26
9. Install the driven clutch; then install
the drive belt (see Drive Belt sub-
section in the Maintenance section)
and the belt guard.
10. Install the left-side access panel;
then close the access panel.
11. Position the tips of the skis against a
wall; then using a shielded safety
stand, raise the rear of the snowmo-
bile off the floor making sure the
track is free to rotate.
12. Start the engine and accelerate
slightly. Use only enough throttle to
turn the track several revolutions.
SHUT ENGINE OFF.
13. Open the left-side access panel; then
remove the panel and the belt guard.
14. Remove the drive belt (see Drive Belt
sub-section in the Maintenance sec-
tion); then remove the driven clutch.
15. Using Handlebar Stand (p/n 5639-
152) or a suitable substitute, tip the
snowmobile onto its right side.
16. Remove the drain plug from the gear
case; then install the drain adapter fit-
ting with hose into the drain plug hole.
17. Tip the snowmobile back to the
upright position; then place a drain
pan on the floor next to the drain
hose and tip the snowmobile toward
its left side far enough to allow the
flush fluid to drain from the gear
case into the drain pan.
18. Secure the snowmobile in this posi-
tion until the flush fluid is com-
pletely drained.
19. When the fluid has completely
drained from the gear case, tip the
snowmobile back to the upright
position, remove the drain adapter,
and install and securely tighten the
drain plug; then remove the check/
fill plug.
20. Pour the exact amount of Arctic Cat
Synthetic ACT Gear Case Fluid into
the check/fill hole; then install the
plug. Tighten securely.
21. Install the driven clutch; then install
the drive belt (see Drive Belt sub-
section in the Maintenance section)
and the belt guard.
22. Install the left-side access panel;
then close the access panel.
Front Suspension
NOTE: Arctic Cat recommends
that Arctic Cat All-Temp Grease (p/n
4639-365) be used for this proce-
dure.
It is very important that the front suspen-
sion is greased on a monthly basis using
all-temperature grease. The front suspen-
sion should also be greased after traile-
ring the snowmobile on an open trailer.
Pump grease into the spindle grease fit-
ting (both sides) until grease is noted
coming out of the top and bottom of the
spindle. Wipe excess grease from the
spindle.
! WARNING
The tips of the skis must be positioned
against a wall or similar object.
! WARNING
DO NOT stand behind the snowmo-
bile or near the rotating track. NEVER
run the track at high speed when the
track is suspended.
CAUTION
It is critical that all of the flush fluid
be drained from the gear case prior to
filling with new lubricant.
CAUTION
The correct lubricant to use in the
gear case is Arctic Cat Synthetic ACT
Gear Case Fluid (see chart). Any sub-
stitute may cause serious damage to
the drive system.
Gear Case Lubricant
Model
p/n
Amount
5000
4639-628 354 ml (12 fl oz)
2000
5639-219 444 ml (15 fl oz)
CAUTION
Do not add more or less than the rec-
ommended amount of lubricant to the
gear case or damage to the gear case
will occur. Oil level should be at the
Oil Fill Level on the gear case cover.
