Snowmobile Arctic Cat (2007 year). Instruction - part 84

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 84

 

 

8-39

8

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.

15. 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

16. If the lower reverse sprocket was disassembled,

assemble the thrust washer, bearing, and thrust

washer. Secure with the snap ring. Apply trans-

mission lube to the bearing and rotate by hand.

AI021

17. Slide the reverse gear onto the driveshaft exten-

sion; then position the spring into the reverse

gear and secure with heavy washer and cap

screw (coated with green Loctite #609). Tighten

to specifications.

AF428

18. Install the chain tensioner arm, apply blue Loc-

tite #243 to the stud threads, and tighten the

shoulder nut to specifications.

19. Remove the set screw from the chain adjuster

housing and install the adjuster plug.

20. Check that the chain-case O-ring seal is posi-

tioned correctly on the housing.

21. Position the shift fork behind the large thrust

washer and bearing on the reverse gear; then

position the cover on the housing.

AF075

22. Apply blue Loctite #243 to the threads of the

cap screw; then install the cap screw (A)

through the center of the cover and into the idler

shaft. 

8-40

741-158A

23. Place the shift pivot and reverse switch bracket

into position on the cover; then secure the chain-

case cover with the remaining cap screws and

lock washers. Tighten the cap screws to specifi-

cations.

24. Place the shift linkage into position on the back

side of the arm and secure with a cap screw and

lock nut. Tighten to specifications.

25. Place the reverse lever into position on the shift

pivot and secure with a clevis pin and cotter pin.

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

lock washers. Tighten the cap screws to specifi-

cations.

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

the lock collar against the bearing, drive the col-

lar in the direction of rotation until tight, and

tighten the collar set screw.

AF054

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

29. On the non-turbo Bearcat W/T, place the intake

plenum into position and secure with the torx-

head screws; then install the gas tank (see Sec-

tion 7).

30. 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 align-

ment washers (as required) and key. Install the

stub shaft and driven pulley, alignment washers

(as required), washer, and cap screw. Tighten to

specifications.

„ 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.

SC013D

AO372

31. Check the alignment of the drive clutch/driven

pulley (see appropriate Drive Clutch/Driven

Pulley in this section).

32. Assure that the chain case drain plug is tight-

ened to specifications; then pour 354 ml (12 fl

oz) of Arctic Cat Transmission Lube (p/n 4639-

364) into the chain case.

33. Install the drive belt and check belt deflection.

Secure the belt guard.

„ NOTE: For Installing drive belt on models with
an ACT Roller Driven Pulley, see Removing/Install-
ing Drive Belt (Act Roller driven Pulley) in this sec-
tion.

8-41

8

ADJUSTING REVERSE LINKAGE

1. Start the engine; then test the shifting character-

istics of the reverse transmission.

2. If adjustment of the reverse gear is necessary,

stop the engine and remove the chain case

inspection plug located behind the oil level

stick; then insert the Reverse Gear Adjustment

Gauge (p/n 0644-244) completely into the

inspection hole.

0731-734

3. Pull the shift lever into the reverse position

while holding the adjustment gauge firmly

against the chain case cover. Slight outward

pressure should be felt on the gauge as the lever

locks into reverse.

4. If no contact is noted, loosen the jam nuts secur-

ing the lower shift linkage and adjust the linkage

rod until the gauge is pushed out of the chain

case 0.254-0.381 mm (0.010-0.015 in.). Lock

the adjustment by tightening the jam nuts

securely against the tie rod ends.

„ NOTE: To adjust the linkage rod, the shift lever
must be moved to the forward position.

5. Install the inspection plug.

6. Start the engine; then test the shifting character-

istics of the reverse transmission. Adjust as nec-

essary.

Drive Train/Brake Disc 

(Jaguar Z1)

Removing Gear Case............................................ 8-41
Removing Track Driveshaft ................................... 8-42
Installing Track Driveshaft ..................................... 8-44
Disassembling Gear Case..................................... 8-46
Cleaning and Inspecting Gear Case ..................... 8-49
Removing Drive Sprockets .................................... 8-49
Installing Drive Sprockets ...................................... 8-50
Assembling Gear Case ......................................... 8-52
Installing Gear Case.............................................. 8-55

REMOVING GEAR CASE

„ NOTE: The gear case drive fluid does not have to
be drained for this procedure.

1. Remove the access panels from both sides of the

snowmobile.

„ NOTE: At this point, engage the brake lever lock.

2. Using a 9/16-in. socket and extension, remove

the cap screw securing the driven pulley to the

input shaft. Remove the pulley from the shaft.

ZJ182A

„ NOTE: After removing the driven pulley, account
for the cap screw and washers, sheave adjuster,
alignment washers, and O-ring from outside the
pulley; then from the input shaft, remove the two
1.5 mm (0.060 in.) washers along with any other
alignment washers. These washers must be used
during installing.

3. Disconnect the plug-ins for the shift actuator (A)

and the gear indicator switch (B).

! CAUTION

The linkage must be properly adjusted. If the linkage
is too short, damage to the shift fork may occur. If
the linkage is adjusted too long, the gears will not
shift totally into reverse.

8-42

ZJ183A

4. Remove the torx-head cap screws securing the

toe shield and hook bracket to the chassis; then

remove the shield and bracket.

0742-089

„ NOTE: Either elevate the snowmobile off the
floor with a suitable lift or tip the snowmobile on
its right side positioning the gear 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.

5. Loosen but do not remove the 16 mm cap screw

(from the brake disc side of the inner driveshaft)

securing the driveshaft to the gear case.

742-020A

„ NOTE: For gear case removing purposes at this
time, do not remove the 16 mm cap screw.

6. Remove the seven lock nuts securing the gear

case to the chassis; then remove the remaining

lock nut and torx-head cap screw.

 

742-018A

7. Place the snowmobile in the upright position;

then using a 16 mm socket, long extension, and

a soft hammer, tap against the driveshaft cap

screw until the gear case is free from the studs of

the mounting plate.

8. Remove the cap screw from the inner driveshaft

(from step 5); then remove the gear case. 

„ NOTE: If the gear case is difficult to remove, it
may be necessary to loosen the track tension.

„ NOTE: Account for the snubber bracket.

REMOVING TRACK DRIVESHAFT 

„ NOTE: The gear case drive fluid does not have to
be drained for this procedure.

1. Remove the access panels from both sides of the

snowmobile.

2. Remove the negative cable from the battery;

then remove the positive cable. Remove the

hardware securing the battery to the tray; then

remove the battery.

3. Remove the hairpin clip and springs securing

the resonator; then remove the resonator from

the engine compartment.

4. Remove the two cap screws securing the speed-

ometer sensor bracket. Account for two spacers.

 

 

 

 

 

 

 

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