Snowmobile Arctic Cat (2004 year). Manual - part 99

7-60

FC251

INSTALLING

1. Place the hood screen into position on the hood

cover; then carefully push down (in multiple
locations) until the screen is correctly and firmly
seated in the hood cover.

2. Place the rear hood cover locking tabs into

position on the hood; then carefully lower the
hood cover into position on the hood.

FC250

FC249

3. While supporting the hood cover, carefully open

the hood; then install the two O-rings onto the
front mounting tabs of the cover.

4. Place the intake connector (hose) onto the hood

screen; then secure with the connector clamp.

FC252

Headlight Assembly

(AWS V)

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.

! 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.

7-61

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

(AWS VI)

REMOVING HEADLIGHT

1. Remove the adjustment screw w/knob at the

console.

FC236

2. From beneath the hood, unplug the wiring harness

connectors from the bulbs.

FC237

3. Remove the hairpin clips securing the headlight

assembly to the hood. Account for the adjuster
spring.

FC239

INSTALLING HEADLIGHT

1. Beneath the hood, place the headlight assembly

into position in the mounting tabs.

FC240

2. Place the adjuster spring into position; then thread

the adjustment screw into the headlight assembly.

FC241

3. Install the hairpin clips to secure the headlight

assembly to the hood; then plug in the bulb wiring
connectors.

! 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.

7-62

FC238

REMOVING HEADLIGHT BULB

NOTE: The bulb portion of the headlight is frag-

1. Remove the bulb from the headlight housing and

disconnect the wiring harness from the bulb.

737-299A

INSTALLING HEADLIGHT BULB

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).

Adjusting

Headlight Aim

The headlight can be adjusted for vertical aim of the
HIGH/LOW beam. The geometric center of HIGH
beam zone is to be used for vertical 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).

NOTE: There should be an “average” operating

load on the snowmobile when adjusting headlight
aim.

2. Measure the distance from the floor to 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. Select the headlight dimmer

switch HIGH beam position. DO NOT USE 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.

0738-807

7. Adjust the headlight housing mounting screws

(on AWS V models) or the console adjustment
knobs (on the AWS VI models) until correct aim is
obtained. Shut the engine off.

! 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.

7-63

Torque Specifications

(AWS V)

Torque Specifications

(AWS VI)

Torque Specifications

(General Bolts)

ITEM

TORQUE

Ski

ft-lb

kg-m

21-26

2.9-3.6

Handlebar Adjuster Block

ft-lb

kg-m

1.4

Steering Post Bearing Housings ft-lb

kg-m

2.5

Steering Post/Tie Rod

ft-lb

kg-m

4.2

Drag Link/Tie Rods

ft-lb

kg-m

2.8

Drag Link/Steering-Idler Arms

ft-lb

kg-m

4.2

Spindle Arm/Tie Rod

ft-lb

kg-m

4.2

Tie Rod Jam Nuts

ft-lb

kg-m

12-15

1.7-2.1

Suspension Arms/Spindle

ft-lb

kg-m

4.2

Shock Absorber/Spindle

ft-lb

kg-m

2.8

Front Suspension Arm

ft-lb

(Upper)

kg-m

4.2

Front Suspension Arm

ft-lb

(Lower)

kg-m

5.5

Sway Bar Arm

ft-lb

kg-m

1.8

Ball Joint/Sway Bar

ft-lb

kg-m

3.2

ITEM

TORQUE

Ski

ft-lb

kg-m

21-26

2.9-3.6

Handlebar Adjuster Block Caps

ft-lb

kg-m

3.5

Steering Post Mounting Blocks

ft-lb

kg-m

1.7

Steering Post/Tie Rod

ft-lb

kg-m

4.2

Spindle Arm/Tie Rod

ft-lb

kg-m

5.5

Tie Rod Jam Nuts

ft-lb

kg-m

12-15

1.7-2.1

Suspension Arms/Spindle

ft-lb

(Upper)

kg-m

4.2

Suspension Arms/Spindle

ft-lb

(Lower)

kg-m

5.5

Shock Absorber/Spindle

ft-lb

kg-m

2.8

Front Suspension Arm

ft-lb

(Upper)

kg-m

4.2

Front Suspension Arm

ft-lb

(Lower)

kg-m

4.2

Sway Bar Arm

ft-lb

kg-m

1.5

Ball Joint/Sway Bar

ft-lb

kg-m

4.2

Type of Bolt

Thread

Diameter

(mm)

Torque

kg-m

ft-lb

(Conventional or 4

Marked Bolt)

0.2-0.4

1.5-3.0

0.4-0.7

3.0-5.0

1.0-1.6

7.0-11.5

2.2-3.5

16.0-25.5

(7 Marked Bolt)

0.3-0.6

2.0-4.5

0.8-1.2

6.0-8.5

1.8-2.8

13.0-20.0

4.0-6.0

29.0-43.5

Content .. 97 98 99 100 ..