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4. Place the cylinder head on a Surface Plate covered with

#400 grit wet-or-dry sandpaper. Using light pressure,

move each cylinder head in a figure eight motion.

Inspect the sealing surface for any indication of high

spots. A high spot can be noted by a bright metallic fin-

ish. Correct any high spots before assembly by continu-

ing to move the cylinder head in a figure eight motion

until a uniform bright metallic finish is attained.

CYLINDERS

1. Using a non-metallic carbon removal tool, remove

carbon buildup from the exhaust ports.

2. Wash the cylinders in parts-cleaning solvent.

3. Inspect the cylinders for pitting, scoring, scuffing,

and corrosion. If marks are found, repair the surface

with the Ball Hone and honing oil.



NOTE: To produce the proper 45° crosshatch pat-

tern, maintain a low drill RPM. If honing oil is not
available, use a lightweight, petroleum-based oil.
Thoroughly clean the cylinders after honing using
detergent soap and hot water and dry with com-
pressed air; then immediately apply oil to the cylinder
bores. If a bore is severely damaged or gouged, the
cylinder must be replaced or replated.

4. Place the head surface of each cylinder on the sur-

face plate covered with #400 grit wet-or-dry sandpa-

per. Using light pressure, move each cylinder in a

figure eight motion. Inspect the surface for any indi-

cation of high spots. A high spot can be noted by a

bright metallic finish. Correct any high spots before

assembly by continuing to move the cylinder in a fig-

ure eight motion until a uniform bright metallic fin-

ish is attained.

PISTON

1. Using a non-metallic carbon removal tool, remove

the carbon buildup from the dome of each piston.

CRANKCASE

1. Scrape of any residual silicone from both the top and

bottom crankcase halves making sure not to damage

the sealing surface; then wash the crankcase halves

in parts-cleaning solvent.



NOTE: Before washing the crankcase halves, make

sure the four bearing dowel pins have been removed
and accounted for.

2. Inspect the crankcase halves for scoring, pitting,

scuffing, or any imperfections in the casting.

3. Inspect all threaded areas for damaged or stripped

threads.

4. Inspect the bearing areas for cracks or excessive

bearing movement. If evidence of excessive bearing

movement is noted, the crankcase must be replaced.

5. Inspect the bearing dowel pins for wear.

6. Inspect the sealing surfaces of the crankcase halves

for trueness by placing each crankcase half on the

surface plate covered with #400 grit wet-or-dry sand-

paper. Using light pressure, move each half in a fig-

ure eight motion. Inspect the sealing surfaces for any

indication of high spots. A high spot can be noted by

a bright metallic finish. Correct any high spots by

continuing to move the half in a figure eight motion

until a uniform bright metallic finish is attained.



NOTE: Care must be taken not to remove an exces-

sive amount of aluminum, or the crankcase must be
replaced. If excessive aluminum is removed, too
much pre-load will be exerted on the crankshaft bear-
ings when assembled.

CRANKSHAFT



NOTE: If any servicing of the connecting rods, cen-

ter bearings, or water pump drive gear is necessary,
Arctic Cat recommends the crankshaft be taken to a
qualified crankshaft rebuild shop for that service.

1. Wash the crankshaft with bearings in parts-cleaning

solvent.

2. Inspect the bearings for wear, scoring, scuffing, dam-

age, or discoloration. Rotate the bearings. Bearings

must rotate freely and must not bind or feel rough. If

any abnormal condition is noted, replace the bearing.

CWI-060

3. Inspect the connecting-rod bearings by rotating

them. The bearings must rotate freely and must not

bind or feel rough. If a connecting-rod bearing must

be replaced, the connecting rod and crank pin must

also be replaced.