Snowmobile Arctic Cat (2007 year). Manual - part 40

3-38

8. Remove the springs securing the exhaust pipe to

the exhaust manifold and the resonator to the

chassis; then remove the cable tie and unplug

the oxygen sensor and the oil pressure switch.

9. Remove the bolts securing the exhaust manifold

shield; then remove the shield.

AO279

„ NOTE: On the turbo models to allow room for the
heat shield to be removed, the water tank cap
screws must be removed.

AO371A

10. On the non-turbo models, remove the exhaust

manifold and account for the four copper nuts

and two cap screws.

AO268

AO269

„ NOTE: On the turbo models, the exhaust mani-
fold/turbocharger does not have to be removed.

11. Place an absorbent towel beneath the oil filter;

then using Oil Filter Wrench (p/n 0644-389),

remove the oil filter.

12. Remove the four cap screws securing the water

pump to the engine block, remove the pump

from the block and the inlet pipe, and account

for the O-ring.

AO270

AO278A

13. Inspect the O-ring surface of the engine block

and clean oil residue and dirt from the sealing

surfaces.

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3

14. With a new O-ring on the water pump and on

the inlet pipe, apply a small amount of Sealant

(p/n 1048-044) to the O-rings; then install the

water pump to the engine block. Tighten the cap

screws to 2.1 kg-m (15 ft-lb).

AO278A

15. On the non-turbo models, install the exhaust

manifold and secure with the four copper nuts

and two cap screws. Tighten to 2.4 kg-m (17 ft-

lb).

AO280

16. Install the exhaust manifold heat shield and

secure with the bolts. Tighten to 1.1 kg-m (8 ft-

lb).

AO279

17. Secure the exhaust pipe to exhaust manifold and

the resonator to the chassis with the springs;

then connect the oxygen sensor and the oil pres-

sure switch.

AO267

„ NOTE: At this point, assure that the coolant
drain plug is installed and tightened securely.

18. Place the alternator belt onto the pulleys and

tighten the belt to a deflection of 5-6 mm

(0.197-0.237 in.) new or 6-7 mm (0.237-0.275

in.) after break-in. Tighten the pivot cap screw

to 5.1 kg-m (37 ft-lb) and the adjustment cap

screw to 2.2 kg-m (16 ft-lb).

19. Install the engine belt cover with two cap screws

and one lock nut; then tighten securely.

20. Install the air silencer (see appropriate Servicing

Air Silencer in this section).

„ NOTE: Steps 21-23 are for turbo models. For
non-turbo models, proceed to  step 24.

21. Position the intercooler onto the mounting

brackets; then connect the intercooler hoses to

the turbo, to the throttle body, to the air bypass

valve, and to the pressure sensor hose. Tighten

all hose clamps securely.

22. With the two flange nuts, secure the intercooler

to the mounting brackets. Tighten securely.

AO360

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AO359

23. Connect the air bypass hose to the bypass valve

on the turbo. Secure with the two clamps.

AO377A

24. Fill the coolant system with engine coolant (see

appropriate Liquid Cooling System in this sec-

tion).

25. After the cooling system has been properly

filled, connect the negative battery cable and

start the engine; then inspect for any coolant

leaks.

Servicing Air Silencer

(1100 cc Z1)

„ NOTE: A number of servicing procedures for the
1100 cc Z1 engine-related items will require that
the air silencer be removed and installed. Pay
close attention to the 

„ NOTE: preceding a particu-

lar servicing procedure that will direct the techni-
cian to this sub-section for removing/installing the
air silencer.

REMOVING/INSPECTING/

CLEANING

1. Adjust the seat to the lowest position; then while

lifting on the top forward part of the seat,

remove the machine screw from the right side of

the seat support assembly. Remove the seat.

ZJ100A

2. Remove the two torx-head cap screws (A)

securing the console to the chassis; then lift up

the rearward end of the console and disconnect

the console harness plug-in. Remove the con-

sole.

741-744A

3. Remove the torx-head cap screws securing the

upper front/rear panels (A) and the handlebar

close-off panel (B) along with the body screws

securing the knee-pads to the steering support.

4. Remove the torx-head cap screws (D) securing

the upper front panel to the front bumper.

5. Remove the four cap screws securing the upper

bearing bracket to the upper support plate.

ZJ097A

6. Remove the four cap screws securing the sup-

port plate to the steering support.

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3

ZJ009A

7. Remove the six torx-head screws securing the

seat support assembly to the tunnel; then slide

the support back out of the way.

ZJ010A

8. Disconnect the fuel pump four-wire connector;

then slide the gas tank rearward enough to gain

access to the gasline hose connector.

ZJ011A

9. Compress the clip on the gasline hose connector

and remove the hose from the gas tank; then dis-

connect the vent hose and remove the gas tank.

ZJ012A

„ NOTE: After the gas tank vent hose has been
removed, it is advisable to plug the hose outlet of
the gas tank to avoid gas leakage.

10. Remove the two torx-head cap screws securing

the air silencer to the chassis; then loosen the

screws on the clamps securing intake boot to the

throttle bodies.

ZJ013A

11. Remove the breather hose from the air silencer.

ZJ096B

! CAUTION

The gasoline supply hose may be under pressure.
Place an absorbent towel around the connection to
absorb gasoline; then remove the hose slowly to
release the pressure.