Illustrated Parts Manual. Model Number S2005BCFWTUSS Model Number S2005BCFWTOSS (International)2

Transcription

1 Illustrated Parts Manual Bearcat Wide Track Model Number S2005BCFWTUSS Model Number S2005BCFWTOSS (International)2 00 5

2 TABLE OF CONTENTS (Model No. S2005BCFWTUSS) (Model No. S2005BCFWTOSS - International) 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 ARTICULATING SKID FRAME ASSEMBLY REAR SUSPENSION FRONT ARM ASSEMBLY REAR SUSPENSION REAR ARM ASSEMBLY FRONT FRAME AND FOOTREST ASSEMBLY STEERING SUPPORT 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 ASSEMBLY SEAT ASSEMBLY FUEL PUMP ASSEMBLY TUNNEL ASSEMBLY BACKREST ASSEMBLY RACK, HITCH, AND TAILLIGHT ASSEMBLIES 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 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 July 2004 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

3 SKI AND SPINDLE ASSEMBLY Ski, Plastic - Black Wearbar Spacer Nut, Lock Spacer Axle, Spindle Nut, Lock Washer Damper, Ski Saddle, Ski - Black (inc. 11) Insert, Ski Saddle Pin, Cotter Screw, Cap Spindle, Steering - Right - Platinum (inc ) Spindle, Steering - Left - Platinum (inc ) Insert, Spindle Fitting, Grease Bearing Decal, AWS - Spindle - Right Decal, AWS - Spindle - Left Cap, Spindle Screw, Machine Nut, Lock Handle, Plastic - Black Nut, Lock Screw, Cap Screw, Cap 1

4 A-ARM ASSEMBLY Arm, Lower - Right - Platinum (inc. 2 and 4) Arm, Lower - Left - Platinum (inc. 2 and 4) Bearing Arm, Upper - Platinum (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 - Blue 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 Nut, Lock Nut, Lock Washer Plate, Backing - Steering Support Screw, Cap Ball Joint, Steering - Left Nut, Hex - Left Tube, Tie Rod Ball Joint, Tie Rod - Right Nut, Hex - 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 Screw, Self-Tapping Element, Handwarmer Tool, Removal - Kit - Throttle Cable Element, Thumbwarmer Pad, Insulator Clip, Wire Cable, Throttle AR Cable Tie - 8 in. 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 Track Drive Assembly (inc. 2-6) Driveshaft Sprocket, Drive - Inner Sprocket, Drive - Outer Idler, Center Bushing, Drive Plate, Flange - Bearing Assembly (inc. 8-11) Bolt, Carriage Plate, Flange Bearing, 1 in. w/lock Collar Ring, Solder Cable, Adapter Adapter, Drive (inc. 14) Fitting, Grease Nut, Lock Screw, Cap Disc, Brake Key Shaft, Driven Key Bracket, Mounting - Magnetic Switch Switch, Magnetic Screw, Self-Tapping Magnet Bearing, 1 in. w/lock Collar - Re-Lubricative Plate, Flange Screw, Cap AR Washer AR Washer Shaft, Stub Clutch, Driven AR Washer AR Washer Washer Screw, Cap Caliper, Brake - Assembly (inc ) 36 * 1 Housing O-Ring, Housing O-Ring Piston Pad, Brake - Set (inc. 41) Pin, Retaining 42 * 1 Housing Screw, Bleed - Assembly Fitting, Adapter Screw, Cap Washer 8

11 *Not a Service Part DRIVE/REVERSE DROPCASE ASSEMBLY Sprocket Assembly - 40T (15 Wide) (inc. 2-8) 2 * 1 Sprocket Retainer, Spring Pin, Slip Spring, Compression Screw, Cap Nut, Lock Bearing Spacer, Shaft Chain - 70P (15 Wide) 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 - 18T (15 Wide) 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 Bolt, Carriage Nut, Lock Bolt, Carriage AR Washer Bolt, Carriage Screw, Cap Guard, Dropcase Adapter, Manual Adjust Seal, Chain Adjuster Washer Nut Adjuster, Chain Plug, Drain - Magnetic O-Ring Plug, Drain Screw, Cap Cover, Dropcase Shaft, Shift Fork Seal, O-Ring Pin, Spring Cover, Oil Vent Screw, Self-Tapping Fork, Shift Seal, Dropcase Stick, Oil Level O-Ring, Oil Level Stick Roller, Chain Tightener (inc. 33) Bearing, Chain Tightener Shaft, Chain Roller Washer Arm, Chain Roller Screw, Cap Nut, Lock Nut, Roller Arm Washer Bracket, Chain Backing Nut, Lock 10

13 *Not a Service Part REVERSE SHIFT LEVER ASSEMBLY Lever, Reverse 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 ; p/n International) Rail, Formed Support, Rail 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 Nut, Lock Block, Spring Tension Screw, Cap Track Assembly (inc ) Clip, Wear Clip, Guide 12

15 IDLER WHEEL ASSEMBLY Screw, Cap Washer Wheel, Idler (inc. 4-7) Insert, Wheel - Inside Ring, Retaining Bearing Insert, Wheel - Outside Axle, Serrated Block, Mounting - Idler Wheel Screw, Cap Nut, Lock Axle, Steel Bracket, Mounting - Front Shock Washer Wheel, Idler (inc. 4-7) Spacer Washer Screw, Cap Spacer Pivot, Shock (inc ) Fitting, Grease Washer, Grease Fitting Washer Bushing, Overload Spring Spacer, Spring Slide Slide, Spring Washer Spring, Overload Assembly (inc ) Block, Wear Screw, Machine Nut, Lock Clip, Retaining Nut, Lock 13

16 ARTICULATING SKID FRAME ASSEMBLY Bracket, Mounting - Articulating Skid Frame Spacer Screw, Cap Nut, Lock Bracket, Spring Tube, Axle Axle Washer Axle, Outer - Idler Wheel Wheel, Idler (inc ) Insert, Wheel - Outside Insert, Wheel - Inside Ring, Retaining Bearing Washer Screw, Cap Screw, Cap Washer Axle, Serrated Bracket, Mounting - Rear Axle Arm, Swing (inc. 22) Bushing, Rear Arm Axle, Swing Arm Cap, Idler Wheel Block, Slide Washer Spring Nut, Lock Axle, Slide Block Spacer, Articulating Skid Frame Screw, Cap Nut Adjuster, Track Screw, Cap Screw, Cap Bumper, Track Guide Nut, Lock Washer Bushing, Spacer Axle, Rear Wheel Spacer, Center Wheel, Idler (inc ) Bushing, Adjuster Wheel, Idler (inc and 45) Insert, Idler Wheel 14

17 REAR SUSPENSION FRONT ARM ASSEMBLY Arm, Front Suspension (inc. 2-4) Fitting, Grease Bushing, Front Arm Bearing Tube, Axle Axle, Serrated 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 Screw, Cap Washer Nut, Lock Screw, Cap Adjuster, Front Arm Axle, Inner Carriage Screw, Cap Washer, Lock Washer 15

18 REAR SUSPENSION REAR ARM ASSEMBLY Arm, Idler (inc. 2 and one No. 3) Bushing, Flared Fitting, Grease Arm, Rear (inc. one No. 3) Screw, Cap Axle, Serrated Tube, Axle Nut, Lock Strap, Limiter Screw, Cap Washer Nut, Lock 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, Rear Shock Screw, Cap Spacer, Shock Link Nut, Lock Nut, Lock Shock Absorber - Rear Arm (inc ) Shock Absorber - Rear Arm (inc ) (International) Bushing, Shock Sleeve, Shock 16

19 FRONT FRAME AND FOOTREST ASSEMBLY Chassis Assembly (inc. 2-5) Insert Insert, Upper A-Arm Mount Insert, Lower A-Arm Mount Insert Ring, Exhaust Outlet Boot, Exhaust Rivet Belly Pan - Center Screw, Self-Tapping Plug, Oil Drain Access Footrest - Right - Black Footrest - Left - Black AR Rivet Bracket, Footrest - Right - Black Bracket, Footrest - Left - Black Plate, Backing - Footrest Rivet Plate, Backing - Footrest - Right - Black Plate, Backing - Footrest - Left - Black Mount, Cable Tie Rivet AR Rivet Support, Gas Tank Cover, Front Screw, Cap Nut, Lock Bracket, Harness Bracket, Hold-Down Clamp, Wire 17

20 STEERING SUPPORT ASSEMBLY Support, Steering Plate, Backing Vent - Right Nut, Lock Screw, Machine Panel, Recoil Rope Cup Screw, Self-Tapping Plate, Backing Vent - Left Bracket, Belt Guard Rivet Mount, Belly Pan/Hood Strap Hook - Right Mount, Belly Pan/Hood Strap Hook - Left Washer Rivet Nut, Lock Plate, Backing Plate, Backing Brace, Steering Support - Right Brace, Steering Support - Left 18

21 HOOD AND WINDSHIELD ASSEMBLY Hood w/decals - Silver (inc. 2-17) Hood w/o Decals - Silver (inc. 3-13) Foam, Hood - Upper Middle - Right Foam, Hood - Rear - Right Foam, Hood - Rear - Left Foam, Hood - Middle Foam, Hood - Front - Right Foam, Hood - Front - Left Decal, Warning - General and Brake Decal, Caution - Engine/Battery/Fuel Decal, Reverse Foil, Hood - Right Foil, Hood - Left Foil, Hood Screw, Self-Tapping Hinge, Hood Decal, Hood - Lower Right Decal, Hood - Lower Left Decal, Hood - Upper Right Decal, Hood - Upper Left Decal, Arctic Cat - Hood Decal, Hood - Crest Screw, Machine Clip, Hairpin Cable, Hood Strap, Hold-Down Mirror - Kit (inc. six No ) Windshield Nut, Expansion Snap Cap w/washer Screw, Machine O-Ring Clip, Retaining Screen, Hood - Right - Blue Screen, Hood - Upper Left - Blue Screen, Hood - Left - Blue 19

22 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES *Included in Hood w/decals Speedometer (inc. 2-3, three No. 4, and one No. 5) Speedometer (inc. 2-3, three No. 4, and one No. 5) (International) Knob, Tripmeter Harness, Bulb - Speedometer (inc. three No. 4 and one No. 5) Bulb, Indicator Bulb, Instrument Tachometer (inc. two No. 4, one No. 5, and 7) Harness, Tachometer (inc. two No. 4 and one No. 5) Ring, Rubber Cushion Ring, Retaining Bracket Washer Nut w/washer Cable, Speedometer AR Cable Tie - 8 in Harness, Hood Harness, Main Nut, U Lens/Reflector - Headlight Bulb, Headlight - High Beam Bulb, Headlight - Low Beam Spring, Adjuster Screw, Thumb Clip, Hairpin Decal, Instrument - Hood* Decal, Made In U.S.A. - Domed* 20

23 CONSOLE AND SWITCH ASSEMBLY Console Door, Console Switch, Ignition Key Washer Washer, Lock - Internal Tooth Decal, Console - Right Nut, Retaining Screw, Self-Tapping Decal, Console - Left Outlet, Accessory 21

24 BELLY PAN AND FRONT BUMPER ASSEMBLY Belly Pan - Right Belly Pan - Right (International) Belly Pan - Left Foam, Belly Pan - Left Reflector, Front - Amber Clip, Retaining Panel, Access - Drive Clutch Screw, Self-Tapping Nut, U Nut, Lock Screw, Cap Bumper, Front Screw, Self-Tapping Boot, Steering - Right Boot, Steering - Left Screw, Self-Tapping AR Tape, Foil Washer Screw, Shoulder 22

25 A BELT GUARD ASSEMBLY 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 23

26 GAS TANK ASSEMBLY Tank, Gas (inc. 2-6) Vent, Gas Tank Grommet Cap, Gas Tank (inc. 5) Seal, Tank Cap Gauge, Fuel - Assembly w/gasket (Press-Fit) Clip, Routing AR Hose, Vent ft AR Hose, Vent - 50 ft Clamp, Hose Bracket, Hold-Down - Gas Tank Rivet 24

27 SEAT ASSEMBLY Complete Seat Assembly - Front (inc. 2-18, one No. 19, seven No. 20, and four No. 21) AR Staple Insert, Seat Foam Screw, Self-Tapping Foam, Seat Wire, Seat Extension, Toolbox Plate, Stud Base, Seat Plate, Seat Hook Latch, Seat - Assembly (inc ) Cover, Seat Latch Lever, Seat Latch Clip, Spring Back, Seat Latch Spacer Screw, Machine Cover, Seat (inc. one No. 19) Wire, Seat Nut, Lock Screw, Self-Tapping Stud, Latch Washer Nut, Lock Nut, Lock Complete Seat Assembly - Passenger (inc. 2, one No. 19, ten No. 20, four No. 21, and 27-33) Foam, Seat Cover, Seat (inc. one No. 19) Extension, Toolbox Plate, Stud Base, Seat Mount, Backrest Wire, Seat Knob, Seat Retainer 25

28 FUEL PUMP ASSEMBLY Pump, Fuel - Assembly (inc. 2-14) Harness, Fuel Pump Seal, Fuel Pump Housing Screw, Machine - Harness Nut, Retaining - Fuel Pump O-Ring O-Ring Regulator, Fuel Pump Spring, Fuel Pump Assembly Ring, Retaining Clamp, Hose Hose, Fuel Pump - Top Pump, Fuel Housing, Fuel Pump Clamp, Hose Hose, Gasline Pickup, Fuel Clamp, Hose AR Hose, Gasline - 10 ft 26

29 TUNNEL ASSEMBLY Tunnel Assembly (inc. 2-5) Plate, End - Tunnel AR Rivet Bracket, Suspension Mounting - Right Bracket, Suspension Mounting - Left AR Rivet Plate, Suspension Mounting - Front AR Rivet Screw, Self-Tapping Footrest, Rear - Right Footrest, Rear - Left Rivet Retainer, Side Snowflap Snowflap, Side Strap, Side Snowflap Snowflap Screw, Machine Nut, Lock Plug, Hole Pad, Toolbox Decal, Tunnel - Right Decal, Tunnel - Left Seal, Seat-Base Plate, Seat Riser - Rear Plate, Seat Riser - Right Plate, Seat Riser - Left Seal, Seat-Base Bracket, Riser Reinforcement Rivet Bracket, Mounting - Tank Hold- Down - Right Bracket, Mounting - Tank Hold-Down - Left 27

30 BACKREST ASSEMBLY Riser, Seat - Right Riser, Seat - Front Riser, Seat - Rear Riser, Seat - Left Rivet Bracket, Backrest - Right Bracket, Backrest - Left Bracket, Mounting - Wind Deflector - Right Bracket, Mounting - Wind Deflector - Left Deflector, Wind - Right Deflector, Wind - Left Rivet Screw, Cap Backrest (inc ) Cover, Backrest Axle Washer, Cup Block, Tension - Backrest Screw, Machine 28

31 RACK, HITCH, AND TAILLIGHT ASSEMBLIES Rack Mat, Rack Guard, Taillight Nut, Lock Screw, Machine Lens, Taillight Housing, Taillight Bulb, Taillight Screw, Machine Nut, Lock Pin, Receiver Hitch, Pintle Latch, Hitch Screw, Cap Pin, Lock Clip, Hairpin Spring, Return Screw, Cap Nut, Cap Washer Plug, Hole Reflector - Red Clip, Retaining Decal, Warning - Towing (English) Decal, Warning - Max Payload (English) Decal, Warning - Max Payload (French) Decal, Warning - Towing (French) 29

32 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 ft AR Hose - 50 ft Cap, Drain Adapter, Fitting Clamp, Hose Cable Tie in AR Hose, Coolant - Drain - 10 ft Clamp, Hose Hose, Coolant - Heater/Engine Protector, Hose Heater, Inline Heater, Inline (International) Hose, Coolant - Heater/T-Fitting T-Fitting - Double Hose, Coolant - Front Heat Exchanger/ T-Fitting Hose, Coolant - Y-Fitting/T-Fitting Clamp, Hose Y-Fitting Hose, Coolant - Thermostat/Y-Fitting Hose, Coolant - Throttle Body/Y-Fitting Clamp, Hose Hose, Coolant - Front Heat Exchanger/ Rear Heat Exchanger Hose, Filler Neck/Rear Heat Exchanger Neck, Filler Cap, Filler Neck Hose, Coolant - Filler Neck/Engine Heat Exchanger, Rear Rivet Clamp, Hose 30

33 ENGINE AND RELATED PARTS Engine Bracket, Engine Belt Cover Cover, Engine Belt Screw, Cap Nut, Lock Washer 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 Spacer Screw, Cap Guard, Ring Gear Screw, Cap Screw, Cap Clutch, Drive Belt, Drive Washer, High Collar Bolt, Drive Clutch Bracket, Mounting - Starter Motor Bushing Screw, Cap Washer Clamp, Fuel Filter Filter, Fuel Nut, Lock AR Hose, Gasline - 10 ft Clamp, Hose Fitting, Grease Bracket, Engine Mounting/Bearing Support Nut, Lock Screw, Cap Bumper, Torque - Engine Nut Washer, Lock Washer Nut, Lock Bracket, Engine Mounting - Left - Rear Mount, Engine - Rear Bracket, Engine Mounting - Right - Rear Screw, Cap Screw, Machine Bracket, Filler Neck 31

34 EXHAUST ASSEMBLY Muffler Assembly (inc. 2-7) Wrap, Upper Packing, Upper Muffler Packing, Lower Wrap, Lower Tie, Band - 42 in Gasket, Exhaust Spring, Extension Bumper, Rubber Spring, Extension Bracket, Mounting - Muffler Screw, Cap 32

35 BATTERY ASSEMBLY Battery (inc. 2) Wrap, Heat - Battery Cable, Battery/Ground Nut, Wing Washer Strap, Battery - Top Strap, Battery - Side Nut, Lock Fuse Box/ECU Holder Mount, ECU Screw, Cap Tray, Battery Bracket, Mounting - Battery Tray Washer 33

36 AIR SILENCER ASSEMBLY Silencer, Air - Assembly (inc. 2-6 and one No. 7) Cover, Outer Cover, Inner Screw, Cap Fitting, Elbow Grommet Fitting, Straight Tube, Outlet Clamp, Hose Tube, Inlet Clamp, Tube Plenum, Air Silencer Screen, Plenum Clip, Retaining Isolator, Rubber Bushing Screw, Self-Tapping Bracket, Mounting - Air Silencer Nut, Lock Hose, Drain Screw, Machine Hose, Breather Sensor, Air Temperature Grommet 34

37 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 (inc. 7) (Over 5,000 ft Alt.) Screw, Set Nut, Lock Washer, Spacer Washer, Spacer Spider Assembly Spring, Drive Clutch - Gold Nut Cover Washer, Lock - Spring Screw, Machine Button, Torque Plug, Torque Button 35

38 DRIVEN CLUTCH (Assembly p/n ) Sheave, Movable (inc. one No. 2) Bearing Washer, Thrust: in Washer, Thrust: in Sheave, Stationary Bracket, Torque 57 / Bracket, Torque 49 (5-9,000 ft Alt.) Bracket, Torque 45 (Over 9,000 ft Alt.) Washer, Lock Screw, Cap Spring, Driven Clutch - Red/White Plate, Roller - Assembly (inc. one No. 2 and 10-13) Pin, Spring Pin, Cam Roller Washer, Thrust - Cam Roller Roller, Cam Nut, Lock 36

39 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 Bolt, Coil Cover Bolt, Cylinder Head Cover Bolt, Cylinder Head Cover Spark Plug (NGK KR8AI) Cap, Oil Filler Cover, Coil Clamp, Hose Bolt Clamp, Hose 37

40 CYLINDER BLOCK/BASE ASSEMBLY Cylinder Block/Base Assembly (inc. 2-8) Plug, Oil Venturi Bolt Plug, Oil Gallery Bolt Gasket Plug, Oil Drain Pin, Dowel Stand, Oil Filter Filter, Oil - Assembly Sensor, Knock - Assembly Cooler, Oil (inc. 13) Gasket 38

41 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 39

42 *Optional CRANKSHAFT ASSEMBLY 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 40

43 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 41

44 CAM CHAIN ASSEMBLY Chain, Timing Guide, Chain Bolt Tensioner, Chain Spacer Pad Link Gasket, Tension Adjuster Adjuster, Tensioner - Assembly Bolt Bolt Bolt 42

45 INTAKE MANIFOLD ASSEMBLY Manifold, Intake Gasket Bracket, Stiffener Bolt, Stud Bolt, Stud Bolt Bolt Nut Bracket, Stiffener Bolt Clamp 43

46 THROTTLE BODY ASSEMBLY Throttle Body Assembly (inc. 2-6) Screw Valve, ISC Gasket Sensor, Throttle Position Screw, Machine Bolt Gasket Bolt Guide, Throttle Cable Screw Sensor, Pressure 44

47 EXHAUST MANIFOLD ASSEMBLY Manifold, Exhaust Shield, Heat Gasket Bolt Bolt Bolt, Stud Nut Sensor, Oxygen Clamp, Sensor 45

48 DELIVERY PIPE ASSEMBLY Pipe, Delivery Bolt Injector, Fuel - Assembly (inc. 4) Grommet Set Cushion 46

49 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 47

50 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 Clamp, Hose Hose - Oil Cooler/Inlet Pipe Hose - Water Tank/Oil Cooler 48

51 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 Bolt Decal, Fuse Box Decal, Fuse Box 18 * 1 Resistor Controller, Injection Screw, Machine Sensor, Cam Position - Assembly Coil, Ignition *Resistor is coded to engine; see dealer to determine part number. 49

52 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 50

53 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 51

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

55 RELATED ITEMS (Model No. S2005BCFWTUSS) (Model No. S2005BCFWTOSS - International) Altitude Kit ( ft) Altitude Kit (Over 9000 ft) Cover, Machine (Deluxe) Handbook, Safety (E/F) Handlebar Muffs Manual, Illustrated Parts Manual, Operator s (E/F) MRP Rack Paint, Hood - Silver (1/2 oz) Paint, Metal - Black Rear Rack Bag NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A. p/n