Arctic Cat M 8000, Service Manual

Page: 59 / 210

58
Engine Servicing - 4000
This engine sub-section has been organized to show a
progression for servicing of the Arctic Cat 4000 engine.
For consistency purposes, this sub-section shows a com-
plete and thorough progression; however, for efficiency it
may be preferable to disassemble only those components
needing to be addressed. Also, some components may
vary from model to model. The technician should use
discretion and sound judgment.

NOTE: Some illustrations and photographs used in
this section are used for clarity purposes only and are
not designed to depict actual conditions.

NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this engine
section.
 NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Disassembling
1. Remove the exhaust manifold from the engine.
Account for flange nuts and gaskets; then remove the
clamp securing the coolant supply hose from the cyl-
inder head to the water pump. Remove the hose from
the engine.
2. Using the Flywheel Spanner Wrench to secure the
flywheel, remove the flywheel cap screw and flat
washer; then remove the three starter pulley cap
screws and remove the pulley.
FC014
3. Install Flywheel Puller Insert onto the end of the
crankshaft; then using Flywheel Puller, remove the
flywheel from the crankshaft by tightening the puller
bolt, striking the head of the puller bolt with a ham-
mer, and tightening again. Repeat this procedure
until the flywheel is free. Account for the key.
FC016
CM013

NOTE: To ensure the cleanliness of the flywheel
magnets, place the flywheel (with the magnets facing
upward) on a clean bench.
4. Remove the ignition timing sensor and clamp.
Description p/n
Ball Hone 0644-292
Flywheel Spanner Wrench 0144-007
Flywheel Puller 0744-040
Flywheel Puller Insert 0644-179
Oil Seal Protector Tool 0644-219
Piston Pin Puller 0644-328
Surface Plate 0644-016
Water Pump Bearing and Seal Tool Kit 0644-557
Vacuum Test Pump 0644-131
V Blocks 0644-535
CAUTION
To prevent damage to the crankshaft, do not thread
puller bolts more than 1/2 in. into the flywheel. Damage
to the coils may result.