Snowmobile Arctic Cat (2004 year). Instruction - part 9

 

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Snowmobile Arctic Cat (2004 year). Instruction - part 9

 

 

2-23

2

CYLINDER HEAD VOLUME SPECIFICATIONS

„

NOTE: For accurate reading when using the head installed volume method, subtract 2.44 cc from the total amount of fluid used (if using a BR9EYA

spark plug) or 2.20 cc (if using a BR9ES spark plug).

CRANKSHAFT RUNOUT SPECIFICATIONS

728-144A

„

NOTE: Measure in from the shaft end the specified amount when checking runout at points D-F. When checking runout in the center, place indicator

on center of bearing as shown at Point E. Maximum runout at any of the 3 measuring points is ±0.05 mm (0.002 in.).

ENGINE TYPE

SQUISH - GAP

HEAD INSTALLED VOLUME (cc)

FLAT PLATE VOLUME (cc)

370 cc

mm

2.27-2.95

in.

.089-.116

19.1-22.0

24.3-25.1

440 cc 

mm

1.39-1.87

in.

.055-.074

20.4-26.4

25.2

700 cc

“Laydown”

mm

1.5

in.

.059

30.5

34.5

570 cc

mm

1.3

in.

.051

27.01

28.8

550 cc

mm

1.41-1.94

in.

.056-.076

23.5-26.5

34.4-35.0

500 cc

mm

1.4

in.

.055

22.43

20.45

600 cc (STD)

mm

1.36

in.

.054

27.8

28.4

600 cc

“Laydown”

mm

1.5

in.

.059

25.0-27.6

29.7

800 cc

mm

1.58

in.

.062

34.6

38.3

900 cc

mm

1.36

in.

.054

34.1-38.0

39.9

! CAUTION

The above specifications are not intended to be used for engine modification. Reducing the head volume
to the smaller specification could cause piston detonation problems which is not a warranty situation.

Engine

Bore X

Stroke

A

B

C

G

Runout D, E, F Point

370 cc

mm

440 cc

(in.)

(± .002)

60 X 65

65 X 65

100 ± 0.15

(3.937 ± 0.006)

55 ± 0.15

(2.165 ± 0.006)

100

(3.937)

22

(0.866)

D

35

(1.377)

F

22

(0.866)

700 cc

mm

(in.)

(± .002)

79.7 X 70

119.7 ± 0.15

(4.712 ± 0.006)

64 ± 0.15

(2.519 ± 0.006)

118 ± 0.4

(4.645 ± 0.015)

30

(1.181)

D

5

(0.196)

F

5

(0.196)

550 cc

mm

(in.)

(± .002)

73.4 X 65

112.5 ± 0.15

(4.409 ± 0.006)

60 ± 0.15

(2.362 ± 0.006)

106 ± 0.4

(4.174)

27

(1.062)

D

30

(1.181)

F

5

(0.197)

mm

500 cc

   (in.)

(± .002)

71 X 63

114.7 ± 0.15

(4.515 ± 0.006)

66.5 ± 0.15

(2.618 ± 0.006)

106 ± 0.4

(4.465 ± 0.015)

27

(1.062)

D

5

(0.196)

F

5

(0.197)

mm

600 cc (STD)

(in.)

(± .002)

78 X 62.7

114 ± 0.15

(4.88 ± 0.006)

66.5 ± 0.15

(2.62 ± 0.006)

105.8-106

(4.165-4.173)

30

(1.2)

D

30

(1.181)

F

5

(0.197)

600 cc (“Laydown”)

mm

(in.)

(± .002)

73.8 X 70

119.7 ± 0.15

(4.712 ± 0.006)

64 ± 0.15

(2.519 ± 0.006)

118 ± 0.4

(4.645 ± 0.015)

30

(1.181)

D

5

(0.196)

F

5

(0.196)

570 cc

mm

(in.)

(± .002)

73.8 X 66

119 ± 0.15

(4.70 ± 0.006)

62.3 ± 0.15

(2.45 ± 0.006)

109.7

(4.320)

24

(0.945)

D

30

(1.181)

F

15

(0.590)

800 cc 

mm

(in.)

(± .002)

81 X 76

125.5 ± 0.15

(4.94 ± 0.006)

68 ± 0.15

(2.68 ± 0.006)

123 + 0-0.4

(4.84 + 0-0.015)

30

(1.2)

D

30

(1.181)

F

15

(0.590)

900 cc

mm

(in.)

(± .002)

85 X 76

125.5 ± 0.15

(4.94 ± 0.006)

68 ± 0.15

(2.68 ± 0.006)

123 + 0-0.4

(4.84 + 0-0.015)

30

(1.2)

D

30

(1.181)

F

15

(0.590)

2-24

Engine

This engine servicing section has been organized into
sub-sections which show a progression for the com-
plete servicing of the Arctic Cat engine. For consis-
tency purposes, this section shows a complete and
thorough progression; however, for efficiency it may
be preferable to remove the engine as a complete
assembly, to remove and disassemble only those com-
ponents which need to be addressed, and to service
only those components. 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.

Removing Engine

Table of Contents

Twin F/C Models.................................................... 2-24
600 STD/800/900 cc Models................................. 2-26
550 cc Model......................................................... 2-28
500/600/700 cc “Laydown” Engine Models ........... 2-29

Removing Engine

(Twin F/C Models)

„

NOTE: If equipped with electric start, disconnect

the battery.

1. Turn the gas tank shut-off valve to the CLOSED

position.

2. Open the belt guard.

3. Remove the drive belt; then remove the plug from

the belly pan.

„

NOTE: Before installing the clutch puller, apply

oil to the threads of the puller and a small amount
of grease to the tip of the puller.

4. Remove the bolt and lock washers securing the

drive clutch to the crankshaft; then using the Drive
Clutch Puller (p/n 0644-207) and an impact
wrench or a breaker bar and Drive Clutch Spanner
Wrench (p/n 0644-136), tighten the puller. If the
drive clutch will not release, sharply strike the
head of the puller with a hammer. Repeat this
procedure until the clutch releases.

AF472D

AF476D

5. Remove the clutch from the engine compartment.

6. Remove the cap screw and washer securing the

driven pulley; then slide the pulley off the driven
shaft. Account for and note the position of any
alignment washers.

„

NOTE: If the driven pulley will not slide off the

driven shaft, use the Driven Pulley Puller (p/n
0744-023) for removal.

SC013D

7. Remove the torque bumper. Account for any

engine mount shims.

2-25

2

AF473D

8. Remove the springs securing the expansion

chamber to the exhaust manifold and resonator;
then remove expansion chamber.

AC067

9. Remove the cap screws and lock washers securing

the recoil starter; then remove the starter. Leave it
in the engine compartment.

AB082

10. Disconnect the four-prong main wiring harness

connector and the CDI unit wiring harness.

11. Disconnect the impulse hose from the crankcase.

12. Disconnect the spark plug caps.

13. Loosen the carburetor flange clamp(s). Remove

the carburetor(s) from the intake flange(s) and
carburetor boot(s). Place the carburetor(s) to the
side in an upright position.

„

NOTE: If equipped with electric start, remove the

lock nuts and washers securing the starter motor
to the engine mounting bracket and remove the
starter motor.

14. Disconnect the oil-injection cable from the oil-

injection pump. Account for the E-clip and
washer; then disconnect the oil supply hose from
the pump and plug the hose to prevent leakage.

AB081

„

NOTE: If equipped with electric start, remove the

two lock nuts and washers securing the starter
motor bracket; then remove the three remaining
cap screws, washers, and lock washers securing
the star ter motor bracket and ground cable .
Remove the starter motor bracket.

15. Remove the cap screws securing the engine to the

front end. Account for washers, cap screws, and
lock nuts.

AL201D

16. Lift the engine out of the engine compartment.

17. Remove the cap screws, washers, and lock

washers securing the engine mounting brackets to
the engine; then remove the brackets.

2-26

Removing Engine

(600 (STD)/800/900 cc Models)

„

NOTE: If applicable, disconnect the battery

cables.

1. Remove all springs securing the expansion

chamber(s) and remove the expansion chamber(s)
from the engine compartment.

2. Open the belt guard; then remove the drive belt.

3. Remove the plug from the belly pan. Using a ½-in.

12-point socket, remove the cap screw and lock
washer securing the drive clutch to the crankshaft. 

4. Using Clutch Puller (p/n 0644-207) and an impact

wrench or a breaker bar and Spanner Wrench (p/n
0644-136), tighten the puller. If the drive clutch
will not release, sharply strike the head of the
puller. Repeat this step until the clutch releases.
Remove the drive clutch. If applicable, account for
the two sleeves.

AN380D

5. Remove the cap screw and washer securing the

driven pulley; then slide the driven pulley off the
driven shaft. Account for a key, stub shaft, and
alignment washers.

AF120D

„

NOTE: If the driven pulley is tight on the driven

shaft, pull the driven pulley off using the Driven
Pulley Puller (p/n 0744-023).

6. Remove the two cap screws securing the

servomotor cover.

AP116A

7. Using a small screwdriver, pry off the cable

retaining cover.

AP117A

8. Rotate the servomotor actuator counterclockwise

to loosen the cable; then pull the cable housings
out of the holder.

AP118A

9. Pull the cable up and out of the cable housing

holder; then slide each cable drum to the left and
out of the servomotor actuator.

 

 

 

 

 

 

 

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