Snowmobile Arctic Cat (2004 year). Manual - part 143

9-88

AG539D

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. Install the idler wheel.

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

FC164

3. 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).

FC158

AG593D

4. Place the short spring leg onto the adjusting cam

using the rear suspension spring tool.

FC159

9-89

9

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 rear axle nut; then remove the two

track adjusting bolts. Account for mounting hard-
ware.

FC160

FC161

„

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. Remove the rear axle, idler wheels, spacer, and

track adjuster bushings.

FC167

„

NOTE: Note the position of the opening in the

adjuster bushings for assembling purposes.

FC169A

3. Carefully slide the shaft out from the inner idler

wheels and note the position of the spacers and
washers.

FC166

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 the outer rubber portion of the idler wheels

for cracks and poor bonding.

3. Inspect the shaft for wear and damaged threads.

9-90

4. Inspect all idler wheel bearings. Turn each bearing

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

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

A. Remove 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

ASSEMBLING

1. From the left-hand side, slide the adjuster bushing

onto the axle noting the position of the opening
from disassembling; then slide the axle through
the slide rail. Place the inner idler wheel, spacer,
the remaining idler wheel, and the adjuster bush-
ing noting the position of the opening from disas-
sembling. Push the axle through the slide rail.

FC168A

FC166

2. Insert the track adjuster bolts through the adjuster

bushing; then secure with washers and lock nuts. 

FC161

3. Install the axle shaft nut; then tighten only until

snug.

! CAUTION

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

9-91

9

FC160

4. Install the skid frame (see Installing Skid Frame in

this sub-section).

5. Adjust track alignment (see Track Alignment in

this sub-section).

6. 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 spring and sleeve from the idler arm.

FC159

FC164

2. Using Idler Wheel Puller Kit (p/n 0644-400),

remove the idler wheel from the upper arm.

FC157

3. Noting the mounting location for assembling pur-

poses, remove the cap screw and lock nut securing
the upper shock eyelet to the idler arm. Account
for a spacer, cap screw, and lock nut.

4. Remove the two Allen-head cap screws securing

the coupler blocks.

FC192

5. Noting the mounting location for assembling pur-

poses, remove the cap screw and lock nut securing
the upper shock links to the idler arm. Account for
a lock nut, spacer, flat washers, and axle links.