ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 1 of 50 A-ARM, FLOOR PANEL, AND BUMPER ASSEMBLY

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1 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 1 of 50 A-ARM, FLOOR PANEL, AND BUMPER ASSEMBLY

2 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 2 of 50 A-ARM, FLOOR PANEL, AND BUMPER ASSEMBLY Ref # Part Number Qty S/P/F Description A-Arm, Suspension - Left A-Arm, Suspension - Right Bushing, Rubber Bushing Bushing Nut, Flange Cover, Waterproof /P Cover, Dustproof Screw, Cap Panel, Floor Fitting, Grease Cap, Grease Fitting Screw, Cap Screw, Cap Bumper Screw, Cap Nut, Nylon Cap, Floor Panel - Rubber Cover, Bumper Screw, Self-Tapping Guard, Floor Panel - Left Guard, Floor Panel - Right Reflector - Amber Washer, Spring

3 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 3 of 50 BODY AND SEAT ASSEMBLY

4 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 4 of 50 BODY AND SEAT ASSEMBLY Ref # Part Number Qty S/P/F Description Cover, Front Panel, Floor - Left Panel, Floor - Right Cover, Rear Screw, Machine Screw, Machine Seat Assembly (inc. 8-9) Bracket, Seat Bolt, Seat Strip, Rubber Bag, Tool Spring, Reset Cable, Seat Release Seat Lock Assembly Screw, Cap Bolt, Carriage Washer Nut, Nylon Reflector /P Screw, Cap Nut, Flange S U-Nut

5 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 5 of 50 BRAKELIGHT AND FLAG ASSEMBLIES

6 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 6 of 50 BRAKELIGHT AND FLAG ASSEMBLIES Ref # Part Number Qty S/P/F Description Bracket, Brakelight Brakelight Assembly (inc. 3-6) Bulb, Brakelight Screw, Machine Base, Brakelight Lens, Brakelight Flag/Spring Assembly (inc. 8-11) Flag Spring, Flag /P Screw, Cap Washer Screw, Cap Washer Nut, Flange

7 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 7 of 50 CARBURETOR ASSEMBLY

8 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 8 of 50 CARBURETOR ASSEMBLY Ref # Part Number Qty S/P/F Description Carburetor Assembly (inc. 2-25) Gasket, Carburetor Spring, Throttle Valve S Screw, Machine Washer, Spring Valve, Throttle Set, Jet Needle Needle Jet Seal, Float Chamber Main Jet Tube, Overflow Pilot Jet Screw, Air Adjustment Plug, Drain Screw, Machine Washer, Spring Screw, Machine /P Choke Assembly - Electric (inc. 19) O-Ring Screw, Throttle Needle Valve Assembly Pin, Float Float Chamber, Float Nut, Cable Adjust /P Plug, Purge Hole Tube, Breather Shroud, Carburetor

9 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 9 of 50 CLUTCH ASSEMBLY

10 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 10 of 50 CLUTCH ASSEMBLY Ref # Part Number Qty S/P/F Description Driven Face Assembly (inc. 2-15) Seal, Oil Seat, Secondary Spring Spring, Compression Weight Set, Clutch (inc. 6-7) Carrier, Clutch Weight Spring Nut Pin, Guide Face, Fixed Driven Bearing, Needle S Circlip Bearing, Radial Ball Face, Movable Driven O-Ring Cover, Clutch Nut O-Ring Drive Face Assembly (inc ) Plate, Cam Roller, Weight Bushing Face, Movable Drive Slide, Cam Plate V-Belt Bushing Face, Fixed Drive Washer, Lock - External Tooth Clutch, One-Way Washer, Cone Spring Nut, Flange Bushing, Clutch

11 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 11 of 50 CRANKCASE ASSEMBLY

12 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 12 of 50 CRANKCASE ASSEMBLY Ref # Part Number Qty S/P/F Description Crankcase - Left Bushing, Rubber Plate, Cover Fitting, Breather Hose Crankcase - Right Hose, Breather Pin, Dowel Screw, Cap Screw, Self-Tapping Clamp Cover, Mission Gasket, Mission Cover Gasket, Crankcase Cover Pin, Dowel Screw, Cap Cover, Crankcase - Left Shaft, Idler Screw, Cap Screw, Cap Plug, Oil O-Ring Screw, Cap Washer Bracket, Oil Seal Screw, Cap Gasket, Magneto Screw, Cap Shaft, Crankcase Fixed Bracket, Carburetor Tube Protector, Shroud Shaft, Fixed Bracket, Crankcase O-Ring Washer Nut, Flange Screw, Cap Nut, Flange Bushing

13 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 13 of 50 CRANKSHAFT AND PISTON ASSEMBLY

14 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 14 of 50 CRANKSHAFT AND PISTON ASSEMBLY Ref # Part Number Qty S/P/F Description Crankshaft Assembly (inc. 2-7) Crank, Left Pin, Crank Bearing, Needle Rod, Connecting Crank, Right Key Washer Bearing, Radial Ball Seal, Oil Seal, Oil Collar, Crank Piston Pin, Piston Ring, Piston - Set Clip, Piston Pin Bearing, Needle

15 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 15 of 50 CYLINDER AND HEAD ASSEMBLY

16 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 16 of 50 CYLINDER AND HEAD ASSEMBLY Ref # Part Number Qty S/P/F Description Cylinder Head Gasket, Cylinder Head /P Plug, Spark Nut, Flange Cylinder Gasket, Cylinder Bolt, Stud

17 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 17 of 50 DECALS

18 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 18 of 50 DECALS Ref # Part Number Qty S/P/F Description Decal, Graphic - Left Decal, Graphic - Right Decal, Graphic - Upper Right Decal, Graphic - Upper Left Decal, Graphic - Front Decal, Graphic - Rear Decal, Graphic - Lower Left Decal, Graphic - Lower Right Decal, Graphic - Cowl Decal, Warning - General Decal, Warning - Pre-Ride Decal, Warning - Age Decal, Warning - Passenger Decal, Fuel Shut-Off Decal, Warning - Tire/Load Decal, Warning - Clutch Cover

19 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 19 of 50 ELECTRICAL

20 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 20 of 50 ELECTRICAL Ref # Part Number Qty S/P/F Description Harness, Main (inc. 16) Battery CDI Unit Regulator Relay, Starter Switch, Ignition Screw, Machine Screw, Cap Cap, Rubber Screw, Machine Coil, Ignition Cap, Spark Plug Decal, Warning - Battery Washer, Spring Washer, Spring Fuse - 7 Amp

21 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 21 of 50 EXHAUST ASSEMBLY

22 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 22 of 50 EXHAUST ASSEMBLY Ref # Part Number Qty S/P/F Description Pipe, Exhaust - Assembly (inc. 2-13, four No. 14, and two No. 15) Gasket, Exhaust Pipe Pipe, Exhaust - Front Washer, Spring Nut, Flange Muffler (inc. 7-11) Arrester, Spark (inc. 8-10) Screen, Spark Arrestor Gasket /P End Cap, Muffler Washer, Lock Screw, Machine Shroud, Muffler Packing Screw, Cap Screw, Cap Washer, Spring Screw, Cap Screw, Cap /P Washer Nut, Nylon Insulator Screw, Cap

23 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 23 of 50 FAN AND AIR SHROUD ASSEMBLY

24 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 24 of 50 FAN AND AIR SHROUD ASSEMBLY Ref # Part Number Qty S/P/F Description Air Shroud, Cylinder Grommet Cover, Magneto Screw, Cap Washer Screw, Self-Tapping Damper Fan Deflector Screw, Cap Cover, Magneto - Outer Screw, Self-Tapping Washer

25 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 25 of 50 FRAME AND RELATED PARTS

26 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 26 of 50 FRAME AND RELATED PARTS Ref # Part Number Qty S/P/F Description Frame Bearing, Radial Ball Circlip Nut, Nylon Bumper, Rubber Pad, Foam Plate, Engine Mounting - Right Plate, Engine Mounting - Left Screw, Cap Screw, Cap /P Screw, Cap Plate, Frame No Rivet Screw, Cap Nut, Nylon Spacer, Swing Arm Screw, Cap Sleeve, Rubber Swing Arm Sub-Assembly Bushing Bracket, Rear Cover Mounting - Lower Right Bracket, Rear Cover Mounting - Upper Bracket, Front Cover Mounting - Left Bracket, Front Cover Mounting - Right Screw, Cap Cover, Swing Arm Seal Nut, Nylon Washer Washer Washer, Rubber Bracket, Rear Cover Mounting - Lower Left Clamp, Cable - Rubber Bracket, Gas Cup /P Screw, Cap Decal, CE /P Reflector - Red Nut, Flange

27 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 27 of 50 FRONT BRAKE ASSEMBLY

28 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 28 of 50 FRONT BRAKE ASSEMBLY Ref # Part Number Qty S/P/F Description Panel, Brake - Front - Left Arm, Brake - Front - Left Screw, Cap Panel, Brake - Front - Right Arm, Brake - Front - Right Cable, Brake - Front Camshaft, Brake - Front Shoe, Brake - Front (inc. 9) Spring, Shoe Retainer O-Ring Spring, Return

29 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 29 of 50 GAS TANK AND OIL TANK ASSEMBLIES

30 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 30 of 50 GAS TANK AND OIL TANK ASSEMBLIES Ref # Part Number Qty S/P/F Description Tank, Oil Cap, Oil Tank Screw, Cap Pad, Foam Tank, Gas (inc. 6) Tube, Gas Tank Tank Cap Assembly (inc. 8-9) Cap, Tank Gasket, Cap Gasket, Front Cover - Rubber Cup, Oil Filter Tube Tube Cup, Gas (inc ) Body, Gas Cup Knob, Gas Cup Screw, Machine Screw, Machine Clip Cover, Tube Tube Tube Hose, Breather Cover, Tube

31 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 31 of 50 HANDLEBAR ASSEMBLY

32 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 32 of 50 HANDLEBAR ASSEMBLY Ref # Part Number Qty S/P/F Description Handlebar Grip, Handlebar Clamp, Handlebar - Bottom Clamp, Handlebar - Left Clamp, Handlebar - Right Screw, Cap S Lever Assembly - Right (inc. 8-13) Bracket, Throttle Cable Lever, Brake - Right Bracket, Cable Spring, Throttle Lever Bracket, Lever Lever, Throttle Cover, Lever Body /P Cable, Throttle Cable Tie /P Pad, Handlebar - Assembly (inc ) S Cover, Pad Pad, Handlebar Lever Assembly - Left (inc ) Lever, Brake - Left Harness, Brake Switch Switch Assembly S Washer Nut, Nylon

33 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 33 of 50 MAGNETO AND STARTER MOTOR ASSEMBLY

34 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 34 of 50 MAGNETO AND STARTER MOTOR ASSEMBLY Ref # Part Number Qty S/P/F Description Starter Motor Assembly (inc. 2-6) /P Brush Set O-Ring O-Ring Bolt w/washer Harness, Starter Motor Screw, Cap Screw, Cap Magneto Assembly (inc ) Rotor/Flywheel Stator Assembly Washer Nut, Flange

35 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 35 of 50 OIL PUMP ASSEMBLY

36 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 36 of 50 OIL PUMP ASSEMBLY Ref # Part Number Qty S/P/F Description Gear, Pump Drive Circlip Pin, Crankshaft Pump, Oil - Assembly (inc. 5-7) Gear, Oil Pump O-Ring Seal, Oil Ring, Steel Tube, Oil Clip Clip Tube /P Cup, Oil Filter Tube Screw, Machine Washer, Wave Cover, Tube

37 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 37 of 50 REAR DRIVE ASSEMBLY

38 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 38 of 50 REAR DRIVE ASSEMBLY Ref # Part Number Qty S/P/F Description Axle, Rear Wheel Collar, Spacer - Right Collar, Spacer - Left Rear Sprocket Assembly (inc. 5-7) Flange, Final Drive Screw, Cap Sprocket, Rear Chain, Drive Guard, Chain Screw, Cap Adjuster, Drive Chain Drive Sprocket Assembly Washer Nut, Nylon Nut, Flange /P Guard, Chain - Rear Screw, Cap Nut, Flange

39 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 39 of 50 REED VALVE AND AIR CLEANER ASSEMBLY

40 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 40 of 50 REED VALVE AND AIR CLEANER ASSEMBLY Ref # Part Number Qty S/P/F Description Valve, Reed - Assembly Gasket, Reed Valve Manifold, Intake Screw, Cap Clamp, Hose - Intake Manifold Clip Air Cleaner Assembly (inc. 8-15) Base, Air Cleaner Cover, Air Cleaner Pipe, Guide Element, Air Cleaner Connecter, Air Cleaner Screw, Self-Tapping Grommet Screw, Self-Tapping /P Joint, Air Cleaner Screw, Cap Screw, Cap Bracket, Air Cleaner /P Clip S Gasket, Air Cleaner Isolation Screw, Cap Nut, Flange Duct, Air

41 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 41 of 50 RELATED ITEMS

42 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 42 of 50 RELATED ITEMS Ref # Part Number Qty S/P/F Description Illustrated Parts Manual Operator's Manual (E) Manuel d'utilisation (F) Skid Plate Windshield

43 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 43 of 50 STARTER ASSEMBLY

44 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 44 of 50 STARTER ASSEMBLY Ref # Part Number Qty S/P/F Description Bearing, Needle Boss, Bearing Washer Washer Bearing, Needle Gear, Idler Washer, Wave Shaft, Idler Screw, Cap Plate, Idler Gear Screw, Cap Starter Shaft Assembly Spring, Reset - Starter Shaft Bushing Washer Circlip S Starter Crank Assembly Clip, Spring - Starter Pinion Starter Pinion Assembly Starter Clutch - Electric - Assembly (inc ) Wheel, Starter Clutch Clutch Set, Electric Starter (inc ) Spring, Clutch Guide, Clutch Roller, Clutch

45 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 45 of 50 STEERING ASSEMBLY

46 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 46 of 50 STEERING ASSEMBLY Ref # Part Number Qty S/P/F Description Steering Post Assembly Seal, Oil Seal, Oil Spacer Nut, Nylon Nut, Flange Bushing, Steering Post Holder, Steering Post Collar, Spacer S Tie Rod Assembly - Left (inc. one No ) Tie Rod Joint, Ball - Left Thread Joint, Ball - Right Thread S Tie Rod Assembly - Right (inc. one No ) Pin, Cotter Nut, Slotted Knuckle, Left Knuckle, Right Nut, Nylon S Washer Pin, Cotter

47 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 47 of 50 TRANSMISSION ASSEMBLY

48 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 48 of 50 TRANSMISSION ASSEMBLY Ref # Part Number Qty S/P/F Description Axle, Main Bearing, Radial Ball Washer Axle, Drive Bearing, Needle Seal, Oil Circlip Bearing, Radial Ball Circlip Gear, Primary Drive Screw, Cap Bearing, Radial Ball Washer Circlip Seal, Oil Bearing, Radial Ball Washer, Spring

49 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 49 of 50 WHEEL, TIRE, AND SUSPENSION ASSEMBLY

50 2004 ATV 50 Y-6 YOUTH CAT GREEN (A2004ATA2BUSZ) Page 50 of 50 WHEEL, TIRE, AND SUSPENSION ASSEMBLY Ref # Part Number Qty S/P/F Description Tire Wheel Screw, Cap Washer Drum, Brake - Front Seal, Oil Spacer Collar - Front Bearing, Radial Ball Bearing, Radial Ball Nut, Slotted /P Stem, Valve Cover, Rubber Pin, Cotter Shock, Front Screw, Cap Nut, Nylon Shock, Rear Screw, Cap Connector, Shaft Washer Nut, Slotted

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