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Snowmobile Arctic Cat (2008 year). Instruction - part 163

8-55

739-527A

1. Remove the O-rings securing windshield to the

hood.

2. Remove the caps covering the screws; then

remove the screws w/snaps.

3. Remove the windshield.

INSTALLING

1. Place the windshield into position and install the

O-rings.

2. Secure the windshield to the hood with screws w/

snaps. Install the caps.

Windshield

(F-Series/T-Series)

REMOVING

1. Remove the plastic rivet securing the front of the

windshield to the windshield bracket.

2. Remove the two torx-head screws securing the

windshield to the console; then separate the wind-

shield from the console.

INSTALLING

741-637A

1. Place the windshield into position on the console.

2. Secure the windshield to the console with the torx-

head screws.

3. Using a new plastic rivet, secure the windshield to

the windshield bracket.

Backrest/Rack

Assembly

(Bearcat/Panther)

NOTE: Some components may vary from model
to model. The technician should use discretion
and sound judgment.

REMOVING

1. Remove the cap screws, washers, and cap nuts

securing the rack to the backrest.

2. In turn on each side, remove the two cap screws

(inside the tunnel) securing the backrest assembly

to the tunnel. Account for the washers.

3. If applicable, disconnect the passenger hand-

warmer wiring harness.

4. Remove the backrest assembly from the tunnel.

Account for the two spacers.

INSTALLING

1. Place the backrest assembly and spacers (located

on the rear hole on each side) into position and

align holes with tunnel mounting holes.

2. Install the cap screws with washers from the inside

of the tunnel and secure with the washers and lock

nuts. Tighten securely.

3. In turn on each side, install the 1/4-in. cap screw in

the front hole and the 5/16-in. cap screw in the rear

hole. Secure with a flat washer and lock nut.

Tighten securely.

4. If applicable, connect the passenger handwarmer

wiring harness.

5. Place the rack into position and secure with the

cap screws, washers, and cap.

Tunnel/Rear Bumper/

Snowflap

(Bearcat/Panther)

NOTE: Some components will vary from model
to model. The technician should use discretion
and sound judgment.

REMOVING/DISASSEMBLING

NOTE: The snowflap can be removed without
removing the bumper by removing the three
bumper/snowflap cap screws.

KEY

1. Windshield

2. Machine Screw

3. Snap and Cap

4. Expansion Nut

5. O-Ring

6. Mirror

Bearcat/
Panther

8-56

1. Remove the cap screws securing the bumper

assembly to the tunnel. Account for the U-nuts and

cap screws.

2. Slide the bumper/snowflap off the tunnel.

3. Remove the cap screws securing the snowflap to

the bumper and separate the bumper and snowflap.

Account for cap screws, washers, and lock nuts.

ASSEMBLING/INSTALLING

1. Secure the snowflap to the bumper with the cap

screws, washers, and lock washers taking care to

place the washers next to the underside of the

snowflap. Finger-tighten the cap screws to the lock

nuts; then tighten the cap screws securely.

2. Place the bumper assembly into position on the

tunnel and secure with the cap screws and U-nuts.

Tighten the cap screws securely.

Tunnel/Chassis/

Rear Bumper/Snowflap

(Crossfire/M-Series)

REMOVING/REPLACING TUNNEL

To remove and/or replace a tunnel on a particular

snowmobile, a number of removing and installing

component sequences must be followed. The techni-

cian must in turn go to the following sections in this

manual and refer to the appropriate removing/install-

ing sub-sections. When doing these sequences, the

technician should use discretion and sound judgment.

A. Section 2 - Engine

B. Section 6 - Drive Train and Brake Systems

C. Section 7 - Track/Rear Suspension

D. Section 8 - Steering and Body

REMOVING BUMPER/SNOWFLAP

1. Remove the machine screw securing the taillight

housing to the bumper assembly; then disconnect

the taillight wiring harness.

2. Remove the torx-head screws securing the snowflap

to the bumper; then remove the snowflap.

FC232

3. Remove the torx-head screws securing the bumper

to the tunnel.

4. Remove the taillight/bumper assembly from the

tunnel.

INSTALLING BUMPER/SNOWFLAP

1. Install the bumper assembly to the tunnel; then

secure with the torx-head cap screws.

2. Secure the snowflap to the bumper with the torx-

head screws.

3. Connect the taillight wiring harness; then install

the taillight housing onto the bumper assembly.

Tunnel/Chassis/

Rear Bumper/Snowflap

(F-Series/T-Series)

REMOVING/REPLACING TUNNEL

To remove and/or replace a tunnel on a particular

snowmobile, a number of removing and installing

component sequences must be followed. The techni-

cian must in turn go to the following sections in this

manual and refer to the appropriate removing/install-

ing sub-sections. When doing these sequences, the

technician should use discretion and sound judgment.

A. Section 2 - Engine

B. Section 6 - Drive Train and Brake Systems

C. Section 7 - Track/Rear Suspension

D. Section 8 - Steering and Body

REMOVING BUMPER/SNOWFLAP

NOTE: The snowflap can be removed without
removing the bumper by removing the two self-
tapping screws securing the snowflap to the heat
exchanger.

8-57

1. Carefully pry upward on the tunnel fender until the

fender tabs clear the slots in the tunnel; then lift

upward and outward on the fender to access the

machine screws and lock nuts securing the bumper

to the tunnel.

ZJ298A

2. Remove the four machine screws and lock nuts

securing the bumper to the tunnel.

3. Remove the two self-tapping screws securing the

snowflap to the heat exchanger; then slide the

snowflap away from the fender and bumper.

4. Remove the two self-tapping screws securing the

bumper to the heat exchanger. Account for the

bracket covers.

5. Remove the two self-tapping screws securing the

fender to the bumper; then remove the bumper.

INSTALLING BUMPER/SNOWFLAP

1. Place the bumper into position on the tunnel; then

install the four machine screws and lock nuts

securing the bumper to the tunnel. Tighten the lock

nuts securely.

2. Place the tunnel fender into position engaging the

tabs of the fender with the slots of the tunnel.

3. Install the two self-tapping screws (threads coated

with blue Loctite #243) securing the bumper to the

heat exchanger. Tighten the screws to 25 ft-lb.

ZJ297B

4. Secure the tunnel fender to the bumper with the two

self-tapping screws. Tighten the screws securely.

5. Place the snowflap into position; then secure the

snowflap to the heat exchanger with the two self-

tapping screws (threads coated with blue Loctite

#243). Tighten the screws to securely.

FS263A

Rear Storage

Compartment

(F-Series)

REMOVING

0741-970

1. Remove the six self-tapping screws (A) securing

the storage compartment to the tunnel fender.

2. Remove the four body screws (B) securing the

fender to the tunnel; then disconnect the taillight

plug-in and remove the fender.

INSTALLING

1. Connect the taillight harness plug-in and install the

fender with the four body screws (B); then tighten

the screws securely.

2. Place the storage compartment into position on the

fender; then install the six self-tapping screws (A).

Tighten the screws securely.

8-58

Air Silencer Assembly

(Crossfire/M-Series)

REMOVING

1. Remove the connector clamp securing the intake

connector (hose) to the hood screen (right-side).

FC248

2. With the hood closed, loosen the headlight adjust-

ment knobs.

3. Carefully push the headlight lenses rearward far

enough to remove the torx-head screws securing

the air silencer plenum to the hood.

4. Open the hood; then remove the O-rings securing

the air silencer plenums to the hood and remove

the air silencer plenums.

INSTALLING

1. Press the air silencer plenums into place on the

hood and secure with the O-rings; then close the

hood.

2. Carefully push the headlight lenses rearward far

enough to install the torx-head screws. Tighten the

screws securely.

3. Tighten the headlight adjustment knobs.

4. Check headlight aim (see Adjusting Headlight

Aim in this sub-section).

Headlight Assembly

(Bearcat/Panther)

REMOVING HEADLIGHT BULB

NOTE: The bulb portion of the headlight is frag-
ile. HANDLE WITH CARE. When replacing the
headlight bulb, the bulb assembly must first be
removed from the housing. Do not touch the glass
portion of the bulb. If the glass is touched, it must
be cleaned with a dry cloth before installing.

1. Pull the wiring harness retaining clip away from

the headlight bulb base and disconnect the wiring

harness from the bulb.

0733-178

2. Rotate the headlight bulb base counterclockwise

and remove the bulb from the headlight housing.

INSTALLING HEADLIGHT BULB

1. While holding the bulb by its base, insert the bulb

into the headlight housing and rotate it clockwise

until it locks into the housing.

2. Plug the wiring harness into the headlight bulb

base making sure the retaining clip locks onto the

base.

3. Check headlight aim (see Adjusting Headlight

Aim in this section).

Headlight Assembly

(F-Series/T-Series)

REMOVING HEADLIGHT BULB

To access the headlight bulbs, use the following proce-

dure:

! CAUTION

Do not touch the glass portion of the bulb. If the
glass portion is touched, it must be cleaned with a
dry cloth before installing.

! WARNING

Do not operate the snowmobile unless headlight
beam is adjusted properly. An incorrectly adjusted
beam will not provide the operator the optimum
amount of light.

Content .. 161 162 163 164 ..