Snowmobile Arctic Cat (2002 year). Manual - part 145

9-58

Rear Upper Idler 

Wheels/Rear Springs

„

NOTE: The skid frame must be removed for this

procedure (see Removing Skid Frame in this sub-
section).

REMOVING

1. Using the Rear Suspension Spring Tool (p/n 0144-

311), remove the spring from the adjusting cam.

AG624DA

2. Mark the offset pivot idler and the idler arm for

assembly purposes.

AG675D

3. Remove the cap screws securing the offset pivot

idler arm assembly to the idler arm; then remove

the offset pivot arm idler assembly. Account for a

flanged axle, flared bushing, idler spacer collar,

and lock nuts.

AG677D

4. Remove the idler wheel.

„

NOTE: It may be necessary to use the Idler

Wheel Puller Kit (p/n 0644-122) to remove the
wheel.

AG461D

5. Remove the cap screw and flat washer securing

the spring slide to the rail. Account for a slide

block and washer.

AG593D

6. Remove the spring and sleeve from the idler arm.

! WARNING

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

9-59

9

AG681D

„

NOTE: Use the same procedure for the other

side.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Clean the bearing with a clean cloth.

2. Inspect each idler wheel and plastic hub for cracks

or damage.

3. Rotate the idler wheel bearings (by hand) and

inspect for binding or roughness.

4. If a bearing must be replaced, use this procedure.

A. Remove the wheel insert and the snap ring.

B. Using a hydraulic press, press the bearing out

the inside of the wheel.

C. Press the new bearing (on its outer race) into

the idler wheel.

AG538D

D. Install the snap ring making sure the “sharp

side” is directed away from the bearing.

AG539D

E. Install the insert.

AG540D

5. Inspect the spring, spring slide, sleeve, washers,

slide block insert, and shaft area for wear.

6. Inspect the adjusting cams and arms for cracks.

INSTALLING

1. Slide the sleeve and spring onto the idler arm.

AG655D

2. Place the spring slide and slide block (with spring

in slide block) into position on the slide rail.

Secure with a cap screw (coated with red Loctite

#271) and washer. Tighten to 3.2 kg-m (23 ft-lb).

! CAUTION

Do not remove the bearing unless it is absolutely
necessary. The bearing will be damaged during
removal.

9-60

AG680D

AG593D

3. Install the rear upper idler wheel on the idler arm.

AG545D

4. Install the idler spacer collar onto the idler arm.

AG677D

5. Place the flanged axle with a thin flat washer

through the notched side of the offset pivot idler

arm assembly.

„

NOTE: If the flanged axle in the offset pivot idler

arm is loose, it must be cleaned and green Loctite
#609 must be applied to it prior to installation.

6. Align the marks on the idler arm to the centerline

of the offset pivot idler arm assembly. Secure the

offset pivot idler arm to the idler arm with cap

screws and lock nuts. Tighten to 2.6 kg-m

(19 ft-lb).

AG675D

7. Place the short spring leg onto the adjusting cam

using the rear suspension spring tool.

AG624DA

9-61

9

Rear Axle and

Idler Wheels

„

NOTE: The skid frame must be removed for this

procedure (see Removing Skid Frame in this sub-
section).

DISASSEMBLING

1. Remove the cap screw and large flat washer secur-

ing the outer rear idler wheel. Remove the outer

idler wheel from the shaft.

AG548D

„

NOTE: The large flat side of the wheel insert is

positioned next to the inner plastic adjuster bush-
ing. The idler wheel must be installed with the
wheel insert properly positioned.

2. Loosen the track adjusting bolts. Slide the outer

adjuster bushings off the axle.

AG627D

AG628D

3. Carefully slide the shaft out from the inner idler

wheels and note the position of the spacers and

washers.

AG805D

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Clean the bearings with a clean cloth.

2. Inspect all idler wheel inserts (inner and outer) for

any cracks.

3. Inspect the outer rubber portion of the idler wheels

for cracks and poor bonding.

4. Inspect the plastic insert of each idler wheel for

cracks.

5. Inspect the shaft for wear and damaged threads.

6. Inspect all idler wheel bearings. Turn each bearing

(by hand) and if any roughness or binding is noted,

replace the bearing.

7. If a bearing must be replaced, use this procedure.

A. Remove the wheel insert and the snap ring.

! CAUTION

Do not remove the bearing unless it is absolutely
necessary. The bearing will be damaged during
removal.