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2. Place the front bumper assembly (with spar panels) into
position on the snowmobile; then secure the front and
rear spar panels together with the torx-head cap screws
and lock nuts (A). Tighten the lock nuts securely.
3. Install the body screws and lock nuts (C) from each
side and the self-tapping screws (B) from each side
securing the front bumper assembly to the chassis.
Tighten all hardware securely.
4. Connect the air temperature sensor and place the sen-
sor harness beneath the intake duct; then install the
duct into the silencer.
NOTE: To aid in installing the duct, it can be helpful
to apply a thin film of WD-40 to the air silencer seal
and to work the duct back and forth until the sleeve of
the duct is properly seated into the silencer.
CAUTION
Make sure to place the sensor harness beneath the
intake duct to avoid contact with exhaust components.
5. Secure the intake duct to the upper frame with the
cap screw. Tighten securely.
NOTE: If the ECU was removed to gain access to
the duct cap screw, install the ECU using the two cap
screws. Tighten the cap screws securely; then con-
nect the harness plug-ins to the ECU.
6. Using the illustration following step 2, secure the
left-side rear spar panel to the gas tank and support
tube with the three torx-head screws (D). Tighten the
screws securely.
7. Install the seat; then install the machine screw
(threads coated with blue Loctite #243) to the right
side of the seat support.
8. Place the rubber exhaust bumper into position on the
air silencer.
742-207A
9. Place gaskets on the resonator and exhaust manifold;
then install the expansion chamber. Secure the cham-
ber to manifold and upper frame with the springs.
10. Secure the console to the steering support with the
torx-head screws and tighten the screws securely;
then close the left-side and right-side access panels
and close the hood.
(Bearcat/T-Series 1100
cc Non-Turbo)
REMOVING/INSPECTING/CLEANING
1. Remove the two torx-head cap screws (A) securing
the console to the chassis; then lift up the rearward
end of the console and disconnect the console har-
ness plug-in. Remove the console.
FS202A
Air Silencer
FS203A
3
0743-777
3-23
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Table of Contents
Troubleshooting
