis and

secure the front of the brace with the four cap

screws (coated with blue Loctite # 243). Tighten

securely.

CM210A

„NOTE: It is advisable to install the two front lower
cap screws first to attain proper alignment for the
remaining cap screws.

16. After securing the front of the brace, secure the

rear of the brace and the steering support to the

chassis with the cap screws (coated with blue Loc-

tite # 243). Tighten to 20 ft-lb.

CM209A

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

tem in Section 3).

18. Place the recoil starter into position and secure the

starter with the cap screws. Tighten to 8 ft-lb.

! CAUTION

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

600 cc