Illustrated Parts Manual. 700 Diesel

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1 ATV Illustrated Parts Manual A R C T I C C A T 700 Diesel Model Number A2007TBT4DUSR (Red) Model Number A2007TBT4DUSG (Green) Model Number A2007TBT4DOSG (Green - International) MORE TO GO ON.

2 TABLE OF CONTENTS 2007 ATV 700 Diesel Red (Model No. A2007TBT4DUSR) Green (Model No. A2007TBT4DUSG) Green - International (Model No. A2007TBT4DOSG) FRONT BODY PANEL ASSEMBLY... 1 REAR BODY PANEL ASSEMBLY... 2 TAILLIGHT ASSEMBLY... 3 DECALS... 4 FRAME AND RELATED PARTS... 5 SEAT ASSEMBLY... 6 REAR RACK AND BACKREST ASSEMBLY... 7 STEERING POST ASSEMBLY... 8 HANDLEBAR ASSEMBLY... 9 FRONT SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY WHEEL AND TIRE ASSEMBLY AUXILIARY BRAKE ASSEMBLY HYDRAULIC HAND BRAKE ASSEMBLY HYDRAULIC BRAKE ASSEMBLY FUEL TANK ASSEMBLY REVERSE 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 DRIVE BELT ASSEMBLIES TRANSMISSION RIGHT-SIDE ASSEMBLY TRANSMISSION LEFT-SIDE ASSEMBLY CRANKSHAFT ASSEMBLY PISTON SET AND CONNECTING ROD ASSEMBLY FLYWHEEL AND RING GEAR ASSEMBLY DRIVE PULLEY AND ALTERNATOR BELT ASSEMBLY CRANKCASE, CRANKSHAFT SUPPORT, AND OIL FILTER ASSEMBLIES CYLINDER HEAD AND PRECOMBUSTION CHAMBER 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 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 TOP END GASKET SET ASSEMBLY BOTTOM END GASKET SET 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 2007 model year Arctic Cat Inc. Printed December 2006 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

3 FRONT BODY PANEL ASSEMBLY Rack - Front - Assembly (inc. 2-5) Decal, Warning - Front Rack Load Bushing, Rack Bushing, Rack Plug, Rack Screw, Machine Spacer Grommet Nut, Lock Panel, Fender - Front (inc. 11) Panel, Fender - Front (Green) (inc. 11) Decal, Reflector - Front - Right Decal, Reflector - Front - Left Cover, Access Rivet, Reinstallable Cover, Steering Post Rivet, Reinstallable Cover, Storage Box Lid, Storage Box w/latch (inc ) Lid, Storage Box Latch, Storage Box AR Cable Tie in Panel, Side - Lower - Right Panel, Side - Lower - Left Screw, Body Screw, Shoulder Washer Nut, Lock Headlight Assembly - Right (inc. 27) Headlight Assembly - Left (inc. 27) Bulb, Headlight Screw, Self-Tapping Washer Grommet Knob, Adjuster Spring, Adjuster Stud, Adjuster - Headlight Panel, Splash - Right Panel, Splash - Left Screw, Self-Tapping 1

4 REAR BODY PANEL ASSEMBLY Rack, Rear - Assembly (inc. 2-6) Pin - Assembly (inc. 3) Pin, Roll Collar Spring Bushing, Rack Screw, Machine Spacer Grommet Nut, Lock Panel, Fender - Red (inc. 12) Panel, Fender - Green (Green) (inc. 12) Decal, Reflector - Right Decal, Reflector - Left Screw, Shoulder Bracket, Rear Fender - Right Bracket, Rear Fender - Left Washer 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 Decal, Storage 2

5 TAILLIGHT ASSEMBLY Taillight Assembly (inc. 2-4) Housing, Taillight Bulb, Taillight Socket, Taillight Screw, Self-Tapping Washer, Lock - External Tooth 3

6 DECALS *Included on Front/Rear Fender Panels Decal, Warning - Reverse/Pre-Ride* Decal, Warning - Hill* Decal, Warning - Clutch Cover Decal, Instrument Pod Decal, Instrument Pod (Green) Decal, Warning - Differential Lock Decal, Passenger* Decal, Warning - Tire Pressure* Decal, Side - Upper Right Decal, Side - Upper Left Decal, Side - Upper Right (Green) Decal, Side - Upper Left (Green) Decal, Graphic - Lower Decal, Graphic - Lower (Green) Decal, Speedrack Decal, Front Bumper - Arctic Cat Decal, Warning - Passenger* Decal, Warning - Seat/Passenger* Decal, Warning - Towing Decal, Warning - Off-Road Only* Decal, Warning - Age/General 4

7 FRAME AND RELATED PARTS Frame, Main Screw, Cap Channel, Shock Support Screw, Cap Channel, Bumper Mounting - Right Channel, Bumper Mounting - Left Bracket, Mounting - Bumper - Right Bracket, Mounting - Bumper - Left Bumper Screw, Machine Strap, Bumper Support Nut, Lock Nut, Lock Brace, A-Arm Screw, Cap Panel, Belly Screw, Body Pad, Frame Nut, Flange Screw, Cap Strap, Footrest - Right Strap, Footrest - Left Footrest - Right Footrest - Left 5

8 SEAT 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 6

9 *Not Illustrated REAR RACK AND BACKREST ASSEMBLY (Rear Rack Kit p/n ) Rack, Rear - Assembly (inc. 2-7) Plug Bushing Bushing Decal, Arctic Cat Decal, Warning - Rear Rack Load Decal, Speedrack Bracket, Backrest Screw, Cap Backrest Screw, Machine Pin * Instructions 7

10 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-Hand Thread Nut - Left-Hand Thread Tie Rod Nut - Right-Hand Thread Ball Joint, Tie Rod - Right-Hand Thread Nut, Top Lock Pin, Cotter 8

11 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) Rivet, Reinstallable Gauge, LCD Clamp, Plastic Nut w/washer Control, Differential Lock (inc. 17) Clamp, Differential Lock Control - Kit Cable, Differential Lock Outlet, Accessory - 12V Light, Indicator - Glow Plug Light, Indicator - Battery Cable, Throttle 9

12 FRONT SUSPENSION ASSEMBLY Shock Absorber - Front (inc. 2-3) Bushing, Shock Absorber Sleeve, Shock Cam, Spring Adjuster Spring, Shock Absorber - Platinum Spring, Shock Absorber - Black (Green) Retainer, Spring 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 ) 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 Wrench, Spanner 10

13 REAR SUSPENSION ASSEMBLY Knuckle, Right Rear - Assembly (inc. 2-5) Knuckle, Left Rear - Assembly (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) A-Arm, Rear - Lower Right - Black (inc. 7-8) (Green) A-Arm, Rear - Lower Left - Black (inc. 7-8) (Green) Bushing Collar Nut, Lock Screw, Cap A-Arm, Rear - Upper Right - Platinum (inc. 7-8) A-Arm, Rear - Upper Left - Platinum (inc. 7-8) A-Arm, Rear - Upper Right - Black (inc. 7-8) (Green) A-Arm, Rear - Upper Left - Black (inc. 7-8) (Green) 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 Wrench, Spanner Retainer, Spring Spring, Suspension - Platinum Spring, Suspension - Black (Green) Cam, Spring Adjuster Shock Absorber - Rear (inc ) Bushing, Double-Bonded Bushing, Shock Absorber Sleeve, Shock Absorber Washer Screw, Cap Screw, Cap Cable Tie 11

14 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 Wheel - Front - Gray (Green) Wheel - Rear - Gray (Green) Nut, Mounting - Wheel Tire - Front Tire - Rear Stem, Valve (inc. 12) Cap, Valve Stem 12

15 R *Not a Service Part AUXILIARY BRAKE ASSEMBLY (Fully Bled Master Cylinder Replacement Kit p/n ) Lever, Brake O-Ring Washer Screw, Cap Spring, Brake Lever Brake Assembly (inc. 7-9) 7 * 1 Master Cylinder Hose, Brake Reservoir w/clamps Reservoir, Brake Nut, Flanged Screw, Machine Cable Tie in Hose, Brake Washer, Crush Bolt, Banjo-Fitting Bracket, Switch Screw, Cap Spring, Brake Switch Screw, Cap Caliper, Brake (inc ) Housing, Caliper - Assembly - Right Rear (inc ) Piston/Seal Set (inc. 23) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Clip, Brake Hose Adapter, Hose 13

16 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 Washer, Crush Bolt, Banjo-Fitting 14

17 HYDRAULIC BRAKE ASSEMBLY Hose, Brake - Assembly Screw, Cap Screw, Cap Caliper, Brake - Right Front (inc. 5-11) Caliper, Brake - Left Front (inc. 5-11) Housing, Caliper - Assembly - Right Front (inc. 6-8) Housing, Caliper - Assembly - Left Front (inc. 6-8) Piston/Seal Set (inc. 7) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Washer, Crush Bolt, Banjo-Fitting 15

18 FUEL TANK ASSEMBLY Tank, Fuel - Assembly w/straps (inc. 2-11) Cap, Fuel Tank Sensor, Fuel Level (inc. 4) Seal, Fuel Level Sensor Plate, Mounting - Fuel Level Sensor Screw, Plastite Strap, Mounting - Fuel Tank - Front Strap, Mounting - Fuel Tank - Rear Screw, Machine Nut, Lock Screw, Machine Screw, Mounting - Fuel Tank Clip, Mounting - Fuel Tank Clamp, Hose AR Hose, Fuel - 25 ft Clamp, Hose Fitting, T Clamp, Hose Shield, Fuel Tank Shield, Heat Screw, Self-Tapping AR Hose, Fuel - 25 ft AR Hose, Fuel - 25 ft 16

19 REVERSE SHIFT LEVER ASSEMBLY Knob, Reverse Shift Lever Clip, Push Plate, Shift Nut, Stamped Lever, Reverse Shift Spring, Reverse Shift Lever Axle, Reverse Shift Lever Nut O-Ring Axle, Pivot O-Ring Screw, Cap Washer Nut End, Rod Linkage, Shift Bushing, Shift Linkage Washer E-Ring 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 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 20

23 COOLING ASSEMBLY Radiator Assembly (inc. 2-10) Radiator Screen, Radiator Grommet Shroud, Fan Fan, Cooling Screw, Machine Clamp, Cable Sensor, Temperature - Coolant O-Ring AR Hose - 25 ft Cap, Radiator Tank, Coolant Fill Screw, Shoulder Nut w/washer Bushing, Stem Clamp, Hose Hose, Coolant Hose, Coolant Clamp Hose, Coolant - Coupler Clamp, Hose Tank, Coolant Overflow Stopper, Coolant Tank AR Hose, Clear - 25 ft Cable Tie Cable Tie 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 Cable Tie 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 Cable Tie Fitting, Vent 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. 2-7) 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 AR Cable Tie 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 26

29 CLUTCHES AND DRIVE BELT ASSEMBLIES Pulley, Driven - Assembly (inc 2-10) Face, Driven - Movable (inc. 3-4) Screw, Cam Cam, Shoe Ring, Retaining Cam Spring Shim Key Face, Driven - Fixed Washer Nut, Driven Pulley Belt, Drive 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 Key 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 (42 Tooth) AR Shim, 24 x 48 x AR Shim, 24 x 48 x AR Shim, 24 x 48 x AR Shim, 24 x 48 x AR Shim, 24 x 48 x 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 Sensor, Gear Shift Position O-Ring Screw, Cap Screw, Cap Washer, Steel 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 Contacts 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 (18 Tooth) 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 (40 Tooth) Shim, Drive Gear Spacer Countershaft Dog, Sliding Driven Gear - High/Low Gear, Driven - High (30 Tooth) 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 O-Ring Yoke, Propeller Shaft Joint, Universal - Set (inc. 58) Ring, Retaining - Universal Joint Nut, Hex Washer Yoke, Drive Output - Front Assembly Seal, Oil - Driven Shaft Bearing, Driven Shaft Shim, x 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 - Tube O-Ring Screw, Self-Tapping 29

32 CRANKSHAFT ASSEMBLY Crankshaft Assembly (inc. 2-5) Plug Key Pin Key 30

33 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) 31

34 FLYWHEEL AND RING GEAR ASSEMBLY Flywheel (inc. 2) Gear, Ring Bolt Axle, Stub 32

35 DRIVE PULLEY AND ALTERNATOR BELT ASSEMBLY Belt Pulley Screw Screw 33

36 CRANKCASE, CRANKSHAFT SUPPORT, AND OIL FILTER ASSEMBLIES *Not a Service Part Crankcase (inc. 2-6, two No. 7, and 8) 2 * 1 Housing - Front 3 * 1 Housing - Center 4 * 1 Housing - Rear Gasket Screw Sleeve Pin, Tapered Pin, Lock Gasket Plug Plug 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 34

37 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 35

38 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 36

39 *Not a Service Part FUEL SYSTEM INJECTION PUMP ASSEMBLY Pipe, Delivery (inc. 2-4) Screw, Fit 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, Delivery Valve Gasket, Valve Valve, Delivery 24 * 1 Plunger, Injection O-Ring Sleeve Screw Spring, Tappet 29 * 1 Push Rod Circlip Plate, Locking 37

40 CAMSHAFT AND FUEL PUMP DRIVE ECCENTRIC Camshaft Sleeve Cam Sleeve Screw 38

41 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 - Extra Screw Lever, Governor - Assembly (inc ) Pin, Lever Seal Sleeve Journal Nut Screw Device, Min-Max 39

42 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 Cover Screw Elbow, Pipe Switch, Oil Valve, Exhaust Valve, Intake 40

43 EXHAUST MANIFOLD ASSEMBLY Manifold, Exhaust Stud Nut Stud Gasket, Exhaust Manifold 41

44 THERMOSTAT, WATER INLET FLANGE, AND OIL LEVEL STICK ASSEMBLIES Thermostat - Assembly (inc. 2-8) Screw Cover, Thermostat O-Ring Thermostat Body, Thermostat - Assembly Gasket ECT Switch/Thermistor Screw Gasket Gasket Flange Clamp Hose Clamp Washer Stick, Oil Level (inc. 18) Seal O-Ring Guard, Oil Level Stick Screw 42

45 OIL PUMP ASSEMBLY *Not a Service Part Pump, Oil (inc. 2-10) Rotors, Oil Pump Plug Gasket Spring, Pressure Valve Rod, Drive O-Ring 8 * 1 Plate Screw Gasket Bolt Screw Ring, Seal Screw 43

46 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 Stud, Hollow Washer Washer Clamp Screw Gasket Gasket Cover, Oil Pan Screw Gasket, Copper Plug Gasket 44

47 THROTTLE CONTROL AND LOCKED TORQUE DEVICE ASSEMBLIES *Not a Service Part Nail Plate, Safety Plate, Safety Gasket, Copper Bolt Screw Nut Device, Locked Torque (inc. 9-10) 9 * 1 Nut Gasket Nut Washer Rod, Tie Lever, Throttle Control Circlip Circlip Pin Washer Seal, Oil Nut Bolt 45

48 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 46

49 FUEL FEED PUMP AND PUSH ROD ASSEMBLIES Bolt, Banjo-Fitting Washer, Crush Nut Washer Stud Pump Rod, Push O-Ring Banjo-Fitting 47

50 WATER PUMP ASSEMBLY Pump, Water - Assembly Screw Screw Gasket 48

51 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 49

52 EXTERNAL ALTERNATOR ASSEMBLY Alternator Support, Alternator Nut Washer Bolt Washer Screw Bolt Nut Wire w/diode Clamp 50

53 STARTER MOTOR ASSEMBLY R Motor, Starter Washer, Lock Nut Screw, Flange Head Gasket 51

54 BELT GUARD ASSEMBLY Guard, Belt Screw Screw Cap Gasket Plug 52

55 CONTROL SWITCH HOUSING ASSEMBLY Switch, Control - Assembly (inc. 2-3) Screw, Machine Screw, Machine Cover, Switch Housing 53

56 THROTTLE CASE ASSEMBLY Case, Throttle - Assembly (inc. 2-9) Lever Screw, Cap Washer, Lock Washer Screw Nut Screw Cover, Throttle Case w/switch 54

57 TOP END GASKET SET ASSEMBLY (Top End Gasket Set p/n ) Retainer, Valve - Cylinder Head Gasket, Rocker Arm Cover Connection, Rocker Arm Cover Seal, Ring - Delivery Pipe Seal, Delivery Pipe O-Ring, Injection Nozzle Gasket, Copper - Injection Nozzle Arrester, Spark - Injection Nozzle Ring, Seal - Governor Cover Seal, Oil - Governor Cover Seal, Governor Lever O-Ring, Cylinder Head Flange Gasket, Exhaust Manifold Gasket, Exhaust O-Ring, Thermostat Washer, Crush O-Ring, Fuel Feed Pump Gasket, Intake Manifold Gasket, Intake Flange 55

58 BOTTOM END GASKET SET ASSEMBLY (Bottom End Gasket Set p/n ) Gasket, Crankcase Ring, Engine Flange Gasket, Engine Flange Gasket, Thermostat O-Ring, Oil Pump Gasket, Oil Pump Ring, Seal - Oil Pump Seal, Oil - Oil Pan Seal, Oil - Oil Pan Gasket, Water Pump 56

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