Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 78

 

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Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 78

 

 

6-6

Testing Handlebar 

Warmer/Thumb

Warmer Switch 

(EFI Models/Panther 570)

REMOVING/TESTING

1. Remove the handlebar pad.

2. Remove the four screws securing the left-side han-

dlebar control assembly; then remove the control

assembly from the handlebar.

3. Disconnect the handlebar/thumb warmer harness

from the switch.

4. With the thumb warmer toggle in the low position,

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 position,

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; then install the han-

dlebar pad.

Testing Thumb

Warmer Switch

(Bearcat 570/Panther 370/

Z 370/Z 570)

1. Remove the handlebar pad.

2. Disconnect the thumb warmer two-wire connector.

3. In the switch connector, connect one ohmmeter

lead to each terminal.

4. With the switch in the OFF position, the meter

must read an open circuit. With the switch in the

ON position, the meter must read 1 ohm or less

resistance.

5. Connect the leads; then install and secure the han-

dlebar pad.

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 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.

3. With the switch in the MED position, connect one

ohmmeter lead to the green/red wire at the connec-

tor; then connect the other ohmmeter lead to the

brown wire at the connector. The meter must read

less than 1 ohm of resistance.

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.

6-7

6

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 con-

nect 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 

Speedometer Sensor

(EFI Models)

„NOTE: The following test should be made using
MaxiClips (p/n 0744-041) and the Fluke Model 73
Multimeter (p/n 0644-191) set to the DC Volt scale.

„NOTE: Prior to testing the sensor, inspect the
three-wire connector on the sensor harness for
contamination, broken pins, and/or corrosion.
Note that there is a power supply of 10.8-13.2 DC
volts at the main harness connector.

ZJ210B

1. Elevate the rear of the snowmobile onto a suitable

safety stand.

2. Set the meter selector to the DC Voltage position.

3. At the sensor plug-in, connect the red maxiclip

and meter lead to the red/blue lead; then connect

the black maxiclip and meter lead to the black

lead.

4. Connect a 12-volt DC power supply to the meter

leads; then rotate the driven pulley.

5. The meter must read 0 volts and 12 volts alter-

nately.

„NOTE: Voltage should appear when the tab (A) of
the brake disc jam nut is aligned with the sensor
(B).

ZJ210C

Testing Reverse 

Alarm Switch 

(Bearcat 570/Panther 370/570)

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

1. Disconnect the alarm switch two-wire connector.

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 

(Crossfire/F-Series/M-Series)

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

1. Disconnect the alarm switch two-wire connector.

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 violet/

black wire.

6-8

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

(Crossfire/F-Series/M-Series)

„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/vio-

let 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 

(Crossfire/F-Series/M-Series)

„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 volt-

age 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 (Bearcat/Panther/Z) .......................... 7-2
Steering Post 

(Crossfire/M-Series)............................................. 7-6

Steering Post (F-Series).......................................... 7-8
Ski ......................................................................... 7-11
Ski Wear Bar ......................................................... 7-12
Drag Link (Bearcat/Panther/Z) .............................. 7-13
Drag Link (F-Series).............................................. 7-14
Front Tie Rods (Bearcat/Panther/Z) ...................... 7-16
Front Tie Rods 

(Crossfire/M-Series)........................................... 7-17

Tie Rods (F-Series)............................................... 7-18
Spindle (Bearcat/Panther/Z).................................. 7-19
Spindle (Crossfire/M-Series) ................................. 7-20
Spindle (F-Series) ................................................. 7-23
Steering Tie Rod 

(Bearcat/Panther/Z) ........................................... 7-25

Steering Tie Rod 

(Crossfire/M-Series)........................................... 7-26

Steering Tie Rod (F-Series) .................................. 7-27
Ski Alignment ........................................................ 7-28
Front Suspension Arms 

(Bearcat/Panther/Z) ........................................... 7-30

Front Suspension Arms 

(Crossfire/M-Series)........................................... 7-32

Front Suspension Arms (F-Series)........................ 7-36
Front Suspension (Ski) Shock Absorber ............... 7-38
Sway Bar (Bearcat/Panther/Z) .............................. 7-38
Sway Bar (F-Series).............................................. 7-39
Front Suspension Mounting Bracket (F-Series) .... 7-39

Console (Crossfire/M-Series)................................ 7-43
Console (Bearcat/Panther/Z)................................. 7-44
Console (F-Series) ................................................ 7-44
Belly Pan (Bearcat/Panther/Z)............................... 7-44
Belly Pan (Crossfire/M-Series) .............................. 7-51
Gas Tank/Seat Assembly 

(Bearcat/Panther/Z)............................................ 7-53

Gas Tank/Seat Assembly

(Crossfire/M-Series)........................................... 7-53

Gas Tank/Seat Assembly (F-Series) ..................... 7-54
Seat Cushion......................................................... 7-55
Taillight/Brakelight Assembly ................................. 7-56
Windshield

(Bearcat/Crossfire/M-Series/Panther/Z)............. 7-57

Windshield (F-Series — Non-Adjustable) ............. 7-58
Windshield (F-Series — Adjustable) ..................... 7-58
Backrest/Rack Assembly....................................... 7-58
Tunnel/Rear Bumper/Snowflap 

(Bearcat/Panther/Z)............................................ 7-59

Tunnel/Chassis/Rear Bumper/Snowflap

(Crossfire/M-Series)........................................... 7-59

Tunnel/Chassis/Rear Bumper/Snowflap

(F-Series) ........................................................... 7-60

Rear Storage Compartment (F-Series) ................. 7-61
Air Silencer Assembly 

(Crossfire/M-Series)........................................... 7-61

Headlight Assembly 

(Bearcat/Panther/Z)............................................ 7-61

Headlight Assembly (F-Series) ............................. 7-62
Headlight Assembly (Crossfire/M-Series) ............. 7-63
Adjusting Headlight Aim  ....................................... 7-64
Torque Specifications 

(Bearcat/Panther/Z)............................................ 7-64

Torque Specifications

(Crossfire/M-Series/F-Series) ............................ 7-65

Torque Specifications (General Bolts) ................... 7-66

 

 

 

 

 

 

 

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