Snowmobile Arctic Cat (2004 year). Manual - part 105

8-20

AM072A

FC088

6. Apply green Loctite #620 to the threads of the

stationary shaft above the spider. Install the spider
retainer nut and tighten to 11.8 kg-m (85 ft-lb).

AM066

FC089

„ NOTE: Grasp the movable sheave and lift it
upward; then release it. It must move freely and
not bind at any point.

7. On the 6-post style with a suitable driving tool,

carefully install the new cam arm pin bushings
into the movable sheave.

FS005

8. With the head of each cam arm pin positioned

towards the direction of the drive clutch rotation,
install the cam arms.

„ NOTE: The drive clutch rotates counterclock-
wise.

9. On the 6-post style with the cam arm pin properly

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

739-040A

10. On the 6-post style, 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).

11. Place the spring and cover into position making

sure the timing mark on the cover is properly
aligned; then compress the spring and install the
nine machine screws coated with blue Loctite
#242 and lock washers. In a crisscross pattern,
tighten evenly to 1.4 kg-m (10 ft-lb).

! CAUTION

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

8-21

8

AM075

FC090

AM076

FC091

INSTALLING

1. Install any spacers as accounted for in removing;

then insert the clutch bolt with lock washer.

„ NOTE: Be sure to wipe the clutch taper and
crankshaft taper clean of any oil film or dirt before
installing the drive clutch.

2. Place the clutch into position on the crankshaft.

3. Using a 12-point 1/2-in. socket and the drive

clutch spanner wrench, tighten the clutch bolt to
6.9-7.6 kg-m (50-55 ft-lb).

AF477D

FC002

4. Check alignment between the drive clutch and

driven pulley (see Drive Clutch/Driven Pulley in
this section).

! CAUTION

Care must be taken when installing the cover not
to damage the bushing.

! CAUTION

When installing the drive clutch, do not tighten
the clutch bolt with any kind of impact tool.
Tighten clutch bolt using a hand torque wrench
only. Failure to do so could result in stationary
sheave or crankshaft damage.

8-22

AF468D

FC092

5. Install the drive belt. Check drive belt deflection

(see Drive Clutch/Driven Pulley in this section).
Secure the belt guard and install the plug in the
belly pan.

6. Either test drive the snowmobile or run the engine

for five minutes; then tighten the drive clutch bolt
to 6.9-7.6 kg-m (50-55 ft-lb).

REPLACING CAM ARM BUSHINGS    
(9-Post Style)

1. Using a vise, spread the jaws just enough to allow

room for the bushing to pass between.

2. Position the cam arm over the spread jaws.

AM094

3. Slide a new bushing onto one of the cam arm pins;

then position the pin through the cam arm bushing.

AM095

4. Using the new bushing as a tool, drive the worn

bushing from the cam arm. When the head of the
cam arm pin contacts the cam arm, the new
bushing will be properly seated.

AM096

ACT Roller Driven Pulley

REMOVING

1. Open the hood; then open the belt guard.

2. Remove the drive belt.

3. Remove the cap screw and washer securing the

driven pulley; then account for and note the
position of any alignment washers.

! WARNING

Never operate the engine without the belt guard
secured.

8-23

8

SC013D

4. Slide the driven pulley off the driven shaft; then

remove pulley from the engine compartment.

„ NOTE: If the driven pulley is tight on the shaft,
pull the driven pulley off using the Driven Pulley
Puller (p/n 0744-023).

5. Remove the key, alignment washers, and stub

shaft from the driven shaft.

AF120D

DISASSEMBLING

1. Scribe a line across all driven pulley components

to ensure correct assembly and pulley balance.

SC001D

2. Place the driven pulley on a work fixture so the

roller plate is directed upward.

SC002D

„ NOTE: To aid in driven pulley servicing, use a
roll of duct tape as a work fixture. The work fixture
will increase the stability of the pulley during the
repair procedure.

3. Remove the three lock nuts securing the roller

plate; then carefully slide the plate off the
stationary shaft allowing the spring to release
tension.

SC003D

4. Remove the spring.

B458D

! WARNING

The roller plate is under spring pressure. Care must
be taken when removing the lock nuts to prevent
the plate from ejecting prematurely.