Snowmobile Arctic Cat (2002 year). Instruction - part 117

 

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Snowmobile Arctic Cat (2002 year). Instruction - part 117

 

 

8-26

Drive Train/Brake Disc 

(w/Reverse)

DISASSEMBLING

1. Remove the chain-case drain plug located on the

lower back side of the chain case inside the tunnel

and drain the chain case lubricant.

2. Disconnect the battery cables. Remove the battery

and battery tray.

3. Open the belt guard and remove the drive belt.

4. Remove the cap screw and washer securing the

driven pulley; then account for and note the

position of any alignment washers.

SC013D

5. Slide the driven pulley off the driven shaft; then

remove the driven pulley from the engine

compartment. Account for the key, stub shaft, and

alignment washers.

„ NOTE: If the driven pulley is tight on the driven
shaft, pull the driven pulley off using the Driven
Pulley Puller (p/n 0744-023).

AF120D

„ NOTE: Tip the snowmobile on its left side posi-
tioning the chain case side of the snowmobile up.
Place a piece of cardboard under the side of the
snowmobile to prevent scratching of bumper and
belly pan.

6. Disconnect the shift linkage from the arm on chain

case.

7. Remove the cap screw from the center of the chain

case.

AI025

8. Remove the cap screws securing the chain case

cover; then remove the cover by pulling outward

and lifting up so the shift fork clears the large

inner washer.

AI010

9. Remove the screw from the chain adjuster housing

and install an 8-32 set screw to lock the chain

adjuster in position.

! CAUTION

Before tipping the snowmobile on its side, pull
the mirrors close to the hood or damage may
occur.

8-27

8

AF426

10. Remove the shim washer from the idler sprocket.

AF436

11. Remove the outer idler sprocket from the shaft.

AF437

12. Slide the small rubber alignment pin from the face

of the inner idler sprocket and place in safe

location until assembly.

AF439

13. Remove the lock nut securing the top sprocket.

AF432

14. Remove the spring washer in front of the top

sprocket.

AF444

15. Set the brake lever lock. Remove the cap screw

and large washer securing the bottom sprocket.

„ NOTE: The bottom sprocket cap screw and
washer are spring loaded.

8-28

AF428

16. Remove the reverse gear.

AF442

17. Remove the top sprocket, chain, and idler gear.

Account for one shim washer located behind the

idler gear.

AF433

„ NOTE: If the chain is too tight and wont allow the
top sprocket to be removed, remove the PTO-side
driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will loosen
the chain.

18. Remove the driveshaft extension, bottom sprocket,

and spacer washer.

AF427

19. Check the idler gear shaft. If the shaft surface is

rough, remove the shaft using a pair of vise-grip

pliers. Rotate the shaft counterclockwise.

20. Remove the shoulder nut securing the chain

tightener arm; then remove the arm from the chain

case.

AF447

21. Remove the three lock nuts securing the top

bearing flange plate. Remove the flange plate,

seal, and bearing.

AI018

22. Remove the three lock nuts securing the bottom

bearing flange plate. Remove the flange plate,

seal, and bearing.

23. Remove the screw securing the air-intake silencer

to the steering support; then pull the silencer

forward and place it on the carburetor/throttle

body assembly.

8-29

8

„ NOTE: Using a hold-down strap, secure the air-
intake silencer to the engine.

24. Loosen the set screw on the PTO-side driven shaft

collar. Drive the collar clockwise (opposite shaft

rotation) until it is free.

„ NOTE: A fine file should be used to remove any
burrs left by the collar set screw.

25. Remove the lock nuts and carriage bolts securing

the PTO-side driven shaft flange plates.

AF002D

26. Force the driven shaft toward the PTO-side

(rotating the shaft to prevent the brake disc from

binding on the shaft) until brake disc is free.

Account for the key.

27. Continue to slide the driven shaft until it is out of

the PTO-side. Account for a bearing, two flange

plates, and the PTO-side driven shaft collar.

28. Remove the skid frame from the tunnel (see

Section 9).

29. Remove the three PTO-side lock nuts securing the

driveshaft flange bearing assembly and cable

adapter. Remove the adapter and speedometer

cable.

AF053

30. Tap the driveshaft toward the chain case to unseat

the MAG-side bearing. Remove the bearing.

31. Slide the driveshaft toward the MAG-side until the

PTO-side of the driveshaft is out of its mounting

hole. Tilt the end of the driveshaft away from the

tunnel and slide the driveshaft free of the tunnel.

Remove the track.

AF055

32. Scribe a line on the driveshaft along the edge of

each sprocket to aid in assembly. Loosen the set

screw on the collar and drive the collar clockwise

until free; then remove the bearing and flange

plates from the driveshaft.

33. Press the sprockets off the driveshaft.

34. Remove the six socket-head cap screws and lock

nuts securing the brake disc to the hub; then

separate disc and hub.

AF446

CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Thoroughly wash all metallic components in parts-

cleaning solvent. Dry using compressed air.

2. Wash all non-metallic components with soap and

water.

3. Inspect the driveshaft and driven shaft for

damaged splines or stripped threads.

4. Inspect the bearings for any roughness or damage.

5. Inspect the seals for any breaks or damage.

 

 

 

 

 

 

 

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