Snowmobile Arctic Cat (2007 year). Instruction - part 14

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 14

 

 

2-41

2

„ NOTE: Care should be taken not to tip the cylin-
der head upside down or the shim buckets and
shims will fall out.

MD1530

„ NOTE: Because the connecting rods and con-
necting rod caps are unique, it is recommended
that the technician mark them and keep all associ-
ated parts together for assembling purposes.

AO211

34. Remove the two connecting rod cap nuts from

one of the connecting rods; then remove the

connecting rod cap. Account for two connecting

rod bearings.

MD1542

35. Push the piston/connecting rod assembly out

through the top of the cylinder bore. Repeat for

the remaining two piston/connecting rod assem-

blies.

MD1539

36. For assembling purposes, take note that the

arrow on each piston points toward the timing

cover side of the engine; then number the dome

of each piston starting from the timing cover

side. Remove the timing cover side circlip from

each piston.

37. Using Piston Pin Puller (p/n 0644-328), remove

the piston pin from each piston. 

38. Remove  the  inner  and  outer  cap screws secur-

ing the lower crankcase half to the upper crank-

case half; then separate the crankcase halves.

Account for four dowel pins, eight crankshaft

bearings, and two thrust washer halves.

MD1549

39. Remove the crankshaft. Account for the remain-

ing crankshaft bearings.

! CAUTION

Install two lengths of gasline hose approximately
12.7 cm (5 in.) long onto the connecting rod studs to
avoid damaging the crankshaft journals and cylinder
walls.

2-42

Disassembling Engine 

(1100 cc Z1)

 

1. With the engine secured to a suitable engine

stand, remove the coolant drain plug allowing

the remaining coolant to drain from the engine.

ZJ028A

2. Remove the remaining coolant hoses; then

remove the hoses connecting the oil reservoir to

the engine.

„ NOTE: For assembling purposes, note the loca-
tion of the oil and coolant hoses.

 3.  Remove the six flange nuts securing the exhaust

manifold to the cylinder head; then remove the

manifold and account for the gaskets.

ZJ048A

4. Remove the two cap screws (A) securing the

water inlet hose fitting and remove the fitting;

then remove the cap screws (B) securing the

starter motor to the engine. Remove the starter

motor.

ZJ028B

5. Remove the cap screws securing the two intake

flanges to the cylinder head; then remove the

flanges.

ZJ029A

6. Remove the three cap screws securing the ther-

mostat cap to the engine; then remove the cap

and thermostat and account for the harness

bracket from the lower cap screw.

ZJ030A

„ NOTE: Note the position of the thermostat
bypass/check valve for assembling purposes.

„ NOTE: If engine case cleaning is necessary,
remove the coolant and oil sensors from the
engine case.

2-43

2

ZJ031A

7. Remove the eighteen cap screws securing the

magneto cover to the engine; then remove the

cover and account for the starter idler gears,

idler pins, spacers, dowel pins, and the oil pump

seal.

ZJ032A

„ NOTE: Care must be taken when removing the
magneto cover not to tip the cover downward. Tip-
ping the cover downward will allow the starter
torque limiter/idler gear assembly to slide out of
the cover.

8. Remove the four cap screws securing the oil

scavenge pump to the engine; then remove the

pump and account for the remaining oil seal.

ZJ033A

9. To remove the flywheel, first remove the cap

screw securing the flywheel to the crankshaft;

then using Flywheel Puller (p/n 0644-480),

remove the flywheel.

ZJ034

10. Remove the flywheel key from the crankshaft;

then remove the starter gear.

ZJ036A

11. Remove the cap screws securing the two cylin-

der ignition coils to the cylinder head cover;

then remove the coils.

ZJ049A

12. Remove the four cap screws securing the cylin-

der head cover to the cylinder head; then remove

the cover.

„ NOTE: If cleaning or replacing the cylinder head
cover is necesssary, the crankshaft position sen-
sor must be removed.

2-44

ZJ037A

13. Obtain top-dead-center by rotating the crank-

shaft until the arrows on the intake camshaft

face (A) are in the 12 o’clock and 9 o’clock

positions and the arrows on the exhaust cam-

shaft face (B) are in the 12 o’clock and 3 o’clock

positions.

741-593A

14. Remove the tension adjuster bolt and washer

(A) from the chain tensioner assembly; then

remove the two cap screws (B) securing the

assembly to the engine. Remove the assembly

and account for the spring and ball.

ZJ038A

15. Remove the cap screws securing the camshaft

covers to the cylinder head; then with the covers

removed, remove the timing chain from the

camshaft sprockets. Remove the camshafts from

the cylinder head.

ZJ039A

16. Using a magnet, carefully remove the tappets

from the cylinder head.

ZJ050

„ NOTE: For assembling purposes when removing
the tappets, note the location of the tappet, the
valve from which the tappet was removed, and the
shim number (A) of the tappet.

ZJ051A

17. Remove the six nuts and two cap screws (A)

from outside the cylinder head; then remove the

six cap screws (B) from inside the cylinder

head. Remove the head and account the gasket

and two dowel pins.

 

 

 

 

 

 

 

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