Snowmobile Arctic Cat (2004 year). Manual - part 97

7-52

0738-526

0738-399

KEY

1. Tunnel Assy
2. Bracket
3. Rivet
4. Plate - Front
5. Tunnel Roll
6. Rivet
7. Footrest
8. Bracket
9. Rivet

10. Clamp
11. Hole Plug
12. Bumper
13. U-Nut
14. U-Nut
15. Decal
16. Decal
17. Machine Screw
18. Machine Screw
19. Washer
20. Lock Nut
21. Washer
22. Snowflap
23. Machine Screw
24. Decal

KEY

1. Tunnel Assy
2. Bracket
3. Tunnel Plate - Rear
4. Rivet
5. Rivet
6. Mounting Plate - 

Front

7. Rivet
8. Rivet
9. Bracket

10. Clamp
11. Plug
12. U-Nut
13. U-Nut
14. Rear Bumper
15. Decal
16. Decal
17. Machine Screw
18. Machine Screw
19. Washer
20. Lock Nut
21. Washer
22. Snowflap
23. Reflector
24. Retaining Clip
25. Decal
26. Decal

7-53

7

0738-621

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.

KEY

1. Tunnel Assy
2. Tunnel - Front
3. Tunnel - Rear
4. Stud
5. Rivet
6. Rivet
7. Bracket - Rear
8. Rivet
9. Roll

10. Mounting Plate - 

Front

11. Rivet
12. Bracket
13. Driven Shaft Cover
14. Backing Plate
15. Plug
16. Pad
17. Bumper
18. U-Nut
19. U-Nut
20. Decal
21. Decal
22. Snowflap
23. Machine Screw
24. Washer
25. Lock Nut
26. Machine Screw
27. Machine Screw
28. Decal
29. Decal

30. Decal
31. Cable Tie
32. Washer

7-54

Tunnel/Rear Bumper/ 

Snowflap

(AWS VI)

0738-703

REMOVING

1. Remove the three torx-head screws securing the

s n o w f l a p   t o   t h e   b u m p e r ;   t h e n   r e m o v e   t h e
snowflap.

FC232

2. Remove the 10 torx-head screws securing the

bumper to the tunnel.

3.  From inside the rear compartment, remove the nut

and washer securing the seat assembly to the
tunnel; then disconnect the taillight wiring
harness.

FC228

FC233

KEY

1. Tunnel Assy
2. Bracket - Rear
3. Plate
4. Rivet
5. Self-Tapping Screw
6. Foil
7. Rivet
8. Harness Protector
9. Lock Nut

10. Machine Screw
11. Decal
12. Foam
13. Machine Screw
14. Lens
15. Taillight  w/Socket
16. Housing
17. Bulb
18. Speed Nut
19. Bumper
20. Self-Tapping Screw
21. Lock Nut
22. Machine Screw
23. Machine Screw
24. Speed Nut
25. Washer
26. Snowflap
27. Decal
28. Decal
29. Foam
30. Decal

7-55

7

4. Remove the taillight/bumper assembly from the

tunnel.

FC234

5. From the underside of the bumper, remove the

four torx-head screws securing the taillight
assembly to the bumper. 

FC235

INSTALLING

1. Place the taillight assembly into position on the

bumper; then secure with the four torx-head
screws.

FC235

2. Place the taillight/bumper assembly into position

on the tunnel.

FC234

3.  Secure the taillight/bumper assembly to the tunnel

with the 10 torx-head screws.

4.  Connect the taillight wiring harness; then position

the seat assembly onto the tunnel.

FC233

5.  From inside the rear compartment, secure the seat

assembly to the tunnel with the nut and washer. 

FC228

6. Secure the snowflap to the bumper with the three

torx-head screws.