Drive Chain And Sprockets (Models With Reverse) - Arctic Cat Cougar Service Manual

374
NOTE
Engage the brake to hold the shafts from
turning when tightening the retaining
nuts or screws in Step 5.
5. Install the washers and retaining nuts (A and
B, Figure 5) or bolts. Tighten to the torque listed
in Table 2.
6A. On models with manual tension adjustment,
install and adjust the chain tensioner assembly as
follows:
a. Install the tensioner assembly (24, Figure
1) and tighten the self-locking nut (26, Fig-
ure 1).
b. Tum the adjusting screw (33, Figure 1) in
finger-tight. Lock the position by tighten-
ing the locknut (34, Figure 1).
6B. On models with automatic chain adjustment,
install the chain tensioner at the rear (24, Figure
1).
On these models, the unit is similar to the
front unit (25, 26, 27, 28, 29, 41, 42 and 43,
Figure 1).
7. Install the front roller assembly (25, 26, 27,
28, 29, 41, 42 and 43, Figure 1).
8. Install the inner washers (22, Figure 1).
9. Attach the spring tensioner (C, Figure 3).
Install the outer washers (22, Figure 1) and
cotter pins (21, Figure 1).
10. Install the dropcase cover together with the
seal ring (20, Figure 1). Make sure the seal fits
in the groove properly. Install the cover and its
attaching screws. Tighten the screws securely.
11. Fill the dropcase with the amount and type
of gear oil specified in Chapter Three.
12. Close and secure the hood.
DRIVE CHAIN AND SPROCKETS
(MODELS WITH REVERSE)
Removal
Refer to Figure 8 when performing this pro-
cedure.
1. Open the hood.
CHAPTER FOURTEEN
2. Disconnect the shift linkage from the shift
fork shaft on the dropcase.
3. Remove the screw (25, Figure 8) from the
center of the dropcase cover.
4. Remove the drain plug (75, Figure 8). On
some models, the drain plug may be located in
the cover.
5. Place shop rags under the dropcase cover to
absorb any spilled oil.
NOTE
The dropcase is filled with oil that will
spill when the dropcase cover is re-
moved. Use rags to absorb as much
spilled oil as possible.
6. Remove the screws securing the cover (8,
Figure 8).
7. Remove the cover and gasket (3 and 16, Fig-
ure 8). Discard the gasket. Pull the cover up as
it is being removed so the shift fork will clear the
internal mechanism.
8. Clean up as much oil as possible before pro-
ceeding with the removal.
9. Remove the spacer washer (27, Figure 8)
from the idler sprocket shaft.
1 OA. On models with an external chain tensioner
(Figure 9), proceed as follows:
a. Remove screw (8, Figure 9) and install a
setscrew in place of the original screw.
Tighten the setscrew sufficiently to hold the
adjuster shaft in position.
b. Remove the adjuster assembly by turning
the housing (7, Figure 9) counterclockwise
using a 3/4-inch wrench.
1 OB. On models with an internal chain tensioner,
lift the chain tensioner off the ratchet block (90,
Figure 8) and hold it against the chaincase with
locking pliers (Figure 10).
11. Engage the brake to hold the shaft, then
remove the nut and lockwasher ( 17 and 18, Fig-
ure 8) from the top shaft.
NOTE
The lower sprocket bolt and washer are
spring loaded. Hold the bolt and washer