Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 111

8-64

FS268A

13. Remove the seven lock nuts securing the gear case

to the chassis; then remove the remaining lock nut

and torx-head cap screw.

0742-017

14. 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.

15. Remove the cap screw from the inner driveshaft

(from step 4); then remove the gear case.

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

16. With the gear case removed, pull the driveshaft

toward the gear case side of the tunnel until it

clears the brake caliper housing; then remove the

driveshaft. Account for the rubber seal. 

ZJ212

INSTALLING TRACK DRIVESHAFT 

„NOTE: Prior to installing the driveshaft, apply a
coat of Anti-Seize Thread Compound (p/n 0678-
146) to the internal splines of the driveshaft.

ZJ213A

1. Place the track/driveshaft assembly into the bear-

ing of the brake housing just far enough to allow

the brake disc to be installed in the brake housing

assembly. 

ZJ214A

„NOTE: Prior to installing the driveshaft, ensure
that the bearing spacer is positioned to the inner
bore of the brake caliper housing.

2. With the brake lever lock engaged and the brake

disc positioned in the brake housing assembly, prop-

erly align the splines of the driveshaft with the brake

disc; then push the driveshaft the rest of the way

into the brake housing until it is properly seated.

ZJ215A

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8

„NOTE: Prior to placing the gear case onto the
driveshaft, apply a light coat of Anti-Seize Thread
Compound (p/n 0678-146) to the splines of the ring
gear shaft.

3. Place the gear case onto the driveshaft; then press

the gear case toward the sprocket until it properly

seats into place on the chassis. It may be necessary

to rotate the driveshaft slightly for proper seating.

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.

0742-017

„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); then install the left-side

footrest cover and secure with the screws.

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 ring gear with the cap

screw (coated with blue Loctite #243) and washer.

Tighten to specifications.

742-020A

10. Install the torque bumper behind the engine

mounting block; then carefully work it into place

with the aid of a flat-blade screwdriver.

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.

! 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.

8-66

ZJ250A

14. Install the drive belt.

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 torx-head cap screw securing the shift

actuator to the gear case and remove the actuator;

then remove the gear indicator switch.

FS269A

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.

0742-196

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.

! CAUTION

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

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8

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

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.

! CAUTION

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