Snowmobile Arctic Cat (2002 year). Manual - part 18

2-55

2

3. Place the cylinder head on a surface plate covered

with #400 grit wet-or-dry sandpaper. Using light

pressure, move the cylinder head in a figure eight

motion. Inspect the sealing surface for any

indication of high spots. A high spot can be noted

by a bright metallic finish. Correct any high spots

before assembly by continuing to move the

cylinder head in a figure eight motion until a

uniform bright metallic finish is attained.

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustion

chamber.

2. Lay a straightedge across the cylinder head; then

using a feeler gauge, check the distortion factor

between the head and the straightedge.

3. Maximum distortion is 0.03 mm (0.0012 in.).

GM130D

Cleaning/Inspecting/Measuring 

Cylinder

1. Wash the cylinder in parts-cleaning solvent.

2. Check the gasket surface of the cylinder for

distortion with a straightedge and thickness gauge

taking a clearance reading at several places. If the

largest reading at any position of the straightedge

exceeds the limit, replace the cylinder.

3. Maximum cylinder distortion limit is 0.03 mm

(0.0012 in.).

GEN-0030

4. Inspect the cylinder for pitting, scoring, scuffing,

warpage, and corrosion. If marks are found, repair

the surface using the Cylinder Hone Set (p/n 0644-

041) (see Honing Cylinder in this sub-section).

5. Place the cylinder on the surface plate covered

with #400 grit wet-or-dry sandpaper. Using light

pressure, move the cylinder in a figure eight

motion. Inspect the sealing surface for any

indication of high spots. A high spot can be noted

by a bright metallic finish. Correct any high spots

before assembly by continuing to move the

cylinder in a figure eight motion until a uniform

bright metallic finish is attained.

Honing Cylinder

1. Wash the cylinder in parts-cleaning solvent.

2. Inspect the cylinder for pitting, scoring, scuffing,

and corrosion. If marks are found, repair the

surface using the cylinder hone.

„

NOTE: To produce the proper 60° cross-hatch

pattern, use a low RPM drill (600 RPM) at the rate
of 30 strokes per minute. If honing oil is not avail-
able, use a lightweight petroleum-based oil. Thor-
oughly clean cylinder after honing using soap and
hot water. Dry with compressed air; then immedi-
ately apply oil to the cylinder bore. If the bore is
severely damaged or gouged, replace the cylinder.

3. If any measurement exceeds the limit, hone the

cylinder and install an oversized piston or replace

the cylinder.

„

NOTE: Oversized piston and rings are available.

The oversized piston and rings are marked for
identification purposes.

! CAUTION

Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

! CAUTION

Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

2-56

ATV-1068

CAM LOBE WEAR

Worn cam lobes result in reduced power output. The

limit of cam lobe wear is specified for both intake and

exhaust lobes in terms of cam height which is to be

measured with a micrometer. Replace the camshaft if

found to be worn below specifications.

Measurement must be within a range of 30.20-

30.56 mm (1.189-1.203 in.).

GEN0028B

GEN-0029

MEASURING CONNECTING ROD 

SMALL END BORE INSIDE DIAMETER 

1. Using a small bore gauge, measure the connecting

rod small end bore inside diameter.

2. Measurement must be within a range of 15.006-

15.030 mm (0.5908-0.5917 in.).

GEN-0034

3. If the difference between the connecting rod small

end bore inside diameter and the piston pin outside

diameter exceeds the limit, replace both

connecting rod and piston pin. The measurement

must be within a range of 0.006-0.050 mm

(0.0002-0.0020 in.).

GEN-0035

CRANKSHAFT RUNOUT

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

a dial indicator to read crankshaft runout.

„

NOTE: The contact point of the dial indicator

should be on the seal area of the crankshaft.

2. Total indicator reading on the dial must be

0.10 mm (0.004 in.) or less.

GEN-0031

3. If not within specification, either straighten the

crankshaft or replace it.

2-57

2

MEASURING CONNECTING ROD BIG 

END SIDE CLEARANCE

1. Check the connecting rod side clearance by using

a thickness gauge. If the clearance exceeds the

limit, replace the connecting rod or crankshaft.

2. Clearance measurement must be within a range of

0.20-1.20 mm (0.0079-0.0472 in.).

GEN-0036

MEASURING CRANK PIN/

CONNECTING ROD CLEARANCE

1. Measure the crank pin diameter.

2. Measurement must be within a range of 25.990-

26.000 mm (1.0232-1.0236 in.).

GEN-0037

3. Measure the connecting rod big end inside

diameter.

4. Measurement must be within a range of 26.015-

26.025 mm (1.0242-1.0246 in.).

GEN-0038

5. Measure the crank pin/connecting rod clearance.

6. Measurement must be within a range of 0.015-

0.070 mm (0.0006-0.0028 in.).

GEN-0039

CARBURETOR INSULATOR PLATE

1. Inspect for cracks, scoring, pitting, imperfections,

or warping.

2. Inspect the sealing surfaces for trueness by placing

each on the surface plate covered with #400 grit

wet-or-dry sandpaper. Using light pressure, move

both sides in a figure eight motion. Inspect the

sealing surfaces for any indication of high spots or

warping. Correct highs spots by continuing to

move each side in a figure eight motion. Warped

components must be replaced.

A932

2-58

Cleaning and Inspecting 

Engine

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

CYLINDER HEADS

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the combustion chambers

being careful not to nick, scrape, or damage the

combustion chambers or the sealing surfaces.

2. Inspect the spark-plug holes for any damaged

threads. Repair damaged threads using a heli-coil

insert.

3. Place the cylinder heads on a Surface Plate (p/n

0644-016) covered with #400 grit wet-or-dry

sandpaper. Using light pressure, move each

cylinder head in a figure eight motion. Inspect the

sealing surface for any indication of high spots. A

high spot can be noted by a bright metallic finish.

Correct any high spots before assembly by

continuing to move the cylinder head in a figure

eight motion until a uniform bright metallic finish

is attained.

AQ132D

CYLINDER HEAD (500/600 cc)

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the combustion chambers

being careful not to nick, scrape, or damage the

combustion chambers or the sealing surfaces.

2. Inspect the spark-plug holes for any damaged

threads. Repair damaged threads using a heli-coil

insert.

3. Inspect the cylinder head for flatness using a

straightedge and a feeler gauge. Acceptable

warpage must not exceed 0.05 mm (0.002 in.).

„

NOTE: If the warpage exceeds specification,

resurface the cylinder head using procedures
identified in step 6 in the Crankcase sub-section of
Cleaning and Inspecting Engine.

AN426D

CYLINDERS

1. Using a non-metallic carbon removal tool, remove

carbon buildup from the exhaust ports.

2. Wash the cylinders in parts-cleaning solvent.

3. Inspect the cylinders for pitting, scoring, scuffing,

and corrosion. If marks are found, repair the

surface with Ball Hone (p/n 0644-036) for the 600

cc or (p/n 0644-037) for the 800 cc or with #500

grit stones and honing oil.

! CAUTION

Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surfaces may result.

! CAUTION

Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

! CAUTION

Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.