Snowmobile Arctic Cat (2002 year). Manual - part 102

7-20

AL655D

5. Remove the two cap screws and lock nuts securing

the spindle to the suspension arms. Account for all

mounting hardware.

AL159D

AL160D

6. Inspect the tie-rod ball joint in place. If damage,

wear, or unusual bends are noted, loosen the jam

nut; then remove the ball joint from the tie rod.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the spindle for excessive wear, cracks,

bends, or imperfections.

2. Inspect all welds for cracking.

3. Inspect the suspension arm bushings and axle area

for wear.

4. Secure the spindle in a vise. Rotate the spindle

clockwise and counterclockwise. The movement

should be smooth and free. If the spindle

movement is rough or binding, grease the spindle

with a good low-temperature grease. Rotate the

spindle. If the movement remains rough, replace

the spindle.

„

NOTE: When greasing the spindle, use enough

grease so that it can be seen coming out at both
the top and bottom of the spindle.

5. Inspect the spindle axle and bearings for wear,

damage, or loose fit. Replace the bearings as a set.

„

NOTE: Replacing the ski bolt bushings is diffi-

cult. The existing bushings will be damaged dur-
ing removal. Be careful, however, not to damage
the spindle when removing the bearing. Press the
new bushings into the spindle.

INSTALLING

1. Place the upper and lower suspension arm ends

with bushings in position into the spindle. Secure

with cap screws and lock nuts. Tighten to

4.2 kg-m (30 ft-lb).

2. Place the steering tie-rod ball joint into position

(threads coated with green Loctite #609) on the

spindle arm as noted during removing (with

washer and O-ring) and secure with a lock nut.

Tighten to 3.5 kg-m (25 ft-lb).

AL108

AL655D

3. Install the ski.

7-21

7

4. Align the lower shock eyelet with the mounting

hole in the spindle; then secure with the cap screw,

optional washers, and lock nut. Tighten to

3.2 kg-m (23 ft-lb).

5. Remove the safety stand from beneath the front

end.

Steering Tie Rod

REMOVING

1. Remove the screws securing the skid plate; then

remove the skid plate.

„

NOTE: The front machine screw on some mod-

els is secured with a washer and lock nut.

AL144D

2. Remove the cotter pins, cap screws, and slotted

nuts securing the steering tie rod to the steering

post and steering arm; then remove the tie-rod

assembly.

AL089

3. Loosen the jam nuts securing the ball joints to the

steering tie rod; then remove the ball joints.

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

1. Position the handlebar in the straight-ahead

position; then position the skis straight ahead.

2. Thread the jam nuts onto the ball joints; then

equally thread the ball joints onto the steering tie

rod.

„

NOTE: There must be an approximate equal

number of threads exposed on each ball joint.

3. Place the tie-rod assembly into position; then

rotate the steering tie rod until the holes in the ball

joints align with the holes in the steering post and

steering arm.

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.

! WARNING

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

7-22

AL144D

Ski Alignment

(120 cc)

CHECKING

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

2. Measure the distances to the inside edges of the

skis in two places. Make sure the measurements

are taken behind the spindle mount and ahead of

the spindle mount.

0735-446

„

NOTE: Ski alignment is correct when the skis are

parallel to each other (equal measurements front
and rear) or when the skis have up to a maximum
of 6 mm (1/4 in.) toe out (front measurement 6 mm
(1/4 in.) more than rear measurement).

3. If ski alignment is not as specified, the snowmo-

bile will have a tendency to wander and may be

difficult to control; therefore, an adjustment is

necessary.

ADJUSTING

1. Make sure the ignition key is in the OFF position.

2. Visually examine the skis to determine which ski

is out of alignment with respect to the handlebar.

3. Open the hood and loosen the jam nut on each end

of the tie rod.

4. While holding the straight ski in position, rotate

the tie rod until the measurement between the skis

is within specifications.

5. When the ski alignment is correct, apply blue

Loctite #243 to the jam nut threaded areas and

tighten each jam nut securely against the tie rod.

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;

then tighten the ski mounting cap screws to

3.6 kg-m (26 ft-lb).

2. Turn the handlebar to the straight-ahead position

until the hole in the middle of the drag link is

aligned with the notch (half-moon shaped) in the

chassis. Visually inspect the handlebar for being

centered and in the straight-ahead position.

0734-407

„

NOTE: 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.

! WARNING

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

Toe-Out Range

1.6-6.4 mm (1/16-1/4 in.)

7-23

7

3. With the drag link centered and handlebar in the

straight-ahead position, secure the handlebar to

prevent the drag link and handlebar 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.

729-887A

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) 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

2. Adjust ski alignment by rotating the adjustment 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.

! 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.