Prowler XTZ Model Number U2013P4W1PUSU Model Number U2013P4W1POSU - International SHARE OUR PASSION.
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1 2013 Prowler XTZ Model Number U2013P4W1PUSU Model Number U2013P4W1POSU - International TM SHARE OUR PASSION.
2 TABLE OF CONTENTS 2013 Prowler XTZ (Model No. U2013P4W1PUSU) (Model No. U2013P4W1POSU - International) HOOD AND HEADLIGHT ASSEMBLY... 1 CONSOLE AND FLOOR PANEL ASSEMBLY... 2 CARGO BOX AND TAILGATE ASSEMBLY... 3 FRAME AND RELATED PARTS... 4 TILT FRAME ASSEMBLY... 5 SEAT ASSEMBLY... 6 ROPS AND TAILLIGHT ASSEMBLY... 7 DASH ASSEMBLY... 8 STEERING ASSEMBLY... 9 FRONT SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY SWAY BAR ASSEMBLY WHEEL AND TIRE ASSEMBLY FRONT BRAKE ASSEMBLY REAR AND PARKING BRAKE ASSEMBLY ACCELERATOR ASSEMBLY GAS TANK ASSEMBLY SHIFTER ASSEMBLY AIR INTAKE ASSEMBLY ENGINE AND EXHAUST COOLING ASSEMBLY DRIVE TRAIN ASSEMBLY FRONT DRIVE GEARCASE ASSEMBLY REAR DRIVE GEARCASE ASSEMBLY WIRING HARNESS ASSEMBLY BATTERY AND STARTER MOTOR ASSEMBLY THROTTLE BODY ASSEMBLY CYLINDER ASSEMBLY CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY CAM CHAIN ASSEMBLY CRANKCASE ASSEMBLY CRANKSHAFT AND PISTON ASSEMBLY STARTER CLUTCH ASSEMBLY OIL PUMP ASSEMBLY WATER PUMP ASSEMBLY TRANSMISSION ASSEMBLY SECONDARY TRANSMISSION ASSEMBLY GEAR SHIFTING ASSEMBLY SECONDARY DRIVE ASSEMBLY MAGNETO ASSEMBLY MAGNETO SIDE ENGINE COVERS CLUTCH SIDE ENGINE COVERS 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 2012 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
3 HOOD AND HEADLIGHT ASSEMBLY Hood - Assembly - Orange (inc. 2) Decal, Reflector - Right - Amber Decal, Reflector - Left - Amber Screen, Grille Clip, U Bracket, Hood AR Shim, Hood Screw, Cap Nut, Lock Pin, Hood Strap, Hold-Down Trim, Hood/Dash X 1 Decal, Hood - Prowler - Right X 1 Decal, Hood - Prowler - Left X 1 Decal, Hood - XTZ Right X 1 Decal, Hood - XTZ Left X 1 Decal, Arctic Cat Nut, Lock Louver - Right Louver - Left Screw, Shoulder Screw, Shoulder Storage, Under-Hood - Assembly (inc ) Box, Storage Seal, Storage Box Valve, Drain Cover, Access - Master Cylinder AR Trim, Dash Support Screw, Machine Nut Headlight Assembly - Right (inc. 28) Headlight Assembly - Left (inc. 28) Bulb, Headlight Stud, Adjuster Spring, Adjuster Knob, Adjuster Screw, Self-Tapping Washer Grommet 1
4 CONSOLE AND FLOOR PANEL ASSEMBLY Panel, Fender - Inner Clip, U-Nut Boot, Steering Rivet, Reinstallable AR Screw, Self-Tapping Cap, Reinforcement Panel, Side Screw, Machine Screw, Machine Latch, Side Restraint Nut, Lock Bracket, Support - Right Bracket, Support - Left Grommet Screw, Shoulder Washer Fender, Front - Right - Orange Fender, Front - Left - Orange Nut, Lock Bracket, Support Screw, Machine Screw, Machine Console - Front Net, Storage Insert, Cupholder New Qty Description Foam, Console Foam, Console Floor Screw, Shoulder Bracket, Side Panel - Right Bracket, Side Panel - Left Plug, Switch-Hole Switch, Reverse Override Panel, Switch-Mount Gate, Shift (inc. 33) Decal, Shift Gate Boot, Parking Brake Lever Console, Center Decal, Warning - Console Decal, Brake Lever Slide, Shift Gate Slide, Shift Panel, Splash - Right Panel, Splash - Left Nut Clip, U-Nut Fender, Rear - Lower - Right - Orange Fender, Rear - Lower - Left - Orange Bracket, Fender Support - Lower 2
5 CARGO BOX AND TAILGATE ASSEMBLY Tailgate Assembly - Black (inc. 2-9) Panel, Tailgate - Inner Shaft, Pivot - Tailgate Screw, Self-Tapping Brace, Tailgate Screw, Shoulder Latch, Tailgate - Assembly Bushing Panel, Tailgate - Outer - Black Decal, Box - Arctic Cat Screw, Machine Cable, Tailgate Washer Nut, Lock Screw, Machine Screw, Machine Striker, Tailgate - Right Striker, Tailgate - Left Nut Bolt, Carriage Plate, Retainer Nut Strip, Foam Box, Cargo - Black Decal, Warning - Cargo Bracket, Tailgate Foam, Cargo Box Foam, Cargo Box Nut, Lock Bracket, Cargo Box Latch Screw, Machine Panel, Box - Right - Black Panel, Box - Left - Black Decal, Reflector - Right - Red Decal, Reflector - Left - Red Screw, Self-Tapping X 1 Decal, Box - Right X 1 Decal, Box - Left Bracket, Fender Support - Right Bracket, Fender Support - Left Fender, Rear - Assembly - Upper Right - Orange (inc ) Fender, Rear - Assembly - Upper Left - Orange (inc ) Pad, Foam Strip, Foam Ring, Trim Decal, Warning - Pinch Point 3
6 Frame, Main (inc. 2) Bumper, Seat Screw, Cap Bracket, Seat Support - Rear Clip, U-Nut Nut, Lock Bracket, Seat Support - Front - Right Bracket, Seat Support - Front - Left Screw, Cap X 1 Support, Overhead - Right X 1 Support, Overhead - Left Screw, Machine Spacer Screw, Machine Decal, Warning - ROPS Support, ROPS Screw, Machine X 1 Support, Steering Screw, Cap FRAME AND RELATED PARTS New Qty Description Screw, Machine Bracket, Steering Support - Right Bracket, Steering Support - Left Nut Screw, Cap Bracket, Mounting - Bumper Nut, Lock Bumper Screw, Cap Screw, Machine Fascia, Bumper - Front Plate, Skid - Center Panel, Belly - Side Screw, Shoulder Plate, Skid - Side Screw, Self-Tapping Decal, Warning - Towing - Front Decal, Warning - Towing - Rear 4
7 Rod, Cargo Box Latch Grip, Latch Rod Bushing, Pivot Screw, Cap Frame, Box Nut, Lock Grommet Nut, Lock TILT FRAME ASSEMBLY Spring Screw, Shoulder Support, Lift Screw, Shoulder Cap, Housing Housing, Lower Housing, Upper 5
8 Panel, Seat - Assembly (inc. 2-6 and five No. 7) Clip, Retaining Panel, Seat - Front Right Panel, Seat - Front Left Panel, Seat - Rear Right Panel, Seat - Rear Left Seal, Seat Panel Screw, Machine Clip, U-Nut Screw, Self-Tapping Screw, Machine Base, Seat - Right Base, Seat - Left Cover, Access - Air Filter AR Foil, Protective Tool Kit - Assembly X 6 Screw, Cap SEAT ASSEMBLY New Qty Description X 2 Belt, Seat X 6 Nut, Lock Screw, Shoulder - Assembly (inc ) 18 2 Nut, Lock - Not a Service Part 19 2 Washer - Not a Service Part 20 2 Screw, Shoulder - Not a Service Part Cover, Seat Belt Seat, Low-Back Screw, Machine Plate, Base - Seat Bumper, Seat Screw, Machine Stud, Latch - Seat Latch - Assembly (inc. 298) Lever, Release - Seat Latch Nut w/washer Washer Nut 6
9 X 1 ROPS - Front Screw, Cap X 8 Nut, Lock Kit, Mirror Nut, Lock X 8 Screw, Cap X 1 Support, ROPS Decal, Arctic Cat X 1 ROPS - Rear Taillight Assembly (inc ) Socket, Taillight Bulb, Taillight Housing, Taillight Bracket, Taillight Mounting Screw, Self-Tapping Screw, Machine Nut, Lock Cover, Taillight Screw, Machine ROPS AND TAILLIGHT ASSEMBLY Pad, Headrest - Assembly (inc ) Pad, Headrest Mount, Headrest Clip, Retaining Bracket, Mounting - Flag Screw, Machine X 1 Panel, Side Restraint - Inner Right X 1 Panel, Side Restraint - Inner Left Screw, Machine X 1 Support, Side Restraint - Right X 1 Support, Side Restraint - Left X 2 Spacer X 1 Panel, Side Restraint - Outer Right X 1 Panel, Side Restraint - Outer Left X 1 Restraint, Side - Right X 1 Restraint, Side - Left X 4 Nut, Lock X 4 Screw, Shoulder 7
10 Panel, Dash Screw, Self-Tapping Plug Screw, Machine Decal, Starting Decal, Warning - Differential Lock Outlet, Accessory - 12V Switch, Ignition (inc. 9-11) Nut, Retaining Key, Ignition - Series (Y Series - Left-Side Cut) Key, Ignition - Series (Z Series - Right-Side Cut) Cover, Key DASH ASSEMBLY New Qty Description Grommet, Latch - Glove Box Cover, Glove Box (inc. 14) Decal, Warning - Passenger Panel, Switch-Mount Light, Indicator Switch, Light Switch, 2WD/4WD/Differential Lock Screw, Self-Tapping Pod, Instrument Decal, Warning - Dash Gauge, Analog/LCD Bracket, Retaining Nut w/washer 8
11 Cap, Steering Wheel (inc. 2) Decal, Steering Wheel Nut Wheel, Steering - Assembly Washer Washer Bushing Clip, Retaining Shaft, Upper Steering Screw, Cap Shaft, Steering - Assembly Screw, Cap Nut, Lock X 1 Assembly, Electronic Power Steering Bracket, Mounting Screw, Cap STEERING ASSEMBLY Screw, Cap Coupler, Steering Screw, Cap Nut, Lock Screw, Cap Washer Housing, Rack and Pinion (inc ) X 2 Tie Rod - Assembly (inc ) Plate, Retaining Kit, Tie Rod Boot (inc ) Tie, Cable in Pin, Cotter Kit, Nut (inc. 28) Kit, Tie Rod End (inc. 28) Nut 9
12 Retainer, Spring Spring, Suspension - White Shock Absorber (inc. 4) Sleeve, Shock - Threaded Nut, Spring Retainer Screw, Cap Nut, Lock A-Arm, Upper Right - Black (inc. 9-12) A-Arm, Upper Left - Black (inc. 9-12) Bushing Axle Ring, Retaining Ball Joint Screw, Self-Tapping Clamp, Routing Screw, Cap FRONT SUSPENSION ASSEMBLY New Qty Description A-Arm, Lower Right - Black (inc. 9-12) A-Arm, Lower Left - Black (inc. 9-12) Guard, Boot - Right - Black Guard, Boot - Left - Black Screw, Shoulder Axle - Front - Right (inc ) Axle - Front - Locking - Left (inc ) Repair Kit, Boot (inc. 21) Clip, Retaining Pin, Detent Clip, Retaining Knuckle - Assembly - Right (inc ) Knuckle - Assembly - Left (inc ) Bearing Ring, Retaining Screw, Shoulder 10
13 Retainer, Spring Spring, Suspension - White Shock Absorber (inc. 4) Sleeve, Shock - Threaded Nut, Spring Adjuster Screw, Cap Nut, Lock X 1 A-Arm, Rear - Upper Right - Black (inc. 9-10) X 1 A-Arm, Rear - Upper Left - Black (inc. 9-10) Bushing Axle A-Arm, Rear - Lower Right - Black (inc. 9-10) A-Arm, Rear - Lower Left - Black (inc. 9-10) REAR SUSPENSION ASSEMBLY Screw, Cap Screw, Cap Knuckle, Rear - Assembly (inc ) Bearing Ring, Retaining Axle Bushing Guard, Boot - Right - Black Guard, Boot - Left - Black Screw, Shoulder Axle, Drive (inc ) Repair Kit, Boot (inc. 23) Clip, Retaining Pin, Detent Clip, Retaining 11
14 SWAY BAR ASSEMBLY New Qty Description Bar, Sway Nut, Lock Clamp, Sway Bar Bushing Screw, Cap Bushing, Sway Bar - Upper Washer Bushing, Sway Bar - Lower Bushing Screw, Cap Spacer 12
15 Screw, Shoulder Disc, Brake - Front Disc, Brake - Rear Hub, Wheel - Front (inc. 4) Hub, Wheel - Rear (inc. 4) Stud Pin, Cotter Nut, Castle WHEEL AND TIRE ASSEMBLY X 2 Wheel - Front (inc. 8) X 4 Cap, Wheel Stem, Valve (inc. 10) Cap, Valve Stem Tire - Front Nut, Lug - Chrome X 2 Wheel - Rear (inc. 8) Tire - Rear 13
16 Cylinder, Master Brake - Assembly (inc. 2-4) Cap, Reservoir Nut Clevis Pin, Clevis Washer Pin, Cotter Nut Screw, Cap Washer, Crush Bolt, Double Banjo-Fitting Bolt, Banjo-Fitting Hose, Brake - Left Hose, Brake - Right Caliper, Brake - Front Right (inc ) Caliper, Brake - Front Left (inc ) FRONT BRAKE ASSEMBLY New Qty Description Housing, Caliper - Assembly - Front Right (inc ) Housing, Caliper - Assembly - Front Left (inc ) Piston/Seal Set (inc. 18) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Screw, Cap Spring, Brake Switch Switch, Brake - Assembly Lever, Brake O-Ring Washer Screw, Cap 14
17 REAR AND PARKING BRAKE ASSEMBLY Caliper, Brake - Right (inc. 2-8 and two No. 9) Caliper, Brake - Left (inc. 2-8 and two No. 9) Housing, Caliper - Assembly - Right (inc. 3-5) Housing, Caliper - Assembly - Left (inc. 3-5) Piston/Seal Set (inc. 4) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Screw, Cap Hose, Brake Screw, Machine Nut w/washer Bolt, Banjo-Fitting Washer, Crush Disc, Brake Screw, Shoulder Caliper, Parking Brake (inc. 18) Pad, Brake - Set Screw, Cap Bracket, Mounting - Cable Screw, Cap Nut, Lock Cable, Parking Brake Pin, Retaining - Assembly (inc ) Pin Washer Pin, Cotter Lever, Parking Brake - Assembly (inc ) Switch, Limiter Screw, Machine Screw, Machine Screw, Cap 15
18 Pedal, Accelerator Spring Axle O-Ring Nut, Lock ACCELERATOR ASSEMBLY New Qty Description Screw, Machine Bracket, Accelerator Pedal Nut, Lock Cable, Accelerator 16
19 Tank, Gas - Assembly (inc. 2-5) Cap, Gas Tank (inc. 3) Gasket, Gas Tank Cap Screw, Self-Tapping Plate, Retaining Pump, Fuel - Assembly (inc. 7-8) Float Seal Hose, Gasline AR Tie, Cable - 8 in Insert, Gas Tank Cap GAS TANK ASSEMBLY Nut, Stamped Bracket, Hold-Down - Right Screw, Self-Tapping Bracket, Hold-Down - Left Screw, Machine Nut, Lock Screw, Machine Bracket, Hold-Down - Front Nut w/washer Clamp, Hose AR Hose, Gasline - 25 ft 17
20 SHIFTER ASSEMBLY New Qty Description Mount, Shift Screw, Shoulder Screw, Machine Axle, Shift Clip, U-Nut Nut Screw, Machine Nut, Lock Retainer, Shift Linkage Cable, Shift X 1 Knob, Shift Screw, Shoulder Nut Bracket, Shift Cable Lever, Shift Screw, Machine Spring E-Ring 18
21 Cover, Air Intake Screen, Air Filter Filter, Air Housing, Air Intake Clip, Spring Clamp, Hose Cap, Drain Clamp, Hose Valve, Drain Screw, Self-Tapping Sensor, Air Temperature (inc. 12) O-Ring Clamp Boot, Intake Clamp Clamp Duct, Intake Duct, Intake Screw, Self-Tapping Filter, Intake Bracket, Support Screw, Machine AIR INTAKE ASSEMBLY Boot, Air-In Duct, Air-In Boot, Air-In Duct, Air-In Valve, Drain Clamp Boot, Air-In Clamp Boot, Air-Out Clamp Duct, Air-Out Foil, Protective Boot, Air-Out Duct, Air-Out Duct, Air-Out Fitting, Elbow Hose, Vent Clamp, Hose Hose, Vent Hose, Vent Separator, Oil Foil, Protective 19
22 Engine, A950GH2 (inc. 2-3) Spacer, Engine Mount Mount, Engine Washer Screw, Cap Screw, Cap Nut, Lock Decal, Warning - Clutch Cover Gasket, Exhaust Pipe Screw, Cap Pipe, Exhaust - Front Shield, Exhaust Pipe - Upper Shield, Exhaust Pipe - Lower Screw, Cap Washer Isolator ENGINE AND EXHAUST New Qty Description Isolator Pipe, Exhaust - Rear Shield, Exhaust Pipe - Rear Shield, Heat Screw, Machine Clip, U-Nut Spring, Extension Seal, Exhaust Pipe Muffler - Assembly (inc and three No. 14) Gasket, Spark Arrester Arrester, Spark - Assembly Screw, Machine Bracket, Muffler Support Bushing Cover, Muffler 20
23 Radiator Assembly (inc. 2-13) Cooler, Oil Radiator Cap, Radiator Clip, U-Nut Plug, Drain O-Ring Bracket, Mounting - Fan Fan, Cooling Screw, Machine AR Hose - 25 ft Clamp, Routing Grommet Screw, Shoulder Nut w/washer Bushing, Stem Clamp, Hose Hose, Oil Cooler - In Hose, Oil Cooler - Out Clamp, Hose Hose, Coolant - Radiator/Coolant Pipe Pipe, Coolant Screw, Self-Tapping Clamp, Routing Screw, Machine Clip, U-Nut COOLING ASSEMBLY Hose, Coolant - Coolant Pipe/Water Pump Hose, Coolant - Crossover Hose, Coolant - Crossover Hose, Coolant - Cylinder/Thermostat Hose, Coolant - Cylinder/Thermostat Screw, Machine Cover, Thermostat O-Ring Thermostat Sensor, Engine Coolant Temperature Housing, Thermostat Clamp, Hose Hose, Coolant - Thermostat/Coolant Pipe Pipe, Coolant w/bleed Valve Screw, Bleed O-Ring Hose, Coolant - Coolant Pipe/Radiator AR Cable Tie in AR Tie, Cable - 14 in Plug Bottle, Overflow Bracket, Mounting - Overflow Bottle Screw, Machine Clamp, Hose 21
24 Bladder, Gearcase Clamp, Hose Nut, Lock Washer Screw, Cap Gearcase, Front Driveshaft, Front Screw, Cap Boot, Shaft Gearcase, Rear AR Hose, Vent - 25 ft DRIVE TRAIN ASSEMBLY New Qty Description AR Conduit, Flexible - 3 ft Fitting, Vent O-Ring Driveshaft, Rear - Assembly (inc ) Yoke, Slip Joint, Universal (inc. 18) Ring, Retaining Driveshaft, Rear Yoke, Flange Screw, Cap AR Tie, Cable - 8 in. 22
25 FRONT DRIVE GEARCASE ASSEMBLY Complete Front Drive Gearcase Assembly Shaft, Coupler - Assembly (inc. 2-5) Coupler, Driveshaft Joint, Universal (inc. 4) Ring, Retaining Yoke, Slip Seal Ring, Retaining Bracket, Actuator Actuator (inc. 10) O-Ring O-Ring Screw, Self-Tapping Bearing Screw, Self-Tapping Housing, Pinion Gasket Ring, Retaining Shaft, Selector Ring, Retaining Fork, Selector Shaft, Shuttle O-Ring Spring, Return Coupler, Drive Ring, Retaining Gear, Pinion - Assembly - 11T (inc ) Collar, Retaining Bearing Housing, Gearcase Fitting, Elbow Bearing Pin, Dowel Plug, Magnetic (inc. one No. 34) O-Ring O-Ring Bearing AR Shim, 41 x 49 x 1.3 mm AR Shim, 41 x 49 x 1.4 mm AR Shim, 41 x 49 x 1.5 mm AR Shim, 41 x 49 x 1.6 mm AR Shim, 41 x 49 x 1.7 mm Gear, Ring - 34T AR Shim, 61 x 69 x 1.3 mm AR Shim, 61 x 69 x 1.4 mm AR Shim, 61 x 69 x 1.5 mm AR Shim, 61 x 69 x 1.6 mm AR Shim, 61 x 69 x 1.7 mm Cover, Gearcase (inc. one No. 34, 41-51, and one No. 52) Bearing Flange, Bearing Pin, Alignment Collar, Sliding Fork Ring, Retaining Spring Spring Shaft, Lock Plug, Oil Level (inc. one No. 34) Seal Seal Plug, Fill (inc. 54) O-Ring 23
26 Complete Rear Drive Gearcase Assembly Housing, Gearcase Fitting, Elbow Seal Bearing AR Shim, 41 x 49 x 1.3 mm AR Shim, 41 x 49 x 1.4 mm AR Shim, 41 x 49 x 1.5 mm AR Shim, 41 x 49 x 1.6 mm AR Shim, 41 x 49 x 1.7 mm Gear, Ring - 34T Cover, Gearcase O-Ring Button, Thrust AR Shim, 6.3 x 18 x 1.3 mm AR Shim, 6.3 x 18 x 1.4 mm AR Shim, 6.3 x 18 x 1.5 mm AR Shim, 6.3 x 18 x 1.6 mm AR Shim, 6.3 x 18 x 1.7 mm Plug, Magnetic (inc. 12) O-Ring REAR DRIVE GEARCASE ASSEMBLY New Qty Description Plug, Fill (inc. 14) O-Ring Screw, Self-Tapping Pin, Dowel Gasket Bearing Gear, Pinion - Assembly - 11T (inc ) Bearing Collar, Retaining Ring, Retaining Screw, Self-Tapping Shaft, Input (inc ) Cartridge, Clutch - Assembly Ring, Retaining - External Basket, Clutch Ring, Retaining - Internal Bearing, Flange Bearing Seal Housing, Input 24
27 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 Diode Decal, Fuse Block Seal Cover, Diagnostics Connector Repair Kit, Connector - LCD Gauge AR Repair Kit, Connector - Headlight Repair Kit, Connector - Tilt Sensor Repair Kit, Connector - Idle Speed Control Coil, Ignition - Assembly WIRING HARNESS ASSEMBLY Cap, Spark Plug Screw, Machine Nut w/washer Harness, Console Cushion, ECM ECM Screw, Machine Nut Regulator, Voltage Screw, Machine Washer Nut w/washer Sensor, Tilt Harness, Adapter - Taillight AR Tie, Cable - 8 in AR Tie, Cable in AR Tie, Cable in. 25
28 BATTERY AND STARTER MOTOR ASSEMBLY X 1 Battery (inc. 2-3) Decal, Warning Kit, Hardware Screw, Thumb Cover, Battery Box Clip, U-Nut Box, Battery Screw, Machine Hold-Down, Battery Box - Right Hold-Down, Battery Box - Left New Qty Description Nut Cable, Battery/Ground Boot, Terminal Cable, Battery/Solenoid Nut w/washer Cable, Solenoid/Starter Boot, Terminal - Solenoid Solenoid Screw, Machine Motor, Starter - Assembly 26
29 Throttle - Assembly (inc. 2-14) Screw, Machine Bracket, MAP Sensor Sensor, MAP O-Ring, MAP Sensor Screw, Machine Sensor, Throttle Position O-Ring, Throttle Position Sensor Plate, ISC Valve O-Ring, ISC Valve Valve, ISC O-Ring Cover Screw, Machine THROTTLE BODY ASSEMBLY Manifold, Intake - Assembly (inc ) Screw, Machine Rail, Fuel - Front Cylinder O-Ring, Fuel Injector Injector, Fuel Ring, Seal - Fuel Injector Manifold, Intake Clamp Boot, Intake - Manifold Plenum, Intake Rail, Fuel - Rear Cylinder O-Ring Screw, Machine X 1 Clamp, Routing - Optional 27
30 Gasket, Head Cylinder Pin, Dowel Bolt, Stud Bolt, Stud Nut Gasket, Base Plug, Cylinder CYLINDER ASSEMBLY New Qty Description O-Ring Union, Coolant Hose Screw, Machine Union, Coolant Hose Screw, Machine Cover, Breather Gasket 28
31 CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY Head, Cylinder - Assembly (inc. 2-17) Pin, Dowel Plug, Shaft Arm, Valve Rocker - Exhaust (inc. two No. 5-6) Screw, Adjuster Nut Arm, Valve Rocker - Intake (inc. two No. 5-6) Shaft, Rocker Arm - Intake Shaft, Rocker Arm - Exhaust Cotter, Valve Retainer, Spring Spring, Valve Seal, Oil Seat, Spring - Valve Valve, Intake Valve, Exhaust Screw, Cap Gasket Screw, Cap Screw, Cap Screw, Cap Screw, Cap 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 29
32 CAM CHAIN ASSEMBLY New Qty Description Chain, Cam Gasket Guide, Chain Screw, Machine Tensioner, Chain Screw, Cap Pivot, Tensioner Washer Adjuster, Tensioner - Assembly 30
33 X 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 CRANKCASE ASSEMBLY Valve, Oil-Relief - Assembly O-Ring, Oil Filler Cover Cover, Oil Filler Stick, Oil Level O-Ring Fitting, Oil - Threaded Cover, Breather Screw, Machine Pin, Dowel Bearing Circlip Gasket, Breather Screw, Cap Screw, Cap Screw, Machine Screw, Machine Screw, Machine Screw, Cap Screw, Cap 31
34 CRANKSHAFT AND PISTON ASSEMBLY Piston Set - Assembly (inc. 2-4) Ring, Piston - Set Circlip, Piston Pin New Qty Description Pin, Piston Crankshaft - Assembly Washer, Thrust 32
35 Gear, Starter Idler - No Shaft, Starter Gear Gear, Starter Idler - No Spacer, Starter Idler Gear No Shaft, Starter Gear STARTER CLUTCH ASSEMBLY Gear, Starter Clutch (inc. 7) Bearing Clutch, Starter Screw, Cap Washer, Wave 33
36 OIL PUMP ASSEMBLY New Qty Description Gerotor - Set Gear, Driven Pin, Dowel Ring, Retaining O-Ring Strainer, Oil Housing, Oil Pump Screw, Machine Screw, Machine Cap, Oil Strainer Seal, Oil Pump Screw, Machine Shim Plug, Drain Shaft, Oil Pump Gasket, Drain Plug 34
37 Pump, Water - Assembly (inc. 2) O-Ring Screw, Machine Bearing Circlip Shaft, Driven Gear Ring, Retaining Gear, Driven WATER PUMP ASSEMBLY Pin, Dowel Ring, Retaining Bearing Spacer, Idler - Water Pump Shaft, Water Pump Idler Gear Ring, Retaining Gear, Idler - Water Pump - Drive Ring, Retaining 35
38 Pulley, Driven - Assembly (inc. 2-4) Shoe, Cam Screw, Machine Nut, Driven Pulley Bearing Seal Retainer, Bearing Screw, Machine Nut Washer Plate, Movable Drive Face Damper, Movable Drive Face Spacer, Movable Drive Face Roller, Movable Drive Face TRANSMISSION ASSEMBLY New Qty Description Face, Movable Drive Belt, Drive Face, Fixed Drive Spacer, Fixed Drive Face O-Ring Seal, Clutch Housing - Right Bearing Housing, Clutch Screw, Machine Retainer, Bearing Seal, Clutch Housing - Left Nut Clutch, One-Way Clutch, Centrifugal - 6 Plate 36
39 SECONDARY TRANSMISSION ASSEMBLY 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 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 37
40 Screw, Machine Switch, Gear Position Contact Spring Washer Shaft, Gear Shift - Assembly Spacer Cam, Gear Shift Screw, Cap Washer Ring, Retaining GEAR SHIFTING ASSEMBLY New Qty Description Shaft, Sub-Gear Shift Arm, Shift Screw, Machine Washer Stopper, Cam Support, Cam Stopper Spring Washer Nut Fork, Shift Shaft, Shift Fork 38
41 Yoke, Drive Output Joint, Universal - Set (inc. 3) Ring, Retaining Nut Washer Yoke, Propeller Shaft Joint Seal, Oil Bearing AR Shim, 25 x 34 x 0.25 mm AR Shim, 25 x 34 x 0.30 mm AR Shim, 25 x 34 x 0.70 mm AR Shim, 25 x 34 x 0.90 mm AR Shim, 25 x 34 x 0.95 mm AR Shim, 25 x 34 x 1.00 mm AR Shim, 25 x 34 x 1.05 mm AR Shim, 25 x 34 x 1.10 mm AR Shim, 25 x 34 x 1.15 mm Shaft, Secondary Driven - Front SECONDARY DRIVE ASSEMBLY Bearing, Driven Gear Gear, Secondary Driven Ring, Driven Bearing Shaft, Secondary Driven - Rear Flange, Output Joint Gear, Secondary Drive AR Shim, 30 x 48 x 0.25 mm AR Shim, 30 x 48 x 0.30 mm AR Shim, 30 x 48 x 0.35 mm AR Shim, 30 x 48 x 0.90 mm AR Shim, 30 x 48 x 0.95 mm AR Shim, 30 x 48 x 1.00 mm AR Shim, 30 x 48 x 1.05 mm AR Shim, 30 x 48 x 1.10 mm AR Shim, 30 x 48 x 1.15 mm Bearing Nut Bearing 39
42 MAGNETO ASSEMBLY New Qty Description Rotor/Flywheel Stator - Assembly Key Clamp Nut Screw, Machine Screw, Cap 40
43 Cover, Magneto Gasket, Magneto Cover Bearing Plug, Check Washer, Crush MAGNETO SIDE ENGINE COVERS Seal, Cap Cap, Magneto Cover Screw, Machine Screw, Machine Screw, Machine 41
44 CLUTCH SIDE ENGINE COVERS New Qty Description Cover, Outside Screw, Machine Gasket, Cover Screw, Machine Cover, Inside Pin, Dowel Cover, Clutch Washer, Crush Gasket, Clutch Cover Screw, Cap 42
45 Ref. Part No. Qty. Description Ref. Part No. Qty. Description Printed in U.S.A. p/n
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B B B
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A1 CYLINDER - CYLINDER HEAD 1 3FA-11110-00-00 CYLINDER HEAD ASSEMBLY. 1 2 95612-06625-00. BOLT, STUD............. 2 3 22F-11134-10-00. GUIDE, EXHAUST VALVE... 2 4 93440-10109-00. CIRCLIP.................
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CYLINDER HEAD. Ref. Part No. Number Description Qty Remarks
A1 A2 A3 A4 CYLINDER HEAD 1 3FA-11110-01-00 CYLINDER HEAD ASSY...... 1 2 90116-06541-00. BOLT, STUD............. 2 3 22F-11134-10-00. GUIDE, EXHAUST VALVE... 2 4 93440-10109-00. CIRCLIP.................
S/N 1H019H - 1H310H Page 1 of 33 46" Cutting Deck Assembly
1180 S/N 1H019H - 1H310H Page 1 of 33 46" Cutting Deck Assembly 1180 S/N 1H019H - 1H310H Page 2 of 33 46" Cutting Deck Assembly 1 17982 1 S Reinforcement Spindle Plate 2 618-0430 1 S Spindle Assembly w/
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A1 CYLINDER HEAD - CYLINDER 1 8AY-11111-00-00 HEAD, CYLINDER 1......... 1 2 8A7-12499-00-00 JOINT................... 1 3 NGK-BR9ES-00-00 PLUG, SPARK............. 2 4 8AY-11181-00-00 GASKET, CYLINDER HEAD
CYLINDER. Ref. Part No. Number Description Qty Remarks
A1 CYLINDER 1 2GU-11111-00-00 HEAD, CYLINDER 1......... 1 2 NGK-B8ES0-00-00 NGK B8ES 10PK........... 2 3 90116-08394-00 BOLT, STUD.............. 8 4 95912-08640-00 BOLT, STUD.............. 2 5 90179-08491-00
120 XC SP Model #S03WB1AS Rev. 01. E 2002 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /03
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