Snowmobile Arctic Cat (2002 year). Manual - part 114

8-14

ASSEMBLING

0733-501

1. Place the roller and thrust washer (toward the

outside of the roller plate) and secure with the

roller pin.

2. Secure the roller, thrust washer, and pin into

position with the spring pin. Drive the pin in until

it is flush with the plate.

SC012D

3. Place the torque bracket (cam) into position on the

stationary sheave making sure the degree number

on the bracket aligns with the part number on the

stationary sheave. Install the three socket head

screws and lock washers. DO NOT tighten at this

time.

AI062

4. Place any thrust washers (as noted during

disassembly) on the stationary sheave shaft.

B460

5. Align the scribed line made during disassembly;

then slide the movable sheave onto the stationary

sheave shaft.

KEY

1. Movable Sheave
2. Stationary Sheave
3. Torque Bracket (Cam)
4. Lock Washer
5. Socket Head Screw
6. Spring
7. Roller Plate
8. Bearing
9. Lock Nut

10. Spring Pin
11. Thrust Washer
12. Roller Thrust Washer
13. Roller
14. Roller Pin
15. Cover
16. Cover
17. Self-Tapping Screw

8-15

8

B459D

6. Place the sheaves on a work fixture (roll of duct

tape, etc.).

7. Place the spring over the stationary sheave hub

and hook the turned down end of the spring into

the hole in the casting of the stationary sheave.

B458D

8. Place the roller plate over the spring and hook the

turned-up end of the spring in the 3rd hole

(standard spring tension) of the plate.

9. While holding the sheaves to prevent them from

rotating, grasp the plate and rotate it

approximately 120° clockwise until the mounting

holes align; then push the plate into position and

install the three lock nuts. Tighten the lock nuts to

1.5-1.8 kg-m (11-13 ft-lb).

„ NOTE: The line scribed during disassembly
should be aligned.

SC003D

10. Rotate the movable sheave to ensure free

movement without binding.

11. Rotate the torque bracket (cam) until it is tight;

then using a long hex wrench, tighten the three

socket-head cap screws securing the bracket.

SC011D

INSTALLING

1. Slide the alignment washers onto the end of the

driven shaft.

2. Install the key in the driven shaft keyway; then

place the stub shaft into the driven pulley. Place

the driven pulley on the shaft. Align its keyway

with the driven shaft keyway.

„ NOTE: A small amount of Loctite Anti-Seize
Thread Compound (p/n 0678-146) applied to the
dri v en s ha ft wil l ai d in  fu ture driv e n pul le y
removal.

3. Secure the driven pulley by installing any

alignment washers, the washer, and cap screw.

Tighten the cap screw to 2.6-3.3 kg-m (19-

24 ft-lb).

SC013D

4. Check drive clutch/driven pulley alignment (see

Drive Clutch/Driven Pulley in this section); adjust

as necessary.

5. Install the drive belt and check drive belt

deflection (see Drive Clutch/Driven Pulley in this

section). Secure the belt guard.

8-16

Drive Clutch/

Driven Pulley

CHECKING OFFSET

If premature drive belt wear is experienced or if the

drive belt turns over, parallelism/offset must be

checked. Also, parallelism/offset must be checked

whenever either the drive clutch or driven pulley is

serviced. To check the parallelism/offset, use the

Clutch Alignment Bar (p/n 0644-003) and the follow-

ing procedure.

1. Open the belt guard and remove the drive belt.

2. Install the clutch alignment bar between the drive

clutch sheaves and against the outside edge of the

driven pulley stationary sheave.

3. Allow the alignment bar to rest on the drive clutch

shaft.

0733-912

„ NOTE: The alignment bar must extend beyond
the front edge of the drive clutch.

4. With the bar against the outside edge of the driven

pulley stationary sheave at points A and B, the bar

should just clear the inside edge of the stationary

sheave of the drive clutch and rest on the

stationary shaft. If the bar does not clear the inside

edge or is more than 1.5 mm (0.060 in.) from the

inside edge, the offset must be corrected.

„ NOTE: On the model with a wide ratio driven pul-
ley with the bar against the outside edge of the
driven pulley stationary sheave at points A and B,
the bar should have between 2.5-4 mm (0.100-
0.160 in.) clearance to the inside edge of the sta-
tionary sheave of the drive clutch while resting on
the stationary shaft. If the clearance is not within
specifications, the offset must be corrected.

AF465D

733-912B

CORRECTING OFFSET

1. To correct offset, the driven pulley must be moved

laterally on the driven shaft. Remove the cap

screw and washers securing the driven pulley; then

remove the driven pulley.

„ NOTE: If the driven pulley is tight on the driven
shaft, pull the driven pulley off using the Driven
Pulley Puller (p/n 0744-023).

2. To move the driven pulley inward on the shaft,

remove washer(s) as required from behind the

pulley.

3. To move the driven pulley outward on the shaft,

add alignment washer(s) as required behind the

driven pulley.

„ NOTE: Make sure the keyways match when
installing the driven pulley. Arrange washers to
allow the least amount of “float” on the driven
shaft. A maximum of 1.5 mm (0.060 in.) of float is
acceptable.

4. Install the driven pulley and secure with a cap

screw and washers. Tighten the cap screw to 2.6-

3.3 kg-m (19-24 ft-lb).

8-17

8

CHECKING PARALLELISM

1. Check parallelism of the drive clutch/driven pulley

using the alignment bar and reference points X and

Y with the alignment bar against the driven pulley

at points A and B. Using a calipers or a machinist's

scale, measure X and Y from the back side of the

alignment bar. Measurements X and Y must be

equal or measurement Y must be more than

measurement X, but Y must not exceed

measurement X by more than 1.6 mm (0.062 in.).

733-912A

AF041

„ NOTE: The offset must be correct before check-
ing parallelism.

2. If parallelism is not within specifications, the

parallelism must be corrected.

CORRECTING PARALLELISM (Torque 

Bumper w/Bearing Support Bracket)

1. To correct parallelism, minor adjustments can be

made by adjusting the torque bumper on the left-

rear engine mount.

A. Loosen the cap screws and nuts securing the

engine mounting brackets to the front end.

B. Using the jam nuts on the torque bumper, adjust

parallelism and periodically check the parallel-

ism. When the parallelism is correct, tighten the

cap screws and nuts securing the engine mount-

ing brackets to the front end; then tighten the

torque bumper jam nuts allowing 1.5 mm

(0.060 in.) clearance between the torque

bumper and the engine.

AN610D

2. Recheck both offset and parallelism to ensure

accuracy and make further adjustments as

necessary.

„ NOTE: After parallelism and offset have been
corrected, check for proper drive belt deflection.
This is critical for optimum performance.

CORRECTING PARALLELISM (Torque 

Bumper w/Shims)

1. To correct parallelism, minor adjustments can be

made by removing shims from or installing shims

on the left-rear engine mount.

A. Loosen the cap screws securing the engine

mounting brackets to the front end.

B. Add or remove shims as needed to attain cor-

rect parallelism.

C. When parallelism is correct, secure the engine

mounting brackets to the front end.

2. Recheck both offset and parallelism to ensure

accuracy and make further adjustments as

necessary.

„ NOTE: After parallelism and offset have been
corrected, check for proper drive belt deflection.
This is critical for optimum performance.

CORRECTING PARALLELISM (Engine 

Snubber w/Engine Plate)

1. To correct parallelism, minor adjustments can be

made by adjusting the engine snubber on the left-

rear engine mount.

A. Loosen the cap screws securing the engine

plate to the engine mounts.

B. Either lengthen or shorten the snubber and peri-

odically check the parallelism measurement.

When the parallelism measurement is correct,

loosen the snubber to allow 1.5 mm (0.060 in.)

clearance between the snubber and the engine;

then lock the jam nuts on the snubber and

tighten the cap screws securing the engine

plate.