RANGER Model #ARF0AA Rev. 0 E 00 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN 0 /0
A A- ARM/STRUT MOUNTING... C AIR BOX... A BRAKE LINES... B C CAB FRAME... A CARBURETOR... D- CHASSIS\BODY... A CLUTCH COVER... C0 CONSOLE... A COOLING SYSTEM... A CRANKCASE... D CRANKSHAFT and PISTON... D0 CYLINDER... D- DECALS... DRIVE CLUTCH... DRIVE SHAFT, FRONT... DRIVE SHAFT, MID AXLE (LH)... DRIVE SHAFT, MID AXLE (RH)... DRIVE SHAFT, TAIL... DRIVEN CLUTCH... D E TABLE OF CONTENTS Parts Manual C A0 C B B0 B B C ELECTRICAL / BATTERY... B ENGINE MOUNTING... B- EXHAUST SYSTEM... B F FOOT BRAKE... C FRONT BRAKE... B FRONT HOUSING... D- FRONT STRUT... B FRONT WHEEL... B FUEL TANK... A GEAR SELECTOR... G GEARCASE (CASES & SNORKEL)... G D D GEARCASE (INTERNAL COMPONENTS)... D- HOOD H... INSTRUMENT PANEL... INTAKE and EXHAUST... I M MAGNETO... MID ANGLE DRIVE... MIDDLE BRAKE / PARKING BRAKE... MIDDLE SHOCK MOUNTING... MIDDLE WHEEL DRIVE... MOLDING AND SEAT... OIL FILTER... OIL PUMP... OIL TANK... PROP SHAFT... PART NUMBER INDEX... REAR BOX AND SHOCK MOUNTING... REAR BRAKE... REAR GEARCASE... REAR WHEEL DRIVE... RECOIL STARTER... STARTING MOTOR... STEERING... SWING ARM/REAR SHOCK... THROTTLE... TOOL KIT... TRANSMISSION/ENGINE MOUNTING... WATER PUMP O P R S T W... A A E E D C C C A E E A B E-F The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. A C C C E E B C C E B E
E 00 Polaris Sales Inc. CAB FRAME Cab for models built after /0/ 0 Cab for models built prior to /0/ 0 00 0 Cable Tie 0 Pad, Cab Frame, Center/Side Rivet 00- Roof, Cab Frame, RH 0 Pad, Cab, Frame, Front 00- CabFrame,Rear,RH 0 Pad, Cab Frame, Top, Rear 0- Tube, Coupler, Top, Rear 0 Washer 0 0- Tube, Coupler, Rear, Center 0 Washer 0 Bolt 00- CabFrame,Rear,LH Plug, Nylon Bolt A 00- Base, Cab Frame Bolt 0 Bolt Nut 0 00 Spring, Exhaust 00- Roof, Cab, Frame, LH Nut Bolt - - Asm., Backrest, Gray Covering, Backrest, Gray 0- Tube, Cab Frame, Top, Front 000- Cab Frame, Rear (For models manufactured prior to /0/) 00- Cab Frame, Front (For models manufactured prior to /0/) 0/00
CHASSIS\BODY 0 0 0 0 0 0 Mat, Floor 0-0 0-0 Bracket, Body, Front, Top, LH Bracket, Body, Front, Top, RH 0 Rivet -0-0 Body (If Built prior to /0/) Body (If Built after /0/) Nut -0-0 Bracket, Fender, Rear, LH Bracket, Fender, Rear, RH 0 Washer 0-0 Plate, Mount, Shifter Nutsert 0 Bolt 0 Bumper, Rubber 00-0 Brace, Upper Chassis 000-0 Chassis, Upper Screw 00-0 Shock Tower, Mid-Axle A 0 00-0 Chassis 000-0 Brace, Engine Compartment 00-0 00-0 Support, Strut, LH Support, Strut, RH Rivet 0-00 End Cap, Bumper, Front Nut Bolt 0-0 Bumper 0-0 0-0 Footwell LH (If Built after //) Footwell RH (If Built after //) 0-0 Body, Front (If Built after //) 0-0 Body, Rear (If Built after //) -0 Brace, Wheel Well -0 Brace, Floorboard 00-0 00-0 Support, Fender, Front, LH Support, Fender, Front, RH /
MOLDING AND SEAT 0 0 0 Asm., Seat Screw 000 Latch, Seat Belt 0 Washer Nut 000 Belt, Seat, Lap Washer Fender, Box 0 Screw 0 Fender, Rear, LH (Built before Serial Number 0000) Fender, Rear, RH (Built before Serial Number 0000) Fender, Rear, LH (Built after Serial Number 0000) Fender, Rear, RH (Built after Serial Number 0000) Panel, Engine Access, LH Panel, Engine Access, RH 00 Decal - Demand Drive Handle, Access Panel A 00 Pin, Latch, Seat Nut Rivet -0 Support, Access Panel 0 Fender, Front, LH Fender, Front, RH 00 Clip, Dart, Plastic 0 Panel, Wheel Well, Rear, LH 0 Grommet, Mount, Rubber Panel, Wheel Well, Front, LH Liner, Hood 0 Screw 00 Clip, Rosebud Plate, Exhaust, Wheel Well Panel, Wheel Well, RH Rivet 0 Washer 0 Nut /00
CONSOLE 0 - Cover, Instrument Panel, Gray - Console, Gray 00 Decal - Driving Range Boot, Tie Rod, CRC Rivet 0 Tray, Console (If built before //00) Tray, Console (If built after //00) 0 Grommet, Mount, Rubber 0 Rivet 00 Pin, Latch, Seat 0 Nut -0 Plate, Console Lid Rivet Base, Console Lid -0 Bracket, Console Lid 000 Hinge, Console Lid Screw 0 Screw -0 Plate, Boot /00 A
HOOD 0 0 0 0 Harness, Headlight Screw - Hood, E.B. Green Nut 0 Rivet -0 Bracket, Hood Strap 0 Cup, Hood Latch 00 Strap, Hood Latch Bolt 0-0 -0 Hinge, Hood, RH Hinge, Hood, LH -0 Spacer, Hinge 0 Nutsert 0 Decal - Headlamp Information Washer 0 Washer -0 Bracket, Headlight A Washer 0 Nut 0 Bolt 0 00 Cable, Hood Retainer Screw 00 Spring, Extension Rivet 00 Clamp, Retainer 000 000 00 000 000 Nut -0 Mount, Hinge Screw 0 Rivet Headlight, Single Beam, Fog Bulb/Harness, High Beam Bulb, Cargo Lamp Headlight, Single Beam, W Bulb, Replacement /00
REAR BOX AND SHOCK MOUNTING 0 0 - Panel, Side, Box, LH 00- Box, Flatbed Nut 00- Latch, Box Bolt 0 Screw Screw 00-00- Cap, Front Panel, RH Cap, Front Panel, LH - Panel, Side, Box, RH 0 000-00- Cap, Rear Panel, RH Cap, Rear Panel, LH Pad, Tailgate 0 Screw 0 Pin, Clevis Pin, Hitch A 0 Shock, Dump Box 000-0 Pin, Hinge, Box 0 Screw 00- Tailgate 00 Spring, Latch, Tailgate 0 Handle, Tailgate Washer, Flat Screw 00 Pivot Rod 00 Cable, Tailgate 00 Pivot Rod, Tapered 0 Nut U-Bolt 0 Washer 0 Nut /0
INSTRUMENT PANEL 0 0 0 00 Meter, Hour 0 Ignition Key w/cap NOTE: When ordering ignition key PN 0 be sure to specify if for an A,B,C,D, or E switch. Letter code will be labeled on underside of switch body behind console. Key dot code found on key cap (i.e. one dot = A, two dots = B, etc.). 0 Nut - - - - - - - Decal - Passenger Warning (See Decal Pg. A0, Ref. )) 000 Indicator, Neutral/Reverse 000 Indicator, Brake Warning 000 Indicator, Hot Temp - - - - - - - Decal - Ignition w/start (See Decal Pg. A0, Ref. 0) 0 Plug, Hole, Eaton Switch 0 0 Switch, Rocker 0 Switch, Hi/Fog Beam 0 0 Asm., Fuel Gauge Fuel Gauge A 00 Asm., Power Plug, V Panel, Instrument 0 Clamp 0 Bolt 0 Washer 0 Washer - - - - - - - Decal - POLARIS, Domed (See Decal Pg. A0, Ref. ) 0 00 Nut Spacer 00 Switch, Ignition 00-0 Support, Instrument Panel Insert Screw Rivet 00 Clip, Rosebud 000 Hinge, Panel 0 Harness, Instrument Panel 0 00 Diode, VDC, AMP /00
DECALS RH 0 LH 0 Decal - POLARIS RANGER 0 Decal - Rider Warning 0 Decal - x 0 Decal - Hood, RH 00 Decal - MacPherson Strut 0 Decal - Warning, Discretionary 0 Decal - Passenger Warning 0 Decal - POLARIS, Domed 0 Decal - POLARIS, Dash Panel 0 00 Decal - Ignition w/start A0 0 Decal - Warning, Safety Belt/Off Road 0 Decal - POLARIS, Hood 0 Decal - Hood, LH 00 Reflector, Amber 0 Decal - Operator/Load Warning 0 Decal - Tire Pressure 000 Reflector, Red 0 Decal - POLARIS 0 Decal - Warning, Cab Frame /
COOLING SYSTEM 0 Main Harness Wire 0 000 Clamp, Hose 00 Clamp, Hose Worm Gear 000-0 AR Hose, Water 000 0 Switch, Thermal (If Built Before /0/) Switch, Thermal (If Built After /0/) Shroud, Fan Cap, Pressure 0 Washer, Flat 0 Washer 0 Bolt 0 00 Radiator, U-Flow 0 Bushing, Mount, Lower Radiator -0 Bracket, Backing, Fan 0 Valve, Drain Cock 00 Spacer, Mount, Radiator A 00 Mount, Rubber, Radiator Nut, Nylok 0 Blade, Fan 00 Motor, Fan w/connectors 00 Nut, Nylok 0 0 Washer -0 Bracket, Cooling Fan Screw Tank, Surge 000- Line, Fuel 00 Fitting, Barbed, 0 Degree 0 Screw Plug, Cap 0 Gasket, Overflow Cap 0 Cap, Overflow Bottle, Drilled /
FUEL TANK 0 0 Underside of Fuel Tank 0 Cap, Fuel, Ratchet 0 Seal, Fuel Cap Inlet, Fuel 00 Clamp, Band, Narrow Hose, Fill, Fuel Pad, Fuel Tank, Bottom 0 Pad, Fuel Tank, Top Tank, Fuel 00 Sender, Fuel w/pickup (If built before //00) 0 Sender, Fuel w/pickup (If built after //00) 0 0 Gasket, Sending Unit A 0 Screw 0000 AR Clamp, Hose (Use Qty. if built before //00 and Qty. if built after //00) 000-00 AR Line, Fuel 000 Filter 0 Decal - Fuel Lever (If built before //00) 0 Screw (If built before //00) Knob, Fuel Valve (If built before //00) Nut, Fuel Valve (If built before //00) 0 Valve, -Way (If built before //00) 0 00 Cable Tie 00 Clamp /00
OIL TANK To Airbox 0 To Lower Oil Pump Fitting on Engine To Top Oil Pump Fitting on Engine 0 0 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Screw Plate, Vent, Oil Tank 00 Gasket, Oil Reservoir 0 Fitting AR Line, Breather Dipstick 0 O-Ring 0 Bolt, Banjo Washer, Copper 0 00 Tube, Banjo Return 000 Screen, Oil Filter Tank, Oil, LH (Side Drain) Body, Oil Tank (Bottom Drain) A 0 Grommet 0 Grommet, Mounting, Reservoir 0 Bushing 0 Washer 0 Washer Bolt 0 Plug, Mag. 0 0 Washer Screw Tank, Oil, RH (Side Drain) Cover, Oil Tank (Bottom Drain) /0
AIR BOX 0 0 0 Decal - Carb Information 0 Decal - Filter Element 0 Cover, Air Box Seal, Air Box Cover 0 Gasket, Carb Inlet Duct Duct, Carb Inlet 00 Clamp AR Hose, Breather 00 Filter, Breather, In-Line 0 00 Clamp, Hose 00 Clamp Boot, Carb, Air Box 00 Clamp, Band, Narrow A 00-00 AR Line, Breather Rivet 0-0 Bracket, Air Box Insert 00 Pad, Battery 00 Box, Air Intake 0 0 Clip, Air Box 0 Collar, Carb Inlet 00 Filter, Air Intake Foam, Filter Screw 0 Washer 0 Washer /
B ENGINE MOUNTING 0 0 0 0
ENGINE MOUNTING 0 Nut 0 Washer, Wrought 00 Cable, Ground, Engine 00 Mount, Motor -0 Mount, Engine, Top 0 Washer, Spring Lock Screw 000-00 AR Line, Fuel 0000 Clamp, Hose, Red 0 00 Cable, Throttle Control 000- AR Line, Fuel 00 Fitting, Tee 00 Cable, Choke Control 00 Cable, Solenoid/Starter 0 Nut, Flange - - - - - - - Asm., Carburetor (See Carburetor Pg. D, Ref. ) 000 Clamp 00-00 AR Hose 00 Cable, Ground/Battery/Engine/Chassis 0 00 Bolt and Washer Screw 0 Washer, Interlock 0 Washer 0 Bushing 0 Boot, Clutch Intake 00 Clamp, Narrow Band 00 Clamp, Hose, Worm Drive 0 Nut, Flange Lock 000-0 AR Hose 0 0 Engine, Short Block (EH0PLE0) NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization required for warranty consideration. 000 Clamp, Hose 000 Pump, Fuel 0 Screw - - - - - - - Gasket (See Cylinder Pg. D, Ref. ) 0-0 Manifold - - - - - - - Washer, Lock (See Cylinder Pg. D, Ref. ) - - - - - - - Nut (See Cylinder Pg. D, Ref. ) 0 Decal - Drain Recoil 0-0 Mount, Engine, Front, Lower 0 Screw 00 Clamp - - - - - - - Bracket, Retainer, Seal (See Clutch Cover Pg. C0, Ref. ) - - - - - - - Screw and Washer (See Crankcase Pg. D, Ref. ) - - - - - - - Asm., Drive Clutch (See Drive Clutch Pg. C For Details) 0-0 Plate, Bolt Thin Coupler 0-0 Bracket, Bolt Plate 00 Washer 0 Screw 0 Washer /00 B
EXHAUST SYSTEM 0 Nut, Nylok Washer 0 Washer, Rubber Washer 00 Bushing 0 Dampener, Vibration Bolt, Carriage 0-0 Silencer, Exhaust 00 Spring, Exhaust 0 0-0 Pipe, Exhaust 00 Spring, Exhaust Rivet -0 Bracket, Mount, Exhaust Pipe 0 Seal, Exhaust 0-0 Headpipe / B
TRANSMISSION/ENGINE MOUNTING 0 Left Side 0 0 0 Screw 0 Washer Screw 00-0 Bracket, Engine/Transmission/Coupler - - - - - - - Screw (See Gearcase Pg. D Ref. ) - - - - - - - Bracket, Mount, Caliper, Rear (See Middle Brake/Parking Brake Pg. C, Ref. ) Coupler, Engine/Transmission 000 Mount, Engine 0 Washer 0 0 Nut, Flange Lock Screw B Washer Washer 00 Mount, Motor 00-0 Mount, Transmission, Rear, RH - - - - - - - Asm. Transmission (See Mid Angle Drive Pg. D, and Gearcase Pg. D) 0 Nut Screw 00 Mount, Rubber, Rear 0 00-0 Mount, Transmission, Rear, Top 00-0 Mount, Transmission, Rear, LH /00
ELECTRICAL / BATTERY 0 First Build Machines Have One Taillight. 0 0 (If built after /0/0) Later Build Machines Have Two Taillights. 0 0 LH 0 RH 00 Nut, Speed Rivet -0 Isolator, Taillight 0 Asm., Taillight 00 Screw 00 Lens 000 Bulb 00 Gasket 000 00 Backing, LH Backing, RH 0 Grommet -0 Bracket, Ignition Coil 00 Screw 0 Coil, Ignition Nut 0 Screw 00 Rectifier, Regulator, LR 00 Cut-Off, LR, VDC Heat Sink Screw 0 Bracket, CDI B 0 Pad, Mount, Rack 0 CDI Pad, Battery, Side 0 Switch, Magnetic 0 Screw D Hook 00 Cable, Positive, Bat./Solenoid/Reg. 00 Vent Tube Clip, Snap In Strap, Rubber 0 0 Retainer, Battery 0 Kit - Battery Bolt (If built before /0/0) 00 Battery, 0 Amp (If built before /0/0) 00 Kit - Battery Bolt (If built after /0/0) 000 Battery, 0 Amp (If built after /0/0) Pad, Battery 00 Cable, Solenoid/Starter 00-0 Box, Battery 0 Harness, Main Wire 0 Taillight, 0 0 Taillight, /0
FRONT DRIVE SHAFT 0 Asm., Front Drive Shaft 00 Kit - Boot Replacement Pin, Spring 0 Yoke 00 Kit - Cross and Bearing Sleeve, Drive Shaft /00 B
TAIL DRIVE SHAFT 0 Asm., Tail Drive Shaft 00 Yoke 00 Kit - Cross and Bearing 00 Shaft, Yoke Boot, Tail Shaft Coupler, Tail Shaft Pin, Spring / B
PROP SHAFT 0 Asm., Prop Shaft 0 Yoke 00 Kit - Cross and Bearing 00 Shaft, Prop 0 Yoke 0 O-Ring Pin, Spring / B
MID AXLE DRIVE SHAFT (RH) 0 Asm., Drive Shaft, Mid Axle, RH 00 Yoke, Wheel End 0 Asm. Joint Cardan 00 Yoke, Tube and Sleeve Boot Clamp, Boot 00 Shaft, Yoke 00 Yoke 0 Pin, Spring / B
MID AXLE DRIVE SHAFT (LH) 0 Asm., Drive Shaft, Mid Axle, LH 00 Yoke, Wheel End 0 Asm., Joint Cardan 000 Yoke, Tube and Sleeve Boot Clamp, Boot 00 Shaft, Yoke 00 Yoke 0 Pin, Spring / B0
FRONT STRUT 0 0 0 Bumper, Strut (Before //) Bumper, Strut (After //) 0 0 Strut, Front (Before //) Strut, Front (After //) Washer 00 Clamp, Rubber Coated 0 Washer, Lock 0 Nut, FLEXLOC Screw 0 Washer, Spring Lock 0 Retainer, Strut Casting Wire 0 - - - - - - - Caliper, Brake (See Front Brake Pg. B, Ref. ) 0 Bearing, Roller, Tapered 0 Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal 000 Fitting, Lubrication w/ball 000 Coil, Magnetic 00 00 Asm., Hubstrut, LH (Incl.,-,) Asm., Hubstrut, RH (Incl.,-,) 0- Spring, Coil, Front Shock 00 Retainer, Spring, Top (Before //) Retainer, Spring, Top (After //) Pivot, Ball, Bottom 0 Bolt 0 0 Spacer (Before //) Spacer (After //) - - - - - - - Asm., Drive Shaft w/sleeve (See Front Drive Shaft Pg.B) 00 Seal, Hubstrut Pivot, Ball, Top 0 Spacer, Rubber Washer 0 0 Nut, FLEXLOC (Before //) Nut, FLEXLOC (After //) B /00
FRONT WHEEL 0 DETAIL A A 0 Bolt Disc, Brake (If built before /0/) 00 Seal, Front Hub Plate, Armature 0 Asm. Clutch, Front Hub, Elec./Mech. 0 Bearing, Tapered Roller Cone 0 Bearing, Tapered Roller Cup 0 Asm.Hub(Incl.,,) 00 Cage, Roll 0 000 Roll 00 Spring, Garter Spacer (Splined Drive Shaft) 000 Cam (Splined Drive Shaft) 00 Plug, Magnetic Drain Stud Disc, Brake (If built after /0/) 0 Valve, Rim 0- Rim, Front, Silver Tire (x0-) 0 00 Washer 0 Nut 0 Pin, Cotter 00 O-Ring Cap, Hub 0 Screw Nut, Lock /00 B
FRONT BRAKE 0 0 Asm., Brake Caliper, Front, LH 00 Square Ring, Molded (.0 x.) (Incl. -)(Before /0/) Seal, Caliper, Outer,. 00 Asm., Brake Caliper, Front, LH 000 Piston, Caliper (Before //) (Incl. -)(After /0/) Piston, Brake, Long (After //) 0 Asm., Brake Caliper, Front,., LH 0 Piston, Caliper,. (Incl. -)(After /0/00) 0 00 0 Asm., Brake Caliper, Front, RH (Incl. -)(Before /0/) Asm., Brake Caliper, Front, RH (Incl. -)(After /0/) Asm., Brake Caliper, Front,., RH (Incl. -)(After /0/00) 0 Kit - Front Brake Boot 00 Screw, Bleeder Screw, Socket Set 0 Caliper,Brake,LH (Use w/0,00) Caliper,Brake,RH (Use w/0,00) Caliper, Brake, LH (Use w/0) Caliper, Brake, RH (Use w/0) 0 Kit - Piston and Insulator Seal (Incl. -) 0 Square Ring, Molded (.0) Seal, Caliper, Inner,. B 00 Insulator, Caliper (Before //) 000 00 0 0 Kit - Severe Duty Brake Pad, Front (Complete set of pads) Kit - Brake Pad, Front (Complete set of pads) Kit - Brake Pads, Soft, Front Kit - Brake Pads (Use w/0,0) 0 0 0 Caliper Mount (Before /0/) Caliper Mount (After /0/) 0 Boot, Bushing 0 Boot, Pin Seal - - - - - - - Washer (See Front Strut Pg. B, Ref. ) - - - - - - - Washer, Spring Lock (See Front Strut Pg. B, Ref. ) - - - - - - - Screw (See Front Strut Pg. B, Ref. ) /0
STEERING 0 0-0 Shaft, Steering, Upper Joint, Steering Screw -0 Shaft, Steering Screw Asm., Gear Box, Steering Boot, Steering Screw Screw 0-0 Plate, Access, Lower Steering 0 Nut -0 Brace, Steering, Upper Nut 00-0 Mount, Brake Rivet B 0 Bolt 0 Washer -0 Spacer Screw 0 Cap, Steering Wheel 0 Screw 0 Washer Washer 0 Wheel, Steering 0 Bushing, Steering Column 00-0 Column, Steering 00-0 Mount, Steering, LH Nut 0 Ring, Retaining 00-0 Mount, Steering, RH /
A-ARM/STRUT MOUNTING Use in this location with only. 0 0 - - - - - - - Asm., Gearbox, Steering (See Steering Pg. B, Ref. ) 00 00 Tie Rod, LH Tie Rod, RH 0 Nut, LH Screw (If built before //) Screw (If built after //) 0 Bolt, Washer Head (If built after /0/0) 0 Washer, Flat (If built before //)(If built after // use Qty. ) 00 00 Rod End (If built before //) Rod End (If built after //) 0 Nut Nut, Lock (If built after /0/0) 0 Pin, Cotter - - - - - - - Asm., Hubstrut (See Front Strut Pg. B, Ref. ) 0 Bracket, Ball Joint C Screw 0 Boot, Rubber 00 Joint, Ball, High Angle (If built before /0/00) 00 Joint, Ball (If built after /0/00) Nut 0 Bushing, A-Arm, Long 00 Bushing 00 Fitting, Lubrication 00-0 00-0 A-Frame, LH A-Frame, RH Shaft, A-Arm 0 0 Shield, CV, RH Shield, CV, LH 0 Screw Screw 0 Washer, Spring Lock /0
FOOT BRAKE 0 Nut Bolt 0 Bolt Bolt 0 Washer 0 Nut 00 Rod End, RH 00 Nut 00-0 Foot Brake 0 Bushing 0 Spacer, Brake Screw / C
THROTTLE 0 00 Cable, Throttle Control 00 Spring, Latch, Return Nut 000-0 Link, Throttle -0 Pedal, Throttle Washer C 0 Pin, Cotter 0 Block, Pivot, Throttle 0 Screw 0 0 Nut 0-0 Bracket, Throttle Rivet /00
BRAKE LINES 0 - - - - - - - Asm.,Caliper,Brake,Front,LH (See Front Brake Pg. B) 0 Line, Brake, Front, LH w/fitting 0 Switch 0 Fitting, Cross, Inverted Flare 0 Line, Brake, Front, RH w/fitting - - - - - - - Asm.,Caliper,Brake,Front,RH (See Front Brake Pg. B) 00 Bolt C 0 Washer 0 Nutsert 0 0 Line, Brake, Master Cylinder 00 Clip, Brake Line 00 00 Asm., Master Cylinder Kit - Rebuild, Master Cylinder 000 Clamp, Worm Drive 0 Asm., Caliper, Rear 0 Line, Brake, Rear /
MIDDLE BRAKE / PARKING BRAKE 0 0 00 0 Asm., Lever, Park Brake Handle, Replacement Switch, Parking Brake Screw 0 Pin 0 Caliper, Park Brake (Incl. -,) 0 Kit - Cam, Park Brake Lever 0 Kit - Castle Nut 00 Kit - Push Pin, Park Brake Bolt Pin, Clevis 0 00 Cable, Park Brake - - - - - - - Screw (See Transmission/Engine Mounting Pg. B, Ref. ) 00 Nut C Nut 0 Screw Screw 0 Washer, Lock 0-0 Bracket, Brake Mount Support -0 Bracket, Mount, Caliper, Rear 0 Kit - Brake Pad, Park, Ranger 0 0 Nut Spacer 00 Hub, Brake, Middle Axle 0 0 Disc, Brake (If built before /0/00) Disc, Brake (If built after /0/00) Washer, Tab-Lock, Pinion 0 Nut /0
MIDDLE WHEEL DRIVE 0 0 Pin, Cotter Nut Hub, Wheel 00 Ring, Retaining - - - - - - - Carrier, Bearing, Wheel (See Middle Shock Mounting Pg. C, Ref. ) Stud Tire (x-0) 0 Valve, Rim 0- Rim, Silver 0 Washer, Cone 00 Nut, Castle Cover, Dust, Hub /00 C
MIDDLE SHOCK MOUNTING 0 0 0 Nut Screw 0 Retainer, Spring 0 Retainer, Spring Coil, Top 0- Spring 0 Shock, Middle Axle 0 Washer 00 0 Fitting, Lubrication 00 Shaft, A-Arm, Short, Middle Axle 0 00 Bushing 0 Bushing, A-Arm, Short Screw Screw C 0 0 0 0 Bushing, A-Arm, Long 00 Shaft, A-Arm 00-0 A-Arm, Middle Axle, Lower Washer Bushing, Bearing, Carrier 0 Bushing, Control, Lower 0 Screw 00-0 A-Arm, Middle Axle, Upper Screw 00 Fitting, Lubrication 00 Shaft, A-Arm, Short Carrier, Bearing, Wheel 0 Bearing, Carrier Wheel /
DRIVE CLUTCH 0 Bolt 0 Washer, Spring Lock 0 Cover, Bearing 0 Spring, Clutch 0 Washer, Multilube Roller and Bushing Button, Clutch, Stemless 0 0 0 AR AR AR AR Spacer (.00) Spacer (.0) Spacer (.0) Spacer (.00) 00 Weight, Shift (S-) 0 Bolt, Shoulder 0 Nut, FLEXLOC 0 Bearing, Moveable, / 00 Pin, Roller Asm., Drive Clutch (Incl. All Less,) / C
DRIVEN CLUTCH 0 00 Spacer 0 Bushing 0 Belt, Drive Asm., Driven Clutch (Incl. -) 0 Washer, Domed 0 Washer, Spring Lock Bolt AR Washer (.00 Spacer) 0 AR Washer 0 0 AR Washer 0 Bearing, Moveable, / Bearing, Moveable, 0 Spring, Clutch Ramp, Stationary 0 Spacer 0 Ring, Retaining Bolt 0 Button, Ramp /00 C
CLUTCH COVER 0 0 Duct, Air Inlet 0 Seal, Cover, Case 00 Kit - Inner Clutch Cover (Incl.,,) Washer Screw 0 Seal, Clutch Cover Cover, Clutch, Outer 00 Clip, Clutch Cover 0 Screw 0 0 Decal - Eng/Clutch Modification (If built before 0/0/) 0 Decal - Warning, Clutch Cover (If built after 0/0/) 0 Decal - Automatic Transmission C0 0 Screw 00 Cable Tie Hose, Air Out, Clutch Duct, Clutch, Air Outlet Bolt -0 Bracket, Reservoir Rivet Nut 0 - - - - - - - Screw & Washer (See Carburetor Pg. D, Ref. ) 00-0 Bracket, Retainer, Seal 0 Seal, Cover 00 Clamp, Narrow Band /00
SWING ARM/REAR SHOCK 0 0 0 RH LH 0 0 Nut 0- Spring, Comp. Retainer, Shock Screw 0 Shock, Rear Axle 0 Cam, Adjusting, Spring Bolt Nut 0 Nut 0 Bushing, Swing Arm 00 Shaft, Pivot, Swing Arm Spacer, Swing Arm - - - - - - - Asm., Rear Gearcase (See Rear Gearcase Pg. C) 0 Screw Bearing, Ball C O-Ring 0 Spacer, Bearing 00 Seal, Rear Axle 0 Ring, Retaining 0 - - - - - - - Hub, Wheel (See Rear Wheel Drive Pg. C, Ref. ) 0 Drive Shaft, Axle, LH 00-0 Axle Tube, LH 000-0 Axle Tube, RH 0 Bolt 0 Drive Shaft, Axle, RH Screw 00 Fitting Screw 0 Decal - Hitch 0 00-0 Swing Arm, Black /00
REAR BRAKE 00 00 00 Screw, Bleeder Kit - Brake Pad, Rear Kit - Brake Caliper Rebuild (Incl. Pistons, Square Rings & O-Rings) 0 O-Ring, Crossover 0 Asm., Caliper, Rear (Incl. -) 00 Washer Screw / C
REAR WHEEL DRIVE 0 0 Pin, Cotter Nut Hub, Wheel Stud Tire (x-0) 0 Valve, Rim 0- Rim, Silver Washer, Cone 00 Nut, Castle 0 Cover, Dust, Hub /00 C
REAR GEARCASE 0 Asm., Gearcase Screw Cup, Bearing, Timken Asm., Gear Shaft 00 00 00 00 00 AR AR AR AR AR Shim, Ring Gear (.0) Shim, Ring Gear (.00) Shim, Ring Gear (.0) Shim, Ring Gear (.0) Shim, Ring Gear (.00) Asm., Gear Housing, Rear Seal 00 00 00 000 00 AR AR AR AR AR Shim, Pinion, Angle Drive (.0) Shim, Pinion, Angle Drive (.00) Shim, Pinion, Angle Drive (.0) Shim, Pinion, Angle Drive (.0) Shim, Pinion, Angle Drive (.00) 00 Seal, Pinion Housing Cover, Pinion 0 O-Ring 0 Asm., Pinion Screw O-Ring Cover, Angle Drive, Rear / C
MID ANGLE DRIVE 0 Asm., Mid Angle Drive (Incl. -) 0 Screw 0 Washer Cover, Angle Drive, Mid O-Ring Cup, Bearing, Timken Asm., Gear Shaft 00 AR 00 AR 00 AR 00 AR Shim, Ring Gear (.0) Shim, Ring Gear (.00) Shim, Ring Gear (.0) Shim, Ring Gear (.0) 00 AR Shim, Ring Gear (.00) Asm., Mid Gear Housing (Incl. 0,) D Seal 0 0 Plug, Drain 00 AR 00 AR 00 AR 000 AR Shim, Pinion, Angle Drive (.0) Shim, Pinion, Angle Drive (.00) Shim, Pinion, Angle Drive (.0) Shim, Pinion, Angle Drive (.0) 00 AR Shim, Pinion, Angle Drive (.00) 0 Asm., Pinion 00 Seal, Pinion Housing Cover, Pinion O-Ring Screw /
FRONT HOUSING 0 0 0 Asm., Gearcase, Front (Incl. -,-,-) NOTE: Used on Machines Built Before /0/. Seal O-Ring Cover, Front Housing Input 0 Bearing, Ball 0 Ring, Retaining 00 Bearing, Ball Shaft, Input, Front Housing Bearing, Needle 0 Washer 0 Seal 0 Ring, Retaining Screw 000-00 AR Line, Fuel 00 Cable Tie 00 Clip D 000 Clamp 0 Tube, Vent Front Housing, Gearcase Rivet 0 Washer Plug, Drain 0 Washer Screw Washer Plug Bearing, Needle Shaft, Output, Front Housing Gear, T, Spiral Bevel Washer, Thrust 0 Washer, Thrust Bearing, Ball 0 Cover, Output, Front Housing O-Ring /
FRONT HOUSING 0 0 Asm., Gearcase, Front (Incl. -,- ) NOTE: UsedonMa- chines Built Before /0/ and After /0/ Screw Seal 0 Cover, Input, Front Housing 00 O-Ring Ring, Retaining Bearing Pinion, Input Bushing Seal, Oil 0 Bushing Washer Plug D 00 Cable Tie 000 Clamp 000- AR Line, Fuel Tube, Vent Gearcase, Front Housing 0 SubAsm., Output Shaft 00 Bearing, Ball 0 AR Shim O-Ring Cover, Output, Front Housing AR Shim 0 Button, Thrust Plug, Drain Washer /0
FRONT HOUSING 0 0 Asm., Front Gearcase (Incl. -,-) NOTE: Used on Machines Built After /0/. Screw Seal 0 Cover, Input, Front Housing 00 O-Ring Ring, Retaining Bearing Pinion, Input, T Bushing Seal, Oil 0 Bushing Washer Plug 000 Clamp D 000- AR Line, Fuel 000 Clamp, Hose Tube, Vent Gearcase, Front Housing Shaft, Output, T 00 Bearing, Ball 0 AR Shim O-Ring Cover, Output, Front Housing AR Shim Button, Thrust Washer Plug, Drain 0 Washer, Lock Screw /
GEAR SELECTOR 0 0 0 0 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. 0 Asm., Gear Selector(Incl. -,-) 0 Asm., Knob 0 Screw Strap, Wire Clamp Boot, Gear Selector Cover, Gear Selector Spring, Holding Subasm., Handle 0 Cup, Bearing 0 0 Spring, Centering 0 Pin, Stop 0 Spring, Detent 00 Bullet, Detent Switch, Gear Selector 00 Strap, Wire 00 Rod End, Male, RH 0 Nut, FLEXLOC 00 End, Rod,RH 0 Nut, LH 0 Rod, Shift Linkage, High Range 0 Nut, RH D 00 End, Rod, LH 0 Pin, Clevis 0 Pin, Cotter 00 Clevis, Threaded Slide, High/Reverse 0 O-Ring 0 Slide, Low Body, Gear Selector 0 0 Butterfly, Interlock 00 Pin, Interlock Bolt 0 Washer 0 Washer Spacer 0 Nut 00-0 Bracket, Shift 0 Bolt Screw 0 Washer, Lock Screw Screw 0/0
GEARCASE (Cases and Snorkel) 0 0 0 - - - - - - - Asm., Gearcase (See Gearcase - Internal Components Pg. D for Details) Seal Screw Bolt Washer, Wrought 0 Adapter, Drive 0 Key, Speedometer 0 Seal 0 Screw Seal 0 Gearcase, LH Pin, Dowel 0 Vent Dipstick - - - - - - - Washer (See Gearcase - Internal Components Pg. D, Ref. 0) Screw Washer Gear, T, Extended - - - - - - - Ball Bearing (See Gearcase - Internal Components Pg. D, Ref. ) D Shaft, Snorkel 0 0 O-Ring 0 Snorkel 0 Bearing, Ball AR AR AR AR AR Spacer (.0 x. x.00) Spacer (.0 x. x.0) Spacer (.0 x. x.00) Spacer (.0 x. x.00) Spacer (.0 x. x.00) 0 Ring, Retaining Gear, Snorkel, Bolt Lock Bolt Nut, FLEXLOC Bushing Cover, Center Drive Shaft 0 Stamping, Cover Plate Washer, Lock Screw Plug, Drain Washer, Plug Gearcase, RH /
GEARCASE (Internal Components) 0 0 0 0 0 0 D
GEARCASE (Internal Components) Asm., Gearcase (Incl. - on this page and,,- on Cases & Snorkel Pg. D) 0 Bearing Shaft, Input, HCR 0 Chain, Silent, P 0 Bearing Shaft, Shift, H/R O-Ring 00 Washer 0 Ring, Retaining Bellcrank, HLR 0 0 Washer 0 Nut Shaft, Shift, Low Fork, Shift, Low 0 Fork, Shift, H/R 0 Screw 0 Pin, Interlock 0 Bracket, Interlock 0 Spring Ring, Retaining 0 Washer, Thrust 0 Bearing, Needle Gear, 0T, HCR 00 Washer Engagement Dog, High/Rev. 0 Ring, Retaining 0 Washer 0 Bearing, Needle Sprocket, T Shaft, Reverse, T 0 Engagement Dog, Low 00 Bearing, Needle Gear, T 00 Washer 00 Bearing Shaft, Center Drive Gear, 0T Screw 0 Washer, Spring Lock Cover, Center Drive Bearing 0 Ring, Retaining Bearing, Ball Gear, T, Spiral Bevel, Snorkel Screw Screw Deflector, Oil Washer Cam, Chain Tensioner Shoe, Chain Tensioner Pin, Dowel 0 Spring, Torsion Bearing, Ball 0 Sprocket, 0T 0 Chain, Silent / D
CRANKCASE 0 0 0 Bushing Starter 0 Asm., Crankcase (Incl.,,,,,0,,,,0,) 0 Pin, Straight 00 Ball Bearing 00 Pin, Dowel 00 Screw and Washer 0 Seal, Oil 0 Pipe, Air Breather 0 Union 0 0 Bearing, Ball 0 Bearing, Ball D 0 Plug 0 Gasket, Aluminum 0 Spring, One Way Valve 00 Valve, One Way 0 0 Bolt, Flange 0 Gasket 0 Plug 0 Seal, Mechanical 0 0 Seal, Oil 0 O-Ring 000 Pin, Dowel /0
CRANKSHAFT and PISTON 0 0 0 Clip 00 0 Piston Set (Std)(Incl. Piston Pin) Piston Set (0. O/S)(Incl. Piston Pin) 0 Piston Set (0.0 O/S)(Incl. Piston Pin) 0 00 0 Piston Ring Set (Std) Piston Ring Set (0. O/S) Piston Ring Set (0.0 O/S) 0 Crankshaft 0 Pin, Crank 0 Rod, Connecting 000 Bearing, End, Large 00 Ball, Steel 0 0 Asm., Crankshaft (Incl. -0,) Crankshaft 0 0 Balancer Gear D0 00 Balancer Shaft 0 0 Spacer (0.) Spacer (.0) 0 Spacer (.) 00 0 0 0 Spacer (0.) Spacer (0.) Spacer (.0) Spacer (.) 0 Sprocket 0 Nut, Slit 00 Washer 00 Nut, Lock 0 Pin, Dowel 0 Key 0 000 Key, Woodruff /0
D CYLINDER 0 0 0 0 0
CYLINDER 0 Band, Adapter (Incl. 0) 00 Bolt 0 Adapter 0 Adapter, Intake 0 Pin, Straight 0 Guide, Valve 0 Seal, Intake Valve 0 O-Ring 00 Adapter, Water Out 0 0 0 Bolt, Flange 0 Adapter, Camshaft 00 Gasket, Rocker Cover 00 Cover, Rocker 0 0 Bolt, Flange 0 Seal, Exhaust Valve 0 Bolt, Cylinder Head 00 Plug 0 Gasket 0 Plug, Blind 0 0 Bolt, Flange 00 Gasket, Exhaust 0 Stud 00 Nut 000 Washer, Lock 0 Bolt, Rocker Shaft 0 Bolt 0 Support, Valve Rocker Shaft (PTO) 0 Support, Valve Rocker Shaft (MAG) 0 Pin, Straight 0 0 Union, Oil Pump 0 Bolt, Flange 0 Cylinder (Incl. ) 00 Elbow Pipe 00 Gasket, Cylinder 0 Cover, Camshaft 000 Gasket, Cover, Cam 0 Cylinder Head (Incl. -,,-,) 0 Gasket, Head 0 Gasket, Intake Adapter 0 0 Screw / D
D CARBURETOR 0 0 0 0 0
CARBURETOR 00 Ring 00 E-Ring 0 Needle, Jet (D-) 0 Ring 0 Diaphragm 0 Jet, Needle (Q-) 0 Screw 00 Washer, Spring 00 Block, Jet 0 00 Washer, Needle Jet Setter 0 Jet, Main (#) 0 Seal 0 Packing 0 E-Ring 0 Cap 0 Pin, Float 0 Plate 0 O-Ring 00 Screw 0 Body, Float 0 Screw 0 Float 0 Screw Valve, Needle (.) 0 O-Ring 0 Jet, Pilot (#.) 0 O-Ring 0 Washer 0 Spring 0 0 Adjuster 0 Screw, Adjust 0 Ring 0 Spring 00 Valve, Throttle (00) 0 Spring 0 Ring 00 Screw 0 Shaft, Throttle 0 Guide, Cable 0 0 Screw 0 Cover 0 O-Ring 0 Holder, Guide 0 Spring 0 Plunger 0 Jet, Air (#0) 0 Asm., Carburetor (Incl. -,-) 00 Screw and Washer 00 Spring 0 00 Cover 0 Screw / D
INTAKE and EXHAUST 0 0 0 Plug 00 Gasket, Plug 0 Spring, Tensioner 0 Asm., Tensioner (Incl. -) 0 Gasket, Tensioner 00 Asm.,RockerArm,Intake(Incl.,) 0 Asm., Rocker Arm, Exhaust (Incl.,) 0 Nut 0 Screw, Adjusting 0 00 Shaft, Rocker 00 Collet, Valve 00 Retainer, Spring 00 Spring, Valve 0 Camshaft (Incl. -) E 0 Pin, Dowel 0 Lever, Release 00 Spring, Return 0 Pin, Dowel 0 Sprocket 0 0 Bolt and Washer 0 Guide, Chain 0 Chain, Timing 0 Bolt, Pivot, Lever 0 Lever 0 Valve, Intake 0 Valve, Exhaust 0 Bolt, Flange /
RECOIL STARTER 0 0 Reel 0 Spring, Return 0 Ratchet 0 Spring, Friction 0 Plate, Friction 0 Bolt and Washer 0 Plug 0 Gasket E 0 Bushing, Starter 0 0 Spring, Power 00 Bushing 0 Gasket, Recoil 0 Bolt, Flange 0 0 Asm., Recoil (Incl. -,-,,) Starter Case (Incl. ) 00 Rope /
WATER PUMP 0 00 Thermostat 0 Switch, Thermostat 0 Clamp, Hose 0 Hose, Main 0 Bolt, Flange 0 Gasket, Aluminum 0 Cover, Water Pump E 00 Gasket, Water Pump 00 Nut, Self Lock 0 0 Gasket 0 Impeller 0 Washer, Seal 0 Bolt, Flange /
OIL PUMP 0 0 Oil Pump Case 0 Rotor, Outer (Feed) 0 Rotor, Inner (Feed) 0 0 Asm., Oil Pump (Incl. -,0-) Oil Pump Case 0 Screw 0 Pin, Dowel 0 Pin, Dowel 0 Washer 0 Bolt and Washer E 0 0 Pump, Oil Pump Case 00 Rotor, Inner (Scav) 0 Rotor, Outer 0 Oil Strainer Unit 00 Screw and Washer 0 Shaft, Pump Complete 0 Gear, Pump 0 00 0 AR AR AR Spacer (0.) Spacer (.0) Spacer (.) /
OIL FILTER 0 Oil Filter 0 Gasket, Aluminum 0 Bolt, Banjo 0 Oil Delivery Pipe 0 Oil Delivery Pipe / E
MAGNETO 0 0 0 0 Asm., Ignition Coil (Incl.,) Ignition Coil 00 Cap, Spark Plug 00 Plug, Spark 0 O-Ring 0 Metal, Bearing 00 00 0 Asm., Plate (Incl.,,-,,) (Up to S#-000) Plate (Up to S#-000) Asm., Plate (Incl.,,-,,) (S#-000 & after) Plate (S#-000 & after) 0 0 Bolt and Washer 0 Seal, Oil 0 0 Stator (Incl. ) (Up to S#-000) Stator (Incl. ) (S#-000 & after) E 0 0 0 Screw and Washer (Up to S#-000) Screw and Washer (S#-000 & after) 0 Band, Pulse 0 Screw and Washer 00 Coil, Pulser 0 Clamp 0 Screw and Washer 0 0 CDI System (Up to S#-000) CDI System (S#-000 & after) 00 Nut 000 Washer, Spring 0 Switch, Magnetic 0 0 0 Flywheel w/ring Gear (Up to S#-000) Flywheel w/ring Gear (S#-000 & after) /0
STARTING MOTOR 0 0 Starting Motor (Incl. -,-) 0 Washer Set 0 Armature 00 Brush 0 Nut, Flange 00 O-Ring 00 Bolt and Washer 00 Rear Bracket 00 Front Bracket (Incl. 0) E 0 0 O-Ring 0 Asm., Set Bolt (Incl. ) 00 Ring, Rubber 0 Washer, Gear Shaft 0 Clip 0 Spring, Weight 00 Spring, Return 00 Clip 0 Asm., Gear Shaft (Incl. -) /
TOOL KIT 0 Asm.,ToolKit(Incl.-) 0 Gauge, Tire Pressure 000 Wrench, Open -0mm 000 Wrench, Open -mm 0 Wrench, Box 0 Handle, Wrench 0 Screw Driver, Phillips 00 Pouch, Tool Kit Lube, U-Joint, oz., Case 0 Owner s Manual, RANGER Supplement, Owner s Manual 0 0 Pigtail, Power 0-0 Wrench, Spanner, Cam / E
PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN 0 /0
Changed pages in 0 A cover toc B x C D E F G 0