Snowmobile Arctic Cat (2002 year). Instruction - part 142

9-46

A005

5. Compress and hold the brake lever; then install the

cap screw (coated with blue Loctite #243) and

washer securing the rear chain sprocket. Tighten

the cap screw securely; then release the lever.

6. Place the exhaust gasket into position on the

engine exhaust studs.

7. Place the muffler into position in the engine com-

partment; then press down on the muffler and

swing the intake pipe onto the engine exhaust

studs. Secure with two nuts and the hold-down

spring.

8. Place the front and rear chain guards into position

making sure the hood cable is properly positioned.

Tighten securely.

Drive Chain, Track,

and Driveshaft

„

NOTE: The skid frame must be removed for this

procedure.

REMOVING

1. Remove the five machine screws securing the rear

chain guard; then remove the guard.

A017A

2. Compress and hold the brake lever; then remove

the cap screw securing the rear chain sprocket to

the driveshaft. Release the lever.

3. Slide the chain sprocket off the driveshaft and set

aside. Account for the key.

4. Remove the four lock nuts securing the drive

sprocket bearings to the tunnel; then remove the

four carriage bolts from the tunnel.

A021

5. Position the bearing flanges so they are directed

towards the rear; then spread the tunnel slightly

and slide the driveshaft assembly out of the tunnel.

A022

6. Remove the cap screws securing the upper idler

wheel assembly to the tunnel; then remove the

assembly from the tunnel.

A013

7. Remove the track from the tunnel.

9-47

9

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the driveshaft for damage and for stripped

threads.

2. Inspect the bearings for roughness or damage.

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

4. Inspect the keyways in the driveshaft and in the

chain sprocket for wear or damage.

5. Inspect the chain and chain sprocket for damage or

wear.

6. Inspect the track drive sprockets for wear or dam-

age.

INSTALLING

735-370B

„

NOTE: The snowmobile should be tipped on its

side for this procedure.

1. Place the track into position in the tunnel.

A022

2. Slide the driveshaft assembly into position in the

tunnel; then secure with carriage bolts and lock

nuts. Tighten securely.

A021

3. Place the upper idler wheel assembly into position

in the tunnel; then secure with cap screws. Tighten

securely.

4. Install the skid frame (see Installing Skid Frame in

this sub-section).

5. Place the snowmobile in the upright position.

6. Place the key on the driveshaft; then slide the

chain sprocket w/chain onto the driveshaft. Secure

with a cap screw (coated with blue Loctite #243),

lock washer, and washer. Tighten securely.

KEY

1. Lock Washer
2. Carriage Bolt
3. Bearing
4. Track Drive Assy
5. Drive Sprocket
6. Driveshaft
7. Key
8. Chain Sprocket
9. Lock Nut

10. Cap Screw
11. Washer
12. Chain

! CAUTION

A piece of cardboard should be used to protect
the finish on the hood.

9-48

7. Inspect the chain for proper engagement with the

clutch sprocket and the chain sprocket.

8. Inspect that the chain tensioner assembly is in

place and functioning properly.

9. Install the rear chain guard and secure with five

machine screws. Tighten securely.

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 rear suspension arm with the appro-

priate mounting hole in the tunnel. Slide the lock

washer onto the cap screw; then secure the arm to

the tunnel with the cap screw and lock washer.

Thread the cap screw in only half way. DO NOT

TIGHTEN AT THIS TIME.

„

NOTE: To aid in centering the rear arm with the

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

4. Place the snowmobile in the upright position; then

secure the opposite side upper idler wheel assem-

bly.

5. Securely tighten all upper idler wheel mounting

hardware.

6. Tighten all skid frame/axle mounting cap screws

securely.

7. Check track tension; adjust as necessary (see

Track Tension in this sub-section).

Track Tension

„

NOTE: Track tension and track alignment are

interrelated; therefore, always check both, even if
only one adjustment seems necessary.

Track tension is directly related to the overall perfor-

mance of the snowmobile. If the track is too loose, it

may slap against the tunnel causing wear, or it may

ratchet on the track drive sprockets. Arctic Cat recom-

mends that the track tension be checked once a month

and adjusted accordingly.

CHECKING

1. Remove excess ice and snow buildup from the

track, track drive sprockets, and the inside of the

skid frame.

2. Place the rear of the snowmobile up on a safety

stand high enough so the track is free of the floor.

3. Without exerting any pressure on the track, mea-

sure the distance between the bottom of the wear

strip and the inside surface of the track. The mea-

surement must be within specifications. If the

measurement is not within specifications, an

adjustment is necessary.

735-669A

! WARNING

Track tension must be properly maintained. Per-
sonal injury could result if a track is allowed to
become excessively loose.

! WARNING

DO NOT attempt to check or adjust track tension
with engine running. Turn ignition key to the OFF
position. Personal injury could result from contact
with a rotating track.

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9

ADJUSTING

1. Loosen the idler wheel cap screws.

2. Loosen the rear idler wheel adjusting bolt jam

nuts.

0735-454

„

NOTE: To ensure proper track tension adjust-

ment, perform all adjustments on both sides of the
snowmobile.

3. If the deflection (distance between the bottom of

the wear strip and the inside of the track) exceeds

specifications, tighten the adjusting bolts to take

up excessive slack in the track.

4. If the distance between the bottom of the wear

strip and the inside surface of the track is less than

specified, loosen the adjusting bolts to increase the

slack in the track.

5. Check track alignment (see Track Alignment in

this sub-section).

6. When proper track tension is obtained, tighten the

adjusting bolt jam nuts against the axle housings.

7. Tighten the idler wheel cap screws securely.

„

NOTE: Since track tension and track alignment

are interrelated, always check both even if only
one adjustment seems necessary.

Track Alignment

Proper track alignment is obtained when the rear idler

wheels are equal distance from the inner track drive

lugs. Excessive wear to the idler wheels, drive lugs,

and track will occur if the track is improperly aligned.

Arctic Cat recommends that the track alignment be

checked once a week or whenever the track tension is

adjusted.

CHECKING

1. Remove excess ice and snow buildup from the

track, track drive sprockets, and the inside of the

skid frame.

2. Position the tips of the skis against a wall; then

using a shielded safety stand, raise the rear of the

snowmobile off the floor making sure the track is

free to rotate.

3. Start the engine and accelerate slightly. Use only

enough throttle to turn the track several revolu-

tions. SHUT ENGINE OFF.

„

NOTE: Allow the track to coast to a stop. DO

NOT apply the brake because it could produce an
inaccurate alignment condition.

4. When the track stops rotating, check the relation-

ship of the rear idler wheels and the inner track

drive lugs. If the distance from the rear idler

wheels to the inner track drive lugs is the same on

both sides, no adjustment is necessary.

0727-729

! WARNING

If jam nuts are not tightened properly, the adjusting
bolts could loosen causing the track to become
extremely loose and, under some operating condi-
tions, allow the idler wheels to climb over the track
lugs forcing the track against the tunnel causing
the track to “lock.” If a track “locks” during opera-
tion, severe personal injury could result.

! WARNING

Make sure the ignition key is in the OFF position
and the track is not rotating before checking or
adjusting track alignment. Personal injury could
result if contact is made with a rotating track.

! WARNING

The tips of the skis must be positioned against a
wall or similar object for safety.