TABLE OF CONTENTS H1 EFI EFT T3

Transcription

1 700 H1 EFT T3 2010

2 Red Cat Green TABLE OF CONTENTS H1 EFI EFT T3 Green Black - LE FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES... 1 FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES (LE)... 2 REAR RACK, BODY PANEL, AND FOOTWELL ASSEMBLIES... 3 FRAME AND RELATED PARTS... 4 WINCH ASSEMBLY... 5 LICENSE PLATE HOLDER ASSEMBLY... 6 SEAT ASSEMBLY... 7 STEERING ASSEMBLY... 8 HANDLEBAR ASSEMBLY... 9 HANDLEBAR ASSEMBLY (LE) INSTRUMENT POD ASSEMBLY INSTRUMENT POD ASSEMBLY (LE) FRONT SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY WHEEL AND TIRE ASSEMBLY AUXILIARY BRAKE ASSEMBLY PARKING BRAKE ASSEMBLY HYDRAULIC HAND BRAKE ASSEMBLY HYDRAULIC BRAKE ASSEMBLY GAS TANK ASSEMBLY SHIFT LEVER ASSEMBLY AIR INTAKE ASSEMBLY BATTERY ASSEMBLY ENGINE AND EXHAUST COOLING ASSEMBLY CASE/BELT COOLING ASSEMBLY DRIVE TRAIN ASSEMBLY DRIVE TRAIN ASSEMBLY (LE) FRONT DRIVE GEARCASE ASSEMBLY FRONT DRIVE GEARCASE ASSEMBLY (LE) REAR DRIVE GEARCASE ASSEMBLY WIRING HARNESS ASSEMBLY WIRING HARNESS ASSEMBLY (LE) THROTTLE BODY ASSEMBLY CYLINDER ASSEMBLY CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY CAM CHAIN ASSEMBLY CRANKCASE ASSEMBLY CRANKSHAFT AND PISTON ASSEMBLY CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY STARTER CLUTCH ASSEMBLY CRANK BALANCER ASSEMBLY OIL FILTER/PUMP ASSEMBLY WATER PUMP ASSEMBLY TRANSMISSION ASSEMBLY SECONDARY TRANSMISSION ASSEMBLY (Engine Serial No. Up to 0700A ) SECONDARY TRANSMISSION ASSEMBLY (Engine Serial No. 0700A and Up) GEAR SHIFTING ASSEMBLY SECONDARY DRIVE ASSEMBLY (Engine Serial No. Up to 0700A ) SECONDARY DRIVE ASSEMBLY (Engine Serial No. 0700A and Up) STARTER MOTOR ASSEMBLY MAGNETO ASSEMBLY n NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not to be used for assembly. For assembly procedures, use an Arctic Cat Service Manual. Underlined part numbers are new for the 2010 model year. For a complete list of related items, refer to the current accessory catalog Arctic Cat Inc. Printed December 2009 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

3 FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES Rack, Front - Assembly (inc. 2-3) l Decal, Warning - Load l Bushing Screw, Cap Spacer Grommet Nut, Lock Screw, Shoulder Washer Nut, Lock Headlight Assembly - Right (inc ) Headlight Assembly - Left (inc ) l Bulb, Headlight l Retainer, Spring l Boot, Rubber l Bulb, Turn Signal l Socket, Turn Signal Bulb l Socket, Position Bulb l Bulb, Position Stud, Adjuster - Headlight Spring, Adjuster Knob, Adjuster Screw, Self-Tapping Washer Grommet Panel, Side - Lower - Right Panel, Side - Lower - Left Grommet Cover, Access Rivet, Reinstallable Cover, Steering Post Rivet, Reinstallable Cover, Storage Box Box, Storage Lid, Storage Box w/latch (inc ) l Latch, Storage Box l Lid, Storage Box Screw, Shoulder Panel, Fender - Front - Red Panel, Fender - Front - Green (Green) Panel, Fender - Front - Cat Green (Cat Green) Decal, Side - Upper Right Decal, Side - Upper Left Decal, Front Decal, Reflector - Front - Right Decal, Reflector - Front - Left Decal, Speedrack 42 AC Mirror T3 43 AC Bracket Mirror T3 44 AC Screw M6x20 45 AC Pipe Clamp 20/15 46 AC Washer 6 1

4 FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES (LE) Rack, Front - Assembly (inc. 2-3) l Decal, Warning - Load l Bushing Screw, Cap Spacer Grommet Nut, Lock Screw, Shoulder Washer Nut, Lock Headlight Assembly - Right (inc ) Headlight Assembly - Left (inc ) l Bulb, Headlight l Retainer, Spring l Boot, Rubber l Bulb, Turn Signal l Socket, Turn Signal Bulb l Socket, Position Bulb l Bulb, Position Stud, Adjuster - Headlight Spring, Adjuster Knob, Adjuster Screw, Self-Tapping Washer Grommet Panel, Side - Lower - Right Panel, Side - Lower - Left Grommet Cover, Access Rivet, Reinstallable Cover, Steering Post Rivet, Reinstallable Cover, Storage Box Box, Storage Lid, Storage Box w/latch (inc ) l Latch, Storage Box l Lid, Storage Box Screw, Shoulder Panel, Fender - Front - Black Decal, Side - Upper Right Decal, Side - Upper Left Decal, Front Decal, Reflector - Front - Right Decal, Reflector - Front - Left Decal, Speedrack 2

5 30 REAR RACK, BODY PANEL, AND FOOTWELL ASSEMBLIES Rack, Rear - Assembly (inc. 2-3) l Decal, Warning - Load l Bushing Screw, Cap Spacer Grommet Nut, Lock Screw, Shoulder Washer Nut, Lock Screw, Shoulder Footwell - Right Footwell - Left Rivet, Reinstallable Screw, Machine Screw, Shoulder Footpeg Panel, Fender - Rear - Red Panel, Fender - Rear - Green (Green) Panel, Fender - Rear - Cat Green (Cat Green) Panel, Fender - Rear - Black (LE) Decal, Rear Decal, Rear (LE) Decal, Reflector - Rear - Right Decal, Reflector - Rear - Left Decal, Warning - Tire Pressure Foil, Protective Decal, Speedrack Taillight Assembly - Right (inc ) Taillight Assembly - Left (inc ) l Bulb, Turn Signal - Rear l Bulb, Taillight l Socket, Taillight - Right l Socket, Taillight - Left Clip, U-Nut Bezel, Taillight - Right Bezel, Taillight - Left Screw, Machine 30 AC Reflector 3

6 FRAME AND RELATED PARTS Frame, Main Screw, Cap Channel, Bumper Mounting Bracket, Mounting - Bumper - Right Bracket, Mounting - Bumper - Left Screw, Cap Bumper Grille, Bumper Screw, Machine Screw, Shoulder Nut, Lock Brace, A-Arm Screw, Cap Pad, Frame Panel, Belly Nut Screw, Cap Footrest - Right Footrest - Left Rod, Support Screw, Machine Nut w/washer Bracket, Mounting - Horn Horn, Electric - 12V 23 AC Mount, Ball Hitch 24 AC Nut, Lock M16 25 AC Screw, M16x80 AC Washer 16 (not shown) Decal, Warning - Towing 27 AC Type Plate 28 AC Washer 6 29 AC Rivet Blind 5x18 30 AC Towing Device, Front, T3 31 AC Bolt Towing Device 32 AC Bracket Towing Device 33 AC Safety Pin, 9mm 4

7 WINCH ASSEMBLY Winch (inc. 2-3) l Cable, Winch l Decal, Warning Washer, Lock Screw, Cap Hook, Winch w/strap Pin Cotter Pin Roller, Winch Screw, Machine AR Cable Tie - 8 in Cable, Winch/Solenoid - Yellow Cable, Winch/Solenoid - Blue Nut w/washer Cable, Solenoid/Battery - Black Cable, Solenoid/Battery - Red Boot, Terminal Solenoid Screw, Machine Switch, Winch - Assembly (inc ) l Connector, Harness l Bracket, Winch Switch l Washer, Internal Tooth Lock l Screw, Machine l Washer, External Tooth Lock l Harness, Adapter - Solenoid 5

8 LICENSE PLATE HOLDER ASSEMBLY *Not a Service Part Mount, License Plate Light, License Plate Assembly (inc. 3-4) 3 * 2 l Screw, Self-Tapping l Bulb Screw, Self-Tapping Nut, Lock Washer Screw, Machine 9 AC Number Plate Light 10 AC Harness Light License Plate 11 AC Blade Terminal Insulated 12 AC Self-Tapping Screw 3,9x16 13 AC Nut 3,9 14 AC Bulb 10W 6

9 SEAT ASSEMBLY Seat Assembly (inc. 2-9) Seat Assembly (inc. 2-9) (LE) l Cover, Seat l Cover, Seat (LE) l Foam, Seat l Foam, Seat (LE) l Base, Seat - Assembly (inc. 5-6) ll Bumper, Seat - Rear ll Bumper, Seat - Front AR l Staple l Spring, Seat Latch l Latch, Seat Wrench, Spanner 11 AC Mount, Seat Below T3 12 AC Mount, Seat Above T3 13 AC Seat T3 14 AC Washer 23x8,4x4 15 AC Knob Astral M6x25 16 AC Diameter Washer 25x6,4x1, Bumper, Seat 18 AC Washer M6 19 AC Nut M6 20 AC Screw M6x20 21 AC Blind Rivet Nut M6 7

10 STEERING ASSEMBLY *Not a Service Part Screw, Cap Cap, Steering Adjuster Screw, Shoulder Cap, Housing Housing, Lower Housing, Upper Post, Steering Screw, Cap Steering Lock Assembly (inc ) l Latch l Bracket, Mounting - Lock l Lock Flange, Bearing Bearing w/inverted Oil Seal Washer Screw, Cap Tie Rod - Assembly (inc ) l End, Tie Rod - Left-Hand Thread - Kit (inc ) 19 * 2 ll End, Tie Rod - Left-Hand Thread ll Nut - Left-Hand Thread l Tie Rod l End, Tie Rod - Right-Hand Thread - Kit (inc ) ll Nut - Right-Hand Thread 24 * 2 ll End, Tie Rod - Right-Hand Thread Nut, Lock Pin, Cotter 8

11 25 26 HANDLEBAR ASSEMBLY Handlebar Plug, Handlebar Grip, Handlebar End Cap, Handlebar Washer Screw, Machine Case, Throttle - Assembly (inc. 8-15) l Cover, Throttle Case w/switch l Screw, Cap l Washer, Lock l Washer l Screw, Machine l Nut l Screw, Machine l Lever Decal, Warning - Differential Lock Decal, Warning - Brake Lever Lock Switch, Control Mirror - Right Mirror - Left Control, Differential Lock (inc ) l Clamp, Differential Lock Control - Kit (inc ) ll Screw, Cap ll Washer Cable, Differential Lock 25 AC Screw M8x16 26 AC Washer 6 9

12 HANDLEBAR ASSEMBLY (LE) Handlebar Plug, Handlebar End Cap, Handlebar Washer Screw, Machine Grip, Handlebar Decal, Warning - Differential Lock Decal, Warning - Brake Lever Lock Case, Throttle - Assembly (inc ) l Lever l Screw, Cap l Washer, Lock l Washer l Screw, Machine l Nut l Screw, Machine l Cover, Throttle Case w/switch Switch, Control Mirror - Right Mirror - Left Harness, Handlebar Element, Handwarmer Tube, Shrink Pad, Insulator Element, Thumbwarmer 10

13 INSTRUMENT POD ASSEMBLY Switch, Ignition - Assembly (inc. 2-4) l Nut, Retaining l Key, Ignition (Y Series - Left-Side Cut) l Key, Ignition (Z Series - Right-Side Cut) l Cover, Key Instrument Pod Instrument Pod (Green) Instrument Pod (Cat Green) Outlet, Accessory - 12V Gauge, LCD Bracket, Retaining Nut w/washer Bracket, Mounting - Instrument Pod Rivet, Reinstallable Decal, Instrument Pod 11

14 INSTRUMENT POD ASSEMBLY (LE) Switch, Ignition - Assembly (inc. 2-4) l Nut, Retaining l Key, Ignition (Y Series - Left-Side Cut) l Key, Ignition (Z Series - Right-Side Cut) l Cover, Key Instrument Pod Outlet, Accessory - 12V Gauge, LCD Bracket, Retaining Nut w/washer Bracket, Mounting - Instrument Pod Rivet, Reinstallable Switch, Differential Lock Decal, Instrument Pod Switch, Handwarmer 12

15 FRONT SUSPENSION ASSEMBLY Shock Absorber (inc. 2) Shock Absorber (inc. 2) (LE) l Bushing Cam, Spring Adjuster Spring, Suspension - Platinum Retainer, Spring Screw, Cap Nut, Lock A-Arm, Upper Right - Platinum (inc. 9-12) A-Arm, Upper Left - Platinum (inc. 9-12) l Bushing l Axle l Ring, Retaining l Ball Joint A-Arm, Lower Right - Platinum (inc and two No ) A-Arm, Lower Left - Platinum (inc and two No ) l Bushing l Axle Knuckle - Assembly - Right (inc ) Knuckle - Assembly - Left (inc ) l Bearing l Ring, Retaining Screw, Cap Screw, Cap Screw, Cap Axle, Drive - Right (inc ) Axle, Drive - Left (inc ) l Clip, Retaining l Repair Kit, Boot Guard, Boot - Right - Red Guard, Boot - Left - Red Guard, Boot - Right - Green (Green) Guard, Boot - Left - Green (Green) Guard, Boot - Right - Cat Green (Cat Green) Guard, Boot - Left - Cat Green (Cat Green) Guard, Boot - Right - Black (LE) Guard, Boot - Left - Black (LE) Screw, Shoulder 13

16 Knuckle, Right Rear - Assembly (inc. 2-5) Knuckle, Left Rear - Assembly (inc. 2-5) l Bearing l Ring, Retaining l Axle l Bushing A-Arm, Rear - Lower Right - Platinum (inc. 7-8) A-Arm, Rear - Lower Left - Platinum (inc. 7-8) l Bushing l Axle Nut, Lock Screw, Cap A-Arm, Rear - Upper Right - Platinum (inc. 7-8) A-Arm, Rear - Upper Left - Platinum (inc. 7-8) Guard, Boot - Rear - Right - Red Guard, Boot - Rear - Left - Red Guard, Boot - Rear - Right - Green (Green) Guard, Boot - Rear - Left - Green (Green) Guard, Boot - Rear - Right - Cat Green (Cat Green) Guard, Boot - Rear - Left - Cat Green (Cat Green) Guard, Boot - Rear - Right - Black (LE) Guard, Boot - Rear - Left - Black (LE) REAR SUSPENSION ASSEMBLY Screw, Shoulder Screw, Cap Axle, Drive (inc ) l Clip, Retaining l Repair Kit, Boot AR Tie, Cable - 8 in Retainer, Spring Spring, Suspension - Platinum Spring, Suspension - Platinum (LE) Cam, Spring Adjuster Shock Absorber (inc ) l Bushing, Double-Bonded l Bushing l Sleeve Washer Screw, Cap Screw, Cap - Right Screw, Cap - Left 14

17 WHEEL AND TIRE ASSEMBLY Screw, Shoulder Disc, Brake Hub, Wheel - Front (inc. 4) l Stud Hub, Wheel - Rear - Right (inc. 4) Hub, Wheel - Rear - Left (inc. 4) Nut, Castle Pin, Cotter Wheel - Front - Platinum Wheel - Rear - Platinum Wheel - Front - Black (LE) Wheel - Rear - Black (LE) Nut, Lug Nut, Lug (LE) Tire - Front Tire - Rear Stem, Valve (inc. 12) l Cap, Valve Stem 15

18 AUXILIARY BRAKE ASSEMBLY Lever, Brake O-Ring Washer Screw, Cap Spring, Brake Lever Spring, Brake Switch Master Cylinder Hose, Brake Washer, Crush Bolt, Banjo-Fitting Bolt, Banjo-Fitting - Double Hose, Brake Clip, Brake Hose AR Cable Tie - 8 in Caliper, Brake (inc ) l Housing, Caliper - Assembly - Left Rear (inc ) ll Piston/Seal Set (inc. 18) lll Seal Set ll Valve, Bleed l O-Ring, Guide - Set l Bracket Assembly l Pad, Brake - Set l Screw, Cap Bracket, Switch Screw, Cap Pin, Clevis Pin, Cotter Washer 16

19 PARKING BRAKE ASSEMBLY Lever, Parking Brake - Assembly (inc. 2-6) l Lever, Parking Brake - Kit l Clamp, Handlebar - Kit l Adjuster, Thumb Nut - Kit l Lock, Parking Brake Lever - Kit l Cable, Brake - Rear Mechanical Brake Assembly Pad, Brake Screw, Cap Wire Form, Cable 17

20 HYDRAULIC HAND BRAKE ASSEMBLY Brake Assembly (inc. 2-10) l Screw, Machine - Kit l Cover, Reservoir l Screw, Machine - Kit l Clamp, Master Cylinder l Master Cylinder Assembly l Lever Assembly - Kit (inc. 8-9) ll Lock, Brake Lever - Kit ll Lever Pin - Kit l Switch, Brake Washer, Crush Bolt, Banjo-Fitting 18

21 HYDRAULIC BRAKE ASSEMBLY Hose, Brake - Assembly Screw, Machine Screw, Cap Caliper, Brake - Right Front (inc. two No. 3 and 5-11) Caliper, Brake - Left Front (inc. two No. 3 and 5-11) l Housing, Caliper - Assembly - Right Front (inc. 6-8) l Housing, Caliper - Assembly - Left Front (inc. 6-8) ll Piston/Seal Set (inc. 7) lll Seal Set ll Valve, Bleed l O-Ring, Guide - Set l Bracket Assembly l Pad, Brake - Set Washer, Crush Bolt, Banjo-Fitting Nut w/washer 19

22 GAS TANK ASSEMBLY *Not a Service Part Tank, Gas - Assembly (inc. 2-5 and one No. 9) l Cap, Gas Tank (inc. 3) ll Gasket, Gas Tank Cap l Plate, Mounting - Fuel Pump l Screw, Self-Tapping Pump, Fuel - Assembly (inc. 7-9) l Sensor, Fuel Level - Kit (inc. 8-9) ll Seal, Fuel Pump ll Seal, Fuel Pump Hose, Gasline - Assembly (inc ) l Filter, Fuel - Kit (inc ) 12 * 2 ll Clamp, Hose 13 * 1 ll Filter, Fuel AR Hose, Gasline - 25 ft Filter, In-Line Rivet Bracket, Fuel Filter Bracket, Filter Mounting AR Tie, Cable - 8 in Screw, Shoulder Nut w/washer Grommet Grommet Screw, Self-Tapping Shield, Heat - Gas Tank - Front Shield, Heat - Gas Tank - Rear 20

23 SHIFT LEVER ASSEMBLY Knob, Shift Clip, Retaining Plate, Shift Shield, Shift Plate Nut, Stamped Lever, Shift Spring, Shift Lever Nut Actuator, Shift O-Ring Axle, Pivot O-Ring Washer Screw, Cap Nut Bushing Pin, Mounting Washer E-Ring Linkage, Shift - Assembly (inc ) l Nut, Hex - Right-Hand Thread l Nut, Hex - Left-Hand Thread 21

24 AIR INTAKE ASSEMBLY Cover, Intake Screen, Air Filter Filter, Air Housing, Intake Clip, Spring Duct, Engine Intake Grommet Resonator Boot Screw, Self-Tapping Clamp, Boot Valve, Drain Hose, Vent Clamp, Hose Cap, Drain Clamp Clamp, Boot Boot Sensor, Air Temperature (inc. 20) l O-Ring Panel, Shield Rivet, Reinstallable 22

25 *Not Illustrated Battery Cover/Tool Tray Assembly (inc. 2-3) l Cover, Battery l Pad, Battery * l Kit, Tool BATTERY ASSEMBLY Battery Assembly (inc. 5) l Decal, Warning Screw, Machine Foam, Battery 23

26 ENGINE AND EXHAUST Engine, A700FH Screw, Cap Screw, Cap Nut, Lock Mount, Rubber - Engine Mount, Rubber - Engine Screw, Cap Pipe, Exhaust - Assembly (inc. 9-14) l Shield, Exhaust Pipe - Outer - Rear l Shield, Exhaust Pipe - Inner - Rear l Shield, Exhaust Pipe - Inner - Front l Shield, Exhaust Pipe - Outer - Front l Pipe, Exhaust l Clamp Gasket, Exhaust Seal, Exhaust Spring, Extension Bushing Channel, Muffler Support Muffler - Assembly (inc ) l Cover, Muffler l Screw, Machine l Washer Decal, Warning - Clutch Cover 24

27 COOLING ASSEMBLY Radiator Assembly (inc. 2-13) l Radiator l Screen l Cap l Grommet AR l Hose - 25 ft AR l Hose ft l Shroud, Fan l Fan, Cooling l Screw, Machine l Clamp, Wire l Screw, Self-Tapping l Plug, Drain l O-Ring Screw, Shoulder Nut w/washer Bushing, Stem Hose, Coolant - Upper Hose, Coolant - Crossover Hose, Coolant - Lower Clamp, Hose AR Tie, Cable in Hose, Oil Cooler Clamp, Hose Cooler, Oil Screw, Machine Bracket, Mounting - Oil Cooler - Upper 25

28 CASE/BELT COOLING ASSEMBLY Clamp, Plastic Screw, Self-Tapping Boot, Duct - Air Intake - Front Clamp, Boot AR Valve, Drain Duct, Air Intake - Front - Lower Duct, Air Intake - Front - Upper Cup, Air Intake Clamp, Boot Boot, Duct - Air Out - Rear Duct, Air Out - Rear (inc. three No. 12 and 13-14) l Screw, Self-Tapping l Duct l Duct Clamp, Hose 26

29 DRIVE TRAIN ASSEMBLY Bladder, Gearcase Clamp, Hose Nut, Lock Washer Screw, Cap Gearcase, Front Boot, Shaft Plate, Cable Screw, Self-Tapping Gearcase, Rear AR Hose, Vent Fitting, Vent Clamp, Boot Boot Clamp, Boot Bumper, Shaft Shaft, Propeller Screw, Cap Flange, Output Spring AR Tie, Cable - 8 in. 27

30 DRIVE TRAIN ASSEMBLY (LE) Bladder, Gearcase Clamp, Hose Nut, Lock Washer Screw, Cap Gearcase, Front Boot, Shaft Gearcase, Rear AR Hose, Vent Fitting, Vent Clamp, Boot Boot Clamp, Boot Bumper, Propeller Shaft Shaft, Propeller Spring Flange, Output Screw, Cap AR Tie, Cable - 8 in. 28

31 FRONT DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n ) Shaft, Propeller - Assembly (inc. 2-6) l Clamp, Boot l Boot, Propeller Shaft l Clamp, Boot l Shaft, Output l Shaft, Input Seal Ring, Retaining Bracket, Actuator Actuator (inc. one No. 11) l O-Ring Screw, Self-Tapping Bearing Screw, Self-Tapping Housing, Pinion Gasket, Flange Shaft, Selector Fork, Selector Shaft, Shuttle Ring, Retaining O-Ring Spring, Return Ring, Retaining Collar, Lock Coupler, Drive Gear, Pinion - Assembly - 11T (inc ) l Collar, Retaining l Bearing Bearing Pin, Dowel Housing, Gearcase Plug, Magnetic (inc. one No. 33) l O-Ring O-Ring Bearing AR Shim AR Shim AR Shim AR Shim AR Shim Gear, Ring - 34T AR Shim AR Shim AR Shim AR Shim AR Shim Cover, Gearcase (inc. one No. 33, 40-55, and one No. 56) l Bearing l Flange, Bearing l Pin, Parallel l Collar, Sliding l Fork l Ring, Retaining l Spring l Fitting l Switch, Indicator l Spring l Shaft, Lock l Seal l O-Ring l Washer l Ring, Retaining l Plug, Oil Level (inc. one No. 33) l Seal Plug, Fill (inc. 58) l O-Ring 29

32 FRONT DRIVE GEARCASE ASSEMBLY (LE) (Complete Assembly p/n ) Shaft, Propeller - Assembly (inc. 2-6) l Clamp, Boot l Boot, Propeller Shaft l Clamp, Boot l Shaft, Output l Shaft, Input Seal Ring, Retaining Bracket, Actuator Actuator O-Ring Screw, Self-Tapping Bearing Screw, Self-Tapping Housing, Pinion Gasket, Flange Shaft, Selector Fork, Selector Shaft, Shuttle Ring, Retaining O-Ring Spring, Return Ring, Retaining Collar, Lock Coupler, Drive Gear, Pinion - Assembly - 11T (inc ) l Collar, Retaining l Bearing Bearing Pin, Dowel Housing, Gearcase Plug, Magnetic (inc. one No. 33) l O-Ring O-Ring Bearing AR Shim AR Shim AR Shim AR Shim AR Shim Gear, Ring - 34T AR Shim AR Shim AR Shim AR Shim AR Shim Cover, Gearcase (inc. one No. 33, 40-51, and one No. 52) l Bearing l Flange, Bearing l Pin, Parallel l Collar, Sliding l Fork l Ring, Retaining l Spring l Fitting l Spring l Shaft, Lock l Seal l Plug, Oil Level (inc. one No. 33) l Seal Plug, Fill (inc. 54) l O-Ring 30

33 Housing, Gearcase Housing, Gearcase (LE) Bearing Seal Gear, Ring - 34T AR Shim AR Shim AR Shim AR Shim AR Shim Button, Thrust AR Shim AR Shim AR Shim AR Shim AR Shim O-Ring Cover, Gearcase Plug, Magnetic (inc. 11) l O-Ring Fitting REAR DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n ; p/n LE) Screw, Self-Tapping Plug, Fill (inc. one No. 15) Plug, Fill (inc. one No. 15) (LE) l O-Ring Bearing Gear, Pinion - Assembly - 11T (inc ) l Bearing l Collar, Retaining Pin, Dowel Collar, Lock Washer, Wave Collar, Shaft Gasket, Flange Housing, Pinion Ring, Retaining Bearing Ring, Retaining Seal Shaft, Input Plug, Oil Level (inc. one No. 15) 31

34 WIRING HARNESS ASSEMBLY Harness, Main (inc. 2-10) l Tether, Accessory Connector l Cover, Fuse Block l Holder, Fuse l Diode l Relay (4-Pin) - 20 Amp l Fuse - 10 Amp l Fuse - 15 Amp l Fuse - 30 Amp l Decal, Fuse Block l Flasher (3-Pin) l Relay (5-Pin) - 30 Amp AR Tie, Cable - 8 in Cable, Solenoid/Starter (inc. 13) l Boot, Terminal Boot, Terminal Nut w/washer Solenoid Screw, Machine Tray, Electrical Rivet, Reinstallable Cushion, ECU ECU AR Tie, Cable in Regulator, Voltage Cable, Battery/Ground Coil, Ignition - Assembly Cap, Spark Plug Screw, Machine Switch, Tilt Sensor Screw, Machine Washer Nut w/washer Switch, Brake - Assembly Cable, Battery/Solenoid 32

35 WIRING HARNESS ASSEMBLY (LE) Harness, Main (inc. 2-9) l Tether, Accessory Connector l Cover, Fuse Block l Holder, Fuse l Diode l Relay (4-Pin) - 20 Amp l Fuse - 10 Amp l Fuse - 15 Amp l Fuse - 30 Amp l Decal, Fuse Block l Flasher (3-Pin) AR Tie, Cable - 8 in Cable, Solenoid/Starter (inc. 12) l Boot, Terminal Boot, Terminal Cable, Battery/Solenoid Nut w/washer Solenoid Screw, Machine Tray, Electrical Rivet, Reinstallable Cushion, ECU ECU Cable, Battery/Ground Regulator, Voltage AR Tie, Cable in Coil, Ignition Cap, Spark Plug Switch, Brake - Assembly Switch, Tilt Sensor Screw, Machine Washer Nut w/washer Screw, Machine 33

36 THROTTLE BODY ASSEMBLY *Not a Service Part Throttle - Assembly (inc. 2-19) 2 * 1 l Throttle Body l Sensor, Throttle Position l O-Ring l Screw, Machine l Valve, ISC l O-Ring l Screw, Machine l Rail, Fuel l O-Ring l Injector, Fuel l Seal l Bracket, MAP Sensor l Screw, Machine l Sensor, MAP l O-Ring l Plate, ISC Valve l Cover l Screw, Machine Cable, Throttle 34

37 CYLINDER ASSEMBLY Cylinder Bolt, Stud Nut Gasket, Base Pin, Dowel Union, Coolant Hose Screw, Machine O-Ring Gasket, Cylinder Head Bolt, Stud O-Ring Pin, Dowel 35

38 CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY Head, Cylinder - Assembly (inc. 2-17) l Pin, Dowel l Screw, Cap l Arm, Valve Rocker - Exhaust (inc. two No. 5-6) ll Screw, Adjuster ll Nut l Arm, Valve Rocker - Intake (inc. two No. 5-6) l Shaft, Rocker Arm - Intake l Shaft, Rocker Arm - Exhaust l Cotter, Valve l Retainer, Spring l Spring, Valve l Seal, Oil l Seat, Spring - Valve l Valve, Intake l Valve, Exhaust l Plug, Shaft Camshaft Sprocket Screw, Cap Plate, Retainer Pin, Dowel C-Ring Plug, Cylinder Head Screw, Cap Cap, Inspection O-Ring Screw, Cap Washer Gasket Screw, Cap Screw, Cap Screw, Cap Spark Plug (CPR8E) Flange, Intake Manifold O-Ring Screw, Machine Boot Clamp O-Ring Plug Cover, Thermostat Thermostat Sensor, Engine Coolant Temperature Bolt, Stud Nut Bolt, Stud Nut 36

39 CAM CHAIN ASSEMBLY Chain, Cam Guide, Chain Tensioner, Chain Pivot, Tensioner Washer, Crush Adjuster, Tensioner - Assembly Gasket Screw, Machine Gasket Screw, Cap Washer 37

40 CRANKCASE ASSEMBLY Crankcase Assembly (inc. 2-15) l Plug l Plug l Bearing l Bearing l Bearing l Bearing l Bearing l Bearing l Bearing l Seal, Countershaft l Screw, Machine l Retainer, Bearing l Pipe, Breather l Seal, Driveshaft Screw, Cap Pin, Dowel Pin, Dowel Screw, Machine Screw, Machine Screw, Machine Screw, Cap Screw, Cap Gasket Screw, Cap Screw, Cap Screw, Machine Screw, Machine Housing, Secondary Shaft (inc. one No. 7) Screw, Cap Screw, Cap Pipe, Breather Stick, Oil Level O-Ring 38

41 CRANKSHAFT AND PISTON ASSEMBLY Crankshaft Assembly Piston Set (inc. 3-6) l Ring, Piston - Set l Circlip, Piston Pin l Piston l Pin, Piston 39

42 CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY Cover, V-Belt Pin, Dowel Washer, Crush Screw, Cap Bearing Ring, Retaining Gasket, V-Belt Cover Cover, Clutch Screw, Machine Plate, Air Intake Seal Bearing Retainer, Bearing Gasket, Clutch Cover Gasket, Magneto Cover Cover, Magneto - Assembly Plug Washer, Crush Clamp, Wire Bearing Seal Retainer, Seal Screw, Machine O-Ring Bushing Nut Cover, Magneto Screw, Machine Screw, Machine Screw, Machine Screw, Machine Screw, Machine Screw, Machine 40

43 STARTER CLUTCH ASSEMBLY Gear, Starter Idler - No Shaft, Starter Gear Gear, Starter Idler - No Spacer, Starter Idler Gear No Shaft, Starter Gear Gear, Starter Clutch (inc. 7) l Bearing Clutch, Starter Screw, Machine Washer 41

44 CRANK BALANCER ASSEMBLY Screw, Cap Washer Gear, Oil Pump Drive Pin, Dowel Spacer Gear, Driven Key Balancer, Crank 42

45 OIL FILTER/PUMP ASSEMBLY Pump, Oil Gear, Driven Pin Washer Ring, Retaining Screw, Machine Strainer, Oil Screw, Machine Filter, Oil Cap, Oil Strainer Screw, Machine Valve, Oil-Relief - Assembly Plug, Drain Gasket, Drain Plug Stand, Oil Fitting Tower, Oil Fitting O-Ring, Oil Fitting 43

46 WATER PUMP ASSEMBLY Pump, Water - Assembly (inc. 2) l O-Ring Gear, Driven Shaft, Driven Gear Pin, Driven Gear Ring, Retaining Bearing, Shaft Ring, Retaining Gear, Water Pump Drive Pin, Alignment Ring, Retaining Screw, Machine 44

47 TRANSMISSION ASSEMBLY Pulley, Driven - Assembly (inc. 2-4) l Shoe, Cam l Screw, Machine l Nut Nut Washer Plate, Movable Drive Face Damper, Movable Drive Face Face, Movable Drive Belt, Drive Spacer Roller Face, Fixed Drive Shroud, Drive Face Screw, Self-Tapping Spacer, Fixed Drive Face O-Ring Housing, Clutch - Assembly Seal Nut Clutch, One-Way Clutch, Centrifugal - 6 Plate 45

48 SECONDARY TRANSMISSION ASSEMBLY (Engine Serial No. Up to 0700A ) Countershaft Assembly (inc. 2-16) l Gear, Drive l Gear Select, Reverse l Ring, Retaining l Spacer, Reverse Driven Gear l Washer l Gear, Reverse Driven l Bearing l Bushing l Washer, Lock l Washer, Lock l Gear, Driven - Low l Washer, Driven Gear l Countershaft l Gear Select, Sliding l Gear, Driven - High Washer Washer, Thrust Ring, Retaining Washer, Thrust Trigger, Speedometer Sensor Ring, Retaining Gasket Pin, Dowel Housing, Speedometer Sensor Sensor, Speedometer Screw, Machine Screw, Machine Seal, Fastener Driveshaft Washer, Thrust Gear, Reverse Idle Bushing Shaft, Reverse Idle 46

49 SECONDARY TRANSMISSION ASSEMBLY (Engine Serial No. 0700A and Up) Countershaft Assembly (inc. 2-15) l Gear Select, Reverse l Ring, Retaining l Spacer, Reverse Driven Gear l Washer l Gear, Reverse Driven l Bearing l Bushing l Washer, Lock l Washer, Lock l Gear, Driven - Low l Washer, Driven Gear l Countershaft l Gear Select, Sliding l Gear, Driven - High Gear, Drive Washer Washer, Thrust Ring, Retaining Washer, Thrust Trigger, Speedometer Sensor Ring, Retaining Gasket Pin, Dowel Housing, Speedometer Sensor Sensor, Speedometer Screw, Machine Screw, Machine Seal, Fastener Driveshaft Washer, Thrust Gear, Reverse Idle Bushing Shaft, Reverse Idle 47

50 GEAR SHIFTING ASSEMBLY Screw, Machine Switch, Gear Shift Position Contact Spring Washer Shaft, Gear Shift - Assembly Washer Bearing, Thrust Washer Plate, Gear Shift Cam Screw, Cap Washer Ring, Retaining Shaft, Sub-Gear Shift Seal, Sub-Gear Shift Shaft Arm, Select Screw, Machine Washer Stopper, Cam Support, Cam Stopper Spring Washer Nut Fork, Shift Shaft, Shift Fork 48

51 Yoke, Propeller Shaft Joint Joint, Universal - Set (inc. 3) l Ring, Retaining Nut Washer Yoke, Drive Output Seal, Oil Bearing AR Shim, 25 x 34 x 0.25 mm AR Shim, 25 x 34 x 0.30 mm AR Shim, 25 x 34 x 0.70 mm AR Shim, 25 x 34 x 0.90 mm AR Shim, 25 x 34 x 0.95 mm AR Shim, 25 x 34 x 1.00 mm AR Shim, 25 x 34 x 1.05 mm AR Shim, 25 x 34 x 1.10 mm AR Shim, 25 x 34 x 1.15 mm Shaft, Secondary Driven - Front SECONDARY DRIVE ASSEMBLY (Engine Serial No. Up to 0700A ) AR Shim, 24 x 48 x 0.25 mm AR Shim, 24 x 48 x 0.30 mm AR Shim, 24 x 48 x 0.35 mm AR Shim, 24 x 48 x 0.90 mm AR Shim, 24 x 48 x 0.95 mm AR Shim, 24 x 48 x 1.00 mm AR Shim, 24 x 48 x 1.05 mm AR Shim, 24 x 48 x 1.10 mm AR Shim, 24 x 48 x 1.15 mm Gear, Secondary Drive Washer Nut Bearing Gear, Secondary Driven Ring, Driven Bearing Shaft, Secondary Driven - Rear Flange, Output Joint 49

52 Yoke, Propeller Shaft Joint Joint, Universal - Set (inc. 3) l Ring, Retaining Nut Washer Yoke, Drive Output Seal, Oil Bearing AR Shim, 25 x 34 x 0.25 mm AR Shim, 25 x 34 x 0.30 mm AR Shim, 25 x 34 x 0.70 mm AR Shim, 25 x 34 x 0.90 mm AR Shim, 25 x 34 x 0.95 mm AR Shim, 25 x 34 x 1.00 mm AR Shim, 25 x 34 x 1.05 mm AR Shim, 25 x 34 x 1.10 mm AR Shim, 25 x 34 x 1.15 mm SECONDARY DRIVE ASSEMBLY (Engine Serial No. 0700A and Up) Shaft, Secondary Driven - Front Gear, Secondary Drive Nut Bearing Gear, Secondary Driven Ring, Driven Bearing Shaft, Secondary Driven - Rear Flange, Output Joint 50

53 STARTER MOTOR ASSEMBLY Motor, Starter - Assembly Screw, Machine Nut w/washer 51

54 MAGNETO ASSEMBLY Stator - Assembly Rotor/Flywheel Screw, Machine Key Nut Screw, Machine Clamp - No Clamp - No. 2 52

55 Printed in EU