Yet another setback

Well, I got past the impulse line...no big deal.   I was then at the point where I wanted to install the engine in the chassis.  So i read through the service manual, step-by-step, and look at the chassis.   Seems that there is one more part that I will need to swap that the carb motors do not share with the efi's, the cylinder head.  The EFI motors have a coolant hose running from the throttle body to the thermostat housing on the cylinder head, and the carbs do not.   So now I have to locate the correct cylinder head.

Impulse Line replaced

I was lucky that one of my local Arctic Cat Dealers had the crankcase plug and gasket in stock, so I went an purchased them for $6.34 total - Thanks Groves!  Since I couldn't locate the torque specs for the plug I tightened it as much as I dared to before I though it would break.

Impulse hose

Confirmed that the hose in question from my previous post is in fact an impulse hose that is used for the fuel pump on carburetor ZR600's.  So obviously the engine I received is from a 1998 ZR 600 carburetor model and not EFI.  I don't think it will be a problem, just remove the impulse line and replace it with the crankcase plug and gasket that is in the EFI models.....around $7 from the dealer.

Ohm spec for a 2000 ZR600 EFI among others

Mystery hose

Not sure what this hose is for, I think an impulse line which the efi does not use, but the carb does.

Flywheel and starter pulley

Piece of cake.....put the flwheel on over the crank key and the magnets sucked the flywheel all the way on to the shaft......

Stator II

After a trip to my local cycle salvage (Slicks in Mason MI) I picked up a few rubber grommets.  While none of them were an exact fit, I was able to trim one to fit, kind of.   I am going to put some high temp epoxy on the outside of the grommet to hold it in place before I install the motor in the chassis.....stator installed, on to the flywheel and starter pulley.

Stator

The timing sensor went in no problem.   Only two screws so how could it not??!   On to the replacement stator.    I applied the blue loctite to the screws and then torqued them down the best I could as I do not have any allen wrenches that will work with any of my torque wrenches.  No issues until I put the magneto housing on.  I seem to have mis-placed the rubber grommet that goes around the stator and timing sensor wires!   More delay................

Timing Sensor installed...

Turns out there was a period from 98-99 where the timing sensor was in the 92-100 ohms range.  At least according to the various snowmobile forums, and since the sensor worked fine before the crank bearings blew I went a head and installed it.

Timing Sensor

After many more setbacks I am back at it.    First thing I needed to do was install the timing sensor before isntalling the stator.   Not wanting to take the engine apart again any time soon I put my OHM meter on the sensor to test it.     According to my Arctic Cat manual the ohms should read between 128 and 150....hmmm, this sensor reads 95.   Doing a quick search on google shows that there may be an error in the manual for this model year.....doing some digging.

Happy New Year!

Ok, I know it's a little late but it was a hectic end of year...hopefully things will stay quiet and I can get back at it.