Snowmobile Arctic Cat (2002 year). Manual - part 156

9-102

AG634D

4. Mark the hole that the upper shock links are

mounted in for assembly purposes; then remove

the cap screw and lock nut securing the shock

links to the upper arm bracket. Account for all

mounting hardware.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Clean shock pivot and idler wheel axle in part-

cleaning solvent. Dry with compressed air.

2. Clean the idler wheel bearings with a clean cloth.

3. Closely inspect the idler wheel axle for wear,

bends, or damaged threads at either end.

4. Inspect the idler wheels for signs of cracking,

wear, or outer rubber separation from plastic

wheel.

5. Rotate the idler wheel bearings (by hand) and

inspect for any signs of binding or roughness.

6. If a bearing must be replaced, use this procedure.

A. Remove the wheel insert and the snap ring.

B. Using a hydraulic press, press the bearing out

the inside of the wheel.

C. Press the new bearing (on its outer race) into

the idler wheel.

AG538D

D. Install the snap ring making sure the “sharp

side” is directed away from the bearing.

AG539D

E. Install the insert.

7. Inspect the shock absorber for any signs of oil

leakage especially at the point where the shock

shaft enters the shock body.

8. Inspect the rubber shock bushings located in the

shock absorber eyelets for cracks or deterioration.

9. Inspect the shock absorber eyelet welds (at each

end) for any cracks or signs of separation.

10. Inspect the welds securing the eyelets of the shock

links for cracks or signs of separation. Either weld

the eyelet or replace the shock link.

11. Inspect the axle surfaces for any signs of corro-

sion. If corrosion is found, lightly buff the surface

of the axle with #400 wet-or-dry sandpaper; then

apply a light coat of grease.

! WARNING

Always wear an approved pair of safety glasses
when using compressed air.

! CAUTION

Do not remove the bearing unless it is absolutely
necessary. The bearing will be damaged during
removal.

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9

ASSEMBLING

1. Secure the shock eyelet to the idler arm with

bushings, sleeve, lock nut, and a cap screw.

Tighten to 3.2 kg-m (23 ft-lb).

AG634D

2. Secure the rear shock links and the lower shock

absorber eyelet to the shock pivot bracket by plac-

ing the bushings and shock sleeve into the shock

eyelet; then install the axle links into the rear

shock links. Secure the assembly by installing a

cap screw and thin flat washer through the shock

link assembly, thick flat washer, shock pivot

bracket and shock eyelet assembly, thick flat

washer, shock link assembly, and a thin flat

washer. Secure the assembly with a lock nut.

Tighten to 3.2 kg-m (23 ft-lb).

AG692D

3. Position the shock links in the appropriate holes of

the idler arm brackets (see Chassis and Skid Frame

Mounting Locations in this section). Place a

spacer between the center of the brackets; then

place a flat washer on the cap screw. Insert the

axle links into the upper shock link eyelets; then

insert the cap screw with washer through the eye-

lets. Secure with a cap screw, washer, and lock

nut. Tighten to 3.2 kg-m (23 ft-lb).

Slide Rails

„

NOTE: The skid frame must be removed for this pro-

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

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, axles, and brackets
in their correct assembly order. Always mark the
mounting hole locations during disassembly to
speed up the assembly process and to prevent any
damage. This method is much quicker than to
completely disassemble the entire skid frame. To
replace either rail, use the following procedure.

1. Remove the end cap from the slide rail. Account

for a cap screw, lock nut, and two flat washers.

AG506D

2. Remove the machine screw and lock nut securing

the wear strip to the front of the slide rail.

AG509D

3. 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 the pipe
wrench.

9-104

AG510D

4. Remove the cap screws securing the crossbraces to

the slide rail.

AG511D

5. Remove the cap screws and lock nuts securing the

front outer idler wheel and the idler wheel mount-

ing block. Account for flat washers and an axle.

AG678D

AG686D

6. Remove the cap screw and lock washer securing

the front inner idler wheel.

AG687D

7. Remove the short spring leg from the adjusting

cam.

AG624DA

8. Remove the cap screw and flat washer securing

the spring slide to the rail. Account for a spacer

and the slide block.

AG679D

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9

AG680D

9. Mark the mounting position of the front arm

mounting bracket.

AG637D

10. Remove the cap screws securing the front arm

mounting bracket. Account for lock nuts.

AG638D

11. Mark the mounting position of the rear inner idler

wheels.

AG693D

12. Remove the cap screws and lock nut securing the

rear inner idler wheels and mounting block.

AG672D

AG673D

13. Mark the mounting position of the rear arm limiter

and rear arm.

AG683D