Snowmobile Arctic Cat (2002 year). Manual - part 111

8-2

Drive Train and

Brake Systems

This section has been organized into sub-sections for

servicing drive train and brake systems; however,

some components may vary from model to model. The

technician should use discretion and sound judgment

when removing and installing components.

„ NOTE: Some illustrations and photographs used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.

Drive Chain

and Sprockets

(120 cc)

REMOVING

1. Remove the screws securing the front and rear

chain guards; then remove the guards from the

engine compartment. Note the position of the hood

cable.

A017A

„ NOTE: It will be necessary to support the hood
once the hood cable is removed.

2. Remove the muffler hold-down spring from the

muffler and support bracket.

A018

3. Remove the two nuts securing the muffler to the

engine.

A019

4. Press down on the muffler and pull it to the side

until the muffler flange clears the engine exhaust

studs; then remove the muffler from the engine

compartment. Account for the exhaust gasket.

5. Compress and hold the brake lever; then remove

the cap screw securing the rear chain sprocket to

the driveshaft. Release the lever.

6. Remove the snap ring securing the brake band.

Account for a washer.

A003

7. Loosen the rear brake cable adjustment jam nut

and slide the cable out of the brake bracket. Set the

band assembly aside.

A005

8-3

8

8. Secure the centrifugal clutch with a pair of

channel-lock pliers at the outer clutch collar; then

remove the cap screw securing the clutch. Account

for a washer and a spacer.

A020

9. Slide the chain sprocket and clutch with the drive

chain off the respective shafts and remove from

the engine compartment. Account for the rear

driveshaft key.

CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Thoroughly wash all metallic components in parts-

cleaning solvent. Dry using compressed air.

2. Wash all non-metallic components with soap and

water.

3. Inspect the sprocket driveshaft for damage or for

stripped threads.

4. Inspect the keyways in the driveshaft, chain

sprocket, and clutch for wear or damage.

5. Inspect the chain and chain sprocket for wear or

damage.

6. Inspect the driveshaft sprockets for wear or

damage.

INSTALLING

736-148A

1. Position the key on the rear driveshaft; then slide

the chain sprocket/clutch/drive chain assembly

into position.

2. Secure the clutch with a pair of channel-lock pliers

at the outer clutch collar; then install the cap screw

(coated with blue Loctite #243) with washer and

spacer. Tighten to 2.1-2.3 kg-m (15-16.5 ft-lb).

A020

3. Slide the brake band over the clutch and position

the brake cable in the bracket; then secure the

brake band with a washer and snap ring.

A003

KEY

1. Cap Screw
2. Carriage Bolt
3. Bearing
4. Track Drive Assy
5. Drive Sprockets
6. Driveshaft
7. Key
8. Chain Sprocket
9. Lock Nut

10. Washer
11. Chain
12. Spacer
13. Bearing
14. Lock Washer

8-4

4. Tighten the rear brake cable adjustment jam nut

securely; then adjust brake lever travel as

necessary. See Brake System (120 cc) in this

section.

A005

5. Compress and hold the brake lever; then install the

cap screw (coated with blue Loctite #243) and

washer securing the rear chain sprocket. Tighten

the cap screw securely; then release the lever.

6. Place the exhaust gasket into position on the

engine exhaust studs.

7. Place the muffler into position in the engine

compartment; then press down on the muffler and

swing the intake pipe onto the engine exhaust

studs. Secure with two nuts and the hold-down

spring.

8. Place the front and rear chain guards into position

making sure the hood cable is properly positioned.

Tighten securely.

Drive Belt

The belt dimensions and construction are two factors

that influence the performance of the drive system.

The two belt dimensions that are important to the per-

formance of the snowmobile are the outside circumfer-

ence and the width. Both of these dimensions will

influence shifting characteristics.

If the drive belt is longer than specified, the drive

clutch and driven pulley will not have the full shift

ratio. Also, a too-long drive belt will cause poor accel-

eration and a decrease in top speed.

If the drive belt is shorter than specified, the drive

clutch and driven pulley will have a different shift pat-

tern because they are in different ratios from those for

which they were originally matched. A too-short drive

belt will cause a loss in performance and a bog on

engagement.

„ NOTE: A drive belt that is worn thin may produce
the same effect as one that is too long.

Drive belt construction has an influence on the way the

drive clutch and driven pulley will shift and on the

amount of power that will be transmitted through the

system. ONLY ARCTIC CAT DRIVE BELTS

SHOULD BE USED. Different brands of belts may

not have the same construction causing either more

friction or more slippage when the belt is wedged

between the sheaves and, thus, a loss of efficiency.

„ NOTE: A stiff belt causes a HP loss to the track.
As a belt warms up, it gets more flexible and trans-
mits power with less HP loss.

Drive Clutch

CHANGING CAM ARMS

The cam arms on the drive clutch can be changed

without disassembling the clutch. To change the cam

arms, use the following procedure.

1. Check to make sure the ignition switch is in the

OFF position.

2. Remove the drive belt.

3. Compress the movable sheave approximately 2.5

cm (1 in.) and while holding it in this position,

insert a flat bar firmly between the bottom side of

the spider and the inner surface of the movable

sheave. Slowly release the movable sheave.

4. Remove the lock nuts from the three cam arm

pins.

5. Remove the cam arm pins one at a time; then

remove the cam arm with bushing and account for

the washers.

„ NOTE: When installing cam arms, always use
new lock nuts. Make sure the head of each cam
arm pin is positioned towards the direction of
drive clutch rotation. Tighten nuts until they con-
tact the shoulder of the cam arm pin; then tighten
an additional 1/8 turn.

733-452B

KEY

1. Lock Nut
2. Cam Arm
3. Bushing
4. Washer
5. Pin

8-5

8

6. Change the cam arms and secure with new lock

nuts and existing pins making sure the head of

each pin is positioned toward the direction of drive

clutch rotation.

„ NOTE: The drive clutch rotates counterclock-
wise.

REMOVING

1. Open the belt guard; then remove the drive belt

and the plug from the belly pan.

2. Remove the bolt and lock washer securing the

drive clutch to the crankshaft.

AN380D

„ NOTE: Before installing the clutch puller, apply
oil to the threads of the puller and a small amount
of grease to the tip of the puller.

3. Using the Clutch Puller (p/n 0644-207) and an

impact wrench or a breaker bar and the Drive

Clutch Spanner Wrench (p/n 0644-136), tighten

the puller. If the drive clutch will not release,

sharply strike the head of the puller. Repeat this

step until the clutch releases.

AN381D

4. Remove the drive clutch from the engine

compartment. Account for any spacers.

DISASSEMBLING

„ NOTE: Note the timing marks on the cover, spi-
der, and movable sheave. These must be aligned
when assembling the drive clutch for balance pur-
poses.

1. Loosen the nine machine screws securing the

cover. Remove every other cap screw and lock

washer from the cover; then while firmly holding

the cover, remove the four remaining screws and

lock washers equally.

AM059D

2. Remove the cover and spring.

AM061D

3. Position the drive clutch over the Clutch Holder

(p/n 0644-058).

„ NOTE: The holder should either be secured in a
vise or bolted to a sturdy work bench.

AM063D

! WARNING

Do not run the engine with the drive belt removed
or the bar in the clutch.