Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 104

8-36

4. Remove the cap screw and washer securing the

driven pulley; then account for and note the posi-

tion of any alignment washers.

SC013D

5. Slide the driven pulley off the driven shaft; then

remove the driven pulley from the engine com-

partment. Account for the key, stub shaft, and

alignment washers.

„NOTE: If the driven pulley is tight on the driven
shaft, pull the driven pulley off using the Driven
Pulley Puller (p/n 0744-023).

AF120D

„NOTE: Tip the snowmobile on its left side posi-
tioning the chain case side of the snowmobile up.
Place a piece of cardboard under the side of the
snowmobile to prevent scratching of bumper and
belly pan.

6. Disconnect the shift linkage from the arm on chain

case.

7. Remove the cap screw (A) from the center of the

chain case; then remove the remaining cap screws

securing the chain case cover; then remove the

cover by pulling outward and lifting up so the shift

fork clears the large inner washer.

741-158A

8. Remove the screw from the chain adjuster housing

and install an 8-32 set screw to lock the chain

adjuster in position.

AF426

9. Remove the shim washer from the idler sprocket.

AF436

10. Remove the outer idler sprocket from the shaft.

AF437

! CAUTION

On models with mirrors before tipping the snowmo-
bile on its side, position a block of wood under the
side of the snowmobile to keep the mirrors from
contacting the floor or damage may occur.

8-37

8

11. Slide the small rubber alignment pin from the face

of the inner idler sprocket and place in safe loca-

tion until assembly.

AF439

12. Remove the lock nut securing the top sprocket.

AF432

13. Remove the spring washer in front of the top

sprocket.

AF444

14. Set the brake lever lock. Remove the cap screw

and large washer securing the bottom sprocket.

„NOTE: The bottom sprocket cap screw and
washer are spring loaded.

AF428

15. Remove the reverse gear.

AF442

16. Remove the top sprocket, chain, and idler gear.

Account for one shim washer located behind the

idler gear.

AF433

„NOTE: If the chain is too tight and wont allow the
top sprocket to be removed, remove the PTO-side
driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will loosen
the chain.

17. Remove the driveshaft extension, bottom sprocket,

and spacer washer.

8-38

AF427

18. Check the idler gear shaft. If the shaft surface is

rough, remove the shaft using a pair of vise-grip

pliers. Rotate the shaft counterclockwise.

19. Remove the shoulder nut securing the chain tight-

ener arm; then remove the arm from the chain

case.

AF447

20. Remove the three lock nuts (A) securing the top

bearing flange plate. Remove the flange plate, seal,

and bearing; then remove the three lock nuts (B)

securing the bottom bearing flange plate. Remove

the flange plate, seal, and bearing. 

AF431A

„NOTE: Steps 21-25 are for Bearcat/Panther/Z
models.

21. Remove the screw securing the air-intake silencer

to the steering support; then pull the silencer for-

ward and place it on the carburetor/throttle body

assembly.

„NOTE: Using a hold-down strap, secure the air-
intake silencer to the engine.

22. Loosen the set screw on the PTO-side driven shaft

collar. Drive the collar clockwise (opposite shaft

rotation) until it is free.

„NOTE: A fine file should be used to remove any
burrs left by the collar set screw.

23. Remove the lock nuts and carriage bolts securing

the PTO-side driven shaft flange plates.

AF002D

24. Force the driven shaft toward the PTO-side (rotat-

ing the shaft to prevent the brake disc from bind-

ing on the shaft) until brake disc is free. Account

for the key.

25. Continue to slide the driven shaft until it is out of

the PTO-side. Account for a bearing, two flange

plates, and the PTO-side driven shaft collar.

26. Remove the skid frame from the tunnel (see Sec-

tion 9).

27. Remove the three PTO-side lock nuts securing the

driveshaft flange bearing assembly and cable

adapter. Remove the adapter and speedometer

cable.

AF053

28. Tap the driveshaft toward the chain case to unseat

the MAG-side bearing. Remove the bearing.

8-39

8

29. Slide the driveshaft toward the MAG-side until the

PTO-side of the driveshaft is out of its mounting

hole. Tilt the end of the driveshaft away from the

tunnel and slide the driveshaft free of the tunnel.

Remove the track.

AF055

30. Scribe a line on the driveshaft along the edge of

each sprocket to aid in assembly. Loosen the set

screw on the collar and drive the collar clockwise

until free; then remove the bearing and flange

plates from the driveshaft.

31. Press the sprockets off the driveshaft.

CLEANING AND INSPECTING

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

1. Thoroughly wash all metallic components in parts-

cleaning solvent. Dry using compressed air.

2. Wash all non-metallic components with soap and

water.

3. Inspect the driveshaft and driven shaft for dam-

aged splines or stripped threads.

4. Inspect the bearings for any roughness or damage.

5. Inspect the seals for any breaks or damage.

6. Inspect the track for cuts, gouges, or wear.

7. Inspect the keyways in the driven shaft for wear or

damage.

8. Inspect the brake disc for wear or cracks.

9. Inspect the track drive sprockets for wear or dam-

age.

10. Inspect the top sprocket for any chipped or worn

teeth.

11. Inspect the bottom sprocket teeth for wear. Turn

the inner sprocket bearing by hand and inspect for

any signs of being rough.

12. Inspect the three bottom sprocket drive pins.

Check the pin edges for chipping and wear.

13. Inspect the drive pin springs for tension by push-

ing each pin into the sprocket and releasing it. It

must snap back out without any signs of binding.

If any of these items (pins, bearing, sprocket,

teeth) appear worn, replace the sprocket as an

assembly.

AI019

14. Inspect the idler gear sprocket teeth and bearings.

Rotate the inner bearings by hand. Check each

sprocket tooth for any signs of chipping and wear.

15. Closely inspect the drive chain for broken links.

16. Inspect the reverse gear. Inspect the teeth for wear

and chipping. Inspect the edges of drive pin holes

for any signs of chipping and wear.

17. Remove the snap ring from the reverse gear.

Remove the outer thrust washer, thrust bearing,

and inner thrust washer. Inspect the thrust bearing

by placing it between the two thrust washers and

rotating the thrust washer. Rotation must feel

smooth. If any roughness is noted, replace the

thrust washers and bearing as a set.

18. Inspect the chain tightener bearing. Rotate the

tightener roller and check for smooth rotation. If

rotation feels rough, replace roller and bearing

assembly.

ASSEMBLING

1. Press the sprockets on the driveshaft noting the

scribed marks on the shaft and the timing mark

found on one tooth of each sprocket. The timing

mark is an arrow molded into the outer surface of

one drive tooth. All the arrow markings must be in

alignment.

„NOTE: Sprocket style will vary from model to
model.