Snowmobile Arctic Cat (2008 year). Manual - part 56

2-162

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

FS218A

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

the engine compartment.

800 cc

1000 cc

2-163

2

FS186

33. After the engine has been removed, remove the

clamps securing the coolant supply hoses to the

engine; then remove the hoses.

FS216A

„NOTE: At this point if necessary, remove the
cable tie securing the wire harness to the coolant
temperature sensor; then remove the 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 onto the end of the

crankshaft.

FC016

3. Using Flywheel Puller or suitable substitute,

remove the flywheel from the crankshaft by tight-

ening the puller bolt, striking the head of the puller

bolt with a hammer, and tightening again. Repeat

this procedure until the flywheel is free. Account

for the key.

! CAUTION

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

! CAUTION

To prevent damage to the crankshaft, do not thread
puller bolts more than 1/2 in. into the flywheel. Dam-
age to the coils may result.

2-164

CM140

„NOTE: To ensure the cleanliness of the flywheel
magnets, place the flywheel (with the magnets fac-
ing upward) on a clean bench.

„NOTE: On the 1000 cc, remove the Allen-head
cap screws securing the magneto case to the
crankcase. Account for four alignment pins.

CM144A

4. Remove the cap screw securing the ground wire to

the crankcase.

CM142A

5. Remove the Allen-head cap screw (A) securing

the stator lead wire plate to the crankcase; then

remove the Allen-head cap screws (B) securing

the timing sensors, remove the sensors, and

account for the harness grommets.

CM141C

6. Remove the Allen-head cap screws securing the

stator to the stator plate. Route the stator lead wire

out of the crankcase; then remove the stator

assembly.

CM143A

7. Remove the cap screws securing the stator plate to

the engine; then remove the plate.

CM145D

„NOTE: For assembling purposes, note that the
indentation (A) of the stator plate is aligned with
the harness opening (B) in the crankcase.

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2

CM145C

„NOTE: The stator plate screws had Loctite
applied to the threads during assembly. Using an
impact driver, apply a sharp blow to the head of
each screw to break the Loctite loose before
removal.

8. Remove the cap screws securing the APV assem-

blies to the cylinders; then remove the APV

assemblies and set them aside.

„NOTE: For assembling purposes, note that the
APV exhaust valves and gaskets are directional.

CM146A

CM147

9. Remove the spark plugs.

„NOTE: On the 800 cc at this point, remove the
knock sensor and lock plate from the cylinder
head by bending the lock plate tabs down and
unthreading the sensor.

10. Remove the cap screws with O-rings securing the

cylinder head; then separate from the cylinders.

Account for the O-rings.

„NOTE: When removing the cylinders, place the
engine on its intake flanges on a drain tray to allow
residual coolant to drain from the cylinder/crank-
case water jacket.

11. Remove the four nuts and four cap screws secur-

ing the cylinders to the crankcase; then using a soft

hammer, gently tap the cylinders and remove from

the crankcase by lifting them straight up off their

studs. Account for gasket(s) and alignment pins.

CM148

12. Remove the PTO-side piston-pin circlip from the

PTO-side piston; then remove the MAG-side pis-

ton-pin circlip from the MAG-side piston.

CM149

13. Using Piston Pin Puller, remove the piston pins

from both pistons.

„NOTE: For proper assembly, keep all MAG-side
components and all PTO-side components sepa-
rated. Assemble them on their proper sides.

! CAUTION

When removing a cylinder, be sure to support the
piston to prevent damage to the crankcase and pis-
ton.