Snowmobile Arctic Cat (2008 year). Manual - part 62

2-186

FS214A

20. Rotate the servomotor clockwise to remove any

slack from the cables.

21. Slide the APV cable drums into the servomotor

actuator; then place the cable housings into posi-

tion in the servomotor. Secure with the cable

holder and the servomotor retaining clip. Check

APV cable adjustment. See Arctic Power Valve

(APV) System in Section 3.

FS176

FS273A

„NOTE: Prior to installing the drive clutch, be sure
to wipe both the crankshaft taper and clutch
mounting taper clean using a clean towel.

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

shaft and secure with the cap screw and lock

washer. Tighten to 55 ft-lb.

„NOTE: On the 1000 cc to aid in proper tightening
of the drive clutch cap screw, apply oil to the
threads of the cap screw prior to installing.

23. Install the alignment washers (if applicable); then

install the driven pulley on the gear case input

shaft. Tighten the cap screw to 32 ft-lb.

FS192

24. Check drive clutch/driven pulley alignment (see

Section 6). 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 8 ft-lb.

FS182A

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

! 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.

2-187

2

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.

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. On the standard models, place the seat into posi-

tion on the chassis; then push down on the rear of

the seat until it locks securely in place.

„NOTE: On the LXR and Sno Pro models, 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 chassis.

! 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.”

2-188

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.

741-722A

! CAUTION

Never run the engine with the console harness dis-
connected 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.

! CAUTION

If the engine had a major overhaul or if any major
component was replaced, proper engine break-in
procedures must be followed (see Section 1). If the
proper engine break-in procedures are not followed,
severe engine damage may result.

2-189

2

Troubleshooting Engine 

(Carbureted Models)

Problem: Engine Does Not Start (No Spark at Spark Plugs)

Condition

Remedy

1. Ignition switch malfunctioning — not in RUN position

2. Wiring harness shorting — connection poor

3. Emergency stop switch knob in DOWN position — 

malfunctioning

4. Throttle/ignition monitor switch adjusted too tight —

malfunctioning

5. Carburetor safety switches adjusted incorrectly — 

malfunctioning

6. Spark plugs fouled — damaged

7. Spark-plug caps damaged — leaking — shorting

8. High tension wires/coil loose — grounded — faulty

9. CDI unit faulty

10. Charge coil (1) faulty

11. Charge coil (2) faulty

12. Flywheel magnets weak

13. Flywheel key sheared

1. Replace ignition switch — turn switch to RUN position

2. Repair — connect — replace wiring harness

3. Move knob to UP position — replace throttle switch

4. Adjust (loosen) throttle cable — replace throttle switch

5. Adjust — replace carburetor safety switches

6. Clean — gap — replace spark plugs

7. Replace spark-plug caps

8. Service — replace high tension wires/coil

9. Replace CDI unit

10. Replace coil

11. Replace coil

12. Replace flywheel

13. Replace key

Problem: Engine Does Not Start (No Fuel at Cylinders)

Condition

Remedy

1. Gas tank empty

2. Shut-off valve closed 

3. Fuel hose broken — pinched

4. Gas-tank vent — hose obstructed

5. In-line fuel filter obstructed — damaged

6. Fuel pump malfunctioning — faulty

7. Impulse hose cracked — broken — pinched — discon-

nected

8. Carburetors adjusted incorrectly — dirty — damaged

9. Primary compression (crankcase) absent

1. Fill tank

2. Open shut-off valve

3. Replace — service hose

4. Remove obstruction — replace vent — hose

5. Remove obstruction — replace in-line fuel filter

6. Replace — repair — clean fuel pump

7. Replace — connect impulse hose

8. Troubleshoot — clean — replace carburetors

9. Repair — replace damaged — worn engine compo-

nents