Snowmobile Arctic Cat (2002 year). Instruction - part 150

9-78

AG527D

3. Place the rail into position; then install the adjuster

bushing and rear idler wheel. Secure with a cap

screw (coated with red Loctite #271) and flat

washer. Tighten to 3.2 kg-m (23 ft-lb); then install

the wheel insert.

AG551D

AG626D

4. Install the rear arm limiter cap screw (coated with

red Loctite #271) in the appropriate hole (as noted

during disassembly) and tighten to 3.2 kg-m

(23 ft-lb).

5. Install the rear inner idler wheels in the appropri-

ate hole as noted during disassembly and secure

with cap screws (coated with red Loctite #271)

and lock nuts. Tighten to 3.2 kg-m (23 ft-lb).

AG592D

6. Secure the front arm mounting bracket with the

cap screws (coated with red Loctite #271) and lock

nuts. Tighten to 2.4 kg-m (17 ft-lb).

AG497D

7. Place the spring into the slide blocks; then place

the spring slide and slide block assembly into posi-

tion on the slide rail. Secure with a cap screw

(coated with red Loctite #271) and washer.

Tighten to 3.2 kg-m (23 ft-lb).

AG680D

9-79

9

AG593D

8. Secure the front shock absorber axle with a new

cap screw (coated with green Loctite #609) and

lock washer. Tighten to 4.2 kg-m (30 ft-lb).

„

NOTE: Make sure the axle threads are clean;

also, always use new cap screws whenever install-
ing.

AG514D

9. Secure the outer idler wheel mounting block with

the cap screw and lock nut. Tighten to 3.2 kg-m

(23 ft-lb).

AG686D

10. Secure the outer idler wheel to the mounting block

with a cap screw, flat washers, idler wheel, axle,

and a lock nut. Tighten to 3.2 kg-m (23 ft-lb).

AG512D

11. Secure the crossbraces with cap screws (coated

with red Loctite #271). Tighten to 1.5 kg-m

(11 ft-lb).

AG511D

12. Install the rear arm in the appropriate hole as noted

during disassembly; then secure with a cap screw

(coated with red Loctite #271) and lock nut.

Tighten to 3.2 kg-m (23 ft-lb).

AG694D

„

NOTE: Apply a light coat of grease to the slide

rail surface to aid in installing a new wear strip. If
there are any sharp edges on the lower portion of
the rail, use a file to remove them.

9-80

AG534D

13. From the back, start the wear strip onto the rail;

then using a block of wood and a hammer, drive

the wear strip forward into position. Secure with a

machine screw and lock nut. Tighten to 1.1 kg-m

(8 ft-lb).

AG535D

AG509D

14. Secure the end cap onto the slide rail using a cap

screw, flat washers, and a lock nut. Tighten to

1.1 kg-m (8 ft-lb).

AG506D

„

NOTE: On models with remote adjuster, install

all cable ties securing the hose to the slide rail and
arm.

15. Install the short spring leg onto the adjusting cam.

AG516DA

16. Adjust suspension.

17. After the skid frame has been installed, adjust

track tension deflection (see Track Tension in this

sub-section) and track alignment (see Track Align-

ment in this sub-section).

9-81

9

Installing Skid Frame

1. Place a piece of cardboard on the floor to protect

against scratching and tip the snowmobile onto

one side.

2. Pull the track away from the tunnel and spread

open; then place the skid frame into the track.

3. Position the front of the skid frame into the tunnel

and align the front arm with the appropriate

mounting hole in the tunnel. Insert the cap screw

with washers through the tunnel mounting hole

and through the front arm. DO NOT TIGHTEN

AT THIS TIME. Repeat this procedure on the

other side.

„

NOTE: To aid in centering the front arm with the

hole in the tunnel, position the skid frame and
track at a 45° angle to the bottom of the tunnel.

4. Elevate the rear of the skid frame and the track

into position in the tunnel.

5. Align the offset pivot idler arm assembly with the

appropriate hole in the tunnel. Secure the offset

pivot idler arm assembly with a cap screw (coated

with red Loctite #271), lock washer, and flat

washer. DO NOT TIGHTEN AT THIS TIME.

„

NOTE: Do not install the short legs of the rear

springs onto the adjusting cams at this time.

6. At this time, tighten all four skid frame mounting

cap screws to 3.2 kg-m (23 ft-lb).

7. Using the Rear Suspension Spring Tool (p/n 0144-

311), install the short legs of the rear springs onto

the adjusting cams making sure the cams are in the

same adjustment positions.

„

NOTE: On models with remote adjuster, guide

the adjuster reservoir hose through the hole in the
left-side tunnel panel. Route the hose through the
clamp attached to the speedometer drive; then
attach to the quick-coupler.

8. Tighten the two track tension adjusting bolt evenly

until track deflection is within specifications; then

lock the jam nuts to secure the adjustment.

9. Check track tension deflection and alignment;

adjust if necessary (see Track Tension and Track

Alignment in this sub-section).

Track Tension

CHECKING DEFLECTION

1. Tip the snowmobile on its side.

2. Hook a spring scale around a track clip at mid-

span; then pull the track down with the scale to 9

kg (20 lb) and measure the distance between the

bottom of the wear strip and the inside surface of

the track clip. Track deflection must be within

specifications.

729-429A

„

NOTE: If the track is new, it will stretch slightly

and take a “set” within the first 300 to 500 miles of
operation.

ADJUSTING DEFLECTION

1. Place the snowmobile up on a shielded safety

stand. Check to make sure the track is 2-3 in. off

the floor.

2. If the measurement is not as specified, loosen the

jam nuts of the adjusting bolts.

! WARNING

Deactivate all switches.

Rear Suspension 

Style

Setup

Tension

After Break-In

Tension

FasTrack w/o Torque 

Sensing Link

19-25 mm 

(3/4-1 in.)

25-32 mm

(1-1 1/4 in.)

FasTrack w/Torque 

Sensing Link

(121 in. Track)

32-38 mm

(1 1/4-1 1/2 in.)

38-44 mm

(1 1/2-1 3/4 in.)

FasTrack w/Torque 

Sensing Link 

(136 in. Track)

38-44 mm

(1 1/2-1 3/4 in.)

50.8-57.2 mm 

(2-2 1/4 in.)