ILLUSTRATED PARTS MANUAL
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1 ILLUSTRATED PARTS MANUAL TRV 1000 XT EFT Model Number A2014TGW1PETL TM SHARE OUR PASSION.
2 TABLE OF CONTENTS 2014 TRV 1000 XT EFT (Model No. A2014TGW1PETL) FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES... 1 REAR BODY PANEL AND FOOTWELL ASSEMBLIES... 2 REAR RACK ASSEMBLY... 3 FRAME AND RELATED PARTS... 4 WINCH ASSEMBLY... 5 LICENSE PLATE HOLDER ASSEMBLY... 6 SEAT ASSEMBLY... 7 PASSENGER SEAT AND BACKREST ASSEMBLY... 8 STEERING ASSEMBLY... 9 HANDLEBAR ASSEMBLY INSTRUMENT POD ASSEMBLY FRONT SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY SWAYBAR ASSEMBLY WHEEL AND TIRE ASSEMBLY HYDRAULIC BRAKE ASSEMBLY PARKING BRAKE ASSEMBLY GAS TANK ASSEMBLY SHIFT LEVER ASSEMBLY AIR INTAKE ASSEMBLY ENGINE AND EXHAUST COOLING ASSEMBLY CASE/BELT COOLING ASSEMBLY DRIVE TRAIN ASSEMBLY FRONT DRIVE GEARCASE ASSEMBLY REAR DRIVE GEARCASE ASSEMBLY WIRING HARNESS ASSEMBLY BATTERY AND STARTER 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 2013 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
3 FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES Rack, Front - Assembly (inc. 2-3) Decal, Warning - Load Bushing Screw, Cap Spacer Grommet Nut, Lock Screw, Shoulder Washer Nut, Lock Headlight Assembly - Right (inc ) Headlight Assembly - Left (inc ) Socket, Position Bulb Bulb, Position Bulb, Turn Signal Socket, Turn Signal Bulb Bulb, Headlight Retainer, Spring Boot, Rubber Stud, Adjuster - Headlight Spring, Adjuster Knob, Adjuster Screw, Self-Tapping Washer Grommet Panel, Side - Lower - Right Panel, Side - Lower - Left Grommet Cover, Access Rivet, Reinstallable Cover, Steering Post Rivet, Reinstallable Cover, Storage Box Box, Storage Lid, Storage Box w/latch (inc ) Latch, Storage Box Lid, Storage Box Screw, Shoulder X 1 Panel, Fender - Blue Decal, Reflector - Right - Amber Decal, Reflector - Left - Amber Decal, Warning - Throttle Decal, Arctic Cat X 2 Decal, 1000 EFI X 1 Decal, Side - Upper Right X 1 Decal, Side - Upper Left 1
4 REAR BODY PANEL AND FOOTWELL ASSEMBLIES X 1 Fender, Rear - Assembly - Blue Decal, Reflector - Right - Red Decal, Reflector - Left - Red Decal, Warning - Tire Pressure X 1 Decal, XT X 1 Decal, XT Nut, Lock Screw, Shoulder Footwell, Rear - Right Footwell, Rear - Left Screw, Machine Footwell - Right Footwell - Left New Qty Description Screw, Shoulder X 4 Footpeg Screw, Machine Screw, Machine Bezel, Taillight - Right Bezel, Taillight - Left Taillight Assembly - Right (inc ) Taillight Assembly - Left (inc ) Bulb, Turn Signal Bulb, Taillight Clip, U-Nut 2
5 Rack, Rear (inc. 2) Decal, Warning - Load Screw, Cap Washer Nut, Cap Screw, Cap Bracket, Mounting - Safety Flag Base, MRP - Assembly (inc. 9-13) Pin - Assembly (inc ) Pin, Roll Bushing, Flanged Spring REAR RACK ASSEMBLY Bushing Screw, Cap Spacer Grommet Nut, Lock Washer Screw, Shoulder Bracket, Rear Fender - Right Bracket, Rear Fender - Left Washer Nut, Lock 3
6 Frame, Main Clip, Routing Channel, Mounting - Bumper - Right Channel, Mounting - Bumper - Left Screw, Cap Bracket, Mounting - Bumper - Right Bracket, Mounting - Bumper - Left Screw, Cap Bumper, Front Fascia, Bumper - Front Screw, Machine Screw, Shoulder Panel, Belly Screw, Cap Brace, A-Arm Nut, Lock Screw, Machine Screw, Machine FRAME AND RELATED PARTS New Qty Description Bracket, Support - Right Bracket, Support - Left Nut w/washer Bracket, Mounting - Horn Horn, Electric - 12V Pad, Foam Pad, Foam Nut Screw, Cap Footrest - Right Footrest - Left Strap, Footrest - Right Strap, Footrest - Left Bracket, Support Decal, Warning - Towing Mount, Ball Hitch (inc ) Nut, Lock Screw, Cap 4
7 Winch (inc. 2-3) Decal, Warning Cable, Winch Washer, Lock Screw, Cap Roller, Winch (inc. 7) Decal, Warning - Pinch Point Screw, Machine Pin, Cotter Hook, Winch Strap Pin Boot, Terminal Nut w/washer Cable, Winch/Solenoid - Yellow WINCH ASSEMBLY Cable, Winch/Solenoid - Blue Cable, Solenoid/Battery - Red Cable, Solenoid/Battery - Black Solenoid Screw, Machine Switch, Winch - Assembly (inc ) Connector, Harness Bracket, Winch Switch Washer, Internal Tooth Lock Screw, Machine Harness, Adapter - Solenoid Washer, External Tooth Lock AR Tie, Cable - 8 in AR Tie, Cable in. 5
8 LICENSE PLATE HOLDER ASSEMBLY New Qty Description Mount, License Plate Screw, Self-Tapping Light, License Plate Assembly (inc. 3-4) Nut, Lock Screw, Self-Tapping Washer Bulb Screw, Machine 6
9 Seat Assembly (inc. 2-9) Cover, Seat Foam, Seat Base, Seat - Assembly (inc. 5-6) Bumper, Seat - Rear SEAT ASSEMBLY Bumper, Seat - Front AR Staple Spring, Seat Latch Latch, Seat Wrench, Spanner 7
10 PASSENGER SEAT AND BACKREST ASSEMBLY Seat, Passenger - Assembly (inc. 2-14) Seat, Passenger - Sub-Assembly (inc. 3-6) Foam, Seat - Passenger Cover, Seat - Passenger AR Staple Base, Seat - Inner Base, Seat - Passenger Screw, Machine Handhold, Passenger - Right Handhold, Passenger - Left New Qty Description Nut, Lock Bracket, Seat Support - Assembly Nut, Lock End Cap, Seat Support Screw, Self-Tapping Backrest Assembly (inc ) Foam, Backrest Cover, Backrest Screw, Cap Decal, Arctic Cat 8
11 STEERING ASSEMBLY Screw, Cap Cap, Steering Adjuster Screw, Shoulder Cap, Housing Housing, Upper Housing, Lower Post, Steering Screw, Cap Nut, Lock Assembly, Electronic Power Steering Screw, Cap Arm, Steering Screw, Cap Flange, Bearing Bearing w/inverted Oil Seal X 2 Tie Rod - Assembly (inc ) X 2 End, Tie Rod - Left-Hand Thread - Kit (inc. 18) Nut - Left-Hand Thread Tie Rod X 2 End, Tie Rod - Right-Hand Thread - Kit (inc. 21) Nut - Right-Hand Thread Nut, Lock Pin, Cotter Lock, Steering - Assembly (inc ) Mount, Steering Lock Lock, Steering Screw, Machine Mount, Steering Lock Washer Screw, Cap Nut Tool, Anti-Tamper - Optional 9
12 Handlebar Plug, Handlebar Grip, Handlebar End Cap, Handlebar Washer Screw, Machine Case, Throttle - Assembly (inc. 8-15) Cover, Throttle Case w/switch Screw, Cap Washer, Lock Washer Lever, Throttle HANDLEBAR ASSEMBLY New Qty Description Screw, Machine Nut Screw, Machine Decal, Warning - Differential Lock Mirror - Right (inc ) Mirror - Left (inc ) Cover Nut, Adjuster Washer, Lock Nut Switch, Control - Assembly Decal, Warning - Brake Lever Lock 10
13 Switch, Ignition - Assembly (inc. 2-4) Nut, Retaining Key, Ignition - (Y Series - Left-Side Cut) Key, Ignition - (Z Series - Right-Side Cut) Cover, Key Gauge, LCD INSTRUMENT POD ASSEMBLY Decal, Arctic Cat Outlet, Accessory - 12V X 1 Instrument Pod - Blue Bracket, Retaining Nut w/washer Bracket, Mounting - Instrument Pod Rivet, Reinstallable 11
14 Shock Absorber (inc. 2) Bushing Cam, Spring Adjuster Spring, Suspension - White Retainer, Spring 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 A-Arm, Lower Right - Black (inc and two No ) A-Arm, Lower Left - Black (inc and two No ) FRONT SUSPENSION ASSEMBLY New Qty Description Bushing Axle Screw, Cap Axle, Drive - Right (inc ) Axle, Drive - Locking - Left (inc ) Repair Kit, Boot (inc. 22) Clip, Retaining Pin, Detent Clip, Retaining Knuckle - Assembly - Right (inc ) Knuckle - Assembly - Left (inc ) Ring, Retaining Bearing Screw, Shoulder Guard, Boot - Right - Black Guard, Boot - Left - Black Screw, Shoulder 12
15 Shock Absorber (inc. 2-4) Bushing Bushing Sleeve Retainer, Spring Spring, Suspension - White Cam, Spring Adjuster Screw, Cap Nut, Lock Washer Screw, Cap A-Arm, Rear - Upper Right - Black (inc ) A-Arm, Rear - Upper Left - Black (inc ) Bushing Axle Screw, Cap REAR SUSPENSION ASSEMBLY A-Arm, Rear - Lower Right - Black (inc ) A-Arm, Rear - Lower Left - Black (inc ) Axle, Drive (inc ) Repair Kit, Boot (inc. 19) Clip, Retaining Pin, Detent Clip, Retaining Knuckle, Right - Assembly (inc ) Knuckle, Left - Assembly (inc ) Ring, Retaining Bearing Axle Bushing Screw, Cap Screw, Shoulder Guard, Boot - Rear - Right - Black Guard, Boot - Rear - Left - Black 13
16 SWAYBAR ASSEMBLY New Qty Description Swaybar Screw, Cap Screw, Cap Washer Clamp, Retaining Bushing Bushing, Swaybar - Upper Nut, Lock Bushing, Swaybar - Lower 14
17 Screw, Shoulder Disc, Brake Hub, Wheel (inc. 4) Stud Nut, Castle Pin, Cotter Wheel - Front - Aluminum (inc. 8) WHEEL AND TIRE ASSEMBLY Cap, Wheel Stem, Valve (inc. 10) Cap, Valve Stem Nut, Lug - Chrome Tire - Front Wheel - Rear - Aluminum (inc. 8) Tire - Rear 15
18 Caliper, Brake - Right Front (inc. 2-9) Caliper, Brake - Left Front (inc. 2-9) Caliper, Brake - Rear (inc. 2-9) Housing, Caliper - Assembly - Right Front (inc. 3-6) Housing, Caliper - Assembly - Left Front (inc. 3-6) Housing, Caliper - Assembly - Rear (inc. 3-6) Screw, Cap Piston/Seal Set (inc. 5) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Washer, Crush Bolt, Banjo-Fitting Screw, Machine Nut, Lock Hose, Brakeline - Assembly Bolt, Banjo-Fitting - Double Hose, Brakeline Brake Assembly HYDRAULIC BRAKE ASSEMBLY New Qty Description Pin, Cotter Washer Pin, Clevis Screw, Cap Washer O-Ring Lever, Brake Screw, Cap Bracket, Switch Spring, Brake Switch Hose, Brakeline Brake Assembly (inc ) Screw, Machine - Kit Cover, Reservoir Screw, Machine - Kit Clamp, Master Cylinder Master Cylinder Assembly Lever Assembly - Kit (inc ) Lock, Brake Lever - Kit Lever Pin - Kit Switch, Brake Clip, Brakeline Hose AR Tie, Cable - 8 in AR Fluid, Brake - 12 oz 16
19 Lever, Parking Brake - Assembly (inc. 2-6) Lever, Parking Brake - Kit Clamp, Handlebar - Kit Adjuster, Thumb Nut - Kit Lock, Parking Brake Lever - Kit PARKING BRAKE ASSEMBLY Cable, Brake - Rear Mechanical Brake Assembly (inc. 8) Pad, Brake Screw, Cap Wire Form, Cable 17
20 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, Fuel - Assembly GAS TANK ASSEMBLY New Qty Description AR Clamp, Hose AR Hose, Gasline - 25 ft Filter, In-Line Bracket, Mounting - Filter AR Tie, Cable - 8 in Screw, Shoulder Shield, Heat Screw, Self-Tapping Grommet 18
21 Knob, Shift Clip, Retaining Plate, Shift Shield, Shift Plate Nut, Stamped Lever, Shift Actuator, Shift Lever Nut Spring, Shift Lever O-Ring Axle, Pivot Screw, Cap SHIFT LEVER ASSEMBLY Washer O-Ring Nut Pin, Mounting - Shift Linkage Bushing Washer E-Ring Linkage, Shift - Assembly (inc ) Nut, Hex - Right-Hand Thread Coupler Nut, Hex - Left-Hand Thread 19
22 Diverter, Air - Top Diverter, Air - Bottom Shroud, Splash Rivet, Reinstallable Clamp Screw, Self-Tapping Cap, Air Intake - Diverter Boot, Air Intake AR Clamp Wing Nut Cover, Air Intake Filter, Air Support, Air Filter AIR INTAKE ASSEMBLY New Qty Description Housing, Air Intake Bumper Valve, Drain Boot, Throttle Body Sensor, Air Temperature (inc. 19) O-Ring Clamp, Hose Hose, Separator Tank Tank, Separator Hose, Crankcase Hose, Crankcase Clamp 20
23 Engine, A950K (inc. 2-3) Spacer, Engine Mount Mount, Engine Decal, Warning - Clutch Cover Washer Screw, Cap Screw, Cap Nut, Lock Screw, Cap Gasket, Exhaust Pipe Pipe, Exhaust - Assembly (inc ) Pipe, Exhaust ENGINE AND EXHAUST Shield, Exhaust Pipe Clamp Screw, Machine Pipe, Exhaust - Rear Shield, Exhaust Pipe - Rear Seal, Exhaust Pipe Spring, Extension Bushing Channel, Muffler Support 22-1 Muffler - Assembly - Not Serviced Individually 21
24 Radiator Assembly (inc. 2-13) Radiator Cap, Radiator Clip, U-Nut Plug, Drain O-Ring Bracket, Mounting - Fan Fan, Cooling Screw, Machine Screen, Radiator Clamp, Wire AR Hose - 25 ft Grommet Screw, Shoulder Nut w/washer Bushing, Stem Clamp, Hose Hose, Coolant - Radiator/Thermostat - Upper Screw, Machine Plate, Backing Bracket, Mounting - Thermostat Screw, Machine COOLING ASSEMBLY New Qty Description Cover, Thermostat O-Ring Thermostat Sensor, Engine Coolant Temperature Housing, Thermostat Hose, Coolant - No Hose, Coolant Hose, Coolant - Crossover Hose, Coolant - No Clamp, Hose Hose, Coolant - Lower AR Tie, Cable in Cooler, Oil Screw, Machine Bracket, Mounting - Oil Cooler - Upper Clamp, Hose Hose, Oil Cooler - In Hose, Oil Cooler - Out Plug Bottle, Overflow Clamp, Hose AR Tie, Cable - 14 in. 22
25 Shroud, Air - Air In Duct, Cooling - Air In Clamp Boot, Cooling - Air In Boot, Cooling - Air Out CASE/BELT COOLING ASSEMBLY Clamp Duct, Cooling - Air Out Screw, Self-Tapping Rivet, Reinstallable 23
26 X 1 Gearcase, Front Bladder, Gearcase Clamp, Hose Nut, Lock Washer Screw, Cap Screw, Cap Driveshaft, Rear - Assembly (inc. 9-13) DRIVE TRAIN ASSEMBLY New Qty Description Yoke, Flange Joint, Universal (inc.11) Ring, Retaining Driveshaft, Rear Yoke, Slip X 1 Gearcase, Rear Screw, Cap 24
27 FRONT DRIVE GEARCASE ASSEMBLY X 1 Complete Front Drive Gearcase Assembly Shaft, Propeller - Assembly (inc. 2-3) Shaft, Input Deflector Seal Ring, Retaining Bracket, Actuator Actuator (inc. 8) O-Ring O-Ring Screw, Self-Tapping Bearing Housing, Pinion Screw, Self-Tapping 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 Bearing Pin, Dowel X 1 Fitting, Elbow Plug, Magnetic (inc. one No. 32) 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 X 1 Cover, Gearcase (inc. one No. 32, 39-49, and one No. 50) Bearing Flange, Bearing Pin, Alignment Collar, Sliding Fork Ring, Retaining Spring Spring Shaft, Lock Plug, Oil Level (inc. one No. 32) Seal X 2 Seal Plug, Fill (inc. 52) O-Ring 25
28 X 1 Complete Rear Drive Gearcase Assembly Housing, Gearcase X 1 Fitting, Elbow Plug, Magnetic (inc. one No. 4) O-Ring X 2 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 O-Ring Cover, Gearcase Plug, Fill (inc. 12) O-Ring Plug, Oil Level (inc. one No. 4) Screw, Self-Tapping 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 REAR DRIVE GEARCASE ASSEMBLY New Qty Description Gasket Pin, Dowel Bearing Gear, Pinion - Assembly - 11T (inc ) Bearing Collar, Retaining Ring, Retaining Shaft, Input (inc ) Cartridge, Clutch - Assembly Ring, Retaining - External Basket, Clutch Ring, Retaining - Internal Bearing, Flange Bearing Seal Housing, Input Screw, Self-Tapping 26
29 Harness, Main (inc. 2-10) Tether, Accessory Connector Cover, Fuse Block Relay (4-Pin) - 20 Amp Diode Holder, Fuse Fuse - 10 Amp Fuse - 15 Amp Fuse - 30 Amp Decal, Fuse Block Seal Cover, Diagnostics Connector Repair Kit, Connector - Tilt Sensor Repair Kit, Connector - Idle Speed Control Repair Kit, Connector - LCD Gauge AR Repair Kit, Connector - Headlight/Turn Signal/Position Screw, Machine Control, Turn Signal WIRING HARNESS ASSEMBLY Nut, Lock Switch, Brake - Assembly Nut w/washer Sensor, Tilt Washer Screw, Machine ECM Cushion, ECM Bracket, Mounting - ECM Spacer Screw, Machine Nut w/washer Regulator, Voltage Screw, Machine Coil, Ignition - Assembly Cap, Spark Plug Screw, Machine Screw, Machine AR Tie, Cable - 8 in AR Tie, Cable in. 27
30 BATTERY AND STARTER ASSEMBLY Battery Cover/Tool Tray Assembly (inc. 2-4) Cover, Battery Kit, Tool Pad, Battery Screw, Machine Battery Assembly (inc. 7-8) Kit, Hardware Decal, Warning Foam, Battery Cable, Battery/Ground New Qty Description Cable, Battery/Soleniod Boot, Terminal Nut w/washer Cable, Solenoid/Starter (inc. 15) Boot, Terminal Screw, Machine Solenoid Screw, Machine Motor, Starter - Assembly (inc. 20) Shield, Heat - Starter 28
31 Throttle - Assembly (inc. 2-15) 2-1 Throttle Body - Not a Service Part Sensor, Throttle Position O-Ring, Throttle Position Sensor Screw, Machine Valve, ISC O-Ring, ISC Valve Bracket, MAP Sensor Screw, Machine Sensor, MAP O-Ring, MAP Sensor Plate, ISC Valve O-Ring Cover Screw, Machine THROTTLE BODY ASSEMBLY Manifold, Intake - Assembly (inc ) Clamp Boot, Intake - Manifold Injector, Fuel Rail, Fuel - Front Cylinder Rail, Fuel - Rear Cylinder O-Ring, Fuel Injector Ring, Seal - Fuel Injector Manifold, Intake Plenum, Intake Screw, Machine Screw, Machine Cable, Throttle O-Ring Clamp, Routing 29
32 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 30
33 CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY X 2 Head, Cylinder - Assembly (inc. 2-21) Pin, Dowel Plug, Shaft X 2 Arm, Valve Rocker - Exhaust (inc. two No. 5-6) Screw, Adjuster Nut X 2 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 O-Ring Screw, Cap Screw, Cap Washer, Crush 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 Spark Plug - CPR8E Seal Cover, Thermostat Bolt, Stud Nut Bolt, Stud Nut 31
34 CAM CHAIN ASSEMBLY New Qty Description Chain, Cam Gasket Guide, Chain Screw, Machine Tensioner, Chain Screw, Cap Pivot, Tensioner Washer Adjuster, Tensioner - Assembly 32
35 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 X 1 Plate, Oil Sump Valve, Oil-Relief - Assembly CRANKCASE 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 Gasket Plug 33
36 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 34
37 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 35
38 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 Plug, Drain Shim Gasket, Drain Plug Shaft, Oil Pump 36
39 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 37
40 X 1 Pulley, Driven - Assembly (inc. 2-4) X 1 Pulley, Driven - Uncalibrated X 3 Shoe, Cam Screw, Machine X 1 Key X 1 Ring, Snap - External Cam Spring - Black Nut, Driven Pulley Bearing Seal Retainer, Bearing Screw, Machine Nut Washer Plate, Movable Drive Face Damper, Movable Drive Face TRANSMISSION ASSEMBLY New Qty Description Spacer, Movable Drive Face Roller, Movable Drive Face 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 X 1 Clutch, Centrifugal - 6 Plate Spacer 38
41 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 39
42 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 40
43 Driveshaft, Front - Assembly (inc. 2, one No. 3, four No. 4, and 5) Yoke, Slip Joint, Universal - Set (inc. 4) Ring, Retaining Driveshaft, Front 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 SECONDARY DRIVE ASSEMBLY Shaft, Secondary Driven - Front Bearing, Driven Gear Ring, Driven Bearing Gear, Secondary Driven Shaft, Secondary Driven - Rear Flange, Output Joint - Rear 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 41
44 MAGNETO ASSEMBLY New Qty Description Rotor/Flywheel Stator - Assembly Key Clamp Nut Screw, Machine Screw, Cap 42
45 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 43
46 CLUTCH SIDE ENGINE COVERS New Qty Description Cover, Outside Screw, Machine Gasket, Cover Screw, Machine X 1 Cover, Inside Pin, Dowel Cover, Clutch Washer, Crush Gasket, Clutch Cover Screw, Cap 44
47 Ref. Part No. Qty. Description Ref. Part No. Qty. Description Printed in U.S.A. p/n
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2006 SMF / DSF / DTF 200 1 The drawings in this parts book have been scaled so that parts can be easily recognized. 1 CYLINDER ASSY 2 CYLINDER ASSY Ref # Part # Description 1 410 0001A CYLINDER HEAD COVER
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/
10th letter in VIN: J
08 0th letter in VIN: J Headlight G Br Speedometer Headlight Light Switch B Br Ignition Switch R B Y/R Brake Light Switch B G/Y Starter Relay Fuse A + G Starter Motor Rear Brake Light G/Y Br G Speed Sensor
Figure 1. - Cylinder / Cylinder Head
Page 1 of 42 Figure 1. - Cylinder / Cylinder Head Figure 1. Cylinder / Cylinder Head 1 11111-STG-00 Cylinder comp 1 2 11121-STG-00 Head comp, cylinder 1 3 11127-CHP-00 Nut, cylinder head 1 4 11141-ROA-00
PARTS CATALOGUE POWERMAX-125T REVISED 08/06/04
PARTS CATALOGUE POWERMAX-125T-7 REVISED 08/06/04 ENGINE INDEX FRAME SECTION FIG # FAN COVER/SHROUD E01 SECTION FIG # CYLINDER HEAD E02 CAMSHAFT VALVE E03 SIDE COVER F01 CAM CHAIN TENSIONER E04 R. & L.
CYLINDER HEAD. Ref. Part No. Number Description Qty Remarks
A1 CYLINDER HEAD 1 JN6-11102-00-00 HEAD, CYLINDER.......... 1 2 JN6-11133-10-00. GUIDE, VALVE............ 2 3 JN6-11181-00-00 GASKET, CYLINDER HEAD... 1 4 95817-10070-00 BOLT, FLANGE............ 4 5 99530-14016-00
B B B
FIG CYLINDER Suzuki Worldwide Motorcycle-ATV Page: of -0B00-00 0-00 0-000 0-00 0-0B0-0B0 0-0 0-0 Head, Cylinder Gasket, Cylinder Head Spark Plug (ngk,bphs) Spark Plug (nd,wfp-u) Cylinder Gasket, Cylinder
9/7/2014 F9.9MSHV 1997 / CYLINDER CRANKCASE Yamaha Motor Corporation, U.S.A. All rights reserved.
F9.9MSHV 997 Page of 45 9/7/04 F9.9MSHV 997 / CYLINDER CRANKCASE 04 Yamaha Motor Corporation, U.S.A. All rights reserved. F9.9MSHV 997 Page of 45 9/7/04 Part List F9.9MSHV 997 / CYLINDER CRANKCASE REF
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
PARTS MANUAL PN and MICROFICHE PN /04. SPORTSMAN 600 Model #A05MH59AK Model #A05MH59AN. E 2004 Polaris Sales Inc.
PARTS MANUAL PN and MICROFICHE PN 0 /0 SPORTSMAN 00 Model #A0MHAK Model #A0MHAN E 00 Polaris Sales Inc. TABLE OF CONTENTS Parts Manual A H A -ARM... AIR BOX... C A B BRAKE LINES, FRONT... B BUMPER MOUNTING...
9/7/2014 T9.9ELRZ 2001 / TOP COWLING Yamaha Motor Corporation, U.S.A. All rights reserved.
T9.9ELRZ 00 Page of 56 9/7/0 T9.9ELRZ 00 / TOP COWLING 0 Yamaha Motor Corporation, U.S.A. All rights reserved. T9.9ELRZ 00 Page of 56 9/7/0 Part List T9.9ELRZ 00 / TOP COWLING REF - NO PART NUMBER PART