Arctic Cat Flex-Tec Guard 7639-394 User manual

NOTE: Read these Installation Instructions thoroughly before beginning the installation process. Retain these
Installation Instructions for future reference.
Arctic Cat®Snowmobile
Installation Instructions
REV: 6/16/16 Form No. 2653-092
Flex-Tec Guard Kits
(p/n 7639-394, 7639-395, 7639-396, 7639-397)
Kit includes:
p/n QTY DESCRIPTION
1641-096 1 Right-Side Black Cover - (7639-394)
1641-097 1 Left-Side Black Cover - (7639-394)
1641-098 1 Right-Side Green Cover - (7639-395)
1641-099 1 Left-Side Green Cover - (7639-395)
1641-100 1 Right-Side Orange Cover - (7639-396)
1641-101 1 Left-Side Orange Cover - (7639-396)
1641-102 1 Right-Side White Cover - (7639-397)
1641-103 1 Left-Side White Cover - (7639-397)
1641-104 1 Right-Side Plastic Stiffener
1641-105 1 Left-Side Plastic Stiffener
1641-106 1 Right-Side Mount Assembly
1641-107 1 Left-Side Mount Assembly
1641-108 1 Hardware Kit
2653-092 1 Instructions
Tools Required:
•T30TorxBit
• 10 mm Socket
• 10 mm Wrench
• Ratchet
• Propane Torch
• 4 mm Allen Wrench
1. Loosen the two screws securing the brake assembly
to the handlebar; then move it toward the center of
the handlebar. See Fig. 1.
Fig. 1
XM473A
2. Position Left-Side Mount Assembly (offset mount)
onto the handlebar and secure it with the cap and
screws making sure the mount it up against the dim-
mer control. See Fig. 2.
Fig. 2
XM474
3. Lightly flame treat Left-Side Plastic Stiffener in the
intended area for the velcro making sure to keep the
flame off the plastic. This will allow the velcro to
fully adhere to the plastic. Adhere the velcro from
the cover onto the stiffener. See Fig. 3.
Fig. 3
XM475
4. Secure the plastic stiffener to the mount (in the
desired locations) using two cap screws, two flat
washers, two brackets and two nuts. Tighten
securely. See Fig. 4.
!WARNING
When flame treating, there should be no welding,
smoking, open flames, etc., in the area.

2
Fig. 4
XM476
5. Install the left-side cover over the plastic stiffener
and secure using the strap and velcro. See Fig. 5.
Fig. 5
XM477
6. Repeat for opposite side.
Fig. 6
XM478
NOTE: Depending on the windshield that is
installed, the handlebar and/or guards may need to
be adjusted to clear the windshield when turning
the handlebar.
7. Once everything is adjust correctly, secure the
brake assembly to the handlebar. Tighten to 80 in.-
lb.
!WARNING
When installing the right-side hand guard, be
sure to route the cover strap on the inside of the
throttle cable. DO NOT install over the throttle
cable. See Fig. 6.
Printed in the U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 0616