Snowmobile Arctic Cat (2002 year). Manual - part 104

7-28

AL156D

„

NOTE: Note the number of threads exposed

between the spring adjuster and shock housing
for installing purposes.

3. Using the Shock Spring Removal Tool (p/n 0644-

057), remove the spring from the shock body by

compressing the spring; then remove the spring

retainer from the top of the spring. Inspect the

shock absorber by quickly compressing and

extending the shock plunger while firmly holding

the shock body. Resistance must be felt in both

directions.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the shock absorber seal area for signs of

excessive oil leakage.

2. Inspect the shock absorber mounting eyelet,

bushings, and sleeve for wear or damage.

3. Inspect the threaded shock sleeve for damage or

wear. Clean the sleeve and apply a light coat of

grease to the threads before installing.

INSTALLING

1. Using the shock spring tool, place the spring on

the shock absorber and secure with the retainer.

2. Adjust the retainer nut (spring adjuster) until the

specified amount of threads are exposed between

the spring adjuster and the shock housing (noted in

removing) as an initial setting.

3. Install the bushings, sleeves, and spacers into each

shock end; then place the shock absorber into

position. Install both cap screws from the front.

Tighten the lock nuts to 3.9 kg-m (28 ft-lb).

AL156D

Sway Bar

REMOVING

1. Remove the lock nuts and cap screws securing the

sway bar arm to the links and remove.

2. Remove the lock nuts and cap screws securing the

sway bar arms to the sway bar; then remove the

arms. Pull the sway bar out and account for two

bearings.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the sway bar for any signs of twisting,

fatigue, or wear.

2. Inspect the sway bar arms for cracks or damage.

3. Inspect the links, bushings, bushing retainers, and

hardware for damage or wear.

INSTALLING

736-034A

Key

1. Washer
2. Washer
3. Lock Nut
4. Cap Screw
5. Cap Screw
6. Lock Nut

 7. Link

8. Cap Screw
9. Lock Nut

10. Sway Bar
11. Bearing
12. Arm

7-29

7

1. Place the sway bar into position; then install a

bearing on each end of the sway bar.

2. Slide the sway bar arms onto the sway bar until the

holes in the arms align with the notches in the

sway bar. Install the cap screws and lock nuts.

Tighten to 1.8 kg-m (13 ft-lb).

„

NOTE: Make sure the arms are positioned on the

same flat on both ends of the sway bar.

3. Place the links into position on the sway bar arms;

then secure with cap screws and lock nuts. Tighten

to 3.2 kg-m (23 ft-lb).

Console

(EFI Models)

„

NOTE: Determine which style console is being

removed and installed and refer to the appropriate
illustration for component details; then remove
and install accordingly.

0736-467

0736-633

0736-668

KEY

1. Console
2. Door
3. Ignition Switch
4. Key
5. Spacer
6. Lock Washer
7. Decal

8. Retaining Nut
9. Self-Tapping Screw

10. Self-Tapping Screw
11. Washer

KEY

1. Console
2. Door
3. Ignition Switch
4. Key
5. Spacer
6. Lock Washer
7. Decal
8. Retaining Nut
9. Self-Tapping Screw

10. Self-Tapping Screw

11. Washer
12. Mounting Bracket
13. Machine Screw
14. Reservoir Assy
15. Cap Screw
16. Lock Washer
17. Retainer Bracket
18. Backing Plate
19. Lock Nut

KEY

1. Console
2. Door
3. Ignition Switch
4. Key
5. Spacer
6. Lock Washer
7. Decal - Right

8. Retaining Nut
9. Self-Tapping Screw

10. Self-Tapping Screw
11. Washer
12. Outlet w/Nut
13. Decal - Left

7-30

REMOVING

1. Remove the self-tapping screws securing the

console; then raise the console.

„

NOTE: If applicable, remove the cap screws and

washers securing the remote adjuster clamp to the
console; then lay the adjuster on the air-intake
silencer.

2. Disconnect the wiring harness from the ignition

switch.

3. Remove the console.

INSTALLING

1. Place the console into position.

2. Connect the wiring harness to the ignition switch.

3. Secure the console with the self-tapping screws.

„

NOTE: If applicable, place the remote adjuster

and clamp into position on the console; then
secure with the cap screws and washers. Tighten
securely.

Console

(Carbureted Model - Style A)

0735-935

REMOVING

1. Pull the recoil starter rope outward; then tie a slip-

knot in the recoil rope near the case. Slowly allow

the rope to retract to the knot.

2. Untie the knot in the end of the recoil starter rope;

then remove the handle from the rope. Account for

the cap.

3. Remove the cotter pin and pin securing the shift

lever to the shift pivot; then pull the shift lever out

of the console.

4. Remove the four screws securing the steering post

cover; then remove the steering post cover.

KEY

1. Console
2. 12V Receptacle
3. Foam
4. Washer
5. Self-Tapping Screw
6. Machine Screw
7. Ignition Switch
8. Key
9. Choke Cable

10. Choke Lever Kit
11. Choke Nut
12. Washer
13. Ignition Nut
14. Decal
15. Plate
16. Rivet
17. Latch Cup
18. Rivet
19. Washer
20. Washer
21. Lock Nut
22. Voltage 

Regulator

23. Cap Screw

24. Cable Tie
25. Cable Tie
26. Main Harness
27. Headlight Harness
28. Fuse
29. Ignition Nut
30. Clip
31. Spacer

7-31

7

AF906D

5. Remove the screws securing the console; then

raise the console.

6. Disconnect the wiring harness from the ignition

switch. Remove the knurled nut securing the

choke assembly to the console; then slide the

choke cable out of the console.

7. If applicable, remove the primer; then remove the

console.

INSTALLING

1. Place the console into position; then (if applicable)

install the primer.

2. Connect the wiring harness to the ignition switch.

Secure the choke assembly to the console with the

knurled nut.

3. Secure the console with screws.

4. Secure the steering post cover with four screws.

5. Slide the shift lever into the hole in the console;

then secure the shift lever to the shift pivot with

the pin and cotter pin.

6. Thread the recoil starter rope through the console

and handle. Tie a knot at the end of the recoil rope.

Seat the cap. Remove the slip-knot and allow the

rope to retract.

Console

(Carbureted Models - Style B)

„

NOTE: Determine which type of console is being

removed and installed and refer to the appropriate
illustration for component details; then remove
and install accordingly.

0736-438

0736-596

KEY

1. Console
2. Door
3. Decal
4. Decal
5. Ignition Switch
6. Key

7. Self-Tapping 

Screw

8. Lock Washer
9. Ignition Nut

10. Choke Lever Kit
11. Choke Nut

12. Choke Cable
13. Self-Tapping 

Screw

14. Washer
15. Spacer
16. Nut

KEY

1. Console
2. Door
3. Ignition Switch
4. Key
5. Spacer
6. Lock Washer
7. Decal
8. Nut

9. Choke Cable

10. Nut
11. Choke Nut
12. Decal
13. Self-Tapping Screw
14. Self-Tapping Screw
15. Washer