Snowmobile Arctic Cat (2008 year). Manual - part 68

3-16

0742-120

0741-835

KEY

1. Rear Heat Exchanger

2. Insert

3. Foam

4. Rivet

5. Hose Clamp

6. Hose

7. Hose Protector

8. Rivet

9. Heat Exchanger

10. Heat Exchanger

11. Hose Protector

12. Hose

13. Hose Clamp

14. Hose

15. Hose Clamp

16. Coolant Tank

17. Cap

18. Hose

19. Heat Shield

20. Cable Tie

21. Hose Clamp (1000 cc)

22. Hose

23. Loom (1000 cc)

24. Fitting (1000 cc)

25. Hose Clamp

26. Hose Clamp (1000 cc)

27.  Cable Tie (1000 cc)

28. Hose Protector

29. Hose

30. Hose Clamp

31. Hose Clamp

32. Hose

Crossfire/M-Series

KEY

1. Cap

2. Filler Neck

3. Clamp

4. Hose

5. Coolant Tank

6. Clamp

7. Hose

8. Clamp

9. Clamp

10. Hose

11. Hose

12. Clamp

13. Hose

14. Clamp

15. Machine Screw

16. Clamp

17. Hose

18. Self-Tapping Screw

19. Bracket

20. Cap Screw

F-Series 500/600/T500

3-17

3

0742-029

Recoil Starter

(370/500/600 cc)

REMOVING

1. Tie a slip-knot in the starter rope below the con-

sole and allow the rope to slowly retract against

the starter case.

2. Remove the knot at the handle, remove the handle,

and account for the handle cap; then thread the

rope through the bushing in the console.

3. Remove the cap screws securing the starter assem-

bly to the magneto case; then remove the starter

assembly.

DISASSEMBLING

1. Secure the recoil starter in a vise.

2. Rotate the roller counterclockwise until the notch

of the roller is near the rope guide in the case.

Guide the rope into the notch and slowly allow the

roller to retract until all recoil spring tension is

released.

B522

3. While exerting downward pressure on the friction

plate, remove the nut and washer.

KEY

1. Cap

2. Filler Neck

3. Clamp

4. Hose

5. Coolant Tank

6. Clamp

7. Hose

8. Self-Tapping Screw

9. Machine Screw

10. Hose

11. Hose

12. Clamp

13. Hose

14. Fitting

15. Clamp

16. Clamp

17. Hose

18. Cap Screw

19. Bracket

F-Series 800/1000

! WARNING

Always wear safety glasses when servicing the
recoil starter.

! WARNING

During the disassembly procedure, continuous
downward pressure must be exerted on the reel so it
does not accidentally disengage and cause injury.

! WARNING

Care must be taken when allowing the recoil roller to
unwind. Make sure all spring tension is released
before continuing.

3-18

B523

4. Slowly release the plate and lift the plate with fric-

tion spring free of the recoil roller.

5. Remove the friction spring from the plate.

B524

6. Remove the pawl; then remove the return spring.

B525

7. Carefully lift the roller free of the case making

sure the main spring does not accidentally disen-

gage from the case.

8. Remove the main spring from the case by lifting

the spring end up and out. Hold the remainder of

the spring with thumbs and alternately release

each thumb to allow the spring to gradually release

from the case.

„NOTE: Do not remove the main spring unless
replacement is necessary. It should be visually
inspected in place to save time.

9. Unwind the rope from the roller, untie the slip-

knot, and remove the rope.

CLEANING AND INSPECTING

„NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all recoil starter components.

2. Inspect all springs, washers, and pawl for wear or

damage.

3. Inspect the roller and case for cracks or damage.

4. Inspect the center hub for wear, cracks, or damage.

5. Inspect the rope for breaks or fraying.

6. Inspect the main spring for cracks, crystallization,

or abnormal bends.

7. Inspect the handle for damage, cracks, or deterio-

ration.

ASSEMBLING

0739-364

1. Hook the end of the main spring around the

mounting lug in the case.

2. Insert the main spring into the case; then wind it in

a counterclockwise direction until the complete

spring is installed.

„NOTE: The main spring must seat evenly in the
recoil case.

! WARNING

Care must be taken when lifting the roller free of the
case.

KEY

1. Starter Assy

2. Starter Roller

3. Main Spring

4. Ratchet Set

5. Friction Spring

6. Washer

7. Return Spring

8. Friction Plate

9. Nut

10. Starter Rope

11. Cap Screw

12. Starter Pulley

13. Cap Screw

3-19

3

3. Insert the rope through the hole in the roller and tie

a knot in the end; then wrap the rope counterclock-

wise around the roller leaving approximately 50

cm (20 in.) of rope free of the roller.

4. Apply low-temperature grease to the main spring

and hub.

5. Align the hook in the end of the main spring with

the notch in the roller.

6. Carefully slide the roller over the hub and engage

the spring with the roller.

7. Install the return spring making sure the end is

properly installed in the hole in the roller; then

install the pawl making sure the return spring is

properly preloaded.

B525

8. Slide the end of the rope through the rope guide of

the case; then tie a slip-knot in the rope.

9. Place the friction spring into position on the fric-

tion plate making sure the head of the spring is

opposite the flat of the inner hole. Apply a low-

temperature grease to the plate.

B524

10. Place the plate into position making sure the flat of

the inner hole is correctly positioned in the hub.

Apply blue Loctite #243 to the threads; then

secure the plate with a washer and nut. Tighten the

nut to 10 ft-lb.

B526

11. With 50 cm (20 in.) of rope exposed, hook the

rope in the notch of the roller.

12. Rotate the roller four or five turns counter-clock-

wise; then release the rope from the notch and

allow the rope to retract.

13. Pull the rope out two or three times to check for

correct tension.

„NOTE: Increasing the rotations in step 12 will
increase spring tension.

INSTALLING

1. Place the starter assembly into position against the

magneto case.

2. Secure the starter with cap screws. Tighten to 7 ft-

lb on the L/C models or to 8 ft-lb on the F/C mod-

els.

„NOTE: Before tightening the cap screws, slowly
pull the recoil rope until the pawl engages; then
tighten the cap screws. This will center the recoil
against the magneto case.

3. Thread the rope through the bushing in the con-

sole; then install the handle and secure with a knot.

Seat the cap.

4. Release the slip-knot in the rope.

Recoil Starter

(570/800/1000 cc)

REMOVING

1. Tie a slip-knot in the starter rope below the con-

sole and allow the rope to slowly retract against

the starter case.

2. Remove the knot at the handle, remove the handle,

and account for the handle cap; then thread the

rope through the bushing in the console.

3. Remove the bolts/cap screws securing the starter

assembly to the magneto case; then remove the

starter assembly.