Snowmobile Arctic Cat (2002 year). Manual - part 109

7-48

0736-108

0735-831

KEY

1. Tunnel Assy
2. Bracket
3. Mounting Plate
4. Rivet
5. Decal
6. Decal
7. Rivet
8. Plug
9. End Plate

10. Reflector
11. Retaining Clip
12. Bumper
13. Decal
14. Decal
15. Machine Screw
16. Washer
17. Lock Nut
18. Snowflap
19. U-Nut
20. Bracket
21. Rivet
22. Clamp
23. U-Nut
24. Rivet
25. Plug
26. Roll
27. Pad
28. Machine Screw
29. Lock Nut
30. Machine Screw

31. Cushion Snap
32. Rivet
33. Insert

KEY

1. Tunnel Assy
2. Bracket
3. Mounting Plate
4. Rivet
5. Washer
6. Decal
7. Rear Bumper
8. Self-Tapping Screw
9. Footrest

10. Wear Strip
11. Rivet
12. Clamp
13. Decal
14. Decal
15. Bracket
16. Washer
17. Lock Nut
18. U-Nut
19. Machine Screw
20. Snowflap
21. U-Nut
22. Decal
23. Plug
24. Trim
25. Reflector
26. Clip
27. Rivet
28. Rivet
29. Machine Screw

7-49

0736-590

REMOVING/DISASSEMBLING

NOTE: The snowflap can be removed without

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

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.

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

KEY

1. Tunnel Assy
2. Mounting Plate
3. Bracket
4. Rivet
5. Pad
6. Decal
7. Seal
8. Plate
9. Plate

10. Guide
11. Machine Screw
12. Bumper
13. Cap Screw
14. Carriage Bolt
15. Hinge
16. Washer
17. Lock Nut
18. Reflector
19. Machine Screw
20. Snowflap
21. Plate
22. Plate
23. Plate
24. Insert
25. Plate
26. Plate
27. Clip
28. Plug
29. Decal
30. Footrest

31. Lock Nut
32. Self-Tapping Screw
33. Seal
34. Seal
35. Cap Screw
36. Lock Washer
37. Cap
38. Bracket
39. Lever
40. Bracket
41. Rivet
42. Spring
43. Clamp
44. Rivet
45. Washer
46. Washer
47. Disc
48. Insert
49. Cap

7-50

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.

2. Insert the headlight bulb socket into the headlight

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 illuminaton for
the operator is apparent.

Headlight Assembly

(1 Bulb Halogen)

REMOVING

NOTE: The bulb portion of the headlight is frag-

1. To release the retaining ring, depress the ring and

rotate it counterclockwise. Slide the retaining ring

down the wiring harness.

2. With the harness connector attached to the bulb,

carefully withdraw the bulb from the headlight

housing.

3. Grasp the bulb by the metal base and carefully

remove the headlight harness from the bulb.

4. Between the top center of the headlight and hood,

there is a reusable plastic push rivet. From the

front using a medium-sized standard screwdriver,

push the center post of the rivet back.

0731-844

5. Remove the headlight adjustment thumb screws;

then remove the headlight assembly.

NOTE: Halogen bulbs must not come in contact

with hands or foreign contaminants.

INSTALLING

1. Place the headlight assembly into position. Secure

with a push rivet and two adjustment thumb

screws.

2. While holding bulb by the base, firmly install the

bulb in the harness connector.

3. Install bulb assembly (with harness attached) into

headlight housing. Make sure the bulb is firmly

seated in the headlight housing.

4. Install the retaining ring onto the back of the

headlight. Depress the ring and rotate it clockwise

to lock in place.

AL084D

5. Check headlight aim (see appropriate Adjusting

Headlight Aim in this section).

! 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.

7-51

Adjusting

Headlight Aim

(1 Bulb Halogen)

The headlight HIGH/LOW beam can be adjusted ver-

tically and horizontally. The geometric center of the

HIGH beam light zone is to be used for vertical and

horizontal aiming.

1. Position the snowmobile on a level floor so the

headlight is approximately 8 m (25 ft) from an

aiming surface (wall or similar surface).

2. Measure the distance from the floor to the

midpoint of the headlight.

3. Using the measurement obtained in step 2, make a

horizontal mark on the aiming surface.

4. Make a vertical mark which intersects the

horizontal mark on the aiming surface directly in

front of the headlight.

5. Start the engine. Move the headlight dimmer

switch to the HIGH beam position. DO NOT USE

THE LOW BEAM.

6. Observe the headlight beam aim. Proper aim is

when the most intense beam is centered on the

vertical mark 5 cm (2 in.) below the horizontal

mark on the aiming surface.

0734-485

7. Rotate the adjustment thumb screws until the

correct aim is obtained.

Headlight Assembly

(3 Bulb Halogen)

REMOVING HEADLIGHT BULB

NOTE: The bulb portion of the headlight is frag-

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 appropriate 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.

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