Snowmobile Arctic Cat (2004 year). Manual - part 92

7-32

3. Using the Shock Spring Removal Tool (p/n 0644-

057), remove the spring from the shock body by
compressing the spring; then remove the spring
retainer from the top of the spring. Inspect the
shock absorber by quickly compressing and
extending the shock plunger while firmly holding
the shock body. Resistance must be felt in both
directions.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the shock absorber seal area for signs of

excessive oil leakage.

2. Inspect the shock absorber mounting eyelet,

bushings, and sleeve for wear or damage.

3. Inspect the threaded shock sleeve for damage or

wear. Clean the sleeve and apply a light coat of
grease to the threads before installing.

INSTALLING

1. Using the shock spring tool, place the spring on

the shock absorber and secure with the retainer.

2. Adjust the retainer nut (spring adjuster) until the

specified amount of threads are exposed between
the spring adjuster and the shock housing (noted in
removing) as an initial setting.

3. Install the bushings, sleeves, and spacers into each

shock end; then place the shock absorber into
position. Install both cap screws from the front.
Tighten the lock nuts to 2.8 kg-m (20 ft-lb).

AL156D

Sway Bar

REMOVING

1. Remove the lock nuts and cap screws securing the

sway bar arm to the links and remove.

2. Remove the lock nuts and cap screws securing the

sway bar arms to the sway bar; then remove the
arms. Pull the sway bar out and account for two
bearings.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

1. Inspect the sway bar for any signs of twisting,

fatigue, or wear.

2. Inspect the sway bar arms for cracks or damage.

3. Inspect the links, bushings, bushing retainers, and

hardware for damage or wear.

INSTALLING

736-034A

1. Place the sway bar into position; then install a

bearing on each end of the sway bar.

2. Slide the sway bar arms onto the sway bar until the

holes in the arms align with the notches in the
sway bar. Install the cap screws and lock nuts.
Tighten to 1.8 kg-m (13 ft-lb) on AWS V models
or to 1.5 kg-m (11 ft-lb) on the AWS VI models.

„

NOTE: Make sure the arms are positioned on the

same flat on both ends of the sway bar.

3. Place the links into position on the sway bar arms;

then secure with cap screws and lock nuts. Tighten
to 3.2 kg-m (23 ft-lb) on the AWS V models or to
4.2 kg-m (30 ft-lb) on the AWS VI models.

Key

1. Washer
2. Washer
3. Lock Nut
4. Cap Screw
5. Cap Screw
6. Lock Nut

 7. Link

8. Cap Screw
9. Lock Nut

10. Sway Bar
11. Bearing
12. Arm

7-33

7

Console

(Standard EFI Models)

„

NOTE: Determine which style console is being

removed and installed and refer to the appropriate
illustration for component details; then remove
and install accordingly.

0738-577

0738-512

REMOVING

1. Remove the self-tapping screws securing the

console; then raise the console.

„

NOTE: If applicable, remove the cap screws and

washers securing the remote adjuster clamp to the
console; then lay the adjuster on the air-intake
silencer.

2. Disconnect the wiring harness from the ignition

switch.

3. Remove the console.

INSTALLING

1. Place the console into position.

2. Connect the wiring harness to the ignition switch.

3. Secure the console with the self-tapping screws.

KEY

1. Console
2. Door
3. Ignition Switch
4. Key
5. Spacer
6. Lock Washer
7. Decal

8. Retaining Nut
9. Self-Tapping 

Screw

KEY

1. Console
2. Door
3. Ignition Switch
4. Key
5. Spacer
6. Lock Washer
7. Decal - Right

8. Retaining Nut
9. Self-Tapping Screw

10. Decal - Left
11. Outlet w/Nut

7-34

Console

(AWS VI Models)

„

NOTE: Determine which style console is being

removed and installed and refer to the appropriate
illustration for component details; then remove
and install accordingly.

0737-894

0738-824

REMOVING

1. Pull the recoil starter rope outward; then tie a slip-

knot in the recoil rope near the case. Slowly allow
the rope to retract to the knot.

2. Untie the knot in the end of the recoil starter rope;

then remove the handle from the rope. Account for
the cap.

3. On the carbureted model, remove the knurled nut

securing the choke assembly to the console; then
slide the choke cable out of the console.

4. Disconnect the wiring harness from the ignition

switch.

5. Remove the five torx-head screws securing the

console; then remove the console.

KEY

1. Console
2. Self-Tapping Screw
3. Choke Cable
4. Lock Nut
5. Choke Nut
6. Choke Lever Kit
7. Ignition Switch
8. Key
9. Retaining Nut

10. Ignition Switch Washer
11. Ignition Switch Spacer
12. Molded Bumper

KEY

1. Console
2. Self-Tapping Screw
3. Ignition Switch
4. Key
5. Retaining Nut
6. Ignition Switch Washer
7. Ignition Switch Spacer
8. Molded Bumper

7-35

7

FC227

INSTALLING

1. Place the console into position; then secure the

console with the five torx-head screws.

FC227

2. Connect the wiring harness to the ignition switch. 

3. On the carbureted model, slide the choke cable

through the console. Secure the choke assembly to
the console with the knurled nut.

4. Thread the recoil starter rope through the console

and handle. Tie a knot at the end of the recoil rope.
Seat the cap. Remove the slip-knot and allow the
rope to retract.

Console

(Standard Carbureted Models)

„

NOTE: Determine which type of console is being

removed and installed and refer to the appropriate
illustration for component details; then remove
and install accordingly.

0738-511

0738-391

KEY

1. Console
2. Door
3. Ignition Switch
4. Key
5. Spacer
6. Lock Washer

7. Decal - Right
8. Nut
9. Choke Cable

10. Choke Lever Kit
11. Choke Nut

12. Accessory 

Outlet w/Nut

13. Decal - Left
14. Self-Tapping 

Screw

KEY

1. Console
2. Door
3. Ignition Switch
4. Key
5. Spacer
6. Lock Washer
7. Decal - Right

8. Nut
9. Choke Cable

10. Choke Lever Kit
11. Choke Nut
12. Decal - Left
13. Self-Tapping Screw