Snowmobile Arctic Cat (2007 year). Instruction - part 86

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 86

 

 

8-47

8

742-195B

3. Drain the gear case fluid into a suitable con-

tainer.

4. Remove the shift fork assembly; then remove

the retaining ring securing the shift fork arm to

the shaft and remove the arm. Account for the

retaining rings, O-ring, and slider blocks.

ZJ300

„ NOTE: For assembling purposes, note the posi-
tion of the slider blocks on the shift fork arm.

5. Secure the gear case cover in a suitable clamp-

ing device; then using two flat-blade screwdriv-

ers from opposite sides of the cover bearing,

evenly pry the input shaft bearing up and off the

shaft.

ZJ189

6. With a cap screw threaded into the input shaft

and using a soft hammer, drive the input shaft

out of the gear case cover.

ZJ190

7. Using a suitable bearing press and fixture, press

the input shaft bearing out of the gear case

cover. Account for a bearing and a seal.

ZJ191

! CAUTION

If the input shaft bearing is removed, always replace
it with a new one or severe component damage may
occur.

8-48

MS331

8. Secure the gear case in a suitable clamping

device; then using the procedure from step 5,

remove the outer bearing from the transfer gear.

ZJ192

9. Place the gear case on its side; then using a soft

hammer, tap the output shaft until the slider and

output gear assembly come free of the gear case.

ZJ193

10. Remove the output gear assembly from the

slider housing.

ZJ194

11. Using a suitable bearing puller, remove the inner

bearing from the transfer gear assembly.

Account for a spacer washer.

ZJ195

12. Remove the transfer gear from the planetary

gear assembly and account for the thrust washer

and thrust bearing.

ZJ196

„ NOTE: For assembling purposes, note that the
thrust bearing is positioned between the thrust
washer and the gear assembly.

! CAUTION

If any transfer gear bearings are removed, always
replace them with new ones or severe component
damage may occur.

8-49

8

ZJ197

13. Remove the retaining ring and thrust washer

securing the slider housing assembly to the out-

put shaft assembly.

ZJ200

14. Using a suitable puller, remove the bearing from

the output shaft.

15. Using a suitable seal removing tool, remove the

output shaft seals from the gear case.

ZJ204

CLEANING AND INSPECTING GEAR 
CASE

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

„ NOTE: The planetary gear assembly is a non-ser-
viceable component. If any damage or wear is
detected, it must be replaced.

1. Wash the gear case halves in parts-cleaning sol-

vent.

2. Inspect the gear case halves for scoring, pitting,

scuffing, or any imperfections in the casting.

3. Inspect all threaded areas for damaged or

stripped threads.

4. Inspect the bearing areas for cracks or excessive

bearing movement. If evidence of excessive

bearing movement is noted, replace the compo-

nent.

5. Inspect the sealing surfaces of the gear case

halves for trueness.

6. Wash the unsealed gear case bearings in parts-

cleaning solvent.

7. Inspect the input shaft/transfer gear bearings for

wear, scoring, scuffing, damage, or discolora-

tion. Rotate the bearings. Bearings must rotate

freely and must not bind or feel rough. If any

abnormal condition is noted, replace the bear-

ing.

„ NOTE: The output shaft bearing is a non-service-
able component. If any damage or binding is
noted, the output shaft assembly must be
replaced.

8. Apply a light film of Arctic Cat ACT Drive

Fluid (p/n 4639-025) to the unsealed bearings

prior to assembling.

REMOVING DRIVE SPROCKETS

„ NOTE: The drive sprockets must be removed
from the gear case end of the driveshaft.

ZJ216A

8-50

1. For installing purposes, scribe a line on the

driveshaft (A) next to the drive sprocket for

proper alignment; then scribe a line on the drive-

shaft directly in line with the timing arrows (B)

on the drive sprockets for proper sprocket tim-

ing.

MS357A

2. Using a suitable press positioned against the ten-

sion-collar of the drive sprocket (located on the

gear case) and of the driveshaft, press the drive

sprockets off the driveshaft.

ZJ217

ZJ218A

Cleaning and Inspecting

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Thoroughly wash all metallic components in

parts-cleaning solvent. Dry using compressed

air.

2. Wash all non-metallic components with soap

and water.

3. Inspect the driveshaft for damaged splines or

stripped threads.

4. Inspect the seals for any breaks or damage.

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

6. Inspect the brake disc for wear or cracks.

7. Inspect the track drive sprockets for wear or

damage.

INSTALLING DRIVE SPROCKETS

„ NOTE: The drive sprockets must be installed on
the gear case end of the driveshaft.

ZJ216A

„ NOTE: Prior to installing the sprockets onto the
driveshaft, it is advisable to lightly chamfer the
inside edge of the sprocket to avoid binding.

! CAUTION

Always press against the tension-collar of the drive
sprockets or damage to the components will occur.

 

 

 

 

 

 

 

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