Snowmobile Arctic Cat (2008 year). Manual - part 94

6-20

AF436

10. Remove the outer idler sprocket from the shaft.

AF437

11. Slide the small rubber alignment pin from the face

of the inner idler sprocket and place in safe loca-

tion until assembly.

AF439

12. Remove the lock nut securing the top sprocket.

AF432

13. Remove the spring washer in front of the top

sprocket.

AF444

14. Set the brake lever lock. Remove the cap screw

and large washer securing the bottom sprocket.

„NOTE: The bottom sprocket cap screw and
washer are spring loaded.

AF428

15. Remove the reverse gear.

AF442

16. Remove the top sprocket, chain, and idler gear.

Account for one shim washer located behind the

idler gear.

6-21

6

AF433

„NOTE: If the chain is too tight and will not allow
the top sprocket to be removed, remove the PTO-
side driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will loosen
the chain.

17. Remove the driveshaft extension, bottom sprocket,

and spacer washer.

AF427

18. Check the idler gear shaft. If the shaft surface is

rough, remove the shaft using a pair of vise-grip

pliers. Rotate the shaft counterclockwise.

19. Remove the shoulder nut securing the chain tight-

ener arm; then remove the arm from the chain

case.

AF447

20. Remove the three lock nuts (A) securing the top

bearing flange plate. Remove the flange plate, seal,

and bearing; then remove the three lock nuts (B)

securing the bottom bearing flange plate. Remove

the flange plate, seal, and bearing. 

AF431A

„NOTE: Steps 21-25 are for Bearcat/Panther mod-
els.

21. Remove the screw securing the air-intake silencer

to the steering support; then pull the silencer for-

ward and place it on the carburetor/throttle body

assembly.

„NOTE: Using a hold-down strap, secure the air-
intake silencer to the engine.

22. Loosen the set screw on the PTO-side driven shaft

collar. Drive the collar clockwise (opposite shaft

rotation) until it is free.

„NOTE: A fine file should be used to remove any
burrs left by the collar set screw.

23. Remove the lock nuts and carriage bolts securing

the PTO-side driven shaft flange plates.

AF002D

24. Force the driven shaft toward the PTO-side (rotat-

ing the shaft to prevent the brake disc from bind-

ing on the shaft) until brake disc is free. Account

for the key.

25. Continue to slide the driven shaft until it is out of

the PTO-side. Account for a bearing, two flange

plates, and the PTO-side driven shaft collar.

6-22

26. Remove the skid frame from the tunnel (see Sec-

tion 7).

27. Remove the three PTO-side lock nuts securing the

driveshaft flange bearing assembly and cable

adapter. Remove the adapter and speedometer

cable.

AF053

28. Tap the driveshaft toward the chain case to unseat

the MAG-side bearing. Remove the bearing.

29. Slide the driveshaft toward the MAG-side until the

PTO-side of the driveshaft is out of its mounting

hole. Tilt the end of the driveshaft away from the

tunnel and slide the driveshaft free of the tunnel.

Remove the track.

AF055

30. Scribe a line on the driveshaft along the edge of

each sprocket to aid in assembly. Loosen the set

screw on the collar and drive the collar clockwise

until free; then remove the bearing and flange

plates from the driveshaft.

31. Press the sprockets off the driveshaft.

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 and driven shaft for dam-

aged splines or stripped threads.

4. Inspect the bearings for any roughness or damage.

5. Inspect the seals for any breaks or damage.

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

7. Inspect the keyways in the driven shaft for wear or

damage.

8. Inspect the brake disc for wear or cracks.

9. Inspect the track drive sprockets for wear or dam-

age.

10. Inspect the top sprocket for any chipped or worn

teeth.

11. Inspect the bottom sprocket teeth for wear. Turn

the inner sprocket bearing by hand and inspect for

any signs of being rough.

12. Inspect the three bottom sprocket drive pins.

Check the pin edges for chipping and wear.

13. Inspect the drive pin springs for tension by push-

ing each pin into the sprocket and releasing it. It

must snap back out without any signs of binding.

If any of these items (pins, bearing, sprocket,

teeth) appear worn, replace the sprocket as an

assembly.

AI019

14. Inspect the idler gear sprocket teeth and bearings.

Rotate the inner bearings by hand. Check each

sprocket tooth for any signs of chipping and wear.

15. Closely inspect the drive chain for broken links.

16. Inspect the reverse gear. Inspect the teeth for wear

and chipping. Inspect the edges of drive pin holes

for any signs of chipping and wear.

17. Remove the snap ring from the reverse gear.

Remove the outer thrust washer, thrust bearing,

and inner thrust washer. Inspect the thrust bearing

by placing it between the two thrust washers and

rotating the thrust washer. Rotation must feel

smooth. If any roughness is noted, replace the

thrust washers and bearing as a set.

6-23

6

18. Inspect the chain tightener bearing. Rotate the

tightener roller and check for smooth rotation. If

rotation feels rough, replace roller and bearing

assembly.

ASSEMBLING

1. Press the sprockets on the driveshaft noting the

scribed marks on the shaft and the timing mark

found on one tooth of each sprocket. The timing

mark is an arrow molded into the outer surface of

one drive tooth. All the arrow markings must be in

alignment.

„NOTE: Sprocket style will vary from model to
model.

739-057A

„NOTE: Make sure all sprockets are installed cor-
rectly to ensure correct timing of the sprockets.
The bearing is positioned between the flange
plates.

2. Assemble the driveshaft components on the PTO-

side of the driveshaft. 

3. Install the bearing lock collar; then install the

flange bearing assembly with the bolts facing

towards the tunnel.

4. Position the front of the track up into the tunnel.

Install the driveshaft with the splined end through

its mounting hole in the chain case.

AF055

5. Place the PTO-side of the driveshaft into position

by sliding the bolts of the flange bearing assembly

through the holes in the tunnel.

6. Place the cable adapter into position on the flange

bearing assembly bolts. Secure with three lock

nuts. Tighten to 15 ft-lb.

AF053

7. Slide the MAG-side bearing onto the driveshaft

(inner race flange must be positioned toward drive

chain); then install the O-ring and flange plate.

Secure with three carriage bolts and lock nuts.

Tighten to 15 ft-lb.

„NOTE: Prior to installation, lubricate the O-ring
with Low-Temp Snowmobile Grease.

8. Slide the brake disc into position on the splined

end of the driven shaft.

9. Install the PTO-side bearing with collar and flange

plates on the driven shaft; do not tighten the collar

at this time. Place the driven shaft into position

making sure the brake disc and flange plates are

properly positioned. Secure the PTO-side bearing

and flange plates with two carriage bolts and lock

nuts. Tighten to 11 ft-lb.

10. On the MAG-side driven shaft, install the bearing,

O-ring, and flange plate. Secure with three lock

nuts. Tighten to 11 ft-lb.

„NOTE: Prior to installation, lubricate the O-ring
with Low-Temp Snowmobile Grease.

„NOTE: If washers were removed from behind the
upper sprocket, install them at this time.

11. Install the spacer washer on the driveshaft.

! CAUTION

Tighten the flange plate nuts evenly or the O-ring
seal may be damaged.