700 DIESEL EFT MODEL NUMBER A2008TBT4DETI (RED) MODEL NUMBER A2008TBT4DETM (GREEN) (VADA7D4AV80X VADA7D4AV80X10493) MORE TO GO ON.

Transcription

1 DIESEL EFT MODEL NUMBER A2008TBT4DETI (RED) MODEL NUMBER A2008TBT4DETM (GREEN) (VADA7D4AV80X VADA7D4AV80X10493) MORE TO GO ON. TM

2 TABLE OF CONTENTS 2008 ATV 700 Diesel EFT Red (Model No. A2008TBT4DETI) Green (Model No. A2008TBT4DETM) FRONT RACK AND HEADLIGHT ASSEMBLIES... 1 REAR RACK AND FOOTWELL ASSEMBLIES... 2 FRAME AND RELATED PARTS... 3 WINCH ASSEMBLY... 4 LICENSE PLATE HOLDER ASSEMBLY... 5 SEAT AND BACKREST ASSEMBLY... 6 STEERING POST ASSEMBLY... 7 HANDLEBAR ASSEMBLY... 8 FRONT SUSPENSION ASSEMBLY... 9 REAR SUSPENSION ASSEMBLY WHEEL AND TIRE ASSEMBLY AUXILIARY BRAKE ASSEMBLY PARKING BRAKE ASSEMBLY HYDRAULIC HAND BRAKE ASSEMBLY HYDRAULIC BRAKE ASSEMBLY FUEL TANK ASSEMBLY SHIFT LEVER ASSEMBLY AIR INTAKE ASSEMBLY BATTERY ASSEMBLY ENGINE AND EXHAUST COOLING ASSEMBLY CASE/BELT COOLING ASSEMBLY DRIVE TRAIN ASSEMBLY FRONT DRIVE GEARCASE ASSEMBLY REAR DRIVE GEARCASE ASSEMBLY WIRING HARNESS ASSEMBLY CLUTCHES AND V-BELT ASSEMBLIES TRANSMISSION RIGHT-SIDE ASSEMBLY TRANSMISSION LEFT-SIDE ASSEMBLY... 29,30 CRANKSHAFT ASSEMBLY PISTON SET AND CONNECTING ROD ASSEMBLY FLYWHEEL AND CROWN GEAR ASSEMBLY DRIVE PULLEY AND ALTERNATOR BELT ASSEMBLY CRANKCASE, CRANKSHAFT SUPPORT, AND OIL FILTER ASSEMBLIES CYLINDER HEAD AND PRECOMBUSTION CHAMBER ASSEMBLY PTO VACUUM PUMP ASSEMBLY ROCKER ARM COVER AND BREATHER SYSTEM ASSEMBLIES FUEL SYSTEM INJECTION PUMP ASSEMBLY CAMSHAFT AND FUEL PUMP DRIVE ECCENTRIC CAM PULLEYS, TIMING BELT, AND SPEED GOVERNOR ASSEMBLY ROCKER ARM, VALVES, AND OIL SWITCH ASSEMBLIES EXHAUST MANIFOLD ASSEMBLY EGR SYSTEM ASSEMBLY THERMOSTAT, WATER INLET FLANGE, AND OIL LEVEL STICK ASSEMBLIES OIL PUMP ASSEMBLY OIL PAN ASSEMBLY THROTTLE CONTROL AND LOCKED TORQUE DEVICE ASSEMBLIES FUEL FILTER, ELECTRO-VALVE, AND HOSES ASSEMBLY FUEL FEED PUMP AND PUSH ROD ASSEMBLIES WATER PUMP ASSEMBLY INTAKE MANIFOLD AND THROTTLE CONTROL ASSEMBLY EXTERNAL ALTERNATOR ASSEMBLY STARTER MOTOR ASSEMBLY BELT GUARD ASSEMBLY CONTROL SWITCH HOUSING ASSEMBLY THROTTLE CASE 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. Underlined part numbers are new for the 2008 model year. For a complete list of related items, refer to the current accessory catalog Arctic Cat Inc. Printed April 2008 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

3 FRONT RACK AND HEADLIGHT ASSEMBLIES Rack - Front - Assembly (inc. 2-5) Decal, Warning - Front Rack Load Bushing, Rack Bushing, Rack Plug, Rack Screw, Cap Spacer Grommet Nut, Lock Screw, Shoulder Washer Nut, Lock Rivet, Reinstallable Cover, Access Rivet, Reinstallable Cover, Steering Post Cover, Storage Box Lid, Storage Box w/latch (inc ) Lid, Storage Box Latch, Storage Box Panel, Side - Lower - Right Panel, Side - Lower - Left Screw, Body Panel, Splash - Right Panel, Splash - Left Screw, Self-Tapping AR Tie, Cable in Headlight Assembly - Right (inc ) Headlight Assembly - Left (inc ) Bulb, Headlight Retainer, Spring Boot, Rubber Bulb, Turn Signal Socket, Turn Signal Bulb Socket, Position Bulb Bulb, Position Stud, Adjuster - Headlight Spring, Adjuster Knob, Adjuster Screw, Self-Tapping Washer Grommet Decal, Front Decal, Side - Upper Right Decal, Side - Upper Left Panel, Fender - Front - Red Panel, Fender - Front - Green (Green) Decal, Reflector - Right Decal, Reflector - Left Decal, Speedrack 1

4 REAR RACK AND FOOTWELL ASSEMBLIES Rack - Rear - Assembly (inc. 2-6) Pin - Assembly (inc. 3-5) Pin, Roll Collar Spring Bushing, Rack Screw, Cap Spacer Grommet Nut, Lock Washer Screw, Shoulder Bracket, Rear Fender - Right Bracket, Rear Fender - Left Washer Nut, Lock Screw, Body Screw, Machine Footwell, Rear - Right Footwell, Rear - Left Footwell - Right Footwell - Left Screw, Shoulder Footpeg Screw, Machine Screw, Self-Tapping Panel, Splash Bushing, Splash Panel Washer Screw, Cap Taillight Assembly - Right (inc ) Taillight Assembly - Left (inc ) Bulb, Turn Signal Bulb, Taillight Socket, Taillight - Assembly - Right Socket, Taillight - Assembly - Left Bezel, Taillight - Right Bezel, Taillight - Left Screw, Machine Nut, U-Clip Panel, Fender - Rear - Red Panel, Fender - Rear - Green (Green) Decal, Reflector - Rear - Right Decal, Reflector - Rear - Left Decal, Warning - Tire Pressure 2

5 FRAME AND RELATED PARTS Frame, Main Screw, Cap Channel, Bumper Mounting - Right Channel, Bumper Mounting - Left Bracket, Mounting - Bumper - Right Bracket, Mounting - Bumper - Left Screw, Cap Bumper Grille, Bumper Screw, Machine Screw, Body Nut, Lock Brace, A-Arm Screw, Cap Panel, Belly Pad, Frame Nut, Flange Screw, Cap Footrest - Right Footrest - Left Strap, Footrest - Right Strap, Footrest - Left Channel, Shock Support Screw, Machine Nut w/washer Bracket, Mounting - Horn Horn, Electric - 12V Mount, Ball Hitch Kit, Ball Hitch Bolt Nut, Lock Decal, Warning - Towing 3

6 WINCH ASSEMBLY Winch (inc. 2-3) Cable, Winch Decal, Warning Washer, Lock Screw, Cap Hook, Winch w/strap - Assembly (inc. 7-9) Hook, Winch w/strap Pin Cotter Pin Roller, Winch Screw, Machine AR Tie, Cable in Cable, Winch/Solenoid - Yellow Cable, Winch/Solenoid - Blue Nut w/washer Cable, Solenoid/Battery - Black Cable, Solenoid/Battery - Red Boot, Terminal Solenoid Screw, Machine Switch, Winch - Assembly (inc ) Bracket, Winch Switch Washer, Lock - Internal Tooth Screw, Machine Washer, Lock - External Tooth Harness, Adapter - Solenoid 4

7 LICENSE PLATE HOLDER ASSEMBLY *Not a Service Part Holder, License Plate Light, License Plate (inc. 3-4) 3 * 2 Screw, Self-Tapping Bulb Screw, Self-Tapping Nut, Lock Washer Screw, Machine 5

8 SEAT AND BACKREST ASSEMBLY Seat Assembly (inc. 2-9) Cover, Seat Foam, Seat Base, Seat - Assembly (inc. 5-6) Bumper, Seat - Rear Bumper, Seat - Front AR Staple Spring, Seat Latch Latch, Seat Seat, Passenger - Assembly (inc. 7 and 11-21) Seat, Passenger - Sub-Assembly (inc. 7 and 12-14) Foam, Seat - Passenger Cover, Seat - Passenger Base, Seat - Inner Base, Seat - Passenger Decal, Arctic Cat - White Bracket, Seat Support - Assembly Handhold, Passenger - Right Handhold, Passenger - Left Screw Nut, Hex Nut, Lock Backrest Assembly (inc ) Foam, Backrest Cover, Backrest Screw Wrench, Spanner 6

9 STEERING POST ASSEMBLY *Not a Service Part Screw, Cap Cap, Steering Adjuster Screw, Shoulder Cap, Housing Housing, Lower Housing, Upper Post, Steering Screw, Cap Lock, Steering - Assembly (inc ) Latch Lock Bracket, Mounting - Lock Flange, Bearing Bearing w/inverted Oil Seal Washer Screw, Cap Tie Rod - Assembly (inc ) End, Tie Rod - Left-Hand Thread - Kit (inc and two No ) 19 * 2 End, Tie Rod - Left-Hand Thread Nut - Left-Hand Thread Tie Rod End, Tie Rod - Right-Hand Thread - Kit (inc and two No ) 23 * 2 End, Tie Rod - Right-Hand Thread Nut - Right-Hand Thread Nut, Lock Pin, Cotter 7

10 HANDLEBAR ASSEMBLY Tube, Handlebar Plug, Handlebar End Cap, Handlebar Washer Screw, Machine Grip, Handlebar Switch, Ignition - Assembly (inc. 8-10) Nut, Flange - Ignition Switch Key, Ignition (Y Series - Left-Side Cut) Key, Ignition (Z Series - Right-Side Cut) Cover, Key Instrument Pod Instrument Pod (Green) Outlet, Accessory - 12V Gauge, LCD Light, Indicator - Glow Plug Light, Indicator - Battery Bracket, Mounting - Instrument Pod Rivet, Reinstallable Clamp, Plastic Nut w/washer Mirror - Right Mirror - Left Decal, Warning - Brake Lever Lock Control, Differential Lock (inc. 23) Clamp, Differential Lock Control - Kit Cable, Differential Lock Cable, Throttle Decal, Instrument Pod Decal, Warning - Differential Lock 8

11 FRONT SUSPENSION ASSEMBLY Shock Absorber - Front (inc. 2) Bushing, Double-Bonded Cam, Spring Adjuster Spring, Shock Absorber - Platinum Retainer, Spring Screw, Cap Nut, Lock A-Arm, Upper Right - Platinum (inc. 9-12) A-Arm, Upper Left - Platinum (inc. 9-12) Bushing Collar Clip, Ball Joint Ball Joint - Front A-Arm, Lower Right - Platinum (inc and two No ) A-Arm, Lower Left - Platinum (inc and two No ) Bushing Collar Knuckle - Assembly - Right (inc ) Knuckle - Assembly - Left (inc ) Bearing, Wheel Hub Ring, Retaining Screw, Cap Screw, Cap Screw, Cap Axle, Drive - Front - Left (inc ) Axle, Drive - Front - Right (inc ) Clip, Retaining Repair Kit, Boot Guard, Boot - Right - Red Guard, Boot - Left - Red Guard, Boot - Right - Green (Green) Guard, Boot - Left - Green (Green) Screw, Body 9

12 REAR SUSPENSION ASSEMBLY Knuckle - Assembly - Right (inc. 2-5) Knuckle - Assembly - Left (inc. 2-5) Bearing, Wheel Hub Ring, Retaining Collar, Suspension Bushing Bushing, Suspension A-Arm, Rear - Lower Right - Platinum (inc. 7-8) A-Arm, Rear - Lower Left - Platinum (inc. 7-8) Bushing Collar Nut, Lock Screw, Cap A-Arm, Rear - Upper Right - Platinum (inc. 7-8) A-Arm, Rear - Upper Left - Platinum (inc. 7-8) Guard, Boot - Right - Red Guard, Boot - Left - Red Guard, Boot - Right - Green (Green) Guard, Boot - Left - Green (Green) Screw, Body Screw, Cap Axle, Drive - Rear (inc ) Clip, Retaining Repair Kit, Boot Tie, Cable Retainer, Spring Spring, Suspension - Platinum Cam, Spring Adjuster Shock Absorber - Rear (inc ) Bushing, Double-Bonded Bushing, Shock Absorber Sleeve, Shock Absorber Washer Screw, Cap Screw, Cap 10

13 WHEEL AND TIRE ASSEMBLY Screw, Shoulder w/loctite Disc, Brake Hub, Wheel - Front (inc. 4) Stud, Wheel Hub Hub, Wheel - Rear - Left (inc. 4) Hub, Wheel - Rear - Right (inc. 4) Nut, Castle Pin, Cotter Wheel - Front - Platinum Wheel - Rear - Platinum Nut, Mounting - Wheel Tire - Front Tire - Rear Stem, Valve (inc. 12) Cap, Valve Stem 11

14 AUXILIARY BRAKE ASSEMBLY Lever, Brake O-Ring Washer Screw, Cap Spring, Brake Lever Spring, Brake Switch Master Cylinder Hose, Brake Washer, Crush Bolt, Banjo-Fitting Bolt, Banjo-Fitting - Double Hose, Brake Clip, Brake Hose AR Tie, Cable in Caliper, Brake (inc ) Housing, Caliper - Assembly - Left Rear (inc and 23) Piston/Seal Set (inc. 18) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Screw, Cap Bracket, Switch Screw, Cap Pin, Clevis Pin, Cotter Washer 12

15 PARKING BRAKE ASSEMBLY Lever, Parking Brake - Assembly (inc. 2-5) Kit, Parking Brake Lever Assembly Kit, Handlebar Clamp Kit, Thumb Nut Adjuster Kit, Parking Brake Lever Lock Cable, Brake - Rear Mechanical Brake Assembly Pad, Brake Screw, Cap Wire Form, Cable 13

16 HYDRAULIC HAND BRAKE ASSEMBLY Brake Assembly (inc. 2-10) Screw, Reservoir Cover Cover, Reservoir Screw, Master Cylinder Clamp Clamp, Master Cylinder Master Cylinder Assembly Lever Assembly (inc. 8-9) Lock, Brake Lever - Kit Lever Pin - Kit Switch, Brake Washer, Crush Bolt, Banjo-Fitting 14

17 HYDRAULIC BRAKE ASSEMBLY Hose, Brake - Assembly Screw, Cap Screw, Cap Caliper, Brake - Right Front (inc and two No. 3) Caliper, Brake - Left Front (inc and two No. 3) Housing, Caliper - Assembly - Right Front (inc. 6-8 and two No. 3) Housing, Caliper - Assembly - Left Front (inc. 6-8 and two No. 3) Piston/Seal Set (inc. 7) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Washer, Crush Bolt, Banjo-Fitting Nut, Lock 15

18 FUEL TANK ASSEMBLY Tank, Fuel - Assembly (inc. 2-6) Cap, Fuel Tank Sensor, Fuel Level (inc. 4) Seal, Fuel Level Sensor Plate, Mounting - Fuel Level Sensor Screw, Plastite Clamp, Hose AR Hose, Fuel - 25 ft Clamp, Hose Clamp, Hose AR Hose, Fuel - 25 ft Fitting, T AR Hose, Fuel - 25 ft Clamp Screw, Mounting - Fuel Tank Grommet Shield, Fuel Tank Screw, Self-Tapping 16

19 SHIFT LEVER ASSEMBLY Knob, Shift Lever Clip, Push Plate, Shift Nut, Stamped Lever, Shift Spring, Shift Lever Axle, Shift Lever Nut O-Ring Axle, Pivot O-Ring Screw, Cap Washer Nut, Hex Pin, Mounting - Shift Linkage Bushing, Shift Linkage Washer E-Ring Linkage, Shift - Assembly (inc ) Nut, Hex - Left-Hand Thread Nut, Hex - Right-Hand Thread 17

20 AIR INTAKE ASSEMBLY Diverter, Air - Top Diverter, Air - Bottom Shroud, Splash Rivet, Reinstallable Clamp, Boot Duct, Air Intake Clamp, Boot Duct, Engine Intake Filter, Air - Assembly (inc ) Cap, Air Filter Element, Air Filter - Main Element, Air Filter - Safety Bracket, Mounting - Air Filter Element Screw, Bracket Washer Bracket, Mounting - Air Filter Screw, Machine 18

21 BATTERY ASSEMBLY *Not Illustrated Battery Cover/Tool Tray Assembly (inc. 2-3) Cover, Battery Pad, Battery * Kit, Tool Screw, Machine Nut, Wing Washer Strap, Battery - Top Pad, Battery Strap, Battery - Side Battery Decal, Storage 19

22 ENGINE AND EXHAUST Engine Mount, Engine - Rubber Screw, Cap Nut, Lock Mounting, Bracket - Engine Screw, Cap Screw, Cap Nut Gasket, Exhaust Manifold Pipe, Exhaust - Assembly (inc ) Shield, Exhaust Pipe - Lower Shield, Exhaust Pipe - Upper Pipe, Exhaust Hose Clamp Spring Seal, Exhaust Channel, Muffler Support (inc. one No. 18) Bushing Muffler (inc ) Gasket, Spark Arrester Arrester, Spark Screw, Cap Cover, Muffler Screw, Machine Gearcase - Assembly Bracket, Mounting - Engine - Right Bracket, Mounting - Engine - Left Screw, Cap Washer, Engine Mount Screw, Cap Plate, Mounting - Engine/Transmission Screw, Cap Screw, Cap Bracket, Mounting - Engine - Front Mount, Engine - Rubber Nut Washer, Flat 20

23 COOLING ASSEMBLY Radiator Assembly (inc. 2-11) Radiator Screen, Radiator Grommet Shroud, Fan Clip, U-Nut Screw Fan, Cooling Nut, Hex Switch, Cooling Fan O-Ring Bushing, Stem Nut w/washer Screw, Shoulder Clamp, Hose Hose, Coolant Tank, Coolant Overflow Tie, Cable AR Hose - 25 ft Stopper, Coolant Tank Clamp, Hose AR Hose - 25 ft Cap, Radiator Tank, Coolant Fill Clamp Hose, Coolant - Coupler Hose, Coolant Tie, Cable 21

24 CASE/BELT COOLING ASSEMBLY Duct, Belt Cooling - Front Clamp, Plastic Screw, Self-Tapping Fan, Belt Cooling Screw, Machine Nut, Hex Clamp, Boot Boot, Belt Cooling - Inlet Clamp, Plastic Cover, Clutch Washer, Crush Screw, Cap Gasket, V-Belt Cover Dowel, Split Screw, Machine Screw, Machine Screw, Self-Tapping Cover, Clutch Gasket, Gearcase Gasket, Clutch Cover Boot, Belt Cooling - Outlet Clamp, Boot Valve, Drain Screw, Self-Tapping Duct, Belt Cooling - Rear Tie, Cable 22

25 DRIVE TRAIN ASSEMBLY Bladder, Gearcase Clamp, Fitting Nut, Lock Washer Screw, Cap Gearcase, Front Boot, Shaft Plate, Cable Screw, Self-Tapping Gearcase, Rear AR Hose, Vent Tie, Cable Fitting, Vent Hose Clamp, Boot Boot Clamp, Boot Bumper, Propeller Shaft Shaft, Propeller Screw, Cap Flange, Output Spring Shaft, Propeller Screw, Cap 23

26 FRONT DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n ) Yoke, Flange Joint, Universal - Set (inc. 3) Retainer Yoke, Front End - Assembly Seal Ring, Retaining Actuator (inc. one No. 8) O-Ring Screw, Self-Tapping Bracket, Actuator Bearing Screw, Self-Tapping Housing, Pinion Gasket, Flange Ring, Retaining Shaft, Selector Fork, Selector Shaft, Shuttle Ring, Retaining O-Ring Spring, Return Coupler, Drive Collar, Lock Gear, Pinion - Assembly - 10T (inc ) Collar, Retaining Bearing Bearing Housing, Gearcase Pin, Dowel Seal Plug, Magnetic (inc. one No. 32) O-Ring O-Ring Bearing AR Shim AR Shim AR Shim AR Shim AR Shim Gear, Ring - 36T AR Shim AR Shim AR Shim AR Shim AR Shim Cover, Gearcase (inc. one No. 30, one No. 32, and 39-54) Bearing Flange, Bearing Pin, Parallel Collar, Sliding Fork Ring, Retaining Spring Fitting Switch, Indicator Spring Shaft, Lock Seal O-Ring Washer Ring, Retaining Plug, Oil Level (inc. one No. 32) Plug, Fill (inc. 56) O-Ring 24

27 REAR DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n ) Housing, Gearcase Bearing Seal Gear, Ring - 36T AR Shim AR Shim AR Shim AR Shim AR Shim Button, Thrust AR Shim AR Shim AR Shim AR Shim AR Shim O-Ring Cover, Gearcase Plug, Fill (inc. 11) O-Ring Fitting Screw, Self-Tapping Plug, Magnetic (inc. one No. 15) O-Ring Bearing Gear, Pinion - Assembly - 10T (inc ) Bearing Collar, Retaining Pin, Dowel Collar, Lock Washer, Wave Collar, Shaft Gasket, Flange Housing, Pinion Ring, Retaining Bearing Ring, Retaining Seal Shaft, Input Plug, Oil Level (inc. one No. 15) 25

28 WIRING HARNESS ASSEMBLY Harness, Main (inc. 2-8) Tether, Accessory Connector Cover, Fuse Block Holder, Fuse Relay (5-Pin) - 20 Amp Relay (4-Pin) - 20 Amp Fuse - 10 Amp Fuse - 15 Amp Fuse - 30 Amp Decal, Fuse Block Flasher (3-Pin) AR Tie, Cable in Switch, Brake - Assembly Cable, Battery/Ground Solenoid Screw, Machine Nut w/washer Boot, Terminal Cable, Battery - Assembly Boot, Terminal Tray, Electrical Screw, Machine Rivet, Reinstallable Screw, Machine Nut, Hex Relay, Glow Plug Wire, Glow Plug Plug, Glow Nut Washer Boot, Terminal 26

29 CLUTCHES AND V-BELT ASSEMBLIES Pulley, Driven - Assembly (inc 2-10) Face, Driven - Movable (inc. 3-4) Screw, Cam Shoe, Cam Ring, Retaining Cam Spring Shim Key Face, Driven - Fixed Washer Nut, Driven Pulley V-Belt Pulley, Drive - Assembly (inc ) Nut, Hex Washer, Lock Plate, Movable Drive Face Damper, Movable Drive Face Face, Drive - Movable Block, Weight - Assembly (inc ) Weight Block, Weight Spring Stopper Seat, Spring Face, Drive - Fixed Washer Bolt, Hex 27

30 TRANSMISSION RIGHT-SIDE ASSEMBLY Housing, Gearcase - Set Screw, Cap Housing, Secondary Output Shaft Bearing Dowel, Split Bearing, Secondary Output Shaft Washer, Thrust Shaft, Reverse Idle Bushing, Reverse Idle Gear Gear, Reverse Idle Dowel, Split Shaft, Output - Secondary Bearing, Output - Secondary Shaft Ring, Retaining Gear, Driven - No. 2 (42T) AR Shim, 24 x 48 x AR Shim, 24 x 48 x AR Shim, 24 x 48 x AR Shim, 24 x 48 x Gear, Secondary Drive Washer, Thrust Nut, Hex Bearing Shaft, Input Bearing, Driveshaft Seal, Driveshaft Screw, Machine Switch, Gear Shift Position O-Ring Screw, Cap Screw, Cap Washer Shaft, Gear Shift - Assembly (inc ) Ring, Retaining Washer Spring, Cam - Gear Shift Cam, Reverse - Gear Shift C-Ring Cam, Forward - Gear Shift Shaft, Gear Shift Pin, Dowel Spring, Gear Shift Contact Contact, Gear Shift Washer, Thrust Bearing Bearing, Thrust - Roller Washer Gasket 28

31 TRANSMISSION LEFT-SIDE ASSEMBLY Bearing Washer, Thrust - Secondary Transmission Gear, Drive - No. 2 (18T) Countershaft (inc. 5-18) Ring, Retaining Dog, Reverse Gear Insert, Gear Washer, Secondary Transmission Gear, Reverse Driven Bearing Bushing Washer, Lock - Secondary Transmission Washer, Secondary Transmission Gear, Driven - Low (40T) Shim, Drive Gear Spacer Countershaft Dog, Sliding Driven Gear - High/Low Gear, Driven - High (30T) Washer Fork, Shift Shaft, Shift Fork Seal, Countershaft - Right Ring, External Retaining Trigger, Speedometer Sensor Washer, Thrust Ring, External Retaining Gasket, Odometer Drive Pin, Solid Dowel Housing, Speedometer Sensor Seal, Fastener Screw, Machine Sensor, Speedometer Screw, Machine Washer Stopper, Swing Arm - Cam Assembly Support, Cam Stopper Spring, Torsion - Cam Arm Washer Nut, Hex Flange Stop, Spring - Selector Washer Ring, Retaining Shaft, Sub - Gear Shift Gasket, Cover - Selector Cover, Selector - Gearcase Screw, Cap Seal, Sub - Gear Shift Arm, Selector Plate, Gear Shift Cam Screw, Cap Plug, Drain - Magnetic Gasket, Compression Fitting, Plug, Fill (inc. 55) O-Ring Yoke, Propeller Shaft Joint, Universal - Set (inc. 58) Ring, Retaining - Universal Joint Nut, Hex (Continued on Page 30) 29

32 TRANSMISSION LEFT-SIDE ASSEMBLY (Continued) Washer Yoke, Drive Output - Front Assembly Seal, Oil - Driven Shaft Bearing, Driven Shaft Shim, 25 x 34 x Shaft, Output - Secondary Gear, Secondary Driven Sleeve, Bearing - Output Shaft Bearing, Driven Gear Ring, Driven Bearing Flange, Output Joint - Assembly Level Stick, Lubricant Tube, Level Stick Grommet Bracket, Level Stick Tube O-Ring Screw, Self-Tapping 30

33 CRANKSHAFT ASSEMBLY Crankshaft Assembly (inc. 2-5) Plug Key Pin Key 31

34 PISTON SET AND CONNECTING ROD ASSEMBLY Piston - Set (inc. 2-4) Piston - Set (+0.50 mm) Piston - Set (+1.00 mm) Ring - Set Ring - Set (+0.50 mm) Ring - Set (+1.00 mm) Piston Pin Circlip Connecting Rod (inc. 6-7) Bushing Bolt Bushing Bushing (-0.25 mm) Bushing (-0.50 mm) 32

35 FLYWHEEL AND CROWN GEAR ASSEMBLY Flywheel (inc. 2) Gear, Crown Bolt Axle, Stub 33

36 DRIVE PULLEY AND ALTERNATOR BELT ASSEMBLY Belt Pulley Screw Screw 34

37 CRANKCASE, CRANKSHAFT SUPPORT, AND OIL FILTER ASSEMBLIES *Not a Service Part Crankcase (inc. 2-6, two No. 7, and 8-10) 2 * 1 Housing - Front 3 * 1 Housing - Center 4 * 1 Housing - Rear Gasket Screw Sleeve Pin, Tapered Plug Plug Pin, Lock Gasket Bearing Bearing (-0.25 mm) Bearing (-0.50 mm) Washer Washer (+0.10 mm) Washer (+0.20 mm) Gasket Plug Connector, Oil Filter Cartridge, Oil Filter Flange, Engine (inc ) Ring Screw Sensor, Engine Coolant Temperature Gasket 35

38 CYLINDER HEAD AND PRECOMBUSTION CHAMBER ASSEMBLY Cylinder Head (inc. 2-14) Plug Retainer Spring, Valve Washer O-Ring Plug Retainer Washer Bolt Guide, Valve Guide, Valve (+0.50 mm) Seat, Exhaust Valve Retainer, Valve Seat, Intake Valve Screw Washer Gasket, Head (1 small hole) Gasket, Head (2 small holes) Gasket, Head (3 small holes) Chamber, Precombustion Spacer Nut, Locking Bolt Brace, Lifting 36

39 PTO VACUUM PUMP ASSEMBLY O-Ring Flange, Vacuum Pump Screw Gasket Pump, Vacuum Screw Clamp Hose, Union Union 37

40 ROCKER ARM COVER AND BREATHER SYSTEM ASSEMBLIES Cap, Oil Filler (inc. 2) O-Ring Cover, Rocker Arm Gasket Connection Separator Screw Screw Clamp Hose, Connection Hose, Drain Valve, Suction Tube, Valve Clamp 38

41 *Not a Service Part FUEL SYSTEM INJECTION PUMP ASSEMBLY Pipe, Delivery (inc. 2-4) Screw Seal, Ring Seal, Delivery Pipe Valve, Bleed Gasket Spacer Spacer Spacer Spacer Spacer Spacer Spacer Spacer Spacer Spacer Spacer * 1 Spring, Pressure Drive Rod Spacer O-Ring Nozzle Nut Pump, Injection - Nozzle Stud Tappet O-Ring Gasket, Copper Arrester, Spark Filler Spring, Valve Gasket, Valve Valve, Delivery 24 * 1 Plunger, Injection O-Ring Sleeve Screw Spring, Tappet 29 * 1 Push Rod Circlip 31 * 1 Retainer, Lower Plate, Locking 39

42 CAMSHAFT AND FUEL PUMP DRIVE ECCENTRIC Camshaft Cam Sleeve Screw 40

43 CAM PULLEYS, TIMING BELT, AND SPEED GOVERNOR ASSEMBLY Pulley, Cam Driven Belt, Timing Washer Screw Pulley Stud Washer Nut Pulley, Cam Drive Camshaft Support (inc ) Ring, Seal Screw Bearing, Ball Seal, Oil Plate Screw Flyweight - Assembly Sleeve, Control (inc. 19) Sleeve Roller, Thrust (inc. 21) Washer, Thrust Rail, Injection Pump (inc ) Plate Plate Screw Washer Spring, Fuel Screw Lever, Governor - Assembly (inc ) Pin, Lever Seal Sleeve Journal Nut Screw Device, Min-Max 41

44 ROCKER ARM, VALVES, AND OIL SWITCH ASSEMBLIES Arm, Rocker - Assembly (inc. 2-11) Support Nut Screw Arm, Rocker - Intake/Exhaust Arm, Rocker - Injection Pump Nut Screw Shaft, Rocker Arm Plug Pin, Lock Washer Nut Stud, Bolt O-Ring Flange Screw Elbow, Pipe Switch, Oil Valve, Exhaust Valve, Intake 42

45 EXHAUST MANIFOLD ASSEMBLY Manifold, Exhaust w/front Outlet Stud Nut Stud Gasket, Exhaust Manifold 43

46 EGR SYSTEM ASSEMBLY *Not a Service Part Valve, EGR Gasket, EGR Valve Screw Clamp Screw Nut Pipe, Union Ring, Seal Hose, Union Hose, Union Clamp Screw Spacer Spacer Bracket Sheathing, Rubber Clamp Spacer 19 * 1 Screw 44

47 THERMOSTAT, WATER INLET FLANGE, AND OIL LEVEL STICK ASSEMBLIES Thermostat - Assembly (inc. 2-8) Screw Cover, Thermostat O-Ring Thermostat Body, Thermostat - Assembly Gasket Sensor/Thermistor, Engine Coolant Temperature Screw Gasket Gasket Flange Clamp Hose Clamp Screw Stick, Oil Level (inc. 18) Seal O-Ring Guard, Oil Level Stick 45

48 OIL PUMP ASSEMBLY *Not a Service Part Pump, Oil (inc. 2-10) Rotor, Oil Pump - Assembly Plug Gasket Spring, Pressure Valve Rod, Drive O-Ring 8 * 1 Plate Screw Gasket Bolt Screw Ring, Seal Screw 46

49 OIL PAN ASSEMBLY *Not a Service Part Pan, Oil - Assembly (inc. 2-5) 2 * 1 Pipe, Oil - Intake Screw 4 * 1 Pipe, Oil - Return 5 * 1 Pan, Oil Seal, Oil Seal, Oil Gasket Stud, Hollow Washer Clamp Screw Gasket Gasket Cover, Oil Pan Screw Gasket, Copper Plug 47

50 THROTTLE CONTROL AND LOCKED TORQUE DEVICE ASSEMBLIES *Not a Service Part Device, Locked Torque (inc. 2-3) 2 * 1 Nut Gasket Gasket, Copper Gasket, Copper Screw Washer Sensor, Cam Circlip Nut Washer Rod, Tie Lever, Throttle Control Circlip Pin Seal, Oil Bolt Washer Safety Plate Valve, Vacuum Bolt Screw Support Screw 48

51 FUEL FILTER, ELECTRO-VALVE, AND HOSES ASSEMBLY Hose, Fuel Washer, Crush Electro-Valve Cap, Filler Washer, Crush Bolt, Banjo-Fitting Gasket Banjo Fitting Hose, Fuel Fuel Filter - Assembly (inc. 11) Fuel Filter Hose, Fuel Bolt, Banjo-Fitting Bolt, Banjo-Fitting w/valve Bolt, Banjo-Fitting Nut, Lock Screw, Cap Clamp, Hose Clamp, Hose 49

52 FUEL FEED PUMP AND PUSH ROD ASSEMBLIES Bolt, Banjo-Fitting Washer, Crush Nut Washer Stud Pump Rod, Push O-Ring Banjo Fitting 50

53 WATER PUMP ASSEMBLY Pump, Water - Assembly Screw Screw Gasket 51

54 INTAKE MANIFOLD AND THROTTLE CONTROL ASSEMBLY Screw Manifold, Intake Gasket, Intake Manifold Lever, Internal Spring, Recovery Sleeve Screw Screw Screw Pin Lever, External Circlip O-Ring Flange, Intake Gasket Screw Washer Screw Nut Bolt 52

55 EXTERNAL ALTERNATOR ASSEMBLY Alternator Support, Alternator Nut Washer Bolt Washer Screw Bolt Nut Wire w/diode Clamp 53

56 STARTER MOTOR ASSEMBLY Motor, Starter Washer, Lock Nut Screw, Cap Gasket, Starter Motor 54

57 BELT GUARD ASSEMBLY Guard, Belt Screw Screw Plug Gasket 55

58 CONTROL SWITCH HOUSING ASSEMBLY Switch, Control - Assembly Cover, Switch Housing 56

59 THROTTLE CASE ASSEMBLY Case, Throttle - Assembly (inc. 2-9) Lever Screw, Cap Washer, Lock Washer Screw Nut Screw Cover, Throttle Case w/switch 57

60 Printed in U.S.A. p/n