REMOVING
Engine-Related Items
1. Tie a slip-knot in the starter rope below the console and allow the rope to slowly retract against the starter case.
NOTE: Whenever a part is worn excessively,
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.
cracked, or damaged in any way, replacement is necessary.
SPECIAL TOOLS
A number of special tools must be available to the technician when servicing the engine-related items. NOTE: When indicated for use, each special tool
will be identified by its specific name, as shown in the chart below, and capitalized. Description
p/n
Blind-Hole Bearing Puller
0644-500
Coolant Cap
0644-156
Drive Clutch Spanner Wrench
0644-136
Valve and Spring Retainer Tool
0644-448
Fan Spanner Wrench
0644-340
Water Pump Bearing and Seal Tool Kit
0644-557
Oil Seal Protector Tool
0644-219
Engine Leak-Down Test Kit
0644-522
Vacuum Test Pump
0644-131
Hood Harness Extension
1686-659
Hood Harness Extension
1686-660
Oil Filter Wrench
0644-551
NOTE: Special tools are available from the Arctic Cat Service Parts Department.
3. Remove the cap screws (A) securing the starter assembly to the magneto case; then remove the starter assembly. DISASSEMBLING
! WARNING Always wear safety glasses and gloves when servicing the recoil starter.
1. Secure the recoil starter in a vise.
! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury.
2. Rotate the roller (B) 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.
! WARNING Care must be taken when allowing the recoil roller to unwind. Make sure all spring tension is released before continuing.
3. While exerting downward pressure on the friction plate (C), remove the cap screw (D).
Pressure Testing Engine
4. Slowly release the friction plate and lift the plate with pawl activator (E) free of the recoil roller; then remove the pawl activator from the friction plate.
NOTE: To pressure test the engine, use Engine
5. Remove the pawl (F) and the return spring (G); then remove the friction plate spring (H).
Leak-Down Test Kit.
Recoil Starter
6. Carefully lift the roller free of the case making sure the main spring (I) does not disengage from the case. Account for the bushing.
! WARNING KEY A. Cap Screw B. Roller C. Friction Plate D. Cap Screw E. Pawl Activator F. Pawl G. Return Spring H. Friction Plate Spring I. Main Spring
743-711A
Care must be taken when lifting the roller free of the case.
7. 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.
8. Unwind the rope from the roller, untie the slip-knot, and remove the rope. CLEANING AND INSPECTING
1. Clean all recoil starter components. 38
