Snowmobile Arctic Cat (2007 year). Manual - part 77

8-11

8

ADJUSTING BRAKE LEVER TRAVEL

0735-457

„ NOTE: The brake band should lock tightly when
the brake lever is compressed and should disen-
gage when the lever is released. If adjustment is
necessary, use the following steps.

1. Loosen the rearward jam nut on the brake cable.

2. Tighten the forward jam nut to set up the brake.

3. Check the brake lever travel distance periodi-

cally while tightening the forward jam nut.

When the distance is within the specified range

of 6-13 mm (1/4-1/2 in.), tighten the rearward

jam nut to secure the adjustment.

Drive Belt

The belt dimensions and construction are two fac-

tors that influence the performance of the drive sys-

tem. The two belt dimensions that are important to

the performance of the snowmobile are the outside

circumference and the width. Both of these dimen-

sions will influence shifting characteristics.

If the drive belt is longer than specified, the drive

clutch and driven pulley will not have the full shift

ratio. Also, a too-long drive belt will cause poor

acceleration and a decrease in top speed.

If the drive belt is shorter than specified, the drive

clutch and driven pulley will have a different shift

pattern because they are in different ratios from

those for which they were originally matched. A

too-short drive belt will cause a loss in performance

and a bog on engagement.

„ NOTE: A drive belt that is worn thin may produce
the same effect as one that is too long.

Drive belt construction has an influence on the way

the drive clutch and driven pulley will shift and on

the amount of power that will be transmitted

through the system. ONLY ARCTIC CAT DRIVE

BELTS SHOULD BE USED. Different brands of

belts may not have the same construction causing

either more friction or more slippage when the belt

is wedged between the sheaves and, thus, a loss of

efficiency.

„ NOTE: A stiff belt causes a HP loss to the track.
As a belt warms up, it gets more flexible and trans-
mits power with less HP loss.

Removing/Installing 

Drive Belt 

(ACT Roller Driven Pulley)

1. Turn ignition key to the OFF position and wait

for all moving parts to stop.

2. Set the brake lever lock.

3. Open the hood; then open the belt guard.

4. On the Jaguar Z1, open the left-side access

panel.

5. Remove the driven pulley plug from the belly

pan.

6. Using the Drive Belt Deflection Tool (p/n 0644-

412), remove the sheave adjuster from the end

of the driven pulley. Account for and remove the

O-ring and shim washers. Note the orientation

of the components for installing purposes.

„ NOTE: The sheave adjuster has left-hand
threads.

739-266B

7. On the Jaguar Z1, remove the cap screw and

sheave adjuster from the end of the driven pul-

ley. Account for and remove the O-ring and

shim washers. Note the orientation of the com-

ponents for installing purposes.

8-12

741-721B

8. With the O-ring and shim washers removed,

carefully thread the sheave adjuster back into

the driven pulley; then tighten the adjuster with

the deflection tool until it bottoms against the

driven shaft.

„ NOTE: By bottoming the sheave adjuster against
the driven shaft, the sheaves of the driven pulley
will spread far enough to allow the removal of the
drive belt.

9. On the Jaguar Z1 with the O-ring and shim

washers removed, install the sheave adjuster and

cap screw back into the driven pulley; then

tighten the cap screw until the sheave adjuster

bottoms against the input shaft.

„ NOTE: By bottoming the sheave adjuster against
the input shaft, the sheaves of the driven pulley
will spread far enough to allow the removal of the
drive belt.

10. Remove the drive belt from the drive clutch and

driven pulley.

739-267B

11. Place the drive belt (so the part number can be

read) between the sheaves of the drive clutch

first; then between the sheaves of the driven pul-

ley.

12. Using the deflection tool, remove the sheave

adjuster from the end of the driven pulley. Place

the shim washers and O-ring (as noted in remov-

ing) onto the sheave adjuster; then carefully

thread the sheave adjuster back into the driven

pulley. Tighten the adjuster securely using the

deflection tool.

13. On the Jaguar Z1, place the shim washers and

O-ring (as noted in removing) onto the sheave

adjuster; then install the cap screw and sheave

adjuster back into the driven pulley. Tighten the

cap screw to 4.4 kg-m (32 ft-lb). Install the left-

side access panel.

14. Close the belt guard; then install the driven pul-

ley plug.

15. Release the brake lever lock.

Drive Clutch

(660 cc/1100 cc Z1)

CHANGING CAM ARMS/SPRING 

Removing 

1. Open the belt guard; then remove the drive belt

and the plug from the belly pan.

„ NOTE: For removing drive belt on models with
the ACT Roller Driven Pulley, see Removing/
Installing Drive Belt (ACT Roller Driven Pulley) in
this section.

2. On the 660 cc, remove the bolt and lock washer

securing the drive clutch to the crankshaft.

CM111

! WARNING

Never operate the snowmobile without the belt
guard secured in place.

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8

3. On the 1100 cc Z1 using Drive Clutch Bolt Tool

(p/n 0644-281), remove the 12-mm Allen-head

cap screw and washer securing the drive clutch

to the crankshaft.

ZJ292

„ NOTE: Before installing the clutch puller, apply
oil to the threads of the puller and a small amount
of grease to the tip of the puller.

4. Using the Clutch Puller (p/n 0644-207) - 660 cc

or (p/n 0644-446) - 1100 cc Z1 and a breaker bar

and the Drive Clutch Spanner Wrench (p/n

0644-136), tighten the puller. If the drive clutch

will not release, sharply strike the head of the

puller. Repeat this step until the clutch releases.

CM112

ZJ293

5. Remove the drive clutch from the engine com-

partment. Account for any spacers.

Disassembling

„ NOTE: Note the timing marks on the cover, spi-
der, and movable sheave. These must be aligned
when assembling the drive clutch for balance pur-
poses.

1. Loosen the machine screws securing the cover.

Remove every other cap screw and lock washer

from the cover; then while firmly holding the

cover, remove the three remaining screws and

lock washers equally.

FC054

2. Remove the cover and spring.

FC055

8-14

3. Remove the cam arm pin lock nuts; then using a

small torch, apply heat to the cam arm set

screws to loosen the Loctite used in assembly.

FS001

„ NOTE: Heat must be applied to the cam arm in
order to remove the set screws.

4. After the lock nuts and set screws have been

removed, remove the cam arm pins one at a time

noting the position of the alignment notches for

assembly purposes. Account for the O-rings.

0739-038

Cleaning And Inspecting

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, drive clutch
replacement is necessary.

1. Using parts-cleaning solvent, wash grease, dirt,

and foreign matter off all components; dry with

compressed air.

2. Remove any drive belt dust accumulation from

the stationary sheave, movable sheave, and

bushings using parts-cleaning solvent only.

3. Inspect stationary sheave, movable sheave, spi-

der, and cover for cracks or imperfections in the

casting.

4. Inspect the cam arm pins for wear or bends.

5. Inspect the spring for proper compression rate

qualities (see Drive System Components in this

section).

6. Inspect rollers for damage or wear.

Assembling

1. With the head of each cam arm pin positioned

towards the direction of the drive clutch rota-

tion, install the cam arms.

„ NOTE: The drive clutch rotates counterclock-
wise.

2. With the cam arm pin properly positioned, apply

green Loctite #620 to the set screw holes in the

cam arm, install the new set screws (pre-coated

with Loctite), and tighten securely.

739-040A

3. Secure the cam arm pins with new lock nuts and

tighten to specifications.

4. Place the spring and cover into position making

sure the timing mark on the cover is properly

aligned; then compress the spring and install the

machine screws coated with blue Loctite #243

and lock washers. In a crisscross pattern, tighten

evenly to specifications.

! CAUTION

It is critical that green Loctite #620 be applied to the
set screw holes in the cam arms or component dam-
age may occur.

! CAUTION

When installing cam arms, always use new lock nuts
and cam arm set screws.