126
Drive and Brake Systems
GENERAL INFORMATION
The die-cast aluminum housings have been assembled
with thread-rolling screws (trilobular). When assembling
with these screws, start the screws carefully into the hous-
ing; then use the following torque values.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appropri-
ate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Front Drive Actuator
NOTE: The actuator is not a serviceable compo-
nent. If it is defective, it must be replaced.
NOTE: The actuator will operate only when the igni-
tion switch is in the ON position.
The front drive actuator is located on the left side of the
front differential input housing. With the engine stopped
and the ignition switch in the ON position, a momentary
“whirring” sound can be heard each time the drive select
switch is shifted. If no sound is heard, see Electrical Sys-
tem. If the actuator runs constantly or makes squealing or
grinding sounds, the actuator must be replaced.
REMOVING
1. Select LOCK on the drive select switch; then discon-
nect the connector on the actuator harness.
2. Using a T-30 torx wrench, remove the mounting cap
screw from the driveshaft side of the actuator.
PR189A
3. Remove the mounting cap screw from above the actu-
ator on the suspension side.
PR190A
4. Loosen but do not remove the mounting cap screw at
the front of the actuator; then slide the actuator to the
rear enough to clear the slotted mounting tab and the
selector shaft. Remove from the right side.
AG928
INSTALLING
1. Lubricate the O-rings on the actuator; then ensure all
mounting surfaces are clean and free of debris.
2. Align the actuator with the selector shaft and slide it
forward onto the shaft taking care to engage the cap
screw in the slot of the front mounting tab.
NOTE: Make sure to properly align the differential
lock actuator lever with the hole in the differential
lock plunger.
Size
New Housing
Reassembled Housing
M6 (Torx T-30 Recess)
9 ft-lb
8 ft-lb
M8 (Torx T-40 Recess)
28 ft-lb
23 ft-lb
Description
p/n
Backlash Measuring Tool (24-Spline Axle)
0544-010
Backlash Measuring Tool (27-Spline Axle)
0544-011
CV Boot Clamp Tool
0444-120
Hose Clamp Pliers
0644-545
Internal Hex Socket
0444-104
Pinion Gear/Shaft Removal Tool
0444-127
Gear Case Seal Installer Tool
0444-224
