Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 121

8-104

AF462D

7. Secure the brake lever with the pin, washer, and

retaining ring.

AL138D

AL137D

8. Secure the handlebar pad to the handlebar with the

Phillips-head screws.

9. Apply Handlebar Grip Adhesive (p/n 0636-071) to

the bore of the handlebar grip; then using a rubber

hammer, drive the grip into position.

! WARNING

The handlebar adhesive is extremely flammable. The
product contains acetone and the vapors, when
released, can be easily ignited. Keep away from
heat, sparks, and open flame. Use only in a well-ven-
tilated area. Avoid prolonged breathing of vapor.
Avoid eye and skin contact. Keep container closed
when not in use.

8-105

8

Troubleshooting Drive 

Clutch/Driven Pulley

Problem: Midrange Shift-Up (Too Quickly - Lowers RPM)

Condition

Remedy

1. Drive clutch spring weak

1. Replace drive clutch spring

2. Driven pulley spring weak

2. Replace driven pulley spring

3. Driven pulley spring preload tension inadequate

3. Increase spring preload tension

4. Center-to-center distance too close

4. Adjust center-to-center distance

5. Driven pulley bearing worn — damaged

5. Replace bearing — movable sheave

Problem: Midrange Shift-Up (Too Slowly - Raises RPM)

Condition

Remedy

1. Drive clutch components dirty

1. Clean drive clutch components

2. Driven pulley components dirty

2. Clean driven pulley components

3. Driven pulley spring preload tension excessive

3. Decrease spring preload tension

4. Driven pulley bearing worn — dirty

4. Clean — replace bearing — movable sheave

Problem: Excessive Belt Deposits

Condition

Remedy

1. Offset adjusted incorrectly

1. Adjust offset

2. Drive clutch/driven pulley sheaves rough — dam-

aged — dirty

2. Repair — replace — clean drive clutch/driven pulley

3. Driven pulley movable sheave travel impaired

3. Service driven pulley

4. Driven pulley bearing worn — dirty

4. Clean — replace bearing — movable sheave

Problem: Excessive Belt Drag—Impaired Drive Clutch Disengagement

Condition

Remedy

1. Drive clutch components dirty — damaged

1. Clean — replace drive clutch components

2. Drive belt does not meet measurement specifications

2. Replace drive belt

Problem: Engine RPM Suddenly Increases—Drive Clutch Vibrates

Condition

Remedy

1. Cam arm pin bent — damaged

1. Replace pin

2. Cam arm damaged — broken

2. Replace cam arm

3. Drive clutch out of balance

3. Align — replace components — drive clutch

Problem: Driven Pulley Vibrates

Condition

Remedy

1. Sheave rivets loose — broken

1. Replace sheave

2. Driven pulley out of balance

2. Service — replace driven pulley

8-106

Troubleshooting

Drive Belt

Problem: Drive Clutch Engagement (Before Specified RPM)

Condition

Remedy

1. Drive clutch spring weak — bent

1. Replace spring

2. Cam arms incorrect — worn

2. Replace cam arms

Problem: Drive Clutch Engagement (After Specified RPM)

Condition

Remedy

1. Drive clutch spring incorrect

1. Replace spring

2. Spider buttons worn

2. Replace buttons

Problem: Drive Clutch Sticks

Condition

Remedy

1. Drive clutch components dirty

1. Clean drive clutch components

2. Movable sheave bent — binding

2. Clean — replace movable sheave

3. Spider buttons worn

3. Replace buttons

Problem: Drive Clutch Jerks—Shifts Erratically

Condition

Remedy

1. Drive clutch dirty

1. Clean — drive clutch components

2. Rollers worn

2. Replace rollers

3. Cam arms rough

3. Polish — replace cam arms

4. Spider buttons worn

4. Replace buttons

5. Sheaves dirty

5. Clean sheaves

Problem: Drive Belt Glazed

Condition

Remedy

1. Drive belt does not meet measurement specifications

1. Replace drive belt

2. Drive clutch spring tension inadequate

2. Replace drive clutch spring

3. Drive clutch components dirty — damaged

3. Clean — replace drive clutch

4. Offset — parallelism — center-to-center distance

adjusted incorrectly

4. Adjust offset — parallelism — center-to-center dis-

tance

Problem: Drive Belt Lugs Torn Off—Frayed—Worn in One Spot

Condition

Remedy

1. Drive belt does not meet measurement specifications

1. Replace drive belt

2. Offset — parallelism — center-to-center distance

adjusted incorrectly

2. Adjust offset — parallelism — center-to-center dis-

tance

3. Drive clutch engagement — idle RPM too high

3. Service drive clutch — reduce idle RPM

4. Drive clutch components dirty — damaged

4. Clean — replace drive clutch components

5. Driven pulley/shaft rotation impaired

5. Service driven pulley/shaft — chain-case components

6. Drive belt damaged from improper break-in

6. Replace drive belt

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8

Troubleshooting

Hydraulic Brake System

Problem: Caliper Leaks

Condition

Remedy

1. Caliper O-ring deteriorated — severed

1. Replace O-ring

2. Piston — O-ring damaged

2. Repair piston — replace piston — O-ring

Problem: Lever Spongy — Bottoms Out

Condition

Remedy

1. Brake system air bubbles present

1. Bleed brake system

2. Master cylinder damaged — faulty

2. Replace master cylinder

Problem: Oscillation Feedback in Lever

Condition

Remedy

1. Brake pad residue present on brake disc

1. Replace pads — clean disc

2. Caliper loose

2. Tighten mounting bolts

3. Brake disc warped — cracked — damaged — mis-

aligned

3. Replace disc — driven shaft bearing

Problem: Loss of Brake

Condition

Remedy

1. Brake fluid overheated — contaminated

1. Replace fluid

2. Master cylinder damaged — faulty

2. Replace master cylinder

3. Caliper — brake hose leaking

3. Replace caliper O-ring — repair piston —replace pis-

ton — O-ring — brake hose

4. Air ducts obstructed — missing

4. Remove obstruction — replace air ducts

5. Brake lever linkage damaged

5. Repair — replace lever — mounting bolt

Problem: Brakes Drag

Condition

Remedy

1. Master cylinder damaged — faulty

1. Replace master cylinder

2. Brake disc warped — damaged — misaligned

2. Replace disc — driven shaft bearing

3. Brake pads worn — tapered

3. Replace pads

Problem: Snowmobile Won’t Stop — Have to Pull Too Hard on Lever

Condition

Remedy

1. Pads/brake disc glazed

1. Replace pads — clean disc

2. Brake lever binding

2. Loosen pivot bolt — replace master cylinder

3. Caliper pistons binding

3. Service caliper assembly