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2 FOREWORD Since Arctic constanty refines and improves its products, severa improvements in the 1980 Panther and Pantera Snowmobies occurred during the snowmobie season. This suppement wi cover the most significant improvements. Use this suppement in conjunction with th e Arctic Cat Service Manua Panther/Pantera January 1980 edition. Major changes may be added to or deeted from the Service Manua in entirety as noted by the word s Add or Deete. Minor deetions are noted by ining out ( --); minor additions are noted by underining ( ). This suppement uses the words Warning, Caution, and Note to emphasize certain information. The symbo A WARNNG & identifies persona safety-reated information. Therefore, be sure to read th e directive because it deas with the possibiity of persona injury. The symbo CAUTON identifies snowmobiereated information. Be sure to read the directive because it deas with the possibiity of damaging a part or parts of the snowmobie. f the directive is vioated, the snowmobie wi usuay sustain major damage. The symbo NOTE: identifies suppementary information worthy of particuar attention. At the time of pubication, a information, photographs, specifications, and iustrations were technicay correct. Because Arctic Enterprises, nc. constanty refines and improves its products, no retroactive obigation is incurred. Keep this suppement and the corresponding Service Manua accessibe in the shop area for reference. Pubications Section Product s ervices Department Arctic Enterprises, nc. ri~b 1n erv1ce u t...:m& 1iStt.A :.. \fttt.,..,,.,, Arctic Enterprises, nc. 1980

3 f i i TABLE OF CONTENTS 1 SECTON Page 1 m Genera nformation 3a Fue Syste a Drive Syste a Steering and Body 13-1,! i \!.i

4 ..

5 i i \ i f.. TABLE OF CONTENrrS } Specifications... 2 Preparatiora After Storage

6 ,. Page 2 of the 1980 Panther/Pantera Service Manua. Brake Type Hydrauic Caiper Disc w/parking Brake Hydrauic Caiper Disc w/parking Brake Preparation After Storage Page 5 of the 1980 Panther/Pantera Service Manua. Step 5. - nspect brake ever trave, brake fuid eve, brake puck/brake disc cearance, a con tros, headight, taiight, brakeight, ski aignment, ski wear-bars, wear-strips, and headight aim; adjust or repace as necessary. 2

7 , TABLE OF CONTENTS f Synchronizing Qi-njection System... 4 Checking... 4 Adjusting

8 NOTE: Figures 3 2 to 3.33 on pages of the 1980 Panther/Pantera Service Manua show the origina oi-injection inkage which has been improved as specified in Service Buetin Revised. The improved inkage is shown in the foowing figure aong with the origina. Fig. 3 1 Synchronizing Oi-njection Syste111 Origina mproved Page 41 Manua. of the 1980 Panther/Pan tera Service CHECKNG Step 2. - Deete origina step and su bstitute the foowing: The upper edge of the contro arm must aig n with the ower edge of the oi-injection pump boss. f the upper edge of the contro arm does not aign with the ower edge of the oi -inject ion pump boss, an adjustment is necessary Fig gnore iustration and substitute the foowing iustration: f the oi-injection inkage needs to be serviced, use the foowing: 1. To disassembe the inkage, bend the ock pate away from the jam nut and oosen the jam nut. n order remove the socket, ock pate, jam nut, and adjustment rod w/spacer. 2. To assembe the inkage, insert the adjustment rod w/spacer through ever bushing, insta the jam nut, pace ock pate over socket, and insta the socket. Fig. 3-3 Jam Nut ~ Adjustment Rod Lock Pate Oi-njection Pump Boss 3. After the oi-injection system is adjusted correcty, tighten the jam nut and bend the ock pate against the jam nut to secure the adjustment. Contro Arm f.g. 3-2 Adjustment Rod ADJUSTNG Jam Nut Lock Pate Step 2. - Deete origina step and substitute the foowing: Bend the ock pate away from the adjustment rod jam nut and oosen the jam nut. Fig gnore iustration and substitute Fig. 3-3 above. Step 4. - Add: Bend ock pate against jam nut

9 TABLE OF CON~ENTS Drive Train... 6 Disassembing... 6 Assembing... 6 Hydrauic Brake... 6 Brake... 6 Removing and Disassembing... 6 Ceaning and nspecting... 8 Assembing and nstaing... 8 Checking Brake-Lever Trave Adjusting Brake-Lever Trave ~~~~~~~- ~~~~~~~~~~~~~~~~~~~~~~~~~ 5

10 Drive Train Brake DSASSEMBLNG Page 62 of the 1980 Panther/Pantera Service Manua Step Add: Remove the coar positioned against the brake disc. Discard the coar since it is no onger used. REMOVNG AND DSASSEMBLNG 1. Remove the two cap screws and ock nuts securing the brake assemby to the chain case; then remove the bracket, actuator assemby, backing pate, and movabe brake puck. Fig. 4 1 ASSEMBLNG Pages of the 1980 Panther/Pantera Service Manua. Fig Deete item 65, Lock Coar. Step 9. - Shoud read: nsta key into driven shaft brake disc keyway. Step Deete entire step; ignore Fig Disconnect the brake cabe from the cevis and account for the spring. Loosen a cabe fange nut and separate cabe and bracket. Hydrauic Brake Fig. 4-2 ~---~--, ~.... Deete entire section pages When servicing a Panther or Pantera brake, use the foowing section ( J.. _ Rotate the spira shaft _w/actuator coar and actuator ever out of the housing. &

11 Fig Cut the cabe ties securing the handebar pad; then ro pad forward to expose brake cabe and wiring harness. --- \ \ 8. Remove the handebar grip from the handebar. NOTE: Because of the adhesive used, it may be necessary to cut the handebar grip off the handebar _, Remove the cap- ock screw securing the actuator ever, actuator coar, and the spira shaft; then separate components. Fig Disconnect the wiring harness from the brake switch. 10. Remove the retaining ring from the retaining pin; then carefuy remove the retaining pin from the brake switch. Account for the parking brake actuator and spring. Fig Remove the cap screw and thin-ock nut securin g the cevis and bu shing to the actuator ever; then separate components. Fig Disconnect the brake cabe from the seat in the brake ever; then side cabe free of brake switch and remove the brake cabe. Account for the brake ever. 12. Remove the tapping screw securing brake switch to the handebar; then side brake switch off handebar. Fig Remove the stationary brake puck NOTE: Do not remove the stationary brake puck uness repacement is necessary. 7

12 CLEANNG AND NSPECTNG NOfE: Whenever a part is worn excessivey, cracked, defective, or damaged in any way, repacement is necessary. 1. Wash a metaic parts in parts-ceaning sovent. Dry thoroughy. 2. Wash a non-metaic parts with soap and hot water. Dry thoroughy. 3. nspect parts for any signs of cracking or fatigue. 2. Route the brake cabe through the handebar pad. 3. Side the brake cabe into position in the brake switch; then appy petroeum jey to the end of the cabe and secure to the seat in the brake ever. 4. nsta the parking brake actuator and spring. Secure actuator, spring, and brake ever to the brake switch with the retaining pin and retain- 1ng ring. Fig. 4 9 J 4. nspect a threaded areas for damaged or stripped threads. 5. nspect the brake cabe for excessive bends, kinks, or fraying. 6. nspect the springs for cracks or unusua bends. 7. nspect the brake pucks for wear. Brake pucks must be at east 4.5 mm (0.18 in.) thick. NOTE: f a brake puck needs to be repaced, repace both pucks as a set nspect the brake disc for any signs of cracking or gouging. 5. Connect the wiring harness to the brake switch. 9. nspect the brake disc hub for cracking or wear. 10. nspect the brake hub/driven shaft key and keyways for excessive cearance or wear. The brake hub must foat freey on the driven shaft. 6. Appy Scotch-Grip ndustria Adhesive 847 (p/n ) to the bore of the handebar grip and using a rubber hammer, drive the grip into position. 7. nsta the stationary brake puck into the chain case using LOCTTE SUPERBONDER ADHESVE or a high-strength adhesive equivaent. ASSEMBLNG AND NSTALLNG Fig ~Stationary Brake Puck 1. Side the brake switch into position on the handebar; then secure with the tapping screw. ~ /""Movabe Brake Puck ~a ~ /Actuator Housing Bracket Fig. 4-8 Backing Pate,,.,...-:~..& :;,/. /..~ Spira Shaft~ Bushing f)/ / " ~ Actuator /:" Lever / (", ~ Cevis Actuator Coar Pace the backing pate and movabe brake puck into the actuator housing Pace the actuator housing w/backing pate and movabe brake puck and the bracket into position on the chain case. Secure with two cap screws and ock nuts. 8

13 Fig NOTE: Be sure the heads of the cap screws are positioned toward the engine. 10. Appy a ight coat of Moykote Spray Lubricant (Dow Corn ing 321 R or equivaent) to the spira shaft; then insta shaft in to actuator housing. 11. Pace the bushing into position in the actuator ever; then secure the cevis to the ever using a cap screw and thin-ock nut. Carefuy tighten thin-ock nut to a point just ensuring free c evis movement Pace the brake cabe assemby into position in the bracket and adjust the fange nuts unti an equa number of threads are exposed above and beow the fange nuts. 14. Pace the actuator coar onto the spira shaft; then insta the actuator ever onto the coar making sure the return spring is propery preoaded (tensioned) and the actuator ever and actuator coar are propery meshed. Secure with the cap-ock screw. Fig.4-14 Fig : NOTE: The head of the cap screw must be on the coar side of the actuator ever CAUTON 8531 The return spring must be propery preoaded (tensioned). CAUTON Overtightening the thin-ock nut may restrict cevis movement and cause premature brake cabe faiure. 12. Side the return spring onto the end of the brake cabe; then attach ba of the brake cabe to the cevis. 15. nsta a necessary cabe ties; then insta handebar pad and secure with cabe ties. CAUTON Route and secure a cabes and eectrica wires away from the actuator assemby and any moving or rotating components. 16. Check and adjust brake-ever trave. 9

14 CHECKNG BRAKE-LEVER TRAVEL 1. Rotate the brake disc aternatey forward and backward whie sowy compressing the brake ever. 2. At the point where the disc cannot be easiy rotated, check the trave distance between the brake ever and the ever stop. The correct distance is 6-13 mm ( 1 /4 1/2 in.). Fig Brake Lever 1. To decrease the brake-ever trave (set up the brake), oosen the ower fange nut whie tightening the upper fange nut. Check the brake-ever trave distance periodicay u nt i correct trave distance is attained. 2. To increase the brake-ever trave, oosen the upper fange nut whie tightening the ower fange nut. Check the brake-ever trave distance periodicay unti correct trave distance is attained. 3. Lock the fange nuts securey after adjustment is competed. - Lever stop 6 13 mm (1/4 1/2 in.) NOTE: f further adjustment is required to maintain the specified brake-ever trave distance once the imit is reached on the initia adjustment, use steps f trave distance is not within the toerance given, adjust brake-ever trave. ADJUSTNG BRAKE-LEVER TRAVEL NOTE: f a minor adjustment is needed, use steps 1 3. f a major adjustment is needed, use steps Loosen the upper fange nut whie tightening the ower fange nut unti three cois of the spring are visibe over the threads of the brake cabe adjuster. 5. Loosen the actuator ever cap-ock screw severa revoutions. Fig Fig Upper Fange Nut.. Actuator Lever Cap-Lock Screw Lower Fange Nut Fuy compress the brake ever; then hod the cap-ock screw in position with a wrench. 7. Reease the brake ever to aow the actuator ever to sip one position on the actuator coar. 8. Tighten the actuator ever cap-ock screw. 10

15 9. Make the fina adjustment using the fange nuts on the brake cabe bracket to obtain the correct trave distance. Fig. 4 18,-- Actuator Housing 10. Lock the fange nuts securey. 11. Compress the brake ever fuy and check the cearance between the actuator coar and the actuator housing. The cearance must be greater than 1 mm (0.040 in.). f the cearance is ess, repacement of both brake pucks is necessary. Actuator Lever ~ 1 mm (0.040 in.)

16 , t

17 TABLE OF CONTENTS Assembing and nstaing Throtte Switch Removing Master-Cyinder Housing Removing Brake Switch nstaing Master-Cyinder Housing nstaing Brake Switch

18 Asse111bing and nstaing Throtte Switch 2. Disconnect wiring harness from the brake switch. 3. Remove the retaining ring from the retaining pin; then carefuy remove th e retaining pin from the brake switch. Account for the parking brake actuator and spring. Fig. 6 1 When instaing a Panther or Pantera throtte switch, note the foowing changes on page 90. Step 2. - Shoud read: Appy petroeum jey to the end of the throtte cabe; then side the throtte cabe into groove of throtte switch and secure with retaining ring. 1 Step 4. - Shoud read: Appy a thin fim of NYE 723-E grease to the pin and seas of the throtte ever; then secure throtte ever with pin, seas, and retaining ring. Step 6. - Appy gue (Scotch-Grip Pastic ndustria Adhesive (p/n ) or equivaent) to the bore of the hande grip and using a rubber hammer, drive the hande grip into position Di sconnect the brake cabe from the seat in the brake eve r; then side cabe free of the brake switch. Account for the brake ever. 5. Remove the handebar grip from the handebar. Removing Master-Cyinder Housing NOTE: Because of the adhesive used, it may be necessary to cut the handebar grip off the handebar. 6. Remove the tapping screw securing the brake switch to th e handebar; then side brake switch off the handebar. Fig. 6 2 Deete entire section page 91. When removing a Panther or Pantera brake switch, use the foowing section. Removing \ Brake Switch Cut the cabe ties securing the handebar pad; then ro the pad forward to expose brake cabe and wiring harness. 14

19 Fig. 6 4 nstaing Master-Cyinder Housing De ete entire section page 91. When instaing a Panther or Pantera brake switch, use the foowing section S ide brake cabe into position in the brake switch. 3. Appy petroeum jey to the end of the cabe and secure to the seat in the brake ever. 4. nsta the parking brake actuator and spring. Secure actuator, spring, and brake ever to the brake switch with the retaining pin and retain- 1ng ring. BTTstaing Fig. 6-5 tbrrake Switch Fig a v 8030 KEY s_a 2 5. Connect the wiring harness to the brake switch. 6. Appy Scotch-Grip ndustria Adhesive 847 (p/n ) to the bore of the handebar grip and using a rubber hammer, drive the grip into position. 1. Handebar Grip 2. Brake Lever 3. Brake Switch 4. Retaining Pin 5. Retaining Ring 6. Tapping Screw 7. Parking Brake Actuator 8. Spring 7. nsta handebar pad and secure with cabe ties Side the brake switch into position on the handebar; then secure with a tapping screw. 15

20 ,. ~.... j.... Printed November, 1980 Part Number Printed in U.S.A. by Arctic Printing Dept....