Snowmobile Arctic Cat (2007 year). Instruction - part 37

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 37

 

 

3-26

11. With a light film of engine oil applied to the tap-

pets, install the correct shim (A) and tappet (B)

to each valve being adjusted.

ZJ083A

„ NOTE: Prior to installing the camshaft, it is
advisable to apply engine-assembly grease to the
camshaft journals and lobes.

12. With the crankshaft rotated to the top-dead-cen-

ter position, place the cam chain over the

sprocket of the exhaust camshaft.

„ NOTE: The exhaust camshaft must be installed
first.

ZJ084

13. With the timing marks (A) on the face of the

exhaust camshaft gear properly aligned, place

the camshaft into position on the cylinder head.

0741-801

14. With the cam chain properly seated to the gears

of the crankshaft and exhaust camshaft, install

the intake camshaft noting that the timing marks

(B) are properly aligned.

„ NOTE: With the camshafts and cam chain in
place, there should be exactly 16 pins from intake
cam mark 3 to exhaust cam mark 2.

741-780A

15. Install the cam chain tensioner adjuster by first

compressing the locking clip; then by pushing in

the tensioner shaft until completely compressed.

ZJ085A

16. Install the tensioner and secure with two Allen-

head cap screws (B); then tighten to 1.0 kg-m (7

ft-lb). Install the ball, spring, and tensioner bolt

(A) and tighten to 1.0 kg-m (7 ft-lb).

ZJ106A

3-27

3

17. With the camshafts in position and properly

timed, install the camshaft covers along with

cam chain tensioner guide number two; then

using the pattern shown, tighten the twelve cap

screws to 1.0 kg-m (7 ft-lb).

741-624A

18. Rotate the engine until the camshaft lobe of the

valve being measured is directly away from the

tappet.

19. With the engine at top-dead-center, measure the

valve/tappet clearance of the cylinder that is on

the compression stroke; then rotate the engine

another 360° and measure the clearances of the

other cylinder.

ZJ105

„ NOTE: When measuring valve/tappet clearance
on the outer exhaust valves, rotate the engine until
the decompression pin (A) is deactivated.

ZJ109C

20. After rechecking for proper valve/tappet clear-

ance, install the timing inspection plug to the

magneto case and tighten to 3.0 kg-m (22 ft-lb).

„ NOTE: At this time, remove the items used to
close off the intake ports of the cylinder head.

21. With the engine cover alignment pins in place,

install the engine cover and  gasket; then secure

with four cap screws and plastic washers. Using

the pattern shown, tighten the cap screws to 1.4

kg-m (10 ft-lb).

741-580A

„ NOTE: It is advisable to apply a light coat of
High-Temp Sealant (p/n 0636-069) to the camshaft
inspection area of the cylinder head.

ZJ127A

22. Install the ignition coils and secure with the cap

screws; then install the wiring harness plug-ins

to the coils (A) and the crankshaft poition sensor

(B).

3-28

ZJ094A

23. Install and secure the throttle bodies to the

intake flanges with the flange clamps; then

secure the wiring harness to the fuel rail with

cable ties as noted during disassembling.

Installing Spark Plugs

(1100 cc Z1)

„ NOTE: Prior to installing the new spark plugs,
check the gap between the electrode and the
ground strap. The clearance should be 0.7-0.8 mm
(0.028-0.031 in.).

1. Apply a small amount of Anti-Seize Thread

Compound (p/n 0678-146) to each spark plug

and install the spark plugs. Tighten to 1.8 kg-m

(13 ft-lb).

2. Install the ignition coils onto the valve cover and

tighten the two 6 mm cap screws to 1.3 kg-m

(9.5 ft-lb).

ZJ094C

„ NOTE: Before installing the air silencer, make
sure the gasline hose is routed over the air
silencer.

„ NOTE: To finalize this procedure, it is necessary
to install the air silencer. Proceed to Servicing Air
Silencer (1100 cc Z1) sub-section and follow steps
3-12 of INSTALLING.

Ignition Timing

(660 cc)

„ NOTE: Before starting this procedure, the engine
must be at operating temperature.

1. Verify the engine idle speed. The idle speed

specification is 1100 RPM ± 100 RPM.

2. Remove the air silencer (see appropriate Servic-

ing Air Silencer in this section).

3. Remove the two cap screws, one lock nut, and

washer securing the alternator/water pump belt

cover.

4. Remove the fuse block cover and locate the

diagnostic plug; then install the jumper wire to

the connections marked TS and GND terminals.

AO240

738-496B

5. Connect the timing light to a 12-volt source (if

needed); then hook the inductive pickup to the

green covered coil wire. This is the number one

cylinder lead.

3-29

3

738-478A

6. Start the engine and allow it to idle; then

observe the timing marks with the timing light.

Timing should be 5° ± 1° BTDC @ 1150 RPM.

AO242

7. If the timing is out of specification, verify that

the engine idle is within specification and the

engine is up to operating temperature. If those

specifications are correct, check the fuse block

timing resistor and verify the number on the side

of the resistor. If there is a number nine timing

resistor and the timing is advanced 2°, the tim-

ing would be at 7°. A number seven timing

resistor should be installed to bring the timing

down 2° and back to 5° ± 1°.

„ NOTE: There are eleven different resistors avail-
able. The number one resistor has the most
retarded timing and the number eleven resistor
has the most advanced timing.

Changing Oil/Filter

(660 cc)

„ NOTE: The oil should be changed when the
engine is warm to allow all oil to drain from the
crankcase.

„ NOTE: Recycle or properly dispose of the used
engine oil.

1. Using a putty knife, remove the belly pan plug.

2. Place a drain pan beneath the belly pan plug

hole; then remove the oil drain plug and washer

from the underside of the crankcase.

3. Remove the oil fill cap from the top of the

engine.

4. After the oil has drained completely, install the

oil drain plug and washer and tighten to 5.0 kg-

m (36 ft-lb).

5. Install a new belly pan plug.

6. Remove the oil filter using Oil Filter Wrench (p/

n 0644-389).

7. Apply a light coat of fresh engine oil to the gas-

ket of the new oil filter.

8. Install the new oil filter by turning the oil filter

by hand until the gasket has contacted the oil

filter mounting surface; then tighten the oil fil-

ter 3/4 turn by hand.

9. Pour 2.9 l (3 U.S. qt) of the recommended

engine oil into the oil fill tube; then check the oil

level.

10. Start the engine and inspect for any signs of oil

leaks.

Timing Resistors

Retarded                                  Advanced

1     2      3      4      5      6      7      8      9      10     11 

! CAUTION

Running the engine out of timing specifications can
cause serious engine damage.

! WARNING

Care must be taken if a hot drain plug is removed by
hand. Burning could occur.

 

 

 

 

 

 

 

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