Snowmobile Arctic Cat (2007 year). Manual - part 20

2-65

2

GM124D

2. Install the crankshaft with the connecting rod

journal facing down.

GM124D

3. Note the direction of the arrow on the connect-

ing rod and the marks on the connecting rod and

end cap made during disassembly.

GM121D

GM120D

„ NOTE: Coat the cylinder wall, connecting rod
bearing surface, and the crankshaft with light-
weight oil.

4. Compress the piston rings and install the piston

and connecting rod assembly taking care not to

damage the crankshaft with the connecting rod

studs.

„ NOTE: When installing the piston, rotate the
crankshaft until the piston is at the bottom of the
stroke.

5. Install the connecting rod end cap with the

splasher plate, lock tab, and nuts. Tighten the

nuts to specifications.

GM123D

6. Apply lightweight oil to the tappets and cam-

shaft; then install the tappets and camshaft.

GM217D

! CAUTION

The arrow on the connecting rod must be directed
towards the camshaft.

2-66

GM216D

„ NOTE: Make sure the timing marks are aligned.

GM215D

7. Install the washer onto the camshaft.

GM214D

8. Place the dowel pins and a gasket into position.

GM213D

9. Secure the crankcase side cover to the crankcase

with the cap screws. Tighten to specifications.

10. Install the dowel pins and a new gasket; then

secure the head to the cylinder with the cap

screws. Tighten to specifications.

GM210D

11. Apply lightweight oil to the ends of the push

rods; then install the rods.

GM209D

12. Loosely secure the rocker arms to the cylinder

head with the pivots and lock nuts; then place

the piston to the top of the compression stroke,

set the valve clearance to the recommended set-

ting with a feeler gauge, and while holding the

adjustment nut, tighten the rocker arm lock nuts

securely. Verify valve clearance.

VALVE CLEARANCE RANGE (Cold)

0.030-0.070 mm

(0.0012-0.0028 in.)

2-67

2

GM208D

13. Secure the reed stopper to the air breather body

assembly with the screws.

GM207D

14. Place the air breather body assembly with gasket

onto the cylinder head cover.

GM206D

15. Install the valve cover with gasket. Tighten to

specifications.

GM205D

16. Secure the ignition coil to the crankcase housing

with the cap screws.

GE318D

17. Connect the ignition coil wire.

„ NOTE: The spark plug should be removed and
cleaned or replaced. Adjust gap to specification
and tighten the plug to specifications.

18. Connect the high tension lead to the spark plug

and secure with the two wire forms.

19. Install the flywheel and secure with the nut.

Tighten to specifications.

GM203D

„ NOTE: The ignition coil to flywheel air gap must
have a clearance of 0.5 mm (0.020 in.).

20. Secure the recoil starter pulley to the flywheel

with the screws.

2-68

GM202D

21. Install the recoil starter/fan housing assembly.

GM201D

22. Install the carburetor (with a gasket, insulator

block, and a gasket) onto the mounting studs.

GF318D

23. Noting the locations of the springs from disas-

sembly, install the rod and spring onto the car-

buretor.

GF208D

24. Install the gasket onto the mounting studs; then

install the air cleaner housing onto the carbure-

tor. Install the air breather hose onto the air

cleaner housing.

GF316D

A001

25. Secure the air cleaner housing to the carburetor

and engine with the cap screw and flanged nuts.

! WARNING

When performing service work on the fuel system,
do not smoke or allow open flames near the snow-
mobile.