400 4x4 FIS. (Automatic Transmission)

Transcription

1 400 4x4 FIS (Automatic Transmission) Model Number A2005ISH4BUSI (Red) Model Number A2005ISH4BUSH (Green) Model Number A2005ISH4BUSJ (Cat Green) Model Number A2005ISH4BUSN (Red - LE) Model Number A2005ISH4BUSM (Green - LE) Model Number A2005ISH4BUSA (Cat Green - LE) Illustrated Parts Manual 2005

2 TABLE OF CONTENTS 2005 ATV 400 FIS (Automatic Transmission) Red (Model No. A2005ISH4BUSI) Green (Model No. A2005ISH4BUSH) Cat Green (Model No. A2005ISH4BUSJ) Red - LE (Model No. A2005ISH4BUSN) Green - LE (Model No. A2005ISH4BUSM) Cat Green - LE (Model No. A2005ISH4BUSA) FRONT BODY PANEL ASSEMBLY REAR BODY PANEL ASSEMBLY TAILLIGHT ASSEMBLY DECALS FRAME AND RELATED PARTS FRAME AND RELATED PARTS (LE) WINCH ASSEMBLY (LE) SEAT ASSEMBLY STEERING POST ASSEMBLY HANDLEBAR ASSEMBLY FRONT SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY WHEEL AND TIRE ASSEMBLY WHEEL AND TIRE ASSEMBLY (LE) AUXILIARY BRAKE ASSEMBLY HYDRAULIC HAND BRAKE ASSEMBLY HYDRAULIC BRAKE ASSEMBLY GAS TANK ASSEMBLY REVERSE SHIFT LEVER ASSEMBLY AIR INTAKE ASSEMBLY STORAGE BOX AND BATTERY ASSEMBLY ENGINE AND EXHAUST OIL COOLER ASSEMBLY CASE/BELT COOLING ASSEMBLY DRIVE TRAIN ASSEMBLY FRONT DRIVE GEARCASE ASSEMBLY REAR DRIVE GEARCASE ASSEMBLY WIRING HARNESS ASSEMBLY CARBURETOR CYLINDER HEAD ASSEMBLY CYLINDER ASSEMBLY CRANKCASE ASSEMBLY CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY CRANKSHAFT ASSEMBLY STARTER CLUTCH ASSEMBLY CRANK BALANCER ASSEMBLY CAMSHAFT/VALVE ASSEMBLY CAM CHAIN ASSEMBLY RECOIL STARTER ASSEMBLY OIL FILTER/PUMP ASSEMBLY TRANSMISSION ASSEMBLY SECONDARY TRANSMISSION ASSEMBLY SECONDARY DRIVE ASSEMBLY GEAR SHIFTING ASSEMBLY STARTER MOTOR ASSEMBLY MAGNETO ASSEMBLY CONTROL SWITCH HOUSING ASSEMBLY THROTTLE CASE ASSEMBLY RELATED ITEMS Back Cover 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 2005 model year Arctic Cat Inc. Printed June 2004 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

3 FRONT BODY PANEL ASSEMBLY Rack - Front - Assembly (inc. 2-4) Decal, Warning - Front Rack Load Bushing, Rack Bushing, Rack Screw, Cap Screw, Cap Decal, Reflector - Amber Flare - Front - Right Flare - Front - Left Nut, Stamped Panel, Fender - Front (inc. 11) Panel, Fender - Front (inc. 11) (Green) Panel, Fender - Front (inc. 11) (Cat Green) Cover, Access Cover, Access (Green) Cover, Access (Cat Green) AR Screw, Body Nut, Speed Screw, Machine Screw, Self-Tapping Grommet, Fuel Shut-Off Valve Panel, Side - Right Panel, Side - Left Panel, Side - Right (Green) Panel, Side - Left (Green) Panel, Side - Right (Cat Green) Panel, Side - Left (Cat Green) Shield, Heat Nut, Expansion Screw, Shoulder T-Nut w/teeth Rivet, Reinstallable Panel, Fender - Inner - Upper Panel, Fender - Inner - Lower AR Cable Tie in Panel, Kick - Right Panel, Kick - Left AR Rivet, Plastic Screw, Machine T-Nut w/teeth Extension, Flare 1

4 REAR BODY PANEL ASSEMBLY Rack - Rear - Assembly (inc. 2-5) Rack - Rear - Assembly (inc. 2-5) (LE) Decal, Arctic Cat Decal, Arctic Cat (LE) Decal, Warning - Rear Rack Load Bushing, Rack Bushing, Rack Screw, Cap Decal, Reflector - Red AR Screw, Body AR Rivet, Plastic Panel, Fender - Rear Panel, Fender - Rear (Green) Panel, Fender - Rear (Cat Green) Shield, Fuse Block Key, Fuse Block Shield Spring, Fuse Block Shield Screw, Machine Shield, Heat Shield, Heat Flare, Rear - Right Flare, Rear - Left Screw, Self-Tapping Screw, Shoulder T-Nut w/teeth Fender Extension - Rear - Right Fender Extension - Rear - Left Shield, Heat Screw, Self-Tapping Clip, Tinerman 2

5 TAILLIGHT ASSEMBLY (Complete Taillight Assembly p/n ) Bulb, Stop/Taillight Taillight w/socket Assembly Gasket, Taillight Lens Lens, Taillight Screw, Machine Screw, Self-Tapping Washer, Lock - External Tooth 3

6 DECALS Decal, Warning - Reverse/Pre-Ride Decal, Warning - Turn Decal, Warning - Clutch Cover Decal, Warning - Differential Lock Decal, Passenger Decal, Warning - Towing Decal, Warning - General Decal, Warning - Tire Pressure Decal, Side - Right Decal, Side - Left Decal, Side - Right (Green) Decal, Side - Left (Green) Decal, Side - Right (Cat Green) Decal, Side - Left (Cat Green) Decal, Warning - Age Decal, Front Decal, Front (Green) Decal, Front (Cat Green) Decal, Crest Decal, Crest (Green) Decal, Crest (Cat Green) Decal, Speedrack 4

7 FRAME AND RELATED PARTS Frame, Main Headlight Assembly - Right (inc. 3-6) Headlight Assembly - Left (inc. 3-6) Bulb, Headlight Screw, Cap Bracket, Headlight Mounting Nut, Lock Nut, Flange Screw, Cap Channel, Bumper Mounting Screw, Cap Bumper Cap, Bumper Grille, Upper Screw, Machine Grille, Bumper - Lower Screw, Machine Plate, Skid Plate, Skid (Green) Plate, Skid (Cat Green) AR Screw, Body Panel, Belly Screw, Cap Footrest - Right Footrest - Left Nut, Flange Foam, Frame Pad, Frame 5

8 FRAME AND RELATED PARTS (LE) Frame, Main Headlight Assembly - Right (inc. 3-6) Headlight Assembly - Left (inc. 3-6) Bulb, Headlight Screw, Cap Bracket, Headlight Mounting Nut, Lock Nut, Flange Screw, Cap Channel, Bumper Mounting Screw, Cap Bumper Cap, Bumper Grille, Upper Plate, Bumper Tube Tube, Bumper Cap, Bumper Screw, Cap Washer, Lock Washer Spacer Washer Washer, Lock Screw, Cap Washer Washer, Lock Screw, Cap Plate, Skid Plate, Skid (Green) Plate, Skid (Cat Green) AR Screw, Body Panel, Belly Foam, Frame Pad, Frame Screw, Cap Nut, Flange Footrest - Right Footrest - Left Bumper, Rear Screw, Machine Bracket, Clamp Nut, Lock Spacer Screw, Cap Support, Rear Bumper Nut, Lock Screw, Cap 6

9 WINCH ASSEMBLY (LE) Winch (inc. 2-3) Cable, Winch Hook, Winch Decal, Winch Plate, Winch Screw, Machine Washer, Lock Screw, Cap Roller, Winch Cable, Solenoid/Battery - Black Cable, Solenoid/Battery - Red Boot, Terminal Solenoid (inc ) Nut Washer, Lock Cable, Winch/Solenoid - Yellow Cable, Winch/Solenoid - Blue AR Cable Tie in Switch, Control Bracket, Mounting - Solenoid Nut, Lock Holder, Control Switch Cover, Switch Screw, Self-Tapping Screw, Machine Pad 7

10 SEAT ASSEMBLY Seat Assembly (inc. 2-8) Cover, Seat Foam, Seat Foam, Sound Base, Seat Assembly (inc. 6-7) Bumper, Seat - Front Bumper, Seat - Rear AR Staple Plate, Retainer Rivet Spring, Seat Latch Latch, Seat 8

11 STEERING POST ASSEMBLY Screw, Cap Cap, Steering Adjuster Screw, Shoulder Cap, Housing Housing, Lower Housing, Upper Post, Steering Screw, Cap Flange, Bearing Bearing w/inverted Oil Seal Washer Screw, Cap Tie Rod - Assembly (inc ) Ball Joint, Tie Rod - Left Nut - Left Tie Rod Nut - Right Ball Joint, Tie Rod - Right Nut, Top Lock Pin, Cotter 9

12 HANDLEBAR ASSEMBLY Tube, Handlebar Plug, Handlebar End Cap, Handlebar Washer Screw, Machine Grip, Handlebar Cover, Key Switch, Ignition - Assembly (inc. 9) Key, Ignition - Blank (C Series) Key, Ignition - Blank (D Series) Key, Ignition - Blank (E Series) Key, Ignition - Blank (F Series) Bracket, Mounting - Instrument Pod Instrument Pod Instrument Pod (Green) Instrument Pod (Cat Green) Rivet, Reinstallable Screw, Shoulder Gauge, Digital Nut, Flange Grommet Control, Differential Lock (inc. 18) Clamp, Differential Lock Control - Kit Cable, Differential Lock 10

13 FRONT SUSPENSION ASSEMBLY Retainer, Spring Shock Absorber - Front (inc. 3-4) Bushing, Shock Absorber Sleeve, Shock Cam, Spring Adjuster Spring, Shock Absorber - Platinum Spring, Shock Absorber - Black (Green) Screw, Cap Nut, Lock A-Arm, Upper Right - Platinum (inc ) A-Arm, Upper Left - Platinum (inc ) A-Arm, Upper Right - Black (inc ) (Green) A-Arm, Upper Left - Black (inc ) (Green) Bushing Collar Clip, Ball Joint Ball Joint - Front A-Arm, Lower Right - Platinum (inc and 15-16) A-Arm, Lower Left - Platinum (inc and 15-16) A-Arm, Lower Right - Black (inc and 15-16) (Green) A-Arm, Lower Left - Black (inc and 15-16) (Green) Bushing Collar Knuckle - Assembly - Right (inc ) Knuckle - Assembly - Left (inc ) Knuckle, Steering - Right Knuckle, Steering - Left Bearing, Wheel Hub Ring, Retaining Screw, Cap Screw, Cap Screw, Cap Axle, Drive - Front - Right (inc ) Axle, Drive - Front - Left (inc ) Clip, Retaining Repair Kit, Boot - Front Axle Guard, Boot - Axle - Right Guard, Boot - Axle - Left Guard, Boot - Axle - Right (Green) Guard, Boot - Axle - Left (Green) Guard, Boot - Axle - Right (Cat Green) Guard, Boot - Axle - Left (Cat Green) Screw, Body Wrench, Spanner 11

14 REAR SUSPENSION ASSEMBLY Knuckle, Right Rear - Assembly (inc. 2-6) Knuckle, Left Rear - Assembly (inc. 2-6) Knuckle - Right Knuckle - Left Bearing, Wheel Hub Ring, Retaining Collar, Suspension Bushing Bushing, Suspension A-Arm, Rear - Lower Right - Platinum (inc. 8-9) A-Arm, Rear - Lower Left - Platinum (inc. 8-9) A-Arm, Rear - Lower Right - Black (inc. 8-9) (Green) A-Arm, Rear - Lower Left - Black (inc. 8-9) (Green) Bushing Collar Nut, Lock Screw, Cap A-Arm, Rear - Upper Right - Platinum (inc. 8-9) A-Arm, Rear - Upper Left - Platinum (inc. 8-9) A-Arm, Rear - Upper Right - Black (inc. 8-9) (Green) A-Arm, Rear - Upper Left - Black (inc. 8-9) (Green) Guard, Boot - Right Guard, Boot - Left Guard, Boot - Right (Green) Guard, Boot - Left (Green) Guard, Boot - Right (Cat Green) Guard, Boot - Left (Cat Green) Screw, Body Guard, Boot - Right Guard, Boot - Left Axle, Drive (inc ) Clip, Retaining Repair Kit, Boot - Rear Axle Screw, Cap Retainer, Spring Spring, Suspension - Platinum Spring, Suspension - Black (Green) Shock Absorber - Rear (inc ) Bushing, Shock Absorber Sleeve, Shock Absorber Cam, Spring Adjuster Screw, Cap Washer Screw, Cap Wrench, Spanner 12

15 WHEEL AND TIRE ASSEMBLY Screw, Machine Disc, Brake Hub, Wheel - Front (inc. 4) Stud, Wheel Hub Pin, Cotter Nut, Castle Wheel - Front - Platinum Wheel - Front - Gray (Green) Nut, Mounting - Wheel Tire - Front Stem, Valve (inc. 11) Cap, Valve Stem Hub, Wheel - Rear - Left (inc. 4) Hub, Wheel - Rear - Right (inc. 4) Wheel - Rear - Platinum Wheel - Rear - Gray (Green) Tire - Rear 13

16 WHEEL AND TIRE ASSEMBLY (LE) Screw, Machine Disc, Brake Hub, Wheel - Front (inc. 4) Stud, Wheel Hub Pin, Cotter Nut, Castle Wheel - Front - Spoked Nut, Mounting - Wheel Tire - Front Stem, Valve (inc. 11) Cap, Valve Stem Hub, Wheel - Rear - Left (inc. 4) Hub, Wheel - Rear - Right (inc. 4) Wheel - Rear - Spoked Tire - Rear 14

17 *Not a Service Part AUXILIARY BRAKE ASSEMBLY Lever, Brake O-Ring Spring, Brake Lever Nut Axle, Brake Lever Pin, Clevis Washer Pin, Cotter Brake Assembly (inc ) Actuator, Push Rod Nut, Jam 12 * 1 Master Cylinder Fitting, Banjo Bolt, Banjo Fitting Clamp, Hose Hose, Brake Reservoir Reservoir, Brake Nut, Flanged Bracket, Mounting - Reservoir Screw, Machine Hose, Brake Bolt, Banjo Fitting Washer, Crush Screw, Cap Caliper, Brake (inc ) 26 * 1 Housing, Caliper Pin, Brake Caliper Pad, Brake Pin, Cotter Cap, Bleed Valve Valve, Bleed Piston O-Ring, Brake Caliper 34 * 1 O-Ring 35 * 1 Plug 36 * 1 Ring, Retaining AR Cable Tie in. 15

18 HYDRAULIC HAND BRAKE ASSEMBLY Brake Assembly (inc. 2-10) Screw, Reservoir Cover - Kit Cover, Reservoir - Kit Screw, Master Cylinder Clamp - Kit Clamp, Master Cylinder - Kit Master Cylinder Assembly - Kit Lever Assembly - Kit (inc. 8-9) Lock, Brake Lever - Kit Lever Pin - Kit Switch, Brake - Kit Brakeline, Hydraulic 16

19 HYDRAULIC BRAKE ASSEMBLY Screw, Cap Hose, Brake - Front - Right Hose, Brake - Front - Left Block, Junction Plug Screw, Cap Caliper, Brake - Right Front (inc. 7-13) Caliper, Brake - Left Front and Right Rear (inc. 7-13) Housing, Caliper - Assembly - Right Front (inc. 8-10) Housing, Caliper - Assembly - Left Front and Right Rear (inc. 8-10) Piston/Seal Set (inc. 9) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Washer, Crush Bolt, Banjo Fitting Hose, Brake - Rear 17

20 GAS TANK ASSEMBLY Tank, Gas - Assembly (inc. 2-10) Cap, Gas Tank (inc. 3) Gasket, Tank Cap Gauge, Fuel w/gasket (Press-Fit) Nut, Lock Hose, Vent AR Hose, Gasline - 25 ft Clamp, Hose - Spring Valve, Fuel Shut-Off (inc. 10) Gasket, Fuel Shut-Off Valve Knob, Fuel Shut-Off Valve Screw, Fuel Shut-Off Valve Knob Screw, Gas Tank 18

21 REVERSE SHIFT LEVER ASSEMBLY Nut Screw, Cap Axle, Reverse Shift Lever Lever, Reverse Shift O-Ring O-Ring Washer Spring, Reverse Shift Lever Axle, Pivot Handle, Reverse Shift Lever Clip, Push Linkage, Shift End, Rod Nut Bushing, Shift Linkage Washer E-Ring Plate, Shift Shield, Linkage Screw, Machine Screw, Self-Tapping 19

22 AIR INTAKE ASSEMBLY Clamp Boot, Air Intake Clamp Housing, Air Intake Filter, Air Gasket Snorkel Clamp Spring Screw, Machine Nut, Expansion Support, Air Intake Flange Shield, Heat Valve, Drain Clip, Retaining Cap, Drain Tube Clamp, Hose Clamp, Hose - Spring Hose, Crankcase Vent 20

23 STORAGE BOX AND BATTERY ASSEMBLY Strap, Battery w/pads (inc. 2-3) Pad, Battery - Upper Front Pad, Battery - Upper Rear Battery Assembly (inc. 5-8) Cap, Battery Clamp, Hose Hose, Battery Vent Label, Warning - Battery Pad, Battery - Lower Kit, Tool Screw, Thumb Cable Tie in Storage Box - Assembly (inc. 14) Shield, Heat Cover, Storage Box Screw, Self-Tapping 21

24 ENGINE AND EXHAUST Engine Bracket, Engine - Right Bracket, Engine - Left Nut Screw, Cap Bracket, Engine - Upper Screw, Cap Screw, Cap Washer, Engine Spacer, Engine Nut, Lock Seal, Exhaust Screw, Cap Pipe, Exhaust Cover, Exhaust Pipe - Front Screw, Machine Bushing, Exhaust Gasket, Exhaust Spring, Exhaust Muffler Cover, Muffler Gasket, Switch Switch, Cooling Fan Switch, Oil Light Gasket, Switch Cover, Exhaust Pipe - Rear 22

25 OIL COOLER ASSEMBLY Cooler, Oil - Assembly (inc. 2-10) Cooler, Oil Screen, Oil Cooler Screw, Thumb Shroud, Fan Screw, Machine Fan, Cooling Plug, Drain O-Ring Grommet Nut w/washer Screw, Shoulder Bushing, Stem Clamp, Hose Hose, Oil Fitting, Oil O-Ring, Oil Fitting Screw, Cap Fitting, Oil - Angled 23

26 CASE/BELT COOLING ASSEMBLY Duct, Belt Cooling - Rear Screw, Self-Tapping Clamp, Boot Boot, Duct - Rear Clamp, Boot Boot, Duct - Front Duct, Belt Cooling - Front Cable Tie in. 24

27 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 Clip, Routing - Snap-In Fitting, Vent Bumper, Propeller Shaft Shaft, Propeller Clamp, Boot Boot Flange, Output Screw, Cap 25

28 FRONT DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n ) Shaft, Propeller - Assembly (inc. 2-6) Clamp, Boot Boot, Propeller Shaft Clamp, Boot Shaft, Output Shaft, Input Seal Ring, Retaining Bracket, Actuator Actuator (inc. 11) O-Ring Screw, Self-Tapping Bearing Screw, Self-Tapping Housing, Pinion Gasket, Flange Shaft, Selector Fork, Selector Shaft, Shuttle Ring, Retaining O-Ring Spring, Return Ring, Retaining Collar, Lock Coupler, Drive Gear, Pinion - Assembly - 10T (inc ) Collar, Retaining Bearing AR Shim AR Shim AR Shim AR Shim AR Shim Bearing Pin, Dowel Housing, Gearcase Plug, Magnetic (inc. one No. 34) 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. 34, 41-56, and one No. 57) 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. 34) Seal Plug, Fill (inc. 59) O-Ring

29 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. 15) O-Ring Bearing Gear, Pinion - Assembly - 10T (inc ) AR Shim AR Shim AR Shim AR Shim AR Shim Bearing Collar, Retaining Pin, Dowel Collar, Lock Washer, Wave Collar, Shaft Gasket, Flange Housing, Pinion Ring, Retaining Bearing Ring, Retaining Seal Shaft, Input 27

30 WIRING HARNESS ASSEMBLY Harness, Main (inc. 2-7 and two No. 8) Cover, Fuse Block Fuse - 10 Amp Fuse - 15 Amp Fuse - 30 Amp Relay Diode Holder, Fuse Decal, Fuse Block AR Cable Tie in Boot, Terminal Cable, Solenoid/Starter Solenoid Nut w/washer Cable, Battery/Solenoid (inc. one No. 14) Boot, Terminal Cable, Battery/Ground Switch, Brake - Assembly Retainer, Switch Bracket, CDI Screw, Machine CDI Unit Screw, Machine Regulator, Voltage Harness, Adapter - Electric Choke Receptacle, 12V (inc. 25) Nut, Retainer Diode Assembly Coil, Ignition - Assembly Seal, High Tension Wire Cap, Spark Plug Seal, Spark Plug Nut, Flange Screw, Machine AR Cable Tie in. 28

31 *Not a Service Part **Optional CARBURETOR (Complete Assembly p/n ) Cover, Top Screw, Top Cover Spring Piston, Vacuum Seat, Spring Jet Needle Needle Jet Holder, Needle Jet Main Jet Main Jet - 150** Main Jet - 147** Main Jet - 145** Main Jet - 140** Slow Jet Starter Jet Valve, Float - Set (inc. 13) 13 * 1 Clip Float Set (inc. 15) 15 * 1 Pin, Float Screw, Pilot Air - Set (inc ) 17 * 1 Spring 18 * 1 Washer 19 * 1 O-Ring Screw, Idle Adjust Washer Spring Plate Screw Choke, Electric Cover, Electric Choke Chamber, Float - Assembly (inc ) O-Ring, Float Chamber Screw, Drain Spring Diaphragm Assembly 32 * 1 Housing, Pump U-Ring Screw Screw Cable, Throttle Cover Screw Hose, Vent 29

32 *Not Illustrated CYLINDER HEAD ASSEMBLY Head, Cylinder - Assembly (inc. 2-5) Guide, Valve Ring, Valve Guide Pin, Dowel Bolt Gasket, Cylinder Head Pin, Dowel Gasket Nut, Cylinder Head Bolt, Head Cover Bolt, Head Cover Washer, Cylinder Head Nut Bolt, Head Cover Bolt, Head Cover Plug, Oil Gallery Gasket, Oil Gallery Plug Spark Plug (NGK CR7E) Cap, Inspection O-Ring Bolt, Inspection Cap Plug, Head O-Ring Screw, Machine Manifold, Intake Clamp * Plug, Frost 30

33 CYLINDER ASSEMBLY Cylinder Bolt, Stud Bolt, Stud Bolt Bolt Bolt Nut Gasket, Cylinder Pin, Dowel 31

34 CRANKCASE ASSEMBLY Crankcase Assembly (inc. 2-9) Bolt Bolt Bolt Gasket, Oil Pressure Plug Plug, Oil Pressure Pin, Dowel Bolt Bolt Plate, Oil Guide - Right Screw, Oil Guide Plate Plate, Oil Guide - Left 32

35 CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY Cover, Clutch Gasket Pin, Dowel Bolt Bolt Gasket Cover, V-Belt Gasket, V-Belt Cover Bolt Screw Plate, Air Intake Gasket, Drain Plug Plug, Drain Plug Gasket Cover, Magneto Gasket, Magneto Cover Plug, Oil Gallery Gasket Stick, Oil Level O-Ring, Oil Level Stick Bolt Bolt 33

36 *Optional CRANKSHAFT ASSEMBLY Crankshaft Assembly (inc. 2-8) Rod, Connecting Pin, Crank Bearing Washer Crankshaft - Right Crankshaft - Left Gear, Crank Balancer Drive Bearing - Right Bearing - Middle Seal, Crankshaft Oil Retainer, Crankshaft Oil Seal - Middle Screw, Retainer Bearing O-Ring Spacer Seal, Oil O-Ring Retainer, Crankshaft Oil Seal - Left Piston Ring, Piston - Set Circlip Pin, Piston Piston Set (Oversized 0.50 mm)* 34

37 STARTER CLUTCH ASSEMBLY Gear, Starter Idler - No Gear, Starter Idler - No Pin, Starter Idler Gear No Pin, Starter Idler Gear No Clutch, Starter - Set (inc. 6) Bearing Bolt 35

38 CRANK BALANCER ASSEMBLY Balancer, Crank Bearing Key Gear, Driven Gear, Oil Pump Drive Pin, Drive Gear Washer, Drive Gear Bolt, Drive Gear 36

39 CAMSHAFT/VALVE ASSEMBLY Camshaft Sprocket Pin Washer Bolt C-Ring Arm, Valve Rocker - Intake (inc. two No. 8-9) Screw Nut Arm, Valve Rocker - Exhaust (inc. two No. 8-9) Seat, Spring Seal, Oil Shaft, Rocker Arm Shaft, Rocker Arm Washer Plug, Shaft Gasket Valve, Intake Valve, Exhaust Spring, Valve Retainer, Spring Cotter, Valve 37

40 CAM CHAIN ASSEMBLY Chain, Cam Guide, Cam Chain Tensioner, Cam Chain Bolt Washer Adjuster, Tensioner - Assembly (inc. 7-9) Spring Plug O-Ring Gasket, Adjuster Bolt 38

41 RECOIL STARTER ASSEMBLY Starter, Recoil - Assembly (inc. 2-8) Reel Spring, Spiral Ratchet - Assembly (inc. 5-6) Ratchet Guide, Ratchet Nut Rope Assembly Screw, Cap Cup, Starter Nut 39

42 OIL FILTER/PUMP ASSEMBLY Pump, Oil Gear, Driven Pin Washer Circlip Screw Strainer, Oil Screw Cap, Oil Strainer O-Ring Screw, Cap Filter, Oil Plug, Drain Gasket, Drain Plug Valve, Oil Relief - Assembly Pin, Oil Pump 40

43 TRANSMISSION ASSEMBLY Face, Fixed Drive Face, Movable Drive Seal, Movable Drive Face Spacer, Movable Drive Face Face, Fixed Driven Face, Movable Driven Spring, Movable Driven Face O-Ring, Movable Driven Face Seal, Movable Driven Face Pin, Movable Driven Face Spacer, Movable Driven Face Plate, Movable Drive Face Sleeve, Movable Driven Face Damper, Movable Drive Face Nut, Driven Pulley Holder, Movable Driven Face Spring Roller, Movable Drive Face Nut V-Belt Housing, Clutch Spacer, Fixed Drive Face Seal, Clutch Housing Seal, Clutch Housing Circlip Clutch, One Way Shoe, Clutch - Assembly Retainer, Bearing Screw, Bearing Retainer Bearing Bearing O-Ring Nut 41

44 SECONDARY TRANSMISSION ASSEMBLY Washer, Reverse Idle Gear Gear, Reverse Idle Bushing, Reverse Idle Gear Shaft, Reverse Idle Spacer, Reverse Idle Gear Seal, Driveshaft Bearing, Driveshaft Driveshaft Bearing, Driveshaft - Left Bearing, Shaft Dog, Reverse Driven Gear Circlip Washer Bushing Bearing Gear, Reverse Driven Gear, Driven - Low Dog, Sliding Washer Gear, Driven - High Countershaft Bearing, Shaft Gear, Drive - No Circlip Bearing, Output Shaft Screw, Bearing Retainer Retainer, Bearing Shaft, Output Spacer, Output Shaft Gasket, Housing Housing, Speedometer Sensor Seal, Shaft Shaft, Output Washer Rotor Washer Bearing O-Ring Cover, Speedometer Sensor Housing Gasket Bolt Sensor, Speedometer Bolt 42

45 SECONDARY DRIVE ASSEMBLY Gear, Secondary Drive Shim, Secondary Drive Gear - Set Nut Washer Yoke, Propeller Shaft Joint, Universal - Set (inc. 7) Circlip Nut Washer Yoke, Drive Output - Front Seal, Oil Bearing, Front Secondary Driven Shaft Shaft, Secondary Driven - Front Washer, Secondary Driven Gear Nut, Secondary Driven Gear Gear, Secondary Driven Bearing, Driven Gear C-Ring, Driven Bearing Shaft, Secondary Driven - Rear AR Shim, 25 x 34 x 0.60 mm AR Shim, 25 x 34 x 0.65 mm AR Shim, 25 x 34 x 0.70 mm AR Shim, 25 x 34 x 0.75 mm AR Shim, 25 x 34 x 0.80 mm AR Shim, 25 x 34 x 0.85 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 AR Shim, 25 x 34 x 1.20 mm Bearing, Rear Secondary Driven Shaft Flange, Output Joint - Rear 43

46 GEAR SHIFTING ASSEMBLY Cam, Reverse Stopper, Cam Spring, Cam Stopper Support, Cam Stopper Plate, Gear Shift Cam Shaft, Shift Fork Shaft, Sub-Gear Shift Fork, Shift Clamp, Wire Cam, Gear Shift Shaft, Gear Shift Washer, Cam Stopper Spring Washer, Sub-Gear Shift Shaft Washer, Gear Shift Cam Plate Seal, Sub-Gear Shift Shaft C-Ring, Cam Bolt, Gear Shift Cam Plate Washer, Cam Stopper Nut, Cam Stopper Spring Circlip, Sub-Gear Shift Shaft Spring, Cam Contact Washer, Cam Spring Circlip, Cam Spring Washer, Shift Shaft Washer, Shift Shaft Arm, Select Washer, Select Arm Bolt, Select Arm E-Ring Base, Gear Shift - Assembly Bolt Spring 44

47 STARTER MOTOR ASSEMBLY Motor, Starter Assembly (inc. 2-10) Terminal Set, Brush Holder Set, Brush (inc. 4) Spring, Brush O-Ring O-Ring Washer Set O-Ring Through-Bolt (inc. 10) O-Ring Bolt Nut 45

48 MAGNETO ASSEMBLY Stator Assembly Rotor/Flywheel Bolt Key Nut Bolt Clamp Clamp Clamp, Wire 46

49 CONTROL SWITCH HOUSING ASSEMBLY Switch, Control - Assembly (inc. 2-3) Screw Screw, Cap Cover, Choke Lever 47

50 THROTTLE CASE ASSEMBLY Case, Throttle - Assembly (inc. 2-9) Lever Screw, Cap Washer, Lock Washer Screw Nut Screw Cover, Throttle w/switch 48

51 RELATED ITEMS 2005 ATV 400 FIS (Automatic Transmission) Red (Model No. A2005ISH4BUSI) Red - LE (Model No. A2005ISH4BUSN) Green (Model No. A2005ISH4BUSH) Green - LE (Model No. A2005ISH4BUSM) Cat Green (Model No. A2005ISH4BUSJ) Cat Green - LE (Model No. A2005ISH4BUSA) Articulating Spool Mount Articulating Spool Receiver Mount Adapter Bag, Fender - Black Bag, Rack, Front - Black Bar, Utility/Gun Rack Brush Guard/Bumper Bucket Holder Bumper (Rear) Camp Stove Cradle Cargo Box Cargo Box Quick-Release Kit Carryall (9 x 12) Carryall (11 x 17) Carryall (14 x 27) Chain Saw Lock Cord Reel Cover, Black and Green Cover, Timber Camo Engine Oil - 10W Engine Oil - 5W Fender Box Gear Cradle Gear Lube (Diff) - 80W Grease, High-Performance Gun Scabbard Kit Gun Scabbard Mount Hand Guards - Black Hand/Thumb Warmers Ice Auger Holder Light Bar Manual, Illustrated Parts Manual, Operator s (E) Manuel d utilisation (F) Rack Basket Rack Extension, 4 in. (Front) Rack Extension, 8 in. (Rear) Rapid Blind (Break-Up) Rapid Blind (Shadow Grass) Rapid Shack (Blue Ice) Rod Holder - Adjustable Snowplow Attachment Kit Snowplow Blade, 50 in. - Straight Snowplow Blade, 50 in. - One-Way Snowplow Blade, 60 in. - Straight Snowplow Blade, 60 in. - One-Way Snowplow, Push Frame Speedclamp, Double Sprayer System Sprayer Boom (120 in.) Table, Expansion Tire, Titan AT589 (25x8-12, Mud & Snow) Tire, Titan AT589 (25x10-12, Mud & Snow) Tool Caddy Tool Holder - Double Tool Holder - Single Tree Stand/Bow Case Holder Winch, 2500 lb Winch Mounting Kit Windshield, Clear w/black Accent Workbase (8 in.) NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A. p/n