Engine Servicing - 8000 - Arctic Cat ZR4000 Service Manual

Engine Servicing - 8000

This engine sub-section has been organized to show a
progression for servicing of the Arctic Cat 8000 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 three starter clutch cap
screws and remove the clutch.
CM138
CM139
2. Install the Flywheel Puller Insert onto the end of the
crankshaft.
p/n
0644-294
0144-007
0744-040
0644-568
0643-074
0644-219
0644-328
0644-016
0644-557
0644-535
IO013
0644-131
3. Using Flywheel Puller or suitable substitute, remove
the flywheel from the crankshaft by tightening the
puller bolt, striking the head of the puller bolt with a
hammer, and tightening again. Repeat this procedure
until the flywheel is free. Account for the key.
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.
CM140
NOTE: To ensure the cleanliness of the flywheel

magnets, place the flywheel (with the magnets facing
upward) on a clean bench.
4. Remove the cap screw securing the ground wire to
the crankcase.
CAUTION
87