Snowmobile Arctic Cat (2007 year). Manual - part 35

3-18

AO230

9. Using a 17 mm socket and ratchet, rotate the

crankshaft clockwise until the #1 piston is at

TDC; then rotate the crankshaft clockwise until

the intake cam lobes are at 180° to the shim

face. 

AO231

AO232A

10. To obtain the proper valve clearance, an 0.17

mm (0.007 in.) feeler gauge will go between the

camshaft and shim and an 0.23 mm (0.009 in.)

feeler gauge will not go between the camshaft

and shim. This will indicate a properly adjusted

valve.

„ NOTE: This procedure must be done without
applying any force to the feeler gauge.

„ NOTE: To determine the valve clearance, use a
feeler gauge in the following manner. Using the
illustration below to note that one intake valve set
and one exhaust valve set at a time will be checked
before rotating the crankshaft to the next set of
valves. 

„ NOTE: All valve clearance checks should be
done prior to any adjusting or shimming; there-
fore, record each valve clearance value in the
sequence for reference. 

11. Check clearance for #1 and #6 (record the clear-

ances).

12. Check clearance for #3 and #5 (record the clear-

ances).

13. Check clearance for #2 and #4 (record the clear-

ances).

0738-495

Non-Turbo Valve Clearance (Cold)                                      

15° - 25° C

(59° - 77° F)

Intake/       0.18 - 0.23 mm

Exhaust:      (0.008 - 0.009 in.)

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3

 

AO233

REPLACING VALVE SHIM

1. With the valve closed, turn the shim bucket so

the notched section faces toward the center of

the engine.

AO234A

2. Rotate the crankshaft clockwise until the two

sets of valves are fully open; then remove the

camshaft bearing cap screws and install Valve

and Spring Retainer Tool (p/n 0644-448) as

shown and tighten the cap screws to 1.1 kg-m (8

ft-lb). Rotate the crankshaft 90° clockwise and

remove the shim.

AO235A

AO236A

„ NOTE: The valve shimming tool is marked IN. for
intake valve and EX. for exhaust valve.

3. Using a small flat-blade screwdriver, pry the

shim up; then remove the shim from the bucket

using a tweezers or small magnet.

AO237

4. Measure the thickness of the shim; then calcu-

late the thickness of the new shim to be

installed.

Example: (B+C) - 0.20 mm  = A

A = Thickness of the new shim 2.58 mm

B = Removed shim thickness 2.50 mm

C = Valve clearance as measured 0.279 mm

Turbo Valve Clearance (Cold)                                      

15° - 25° C

(59° - 77° F)

Intake:

0.18 - 0.23 mm

(0.008 - 0.009 in.)

15° - 25° C

(59° - 77° F)

Exhaust:

0.30 - 0.35 mm

(0.011 - 0.013 in.)

3-20

„ NOTE: Round off the last two digits to the near-
est even whole number.

„ NOTE: If the valve clearance is in between shim
sizes, always adjust to the looser side of the spec-
ification.

5. After the new shim has been selected, install the

shim into the bucket with the number side of the

shim facing down and make certain that the

shim is sitting flat in the bucket seat. Then rotate

the crankshaft counterclockwise 90° and remove

the special tool. Install the camshaft bearing cap

and cap screws and tighten to 1.1 kg-m (8 ft-lb).

AO238

6. Recheck the valve clearances to make sure the

adjustment is within specification.

AO233

7. Apply a high-temp sealant to the engine cover,

camshaft rubber plug corners, and timing cover

to cylinder head mating surfaces.

AO239A

8. Install the engine cover making sure that the

inner spark plug hole gaskets are positioned

properly and tighten to 1.1 kg-m (8 ft-lb).

AO228

9. Install the spark plugs (see Removing/Installing

Spark Plugs (660 cc) in this section).

10. Install the water pump/alternator belt cover and

secure with the two cap screws, one lock nut,

and washer.

11. Connect the coolant tube to the valve cover and

secure with the two cap screws. 

AO223

12. Secure the intake plenum brace to the intake

manifold with the three cap screws.

Shim Thickness (mm)

2.18

2.30

2.42

2.54

2.66

2.78

2.90

2.20

2.32

2.44

2.56

2.68

2.80

2.92

2.22

2.34

2.46

2.58

2.70

2.82

2.94

2.24

2.36

2.48

2.60

2.72

2.84

2.96

2.26

2.38

2.50

2.62

2.74

2.86

2.98

2.28

2.40

2.52

2.64

2.76

2.88

3.00

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3

AO224

13. Connect the breather tube to the engine cover.

AO225

„ NOTE: Make sure that the breather tube is con-
nected to the clamp at the top cap screw on the
intake plenum brace.

AO224A

14. After verifying hose and cable routings are cor-

rect, connect the ground cable to the battery.

Removing Spark Plugs

(1100 cc Z1)

„ NOTE: To remove the spark plugs, it will be nec-
essary to remove the air silencer. Proceed to Ser-
vicing Air Silencer (1100 cc Z1) sub-section and
follow steps 1-12 of REMOVING.

„ NOTE: To finalize the removing of the spark
plugs, use the following step 13.

13. Remove the two cap screws securing the igni-

tion coils to the engine cover; then using a 3/8-

inch drive ratchet, adapter, and a 5/8-in. spark

plug socket, remove the two spark plugs.

„ NOTE: For installing the spark plugs, proceed to
Installing Spark Plugs (1100 cc Z1) in this section.

Checking Compression

(1100 cc Z1)

„ NOTE: Prior to this test procedure, make certain
the battery is fully charged and the console is
positioned over the support bracket with the hood/
main harness plugged in.

„ NOTE: This test must be done with the engine at
“full-cranking RPM” and the decompression sys-
tem active.

With the spark plugs removed, install the compres-

sion tester gauge with adapter into the spark plug

hole; then with the throttle valve in the full-open

position, crank the engine over to get the psi read-

ing. Compression should be 8.4 kg-cm² (120 psi).

„ NOTE: Make certain that both cylinder compres-
sion readings are within 10% of each other.

Servicing Valves

(1100 cc Z1)

„ NOTE: For this procedure, disconnect the nega-
tive cable from the battery.

1. Disconnect the wiring harness plug-ins from the

ignition coils (A) and the camshaft position sen-

sor (B); then remove the two cap screws.

! CAUTION

Do not ground the spark plug on the cylinder head
cover. The cover is made of magnesium and any
contact with spark or electrical arc will severely pit
the surface.