Snowmobile Arctic Cat (2004 year). Manual - part 133

9-48

AG638D

8. Place the spring into the slide block; then place the

spring slide and slide block assembly into position
on the slide rail. Secure with a cap screw and
washer. Tighten to 6.2 kg-m (45 ft-lb).

FC185

9. Secure the outer idler wheel mounting block with

the cap screw and lock nut. Tighten to 5.5 kg-m
(40 ft-lb).

AG686D

10. Secure the outer and inner idler wheels to the

mounting blocks with existing hardware. Tighten
to 5.5 kg-m (40 ft-lb).

FC151

11. Secure the crossbraces with cap screws (coated

with blue Loctite #243). Tighten to 6.9 kg-m
(50 ft-lb).

FS051

NOTE: Apply a light coat of grease to the slide

rail surface to aid in installing a new wear strip. If
there are any sharp edges on the lower portion of
the rail, use a file to remove them.

AG534D

12. From the back, start the wear strip onto the rail;

then using a block of wood and a hammer, drive
the wear strip forward into position. Secure with a
machine screw and lock nut. Tighten to 1.1 kg-m
(8 ft-lb).

9-49

AG535D

AG509D

13. Secure the end cap onto the slide rail using a cap

screw, flat washers, and a lock nut. Tighten to
1.1 kg-m (8 ft-lb).

AG506D

14. After the skid frame has been installed, adjust

track tension deflection (see Track Tension in this
sub-section) and track alignment (see Track Align-
ment in this sub-section).

Installing Skid Frame

1. Place a piece of cardboard on the floor to protect

against scratching and tip the snowmobile onto
one side.

2. Pull the track away from the tunnel and spread

open; then place the skid frame into the track.

3. Position the front of the skid frame into the tunnel

and align the front arm with the appropriate
mounting hole in the tunnel. Insert the cap screw
with washers through the tunnel mounting hole
and through the front arm. DO NOT TIGHTEN
AT THIS TIME. Repeat this procedure on the
other side.

739-204A

NOTE: To aid in centering the front arm with the

hole in the tunnel, position the skid frame and
track at a 45° angle to the bottom of the tunnel.

4. Elevate the rear of the skid frame and the track

into position in the tunnel.

5. Align the offset pivot idler arm assembly with the

appropriate hole in the tunnel. Secure the offset
pivot idler arm assembly with a cap screw (coated
with red Loctite #271), lock washer, and flat
washer. DO NOT TIGHTEN AT THIS TIME.

NOTE: Do not install the short legs of the rear

springs onto the adjusting cams at this time.

6. At this time, tighten all four skid frame mounting

cap screws to 3.2 kg-m (23 ft-lb).

7. Using the Rear Suspension Spring Tool (p/n 0144-

311), install the short legs of the rear springs onto
the adjusting cams making sure the cams are in the
same adjustment positions.

8. Tighten the two track tension adjusting bolt evenly

until track deflection is within specifications; then
lock the jam nuts to secure the adjustment.

9. Check track tension deflection and alignment;

adjust if necessary (see Track Tension and Track
Alignment in this sub-section).

! CAUTION

When installing the skid frame, make sure the
rear arm shock mounting location on the pivot/
axle is positioned correctly above the axle or
component damage will occur.

9-50

Track Tension

CHECKING DEFLECTION

1. Tip the snowmobile on its side.

2. Hook a spring scale around a track clip at mid-

span; then pull the track down with the scale to 9
kg (20 lb) and measure the distance between the
bottom of the wear strip and the inside surface of
the track clip. Track deflection must be within
specifications.

729-429A

NOTE: If the track is new, it will stretch slightly

and take a “set” within the first 300 to 500 miles of
operation.

ADJUSTING DEFLECTION

1. Place the snowmobile up on a shielded safety

stand. Check to make sure the track is 2-3 in. off
the floor.

2. If the measurement is not as specified, loosen the

jam nuts of the adjusting bolts.

0727-456

3. If the measurement obtained in step 2 is more than

specified, tighten the adjusting bolts. If the mea-
surement obtained is less than specified, loosen
the adjusting bolts. When the measurement is
within specification range, lock the adjustment by
bottoming the jam nuts against the axle housings.

NOTE: Vigorously push the underside of the

track up and down. Track must not hit the top of
the tunnel or slap the skid frame.

4. After correct track tension is obtained, check track

alignment (see Track Alignment in this sub-sec-
tion).

NOTE: Track tension and track alignment are

interrelated; always check both even if only one
adjustment seems necessary. Always establish
correct track tension before checking and/or
adjusting alignment.

! WARNING

Deactivate all switches.

Rear Suspension

Style

Setup

Tension

After Break-In

Tension

FasTrack w/o Torque

Sensing Link

19-25 mm

(3/4-1 in.)

25-32 mm

(1-1 1/4 in.)

FasTrack w/Torque

Sensing Link

(121 in. Track)

32-38 mm

(1 1/4-1 1/2 in.)

38-44 mm

(1 1/2-1 3/4 in.)

FasTrack w/Torque

Sensing Link

(136 in., 144 in., 151

in., 159 in. Track)

38-44 mm

(1 1/2-1 3/4 in.)

50.8-57.2 mm

(2-2 1/4 in.)

9-51

Track Alignment

NOTE: Proper track alignment is when the rear

idler wheels are equidistant from the inner drive
lugs on the inside surface of the track.

CHECKING

1. Using a shielded safety stand, raise the rear of the

snowmobile off the floor making sure the track is
free to rotate.

2. Start the engine and accelerate slightly. Use only

enough throttle to rotate the track several revolu-
tions. SHUT THE ENGINE OFF.

NOTE: Allow the track to coast to a stop. Do not

apply the brake because it could produce inaccu-
rate alignment conditions.

3. When the track stops rotating, check the relation-

ship of the rear idler wheels and the inner track
drive lugs. If the distance from the idler wheels to
the inner drive lugs is the same on both sides, no
adjustment is necessary.

725-070A

4. On the side of the track which has the inner drive

lugs closer to the rear idler wheel, loosen the
adjusting bolt jam nut; then rotate the adjusting
bolt clockwise 1-1 1/2 turns.

5. Continue to check the track alignment and make

the necessary adjustments until proper alignment
is obtained.

6. After proper track alignment is obtained, lock the

jam nut against the axle housing.

NOTE: Make sure correct track tension is main-

tained after adjusting track alignment.

NOTE: Field test the track under actual condi-

tions and, after the field test, check track align-
ment and track tension; adjust as necessary.

Repair Procedure 2 -

Track/Rear Suspension

This Track/Rear Suspension sub-section (Repair Pro-
cedure 2) has been organized so each procedure can be
completed individually and efficiently. Each sub-sec-
tion has (as necessary) Removing, Disassembling,
Cleaning and Inspecting, Assembling, and Installing
procedures. Some components may vary from model
to model. The technician should use discretion and
sound judgment when removing and installing compo-
nents.

NOTE: Some illustrations and photographs used

in this sub-section are used for clarity purposes
only and are not designed to depict actual condi-
tions.

Removing

Skid Frame

NOTE: Many service procedures can be per-

formed without removing the skid frame. Closely
observe the note introducing each sub-section for
this important information.

1. Loosen the jam nuts and two track-tension adjust-

ing bolts.

FS082

2. Place a support stand under the rear bumper; then

while holding the flared bushing, remove the rear
cap screws securing the skid frame to the tunnel.
Account for lock washers and flat washers.

NOTE: The support stand should hold the snow-

mobile level but not raised off the floor.

3. Remove the front cap screws securing the skid

frame to the tunnel. Account for a flat washer and
a lock washer.

4. Remove the support stand; then tip the snow-

mobile onto one side using a piece of cardboard to
protect against scratching. Remove the skid frame.

! WARNING

The tips of the skis must be positioned against a
wall or similar object for safety. Keep hands, feet,
and clothing away from moving components.

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