Arctic Cat 660 cc, Service Manual

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Measuring Piston Pin Diameter
1. Measure the piston pin diameter at each end and in
the center. Measurement must be within
specifications. If measurement is less than
minimum specifications, the piston pin must be
replaced.
2. Piston pin diameter must be within specifications.
ATV-1070
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 specifications.
AO344
„
NOTE: Check piston pin, connecting rod small
end bore, and piston bore for wear or damage pay-
ing particular attention to condition of small end
bore bushing. If pin, connecting rod small end
bore, or piston bore is badly worn or damaged,
replace pin, connecting rod, or piston.
Cleaning/Inspecting/Measuring
Cylinder Block
1. Wash the cylinder block in parts-cleaning solvent.
2. Check the gasket surface of the cylinder for
distortion.
3. Using a straightedge and feeler gauge, check
surface at a total of 6 locations. If distortion limit
is exceeded, correct surface with a surface plate
and abrasive paper of about #400 grit.
AO349
4. Place paper on and over surface plate and rub
surface against paper to grind off high spots.
Should this fail to reduce gauge readings to within
limit, replace cylinder block.
5. Inspect the cylinder bore for pitting, scoring,
scuffing, warpage, and corrosion. If marks are
found, repair the surface using a #600 grit cylinder
hone and honing oil.
6. Hone the cylinder to produce a 15°-35°
crosshatch.
AO347
7. Wash the cylinder block thoroughly with hot
soapy water; then rinse with hot water.
8. Blow dry the cylinder block with compressed air
and apply oil to all of the steel cylinder surfaces.
9. If any measurement exceeds the limit, the
cylinders must be bored, oversized pistons must be
installed, or the cylinder block must be replaced.
PISTON SELECTION
„
NOTE: Two sizes of pistons are available as
standard size spare parts to ensure proper piston-
to-cylinder clearance. When installing a standard
size piston, make sure to match piston with cylin-
der using the following procedure.
1. Each piston has stamped number 1 or 2 as shown.
It represents outer diameter of piston.