Snowmobile Arctic Cat (2008 year). Manual - part 61

2-182

47. 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.

FC080

48. Secure the starter pulley while using the spanner

wrench and tighten the three cap screws (from step

46) evenly to 18 ft-lb.

FC081

49. Using the spanner wrench, tighten the flywheel

cap screw (from step 47) to 50 ft-lb.

„NOTE: On the 1000 cc with alignment pins in
place, install the magneto case on the crankcase
with the cap screws. Tighten cap screws to 8 ft-lb.

CM144A

50. Install the coolant inlet hose to the cylinder head

and water pump; then tighten the hose clamps

securely.

CM181

Installing Engine

1. Install the engine coolant hoses to the engine; then

secure with the hose clamps.

FS216A

2. Place the engine into the engine compartment

from the MAG-side; then tip the engine forward

and support the engine in this position.

FS186

3. Install the MAG-side engine mounting bracket to

the engine with the two cap screws (F) (coated

with blue Loctite #243). Tighten to 23 ft-lb.

! CAUTION

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

2-183

2

742-201A

742-213A

4. Position the engine to the chassis mounts; then

install cap screw (E) securing the MAG-side

mounting bracket to the chassis. Tighten cap screw

to 50 ft-lb.

5. Release the tie-down securing the engine/pin-

ion bracket in the forward position; then posi-

tion the engine to the bracket and secure with

four cap screws (D) (coated with green Loctite

#609). Tighten to 50 ft-lb.

„NOTE: At this point prior to installing the PTO-
side engine mounting bracket, install the coolant
hose to the thermostat housing and secure with
the clamp.

FS217A

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 appropriate illustration following step 3,

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 23 ft-lb.

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 hose and the chassis; then secure the

ignition harness to the coolant hose with a cable tie

in the position as noted in removing. 

! CAUTION

Position the hose clamp screw so it is directed to the
12 o’clock position of the thermostat housing to
avoid contacting the chassis.

800 cc

1000 cc

2-184

FS197

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

10. Connect all ignition/main harness plug-ins and the

two-wire connector; then install the harness wrap.

FS181

11. Place the recoil starter into position and secure the

starter with six cap screws. In a crisscross pattern,

tighten to 8 ft-lb.

FS210

12. On the LXR, install the starter motor using the fol-

lowing sequence:

A. Place the flex-drive shaft into position on the

pinion driveshaft so the set screws are aligned

with the flat-side of the pinion driveshaft; then

tighten the set screws (coated with blue Loctite

#243) securely.

FS204

B. Place the starter motor with bracket into posi-

tion on the chassis and upper frame; then secure

with the cap screws and lock nuts. Tighten

securely.

„NOTE: For installing purposes, it may be neces-
sary to loosen the lock nut securing the bracket to
the starter motor.

C. Place the positive and negative cables on the

starter motor; then secure with the lock nuts.

Tighten securely.

FS205A

13. Connect the oil supply hose (A) to the oil injection

pump and secure with a clamp; then remove the oil

bleed plug (B) 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.

! CAUTION

If the bracket/starter motor lock nut was loosened for
installing purposes, tighten the lock nut securely.

2-185

2

CM184B

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

14. Install the throttle body assembly and secure with

the flange clamps; then connect the oil pump con-

trol rod.

FS209A

„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.

15. Connect the two throttle body coolant hoses to the

PTO-side and MAG-side throttle body and secure

with the clamps.

FS198A

16. Apply a thin coat of high-temperature silicone

sealant to each exhaust port; then install the

exhaust gaskets.

17. 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 eight nuts. Using the pattern shown,

tighten to 17 ft-lb.

0742-292

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

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

clamp securely.

19. Connect the coolant overflow hose to the cylinder

head; then connect the spark plug wires to the

spark plugs.

„NOTE: On the 800 cc, connect the knock sensor
wiring to the wiring harness; then secure the con-
nector to the coolant filler neck bracket with the
push-mount cable tie.

FS212A

„NOTE: At this point, secure the coolant hose,
gasline hose, and on the LXR, the battery cables
together.

! CAUTION

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