Snowmobile Arctic Cat (2007 year). Manual - part 56

6-5

6

Testing Thumb

Warmer Switch

(Panther 660 - HI/OFF/LO Function)

1. Remove the handlebar pad.

2. Disconnect the thumb warmer three-wire

connector.

3. In the switch connector, connect one ohmmeter

lead to the green/white lead; then connect the other

ohmmeter lead to the green lead.

4. With the switch in the OFF (middle) position, the

meter must read an open circuit. With the switch

in the HI position, the meter must read 1 ohm or

less resistance.

5. In the switch connector, connect one ohmmeter

lead to the green/black lead; then connect the other

ohmmeter lead to the green lead.

6. With the switch in the OFF (middle) position, the

meter must read an open circuit. With the switch

in the LO position, the meter must read 1 ohm or

less resistance.

7. Connect the leads; then install and secure the

handlebar pad.

Testing Handlebar 

Warmer/Thumb Warmer 

Switch

„ NOTE: This procedure is for all models (except
the Panther 660). For the Panther 660, see Testing
Handlebar Warmer Switch (Panther 660) and/or
Testing Thumb Warmer Switch (Panther 660) in
this section.

REMOVING/TESTING

1. Remove the handlebar pad.

2. Remove the four screws securing the left-side

handlebar control assembly; then remove the

control assembly from the handlebar.

3. Disconnect the handlebar/thumb warmer har-

ness from the switch.

4. With the thumb warmer toggle in the low posi-

tion, connect one ohmmeter lead to pin (C) and

the other ohmmeter lead to pin (B). The meter

must read 1 ohm or less resistance.

CM110A

5. With the thumb warmer toggle in the high posi-

tion, connect one ohmmeter lead to pin (C) and

the other ohmmeter lead to pin (A). The meter

must read 1 ohm or less resistance.

„ NOTE: If either test does not read within specifi-
cation, replace the complete control assembly.

6. With the handwarmer toggle in the low position,

connect one ohmmeter lead to pin (C) and the

other ohmmeter lead to pin (D). The meter must

read 1 ohm or less resistance.

7. With the handwarmer toggle in the high posi-

tion, connect one ohmmeter lead to pin (C) and

the other ohmmeter lead to pin (E). The meter

must read 1 ohm or less resistance.

„ NOTE: If either test does not read within specifi-
cation, replace the complete control assembly.

INSTALLING

1. Connect the handlebar/thumb warmer harness to

the switch; then place the control assembly on

the handlebar.

2. Secure with the four screws.

Testing Passenger 

Handwarmer Switch

1. Disconnect the lead wires from the switch.

2. With the switch in the LO position, connect one

ohmmeter lead to the green/white wire at the

connector; then connect the other ohmmeter

lead to the brown wire at the connector. The

meter must read less than 1 ohm of resistance.

3. With the switch in the MED position, connect

one ohmmeter lead to the green/red wire at the

connector; then connect the other ohmmeter

lead to the brown wire at the connector. The

meter must read less than 1 ohm of resistance.

6-6

4. With the switch in the HI position, connect one

ohmmeter lead to the green/blue wire at the con-

nector; then connect the other ohmmeter lead to

the brown wire at the connector. The meter must

read less than 1 ohm of resistance.

Testing Passenger 

Handwarmer Elements

„ NOTE: During this test, resistance will vary due
to temperature; therefore, this test should be made
at room temperature of 20° C (68° F).

1. Disconnect the lead wires from the main wiring

harness.

2. For the LO position, connect one ohmmeter lead

to the green/white wire from the element; then

connect the other ohmmeter lead to the green

wire from the element. The meter must read

between 23.8-32.2 ohms.

3. For the MED position, connect one ohmmeter

lead to the green/red wire from the element; then

connect the other ohmmeter lead to the green

wire from the element. The meter must read

between 13.6-18.4 ohms.

4. For the HI position, connect one ohmmeter lead

to the green/blue wire from the element; then

connect the other ohmmeter lead to the green

wire from the element. The meter must read

between 8.7-11.7 ohms.

Testing Seat Heater 

Harness/Switches (LE)

„ NOTE: This procedure applies to both the opera-
tor and the passenger seat heater switches.

„ NOTE: The seat heater elements cannot be
tested.

OPERATOR HEATER SWITCH - 
Resistance

„ NOTE: On the Trail models, the seat must be
removed for this procedure. On the Touring mod-
els, the element connectors are located at the rear
of the front seat beneath the flap.

1. Disconnect the main harness/element connector.

2. Connect one ohmmeter lead to the red/yellow

main harness connector; then connect the other

ohmmeter lead to the green/red main harness

connector. The meter must read the following ±

5%:

LO =

4.32K ohms,

MED = 3.92K ohms,
HI =

3.57K ohms.

„ NOTE: If this resistance test does not read within
specification, troubleshoot the switch connector
located below the steering support. If the switch
connector tests good, replace the switch.

PASSENGER HEATER SWITCH 
(Touring) - Resistance

1. Disconnect the main harness/element connector.

2. Connect one ohmmeter lead to the red/blue main

harness connector; then connect the other ohm-

meter lead to the green/red main harness con-

nector. The meter must read the following ± 5%:

LO =

4.32K ohms,

MED = 3.92K ohms,
HI =

3.57K ohms.

„ NOTE: If this resistance test does not read within
specification, troubleshoot the switch connector
located beneath the seat. If the switch connector
test good, replace the switch.

OPERATOR/PASSENGER SWITCH - 
Voltage

1. Disconnect the main harness/element connector.

„ NOTE: For this procedure, test the main harness
side of the connector, not the element side of the
connector.

2. Connect one meter lead to the red/blue main

harness connector; then connect the other meter

lead to the black main harness connector.

3. Start the engine. The meter must read 12-15

volts.

„ NOTE: If this voltage test does not read within
specification, troubleshoot the main harness, F-2
fuse, K-2 relay, or the F-7 main fuse.

6-7

6

Testing Reverse Alarm 

Switch 

(660 cc)

„ NOTE: The switch is in a bracket on the chain
case.

1. Disconnect the alarm switch two-wire connec-

tor.

2. Connect one ohmmeter lead to the yellow wire;

then connect the other ohmmeter lead to the

orange wire.

3. With the lever in the reverse position, the meter

must read less than 1 ohm of resistance. With

the lever in the forward position, the meter must

read OL (open).

„ NOTE: If the meter does not read as specified in
either test, the switch is defective and must be
replaced.

Testing Reverse Alarm 

Switch 

(1100 cc Z1)

„ NOTE: The switch is located on the gear case
above the left-side footrest.

1. Disconnect the alarm switch two-wire connec-

tor.

2. Remove the six torx-head cap screws securing

the left-side footrest to the chassis and remove

the footrest; then un-thread the alarm switch

from the gear case.

3. Connect one ohmmeter lead to the black wire;

then connect the other ohmmeter lead to the vio-

let/black wire.

4. With the reverse button pressed in, the meter

must read less than 1 ohm of resistance. With

the reverse button released, the meter must read

OL (open).

„ NOTE: If the meter does not read as specified in
either test, the switch is defective and must be
replaced.

Testing Shift 

Actuator Switch

(1100 cc Z1)

„ NOTE: The shift actuator switch is located on the
right-side handlebar control.

1. Disconnect the actuator two-wire connector

from the handlebar control.

2. Connect one ohmmeter lead to the black wire;

then connect the other ohmmeter lead to the

white/violet wire.

3. With the reverse button pressed in, the meter

must read less than 1 ohm of resistance. With

the reverse button released, the meter must read

OL (open).

„ NOTE: If the meter does not read as specified in
either test, the switch is defective and must be
replaced.

Testing Shift Actuator 

(1100 cc Z1)

„ NOTE: The actuator is located on the gear case
above the left-side footrest.

1. Disconnect the actuator two-wire connector;

then connect Actuator Test Harness (p/n 0644-

518) onto the harness side of the connector.

2. Connect one meter lead to the violet/black lead

of the test harness; then connect the other meter

lead to the black wire lead of the test harness.

3. Secure the belt guard into position; then start the

engine.

4. Press the reverse button; there should be a flash

of DC battery voltage indicated on the meter.

Release the reverse button; then again press the

reverse button; there should be a flash of DC

battery voltage indicated on the meter.

„ NOTE: If the meter indicates a flash of voltage
but the actuator does not function, the actuator is
defective and must be replaced.

„ NOTE: If the meter does not indicate a flash of
voltage, troubleshoot the main harness.

! CAUTION

Do not run the engine without the belt guard secured
in place.

7-1

7

SECTION 7 — STEERING AND BODY

TABLE OF

CONTENTS

Steering and Body .................................................. 7-2
Steering Post (120 cc)............................................. 7-2
Steering Post (Bearcat Wide Track/

Panther 660/T660)  .............................................. 7-5

Steering Post (Jaguar Z1) ....................................... 7-8
Ski (120 cc) ........................................................... 7-12
Ski (Bearcat Wide Track/Jaguar Z1/

Panther 660/T660) ............................................. 7-12

Ski Wear Bar (Bearcat Wide Track/Jaguar Z1/

Panther 660/T660) ............................................. 7-14

Drag Link (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-15

Drag Link (Jaguar Z1) ........................................... 7-16
Tie Rods (120 cc).................................................. 7-18
Tie Rods (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-19

Tie Rods (Jaguar Z1) ............................................ 7-20
Spindle (120 cc) .................................................... 7-21
Spindle (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-23

Spindle (Jaguar Z1)............................................... 7-24
Steering Tie Rod (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-27

Steering Tie Rod (Jaguar Z1)................................ 7-28
Ski Alignment (120 cc) .......................................... 7-29
Ski Alignment (Bearcat Wide Track/Jaguar Z1/

Panther 660/T660) ............................................. 7-30

Front Suspension A-Arms (120 cc) ....................... 7-32
Front Suspension Arms (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-33

Front Suspension Arms (Jaguar Z1) ..................... 7-35
Front Suspension (Ski) Shock Absorber 

(Bearcat Wide Track/Jaguar Z1/Panther 660/ 
T660) ................................................................. 7-38

Sway Bar (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-39

Sway Bar (Jaguar Z1) ........................................... 7-39
Front Suspension Mounting Bracket (Jaguar Z1) .. 7-40
Console (Bearcat Wide Track/Jaguar Z1/

Panther 660/T660) ............................................. 7-45

Belly Pan (120 cc) ................................................. 7-46
Belly Pan (Bearcat Wide Track/Jaguar Z1/

Panther 660/T660) ............................................. 7-47

Gas Tank/Seat Assembly (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-53

Gas Tank/Seat Assembly (Jaguar Z1)................... 7-54
Seat/Cushion/Taillight Housing (120 cc) ............... 7-56
Seat Cushion (Bearcat Wide Track/Jaguar Z1/

Panther 660/T660) ............................................. 7-58

Taillight Housing (Bearcat Wide Track/Jaguar Z1/

Panther 660/T660) ............................................. 7-59

Windshield (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-59

Windshield (Jaguar Z1) ......................................... 7-60
Backrest/Rack/Taillight Assembly 

(Bearcat Wide Track/Panther 660/T660) ............ 7-60

Rear Storage Compartment (Jaguar Z1) .............. 7-62
Tunnel/Chassis/Rear Bumper/Snowflap

(Bearcat Wide Track/Jaguar Z1/Panther 660/
T660).................................................................. 7-63

Headlight Assembly (120 cc)................................. 7-67
Headlight Assembly (Bearcat Wide Track/

Jaguar Z1/Panther 660/T660) ............................ 7-68

Adjusting Headlight Aim (Bearcat Wide Track/

Jaguar Z1/Panther 660/T660)  ........................... 7-70

Torque Specifications (Bearcat Wide Track/

Panther 660/T660) ............................................. 7-70

Torque Specifications (Jaguar Z1)......................... 7-71
Torque Specifications (120 cc) .............................. 7-71
Torque Specifications (General Bolts) ................... 7-71