Snowmobile Arctic Cat (2004 year). Manual - part 91

7-28

FC219

FC220

10. Remove the remaining eight torx-head screws

securing the front bumper. Account for the center
belly pan screen.

FC221

FC222

11. Remove the cap screw and lock nut securing the

upper arm. Account for the washer.

FC223

12. Remove the 10 torx-head screws securing the

center belly pan to the frame. Note the location of
the different-length screws for installing purposes. 

FC224

13. Remove the rear belly pan.

! CAUTION

To avoid damage to the hood, carefully close it
and rest it on the handlebar.

7-29

7

FC225

14. Remove the two cap screws and lock nuts securing

the lower arm; then remove the arm. Account for
all mounting hardware.

FC226

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the arm welded areas for cracks or any

signs of deterioration.

2. Inspect the bearings and axles for wear or damage.

3. Inspect the arm tubing for signs of twisting or

bending.

INSTALLING

0737-858

1. Place the suspension arms into position on the

front end and secure with the cap screws and lock
nuts. Tighten each cap screw (threads coated with
green Loctite #609) and lock nut to 4.2 kg-m (30
ft-lb).

FC226

2.  Place the rear belly pan into position; then secure

with the 10 torx-head screws.

FC224

KEY

1. Lower Arm
2. Bearing
3. Upper Arm
4. Bearing
5. Axle
6. Axle

7. Axle Tube
8. Washer
9. Cap Screw

10. Cap Screw
11. Lock Nut
12. Cap Screw

13. Lock Nut
14. Brace
15. Cap Screw
16. Washer
17. Lock Nut
18. Axle

7-30

3. Place the front bumper into position; then secure

with the eight torx-head screws. Place the center
belly pan screen into position.

FC221

FC222

4. Place the hood into position on the front bumper;

then install the two hood pins and hairpin clips.

FC219

5.  Place the side belly pans into position on the front

bumper; then secure with the two torx-head cap
screws.

FC218

6. Place the air silencer into position on the front

bumper; then secure with the three torx-head
screws.

FC217

7.  Secure the sway bar link to the front arm with the

cap screw and lock nut. Tighten the lock nut to 4.2
kg-m (30 ft-lb).

FC216

8. Secure the arms to the spindle with existing

hardware. Tighten the upper arm lock nut to 4.2
kg-m (30 ft-lb) and the lower arm lock nut to 5.5
kg-m (40 ft-lb).

7-31

7

FS018

FS019

9. Secure the tie rod to the steering arm with the

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

FC209

10. Place the front shock absorber into position; then

secure with existing hardware. Tighten to 2.8 kg-
m (20 ft-lb).

FS017

11. Install the ski with existing hardware. 

12.  Remove the snowmobile from the safety stand. 

Front Suspension (Ski)

Shock Absorber

REMOVING

1. Position the front of the snowmobile up onto a

safety stand taking all pressure off the skis.

2. Remove the cap screws securing the shock

absorber to the front end assembly and spindle;
then remove the shock absorber. Account for all
mounting hardware.

„

NOTE: On models with a remote reservoir,

remove the clamp securing the reservoir to the
belly pan.

AL156D

„

NOTE: Note the number of threads exposed

between the spring adjuster and shock housing
for installing purposes.