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Installing 06-08 Crossfire Tunnel Protector Kit
| Johnmaster P/N 136CFTP Fits all 06-08 Arctic Cat Crossfire 136" models |
These have not yet been tested for fitment on 06 EB early build models with the short rear heat exchanger.
1. Read and understand all instructions before starting installation. Like most any aftermarket product, installation of this product is considered a modification of your snowmobile. Like most aftermarket products, by purchasing and installing these products, you assume all risks and responsibilities associated with them. These risks include but are not limited to property damage or loss and personal injury during installation and use, and the possibility of voiding your snowmobile manufacturer's warranty. If you do not wish to accept these risks, do not proceed with installation. There are no warrantees or guarantees regarding this product, implied or express.
2. Tools you will need:
A helper
Pneumatic Rivet Gun (Steel pin rivets are almost impossible to set properly with a small handheld riveter)
Socket wrench set
7/16" nut driver or shallow 1/4" drive socket
#2 Phillips screwdriver
Wrenches
Cordless drill motor
3/16" drill bit
1/4" drill bit
Center punch
Permanent marker
Steel rule
Measuring tape
Hole deburring tool or sandpaper
Compressed air/blow gun
3. Remove the seat. Raise and safely support the rear of the sled at a comfortable working level. Make sure the underside of the tunnel is clean of all dirt and debris.
4. You will want to lower the rear of the skidframe to gain access to the underside of the tunnel. To release spring pressure from the skidframe bolts, remove the spring slide mounts bolted to the middle of the suspension rails and release the springs from the rails. *Caution: They are under high pressure. Now that the spring pressure is released from the rear skid, you can support the skidframe, remove the two rear bolts that attach the suspension to the sled, and lower the skidframe to gain access. The previous steps will save you time and hassle re-installing the skid frame as you will be able to freely move the suspension cross shaft to align it with the holes in the tunnel.
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First Rivet Location
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5. Next, locate one of the mid-tunnel U-shaped protector strips and make note of which end is the front. The front has about
6+ inches of undrilled area before the first hole, the rear of the strip has a hole about 1" from the end. To mark and drill the front hole for the first strip, locate the rear ear of the gas tank where it bolts to the sled. Set your riveter inside the notch where the body of the gas tank starts to note how much clearance you will have for pulling the rivet. If your riveter allows, you will want the center of the hole for the rivet about 3/8" inboard of the ear and about 3/8" behind where the actual gas tank starts. To overstate the obvious, DO NOT DRILL INTO YOUR GAS TANK! Mark the location in the tunnel with a center punch and drill it with a 3/16" drill bit. Use the photo as a guide. Deburr both sides of the drilled hole and work with a helper to attach one of the strips using (1) smaller 3/8" headed rivet and (1) rivet washer.
Use riveter head to check clearance
6. Once the strip is attached with the front rivet, use a measuring tape to square it to the side of the tunnel. Mark the edge of it inside the tunnel so you can be sure it doesnt move during the next step. Use the three remaining holes as a guide and drill with a 3/16" drill bit from the inside of the tunnel out. Hold the strip firmly in place on your mark, and start by drilling the hole closest to the front rivet and work back as you go. Slide a rivet into each hole temporarily, after you drill each one. This will help keep the strip aligned and ensure the rivets will line up after you are done drilling.
7. Once you have the back three holes drilled in the tunnel, shift the protector out of the way, blow any cutting chips out from underneath the protector and deburr the holes top and bottom.
8. Use the small headed rivets and rivet washers to finish attaching the strip. Work from the front to the back. Have someone help you hold the washer in place and make sure everything is held tight together before starting to squeeze the rivet.
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First strip attached
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9. Now that you have one strip installed, repeat steps 5-8 to install the other one.
10. Once you have both of the mid-tunnel protector strips completely installed, you can install one of the rear heat exchanger protector blocks. It should be pretty obvious which one goes on the left and which goes on the right, the taper goes toward the front. Hold each of them up into place and make sure they sit nicely in place up against the tunnel. Using the 1/4" drill bit and one of the protectors held firmly in place as a guide, drill all four of the holes into the tunnel. Take the protector down, clean all drilling chips out and deburr the holes top and bottom.
11. Put the protector back in place and drop 3 long phillips screws and 1 short phillips screw into the holes from the top of the tunnel. The short bolt goes into the front hole. Put a 1/4" washer into the hole and use the nut driver or short 1/4" drive socket to run one of the nuts onto one of the bolts. Tighten using the Phillips screwdriver and socket. Repeat for all four fasteners.
12. Repeat steps 10 and 11 for the opposing rear block.
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All strips bolted on
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13. Now that all 4 protector strips are installed you can re-install the suspension rear bolts (consider using loc-tite to make sure they don't loosen), reattach the spring mounts onto the skid frame and re-install the seat. Adjust track tension if necessary. After your first use check your work to make sure protectors are still firmly attached and make it a part of your pre-trip inspection routine. If you change out your track for a deep lug mountain track, remove the protectors to avoid possible interference. If you change tracks back in the future, replace the protectors using only steel body rivets of the same length.
When you are done, all the fasteners except these two will be hidden under your seat making for a very clean install.
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Only 2 bolts exposed
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Many thanks go to our customer Jim P. for submitting these excellent installation photos as taken of his brand new 08 Crossfire 1000. Jim is installing 162 of the Warthog XZP studs with Big AL nuts into the new Cobra track he installed. Thank you Jim!
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