Bearcat Z1 XT GS. Model Number S2012BCNWGUSO Model Number S2012BCNWGOSO - International SHARE OUR PASSION.

Transcription

1 2012Snowmobile Illustrated Parts Manual Bearcat Z1 XT GS Model Number S2012BCNWGUSO Model Number S2012BCNWGOSO - International TM SHARE OUR PASSION.

2 TABLE OF CONTENTS 2012 Bearcat Z1 XT GS (Model No. S2012BCNWGUSO) (Model No. S2012BCNWGOSO - International) SKI AND SPINDLE ASSEMBLY (WGUSO)... 1 SKI AND SPINDLE ASSEMBLY (WGOSO)... 2 A-ARM ASSEMBLY... 3 FRONT SUSPENSION SHOCK ABSORBER ASSEMBLY... 4 STEERING POST ASSEMBLY... 5 TIE ROD ASSEMBLY... 6 STEERING SUPPORT ASSEMBLY... 7 HANDLEBAR AND CONTROLS... 8 HYDRAULIC BRAKE CONTROL ASSEMBLY... 9 DRIVE TRAIN SHAFT AND BRAKE ASSEMBLIES GEARCASE ASSEMBLY SLIDE RAIL AND TRACK ASSEMBLY IDLER WHEEL ASSEMBLY REAR SUSPENSION FRONT ARM ASSEMBLY REAR SUSPENSION REAR ARM ASSEMBLY ARTICULATING SKID FRAME ASSEMBLY CHASSIS ASSEMBLY HOOD, WINDSHIELD, AND FRONT BUMPER ASSEMBLY WINCH ASSEMBLY HEADLIGHT AND WIRING ASSEMBLIES CONSOLE ASSEMBLY SKID PLATE AND SIDE PANEL ASSEMBLY BELT GUARD ASSEMBLY GAS TANK ASSEMBLY FUEL PUMP ASSEMBLY SEAT SUPPORT ASSEMBLY FRONT SEAT ASSEMBLY REAR BUMPER, RACK RAIL, SNOWFLAP, AND TAILLIGHT ASSEMBLY STROBE AND WORK LIGHT ASSEMBLY COOLING ASSEMBLY ENGINE AND RELATED PARTS EXHAUST ASSEMBLY BATTERY AND TRAY ASSEMBLY AIR SILENCER ASSEMBLY OIL SEPARATOR ASSEMBLY OIL TANK ASSEMBLY DRIVE CLUTCH DRIVEN CLUTCH CYLINDER HEAD ASSEMBLY CRANKCASE ASSEMBLY MAGNETO COVER PISTON AND CRANKSHAFT ASSEMBLY STARTER CLUTCH ASSEMBLY CRANK BALANCER ASSEMBLY CAM CHAIN ASSEMBLY CAMSHAFT/VALVE ASSEMBLY EXHAUST MANIFOLD GASKET/INTAKE FLANGE ASSEMBLY OIL PAN ASSEMBLY OIL PUMP ASSEMBLY OIL COOLER ASSEMBLY WATER PUMP ASSEMBLY WATER HOSE ASSEMBLY THROTTLE BODY ASSEMBLY STARTER MOTOR ASSEMBLY MAGNETO ASSEMBLY 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 Arctic Cat Inc. Effective August 2011 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

3 SKI AND SPINDLE ASSEMBLY (WGUSO) Cap, Spindle Spindle, Steering - Right - Platinum (inc. 3-10) Spindle, Steering - Left - Platinum (inc. 3-10) Ring, Retaining Arm, Spindle - Right - Platinum Arm, Spindle - Left - Platinum Screw, Cap Washer, Thrust Fitting, Grease Bearing Screw, Cap Bearing Axle, Spindle Spacer Damper, Ski Ski, Plastic - Black Insert Handle, Plastic - Black Nut, Lock Screw, Machine Screw, Machine Wearbar - Right Wearbar - Left Nut, Lock Nut, Lock Washer Pin, Cotter Screw, Cap 1

4 SKI AND SPINDLE ASSEMBLY (WGOSO) Cap, Spindle Spindle, Steering - Right - Platinum (inc. 3-10) Spindle, Steering - Left - Platinum (inc. 3-10) Ring, Retaining Arm, Spindle - Right - Platinum Arm, Spindle - Left - Platinum Screw, Cap Washer, Thrust Fitting, Grease Bearing Screw, Cap Bearing Axle, Spindle New Qty Description Spacer Damper, Ski Ski, Plastic - Black Insert Handle, Plastic - Black Nut, Lock Screw, Machine Screw, Machine Wearbar Nut, Lock Nut, Lock Washer Pin, Cotter Screw, Cap 2

5 A-Arm, Lower - Platinum (inc. eight No. 2) Bearing Screw, Cap Axle, Inner - Lower A-Arm - Front Screw, Cap Axle, Lower A-Arm - Rear Nut, Lock A-ARM ASSEMBLY Bearing, Split Screw, Cap Axle, Spindle A-Arm, Upper - Front - Platinum (inc. four No. 2) A-Arm, Upper - Rear - Platinum (inc. four No. 2) Axle, Inner - Upper A-Arm 3

6 FRONT SUSPENSION SHOCK ABSORBER ASSEMBLY Shock, Ski (inc. 2-3) Bushing Sleeve Sleeve Screw, Cap New Qty Description Nut, Lock Sleeve, Threaded Nut, Adjuster Spring, Compression - White Retainer, Spring 4

7 Screw, Cap Cap, Adjusting Block Block, Adjusting X 1 Block, Riser - 2 in Nut, Lock Post, Steering Washer Nut, Lock STEERING POST ASSEMBLY AR Tie, Cable - Push-Mount Bracket, Bearing Plate, Bearing Bracket Bracket, Wire Protector Screw, Cap Clamp, Throttle Cable Screw, Cap 5

8 Nut, Lock Axle, Steering Arm Arm, Steering - Assembly (inc. 4) Fitting, Grease Screw, Cap Drag Link (inc. 7) Bearing Screw, Shoulder Screw, Cap TIE ROD ASSEMBLY New Qty Description Screw, Cap Nut, Lock Ball Joint, Tie Rod - Right-Hand Thread Nut, Hex - Right-Hand Thread Tube, Tie Rod - Spindle Nut, Hex - Left-Hand Thread Ball Joint, Steering - Left-Hand Thread Ball Joint, Tie Rod - Left-Hand Thread Tube, Tie Rod 6

9 Screw, Cap Nut, Lock X 1 Frame, Upper - Right Frame, Upper - Left Bracket, Support - Headlight w/heat Shield Spacer Screw, Cap Screw, Cap Nut, Lock AR Clamp, Wire Gusset, Steering Support - Right Alarm, Reverse (inc. 12) Ring, Retaining Clamp, Routing Clamp, Routing Screw, Cap STEERING SUPPORT ASSEMBLY Clamp, Routing Screw, Cap Support, Steering Plate, Nut Screw, Self-Tapping Bracket, Mounting - Air Silencer Clip, U-Nut Bracket, Mounting - MAP Sensor X 1 Gusset, Steering Support - Left Mount, ECU Bracket, Support - Belt Guard Screw, Cap Bracket, Footrest - Right Bracket, Footrest - Left Rivet AR Tie, Cable - 8 in AR Tie, Cable in. 7

10 HANDLEBAR AND CONTROLS Screw, Self-Tapping Washer, Backing Grip, Handlebar Control, Throttle - Rear (inc. 5-10) Kit, Throttle Lever Mounting (inc. 6-9) 6 1 Axle, Lever - Throttle - Included in Kit 7 2 Cap, Lever Axle - Included in Kit 8 1 Spacer, Lever Axle - Included in Kit Nut, Push - Included in Kit Lever, Throttle Pad, Insulator Element, Thumbwarmer Clip, Retaining Control, Throttle - Front Cover, Connector Screw, Machine New Qty Description Screw, Self-Tapping Handlebar (inc ) Insert, Handlebar Rivet Element, Handwarmer - Right Element, Handwarmer - Left Control, Dimmer - Rear Control, Dimmer - Front AR Tie, Cable - 4 in AR Tie, Cable - 8 in AR Tie, Cable in X 1 Harness, Handlebar X 1 Wrap, Handlebar Cable, Throttle Switch, Winch Kit, Mounting - Winch Switch 8

11 HYDRAULIC BRAKE CONTROL ASSEMBLY Brake Assembly (inc. 2-10) Master Cylinder - Assembly Lever, Brake (inc. 4) Lock, Brake Lever - Kit Cover, Reservoir Screw, Machine Clamp, Brake Screw, Machine Pin, Brake Lever - Kit Switch, Brake Washer, Crush Bolt, Banjo-Fitting Brakeline, Hydraulic AR Fluid, Brake - High Temperature - 12 oz - Not Illustrated 9

12 DRIVE TRAIN SHAFT AND BRAKE ASSEMBLIES Nut, Retaining Screw, Cap Disc, Brake Spacer, Brake Caliper Shield, Bearing Track, Drive - Assembly (inc. 7-8) Driveshaft Sprocket, Drive Spacer Seal Plate, Mounting - Reverse Nut, Push X 1 Gearcase Assembly Nut, Lock Screw, Machine Bracket, Rubber Snubber Snubber, Rubber Shield, Actuator AR Trim AR Washer, Shim (.030 in.) AR Washer, Shim (.060 in.) X 1 Clutch, Driven - Assembly O-Ring AR Washer, Shim (.090 in.) AR Washer, Shim (.030 in.) AR Washer, Shim (.060 in.) New Qty Description Adjuster, Sheave (inc. 25) Washer, Thrust Washer Washer, Lock Screw, Cap Caliper, Brake - Assembly (inc ) Bolt, Carriage - Ribbed Fitting, Bleed Piston O-Ring Pad, Brake - Set (inc ) Clip, Anti-Rattle Clip, Hairpin Pin, Retaining - Brake Pad O-Ring, Housing Spacer Washer Screw, Cap Screw, Cap Bearing Sleeve, Driveshaft Ring, Retaining Fitting, Inlet X 1 Plate, Mounting - Speedometer Sensor Sensor, Speedometer Screw, Machine 10

13 GEARCASE ASSEMBLY X 1 Complete Gearcase Assembly X 1 Housing, Gearcase (inc. 2-4) Pin, Dowel Bearing Seal, Oil Plug, Plastic Actuator, Shift Screw, Machine Fork, Shift - Assembly (inc. 9-11) Seal, Oil Ring, Retaining X 1 Arm, Shift Fork Block, Slider Slider Assembly (inc ) Ring, Retaining Washer, Thrust 16 1 Shaft, Output (inc. 17) - Not a Service Part 17 1 Bearing - Not a Service Part Slider, Outer Gear, Output - 66T/34T - Assembly (inc and one No. 26) Bearing Washer, Thrust Gear, Planetary - Assembly Bearing, Thrust Washer, Thrust Gear, Transfer - 66T/34T (inc. one No. 26) Bearing Shaft, Input - 54T (inc. one No. 26) Cover, Gearcase (inc ) Seal, Oil Bearing Switch, Gear Indicator Plug, Drain O-Ring Screw, Machine Gasket AR Fluid, Gearcase - 12 oz - Not Illustrated 11

14 X 1 Complete Skid Frame Assembly Rail, Formed Insert, Rail Screw, Cap Axle Screw, Machine End Cap, Slide Rail Nut, Lock Wearstrip, Slide Rail Screw, Machine Nut, Lock SLIDE RAIL AND TRACK ASSEMBLY New Qty Description Rivet Bracket, Retaining Pad, Shock Screw, Cap Bushing, Stop - Rear Arm Nut, Lock Block, Spring Tension Screw, Cap Track Assembly (inc ) Clip, Guide Guide, Wear 12

15 Cap, Idler Wheel Screw, Cap Washer Wheel, Idler - White (inc. 5-6) Bearing Ring, Retaining Screw, Cap Block, Mounting - Idler Wheel Nut, Lock Screw, Cap Spacer X 8 Wheel, Idler Spacer Bracket, Mounting - Front Shock Axle Nut, Lock IDLER WHEEL ASSEMBLY Spacer Axle Pivot, Shock (inc ) Washer Fitting, Grease Spring, Overload - Assembly (inc ) Screw, Machine Block, Wear Nut, Lock Clip, Retaining Bushing, Overload Spring Washer Spacer, Spring Slide Slide, Spring 13

16 REAR SUSPENSION FRONT ARM ASSEMBLY Arm, Front Suspension - Black (inc. 2-4) Fitting, Grease Bushing, Flared Bearing Axle Nut, Lock Screw, Cap Nut, Lock Adjuster, Front Arm Washer Screw, Machine X 2 Strap, Limiter Screw, Cap Washer New Qty Description Nut, Lock Axle, Inner Carriage Screw, Cap Cover, Shock Spring, Compression - Black Nut, Adjuster Sleeve, Threaded Retainer, Spring Axle Screw, Cap Shock Absorber Bushing Axle Screw, Cap 14

17 REAR SUSPENSION REAR ARM ASSEMBLY Arm, Idler - Black (inc. 2 and one No. 3) Bushing, Flared Fitting, Grease Arm, Rear - Black (inc. one No. 3 and 5) Washer Screw, Cap Bushing Axle Nut, Lock Screw, Cap Axle Block, Spring Adjuster - Right Block, Spring Adjuster - Left Ring, Retaining Screw, Cap Pivot - Idler Arm (inc ) Nut, Lock Screw, Cap Bushing, Flared Washer Axle Spacer, Pivot - Idler Arm Wheel, Idler (inc ) Bearing Ring, Retaining Spring, Suspension - Right Spring, Suspension - Left Sleeve, Spring Axle Screw, Cap Link, Rear Shock Spacer Screw, Cap Shock Absorber (inc ) Bushing Sleeve 15

18 ARTICULATING SKID FRAME ASSEMBLY Cap, Idler Wheel Screw, Cap Washer Wheel, Idler - White (inc. 5-6) Bearing Ring, Retaining Block, Mounting - Idler Wheel Screw, Cap Nut, Lock Screw, Cap Axle Nut, Lock Rod, Adjuster Spring Nut, Lock New Qty Description Axle Arm, Swing (inc ) Bushing, Flared Fitting, Grease Adjuster, Track Nut Screw, Cap Washer Axle, Rear Wheel Spacer Wheel, Idler (inc. 5-6) Spacer Wheel, Idler - White (inc. 5-6) Washer Screw, Cap 16

19 X 1 Chassis - Assembly (inc. 2-5 and four No. 6) Screw, Cap Screw, Machine Insert Insert Nut, Lock End Cap, Tunnel Rivet Plug Clip, U-Nut Bracket, Toe Hook - Right Bracket, Toe Hook - Left Shield, Toe - Right Shield, Toe - Left Screw, Machine Nut w/washer Washer, External Tooth Lock Foil, Protective Strap, Hold-Down - Right Strap, Hold-Down - Left AR Tie, Cable - Push-Mount Clip, Routing - Snap-In Screw, Cap Regulator, Voltage CHASSIS ASSEMBLY Bracket, Mounting - Fuel Filter Rivet Mat, Rack Bracket, Mounting - Front Suspension (inc ) Bushing Bolt, Ribbed Frame, Mounting - Shock - Right Frame, Mounting - Shock - Left Screw, Cap Screw, Cap Nut, Lock Screw, Cap Screw, Machine Close-Off, Front End Bumper Screw, Machine Tab, Mounting - Resonator Decal, Reflector - Right - Red Decal, Reflector - Left - Red X 1 Decal, Tunnel - Right X 1 Decal, Tunnel - Left Carrier, Winch Decal, Warning - Winch Transport 17

20 HOOD, WINDSHIELD, AND FRONT BUMPER ASSEMBLY X 1 Hood w/decals - Orange (inc. 2-10) X 1 Hood w/o Decals - Orange (inc. 3-8) Vent, Hood - Outer Front - Right - Black Vent, Hood - Outer Front - Left - Black Vent, Hood - Outer Rear - Right - Black Vent, Hood - Outer Rear - Left - Black Vent, Hood - Inner - Right - Black Vent, Hood - Inner - Left - Black Pin, Retaining Clip, Hood Hold-Down - Right Clip, Hood Hold-Down - Left Nut, Push X 1 Decal, Arctic Cat - Right X 1 Decal, Arctic Cat - Left X 1 Decal, 50th Anniversary Bracket, Hinge Nut, Stamped Strap, Hold-Down X 1 Spar, Front w/decals - Right - Black (inc ) X 1 Spar, Front w/decals - Left - Black (inc. 15 and 17) Spar, Front w/o Decals - Right - Black Spar, Front w/o Decals - Left - Black Foil, Spar - Right X 1 Decal, Front Spar - Right X 1 Decal, Front Spar - Left New Qty Description Bezel, Intake - Right - Orange Bezel, Intake - Left - Orange Bracket, Windshield - Hold-Down Bracket, Windshield Screw, Self-Tapping Screw, Machine Washer, Rubber Washer Screw, Machine Support, Windshield Mirror Kit (inc ) Nut, Expansion Snap Cap w/washer Screw, Machine Windshield Rivet, Plastic Screw, Self-Tapping Clamp, Routing Clip, U-Nut X 1 Fascia, Front - Black Rivet, Reinstallable Screw, Self-Tapping Washer, External Tooth Lock Nut, Lock Screw, Shoulder Bumper, Front (inc. 43) Decal, Reflector - Right - Amber Decal, Reflector - Left - Amber Screw, Cap Nut, Lock 18

21 Winch (inc. 2-3) Decal, Warning Cable, Winch Screw, Cap Roller, Winch (inc. 6) Decal, Warning - Pinch Point Screw, Cap Nut, Lock Bracket, Mounting - Winch Pin Clip, Hairpin Pin, Cotter Hook, Winch WINCH ASSEMBLY Strap Pin Nut w/washer Boot, Terminal Cable, Winch/Quick Disconnect Cover, Winch Cable Cable, Quick Disconnect/Solenoid Screw, Cap Bracket, Mounting - Solenoid Solenoid Nut, Lock Cable, Solenoid/Battery 19

22 HEADLIGHT AND WIRING ASSEMBLIES Lens/Reflector - Headlight - Right (inc. 2-4) Lens/Reflector - Headlight - Left (inc. 2-4) Bulb, Headlight - Low Beam Bulb, Headlight - High Beam Adjuster, Headlight - Assembly Harness, Console Harness, Main (inc. 7-13) Cover, Fuse Block Seal, Cover New Qty Description Holder, Fuse Fuse - 15 Amp Fuse - 20 Amp Fuse - 25 Amp Fuse - 30 Amp Relay (4-Pin) - 20 Amp Relay (5-Pin) - 30 Amp Decal, Fuse Block Tether, Accessory Connector AR Tie, Cable - 8 in AR Tie, Cable in. 20

23 CONSOLE ASSEMBLY Housing, Speedometer/Tachometer Speedometer/Tachometer Bracket, Retaining Nut w/washer Washer Switch, Ignition (inc. 7-9) Nut, Retaining Key, Ignition Y Series - Left-Side Cut Key, Ignition Z Series - Right-Side Cut Cover, Key Console - Black (inc ) Decal, Warning - Touring - French Decal, Warning - Touring - English Decal, Caution - French Decal, Caution - English Foam, Console - Front Screw, Self-Tapping Screw, Self-Tapping Foam, Console - Rear Screw, Self-Tapping Screw, Shoulder X 2 Switch, Actuator Housing, Switch/Console X 1 Harness, Adapter - Actuator Switch Outlet, Accessory - 12V Panel, Close-Off Nut, Retaining Rivet, Reinstallable Close-Off, Handlebar 21

24 SKID PLATE AND SIDE PANEL ASSEMBLY X 1 Panel, Side - Upper - Right w/decals - Black (inc. 2-5) X 1 Panel, Side - Upper - Left w/decals - Black (inc. 2-3 and 5) Panel, Side - Upper - Right w/o Decals - Black (inc. 3-4) Panel, Side - Upper - Left w/o Decals - Black (inc. 3) Foam, Upper Side Panel - Right Foam, Upper Side Panel - Left Foil, Protective X 2 Decal, Upper Side Panel Vent, Upper Side Panel - Front - Right Vent, Upper Side Panel - Front - Left Vent, Upper Side Panel - Rear - Right Vent, Upper Side Panel - Rear - Left X 1 Panel, Side - Lower - Right w/decals - Black (inc. 9-12) Panel, Side - Lower - Right w/o Decals - Black (inc ) Foil, Protective Foil, Protective X 1 Decal, Lower Side Panel - Right X 1 Foil, Protective Foil, Protective Foil, Protective Foil, Protective X 1 Panel, Side - Lower - Left w/decals - Black (inc ) New Qty Description Panel, Side - Lower - Left w/o Decals - Black (inc ) Foam, Lower Side Panel - Rear - Left Foam, Lower Side Panel - Front - Left X 1 Decal, Lower Side Panel - Left Screw, Cap Nut, Lock Screw, Cap Clamp, Wire Plate, Skid - Right Plate, Skid - Left Foil, Protective X 1 Foil, Protective Foil, Protective Foil, Protective Shield, Heat X 1 Shield, Heat Rivet Rivet Seal, Exhaust - Outlet Shield, Heat - Exhaust Outlet Screw, Self-Tapping Strap, Hold-Down Screw, Self-Tapping 22

25 Guard, Belt Decal, EFI Diagnostics Decal, Warning - Belt Guard X 1 Decal, Clutching Chart Hinge, Belt Guard - Front BELT GUARD ASSEMBLY Rivet Hinge, Belt Guard - Rear Rivet Pin, Belt Guard 23

26 GAS TANK ASSEMBLY New Qty Description Tank, Gas - Assembly (inc. 2-5) Knee Pad, Right Cap, Gas Tank - Assembly (inc. 3) Knee Pad, Left Seal, Gas Tank Cap Screw, Machine Valve, Check Screw, Shoulder Grommet Clip, U-Nut Clamp, Hose AR Tape, Foam - 1 ft AR Hose, Gasline ft AR Hose, Gasline - 50 ft 24

27 Screw, Self-Tapping Plate, Retaining - Fuel Pump Pump, Fuel - Assembly (inc. 4) Float Seal Pickup, Fuel - Assembly (inc. 7 and one No. 8) AR Hose, Gasline - 10 ft FUEL PUMP ASSEMBLY Clamp, Hose Fitting, Quick-Connect Hose, Gasline AR Conduit, Flexible - 5 ft Filter, Fuel Hose, Gasline AR Tie, Cable - 8 in AR Tie, Cable in. 25

28 Spar, Rear - Right - Black Spar, Rear - Left - Black Screw, Self-Tapping Screw, Shoulder Screw, Shoulder Nut, Lock Tube, Support SEAT SUPPORT ASSEMBLY New Qty Description Screw, Cap Clip, U-Nut Screw, Cap Plate, Support - Upper Rivet Bracket, Nut Holder Nut 26

29 Seat Assembly - Front (inc and two No. 15) Cover, Seat (inc. 3) Wire, Seat Foam, Seat Wire, Seat AR Staple Latch, Seat - Assembly (inc. 8-11) FRONT SEAT ASSEMBLY Lever, Seat Latch Cover, Seat Latch Clip, Spring Back, Seat Latch Plate, Backing Rivet Base, Seat Screw, Self-Tapping 27

30 REAR BUMPER, RACK RAIL, SNOWFLAP, AND TAILLIGHT ASSEMBLY X 1 Riser, Seat - Assembly Stud, Seat Nut Nut, Lock Washer Rivet Cable Screw, Self-Tapping Hinge, Seat-Base Seal Seal X 1 Kit, Tool Insert Screw, Machine X 1 Mount, Rack - Right X 1 Mount, Rack - Left New Qty Description Nut, Lock Screw, Machine Washer Snowflap Nut, Lock Bumper, Rear Decal, Warning - Towing (French) Decal, Warning - Towing (English) Screw, Machine Screw, Self-Tapping Clamp, Wire Taillight, LED Screw, Cap Washer Hitch, Pintle 28

31 STROBE AND WORK LIGHT ASSEMBLY X 1 Bar, Light Pin, Mounting X 4 Pad Screw, Machine X 1 Light, Strobe Nut, Lock X 1 Decal, Caution - Light Bar X 1 Shield, Work Light Screw, Self-Tapping X 1 Harness, Adapter - Switch/Light Switch, Light (inc. 12) Nut Nut, Lock X 1 Light, Work - Assembly (inc ) Nut Washer, Lock Nut, Lock Bolt, Carriage Bolt, Carriage X 1 Harness, Adapter - Strobe/Work Light X 1 Harness, Adapter - Groomer (inc ) Cover, Fuse Block Seal, Cover Holder, Fuse Fuse - 10 Amp Fuse - 15 Amp Fuse - 20 Amp Fuse - 30 Amp Relay (4-Pin) - 20 Amp Relay (5-Pin) - 30 Amp X 1 Decal, Fuse Block Tether, Accessory Connector Rivet X 1 Bracket, Mounting - PDM Nut, Lock Screw, Machine 29

32 COOLING ASSEMBLY Exchanger, Heat Clip, U-Nut Clip, U-Nut Screw, Machine Rivet Hose, Coolant - Engine/Heat Exchanger AR Conduit - 5 ft Screw, Cap Bracket, Coolant Hose Clamp, Hose Cap Neck, Filler Nut, Stamped Clamp, Hose AR Hose, Recovery - Green - 25 ft AR Hose, Recovery - Green ft Clamp, Hose Hose, Coolant - Bypass Hose, Coolant - Coolant Tank/Engine Hose, Coolant - Heat Exchanger Tie, Cable - Triple Cap, Coolant Tank Gasket New Qty Description Tank, Coolant (inc. 24) Fitting, Vent Screw, Cap Spacer Nut, Lock Screw, Cap AR Hose, Coolant - 25 ft AR Tie, Cable - 8 in Clamp, Hose Adapter, Hose Clamp, Hose Hose, Coolant - Adapter/Radiator AR Conduit, Flexible - 5 ft Radiator Sensor, Engine Coolant Temperature Bracket, Hold-Down - Rear Screw, Machine Bracket, Hold-Down - Front Right Bracket, Hold-Down - Front Left Rivet, Reinstallable Fan, Cooling Hose, Coolant - Radiator/Filler Neck 30

33 Engine, AA11L Belt, Drive X 1 Clutch, Drive - Uncalibrated Washer, High Collar Bolt, Clutch Mount, Engine - Rear Screw, Cap Nut, Lock Mount, Engine - Front Bracket, Mounting - Engine ENGINE AND RELATED PARTS Screw, Cap Washer, Lock Nut, Lock Washer X 1 Screw, Cap Adapter, Heater Element Element, Heater (WGUSO) Element, Heater (WGOSO) Harness, Heater Element (WGUSO) Harness, Heater Element (WGOSO) 31

34 EXHAUST ASSEMBLY New Qty Description X 1 Resonator Manifold, Exhaust Bushing Bracket, Exhaust Bracket, Mounting - Resonator Rivet Spring, Extension Bumper, Molded Gasket, Exhaust Washer Pipe, Exhaust Clip, Hairpin 32

35 Battery (inc. 2-3) Kit, Hardware Decal, Warning Screw, Cap Tray, Battery Screw, Machine Nut, Lock Screw, Cap AR Clamp, Wire Nut, Lock Bracket, Hold-Down - Battery Screw, Shoulder Nut, Wing Washer BATTERY AND TRAY ASSEMBLY Rod, Hold-Down - Battery AR Foil, Protective - 30 ft Shield, Heat X 1 Solenoid, Starter Relay Nut w/washer AR Tie, Cable - 8 in Cable, Battery/Solenoid (inc. 22) Boot, Terminal - Battery Cable, Battery/Ground Cable, Starter-to-Ground Cable, Solenoid/Starter (inc. 26) Boot, Terminal Screw, Cap w/washer 33

36 Intake, Support - Assembly (inc. 2-5) Intake, Support - Top Resonator, Top - Plenum Intake, Support - Bottom Screw, Self-Tapping Cover, Top Plenum - Right Cover, Top Plenum - Left Grommet Screw, Shoulder Washer Grommet Nut, Lock Foam, Air Silencer - Right Foam, Air Silencer - Left X 1 Silencer, Air - Assembly (inc ) AIR SILENCER ASSEMBLY New Qty Description X 1 Seal X 1 Bracket, Latch X 13 Screw, Machine X 1 Pin, Retaining AR Foil, Protective - 30 ft Fitting, Elbow Grommet Screw, Self-Tapping Screw, Machine Grommet Fitting, Elbow AR Hose - Green - 25 ft AR Hose - Green ft Boot, Dual Intake Clip, Retaining 34

37 Clamp, Hose Hose, Breather Tank, Separator Screw, Machine Bracket, Mounting Nut, Lock OIL SEPARATOR ASSEMBLY Screw, Cap Clamp, Hose Hose, Breather - Separator Clamp, Hose Clamp, Hose 35

38 Tank, Oil - Assembly (inc and two No. 11) Cap, Oil Tank (inc. 3) Seal Bushing, Flanged Grommet Screen, Oil Tank Plug, Drain (inc. 8) O-Ring Hose, Oil - Feed Hose, Oil - Return OIL TANK ASSEMBLY New Qty Description Clamp, Hose AR Conduit - 5 ft AR Conduit, Flexible - 5 ft O-Ring Fitting, Oil Supply - Engine Screw, Cap Fitting, Oil Return - Engine Screw, Machine Clamp, Hose Hose, Breather - Oil Tank Clamp, Hose 36

39 X 1 Clutch, Drive - Uncalibrated (inc. 2-4) Screw, Shoulder Washer, Lock Spring, Drive Clutch - Black/White Spring, Drive Clutch - Black/Gold - Over 9,000 ft Alt Kit, Cam Arm (inc. 6-9) DRIVE CLUTCH Nut, Lock O-Ring Screw, Set Pin, Cam Arm Arm, Cam (inc. 8) X 3 Arm, Cam (inc. 8) - Over 9,000 ft Alt. 37

40 X 1 Clutch, Driven - Assembly Bracket, Torque 36 (inc. 2-3) Ring, Snap Bearing Seat, Spring - Driven Clutch Spring, Driven Clutch - Orange Spacer DRIVEN CLUTCH New Qty Description Seat, Spring Pin, Cam Roller X 3 Roller, Cam Pin, Spring Roller, Cam Retainer, Torque Bracket (inc. 13) Screw, Machine 38

41 Head, Cylinder - Assembly (inc. 2-3 and four No. 4) Guide, Valve Screw, Cap Pin, Dowel Gasket, Cylinder Head Screw, Cap Gasket Screw, Cap Washer Screw, Cap Bolt, Stud Nut CYLINDER HEAD ASSEMBLY Gasket Plug, Oil Pin, Dowel Fitting, Hose Cover, Cylinder Head Gasket, Cover Gasket Screw, Machine Washer Plug, Spark (MR8AI-9) Bracket, Harness Coil, Ignition Screw, Cap 39

42 Crankcase Assembly (inc. 2) Pin, Dowel Bolt, Stud Bolt, Stud Gasket Plug, Drain Gasket, Oil Plug Plug, Oil Gasket, Oil Plug Plug, Oil Gasket, Oil Plug Plug, Oil O-Ring, Crankcase Screw, Cap CRANKCASE ASSEMBLY New Qty Description Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Plate, Oil Separator - Right Plate, Oil Separator - Left Screw, Cap Screw, Cap Fitting, Hose Gasket O-Ring Jet, Piston Cooling 40

43 Cover (inc. 2-3) Screw, Cap Gasket Gasket, Cover Pin, Dowel Screw, Cap MAGNETO COVER Gasket Plug, TDC Plug, Crankshaft Hole O-Ring Gasket, Oil Plug Plug, Oil 41

44 PISTON AND CRANKSHAFT ASSEMBLY Piston Ring Set, Piston Pin, Piston Circlip, Piston Connecting Rod - Assembly (inc. 6-7) Screw, Cap Pin, Alignment Bearing, Crankshaft Pin - Green Bearing, Crankshaft Pin - Black Bearing, Crankshaft Pin - Brown Bearing, Crankshaft Pin - Yellow Crankshaft New Qty Description Bearing, Thrust - Green AR Bearing, Thrust - Green AR Bearing, Thrust - Red AR Bearing, Thrust - Black AR Bearing, Thrust - Blue AR Bearing, Thrust - Yellow AR Bearing, Thrust - White Bearing, Crankshaft - Green Bearing, Crankshaft - Black Bearing, Crankshaft - Brown Seal, Oil 42

45 Limiter, Starter Idler Gear Gear, Starter Idler - No Clutch, Starter - One-Way Pin, Starter Idler STARTER CLUTCH ASSEMBLY Gear, Starter Clutch Screw, Machine Spacer Spacer, Idler Gear No. 2 43

46 CRANK BALANCER ASSEMBLY New Qty Description Balancer, Crank - No Plug, Crank Balancer Balancer, Crank - No Bearing, Crank Balancer - Green Bearing, Crank Balancer - Black Bearing, Crank Balancer - Brown 44

47 CAM CHAIN ASSEMBLY Guide, Cam Chain - No Guide, Cam Chain - No Chain, Cam Tensioner, Cam Chain Screw, Shoulder Washer Adjuster, Tensioner - Assembly (inc. 8-9) Spring Ball Gasket Bolt, Adjuster Washer Screw, Cap 45

48 Camshaft, Intake Camshaft, Exhaust Tappet AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm CAMSHAFT/VALVE ASSEMBLY New Qty Description Valve, Intake Valve, Exhaust Spring, Valve Retainer, Valve Spring Cotter, Valve Seat, Valve Spring Seal, Valve Stem 46

49 EXHAUST MANIFOLD GASKET/INTAKE FLANGE ASSEMBLY Flange, Intake O-Ring Screw, Cap Clamp, Intake Flange Clamp, Air Silencer Gasket, Exhaust Manifold Bolt, Stud Nut 47

50 OIL PAN ASSEMBLY New Qty Description Gasket, Oil Pan Plug, Drain Pan, Oil Plate, Oil Pan Screw, Cap Screw, Cap Screw, Cap Fitting Gasket Gasket Plug, Drain Clamp, Hose Gasket Hose, Drain 48

51 Pump, Oil - Feed Screw, Cap Pump, Oil - Scavenge Screw, Cap Screw, Cap Pin, Dowel Seal, Oil Gear, Driven Washer OIL PUMP ASSEMBLY Pin Circlip Valve, Oil-Relief Seat, Oil-Feed Check Valve Spring, Oil-Feed Check Valve Ball, Oil-Feed Check Valve Filter, Oil Strainer, Oil 49

52 OIL COOLER ASSEMBLY New Qty Description Bolt, Union Hose, Inlet Cooler, Oil Hose, Outlet Washer Clamp, Hose O-Ring 50

53 Pump, Water - Assembly (inc. 2-9) Impeller/Shaft Seal, Mechanical Bearing Seal, Oil WATER PUMP ASSEMBLY O-Ring O-Ring Screw, Machine E-Ring Screw, Cap 51

54 WATER HOSE ASSEMBLY New Qty Description Thermostat Clamp, Hose - No Cap, Thermostat (U.S.) Clamp, Hose - No Screw, Cap Clamp, Hose - No Hose, Inlet Clamp, Hose Hose, Bypass - No Fitting, Hose Hose, Bypass - No O-Ring Hose, Bypass - No Screw, Cap Fitting, Hose Clip, Retaining 52

55 Body, Throttle - Assembly (inc. 2-18) Injector, Fuel - Assembly (inc. 3-4) O-Ring O-Ring Screw, Machine Rail, Fuel Clamp, Hose Screw, Stop (inc. 9) Nut Sensor, Throttle - Assembly (inc. 11) O-Ring Screw, Machine Valve, ISC - Kit Screw, Machine Screw, Machine THROTTLE BODY ASSEMBLY Fitting Hose Hose Sensor, Oxygen Switch, Oil Pressure Sensor, Boost/Air Pressure (inc. 22) Cover Tie, Cable - Triple Sensor, Air/Water Temperature Gasket Sensor, Cam Position Screw, Cap Protector, Cam Position Sensor Conduit - 5 ft X 1 ECU 53

56 Complete Starter Motor Assembly Screw, Cap Brush Assembly Screw, Cap O-Ring Armature Assembly (inc. 6) STARTER MOTOR ASSEMBLY New Qty Description Ring, Snap Plate, Locking Shim Housing - Assembly (inc. 10) Seal, Oil O-Ring 54

57 Stator Rotor/Flywheel Screw, Cap Washer Screw, Cap MAGNETO ASSEMBLY Screw, Cap Clamp, Lead Wire Screw, Cap Key 55

58 Ref. Part No. Qty. Description Ref. Part No. Qty. Description Printed in U.S.A. p/n