2009 Crossfire 500 EFI Parts Manual.pdf - Google Drive

Arctic Cat Parts & Free Mechanical Advice | www.FunOutfitters.com | 1 866-531-0123

SH A R E O U R PASSION. TM

Crossfire™ 500 EFI

Model Number S2009CFC1EUSB


TABLE OF CONTENTS 2009 Crossfire 500 EFI (Model No. S2009CFC1EUSB) SKI AND SPINDLE ASSEMBLY .............................................................................................................................. 1 A-ARM ASSEMBLY ................................................................................................................................................. 2 SHOCK ABSORBER AND SWAY BAR ASSEMBLY .............................................................................................. 3 STEERING POST ASSEMBLY ............................................................................................................................... 4 TIE ROD ASSEMBLY .............................................................................................................................................. 5 HANDLEBAR AND CONTROLS .............................................................................................................................. 6 HYDRAULIC BRAKE CONTROL ASSEMBLY ........................................................................................................ 7 DRIVE TRAIN SHAFT AND BRAKE ASSEMBLIES ................................................................................................ 8 GEARCASE ASSEMBLY ......................................................................................................................................... 9 SLIDE RAIL AND TRACK ASSEMBLY ................................................................................................................. 10 IDLER WHEEL ASSEMBLY .................................................................................................................................. 11 REAR SUSPENSION FRONT ARM ASSEMBLY .................................................................................................. 12 REAR SUSPENSION REAR ARM ASSEMBLY .................................................................................................... 13 FRONT FRAME AND FOOTREST ASSEMBLY .................................................................................................... 14 HOOD AND WINDSHIELD ASSEMBLY ................................................................................................................ 15 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES ............................................................................... 16 CONSOLE AND SWITCH ASSEMBLY ................................................................................................................. 17 BELLY PAN ASSEMBLY ....................................................................................................................................... 18 BELT GUARD ASSEMBLY .................................................................................................................................... 19 GAS TANK ASSEMBLY ........................................................................................................................................ 20 FUEL PUMP ASSEMBLY ...................................................................................................................................... 21 SEAT ASSEMBLY ................................................................................................................................................. 22 TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY ................................................................................... 23 COOLING ASSEMBLY .......................................................................................................................................... 24 ENGINE AND RELATED PARTS .......................................................................................................................... 25 EXHAUST ASSEMBLY .......................................................................................................................................... 26 AIR INTAKE ASSEMBLY ....................................................................................................................................... 27 AIR SILENCER ASSEMBLY .................................................................................................................................. 28 OIL TANK ASSEMBLY .......................................................................................................................................... 29 DRIVE CLUTCH .................................................................................................................................................... 30 DRIVEN CLUTCH .................................................................................................................................................. 31 CYLINDER AND HEAD ASSEMBLY ..................................................................................................................... 32 CRANKCASE ASSEMBLY .................................................................................................................................... 33 PISTON AND CRANKSHAFT ................................................................................................................................ 34 REED VALVE/THROTTLE BODY ASSEMBLY ..................................................................................................... 35 OIL PUMP .............................................................................................................................................................. 36 WATER PUMP/WATER MANIFOLD ..................................................................................................................... 37 RECOIL STARTER ................................................................................................................................................ 38 MAGNETO ............................................................................................................................................................. 39 ELECTRICAL ......................................................................................................................................................... 40

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 July 2008


2009 Crossfire 500 EFI

SKI AND SPINDLE ASSEMBLY 0743-433

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12

2603-599 2703-375 8047-426 2603-598 8047-366 1623-689 1623-688 0623-776 0123-458 0623-728 2603-397 0123-296

2 2 8 2 4 2 2 2 2 4 4 2

Ski, Plastic - Black Wearbar Nut, Lock Handle, Plastic - Black Nut, Lock Screw, Machine Screw, Machine Screw, Cap Pin, Cotter Washer Insert, Ski Nut, Lock

Ref. Part No. Qty. Description 13 2603-553 14 2703-246

2 1

2703-247

1

0603-647 1623-010 0603-083 0603-158 2603-208 2603-769 0623-831

4 2 4 4 4 2 2

15 16 17 18 19 20 21

Damper, Ski Spindle, Steering - Right - Platinum (inc. 15-18) Spindle, Steering - Left - Platinum (inc. 15-18) Insert, Spindle Fitting, Grease Bearing Bearing Spacer Axle, Spindle Cap, Spindle

1



A-ARM ASSEMBLY 0743-435

Ref. Part No. Qty. Description 1 2703-102 2703-103 2 1603-895 3 1703-094 4 0603-083 5 0623-952 6 0623-664 7 2603-771 8 8047-486 9 2603-770

2

1 1 8 2 8 2 2 2 6 2

A-Arm, Lower - Right - Platinum (inc. 2) A-Arm, Lower - Left - Platinum (inc. 2) Bearing A-Arm, Upper - Platinum (inc. 4) Bearing Screw, Cap Washer Axle, Inner - Upper Arm Nut, Lock Tube, Axle

Ref. Part No. Qty. Description 10 11 12 13 14 15 16 17 18

8020-230 8050-282 2603-305 4606-402 1623-009 8040-546 1603-616 8026-232 8047-490

4 4 4 2 2 2 4 2 2

Screw, Cap Washer Axle, Inner - Lower Arm Brace, Lower A-Arm Screw, Cap Nut, Lock Axle, Powder Metal Screw, Cap Nut, Lock



SHOCK ABSORBER AND SWAY BAR ASSEMBLY 0743-594

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10

1603-889 2703-442 2603-532 8047-486 0623-991 1603-023 2603-617 0603-955 1603-209 2603-493

2 2 1 4 2 4 2 8 4 2

Retainer, Spring Spring, Compression - Green Retainer, Spring Nut, Lock Washer Sleeve, Shock Shock, Ski (inc. 8-9) Bushing, Shock Sleeve, Shock Spacer, Shock Mount


8020-232 2703-094 2603-648 1623-584 2703-096 8047-426 8020-045 2603-649 8047-366

2 1 2 2 2 2 4 2 4

Screw, Cap Sway Bar Bearing Bolt, Carriage Arm, Sway Bar Nut, Lock Screw, Cap Link, Sway Bar Nut, Lock

3



STEERING POST ASSEMBLY 0743-595

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14

4

8002-138 0605-506 0605-507 1705-253 8047-426 0605-576 0605-943 8060-888 0623-044 0623-025 8004-225 0605-504 0623-294 0605-856

4 2 1 1 6 2 1 3 2 3 1 1 1 1

Screw, Cap Cap, Adjusting Block Block, Adjusting Post, Steering Nut, Lock Block, Mounting - Steering Post Stop, Steering Post Rivet Washer Nut, Lock Screw, Cap Ball Joint, Tie Rod - Right-Hand Thread Nut, Hex - Right-Hand Thread Tube, Tie Rod

Ref. Part No. Qty. Description 15 16 17 18 19 20 21 22 23 24 25 26 27

0123-917 0605-511 5606-501 1623-353 1705-260 0623-677 1623-406 8050-252 1623-717 1623-482 0706-371 0123-788 0617-538

1 1 1 3 1 AR AR 2 AR 4 AR AR 1

Nut, Hex - Left-Hand Thread Ball Joint, Tie Rod - Left-Hand Thread Panel, Close-Out Screw, Self-Tapping Support, Steering Tie, Cable - Push-Mount Clip, Retaining Washer Clip, Retaining Screw, Cap Trim Tie, Cable - 8 in. Foam, Steering Post



TIE ROD ASSEMBLY 0743-530


1705-178 0623-954 0623-955 1705-262 1623-359 0623-956 2603-721 1705-224 0605-807 0623-987 8047-426 1705-184

1 2 4 1 2 2 2 1 2 2 2 1

Shaft, Steering Washer, Thrust Washer, Thrust Arm, Shaft - Right (inc. one No. 5) Bolt, Carriage Snap Ring Axle, Steering Link Link, Steering (inc. 9) Bearing Washer Nut, Lock Shaft, Idler

Ref. Part No. Qty. Description 13 14 15 16 17 18 19 20 21 22 23

1705-263 1623-791 1623-741 0605-607 0123-917 0605-961 0623-294 8020-226 0605-788 8047-486 3606-799

1 2 2 2 2 2 2 2 2 2 2

Arm, Shaft - Left (inc. one No. 5) Screw, Cap Screw, Cap Ball Joint, Tie Rod - Left-Hand Thread Nut, Hex - Left-Hand Thread Tube, Tie Rod - Spindle Nut, Hex - Right-Hand Thread Screw, Cap Ball Joint, Tie Rod - Right-Hand Thread Nut, Lock Plug

5



HANDLEBAR AND CONTROLS 0743-596 *Included in Kit

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

6

1623-618 1623-754 4606-945 0609-826 0609-859 * * * 0123-766 0609-795 0617-248 0609-775 0609-595 0609-864 0609-792 0609-793

2 2 2 1 1 1 2 1 1 1 1 1 1 1 1 1

Screw, Machine Washer, Backing Grip, Handlebar Control, Throttle - Rear (inc. 5-10) z Kit, Throttle Lever Mounting (inc. 6-9) z z Axle, Lever - Throttle z z Cap, Lever Axle z z Spacer, Lever Axle z z Nut, Push z Lever, Throttle Pad, Insulator Element, Thumbwarmer Clip, Retaining Control, Throttle - Front Cover, Connector Screw, Machine


0609-791 8 Screw, Self-Tapping 1705-229 1 Handlebar (inc. 19-20) 0605-945 2 z Insert, Handlebar 8060-682 2 z Rivet 0609-828 1 Element, Handwarmer - Right 0609-829 1 Element, Handwarmer - Left 0123-811 AR Tie, Cable - 4 in. 0609-811 1 Control, Dimmer - Rear 0609-805 1 Control, Dimmer - Front 1686-488 1 Harness, Handlebar 1705-149 1 Wrap, Handlebar 0687-217 1 Cable, Throttle 0124-057 1 E-Ring 0124-056 1 Washer 0123-788 AR Tie, Cable - 8 in.



HYDRAULIC BRAKE CONTROL ASSEMBLY 0740-889 *Not Illustrated

Ref. Part No. Qty. Description 1 2 3 4 5 6 7

1602-930 1602-929 1602-931 1602-932 1602-933 1602-934 1602-935

1 1 1 1 1 2 1

Brake Assembly (inc. 2-10) Master Cylinder - Assembly Lever, Brake (inc. 4) Lock, Brake Lever - Kit Cover, Reservoir Screw, Machine Clamp, Brake

Ref. Part No. Qty. Description 8 9 10 11 12 13 *

1602-936 2 1602-937 1 1602-938 1 0423-178 2 0423-413 1 2602-171 1 0436-908 AR

Screw, Machine Pin, Brake Lever - Kit Switch, Brake Washer, Crush Bolt, Banjo-Fitting Brakeline, Hydraulic Fluid, Brake - Synthetic Race - 12 oz

7



DRIVE TRAIN SHAFT AND BRAKE ASSEMBLIES 0743-529 *Not a Service Part

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

8

1602-957 1623-461 1602-656 1602-497 2602-076 0728-170 0702-940 1602-592 2602-068 1602-984 0702-882 1623-355 1702-048 8047-426 0726-275 0648-441 0648-714 0648-715 0648-716 1702-114 0648-788 8050-277 8051-272 1623-572 1702-014

1 1 1 1 1 1 1 2 1 1 1 8 1 13 1 1 AR AR AR 1 1 1 1 1 1

Nut, Retaining Screw, Cap Disc, Brake Spacer, Brake Caliper Shield, Bearing Track, Drive - Assembly (inc. 7-8) Driveshaft Sprocket, Drive Spacer Seal Plate, Mounting - Gearcase Nut, Push Gearcase Assembly Nut, Lock Clutch, Driven O-Ring Washer Washer Washer Adjuster, Sheave (inc. 19) Washer, Thrust Washer Washer, Lock Screw, Cap Caliper, Brake - Assembly (inc. 24-42)

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

1623-360 * 1602-458 1602-461 1602-669 0702-563 1602-466 1602-467 1602-464 * 0602-729 0402-165 1602-671 1602-670 2602-132 2602-131 1602-463 1602-456 0602-590 4606-309 8468-617 1623-676 0630-207 8060-602

5 1 1 2 2 1 4 1 1 1 1 4 2 2 2 2 2 1 1 1 1 1 1 1

Bolt, Carriage - Ribbed Housing Fitting, Bleed Piston O-Ring Pad, Brake - Set (inc. 30-31) Clip, Anti-Rattle Clip, Hairpin Pin, Retaining - Brake Pad Housing O-Ring, Housing Washer Screw, Cap Screw, Cap Spacer, Speedometer Bracket Bearing Sleeve, Driveshaft Ring, Retaining Fitting, Adapter Plate, Mounting - Speedometer Sensor Screw, Machine Clamp, Speedometer Sensor Sensor, Speedometer Rivet



GEARCASE ASSEMBLY (Complete Gearcase Assembly p/n 1702-048) 0743-466 *Not a Service Part **Not Illustrated

Ref. Part No. Qty. Description 1 2 3 4

1702-047 1602-915 2602-172 0702-891

1 4 1 1

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1602-916 0630-228 0423-538 0630-236 8468-536 1702-001 2602-013 2602-057 2602-007 2602-127 0702-910 2602-040 2602-064 * *

1 1 1 1 3 1 2 2 1 2 1 1 1 1 1

Gearcase (inc. 2-3) Pin, Dowel Seal, Oil Bracket, Mounting - Reverse Actuator (inc. 5-6) Bearing Switch, Alarm Screw, Self-Tapping Actuator, Reverse Screw, Machine Fork, Shift - Assembly (inc. 11-13) Seal, Oil Ring, Retaining Arm, Shift Fork Block, Slider Slider Assembly (inc. 16-20) Ring, Retaining Washer, Thrust Shaft, Output (inc. 19) Bearing


1 1

Slider Gear, Transfer - 66T/34T - Assembly (inc. 22-27 and one No. 28) 22 1602-842 1 Bearing 23 2602-058 1 Washer, Spacer 24 0702-867 1 Gear, Planetary - Assembly 25 1602-840 1 Bearing, Thrust 26 1602-841 1 Washer, Thrust 27 0702-852 1 Gear, Transfer (inc. one No. 28) 28 1602-981 2 Bearing 29 0702-686 1 Shaft, Input - 54T (inc. one No. 28) 30 0702-953 1 Cover, Gearcase (inc. 31-34) 31 2602-160 1 Seal, Oil 32 1602-982 1 Bearing 33 2602-099 2 Plug, Gearcase 34 1602-213 2 O-Ring 35 1623-683 13 Screw, Machine 36 2602-174 1 Gasket, Gearcase ** 4639-628 AR Fluid, Gearcase - 12 oz

9



SLIDE RAIL AND TRACK ASSEMBLY (Complete Skid Frame Assembly p/n 1704-768) 0743-469


10

3604-395 3604-401 1623-502 3604-402 8002-043 8050-217 3604-003 8047-366 0123-859 3604-424 0123-767 0104-631

2 1 4 1 2 4 2 8 2 2 2 2

Rail, Formed Axle, Crossbrace/Limiter Screw, Cap Axle, Crossbrace Screw, Cap Washer End Cap, Slide Rail Nut, Lock Screw, Machine Wearstrip, Slide Rail Rivet, Solid Pad, Shock


0123-766 2 1604-429 2 8017-405 2 8041-246 2 1623-566 2 3604-400 2 0704-352 2 8002-042 4 2604-733 2 2602-169 1 2602-081 48

Nut, Push Pad, Shock Screw, Machine Nut, Lock Screw, Cap Bushing, Stop - Rear Arm Adjuster, Track Screw, Cap Insert, Rail Track Assembly (inc. 23) Clip, Guide



IDLER WHEEL ASSEMBLY 0743-497

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

8020-142 8450-133 3604-039 3604-033 0623-946 3604-004 8020-134 8047-426 3604-080 0623-912 3604-083 1623-037 0623-439 8047-490 8047-486 2604-378 2604-515 8050-282 8020-229 1704-016 1623-011

2 2 2 6 6 2 2 4 1 2 2 2 2 2 2 2 2 2 2 1 1

Screw, Cap Washer Wheel, Idler (inc. 4-5) Bearing Ring, Retaining Block, Mounting - Idler Wheel Screw, Cap Nut, Lock Axle Washer Spacer, Shock - Front Arm Screw, Cap Washer Nut, Lock Nut, Lock Block, Slide Slide, Spring Washer Screw, Cap Pivot, Rear Shock (inc. 21-22) Washer

Ref. Part No. Qty. Description 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

1623-010 0603-105 1604-209 0623-675 1604-213 1604-684 1604-772 0123-798 0107-598 1604-773 1604-810 2604-283 3604-073 1704-489 0123-150 0124-310 3604-075 0623-664 1623-248 1604-952

1 1 1 4 2 2 2 2 2 2 1 1 2 4 2 2 2 2 2 2

Fitting, Grease Spacer Axle Washer Spacer Wheel, Idler (inc. 28-31) Insert, Wheel - Inside Ring, Retaining Bearing Insert, Wheel - Outside Spacer, Rear Wheel Axle, Rear Wheel, Idler (inc. 4-5) Bushing, Adjuster Nut Screw, Cap Wheel, Idler - Green (inc. 4-5) Washer Screw, Cap Cap, Idler Wheel

11



REAR SUSPENSION FRONT ARM ASSEMBLY 0743-599


12

1704-792 1623-011 1623-010 0604-889 3604-028 2604-591 1604-162 1623-248 8020-229 0114-197 8047-486 8002-043

1 1 3 4 2 1 2 2 2 2 2 4

Arm, Front Suspension - Black (inc. 2-5) Washer Fitting, Grease Bushing, Front Arm Bushing, Flared Axle, Aluminum Axle, Inner Carriage Screw, Cap Screw, Cap Washer Nut, Lock Screw, Cap


0623-184 3604-459 8047-366 0604-590 1704-461 1604-889 1603-531 8020-226 8041-486 3604-334 2603-719 1604-791

8 2 4 1 1 1 1 1 1 1 1 1

Washer Strap, Limiter Nut, Lock Cover, Shock Spring, Compression - Black Retainer, Spring Axle Screw, Cap Nut, Lock Shock Absorber Retainer, Spring Bushing



REAR SUSPENSION REAR ARM ASSEMBLY 0743-600

Ref. Part No. Qty. Description 1 1704-793 2 3 4 5 6 7 8 9 10 11 12 13 14

3604-028 1623-010 1623-011 2604-147 1704-019 1623-037 0623-439 2604-664 2604-663 8047-490 1623-503 2604-176 1604-204 1604-205 15 0623-138

1 2 3 2 2 1 1 1 2 1 1 2 1 1 1 2

Arm, Idler - Black (inc. 2, one No. 3-4, and 5) Bushing, Flared Fitting, Grease Washer Bearing Arm, Rear - Black (inc. one No. 3-4) Screw, Cap Washer Bushing, Rear Arm Axle, Inner Nut, Lock Screw, Cap Axle Block, Spring Adjuster - Right Block, Spring Adjuster - Left Ring, Retaining

Ref. Part No. Qty. Description 16 2604-764 17 3604-085 18 1704-808 1704-809 19 1604-690 20 0107-598 21 0123-798 22 1623-166 23 1604-139 24 0704-350 25 1604-498 26 8020-233 27 8041-486 28 8020-226 29 3604-154 30 1604-262 31 1604-397

4 1 1 1 2 2 2 2 3 2 4 2 3 1 1 4 2

Sleeve, Spring Axle, Inner Carriage Spring, Suspension - Right Spring, Suspension - Left Wheel, Idler (inc. 20-21) Bearing Ring, Retaining Screw, Cap Sleeve, Shock Link, Rear Shock - Black Axle, Link - Flanged Screw, Cap Nut, Lock Screw, Cap Shock Absorber (inc. 30-31) Bushing Sleeve

13



FRONT FRAME AND FOOTREST ASSEMBLY (Complete Chassis Assembly p/n 1707-293) 0743-822

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

14

1707-178 1 Chassis - Assembly (inc. 2-8) 1623-359 3 Bolt, Carriage - Ribbed 1623-019 2 Bolt, Carriage - Ribbed 0675-161 4 Bearing 0607-656 2 Bushing, Upper A-Arm Mount 0607-657 6 Bushing, Lower A-Arm Mount 1623-010 2 Fitting, Grease 0623-581 8 Insert 1623-022 2 Screw, Machine 1623-480 4 Screw, Cap 1623-481 3 Screw, Cap 4606-200 1 Brace, Side Plate - Right 1623-561 1 Screw, Cap 4606-793 1 Protector, Main Harness 1623-353 3 Screw, Self-Tapping 1623-204 1 Screw, Self-Tapping 0608-449 1 Guide, Rope 8041-426 1 Nut, Lock 2706-580 2 Plate, Backing 8060-686 AR Rivet 4706-034 1 Footrest - Right (inc. 22-24 and 26) 4706-035 1 Footrest - Left (inc. 22-26)

Ref. Part No. Qty. Description 22 23 24 25 26 27 28 29

8060-484 AR Rivet 3606-837 2 Plate, Retaining 1623-657 8 Insert 0607-835 1 Plate, Mounting - Belt Guard 1623-706 4 Stud, Captive 1623-529 2 Grommet 1623-264 8 Rivet 3606-904 1 Bracket, Support - Footrest - Right 4606-353 1 Bracket, Support - Footrest - Left 30 3706-673 1 Panel, Close-Out - Footrest (inc. two No. 24) 31 1623-498 12 Screw, Machine 32 4606-742 1 Bracket, Support - Footrest - Lower Right 4606-743 1 Bracket, Support - Footrest - Lower Left 33 4606-434 1 Cover, Footrest - Right 4606-435 1 Cover, Footrest - Left 34 0623-677 AR Tie, Cable - Push-Mount 35 1623-717 1 Clip, Routing 36 1623-406 AR Clip, Routing 37 3706-921 1 Brace, Side Plate - Left 38 0706-371 AR Trim



HOOD AND WINDSHIELD ASSEMBLY 0743-601


2718-501 2718-146 1623-026 0623-847 6611-143 6611-144 6611-145 8611-350 8611-351 8611-352 8611-353 8611-267 8611-354 2706-793 3706-260 3706-261

1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1

Hood w/Decals - Black (inc. 2-10) Hood w/o Decals - Black (inc. 3-6) Pin, Clevis Clip, Hairpin Decal, Caution Decal, Warning - English Decal, Warning - French Decal, Hood - Lower Right Decal, Hood - Lower Left Decal, Hood - Forward Right Decal, Hood - Forward Left Decal, AirCat - Chrome Decal, Hood - Crest Screen, Vent - Center Screen, Vent - Front - Right Screen, Vent - Front - Left

Ref. Part No. Qty. Description 13 2706-796 1 Screen, Vent - Rear - Right 2706-797 1 Screen, Vent - Rear - Left 14 1623-694 38 Clip, Retaining 15 0617-510 1 Foam, Hood - Right 0617-545 1 Foam, Hood - Left 16 0617-489 1 Foam, Hood - Rear 17 0623-302 4 Screw, Self-Tapping 18 2606-726 2 Cable, Hood 19 1623-052 2 Clip, U-Nut 20 0623-362 6 Rivet, Reinstallable 21 5606-080 1 Bezel, Intake - Right 5606-081 1 Bezel, Intake - Left 22 0617-486 1 Foam, Intake Bezel - Right 0617-487 1 Foam, Intake Bezel - Left 23 4606-117 1 Windshield 24 0616-032 2 O-Ring

15



HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES 0743-602

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13

16

0620-325 0620-322 0423-493 0609-848 0609-849 0609-251 0609-693 1623-025 0623-360 1623-024 1623-137 1623-272 1623-273 0617-501 1686-396

1 1 2 1 1 2 2 2 2 2 2 2 2 2 1

Tachometer/Speedometer Bracket, Retaining Nut w/Washer Lens/Reflector - Headlight - Right (inc. 5-6) Lens/Reflector - Headlight - Left (inc. 5-6) Bulb, Headlight Bulb, Headlight Insert Spring, Adjuster Screw, Adjuster Clip, Hairpin Clip - Right Clip - Left Foam, Hood/Headlight Harness, Hood


1686-483 1 Harness, Main (inc. 15-17) 0630-024 1 Fuse, 15 Amp 0630-102 1 Cover, Fuse 0486-164 1 Tether, Accessory Connector 0123-903 AR Tie, Cable - 11.5 in. 3706-761 1 Wrap 0630-243 1 Alarm, Reverse (inc. 21) 0630-017 1 Ring, Retaining 0630-246 1 Unit, Chassis Control 8047-366 2 Nut, Lock 8017-584 2 Screw, Machine 0123-788 AR Tie, Cable - 8 in. 1686-543 1 Harness, Extension - Taillight 1686-173 1 Harness, Adapter - Engine Coolant Temperature Sensor



CONSOLE AND SWITCH ASSEMBLY 0743-508

Ref. Part No. Qty. Description 1 2 3 4 5 6

3606-442 6611-581 0609-728 * 0609-113 0123-899

1 1 1 1 1 1

Console Decal, Console Switch, Ignition (inc. 4) Key Nut, Retaining Washer, Ignition Switch


1 7

Spacer, Ignition Switch Screw, Machine * Key is coded to switch; see dealer to determine part number.

17



BELLY PAN ASSEMBLY 0743-666

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

18

4606-040 1 Bumper, Front - Black 5606-483 1 Belly Pan, Center - Black 1623-129 9 Screw, Self-Tapping 0623-784 12 Screw, Self-Tapping 2606-911 1 Screen, Belly Pan - Center 1612-853 1 Shield, Heat 1612-861 1 Deflector, Exhaust - Outlet 0623-778 14 Rivet 1623-739 2 Screw, Retaining - Access Panel 8017-581 4 Screw, Machine 8050-217 4 Washer 8047-366 4 Nut, Lock 1623-030 2 Clip, U-Nut 4706-076 1 Belly Pan - Right - Black 3706-429 1 Belly Pan - Left - Black 4606-207 1 Foil, Protective - Upper 4606-208 1 Foil, Protective - Lower 0623-797 21 Screw, Self-Tapping 8611-604 1 Decal, Clutching


0607-447 2 Cable 0605-283 2 Clip, Hairpin 8061-426 2 Rivet 5606-305 1 Deflector, Driven Clutch Protector 4606-417 1 Protector, Driven Clutch 0123-802 5 Washer 8061-628 7 Rivet 4606-256 1 Panel, Access - Right - Black 4606-257 1 Panel, Access - Left - Black 7611-160 1 Decal, Reflector - Amber - Right 7611-161 1 Decal, Reflector - Amber - Left 5606-052 1 Foil, Protective - Access Panel 0617-502 1 Foam, Side Panel - Right 0617-503 1 Foam, Side Panel - Left 1623-694 11 Clip, Retaining 2606-624 2 Strap, Hold-Down 8611-356 1 Decal, Access Panel - Right 8611-357 1 Decal, Access Panel - Left



BELT GUARD ASSEMBLY 0741-638


1707-094 1611-565 3611-969 0707-582

1 1 1 1

Guard, Belt Decal, Warning - Belt Guard Decal, “ACT - Roller Driven Clutch” Retainer, Drive Belt

Ref. Part No. Qty. Description 5 0617-497 6 0607-836 7 8061-506

1 1 4

Foam, Belt Guard Bracket, Mounting Rivet

19



GAS TANK ASSEMBLY 0742-454


0770-810 1670-824 0470-400 1670-447 1670-511 1705-116

1 1 1 1 1 1

7 8 9 10

1623-447 1623-448 1623-483 1670-801

2 4 2 1

20

Tank, Gas (inc. 2-16) Gauge, Fuel w/Seal (inc. 3) Seal, Fuel Gauge Cap, Gas Tank (inc. 5) Seal, Gas Tank Cap Plate, Mounting - Steering Post (inc. 7 and two No. 8) Bolt, Carriage O-Ring Nut, Aluminum Neck, Gas Tank Extension


8061-630 3606-173 4606-160 8050-157 5606-107 5606-049 8047-366 0123-765 1623-077 8017-582

2 1 1 2 1 1 2 2 2 2

Rivet Strap, Hold-Down - Coolant Tank Strap, Hold-Down - Spark Plug Washer Foil, Protective Foil, Protective Nut, Lock Washer, Cup Nut Screw, Machine



FUEL PUMP ASSEMBLY 0743-511


1670-851 1 1670-535 1 1670-476 1 1670-475 1 1670-534 1 1670-479 1 1670-478 1 1670-477 1 1670-579 1 0610-563 2 0610-691 AR

Pump, Fuel - Assembly (inc. 2-9) Grommet O-Ring Nut, Fuel Pump Fitting Grommet Washer, Sealing - Threaded Washer Nut, Mounting Retainer, Wire Clamp, Hose Hose, Gasline - 10 ft


1670-701 1670-706 1670-703 1670-705 1670-702 1670-619 1670-704 1670-618 0623-373 4706-549 0123-788

1 6 1 1 1 1 1 1 2 1 2

Pickup, Fuel Clamp, Hose Hose, Gasline Y-Fitting Hose, Gasline Pickup, Fuel Hose, Gasline Pickup, Fuel Clamp, Hose Conduit, Flexible Tie, Cable - 8 in.

21



SEAT ASSEMBLY 0743-512 *Not Illustrated


22

7800-231 1 Complete Seat Assembly (inc. 2-8) 4706-257 1 Cover, Seat 0624-528 AR Staple, Seat Cover 3706-118 1 Foam, Seat Cushion 4606-128 1 Seat-Base 1623-393 2 Clip, Retaining - Seat-Base 0123-788 2 Tie, Cable - 8 in.

Ref. Part No. Qty. Description 8 9 10 11 12 13 *

0617-512 8047-426 1623-458 4606-322 8061-628 3706-033 3706-731

1 2 2 1 1 1 1

Foam, Compartment - Seat Nut, Lock Stud, Latch - Seat-Base Cover, Latch - Seat - Right Rivet Retainer, Tool Kit Kit, Tool



TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY (Complete Chassis Assembly p/n 1707-293) 0743-513


2718-724 1 Tunnel Assembly (inc. 2-11) 2718-723 1 Tunnel, Front (inc. 3-4) 1623-562 2 Insert 1623-657 4 Insert 5606-808 1 Tunnel, Rear 5606-402 1 Bracket, Tunnel Support - Right 5606-403 1 Bracket, Tunnel Support - Left 7 8060-686 AR Rivet 8 2706-456 1 Bracket, Suspension Mounting - Right Rear 2706-457 1 Bracket, Suspension Mounting - Left Rear 9 8060-682 2 Rivet 10 8060-688 AR Rivet 11 8060-484 AR Rivet 12 5606-594 1 Gusset, Tunnel Roll - Right 5606-595 1 Gusset, Tunnel Roll - Left 13 8060-488 4 Rivet 14 5606-253 1 End Cap, Tunnel

Ref. Part No. Qty. Description 15 5606-809 1 Bumper, Rear 16 8611-520 1 Decal, Reflector - Red - Right 8611-521 1 Decal, Reflector - Red - Left 17 0623-562 1 Plug, Hole 18 5606-490 1 Roll, Tunnel - Right 5606-491 1 Roll, Tunnel - Left 19 8060-482 AR Rivet 20 0609-855 1 Taillight, LED 21 0623-301 2 Screw, Self-Tapping 22 5606-525 1 Snowflap 23 8061-710 5 Rivet 24 5611-853 1 Decal, Warning - Towing (English) 25 5611-852 1 Decal, Warning - Towing (French) 26 0123-802 6 Washer 27 4606-790 1 Guide, Track - Tunnel - Right 4606-791 1 Guide, Track - Tunnel - Left 28 1623-671 2 Screw, Machine 29 1623-045 2 Spacer 30 0123-788 1 Tie, Cable - 8 in.

23



COOLING ASSEMBLY 0743-603


24

4706-179 1 Heat Exchanger - Rear 8060-686 12 Rivet 1623-349 6 Clamp, Hose 0610-567 2 Hose, Coolant 5606-806 1 Heat Exchanger - Right 5606-807 1 Heat Exchanger - Left 8060-484 AR Rivet 8060-488 AR Rivet 4606-270 1 Protector, Hose 0610-679 1 Hose, Coolant - Front/Left Heat Exchanger 1623-656 1 Clamp, Hose 0610-659 1 Hose, Coolant - Tank/Right Heat Exchanger 1623-093 2 Clamp, Hose


1619-038 1 Protector, Hose - 7 in. 0610-625 1 Hose, Coolant Tank/Engine 1623-229 1 Clamp, Screw 3706-684 1 Tank, Coolant 4606-209 1 Cap, Filler Neck 0124-045 1 Clamp, Hose 0610-538 AR Hose, Coolant - 25 ft 2604-539 AR Conduit, Flexible - 10 ft 1623-619 1 Clamp, Hose 1623-322 1 Clamp, Hose 0619-619 1 Conduit, Flexible - 4 in. 0610-700 1 Hose, Coolant - Engine/Front Heat Exchanger 25 1623-350 1 Clamp, Hose



ENGINE AND RELATED PARTS 0742-484


0662-572 1 Engine, AX50L8 w/o EFI Components 0636-363 1 Handle, Recoil 0606-885 1 Cap, Recoil Handle 8020-136 1 Screw, Cap 0708-498 1 Bracket, Engine Mounting - Rear - Right 8047-426 4 Nut, Lock 8413-831 2 Screw, Cap 1670-328 1 Foil, Protective 0619-619 1 Conduit, Flexible - 4 in. 0619-994 1 Conduit, Flexible (3/4 in. ID) - 6 in. 0623-373 5 Clamp, Hose 0610-076 AR Hose, Coolant - 10 ft 0610-581 3 Clamp, Hose 1670-596 1 Y-Fitting


0619-776 AR Conduit, Flexible - 5 ft 0610-699 1 Hose, Coolant 1623-659 1 Clamp, Push-Mount 0708-507 1 Bracket, Engine Mounting - Left (inc. 19-20) 8060-730 2 Rivet 0608-565 1 Plate, Backing - Torque Bumper 0608-462 1 Bumper, Torque 8408-821 4 Screw, Cap 0746-209 1 Clutch, Drive - Uncalibrated 0627-067 1 Belt, Drive 0623-210 1 Washer, High Collar 0623-804 1 Bolt, Clutch 0623-677 1 Tie, Cable - Push-Mount 0123-788 AR Tie, Cable - 8 in.

25



EXHAUST ASSEMBLY 0742-486

Ref. Part No. Qty. Description 1 1712-361 1 2 1712-360 1 3 0624-552 AR 0624-541 AR 4 1612-178 3 5 1612-693 1 6 1612-696 1 7 1612-695 1 8 1612-694 1 9 1712-312 1 10 2612-399 4

26

Chamber, Expansion - Assembly (inc. 2-8) Chamber, Expansion Tie, Perforated Band - 5 ft Tie, Perforated Band - 25 ft Spring, Exhaust Packing, Expansion Chamber - Upper Cover, Expansion Chamber - Upper Cover, Expansion Chamber - Lower Packing, Expansion Chamber - Lower Manifold, Exhaust Spring, Exhaust


2612-059 0612-693 1712-509 0612-471 1623-569 1623-375 1623-379 2612-186 2612-210 8047-486

1 1 1 3 1 1 1 2 1 1

Gasket, Exhaust - Manifold Gasket, Exhaust - Tailpipe Resonator Spring, Extension Pin, Mounting - Resonator Grommet Clip, Hairpin Grommet Washer, Tab Nut, Lock



AIR INTAKE ASSEMBLY 0740-143


0617-500 8017-581 5606-048 1623-137 1623-409 0623-184 8047-366 0623-600

2 2 1 1 2 2 2 1

Foam, Air Intake Screw, Machine Intake, Air - Right Clip, Hairpin Nut, Push Washer Nut, Lock Plug


0617-488 3606-811 3606-779 0623-165 1670-517 0617-499 3606-481

1 1 1 6 1 1 1

Foam, Air Intake Foil, Protective Foil, Protective Clip, Retaining Screen, Vent Seal, Air Intake Intake, Air - Left

27



AIR SILENCER ASSEMBLY 0743-604


28

0770-719 1670-473 1670-754 1670-514 1623-132 1623-031 3606-146

1 1 1 1 1 1 1

Silencer, Air - Assembly (inc. 2-3) Intake, Air Silencer, Air Connector, Air-Intake Clamp, Air-Intake Connector Screw, Self-Tapping Hold-Down, Air Silencer


1623-204 1670-793 0623-165 8611-251 3002-964 0617-485 0623-144

2 1 2 1 1 2 1

Screw, Plastite Boot, Air Silencer Clip, Retaining Decal, EFI Diagnostics Clamp, Wire Foam, Air Silencer Cable Tie - 17.5 in.



OIL TANK ASSEMBLY 0743-970


1670-930 1670-325 1670-481 0609-503 0609-518 0609-237 1670-365 0109-733 1611-564

1 1 1 1 1 1 1 1 1

Tank, Oil Grommet Fitting, Oil Tank Sensor, Low Oil - Assembly (inc. 5-6) Switch, Oil Sensor w/Harness Seal, Grommet - Oil Sensor Cap, Oil Tank (inc. 8) Seal, Cap - Oil Tank Decal, Oil Tank

Ref. Part No. Qty. Description 10 0124-045 2 11 0610-693 AR 0610-692 AR 12 1623-256 1 13 3606-982 1 14 1623-705 2 15 1623-779 3 16 8050-217 2

Clamp, Hose Hose, Oil - 100 ft Hose, Oil - 25 ft Grommet Shield, Heat Screw, Machine Screw, Machine Washer

29



Cam Arm Kit - p/n 4639-674 (inc. 5-8)

DRIVE CLUTCH (Uncalibrated Drive Clutch - p/n 0746-209) 0741-939


30

1623-442 8051-212 0646-149 0746-702 0746-668 0746-663 0746-792

6 6 1 3 3 3 3

Screw, Cap Washer, Lock Spring, Drive Clutch - Red Arm, Cam (inc. 5) Arm, Cam (inc. 5) (3-6,000 ft Alt.) Arm, Cam (inc. 5) (6-9,000 ft Alt.) Arm, Cam (inc. 5) (Over 9,000 ft Alt.)


1623-183 1602-692 0646-747 8048-366

3 6 3 3

Screw, Set O-Ring Pin, Cam Arm Nut, Lock



DRIVEN CLUTCH (Assembly p/n 0726-275) 0741-959

Ref. Part No. Qty. Description 1 0748-679 0748-662

1 1

2 3 4 5

1 1 3 1

0648-433 0648-009 0648-713 0648-693

Bracket, Torque 42°/36° (inc. 2-3) Bracket, Torque 36° (inc. 2-3) (Over 6,000 ft Alt.) Ring, Snap Bearing Seat, Spring Spring, Driven Clutch - White


0648-753 0648-453 0648-097 0648-139 8070-224 0648-650 1623-517

1 1 6 6 6 1 9

Spacer Seat, Spring Pin, Cam Roller Roller, Cam Pin, Spring Retainer, Torque Bracket Screw, Machine

31



CYLINDER AND HEAD ASSEMBLY 0739-389


32

3007-611 1 Head, Cylinder 0217-709 2 Plug, Spark (BR9EYA) 3006-419 2 Screw, Cap 3006-420 2 O-Ring 3007-460 12 Screw, Cap 3003-227 12 O-Ring 3003-224 2 O-Ring 3003-226 2 O-Ring


3007-390 3007-391 3004-975 3006-743 3006-748 3006-745 3006-423 3007-415

6 8 4 8 2 2 1 6

Nut Nut Pin, Dowel Bolt, Stud Gasket, Exhaust Cylinder Gasket, Cylinder Bolt, Stud



CRANKCASE ASSEMBLY 0739-390


3007-612 1 Crankcase (inc. 2-7) 3006-483 10 Screw, Cap 3007-409 1 Screw, Cap 3007-461 1 Screw, Cap


3007-399 3003-647 3005-206 0630-140

4 1 2 1

Screw, Cap Bushing Pin, Dowel Switch, Engine Coolant Temperature

33



PISTON AND CRANKSHAFT 0742-568

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

34

3006-746 3005-828 3005-304 3005-816 3008-500 3008-503 3007-613 3007-614 3005-494 3005-505 3005-502 3005-507 3005-603 3007-045 3005-500

2 2 4 2 4 2 1 2 2 2 2 1 1 1 2

Piston Set (inc. 2-3) Ring Set, Piston Circlip, Piston Pin, Piston Washer Bearing Crankshaft Assembly (inc. 8-24) Connecting Rod Washer, Crank Pin Bearing Bearing Washer Bearing Shim Crankshaft - Right Balancer, Crankshaft


3007-440 3007-615 3005-508 3005-504 3005-597 3006-353 3006-347 3007-616 3007-439 3003-658 3003-759 3008-525 3004-540 3003-359

6 1 2 2 2 1 1 1 1 4 1 1 1 1

Screw, Machine Wheel, Crankshaft Ring, Middle Crank Seal Bearing Race, Middle Crank Seal Gear, Oil Pump Drive Crankshaft - Middle Crankshaft - Left Bearing Pin, Alignment Seal, Oil Seal, Oil Key C-Ring



REED VALVE/THROTTLE BODY ASSEMBLY 0741-871


3005-876 2 Valve, Reed - Assembly (inc. 2-4) 3005-877 4 Stopper 3005-878 4 Valve, Reed 3004-506 16 Screw, Machine 3005-879 2 Gasket, Reed Valve 3007-462 1 Pipe, Intake - RH 3007-463 1 Pipe, Intake - LH 3007-464 2 Clamp 3007-465 2 Bolt, Stud 3007-373 2 Nut 3007-409 10 Screw, Cap


3007-466 3007-467 3006-652 3007-468 3007-469 3423-814 3007-051 3007-052 3007-053 18 3403-121 19 3002-964

1 1 2 2 1 2 2 2 2 2 1

Body, Throttle - Assembly (inc. 12-18) Sensor, Throttle - Assembly Screw, Machine O-Ring Pipe, Delivery Screw, Machine Injector, Fuel - Assembly O Injector, Fuel - Assembly Q Injector, Fuel - Assembly V Cushion, Injector Clamp, Wire

35



OIL PUMP 0742-143


36

3007-694 3006-354 3004-804 3004-805 3402-009 3005-049 3008-030 3005-126

1 1 1 1 2 1 1 1

Pump, Oil w/90° Fitting Gear, Driven Retainer, Input Shaft Valve, Check Gasket Shim O-Ring O-Ring


3008-035 3005-357 3004-346 3008-037 3007-471 3005-696 3007-472

2 1 1 6 2 1 1

Hose, Oil Hose, Oil Bolt, Union Clamp, Hose Screw, Cap Clamp, Wire Bracket, Cable



WATER PUMP/WATER MANIFOLD 0742-569


3006-914 3007-446 3007-041 3005-899 3006-942 3007-409 3006-324 3006-360

1 3 1 2 1 6 2 1

Cap, Thermostat Screw, Cap Thermostat Pin, Dowel Cover, Water Pump Screw, Cap Clamp, Hose Hose, Water Inlet


3006-356 3005-697 3003-431 3003-432 3003-426 3007-180 3004-009 3007-431

1 1 1 1 1 1 1 1

O-Ring, Cover Impeller Washer Gasket Screw, Cap Seal, Water Pump Ring, Retaining Seal, Oil

37



RECOIL STARTER 0741-066 *Not a Service Part


38

3006-915 3003-179 3002-921 3006-457 * * *

1 1 1 1 1 1 1

Starter Assembly (inc. 2-10) Roller, Starter Spring Ratchet Set (inc. 5-7) Spring, Friction Washer Spring, Return


3006-475 3006-456 3006-889 3007-609 3005-531 3007-407

1 1 1 4 1 3

Plate, Friction Nut Rope, Starter Screw, Cap Pulley, Starter Screw, Cap



MAGNETO 0741-803


3007-449 3006-524 3007-693 3007-371 3007-473 3007-450 3005-987

4 1 1 1 1 3 1

Screw, Cap Base, Stator - Plate Stator Screw, Cap Rotor/Flywheel Screw, Cap Washer


3006-476 3007-433 3003-972 3006-453 3005-960 3005-775

1 3 1 1 1 1

Screw, Cap Screw, Cap Clamp, Sensor Sensor, Ignition Timing Plate, Stator Lead Wire Grommet, Stator Lead Wire

39



ELECTRICAL 0741-067


40

3007-451 3006-367 3005-387 3006-728 3005-233 3007-060

1 2 1 1 1 1

Coil, Ignition - Assembly Cap, Spark Plug Clamp Sensor, Temperature Washer Sensor, Coolant

Ref. Part No. Qty. Description 7 3007-634 3007-635 3007-636 8 3005-908 9 3005-237

1 1 1 1 1

ECU O ECU Q ECU V Cap, Rubber Tie, Cable


Ref. Part No. Qty. Description

Printed in U.S.A.

Ref. Part No. Qty. Description

p/n 2258-248