Snowmobile Arctic Cat (2002 year). Instruction - part 97

0737-338

6-40

Harness

V

(p/n 0686-699)

7-1

7

SECTION 7 — STEERING AND BODY

TABLE OF

CONTENTS

Steering and Body................................................... 7-2
Steering Post (120 cc)............................................. 7-2
Steering Post (AWS III) ........................................... 7-5
Steering Post (AWS V) ............................................ 7-7
Ski ......................................................................... 7-11
Ski (120 cc) ........................................................... 7-12
Ski Wear Bar ......................................................... 7-13
Drag Link ............................................................... 7-14
Tie Rods (120 cc) .................................................. 7-15
Front Tie Rods....................................................... 7-16
Spindle (120 cc) .................................................... 7-18
Spindle .................................................................. 7-19
Steering Tie Rod ................................................... 7-21
Ski Alignment (120 cc) .......................................... 7-22
Ski Alignment ........................................................ 7-22
Front Suspension A-Arms (120 cc) ....................... 7-24
Front Suspension Arms......................................... 7-25
Front Suspension (Ski) Shock Absorber ............... 7-27
Sway Bar ............................................................... 7-28
Console (EFI Models) ........................................... 7-29
Console (Carbureted Model - Style A) .................. 7-30
Console (Carbureted Models - Style B)................. 7-31
Belly Pan (120 cc) ................................................. 7-34
Belly Pan ............................................................... 7-35
Seat/Cushion/Taillight Housing (120 cc) ............... 7-41
Taillight Housing .................................................... 7-43
Windshield............................................................. 7-44
Backrest/Rack/Taillight Assembly.......................... 7-44
Tunnel/Rear Bumper/Snowflap.............................. 7-46
Headlight Assembly (120 cc)................................. 7-49
Headlight Assembly (1 Bulb Halogen)................... 7-50
Adjusting Headlight Aim (1 Bulb Halogen) ............ 7-51
Headlight Assembly (3 Bulb Halogen)................... 7-51
Adjusting Headlight Aim (3 Bulb Halogen) ............ 7-52
Torque Specifications ............................................ 7-53
Torque Specifications (120 cc) .............................. 7-53
Torque Specifications (General Bolts) ................... 7-53

7-2

Steering and Body

This section has been organized into sub-sections for

servicing steering and body components; however,

some components may vary from model to model. The

technician should use discretion and sound judgment

when removing and installing components.

„

NOTE: Some illustrations and photographs used

in this section are used for clarity purposes only
and are not designed to depict actual conditions.

Steering Post

(120 cc)

REMOVING

„

NOTE: Perform steps 1-8 for both the brake and

throttle cables.

1. Remove the handlebar pad.

2. Remove the C-clips securing the brake and throttle

lever pins in the brake housing and throttle

control; then remove the pins and levers.

A979

A998

3. Disconnect the brake and throttle cables from the

levers; then slide the cables out of the levers.

A999

A980

4. Remove the C-clip securing the throttle cable in

the throttle control; then remove the cable from the

throttle control.

A981

A982

5. Cut the cable ties securing the cables to the

steering post.

7-3

7

6. Using a sharp knife, cut the grip off the handlebar.

7. Using a solvent, clean the old adhesive from the

handlebar.

8. Loosen the screw securing the emergency stop

switch to the handlebar; then remove the stop

switch.

9. Remove the two cap screws and lock nuts securing

the upper steering post bearing retainer; then

remove the retainer and bearing.

A023A

10. Pull the steering post up and out of the lower

bearing.

11. Remove the lock nuts securing the tie rods to the

steering post.

A024

„

NOTE: Use an additional wrench to keep the tie

rod end shaft from turning while removing the tie
rod lock nut.

12. Remove the steering post from the engine

compartment.

13. Remove the two cap screws and lock nuts securing

the lower steering post bearing retainer; then

remove the retainer and bearing.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect all welded areas for cracks or deteriora-

tion.

2. Inspect the steering post and bearing retainers for

cracks, bends, or wear.

3. Inspect the steering post bearings for wear, cracks,

or deterioration.

4. Inspect the tie rod ends for wear or damage.

INSTALLING

0737-141

1. Place the lower steering post bearing and retainer

into position on the front end; then loosely secure

with cap screws and lock nuts.

2. Place the steering post into position in the engine

compartment and secure the tie rods to the steering

post with washers and lock nuts. Tighten to 2.5-

2.8 kg-m (18-20 ft-lb).

„

NOTE: Use an additional wrench to keep the tie

rod end shaft from turning while tightening the tie
rod lock nut.

KEY

1. Steering Post
2. Handlebar Grip
3. Retaining Ring
4. Throttle/Brake 

Lever

5. Spring Pin
6. Engine Stop 

Decal

7. Throttle Control
8. Pin
9. Pad Cover

10. Pad
11. Brake Housing

12. Brake Cable
13. Cap Screw
14. Bearing 

Retainer

15. Bearing
16. Support
17. Tether Switch 

Assy

18. Tether Cord
19. Spring
20. Rivet
21. Lock Nut
22. Lock Nut

23. Washer
24. Tie Rod End
25. Hex Nut
26. Tie Rod
27. Hex Nut
28. Tie Rod End
29. Throttle Cable
30. Lock Washer
31. Engine Stop 

Switch

32. Cable Tie