Snowmobile Arctic Cat (2004 year). Manual - part 106

8-24

5. Slide the movable sheave off the stationary shaft;

then remove any thrust washers located between
the sheaves noting the position of washers for
assembling purposes.

B459D

B460

6. Remove the three socket head screws and lock

washers securing the torque bracket (cam) to the
stationary sheave; then remove torque bracket.

AI062

7. Place the roller plate on a work fixture (roll of duct

tape, etc.).

SC004D

8. Using a 1/8-in. punch, remove the spring pin

securing the roller, roller pin, and thrust washer to
the plate.

SC005D

9. Using the Roller Pin Removal Tool (p/n 0644-

276) from inside the plate, drive the roller pin out
of the plate. Account for the pin, thrust washer,
and roller.

SC006D

8-25

8

SC007D

CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Using parts-cleaning solvent, wash grease, drive

belt dust, and foreign matter off all components.

2. Inspect the rollers for damage, cracks, or wear.

3. Inspect the sheaves for any gouges, cracks, or

other damage. Also, inspect threaded areas of
sheaves for damaged or stripped threads.

4. Inspect the torque bracket (cam) for cracks or

damage. The ramp portions of the bracket and
caps must be free of gouges and damage. Minor
scratches may be repaired using #320 grit wet-or-
dry sandpaper.

B465

5. Inspect spring for distortion, crystallization, or

breaks.

6. Inspect the roller plate, rollers, pins, and spring

mounting holes for cracks, damage, or wear.

7. Inspect the roller plate and movable sheave

bearings for wear. For each respective bearing,
measure the outside diameter of the shaft and the
inside diameter of the bearing. Compare the
readings. Clearance between the shaft and the
respective bearing must not exceed 0.5 mm
(0.020 in.). If the clearance exceeds the
specification, the bearing must be replaced.

B466D

B467

REMOVING BEARINGS

To remove driven pulley bearings, use the Bearing
Removal and Installation Tool (p/n 0644-167) and the
following procedure.

„ NOTE: To remove the movable sheave bearing,
heat must be applied around the bearing.

1. Place the movable sheave (or roller plate) flat on a

press.

2. Using the bearing tool, press the bearing out.

! CAUTION

Do not use steel wool or a wire brush to clean
driven pulley components. A wire brush or steel
wool will cause the sheaves to be gouged (thus,
the drive belt may not slide properly between
sheaves). Decreased performance and possible
accelerated drive belt wear will result.

! WARNING

Always wear safety glasses when using the bearing
driver.

8-26

AF154

INSTALLING BEARINGS

„ NOTE: Before installing a bearing, apply red
Loctite #271 to the outside face of the bearing.

1. Place the movable sheave (or roller plate) flat on a

press.

2. Using the bearing tool, press the bearing into

position. The bearing must be flush with the
outside of the bearing boss.

3. Wipe off excess Loctite. Allow the Loctite to cure

for 24 hours at room temperature.

ASSEMBLING

0737-913

1. Place the roller and thrust washer (toward the

outside of the roller plate) and secure with the
roller pin.

2. Secure the roller, thrust washer, and pin into

position with the spring pin. Drive the pin in until
it is flush with the plate.

SC012D

3. Place the torque bracket (cam) into position on the

stationary sheave making sure the degree number
on the bracket aligns with the part number on the
stationary sheave. Install the three socket head
screws and lock washers. DO NOT tighten at this
time.

AI062

4. Place any thrust washers (as noted during

disassembly) on the stationary sheave shaft.

KEY

1. Movable Sheave
2. Bearing
3. Thrust Washer
4. Stationary Sheave
5. Torque Bracket (Cam)
6. Lock Washer
7. Socket Head Screw
8. Spring
9. Roller Plate

10. Spring Pin
11. Roller Pin
12. Spring Washer
13. Roller
14. Lock Nut
15. Cover
16. Cover
17. Self-Tapping Screw

8-27

8

B460

5. Align the scribed line made during disassembly;

then slide the movable sheave onto the stationary
sheave shaft.

B459D

6. Place the sheaves on a work fixture (roll of duct

tape, etc.).

7. Place the spring over the stationary sheave hub

and hook the turned down end of the spring into
the hole in the casting of the stationary sheave.

B458D

8. Place the roller plate over the spring and hook the

turned-up end of the spring in the 3rd hole
(standard spring tension) of the plate.

9. While holding the sheaves to prevent them from

rotating, grasp the plate and rotate it
approximately 120° clockwise until the mounting
holes align; then push the plate into position and
install the three lock nuts. Tighten the lock nuts to
2.8 kg-m (20 ft-lb).

„ NOTE: The line scribed during disassembly
should be aligned.

SC003D

10. Rotate the movable sheave to ensure free

movement without binding.

11. Rotate the torque bracket (cam) until it is tight;

then using a long hex wrench, tighten the three
socket-head cap screws securing the bracket.

SC011D

INSTALLING

1. Slide the alignment washers onto the end of the

driven shaft.

2. Install the key in the driven shaft keyway; then

place the stub shaft into the driven pulley. Place
the driven pulley on the shaft. Align its keyway
with the driven shaft keyway.

„ NOTE: A small amount of Loctite Anti-Seize
Thread Compound (p/n 0678-146) applied to the
drive n sha ft w ill aid in future  drive n pulle y
removal.

3. Secure the driven pulley by installing any

alignment washers, the washer, and cap screw.
Tighten the cap screw to 2.6-3.3 kg-m (19-
24 ft-lb).