Snowmobile Arctic Cat (2002 year). Manual - part 158

9-110

AG694D

„

NOTE: Apply a light coat of grease to the slide

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

AG534D

13. 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. Secure with a

machine screw and lock nut. Tighten to 1.1 kg-m

(8 ft-lb).

AG509D

14. Secure the end cap onto the slide rail using a cap

screw, flat washers, and a lock nut. Tighten to

1.1 kg-m (8 ft-lb).

AG506D

15. Install the short spring leg onto the adjusting cam.

AG516DA

16. Adjust suspension.

17. After the skid frame has been installed, adjust

track tension deflection (see Track Tension in this

sub-section) and track alignment (see Track Align-

ment in this sub-section).

9-111

9

Installing Skid Frame

1. Place a piece of cardboard on the floor to protect

against scratching and tip the snowmobile onto

one side.

2. Pull the track away from the tunnel and spread

open; then place the skid frame into the track.

3. Position the front of the skid frame into the tunnel

and align the front arm with the appropriate

mounting hole in the tunnel. Insert the cap screw

with washers through the tunnel mounting hole

and through the front arm. DO NOT TIGHTEN

AT THIS TIME. Repeat this procedure on the

other side.

„

NOTE: To aid in centering the front arm with the

hole in the tunnel, position the skid frame and
track at a 45° angle to the bottom of the tunnel.

4. Elevate the rear of the skid frame and the track

into position in the tunnel.

5. Align the offset pivot idler arm assembly with the

appropriate hole in the tunnel. Secure the offset

pivot idler arm assembly with a cap screw (coated

with red Loctite #271), lock washer, and flat

washer. DO NOT TIGHTEN AT THIS TIME.

„

NOTE: Do not install the short legs of the rear

springs onto the adjusting cams at this time.

6. At this time, tighten all four skid frame mounting

cap screws to 3.2 kg-m (23 ft-lb).

7. Using the Rear Suspension Spring Tool (p/n 0144-

311), install the short legs of the rear springs onto

the adjusting cams making sure the cams are in the

same adjustment positions.

8. Tighten the two track tension adjusting bolt evenly

until track deflection is within specifications; then

lock the jam nuts to secure the adjustment.

9. Check track tension deflection and alignment;

adjust if necessary (see Track Tension and Track

Alignment in this sub-section).

Track Tension

CHECKING DEFLECTION

1. Tip the snowmobile on its side.

2. Hook a spring scale around a track clip at mid-

span; then pull the track down with the scale to 9

kg (20 lb) and measure the distance between the

bottom of the wear strip and the inside surface of

the track. Track deflection must be within specifi-

cations.

729-429A

„

NOTE: If the track is new, it will stretch slightly

and take a “set” within the first 300 to 500 miles of
operation.

ADJUSTING DEFLECTION

1. Place the snowmobile up on a shielded safety

stand. Check to make sure the track is 2-3 in. off

the floor.

2. If the measurement is not as specified, loosen the

jam nuts of the adjusting bolts.

! WARNING

Deactivate all switches.

Rear Suspension 

Style

Setup

Tension

After Break-In 

Tension

FasTrack w/o Torque 

Sensing Link

19-25 mm

(3/4-1 in.)

25-32 mm

(1-1 1/4 in.)

FasTrack w/Torque 

Sensing Link

(121 in. Track)

32-38 mm

1 1/4-1 1/2 in.)

38-44 mm

(1 1/2-1 3/4 in.)

FasTrack w/Torque 

Sensing Link

(136 in. Track)

38-44 mm

(1 1/2-1 3/4 in.)

50.8-57.2 mm

(2-2 1/4 in.)

9-112

0727-456

3. If the measurement obtained in step 2 is more than

specified, tighten the adjusting bolts. If the mea-

surement obtained is less than specified, loosen

the adjusting bolts. When the measurement is

within specification range, lock the adjustment by

bottoming the jam nuts against the axle housings.

„

NOTE: Vigorously push the underside of the

track up and down. Track must not hit the top of
the tunnel or slap the skid frame.

4. After correct track tension is obtained, check track

alignment (see Track Alignment in this sub-sec-

tion).

„

NOTE: Track tension and track alignment are

interrelated; always check both even if only one
adjustment seems necessary. Always establish
correct track tension before checking and/or
adjusting alignment.

Track Alignment

„

NOTE: Proper track alignment is when the rear

idler wheels are equidistant from the inner drive
lugs on the inside surface of the track.

CHECKING

1. Using a shielded safety stand, raise the rear of the

snowmobile off the floor making sure the track is

free to rotate.

2. Start the engine and accelerate slightly. Use only

enough throttle to rotate the track several revolu-

tions. SHUT THE ENGINE OFF.

„

NOTE: Allow the track to coast to a stop. Do not

apply the brake because it could produce inaccu-
rate alignment conditions.

3. When the track stops rotating, check the relation-

ship of the rear idler wheels and the inner track

drive lugs. If the distance from the idler wheels to

the inner drive lugs is the same on both sides, no

adjustment is necessary.

725-070A

4. On the side of the track, which has the inner drive

lugs closer to the rear idler wheel, loosen the

adjusting bolt jam nut; then rotate the adjusting

bolt clockwise 1-1 1/2 turns.

5. Continue to check the track alignment and make

the necessary adjustments until proper alignment

is obtained.

6. After proper track alignment is obtained, lock the

jam nut against the axle housing.

„

NOTE: Make sure correct track tension is main-

tained after adjusting track alignment.

„

NOTE: Field test the track under actual condi-

tions and after the field test, check track alignment
and track tension; adjust as necessary.

! WARNING

The tips of the skis must be positioned against a
wall or similar object for safety. Keep hands, feet,
and clothing away from moving components.

9-113

9

Repair Procedure 4 - 

Track/Rear Suspension

This Track/Rear Suspension sub-section (Repair Pro-

cedure 4) has been organized so each procedure can be

completed individually and efficiently. Each sub-sec-

tion has (as necessary) Removing, Disassembling,

Cleaning and Inspecting, Assembling, and Installing

procedures. Some components may vary from model

to model. The technician should use discretion and

sound judgment when removing and installing compo-

nents.

„

NOTE: Some illustrations and photographs used

in this sub-section are used for clarity purposes
only and are not designed to depict actual condi-
tions.

Removing

Skid Frame

„

NOTE: Many service procedures can be per-

formed without removing the skid frame. Closely
observe the note introducing each subsequent
sub-section for this important information.

1. Loosen the jam nuts and the two track tension

adjusting bolts.

0727-456

2. Place a support stand under the rear bumper; then

remove the four cap screws securing the skid

frame to the tunnel.

„

NOTE: The support stand should hold the snow-

mobile level and not raised off the floor.

3. Remove the support stand; then tip the snowmo-

bile onto one side using a piece of cardboard to

protect against scratching. Remove the skid frame.

End Cap

„

NOTE: The skid frame does not have to be

removed for this procedure.

REMOVING

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

securing the end cap.

AG297D

2. Using a hammer, tap the end cap off the rail.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the end cap area of the slide rail for cracks

and wear.

2. Inspect the end cap for any signs of cracking or

wear.

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).

! WARNING

Always wear safety glasses when using com-
pressed air.