TABLE OF CONTENTS 2001 ATV

Transcription

1 TABLE OF CONTENTS 2001 ATV 400/500 cc Manual Transmission 400 2x4 Red (Model No. A2001ATI2AUSR) 400 2x4 Green (Model No. A2001ATI2AUSG) 400 4x4 Red ( Model No. A2001ATI4AUSR) 400 4x4 Green (Model No. A2001ATI4AUSG) 500 Red (Model No. A2001ATM4AUSR) 500 Green (Model No. A2001ATM4AUSG) BODY PANEL ASSEMBLY TAILLIGHT ASSEMBLY DECALS FRAME AND RELATED PARTS SEAT ASSEMBLY STEERING ASSEMBLY FRONT SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY WHEEL AND TIRE ASSEMBLY MECHANICAL BRAKE ASSEMBLY HYDRAULIC HAND BRAKE ASSEMBLY HYDRAULIC BRAKE ASSEMBLY GAS TANK ASSEMBLY REVERSE SHIFT LEVER ASSEMBLY FRONT SHIFT LINKAGE ASSEMBLY AIR INTAKE ASSEMBLY STORAGE BOX AND BATTERY ASSEMBLY ENGINE AND EXHAUST COOLING ASSEMBLY REAR AXLE ASSEMBLY WIRING HARNESS ASSEMBLY CARBURETOR CYLINDER HEAD ASSEMBLY CYLINDER ASSEMBLY CRANKCASE ASSEMBLY CRANKCASE COVER ASSEMBLY CRANKSHAFT ASSEMBLY STARTER CLUTCH ASSEMBLY CRANK BALANCER ASSEMBLY CAMSHAFT/VALVE ASSEMBLY CAM CHAIN ASSEMBLY RECOIL STARTER ASSEMBLY OIL FILTER/PUMP ASSEMBLY WATER PUMP ASSEMBLY CLUTCH ASSEMBLY TRANSMISSION ASSEMBLY SECONDARY TRANSMISSION ASSEMBLY SPEEDOMETER DRIVE ASSEMBLY (4X4) SECONDARY DRIVE ASSEMBLY GEAR SHIFTING ASSEMBLY SHIFTER ASSEMBLY (2X4) HI/LOW SHIFTER ASSEMBLY (4X4) FRONT BEVEL GEAR ASSEMBLY (400 cc 4X4) SECONDARY GEAR SHIFT ASSEMBLY (500 cc) FINAL BEVEL GEAR ASSEMBLY (Front cc) STARTER MOTOR ASSEMBLY MAGNETO ASSEMBLY CONTROL SWITCH HOUSING ASSEMBLY THROTTLE CONTROL ASSEMBLY 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 2001 model year Arctic Cat Inc. Printed June 2000 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

2 Panel, Fender - Front (Red) (2X4) Panel, Fender - Front (Green) (2X4) Panel, Fender - Front (Red) (4X4) Panel, Fender - Front (Green) (4X4) Cover, Access (Red) Cover, Access (Green) Flare - Front Right (2X4) Flare - Front Left (2X4) Flare - Front Right (4X4) Flare - Front Left (4X4) Rack - Front (400) Rack - Front (500) Reflector, Front - Yellow Clip, Retaining Panel, Side - Right (Red) (400) Panel, Side - Right (Red) (500) Panel, Side - Left (Red) Panel, Side - Right (Green) (400) Panel, Side - Right (Green) (500) Panel, Side - Left (Green) Panel, Fender - Rear (Red) (2X4) Panel, Fender - Rear (Green) (2X4) Panel, Fender - Rear (Red) (4X4) Panel, Fender - Rear (Green) (4X4) Rack - Rear (400) Rack - Rear (500) Wrap, Tube - Rear Rack Foam, Access Panel BODY PANEL ASSEMBLY Reflector, Rear - Red Flare, Rear Right (4X4) Flare, Rear Left (4X4) Mud Flap - Right (4X4) Mud Flap - Left (4X4) AR Rivet, Plastic Fender Extension - Rear Right (2X4) Fender Extension - Rear Left (2X4) Fender Extension - Rear Right (4X4) Fender Extension - Rear Left (4X4) T-Nut w/teeth (2X4) AR Screw, Body Clip, Tinerman Screw, Self-Tapping Screw, Cap Screw, Machine Nut, Speed Nut, Expansion Screw, Machine Washer Screw, Machine Plate, Heat - Rear Panel Screw, Machine Screw, Machine Screw, Machine (2X4) Grommet, Fuel Shut-Off Valve Rivet, Plastic 1

3 Bulb, Stop/Taillight Taillight w/socket Assembly Gasket, Taillight Lens Lens, Taillight TAILLIGHT ASSEMBLY (Complete Taillight Assembly p/n ) Screw, Machine Screw, Self-Tapping Washer, Lock - External Tooth 2

4 DECALS Decal, Warning - Front Rack Load (2X4) Decal, Warning - Front Rack Load (4X4) 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, Right Side (Red) Decal, Left Side (Red) Decal, Right Side (Green) Decal, Left Side (Green) Decal, Right Side (Red) Decal, Left Side (Red) Decal, Right Side (Green) Decal, Left Side (Green) Decal, Warning - Tire Pressure (400 2X4) Decal, Warning - Tire Pressure (400 4X4) Decal, Warning - Tire Pressure (500) Decal, Instruction - Start in Gear Decal, Warning - Rear Rack Load (2X4) Decal, Warning - Rear Rack Load (4X4) Decal, Arctic Cat Decal, Warning - Towing (2X4) Decal, Warning - Towing (4X4) Decal, Shift Pattern Decal, Caution - Electrical Decal, Hi/Low Range Decal, Instruction - Choke 3

5 Headlight Assembly (inc. 3 and 13) Nut Bulb, Headlight Washer, Lock - External Tooth Screw, Cap Screen, Bumper - Lower (400) Screen, Bumper - Lower (500) Yoke, Headlight Mount, Headlight Screw, Cap Guard, Brush (400) Guard, Brush (500) Footrest - Right Footrest - Left Screw, Machine FRAME AND RELATED PARTS AR Screw, Cap Frame, Main Washer AR Screw, Body Panel, Belly Tube, Cross - Bumper (500) Cap, Bumper (500) Screw, Cap (4X4) Bracket, Differential (4X4) Nut, Lock (4X4) Screw, Cap (4X4) Channel, Bumper Mounting (500) AR Screw, Cap Washer, Lock - High Collar 4

6 *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 SEAT ASSEMBLY Spring, Seat Latch Washer Collar, Front Seat-Base Bumper, Seat-Base - Front Cap, Protector Latch, Seat - Assembly Screw, Machine (2X4) Screw, Machine (4X4) Decal, Cold Start 5

7 Cable, Speedometer (4X4) Screw, Machine Speedometer (inc ) (4X4) Collar, Body Switch, Ignition - Assembly (inc. 6) Key, Ignition - Blank (C Series) Key, Ignition - Blank (D Series) Key, Ignition - Blank (E Series) Key, Ignition - Blank (F Series) Panel, LED Knob, Speedometer Trip Instrument Pod Cover, Key Rivet Washer (4X4) Pin, Retainer (4X4) Screw, Cap Cap, Steering Adjuster Bracket, Ignition Switch Tube, Handlebar Grip, Handlebar STEERING ASSEMBLY Housing, Bearing - Lower Bearing, Steering Post Housing, Bearing - Upper Pin, Cotter Post, Steering Screw, Cap Flange, Bearing Bearing w/inverted Oil Seal Washer Screw, Cap Nut, Top Lock Tie Rod, Assembly (inc ) Nut - Right Ball Joint, Tie Rod - Right Ball Joint, Tie Rod - Left Nut - Left Tie Rod Bulb, Speedometer Harness, Speedometer (4X4) Bracket, Speedometer (4X4) Mount, Rubber (4X4) 6

8 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 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 ) (2X4) A-Arm, Lower Left (inc ) (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 Repair Kit, Inner Boot - Front Axle Retainer, Spring - Lower Axle, Stub (2X4) Guard, Boot - Axle Screw, Body 7

9 Screw, Cap Screw, Cap Arm, Swing Nut, Lock Washer, Spring Adjustment Arm, Swing Retainer, Spring - Lower REAR SUSPENSION ASSEMBLY Shock Absorber - Rear (inc. 9-10) Sleeve, Shock Absorber Bushing, Shock Absorber Retainer, Spring Screw, Cap Spring, Shock Absorber Collar, Spring 8

10 Nut, Hex Cap, Valve Stem Stem, Valve Wheel - Front Tire - Front (400) Tire - Front (500) Pin, Cotter Washer Seal, Hub WHEEL AND TIRE ASSEMBLY Hub, Wheel - Front (2X4) Hub, Wheel - Front (4X4) Disc, Brake Screw, Machine Hub, Wheel - Rear Wheel - Rear Tire - Rear Cap, Wheel - Center Nut, Mounting - Wheel 9

11 *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 Axle, Foot Brake Nut 10

12 HYDRAULIC HAND BRAKE ASSEMBLY Cylinder, Master - Assembly (inc. 2-13) Lever, Brake Screw Nut, Lock Cover, Reservoir Bladder, Reservoir Screw Clamp, Master Cylinder Screw Lever, Brake - Lock Rivet Spring, Lever Lock Washer, Lock - Retaining Hose, Brakeline Screw, Machine 11

13 *Not a Service Part HYDRAULIC BRAKE ASSEMBLY Tube, Brakeline - Front Hose, Brake - Front Block, Mounting Bolt, Oil Washer, Crush Caliper, Brake - Right Front (inc and 23) Caliper, Brake - Left Front and Rear (inc and 23) 7 * 3 Housing, Caliper O-Ring Pin, Cotter Pin, Brake Caliper Cap, Bleeder Valve Pad, Brake Valve, Bleeder O-Ring, Brake Caliper Screw, Cap Hose, Brake - Rear Clip, Brakeline Tube, Brakeline - Rear Screw, Cap Screw, Cap Screw, Cap Switch, Brake Pressure 23 * 3 Housing, Caliper 12

14 *Not a Service Part Tank, Gas - Assembly (inc. 2-14) Cap, Gas (inc. 3-5) Gasket, Gas Cap Retainer, Gasket Screw, Machine Hose, Vent AR Hose, Gasline - 25 ft Clamp, Hose - Spring GAS TANK ASSEMBLY Valve, Fuel Shut-Off (inc. 10) Gasket, Fuel Shut-Off Valve Knob, Fuel Shut-Off Valve Screw, Fuel Shut-Off Valve Knob Nut, Lock Gauge, Fuel w/gasket (Press-Fit) Screw, Gas Tank 13

15 Axle, Reverse Shift Screw, Cap Arm, Reverse Shift Lever, Reverse (400) O-Ring E-Ring Spring, Reverse Lever Reverse Switch REVERSE SHIFT LEVER ASSEMBLY Retainer, Switch Handle, Reverse Shift Lever (400) E-Ring Cable, Shift Handle, Lever - Shift (500) Cap, Shift Lever (500) Screw, Machine (500) Lever, Reverse (500) 14

16 FRONT SHIFT LINKAGE ASSEMBLY Linkage, Shift Bushing, Shift Linkage Washer Pin, Cotter Bracket, Shift Linkage Screw, Body Bushing Collar Screw, Machine Washer Arm, Select Screw, Machine 15

17 *Not a Service Part Clamp Boot, Air Cleaner Clamp Housing, Air Cleaner Screw, Self-Tapping Gasket, Air Cleaner Snorkel, Air Cleaner Clamp, Air Cleaner Spring, Air Cleaner Screw, Machine Nut, Expansion Hose, Crankcase Vent Filter, Air Cleaner AIR INTAKE ASSEMBLY Screw, Self-Tapping Valve, Air Cleaner Cap, Fitting - Air Cleaner Clamp, Hose Clamp, Hose - Spring Support, Air Cleaner Flange Plate, Heat - Air Intake Box, Fuse - Assembly (inc ) 22 * 1 Block, Fuse 23 * 1 Lid, Fuse Box Decal, Fuse Block Fuse - 10 Amp Fuse - 15 Amp 16

18 STORAGE BOX AND BATTERY ASSEMBLY *Not a Service Part Screw, Machine Strap, Battery w/pads (inc. 3 and 11) Pad, Battery - Upper Rear Battery Assembly (inc. 5-7) Cap, Battery Clamp, Hose Hose, Battery Vent Cable Tie in Pad, Battery - Lower Kit, Tool Pad, Battery - Upper Front Storage Box - Assembly (inc ) (4X4) Box, Tool (4X4) Washer (4X4) Lid, Tool Box (4X4) Chain, Storage (4X4) Rivet (4X4) Nut, Expansion (4X4) Seal, Storage Cover (4X4) Ring, Mounting - Storage Box Lid (4X4) Rivet (4X4) Screw, Self-Tapping Clamp, Tube (4X4) Decal, Warning - Battery 17

19 Pipe, Exhaust Screw, Cap Screw, Cap Washer, Engine Spacer, Engine Engine (400 2X4) Engine (400 4X4) Engine (500) Nut, Lock Seal, Exhaust Nut Screw, Cap Screw, Cap Bracket, Engine - Upper ENGINE AND EXHAUST Lever, Shift Screw, Cap Clamp, Exhaust Bushing, Exhaust Muffler Screw, Machine - Shoulder Cover, Exhaust Screw, Machine Clamp, Hose Plate, Heat - Muffler Washer, Lock - External Tooth Nut, Flange Screw, Cap Spacer 18

20 *Not a Service Part Screen, Radiator Clamp, Wire Screw, Cap Grommet Collar AR Hose - 25 ft Cap, Radiator Radiator Assembly (inc. 1, 4, 7, 10, and 21) Clamp, Hose 10 * 1 Radiator Clamp, Hose Hose, Coolant - Upper Blade, Fan Motor, Fan Screw, Machine COOLING ASSEMBLY Hose, Coolant - Lower Hose, Coolant - Crossover Screw, Body Washer Panel, Fender - Inner (400 4X4) Screw, Thumb Nut, Speed Nut - Left Washer Bushing, Stem Screw, Machine Cable Tie - 7 in Shroud, Fan (400 2X4 /500) Panel, Fender - Inner (400 2X4 /500) Nut, Flange 19

21 Gear Case Assembly Hitch, Trailer Panel, Gear Case - Right Slinger, Rear Drive - Right Seal, Rear Drive Slinger O-Ring Screw, Body Housing, Axle - Right Housing, Axle - Left Gasket, Axle Housing Disc, Brake Axle Assembly - Right Axle Assembly - Left Seal Ring, Retaining Bearing Housing, Bearing - Left Housing, Bearing - Right REAR AXLE ASSEMBLY Ring, Retaining Bladder, Rear Drive Case Cable Tie - 4 in Plug, Fill O-Ring, Fill Plug Plug, Drain O-Ring, Drain Plug Plug, Drain - Magnetic Screw, Machine Nut, Speed Screw, Cap Screw, Self-Tapping Screw, Self-Tapping Retainer, Axle - Assembly - Right (inc , 14-16, and 18-19) Retainer, Axle - Assembly - Left (inc and 19) 20

22 Harness, Main Harness, Main (Vehicle Identification Number S71T and Up) Diode (Start in Gear) AR Cable Tie in Diode Assembly Receptacle, 12V (4X4) Retainer, Switch Harness, 12V Receptacle (4X4) Switch, Brake - Assembly Seal, Spark Plug Cap, Spark Plug Seal, High Tension Wire Nut Spacer Coil, Ignition - Assembly Screw, Cap WIRING HARNESS ASSEMBLY Cable Tie - Push Mount Base, Cable Tie Regulator, Voltage Regulator, Voltage (Vehicle Identification Number S71T and Up) Screw, Machine Screw, Machine CDI Unit Relay, Neutral Start - Assembly Relay, Starter Motor - Assembly (inc. 25) Screw, Cap Fuse, 30 Amp Cable, Battery/Electric Start Relay Cable, Battery/Electric Start Boot, Terminal Cable, Battery/Ground 21

23 *Optional Cover Assembly Spring Ring E-Clip Ring Jet Needle Screw Diaphragm Screw Plunger Assembly O-Ring Washer Spring Screw Screw, Pilot Pilot Jet Main Jet Needle Jet P Float Assembly Seat, Valve Seat, Valve 2.3* O-Ring, Float Chamber Filter Chamber, Float CARBURETOR (400 cc) (Complete Assembly p/n ) Jet, Pilot Air Screw Spring Cable, Adjuster - Assembly Cover Washer Screw O-Ring Guide, Cable Washer Screw Clip Hose Clip Hose Spring Pin, Float Washer Cable, Throttle Cable, Choke O-Ring Screw, Cap Cover, Primer - Assembly Holder, Carburetor 22

24 *Not a Service Part **Optional Cover, Top Screw, Top Cover Spring Piston, Vacuum Spring, Seat Jet Needle Needle Jet Holder, Needle Jet Main Jet Main Jet 150** Main Jet 147** Main Jet 142** Main Jet 140** Slow Jet Starter Jet Valve, Float - Set (inc. 13) 13 * 1 Clip 14 * 1 Pin, Float Float Set (inc. 14) Screw, Drain Screw Screw, Pilot Air - Set (inc ) 19 * 1 O-Ring CARBURETOR (500 cc) (Complete Assembly p/n ) 20 * 1 Spring 21 * 1 Washer Valve, Starter Spring O-Ring Cap Cap, Rubber Screw, Stop Washer Spring Tube, Vinyl Diaphragm Assembly Spring 33 * 1 Housing, Pump U-Ring Screw Cover Screw Cable, Choke Cable, Throttle 40 * 1 Chamber, Float - Assembly (inc. 16, 31-35, and 41) O-Ring, Float Chamber 23

25 Head, Cylinder - Assembly (inc. 2-6) (400) Head, Cylinder - Assembly (inc. 2-6) (500) Guide, Valve Circlip Pin, Dowel Screw, Cap Screw, Cap Gasket, Cylinder Head (400) Gasket, Cylinder Head (500) Pin, Dowel Screw, Cap Screw, Cap Bolt, Stud Bolt, Stud Bolt, Stud Screw, Cap Screw, Cap Nut Nut Gasket Gasket, Head Nut Spark Plug (NGKCR6E) CYLINDER HEAD ASSEMBLY (Complete Gasket Set p/n cc; cc) Cap, Inspection O-Ring Screw, Cap Plug, Cylinder Head Pipe, Intake - Assembly (inc. 26) (400) Pipe, Intake - Assembly (500) Pipe, Intake - Assembly (500) O-Ring (400) O-Ring (500) Screw, Cap (400) Screw, Cap (500) Clamp Screw, Cap (400) Screw, Cap (500) Thermostat (400) Thermostat (500) Switch, Water Temperature - Assembly Cover, Thermostat Stud, Thermostat Cover (500) Nut (500) Tube, Intake 24

26 Cylinder (400) Cylinder (500) Bolt, Stud Nut CYLINDER ASSEMBLY Gasket, Cylinder (400) Gasket, Cylinder (500) Pin, Dowel Union, Water Hose Screw, Cap O-Ring 25

27 Crankcase Set (inc. 2-7 and 17) (400 2X4) Crankcase Set (inc. 2-7) (400 4X4) Crankcase Set (inc. 2-8, 10, 15, and 16) (500) Pin, Dowel Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap CRANKCASE ASSEMBLY O-Ring (400 4X4 and 500) Gasket O-Ring (500) Screw, Cap Nut Washer Plug, Oil Gallery Jet, Piston Cooling (500) Screw (500) Plug, (400 2X4) 26

28 Cover, Clutch (inc. 2) (400) Cover, Clutch (inc. 2) (500) Lens, Oil Inspection Gasket Pin, Dowel Screw, Cap Screw, Cap Gasket Plug, Oil Gallery Gasket Cap, Engine Oil Filler O-Ring Cap, Inspection (400) Cap, Inspection (500) O-Ring Screw, Cap Plug, Oil Pressure (400) Plug, Oil Pressure (500) CRANKCASE COVER ASSEMBLY Gasket Cover Set, Transfer (inc ) (400) Cover Set, Transfer (inc ) (500) Jet, Oil Mission O-Ring Gasket Clip Screw, Cap Screw, Cap Gasket Plug, Oil Gallery (400) Plug, Oil Gallery (500) Gasket Plug, Allen-Head Gasket Union, Water Drain Hose 27

29 *Not a Service Part Crankshaft Assembly (inc. 2-9) (400) Crankshaft Assembly (inc. 2-9) (500) Rod, Connecting (400) Rod, Connecting (500) Pin, Crank (400) Pin, Crank (500) Bearing (400) Bearing (500) Washer (400) Washer (500) Crankshaft Set - Right (inc. 8-9) (400) Crankshaft Set - Right (inc. 8-9) (500) Crankshaft - Left (400) Crankshaft - Left (500) 8 * 1 Gear, Balancer Drive 9 * 1 Pin Bearing - Right (400) Bearing - Right (500) Bearing - Center Bearing - Left Retainer, Bearing - Right (400) Retainer, Bearing - Right (500) Screw, Cap (400) Retainer, Oil Seal - Left Screw, Cap CRANKSHAFT ASSEMBLY Piston (400) Piston (500) Ring Set, Piston (400) Ring Set, Piston (Oversized 0.50 mm) (400) Ring Set, Piston (Oversized 1.00 mm) (400) Ring Set, Piston (500) Pin (400) Pin (500) Circlip (400) Circlip (500) Piston Assembly (inc. 17, 18, and 20) (400) Piston Set (Oversized 0.50 mm) (400) Piston Set (Oversized 1.00 mm) (400) Piston Assembly (inc. 17, 18, and 20) (500) Bearing Seal, Oil Spacer O-Ring O-Ring Spacer, Bearing - Left Nut Seal, Oil Circlip 28

30 STARTER CLUTCH ASSEMBLY Gear, Starter - Idle No.1 (400) Limiter, Idle Gear - Assembly (500) Bushing (500) Washer (500) Gear, Starter Idle No. 2 (400) Gear, Starter Idle (500) Pin Clutch, Starter - Set (inc. 7) (2X4) Clutch, Starter - Set (inc. 7) Bearing Washer Screw, Cap Spacer (500) Pin (400) 29

31 Balancer, Crank (400) Balancer, Crank (500) Bearing Washer Gear, Driven (400) Gear, Driven (500) Race, Driven Gear - Inner Pin Spring CRANK BALANCER ASSEMBLY Key Washer Circlip Gear, Oil Pump Drive (400) Gear, Oil Pump Drive (500) Pin Spacer Nut, Lock Washer 30

32 Camshaft Sprocket (400) Sprocket (500) Pin Washer Screw, Cap C-Ring Arm, Valve Rocker (inc. 8-9) Screw, Cap Nut Arm, Valve Rocker (inc. 8-9) Seat, Spring CAMSHAFT/VALVE ASSEMBLY Seal, Oil Shaft, Rocker Arm Shaft, Rocker Arm Washer Plug, Shaft Gasket Valve, Intake Valve, Exhaust Spring, Valve - Set Retainer, Spring Cotter, Valve 31

33 Chain, Cam (400) Chain, Cam (500) Guide, Chain (400) Guide, Chain (500) Tensioner, Chain (400) Tensioner, Chain (500) CAM CHAIN ASSEMBLY Screw, Cap Washer Adjuster, Tensioner - Assembly Gasket Screw, Cap Gasket 32

34 *Not a Service Part RECOIL STARTER ASSEMBLY Starter, Recoil - Assembly (inc. 2-12) Reel Ratchet Assembly (inc. 4 and 6-10) 4 * 1 Pin, Ratchet Spring, Spiral 6 * 1 Spring, Friction 7 * 1 Shaft 8 * 1 Cover, Spring 9 * 1 Plate, Friction 10 * 1 Guide, Ratchet Nut Rope Assembly Gasket Screw, Cap Cup, Starter (400) Cup, Starter (500) Nut O-Ring 33

35 Pump, Engine Oil Gear, Driven Pin Washer Circlip Screw, Cap Strainer, Engine Oil Screw, Cap Cap, Oil Strainer OIL FILTER/PUMP ASSEMBLY O-Ring Screw, Cap Filter, Engine Oil Plug, Drain Gasket Valve, Assembly - Oil Relief (400) Valve, Assembly - Oil Relief (500) Union, Oil Filter 34

36 Case, Water Pump (inc. 2-3) (400) Case, Water Pump (inc. 2-3) (500) Screw, Cap (400) Screw, Cap (500) Gasket O-Ring Screw, Cap Screw, Cap WATER PUMP ASSEMBLY Joint, Pump Drive (400) Joint, Pump Drive (500) Shaft, Water Pump w/bearing Pin Seal, Pump Drive Seal, Mechanical Impeller Screw, Cap Washer Gasket 35

37 Housing, Starter Clutch (400) Housing, Starter Clutch (500) Clutch, Primary Drive One Way Shoe, Starter Clutch (400) Shoe, Starter Clutch (500) Nut, Starter Clutch Shoe Washer, Starter Clutch Shoe Washer, Primary Driven Washer, Primary Driven (400) Washer, Primary Driven (500) Gear, Primary Driven - Assembly Hub, Clutch Sleeve (400) Hub, Clutch Sleeve (500) Screw, Cap - Clutch Spring Spring, Clutch Plate, Clutch Drive (400) Plate, Clutch Drive (500) Plate, Clutch Driven (400) Plate, Clutch Driven (500) CLUTCH ASSEMBLY Disc, Clutch Pressure Plate, Clutch Release Nut, Clutch Sleeve Hub Washer, Sleeve Hub Arm, Clutch Release Bolt, Clutch Release (No. 1) (400) Bolt, Clutch Release (No. 1) (500) Bolt, Clutch (No. 2) Guide, Release Roller Roller, Clutch Release - Assembly Bolt, Clutch Release Arm Nut, Clutch Release (No. 2) Nut, Clutch Release (No. 1) (400) Nut, Clutch Release (No. 1) (500) Washer, Clutch (No. 2) Bearing, Clutch Washer, Clutch Release (No. 1) (400) Washer, Clutch Release (No. 1) (500) 36

38 Countershaft Gear, 2nd Drive Gear, 3rd Drive Gear, 4th Drive Gear, 5th Drive Bushing, 5th Drive Gear Washer, 5th Drive Gear Bearing, Center Shaft - Right Bushing, 4th Drive Gear Circlip, 4th Drive Circlip, Reverse Idle Bearing, Center Shaft Shim Washer, 4th Drive Washer, Reverse Idle Driveshaft (400) Driveshaft (500) Gear, 1st Driven (400) Gear, 1st Driven (500) Gear, 2nd Driven Gear, 3rd Driven Bushing, 3rd Driven TRANSMISSION ASSEMBLY Gear, 4th Driven Gear, 5th Driven Gear, Reverse Driven Dog, Reverse Bushing, Reverse Driven Washer, 3rd Driven - Right Washer, 3rd Driven - Left Washer, 3rd Driven - Left Bearing, Driveshaft Bushing, 1st Driven Bushing, 2nd Driven Circlip, 2nd Driven Bushing, Reverse Idle Bearing, Driveshaft - Right Washer, Reverse Driven Gear, Reverse Idle Washer, 1st Driven - Right Washer, 2nd Driven (400) Washer, 2nd Driven (500) Circlip, Reverse Driven Shaft, Reverse Idle 37

39 SECONDARY TRANSMISSION ASSEMBLY (2X4) Shaft, Output Spacer, Idle Gear Gear, Driven Washer Spacer, Drive Washer Gear, Drive (No. 1) Washer Washer Bearing, Driveshaft - Left Bearing, Center Shaft - Left Circlip Bearing Spacer 38

40 SECONDARY TRANSMISSION ASSEMBLY (4X4) Shaft, Output Gear, Idle Gear, Driven Washer (400) Washer (500) Spacer, Drive Gear No. 2 (400) Gear No. 2 (500) Dog, Select Sliding (400) Dog, Select Sliding (500) Washer Bushing Bearing, Driveshaft - Left Bearing, Center Shaft - Left Circlip No Washer, Gear No. 2 (400) Washer, Gear No. 2 (500) Spacer (400) Spacer (500) Spacer, Idle Gear Gear No. 1 (400) Gear No. 1 (500) Bushing (400) Bushing (500) Bearing Set - Left Washer 39

41 SPEEDOMETER DRIVE ASSEMBLY (4X4) Retainer, Bearing Washer, Drive Screw, Retainer Seal, Driven Gear Gear Shim Set Nut Washer Washer - Right Spacer, Drive Gear Bolt, Gear Washer O-Ring Washer Bolt, Housing Bearing Set - Right Housing, Speedometer Gear Sleeve Gasket Gear, Drive Gear, Driven 40

42 SECONDARY DRIVE ASSEMBLY (2X4) Joint Assembly, Rear Output (inc. 2-6) Boot Set, Joint (inc. 3-6) Ring, Snap Clamp Boot Clamp Gear, Secondary Driven Bevel Shaft - Rear AR Shim, 25 x 34 x 0.60 mm AR Shim, 25 x 34 x 0.65 mm AR Shim, 25 x 34 x 0.70 mm AR Shim, 25 x 34 x 0.75 mm AR Shim, 25 x 34 x 0.80 mm AR Shim, 25 x 34 x 0.85 mm AR Shim, 25 x 34 x 0.90 mm AR Shim, 25 x 34 x 0.95 mm AR Shim, 25 x 34 x 1.00 mm AR Shim, 25 x 34 x 1.05 mm AR Shim, 25 x 34 x 1.10 mm AR Shim, 25 x 34 x 1.15 mm AR Shim, 25 x 34 x 1.20 mm Seal, Oil Flange, Output Joint Washer, Rear Output Flange Nut Bearing C-Ring Screw Retainer Nut, Secondary Driven Gear Washer Screw, Cap Bearing w/snap Ring Nut Washer Gear, Secondary Drive Bevel Shim Set Plug, Transfer Cover Hole Retainer, Transfer Cover Bolt Retainer, Secondary Driveshaft Bearing Bearing, Sub-Transmission Gasket, Retainer Cover 41

43 SECONDARY DRIVE ASSEMBLY (4X4) Yoke, Drive Output (inc. 2-5) Collar, Yoke Plate, Yoke Collar Plate, Yoke Collar O-Ring, Yoke Collar Yoke, Universal Joint Shaft, Propeller Boot, Propeller Shaft Gear Shaft - Front Shaft - Rear Flange, Output Joint Joint Assembly, Rear Output (inc ) Nut, Front Drive Bevel Gear Nut Washer, Rear Output Flange AR Shim, 25 x 34 x 0.60 mm AR Shim, 25 x 34 x 0.65 mm AR Shim, 25 x 34 x 0.70 mm AR Shim, 25 x 34 x 0.75 mm AR Shim, 25 x 34 x 0.80 mm AR Shim, 25 x 34 x 0.85 mm AR Shim, 25 x 34 x 0.90 mm AR Shim, 25 x 34 x 0.95 mm AR Shim, 25 x 34 x 1.00 mm AR Shim, 25 x 34 x 1.05 mm AR Shim, 25 x 34 x 1.10 mm AR Shim, 25 x 34 x 1.15 mm AR Shim, 25 x 34 x 1.20 mm Bearing w/groove Bearing w/ Locating Ring and Pin Joint Set, Universal (inc. 21) Circlip Seal, Oil Ring, Bearing Washer Nut Screw, Cap Screw, Cap Bootset, Output Joint (inc ) Ring, Snap Band Boot Band Seal, Plate Retainer, Center Shaft Bearing 42

44 Fork (No. 2) Fork (No. 3) Fork, Reverse Shaft, Gear Shift Fork Cam, Gear Shift (inc. 6) Pin, Gear Shift Cam, Reverse Shift Plate, Gear Shift Cam Guide, Gear Shift Cam Plate Washer, Reverse Shift Cam Bearing, Gear Shift Cam Bolt, Clutch Release Arm Screw, Cam Bearing Retainer Retainer, Bearing Stopper, Gear Shift Cam Stopper, Reverse Shift Cam Housing, Reverse Cam Stopper Spring, Shift Cam Stopper Arm Support, Shift Cam Stopper Gasket, Cam Stopper Housing Spring, Reverse Cam Stopper Washer, Gear Shift Cam Washer, Cam Stopper Arm Nut, Cam Stopper Arm Support GEAR SHIFTING ASSEMBLY Shaft, Gear Shift (inc. 42) Spacer, Gear Shift Shaft Stopper, Gear Shift Arm Seal, Gear Shift Shaft Oil (400) Seal, Reverse Shift Oil Spring, Gear Shift Return Arm, Reverse Gear Shift Washer, Gear Shift Cable Arm (400) Washer, Gear Shift Cable Arm (500) E-Ring, Gear Shift Cable Arm Screw, Cap Base Assembly Contact, Neutral O-Ring, Neutral Clamp Clamp Spring Hub, Gear Shift Spring, Gear Shift AR Tape, Foil Circlip, Reverse Shift Cam Seal, Gear Shift Shaft Oil (500) Bearing, Gear Shift (500) Bolt 43

45 Plug, Oil Guide, Gear Shift Shaft Gasket, Oil Plug SHIFTER ASSEMBLY (2X4) Seal, Oil Washer, Thrust Circlip 44

46 HI/LOW SHIFTER ASSEMBLY (4X4) Stopper, Shift Cam Housing, Shift Cam Stopper Shaft, Shift Fork Fork, Shift Cam, Shift (400) Cam, Shift (500) Spring Shaft, Shift Plate, Lever Stop Lever, Shift - Assembly (inc ) Sub-Rod Spring Washer Circlip Pin Collar Washer E-Clip Handle Spacer Gasket, Shift Cam Stopper Seal, Oil Spring Bolt, Lever Stop Plate Screw, Shift Handle Washer, Cam Stop Washer, Shaft - Left Circlip, Cam Spring Circlip, Shift Lever Circlip, Shaft - Left Spacer Set (400) Spacer Set (500) 45

47 FRONT BEVEL GEAR ASSEMBLY (400 cc 4X4) (Complete Assembly p/n ) *Not Included in Assembly Flange, Gear (inc. 2-5)* Collar, Gear* Plate, Oil Seal* Plate, Gear* O-Ring, Collar* Gear, Bevel Housing, Bevel Gear Shim Set, Housing Nut, Gear* Washer, Bevel Gear* Spacer, Bevel Gear Bearing Bearing O-Ring Seal, Joint Bolt, Housing Gear Shim Set Shim Set Bearing Seal - Left Bearing - Left Differential - Assembly (500) Differential - Assembly (400) Bearing, Differential Case - Right Seal, Output Oil Housing (inc. 27) Union, Breather Case, Bearing Bolt, Mounting Gasket, Oil Drain Plug Gasket, Oil Filler Plug Plug, Oil Drain Plug, Oil Filler Plug O-Ring O-Ring Screw, Cap Ring, Driveshaft - Front Coupling, Propeller Shaft* Screw, Cap* Nut* Bladder, Housing* Cable Tie - 4 in.* Nut, Lock 46

48 SECONDARY GEAR SHIFT ASSEMBLY (500 cc) Washer, Cam - Left Cam, Select Stopper, Cam (inc. 4) Ball, Steel Housing, Cam Stopper Shaft, Shift Fork Camshaft Fork, Shift Gasket, Cam Stopper Washer, Cam Seal, Oil - Cam Spring, Cam Stopper Spring, Cam 47

49 FINAL BEVEL GEAR ASSEMBLY (Front cc) Yoke, Drive Bevel Gear (inc. 2-5) Collar, Yoke Plate, Yoke Plate, Yoke Collar O-Ring, Yoke Collar Yoke, Propeller Shaft Joint, Universal - Set Circlip, Universal Joint Gear, Drive Bevel Housing, Drive Bevel Gear Shim Set Nut, Drive Bevel Gear Washer, Drive Bevel Gear Spacer, Drive Bevel Gear Bearing, Drive Bevel Gear Bearing, Drive Bevel Gear O-Ring, Drive Bevel Gear Housing Seal Bolt Gear, Driven Bevel Shim Set - Gear Shim Set - Bearing Dog, Differential Lock Bearing, Driven Bevel Pin, Dowel Bearing, Driven Output Shaft Differential Assembly Bearing, Differential Case - Right Bolt, Case Cover Housing, Differential Gear (inc. 31) Union, Breather Case, Driven Gear Bearing Bolt, Mounting - Differential Housing Bolt, Mounting - Differential Housing Gasket, Oil Drain Plug - Gear Gasket, Oil Filler Plug - Gear Plug, Oil Drain - Gear Plug, Oil Filler - Gear O-Ring, Driven Gear Bearing Case Bolt, Case Cover Nut, Mounting - Differential Housing Ring, Driveshaft Cover, Driven Gear Case Gasket, Case Cover 48

50 STARTER MOTOR ASSEMBLY Motor, Starter Assembly (inc. 2-9) (400) Motor, Starter Assembly (inc. 2-9) (500) Terminal Set, Brush Holder Set, Brush Spring, Brush O-Ring O-Ring Washer Set O-Ring Screw, Cap Screw, Cap Nut Circlip Bearing, Pinion Shaft 49

51 Stator Assembly Rotor/Flywheel Bolt Key Nut MAGNETO ASSEMBLY Screw, Cap Clamp (No. 1) Clamp (No. 2) Clamp (No. 3) 50

52 CONTROL SWITCH HOUSING ASSEMBLY Switch, Handlebar Control - Assembly (inc. 2-5) Lever, Choke Cover, Choke Screw, Cap Screw, Cap 51

53 THROTTLE CONTROL ASSEMBLY Control, Throttle - Assembly (inc. 2-9) Lever Screw, Cap Washer, Lock Washer Screw Nut Screw Screw 52

54 Related Items 2001 ATV 400/500 cc Manual Transmission (Model No. A2001ATI2AUSR x4 Red) (Model No. A2001ATI2AUSG x4 Green) (Model No. A2001ATI4AUSR x4 Red) (Model No. A2001ATM4AUSR Red) (Model No. A2001ATI4AUSG x4 Green) (Model No. A2001ATM4AUSG Green) Bag, Rack, Front, Black Bag, Rack, Rear, Black Bag, Tank, Black Battery, Heavy Duty Cargo Trailer - Deluxe Cover, Black and Green Cover, Gray Universal CV Joint Protectors, Deluxe (Front) Electrical Plug Engine Block Heater Gun Scabbard w/mount Handwarmers Hourmeter Illustrated Parts Manual Lunch Pack, Black Mirror Mud Flap Kit, Front Operator s Manual Paint, Metal - Black Prefilter, Air Filter Rack Extension, 4 in Rack Extension, 8 in Rack Pouch, Deluxe Rack, Black Safety Flag Shock Covers, Front Snowplow Blade, 50 in. - Straight (use w/ ) Snowplow Blade, 50 in. - One-Way (use w/ ) Snowplow Blade, 60 in. - Straight (use w/ ) Snowplow Mount Snowplow Remote Angle Adjust Snowplow, Hand Lift Lever Kit Tire Chains, Size B Tire Chains, Size C (26x Tires) Tire, Titan AT471 (25x8-12, Deep Lug) Tire, Titan AT471 (25x10-12, Deep Lug) Tire, Titan AT489A (25x10-12) Tire, Titan AT489A (25x8-12) Tire, Titan AT495 (26x ) Tire, Titan AT589 (25x10-12, Mud & Snow) Tool Holder - Double (Pair) Tool Holder - Single (Pair) Winch Accessories Kit Winch Kit, 2000 lb Winch Kit, 2500 lb Winch Mounting Kit Winch Mounting Kit Windshield, Clear Windshield, Clear w/accent Windshield, Smoke w/accent ARCTIC CAT Printed in U.S.A. p/n