Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 4

 

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Snowmobile Arctic Cat 2-Stroke (2007 year). Instruction - part 4

 

 

2-1

2

SECTION 2 — ENGINE

TABLE OF

CONTENTS

Arctic Cat Engine Specifications ............................. 2-2
Torque Conversions ................................................ 2-3
Piston Replacement Guide ..................................... 2-3
Assembly Schematics (Table of Contents) .............. 2-4
Cylinder Head Volume Specifications ................... 2-18
Engine Piston Travel Versus Crank Angle Chart ... 2-18
Crankshaft Runout/Repair Specifications ............. 2-19
Engine - Panther 370/Z 370 .................................. 2-20
Engine - Bearcat 570/Panther 570/Z 570.............. 2-35 
Engine - Crossfire 500/600 - M-Series 600........... 2-57
Engine - Crossfire 800/1000 - 

M-Series 800/1000............................................. 2-86

Engine - F-Series 500/600 .................................. 2-120
Engine - F-Series 800/1000 ................................ 2-148
Troubleshooting Engine (Carbureted Models) ..... 2-178
Troubleshooting Engine (EFI Models) ................. 2-181

2-2

Arctic Cat Engine 

Specifications

* F-Series/Crossfire
** M-Series

ITEM

370 cc

500 cc

570 cc

600 cc

800 cc

1000 cc

Engine Model Number

AA37A9

AX50L6

AA56A6

AJ60L4

AB80L1

AB10L1

Displacement — 

cc

— cu in.

367 
22.41

499 
30.4

565 
34.5

599 
36.54

794
48.45

999
60.96

No. of Cylinders

2

2

2

2

2

2

Bore

— mm
— in.

60
2.362

71
2.795

73.8 
2.910

73.8
2.906

85
3.346

90.3
3.556

Stroke

— mm

 

— in.

65 
2.559

63
2.480

66 
2.598

70
2.755

70
2.755

78
3.071

Compression Ratio

6.30:1

6.38:1

6.41:1

6.46:1

6.39:1

6.41:1

Cooling System

Fan Cooled

Liquid Cooled

Fan Cooled

Liquid Cooled Liquid Cooled

Liquid Cooled

Gasoline Octane (min)

87

87

87

87

87

87

Fuel Mixture

Oil Injection

Oil Injection

Oil Injection

Oil Injection

Oil Injection

Oil Injection

Ignition Timing
Engine Warm
@2000 RPM

degrees
— mm
— in.

18
2.012 
0.079

12
0.867
0.034

20
2.522
0.099

15
1.509
0.059

15
1.509
0.059

12*

15**

1.062

1.655

0.042

0.065

Spark Plug (NGK)

BR9EYA

BR9EYA

BR9EYA

BR9EYA

BR9EYA

BR9EYA

Spark Plug Gap

— mm
— in.

0.7-0.8 
0.028-0.031

0.7-0.8
0.028-0.031

0.7-0.8 
0.028-0.031

0.7-0.8 
0.028-0.031

0.7-0.8
0.028-0.031

0.7-0.8 
0.028-0.031

Lighting Coil Output

12V/185W

12V/280W

12V/210W

12V/280W

12V/280W

12V/280W

Ignition Type

CDI/NOI

CDI/NOI

CDI/NOI

CD/NOI

CDI/NOI

CDI/NOI

Piston Skirt/Cylinder 
Clearance Range

— mm
— in.

0.066-0.086
0.0026-0.0034

0.075-0.105
0.0029-0.0041

0.085-0.115
0.0035-0.0045

0.075-0.105
0.0029-0.0041

0.075-0.105
0.0029-0.0041

0.075-0.105
0.0029-0.0041

Piston Ring End Gap 
Range

— mm
— in.

0.15-0.35
0.006-0.014

0.20-0.40
0.008-0.016

0.30-0.50
0.012-0.0196

0.30-0.50
0.012-0.0196

0.30-0.50
0.012-0.0196

0.30-0.50
0.012-0.0196

Cylinder Trueness 
Limit (max)

— mm
— in.

0.1 
0.004

0.1
0.004

0.1 
0.004

0.1 
0.004

0.1
0.004

0.1 
0.004

Piston Pin Diameter 
Range

— mm
— in.

17.995-18.000
0.7085-0.7087

21.995-22.000
0.8659-0.8661

17.995-18.000
0.7085-0.7087

21.995-22.000
0.8659-0.8661

21.995-22.000
0.8659-0.8661

23.995-24.000
0.9447-0.9449

Piston Pin Bore 
Diameter Range

— mm
— in.

18.002-18.010
0.7087-0.7090

22.002-22.010
0.8662-0.8665

18.002-18.010
0.7087-0.7090

22.002-22.010
0.8662-0.8665

22.002-22.010
0.8662-0.8665

24.002-24.010
0.9450-0.9453

Connecting Rod 
Small End Bore 
Diameter Range

— mm
— in.

23.003-23.011
0.9056-0.9059

27.003-27.011
1.0631-1.0634

23.003-23.011
0.9056-0.9059

27.003-27.011
1.0631-1.0634

27.003-27.011
1.0631-1.0634

29.003-29.011
1.1410-1.1420

Connecting Rod 
Radial Play Range

— mm
— in.

0.003-0.020
0.0001-0.0008

0.003-0.020
0.0001-0.0008

0.003-0.020
0.0001-0.0008

0.003-0.020
0.0001-0.0008

0.003-0.020
0.0001-0.0008

0.003-0.020
0.0001-0.0008

Crankshaft Runout 
(t.i.r.)

— mm
— in.

0.05 
0.002

0.05
0.002

0.05 
0.002

0.05
0.002

0.05
0.002

0.05 
0.002

Crankshaft End Play 
Range

— mm
— in.

0.05-0.10
0.002-0.004

0.05-0.10
0.002-0.004

0.05-0.10
0.002-0.004

0.05-0.10
0.002-0.004

0.05-0.10
0.002-0.004

0.05-0.10
0.002-0.004

Reed Stopper Height — mm

— in.

N/A

8.0
0.315

6.0
0.236

11.0
0.433

11.0
0.433

13.0
0.512

2-3

2

Torque Conversions

Piston Replacement 

Guide

* Not a Service Part

ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

1

0.1

21

2.9

41

5.7

61

8.4

81

11.2

2

0.3

22

3.0

42

5.8

62

8.6

82

11.3

3

0.4

23

3.2

43

5.8

63

8.7

83

11.5

4

0.6

24

3.3

44

6.1

64

8.9

84

11.6

5

0.7

25

3.5

45

6.2

65

9.0

85

11.8

6

0.8

26

3.6

46

6.4

66

9.1

86

11.9

7

1.0

27

3.7

47

6.5

67

9.3

87

12.0

8

1.1

28

3.9

48

6.6

68

9.4

88

12.2

9

1.2

29

4.0

49

6.8

69

9.5

89

12.3

10

1.4

30

4.2

50

6.9

70

9.7

90

12.5

11

1.5

31

4.3

51

7.1

71

9.8

91

12.6

12

1.7

32

4.4

52

7.2

72

10.0

92

12.8

13

1.8

33

4.6

53

7.3

73

10.1

92

12.9

14

1.9

34

4.7

54

7.5

74

10.2

94

13.0

15

2.1

35

4.8

55

7.6

75

10.4

95

13.1

16

2.2

36

5.0

56

7.7

76

10.5

96

13.3

17

2.4

37

5.1

57

7.9

77

10.7

97

13.4

18

2.5

38

5.3

58

8.0

78

10.8

98

13.6

19

2.6

39

5.4

59

8.2

79

10.9

99

13.7

20

2.8

40

5.5

60

8.3

80

11.1

100

13.8

ENGINE SIZE

YEAR 

PISTON

RING

PISTON & RING SET

370 cc

2007

*

3004-825

3005-913

500 cc

2007

*

3005-828

3006-746

570 cc

2007

*

3006-004

3006-528

600 cc 

2007

*

3006-004

3006-645

800 cc

2007

*

3006-394

3007-528

1000 cc

2007

*

3007-257

3007-258

2-4

Assembly Schematics

Table of Contents

370 cc  .................................................................... 2-6
570 cc ..................................................................... 2-8
500 cc ................................................................... 2-10
600 cc  .................................................................. 2-12
800 cc ................................................................... 2-14
1000 cc ................................................................. 2-16

Listed in the table below are symbols indicating spe-

cial instructions and other important information nec-

essary for proper servicing. Please note the definition

for each symbol. These symbols are used throughout

this manual.

SYMBOL

DESCRIPTION

Torque control required

243 - apply blue Loctite #243 (p/n 1639-413)
270 - apply green Loctite #270 (p/n 1639-817)
271 - apply red Loctite #271 (p/n 1639-820)
609 - apply green Loctite #609 (p/n 1639-821)

Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286) - Non-APV Engines
Lubricate with Arctic Cat Synthetic APV 2-Cycle Oil (p/n 2639-512) - APV Engines

Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)

3B - Three Bond Sealant (p/n 0636-070)
HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)

 

 

 

 

 

 

 

 

 

 

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