Engine Servicing - 6000 - Arctic Cat ZR4000 Service Manual

Engine Servicing - 6000

This engine sub-section has been organized to show a
progression for servicing of the Arctic Cat 6000 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.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this engine
section.
Description
Ball Hone
Flywheel Spanner Wrench
Flywheel Puller
Flywheel Puller Insert
Extractor Nut (Medium)
Oil Seal Protector Tool
Piston Pin Puller
Surface Plate
Water Pump Bearing and Seal Tool Kit
V Blocks
Vacuum Test Pump
 NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Disassembling
NOTE: When disassembling top-side components,

mark MAG-side and PTO-side components for
assembling purposes.
1. Using the Flywheel Spanner Wrench to secure the
flywheel, remove the flywheel cap screw and
washer; then remove the cap screws securing the
recoil cup.
CWI-070
2. Install the Flywheel Puller Insert onto the end of the
crankshaft.
CWI-072
3. Using Flywheel Puller or suitable substitute, remove
the flywheel from the crankshaft by tightening the
puller bolt using an pneumatic gun. Account for the
key.
p/n
0644-294
To prevent damage to the crankshaft, do not thread
0144-007
puller bolts more than 1/2 in. into the flywheel. Damage
0744-040
to the stator may result.
0644-568
0643-074
NOTE: To ensure the cleanliness of the flywheel

0644-219
magnets, place the flywheel (with the magnets facing
0644-328
upward) on a clean bench.
0644-016
4. Remove the cap screw securing the ground wire to
0644-557
the crankcase.
0644-535
0644-131
5. Remove the screw (A) securing the stator lead wire
plate to the crankcase; then remove the screws (B)
securing the timing sensors and bracket, remove the
sensors, and account for the harness grommets.
CWI-074A
6. Remove the screws securing the stator to the stator
plate. Route the stator lead wire out of the crankcase;
then remove the stator assembly.
7. Remove the screws securing the stator plate to the
engine; then remove the plate.
CAUTION
73