Snowmobile Arctic Cat (2002 year). Manual - part 107

7-40

2. Install the nosepiece torx-head screws to the front

belly pan.

AL182D

3. Install the nosepiece Phillips-head screw to the

front belly pan.

AL181D

4. Install the belly pan torx-head screws underneath

the shock mount.

AL179D

5. Install the shock absorber. Tighten to 3.9 kg-m

(28 ft-lb).

AL178D

6. Install the right-side steering tie rod boot. Secure

with the screws.

AL190D

7. Install the right-side belly pan torx-head screws to

the center belly pan and tunnel; then return the

snowmobile to an upright position.

AL188D

8. Install the right-side cap screws securing the

bumper to the air-intake silencer plenum.

7-41

7

AL186D

9. Insert the right-side louver foam.

AL185D

10. Install the right-side louver.

AL184D

11. Install the right-side front belly pan cap screw,

washer, and lock nut.

AL183D

Seat/Cushion/

Taillight Housing

(120 cc)

REMOVING

1. Remove the retaining nut securing the ignition

switch to the console; then slide the switch

forward and out of the console.

A041

2. Remove the screw securing the choke knob to the

cable; then remove the knob.

A042

3. Remove the two nuts securing the choke cable to

the console; then slide the cable forward and out of

the console.

A043

7-42

4. Pull the recoil starter rope out approximately 60

cm (24 in.); then tie a slip-knot in the starter rope

below the console and allow the rope to slowly

retract against the starter case.

5. Remove the knot at the handle and remove the

handle; then thread the rope through the bushing in

the console.

6. Turn the gas tank shut-off valve to the CLOSED

position; then disconnect the fuel hose from the

carburetor.

7. Remove the vent hose from the top of the gas tank.

A044

8. Raise the flap at the rear of the seat and remove the

two cap nuts securing the seat assembly to the

tunnel. Account for two washers.

9. Raise the rear of the seat assembly high enough to

disconnect the taillight wiring harness; then

disconnect the taillight from the main wiring

harness.

A045

10. Remove the seat assembly.

„

NOTE: If necessary, use a sharp tool to pry out

all staples securing the seat cover to the plastic
seat base; then remove the cover from the seat
base and seat foam.

! WARNING

Whenever any maintenance or inspection is made
on a fuel system when there may be fuel leakage,
there should be no welding, smoking, open flames,
etc., in the area.

7-43

7

INSTALLING

„

NOTE: If the seat cover was removed, position

the cover over the seat foam and plastic seat base.
Check to make sure it is positioned straight; then
fold the rear edge of the cushion down and around
the base. Using a staple gun and 6 mm (1/4 in.) sta-
ples, staple the rear flap of the cushion to the base
in the same areas as the original staples were
located. Position staples 2.5 cm (1 in.) apart. Fold
the sides of the cushion down around the bottom
edge of the base. Position the staples in the same
areas as the original staples were located.

0736-891

1. Place the seat assembly into position and connect

the taillight wiring harness.

2. Secure the seat assembly to the tunnel with

washers and cap nuts.

3. Connect the vent hose to the top of the gas tank.

4. Thread the recoil starter rope through the bushing

in the console and the handle; then tie a knot at the

end of the rope and pull the handle up and onto the

knot.

5. Untie the slip-knot at the starter case and allow it

to slowly rewind into the case.

6. Slide the choke cable through the console and

secure with two lock nuts; then using a screw

(coated with blue Loctite #243), secure the choke

knob to the end of the cable.

7. Slide the ignition switch into position on the

console; then secure with the retaining nut.

8. Connect the fuel hose to the carburetor and turn

the gas tank shut-off valve to the OPEN position.

Taillight Housing

REMOVING

1. Remove the four screws securing the taillight lens

to the housing. Account for a gasket.

2. Remove the four machine screws securing the

backing plate to the taillight housing.

3. Remove the two screws, lock washers, and

washers securing the seat base to the tunnel. Lift

the seat from the tunnel. Disconnect the taillight

wiring harness.

4. Remove the two lock nuts and washers securing

the taillight housing to the rear of the seat base.

Pull the housing free of the base.

KEY

1. Seat Assy

30.   Cable Tie

2. Gas Tank/Seat-Base

31.   Cable Clip

3. Seat Cover 

32.   Bushing

4. Foam
5. Cap
6. Seal
7. Seat Wire
8. Seat Wire
9. Shut-Off Valve

10. Fuel Hose
11. Fuel Filter
12. Teflon Tape
13. Taillight Assy
14. Bulb
15. Washer
16. Nut w/Lock Washer
17. Washer
18. Cap Nut
19. Choke Cable
20. Staple
21. Nut
22. Decal
23. Retaining Nut
24. Ignition Switch
25. Ignition Switch Key
26. Lock Nut
27. Cap Screw
28. Decal
29. Push Nut