XF 800 Sno Pro SHARE OUR PASSION.

Transcription

1 2012Snowmobile Illustrated Parts Manual XF 800 Sno Pro Model Number S2012XFHSPUSG Model Number S2012XFHSPUSO Model Nubmer S2012XFHSPOSG - International Model Number S2012XFHSPOSO - International TM SHARE OUR PASSION.

2 (Model No. S2012XFHSPUSG) (Model No. S2012XFHSPUSO) TABLE OF CONTENTS 2012 XF 800 Sno Pro (Model No. S2012XFHSPOSG - International) (Model No. S2012XFHSPOSO - International) SKI AND SPINDLE ASSEMBLY... 1 A-ARM AND SWAY BAR ASSEMBLY... 2 SHOCK ABSORBER ASSEMBLY... 3 FRONT SUSPENSION SHOCK ABSORBER... 4 TIE ROD ASSEMBLY... 5 STEERING POST ASSEMBLY... 6 HANDLEBAR AND CONTROLS... 7 HYDRAULIC BRAKE CONTROL ASSEMBLY... 8 DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES... 9 CHAIN CASE ASSEMBLY OIL TANK ASSEMBLY SLIDE RAIL AND TRACK ASSEMBLY IDLER WHEEL ASSEMBLY REAR SUSPENSION FRONT ARM ASSEMBLY REAR SUSPENSION FRONT ARM SHOCK ABSORBER REAR SUSPENSION REAR ARM ASSEMBLY REAR SUSPENSION REAR ARM SHOCK ABSORBER STEERING SUPPORT ASSEMBLY FRONT BUMPER AND FRAME ASSEMBLY TUNNEL, REAR BUMPER, AND SNOWFLAP ASSEMBLY HOOD AND AIR INTAKE ASSEMBLY WINDSHIELD AND INSTRUMENTS ASSEMBLIES CONSOLE ASSEMBLY HEADLIGHT AND WIRING ASSEMBLIES SKID PLATE AND SIDE PANEL ASSEMBLY BELT GUARD ASSEMBLY GAS TANK ASSEMBLY FUEL PUMP ASSEMBLY SEAT ASSEMBLY COOLING ASSEMBLY ENGINE AND RELATED PARTS EXHAUST ASSEMBLY DRIVE CLUTCH DRIVEN CLUTCH CYLINDER AND HEAD ASSEMBLY CRANKCASE ASSEMBLY PISTON AND CRANKSHAFT REED VALVE ASSEMBLY THROTTLE BODY ASSEMBLY OIL PUMP WATER PUMP AND THERMOSTAT RECOIL STARTER MAGNETO ELECTRICAL SERVOMOTOR 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. For a complete list of related items, refer to the current accessory catalog Arctic Cat Inc. Effective October 2011 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

3 SKI AND SPINDLE ASSEMBLY X 1 Spindle, Steering - Right - Green (inc. 2) (SPUSG/SPOSG) X 1 Spindle, Steering - Left - Green (inc. 2) (SPUSG/SPOSG) X 1 Spindle, Steering - Right - Black (inc. 2) (SPUSO/SPOSO) X 1 Spindle, Steering - Left - Black (inc. 2) (SPUSO/SPOSO) Bearing Axle, Spindle Spacer X 2 Damper, Ski Ski, Plastic - Black Insert X 2 Handle, Plastic - Black Nut, Lock Screw, Machine Screw, Machine Wearbar Nut, Lock Nut, Lock Washer Pin, Cotter Screw, Cap 1

4 X 1 A-Arm, Upper Right - Green (SPUSG/SPOSG) X 1 A-Arm, Upper Left - Green (SPUSG/SPOSG) X 1 A-Arm, Upper Right - Black (SPUSO/SPOSO) X 1 A-Arm, Upper Left - Black (SPUSO/SPOSO) Screw, Cap X 4 Axle Nut, Lock Nut, Lock X 2 Bushing X 1 Bar, Sway X 2 Bushing X 2 Bracket, Mounting - Sway Bar Screw, Machine Screw, Machine A-ARM AND SWAY BAR ASSEMBLY New Qty Description X 2 Link, Sway Bar X 1 A-Arm, Lower Right - Green (inc ) (SPUSG/SPOSG) X 1 A-Arm, Lower Left - Green (inc ) (SPUSG/SPOSG) X 1 A-Arm, Lower Right - Black (inc ) (SPUSO/SPOSO) X 1 A-Arm, Lower Left - Black (inc ) (SPUSO/SPOSO) Bearing X 4 Bearing X 2 Nut, Lock X 1 Brace, Lower A-Arm X 2 Axle, Inner - Lower A-Arm - Front X 2 Screw, Cap Screw, Cap Axle, Lower A-Arm - Rear Nut, Lock 2

5 Pump, Air - Shock X 2 Shock, Ski Sleeve SHOCK ABSORBER ASSEMBLY Screw, Cap Nut, Lock 3

6 FRONT SUSPENSION SHOCK ABSORBER X 1 Complete Shock Absorber Cap, Air Valve End Cap, Shock (inc. 3) Valve, Air Bushing Sleeve Kit, Seal/Cap Rebuild Body, Shock - Upper Decal, Shock Bearing - Assembly Ball, Bleed Screw, Set X 1 Rod, Shock Guide, Spring Spring Washer, Top Out Valve, x in Valve, x in Valve, x in. New Qty Description Valve, x in Valve, x in Valve, x in Valve, x in Valve, x in Valve, x in X 1 Piston, in. - Orifice Valve, x in Valve, x in Valve, x in Washer, Backup Nut X 1 Piston, Floating X 1 Body, Shock - Lower Plug, Rubber - Valve Screw, Set Ball, Air Valve AR Fluid, Float Shock - 8 oz AR Oil, Shock - 1 qt 4

7 TIE ROD ASSEMBLY Screw, Cap X 2 Washer X 2 Bushing X 1 Arm, Steering Nut, Lock X 3 Screw, Machine Nut, Lock X 3 Ball Joint, Tie Rod - Right-Hand Thread Nut, Hex - Right-Hand Thread X 2 Tube, Tie Rod - Spindle Nut, Hex - Left-Hand Thread Ball Joint, Steering - Left-Hand Thread Washer Nut, Lock Ball Joint, Tie Rod - Left-Hand Thread X 1 Tube, Tie Rod - Steering 5

8 Screw, Machine X 4 Cap, Riser Block X 1 Block, Riser Nut, Lock X 1 Plate, Retaining X 1 Block, Mounting - Steering Post STEERING POST ASSEMBLY New Qty Description X 1 Block, Mounting - Steering Post Screw, Machine Screw, Cap X 1 Post, Steering Nut, Lock 6

9 X 1 Handlebar (inc. 2-3) Rivet Insert, Handlebar Grip, Handlebar Washer, Backing Screw, Self-Tapping Control, Throttle - Rear (inc. 8-13) Kit, Throttle Lever Mounting (inc. 9-12) 9 1 Axle, Lever - Throttle - Included in Kit 10 2 Cap, Lever Axle - Included in Kit 11 1 Spacer, Lever Axle - Included in Kit Nut, Push - Included in Kit Lever, Throttle HANDLEBAR AND CONTROLS Pad, Insulator Element, Thumbwarmer Clip, Retaining Control, Throttle - Front Cover, Connector Screw, Machine Screw, Self-Tapping X 1 Cable, Throttle X 1 Element, Handwarmer - Right X 1 Element, Handwarmer - Left X 1 Control, Dimmer - Front Control, Dimmer - Rear X 1 Harness, Handlebar AR Cable Tie - 4 in AR Tie, Cable - 8 in. 7

10 HYDRAULIC BRAKE CONTROL ASSEMBLY X 1 Brake Assembly (inc. 2-14) X 1 Piston Assembly X 1 Lever, Brake - Assembly (inc. 4-5) X 1 Lock, Brake Lever - Kit X 1 Screw, Shoulder Screw, Machine Clamp, Handlebar X 1 Reservoir (inc. 9-10) X 1 O-Ring New Qty Description X 3 Screw, Self-Tapping X 1 Cover, Reservoir (inc. 12) X 1 Gasket X 3 Screw, Self-Tapping X 1 Switch, Brake Bolt, Banjo-Fitting X 1 Brakeline, Hydraulic Washer, Crush AR Fluid, Brake - 12 oz 8

11 DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES X 1 Track, Drive - Assembly (inc. 2-8) X 1 Ring, Retaining X 1 Plug, Magnetic - Assembly (inc. 4) X 2 Magnet X 1 Driveshaft Sprocket, Drive X 1 Plate, Retaining - Seal (inc. 8) Seal Screw, Cap X 2 Ring, Retaining X 1 Disc, Brake X 1 Caliper, Brake - Assembly (inc ) X 1 Seal X 1 Bearing X 1 Ring, Retaining X 2 Piston Set X 1 Pad, Brake - Set (inc. 18) X 1 Pin, Retaining X 1 Fitting, Bleed X 2 Screw, Cap X 1 Shaft, Driven - Assembly (inc ) X 1 Shaft, Driven X 1 Hub, Bearing X 1 Bearing X 1 Ring, Retaining X AR Washer, Shim (.030 in.) X AR Washer, Shim (.060 in.) X AR Washer, Shim (.090 in.) X 1 Clutch, Driven - Assembly O-Ring AR Washer, Shim (.030 in.) AR Washer, Shim (.060 in.) AR Washer, Shim (.090 in.) Adjuster, Sheave (inc. 31) Washer, Thrust Washer Washer, Lock Screw, Cap 9

12 X 1 Chain Case Assembly (inc. 2-11) Seal X 1 Bearing X 1 Ring, Retaining X 1 Seal X 1 Spacer X 1 Bearing X 1 Ring, Retaining X 1 Sleeve, Adapter Fitting, Elbow X 1 Hose, Vent X 1 Ring, Retaining X 1 Sprocket - 22T (13 Wide) Washer, Spring CHAIN CASE ASSEMBLY New Qty Description Screw, Cap X 1 Sprocket - 48T (13 Wide) X 1 Chain - 90P (13 Wide) X 1 Arm, Tensioner - Assembly X 1 Spring X 1 Plate, Ratchet Nut, Lock Screw, Machine X 17 Screw, Self-Tapping X 1 Seal, Chain Case X 1 Cover, Chain Case (inc ) X 1 Glass, Sight X 1 Kit, Speedometer Sensor X 1 Plug, Fill 10

13 Cap, Oil Tank (inc. 2) Seal, Cap - Oil Tank X 5 Screw, Self-Tapping Decal, Oil Tank X 1 Neck, Oil Fill X 1 O-Ring X 7 Screw, Self-Tapping X 1 Glass, Sight X 1 Tank, Oil OIL TANK ASSEMBLY X 1 Sensor, Low Oil O-Ring X 1 Fitting, Outlet Clamp, Hose AR Hose - Green - 25 ft AR Hose - Green ft AR Conduit, Flexible - 3 ft AR Sealant - 70 ml 11

14 X 1 Complete Skid Frame Assembly X 2 Rail, Formed Insert, Rail Screw, Cap X 1 Axle Nut, Lock End Cap, Slide Rail Screw, Machine Nut, Lock X 2 Wearstrip, Slide Rail Screw, Machine SLIDE RAIL AND TRACK ASSEMBLY New Qty Description Rivet, Solid Pad, Shock Nut, Push Nut, Lock Pad, Shock Screw, Machine X 1 Axle X 2 Bushing, Stop - Rear Arm Track Assembly (inc. 20) Clip, Guide 12

15 Screw, Cap Washer Wheel, Idler - Black (inc. 4-5) Bearing Ring, Retaining Screw, Cap Block, Mounting - Idler Wheel Nut, Lock Screw, Cap Spacer, Shock - Front Arm Washer Axle Nut, Lock IDLER WHEEL ASSEMBLY Screw, Cap Block, Mounting - Idler Wheel X 2 Wheel, Idler Screw, Cap X 2 Washer X 2 Bushing, Adjuster Nut, Lock X 2 Wheel, Idler X 1 Axle, Rear Screw, Cap X 2 Adjuster, Track Nut, Lock Screw, Cap 13

16 REAR SUSPENSION FRONT ARM ASSEMBLY X 1 Arm, Front Suspension - Black (inc. 2-5) Washer Fitting, Grease Bushing Bushing, Flared X 1 Axle Screw, Cap Screw, Cap X 2 Axle Washer Nut, Lock New Qty Description Screw, Cap Washer Strap, Limiter Nut, Lock Cover, Shock Spring, Compression - Black Retainer, Spring Axle Screw, Cap X 1 Shock Absorber 14

17 REAR SUSPENSION FRONT ARM SHOCK ABSORBER X 1 Complete Shock Absorber Eyelet, Shock Rod, Shock Bearing - Assembly Kit, Seal/Rebuild Washer, Top Out Valve, x in Valve, x in Valve, x in Valve, x in Valve, x in Piston, in. - Orifice Valve, x in Valve, x in Valve, x in Washer, Backup Nut Piston, Floating Screw, Machine w/o-ring (inc. 19) O-Ring Retainer, Wear Sleeve Sleeve, Wear Nut, Adjuster Collar, Locking - Adjuster Nut Decal, Shock Body, Shock End Cap, Shock - Assembly (inc ) Valve, Pressure - Assembly (inc. 28) O-Ring Screw, Valve Sleeve AR Oil, Shock - 1 qt 15

18 REAR SUSPENSION REAR ARM ASSEMBLY Screw, Cap X 1 Axle X 1 Arm, Rear - Black (inc. one No. 4) Fitting, Grease Screw, Cap X 1 Axle X 1 Arm, Idler - Black (inc. two No. 4 and 8-10) Bushing, Flared Washer Bushing X 1 Axle, Inner Carriage New Qty Description Washer, Wave Wheel, Idler (inc ) Bearing Ring, Retaining Ring, Retaining Screw, Cap Link, Rear Shock - Black Screw, Cap Sleeve Nut, Lock X 1 Shock Absorber 16

19 REAR SUSPENSION REAR ARM SHOCK ABSORBER X 1 Complete Shock Absorber End Cap, Shock (inc. 2) Valve, Air Cap, Air Valve Bushing Sleeve Kit, Seal/Cap Rebuild Body, Shock - Upper Decal, Shock Rod, Shock X 1 Bearing - Assembly Ball, Bleed Screw, Set Bumper, Internal - Top Out Washer, Top Out Valve, x in Valve, x in Valve, x in Valve, x in Valve, x in Valve, x in Valve, x in Valve, x in Piston, in. - Orifice Valve, x in Valve, x in Nut Piston, Floating Body, Shock - Lower Plug, Rubber - Valve Screw, Set Ball, Air Valve AR Oil, Shock - 1 qt AR Fluid, Float Shock - 8 oz 17

20 Nut, Lock Rivet X 1 Bracket, Mounting - Servomotor X 4 Insert X 1 Support, Shock Mount Bracket Screw, Cap Nut, Lock Nut, Lock X 6 Insert Screw, Cap X 2 Clamp, Routing X 2 Spar, Front Screw, Cap X 1 Tab, Spring - Resonator X 1 Support, Chassis - Right X 1 Support, Chassis - Left Screw, Cap Screw, Machine X 1 Bolt, Carriage STEERING SUPPORT ASSEMBLY New Qty Description Screw, Cap X 1 Support, Side - Rear Right X 1 Support, Side - Rear Left Screw, Cap Washer, External Tooth Lock Nut, Lock Screw, Machine Screw, Machine X 1 Bracket, Mounting - Coil Screw, Machine Clamp, Wire Spacer Screw, Machine X 1 Support, Steering X 1 Spar, Rear - Right X 1 Spar, Rear - Left (inc ) X 1 Bracket, Hold-Down - Seat-Base Rivet 18

21 FRONT BUMPER AND FRAME ASSEMBLY X 1 Panel, Front - Assembly - Black (inc. 2-5) Clip, U-Nut X 1 Tab, Spring - Resonator Screw, Self-Tapping X 1 Bracket, Shock Mount - Upper Right - Black X 1 Bracket, Shock Mount - Upper Left - Black X 4 Bracket, Mounting - Upper A-Arm Rivet X 1 Bracket, Re-enforcement X 1 Bracket, Steering Stop Screw, Machine Regulator/Rectifier Nut, Lock X 7 Screw, Self-Tapping Nut, Lock X 4 Screw, Shoulder X 1 Boot, Steering - Right X 1 Boot, Steering - Left Rivet X 1 Frame, Front - Lower Rivet Screw, Machine X 1 Belly Pan - Center Clip, U-Nut X 1 Panel, Access Screw, Self-Tapping X 1 Belly Pan - Front X 1 Bumper, Front - Assembly - Green (inc. eight No. 7 and 27-28) (SPUSG/SPOSG) X 1 Bumper, Front - Assembly - Black (inc. eight No. 7 and 27-28) (SPUSO/SPOSO) X 1 Bracket, Mounting - Bumper - Right - Black X 1 Bracket, Mounting - Bumper - Left - Black X 1 Bumper, Front - Green (SPUSG/SPOSG) X 1 Bumper, Front - Black (SPUSO/SPOSO) 19

22 TUNNEL, REAR BUMPER, AND SNOWFLAP ASSEMBLY X 1 Complete Chassis Assembly X 1 Tunnel Assembly (inc. 2-9) X 1 Tunnel, Front - Assembly Rivet X 1 Bracket, Mounting - Rear Spar - Right X 1 Bracket, Mounting - Rear Spar - Left Rivet AR Rivet X 1 Tunnel, Rear Rivet X 1 End Cap, Tunnel Clamp, Wire Screw, Machine X 1 Support, Footrest - Right X 1 Support, Footrest - Left Nut, Lock X 1 Kit, Tool Screw, Machine Clip, U-Nut X 1 Footrest - Right X 1 Footrest - Left Screw, Machine X 1 Protector, Chain Case Rivet X 1 Mount, Clutch Guard Screw, Self-Tapping Clip, U-Nut X 1 Shield, Brake Disc - Center New Qty Description X 1 Shield, Brake Disc - Front Screw, Cap X 1 Shield, Brake Disc - Rear X 1 Protector, Brake Disc AR Rivet X 1 Protector, Harness - Taillight Extension X 2 Roll, Tunnel Rivet Rivet X 1 Gusset, Running Board - Right X 1 Gusset, Running Board - Left X 1 Gusset, Tunnel Roll - Right X 1 Gusset, Tunnel Roll - Left X 1 Decal, Reflector - Right - Red X 1 Decal, Reflector - Left - Red X 2 Decal, Tunnel - Sno Pro X 1 Bracket, Mounting - Taillight Screw, Machine X 1 Taillight, LED Nut, Lock X 1 Snowflap Decal, Warning - Towing (French) Decal, Warning - Towing (English) Screw, Machine Rivet Washer Screw, Machine X 1 Bumper, Rear 20

23 HOOD AND AIR INTAKE ASSEMBLY X 1 Hood, Right - Assembly - Green (inc. 2) (SPUSG/SPOSG) X 1 Hood, Left - Assembly - Green (inc. 2-3) (SPUSG/SPOSG) X 1 Hood, Right - Assembly - Orange (inc. 2) (SPUSO) X 1 Hood, Left - Assembly - Orange (inc. 2-3) (SPUSO) X 1 Hood, Right - Assembly - Orange (inc. 2) (SPOSO) X 1 Hood, Left - Assembly - Orange (inc. 2-3) (SPOSO) X 1 Foam, Hood - Right X 1 Foam, Hood - Left X 1 Foil, Protective Screw, Self-Tapping X 4 O-Ring X 1 Plenum, Intake - Upper (inc. 7) X 1 Foam, Intake X 1 Decal, 50th Anniversary (SPUSG/SPOSG) X 1 Decal, 50th Anniversary (SPUSO/SPOSO) X 1 Guard, Steering Post - Black X 15 Screw, Self-Tapping X 2 Boot, Intake Clip, Retaining Screw, Self-Tapping X 6 Clip, U-Nut X 4 Screw, Self-Tapping Clip, U-Nut Screw, Self-Tapping X 1 Plenum, Intake - Lower Front (inc. 19) X 2 Decal, Reflector - Amber X 1 Foam, Intake X 1 Plenum, Intake - Lower Rear (inc. 22) X 1 Foil, Protective X 1 Adapter, Boot X 1 Boot Clamp 21

24 WINDSHIELD AND INSTRUMENTS ASSEMBLIES X 1 Pod, Instrument X 1 Vent, Intake - Right X 1 Vent, Intake - Left Screw, Self-Tapping Outlet, Accessory - 12V X 1 Switch, Ignition (inc. 6-8) Nut, Retaining Key, Ignition Y Series - Left-Side Cut Key, Ignition Z Series - Right-Side Cut Cover, Key X 1 Gauge, Speedometer New Qty Description X 1 Bracket, Speedometer Gauge - Center Nut w/washer Screw, Cap X 1 Bracket, Speedometer Gauge - Right X 1 Bracket, Speedometer Gauge - Left Washer, External Tooth Lock Nut, Lock Screw, Shoulder Nut, Expansion X 1 Windshield - Low - Black Screw, Machine 22

25 X 1 Console, Upper Screw, Self-Tapping X 1 Nut, Retaining X 2 Clip, U-Nut Alarm, Reverse (inc. 6) Ring, Retaining X 1 Console, Lower w/decals (inc. 8-11) (SPUSG/SPOSG) X 1 Console, Lower w/decals (inc. 8-11) (SPUSO/SPOSO) X 1 Console, Lower (inc. 9-10) X 1 Decal, Warning - English CONSOLE ASSEMBLY X 1 Decal, Warning - French X 1 Decal, Console - Right (SPUSG/SPOSG) X 1 Decal, Console - Left (SPUSG/SPOSG) X 1 Decal, Console - Right (SPUSO/SPOSO) X 1 Decal, Console - Left (SPUSO/SPOSO) Pin, Retaining Nut, Push 23

26 HEADLIGHT AND WIRING ASSEMBLIES X 1 Headlight Assembly (inc. 2-4) Bulb Retainer X 2 Boot X 4 Screw, Self-Tapping Clamp, Routing Clip, U-Nut X 1 Harness, Hood X 1 Wrap, Harness AR Tie, Cable - 4 in AR Tie, Cable - 8 in AR Tie, Cable in. New Qty Description X 1 Harness, Main (inc ) Cover, Fuse Holder Fuse Amp Cover, Diagnostics Connector Tether, Accessory Connector - Optional X 1 Harness, Extension - Taillight AR Tie, Cable - Push-Mount Clip, Routing - Snap-In 24

27 SKID PLATE AND SIDE PANEL ASSEMBLY X 1 Panel, Side - Right w/decals - Black (inc. 2-10) (SPUSG/SPOSG) X 1 Panel, Side - Right w/decals - Black (inc. 2-10) (SPUSO/SPOSO) X 1 Panel, Side - Right w/o Decals - Black (inc. 3-7) X 1 Foam, Side Panel - Upper Front - Right X 1 Foil, Protective X 1 Foam, Side Panel - Upper Rear - Right X 1 Foam, Side Panel - Lower Front - Right X 1 Foam, Side Panel - Lower Rear - Right X 1 Decal, Side Panel - Upper Front - Right (SPUSG/SPOSG) X 1 Decal, Side Panel - Upper Front - Right (SPUSO/SPOSO) X 1 Decal, Side Panel - Lower Front - Right (SPUSG/SPOSG) X 1 Decal, Side Panel - Lower Front - Right (SPUSO/SPOSO) X 1 Decal, Side Panel - Lower Rear - Right (SPUSG/SPOSG) X 1 Decal, Side Panel - Lower Rear - Right (SPUSO/SPOSO) X 1 Panel, Side - Left w/decals - Black (inc ) (SPUSG/SPOSG) X 1 Panel, Side - Left w/decals - Black (inc ) (SPUSO/SPOSO) X 1 Panel, Side - Left w/o Decals - Black (inc ) X 1 Foam, Side Panel - Center Front - Left X 1 Foam, Side Panel - Upper Rear - Left X 1 Foam, Side Panel - Lower Front - Left X 1 Foam, Side Panel - Lower Rear - Left X 1 Decal, Side Panel - Upper Front - Left (SPUSG/SPOSG) X 1 Decal, Side Panel - Upper Front - Left (SPUSO/SPOSO) X 1 Decal, Side Panel - Lower Front - Left (SPUSG/SPOSG) X 1 Decal, Side Panel - Lower Front - Left (SPUSO/SPOSO) X 1 Decal, Side Panel - Lower Rear - Left (SPUSG/SPOSG) X 1 Decal, Side Panel - Lower Rear - Left (SPUSO/SPOSO) Washer Rivet Cable Clip, Hairpin AR Foil, Protective - 30 ft X 1 Screen, Intake X 1 Duct, Air - Clutch (inc. 27) X 1 Foil, Protective Clip, U-Nut Screw, Self-Tapping X 1 Plate, Skid - Right w/decals - Black (inc and one No. 38) X 1 Plate, Skid - Right w/o Decals - Black (inc ) X 1 Foam, Skid Plate - Upper Front - Right X 1 Foam, Skid Plate - Center Front - Right X 1 Foam, Skid Plate - Upper Rear - Right Rivet X 1 Deflector, Heat Washer X 2 Decal, Arctic Cat X 1 Plate, Skid - Left w/decals - Black (inc and one No. 38) (Continued on Page 26) 25

28 SKID PLATE AND SIDE PANEL ASSEMBLY (Continued) X 1 Plate, Skid - Left w/o Decals - Black (inc ) X 1 Foam, Skid Plate - Upper Front - Left X 1 Foam, Skid Plate - Center Front - Left X 1 Foam, Skid Plate - Upper Rear - Left Clip, Retaining Pin, Retaining X 1 Plate, Exhaust Outlet New Qty Description X 1 Seal, Exhaust Outlet Rivet Screw, Self-Tapping X 1 Fascia, Front Right - Black X 1 Fascia, Front Left - Black (inc. 52) X 1 Foil, Protective Screw, Self-Tapping Clip, U-Nut Screw, Cap X 1 Shield, Heat - ECU 26

29 X 1 Guard, Belt - Front X 1 Decal, EFI Diagnostic Codes Screw, Self-Tapping Screw, Cap X 1 Tab, Spring - Resonator BELT GUARD ASSEMBLY Nut, Lock X 1 Guard, Belt - Rear (inc. 8-9) X 1 Decal, Warning - English X 1 Decal, Warning - French 27

30 X 1 Tank, Gas - Assembly (inc. 2-5) Cap, Gas Tank - Assembly (inc. 3) Seal, Gas Tank Cap Valve, Check Grommet AR Foil, Protective - 30 ft Clamp, Hose GAS TANK ASSEMBLY New Qty Description AR Hose, Gasline - 50 ft AR Hose, Gasline ft Screw, Machine Washer Screw, Machine X 1 Bracket, Hold-Down Nut, Lock 28

31 Screw, Self-Tapping Plate, Retaining - Fuel Pump X 1 Pump, Fuel - Assembly (inc. 4) Float Seal X 1 Pickup, Fuel - Assembly Clamp, Hose FUEL PUMP ASSEMBLY X 1 Hose, Fuel Pump/Pickup Fitting, Quick-Connect AR Hose, Gasline - 10 ft Clamp, Hose AR Tie, Cable - 8 in AR Tie, Cable in. 29

32 X 1 Complete Seat Assembly - Green (inc. 2-9) (SPUSG/SPOSG) X 1 Complete Seat Assembly - Black (inc. 2-9) (SPUSO/SPOSO) X 1 Cover, Seat - Green (inc. 3) (SPUSG/SPOSG) X 1 Cover, Seat - Black (inc. 3) (SPUSO/SPOSO) SEAT ASSEMBLY New Qty Description Wire, Seat X 1 Foam, Seat X 1 Wire, Seat AR Staple X 1 Seat-Base (inc. 8-9) X 1 Latch, Seat Rivet 30

33 X 1 Exchanger, Heat (inc. 2) Insert Screw, Machine X 2 Spacer Screw, Machine X 2 Spacer AR Rivet Nut, Lock Screw, Machine Rivet X 1 Plate, Retaining Rivet AR Foil, Protective - 30 ft Clamp, Hose COOLING ASSEMBLY AR Hose, Vent - 25 ft Clamp, Hose Cap X 1 Neck, Filler X 1 Clamp, Hose X 1 Hose, Coolant - Filler Neck/Heat Exchanger Clamp, Hose X 1 Hose, Coolant - Engine/Heat Exchanger Conduit, Flexible - 4 in Clamp, Hose X 1 Hose, Coolant - Heat Exchanger/Engine Clamp, Hose 31

34 Engine, AB80L4 w/o EFI Components Handle, Recoil Cap, Recoil Handle X 1 Bracket, Engine Mounting - MAG (inc. 5-6) X 1 Mount, Engine X 1 Bushing Screw, Cap Foil, Protective Conduit, Flexible - (3/4 in. ID) - 12 in AR Tie, Cable - 8 in Clamp, Hose Hose, Coolant - MAG/Throttle Body AR Conduit, Flexible - 5 ft X 1 Hose, Coolant - PTO/Throttle Body Screw, Cap Screw, Cap X 1 Plate, Engine Mounting - Lower ENGINE AND RELATED PARTS New Qty Description X 2 Mount, Engine - Lower Mount, Engine - Lower X 6 Screw, Shoulder Nut, Lock Screw, Cap Screw, Machine Washer X 1 Screw, Cap Washer, Spring X 1 Plate, Engine Mounting - PTO X 4 Screw, Cap Screw, Machine Ring, Damper X 1 Clutch, Drive - Uncalibrated X 1 Belt, Drive Washer, High Collar Bolt, Clutch 32

35 X 1 Resonator Assembly X 1 Cover, Resonator X 2 Grommet, Resonator Mount X 1 Grommet, Resonator Mount Spring, Exhaust Spring, Exhaust Gasket, Exhaust - Tailpipe X 1 Chamber, Expansion - Assembly (inc. 9-15) X 1 Chamber, Expansion X 1 Cover, Expansion Chamber - Upper X 1 Packing, Expansion Chamber - Upper EXHAUST ASSEMBLY X 1 Cover, Expansion Chamber - Lower X 1 Packing, Expansion Chamber - Lower AR Tie, Perforated Band - 5 ft AR Tie, Perforated Band - 25 ft Spring, Exhaust Sensor, Exhaust Temperature X 1 Grommet, Expansion Chamber Mount Manifold, Exhaust Gasket, Exhaust - Manifold Spring, Extension 33

36 X 1 Clutch, Drive - Uncalibrated (inc. 2-3) Screw, Shoulder Washer, Lock Spring, Drive Clutch - Yellow/White Kit, Cam Arm (inc. 6-9) Nut, Lock O-Ring DRIVE CLUTCH New Qty Description Screw, Set Pin, Cam Arm X 3 Arm, Cam (inc. 8) Arm, Cam (inc. 8) - 3-6,000 ft Alt Arm, Cam (inc. 8) - 6-9,000 ft Alt Arm, Cam (inc. 8) - Over 9,000 ft Alt. 34

37 X 1 Clutch, Driven - Assembly X 1 Bracket, Torque 42 /40 (inc. 2-3) X 1 Bracket, Torque 36 (inc. 2-3) - Over 3,000 ft Alt Bearing X 1 Ring, Snap X 2 Seat, Spring DRIVEN CLUTCH X 1 Spring, Driven Clutch - Blue X 2 Roller, Cam X 2 Washer, Tab X 2 Screw, Shoulder X 2 Cam, Back Screw, Self-Tapping X 4 Screw, Machine 35

38 Head, Cylinder O-Ring O-Ring O-Ring Screw, Cap Plug, Spark - BR9EYA Cylinder Gasket, Cylinder Gasket, Exhaust Valve Case Gasket, Exhaust Valve Cover Pin, Exhaust Valve Valve, Exhaust Stopper, Exhaust Valve Plate, Exhaust Valve Cover, Exhaust Valve Pin, Dowel O-Ring CYLINDER AND HEAD ASSEMBLY New Qty Description Seal, Oil Spring Screw, Cap Cable, Exhaust Valve - MAG Cable, Exhaust Valve - PTO Holder, Exhaust Valve Cable Screw, Cap Bolt, Stud Clamp, Exhaust Valve Cable Screw, Cap Pin, Dowel Nut Gasket, Exhaust Bolt, Stud Nut Gasket Set - Not Illustrated 36

39 Crankcase (inc. 2-7) Screw, Cap Screw, Cap Screw, Cap CRANKCASE ASSEMBLY Screw, Cap Bushing Pin, Dowel 37

40 Piston Set (inc. 2-3) Ring Set, Piston Circlip, Piston Pin, Piston Washer Bearing Crankshaft Assembly (inc. 8-24) Connecting Rod Crankshaft - Right Crankshaft - Middle Wheel, Crankshaft Crankshaft - Left Balancer, Crankshaft Race, Middle Crank Seal Ring, Middle Crank Seal PISTON AND CRANKSHAFT New Qty Description Gear, Oil Pump Drive Washer Washer Washer Bearing Bearing Bearing - Left Bearing - Right Screw, Machine Seal, Oil - Right Seal, Oil - Left C-Ring Pin, Alignment Spacer, Oil Seal 38

41 Valve, Reed - Assembly (inc. 2-4) Stopper Valve, Reed Screw, Machine Gasket REED VALVE ASSEMBLY Pipe, Intake Clamp Screw, Cap Clamp, Wire 39

42 Body, Throttle - Assembly (inc. 2-9) Injector, Fuel - Assembly Injector, Fuel - Assembly Injector, Fuel - Assembly Pipe, Delivery O-Ring - Set THROTTLE BODY ASSEMBLY New Qty Description Hose Clamp, Hose Screw, Machine Sensor, Throttle - Assembly Screw, Machine Rod, Control 40

43 Pump, Oil Gear, Driven Retainer, Input Shaft Valve, Check Protector Gasket Shim, Oil Pump Shaft O-Ring OIL PUMP O-Ring Hose, Oil Hose, Oil Clamp, Hose Bolt, Union Union Screw, Cap 41

44 Cover, Water Pump O-Ring, Cover Seal Impeller Screw, Cap Washer Washer Hose, Water Inlet Seal, Oil WATER PUMP AND THERMOSTAT New Qty Description Clamp, Hose Screw, Cap Pin, Dowel Circlip Thermostat Cap, Thermostat Gasket, Thermostat Cap Screw, Cap Screw, Machine 42

45 Starter Assembly (inc. 2-6) Roller, Starter Ratchet Set Plate, Friction Bolt w/washer RECOIL STARTER Spring Rope, Starter Pulley, Starter Screw, Cap Screw, Cap 43

46 MAGNETO New Qty Description Stator Screw, Cap Rotor/Flywheel Washer Base, Stator - Plate Screw, Cap Sensor, Ignition Timing Screw, Cap Sensor, Ignition Timing Screw, Cap Plate, Stator Lead Wire Key Screw, Cap Grommet Grommet, Stator Lead Wire 44

47 Coil, Ignition - Assembly Cap, Spark Plug Clip Sensor, Temperature Sensor, Coolant Washer, Coolant Sensor ELECTRICAL X 1 ECU X 1 ECU X 1 ECU Cable Tie Sensor, Knock Plate, Knock Sensor Lock 45

48 SERVOMOTOR ASSEMBLY New Qty Description Servomotor Nut Pulley, Controller 46

49 Ref. Part No. Qty. Description Ref. Part No. Qty. Description Printed in U.S.A. p/n