®

ARCTIC CAT Special

Tools
Catalog

Snowmobile

Effective Date: May, 2004

 FOREWORD
This publication is designed to help authorized Arctic Cat Snowmobile dealers in identifying the special tools avail-
able from Arctic Cat Inc. Each of these special tools is identified by part number and by name. A brief function
description is also included for each special tool.

In several cases, two or more tools of those listed will serve the same purpose. Determine which of the tools will
best suit your needs and order accordingly. If additional information is required about any of the special tools, call
the Service Parts Department at Arctic Cat Inc.

Order all special tools using any of the following methods:

Q NOTE: Alaskan dealers should order the special tools from their distributor at 907-272-5351.

A. For Phone Orders, call our WATS line (7 a.m. to 6 p.m. Central Time) - U.S.
1-800-279-2281

B. For Telefax Orders, call (24 hours a day, 7 days a week - after hours voice mail) 218-681-2822

C. For Mail Orders, address to ARCTIC CAT INC.

P.O. Box 810
Thief River Falls, MN 56701
ATTN: Service Parts Department

Pickup Orders require 24-hour notice. Pickup Orders will automatically be shipped 3 days after processing unless
a special pickup date is requested.

Remember to include Dealer Name

Dealer Number
Purchase Order Number
Method of Shipment (1 day or 2 day service is available)
Specify if Emergency Service Processing (ESP) is desired

1
 TABLE OF
CONTENTS

Accessory Adapter . . . . . . . . . . . . . . . . . . . . . . . . .11 Idle Speed Screw Jam Nut Wrench . . . . . . . . . . . . . 10

Alcohol Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Idler Wheel Alignment Tool . . . . . . . . . . . . . . . . . . . 20
Angle Finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Idler Wheel Puller Kit . . . . . . . . . . . . . . . . . . . . . . . . 20
Ball Hone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Ignition Test Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ball Joint Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Inflation Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Inflation Needle Replacement . . . . . . . . . . . . . . . . . 18
Bearing Cap Seal Protector. . . . . . . . . . . . . . . . . . .19 Insert Holder (5/16 in.) . . . . . . . . . . . . . . . . . . . . . . . 15
Bearing Removal Tool . . . . . . . . . . . . . . . . . . . . . . .24 Jack Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bearing Removal and Installation Tool . . . . . . . . . .23 Linkage Wrench (8 mm). . . . . . . . . . . . . . . . . . . . . . 10
Blind-Hole Bearing Puller . . . . . . . . . . . . . . . . . . . . .5 Multimeter (Fluke Model 73 w/Case) . . . . . . . . . . . . 12
Brake Disc Socket Wrench (ACT Drive) . . . . . . . . .25 Nitrogen Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Bushing Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Oil Filter Wrench (Adjustable) . . . . . . . . . . . . . . . . . . 9
Carbide & Stud Specifications Gauge . . . . . . . . . . .20 Oil Injection Usage Tool . . . . . . . . . . . . . . . . . . . . . . . 8
Carburetor Adjustment Screwdriver (90°) . . . . . . . . .9 Oil Seal Installation Tool. . . . . . . . . . . . . . . . . . . . . . . 5
Carburetor Synchronizer . . . . . . . . . . . . . . . . . . . . . .8 Peak Voltage Reading Adapter . . . . . . . . . . . . . . . . 12
Carburetor Synchronizing Tool Adapter. . . . . . . . . . .8 Phillips-Head Bits (1/4 in. Hex Drive) . . . . . . . . . . . . 14
Carburetor Tool Set (Mikuni) . . . . . . . . . . . . . . . . . . .8 Pinion Shimming Tool
Chip Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 (650 and 700 cc Engines) . . . . . . . . . . . . . . . . . . . . 5
Clutch Alignment Bar. . . . . . . . . . . . . . . . . . . . . . . .23 Piston Location Tool . . . . . . . . . . . . . . . . . . . . . . . . . 18
Clutch Bushing Installation Tool (Arctic) . . . . . . . . .21 Piston Pin Puller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clutch Compressor . . . . . . . . . . . . . . . . . . . . . . . . .22 Quick-Disconnect Coupler . . . . . . . . . . . . . . . . . . . . 15
Clutch Compressor (Arctic Round-Shaft) . . . . . . . .22 Rear Axle Nut Socket . . . . . . . . . . . . . . . . . . . . . . . . 15
Clutch Compressor (Comet) . . . . . . . . . . . . . . . . . .22 Rear Shock Adjuster . . . . . . . . . . . . . . . . . . . . . . . . 15
Clutch Puller (Arctic) . . . . . . . . . . . . . . . . . . . . . . . .21 Rear Suspension Spring Tool. . . . . . . . . . . . . . . . . . 15
Clutch Puller (Comet) . . . . . . . . . . . . . . . . . . . . . . .22 Replacement Bolt (Center). . . . . . . . . . . . . . . . . . . . 17
Compression/Pressure Tester Kit . . . . . . . . . . . . . . .7 Replacement Bolt (Side) . . . . . . . . . . . . . . . . . . . . . 17
Coolant Cap (Non-Pressurized) . . . . . . . . . . . . . . . .7 Replacement Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankshaft Bearing Remover . . . . . . . . . . . . . . . . . .4 Reverse Gear Adjustment Gauge . . . . . . . . . . . . . . 24
Crankshaft Protector Cap . . . . . . . . . . . . . . . . . . . . .4 Rigid Hone Stone Set (2.7-4.1 in.) . . . . . . . . . . . . . . . 6
Drive Belt Deflection Tool. . . . . . . . . . . . . . . . . . . . .24 Ring Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drive Belt Deflection Tool. . . . . . . . . . . . . . . . . . . . .25 Rivnut Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive Belt Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Rivnut Tool Insert Bit . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive Belt Replacement Tool . . . . . . . . . . . . . . . . . .25 Roller Pin Removal Tool . . . . . . . . . . . . . . . . . . . . . . 24
Drive Clutch Spanner Wrench . . . . . . . . . . . . . . . . .22 Shock Absorber Air Pump . . . . . . . . . . . . . . . . . . . . 16
Driven Pulley Puller . . . . . . . . . . . . . . . . . . . . . . . . .24 Shock Rod Clamping Tool . . . . . . . . . . . . . . . . . . . . 17
Driven Pulley Compressor Tool . . . . . . . . . . . . . . . .25 Shock Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . 16
Driven Pulley Spring Adjustment Tool . . . . . . . . . . .25 Shock Spring Removal Tool . . . . . . . . . . . . . . . . . . . 15
Duck-Foot T-Handle Wrench (8 mm) . . . . . . . . . . .10 Side Guard Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EFI Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Spider Removal Kit . . . . . . . . . . . . . . . . . . . . . . . . . 21
EFI Analyzer Test Harness . . . . . . . . . . . . . . . . . . .11 Spring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EFI Throttle Cable Jam Nut/ Starter Assembly Tool . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil-Injection Pump Jam Nut Wrench. . . . . . . . . .10 Stud Runner (6, 8, & 10 mm) . . . . . . . . . . . . . . . . . . 13
Engine Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Surface Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Timing Gauge . . . . . . . . . . . . . . . . . . . . . . . .6 Synchronizer Repair Kit . . . . . . . . . . . . . . . . . . . . . . . 8
Exhaust Spring Pliers . . . . . . . . . . . . . . . . . . . . . . . .9 T-Handle Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan Spanner Wrench (Suzuki) . . . . . . . . . . . . . . . . .5 T Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Floating Piston Location Gauge . . . . . . . . . . . . . . .18 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Floating Piston Removal Tool . . . . . . . . . . . . . . . . .18 Throttle Position Sensor (TPS)
Floating Piston Removal Tool Kit . . . . . . . . . . . . . . .19 Adjustment Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 12
Flywheel Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Timing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flywheel Puller Insert . . . . . . . . . . . . . . . . . . . . . . . .4 Torx Bit Insert (5/16 in. Hex Drive) . . . . . . . . . . . . . . 14
Flywheel Puller/Spanner Wrench . . . . . . . . . . . . . . .3 Torx Bits (1/4 in. Hex Drive) . . . . . . . . . . . . . . . . . . . 14
Flywheel Spanner Wrench . . . . . . . . . . . . . . . . . . . .4 Track Clip Installation Tool . . . . . . . . . . . . . . . . . . . . 19
Fuel Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . .7 Track Stud Hole Drill (7 mm) . . . . . . . . . . . . . . . . . . 20
Fuel Pump Socket Wrench . . . . . . . . . . . . . . . . . . .10 Track Stud Hole Drill (1/4 in.) . . . . . . . . . . . . . . . . . . 20
Gas Gauge Removal Tool . . . . . . . . . . . . . . . . . . . . .9 V Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gas Shock Retaining Blocks . . . . . . . . . . . . . . . . . .17 Vacuum Test Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gas Shock Rod/Body Clamping Tool. . . . . . . . . . . .17 Water Pump Bearing & Seal Kit . . . . . . . . . . . . . . . . . 5
Hex Bits (1/4 in. Hex Drive) . . . . . . . . . . . . . . . . . . .14 Zipper Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hex Clutch Puller (Arctic). . . . . . . . . . . . . . . . . . . . .21

2
Piston Pin Puller Flywheel Puller
p/n: 0644-328 (Complete Set) p/n: 0644-423 (Complete Set)
p/n: 0643-073 (Extractor Nut Only-Small) p/n: 0643-086 (Body)
p/n: 0643-074 (Extractor Nut Only-Medium) p/n: 0643-087 (Bolt)
p/n: 0643-075 (Extractor Nut Only-Large) p/n: 0423-482 (6 mm Cap Screw)
p/n: 0643-072 (Threaded T-Handle) p/n: 0423-483 (8 mm Cap Screw)
Usage: Remove piston pins. Usage: Pull flywheel off crankshaft on all Arctic Cat 2-
Fig. 1 stroke models.
Fig. 3

0644-328

Ring Compressor
p/n: 0644-378
Usage: Compress piston rings for cylinder installation. 0644-423
Features a quick-release function for removing tool from
underside of piston. Flywheel Puller/Spanner Wrench
Fig. 2
p/n: 0144-310
Usage: Pull flywheel off crankshaft and hold Arctic-style
clutches.
Fig. 4

0644-378

AE047

3
Flywheel Spanner Wrench Crankshaft Bearing Remover
p/n: 0144-007 p/n: 0144-302
Usage: Hold starter cup while removing/installing fly- Usage: Remove crankshaft bearings.
wheel nut. Fig. 8
Fig. 5

AE030

Flywheel Puller Insert AE043

p/n: 0644-179
Usage: Protect the crankshaft end on the 900 cc engine
Surface Plate
during flywheel removal. p/n: 0644-016
Fig. 6 Usage: True sealing surfaces.
Fig. 9

AE109 AE058

Crankshaft Protector Cap V Blocks

p/n: 0644-234 p/n: 0644-022
Usage: Protect the crankshaft end during flywheel Usage: Check crankshaft runout.
removal. Fig. 10
Fig. 7

0644-234
0644-022

4
Fan Spanner Wrench (Suzuki) Water Pump Bearing & Seal Kit
p/n: 0644-340 p/n: 0644-084
Usage: Hold fan in place during disassembly and Usage: Remove/install crankcase water pump bearings
assembly. and seals.
Fig. 11 Fig. 14

AE104

Engine Stand AE080

p/n: 0644-079
Usage: Hold engine during assembling/disassembling. Oil Seal Installation Tool
Fig. 12 p/n: 0644-219
Usage: Install the oil seal on the water pump driveshaft
on the 440, 550, 580, 650, 700, 800, and 900 cc Arctic
Cat engines.
Fig. 15

AE079

Pinion Shimming Tool (650 and

700 cc Engines)
p/n: 0644-055 AE130
Usage: Determine size and number of pinion gear
shims. Blind-Hole Bearing Puller
Fig. 13
p/n: 0644-381
Usage: Remove small and large blind bearings on all
models.
Fig. 16

AE073

0644-381

5
Rigid Hone Stone Set (2.7-4.1 in.) Angle Finder
p/n: 0644-043 p/n: 0644-097
Usage: Replacement stones for Cylinder Hone Set (p/n Usage: Identify levelness and pitch.
0644-041). Fig. 20
Fig. 17

AE090
AE068

Engine Timing Gauge

Ball Hone p/n: 0144-009
p/n: 0644-290 (60-64 mm) Usage: Static time engines without CDI ignition.
p/n: 0644-291 (65-70 mm) Fig. 21
p/n: 0644-292 (72-74 mm)
p/n: 0644-293 (76-83 mm)
p/n: 0644-294 (83-88 mm)
Usage: Deglaze Nicosil plated cylinders. All are 320 grit
and are recommended for reconditioning all Arctic Cat
snowmobile engine cylinders (1976-2000).
Fig. 18

AE031

Timing Light
p/n: 0644-296
AE065
Usage: Check ignition timing.
Fig. 22

Ignition Test Plug

p/n: 0144-306
Usage: Test engine ignition.
Fig. 19

AE054

AE045

6
Starter Assembly Tool Fuel Pressure Tester
p/n: 0644-052 p/n: 0644-203
Usage: Hold brushes for assembling UTC brand starter Usage: Test fuel pressure on both EFI and carbureted
motor. models. A valuable tool for troubleshooting EFI fuel sys-
Fig. 23 tems.
Fig. 25

AE072

Compression/Pressure Tester Kit

p/n: 0644-366 (Complete Kit w/Case) AE124

p/n: 0644-388 (T-Fitting - Fuel Pressure Gauge)

p/n: 0644-133 (Three Carburetor Plugs)* Coolant Cap (Non-Pressurized)
p/n: 0644-176 (Three Rubber Gaskets)* p/n: 0644-156
p/n: 0644-177 (Three Exhaust Plates)* Usage: Fill cooling system on the 1992, 1995, and 1996
p/n: 0644-367 (Twelve 8 mm Nuts and Bolts) models equipped with bleed system.
p/n: 0644-368 (Vacuum Plugs) Fig. 26

p/n: 0644-369 (Two Exhaust Plates)*

p/n: 0644-370 (Three Exhaust Valve Cover
Plates - Standard APV Engine)*
p/n: 0644-406 (Exhaust Valve Cover
Plates - Laydown APV Engine)*
p/n: 0644-371 (8 mm Oil Pressure Adapter)
p/n: 0644-372 (10 mm Compression Tester
Adapter)
p/n: 0644-373 (12 mm Compression Tester
Adapter) AE129

p/n: 0644-374 (Hose Assembly)

p/n: 0644-375 (Oil/Fuel Pressure Gauge) Vacuum Test Pump
p/n: 0644-376 (Compression Gauge) p/n: 0644-131
p/n: 0644-377 (Leak-Down Tester Gauge) Usage: Check components for air leaks.
Usage: Test all compression/pressure-related assem- Fig. 27
blies on all Arctic Cat products. Contains all necessary-
components to test oil/fuel pressure, compression, and
leak-down. *Can be ordered individually.
Fig. 24

AE099

644-366A

7
Oil Injection Usage Tool Carburetor Synchronizing Tool
p/n: 0644-007 Adapter
Usage: Measure exact amount of oil used by the oil
p/n: 0644-023
injection pump during a given time period.
Usage: Threads into carburetor fitting and slides into
Fig. 28
synchronizer hose.
Fig. 31

CE029

AE108 Carburetor Tool Set (Mikuni)

p/n: 0636-072
Alcohol Test Kit Usage: Disassemble/assemble Mikuni carburetors.
p/n: 0644-044 Fig. 32
Usage: Test gasoline for alcohol.
Fig. 29

AE049

AE069
Synchronizer Repair Kit
Carburetor Synchronizer p/n: 0644-062
p/n: 0644-069 Usage: Replacement components for Carburetor Syn-
Usage: Synchronize Mikuni carburetors. chronizer (p/n 0644-069).
Fig. 30 Fig. 33

AE138
AE076

8
Carburetor Adjustment Exhaust Spring Pliers (90°)
Screwdriver (90°) p/n: 0644-397
Usage: Remove/install exhaust springs.
p/n: 0644-289
Fig. 37
Usage: Make carburetor adjustments on all twin and tri-
ple cylinder engines. Will be especially useful for adjust-
ing the pilot circuit screw on all TM-style carburetors.
Fig. 34

0644-397

Spring Tool
0644-289 p/n: 0644-072
Usage: Remove/install exhaust springs.
Gas Gauge Removal Tool Fig. 38

p/n: 0644-357
Usage: Remove gauge from the gas tank.
Fig. 35

AE077

Oil Filter Wrench (Adjustable)

0644-357 p/n: 0644-389
Usage: Remove oil filters from 4-stroke engines. Fea-
Exhaust Spring Pliers (0°) tures adjustments between 62-96 mm.
p/n: 0644-391 Fig. 39
Usage: Remove/install exhaust springs.
Fig. 36

0644-389

644-391A

9
EFI Throttle Cable Jam Nut/Oil- Idle Speed Screw Jam Nut
Injection Pump Jam Nut Wrench Wrench
(10 mm) p/n: 0644-311
Usage: Loosen/tighten idle speed screw jam nut on bat-
p/n: 0644-242
teryless EFI system.
Usage: Loosen and tighten jam nuts on both the oil-
Fig. 43
injection pump and EFI throttle cable.
Fig. 40

BE024
0644-311

Duck-Foot T-Handle Wrench Fuel Pump Socket Wrench

(8 mm) p/n: 0644-364
p/n: 0644-332 Usage: Remove plastic nut securing the fuel pump to
Usage: Adjust oil-injection pump mechanical linkage. the gas tank.
Fig. 41 Fig. 44

0644-364
BE024

Chip Puller
Linkage Wrench (8 mm) p/n: 0644-188
p/n: 0644-333 Usage: Safely remove EPROM chip from the ECU on all
Usage: Adjust oil-injection pump mechanical linkage. EFI models.
Fig. 42 Fig. 45

0644-333
AE117

10
EFI Analyzer EFI Analyzer Test Harness
p/n: 0644-342 p/n: 0644-624
p/n: 0644-422 (Harness) Usage: Troubleshoot EFI battery system (1997-1998
p/n: 0644-341 (Complete Kit) models).
p/n: 0643-081 (EPROM) Fig. 48
p/n: 0686-716 (Harness)
Usage: Troubleshoot all Arctic Cat EFI systems. A valu-
able tool to assist the technician in locating EFI problems
quickly.
Fig. 46

AE143

Tachometer
p/n: 0644-386
Usage: Measure engine RPM for 2-stroke and 4-stroke
engines.
Fig. 49

0644-342

EFI Analyzer Test Harness

p/n: 0644-181
Usage: Troubleshoot EFI system (1993-1996 models).
Fig. 47

0644-386

Accessory Adapter
p/n: 0644-387
Usage: With Tachometer (p/n 0644-386), measure RPM
for diesel engines.
Fig. 50
AE113

0644-387

11
Throttle Position Sensor (TPS) Zipper Case
Adjustment Tool Kit p/n: 0644-190
Usage: Protect the Fluke Multimeter.
p/n: 3639-891 (Complete Set)
Fig. 53
p/n: 0686-999 (Harness Only)
p/n: 0644-359 (Torx-Head Screwdriver - #25
Only)
p/n: 0644-344 (Torx-Head Screwdriver - #30
Only)
p/n: 0644-345 (Pin Gauge Only)
Usage: Precisely adjust the throttle position sensor on
carbureted and EFI models.
Fig. 51

0644-190

Peak Voltage Reading Adapter

p/n: 0644-307
Usage: With Fluke Model 73 Multimeter (p/n 0644-191),
read peak voltage.
Fig. 54

3639-891

Battery Charger
p/n: 0436-634
Usage: Charge sealed, maintenance-free batteries.
Fig. 52 0644-307

Multimeter (Fluke Model 73 w/

Case)
p/n: 0644-191
Usage: Ditgital multimeter accurate to within ± 0.5%.
Fig. 55

0436-634

AE114

12
Stud Runner Rivnut Tool
p/n: 0644-018 (6 mm) p/n: 0644-232
p/n: 0644-019 (8 mm) Usage: Collapse and install rivnuts.
p/n: 0644-020 (10 mm) Fig. 59
Usage: Install studs on cylinders and crankcase.
Fig. 56

0644-232

AE059
Rivnut Tool Insert Bit
p/n: 0644-233 (1/4 x 20)
T Wrench p/n: 0644-405 (10-32)
p/n: 0644-021 p/n: 0644-430 (5/16 x 18)
Usage: Drive 3/8 in. square-drive sockets. p/n: 0644-431 (3/8 x 16)
Fig. 57 Usage: With Rivnut Tool (p/n 0644-232) and Replace-
ment Rivnuts, replace rivnuts.
Fig. 60

AE060

T-Handle Wrench 0644-233

p/n: 0644-257 (8 mm)
p/n: 0644-024 (10 mm)
p/n: 0644-025 (12 mm)
p/n: 0644-026 (14 mm)
Usage: Remove and install nuts and bolts.
Fig. 58

AE115

13
Replacement Rivnuts Phillips-Head Bits (1/4 in. Hex
p/n: 0623-557 (1/4 x 20) Drive)
p/n: 0623-582/627 (1/4 x 20) p/n: 0644-319 (#2)
p/n: 0623-581 (5/16 x 18) p/n: 0644-318 (#3)
p/n: 0623-699 (3/8 x 16) Usage: With Quick-Disconnect Coupler (p/n 0644-308),
p/n: 0623-874 (8-32) remove and install Phillips-head screws.
p/n: 0623-529/779 (10-32) Fig. 63
Usage: With Rivnut Tool (p/n 0644-232), replace rivnuts.
Fig. 61

0644-318

Torx Bits (1/4 in. Hex Drive)

0623-557 p/n: 0644-312 (#25)
p/n: 0644-393 (#27)
Hex Bits (1/4 in. Hex Drive) p/n: 0644-215 (#30)
p/n: 0644-317 (5 mm) p/n: 0644-313 (#40)
p/n: 0644-316 (6 mm) Usage: With Quick-Disconnect Coupler (p/n 0644-308),
Usage: With Quick-Disconnect Coupler (p/n 0644-308), remove and install torx-head screws.
remove and install bolts and screws. Fig. 64
Fig. 62

BE012

0644-316 Torx Bit Insert (5/16 in. Hex Drive)

p/n: 0644-314
Usage: With Insert Holder (p/n 0644-315), remove and
install torx-head screws.
Fig. 65

BE012

14
Insert Holder (5/16 in.) Rear Axle Nut Socket
p/n: 0644-315 p/n: 0644-399
Usage: With Torx Bit Insert (p/n 0644-314), remove and Usage: Loosen/tighten rear axle nut on 2004 and earlier
install torx-head screws. AWS VI models.
Fig. 66 Fig. 69

0644-315 0644-399

Quick-Disconnect Coupler Rear Shock Adjuster

p/n: 0644-308 p/n: 0644-015
Usage: Hold 1/4 in. hex drive Torx Bits (Fig. 64), Hex Usage: Rotate rear shock adjusting cam on external
Bits (Fig. 62), and Phillips-Head Bits (Fig. 63). AFS models.
Fig. 67 Fig. 70

0644-308 AE057

Rear Suspension Spring Tool Shock Spring Removal Tool

p/n: 0144-311 p/n: 0644-057
Usage: Install/remove rear suspension springs. Usage: Remove/install shock absorber spring.
Fig. 68 Fig. 71

AE074
AE048

15
Shock Spanner Wrench Shock Absorber Air Pump
p/n: 2604-878 p/n: 2603-324
Usage: Adjust pre-load on Fox Zero Pro shock absorber. Usage: Adjust air pressure on Fox Air Shocks.
Fig. 72 Fig. 75

2604-878 2603-324

Shock Spanner Wrench Jack Stand

p/n: 0644-398 p/n: 0644-076 (Standard Models - Low)
Usage: Adjust pre-load on front arm rebuildable shock p/n: 0639-462 (ETT Models - High)
absorber. Usage: Support rear of snowmobile off the ground.
Fig. 73 Fig. 76

0644-398

Shock Spanner Wrench

p/n: 0644-305
Usage: Adjust pre-load on front arm standard shock AE133

absorber.
Fig. 74

Side Guard Kit

p/n: 0639-611
Usage: With Jack Stand (p/n 0644-076/0639-462).
Fig. 77

0644-305

0639-611

16
Replacement Bolt (Side) Gas Shock Rod/Body Clamping
p/n: 0644-101 Tool
Usage: Replaces side bolt in Track Clip Tool (p/n 0144-
p/n: 0644-425
301).
Usage: Hold gas shock absorber for servicing.
Fig. 78
Fig. 81

0644-425

AE093 Gas Shock Retaining Blocks

p/n: 0644-334
Replacement Bolt (Center) Usage: Hold gas shock secure during disassembly and
p/n: 0644-103 assembly.
Usage: Replaces center bolt in Track Clip Tool (p/n Fig. 82
0144-301).
Fig. 79

AP042

AE094

Shock Rod Clamping Tool Nitrogen Regulator

p/n: 0744-021 p/n: 0644-151
Usage: Hold shock absorber rod for servicing. Usage: Recharge rebuildable gas shock absorbers.
Fig. 80 Fig. 83

AE145D

AE095

17
Inflation Needle Floating Piston Location Gauge
p/n: 0744-020 p/n: 0644-350
Usage: Pressurize rebuildable gas shock absorbers with Usage: Precisely locate and measure floating piston
nitrogen. depth without use of a calipers.
Fig. 84 Fig. 87

AE110 0644-350

Inflation Needle Replacement Floating Piston Removal Tool

p/n: 0644-162 p/n: 0644-348
Usage: Replacement needle assembly for Inflation Nee- Usage: Remove floating piston from cross-link suspen-
dle (p/n 0744-020). sion shocks on 2002 models.
Fig. 85 Fig. 88

0644-162
0644-348

Piston Location Tool

p/n: 0644-169
Usage: Precisely locate the floating piston in the rebuild-
able gas shock absorber.
Fig. 86

AE135

18
Floating Piston Removal Tool Kit Bearing Cap Seal Protector
p/n: 0644-402 (Complete Kit) p/n: 0644-403 (1/2 in.)
p/n: 0644-416 (Removal Tool) p/n: 0644-404 (5/8 in.)
p/n: 0644-417 (Location Gauge) Usage: Protect cap seal on rebuildable shock absorbers
p/n: 0644-418 (Gauge Set Screw) on 2003 and newer models.
p/n: 0644-419 (Gauge Stop Collar) Fig. 91
Usage: Remove floating piston from rebuildable gas
shock absorbers.
Fig. 89

AE142

Ball Joint Fork

p/n: 0644-098
0644-402
Usage: Separate ball joint from spindle or drag link.
Fig. 92
Bearing Cap Seal Protector
p/n: 0644-268
Usage: Protect cap seal on rebuildable shock absorbers
through 2002 models.
Fig. 90

AE091

Track Clip Installation Tool

p/n: 0644-194
AE142
Usage: Install track clips on Camoplast and Yokohama
rubber tracks.
Fig. 93

0644-194

19
Track Stud Hole Drill (7 mm) Idler Wheel Puller Kit
p/n: 1639-629 p/n: 0644-122 (Complete Kit - 6 in.)
Usage: Drill 7 mm hole through rubber tracks for install- p/n: 0644-400 (Complete Kit - 8 in.)
ing studs. p/n: 0644-114 (A. Handle - 6 in.)
Fig. 94 p/n: 0644-401 (A. Handle - 8 in.)
p/n: 0644-111 (B. Insertion Tool)
p/n: 0644-120 (C. Pivot Plate)
p/n: 0644-118 (D. Adapter Plate)
p/n: 0623-310 (E. Cap Screw)
p/n: 0644-119 (F. Puller Bolt) - 6 in. Kit
p/n: 0644-432 (F. Puller Bolt) - 8 in. Kit
Usage: Remove/install skid frame idler wheels.
Fig. 97

AE137

Track Stud Hole Drill (1/4 in.)

p/n: 1639-628
Usage: Drill 1/4 in. hole through rubber track for install-
ing studs.
Fig. 95

AE097B

Idler Wheel Alignment Tool

p/n: 0644-228
Usage: Align center idler wheels during replacement
without removing the suspension.
Fig. 98

AE137

Carbide & Stud Specifications

Gauge
p/n: 1639-632
Usage: Check stud length and carbide angle.
Fig. 96

BE025

AE088

20
Spider Removal Kit Hex Clutch Puller (Arctic)
p/n: 0644-449 (Complete Kit) p/n: 0644-010
p/n: 0744-037 (Handle) Usage: Remove Arctic hex-drive clutch from crankshaft.
p/n: 0744-036 (Removal Tool) Fig. 101
p/n: 0644-380 (Clutch Holder - 33 mm)
p/n: 0744-035 (Clutch Holder - 30 mm)
p/n: 0644-138 (Thin Wall Deep Socket - 1 7/16 in.)
Usage: Disassemble/assemble/remove spider on Comet
and Arctic drive clutches.
p/n: 0644-380 (33 mm)
Usage: Hold clutch stationary sheave for 33 mm crank-
shaft on 2001 and later 800/900 cc and 2003 and later
700 cc “Laydown” engines.
p/n: 0744-035 (30 mm)
Usage: Aid in assembling/disassembling of 108 & 102C
Comet and Arctic drive clutches.
AE056
p/n: 0644-138 (1 7/16 in.)
Usage: Remove and install spider nut on Arctic round-
shaft drive clutch. Clutch Puller (Arctic)
Fig. 99 p/n: 0644-207
Usage: Remove Arctic round-shaft drive clutch from the
crankshaft.
Fig. 102

AE125

0644-449

Clutch Bushing Installation Tool

(Arctic)
p/n: 0644-006
Usage: Replace sheave/cover bushings on Arctic hex-
drive clutches.
Fig. 100

AE053

21
Clutch Puller (Comet) Clutch Compressor (Comet)
p/n: 0644-096 p/n: 0644-123
Usage: Remove Comet drive clutch (short bolt w/ Usage: Compress and hold drive clutch in the com-
retainer plug style). pressed position for changing cam arms.
Fig. 103 Fig. 106

AE098

AE089
Clutch Compressor
Clutch Puller (Comet) p/n: 0644-420
p/n: 0644-100 Usage: Compress and hold drive clutch in the com-
Usage: Remove Comet drive clutch (long bolt style). pressed position for changing cam arms and removing/
Fig. 104 installing six-post drive clutch on AWS VI models.
Fig. 107

0644-420
AE055

Clutch Compressor (Arctic Drive Clutch Spanner Wrench

p/n: 0644-136
Round-Shaft) Usage: Hold Comet and Arctic round-shaft drive clutch
p/n: 0644-245 in place during removal and installation.
Usage: Compress and hold Arctic round-shaft drive Fig. 108
clutch in the compressed position for changing cam
arms.
Fig. 105

AE101

AE132

22
Bushing Tool Kit Clutch Alignment Bar (1.562 in.
p/n: 0644-137 Offset)
Usage: Remove and install cover plate and movable
p/n: 0644-246
sheave bushings in Arctic round-shaft drive clutch
Usage: Align drive clutch and driven pulley on 1997
through 1998.
models using the Arctic internal-helix driven pulley.
Fig. 109
Fig. 112

AE140
AE127A

Bearing Removal and Installation Clutch Alignment Bar (1.485 in.

Tool Offset)
p/n: 0644-167 p/n: 0644-428
Usage: Remove and install bearings in the driven clutch Usage: Align drive clutch and driven pulley on Bearcat
movable sheave and button plate. Wide Track models.
Fig. 110 Fig. 113

0644-428
AE112

Clutch Alignment Bar (1.365 in. Clutch Alignment Bar (1.620 in.
Offset) Offset)
p/n: 0644-427
p/n: 0644-320 Usage: Align drive clutch and driven pulley on ACT Drive
Usage: Align the drive clutch and driven pulley on mod- models.
els using the reverse cam driven pulley.
Fig. 114
Fig. 111

AE052A

AE052A

23
Reverse Gear Adjustment Gauge Bearing Removal Tool
p/n: 0644-244 p/n: 0644-421
Usage: Adjust reverse gear linkage on all 1996-2002 Usage: Remove chain case bearings on 2003 and
reverse gear transmissions. newer models.
Fig. 115 Fig. 118

BE027 0644-421

Driven Pulley Puller Drive Belt Gauge

p/n: 0744-023 p/n: 0644-443
Usage: Remove driven pulley from driven shaft. It can Usage: Measure drive belt width.
be used on both the roller and button style. Fig. 119
Fig. 116

0644-443

Drive Belt Deflection Tool

0744-023
p/n: 0644-412
Usage: Adjust driven pulley for proper drive belt deflec-
Roller Pin Removal Tool tion and aid in drive belt removal on models using the
p/n: 0644-276 ACT Roller Driven Pulley.
Usage: Remove roller pins from retainer plate on driven Fig. 120
pulley.
Fig. 117

0644-412
AE146D

24
Drive Belt Replacement Tool Driven Pulley Compressor Tool
p/n: 0644-435 p/n: 0644-444
Usage: Replace drive belt and adjust belt deflection on p/n: 0644-439 (A. Compressor Assembly Only)
models using the ACT Roller Driven Pulley. p/n: 0643-095 (B. Disc Only)
Fig. 121 Usage: Disassemble/assemble Arctic ACT and Team
Industries roller driven pulleys.
Fig. 124

0644-435

Driven Pulley Spring Adjustment

Tool 644-444A
p/n: 0644-413
Usage: Adjust driven pulley spring pre-load on models Brake Disc Socket Wrench
using the ACT Driven Pulley.
Fig. 122 (ACT Drive)
p/n: 0644-415
Usage: Remove/install brake disc on ACT Drive models.
Fig.125

0644-413

Drive Belt Deflection Tool

p/n: 0644-424
Usage: Adjust driven pulley for proper drive belt deflec-
tion and aid in drive belt removal on 2004 440 Sno Pro
0644-415
model.
Fig. 123

0644-424

25
Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2257-251