Arctic Cat Panther 1974 User manual

TABLE OF CONTENTS
Page
Millimeter/Decimal/Inch Conversion Tab le
1- 2 ,3,4
Identification
1-5
Specifications 1-6
Bolt Torque Chart
1-7
Chaincase Lubricant
1-7
Fuel Mixing. . . 1-8
Know the Controls 1-9
Safety Checks . . 1-10
Star tin g/ Stopp ing Instructions 1-10
,
Section I
@A rct ic Ent e rpr is e s, Inc. 1973
Form No . 0153-030

Millimeter/Decimal/Inch Conversion Table
Decimal
Decimal
~
MM Equiv. Inches
tor -
MM
Equiv. Inches +
or-
1 0.0394 1/32
t 53 2.0866
23/32
2 0.0787 3/32
54 2.1260 2 1/8 +
3 0.1181 1/8
55 2.1654
25/32
+
4 0.1575 5/32 + 56 2.2047
27/32
5 0.1969 3/16 + 57 2.2441 2
1/4
6 0.2362 1/4
58 2.2835
29/32
+
7 0.2756 9/32
59 2.3228 25 /1 6 +
8 0.3150
5/16 + 60 2.3622 2
3/8
9 0.3543
11/32 +
61
2.4016 2 13/32
10 0.3937
13/32
62 2.4409
27/16 +
11
0.4331 7/16 63 2.4803 2
15/32 +
12
0.4724 15/32 + 64 2.5197 2
17/32
13 0.5118 1/2
+ 65 2.5591
29/16
14 0.5512 9/16
66 2.5984 2
19/32 +
15 0.5906
19/32
67 2.6378
25/8 +
16 0.6299 5/8 + 68 2.6772 2
11/16
17 0.6693 21/32
+ 69 2.7165
223/32
18 0.7087 23/32
70 2.7559 23/4 +
19 0.7480 3/4
71 2.7953 225/32 +
20 0.7874
25/32 + 72 2.8346
227/32
21 0.8268 13/16
+ 73 2.
8740 27/8
22 0.8661 7/8
74 2.9134 229/32 +
23 0.9055 29/32
75 2.9528 2
15/16
+
24 0.9449 15/16
+ 76 2.9921 3.0 )
25 0.9843 31/32
+ 77 3.0315 3 1/32 +
26 1.0236 1
1/32
78 3.0709 3 1/16 +
27 1.0630 1 1/16
+ 79 3.1102 3 1/8
28 1.1024 1 3/32 + 80 3.1496
35/32
29 1.1417 1 5/32
81 3.1890 33/16
+
30 1.1811 1 3/16
82 3.2283
37/32
+
31 1.2205 1 7/32
+ 83 3.2677
39/32
32 1.2598 1
1/4
+ 84 3.3071
35/16
33 1.2992 1 5 /1 6 85 3.3465 3
11/32 +
34 1.3386 1
11/32
86 3.3858
33/8 +
35 1.3780 1 3/8 + 87 3.4252
37/16
36 1.4173 1
13/32
+ 88 3.4646 3 15/32
37 1.4567 1 15/32
89 3.5039 3 1/2 +
38 1.4961 1
1/2
90 3.5433 3 17/32 +
39 1.5354 1
17/32 +
91 3.5827 3
19/32
40
1.5748 1 9/16 + 92 3.6220 3 5/8
41 1.6142 1 5/8
93 3.6614
321/32
+
42 1.6535 1 21 /32 94 3.7008
311/16
+
43 1.6929 1 11/16 + 95 3.7402 3
3/4
44 1.7323 1
23/32
+ 96 3.7795
325/32
45 1.7717 1 25/32 97 3.8189 3
13/16
+
46 1.8110 1 13/16
98 3.8583
327/32
+
47 1.8504 1 27/32 + 99 3.8976
329/32
48 1.8898 1 7/8 + 100 3.9370 3 15/16
49 1.9291 1 15/16
101
3.9764 331/32 + )
50 1.9685 1 31 /32 102 4.0157 4 1/32
51
2.0079 2.0 + 103 4.0551 4
1/16
52 2.0472 2 1/16
104 4.0945
43/32
+
+ = Decimal equivalent is greater than the fraction .
1-2
Decimal equivalent is less than the fraction.

Millimeter/Decimal /inch Conversion Table
C Decimal Decimal
MM
Equiv. Inches + or -
MM
Equiv. Inches
+or -
105 4.1339 4 1/8 + 157 6.1811
63/16
106 4.1732
43/16
158 6.2205 67/32
+
107 4.2126
47/32
159 6.2598 6 1/4 +
108 4.2520
41/4
+ 160 6.2992
65/16
109 4.2913
49/32
+
161 6.3386 6 11/32
110 4.3307 4 11/32 162 6.3779 6 3/8 +
111
4.3701 4 3/8 163 6.4173 6 13/32 +
112 4.4094 4 13/32 + 164 6.4567 6 15/32
113 4.4488
47/16 + 165 6.4961 6 1/2
114 4.4882 4 1/2 166 6.5354 6 17/32 +
115 4.5276 4 17/32 167 6.5748
69/16
+
116 4.5669
49 /16 + 168 6.6142 6 5/8
117 4.6063 4 19/32 + 169 6,.6535
621/32
118 4.6457
421/32
170 6.6929 6 11/16 +
119 4.6850 4 11/16
171 6.7323 623/32
+
120 4.7244
423/32
+ 172 6.7716
625/32
121
4.7638 43/4
+ 173 6.8110 6 13/16
122 4.8031 4 13/16 174 6.8504
627/32
+
123 4.8425
427/32
175 6.8898
67/8
+
124 4.8819 47/8 + 176 6.9291 6 15/16
125 4.9213
429/32
+ 177 6.9685
631/32
126 4.9606
431/32
178 7.0079 7.0 +
127 5.0000 5.0 179 7.0472 7 1/16
128 5.0394 5 1/32 + 180 7.0866
73/32
129 5.0787
53/32
181 7.1260 7 1/8 +
130 5.1181 5 1/8 182 7.1653
75/32
+
131
5.1575 55/32 + 183 7.2047
77/32
132 5.1968
53/16 + 184 7.2441 7
1/4
133 5.2362 5 1/4 185 7.2835
79/32
+
134 5.2756
59/32
186 7.3228 75/16
+
135 5.3150
55/16 + 187 7.3622 7 3/8
'136 5.3543 5 11/32 + 188 7.4016 7 13/32
137 5.3937 5 13/32 189 7.4409
77/16
+
138 5.4331
57/16
190 7.4803 7 15/32 +
139 5.4724 5 15/32 +
191 7.5197 7 17/32
140 5.5118 5 1/2 + 192 7.5590
79/16
141
5.5512 59 /1 6 193 7.5984 7 19/32 +
142 5.5905 5 19/32 194 7.6378 7 5/8 +
143 5.6299 5 5/8 + 195 7.6772 7 11/16
144 5.6693
521/32 + 196 7.7165
723/32
145 5.7087
523/32
197 7.7559
73/4
+
146 5.7480 5 3/4 198 7.7953
725/32
+
147 5.7874
525 / 32 + 199 7.8346
727/32
148 5.8268 5 13/16 + 200 7.8740
77/8
149 5.8661 57 /8
201 7.9134
729/32
+
150 5.9055
529 /32 202 7.9527 7
15 / 16
+
151
5.9449 5 15 / 16
+ 203 7.9921 8.0
152 5.9842
531/32 + 204 8.0315 8 1/32 +
C 153 6.0236 6 1/32 205 8.0709 8 1/16 +
154 6.0630 6 1/ 16 + 206 8.1102 8 1/8
155 6.1024
63 / 32 + 207 8.1496
85/32
156 6.1417
65 /32 208 8.1890
83 /1 6 +
+ = Decimal equivalent
is greater than the fraction.
Decimal equivalent is less than the fraction.
1-3

Millimeter/Decimal/Inch Conversion Table
Decimal Decimal )
MM Equiv. Inches
+or - MM
Equiv. Inches +
or-
209 8.2283
87/32
+ 255 10.0393 10 1/32 +
210 8.2677 89/32
256 10.0787
103/32
211 8.3071 85/16
257 10.1181
101/8
212 8.3464 8 11/32 + 258 10.1575
105/32 +
213 8.3858 8 3/8 + 259 10.1968
103/16 +
214 8.4252
87/16
260 10.2362 10 1/4
215 8.4646 8 15/32
261
10.2756
109/32
216 8.5039 81/2
+ 262 10.3149
105/16 +
217 8.5433 8 17/32 + 263 10.3543 10 11/32 +
218 8.5827
819/32
264 10.3937 10 13/32
219 8.6220
85/8
265 10.4330
107/16
220 8.6614
821/32
+ 266 10.4724 10 15/32 +
221
8.7008 8 11/16 + 267 10.5118
101/2
+
222 8.7401 8
3/4
268 10.5512
109/16
223 8.7795
825/32
269 10.5905
1019/32
224 8.8189 8 13/16 + 270 10.6299
105/8 +
225 8.8583
827/32
+
271
10.6693
1021/32 +
226 8.8976
829/32
272 10.7086
1023/32
227 8.9370 8 15/16 273 10.7480
103/4
228 8.9764
831/32
+ 274 10.7874
1025/32 +
229 9.0157 9 1/32 275 10.8268
1013/16
+
230 9.0551 9 1/16 276 10.8661
107/8
231
9.0945 93/32 + 277 10.9055
1029/32
232 9.1338 9 1/8 + 278 10.9449
1015/16
+
233 9.1732
93/16
279 10.9842
1031/32
+
234 9.2126
97/32
280 11.0236
11 1/32
235 9.2520 9 1/4 +
281 11.0630
11 1/16 +
236 9.2913
99/32 + 282 11.1023
11 3/32 +
237 9.3307 9 11/32 283 11.1417
11 5/32
238 9.3701 9 3/8 284 11.1811
11 3/16
239 9.4094 9 13/32 + 285 11.2204
11 7/32 +
240 9.4488
97/16 + 286 11.2598
11 1/4 +
241
9.4882 9 1/2 287 11.2992
11 5/16
242 9.5275 9 17/32 288 11.3386
11 11/32
243 9.5669
99/16
+ 289 11.3779
11 3/8 +
244 9.6063 9 19/32 + 290 11.4173
11 13/32 +
245 9.6457
921/32
291
11.4567
11 15/32
246 9.6850 9 11/16 292 11.4960
11 1/2
247 9.7244
923/32 + 293 11.5354
11 17/32 +
248 9.7638
93/4 + 294 11.5748
11 9/16 +
249 9.8031 9 13/16 295 11.6142
11 5/8
250 9.8425
927/32
296 11.6535
11 21/32
251
9.8819 97/8 + 297 11.6929
1111/16
+
252 9.9212
929/32
+ 298 11.7323
11 23/32 +
253 9.9606
931/32
299 11.7716
11 25/32
254 10.0000 10.0 300 11.8110
11 13/16
+ Decimal equivalent
is greater than the fraction.
Decimal equivalent is less than the fraction.
Conversions )
Number of Cubic Centimeters x 0.061 = Cubic Inches
Number of Cubic I nches x 16.387 = Cubic Centimeters
14 Number
of Foot Pounds x 0.1383 = Kilograms in Meters
Number
of Kilogram Meters x 7.235 = Foot Pounds

IDENTIFICA TION
r The 1974 Arctic Cat Panther has 3 identifying
numbers; chassis model and serial number, a body
serial number, and an engine model and serial
number.
'-
Chassis Model and Serial Number The
identification plate, Fig. 1-1 (A), is located on the
right front side of the body tunnel. All internal
records are maintained by the chassis serial
number.
Body Serial Number - The number is stamped into
the body tunnel, Fig. 1-1 (B), near the chassis serial
number plate. This number is of great importance
because
it can be used to trace and identify a
stolen snowmob ile.
Fig . I·'
A
Fig. 1·3
Engine Model and Serial Number - The engine
model and serial numbers are stamped into the
engine name plate, which is located to the left of
the engine wiring connector.
The chassis,
body and engine numbers are required
to properly complete warranty claims and to
ensure that correct replacement parts are obtained.
Under no circumstances is
warranty to be allowed
if the chassis model and ser ial number plate has
been tampered with or removed. When a new
engine
is installed, notify the distributor and the
factory of the new engine model and serial
number.
1-5

Engine:
Engine (Sachs Wankel)
Rotor Chamber Volume
Compression Ratio
Horsepower @ 6000
RPM
Cooling
Ignition
Pole Shoe Gap
"Timing (Align Timing Marks)
Vo Itage/Wattage
Point Gap
Spark Plug
Plug Gap
Carburetor
Carburetor
Type
Low Speed Mixture Needle
High Speed Mixture Needle
Fuel Pump Suction Height
Fuel Mixture Ratio
SPECIFICATIONS
KM 24
294cc/17.940
Cu . In.
8.5:1
23
(DIN)
Air Cooled by Fan
Bosch Magneto Generator
0.315 -0.472 In.
160
BTDC
12 Volt 100 Watt
0. 014 -0.018 In.
Bosch W240Tl
0.020 In.
Walbro
WRCl
Diaphram w/Throttle, Choke Butterfly
1 Turn Open
1-1/8 Turns Open
19.6 In. (Approximate)
25:1
*Align scribe mark on the inside sheave of auxiliary rope pulley with the "M" mark in the fan housing.
Drive Clutch:
Model (0225-014)
Spring
Color
Spring Tension
Engagement Speed
Drive
Belt Width
Outside Drive Belt Circumference
Driven Pulley:
Model (0226-004)
Spring
Color
Cam Angle
Drive/Driven Pulley:
Center
to Center Distance
Offset
Chassis:
Chassis Material
Belly Pan Material
Hood Material
Console Material
Length
w/Skis
Height w/Windshield
Width Overall
Track Width
Track Length on Ground
Fuel Tank Capacity
Chaincase Capacity
Curb Weight -
Approximate
Dry Weight - Approximate
1-6
Arctic
White
25 Lbs.
Per Inch
2700 RPM (Approximate)
1-1/4 In. :1/16 In.
43-1/4 In. :1/4 In.
Arctic
Black
300
10.866 In.
0.320 In.
Aluminum
Aluminum
Fiberglass
Polycarbonate (Lexan)
104 In.
43 In.
34 In.
17 In.
36 In.
6- 1/4 U.S. Gallons
8 Ounces
425 Pounds
380 Pounds

(
BOLT TORQUE CHART
Bolt Grade SAE-2 SAE-5 SAE-8
Socket or Wrench
Minimum
Tensile 64,000 105,000 150,000
Strength
PSI
PSI PSI
Grade Marking
on Bolt
<=>
<»>
«) (»
U.S. Standard
Bolt U.S. Dec.
Ft./Lbs. Torque "t 1 0%
Bolt
Nut
Diameter Equiv. Head
1/4 0.250 6 10 14
7/16
7/16
5/16 0.3125 13 20 30 1/2 1/2
3/8 0.375
23
35 50 9 /1 6
9/16
7/16
0.4375 35 55
80
5/8
11/16
1/2 0.500 55
85
120
3/4
3/4
9/16
0.5625 75 130 175
13/16
7/8
5/8 0.625 105 170
240
15/16 15/16
3/4
0.750 185
300
425
1-1/8 1-1/8
7/8
0.875 160
445
685 1-5/16 1-5/16
1 1.000 250 670 1030 1-1/2 1-1/2
II Note: Multiply foot pound value by 12 to obtain inch pound torque value.
CHAINCASE LUBRICANT
The lubricant used in the chaincase is to be Arctic
Chainlube. Lubricant level must be at the point of
overflowing in the check plug hole, Fig. 1-4.
Capacity of the chaincase is 8 ounces.
To drain the lubricant from the chaincase, place
rags in the belly pan, remove chaincase cover and
allow lubricant to drain into the rags. Lubricant is
to be changed at the end of every snow season or
after 100 hours of operation.
Fig. 1-4
1 -7

FUEL MIXING
Equipment Necessary: Gas Can, Arctic Cat
Rotolube -Improved Formula or SAE 30 HD Shell
Rotella T and Gasoline
(90 Octane Minimum)
The correct fuel mixture ratio is 6 U.S. gallons of
regular gasoline (90 octane minimum) plus 1 U.S.
quart of Arctic Cat Rotolube - Improved Formula
or equivalent ( SA E 30 HD Shell Rotella T), Fig.
1-5. This mixture is equivalent to a 25:1 ratio.
Fig . 1·5
+
OIL
• WARNING.
When mixing gas/oil or when the snowmobile
fuel tan k is filled, do so outdoors. Do not
smoke; keep away from camp fires if fueling in
a camping or rest area. The engine must not be
running when fueling to prevent the possibility
of afire
or an explosion, Fig. 1-6.
I nstruct the customer that the Wankel engine
requires the lubricating
oil to be mixed with
gasoline for lubrication and internal engine cooling.
Do not use outboard motor oil, non-detergent oil
or standard two-cycle oil in the Wankel engine.
1-8
Fig. 1-6
II
Note: Gasoline and oil must be premixed in a
clean container. Impress upon
the customer
that no attempt should be made to mix gasoline
and oil in the snowmobile fuel tank. Gasoline and
oil will not mix well in extremely cold
temperatures. Therefore, it is recommended that
the oil be at room temperature (+700F.) when
mixing.
1. Fill a clean container (gas can) with 3 U.S.
gallons
of gasoline (90 octane minimum). Add
the recommended amount of oil (1 U.S. quart
of Arctic Cat Rotolube -Improved Formula)
and shake the mixture vigorously.
2. Add the remainder of gaso line (3 U.S. gallons)
and again, shake the mixture vigorously.
3. Using a funnel with a fine mesh screen to
prevent the entry of dirt or other foreign
particles,
fill the snowmobile fuel tank. Wipe
up any fuel
that may have spilled. DO NOT
fill when the engine is hot.
II
Note: When using a gasoline/oil mixture that
has been setting for some time (settling of oil
may have occurred), the mixture is to be shaken
vigorously before the snowmobile fuel tank is
filled.
)

KNOVV THE CONTROLS
Prior to starting the engine, the operation and
function of every control, Figs. 1-7 and 1-8, must
be understood. Even if you have driven and ser-
viced
an Arctic Cat before, read this material to
familiarize yourself with the location of controls
and operational characteristics so that you can
better explain them to the customer. KNOW TH E
CONTROLS.
1. Headlight Dimmer Switch (A) -Depress the
headlight dimmer switch to obtain the desired
low or high beam po sition. When the switch is
in a depressed position, headlight is at low
beam. When switch is in a released position,
headlight
is at high beam.
2. Brake
Control (B) -When depressed, braking
action
will retard or stop the forward
movement.
3. Ignition Switch (C) -Three positions (OFF,
ON and START). OFF position used to shut
engine
off. Rotate key to ON position to start
recoil equipped engine. START position used
to crank engine equipped with an electric
starter.
_ Note: Ignition key must be in the OFF
_ position before it can be rotated to the ON or
START position. Key will not rotate from ON to
START.
4. Light Switch (D) -Move switch to ON
position to activate headlight and taillights.
Lights work only while engine is running.
5. Recoil Starter Handle (E) - After ignition
key is rotated to the ON position, pull recoil
starter handle to start the engine.
6. Choke (F) -
To sta rt a cold engine, cl ose
choke by pulling fully outward . When engine
starts, regulate choke as neces sary. A warm
engine
will require little or no choking .
7. Throttle Control (G) - Used to operate
engine
at various speeds. Speed is directly
proportionate to throttle lever movement.
When
throttle is released, it automatically
returns carburetor throttle arm to idle posi-
tion. If carburetor throttle or throttle linka ge
freezes or jams in an open position, throttle
safety switch will automatically shut engine
off when handle- mounted throttle control is
released.
8. Emerge ncy Shut-Off Switch (H) - To be used
if an emergency occurs and the engine must
be shut off quickly. Depress the emergency
shut-off switch to obtain the ON or 0 FF
position. When the switch
is in a depressed
position, the engine will shut off and will not
start. When the switch is in a released
position,
the engine can be started. The
emergency shut-off switch works
independently of the ignition switch.
Fig. 1-7
9. Full Tank Gauge Cap (I) - Indicates full level.
Fig. 1-8
Keep vent hole in the top of the cap
unobstructed.
II
Note: Tachometer, speedometer, heat gauges
and an electric starter are optional equipment
for the 1974 Wankel Panther. Additional acces-
sories are listed in the 1974 Arctic Cat Snowmobile
Accessory Brochure.
1-9

SAFETY CHECKS
Before the snowmobi le is test driven and re· turned
to the customer after service work is completed,
the following critical items are to be checked so
that the operating systems are working properly.
1. Check the cooling system. Cooling fan must
not have damaged blades and the finned parts
of the engine must not be obstructed.
2. Ensure the carburetor and exhaust systems
are securely fastened.
3. Check the operation of the throttle control.
The throttle control is to depress without
exce ssive effort and return freely to the idle
position.
4. Check the brake control. Brake is to fully
engage when brake control is depressed
approximately 3 /4-in ch and disengage freely
when released. If more than 3/4-inch brake
control travel is necessary to fully engage the
brake, an adjustment of the brake is
necessary.
5. Check the steering; skis must turn freely. If
difficulty is encountered, repair before
operating. Check the ski alignment; skis must
be parallel or have l/4-inch (max.) "toe in".
6. Ensure the headlight, brakelight and taillights
are working properly.
7. Check the operation of the th rottle safety
switch. Prop the back end of the snowmobile
up on a Quik Jack and start the engine. Check
the operation of the throttle safety switch by
opening the carburetor throttle
approximately 1/8-inch. DO NOT compress
throttle control on the steering handle. When
engine starts to cut out, release the carburetor
throttle. Engine cutout indicates throttle
safety switch is operating properly. If cutout
does not occur, an adjustment is necessary.
STARTING/STOPPING INSTRUCTIONS
.. WARNING ....
Never allow anyone to stand in front of the
snowmobile at any time, especially when
starting.
1. Ensure all Safety Checks are carried out.
2. Depress the emergency shut-off switch so that
it is in a released position. This released
position allows the engine to be started.
3. Pull the choke fully outward and hold the
throttle control approximately 1 /4 -inch open .
If the carburetor is equipped with a primer,
pull once or twice to prime the engine.
_ Note: If the engine is warm, choking and
- priming is not normally necessary.
4. Rotate the ignition key to the ON position.
5. Pull recoil starter handle until pawls engage;
then give a short quick pull.
1- 10
CAUTION
DO NOT pull the recoil rope to its limit or drop
the rope from an extended recoil position.
Failure to comply may result in damage to the
recoil starter.
6. When the engine starts, regulate the choke as
necessary. Allow a cold engine to idle for
approximately 2 minutes before operating.
7. Stopping - To stop (shut-off) the engine
under normal conditions, rotate the ignition
key to the OF F position after coming to a
complete stop.
8. Emergency Stopping -If the engine must be
shut off quickly because of an emergency,
depress the emergency shut -off switch. Engine
will shut off.

NOTES
c
c
c
1-11

NOTES
1-12

TABLE OF CONTENTS
Page
Setting Up Instructions IA-2 -10
Install Skid Frame
IA -2
Install Skis IA-2
Align Skis IA-4
Install Windshield
IA-5
Check Hood Latches
IA -5
Check Chain Alignment, Tension and Lubricate
IA -6
Adjust Suspension and Track . . . . . . IA-7
Adjust Choke, Brake and Thrott le Controls
IA-8
Time the Engine (Ignition) IA-8
Adjust Carburetor . .
IA -9
Check Switch Operation IA-1O
c
Adjust Headlight .
IA - 1O
Break-In ...
IA-1O
5 Hour Checkup IA-11
Section IA
© Arctic Enterpr ises, Inc . 1973
Form No. 0153 - 030

SETTING UP INSTRUCTIONS
Install Skid Frame
Equipment Necessary: 1/2-lnch Wrench, 1/2-lnch
Socket, Cardboard, Four 3/8 x 1-1/4-lnch Bolts,
Four 3/8-1 nch Lockwashers, 9/16-1nch Socket and
Torque Wrench
1. Remove all
mounting hardware that secures
the snowmobile to the pallet, using a 1/2-inch
wrench and socket.
Lift the snowmobile off
the pallet and set on the floor.
2. Tip the snowmobile onto its side and use a
piece
of cardboard to protect against
scratching.
3. Move the
front mounting arm of the skid
frame
into position with the front mounting
holes in the tunnel. Slide lockwasher onto
bolt and secure skid frame to tunnel, using a
9/16 -inch socket. DO NOT TIGHTEN BOLT
- THREAD IN ONLY HALF WAY, Fig. IA-
1.
II
Note: To aid in centering the front arm with
the mounting holes in the tunnel, position the
skid frame at a 45
0 angle
to the bottom of the
tunnel.
Fig. 1~.1
'1
4. Push skid frame, track and tunnel together
and
tip over on opposite side. Use a piece of
cardboard to protect against scratching.
5. Secure the front mounting arm, following the
directions given in step 3.
6. Move the rear mounting arm
of the skid frame
into position with the rear mounting holes in
IA-2
the tunnel. Slide lockwasher onto bolt and
secure skid frame
to tunnel, using a 9/16 -inch
socket. DO
NOT TIGHTEN BOLT
THREAD IN ONLY HALF WAY, Fig. IA-2.
II
Note: The rear mounting arm of the skid
frame
may not line up with the holes in the
tunnel. To obtain mounting arm and mounting
hole alignment, drive the rear mounting arm in the
proper direction until alignment is obtained; a
rubber hammer
is to be used.
Fig . IA·2
7. Tip snowmobile over on opposite side and use
a piece of cardboard to protect against
scratchi
ng.
8. Secure the rear mounting arm to the tunnel
with a bolt and lockwasher, using a 9/16-inch
socket. Tip snowmobile upright.
9. Tighten all skid frame mounting bolts to 35
ft . Ibs. torque, using a 9/16-inch socket and
torque wrench.
Install Skis
Equipment Necessary: Shock Absorbers, Long
Sleeves, Plastic Bushings, Two 7/16 x 3-1/4-lnch
Bolts, Four 7/16-lnch Locknuts, Low-Temperature
Grease,
5/8-lnch Wrench, 5/8-lnch Socket, Torque
Wrench, Cardboard, Two 3/8 x 4-1/4 - lnch Bolts,
)
)
Two 3/8-lnch Locknuts, 9/16-lnch Socket, Short )
Sleeves and Two 7/16 x 2-1/4-lnch Bolts
1. Locate the 2 skis and shock absorbers.

SETTING UP INSTRUCTIONS
,. 2. Slide a long sleeve through the stationary end
of the shock absorber and place a plastic
bushing
on each end of the long sleeve, Fig.
IA-3.
II
Note: Flat end surface of the plastic bushing
is to contact the shock absorber and radiused
end surface to contact the shock mounting
bracket.
Fig.IA·3
Shock -..
Absorber
Bushing
t .
Long Sleeve
3. Place shock assembly into position between
the shock mounting bracket and secure in
place with bolt and locknut, Fig. IA-4. Bolt
is to be started from the outside. Tighten the
bolt to 50 ft. Ibs. torque, using a 5/8-inch
wrench, 5/8-inch socket and torque wrench.
II
Note: Apply low-temperature grease (Texaco
2346 EP) on the non - threaded portion of the
bolt to prevent the possibility of binding or
corrosion.
Fig. IA·4
4. Install remaining shock absorber on ski,
following
the directions given in steps 2 and
3.
5. Tip the snowmobile onto its side and use a
piece
of cardboard to protect against
scratching.
6. Place ski assembly into position on spindle
and secure
in place with a bolt, Fig. IA-5.
Threaded hole in the ski saddle is to be to the
inside, and therefore, the bolt, Fig. IA-5, must
be started from the outside. Tighten the bolt
to 30 ft. Ibs. torque, using a 9/16-inch socket
and torque wrench. Thread locknut onto bolt
and tighten to 30 ft. Ibs. torque, using a
9/16-inch socket and torque wrench.
II
Note: Apply low-temperature grease (Texaco
2346 EP) on the non - threaded portion of the
bolt to prevent the possibility of binding or
corrosion.
7. Slide a short sleeve through the movable end
of the shock absorber and position the end
between the spindle mounting bracket. Secure
in place with bolt and locknut, making sure
the bolt is started from the outside, Fig.
IA -5. Tighten the bolt to 50 ft. Ibs. torque,
using a 9/16 -inch socket cmd torque wrench.
II
Note: Apply low-temperature grease (Texaco
2346 EP) on the non-threaded portion of the
bolt to prevent the possibility of binding or
corrosion.
Fig.IA ·5
IA-J

SETTING UP INSTRUCTIONS
8. Tip the snowmobile on the opposite side,
using a piece
of cardboard to protect against
scratching. Install remaining ski assembly
to
the ski spindle, following the directions given
in steps 6 and
7.
9. Position the snowmobile upright.
Align Skis
Equipment Necessary: Allen Wrench (As
Supplied), 9/16-lnch Wrench, 9/16 -lnch Socket,
8-lnch Extension, Tape Measure and Torque
Wrench
1. Position the brake control handle properly
and secure in place with the Allen wrench
supplied
with each snowmobile, Fig. IA-6.
2. Open the hood and remove the capscrew and
locknut that secures the tie rod end to the
spindle arm, using a 9/ 16-inch wrench,
9/16-inch socket and
an 8-inch extension,
Fig. IA-7. Separate
tie rod end from the
spindle arm. Perform this step on opposite
tie rod.
Fig.IA-7
IA-4
3. Position the skis straight forward and estab-
lish a parallel relationship, Fig. IA-8.
4. Measure the distance between the skis from
the outside edge of the ski itself, making sure
the measurement
is taken behind the front
spring mount and ahead of the rear spring
mount. Skis are to be parallel or have a slight
"toe - in" (0.25 inch maximum), Fig. IA-8.
5. Position the handlebars straight forward in
relation
to the skis.
Fig.IA·8
6. Rotate the tie rod end until the mounting
hole lines up with the hole in the spindle arm.
Secure the
tie rod end to the spindle arm with

SETTING UP INSTRUCTIONS
a capscrew and locknut, using a 9/16-inch
wrench, 9/16-inch socket, 8-inch extension
and
torque wrench. Tighten capscrew and
locknut to 35 ft. Ibs. torque.
~ WARNING ~
To ensure the utmost safety of the operator, all
nuts, bolts and tie rod ends must be tightened
securely and without noticeable damage. If
bolts and nuts are not tight or if a component is
damaged, serious injury to the operator and/or
passenger may occur.
7. Perform step 6 on remaining tie rod end and
spindle arm.
Install Windshield
Equipment Necessary: 8 Rubber Well-Nuts,
Windshield,
Trim, 8 Phillips Screws and Phillips
Screwdriver
1. Remove the protective covering and plastic
bag from the windshield. Properly dispose of
the protective coveri ng and plastic bag.
2. Separate the windshield and trim by removing
the 2
twist-lock ties.
3.
Push the rubber well-nuts into the mounting
holes in the hood.
Fig.IA -9
4. Position the windshield and trim in place and
retain
with 2 phillips screws on each side of
center, Fig. IA-9 . Thread the screws 3/4 of
the way in, using a phillips screwdriver. DO
NOT TIGHTEN SCREWS.
5. Work from side to side and install the
remaining
phillips screws, which will position
the windshield and
trim on the hood. DO
NOT TIGHTEN SCREWS.
6. When al l screws are installed and the wind-
shield
is in place, tighten all screws, working
from the center to the outside, Fig. IA-9 .
Check Hood Latches
Eq ui
pment Necessary: Phillips Screwdriver,
11/32-lnch Wrench and 3/8-lnch Wrench
1. Open the hood and allow the hood to rest on
the latch strike.
2. Examine the alignment between the latch
strike and the cut - out in the bottom of the
hood latch. The latch strike is to be
positioned directly over the cut-out in the
bottom of the hood latch, Fig. IA-lO. If
proper al ignment is evident, proceed to step
4.
If proper alignment is not evident, proceed
to step 3.
Fig. IA-l0
Hood Latch
Cut- Out
Latch Strike
IA-S

SETTING UP INSTRUCTIONS
3. Loosen the 4 l ocknuts and phillips machine
screws that secure the hood latch, using a
phillips screwdriver and 11 / 32-inch wrench,
Fig. IA-lO. Taking into consideration the
alignment obtained in step 2, slide the hood
latch into proper position as described in step
2. When proper al ignment is obtained, tighten
the phillips machine screws and locknuts,
using a phillips screwdriver and 11/32-inch
wrench. Proceed to step 4.
4. Close
the hood. Push down on each side and
determine how much "free-play" exists
between the hood latch and latch strike.
Virtually no "free-play" is to be evident. If
"free-play" is evident, proceed to step 5. If
"free-play" is not evident, proceed to step 6.
5. Loosen
the 2 carriage bolts and locknuts that
secure the latch strike, using a 3/8-inch
wrench, Fig. IA-lO. If the hood had "free-
play" when checked . as described in step 4,
move the latch strike down. If hood was too
tight and was difficult to open, move the
latch strike up. The most advantageous adjust-
ment is when the hood is tightly secured (no
"free-play") and opening/closing can be per -
formed without undue binding of the hood
latch and latch strike. When proper adjust-
ment is obtained, tighten the 2 carriage bolts
and locknuts, using a 3/8-inch wrench, Fig.
IA-lO.
6. Close the hood and check again for proper
operation.
Check Chain Alignment, Tension and Lubricate
Equipment Necessary: Straight Edge, Screwdriver,
Arctic Chainlube and Low-Temperature Grease
(Texaco 2346 EP)
1.
Open the hood and remove the 3 thumb
screws and washers that secure the chaincase
cover. Remove
the chaincase cover and gasket
from the backing plate.
II
Note: Exercise care when removing the
chaincase cover so as not to damage the
gasket.
2. Check the chain alignment in relation to the
sprockets by placing a 12-inch straight edge
on the bottom and top sprocket. No visible
gap is to exist between the surface of the
IA-6
straight edge and face of the sprockets. If
alignment is correct, proceed to step 3. If
al ignment is not correct, adj ust sprockets
accordingly (see Section V, Drive System).
Fig.IA-"
3. Check the chain tension (see Section V -
Drive
System, Chain Tension).
4. If chain tension is correct, proceed to step 6.
If tension is not correct, proceed to step 5.
5.
Adjust chain tension (see Section V - Drive
System, Chain Tension Adjustment).
6. Remove the rubber filler plug and the check
plug from the chaincase cover, using a
screwdriver.
7. Install
the chaincase gasket and cover to the
chaincase backing plate. Secure in place with
the 3 thumb screws and washers, Fig. IA-12.
e CAUTION e
Make sure the chaincase gasket is installed
evenly so that a good seal exists between the
chaincase cover and backing plate_ If after being
filled with chainlube and a leak develops,
mechanical damage will occur resulting in
component failure when operated. I

SETTING UP INSTRUCTIONS
8. Using a funnel, fill the chaincase with 8
ounces
of Arctic Chainlube, which is located
in the
toolbox. Lubricant level is to be at the
point of overflowing in the check plug hole,
Fig. IA-12. If not at the point of overflowing,
carefully top up with Arctic Chainlube. Wipe
any chainlube
that may have spilled.
Fig.IA-12
e CAUTION e
Make sure the chaincase cover and gasket are
sealing properly against the chaincase backing
plate. Chainlube will leak if an improper seal
exists and damage will occur resulting in
component failure when operated.
9. Install the rubber filler plug and the check
plug
with a short screwdriver. Check plug
must
be adequately tightened to prevent
chainlube leakage. Lubricate the eccentric
bearing
with low-temperature grease (Texaco
2346
EP or equivalent).
Adjust Suspension and Track
Equipment Necessary:
Low -Temperature Grease
(Texaco 2346 EP) and Grease Gun
1. Lubricate the rear suspension arms with low-
temperature grease (Texaco 2346 EP or equiv-
alent), Fig. IA-13.
II
Note: Due to the grease fitting position, a
flexible
hose grease gun must be used.
Fig.IA - 13
2. Adjust the suspension (see Section VI - Sus-
pension, Suspension Adjustment), Fig. IA-14.
Fig.IA-14
3. Adjust the track tension (see Section VI -
Suspension, Track Tension), Fig.
IA -15.
Fig.IA-15
4. Adjust the track alignment (see Section VI -
Suspension, Track
Alignment), Fig. IA-16.
Fig. IA - 16
IA-7

SETTING UP INSTRUCTIONS
Adjust Choke, Brake and Throttle Controls
Equipment Necessary: Screwdriver, 1/2-lnch
Socket, 1 /2-lnch Wrench and Pliers
1. Loosen the choke cable retaini ng screw, using
a screwdriver. Move
carburetor - mounted
choke arm fully forward (toward engine) and
hold in this position.
2. Position the front edge of the
console-mounted choke knob 1/8-inch from
the console. When knob is in proper position,
tighten choke cable retaining screw, using a
screwdriver.
II
Note: The choke cable is adjusted with
1I8-inch between the front edge of the choke
knob and console to ensure carburetor choke is
fully forward when choke is not used (pushed in).
3. Loosen the 2 brake
mounting bolts, using a
1/2-inch socket, Fig.
IA-17. Squeeze the
handle-mounted brake lever,
which will center
the brake on the driven pulley contact sur-
face; tighten the 2 brake
mounting bolts,
using a 1/2-inch socket.
Fig.IA-17
4. Squeeze the brake lever. When brake is fully
engaged, there is to be from 1/4 - 1/2 -inch
between
the front of the brake lever and the
brake lever stop. If specification (1/4 -1/2-
inch)
is not obtained, rotate the brake ad-
justing nut, Fig. IA -17, clockwise or counter-
clockwise, using a 1/2-inch wrench,
until the
specified adjustment
is obtained.
IA-8
5. Loosen the throttle cable retaining screw,
using a screwdriver,
which will allow the
carburetor
throttle arm to contact the idle
screw. Pull all slack
from the throttle cable
plus
an additional 1/ 16-inch to preload the
throttle safety switch spring, using a pliers.
6. Hold
throttle cable in place and tighten the
throttle cable retaining screw, using a
screwdriver.
II
Note: The desired adjustment is when the
handle-mounted
throttle lever lightly contacts
the handle grip and the
carburetor throttle plate is
fully open.
Time the Engine (Ignition)
Equipment Necessary: 13/16 - lnch Spark Plug
Socket, Feeler Gauge and
13 mm Wrench
It is recommended that the ignition timing be
checked at time of "Set-Up" and each time the
engine
is serviced. Incorrect ignition timing has a
negative
effect on engine performance and can
be accountable for lighting problems.
1. Disconnect the high tension wire from the
spark plug. Remove the spark plug and
washer, using a
13/16 -inch spark plug socket
and check
for proper type and heat range
(Bosch W260
T1). Set the air gap at 0.020
inch, using a feeler gauge.
2. Install the spark plug and washer. Tighten to
16-18 ft. Ibs. torque, using a 13/16-inch spark
plug socket and
torque wrench. Connect the
high tension wire
to the spark plug.
3. Remove the 2 bolts, lockwashers and flat
washers that secure the fuel pump to the
recoil housing, using a 13
mm wrench, Fig.
IA -18. Remove fuel pump and lay in bottom
of belly pan.
4. Remove the 4 screws and lockwashers
that
secure the recoil assembly to the fan housing,
using a short screwdriver. Just before the last
screw is removed, grasp the recoil assembly
with hand, remove the screw and allow recoil
to retract against the recoil handle mounting
bracket.
5. Check the timing, using a timing buzzer
(see Section IV -Electrical System, Ignition
Timing).