Snowmobile Arctic Cat (2007 year). Instruction - part 85

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 85

 

 

8-43

8

ZJ210A

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. Using Brake Disc Socket Wrench (p/n 0644-

481), remove the retaining nut from the drive-

shaft.

ZJ211

7. Using the Rear Suspension Spring Tool (p/n

0144-311), remove the spring from the adjusting

cam.

8. Remove the rear cap screws securing the skid

frame to the tunnel. Account for lock washers

and flat washers.

9. Slide the skid frame rearward far enough to drop

the front arm out of the slider axle; then remove

the skid frame.

10. Tip the snowmobile onto the right side position-

ing the gear case side of the snowmobile up.

Place a piece of cardboard under the side of the

snowmobile to protect against scratching.

Remove the skid frame.

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

the cap screw securing the driven pulley to the

input shaft.

ZJ182A

12. Slide the driven pully off the shaft.

„ 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.

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

and the gear indicator switch (B).

ZJ183A

14. Remove the torx-head cap screws securing the

toe shield and hook bracket to the chassis; then

remove the shield and bracket.

! WARNING

Care must be taken when removing the spring or
damage or injury could result.

8-44

0742-089

15. 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

16. 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.

17. 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.

18. With the gear case removed, pull the driveshaft

toward the gear case side of the tunnel until it

clears the brake caliper housing; then remove

the driveshaft. Account for the rubber seal.

ZJ212

INSTALLING TRACK DRIVESHAFT 

„ NOTE: Prior to installing the driveshaft, apply a
coat of Anti-Seize Thread Compound (p/n 0678-
146) to the internal splines of the driveshaft.

ZJ213A

1. Place the track/driveshaft assembly into the

bearing of the brake housing just far enough to

allow the brake disc to be installed in the brake

housing assembly. 

ZJ214A

„ NOTE: Prior to installing the driveshaft, ensure
that the bearing spacer is positioned to the inner
bore of the brake caliper housing.

8-45

8

0742-087

2. With the brake lever lock engaged and the brake

disc correctly positioned in the brake housing

assembly, properly align the splines of the drive-

shaft with the brake disc; then push the drive-

shaft the rest of the way into the brake housing

until it is properly seated.

ZJ215A

„ NOTE: Prior to placing the gear case onto the
driveshaft, apply a light coat of Anti-Seize Thread
Compound (p/n 0678-146) to the splines of the ring
gear shaft.

3. Place the gear case onto the driveshaft; then

press the gear case toward the sprocket until it

properly seats into place on the chassis. It may

be necessary to rotate the driveshaft slightly for

proper seating.

4. Loosely secure the gear case by first installing

the six lock nuts and finger tighten; then install

the snubber bracket and a torx-head cap screw

and the two remaining lock nuts and tighten all

the nuts to specifications.

742-018A

„ NOTE: When tightening the nuts to the proper
torque factor, it is advisable to begin tightening the
nuts located on the bottom of the gear case and
working upward in a crisscross pattern until all
nuts are tightened to the proper torque factor.

„ NOTE: With the gear case secured, adjust the
snubber bracket until the rubber lightly contacts
the engine.

ZJ209

5. Connect shift actuator harness (A) and gear indi-

cator switch harness (B).

ZJ183A

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

7. Apply Anti-Seize Thread Compound (p/n 0678-

146) to the threads of the brake disc retaining

nut; then install the nut.

8-46

8. Using Brake Disc Socket Wrench (p/n 0644-

481), tighten the brake disc retaining nut to

specifications.

MS323

„ NOTE: After the retaining nut is tightened to
specifications, peen the nut at the flat spot of the
driveshaft.

9. Secure the driveshaft to the output shaft with the

cap screw (coated with blue Loctite #243) and

washer. Tighten to specifications.

742-020A

10. Place the resonator into position and secure with

the springs and hairpin clip.

11. Install the speedometer sensor mounting bracket

(with two spacers); then secure with the two cap

screws. Tighten to specifications.

12. Slide the driven pulley onto the input shaft mak-

ing sure alignment washers are in place.

13. Secure the driven pulley with components and

hardware as noted in removing. Tighten to spec-

ifications.

ZJ250A

14. Install the drive belt.

„ NOTE: For installing drive belt, see Removing/
Installing Drive Belt (ACT Roller Driven Pulley) in
this section.

15. Place the access panels into position and secure

with existing hardware.

16. Check the track for alignment and recom-

mended tension; then tighten the cap screws

securely (see Section 9).

DISASSEMBLING GEAR CASE

1. Remove the three torx-head cap screws securing

the shift actuator to the gear case and remove the

actuator; then remove the gear indicator switch.

ZJ186A

2. Remove the 13 torx-head cap screws securing

the gear case cover to the gear case assembly;

then insert two flat-blade screwdrivers into the

slots on the gear case. Working back and forth,

pry the cover up and off the gear case.

! CAUTION

It is critical that the two 1.5 mm (0.060 in.) washers
are in place on the input shaft when installing the
driven pulley.

 

 

 

 

 

 

 

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