Snowmobile Arctic Cat (2007 year). Instruction - part 73

 

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Snowmobile Arctic Cat (2007 year). Instruction - part 73

 

 

7-66

0741-989

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/

installing sub-sections. When doing these

sequences, the technician should use discretion and

sound judgment.

A. Section 2 - Engine

B. Section 7 - Steering and Body

C. Section 8 - Drive Train and Brake Systems

D. Section 9 - Track/Rear Suspension

REMOVING BUMPER/SNOWFLAP 
(660 cc)

„

NOTE: The snowflap can be removed without

removing the bumper by removing the three
bumper/snowflap screws.

1. Remove the screws securing the bumper assem-

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

screws.

2. Slide the bumper/snowflap off the tunnel.

3. Remove the screws securing the snowflap to the

bumper and separate the bumper and snowflap.

Account for screws, washers, and lock nuts.

REMOVING BUMPER/SNOWFLAP 
(1100 cc Z1)

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

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.

KEY

1. Fender - Tunnel

2. Decal

3. Decal

4. Body Screw

5. Storage Box

6. Decal

7. Decal

8. Cover

9. Self-Tapping 

Screw

10. Lid

11. Latch

12. Taillight Assy

13. Housing

14. Bulb

15. Socket

16. Washer

17. Self-Tapping 

Screw

18. Rear Bumper

19. Bracket Cover

20. Self-Tapping 

Screw

21. Cap Screw

22. Machine Screw

23. Lock Nut

24. Snowflap

25. Self-

Tapping 
Screw

26. Decal

Jaguar Z1

7-67

7

5. Remove the two self-tapping screws securing

the fender to the bumper; then remove the

bumper. 

INSTALLING BUMPER/SNOWFLAP 
(660 cc)

1. Secure the snowflap to the bumper with the

screws, washers, and lock washers taking care to

place the washers next to the underside of the

snowflap. Finger-tighten the screws to the lock

nuts; then tighten the screws securely.

2. Place the bumper assembly into position on the

tunnel and secure with the screws and U-nuts.

Tighten the screws securely. 

INSTALLING BUMPER/SNOWFLAP 
(1100 cc Z1)

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 specifications.

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 specifica-

tions.

ZJ299A

Headlight Assembly

(120 cc)

REMOVING

„ 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. Peel back the rubber headlight socket cap; then

push in and turn the headlight socket counter-

clockwise and remove it from the headlight

housing.

2. Remove the caps covering the four headlight

adjustment screws; then remove the adjustment

screws. Remove the headlight from the hood.

A038

INSTALLING

1. Secure the headlight housing to the hood with

the four adjustment screws; then snap the caps

on the screws.

„ NOTE: The hood cable is secured with the lower
right-hand adjustment screw.

7-68

2. Insert the headlight bulb socket into the head-

light housing; then rotate the socket clockwise

to lock it into the housing.

3. Place the rubber headlight socket cap over the

headlight housing bead around the socket.

„ NOTE: To adjust headlight aim, adjust the four
adjustment screws until maximum illumination for
the operator is apparent.

Headlight Assembly

(Bearcat Wide Track/Jaguar Z1/ 

Panther 660/T660)

REMOVING HEADLIGHT BULB 

(Bearcat W/T/Panther 660 Models)

„

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 wir-

ing harness from the bulb.

0733-178

2. Rotate the headlight bulb base counterclockwise

and remove the bulb from the headlight housing.

INSTALLING HEADLIGHT BULB 
(Bearcat W/T/Panther 660 Models)

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).

REMOVING HEADLIGHT BULB 
(T660 Models)

„ 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. Remove the bulb from the headlight housing. 

737-299A

2. Disconnect the wiring harness from the bulb.

INSTALLING HEADLIGHT BULB 

(T660 Models)

1.  Plug the wiring harness into the headlight bulb.

2.  Insert the bulb into the headlight housing.

3. Check headlight aim (see Adjusting Headlight

Aim in this section).

! 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.

! 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.

7-69

7

REMOVING HEADLIGHT BULB 
(Jaguar Z1 Model)

„

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.

To access the headlight bulbs, use the following pro-

cedure:

1. Release the latches securing the windshield to

the windshield base; then remove the wind-

shield.

2. Remove the two torx-head cap screws located to

the outside of the headlight adjustment knobs;

then remove the single torx-head cap screw

from beneath the console (located between the

headlights).

741-505A

3. Remove the cap screw and lock nut securing the

front of the headlight assembly to the air-intake

silencer.

4. Lift the front of the console enough to allow the

headlight housing to be removed; then remove

the housing.

5. Remove the bulb from the headlight housing

and disconnect the wiring harness from the bulb.

741-329A

INSTALLING HEADLIGHT BULB 
(Jaguar Z1 Model)

1. Insert the bulb into the headlight housing; then

lock the bulb into position.

2. Plug the wiring harness into the headlight bulb.

3. Lift the front of the console enough to allow the

headlight housing to be installed; then install the

housing making sure the forks of the housing go

into the grommets on top of the air-intake

silencer. Secure with the cap screw and lock nut.

0741-506

4. Position the console onto the air-intake silencer;

then secure with the single torx-head cap screw

beneath the console (located between the head-

lights).

5. Install the two torx-head cap screws located to

the outside of the headlight adjustment knobs;

then tighten securely.

6. Place the windshield into position on the wind-

shield base; then secure with the latches.

! 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.

! 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.

 

 

 

 

 

 

 

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