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Snowmobile Arctic Cat (2004 year). Manual - part 121

8-84

Troubleshooting

Hydraulic Brake

System

Problem: Caliper Leaks

Condition

Remedy

1. Caliper O-ring deteriorated — severed

2. Piston — O-ring damaged

1. Replace O-ring

2. Repair piston — replace piston — O-ring

Problem: Lever Spongy — Bottoms Out

Condition

Remedy

1. Brake system air bubbles present

2. Master cylinder damaged — faulty

1. Bleed brake system

2. Replace master cylinder

Problem: Oscillation Feedback in Lever

Condition

Remedy

1. Brake pad residue present on brake disc

2. Caliper loose

3. Brake disc warped — cracked — damaged —

misaligned

1. Replace pads — clean disc

2. Tighten mounting bolts

3. Replace disc — driven shaft bearing

Problem: Loss of Brake

Condition

Remedy

1. Brake fluid overheated — contaminated

2. Master cylinder damaged — faulty

3. Caliper — brake hose leaking

4. Air ducts obstructed — missing

5. Brake lever linkage damaged

1. Replace fluid

2. Replace master cylinder

3. Replace caliper O-ring — repair piston —

replace piston — O-ring — brake hose

4. Remove obstruction — replace air ducts

5. Repair — replace lever — mounting bolt

Problem: Brakes Drag

Condition

Remedy

1. Master cylinder damaged — faulty

2. Brake disc warped — damaged — misaligned

3. Brake pads worn — tapered

1. Replace master cylinder

2. Replace disc — driven shaft bearing

3. Replace pads

Problem: Snowmobile Won’t Stop — Have to Pull Too Hard on Lever

Condition

Remedy

1. Pads/brake disc glazed

2. Brake lever binding

3. Caliper pistons binding

1. Replace pads — clean disc

2. Loosen pivot bolt — replace master cylinder

3. Service caliper assembly

9-1

SECTION 9 — TRACK/REAR

SUSPENSION

TABLE OF

CONTENTS

Understanding the Suspension ............................... 9-2
Suspension Setup Basics ....................................... 9-3
Suspension Mounting Location Chart ..................... 9-6
Chassis and Skid Frame

Mounting Locations.............................................. 9-7

Reservoir.......................................................... 9-153

Bearing Cap and Shaft Seal................................ 9-157
Shaft Eyelet ......................................................... 9-158
Ski Shocks Bottom-Out Bumper.......................... 9-159
Pressurizing Rebuildable Shocks ........................ 9-159
Troubleshooting Track ......................................... 9-160

9-2

UNDERSTANDING THE SUSPENSION

GENERAL

Quick acceleration and the ability to go through the
turns with power are the most important handling
qualities. This section explains how the skid frame
functions to provide these two important handling
qualities. Before proceeding, however, note these
terms.

Weight Transfer — A shift in the center of gravity in
any direction depends on the force applied.

Track Tension — The amount of tightness or loose-
ness of the track when correctly mounted in the chas-
sis.

Spring Tension — The amount of force exerted on the
spring by either fork tension adjustment or eyebolt
adjustment.

Ski Pressure — The amount of force exerted down-
ward on the skis.

Good weight transfer characteristics are needed for
fast acceleration (shift of weight from skis to track)
and for cornering (shift of weight back to skis to hold
the front end in turns). Effective weight transfer
depends on suspension tension, position of rider, and
the position of the front arm limiter.

To understand how the suspension system works,
think of the entire system in terms of three points; the
skid frame rear axle center, the skid frame front arm,
and the ski saddle center.

Assume that the front arm functions as a stationary
pivot point between the rear axle center and the ski
saddle center. Also assume that the ski saddle center is
the same height off the ground as the rear axle center.
This produces the standard position arrangement.

0728-180

Under acceleration when the center of gravity is trans-
ferred to the rear of the machine, the rear suspension
collapses slightly. This brings the rear arm point
downward and with the front arm stationary, the tee-
ter-totter effect reduces the pressure on the skis, posi-
tion A.

However, for controlled cornering, more pressure is
needed on the skis. So when the driver decelerates
coming into a corner, the center of gravity is trans-
ferred forward, putting the required pressure onto the
skis and reducing the pressure on the rear suspension,
position C.

0728-181

This is essentially what weight transfer is all about —
the shift of weight to the rear of the machine for posi-
tive traction and good acceleration or to the front of
the machine for positive handling and cornering con-
trol.

9-3

SUSPENSION SETUP BASICS

FRONT ARM SPRING TENSION

NOTE: Read the following information closely as

it pertains to all suspensions used in the last sev-
eral years. If there are any questions, please con-
tact the Arctic Cat Service Department.

It is desirable to run with very light front arm spring
tension. When riding in 4 in. or more of snow, the
machine will be quicker if the front spring tension is
adjusted lightly.

If the spring tension is adjusted too stiff, the track
angle at the front of the skid frame is steep. This steep
angle prevents the snowmobile from getting up on
plane and slows down by 5 to 8 mph.

When riding in sticky snow (springtime or warm days)
or hill climbing on hard snow, it may be desirable to
stiffen the front arm spring tension. When this is done,
weight is transferred back quicker. The problem with
too much front arm spring tension is that the feel of the
snowmobile becomes very short. The reason for this is
the front arm becomes the pivot point between the
spindles and rear of the machine. With dominant
spring tension on the front arm, the suspension is basi-
cally contacting the snow from a point below the front
arm to the skis or the spindle pressure point. This
makes for a very short and darting machine on the
trail. This is especially true when decelerating and the
center of gravity is transferred forward.

A good method for adjusting the front spring tension
follows.

NOTE: On those models having a coil spring

over the front arm shock absorber, the spring ten-
sion should be set as soft as possible when oper-
ating on trails and in deep snow.

0729-662

FRONT ARM LIMITER STRAPS

Under no circumstances should the front arm limiter
strap be lengthened. If lengthened, it may cause shock
absorber travel problems.

The two limiter straps on AWS models can be short-
ened if desired. This adjustment must be made to suit
driving style and some test driving time. With the rear
arm in its present mounting location, no advantage has
been noted from changing the strap length. If the front
arm straps are shortened, the result will be more ski
pressure and aggressive steering.

SKI SHOCK ABSORBER SPRINGS

The shock absorber springs have been matched to the
shock valving and rear suspension. These springs are
the result of hours of testing and comparison riding
trying many different combinations of springs and
shocks. If there is a need to make changes, there are
several spring and shock sizes to choose from. While
making these changes, keep the following points in
mind.

Heavier Or Stiffer Springs

1. These will require shocks with more rebound con-

trol, or the front end will become like a pogo stick.

2. With stiffer springs, the front end will become

more aggressive in the corners as more weight will
be transferred to the skis when decelerating. Also,
more weight is transferred to the rear on accelera-
tion and can cause the rear shocks and spring to
bottom out.

3. If the springs are too stiff for general riding condi-

tions and style, the ride comfort is gone.

Spring Tension Too Soft

1. Front end bottoms out; hard on front end parts.

2. Less aggressive steering in corners on decelera-

tion, and less weight is transferred to the skis
because of softer springs.

3. Less weight gets transferred to rear of the machine

upon acceleration.

NOTE: When softening the ski springs, also

soften the rear to match entire suspension.

FRONT ARM SPRING TENSION TOO
STIFF

1. Slows machine down in loose snow.

2. Causes the machine to dart and dive as a result of

less track on the ground on deceleration.

! CAUTION

If the ski shock spring is adjusted too loose, the
spring retainer may fall out. If the spring is
adjusted beyond specification, the spring will
coil bind and spring adjuster damage will occur.

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