Arctic Cat Panther 1980 Operating manual

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FOREWORD
Since Arctic constantly refines and improves its products, several improvements in the 1980 Panther and
Pantera
Snowmobiles occurred during the 1979-1980 snowmobile season. This supplement will cover the
most significant improvements. Use this supplement in conjunction with the Arctic Cat Service Manual
-1980 Panther/Pantera January 1980 edition.
Major changes may be added to or deleted from the Service Manual in entirety as noted by the wo rd s
''Add'' or ''Delete''. Minor deletions are noted by lining out ( --) ; minor additions are noted by
underlining ( ).
This supplement uses the words Warning, Caution, and Note to emphasize certain information. The sym-
bol A
WARNING & identifies personal safety-related information. Therefore, be sure to read the directive
because
it deals with the possibility of personal injury. The symbol •CAUTION• identifies snowmobile-
related
information. Be sure to read the directive because it deals with the possibility of damaging a part
or parts of the snowmobile. If the directive is violated, the snowmobile will usually sustain major damage.
The
symbol NOTE: identifies supplementary information worthy of particular attention.
At the time of publication, all information, photographs, specifications, and illustrations were technically
correct. Because
Arctic Enterprises, Inc. constantly refines and improves its products , no retroactive
obligation is incurred.
Keep
this supplement and the corresponding Service Manual accessible in the shop area for reference.
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©Arctic Enterprises, Inc. 1980
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Publi cations Section
Product s·ervices Department
Arctic Enterprises, In c.

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TABLE OF
CONTENTS
SECTION
1m General Informat ion
3a Fuel Syste111
4a Drive Syste111
6a Steering and Body
Page
1
3
5
13
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TABLE OF
CONTENrrS
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Specifications ............................. 2
Preparatiora After Storage . ................... 2
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Page 2 of the 1980 Panther/Pantera Service Manual.
Brake Type Hydraulic Caliper Disc
w/Parking Brake
Preparation
After Storage
Page 5 of the 1980 Panther/Pantera Service
Manual.
Step
5. -Inspect brake lever travel, brake fluid
level, brake puck/brake
disc clearance, all con·
trols, headlight,
taillight, brakelight, ski align-
ment, ski wear-bars, wear-strips, and headlight
aim;
adjust or replace as necessary.
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Hydraulic Caliper Disc
w/Parking Brake
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TABLE OF
CONTENTS
Synchronizing Qi-Injection System ............ 4
Checking
............................... 4
Adjusting
............................... 4
3
,

NOTE: Figures 3·2 to 3.33 on pages 32-42 of
the 1980 Panther/Pantera Service Manual
show the original oil-injection linkage which has
been
improved as specified in Service Bulletin
80·13 Revised. The improved linkage is shown in
the following figure along with the original.
Fig. 3·1
Original Improved
•
07 26-602
If the oil-injection linkage needs to be serviced,
use the
following:
1. To disassemble the linkage , bend the lock
plate away from the jam nut and loosen the
jam nut. In order remove the socket, lock
plate, jam nut, and adjustment rod w/spacer.
2. To assemble the linkage, insert the adjust-
ment rod w/spacer through lever bushing, in-
stall the jam nut, place lock plate oversocket,
and install the socket.
3. After the oil-injection system is adjusted cor-
rectly,
tighten the jam nut and bend the lock
plate against the jam nut to secure the adjust-
ment.
f.lg. 3-2
4
Jam
Nut
Adjustment
Rod
Lock
Plate
0728-609
Synchroniz in g
Oil-Injecti on
Syste1 11
Page 41 of the 1980 Panther/Pantera Service
Manual.
CHECKING
Step 2. - Delete original step and substitute the
following :
The upper edge of the c
ontr ol a rm must align
with the lower edge of the oil-injection pump
boss. If the upper edge
of the co nt ro l arm does
not align with the lower edge of the oil-injection
pump boss, an adjustment is necessary.
Fig.
3-31 -Ignore illustration and substitute t he
following ill ustrati o n:
Fig. 3-3
Jam
Nut ~
Control
Arm
ADJUSTING
Adjustment
Rod
Lock
Plate Oil-
Injection
Pump Boss
0726·559
Step 2. -Delete original step and substitute the
following:
Bend the lock plate away from the adjustment rod
jam nut and loosen the jam nut.
Fig. 3-32 -Ignore
illustration and substitute Fig.
3-3 above.
Step
4. -Add: Bend lock plate against jam nut.
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TABLE OF
CON~ENTS
Drive Train ................................. 6
Disassembling ........................... 6
Assembling
............................. 6
Hydraulic Brake
............................ 6
Brake ...................................... 6
Removing and Disassembling .............. 6
Cleaning and Inspecting
................... 8
Assembling and
Installing ................. 8
Checking Brake-LeverTravel
.............. 10
Adjusting Brake-LeverTravel
.............. 10
5
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Drive Train
DISASSEMBLING
Page 62
of the 1980 Panther/Pantera Service
Manual
Step 11. -Add: Remove the collar positioned
against the brake disc. Discard the collar since it
is no longer used.
ASSEMBLING
Pages 63-65
of the 1980 Panther/Pantera Service
Manual.
Fig. 4-52 -Delete
item 65, Lock Collar.
Step
9. -Should read: Install key into driven shaft
brake disc keyway.
Step 15. -Delete entire step; ignore Fig. 4-58.
Hydraulic Brake
Delete entire section pages 66-71. When servicing
a Panther
or Pantera brake, use the following sec-
tion.
&
Brake
REMOVING AND DISASSEMBLING
1. Remove the two cap screws and lock nuts
securing the brake assembly
to the chain
case; then remove the bracket,
actuator
assembly, backing plate, and movable brake
puck.
Fig. 4·1
85 27
2. Disconnect the brake cable from the clevis
and
account for the spring. Loosen a cable
flange
nut and separate cable and bracket.
Fig. 4-2
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8528
3. Rotate the spiral shaft _w/actuator collar and
actuator ·lever out of the housing.
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Fig. 4·3
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8529
4. Remove the cap-lock s cr ew securing the ac-
tuator lever, actuator co llar , and the spiral
shaft; then separate
co mponent s.
Fig. 4-4
8530
5. Re move the cap screw and thin-lock nut
securing the cl ev is and bushing to the ac-
tuator lever; then separate
co mponent s.
Fig. 4·5
8 53 1
6. Remove the stationary brake puck.
NOTE: Do
not remove the stationary brake
puck unless replacement is necessary.
7. Cut the cable ties securing the handlebar
pad; then roll pad forward
to expose brake
cable and
wiring harness.
8. Remove the handlebar grip from the
handlebar.
NOTE: Because
of the adhesive used, it may
be necessary
to cut the handlebar grip off
the handlebar.
9. Disconnect the wiring harness
from the brake
switch.
10. Remove the retaining ring from the retaining
pin; then
carefully remove the retaining pin
from the brake
switch. Account for the park-
ing brake
actuator and spring.
Fig. 4·6
8030
11 . Disconnect the brake cable from the '' seat '' in
the brake lever; then
slide cable free of brake
switch and remove the brake cable. Account
for the brake lever.
12. Remove the tapping screw securing brake
switch to the handlebar; then slide brake
switch off handlebar.
Fig. 4·7
8031
7

CLEANING AND INSPECTING
NOfE: Whenever a part is worn excessively,
cracked, defective, or damaged in any way,
replacement
is necessary.
1. Wash all metallic parts in parts-cleaning sol-
vent.
Dry thoroughly.
2. Wash all non-metallic parts with soap and hot
water. Dry thoroughly.
3. Inspect parts for any signs of cracking or
fatigue.
4. Inspect all threaded areas for damaged or
stripped threads.
5. Inspect the brake cable for excessive bends,
kinks,
or fraying.
6. Inspect the springs for cracks or unusual
bends.
7. Inspect the brake pucks for wear. Brake
pucks must be at least 4.5 mm (0.18 in.) thick.
NOTE: If a brake puck needs to be replaced,
replace both pucks as a set.
8. Inspect the brake disc for any signs of crack-
ing
or gouging.
9. Inspect the brake disc hub for cracking or
wear.
10. Inspect the brake hub/driven shaft key and
keyways
for excessive clearance or wear. The
brake
hub must float freely on the driven
shaft.
ASSEMBLING AND INSTALLING
1. Slide the brake switch into position on the
handlebar;
then secure with the tapping
screw.
Fig. 4-8
8031
8 •
2. Route the brake cable through the handlebar
pad.
3. Slide the brake cable into position in the
brake
switch; then apply petroleum jelly to
the end of the cable and secure to the ''seat''
in the brake lever.
4. Install the parking brake actuator and spring.
Secure
actuator ,spring, and brake lever to the
brake
switch with the retaining pin and retain-
• •
1ng ring.
Fig. 4·9
8030
5. Connect the wiring harness to the brake
switch.
6. Apply Scotch-Grip Industrial Adhesive 847
(p/n 0219-408) to the bore of the handlebar grip
and using a rubber hammer, drive the grip into
position.
7. Install the stationary brake puck into the
chain case using LOCTITE SUPERBONDER
ADHESIVE
or a high-strength adhesive
equivalent.
Fig.4·10 ~Stationary Brake Puck
~ /""Movable Brake Puck
~a ~ /Actuator Housing Bracket
Backing
Plate
•
Spiral Shaft~
Bushing
,,.,...-:'~ ..& §:';, /'
. /'.. ~
Actuator
/:" Lever
fl) /
/ "
~
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(" ,
Clevis
Actuator
Collar
~
0726·556
8. Place the backing plate and movable brake
puck into the actuator housing.
9. Place the actuator housing w/backing plate
and movable brake
puck and the bracket into
position on the chain case. Secure with two
cap screws and lock nuts. •
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853 2
NOTE: Be sure the heads of the cap screws
are positioned toward the engine.
10.
Apply a lig ht coa t of Molykote Spray Lubri-
cant (Dow Co rn ing 321 R or equivalent) to the
spiral s haft ; then install shaft into actuator
housing .
1
1. Place the bu shing int o position in the ac-
tuator lever; then secure the clevis to the lever
using a
cap screw and thin-lo ck nut. Care fully
tight en thin-lock nut to a point just ensuring
free clevis movement.
: NOTE: The head
of the cap screw must be on
the
collar side of the actuator lever.
Fig. 4·12
CAUTION
Overtightening the thin-lock nut may restrict clevis
movement and cause premature brake cable failure.
l
8531
12. Slide the return spring onto the end of the
brake cable; then attach ball of the brake
cable to the clevis.
Fig. 4·13
8533
13. Place the brake cable assembly into position
in the bracket and adjust the flange nuts until
an equal number of threads are exposed
above and
below the flange nuts.
14. Place the
actuator collar onto the spiral shaft;
then install the actuator lever onto the collar
making sure the return spring is properly
preloaded (tensioned) and the
actuator lever
and
actuator collar are properly meshed.
Secure
with the cap-lock screw.
Fig.4-14
CAUTION
The return spring must be properly preloaded (tension-
ed).
8534
15. I nstal I alI necessary cable ties; then instal I
handlebar pad and secure with cable ties.
CAUTION
Route and secure all cables and electrical wires away
from the actuator assembly and any moving or rotating
components.
16. Check and adjust brake-lever travel.
9

CHECKING BRAKE-LEVER TRAVEL
1. Rotate the brake disc alternately forward and
backward
while slowly compressing the
brake lever.
2. At the point where the disc cannot be easily
rotated,
check the travel distance between
the brake lever and the lever
''stop''. The cor-
rect distance is 6-13 mm (1 /4·
1
/2 in.).
Fig. 4·15
Lever
••stop''
•
6·13 mm
(1/4·1/2 in.)
Brake
Lever
0726-099
3. If travel distance is not within the tolerance
given,
adjust brake-lever travel.
ADJUSTING BRAKE-LEVER TRAVEL
NOTE:
If a minor adjustment is needed, use
steps 1·3. If a major adjustment is needed,
use steps 4·11.
Fig. 4·16
10
Actuator Lever
Cap-Lock Screw
Upper
Flange
Nut
Lower
Flange
Nut
0726·825
1. To decrease the brake-lever travel (set up the
brake), loosen the
lower flange nut while
tightening the upper flange nut . Check the
brake-lever travel
distance periodically untiI
correct travel distance is attained .
2. To increase the brake-lever travel, loosen the
upper flange
nut while tightening the lower
flange nut. Check the brake-lever travel
distance periodically until correct travel
distance is attained.
3. Lock the flange nuts securely after adjust-
ment is completed.
NOTE:
If further adjustment is required to
maintain the specified brake-lever travel
distance once the limit is reached on the initial
adjustment, use steps 4·11 .
4. Loosen the upper flange nut while tight ening
the lower flange
nut until three coils of the
spring are visible over the threads of the
brake cable adjuster.
5. Loosen the actuator lever cap-lock screw
several revolutions.
Fig. 4-17
6. Fully compress the brake lever; then hold the
cap-lock screw in
position with a wrench.
7. Release the brake lever to allow the actuator
lever to slip one position on the actuator col-
lar.
8. Tighten the actuator lever cap-lock screw.
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9. Make the final adjustment using the flange
nuts on the brake cable bracket to obtain the
correct travel distance.
10 . Lock the flange nuts securely.
11. Compress the brake lever fully and check the
clearance between the
actuator collar and the
actuator housing. The clearance must be
greater than 1 mm (0.040 in.). If the clearance
is less, replacement
of both brake pucks is
necessary.
•
Fig.4·18
Actuator
Lever ~
•
1 mm
(0.040 in.)
Actuator
,--
Housing
0726-153 •
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TABLE OF
CONTENTS
Assembling and InstallingThrottleSwitch .... 14
Removing Master-CylinderHousing
.......... 14
Removing Brake Switch .............•...... 14
Installing Master-CylinderHousing
.......... 15
Installing BrakeSwitch
..................... 15
13

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Asse111bling and
Installing Throttle
Switch
When installing a Panther or Pantera throttle
switch, note the following changes on page 90.
Step
2. -Should read: Apply petroleum jelly to the
end
of the throttle cable; then slide the throttle
cable into groove of throttle switch and secure
with retaining ring.
Step
4. - Should read: Apply a thin film of NYE
723-E grease
to the pin and seals of the throttle
lever; then secure throttle lever with pin, seals,
and retaining ring.
Step
6. - Apply glue (Scotch-Grip Plastic Industrial
Adhesive 1099 847 (p/n 0219-408) or equivalent) to
the bore of the handle grip and using a rubber
hammer, drive the handle grip
into position .
Removing
Master-Cylinder
•
Housing
Delete entire section page 91. When removing a
Panther
or Pantera brake switch, use the follow-
ing
section.
Removing
Brake Switch
1. Cut the cable ties securing the handlebar
pad; then roll the pad forward to expose brake
cable and wiring harness.
14
•
2.
Disconnect wiring harness from the brake
switch.
3. Remove the retaining ring from the retaining
pin; then carefully remove the retaining pin
from the brake s
witch. A cco unt for the park-
ing brake actuator and spring.
Fig. 6·1
8030
4. Di sc onnect the brake cable from the ''seat '' in
the brake lever; then slide cable free
of the
brake
swit ch. A cco unt for the brake lever.
5. Remo ve the h andlebar grip from the
handlebar.
NOTE: Because of the adhesive used, it may
be
necessary to cut the handlebar grip off
the handlebar.
6. Remove the tapping screw securing the brake
switch to the handlebar; then slide brake
s
witch off the handlebar.
Fig. 6·2
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80 31
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Installing
Master-Cylinder
Housing
Del ete entire section page 91. When installing a
Panther or Pantera brake switch, use the follow-
ing section.
Fig. 6·3
•
BITTlstalling
tBrrake Swi tch
7
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2
KEY
1. Handlebar Grip
2. Brake Lever
3. Brake Switch
4. Retaining Pin
5. Retaining Ring
6. Tapping Screw
7. Parking Brake Actuator
8. Spring
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0726-210
1. Slide the brake switch into position on the
handlebar; then secure with a tapping screw.
Fig. 6·4
8031
2. SI ide brake cable into position in the brake
switch .
3. Apply petroleum jelly to the end of the cable
and secure
to the ''seat'' in the brake lever.
4. Install the parking brake actuator and spring.
Secure actuator, spring, and brake lever
to the
brake switch with the retaining pin and retain-
• •
1ng ring.
Fig. 6-5
• •
8030
5. Connect the wiring harness to the brake
switch.
6. Apply Scotch-Grip Industrial Adhesive 847
(p/n 0219-408) to the bore of the handlebar grip
and using a rubber hammer, drive the grip into
position.
7. Install handlebar pad and secure with cable
ties.
15

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.Printed November, 1980
Part Number0153·333.
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Printed in U.S.A.
by Arctic Printing Dept.
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