Snowmobile Arctic Cat (2004 year). Manual - part 89

7-20

4. Ensure correct handlebar/ski alignment (adjust

steering tie rod as necessary); then apply blue
Loctite #242 to the jam nut threaded area and
tighten to 1.7-2.1 kg-m (12-15 ft-lb).

5. Secure the tie-rod assembly with the two cap

screws (coated with green Loctite #609), washers,
and slotted nuts. Tighten to 4.2 kg-m (30 ft-lb);
then install the cotter pins and spread the cotter
pins.

AL089

6. Install the skid plate; then secure with screws.

„

NOTE: The front machine screw on some mod-

els is secured with a washer and lock nut.

AL144D

Steering Tie Rod

(AWS VI)

REMOVING

1. Remove the cap screw and lock nut securing the

steering tie rod to the steering post. 

FC202

2. Remove the cap screw and lock nut securing the

steering tie rod to the upper arm of the steering
shaft. Account for the washer. 

FC206

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the ball joints for damaged threads or

wear. 

2. Inspect the tie rod for damage, unusual bends, or

wear.

INSTALLING

„

NOTE: There must be an approximate equal

number of threads exposed on each ball joint.

1. Place the steering tie rod into position on the upper

arm of the steering shaft. Secure with the cap
screw (coated with green Loctite #609), washer,
and lock nut. Tighten the lock nut to 4.3 kg-m (31
ft-lb).

! WARNING

Neglecting to lock the jam nuts against the tie rod
may cause loss of snowmobile control and possible
personal injury.

7-21

7

FC206

2. Place the steering tie rod into position on the

steering post. Secure with the cap screw coated
with green Loctite #609 and lock nut. Tighten lock
nut to 4.2 kg-m (30 ft-lb).

FC202

Ski Alignment

CHECKING

„

NOTE: Track tension and alignment must be

properly adjusted prior to checking or adjusting
ski alignment. Ski alignment must be performed
on a flat, level surface. Ski toe-out must fall within
the range of 1.6- 6.4 mm (1/16-1/4 in.).

1. Raise the front end of snowmobile just high

enough to keep the skis from contacting the floor.

2. Turn the handlebar to the straight-ahead position.

Visually inspect the handlebar for being centered
and in the straight-ahead position.

„

NOTE: At this point on AWS V models, the hole

in the middle of the drag link should be aligned
with the notch (half moon shaped) in the chassis. 

0734-407

„

NOTE: On AWS V models if the handlebar is not

in the straight- ahead position when the hole in the
middle of the drag link aligns with the notch in the
chassis, the steering tie rod must be adjusted.
When handlebar alignment is correct, apply blue
Loctite #242 to the jam nut threaded area and
tighten to 1.7-2.1 kg-m (12-15 ft-lb). Tighten both
jam nuts against the steering tie rod.

3. With the handlebar in the straight-ahead position,

secure the handlebar to prevent the alignment from
becoming disturbed during the remainder of the
alignment procedure.

„

NOTE: Track tension and alignment must be

properly adjusted prior to placing the straightedge
against the outside edge of the track.

4. Place a long straightedge against the outside edge

of the track so it lies near the inside edge of the
left-side ski.

729-887B

„

NOTE: The straightedge should be long enough

to extend from the back of the track to the front of
the ski.

5. Measure the distance from the straightedge to the

left-side ski wear bar bolts in two places: approxi-
mately 18-20 cm (7-8 in.) in front of the spindle
and 18-20 cm (7-8 in.) behind the spindle. Record
the measurements taken for the left side.

Toe-Out Range

1.6-6.4 mm (1/16-1/4 in.)

7-22

729-887A

0734-408

6. Place the straightedge against the outside edge of

the track so it lies near the inside edge of the right-
side ski.

7. Measure the distance from the straightedge to the

right-side ski wear bar bolts in two places: 18-20
cm (7-8 in.) in front of the spindle and 18-20 cm
(7-8 in.) behind the spindle. Record the measure-
ments taken for the right side.

8. If ski alignment is not as specified, adjust the

alignment of the ski(s) not parallel to the straight-
edge.

ADJUSTING

„

NOTE: The following procedure can be used to

adjust the alignment of either ski.

1. Unlock the appropriate adjustment tie rod(s) on

AWS V models or from beneath the hood, the
steering tie rod on AWS VI models by loosening
the jam nuts.

„

NOTE: The outside jam nuts are left-hand thread.

Care should be taken to rotate them in the proper
direction.

0729-883

738-167A

2. Adjust ski alignment by rotating the adjustment/

steering tie rod.

3. When ski alignment is correct, apply blue Loctite

#242 to the jam nut threaded area and tighten to
1.7-2.1 kg-m (12-15 ft-lb). Tighten both jam nuts
against the tie rod.

VERIFYING

1. With the handlebar in the straight-ahead position,

verify ski alignment by measuring across from the
outside edge of the left-side wear bar bolts to the
outside edge of the right-side wear bar bolts
(without using the straightedge) in two places:
approximately 18-20 cm (7-8 in.) in front of the
spindle and 18-20 cm (7-8 in.) behind the spindle.

2. The measurement from in front of the spindle to

the outer edge of the wear bar bolts (without using
the straightedge) must not exceed the rear
measurement by more than 1.6-6.4 mm (1/16-1/4
in.) toe-out.

! WARNING

The measurement from the front and rear wear bar
bolts to the straightedge can be equal (ski parallel
to the track), but the front measurement must never
be less (ski toed-in) or poor handling will be experi-
enced. The front wear bar bolt measurement to the
straightedge must not exceed the measurement
from the rear wear bar bolt to the straightedge (ski
toed-out) by more than 3.9 mm (5/32 in.).

! WARNING

Neglecting to lock the tie rod by tightening the jam
nuts may cause loss of snowmobile control and
possible personal injury.

7-23

7

0734-408

Front

Suspension Arms 

(AWS V)

REMOVING

1. Remove the expansion chamber if necessary.

2. Position the front of the snowmobile up onto a

safety stand.

3. Remove the lock nuts and cap screws securing the

shock absorber; then remove the shock absorber.
Account for all mounting hardware.

AL156D

4. Remove the cap screws and lock nuts securing the

spindle to the front suspension arms. Account for
all mounting hardware.

AL159D

AL160D

5. On models with a sway bar, remove the cap screw

and lock nut securing the sway bar link to the front
suspension arm.

6. Remove the screws and lock nut securing the skid

plate; then remove the skid plate.

AL144D

7. If applicable, remove the self-tapping screws

securing the steering boot to the front end.

8. Remove the cap screws and lock nuts securing the

suspension arms to the front end; then remove the
arms.

! WARNING

The measurement taken in front of the spindle must
never be less than the measurement taken behind
the spindle or poor handling will be experienced.
Neglecting to lock the tie rod by tightening the jam
nuts may cause loss of snowmobile control and
possible personal injury.