Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 108

8-52

ZJ183A

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

7. Apply Anti-Seize Thread Compound (p/n 0678-

146) to the threads of the brake disc retaining nut;

then install the nut.

8. Using Brake Disc Socket Wrench (p/n 0644-481),

tighten the brake disc retaining nut to specifica-

tions.

MS323

„NOTE: After the retaining nut is tightened to
specifications, peen the nut at the flat spot of the
driveshaft.

9. Secure the driveshaft to the output shaft with the

cap screw (coated with blue Loctite #243) and

washer. Tighten to specifications.

742-020A

10. Place the resonator into position and secure with

the springs and hairpin clip.

11. Install the speedometer sensor mounting bracket

(with two spacers); then secure with the two cap

screws. Tighten to specifications.

12. Slide the driven pulley onto the input shaft making

sure alignment washers are in place.

13. Secure the driven pulley with components and

hardware as noted in removing. Tighten to specifi-

cations.

ZJ250A

14. Install the drive belt.

„NOTE: For installing drive belt, see Removing/
Installing Drive Belt (ACT Roller Driven Pulley) in
this section.

15. Place the access panels into position and secure

with existing hardware.

16. Check the track for alignment and recommended

tension; then tighten the cap screws securely (see

Section 9).

DISASSEMBLING GEAR CASE

1. Remove the three torx-head cap screws securing

the shift actuator to the gear case and remove the

actuator; then remove the gear indicator switch.

ZJ186A

! CAUTION

It is critical that no less than two 1.5 mm (0.060 in.)
washers are in place on the input shaft when install-
ing the driven pulley.

8-53

8

2. Remove the 13 torx-head cap screws securing the

gear case cover to the gear case assembly; then

insert two flat-blade screwdrivers into the slots on

the gear case. Working back and forth, pry the

cover up and off the gear case.

742-195B

3. Drain the gear case fluid into a suitable container.

4. Remove the shift fork assembly; then remove the

retaining ring securing the shift fork arm to the

shaft and remove the arm. Account for the retain-

ing rings, O-ring, and slider blocks.

ZJ300

„NOTE: For assembling purposes, note the posi-
tion of the slider blocks on the shift fork arm.

5. Secure the gear case cover in a suitable clamping

device; then using two flat-blade screwdrivers

from opposite sides of the cover bearing, evenly

pry the input shaft bearing up and off the shaft.

ZJ189

6. With a cap screw threaded into the input shaft and

using a soft hammer, drive the input shaft out of

the gear case cover.

ZJ190

7. Using a suitable bearing press and fixture, press

the input shaft bearing out of the gear case cover.

Account for a bearing and a seal.

ZJ191

MS331

! CAUTION

If the input shaft bearing is removed, always replace
it with a new one or severe component damage may
occur.

8-54

8. Secure the gear case in a suitable clamping device;

then using the procedure from step 5, remove the

outer bearing from the transfer gear.

ZJ192

9. Place the gear case on its side; then using a soft

hammer, tap the output shaft until the slider and

output gear assembly come free of the gear case.

ZJ193

10. Remove the output gear assembly from the slider

housing.

ZJ194

11. Using a suitable bearing puller, remove the inner

bearing from the transfer gear assembly. Account

for a spacer washer.

ZJ195

12. Remove the transfer gear from the planetary gear

assembly and account for the thrust washer and

thrust bearing.

ZJ196

„NOTE: For assembling purposes, note that the
thrust bearing is positioned between the thrust
washer and the gear assembly.

ZJ197

13. Remove the retaining ring and thrust washer

securing the slider housing assembly to the output

shaft assembly.

! CAUTION

If any transfer gear bearings are removed, always
replace them with new ones or severe component
damage may occur.

8-55

8

ZJ200

14. Using a suitable puller, remove the bearing from

the output shaft.

15. Using a suitable seal removing tool, remove the

output shaft seals from the gear case.

ZJ204

CLEANING AND INSPECTING GEAR 

CASE

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

„NOTE: The planetary gear assembly is a non-ser-
viceable component. If any damage or wear is
detected, it must be replaced.

1. Wash the gear case halves in parts-cleaning sol-

vent.

2. Inspect the gear case halves for scoring, pitting,

scuffing, or any imperfections in the casting.

3. Inspect all threaded areas for damaged or stripped

threads.

4. Inspect the bearing areas for cracks or excessive

bearing movement. If evidence of excessive bear-

ing movement is noted, replace the component.

5. Inspect the sealing surfaces of the gear case halves

for trueness.

6. Wash the unsealed gear case bearings in parts-

cleaning solvent.

7. Inspect the input shaft/transfer gear bearings for

wear, scoring, scuffing, damage, or discoloration.

Rotate the bearings. Bearings must rotate freely

and must not bind or feel rough. If any abnormal

condition is noted, replace the bearing.

„NOTE: The output shaft bearing is a non-service-
able component. If any damage or binding is
noted, the output shaft assembly must be
replaced.

8. Apply a light film of Arctic Cat ACT Drive Fluid

(p/n 4639-025) to the unsealed bearings prior to

assembling.

REMOVING DRIVE SPROCKETS

„NOTE: The drive sprockets must be removed
from the gear case end of the driveshaft.

ZJ216A

1. For installing purposes, scribe a line on the drive-

shaft (A) next to the drive sprocket for proper

alignment; then scribe a line on the driveshaft

directly in line with the timing arrows (B) on the

drive sprockets for proper sprocket timing.

MS357A

2. Using a suitable press positioned against the ten-

sion-collar of the drive sprocket (located on the

gear case) and of the driveshaft, press the drive

sprockets off the driveshaft.