700 H1 EFI Cruiser EFT PM Street Legal MY09

SH A R E O U R PASSION.

TM

700 H1 Cruiser EFT

Model Number A2009TCT4EETV (Steel Blue)

TABLE OF CONTENTS2009 ATV 700 H1 Cruiser EFTSteel Blue (Model No. A2009TCT4EETV)

FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES .......................................................................... 1 REAR RACK, BODY PANEL, AND FOOTWELL ASSEMBLIES ............................................................................. 2 FRAME AND RELATED PARTS ............................................................................................................................. 3 WINCH ASSEMBLY ................................................................................................................................................ 4 LICENSE PLATE HOLDER ASSEMBLY ................................................................................................................. 5 SEAT ASSEMBLY ................................................................................................................................................... 6 PASSENGER SEAT AND BACKREST ASSEMBLY ............................................................................................... 7 STORAGE BOX ASSEMBLY .................................................................................................................................. 8 STEERING ASSEMBLY .......................................................................................................................................... 9 HANDLEBAR ASSEMBLY ..................................................................................................................................... 10 INSTRUMENT POD ASSEMBLY .......................................................................................................................... 11 WINDSHIELD ASSEMBLY .................................................................................................................................... 12 FRONT SUSPENSION ASSEMBLY ...................................................................................................................... 13 REAR SUSPENSION ASSEMBLY ........................................................................................................................ 14 WHEEL AND TIRE ASSEMBLY ............................................................................................................................ 15 AUXILIARY BRAKE ASSEMBLY ........................................................................................................................... 16 PARKING BRAKE ASSEMBLY ............................................................................................................................. 17 HYDRAULIC HAND BRAKE ASSEMBLY .............................................................................................................. 18 HYDRAULIC BRAKE ASSEMBLY ......................................................................................................................... 19 GAS TANK ASSEMBLY ........................................................................................................................................ 20 SHIFT LEVER ASSEMBLY ................................................................................................................................... 21 AIR INTAKE ASSEMBLY ....................................................................................................................................... 22 BATTERY ASSEMBLY .......................................................................................................................................... 23 ENGINE AND EXHAUST ....................................................................................................................................... 24 COOLING ASSEMBLY .......................................................................................................................................... 25 CASE/BELT COOLING ASSEMBLY ..................................................................................................................... 26 DRIVE TRAIN ASSEMBLY .................................................................................................................................... 27 FRONT DRIVE GEARCASE ASSEMBLY ............................................................................................................. 28 REAR DRIVE GEARCASE ASSEMBLY ................................................................................................................ 29 WIRING HARNESS ASSEMBLY ........................................................................................................................... 30 THROTTLE BODY ASSEMBLY ............................................................................................................................ 31 CYLINDER ASSEMBLY ........................................................................................................................................ 32 CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY .................................................................................... 33 CAM CHAIN ASSEMBLY ...................................................................................................................................... 34 CRANKCASE ASSEMBLY .................................................................................................................................... 35 CRANKSHAFT AND PISTON ASSEMBLY ........................................................................................................... 36 CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY .............................................................................................. 37 STARTER CLUTCH ASSEMBLY .......................................................................................................................... 38 CRANK BALANCER ASSEMBLY .......................................................................................................................... 39 OIL FILTER/PUMP ASSEMBLY ............................................................................................................................ 40 WATER PUMP ASSEMBLY .................................................................................................................................. 41 TRANSMISSION ASSEMBLY ............................................................................................................................... 42 SECONDARY TRANSMISSION ASSEMBLY ........................................................................................................ 43 GEAR SHIFTING ASSEMBLY ............................................................................................................................... 44 SECONDARY DRIVE ASSEMBLY ........................................................................................................................ 45 STARTER MOTOR ASSEMBLY ........................................................................................................................... 46 MAGNETO ASSEMBLY ........................................................................................................................................ 47

NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not to be used for assembly. For assembly procedures, use an Arctic Cat Service Manual. Underlined part numbers are new for the 2009 model year. For a complete list of related items, refer to the current accessory catalog. 2008 Arctic Cat Inc. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 Printed December 2008

2009 ATV 700 H1 Cruiser EFT

FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES0744-256

Ref. Part No. Qty. Description 1 2506-477 2 0411-818 0411-819 3 1411-725 4 1411-634 1411-635 5 0423-101 6 0423-654 7 2516-380 2516-381 8 8050-222 9 0423-540 10 8410-830 11 0423-669 12 0423-465 13 8432-802 14 2406-324 2406-421 15 0423-678 16 1406-358 17 0423-535 18 1406-484 1 1 1 1 1 1 2 2 1 1 2 2 4 4 4 4 1 1 8 1 2 1 Panel, Fender - Front - Steel Blue Decal, Reflector - Front - Right Decal, Reflector - Front - Left Decal, Front Decal, Side - Upper Right Decal, Side - Upper Left Screw, Shoulder Screw, Shoulder Bracket, Fender Support - Right Bracket, Fender Support - Left Washer Nut, Lock Screw, Cap Spacer Grommet Nut, Lock Panel, Side - Lower - Right Panel, Side - Lower - Left Grommet Cover, Access Rivet, Reinstallable Cover, Steering Post

Ref. Part No. Qty. Description 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 0623-362 0470-513 1406-573 2506-234 1406-599 0470-514 0509-036 0509-037 0409-101 0409-102 0409-099 0409-100 0409-096 0409-097 0409-098 0423-514 0423-522 0423-513 0623-785 8050-217 0423-447 4 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 4 8 4 Rivet, Reinstallable Cover, Storage Box Box, Storage Lid, Storage Box w/Latch (inc. 23-24) Latch, Storage Box Lid, Storage Box Headlight Assembly - Right (inc. 26-32) Headlight Assembly - Left (inc. 26-32) Bulb, Position Socket, Position Bulb Bulb, Turn Signal - Front Socket, Turn Signal Bulb Bulb, Headlight Retainer, Spring Boot, Rubber Stud, Adjuster - Headlight Spring, Adjuster Knob, Adjuster Screw, Self-Tapping Washer Grommet

1

2009 700 H1 Cruiser EFT

REAR RACK, BODY PANEL, AND FOOTWELL ASSEMBLIES0744-258

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2516-339 1 Cover, Rack (inc. 2) 1411-201 1 Decal, Warning - Load 8410-640 4 Screw, Cap 8050-223 4 Washer 0423-891 2 Nut, Cap 0423-540 38 Nut, Lock 2516-169 1 Rack, Rear - Assembly (inc. 8-12) 0441-592 4 Bushing 0541-504 2 Pin - Assembly (inc. 10-12) 0423-635 2 Pin, Roll 0423-677 2 Bushing, Flanged 0423-636 2 Spring 8410-835 4 Screw, Cap 0423-669 4 Spacer 0423-465 4 Grommet 0423-654 2 Screw, Shoulder 2506-092 1 Bracket, Rear Fender - Right 2506-093 1 Bracket, Rear Fender - Left 8050-222 2 Washer 0423-087 2 Washer 8432-802 4 Nut, Lock 2506-892 1 Fender, Rear - Steel Blue

Ref. Part No. Qty. Description 22 1411-592 1 Decal, Reflector - Rear - Right 1411-593 1 Decal, Reflector - Rear - Left 23 1411-957 1 Decal, Warning - Tire Pressure 24 0423-101 2 Screw, Shoulder 25 0423-419 22 Screw, Machine 26 2406-042 1 Footwell, Rear - Right 2406-043 1 Footwell, Rear - Left 27 0623-362 2 Rivet, Reinstallable 28 8477-620 2 Screw, Machine 29 1506-813 1 Footwell - Right 2406-471 1 Footwell - Left 30 0423-355 8 Screw, Shoulder 31 1506-125 4 Footpeg 32 0409-112 1 Bezel, Taillight - Right 0409-113 1 Bezel, Taillight - Left 33 3313-392 1 Taillight Assembly - Right (inc. 34-35) 3313-393 1 Taillight Assembly - Left (inc. 34-35) 34 3303-849 2 Bulb, Taillight 35 3313-506 2 Bulb, Turn Signal 36 3304-061 6 Clip, U-Nut 37 8476-516 6 Screw, Machine

2


FRAME AND RELATED PARTS0744-259

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2506-881 1 Frame, Main 8409-020 4 Screw, Cap 1506-596 2 Channel, Bumper Mounting 1506-562 1 Bracket, Mounting - Bumper - Right 1506-563 1 Bracket, Mounting - Bumper - Left 8408-816 11 Screw, Cap 1506-855 1 Bumper 1406-360 1 Grille, Bumper 0423-419 2 Screw, Machine 0423-101 12 Screw, Shoulder 0423-744 2 Nut, Lock 1506-429 1 Brace, A-Arm 8409-025 2 Screw, Cap 2406-091 1 Panel, Belly 0406-289 2 Pad, Frame 8424-802 4 Nut

Ref. Part No. Qty. Description 16 8409-016 17 1506-848 1506-849 18 2406-216 2406-217 19 2506-447 20 1411-077 21 0541-766 22 0423-690 23 0423-693 24 8477-616 25 8050-217 26 2406-321 27 0623-038 28 0430-053 4 1 1 1 1 1 1 1 1 1 3 1 1 3 1 Screw, Cap Footrest - Right Footrest - Left Strap, Footrest - Right Strap, Footrest - Left Bracket, Support Decal, Warning - Towing Mount, Ball Hitch (inc. 22-23) Nut, Lock Screw, Cap Screw, Machine Washer Bracket, Mounting - Horn Nut w/Washer Horn, Electric - 12V

3


WINCH ASSEMBLY0744-137

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 1441-657 1 Winch (inc. 2-3) 0441-061 1 Cable, Winch 1411-826 1 Decal, Warning 8051-246 4 Washer, Lock 8408-820 4 Screw, Cap 0541-760 1 Hook, Winch w/Strap 1441-130 1 Pin 1441-129 1 Cotter Pin 0441-403 1 Roller, Winch 8468-820 2 Screw, Machine 0123-788 AR Cable Tie - 8 in. 0445-068 1 Cable, Winch/Solenoid - Yellow 0445-069 1 Cable, Winch/Solenoid - Blue

Ref. Part No. Qty. Description 14 15 16 17 18 19 20 21 22 23 24 25 26 0623-038 1441-112 1441-113 0441-060 0409-066 8476-625 0505-552 1441-428 0505-551 8052-093 8009-243 8053-212 0486-276 8 1 1 3 1 2 1 1 1 2 2 1 1 Nut w/Washer Cable, Solenoid/Battery - Black Cable, Solenoid/Battery - Red Boot, Terminal Solenoid Screw, Machine Switch, Winch - Assembly (inc. 21-26) Connector, Harness Bracket, Winch Switch Washer, Internal Tooth Lock Screw, Machine Washer, External Tooth Lock Harness, Adapter - Solenoid

4


LICENSE PLATE HOLDER ASSEMBLY0743-236 *Not a Service Part

Ref. Part No. Qty. Description 1 2506-914 2 3304-772 3 * 4 3303-847 1 1 2 1 Mount, License Plate Light, License Plate Assembly (inc. 3-4) Screw, Self-Tapping Bulb

Ref. Part No. Qty. Description 5 6 7 8 0123-950 8432-802 8050-247 8468-820 2 2 2 2 Screw, Self-Tapping Nut, Lock Washer Screw, Machine

5


SEAT ASSEMBLY0743-243

Ref. Part No. Qty. Description 1 2 3 4 5 2506-805 2506-756 2506-755 2406-144 0406-879 1 1 1 1 2 Seat Assembly (inc. 2-9) Cover, Seat Foam, Seat Base, Seat - Assembly (inc. 5-6) Bumper, Seat - Rear

Ref. Part No. Qty. Description 6 7 8 9 10 0406-877 4 Bumper, Seat - Front 0624-528 AR Staple 1406-592 1 Spring, Seat Latch 1506-156 1 Latch, Seat 0441-587 1 Wrench, Spanner

6


PASSENGER SEAT AND BACKREST ASSEMBLY0744-079

Ref. Part No. Qty. Description Seat, Passenger - Assembly (inc. 2-19) Seat, Passenger - Sub-Assembly (inc. 3-6) 3 2506-944 1 Cover, Seat - Passenger 4 2506-942 1 Foam, Seat - Passenger 5 2406-110 1 Base, Seat - Inner 6 0624-263 AR Staple 7 2406-044 1 Base, Seat - Passenger 8 0411-814 1 Decal, Arctic Cat 9 2406-744 1 Handhold, Passenger - Right 2406-745 1 Handhold, Passenger - Left 10 8432-802 6 Nut, Lock 11 8468-830 6 Screw, Machine 12 0409-126 1 Switch, Handwarmer 1 2506-938 2 2506-940 1 1

Ref. Part No. Qty. Description 13 14 15 16 17 18 19 20 21 22 23 24 25 2416-042 0423-342 0486-318 2516-040 2406-895 0423-538 8427-602 2506-806 2406-765 2406-768 8408-816 2506-955 0423-889 1 2 1 1 2 2 4 1 1 1 4 1 4 Cover, Switch Screw, Self-Tapping Harness, Adapter - Handwarmer Bracket, Seat Support - Assembly End Cap, Seat Support Screw, Self-Tapping Nut, Lock Backrest Assembly (inc. 21-22) Foam, Backrest Cover, Backrest Screw, Cap Bracket, Backrest Support Screw, Machine

7


STORAGE BOX ASSEMBLY0744-076

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2516-443 2506-802 1411-725 2406-907 2406-787 2516-122 2406-793 0423-895 2516-116 0423-901 2516-117 2516-337 1411-877 2406-792 1 1 1 1 1 1 1 8 2 8 2 1 1 1 Box, Storage - Assembly (inc. 2-22) Lid, Storage Box Decal, Arctic Cat Latch, Storage Box Top Seal, Storage Box Lid Top, Storage Box Seal, Storage Box Top Bolt, Carriage Plate, Retaining Nut, Cap Plate, Retaining Bottom, Storage Box (inc. 13) Decal, Warning - Storage Box Latch, Storage Box Lid

Ref. Part No. Qty. Description 15 16 17 18 19 20 21 22 23 24 25 26 27 2506-922 1 Brace, Lid - Storage Box 2516-383 1 Brace, Top - Storage Box 0423-355 4 Screw, Shoulder 0423-087 8 Washer 2406-760 2 Hinge, Half w/Slot 0623-675 4 Washer 2406-761 2 Hinge, Half w/Tab 8477-616 12 Screw, Machine 0423-889 10 Screw, Machine 2406-843 4 Plug 8477-620 3 Screw, Machine 2506-926 1 Bracket, Mounting - Safety Flag 0423-540 3 Nut, Lock

8


STEERING ASSEMBLY0743-209 *Not a Service Part

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 8408-860 0405-035 0423-505 0505-484 0405-138 0405-139 0505-451 8408-820 2406-355 2506-173 2406-349 2406-354 0602-233 0405-052 4 4 2 1 1 1 1 2 1 1 1 1 1 1 Screw, Cap Cap, Steering Adjuster Screw, Shoulder Cap, Housing Housing, Lower Housing, Upper Post, Steering Screw, Cap Steering Lock Assembly (inc. 10-12) Latch Bracket, Mounting - Lock Lock Flange, Bearing Bearing w/Inverted Oil Seal

Ref. Part No. Qty. Description 15 16 17 18 0423-073 8409-020 0505-499 0505-511 1 1 2 2 2 2 2 2 2 2 4 4 Washer Screw, Cap Tie Rod - Assembly (inc. 18-24) End, Tie Rod - Left-Hand Thread - Kit (inc. 19-20) End, Tie Rod - Left-Hand Thread Nut - Left-Hand Thread Tie Rod End, Tie Rod - Right-Hand Thread - Kit (inc. 23-24) Nut - Right-Hand Thread End, Tie Rod - Right-Hand Thread Nut, Lock Pin, Cotter

19 * 20 0423-013 21 0405-281 22 0505-510 23 8420-002 24 * 25 0423-157 26 0623-175

9


HANDLEBAR ASSEMBLY0744-260

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0505-522 0405-218 0405-149 8050-247 8477-845 0405-147 0411-966 1411-865 0509-045 3409-001 3007-392 3004-447 3003-030 3423-014 1 2 2 2 2 2 1 1 1 1 1 1 1 1 Handlebar Plug, Handlebar End Cap, Handlebar Washer Screw, Machine Grip, Handlebar Decal, Warning - Differential Lock Decal, Warning - Brake Lever Lock Case, Throttle - Assembly (inc. 10-17) Lever Screw, Cap Washer, Lock Washer Screw, Machine

Ref. Part No. Qty. Description 15 16 17 18 19 20 21 22 23 24 25 26 27 3423-327 3423-199 0409-119 0409-081 2406-630 2406-631 0423-985 0423-986 0423-987 0423-988 0609-800 0441-498 0617-248 0409-117 1 2 1 1 1 1 2 2 2 2 2 1 1 1 Nut Screw, Machine Cover, Throttle Case w/Switch Switch, Control Mirror - Right (inc. 20-23) Mirror - Left (inc. 20-23) Cover Nut, Adjuster Washer, Lock Nut Element, Handwarmer Tube, Shrink Pad, Insulator Element, Thumbwarmer

10


INSTRUMENT POD ASSEMBLY0743-962

Ref. Part No. Qty. Description 1 0430-090 2 0430-050 3 0430-042 0430-043 4 0430-054 5 0505-546 6 0641-897 7 0520-034 1 1 1 1 1 1 1 1 Switch, Ignition - Assembly (inc. 2-4) Nut, Retaining Key, Ignition (Y Series - Left-Side Cut) Key, Ignition (Z Series - Right-Side Cut) Cover, Key Instrument Pod Outlet, Accessory - 12V Gauge, LCD

Ref. Part No. Qty. Description 8 9 10 11 12 13 14 0420-065 0423-493 2506-470 0423-535 0409-120 1411-564 0409-121 1 2 1 2 1 1 1 Bracket, Retaining Nut w/Washer Bracket, Mounting - Instrument Pod Rivet, Reinstallable Switch, Differential Lock Decal, Instrument Pod Switch, Handwarmer

11


WINDSHIELD ASSEMBLY0744-261

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 0405-333 0423-767 0505-556 1411-988 1411-989 0405-332 0423-950 0623-562 0641-897 0405-353 1441-839 1 6 1 1 1 1 6 2 1 1 1 Windshield Clip, Retaining Base, Windshield - Steel Blue Decal, Base - 700 EFI Decal, Base - 4x4 Console - Black Screw, Self-Tapping Plug Outlet, Accessory - 12V Cover, Flashlight Flashlight

Ref. Part No. Qty. Description 12 13 14 15 16 17 18 19 20 21 22 0486-319 0405-352 0423-949 0423-948 8450-128 8431-803 1441-624 0405-350 0405-351 8471-520 8431-503 1 2 4 4 2 4 2 2 2 2 2 Adapter, Harness - Outlet Accessory Pin, Mounting - Tapered Screw, Cap Washer Washer Nut, Lock Knob, Adjuster Clamp, Handlebar Cap, Handlebar Clamp Screw, Machine Nut, Lock

12


FRONT SUSPENSION ASSEMBLY0743-294

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 0403-209 2 Shock Absorber (inc. 2) 0403-182 4 Bushing 0403-102 2 Cam, Spring Adjuster 0503-354 2 Spring, Suspension - Platinum 1603-889 2 Retainer, Spring 8409-040 4 Screw, Cap 0423-744 10 Nut, Lock 0503-272 1 A-Arm, Upper Right - Platinum (inc. 9-12) 0503-273 1 A-Arm, Upper Left - Platinum (inc. 9-12) 0403-081 4 Bushing 0403-080 2 Axle 0423-009 4 Ring, Retaining 0405-115 4 Ball Joint 0503-380 1 A-Arm, Lower Right - Platinum (inc. 14-15 and two No. 11-12) 0503-381 1 A-Arm, Lower Left - Platinum (inc. 14-15 and two No. 11-12)

Ref. Part No. Qty. Description 14 0403-115 15 0403-114 16 0505-576 0505-577 17 1402-809 18 0423-423 19 8409-030 20 0423-334 21 8409-075 22 1502-344 1502-345 23 0423-844 24 0436-276 25 1406-034 1406-035 26 0423-545 8 4 1 1 2 2 4 2 4 1 1 2 2 1 1 4 Bushing Axle Knuckle - Assembly - Right (inc. 17-18) Knuckle - Assembly - Left (inc. 17-18) Bearing Ring, Retaining Screw, Cap Screw, Cap Screw, Cap Axle, Drive - Right (inc. 23-24) Axle, Drive - Left (inc. 23-24) Clip, Retaining Repair Kit, Boot Guard, Boot - Right - Black Guard, Boot - Left - Black Screw, Shoulder

13


REAR SUSPENSION ASSEMBLY0743-295

Ref. Part No. Qty. Description Knuckle, Right Rear - Assembly (inc. 2-5) Knuckle, Left Rear - Assembly (inc. 2-5) Bearing Ring, Retaining Axle Bushing A-Arm, Rear - Lower Right - Platinum (inc. 7-8) 0504-577 1 A-Arm, Rear - Lower Left - Platinum (inc. 7-8) 7 0403-115 16 Bushing 8 0403-114 8 Axle 9 0423-744 14 Nut, Lock 10 8409-000 4 Screw, Cap 11 0504-586 1 A-Arm, Rear - Upper Right - Platinum (inc. 7-8) 0504-587 1 A-Arm, Rear - Upper Left - Platinum (inc. 7-8) 1 0504-616 0504-549 2 1402-809 3 0423-423 4 0403-038 5 0403-032 6 0504-576 1 1 2 2 4 8 1

Ref. Part No. Qty. Description 12 1406-068 1 Guard, Boot - Rear - Right - Black 1406-069 1 Guard, Boot - Rear - Left - Black 13 0423-545 4 Screw, Shoulder 14 8409-075 8 Screw, Cap 15 1502-343 2 Axle, Drive (inc. 16-17) 16 0423-845 2 Clip, Retaining 17 0436-276 2 Repair Kit, Boot 18 0123-788 AR Tie, Cable - 8 in. 19 1603-889 2 Retainer, Spring 20 0504-543 2 Spring, Suspension - Platinum 21 0404-057 2 Cam, Spring Adjuster 22 0404-158 2 Shock Absorber (inc. 23-25) 23 0403-182 2 Bushing, Double-Bonded 24 0603-955 4 Bushing 25 1603-219 2 Sleeve 26 0423-087 2 Washer 27 8408-820 2 Screw, Cap 28 8409-050 2 Screw, Cap

14


WHEEL AND TIRE ASSEMBLY0743-260

Ref. Part No. Qty. Description 1 2 3 4 5 0423-557 12 Screw, Shoulder 1436-164 3 Disc, Brake 3323-100 2 Hub, Wheel - Front (inc. 4) 0402-974 16 Stud 3323-100 1 Hub, Wheel - Rear - Right (inc. 4) 3323-113 1 Hub, Wheel - Rear - Left (inc. 4) 6 0423-607 4 Nut, Castle 7 0423-407 4 Pin, Cotter

Ref. Part No. Qty. Description 8 1402-424 2 Wheel - Front - Black 1402-425 2 Wheel - Rear - Black 9 0423-618 16 Nut, Lug - Chrome 10 1402-858 2 Tire - Front 1402-859 2 Tire - Rear 11 0402-064 4 Stem, Valve (inc. 12) 12 0402-140 4 Cap, Valve Stem

15


AUXILIARY BRAKE ASSEMBLY0744-263

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1502-063 1 Lever, Brake 1602-213 2 O-Ring 8050-252 1 Washer 8408-816 1 Screw, Cap 0502-807 1 Spring, Brake Lever 0502-785 1 Spring, Brake Switch 1502-147 1 Master Cylinder 1402-592 1 Hose, Brake 0423-178 7 Washer, Crush 0423-413 2 Bolt, Banjo-Fitting 0423-610 1 Bolt, Banjo-Fitting - Double 1402-594 1 Hose, Brake 1502-115 2 Clip, Brake Hose 0123-788 AR Cable Tie - 8 in. 1436-163 1 Caliper, Brake (inc. 16-22)

Ref. Part No. Qty. Description 16 1436-161 17 18 19 20 21 22 23 24 25 26 27 28 0502-606 0502-607 0502-609 0502-608 0502-605 1436-165 8408-821 0502-840 8408-625 1402-377 0117-868 8050-217 1 1 1 1 1 1 1 2 1 2 1 1 1 Housing, Caliper - Assembly - Left Rear (inc. 17-19) Piston/Seal Set (inc. 18) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Screw, Cap Bracket, Switch Screw, Cap Pin, Clevis Pin, Cotter Washer

16


PARKING BRAKE ASSEMBLY0743-214

Ref. Part No. Qty. Description 1 2 3 4 5 1502-278 1502-429 1502-432 1502-430 1502-431 1 1 1 1 1 Lever, Parking Brake - Assembly (inc. 2-6) Lever, Parking Brake - Kit Clamp, Handlebar - Kit Adjuster, Thumb Nut - Kit Lock, Parking Brake Lever - Kit

Ref. Part No. Qty. Description 6 7 8 9 10 0487-055 1502-176 1402-602 8408-826 0402-379 1 1 2 2 1 Cable, Brake - Rear Mechanical Brake Assembly Pad, Brake Screw, Cap Wire Form, Cable

17


HYDRAULIC HAND BRAKE ASSEMBLY0741-458

Ref. Part No. Qty. Description 1 2 3 4 5 6 0502-914 0502-566 0502-868 0502-568 0502-869 0502-704 1 1 1 1 1 1 Brake Assembly (inc. 2-10) Screw, Machine - Kit Cover, Reservoir Screw, Machine - Kit Clamp, Master Cylinder Master Cylinder Assembly

Ref. Part No. Qty. Description 7 8 9 10 11 12 0502-866 0502-867 0502-580 0502-564 0423-178 0423-413 1 1 1 1 2 1 Lever Assembly - Kit (inc. 8-9) Lock, Brake Lever - Kit Lever Pin - Kit Switch, Brake Washer, Crush Bolt, Banjo-Fitting

18


HYDRAULIC BRAKE ASSEMBLY0743-262

Ref. Part No. Qty. Description 1 2 3 4 1502-148 8476-625 8408-821 1436-162 1436-163 5 1436-160 1436-161 1 1 4 1 1 1 1 Hose, Brake - Assembly Screw, Machine Screw, Cap Caliper, Brake - Right Front (inc. two No. 3 and 5-11) Caliper, Brake - Left Front (inc. two No. 3 and 5-11) Housing, Caliper - Assembly - Right Front (inc. 6-8) Housing, Caliper - Assembly - Left Front (inc. 6-8)

Ref. Part No. Qty. Description 6 7 8 9 10 11 12 13 14 0502-606 0502-607 0502-609 0502-608 0502-605 1436-165 0423-178 0423-413 0623-038 2 2 2 2 2 2 4 2 1 Piston/Seal Set (inc. 7) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Washer, Crush Bolt, Banjo-Fitting Nut w/Washer

19


GAS TANK ASSEMBLY0743-224 *Not a Service Part

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 0570-206 0470-438 0109-733 0470-606 8476-612 0570-271 0570-252 0470-614 0470-613 0570-277 0570-246 * 1 1 1 1 4 1 1 1 1 1 1 2 Tank, Gas - Assembly (inc. 2-5) Cap, Gas Tank (inc. 3) Gasket, Gas Tank Cap Plate, Mounting - Fuel Pump Screw, Self-Tapping Pump, Fuel - Assembly (inc. 7-9) Sensor, Fuel Level - Kit (inc. 8-9) Seal, Fuel Pump Seal, Fuel Pump Hose, Gasline - Assembly (inc. 11-13) Filter, Fuel - Kit (inc. 12-13) Clamp, Hose

Ref. Part No. Qty. Description 13 14 15 16 17 18 19 20 21 22 23 24 * 1 Filter, Fuel 0410-070 AR Hose, Gasline - 25 ft 0510-335 1 Filter, In-Line 8060-628 1 Rivet 1670-826 1 Bracket, Fuel Filter 0470-794 1 Bracket, Filter Mounting 0123-788 AR Tie, Cable - 8 in. 0423-688 2 Clamp, Hose 0423-460 2 Grommet 0423-732 2 Screw, Shoulder 0470-822 1 Shield, Heat 0623-797 4 Screw, Self-Tapping

20


SHIFT LEVER ASSEMBLY0742-508

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 0402-843 0423-345 1402-576 2406-345 0423-357 0502-659 0402-678 8424-602 1502-332 0423-299 0402-675 1 1 1 1 4 1 1 1 1 2 1 Knob, Shift Clip, Retaining Plate, Shift Shield, Shift Plate Nut, Stamped Lever, Shift Spring, Shift Lever Nut Actuator, Shift O-Ring Axle, Pivot

Ref. Part No. Qty. Description 12 13 14 15 16 17 18 19 20 21 22 0423-182 0423-087 8408-812 8424-802 0423-091 1402-621 0623-094 0423-169 1502-200 0623-294 0123-917 2 1 1 1 2 1 2 2 1 1 1 O-Ring Washer Screw, Cap Nut Bushing Pin, Mounting Washer E-Ring Linkage, Shift - Assembly (inc. 21-22) Nut, Hex - Right-Hand Thread Nut, Hex - Left-Hand Thread

21


AIR INTAKE ASSEMBLY0742-598

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 0470-850 0470-560 0470-558 0470-728 0423-455 0470-749 0423-763 0570-215 0470-729 0423-342 0423-019 1 1 1 1 4 1 1 1 1 4 2 Cover, Intake Screen, Air Filter Filter, Air Housing, Intake Clip, Spring Duct, Air Intake - Engine Grommet Resonator Boot Screw, Self-Tapping Clamp, Boot

Ref. Part No. Qty. Description 12 13 14 15 16 17 18 19 20 21 22 0470-442 0410-172 1623-281 0423-766 1623-287 0423-554 0470-511 0430-055 5507-224 2406-604 0623-362 1 1 2 1 1 1 1 1 1 1 2 Valve, Drain Hose, Vent Clamp, Hose Cap, Drain Clamp Clamp, Boot Boot Sensor, Air Temperature (inc. 20) O-Ring Panel, Shield Rivet, Reinstallable

22


BATTERY ASSEMBLY0742-782 *Not Illustrated

Ref. Part No. Qty. Description 1 2 3 * 5991-655 2406-815 0417-016 0444-122 1 1 1 1 Battery Cover/Tool Tray Assembly (inc. 2-3) Cover, Battery Pad, Battery Kit, Tool

Ref. Part No. Qty. Description 4 5 6 7 0645-480 0645-430 8476-620 0417-017 1 1 2 1 Battery Assembly (inc. 5) Decal, Warning Screw, Machine Foam, Battery

23


ENGINE AND EXHAUST0744-264

Ref. Part No. Qty. Description 1 0800-065 1 Engine, A700FH1 2 0801-108 4 Mount, Rubber - Engine 3 1506-740 1 Bracket, Engine - Right 1506-741 1 Bracket, Engine - Left 4 0423-405 2 Screw, Cap 5 0423-042 1 Spacer, Engine 6 8428-002 2 Nut, Lock 7 2406-065 4 Mount, Engine 8 8408-820 10 Screw, Cap 9 8408-012 4 Screw, Cap 10 8432-802 8 Nut, Lock 11 0512-363 1 Pipe, Exhaust - Assembly (inc. 12-17) 12 0412-355 1 Shield, Exhaust Pipe - Lower - Rear 13 0412-354 1 Shield, Exhaust Pipe - Upper - Rear

Ref. Part No. Qty. Description 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0412-349 0412-348 0512-362 0423-317 0412-338 0412-375 0612-668 0412-215 1506-732 0512-430 0412-489 8477-610 0412-490 0411-426 1 1 1 4 1 1 2 3 1 1 1 4 4 1 Shield, Exhaust Pipe - Inner - Front Shield, Exhaust Pipe - Outer - Front Pipe, Exhaust Clamp Gasket, Exhaust Pipe Seal, Exhaust Spring, Extension Bushing Channel, Muffler Support Muffler - Assembly (inc. 24-26) Cover, Muffler Screw, Machine Washer Decal, Warning - Clutch Cover

24


COOLING ASSEMBLY0742-668

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 0413-199 1 Radiator Assembly (inc. 2-13) 0413-205 1 Radiator 0413-007 1 Screen 0413-002 1 Cap 0423-030 2 Grommet 0610-016 AR Hose - 25 ft 0610-015 AR Hose - 100 ft 0413-203 1 Shroud, Fan 0413-123 1 Fan, Cooling 8475-512 4 Screw, Machine 0423-351 1 Clamp, Wire 0623-378 8 Screw, Self-Tapping 0413-195 1 Plug, Drain 1602-213 1 O-Ring

Ref. Part No. Qty. Description 14 15 16 17 18 19 20 21 22 23 24 25 26 0423-484 2 Screw, Shoulder 0623-038 4 Nut w/Washer 0423-028 2 Bushing, Stem 0410-002 1 Hose, Coolant - Upper 0410-022 1 Hose, Coolant - Crossover 0410-041 1 Hose, Coolant - Lower 0423-496 6 Clamp, Hose 0123-903 AR Tie, Cable - 11.5 in. 0410-127 2 Hose, Oil Cooler 0423-632 4 Clamp, Hose 0413-211 1 Cooler, Oil 8476-612 2 Screw, Machine 0513-022 1 Bracket, Mounting - Oil Cooler - Upper

25


CASE/BELT COOLING ASSEMBLY0743-712

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 0423-550 2 Clamp 0423-342 5 Screw, Self-Tapping 0413-198 1 Boot, Duct - Air Intake - Front 0423-551 1 Clamp 0470-442 AR Valve, Drain 0513-027 1 Duct, Air Intake - Front - Lower 0470-750 1 Duct, Air Intake - Front - Upper 0470-729 1 Cup, Air Intake

Ref. Part No. Qty. Description 9 0423-730 10 0413-206 11 0470-824 12 13 14 15 0623-784 0470-825 0470-778 0423-019 1 1 1 4 1 1 1 Clamp Boot, Duct - Air Out - Rear Duct, Air Out - Rear (inc. three No. 12 and 13-14) Screw, Self-Tapping Duct Duct Clamp

26


DRIVE TRAIN ASSEMBLY0743-966

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 1402-620 2 Bladder, Gearcase 0423-315 4 Clamp, Hose 8428-002 4 Nut, Lock 0423-426 8 Washer 0423-404 4 Screw, Cap 1502-393 1 Gearcase, Front 0402-966 1 Boot, Shaft 1502-401 1 Gearcase, Rear 0410-070 AR Hose, Vent - 25 ft 0470-702 1 Fitting, Vent

Ref. Part No. Qty. Description 11 12 13 14 15 16 17 18 19 0423-393 2 0402-985 2 0423-411 2 0673-618 2 1402-092 1 1402-026 2 0402-950 1 8408-820 4 0123-788 AR Clamp, Boot Boot Clamp, Boot Bumper, Propeller Shaft Shaft, Propeller Spring Flange, Output Screw, Cap Tie, Cable - 8 in.

27


FRONT DRIVE GEARCASE ASSEMBLY(Complete Assembly p/n 1502-393)0743-250

Ref. Part No. Qty. Description 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 1502-083 1 Shaft, Propeller - Assembly (inc. 2-6) 0423-411 1 Clamp, Boot 0402-985 1 Boot, Propeller Shaft 0423-393 1 Clamp, Boot 1402-045 1 Shaft, Output 1502-085 1 Shaft, Input 1402-011 1 Seal 0423-423 1 Ring, Retaining 1502-237 1 Bracket, Actuator 0502-585 1 Actuator 0423-892 1 O-Ring 0423-396 3 Screw, Self-Tapping 1402-043 1 Bearing 0423-118 11 Screw, Self-Tapping 0502-528 1 Housing, Pinion 0402-947 1 Gasket, Flange 0402-997 1 Shaft, Selector 0402-998 1 Fork, Selector 0402-417 1 Shaft, Shuttle 0423-402 1 Ring, Retaining 0423-147 1 O-Ring 0402-999 1 Spring, Return 0423-417 1 Ring, Retaining 0402-357 1 Collar, Lock 0402-413 1 Coupler, Drive 0502-784 1 Gear, Pinion - Assembly - 11T (inc. 27-28) 0402-336 1 Collar, Retaining 0402-327 1 Bearing 0402-328 1 Bearing 0402-411 1 Pin, Dowel 0502-514 1 Housing, Gearcase 1402-210 1 Plug, Magnetic (inc. one No. 33)

Ref. Part No. Qty. Description 33 34 35 36 0423-153 0423-149 0402-393 0402-405 0402-406 0402-407 0402-408 0402-409 37 1502-554 38 1402-074 1402-075 1402-076 1402-077 1402-078 39 1502-389 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 1402-053 0502-413 1402-079 1402-042 1402-054 1402-058 1402-057 1402-104 1402-063 1402-656 1402-056 1402-211 1402-713 0402-333 0423-154 2 1 1 AR AR AR AR AR 1 AR AR AR AR AR 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 O-Ring O-Ring Bearing Shim Shim Shim Shim Shim Gear, Ring - 34T Shim Shim Shim Shim Shim Cover, Gearcase (inc. one No. 33, 40-51, and one No. 52) Bearing Flange, Bearing Pin, Parallel Collar, Sliding Fork Ring, Retaining Spring Fitting Spring Shaft, Lock Seal Plug, Oil Level (inc. one No. 33) Seal Plug, Fill (inc. 54) O-Ring

28


REAR DRIVE GEARCASE ASSEMBLY(Complete Assembly p/n 1502-401)0741-524

Ref. Part No. Qty. Description 1 2 3 4 5 1502-317 0402-393 1402-713 1402-033 0402-405 0402-406 0402-407 0402-408 0402-409 0402-326 0402-429 0402-430 0402-431 0402-432 0402-433 0423-149 1502-082 0402-333 0423-154 1402-102 1 2 2 1 AR AR AR AR AR 1 AR AR AR AR AR 1 1 1 1 1 Housing, Gearcase Bearing Seal Gear, Ring - 34T Shim Shim Shim Shim Shim Button, Thrust Shim Shim Shim Shim Shim O-Ring Cover, Gearcase Plug, Magnetic (inc. 11) O-Ring Fitting

Ref. Part No. Qty. Description 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 0423-118 11 Screw, Self-Tapping 1402-210 1 Plug, Fill (inc. one No. 15) 0423-153 2 O-Ring 0402-328 1 Bearing 0502-784 1 Gear, Pinion - Assembly - 11T (inc. 18-19) 0402-327 1 Bearing 0402-336 1 Collar, Retaining 0402-411 1 Pin, Dowel 0402-331 1 Collar, Lock 0402-982 1 Washer, Wave 0402-981 1 Collar, Shaft 0402-947 1 Gasket, Flange 0502-529 1 Housing, Pinion 0423-417 1 Ring, Retaining 1402-043 1 Bearing 0423-423 1 Ring, Retaining 1402-011 1 Seal 1502-085 1 Shaft, Input 1402-211 1 Plug, Oil Level (inc. one No. 15)

6 7

8 9 10 11 12

29


WIRING HARNESS ASSEMBLY0744-265

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0486-309 1 Harness, Main (inc. 2-9) 0486-164 2 Tether, Accessory Connector 0530-008 1 Cover, Fuse Block 0430-037 1 Holder, Fuse 0430-034 2 Diode 0430-045 5 Relay (4-Pin) - 20 Amp 0430-032 6 Fuse - 10 Amp 0430-031 3 Fuse - 15 Amp 0430-030 2 Fuse - 30 Amp 1411-940 1 Decal, Fuse Block 0430-049 1 Flasher (3-Pin) 0123-788 AR Tie, Cable - 8 in. 0623-038 8 Nut w/Washer 0824-037 1 Regulator, Voltage 8476-625 4 Screw, Machine 0409-089 1 Switch, Brake - Assembly 0445-058 1 Solenoid 8050-217 1 Washer

Ref. Part No. Qty. Description 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 0445-062 1 0445-064 1 0645-019 1 0645-327 1 0445-070 1 0824-043 1 0824-049 1 8476-620 2 0409-064 1 8468-425 2 0123-802 2 0423-493 2 0530-031 1 0430-076 1 0623-362 3 2406-643 1 0123-903 AR Cable, Battery/Solenoid Cable, Solenoid/Starter (inc. 19) Boot, Terminal Boot, Terminal Cable, Battery/Ground Coil, Ignition Cap, Spark Plug Screw, Machine Switch, Tilt Sensor Screw, Machine Washer Nut w/Washer ECU Cushion, ECU Rivet, Reinstallable Tray, Electrical Tie, Cable - 11.5 in.

30


THROTTLE BODY ASSEMBLY0742-670 *Not a Service Part

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 0470-753 * 0430-072 5507-234 5507-231 0430-074 5507-233 5507-238 0470-687 0470-767 1 1 1 1 1 1 1 1 1 1 Throttle - Assembly (inc. 2-19) Throttle Body Sensor, Throttle Position O-Ring Screw, Machine Valve, ISC O-Ring Screw, Machine Rail, Fuel O-Ring

Ref. Part No. Qty. Description 11 12 13 14 15 16 17 18 19 20 0470-762 0470-768 5507-227 5507-117 0430-073 5507-232 5507-229 5507-223 5507-037 0487-057 1 1 1 2 1 1 1 1 1 1 Injector, Fuel Seal Bracket, MAP Sensor Screw, Machine Sensor, MAP O-Ring Plate, ISC Valve Cover Screw, Machine Cable, Throttle

31


CYLINDER ASSEMBLY0743-952

Ref. Part No. Qty. Description 1 2 3 4 5 6 0804-024 0827-002 8424-604 0830-111 0829-002 0804-047 1 2 4 1 2 1 Cylinder Bolt, Stud Nut Gasket, Base Pin, Dowel Union, Coolant Hose

Ref. Part No. Qty. Description 7 8 9 10 11 12 8468-612 0830-007 0830-112 0827-054 0830-113 0829-001 1 1 1 2 4 2 Screw, Machine O-Ring Gasket, Cylinder Head Bolt, Stud O-Ring Pin, Dowel

32


CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY0743-872

Ref. Part No. Qty. Description 1 2 3 4 0808-082 0829-001 0826-001 0809-205 1 2 4 1 4 4 1 1 1 8 4 4 4 4 2 2 2 1 1 2 1 1 1 Head, Cylinder - Assembly (inc. 2-17) Pin, Dowel Screw, Cap Arm, Valve Rocker - Exhaust (inc. two No. 5-6) Screw, Adjuster Nut Arm, Valve Rocker - Intake (inc. two No. 5-6) Shaft, Rocker Arm - Intake Shaft, Rocker Arm - Exhaust Cotter, Valve Retainer, Spring Spring, Valve Seal, Oil Seat, Spring - Valve Valve, Intake Valve, Exhaust Plug, Shaft Camshaft Sprocket Screw, Cap Plate, Retainer Pin, Dowel C-Ring

Ref. Part No. Qty. Description 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 0808-077 0826-007 0808-003 0830-167 0808-037 0830-147 0830-107 0826-002 0826-005 0826-006 0217-799 0470-668 0830-090 0826-008 0470-669 0423-066 0830-168 0830-169 0808-113 0808-078 0808-124 0827-031 8424-804 0827-002 8424-604 1 6 2 2 4 4 4 2 2 2 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 Plug, Cylinder Head Screw, Cap Cap, Inspection O-Ring Screw, Cap Washer Gasket Screw, Cap Screw, Cap Screw, Cap Spark Plug (CPR8E) Flange, Intake Manifold O-Ring Screw, Machine Boot Clamp O-Ring Plug Cover, Thermostat Thermostat Sensor, Engine Coolant Temperature Bolt, Stud Nut Bolt, Stud Nut

5 0809-033 6 0827-007 7 0809-202 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 0809-007 0809-008 0809-014 0809-013 0809-138 0830-016 0809-006 0809-039 0809-040 0831-066 0809-245 0809-002 0826-034 0828-004 0829-049 0809-003

33


CAM CHAIN ASSEMBLY0732-308

Ref. Part No. Qty. Description 1 2 3 4 5 6 0810-001 0810-002 0810-003 0826-036 0830-025 0810-004 1 1 1 1 1 1 Chain, Cam Guide, Chain Tensioner, Chain Pivot, Tensioner Washer, Crush Adjuster, Tensioner - Assembly

Ref. Part No. Qty. Description 7 8 9 10 11 0830-018 8468-625 0830-107 8400-610 0828-129 1 2 2 1 1 Gasket Screw, Machine Gasket Screw, Cap Washer

34


CRANKCASE ASSEMBLY0743-953

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0801-153 0812-064 0801-002 0832-043 0832-044 0832-049 0832-050 0832-042 0832-048 0832-015 0822-052 0826-100 0822-010 0801-028 0830-035 8412-850 0829-003 1 2 1 1 2 1 3 1 1 1 1 4 4 1 1 4 1 Crankcase Assembly (inc. 2-15) Plug Plug Bearing Bearing Bearing Bearing Bearing Bearing Bearing Seal, Countershaft Screw, Machine Retainer, Bearing Pipe, Breather Seal, Driveshaft Screw, Cap Pin, Dowel

Ref. Part No. Qty. Description 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 0829-002 8468-645 8468-655 8468-675 8412-860 0826-017 0830-008 0826-019 0826-018 8468-695 8468-680 0801-029 0826-105 0826-038 0801-069 0801-143 0830-010 5 3 3 2 1 1 2 1 1 1 1 1 3 1 1 1 1 Pin, Dowel Screw, Machine Screw, Machine Screw, Machine Screw, Cap Screw, Cap Gasket Screw, Cap Screw, Cap Screw, Machine Screw, Machine Housing, Secondary Shaft (inc. one No. 7) Screw, Cap Screw, Cap Pipe, Breather Stick, Oil Level O-Ring

35


CRANKSHAFT AND PISTON ASSEMBLY0739-932

Ref. Part No. Qty. Description 1 0805-032 2 0805-297 3 0805-132 1 1 1 Crankshaft Assembly Piston Set (inc. 3-6) Ring, Piston - Set

Ref. Part No. Qty. Description 4 0831-001 5 0805-296 6 0805-210 2 1 1 Circlip, Piston Pin Piston Pin, Piston

36


CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY0743-969

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0806-089 0829-002 0830-013 8408-812 0832-060 0831-078 0830-174 0806-086 0826-029 0806-048 0830-188 0832-047 0822-010 0830-116 0830-128 0806-082 0806-022 1 6 1 1 1 1 1 1 5 1 1 1 2 1 1 1 1 Cover, V-Belt Pin, Dowel Washer, Crush Screw, Cap Bearing Ring, Retaining Gasket, V-Belt Cover Cover, Clutch Screw, Machine Plate, Air Intake Seal Bearing Retainer, Bearing Gasket, Clutch Cover Gasket, Magneto Cover Cover, Magneto - Assembly Plug

Ref. Part No. Qty. Description 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 0830-015 1 Washer, Crush 3002-964 1 Clamp, Wire 0832-045 1 Bearing 0830-158 1 Seal 0805-008 1 Retainer, Seal 0826-031 3 Screw, Machine 0830-108 1 O-Ring 0820-061 1 Bushing 0827-008 1 Nut 0820-062 1 Cover, Magneto 8468-616 4 Screw, Machine 8468-645 14 Screw, Machine 8468-655 2 Screw, Machine 8468-625 2 Screw, Machine 8468-640 26 Screw, Machine 8468-675 2 Screw, Machine

37


STARTER CLUTCH ASSEMBLY0739-940

Ref. Part No. Qty. Description 1 2 3 4 5 0815-001 0829-031 0815-002 0815-003 0829-032 1 1 1 1 1 Gear, Starter Idler - No. 1 Shaft, Starter Gear Gear, Starter Idler - No. 2 Spacer, Starter Idler Gear No. 2 Shaft, Starter Gear

Ref. Part No. Qty. Description 6 7 8 9 10 0815-004 0832-079 0802-035 0826-069 0828-094 1 1 1 6 1 Gear, Starter Clutch (inc. 7) Bearing Clutch, Starter Screw, Machine Washer

38


CRANK BALANCER ASSEMBLY0739-941

Ref. Part No. Qty. Description 1 2 3 4 0826-033 0828-003 0811-003 0829-007 1 1 1 1 Screw, Cap Washer Gear, Oil Pump Drive Pin, Dowel

Ref. Part No. Qty. Description 5 6 7 8 0811-004 0811-002 0829-006 0811-017 1 1 1 1 Spacer Gear, Driven Key Balancer, Crank

39


OIL FILTER/PUMP ASSEMBLY0742-688

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 0812-023 0812-002 0829-009 0828-007 0831-002 0826-039 0812-057 0826-040 0812-029 1 1 1 1 1 3 1 2 1 Pump, Oil Gear, Driven Pin Washer Ring, Retaining Screw, Machine Strainer, Oil Screw, Machine Filter, Oil

Ref. Part No. Qty. Description 10 11 12 13 14 15 16 17 0812-053 8468-625 0812-007 0812-006 0830-017 0812-056 0812-055 0830-166 1 4 1 1 1 1 1 1 Cap, Oil Strainer Screw, Machine Valve, Oil-Relief - Assembly Plug, Drain Gasket, Drain Plug Stand, Oil Fitting Tower, Oil Fitting O-Ring, Oil Fitting

40


WATER PUMP ASSEMBLY0739-945

Ref. Part No. Qty. Description 1 2 3 4 5 6 0813-001 0830-029 0813-004 0813-005 0829-009 0831-002 1 1 1 1 1 2 Pump, Water - Assembly (inc. 2) O-Ring Gear, Driven Shaft, Driven Gear Pin, Driven Gear Ring, Retaining

Ref. Part No. Qty. Description 7 8 9 10 11 12 0832-046 0831-004 0811-003 0829-007 0831-005 8468-665 1 1 1 1 1 2 Bearing Ring, Retaining Gear, Water Pump Drive Pin, Alignment Ring, Retaining Screw, Machine

41


TRANSMISSION ASSEMBLY0743-967

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 0823-157 0823-176 0823-177 0823-178 0827-010 0828-106 0823-008 0823-010 0823-159 0823-013 0823-149 1 3 3 1 1 1 1 4 1 1 1 Pulley, Driven - Assembly (inc. 2-4) Shoe, Cam Screw, Machine Nut Nut Washer Plate, Movable Drive Face Damper, Movable Drive Face Face, Movable Drive Belt, Drive Spacer

Ref. Part No. Qty. Description 12 13 14 15 16 17 18 19 20 21 22 0823-167 0823-156 0823-131 0623-914 0823-015 0470-531 0823-096 0830-189 0827-011 0823-018 0823-098 8 1 1 6 1 1 1 1 1 1 1 Roller Face, Fixed Drive Shroud, Drive Face Screw, Self-Tapping Spacer, Fixed Drive Face O-Ring Housing, Clutch - Assembly Seal Nut Clutch, One-Way Clutch, Centrifugal - 6 Plate

42


SECONDARY TRANSMISSION ASSEMBLY0743-765

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1502-149 0822-014 0831-011 0822-045 0828-008 0822-013 0832-011 0822-005 0828-014 0828-015 0822-004 0822-046 0822-003 0822-007 0822-006 0822-089 0828-011 1 1 2 1 2 1 3 3 1 1 1 2 1 1 1 1 1 Countershaft Assembly (inc. 2-15) Gear Select, Reverse Ring, Retaining Spacer, Reverse Driven Gear Washer Gear, Reverse Driven Bearing Bushing Washer, Lock Washer, Lock Gear, Driven - Low Washer, Driven Gear Countershaft Gear Select, Sliding Gear, Driven - High Gear, Drive Washer

Ref. Part No. Qty. Description 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 0828-019 0831-040 0828-069 0822-050 0831-039 0830-129 0829-023 0822-049 0824-042 8468-620 8468-645 0830-107 0822-001 0828-016 0822-011 0822-012 0822-015 1 1 1 1 1 1 2 1 1 1 2 2 1 2 1 1 1 Washer, Thrust Ring, Retaining Washer, Thrust Trigger, Speedometer Sensor Ring, Retaining Gasket Pin, Dowel Housing, Speedometer Sensor Sensor, Speedometer Screw, Machine Screw, Machine Seal, Fastener Driveshaft Washer, Thrust Gear, Reverse Idle Bushing Shaft, Reverse Idle

43


GEAR SHIFTING ASSEMBLY0743-770

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 8470-520 0409-090 0818-013 0818-017 0828-040 0818-046 0828-095 0832-052 0828-037 0818-089 0826-006 0828-036 0831-010 2 1 2 2 1 1 2 1 1 1 1 2 2 Screw, Machine Switch, Gear Shift Position Contact Spring Washer Shaft, Gear Shift - Assembly Washer Bearing, Thrust Washer Plate, Gear Shift Cam Screw, Cap Washer Ring, Retaining

Ref. Part No. Qty. Description 14 15 16 17 18 19 20 21 22 23 24 25 0818-007 0830-044 0818-014 8468-620 0828-038 0818-002 0818-004 0818-090 0828-035 8424-602 0818-072 0818-006 1 1 1 1 1 1 1 1 1 1 2 1 Shaft, Sub-Gear Shift Seal, Sub-Gear Shift Shaft Arm, Select Screw, Machine Washer Stopper, Cam Support, Cam Stopper Spring Washer Nut Fork, Shift Shaft, Shift Fork

44


SECONDARY DRIVE ASSEMBLY0743-766

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 0819-063 1402-164 0423-450 0827-013 0828-020 0819-061 0830-043 0832-017 0828-021 0828-022 0828-023 0828-024 0828-025 0828-026 0828-027 0828-028 0828-029 1 1 4 2 2 1 2 2 AR AR AR AR AR AR AR AR AR Yoke, Propeller Shaft Joint Joint, Universal - Set (inc. 3) Ring, Retaining Nut Washer Yoke, Drive Output Seal, Oil Bearing Shim, 25 x 34 x 0.25 mm Shim, 25 x 34 x 0.30 mm Shim, 25 x 34 x 0.70 mm Shim, 25 x 34 x 0.90 mm Shim, 25 x 34 x 0.95 mm Shim, 25 x 34 x 1.00 mm Shim, 25 x 34 x 1.05 mm Shim, 25 x 34 x 1.10 mm Shim, 25 x 34 x 1.15 mm

Ref. Part No. Qty. Description 10 11 12 13 14 15 16 17 0819-003 0822-107 0827-052 0832-016 0822-106 0819-011 0819-053 0819-005 1 1 1 1 1 1 1 1 Shaft, Secondary Driven - Front Gear, Secondary Drive Nut Bearing Gear, Secondary Driven Ring, Driven Bearing Shaft, Secondary Driven - Rear Flange, Output Joint

45


STARTER MOTOR ASSEMBLY0743-180

Ref. Part No. Qty. Description 1 0825-013 2 8476-625 1 2 Motor, Starter - Assembly Screw, Machine

Ref. Part No. Qty. Description 3 0623-038 1 Nut w/Washer

46


MAGNETO ASSEMBLY0742-692

Ref. Part No. Qty. Description 1 2 3 4 0802-041 0802-048 0826-102 0829-012 1 1 3 1 Stator - Assembly Rotor/Flywheel Screw, Machine Key

Ref. Part No. Qty. Description 5 6 7 8 0827-014 8470-510 0802-015 0802-016 1 3 1 1 Nut Screw, Machine Clamp - No. 1 Clamp - No. 2

47

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

Printed in U.S.A.

p/n 2258-517

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