Arctic Cat 700 Diesel ATV 2007 Service Manual page 85

5. Make sure the cylinder deck plane is completely
free of all gasket material, carbon, and sealant;
then using a precision straight edge and feeler
gauge, check for cylinder deck trueness. Maxi-
mum variation must not exceed 0.1 mm (0.0039
in.).
NOTE: Planing the engine block is not recom-
mended as it will directly affect piston-to-cylinder
head clearance. To determine if the cylinder deck
can be planed, use the following procedure.
A. Determine the maximum cylinder deck varia-
tion (V ).
d
B. Add the deck variation (V
trusion (P ) determined during removing (V
p
P ) to determine final piston protrusion (P
p
V + P = P
d p pf
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3-62
) to the piston pro-
d
.
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C. Compare the final piston protrusion (P
chart to determine if gaskets are available that
would allow planing of the cylinder deck.
Final Piston
) Gasket Thickness
Protrusion (P
pf
0.82-0.91 mm
(0.032-0.036 in.)
0.92-1.01 mm
(0.036-0.040 in.)
1.02-1.10 mm
(0.040-0.043 in.)
Example 1:
DE605
P = 0.82 mm (0.032 in.)
p
V = 0.13 mm (0.005 in.)
d
0.82 + 0.13 = 0.95 mm (0.037 in.)
P = 0.95 mm (0.037 in.)
pf
Using the preceding chart, the middle gasket could be
used; therefore, the cylinder deck could be planed suf-
ficiently to be salvaged.
Example 2:
P = 0.82 mm (0.032 in.)
p
V = 0.30 mm (0.012 in.)
d
0.82 + 0.30 = 1.12 mm (0.044 in.)
P = 1.12 mm (0.044 in.)
pf
Using the preceding chart, it can be determined that no
gasket would be available to allow sufficient pis-
ton-to-cylinder head clearance; therefore the engine
block must be replaced.
D. If engine block is not serviceable, it must be
DE348
replaced with a new block.
6. Thoroughly clean the engine block using a
non-caustic engine cleaning solution; then rinse
with hot water and dry with compressed air.
Always wear safety glasses when using compressed
air.
7. Using a cylinder bore gauge or suitable snap gauge
and micrometer, measure the cylinder bore at three
locations taking measurements at 45° intervals. If
DE347 the cylinder is found to be 72.050 mm (2.836 in.)
or greater at any measurement point, the cylin-
der(s) must be bored. Oversized pistons/rings are
available in 0.50 mm (0.020 in.) and 1.00 mm
(0.039 in.) sizes.
+
d
).
pf
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# of Holes
1.56-1.64 mm
(0.061-0.065 in.)
1.66-1.74 mm
(0.065-0.069 in.)
1.76-1.84 mm
(0.069-0.072 in.)
! WARNING
) to the
pf
1
2
3
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