Snowmobile Arctic Cat (2002 year). Manual - part 100

7-12

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.

3. Inspect the wear bar for wear.

4. Inspect all hardware and the spindle bushings for

wear and damage.

5. Inspect the rubber damper for damage or wear.

INSTALLING

0736-423

0736-533

1. Position the ski over the saddle.

2. Apply a low-temperature grease to the non-

threaded portion of the cap screw; then slide the

cap screw (with washer as required) through the

ski and saddle accounting for the rubber damper.

„

NOTE: Install the cap screw so the lock nut will

be located to the inside of the ski.

3. Apply red Loctite #271 to the threads of the cap

screw; then tighten the lock nut (with washer as

required) to 6.2 kg-m (45 ft-lb).

4. Place the cotter pin into the ski cap screw and

spread the pin.

Ski

(120 cc)

REMOVING

1. Place the cap screw and lock nut securing the ski

to the spindle.

KEY

1. Ski
2. Wear Bar
3. Washer
4. Lock Nut
5. Cap Screw
6. Lock Nut
7. Damper
8. Spindle Axle
9. Spindle

10. Bearing
11. Bearing
12. Spindle Insert
13. Grease Fitting
14. Spacer
15. Cotter Pin
16. Ski Saddle
17. Ski Saddle 

Insert

18. Cap Screw

19. Lock Nut
20. Plastic Handle
21. Cap Screw
22. Washer
23. Lock Nut
24. Machine Screw
25. Decal
26. Washer
27. Spindle Cap

KEY

1. Spindle
2. Grease Fitting
3. Spindle Insert
4. Bearing
5. Damper
6. Ski Saddle
7. Ski 

8. Ski Insert
9. Wear Bar

10. Washer
11. Cotter Pin
12. Cap Screw
13. Lock Nut
14. Washer

15. Lock Nut
16. Washer
17. Spindle Cap
18. Decal
19. Axle

7-13

7

A027

2. Remove the ski and account for two washers.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect all hardware and spindle axles for any

signs of damage.

2. Inspect the welded areas for cracks or deteriora-

tion.

3. Inspect the ski for abnormal bends or cracks.

INSTALLING

0736-145

1. Place the ski the ski into position on the spindle;

then secure with a cap screw, two washers, and a

lock nut.

2. Tighten the lock nut securely making sure the ski

is free to pivot.

Ski Wear Bar

The ski wear bar is a replaceable bar attached to the

underside of the ski. The purpose of the wear bar is to

assist in turning the snowmobile, to minimize ski

wear, and to maintain good steering control. If the

snowmobile is operated primarily in deep snow, ski

wear bar wear will be minimal; however, if the snow-

mobile is operated on terrain where the snow cover is

minimal, the ski wear bar will wear faster. Arctic Cat

recommends that the ski wear bars be checked once a

week and replaced if worn to 1/2 of original diameter.

REMOVING

1. Remove ice and snow buildup from the ski.

2. With the gas tank nearly empty (less that 1/4 full),

lay the snowmobile on its side.

3. Remove the lock nuts and washers securing the

wear bar to the ski. Account for any spacers.

0735-453

731-037D

4. Pry the rear of the wear bar down until the wear

bar studs are clear of the ski; then slide the wear

bar rearward until the front of the wear bar is free

from the ski.

5. Remove the wear bar.

! CAUTION

Do not over-tighten the ski lock nut or binding
will occur.

KEY

1. Ski
2. Wear Bar
3. Cap Screw
4. Washer
5. Lock Nut
6. Spindle
7. Grease Fitting
8. Axle
9. Spindle Cap

10. Decal
11. Lock Nut
12. Washer
13. Insert

! CAUTION

A piece of cardboard should be used to protect
the finish on the hood.

7-14

INSTALLING

1. Place spacers (if applicable) on the wear bar studs;

then insert the front of the wear bar into the hole at

the front of the ski and swing the wear bar upward.

2. Insert the wear bar studs into the holes in the ski.

3. Center the wear bar studs in the holes and install

the washers and lock nuts.

4. Tighten lock nuts securely.

Drag Link

REMOVING

1. Remove the expansion chamber if necessary.

2. Remove the lock nuts securing the tie rods to the

spindles on both sides of the snowmobile. Account

for  O-rings and washers.

„

NOTE: Note whether the tie rod is installed on

the top side or on the bottom side of the spindle
arm for installing purposes.

AL108

AL655D

3. On the side from which the drag link will be

removed, remove the self-tapping screws securing

the steering boot to the front end (bulk head).

4. Remove the cap screws and lock nuts securing the

steering tie rod to the steering arm. Account for

washers.

AL092

5. Move the drag link from side to side to gain access

to the lock nuts and cap screws securing the

steering arms to the drag link; then remove the cap

screws and lock nuts. Account for washers and

drag link bearing axles.

6. From the opposite side from which the boot was

removed, carefully pull the steering boot over the

tie rod end; then remove the drag link.

„

NOTE: Applying soapy water to the steering

boot will aid in pulling the boot over the tie rod
end.

7. Place the drag link in a vise and remove the tie rod

ends from the drag link.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the entire drag link (especially in the areas

where the ball joints attach) for any signs of

cracks, wear, or damage.

2. Inspect the bearings, inserts, and axles for wear or

damage.

! WARNING

DO NOT bend the ski wear bar excessively when
installing. Excessive bending of the ski wear bar
may cause premature wear, breakage, and possible
injury.

7-15

7

INSTALLING

0736-486

1. Place the drag link in a vise; then secure the tie rod

to the drag link with cap screws, washers, and

lock nuts (threads coated with green Loctite #609).

Tighten to 2.8 kg-m (20 ft-lb).

2. Slide the drag link in from the side of the snowmo-

bile from which the steering boot was removed;

then carefully slide the boot over the tie rod end.

„

NOTE: Applying soapy water to the steering

boot will aid in sliding the boot over the tie rod
end.

3. Secure the drag link to the steering and idler arms

with cap screws (coated with green Loctite #609),

washers, bearing axles, and lock nuts. Tighten to

4.2 kg-m (30 ft-lb).

AL092

4. Secure the steering tie rod to the steering arm with

a cap screw (coated with green Loctite #609),

washer, and a lock nut. Tighten to 4.2 kg-m (30 ft-

lb).

5. Place the steering boot into position on the front

end (bulk head). Secure with self-tapping screws.

6. Install the tie rods (threaded area coated with

green Loctite #609) on the spindle arms as noted

during removing. Secure with O-rings, washers,

and lock nuts. Tighten to 3.5 kg-m (25 ft-lb).

AL108

AL655D

„

NOTE: Check all drag link and ball joint fasten-

ers to ensure they are tight. Turn the handlebars
full-left and full-right several times to ensure free
movement.

7. Install and secure the expansion chamber (if

removed).

8. Check and adjust ski alignment (see appropriate

Ski Alignment in this section).

Tie Rods

(120 cc)

REMOVING AND DISASSEMBLING

1. Remove the tie rod from the spindle.

KEY

1. Drag Link
2. Bearing
3. Steering Arm
4. Insert
5. Steering Arm
6. Cap Screw
7. Washer
8. Washer

9. Lock Nut

10. Cap Screw
11. Washer
12. Lock Nut
13. Axle
14. Cap Screw
15. Cap Screw
16. Washer

17. Lock Nut
18. Ball Joint
19. Hex Nut
20. Tie Rod Tube
21. Hex Nut
22. Ball Joint
23. O-Ring
24. Lock Nut