Content .. 41 42 43 44 ..

Snowmobile Arctic Cat (2002 year). Manual - part 43

2-155

CYLINDER HEAD VOLUME TESTS

CYLINDER HEAD VOLUME

(Squish-Gap Method)

To check the squish gap, a micrometer and a heavy

piece of solder will be needed.

1. Remove the spark plugs from the engine.

2. Insert the solder piece down through the spark

plug hole and push it up against the inner cylinder

bore towards the MAG-side of the engine.

3. Pull the recoil rope and crank the engine over

several times while the solder is being held firmly

in place.

4. Remove the solder from the cylinder. Using the

micrometer, measure the very end of the squeezed

solder piece. Record the reading.

NOTE: If the solder hasn’t been squeezed by the

piston, a larger piece of solder must be used.
Repeat procedure.

5. Using the opposite end of the solder piece, insert it

down through the spark plug hole towards the

PTO-side of the engine. Push on the solder until it

contacts the inner cylinder bore.

6. Pull the recoil rope and crank the engine over

several times. Remove the solder from the

cylinder and measure the squeezed end with a

micrometer. Record reading and refer to the chart.

NOTE: Measure from PTO to MAG-side of the

piston to accurately measure the squish gap.
Never measure across piston, exhaust to carbure-
tor side, as the piston will rock and the reading
won’t be accurate.

Readings may vary from side to side. Make sure the

smaller reading is within the specifications listed.

CYLINDER HEAD VOLUME

(Cylinder Head

Installed Method)

To check the cc volume, a measuring tool called a

buret will be needed. It is capable of measuring a liq-

uid in cc volumes.

1. Fill buret with 10W engine oil.

2. Remove the spark plugs from the cylinders.

3. Run piston up to TDC (Top Dead Center).

4. Insert buret into spark plug hole and open buret

valve. Run oil into the spark plug hole until it

reaches the top of the spark plug hole. Turn off the

buret valve.

5. Check the buret scale to see how much oil has

been used to fill the combustion chamber. From

the total amount, subtract 2.20 cc or 2.44 cc.

Compare the findings with the chart.

NOTE: The above procedure will work fine on a

new engine. Engines with many hours of use, may
require a small change in the procedure. In step 3,
remove the cylinder head. Wipe a small amount of
heavy grease around the outer diameter of the pis-
ton to seal space between the piston and cylinder
bore. Replace head and tighten to specification;
then continue with steps 4 and 5.

CYLINDER HEAD VOLUME

(Flat Plate Method)

The third method of checking for proper combustion

chamber volume will require a 1/8 in. or 3/16 in. thick

piece of plexiglass, some heavy grease, and a buret.

The plexiglass piece must be flat and also large enough

to cover the entire gasket surface of the cylinder head.

Using a 3/16 in. drill bit, drill two holes through the

plexiglass piece. Locate the holes one inch apart inside

the combustion chamber area (towards center of

piece).

1. Remove the cylinder head from the engine. Clean

all carbon from the combustion chamber area.

2. Position the cylinder head squarely in a vise with

its gasket surface up. Leave a BR9ES spark plug

in place and grip the metal portion of the spark

plug for holding the cylinder head.

3. Apply a light coat of grease to the gasket surface

of the head. Squeeze the piece of plexiglass firmly

down onto the gasket surface. The grease will act

as a sealant between the two pieces.

4. Using a buret filled with light oil, fill the

combustion chamber through either of the two

holes drilled in the plexiglass. Continue to fill the

combustion chamber until the fluid appears at the

bottom of the second hole. Stop filling procedure

and take a reading off the buret as to how much

fluid was used. The specification found in the

chart includes the spark plug volume, so there

won’t be any need to subtract from the reading.

2-156

CYLINDER HEAD VOLUME SPECIFICATIONS

NOTE: For accurate reading when using the head installed volume method, subtract 2.44 cc from the

total amount of fluid used (if using a BR9EYA spark plug) or 2.20 cc (if using a BR9ES spark plug).

ENGINE TYPE

SQUISH - GAP

HEAD INSTALLED

VOLUME (cc)

FLAT PLATE

VOLUME (cc)

340 cc

1990-2000

1.70-2.99

in.

.067-.118

16.6-20.1

19.5

370 cc

1999-2002

2.27-2.95

in.

.089-.116

19.1-22.0

24.3-25.1

440 cc

1999 Z

.91-2.2

in.

.036-.087

20.5-25.8

24.9

440 cc F/C

1984-2002

1.39-1.87

in.

.055-.074

20.4-26.4

25.2

440 cc F/C

2000-2001 Z (Sno-Pro)

2.3

in.

.090

17.8-19.4

24.2

700 cc

1991-1995 (Carb)
1999-2000

1.76-2.32

in.

.069-.091

29.6-33.4

43.2

440 cc L/C (L/W)

1996 Jag, Panther
1997-1999 ZL

1.29-2.15

in.

.051-.084

21.2

25.7

550 cc

1993-2002

1.52-2.00

in.

.060-.079

27.7-29.9

33.7-34.7

570 cc F/C

2002

1.3

in.

.051

27.01

28.8

580 cc

1993-2001

1.47-2.01

in.

.057-.079

25.3

35.5

900 cc

1993-1997 Thundercat

1.78-2.15

in.

.070-.085

23.3-28.5

36.4

800 cc (Triple)

1995-2001

1.46-2.01

in.

.057-.079

22.4

31.3

600 cc (Triple)

1995-2002

1.00-1.59

in.

.039-.062

17.4-19.5

18.5

440 cc

1997 ZR

.94-1.67

in.

.037-.066

16-18

17.2

440 cc

1998 ZR (Consumer Model)

1.09-1.82

in.

.043-.072

16.6-18.6

17.8

500 cc (Twin)

1998 -2001 (w/o APV)

1.3

in.

.051

19.4-21.9

20.8

500 cc (Twin)

2001-2002 (w/APV)

1.53

in.

.060

22.78

20.7

600 cc (Twin)

1998 -2001 (w/o APV)

1.3

in.

.051

25.9

26.1

600 cc (Twin)

2000-2002 (w/APV)

1.36

in.

.054

27.8

28.4

800 cc (Twin)

2001

1.55

in.

.061

32.9-35.9

38.3

800 cc (Twin)

2002

1.58

in.

.062

34.6

38.3

1000 cc

1998-2002

1.99

in.

.078

28.4-31.7

37.7

! CAUTION

The above specifications are not intended to be used for engine modification. Reducing the head volume
to the smaller specification could cause piston detonation problems which is not a warranty situation.

2-157

CRANKSHAFT RUNOUT SPECIFICATIONS

728-144A

NOTE: Measure in from the shaft end the specified amount when checking runout at points D-F. When checking runout in the center, place indicator

on center of bearing as shown at Point E. Maximum runout at any of the 3 measuring points is ±0.05 mm (0.002 in.).

Engine

Bore X

Stroke

Runout D, E, F Point

370 cc

440 cc

(in.)

(µ .002)

60 X 65

65 X 65

100 µ 0.15

(3.937 µ 0.0006)

55 µ 0.15

(2.165 µ 0.006)

100

(3.937)

(.866)

(1.377)

(.866)

550 L/C-E

AH50L

(in.)

(µ .002)

70 X65

103 µ 0.02

(4.055 µ 0.0007)

60 µ 0.02

(2.362 µ 0.0007)

102

(4.015)

(.944)

(1.181)

(.393)

120 cc

mm
(in.)

(µ .002)

60 X 42

- -

.10

(0.004)

.10

(0.004)

340 cc

mm
(in.)

(µ .002)

60 X 60

93 µ 0.15

(3.661 µ 0.006)

53 µ 0.15

(2.087 µ 0.006)

(3.701)

(.866)

(1.377)

(.590)

500 F/C-CCI

AL50A

(in.)

(µ .002)

70 X 65

103 µ 0.02

(4.055 µ .0007)

55 µ 0.02

(2.165 µ 0.0007)

100

(3.937)

(.866)

(1.377)

(.590)

500 F/C-E

AM50A

(in.)

(µ .002)

70 X 65

103 µ 0.02

(4.055 µ .0007)

55 µ 0.02

(2.165 µ 0.0007)

100

(3.937)

(.866)

(1.377)

(.590)

440 L/C-CI

AH44L

(in.)

(µ .002)

68 X 60

103 µ 0.02

(4.055 µ .0007)

60 µ 0.2

(2.362 µ 0.007)

102

(4.015)

(.944)

(1.181)

(.393)

530 L/C

AA53L

(in.)

(µ .002)

72 X 65

103 µ 0.02

(4.055 µ 0.008)

60 µ 0.2

(2.362 µ 0.008)

102

(4.015)

(.945)

(1.181)

(.393)

650 L/C

700 L/C

(in.)

(µ .002)

78 X 68

81 X 68

130 µ 0.15

(5.118 µ .006)

64 µ 0.15

(2.520 µ 0.006)

116 µ 0.2

(4.567 µ 0.007)

(1.102)

(1.377)

(.590)

440 L/C-LW

AJ44L

(in.)

(µ .002)

68 X 60

108.5 µ 0.15

(4.271 µ 0.006)

55 µ 0.15

(2.165 µ 0.006)

95 µ 0.4

(3.740 µ .015)

(.866)

30.5

(1.200)

(.393)

550 cc

580 cc

(in.)

(µ .002)

73.4 X 65

75.4 X 65

112.5 µ 0.15

(4.409 µ 0.006)

60 µ 0.15

(2.362 µ 0.006)

106

(4.174)

(1.024)

(1.181)

(.197)

440 L/C-LWR

mm
(in.)

(µ .002)

68 X 60

109.5 µ 0.15

(4.311 µ 0.006)

60 µ 0.15

(2.362 µ 0.006)

106

(4.173)

(0.945)

(1.181)

(.197)

440 L/C-ZR

AR44L1

(in.)

(µ .002)

66.5 X 63

114 µ 0.16

(4.48 µ 0.006)

66.5 µ 0.15

(2.62 µ 0.006)

106

(4.173)

(1.024)

(1.181)

(.197)

500 cc

600 cc (Twin)

(in.)

(µ .002)

71 X 62.7

78 X 62.7

114 µ 0.15

(4.88 µ 0.006)

66.5 µ 0.15

(2.62 µ 0.006)

105.8-106

(4.165-4.173)

(1.2)

(1.181)

(.197)

570 cc

mm
(in.)

(µ .002)

73.8 X 66

119 µ 0.15

(4.70 µ 0.006)

62.3 µ 0.15

(2.45 µ 0.006)

109.7

(4.320)

(0.945)

(1.181)

(.590)

800 cc (Twin)

mm
(in.)

(µ .002)

81 X 76

125.5 µ 0.15

(4.94 µ 0.006)

68 µ 0.15

(2.68 µ 0.006)

123 + 0-0.4

(4.84 + 0-0.015)

(1.2)

(1.181)

(.590)

2-158

CRANKSHAFT RUNOUT SPECIFICATIONS

(cont)

0731-579

NOTE: Measure in from the shaft end the specified amount when checking runout at points D-F. When

checking runout in the center, place indicator on center of bearing as shown at Point E. Maximum runout at
any of the 3 measuring points is ±0.05 mm (0.002 in.).

CRANKSHAFT REPAIR

For those who have crankshaft work sent out to another shop, it is advisable to provide them with this information.

To use the specifications, first refer to the drawing; then find the letter which indicates the specification and refer to
the chart below the illustration. Be sure to note the proper engine column. Specifications are called out in both mil-
limeters and inches.

NOTE: We have given the proper location for checking crankshaft runout as the very edge of the straight

portion of the shaft where the oil seal makes contact. From the drawings, note that Suzuki has called out
three check points: at either end, out on the taper as shown, and also on the center bearing race. The
crankshaft is still supported on the outer bearings using V blocks. The maximum runout shouldn’t exceed
0.05 mm (0.002 in.).

Model

Bore X

Stroke

Runout

D, E, F Point

600 cc

(in.)

(Triple)

mm
(in.)

(µ .002)

66.5 X 57

102.8 µ 0.15

(4.047 µ 0.006)

105.3 µ 0.15

(4.145 µ 0.0006

58 µ 0.15

(2.303 µ 0.0006)

99 µ 0.15

(3.897 µ 0.0006)

(1.023)

(1.181)

(.590)

800 cc

(Triple)

(in.)

(µ .002)

72 X 65

A1 & A2

124.4 µ 0.015

(4.897 µ 0.0006)

64 µ 0.15

(2.519 µ 0.0006)

112 µ 0.15

(4.409 µ 0.0006)

(1.181)

(.197)

(.590)

900 cc

mm
(in.)

(µ .002)

76 X 65

A1 & A2

124.4 µ 0.15

(4.897 µ 0.0006)

64 µ 0.15

(2.519 µ 0.0006)

112 µ 0.15

(4.409 µ 0.0006)

(1.181)

(.197)

(.590)

1000 cc

mm
(in.)

81 X 64.6

(µ .002)

124.4 µ 0.15

(4.900 µ 0.006)

64 µ 0.15

(2.520 µ 0.006)

111.8-112

(4.402-4.409)

(1.0236)

(1.181)

(0.197)

Content .. 41 42 43 44 ..