Content .. 92 93 94 95 ..

Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 94

7-62

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.

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

(F-Series)

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.

To access the headlight bulbs, use the following pro-

cedure:

1. On the LXR, release the latches securing the

windshield to the windshield base; then remove

the windshield.

2. Remove the two torx-head cap screws located to

the outside of the headlight adjustment knobs;

then remove the single torx-head cap screw

from beneath the console (located between the

headlights).

741-505A

3. Remove the cap screw and lock nut securing the

front of the headlight assembly to the air-intake

silencer.

4. Lift the front of the console enough to allow the

headlight housing to be removed; then remove

the housing.

5. Remove the bulb from the headlight housing

and disconnect the wiring harness from the bulb.

741-329A

INSTALLING HEADLIGHT BULB

1. Insert the bulb into the headlight housing; then

lock the bulb into position.

2. Plug the wiring harness into the headlight bulb.

! 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.

! 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.

7-63

3. Lift the front of the console enough to allow the

headlight housing to be installed; then install the

housing making sure the forks of the housing go

into the grommets on top of the air-intake

silencer. Secure with the cap screw and lock nut.

0741-506

4. Position the console onto the air-intake silencer;

then secure with the single torx-head cap screw

beneath the console (located between the head-

lights).

5. Install the two torx-head cap screws located to

the outside of the headlight adjustment knobs;

then tighten securely.

6. On the LXR, place the windshield into position

on the windshield base; then secure with the

latches.

7. Check headlight aim (see Adjusting Headlight

Aim in this section).

Headlight Assembly

(Crossfire/M-Series)

REMOVING HEADLIGHT BULB/
HEADLIGHT

To access the headlight assembly, use the following

procedure.

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

ment knobs.

2. Open the hood; then on the right-side air intake,

remove the rubber plug and hairpin clip at the for-

ward end of the intake assembly.

NOTE: Carefully push the headlight lenses
inward far enough to access the torx-head screws
securing the air intake assembly to the hood.

3. Remove the lock nuts from the torx-head screws

and the O-rings securing the air intake assembly to

the hood and remove the air intake assembly to

access the bulbs.

0740-796

NOTE: If replacing the headlight assembly, the
adjustment knobs must be removed.

4. If replacing the bulb(s), remove the bulb(s) from

the headlight housing and disconnect the wiring

harness from the bulb(s).

5. Remove the hairpin clips securing the headlight

assembly to the hood; then remove the assembly.

INSTALLING HEADLIGHT BULB/
HEADLIGHT

1. Install the headlight assembly on the hood; then

secure with the hairpin clips.

2. If the bulb(s) was replaced, plug the wiring har-

ness into the headlight bulb and secure with cable

ties.

3. Insert the bulb into the headlight housing.

4. Press the air intake assembly into place on the

hood and secure with the O-rings and hairpin

clips.

5. Carefully push the headlight lenses inward far

enough to access the torx-head screws. Install the

lock nuts and tighten securely.

! 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.

! 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.

7-64

6. Install the headlight adjustment knobs.

7. Check headlight aim (see Adjusting Headlight

Aim in this sub-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 horizon-

tal 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 ver-

tical mark 5 cm (2 in.) below the horizontal mark

on the aiming surface.

0741-448

7. Adjust the headlight housing mounting screws (on

the 3-bulb models) or the console adjustment

knobs (on the 4-bulb models) until correct aim is

obtained. Shut the engine off.

Torque Specifications

(Bearcat/Panther/Z)

* w/Green Loctite #609

ITEM

TORQUE

Ski

ft-lb
kg-m

21-26
2.9-3.6

Handlebar Adjuster Block

ft-lb
kg-m

10
1.4

Steering Post/Tie Rod*

ft-lb
kg-m

30
4.2

Drag Link/Tie Rod*

ft-lb
kg-m

20
2.8

Drag Link/Steering/Idler Arm*

ft-lb
kg-m

30
4.2

Spindle Arm/Tie Rod*

ft-lb
kg-m

30
4.2

Suspension Arms/Spindle*

ft-lb
kg-m

30
4.2

Shock Absorber/Spindle

ft-lb
kg-m

20
2.8

Front Suspension Arm*
(Upper)

ft-lb
kg-m

30
4.2

Front Suspension Arm*
(Lower)

ft-lb
kg-m

40
5.5

Steering Post/Chassis*

ft-lb
kg-m

30
4.2

Tie Rod/Steering Arm*

ft-lb
kg-m

30
4.2

Steering Arm/Chassis*

ft-lb
kg-m

30
4.2

7-65

Torque Specifications

(Crossfire/M-Series)

* w/Green Loctite #609
** w/Blue Loctite #243

Torque Specifications

(F-Series)

* w/Green Loctite #609
** w/Blue Loctite #243

ITEM

TORQUE

Ski

ft-lb
kg-m

21-26
2.9-3.6

Handlebar Adjuster Block

ft-lb
kg-m

10
1.4

Steering Post Mounting Block

ft-lb
kg-m

8
1.1

Steering Post Stop**

ft-lb
kg-m

2
0.3

Steering Tie Rod/Shaft Arm*

ft-lb
kg-m

30
4.2

Steering Post/Tie Rod*

ft-lb
kg-m

30
4.2

Spindle Arm/Tie Rod*

ft-lb
kg-m

40
5.5

Suspension Arm/Spindle*
(Upper)

ft-lb
kg-m

30
4.2

Suspension Arm/Spindle*
(Lower)

ft-lb
kg-m

40
5.5

Shock Absorber/Spindle

ft-lb
kg-m

20
2.8

Front Suspension Arm/Chassis*
(Upper)

ft-lb
kg-m

30
4.2

Front Suspension Arm/Chassis*
(Lower)

ft-lb
kg-m

30
4.2

Steering Post/Chassis*

ft-lb
kg-m

30
4.2

Steering Support/Chassis**

ft-lb
kg-m

20
2.8

Tie Rod (Center)/Steering Arm*

ft-lb
kg-m

40
5.5

ITEM

TORQUE

Ski

ft-lb

kg-m

3.6

Spindle Arm/Spindle**

ft-lb

kg-m

4.2

Suspension Arm/Spindle*

ft-lb

kg-m

6.2

Front Suspension Arm

ft-lb

(Upper)

kg-m

6.2

Front Suspension Arm

ft-lb

(Lower)

kg-m

6.2

Steering Arm/Suspension

ft-lb

Mounting Bracket

kg-m

4.2

Sway Bar Mounting Bracket/

ft-lb

Suspension Mounting Bracket

kg-m

1.4

Tie Rod Jam Nut**

ft-lb

kg-m

12-15

1.7-2.1

Spindle Arm/Tie Rod*

ft-lb

kg-m

4.2

Steering Post/Steering Tie Rod*

ft-lb

kg-m

5.5

Drag Link/Steering and

ft-lb

Spindle Tie Rods*

kg-m

5.5

Steering Post/Suspension

ft-lb

Mounting Bracket*

kg-m

5.5

Drag Link/Steering Arm**

ft-lb

kg-m

1.7

Shock Absorber/Shock

ft-lb

Mounting Frame

kg-m

6.2

Upper Bearing Bracket/

ft-lb

Support Plate**

kg-m

1.1

Shock Absorber/Spindle

ft-lb

kg-m

6.2

Suspension Mounting Bracket/

ft-lb

Chassis (Lower)

kg-m

1.7

Suspension Mounting Bracket/

ft-lb

Chassis (Upper)

kg-m

4.2

Steering Support Plate/

ft-lb

Steering Support

kg-m

1.1

Shock Mount Frame/

ft-lb

Suspension Mounting Bracket

kg-m

1.1

Shock Mount Frame/

ft-lb

Front Upper Frame

kg-m

2.1

Spindle Retainer/Spindle**

ft-lb

kg-m

1.8

Rear Bumper/Heat Exchanger**

ft-lb

kg-m

3.5

Content .. 92 93 94 95 ..