Snowmobile Arctic Cat (2004 year). Manual - part 136

9-60

A. Remove the wheel insert (if applicable) and the

snap ring.

B. Using a hydraulic press, press the bearing out

the inside of the wheel.

C. Press the new bearing (on its outer race) into

the idler wheel.

AG538D

D. Install the snap ring making sure the “sharp

side” is directed away from the bearing.

AG539D

E. Install the insert (if applicable).

AG540D

5. Inspect the spring, spring slide, sleeve, washers,

slide block insert, and shaft area for wear.

6. Inspect the adjusting cams and arms for cracks.

INSTALLING

1. Slide the sleeve and spring onto the idler arm.

AG681D

2. Place the spring slide and slide block (with spring

in slide block) into position on the slide rail.
Secure with a cap screw (coated with red Loctite
#271) and washer. Tighten to 3.2 kg-m (23 ft-lb).

„

NOTE: Make sure the spring is located above the

spring slide mounting bolt.

AG680D

AG679D

3. Install the front outer idler wheel; then secure with

the cap screw, washer, and lock nut. Tighten to
3.2 kg-m  (23 ft-lb).

! CAUTION

Do not remove the bearing unless it is absolutely
necessary. The bearing will be damaged during
removal.

9-61

9

AG678D

4. Install the spacer.

AG677D

5. Install the rear upper idler wheel on the idler arm.

AG545D

6. Making sure the marks made during disassembly

are aligned, install the offset pivot idler to the idler
arm and secure with the cap screws, washers, and
lock nuts. Tighten to 2.6 kg-m (19 ft-lb).

„

NOTE: When tightening the pivot idler arm lock

nuts, tighten the lower lock nut first or binding
may occur.

AG675D

7. Place the short spring leg onto the adjusting cam

using the rear suspension spring tool.

AG624DA

Rear Axle and

Idler Wheels

„

NOTE: The skid frame must be removed for this

procedure (see Removing Skid Frame in this sub-
section).

DISASSEMBLING

1. Remove the cap from the idler wheel; then remove

the cap screw and large flat washer securing the
outer rear idler wheel. Remove the outer idler
wheel from the shaft.

FC194

9-62

„

NOTE: The large flat side of the wheel insert is

positioned next to the inner plastic adjuster bush-
ing. The idler wheel must be installed with the
wheel insert properly positioned.

2. Loosen the track adjusting bolts. Slide the outer

adjuster bushings off the axle.

AG627D

AG628D

3. Carefully slide the shaft out from the inner idler

wheels and note the position of the spacers and
washers.

FC165

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean the bearings with a clean cloth.

2. Inspect all idler wheel inserts (inner and outer) for

any cracks.

3. Inspect the outer rubber portion of the idler wheels

for cracks and poor bonding.

4. Inspect the plastic insert of each idler wheel for

cracks.

5. Inspect the shaft for wear and damaged threads.

6. Inspect all idler wheel bearings. Turn each bearing

(by hand) and if any roughness or binding is noted,
replace the bearing.

7. If a bearing must be replaced, use this procedure.

A. Remove the wheel insert (if applicable) and the

snap ring.

B. Using a hydraulic press, press the bearing out

the inside of the wheel.

C. Press the new bearing (on its outer race) into

the idler wheel.

AG538D

D. Install the snap ring making sure the “sharp

side” is directed away from the bearing.

AG539D

E. Install the insert (if applicable).

! CAUTION

Do not remove the bearing unless it is absolutely
necessary. The bearing will be damaged during
removal.

9-63

9

AG540D

ASSEMBLING

1. In order from the right-hand side, slide the axle

through the slide rail axle bracket; then place a flat
washer, short spacer with bushings, inner idler
wheel with insert, long spacer with bushings, the
remaining inside idler wheel and bushing, and flat
washer on the axle. Slide the axle through the
opposite slide rail axle bracket. Place the plastic
adjuster bushings on the axle (on the outside of
each axle bracket). Make sure the hole in the
adjuster bushing is aligned directly with the
adjusting bolt.

FC165

AG551D

2. Place the outer idler wheels on the axle (with the

large flat of the insert directed inward) and secure
with two cap screws (coated with red Loctite
#271) and large flat washers. Tighten cap screws
to 3.2 kg-m (23 ft-lb); then install the caps.

FC194

3. Adjust track alignment (see Track Alignment in

this sub-section).

4. Adjust track tension deflection (see Track Tension

in this sub-section).

Idler Arm

„

NOTE: The skid frame must be removed for this

procedure (see Removing Skid Frame in this sub-
section).

DISASSEMBLING

1. Remove the rear upper idler wheels and springs

(see Rear Upper Idler Wheels/Rear Springs in this
sub-section).

AG545D

2. Remove the cap screw and lock nut securing the

upper shock eyelet to the idler arm. Account for a
spacer, lock nut, and bushings.