Snowmobile Arctic Cat (2004 year). Manual - part 112

8-48

5. Remove the cap screws and lock washers securing

the chain-case cover; then remove the cover.

AF111D

6. Loosen the mechanical chain tensioner bolt; then

remove the cotter pins and washers securing the
tensioner spring to the link pins. Remove the
spring, rollers, and washers.

AF347D

7. Remove the flex nut securing the front roller cage

and roller. Remove the cage and roller.

8. Set the brake lever lock; then remove the lock nut

and spring washer securing the bottom sprocket
and the lock nut and spring washer securing the
top sprocket.

AF345D

AF344D

9. Slide both sprockets with chain off the shafts.

Account for washer(s) behind the top sprocket.
Release the brake lever lock.

„ NOTE: If a sprocket will not slide off the shaft,
thread the nut onto the shaft; then use a puller to
loosen the sprocket. The nut will prevent damage
to the threads.

10. Remove the six lock nuts securing the top and

bottom chain case flange plates. Remove the
flange plates, seals, and bearings.

AF116D

11. On standard models, remove the screws securing

the air-intake silencer to the steering support; then
pull the silencer forward and place it on the
carburetors/throttle body.

„ NOTE: Using a hold-down strap, secure the air-
intake silencer to the engine.

12. Loosen the set screw on the PTO-side driven shaft

collar. Drive the collar clockwise (opposite shaft
rotation) until it is free.

„ NOTE: A fine file should be used to remove any
burrs left by the collar set screw.

13. Remove the two lock nuts and carriage bolts

securing the PTO-side driven shaft flange plate.

14. Force the driven shaft toward the PTO-side

(rotating the shaft to prevent the brake disc from
binding on the shaft) until the brake disc is free.
Account for the key.

8-49

8

15. Continue to slide the driven shaft until it is out of

the PTO-side. Account for a bearing, flange plate,
and the PTO-side driven shaft collar.

16. Remove the skid frame from the tunnel (see

Section 9).

17. On standard models, remove the three PTO-side

lock nuts securing the driveshaft flange bearing
assembly and the speedometer cable adapter.
Remove the cable adapter and speedometer cable.

AF053

„ NOTE: On AWS VI models, remove the three lock
nuts securing the voltage requlator/speedometer
pickup module; then remove the module. 

FC257

18. Tap the driveshaft toward the chain case to unseat

the MAG-side bearing. Remove the bearing.

19. Slide the driveshaft toward the MAG-side until the

PTO-end of the driveshaft is out of its mounting
hole. Tilt the end of the driveshaft away from the
tunnel and slide the driveshaft free of the tunnel.
Remove the track.

AF055

20. Scribe a line on the driveshaft along the edge of

each sprocket to aid in assembly. Loosen the set
screw on the collar and drive the collar clockwise
until free; then remove the bearing and flange
plates from the driveshaft.

21. Press the sprockets off the driveshaft.

22. If applicable, remove the six socket-head cap

screws and lock nuts securing the brake disc to the
hub; then separate disc and hub.

AF446

CLEANING AND INSPECTING

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

1. Thoroughly wash all metallic components in parts-

cleaning solvent. Dry using compressed air.

2. Wash all non-metallic components with soap and

water.

3. Inspect the driveshaft and driven shaft for

damaged splines or stripped threads.

4. Inspect the bearings for any roughness or damage.

5. Inspect the seals for any breaks or damage.

6. Inspect the track for cuts, gouges, or wear.

7. Inspect the keyways in the driven shaft and the

brake hub (if applicable) for wear or damage.

8. Inspect the brake disc for wear or cracks.

8-50

9. Inspect the chain, sprockets, and chain tensioner

components for wear or damage.

10. Inspect the track drive sprockets for wear or

damage.

ASSEMBLING

1. If applicable, secure the hub to the brake disc with

the six socket-head cap screws and lock nuts.
Tighten the lock nuts to 0.4 kg-m (36 in.-lb).

AF445

2. Press the sprockets on the driveshaft noting the

scribed marks on the shaft and the timing mark
found on one tooth of each sprocket. The timing
mark is the letter T molded into the outer surface
of one drive tooth of the inside sprockets and on
the inside surface of the outside sprockets. All the
T markings must be in alignment.

„ NOTE: Sprocket style will vary from model to
model.

739-057A

739-059A

„ NOTE: Make sure the sprockets are installed
correctly and the bearing is positioned between
the flange plates ensuring correct timing of the
sprockets.

3. Assemble the driveshaft components on the PTO-

end of the driveshaft. Install the bearing lock
collar; then install the flange bearing assembly
with the bolts facing towards the tunnel.

4. Position the front of the track into the tunnel.

Install the driveshaft with the splined end through
its mounting hole in the chain case.

AF055

5. Place the PTO-end of the driveshaft into position

by sliding the bolts of the flange bearing assembly
through the holes in the tunnel.

6. On standard models, place the cable adapter into

position on the flange bearing assembly bolts.
Secure with three lock nuts. Tighten to 2.2-
2.5 kg-m (16-18 ft-lb).

AF053

„ NOTE: On AWS VI models, place the voltage reg-
ulator/speedometer pickup module into position.
Install and tighten the three lock nuts to 2.1 kg-m
(15 ft-lb).

8-51

8

FC257

7. Slide the MAG-side bearing onto the driveshaft

(inner race flange must be positioned toward drive
chain); then install the O-ring seal and flange
plate. Insert the cap screws from the inside of the
tunnel through the chain case, seal, and flange.
Secure with three lock nuts. Tighten to 2.2-
2.5 kg-m (16-18 ft-lb).

8. Place the bottom sprocket onto the splines. Finger-

tighten a lock nut (threads coated with blue Loctite
#242) and spring washer. DO NOT TIGHTEN AT
THIS TIME.

9. Install the brake hub key into the driven shaft

keyway.

10. Install the PTO-side bearing with collar and flange

plate on the driven shaft; do not tighten the collar
at this time. Place the driven shaft into position
making sure the brake disc and flange plate are
properly positioned. Secure the PTO-side bearing
and flange plate with two carriage bolts and lock
nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb).

11. On the MAG-side of the driven shaft, install the

bearing, seal, and flange plate. Secure with three
lock nuts. Tighten to 2.2-2.5 kg-m (16-18 ft-lb).

„ NOTE: If washers were removed from behind the
top sprocket; install them at this time.

12. Loop the chain around the bottom sprocket and

slide the top sprocket with chain onto the driven
shaft. Secure the top sprocket with a lock nut
(threads coated with green Loctite #609) and
spring washer. Tighten to 4.8-5.5 kg-m (35-
40 ft-lb). Tighten the bottom sprocket lock nut to
4.8-5.5 kg-m (35-40 ft-lb).

AF344D

AF345D

13. Check the alignment of the sprockets using the

following procedure.

A. Place a straightedge against the faces of the

sprockets.

B. Using a feeler gauge, check for clearance along

the faces of both sprockets. If clearance
exceeds 0.8 mm (0.030 in.), shimming is neces-
sary.

0725-171

„ NOTE: Sprockets can only be shimmed out.

14. On standard models on the PTO-side of the driven

shaft and 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 to 0.4 kg-m (36 in.-lb).