Snowmobile Arctic Cat (2007 year). Instruction - part 19

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 19

 

 

2-61

2

AO345

CRANKSHAFT RUNOUT

1. Support the crankshaft using a set of V blocks;

use a dial indicator to read crankshaft runout.

„ NOTE: On the 660 cc, the contact point of the
dial indicator should be on the center of each
crankshaft journal. 

AO348

„ NOTE: On the 1100 cc Z1, the contact point of
the dial indicator should be on either side of the oil
port hole of the center crankshaft journal and to
the outside of the oil port hole on the Mag and PTO
end of the crankshaft.

ZJ058A

2. Rotate the crankshaft slowly.

3. The reading must be within specifications or

crankshaft repairing/replacing will be necessary.

MEASURING CONNECTING ROD 
BIG END SIDE CLEARANCE

1. Check big end of connecting rod for side clear-

ance with rod fitted and connected to its crank

pin in the normal manner. 

2. Clearance measurement must be within specifi-

cations.

0738-541

ZJ111C

3. If measured clearance is found to exceed its

limit, replace connecting rod.

Piston

Cylinder

Number 

at the 

top 

(mark)

Outer Diameter

Color 

(paint)

Bore Diameter

1

67.98-67.99 mm

(2.6764-2.6768 

in.)

Red

68.01-68.02 mm

(2.6776-2.6780 

in.)

2

67.97-67.98 mm

(2.6760-2.6764 

in.)

Blue

68.00-68.01 mm

(2.6772-2.6776 

in.)

660 cc

2-62

MEASURING CRANKSHAFT 
JOURNALS (Bearing Surfaces)

1. Using a micrometer, measure each journal from

along its length and 180° from the first measure-

ment. Measurement must not exceed specifica-

tions. 

2. If any journal is badly damaged or has wear that

exceeds the specifications, the crankshaft must

be replaced.

0738-539

ZJ062A

MEASURING CRANKSHAFT 

THRUST PLAY

1. Using a dial indicator, measure the amount of

thrust play in the crankshaft. Measurement must

not exceed specifications.

2. If the limit exceeds the specifications, the thrust

bearing must be replaced by a standard size (or

oversized on the 660 cc) to obtain the proper

thrust play. 

0738-540

MAIN BEARINGS

1. Check the main bearings for signs of pitting,

scratches, wear, or damage. If any of these con-

ditions are found, the bearings must be replaced.

„ NOTE: Always replace the bearings as a set;
never replace one side only or severe engine dam-
age will occur.

MAIN BEARING SELECTION

(660 cc)

„ NOTE: This information is needed only if the
crankshaft or the engine block has been replaced
or if the bearings are out of specification.

1. Locate the four numbers on the PTO-side of the

engine block on the oil pan sealing surface.

AO350A

2. Locate the four numbers on the crankshaft coun-

terweight.

660 cc

2-63

2

AO351A

3. Using the chart below, select the proper main

bearing set.

„ NOTE: Bearing journal #3 is different from bear-
ing journals #1, #2, and #4.

„ NOTE: There is no bearing selection for the con-
necting rod big end. Only one bearing set is avail-
able. 

CONNECTING ROD/MAIN BEARING 

SELECTION (1100 cc Z1)

„ NOTE: This information is needed only if the
crankshaft or the engine cases have been replaced
or if the bearings are out of specification.

Bearing Selection Charts

To select the correct main or balancer shaft bearing

insert, read the letter stamped for the bearing loca-

tion on the crankcase; then read the letter stamped

on the crankshaft or balancer shaft corresponding to

the same bearing location.

„ NOTE: The corresponding letters on the crank-
case are located to the upper-left of the oil filter.

ZJ181A

Crankcase Stamping

Crankshaft Stamping

Balancer Shaft Journal Stamping

Refer to the proper chart and select the correct bear-

ing.

Main Bearing Selection

Main

Bearing

Selection

Crankshaft Code

1

2

3

Engine

Case
Code

1

Brown

Green

Black

2

Green

Black

No Color

3

Black

No Color

Yellow

Right Front 

Balancer

(A or B)

Center Front

Balancer

(A or B)

Left Front

Balancer

(A or B)

Right Main

(A or B)

Center Main

(A or B)

Left Main

(A or B)

Right Rear 

Balancer

(A or B)

Center Rear

Balancer

(A or B)

Left Rear

Balancer

(A or B)

Left Rod Journal

(1, 2, or 3)

Right Rod Journal

(1, 2, or 3)

Left Main Journal

(A or B)

Center Main Journal

(A or B)

Right Main Journal

(A or B)

L

Left Journal

(A or B)

Center Journal

(A or B)

Right Journal

(A or B)

R

Crankcase Mark

Crankshaft Mark

A

B

A

Green

p/n 3007-121

Black

p/n 3007-122

B

Black

p/n 3007-122

Brown

p/n 3007-123

2-64

Balancer Shaft Bearing Selection

To select the correct rod bearing insert, read the

number stamped on the crankshaft counterweight;

then read the number stamped on the connecting rod

cap. Refer to the following chart to select the correct

bearing.

Connecting Rod Bearing Selection

To select the correct thrust bearing for proper crank-

shaft and clearance, use the following procedure.

1. Install the main bearing upper half inserts in the

crankcase; then place the crankshaft into posi-

tion.

2. Select a thrust bearing (blue or green) and install

making sure the oil relief (A) is directed toward

the crankshaft.

ZJ074A

„ NOTE: Always install a green-marked thrust
bearing on mag-side; then use proper bearing
from the following chart on the PTO-side of the
main bearing journal to obtain clearance.

Thrust Bearing Selection

3. Using a feeler gauge, measure between the

crankcase and crankshaft on the side opposite

the thrust bearing.

ZJ111A

4. Use the reading obtained to select the correct

thrust bearing from the chart.

5. Install the selected thrust bearing; then using a

feeler gauge, check that the clearance is as spec-

ified.

Assembling Engine

(120 cc)

„ NOTE: The use of new gaskets and seals is rec-
ommended when assembling the engine.

„ NOTE: When the use of a lubrication is indi-
cated, use a lightweight engine oil.

Crankcase Mark

Balancer Mark

A

B

A

Green

p/n 3007-135

Black

p/n 3007-136

B

Black

p/n 3007-136

Brown

p/n 3007-137

Rod

Crankshaft

1

2

3

1

Green

p/n 3007-109

Black

p/n 3007-110

Brown

p/n 3007-111

2

Black

p/n 3007-110

Brown

p/n 3007-111

Yellow

p/n 3007-112

Feeler Gauge Reading

Color

2.560-2.585 mm (0.100-0.102 in.)

White

2.535-2.560 mm (0.099-0.100 in.)

Yellow

2.510-2.535 mm (0.098-0.099 in.)

Green

2.485-2.510 mm (0.097-0.098 in.)

Blue

2.460-2.485 mm (0.096-0.097 in.)

Black

2.430-2.460 mm (0.095-0.096 in.)

Red

1. Secure the oil level sensor plate to the crankcase

with the cap screws.

 

 

 

 

 

 

 

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