Snowmobile Arctic Cat (2007 year). Manual - part 87

8-51

8

MS362

1. Properly align the scribed line on the driveshaft

(from removing) with the timing arrow on the

drive sprocket; then slide the sprocket onto the

driveshaft as far as it will go.

MS360A

2. Using a suitable press and fixture, press the

driveshaft into the sprocket until it aligns with

the line scribed in removing.

MS361A

3. Slide the remaining sprocket onto the driveshaft

making sure the timing arrow/lines (from

removing) are aligned; then using the press/fix-

ture, press the sprocket to the remaining align-

ment line.

MS359A

4. Using a calipers, measure distances between the

sprockets and from the sprockets to each end of

the driveshaft for proper location (see illustra-

tions).

0742-042

MS364

! CAUTION

Always press against the tension-collar of the drive
sprockets or damage to the components will occur.

8-52

ASSEMBLING GEAR CASE

0741-734

1. Using an appropriate seal installation tool,

install the oil seal into the output shaft opening

of the gear case.

„ NOTE: Grease must be applied to the seal prior
to installing.

ZJ204

2. Place the output shaft assembly into position in

the slider housing; then secure the assembly to

the housing with the thrust washer and retaining

ring.

ZJ200

3. Using a suitable bearing press, install the bear-

ing onto the ring gear.

ZJ199

4. In order, install the thrust washer and then the

thrust bearing onto the transfer gear shaft.

ZJ196

ZJ197

KEY

1. Gear Case

2. Dowel Pin

3. Bearing

4. Oil Seal

5. Plug

6. Shift Actuator

7. Machine Screw

8. Shift Fork 

Assembly

9. Oil Seal

10. Retaining Ring

11. Shift Fork Arm

12. Slider Block

13. Outer Slider 

Assembly

14. Retaining Ring

15. Thrust Washer

16. Output Shaft

17. Bearing

18. Outer Slider

19. Output Gear

20. Bearing

21. Spacer Washer

22. Planetary Gear 

Assembly

23. Thrust Washer

24. Thrust Bearing

25. Transfer Gear

26. Bearing

27. Input Shaft

28. Gear Case 

Cover

29. Oil Seal

30. Bearing

31. Gear Indicator 

Switch

32. Magnetic Drain 

Plug

33. Metal Gasket

34. Gear Case Plug

35. O-Ring

36. Machine Screw

8-53

8

5. Position the planetary gear assembly onto the

transfer gear shaft; then install the spacer

washer. Using a suitable press, install the inner

bearing onto the transfer gear shaft.

ZJ208

6. Install the output gear assembly into the slider

assembly until the inner bearing is properly

seated.

ZJ194

7. With the alignment notches of the slider and

gear case properly positioned, install the slider/

output gear assembly into the gear case.

ZJ201

8. Using a suitable bearing press, install the outer

bearing onto the transfer gear shaft.

ZJ199

9. Using a suitable bearing press and fixture,

install the input shaft bearing to the gear case;

then install the oil seal.

„ NOTE: Grease must be applied to the seal prior
to installing.

ZJ202

ZJ204

10. Using a suitable press, install the input shaft to

the gear case cover.

8-54

MS349

11. Install the first retaining ring onto the shift fork

shaft; then install a new oil seal.

„ NOTE: It is advisable to apply a film of grease to
the oil seal prior to installing.

12. With the alignment marks properly positioned,

install the shift fork arm to the shaft. Secure the

arm with the remaining retaining ring.

ZJ301A

13. Install the slider blocks to the shift fork assem-

bly; then install the fork assembly into the slider

and gear case.

ZJ205

„ NOTE: Make sure to install the slider blocks with
the rounded end up and the raised edges facing to
the outside of each other.

ZJ302

14. Apply a 1/8-in. bead of Loctite Sealant (p/n

1048-059) to the sealing surfaces of the gear

case.

ZJ207

15. With the dowel pins in place, install the cover to

the gear case and secure with 13 torx-head cap

screws; then in a crisscross pattern, tighten to

specifications.

742-195A

16. Install the shift actuator and secure with the

three torx-head cap screws. Tighten to specifica-

tions. Install the gear indicator switch; then

tighten to specifications.

! CAUTION

Care must be taken not to allow silicone sealant into
the cap screw holes and dowel pin holes or damage
to the gear case may occur when tightening the cap
screws.