Arctic Cat Cougar Service Manual page 385

BRAKE, DRIVEN SHAFT, DROPCASE AND DRIVESHAFT
375
during removal in Step 12 to prevent
parts from flying off.
12. Loosen the bolt ( 46, Figure 8) securing the
lower sprocket. Carefully remove the bolt, lock-
washer, retainer and spring.
13. Remove the reverse gear (Figure 11) from
the driveshaft extension.
14. Remove the upper sprocket, drive chain and
idler gears. Be sure the alignment pin (30, Figure
8), located between the two idler gears, is not
lost.
15. Remove the driveshaft extension, lower
sprocket and spacer washer (54, 56 and 63, Fig-
ure 8).
16A. On models with an external chain tensioner
(Figure
9),
unscrew the shoulder nut ( 19, Figure
9) and remove the tensioner arm assembly (12,
Figure
9).
16B. On models with an internal chain tensioner,
release the locking pliers from the tensioner as-
sembly and remove the tensioner assembly as
follows.
a. Use needlenose pliers to unhook the spring
(88, Figure 8).
b. Remove the shoulder nut (84, Figure 8),
then remove the tension roller assembly.
c. If necessary, remove the nut (81, Figure 8)
and disassemble the roller assembly.
Inspection
Refer to Figure 8 for this procedure.
1. Clean all components thoroughly in solvent.
Remove any gasket residue from the cover and
housing surfaces.
2. Inspect the upper and lower sprockets, idler
gears and reverse gear for cracks, deep scoring,
excessive wear or tooth damage.
3. Inspect the shaft splines for damage.
4. Check the lower sprocket drive pins for
rounding, scoring or excessive wear. The pins are
spring-loaded and must move without any sign
of binding or roughness. Check pin movement
by pressing the pins by hand.
5. Check all bearings by turning the race by
hand. Bearings should operate smoothly.
6. Inspect the reverse gear (53, Figure 8) as
follows:
a. Remove the snap ring (50, Figure
8),
outer
washer (51, Figure
8),
bearing (52, Figure
8)
and inner washer (51, Figure
8)
from the
reverse gear. Check the washers and bear-
ing for roughness or excessive wear. Install
the bearing and washers as an assembly.
b. Check the reverse gear pin holes for chip-
ping, rounding or other wear. Install a new
reverse gear, if necessary.
7. Assemble the reverse gear as follows:
a. Oil the bearing and washers before assem-
bling.
b. Install the inner washer, followed by the
bearing and outer washer.
c. Install the snap ring making sure it seats
firmly in the gear.
8A. On models equipped with an external chain
tensioner (Figure 9), turn the chain tension roller
(14, Figure 9) and check the condition of the
roller and the bearing for smoothness.
8B. Check the internal chain tensioner on models
so equipped as follows:
a. Turn the chain tension roller (79, Figure 8)
and check the condition of the roller and the
bearing for smoothness.
b. Check the ratchet block (90, Figure 8) for
damage and replace as necessary.
c. Check the brackets and spring for signs of
damage and replace as necessary.
d. Disassemble and replace parts as necessary.
9. Check the shift fork for wear or damage at the
tips of the fork. Replace the shift fork, if it is
damaged.
10. Check the shift fork shaft movement. If the
shaft binds or is damaged, remove the roll pin
(12, Figure 8) securing the fork and separate the
parts.