ATV I l. l u. r a. Parts Manual ARCTIC CAT. 250 cc/300 cc
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- Tiffany Jackson
- 5 years ago
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1 2000 I l l u st ATV 250 cc/300 cc Model No. A2000ATE2AUSG (250 - Green) Model No. A2000ATE2AUSR (250 - Red) Model No. A2000ATF2AUSG (300 2x4 - Green) Model No. A2000ATF2AUSR (300 2x4 - Red) Model No. A2000ATF4AUSG (300 4x4 - Green) Model No. A2000ATF4AUSR (300 4x4 - Red) ARCTIC CAT r a te d Parts Manual
2 TABLE OF CONTENTS 2000 ATV 250/300 2X4/300 4X4 250 Red (Model No. A2000ATE2AUSR) 250 Green (Model No. A2000ATE2AUSG) 300 2X4 Red (Model No. A2000ATF2AUSR) 300 2X4 Green (Model No. A2000ATF2AUSG) 300 4X4 Red (Model No. A2000ATF4AUSR) 300 4X4 Green (Model No. A2000ATF4AUSG) BODY PANEL ASSEMBLY... 1 TAILLIGHT ASSEMBLY... 2 DECALS... 3 FRAME AND RELATED PARTS... 4 SEAT ASSEMBLY... 5 STEERING ASSEMBLY... 6 FRONT SUSPENSION ASSEMBLY... 7 REAR SUSPENSION ASSEMBLY... 8 WHEEL AND TIRE ASSEMBLY... 9 MECHANICAL BRAKE ASSEMBLY HYDRAULIC BRAKE CONTROL ASSEMBLY HYDRAULIC BRAKE ASSEMBLY HYDRAULIC BRAKE ASSEMBLY FUEL TANK ASSEMBLY REVERSE SHIFT LEVER ASSEMBLY AIR INTAKE ASSEMBLY SHIFTER ASSEMBLY ENGINE AND RELATED PARTS OIL COOLER ASSEMBLY ELECTRICAL COMPONENTS CARBURETOR CYLINDER HEAD ASSEMBLY CYLINDER ASSEMBLY CRANKCASE ASSEMBLY CRANKCASE COVER ASSEMBLY CRANKSHAFT ASSEMBLY STARTER CLUTCH ASSEMBLY CAMSHAFT/VALVE ASSEMBLY CAM CHAIN ASSEMBLY RECOIL STARTER ASSEMBLY OIL PUMP ASSEMBLY CLUTCH ASSEMBLY TRANSMISSION ASSEMBLY SECONDARY TRANSMISSION ASSEMBLY SECONDARY GEAR/OUTPUT SHAFT ASSEMBLY GEAR SHIFTING ASSEMBLY DIFFERENTIAL GEAR ASSEMBLY (4X4) DIFFERENTIAL LOCK ASSEMBLY (4X4) STARTER MOTOR ASSEMBLY MAGNETO ASSEMBLY CONTROL SWITCH HOUSING ASSEMBLY THROTTLE CASE ASSEMBLY 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 2000 model year. For a complete list of related items, refer to the current accessory catalog. Trademarks of Arctic Cat Inc., Thief River Falls, MN Printed June 2008
3 BODY PANEL ASSEMBLY Panel, Fender - Front (2X4) (Red) Panel, Fender - Front (2X4) (Green) Panel, Fender - Front (4X4) (Red) Panel, Fender - Front (4X4) (Green) Cover, Access (Red) Cover, Access (Green) Flare - Front Right (4X4) Flare - Front Left (4X4) Rack - Front (2X4) Rack - Front (4X4) Reflector, Front - Amber Clip, Retaining Panel, Side - Right (Red) Panel, Side - Left (Red) Panel, Side - Right (Green) Panel, Side - Left (Green) Panel, Fender - Rear (2X4) (Red) Panel, Fender - Rear (2X4) (Green) Panel, Fender - Rear (4X4) (Red) Panel, Fender - Rear (4X4) (Green) Rack - Rear (2X4) Rack - Rear (4X4) Wrap, Tube - Rear Rack Foam, Access Panel Reflector, Rear - Red Flare - Rear Right (4X4) Flare - Rear Left (4X4) Mud Flap - Right (4X4) Mud Flap - Left (4X4) Rivet, Plastic (2X4) Rivet, Plastic (4X4) Fender Extension - Rear Right (2X4) Fender Extension - Rear Left (2X4) Fender Extension - Rear Right (4X4) Fender Extension - Rear Left (4X4) Rivet, Plastic AR Screw, Machine Clip, Tinerman Screw, Self-Tapping Screw, Cap Screw, Cap Nut, Speed Nut, Expansion Screw, Machine Screw, Machine (2X4) Screw, Machine Panel, Deflector T-Nut w/teeth (2X4) Flare - Front Right (2X4) Flare - Front Left (2X4) AR Tape, Foil 1
4 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 2
5 DECALS Decal, Warning - Front Rack Load Decal, Front (2X4) (Red) Decal, Front (2X4) (Green) Decal, Front (4X4) (Red) Decal, Front (4X4) (Green) Decal, Made In U.S.A Decal, Warning - Turn Decal, Warning Reverse/Pre-Ride Decal, Warning - Age Decal, Warning - General Decal, Side Right (2X4) (Red) Decal, Side Left (2X4) (Red) Decal, Side Right (2X4) (Green) Decal, Side Left (2X4) (Green) Decal, Side Right (2X4) (Red) Decal, Side Left (2X4) (Red) Decal, Side Right (2X4) (Green) Decal, Side Left (2X4) (Green) Decal, Side Right (4X4) (Red) Decal, Side Left (4X4) (Red) Decal, Side Right (4X4) (Green) Decal, Side Left (4X4) (Green) Decal, Warning - Tire Pressure (250) Decal, Warning - Tire Pressure (300 2X4) Decal, Warning - Tire Pressure (4X4) Decal, Shift Pattern Decal, Warning - Rear Rack Load Decal, Arctic Cat (4X4) Decal, Warning - Towing Decal, Hi/Low Range (2X4) Decal, Hi/Low Range (4X4) Decal, 2X4/4X4 Shift (4X4) 3
6 FRAME AND RELATED PARTS Frame, Main Bracket, Body Hold-Down Screw, Machine Footrest - Right Footrest - Left Screw, Cap Screw, Cap Washer Screw, Body Guard, Brush Panel, Belly AR Cable Tie - 7 in Screen, Bumper - Lower (300) Nut Screw, Cap Mount, Headlight Yoke, Headlight Washer, Lock - External Tooth Panel, Inner Fender (300) Headlight Assembly (inc ) Bulb, Headlight Screw, Machine Bracket, Differential (4X4) Screw, Cap (4X4) Cover, Front Driveshaft (4X4) Screw, Cap (4X4) Washer, Lock - High Collar 4
7 SEAT ASSEMBLY *Not a Service Part Seat Assembly (inc. 2-8) Cover, Seat Foam, Seat Base, Seat - Assembly (inc. 5-7) 5 * 1 Base, Seat Rivet Pin, Seat-Base - Front AR Staple Grommet, Seat - Center Screw, Cap Spring, Seat Latch Washer Collar, Front Seat-Base Bumper, Seat-Base - Front Cap, Protector Latch, Seat - Assembly Screw, Machine 5
8 STEERING ASSEMBLY Cable, Speedometer (4X4) Screw, Machine Speedometer (inc ) (4X4) Collar, Body Switch, Ignition - Assembly (inc. 6) Switch, Ignition - Assembly (inc. 6) (Vehicle Identification Number J6YT And Up) Key, Ignition - Blank (C Series) Key, Ignition - Blank (D Series) Bezel/Lens, Warning - Assembly Housing, Instrument (300) Plug, Instrument Pod (2X4) Bulb, Light Bar (250) Light, Warning - Assembly (250) Panel, LED (300) Screw, Self-Tapping (250) Screw, Cap Cap, Steering Adjuster Bracket, Key Switch Tube, Handlebar Grip, Handlebar Housing, Bearing - Lower Bearing, Steering Post Housing, Bearing - Upper Pin, Cotter Post, Steering Screw, Cap Flange, Bearing Bearing, Steering Washer Screw, Cap Nut, Lock Tie Rod - Assembly (inc ) Nut Ball Joint, Tie Rod - Right Ball Joint, Tie Rod - Left Nut - Left Tie Rod Head, Speedometer (4X4) Knob, Speedometer Trip (4X4) Bracket, Speedometer (4X4) Mount, Rubber (4X4) Washer (4X4) Pin, Retainer (4X4) Plate, Arctic Cat - Instrument Pod (250) Cover, Key Rivet 6
9 FRONT SUSPENSION ASSEMBLY Retainer, Spring Shock Absorber - Front (inc. 3-4) (2X4) Shock Absorber - Front (inc. 3-4) (4X4) Bushing, Shock Absorber Sleeve, Shock Nut, Lock Screw, Cap Spring, Shock Absorber (2X4) Spring, Shock Absorber (4X4) Collar, Spring Washer, Spring A-Arm, Upper Right - Assembly (inc ) A-Arm, Upper Left - Assembly (inc ) Ball Joint - Front Clip, Ball Joint Knuckle - Assembly - Right (inc ) Knuckle - Assembly - Left (inc ) Knuckle, Steering - Right Knuckle, Steering - Left Bearing, Wheel Hub - Front Clip, Bearing Seal, Wheel Bearing - Front Seal, Wheel Bearing - Front Screw, Cap Screw, Cap A-Arm, Lower Right (inc ) (250) A-Arm, Lower Left (inc ) (250) A-Arm, Lower Right (inc ) (300 2X4) A-Arm, Lower Left (inc ) (300 2X4) A-Arm, Lower Right (inc ) (4X4) A-Arm, Lower Left (inc ) (4X4) Axle, Drive - Front Right (4X4) Axle, Drive - Front Left (4X4) Repair Kit, Outer Boot - Front Axle (4X4) Repair Kit, Inner Boot - Front Axle (4X4) Retainer, Spring - Lower Axle, Stub (2X4) 7
10 REAR SUSPENSION ASSEMBLY Knuckle, Right Rear - Assembly (inc. 2, 5-8, and 28) Knuckle, Left Rear - Assembly (inc. 2, 5-8, and 28) Fitting, Grease Collar, Suspension Bushing Bushing, Suspension Bearing, Wheel Clip, Bearing Seal Seal Axle, Drive Arm, Rear - Upper (inc. 2) A-Arm, Rear - Lower Right A-Arm, Rear - Lower Left Shock Absorber - Rear Sleeve, Shock Absorber Bushing, Shock Absorber Retainer, Spring - Lower Washer, Spring Adjust Collar, Spring Retainer, Spring Spring, Suspension Washer Nut, Lock Screw, Cap Screw, Cap Screw, Cap Screw, Cap Repair Kit, Inner Boot - Rear Axle Repair Kit, Outer Boot - Rear Axle Knuckle - Right Knuckle - Left 8
11 WHEEL AND TIRE ASSEMBLY Nut, Hex Cap, Valve Stem Stem, Valve Wheel - Front Tire - Front (2X4) Tire - Front (4X4) Pin, Cotter Washer Seal, Hub Hub, Wheel - Front (2X4) Hub, Wheel - Front (4X4) Disc, Brake Screw, Machine Hub, Wheel - Rear Wheel - Rear Tire, Rear (250) Tire, Rear (300) Cap, Wheel - Center Screw, Cap 9
12 *Not a Service Part MECHANICAL BRAKE ASSEMBLY Mechanical Brake Assembly (inc. 2-7) Arm, Inner Pin, Arm Pad, Brake Arm, Outer Spring, Arm 7 * 1 Housing, Brake Cable, Brake - Rear Screw, Cap Spring, Brake Washer, Brake Lever Ring, Snap Bracket, Brake Switch Screw, Cap O-Ring Lever, Brake Wire Form, Cable 10
13 *Not a Service Part HYDRAULIC BRAKE CONTROL ASSEMBLY Lever, Brake - Assembly (inc and 17-20) Lever, Brake Bolt, Lever Mounting Screw, Cover Cover, Reservoir Gasket, Reservoir Cover Reservoir, Brake O-Ring, Reservoir 9 * 1 Master Cylinder Screw, Reservoir Mount Nut, Lock Washer, Lock Screw, Clamp Clamp Hose, Master Cylinder Screw, Cap Wedge, Parking Brake Spring Nut, Press Pin 11
14 *Not a Service Part HYDRAULIC BRAKE ASSEMBLY Tube, Brake Line - Front (2X4) Tube, Brake Line - Front (4X4) Hose, Brake - Front (2X4) Hose, Brake - Front (4X4) Block, Mounting Bolt, Oil Washer, Crush Caliper, Brake - Right Front (inc. 7-16) Caliper, Brake - Left Front and Rear (inc. 7-16) 7 * 3 Housing, Caliper O-Ring Pin, Cotter Pin, Brake Caliper Cap, Bleed Valve Pad, Brake Valve, Bleed O-Ring, Brake Caliper Washer Screw, Socket Head Hose, Brake - Rear Clip, Brake Line Tube, Brake Line - Rear Screw, Machine Screw, Cap Clamp, Cable Screw, Machine Nut Switch, Brake Pressure (4X4) 12
15 *Not a Service Part HYDRAULIC BRAKE ASSEMBLY (Vehicle Identification Number H7YT And Up) Tube, Brake Line - Front (2X4) Tube, Brake Line - Front (4X4) Hose, Brake - Front (2X4) Hose, Brake - Front (4X4) Block, Mounting Bolt, Oil Washer, Crush Caliper, Brake - Right Front (inc and 26) Caliper, Brake - Left Front and Rear (inc and 26) 7 * 3 Housing, Caliper O-Ring Pin, Cotter Pin, Brake Caliper Cap, Bleed Valve Pad, Brake Valve, Bleed O-Ring, Brake Caliper Screw, Socket Head Hose, Brake - Rear Clip, Brake Line Tube, Brake Line - Rear Screw, Machine Screw, Cap Screw, Cap Switch, Brake Pressure (4X4) Clamp, Cable Screw, Machine Nut 26 * 1 Housing, Caliper 13
16 FUEL TANK ASSEMBLY Tank, Fuel (inc. 2-3 and 6-12) (250) Tank, Fuel (inc. 2-3 and 6-12) (300) Cap, Fuel Tank (inc. 3) (250) Cap, Fuel Tank (inc. 3) (300) Hose, Fuel Cap Vent Screw, Cap Washer Bushing, Fuel Tank Mount Collar, Fuel Tank Mount AR Hose, Fuel Clamp, Hose - Spring Gasket, Fuel Shut-Off Valve Valve, Fuel Shut-Off (inc. 10) Screw, Machine Pad, Fuel Tank Clamp, Hose Pad, Fuel Tank - Front 14
17 REVERSE SHIFT LEVER ASSEMBLY Axle, Reverse Shift Cable, Shift E-Ring Lever, Reverse O-Ring E-Ring Spring, Reverse Lever Reverse Switch Retainer, Switch Handle, Reverse Shift Lever Clip, Cable 15
18 AIR INTAKE ASSEMBLY Intake, Air - Assembly (inc. 2-5) Slider, Retainer - Filter Filter, Air Cleaner Sleeve, Filter Cap Screw, Cap Joint Clamp Clip Plug, Drain Valve, Air Cleaner Clamp Tube, Crankcase Breather Clamp Boot, Air Cleaner Clamp Snorkel, Air Intake Washer, Lock Strap, Tool Kit Rivet, Plastic Kit, Tool Screw, Cap Spring, Vent Tube Plug, Breather Valve, Check 16
19 SHIFTER ASSEMBLY Lever, Footshift O-Ring Axle, Lever Nut Screw, Cap Washer Collar Bushing Bushing Washer E-Ring Linkage, High/Low Cable, Lever Pin, Cotter Clip, Cable Arm, 2X4/4X4 - Shift (4X4) Cable, 2X4/4X4 - Shift (4X4) Nut Handle Pin, Cotter Collar, Body Screw, Cap (4X4) Plate, Backing (4X4) Washer (4X4) 17
20 ENGINE AND RELATED PARTS Engine (250) Engine (300 2X4) Engine (300 4X4) Sub-Frame Muffler (250) Muffler (300) Clamp, Exhaust Screw, Cap Pipe, Exhaust (250) Pipe, Exhaust (300) Cover, Exhaust - Rear Washer, Lock Screw, Cap Cover, Exhaust Gasket, Exhaust Coupler, Exhaust Nut Spring, Extension Pipe, Header Seal, Exhaust Pipe Panel, Belly - Sub-Frame (300) Nut Screw, Body Screw, Cap Screw, Cap Mount, Engine Screw, Cap Mount, Engine Washer Screw, Cap Nut Spacer, Engine Mount - Long Spacer, Engine Mount - Short Cap, Sub-Frame Driveshaft (4X4) Bushing, Engine Mount 18
21 OIL COOLER ASSEMBLY Cooler, Oil Grommet Screw, Cap Washer Collar Clamp, Hose Hose, Oil - Output Hose, Oil - Input Screw, Cap O-Ring, Oil Fitting Fitting, Oil - Angled Fitting, Oil 19
22 ELECTRICAL COMPONENTS Harness, Main (250) Harness, Main (300 2X4) Harness, Main (300 4X4) Harness, Main (250) (Vehicle Identification No. J6YT And Up) Harness, Main (300 2X4) (Vehicle Identification No. J6YT And Up) Harness, Main (300 4X4) (Vehicle Identification No. J6YT And Up) Screw, Self-Tapping Fuse Box Assembly Decal, Fuse Box Fuse, 10 AMP Screw, Cap Switch, Brake Retainer, Switch Coil, Ignition (250) Coil, Ignition (300) Screw, Cap Relay, Starter CDI Unit (250) CDI Unit (300) Regulator, Voltage Bracket, Battery Pad, Battery Battery (inc ) Cap, Battery Clamp, Hose Hose, Battery Vent AR Cable Tie - 7 in Cable, Battery - Ground Cable, Battery - Relay Cable, Battery - Starter Bolt, Terminal - Battery Seal, High Tension Wire Seal, Spark Plug Cap, Spark Plug Relay, Neutral Start Foam, Battery Bracket Diode (Start in Gear) (300 4X4) Nut, Starter Relay Label, Warning - Battery 20
23 *California Models Only CARBURETOR (Complete Assembly p/n ; p/n ) Cover - Assembly Spring Ring E-Clip Ring Jet Needle J8-4D Screw Diaphragm Screw Plunger Assembly O-Ring Washer Spring Screw Screw, Pilot Jet, Pilot Jet, Main 130 (250) Jet, Main (300) Jet, Main 142.5* Needle Jet P-8M Needle Jet P-6M Float Assembly Seat, Valve 2.0 w/needle O-Ring, Float Chamber Filter Chamber, Float Jet, Pilot - Air Screw Spring Adjuster, Cable - Assembly Cover Washer Screw O-Ring, Cover Guide, Cable Washer Screw Clip Hose O-Ring Cable, Choke Spring Pin Washer Cable, Throttle Clip 21
24 CYLINDER HEAD ASSEMBLY Head, Cylinder - Assembly (inc. 2-6) (250) Head, Cylinder - Assembly (inc. 2-6) (300) Guide, Valve Ring, Valve Guide Pin, Dowel Screw, Cap Screw, Cap Gasket, Cylinder Head (250) Gasket, Cylinder Head (300) Pin, Dowel Gasket Nut Nut Gasket Bolt, Stud Spark Plug (NGK DR7EA) Cap, Inspection O-Ring Plug, Head Pipe, Intake O-Ring Screw, Cap Clamp Gasket, Intake Pipe 22
25 CYLINDER ASSEMBLY Cylinder (250) Cylinder (300) Bolt, Stud (250) Bolt, Stud (300) Bolt, Stud (250) Bolt, Stud (300) Bolt, Stud Bolt, Stud Nut Gasket, Cylinder (250) Gasket, Cylinder (300) Pin, Dowel O-Ring 23
26 CRANKCASE ASSEMBLY Crankcase Set (inc (250) Crankcase Set (inc. 2-13) (300 2X4) Crankcase Set (inc. 2-13) (4X4) Pin, Dowel Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Gasket O-Ring, Oil Gallery Jet Jet, Oil Gallery Plug Gasket Cap, Oil Filler O-Ring Plug, Oil Drain (250) Plug, Oil Drain (300) Gasket Pipe, Breather (250) Pipe, Breather (300) Separator, Oil Breather Plug, Reverse Switch Hole O-Ring 24
27 CRANKCASE COVER ASSEMBLY Cover, Clutch (inc. 2) Lens, Oil Inspection Gasket Pin, Dowel Screw, Cap Screw, Cap Screw, Cap Screw, Cap Gasket Plug, Oil Gallery Gasket Switch, Oil Sensor (300) Gasket (300) Cap, Clutch Adjust O-Ring Cover, Transfer Gasket, Transfer Cover Screw, Cap Plug, Oil Gallery Gasket Screw, Cap Clamp, Breather Hose (250) Clamp, Breather Hose (300) Screw, Cap Screw, Cap Bracket, Shift Cable Plug, Oil Gallery Cap, Oil Gallery Plug 25
28 CRANKSHAFT ASSEMBLY Crankshaft Assembly (inc. 2-7) (250) Crankshaft Assembly (inc. 2-7) (300) Rod, Connecting (250) Rod, Connecting (300) Pin, Crank (250) Pin, Crank (300) Bearing (250) Bearing (300) Washer Crankshaft - Right (250) Crankshaft - Right (300) Crankshaft - Left (250) Crankshaft - Left (300) Bearing - Right Bearing - Middle Bearing - Left (250) Bearing - Left (300) O-Ring Gear, Oil Pump Drive (250) Gear, Oil Pump Drive (300) Pin Piston (250) Piston (300) Ring, Piston - Set (250) Ring, Piston - Set (300) Ring, Piston - Set (Oversized 0.50 mm) (250) Ring, Piston - Set (Oversized 1.00 mm) (250) Ring, Piston - Set (Oversized 0.50 mm) (300) Ring, Piston - Set (Oversized 1.00 mm) (300) Pin, Piston (250) Pin, Piston (300) Circlip (250) Circlip (300) Seal, Oil Piston Set (Oversized 0.50 mm) (250) Piston Set (Oversized 1.00 mm) (250) Piston Set (Oversized 0.50 mm) (300) Piston Set (Oversized 1.00 mm) (300) 26
29 STARTER CLUTCH ASSEMBLY Gear, Starter Idler Pin Spacer Clutch Set, Starter (inc. 5) Bearing Screw, Cap 27
30 CAMSHAFT/VALVE ASSEMBLY Camshaft (250) Camshaft (300) Sprocket (250) Sprocket (300) Pin Washer Screw C-Ring Arm, Valve Rocker (inc. 8-9) Screw, Cap Nut Seal, Oil Seat, Valve Spring (250) Seat, Valve Spring (300) Cotter, Valve Shaft, Decompression Lever Lever, Decompression Seal, Oil Spring Nut Shaft, Rocker Arm O-Ring Washer Gasket Screw, Cap Valve, Intake Valve, Exhaust Spring, Valve - Set (250) Spring, Valve - Set (300) Retainer, Spring (250) Retainer, Spring (300) 28
31 CAM CHAIN ASSEMBLY Chain, Camshaft (250) Chain, Camshaft (300) Guide, Camshaft Chain (250) Guide, Camshaft Chain (300) Tensioner, Camshaft Chain (250) Tensioner, Camshaft Chain (300) Washer Screw, Cap Adjuster, Tensioner - Assembly (inc. 7-10) Spring Plug Bar O-Ring Gasket, Adjuster Screw, Cap 29
32 RECOIL STARTER ASSEMBLY Starter, Recoil - Assembly (inc. 2-6) Reel Ratchet - Assembly Spring, Spiral Nut Rope Assembly Gasket, Recoil Screw, Cap Gasket Cup, Starter Nut Washer, Lock 30
33 OIL PUMP ASSEMBLY Pump, Engine Oil Gear, Driven Pin Circlip Screw, Cap Strainer, Engine Oil Screw, Cap Cap, Oil Strainer O-Ring Screw, Cap Plug, Drain (250) Plug, Drain (300) Gasket Filter, Engine Oil O-Ring Cap, Oil Filter Plug, Oil Check Gasket O-Ring Spring Bolt, Stud Bolt, Stud Nut 31
34 CLUTCH ASSEMBLY Gear, Primary Drive (250) Gear, Primary Drive (300) Race, Inner Clutch, One Way Clutch Assembly (250) Clutch Assembly (300) Nut Washer, Lock Washer, Lock Gear, Primary - Assembly (250) Gear, Primary - Assembly (300) Spacer Washer Hub, Clutch (250) Hub, Clutch (300) Nut Washer Plate, Drive Plate, Driven Plate, Clutch Pressure (250) Plate, Clutch Pressure (300) Spring Screw, Cap Plate, Release Rod, Push Bearing Guide, Ball - Outer Guide, Ball - Inner Ball, Release Screw, Adjuster Nut, Adjuster Arm, Release Screw, Cap Screw, Cap Nut Seal, Cap Screw 32
35 TRANSMISSION ASSEMBLY Countershaft Gear, 2nd Drive Gear, 3rd Drive Gear, 4th Drive Bushing Washer Circlip Gear, 5th Drive Washer Bearing - Right Retainer Screw Bearing - Middle Driveshaft Gear, 1st Driven Bushing Washer Circlip Gear, 2nd Driven Bushing Washer Gear, 3rd Driven Washer, Lock Washer, Lock Gear, 4th Driven Gear, 5th Driven Gear, Reverse Driven Bushing Dog, Reverse Washer Bearing - Right Bearing - Middle Housing, Speedometer Gear (4X4) Gasket (4X4) Gear, Speedometer Drive (4X4) Washer - Right (4X4) Washer - Left (4X4) Spacer (4X4) Gear, Speedometer Driven (4X4) Washer (4X4) Sleeve (4X4) Seal, Oil (4X4) O-Ring (4X4) Screw, Cap (4X4) Screw, Cap (4X4) Washer (4X4) Shaft, Reverse Idle Gear, Reverse Idle Bushing Spacer Washer Plug, Cover Hole (2X4) Retainer, Cover Plug (250) Retainer, Cover Plug (300 2X4) Bolt, Retainer (250) Bolt, Retainer (300 2X4) Cap, Speedometer Drive Gasket, Speedometer Gear (250) Gasket, Speedometer Gear (300) 33
36 SECONDARY TRANSMISSION ASSEMBLY Shaft, Sub-Transmission (2X4) Shaft, Sub-Transmission (4X4) Gear, Driven (2X4) Gear, Driven (4X4) Washer - Right (4X4) Washer - Left (4X4) Gear, Driven (4X4) Dog, Driven Gear (4X4) Washer (4X4) Circlip Bearing - Right Bearing - Left Bearing - Middle (250) Bearing - Middle (300) Retainer Retainer Screw Screw Gear, Drive Bushing (250) Bushing (300) Washer Gear, Drive Dog, Drive Gear Washer Spacer Circlip Gear, Idler Washer Washer Bearing, Drive - Left Bearing, Countershaft - Left Fork Fork (4X4) Shaft Shaft (4X4) Cam, Sub-Transmission Gear (2X4) Cam, Sub-Transmission Gear (4X4) Stopper Spring Washer Screw, Cap Pin (4X4) Arm Screw, Cap Washer E-Ring Seal, Oil 34
37 SECONDARY GEAR/OUTPUT SHAFT ASSEMBLY Gear, Secondary Drive Bevel (4X4) Shim Set, Secondary Drive Bevel (4X4) Washer (4X4) Nut (4X4) Bearing, Front (4X4) Bearing, Rear (4X4) Ring (4X4) Shaft, Secondary Output (4X4) AR Shim, 25 x 34 x 0.50 mm (4X4) AR Shim, 25 x 34 x 0.60 mm (4X4) AR Shim, 25 x 34 x 0.65 mm (4X4) AR Shim, 25 x 34 x 0.70 mm (4X4) AR Shim, 25 x 34 x 0.75 mm (4X4) AR Shim, 25 x 34 x 0.80 mm (4X4) AR Shim, 25 x 34 x 0.85 mm (4X4) AR Shim, 25 x 34 x 0.90 mm (4X4) AR Shim, 25 x 34 x 0.95 mm (4X4) AR Shim, 25 x 34 x 1.00 mm (4X4) AR Shim, 25 x 34 x 1.05 mm (4X4) AR Shim, 25 x 34 x 1.10 mm (4X4) AR Shim, 25 x 34 x 1.15 mm (4X4) AR Shim, 25 x 34 x 1.20 mm (4X4) Seal, Oil Circlip (4X4) Shaft, Rear Final Driven Gear, Driven Bearing Seal, Oil Boot (4X4) Yoke, Output Shaft Joint (4X4) Nut (4X4) Washer (4X4) Gear, Secondary Driven Bevel (4X4) Ring Circlip Coupling (4X4) Joint, Universal (inc. 25) (4X4) Circlip Screw, Cap (4X4) Nut (4X4) Yoke, Output - Front (inc ) (4X4) O-Ring Plate Collar Plate, Oil Seal 35
38 GEAR SHIFTING ASSEMBLY Fork, Gear Shifting Fork, Gear Shifting Fork, Gear Shifting Shaft Fork, Gear Shifting Shaft Cam, Gear Shifting (inc. 8) Pin Retainer, Pin Pin Bearing Retainer Retainer Screw, Cap Stopper, Cam Screw, Cap Washer Spring Pin Plate, Stopper Screw, Cap Pin Cam, Reverse Shifting Washer Stopper, Cam Gasket Shaft, Gear Shifting Arm, Gear Shifting (inc ) Spring E-Ring (250) E-Ring (300) Arm, Link Spring Stopper, Arm Roller Screw, Cap Washer Seal, Oil Arm Arm, Gear Shifting Cable Screw, Cap Screw, Cap Washer E-Ring Base, Gear Shift - Assembly O-Ring Screw, Cap Contact Spring 36
39 *Not in Assembly DIFFERENTIAL GEAR ASSEMBLY (4X4) (Complete Assembly p/n ) Gear, Front Drive Bevel Spacer Bearing, Front Bearing, Rear Bearing Case, Differential Pinion, Differential Side Gear, Right Gear, Left Shaft, Pinion Hub Shaft, Driven Output AR Washer AR Washer AR Washer Washer Washer Pin, Pinion Shaft Screw, Cap Housing, Differential Gear (inc. 19) Union, Breather Housing, Drive Bevel Gear Washer Shim Set, Front Drive Bevel Gear Shim Set, Drive Gear Bearing Shim Set, Front Drive Bevel Housing O-Ring O-Ring Case, Driven Gear Bearing Cover Bearing, Left Bearing, Right Seal, Oil Gasket, Case Cover Screw, Cap Screw, Cap Screw, Cap Screw, Cap Pin, Dowel Flange, Drive Bevel Gear (inc ) Plate Collar Plate, Oil Seal O-Ring Nut Washer Plug, Drain Gasket Plug, Filler O-Ring Bladder, Housing* Tie, Cable* Dog Nut Circlip Gear, Front Driven Bevel 37
40 DIFFERENTIAL LOCK ASSEMBLY (4X4) Fork, Differential Locking Shaft, Fork Cam, Differential Locking Shaft, Cam Spring Washer, Right Washer, Left Seal, Oil Stopper, Shift Cam Plug, Oil Spring Gasket 38
41 STARTER MOTOR ASSEMBLY (Complete Assembly p/n ) Armature Holder Set, Brush Terminal Set, Brush (inc. 4) O-Ring Washer Set Spring, Brush Bracket, Front - Assembly Bolt Set (inc. 4) O-Ring O-Ring Nut Screw, Cap 39
42 MAGNETO ASSEMBLY Stator - Assembly Rotor/Flywheel (250) Rotor/Flywheel (300) Bolt, Magneto Screw, Cap Nut, Magneto Key Plate Screw, Cap Sheet, Heat Protection 40
43 CONTROL SWITCH HOUSING ASSEMBLY Switch, Handlebar Control - Assembly (inc. 2-5) Lever, Choke Cover, Choke Lever Screw, Cap Screw, Cap 41
44 THROTTLE CASE ASSEMBLY Case, Throttle - Assembly (inc. 2-9) Lever Screw, Cap Washer, Lock Washer Screw Nut Screw Screw 42
45 Printed in U.S.A. p/n
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A1 CYLINDER 1 3R9-11111-00-00 HEAD, CYLINDER 1......... 1 2 1W2-11161-00-00 ABSORBER 1............. 2 3 (1W2-11127-00-00) ABSORBER 3............. 1 4 2X3-11181-00-00 GASKET, CYLINDER HEAD 1. 1 5 90116-08321-00
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A1 CYLINDER HEAD 1 4JY-11111-00-00 HEAD, CYLINDER 1 (4JY-11111-01-00).......... 1 2 90116-08394-00 BOLT, STUD.............. 5 3 90176-08026-00 NUT, CROWN............. 5 4 90201-08087-00 WASHER, PLATE...........
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A1 CYLINDER HEAD 1 3BM-11101-00-00 CYLINDER HEAD ASSEMBLY. 1 2 4H7-11133-10-00. GUIDE, INTAKE VALVE..... 2 3 93440-12052-00. CIRCLIP................. 2 4 3BM-11101-10-00 CYLINDER HEAD ASSEMBLY. 1 5 4H7-11133-10-00.
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A1 CYLINDER 1 50W-11111-00-00 HEAD, CYLINDER 1......... 1 2 87A-11181-00-00 GASKET, CYLINDER HEAD... 1 3 NGK-BR8HS-00-00 PLUG, SPARK............. 1 4 87A-11311-00-00 CYLINDER 1.............. 1 5 50W-11351-00-00
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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
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A1 A2 A3 A4 CYLINDER HEAD 1 15A-11110-03-00 CYLINDER HEAD ASSY...... 1 2 93440-10085-00. CIRCLIP................. 2 3 90153-06029-00. SCREW, HEXAGON........ 1 4 90430-06014-00. GASKET................ 1
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A1 CYLINDER 1 (3R4-11111-00-00) HEAD, CYLINDER 1......... 1 2 1W3-11181-00-00 GASKET, CYLINDER HEAD 1. 1 3 (CMP-N2G00-00-00) CHAMPION N2G 10PK....... 1 4 90116-08321-00 BOLT, STUD.............. 6 5 90179-08491-00
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