Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 105

8-40

739-057A

„NOTE: Make sure all sprockets are installed cor-
rectly to ensure correct timing of the sprockets.
The bearing is positioned between the flange
plates.

2. Assemble the driveshaft components on the PTO-

side of the driveshaft. 

3. Install the bearing lock collar; then install the

flange bearing assembly with the bolts facing

towards the tunnel.

4. Position the front of the track up into the tunnel.

Install the driveshaft with the splined end through

its mounting hole in the chain case.

AF055

5. Place the PTO-side of the driveshaft into position

by sliding the bolts of the flange bearing assembly

through the holes in the tunnel.

6. Place the cable adapter into position on the flange

bearing assembly bolts. Secure with three lock

nuts. Tighten to specifications.

AF053

7. Slide the MAG-side bearing onto the driveshaft

(inner race flange must be positioned toward drive

chain); then install the O-ring and flange plate.

Secure with three carriage bolts and lock nuts.

Tighten to specifications.

„NOTE: Prior to installation, lubricate the O-ring
with Low-Temp Snowmobile Grease (p/n 0636-593).

8. Slide the brake disc into position on the splined

end of the driven shaft.

9. Install the PTO-side bearing with collar and flange

plates on the driven shaft; do not tighten the collar

at this time. Place the driven shaft into position

making sure the brake disc and flange plates are

properly positioned. Secure the PTO-side bearing

and flange plates with two carriage bolts and lock

nuts. Tighten to specifications.

10. On the MAG-side driven shaft, install the bearing,

O-ring, and flange plate. Secure with three lock

nuts. Tighten to specifications.

„NOTE: Prior to installation, lubricate the O-ring
with Low-Temp Snowmobile Grease (p/n 0636-593).

„NOTE: If washers were removed from behind the
upper sprocket, install them at this time.

11. Install the spacer washer on the driveshaft.

AF090

! CAUTION

Tighten the flange plate nuts evenly or the O-ring
seal may be damaged.

8-41

8

12. Install the bottom sprocket and driveshaft exten-

sion.

AF427

13. Position one shim washer on the idler gear shaft.

AF430

14. Position the chain around the lower reverse

sprocket; then place the idler sprocket and top

sprocket into the chain. Slide sprockets into posi-

tion on the idler shaft and driven shaft.

AF441

„NOTE: If the chain tension is too tight to allow
installation of the top sprocket, remove the PTO-
side driven shaft bearing. This will allow the driven
shaft to be lifted at the PTO-side and will allow the
sprocket to slide onto the splined end of the driven
shaft.

15. Secure the top sprocket with a spring washer (with

the high side directed away from the sprocket) and

lock nut (coated with green Loctite #609). Tighten

the lock nut to specifications.

AF432

„NOTE: If the PTO-side driven shaft bearing was
removed to make the sprocket installation easier,
install the bearing and flange plate. Lock the bear-
ing collar by driving it in the direction of rotation to
lock the collar to the bearing and shaft. Tighten the
collar set screw.

16. Place the rubber alignment pin into position in the

idler sprocket; then slide the outer idler gear on the

shaft. Install shim washer on the shaft.

AF436

17. If the lower reverse sprocket was disassembled,

assemble the thrust washer, bearing, and thrust

washer. Secure with the snap ring. Apply transmis-

sion lube to the bearing and rotate by hand.

AI021

18. Slide the reverse gear onto the driveshaft exten-

sion; then position the spring into the reverse gear

and secure with heavy washer and cap screw

(coated with blue Loctite #243). Tighten to speci-

fications.

8-42

AF428

19. Install the chain tensioner arm, apply blue Loctite

#243 to the stud threads, and tighten the shoulder

nut to specifications.

20. Remove the set screw from the chain adjuster

housing and install the adjuster plug.

21. Check that the chain-case O-ring seal is positioned

correctly on the housing.

22. Position the shift fork behind the large thrust

washer and bearing on the reverse gear; then posi-

tion the cover on the housing.

AF075

23. Apply blue Loctite #243 to the threads of the cap

screw; then install the cap screw through the cen-

ter of the cover and into the idler shaft. Tighten the

cap screw enough to draw the idler shaft into the

cover.

24. Place the shift pivot and reverse switch bracket

into position on the cover; then secure the chain-

case cover with cap screws and lock washers.

Tighten the cap screws to specifications.

25. Place the shift linkage into position on the back

side of the arm and secure with a cap screw and

lock nut. Tighten to specifications.

26. Place the reverse lever into position on the shift

pivot and secure with a clevis pin and cotter pin.

27. On the PTO-side of the track driveshaft, slide the

lock collar against the bearing, drive the collar in

the direction of rotation until tight, and tighten the

collar set screw.

AF054

28. Install the skid frame (see Section 9).

29. Remove the hold-down strap securing the air-

intake silencer; then place the silencer into posi-

tion making sure the boot is properly positioned on

the carburetor/throttle body assembly. Secure the

silencer to the steering support with the two

screws.

30. Apply a light coat of grease or Loctite Anti-Seize

Thread Compound (p/n 0678-146) to the driven

shaft; then install the driven shaft alignment wash-

ers (as required) and key. Install the stub shaft and

the driven pulley, alignment washers (as required),

washer, and cap screw (coated with blue Loctite

#243). Tighten to specifications.

„NOTE: Make sure the keyways match when
installing the driven pulley. Arrange washers to
allow the least amount of float on the driven shaft.
A maximum of 1.5 mm (0.060 in.) float is allowable.

SC013D

31. Check the alignment of the drive clutch/driven

pulley (see appropriate Drive Clutch/Driven Pul-

ley in this section).

32. Assure that the chain case drain plug is tightened

to specifications; then pour 354 ml (12 fl oz) of

Arctic Cat Transmission Lube (p/n 0636-817) into

the chain case.

33. Install the drive belt and check belt deflection.

Secure the belt guard.

34. Install and secure the battery tray and battery; then

connect the battery cables making sure to connect

the positive cable first.

8-43

8

ADJUSTING REVERSE LINKAGE

1. Start the engine; then test the shifting characteris-

tics of the reverse transmission.

2. If adjustment of the reverse gear is necessary, stop

the engine and remove the chain case inspection

plug located behind the oil level stick; then insert

the Reverse Gear Adjustment Gauge (p/n 0644-

244) completely into the inspection hole.

0731-734

3. Pull the shift lever into the reverse position while

holding the adjustment gauge firmly against the

chain case cover. Slight outward pressure should

be felt on the gauge as the lever locks into reverse.

4. If no contact is noted, loosen the jam nuts securing

the lower shift linkage and adjust the linkage rod

until the gauge is pushed out of the chain case

0.254-0.381 mm (0.010-0.015 in.). Lock the

adjustment by tightening the jam nuts securely

against the tie rod ends.

„NOTE: To adjust the linkage rod, the shift lever
must be moved to the forward position.

5. Install the inspection plug.

6. Start the engine; then test the shifting characteris-

tics of the reverse transmission. Adjust as neces-

sary.

Drive Train/Brake Disc 

(Standard w/o Reverse)

DISASSEMBLING

1. Remove the chain-case drain plug (located on the

lower back side of the chain case inside the tunnel)

and drain the chain case lubricant.

2. Open the belt guard and remove the drive belt.

3. Remove the cap screw and washer securing the

driven pulley; then account for and note the posi-

tion of any alignment washers.

SC013D

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

remove the driven pulley from the engine com-

partment. Account for the stub shaft, key, 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

5. Remove the cap screws and lock washers securing

the chain-case cover; then remove the cover.

AF111D

6. Loosen the mechanical chain tensioner bolt; then

remove the cotter pins and washers securing the

tensioner spring to the link pins. Remove the

spring, rollers, and washers.

! CAUTION

The linkage must be properly adjusted. If the linkage
is too short, damage to the shift fork may occur. If
the linkage is adjusted too long, the gears will not
shift totally into reverse.