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Snowmobile Arctic Cat (2004 year). Manual - part 85

7-4

AL153D

13. Move the air-intake silencer forward.

AL154D

14. Carefully slide the steering post out of the chassis.

Be careful not to hook any wires or hoses.

INSPECTING

NOTE: Whenever a part is worn excessively,

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

1. Inspect all welded areas for cracks or deteriora-

tion.

2. Inspect the steering post and steering-post brackets

for cracks, bends, or wear.

3. Inspect the bearing halves, bearing caps, and

bearing housings for cracks or wear.

INSTALLING

0738-352

0738-594

1. Carefully slide the steering post into position in

the chassis. Be careful not to hook any wires or
hoses.

KEY

1. Steering Post
2. Cap Screw
3. Adjuster Cap
4. Adjuster Block
5. Lock Nut
6. Cap Screw
7. Housing Cap

8. Bearing Half
9. Bearing

Housing

10. Lock Nut
11. Lock Nut
12. Washer
13. Backing Plate

14. Cap Screw
15. Ball Joint (Left)
16. Hex Nut (Left)
17. Tie Rod Tube
18. Hex Nut (Right)
19. Ball Joint

(Right)

KEY

1. Steering Post
2. Cap Screw
3. Adjuster Cap
4. Adjuster Block
5. Lock Nut
6. Cap Screw
7. Housing Cap
8. Bearing Half

9. Bearing

Housing

10. Hood Switch

Mounting
Bracket

11. Lock Nut
12. Washer
13. Backing Plate
14. Cap Screw

15. Lock Nut
16. Washer
17. Ball Joint (Left)
18. Hex Nut (Left)
19. Tie Rod Tube
20. Hex Nut (Right)
21. Ball Joint

(Right)

7-5

2. Secure the air-intake silencer to the steering

support with the washers, lock washers, spacers,
and cap screws.

AL153D

3. Secure the oil reservoir to the steering support

with the washer and lock nut.

AL152D

4. Secure the steering support to the footrest (both

sides) with the cap screws.

AL151D

5. Secure the recoil starter rope wire form with the

cap screws and lock nut.

AL150D

6. Secure the recoil starter rope cup with the sheet

metal screws.

AL149D

7. On the upper end of the steering post, apply a light

oil to the bearing halves and place into position
around the steering post; then place the bearing
cap between the steering support and the steering
post. Place the bearing housing into position and
secure with the backing plate, two cap screws,
washers, and lock nuts. Tighten to 2.5 kg-m
(18 ft-lb).

AL090

8. Secure the console with the Phillips-head screws.

7-6

AL142D

9. Place the adjuster block, handlebar assembly, and

adjuster caps into position; then secure with four
cap screws and lock nuts. Tighten lock nuts evenly
to 1.4 kg-m (10 ft-lb).

AL147D

10. Secure the handlebar pad.

AL136D

11. Tip the snowmobile on its side; then place the tie

rod into position. Secure with a cap screw (coated
with green Loctite #609) and lock nut. Tighten to
4.2 kg-m (30 ft-lb). Install the cotter pin and
spread the pin.

AL146D

12. On the lower end of the steering post, apply a light

oil to the bearing halves and place into position
around the steering post; then place the bearing
cap and bearing housing into position. Install the
backing plate and secure with two cap screws,
washers, and lock nuts. Tighten to 2.5 kg-m
(18 ft-lb).

AL145D

13. Install the skid plate. Secure with screws.

AL144D

NOTE: Turn the handlebar to the full-left and full-

right to ensure free movement.

7-7

Steering Post

(AWS VI)

REMOVING

1. Using a piece of cardboard to protect the hood and

belly pan, tip the snowmobile on its PTO-side.

2. From beneath the front end, remove the lock nut

and washer securing the steering post to the
steering post stop.

FC199

3. Tip the snowmobile upright. Remove the

handlebar pad.

4. Cut the cable ties securing the wiring and brake-

line hose to the steering post.

5. Remove the four lower Allen-head cap screws

securing the handlebar riser to the steering post;
then lay the handlebar riser assembly aside.
Account for the lower adjuster caps.

FC200

6. Remove the five torx-head screws securing the

console to the gas tank; then lay the console aside.

FC227

7. Remove the cap screw and lock nut securing the

steering tie rod to the steering post.

FC202

8. Remove the two lock nuts and two torx-head cap

screws with nuts securing the steering post
mounting block. Account for the plastic steering
post mounting block and the retaining plate.