Snowmobile Arctic Cat (2007 year). Instruction - part 21

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 21

 

 

2-69

2

GF314D

A002

26. Secure the air cleaner end cap to the air cleaner

housing with the wing nut.

Assembling Engine    

(660 cc)

 

„ NOTE: During assembling, Plastigauge is used
to determine proper oil clearances. 

„ NOTE: Arctic Cat recommends that new gaskets,
seals, and O-rings be installed whenever assem-
bling the engine.

1. With the upper crankcase half upside down on

the workbench, install the four upper crankcase-

to-lower crankcase dowel pins; then clean the

bearing surfaces and install the dry bearings into

the upper and lower crankcase halves.

„ NOTE: Make sure the tabs and the oil holes in
the bearings line up with the notches and oil pas-
sages in the upper and lower crankcase halves.

MD1571

MD1551A

2. Lay the crankshaft into position and place a

small piece (about the width of the bearing) of

plastigauge onto all four journal surfaces of the

crankshaft. Install the lower crankcase half over

the crankshaft and onto the upper crankcase

half.

MD1567

3. Install the lower crankcase-to-upper crankcase

mounting cap screws; then using a crisscross

pattern, tighten them in two steps to specifica-

tions for step one and to specifications for step

two for the 10 mm cap screws and to specifica-

tions for step one and to specifications for step

two for the 8 mm cap screws.

„ NOTE: Leave in the assembled condition for
three minutes. DO NOT rotate or move crankshaft.

2-70

MD1573

4. Remove the lower crankcase-to-upper crankcase

mounting cap screws; then carefully separate the

crankcase halves.

5. Using the scale supplied with the plastigauge,

verify that the oil clearance for each is 0.020-

0.040 mm (0.00079-0.00157 in.) with a maxi-

mum limit of 0.065 mm (0.00256 in.). Remove

the plastigauge; then clean the bearings and

crankshaft journals.

MD1566

6. After cleaning, return the upper crankcase half

to the upside-down position on the workbench.

AO318

„ NOTE: Make sure the tabs and the oil holes in
the bearings are still aligned with the notches and
oil passages in the upper and lower crankcase
halves.

7. Install the half bearings; then lubricate the lower

crankcase half bearing faces liberally with

engine oil taking care not to get oil on the crank-

case bearing journals. 

AO319

„ NOTE: Take care not to get sealant on the bear-
ing surfaces. Sealant should be at least 3 mm (0.12
in.) from the bearing surfaces. 

AO319A

8. Lubricate the lips of the crankshaft seal with

grease and install the crankshaft seal over the

PTO end of the crankshaft with the spring side

of the seal directed toward the crankshaft.

9. Install the crankshaft into the crankcase. Lubri-

cate the thrust bearings with engine oil; then

with the grooved side of the bearing facing

toward the crankshaft, insert each bearing and

roll it into place.

„ NOTE: To install the opposite end thrust bearing,
push the crankshaft towards the bearing just
installed; then install the bearing for that journal.
Continue this procedure until all thrust bearings
are installed.

2-71

2

AO320A

AO321

10. Coat the lower crankcase half sealing surface

with  Sealant (p/n 1048-044); then set it over the

crankshaft.

„ NOTE: Take care not to get sealant on the bear-
ing surfaces or journals.

„ NOTE: Mate the crankcase halves within 10 min-
utes of applying the sealant to ensure the sealant
does not dry before it can seal.

11. Install the lower crankcase-to-upper crankcase

mounting cap screws; then tighten them in two

steps to specifications for step one and to speci-

fications for step two for the 10 mm cap screws

and to specifications for step one and to specifi-

cations for step two for the 8 mm cap screws. 

MD1573

0738-513

12. Install one piston pin circlip into one of the pis-

tons making sure the open end is directed either

up or down. Place the connecting rod in position

with the arrows on the rod cap and piston dome

aligned.  Install the piston pin and piston pin cir-

clip making sure the open end is directed either

up or down. Repeat for the other piston/connect-

ing rod assemblies.

AO322A

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

oil ring in the bottom groove of the piston.

MD1668B

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

oil rings until they are on directly opposite sides

of the piston.

2-72

15. 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

16. Install the connecting rod bearings into the con-

necting rods; then using a ring compressor and a

soft dowel (wood or plastic), lubricate each pis-

ton and cylinder thoroughly with engine oil and

slide each piston into the cylinder and over the

connecting rod journals. Make sure the arrow on

the top of the piston is facing toward the timing

chain end of the crankcase. 

0738-463

„ NOTE: To aid in guiding the connecting rod to
the journal on the crankshaft, install two pieces of
fuel hose (approximately 12 cm or 5 in.) to the
studs on the end of the connecting rod.

MD1583

17. Remove the protective hoses from the connect-

ing rod studs; then seat the connecting rods over

the connecting rod journals.

„ NOTE: Make sure the tabs and the oil holes in
the connecting rod bearings are aligned with the
notches and oil passages in the connecting rods.
Keep the connecting rods and connecting rod
caps in their appropriate pairs by aligning the
matching letters on the sides of the connecting
rod/connecting rod cap pairs.

18. Place a small piece (about the width of the bear-

ing) of Plastigauge onto the face of the connect-

ing rod journal for all three connecting rods.

Place the connecting rod bearings into position.

„ NOTE: Make sure the identification numbers
stamped on the side of the connecting rod caps
and the “V” arrow on the top of the connecting rod
caps are facing the timing chain end of the crank-
case. The “V” arrow should be on the same side as
the oil squirter boss. 

MD1536

! CAUTION

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

 

 

 

 

 

 

 

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