XRT 1500/Carryall 294

Transcription

2006
XRT 1500/Carryall 294
Illustrated Parts List
Gasoline and Diesel Vehicles
Manual Number 102907608
Edition Code 0307L0112K
USING THE ILLUSTRATED PARTS LIST
ý WARNING
• This manual is to be used only for identification and ordering of service parts. Be sure to read and use
the maintenance and service manual before attempting any vehicle repairs.
This manual covers all XRT 1500 and Carryall 294 vehicles.
The manual is divided into 15 sections. Sections 1 through 14 pertain to service parts for the vehicles, and Section
15 pertains to tools that are used on all Club Car products.
Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table
of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that
section. The index can be used to find specific parts and assemblies. The index is divided into numerical and
alphabetical listings with the page numbers in italic text.
There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an
illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon.
The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding
to the numbers on the illustration), part descriptions, and quantity of parts used.
Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the
numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented
to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level
2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part
quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A
part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of
the vehicle illustrated on that particular spread.
HOW TO ORDER PARTS
Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You
can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our
web site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts and
Technical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3887.
P. O. Box 204658
Augusta, Georgia 30917-4658 USA
Telephone 706-863-3000
Service Parts Fax 706-855-7413
www.clubcar.com
NOTE: This illustrated parts list represents the most current information at the time of publication. Club Car, Inc. is
continually working to further improve its vehicles and other products. These improvements may affect the
parts used to service the vehicle. Any modification and/or significant change in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of
this illustrated parts list.
Club Car, Inc. reserves the right to change specifications and designs at any time without notice and without
the obligation of making changes to units previously sold.
Copyright © 2007 Club Car, Inc.
Club Car is a registered trademark of Club Car, Inc.
This manual effective July 15, 2005.
2006 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List
CONTENTS
SECTION 1 – BODY AND TRIM
Front Body Trim, Gasoline Vehicles .........................................................................................................................................
1-3
Front Body Trim, Diesel Vehicles ..............................................................................................................................................
1-5
Front Body Components .............................................................................................................................................................
1-7
Front Seats and Cup Holder .......................................................................................................................................................
1-9
ROPS ....................................................................................................................................................................................................
1-11
Tilt Bed and Hinge ..........................................................................................................................................................................
1-13
Electric Bed Lift ................................................................................................................................................................................
1-15
Rear Body Trim ................................................................................................................................................................................
1-17
Cargo Box (Steel) ............................................................................................................................................................................
1-19
SECTION 2 – WHEELS AND TIRES
Wheels and Tires .............................................................................................................................................................................
2-3
SECTION 3 – DECALS
Safety Decals, Gasoline Vehicles ...............................................................................................................................................
3-3
Safety Decals, Gasoline Vehicles, Continued .......................................................................................................................
3-5
Safety Decals, Diesel Vehicles ....................................................................................................................................................
3-7
Safety Decals, Diesel Vehicles, Continued .............................................................................................................................
3-9
Badging Decals, XRT 1500 Vehicles .........................................................................................................................................
3-11
Badging Decals, Carryall 294 Vehicles ....................................................................................................................................
3-13
SECTION 4 – BRAKE SYSTEMS
Front Brake Assembly ...................................................................................................................................................................
4-3
Rear Brake Assembly .....................................................................................................................................................................
4-5
Master Cylinder ...............................................................................................................................................................................
4-7
Hydraulic Brake Lines and Clips ................................................................................................................................................
4-9
Park Brake Assembly with Pulley System ..............................................................................................................................
4-11
Park Brake Assembly with Bellcrank System ........................................................................................................................
4-13
SECTION 5 – PEDAL GROUP
Accelerator Pedal Assembly .......................................................................................................................................................
5-3
Brake Pedal Assembly ...................................................................................................................................................................
5-5
Park Brake Pedal Assembly .........................................................................................................................................................
5-7
Park Brake Pedal Assembly with Bellcrank System ............................................................................................................
5-9
Page 1
CONTENTS
SECTION 6 – STEERING AND SUSPENSION
Steering Column .............................................................................................................................................................................
6-3
Steering Gear Assembly ...............................................................................................................................................................
6-5
Front Suspension – A-Arms .........................................................................................................................................................
6-7
Front Suspension (Standard) ......................................................................................................................................................
6-9
Front Suspension (High-Capacity Option) .............................................................................................................................
6-11
Rear Suspension (Standard) ........................................................................................................................................................
6-13
Rear Suspension (High-Capacity Option) ...............................................................................................................................
6-15
SECTION 7 – ELECTRICAL SYSTEM
Wiring – Gasoline Vehicles ..........................................................................................................................................................
7-5
Wiring – Gasoline Vehicles ..........................................................................................................................................................
7-9
Wiring – Diesel Vehicles ................................................................................................................................................................
7-13
Headlights .........................................................................................................................................................................................
7-15
Electrical Component Box, Gasoline Vehicles ......................................................................................................................
7-17
Electrical Component Box, Diesel Vehicles ...........................................................................................................................
7-19
Electrical Components, Instrument Panel, Gasoline Vehicles ........................................................................................
7-21
Electrical Components, Instrument Panel, Diesel Vehicles ..............................................................................................
7-23
Battery – Gasoline Vehicles .........................................................................................................................................................
7-25
Battery – Diesel Vehicles ..............................................................................................................................................................
7-27
SECTION 8 – DIESEL ENGINE – CLOSED BREATHER
Kubota D722 Diesel Engine Mounting ....................................................................................................................................
8-3
Crankcase ...........................................................................................................................................................................................
8-5
Oil Pan .................................................................................................................................................................................................
8-7
Cylinder Head ...................................................................................................................................................................................
8-9
Gear Case ...........................................................................................................................................................................................
8-11
Head Cover ........................................................................................................................................................................................
8-13
Dipstick and Guide .........................................................................................................................................................................
8-15
Oil Pump .............................................................................................................................................................................................
8-17
Main Bearing Case ..........................................................................................................................................................................
8-19
Camshaft and Idle Gear ................................................................................................................................................................
8-21
Piston and Crankshaft ...................................................................................................................................................................
8-23
Flywheel .............................................................................................................................................................................................
8-25
Shaft .....................................................................................................................................................................................................
8-27
Idle Apparatus ..................................................................................................................................................................................
8-29
Stop Solenoid ...................................................................................................................................................................................
8-31
40-Amp Alternator .........................................................................................................................................................................
8-33
Page 2
CONTENTS
60-Amp Alternator .........................................................................................................................................................................
8-35
Injection Pump ................................................................................................................................................................................
8-37
Speed Control Plate .......................................................................................................................................................................
8-39
Nozzle Holders and Glow Plugs ................................................................................................................................................
8-41
Governor Components ................................................................................................................................................................
8-43
Starter .................................................................................................................................................................................................
8-45
Valves and Rocker Arms ...............................................................................................................................................................
8-47
Diesel Inlet Manifold .....................................................................................................................................................................
8-49
Exhaust Manifold ............................................................................................................................................................................
8-51
Gasket Kits .........................................................................................................................................................................................
8-53
Piston Kit ............................................................................................................................................................................................
8-55
SECTION 9 – HONDA GX620 GASOLINE ENGINE
Honda GX620 Gasoline Engine Mounting ............................................................................................................................
9-3
Shrouds and Brackets ...................................................................................................................................................................
9-5
Ignition Components and Flywheel ........................................................................................................................................
9-7
Oil Circulation ..................................................................................................................................................................................
9-9
Cylinder Head ..................................................................................................................................................................................
9-11
Crankcase and Crankshaft ...........................................................................................................................................................
9-13
Oil Filter Adapter and Voltage Regulator ..............................................................................................................................
9-15
SECTION 10 – FUEL, INTAKE, AND GOVERNOR SYSTEM
Fuel System – Gasoline Vehicles ...............................................................................................................................................
10-3
Fuel Tank – Gasoline Vehicles ....................................................................................................................................................
10-5
Fuel System – Diesel Vehicles ....................................................................................................................................................
10-7
Fuel Tank – Diesel Vehicles .........................................................................................................................................................
10-9
Carburetor Assembly, Honda Gasoline Vehicles .................................................................................................................
10-11
Carburetor Installation – Honda Gasoline Vehicles ...........................................................................................................
10-13
Governor and Accelerator Cables, Gasoline Vehicles .......................................................................................................
10-15
Choke Cable, Gasoline Vehicles ................................................................................................................................................
10-17
Accelerator Cable, Diesel Vehicles ...........................................................................................................................................
10-19
Governor Cover – Gasoline Vehicles .......................................................................................................................................
10-21
Governor System – Gasoline Vehicles ....................................................................................................................................
10-23
Intake Duct and Air Box Assembly – Honda Gasoline Vehicles .....................................................................................
10-25
Intake Duct and Air Box Assembly – Diesel Vehicles .........................................................................................................
10-27
SECTION 11 – EXHAUST SYSTEM
Exhaust System, Gasoline Vehicles ..........................................................................................................................................
11-3
Exhaust System, Diesel Vehicles ...............................................................................................................................................
11-5
Page 3
CONTENTS
SECTION 12 – CLUTCHES
Clutch Cover (Standard) ...............................................................................................................................................................
12-3
Clutch Cover (Sealed) ....................................................................................................................................................................
12-5
Drive Belt ............................................................................................................................................................................................
12-7
Drive Clutch – Gasoline Vehicles ...............................................................................................................................................
12-9
Drive Clutch – Diesel Vehicles ....................................................................................................................................................
12-11
Driven Clutch ....................................................................................................................................................................................
12-13
SECTION 13 – DRIVETRAIN COMPONENTS
Front Differential Mounting and Half Shafts .........................................................................................................................
13-3
Front Differential (Output Components) ...............................................................................................................................
13-5
Front Differential (Input Components) ...................................................................................................................................
13-7
Prop Shafts ........................................................................................................................................................................................
13-9
Forward/Reverse Shifter Assembly ..........................................................................................................................................
13-11
Transmission .....................................................................................................................................................................................
13-13
Transmission, Continued .............................................................................................................................................................
13-15
Transmission Shift Shaft and Bell CrankTransmission Shift Shaft and Bell Crank (Style A) ..................................
13-17
Transmission Shift Shaft and Bell Crank (Style B) ................................................................................................................
13-19
Transmission, Continued .............................................................................................................................................................
13-21
Transmission Cable ........................................................................................................................................................................
13-23
Rear Differential ...............................................................................................................................................................................
13-25
Rear Differential, Continued .......................................................................................................................................................
13-27
SECTION 14 – RADIATOR AND COOLANT SYSTEM (DIESEL VEHICLES)
Radiator ..............................................................................................................................................................................................
14-3
Coolant Expansion Tank ...............................................................................................................................................................
14-5
Coolant Pipes and Hoses ..............................................................................................................................................................
14-7
Water Flange and Thermostat ....................................................................................................................................................
14-9
Water Pump ......................................................................................................................................................................................
14-11
Block Coolant Pipe ..........................................................................................................................................................................
14-13
SECTION 15 – MAINTENANCE AND SERVICE TOOLS
Maintenance and Service Tools .................................................................................................................................................
15-3
Maintenance and Service Tools, Continued .........................................................................................................................
15-5
15-7
15-9
15-11
Page 4
CONTENTS
SECTION i – INDEX
Page 5
BODY AND TRIM
1
G
E
D
1
26
G
27
25
5
E
24
D
21
6
14 15 16 17 18
4
29
19
29
24
1
1
24
29
24
29
10
9
3
30
2
20
22
7
12
28
13
23
11
8
Page 1-2
000014-001
FRONT BODY TRIM, GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1014306
102021502
102021602
102021802
102045001
102048401
102289002
102298130
102410603
102418501
N/A
102429301
102432001
102459710
102459714
102459715
102459716
102459718
102477301
102491501
102492801
102617201
102618601
102628601
102760501
102760701
102760801
102778001
102967901
96715552
Washer, 1/4" Type B Flat ..........................................................................................................................
Fender, Left Front .......................................................................................................................................
Fender, Right Front ....................................................................................................................................
Dashboard with Access Hole .................................................................................................................
Cap, 1/4" Plastic Screw Head .................................................................................................................
Washer, 1/4 Id Scalloped Plast ...............................................................................................................
Screw, M8 X 1.25 X 30 Tri, Blk .................................................................................................................
Bolt, Flange Head, M8 X 30.0 .................................................................................................................
P-Clamp, Insulated .312 In ......................................................................................................................
Weldment, Support, ROPS ......................................................................................................................
Plate, Brush Mount ....................................................................................................................................
Grill, Flat .........................................................................................................................................................
Mat, Floor ......................................................................................................................................................
Cowl, Machined, Dark Green .................................................................................................................
Cowl, Machined, Dark Gray ....................................................................................................................
Cowl, Machined, Red ................................................................................................................................
Cowl, Machined, White ............................................................................................................................
Cowl, Machined, Camo ............................................................................................................................
Support, Access Panel, Dash ..................................................................................................................
Washer Hard,m10 ......................................................................................................................................
Rivet, .125" Dia, .311" Panel ....................................................................................................................
Nut Flg M10 X 1.5 Mech Def ..................................................................................................................
Lock Nut, Flg M8 X 1.25 Nylon ..............................................................................................................
Screw, 1/4-20 X 1.0 Pn Hd Torx ..............................................................................................................
Panel, Access, Dash ...................................................................................................................................
Cam Lock Body ...........................................................................................................................................
Latch, Cam, Access Panel ........................................................................................................................
Asm, Brush Guard ......................................................................................................................................
Rivet, Removable, Tuflok 1/4" ................................................................................................................
Bolt, M10 X 1.50 X 65 ................................................................................................................................
7
1
1
1
5
5
4
4
1
1
1
1
1
1
1
1
1
1
1
4
5
4
4
13
1
1
1
1
15
4
Page 1-3
1
G
E
D
1
25
G
26
24
5
E
23
20
D
6
13 14 15 16 17
4
29
18
29
23
1
1
23
29
23
10
9
3
30
2
19
21
7
28
27
12
22
11
8
Page 1-4
000014-002
FRONT BODY TRIM, DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1014306
102021502
102021602
102021802
102045001
102048401
102289002
102298130
102410603
102418501
N/A
102432001
102459710
102459714
102459715
102459716
102459718
102477301
102491501
102492801
102617201
102618601
102628601
102760501
102760701
102760801
102778001
102831601
102967901
8248
Fender, Left Front .......................................................................................................................................
Fender, Right Front ....................................................................................................................................
Dashboard with Access Hole .................................................................................................................
Cap, 1/4" Plastic Screw Head .................................................................................................................
Washer, 1/4 Id Scalloped Plast ...............................................................................................................
Screw, M8 X 1.25 X 30 Tri, Blk .................................................................................................................
Plate, Brush Mount ....................................................................................................................................
Mat, Floor ......................................................................................................................................................
Cowl, Machined, Dark Green .................................................................................................................
Cowl, Machined, Dark Gray ....................................................................................................................
Cowl, Machined, Red ................................................................................................................................
Cowl, Machined, White ............................................................................................................................
Cowl, Machined, Camo ............................................................................................................................
Support, Access Panel, Dash ..................................................................................................................
Washer Hard,m10 ......................................................................................................................................
Rivet, .125" Dia, .311" Panel ....................................................................................................................
Screw, 1/4-20 X 1.0 Pn Hd Torx ..............................................................................................................
Panel, Access, Dash ...................................................................................................................................
Cam Lock Body ...........................................................................................................................................
Latch, Cam, Access Panel ........................................................................................................................
Asm, Brush Guard ......................................................................................................................................
Guard, Radiator ...........................................................................................................................................
Screw, 1/4-20 X 0.75 Truss-Head Machine ........................................................................................
7
1
1
1
5
5
4
4
1
1
1
1
1
1
1
1
1
1
4
5
4
4
13
1
1
1
1
1
15
4
Page 1-5
1
G
E
D
1
G
E
D
9
2
9
8
6
3
7
4
5
6
7
1
7
000017-001
Page 1-6
FRONT BODY COMPONENTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
1016967
102289001
102373401
102437201
102491301
102491501
102617201
****
96715552
Blind Rivet, Push Type ..............................................................................................................................
Screw, M8X1.25X30, Hex .........................................................................................................................
Weldment, Dash, Front ............................................................................................................................
Guard, Splash ..............................................................................................................................................
Bolt, M10x1.50x100 (Black) ....................................................................................................................
Washer Hard,m10 ......................................................................................................................................
Bracket, Support, Steering ......................................................................................................................
Bolt, M10 X 1.50 X 65 ................................................................................................................................
8
1
1
1
4
7
11
1
7
**** Special order item available upon request.
Page 1-7
1
G
E
D
1
G
E
D
17
5
28
14
8
18
16
19
15
10
12
13
7
23
6
25
9
11
29
27
26
24
22
21
20
31
1
3
30
4
2
000028-001
Page 1-8
FRONT SEATS AND CUP HOLDER
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
1014471
102425401
102425501
102442001
102473701
1011652
102047001
102059401
102061101
102298130
102298401
102456001
102458901
102473501
102473601
102475901
103267001
451
N/A
1011652
1012830
1013734
102023703
102047001
102059401
102061101
102458901
103267001
451
102486201
102967901
Tape, Vinyl Foam 1/8" x 3/4" * ................................................................................................................
Closeout, Driver Side ................................................................................................................................
Closeout, Passenger Side ........................................................................................................................
Pan, Center, Closeout ................................................................................................................................
Asm, Bucket Seat Adjustable (includes items 6 through 18) .....................................................
Hinge Plate .............................................................................................................................................
Rivet, 1/4 X .438 Blind .........................................................................................................................
Screw, 6m-1.00 X 10mm Hex Head ................................................................................................
Seat Holder Cup ....................................................................................................................................
Bolt, Flange Head, M8 X 30.0 ............................................................................................................
Nut,m8,all Metal Lock .........................................................................................................................
Pan, Seat, Driver Asm ..........................................................................................................................
Decal, Hot Surface Warning ..............................................................................................................
Adjuster, Forward/Aft ..........................................................................................................................
Adjuster, Slider ......................................................................................................................................
Washer, Bell .............................................................................................................................................
Seat, Bucket, Gray .................................................................................................................................
Lockwasher, 1/4 Split ..........................................................................................................................
Assembly, Bucket Seat w/Spacers (includes items 20 through 29) .........................................
Hinge Plate .............................................................................................................................................
Screw, M8-125 X 22 Hex-Head .........................................................................................................
Lockwasher, 8mm Split ......................................................................................................................
Pan, Seat, Passenger ............................................................................................................................
Rivet, 1/4 X .438 Blind .........................................................................................................................
Screw, 6m-1.00 X 10mm Hex Head ................................................................................................
Seat Holder Cup ....................................................................................................................................
Decal, Hot Surface Warning ..............................................................................................................
Seat, Bucket, Gray .................................................................................................................................
Lockwasher, 1/4 Split ..........................................................................................................................
Console, Center, Drink Holder ...............................................................................................................
2
1
1
1
1
2
4
1
1
4
4
1
1
1
1
4
1
1
1
2
4
4
1
4
1
1
1
1
1
1
4
* Note: Item not shown.
Page 1-9
1
G
E
D
1
5
G
4
E
3
6
D
22
12
21
21
11
15
14
23
19
13
8
10
20
25
16
21
7
2
27
26
1
17
18
9
20
24
000029-001
Page 1-10
ROPS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
101887601
102059001
102418401
102459401
102621101
N/A
102418501
102447601
102447602
102482201
102419901
102420001
102718001
102718101
102718201
102491301
102491501
102617201
102670601
102671201
102718101
102718201
102732401
102739201
102886101
332
96742515
Locknut, M6-1.00 Nylon Insert ..............................................................................................................
Seat Holder Base ........................................................................................................................................
Weldment, Top, ROPS (includes items 4 through 6) ......................................................................
Decal, Young Driver Warning ...........................................................................................................
Decal, ROPS Certification/Warning ................................................................................................
Weldment, ROPS, Top, Unlabeled ...................................................................................................
Buckle, Seat Belt with Sleeve .................................................................................................................
Retractor, Seat Belt ....................................................................................................................................
Kit, ROPS (includes items 11 through 15) ..........................................................................................
Tube, Support, Front, ROPS ..............................................................................................................
Tube, Support, Rear, ROPS ................................................................................................................
Bolt, M10 X 55, Zn-Ni (Black) ............................................................................................................
Washer, Hard, M10, Zn-Ni/Blk ..........................................................................................................
Nut, Hex Cap, M10, Zn-Ni/Blk ...........................................................................................................
Bolt, M10x1.50x100 (Black) ....................................................................................................................
Washer Hard,m10 ......................................................................................................................................
Bracket, Seatbelt, Bolt-On .......................................................................................................................
Screw,m12x1.75x30 Thd Form Blk .......................................................................................................
Washer, Hard, M10, Zn-Ni/Blk ................................................................................................................
Nut, Hex Cap, M10, Zn-Ni/Blk ................................................................................................................
Bolt, M10 X 45, Zn-Ni (Black) ..................................................................................................................
Barrier, Heat, Neoprene ...........................................................................................................................
Weldment, Supp, Seat, Rops ..................................................................................................................
Washer, 1/4 Type A Narrow Flat ............................................................................................................
Bolt, M6 X 1 X 45 .........................................................................................................................................
2
2
1
1
1
1
1
2
2
1
2
2
8
16
8
4
4
4
1
4
8
2
2
1
1
2
2
Page 1-11
1
G
E
D
1
G
15
E
7
D
9
12
13
14
11
8
9.4’
15
10
19
18
3
2
1
3
16
4
5
17
000157-001
Page 1-12
TILT BED AND HINGE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1012303
1015356
1015583
102065901
102066001
102171504
1010435
1014471
1015258
N/A
1015399
102725801
102725901
7473
102614101
7561
8754
8755
Bushing, Steel ..............................................................................................................................................
Hinge ..............................................................................................................................................................
Bushing, Urethane .....................................................................................................................................
Locknut, 3/8-16 Flanged Dimple ..........................................................................................................
Washer, 3/8 Type B Hard Flat .................................................................................................................
Assembly, Tilt Bed, Electric Lift (includes items 7 through 14) ..................................................
Bolt, Carriage, 5/16-18 X 1.00 ...........................................................................................................
Tape, Vinyl Foam 1/8" x 3/4" * ..........................................................................................................
Plate, Floor Bed .....................................................................................................................................
Frame Assembly ....................................................................................................................................
Screw, 5/16-18 X 0.88 Torx Truss-Head .........................................................................................
Foam, Barrier, Heat, Bed, Frt .............................................................................................................
Foam, Barrier, Heat, Bed, Rail ............................................................................................................
Locknut, 5/16-18 Nylon Insert .........................................................................................................
Plate, Back .....................................................................................................................................................
Bolt, 3/8-16 X 3.00 Hex Head .................................................................................................................
Locknut, 3/8-16 Hex ..................................................................................................................................
Screw, 3/8-16 X 3.375 Hex Cap ..............................................................................................................
2
2
2
4
4
1
4
1
1
1
4
1
1
8
2
4
2
2
Page 1-13
1
G
E
D
1
G
1
15
6
6
E
D
7
6
10
9
8
14
14
4
6
14
6
15
3
5
2
13
13
15
14
5
2
8
11
12
16
000158-001
Page 1-14
ELECTRIC BED LIFT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1010200
1016603
1017162
1017167
1017774
102066001
102426601
102465701
102614101
102618601
102629001
102673901
357
8754
8755
8990
Bolt, 3/8-16 X 4.25 Hex Head .................................................................................................................
Bushing Long ..............................................................................................................................................
Actuator Assembly, Electric ....................................................................................................................
Actuator Adapter .......................................................................................................................................
Body Spacer .................................................................................................................................................
Washer, 3/8 Type B Hard Flat .................................................................................................................
Bumper, Bed, Mtg, Front ..........................................................................................................................
Weldment, Bracket, Actuator .................................................................................................................
Plate, Back .....................................................................................................................................................
Tie Wrap, 8.00" With Mount ....................................................................................................................
Wire Harness, Electric Lift ........................................................................................................................
Lockwasher, 3/8 Split ................................................................................................................................
Locknut, 3/8-16 Hex ..................................................................................................................................
Screw, 3/8-16 X 3.375 Hex Cap ..............................................................................................................
Tie Wrap, 8" Nylon .....................................................................................................................................
1
2
1
1
8
8
2
1
1
2
2
1
2
9
6
5
Page 1-15
1
G
E
D
1
G
5
E
D
10
7
12
3
11
4
11
13
11
14
9
8
14
2
1
6
2
14
000027-001
Page 1-16
REAR BODY TRIM
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1012769
1014306
1014321
101438702
102251601
102251701
102454001
102454101
102454201
102466201
102491701
102621501
102684501
8251
Screw, M6-1.00 X 25mm Hex Cap ........................................................................................................
Screw, #10 Truss-Head Torx ....................................................................................................................
Corner Cap AWD ........................................................................................................................................
Fender, Right Rear .....................................................................................................................................
Fender, Left Rear .........................................................................................................................................
Assembly, Panel (Passenger Side) ........................................................................................................
Assembly, Panel (Driver Side) ................................................................................................................
Panel, Front ..................................................................................................................................................
Bezel, Fuel Fill ..............................................................................................................................................
Well Nut 1/4-20 ...........................................................................................................................................
Nut Flg, M6 X 1.0 Nylon ...........................................................................................................................
Washer, M12 Hard Regular .....................................................................................................................
Screw, 1/4-20 X 1.0 Truss-Head Machine ...........................................................................................
2
8
2
2
1
1
1
1
1
1
14
2
2
14
Page 1-17
1
G
E
D
1
G
2
5
E
25
D
27
12
10
26
11
23
19
18
6
9
8
21
22
14
13
24
4
5
7
16
17
26
20
7
26
3
15
000038-001
Page 1-18
CARGO BOX (STEEL)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
N/A
1010435
1010436
1014306
1014415
1014537
1015399
101894304
101963401
102221301
102221401
102221501
102221701
102222001
102239901
102614401
1013366
1014415
N/A
102221801
102222101
102222201
102673201
8233
332
7473
8233
Instl, Steel Box, XRT (includes items 2 through 27) ........................................................................
Bolt, Carriage, 5/16-18 X 1.00 ...........................................................................................................
Bumper, Rubber ....................................................................................................................................
Washer, 1/4" Type B Flat .....................................................................................................................
Screw, 1/4-20 X 0.75 Torx Truss-Head ...........................................................................................
Stud, Self-Clinching Flush Head ......................................................................................................
Screw, 5/16-18 X 0.88 Torx Truss-Head .........................................................................................
Box Bed Tailgate Angle .......................................................................................................................
Locknut, 5/16-18 Hex Flange ...........................................................................................................
Front Panel Weldment ........................................................................................................................
Left Panel Weldment ...........................................................................................................................
Right Panel Weldment ........................................................................................................................
Front Corner Cap ..................................................................................................................................
Slam Latch ...............................................................................................................................................
Washer, Rubber, 3/8 .............................................................................................................................
Assembly, Tailgate (includes items 17 through 24) .................................................................
Hair Pin Clip ......................................................................................................................................
Screw, 1/4-20 X 0.75 Torx Truss-Head .....................................................................................
Tailgate, Weldment ........................................................................................................................
Tether Assembly .............................................................................................................................
Spring Latch Left ............................................................................................................................
Spring Latch Right .........................................................................................................................
Decal, Club Car Tailgate ...............................................................................................................
Locknut, 1/4-20 Nylon Insert .....................................................................................................
Washer, 1/4 Type A Narrow Flat ......................................................................................................
Locknut, 5/16-18 Nylon Insert .........................................................................................................
Locknut, 1/4-20 Nylon Insert ............................................................................................................
1
13
4
4
8
4
18
1
4
1
1
1
2
2
4
1
4
4
1
2
1
1
1
4
4
31
4
Page 1-19
1
G
E
D
1
G
E
D
WHEELS AND TIRES
2
G
E
D
2
G
E
D
8
7
5
6
4
1
3
2
17
16
15
13
14
12
11
9
10
000009-001
Page 2-2
WHEELS AND TIRES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
102021406
102021305
102374801
7310
102021407
102021302
102374801
7310
102021408
102021306
102374801
7310
102021409
102021306
102374801
7310
102736901
Gray Tire Assembly, HDAT, 8-Inch (includes items 2 through 4) ...............................................
HDAT Tire, 8" ...........................................................................................................................................
Wheel, Indus Spider, Gray ..................................................................................................................
Valve Stem ..............................................................................................................................................
Gray Tire Assembly, HDAT 10.5-Inch (includes items 6 through 8) ..........................................
Tire, HDAT ................................................................................................................................................
Valve Stem ..............................................................................................................................................
Gray Tire Assembly, AT489 LH (includes items 10 through 12) .................................................
Tire, AT489 ...............................................................................................................................................
Valve Stem ..............................................................................................................................................
Gray Tire Assembly, AT489 RH (includes items 14 through 16) .................................................
Tire, AT489 ...............................................................................................................................................
Valve Stem ..............................................................................................................................................
Nut, Lug, 1/2-20 SAE J2283 ....................................................................................................................
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
16
Page 2-3
2
G
E
D
2
G
E
D
DECALS
3
G
E
D
3
G
E
7
D
9
2
5
4
1
3
6
10
8
000005-001
Page 3-2
SAFETY DECALS, GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
1011553
101553901
101609401
102224001
102455201
102459301
102459401
102459601
102621101
102682301
Decal, Trailer Hitch .....................................................................................................................................
Decal, Bed Load Warning ........................................................................................................................
Decal, Crush Area Warning .....................................................................................................................
Decal, Rotating Parts Warning ..............................................................................................................
Decal, Instrument Panel Warning, Gasoline Vehicle .....................................................................
Decal, Bed Crush Area Warning ............................................................................................................
Decal, Young Driver Warning ................................................................................................................
Decal, Vehicle Loading, High-Capacity ..............................................................................................
Decal, ROPS Certification/Warning .....................................................................................................
Decal, Vehicle Loading, Standard Capacity ......................................................................................
1
1
2
1
1
1
1
1
1
1
Page 3-3
3
G
E
D
3
G
E
D
1
3
2
4
5
6
000006-001
Page 3-4
SAFETY DECALS, GASOLINE VEHICLES, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
101547601
102231601
102455001
102458901
102459101
102459501
Decal, Gasoline Explosion/Fire Warning ............................................................................................
Decal, Winch Cable Fracture Warning ................................................................................................
Decal, Operating Instructions, Gasoline ............................................................................................
Decal, Hot Surface Warning ...................................................................................................................
Decal, Frame Ground Warning ..............................................................................................................
Decal, Rotating Parts and Hot Exhaust Warning ............................................................................
1
1
1
3
1
1
Page 3-5
3
G
E
D
3
G
E
8
D
10
2
5
6
4
1
3
7
11
9
000005-002
Page 3-6
SAFETY DECALS, DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
1011553
101553901
101609401
102224001
102455301
102458801
102459301
102459401
102459601
102621101
102682301
Decal, Trailer Hitch .....................................................................................................................................
Decal, Bed Load Warning ........................................................................................................................
Decal, Crush Area Warning .....................................................................................................................
Decal, Warning, Diesel .............................................................................................................................
Decal, Diesel Fuel Only .............................................................................................................................
Decal, Bed Crush Area Warning ............................................................................................................
Decal, Young Driver Warning ................................................................................................................
Decal, Vehicle Loading, High-Capacity ..............................................................................................
Decal, ROPS Certification/Warning .....................................................................................................
Decal, Vehicle Loading, Standard Capacity ......................................................................................
1
1
2
1
1
1
1
1
1
1
1
Page 3-7
3
G
E
D
3
G
E
D
6
2
8
4
1
7
5
3
000006-002
Page 3-8
SAFETY DECALS, DIESEL VEHICLES, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
102231601
102455101
102458901
102459001
102459101
102459201
102459501
102460201
Decal, Winch Cable Fracture Warning ................................................................................................
Decal, Operating Instructions, Diesel .................................................................................................
Decal, Hot Manifold Warning ................................................................................................................
Decal, Frame Ground Warning ..............................................................................................................
Decal, Diesel Explosion/Fire Warning .................................................................................................
Decal, Rotating Parts and Hot Exhaust Warning ............................................................................
1
1
5
1
1
1
1
1
Page 3-9
3
G
E
D
3
G
E
D
1
5
2
3
7
4
6
000011-001
Page 3-10
BADGING DECALS, XRT 1500 VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102046501
102622701
102622801
102623301
102623501
102673201
102673301
Decal, CC Nameplate, Utility ..................................................................................................................
Decal, XRT 1500 (driver-side) .................................................................................................................
Decal, XRT 1500 (passenger-side) ........................................................................................................
Decal, 4x4 ......................................................................................................................................................
Decal, Diesel ................................................................................................................................................
Decal, Club Car Tailgate ...........................................................................................................................
Decal, High-Capacity (optional accessory) .......................................................................................
1
1
1
2
2
1
2
Page 3-11
3
G
E
D
3
G
E
D
1
5
2
3
7
4
6
000011-002
Page 3-12
BADGING DECALS, CARRYALL 294 VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102046501
102622901
102623001
102623301
102623501
102673201
102673301
Decal, CC Nameplate, Utility ..................................................................................................................
Decal, Carryall 294 (driver-side) ............................................................................................................
Decal, Carryall 294 (passenger-side) ...................................................................................................
Decal, 4x4 ......................................................................................................................................................
Decal, Diesel ................................................................................................................................................
Decal, Club Car Tailgate ...........................................................................................................................
Decal, High-Capacity (optional accessory) .......................................................................................
1
1
1
2
2
1
2
Page 3-13
3
G
E
D
3
G
E
D
BRAKE SYSTEMS
4
G
E
D
4
G
E
4
D
1
6
2
3
4
5
000067-001
Page 4-2
FRONT BRAKE ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102367601
102488001
102491601
102493301
102714001
103418801
Brake Caliper, Front, with Brake Pads ..................................................................................................
Bolt, Banjo, M10x1x19 ..............................................................................................................................
Washer, Copper, M10 Crush ...................................................................................................................
Bolt Flange Head, 3/8-24x.750 with Loctite .....................................................................................
Service Kit, Brake Pad (4 Pads) ...............................................................................................................
Pin, Slide, 7/16 .............................................................................................................................................
2
2
4
4
1
2
Page 4-3
4
G
E
D
4
G
2
E
5
1
D
5
8
6
4
3
000068-001
Page 4-4
REAR BRAKE ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
102399201
102399202
102488001
102491601
102493301
102714001
103418701
103418801
Caliper, Brake, Hydro-Mechanical, LH .................................................................................................
Caliper, Brake, Hydro-Mechanical, RH ................................................................................................
Bolt, Banjo, M10x1x19 ..............................................................................................................................
Washer, Copper, M10 Crush ...................................................................................................................
Bolt Flange Head, 3/8-24x.750 with Loctite .....................................................................................
Service Kit, Brake Pad (4 Pads) ...............................................................................................................
Spring, Brake Caliper, Return .................................................................................................................
Pin, Slide, 7/16 .............................................................................................................................................
1
1
2
4
4
1
1
2
Page 4-5
4
G
E
D
4
7
G
6
8
E
2
D
3
12
9
10
5
4
11
1
10
000069-001
Page 4-6
MASTER CYLINDER
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
101082903
1014306
101887601
102176901
102402801
102402901
102051401
N/A
102541465
102618401
102618601
102715701
Clevis Pin, 5/16 X 1 .....................................................................................................................................
Pin, Rue ..........................................................................................................................................................
Cylinder, Master, Tandem ........................................................................................................................
Assembly, Reservoir, Remote (includes items 7 and 8) ................................................................
Filler Cap Asm ........................................................................................................................................
Reservoir, Brake Fluid, Without Cap ...............................................................................................
Bolt, M 6 X 1.0 X 65 Hex, Flange, Head, Black ...................................................................................
Bolt Flanged Head, M8 X 1.25 X 35 ......................................................................................................
Line, Reservoir, Brake ................................................................................................................................
1
1
1
1
1
1
1
1
1
2
2
2
Page 4-7
4
G
E
D
4
G
E
3
D
8
9
4
2
10
2
4
1
15
6
5
11
4
14
12
7
13
000015-001
Page 4-8
HYDRAULIC BRAKE LINES AND CLIPS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
101887601
102296140
102296401
102296716
102407801
102407901
102410603
102474101
102474102
102474301
102475701
102689001
102689101
102689102
8639
Bolt, Flanged Head, M6x1.0x40 ............................................................................................................
Nut-m6x1.0 Flng All Mtl Lock ................................................................................................................
Screw, M6 X 16 Tt Hx Fl Hd .....................................................................................................................
Assembly, Brake Line, Rear .....................................................................................................................
Assembly, Brakeline, Front (includes item 7) ...................................................................................
P-Clamp, Insulated .312 In .................................................................................................................
Bracket, Brake Line, Left ...........................................................................................................................
Bracket, Brake Line, Right ........................................................................................................................
Bracket, Tee, Brakeline ..............................................................................................................................
Clip, Brake Line ............................................................................................................................................
Bracket, Line, Hydraulic ...........................................................................................................................
Brkt, Line, Hyd, Shk Mnt, Drv .................................................................................................................
Brkt, Line, Hyd, Shk Mnt, Pass ................................................................................................................
Tie Wrap, 11" Nylon ...................................................................................................................................
1
3
2
7
1
1
1
1
1
1
6
2
1
1
1
Page 4-9
4
G
E
D
4
G
3
2
17
2
E
17
6
D
3
6
10
18
15
16
9
11
8
5
12
4
14
1
13
7
000087-001
Page 4-10
PARK BRAKE ASSEMBLY WITH PULLEY SYSTEM
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1011779
1012438
101260202
1013531
101990802
102028302
102442701
102442801
102618301
102618601
102770001
1010521
102052801
102492401
102692801
1241
183
8639
E-Clip, 1/2 ......................................................................................................................................................
Locknut, #10-24 Nylon Insert ................................................................................................................
Screw, #10-24 X 3/4 Socket-Head ........................................................................................................
Spring, Brake Return .................................................................................................................................
Equalizer Bracket ........................................................................................................................................
Pulley, 2-Inch Flat Mount ........................................................................................................................
Cable, Brake, Parking, Left .......................................................................................................................
Cable, Brake, Parking, Right ....................................................................................................................
Brake Cable, Park, Kit, Front (includes items 12 through 16) .....................................................
Nut, 5/16-24 Hex ...................................................................................................................................
Nut, 5/16-24 Hex Cone .......................................................................................................................
Cable, Brake, Parking, Front ..............................................................................................................
Ring, Retaining, External, 9mm .......................................................................................................
Washer, 5/16 Type A Flat ....................................................................................................................
Washer, #10 Type A Flat ...........................................................................................................................
Tie Wrap, 11" Nylon ...................................................................................................................................
2
12
12
1
1
3
1
1
1
1
1
1
1
1
1
1
12
2
Page 4-11
4
G
E
D
4
G
E
6
D
1
13
5
14
4
12
3
2
10
11
7
8
000533-003
Page 4-12
PARK BRAKE ASSEMBLY WITH BELLCRANK SYSTEM
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1011779
1013531
101990802
102618301
102618601
102712601
102763301
102763401
102770301
1010521
102052801
102712701
1035
8639
E-Clip, 1/2 ......................................................................................................................................................
Spring, Brake Return .................................................................................................................................
Equalizer Bracket ........................................................................................................................................
Cable, Crank, Bell, Front ...........................................................................................................................
Cable, Noncoated, Pbrake, Left .............................................................................................................
Cable, Noncoated, Pbrake, Rght ...........................................................................................................
Kit, Cable, Brake, Crank, Fr (includes items 10 through 13) ........................................................
Nut, 5/16-24 Hex ...................................................................................................................................
Nut, 5/16-24 Hex Cone .......................................................................................................................
Cable, Crank, Bell, Main ......................................................................................................................
Cotter Pin, 3/32 x 1 ...............................................................................................................................
Tie Wrap, 11" Nylon ...................................................................................................................................
2
1
1
1
1
1
1
1
1
1
1
1
1
2
Page 4-13
4
G
E
D
4
G
E
D
PEDAL GROUP
5
G
E
D
5
G
E
D
2
6
2
7
18
18
5
19
11
12
9
16
3
17
8
4
10
15
4
19
13
14
000026-001
Page 5-2
ACCELERATOR PEDAL ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102489901
102296401
N/A
102442901
102445201
N/A
N/A
N/A
102469401
N/A
102476301
102476401
102479301
N/A
102618101
103273101
96706825
102618301
102618601
Asm, Pedal, Accelerator (includes items 2 through 17) ................................................................
Nut-m6x1.0 Flng All Mtl Lock ...........................................................................................................
Pullrod, Spring, Compression ...........................................................................................................
Bushing, Greaseless .............................................................................................................................
Spring, Comp, Pedal, Pullrod ............................................................................................................
Washer, Retaining Spring, 7mm ......................................................................................................
Guide, Cable, Accelerator ..................................................................................................................
Weldment, Bracket, Pedal ..................................................................................................................
Weldment, Lever, Motion, Lost ........................................................................................................
Spring, Torsion .......................................................................................................................................
Spring, Stop, Pedal ...............................................................................................................................
Bolt, Stop, Pedal ....................................................................................................................................
Pad, Grip Tape, Accelerator ...............................................................................................................
Weldment, Pedal, Accel ......................................................................................................................
Nut M6x1 Mech Def Center ..............................................................................................................
Bolt, Shoulder, M8 X 70, Hc ...............................................................................................................
Bolt, M6 X 1 X 70 ...................................................................................................................................
1
3
1
4
1
2
1
1
1
1
1
1
1
1
1
1
2
2
2
Page 5-3
5
G
E
D
5
G
E
D
4
3
8
2
1
6
5
7
000088-001
Page 5-4
BRAKE PEDAL ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
102380601
102618101
102618301
102618601
N/A
102442901
102626201
103273101
Bracket, Pedal, Brake .................................................................................................................................
Nut M6x1 Mech Def Center ....................................................................................................................
Asm, Pedal, Brake, Hung (includes items 6 and 7) .........................................................................
Bushing, Greaseless .............................................................................................................................
Weldment, Pedal, Brake, Hung ........................................................................................................
Bolt, Shoulder, M8 X 70, Hc ....................................................................................................................
1
1
2
2
1
2
1
1
Page 5-5
5
G
E
D
5
1
G
2
E
3
D
4
5
8
6
7
000086-001
Page 5-6
PARK BRAKE PEDAL ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
102438101
102758701
N/A
102618301
102618601
102892401
N/A
102896601
Pedal Asm, Brake, Park (includes items 2 and 3) .............................................................................
Kit, Handle, Brake, Park .......................................................................................................................
Pedal, Brake, Park ..................................................................................................................................
Asm, Pedal, Brake, Hard (includes items 7 and 8) ...........................................................................
Pedal, Brake, Park ..................................................................................................................................
Handle, Release, Park Brake ..............................................................................................................
1
1
1
3
3
1
1
1
Note: Item 1 has been discontinued. Use item 6 for replacement of the
complete assembly.
Page 5-7
5
G
E
D
5
13
10
G
E
D
11
9
15
8
18
16
17
1
2
12
3
14
15
4
7
5
000086-003
Page 5-8
PARK BRAKE PEDAL ASSEMBLY WITH BELLCRANK SYSTEM
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
102438101
102758701
N/A
102618301
102618601
102751501
102323501
102716001
102741501
102741601
102751301
102751401
103305001
103305101
1035
102892401
N/A
102896601
Pedal Asm, Brake, Park (includes items 2 and 3) .............................................................................
Kit, Handle, Brake, Park .......................................................................................................................
Pedal, Brake, Park ..................................................................................................................................
Asm, Sub, Bracket, Park Brake (includes items 7 through 15) ....................................................
Washer, Flat, 3/8, Blk Fin .....................................................................................................................
Cable, Crank, Bell ..................................................................................................................................
Bolt Flg, M8x1.25 X 35, Gr10.9 .........................................................................................................
Nut Flg M8 X 1.25 Gr 10 ......................................................................................................................
Asm, Bellcrank, Upper .........................................................................................................................
Asm, Bellcrank, Lower .........................................................................................................................
Brkt, Bellcrank, Prk Brk, Awd .............................................................................................................
Spacer, Pivot, Park Brk, Awd ..............................................................................................................
Cotter Pin, 3/32 x 1 ...............................................................................................................................
Asm, Pedal, Brake, Hard (includes items 17 and 18) ......................................................................
Pedal, Brake, Park ..................................................................................................................................
Handle, Release, Park Brake ..............................................................................................................
1
1
1
3
3
1
2
1
2
2
1
1
1
2
2
1
1
1
Note: Item 1 has been discontinued. Use item 16 for replacement of the
complete assembly.
Page 5-9
5
G
E
D
5
G
E
D
STEERING AND SUSPENSION
6
G
E
D
6
G
E
9
D
1
3
10
2
6
8
5
4
7
000070-001
Page 6-2
STEERING COLUMN
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
102290120
102298130
102363802
102364201
102298130
102571301
102676801
N/A
102367101
102618601
Bolt, M10 X 20 Hex Washer Hd ..............................................................................................................
Steering Wheel, Viper, Hex Hub ............................................................................................................
Steering Column (includes items 5 through 8) ...............................................................................
Shroud, Steering Column ..................................................................................................................
Knuckle, Steering, Slider ....................................................................................................................
Column, Steering without Knuckle and Shroud .......................................................................
Cap, Steering Wheel, Viper .....................................................................................................................
1
1
1
1
1
1
1
1
1
3
Page 6-3
6
G
E
D
6
G
E
2
18
3
4
11
6
7
8
13
15
16
9
10
5
14
12
D
22
17
21
1
19
20
000071-002
Page 6-4
STEERING GEAR ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1013042
102010102
1013035
1013042
1013044
1013051
1013052
101879401
101879701
101879801
101879901
101880201
N/A
N/A
N/A
N/A
N/A
8990
102022601
102022901
102449901
102687801
Nut, 12mm Hex ...........................................................................................................................................
Steering Rack (includes items 3 through 18) ...................................................................................
Bellows, Long .........................................................................................................................................
Nut, 12mm Hex .....................................................................................................................................
Rack Screw Locknut .............................................................................................................................
Snap Ring ................................................................................................................................................
Seal, Steering Pinion Dust .................................................................................................................
Bearing, Ball ............................................................................................................................................
Support Yoke .........................................................................................................................................
Rack Guide Pressure Spring ..............................................................................................................
Ring, Stop, C-Type ................................................................................................................................
Inner Ball Joint Asm .............................................................................................................................
Pinion, Steering .....................................................................................................................................
Bearing, Lower Pinion .........................................................................................................................
Screw, Rack Guide ................................................................................................................................
Housing, Steering Gear ......................................................................................................................
Rack, Steering ........................................................................................................................................
Tie Wrap, 8" Nylon ................................................................................................................................
End, Tie Rod M12 X 1.25 Rh ....................................................................................................................
Locknut, M12-1.25 Nylon ........................................................................................................................
Link, Drag ......................................................................................................................................................
Bolt, Flange Head, M10x 1.5 X 40 with Loctite ................................................................................
2
1
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
2
2
2
2
4
Page 6-5
6
G
E
D
6
9
G
E
12
15
13
11
14
10
24
2
22
D
7
3
4
6
8
5
17
24
22
24
16
24
1
23
20
24
24
1
23
18
20
19
25
19
21
21
000074-001
Page 6-6
FRONT SUSPENSION – A-ARMS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
102022901
102368501
102296140
102296401
102361901
102368801
102474101
102722301
102368502
102296140
102296401
102361901
102368802
102474102
102722301
102408401
102437001
102437101
102446901
102469901
102490801
102616301
102617701
102620501
103256701
Locknut, M12-1.25 Nylon ........................................................................................................................
Sub-assembly, A-Arm, Upper, LH (includes items 3 through 8) ................................................
Bolt, Flanged Head, M6x1.0x40 .......................................................................................................
Joint, Ball .................................................................................................................................................
A-Arm, Upper, Left ...............................................................................................................................
Bracket, Brake Line, Left .....................................................................................................................
Ring, Retaining, Ext, 1-1/4" ................................................................................................................
Sub-assembly, A-Arm, Upper, RH (includes items 10 through 15) ...........................................
Bolt, Flanged Head, M6x1.0x40 .......................................................................................................
Joint, Ball .................................................................................................................................................
A-Arm, Upper, Right ............................................................................................................................
Bracket, Brake Line, Right ..................................................................................................................
Ring, Retaining, Ext, 1-1/4" ................................................................................................................
Bushing, A-Arm ...........................................................................................................................................
Sleeve, Upper ..............................................................................................................................................
Sleeve, Lower ...............................................................................................................................................
Arm, Lower ...................................................................................................................................................
Bushing, Lower Arm ..................................................................................................................................
Bolt, Flange Head, M12x 1.75x 30 with Loctite ...............................................................................
Bolt, Flange Head, M12 X 1.75 X 70 .....................................................................................................
Nut, Square, M12x 1.75 ............................................................................................................................
Nut Flg, M12x1.75, Nylon Gr 10 ............................................................................................................
Bolt Flg, M12 X 1.75 X 200 10. ................................................................................................................
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
4
2
2
4
4
4
4
6
2
Page 6-7
6
G
E
D
6
G
E
D
5
3
2
1
4
000072-001
Page 6-8
FRONT SUSPENSION (STANDARD)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
102298240
102394002
102616301
102618601
102620501
Bolt, Flange Head, M8-1.25 X 40 ...........................................................................................................
Shock, Coil Over, Front Hd ......................................................................................................................
4
2
2
4
2
Page 6-9
6
G
E
D
6
5
G
18
8
7
E
13
14
D
2
16
1
17
11
4
9
8
11
10
9
11
15
12
6
4
14
-
15
3
000072-002
Page 6-10
FRONT SUSPENSION (HIGH-CAPACITY OPTION)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
102298240
102394002
102468802
1016183
102298130
102298240
102446601
102464601
102470101
102470501
102470601
102477201
102495001
102618601
8754
102616301
102618601
102620501
Bolt, Flange Head, M8-1.25 X 40 ...........................................................................................................
Shock, Coil Over, Front Hd ......................................................................................................................
Kit, Anti-Sway Bar (includes items 4 through 15) ...........................................................................
Screw, 3/8-16 X 7.00 Hex Cap ...........................................................................................................
Bolt, Flange Head, M8-1.25 X 40 .....................................................................................................
Bushing, Anti-Sway Bar, 1-1/8 ..........................................................................................................
Bar, Sway, Formed ................................................................................................................................
Bushing, Link ..........................................................................................................................................
Sleeve, Link .............................................................................................................................................
Washer, Cup, Bushing .........................................................................................................................
Mount, Link .............................................................................................................................................
Bracket, Anti-Sway Bar ........................................................................................................................
Lock Nut, Flg M8 X 1.25 Nylon .........................................................................................................
Locknut, 3/8-16 Hex ............................................................................................................................
4
2
1
2
4
4
2
1
8
2
8
2
2
8
2
2
4
2
Page 6-11
6
G
E
D
6
G
E
D
12
13
1
14
7
18
9
10
7
4
8
9
11
6
14
3
5
15
4
16
17
7
2
000031-001
Page 6-12
REAR SUSPENSION (STANDARD)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1015597
102365601
102393501
102616301
102619801
102620401
102620501
N/A
102398901
102477001
103282301
102682701
102682901
102684501
102685601
102689101
102689102
102737101
Fitting, 1/4-28 Thread-Forming Grease ..............................................................................................
Shock, Coil Over Rear ...............................................................................................................................
Weldment, Receiver, Rear .......................................................................................................................
Washer, Strip, Swingarm ..........................................................................................................................
Bolt Flanged Head, M12 X 1.75 X 50 ...................................................................................................
Sub Asm Swingarm (includes items 9 through 11) .......................................................................
Bushing, Pivot, Urethane ...................................................................................................................
Bushing, Teflon ......................................................................................................................................
Swingarm, Rear, Awd ..........................................................................................................................
Insert, Flanged, H-Bracket .......................................................................................................................
Pin, Swingarm, Weldment ......................................................................................................................
Nut Flg M12 X 1.75 Cl10 ..........................................................................................................................
Cotter, Rue Ring, 1/2" ................................................................................................................................
2
2
1
4
2
8
6
2
2
2
1
4
2
10
8
1
1
2
Page 6-13
6
G
E
D
6
G
E
D
12
13
1
14
7
18
9
10
7
4
8
9
11
6
14
3
5
15
4
16
17
7
2
000031-001
Page 6-14
REAR SUSPENSION (HIGH-CAPACITY OPTION)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1015597
102365602
102393501
102616301
102619801
102620401
102620501
N/A
102398901
102477001
103282301
102682701
102682901
102684501
102685601
102689101
102689102
102737101
Fitting, 1/4-28 Thread-Forming Grease ..............................................................................................
Shock, Coil Over, Rear HD .......................................................................................................................
Weldment, Receiver, Rear .......................................................................................................................
Washer, Strip, Swingarm ..........................................................................................................................
Bolt Flanged Head, M12 X 1.75 X 50 ...................................................................................................
Sub Asm Swingarm (includes items 9 through 11) .......................................................................
Bushing, Pivot, Urethane ...................................................................................................................
Bushing, Teflon ......................................................................................................................................
Swingarm, Rear, Awd ..........................................................................................................................
Insert, Flanged, H-Bracket .......................................................................................................................
Pin, Swingarm, Weldment ......................................................................................................................
Nut Flg M12 X 1.75 Cl10 ..........................................................................................................................
Cotter, Rue Ring, 1/2" ................................................................................................................................
2
2
1
4
2
8
6
2
2
2
1
4
2
10
8
1
1
2
Page 6-15
6
G
E
D
6
G
E
D
ELECTRICAL SYSTEM
7
G
E
D
7
G
E
16_BRN(W05)
LIGHT SWITCH
BRAKE SWITCH
D
14_YEL(W07)
16_BLU(W03)
16_BLU(W01)
16_BLU(W09)
14_YEL(W76)
16_BLU(W04)
BUZZER
18_RED_WHT_STP(W16)
16_BLK(W13)
18_BLK(W15)
REVERSE SWITCH
OIL LIGHT
1
2
18_BLU(W53)
18_PUR(W49)
FUEL/HR METER
18_RED(W59)
16_BLK(W14)
18_BLK_WHT_STP(W17)
18_ORG(W20)
18_BLK(W22)
3
18_WHT(W18)
4
18_BLK(W21)
18_BLK(W23)
18_BLK(W24)
DIODE 2
18_BLK(W31)
18_BLK(W32)
18_YEL(W40)
18_YEL(W41)
KEY SWITCH
MM+
DIODE 1
S
L
DIODE 3
18_PUR(W48)
18_YEL(W45)
16_GRN(W43)
18_PUR(W47)
16_RED(W37)
B
18_PINK(W63)
START RELAY
18_GRAY(W34)
16_BLK(W36)
FRONT DIFFERENTIAL
18_GRAY(W35)
NC
NO
18_LHT_GRN(W44)
18_BLK(W60)
18_PUR(W51)
DIFF RELAY
18_GRAY(W33)
NC
NO
18_PUR(W50)
14_RED(W66)
ACC RELAY
18_BLK(W61)
18_PUR(W52)
POWER POINT
NC
NO
14_RED(W74)
18_BLK(W62)
16_ORG_WHT_STP(W46)
DIODE 4
18_BLK(W64)
18_BLK(W65)
DIODE 5
12_BLK(W75)
000001-002
Page 7-2
7
16_PINK(W68)
18_YEL(W10)
18_RED(W77)
18_RED(W78)
18_WHT(W11)
BRK
RIGHT
LEFT
TL
GND
16_PINK(W06)
18_RED(W83)
16_YEL(W12)
G
E
FUEL SOLENOID
18_YEL(W55)
18_BLK(W21)
STATOR
18_YEL(W39)
16_BLK(W67)
18_YEL(W54)
14_BLU(W25)
14_BLU(W26)
14_RED(W27)
14_BLK(W69)
14_RED(W28)
FUEL SENDER
14_BLU(W08)
D
REGULATOR
WHT
WHT/BLU
BLK/YEL
BLK
GRAY
GRAY
OIL PRESSURE SWITCH
16_BLK_WHT_STP(W79)
16_BLK_WHT_STP(W19)
18_WHT_BLK_STP(W38)
IG
14_RED
16_RED(W30)
10_RED(W73)
16_GRN(W42)
16_GRN(W58)
STARTER
DIODE 7
18_BLK(W70)
6_RED(W80)
18_BLK(W71)
6_BLK(W81)
ENGINE GROUND
6_BLK(W82)
14_RED(W29)
DIODE 6
18_GRN(W57)
-
+
12_BLK(W72)
FRAME GROUND
14_RED
20A
10A
CIRCUIT BREAKER
5A
25A
18_BLK(W56)
BED LIFT SWITCH
NEUTRAL SWITCH
14_RED
14_RED
14_YEL
14_BLK
14_RED
14_RED
BED LIFT
MOTOR
18_BLK_WHT_STP(W02)
14_YEL
000001-002
Page 7-3
7
G
E
D
See previous two pages for illustration.
Page 7-4
WIRING – GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
102435301
Wire Harness, Awd, Gas ...........................................................................................................................
1
7
G
E
D
Page 7-5
7
G
E
16_BRN(W05)
LIGHT SWITCH
BRAKE SWITCH
D
14_YEL(W07)
16_BLU(W03)
16_BLU(W01)
16_BLU(W09)
14_YEL(W76)
16_BLU(W04)
BUZZER
18_RED_WHT_STP(W16)
16_BLK(W13)
18_BLK(W15)
REVERSE SWITCH
OIL LIGHT
1
2
18_BLU(W53)
18_PUR(W49)
FUEL/HR METER
18_RED(W59)
16_BLK(W14)
18_BLK_WHT_STP(W17)
18_ORG(W20)
18_BLK(W22)
3
18_WHT(W18)
4
18_BLK(W21)
18_BLK(W23)
18_BLK(W24)
DIODE 2
18_BLK(W31)
18_BLK(W32)
18_YEL(W40)
18_YEL(W41)
KEY SWITCH
MM+
DIODE 1
S
L
DIODE 3
18_PUR(W48)
18_YEL(W45)
16_GRN(W43)
16_PUR_WHT(W27)
16_PUR(W47)
16_RED(W37)
B
18_PINK(W63)
START RELAY
18_GRAY(W34)
16_BLK(W36)
FRONT DIFFERENTIAL
18_GRAY(W35)
NC
NO
18_LHT_GRN(W44)
18_BLK(W60)
18_PUR(W51)
DIFF RELAY
18_GRAY(W33)
NC
NO
18_PUR(W50)
14_RED(W66)
ACC RELAY
18_BLK(W61)
18_PUR(W52)
POWER POINT
NC
NO
14_RED(W74)
18_BLK(W62)
16_ORG_WHT_STP(W46)
DIODE 4
18_BLK(W64)
18_BLK(W65)
DIODE 5
12_BLK(W75)
000001-002
Page 7-6
7
16_PINK(W68)
18_YEL(W10)
18_RED(W77)
18_RED(W78)
18_WHT(W11)
BRK
RIGHT
LEFT
TL
GND
16_PINK(W06)
18_RED(W83)
16_YEL(W12)
G
E
FUEL SOLENOID
18_YEL(W55)
18_BLK(W21)
STATOR
18_YEL(W39)
16_BLK(W67)
18_YEL(W54)
14_BLU(W25)
14_BLU(W26)
14_BLK(W69)
14_RED(W28)
16_PUR_WHT(W27)
FUEL SENDER
14_BLU(W08)
D
REGULATOR
WHT
WHT/BLU
BLK/YEL
BLK
GRAY
GRAY
OIL PRESSURE SWITCH
16_BLK_WHT_STP(W79)
16_BLK_WHT_STP(W19)
18_WHT_BLK_STP(W38)
IG
16_RED(W30)
14_RED
10_RED(W73)
16_GRN(W42)
16_GRN(W58)
STARTER
DIODE 7
18_BLK(W70)
6_RED(W80)
18_BLK(W71)
6_BLK(W81)
ENGINE GROUND
6_BLK(W82)
14_RED(W29)
DIODE 6
18_GRN(W57)
-
+
12_BLK(W72)
FRAME GROUND
14_RED
20A
10A
CIRCUIT BREAKER
5A
25A
18_BLK(W56)
BED LIFT SWITCH
NEUTRAL SWITCH
14_RED
14_RED
14_YEL
14_BLK
14_RED
14_RED
BED LIFT
MOTOR
18_BLK_WHT_STP(W02)
14_YEL
000001-003
Page 7-7
7
G
E
D
Page 7-8
WIRING – GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
102435301
Wire Harness, Awd, Gas ...........................................................................................................................
1
7
G
E
D
Page 7-9
7
G
18_BRN(W77)
E
16_BRN_WHT_STP(W67)
D
16_BRN(W05)
LIGHT SWITCH
BRAKE SWITCH
16_BLU(W03)
16_BLU(W01)
14_YEL(W07)
16_BLU(W09)
14_YEL(W68)
BUZZER
18_RED_WHT_STP(W16)
18_ORG(W20)
16_BLK(W13)
REVERSE SWITCH
16_BLU(W04)
WATER TEMP LIGHT
18_GRN_WHT_STP(W38)
18_PUR(W30)
18_BLK(W15)
18_BLK_WHT_STP(W17)
18_PUR(W49)
FUEL/HR METER
1
2
18_RED(W59)
16_BLK(W14)
OIL LIGHT
18_BLU(W53)
18_BLK(W22)
3
18_WHT(W18)
4
18_BLK(W21)
18_BLK(W55)
Diode 1
KEY SWITCH
B+
Diode 2
12_BLU(W27)
ST
16_BLK(W36)
FRONT DIFFERENTIAL
12_RED(W25)
12_BLU(W26)
IG1
IG2
18_GRAY(W35)
14_BLK(W71)
AC
18_PUR(W29)
16_RED_WHT_STP(W37)
18_BLK(W32)
18_BLK(W31)
18_BLK(W23)
18_RED(W24)
PR
18_LHT_GRN(W44)
GR
18_GRAY(W33)
18_GRAY(W34)
FAN
14_BLU(W69)
18_BLK(W60)
14_BLU(W66)
16_ORG_WHT_STP(W46)
18_BLK(W61)
18_BLU(W56)
POWER POINT
Diode 3
12_BLK(W84)
Diode 4
000002-002
Page 7-10
7
16_PINK(W51)
18_RED(W88)
18_RED(W87)
G
BRK
18_YEL(W10)
RIGHT
18_WHT(W11)
LEFT
18_RED(W89)
LIGHT
THERMOSTAT
GND
16_PINK(W06)
16_YEL(W12)
E
THERMOSTAT
TAIL
18_YEL_BLK_STP(W39)
D
FAN
GLOW PLUG
14_BLU(W08)
FUEL PUMP
18_GRAY(W40)
FUEL SENDER
FUEL SOLENOID
HOLD COIL
FUEL SOLENOID
PULL COIL
FUEL SOLENOID COMMON
OIL PRESSURE SWITCH
14_BLK(W54)
18_GRAY(W41)
10_RED(W47)
14_BLU(W43)
16_BLK_WHT_STP(W90)
16_BLK_WHT_STP(W19)
ALTERNATOR
B+
IG
L
12_BLU(W28)
18_PUR(W48)
16_BLK(W63)
50A BREAKER
18_ORG(W83)
10_RED(W45)
16_GRN(W42)
16_GRN(W58)
18_GRAY(W52)
STARTER
18_GRN(W57)
18_PUR_WHT(W80)
NC
NO
16_GRN_WHT_STP(W76)
ENGINE
GROUND
14_RED
18_BLK(W82)
DIFF RELAY
6_BLK(W92)
NC
NO
18_BLK(W70)
START RELAY
6_BLK(W93)
10_RED(W73)
12_RED(W02)
Diode 6
Diode 5
18_YEL(W81)
6_RED(W91)
18_PUR(W50)
__
+
14_YEL(W74)
NC
NO
14_YEL(W75)
20A
30A
5A
30A
12_BLK(W72)
FAN RELAY
14_RED
CIRCUIT BREAKER
14_RED(W86)
18_BLK(W78)
ACC RELAY
NC
NO
14_RED(W85)
FRAME
GROUND
14_RED
14_RED
14_YEL
14_BLK
18_BLK(W62)
BED LIFT
MOTOR
14_RED
18_BLK(W64)
18_BLK(W65)
NEUTRAL SWITCH
18_BLK_WHT_STP(W79)
14_RED
BED LIFT SWITCH
14_YEL
000002-002
Page 7-11
7
G
E
D
Page 7-12
WIRING – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
102444201
Wire Harness, Awd, Diesel .......................................................................................................................
1
7
G
E
D
Page 7-13
7
G
E
D
11
14
15
13
20
17
12
19
18
16
1
6
3
5
7
2
9
4
8
10
000073-001
Page 7-14
HEADLIGHTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
101988001
1013461
1016880
1017
1017062
1017064
1017065
101987901
101988101
101988201
101988002
1013461
1016879
1017
1017062
1017064
1017065
101987901
101988101
101988201
Headlight Assembly, Driver-Side Single Beam (includes items 2 through 10) ....................
Screw, #10-16 Hex-Head Hi-Lo ........................................................................................................
Headlight Bezel, Left ...........................................................................................................................
Nut, #10-24 Stainless-Steel Hex Machine ....................................................................................
Turn Signal Lens Assy ..........................................................................................................................
Mounting Bracket .................................................................................................................................
Retainer, Headlight ..............................................................................................................................
Connector Harness Assembly, Headlight ....................................................................................
Bulb, Headlight ......................................................................................................................................
Lens, Headlight .....................................................................................................................................
Headlight Assy, Passenger-Side Single Beam (includes items 12 through 20) ....................
Headlight Bezel, Right ........................................................................................................................
Nut, #10-24 Stainless-Steel Hex Machine ....................................................................................
Turn Signal Lens Assy ..........................................................................................................................
Mounting Bracket .................................................................................................................................
Retainer, Headlight ..............................................................................................................................
Connector Harness Assembly, Headlight ....................................................................................
Bulb, Headlight ......................................................................................................................................
Lens, Headlight .....................................................................................................................................
1
2
1
2
1
2
1
1
1
1
1
2
1
2
1
2
1
1
1
1
Page 7-15
7
G
E
D
7
G
E
D
7
10
1
10
8
3
5
9
11
4
8
12
2
6
000076-001
Page 7-16
ELECTRICAL COMPONENT BOX, GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
1012295
1015521
1015741
102420201
****
102420401
102420501
102447901
102448001
102492201
1108
332
Fuse, 10-Amp ...............................................................................................................................................
Screw, 1/4-20 X .88 Hex Hd Cap ............................................................................................................
Fuse Block .....................................................................................................................................................
Relay, Mini ISO, SPDT ................................................................................................................................
Connector, Relay ........................................................................................................................................
Plate, Electrical ............................................................................................................................................
Cover, Electrical ..........................................................................................................................................
Fastener, Push-in ........................................................................................................................................
Rivet, Drive ...................................................................................................................................................
Fuse, 25-Amp ...............................................................................................................................................
Locknut, 1/4-20 Dimpled ........................................................................................................................
2
1
1
2
3
1
1
7
2
2
2
1
Page 7-17
7
G
E
D
7
G
E
D
7
10
11
1
8
3
5
9
12
4
8
13
2
6
000076-002
Page 7-18
ELECTRICAL COMPONENT BOX, DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
1012295
1015521
1015741
102420201
****
102420401
102420501
102447901
102448001
102492201
102492301
1108
332
Fuse, 10-Amp ...............................................................................................................................................
Screw, 1/4-20 X .88 Hex Hd Cap ............................................................................................................
Fuse Block .....................................................................................................................................................
Relay, Mini ISO, SPDT ................................................................................................................................
Connector, Relay ........................................................................................................................................
Plate, Electrical ............................................................................................................................................
Cover, Electrical ..........................................................................................................................................
Fastener, Push-in ........................................................................................................................................
Rivet, Drive ...................................................................................................................................................
Fuse, 25-Amp ...............................................................................................................................................
Fuse, 30-Amp ...............................................................................................................................................
Locknut, 1/4-20 Dimpled ........................................................................................................................
1
1
1
3
4
1
1
8
2
1
2
2
1
Page 7-19
7
G
E
D
7
G
E
D
15
5
14
13
4
7
3
3
2
1
10
11
9
6
8
16
12
000080-003
Page 7-20
ELECTRICAL COMPONENTS, INSTRUMENT PANEL, GASOLINE
VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1013857
1014557
1015636
N/A
1016630
102044702
102044801
N/A
102051601
102051701
102051901
102198001
102739901
102967901
103348101
103348201
Knob, Light Switch ....................................................................................................................................
Washer, 7/16 Flat ........................................................................................................................................
Toggle Switch (includes item 4) ............................................................................................................
Nut, Toggle Switch ...............................................................................................................................
Light, Oil ........................................................................................................................................................
Key Switch 12v Key Start .........................................................................................................................
Key Set ...........................................................................................................................................................
Connector, 5 Way, Female .......................................................................................................................
Spacer, Keyswitch ......................................................................................................................................
Nut, Key Switch ...........................................................................................................................................
Switch, Light ................................................................................................................................................
Receptacle, Accessory ..............................................................................................................................
Panel, Instrument - Gas ............................................................................................................................
Gauge Fuel-hour Sep Gnd ......................................................................................................................
Clip, Meter, Round .....................................................................................................................................
1
1
1
1
1
1
1
1
1
1
1
1
1
7
1
1
Page 7-21
7
G
E
D
7
G
E
11
D
16
12
5
13
15
8
10
14
4
3
3
2
1
6
13
9
17
7
000080-004
Page 7-22
ELECTRICAL COMPONENTS, INSTRUMENT PANEL, DIESEL
VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1013857
1014557
1015636
N/A
1016630
102051901
102198001
102375401
N/A
102457301
102731701
N/A
N/A
102739902
102967901
103348101
103348201
Knob, Light Switch ....................................................................................................................................
Washer, 7/16 Flat ........................................................................................................................................
Toggle Switch (includes item 4) ............................................................................................................
Nut, Toggle Switch ...............................................................................................................................
Light, Oil ........................................................................................................................................................
Switch, Light ................................................................................................................................................
Receptacle, Accessory ..............................................................................................................................
Light, Indicator, Coolant Temp ..............................................................................................................
Connector, 6 Way, 56 Series ...................................................................................................................
Switch, Key (includes items 11 through 13) .....................................................................................
Key Set (1 pair) .......................................................................................................................................
Nut, Key Switch .....................................................................................................................................
Switch, Key without Nut ....................................................................................................................
Panel, Instrument - Diesel .......................................................................................................................
Gauge Fuel-hour Sep Gnd ......................................................................................................................
Clip, Meter, Round .....................................................................................................................................
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7
1
1
Page 7-23
7
G
E
D
7
G
2
4
E
1
D
5
3
9
7
6
10
11
8
000077-001
Page 7-24
BATTERY – GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
1010934
1014375
101898001
102355301
102442201
102442301
102442401
102490301
N/A
1241
7473
Screw, 5/16-18 X 1.00 Hex Cap ..............................................................................................................
Screw, 3/8-16 X 0.50 Stainless Steel Hex-Head ...............................................................................
Clamp, Battery .............................................................................................................................................
Lockwasher, #10 Split Ss ..........................................................................................................................
Asm, #6 Red Wire .......................................................................................................................................
Asm, #6 Blk Wire .........................................................................................................................................
Asm, #6 Blk Wire .........................................................................................................................................
Bolt, M6 X 1 X 16 Loctite ..........................................................................................................................
Battery, Start, 12v .......................................................................................................................................
Washer, 5/16 Type A Flat .........................................................................................................................
Locknut, 5/16-18 Nylon Insert ...............................................................................................................
1
2
1
2
1
1
1
1
1
1
1
Page 7-25
7
G
E
D
7
G
2
4
E
1
D
5
3
9
6
7
10
11
8
000077-002
Page 7-26
BATTERY – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
1010934
1014375
101898001
102355301
102442201
102448401
102448501
102498201
N/A
1241
7473
Screw, 5/16-18 X 1.00 Hex Cap ..............................................................................................................
Screw, 3/8-16 X 0.50 Stainless Steel Hex-Head ...............................................................................
Clamp, Battery .............................................................................................................................................
Lockwasher, #10 Split Ss ..........................................................................................................................
Asm, #6 Red Wire .......................................................................................................................................
Wire Asm, #6 Blk, Awd, 350 ....................................................................................................................
Wire Asm, #6 Blk, Awd, 325 ....................................................................................................................
Bolt, M10 X 1.25 X 25 Loctite .................................................................................................................
Battery, Start, 12v .......................................................................................................................................
Washer, 5/16 Type A Flat .........................................................................................................................
Locknut, 5/16-18 Nylon Insert ...............................................................................................................
1
2
1
2
1
1
1
1
1
1
1
Page 7-27
7
G
E
D
7
G
E
D
DIESEL ENGINE – CLOSED BREATHER
8
G
E
D
8
G
E
D
12
28
20
9
24
17
30
4
19
22
30
23
19
30
8
18
27
1
7
11
29
30
16
15
6
14
10
25
3
29
4
16
30
26
21
5
13
2
4
000025-002
Page 8-2
KUBOTA D722 DIESEL ENGINE MOUNTING
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1012769
101833101
101833201
102298401
102370101
102370501
102370601
102382401
102410603
102414701
102414801
102462301
102462501
102465901
102490101
102490201
102490501
102494401
102498201
102618601
102621301
102621501
102670701
102934601
96701412
96704622
96704721
96718978
96741038
96741046
Stud, M8-1.25 X 50 mm Two-Ended ....................................................................................................
Stud, M8-1.25 X 60mm Two-Ended .....................................................................................................
Nut,m8,all Metal Lock ...............................................................................................................................
Spacer, Engine, Diesel ..............................................................................................................................
Isolator Ring and Bushing .......................................................................................................................
Washer, Snubbing, Ring N Bush ...........................................................................................................
Bracket, FNR Trans Cable .........................................................................................................................
Plate, Engine Mounting, Weld, Left-Hand .........................................................................................
Plate, Engine Mounting, Weld, Right-Hand ......................................................................................
Hose, Vent, Transmission .........................................................................................................................
Cover, CVT Inner, Diesel ...........................................................................................................................
Shaft, CVT Adapter ....................................................................................................................................
Bolt, M10 X 1.5 X 20 Loctite ....................................................................................................................
Bolt, M8 X 1.25 X 25 Loctite ....................................................................................................................
Bolt, M10 X 1.5 X 100 Loctite .................................................................................................................
Bracket, Transmission Mounting ..........................................................................................................
Bolt, M10 X 1.25 X 25 Loctite .................................................................................................................
Bolt, M8 X 1.25 X 40 with Loctite ..........................................................................................................
Nut Flg, M6 X 1.0 Nylon ...........................................................................................................................
Nut Flg M10 X 1.5 Nylon ..........................................................................................................................
Engine, Kubota, D722, with Closed Breather, 60a ..........................................................................
Washer, M12 Hard ......................................................................................................................................
Locknut, M12x1.75 Nylon Insert ...........................................................................................................
Bolt, M12 X 1.75 X 90 ................................................................................................................................
Bolt, M8 X 1.25 X 80 ...................................................................................................................................
Washer, M8 Hard ........................................................................................................................................
Washer, M10 Hard ......................................................................................................................................
3
1
1
7
1
4
4
1
1
1
1
1
1
1
4
7
1
2
8
1
3
3
1
1
4
4
4
1
10
12
Page 8-3
8
G
E
D
8
G
15
E
4
D
16
13
12
11
11
14
3
2
5
21
19
6
18
17
11
10
9
20
12
6
7
8
2
2
-
15
1
000039-001
Page 8-4
CRANKCASE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
102600001
102600101
102600201
102600401
102600601
102600701
102600801
102601001
102601301
102726201
102726301
102726401
102726501
102726601
N/A
102600301
102601401
102631601
N/A
102730801
102732601
Engine Block (includes items 2 through 15) ....................................................................................
Pin, Pipe, Dia 8 X 14 ..............................................................................................................................
Pin, Straight, Dia 5 X 10 ......................................................................................................................
Pin, Pipe, Dia 7 X 14 ..............................................................................................................................
Pin, Straight, Dia 8 X 16 ......................................................................................................................
Plug, 1/8" .................................................................................................................................................
Plug, 3/32" ...............................................................................................................................................
Plug, 1/4" .................................................................................................................................................
Pin, Pipe, Dia 8 X 11 ..............................................................................................................................
Cap, Sealing, Small ...............................................................................................................................
Cap, Sealing, Med .................................................................................................................................
Cap, Sealing, Large ...............................................................................................................................
Cover, Fuel Camshaft ...........................................................................................................................
Plug, Expansion .....................................................................................................................................
Block, Engine ..........................................................................................................................................
O Ring, 8 X 7 .................................................................................................................................................
Cock, Drain ...................................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Plate, Engine Block ....................................................................................................................................
Switch, Oil Pressure ...................................................................................................................................
Gasket, Fuel Pump, D722 ........................................................................................................................
1
2
2
1
2
3
5
1
2
3
5
2
1
1
1
1
1
2
1
1
1
Page 8-5
8
G
E
D
8
G
E
D
7
2
6
1
5
4
3
000040-001
Page 8-6
OIL PAN
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102605101
102606901
102607001
102607201
102607301
102607401
102654601
Bolt, M6 X 1 X 14 .........................................................................................................................................
Bolt, M8 X 1.25 X 15 ...................................................................................................................................
Oil Pan ............................................................................................................................................................
Plug, Drain, M12 X 14 ...............................................................................................................................
Gasket, 20 X 13 ............................................................................................................................................
Filter, Oil, Pick Up ........................................................................................................................................
O Ring, 20 X 17 ............................................................................................................................................
22
1
1
1
1
1
1
Page 8-7
8
G
E
D
8
G
E
D
10
11
2
12
7
3
13
6
4
5
9
1
9
-
13
8
000041-002
Page 8-8
CYLINDER HEAD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102600301
102652801
102653901
102654101
102701001
102726701
102727101
102798001
102600801
102653401
102653501
102726901
102727001
O Ring, 8 X 7 .................................................................................................................................................
Bolt, Cylinder Head ....................................................................................................................................
Hook, Engine ...............................................................................................................................................
Gasket, Cylinder Head ..............................................................................................................................
Spring, Start .................................................................................................................................................
Bolt, Engine Hook ......................................................................................................................................
Stay, Cylinder Head ...................................................................................................................................
Head, Cylinder, Complete (includes items 9 through 13) ............................................................
Plug, 3/32" ...............................................................................................................................................
Guide, Exhaust Valve ...........................................................................................................................
Guide, Inlet Valve ..................................................................................................................................
Cap, Sealing, Head ...............................................................................................................................
Cap, Sealing, Head, Top ......................................................................................................................
1
14
2
1
1
2
1
1
1
3
3
1
2
Page 8-9
8
G
E
D
8
G
E
D
17
18
19
14
10
12
9
1
2
3
8
4
7
6
7
5
11
13
9
16
000042-002
Page 8-10
GEAR CASE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102601801
102601901
102602001
102602101
102602301
102602401
102602601
102602701
102602801
102654301
102703301
102727401
102727501
102729301
N/A
102601001
102727601
N/A
102798201
O Ring, 18 X 13 ............................................................................................................................................
Spring, Valve ................................................................................................................................................
Ball, Valve ......................................................................................................................................................
Seat, Valve .....................................................................................................................................................
Joint, Pipe .....................................................................................................................................................
Washer, Plain, Special ...............................................................................................................................
Bolt, M6 X 1 X 60 .........................................................................................................................................
Seal, Oil ..........................................................................................................................................................
Bolt, D722, Front Case ..............................................................................................................................
Bolt, D722 Intake Manfld Lower ...........................................................................................................
Filter, Engine Oil, D722 .............................................................................................................................
Bolt, Gearcase, Top ....................................................................................................................................
Bolt, Gearcase, Lower ...............................................................................................................................
Gasket, Gearcase, D722 ...........................................................................................................................
Case, Gear (includes items 16 through 19) .......................................................................................
Plug, 1/4" .................................................................................................................................................
Screw, Breather .....................................................................................................................................
Case, Gear ................................................................................................................................................
Stay, Spring .............................................................................................................................................
3
1
1
1
1
1
2
1
9
1
1
2
1
1
1
2
2
1
1
Page 8-11
8
G
E
D
8
G
E
D
9
12
8
7
11
13
4
2
1
10
6
5
000181-001
Page 8-12
HEAD COVER
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102644001
102644101
102798401
102633301
102798501
102798601
102799001
102799101
102799201
N/A
102798701
102798801
102798901
O Ring, 30 X 36 ............................................................................................................................................
Plug, Oil Filler ...............................................................................................................................................
Assembly, Cylinder Head Cover (includes items 4 through 10) ................................................
Pipe, Water Return, D722 ...................................................................................................................
Gasket, Cylinder Head Cover ............................................................................................................
Shield, Breather .....................................................................................................................................
Valve, Breather .......................................................................................................................................
Cover, Breather ......................................................................................................................................
Screw, Breather .....................................................................................................................................
Cover, Cylinder Head ...........................................................................................................................
Bolt, Cylinder Head Cover .......................................................................................................................
Tube, Breather .............................................................................................................................................
Clamp, Breather Tube ...............................................................................................................................
1
1
1
1
1
1
1
1
4
1
4
1
2
Page 8-13
8
G
E
D
8
G
E
D
1
2
000044-002
Page 8-14
DIPSTICK AND GUIDE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
102606701
102727701
Gauge, Oil .....................................................................................................................................................
Guide, Oil Gauge ........................................................................................................................................
1
1
8
G
E
D
Page 8-15
8
G
E
D
5
4
3
2
1
6
000045-001
Page 8-16
OIL PUMP
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102606201
102606301
102606401
102606501
102606601
102727901
Nut, Flange, D722 Oil Pump ...................................................................................................................
Gear, Oil Pump Drive .................................................................................................................................
Key, Feather, 8x4 .........................................................................................................................................
Assy, Pump, Oil ............................................................................................................................................
Gasket, Oil Pump ........................................................................................................................................
Bolt, Oil Pump .............................................................................................................................................
1
1
1
1
1
3
Page 8-17
8
G
E
D
8
G
E
D
10
12
11
3
2
1
4
5
5
5
6
7
9
8
8
000046-001
Page 8-18
MAIN BEARING CASE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
102608201
102608301
102608601
102608701
102608901
102609101
102609301
102609401
102609601
102728001
102608401
102608501
Gasket, Bearing Case ................................................................................................................................
Gasket, Cover ...............................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Bolt, M6 X 1 X 22 .........................................................................................................................................
Bolt, Bearing Case, Top .............................................................................................................................
Assy Case, Main Brg, First ........................................................................................................................
Assy Case, Main Brg, Sec ..........................................................................................................................
Bolt, Bearing Case, Bottom .....................................................................................................................
Assy Case, Main Brg, Third ......................................................................................................................
Assy, Cover, Bearing Case (includes items 11 and 12) ..................................................................
Cover, Bearing Case .............................................................................................................................
Seal, Oil .....................................................................................................................................................
1
1
8
8
6
1
1
2
1
1
1
1
Page 8-19
8
G
E
D
8
G
E
D
6
5
2
3
4
8
16
9
7
15
1
14
11
10
13
12
000047-002
Page 8-20
CAMSHAFT AND IDLE GEAR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
102604201
102604901
102603201
N/A
102605001
102605101
102605301
102605401
102605501
102605801
102605601
102605901
102606001
N/A
102799401
102654401
Bolt, D722, Cam End .................................................................................................................................
Gear, Idle (includes items 3 and 4) .......................................................................................................
Bushing, D722 Idle Gear .....................................................................................................................
Gear, Idle ..................................................................................................................................................
Shaft, Idle Gear ............................................................................................................................................
Bolt, M6 X 1 X 14 .........................................................................................................................................
Ring, Snap .....................................................................................................................................................
Push Rod .......................................................................................................................................................
Tappet ............................................................................................................................................................
Assy Camshaft, Long (includes items 11 through 15) ..................................................................
Key, Feather, Long Camshaft ............................................................................................................
Gear, Cam ................................................................................................................................................
Stopper, Camshaft ................................................................................................................................
Camshaft .................................................................................................................................................
Ball, Check ...............................................................................................................................................
Collar, Idle Gear ...........................................................................................................................................
2
1
1
1
1
3
1
6
6
1
1
1
1
1
1
1
Page 8-21
8
G
E
D
8
G
E
D
2
3
11
36 37
24
26
35
25
34
9
4
12 13 14
10
6
7
8
5
15 16 17
1
18 19 20
30
31
32
33
21 22 23
27 28 29
000048-002
Page 8-22
PISTON AND CRANKSHAFT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
102604401
102607601
102607602
102607801
102607901
102630701
N/A
102630703
102732201
N/A
102608101
102608801
N/A
102608803
102608804
N/A
102608806
102609001
N/A
102609003
102609801
N/A
102609803
102610001
102608001
N/A
102630001
N/A
102630003
102630101
102630201
102630301
102630401
102630901
102631001
102728101
102728102
Key, Feather, Short Camshaft .................................................................................................................
Assy Piston Ring, D722 Std .....................................................................................................................
Assy Piston Ring, D722 +.025 ................................................................................................................
Assy, Connecting Rod (includes items 5 through 10) ...................................................................
Bolt, Connecting Rod ..........................................................................................................................
Metal, Crank, Rod, D722, Std ............................................................................................................
Metal, Crank, Rod, D722, .020 ..........................................................................................................
Metal, Crank, Rod, D722, .040 ..........................................................................................................
Bushing, Piston Pin, D722 ..................................................................................................................
Rod, Connecting ...................................................................................................................................
Sleeve, Crankshaft .....................................................................................................................................
Metal,crank, O Side, Std ...........................................................................................................................
Metal,crank, O Side, +.020 ......................................................................................................................
Metal,crank, O Side, +.040 ......................................................................................................................
Metal,crank, I Side, Std .............................................................................................................................
Metal,crank, I Side, +.020 ........................................................................................................................
Metal,crank, I Side, +.040 ........................................................................................................................
Metal, Crank, Main, Rear Std ..................................................................................................................
Metal, Crank, Main, Rear -.020 ...............................................................................................................
Metal, Crank, Main, Rear -.040 ...............................................................................................................
Metal, Crank, Main, Mid Std ...................................................................................................................
Metal, Crank, Main, Mid +.020 ...............................................................................................................
Metal, Crank, Main, Mid +.040 ...............................................................................................................
Crankshaft (includes items 25 and 26) ...............................................................................................
Ball, Crankshaft ......................................................................................................................................
Crankshaft ...............................................................................................................................................
Metal, Crank, D722, Frnt, Std .................................................................................................................
Metal, Crank, 722, Frnt, -.020 .................................................................................................................
Metal, Crank, 722, Frnt, -.040 .................................................................................................................
Gear, Crank ...................................................................................................................................................
Slinger, Oil .....................................................................................................................................................
O Ring, 23 X 26 ............................................................................................................................................
Collar, Crankshaft .......................................................................................................................................
Circlip, Piston Pin ........................................................................................................................................
Pin, Piston .....................................................................................................................................................
Piston, D722, Std ........................................................................................................................................
Piston, D722, +0.25 ....................................................................................................................................
1
3
3
3
6
3
3
3
3
1
1
2
2
2
2
2
2
1
1
1
4
2
2
1
3
1
1
1
1
1
1
1
1
6
3
3
3
Page 8-23
8
G
E
D
8
G
E
D
5
1
6
4
3
2
000049-001
Page 8-24
FLYWHEEL
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102647501
102647801
102647901
N/A
102648001
102728301
Plate, Rear End ............................................................................................................................................
Flywheel (includes items 3 and 4) ........................................................................................................
Gear, Ring, D722 ....................................................................................................................................
Flywheel ...................................................................................................................................................
Bolt, Flange Head, M10 X 1.5 X 25 .......................................................................................................
Bolt, End Plate .............................................................................................................................................
1
1
1
1
5
10
Page 8-25
8
G
E
D
8
G
E
D
14
1
3
2
13
12
11
10
9
8
7
4
6
5
000050-001
Page 8-26
SHAFT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
102604201
102604701
N/A
102728401
102603601
102603701
102603801
102603901
102604001
102604101
102604301
102604401
102604501
102728501
Bolt, D722, Cam End .................................................................................................................................
Circlip, External ...........................................................................................................................................
Stopper, Fuel, C/shaft ...............................................................................................................................
Assy, Fuel Camshaft (includes items 5 through 13) .......................................................................
Gear, Injection Pump ...........................................................................................................................
Ball, Injection Pump .............................................................................................................................
Sleeve, Governor ...................................................................................................................................
Ball, Governor ........................................................................................................................................
Case, Governor Ball ..............................................................................................................................
Circlip ........................................................................................................................................................
Bearing, Ball ............................................................................................................................................
Key, Feather, Short Camshaft ...........................................................................................................
Camshaft, Fuel, Short ..........................................................................................................................
Bearing, Ball .................................................................................................................................................
2
1
1
1
1
8
1
32
1
1
1
1
1
1
Page 8-27
8
G
E
D
8
G
7
E
11
5
6
D
11
2
8
10
9
12
1
13
3
4
000051-002
Page 8-28
IDLE APPARATUS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102635301
102635701
102637001
102637101
102728601
102635501
102635801
102635901
102728701
N/A
102728801
102728901
102799501
Gasket, 6 X 10 ..............................................................................................................................................
Cap, Bolt Assy ..............................................................................................................................................
Nut, Lock, Special .......................................................................................................................................
Nut, Special ..................................................................................................................................................
Assy, Idle Apparatus (includes items 6 through 11) ......................................................................
Nut, M8, D722 Idle App, Specl .........................................................................................................
Nut, M8, D722 Idle App ......................................................................................................................
Assy, Bolt, Adjusting (includes items 9 and 10) .........................................................................
Spring, Idle Apparatus ..................................................................................................................
Stud, Idle Adjustment ...................................................................................................................
Gasket, Idle Apparatus, Rear .............................................................................................................
Gasket, Idle Apparatus, Front ................................................................................................................
Bolt, Idle Adjusting ....................................................................................................................................
1
1
1
1
1
1
1
1
1
1
2
1
1
Page 8-29
8
G
E
D
8
G
E
D
2
4
5
3
1
6
000182-001
Page 8-30
STOP SOLENOID
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102640601
102729101
102799601
102799701
102799801
N/A
Washer, Spring, M6, D722 .......................................................................................................................
Bolt, Solenoid, Stop, D722 ......................................................................................................................
Solenoid, Stop .............................................................................................................................................
Stay, Stop Solenoid ...................................................................................................................................
O-Ring, Stop Solenoid ..............................................................................................................................
Bolt, Stop Solenoid ....................................................................................................................................
2
2
1
1
1
2
Page 8-31
8
G
E
D
8
G
E
D
5
12
7
3
13
4
1
8
15
11
6
2
15
9
10
14
000057-002
Page 8-32
40-AMP ALTERNATOR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
102601101
102630601
102631601
102647701
102701201
102730001
102730101
102730201
102730301
102730401
102730601
102731301
102732501
102800701
102801001
V-Belt ..............................................................................................................................................................
Pulley, Fan Drive .........................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Nut, M8, Plate ..............................................................................................................................................
Pulley, Water Pump ...................................................................................................................................
Alternator, 40-Amp ....................................................................................................................................
Stay, Alternator Assy, D722 .....................................................................................................................
Collar, Alternator Assy, D722 ..................................................................................................................
Cover, Alternator Assy, D722 ..................................................................................................................
Bolt, Alt, D722, Adjuster ...........................................................................................................................
Bolt, Alt, D722, Drive Pulley ....................................................................................................................
Bolt, D722, Drive Pulley ...........................................................................................................................
Washer, Spring, D722, Starter ................................................................................................................
Bolt, Alternator, Lower .............................................................................................................................
Washer, Alternator, Upper ......................................................................................................................
1
1
2
1
1
1
1
1
1
1
1
4
1
1
2
Page 8-33
8
G
E
D
8
G
E
D
4
8
13
2
9
3
14
5
11
7
12
1
11
15
6
10
000057-003
Page 8-34
60-AMP ALTERNATOR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
102630601
102631601
102647701
102701201
102730201
102730401
102730601
102731301
102732501
102800701
102801001
102934701
102934801
102934901
103239901
Pulley, Fan Drive .........................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Nut, M8, Plate ..............................................................................................................................................
Pulley, Water Pump ...................................................................................................................................
Collar, Alternator Assy, D722 ..................................................................................................................
Bolt, Alt, D722, Adjuster ...........................................................................................................................
Bolt, Alt, D722, Drive Pulley ....................................................................................................................
Bolt, D722, Drive Pulley ...........................................................................................................................
Bolt, Alternator, Lower .............................................................................................................................
Washer, Alternator, Upper ......................................................................................................................
Alternator, 60 Amp ....................................................................................................................................
Brkt, Alt, D722, 60 Amp ............................................................................................................................
Belt, Acc Drive, D722, 60 Amp ...............................................................................................................
Guard, Acc Belt ............................................................................................................................................
1
2
1
1
1
1
1
4
1
1
2
1
1
1
1
Page 8-35
8
G
E
D
8
G
9
E
10
D
8
1
11
2
3
2
4
5
6
7
000053-002
Page 8-36
INJECTION PUMP
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
102640501
102640601
102640701
102640901
102641001
102641101
102641201
102800101
102637701
102640401
N/A
Bolt, Hex-Head, M5 X 0.75 X ...................................................................................................................
Washer, Spring, M6, D722 .......................................................................................................................
Nut, Special ..................................................................................................................................................
Shim, Injection Pump, 0.20 mm ............................................................................................................
Stud, M5 X 25 ...............................................................................................................................................
Assembly, Fuel Injection Pump (includes items 9 through 11) .................................................
Screw, Hollow, D722, Inj Pump ........................................................................................................
Joint, Eye ..................................................................................................................................................
Pump, Injection .....................................................................................................................................
2
4
2
1
1
1
2
1
1
1
1
Page 8-37
8
G
E
D
8
G
6
E
15
14
D
7
13
8
12
5
9
10
16
17
1
18
11
19
4
2
3
000054-002
Page 8-38
SPEED CONTROL PLATE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102634501
102635201
102635301
102654301
102800401
102633701
102633801
102633901
102634001
102634101
102634401
102634601
102634701
102729401
102729501
N/A
N/A
102800501
102800601
Gasket, Control Plate ................................................................................................................................
Bolt, M6 X 1 X 30 .........................................................................................................................................
Gasket, 6 X 10 ..............................................................................................................................................
Assembly, Speed Plate (includes items 6 through 19) .................................................................
Lever, Engine Stop ................................................................................................................................
Nut, Speed Control ..............................................................................................................................
Lever, Speed Control ...........................................................................................................................
O Ring, 19 X 16 ......................................................................................................................................
Plate, Speed Control ............................................................................................................................
O Ring, 9 X 7 ...........................................................................................................................................
Collar, Lever ............................................................................................................................................
Spring, Return ........................................................................................................................................
Cap, Speed Cntrl Plate Rtrn ...............................................................................................................
Pin, Spring, Speed Plate .....................................................................................................................
Nut, Speed Control ..............................................................................................................................
Bolt, Speed Control ..............................................................................................................................
Lever, Governor .....................................................................................................................................
Shaft, Governor Lever .........................................................................................................................
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
Page 8-39
8
G
E
D
8
G
E
4
D
3
5
6
7
8
9
1
10
17
19
16
11
18
14
12
13
15
2
000055-001
Page 8-40
NOZZLE HOLDERS AND GLOW PLUGS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102605701
102635301
102642401
102642501
102642601
102642801
102642901
102643001
102643101
102643201
102643301
102643401
102729601
N/A
102643701
102729701
102641501
102642701
102643601
Assy Pipe, D722 Fuel Over Flow ............................................................................................................
Gasket, 6 X 10 ..............................................................................................................................................
Cord, Glow Plug ..........................................................................................................................................
Nut, Flange,m4 ............................................................................................................................................
Glow Plug .....................................................................................................................................................
Screw, Washer .............................................................................................................................................
Clamp, Pipe, Top .........................................................................................................................................
Pipe, Injection, Left ....................................................................................................................................
Pipe, Injection, Right .................................................................................................................................
Pipe, Injection, Middle .............................................................................................................................
Clamp, Pipe, Bottom .................................................................................................................................
Assy Pipe, Over Flow (includes items 13 and 14) ...........................................................................
Clip, Pipe, Return ..................................................................................................................................
Hose, Overflow ......................................................................................................................................
Screw, Air Bleeder ......................................................................................................................................
Kit, Holder, Nozzle (includes items 17 through 19) .......................................................................
Assembly, Nozzle Holder ...................................................................................................................
Seal, Heat .................................................................................................................................................
Gasket, Nozzle .......................................................................................................................................
1
1
1
3
3
2
2
1
1
1
2
1
2
1
1
3
3
3
3
Page 8-41
8
G
E
D
8
G
E
D
1
3
10
11
12
9
2
8
5
4
7
6
000056-002
Page 8-42
GOVERNOR COMPONENTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
102635101
102636301
102800201
102800301
102636201
102636401
102636501
N/A
N/A
102633601
102636601
N/A
Spring, Governor ........................................................................................................................................
Bolt, M5 X 0.75 X 25 ...................................................................................................................................
Spring, Start .................................................................................................................................................
Assembly, Governor Fork (includes items 5 through 9) ...............................................................
Holder, Fork Lever ................................................................................................................................
Bolt, M5 X 0.75 X 11 .............................................................................................................................
Washer, Spring, M5 ..............................................................................................................................
Lever, Fork, Middle, D722 CB ............................................................................................................
Assembly, Governor Fork Level, Lower, D722 CB (includes items 10 through 12) ........
Pin, Spring .........................................................................................................................................
Shaft, Fork Lever .............................................................................................................................
Lever, Fork, End, D722 CB ............................................................................................................
1
2
1
1
1
1
1
1
1
1
1
1
Page 8-43
8
G
E
D
8
G
E
D
2
5
3
4
5
1
3
000058-001
Page 8-44
STARTER
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
102645501
102647701
102648401
102648501
102732501
Nut, D722, Starter ......................................................................................................................................
Nut, M8, Plate ..............................................................................................................................................
Bolt, M8 X 1.25 X 28 ...................................................................................................................................
Motor, Starter ..............................................................................................................................................
2
2
2
1
4
Page 8-45
8
G
E
D
8
G
E
10
9
D
12
19
5
11
7
6
14
8
13
18
2
15
4
3
1
16
17
000062-002
Page 8-46
VALVES AND ROCKER ARMS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102646401
102651301
102651601
102651801
102652001
102651501
102651701
N/A
102652601
102652701
102652901
102653001
102653101
102653201
102653301
102653601
102653701
102801101
102801201
Bolt, M6 X 1 X 8 ...........................................................................................................................................
Washer, D722, Plain, Rocker ...................................................................................................................
Washer, Rocker Arm ..................................................................................................................................
Pin, Spring, D722, Rocker ........................................................................................................................
Assy Rocker Arm (includes items 6 through 8) ...............................................................................
Nut, M6 .....................................................................................................................................................
Screw-Adjusting ....................................................................................................................................
Arm, Rocker ............................................................................................................................................
Shaft, Rocker Arm ......................................................................................................................................
Spring, Rocker Arm ...................................................................................................................................
Collet, Valve Spring, Set ...........................................................................................................................
Cap, Valve, D722 .........................................................................................................................................
Spring, Valve ................................................................................................................................................
Retainer, Spring ..........................................................................................................................................
Seal, Valve Stem ..........................................................................................................................................
Valve, Exhaust ..............................................................................................................................................
Valve, Inlet ....................................................................................................................................................
Bracket, Rocker Arm, D722 Closed-Breather ....................................................................................
Bolt, Rocker Arm .........................................................................................................................................
2
2
2
1
6
6
6
1
1
2
6
6
6
6
6
3
3
3
3
Page 8-47
8
G
E
D
8
G
E
D
3
1
5
6
4
2
000063-002
Page 8-48
DIESEL INLET MANIFOLD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102646101
102654301
102801301
102646001
102801401
102801501
Bolt, M6 X 1 X 45 .........................................................................................................................................
Assembly, Intake Manifold (includes items 4 through 6) ............................................................
Gasket, Intake Manifold .....................................................................................................................
Pipe, Breather .........................................................................................................................................
Manifold, Intake ....................................................................................................................................
3
2
1
1
1
1
Page 8-49
8
G
E
D
8
G
E
D
3
2
7
1
6
5
4
7
000064-001
Page 8-50
EXHAUST MANIFOLD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102646301
102646501
102646601
102647101
102647201
102731501
102731601
Cover, Heat Proof .......................................................................................................................................
Stud, M6 X 26 ...............................................................................................................................................
Gasket, Ex-manifold ..................................................................................................................................
Nut, Flange, M6, Ubs .................................................................................................................................
Bolt, Flange Head, M6 X 1 X 16 .............................................................................................................
Manifold, Exhaust, D722 ..........................................................................................................................
Bolt, D722, Exhst Manfld Cover .............................................................................................................
1
3
1
3
3
1
2
Page 8-51
8
G
E
D
8
G
11
E
12
9
D
4
2
1
10
5
6
3
7
13
8
20
26
27
25
22
21
15
14
24
19
23
17
18
16
000065-001
Page 8-52
GASKET KITS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
102731801
102422301
102600301
102633401
102635301
102644001
102644501
102646001
102646601
102653301
102654101
102654701
102798501
102731901
102601801
102606601
102608201
102608301
102630301
102632701
102634001
102634401
102634501
102654601
102728801
102729301
102732601
Kit, Gasket Upper, D722 (includes items 2 through 13) ...............................................................
Gasket, Exhaust Diesel ........................................................................................................................
O Ring, 8 X 7 ...........................................................................................................................................
Gasket, Thermostat ..............................................................................................................................
Gasket, 6 X 10 .........................................................................................................................................
O Ring, 30 X 36 ......................................................................................................................................
Gasket, Head Cover ..............................................................................................................................
Gasket, Intake Manifold .....................................................................................................................
Gasket, Ex-manifold .............................................................................................................................
Seal, Valve Stem ....................................................................................................................................
Gasket, Cylinder Head .........................................................................................................................
Gasket, Water Flange ..........................................................................................................................
Gasket, Cylinder Head Cover ............................................................................................................
Kit, Gasket Lower, D722 (includes items 15 through 27) .............................................................
O Ring, 18 X 13 ......................................................................................................................................
Gasket, Oil Pump ..................................................................................................................................
Gasket, Bearing Case ...........................................................................................................................
Gasket, Cover .........................................................................................................................................
O Ring, 23 X 26 ......................................................................................................................................
Gasket, Water Pump, D722 ...............................................................................................................
O Ring, 19 X 16 ......................................................................................................................................
O Ring, 9 X 7 ...........................................................................................................................................
Gasket, Control Plate ...........................................................................................................................
O Ring, 20 X 17 ......................................................................................................................................
Gasket, Idle Apparatus, Rear .............................................................................................................
Gasket, Gearcase, D722 ......................................................................................................................
Gasket, Fuel Pump, D722 ...................................................................................................................
1
1
1
1
3
1
1
1
1
6
1
1
1
1
3
1
1
1
1
1
1
1
1
1
2
1
1
Page 8-53
8
G
E
D
8
G
E
D
2
1
5
3
4
3
6
000066-001
Page 8-54
PISTON KIT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102732001
102607601
102630901
102631001
102728101
102732201
Kit, Piston Rebuild, D722 (includes items 2 through 6) ................................................................
Assy Piston Ring, D722 Std ................................................................................................................
Circlip, Piston Pin ..................................................................................................................................
Pin, Piston ................................................................................................................................................
Piston, D722, Std ...................................................................................................................................
Bushing, Piston Pin, D722 ..................................................................................................................
1
1
2
1
1
1
Page 8-55
8
G
E
D
8
G
E
D
HONDA GX620 GASOLINE ENGINE
9
G
E
D
9
G
E
D
17
8
22
14
9
6
24
24
16
10
2
16
12
5
1
20
15
23
13
4
11
3
7
23
24
11
18
21
19
000025-003
Page 9-2
HONDA GX620 GASOLINE ENGINE MOUNTING
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1012769
102298401
102370501
102370601
102382401
102410603
102414901
102462301
102462502
102490101
102490201
102490501
102494401
102618601
102621501
102670701
103252201
96701412
96704622
96704721
96704960
96718978
96741038
96741046
Isolator Ring and Bushing .......................................................................................................................
Washer, Snubbing, Ring N Bush ...........................................................................................................
Plate, Eng Mtg, Weld, Honda .................................................................................................................
Hose, Vent, Transmission .........................................................................................................................
Cover, CVT Inner, Honda ..........................................................................................................................
Bolt, M10 X 1.5 X 20 Loctite ....................................................................................................................
Bolt, M8 X 1.25 X 25 Loctite ....................................................................................................................
Bolt, M10 X 1.5 X 100 Loctite .................................................................................................................
Bracket, Transmission Mounting ..........................................................................................................
Nut Flg, M6 X 1.0 Nylon ...........................................................................................................................
Nut Flg M10 X 1.5 Nylon ..........................................................................................................................
Engine, Honda, No Acr .............................................................................................................................
Washer, M12 Hard ......................................................................................................................................
Locknut, M12x1.75 Nylon Insert ...........................................................................................................
Bolt, M12 X 1.75 X 90 ................................................................................................................................
Bolt, M10 X 1.5 X 60 ...................................................................................................................................
Bolt, M8 X 1.25 X 80 ...................................................................................................................................
Washer, M8 Hard ........................................................................................................................................
Washer, M10 Hard ......................................................................................................................................
3
2
4
4
1
1
1
1
1
4
6
1
2
1
3
5
1
4
4
4
4
1
6
9
Page 9-3
9
G
E
D
9
11
G
E
12
D
14
1
16
13
10
15
9
2
8
16
6
7
17
16
5
18
3
4
Page 9-4
000019-001
SHROUDS AND BRACKETS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
102657501
102666201
102666801
102666901
102667001
102667101
102667201
102667301
102667401
102667501
102667601
102667701
102667901
102668001
102668101
102668301
102668401
102759401
Cap Assy, Noise Suppressor ...................................................................................................................
Cover, Fan, Bright Red ..............................................................................................................................
Nut, Flange, M6 ...........................................................................................................................................
Fan, Cooling .................................................................................................................................................
Holder, Screen Grid ...................................................................................................................................
Grid Screen, PTO .........................................................................................................................................
Plate, R Side ..................................................................................................................................................
Shroud, R .......................................................................................................................................................
Shroud, Head ...............................................................................................................................................
Hanger, Engine ...........................................................................................................................................
Shroud, L .......................................................................................................................................................
Plate, Left Side .............................................................................................................................................
Nut, Square, 5mm ......................................................................................................................................
2
2
1
4
1
1
3
3
1
1
1
2
2
2
1
6
1
2
Note: The part number for a complete engine is 102402701.
Page 9-5
9
G
E
D
9
G
E
D
13
12
15
2
16
1
17
2
11
14
10
19
6
9
8
5
7
18
2
4
3
000018-001
Page 9-6
IGNITION COMPONENTS AND FLYWHEEL
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102655301
102661901
102664601
102664701
102664801
102664901
102665001
102665101
102665301
102665401
102665501
102665601
102665701
102665901
102666001
102666201
102668201
102831201
AM1232301
Stud, Engine .................................................................................................................................................
Flywheel ........................................................................................................................................................
Washer, M20 .................................................................................................................................................
Nut, Flange, M20 ........................................................................................................................................
Key, Special Woodruff, 25 X 18 ..............................................................................................................
Coil Assy, Charge, 12-Volt, 20-Amp ......................................................................................................
Pin, Dowel, 10x12 .......................................................................................................................................
Diode Assembly .........................................................................................................................................
Bolt, Flange Head, M6 X 1 X 8 ................................................................................................................
Grommet, Tool ............................................................................................................................................
Motor, Starter ..............................................................................................................................................
Coil Assy, R, Ignition ..................................................................................................................................
Coil Assy, L, Ignition ..................................................................................................................................
Cap Assy, Noise Suppressor ...................................................................................................................
Clamp, Wire ..................................................................................................................................................
Switch, Oil Pressure ...................................................................................................................................
Spark Plug, BPR2ES ....................................................................................................................................
2
9
1
1
1
1
1
2
1
1
1
1
2
2
2
2
1
1
2
Page 9-7
9
G
E
D
9
11
G
13
14
E
10
D
15
1
12
23
22
4
3
8
7
6
9
5
2
16
21
17
20
Page 9-8
18
19
000022-001
OIL CIRCULATION
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
102658001
102658101
102658801
102659601
102724301
102724401
102724501
102724601
N/A
102658201
102658301
102658401
102658501
102658601
102658701
102658901
102659001
102659101
102659201
102659301
102659401
102659501
102724701
Gasket, Case Cover ....................................................................................................................................
Cover Assembly, Crankcase (includes items 3 through 9) ..........................................................
Governor Assembly .............................................................................................................................
Washer, Plain, M6 ..................................................................................................................................
Seal, Oil, 38 X 58 X 9 .............................................................................................................................
Slider, Governor ....................................................................................................................................
Washer, 6 X 16 ........................................................................................................................................
Clip, Governor ........................................................................................................................................
Cover, Crankcase ...................................................................................................................................
Dipstick, Oil ..................................................................................................................................................
Cap, Oil Filler ................................................................................................................................................
Pin A, Dowel, 8 X 14 ...................................................................................................................................
Washer, Drain Plug, M14 ..........................................................................................................................
Bolt, Drain Plug , M14 ...............................................................................................................................
Bolt, Flange Head, M8 X 1.25 X 50 ......................................................................................................
Cover, Oil Filter ............................................................................................................................................
Cover Assembly, Oil Pump ......................................................................................................................
Rotor, Oil Pump, Outer .............................................................................................................................
Spring, Relief Valve ....................................................................................................................................
Ball, Steel , 3/8, #12 ....................................................................................................................................
Bolt, Socket ..................................................................................................................................................
Screen, Oil Filter ..........................................................................................................................................
1
1
1
1
1
1
1
1
1
1
1
2
1
1
9
1
1
1
1
1
2
3
1
Page 9-9
9
G
E
D
9
G
21
22
E
20
D
28
23
26
22
17
27
15
18
14
9
16
13
11
10
19
3
12
2
29
1
24
8
7
25
6
4
5
000013-001
Page 9-10
CYLINDER HEAD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
102657601
102657701
102657801
102662101
N/A
102662201
102662301
102662401
102662601
102662701
102662801
102662802
102662901
102663001
102663101
102663201
102663301
102663401
102663501
102663801
102663901
102664001
102664101
102664301
102664401
102722701
102722801
102722901
AM1232301
Gasket, Intake Manifold ...........................................................................................................................
Manifold, Inlet .............................................................................................................................................
Bolt, Socket, M8 X 1.25 X 45 ...................................................................................................................
Cover, Head ..................................................................................................................................................
Cover, Head Filler .......................................................................................................................................
Gasket, Cylinder Head Cover .................................................................................................................
Bolt, Head Cover .........................................................................................................................................
Washer, Head Cover ..................................................................................................................................
Bolt, Stud, M8x22 .......................................................................................................................................
Cylinder Head, #2 .......................................................................................................................................
Cylinder Head, #1 .......................................................................................................................................
Plate, Push Rod Guide ..............................................................................................................................
Pivot, Rocker Arm .......................................................................................................................................
Arm, Valve Rocker ......................................................................................................................................
Bolt, Pivot, M8 .............................................................................................................................................
Nut, Pivot Adj ...............................................................................................................................................
Valve, Ex .........................................................................................................................................................
Valve, In .........................................................................................................................................................
Rod, Push ......................................................................................................................................................
Retainer, In Valve Spring ..........................................................................................................................
Spring, Valve ................................................................................................................................................
Seal, Valve Stem ..........................................................................................................................................
Gasket, Cylinder Head ..............................................................................................................................
Pin A, Dowel ,12 X 20 ................................................................................................................................
Retainer, Ex Valve Spring .........................................................................................................................
Seat, Valve Spring ......................................................................................................................................
Rotator, Valve ...............................................................................................................................................
Spark Plug, BPR2ES ....................................................................................................................................
2
1
4
1
1
2
2
2
8
4
1
1
2
4
4
4
4
2
2
4
2
4
2
2
4
2
2
2
2
Page 9-11
9
G
E
D
9
17 18 19 20
G
E
15
D
22
15
16
21
7
8
9
10
23
24
13
11
14
22
12
25
3
5
21
4
26
2
34
6
32
27
28
31
33
30
31
29
1
35
000023-001
Page 9-12
CRANKCASE AND CRANKSHAFT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
102659801
102659901
102660001
102660101
102660201
102660301
102660401
102660402
102660403
102660404
102660501
102660901
N/A
N/A
102660601
102660701
102660801
102660802
102660803
102660804
102661001
102661101
102661201
102661202
102661301
102661401
102661501
102661601
102661701
102661801
102661901
102664901
102668201
102725101
102725201
Crankshaft ....................................................................................................................................................
Camshaft Assembly ..................................................................................................................................
Lifter Assembly, Valve ...............................................................................................................................
Bearing, Radial Ball, 6003 ........................................................................................................................
Bolt, Flange Head, M6 X 1 X 25 ............................................................................................................
Piston, Std .....................................................................................................................................................
Piston, Over-Sized 0.25 ............................................................................................................................
Piston, Over-Sized 0.50 ............................................................................................................................
Piston, 0.75 ...................................................................................................................................................
Rod Assy., Connecting (includes items 12 through 14) ...............................................................
Bolt, Connecting Rod, 6 X 37 ............................................................................................................
Connecting Rod ....................................................................................................................................
Cap, Connecting Rod ..........................................................................................................................
Clip, Piston Pin, 18mm .............................................................................................................................
Pin, Piston .....................................................................................................................................................
Ring Set, Piston, Std ..................................................................................................................................
Ring Set, Piston, OS 0.25 ..........................................................................................................................
Washer, Plain, M8 .......................................................................................................................................
Pin, Lock, 8 Mm ...........................................................................................................................................
Bearing, Needle, 8 X 12.7 X 11 ...............................................................................................................
Oil Seal, 8 X 14 X 5 ......................................................................................................................................
Bearing, Needle, 8 X 12 X 10 ..................................................................................................................
Oil Seal, 38 X 58 X 9 ...................................................................................................................................
Shaft, Governor Arm .................................................................................................................................
Cover, Breather ...........................................................................................................................................
Gasket, Breather Cover ............................................................................................................................
Valve, Breather ............................................................................................................................................
Key, Special Woodruff, 25 X 18 ..............................................................................................................
Clamp, Wire ..................................................................................................................................................
Pin A, Dowel .................................................................................................................................................
Bolt, Flange Head, 6 X 16 .........................................................................................................................
1
1
1
1
1
1
2
2
2
2
2
2
1
1
4
2
2
2
2
2
3
2
1
1
1
1
1
1
1
1
2
1
1
1
1
Page 9-13
9
G
E
D
9
G
2
E
D
12
1
13
10
14
11
17
6
4
15
7
12
6
8
3
18
5
9
16
000083-001
Page 9-14
OIL FILTER ADAPTER AND VOLTAGE REGULATOR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
102289001
102331401
102371401
102434801
102443501
102443601
102457501
102457601
102475301
102490401
102618601
102670801
102710301
102721901
102722001
102827901
102849401
96705587
Screw, M8X1.25X30, Hex .........................................................................................................................
Regulator, Voltage .....................................................................................................................................
Bracket, Oil Filter Mount ..........................................................................................................................
Adapter, 90, 5/16 Tube .............................................................................................................................
Hose, 3/8, Remote Oil, Honda ...............................................................................................................
Clamp, Hose .................................................................................................................................................
Adapter, 90, 3/8 Tube ...............................................................................................................................
Hose, 5/16, Remote Oil, Honda .............................................................................................................
Nipple, M20, Remote Oil .........................................................................................................................
O-ring 11.8 X 2.4 .........................................................................................................................................
Screw, M6 X 1 X 25 Thd Form ................................................................................................................
Plate, Fuel/Oil System ...............................................................................................................................
Adapter, 3/8 Hose ......................................................................................................................................
Adapter, 5/16 Hose ....................................................................................................................................
Filter, Oil, Honda Service .........................................................................................................................
Adapter, Oil Filter, Honda Eng ...............................................................................................................
Bolt, M8 X 1.25 X 30 ...................................................................................................................................
3
1
1
1
1
4
1
1
1
2
2
5
1
1
1
1
1
2
Page 9-15
9
G
E
D
9
G
E
D
FUEL, INTAKE, AND GOVERNOR
SYSTEM
10
G
E
D
10
G
E
D
7
8
5
6
9
5
1
4
2
3
000081-002
Page 10-2
FUEL SYSTEM – GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
1013746
101587703
101824401
102298401
102411202
102426301
102657201
102657301
103307901
Clamp, 0.301 ID Hose ................................................................................................................................
Hose, Fuel, Vent, 22" Long ......................................................................................................................
Vent Barb ......................................................................................................................................................
Clamp, Hose, Ctb 13mm ..........................................................................................................................
Strap, Tank, Fuel ..........................................................................................................................................
Clip, Tube, B10 .............................................................................................................................................
Filter, Fuel ......................................................................................................................................................
Hose, Tank To Filter, Fh680d ...................................................................................................................
2
1
1
1
2
1
1
1
1
Page 10-3
10
G
E
D
10
G
E
14
D
6
13
2
7
8
3
10
5
4
11
9
12
000082-004
Page 10-4
FUEL TANK – GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
102952102
1013461
1013462
1015139
1015143
1016
N/A
N/A
102522001
102670901
102751601
N/A
183
8797
Asm, Tank, Fuel, Gas, 4x4 (includes items 2 through 14) .............................................................
Sending Unit, Fuel Level * .................................................................................................................
Insulation Grommet ............................................................................................................................
Vent, Fuel Tank ......................................................................................................................................
Lockwasher, #10 Split ..........................................................................................................................
Wire Asm, Blk, 170mm ........................................................................................................................
Wire Asm, Org, 170mm .......................................................................................................................
Gasket, Rubber ......................................................................................................................................
Valve, Pickup Tube, Fuel .....................................................................................................................
Cap, Fuel Tank, Gasoline ....................................................................................................................
Tank, Fuel, Gas, 4x4 ..............................................................................................................................
Washer, #10 Type A Flat ......................................................................................................................
Nut, #10-32 Brass Hex .........................................................................................................................
1
5
1
1
1
1
1
1
1
1
1
1
1
1
* Note: Must replace fuel sending unit gasket when servicing this
component.
Page 10-5
10
G
E
D
10
G
E
D
13
9
10
1
5
7
17
8
18
11
2
8
16
19
14
15
8
8
6
17
3
4
12
000081-005
Page 10-6
FUEL SYSTEM – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
101313402
1013746
101587703
101824401
102289001
102296716
102410801
102411203
102426301
102430001
102430201
102430301
102430401
102434601
102434701
102434801
102618601
102710301
96705587
Clamp, Green Hose ....................................................................................................................................
Clamp, 0.301 ID Hose ................................................................................................................................
Hose, Fuel, Vent, 22" Long ......................................................................................................................
Vent Barb ......................................................................................................................................................
Screw, M8X1.25X30, Hex .........................................................................................................................
Pump, Diesel Fuel Electric .......................................................................................................................
Clamp, Hose, Ctb 14mm ..........................................................................................................................
Strap, Tank, Fuel ..........................................................................................................................................
Hose, Tank To Prefilter Diesel .................................................................................................................
Hose, Fuel Pump To Filter ........................................................................................................................
Hose, Fuel Filter To Eng ............................................................................................................................
Hose, Fuel Return .......................................................................................................................................
Filter Assy, Fuel ............................................................................................................................................
Filter, Fuel ......................................................................................................................................................
Adapter, 90, 5/16 Tube .............................................................................................................................
Plate, Fuel/Oil System ...............................................................................................................................
Bolt, M8 X 1.25 X 30 ...................................................................................................................................
1
2
1
1
5
1
1
5
1
1
1
1
1
1
1
2
3
1
2
Page 10-7
10
G
E
D
10
G
E
16
D
6
15
2
7
8
3
11
5
12
4
13
10
9
14
000082-005
Page 10-8
FUEL TANK – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
102952101
1013461
1013462
1015139
1015143
1016
N/A
N/A
102406701
102406801
102478501
102494701
102522001
N/A
183
8797
Asm, Tank, Fuel, Diesel, 4x4 (includes items 2 through 16) ........................................................
Sending Unit, Fuel Level * .................................................................................................................
Insulation Grommet ............................................................................................................................
Vent, Fuel Tank ......................................................................................................................................
Lockwasher, #10 Split ..........................................................................................................................
Wire Asm, Blk, 170mm ........................................................................................................................
Wire Asm, Org, 170mm .......................................................................................................................
Bushing, Line, Return ..........................................................................................................................
Elbow, 90 Barbed ..................................................................................................................................
Pickup Tube, Fuel ..................................................................................................................................
Cap, Fuel (Diesel) ..................................................................................................................................
Gasket, Rubber ......................................................................................................................................
Tank, Fuel, Diesel, 4x4 .........................................................................................................................
Washer, #10 Type A Flat ......................................................................................................................
Nut, #10-32 Brass Hex .........................................................................................................................
1
5
1
1
1
1
1
1
2
1
1
1
1
1
1
1
* Note: Must replace fuel sending unit gasket when servicing this
component.
Page 10-9
10
G
E
D
10
G
E
D
13
12
5
6
2
3
4
7
8
9
10
11
000020-001
Page 10-10
CARBURETOR ASSEMBLY, HONDA GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
103201601
102623802
102623805
102623808
102655401
102655501
102655601
102655701
102655801
102655901
102656001
102724101
102724201
Carburetor, Seal Shaft (includes items 2 through 13) ...................................................................
Jet, GX620, #102 (8000 ft. and higher (2438 m and higher)) ................................................
Jet, GX620, #105 (5000-8000 ft. (1524-2438 m)) .......................................................................
Jet, GX620, #108 (0-5000 ft. (0-1524 m)) ......................................................................................
Nozzle, Main ...........................................................................................................................................
Float Set ...................................................................................................................................................
Gasket Set ...............................................................................................................................................
Screw Set, Drain ....................................................................................................................................
Screw-Washer, M4 X 14 ......................................................................................................................
Valve Assy., Solenoid ...........................................................................................................................
Screw-Washer, M5 X 12 ......................................................................................................................
Screw Set, Left .......................................................................................................................................
Screw Set, Right ....................................................................................................................................
1
1
1
1
1
1
1
1
4
1
2
1
1
Page 10-11
10
G
E
D
10
G
8
4
1
E
19
D
18
17
15
24
16
2
5
25
3
7
9
14
13
11
12
20
21
6
10
22
23
000021-001
Page 10-12
CARBURETOR INSTALLATION – HONDA GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
102385801
102462601
102493001
102617301
102620801
102656101
102656201
102656301
102656402
102656501
102656601
102656701
102656801
102656901
102657001
102657101
102657201
102657301
102657401
102657501
102657601
102657701
102657801
102710501
102725401
Bracket, Choke Cable ................................................................................................................................
Insert, Adapter, Carburetor .....................................................................................................................
Gasket, Adapter, Carburetor ..................................................................................................................
Screw Tapping, M5 X 0.8x10 ..................................................................................................................
Adapter, Intake Honda GX620 ...............................................................................................................
Clip, Breather Tube ....................................................................................................................................
Grommet, Reserve Tank ..........................................................................................................................
Bolt, Flange Head, M6 X 1 X 120 ...........................................................................................................
Pump Assy., Fuel, Sup ...............................................................................................................................
Tube, Breather .............................................................................................................................................
Stay, Fuel Pump ..........................................................................................................................................
Gasket, Carburetor ....................................................................................................................................
Insulator, Carburetor .................................................................................................................................
Srew-Washer, M6 X 16 ..............................................................................................................................
Tube B, Fuel ..................................................................................................................................................
Tube, Diaphragm .......................................................................................................................................
Clip, Tube, B10 .............................................................................................................................................
Filter, Fuel ......................................................................................................................................................
Clip, Wire Harness ......................................................................................................................................
Gasket, Intake Manifold ...........................................................................................................................
Manifold, Inlet .............................................................................................................................................
Bolt, Socket, M8 X 1.25 X 45 ...................................................................................................................
Spring, Continuity, Solenoid ..................................................................................................................
Tube A, Fuel ..................................................................................................................................................
1
2
1
2
1
1
1
2
1
1
1
2
1
2
1
1
3
1
1
2
2
1
4
1
1
Page 10-13
10
G
E
D
10
G
E
1
D
2
2
000033-001
Page 10-14
GOVERNOR AND ACCELERATOR CABLES, GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
102475701
102498701
Clip, Brake Line ............................................................................................................................................
Cable, Accelerator, GX620 .......................................................................................................................
2
1
10
G
E
D
Page 10-15
10
G
E
1
D
2
2
000034-001
Page 10-16
CHOKE CABLE, GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
102475701
102826101
Clip, Brake Line ............................................................................................................................................
Cable, Choke ................................................................................................................................................
2
1
10
G
E
D
Page 10-17
10
G
E
1
D
2
2
000035-001
Page 10-18
ACCELERATOR CABLE, DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
102475701
102498801
Clip, Brake Line ............................................................................................................................................
Cable, Accelerator, Diesel ........................................................................................................................
2
1
10
G
E
D
Page 10-19
10
G
E
D
4
1
2
3
000085-001
Page 10-20
GOVERNOR COVER – GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
102451001
102498101
102707101
96705736
Cover, Engine, Honda ...............................................................................................................................
Bolt, M8 X 1.25 X 20 ...................................................................................................................................
Grommet, Split, 50 Durometer ..............................................................................................................
Bolt, M5 X .8 X 20 ........................................................................................................................................
1
2
2
2
Page 10-21
10
G
E
D
10
G
5
E
4
D
15
7
3
2
14
1
22
12
10
6
18
21
3
16
20
13
17
8
2
9
11
1
19
000089-001
Page 10-22
GOVERNOR SYSTEM – GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1014007
101886101
102296716
102423701
102433101
102433501
102451201
102452301
102454801
102454901
102457001
102457101
102457201
102490101
102499601
102616801
102616901
102618601
8233
96714464
96718978
96741038
Washer, 1/4 Flat ..........................................................................................................................................
Screw, 1/4-20 X 1.00 Square-Head ......................................................................................................
Cable, Engine Governor ...........................................................................................................................
Bracket, Governor, Arm, Trans ...............................................................................................................
Wire, Governor ............................................................................................................................................
Bracket, Governor, Trans Cable .............................................................................................................
Adjuster, Spring, Idle .................................................................................................................................
Bracket, Arm, Gov, Engine .......................................................................................................................
Bracket, Cable, Gov, Engine ....................................................................................................................
Spring .............................................................................................................................................................
Spring, Carb .................................................................................................................................................
Spring, Compression, Adj, Idle ..............................................................................................................
Bolt, M10 X 1.5 X 20 Loctite ....................................................................................................................
Guard, Governor, Ground Speed ..........................................................................................................
Bolt, M4 X .7 X 60 ........................................................................................................................................
Nut Flg, M4 X 0.7 Mech Def ....................................................................................................................
Locknut, 1/4-20 Nylon Insert .................................................................................................................
Washer, M4 ...................................................................................................................................................
Bolt, M8 X 1.25 X 80 ...................................................................................................................................
Washer, M8 Hard ........................................................................................................................................
2
2
3
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
Page 10-23
10
G
E
D
10
G
E
D
8
12
9
10
11
3
1
4
6
5
7
3
2
000090-001
Page 10-24
INTAKE DUCT AND AIR BOX ASSEMBLY –
HONDA GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
102378901
102395601
102411210
102541465
102621201
102621501
N/A
102810701
102498601
102725501
102725601
N/A
Hose, Intake, GX620 ..................................................................................................................................
Hose, Intake, Primary ................................................................................................................................
Clamp, Hose, Ctb 64mm ..........................................................................................................................
Bolt Flanged Head, M8 X1.25x 16 with Loctite ...............................................................................
Nut Flg, M6 X 1.0 Nylon ...........................................................................................................................
Weldment, Support, Air Cleaner ..........................................................................................................
Filter, Air, Canister, W/labe (includes items 9 through 12) ..........................................................
Element, Filter, Air, 5 In .......................................................................................................................
Valve, Evacuator, Filter Air .................................................................................................................
Cap, Latch Lock, Filter, Air ..................................................................................................................
Body, Canister, Filter, Air .....................................................................................................................
1
1
4
2
2
2
1
1
1
1
1
1
Page 10-25
10
G
E
D
10
G
E
1
D
3
10
13
11
8
9
12
4
5
5
7
6
3
2
000090-002
Page 10-26
INTAKE DUCT AND AIR BOX ASSEMBLY – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102379001
102395601
102411209
102541465
102621201
102621501
N/A
102810701
102498601
102725501
102725601
N/A
103441401
Hose, Intake, D722 .....................................................................................................................................
Hose, Intake, Primary ................................................................................................................................
Clamp, Hose, Ctb 55mm ..........................................................................................................................
Nut Flg, M6 X 1.0 Nylon ...........................................................................................................................
Weldment, Support, Air Cleaner ..........................................................................................................
Filter, Air, Canister, W/labe (includes items 9 through 12) ..........................................................
Element, Filter, Air, 5 In .......................................................................................................................
Valve, Evacuator, Filter Air .................................................................................................................
Cap, Latch Lock, Filter, Air ..................................................................................................................
Body, Canister, Filter, Air .....................................................................................................................
Clamp, Worm Screw, Hose, 2" ................................................................................................................
1
1
3
2
2
2
1
1
1
1
1
1
1
Page 10-27
10
G
E
D
10
G
E
D
EXHAUST SYSTEM
11
G
E
D
11
G
E
9
D
10
2
3
5
8
6
7
4
2
1
000075-001
Page 11-2
EXHAUST SYSTEM, GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
102409401
102409501
102409601
102621201
102812801
102409501
N/A
N/A
102834901
96704416
Pipe, Exhaust Intermediate ....................................................................................................................
Spring, Exhaust ...........................................................................................................................................
Header, Exhaust, Gas ................................................................................................................................
Asm, Muffler, AWD Homologation (includes items 6 through 8) .............................................
Spring, Exhaust ......................................................................................................................................
Muffler ......................................................................................................................................................
Bracket, Muffler .....................................................................................................................................
Gasket, Exhaust, Gx620 ............................................................................................................................
Nut Flg, M8 X 1.25 Serrated ....................................................................................................................
1
4
1
2
1
4
1
1
2
4
Page 11-3
11
G
E
D
11
G
E
9
8
D
1
7
7
6
10
5
2
13
11
12
4
3
000075-002
Page 11-4
EXHAUST SYSTEM, DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102298401
102409301
102409401
102409501
102422301
102621201
102621301
102628101
102731601
102812801
102409501
N/A
N/A
Pipe, Exhaust Diesel Main .......................................................................................................................
Pipe, Exhaust Intermediate ....................................................................................................................
Spring, Exhaust ...........................................................................................................................................
Gasket, Exhaust Diesel .............................................................................................................................
Bolt, M8 X 1.25 X 40 with Loctite ..........................................................................................................
Shield, Diesel Exhaust ..............................................................................................................................
Bolt, D722, Exhst Manfld Cover .............................................................................................................
Asm, Muffler, AWD Homologation (includes items 11 through 13) ........................................
Spring, Exhaust ......................................................................................................................................
Muffler ......................................................................................................................................................
Bracket, Muffler .....................................................................................................................................
3
1
1
4
1
2
3
1
1
1
4
1
1
Page 11-5
11
G
E
D
11
G
E
D
CLUTCHES
12
G
E
D
12
G
E
D
1
2
4
3
000008-002
Page 12-2
CLUTCH COVER (STANDARD)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
102296716
102411210
N/A
103320601
Clamp, Hose, Ctb 64mm ..........................................................................................................................
Cover, Cvt, Open .........................................................................................................................................
Hose, Outlet, Cvt ........................................................................................................................................
7
1
1
1
Page 12-3
12
G
E
D
12
G
E
D
8
3
10
9
2
4
4
11
6
7
4
5
2
1
Page 12-4
11
000008-001
CLUTCH COVER (SEALED)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
102616003
101856102
102296716
102411210
102414501
102481001
102481201
102481301
102616101
102628001
103320601
Kit, Sealed CVT Cover (includes items 2 through 11) ....................................................................
Screw, 1/4-15 X 1.50 Hi-lo Hex .........................................................................................................
Screw, M6 X 16 Tt Hx Fl Hd ................................................................................................................
Clamp, Hose, Ctb 64mm ....................................................................................................................
Cover, CVT Outer ..................................................................................................................................
Hose, Inlet, Cover, CVT ........................................................................................................................
Bracket, Inlet, Cover, CVT ...................................................................................................................
Gasket, Cover, CVT ...............................................................................................................................
Cap, Inlet, Cover, CVT ..........................................................................................................................
Filter, Inlet, Cover, CVT ........................................................................................................................
Hose, Outlet, Cvt ...................................................................................................................................
1
3
7
2
1
1
1
1
1
1
1
Page 12-5
12
G
E
D
12
G
E
1
D
000084-001
Page 12-6
DRIVE BELT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
102374901
Belt, Drive ......................................................................................................................................................
1
12
G
E
D
Page 12-7
12
G
11
6
E
D
12
4
10
5
14
17
22
19
23
13
15
8
18
7
9
16
20
1
21
4
-
23
2
3
000007-003
Page 12-8
DRIVE CLUTCH – GASOLINE VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
102385601
102490001
103185401
102690501
102690701
102691001
102691401
102691601
102691701
102691801
N/A
N/A
N/A
102690201
102690301
102690501
102690701
102691901
N/A
102839401
N/A
103185801
103185901
Washer, Stepped ........................................................................................................................................
Bolt, M10x1.25x200 Loctite ....................................................................................................................
Clutch, 4x4, Gas, W/cover (includes items 4 through 23) ............................................................
Screw, Shlder Hex, .312 X 1.75 .........................................................................................................
Nut, Lock Hex, 1/14-20, Flexlc ..........................................................................................................
Sub Assy, Wt Clutch, Gas ....................................................................................................................
Spring, Compression, Primary .........................................................................................................
Washer, Lock, H-Spring, 1/4 ..............................................................................................................
Screw, Cap, Hex Hd, 1/4 X 1.25 ........................................................................................................
Shim, 1.63 X 1.33 ...................................................................................................................................
Subassembly, Drive Clutch ...............................................................................................................
Subassembly, Moveable, Drive Clutch ..........................................................................................
Spider Subassembly (Gasoline) (includes items 14 through 20) .........................................
Pin, Spring Slotted,1.25 X 1.0 .....................................................................................................
Pin, Dowel, .375 X 1.50 .................................................................................................................
Screw, Shlder Hex, .312 X 1.75 ...................................................................................................
Nut, Lock Hex, 1/14-20, Flexlc ....................................................................................................
Roller, Torque, Gas ..........................................................................................................................
Spider, Drive Clutch .......................................................................................................................
Sub Assy, Roller Weight ................................................................................................................
Cover, Drive Clutch ..............................................................................................................................
Cover, Clutch, 4x4 .................................................................................................................................
Gasket, Cover, Clutch, 4x4 .................................................................................................................
1
1
1
2
2
2
1
4
4
1
1
1
1
2
2
2
2
4
1
2
1
1
1
Page 12-9
12
G
E
D
12
G
11
6
E
D
12
4
10
5
14
18
22
19
23
13
15
8
16
7
9
17
20
1
21
4
-
23
2
3
000007-004
Page 12-10
DRIVE CLUTCH – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
102385601
102616501
103185501
102690501
102690701
102690801
102691401
102691601
102691701
102691801
N/A
N/A
N/A
102690201
102690301
102690401
102690501
102690701
N/A
102839401
N/A
103185801
103185901
Washer, Stepped ........................................................................................................................................
Bolt, M10 X 1.5 X 160 ................................................................................................................................
Clutch, 4x4, Diesel, W/cover (includes items 4 through 23) .......................................................
Screw, Shlder Hex, .312 X 1.75 .........................................................................................................
Nut, Lock Hex, 1/14-20, Flexlc ..........................................................................................................
Sub Assy, Wt Clutch, Diesel ...............................................................................................................
Spring, Compression, Primary .........................................................................................................
Washer, Lock, H-Spring, 1/4 ..............................................................................................................
Screw, Cap, Hex Hd, 1/4 X 1.25 ........................................................................................................
Shim, 1.63 X 1.33 ...................................................................................................................................
Subassembly, Drive Clutch ...............................................................................................................
Subassembly, Moveable, Drive Clutch ..........................................................................................
Subassembly, Spider Utility, Diesel (includes items 14 through 20) ..................................
Pin, Spring Slotted,1.25 X 1.0 .....................................................................................................
Pin, Dowel, .375 X 1.50 .................................................................................................................
Roller, Torque, Diesel .....................................................................................................................
Screw, Shlder Hex, .312 X 1.75 ...................................................................................................
Nut, Lock Hex, 1/14-20, Flexlc ....................................................................................................
Spider, Drive Clutch .......................................................................................................................
Sub Assy, Roller Weight ................................................................................................................
Cover, Drive Clutch ..............................................................................................................................
Cover, Clutch, 4x4 .................................................................................................................................
Gasket, Cover, Clutch, 4x4 .................................................................................................................
1
1
1
2
2
2
1
4
4
1
1
1
1
2
2
4
2
2
1
2
1
1
1
Page 12-11
12
G
E
D
12
G
E
9
D
10
8
3
2
4
6
7
5
2
-
8
1
Page 12-12
000003-001
DRIVEN CLUTCH
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
102369901
102695401
N/A
102695601
102695701
102695801
102695901
N/A
102385701
102719301
CVT, Secondary (includes items 2 through 8) ..................................................................................
Washer, Thrust, 1.53 X 1.92 ...............................................................................................................
Sheave, Driven Clutch .........................................................................................................................
Retainer, Spring, Inner ........................................................................................................................
Spring, Compression, Secondary ....................................................................................................
Retainer, Spring, Outer .......................................................................................................................
Ring, Retaining, External ....................................................................................................................
Driven Clutch Base Sheave ...............................................................................................................
Washer, Stepped ........................................................................................................................................
Bolt, M10 X 1.50 X 90, Loctite ................................................................................................................
1
1
1
1
1
1
1
1
1
1
Page 12-13
12
G
E
D
12
G
E
D
DRIVETRAIN COMPONENTS
13
G
E
D
13
G
20
E
21
22
15
18
23
D
16
24
26
25
17
19
33
27
33
2
34
31
32
28
30
1
29
7
5
4
13
14
12
11
3
6
10
9
8
000012-001
Page 13-2
FRONT DIFFERENTIAL MOUNTING AND HALF SHAFTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
102274101
102381701
102436001
102022901
102368201
102368301
102374701
102376601
N/A
102475801
102479001
102361901
102447001
102722301
102436101
102022901
102368201
102368302
102374701
102376601
N/A
102475801
102479001
102361901
102447001
102722301
102462401
102491001
102491101
102617501
102617801
102711601
102865201
103244701
Center Cap, Rubber ...................................................................................................................................
Spacer Block, Diff .......................................................................................................................................
Upright Sub-Assembly, LH (includes items 4 through 11) ..........................................................
Locknut, M12-1.25 Nylon ..................................................................................................................
Bearing .....................................................................................................................................................
Upright, Left ...........................................................................................................................................
Internal Retaining Ring, 80mm Bore .............................................................................................
Assy, Rotor, Brake, Front (includes items 9 and 10) ..................................................................
Rotor, Brake, Front ..........................................................................................................................
Stud, Wheel Lug ..............................................................................................................................
Asm, Adjuster, Slide (includes items 12 through 14) ...............................................................
Joint, Ball ...........................................................................................................................................
Slide, Adjuster ..................................................................................................................................
Ring, Retaining, Ext, 1-1/4" .........................................................................................................
Upright Sub-Assembly, RH (includes items 16 through 23) .......................................................
Locknut, M12-1.25 Nylon ..................................................................................................................
Bearing .....................................................................................................................................................
Upright, Right ........................................................................................................................................
Internal Retaining Ring, 80mm Bore .............................................................................................
Assy, Rotor, Brake, Front (includes items 21 and 22) ................................................................
Rotor, Brake, Front ..........................................................................................................................
Stud, Wheel Lug ..............................................................................................................................
Asm, Adjuster, Slide (includes items 24 through 26) ...............................................................
Joint, Ball ...........................................................................................................................................
Slide, Adjuster ..................................................................................................................................
Ring, Retaining, Ext, 1-1/4" .........................................................................................................
Hose, Vent, Front Diff ................................................................................................................................
Bolt Flanged Head, 3/8-16x1.0 with Loctite .....................................................................................
Bolt Flanged Head, 3/8-16x1.500 with Loctite ................................................................................
Nut Flg, M22 X 1.5 Mech Def ..................................................................................................................
Washer Hard, M22 ......................................................................................................................................
Shaft, Half .....................................................................................................................................................
Asm, Mount, Diff Plate .............................................................................................................................
2
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
2
2
2
2
4
2
1
Page 13-3
13
G
E
D
13
2
G
8
E
6
7
9
3
10
11
12
13
4
5
D
33
34
32
35
26
28
29
27
31
30
20
21
22
23
24
25
35
17
15
18
16
14
19
40
38
36
39
37
000010-001
Page 13-4
FRONT DIFFERENTIAL (OUTPUT COMPONENTS)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
102371801
102438201
102439001
102439101
102439201
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
102438301
102439401
102439501
N/A
N/A
N/A
102438401
102439601
102439801
102439901
102439701
N/A
102438501
102438601
N/A
N/A
N/A
N/A
102438701
102438801
102438901
102439301
102440101
N/A
N/A
102440301
N/A
Differential, Front * (includes items 2 through 40) ........................................................................
Kit, Assy, Output Cover Plate (includes items 3 through 13) ................................................
Set Screw, #10-24 UNC-3A with Patch ....................................................................................
Thrust Button ...................................................................................................................................
Thrust Plate ......................................................................................................................................
Mate-N-Lock Pin .............................................................................................................................
Mate-N-Lock Housing ...................................................................................................................
Oil Seal ...............................................................................................................................................
Grommet ...........................................................................................................................................
Plate, Output Cover .......................................................................................................................
O-Ring ................................................................................................................................................
Coil, Pocket Insert ...........................................................................................................................
Coil with Press-Fit Bobbin ...........................................................................................................
Kit, Assy, Race Output Hub (includes items 15 through 19) .................................................
Pin, Dowel .........................................................................................................................................
Bearing, Needle ..............................................................................................................................
Race/Output Hub, Male ...............................................................................................................
Bushing, PermiGlide ......................................................................................................................
Race/Output Hub, Female ..........................................................................................................
Kit, Assy, Clutch (includes items 21 through 23) .......................................................................
Clutch Hsg/Ring Gear, Machined .............................................................................................
Kit, Roller (contains 14 rollers) ...................................................................................................
Kit, Assy, Roll Cage (includes items 24 and 25) ....................................................................
Kit, H-Clip Spring (contains 14 clips) .................................................................................
Roll Cage, Plastic .......................................................................................................................
Kit, Bolt (contains 7 bolts) ..................................................................................................................
Kit, Minor Repair (includes items 28 through 31) .....................................................................
Oil Seal ...............................................................................................................................................
O-Ring ................................................................................................................................................
O-Ring ................................................................................................................................................
Oil Seal, Triple-Lipped ..................................................................................................................
Retaining, Ring Internal ......................................................................................................................
Plate, Armature .....................................................................................................................................
Shim, Armature, Plate .........................................................................................................................
Bearing, Ball ............................................................................................................................................
Kit, Assy, Drain Plug (includes items 37 and 38) ........................................................................
Plug, Oil Drain ..................................................................................................................................
Washer, Nylon, 0.625 x 0.382 x 0.06 .........................................................................................
Plug, Oil Fill .............................................................................................................................................
Bushing, Self-Lubricating, 80 x 85 x 20 .........................................................................................
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
1
1
1
1
1
* Note: This assembly also contains components listed on the following two
pages.
Page 13-5
13
G
E
D
13
G
E
D
4
1
2
3
5
6
7
000010-002
Page 13-6
FRONT DIFFERENTIAL (INPUT COMPONENTS)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102440201
102440601
N/A
N/A
102440401
102440501
N/A
Kit, Assy, Input Cover Plate (includes items 2 through 4) ............................................................
Cover, Input, Machined ......................................................................................................................
O-Ring .......................................................................................................................................................
Oil Seal, Triple-Lipped .........................................................................................................................
Shaft, Pinion, Machined ...........................................................................................................................
Bearing, Ball .................................................................................................................................................
Bushing, Plain 16 Id X 15 Wide ..............................................................................................................
1
1
1
1
1
1
1
Note: This page contains a list of components internal to the front
differential. See the previous pages for other front differential components.
Page 13-7
13
G
E
D
13
G
E
D
4
2
3
000091-001
Page 13-8
PROP SHAFTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
N/A
102371701
102372101
95293643
Inst, Prop Shafts, Awd (includes items 2 through 4) .....................................................................
Prop Shaft, Front ...................................................................................................................................
Prop Shaft, Rear .....................................................................................................................................
Pin, Spring, 5/16 X 1-1/2 Hd ..............................................................................................................
1
1
1
2
Page 13-9
13
G
E
D
13
G
E
D
9
19
12
8
15
16
13
15
7
14
10
6
17
18
2
3
5
11
4
000030-001
Page 13-10
FORWARD/REVERSE SHIFTER ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102470801
1014727
1014808
1016851
1016896
102298401
102375801
102375901
102376001
N/A
102499001
102615701
102616701
102618301
102684501
102684601
8057
8058
8717
Asm, FNR (includes items 2 through 19) ...........................................................................................
Washer, #4 Nylon Flat ..........................................................................................................................
Switch, Limit ...........................................................................................................................................
Buzzer, Reverse (9-48 VDC) ...............................................................................................................
Screw, #4-40 X 1.125 Hx Hd Mch ....................................................................................................
Nut,m8,all Metal Lock .........................................................................................................................
Weldment, FNR Shifter .......................................................................................................................
Bushing, Fnr ............................................................................................................................................
Knob, Fnr .................................................................................................................................................
Weldment, FNR Shifter Bracket .......................................................................................................
Rivet, Micro Tuflok ................................................................................................................................
Stud, Ball, .346 Dia ................................................................................................................................
Locknut, M10x1.5 Nylon Insert ........................................................................................................
Bolt Flanged Head, M8 X 1.25 X 65 ................................................................................................
Washer, M12 Hard Regular ................................................................................................................
Shoulder Bolt,m12 X 20 M10 Thd ...................................................................................................
Nut, #4-40 Hex Machine .....................................................................................................................
Lockwasher, #4 Split ............................................................................................................................
Locknut, 1/4-28 Nylon Insert ............................................................................................................
1
2
1
1
2
3
1
1
1
1
2
1
1
3
2
1
2
2
1
Page 13-11
13
G
E
D
13
G
13
E
16
10
D
17
15
14
12
11
8
3
5
7
4
6
9
24
25
21
28
26
20
27
19
18
22
28
2
23
000016-001
Page 13-12
TRANSMISSION
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
102369401
102693301
102764201
102694201
102696301
102697401
102698301
102698901
102699401
N/A
102693401
102693501
102694201
102696101
102697301
102699401
102721501
102765201
102696201
102696501
102696701
102696801
102696901
102697101
102697601
102697701
102699201
102699701
Transmission, Parallel Shaft * (includes items 2 through 18) .....................................................
Screw,hex Flange, M8 X 35 ................................................................................................................
Asm, Gear Case, Rear (includes items 4 through 9) ..................................................................
Plug, Square Skt, 1/12-14, Ptf .....................................................................................................
Oil, Deflector ....................................................................................................................................
Gearcase, Rear .................................................................................................................................
Vent, Trans ........................................................................................................................................
Screw, Tapping # 10-24 X .375 ...................................................................................................
Seal, Triple, 25 X 35 X 7.8 .............................................................................................................
Asm, Gear Case, Front (includes items 11 through 17) ...........................................................
Plug,3/8-16, Hex Flange ...............................................................................................................
Washer, .625 X .382 X .60 .............................................................................................................
Plug, Square Skt, 1/12-14, Ptf .....................................................................................................
Pin, Dowel, 6 X 20 ...........................................................................................................................
Gearcase, Front ...............................................................................................................................
Seal, Triple, 25 X 35 X 7.8 .............................................................................................................
Seal, Dual-Lip ...................................................................................................................................
Kit, Reverse Gear Repair (includes items 19 through 28) .......................................................
Ring, Retaining, Basic External ..................................................................................................
Washer, Thrust, 1.007 X .062 .......................................................................................................
Washer, 26.231 X 39.167 X 1.57 .................................................................................................
Bearing, Ball ......................................................................................................................................
Bearing, Ball ......................................................................................................................................
Bearing, Needle ..............................................................................................................................
Sprocket, 19-Tooth .........................................................................................................................
Sprocket, 51-Tooth .........................................................................................................................
Chain, .375p, .75 Wide, 60ptch ..................................................................................................
Ring, Retaining, E-Ring .................................................................................................................
1
11
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
2
* Note: This assembly also contains components listed on the following four
pages.
Page 13-13
13
G
E
D
13
G
11
E
13
14
12
15
D
18
17
16
21
22
20
18
19
23
1
2
7
8
6
4
5
3
10
9
000016-008
Page 13-14
TRANSMISSION, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
102697501
102698701
102764901
102696201
102696501
102696801
102696901
102697101
102697901
102698001
102765101
102697201
N/A
102698601
102699301
Dog, Engagement ......................................................................................................................................
Shaft, Intermediate ...................................................................................................................................
Kit, Forward Gear Repair (includes items 4 through 10) ..............................................................
Ring, Retaining, Basic External .........................................................................................................
Washer, Thrust, 1.007 X .062 .............................................................................................................
Bearing, Ball ............................................................................................................................................
Bearing, Ball ............................................................................................................................................
Bearing, Needle .....................................................................................................................................
Gear, Helical 58-Tooth .........................................................................................................................
Kit, Neutral Switch Repair (includes items 12 through 15) .........................................................
Spring, .484 X .340 X 1.076 ................................................................................................................
Guide, Detent Bullet ............................................................................................................................
Bullet, Detent .........................................................................................................................................
Switch, Indicator, Pollak .....................................................................................................................
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
Note: This page contains a list of components internal to the transmission.
See the previous pages for other transmission components.
Page 13-15
13
G
E
D
13
G
E
D
5
8
6
4
3
9
2
10
11
000016-009
Page 13-16
TRANSMISSION SHIFT SHAFT AND BELL
CRANKTRANSMISSION SHIFT SHAFT AND BELL CRANK (STYLE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
102765001
102696001
102696401
102696601
N/A
102699601
103294301
1010177
N/A
334
8754
Kit, Trans Shift Shaft Repair (includes items 2 through 6) ...........................................................
Nut, Lock Hex, Nylon, 5/16-24 .........................................................................................................
Ring, Retaining, External 9/16 ..........................................................................................................
Washer, Flat, .58 X 1.08 X .05 .............................................................................................................
Weldment, Shift, Shaft ........................................................................................................................
Seal, Dul Lip, .88 X .56 X .19 ...............................................................................................................
Kit, Bellcrank, D Shape, Clamp (includes items 8 through 11) ...................................................
Bolt, 3/8-16 X 2.00 Hex Head ............................................................................................................
Asm, Bellcrank, D Shape, Clamp .....................................................................................................
Washer, 3/8 Type A Flat ......................................................................................................................
Locknut, 3/8-16 Hex ............................................................................................................................
1
1
1
1
1
1
1
1
1
1
1
Page 13-17
13
G
E
D
13
G
E
D
6
4
3
2
5
1
000016-010
Page 13-18
TRANSMISSION SHIFT SHAFT AND BELL CRANK (STYLE B)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102696001
102696401
102696601
102699601
103239501
103239801
Nut, Lock Hex, Nylon, 5/16-24 ...............................................................................................................
Ring, Retaining, External 9/16 ...............................................................................................................
Washer, Flat, .58 X 1.08 X .05 ..................................................................................................................
Seal, Dul Lip, .88 X .56 X .19 ....................................................................................................................
Bellcrank, Alum ...........................................................................................................................................
Shaft, Shift ....................................................................................................................................................
1
1
1
1
1
1
Page 13-19
13
G
E
D
13
G
6
3
5
E
4
D
14
16
13
17
12
15
9
8
10
7
11
6
1
2
000016-003
Page 13-20
TRANSMISSION, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
102697801
102698801
102699501
102764701
102696201
102696901
102697001
102698101
102698401
102699001
102699701
102700201
102700301
102764801
102700001
102700101
102721501
Fork, Transmission .....................................................................................................................................
Shaft, Output ...............................................................................................................................................
Plug, 19mm ..................................................................................................................................................
Kit, Input Shaft Repair (includes items 5 through 13) ...................................................................
Ring, Retaining, Basic External .........................................................................................................
Bearing, Ball ............................................................................................................................................
Bearing, Ball ............................................................................................................................................
Shaft, Input .............................................................................................................................................
Gear, Helical, 31-tooth ........................................................................................................................
Ring, Retaining, E-Ring .......................................................................................................................
Sub Assy, Fly Weight ............................................................................................................................
Sub Assy, Governor Spool .................................................................................................................
Kit, Governor Shaft Repair (includes items 15 through 17) ........................................................
Ring, Retaining ......................................................................................................................................
Assy, Governor Arm .............................................................................................................................
Seal, Dual-Lip .........................................................................................................................................
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
Note: This page contains a list of components internal to the transmission.
See the previous pages for other transmission components.
Page 13-21
13
G
E
D
13
G
3
E
4
7
D
2
6
1
5
1
5
6
000032-001
Page 13-22
TRANSMISSION CABLE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
1011084
1012769
102382401
102475701
102495801
102615801
102621501
Nut, 1/4-28 Hex Jam .................................................................................................................................
Clip, Brake Line ............................................................................................................................................
Cable, Transmission Shift ........................................................................................................................
Joint, Ball, .346 Dia .....................................................................................................................................
Nut Flg, M6 X 1.0 Nylon ...........................................................................................................................
2
3
1
2
1
2
3
Page 13-23
13
G
E
D
13
G
19
E
9
20
2
D
10
8
11
3
7
13
17
6
18
12
5
4
16
14
15
9
19
7
10
8
3
11
20
2
Page 13-24
000004-001
REAR DIFFERENTIAL
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
102831501
102276001
102376602
102449101
102463501
102463601
102463801
102672101
102672201
102672301
102672401
N/A
102693301
102693401
102693501
102694201
102694301
102694401
102694701
102694801
Axle, Rear, Guard Mounts (Complete Assembly) (includes items 2 through 20) ................
Locking Cap, Nut ..................................................................................................................................
Assy, Rotor, Brake, Rear .......................................................................................................................
Gearcase, Lower, Machined ..............................................................................................................
Axle, Right-hand ...................................................................................................................................
Axle, Left-Hand ......................................................................................................................................
Ring, Retaining, Internal .....................................................................................................................
Washer,counterbored 51 X 30 .........................................................................................................
Washer, Bellevle, 1.063 X .043 ..........................................................................................................
Washer, Belleville, 49 X 4 ....................................................................................................................
Nut, Hex, M20 X 1.5 , Modified ........................................................................................................
Screw, M10 X 25 ....................................................................................................................................
Screw,hex Flange, M8 X 35 ................................................................................................................
Plug,3/8-16, Hex Flange .....................................................................................................................
Washer, .625 X .382 X .60 ...................................................................................................................
Plug, Square Skt, 1/12-14, Ptf ...........................................................................................................
Bellows, Vent, Upper Housing .........................................................................................................
Clamp, Hose, Dw-9.5 ...........................................................................................................................
Screw, Hex Fl, M12 X 1.75 X 30 .........................................................................................................
Pin, Cotter, 5/32 X 1.25 ........................................................................................................................
1
2
2
1
1
1
2
2
12
2
2
8
9
1
1
1
1
1
12
2
Page 13-25
13
G
E
D
13
G
8
E
10
11
9
D
27
30
29
24
1
3
28
2
25
15
27
13
26
16
12
15
17
18
22
14
21
20
23
19
4
5
7
6
000004-002
Page 13-26
REAR DIFFERENTIAL, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
102765301
102449201
102694001
102765401
102463401
102463801
102464301
102765501
102463301
102463801
102464301
102765801
102464201
102464401
102464501
102762601
102765701
102463101
102463901
102464001
102464101
102693601
102694502
102961501
102464201
102464401
102464501
102961301
102961401
102961601
Asm, Gearcase, Upper (includes items 2 and 3) ..............................................................................
Gearcase, Upper, Machined ..............................................................................................................
Vent, Top, Upper Housing .................................................................................................................
Asm, Axle Tube, RH (includes items 5 through 7) ..........................................................................
Weldment, Axle Tube Rh ...................................................................................................................
Bearing .....................................................................................................................................................
Asm, Axle Tube, LH (includes items 9 through 11) ........................................................................
Weldment, Axle Tube Lh ....................................................................................................................
Bearing .....................................................................................................................................................
Kit, Rear Axle Gear Repair (includes items 13 through 17) .........................................................
Bearing, Ball ............................................................................................................................................
Seal, Dual-Lip 25x 62x 7tc ..................................................................................................................
Gear, Ring, 33-Tooth ............................................................................................................................
Asm, Pinion W/ Bearings (includes items 18 through 23) .....................................................
Pinion, I0t Machined .....................................................................................................................
Ring, Retaining, External .............................................................................................................
Bearing, Ball ......................................................................................................................................
Bearing, Needle, Drawn Shell ....................................................................................................
Washer, 2.625 X 2.367 X .06 ........................................................................................................
Shim, 1.50 X 1.189 X .008 .............................................................................................................
Asm, Differential & Carrier (includes items 25 through 30) ........................................................
Bearing, Ball ............................................................................................................................................
Housing, Differential, Mach ..............................................................................................................
Pin, Dowel, 4 X 35 .................................................................................................................................
Asm, Locker, Nongrease/Spacers ....................................................................................................
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
2
1
1
1
Page 13-27
13
G
E
D
13
G
E
D
RADIATOR AND COOLANT SYSTEM
(DIESEL VEHICLES)
14
G
E
D
14
G
22
E
16
D
2
24
17
7
21
6
9
14
8
18
13
20
19
1
12
15
23
15
5
11
4
10
3
000024-001
Page 14-2
RADIATOR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1014471
102289001
102377801
102377901
102380301
102410301
102737301
102737401
102411207
102411208
102411301
102436701
102452101
102490301
102493401
102498101
102618601
102684401
102685001
102855501
96704416
96705199
96741038
Tape, Vinyl Foam 1/8" x 3/4" * ................................................................................................................
Screw, M8X1.25X30, Hex .........................................................................................................................
Hose, Coolant Lower Pipe .......................................................................................................................
Hose, Coolant Lower Rad ........................................................................................................................
Tee, Coolant Fill ...........................................................................................................................................
Exchanger, Engine Coolant (includes items 7 and 8) ....................................................................
Cap, Radiator ..........................................................................................................................................
Drain Cock, Radiator ............................................................................................................................
Clamp, Hose, Ctb 35mm ..........................................................................................................................
Clamp, Hose, Ctb 38mm ..........................................................................................................................
Nut, Self Retaining .....................................................................................................................................
Fan, Cooling 12 In Elect ...........................................................................................................................
Guard, Radiator, Top .................................................................................................................................
Bolt, M6 X 1 X 16 Loctite ..........................................................................................................................
Bracket, Upper Radiator Mount ............................................................................................................
Bolt, M8 X 1.25 X 20 ...................................................................................................................................
Bumper, 13mm Stud .................................................................................................................................
Isolator, Twin-Stud .....................................................................................................................................
Shroud, Radiator Fan ................................................................................................................................
Nut Flg, M8 X 1.25 Serrated ....................................................................................................................
Washer, M6 ...................................................................................................................................................
Washer, M8 Hard ........................................................................................................................................
1
2
1
1
1
1
1
1
2
1
4
1
1
8
2
2
2
2
2
1
2
4
2
Page 14-3
14
G
E
D
14
G
E
D
11
11
7
4
6
8
9
5
2
10
1
4
-
11
3
000078-001
Page 14-4
COOLANT EXPANSION TANK
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
102289001
102460801
N/A
102411204
102411205
102411701
102427501
102434501
102435201
102807601
102807801
Screw, M8X1.25X30, Hex .........................................................................................................................
Bracket, Coolant Bottle ............................................................................................................................
Asm, Tank, Expansion (includes items 4 through 11) ...................................................................
Clamp, Hose, CTB 15mm ...................................................................................................................
Clamp, Hose, CTB 22mm ...................................................................................................................
Fitting, Tee ...............................................................................................................................................
Cap, Radiator ..........................................................................................................................................
Tank, Expansion ....................................................................................................................................
Hose, Tee To Vent Tube, Coolnt .......................................................................................................
Hose, Clnt, 5/8 Sae J20r3 Bulk ..........................................................................................................
Hose, Clnt 5/16 Sae J20r3 Bulk ........................................................................................................
2
1
1
4
1
1
1
1
1
1
1
Page 14-5
14
G
E
D
14
G
E
7
D
1
3
13
4
6
13
11
6
6
8
3
3
12
12
9
15
14
10
2
5
6
000079-001
Page 14-6
COOLANT PIPES AND HOSES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
102377501
102377601
102411204
102411205
102411206
102411207
102411208
102427601
102435001
102458901
102480501
102618301
102618601
102628701
102377401
102377701
N/A
N/A
N/A
96747126
Hose, Coolant Upper Rad ........................................................................................................................
Hose, Coolant Lower Eng ........................................................................................................................
Clamp, Hose, CTB 15mm .........................................................................................................................
Clamp, Hose, CTB 22mm .........................................................................................................................
Clamp, Hose, Ctb 30mm ..........................................................................................................................
Clamp, Hose, Ctb 35mm ..........................................................................................................................
Clamp, Hose, Ctb 38mm ..........................................................................................................................
Clamp, Bar .....................................................................................................................................................
Hose, Vent Tube To Eng, Coolnt ............................................................................................................
Hose, Coolant, Return, Engine ...............................................................................................................
Weldment, Group, Coolant Pipe (includes items 15 through 19) .............................................
Pipe, Coolant Upper ............................................................................................................................
Pipe, Coolant Lower .............................................................................................................................
Tab, Rear Mntg, Coolant Pipe ...........................................................................................................
Pipe, Vent, Coolant ...............................................................................................................................
Tab, Cooling Pipe Mount ...................................................................................................................
Bolt, M8 X 1.25 X 130 ................................................................................................................................
1
1
4
1
1
5
1
1
1
2
1
2
3
1
1
1
2
1
1
1
Page 14-7
14
G
E
D
14
G
E
D
12
13
2
3
9
5
7
8
6
11
10
4
1
000059-001
Page 14-8
WATER FLANGE AND THERMOSTAT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102410001
102631301
102631401
102631601
102633001
102633201
102633301
N/A
102633401
102654701
102730901
102731001
102731101
Sensor, Coolant Temp ...............................................................................................................................
Cover, Thermostat .....................................................................................................................................
Assy, Thermostat ........................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Band, Pipe .....................................................................................................................................................
Flange, Water (includes items 7 and 8) ..............................................................................................
Pipe, Water Return, D722 ...................................................................................................................
Flange, Water .........................................................................................................................................
Gasket, Thermostat ...................................................................................................................................
Gasket, Water Flange ................................................................................................................................
Bolt, Alt, D722, Stay Lower ......................................................................................................................
Pipe, Water Return, D722 ........................................................................................................................
Bolt, D722, Thermostat Cover ...............................................................................................................
1
1
1
2
2
1
1
1
1
1
1
1
2
Page 14-9
14
G
E
D
14
G
E
D
2
3
1
000060-001
Page 14-10
WATER PUMP
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
102608701
102632701
102731201
Bolt, M6 X 1 X 22 .........................................................................................................................................
Gasket, Water Pump, D722 .....................................................................................................................
Water Pump Assembly .............................................................................................................................
4
1
1
14
G
E
D
Page 14-11
14
G
E
D
1
5
3
2
1
4
000061-001
Page 14-12
BLOCK COOLANT PIPE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
102631701
102631801
102632001
102632101
102632201
Band, Pipe, with Nut .................................................................................................................................
Pipe, Water, Bent ........................................................................................................................................
Nut, Flange, M6 ...........................................................................................................................................
Pipe, Water, Bent ........................................................................................................................................
Stud, M6 X 15 ...............................................................................................................................................
2
1
1
1
1
Page 14-13
14
G
E
D
14
G
E
D
MAINTENANCE AND SERVICE TOOLS
15
G
E
D
15
G
E
D
1
2
4
3
7
6
5
8
9
15
14
10
16
Page 15-2
11
12
17
13
18
19
MAINTENANCE AND SERVICE TOOLS
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
G
1 2 3 4
The following tool list includes all tools available from Club Car for
maintenance and service procedures for gasoline, electric, and/or
diesel vehicles, both past and present models. Be sure to carefully
examine the tool list for applicability to your vehicle before ordering.
1
2
3
4
5
6
7
8
9
10
11
101871001
101813202
101641202
101831901
1014305
1011767
1016417
1016416
1012811
1012812
1013582
12
13
102555501
102249901
14
15
16
17
18
19
****
****
101887101
101808401
102562401
102686101
Accelerator Pedal Adjustment Tool .......................................................................
Adhesive, Guide Ring, 3-Gram Tube .....................................................................
Arbor ................................................................................................................................
Battery Discharge Machine, 36/48 Volt ................................................................
Battery Terminal Protector Spray ...........................................................................
Battery Thermometer .................................................................................................
Bearing and Oil Seal Remover Assembly ............................................................
Bearing Driver Set ........................................................................................................
Bearing Puller ................................................................................................................
Bearing Puller Wedge Attachment ........................................................................
Brake Adjustment Tool (used only on vehicles with
manually adjusted mechanical brakes) ...............................................................
Brake Cable Release Tool ...........................................................................................
Brake Pedal Adjustment Tool Kit (used for the Carryall Electric
Industrial Truck only) (includes items 14 and 15)..............................................
Brake Pedal Adjustment Tool .............................................................................
Brake Pedal Tension Tool .....................................................................................
Calibration Test Module ............................................................................................
Cam Installation Tool ..................................................................................................
Charger Bezel Tool .......................................................................................................
Clutch Removal Tool (for 4x4 vehicles) .................................................................
E
D
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Please refer to the maintenance and service manual
for proper tool application.
****
15
Special order item available upon request
Page 15-3
15
G
G
IN
N
R
A
W
E
D
21
24
23
22
27
26
25
20
28
30
29
32
31
COMMUNICATION
DISPLAY MODULE
DISPLAY FUNCTIONS:
PRESS AND HOLD
BUTTON TO SHOW
FUNCTION NUMBER.
RELEASE BUTTON TO
SHOW FUNCTION VALUE.
Func1 - Battery voltage.
Func2 - Energy units removed since last charge cycle.
Func3 - Total accumulated energy units removed.
Func4 - Last charge termination type (1 = Incomplete,
2 = DVDT, 4 = Normal, 8 = Max. timer).
POWER
ON
OFF
R
Club Car
PART #17075
33
38
Page 15-4
39
36
35
34
40
41
42
37
43
MAINTENANCE AND SERVICE TOOLS, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
G
1 2 3 4
20
21
1014510
1014498
22
23
24
25
26
27
28
1014496
1014497
1014508
1014507
1015524
101809101
102601501
29
102603501
30
102605201
31
102606101
32
102607501
33
34
35
36
37
38
39
40
101831801
101641002
1011273
102773801
102773901
102774101
102774101
102675401
41
42
43
102774201
102774301
102774401
Clutch Tool Kit (includes items 21 - 27) ................................................................
Clutch Alignment Tool (for pre-unitized transaxle
vehicles built prior to 1997 model year) ........................................................
Drive Clutch Puller (for Kawasaki engines only) ..........................................
Drive Clutch Hub Puller (for Kawasaki engines only) ................................
Driven Clutch Cam Puller (for Kawasaki engines only) .............................
Driven Clutch Puller Plug (for Kawasaki engines only) .............................
Drive Clutch Holder Tool Assembly (for Kawasaki engines only) ..........
Press Weldment (for Kawasaki engines only) ...............................................
Drive ClutchFixed Sheave Tool
(for 4x4 vehicles) ...........................................................................................................
Driven Clutch Spring Compression Base (for use with items 30
and 31) (for 4x4 vehicles) ...........................................................................................
Driven Clutch Spring Compression Collar (for use with items 29
Driven Clutch Spring Compression Nut (for use with items 29
Drive Clutch Spider Removal Tool
(for 4x4 vehicles) ...........................................................................................................
Communication Display Module ...........................................................................
Compression Gauge and Adapter .........................................................................
Continuity Tester ..........................................................................................................
Cutter, Valve Seat, #122 ..............................................................................................
Cutter, Valve Seat #115 ...............................................................................................
Wrench, T, #505..............................................................................................................
Adapter, T-Wrench........................................................................................................
Cutter, Valve Seat, 60 Degree (requires item 51)
(for Honda GX620 Gasoline Engines) ...................................................................
Pilot, 6.6 MM ...................................................................................................................
Pilot, 6.62 MM.................................................................................................................
Pilot, 6.65 MM.................................................................................................................
1
E
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
D
1
1
1
1
1
1
1
1
1
1
1
1
15
Page 15-5
15
G
E
D
44
45
46
47
48
49
50
51
2
56
57
3
54
52 53
58
Page 15-6
59 60
61
Liquid
Gasket
55
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
1
1
1
1 2 3 4
44
45
46
1012151
1016627
102669901
47
48
49
1016418
101933101
102169401
50
51
52
1011478
1013593
102248803
53
102248804
54
55
56
57
58
59
59
59
59
59
59
59
59
59
59
60
61
102251501
102241502
102241501
101928701
102243402
101997201
101997207
101997212
101997211
101997205
101997209
101997204
101997203
101997206
101997202
102562301
102587201
Dry Moly Lubricant ......................................................................................................
Flywheel Puller Kit (for Kawasaki Engines) .........................................................
Gauge, Carburetor Float Level
Gear Yoke ........................................................................................................................
Governor Shaft Installation Tool (for Kawasaki Engine Vehicles) ...............
Hydraulic Brake Adjuster (for Turf/CA 272/472, Pioneer/XRT 1200,
Bobcat 2100, HUV 4213) ............................................................................................
Hydrometer ....................................................................................................................
Internal Retaining Ring Pliers ..................................................................................
IQ Display Module (IQDM) Kit (IQ System and IQ Plus vehicles) .................
(includes items 54 and 55)
IQ Display Module (IQDM-P) Kit (IQ System and IQ Plus vehicles)..............
(includes items 54 and 55)
Adaptor, Cable .........................................................................................................
IQDM Series 2 Cable ..............................................................................................
IQDM Series 1 Cable (replacement) ......................................................................
Liquid Gasket (transaxle case) .................................................................................
Moly-Teflon Lubricant (4-oz. (113-gram) tube) .................................................
Paint, Touch-Up – Beige* ..........................................................................................
Paint, Touch-Up – Black* ...........................................................................................
Paint, Touch-Up – Burgundy* ..................................................................................
Paint, Touch-Up – Classic Blue (Navy)* .................................................................
Paint, Touch-Up – Dark Gray* ..................................................................................
Paint, Touch-Up – Dark Green* ...............................................................................
Paint, Touch-Up – Gray* .............................................................................................
Paint, Touch-Up – Red* ..............................................................................................
Paint, Touch-Up – Royal Blue (Pacific Blue)* .......................................................
Paint, Touch-Up – White* ..........................................................................................
Paint, Precedent Underbody – Gray.......................................................................
Paint Pen, Touch-Up, Precedent Underbody – Black .......................................
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* Item 59 is not for use on Surlyn® body material, which is used
on Precedent vehicles.
G
E
1
1
15
Page 15-7
D
15
G
E
D
63
62
66
65
64
Safety First
Never use a vehicle that is unsafe.
Inspect each day.
Inspect
GOOD
NEED(S)
ATTENTION
• Brakes
• Park Brake
• Steering
• Accelerator
• F & R Selector
• Reverse Buzzer
• Key Switch
• Speeds
• Tires
• Bag Straps and Buckles
Other Mechanical Problems
• Unusual Noise
• Will Not Run
• Stopped on Course
• Other:
•
•
•
Damage
• Right Side
• Left Side
• Front
• Rear
• Other: ______________
No Damage
NEED(S)
ATTENTION
Cleanliness
• Seats
• Floor Mat
• Dash Compartments
• Bag Well
• Beverage Holders
• Overall Appearance: ___________________
Date: _____________ Inspected By: _________________
Car No. ___________
(Over)
CCI 1018231
69
68
67
71
70
72
AM10753
ON
OFF
STR
SPK
MAX
MIN
GAS
DSL
GAS/DIESEL
TACHOMETER
73
77
Page 15-8
83
76
75
74
84
85
86
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
G
1 2 3 4
62
63
64
65
66
67
68
69
1016414
1016415
102668801
1012549
1012560
101823101
1012809
102330901
70
71
72
73
74
75
76
77
78
1014264
1014259
102061201
AM10753
AM10771
1014162
1014161
1014115
101611003
79
AM11804
80
AM11805
81
AM1220301
82
AM1232401
83
84
1016413
102674601
85
86
101641201
102674401
Piston Ring Compressor Kit (FE290, FE350 and FE400 engines) .................
Piston Ring Pliers (for Kawasaki Engines) ............................................................
Puller, Special Use (for Kubota D722 Diesel Engines) .....................................
Retaining Ring Pliers, 45° External .........................................................................
Retaining Ring Pliers, 90° Internal ..........................................................................
Safety First Card (50 per pack) .................................................................................
Seal Puller .......................................................................................................................
Spanner Wrench (for coil over shock front
suspension vehicles only) .........................................................................................
Steering Column Bearing Press Tool .....................................................................
Steering Column Retaining Ring Tool ..................................................................
Steering Wheel Puller Tool .......................................................................................
Tachometer (includes gasoline engine pick up lead only) ...........................
Tachometer Diesel Probe (for use with item 73) ..............................................
Transaxle Axle Seal Tool .............................................................................................
Transaxle Pinion Seal Tool .........................................................................................
Transmission Tool Kit ..................................................................................................
Tune-Up Kit, All OHV (for FE290, FE350, FE400 only) (includes
air filter, spark plug, oil filter, fuel filters) (not shown) ....................................
Tune-Up Kit, Gx620 (for Honda Engines) (includes air filter,
spark plug, oil filter, fuel filters) (not shown) ......................................................
Tune-Up Kit, D722 (for Kubota Engines) (includes air filter,
oil filter, fuel filters, water separator filter) (not shown) .................................
Tune-Up Kit, Precedent (for FE290/350 Engines) (includes air
filter, spark plug, oil filter, fuel filters) (not shown) ...........................................
Tune-Up Kit, FH680D (for Kawasaki V-Twin Engines) (includes oil
filter, fuel filter, air filter, and spark plugs) (not shown)...................................
Valve Clearance Adjuster Screw Holder (for FE290 engines only) .............
Valve Guide Driver
Valve Guide Reamer (FE290, FE350, and FE400 only) ......................................
Valve Guide Reamer, 6.6 mm
1
1
1
1
1
1
1
1
1
1
1
E
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
15
1
1
1
1
1
1
Page 15-9
D
15
G
E
D
87
88
-
45
45
89
90
+
WAVETEK
V
5XL
1000
V
OFF
500
200
200
20
200
2m
2
200
m
20
m
200
m
2000
k
200k
20k
V
!
MAX
1000 --750V
Page 15-10
200
A
2k
!
COM
200nA
FUSED
91
92
95
96
93
94
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
G
1 2 3 4
87
88
89
90
91
92
93
94
95
96
1016552
1016551
1016553
1016554
101641101
1011480
102570401
103601401
103601701
103600501
Valve Seat Cutter Guide .............................................................................................
Valve Seat Cutter T-Wrench ......................................................................................
Valve Seat Cutter, 45° (32 mm diameter) (for FE290 engines only) ...........
Valve Seat Cutter, 45°/30° (35 mm diameter) ....................................................
Valve Spring Compressor ..........................................................................................
Volt Ohm Meter ............................................................................................................
Tool, Tensioning, Starter Generator (For Precedent vehicles) ......................
Puller, Drive Clutch, XRT 950*...................................................................................
Tool, Disassembly, Driven Clutch, XRT 950 ..........................................................
Screw, Driven Clutch Disassembly, M6, XRT 950 ...............................................
1
1
1
1
1
1
1
1
1
1
1
E
D
1
*Note: The XRT 950 Drive Clutch Puller requires the use of Screw,
Driven Clutch Disassembly, CCI Part Number 103600501.
15
Page 15-11
INDEX
Part Number and Page
AM10753 15-9
AM10771 15-9
AM1232301 9-7, 9-11
183 4-11, 10-5, 10-9
332 1-11, 1-19, 7-17, 7-19
334 13-17
357 1-15
451 1-9
1016 10-5, 10-9
1017 7-15
1035 4-13, 5-9
1108 7-17, 7-19
1241 4-11, 7-25, 7-27
7310 2-3
7473 1-13, 1-19, 7-25, 7-27
7561 1-13
8057 13-11
8058 13-11
8233 1-19, 10-23
8248 1-5
8251 1-17
8639 4-9, 4-11, 4-13
8717 13-11
8754 1-13, 1-15, 6-11, 13-17
8755 1-13, 1-15
8797 10-5, 10-9
8990 1-15, 6-5
1010177 13-17
1010200 1-15
1010435 1-13, 1-19
1010436 1-19
1010521 4-11, 4-13
101082903 4-7
1010934 7-25, 7-27
1011084 13-23
1011273 15-5
1011478 15-7
1011480 15-11
1011553 3-3, 3-7
1011652
1011767
1011779
1-9
15-3
4-11, 4-13
1012151
1012295
1012303
1012438
1012549
1012560
15-7
7-17, 7-19
1-13
4-11
15-9
15-9
101260202 4-11
1012769 1-17, 8-3, 9-3, 13-23
1012809 15-9
1012811 15-3
1012812 15-3
1012830 1-9
1013035 6-5
1013042 6-5
1013044 6-5
1013051 6-5
1013052 6-5
101313402 10-7
1013366 1-19
1013461 7-15, 10-5, 10-9
1013462 10-5, 10-9
1013531 4-11, 4-13
1013582 15-3
1013593 15-7
1013734 1-9
1013746 10-3, 10-7
1013857 7-21, 7-23
1014007 10-23
1014115 15-9
1014161 15-9
1014162 15-9
1014259 15-9
1014264 15-9
1014305 15-3
1014306 1-3, 1-5, 1-17, 1-19, 4-7
1014321 1-17
1014375 7-25, 7-27
101438702 1-17
1014415 1-19
1014471 1-9, 1-13, 14-3
1014496 15-5
1014497 15-5
1014498 15-5
1014507 15-5
1014508 15-5
1014510 15-5
1014537 1-19
1014557 7-21, 7-23
1014727 13-11
1014808 13-11
1015139 10-5, 10-9
1015143 10-5, 10-9
1015258 1-13
1015356 1-13
1015399 1-13, 1-19
101547601 3-5
1015521 7-17, 7-19
1015524 15-5
101553901 3-3, 3-7
1015583 1-13
1015597 6-13, 6-15
1015636 7-21, 7-23
1015741 7-17, 7-19
101587703 10-3, 10-7
101609401 3-3, 3-7
101611003 15-9
1016183 6-11
101641002 15-5
101641101 15-11
101641201 15-9
101641202 15-3
1016413 15-9
1016414 15-9
1016415 15-9
1016416 15-3
1016417 15-3
1016418 15-7
1016551 15-11
1016552 15-11
1016553 15-11
1016554 15-11
1016603 1-15
1016627 15-7
1016630 7-21, 7-23
1016851 13-11
1016879 7-15
1016880 7-15
1016896 13-11
1016967 1-7
1017062 7-15
1017064 7-15
1017065 7-15
1017162 1-15
1017167 1-15
1017774 1-15
101808401 15-3
101809101 15-5
101813202 15-3
101823101 15-9
101824401 10-3, 10-7
101831801 15-5
101831901 15-3
101833101 8-3
101833201 8-3
101856102 12-5
101871001 15-3
101879401 6-5
101879701 6-5
101879801 6-5
101879901 6-5
101880201 6-5
101886101 10-23
101887101 15-3
101887601 1-11, 4-7, 4-9
101894304 1-19
101898001 7-25, 7-27
101928701 15-7
101933101 15-7
101963401 1-19
101972001 15-7
101972002 15-7
101972003 15-7
101972004 15-7
101972005 15-7
Page i-1
INDEX
102231601
102239901
102241501
102241502
102243402
102248803
102249901
102251501
102251601
102251701
102274101
102276001
102289001
102169401
102171504
102176901
15-7
15-7
15-7
15-7
15-7
7-15
7-15
7-15
7-15
7-15
4-11, 4-13
6-5
2-3
2-3
2-3
2-3
2-3
2-3
2-3
1-3, 1-5
1-3, 1-5
1-3, 1-5
6-5
6-5, 6-7, 13-3
1-9
4-11
7-21
7-21
1-3, 1-5
3-11, 3-13
1-9
1-3, 1-5
4-7
7-21
7-21
7-21, 7-23
4-11, 4-13
1-11
1-9
1-9
15-9
1-13
1-13, 1-15
15-7
1-13
4-7
102370601
102371401
102371701
3-5, 3-9
1-19
15-7
15-7
15-7
15-7
15-3
15-7
1-17
1-17
13-3
13-25
1-7, 9-15, 10-7, 14-3, 14-5
1-3, 1-5
6-3
4-9, 6-7
4-9, 5-3, 6-7
4-9, 10-7, 10-23, 12-3, 12-5
1-3, 1-5, 1-9, 6-3, 6-11
6-9, 6-11
1-9, 8-3, 9-3, 10-3, 11-5, 13-11
5-9
15-9
9-15
7-25, 7-27
6-7, 13-3
6-3
6-3
6-13
6-15
6-3
4-3
13-3
13-3
13-3
6-7
6-7
6-7
6-7
13-13
12-13
8-3
8-3, 9-3
8-3, 9-3
9-15
13-9
102198001
102221301
102221401
102221501
102221701
102221801
102222001
102222101
102222201
102224001
7-21, 7-23
1-19
1-19
1-19
1-19
1-19
1-19
1-19
1-19
3-3, 3-7
102371801
102372101
102373401
13-5
13-9
1-7
102374701
102374801
102374901
102375401
102375801
102375901
102376001
13-3
2-3
12-7
7-23
13-11
13-11
13-11
101972006
101972007
101972009
101972011
101972012
101987901
101988001
101988002
101988101
101988201
101990802
102010102
102021302
102021305
102021306
102021406
102021407
102021408
102021409
102021502
102021602
102021802
102022601
102022901
102023703
102028302
102044702
102044801
102045001
102046501
102047001
102048401
102051401
102051601
102051701
102051901
102052801
102059001
102059401
102061101
102061201
102065901
102066001
Page i-2
102289002
102290120
102296140
102296401
102296716
102298130
102298240
102298401
102323501
102330901
102331401
102355301
102361901
102363802
102364201
102365601
102365602
102367101
102367601
102368201
102368301
102368302
102368501
102368502
102368801
102368802
102369401
102369901
102370101
102370501
102376601
102376602
102377401
102377501
102377601
102377701
102377801
102377901
102378901
102379001
13-3
13-25
14-7
14-7
14-7
14-7
14-3
14-3
10-25
10-27
102380301
102380601
102381701
102382401
102385601
102385701
102385801
102393501
102394002
14-3
5-5
13-3
8-3, 9-3, 13-23
12-9, 12-11
12-13
10-13
6-13, 6-15
6-9, 6-11
10-25, 10-27
6-13, 6-15
4-5
4-5
4-7
4-7
102395601
102398901
102399201
102399202
102402801
102402901
102406701
102406801
102407801
102407901
102408401
102409301
102409401
102409501
102409601
102410001
102410301
102410603
102410801
102411202
102411203
102411204
102411205
102411206
102411207
102411208
102411209
102411210
102411301
102411701
102414501
102414701
102414801
102414901
102418401
102418501
102419901
10-9
10-9
4-9
4-9
6-7
11-5
11-3, 11-5
11-3, 11-5
11-3
14-9
14-3
1-3, 1-5, 4-9, 8-3, 9-3
10-7
10-3
10-7
14-5, 14-7
14-5, 14-7
14-7
14-3, 14-7
14-3, 14-7
10-27
10-25, 12-3, 12-5
14-3
14-5
12-5
8-3
8-3
9-3
1-11
1-3, 1-5, 1-11
1-11
INDEX
102420001
102420201
1-11
7-17, 7-19
102420401
102420501
102422301
102423701
102425401
102425501
102426301
102426601
102427501
102427601
102429301
102430001
102430201
102430301
102430401
102432001
102433101
102433501
102434501
102434601
102434701
102434801
102435001
102435201
102435301
102436001
102436101
102436701
102437001
102437101
102437201
102438101
7-17, 7-19
7-17, 7-19
8-53, 11-5
10-23
1-9
1-9
10-3, 10-7
1-15
14-5
14-7
1-3
10-7
10-7
10-7
10-7
1-3, 1-5
10-23
10-23
14-5
10-7
10-7
9-15, 10-7
14-7
14-5
7-5, 7-9
13-3
13-3
14-3
6-7
6-7
1-7
5-7, 5-9
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-5
13-7
13-5
13-7
102438201
102438301
102438401
102438501
102438601
102438701
102438801
102438901
102439001
102439101
102439201
102439301
102439401
102439501
102439601
102439701
102439801
102439901
102440101
102440201
102440301
102440401
102440501
102440601
102442001
102442201
102442301
102442401
102442701
102442801
102442901
102443501
102443601
102444201
102445201
102446601
102446901
102447001
102447601
102447602
102447901
102448001
102448401
102448501
102449101
102449201
102449901
102451001
102451201
102452101
102452301
102454001
102454101
102454201
102454801
102454901
102455001
102455101
102455201
102455301
102456001
102457001
102457101
102457201
102457301
102457501
102457601
102458801
102458901
102459001
102459101
102459201
102459301
102459401
102459501
102459601
102459710
102459714
13-7
13-7
1-9
7-25, 7-27
7-25
7-25
4-11
4-11
5-3, 5-5
9-15
9-15
7-13
5-3
6-11
6-7
13-3
1-11
1-11
7-17, 7-19
7-17, 7-19
7-27
7-27
13-25
13-27
6-5
10-21
10-23
14-3
10-23
1-17
1-17
1-17
10-23
10-23
3-5
3-9
3-3
3-7
1-9
10-23
10-23
10-23
7-23
9-15
9-15
3-7
1-9, 3-5, 3-9, 14-7
3-9
3-5, 3-9
3-9
3-3, 3-7
1-11, 3-3, 3-7
3-5, 3-9
3-3, 3-7
1-3, 1-5
1-3, 1-5
102459715
102459716
1-3, 1-5
1-3, 1-5
102459718
102460201
102460801
102462301
102462401
102462501
102462502
102462601
102463101
102463301
102463401
102463501
102463601
102463801
102463901
102464001
102464101
102464201
102464301
102464401
102464501
102464601
102465701
102465901
102466201
102468802
102469401
102469901
102470101
102470501
102470601
102470801
102473501
102473601
102473701
102474101
102474102
102474301
1-3, 1-5
3-9
14-5
8-3, 9-3
13-3
8-3
9-3
10-13
13-27
13-27
13-27
13-25
13-25
13-25, 13-27
13-27
13-27
13-27
13-27
13-27
13-27
13-27
6-11
1-15
8-3
1-17
6-11
5-3
6-7
6-11
6-11
6-11
13-11
1-9
1-9
1-9
4-9, 6-7
4-9, 6-7
4-9
102475301
102475701
102475801
102475901
102476301
102476401
102477001
102477201
102477301
9-15
4-9, 10-15, 10-17, 10-19, 13-23
13-3
1-9
5-3
5-3
6-13, 6-15
6-11
1-3, 1-5
102478501
102479001
102479301
102480501
102481001
102481201
102481301
10-9
13-3
5-3
14-7
12-5
12-5
12-5
Page i-3
INDEX
102482201
102486201
102488001
102489901
102490001
102490101
102490201
102490301
102490401
102490501
102490801
102491001
102491101
102491301
102491501
102491601
102491701
102492201
102492301
102492401
102492801
102493001
102493301
102493401
102494401
102494701
102495001
102495801
102498101
102498201
102498601
102498701
102498801
102499001
102499601
102522001
102541465
102555501
102562401
102570401
102571301
102600001
102600101
102600201
102600301
102600401
102600601
102600701
102600801
102601001
102601101
102601301
102601401
102601501
102601801
102601901
Page i-4
1-11
1-9
4-3, 4-5
5-3
12-9
8-3, 9-3, 10-23
8-3, 9-3
7-25, 14-3
9-15
8-3, 9-3
6-7
13-3
13-3
1-7, 1-11
1-3, 1-5, 1-7, 1-11
4-3, 4-5
1-17
7-17, 7-19
7-19
4-11
1-3, 1-5
10-13
4-3, 4-5
14-3
8-3, 9-3
10-9
6-11
13-23
10-21, 14-3
7-27, 8-3
10-25, 10-27
10-15
10-19
13-11
10-23
10-5, 10-9
4-7, 10-25, 10-27
15-3
15-3
15-11
6-3
8-5
8-5
8-5
8-5, 8-9, 8-53
8-5
8-5
8-5
8-5, 8-9
8-5, 8-11
8-33
8-5
8-5
15-5
8-11, 8-53
8-11
102602001
102602101
102602301
102602401
102602601
102602701
102602801
102603201
102603501
102603601
102603701
102603801
102603901
102604001
102604101
102604201
8-11
8-11
8-11
8-11
8-11
8-11
8-11
8-21
15-5
8-27
8-27
8-27
8-27
8-27
8-27
8-21, 8-27
102608701
102608801
102608803
102608804
102608806
102608901
102609001
102609003
102609101
102609301
102609401
102609601
102609801
102609803
102610001
102614101
102604301
102604401
102604501
102604701
102604901
102605001
102605101
102605201
102605301
102605401
102605501
102605601
102605701
102605801
102605901
102606001
102606101
102606201
102606301
102606401
102606501
102606601
102606701
102606901
102607001
102607201
102607301
102607401
102607501
102607601
8-27
8-23, 8-27
8-27
8-27
8-21
8-21
8-7, 8-21
15-5
8-21
8-21
8-21
8-21
8-41
8-21
8-21
8-21
15-5
8-17
8-17
8-17
8-17
8-17, 8-53
8-15
8-7
8-7
8-7
8-7
8-7
15-5
8-23, 8-55
8-23
8-23
8-23
8-23
8-23
8-19, 8-53
8-19, 8-53
8-19
8-19
8-19
102614401
102615701
102615801
102616003
102616101
102616301
102607602
102607801
102607901
102608001
102608101
102608201
102608301
102608401
102608501
102608601
102616501
102616701
102616801
8-19, 14-11
8-23
8-23
8-23
8-23
8-19
8-23
8-23
8-19
8-19
8-19
8-19
8-23
8-23
8-23
1-13, 1-15
1-19
13-11
13-23
12-5
12-5
6-7, 6-9, 6-11, 6-13, 6-15
12-11
13-11
10-23
102616901 10-23
102617201 1-3, 1-5, 1-7, 1-11
102617301 10-13
102617501 13-3
102617701 6-7
102617801 13-3
102618101 5-3, 5-5
102618301 4-11, 4-13, 5-3, 5-5, 5-7, 5-9, 13-11,
14-7
102618401 4-7
102618601 1-3, 1-5, 1-15, 4-7, 4-11, 4-13, 5-3,
5-5, 5-7, 5-9, 6-3, 6-9, 6-11, 8-3, 9-3, 9-15,
10-7, 10-23, 14-3, 14-7
102619801 6-13, 6-15
102620401 6-13, 6-15
102620501 6-7, 6-9, 6-11, 6-13, 6-15
102620801 10-13
102621101 1-11, 3-3, 3-7
102621201 10-25, 10-27, 11-3, 11-5
102621301 8-3, 11-5
102621501 1-17, 8-3, 9-3, 10-25, 10-27, 13-23
102622701 3-11
102622801 3-11
102622901 3-13
102623001
102623301
102623501
102623802
102623805
102623808
102626201
3-13
3-11, 3-13
3-11, 3-13
10-11
10-11
10-11
5-5
INDEX
102628001
102628101
102628601
102628701
102629001
102630001
102630003
102630101
102630201
102630301
102630401
102630601
102630701
102630703
102630901
102631001
102631301
102631401
102631601
102631701
102631801
102632001
102632101
102632201
102632701
102633001
102633201
102633301
102633401
102633601
102633701
102633801
102633901
102634001
102634101
102634401
102634501
102634601
102634701
102635101
102635201
102635301
102635501
102635701
102635801
102635901
102636201
102636301
102636401
102636501
102636601
102637001
102637101
102637701
102640401
102640501
12-5
11-5
1-3, 1-5
14-7
1-15
8-23
8-23
8-23
8-23
8-23, 8-53
8-23
8-33, 8-35
8-23
8-23
8-23, 8-55
8-23, 8-55
14-9
14-9
8-5, 8-33, 8-35, 14-9
14-13
14-13
14-13
14-13
14-13
8-53, 14-11
14-9
14-9
8-13, 14-9
8-53, 14-9
8-43
8-39
8-39
8-39
8-39, 8-53
8-39
8-39, 8-53
8-39, 8-53
8-39
8-39
8-43
8-39
8-29, 8-39, 8-41, 8-53
8-29
8-29
8-29
8-29
8-43
8-43
8-43
8-43
8-43
8-29
8-29
8-37
8-37
8-37
102640601
102640701
102640901
102641001
102641101
102641201
102641501
102642401
102642501
102642601
102642701
102642801
102642901
102643001
102643101
102643201
102643301
102643401
102643601
102643701
102644001
102644101
102644501
102645501
102646001
102646101
102646301
102646401
102646501
102646601
102647101
102647201
102647501
102647701
102647801
102647901
102648001
102648401
102648501
102651301
102651501
102651601
102651701
102651801
102652001
102652601
102652701
102652801
102652901
102653001
102653101
102653201
102653301
102653401
102653501
102653601
8-31, 8-37
8-37
8-37
8-37
8-37
8-37
8-41
8-41
8-41
8-41
8-41
8-41
8-41
8-41
8-41
8-41
8-41
8-41
8-41
8-41
8-13, 8-53
8-13
8-53
8-45
8-49, 8-53
8-49
8-51
8-47
8-51
8-51, 8-53
8-51
8-51
8-25
8-33, 8-35, 8-45
8-25
8-25
8-25
8-45
8-45
8-47
8-47
8-47
8-47
8-47
8-47
8-47
8-47
8-9
8-47
8-47
8-47
8-47
8-47, 8-53
8-9
8-9
8-47
102653701
102653901
102654101
102654301
102654401
102654601
102654701
102655301
102655401
102655501
102655601
102655701
102655801
102655901
102656001
102656101
102656201
102656301
102656402
102656501
102656601
102656701
102656801
102656901
102657001
102657101
102657201
102657301
102657401
102657501
102657601
102657701
102657801
102658001
102658101
102658201
102658301
102658401
102658501
102658601
102658701
102658801
102658901
102659001
102659101
102659201
102659301
102659401
102659501
102659601
102659801
102659901
8-47
8-9
8-9, 8-53
8-11, 8-39, 8-49
8-21
8-7, 8-53
8-53, 14-9
9-7
10-11
10-11
10-11
10-11
10-11
10-11
10-11
10-13
10-13
10-13
10-13
10-13
10-13
10-13
10-13
10-13
10-13
10-13
10-3, 10-13
10-3, 10-13
10-13
9-5, 10-13
9-11, 10-13
9-11, 10-13
9-11, 10-13
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-9
9-13
9-13
102660001
102660101
102660201
9-13
9-13
9-13
102660301
9-13
Page i-5
INDEX
102660401
102660402
102660403
102660404
102660501
102660601
102660701
102660801
102660802
102660803
102660804
102660901
102661001
102661101
102661201
102661202
102661301
102661401
102661501
102661601
102661701
102661801
102661901
102662101
102662201
102662301
102662401
102662601
102662701
102662801
102662802
102662901
102663001
102663101
102663201
102663301
102663401
102663501
102663801
102663901
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-13
9-7, 9-13
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
9-11
102664001
102664101
102664301
102664401
102664601
102664701
102664801
102664901
102665001
102665101
102665301
102665401
102665501
102665601
102665701
102665901
9-11
9-11
9-11
9-11
9-7
9-7
9-7
9-7, 9-13
9-7
9-7
9-7
9-7
9-7
9-7
9-7
9-7
Page i-6
102666001
102666201
9-7
9-5, 9-7
102690201
102690301
12-9, 12-11
12-9, 12-11
102666801
102666901
102667001
102667101
102667201
102667301
102667401
102667501
102667601
102667701
102667901
102668001
102668101
102668201
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-7, 9-13
102690401
102690501
102690701
102690801
102691001
102691401
102668301
102668401
102668801
102669901
102670601
102670701
9-5
9-5
15-9
15-7
1-11
8-3, 9-3
9-15
10-5
1-11
102694301
102694401
102694502
102694701
102694801
102695401
102695601
102695701
102695801
102695901
102696001
102696101
102696201
102696301
102696401
102696501
102696601
102696701
102696801
102696901
102697001
12-11
12-9, 12-11
12-9, 12-11
12-11
12-9
12-9, 12-11
12-9, 12-11
12-9, 12-11
12-9, 12-11
12-9
4-11
13-13, 13-25
13-13, 13-25
13-13, 13-25
13-27
13-27
13-13, 13-25
13-25
13-25
13-27
13-25
13-25
12-13
12-13
12-13
12-13
12-13
13-17, 13-19
13-13
13-13, 13-15, 13-21
13-13
13-17, 13-19
13-13, 13-15
13-17, 13-19
13-13
13-13, 13-15
13-13, 13-15, 13-21
13-21
102697101
102697201
102697301
102697401
102697501
102697601
102697701
102697801
102697901
102698001
102698101
102698301
102698401
102698601
102698701
102698801
13-13, 13-15
13-15
13-13
13-13
13-15
13-13
13-13
13-21
13-15
13-15
13-21
13-13
13-21
13-15
13-15
13-21
102670801
102670901
102671201
102672101
102672201
102672301
102672401
102673201
102673301
102673901
102674001
102674101
102674201
102674401
102674601
102675001
102675101
102675201
102675301
102675401
102676801
102682301
102682701
102682901
102684401
102684501
102684601
102685001
102685601
102686101
102687801
102689001
102689101
102689102
13-25
13-25
13-25
13-25
1-19, 3-11, 3-13
3-11, 3-13
1-15
15-5
15-5
15-5
15-9
15-9
15-5
15-5
15-5
15-5
15-5
6-3
3-3, 3-7
6-13, 6-15
6-13, 6-15
14-3
1-17, 6-13, 6-15, 13-11
13-11
14-3
6-13, 6-15
15-3
6-5
4-9
4-9, 6-13, 6-15
4-9, 6-13, 6-15
102691601
102691701
102691801
102691901
102692801
102693301
102693401
102693501
102693601
102694001
102694201
INDEX
102698901
102699001
102699201
102699301
102699401
102699501
102699601
102699701
102700001
102700101
102700201
102700301
102701001
102701201
102703301
102707101
102710301
102710501
102711601
102712601
102712701
102714001
102715701
102716001
102718001
102718101
102718201
102719301
102721501
102721901
102722001
102722301
102722701
102722801
102722901
102724101
102724201
102724301
102724401
102724501
102724601
102724701
102725101
102725201
102725401
102725501
102725601
102725801
102725901
102726201
102726301
102726401
102726501
102726601
102726701
102726901
13-13
13-21
13-13
13-15
13-13
13-21
13-17, 13-19
13-13, 13-21
13-21
13-21
13-21
13-21
8-9
8-33, 8-35
8-11
10-21
9-15, 10-7
10-13
13-3
4-13
4-13
4-3, 4-5
4-7
5-9
1-11
1-11
1-11
12-13
13-13, 13-21
9-15
9-15
6-7, 13-3
9-11
9-11
9-11
10-11
10-11
9-9
9-9
9-9
9-9
9-9
9-13
9-13
10-13
10-25, 10-27
10-25, 10-27
1-13
1-13
8-5
8-5
8-5
8-5
8-5
8-9
8-9
102727001
102727101
102727401
102727501
102727601
102727701
102727901
102728001
102728101
102728102
102728301
102728401
102728501
102728601
102728701
102728801
102728901
102729101
102729301
102729401
102729501
102729601
102729701
102730001
102730101
102730201
102730301
102730401
102730601
102730801
102730901
102731001
102731101
102731201
102731301
102731501
102731601
102731701
102731801
102731901
102732001
102732201
102732401
102732501
102732601
102736901
102737101
102737301
102737401
102739201
102739901
102739902
102741501
102741601
102751301
102751401
8-9
8-9
8-11
8-11
8-11
8-15
8-17
8-19
8-23, 8-55
8-23
8-25
8-27
8-27
8-29
8-29
8-29, 8-53
8-29
8-31
8-11, 8-53
8-39
8-39
8-41
8-41
8-33
8-33
8-33, 8-35
8-33
8-33, 8-35
8-33, 8-35
8-5
14-9
14-9
14-9
14-11
8-33, 8-35
8-51
8-51, 11-5
7-23
8-53
8-53
8-55
8-23, 8-55
1-11
8-33, 8-35, 8-45
8-5, 8-53
2-3
6-13, 6-15
14-3
14-3
1-11
7-21
7-23
5-9
5-9
5-9
5-9
102751501
102751601
102758701
102759401
102760501
102760701
102760801
102762601
102763301
102763401
102764201
102764701
102764801
102764901
102765001
102765101
102765201
102765301
102765401
102765501
102765701
102765801
102770001
102770301
102778001
102798501
102798601
102798701
102798801
102798901
102799001
102799101
102799201
102799401
102799501
102799601
102799701
102799801
102800101
102800201
102800301
102800401
102800501
102800601
102800701
102801001
5-9
10-5
5-7, 5-9
9-5
1-3, 1-5
1-3, 1-5
1-3, 1-5
13-27
4-13
4-13
13-13
13-21
13-21
13-15
13-17
13-15
13-13
13-27
13-27
13-27
13-27
13-27
4-11
4-13
1-3, 1-5
8-9
8-11
8-13
8-13, 8-53
8-13
8-13
8-13
8-13
8-13
8-13
8-13
8-21
8-29
8-31
8-31
8-31
8-37
8-43
8-43
8-39
8-39
8-39
8-33, 8-35
8-33, 8-35
102801101
102801201
102801301
102801401
102801501
102807601
102807801
8-47
8-47
8-49
8-49
8-49
14-5
14-5
102798001
102798201
102798401
Page i-7
INDEX
102810701
102812801
102826101
102827901
102831201
102831501
102831601
102834901
102839401
102849401
102855501
102865201
102886101
102892401
102896601
102934601
102934701
102934801
102934901
102952101
102952102
102961301
102961401
102961501
102961601
102967901
103185401
103185501
103185801
103185901
103201601
103239501
103239801
103239901
103244701
103252201
103256701
103267001
103273101
103282301
103294301
103305001
103305101
103307901
103320601
103348101
103348201
103418701
103418801
10-25, 10-27
11-3, 11-5
10-17
9-15
9-7
13-25
1-5
11-3
12-9, 12-11
9-15
14-3
13-3
1-11
5-7, 5-9
5-7, 5-9
8-3
8-35
8-35
8-35
10-9
10-5
13-27
13-27
13-27
13-27
1-3, 1-5, 1-9, 7-21, 7-23
12-9
12-11
12-9, 12-11
12-9, 12-11
10-11
13-19
13-19
8-35
13-3
9-3
6-7
1-9
5-3, 5-5
6-13, 6-15
13-17
5-9
5-9
10-3
12-3, 12-5
7-21, 7-23
7-21, 7-23
4-5
4-3, 4-5
103441401 10-27
95293643 13-9
96701412 8-3, 9-3
96704416 11-3, 14-3
96704622 8-3, 9-3
96704721 8-3, 9-3
96704960 9-3
Page i-8
96705199
96705587
14-3
9-15, 10-7
bucket seat 1-9
camshaft 8-21, 9-13
96705736
96706825
96714464
96715552
96718978
96741038
10-21
5-3
10-23
1-3, 1-7
8-3, 9-3, 10-23
8-3, 9-3, 10-23, 14-3
8-3, 9-3
1-11
14-7
case, main bearing 8-19
connecting rod 8-23, 9-13
crankcase cover 9-9
cylinder head cover 8-13
drain cock 8-5
filler cap 4-7
forward/reverse 13-11
fuel camshaft 8-27
96741046
96742515
96747126
fuel cap 10-9
fuel filter 10-7
fuel injection pump
A
A-arm 6-7
absorber, shock 6-9, 6-11
accelerator cable 10-15, 10-19
accelerator pedal 5-3
accelerator pedal adjustment tool
accessory receptacle 7-21, 7-23
actuator 1-15
adapter
actuator 1-15
cable (IQDM) 15-7
hose 9-15
intake, engine 10-13
tube 9-15, 10-7
adapter, oil filter 9-15
adhesive, guide ring 15-3
adjuster
hydraulic brake 15-7
adjuster, forward/aft 1-9
adjuster, slide 13-3
adjuster, slider 1-9
adjuster, spring 10-23
air clean support 10-25, 10-27
air filter 10-25, 10-27
air filter canister 10-25, 10-27
air filter evacuator 10-25, 10-27
alternator 8-33, 8-35
alternator belt 8-35
arbor 15-3
arm
A- 6-7
governor 13-21
lower 6-7
rocker 8-47
valve rocker 9-11
arm, swing 6-13, 6-15
assembly
accelerator pedal 5-3
adjusting bolt 8-29
alternator 8-33
bearing case cover 8-19
brake line 4-9
brake pedal 5-5, 5-7, 5-9
brake rotor 13-3, 13-25
8-37
fuel pump 10-7, 10-13
fuel tank vent 10-5, 10-9
gear case 13-13, 13-27
15-3
governor 9-9
governor arm 13-21
governor fork 8-43
governor fork lever 8-43
headlight 7-15
headlight harness 7-15
hinge, tilt bed 1-13
idle apparatus 8-29
inner ball joint 6-5
intake manifold 8-49
muffler 13-3
nozzle holder 8-41
oil pump 8-17
oil pump cover 9-9
overflow pipe 8-41
park brake pedal 5-7, 5-9
pinion 13-27
piston ring 8-23, 8-55
reservoir, remote 4-7
rocker arm 8-47
slide adjuster 13-3
speed plate 8-39
tailgate 1-19
tank, coolant expansion 14-5
tether 1-19
thermostat 14-9
tilt bed 1-13
tire 2-3
turn signal lens 7-15
valve, lifter 9-13
valve, solenoid 10-11
water pump 14-11
wire 7-25, 7-27, 10-5, 10-9
assembly, subA-arm, upper 6-7
fly weight 13-21
front differential upright 13-3
gear case 13-13
governor spool 13-21
moveable drive clutch 12-9, 12-11
INDEX
spider 12-9, 12-11
stationary 12-9, 12-11
swingarm 6-13, 6-15
weight clutch 12-9, 12-11
axle 13-25
axle tube 13-27
axle, rear, guard mounts 13-25
B
ball
check 8-21
crankshaft 8-23
governor 8-27
injection pump 8-27
steel 9-9
valve 8-11
ball joint 6-7, 13-3, 13-23
ball stud 13-11
band, pipe 14-9, 14-13
banjo bolt 4-3, 4-5
bar clamp 14-7
bar, sway 6-11
barb, vent 10-3, 10-7
barrier, heat 1-11
base, seat holder 1-11
battery 7-25, 7-27
battery clamp 7-25, 7-27
battery discharge machine 15-3
battery terminal protector spray 15-3
battery thermometer 15-3
bearing 13-27
ball (steering pinion) 6-5
lower pinion 6-5
needle 9-13, 13-5, 13-13, 13-15, 13-27
radial ball 9-13
bearing and oil seal remover 15-3
bearing case cover 8-19
bearing case, main 8-19
bearing driver set 15-3
bearing puller 15-3
bearing puller wedge 15-3
bed floor plate 1-13
bed, tilt 1-13
bell crank kit 4-13
bellcrank 5-9, 13-17, 13-19
bellows 6-5, 13-25
belt guard 8-35
belt, alternator 8-35
belt, drive 12-7
belt, V- 8-33
bezel, fuel fill 1-17
bezel, headlight 7-15
block, differential spacer 13-3
block, engine 8-5
block, fuse 7-17, 7-19
bobbin, coil with press fit 13-5
body, front 1-3, 1-5
bolt
adjusting 8-29
banjo 4-3, 4-5
drain plug 9-9
box
cargo 1-19
bracket
actuator 1-15
anti-sway bar 6-11
brake line 4-9, 6-7
brake pedal 5-5
choke cable 10-13
coolant bottle 14-5
cover inlet 12-5
equalizer 4-11, 4-13
governor arm 10-23
governor cable 10-23
headlight mounting 7-15
hydraulic line 4-9, 6-13, 6-15
muffler 11-3, 11-5
oil filter mount 9-15
park brake 5-9
radiator mount, upper 14-3
rocker arm 8-47
seatbelt 1-11
steering support 1-7
transmission cable 8-3, 9-3, 13-23
transmission mounting 8-3, 9-3
brake adjustment tool 15-3
brake cable 4-13
brake cable release tool 15-3
brake caliper 4-3, 4-5
brake caliper return spring 4-5
brake fluid reservoir 4-7
brake line 4-9
brake pad service kit 4-3, 4-5
brake pedal 5-5, 5-7, 5-9
brake pedal adjustment tool 15-3
brake pedal tension tool 15-3
brake return spring 4-11, 4-13
brake rotor 13-3, 13-25
brake, park, cable pulley kit 4-11
breather cover 8-13
breather shield 8-13
breather tube 8-13, 10-13
breather valve 8-13, 9-13
brush guard 1-3, 1-5
bucket seat 1-9
buckle, seatbelt 1-11
bulb, headlight 7-15
bullet, detent 13-15
bumper
bed 1-15
front 1-3, 1-5
rubber 1-19
stud 14-3
bushing 1-15
A-arm 6-7
anti-sway bar 6-11
arm, lower 6-7
flanged bronze 8-21
forward/reverse 13-11
greaseless 5-3, 5-5
link 6-11
Permiglide 13-5
piston pin 8-23, 8-55
pivot, urethane 6-13, 6-15
plain 13-7
return line 10-9
self-lubricating 13-5
steel 1-13
teflon 6-13, 6-15
urethane 1-13
button, thrust 13-5
buzzer, reverse 13-11
C
cable
accelerator 10-15, 10-19
bell crank 4-13, 5-9
brake 4-13
choke 10-17
governor 10-23
IQDM 15-7
park brake 4-11
transmission 13-23
cage, roll 13-5
calibration test module 15-3
caliper, brake 4-3, 4-5
cam installation tool 15-3
camshaft 8-21, 9-13
camshaft, fuel 8-27
canister, air filter 10-25, 10-27
cap
air filter 10-25, 10-27
bolt assembly 8-29
connecting rod 9-13
filler 4-7
fuel 10-9
fuel tank 10-5
inlet 12-5
noise suppressor 9-5, 9-7
oil filler 9-9
pressure 14-5
radiator 14-3
rubber 13-3
sealing 8-5, 8-9
spark plug 9-5, 9-7
speed control plate 8-39
steering wheel 6-3
valve 8-47
Page i-9
INDEX
cap, front corner 1-19
carburetor air vent tube
10-3, 10-7
carburetor float level tool 15-7
carburetor, Honda 10-11
card, safety first 15-9
cargo box 1-19
case
gear 8-11, 13-13, 13-25, 13-27
governor ball 8-27
main bearing 8-19
case cover, bearing 8-19
chain, transmission 13-13
charge coil 9-7
charger bezel tool 15-3
choke cable 10-17
clamp
bar 14-7
battery 7-25, 7-27
breather tube 8-13
hose 10-3, 10-7
p- (fuel filter) 1-3, 1-5, 4-9, 8-3, 9-3
pipe 8-41
wire 9-7, 9-13
clevis pin 4-7
clip
hair pin 1-19
clip, brake line 4-9, 10-15, 10-17, 10-19, 13-23
clip, breather tube 10-13
clip, governor 9-9
clip, meter 7-21, 7-23
clip, piston pin 9-13
clip, return pipe 8-41
clip, tube 10-3, 10-13
clip, wire harness 10-13
closeout 1-9
clutch 12-13
clutch alignment tool 15-5
clutch cover 12-9, 12-11
clutch housing 13-5
clutch removal tool 15-3
clutch tool kit 15-5
clutch, diesel 12-11
clutch, gas 12-9
coil
charge 9-7
ignition 9-7
pocket insert 13-5
coil with press-fit bobbin 13-5
collar, alternator assembly 8-33, 8-35
collar, crankshaft 8-23
collar, idle gear 8-21
collar, lever 8-39
collet 8-47
column, steering 6-3
communication display module
compression gauge 15-5
Page i-10
15-5
D
compressor, piston ring 15-9
compressor, valve spring 15-11
connecting rod 8-23, 9-13
connector, relay 7-17, 7-19
console, drink holder 1-9
continuity tester 15-5
coolant exchanger 14-3
coolant expansion tank 14-5
coolant fill tee 14-3
coolant lamp sensor 14-9
coolant pipe 14-7
coolant pipe mounting tab 14-7
coolant temperature indicator light
7-23
cooling fan 9-5, 14-3
cord, glow plug 8-41
corner cap 1-19
cotter, rue ring 6-13, 6-15
cover 9-9
alternator assembly 8-33
bearing case 8-19
breather 8-13, 9-13
clutch 12-9, 12-11
crankcase 9-9
CVT 8-3, 9-3, 12-3, 12-5, 12-9, 12-11
cylinder head 8-13
electrical 7-17, 7-19
engine 10-21
fan 9-5
fuel camshaft 8-5
head 9-11
head filler 9-11
heat proof 8-51
input 13-7
oil filter 9-9
oil pump 9-9
thermostat 14-9
cover plate, output 13-5
cover, steering column 6-3
cowl 1-3, 1-5
cowl support, ROPS 1-3, 1-5, 1-11
crank 8-23
crankcase 9-9
crankcase cover 9-9
crankshaft 8-23, 9-13
C-type stop ring 6-5
cup holder, seat 1-9
cutter, valve seat 15-5, 15-11
CVT 12-13
CVT cover 12-3
CVT cover kit, sealed 12-5
CVT cover kit, unsealed 12-5
cylinder head 8-9, 9-11
cylinder head cover 8-13
cylinder, master 4-7
dash, front 1-7
dashboard 1-3, 1-5
decal
4x4 3-11, 3-13
bed load warning 3-3, 3-7
Carryall 294 3-13
Club Car 3-11, 3-13
Club Car tailgate 1-19, 3-11, 3-13
crush area warning 3-3, 3-7
diesel 3-11, 3-13
diesel fuel only 3-7
driver/passenger 3-5, 3-9
ground warning 3-5, 3-9
high capacity 3-11, 3-13
hot manifold warning 3-9
hot surface warning 1-9, 3-5, 3-9, 14-7
operating instructions 3-5, 3-9
ROPS certification 1-11, 3-3, 3-7
rotating parts 3-3, 3-7
rotating parts and hot manifold 3-5, 3-9
rotating parts warning 3-9
trailer hitch 3-3, 3-7
under 16 warning 1-11, 3-3, 3-7
vehicle loading 3-3, 3-7
warning, diesel 3-7
warning, gas 3-3
winch cable warning 3-5, 3-9
XRT 1500 3-11
deflector oil 13-13
diaphragm tube 10-13
diesel tachometer probe 15-9
differential housing 13-27
differential, front 13-5
diode, engine stop 9-7
dipstick, oil 9-9
disc 4-11
dowel pin 13-5
drag link 6-5
drain cock 8-5
drink holder console 1-9
drive belt 12-7
drive clutch fixed sheave tool 15-5
drive clutch holder tool 15-5
drive clutch hub puller 15-5
drive clutch puller 15-5
drive clutch spider removal tool 15-5
drive clutch, moveable 12-9, 12-11
drive shaft 13-9
driven clutch base sheave 12-13
driven clutch cam puller 15-5
driven clutch puller plug 15-5
driven clutch spring compression base tool
15-5
driven clutch spring compression collar tool
15-5
INDEX
driven clutch spring compression nut tool
15-5
dry moly lubricant 15-7
E
E-clip 4-11, 4-13
elbow 10-9
end, tie rod 6-5
engine block 8-5
engine, diesel, Kubota D722 with closed
breather 8-3
engine, Honda 9-3
equalizer 4-11, 4-13
exchanger, engine coolant 14-3
exhaust header 11-3
exhaust valve 8-47, 9-11
expansion tank, coolant 14-5
F
fan shroud 14-3
fan, cooling 9-5, 14-3
fastener, push-in 7-17, 7-19
fender, front 1-3, 1-5
fender, rear 1-17
filler cap 4-7
filter
air 10-25, 10-27
fuel 10-3, 10-7, 10-13
inlet cover 12-5
oil 8-7, 8-11, 9-15
filter, air, canister 10-25, 10-27
fitting, thread-forming grease 6-13, 6-15
flange, water 14-9
float set 10-11
floor mat 1-3, 1-5
floor plate, bed 1-13
fly weight 13-21
flywheel 8-25, 9-7
flywheel puller 15-7
FNR shifter bracket 8-3, 9-3, 13-23
fork, transmission 13-21
forward/reverse assembly 13-11
Forward/Reverse shifter 13-11
frame, tilt bed 1-13
front body 1-3, 1-5
front differential 13-5
fuel camshaft 8-27
fuel cap 10-9
fuel filter 10-3, 10-7, 10-13
fuel gauge sending unit 10-5, 10-9
fuel injection pump 8-37
fuel pickup tube 10-9
fuel pump 10-7, 10-13
fuel tank (diesel) 10-9
fuel tank (gasoline) 10-5
fuel tank cap 10-5
fuel tank strap 10-3, 10-7
fuel tank vent 10-5, 10-9
fuel tank, diesel 10-9
fuel tank, gas 10-5
fuel tube 10-13
fuel-hour gauge 7-21, 7-23
fuse
10-amp 7-17, 7-19
25-amp 7-17, 7-19
30-amp 7-19
fuse block 7-17, 7-19
G
gasket
bearing case 8-19, 8-53
breather cover 9-13
carburetor 10-13
carburetor adapter 10-13
carburetor bowl 10-11
case cover 9-9
clutch cover 12-9, 12-11
control plate 8-39, 8-53
cover 8-19, 8-53, 12-5
cylinder head 8-9, 8-53, 9-11
cylinder head cover 8-13, 8-53, 9-11
drain plug 8-7
exhaust 8-53, 11-3, 11-5
ex-manifold 8-51, 8-53
fuel pump 8-5, 8-53
gearcase 8-11, 8-53
head cover 8-53
head cover nut 8-29, 8-39, 8-41, 8-53
idle apparatus 8-29, 8-53
intake manifold 8-49, 8-53, 9-11, 10-13
liquid 15-7
nozzle 8-41
oil pump 8-17, 8-53
sending unit 10-5, 10-9
thermostat 8-53, 14-9
water flange 8-53, 14-9
water pump 8-53, 14-11
gauge, compression 15-5
gauge, fuel-hour 7-21, 7-23
gauge, oil 8-15
gear
cam 8-21
case 8-11, 13-13, 13-25, 13-27
crank 8-23
helical 13-15, 13-21
idle 8-21
injection pump 8-27
oil pump drive 8-17
ring 8-25, 13-5, 13-27
gear ring engagement 13-15
gear yoke 15-7
glow plug 8-41
glow plug cord 8-41
governor 9-9
governor arm 13-21
governor cable 10-23
governor fork lever 8-43
governor guard 10-23
governor lever 8-39
governor shaft installation tool 15-7
governor spool 13-21
governor wire 10-23
grid, screen 9-5
grill 1-3
grip tape, accelerator pad 5-3
grommet 10-5, 10-9, 10-13, 13-5
grommet tool 9-7
guard
governor 10-23
radiator 14-3
splash 1-7
guard, belt 8-35
guard, brush 1-3, 1-5
guide
accelerator cable 5-3
detent bullet 13-15
exhaust valve 8-9
inlet valve 8-9
oil gauge 8-15
valve seat cutter
guide ring adhesive
15-11
15-3
H
hair pin clip 1-19
half shaft 13-3
handle, park brake 5-7, 5-9
hanger, engine 9-5
harness, wire 7-5, 7-9, 7-13
head, cylinder 8-9, 9-11
header, exhaust 11-3
headlight assembly 7-15
headlight bulb 7-15
headlight harness 7-15
headlight retainer 7-15
heat barrier 1-11
heat seal 8-41
helical gear 13-15, 13-21
hinge plate 1-9
hinge, tilt bed 1-13
holder
drink 1-9
fork lever 8-43
screen grid 9-5
Honda engine 9-3
hook, engine 8-9
hose 14-5
coolant 14-3, 14-7
fuel filter 10-7
Page i-11
INDEX
fuel pump 10-7
fuel return 10-7
inlet cover 12-5
intake 10-25, 10-27
oil, remote 9-15
overflow 8-41
vent 8-3, 9-3, 13-3, 14-5, 14-7
hose, outlet 12-3, 12-5
housing
clutch 13-5
differential 13-27
Mate-N-Lock 13-5
steering gear 6-5
hub 4-11
hub, race/output 13-5
hydraulic brake adjuster 15-7
hydrometer
15-7
I
idle apparatus 8-29
idle gear 8-21
ignition coil 9-7
injection pump gear 8-27
inlet valve 8-47, 9-11
insert, carburetor adapter 10-13
insulator, carburetor 10-13
intake adapter, engine 10-13
intake manifold 8-49
internal retaining ring pliers 15-7
IQ display module (IQDM) 15-7
isolator ring and bushing 8-3, 9-3
isolator, twin stud 14-3
J
jet, main 10-11
joint
ball 6-7, 13-3, 13-23
eye 8-37
pipe 8-11
K
key
feather
8-17, 8-21, 8-23, 8-27
pair 7-23
woodruff 9-7, 9-13
key (pair) 7-21
key switch 7-21, 7-23
key switch spacer 7-21
keyswitch nut 7-21
kit
anti-sway 6-11
bolt 13-5
brake pad service 4-3, 4-5
brake pedal adjustment tool
clutch 13-5
Page i-12
cover plate, input 13-7
cover plate, output 13-5
drain plug 13-5
forward gear repair 13-15
gasket 8-53
governor shaft repair 13-21
H-clip spring 13-5
input shaft repair 13-21
IQ display module (IQDM) 15-7
neutral switch repair 13-15
nozzle holder 8-41
park brake handle 5-7, 5-9
piston rebuild 8-55
race output hub 13-5
rear axle gear repair 13-27
repair, minor 13-5
reverse gear repair 13-13
roll cage 13-5
roller 13-5
ROPS 1-11
transmission shift shaft repair 13-17
tune-up 15-9
knob, forward/reverse 13-11
knob, light switch 7-21, 7-23
knuckle, slider steering 6-3
latch, access panel 1-3, 1-5
latch, slam 1-19
latch, spring 1-19
lens, headlight 7-15
lever
engine stop 8-39
fork 8-43
governor 8-39
lost motion 5-3
speed control 8-39
light
oil 7-21, 7-23
light switch 7-21, 7-23
light switch knob 7-21, 7-23
light, coolant temperature indicator
limit switch 13-11
line, brake reservoir 4-7
7-21, 7-23
lubricant, dry moly 15-7
lubricant, moly-teflon 15-7
M
15-3
main jet 10-11
manifold
exhaust 8-51
inlet 9-11, 10-13
8-49
1-3, 1-5
Mate-N-Lock housing 13-5
Mate-N-Lock pin 13-5
meter clip 7-21, 7-23
meter, volt ohm 15-11
module
calibration test 15-3
communication display 15-5
moly-teflon lubricant 15-7
motor
starter 8-45, 9-7
mount, link 6-11
moveable drive clutch 12-9, 12-11
muffler 11-3, 11-5, 13-3
N
nipple, remote oil 9-15
noise suppressor cap 9-5, 9-7
nongrease/spacers locker 13-27
nozzle holder 8-41
nozzle, main 10-11
nut, keyswitch 7-21
7-21, 7-23
nut, toggle switch
O
L
link, drag 6-5
liquid gasket 15-7
low oil warning light
intake
mat, floor
oil deflector 13-13
oil dipstick 9-9
oil filter 8-7, 8-11, 9-15
oil filter screen 9-9
oil pan 8-7
oil pressure switch 8-5, 9-7
oil pump 8-17
oil pump drive gear 8-17
oil seal 8-11, 8-19, 9-9, 9-13, 13-5, 13-7
oil slinger 8-23
oil warning light, low 7-21, 7-23
O-ring 8-5, 8-7, 8-9, 8-11, 8-13, 8-23, 8-31, 8-39,
8-53, 9-15, 13-5, 13-7
overflow pipe 8-41
7-23
P
paint, touch-up
pan
center 1-9
oil 8-7
15-7
seat 1-9
panel
access 1-3, 1-5
left 1-19
right 1-19
side 1-17
panel, front 1-17, 1-19
park brake cable 4-11
park brake pedal 5-7, 5-9
INDEX
p-clamp (fuel filter) 1-3, 1-5, 4-9, 8-3, 9-3
pedal, accelerator 5-3
pedal, brake 5-5, 5-7, 5-9
pin, clevis 4-7
pin, dowel 13-5
pin, Mate-N-Lock 13-5
pin, piston 8-23, 8-55, 9-13
pin, slide, caliper slide pin 4-3, 4-5
pinion 13-27
pinion, steering 6-5
pipe
breather 8-49
coolant 14-7
exhaust 11-3, 11-5
injection 8-41
overflow 8-41
water 14-13
water return 8-13, 14-9
pipe band 14-9, 14-13
pipe clamp 8-41
pipe, coolant 14-7
piston 8-23, 8-55, 9-13
piston pin 8-23, 8-55, 9-13
piston ring 8-23, 8-55
piston ring compressor 15-9
piston ring pliers 15-9
piston ring set 9-13
pivot, rocker arm 9-11
plate
armature 13-5
back 1-13, 1-15
brush mount 1-3, 1-5
cover, output 13-5
electrical 7-17, 7-19
engine block 8-5
engine mounting 8-3, 9-3
engine, left side 9-5
fuel/oil 9-15, 10-7
hinge 1-9
push rod guide 9-11
shroud 8-25, 9-5
speed 8-39
speed control 8-39
thrust 13-5
pliers
internal retaining ring 15-7
piston ring 15-9
retaining ring 15-9
plug
drain 8-7
driven clutch puller 15-5
engine block 8-5, 8-9, 8-11, 13-13, 13-25
expansion 8-5
gearcase 13-13, 13-25
glow 8-41
oil drain
13-5
oil fill 13-5
oil filler 8-13
plug, spark 9-7, 9-11
press weldment 15-5
prop shaft 13-9
protector spray, battery terminal 15-3
puller
bearing 15-3
clutch 15-3
drive clutch 15-5
drive clutch hub 15-5
driven clutch cam 15-5
flywheel 15-7
seal 15-9
special use tool 15-9
pulley
fan drive 8-33, 8-35
mount 4-11
water pump 8-33, 8-35
pulley, brake, park, cable, kit 4-11
pullrod, compression spring 5-3
pump
fuel 10-7, 10-13
fuel injection 8-37
oil 8-17
water 14-11
push rod 8-21, 9-11
R
rack guide pressure spring 6-5
rack, steering 6-5
radiator cap 14-3
radiator guard 1-5, 14-3
radiator pipe 14-7
reamer, valve guide 15-9
receiver, rear 6-13, 6-15
receptacle, accessory 7-21, 7-23
regulator, voltage 9-15
relay 7-17, 7-19
relay connector 7-17, 7-19
remover, bearing and oil seal 15-3
reservoir, brake fluid 4-7
reservoir, remote 4-7
retainer
headlight 7-15
spring (driven clutch) 12-13
valve spring 8-47, 9-11
retaining ring 13-3
retaining ring pliers 15-9
retractor, seat belt 1-11
reverse buzzer 13-11
ring
piston 8-23, 8-55
snap 6-5
ring gear 8-25, 13-5, 13-27
ring set, piston 9-13
ring, C-type stop 6-5
ring, retaining 13-3
ring, retaining, ext 6-7, 13-3
rivet, blind push 1-7
rocker arm 8-47
rocker arm pivot 9-11
rod
connecting 8-23, 9-13
crank crank rod 8-23
push 8-21, 9-11
roll cage 13-5
roller weight 12-9, 12-11
roller, torque 12-9, 12-11
ROPS certification decal 1-11, 3-3, 3-7
ROPS cowl support 1-3, 1-5, 1-11
ROPS kit 1-11
ROPS support tube 1-11
ROPS top 1-11
ROPS weldment 1-11
rotator, valve 9-11
rotor, brake 13-3, 13-25
rotor, oil pump 9-9
rubber bumper 1-19
S
safety first card 15-9
screen grid 9-5
screen, oil filter 9-9
screw, valve clearance adjuster 15-9
seal
dual lip 13-13, 13-17, 13-19, 13-21, 13-27
heat 8-41
oil 8-11, 8-19, 9-9, 9-13, 13-5, 13-7
steering pinion dust 6-5
triple lip 13-13
valve stem 8-47, 8-53, 9-11
seal puller 15-9
seat
bucket 1-9
valve 8-11
valve spring 9-11
seat belt retractor 1-11
seat holder base 1-11
seat, bucket 1-9
seatbelt buckle 1-11
sending unit, fuel gauge 10-5, 10-9
sensor, coolant lamp 14-9
service kit, brake pad 4-3, 4-5
shaft
CVT adapter 8-3
drive 13-9
fork lever 8-43
governor arm 9-13
governor lever 8-39
idle gear 8-21
input 13-21
Page i-13
INDEX
intermediate 13-15
output 13-21
pinion 13-7
prop 13-9
rock arm 8-47
shift 13-19
shaft shift 13-17
shaft, half 13-3
sheave, drive clutch base 12-13
sheave, driven clutch 12-13
shield, breather 8-13
shield, exhaust 11-5
shift, shaft 13-17
shim 12-9, 12-11, 13-27
shim, armature plate 13-5
shim, injection pump 8-37
shock absorber 6-9, 6-11, 6-13, 6-15
shroud 9-5
head 9-5
shroud, fan 14-3
slam latch 1-19
sleeve
crankshaft 8-23
governor 8-27
link 6-11
lower suspension 6-7
upper suspension 6-7
slide pin 4-3, 4-5
slide, adjuster 13-3
slider, governor 9-9
slinger, oil 8-23
snap ring 6-5
solenoid, stop 8-31
spacer
engine 8-3
key switch 7-21
spacer block, differential 13-3
spanner wrench 15-9
spark plug 9-7, 9-11
spark plug cap 9-5, 9-7
speed plate 8-39
spider 12-9, 12-11
splash guard 1-7
spray, battery terminal protector 15-3
spring
access panel 1-3, 1-5
brake caliper return 4-5
brake return 4-11, 4-13
carburetor 10-23
choke spring 10-23
compression 10-23, 12-9, 12-11, 12-13
continuity 10-13
detent bullet 13-15
exhaust 11-3, 11-5
governor 8-43
governor idle
Page i-14
10-23
idle apparatus 8-29
pedal 5-3
pedal stop 5-3
rack guide pressure 6-5
relief valve 9-9
return 8-39
rocker arm 8-47
start 8-9, 8-43
torsion 5-3
valve 8-11, 8-47, 9-11
spring latch 1-19
sprocket 13-13
start spring 8-43
starter motor 8-45, 9-7
stay
alternator assembly 8-33
cylinder head 8-9
fuel pump 10-13
spring 8-11
stop solenoid 8-31
steel bushing 1-13
steering column 6-3
steering column bearing press tool
steering column cover 6-3
steering column retaining ring tool
steering gear housing 6-5
steering pinion dust seal 6-5
steering rack 6-5
steering wheel 6-3
steering wheel puller tool 15-9
stem, valve 2-3
stop solenoid stay 8-31
stopper, camshaft 8-21
stopper, fuel camshaft 8-27
strap, fuel tank 10-3, 10-7
stud 8-3, 8-37, 8-51, 14-13
engine 9-7
idle adjustment 8-29
self-clinching 1-19
stud, ball 13-11
support yoke (steering) 6-5
support, access panel 1-3, 1-5
sway bar 6-11
swingarm 6-13, 6-15
switch
indicator (transmission) 13-15
key 7-21, 7-23
light 7-21, 7-23
limit 13-11
oil pressure 8-5, 9-7
toggle 7-21, 7-23
T
tab, coolant pipe mounting 14-7
tachometer 15-9
tachometer probe, diesel 15-9
15-9
15-9
tailgate 1-19
tailgate angle 1-19
tank
coolant expansion 14-5
tank, fuel 10-5, 10-9
tank, fuel (diesel) 10-9
tank, fuel (gasoline) 10-5
tape, grip, accelerator pad 5-3
tape, vinyl foam 1-9, 1-13, 14-3
tappet 8-21
tee, coolant fill 14-3
temperature indicator light, coolant 7-23
tester, continuity 15-5
tether 1-19
thermometer, battery 15-3
thermostat 14-9
thread-forming grease fitting 6-13, 6-15
thrust button 13-5
thrust plate 13-5
tie rod end 6-5
tie wrap 1-15, 4-9, 4-11, 4-13, 6-5
tilt bed 1-13
tilt bed frame 1-13
tire 2-3
toggle switch 7-21, 7-23
tool
accelerator pedal adjustment 15-3
belt tensioning, starter/generator 15-11
brake adjustment 15-3
brake cable release 15-3
brake pedal adjustment 15-3
brake pedal tension 15-3
cam installation 15-3
carburetor float level 15-7
charger bezel 15-3
clutch alignment 15-5
cT-wrench 15-5
drive clutch fixed sheave 15-5
drive clutch holder 15-5
drive clutch spider removal 15-5
driven clutch spring compression base
15-5
driven clutch spring compression collar
15-5
driven clutch spring compression nut 15-5
governor shaft installation 15-7
grommet 9-7
puller, special use 15-9
steering column bearing press 15-9
steering column retaining ring 15-9
steering wheel puller 15-9
transaxle axle seal 15-9
transaxle pinion seal 15-9
transmission 15-9
valve guide driver 15-9
valve seat cutter 15-5
INDEX
tool kit, clutch 15-5
top, ROPS 1-11
torque converter 12-13
torque roller 12-9, 12-11
touch-up paint 15-7
transaxle axle seal tool 15-9
transaxle housing 13-27
transaxle pinion seal tool 15-9
transmission cable 13-23
transmission cable bracket 8-3, 9-3, 13-23
transmission chain 13-13
transmission fork 13-21
transmission tool 15-9
transmission, parallel shaft 13-13
tube
axle 13-27
breather 8-13, 10-13
carburetor air vent 10-3, 10-7
diaphragm 10-13
fuel 10-13
fuel pickup 10-9
ROPS support 1-11
tune-up kit 15-9
turn signal lens 7-15
T-wrench tool 15-5
U
upright, front differential
urethane bushing 1-13
13-3
V
valve 10-25, 10-27
breather 8-13, 9-13
exhaust 8-47, 9-11
fuel pickup tube 10-5
inlet 8-47, 9-11
lifter 9-13
rocker arm 9-11
rotator 9-11
volt ohm meter 15-11
voltage regulator 9-15
W
warning light, low oil 7-21, 7-23
water flange 14-9
water pump 14-11
wedge, bearing puller 15-3
weight clutch 12-9, 12-11
weldment
press 15-5
weldment, accelerator pedal 5-3
weldment, accelerator pedal bracket 5-3
weldment, actuator bracket 1-15
weldment, air cleaner support 10-25, 10-27
weldment, brake pedal 5-5
weldment, coolant pipe 14-7
weldment, cowl support, ROPS 1-3, 1-5, 1-11
weldment, dash, front 1-7
weldment, Forward/Reverse shifter 13-11
weldment, Forward/Reverse shifter bracket
13-11
weldment, lever, lost motion 5-3
weldment, receiver 6-13, 6-15
weldment, shaft shift 13-17
weldment, tilt bed frame 1-13
weldment, top, ROPS 1-11
wheel 2-3
wheel, steering 6-3
wire assembly 7-25, 7-27, 10-5, 10-9
wire harness 7-5, 7-9, 7-13
wire harness, electric lift 1-15
wire, governor 10-23
wrap, tie 1-15, 4-9, 4-11, 4-13, 6-5
wrench, spanner 15-9
Y
yoke, gear 15-7
yoke, support (steering)
6-5
seat 8-11
solenoid 10-11
spring seat 9-11
valve clearance adjuster screw 15-9
valve guide driver tool 15-9
valve guide reamer 15-9
valve seat cutter 15-5, 15-11
valve seat cutter guide 15-11
valve seat cutter tool 15-5
valve seat t-wrench 15-11
valve spring compressor 15-11
valve stem 2-3
V-belt 8-33
vent barb 10-3, 10-7
vent, housing, upper 13-27
vent, transmission 13-13
Page i-15
Club Car, Inc.
P.O. Box 204658
Augusta, GA 30917-4658
USA
Web www.clubcar.com
Phone 1.706.863.3000
1.800.ClubCar
Int’l
+1 706.863.3000
Fax
1.706.863.5808

XRT 1500/Carryall 294

Transcription

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