Wildcat 1000 GT NH

2012 ROV Illustrated Parts Manual WILDCAT 1000 GT

Model Model Model Model

Number Number Number Number

U2012W2W1PUSQ U2012W2W1POSQ U2012W2W1PUSA U2012W2W1POSA

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TABLE OF CONTENTS 2012 Wildcat 1000 GT Metallic Black (Model No.U2012W2W1PUSQ) Metallic Black - International (Model No. U2012W2W1POSQ) Metallic Green (Model No.U2012W2W1PUSA) Metallic Green - International (Model No. U2012W2W1POSA) FRONT AND SIDE PANEL ASSEMBLIES .............................................................................................................. 1 DASH ASSEMBLY ................................................................................................................................................... 2 CONSOLE AND FLOOR PANEL ASSEMBLY ........................................................................................................ 3 SEAT ASSEMBLY ................................................................................................................................................... 4 CARGO BOX AND TAILLIGHT ASSEMBLY ........................................................................................................... 5 FRAME, HEADLIGHTS, AND RELATED PARTS ................................................................................................... 6 ROPS ASSEMBLY .................................................................................................................................................. 7 DOOR ASSEMBLY .................................................................................................................................................. 8 STEERING ASSEMBLY .......................................................................................................................................... 9 RACK AND PINION ASSEMBLY ........................................................................................................................... 10 FRONT SUSPENSION ASSEMBLY ...................................................................................................................... 11 REAR SUSPENSION ASSEMBLY ........................................................................................................................ 12 REAR SUSPENSION SHOCK ASSEMBLY .......................................................................................................... 13 WHEEL AND TIRE ASSEMBLY ............................................................................................................................ 14 HYDRAULIC BRAKE ASSEMBLY ......................................................................................................................... 15 ACCELERATOR ASSEMBLY ................................................................................................................................ 16 SHIFTER ASSEMBLY ........................................................................................................................................... 17 GAS TANK ASSEMBLY ........................................................................................................................................ 18 AIR INTAKE ASSEMBLY ....................................................................................................................................... 19 CASE/BELT COOLING ASSEMBLY ..................................................................................................................... 20 ENGINE AND EXHAUST ....................................................................................................................................... 21 COOLING ASSEMBLY .......................................................................................................................................... 22 OIL COOLER ASSEMBLY ..................................................................................................................................... 23 DRIVE TRAIN ASSEMBLY .................................................................................................................................... 24 FRONT DRIVE GEARCASE ASSEMBLY ............................................................................................................. 25 REAR DRIVE GEARCASE ASSEMBLY ................................................................................................................ 26 WIRING HARNESS ASSEMBLY ........................................................................................................................... 27 BATTERY AND STARTER MOTOR ASSEMBLY ................................................................................................. 28 THROTTLE BODY ASSEMBLY ............................................................................................................................ 29 CYLINDER ASSEMBLY ........................................................................................................................................ 30 CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY .................................................................................... 31 CAM CHAIN ASSEMBLY ...................................................................................................................................... 32 CRANKCASE ASSEMBLY .................................................................................................................................... 33 CRANKCASE ASSEMBLY .................................................................................................................................... 34 CRANKSHAFT AND PISTON ASSEMBLY ........................................................................................................... 35 STARTER CLUTCH ASSEMBLY .......................................................................................................................... 36 OIL PUMP ASSEMBLY ......................................................................................................................................... 37 WATER PUMP ASSEMBLY .................................................................................................................................. 38 WATER PUMP ASSEMBLY .................................................................................................................................. 39 TRANSMISSION ASSEMBLY ............................................................................................................................... 40 TRANSMISSION ASSEMBLY ............................................................................................................................... 41 SECONDARY TRANSMISSION ASSEMBLY ........................................................................................................ 42 GEAR SHIFTING ASSEMBLY ............................................................................................................................... 43 SECONDARY DRIVE ASSEMBLY ........................................................................................................................ 44 MAGNETO ASSEMBLY ........................................................................................................................................ 45 MAGNETO SIDE ENGINE COVERS ..................................................................................................................... 46 CLUTCH SIDE ENGINE COVERS ......................................................................................................................... 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. For a complete list of related items, refer to the current accessory catalog. ©2012 Arctic Cat Inc. ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

Effective February 2012

2012 Wildcat 1000 GT

FRONT AND SIDE PANEL ASSEMBLIES 0746-547

Ref Part No.

1 2 3 4 5 6 7 8

9 10

2416-685 2411-943 0423-609 0423-101 4506-772 4506-786 9611-603 2411-945 2411-958 2411-959 2411-946 2411-947 0423-577 4506-756

New Qty Description

X X X X X X X X X X X

1 1 16 12 1 1 1 2 1 1 1 1 6 1

4506-757 X

1

4506-788 X

1

4506-789 X

1

11 2416-988 X 2416-989 X

1 1

Fascia, Front - Black Decal, “Arctic Cat” Screw, Machine Screw, Shoulder Hood - Black (1PUSQ/1POSQ) Hood - Green (1PUSA/1POSA) Decal, 50th Anniversary Decal, “1000 V-Twin” Decal, Hood - Right (1PUSQ/1POSQ) Decal, Hood - Left (1PUSQ/1POSQ) Decal, Hood - Right (1PUSA/1POSA) Decal, Hood - Left (1PUSA/1POSA) Clip, U-Nut Fender, Front - Right - Black (1PUSQ/1POSQ) Fender, Front - Left - Black (1PUSQ/1POSQ) Fender, Front - Right - Green (1PUSA/1POSA) Fender, Front - Left - Green (1PUSA/1POSA) Panel, Side - Lower Right - Black Panel, Side - Lower Left - Black

Ref Part No.

New Qty Description

12 2411-966 X

1

2411-967 X

1

2411-954 X

1

2411-955 X

1

13 1423-133 X 14 2416-990 X 2416-991 X 15 2411-968 X

6 1 1 1

2411-969 X

1

2411-956 X

1

2411-957 X

1

16 8427-602

4

Decal, Lower Side Panel - Right (1PUSQ/1POSQ) Decal, Lower Side Panel - Left (1PUSQ/1POSQ) Decal, Lower Side Panel - Right (1PUSA/1POSA) Decal, Lower Side Panel - Left (1PUSA/1POSA) Screw, Shoulder Panel, Side - Upper Right - Black Panel, Side - Upper Left - Black Decal, Upper Side Panel - Right (1PUSQ/1POSQ) Decal, Upper Side Panel - Left (1PUSQ/1POSQ) Decal, Upper Side Panel - Right (1PUSA/1POSA) Decal, Upper Side Panel - Left (1PUSA/1POSA) Nut, Lock

1


DASH ASSEMBLY 0746-552

Ref Part No.

1 2 3 4 5 6 7 8 9

4406-168 2411-894 2411-893 2411-892 0409-149 0409-070 0430-089 0430-050 0430-042

New Qty Description

X X X X X

1 1 1 1 1 4 1 1 1

0430-043

1

10 0430-054 11 0409-148 X 12 0423-493

1 1 2

2

Panel, Dash (inc. 2-4)  Decal, Warning - Age  Decal, Warning - Dash - Left  Decal, Warning - Dash - Right Switch, Light Plug, Switch-Hole Switch, Ignition (inc. 8-10)  Nut, Retaining  Key, Ignition (Y Series - Left-Side Cut)  Key, Ignition (Z Series - Right-Side Cut)  Cover, Key Switch, 2WD/4WD/Differential Lock Nut w/Washer

Ref Ref Part No No. New NewQty Qty Description Description

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

0620-322 0520-206 2416-985 2416-984 4406-169 2411-970 2411-971 2416-842 0423-342 0423-356 1423-104 1423-133 8477-620 2416-840 0423-577

X X X X X X X X X X

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

Bracket, Retaining Gauge, Analog/LCD Latch, Glove Box Clip, Retaining Cover, Glove Box (inc. 18-19)  Decal, Warning - Occupant - Right  Decal, Warning - Occupant - Left Box, Glove Screw, Self-Tapping Screw, Shoulder Grommet Screw, Shoulder Screw, Machine Panel, Access - Master Cylinder Clip, U-Nut


CONSOLE AND FLOOR PANEL ASSEMBLY 0746-556

Ref Part No.

1 2416-592 2416-593 2 2416-983 3 0623-544 4 0423-609 5 0423-577 6 1423-083 7 1423-125 8 2416-516 2416-517 9 1423-142 10 2516-863 11 0707-582

New Qty Description

X X X

X X X X X

1 1 1 4 38 48 4 4 1 1 16 1 1

Panel, Fender - Inner Right Panel, Fender - Inner Left Panel, Filler - Brake Pedal Clip, Retaining Screw, Machine Clip, U-Nut Screw, Self-Tapping Screw, Shoulder Panel, Floor - Right Panel, Floor - Left Screw, Cap w/Washer Kit, Tool Retainer, Tool Kit

Ref Part No.

12 13 14 15 16 17 18 19 20 21 22

4406-170 2411-895 2411-940 2411-311 0641-897 0409-070 0409-071 2416-109 2416-841 0623-362 2416-518 2416-519 23 1423-104

New Qty Description

X X X X

X X X X

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

Console - Front (inc. 13-15)  Decal, Warning - Reverse  Decal, Pre-Ride  Decal, Starting Instruction Outlet, Accessory - 12V Plug, Switch-Hole Switch, Override Insert, Cupholder Cover, Access - Battery Rivet, Reinstallable Panel, Splash - Right Panel, Splash - Left Grommet

3


SEAT ASSEMBLY 0746-557

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11

4

New Qty Description

4506-532 X 4506-662 X 0423-817 8468-620 2706-164 2606-854 1673-635 0673-023 1673-634 0623-038 0423-559

2 2 8 4 2 2 2 2 2 4 2

Seat - Assembly Base, Seat Screw, Machine Screw, Machine Latch, Seat - Assembly (inc. 6-9)  Lever, Seat Latch  Cover, Seat Latch  Clip, Spring  Back, Seat Latch Nut w/Washer Stud, Latch - Seat


12 13 14 15 16 17 18 19 20 21

0423-073 8424-002 8408-821 4506-691 0623-784 2416-936 2416-937 0423-915 2516-886 8409-025 8427-002

X X X X

2 2 8 4 4 1 1 2 2 6 4

Washer Nut Screw, Cap Bracket, Hold-Down Screw, Self-Tapping Cover, Seat Belt - Right Cover, Seat Belt - Left Screw, Shoulder - Assembly Belt, Seat - Assembly Screw, Cap Nut, Lock


CARGO BOX AND TAILLIGHT ASSEMBLY 0746-561

Ref Part No.

New Qty Description

1 4506-774 X 4506-787 X 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

2411-945 0423-609 8427-602 1423-107 0423-535 2416-825 2416-956 0123-987 4406-167 2411-890 0423-577 2416-573 4506-634 8468-625 1423-109

X X X X X X X X X

1

Panel, Rear Body - Black (1PUSQ/1POSQ) 1 Panel, Rear Body - Green (1PUSA/1POSA) 1 Decal, “1000 V-Twin” 19 Screw, Machine 24 Nut, Lock 2 Screw, Shoulder 2 Rivet, Reinstallable 1 Cover, Access - Radiator 1 Screen, Vent 12 Clip, U 1 Box, Cargo (inc. 11) 1  Decal, Warning - Cargo Box 5 Clip, U-Nut 4 Plate, Backing 4 Bracket, Hold-Down 8 Screw, Machine 4 Screw, Shoulder

Ref Part No.

New Qty Description

17 2411-944 X 18 0509-056 X 0509-057 X 19 0406-877 20 4506-760 X

1 1 1 12 1

4506-761 X

1

4506-790 X

1

4506-791 X

1

21 2411-964 X

1

2411-965 X

1

2411-952 X

1

2411-953 X

1

Decal, “Arctic Cat” Taillight - Right Taillight - Left Bumper Fender, Rear - Right - Black (1PUSQ/1POSQ) Fender, Rear - Left - Black (1PUSQ/1POSQ) Fender, Rear - Right - Green (1PUSA/1POSA) Fender, Rear - Left - Green (1PUSA/1POSA) Decal, Rear Fender - Right (1PUSQ/1POSQ) Decal, Rear Fender - Left (1PUSQ/1POSQ) Decal, Rear Fender - Right (1PUSA/1POSA) Decal, Rear Fender - Left (1PUSA/1POSA)

5


FRAME, HEADLIGHTS, AND RELATED PARTS 0746-562

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12

6

5506-050 2411-941 2411-974 0406-877 4506-703 8409-018 0423-101 4506-406 1423-109 4506-407 2416-962 8409-025

New Qty Description

X X X X X X X X

1 1 2 1 1 4 2 1 21 1 2 2

Frame, Main (inc. 2-3)  Decal, Warning - ROPS  Decal, Reflector - Red Bumper Bracket, Support - Front Gearcase Screw, Cap Screw, Shoulder Plate, Skid - Front Screw, Self-Tapping Plate, Skid - Rear Plug, Hole Screw, Cap


13 14 15 16 17 18 19 20

4506-637 8428-002 4506-680 8408-840 4506-682 0423-356 1423-104 0509-064 0509-065 21 2411-972 2411-973

X X X X X X X X

1 2 1 4 1 6 6 1 1 1 1

Bracket, Support - Rear Gearcase Nut, Lock Tube, Support - Front Screw, Cap Tube, Support - Rear Screw, Shoulder Grommet Headlight Assembly - Right (inc. 21) Headlight Assembly - Left (inc. 21)  Decal, Reflector - Right - Amber  Decal, Reflector - Left - Amber


ROPS ASSEMBLY 0746-565

Ref Part No.

New Qty Description

1 4506-409 X 2 0411-501 3 8410-835

1 ROPS - Front Assembly 1 Decal, “Arctic Cat” 16 Screw, Cap

Ref Part No.

New Qty Description

4 8427-805 5 4506-499 X

16 Nut, Lock 1 ROPS - Rear Assembly

7


DOOR ASSEMBLY 0746-563

Ref Part No.

1 4406-133 4406-140 2 1423-156 3 1423-120 4 1423-152 5 1423-157 6 0826-029 7 0423-540 8 1436-450 1436-451 9 4406-013 10 4406-148 4406-142 11 1436-476 1436-454 12 0423-817 13 5506-082

New Qty Description

X X X X X X X X X X X X X X

1 1 8 16 14 8 4 2 1 1 4 1 1 1 1 4 1

5506-083 X

1

5506-080 X

1

5506-081 X

1

14 4406-036 X 5506-061 X

1 1

8

Net, Restraint - Upper Right Net, Restraint - Upper Left Screw, Shoulder Washer, Lock Washer Screw, Shoulder Screw, Machine Nut, Lock Frame, Door - Right Frame, Door - Left Plug, Hole Net, Restraint - Lower Right Net, Restraint - Lower Left Hinge, Door - Right Assembly Hinge, Door - Left Assembly Screw, Machine Door w/Decals - Right - Black (inc. 14 and 16-17) (1PUSQ/1POSQ) Door w/Decals - Left - Black (inc. 14-17) (1PUSQ/1POSQ) Door w/Decals - Right - Black (inc. 14 and 16-17) (1PUSA/1POSA) Door w/Decals - Left - Black (inc. 14-17) (1PUSA/1POSA)  Door w/o Decals - Right - Black  Door w/o Decals - Left - Black (inc. 15)


15 2411-891 X 16 2411-960 X

1 1

2411-961 X

1

2411-948 X

1

2411-949 X

1

17 2411-962 X

1

2411-963 X

1

2411-950 X

1

2411-951 X

1

18 1423-114 X 19 1436-452 X 1436-453 X 20 1436-475 X 21 8468-612

2 1 1 2 4

 Decal, Warning - Tire Pressure  Decal, Door - Upper Right (1PUSQ/1POSQ)  Decal, Door - Upper Left (1PUSQ/1POSQ)  Decal, Door - Upper Right (1PUSA/1POSA)  Decal, Door - Upper Left (1PUSA/1POSA)  Decal, Door - Lower Right (1PUSQ/1POSQ)  Decal, Door - Lower Left (1PUSQ/1POSQ)  Decal, Door - Lower Right (1PUSA/1POSA)  Decal, Door - Lower Left (1PUSA/1POSA) Screw, Machine Latch, Door - Right Assembly Latch, Door - Left Assembly Guide, Door Latch - Assembly Screw, Machine


STEERING ASSEMBLY 0746-595

Ref Part No.

New Qty Description

1 2 3 4 5 6 7 8 9 10

0502-884 0423-613 0405-239 1411-798 0423-884 1423-045 1423-110 X 0828-071 0423-558 0505-721 X

1 3 1 1 1 1 1 1 1 1

11 12 13 14 15 16

0405-472 X 0405-405 X 0405-473 X 0423-669 8408-831 8427-802

1 2 1 2 2 4

Wheel, Steering - Assembly (inc. 2-3)  Screw, Self-Tapping  Cap, Steering Wheel Decal, Steering Wheel Nut Clip, Retaining Ring, Retaining Washer Washer Bracket, Mounting - Tilt Steering (inc. 11-13)  Bushing  Bushing  Bushing Spacer Screw, Cap Nut, Lock

Ref Part No.

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

0405-468 1423-148 0624-250 1423-111 0405-403 8408-830 0505-765 8408-617 1423-073 0505-758 8427-602 8408-816 0505-787 4506-619 8409-020 8408-818

New Qty Description

X X X X X X X X X X

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

Lift, Support Screw, Shoulder Nut, Lock Ring, Retaining Shaft, Steering Screw, Cap Bracket, Retaining Screw, Cap U-Clamp Bracket, Mounting Nut, Lock Screw, Cap Assembly, Electronic Power Steering Bracket, Mounting Screw, Cap Screw, Cap

9


RACK AND PINION ASSEMBLY 0746-594

Ref Part No.

New Qty Description

1 0505-756 X

1

2 3 4 5 6 7 8 9

1 4 1 1 1 1 4 4

10

0405-463 8408-872 0505-814 8409-847 0505-775 0405-414 0405-445 0405-461

X X X X X X

 Complete Rack and Pinion Assembly (inc. 2-11)  Collar, Locking  Screw, Cap  Rack and Pinion  Screw, Cap  Rack, Steering - Assembly (inc. 7-9)  Pad, Felt  Bushing  Seal


10 11 12 13 14 15 16 17 18 19

0405-457 4506-688 0623-044 8408-818 0505-714 0505-812 1423-072 0623-175 0505-811 0405-404

X X

X X X X

2 1 4 4 2 2 4 4 2 2

 Rod, Support  Bracket, Mounting Washer Screw, Cap Tie Rod - Assembly (inc. 15-19)  Kit, Tie Rod End - Outer (inc. 16-17)  Nut, Castle  Pin, Cotter  Kit, Tie Rod End - Inner (inc. 16-17)  Tie Rod


FRONT SUSPENSION ASSEMBLY 0746-566

Ref Part No.

1 2 3 4 5 6 7 8 9 10

8409-050 0403-251 0403-273 0403-268 0503-503 0403-267 0503-502 0403-272 8428-002 0503-523

New Qty Description

X X X X X X X X

0503-518 X 0503-494 X 0503-495 X 11 12 13 14 15

3313-113 0403-264 X 0403-250 X 0423-009 0405-483 X

4 2 8 8 2 2 2 2 12 1

Screw, Cap Shock Absorber (inc. 3-4)  O-Ring  Spacer Spring, Suspension - Upper - White Guide, Spring Spring, Suspension - Lower - White Retainer, Spring Nut, Lock A-Arm, Upper Right - Green (inc. 11-15) (1PUSQ/1POSQ) 1 A-Arm, Upper Left - Green (inc. 11-15) (1PUSQ/1POSQ) 1 A-Arm, Upper Right - Black (inc. 11-15) (1PUSA/1POSA) 1 A-Arm, Upper Left - Black (inc. 11-15) (1PUSA/1POSA) 16  Seal 16  Bushing 8  Axle 4  Ring, Retaining 4  Ball Joint

Ref Part No.

New Qty Description

16 8413-090 17 0503-521 X

8 1

0503-516 X

1

0503-496 X

1

0503-497 X

1

1502-774 1436-410 1441-988 1402-885 1402-889 0423-998 0503-484 0503-485 1402-809 0423-423 0423-946 0403-257

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

18 19 20 21 22 23 24 25 26 27 28

X

X X

X

Screw, Cap A-Arm, Lower Right - Green (inc. 11-15) (1PUSQ/1POSQ) A-Arm, Lower Left - Green (inc. 11-15) (1PUSQ/1POSQ) A-Arm, Lower Right - Black (inc. 11-15) (1PUSA/1POSA) A-Arm, Lower Left - Black (inc. 11-15) (1PUSA/1POSA) Axle - Front - Locking (inc. 19-22)  Repair Kit, Boot (inc. 20)  Clip, Retaining  Pin, Detent  Clip, Retaining Screw, Shoulder Knuckle - Assembly - Right (inc. 25-26) Knuckle - Assembly - Left (inc. 25-26)  Bearing  Ring, Retaining Screw, Self-Tapping Clip, Routing

11


REAR SUSPENSION ASSEMBLY 0746-571

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12

8409-060 8428-002 8409-030 0504-708 1423-150 0504-724 0404-246 2402-061 0504-744 0423-394 0423-407 0504-687

New Qty Description

X X X X X X X

6 14 2 1 4 2 4 2 2 4 2 2

0504-740 X

2

13 14 15 16

0404-248 1423-085 1423-087 0504-748

X X X X

12 18 8 2

17 18 19 20 21 22

1423-159 2402-077 0404-285 8413-200 8427-202 0504-690

X X X

16 12 6 6 8 2

X

0504-742 X

2

23 0423-889 24 0504-701 X 25 2416-952 X 2416-953 X 26 8427-602 27 0504-700 X

8 2 1 1 4 2

12

Screw, Cap Nut, Lock Screw, Cap Bar, Sway Screw, Cap Clamp, Retaining Bushing Washer, Thrust Link, Sway Bar Nut, Castle Pin, Cotter Link, Sway Bar - Green (inc. 13-14) (1PUSQ/1POSQ) Link, Sway Bar - Black (inc. 13-14) (1PUSA/1POSA)  Bearing  Ring, Retaining Screw, Shoulder Mount, Lower Trailing Arm - Assembly (inc. 17-19)  Seal  Bearing  Axle Screw, Cap Nut, Lock Arm, Trailing - Lower - Green (1PUSQ/1POSQ) Arm, Trailing - Lower - Black (1PUSA/1POSA) Screw, Cap Bracket, Retaining - Front Guard, Trailing Arm - Right - Black Guard, Trailing Arm - Left - Black Nut, Lock Bracket, Retaining - Rear


28 0504-756 X

2

29 30 31 32 33 34

X X

4 2 2 8 8 2

0504-743 X

2

1502-914 X 1436-410 1441-988 1402-885 1402-889 0504-648 X

2 2 2 4 2 4

0504-738 X

4

41 0404-249 X 42 0504-645 X

6 2

0504-736 X

2

43 0504-654 X

1

0504-655 X

1

1402-809 0423-423 0404-243 X 1423-086 X 8409-025 1423-147 X

2 2 2 2 2 2

35 36 37 38 39 40

44 45 46 47 48 49

2402-076 0404-289 8413-275 0423-946 0403-271 0504-692

X X

Mount, Upper Trailing Arm - Assembly (inc. 17-19 and 29-30)  Bearing  Axle Screw, Cap Screw, Self-Tapping Clip, Routing Arm, Trailing - Upper - Green (1PUSQ/1POSQ) Arm, Trailing - Upper - Black (1PUSA/1POSA) Axle, Drive (inc. 36-39)  Repair Kit, Boot (inc. 37)  Clip, Retaining  Pin, Detent  Clip, Retaining Link, Suspension - Upper - Green (inc. 13-14 and 41) (1PUSQ/1POSQ) Link, Suspension - Upper - Black (inc. 13-14 and 41) (1PUSA/1POSA)  Bearing Link, Suspension - Lower - Green (inc. 13-14 and 41) (1PUSQ/1POSQ) Link, Suspension - Lower - Black (inc. 13-14 and 41) (1PUSA/1POSA) Knuckle - Assembly - Right (inc. 13-14 and 44-47) Knuckle - Assembly - Left (inc. 13-14 and 44-47)  Bearing  Ring, Retaining  Bearing  Ring, Retaining Screw, Cap Pin, Spring


REAR SUSPENSION SHOCK ASSEMBLY 0746-574

Ref Part No.

1 2 3 4 5 6

8409-060 0404-213 0404-264 0403-273 0404-275 0504-699

New Qty Description

X X X X X

2 2 8 8 2 2

Screw, Cap Shock Absorber (inc. 3-5)  Spacer  O-Ring  Collar, Locking - Adjuster Nut Spring, Suspension - Upper - White

Ref Part No.

7 8 9 10 11 12

New Qty Description

0403-267 X 0504-698 X 0403-272 X 8428-002 0623-664 8409-030

2 2 2 2 2 2

Guide, Spring Spring, Suspension - Lower - White Retainer, Spring Nut, Lock Washer Screw, Cap

13


WHEEL AND TIRE ASSEMBLY 0746-575

Ref Part No.

1 0423-557 2 1436-418 1436-164 3 1502-971 4 0402-974 5 2402-088 6 1423-164 7 2402-087 8 2402-017

14

New Qty Description

X X X X X

16 2 2 4 16 4 4 4 2

Screw, Shoulder Disc, Brake - Front Disc, Brake - Rear Hub, Wheel (inc. 4)  Stud Washer Nut, Castle Plate, Retaining Wheel - Front (inc. 9-10)


9 10 11 12 13 14 15 16

1423-079 2402-003 0402-064 0402-140 1402-953 0423-618 2402-018 1402-954

X X X X X

28 4 4 4 2 16 2 2

 Insert, Cap Screw  Cap, Wheel Stem, Valve (inc. 12)  Cap, Valve Stem Tire - Front Nut, Lug - Chrome Wheel - Rear (inc. 9-10) Tire - Rear


HYDRAULIC BRAKE ASSEMBLY 0746-579

Ref Part No.

New Qty Description

1 0502-786 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1

0405-225 0402-592 1402-520 1402-377 8050-217 0117-868 8408-850 0402-872 1602-213 1502-871 X 8422-002 1612-178 8408-826 1502-724 1502-725 1502-725 1502-724 16 1436-160

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

1436-161

1

1436-161

1

1436-160

1

Cylinder, Master Brake - Assembly (inc. 2-4)  Cap, Reservoir  Nut  Clevis Pin, Clevis Washer Pin, Cotter Screw, Cap Axle O-Ring Lever, Brake Nut, Lock Spring Screw, Cap Caliper, Brake - Front Right (inc. 16-22) Caliper, Brake - Front Left (inc. 16-22) Caliper, Brake - Rear Right (inc. 16-22) Caliper, Brake - Rear Left (inc. 16-22)  Housing, Caliper - Assembly - Front Right (inc. 17-19)  Housing, Caliper - Assembly - Front Left (inc. 17-19)  Housing, Caliper - Assembly - Rear Right (inc. 17-19)  Housing, Caliper - Assembly - Rear Left (inc. 17-19)

Ref Part No.

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

New Qty Description

0502-606 0502-607 0502-609 0502-608 0502-605 1502-694 0423-413 0423-178 1402-956 X 8476-616 0619-776 0123-903 3313-239 1402-955 X 0623-038 8408-831

4 4 4 4 4 4 5 12 1 2 AR AR 1 1 1 4

 Piston/Seal Set (inc. 18)  Seal Set  Valve, Bleed  O-Ring, Guide - Set  Bracket Assembly  Pad, Brake - Set Bolt, Banjo-Fitting Washer, Crush Hose, Brake - Front Screw, Machine Conduit, Flexible - 5 ft Tie, Cable - 11.5 in. Switch, Brake Pressure Hose, Brake - Rear Nut w/Washer Screw, Cap

15


ACCELERATOR ASSEMBLY 0746-585

Ref Part No.

1 2 3 4 5

16

New Qty Description

1502-869 X 0405-233 0402-872 1602-213 8422-002

1 1 1 2 1

Pedal, Accelerator Spring Axle O-Ring Nut, Lock


6 7 8 9

8477-620 0502-991 8427-602 0487-083 X

2 1 2 1

Screw, Machine Bracket, Accelerator Pedal Nut, Lock Cable, Accelerator


SHIFTER ASSEMBLY 0746-589

Ref Part No.

1 2 3 4 5 6 7 8

2402-004 0423-885 2416-765 1502-841 1402-275 0423-910 0423-356 0487-082

New Qty Description

X X X

X

1 1 1 1 2 4 1 1

Knob, Shift Nut Boot, Shift Lever Lever, Shift Retainer, Shift Linkage Screw, Machine Screw, Shoulder Cable, Shift

Ref Part No.

9 10 11 12 13 14 15 16

8427-602 0124-057 1423-135 1423-134 1502-843 8468-635 0423-946 2402-064

New Qty Description

X X X X

1 1 1 1 1 2 3 1

Nut, Lock E-Ring Screw, Cap Spacer Bracket, Shift Cable Screw, Machine Screw, Self-Tapping Shield, Heat

17


GAS TANK ASSEMBLY 0746-591

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

New Qty Description

0570-359 X 1670-822 1670-787 0423-898 2670-042 0570-358 X 2670-235 0470-838 0570-343 X 8476-616 1623-675 0423-577 0423-688 0410-070 0123-788 0123-903 16 0470-438

18

1 1 1 6 1 1 1 1 1 1 2 1 1 AR AR AR 1

Tank, Gas - Assembly (inc. 2-4)  Grommet  Valve, Check  Screw, Self-Tapping  Plate, Retaining Pump, Fuel - Assembly (inc. 7)  Float Seal Hose, Gasline Screw, Machine Clamp, Routing Clip, U-Nut Clamp, Hose Hose, Gasline - 25 ft Tie, Cable - 8 in. Tie, Cable - 11.5 in. Cap, Gas Tank (inc. 17)


17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

0109-733 8060-628 0670-304 0123-802 0470-970 0624-390 0410-231 8408-825 0570-352 0570-350 8427-805 8477-616 8427-602 8060-602 0412-632 0412-633 0623-966

X X X X

X X

1 6 1 6 1 2 1 4 1 1 4 4 4 4 1 1 5

 Gasket, Gas Tank Cap Rivet Plate, Retaining Washer Neck, Fill Clamp, Hose Hose, Gasline Screw, Cap Bracket, Hold-Down Bracket, Gas Tank Nut, Lock Screw, Machine Nut, Lock Rivet Shield, Heat - Upper Shield, Heat - Lower Screw, Self-Tapping


AIR INTAKE ASSEMBLY 0746-593

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

0470-936 0470-937 0470-942 8477-516 0470-946 0470-891 8427-502 0570-347 0423-455 0623-038 0470-977 0423-669 0423-465 8476-625 0470-947 0470-939 0423-730

New Qty Description

X X X X X X X

X X

1 1 1 2 1 1 2 1 5 1 1 3 3 3 1 1 2

Cover, Air Intake Gasket Filter, Air Screw, Machine Bracket, Retaining - Filter Filter Nut, Lock Housing, Air Intake Clip, Spring Nut w/Washer Bracket, Support Spacer Grommet Screw, Machine Valve, Drain Bracket, Mounting - Air Intake Clamp

Ref Part No.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

0470-940 0470-938 0470-945 0423-045 8476-616 1623-675 8476-612 0623-784 0470-967 0470-857 0410-243 0410-258 0410-245 1623-281 0470-943 0410-244

New Qty Description

X X X

X X X X X X

1 1 1 6 1 1 2 1 1 1 1 1 1 2 1 1

Boot, Air-In Duct, Intake Grommet Clamp, Hose Screw, Machine Clamp, Routing Screw, Machine Screw, Self-Tapping Bracket, Mounting - Oil Separator Separator, Oil Hose, Vent Hose, Vent Hose, Vent Clamp, Hose Valve, Check Hose, Vent

19


CASE/BELT COOLING ASSEMBLY 0746-592

Ref Part No.

1 2 3 4 5 6 7

20

2416-974 0423-577 0423-609 0470-945 0413-295 0423-730 0413-294

New Qty Description

X X X X

1 6 6 1 1 4 1

Shield, Heat Clip, U-Nut Screw, Machine Grommet Duct, Air-In Clamp Boot, Air-In


8 9 10 11 12 13 14

8476-625 0423-669 0423-465 0513-047 0413-307 2416-818 0413-296

X X X X

1 1 1 1 1 1 1

Screw, Machine Spacer Grommet Duct, Air-Out (inc. 12)  Foil, Protective Bracket, Support Boot, Air-Out


ENGINE AND EXHAUST 0746-590

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0800-113 0801-091 0801-128 0423-451 0423-426 0423-734 8428-002 0411-426 0412-338 0412-636 0512-588 1423-084 0412-375 0612-668 0512-589

New Qty Description

X

X X X X

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

Engine, A950L (inc. 2-3)  Mount, Engine  Spacer, Engine Mount Screw, Cap Washer Screw, Cap Nut, Lock Decal, Warning - Clutch Cover Gasket, Exhaust Pipe Spacer, Exhaust Pipe Pipe, Exhaust - Front Screw, Cap Seal, Exhaust Pipe Spring, Extension Pipe, Exhaust - Rear

Ref Part No.

16 17 18 19 20 21 22 23 24 25 26 27 28 29

0512-599 0412-614 0512-585 8408-616 0512-590 1623-797 8061-283 0512-591 0412-591 8470-512 8476-612 0412-553 0412-544 0412-641

New Qty Description

X X X X X X

X

1 1 1 3 1 5 8 1 1 5 4 1 4 1

Muffler - Assembly (inc. 17-19)  Gasket, Spark Arrester  Arrester, Spark - Assembly  Screw, Cap Shield, Heat - Upper (inc. 21)  Insert Rivet Shield, Heat - Lower (inc. 21) Shield, Heat - Rear Screw, Machine Screw, Machine Bracket, Muffler Support Bushing Bracket, Muffler Support

21


COOLING ASSEMBLY 0746-588

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

0413-278 8470-510 0413-123 8009-549 0413-292 0413-293 0413-195 1602-213 0423-030 0423-484 0623-038 2416-966 0423-490 0410-238 0423-496 0410-115

New Qty Description

X

X X

X X

1 8 2 6 1 1 2 2 4 4 4 1 4 1 9 1

17 0410-116

1

18 8470-520 19 0808-092

4 1

22

Radiator Assembly (inc. 2-9)  Screw, Machine  Fan, Cooling  Screw, Machine  Shroud, Fan  Radiator  Plug, Drain  O-Ring  Grommet Screw, Shoulder Nut w/Washer Bracket, Mounting - Coil Clamp, Hose Hose, Coolant - Radiator/Water Pump Clamp, Hose Hose, Coolant - Water Pump/Front Cylinder Hose, Coolant - Water Pump/Rear Cylinder Screw, Machine Cover, Thermostat


20 21 22 23 24

0830-173 0808-093 0808-124 0808-189 0410-191

1 1 1 1 1

25 0410-253 X 26 27 28 29 30 31 32 33 34 35 36 37 38

0623-761 1623-093 0410-239 1619-038 8475-512 0413-255 0413-280 8427-502 2416-976 0413-087 0413-300 0610-011 0410-237

X

X X X X

O-Ring Thermostat Sensor, Engine Coolant Temperature Housing, Thermostat Hose, Coolant - Front Cylinder Head/ Thermostat 1 Hose, Coolant - Rear Cylinder Head/ Thermostat 1 Clamp 1 Clamp, Hose 1 Hose, Coolant - Thermostat/Filler Neck 1 Conduit, Flexible 6 Screw, Machine 1 Cap, Radiator 1 Neck, Filler 4 Nut, Lock 1 Bracket, Mounting - Overflow Bottle 1 Plug 1 Bottle, Overflow AR Hose - 25 ft 1 Hose, Coolant - Filler Neck/Radiator


OIL COOLER ASSEMBLY 0746-578

Ref Part No.

1 0413-241 2 8476-616 3 0423-632

New Qty Description

1 3 4

Cooler, Oil Screw, Machine Clamp, Hose

Ref Part No.

New Qty Description

4 0410-240 X 5 0410-241 X 6 0123-903

1 Hose, Oil Cooler - In 1 Hose, Oil Cooler - Out AR Tie, Cable - 11.5 in.

23


DRIVE TRAIN ASSEMBLY 0746-577

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

24

1502-854 0423-315 1402-620 0423-404 0423-426 8428-002 0423-393 0402-985 0423-411 1423-090 8408-020 1402-968 4506-725 8422-002 8408-816 2402-058

New Qty Description

X

X X X X

1 2 2 3 9 4 3 1 1 1 2 1 1 2 4 1

Gearcase, Front Clamp, Hose Bladder, Gearcase Screw, Cap Washer Nut, Lock Clamp Boot, Shaft Clamp O-Ring Screw, Cap Bearing Assembly Bracket, Mounting - Bearing Assembly Nut, Lock Screw, Cap Driveshaft, Front


17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

8424-002 2402-062 1423-094 2402-056 1423-093 1423-061 1402-951 1402-026 2402-019 1502-822 0423-576 1423-062 8408-826 8050-252 0123-788

X X X X X X X X X

9 2 9 1 3 2 2 1 1 1 1 2 1 1 AR

Nut Isolator, Driveshaft Screw, Cap Driveshaft, Center Screw, Cap Clamp Boot Spring Driveshaft, Rear Gearcase, Rear Screw, Cap Spacer Screw, Cap Washer Tie, Cable - 8 in.


FRONT DRIVE GEARCASE ASSEMBLY 0746-055

Ref Part No.

New Qty Description

- 1502-854 X 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

1502-909 X 1402-981 1502-237 0423-892 0423-396 1502-085 1402-011 0423-423 0423-118 1402-043 0502-528 0402-947 0423-417 0402-997 0423-402 0402-998 0402-417 0423-147 0402-999 0402-413 1423-067 X 1502-851 X

23 24 25 26 27 28

1402-977 X 0402-327 0402-328 1502-856 X 1402-442 0402-411

1

Complete Front Drive Gearcase Assembly 1 Actuator (inc. 2) 1  O-Ring 1 Bracket, Actuator 1 O-Ring 3 Screw, Self-Tapping 1 Shaft, Input 1 Seal 1 Ring, Retaining 11 Screw, Self-Tapping 1 Bearing 1 Housing, Pinion 1 Gasket, Flange 1 Ring, Retaining 1 Shaft, Selector 1 Ring, Retaining 1 Fork, Selector 1 Shaft, Shuttle 1 O-Ring 1 Spring, Return 1 Coupler, Drive 1 Ring, Retaining 1 Gear, Pinion - Assembly - 11T (inc. 23-24) 1  Collar, Retaining 1  Bearing 1 Bearing 1 Housing, Gearcase 1 Fitting, Elbow 1 Pin, Dowel

Ref Part No.

New Qty Description

29 30 31 32 33

1402-210 0423-153 0423-149 0402-393 0402-405 0402-406 0402-407 0402-408 0402-409 34 1502-919 X 35 1402-074 1402-075 1402-076 1402-077 1402-078 36 1502-858 X

1 2 1 1 AR AR AR AR AR 1 AR AR AR AR AR 1

37 38 39 40 41 42 43 44 45 46 47 48 49 50

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

1402-053 0502-413 1402-079 1402-042 1402-054 1402-058 1402-057 1402-063 1402-656 1402-211 1402-056 1402-930 X 0402-333 0423-154

Plug, Magnetic (inc. one No. 30)  O-Ring O-Ring Bearing Shim, 41 x 49 x 1.3 mm Shim, 41 x 49 x 1.4 mm Shim, 41 x 49 x 1.5 mm Shim, 41 x 49 x 1.6 mm Shim, 41 x 49 x 1.7 mm Gear, Ring - 34T Shim, 61 x 69 x 1.3 mm Shim, 61 x 69 x 1.4 mm Shim, 61 x 69 x 1.5 mm Shim, 61 x 69 x 1.6 mm Shim, 61 x 69 x 1.7 mm Cover, Gearcase (inc. one No. 30, 37-47, and one No. 48)  Bearing  Flange, Bearing  Pin, Parallel  Collar, Sliding  Fork  Ring, Retaining  Spring  Spring  Shaft, Lock  Plug, Oil Level (inc. one No. 30)  Seal  Seal Plug, Fill (inc. 50)  O-Ring

25


REAR DRIVE GEARCASE ASSEMBLY 0746-576

Ref Part No.

New Qty Description

- 1502-822 X

1

1 2 3 4 5 6 7 8 9

1 1 1 1 1 1 2 2 AR AR AR AR AR 1 1 1 6 2 1

10 11 12 13 14 15

26

1502-921 2402-043 2402-044 0402-333 0423-154 1402-442 2402-040 2402-042 0402-405 0402-406 0402-407 0402-408 0402-409 2402-035 0423-149 1502-922 0423-118 0423-115 0402-326

X X X

X X

X X

Complete Rear Drive Gearcase Assembly Housing, Gearcase Plug, Drain - Magnetic Washer Plug, Fill (inc. 5)  O-Ring Fitting, Elbow Seal Bearing Shim, 41 x 49 x 1.3 mm Shim, 41 x 49 x 1.4 mm Shim, 41 x 49 x 1.5 mm Shim, 41 x 49 x 1.6 mm Shim, 41 x 49 x 1.7 mm Gear, Ring - 34T O-Ring Cover, Gearcase Screw, Self-Tapping Screw, Self-Tapping Button, Thrust


16 0402-429 0402-430 0402-431 0402-432 0402-433 17 0402-411 18 0402-947 19 0402-328 20 2402-037 21 0402-324 22 1423-067 23 1502-833 24 1502-845 25 1402-966 26 1402-965 27 0423-798 28 1402-677 29 1502-838 30 0402-089 31 1423-065

X X X X X X X X

AR AR AR AR AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3

Shim, 6.3 x 18 x 1.3 mm Shim, 6.3 x 18 x 1.4 mm Shim, 6.3 x 18 x 1.5 mm Shim, 6.3 x 18 x 1.6 mm Shim, 6.3 x 18 x 1.7 mm Pin, Dowel Gasket Bearing Gear, Pinion - Assembly - 11T Bearing Ring, Retaining Shaft, Input (inc. 24-30)  Cartridge, Clutch - Assembly  Bearing, Flange  Basket, Clutch  Ring, Retaining  Bearing  Housing, Input  Seal Screw, Self-Tapping


WIRING HARNESS ASSEMBLY 0746-573

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13

0486-441 0486-164 0430-085 0430-037 0430-032 0430-031 0430-030 0430-045 2411-883 0430-086 0430-103 0430-102 1436-415 1436-487 1436-416

New Qty Description

X

X X X X

1 1 1 1 7 4 4 6 1 1 1 AR 1 AR 1

Harness, Main (inc. 2-10)  Tether, Accessory Connector  Cover, Fuse Block  Holder, Fuse  Fuse - 10 Amp  Fuse - 15 Amp  Fuse - 30 Amp  Relay (4-Pin) - 20 Amp  Decal, Fuse Block  Seal  Cover, Diagnostics Connector  Clip, Routing Repair Kit, Connector - LCD Gauge Repair Kit, Connector - Headlight Repair Kit, Connector - Tilt Sensor

Ref Part No.

14 15 16 17 18 19 20 21 22 23 24 25 26 27

8476-625 0824-072 0623-038 8468-425 0423-493 0824-071 0824-049 0623-784 4506-731 8060-686 0745-388 8476-620 0530-064 0123-788 0123-903

New Qty Description

X

X X X X

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

Screw, Machine Regulator, Voltage Nut w/Washer Screw, Machine Nut w/Washer Coil, Ignition - Assembly (inc. 20)  Cap, Spark Plug Screw, Self-Tapping Tray, Electrical Rivet Bracket, Mounting - PDM Screw, Machine ECM Tie, Cable - 8 in. Tie, Cable - 11.5 in.

27


BATTERY AND STARTER MOTOR ASSEMBLY 0746-572

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11

28

0645-398 0645-430 0445-082 0417-022 4506-730 8476-616 0445-090 0645-019 0445-062 0645-067 0623-038

New Qty Description

X X X X

1 1 1 1 1 2 1 1 1 1 3

Battery (inc. 2-3)  Decal, Warning  Kit, Hardware Pad, Battery Hold-Down, Battery Screw, Machine Cable, Battery/Ground Boot, Terminal - Dual Cable, Battery/Solenoid Boot, Terminal Nut w/Washer


12 13 14 15 16 17 18 19 20 21

0445-092 8476-620 0445-093 8476-625 0825-023 0412-629 8468-425 0123-802 0409-064 0423-493

X

1 2 X 1 2 X 1 X 1 2 2 1 2

Solenoid Screw, Machine Cable, Solenoid/Starter Screw, Machine Motor, Starter - Assembly (inc. 17)  Foil, Protective Screw, Machine Washer Sensor, Tilt Nut w/Washer


THROTTLE BODY ASSEMBLY 0746-580

Ref Part No.

1 2 3 4 5 6 7 8 9 10

0470-932 1423-041 0570-336 1423-081 0824-054 0832-088 1423-080 0824-052 0824-067 3306-150

New Qty Description

X X X X X X

1 2 1 3 1 1 1 1 1 1

Boot, Intake Clamp Throttle Body - Assembly (inc. 4-12)  Screw, Cap  Valve, Bypass - Idle Air  Seal  Screw, Machine  Sensor, MAP  Sensor, Throttle Position  O-Ring

Ref Part No.

11 12 13 14 15 16 17 18 19

0470-961 1423-095 0470-933 8468-620 0470-885 0470-889 0470-910 0570-345 0830-090

New Qty Description

X X X

X X

1 1 1 8 2 2 2 1 2

 Cover  Screw, Cap Boot, Intake Screw, Machine Rail, Fuel Clip, Retaining Injector, Fuel Manifold, Intake O-Ring

29


CYLINDER ASSEMBLY 0746-581

Ref Part No.

1 2 3 4 5 6 7 8

30

0830-209 0804-031 0827-002 0829-002 0830-193 0804-037 1623-675 8468-612

New Qty Description

2 2 4 8 2 1 1 3

Gasket, Head Cylinder Bolt, Stud Pin, Dowel Gasket, Base Plug, Cylinder Clamp, Routing Screw, Machine


9 10 11 12 13 14 15 16

0804-046 0830-007 0804-030 8468-620 0801-174 0830-134 0827-018 8424-604

1 2 1 2 1 1 4 8

Union, Coolant Hose O-Ring Union, Coolant Hose Screw, Machine Cover, Breather Gasket Bolt, Stud Nut


CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY 0746-582

Ref Part No.

1 2 3 4

5 0809-240 6 0827-059 7 0809-234 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

New Qty Description

0808-175 0829-048 0831-092 X 0809-237

0809-241 0809-242 0809-233 0809-232 0809-231 0830-186 0809-230 0809-228 0809-229 0826-149 0830-155 0826-002 0826-005 0826-006 0808-090

2 4 4 2

Head, Cylinder - Assembly (inc. 2-17)  Pin, Dowel  Plug, Shaft  Arm, Valve Rocker - Exhaust (inc. two No. 5-6) 8  Screw, Adjuster 8  Nut 2  Arm, Valve Rocker - Intake (inc. two No. 5-6) 2  Shaft, Rocker Arm - Intake 2  Shaft, Rocker Arm - Exhaust 16  Cotter, Valve 8  Retainer, Spring 8  Spring, Valve 8  Seal, Oil 8  Seat, Spring - Valve 4  Valve, Intake 4  Valve, Exhaust 8  Screw, Cap 8 Gasket 4 Screw, Cap 4 Screw, Cap 4 Screw, Cap 8 Screw, Cap

Ref Part No.

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

New Qty Description

0830-147 0808-077 0826-007 0808-003 0830-167 0826-034 0828-004 0809-212 X 0809-246 0809-248 0809-003 0829-049 8400-812 0830-025 0217-799 0830-120 0808-210 X 0830-213 0826-157 0827-062 8424-804 0827-030 8424-604

8 2 12 4 4 4 2 2 1 1 2 2 2 2 2 2 2 2 2 2 2 4 4

Washer Plug, Cylinder Head Screw, Cap Cap, Inspection O-Ring Screw, Cap Plate, Retainer Sprocket Camshaft, Front Cylinder Camshaft, Rear Cylinder C-Ring Pin, Dowel Screw, Cap Washer, Crush Spark Plug - CPR8E Seal Cover, Thermostat O-Ring Screw, Cap Bolt, Stud Nut Bolt, Stud Nut

31


CAM CHAIN ASSEMBLY 0745-069

Ref Part No.

1 2 3 4 5

32

New Qty Description

0810-001 0810-069 X 0810-070 X 0826-106 0810-004

2 2 2 2 2

Chain, Cam Guide, Chain Tensioner, Chain Pivot, Tensioner Adjuster, Tensioner - Assembly


6 7 8 9

0830-134 8468-620 8400-610 0828-129

2 4 2 2

Gasket Screw, Machine Screw, Cap Washer


CRANKCASE ASSEMBLY (Engine Serial No. Up to 2010689) 0745-063

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0801-172 0830-035 0832-048 0832-042 0832-050 0832-049 0832-055 0832-057 0801-002 0822-052 0829-003 0829-002 0812-008 0812-029 0830-172 0812-060 8468-616 0623-914 0812-079 0812-052

New Qty Description

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

Crankcase - Assembly (inc. 2-13)  Seal, Driveshaft  Bearing  Bearing  Bearing  Bearing  Bearing - Assembly (inc. 8)  Bearing  Plug, Engine Case  Seal, Countershaft - Right  Pin, Dowel  Pin, Dowel  Union, Oil Filter Filter, Oil O-Ring Fitting, Oil Screw, Machine Screw, Self-Tapping Plate, Oil Sump Valve, Oil-Relief - Assembly

Ref Part No.

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

0830-162 0812-081 8468-616 0801-073 0830-010 0812-078 0830-191 0829-048 0832-084 0831-086 0801-193 8468-625 8468-630 8412-875 8468-660 8468-640 8412-830 8412-860 8412-850 0818-103

New Qty Description

1 1 3 1 1 1 1 2 1 1 1 5 2 1 8 2 3 10 1 1

O-Ring, Oil Filler Cover Cover, Oil Filler Screw, Machine Stick, Oil Level O-Ring Fitting, Oil - Threaded Gasket, Breather Pin, Dowel Bearing Circlip Cover, Breather Screw, Machine Screw, Machine Screw, Cap Screw, Machine Screw, Machine Screw, Cap Screw, Cap Screw, Cap Plug

33


CRANKCASE ASSEMBLY (Engine Serial No. 2010690 and Up) 0746-609

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

34

New Qty Description

0801-211 X 0830-035 0832-048 0832-042 0832-050 0832-049 0832-055 0832-057 0801-002 0822-052 0829-003 0829-002 0812-008 0812-029 0830-172 0812-060 8468-616 0623-914 0812-079 0812-052

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

Crankcase - Assembly (inc. 2-13)  Seal, Driveshaft  Bearing  Bearing  Bearing  Bearing  Bearing - Assembly (inc. 8)  Bearing  Plug, Engine Case  Seal, Countershaft - Right  Pin, Dowel  Pin, Dowel  Union, Oil Filter Filter, Oil O-Ring Fitting, Oil Screw, Machine Screw, Self-Tapping Plate, Oil Sump Valve, Oil-Relief - Assembly


21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

0830-162 0812-081 8468-616 0801-073 0830-010 0812-078 0830-191 0829-048 0832-084 0831-086 0801-193 8468-625 8468-630 8412-875 8468-660 8468-640 8412-830 8412-860 8412-850 0818-103

1 1 3 1 1 1 1 2 1 1 1 5 2 1 8 2 3 10 1 1

O-Ring, Oil Filler Cover Cover, Oil Filler Screw, Machine Stick, Oil Level O-Ring Fitting, Oil - Threaded Gasket, Breather Pin, Dowel Bearing Circlip Cover, Breather Screw, Machine Screw, Machine Screw, Cap Screw, Machine Screw, Machine Screw, Cap Screw, Cap Screw, Cap Plug


CRANKSHAFT AND PISTON ASSEMBLY 0745-070

Ref Part No.

1 0805-299 2 0805-164 3 0805-199

New Qty Description

2 2 4

Piston Set - Assembly (inc. 2-4)  Ring, Piston - Set  Circlip, Piston Pin

Ref Part No.

New Qty Description

4 0805-198 5 0805-327 X 6 0805-273

2 1 1

 Pin, Piston Crankshaft - Assembly Washer, Thrust

35


STARTER CLUTCH ASSEMBLY 0745-071

Ref Part No.

1 2 3 4 5

36

0815-026 0829-031 0815-002 0815-003 0829-032

New Qty Description

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


6 7 8 9 10

0815-004 0832-079 0802-035 0826-069 0828-113

1 1 1 6 1

Gear, Starter Clutch (inc. 7)  Bearing Clutch, Starter Screw, Cap Washer, Wave


OIL PUMP ASSEMBLY 0745-052

Ref Part No.

1 2 3 4 5 6 7 8

0812-041 0829-009 0812-048 0812-040 8468-625 0812-047 0828-007 0812-046

New Qty Description

1 2 1 1 2 1 1 1

Gerotor - Set Pin, Dowel O-Ring Housing, Oil Pump Screw, Machine Seal, Oil Pump Shim Shaft, Oil Pump

Ref Part No.

9 10 11 12 13 14 15 16

0812-045 0831-002 0812-057 0826-040 0812-053 8468-625 0812-006 0830-017

New Qty Description

1 1 1 2 1 4 1 1

Gear, Driven Ring, Retaining Strainer, Oil Screw, Machine Cap, Oil Strainer Screw, Machine Plug, Drain Gasket, Drain Plug

37


WATER PUMP ASSEMBLY (Engine Serial No. Up to 2010689) 0745-537

Ref Part No.

1 2 3 4 5 6 7 8 9

38

0813-056 0830-029 8468-650 0832-084 0831-086 0813-041 0831-010 0813-043 0829-009

New Qty Description

1 1 2 1 1 1 2 1 1

Pump, Water - Assembly (inc. 2)  O-Ring Screw, Machine Bearing Circlip Shaft, Driven Gear Ring, Retaining Gear, Driven Pin, Dowel


10 11 12 13 14 15 16 17

0831-002 0832-046 0813-028 0813-026 0831-004 0813-027 0831-040 0828-038

1 2 1 1 1 1 1 2

Ring, Retaining Bearing Spacer, Idler - Water Pump Shaft, Water Pump Idler Gear Ring, Retaining Gear, Idler - Water Pump - Drive Ring, Retaining Washer


WATER PUMP ASSEMBLY (Engine Serial No. 2010690 and Up) 0745-053

Ref Part No.

1 2 3 4 5 6 7 8

New Qty Description

0813-059 X 0830-029 8468-650 0832-084 0831-086 0813-041 0831-010 0813-043

1 1 2 1 1 1 2 1

Pump, Water - Assembly (inc. 2)  O-Ring Screw, Machine Bearing Circlip Shaft, Driven Gear Ring, Retaining Gear, Driven

Ref Part No.

9 10 11 12 13 14 15 16

0829-009 0831-002 0832-046 0813-028 0813-026 0831-004 0813-027 0831-040

New Qty Description

1 1 2 1 1 1 1 1

Pin, Dowel Ring, Retaining Bearing Spacer, Idler - Water Pump Shaft, Water Pump Idler Gear Ring, Retaining Gear, Idler - Water Pump - Drive Ring, Retaining

39


TRANSMISSION ASSEMBLY (Engine Serial No. Up to 20044789) 0746-583

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

40

New Qty Description

0828-076 0823-355 X 0823-177 0823-176 0823-178 0823-310 0827-011 0830-189 0821-002 0832-009 0826-029 0822-010 0830-188 0470-531

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

Shim, 25 x 30 x 0.90 mm Pulley, Driven - Assembly (inc. 3-5)  Screw, Machine  Shoe, Cam  Nut, Driven Pulley Clutch, Centrifugal - 6 Plate Nut Seal, Clutch Housing - Left Housing, Clutch Bearing Screw, Machine Retainer, Bearing Seal, Clutch Housing - Right O-Ring


15 16 17 18 19 20 21 22 23 24 25 26 27 28

0823-015 0823-272 0823-231 0823-273 0823-271 0823-295 0823-277 0823-276 0828-106 0827-010 0826-031 0823-020 0830-176 0832-010

X X X X X X

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

Spacer, Fixed Drive Face Face, Fixed Drive Belt, Drive Face, Movable Drive Spacer, Movable Drive Face Roller, Movable Drive Face Damper, Movable Drive Face Plate, Movable Drive Face Washer Nut Screw, Machine Retainer, Bearing Seal Bearing


TRANSMISSION ASSEMBLY (Engine Serial No. 20044790 and Up) 0746-586

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

New Qty Description

0828-076 0823-355 X 0823-177 0823-176 0823-178 0823-310 0827-011 0830-189 0821-002 0832-009 0826-029 0822-010 0830-188 0470-531

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

Shim, 25 x 30 x 0.90 mm Pulley, Driven - Assembly (inc. 3-5)  Screw, Machine  Shoe, Cam  Nut, Driven Pulley Clutch, Centrifugal - 6 Plate Nut Seal, Clutch Housing - Left Housing, Clutch Bearing Screw, Machine Retainer, Bearing Seal, Clutch Housing - Right O-Ring

Ref Part No.

15 16 17 18 19 20 21 22 23 24 25 26 27 28

0823-015 0823-272 0823-231 0823-273 0823-271 0823-295 0823-277 0823-276 0828-106 0827-010 0826-031 0823-020 0806-128 0832-060

New Qty Description

X X X X X X

X

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

Spacer, Fixed Drive Face Face, Fixed Drive Belt, Drive Face, Movable Drive Spacer, Movable Drive Face Roller, Movable Drive Face Damper, Movable Drive Face Plate, Movable Drive Face Washer Nut Screw, Machine Retainer, Bearing Spacer Bearing

41


SECONDARY TRANSMISSION ASSEMBLY 0745-540

Ref Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

42

New Qty Description

0822-144 X 0831-085 0822-120 0822-121 0822-119 0832-082 0822-114 0822-113 0822-145 X 0822-148 X 0822-125 0828-019 0828-011 0831-040 0822-050

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

Countershaft Assembly (inc. 2-10)  Ring, Retaining  Gear Select, Reverse  Shim  Gear, Reverse Driven  Bearing  Gear, Driven - Low  Countershaft  Gear Select, Sliding  Gear, Driven - High Gear, Drive Washer, Thrust Washer Ring, Retaining Trigger, Speedometer Sensor


16 17 18 19 20 21 22 23 24 25 26 27 28 29

0828-069 0831-039 0830-194 0829-048 0806-105 0830-044 8468-630 0430-091 8468-620 0822-001 0828-016 0822-011 0822-012 0822-015

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

Washer, Thrust Ring, Retaining Gasket Pin, Dowel Housing, Speedometer Sensor Seal Screw, Machine Sensor, Speedometer Screw, Machine Driveshaft Washer, Thrust Gear, Reverse Idle Bushing Shaft, Reverse Idle


GEAR SHIFTING ASSEMBLY 0746-409

Ref Part No.

1 2 3 4 5 6 7 8 9 10

New Qty Description

0828-036 0831-010 0818-095 0409-125 0818-014 8468-620 0828-040 0818-149 X 0828-131 X 0818-145 X

1 1 1 1 1 1 1 1 1 1

Washer Ring, Retaining Shaft, Sub-Gear Shift Switch, Gear Position Arm, Shift Screw, Machine Washer Shaft, Gear Shift - Assembly Spacer Cam, Gear Shift

Ref Part No.

11 12 13 14 15 16 17 18 19

New Qty Description

0826-006 0818-072 0818-006 0828-038 0818-002 0818-004 0818-144 X 0828-035 8424-602

1 2 1 1 1 1 1 1 1

Screw, Cap Fork, Shift Shaft, Shift Fork Washer Stopper, Cam Support, Cam Stopper Spring Washer Nut

43


SECONDARY DRIVE ASSEMBLY 0746-584

Ref Part No.

1 2 3 4 5 6

New Qty Description

0827-013 0828-020 0819-126 X 0830-043 0832-017 0828-021 0828-022 0828-023 0828-024 0828-025 0828-026 0828-027 0828-028 0828-029 7 0819-115 X 8 0819-011 9 0832-016

44

1 1 1 1 2 AR AR AR AR AR AR AR AR AR 1 1 1

Nut Washer Flange, Output Joint 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 Shaft, Secondary Driven - Front Ring, Driven Bearing Bearing, Driven Gear


10 11 12 13 14 15

0822-106 0819-122 X 0831-011 0830-214 X 0822-132 0828-119 0828-120 0828-121 0828-122 0828-123 0828-124 0828-125 0828-126 0828-127 16 0832-083 17 0827-060 18 0832-050

1 1 1 1 1 AR AR AR AR AR AR AR AR AR 1 1 1

Gear, Secondary Driven Shaft, Secondary Driven - Rear Ring, Retaining Seal, Oil Gear, Secondary Drive Shim, 30 x 48 x 0.25 mm Shim, 30 x 48 x 0.30 mm Shim, 30 x 48 x 0.35 mm Shim, 30 x 48 x 0.90 mm Shim, 30 x 48 x 0.95 mm Shim, 30 x 48 x 1.00 mm Shim, 30 x 48 x 1.05 mm Shim, 30 x 48 x 1.10 mm Shim, 30 x 48 x 1.15 mm Bearing Nut Bearing


MAGNETO ASSEMBLY 0746-026

Ref Part No.

1 2 3 4

0802-059 0829-012 0827-010 8409-632

New Qty Description

1 1 1 3

Rotor/Flywheel Key Nut Screw, Cap

Ref Part No.

New Qty Description

5 0802-064 X 6 0831-064 7 8470-510

1 1 4

Stator - Assembly Clamp Screw, Machine

45


MAGNETO SIDE ENGINE COVERS 0745-061

Ref Part No.

1 2 3 4 5

46

0806-107 0830-132 0832-010 0826-155 0830-015

New Qty Description

1 1 1 1 1

Cover, Magneto Gasket, Magneto Cover Bearing Plug, Check Washer, Crush


6 7 8 9 10

0830-176 0806-066 8468-650 8468-695 8468-665

1 1 4 1 3

Seal, Cap Cap, Magneto Cover Screw, Machine Screw, Machine Screw, Machine


CLUTCH SIDE ENGINE COVERS 0746-587

Ref Part No.

1 2 3 4 5 6

0806-112 0829-048 0830-013 8408-812 0830-137 0806-110

New Qty Description

1 6 1 1 1 1

Cover, Outside Pin, Dowel Washer, Crush Screw, Cap Gasket, Cover Cover, Inside

Ref Part No.

7 8 9 10 11

8468-630 8468-640 8468-616 0806-109 0830-133

New Qty Description

16 5 9 1 1

Screw, Machine Screw, Machine Screw, Machine Cover, Clutch Gasket, Clutch Cover

47

Ref.

Part No.

Qty. Description

Printed in U.S.A.

Ref.

Part No.

Qty. Description

p/n 2259-412