Snowmobile Arctic Cat (2002 year). Manual - part 103

7-24

VERIFYING

1. With the drag link centered and handlebar in the

straight-ahead position, verify ski alignment by

measuring across from the outside edge of the left-

side wear bar bolts to the outside edge of the right-

side wear bar bolts (without using the straight-

edge) in two places: approximately 18-20 cm (7-8

in.) in front of the spindle and 18-20 cm (7-8 in.)

behind the spindle.

2. The measurement from in front of the spindle to

the outer edge of the wear bar bolts (without using

the straightedge) must not exceed the rear

measurement by more than 1.6-6.4 mm (1/16-1/4

in.) toe-out.

0734-408

Front

Suspension A-Arms

(120 cc)

REMOVING

1. Position the front of the snowmobile up onto a

safety stand.

2. Remove the spindle (see appropriate Spindle in

this section).

„

NOTE: The ski does not have to be removed

from the spindle for this procedure.

3. Remove the cap screw and lock nut securing the

upper shock eyelet to the upper A-arm; then

remove the shock. Account for two shock

bushings.

AO167

4. Remove the lock nuts securing the A-arms to the

chassis; then push the cap screws as far forward as

possible.

AO169A

5. Angle the rear of each A-arm downward and slide

them off the cap screws. Account for two outer

axles and an inner axle for each arm.

A033

„

NOTE: If the cap screw must be removed, it will

be necessary to remove the belly pan (see appro-
priate Belly Pan in this section).

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the A-arm welded areas for cracks or any

signs of deterioration.

! WARNING

The measurement taken in front of the spindle must
never be less than the measurement taken behind
the spindle or poor handling will be experienced.
Neglecting to lock the tie rod by tightening the jam
nuts may cause loss of snowmobile control and
possible personal injury.

7-25

7

2. Inspect the axles for wear or damage.

3. Inspect the tubing for signs of being twisted or

bent.

INSTALLING

0736-880

1. Slide the A-arms onto the cap screws and swing

them up into position on the front end; then tightly

secure with lock nuts.

2. Install the spindle (see appropriate Spindle in this

section).

Front

Suspension Arms

REMOVING

1. Remove the expansion chamber if necessary.

2. Position the front of the snowmobile up onto a

safety stand.

3. Remove the lock nuts and cap screws securing the

shock absorber; then remove the shock absorber.

Account for all mounting hardware.

AL156D

4. Remove the cap screws and lock nuts securing the

spindle to the front suspension arms. Account for

all mounting hardware.

AL159D

AL160D

5. On models with a sway bar, remove the cap screw

and lock nut securing the sway bar link to the front

suspension arm.

6. Remove the screws and lock nut securing the skid

plate; then remove the skid plate.

AL144D

7. If applicable, remove the self-tapping screws

securing the steering boot to the front end.

8. Remove the cap screws and lock nuts securing the

suspension arms to the front end; then remove the

arms.

KEY

1. Upper A-Arm
2. Lower A-Arm
3. Axle
4. Axle
5. Axle
6. Cap Screw

7. Cap Screw
8. Lock Nut
9. Shock Mounting 

Bracket

10. Washer
11. Lock Nut

7-26

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the arm welded areas for cracks or any

signs of deterioration.

2. Inspect the bearings and axles for wear or damage.

3. Inspect the arm tubing for signs of twisting or

bending.

INSTALLING

0736-484

0735-968

KEY

1. Lower Arm
2. Bearing
3. Upper Arm
4. Bearing
5. Axle
6. Washer
7. Axle Tube
8. Axle Tube
9. Axle

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

KEY

1. Lower Arm
2. Bearing
3. Upper Arm
4. Bearing
5. Axle
6. Washer
7. Tube
8. Tube
9. Axle

10. Tube
11. Washer
12. Cap Screw
13. Cap Screw
14. Cap Screw
15. Lock Nut
16. Cap Screw
17. Lock Nut
18. Lock Nut
19. Tube
20. Washer

7-27

7

1. Place the suspension arms into position on the

front end and secure with the cap screws and lock

nuts. Tighten the upper arm cap screw and lock

nut to 4.6 kg-m (33 ft-lb). Tighten the lower arm

cap screw and lock nut to 7.6 kg-m (55 ft-lb).

2. If applicable, place the steering boot into position

on the front end. Secure with the self-tapping

screws.

3. Install the skid plate and secure with the screws,

washer, and lock nut.

AL144D

4. If applicable, place the sway bar link into position

on the suspension arm and secure with cap screw

and lock nut.

5. Accounting for mounting hardware, install the

spindle onto the suspension arm with the cap

screws and lock washers.

AL160D

AL159D

6. Place the shock absorber into position and secure

to the front end and spindle with two cap screws,

washers, axles, spacers, sleeves, and lock nuts.

Tighten to 3.9 kg-m (28 ft-lb).

AL157D

AL156D

7. Install and secure the expansion chamber if

removed.

Front Suspension (Ski)

Shock Absorber

REMOVING

1. Position the front of the snowmobile up onto a

safety stand taking all pressure off the skis.

2. Remove the cap screws securing the shock

absorber to the front end assembly and spindle;

then remove the shock absorber. Account for all

mounting hardware.