ATV Illustrated Parts Manual

Transcription

1 ATV 1998 ATV Illustrated Parts Manual ARCTIC CAT All Terrain Vehicle 454 ATV 2x4 (Model No. 98A2A-AP) 454 ATV 4x4 (Model No. 98A4A-AP)

2 TABLE OF CONTENTS 1998 ATV 454 2x4 & ATV 454 4x4 Model No. 98A4A-AP & 98A2A-AP BODY PANEL ASSEMBLY (4x4)... 1 BODY PANEL ASSEMBLY (2x4)... 2 TAILLIGHT ASSEMBLY... 3 DECALS (4x4)... 4 DECALS (2x4)... 5 FRAME AND RELATED PARTS (4x4)... 6 FRAME AND RELATED PARTS (2x4)... 7 SEAT ASSEMBLY... 8 STEERING ASSEMBLY... 9 FRONT SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY WHEEL AND TIRE ASSEMBLY MECHANICAL BRAKE ASSEMBLY HYDRAULIC BRAKE CONTROL ASSEMBLY HYDRAULIC BRAKE ASSEMBLY GAS TANK ASSEMBLY REVERSE SHIFT LEVER ASSEMBLY AIR INTAKE ASSEMBLY STORAGE BOX AND BATTERY ASSEMBLY ENGINE AND EXHAUST COOLING ASSEMBLY REAR AXLE ASSEMBLY WIRING HARNESS ASSEMBLY CARBURETOR CYLINDER HEAD ASSEMBLY CYLINDER ASSEMBLY CRANKCASE ASSEMBLY CRANKCASE COVER ASSEMBLY CRANKSHAFT ASSEMBLY STARTER CLUTCH ASSEMBLY CRANK BALANCER ASSEMBLY CAM SHAFT VALVE ASSEMBLY CAM CHAIN ASSEMBLY RECOIL STARTER ASSEMBLY OIL FILTER/PUMP ASSEMBLY WATER PUMP ASSEMBLY CLUTCH ASSEMBLY TRANSMISSION ASSEMBLY SECONDARY TRANSMISSION ASSEMBLY (4x4) SECONDARY TRANSMISSION ASSEMBLY (2x4) SPEEDOMETER DRIVE ASSEMBLY SECONDARY DRIVE ASSEMBLY (4x4) SECONDARY DRIVE ASSEMBLY (2x4) GEAR SHIFTING ASSEMBLY HI/LOW SHIFTER ASSEMBLY (4x4) SHIFTER ASSEMBLY (2x4) FRONT BEVEL GEAR ASSEMBLY REAR BEVEL GEAR ASSEMBLY STARTER MOTOR ASSEMBLY MAGNETO ASSEMBLY ELECTRICAL COMPONENTS ASSEMBLY CONTROL SWITCH HOUSING ASSEMBLY THROTTLE CASE ASSEMBLY 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 Arctic Cat Service Manuals. Underlined part numbers are new for the 1998 model year. For a complete list of related items, refer to the current accessory catalog. Trademarks of Arctic Cat Inc., Thief River Falls, MN Printed June 2008

3 BODY PANEL ASSEMBLY (4x4) Panel, Fender - Front Cover, Radiator Access Flare - Front Right Flare - Front Left Rack - Front Reflector - Yellow Clip, Retaining Panel, Side - Right Panel, Side - Left Panel, Fender - Rear Rack - Rear Wrap, Tube - Rear Rack Foam, Radiator Access Panel Reflector - Red Flare - Rear Right Flare - Rear Left Mud Flap - Right Mud Flap - Left Rivet, Plastic Fender Extension - Rear Right Fender Extension - Rear Left Washer, Body Screw, Machine Clip, Tinerman Screw, Self-Tapping Screw, Cap Screw, Cap Nut, Speed Nut, Expansion Screw, Machine Washer Screw, Machine Plate, Heat - Rear Panel Screw, Machine 1

4 BODY PANEL ASSEMBLY (2x4) Panel, Fender - Front Cover, Radiator Access Flair, Fender - Front Right Flair, Fender - Front Left T-Nut Reflector - Yellow Clip, Retaining Panel, Side - Right Panel, Side - Left Panel, Fender - Rear Rack - Rear Screw, Machine Washer Reflector - Red Nut, Expansion Screw, Machine Rivet, Plastic Extension, Fender - Rear Right Extension, Fender - Rear Left Washer, Body Screw, Machine Clip, Tinerman Screw, Self-Tapping Screw, Cap Screw, Machine Nut, Speed Foam, Radiator Access Panel Screw, Machine Plate, Heat - Rear Panel 2

5 TAILLIGHT ASSEMBLY (Complete Taillight Assembly p/n ) Bulb, Stop - Taillight Taillight w/socket Assembly Gasket, Taillight Lens, Taillight Screw, Machine Screw, Self-Tapping Washer, Lock - External Tooth 3

6 DECALS (4x4) Decal, Warning - Front Rack Load Decal, Front Decal, Caution - Electrical Decal, Warning - Turn Decal, Warning Reverse/Pre Ride Decal, Warning - Age Decal, Warning - General Decal, Side Right Decal, Side Left Decal, Warning - Tire Pressure Decal, Shift Pattern Decal, Warning - Rear Rack Load Decal, Arctic Cat Decal, Warning - Towing Decal, Hi/Low Range 4

7 DECALS (2x4) Decal, Warning - Front Rack Load Decal, Front Decal, Shift Pattern Decal, Warning - Turn Decal, Warning Reverse/Pre Ride Decal, Warning - Age Decal, Warning - General Decal, Side Right Decal, Side Left Decal, Warning - Tire Pressure Decal, Arctic Cat Decal, Warning - Rear Rack Load 5

8 FRAME AND RELATED PARTS (4x4) Headlight (inc. 3 and 13) Nut, Lock Bulb, Headlight Washer, Lock Screw, Cap Screen, Bumper Yoke, Headlight Mount, Headlight Screw, Cap Bumper - Front Footrest - Right Footrest - Left Screw, Machine Screw, Cap Frame Washer, Shoulder Screw, Machine Panel, Belly Tube, Cross Cap, Bumper Screw, Cap Bracket, Front Gear Case Nut, Lock Screw, Cap 6

9 FRAME AND RELATED PARTS (2x4) Headlight (inc. 3 and 13) Nut, Lock Bulb, Headlight Washer, Lock Screw, Cap Panel, Belly Yoke, Headlight Mount, Headlight Screw, Cap Bumper - Front Footrest - Right Footrest - Left Screw, Machine Screw, Cap Frame Washer, Shoulder Screw, Machine 7

10 SEAT ASSEMBLY *Not a Service Part Seat - Assembly (inc. 2-8) Cover, Seat Foam, Seat Base, Seat - Assembly (inc. 5-7) 5 * 1 Base, Seat Rivet Pin, Seat Base - Front AR Staple Grommet, Seat - Center Screw, Cap Spring, Seat Latch Washer Collar, Front Seat Base Bumper, Seat Base - Front Cap, Protector Latch, Seat - Assembly Screw, Machine Bumper, Seat Base - Center 8

11 STEERING ASSEMBLY Cable, Speedometer Screw, Machine Speedometer (inc ) Collar, Body Switch, Ignition - Assembly (inc. 6) Key, Ignition - Blank (C Series) Key, Ignition - Blank (D Series) Bezel/Lens, Warning - Assembly Bezel/Lens, Shifting - Assembly Instrument Pod Bulb, Light Bar Light, Warning - Assembly Light, Shift Indicator - Assembly Screw, Self-Tapping Screw, Cap Cap, Steering Adjuster Bracket, Key Switch Tube, Handlebar Grip, Handlebar Housing, Bearing - Lower Bearing, Steering Post Housing, Bearing - Upper Pin, Cotter (4x4) Pin, Cotter (2x4) Post, Steering Screw, Cap Flange, Bearing Bearing - w/inverted Oil Seal Washer Screw, Cap Nut (4x4) Nut (2x4) Tie Rod, Assembly (inc ) (4x4) Tie Rod, Assembly (inc ) (2x4) Nut - Right-Hand Thread Ball Joint, Tie Rod - Right (4x4) Ball Joint, Tie Rod - Right (2x4) Ball Joint, Tie Rod - Left (4x4) Ball Joint, Tie Rod - Left (2x4) Nut - Left-Hand Thread Tie Rod Bulb, Speedometer Harness, Speedometer Bracket, Speedometer Mount, Rubber Washer Pin, Retainer Tube, Loom Cover, Key Rivet Nut (4x4) Nut (2x4) 9

12 FRONT SUSPENSION ASSEMBLY *Early Build Retainer, Spring Shock Absorber - Front (inc. 3-4) (4x4) Shock Absorber - Front (inc. 3-4) (2x4) Bushing, Shock Absorber Sleeve, Shock Nut, Lock Screw, Cap Spring, Shock Absorber Collar, Spring Washer, Spring A-Arm, Upper Right - Assembly (inc. one No ) A-Arm, Upper Left - Assembly (inc. one No ) Ball Joint - Front Clip, Ball Joint Knuckle - Assembly - Right (inc. 14 and one No ) (4x4) Knuckle - Assembly - Left (inc. 14 and one No ) (4x4) Knuckle - Assembly - Right (inc. 14 and one No ) (2x4) Knuckle - Assembly - Left (inc. 14 and one No ) (2x4) Knuckle, Steering - Right (4x4) Knuckle, Steering - Left (4x4) Knuckle, Steering - Right (2x4) Knuckle, Steering - Left (2x4) Bearing, Wheel Hub - Front Clip, Bearing Seal, Wheel Bearing - Front Seal, Wheel Bearing - Front Screw, Cap Screw, Cap A-Arm, Lower Right (inc. one No ) (4x4) A-Arm, Lower Left (inc. one No ) (4x4) A-Arm, Lower (inc. one No ) (2x4) Axle, Drive - Front (4x4)* Axle, Drive - Front (4x4) Repair Kit, Outer Boot - Front Axle (4x4)* Repair Kit, Outer Boot - Front Axle (4x4) Repair Kit, Inner Boot - Front Axle (4x4)* Repair Kit, Inner Boot - Front Axle (4x4) Retainer, Spring - Lower Axle, Stub (2x4) 10

13 REAR SUSPENSION ASSEMBLY Screw, Cap Screw, Cap Arm, Swing Nut, Lock Screw, Cap Arm, Swing Retainer, Spring - Lower Shock Absorber - Rear (inc. two No. 9 and four No. 10) (4x4) Shock Absorber - Rear (inc. two No. 9 and four No. 10) (2x4) Sleeve, Shock Bushing, Shock Absorber Retainer, Spring Screw, Cap Spring, Shock Absorber (4x4) Spring, Shock Absorber (2x4) Collar, Spring Washer, Spring Adjustment Nut, Lock Screw, Cap 11

14 WHEEL AND TIRE ASSEMBLY *Early Build Nut, Hex* Nut, Hex Cap, Valve Stem Valve, Stem Wheel - Front Tire - Front (4x4) Tire - Front (2x4) Pin, Cotter Washer* Washer Seal, Hub* Seal, Hub Hub, Wheel - Front (4x4) Hub, Wheel - Front (2x4) Disc, Brake Screw, Machine Hub, Wheel - Rear Wheel - Rear Tire - Rear Cap, Wheel - Center Screw, Cap 12

15 MECHANICAL BRAKE ASSEMBLY Mechanical Brake Assembly (inc. 2-6) Arm, Inner Pin, Arm Pad, Mechanical Brake Arm, Outer Spring, Arm Lever, Foot Brake Cable, Brake - Rear Screw, Cap Spring, Foot Brake Washer, Brake Lever Ring, Snap Bracket, Brake Switch Screw, Cap O-Ring 13

16 *Not a Service Part HYDRAULIC BRAKE CONTROL ASSEMBLY Brake, Lever - Assembly (inc and 17-20) Lever, Brake Bolt, Lever Mounting Screw, Cover Cover, Master Cylinder Gasket, Cover - Master Cylinder Reservoir, Hydraulic Brake O-Ring, Reservoir 9 * 1 Master Cylinder Screw, Reservoir Mount Nut, Lock Washer, Lock Screw, Clamp Clamp Hose, Master Cylinder Screw, Cap Wedge, Parking Brake Spring Nut, Press Pin 14

17 HYDRAULIC BRAKE ASSEMBLY *Not a Service Part Tube, Brake Line - Front Hose, Brake - Front Block, Mounting Bolt, Oil Washer, Crush Caliper, Brake - Right Front and Rear (inc. 7-13, and two No ) Caliper, Brake - Left Front (inc. 7-13, and two No ) 7 * 3 Housing, Caliper O-Ring Pin, Cotter Pin, Hydraulic Brake Caliper Cap, Bleeder Valve Pad, Hydraulic Brake Valve, Bleeder O-Ring, Hydraulic Brake Caliper Washer Screw, Socket Head Hose, Brake - Rear Clip, Brake Line Tube, Brake Line - Rear Screw, Cap Screw, Cap Screw, Cap 15

18 GAS TANK ASSEMBLY *Not a Service Part Tank, Gas (inc. 2-3 and 8-12) Cap, Gas Tank (inc. 3) Line, Gas Tank Cap Vent Screw, Cap Washer Bushing, Gas Tank Mount Collar, Gas Tank Mount AR Line, Gas Clamp, Hose - Spring 10 * 1 Gasket Valve, Shut-Off (inc. 10) Screw, Cap Pad, Gas Tank 16

19 REVERSE SHIFT LEVER ASSEMBLY Axle, Reverse Shift Screw, Cap Arm, Reverse Shift Lever, Reverse O-Ring E-Ring Spring, Reverse Lever Reverse Switch Retainer, Switch Knob, Reverse Shift Lever E-Ring Cable, Shift 17

20 AIR INTAKE ASSEMBLY Clamp Boot, Air Cleaner Clamp Housing, Air Cleaner Screw, Self-Tapping Gasket, Air Cleaner Snorkel, Air Cleaner Clamp, Air Cleaner Spring Screw, Machine Nut, Expansion Hose, Crankcase Vent Filter, Air Cleaner (inc. 14) Sleeve, Filter Valve, Air Cleaner Cap, Fitting - Air Cleaner Clamp, Hose Clamp, Hose Support, Air Cleaner Flange (4x4) Support, Air Cleaner Flange (2x4) Plate, Heat - Air Intake Clamp, Air Cleaner 18

21 *Not a Service Part STORAGE BOX AND BATTERY ASSEMBLY Screw, Cap Strap, Battery w/pads (inc. 3 and 11) Pad, Battery - Upper Rear Battery - Assembly (inc. 5-7) Cap, Battery Clamp, Hose Hose, Battery Vent AR Tie, Cable Pad, Battery - Lower Kit, Tool Pad, Batter - Upper Front Fuse Box - Assembly (inc ) 13 * 1 Block, Fuse 14 * 1 Lid, Fuse Block Decal, Fuse Block Fuse, 10 Amp Fuse, 15 Amp Screw, Machine (4x4) Storage Box - Assembly (inc ) (4x4) Box, Tool Washer Lid, Tool Box Chain, Storage Rivet Nut, Expansion Seal, Storage Cover Ring, Mounting - Storage Box Lid Rivet Screw, Self-Tapping Clamp, Tube (4x4) 19

22 ENGINE AND EXHAUST Pipe, Exhaust Screw, Cap Screw, Cap Washer, Engine Spacer Engine (4x4) Engine (2x4) Nut, Lock Seal, Exhaust Nut Screw, Cap Screw, Cap Bracket, Upper Engine Lever, Shift Screw, Cap Spacer, Exhaust Bushing, Rubber Muffler Screw, Cap Cover, Exhaust Screw, Machine Washer Clamp Washer, Star Nut Screw, Cap Spacer Clamp, Hose (4x4) Plate, Heat - Muffler (4x4) 20

23 COOLING ASSEMBLY Screen, Radiator Clamp, Wire Screw, Cap Grommet Collar AR Hose - 25 ft Cap, Radiator Radiator - Assembly (inc. 1, 4, 7, 9-10, 21, and 28) O-Ring Switch, Temperature Sensor Clamp, Hose Hose, Coolant - Upper Blade, Fan Motor, Fan Screw, Machine Hose, Coolant - Lower Hose, Coolant - Crossover Screw, Machine Washer, Shoulder Panel, Fender - Inner Screw, Thumb Nut, Speed Nut - Left-Hand Thread Washer Bushing, Stem Screw, Machine Tie, Cable Radiator Washer 21

24 REAR AXLE ASSEMBLY Housing, Axle - Rear Right Screw, Cap Screw, Cap Axle - Rear Gasket, Rear Axle Bladder, Case Tie, Cable Screw, Cap Hitch, Trailer Screw, Cap Gasket, Rear Axle Washer, Shoulder Housing, Axle - Rear Left Seal C-Clip Bearing, Wheel Hub - Rear Nut Nut, Speed Panel, Gear Case - Rear Screw, Cap Washer 22

25 WIRING HARNESS ASSEMBLY Harness, Main Cable, Battery/Electric Start Relay Cable, Battery/Ground AR Tie, Cable Switch, Brake - Assembly Regulator, Voltage Screw, Cap Retainer, Switch Cable, Battery/Electric Start Receptacle, 12V (4x4) Rivet (4x4) Washer (4x4) Harness, 12V Receptacle (4x4) Tube, Loom Base, Cable Tie Cable Tie - Push-Mount Boot, Terminal 23

26 CARBURETOR Complete Assembly p/n (4x4), (2x4) Cover Assembly Spring (4x4) Spring (2x4) Ring E-Ring Ring Jet Needle 5D Screw Diaphram Screw Plunger Assembly O-Ring Washer Spring Screw Screw, Pilot Jet, Pilot Jet, Main (4x4) Jet, Main (2x4) Needle Jet P Float Assembly Seat, Valve 2.0 w/needle O-Ring, Bowl Filter Chamber, Float (2x4) Jet, Pilot - Air Screw Spring Cable Adjust - Assembly Cover Washer Screw O-Ring Guide, Cable Washer Screw Clip Hose Cap Clip Spring Pin, Float Arm Washer Cable, Throttle Cable, Choke O-Ring Chamber, Float (4x4) Cover Assembly, Primer Screw, Cap Hose Clip 24

27 CYLINDER HEAD ASSEMBLY Complete Gasket Set p/n Head, Cylinder - Assembly (inc. 2-6) Guide, Valve Circlip Pin Screw, Cap Screw, Cap Gasket, Cylinder Head Pin Screw, Cap Screw, Cap Screw, Cylinder Head Stud Screw, Cylinder Head Stud Bolt, Stud Screw, Cap Screw, Cap Nut Nut Gasket Gasket, Head Nut Spark Plug (NGK CR8E) Cap, Inspection O-Ring Screw, Cap Plug, Cylinder Head Pipe, Intake - Assembly (inc. 26) O-Ring Screw, Cap Clamp Screw, Cap Thermostat Switch, Water Temp - Assembly Cover, Thermostat 25

28 CYLINDER ASSEMBLY Cylinder Bolt, Stud Nut Gasket, Cylinder Pin Union, Water Hose Screw, Cap O-Ring 26

29 CRANKCASE ASSEMBLY Crankcase Set (inc. 2-8) (4x4) Crankcase Set (inc. 2-8) (2x4) Pin Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Plug (2x4) Gasket O-Ring Screw, Cap Nut Washer (4x4) Washer (2x4) Plug, Oil Gallery 27

30 CRANKCASE COVER ASSEMBLY Cover, Clutch (inc. 2) Lens, Oil Inspection Gasket Pin Screw, Cap Screw, Cap Gasket Plug, Oil Gallery Gasket Cap, Engine Oil Filler O-Ring Cap, Inspection O-Ring Screw, Cap Plug, Oil Pressure Gasket Cover Set, Transfer (inc ) Jet, Oil Mission O-Ring Gasket Clip Screw, Cap Screw, Cap Gasket Plug, Oil Gallery Gasket Plug, Allen Head Gasket Union, Water Drain Hose 28

31 CRANKSHAFT ASSEMBLY *Not a Service Part Crankshaft - Assembly (inc. 2-9) Rod, Connecting Pin, Crank Bearing Washer Crankshaft Set - Right (inc. 8-9) Crankshaft - Left 8 * 1 Gear, Balancer Drive 9 * 1 Pin Bearing - Right Bearing - Center Bearing - Left Retainer, Bearing - Right Screw, Cap Retainer, Oil Seal - Left Screw, Cap Piston Ring Set, Piston Ring, Piston - Set (+0.20 mm) Ring, Piston - Set (+0.40 mm) Pin Circlip Piston Set (+0.20 mm) Ring Set (+0.20 mm) Piston Set (+0.40 mm) Ring Set (+0.40 mm) Bearing Seal, Oil Spacer O-Ring 29

32 STARTER CLUTCH ASSEMBLY Limiter, Idle Gear - Assembly Bushing Washer Gear, Starter Idle Pin Clutch, Starter - Set (inc. 7) Bearing Washer Screw, Cap 30

33 CRANK BALANCER ASSEMBLY Balancer, Crank Bearing Washer Gear, Driven Race, Driven Gear Inner Pin Spring Key Washer Circlip Gear, Oil Pump Drive Pin Spacer Nut, Lock Washer 31

34 CAM SHAFT VALVE ASSEMBLY Cam Shaft Sprocket Pin Washer Screw, Cap C-Ring Arm, Valve Rocker (inc. 8-9) Screw, Cap Nut Arm, Valve Rocker (inc. 8-9) Seat, Spring Seal, Oil Shaft, Rocker Arm Shaft, Rocker Arm Washer Plug, Shaft Gasket Valve, Intake Valve, Exhaust Spring, Valve - Set Retainer, Spring Cotter, Valve 32

35 CAM CHAIN ASSEMBLY Chain, Cam Guide, Chain Tensioner, Chain Screw, Cap Washer Adjuster, Tensioner - Assembly Gasket Screw, Cap Gasket 33

36 RECOIL STARTER ASSEMBLY *Not a Service Part Starter, Recoil - Assembly (inc. 2-12) Reel Ratchet Assembly (inc. 4 and 6-10) 4 * 1 Pin, Ratchet Spring, Spiral 6 * 1 Spring, Friction 7 * 1 Shaft 8 * 1 Cover, Spring 9 * 1 Plate, Friction 10 * 1 Guide, Ratchet Nut Rope Assembly Gasket Screw, Cap Cup, Starter Nut O-Ring 34

37 OIL FILTER/PUMP ASSEMBLY Pump, Engine Oil Gear, Driven Pin Washer Circlip Screw, Cap Strainer, Engine Oil Screw, Cap Cap, Oil Strainer O-Ring Screw, Cap Filter, Engine Oil Plug, Drain Gasket Valve, Oil Relief - Assembly Union, Oil Filter 35

38 WATER PUMP ASSEMBLY Case, Water Pump (inc. 2-3) Screw, Cap Gasket O-Ring Screw, Cap Screw, Cap Joint, Pump Drive (4x4) Joint, Pump Drive (2x4) Shaft, Water Pump w/bearing Pin Seal, Pump Drive Seal, Mechanical Impeller Screw, Cap Washer Gasket 36

39 CLUTCH ASSEMBLY Housing, Starter Clutch Clutch, Primary Drive One Way Shoe, Starter Clutch Nut, Starter Clutch Shoe Washer, Starter Shoe Washer, Primary Driven Washer, Primary Driven Gear, Primary Driven - Assembly Hub, Clutch Sleeve Screw, Cap, Clutch Spring Spring, Clutch Plate, Clutch Drive Plate, Clutch Driven Disk, Clutch Pressure Plate, Clutch Release Nut, Clutch Sleeve Hub Washer, Sleeve Hub Arm, Clutch Release Bolt, Clutch (No. 1) Bolt, Clutch (No. 2) Guide, Release Roller Roller, Clutch Release - Assembly Bolt, Clutch Release Arm Nut, Clutch Release (No. 2) Nut, Clutch Release (No. 1) Washer, Clutch (No. 2) Bearing, Clutch Washer, Clutch (No. 1) 37

40 TRANSMISSION ASSEMBLY Shaft, Counter Gear, 2nd Drive Gear, 3rd Drive Gear, 4th Drive Gear, 5th Drive Bushing, 5th Drive Gear Washer, 5th Drive Gear Bearing, Center Shaft - Right Bushing, 4th Drive Gear Circlip, 4th Drive Circlip, Reverse Idle Bearing, Center Shaft Washer, 2nd Drive (4x4) Shim (2x4) Washer, 4th Drive Washer, Reverse Idle Shaft, Drive Gear, 1st Driven Gear, 2nd Driven Gear, 3rd Driven Bushing, 3rd Driven Gear, 4th Driven Gear, 5th Driven Gear, Reverse Driven Dog, Reverse Bushing, Reverse Driven Washer, 3rd Driven - Right Washer, 3rd Driven - Left Washer, 3rd Driven - Left Bearing, Driveshaft Bushing, 1st Driven Bushing, 2nd Driven Circlip, 2nd Driven Bushing, Reverse Idle Bearing, Driveshaft - Right Washer, Reverse Driven Washer, 1st Driven - Left Washer, 1st Driven - Right Washer, 2nd Driven Circlip, Reverse Driven Shaft, Reverse Idle Gear, Reverse Idle 38

41 SECONDARY TRANSMISSION ASSEMBLY (4x4) Shaft, Output Gear, Idle Gear, Driven Washer Spacer, Drive Gear (No. 2) Dog, Select Sliding Washer Bushing Bearing, Driveshaft - Left Bearing, Center Shaft - Left Circlip (No. 1) Washer, Gear (No. 2) Spacer Spacer, Idle Gear Gear (No. 1) Bushing Bearing Set - Left 39

42 SECONDARY TRANSMISSION ASSEMBLY (2x4) Shaft, Output Spacer, Idle Gear Gear, Driven Washer Spacer, Drive Washer Gearó (No. 1) Washer Washer Bearing, Driveshaft - Left Bearing, Center Shaft - Left Circlip (No. 1) Bearing Set - Left Spacer 40

43 SPEEDOMETER DRIVE ASSEMBLY Retainer, Bearing Washer, Driven Screw, Retainer Seal, Driven Gear Gear Shim Set Nut Washer Washer - Right Spacer, Driven Gear (4x4) Spacer, Driven Gear (2x4) Bolt, Gear Washer O-Ring Washer Bolt, Gear Bearing Set - Right Housing, Odometer Gear Sleeve Gasket Gear, Drive Gear, Driven 41

44 SECONDARY DRIVE ASSEMBLY (4x4) Yoke, Drive Output (inc. 2-5) Collar, Yoke Plate, Yoke Collar Plate, Yoke Collar O-Ring, Yoke Collar Yoke, Joint Shaft, Propeller Boot, Propeller Shaft Gear Shaft - Front Shaft - Rear Flange, Output Joint Joint Assembly, Rear Output (inc ) Nut, Front Drive Bevel Gear Nut Washer, Rear Output Flange Shim, 25 x 34 x 0.60 mm Shim, 25 x 34 x 0.65 mm Shim, 25 x 34 x 0.70 mm Shim, 25 x 34 x 0.75 mm Shim, 25 x 34 x 0.80 mm Shim, 25 x 34 x 0.85 mm Shim, 25 x 34 x 0.90 mm Shim, 25 x 34 x 0.95 mm Shim, 25 x 34 x 1.00 mm Shim, 25 x 34 x 1.05 mm Shim, 25 x 34 x 1.10 mm Shim, 25 x 34 x 1.15 mm Shim, 25 x 34 x 1.20 mm Bearing w/groove Bearing w/locating Ring and Pin Joint Set, Universal (inc. 21) Circlip Seal, Oil Ring, Bearing Washer Nut Screw, Cap Screw, Cap Boot, Joint - Set (inc ) Seal, Plate Ring, Snap Band Boot Band Flange, Output 42

45 SECONDARY DRIVE ASSEMBLY (2x4) Joint Assembly, Rear Output (inc. 2-7) Boot Set, Joint (inc. 3-7) Ring, Snap Clamp Boot Clamp Seal, Plate Shaft - Rear Shim, 25 x 34 x 0.60 mm Shim, 25 x 34 x 0.65 mm Shim, 25 x 34 x 0.70 mm Shim, 25 x 34 x 0.75 mm Shim, 25 x 34 x 0.80 mm Shim, 25 x 34 x 0.85 mm Shim, 25 x 34 x 0.90 mm Shim, 25 x 34 x 0.95 mm Shim, 25 x 34 x 1.00 mm Shim, 25 x 34 x 1.05 mm Shim, 25 x 34 x 1.10 mm Shim, 25 x 34 x 1.15 mm Shim, 25 x 34 x 1.20 mm Seal, Oil Flange, Output Joint Washer, Rear Output Flange Nut Bearing, Roller C-Ring Screw, Cap Retainer Nut, Secondary Driven Gear Washer Screw, Cap Bearing Gear, Secondary Driven Bevel Flange, Output 43

46 GEAR SHIFTING ASSEMBLY Fork (No. 2) Fork (No. 3) Fork, Reverse Shaft, Gear Shift Fork Cam, Gear Shift (inc. 6) Pin, Gear Shift Cam, Reverse Shift Plate, Gear Shift Cam Guide, Gear Shift Cam Plate Spacer, Reverse Shift Cam Bearing, Gear Shift Cam Bolt, Clutch Release Arm Screw, Cam Bearing Retainer Retainer, Bearing Stopper, Gear Shift Cam Stopper, Reverse Shift Cam Housing, Reverse Cam Stopper Spring, Shift Cam Stopper Arm Support, Shift Cam Stopper Gasket, Cam Stopper Housing Spring, Reverse Cam Stopper Washer, Gear Shift Cam Washer, Cam Stopper Arm Nut, Cam Stopper Arm Support Shaft, Gear Shift Spacer, Gear Shift Shaft Stopper, Gear Shift Arm Seal, Gear Shift Shaft Oil Seal, Reverse Shift Oil Spring, Gear Shift Return Arm, Reverse Gear Shift Washer, Gear Shift Cable Arm E-Ring, Gear Shift Cable Arm Screw, Cap Base Assembly (4x4) Base Assembly (2x4) Contact, Neutral O-Ring, Neutral Clamp Clamp Spring Hub, Gear Shift Spring, Gear Shift AR Tape, Foil 44

47 HI/LOW SHIFTER ASSEMBLY (4x4) Stopper, Shift Cam Housing, Shift Stop Shaft, Fork Fork, Shift Cam, Shift Spring Shaft, Shift Plate, Lever Stop Circlip, Shaft - Left Knob Gasket, Cam Stop Seal, Oil Spring Bolt, Stopper Plate Screw, Shift Knob Washer, Cam Stop Washer, Shaft - Left Circlip, Cam Spring Circlip, Shift Lever Lever, Shift - Assembly (inc ) Collar Washer E-Clip Spring Circlip Washer Spacer Spacer 45

48 SHIFTER ASSEMBLY (2x4) Housing, Shift Stop Shaft, Shift Gasket, Cam Stop Seal, Oil Washer, Shaft - Left Circlip, Shaft - Left 46

49 *Not Included in Assembly FRONT BEVEL GEAR ASSEMBLY Complete Assembly p/n Flange, Gear (inc. 2-5) * Collar, Gear * Plate, Oil Seal * Plate, Gear * O-Ring, Collar * Gear, Bevel Housing, Bevel Gear Shim Set, Housing Nut, Gear * Washer, Bevel Gear * Spacer, Bevel Gear Bearing Bearing O-Ring Seal, Joint Bolt, Housing Gear Shim Set Shim Set Bearing Seal - Left Bearing - Left Differential - Assembly Bearing, Differential Case - Right Seal, Output Oil Housing (inc. 27) Union, Breather Case, Bearing Bolt, Mounting Gasket, Oil Drain Plug Gasket, Oil Filler Plug Plug, Oil Drain Plug, Oil Filler Plug O-Ring O-Ring Screw, Cap Ring, Driveshaft - Front Coupling, Propeller Shaft * Screw, Cap * Nut * Bladder, Case * Tie, Cable * Nut, Lock 47

50 REAR BEVEL GEAR ASSEMBLY Complete Assembly p/n Boot, Final Drive Shaft, Rear Final Coupling, Rear Gear Set Stopper, Rear Final Pin, Bearing Stopper Shim Set Shim Set Shim Set Case Case - Right Case - Left Housing Nut, Rear Drive Pinion Washer, Drive Nut Washer - Left Gasket, Bearing Stopper Pin Gasket, Oil Drain Plug Plug, Oil Drain Plug, Gear Oil Filler Bearing Bearing Bearing - Right Bearing, Final Drive Pilot O-Ring, Bearing Case - Right O-Ring, Gear Oil Filler O-Ring, Final Bearing Stopper O-Ring, Bearing Case - Left Seal, Final Driven Seal, Oil Seal, Oil Seal, Oil Clamp - Right Spring Stud, Bolt Stud, Bolt - Left Bolt, Bearing - Right Bearing - Left Nut Nut, Rear Final Housing Circlip Set 48

51 STARTER MOTOR ASSEMBLY Motor, Starter Assembly (inc. 2-9) Terminal Set, Brush Holder Set, Brush Spring, Brush O-Ring O-Ring Washer Set O-Ring Screw, Cap Screw, Cap Nut Circlip Bearing, Pinion Shaft 49

52 MAGNETO ASSEMBLY Stator - Assembly Rotor Bolt, Magneto Key, Magneto Nut, Magneto Screw, Cap Clamp, Magneto (No. 1) Clamp, Magneto (No. 2) Clamp, Magneto (No. 3) (2x4) 50

53 ELECTRICAL COMPONENTS ASSEMBLY Relay, Starter Motor - Assembly Screw, Cap CDI Unit (4x4) CDI Unit (2x4) Coil, Ignition - Assembly Cap, Spark Plug Seal, Spark Plug Seal, High Tension Cord Relay, Neutral Start - Assembly Screw, Cap Fuse, 30 Amp 51

54 CONTROL SWITCH HOUSING ASSEMBLY Switch, Handle - Assembly (inc. 2-5) Lever, Choke Cover, Choke Screw, Cap Screw, Cap 52

55 THROTTLE CASE ASSEMBLY Case, Throttle - Assembly (inc. 2-9) Lever Screw, Cap Washer, Lock Washer Screw, Cap Nut Screw, Cap Screw, Cap 53

56 Printed in U.S.A. p/n