Cylinder Inspection - Arctic Cat Cougar Service Manual

ENGINE
CAUTION
Do not rest the weight of the cylinder on
the reed valve assembly located at the
bottom of the cylinder on 529 cc engines.
8. Repeat the procedure to remove the other
cylinder(s).
9. Remove and discard the cylinder base gasket.
10. Cover the openings in the crankcase around
the connecting rods with clean rags to keep dirt
and loose parts from entering the crankcase.
Inspection
Cylinder measurement requires a precision
inside micrometer or bore gauge. If you do not
have the right tools, have your dealer or a ma-
chine shop measure the parts.
1. On the 529 cc engine, remove the reed valve
from the bottom of the cylinder.
2. Remove all gasket residue from the bottom
gasket surface.
3A. On liquid-cooled engines, clean the cylinder
0-ring groove (Figure 28) with a wooden dowel
sharpened to a point.
3B. On air-cooled engines, clean the top of the
cylinder carefully. Do not scratch the sealing
surface.
167
4. Clean all gasket residue from the exhaust
manifold sealing area of the cylinder.
CAUTION
When cleaning the exhaust port in Step
5, do not allow the wire brush or scraper
to slip inside the cylinder and damage
the cylinder bore. Be especially careful
when using power equipment, such as a
rotating wire brush in an electric drill.
5. Use a soft scraper or a wire brush to remove
all carbon deposits from the exhaust port.
6. Wash the cylinder with hot soapy water, then
rinse with water to remove loose dirt and carbon
particles before attempting to measure the cylin-
der bore. Measurements may be incorrect if the
cylinder is not cleaned thoroughly.
7. Measure the cylinder bore diameter as de-
scribed under Piston/Cylinder Clearance Check
in this chapter.
NOTE
If the cylinder diameters are within
specification, it is possible to buy and
install new standard size pistons without
reboring. New pistons will take up some
of the excessive piston-to-cylinder clear-
ance. However, do not install new stand-
ard size pistons in a cylinder that is worn
past the wear limit.
8. If the cylinder bore is not worn past the serv-
ice limit, check the bore carefully for scratches
or gouges. The hardened surface of the cylinder
bore should also be checked for flaking and bits
of aluminum from the piston stuck to the cylinder
bore.
9. Check all threaded holes in the cylinder block
for thread damage. Minor damage can be cleaned
up with a suitable metric tap. Refer to Chapter
One for information pertaining to threads, fas-
teners and repair tools. If damage is severe, a
thread insert should be installed.
10. Check the cy Iinder base studs for looseness,
stripping or other damage. If necessary, replace
studs as described in this chapter.