Snowmobile Arctic Cat (2007 year). Instruction - part 25

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 25

 

 

2-85

2

Assembling Engine

(1100 cc Z1)

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

„ NOTE: For assembling purposes, it is advisable
to use oil-disolvable molybdenum disulfide grease
as engine-assembly grease.

1. 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

making sure the identification number on the

rod cap (A) is aligned with the intake side of the

piston (B). 

ZJ070A

2. Install the piston pin and piston pin circlip mak-

ing sure the open end is directed either up or

down. Repeat for the other piston/connecting

rod assembly.

3. To install the piston rings, use the following pro-

cedure.

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

thin oil ring in the bottom groove of the pis-

ton. Stagger the end gaps of the upper and

lower thin oil rings until they are on directly

opposite sides of the piston.

741-619A

B. Install the #2 compression ring so the letters

on the top surface of the ring face the dome

of the piston.

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

groove with the face of the ring directed

upward.

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

less than 90° from one another.

„ NOTE: Prior to installing the pistons, make sure
the oil ring end gaps are on directly opposite sides
of the piston, and the compression ring end gaps
are 90° from one another.

4. Lubricate each piston and cylinder with engine

oil; then with the dots on the top of the pistons

directed towards the exhaust side of the engine,

install the piston assemblies into the cylinder.

ZJ071A

5. Using Ring Compressor (p/n 0644-378) and a

soft hammer/hammer handle, carefully drive

each piston into the cylinder until the top of the

piston is flush with the engine case.

ZJ072

! CAUTION

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

2-86

6. Rotate the engine to the upside down position

for installing the crankshaft and counterbalanc-

ers.

„ NOTE: It is advisable to install a cap screw and
large washer to the cylinder head cap screw hole
between pistons to avoid any chance of the pis-
tons sliding out of the cylinder.

ZJ073A

7. With new O-ring, install the piston cooling jets

with Allen-head cap screws; then tighten to

specifications.

ZJ054A

„ NOTE: Prior to installing the jets, make sure the
orifices are clear of any debris or contaminants.

ZJ055A

8. With the proper bearings selected, install the

half-bearings into the upper engine case; then

lubricate the bearing faces liberally with engine-

assembling grease taking care not to get any

grease between the engine case and bearing.

„ NOTE: Make sure the tabs of the bearings are
properly seated to the notches in the upper engine
case.

ZJ069A

9. 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; then

install the crankshaft.

„ NOTE: Position the crankshaft at bottom-dead-
center for assembling purposes.

ZJ053

10. Lubricate the thrust bearings with engine oil;

then with the grooved side of the bearings (A)

facing outward towards the crankshaft counter-

weights, install the first bearing and roll it into

place. Push the crankshaft towards the installed

bearing and install the remaining bearing.

! CAUTION

Prior to lubricating the bearings and journals, make
sure all surfaces are cleaned thoroughly and dried
with compressed air to avoid contaminants between
the bearings and shaft surface.

2-87

2

ZJ074A

11. Install the bearing halves to the connecting rods

and caps; then lubricate the bearing surfaces and

connecting rod journals of the crankshaft.

12. Seat the connecting rods to the crankshaft; then

install the rod caps and cap screws and tighten

only until snug.

13. Alternately, tighten each of the connecting rod

cap screws - in specified increments - to initial

specifications; then in turn tighten each cap

screw an additional 90° turn to obtain the final

recommended torque value.

ZJ075

„ NOTE: Rotate the crankshaft one revolution to
verify free movement.

14. With the O-ring lubricated with engine oil,

install the oil-relief valve.

ZJ076A

„ NOTE: Prior to installing the oil-relief valve,
make sure the valve is free and clear of any con-
taminants.

15. With proper bearings selected, install the coun-

terbalancer bearing halves into the upper engine

case; then apply a light film of engine-assembly

grease to the bearing surfaces.

16. Rotate the crankshaft to the bottom-dead-center

position; then install the rear counterbalancer

with the two dots (A) on the face of the crank-

shaft and balancer gears directy in line with each

other at the sealing surface of the engine case.

„ NOTE: The front counterbalancer has the oil
pump drive gear.

741-596A

17. With the crankshaft at bottom-dead-center,

install the front counterbalancer with the single

dot (B) on the face of the crankshaft and bal-

ancer gears directly in line with each other at the

sealing surface of the engine case.

18. Place the oil-passage O-rings (A) into place in

the upper engine case; then install the three

alignment pins (B) into the case.

! CAUTION

Failure to install the crankshaft thrust bearings
properly could result in severe engine damage.

2-88

ZJ042A

ZJ042B

19. Install the separator plates to the lower crank-

case; then using the torque pattern shown,

secure with eight cap screws. Tighten to specifi-

cations.

741-737A

20. Install the crankshaft and counterbalancer bear-

ing halves to the lower crankcase; then apply a

light film of engine-assembly grease to the bear-

ing surfaces.

„ NOTE: Make sure the bearings are properly
seated to the grooves of the crankcase.

21. Using High-Temp Sealant (p/n 0636-069), apply

a light film of sealant onto the sealing surfaces

of the upper and lower engine cases.

22. Install the lower crankcase half to the upper

engine case; then verify that the cases are prop-

erly seated together.

23. Install the 10 mm, 8 mm, and 6 mm cap screws

into the proper locations in the crankcase; then

with the torque pattern shown as numbered on

the case, tighten the cap screws only until snug.

741-582A

24. For initial tightening of the engine case cap

screws, use this sequence:

A. Cap screws 1-6 to 1.8 kg-m (13 ft-lb).

B. Cap screws 7-24 to 1.4 kg-m (10 ft-lb).

C. Cap screws 25-28 to 1.0 kg-m (7 ft-lb).

25. For final tightening of the engine case cap

screws, use this sequence:

A. Cap screws 1-6 to 3.7 kg-m (27 ft-lb).

B. Cap screws 7-24 to 2.6 kg-m (19 ft-lb).

„ NOTE: Cap screws 25-28 have only the one
torque value.

„ NOTE: After the tightening sequence, rotate the
crankshaft one revolution to verify free movement.

26. With a new O-ring, install the oil cooler, washer,

and the union bolt; then tighten to specifica-

tions.

ZJ077

 

 

 

 

 

 

 

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