Installing Top-Side Components - Arctic Cat ATV 250 Utility 2009 Service Manual

Installing Top-Side
Components
A. Piston
B. Cylinder
1. Install the piston on the connecting rod making sure
there is a circlip on each side and the open end of
the circlip is directed upwards or downwards.
NOTE: The piston should be installed so the IN
mark is toward the intake (rear) side of the cylinder.
2. Place the two alignment pins into position. Place the
cylinder gasket into position; then place a piston
holder (or suitable substitute) beneath the piston skirt
and square the piston in respect to the crankcase.
3. Lubricate the inside wall of the cylinder; then
using a ring compressor or the fingers, compress
the rings and slide the cylinder over the piston.
Route the cam chain up through the cylinder cam
chain housing; then remove the piston holder and
seat the cylinder firmly on the crankcase.
! CAUTION
The cylinder should slide on easily. Do not force the
cylinder or damage to the piston, rings, cylinder, or
crankshaft assembly may occur.
4. Turn the cam chain tensioner screw clockwise to
retract the tensioner spring.
C. Cylinder Head
D. Valve Cover
NOTE: Steps 1-4 in the preceding sub-section
must precede this procedure.
5. While keeping tension on the cam chain, place the
front cam chain guide into the cylinder.
! CAUTION
Care should be taken that the bottom of the chain
guide is secured in the crankcase boss.
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6. Place the head gasket into position on the cylinder.
Place the alignment pins into position; then place
the head assembly into position on the cylinder
making sure the cam chain is routed through the
chain cavity.
! CAUTION
Keep tension on the cam chain to avoid damaging the
crankcase boss.
7. Turn the crankshaft as required to align the "T"
mark on the rotor/flywheel with the index mark on
the right-side crankcase cover.
8. With the index hole in the camshaft gear directed
away from the cylinder head and the two punch
marks aligned with the cylinder head surface,
install the timing gear into the cam chain and seat
the camshaft into the camshaft journals.
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3
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KM779A
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