Snowmobile Arctic Cat (2008 year). Manual - part 93

6-16

FS094

5. Noting the alignment marks made during disas-

sembling, place the movable sheave onto the sta-

tionary sheave.

FS093

6. With the pulley in place on the compressor, install

the compressor flange spacer and wing nut; then

compress the driven pulley spring.

CM069

7. Install the torx-head cap screws securing the mov-

able sheave. Tighten to specifications.

CM061

8. Remove the pulley from the compressor.

INSTALLING

1. Set the brake lever lock.

2. Install the alignment washers (if applicable); then

install the driven pulley on the gear case input

shaft. Tighten to 32 ft-lb.

CM125A

3. Check drive clutch/driven pulley alignment.

4. Install the drive belt.

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

6-17

6

Drive Clutch/

Driven Pulley

(Crossfire/F-Series/M-Series/

T-Series)

CHECKING OFFSET

If premature drive belt wear is experienced or if the

drive belt turns over, parallelism/offset must be

checked. Also, parallelism/offset must be checked

whenever either the drive clutch or driven pulley is

serviced. To check offset, use Clutch Alignment Bar

for the Crossfire/M-Series or for the F-Series. To

check parallelism, use Parallelism Bar.

1. Open the side panel and remove the drive belt.

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

2. Install the clutch alignment bar between the drive

clutch sheaves and against the outside edge of the

driven pulley stationary sheave.

3. Allow the alignment bar to rest on the drive clutch

shaft.

„NOTE: The alignment bar must extend beyond
the front edge of the drive clutch.

4. With the bar against the outside edge of the driven

pulley stationary sheave, the bar should just clear

the inside edge of the stationary sheave of the

drive clutch and rest on the stationary shaft. If the

bar does not clear the inside edge or is more than

1.5 mm (0.060 in.) from the inside edge, the offset

must be corrected.

742-044A

CORRECTING OFFSET

1. To correct offset, the driven pulley must be moved

laterally on the output shaft. Remove the cap

screw and washers securing the driven pulley; then

remove the driven pulley.

„NOTE: If the driven pulley is tight on the shaft,
pull the driven pulley off using the Driven Pulley
Puller.

2. To move the driven pulley inward on the shaft,

remove washer(s) as required from behind the pul-

ley.

3. To move the driven pulley outward on the shaft,

add alignment washer(s) as required behind the

driven pulley.

4. Install the driven pulley and secure with a cap

screw and washers. Tighten the cap screw to spec-

ifications.

CHECKING PARALLELISM

1. Remove the drive belt; then open the driven

sheaves and place Parallelism Bar between the

sheaves. Release the sheaves.

2. Check the parallelism of the drive clutch/driven

pulley using the parallelism bar and reference

points X and Y with the parallelism bar between

the driven sheaves. Using a caliper or a machin-

ist’s scale, measure X and Y from the back side of

the parallelism bar to the back side of the drive

clutch sheave. Measurement Y must be 1.5 mm ±

1.0 mm (0.060 in. ± 0.040 in.) more than measure-

ment X, but Y must not exceed measurement X by

more than 2.54 mm (0.100 in.). 

0742-065

3. If parallelism is not within specifications, the par-

allelism must be corrected by first loosening all

the engine mounting bolts (left side, front, and

right top rear). Then, pry the front of the engine

towards the MAG-side of the engine compart-

ment. Next tighten the left-side mounting bolts

followed by the front and right-top rear bolts. Re-

check the parallelism. If still out of specification,

repeat correction procedure.

! CAUTION

Do not allow the driven pulley to “float” on the out-
put shaft. Damage to the driven pulley will occur. 

6-18

DRIVE BELT DEFLECTION

Drive belt length, condition, and deflection are all

important for peak performance. To check and adjust

drive belt deflection, use the following procedure.

1. Turn the engine off; then open the access panel.

2. Make sure the drive belt is sitting at the top of the

driven pulley sheaves.

3. Place a straightedge on top of the drive belt. The

straightedge should reach from the drive clutch to

the top of the driven pulley.

4. Using a stiff ruler centered between the drive

clutch and driven pulley, push down on the drive

belt just enough to remove all slack. Note the

amount of deflection on the ruler at the bottom of

the straightedge. The deflection should be at

31 mm (1 1/4 in.).

741-464A

„NOTE: Push down on the belt with the ruler only
until the bottom of the belt flexes upward; then
read the amount of deflection.

5. To correct drive belt deflection, remove the sheave

adjuster from the pulley, remove or add shim

washers to the adjuster, and install the adjuster.

„NOTE: Adding shim washers will decrease belt
deflection; removing shim washers will increase
belt deflection.

„NOTE: If the drive belt deflection is above specifi-
cations, the snowmobile will bog and lack power at
clutch engagement. For good performance, proper
belt deflection is critical.

6. Close the access panel.

Removing/Installing 

Drive Belt

(ACT Roller Driven Pulley)

1. Turn ignition key to the OFF position and wait for

all moving parts to stop.

2. Set the brake lever lock.

3. Open the left-side access panel; then remove the

belt guard.

4. Remove the cap screw and sheave adjuster from

the end of the driven pulley. Account for and

remove the O-ring and shim washers. Note the ori-

entation of the components for installing purposes.

741-721A

5. With the O-ring and shim washers removed, install

the sheave adjuster and cap screw back into the

driven pulley; then tighten the cap screw until the

sheave adjuster bottoms against the input shaft.

„NOTE: By bottoming the sheave adjuster against
the input shaft, the sheaves of the driven pulley
will spread far enough to allow the removal of the
drive belt.

6. Remove the drive belt from the drive clutch and

driven pulley.

7. Place the drive belt (so the part number can be

read) between the sheaves of the drive clutch first;

then between the sheaves of the driven pulley.

8. Place the shim washers and O-ring (as noted in

removing) onto the sheave adjuster; then install

the cap screw and the sheave adjuster back into the

driven pulley. Tighten the cap screw to specifica-

tions.

9. Install the belt guard; then close the left-side

access panel.

10. Release the brake lever lock.

! WARNING

Never operate the snowmobile without the belt
guard/access panel secured in place.

6-19

6

Drive Train/Brake Disc 

(Standard w/Reverse)

DISASSEMBLING

1. Remove the chain-case drain plug located on the

lower back side of the chain case inside the tunnel

and drain the chain case lubricant.

2. Disconnect the battery cables. Remove the battery

and battery tray.

3. Open the belt guard and remove the drive belt.

4. Remove the cap screw and washer securing the

driven pulley; then account for and note the posi-

tion of any alignment washers.

SC013D

5. Slide the driven pulley off the driven shaft; then

remove the driven pulley from the engine com-

partment. Account for the key, stub shaft, and

alignment washers.

„NOTE: If the driven pulley is tight on the driven
shaft, pull the driven pulley off using the Driven
Pulley Puller.

AF120D

„NOTE: Tip the snowmobile on its left side posi-
tioning the chain 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.

6. Disconnect the shift linkage from the arm on chain

case.

7. Remove the cap screw (A) from the center of the

chain case; then remove the remaining cap screws

securing the chain case cover; then remove the

cover by pulling outward and lifting up so the shift

fork clears the large inner washer.

741-158A

8. Remove the screw from the chain adjuster housing

and install an 8-32 set screw to lock the chain

adjuster in position.

AF426

9. Remove the shim washer from the idler sprocket.

! CAUTION

On models with mirrors before tipping the snowmo-
bile on its side, position a block of wood under the
side of the snowmobile to keep the mirrors from
contacting the floor or damage may occur.