Drive Train/Track/Brake Systems This section has been organized into sub-sections for servicing drive train, track, and brake systems; however, some components may vary from model to model. The technician should use discretion and sound judgment when removing and installing components. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
REMOVING 1. With the engine off, open the left-side access panel; then remove the belt guard. Loosen the quarter turn screws on the lower console. 2. Remove the cap screw, lock washer and sheave adjuster from the end of the driven clutch; then remove the cap screw, lock washer, and washer from the adjuster. NOTE: Ensure the shims and O-ring are not removed from the adjuster.
SPECIAL TOOLS A number of special tools must be available to the technician when servicing the drive train, track, and brake systems. Description
p/n
Drive Clutch Bolt Tool
0644-281
Driven Shaft Bearing Spanner Wrench Kit - Socket
0644-516
Bearing Removal and Installation Tool
0644-167
Movable Sheave Bearing Tool
0644-594
Brake Disc Socket Wrench
0644-481
Clutch Alignment Bar
0644-428
Drive Clutch Puller
0744-062
Drive Clutch Spanner Wrench
0644-136
Driven Clutch Compressor Tool
0644-444
Driven Clutch Puller
0644-469
Clutch Alignment Bar (Parallelism)
0644-509
Rear Suspension Spring Tool
0144-311
Reverse Gear Adjustment Gauge
0644-244
Roller Pin Removal Tool
0644-276
Gear Case Drain Fitting
0644-552
Deep Socket
0444-237
Brake Caliper Bearing Puller
0744-067
0743-395
3. Reverse the adjuster and install the cap screw without washers into the adjuster. Install the sheave adjuster and cap screw onto the driven clutch; then tighten the cap screw until the movable sheave opens far enough to allow the belt to be removed. 4. Remove the drive belt from the driven clutch first; then from the drive clutch. INSTALLING NOTE: When installing a new drive belt, see After Break-In Checkup - Drive Belt Break-In in the General Information section.
NOTE: Special tools are available from the Arctic Cat Service Parts Department.
1. Place the drive belt (so the arrow is pointing toward the front of the snowmobile) on the drive clutch; then between the sheaves of the driven clutch.
CAUTION
2. Install the sheave adjuster in its original position (beveled side out); then install the cap screw, lock washer, and washer into the driven clutch. Tighten the cap screw to 20 ft-lb.
Never attempt to substitute any other drive clutch puller for the recommended puller or severe clutch damage will occur.
Drive Belt
CAUTION Do not apply Loctite to the driven clutch cap screw or component damage may occur.
If the drive belt is longer than specified, the drive clutch and driven clutch will not achieve full shift ratio. This will result in poor acceleration and a decrease in top speed.
3. Install the belt guard; then close the left-side access panel.
If the drive belt is shorter than specified, the starting ratio will be higher causing the belt to slip. A too-short drive belt will cause a bog on engagement and will not allow the engine to reach peak RPM.
Never operate the snowmobile without the belt guard/ access panel secured in place.
NOTE: A thinly-worn drive belt may produce the same effect as one that is too long. NOTE: A stiff belt causes a HP loss to the track. As a belt warms up, it gets more flexible and transmits power with less HP loss.
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! WARNING
