Snowmobile Arctic Cat (2007 year). Manual - part 88

8-55

8

ZJ186A

17. Pour 236 ml (8 fl oz) for the early-build model

or pour 354 ml (12 fl oz) for the regular-build

model of Arctic Cat ACT Drive Fluid (p/n 4639-

025) into the drain/fill hole; then install the plug.

Tighten securely.

INSTALLING GEAR CASE

1. Using a Scotch Brite pad, clean the gear case/

drive unit seal-mating surface on the track drive-

shaft; then thoroughly wipe clean.

„ NOTE: Prior to placing the gear case onto the
driveshaft, apply a light coat of Arctic Cat Low-
Temp Snowmobile Grease (p/n 0636-593) to the
internal splines of the track driveshaft.

2. Align the gear case output shaft with the splines

of the track driveshaft and position the gear case

onto the mounting studs. Making sure the sensor

wires do not become pinched under the gear

case, push inward on the gear case until it is

seated.

3. Using a rubber mallet, lightly tap inward on the

gear case to ensure that is fully seated to the

chassis.

4. Loosely secure the gear case by first installing

the six lock nuts and finger tighten; then install

the snubber bracket and a torx-head cap screw

and the two remaining lock nuts and tighten all

the nuts to specifications.

742-018A

„ NOTE: When tightening the nuts to the proper
torque factor, it is advisable to begin tightening the
nuts located on the bottom of the gear case and
working upward in a crisscross pattern until all
nuts are tightened to the proper torque factor.

„ NOTE: With the gear case secured, adjust the
snubber bracket until the rubber lightly contacts
the engine.

ZJ209

5. Connect shift actuator harness (A) and gear indi-

cator switch harness (B).

ZJ183A

6. Slide the driven pulley onto the input shaft mak-

ing sure alignment washers are in place.

! CAUTION

Do not add more or less than the recommended
amount of drive fluid (8 fl oz - early-build or 12 fl oz -
regular-build) to the gear case or damage to the
gear case will occur.

8-56

7. Secure the driven pulley with components and

hardware as noted in removing. Tighten to spec-

ifications.

ZJ250A

8. Install the drive belt.

„ NOTE: For installing drive belt, see Removing/
Installing Drive Belt (ACT Roller Driven Pulley) in
this section.

9. Install the toe shield and toe hook bracket; then

install the torx-head cap screws. Tighten

securely.

0742-089

10. Install the 16 mm cap screw securing the drive-

shaft to the gear case output shaft; then tighten

to specifications.

0742-020

11. Install the side panels.

„ NOTE: If the track was loosened to aid in remov-
ing the gear case, tighten track to proper tension
and alignment.

Replacing Driven 

Shaft PTO-End Bearing

(Bearcat Wide Track/

Panther 660/T660)

REMOVING

1. Remove the drive belt.

„ NOTE: For removing drive belt on models with
the ACT Roller Driven Pulley, see Removing/
Installing Drive Belt (ACT Roller Driven Pulley) in
this section.

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

the cap screw securing the driven pulley to the

driven shaft.

3. Slide the driven pulley off the driven shaft.

SC013D

! CAUTION

It is critical that the two 1.5 mm (0.060 in.) washers
are in place on the input shaft when installing the
drain pulley.

8-57

8

ZJ250A

„ NOTE: If the driven pulley is tight on the shaft,
pull the driven pulley off using the Driven Pulley
Puller (p/n 0644-469) for the turbo models or (p/n
0744-023) for non-turbo models.

4. Using Driven Shaft Bearing Removal/Installa-

tion Tool (p/n 0644-516), remove the jam nut

from the bearing; then remove the locking ring.

ZJ259

5. Thread the jam nut (from step 4) onto the bear-

ing sleeve leaving a clearance of 1.59 mm

(0.0625 in.) between the jam nut and the bearing

race; then using Driven Shaft Bearing Removal/

Installation Tool (p/n 0644-516), drive the

sleeve out of the bearing.

6. Remove the two cap screws and lock nuts secur-

ing the upper flange plate to the bearing support;

then remove the flange plate.

ZJ258A

„ NOTE: On the Bearcat W/T (STD) and Panther
660 models at this point, move and secure the
speed sensor bracket out of the way.

7. With the sleeve free from the bearing, remove

the jam nut; then remove the bearing and sleeve

from the driven shaft and on the Bearcat W/T

(STD) and Panther 660 models, account for the

speed sensor magnet.

„ NOTE: The magnet may remain on the driven
shaft or may come off with the sleeve/bearing
assembly.

8. Thoroughly clean the driven shaft with fine

emery cloth or with a scuff pad.

INSTALLING

„ NOTE: On the Bearcat W/T (STD) and Panther
660 models, assure that the speed sensor magnet
is in place on the driven shaft.

1. Slide the sleeve and bearing onto the driven

shaft and into the bearing support; then install

the upper flange plate and secure it to the bear-

ing support with two cap screws and lock nuts.

Tighten to specifications.

ZJ260A

„ NOTE: On the Bearcat W/T (STD) and the Panther
660 models, install the speed sensor bracket to the
flange plate cap screws prior to installing the lock
nuts.

2. With the tab of the locking ring in line with the

slot of the sleeve, install the locking ring to the

bearing sleeve.

8-58

ZJ261A

„ NOTE: The locking ring must be installed with the
beveled tabs directed outward toward the jam nut.

ZJ262

3. Install the jam nut; then using Driven Shaft

Bearing Removal/Installation Tool (p/n 0644-

516), tighten the jam nut to specifications.

ZJ258B

4. Set the brake lever lock.

5. Slide the driven pulley onto the driven shaft

making sure alignment washers are in place.

6. Secure the pulley with the cap screw (coated

with blue Loctite #243) and washer. Tighten to

specifications.

7. Install the drive belt.

„ NOTE: For installing the drive belt on models
with the ACT Roller Driven Pulley, see Removing/
Installing Drive Belt (ACT Roller Driven Pulley) in
this section.

Brake System

(Bearcat Wide Track/

Panther 660/T660)

CHECKING BRAKE LEVER TRAVEL

1. Compress the brake lever fully.

„ NOTE: Do not pump the brake lever as it will pro-
duce an inaccurate reading.

2. Measure the distance between the brake lever

and the handlebar. The distance must be greater

than 2.54 cm (1 in.).

734-505A

3. If the distance is less than specified, check the

brake fluid level (see Checking and Adding

Brake Fluid in this sub-section), inspect for

leakage, and check the brake pads (see Check-

ing and Replacing Brake Pads in this sub-sec-

tion).

! WARNING

Use only Arctic Cat approved Hi-Temp Brake Fluid
(p/n 0638-315). Never substitute or mix different
types or grades of brake fluid. Brake loss may occur.
Brake loss can result in severe injury or even death.

! WARNING

Do not operate the snowmobile if the distance
between the compressed brake lever and handlebar
is less than 2.54 cm (1 in.). Brake loss may occur.
Brake loss can result in severe personal injury.