Snowmobile Arctic Cat (2004 year). Manual - part 114

8-56

FC148

6. Tighten the mechanical chain tensioner finger-

tight; then lock the jam nut against the chain case.

FC138

7. Check the position of the chain-case cover O-ring

seal; then place the chain-case cover into position
and secure with six cap screws. Tighten to 1.7-2.1
kg-m (12-15 ft-lb).

FC137

8. Install the drain plug and tighten to 4.8 kg-m (35

ft-lb); then pour recommended amount of Arctic
Cat Transmission Lube (p/n 0636-817) into the
chain case.

9. Install the four torx-head screws at the front left

side making sure the two lock nuts and the cup
washers are correctly positioned.

10. Install the two torx-head screws on the backside

pan near the left-side hood latch.

11. Replace the two large-head rivets below the left-

side air-out vent on the left-side belly pan.

12. Install the driven pulley (see Driven Pulley in this

section).

FC135

Chain Adjuster

„  NOTE: Some photographs used in this sub-sec-
tion are used for clarity purposes only and are not
designed to depict actual conditions.

REMOVING AND DISASSEMBLING

1. Remove the small plug from the adjuster housing

and install an 8-32 set screw into the threaded hole
of the adjuster housing.

AF416

2. Using a 3/4-in. wrench, remove the chain adjuster

from the chain case.

8-57

8

AF417

3. Remove the adjuster stem from the end of the

adjuster screw.

AF418

4. Using a small piece of wire, remove the small

spring from the end of the adjuster screw.

AF401

5. While holding the end cap in position, remove the

three cap screws securing the end cap to the
adjuster housing.

AF419

6. Slowly and carefully lift the end cap from the

adjuster housing until it is free of the hooked end
of the spring.

AF420

7. Remove the O-ring seal from the adjuster housing.

8. Carefully lift the spring from the housing and

secure the spring using a cable tie.

AF421

9. Remove the set screw from the adjuster housing;

then remove the adjuster socket from the housing
by pulling it free of the adjuster bolt.

8-58

AF422

10. Rotate the adjuster bolt counterclockwise until it is

free of the housing; then remove the adjuster bolt.

AF423

11. Wash all components in parts-cleaning solvent and

inspect all components for any signs of wear.

ASSEMBLING AND INSTALLING

1. Apply a light coat of oil to the threads of the

adjuster bolt; then turn the adjuster bolt clockwise
into the housing a few turns.

AF423

2. Slide the adjuster socket over the end of the

adjuster bolt and push the socket down firmly into
position. Rotate the adjuster socket clockwise until
its flange seats against the housing inner surface.

AF424

3. With the flat surface of the adjuster socket located

under the threaded hole in the housing, install an
8-32 set screw.

AF403

AF425

4. Install the bent tab of the spring into the slot of the

adjuster socket with the outer hooked end of the
spring positioned in the clockwise direction.

8-59

8

AF406

5. With the spring in position, remove the cable tie

used to prevent it from unwrapping.

6. Place the O-ring seal into position; then set the end

cap into position. Make sure its tab is hooked into
the end of the spring.

AF405

7. While holding the end cap down into position,

rotate the end cap 20 turns clockwise to tension the
spring.

AF400

8. Install the three cap screws (coated with blue

Loctite #242) and tighten to 1 kg-m (7 ft-lb).

AF419

9. Apply a thin coat of grease to the spring and place

the spring into position in the end of the adjuster
bolt.

AF401

10. Use a thin coat of grease on the stem shaft to hold

it in position; then place the stem into the end of
the adjuster bolt.

AF418

11. Securely tighten the adjuster assembly to the chain

case.