Snowmobile Arctic Cat (2002 year). Manual - part 140

9-38

3. Clean both the slide rail area and the end cap.

Using compressed air, clean the areas of dirt and

gravel.

4. Inspect the cap screw for cracked, stretched, or

damaged threads. Use a new lock nut when assem-

bling.

INSTALLING

1. Position the end cap on the slide rail; then align the

hole in the end cap with the hole in the slide rail.

2. Secure with a cap screw and new lock nut. Tighten

to 1.1 kg-m (8 ft-lb).

Wear Strip

„

NOTE: The skid frame should be removed for

this procedure.

REMOVING

„

NOTE: Prior to removing the wear strips, inspect

each wear strip for wear. The wear strip must be
10.7 mm (0.42 in.) thick or thicker. If the wear strip
measurement is less than specified, replacement
of both wear strips is necessary.

0735-677

„

NOTE: It is possible to remove and install a wear

strip without removing the skid frame. To do this,
remove the machine screw and lock nut securing
the wear strip at the front of the slide rail; then
align the wear strip with openings (windows) in the
track and drive it rearward off the slide rail. Apply
low-temperature grease to the new wear strip and
slide rail; then align the wear strip with openings
(windows) in the track and drive it forward onto the
slide rail. Secure with the machine screw and lock
nut.

1. Remove the machine screw and lock nut securing

the wear strip to the front of the slide rail.

AG298D

2. Using a pipe wrench and starting from either end,

hook the edge of the wear strip with the pipe

wrench jaw and twist the wear strip off the slide

rail. Move the pipe wrench 7.5 cm (3 in.) and

again twist the wear strip off the rail. Repeat this

procedure until the wear strip is free of the rail.

„

NOTE: The wear strip can also be driven off the

slide rail; however, it is quicker to use a pipe
wrench.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Clean the slide rail using parts-cleaning solvent

and compressed air.

2. Inspect the slide rail for cracks. If any cracks are

found, replace the slide rail.

3. Using a straightedge, inspect the slide rail for any

unusual bends. Place the straightedge along the

bottom surface of the slide rail. If the rail is found

to be bent, it must be replaced.

4. Place the straightedge along the side of the slide

rail. If rail is found to be bent, it must be replaced.

! WARNING

Always wear safety glasses when using com-
pressed air.

! WARNING

Always wear safety glasses while using com-
pressed air.

9-39

9

INSTALLING

„

NOTE: Apply a light coat of grease to the slide

rail surface to aid in installing new wear strips. If
there are any sharp edges on the lower portion of
the rail, use a file to remove them.

AG534D

1. Starting from the back, start the wear strip onto the

rail; then using a block of wood and a hammer,

drive the wear strip forward into position.

AG535D

2. Secure with a machine screw and lock nut.

Tighten securely.

Rear Suspension Arm/

Rear Springs

„

NOTE: The skid frame must be removed for this

procedure.

DISASSEMBLING

1. Remove the cap screws securing the rear arm to

the skid frame; then remove the rear arm. Account

for and note the location of all hardware.

AO159

2. Remove the rear springs and sleeves from the rear

arm.

INSPECTING

„

NOTE: Whenever part is worn excessively,

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

1. Inspect all rear arm weldments for cracks or

unusual bends.

2. Inspect all tubing for cracks or unusual bends.

3. Inspect the axles for wear or damage.

4. Inspect the upper and lower bushings for wear or

damage.

5. Inspect the two adjusting cams (adjuster blocks)

for damage.

6. Inspect the springs for excessive wear, cracks, or

imperfections.

ASSEMBLING

1. Apply a light coat of grease to the axles and the

bushing areas.

2. Place the rear arm into position on the skid frame;

then secure the arm to the skid frame with existing

hardware. Tighten securely.

9-40

Rear Idler Wheels

and Axle

„

NOTE: The skid frame must be removed for this

procedure (see Removing Skid Frame in this sub-
section).

DISASSEMBLING

1. Remove the cap screws and large flat washers

securing the outer idler wheels. Remove the idler

wheels from the shaft.

„

NOTE: The large wheel insert is positioned next

to the inner plastic adjuster bushing. The idler
wheel must be installed with the large wheel insert
properly positioned.

AG328

2. Remove the two cap screws and lock nuts securing

each of the rear axle brackets to the rails. Remove

the brackets and account for spacers.

AG330

3. Carefully slide the axle out of the rear spacer and

note the position of the spacer bushings.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Clean the bearings with a clean cloth.

2. Inspect all idler wheel bearings. Rotate each bear-

ing (by hand) and if any roughness or binding is

noted, replace the idler wheel assembly.

3. Inspect all idler wheel inserts (inner and outer) for

any cracks.

4. Inspect the outer rubber portion of the idler wheels

for cracks and poor bonding.

5. Inspect the plastic hub of each idler wheel for

cracking.

6. Inspect the axle for wear and damaged threads.

Damaged threads may be repaired with a 3/8 x 16

tap.

ASSEMBLING

1. Assemble the rear axle brackets on the slide rails.

Secure each bracket with two cap screws and lock

nuts. Tighten securely.

2. In order, slide the axle through an axle bracket;

then place a spacer bushing, spacer, and spacer

bushing on the axle. Slide the axle through the

opposite axle bracket.

3. Place the plastic adjuster bushings on the axle (on

the outside of each axle bracket). Make sure the

adjuster bushing is positioned towards the adjust-

ing bolt.

4. Place the rear idler wheels on the axle (with the

large insert directed inward) and secure with two

cap screws (coated with blue Loctite #243) and

washers. Tighten securely.

9-41

9

Upper Idler Wheels

„

NOTE: The skid frame does not have to be

removed for this procedure.

REMOVING

1. Remove the two cap screws securing the upper

idler wheel assembly to the tunnel; then remove

the assembly.

A013

2. Account for and note the location of all mounting

hardware.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect each idler wheel for cracks or damage.

2. Rotate the idler wheel bearing (by hand) and

inspect for binding or roughness.

3. Inspect the axle and spacers for cracks or bends.

INSTALLING

1. Lightly grease the axle; then slide the inner spacer

onto the axle.

2. Slide the axle through the rear arm limiter strap;

then slide an idler wheel followed by an outer

spacer onto each end of the axle.

3. Place the idler wheel/axle assembly into position

in the tunnel and secure with cap screws (coated

with blue Loctite #243). Tighten securely.

Slide Rail

„

NOTE: The skid frame must be removed for this

procedure.

REMOVING

„

NOTE: When it is necessary to replace one or

both slide rails, it is recommended that one slide
rail be removed at a time. The remaining slide rail
will then hold the crossbraces and brackets in
their correct assembly order. This method is much
quicker than to completely disassemble the entire
skid frame.

1. Remove the cap screw, washer, and lock nut

securing the end cap to the slide rail. Remove the

end cap from the slide rail.

AG297D

2. Remove the cap screw, lock washer, and flat

washer securing the cross-brace axle to the slide

rail.

AO160

3. Remove the cap screws securing the rear suspen-

sion arm to the bracket.

4. Remove the three cap screws and lock nuts secur-

ing the rear suspension arm bracket and backing

plate to the slide rail.