Snowmobile Arctic Cat (2004 year). Manual - part 86

7-8

2. Inspect the steering post and steering-post

retaining plate for cracks, bends, or wear.

3. Inspect the adjuster caps and mounting block for

cracks or wear. 

INSTALLING

0738-645

1. Carefully slide the steering post into position in

the chassis. Be careful not to hook any wires or
hoses. 

2. Place the steering post mounting block and

retaining plate into position taking care not to
pinch any wiring.

FC203

„

NOTE: The brakeline hose should be positioned

behind the retaining plate. 

FC204

3. Tighten the nuts to 1.4 kg-m (10 ft-lb).

4. Place the steering tie rod into position on the

steering post. Secure with the cap screw (threads
coated with green Loctite #609) and lock nut.
Tighten the lock nut to 4.3 kg-m (31 ft-lb).

FC205

5. Secure the console to the gas tank with the five

torx-head screws. Do not over-tighten the screws.

FC227

6. Place the handlebar/riser assembly onto the

steering post; then secure to the steering post with
the lower adjuster cap and four Allen-head cap
screws. Tighten cap screws to 3.5 kg-m (25 ft-lb). 

KEY

1. Steering Post
2. Riser
3. Adjuster Cap 

(Upper)

4. Adjuster Cap 

(Lower)

5. Cap Screw
6. Retaining Plate

7. Mounting Block
8. Machine Screw
9. Lock Nut

10. Lock Nut
11. Cap Screw
12. Lock Nut
13. Ball Joint 

(Right)

14. Hex Nut
15. Tie Rod Tube
16. Hex Nut
17. Ball Joint (Left)
18. Washer 
19. Steering Post 

Stop

20. Machine Screw

7-9

7

FC200

7. Secure the wiring and brakeline hose to the

steering post with cable ties; then install the
handlebar pad. 

8. Using a piece of cardboard to protect the hood and

belly pan, tip the snowmobile on its PTO-side.

9. From beneath the front end, secure the steering

post to the steering post stop with the washer and
lock nut (threads coated with green Loctite #609).
Tighten the lock nut to 4.3 kg-m (31 ft-lb).

FC199

Ski

REMOVING

1. Place the front of the snowmobile on a support

stand.

2. Remove the cotter pin; then remove the slotted nut

and cap screw securing the ski assembly to the
spindle. Remove the ski. Account for the rubber
damper and washers.

AL095D

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the ski for cracks or deterioration.

2. Inspect the ski for abnormal bends or cracks.

3. Inspect the wear bar for wear.

4. Inspect all hardware and the spindle bushings for

wear and damage.

5. Inspect the rubber damper for damage or wear.

INSTALLING

0737-380

KEY

1. Spindle
2. Grease Fitting
3. Bearing
4. Spindle Insert
5. Bearing
6. Spindle Axle
7. Spacer
8. Damper
9. Ski

10. Ski Saddle
11. Ski Saddle 

Insert

12. Cap Screw
13. Washer
14. Lock Nut
15. Cotter Pin
16. Wear Bar
17. Washer
18. Lock Nut

19. Plastic Handle
20. Lock Nut
21. Washer
22. Cap Screw
23. Cap Screw
24. Lock Nut
25. Machine Screw
26. Decal
27. Spindle Cap

7-10

0737-454

1. Position the ski over the saddle.

2. Apply a low-temperature grease to the non-

threaded portion of the cap screw; then slide the
cap screw (with washer as required) through the
ski and saddle accounting for the rubber damper.

„

NOTE: Install the cap screw so the lock nut will

be located to the inside of the ski.

3. Apply red Loctite #271 to the threads of the cap

screw; then tighten the lock nut (with washer as
required) to 6.2 kg-m (45 ft-lb).

4. Place the cotter pin into the ski cap screw and

spread the pin.

Ski Wear Bar

The ski wear bar is a replaceable bar attached to the
underside of the ski. The purpose of the wear bar is to
assist in turning the snowmobile, to minimize ski
wear, and to maintain good steering control. If the
snowmobile is operated primarily in deep snow, ski
wear bar wear will be minimal; however, if the snow-
mobile is operated on terrain where the snow cover is
minimal, the ski wear bar will wear faster. Arctic Cat
recommends that the ski wear bars be checked once a
week and replaced if worn to 1/2 of original diameter.

REMOVING

1. Remove ice and snow buildup from the ski.

2. With the gas tank nearly empty (less than 1/4 full),

lay the snowmobile on its side.

3. Remove the lock nuts and washers securing the

wear bar to the ski. Account for any spacers.

0739-016

731-037D

4. Pry the rear of the wear bar down until the wear

bar studs are clear of the ski; then slide the wear
bar rearward until the front of the wear bar is free
from the ski.

5. Remove the wear bar.

INSTALLING

1. Place spacers (if applicable) on the wear bar studs;

then insert the front of the wear bar into the hole at
the front of the ski and swing the wear bar upward.

2. Insert the wear bar studs into the holes in the ski.

3. Center the wear bar studs in the holes and install

the washers and lock nuts.

4. Tighten lock nuts securely.

KEY

1. Spindle
2. Grease Fitting
3. Spindle Insert
4. Bearing
5. Damper
6. Ski Saddle
7. Ski 

8. Ski Insert
9. Wear Bar

10. Washer
11. Cotter Pin
12. Cap Screw
13. Lock Nut
14. Washer

15. Lock Nut
16. Washer
17. Spindle Cap
18. Decal
19. Axle

! CAUTION

A piece of cardboard should be used to protect
the finish on the belly pan.

! WARNING

DO NOT bend the ski wear bar excessively when
installing. Excessive bending of the ski wear bar
may cause premature wear, breakage, and possible
injury.

7-11

7

Drag Link

REMOVING

1. Remove the expansion chamber if necessary.

2. Remove the lock nuts securing the tie rods to the

spindles on both sides of the snowmobile. Account
for  O-rings and washers.

„

NOTE: Note whether the tie rod is installed on

the top side or on the bottom side of the spindle
arm for installing purposes.

AL108

AL655D

3. On the side from which the drag link will be

removed, remove the self-tapping screws securing
the steering boot to the front end (bulk head).

4. Remove the cap screws and lock nuts securing the

steering tie rod to the steering arm. Account for
washers.

AL092

5. Move the drag link from side to side to gain access

to the lock nuts and cap screws securing the
steering arms to the drag link; then remove the cap
screws and lock nuts. Account for washers and
drag link bearing axles.

6. From the opposite side from which the boot was

removed, carefully pull the steering boot over the
tie rod end; then remove the drag link.

„

NOTE: Applying soapy water to the steering

boot will aid in pulling the boot over the tie rod
end.

7. Place the drag link in a vise and remove the tie rod

ends from the drag link.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the entire drag link (especially in the areas

where the ball joints attach) for any signs of
cracks, wear, or damage.

2. Inspect the bearings, inserts, and axles for wear or

damage.