ATV ILLUSTRATED PARTS MANUAL

Transcription

ARCTIC CAT
®
TM
ATV
ILLUSTRATED PARTS
MANUAL
‘96
454 4x4
(Model No. 96A4A-AP)
TABLE OF CONTENTS
Model No. 96A4A-AP
BODY PANEL ASSEMBLY ...................................................................................................................................... 1
TAILLIGHT ASSEMBLY .......................................................................................................................................... 2
DECALS ................................................................................................................................................................... 3
FRAME AND RELATED PARTS ............................................................................................................................. 4
SEAT ASSEMBLY ................................................................................................................................................... 5
STEERING ASSEMBLY .......................................................................................................................................... 6
FRONT SUSPENSION ASSEMBLY ........................................................................................................................ 7
REAR SUSPENSION ASSEMBLY .......................................................................................................................... 8
WHEEL AND TIRE ASSEMBLY .............................................................................................................................. 9
MECHANICAL BRAKE ASSEMBLY ...................................................................................................................... 10
HYDRAULIC BRAKE CONTROL ASSEMBLY ...................................................................................................... 11
HYDRAULIC BRAKE ASSEMBLY ......................................................................................................................... 12
FUEL TANK ASSEMBLY ....................................................................................................................................... 13
REVERSE SHIFT LEVER ASSEMBLY ................................................................................................................. 14
AIR INTAKE ASSEMBLY ....................................................................................................................................... 15
STORAGE BOX AND BATTERY ASSEMBLY ...................................................................................................... 16
ENGINE AND EXHAUST ....................................................................................................................................... 17
COOLING ASSEMBLY .......................................................................................................................................... 18
REAR AXLE ASSEMBLY ...................................................................................................................................... 19
WIRING HARNESS ASSEMBLY ........................................................................................................................... 20
CARBURETOR ...................................................................................................................................................... 21
CYLINDER HEAD ASSEMBLY ............................................................................................................................. 22
CYLINDER ASSEMBLY ........................................................................................................................................ 23
CRANKCASE ASSEMBLY .................................................................................................................................... 24
CRANKCASE COVER ASSEMBLY ...................................................................................................................... 25
CRANKSHAFT ASSEMBLY .................................................................................................................................. 26
STARTER CLUTCH ASSEMBLY .......................................................................................................................... 27
CRANK BALANCER ASSEMBLY .......................................................................................................................... 28
CAM SHAFT VALVE ASSEMBLY ......................................................................................................................... 29
CAM CHAIN ASSEMBLY ...................................................................................................................................... 30
RECOIL STARTER ASSEMBLY ........................................................................................................................... 31
OIL FILTER/PUMP ASSEMBLY ............................................................................................................................ 32
WATER PUMP ASSEMBLY .................................................................................................................................. 33
CLUTCH ASSEMBLY ............................................................................................................................................ 34
TRANSMISSION ASSEMBLY ............................................................................................................................... 35
SECONDARY TRANSMISSION ASSEMBLY ........................................................................................................ 36
SPEEDOMETER DRIVE ASSEMBLY ................................................................................................................... 37
SECONDARY DRIVE ASSEMBLY ........................................................................................................................ 38
GEAR SHIFTING ASSEMBLY ............................................................................................................................... 39
HI/LO SHIFTER ASSEMBLY ................................................................................................................................. 40
FRONT BEVEL GEAR ASSEMBLY ...................................................................................................................... 41
REAR BEVEL GEAR ASSEMBLY ......................................................................................................................... 42
STARTER MOTOR ASSEMBLY ........................................................................................................................... 43
MAGNETO ASSEMBLY ........................................................................................................................................ 44
ELECTRICAL COMPONENTS ASSEMBLY .......................................................................................................... 45
CONTROL SWITCH HOUSING ASSEMBLY ........................................................................................................ 46
THROTTLE CASE ASSEMBLY ............................................................................................................................. 47
 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 1996 model year. For a complete list of related items, refer to the current accessory catalog.
©2009 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Printed July 2009
1996 Bearcat 454 4x4
BODY PANEL ASSEMBLY
0732-341
Ref. Part No. Qty. Description
1 0506-156
2 0406-153
3 0506-154
0506-155
4 0506-104
5 0606-526
6 0623-269
7 0506-164
0506-165
8 0506-157
9 0506-103
10 0406-269
11 0123-788
12 0606-029
13 0406-082
0406-083
1
1
1
1
1
2
8
1
1
1
1
1
7
2
1
1
Panel, Fender - Front
Cover, Radiator Access
Flare - Front Right
Flare - Front Left
Rack - Front
Reflector - Amber
Clip, Retaining
Panel, Side - Right
Panel, Side - Left
Panel, Fender - Rear
Rack - Rear
Wrap, Tube - Rear Rack
Tie, Cable
Reflector - Red
Flare - Rear Right
Flare - Rear Left
14 0406-086
0406-087
15 0423-046
16 0506-160
0506-161
17 0423-010
18 8474-616
19 0423-060
20 0623-309
21 8409-020
22 8408-812
23 0423-031
24 0123-010
25 0423-068
26 0706-990
27 8477-616
1
1
54
1
1
14
14
2
2
6
2
2
2
2
AR
2
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
Tape, Foil
Screw, Machine
1
TAILLIGHT ASSEMBLY
(Complete Taillight Assembly p/n 0409-002)
0732-336
1
2
3
4
2
0109-460
0409-011
0409-012
0409-007
1
1
1
1
Bulb, Taillight
Taillight w/Socket Assembly
Gasket, Taillight
Lens, Taillight
5 0409-010
6 0623-302
7 8053-212
2
2
2
Screw, Machine
Screw, Self-Tapping
Washer, Lock
DECALS
0732-340
1
2
3
4
5
6
7
8
0411-006
0411-018
0411-011
0411-045
0411-008
0411-040
0411-010
0411-014
0411-015
1
1
1
1
1
1
1
1
1
Decal, Warning - Front Rack Load
Decal, “Bearcat” - Front
Decal, Caution - Electrical
Decal, Warning - Turn
Decal, Warning - Reverse/Pre Ride
Decal, Warning - Age
Decal, Warning - General
Decal, “Bearcat” - Side Right
Decal, “Bearcat” - Side Left
9
10
11
12
13
14
0411-012
0411-003
0411-007
0411-043
0411-013
0411-009
1
1
1
1
1
1
Decal, Warning - Tire Pressure
Decal, Shift Pattern
Decal, Warning - Rear Rack Load
Decal, “Arctic Cat”
Decal, Warning - Towing
Decal, Hi/Low Range
3
FRAME AND RELATED PARTS
0732-335
1
2
3
4
5
6
7
8
9
10
11
12
4
0409-001
8424-802
0409-005
8053-242
8408-850
0406-175
0406-261
0406-262
8409-020
0506-075
0506-066
0506-067
2
6
2
2
2
1
2
2
8
1
1
1
Headlight
Nut
Bulb, Headlight
Washer, Lock
Screw, Cap
Screen, Bumper
Yoke, Headlight
Mount, Headlight
Screw, Cap
Bumper - Front
Footrest - Right
Footrest - Left
13
14
15
16
17
18
19
20
21
22
23
24
0123-950 2 Screw, Machine
8408-816 10 Screw, Cap
0506-133 1 Frame
0423-010 10 Washer, Body
0406-095 1 Panel, Belly
0506-079 1 Tube, Cross
0406-130 2 Cap, Bumper
8408-820 2 Screw. Cap
0506-149 1 Bracket, Front Gear Case
3423-010 1 Screw, Cap
8428-002 1 Nut, Lock
SEAT ASSEMBLY
0732-342
1
2
3
4
5
6
7
8
9
10
5990-012
0506-054
0506-056
0506-167
0506-166
8061-628
0506-147
8060-630
0406-268
8050-152
1
1
1
1
1
4
1
4
2
4
Seat - Assembly (inc. 2-11)
 Cover, Seat
 Foam, Seat
 Base, Seat - Assembly (inc. 5-10)
 Base, Seat
 Rivet
 Pin, Seat Base - Front
 Rivet
 Plate, Seat Retainer
 Washer
11
12
13
14
15
16
17
18
19
20
0624-263 50  Staple
8050-217 2 Washer
0406-199 2 Collar, Front Seat Base
0406-171 2 Bumper, Seat Base - Front
0623-404 1 Cap, Protector
0406-103 1 Latch, Seat - Assembly
0406-172 2 Bumper, Seat Base - Center
0406-270 2 Bumper, Seat Base - Center
8408-620 2 Screw, Cap
5
STEERING ASSEMBLY
0732-343
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
6
0487-005
8477-616
0420-003
0423-052
3430-013
3409-007
3409-011
0420-011
0420-012
0405-019
0420-013
0420-001
0420-004
0123-950
8408-860
0405-035
0506-139
0505-007
0405-013
0705-064
0405-020
1
3
1
3
1
1
1
1
1
1
9
1
1
4
6
4
1
1
2
1
2
Cable, Speedometer
Screw, Machine
Speedometer
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 - Upper
Bearing, Steering Post
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
0605-171
0117-868
0505-012
8408-816
0602-233
0107-223
0123-570
8409-020
0423-014
0505-001
8480-010
0405-011
0405-010
0423-013
0405-032
0620-149
0420-014
0420-018
0420-016
0420-017
0420-015
1
4
1
2
1
1
1
1
4
2
2
2
2
2
2
1
1
1
2
2
2
Cap, Bearing - Steering
Pin, Cotter
Post, Steering
Screw, Cap
Flange, Bearing
Bearing - w/o Lock Collar
Washer
Screw, Cap
Nut, Hex
Tie Rod - Assembly (inc. 31-35)
 Nut - Left
 Ball Joint, Tie
 Ball Joint, Tie
 Nut - Right
 Tie Rod
Bulb, Speedometer
Harness, Speedometer
Bracket, Speedometer
Mount, Rubber
Washer
Pin, Retainer
FRONT SUSPENSION ASSEMBLY
0732-344
1
2
3
4
5
6
7
8
9
10
0603-033 2 Retainer, Spring
0403-001 2 Shock Absorber - Front (inc. 3-4)
0604-310 8  Bushing, Shock Absorber
0403-028 4  Sleeve, Shock
8478-013 12 Nut, Lock
8409-040 4 Screw, Cap
0403-002 2 Spring, Front
0403-025 2 Collar, Spring
0403-013 2 Washer, Spring
0503-016 1 A-Arm, Upper Right - Assembly
(inc. two No. 11-12)
0503-017 1 A-Arm, Upper Left - Assembly
(inc. two No. 11-12)
11 0405-001 4  Ball Joint - Front
12 0423-009 2  Clip, Ball Joint
13 0505-016 1 Knuckle - Assembly - Right (inc. 14-18)
0505-017 1 Knuckle - Assembly - Left (inc. 14-18)
14 0505-010
0505-011
15 0402-085
16 0423-034
17 0402-089
18 0402-069
19 8409-030
20 8409-060
21 0503-013
0503-012
22 0402-098
23 0436-038
24 0436-037
25 0403-027
1
1
2
2
2
2
4
8
1
1
2
2
2
2
 Knuckle, Steering - Right
 Knuckle, Steering - Left
 Bearing, Wheel Hub - Front
 Clip, Bearing
 Seal, Wheel Bearing - Front
 Seal, Wheel Bearing - Front
Screw, Cap
Screw, Cap
A-Arm, 4x4 Lower Left (inc. two No. 11-12)
A-Arm, 4x4 Lower Right
Axle, Drive - Front
Repair Kit, Outer Boot - Front Axle
Repair Kit, Inner Boot - Front Axle
Retainer, Spring - Lower
7
REAR SUSPENSION ASSEMBLY
0732-345
1
2
3
4
5
6
7
8
8
8409-060
8409-000
0504-001
8428-002
8409-055
0504-005
0403-027
0404-001
3
2
3
9
1
1
2
2
Screw, Cap
Screw, Cap
Arm, Swing
Nut, Lock
Screw, Cap
Arm, Swing
Retainer, Spring - Lower
Shock Absorber - Rear (inc. 9-10)
9
10
11
12
13
14
15
16
0403-028
0604-310
0603-033
8409-040
0404-006
0403-025
0403-013
8422-002
4
8
2
4
2
2
2
1
 Sleeve, Shock
 Bushing, Shock Absorber
Retainer, Spring
Screw, Cap
Spring - Rear
Collar, Spring
Washer, Spring Adjustment
Nut, Lock
WHEEL AND TIRE ASSEMBLY
0735-756
1
2
3
4
5
6
7
8
9
10
11
12
0402-007 2 Tire, Front
0402-140 4 Cap, Valve Stem
0402-064 4 Valve, Stem
0402-005 2 Wheel - Front
0423-015 4 Nut, Hex
0123-458 4 Pin, Cotter
0423-021 4 Washer
0402-099 4 Seal, Hub
0402-088 2 Hub, Wheel - Front
0402-009 3 Disc, Brake
0402-080 2 Hub, Wheel - Rear
13
14
15
16
17
0402-006 2 Wheel - Rear
0402-008 2 Tire - Rear
0403-011 4 Cap, Wheel - Center
8409-020 16 Screw, Cap
0402-074 1 Wheel and Tire Assy - RH
(inc. 1, 4, and 16)
0402-075 1 Wheel and Tire Assy - LH
(inc. 1, 4, and 16)
18 0402-076 1 Wheel and Tire Assy - RH
(inc. 2, 3, 13, and 14)
0402-077 1 Wheel and Tire Assy - LH
(inc. 2, 3, 13, and 14)
9
MECHANICAL BRAKE ASSEMBLY
0732-337 *Not a Service Part
1 0436-099
2
*
3
4
5
6
7
8
9
10
10
0402-125
0502-020
0423-058
0402-129
0402-116
0487-004
0423-049
0117-868
1
1
1
1
2
1
1
1
1
1
 Mechanical Brake Assembly (inc. 2-7)
 Caliper, Mechanical Brake - Assembly
(inc. 3)
 Pin, Actuator
Pad Set
 Screw, Socket Head
 Spring, Mechanical Brake
 Bracket, Spring Retaining
Cable, Brake - Rear
Pin
Pin, Cotter
11
12
13
14
15
16
17
18
19
20
0115-602
0423-064
0502-035
8408-616
0670-183
0502-024
0423-027
0623-237
0502-409
0124-057
1
1
1
2
2
1
1
1
1
1
Spring, Brake Arm Return
Cap, Protector
Brake, Parking
Screw, Cap
O-Ring
Lever, Foot Brake
Washer, Brake Lever
Ring, Snap
Spring, Foot Brake
E-Ring
HYDRAULIC BRAKE CONTROL ASSEMBLY
1
2
3
4
5
6
7
8
0502-021
0402-049
0623-430
0623-506
0602-742
0602-741
0602-740
0602-587
1
1
1
2
1
1
1
1
Brake, Lever - Assembly (inc. 2-14)
 Lever, Brake
 Bolt, Lever Mounting
 Screw, Cover - Master Cylinder
 Cover, Master Cylinder
 Gasket, Cover - Master Cylinder
 Reservoir, Hydraulic Brake
 O-Ring, Reservoir
9
10
11
12
13
14
15
16
*
0623-432
0623-613
8052-212
0623-613
0602-907
0402-050
8408-625
1
2
1
2
2
1
1
1
 Master Cylinder
 Screw, Reservoir Mount
 Nut, Lock
 Washer, Lock
 Screw, Clamp
 Clamp
Hose, Master Cylinder
Screw, Cap
11
HYDRAULIC BRAKE ASSEMBLY
0732-339 *Not a Service Part **Not Illustrated
1
2
3
4
5
6
0402-053
0402-051
0402-073
0423-038
0423-039
0402-010
1
1
2
3
6
2
0402-011
1
0402-011
1
7
*
8 0402-164
9 0117-868
3
3
3
12
Tube, Brake Line - Front
Hose, Brake - Front
Block, Mounting
Bolt, Oil
Washer, Crush
Caliper, Brake - Right Front
(inc. 7-13 and two No. 14-16)
Caliper, Brake - Left Front
(inc. 7-13 and two No. 14-16)
Caliper, Brake - Rear
(inc. 7-13 and two No. 14-16)
 Housing, Caliper
 O-Ring
 Pin, Cotter
10
11
12
13
14
15
16
17
18
19
20
21
22
**
0402-142
0402-143
0502-019
0402-167
0402-141
0402-165
0402-166
0402-052
0402-115
0402-054
8408-625
8408-825
8408-820
0402-143
3
3
1
3
6
6
6
1
1
1
1
2
4
2
 Pin, Hydraulic Brake Caliper
 Cap, Bleeder Valve
 Pad, Hydraulic Brake (Set)
 Valve, Bleeder
 O-Ring, Hydraulic Brake Caliper
 Washer
 Screw, Socket Head
Hose, Brake - Rear
Clip, Brake Line
Tube, Brakeline - Rear
Screw, Cap
Screw, Cap
Screw, Cap
Cap, Bleeder Valve
FUEL TANK ASSEMBLY
0732-346 * Not a Service Part
1
2
3
4
5
6
7
0570-003 1 Tank, Fuel (inc. 2 and 6-9)
0470-315 1  Cap, Fuel Tank (inc. 3)
0610-007 AR  Line, Fuel Cap Vent
8408-650 2 Screw, Cap
0623-184 2 Washer
0406-169 4 Bushing, Fuel Tank Mount
0406-170 2 Collar, Fuel Tank Mount
8
9
10
11
12
13
0610-007 AR Line, Fuel
0423-048 2 Clamp, Hose - Spring
*
1 Gasket, Fuel
0470-314 1 Valve, Shut-Off (inc. 10)
8471-616 2 Screw, Cap
0417-001 4 Pad, Fuel Tank
13
REVERSE SHIFT LEVER ASSEMBLY
0732-334
1
2
3
4
5
6
7
14
8477-830
8050-252
0402-103
0502-022
0423-069
0423-063
0402-136
1
1
1
1
2
2
1
Screw, Cap
Washer
Axle, Reverse Shifter
Lever, Reverse
O-Ring
E-Ring
Spring, Reverse Lever
8
9
10
11
12
13
14
0409-008
0402-130
0402-062
3423-168
0487-003
3446-055
8408-616
1
1
1
1
1
1
1
Reverse Switch
Retainer, Switch
Knob, Reverse Shift Lever
E-Ring
Cable, Shift
Arm, Reverse Gear Shift
Screw, Cap
AIR INTAKE ASSEMBLY
0735-757
1
2
3
4
5
6
7
8
9
10
0423-066
0470-305
0423-018
0570-004
0470-328
0470-324
0470-304
0470-307
0423-037
0123-549
1
1
2
1
1
1
1
6
6
4
Clamp
Boot, Air Cleaner
Clamp
Cleaner, Air - Lower Assembly
Baffle, Splash - Air Cleaner
Gasket, Air Cleaner
Snorkel, Air Cleaner
Clamp, Air Cleaner
Spring
Screw, Machine
11
12
13
14
15
16
17
18
19
20
0123-010 4
0410-004 1
0470-322 4
0470-332 2
0470-309 1
0470-310 1
0423-047 1
0423-045 2
0470-327 2
0706-990 AR
Nut, Expansion
Hose, Crankcase Vent
Filter, Air Cleaner (inc. 14)
 Sleeve, Filter
Valve, Air Cleaner
Cap, Drain - Air Cleaner
Clamp, Hose
Clamp, Hose
Support, Air Cleaner Flange
Tape, Foil (6 in. x 24 in.)
15
STORAGE BOX AND BATTERY ASSEMBLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
8408-616 1 Screw, Cap
0406-242 1 Strap, Battery
0406-252 2 Pad, Battery - Upper
0445-005 1 Battery - Assembly (inc. 5-7)
0645-045 6  Cap, Battery
0645-152 1  Clamp, Hose
0645-179 1  Hose, Battery Vent
0123-788 AR Tie, Cable
0406-227 1 Pad, Battery - Lower
0444-001 1 Kit, Tool
0423-052 1 Collar, Body
0530-001 1 Fuse Box - Assembly (inc. 13-16)
*
*  Block, Fuse
*
*  Lid, Fuse Block
0430-006 1  Decal, Fuse Block
0630-057 3  Fuse, 10 Amp
0630-058 2  Fuse, 15 Amp
17 0623-121
18 0506-102
19
20
21
22
23
24
25
26
27
28
29
6
1
Screw, Machine
Storage Box - Assembly
(inc. 19-23, four No. 24, and 25-27)
0406-257 1  Box, Tool
8050-152 6  Washer
0406-208 1  Lid, Tool Box
0773-401 1  Chain, Storage
0623-620 2  Rivet
0123-010 6  Nut, Expansion
0673-973 1  Seal, Storage Cover
0406-205 1  Ring, Mounting - Storage Box Lid
8060-630 6  Rivet
0706-990 AR Tape, Foil
0423-044 4 Clamp, Tube
ENGINE AND EXHAUST
0732-348
1
2
3
4
5
6
7
8
9
10
11
12
13
0512-001
8408-820
3423-003
0423-050
0423-042
0462-001
8478-002
0412-007
8474-813
8408-860
8409-020
0506-083
0502-016
1
2
3
3
1
1
3
1
1
1
4
1
1
Pipe, Exhaust
Screw, Cap
Screw, Cap
Washer, Engine
Spacer
Engine
Nut, Lock
Seal, Exhaust
Nut, Jam
Screw, Cap
Screw, Cap
Bracket, Upper Motor
Lever, Shift
14
15
16
17
18
19
20
21
22
23
24
25
26
8408-620
0412-003
0412-004
0412-005
8408-830
0406-224
8477-610
8050-252
0214-015
8053-211
8424-602
8408-640
0107-630
1
3
3
1
3
1
4
3
1
4
2
2
2
Screw, Cap
Spacer, Exhaust
Bushing, Rubber
Muffler
Screw, Cap
Cover, Exhaust
Screw, Machine
Washer
Clamp
Washer, Star
Nut
Screw, Cap
Spacer
17
COOLING ASSEMBLY
0732-349
1
2
3
4
5
6
7
8
9
10
11
12
13
14
18
0413-007 1 Screen, Radiator
3002-964 2 Clamp, Wire
8408-620 2 Screw, Cap
0423-030 2 Grommet
0423-036 2 Collar
0610-016 AR Hose - 25 ft
0413-002 1 Cap, Radiator
0413-001 1 Radiator - Assembly (inc. 1, 4, and 21)
0423-062 1 O-Ring
0430-001 1 Switch, Temperature Sensor
0214-015 6 Clamp, Hose
0410-002 1 Hose, Coolant - Upper
0413-006 1 Blade, Fan
0413-004 1 Motor, Fan
15
16
17
18
19
20
21
22
23
24
25
26
27
8474-516
0410-001
0410-003
8474-616
0423-010
0406-200
0413-009
0423-031
0423-056
8050-252
0423-028
8477-616
0123-788
3
1
1
8
8
2
4
4
1
1
2
4
8
Screw, Machine
Hose, Coolant - Lower
Hose, Coolant - Crossover
Screw, Machine
Washer, Body
Panel, Fender - Inner
Screw, Thumb
Nut, Speed
Nut, Left-Hand Thread
Washer
Bushing, Stem
Screw, Machine
Tie, Cable
REAR AXLE ASSEMBLY
0732-350
1
2
3
4
5
6
7
8
9
10
11
0502-018
8409-030
8409-025
0402-145
0402-139
3008-100
0123-811
8408-616
0506-135
8408-840
0402-138
1
2
1
2
1
1
1
2
1
2
1
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
12
13
14
15
16
17
18
19
20
21
0423-010
0502-005
0402-068
0423-033
0402-003
8474-813
0423-031
0406-097
8408-820
8050-252
1
1
2
2
2
2
2
1
1
1
Washer, Shoulder
Housing, Axle - Rear Left
Seal
C-Clip
Bearing, Wheel Hub - Rear
Nut, Jam
Nut, Speed
Panel, Gear Case - Rear
Screw, Cap
Washer
19
WIRING HARNESS ASSEMBLY
0733-409
1
2
3
4
5
6
7
8
9
20
0486-001 1 Harness, Main
0445-003 1 Cable, Battery/Electric Start Relay
0445-002 1 Cable, Battery/Ground
0123-788 AR Tie, Cable
0409-009 1 Switch, Brake - Assembly
0530-002 1 Regulator, Voltage
8408-630 2 Screw, Cap
0402-130 1 Retainer, Switch
0445-004 1 Cable, Battery/Electric Start
10
11
12
13
14
15
16
17
0445-001
8060-430
0123-149
0486-004
0406-266
0423-065
0423-075
0645-019
4
2
2
1
1
1
1
1
Receptacle, 12V
Rivet
Washer
Harness, 12V Receptacle
Sleeve, Cable Clip
Base, Wire Tie
Tie, Cable
Boot, Terminal
CARBURETOR
(Complete Assembly p/n 0470-317)
0732-351
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
4505-001
4505-002
4505-003
4505-004
4505-005
4505-020
4505-007
4505-103
4505-009
4505-010
4505-011
4505-012
4505-013
4505-014
4505-016
4505-017
4505-091
4505-020
4505-021
4505-022
4505-044
4505-045
1
2
1
1
1
1
4
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
Cover - Assembly
Spring
Ring
E-Ring
Ring
Jet Needle 5D40-4
Screw
Diaphram
Screw
Plunger - Assembly
O-Ring
Washer
Spring
Screw
Screw, Pilot
Jet, Pilot 40
Jet, Main 132.5
Needle Jet P-7
Float - Assembly
Seat, Valve 2.0 (With Needle)
O-Ring, Bowl
Filter
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
4505-023
4505-024
4505-025
4505-026
4505-027
4505-028
4505-029
4505-030
4505-031
4505-032
4505-033
4505-042
4505-043
4505-035
4505-036
4505-037
4505-039
6505-153
6505-006
0487-001
0487-002
1
1
5
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
Chamber, Float
Jet, Pilot
Screw
Spring
Cable Adjust - Assembly
Cover
Washer
Screw
O-Ring
Guide, Cable
Washer
Screw
Clip
Hose
Cap
Clip
Spring
Pin
Washer
Cable, Throttle
Cable, Choke
21
CYLINDER HEAD ASSEMBLY
(Complete Gasket Set p/n 3402-107)
0732-300 *Not Illustrated
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
22
3402-098
3402-099
3423-068
3423-043
3423-006
3008-376
3402-163
3423-088
3423-015
3423-016
3423-089
3423-087
3004-492
3423-007
3004-376
3004-488
3004-326
1
4
4
2
4
2
1
2
2
2
2
2
1
2
4
4
1
Head, Cylinder - Assembly (inc. 2-6)
 Guide, Valve
 Circlip
 Pin
 Bolt
 Bolt
Gasket, Cylinder Head
Pin
Bolt
Bolt
Bolt, Cylinder Head Stud
Bolt, Cylinder Head Stud
Bolt, Stud
Bolt
Bolt
Nut
Nut
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
*
3003-290
3402-010
0217-705
3402-100
3402-101
3004-341
3402-035
3402-149
3423-062
3423-019
3402-086
3004-341
3413-005
3530-005
3413-004
3402-048
4
4
1
2
2
4
1
1
1
2
1
2
1
1
1
1
Gasket
Gasket, Head Nut
Spark Plug (NGK CR8E)
Cap, Inspection
O-Ring
Bolt
Plug, Cylinder Head
Pipe, Intake - Assembly (inc. 26)
 O-Ring
Screw, Cap
Clamp
Bolt
Thermostat
Switch, Water Temp - Assembly
Cover, Thermostat
Plug, Frost
CYLINDER ASSEMBLY
0732-301
1
2
3
4
3402-102
3423-090
3004-488
3402-103
1
2
2
1
Cylinder
Bolt, Stud
Nut
Gasket, Cylinder
5
6
7
8
3423-088
3413-006
3423-121
3423-058
2
1
1
1
Pin
Union, Water Hose
Bolt
O-Ring
23
CRANKCASE ASSEMBLY
0732-302
1
2
3
4
5
6
7
24
3402-104
3423-088
3423-091
3423-092
3423-094
0693-303
3423-093
1
4
3
6
2
4
2
Crankcase Set (inc. 2-7)
 Pin
 Bolt
 Bolt
 Bolt
 Bolt
 Bolt
8
9
10
11
12
13
3423-095
3402-011
3423-052
3423-009
3423-024
3004-278
1
1
1
3
3
3
Plug, Oil Gallery
Gasket
O-Ring
Bolt
Nut
Washer
CRANKCASE COVER ASSEMBLY
0732-303
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
3402-199 1 Cover, Clutch (inc. 2)
3402-112 1  Lens, Oil Inspection
3402-108 1 Gasket
3423-088 2 Pin
0693-327 14 Bolt
3423-097 1 Bolt
3003-290 1 Gasket
3004-339 1 Plug, Oil Gallery
3402-009 1 Gasket
3402-042 1 Cap, Engine Oil Filler
3423-055 1 O-Ring
3402-100 1 Cap, Inspection
3402-101 1 O-Ring
3423-096 2 Screw, Cap
3402-037 1 Plug, Oil Pressure
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
3402-012 1 Gasket
3402-106 1 Cover Set, Transfer (inc. 18-19)
3402-097 1  Jet, Oil Mission
3423-051 1  O-Ring
3402-109 1 Gasket
3423-120 1 Clip
3423-098 13 Bolt
3423-092 1 Bolt
3003-290 1 Gasket
3004-705 2 Plug, Oil Gallery
3003-188 2 Gasket
3402-038 1 Plug
3402-013 1 Gasket
3413-009 1 Union, Water Drain
3413-008 1 Hose
25
CRANKSHAFT ASSEMBLY
0732-304
1
2
3
4
5
6
7
8
9
10
11
12
13
14
26
3402-115
3402-111
3402-116
3402-064
3423-030
3402-117
3402-118
3402-127
3423-048
3402-044
3402-058
3402-054
3402-120
3423-017
1
1
1
1
2
1
1
1
1
1
1
1
1
2
Crankshaft - Assembly (inc. 2-7)
 Rod, Connecting
 Pin, Crank
 Bearing
 Washer
 Crankshaft - Right
 Crankshaft - Left
Gear, Balancer Drive
Pin
Bearing - Right
Bearing - Center
Bearing - Left
Retainer, Bearing - Right
Screw, Cap
15
16
17
18
19
20
21
22
23
24
3402-188
3423-018
3402-113
3402-114
3436-007
3436-008
3402-110
3423-069
3402-189
3402-190
3402-051
3402-070
3402-119
1
3
1
1
1
1
1
2
1
1
1
1
1
Retainer, Oil Seal - Left
Screw, Cap
Piston
Ring Set, Piston
Ring Set, Piston (OS: 0.5 mm)
Ring Set, Piston (OS: 1.0 mm)
Pin
Circlip
Piston/Ring Set (OS: 0.5 mm)
Piston/Ring Set (OS: 1.0 mm)
Bearing
Seal, Oil
Spacer
STARTER CLUTCH ASSEMBLY
0732-305
1
2
3
4
5
3402-123
3402-125
3423-103
3402-124
3423-042
1
2
2
1
1
Limiter, Idle Gear - Assembly
Bushing
Washer
Gear, Starter Idle
Pin
6
7
8
9
3402-122
3402-063
3423-104
3423-102
1
1
1
6
Clutch, Starter - Set (inc. 7)
 Bearing
Washer
Bolt
27
CRANK BALANCER ASSEMBLY
0732-306
1
2
3
4
5
6
7
8
28
3402-126
3402-050
3423-033
3402-128
3402-129
3423-041
3402-090
3004-540
1
2
1
1
1
3
6
1
Balancer, Crank
Bearing
Washer
Gear, Driven
Race, Driven Gear Inner
Pin
Spring
Key
9
10
11
12
13
14
15
3423-107
3423-200
3402-150
3423-114
3402-151
3423-025
3423-029
1
1
1
1
1
1
1
Washer
Circlip
Gear, Oil Pump Drive
Pin
Spacer
Nut
Washer
CAM SHAFT VALVE ASSEMBLY
0732-307
1
2
3
4
5
6
7
8
9
10
11
3402-130
3402-131
3423-047
3423-073
3423-013
3423-071
3402-138
3423-075
3423-076
3402-139
3402-148
1
1
1
1
2
1
1
2
2
1
4
Cam Shaft
Sprocket
Pin
Washer
Bolt
C-Ring
Arm, Valve Rocker (inc. 8-9)
 Screw, Cap
 Nut
Arm, Valve Rocker (inc. 8-9)
Seat, Spring
12
13
14
15
16
17
18
19
20
21
22
3402-078
3402-140
3402-141
3423-031
3402-040
3402-012
3402-142
3402-143
3402-144
3402-146
3402-147
4
1
1
2
2
2
2
2
4
4
8
Seal, Oil
Shaft, Rocker Arm
Shaft, Rocker Arm
Washer
Plug, Shaft
Gasket
Valve, Intake
Valve, Exhaust
Spring, Valve - Set
Retainer, Spring
Cotter, Valve
29
CAM CHAIN ASSEMBLY
0743-702
1
2
3
4
5
30
3402-133
3402-134
3402-135
3423-074
3402-436
1
1
1
1
1
Chain, Cam
Guide, Chain
Tensioner, Chain
Bolt
Washer
6
7
8
9
3402-136
3402-137
3004-475
3003-290
1
1
2
2
Adjuster, Tensioner - Assembly
Gasket
Bolt
Gasket
RECOIL STARTER ASSEMBLY
0732-309
1
2
3
4
5
6
7
8
9
3445-003
3445-004
3445-005
3445-014
3445-007
3445-009
3445-010
3445-012
3445-008
1
1
1
1
1
1
1
1
1
Starter, Recoil - Assembly (inc. 2-12)
 Reel
 Ratchet
 Pin, Ratchet
 Spring, Spiral
 Spring, Friction
 Shaft
 Cover, Spring
 Plate, Friction
10
11
12
13
14
15
16
17
3445-006
3004-488
3445-011
3445-013
3423-112
3445-015
3004-491
3423-053
1
1
1
1
6
1
1
1
 Guide, Ratchet
 Nut
 Rope - Assembly
Gasket
Bolt
Cup, Starter
Nut
O-Ring
31
OIL FILTER/PUMP ASSEMBLY
0732-310
1
2
3
4
5
6
7
8
32
3402-153
3402-152
3423-046
3423-115
3423-184
3423-113
3402-156
3423-118
1
1
1
1
1
3
1
2
Pump, Engine Oil
Gear, Driven
Pin
Washer
Circlip
Screw, Cap
Strainer, Engine Oil
Screw, Cap
9
10
11
12
13
14
15
16
3402-157
3423-077
3004-756
3402-155
3402-036
3402-012
3402-154
3402-158
1
1
4
1
1
1
1
1
Cap, Oil Strainer
O-Ring
Bolt
Filter, Engine Oil
Plug, Drain
Gasket
Valve, Oil Relief - Assembly
Union, Oil Filter
WATER PUMP ASSEMBLY
0732-311
1
2
3
4
5
6
7
8
3402-159
3423-185
3003-188
3423-078
3004-507
3423-119
3413-003
3413-002
1
1
1
1
2
1
1
1
Case, Water Pump (inc. 2-3)
 Bolt
 Gasket
O-Ring
Bolt
Bolt
Joint, Pump Drive
Shaft, Water Pump w/Bearing
9
10
11
12
13
14
15
3423-046
3003-356
3003-466
3413-001
3003-426
3003-431
3003-432
1
1
1
1
1
1
1
Pin
Seal, Pump Drive
Seal, Mechanical
Impeller
Bolt
Washer
Gasket
33
CLUTCH ASSEMBLY
0732-312
1
2
3
4
5
6
7
8
9
10
11
12
13
14
34
3446-001
3446-003
3446-010
3423-081
3423-032
3423-122
3423-186
3446-002
3446-004
3423-079
3446-005
3446-006
3446-007
3446-008
1
1
1
1
1
1
1
1
1
4
4
6
5
1
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
Bolt, Clutch Spring
Spring, Clutch
Plate, Clutch Drive
Plate, Clutch Driven
Disk, Clutch Pressure
15
16
17
18
19
20
21
22
23
24
25
26
27
28
3446-009
3423-080
3423-032
3446-011
3423-082
3423-083
3446-012
3446-013
3423-125
3008-014
3423-022
3423-027
3402-186
3004-366
1
1
1
1
1
2
1
1
1
1
1
1
1
1
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)
TRANSMISSION ASSEMBLY
0732-313
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
3446-014
3446-016
3446-017
3446-018
3446-019
3446-020
3423-037
3402-049
3402-081
3423-066
3423-190
3402-179
3423-126
3423-187
3423-126
3446-015
3446-021
3446-022
3446-023
3446-024
3446-025
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
1
1
1
1
1
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
Washer, 4th Drive
Washer, Reverse Idle
Shaft, Drive
Gear, 1st Driven
Gear, 2nd Driven
Gear, 3rd Driven
Bushing, 3rd Driven
Gear, 4th Driven
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
3446-026
3446-029
3446-030
3446-032
3423-038
3423-039
3423-040
3402-053
3402-080
3402-082
3423-188
3402-079
3003-320
3423-129
3423-130
3423-131
3003-605
3423-189
3446-027
3446-028
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
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
35
SECONDARY TRANSMISSION ASSEMBLY
0732-314
1
2
3
4
5
6
7
8
9
36
3446-065
3446-066
3446-072
3423-150
3402-015
3446-070
3446-108
3423-036
3446-103
1
1
1
3
1
1
1
1
1
Shaft, Output
Gear, Idle
Gear, Driven
Washer
Spacer
Gear (No. 2)
Dog, Select Sliding
Washer (No. 1)
Bushing
10
11
12
13
14
15
16
17
18
3402-046
3402-047
3423-066
3423-202
3446-068
3423-148
3446-067
3446-259
3402-045
1
1
1
1
1
1
1
1
1
Bearing, Driveshaft - Left
Bearing, Center Shaft - Left
Circlip (No. 1)
Washer, Gear (No. 2)
Spacer
Spacer, Idle Gear
Gear (No. 1)
Spacer, Drive
Bearing Set - Left
SPEEDOMETER DRIVE ASSEMBLY
0732-459
1
2
3
4
5
6
7
8
9
10
11
3446-031
3402-009
3004-552
3402-077
3446-033
3446-035
3423-023
3423-032
3423-146
3446-062
3423-143
2
1
2
1
1
1
1
1
1
1
1
Retainer, Bearing
Washer, Driven
Screw, Retainer
Seal, Driven Gear
Gear
Shim Set
Nut
Washer
Washer - Right
Spacer, Driven Gear
Bolt, Gear
12
13
14
15
16
17
18
19
20
21
3423-145
3423-056
3423-144
3004-507
3402-055
3446-057
3446-058
3446-059
3446-060
3446-061
1
1
1
2
1
1
1
1
1
1
Washer
O-Ring
Washer
Bolt, Gear
Bearing Set - Right
Housing, Odometer Gear
Sleeve
Gasket
Gear, Drive
Gear, Driven
37
SECONDARY DRIVE ASSEMBLY
0732-315
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
38
3435-001
3435-029
3435-030
3423-035
3423-060
3435-002
3435-004
3435-005
3446-034
3446-036
3446-037
3435-003
3435-010
3423-026
3423-136
3423-028
3402-017
3402-018
3402-019
3402-020
3402-021
3402-022
3402-023
3402-024
3402-025
3402-028
3402-029
3402-030
3402-031
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
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. 28-33)
Nut, Rear Output Joint
Nut
Washer, Rear Output Flange
Shim - 0.60 mm
Shim - 0.65 mm
Shim - 0.70 mm
Shim - 0.75 mm
Shim - 0.80 mm
Shim - 0.85 mm
Shim - 0.90 mm
Shim - 0.95 mm
Shim - 1.00 mm
Shim - 1.05 mm
Shim - 1.10 mm
Shim - 1.15 mm
Shim - 1.20 mm
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
3402-062
3402-067
3435-011
3423-067
3402-072
3423-072
3423-137
3423-026
3004-552
8408-820
3435-066
3423-356
3423-210
3423-211
3435-067
3423-212
0402-950
1
2
1
4
2
1
1
1
1
4
1
1
1
1
1
1
1
Bearing w/Groove
Bearing w/Locating Ring and Pin
Joint Set, Universal (inc. 21)
 Circlip
Seal, Oil
Ring, Bearing
Washer
Nut, Yoke
Screw, Cap
Screw, Cap
Boot, Joint - Set (inc. 29-33)
 Seal, Plate
 Ring, Snap
 Band
 Boot
 Band
Flange, Output
GEAR SHIFTING ASSEMBLY
0732-316
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
3446-038
3446-039
3446-040
3446-052
3446-041
3423-114
3446-042
3446-049
3446-050
3402-014
3402-051
3004-376
3004-552
3423-135
3446-043
3446-044
3446-046
3446-047
3446-048
3402-012
3402-088
3423-141
2
1
1
2
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
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, Gear Shift Cam Plate
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
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
3423-142 1
3004-488 1
3446-053 1
3446-054 1
3446-056 1
3402-068 1
3402-076 1
3402-094 1
3446-055 1
3004-366 1
3423-168 1
3423-166 2
3530-007 1
3423-044 1
3423-059 1
3004-787 1
3004-761 1
3402-087 1
3402-008 1
3402-093 1
0706-990 AR
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
Contact, Neutral
O-Ring, Neutral
Clamp
Clamp
Spring
Hub, Gear Shift
Spring, Gear Shift
Tape, Foil
39
HI/LO SHIFTER ASSEMBLY
0732-317
1
2
3
4
5
6
7
8
9
10
11
12
13
14
40
3446-045
3446-046
3446-051
3446-073
3446-074
3446-075
3446-076
3446-077
3423-193
3446-078
3402-012
3402-071
3402-089
3004-377
1
1
1
1
1
2
1
1
1
1
1
1
1
2
Stopper, Driven Grear
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
15
16
17
18
19
20
21
22
23
24
25
26
27
3423-156
3423-157
3423-158
3423-191
3423-192
3446-079
3446-106
3423-152
3423-153
3446-107
3423-154
3423-155
3402-191
1
1
1
1
2
1
1
1
1
1
1
1
1
Screw, Shift Knob
Washer, Cam Stop
Washer, Shaft - Left
Circlip, Cam Spring
Circlip, Shift Lever
Lever, Shift - Assembly (inc. 21-26)
 Collar
 Washer
 E-Clip
 Spring
 Circlip
 Washer
Spacer
FRONT BEVEL GEAR ASSEMBLY
0732-318
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
3435-009
3435-029
3435-030
3423-034
3423-060
3435-014
3435-021
3435-022
3423-026
3423-028
3402-016
3402-066
3402-065
3423-064
3402-072
3423-175
3435-018
3435-017
3435-020
3402-059
3402-072
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
3402-185
3435-013
3402-057
3402-072
3435-024
3402-084
3435-025
3423-010
3402-012
3402-013
3402-036
3402-041
3423-183
3423-050
3423-061
3423-175
3423-070
3435-007
3423-182
3004-491
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
8
2
1
6
6
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
Bolt
Ring, Driveshaft - Front
Coupling, Propeller Shaft
Bolt
Nut
41
REAR BEVEL GEAR ASSEMBLY
0732-319
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
42
3435-051
3435-006
3435-008
3435-012
3435-015
3435-016
3435-019
3435-020
3435-065
3435-023
3435-026
3435-027
3435-028
3423-025
3423-029
3423-171
3003-290
3402-012
3402-036
3402-039
3402-052
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
3402-056
3402-059
3402-061
3423-049
3423-057
3423-065
3003-335
3435-048
3402-073
3402-074
3402-075
3004-786
3402-092
3004-279
3004-301
3423-175
3402-187
3004-333
3423-176
3423-194
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
9
1
2
4
1
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, Rear Left Case
Nut, Rear Final Housing
Circlip Set
STARTER MOTOR ASSEMBLY
0732-320
1
2
3
4
5
6
7
3545-001
3008-094
3008-095
3008-096
3008-164
3423-084
3436-001
1
1
1
4
1
1
1
Motor, Starter Assembly (inc. 2-9)
 Terminal Set, Brush
 Holder Set, Brush
 Spring, Brush
 O-Ring
 O-Ring
 Washer Set
8
9
10
11
12
13
3008-101
3423-085
3423-162
3423-195
3423-201
3402-043
2
2
2
1
1
1
 O-Ring
 Bolt
Bolt
Nut
Circlip
Bearing, Pinion Shaft
43
MAGNETO ASSEMBLY
0732-321
1
2
3
4
5
44
3430-011
3430-012
3423-162
0691-785
3423-086
1
1
3
1
1
Stator - Assembly
Rotor
Bolt, Magneto
Key, Magneto
Nut, Magneto
6
7
8
9
3423-005
3430-005
3430-006
3004-761
3
1
1
1
Bolt
Clamp, Magneto (No. 1)
ELECTRICAL COMPONENTS ASSEMBLY
0732-322 *Not Illustrated
1
2
3
4
5
6
7
3530-001
3423-020
3530-003
3530-004
3430-007
3430-008
3430-009
1
2
1
1
1
1
1
Relay, Starter Motor - Assembly
Bolt
CDI Unit
Coil, Ignition - Assembly
Cap, Spark Plug
Seal, Spark Plug
Seal, High Tension Cord
8
9
10
*
*
*
3530-008
8408-616
0630-098
8408-640
0107-630
8424-602
1
2
1
2
2
2
Relay, Neutral Start - Assembly
Screw, Cap
Fuse, 30 Amp
Bolt
Spacer, Fuel Pump
Nut, Hex
45
CONTROL SWITCH HOUSING ASSEMBLY
0732-323
1 3509-001
2 3409-009
3 3409-010
46
1
1
1
Switch, Handle - Assembly (inc. 2-5)
 Lever, Choke
 Cover, Choke
4 3423-196
5 3423-197
1
1
 Screw, Cap
 Screw, Cap
THROTTLE CASE ASSEMBLY
0732-324
1
2
3
4
5
3509-002
3409-001
3004-533
3004-447
3003-030
1
1
1
1
1
Case, Throttle - Assembly (inc. 2-9)
 Lever
 Bolt
 Washer, Lock
 Washer
6
7
8
9
3423-014
3423-198
3423-199
3004-638
1
1
2
1
 Screw, Cap
 Nut
 Screw, Cap
 Screw, Cap
47
Printed in U.S.A.
p/n 2255-464

ATV ILLUSTRATED PARTS MANUAL

Transcription

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