Clutch Puller

®
ARCTICCAT Effective Date: May, 2004
Special
Tools
Catalog
Snowmobile

FOREWORD
This publication is designed to help authorized Arctic Cat Snowmobile dealers in identifying the special tools available
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:
� 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

2
TABLE OF
CONTENTS
Accessory Adapter . . . . . . . . . . . . . . . . . . . . . . . . .11
Alcohol Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Angle Finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Ball Hone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Ball Joint Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Bearing Cap Seal Protector. . . . . . . . . . . . . . . . . . .19
Bearing Removal Tool . . . . . . . . . . . . . . . . . . . . . . .24
Bearing Removal and Installation Tool . . . . . . . . . .23
Blind-Hole Bearing Puller . . . . . . . . . . . . . . . . . . . . .5
Brake Disc Socket Wrench (ACT Drive) . . . . . . . . .25
Bushing Tool Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Carbide & Stud Specifications Gauge . . . . . . . . . . .20
Carburetor Adjustment Screwdriver (90°) . . . . . . . . .9
Carburetor Synchronizer . . . . . . . . . . . . . . . . . . . . . .8
Carburetor Synchronizing Tool Adapter. . . . . . . . . . .8
Carburetor Tool Set (Mikuni) . . . . . . . . . . . . . . . . . . .8
Chip Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Clutch Alignment Bar. . . . . . . . . . . . . . . . . . . . . . . .23
Clutch Bushing Installation Tool (Arctic) . . . . . . . . .21
Clutch Compressor . . . . . . . . . . . . . . . . . . . . . . . . .22
Clutch Compressor (Arctic Round-Shaft) . . . . . . . .22
Clutch Compressor (Comet) . . . . . . . . . . . . . . . . . .22
Clutch Puller (Arctic) . . . . . . . . . . . . . . . . . . . . . . . .21
Clutch Puller (Comet) . . . . . . . . . . . . . . . . . . . . . . .22
Compression/Pressure Tester Kit . . . . . . . . . . . . . . .7
Coolant Cap (Non-Pressurized) . . . . . . . . . . . . . . . .7
Crankshaft Bearing Remover . . . . . . . . . . . . . . . . . .4
Crankshaft Protector Cap . . . . . . . . . . . . . . . . . . . . .4
Drive Belt Deflection Tool. . . . . . . . . . . . . . . . . . . . .24
Drive Belt Deflection Tool. . . . . . . . . . . . . . . . . . . . .25
Drive Belt Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Drive Belt Replacement Tool . . . . . . . . . . . . . . . . . .25
Drive Clutch Spanner Wrench . . . . . . . . . . . . . . . . .22
Driven Pulley Puller . . . . . . . . . . . . . . . . . . . . . . . . .24
Driven Pulley Compressor Tool . . . . . . . . . . . . . . . .25
Driven Pulley Spring Adjustment Tool . . . . . . . . . . .25
Duck-Foot T-Handle Wrench (8 mm) . . . . . . . . . . .10
EFI Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
EFI Analyzer Test Harness . . . . . . . . . . . . . . . . . . .11
EFI Throttle Cable Jam Nut/
Oil-Injection Pump Jam Nut Wrench. . . . . . . . . .10
Engine Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine Timing Gauge . . . . . . . . . . . . . . . . . . . . . . . .6
Exhaust Spring Pliers . . . . . . . . . . . . . . . . . . . . . . . .9
Fan Spanner Wrench (Suzuki) . . . . . . . . . . . . . . . . .5
Floating Piston Location Gauge . . . . . . . . . . . . . . .18
Floating Piston Removal Tool . . . . . . . . . . . . . . . . .18
Floating Piston Removal Tool Kit . . . . . . . . . . . . . . .19
Flywheel Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Flywheel Puller Insert . . . . . . . . . . . . . . . . . . . . . . . .4
Flywheel Puller/Spanner Wrench . . . . . . . . . . . . . . .3
Flywheel Spanner Wrench . . . . . . . . . . . . . . . . . . . .4
Fuel Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel Pump Socket Wrench . . . . . . . . . . . . . . . . . . .10
Gas Gauge Removal Tool . . . . . . . . . . . . . . . . . . . . .9
Gas Shock Retaining Blocks . . . . . . . . . . . . . . . . . .17
Gas Shock Rod/Body Clamping Tool. . . . . . . . . . . .17
Hex Bits (1/4 in. Hex Drive) . . . . . . . . . . . . . . . . . . .14
Hex Clutch Puller (Arctic). . . . . . . . . . . . . . . . . . . . .21
Idle Speed Screw Jam Nut Wrench . . . . . . . . . . . . . 10
Idler Wheel Alignment Tool . . . . . . . . . . . . . . . . . . . 20
Idler Wheel Puller Kit . . . . . . . . . . . . . . . . . . . . . . . . 20
Ignition Test Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inflation Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inflation Needle Replacement . . . . . . . . . . . . . . . . . 18
Insert Holder (5/16 in.) . . . . . . . . . . . . . . . . . . . . . . . 15
Jack Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Linkage Wrench (8 mm). . . . . . . . . . . . . . . . . . . . . . 10
Multimeter (Fluke Model 73 w/Case) . . . . . . . . . . . . 12
Nitrogen Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Filter Wrench (Adjustable) . . . . . . . . . . . . . . . . . . 9
Oil Injection Usage Tool . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Seal Installation Tool. . . . . . . . . . . . . . . . . . . . . . . 5
Peak Voltage Reading Adapter . . . . . . . . . . . . . . . . 12
Phillips-Head Bits (1/4 in. Hex Drive) . . . . . . . . . . . . 14
Pinion Shimming Tool
(650 and 700 cc Engines) . . . . . . . . . . . . . . . . . . . . 5
Piston Location Tool . . . . . . . . . . . . . . . . . . . . . . . . . 18
Piston Pin Puller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Quick-Disconnect Coupler . . . . . . . . . . . . . . . . . . . . 15
Rear Axle Nut Socket. . . . . . . . . . . . . . . . . . . . . . . . 15
Rear Shock Adjuster . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear Suspension Spring Tool. . . . . . . . . . . . . . . . . . 15
Replacement Bolt (Center). . . . . . . . . . . . . . . . . . . . 17
Replacement Bolt (Side) . . . . . . . . . . . . . . . . . . . . . 17
Replacement Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . 14
Reverse Gear Adjustment Gauge . . . . . . . . . . . . . . 24
Rigid Hone Stone Set (2.7-4.1 in.) . . . . . . . . . . . . . . . 6
Ring Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rivnut Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rivnut Tool Insert Bit . . . . . . . . . . . . . . . . . . . . . . . . 13
Roller Pin Removal Tool. . . . . . . . . . . . . . . . . . . . . . 24
Shock Absorber Air Pump . . . . . . . . . . . . . . . . . . . . 16
Shock Rod Clamping Tool . . . . . . . . . . . . . . . . . . . . 17
Shock Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . 16
Shock Spring Removal Tool . . . . . . . . . . . . . . . . . . . 15
Side Guard Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Spider Removal Kit . . . . . . . . . . . . . . . . . . . . . . . . . 21
Spring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter Assembly Tool . . . . . . . . . . . . . . . . . . . . . . . . 7
Stud Runner (6, 8, & 10 mm) . . . . . . . . . . . . . . . . . . 13
Surface Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Synchronizer Repair Kit . . . . . . . . . . . . . . . . . . . . . . . 8
T-Handle Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
T Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Throttle Position Sensor (TPS)
Adjustment Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 12
Timing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torx Bit Insert (5/16 in. Hex Drive) . . . . . . . . . . . . . . 14
Torx Bits (1/4 in. Hex Drive) . . . . . . . . . . . . . . . . . . . 14
Track Clip Installation Tool . . . . . . . . . . . . . . . . . . . . 19
Track Stud Hole Drill (7 mm) . . . . . . . . . . . . . . . . . . 20
Track Stud Hole Drill (1/4 in.) . . . . . . . . . . . . . . . . . . 20
V Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Vacuum Test Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water Pump Bearing & Seal Kit . . . . . . . . . . . . . . . . . 5
Zipper Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Piston Pin Puller
p/n: 0644-328 (Complete Set)
p/n: 0643-073 (Extractor Nut Only-Small)
p/n: 0643-074 (Extractor Nut Only-Medium)
p/n: 0643-075 (Extractor Nut Only-Large)
p/n: 0643-072 (Threaded T-Handle)
Usage: Remove piston pins.
Fig. 1
0644-328
Ring Compressor
p/n: 0644-378
Usage: Compress piston rings for cylinder installation.
Features a quick-release function for removing tool from
underside of piston.
Fig. 2
0644-378
Flywheel Puller
p/n: 0644-423 (Complete Set)
p/n: 0643-086 (Body)
p/n: 0643-087 (Bolt)
p/n: 0423-482 (6 mm Cap Screw)
p/n: 0423-483 (8 mm Cap Screw)
Usage: Pull flywheel off crankshaft on all Arctic Cat 2stroke
models.
Fig. 3
0644-423
Flywheel Puller/Spanner Wrench
p/n: 0144-310
Usage: Pull flywheel off crankshaft and hold Arctic-style
clutches.
Fig. 4
AE047
3

Flywheel Spanner Wrench
p/n: 0144-007
Usage: Hold starter cup while removing/installing flywheel
nut.
Fig. 5
4
AE030
Flywheel Puller Insert
p/n: 0644-179
Usage: Protect the crankshaft end on the 900 cc engine
during flywheel removal.
Fig. 6
Crankshaft Protector Cap
p/n: 0644-234
Usage: Protect the crankshaft end during flywheel
removal.
Fig. 7
AE109
0644-234
Crankshaft Bearing Remover
p/n: 0144-302
Usage: Remove crankshaft bearings.
Fig. 8
Surface Plate
p/n: 0644-016
Usage: True sealing surfaces.
Fig. 9
V Blocks
p/n: 0644-022
Usage: Check crankshaft runout.
Fig. 10
AE043
AE058
0644-022

Fan Spanner Wrench (Suzuki)
p/n: 0644-340
Usage: Hold fan in place during disassembly and
assembly.
Fig. 11
AE104
Engine Stand
p/n: 0644-079
Usage: Hold engine during assembling/disassembling.
Fig. 12
Pinion Shimming Tool (650 and
700 cc Engines)
p/n: 0644-055
Usage: Determine size and number of pinion gear
shims.
Fig. 13
AE079
AE073
Water Pump Bearing & Seal Kit
p/n: 0644-084
Usage: Remove/install crankcase water pump bearings
and seals.
Fig. 14
AE080
Oil Seal Installation Tool
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
Blind-Hole Bearing Puller
p/n: 0644-381
Usage: Remove small and large blind bearings on all
models.
Fig. 16
AE130
0644-381
5

Rigid Hone Stone Set (2.7-4.1 in.)
p/n: 0644-043
Usage: Replacement stones for Cylinder Hone Set (p/n
0644-041).
Fig. 17
6
AE068
Ball Hone
p/n: 0644-290 (60-64 mm)
p/n: 0644-291 (65-70 mm)
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
Ignition Test Plug
p/n: 0144-306
Usage: Test engine ignition.
Fig. 19
AE065
AE045
Angle Finder
p/n: 0644-097
Usage: Identify levelness and pitch.
Fig. 20
Engine Timing Gauge
p/n: 0144-009
Usage: Static time engines without CDI ignition.
Fig. 21
Timing Light
p/n: 0644-296
Usage: Check ignition timing.
Fig. 22
AE090
AE031
AE054

Starter Assembly Tool
p/n: 0644-052
Usage: Hold brushes for assembling UTC brand starter
motor.
Fig. 23
AE072
Compression/Pressure Tester Kit
p/n: 0644-366 (Complete Kit w/Case)
p/n: 0644-388 (T-Fitting - Fuel Pressure Gauge)
p/n: 0644-133 (Three Carburetor Plugs)*
p/n: 0644-176 (Three Rubber Gaskets)*
p/n: 0644-177 (Three Exhaust Plates)*
p/n: 0644-367 (Twelve 8 mm Nuts and Bolts)
p/n: 0644-368 (Vacuum Plugs)
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)
p/n: 0644-374 (Hose Assembly)
p/n: 0644-375 (Oil/Fuel Pressure Gauge)
p/n: 0644-376 (Compression Gauge)
p/n: 0644-377 (Leak-Down Tester Gauge)
Usage: Test all compression/pressure-related assemblies
on all Arctic Cat products. Contains all necessarycomponents
to test oil/fuel pressure, compression, and
leak-down. *Can be ordered individually.
Fig. 24
644-366A
Fuel Pressure Tester
p/n: 0644-203
Usage: Test fuel pressure on both EFI and carbureted
models. A valuable tool for troubleshooting EFI fuel systems.
Fig. 25
AE124
Coolant Cap (Non-Pressurized)
p/n: 0644-156
Usage: Fill cooling system on the 1992, 1995, and 1996
models equipped with bleed system.
Fig. 26
Vacuum Test Pump
p/n: 0644-131
Usage: Check components for air leaks.
Fig. 27
AE129
AE099
7

Oil Injection Usage Tool
p/n: 0644-007
Usage: Measure exact amount of oil used by the oil
injection pump during a given time period.
Fig. 28
Alcohol Test Kit
p/n: 0644-044
Usage: Test gasoline for alcohol.
Fig. 29
Carburetor Synchronizer
p/n: 0644-069
Usage: Synchronize Mikuni carburetors.
Fig. 30
8
AE108
AE069
AE076
Carburetor Synchronizing Tool
Adapter
p/n: 0644-023
Usage: Threads into carburetor fitting and slides into
synchronizer hose.
Fig. 31
Carburetor Tool Set (Mikuni)
p/n: 0636-072
Usage: Disassemble/assemble Mikuni carburetors.
Fig. 32
CE029
AE049
Synchronizer Repair Kit
p/n: 0644-062
Usage: Replacement components for Carburetor Synchronizer
(p/n 0644-069).
Fig. 33
AE138

Carburetor Adjustment
Screwdriver (90°)
p/n: 0644-289
Usage: Make carburetor adjustments on all twin and triple
cylinder engines. Will be especially useful for adjusting
the pilot circuit screw on all TM-style carburetors.
Fig. 34
Gas Gauge Removal Tool
p/n: 0644-357
Usage: Remove gauge from the gas tank.
Fig. 35
Exhaust Spring Pliers (0°)
p/n: 0644-391
Usage: Remove/install exhaust springs.
Fig. 36
0644-289
0644-357
644-391A
Exhaust Spring Pliers (90°)
p/n: 0644-397
Usage: Remove/install exhaust springs.
Fig. 37
Spring Tool
p/n: 0644-072
Usage: Remove/install exhaust springs.
Fig. 38
0644-397
Oil Filter Wrench (Adjustable)
p/n: 0644-389
Usage: Remove oil filters from 4-stroke engines. Features
adjustments between 62-96 mm.
Fig. 39
AE077
0644-389
9

EFI Throttle Cable Jam Nut/Oil-
Injection Pump Jam Nut Wrench
(10 mm)
p/n: 0644-242
Usage: Loosen and tighten jam nuts on both the oilinjection
pump and EFI throttle cable.
Fig. 40
Duck-Foot T-Handle Wrench
(8 mm)
p/n: 0644-332
Usage: Adjust oil-injection pump mechanical linkage.
Fig. 41
Linkage Wrench (8 mm)
p/n: 0644-333
Usage: Adjust oil-injection pump mechanical linkage.
Fig. 42
10
BE024
BE024
0644-333
Idle Speed Screw Jam Nut
Wrench
p/n: 0644-311
Usage: Loosen/tighten idle speed screw jam nut on batteryless
EFI system.
Fig. 43
0644-311
Fuel Pump Socket Wrench
p/n: 0644-364
Usage: Remove plastic nut securing the fuel pump to
the gas tank.
Fig. 44
0644-364
Chip Puller
p/n: 0644-188
Usage: Safely remove EPROM chip from the ECU on all
EFI models.
Fig. 45
AE117

EFI Analyzer
p/n: 0644-342
p/n: 0644-422 (Harness)
p/n: 0644-341 (Complete Kit)
p/n: 0643-081 (EPROM)
p/n: 0686-716 (Harness)
Usage: Troubleshoot all Arctic Cat EFI systems. A valuable
tool to assist the technician in locating EFI problems
quickly.
Fig. 46
0644-342
EFI Analyzer Test Harness
p/n: 0644-181
Usage: Troubleshoot EFI system (1993-1996 models).
Fig. 47
AE113
EFI Analyzer Test Harness
p/n: 0644-624
Usage: Troubleshoot EFI battery system (1997-1998
models).
Fig. 48
AE143
Tachometer
p/n: 0644-386
Usage: Measure engine RPM for 2-stroke and 4-stroke
engines.
Fig. 49
0644-386
Accessory Adapter
p/n: 0644-387
Usage: With Tachometer (p/n 0644-386), measure RPM
for diesel engines.
Fig. 50
0644-387
11

Throttle Position Sensor (TPS)
Adjustment Tool Kit
p/n: 3639-891 (Complete Set)
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
Battery Charger
p/n: 0436-634
Usage: Charge sealed, maintenance-free batteries.
Fig. 52
12
3639-891
0436-634
Zipper Case
p/n: 0644-190
Usage: Protect the Fluke Multimeter.
Fig. 53
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
Multimeter (Fluke Model 73 w/
Case)
p/n: 0644-191
Usage: Ditgital multimeter accurate to within ± 0.5%.
Fig. 55
0644-307
AE114

Stud Runner
p/n: 0644-018 (6 mm)
p/n: 0644-019 (8 mm)
p/n: 0644-020 (10 mm)
Usage: Install studs on cylinders and crankcase.
Fig. 56
T Wrench
p/n: 0644-021
Usage: Drive 3/8 in. square-drive sockets.
Fig. 57
T-Handle Wrench
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
AE059
AE060
AE115
Rivnut Tool
p/n: 0644-232
Usage: Collapse and install rivnuts.
Fig. 59
0644-232
Rivnut Tool Insert Bit
p/n: 0644-233 (1/4 x 20)
p/n: 0644-405 (10-32)
p/n: 0644-430 (5/16 x 18)
p/n: 0644-431 (3/8 x 16)
Usage: With Rivnut Tool (p/n 0644-232) and Replacement
Rivnuts, replace rivnuts.
Fig. 60
0644-233
13

Replacement Rivnuts
p/n: 0623-557 (1/4 x 20)
p/n: 0623-582/627 (1/4 x 20)
p/n: 0623-581 (5/16 x 18)
p/n: 0623-699 (3/8 x 16)
p/n: 0623-874 (8-32)
p/n: 0623-529/779 (10-32)
Usage: With Rivnut Tool (p/n 0644-232), replace rivnuts.
Fig. 61
14
0623-557
Hex Bits (1/4 in. Hex Drive)
p/n: 0644-317 (5 mm)
p/n: 0644-316 (6 mm)
Usage: With Quick-Disconnect Coupler (p/n 0644-308),
remove and install bolts and screws.
Fig. 62
0644-316
Phillips-Head Bits (1/4 in. Hex
Drive)
p/n: 0644-319 (#2)
p/n: 0644-318 (#3)
Usage: With Quick-Disconnect Coupler (p/n 0644-308),
remove and install Phillips-head screws.
Fig. 63
0644-318
Torx Bits (1/4 in. Hex Drive)
p/n: 0644-312 (#25)
p/n: 0644-393 (#27)
p/n: 0644-215 (#30)
p/n: 0644-313 (#40)
Usage: With Quick-Disconnect Coupler (p/n 0644-308),
remove and install torx-head screws.
Fig. 64
BE012
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

Insert Holder (5/16 in.)
p/n: 0644-315
Usage: With Torx Bit Insert (p/n 0644-314), remove and
install torx-head screws.
Fig. 66
0644-315
Quick-Disconnect Coupler
p/n: 0644-308
Usage: Hold 1/4 in. hex drive Torx Bits (Fig. 64), Hex
Bits (Fig. 62), and Phillips-Head Bits (Fig. 63).
Fig. 67
Rear Suspension Spring Tool
p/n: 0144-311
Usage: Install/remove rear suspension springs.
Fig. 68
0644-308
AE048
Rear Axle Nut Socket
p/n: 0644-399
Usage: Loosen/tighten rear axle nut on 2004 and earlier
AWS VI models.
Fig. 69
Rear Shock Adjuster
p/n: 0644-015
Usage: Rotate rear shock adjusting cam on external
AFS models.
Fig. 70
Shock Spring Removal Tool
p/n: 0644-057
Usage: Remove/install shock absorber spring.
Fig. 71
0644-399
AE057
AE074
15

Shock Spanner Wrench
p/n: 2604-878
Usage: Adjust pre-load on Fox Zero Pro shock absorber.
Fig. 72
16
2604-878
Shock Spanner Wrench
p/n: 0644-398
Usage: Adjust pre-load on front arm rebuildable shock
absorber.
Fig. 73
Shock Spanner Wrench
p/n: 0644-305
Usage: Adjust pre-load on front arm standard shock
absorber.
Fig. 74
0644-398
0644-305
Shock Absorber Air Pump
p/n: 2603-324
Usage: Adjust air pressure on Fox Air Shocks.
Fig. 75
Jack Stand
p/n: 0644-076 (Standard Models - Low)
p/n: 0639-462 (ETT Models - High)
Usage: Support rear of snowmobile off the ground.
Fig. 76
Side Guard Kit
p/n: 0639-611
Usage: With Jack Stand (p/n 0644-076/0639-462).
Fig. 77
2603-324
AE133
0639-611

Replacement Bolt (Side)
p/n: 0644-101
Usage: Replaces side bolt in Track Clip Tool (p/n 0144-
301).
Fig. 78
Replacement Bolt (Center)
p/n: 0644-103
Usage: Replaces center bolt in Track Clip Tool (p/n
0144-301).
Fig. 79
Shock Rod Clamping Tool
p/n: 0744-021
Usage: Hold shock absorber rod for servicing.
Fig. 80
AE093
AE094
AE145D
Gas Shock Rod/Body Clamping
Tool
p/n: 0644-425
Usage: Hold gas shock absorber for servicing.
Fig. 81
0644-425
Gas Shock Retaining Blocks
p/n: 0644-334
Usage: Hold gas shock secure during disassembly and
assembly.
Fig. 82
Nitrogen Regulator
p/n: 0644-151
Usage: Recharge rebuildable gas shock absorbers.
Fig. 83
AP042
AE095
17

Inflation Needle
p/n: 0744-020
Usage: Pressurize rebuildable gas shock absorbers with
nitrogen.
Fig. 84
18
AE110
Inflation Needle Replacement
p/n: 0644-162
Usage: Replacement needle assembly for Inflation Needle
(p/n 0744-020).
Fig. 85
0644-162
Piston Location Tool
p/n: 0644-169
Usage: Precisely locate the floating piston in the rebuildable
gas shock absorber.
Fig. 86
AE135
Floating Piston Location Gauge
p/n: 0644-350
Usage: Precisely locate and measure floating piston
depth without use of a calipers.
Fig. 87
0644-350
Floating Piston Removal Tool
p/n: 0644-348
Usage: Remove floating piston from cross-link suspension
shocks on 2002 models.
Fig. 88
0644-348

Floating Piston Removal Tool Kit
p/n: 0644-402 (Complete Kit)
p/n: 0644-416 (Removal Tool)
p/n: 0644-417 (Location Gauge)
p/n: 0644-418 (Gauge Set Screw)
p/n: 0644-419 (Gauge Stop Collar)
Usage: Remove floating piston from rebuildable gas
shock absorbers.
Fig. 89
0644-402
Bearing Cap Seal Protector
p/n: 0644-268
Usage: Protect cap seal on rebuildable shock absorbers
through 2002 models.
Fig. 90
AE142
Bearing Cap Seal Protector
p/n: 0644-403 (1/2 in.)
p/n: 0644-404 (5/8 in.)
Usage: Protect cap seal on rebuildable shock absorbers
on 2003 and newer models.
Fig. 91
Ball Joint Fork
p/n: 0644-098
Usage: Separate ball joint from spindle or drag link.
Fig. 92
AE142
AE091
Track Clip Installation Tool
p/n: 0644-194
Usage: Install track clips on Camoplast and Yokohama
rubber tracks.
Fig. 93
0644-194
19

Track Stud Hole Drill (7 mm)
p/n: 1639-629
Usage: Drill 7 mm hole through rubber tracks for installing
studs.
Fig. 94
20
AE137
Track Stud Hole Drill (1/4 in.)
p/n: 1639-628
Usage: Drill 1/4 in. hole through rubber track for installing
studs.
Fig. 95
Carbide & Stud Specifications
Gauge
p/n: 1639-632
Usage: Check stud length and carbide angle.
Fig. 96
AE137
AE088
Idler Wheel Puller Kit
p/n: 0644-122 (Complete Kit - 6 in.)
p/n: 0644-400 (Complete Kit - 8 in.)
p/n: 0644-114 (A. Handle - 6 in.)
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
Idler Wheel Alignment Tool
p/n: 0644-228
Usage: Align center idler wheels during replacement
without removing the suspension.
Fig. 98
AE097B
BE025

Spider Removal Kit
p/n: 0644-449 (Complete Kit)
p/n: 0744-037 (Handle)
p/n: 0744-036 (Removal Tool)
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 crankshaft
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.
p/n: 0644-138 (1 7/16 in.)
Usage: Remove and install spider nut on Arctic roundshaft
drive clutch.
Fig. 99
0644-449
Clutch Bushing Installation Tool
(Arctic)
p/n: 0644-006
Usage: Replace sheave/cover bushings on Arctic hexdrive
clutches.
Fig. 100
AE053
Hex Clutch Puller (Arctic)
p/n: 0644-010
Usage: Remove Arctic hex-drive clutch from crankshaft.
Fig. 101
AE056
Clutch Puller (Arctic)
p/n: 0644-207
Usage: Remove Arctic round-shaft drive clutch from the
crankshaft.
Fig. 102
AE125
21

Clutch Puller (Comet)
p/n: 0644-096
Usage: Remove Comet drive clutch (short bolt w/
retainer plug style).
Fig. 103
Clutch Puller (Comet)
p/n: 0644-100
Usage: Remove Comet drive clutch (long bolt style).
Fig. 104
Clutch Compressor (Arctic
Round-Shaft)
p/n: 0644-245
Usage: Compress and hold Arctic round-shaft drive
clutch in the compressed position for changing cam
arms.
Fig. 105
22
AE089
AE055
AE132
Clutch Compressor (Comet)
p/n: 0644-123
Usage: Compress and hold drive clutch in the compressed
position for changing cam arms.
Fig. 106
AE098
Clutch Compressor
p/n: 0644-420
Usage: Compress and hold drive clutch in the compressed
position for changing cam arms and removing/
installing six-post drive clutch on AWS VI models.
Fig. 107
0644-420
Drive Clutch Spanner Wrench
p/n: 0644-136
Usage: Hold Comet and Arctic round-shaft drive clutch
in place during removal and installation.
Fig. 108
AE101

Bushing Tool Kit
p/n: 0644-137
Usage: Remove and install cover plate and movable
sheave bushings in Arctic round-shaft drive clutch
through 1998.
Fig. 109
AE127A
Bearing Removal and Installation
Tool
p/n: 0644-167
Usage: Remove and install bearings in the driven clutch
movable sheave and button plate.
Fig. 110
AE112
Clutch Alignment Bar (1.365 in.
Offset)
p/n: 0644-320
Usage: Align the drive clutch and driven pulley on models
using the reverse cam driven pulley.
Fig. 111
AE052A
Clutch Alignment Bar (1.562 in.
Offset)
p/n: 0644-246
Usage: Align drive clutch and driven pulley on 1997
models using the Arctic internal-helix driven pulley.
Fig. 112
AE140
Clutch Alignment Bar (1.485 in.
Offset)
p/n: 0644-428
Usage: Align drive clutch and driven pulley on Bearcat
Wide Track models.
Fig. 113
0644-428
Clutch Alignment Bar (1.620 in.
Offset)
p/n: 0644-427
Usage: Align drive clutch and driven pulley on ACT Drive
models.
Fig. 114
AE052A
23

Reverse Gear Adjustment Gauge
p/n: 0644-244
Usage: Adjust reverse gear linkage on all 1996-2002
reverse gear transmissions.
Fig. 115
Driven Pulley Puller
p/n: 0744-023
Usage: Remove driven pulley from driven shaft. It can
be used on both the roller and button style.
Fig. 116
24
BE027
0744-023
Roller Pin Removal Tool
p/n: 0644-276
Usage: Remove roller pins from retainer plate on driven
pulley.
Fig. 117
AE146D
Bearing Removal Tool
p/n: 0644-421
Usage: Remove chain case bearings on 2003 and
newer models.
Fig. 118
Drive Belt Gauge
p/n: 0644-443
Usage: Measure drive belt width.
Fig. 119
0644-421
0644-443
Drive Belt Deflection Tool
p/n: 0644-412
Usage: Adjust driven pulley for proper drive belt deflection
and aid in drive belt removal on models using the
ACT Roller Driven Pulley.
Fig. 120
0644-412

Drive Belt Replacement Tool
p/n: 0644-435
Usage: Replace drive belt and adjust belt deflection on
models using the ACT Roller Driven Pulley.
Fig. 121
0644-435
Driven Pulley Spring Adjustment
Tool
p/n: 0644-413
Usage: Adjust driven pulley spring pre-load on models
using the ACT Driven Pulley.
Fig. 122
0644-413
Drive Belt Deflection Tool
p/n: 0644-424
Usage: Adjust driven pulley for proper drive belt deflection
and aid in drive belt removal on 2004 440 Sno Pro
model.
Fig. 123
0644-424
Driven Pulley Compressor Tool
p/n: 0644-444
p/n: 0644-439 (A. Compressor Assembly Only)
p/n: 0643-095 (B. Disc Only)
Usage: Disassemble/assemble Arctic ACT and Team
Industries roller driven pulleys.
Fig. 124
644-444A
Brake Disc Socket Wrench
(ACT Drive)
p/n: 0644-415
Usage: Remove/install brake disc on ACT Drive models.
Fig.125
0644-415
25

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