Snowmobile Arctic Cat (2007 year). Manual - part 4

2-1

2

SECTION 2 — ENGINE

TABLE OF

CONTENTS

Engine Specifications (660 cc Non-Turbo) .............. 2-2
Engine Specifications (660 cc Turbo) ...................... 2-3
Engine Specifications (120 cc) ................................ 2-4
Engine Specifications (1100 cc Z1)......................... 2-5
Engine Torque Patterns (660 cc)............................. 2-6
Engine Torque Patterns (1100 cc Z1)...................... 2-7
Electrical Components Location Schematic 

(660 cc) ................................................................ 2-9

Electrical Components Location Schematics

(1100 cc Z1)....................................................... 2-10

Assembly Schematic (120 cc) ............................... 2-11
Assembly Schematics (660 cc) ............................. 2-12
Assembly Schematics (1100 cc Z1) ...................... 2-15
Engine ................................................................... 2-18
Removing Engine (120 cc) .................................... 2-18
Removing Engine (660 cc) .................................... 2-19
Removing Engine (1100 cc Z1)............................. 2-25
Disassembling Engine (120 cc)............................. 2-30
Disassembling Engine (660 cc)............................. 2-35
Disassembling Engine (1100 cc Z1)...................... 2-42
Servicing Components (120 cc) ............................ 2-47
Servicing Components (660 cc/1100 cc Z1) ......... 2-57
Assembling Engine (120 cc).................................. 2-64
Assembling Engine (660 cc).................................. 2-69
Assembling Engine (1100 cc Z1) .......................... 2-85
Installing Engine (120 cc) ...................................... 2-93
Installing Engine (660 cc) ...................................... 2-94
Installing Engine (1100 cc Z1)............................... 2-99
Troubleshooting Engine....................................... 2-105

2-2

Engine Specifications

(660 cc Non-Turbo)

        

Cam Lobe Height                      
(Int)

38.03-38.19 mm
(1.497-1.504 in.)

Cam Lobe Height                   
(Exh)

38.24-38.40 mm
(1.506-1.512 in.)

Camshaft Journal                    
(O.D.)

22.934-22.955 mm
(0.9029-0.9037 in.)

Camshaft Journal Bore             
(Dia)

23.000-23.021 mm
(0.9055-0.9063 in.)

Camshaft Journal Clearance

0.045-0.087 mm
(0.0018-0.0034 in.)

Camshaft Runout                     
(Max)

0.10 mm
(0.0039 in.)

Crank Pin                                  
(Dia)

37.982-38.000 mm
(1.4954-1.4961 in.)

Crankshaft Bearing Clearance

0.020-0.040 mm
(0.0008-0.0016 in.)

Crankshaft Rod Journal                
(Out-of-Round/Taper)

0.010 mm
(0.0004 in.)

Crankshaft Thrust Bearings 
(Thickness)

2.50 mm
(0.0984 in.)

Crankshaft Thrust Runout      

0.11-0.31 mm
(0.0043-0.0122 in.)

Crankshaft Main Journal             
(Out-of-Round)

0.010 mm
(0.0004 in.)

Cylinder Bore Diameter           
(Max)

68.020 mm
(2.6779 in.)

Cylinder Head Distortion          
(Max)

0.030 mm
(0.001 in.)

Manifold Distortion                   
(Max)

0.050 mm
(0.002 in.)

Piston Diameter                                          
(19 mm up from skirt                
perpendicular to pin)

67.970-67.990 mm
(2.6760-2.6768 in.)

Piston Skirt/Cylinder                      
Clearance

0.02-0.04 mm
(0.0008-0.0016 in.)

Piston Connecting Rod                 
Small End Bore

18.003-18.013 mm
(0.7088-0.7092 in.)

Piston Pin/Connecting Rod                
Small End Clearance

0.003-0.018 mm
(0.0001-0.0007 in.)

Piston Pin Bore In Piston

18.006-18.014 mm
(0.7089-0.7092 in.)

Piston Pin                                  
(Dia)

17.995-18.000 mm
(0.7085-0.7087 in.)

Piston Ring Groove/Ring              
Clearance                                (1st) 
 
                                                 (2nd)

                                                  (Oil)

0.03-0.07 mm
(0.0012-0.0028 in.)
0.02-0.06 mm
(0.0008-0.0024 in.)
0.06-0.15 mm
(0.0024-0.0059 in.)

Valve Guide Inside Diameter

5.500-5.512 mm
(0.2165-0.2170 in.)

Valve Head                            
(Thickness)                               (Int)
 
                                                 (Exh)

1.0 mm
(0.039 in.)
1.15 mm
(0.045 in.)

Valve Lash Clearance -                 
Cold (59°-77° F)                       (Int)

                                                 (Exh)

0.18-0.23 mm
(0.007-0.009 in.)
0.18-0.23 mm
(0.007-0.009 in.)

Valve Seat Width                     (Int)

                                                 (Exh)

1.80-2.20 mm
(0.0709-0.0866 in.)
1.65-2.05 mm
(0.0650-0.0807 in.)

Valve Stem                              
Diameter                                  (Int)

                                                 (Exh)

5.465-5.480 mm
(0.2152-0.2157 in.)
5.440-5.455 mm
(0.2142-0.2148 in.)

Valve Stem/Guide                       
Clearance                                 (Int)

                                                 (Exh)

0.020-0.047 mm
(0.0008-0.0019 in.)
0.045-0.072 mm
(0.0018-0.0028 in.)

2

Engine Specifications

(660 cc Turbo)

   

Cam Lobe Height                       
(Int)

38.24-38.40 mm
(1.506-1.512 in.)

Cam Lobe Height                     
(Exh)

38.20-38.36 mm
(1.504-1.510 in.)

Camshaft Journal                    
(O.D.)

22.934-22.955 mm
(0.9029-0.9037 in.)

Camshaft Journal Bore             
(Dia)

23.000-23.021 mm
(0.9055-0.9063 in.)

Camshaft Journal Clearance

0.045-0.087 mm
(0.0018-0.0034 in.)

Camshaft Runout                     
(Max)

0.10 mm
(0.0039 in.)

Crank Pin                                  
(Dia)

37.982-38.000 mm
(1.4954-1.4961 in.)

Crankshaft Bearing Clearance

0.020-0.040 mm
(0.0008-0.0016 in.)

Crankshaft Rod Journal                
(Out-of-Round/Taper)

0.010 mm
(0.0004 in.)

Crankshaft Thrust Bearings 
(Thickness)

2.47 mm
(0.0972 in.)

Crankshaft Thrust Runout      

0.11-0.31 mm
(0.0043-0.0122 in.)

Crankshaft Main Journal             
(Out-of-Round)

0.010 mm
(0.0004 in.)

Cylinder Bore Diameter           
(Max)

68.020 mm
(2.6779 in.)

Cylinder Head Distortion          
(Max)

0.030 mm
(0.001 in.)

Manifold Distortion                   
(Max)

0.050 mm
(0.002 in.)

Piston Diameter
(19 mm up from skirt                
perpendicular to pin)

67.970-67.990 mm
(2.6760-2.6768 in.)

Piston Skirt/Cylinder                      
Clearance

0.02-0.04 mm
(0.0008-0.0016 in.)

Piston Connecting Rod                 
Small End Bore

21.003-21.013 mm
(0.8269-0.8273 in.)

Piston Pin/Connecting Rod                
Small End Clearance

0.003-0.018 mm
(0.0001-0.0007 in.)

Piston Pin Bore In Piston

21.002-21.008 mm
(0.8268-0.8271 in.)

Piston Pin                                  
(Dia)

20.995-21.000 mm
(0.8266-0.8268 in.)

Piston Ring Groove/Ring              
Clearance                                (1st) 
 
                                                 (2nd)

                                                  (Oil)

0.04-0.08 mm
(0.0016-0.0032 in.)
0.03-0.07 mm
(0.0012-0.0028 in.)
0.06-0.15 mm
(0.0024-0.0059 in.)

Valve Guide Inside Diameter

5.500-5.512 mm
(0.2165-0.2170 in.)

Valve Head                            
(Thickness)                               (Int)
 
                                                 (Exh)

1.0 mm
(0.039 in.)
1.15 mm
(0.045 in.)

Valve Lash Clearance -                 
Cold (59°-77° F)                       (Int)

                                                 (Exh)
                                                  

0.18-0.23 mm
(0.007-0.009 in.)
0.30-0.35 mm
(0.012-0.014 in.)

Valve Seat Width                     (Int)

                                                 (Exh)

1.80-2.20 mm
(0.0709-0.0866 in.)
1.65-2.05 mm
(0.0650-0.0807 in.)

Valve Stem                              
Diameter                                  (Int)

                                                 (Exh)

5.465-5.480 mm
(0.2152-0.2157 in.)
5.440-5.455 mm
(0.2142-0.2148 in.)

Valve Stem/Guide                       
Clearance                                (Int)

                                                 (Exh)

0.020-0.047 mm
(0.0008-0.0019 in.)
0.045-0.072 mm
(0.0018-0.0028 in.)

2-4

Engine Specifications

(120 cc)

Cam Lobe Height                       

30.20-30.56 mm
(1.189-1.203 in.)

Crank Pin Diameter

25.990-26.000 mm
(1.0232-1.0236 in.)

Crankshaft Runout                  
(Max)

0.100 mm
(0.004 in.)

Cylinder Bore Diameter           
(Max)

60.25 mm
(2.372 in.)

Cylinder Head Distortion         
(Max)

0.03 mm
(0.0012 in.)

Piston Diameter
(14 mm up from  skirt perpendicu-
lar to pin)

59.880-59.990 mm
(2.3575-2.3618 in.)

Piston Skirt/Cylinder                      
Clearance

0.020-0.120 mm
(0.0008-0.0047 in.)

Piston Ring End Gap  (1st & 2nd) 0.20-0.70 mm

(0.0079-0.0280 in.)

Connecting Rod Big End  
Side Clearance

0.20-1.20 mm
(0.0079-0.0472 in.)

Connecting Rod Big End
Inside Diameter

26.015-26.025 mm
(1.0242-1.0246 in.)

Crank Pin/Connecting 
Rod Clearance

0.015-0.070 mm
(0.0006-0.0028 in.)

Connecting Rod Small End Bore

15.006-15.030 mm
(0.5908-0.5917 in.)

Piston Pin/Connecting Rod                
Small End Clearance

0.006-0.050 mm
(0.0002-0.0020 in.)

Piston Pin Bore In Piston

15.006-15.030 mm
(0.5908-0.5917 in.)

Piston Pin Diameter

14.980-14.995 mm
(0.5898-0.5904 in.)

Piston Ring Thickness (1st & 2nd) 1.47-1.49 mm

(0.058-0.059 in.)

Piston Ring Groove     (1st & 2nd)
  Width 
                                                (Oil)
                                                        

1.52-1.54 mm
(0.060-0.061 in.)
2.51-2.53 mm
(0.0988-0.0996 in.)

Piston Ring Groove/Ring              
Clearance                      (1st & 2nd) 
                                                 

0.030-0.099 mm
(0.0012-0.0039 in.)

Valve Guide Hole Diameter

11.200-11.218 mm
(0.4409-0.4416 in.)

Valve Guide Inside Diameter

5.500-5.512 mm
(0.2165-0.2170 in.)

Valve Stem Runout                 
(Max)

0.05 mm
(0.002 in.)

Valve Face/Seat Width

0.8-1.0 mm
(0.032-0.039 in.)

Valve Spring Length                
(Max)

31.0 mm
(1.22 in.)

Valve Stem/Guide Clearance (Int)
(Max)
                                                 (Exh)

0.080 mm
(0.0032 in.)
0.100 mm
(0.0039 in.)