Snowmobile Arctic Cat (2004 year). Manual - part 144

9-92

FC171

AG556D

„

NOTE: Note the mounting hole from which the

rear arm limiter (A) and rear arm (B) were removed
for assembling purposes.

FC256A

6. Remove the cap screw and lock nut securing the

rear arm to the slide rail. Account for the serrated
axles and axle tube.

FS044B

AG560D

7. Remove the cap screw and lock nut securing the

rear arm to the idler arm. Account for the alumi-
num axle and bushing assemblies.

AG477D

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 each idler wheel for cracks or damage.

3. Inspect the bushings (located in the arm pivot

area) for wear or damage.

9-93

9

4. Inspect all welds and the tubing of the upper arm

for cracks or unusual bends.

5. Inspect the two adjusting cams for damage.

6. Rotate the idler wheel bearings (by hand) and

check for binding or roughness.

7. 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.  Install the rear arm onto the idler arm with an alu-

minum axle, bushing assemblies, cap screw, and a
lock nut. Tighten to 4.2 kg-m (30 ft-lb).

AG477D

„

NOTE: Install the rear arm assembly into the

appropriate mounting hole as noted during disas-
sembling.

„

NOTE: On EXT models, the rear arm is mounted

in the first hole forward.

2. Place the rear arm assembly into position (with the

grease fittings directed toward the rear idler
wheels) between the slide rails. Secure with a cap
screw (coated with green Loctite #609) and lock
nut. Tighten to 4.7 kg-m (34 ft-lb).

FS044B

3. Install the rear arm limiter with the cap screw and

new lock nut (threads coated with blue Loctite
#243). Tighten to 6.9 kg-m (50 ft-lb).

FS044A

! CAUTION

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

9-94

4. Position the shock links in the appropriate holes of

the idler arm brackets (see Chassis and Skid Frame
Mounting Locations in this section). Place a
spacer between the center of the brackets; then
place a flat washer on the cap screw. Insert the
axle links into the upper shock link eyelets; then
insert the cap screw with washer through the eye-
lets. Secure with a cap screw, washer, and lock
nut. Tighten to 4.2 kg-m (30 ft-lb).

AG556D

FC171

5. Place the upper shock eyelet with bushings

between the idler arm brackets making sure the
spacer is properly positioned between the brack-
ets. Secure with a cap screw and lock nut. Tighten
to 4.2 kg-m (30 ft-lb).

„

NOTE: Do not over-tighten the shock absorber

cap screw as the shock eyelet must be free to
pivot.

6. Grease the idler arm and rear arm grease fittings

with a low-temperature grease.

7. Install the rear upper idler wheels, rear spring, and

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

Front Arm/Front Shock 

Absorber/Front Inner 

Idler Wheels

„

NOTE: The skid frame must be removed for this

procedure (see Removing Skid Frame in this sub-
section), and the rear springs must be removed
from the adjusting cams.

REMOVING

„

NOTE: On models with remote reservoir, cut the

cable ties securing the front shock absorber hose
to the front arm.

1. Remove the lower cap screws and lock nuts secur-

ing the limiter straps to the rail support. Account
for flat washers.

FC173

2. Remove the cap screw and lock nut securing the

upper front shock absorber eyelet to the front arm.
Pull the shock eyelet free of the bracket. Account
for a bushing.

FC174

3. Remove the cap screws and lock nuts securing the

front arm to the front arm mounting brackets.

9-95

9

FC175

4. Remove the front arm and account for the two

front arm spacers.

FC176

5. Cut the cable ties securing the shock hoses to the

skid frame.

„

NOTE: Note the location of all cable ties secur-

ing the shock hoses for installing purposes.

6. Remove the cap screw, lock nut, and washers

securing the shock mount axle; then remove the
axle and account for spacers, flat washers, and
shock bushings.

„

NOTE: New lock nuts must be used when install-

ing the shock mount axle.

FC177

FC180

FC178

„

NOTE: On models with a remote reservoir,

loosen the two clamps securing the remote reser-
voir; then remove the reservoir with hoses.

FS045

7. Using a plastic mallet, tap the axle from the lower

shock eyelet.

INSPECTING

„

NOTE: Whenever a part is worn excessively,

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

! CAUTION

Care must be taken when removing the remote
reservoir that the hoses are not kinked or
damaged.