Illustrated Parts Manual. Model Number S2005ACFTBUSB

Transcription

1 Illustrated Parts Manual 2 T660 TM Turbo Model Number S2005ACFTBUSB 00 5

2 TABLE OF CONTENTS 2005 T660 Turbo (Model No. S2005ACFTBUSB) SKI AND SPINDLE ASSEMBLY A-ARM ASSEMBLY SHOCK ABSORBER AND SWAY BAR ASSEMBLY STEERING POST ASSEMBLY TIE ROD ASSEMBLY HANDLEBAR AND CONTROLS HYDRAULIC BRAKE CONTROL ASSEMBLY DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES DRIVE/REVERSE DROPCASE ASSEMBLY DROPCASE AND CHAIN TENSION ASSEMBLY REVERSE SHIFT LEVER ASSEMBLY SLIDE RAIL AND TRACK ASSEMBLY IDLER WHEEL ASSEMBLY REAR SUSPENSION FRONT ARM ASSEMBLY REAR SUSPENSION REAR ARM ASSEMBLY REAR SUSPENSION REAR ARM SHOCK ABSORBER FRONT FRAME AND FOOTREST ASSEMBLY HOOD AND WINDSHIELD ASSEMBLY HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES CONSOLE AND SWITCH ASSEMBLY BELLY PAN AND FRONT BUMPER ASSEMBLY BELT GUARD ASSEMBLY GAS TANK, SEAT, AND TAILLIGHT ASSEMBLY FUEL PUMP ASSEMBLY TUNNEL AND REAR BUMPER COOLING ASSEMBLY ENGINE AND RELATED PARTS EXHAUST ASSEMBLY BATTERY ASSEMBLY AIR SILENCER ASSEMBLY DRIVE CLUTCH DRIVEN CLUTCH CYLINDER HEAD ASSEMBLY CYLINDER BLOCK/BASE ASSEMBLY OIL PAN ASSEMBLY CRANKSHAFT ASSEMBLY CAMSHAFT/VALVE ASSEMBLY CAM CHAIN ASSEMBLY INTAKE MANIFOLD ASSEMBLY THROTTLE BODY ASSEMBLY TURBOCHARGER ASSEMBLY INTERCOOLER ASSEMBLY EXHAUST MANIFOLD ASSEMBLY DELIVERY PIPE ASSEMBLY TIMING CHAIN COVER/OIL PUMP ASSEMBLY WATER PUMP AND THERMOSTAT ASSEMBLIES ELECTRICAL STARTER MOTOR ASSEMBLY ALTERNATOR ASSEMBLY GASKET SET 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 Wearbar - Right Wearbar - Left Nut, Lock Axle, Spindle Nut, Lock Washer Damper, Ski Saddle, Ski - Black (inc. 9) Insert, Ski Saddle Pin, Cotter Screw, Cap Spindle, Steering - Right - Black (inc ) Spindle, Steering - Left - Black (inc ) Insert, Spindle Fitting, Grease Bearing Cap, Spindle Decal, AWS - Spindle - Right Decal, AWS - Spindle - Left Screw, Machine Nut, Lock Handle, Plastic - Black Nut, Lock Screw, Cap Screw, Cap 1

4 A-ARM ASSEMBLY Arm, Lower - Right - Black (inc. 2 and 4) Arm, Lower - Left - Black (inc. 2 and 4) Bearing Arm, Upper - Black (inc. 4) Bearing Screw, Cap Washer Axle, Powder Metal Tube, Axle Nut, Lock Screw, Cap Washer Axle, Non-Serrated Tube, Axle Nut, Lock Axle, Spindle Mount Screw, Cap 2

5 SHOCK ABSORBER AND SWAY BAR ASSEMBLY Shock, Front Suspension (inc. 2-3) Sleeve, Shock Bushing, Shock Sleeve, Threaded Nut, Retainer - Spring Spring, Compression - Red Retainer, Spring Screw, Cap Nut, Lock Spacer, Shock Mount - Rear Axle, Lower Shock Mount Spacer, Shock Mount - Front Screw, Cap Sway Bar Bearing, Sway Bar Screw, Cap Arm, Sway Bar Nut, Lock Link, Sway Bar Screw, Cap 3

6 STEERING POST ASSEMBLY Post, Steering Screw, Cap Cap, Adjusting Block Block, Adjusting Nut, Lock Screw, Cap Cap, Bearing Housing Bearing, Half Housing, Bearing Bracket, Mounting - Hood Switch Nut, Lock Nut, Lock Washer Plate, Backing Screw, Cap Ball Joint, Steering - Left Nut, Hex - Left Tube, Tie Rod Nut, Hex - Right Ball Joint, Tie Rod - Right 4

7 TIE ROD ASSEMBLY Drag Link (inc. 2) Bearing Arm, Steering - Assembly Insert Arm, Steering - Idler - Assembly Screw, Cap Nut, Lock Screw, Cap Washer Axle, Drag Link Nut, Lock Screw, Cap Washer Nut, Lock Washer Ball Joint, Tie Rod - Right Nut, Hex - Right Tube, Tie Rod - Spindle Nut, Hex - Left Ball Joint, Steering - Left O-Ring 5

8 HANDLEBAR AND CONTROLS Control, Throttle (High/Low) (inc. 2-10) Control, Throttle - Stop Switch Half Control, Throttle - Thumbwarmer Assembly (High/Low) (inc. 4-10) Control, Throttle - Thumbwarmer Half (High/Low) w/o Components Plug, Rubber Clip, Retaining - Throttle Cable Plate, Cover Screw, Self-Tapping Switch, Thumbwarmer Assembly (High/Low) (inc. three No. 8 and 10) Plate, Cover Screw, Machine Axle, Lever - Throttle Washer Washer, Shoulder - Throttle Lever, Throttle Ring, Retaining Handlebar Grip, Handlebar Pad, Handlebar - Front Pad, Handlebar - Rear Wrap, Handlebar Element, Handwarmer Element, Thumbwarmer Pad, Insulator Cable, Throttle AR Cable Tie - 8 in Clip, Wire Tool, Removal - Kit - Throttle Cable 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, HI/LO 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. 2-9) Sprocket, Drive Driveshaft Magnet, Disc Plate, Flange - Bearing Assembly (inc. 6-9) Plate, Flange Bolt, Carriage Bearing, 1 in Ring, Solder Bracket, Sensor Sensor, Speedometer Screw, Self-Tapping Nut, Lock Disc, Brake Key Shaft, Driven Key Screw, Cap Bearing, 1 in. w/lock Collar - Re-Lubricative Plate, Flange AR Washer AR Washer Spacer, Clutch Clutch, Driven AR Washer Washer Screw, Cap AR Washer AR Washer AR Washer O-Ring Adjuster, Sheave Caliper, Brake - Assembly (inc ) 31 * 1 Housing Screw, Bleed - Assembly O-Ring Piston Pad, Brake - Set (inc. 36) Pin, Retaining O-Ring, Housing 38 * 1 Housing Fitting, Adapter Screw, Cap Washer Screw, Cap 8

11 *Not a Service Part DRIVE/REVERSE DROPCASE ASSEMBLY Sprocket Assembly - 39T (inc. 2-8) 2 * 1 Sprocket Retainer, Spring Pin, Slip Spring, Compression Screw, Cap Nut, Lock Bearing Spacer, Shaft Chain - 70P Extension, Driveshaft Gear, Reverse - 55T (inc ) Washer, Thrust Bearing, Thrust Ring, Retaining Screw, Cap Washer, Tab Lock Washer Retainer, Shaft (inc. 20) Pin, Spring Spring, Return Spacer, Reverse Idler Shaft, Reverse Idler, Reverse - Assembly - 24T (inc. 25) Bearing Aligner, Idler - Pin Idler, Reverse - Assembly - 19T (inc. 28) Bearing Washer, Thrust Screw, Cap Plate, Flange Bearing, 7/8 in O-Ring Nut, Lock Sprocket - 19T Washer, Spring Nut, Lock Bearing, 1 in Nut, Lock 9

12 DROPCASE AND CHAIN TENSION ASSEMBLY Dropcase w/studs (inc. 2-5) Stud, Ribbed O-Ring, Stud Bolt, Ribbed Bolt, Ribbed Nut, Lock Screw, Cap Bolt, Carriage AR Washer Bolt, Carriage Plug, Drain - Magnetic O-Ring Adapter, Manual Adjust Seal, Manual Adjust Washer Nut Adjuster, Chain Guard, Dropcase Bolt, Carriage Nut, Lock Bracket, Chain Backing Cover, Dropcase Shaft, Shift Fork Seal, O-Ring Pin, Spring Cover, Oil Vent Screw, Self-Tapping Fork, Shift Seal, Dropcase Plug, Drain Screw, Self-Tapping O-Ring, Oil Level Stick Tube Stick, Oil Level Tube, Oil Level Stick Screw, Self-Tapping Screw, Cap Washer Roller, Chain Tightener (inc. 39) Bearing, Chain Tightener Shaft, Chain Roller Nut, Roller Arm Washer Arm, Chain Roller Screw, Cap 10

13 REVERSE SHIFT LEVER ASSEMBLY *Not a Service Part Lever Pin, Clevis Pin, Cotter Screw, Cap Shift Pivot Axle Washer Washer, Lock - External Tooth Screw, Cap Bracket, Reverse Switch Switch, Alarm Boot, Switch Alarm, Reverse (inc. 14) Ring, Retaining Screw, Cap Nut, Lock Linkage, Shifting - Assembly (inc ) Rod End - Left Nut, Jam - Left 20 * 1 Rod, Linkage Nut, Jam - Right Rod End - Right 11

14 SLIDE RAIL AND TRACK ASSEMBLY (Complete Skid Frame Assembly p/n ) Rail, Formed Support, Rail Spacer Nut, Lock Washer End Cap, Slide Rail Screw, Cap Wearstrip, Slide Rail - Black Screw, Machine Screw, Cap Rivet Bracket, Retaining Pad, Shock Screw, Cap Bracket, Mounting - Front Arm Nut, Lock Screw, Cap Axle, Aluminum Screw, Cap Block Coupler - Rear Arm Bushing, Coupler Block Nut, Lock Adjuster, Track Screw, Cap Track Assembly (inc ) Clip, Guide Clip, Wear 12

15 IDLER WHEEL ASSEMBLY Cap, Idler Wheel Screw, Cap Washer Wheel, Idler - Red (inc. 5-6) Ring, Retaining Bearing Washer Screw, Cap Block, Mounting - Idler Wheel Nut, Lock Pivot, Rear Shock (inc ) Fitting, Grease Washer, Grease Fitting Axle, Shock Pivot Screw, Cap Screw, Cap Washer Axle, Inner Bracket, Mounting - Front Arm Shock Wheel, Idler (inc. 5-6) Block, Mounting - Idler Wheel Nut, Lock Block, Slide Slide, Spring Washer Screw, Cap Axle, Rear Wheel Washer Spacer, Rear Wheel Wheel, Idler (inc. 5-6) Bushing, Adjuster Nut Screw, Cap Wheel, Idler - Red (inc. 5-6) Screw, Cap 13

16 REAR SUSPENSION FRONT ARM ASSEMBLY Arm, Front Suspension (inc. 2-4) Fitting, Grease Bushing, Front Arm Bearing Tube, Axle Axle, Serrated Washer Screw, Cap Nut, Lock Shock Absorber, Front Arm Bushing, Shock Axle, Pivot - Shock Screw, Cap Nut, Lock Screw, Cap Axle, Serrated Nut, Lock Retainer, Spring Sleeve, Threaded Nut, Retainer - Spring Spring, Compression Cover, Shock Strap, Limiter Nut, Lock Washer Screw, Cap Axle, Inner Carriage Washer Washer, Lock Screw, Cap 14

17 REAR SUSPENSION REAR ARM ASSEMBLY Arm, Idler (inc. 2 and one No. 3) Bushing Fitting, Grease Arm, Rear (inc. one No. 3 and 5) Washer, Grease Fitting Nut, Lock Axle, Serrated Tube, Axle Screw, Cap Screw, Cap Axle, Aluminum Block, Spring Adjuster - Right Block, Spring Adjuster - Left Ring, Retainer 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 Washer Washer, Lock Screw, Cap Screw, Cap Axle, Link - Flanged Link, Inner Carriage Nut, Lock Spacer, Shock Link Screw, Cap Sleeve Shock Absorber - Rear Arm 15

18 REAR SUSPENSION REAR ARM SHOCK ABSORBER (Complete Shock Absorber p/n ) Body, Shock Eyelet, Shock Rod, Shock Cap, Shock (inc. 5) O-Ring Spacer, Shaft Piston, in. - Orifice (inc. 8) Strap, Piston - Teflon 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 Valve, x in Washer, Backup Nut, Lock Piston, Floating (inc ) Strap, Piston - Teflon O-Ring Screw, Set Ball Spring Rod, Spring Ball Valve, Pressure (inc. 30) O-Ring Screw, Valve Bushing, Shock Sleeve, Eyelet AR Oil, Gas Shock - 6 qt Case 16

19 FRONT FRAME AND FOOTREST ASSEMBLY Chassis Assembly (inc. 2-5) Insert Insert Insert, Lower A-Arm Mount Insert, Upper A-Arm Mount Belly Pan - Center - Black Screw, Self-Tapping Plug, Oil Drain Access Screw, Self-Tapping Clamp, Wire Rivet Bracket, Mounting - ECU Screw, Self-Tapping Footrest - Right - Black Footrest - Left - Black Rivet Rivet Plate, Backing - Footrest Bracket, Mounting - Belt Guard AR Rivet Plate, Backing - Right - Black Plate, Backing - Left - Black Screw, Machine Support, Steering Screw, Cap Nut, Lock Clip, Routing Cup, Recoil Rope - Black Plug, Recoil Cup Screw, Self-Tapping Mount, ECU Screw, Machine 17

20 HOOD AND WINDSHIELD ASSEMBLY Hood w/decals - Black (inc and twelve No. 28) Hood w/o Decals - Black (inc. 3-19) Foam, Hood - Middle Foam, Hood - Gauge - Right Foam, Hood - Gauge - Left Foam, Hood - Upper Right Foam, Hood - Upper Left Foam, Hood - Rear - Right Foam, Hood - Rear - Left Foam, Hood - Front - Right Foam, Hood - Front - Left Foil, Hood - Side Foil, Hood - Upper Right Foil, Hood - Upper Left Foil, Hood Foil, Hood - Lower Right Foil, Hood - Upper Decal, Warning - Break-In Decal, Warning (English) Decal, Warning (French) Decal, Reverse Screen, Hood - Rear - Right - Black Screen, Hood - Rear - Left - Black Screen, Hood - Middle - Black Screen, Hood - Front - Left - Black Clip, Retaining Emblem, Hood Decal, Hood - Lower Right Decal, Hood - Lower Left Decal, Hood - Front - Right Decal, Hood - Front - Left Cover, Hood w/decals - Black (inc ) Cover, Hood w/o Decals - Black Decal, Cover - Center Emblem, Cover AR Tape, Foam - 1 ft O-Ring Deflector, Air Intake Screen, Hood - Front - Right - Black Mirror - Kit - Black (inc. six No ) Snap Cap w/washer Screw, Machine Nut, Expansion Windshield Cable, Hood Clip, Hairpin Strap, Hold-Down Foam, Hood - Upper Middle Screw, Shoulder 18

21 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES Harness, Main Harness, Hood AR Cable Tie - 8 in Lens/Reflector - Headlight - Right (inc. 5) Lens/Reflector - Headlight - Left (inc. 5) Bulb, Headlight Spring, Adjuster Insert Clip, Hairpin Screw, Adjuster Tachometer/Speedometer (inc ) Bracket, Retaining Nut w/washer Clip, Adjuster Screw Clip, Headlight - Right Clip, Headlight - Left Clip, Wire Antenna, Control Module Module, Control - Remote Start Control, Remote Screw, Machine Washer Nut, Lock Switch, Hood Boot, Switch Foil, Headlight - Right Foil, Headlight - Left Clamp, Wire 19

22 CONSOLE AND SWITCH ASSEMBLY Console Door, Console Switch, Ignition (inc. 4-5) 4 * 2 Key Nut, Retaining Screw, Self-Tapping Decal, Console - Right Decal, Console - Left Outlet, Accessory *Key is coded to switch; see dealer to determine part number. 20

23 BELLY PAN AND FRONT BUMPER ASSEMBLY Belly Pan - Right - Black Louver, Air-Intake - Right - Black Louver, Air-Intake - Left - Black Screw, Self-Tapping Belly Pan - Left - Black Foam, Belly Pan - Left Screw, Self-Tapping Washer Reflector, Front - Amber Clip, Retaining Panel, Access - Drive Clutch - Black Screw, Self-Tapping Rivet Nut, U Bumper, Front Screw, Cap Nut, Lock Screw, Self-Tapping Cable Tie in Boot, Steering - Right Boot, Steering - Left Screw, Self-Tapping Ring, Exhaust Outlet Boot, Exhaust Deflector, Exhaust Deflector, Exhaust Foil, Protective - Upper Middle AR Tape, Foil Foil, Protective - Upper Rear Foil, Protective - Upper Front Foil, Protective - Lower Foil, Protective - Lower Front Clamp, Wire Rivet 21

24 BELT GUARD ASSEMBLY A Belt Guard Assembly (inc. 2-6) Bushing, Belt Guard Plate, Bushing - Belt Guard Rivet Cable Clip, Hairpin Decal, Clutching Decal, Warning - Belt Guard Decal, ACT - Roller Driven Clutch Pin, Belt Guard Insert, Hinge Bracket, Mounting - Belt Guard Rivet 22

25 GAS TANK, SEAT, AND TAILLIGHT ASSEMBLY Complete Seat Assembly (inc. 2-18) Tank, Gas/Seat-Base (inc. 3-8) Plug, Tank AR Tape, Teflon Vent, Tank Grommet, Tank Cap, Tank (inc. 8) Seal, Tank Cap Cover, Seat (inc. 10) Wire, Seat Insert, Seat Foam Insert, Seat Pad - Right Insert, Seat Pad - Left Screw, Self-Tapping AR Staple, Seat Cover Foam, Seat Cushion Wire, Seat Washer Screw, Self-Tapping Screw, Cap Nut, Lock Washer Cap, Protector Taillight w/socket Assembly Bulb Gasket, Taillight Lens Lens, Taillight Screw, Retaining Clamp, Wire Nut, Lock Seal, Foam - Seat-Base Clip, Routing - Snap-In AR Hose, Vent ft AR Hose, Vent - 50 ft Clamp, Hose 23

26 FUEL PUMP ASSEMBLY Pump, Fuel - Assembly (inc. 2-14) Harness, Fuel Pump (inc. 3) O-Ring Screw, Machine - Harness Spring, Fuel Pump Assembly Nut, Retaining - Fuel Pump Seal, Fuel Pump Housing Ring, Retaining Arm, Float Element, Fuel Sensor Clamp, Hose Hose, Fuel Pump - Top Pump, Fuel Housing, Fuel Pump Clamp, Hose Pickup, Fuel Hose, Gasline AR Hose, Gasline - 25 ft Clamp, Hose AR Loom, Protective Cable Tie - 4 in AR Hose, Gasline - 10 ft 24

27 TUNNEL AND REAR BUMPER *Optional Tunnel Assembly (inc. 2-5) Plate, End - Rear Tunnel Rivet Rivet Bracket, Suspension Mounting - Right - Rear Bracket, Suspension Mounting - Left - Rear AR Rivet AR Rivet AR Rivet* Plate, Suspension Mounting - Front Roll, Tunnel - Right Roll, Tunnel - Left Bumper, Rear Snowflap, Reverse Nut, U Nut, U Decal, Warning - Towing (French) Decal, Warning - Towing (English) Screw, Machine Washer Nut, Lock Washer Clip, Retaining Reflector, Rear - Red Rivet Bracket, Main Harness Protector Plug, Hole Clamp, Wire Decal, Arctic Cat - Tunnel - Right Decal, Arctic Cat - Tunnel - Left Decal - Rear Plug 25

28 COOLING ASSEMBLY Tank, Coolant Cap, Tank Screw, Machine Nut, Lock Fitting, Vent AR Hose, Vent - 25 ft Decal, Fill Level - Coolant Tank AR Tape, Teflon Fitting, Elbow Clamp, Hose AR Hose, Coolant ft AR Hose, Coolant - 50 ft Clamp, Hose Plug, Adapter Adapter, Fitting Clamp, Hose AR Cable Tie - 8 in AR Hose, Coolant - Drain - 10 ft Hose, Coolant - Heater/Engine AR Protector, Hose Clamp, Hose Heater, Inline Hose, Coolant - T-Fitting T-Fitting - Double Hose, Coolant - Y-Fitting/T-Fitting Clamp, Hose Y-Fitting Hose, Coolant - Throttle Body/Y-Fitting Clamp, Hose Hose, Coolant - Thermostat/Y-Fitting Hose, Coolant - Front Heat Exchanger/ Right Heat Exchanger Heat Exchanger - Right Tube Cap, Filler Neck Neck, Filler Hose, Filler Neck/Left Heat Exchanger Heat Exchanger - Left Tube Hose, Coolant - Filler Neck/Engine Hose, Coolant - Rear Rivet Guard, Hose Rivet 26

29 ENGINE AND RELATED PARTS Engine Bracket, Belt Cover Cover, Engine Belt Screw, Shoulder Nut, Lock Washer Screw, Cap Screw, Cap Screw, Cap Bracket, Engine Mounting - Right - Front Screw, Self-Tapping Mount, Engine - Front Screw, Cap Bracket, Engine Mounting - Left - Front Nut Adapter, PTO Gear, Ring Plate, Ring Gear Guard, Ring Gear Screw, Cap Screw, Cap Screw, Cap Clutch, Drive Belt, Drive Washer, High Collar Bolt, Drive Clutch Bracket, Mounting - Starter Motor Bushing Nut, Lock Screw, Cap Clamp, Fuel Filter Filter, Fuel Clamp, Hose AR Hose, Gasline - 10 ft Bracket, Engine Mounting/Bearing Support (inc ) Fitting, Grease Cap, Grease Fitting Screw, Cap Nut, Lock Washer Washer, Lock Bumper, Torque - Engine Nut Bracket, Engine Mounting - Left - Rear Mount, Engine - Rear Bracket, Engine Mounting - Right - Rear Screw, Cap Screw, Cap Bracket, Filler Neck Screw, Cap 27

30 EXHAUST ASSEMBLY Resonator Gasket, Exhaust Bumper, Rubber Spring, Extension Screw, Cap Bracket, Mounting - Resonator Bracket, Spring Retaining Bracket, Mounting - Exhaust Pipe Spring, Exhaust Pipe, Exhaust - Assembly (inc ) Pipe, Exhaust Packing - Right Packing - Left Packing - Center Cover, Exhaust Pipe - Upper Right Cover, Exhaust Pipe - Upper Left Cover, Exhaust Pipe - Lower Right Cover, Exhaust Pipe - Lower Left Tie, Band - 10 in. 28

31 BATTERY ASSEMBLY Battery (inc. 2) Wrap, Heat - Battery Cable, Battery/Ground Nut, Wing Washer Strap, Battery Hold-Down - Top Strap, Battery Hold-Down - Side Screw, Cap Nut, Lock Tray, Battery Shield, Heat Screw, Self-Tapping Bumper, Rubber Bracket, Mounting - Battery Tray 29

32 AIR SILENCER ASSEMBLY Cover, Inlet Tube Tube, Inlet Decal, Air Silencer Screw, Machine Tube, Outlet Clamp, Tube Cover, Air Silencer Filter, Air Silencer, Air Nut w/washer Bushing Screw, Shoulder Bracket, Guard - Harness/Rope Screw, Cap Plenum, Air Silencer Screw, Cap Nut, Lock 30

33 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) Screw, Set Nut, Lock Washer, Spacer Washer, Spacer Spider Assembly Spring, Drive Clutch - Red Spring, Drive Clutch - Yellow/Green (Over 5,000 ft Alt.) Nut Cover Washer, Lock - Spring Screw, Machine Button, Torque Plug, Torque Button 31

34 DRIVEN CLUTCH (Assembly p/n ) Cover, Torque Bracket (inc. 2-3) Ring, Snap Bearing Screw, Machine Adjuster, Spring Spring, Driven Clutch - Platinum Seat, Spring Bracket, Torque 50 / Sheave, Stationary (inc ) Pin, Cam Roller Roller, Cam Pin, Spring Retainer, Torque Bracket Sheave, Movable Screw, Machine Spacer 32

35 CYLINDER HEAD ASSEMBLY Cylinder Head Assembly (inc. 2-5) Guide, Valve Plug Bolt, Camshaft Cap Pin, Camshaft Cap Dowel Bolt, Camshaft Housing Gasket, Cylinder Head Pin, Dowel Cover, Cylinder Head Gasket, Spark Plug Hole Gasket, Cylinder Head Cover Cover, Coil Bolt, Coil Cover Bolt, Cylinder Head Cover Bolt, Cylinder Head Cover Spark Plug (NGK KR8AI) Cap, Oil Filler Hose, Breather Clamp, Hose Clamp, Wire Bolt 33

36 CYLINDER BLOCK/BASE ASSEMBLY Cylinder Block/Base Assembly (inc. 2-6) Plug, Oil Venturi Bolt Plug, Oil Gallery Bolt Pin, Dowel Stand, Oil Filter Filter, Oil - Assembly Cooler, Oil (inc. 10) Gasket Sensor, Knock - Assembly 34

37 OIL PAN ASSEMBLY Pan, Oil Bolt, Stud Bolt Gasket Plug, Oil Drain Nut Bolt Strainer, Oil Pump O-Ring Bolt O-Ring Stick, Oil Level Tube, Oil Level Stick 35

38 CRANKSHAFT ASSEMBLY *Optional Piston (Mark 1) Piston (Mark 2) Piston (Oversized 0.5 mm)* Ring Set, Piston Ring Set, Piston (Oversized 0.5 mm)* Pin, Piston Circlip Connecting Rod Assembly (inc. 6) Nut Bearing, Connecting Rod Crankshaft Bearing Set - Green Bearing Set - Black Bearing Set - No Color Bearing Set - Yellow Bearing Set - Brown Bearing Set - Crankshaft Thrust Bearing Set - Crankshaft Thrust (Undersized) Seal, Oil - Crankshaft - Front Seal, Oil - Crankshaft - Rear Pulley, Crankshaft Bolt Key Sprocket, Crankshaft Timing Belt, Engine 36

39 CAMSHAFT/VALVE ASSEMBLY Camshaft, Intake Camshaft, Exhaust Valve, Intake Valve, Exhaust Spring, Valve Retainer Cotter, Valve Seat, Spring Seal, Valve Stem Tappet AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm AR Shim, Tappet mm 37

40 CAM CHAIN ASSEMBLY Chain, Timing Guide, Chain Bolt Tensioner, Chain Spacer Pad Link Gasket, Tension Adjuster Adjuster, Tensioner - Assembly Bolt Bolt Bolt 38

41 INTAKE MANIFOLD ASSEMBLY Manifold, Intake Gasket Bracket, Stiffener Bolt, Stud Bolt, Stud Bolt Bolt Nut Bracket, Stiffener Bolt Clamp Sensor, Air Temperature Gasket 39

42 THROTTLE BODY ASSEMBLY Throttle Body Assembly (inc. 2-6) Sensor, Throttle Position Screw, Machine Valve, ISC Gasket Screw Gasket Bolt Sensor, Pressure Screw 40

43 TURBOCHARGER ASSEMBLY Turbocharger Assembly Pipe, Oil Inlet Joint, Oil Drain Gasket, Oil Drain Hose, Oil Drain Protector Bolt Bolt Gasket, Oil Inlet Pipe Gasket, Oil Inlet Pipe Clamp, Hose Clamp, Hose Bolt Hose, Air Bypass Pipe, Air Intake Gasket, Air Intake Pipe Valve, Air Bypass Valve Control Bracket, Mounting Valve, Waste Gate Control Valve, Air Bypass Tube, Protective Hose, Vacuum - Bypass Control Valve Hose, Waste Gate Control Valve Clamp, Hose Clamp, Hose Clamp, Hose Clip, Hose Bolt Bolt Bolt Screw Nut Clamp, Hose 41

44 INTERCOOLER ASSEMBLY Intercooler Duct, Intercooler Screw, Machine Bracket, Intercooler Nut Hose, Intercooler - No Clamp, Hose Pipe, Intercooler - Inlet Hose, Intercooler - No Nut Hose, Intercooler - No Pipe, Intercooler - Outlet 42

45 EXHAUST MANIFOLD ASSEMBLY Manifold, Exhaust Pipe, Outlet Bolt Bolt, Stud Cover, Exhaust Manifold Gasket, Exhaust Manifold Gasket, Exhaust Manifold/Turbocharger Gasket, Outlet Pipe Bolt Bolt Bolt Bolt, Stud Bolt, Stud Nut Washer Hook, Engine Bolt Sensor, Oxygen 43

46 DELIVERY PIPE ASSEMBLY Pipe, Delivery Bolt Injector, Fuel - Assembly (inc. 4) Grommet Set Cushion Regulator (inc. 7) O-Ring Bolt AR Hose, Vacuum Clamp, Hose 44

47 TIMING CHAIN COVER/OIL PUMP ASSEMBLY Timing Chain Cover/Oil Pump Assembly (inc. 2-5) Rotor Set Screw Valve Set (inc. 5) Circlip Filter, Oil Gallery Bolt Plug Bolt Bolt Bolt Pin, Dowel Switch, Oil Pressure - Assembly 45

48 WATER PUMP AND THERMOSTAT ASSEMBLIES Water Pump (inc. 2) O-Ring Bolt Bolt Nut Bolt, Stud Bolt Cap, Thermostat Thermostat Case, Thermostat Gasket Hose - Throttle Body/Intake Manifold Plug Clamp, Hose Sensor, Water Temperature Clamp, Hose Bolt Tank, Water (inc ) Union, Air Vent Gasket Hose - Thermostat/Water Tank Pipe, Water Inlet Bolt Spacer O-Ring Hose - Turbocharger/Oil Cooler Hose - Oil Cooler/Inlet Pipe Hose - Water Tank/Turbocharger 46

49 ELECTRICAL Clamp, Oil Pressure Switch Bracket, Chain Cover Bracket, Coil Bolt Bracket, Engine Harness Bolt, Ground Harness Assembly (inc. 8-14) Cover, Fuse Box Fuse (15 Amp) Fuse (30 Amp) Bolt Fuse (80 Amp) Relay Puller, Fuse Holder, Spare Fuse 15 * 1 Resistor Decal, Fuse Box Decal, Fuse Box Controller, Injection Bolt Coil, Ignition Sensor, Cam Position - Assembly *Resistor is coded to engine; see dealer to determine part number. 47

50 STARTER MOTOR ASSEMBLY Motor, Starter - Assembly (inc and one No. 19) Switch Assembly Nut Lever, Pinion Drive Washer, Lock Nut Bushing Nut, Pinion Stop (inc. 9) Ring, Snap Pinion Assembly Armature Commutator Assembly (inc. 13) Brush Spring, Brush Holder, Brush Insulator Bushing Through-Bolt Nut Screw, Cap 48

51 ALTERNATOR ASSEMBLY Alternator Assembly (inc. 2-25) Nut Pulley Spacer Bearing Retainer, Bearing Bolt, Stud Screw Rotor Assembly (inc ) Bearing Cover, Bearing Bolt Nut Regulator, Alternator - Assembly Screw Screw Brush Holder Assembly (inc ) Spring, Brush Brush Rectifier Assembly Screw Bolt Insulator, Terminal Nut Bolt Bracket, Alternator Bolt Bolt Arm, Adjuster - Alternator Bolt Nut 49

52 GASKET SET (Complete Gasket Set p/n ) Gasket, Exhaust Manifold Gasket, Cylinder Head Cover Gasket, Intake Manifold Gasket, Throttle Body Gasket, Cylinder Head O-Ring, Water Pump Gasket, Thermostat Case O-Ring, Water Inlet Pipe Gasket, Air Intake Pipe Gasket, Outlet Pipe Gasket, Oil Drain Gasket, Exhaust Manifold/Turbocharger Gasket, Adjuster 50

53 RELATED ITEMS 2005 T660 Turbo (Model No. S2005ACFTBUSB) Altitude Kit (Over 5000 ft) Cover, Machine (Storage) Cover, Machine (Deluxe) Handbook, Safety (E/F) Handlebar Bag Handlebar Muffs Hitch, Pivot Luggage Rack w/o Backrest Manual, Illustrated Parts Manual, Operator s (E/F) Saddlebags, Sport Touring Tether Switch Seat Trunk Windshield Storage Bag NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A p/n