Snowmobile Arctic Cat (2007 year). Instruction - part 76

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 76

 

 

8-7

8

A003

4. Tighten the rear brake cable adjustment jam nut

securely; then adjust brake lever travel as neces-

sary. See Brake System (120 cc) in this section.

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

compartment; 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 posi-

tion making sure the hood cable is properly

positioned. Tighten securely.

Drive Chain, Track,

and Driveshaft

(120 cc)

„ NOTE: The skid frame must be removed for this
procedure (see Section 9 - Repair Procedure 1).

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 tun-

nel.

A022

8-8

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.

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

damage.

INSTALLING

737-161C

„ 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 posi-

tion in the tunnel; then secure with cap screws.

Tighten securely.

4. Install the skid frame (see Section 9 - Repair

Procedure 1).

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.

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.

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

13. Spacer

! CAUTION

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

8-9

8

9. Install the rear chain guard and secure with five

machine screws. Tighten securely.

Brake System

(120 cc)

REMOVING AND INSPECTING

737-161A

1. Remove the forward drive chain guard.

„ NOTE: It will be necessary to support the hood
once the hood cable is removed.

2. Loosen the Allen-head retaining pin securing

the brake cable to the brake band.

3. Loosen the jam nut securing the threaded por-

tion of the brake cable to the brake bracket; then

remove the brake cable from the bracket and

brake band. Account for a spring.

4. Remove the snap ring securing the brake band to

the mounting bracket; then remove the brake

band from the engine compartment.

A003

5. Remove the C-clip securing the brake lever pin

in the brake housing; then remove the pin and

lever.

A998

6. Disconnect the brake cable from the lever; then

slide the brake cable out of the lever.

A999

7. Remove the handlebar pad and cut the cable tie

securing the brake cable to the steering post.

„ NOTE: Note the location of the cable tie for
assembly.

8. Inspect the brake band and brake cable for wear.

„ NOTE: The brake band pad material thickness
must be at least 1.6 mm (1/16 in.) or replacement is
necessary.

9. Inspect the brake cable for damage or fraying.

KEY

1. Lock Nut

2. Bushing

3. Rivet

4. Chain 

Tensioner

5. Spring

6. Tab

7. Roller

8. Washer

9. Cap Screw

10. Bracket

11. Cap Screw

12. Spacer

13. Clutch

14. Brake Band

15. Retaining Pin

16. Washer

17. Snap Ring

18. Spacer

19. Washer

20. Lock Washer

8-10

INSTALLING

1. Route the cable through the slot in the brake

housing and insert the cable end into the hous-

ing.

2. Seat the cable drum into the brake lever recess;

then secure the brake lever with a pin and C-

clip.

A999

A998

3. Place the brake band into position on the bracket

and secure with a washer and snap ring.

A003

4. Slide the spring onto the brake cable; then insert

the cable end into the brake band. Tighten

securely.

A004

5. Secure the threaded portion of the brake cable to

the bracket with the jam nuts.

A005

6. Secure the brake cable to the steering post with a

cable tie; then install the handlebar pad.

CHECKING BRAKE LEVER TRAVEL

1. Compress the brake lever fully.

2. Check the distance between the brake lever and

the lever stop. The distance must be within a

range of 6-13 mm (1/4-1/2 in.).

0725-565

3. If travel distance is not as specified, adjust the

brake lever travel.

 

 

 

 

 

 

 

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