Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 110

8-60

ZJ207

15. With the dowel pins in place, install the cover to

the gear case and secure with 13 torx-head cap

screws; then in a crisscross pattern, tighten to

specifications.

742-195A

16. Install the shift actuator and secure with the three

torx-head cap screws. Tighten to specifications.

Install the gear indicator switch; then tighten to

specifications.

ZJ186A

17. Pour 354 ml (12 fl oz) of Arctic Cat ACT Drive

Fluid (p/n 4639-025) into the drain/fill hole; then

install the plug. Tighten securely.

INSTALLING GEAR CASE

1. Using a Scotch Brite pad, clean the gear case/drive

unit seal-mating surface on the track driveshaft;

then thoroughly wipe clean.

„NOTE: Prior to placing the gear case onto the
driveshaft, apply a light coat of Arctic Cat Low-
Temp Snowmobile Grease (p/n 0636-593) to the
internal splines of the track driveshaft.

2. Align the gear case output shaft with the splines of

the track driveshaft and position the gear case onto

the mounting studs. Making sure the sensor wires

do not become pinched under the gear case, push

inward on the gear case until it is seated.

3. Using a rubber mallet, lightly tap inward on the

gear case to ensure that is fully seated to the chas-

sis.

4. Loosely secure the gear case by first installing the

six lock nuts and finger tighten; then install the

torque bumper  and a torx-head cap screw and the

two remaining lock nuts and tighten all the nuts to

specifications.

742-018A

„NOTE: When tightening the nuts to the proper
torque factor, it is advisable to begin tightening the
nuts located on the bottom of the gear case and
working upward in a crisscross pattern until all
nuts are tightened to the proper torque factor.

5. Connect shift actuator harness (A) and gear indica-

tor switch harness (B).

! CAUTION

Care must be taken not to allow silicone sealant into
the cap screw holes and dowel pin holes or damage
to the gear case may occur when tightening the cap
screws.

! CAUTION

Do not add more or less than the recommended
amount of drive fluid to the gear case or damage to
the gear case will occur.

8-61

8

ZJ183A

6. Slide the driven pulley onto the input shaft making

sure alignment washers are in place.

7. Secure the driven pulley with components and

hardware as noted in removing. Tighten to specifi-

cations.

ZJ250A

8. Install the drive belt.

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

9. Install the toe shield and toe hook bracket; then

install the torx-head cap screws. Tighten securely.

0742-089

10. Install the 16 mm cap screw (coated with blue

Loctite #243) securing the driveshaft to the gear

case output shaft; then tighten to specifications.

0742-020

11. Install the side panels.

„NOTE: If the track was loosened to aid in remov-
ing the gear case, tighten track to proper tension
and alignment.

Drive Train/Brake Disc 

(Crossfire/M-Series)

Removing Gear Case............................................ 8-61
Removing Track Driveshaft ................................... 8-62
Installing Track Driveshaft ..................................... 8-64
Disassembling Gear Case..................................... 8-66
Cleaning and Inspecting Gear Case ..................... 8-68
Removing Drive Sprockets .................................... 8-69
Installing Drive Sprockets ...................................... 8-69
Assembling Gear Case ......................................... 8-71
Installing Gear Case.............................................. 8-73

REMOVING GEAR CASE

„NOTE: The gear case drive fluid does not have to
be drained for this procedure.

1. Remove the access panels from both sides of the

snowmobile.

„NOTE: At this point, engage the brake lever lock.

2. Remove the belt guard; then using a 9/16-in.

socket and extension, remove the cap screw secur-

ing the driven pulley to the driven shaft. Remove

the pulley from the driven shaft.

! CAUTION

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

8-62

MS291

„NOTE: Account for and remove any alignment
washers. These washers must be used during
installing.

3. Remove the left-side footrest cover; then discon-

nect the plug-ins for the shift actuator (A) and the

gear indicator switch (B).

FS268A

„NOTE: Either elevate the snowmobile off the floor
with a suitable lift or tip the snowmobile on its
right side positioning the gear 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.

4. Release the pressure on the torque bumper

(located between the gear case and left-side engine

plate) by lifting upward on the engine plate with a

short pry bar; then remove the bumper.

MS299

5. Loosen but do not remove the 16 mm cap screw

(from the brake disc side of the inner driveshaft)

securing the driveshaft to the gear case.

. 

742-020A

6. Remove the lock nuts securing the gear case to the

chassis; then remove the remaining lock nut and

torx-head cap screw.

0742-017

7. Place the snowmobile in the upright position; then

using a 16 mm socket, long extension, and a soft

hammer, tap against the driveshaft cap screw until

the gear case is free from the studs of the mounting

plate.

8. Remove the cap screw from the inner driveshaft

(from step 5); then remove the gear case.

„NOTE: If the gear case is difficult to remove, it
may be necessary to loosen the track tension.

REMOVING TRACK DRIVESHAFT 

„NOTE: The gear case drive fluid does not have to
be drained for this procedure.

1. Remove the access panels from both sides of the

snowmobile.

2. Remove the springs securing the resonator; then

remove from the engine compartment.

„NOTE: At this point, engage the brake lever lock.

3. Remove the two cap screws securing the speedom-

eter sensor bracket. Account for two spacers.

8-63

8

ZJ210A

4. Loosen but do not remove the 16 mm cap screw

(from the brake disc side of the inner driveshaft)

securing the driveshaft to the gear case.

. 

742-020A

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

remove the retaining nut from the driveshaft.

ZJ211

6. Using the Rear Suspension Spring Tool (p/n 0144-

311), remove the spring from the adjusting cam.

AG624DA

7. Remove the rear cap screws securing the skid

frame to the tunnel. Account for lock washers and

flat washers.

8. Remove the front cap screws securing the skid

frame to the tunnel. Account for a flat washer and

a lock nut.

9. Tip the snowmobile onto the right side positioning

the gear case side of the snowmobile up. Place a

piece of cardboard under the side of the snowmo-

bile to protect against scratching. Remove the skid

frame.

10. Using a 9/16-in. socket and extension, remove the

cap screw securing the driven pulley to the driven

shaft.

ZJ182A

11. Slide the driven pulley off the driven shaft.

„NOTE: After removing the driven pulley, account
for the cap screw and washers, sheave adjuster,
alignment washers, and O-ring from outside the
pulley; then from the input shaft, remove the two
1.5 mm (0.060 in.) washers along with any other
alignment washers. These washers must be used
during installing.

12. Remove the left-side footrest cover; then discon-

nect the plug-ins for the shift actuator (A) and the

gear indicator switch (B).

! WARNING

Care must be taken when removing the spring or
damage or injury could result.