Snowmobile Arctic Cat (2004 year). Manual - part 109

 

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Snowmobile Arctic Cat (2004 year). Manual - part 109

 

 

8-36

0738-426

0738-556

Drive & Driven Shafts/
Hydraulic Brake Assy

KEY

1. Track Drive Assy
2. Drive Sprocket
3. Driveshaft
4. Drive Bushing
5. Flange Plate
6. Flange
7. Carriage Bolt
8. Bearing
9. Solder Ring

10. Lock Nut
11. Cable Adapter
12. Drive Adapter
13. Grease Fitting
14. Cap Screw
15. Brake Disc
16. Key
17. Driven Shaft
18. Key
19. Cap Screw
20. Bearing
21. Flange
22. Washer
23. Stub Shaft
24. Driven Pulley
25. Washer
26. Washer
27. Washer
28. Cap Screw
29. Brake Caliper 

Assy

30. Housing
31. Housing
32. Cap Screw

33. Bleed Screw
34. Brake Pad Set
35. Retaining Pin
36. O-Ring
37. O-Ring
38. Piston
39. Washer
40. Adapter Fitting

Drive & Driven Shafts/
Hydraulic Brake Assy

KEY

1. Track Drive 

Assy*

2. Drive Sprocket
3. Driveshaft
4. Drive Sprocket
5. Drive Bushing
6. Flange Plate
7. Flange Plate
8. Carriage Bolt
9. Bearing

10. Solder Ring
11. Cable Adapter
12. Drive Adapter
13. Grease Fitting
14. Lock Nut
15. Cap Screw
16. Brake Disc
17. Key
18. Driven Shaft
19. Key
20. Bearing
21. Flange Plate
22. Cap Screw
23. Washer
24. Stub Shaft
25. Driven Pulley
26. Washer
27. Washer
28. Washer
29. Cap Screw
30. Brake Caliper 

Assy

31. Housing

32. Cap Screw
33. Bleed Screw
34. Brake Pad Set
35. Retaining Pin
36. Housing
37. O-Ring
38. O-Ring
39. Piston
40. Washer
41. Adapter Fitting

* Sprocket style will vary from model to model.

8-37

8

0738-647

Drive Train/Brake Disc 

(w/Reverse)

DISASSEMBLING

1. Remove the chain-case drain plug located on the

lower back side of the chain case inside the tunnel
and drain the chain case lubricant.

2. Disconnect the battery cables. Remove the battery

and battery tray.

„ NOTE: On AWS VI models, the expansion cham-
ber and resonator must be removed prior to step 2.

3. Open the belt guard and remove the drive belt.

4. Remove the cap screw and washer securing the

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

SC013D

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

remove the driven pulley from the engine
compartment. Account for the key, stub shaft, and
alignment washers.

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

Drive & Driven Shafts/
Hydraulic Brake Assy

KEY

1. Track Drive Assy
2. Drive Sprocket
3. Driveshaft
4. Flange Plate
5. Bearing
6. Magnet
7. Voltage           

Regulator/ 
Speedometer 
Pickup Module

8. Lock Nut
9. Cap Screw

10. Brake Disc
11. Key
12. Driven Shaft
13. Key
14. Bearing
15. Spacer
16. Washer
17. Stub Shaft
18. O-Ring
19. Driven Pulley
20. Washer
21. Washer
22. Washer
23. Cap Screw
24. Brake Caliper 

Assy

25. Cap Screw
26. Washer
27. Adapter Fitting
28. Housing
29. O-Ring
30. O-Ring
31. Piston
32. Bleed Screw

33. Housing
34. Brake Pad Set
35. Retaining Pin
36. Washer

8-38

AF120D

„ NOTE: Tip the snowmobile on its left side posi-
tioning the chain case side of the snowmobile up.
Place a piece of cardboard under the side of the
snowmobile to prevent scratching of bumper and
belly pan.

6. Disconnect the shift linkage from the arm on chain

case.

7. Remove the cap screw from the center of the chain

case.

AI025

8. Remove the cap screws securing the chain case

cover; then remove the cover by pulling outward
and lifting up so the shift fork clears the large
inner washer.

AI010

9. Remove the screw from the chain adjuster housing

and install an 8-32 set screw to lock the chain
adjuster in position.

AF426

10. Remove the shim washer from the idler sprocket.

AF436

11. Remove the outer idler sprocket from the shaft.

! CAUTION

On models with mirrors before tipping the
snowmobile on its side, position a block of wood
under the side of the snowmobile to keep the
mirrors from contacting the floor or damage may
occur.

8-39

8

AF437

12. Slide the small rubber alignment pin from the face

of the inner idler sprocket and place in safe
location until assembly.

AF439

13. Remove the lock nut securing the top sprocket.

AF432

14. Remove the spring washer in front of the top

sprocket.

AF444

15. Set the brake lever lock. Remove the cap screw

and large washer securing the bottom sprocket.

„ NOTE: The bottom sprocket cap screw and
washer are spring loaded.

AF428

16. Remove the reverse gear.

AF442

17. Remove the top sprocket, chain, and idler gear.

Account for one shim washer located behind the
idler gear.

 

 

 

 

 

 

 

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