DIESEL Model #A00CHCA Rev. 0 E 000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00
A-ARM/STRUT MOUNTING... AIR BOX... A C TABLE OF CONTENTS C B CLUTCH COVER... C CONTROLS - MASTER CYLINDER/BRAKE LINE... B CONTROLS - THROTTLE ASM./CABLE... B COOLING SYSTEM... A CRANKCASE... D CRANKSHAFT and PISTON... D CV JOINT - BTB... B CYLINDER... D- DECALS... DRIVE CLUTCH... DRIVEN CLUTCH... D E A C C ELECTRICAL/TAILLIGHT... C- ENGINE MOUNTING... A EXHAUST SYSTEM... A FRAME MOUNTING... FRONT BRAKE... FRONT CAB... FRONT HOUSING... FRONT RACK and BUMPER MOUNTING... FRONT STRUT... FRONT WHEEL... FUEL TANK... GEAR SELECTOR... GEARCASE (CASES & SNORKEL)... F G B B A D A B B A D C GEARCASE (INTERNAL COMPONENTS)... D- GOVERNOR... H D- HANDLEBAR and HEADLIGHT POD... B- INJECTION PUMP... D INTAKE and EXHAUST... D- G I M MAGNETO... OIL FILTER... OIL PUMP... OIL TANK... PARK BRAKE... PROP SHAFT... O P R E E E B C B REAR BRAKE/FOOT PEDAL... C- REAR CAB and SEAT... A- REAR DRIVE SHAFT... B REAR RACK MOUNTING... A REAR SUSPENSION... C- REAR WHEEL DRIVE... C STARTING MOTOR... STEERING POST... THREE- POINT HITCH A- ARM MOUNTING. TOOL KIT... WATER PUMP S T W... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. E B C E D
BRAKES Type/Brakes Type/Brakes - Auxiliary Park Brake CAPACITIES Coolant Capacity (quarts) Fuel Tank (gallons) Gearcase Oil (ounces) Engine Counter Balance W0 Oil (quarts) Injector Oil (quarts) Engine OW0 Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight Type DRIVE TRAIN DRIVE CLUTCH Center Distance (inches) Clutch Offset (inches) Clutch Weight Spring Color DRIVEN CLUTCH Helix Angle Spring Position DIMENSIONAL FEATURES Approx. Turning Radius Box, Tool Box (cubic inch) Ground Clearance (inches) Height (inches) Length (inches) Seat Height (inches) Weight (lbs. dry) Wheel Base (inches) Width (inches) ENGINE Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (liters) Compression Ratio Cooling Alternator Output Elec. Start Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Air Screw/Pilot Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust 000 DIESEL SPECIFICATIONS GEARCASE Hydraulic Disc Mechanical Hydraulic Lock, All Wheel.. N/A N/A 0 0 Standard Engine Breaking PVT / D0 White Compound N/A N/A. 0.0 DWPLE0 Cycle, Single Cyl. Diesel Dry Sump.x. : Full Stroke Liquid 00W Standard N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Transmission Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type GRAPHICS Body Style Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover w/decal Headlight/Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Tank Cover Tool Box Cover w/lettering Color ELECTRICAL Headlight - Handlebar (watts) Headlight - Front Hood (watts) Headlight - Grill (watts) Taillights (watts) Brake Light (watts) Indicator Bulb SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Adjustment TIRES&WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center PRD Side Lever./././ : -: N/A N/A Shaft Gen IV N/A N/A Bonnie Blue Bonnie Blue Black Semi Flat Black Bonnie Blue Black Bonnie Blue Black Black Aluminum Black Bonnie Blue Black Black N/A N/A N/A Single Beam, 0W N/A Single Beam, W.W.W.0W MacPherson Strut. Independent. - Bore Gas Bag CAM Goodyear xx xx N/A N/A Polaris Industries Inc. reserves theright tomake changes in designand specifications and/or tomake additions or improvements to its products without notice.
MODEL MODEL NO. OWNER S MANUAL 000 DIESEL PUBLICATION NUMBERS OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Diesel A00CHCA 0 0
REAR CAB and SEAT E 000 Polaris Sales Inc. 0 0 0 A
REAR CAB and SEAT Rivet, T-Lock 0 Bolt Washer Foil, Rear Cab, Rear - Cab, Rear, Bonnie Blue Nut, Nylok Retainer, Seat Latch 0 Foil, Tape, Rear Cab Screw Washer, Flat Screw Box, Tool 0 Rivet, Pop Bracket, Lever Retainer 0 Latch, Seat 00 Spring, Latch -00-00 Asm., Seat Covering, Seat Foil, Seat Base, Large Foil, Seat Base, Small Bumper, Rubber Screw 0 Washer Cover, Tool Box Cap, Drain 0 Fitting, Vent 0 Clip, Routing 00 Clip, Rosebud -0 Guard, Clutch Rivet - - - - - - - Asm., Front Housing(See Front Housing Pg. D for Details) 0 Washer, Spring Lock 0 Screw Nut, Nylok 0 Spacer, Footwell Screw 00-0 Frame, Main 0 Decal - Hitch Screw -00-00 Footwell, RH, Black Footwell, LH, Black Foil, Foam, Rear Fender Foil, Rear Cab, Front 0 0 Decal - Filter Element Foil, Foam Screw 00 Nut, U-Type Speed Guard, Mud, Rear, LH Guard, Mud, Rear, RH /00 A
FRONT CAB 0 Foil, Side Panel, RH Foil, Foam, Side Panel 0-0- Panel, Side, RH, Bonnie Blue Panel, Side, LH, Bonnie Blue Screw 0- Cover, Front, Bonnie Blue 00 Clip, Spring - Cab, Front, Bonnie Blue 00 Nut, U-Type Speed 00 Nut, Push-on Rivet, T-Lock Screw Guard, Mud, Front, LH Guard, Mud, Front, RH Nut, Nylok Washer Screw Washer, Flat Nut, Nylok Shield, Deflector 000 Clip, Dart 0 0 Clip, Routing AR Line, Breather -0-0 Guard, Splash, LH Guard, Splash, RH Screw /00 A
REAR RACK MOUNTING 0 Kit - Rack Extender, Rear (Incl. ) Screw 0 Screw 0 Asm., Rack, Rear (Incl. Ref. & Warning Decal) 000 Reflector, Red Screw 00-0 Support, Rear Rack -0 Bracket, Silencer, Frame Bolt 00 Nut, Chimney Nut, Nylok 0-0 0-0 0 Washer, Flat -0 Spacer Screw Mount, Front, Rear Rack, LH Mount, Front, Rear Rack, RH /00 A
FRONT RACK and BUMPER MOUNTING 0 Screw 00 Asm., Rack, Front (Incl. Ref. & Warning Decal) 00 Reflector, Amber Screw 00 Kit - Front Rack Mount Nut, Nylok 0 Washer -00 Bumper Screw 0 Screw Washer -0-0 Support, Front Rack, LH Support, Front Rack, RH Screw 000 Headlight, LH Headlight, RH Bulb, Replacement, W Bolt 0 Washer, Flat Plug, Frame -0-0 Extension, Frame, LH Extension, Frame, RH -0 Guard, Brush 0 0-0 Grill, Brush Guard 0 Rivet, Pop 00 Nut, U-Type Shield, Side, Radiator, LH Shield, Side, Radiator, RH Screw /00 A
DECALS RH 0 LH 0 Decal - Rack/Warning 0 Decal - Load Distribution, W 0 Decal - x ISD, RH 0 Decal - POLARIS, Side Panel 0 Decal - Age Warning, ATV, 000 Decal - Headlight Adjustment 0 Decal - Warning, AWD Switch 0 Decal - Tank Side, RH 0 Decal - Discretionary Warning 0 Decal - Warning, Park Lock 0 Decal - L/C Diesel 0 Logo, Polaris Star 00 Decal - Tank Side, LH 0 Decal - Override Switch, AWD 000 Decal - Auxiliary Engine Shut-Off 000 Decal - Diesel Fuel Only 00 Decal - Passenger Warning 0 Decal - Tire Pressure 0 Decal - x ISD, LH 0 0 Decal - Warning, General, CPSC 00 Decal - MacPherson Strut /00 A
COOLING SYSTEM 0 0 0 00 Clamp, Hose 00 Cap, Pressure Filler, Coolant 0-0 Bracket, Filler, Coolant Rivet 0 Flexguard Hose, Engine, Upper 00 Clamp, Screw Hose, Filler Neck 00 Clamp Screw Asm., Fan and Motor 0 U-Clip 00 Cable Tie 0 Nutsert 0 Mount, Rubber 00 Spacer 0 Shroud, Fan 0 000 Cable Tie 0 Sensor, Thermal w/harness 00 Radiator 0 Washer, Split Lock Screw Cover, Radiator 0 O-Ring 0 Valve, Drain Bushing, Mount 0-0 Bracket, Radiator, Lower 0 Screw 00 Cable Tie Hose, Engine, Lower 0 Plastic, Guard, Hose 000 Clamp, Hose Screw 0 Cap, Overflow, Drilled Gasket, Overflow Cap Plug, Cap Tank, Surge 0 000- Line, Fuel 00 Fitting, Barbed, 0 Degree Screw /00 A
ENGINE MOUNTING 0 0 0 - - - - - - - Bolt (See Cylinder Pg. D, Ref. ) - - - - - - - Cover, Governor (See Cylinder Pg. D, Ref. ) - - - - - - - Gasket, Cover (See Cylinder Pg. D, Ref. ) 0 Engine (DWPLE0) -0 Mount, Engine, Top 0 Mount, Rubber, Top Nut, Flange Lock Screw 0 Cable, Ground, Engine Bolt 0 Washer, Spring Lock 00 Clamp, Nylon Rivet, Pop -0 Strap, Frame Support 0 Spacer 0 Cable, Battery, Red 0 Nut, Flange 00 Clamp, Narrow Band Screw 0 00 Cable, Battery/Ground Boot, Clutch Intake A Washer 0 Mount, Rubber, Front 0 Bushing Washer, Flat 0 Washer, Interlock Bolt - - - - - - - Asm., Drive Clutch, ATV-0 (See Drive Clutch Pg. C, Ref. ) 00 Screw and Washer 0 - - - - - - - Bracket, Retainer, Seal (See Clutch Cover Pg. C, Ref. ) 00 Clamp, Hose Screw 0-0 Mount, Engine, Front 0 Washer, Wrought AR Hose, Chafe Protected 00 Clamp, Hose - - - - - - - Gasket, Exhaust (See Cylinder Pg. D, Ref. 0) 00-0 Manifold, Black 000 Washer, Lock 0 00 Nut /00
EXHAUST SYSTEM Nut, Nylok Washer, Flat Washer, Rubber Washer 0 Bushing - - - - - - Bracket, Silencer, Frame (See Rear Rack Mounting Pg. A, Ref. ) Dampener, Vibration Bolt, Carriage A 0-0 Silencer, Exhaust Bolt 00 Spring, Exhaust Screw Washer Shield, Heat, Exhaust 0-0 Pipe, Exhaust 0 Seal, Exhaust /00
FUEL TANK 0 0 Screw Washer - - - - - - - Tank, Surge Nut 00-00 AR Line, Fuel 000 Clamp, Hose 00 T-Connector 00 Asm., Fuel Filter 000 Packing 00 Plug 00 Asm., Fuel Tank (Incl.,,) 00 Elbow Cap, Gas w/gauge Gasket, Fuel Cap Seal, Foam 000-00 AR Line, Fuel Vent, Tank Screw 0 Washer, Spring Lock 0 0 Washer, Flat -0-0 Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH 0 Nutsert Pad, Fuel Tank Bracket 000-00 AR Line, Fuel 0000 Clamp, Hose, Red 0 Fitting, Outlet 0 Screw Knob, Fuel Valve Nut, Fuel Valve 0 0 Valve, On/Off /00 A
AIR BOX 0 Sleeve, Pre Cleaner 00 Filter, Air Intake 00 Clamp, Narrow Band 0 Collar, Carb Inlet Cover, Air Box Screw Duct, Air Inlet Gasket, Intake Seal, Air Box Cover Seal, Foam 0 Duct, Clutch Air Inlet 00 Clamp, Hose 00-00 AR Line, Breather 00 Filter Line, Breather 00 Clamp, Hose Box, Air 0 Gasket, Carb Inlet Duct Duct, Intake Inlet 0 Line, Breather Plug, Trap 00-0 AR Line, Fuel 000 Clamp, Hose 0 Foil 0 Washer, Flat Screw 0 Clip, Air Box /00 B
CV JOINT - BTB BTB 0 Asm., CV Housing w/sleeve Sleeve, Drive Shaft Seal 0 Clamp, CV Joint, Large 00 Circlip Boot 00 Shaft(Incl.) 00 Cardan (Incl.,,,) 00 Kit - Cross and Bearing 00 Yoke, Splined Pin, Spring 00 Clamp, Band, Small 00 Kit - Boot, CV Joint (Incl.,,) 00 Kit - Drive Shaft w/sleeve, BTB / B
REAR DRIVE SHAFT 0 Asm., Drive Shaft, Rear (Incl. -) 00 CV Joint 00 Clamp, Large 00 Grease, 0g 00 Boot 00 Clamp, Small 00 Grease, 0g 0 Joint, Plunging 00 Ring, Spring 0 Kit - Boot (Gear Side) 0 Kit - Boot (Wheel Side) / B
PROP SHAFT 0 Asm., Prop Shaft Pin 000 End, Yoke 00 Unit, Pack 00 Bar, Shaft 00 Slip, Yoke 00 Fitting O-Ring /00 B
FRONT STRUT 0 0 Bumper 0 Strut, Front Washer 0 Washer, Flat 00 Clamp, Rubber Coated 0 Nut, FLEXLOC Screw 0 Washer, Spring Lock Retainer, Strut Casting Wire - - - - - - - - Asm., Front Brake Caliper, RH (See Front Brake Pg. B) 0 Bearing, Tapered Roller 0 Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal 000 Fitting, Lubrication Coil, Magnetic 0 0 Asm., Hubstrut, LH (Incl.,-,) Asm., Hubstrut, RH (Incl.,-,) 0-0 Spring, Compression Retainer, Spring Ball, Pivot, Bottom 0 Bolt 0 Spacer - - - - - - - Kit - Drive Shaft w/sleeve (See CV Joint - BTB Pg. B, Ref. ) 0 Seal, Hubstrut Ball, Pivot, Top Spacer, Rubber Washer Nut, Nylok /00 B
FRONT WHEEL 0 Bolt Disc, Brake 0 Seal, Front Hub Plate, Armature 0 Clutch, Front Hub, Elec./Mech. 0 Bearing, Tapered Roller Cone 0 Bearing, Tapered Roller Cup Stud 0 Asm., Hub w/bearing Race (Incl.,,) 00 Cage, Roll 00 Roll 00 Spring, Garter B Spacer 000 Cam 00 Plug, Magnetic Drain Tire (x-) 00 Washer Nut, Slotted 0 Pin, Cotter 0 0 O-Ring Cap, Hub Screw Nut, Flange Lock 0- Rim, Front 0 Valve, Rim /00
FRONT BRAKE Asm., Front Brake Caliper, LH (Incl. -,-,-) Asm., Front Brake Caliper, RH (Incl. -,-,-) 00 Screw, Bleeder Screw, Socket Set 0 Caliper,Brake,LH Caliper,Brake,RH Kit - Front Brake Pad 0 Kit - Piston and Seal (Incl. -) Square Ring, Molded (.0) 0 Square Ring, Molded (. x.) Piston, Brake, Long 0 000 0 Kit - Front Brake Pad, General Duty Kit - Front Brake Pad, Severe Duty Kit - Front Brake Pad, Soft Duty Mount, Caliper Boot, Bushing Boot, Pin Seal - - - - - - - Washer, Flat (See Front Strut Pg. B, Ref. ) - - - - - - - Washer, Spring Lock (See Front Strut Pg. B, Ref. ) - - - - - - - Screw (See Front Strut Pg. B, Ref. ) /00 B
CONTROLS - THROTTLE ASM./CABLE O-Ring 00 Cable, Throttle O-Ring 0 Cover, Throttle Control 0 Asm., Throttle Control (Incl. -) 0 Asm., Throttle Clamp /00 B
CONTROLS - MASTER CYLINDER/BRAKE LINE 0 000 000 Asm., Master Cylinder (Incl. -,-) Kit - Master Cylinder Reservoir (Incl. -,) 0 Bolt, Cap 0 Cap, Reservoir 0 Diaphragm 000 Kit - Master Cylinder Clamp 0 Asm. Piston Master Cylinder 00 Rivet 0 Kit - Brake Lever, w/parking Latch (Incl. -) - - - - - - - Spring, Flat 00 Kit - Park Brake Lever (Incl.,) 00 Nut 0 Bolt, Reservoir 00 Bolt 0 Ring, Square, Reservoir B Boot, Brake Line, Rubber Seal Switch - - - - - - - Line, Brake, Rear (See Rear Brake/ Foot Pedal Pg. C, Ref. ) Rivet, Pop 00 Clamp, Nylon 0 00-0 Conduit 0 Line, Brake, Left Front w/fittings 00 Cable Tie Screw 00- Tubing, Convoluted 0 Line, Brake, Right Front w/fittings 0 Fitting, Inverted Flare Cross 0 Line, Brake, Pod 0 Bolt, Banjo /00
STEERING POST 0 Asm., Steering Post (Incl.,) 00 Clip Bushing, Steering, Console 00 Fitting, Lubrication Bolt Washer O-Ring Spacer, Steering Post 0 Nut B Pin, Cotter 0 Bushing, Steering, Lower Rivet Plug, Grease, Steering 00 Fitting, Lubrication Bushing, Steering, Upper -0 Bracket, Upper Steering Bushing Nut, Nylok /00
HANDLEBAR and HEADLIGHT POD 0 0 0 B
HANDLEBAR and HEADLIGHT POD 0 Speedometer, Kilometer 0 000 000 Plug, Indicator Indicator, Hot Temperature Indicator, Neutral/Reverse Screw 00 Nut, U-Type 0 Harness, Headlight Pod - - - - - - Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B, Ref. ) -0 Tube, Handlebar 00 Kit - Handlebar Block (Incl. Blocks and,,0) Block, Handlebar Retainer 0-0 Nut, Brass Washer, Lock Washer, Flat Screw 0 Clamp, Speedometer 0- Pod, Headlight, Upper, Bonnie Blue - - - - - - - Asm., Master Cylinder (See Controls - Master Cylinder/Brake Line Pg. B for details) Spacer, Switch, LH 0 Switch, Handlebar 0 Grip, Handlebar Plug 0 Screw 0-0 Bracket, Pod Mounting Screw 00 Knob, Adjusting Boot, Headlight 00 Collar, Locking 00 0 Lens and Reflector Bulb, Headlight, Halogen 00 Rod, Adjusting O-Ring 00 Cable, Fuel Shut-Off 0 Nut, Nylok 00 Nut, U-Type 0 Receptacle, Pod Mount, V 00 Clip, Cable Retaining 0 Screw -00 Pod, Headlight, Lower 0 0 Cover, Key 00 Nut, Choke Slide 0 Sensor, Hall Effect Cap, Hall Sensor 0 Screw Switch, Ignition (Incl. Key) Key, Blank, Series 000, 00, 00. NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. Key, Blank, Series 00, 00, 00, 00. NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. /00 B
OIL TANK To Airbox To Lower Oil Pump Fitting on Engine To Top Oil Pump Fitting on Engine 0 Screw Plate, Vent, Oil Tank 00 Gasket, Oil Reservoir 0 Fitting AR Line, Breather Dipstick O-Ring Washer, Copper 0 Tube, Banjo Return Bolt, Banjo 0 Tube, Banjo Intake 000 Screen, Oil Filter B Tank, Oil, LH Nut, Nylok Grommet Grommet, Mounting, Reservoir 0 Bushing 0 Washer, Flat 0 Screw 0 0 Plug, Mag. 0 Washer, Nylon Screw Tank, Oil, RH /0
FRAME MOUNTING Pin, Clevis Arm, Shift Tube, Pivot, Internal Bushing 00-0 Shift, Pivot, Low Range 00-0 Shift, Pivot, High Range Screw Screw Nut, Nylok Pin, Cotter Arm, Shift Pin, Clevis /00 B
A-ARM/STRUT MOUNTING 0 0 0 Nut, FLEXLOC Bushing 00 Asm., Tie Rod Boot, Seal, Rod End 0 Rod End Nut 00 Tie Rod 0 Nut, Jam, LH Bolt 0 Rod End, LH 0 Boot, Seal, Rod End 0 Washer, Flat 0 Nut Pin, Cotter 00 Joint, Ball Bracket, Ball Joint Screw Boot, Rubber Nut, Castle 0 Shield, CV Joint, LH Shield, CV Joint, RH Screw 0 Bushing, A-Arm, Long 00 Bushing 00 Shaft, A-Arm 00 00 Kit - A-Frame, LH Kit - A-Frame, RH 00 Fitting, Lubrication - - - - - - - - Asm., Heavy Hubstrut (See Front Strut Pg. B, Ref. ) Screw 0 Washer, Spring Lock 0 Bolt Screw /00 C
DRIVE CLUTCH 0 Clutch, One Way Drive 00 Washer Spacer 0 Nut, FLEXLOC Button, Clutch, Stemless 00 Pin, Roller Bearing 0 Nut, Jam Cover, Bearing 0 Washer, Spring Lock Bolt 0 Spring, Clutch Roller and Bushing 0 Washer, Multilube Bolt, Shoulder 0 Weight, Shift, D0 Asm., Drive Clutch (Incl. All Less,) 00 Washer /00 C
DRIVEN CLUTCH 00 Spacer 0 AR Bushing 0 Asm., Driven Clutch (Incl. -,-) 0 Washer 0 Bushing Ring, Retaining 0 Washer, Domed 0 Washer, Spring Lock Bolt Belt, Drive Screw 00 Roller, Taper, Engine Brake Bearing Washer Bearing, Moveable, 0 Spring, Clutch Ramp, Stationary Spacer Ring, Retaining / C
CLUTCH COVER 0 0-0 Bracket, Clutch Cover, Rear 0 Bolt 0 Seal, Clutch Cover, Trans. 0 Kit - Inner Clutch Cover (Incl.,,,) Washer, Rubber 0 Washer, Split Lock Bolt Bolt Screw 0 Seal, Clutch Cover - Cover, Clutch, Outer 00 Clip, Clutch Cover Screw 0 Decal - Clutch Cover 0 Decal - Automatic/EBS, Clutch 00 Cable Tie Boot, Clutch Duct, Air Outlet Screw 0 - - - - - - Bolt & Washer (See Crankcase Pg. D, Ref. ) 00-0 Bracket, Retainer, Seal Seal, Cover Case Screw -0 Bracket, Clutch Cover Washer 00 Clamp, Narrow Band - - - - - - - Duct, Air Inlet, Clutch (See Airbox Pg. B, Ref. ) /00 C
C ELECTRICAL/TAILLIGHT 0 0 0
ELECTRICAL/TAILLIGHT 0 Harness, Main 00 Kit - Circuit Breaker, 0 AMP 0 Asm., Taillight w/brake Light (Incl. -) 00 Lens, Taillight 00 Screw, Taillight 000 Bulb, Taillight 00 Gasket, Taillight 00 Backing, Taillight/Brake Light 00 Nut, Speed 0 Harness, Jumper 0 Pad, Battery 0 Cable, Battery, Red Cover, Battery 000 Kit - Battery Bolt, Long 0 Cable, Battery/Battery, Black Strap, Battery Holddown 00 Hook, Battery Strap 0 AR Tube, Vent, Battery 000 Battery 0 0 Retainer, Battery 0 Cable, Battery/Battery, Red 00 Battery, 0 AMP Pad, Battery 0-0 Battery Box Pad, Battery, Side Nut, Nylok 0 Washer, Flat 0 Screw 0 Kit - Battery Bolt 0 Strap, Battery Hold Down 00 Cable Tie, 00 Cable Tie 0 Plug, Power, V 0 Pigtail, Power Sink, Heat 0 Anti-Rev. Rotational Mod LR00 000 Cut-Off, LR, VDC 0 Limiter, RPM, LR0 Screw 0 00 Spacer Screw 0 Regulator/Rectifier Screw 0 Harness, Resistor /00 C
C REAR SUSPENSION 0 0 0 0 0 0
REAR SUSPENSION Bolt 0-0 Arm, Stabilizer Bar Nut, Nylok Screw Washer, Flat Bushing, Stabilizer 00 Rod, Linkage, Stabilizer 00 Shaft, A-Arm, Short 0 Bushing, A-Arm, Short 00 Bushing 00 Fitting, Lubrication Screw -0 Bar, Stabilizer Tube Washer Bushing, Stabilizer Tube 0 Washer, Flat Screw 0 Washer, Spring Lock -0 Support, Stabilizer 0 0 Nut, FLEXLOC 0-0 Bracket, A-Arm Pivot Screw Nut, Flange Bolt -0 Support, Transmission 0 Washer, Spring Lock 0 Retainer, Spring 0-0 Spring, Compression, Rear 0 Cam, Adjusting, Spring 0 00 Shock, Rear Screw 0 Bushing, A-Arm, Long 00 Shaft, A-Arm -0-0 Arm, Control, Lower, LH Arm, Control, Lower, RH Nut, Nylok 0 Bushing, Control, Lower 00-0 0-0 Arm, Control, Upper, LH Arm, Control, Upper, RH Bushing, Bearing Carrier Washer 0 Screw 0 0 Shield, LH Shield, RH Screw Carrier, Wheel Bearing 0 Bearing, Wheel Carrier 00 Fitting, Lubrication /00 C
REAR BRAKE/FOOT PEDAL 0 C
REAR BRAKE/FOOT PEDAL Screw 0 Washer, Spring Lock 0 Washer, Flat 0 00 0 0 Caliper, Brake Kit - Brake Pad (Incl. Spacer, Pin) Kit - Caliper Seal Kit - Bleeder Replacement Piston, Stepped Bore 0 Line, Rear Brake 0 Line, Brake, Caliper w/fittings Bolt 0 Reservoir, Rear Brake Nut Hose, Reservoir 0000 Clamp, Hose 0 Bolt 0 Washer, Flat 0-0 Mount, Brake Nut, Nylok 00 Spring, Torsion Washer Bushing, Pivot, Pedal -0 Rod, Brake 0 00 Washer, Spring 0 Pin, Cotter Screw 0 Master Cylinder, Brake, Rear Asm., Brake Disc 0 Washer, Spring 0 Nut, Nylok /0 C
REAR WHEEL DRIVE 0 Pin, Cotter Nut, Flange Lock Hub, Rear Wheel - - - - - - - Carrier, Bearing, Wheel (See Rear Suspension Pg. C, Ref. ) 0 Ring, Retaining Stud Tire, Tracker P (x-) 0 Valve, Rim 0- Rim, Rear Washer, Cone 00 Nut, Castle Cover, Dust, Hub / C
PARK BRAKE 0-0 Bracket, Park Lock Spacer, Park Lock Pin, Clevis Lever, Park Lock Pin, Cotter Washer Bracket, Shift Link Washer, Wave Washer, Flat Screw Nut, FLEXLOC Washer, Flat Handle, Park Lock C Spring, Return Linkage, Park Lock 00 Clevis, Threaded Pin, Cotter Pawl, Park Lock Pin, Cotter 0 0 Bushing Pin, Clevis 0 Bushing 0 Washer, Wave Nut Screw Bolt /
THREE-POINT HITCH A-ARM MOUNTING 0 Screw 0 0 Mount, A-Arm, LH Mount, A-Arm, RH 0 Nut, Nylok Pin, Bent Clip Plate, A-Arm, Top / C
GEARCASE (Cases and Snorkel) 0 0 - - - - - - - Asm., Gearcase (See Gearcase, Internal Components Pg. D) Seal Decal - Switch Seal Screw Gearcase, LH Pin, Dowel 0 Vent Dipstick, Plastic Screw, Tapping Switch, Gear, Position Switch, Gear, Position Bolt - - - - - - - Washer (See Gearcase, Internal Components Pg. D, Ref. ) Washer Gear, T, Extended - - - - - - - Ball Bearing (See Gearcase, Internal Components Pg. D, Ref. ) Shaft, Drive, Snorkel 0 O-Ring C 0 Snorkel 0 0 Bearing, Ball Spacer (.0x.x.0) Spacer (.0x.x.0) Spacer (.0x.x.00) Spacer (.0x.x.00) Spacer (.0x.x.00) NOTE: Ref. indicates choices, may also be used in combinations. 0 Ring, Retaining Bolt Lock, Gear, Snorkel, Bolt Seal Bushing Nut, FLEXLOC Stamping, Cover Plate Washer, Lock 0 Screw Plug, Drain Washer, Plug Gearcase, RH 0 Screw /00
D GEARCASE (Internal Components) 0 0 0 0 0
GEARCASE (Internal Components) 0 Asm., Gearcase (Incl. - and all on Gearcase - Cases and Snorkel Pg. C) 0 Bearing Shaft, Input, HCR 0 Bearing Shaft, Shift O-Ring 00 Washer 0 Ring, Retaining Bellcrank, HLR 0 Washer 0 Nut Shaft, Shift Fork, Shift, Low Fork, Shift, H/R Screw 0 Pin, Interlock 0 Bracket, Interlock Spring Ring, Retaining Washer 0 Bearing, Needle Gear, 0T 0 Ring, Retaining Engagement Dog, High/Rev. Sprocket, T 0 Chain, Silent, P Shaft, Reverse, T Engagement Dog, Low Gear, T 00 Bearing 0 Shaft, Center Drive 0 Gear, Output, 0T, HCR Screw 0 Washer, Spring Lock Cover, Center Drive Bearing Ring, Retaining Bearing, Ball Gear, T, Spiral Bevel, Snorkel Screw Deflector, Oil 0 Cam, Chain Tensioner Shoe, Chain Tensioner Pin, Dowel Spring, Torsion Bearing, Ball 0 Shaft, 0T 0 Chain, Silent /00 D
FRONT HOUSING 0 Asm., Front Gearcase (Incl. -,-) Screw Seal 0 Cover, Front Housing Input 00 O-Ring Ring, Retaining Bearing, Ball Pinion, Input Bushing Seal Bushing Washer Plug, Oil Fill 00 Clip, Snap In 000- AR Line, Fuel D 000 Clamp Tube, Vent Gearcase Shaft, Output 00 Bearing, Ball 0 AR Shim O-Ring Cover, Output, Front Housing AR Shim Button, Thrust Washer, Plug Plug, Drain Screw 0 Washer /
GEAR SELECTOR 0 Asm., Gear Selector (Incl. -,-) Asm., Knob Screw Screw Strap, Wire Cover, Gear Selector Boot Handle, Gear Selector Sphere, Plastic Pin, Groove Pin, Dowel Spring, Detent 00 Bullet, Detent 0 O-Ring Slide, Low 0 Nut, FLEXLOC 0 Rod End, RH 0 Nut, LH 0 Rod End, LH Rod, Shift Linkage, Low-Range 00 Rod, Shift Linkage, Hi-Range 0 0 Nut, RH 0 Slide, High/Reverse Body, Gear Selector Spring, Centering /00 D
CRANKCASE 0 0 00 Pin, Dowel 0 Asm., Crankcase (Incl.,,,,,-,,) 0 Pin, Straight 0 Bearing, Ball 0 Seal, Oil 0 Pipe, Air Breather 0 Union 00 Pin, Dowel 0 Plug 0 Gasket, Aluminum 0 Spring, One Way Valve 0 Valve, One Way 0 Gasket, Cover D 0 Pipe, Water 0 Seal, Oil 0 Bearing, Ball 0 Bearing, Ball 0 Bolt, Flange 00 Bolt and Washer 0 0 Plug 0 Gasket 00 Cover, Flywheel 00 Clamp 0 Seal, Mechanical 0 Bolt, Flange 0 O-Ring /00
CRANKSHAFT and PISTON 0 0 Clip 0 Pin, Piston 0 0 0 Asm., Piston Set (Std) (Incl.,) Asm., Piston Set (0.mm O/S) (Incl.,) Asm., Piston Set 0 0 0 (0.0mm O/S) (Incl.,) Piston Ring Set (Std) Piston Ring Set (0.mm O/S) Piston Ring Set (0.0mm O/S) 0 Crankshaft 000 Pin, Crank 0 Rod, Connecting 000 Bearing, Large End 00 Ball, Steel 0 0 Asm., Crankshaft (Incl. -,) Crankshaft D 0 Balancer Gear 0 Balancer Shaft 0 0 0 Spacer (0.) Spacer (.0) Spacer (.) 00 0 0 0 Spacer (0.) Spacer (0.) Spacer (.0) Spacer (.) 0 Sprocket 00 Nut, Slit 00 Washer 00 Nut, Lock 0 Pin, Dowel 0 0 Key 000 Key, Woodruff /00
CYLINDER 0 0 D
CYLINDER 0 Gasket, Rocker Cover 00 Plug 0 Gasket 0 Stud 0 Bolt, Flange 0 Cover, Governor 00 Gasket, Cover 0 Seal, Oil 0 Cover, Rocker (Incl.,) 0 Bolt, Flange 00 Stud 0 Head, Cylinder (Incl.,,,,0,,) 00 Adapter, Water Out 0 Seal, Intake Valve 0 Bolt, Flange 0 Bolt 0 Adapter, Camshaft 0 Seal, Exhaust Valve 0 Bolt, Cylinder Head 0 00 Pin, Dowel 0 Plug, Blind 0 Pin, Straight 0 Union, Oil Pump 0 Bolt, Flange 0 Cylinder (Incl. ) 00 Pipe, Elbow 0 Bolt, Flange 00 Gasket, Cylinder 0 Bolt, Flange 0 00 Gasket, Exhaust 00 Nut 000 Washer, Spring 000 Stud 0 0 0 0 00 0 0 0 0 0 0 0 Adapter 00 Band, Adapter 0 Screw 00 Bolt,SocketHead 0 Bolt Gasket, Head (.) NOTE: Referto the service manual for measuring procedure to determine the proper head gasket thickness. Do not attempt to measure the old gasket. Gasket, Head (.0) Gasket, Head (.) Gasket, Head (.) Gasket, Head (.) Gasket, Head (.) Gasket, Head (.) Gasket, Head (.) Gasket, Head (.) Gasket, Head (.) Gasket, Head (.) / D
INTAKE and EXHAUST 0 D
INTAKE and EXHAUST 0 Spring, Valve 0 Retainer, Valve Spring 00 Collet, Valve 0 Lifter, Valve 0 0 0 0 0 0000 000 000 000 000 000 000 000 000 000 00 00 00 00 00 00 00 00 00 00 000 00 00 Shim, Valve (.00) Shim, Valve (.0) Shim, Valve (.00) Shim, Valve (.0) Shim, Valve (.00) Shim, Valve (.) Shim, Valve (.0) Shim, Valve (.) Shim, Valve (.00) Shim, Valve (.) Shim, Valve (.0) Shim, Valve (.) Shim, Valve (.00) Shim, Valve (.) Shim, Valve (.0) Shim, Valve (.) Shim, Valve (.00) Shim, Valve (.) Shim, Valve (.0) Shim, Valve (.) Shim, Valve (.00) Shim, Valve (.) Shim, Valve (.0) Shim, Valve (.0) Shim, Valve (.00) Shim, Valve (.000) Shim, Valve (.0) Shim, Valve (.00) 0 0 00 Camshaft(Incl.) Camshaft(Incl.) Camshaft(Incl.) 0 Pin, Dowel 00 Clip 00 Spring, Return 00 O-Ring 00 Lever, Decompression 0 Guide, Chain 0 Bolt, Pivot, Lever 0 Lever 0 Plate, Thrust 0 Bolt, Flange 00 Plate, Governor 0 Sprocket 00 Chain, Timing 0 00 Valve, Intake 0 Valve, Exhaust 0 Gasket, Tensioner 00 Asm., Tensioner (Incl. -) 0 Bolt, Flange 00 Spring, Tensioner 00 Gasket, Plug 0 Plug / D
GOVERNOR 0 0 D
GOVERNOR 00 Governor Lever 0 Stopper Unit 00 O-Ring 00 Spring, Return, Stop 0 Nut 00 Screw, High Idle 00 Plug 0 Gasket 0 Screw, Adjusting 00 Plug, Blind 0 Nut, Flange 00 Washer 0 Spring, Return 00 Lever, Stop 00 Control, Speed 00 Link, Pivot 00 Spring, Governor 0 Governor Lever 0 Spacer 0 00 Clip 00 Washer 000 Spacer 00 Boot, Planger 0 Bolt, Flange 00 Bracket, Solenoid 00 Pin, Spring 0 Solenoid 0 Band, Wire 00 Screw, Idle 0 00 Spring, Control 000 Washer 0 Governor Lever Unit 00 Spring, Rod 00 Rod, Governor 00 Governor Lever 00 Spring, Start /00 D
WATER PUMP 00 Bolt 00 Cover, Water Pump 000 Gasket, Water Pump 00 Nut, Self Lock 0 Gasket 0 Impeller 0 Washer, Seal 0 Gasket, Aluminum 0 Bolt, Flange 0 Clamp, Hose 00 Hose, Main 0 Switch, Thermostat 00 Thermostat / D
INJECTION PUMP 0 Nut, Flange 00 Bracket, Nozzle 00 Gasket, Nozzle 00 O-Ring 00 Nozzle 00 Pipe, Injection 00 Bolt, Eye 00 Gasket, Pump 000 Banjo 0 Nut, Flange 0 Bolt and Washer 00 Injection Pump 00 00 00 Gasket (0.) Gasket (0.) Gasket (0.) /00 D
OIL PUMP 0 Oil Pump Case 0 Rotor, Outer (Feed) 0 Rotor, Inner (Feed) 00 0 0 Screw 0 Pin, Dowel 0 Pin, Dowel 0 Washer 0 Bolt and Washer Asm., Oil Pump (Incl. -,-) Oil Pump Case E 0 Pump, Oil Pump Case 00 Rotor, Inner (Scav) 0 Rotor, Outer 0 Oil Strainer Unit 00 Screw and Washer 0 Shaft, Pump 0 Pump Gear 0 00 0 AR AR AR Spacer (0.) Spacer (.0) Spacer (.) /00
OIL FILTER 0 Oil Filter 0 Gasket, Aluminum 0 Oil Delivery Pipe 0 Bolt, Banjo 0 Oil Delivery Pipe /00 E
MAGNETO 00 00 Asm., Magneto (Incl. ) Flywheel w/ring Gear 00 Ring Gear 0 Clamp 0 Bolt and Washer 00 Stator 0 O-Ring 0 Bolt and Washer /00 E
STARTING MOTOR 0 00 Gasket, Motor 00 Asm., Starting Motor (Incl. -) 00 Bolt, Joint 00 Grommet 00 Gasket, Cover 000 Cover, Motor 00 Bolt and Washer 0 Gasket, Aluminum 0 Plug 00 Wire 00 Bolt, Flange 0 Stopper, Pinion 0 Stopper, Pinion 0 Pinion Set (Incl. ) E 0 Bracket, Front 0 Switch 00 Asm., Clutch Shaft (Incl. -,,) 0 Lever Set 0 Clutch, Over Running 0 0 Packing 0 Ball 0 Bearing, Sleeve 0 Bolt 00 Asm., Rear Bracket (Incl. ) 0 Asm., Brush Holder (Incl. ) 0 Brush Set 0 Armature 0 York /00
TOOL KIT 0 Asm.,ToolKit(Incl.-) 0 Gauge, Tire Pressure 0 Screwdriver 0 Wrench, - Spanner 00 Pouch, Tool Kit Lube, U-Joint, oz., Case 0 Owner s Manual, Diesel Supplement, Owner s Manual, Diesel -0 Wrench, Spanner, Cam 0 Pigtail, Power /00 E
PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN /00
Changed pages in A cover toc spec publ B x C D E F G