Project Arctic Cat.

[OPowersports]

Here are some photos of a bad Nikasil cylinder being bored to accept a cylinder sleeve.

[OPowersports]

The next pic is the fixture I made to hold the cylinder while boring. Photo three is the cylinder ready for boring. The fourth photo is after the first pass that essentially removed the old coating (very hard stuff)

[OPowersports]

Cylinder bored and ready for the sleeve.

[OPowersports]

Cylinder sleeve installed . .004 press fit (requires heating the cylinder to 400 deg to install the sleeve)

[OPowersports]

Finally the sleeve itself is bored and honed the deck is surfaced and the cylinder is ready for use.

[OPowersports]

.

[trx#9]

You have to set up the piston with the new steal sleeve cylinder a little loser than the nikasil cylinder, to prevent the piston from sticking.

[DALEQUAD]

looks good to me matt, is that thing goin to spank the 450's

[OPowersports]

You have to set up the piston with the new steal sleeve cylinder a little loser than the nikasil cylinder, to prevent the piston from sticking.

yes but only by .0005" . Factory calls for .0011~.0018 so I took the mean dimension of .00145 and added .0005 and made it .002" clearance. It is a Cast piston so they don't expand like a forged one and you can run tighter clearances.

looks good to me matt, is that thing goin to spank the 450's

I am sure it will since the rider is Paul and we know how superior his skills are. 

[Paul_S]

Looking great Matt...it's no 400ex but the mud machine looks like it's going to make a return to a Motoplex near you soon. 

[DALEQUAD]

Looking great Matt...it's no 400ex but the mud machine looks like it's going to make a return to a Motoplex near you soon. 

so that goes to the green monster

[OPowersports]

Looking great Matt...it's no 400ex but the mud machine looks like it's going to make a return to a Motoplex near you soon. 

so that goes to the green monster

Yeap!

[DALEQUAD]

OH SNAP 

[OPowersports]

Tinkered with the Arctic Cat a little this weekend.

[OPowersports]

A little worried about how blue the crank is on the left side shown in the picture above but the rod bearing feels good....Probably that freds oil Paul uses.

[OPowersports]

The picture above is what Paul believes to be the only real problem with the cat ( a bad spark plug) It is almost unrecognizable with all that Freds oil baked onto it. The exhaust valves and ports are also caked with oil and carbon build up. I cleaned up the valves with a wire wheel and did a basic port job to remove the build up from the ports. I then lapped the valves to the seats and cleaned the head gasket surface. I also was putting on new valve stem seals and discovered that 1 of the brand new seals was not made correct so now I am held up by a stupid $5.00 seal.

[Motoplex_Hitman]

Nice work !

[Paul_S]

Yeah like I said...new plug should sort it out...plus a couple of quarts of Freds finest.

[SuperCoop]

Its a good thing that you have been spending some time on the 525, you should be able to handle all the power Matt is going to put back in the Artic Cat....

[Andy9933]

Its a good thing that you have been spending some time on the 525, you should be able to handle all the power Matt is going to put back in the Artic Cat....

That's what I was thinking, That will be paul's new mx bike.

[Paul_S]

 

[zman03]

wow!!!!   opowersports  made er shine like new!!!  this guy took care of business!!!  good work!

[Paul_S]

wow!!!!   opowersports  made er shine like new!!!  this guy took care of business!!!  good work!

You ever need your spark plug changed...this is your man. 

[MPTonyT]

wow!!!!   opowersports  made er shine like new!!!  this guy took care of business!!!  good work!

You ever need your spark plug changed...this is your man. 

I heard he does chain adjustments as well. 

[OPowersports]

While working on the Cat I started finding metal filings  in places it should not be. So a complete tear down started. I found a starter gear Idler boss half broken off a busted idler shaft and where the idler gear was eating into the engine case. New engine case is 993.00 so plan b was to try and salvage it, I think it may work.