Snowmobile Arctic Cat (2007 year). Instruction - part 18

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 18

 

 

2-57

2

Servicing Components 

(660 cc/1100 cc Z1)

„ NOTE: Critical engine specifications are located
at the beginning of this section.

Thoroughly clean all non-electrical components in

parts-cleaning solvent; then remove any carbon

buildup from the cylinder head and piston dome.

Visually inspect all engine components for wear or

damage.

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary. 

PISTON ASSEMBLY

„ NOTE: Oversized pistons are available allowing
the cylinder to be bored oversized.

„ NOTE: Whenever a piston, rings, or pins are out
of tolerance, they must be replaced.

Cleaning/Inspecting Piston

1. Using a non-metallic carbon removal tool,

remove any carbon buildup from the dome of

the piston.

2. Inspect the piston for cracks in the piston pin,

dome, and skirt areas.

3. Inspect the piston for seizure marks or scuffing. 

„ NOTE: If seizure marks or scuffing is detected,
the piston must be replaced.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby” indi-

cates worn piston rings or an out-of-round cylin-

der.

Removing Piston Rings

1. Starting with the top ring, slide one end of the

ring out of the ring-groove.

2. Remove each ring by working it toward the

dome of the piston while rotating it out of the

groove.

„ NOTE: If the existing rings will not be replaced
with new ones, note the location of each ring for
proper installation. When installing new rings,
install as a complete set only.

Cleaning/Inspecting Piston Rings

Using a ring-groove cleaning tool, clean carbon

from the ring-grooves. Be sure to position the ring

with its tapered side up.

Measuring Piston-Ring End Gap 

(Installed)

1. Place each piston ring in the wear portion of the

cylinder. Use the piston to position each ring

squarely in the cylinder.

„ NOTE: Remove any carbon; then clean the top of
the cylinder bore before inserting the piston rings.

2. Using a feeler gauge, measure each piston-ring

end gap. Acceptable ring end gap must be

within specifications.

0738-531

Piston Ring/Groove Clearance

„ NOTE: Before checking, piston grooves must be
clean, dry, and free of carbon. 

Fit new piston ring into piston groove and measure

clearance between ring and ringland by using feeler

gauge. Measurement must be within specifications.

If clearance is out of specification, replace piston.

! CAUTION

Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or dam-
age to the sealing surfaces may result.

! CAUTION

Improper cleaning of the ring-grooves by the use of
the wrong type of ring-groove cleaner will result in
severe damage to the piston.

2-58

0738-532

Measuring Piston Skirt/
Cylinder Clearance

1. Measure the cylinder front to back in six places

using a cylinder bore gauge. The amount of

wear is the difference between the largest and

smallest readings. Measurement must be within

specifications. If the determined wear exceeds

the limit indicated, replace the cylinder block.

2. Measure the corresponding piston diameter at a

point 19 mm (0.75 in.) for the 660 cc or 10 mm

(0.4 in.) for the 1100 cc Z1 from the piston skirt

end at a right angle to the piston-pin bore. Piston

diameter must be within specifications.

GEN-0033

3. Piston skirt to cylinder clearance must be within

specifications.

Measuring Piston Pin Bore 
Diameter

1. Insert an inside dial indicator into the piston-pin

bore. The diameter must be within specifica-

tions. Take two measurements to ensure accu-

racy.

2. Piston pin bore must be within specifications.

ATV-1069

Installing Piston Rings (660 cc)

1. Install a thin oil ring, oil ring expander, and thin

oil ring in the bottom groove of the piston.

MD1668B

2. Stagger the end gaps of the upper and lower thin

oil rings until they are on directly opposite sides

of the piston.

3. Install the compression rings so the letter on the

top surface of each ring faces the dome of the

piston. Rotate the rings until the ring end gaps

are no less than 90° from one another.

ATV-1024

! CAUTION

Incorrect installation of the piston rings will result in
engine damage.

2-59

2

Installing Piston Rings 
(1100 cc Z1)

1. Install a thin oil ring, oil ring expander, and thin

oil ring in the bottom groove of the piston. Stag-

ger the end gaps of the upper and lower thin oil

rings until they are on directly opposite sides of

the piston.

741-619A

2. Install the #2 compression ring so the letters on

the top surface of the ring face the dome of the

piston.

3. Install the #1 compression L-ring into the top

groove with the face of the ring directed

upward. 

4. Rotate the rings until the ring end gaps are no

less than 90° from one another.

Measuring Piston Pin Diameter

1. Measure the piston pin diameter at each end and

in the center. Measurement must be within spec-

ifications. If measurement is less than minimum

specifications, the piston pin must be replaced.

2. Piston pin diameter must be within specifica-

tions.

ATV-1070

MEASURING CONNECTING ROD 
SMALL END BORE INSIDE 
DIAMETER 

1. Using a small bore gauge, measure the connect-

ing rod small end bore inside diameter.

2. Measurement must be within specifications.

AO344A

ZJ057A

„ NOTE: Check piston pin, connecting rod small
end bore, and piston bore for wear or damage pay-
ing particular attention to condition of small end
bore bushing. If pin, connecting rod small end
bore, or piston bore is badly worn or damaged,
replace pin, connecting rod, or piston.

! CAUTION

Incorrect installation of the piston rings will result in
engine damage.

2-60

Cleaning/Inspecting/Measuring 
Cylinder Block

1. Wash the cylinder block in parts-cleaning sol-

vent.

2. Check the gasket surface of the cylinder for dis-

tortion. 

3. Using a straightedge and feeler gauge, check

surface at a total of 6 locations. If distortion

limit is exceeded, machining of the block will be

necessary.

AO349A

ZJ056A

4. Inspect the cylinder bore for minor scoring or

scuffing. If marks are found, repair the surface

using an appropriate hone and honing oil. 

5. Hone the cylinder to produce a 45°-60° cross-

hatch.

AO347A

ZJ059A

6. Wash the cylinder block thoroughly with hot

soapy water; then rinse with hot water.

7. Blow dry the cylinder block with compressed air

and apply oil to all of the cylinder surfaces.

8. If any measurement exceeds the limit, the cylin-

der block must be replaced.

PISTON SELECTION (660 cc)

„ NOTE: Two sizes of pistons are available as
standard size spare parts to ensure proper piston-
to-cylinder clearance. When installing a standard
size piston, make sure to match piston with cylin-
der using the following procedure.

1. Each piston has stamped number 1 or 2 as

shown. It represents outer diameter of piston.

738-533A

2. There are paints on the cylinder block. The color

(red or blue) of each paint represents cylinder

bore diameter. The first paint from crank pulley

side represents inner diameter of No. 1 cylinder,

the second paint of No. 2 cylinder, and the third

paint of No. 3 cylinder.

3. Stamped number on piston and paint on cylinder

block should correspond.

 

 

 

 

 

 

 

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