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Snowmobile Arctic Cat (2000 year). Manual - part 98

REMOVING/DISASSEMBLING

NOTE: The snowflap can be removed without

removing the bumper by removing the three
bumper/snowflap cap screws.

1. Remove the cap screws securing the bumper

assembly to the tunnel. Account for the U-nuts and
cap screws.

2. Slide the bumper/snowflap off the tunnel.

3. Remove the cap screws securing the snowflap to the

bumper and separate the bumper and snowflap.
Account for cap screws, washers, and lock nuts.

ASSEMBLING/INSTALLING

1. Secure the snowflap to the bumper with the cap

screws, washers, and lock washers taking care to
place the washers next to the underside of the
snowflap. Finger-tighten the cap screws to the lock
nuts; then tighten the cap screws securely.

2. Place the bumper assembly into position on the

tunnel and secure with the cap screws and U-nuts.
Tighten the cap screws securely.

Headlight Assembly

(1 Bulb Halogen)

REMOVING

NOTE: The bulb portion of the headlight is fragile.

HANDLE WITH CARE. When replacing the headlight
bulb, the bulb assembly must first be removed from
the housing. Do not touch the glass portion of the
bulb. If the glass is touched, it must be cleaned with
a dry cloth before installing.

1. To release the retaining ring, depress the ring and

rotate it counterclockwise. Slide the retaining ring
down the wiring harness.

2. With the harness connector attached to the bulb,

carefully withdraw the bulb from the headlight
housing.

3. Grasp the bulb by the metal base and carefully

remove the headlight harness from the bulb.

4. Between the top center of the headlight and hood,

there is a reusable plastic push rivet. From the front
using a medium-sized standard screwdriver, push
the center post of the rivet back.

Fig. 7-102

0731-844

5. Remove the headlight adjustment thumb screws;

then remove the headlight assembly.

NOTE: Halogen bulbs must not come in contact

with hands or foreign contaminants.

INSTALLING

1. Place the headlight assembly into position. Secure

with a push rivet and two adjustment thumb screws.

2. While holding bulb by the base, firmly install the

bulb in the harness connector.

3. Install bulb assembly (with harness attached) into

headlight housing. Make sure the bulb is firmly
seated in the headlight housing.

4. Install the retaining ring onto the back of the

headlight. Depress the ring and rotate it clockwise
to lock in place.

Fig. 7-103

AL084D

5. Check headlight aim (see Adjusting Headlight Aim

in this section).

! WARNING

Do not operate the snowmobile unless headlight
beam is adjusted properly. An incorrectly
adjusted beam will not provide the operator the
optimum amount of light.

7-31

Adjusting

Headlight Aim

(1 Bulb Halogen)

The headlight HIGH/LOW beam can be adjusted
vertically and horizontally. The geometric center of the
HIGH beam light zone is to be used for vertical and
horizontal aiming.

1. Position the snowmobile on a level floor so the

headlight is approximately 8 m (25 ft) from an
aiming surface (wall or similar surface).

2. Measure the distance from the floor to the midpoint

of the headlight.

3. Using the measurement obtained in step 2, make a

horizontal mark on the aiming surface.

4. Make a vertical mark which intersects the

horizontal mark on the aiming surface directly in
front of the headlight.

5. Start the engine. Move the headlight dimmer switch

to the HIGH beam position. DO NOT USE THE
LOW BEAM.

6. Observe the headlight beam aim. Proper aim is

when the most intense beam is centered on the
vertical mark 5 cm (2 in.) below the horizontal mark
on the aiming surface.

Fig. 7-104

0734-485

7. Rotate the adjustment thumb screws until the

correct aim is obtained.

Headlight Assembly

(3 Bulb Halogen)

REMOVING HEADLIGHT BULB

NOTE: The bulb portion of the headlight is fragile.

1. Pull the wiring harness retaining clip away from the

headlight bulb base and disconnect the wiring
harness from the bulb.

Fig. 7-105

0733-178

2. Rotate the headlight bulb base counterclockwise

and remove the bulb from the headlight housing.

INSTALLING HEADLIGHT BULB

Do not touch the glass portion of the bulb. If the
glass portion is touched, it must be cleaned with
a dry cloth before installing.

1. While holding the bulb by its base, insert the bulb

into the headlight housing and rotate it clockwise
until it locks into the housing.

2. Plug the wiring harness into the headlight bulb base

making sure the retaining clip locks onto the base.

3. Check headlight aim (see Adjusting Headlight Aim

in this section).

! WARNING

Do not operate the snowmobile unless headlight
beam is adjusted properly. An incorrectly
adjusted beam will not provide the operator the
optimum amount of light.

! CAUTION

7-32

Adjusting

Headlight Aim

(3 Bulb Halogen)

The headlight can be adjusted for vertical aim of the
HIGH/LOW beam. The geometric center of HIGH
beam zone is to be used for vertical aiming.

1. Position the snowmobile on a level floor so the

headlight is approximately 8 m (25 ft) from an
aiming surface (wall or similar surface).

NOTE: There should be an “average” operating

load on the snowmobile when adjusting headlight
aim.

2. Measure the distance from the floor to midpoint of

the headlight.

3. Using the measurement obtained in step 2, make a

horizontal mark on the aiming surface.

4. Make a vertical mark which intersects the

horizontal mark on the aiming surface directly in
front of the headlight.

5. Engage the brake lever lock and start the engine.

Move the headlight dimmer switch to the HIGH
beam position. DO NOT USE LOW BEAM.

6. Observe the headlight beam aim. Proper aim is

when the most intense beam is centered on the
vertical mark 5 cm (2 in.) below the horizontal mark
on the aiming surface.

Fig. 7-106

0734-485

7. Adjust the headlight housing mounting screws until

correct aim is obtained. Shut the engine off; then
disengage the brake lever lock.

Torque Specifications

CHASSIS

TORQUE

Ski

ft-lb

kg-m

45
6.2

Handlebar Adjuster Block

ft-lb

kg-m

10
1.4

Steering Post Bearing Housings

ft-lb

kg-m

18
2.5

Steering Post/Tie Rod

ft-lb

kg-m

30
4.2

Drag Link/Tie Rods

ft-lb

kg-m

20
2.8

Drag Link/Steering-Idler Arms

ft-lb

kg-m

30
4.2

Spindle Arm/Tie Rod

ft-lb

kg-m

25
3.5

Tie Rod Jam Nuts

ft-lb

kg-m

12-15
1.7-2.1

Suspension Arms/Spindle

ft-lb

kg-m

30
4.2

Shock Absorber/Spindle

ft-lb

kg-m

28
3.9

Front Suspension A-Arm (upper)

ft-lb

kg-m

33
4.6

Front Suspension A-Arm (lower)

ft-lb

kg-m

55
7.6

Sway Bar Arm

ft-lb

kg-m

13
1.8

Ball Joint/Sway Bar

ft-lb

kg-m

23
3.2

7-33

SECTION 8 - DRIVE TRAIN

AND BRAKE SYSTEMS

TABLE OF

CONTENTS

Drive Belt . . . . . . . . . . . . . . . . . . . . . 8-2
Drive Clutch

. . . . . . . . . . . . . . . . . . . 8-2

Driven Pulley . . . . . . . . . . . . . . . . . . . 8-8
Drive Clutch/Driven Pulley . . . . . . . . . . . 8-14
Drive Train Schematics (w/Reverse) . . . . . . 8-17
Drive Train Schematics (w/o Reverse) . . . . . 8-22
Drive Train/Brake Disc (w/Reverse) . . . . . . 8-24
Drive Train/Brake Disc (w/o Reverse) . . . . . 8-33
Chain Adjuster . . . . . . . . . . . . . . . . . 8-39
Brake System (Hydraulic)

. . . . . . . . . . . 8-43

Brake Lever/Master Cylinder Assembly

(Hydraulic System) . . . . . . . . . . . . . 8-49

Brake System (Mechanical)

. . . . . . . . . . 8-52

Brake System (Mechanical/Quick-Adjust) . . . 8-56
Brake Control (Mechanical System) . . . . . . 8-63
2000 Drive System Specifications . . . . . . . 8-66
Chain Case Performance Specifications

With Tension Pad Tightener System . . . . 8-70

Chain Case Performance Specifications

With Roller Tightener System . . . . . . . . 8-70

Drive System Components . . . . . . . . . . . 8-71
Arctic Cat Cam Arms . . . . . . . . . . . . . . 8-72
Comet Cam Arms

. . . . . . . . . . . . . . . 8-74

Comet-To-Arctic Cat Cam

Arm Conversion Chart

. . . . . . . . . . . 8-75

Chains & Sprockets 1984-2000

. . . . . . . . 8-75

Arctic Cat Drive Belt Dimension Chart . . . . . 8-76
Arctic Cat Drive Belt Replacement Chart . . . . 8-77
Center-To-Center/Offset Specifications

. . . . 8-79

Torque Specifications

. . . . . . . . . . . . . 8-80

Troubleshooting Drive Clutch/Driven Pulley . . 8-81
Troubleshooting Drive Belt . . . . . . . . . . . 8-82
Troubleshooting Hydraulic Brake System

. . . 8-83

8-1

Content .. 96 97 98 99 ..