Snowmobile Arctic Cat (2004 year). Manual - part 103

8-12

Drive Train and

Brake Systems

This section has been organized into sub-sections for
servicing drive train and brake systems; however,
some components may vary from model to model. The
technician should use discretion and sound judgment
when removing and installing components.

„ NOTE: Some illustrations and photographs used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.

Drive Belt

The belt dimensions and construction are two factors
that influence the performance of the drive system.
The two belt dimensions that are important to the per-
formance of the snowmobile are the outside circumfer-
ence and the width. Both of these dimensions will
influence shifting characteristics.

If the drive belt is longer than specified, the drive
clutch and driven pulley will not have the full shift
ratio. Also, a too-long drive belt will cause poor accel-
eration and a decrease in top speed.

If the drive belt is shorter than specified, the drive
clutch and driven pulley will have a different shift pat-
tern because they are in different ratios from those for
which they were originally matched. A too-short drive
belt will cause a loss in performance and a bog on
engagement.

„ NOTE: A drive belt that is worn thin may produce
the same effect as one that is too long.

Drive belt construction has an influence on the way the
drive clutch and driven pulley will shift and on the
amount of power that will be transmitted through the
system. ONLY ARCTIC CAT DRIVE BELTS
SHOULD BE USED. Different brands of belts may
not have the same construction causing either more
friction or more slippage when the belt is wedged
between the sheaves and, thus, a loss of efficiency.

„ NOTE: A stiff belt causes a HP loss to the track.
As a belt warms up, it gets more flexible and trans-
mits power with less HP loss.

Drive Clutch

CHANGING CAM ARMS (9-Post Style)

The cam arms on the drive clutch can be changed
without disassembling the clutch. To change the cam
arms, use the following procedure.

1. Check to make sure the ignition switch is in the

OFF position.

2. Remove the drive belt.

3. Compress the movable sheave approximately 2.5

cm (1 in.) and while holding it in this position,
insert a flat bar firmly between the bottom side of
the spider and the inner surface of the movable
sheave. Slowly release the movable sheave.

4. Remove the lock nuts from the three cam arm

pins.

5. Remove the cam arm pins one at a time; then

remove the cam arm with bushing and account for
the washers.

„ NOTE: When installing cam arms, always use
new lock nuts. Make sure the head of each cam
arm pin is positioned towards the direction of
drive clutch rotation. Tighten nuts until they con-
tact the shoulder of the cam arm pin; then tighten
an additional 1/8 turn.

733-452B

6. Change the cam arms and secure with new lock

nuts and existing pins making sure the head of
each pin is positioned toward the direction of drive
clutch rotation.

„ NOTE: The drive clutch rotates counterclock-
wise.

CHANGING CAM ARMS (6-Post Style)

The cam arms on the drive clutch can be changed
without disassembling the clutch. To change the cam
arms, use the following procedure.

! WARNING

Do not run the engine with the drive belt removed
or the bar in the clutch.

KEY

1. Lock Nut
2. Cam Arm
3. Bushing
4. Washer
5. Pin

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8

1. Check to make sure the ignition switch is in the

OFF position.

2. Remove the drive belt.

3. Using Clutch Compressor (p/n 0644-420),

compress the movable sheave inward; then insert
the compressor clamp and slowly release the
compressor locking the movable sheave.

FC260

FC261

4. Remove the lock nuts from the three cam arm

pins.

5. Using a small torch, apply heat to the cam arm set

screws to loosen the Loctite used in assembly.

FS001

„ NOTE: Heat must be applied to the cam arms in
order to remove the set screws.

6. After the lock nuts and set screws have been

removed, remove the cam arm pins one at a time
noting the position of the alignment notches for
assembling purposes. Account for the O-rings.

0739-038

7. Change the cam arms with existing pins making

sure the head of each pin is positioned toward the
direction of drive clutch rotation.

„ NOTE: The drive clutch rotates counterclock-
wise.

8. With the cam arm pin alignment notch properly

positioned to the cam arm set screw, install the
new cam arm set screws (pre-coated with Loctite)
and tighten securely.

9. Secure the cam arm pins with new lock nuts and

tighten to 0.35 kg-m (2.5 ft-lb) or 0.035 kg-m (25
in.-lb).

REMOVING (9-Post Style)

1. Open the belt guard; then remove the drive belt

and the plug from the belly pan.

2. Remove the bolt and lock washer securing the

drive clutch to the crankshaft.

AN380D

! CAUTION

When installing cam arms, always use new lock
nuts and cam arm set screws.

8-14

„ NOTE: Before installing the clutch puller, apply
oil to the threads of the puller and a small amount
of grease to the tip of the puller.

3. Using the Clutch Puller (p/n 0644-207) and an

impact wrench or a breaker bar and the Drive
Clutch Spanner Wrench (p/n 0644-136), tighten
the puller. If the drive clutch will not release,
sharply strike the head of the puller. Repeat this
step until the clutch releases.

AN381D

4. Remove the drive clutch from the engine

compartment. Account for any spacers.

REMOVING (6-Post Style)

1. Open the belt guard; then remove the drive belt

and the plug from the belly pan.

2. Remove the bolt and lock washer securing the

drive clutch to the crankshaft.

FC002A

3. Using Clutch Compressor (p/n 0644-420),

compress the movable sheave inward; then insert
the compressor clamp and slowly release the
compressor locking the movable sheave.

FC260

FC261

„ NOTE: Before installing the clutch puller, apply
oil to the threads of the puller and a small amount
of grease to the tip of the puller.

4. Using the Clutch Puller (p/n 0644-207) and an

impact wrench or a breaker bar and the Drive
Clutch Spanner Wrench (p/n 0644-136), tighten
the puller. If the drive clutch will not release,
sharply strike the head of the puller. Repeat this
step until the clutch releases.

FC002

5. Remove the drive clutch from the engine

compartment. Account for any spacers.

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8

DISASSEMBLING

„ NOTE: Note the timing marks on the cover, spi-
der, and movable sheave. These must be aligned
when assembling the drive clutch for balance pur-
poses.

1. Loosen the machine screws securing the cover.

Remove every other cap screw and lock washer
from the cover; then while firmly holding the
cover, remove the remaining screws and lock
washers equally.

AM059D

FC054

2. Remove the cover and spring.

AM061D

FC055

3. Position the drive clutch over the Clutch Holder

(p/n 0644-058).

„ NOTE: The holder should either be secured in a
vise or bolted to a sturdy work bench.

AM063D

FC083

4. Secure the drive clutch to the holder using the

clutch bolt and lock washer.