Snowmobile Arctic Cat (2007 year). Manual - part 27

2-93

2

ZJ093

„ NOTE: The intake flanges are directional.

50. Install the starter motor; then secure with the cap

screw. Tighten to specifications.

ZJ028C

51. Install the coolant hoses onto the proper inlets/

outlets of the engine; then install the oil hoses/

oil reservoir onto the proper inlets/outlets.

Secure with clamps.

52. Install the exhaust manifold; then using the

torque pattern shown, secure the manifold with

the six flange nuts. Tighten to specifications.

741-586A

Installing Engine

(120 cc)

1. Place the engine assembly into position in the

engine compartment.

2. On the left-hand side of the engine, install the

three cap screws (coated with blue Loctite #243)

securing the engine and brake bracket to the

front end. DO NOT TIGHTEN AT THIS TIME.

A050A

3. Align the engine with the scribed line made dur-

ing removing; then measure the distance

between the crankshaft and the driveshaft.

Adjust the engine position as necessary.

4. Tighten the three left-hand side mounting cap

screws (from step 2) to specifications.

5. Lay the snowmobile on its side and install the

four lower engine mounting cap screws with

washers and lock nuts. Tighten to specifications.

6. Install the four mounting cap screw plugs in the

belly pan; then place the snowmobile in the

upright position.

7. Thread the recoil starter rope through the bush-

ing in the console and the handle; then tie a knot

at the end of the rope and pull the handle up and

onto the knot.

8. Untie the slip-knot at the starter case and allow

it to slowly rewind into the case.

9. Connect the fuel hose to the carburetor; then

turn the gas tank shut-off valve to the OPEN

position.

10. Connect the engine wiring harness to the main

wiring harness; then secure the wiring harnesses

with a cable tie.

2-94

11. Install the tie rods on the steering post; then

secure with lock nuts (threads coated with green

Loctite #609) and washers. Tighten to 2.5-2.8

kg-m (18-20 ft-lb).

12. Place the steering post in position in the lower

steering post bearing and on the steering post

support.

A025

13. Place the upper steering post bearing into posi-

tion on the steering post and support; then

secure with the bearing retainer, cap screws, and

lock nuts.

A023A

14. Position the choke and throttle cables in the

bracket; then connect them to the carburetor.

A046A

15. Tighten the adjustment jam nuts securely.

„ NOTE: At this point, install the drive chain (see
Drive Chain and Sprockets sub-section in
Section 8).

Installing Engine        

(660 cc)

1. Install the oil pan drain plug to the oil pan and

tighten to specifications and place the access

plug into the drain hole in the belly pan.

2. Using an appropriate hoist, carefully lower the

engine into the engine compartment. 

„ NOTE: Engine lift points consist of a bracket on
the front right side of the exhaust manifold and an
integral eye of the alternator adjustment bracket. 

„ NOTE: It may be necessary to screw the engine
torque bumper in to allow the engine mounts to
line up properly. 

3. Connect the recirculation hose to the main feed

coolant hose; then secure the hose with a clamp.

AO187

4. With the clamps in place on the main coolant

hose, connect the hose to the outlet at the under-

side of the exhaust manifold.

5.  Secure with the hose clamp.

AO187

2-95

2

6. With the clamps in place on the hose, connect

the overflow tank hose to the filler cap housing.

AO182

7. With the engine mounts in place, first secure the

two front and then the two rear engine mount

cap screws (coated with blue Loctite #243).

Tighten the front mounts to specifications and

the rear mounts to specifications.

„ NOTE: At this point if the torque bumper was
turned in, return it to the original position.

AO190

MD1698

8. Connect the starter solenoid and the starter

motor cable. 

MD1700

9. Install the starter to the engine and secure with

the two cap screws. Tighten to specifications.

MD1437

„ NOTE: On the Bearcat W/T models after install-
ing the starter, connect the coolant hose from the
filler neck housing to the heat exchanger.

AO182

10. On the non-turbo models with the alignment

washers in place on the driven shaft, install the

key in the driven shaft keyway; then place the

stub shaft into the driven pulley. Place the

driven pulley on the shaft. Align its keyway

with the driven shaft keyway.

„ NOTE: A small amount of Anti-Seize Thread
Compound (p/n 0678-146) applied to the driven
shaft will aid in future driven pulley removal.

2-96

„ NOTE: On the Bearcat W/T models to install the
driven pulley, the sheaves must be open to allow
the driven pulley to fit between the shaft and the
belly pan. Use the drive belt to hold the sheaves
open; then secure the belly pan to the footrest
bracket.

11. On turbo models, slide the driven pulley onto

the driven shaft making sure alignment washers

are properly positioned.

12. Secure the driven pulley by installing any align-

ment washers, the washer, and cap screw

(coated with blue Loctite #243). Tighten the cap

screw to specifications.

MD1707

AO372

13. Install any spacers as accounted for in remov-

ing; then insert the drive clutch bolt with lock

washer.

„ NOTE: Be sure to wipe the clutch taper and
crankshaft taper clean of any oil film or dirt before
installing the drive clutch.

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

shaft. Using a 12-point 1/2-in. socket and the

drive clutch spanner wrench, tighten the clutch

bolt to specifications.

 

MD2485

15. Install the drive clutch plug to the left side of the

belly pan.

16. On the non-turbo models, install the drive belt.

MD1732

17. On turbo models, install the drive belt using the

following procedure:

A. With the O-ring and shim washers removed,

carefully thread the sheave adjuster back into

the driven pulley; then tighten the adjuster

with the deflection tool until it bottoms

against the driven shaft.

! CAUTION

When installing the drive clutch, do not tighten the
clutch bolt with any kind of impact tool. Tighten
clutch bolt using a hand torque wrench only. Failure
to do so could result in stationary sheave damage.