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Snowmobile Arctic Cat (2002 year). Instruction - part 130

8-78

Troubleshooting

Drive Belt

Problem: Drive Clutch Engagement (Before Specified RPM)

Condition

Remedy

1. Drive clutch spring weak — bent

2. Cam arms incorrect — worn

1. Replace spring

2. Replace cam arms

Problem: Drive Clutch Engagement (After Specified RPM)

Condition

Remedy

1. Drive clutch spring incorrect

2. Spider buttons worn

1. Replace spring

2. Replace buttons

Problem: Drive Clutch Sticks

Condition

Remedy

1. Drive clutch components dirty

2. Movable sheave bent — binding

3. Spider buttons worn

1. Clean drive clutch components

2. Clean — replace movable sheave

3. Replace buttons

Problem: Drive Clutch Jerks—Shifts Erratically

Condition

Remedy

1. Drive clutch dirty

2. Rollers worn

3. Cam arms rough

4. Spider buttons worn

5. Sheaves dirty

1. Clean — drive clutch components

2. Replace rollers

3. Polish — replace cam arms

4. Replace buttons

5. Clean sheaves

Problem: Drive Belt Glazed

Condition

Remedy

1. Drive belt does not meet measurement

specifications

2. Drive clutch spring tension inadequate

3. Drive clutch components dirty — damaged

4. Offset — parallelism — center-to-center

distance adjusted incorrectly

1. Replace drive belt

2. Replace drive clutch spring

3. Clean — replace drive clutch

4. Adjust offset — parallelism — center-to-center

distance

Problem: Drive Belt Lugs Torn Off—Frayed—Worn in One Spot

Condition

Remedy

1. Drive belt does not meet measurement

specifications

2. Offset — parallelism — center-to-center

distance adjusted incorrectly

3. Drive clutch engagement — idle RPM too high

4. Drive clutch components dirty — damaged

5. Driven pulley/shaft rotation impaired

1. Replace drive belt

2. Adjust offset — parallelism — center-to-center

distance

3. Service drive clutch — reduce idle RPM

4. Clean — replace drive clutch components

5. Service driven pulley/shaft — chain-case

components

8-79

Troubleshooting

Hydraulic Brake

System

Problem: Caliper Leaks

Condition

Remedy

1. Caliper O-ring deteriorated — severed

2. Piston — O-ring damaged

1. Replace O-ring

2. Repair piston — replace piston — O-ring

Problem: Lever Spongy — Bottoms Out

Condition

Remedy

1. Brake system air bubbles present

2. Master cylinder damaged — faulty

1. Bleed brake system

2. Replace master cylinder

Problem: Oscillation Feedback in Lever

Condition

Remedy

1. Brake pad residue present on brake disc

2. Caliper loose

3. Brake disc warped — cracked — damaged —

misaligned

1. Replace pads — clean disc

2. Tighten mounting bolts

3. Replace disc — driven shaft bearing

Problem: Loss of Brake

Condition

Remedy

1. Brake fluid overheated — contaminated

2. Master cylinder damaged — faulty

3. Caliper — brake hose leaking

4. Air ducts obstructed — missing

5. Brake lever linkage damaged

1. Replace fluid

2. Replace master cylinder

3. Replace caliper O-ring — repair piston —

replace piston — O-ring — brake hose

4. Remove obstruction — replace air ducts

5. Repair — replace lever — mounting bolt

Problem: Brakes Drag

Condition

Remedy

1. Master cylinder damaged — faulty

2. Brake disc warped — damaged — misaligned

3. Brake pads worn — tapered

1. Replace master cylinder

2. Replace disc — driven shaft bearing

3. Replace pads

Problem: Snowmobile Won’t Stop — Have to Pull Too Hard on Lever

Condition

Remedy

1. Pads/brake disc glazed

2. Brake lever binding

3. Caliper pistons binding

1. Replace pads — clean disc

2. Loosen pivot bolt — replace master cylinder

3. Service caliper assembly

8-80

NOTES

9-1

SECTION 9 — TRACK/REAR

SUSPENSION

TABLE OF

CONTENTS

Understanding the Suspension ............................... 9-2
Suspension Setup Basics ....................................... 9-3
2002 Suspension Mounting Location Chart ............ 9-6
Chassis and Skid Frame

Mounting Locations (2002) .................................. 9-7

Reservoir w/Clicker .......................................... 9-182

Bearing Cap and Shaft Seal................................ 9-186
Shaft Eyelet ......................................................... 9-187
Ski Shocks Bottom-Out Bumper.......................... 9-188
Pressurizing Rebuildable Shocks........................ 9-188
Troubleshooting Track ......................................... 9-189

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