Threaded Holes And Screws; Cylinder Installation - Arctic Cat Cougar Service Manual

ENGINE
8. Follow Loctite's directions on cure time be-
fore installing the cylinder.
Threaded Holes and Screws
Damaged or dirty threaded holes, studs or
bolts will prevent parts from fitting together as
tightly as they should. This will reduce engine
performance and cause engine damage. Be sure
the studs are properly seated and that proper
washers are used.
Installation
1. If the intake adapter or the carburetor mount-
ing flange were removed from the cylinder, in-
stall them using new gaskets.
2. On the 529 cc engine, attach the reed valve
assembly to the cylinder block.
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169
3. Clean the cylinder bore as described under
Inspection
in this chapter.
4. Make sure the top surface of the crankcase
and the bottom cylinder surface are clean prior
to installation.
5. Install a new base gasket.
NOTE
Check the pistons to make sure the piston
pin clips (Figure 41) are installed and
correctly positioned so that the gap is
down.
6. Make sure the end gaps of the piston rings are
aligned with the locating pins in the ring grooves
(Figure 42). Oil the piston rings and the inside
of the cylinder bores lightly with injection oil.
7. Place a piston holding tool or a wooden block
(Figure 43) under one piston and turn the crank-
shaft until the piston is down firmly against the
tool.
NOTE
When reinstalling the original cylinders,
install them in the previously marked
locations.
8. Align the cylinder with the piston so that the
exhaust port will face toward the front of the
engine. Install the cylinder, compressing each
piston ring with your fingers as the cylinder
slides over it. When both rings are in the cylinder,
slide the cylinder down and remove the piston
holding tool. Slide the cylinder all the way down
against the gasket and crankcase. Make sure the
base of the cylinder is fully seated against the
crankcase. See Figure 44.
9. Repeat the procedure to install the other cyl-
inder(s).
NOTE
On air-cooled engines, long studs are
used that pass through the cylinder and
the cylinder head. The cylinder is re-
tained by the cylinder head, which is
secured by nuts on the studs.