how to add a reverse kit

Has your reverse-less snowmobile gotten to be a drag? A drag off thetrailer? A drag to turn around on the trail? A drag when another snowmobilerpins you in at a trail stop?

Aside from digging a submarined sled from two feet of fresh powder, areverse kit can help reduce your chance of a hernia, lower back pain andkicking the tar out of your sled.

Unlike installing an electric start or hand and thumbwarmers, a reversekit is all mechanical-no electric components--unless you decide to installthe hideous backup beeper. Be aware that if you install reverse on yoursnowmobile you must cut into the shell that separates the driver and engine.Expect to spend five to six hours on the project, and be warned that thiscan be a challenging do-it-yourself project. Also know that reverse willadd 15 pounds to your snowmobile's weight. Reverse kits are not designedfor high horsepower motors-they can easily tear them into pieces. Also,expect to spend about $300 to $500 for a kit. If you are uneasy about this,stop here and find a dealer to do the work.

We installed a reverse kit on a 1996 Arctic Cat EXT, but the followinginstructions should apply to all models. Make sure to read the instructionsfor your specific kit, though. Some models may need additional adapters,a new chaincase or a complete set of new gears. No one kit fits all. Also,as a general comment, use Loctite when recommended. Reverse on a snowmobileis a gear-to-gear mechanism and if the snowmobile is weighed down, excessivetorque will be placed on the reverse gearing.

1. Place a drain pan under the chaincase, remove the chaincasedrain plug and drain the oil. Don't figure on saving this oil; use somenew manufacturer-specified chaincase oil. Remove the chaincase cover.

2. Remove the chain tension spring, roller and arm assembliesand sprockets and chain.

3. Wash all metal components in a cleaning solvent, and wash allnon-metal parts in warm, soapy water.

4. Remove the idler shaft location bolt nut and washer from thechaincase. Place the chain backing plate into position on the rear chainadjuster stud.

5. Slide the chain roller onto the arm and secure it with a flex-locknut. Install the entire roller assembly onto the tightener arm. Place thechain tightener arm assembly onto the tightener arm stud and secure.

6. Loop the chain around the upper sprocket and the new lowersprocket, making sure that the pins on the lower sprocket face out. Installthe chain and sprockets.

7. While holding the new lower sprocket out, install the new shiftfork and idler sprocket, with drive lugs facing outward. Install the idlergear; check that the drive lugs and holes align with the idler sprocket'sdrive lugs and those on the previously installed idler adjuster.

8. Place the driveshaft extension into position on the track'sdriveshaft. Install the reverse gear and ensure that the drive holes arefacing the lower sprocket.

9. Reinstall the clean chaincase cover. While installing, positionthe shift fork between the large thrust washer and the reverse gear. Fillchaincase with specified gear-lube oil.

10. If needed, install the new snow flap. Mount it so the trackwon't catch it when putting the sled in reverse.

11. Install the linkage assembly, which in general, will consistof a reverse lever, lever adjustment, console boot and appropriate heimjoints. When installing the reverse lever, place the shift lever hole orshift lever slide pattern on the console and trace with a red magic-markeror a sharp object. Make sure the hole is exactly where the instructionsstate; this will influence how much length is needed for lever adjustment.If the shift lever is a turn-down style, drill a guide hole, then the properlysized hole. If installing a push-pull lever (slide), drill a guide holelarge enough for a jigsaw blade. With the jigsaw, follow the pattern anddrill the appropriate sized slot. Then install the reverse lever consoleboot.

12. Start the snowmobile and place the shift lever in the forwardposition, and loosen the jam nuts on the upper linkage. Rotate the linkageuntil the shift lever is centered in the boot. Once the shift lever is positioned,move the lever forward and back or up and down to verify the snowmobilemoves forward and backward. If it doesn't, make corrections to the adjustmentlever.

Some kits will come with a reverse sounding beeper to install. I find this a nuisance, but if you feel that you must tell everybody that you are backing off the trailer, or that you are stuck and need to sound the rescuebell, then feel free.

Many thanks to Tom Wilson of Wilson's Arctic Cat, Idaho Falls, Idaho,who let me rip into his EXT.