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Snowmobile Arctic Cat (2004 year). Manual - part 88

7-16

AL655D

5. Remove the two cap screws and lock nuts securing

the spindle to the suspension arms. Account for all
mounting hardware.

AL159D

AL160D

6. Inspect the tie-rod ball joint in place. If damage,

wear, or unusual bends are noted, loosen the jam
nut; then remove the ball joint from the tie rod.

INSPECTING

NOTE: Whenever a part is worn excessively,

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

1. Inspect the spindle for excessive wear, cracks,

bends, or imperfections.

2. Inspect all welds for cracking.

3. Inspect the suspension arm bushings and axle area

for wear.

4. Secure the spindle in a vise. Rotate the spindle

clockwise and counterclockwise. The movement
s h o u l d b e s m o o t h a n d f r e e . I f t h e s p i n d l e
movement is rough or binding, grease the spindle
with a good low-temperature grease. Rotate the
spindle. If the movement remains rough, replace
the spindle.

NOTE: When greasing the spindle, use enough

grease so that it can be seen coming out at both
the top and bottom of the spindle.

5. Inspect the spindle axle and bearings for wear,

damage, or loose fit. Replace the bearings as a set.

NOTE: Replacing the ski bolt bushings is diffi-

cult. The existing bushings will be damaged dur-
ing removal. Be careful, however, not to damage
the spindle when removing the bearing. Press the
new bushings into the spindle.

INSTALLING

1. Place the upper and lower suspension arm ends

with bushings in position into the spindle. Secure
with cap screws and lock nuts. Tighten to
4.2 kg-m (30 ft-lb).

2. Place the steering tie-rod ball joint into position

(threads coated with green Loctite #609) on the
spindle arm as noted during removing (with
washer and O-ring) and secure with a lock nut.
Tighten to 4.2 kg-m (30 ft-lb).

AL655D

3. Install the ski.

4. Align the lower shock eyelet with the mounting

hole in the spindle; then secure with the cap screw,
optional washers, and lock nut. Tighten to
2.8 kg-m (20 ft-lb).

5. Remove the safety stand from beneath the front

end.

7-17

Spindle

(AWS VI)

REMOVING

1. Position the front of the snowmobile up on a safety

stand.

2. Remove the ski.

3. Remove the lock nut and cap screw securing the

shock absorber to the spindle. Account for all
mounting hardware.

FC208

4. Remove the Allen-head cap screw securing the tie

rod to the spindle arm.

FC209

5. Remove the snap ring securing the steering arm to

the spindle.

FC210

6. Remove the Allen-head cap screw securing the

steering arm to the spindle.

FC211

7. Remove the cap from the spindle; then using a

plastic mallet, tap the spindle shaft out the bottom
of the spindle. Account for the two washers from
between the steering arm and the spindle.

FC212

8. Remove the two cap screws and lock nuts securing

the spindle to the arms. Account for all mounting
hardware.

! CAUTION

Care must be taken to not over-extend the snap
ring. If the snap ring is over-extended, it must be
replaced.

7-18

FC213

FC214

9. Remove the spindle.

INSPECTING

NOTE: Whenever a part is worn excessively,

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

1. Inspect the spindle for excessive wear, cracks,

bends, or imperfections.

2. Inspect all welds for cracking.

3. Inspect the suspension arm bushings and axle area

for wear.

4. Secure the spindle in a vise. Rotate the spindle

NOTE: When greasing the spindle, use enough

grease so that it can be seen coming out at both
the top and bottom of the spindle.

5. Inspect the spindle axle and bearings for wear,

damage, or loose fit. Replace the bearings as a set.

NOTE: Replacing the ski bolt bushings is diffi-

cult. The existing bushings will be damaged dur-
ing removal. Be careful, however, not to damage
the spindle when removing the bearing. Press the
new bushings into the spindle.

INSTALLING

1. Insert the spindle shaft into the spindle making

sure the two washers are correctly positioned.

2. Place the upper and lower suspension arm ends

with bushings in position into the spindle. Secure
with cap screws and lock nuts. Tighten the lower
lock nut to 4.2 kg-m (30 ft-lb).

FC214

3. Tighten the upper lock nut to 4.2 kg-m (30 ft-lb).

FC213

4. Install the cap onto the spindle; then place the

steering arm into position on the spindle. Secure
with the Allen-head cap screw coated with blue
Loctite #243. Tighten to 4.2 kg-m (30 ft-lb).

FC211

5. Install the snap ring noting the correct direction of

the snap ring.

7-19

NOTE: The sharp side of the snap ring should be

directed away from the spindle arm.

FC210

6. Place the tie rod into position on the spindle arm.

Secure with the Allen-head cap screw coated with
green Loctite #609. Tighten to 5.5 kg-m (40 ft-lb).

FC209

7. Place the shock absorber into position on the

spindle. Secure with the cap screw and lock nut.
Tighten to 2.8 kg-m (20 ft-lb).

8. Install the ski.

9. Remove the safety stand from beneath the front

end.

Steering Tie Rod

(AWS V)

REMOVING

1. Remove the screws securing the skid plate; then

remove the skid plate.

NOTE: The front machine screw on some mod-

els is secured with a washer and lock nut.

AL144D

2. Remove the cotter pins, cap screws, and slotted

nuts securing the steering tie rod to the steering
post and steering arm; then remove the tie-rod
assembly.

AL089

3. Loosen the jam nuts securing the ball joints to the

steering tie rod; then remove the ball joints.

INSPECTING

NOTE: Whenever a part is worn excessively,

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

1. Inspect the ball joints for damaged threads or

wear.

2. Inspect the tie rod for damage, unusual bends, or

wear.

INSTALLING

1. Position the handlebar in the straight-ahead

position; then position the skis straight ahead.

2. Thread the jam nuts onto the ball joints; then

equally thread the ball joints onto the steering tie
rod.

NOTE: There must be an approximate equal

number of threads exposed on each ball joint.

3. Place the tie-rod assembly into position; then

rotate the steering tie rod until the holes in the ball
joints align with the holes in the steering post and
steering arm.

Content .. 86 87 88 89 ..