Snowmobile Arctic Cat (2002 year). Instruction - part 118

 

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Snowmobile Arctic Cat (2002 year). Instruction - part 118

 

 

8-30

6. Inspect the track for cuts, gouges, or wear.

7. Inspect the keyways in the driven shaft and the

brake hub for wear or damage.

8. Inspect the brake disc for wear or cracks.

9. Inspect the track drive sprockets for wear or

damage.

10. Inspect the top sprocket for any chipped or worn

teeth.

11. Inspect the bottom sprocket teeth for wear. Turn

the inner sprocket bearing by hand and inspect for

any signs of being rough.

12. Inspect the three bottom sprocket drive pins.

Check the pin edges for chipping and wear.

13. Inspect the drive pin springs for tension by

pushing each pin into the sprocket and releasing it.

It must snap back out without any signs of

binding. If any of these items (pins, bearing,

sprocket, teeth) appear worn, replace the sprocket

as an assembly.

AI019

14. Inspect the idler gear sprocket teeth and bearings.

Rotate the inner bearings by hand. Check each

sprocket tooth for any signs of chipping and wear.

15. Closely inspect the drive chain for broken links.

16. Inspect the reverse gear. Inspect the teeth for wear

and chipping. Inspect the edges of drive pin holes

for any signs of chipping and wear.

17. Remove the snap ring from the reverse gear.

Remove the outer thrust washer, thrust bearing,

and inner thrust washer. Inspect the thrust bearing

by placing it between the two thrust washers and

rotating the thrust washer. Rotation must feel

smooth. If any roughness is noted, replace the

thrust washers and bearing as a set.

18. Inspect the chain tightener bearing. Rotate the

tightener roller and check for smooth rotation. If

rotation feels rough, replace roller and bearing

assembly.

ASSEMBLING

1. Secure the hub to the brake disc with six socket-

head cap screws (coated with red Loctite #271)

and lock nuts. Tighten lock nuts to 0.4 kg-m

(36 in.-lb).

AF445

2. Press the sprockets on the driveshaft noting the

scribed marks on the shaft and the timing mark

found on one tooth of each sprocket. The timing

mark is the letter T molded into the outer surface

of one drive tooth. All the T markings must be in

alignment.

„ NOTE: Sprocket style will vary from model to
model.

0728-351

0727-829

8-31

8

727-829A

„ NOTE: Make sure all sprockets are installed cor-
rectly to ensure correct timing of the sprockets.
The bearing is positioned between the flange
plates.

3. Assemble the driveshaft components on the PTO-

side of the driveshaft. Install the bearing lock

collar; then install the flange bearing assembly

with the bolts facing towards the tunnel.

AF055

4. Position the front of the track up into the tunnel.

Install the driveshaft with the splined end through

its mounting hole in the chain case.

5. Place the PTO-side of the driveshaft into position

by sliding the bolts of the flange bearing assembly

through the holes in the tunnel.

6. Place the cable adapter into position on the flange

bearing assembly bolts. Secure with three lock

nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb).

AF053

7. Slide the MAG-side bearing onto the driveshaft

(inner race flange must be positioned toward drive

chain); then install the O-ring and flange plate.

Secure with three carriage bolts and lock nuts.

Tighten to 2.2-2.5 kg-m (16-18 ft-lb).

„ NOTE: Prior to installation, lubricate the O-ring
with Low-Temp Snowmobile Grease (p/n 0636-
593).

8. Install the brake hub key into the driven shaft

keyway; then slide the brake disc into position on

the splined end of the driven shaft.

9. Install the PTO-side bearing with collar and flange

plates on the driven shaft; do not tighten the collar

at this time. Place the driven shaft into position

making sure the brake disc and flange plates are

properly positioned. Secure the PTO-side bearing

and flange plates with two carriage bolts and lock

nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb).

10. On the MAG-side driven shaft, install the bearing,

O-ring, and flange plate. Secure with three lock

nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb).

„ NOTE: Prior to installation, lubricate the O-ring
with Low-Temp Snowmobile Grease (p/n 0636-
593).

„ NOTE: If washers were removed from behind the
upper sprocket, install them at this time.

11. Install the spacer washer on the driveshaft.

AF090

12. Install the bottom sprocket and driveshaft

extension.

! CAUTION

Tighten the flange plate nuts evenly or the O-ring
seal may be damaged.

8-32

AF427

13. Position one shim washer on the idler gear shaft.

AF430

14. Position the chain around the lower reverse

sprocket; then place the idler sprocket and top

sprocket into the chain. Slide sprockets into

position on the idler shaft and driven shaft.

AF441

„ NOTE: If the chain tension is too tight to allow
installation of the top sprocket, remove the PTO-
side driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will allow the
sprocket to slide onto the splined end of the driven
shaft.

15. Secure the top sprocket with a spring washer (with

the high side directed away from the sprocket) and

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

the lock nut to 4.8-5.5 kg-m (35-40 ft-lb).

AF432

„ NOTE: If the PTO-side driven shaft bearing was
removed to make the sprocket installation easier,
install the bearing and flange plate. Lock the bear-
ing collar by driving it in the direction of rotation to
lock the collar to the bearing and shaft. Tighten the
collar set screw.

16. Place the rubber alignment pin into position in the

idler sprocket; then slide the outer idler gear on the

shaft. Install shim washer on the shaft.

AF436

17. If the lower reverse sprocket was disassembled,

assemble the thrust washer, bearing, and thrust

washer. Secure with the snap ring. Apply

transmission lube to the bearing and rotate by

hand.

AI021

18. Slide the reverse gear onto the driveshaft

extension; then position the spring into the reverse

gear and secure with heavy washer and cap screw.

Tighten to 2.6-3.3 kg-m (19-24 ft-lb).

8-33

8

AF428

19. Install the chain tensioner arm, apply blue Loctite

#242 to the stud threads, and tighten the shoulder

nut to 0.6-0.7 kg-m (4-5 ft-lb).

20. Remove the set screw from the chain adjuster

housing and install the adjuster plug.

21. Check that the chain-case O-ring seal is positioned

correctly on the housing.

22. Position the shift fork behind the large thrust

washer and bearing on the reverse gear; then

position the cover on the housing.

AF075

23. Apply blue Loctite #242 to the threads of the cap

screw; then install the cap screw through the

center of the cover and into the idler shaft. Tighten

the cap screw enough to draw the idler shaft into

the cover.

AI025

24. Place the shift pivot and reverse switch bracket

into position on the cover; then secure the chain-

case cover with cap screws and lock washers.

Tighten the cap screws to 1.7-2.1 kg-m (12-

15 ft-lb).

25. Place the shift linkage into position on the back

side of the arm and secure with a cap screw and

lock nut. Tighten to 1.7-2.1 kg-m (12-15 ft-lb).

26. Place the reverse lever into position on the shift

pivot and secure with a clevis pin and cotter pin.

27. Secure the chain-case cover with cap screws and

lock washers. Tighten the cap screws to 1.7-

2.1 kg-m (12-15 ft-lb).

28. On the PTO-side of the track driveshaft, slide the

lock collar against the bearing, drive the collar in

the direction of rotation until tight, and tighten the

collar set screw.

AF054

29. Install the skid frame (see Section 9).

30. Remove the hold-down strap securing the air-

intake silencer; then place the silencer into

position making sure the boot is properly

positioned on the carburetor/throttle body

assembly. Secure the silencer to the steering

support with the two screws.

31. Apply a light coat of grease or Loctite Anti-Seize

Thread Compound (p/n 0678-146) to the driven

shaft; then install the driven shaft alignment

washers (as required) and key. Install the stub

shaft and the driven pulley, alignment washers (as

required), washer, and cap screw. Tighten to 2.6-

3.3 kg-m (19-24 ft-lb).

„ NOTE: Make sure the keyways match when
installing the driven pulley. Arrange washers to
allow the least amount of float on the driven shaft.
A maximum of 1.5 mm (0.060 in.) float is allowable.

 

 

 

 

 

 

 

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