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Discussion Starter #1
Hi. I am looking into replacing the fan cooled engine in one of my sleds with the most powerful fan cooled STOCK engine out there, seemingly the Suzuki 570 fan. If I am wrong about that, please enlighten me.

I am wondering about different version of the engine,

1. Which version is the most powerful, models and years?
2. Which versions had electronic reverse, if any?
3. There seem to be some changes made to the engine from 2007 on, which are these?

Help please! Before you even get started on that, NO I am not going to tune any engine in any way, this sled is supposed to remain (almost) totally stock (except for a little engine swap) and always be in working condition :) Well, I might be interested in some small, simple, and reliable mods...
 

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Discussion Starter #3 (Edited)
Szledhead:
Finally one reply, lol. I'm putting it into a 2001 Lynx Ranger FCE, a sled you have most likely never seen in real life ;) It is in my opinion one of the greatest all-around sleds ever made, strangely enough it even is fun to ride. It only has a few irritating drawbacks, one of them being the lack in power.

Ok, I'll start throwing out some information that I believe are "facts" I have been able to find pick up here and there. I know that if I write something wrong, people will chime in and correct me.

Pre-2007: 570 gen 1. It was advertised as around 70 HP.

2007-2009: 570 gen 2. Cleaner and more fuel efficient. It was advertised as around 62-63 HP. The drop in power from gen 1 was clearly noticeable.

2010-: 570 gen 2 with electronic reverse, otherwise the same engine with 62-63 HP.

If somebody has some dyno charts I would be happy. I haven't been able to find a single one.

So it looks like I might have to get an engine from 2010 or later (or at least the electronics from one). Then switch out the cylinders, head and maybe the exhaust for some pre-2007 versions and be all set.

After that I just have to put on an AAEN pipe, some bigger carbs, rework the head, some porting, and... ...here we go again...
 

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Discussion Starter #4 (Edited)
Ok, for everybody interested, here is what I have been able to find out by digging through Arctic Cats part lists. I will only list the parts that are most important for power or function, i.e. electrical reverse.

The exhaust system might work slightly better in some models, though it is impossible to know without more information or testing. For anybody performing an engine swap it is also more likely to start with one that fits the chassis the best, so I omitted that information. If the pipe design changed significantly at all through the years, it is most likely to have happened in 2007 when the new cylinder design came out.

It should also be noted that everytime Arctic Cat changed the CDI unit, they might also have tweaked the ignition mapping. The only thing I am pretty certain of is that the ignition mapping changed significantly in 2007 when the engine was completely reworked. So I think the years 2003-2006 have pretty similar mapping and 2007-2020 are pretty similar. 2002 is the odd man out, I think they more or less took the ignition from whatever and went with that the first year. 2002 might even be the most powerful year of the 570 Fan, but the mapping maybe was deemed too aggressive for Arctic Cat so they changed it for 2003, who knows. Again, without further information or testing, it is impossible to tell the CDI units apart.

One remark about the two different heads used. The one used from 2002-2006 actually does not look too bad, though I suspect the squish clearance is far too big. The design from 2007-2020 looks absolutely horrible in my opinion, but it works.


CYLINDERS:
2002-2006 (70hp) 3005-999
2007-2020 (62hp) 3007-479

HEAD:
2002-2006 3005-997
2007-2020 3007-477

CDI UNIT:
2002 3006-023
2003-2006 3006-532
2007-2009 3007-490
2010-2020 3007-868

STATOR:
2002-2020 (all) 3005-636

FLYWHEEL:
2002-2009 3006-467
2010-2020 3007-867

TRIGGER:
2002-2020 (all) 3005-926

IGNITION COIL:
2002 3005-409
2003-2020 3006-534

CRANKSHAFT MAG:
2002-2020 (all) 3006-007

CRANKCASE:
2002 3006-002
2003-2020 3007-676


TO CONCLUDE, based on educated guesses, it roughly should look like this.

Odd man out 2002

Most power 2003-2006

Lower emissions 2007-2020
and fuel consumption

Ditto, 2010-2020
incl. electrical reverse

So, if you want the most power combined with electrical reverse, use the engine from 2010 and forward (or selected parts) and combine it with the cylinders, head and maybe some pipe from 2002-2006. That is what I'm gonna do. I can see no reason why it shouldn't work except the mapping of the CDI unit not being perfect for the cylinder porting of the older cylinders. Well, I can guarantee that the mapping wasn't perfect any year anyway so... The manufacturers always play it safe, especially back then and for engines like these. The ignition curve should be close enough, at least for good power.

If you combine parts like I suggest above and your engine seizes, don't blame me. You still have to know what you are doing by checking the jetting, the ignition, and other related stuff. But you all know that.

EDIT:
Information about ignition coil added.

EDIT2:
Information about crankshaft mag side and crankcase added.
 

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I never realized there was a difference in the cylinders. just use whatever you find, run the Aaen pipe if you can get one, hit it with a small timing key, run it lean and mean, and call it a day.
 

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I don’t think the 570 ever had electronic reverse. It had push button that shifted the gears in the drive for reverse. The only cats that have ever had it are the efi 600/800/1000 where the engine spins back wards.
 

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Discussion Starter #7 (Edited)
Thank you guys!

stronger800:
I might do all that, but only on the 2002-2006 cylinders. This is my main hobby, I do not care if it costs me some completely unjustifiable money ;)

Greg B.:
Are you really sure about that? Then why did the 570 get a new CDI box AND a new flywheel for 2010, exactly the year when the other engines you mention got electronic reverse? To be sure I'll have to look further into this. If the 570 never did get electronic reverse, it probably is dead to me.

Since the Rotax 550 is a total dog in multiple ways, my second choice would probably be the Polaris 550, and then the Yamaha 540 if it has electronic reverse in its later years. But I am really hoping for the Suzuki 570. Oh, I forgot to mention that my current engine is the Rotax 503 with electronic reverse and about 53hp. Great engine except for the error prone Ducati electronics and the measly power.

EDIT:
It's confimed. The Suzuki 570 HAD engine reverse from 2010 on :)
 

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You are correct, appears the 2010 and later 570's had the shift fork removed from the gearcase.
 

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My sister has one of those...next time I’m over there I’m going to fire it up and shift it. Pretty sure is a ‘10 and I thought it had the reverse servo on the gearcase,
 
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