Snowmobile Arctic Cat (2004 year). Manual - part 111

8-44

AF090

„ NOTE: Steps 12-14 are for AWS VI models.

12. Pull down on the side pan by the left-side hood

latch; then slide the driven shaft into the chasis and
into the chain case.

FC143

13. Place the PTO-side plate brace into position; then

install the three bearing retaining nuts on the PTO-
side plate brace. Tighten nuts securely.

FC140

14. Secure the brace with machine screws.

FC136

15. Install the bottom sprocket and driveshaft

extension.

AF427

16. Position one shim washer on the idler gear shaft.

AF430

17. Position the chain around the lower reverse

sprocket; then place the idler sprocket and top
sprocket into the chain. Slide sprockets into
position on the idler shaft and driven shaft.

8-45

8

AF441

„ NOTE: If the chain tension is too tight to allow
installation of the top sprocket, remove the PTO-
side driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will allow the
sprocket to slide onto the splined end of the driven
shaft.

18. Secure the top sprocket with a spring washer (with

the high side directed away from the sprocket) and
lock nut (coated with green Loctite #609). Tighten
the lock nut to 5.5 kg-m (40 ft-lb).

AF432

„ NOTE: If the PTO-side driven shaft bearing was
removed to make the sprocket installation easier,
install the bearing and flange plate. Lock the bear-
ing collar by driving it in the direction of rotation to
lock the collar to the bearing and shaft. Tighten the
collar set screw.

19. Place the rubber alignment pin into position in the

idler sprocket; then slide the outer idler gear on the
shaft. Install shim washer on the shaft.

AF436

20. If the lower reverse sprocket was disassembled,

assemble the thrust washer, bearing, and thrust
washer. Secure with the snap ring. Apply
transmission lube to the bearing and rotate by
hand.

AI021

21. Slide the reverse gear onto the driveshaft

extension; then position the spring into the reverse
gear and secure with heavy washer and cap screw
(coated with blue Loctite #243). Tighten to
4.2 kg-m  (30 ft-lb).

AF428

22. Install the chain tensioner arm, apply blue Loctite

#243 to the stud threads, and tighten the shoulder
nut to 1.1 kg-m (8 ft-lb).

23. Remove the set screw from the chain adjuster

housing and install the adjuster plug.

24. Check that the chain-case O-ring seal is positioned

correctly on the housing.

25. Position the shift fork behind the large thrust

washer and bearing on the reverse gear; then
position the cover on the housing.

8-46

AF075

26. Apply blue Loctite #243 to the threads of the cap

screw; then install the cap screw through the
center of the cover and into the idler shaft. Tighten
the cap screw enough to draw the idler shaft into
the cover.

AI025

27. Place the shift pivot and reverse switch bracket

into position on the cover; then secure the chain-
case cover with cap screws and lock washers.
Tighten the cap screws to 3.5 kg-m (25 ft-lb).

28. Place the shift linkage into position on the back

side of the arm and secure with a cap screw and
lock nut. Tighten to 3.5 kg-m (25 ft-lb).

29. Place the reverse lever into position on the shift

pivot and secure with a clevis pin and cotter pin.

30. On the PTO-side of the track driveshaft, slide the

lock collar against the bearing, drive the collar in
the direction of rotation until tight, and tighten the
collar set screw.

AF054

31. Install the skid frame (see Section 9).

32. On standard models, remove the hold-down strap

securing the air-intake silencer; then place the
silencer into position making sure the boot is
properly positioned on the carburetor/throttle body
assembly. Secure the silencer to the steering
support with the two screws.

33. Apply a light coat of grease or Loctite Anti-Seize

Thread Compound (p/n 0678-146) to the driven
shaft; then install the driven shaft alignment
washers (as required) and key. Install the stub
shaft and the driven pulley, alignment washers (as
required), washer, and cap screw (coated with blue
Loctite #243). Tighten to 2.6-3.3 kg-m (19-
24 ft-lb).

„ NOTE: Make sure the keyways match when
installing the driven pulley. Arrange washers to
allow the least amount of float on the driven shaft.
A maximum of 1.5 mm (0.060 in.) float is allowable.

SC013D

34. Check the alignment of the drive clutch/driven

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

35. Assure that the chain case drain plug is tightened

to 4.8 kg-m (35 ft-lb); then pour 354 ml (12 fl oz)
of Arctic Cat Transmission Lube (p/n 0636-817)
into the chain case.

36. Install the drive belt and check belt deflection.

Secure the belt guard.

8-47

8

37. Install and secure the battery tray and battery; then

connect the battery cables making sure to connect
the positive cable first.

„ NOTE: On AWS VI models, install the resonator
and expansion chamber.

ADJUSTING REVERSE LINKAGE

1. Start the engine; then test the shifting

characteristics of the reverse transmission.

2. If adjustment of the reverse gear is necessary, stop

the engine and remove the chain case inspection
plug located behind the oil level stick; then insert
the Reverse Gear Adjustment Gauge (p/n 0644-
244) completely into the inspection hole.

0731-734

3. Pull the shift lever into the reverse position while

holding the adjustment gauge firmly against the
chain case cover. Slight outward pressure should
be felt on the gauge as the lever locks into reverse.

4. If no contact is noted, loosen the jam nuts securing

the lower shift linkage and adjust the linkage rod
until the gauge is pushed out of the chain case
0.254-0.381 mm (0.010-0.015 in.). Lock the
adjustment by tightening the jam nuts securely
against the tie rod ends.

„ NOTE: To adjust the linkage rod, the shift lever
must be moved to the forward position.

5. Install the inspection plug.

6. Start the engine; then test the shifting

characteristics of the reverse transmission. Adjust
as necessary.

Drive Train/Brake Disc 

(w/o 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. Open the belt guard and 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.

SC013D

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

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

„ NOTE: On AWS VI models, account for the inner
and outer O-rings. 

„ 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).

AF120D

! CAUTION

The linkage must be properly adjusted. If the
linkage is too short, damage to the shift fork may
occur. If the linkage is adjusted too long, the
gears will not shift totally into reverse.

! CAUTION

Never use an impact driver on models with a
composite chain case. Damage to the chain case
will occur.