Illustrated Parts Manual M5 2. Model Number S2005M5CICUSG Model Number S2005M5CICUSB Model Number S2005M5CICOSG
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1 Illustrated Parts Manual M5 2 Model Number S2005M5CICUSG Model Number S2005M5CICUSB Model Number S2005M5CICOSG 00 5
2 TABLE OF CONTENTS 2005 M5 (Model No. S2005M5CICUSG) (Model No. S2005M5CICUSB) (Model No. S2005M5CICOSG - International) SKI AND SPINDLE ASSEMBLY A-ARM ASSEMBLY FRONT SUSPENSION SHOCK ABSORBER ASSEMBLY STEERING POST ASSEMBLY TIE ROD ASSEMBLY HANDLEBAR AND CONTROLS HYDRAULIC BRAKE CONTROL ASSEMBLY DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES GEARCASE ASSEMBLY SLIDE RAIL AND TRACK ASSEMBLY IDLER WHEEL ASSEMBLY REAR SUSPENSION FRONT ARM ASSEMBLY REAR SUSPENSION REAR ARM ASSEMBLY FRONT FRAME AND FOOTREST ASSEMBLY HOOD AND WINDSHIELD ASSEMBLY HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES CONSOLE AND SWITCH ASSEMBLY BELLY PAN ASSEMBLY BELT GUARD ASSEMBLY GAS TANK ASSEMBLY SEAT ASSEMBLY TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY COOLING ASSEMBLY ENGINE AND RELATED PARTS EXHAUST ASSEMBLY AIR INTAKE ASSEMBLY AIR SILENCER, CARBURETOR, AND FUEL PUMP ASSEMBLY OIL TANK ASSEMBLY DRIVE CLUTCH DRIVEN CLUTCH CARBURETOR CYLINDER AND HEAD ASSEMBLY CRANKCASE ASSEMBLY PISTON AND CRANKSHAFT REED VALVE ASSEMBLY OIL PUMP WATER PUMP/WATER MANIFOLD RECOIL STARTER MAGNETO ELECTRICAL ALTERNATE CARBURETOR PARTS 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 October 2004 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
3 SKI AND SPINDLE ASSEMBLY Ski, Plastic - Black Insert, Ski Wearbar Nut, Lock Handle, Plastic - Black Nut, Lock Screw, Machine Screw, Machine Screw, Cap Pin, Cotter Washer Nut, Lock Damper, Ski Axle, Spindle Spindle, Steering - Right - Platinum (inc ) Spindle, Steering - Left - Platinum (inc ) Insert, Spindle Fitting, Grease Bearing Bearing Washer, Thrust Screw, Cap Arm, Steering Ring, Retaining Cap, Spindle Spacer Decal, AWS - Spindle Decal, AWS - Spindle (Black) 1
4 A-ARM ASSEMBLY A-Arm, Lower - Platinum (inc. 2) Bearing A-Arm, Upper - Platinum (inc. 4) Bearing Screw, Cap Washer Axle, Inner - Upper Arm Nut, Lock Tube, Axle Screw, Cap Brace, Lower A-Arm Axle, Inner - Lower Arm Screw, Cap Screw, Cap Tube, Axle Axle, Powder Metal 2
5 FRONT SUSPENSION SHOCK ABSORBER ASSEMBLY Retainer, Spring Spring, Compression - Green Spring, Compression - Red (Black) Sleeve, Wear Retainer, Spring - Lower Nut, Lock Washer Sleeve, Shock Shock, Ski (inc. 9-10) Bushing, Shock Sleeve, Shock Spacer, Shock Mount Screw, Cap 3
6 STEERING POST ASSEMBLY Screw, Cap Cap, Adjusting Block Block, Adjusting Post, Steering Nut, Lock Block, Mounting - Steering Post Stop, Steering Post Nut, Lock Washer Nut, Lock Screw, Cap Ball Joint, Tie Rod - Right Nut, Hex - Right Tube, Tie Rod Nut, Hex - Left Ball Joint, Tie Rod - Left Panel, Close-Out Screw, Self-Tapping Support, Steering Clip, Retaining Clip, Routing Washer Screw, Cap Clip, Routing Cable Tie, Push-Mount 4
7 TIE ROD ASSEMBLY Shaft, Steering Washer, Thrust Washer, Thrust Arm, Shaft Snap Ring Screw, Cap Shaft, Idler Ball Joint, Tie Rod - Left Screw, Cap Tube, Tie Rod - Spindle Nut, Hex - Left Nut, Hex - Right Ball Joint, Tie Rod - Right Screw, Cap Ball Joint, Tie Rod - Left Tube, Tie Rod Ball Joint, Tie Rod - Right Plug 5
8 HANDLEBAR AND CONTROLS Control - Assembly (inc. 2-10) Control, Throttle - Stop Switch Half Control, Throttle - Thumbwarmer Assembly (inc. 4-10) Control, Throttle - Thumbwarmer Half w/o Components Plug, Rubber Clip, Retaining - Throttle Cable Plate, Cover Screw, Self-Tapping Switch, Thumbwarmer Assembly (inc. three No. 8 and 10) Plate, Cover Screw, Machine Axle, Lever - Throttle Washer Washer, Shoulder - Throttle Lever, Throttle Ring, Retaining Handlebar Assembly End Cap, Throttle - Right End Cap, Brake - Left Grip, Handlebar Element, Handwarmer Pad, Insulator Element, Thumbwarmer Clip, Wire Cable, Throttle (inc. 26) Nut, Locking AR Cable Tie - 8 in Tool, Removal - Kit - Throttle Cable Washer E-Ring Wrap, Handlebar Harness, Adapter 6
9 *Not a Service Part **Not Illustrated HYDRAULIC BRAKE CONTROL ASSEMBLY Brake Assembly (inc. 2-14) Lever, Brake Screw, Lever Mounting Nut, Lock Reservoir Gasket, Cover Cover, Reservoir Screw, Cover Screw, Machine O-Ring 11 * 1 Master Cylinder Washer, Lock - Internal Tooth Screw, Master Cylinder Mounting Clamp, Master Cylinder ** AR Fluid, Brake - High Temperature Control, Dimmer - Assembly (inc ) Housing, Dimmer Control Switch, Dimmer and Brake - Assembly Knob, Dimmer Switch Switch, Handwarmer - Assembly (inc. 20 and three No. 21) Plate, Cover Screw, Self-Tapping Brakeline, Hydraulic 7
10 DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES *Not a Service Part Track Drive Assembly (inc. 2-4) Sprocket, Drive Driveshaft Collar Insert, Driveshaft Spacer, Brake Caliper Disc, Brake Washer, Copper Screw, Cap Nut, Retaining Plate, Mounting - Gearcase Nut, Push Gearcase Assembly Nut, Lock AR Washer AR Washer Clutch, Driven Washer Screw, Cap AR Washer AR Washer AR Washer O-Ring Adjuster, Sheave Caliper, Brake - Assembly (inc ) Bolt, Carriage - Ribbed Screw, Cap Washer 26 * 1 Housing O-Ring, Housing Pin, Retaining - Brake Pad Piston O-Ring Pad, Brake - Set (inc ) Clip, Anti-Rattle Clip, Hairpin Fitting, Bleed Fitting, Adapter 36 * 1 Housing Bearing Sleeve, Driveshaft Ring, Retaining AR O-Ring 8
11 *Not Illustrated GEARCASE ASSEMBLY (Complete Gearcase Assembly p/n ) Gearcase (inc. 2-6) Seal, Oil Pin, Dowel Seal, Oil O-Ring Plug, Gearcase Sensor, Speedometer Clip, Retaining Gear, Ring - 76T (inc ) Bearing Retainer, Magnet Shaft, Input - 57T (inc. one No. 13) Bearing Gear, Planetary - 5 Pinion Ring, Retaining - Planetary Gear Gear, Transfer - 63T/34T (inc. one No. 13 and 17) Bearing Cover, Gearcase (inc ) Bearing Seal, Oil Screw, Machine * AR Fluid, Gearcase - Case 9
12 SLIDE RAIL AND TRACK ASSEMBLY (Complete Skid Frame Assembly p/n ; p/n Black) Rail, Formed - Stamped Support, Rail Spacer Spacer Screw, Cap Washer End Cap, Slide Rail Nut, Lock Screw, Machine Wearstrip, Slide Rail Screw, Cap Rivet, Solid Pad, Shock Bracket, Retaining Insert, Rail Axle, Aluminum Screw, Cap Nut, Lock Pad, Shock Screw, Machine Adjuster, Track Screw, Cap Track Assembly (inc. 24) Clip, Guide 10
13 IDLER WHEEL ASSEMBLY Screw, Cap Washer Axle Washer Spacer, Front Arm Shock Nut, Lock Block, Mounting - Idler Wheel Wheel, Idler - Green (inc. 9-10) Wheel, Idler - Red (inc. 9-10) (Black) Bearing Ring, Retaining Screw, Cap Washer Screw, Cap Washer Slide, Spring Block, Slide Screw, Cap Washer Spacer Washer Wheel, Idler (inc ) Insert, Wheel - Outside Bearing Ring, Retaining Insert, Wheel - Inside Axle, Inner Pivot, Shock (inc ) Fitting, Grease Washer, Grease Fitting Spacer Nut, Lock Washer Spacer, Rear Wheel Axle, Rear Wheel Wheel, Idler (inc. 9-10) Bushing, Adjuster Spacer Washer, Lock Nut Screw, Cap Wheel, Idler - Green (inc. 9-10) Wheel, Idler - Red (inc. 9-10) (Black) Screw, Cap Cap, Idler Wheel 11
14 REAR SUSPENSION FRONT ARM ASSEMBLY Arm, Front Suspension - Platinum (inc. 2-5) Washer, Grease Fitting Fitting, Grease - Self-Tapping Bushing, Front Arm Bushing, Front Arm Axle, Aluminum Axle, Inner Carriage Screw, Cap Screw, Cap Washer Nut, Lock Knob, Adjuster Washer Strap, Limiter Nut, Wing Nut, Lock Screw, Cap Cover, Shock Spring, Compression Nut, Lock Retainer, Spring Axle, Serrated Screw, Cap Shock Absorber, Front Arm Retainer, Spring - Lower Sleeve, Wear 12
15 REAR SUSPENSION REAR ARM ASSEMBLY Arm, Idler - Platinum (inc. 2 and one No. 3-4) Bushing, Flared Washer, Grease Fitting Fitting, Grease - Self-Tapping Arm, Rear - Platinum (inc. one No. 3-4) Screw, Cap Washer Bushing, Rear Arm Tube, Axle Nut, Lock Screw, Cap Axle, Aluminum Block, Spring Adjuster - Right Block, Spring Adjuster - Left Ring, Retaining Sleeve, Spring Spring, Suspension - Right Spring, Suspension - Left Wheel, Idler (inc ) Bearing Ring, Retaining Spacer, Pivot - Idler Arm Axle, Powder Metal Washer, Pivot - Idler Arm Arm, Pivot Idler (inc ) Bushing, Flared Screw, Cap Nut, Lock Screw, Cap Screw, Cap Axle, Link - Flanged Link, Rear Shock Sleeve, Shock Nut, Lock Nut, Lock Screw, Cap Shock Absorber - Rear Arm 13
16 FRONT FRAME AND FOOTREST ASSEMBLY Chassis - Assembly (inc. 2-8) Bolt, Carriage - Ribbed Bolt, Carriage - Ribbed Bearing Bushing, Upper A-Arm Mount Bushing, Lower A-Arm Mount Fitting, Grease Insert Clip Screw, Machine Screw, Cap Brace, Side Plate - Right Mount, Engine Protector, Main Harness Screw, Self-Tapping Screw, Self-Tapping Guide, Rope Nut, Lock Tube, Support - Footrest Guard, Support Tube Screw, Machine Screw, Tube Plate, Backing AR Rivet Footrest - Right (inc ) Footrest - Left (inc ) AR Rivet Grommet Plate, Retaining Plate, Mounting - Belt Guard AR Rivet Bracket, Support - Footrest - Right Bracket, Support - Footrest - Left Bracket, Support - Footrest - Lower Left Brace, Side Plate - Left Clip, Routing Clip, Routing Cable Tie, Push-Mount 14
17 HOOD AND WINDSHIELD ASSEMBLY Hood w/decals - Green (inc. 2-11) Hood w/decals - Black (inc. 2-11) (Black) Hood w/o Decals - Green (inc. 3-6) Hood w/o Decals - Black (inc. 3-6) (Black) Pin, Clevis Clip, Hairpin Decal, Caution Decal, Warning - English Decal, Warning - French Decal, Made In U.S.A. - Domed Decal, Hood - Lower Right Decal, Hood - Lower Left Decal, Hood - Lower Right (Black) Decal, Hood - Lower Left (Black) Decal, Hood - Vent - Upper Right Decal, Hood - Vent - Upper Left Decal, Hood - Vent - Upper Right (Black) Decal, Hood - Vent - Upper Left (Black) Decal, Hood - Vent - Lower Right Decal, Hood - Vent - Lower Left Decal, Hood - Vent - Lower Right (Black) Decal, Hood - Vent - Lower Left (Black) Decal, Hood - Center Decal, Hood - Center (Black) Screen, Vent - Center Screen, Vent - Front - Right Screen, Vent - Front - Left Screen, Vent - Rear - Right Screen, Vent - Rear - Left Clip, Retaining Foam, Hood - Right Foam, Hood - Left Foam, Hood - Rear Screw, Self-Tapping Cable, Hood U-Nut Rivet, Reinstallable Windshield O-Ring Bezel, Intake - Right Bezel, Intake - Left Foam, Intake Bezel - Right Foam, Intake Bezel - Left 15
18 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES Harness, Main Harness, Hood AR Cable Tie - 8 in Lens/Reflector - Headlight - Right (inc. 5-6) Lens/Reflector - Headlight - Left (inc. 5-6) Bulb, Headlight Bulb, Headlight Insert Spring, Adjuster Screw, Adjuster Clip, Hairpin Clip - Right Clip - Left Tachometer/Speedometer (inc ) Bracket, Retaining Nut w/washer Foam, Hood/Headlight Nut, Lock Regulator, Voltage Harness, Extension - Taillight Harness, Adapter 16
19 CONSOLE AND SWITCH ASSEMBLY Console Screw, Machine Screw, Machine Nut, Lock Switch, Ignition (inc. 6) 6 * 1 Key Nut, Retaining Washer, Ignition Switch Spacer, Ignition Switch Decal, Console Cable, Choke (inc. 12) Nut, Retainer * Key is coded to switch; see dealer to determine part number. 17
20 BELLY PAN ASSEMBLY Belly Pan - Right - Black Belly Pan - Left - Black Panel, Access - Right Panel, Access - Left Foam, Side Panel - Right Foam, Side Panel - Left Clip, Retaining Belly Pan, Center - Black Bumper, Front - Black Screen, Belly Pan - Center Screw, Self-Tapping Screw, Self-Tapping Shield, Heat Deflector, Exhaust Rivet Nut, Speed Screw, Machine Washer Nut, Lock AR Tape, Foil Strap, Hold-Down Decal, Belly Pan - Right Decal, Belly Pan - Left Decal, Belly Pan - Right (Black) Decal, Belly Pan - Left (Black) Decal, Clutching Decal, Reflector - Amber - Right Decal, Reflector - Amber - Left Cable Clip, Hairpin Rivet 18
21 BELT GUARD ASSEMBLY Guard, Belt Decal, Warning - Belt Guard Decal, ACT - Roller Driven Clutch Retainer, Drive Belt Foam, Belt Guard Bracket, Mounting Rivet Decal, Caution - Jetting/Storage 19
22 GAS TANK ASSEMBLY Tank, Gas (inc. 2-11) Gauge, Fuel - Assembly w/gasket (Press-Fit) Cap, Gas Tank (inc. 4) Seal, Tank Cap Plate, Mounting - Steering Post Washer, Rubber Nut, Push Strainer AR Hose, Gasline ft AR Hose, Gasline - 50 ft AR Tape, Teflon Outlet, Tank Rivet Strap, Hold-down - Coolant Tank Nut, Lock Washer, Cup Nut Screw, Machine 20
23 SEAT ASSEMBLY Complete Seat Assembly (inc. 2-9) Complete Seat Assembly (inc. 2-9) (Black) Cover, Seat Cover, Seat (Black) AR Staple, Seat Cover Foam, Seat Cushion Seat-Base Clip, Retaining - Seat-Base Rivet Strap, Hold-Down - Seat Pad Washer Stud, Latch - Seat-Base Washer, Crush Nut, Lock Pad, Seat (inc ) Foam, Seat Pad Cover, Seat Pad (inc ) Clip, Retaining - Strap Clip, Hold-Down - Seat Pad 21
24 TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY *Optional Tunnel Assembly (inc. 2-9) Tunnel, Front (inc. 3-4) Insert Stud, Self-Clinching Tunnel, Rear (inc. 6) Insert Bracket, Suspension Mounting - Right - Rear Bracket, Suspension Mounting - Left - Rear AR Rivet Rivet Roll, Tunnel - Right Roll, Tunnel - Left AR Rivet AR Rivet* Plug, Hole Spacer Screw, Machine Rack Screw, Machine Pad, Rubber Nut, Speed Taillight Assembly (inc ) Housing, Taillight Socket, Taillight Bulb, Taillight Screw, Self-Tapping Washer Housing, Taillight Mounting Screw, Machine Bumper, Rear Decal, Warning - Towing (English) Decal, Warning - Towing (French) Screw, Machine Decal, Reflector - Red - Right Decal, Reflector - Red - Left Screw, Machine Snowflap Snowflap (Black) Support, Snowflap Washer Nut, Lock Screw, Self-Tapping Decal, Right Decal, Left Decal, Right (Black) Decal, Left (Black) Decal, Tunnel Decal, Tunnel (Black) Deflector, Snow Washer 22
25 COOLING ASSEMBLY Heat Exchanger - Rear Rivet Clamp, Hose Hose, Coolant Protector, Hose - Rear AR Rivet AR Rivet Heat Exchanger - Right Heat Exchanger - Left Protector, Hose - Front Clamp, Hose Hose, Coolant Tank/Engine Clamp, Hose Tank, Coolant Hose, Coolant Tank/Right Heat Exchanger Decal, Fill Level - Coolant Tank AR Hose, Vent - 25 ft AR Hose, Vent ft Cap, Filler Neck Clamp, Hose AR Hose, Coolant - 25 ft Clamp, Hose Cable Tie in Clamp, Hose Hose, Coolant - Engine/Front Heat Exchanger Protector, Hose - 7 in Pad, Support - Coolant Bottle 23
26 ENGINE AND RELATED PARTS Engine, AW50L Handle, Recoil Cap, Recoil Handle Bracket, Engine Mounting - Right Screw, Cap Screw, Cap Nut, Lock Cable Tie - Push-Mount Foil, Protective Clamp, Hose AR Hose, Coolant - 10 ft Clamp, Hose Y-Fitting Washer Bracket, Engine Mounting - Left (inc. 16 and two No. 17) Spacer, Torque Bumper Screw, Self-Tapping Bumper, Torque Screw, Cap Damper, Clutch Clutch, Drive Belt, Drive Washer, High Collar Bolt, Clutch Washer Conduit, Flexible - 4 in Conduit, Flexible (3/4 in. ID) - 6 in. 24
27 EXHAUST ASSEMBLY Chamber, Expansion - Assembly (inc. 2-8) Chamber, Expansion AR Tie, Perforated Band - 5 ft AR Tie, Perforated Band - 25 ft Spring, Exhaust Packing, Expansion Chamber - Upper Cover, Expansion Chamber - Upper Cover, Expansion Chamber - Lower Packing, Expansion Chamber - Lower Manifold, Exhaust Spring, Exhaust Gasket, Exhaust Gasket, Exhaust - Tailpipe Resonator Spring, Extension Pin, Mounting - Resonator Grommet Clip, Hairpin Grommet Washer, Tab Nut, Lock 25
28 AIR INTAKE ASSEMBLY Foam, Air Intake Screw, Machine Intake, Air - Right Clip, Hairpin Nut, Push Washer Nut, Lock Plug Foam, Air Intake Foil, Protective Foil, Protective Clip, Retaining Screen, Vent Seal, Air Intake Intake, Air - Left 26
29 AIR SILENCER, CARBURETOR, AND FUEL PUMP ASSEMBLY Silencer, Air - Assembly (inc. 2-3) Intake, Air Silencer, Air Connector, Air-Intake Clamp, Air-Intake Connector Screw, Self-Tapping Hold-Down, Air Silencer Screw, Self-Tapping Boot, Air Silencer Carburetor, VM Carburetor, VM (International) Clamp, Hose Hose, Drain Screw, Machine Pump, Fuel Nut, Lock AR Hose, Gasline ft AR Hose, Gasline - 25 ft AR Protector, Hose Clamp, Hose AR Hose, Impulse Clamp, Hose AR Hose, Gasline ft AR Hose, Gasline - 50 ft Cable Tie - Push-Mount Clamp, Wire Clip, Snap Foam, Air Silencer Clip, Hose Filter, Fuel Cable Tie - 4 in. 27
30 OIL TANK ASSEMBLY Tank, Oil Grommet Fitting, Elbow Sensor, Low Oil - Assembly (inc. 5-6) Switch, Oil Sensor w/harness Seal, Grommet - Oil Sensor Cap, Oil Tank (inc. 8) Seal, Cap - Oil Tank Decal, Oil Tank Clamp, Hose AR Hose, Oil ft AR Hose, Oil - 25 ft Grommet Shield, Heat Washer Screw, Machine Screw, Machine Cable Tie - 4 in. 28
31 Cam Arm Kit - p/n (inc. 3-5 and 7-8) Uncalibrated Drive Clutch - p/n DRIVE CLUTCH (Assembly p/n *) Sheave, Stationary Sheave, Movable (inc. 3) Bearing Pin, Cam Arm O-Ring Arm, Cam (inc. 7)* Arm, Cam (0-3,000 ft Alt.) (inc. 7) Arm, Cam (3-6,000 ft Alt.) (inc. 7) Arm, Cam (Over 9,000 ft Alt.) (inc. 7) Screw, Set Nut, Lock Spacer Spider Assembly Spring, Drive Clutch - Yellow/White* Spring, Drive Clutch - Red (0-6,000 ft Alt.) Nut Cover Washer, Lock - Spring Screw, Machine * Drive Clutch (p/n ) is calibrated to 6-9,000 ft Alt. 29
32 DRIVEN CLUTCH (Assembly p/n ) Cover, Torque Bracket (inc. 2-3) Ring, Snap Bearing Screw, Machine Adjuster, Spring Spring, Driven Clutch - White Spacer Bracket, Torque Sheave, Stationary (inc ) Pin, Cam Roller Roller, Cam Pin, Spring Retainer, Torque Bracket Sheave, Movable Screw, Machine Seat, Spring 30
33 CARBURETOR VM (Complete Assembly p/n ); VM (Complete Assembly p/n International) *Not a Service Part 1 * 1 Mixing Body Assembly Cap, Starter Plunger Spring, Starter Plunger Starter Plunger Spring, Throttle Stop Screw Screw, Throttle Stop Spring, Pilot Air Screw Screw, Pilot Air Pilot Jet Pilot Jet 35 (International and 0-3,000 ft Alt. STD) Ring, Baffle Main Jet 250** Main Jet 290** (International) Top, Mixing Body Spring, Piston Valve Plate Block, Magnet Screw w/washer E-Clip Washer, E-Clip Jet Needle 6DF Jet Needle 6DF7-3 (International and 0-3,000 ft Alt. STD) Piston Valve CA Needle Jet P-4 (480) Screw, Self-Tapping Switch, Magnetic - Carburetor Plate Screw w/spring Washer Washer Needle Valve Assembly Pin, Float Arm Arm, Float Cap Float Gasket, Float Chamber Chamber, Float Plate, Hose Hose Screw w/spring Washer O-Ring Screw, Drain Cap Washer **Alternate Carburetor Parts on page 41 31
34 CYLINDER AND HEAD ASSEMBLY Head, Cylinder Plug, Spark (BR9EYA) Bolt O-Ring Bolt O-Ring O-Ring O-Ring Nut Nut Pin, Dowel Bolt, Stud Gasket, Exhaust Cylinder Gasket, Cylinder Bolt, Stud 32
35 CRANKCASE ASSEMBLY Crankcase (inc. 2-7) Bolt Bolt Bolt Bolt Bushing Pin, Dowel Switch, Temperature 33
36 PISTON AND CRANKSHAFT Piston Set (inc. 2-3) Ring Set, Piston Circlip, Piston Pin, Piston Washer Bearing Crankshaft Assembly (inc. 8-25) Connecting Rod Washer, Crank Pin Bearing Bearing Washer Bearing Shim Crankshaft - Right Balancer, Crankshaft Screw Wheel, Crankshaft Ring, Middle Crank Seal Bearing Race, Middle Crank Seal Gear, Oil Pump Drive Bearing Crankshaft - Middle Crankshaft - Left Bearing Pin, Alignment Seal, Oil Seal, Oil Key C-Ring Seal, Mechanical - Water Pump Seal, Water/Oil Pump Gear, Driven - Oil Pump Shim, Oil Pump Shaft 34
37 REED VALVE ASSEMBLY Valve, Reed - Assembly (inc. 2-4) Stopper Valve, Reed Screw Gasket, Reed Valve Pipe, Intake Clamp Bolt Clamp, Wire Bracket, Oil Pump Cable 35
38 OIL PUMP Pump, Oil Bolt O-Ring Retainer, Oil Pump Input Shaft O-Ring Valve, Check Gasket Bolt Clamp, Hose Hose Hose, Oil Clamp 36
39 WATER PUMP/WATER MANIFOLD Cover, Water Pump Bolt O-Ring, Water Pump Cover Pin, Dowel Bolt Gasket Washer Clamp Impeller, Water Pump Circlip Hose, Water Inlet Cap, Thermostat Thermostat Bolt 37
40 RECOIL STARTER *Not a Service Part Starter Assembly (inc. 2-10) Roller, Starter Spring Ratchet Set (inc. 5-7) 5 * 1 Spring, Friction 6 * 1 Washer 7 * 1 Spring, Return Plate, Friction Nut Rope, Starter Screw, Cap Pulley, Starter Screw, Cap 38
41 MAGNETO Bolt Base, Stator - Plate Stator Bolt Bolt Rotor/Flywheel Washer Washer, Lock Bolt Screw Sensor, Ignition Timing Plate, Stator Lead Wire Grommet, Stator Lead Wire 39
42 ELECTRICAL CDI Unit Cover, Connector Coil, Ignition Cap, Spark Plug Clamp 40
43 MAIN JETS AVAILABLE JET P/N JET P/N N N N N N N PISTON VALVES AVAILABLE (VM-Style) SLIDE CARBURETOR SIZE (mm) * For models with carburetor switch. THROTTLE VALVES AVAILABLE (TM-Style) SLIDE CARBURETOR P/N SIZE (mm) ALTERNATE CARBURETOR PARTS P/N * * * * * * NEEDLE JETS AVAILABLE(VM-Style) NEEDLE JET P/N NEEDLE JET P/N O-6 (480) Q-2 (480) O-8 (182) Q-3 (480) O-8 (480) Q-4 (166) P-0 (159) Q-4 (480) P-0 (166) Q-5 (159) P-0 (169) Q-5 (166) P-0 (480) Q-5 (480) P-2 (480) Q-6 (166) P-4 (159) Q-8 (480) P-4 (166) R-0 (166) P-4 (480) Z-4 (224) P-4 (169) Z-5 (224) P-5 (480) Z-6 (224) P-6 (159) Z-8 (224) P-6 (166) Z-9 (224) P-6 (480) AA-0 (224) P-6 (251) AA-1 (224) P-8 (159) AA-2 (224) P-8 (166) AA-3 (224) P-8 (480) AA-4 (224) Q-0 (159) AA-5 (224) Q-0 (166) AA-8 (224) Q-0 (480) BB-0 (224) Q-2 (166) BB-5 (224) JET NEEDLES AVAILABLE JET P/N JET P/N NEEDLE (VM-Style) NEEDLE (TM-Style) 6CH CFH DH DH DH DH DH DEH DH DEH DH EGY DF EH DJ EH DH EH DH EJ EH DFH DFH DFH DEH DFH DFH EH DH EH DFH EFH INLET NEEDLE ASSEMBLIES AVAILABLE (VM-Style) SEAT DIA. CARB. SIZE (mm) P/N 1.5 mm (Steel) 28, 30, 32, mm (Viton) 28, 30, 32, mm (Steel) GVM mm (Steel) 36, 38, 40, mm (Viton) 36, 38, 40, mm (Viton) 36, 38, 40, mm (Viton) 36, 38, 40, INLET NEEDLE ASSEMBLIES AVAILABLE (TM-Style) SEAT DIA. CARB. SIZE (MM) P/N 1.5 mm (Steel) mm (Steel) PILOT JETS AVAILABLE JET NO. P/N JET NO. P/N
44 RELATED ITEMS 2005 M5 (Model No. S2005M5CICUSG) (Model No. S2005M5CICUSB) (Model No. S2005M5CICOSG - International) Altitude Kit ( ft) Altitude Kit ( ft) Altitude Kit (Over 9000 ft) Avalanche Probe Cover, Machine (Deluxe) Cover, Machine (Premium) Gasket Set Handbook, Safety (E/F) Handlebar Muffs Handlebar Bag Hitch, Pivot Manual, Illustrated Parts Manual, Operator s (E/F) Paint, Hood - Green (1/2 oz) Paint, Hood - Black (1/2 oz) Paint, Metal - Black Rack Bag Rack Strap Seat Liner Bag Shovel, Snow w/saw (Deluxe) Skid Plate - Black Tank Pads Tether Switch Windscreen, Low - Chrome Windshield, Mid - Smoke Windshiled, Flair Bag Windshield, Storage Bag NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A p/n
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