Snowmobile Arctic Cat (2008 year). Manual - part 95

6-24

AF090

12. Install the bottom sprocket and driveshaft exten-

sion.

AF427

13. Position one shim washer on the idler gear shaft.

AF430

14. Position the chain around the lower reverse

sprocket; then place the idler sprocket and top

sprocket into the chain. Slide sprockets into posi-

tion on the idler shaft and driven shaft.

AF441

„NOTE: If the chain tension is too tight to allow
installation of the top sprocket, remove the PTO-
side driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will allow the
sprocket to slide onto the splined end of the driven
shaft.

15. Secure the top sprocket with a spring washer (with

the high side directed away from the sprocket) and

lock nut (coated with green Loctite #609). Tighten

the lock nut to 35 ft-lb.

AF432

„NOTE: If the PTO-side driven shaft bearing was
removed to make the sprocket installation easier,
install the bearing and flange plate. Lock the bear-
ing collar by driving it in the direction of rotation to
lock the collar to the bearing and shaft. Tighten the
collar set screw.

16. Place the rubber alignment pin into position in the

idler sprocket; then slide the outer idler gear on the

shaft. Install shim washer on the shaft.

6-25

6

AF436

17. If the lower reverse sprocket was disassembled,

assemble the thrust washer, bearing, and thrust

washer. Secure with the snap ring. Apply transmis-

sion lube to the bearing and rotate by hand.

AI021

18. Slide the reverse gear onto the driveshaft exten-

sion; then position the spring into the reverse gear

and secure with heavy washer and cap screw

(coated with blue Loctite #243). Tighten to 15 ft-

lb.

AF428

19. Install the chain tensioner arm, apply blue Loctite

#243 to the stud threads, and tighten the shoulder

nut to 8 ft-lb.

20. Remove the set screw from the chain adjuster

housing and install the adjuster plug.

21. Check that the chain-case O-ring seal is positioned

correctly on the housing.

22. Position the shift fork behind the large thrust

washer and bearing on the reverse gear; then posi-

tion the cover on the housing.

AF075

23. Apply blue Loctite #243 to the threads of the cap

screw; then install the cap screw through the cen-

ter of the cover and into the idler shaft. Tighten the

cap screw enough to draw the idler shaft into the

cover.

24. Place the shift pivot and reverse switch bracket

into position on the cover; then secure the chain-

case cover with cap screws and lock washers.

Tighten the cap screws to 13 ft-lb.

25. Place the shift linkage into position on the back

side of the arm and secure with a cap screw and

lock nut. Tighten to 25 ft-lb.

26. Place the reverse lever into position on the shift

pivot and secure with a clevis pin and cotter pin.

27. On the PTO-side of the track driveshaft, slide the

lock collar against the bearing, drive the collar in

the direction of rotation until tight, and tighten the

collar set screw.

AF054

28. Install the skid frame (see Section 7).

29. Remove the hold-down strap securing the air-

intake silencer; then place the silencer into posi-

tion making sure the boot is properly positioned on

the carburetor/throttle body assembly. Secure the

silencer to the steering support with the two

screws.

6-26

30. Apply a light coat of grease or Loctite Anti-Seize

Thread Compound to the driven shaft; then install

the driven shaft alignment washers (as required)

and key. Install the stub shaft and the driven pul-

ley, alignment washers (as required), washer, and

cap screw (coated with blue Loctite #243). Tighten

to 24 ft-lb.

„NOTE: Make sure the keyways match when
installing the driven pulley. Arrange washers to
allow the least amount of float on the driven shaft.
A maximum of 1.5 mm (0.060 in.) float is allowable.

SC013D

31. Check the alignment of the drive clutch/driven

pulley (see appropriate Drive Clutch/Driven Pul-

ley in this section).

32. Assure that the chain case drain plug is tightened

to 35 ft-lb; then pour 354 ml (12 fl oz) of Arctic

Cat Transmission Lube into the chain case.

33. Install the drive belt and check belt deflection.

Secure the belt guard.

34. Install and secure the battery tray and battery; then

connect the battery cables making sure to connect

the positive cable first.

ADJUSTING REVERSE LINKAGE

1. Start the engine; then test the shifting characteris-

tics of the reverse transmission.

2. If adjustment of the reverse gear is necessary, stop

the engine and remove the chain case inspection

plug located behind the oil level stick; then insert

the Reverse Gear Adjustment Gauge completely

into the inspection hole.

0731-734

3. Pull the shift lever into the reverse position while

holding the adjustment gauge firmly against the

chain case cover. Slight outward pressure should

be felt on the gauge as the lever locks into reverse.

4. If no contact is noted, loosen the jam nuts securing

the lower shift linkage and adjust the linkage rod

until the gauge is pushed out of the chain case

0.254-0.381 mm (0.010-0.015 in.). Lock the

adjustment by tightening the jam nuts securely

against the tie rod ends.

„NOTE: To adjust the linkage rod, the shift lever
must be moved to the forward position.

5. Install the inspection plug.

6. Start the engine; then test the shifting characteris-

tics of the reverse transmission. Adjust as neces-

sary.

! CAUTION

The linkage must be properly adjusted. If the linkage
is too short, damage to the shift fork may occur. If
the linkage is adjusted too long, the gears will not
shift totally into reverse.

6-27

6

Drive Train/Brake Disc

(F-Series/T-Series)

Removing Gear Case ........................................... 6-27
Removing Track Driveshaft  .................................. 6-28
Installing Track Driveshaft  .................................... 6-30
Disassembling Gear Case .................................... 6-32
Cleaning and Inspecting Gear Case ..................... 6-34
Removing Drive Sprockets.................................... 6-35
Installing Drive Sprockets...................................... 6-36
Assembling Gear Case ......................................... 6-37
Installing Gear Case ............................................. 6-40

REMOVING GEAR CASE

„NOTE: The gear case drive fluid does not have to
be drained for this procedure.

1. Remove the access panels from both sides of the

snowmobile.

„NOTE: At this point, engage the brake lever lock.

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

cap screw securing the driven pulley to the input

shaft. Remove the pulley from the shaft.

ZJ182A

„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.

3. On electronic reverse models, disconnect the plug-

ins for the shift actuator (A) and the gear indicator

switch (B).

ZJ183A

4. Remove the torx-head cap screws securing the toe

shield and hook bracket to the chassis; then

remove the shield and bracket.

0742-089

„NOTE: Either elevate the snowmobile off the floor
with a suitable lift or tip the snowmobile on its
right side positioning the gear case side of the
snowmobile up. Place a piece of cardboard under
the side of the snowmobile to prevent scratching
of the side panel.

5. On mechanical reverse models, remove the E-ring

(A) from the shift fork arm; then remove the link-

age and account for the bushings and washer.

742-864B

6. 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.