Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 93

7-58

Windshield

(F-Series — Non-Adjustable)

REMOVING

1. Remove the plastic rivet securing the front of the

windshield to the windshield bracket.

2. Remove the two torx-head screws securing the

windshield to the console; then separate the wind-

shield from the console.

INSTALLING

741-637A

1. Place the windshield into position on the console.

2. Secure the windshield to the console with the torx-

head screws.

3. Using a new plastic rivet, secure the windshield to

the windshield bracket.

Windshield

(F-Series — Adjustable)

REMOVING

1. Loosen and remove the thumb screw from each

side; then account for the latch with backing plate.

2. Remove the windshield.

INSTALLING

0741-507

1. In turn on each side of the windshield base, install

the latch with the backing plate; then install the

thumb screw leaving enough “gap” to insert the

windshield.

2. Insert the windshield into latches; then tighten the

thumb screws securely.

Backrest/Rack

Assembly

„NOTE: Some components may vary from model
to model. The technician should use discretion
and sound judgment.

REMOVING

1. Remove the cap screws, washers, and cap nuts

securing the rack to the backrest.

2. In turn on each side, remove the two cap screws

(inside the tunnel) securing the backrest assembly

to the tunnel. Account for the washers.

3. If applicable, disconnect the passenger hand-

warmer wiring harness.

4. Remove the backrest assembly from the tunnel.

Account for the two spacers.

INSTALLING

1. Place the backrest assembly and spacers (located

on the rear hole on each side) into position and

align holes with tunnel mounting holes.

2. Install the cap screws with washers from the inside

of the tunnel and secure with the washers and lock

nuts. Tighten securely.

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7

3. In turn on each side, install the 1/4-in. cap screw in

the front hole and the 5/16-in. cap screw in the rear

hole. Secure with a flat washer and lock nut.

Tighten securely.

4. If applicable, connect the passenger handwarmer

wiring harness.

5. Place the rack into position and secure with the

cap screws, washers, and cap.

Tunnel/Rear Bumper/ 

Snowflap 

(Bearcat/Panther/Z)

„NOTE: Some components will vary from model
to model. The technician should use discretion
and sound judgment.

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.

Tunnel/Chassis/

Rear Bumper/Snowflap

(Crossfire/M-Series)

REMOVING/REPLACING TUNNEL

To remove and/or replace a tunnel on a particular

snowmobile, a number of removing and installing

component sequences must be followed. The techni-

cian must in turn go to the following sections in this

manual and refer to the appropriate removing/

installing sub-sections. When doing these

sequences, the technician should use discretion and

sound judgment.

A. Section 2 - Engine

B. Section 7 - Steering and Body

C. Section 8 - Drive Train and Brake Systems

D. Section 9 - Track/Rear Suspension

REMOVING BUMPER/SNOWFLAP

1. Remove the machine screw securing the taillight

housing to the bumper assembly; then disconnect

the taillight wiring harness. 

2. Remove the torx-head screws securing the snowflap

to the bumper; then remove the snowflap.

FC232

3. Remove the torx-head screws securing the bumper

to the tunnel.

4. Remove the taillight/bumper assembly from the

tunnel.

INSTALLING BUMPER/SNOWFLAP

1. Install the bumper assembly to the tunnel; then

secure with the torx-head cap screws.

2. Secure the snowflap to the bumper with the torx-

head screws.

7-60

3. Connect the taillight wiring harness; then install

the taillight housing onto the bumper assembly.

Tunnel/Chassis/

Rear Bumper/Snowflap 

(F-Series)

REMOVING/REPLACING TUNNEL

To remove and/or replace a tunnel on a particular

snowmobile, a number of removing and installing

component sequences must be followed. The techni-

cian must in turn go to the following sections in this

manual and refer to the appropriate removing/

installing sub-sections. When doing these

sequences, the technician should use discretion and

sound judgment.

A. Section 2 - Engine

B. Section 7 - Steering and Body

C. Section 8 - Drive Train and Brake Systems

D. Section 9 - Track/Rear Suspension

REMOVING BUMPER/SNOWFLAP 

„ NOTE: The snowflap can be removed without
removing the bumper by removing the two self-
tapping screws securing the snowflap to the heat
exchanger.

1. Carefully pry upward on the tunnel fender until

the fender tabs clear the slots in the tunnel; then

lift upward and outward on the fender to access

the machine screws and lock nuts securing the

bumper to the tunnel.

ZJ298A

2. Remove the four machine screws and lock nuts

securing the bumper to the tunnel.

3. Remove the two self-tapping screws securing

the snowflap to the heat exchanger; then slide

the snowflap away from the fender and bumper.

4. Remove the two self-tapping screws securing

the bumper to the heat exchanger. Account for

the bracket covers.

5. Remove the two self-tapping screws securing

the fender to the bumper; then remove the

bumper. 

INSTALLING BUMPER/SNOWFLAP 

1. Place the bumper into position on the tunnel;

then install the four machine screws and lock

nuts securing the bumper to the tunnel. Tighten

the lock nuts securely.

2. Place the tunnel fender into position engaging

the tabs of the fender with the slots of the tunnel.

3. Install the two self-tapping screws (threads

coated with blue Loctite #243) securing the

bumper to the heat exchanger. Tighten the

screws to specifications.

ZJ297B

4. Secure the tunnel fender to the bumper with the

two self-tapping screws. Tighten the screws

securely.

5. Place the snowflap into position; then secure the

snowflap to the heat exchanger with the two

self-tapping screws (threads coated with blue

Loctite #243). Tighten the screws to specifica-

tions.

FS263A

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7

Rear Storage 

Compartment

(F-Series)

REMOVING

0741-970

1. Remove the six self-tapping screws (A) securing

the storage compartment to the tunnel fender.

2. Remove the four body screws (B) securing the

fender to the tunnel; then disconnect the taillight

plug-in and remove the fender.

INSTALLING

1. Connect the taillight harness plug-in and install

the fender with the four body screws (B); then

tighten the screws securely.

2. Place the storage compartment into position on

the fender; then install the six self-tapping

screws (A). Tighten the screws securely.

Air Silencer Assembly

(Crossfire/M-Series)

REMOVING

1. Remove the connector clamp securing the intake

connector (hose) to the hood screen (right-side).

FC248

2. With the hood closed, loosen the headlight adjust-

ment knobs.

3. Carefully push the headlight lenses rearward far

enough to remove the torx-head screws securing

the air silencer plenum to the hood.

4. Open the hood; then remove the O-rings securing

the air silencer plenums to the hood and remove

the air silencer plenums.

INSTALLING

1. Press the air silencer plenums into place on the

hood and secure with the O-rings; then close the

hood.

2. Carefully push the headlight lenses rearward far

enough to install the torx-head screws. Tighten the

screws securely.

3. Tighten the headlight adjustment knobs.

4. Check headlight aim (see Adjusting Headlight

Aim in this sub-section).

Headlight Assembly 

(Bearcat/Panther/Z)

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.