Illustrated Parts Manual M5 2 Model Number S2005M5CICUSG Model Number S2005M5CICUSB Model Number S2005M5CICOSG 00 5
TABLE OF CONTENTS 2005 M5 (Model No. S2005M5CICUSG) (Model No. S2005M5CICUSB) (Model No. S2005M5CICOSG - International) SKI AND SPINDLE ASSEMBLY......................................................... 1 A-ARM ASSEMBLY................................................................... 2 FRONT SUSPENSION SHOCK ABSORBER ASSEMBLY.................................... 3 STEERING POST ASSEMBLY.......................................................... 4 TIE ROD ASSEMBLY................................................................. 5 HANDLEBAR AND CONTROLS......................................................... 6 HYDRAULIC BRAKE CONTROL ASSEMBLY.............................................. 7 DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES......................................... 8 GEARCASE ASSEMBLY.............................................................. 9 SLIDE RAIL AND TRACK ASSEMBLY................................................... 10 IDLER WHEEL ASSEMBLY........................................................... 11 REAR SUSPENSION FRONT ARM ASSEMBLY........................................... 12 REAR SUSPENSION REAR ARM ASSEMBLY............................................ 13 FRONT FRAME AND FOOTREST ASSEMBLY............................................ 14 HOOD AND WINDSHIELD ASSEMBLY.................................................. 15 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES................................. 16 CONSOLE AND SWITCH ASSEMBLY................................................... 17 BELLY PAN ASSEMBLY.............................................................. 18 BELT GUARD ASSEMBLY............................................................ 19 GAS TANK ASSEMBLY.............................................................. 20 SEAT ASSEMBLY................................................................... 21 TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY.................................... 22 COOLING ASSEMBLY............................................................... 23 ENGINE AND RELATED PARTS....................................................... 24 EXHAUST ASSEMBLY............................................................... 25 AIR INTAKE ASSEMBLY............................................................. 26 AIR SILENCER, CARBURETOR, AND FUEL PUMP ASSEMBLY.............................. 27 OIL TANK ASSEMBLY............................................................... 28 DRIVE CLUTCH.................................................................... 29 DRIVEN CLUTCH................................................................... 30 CARBURETOR..................................................................... 31 CYLINDER AND HEAD ASSEMBLY.................................................... 32 CRANKCASE ASSEMBLY............................................................ 33 PISTON AND CRANKSHAFT.......................................................... 34 REED VALVE ASSEMBLY............................................................ 35 OIL PUMP......................................................................... 36 WATER PUMP/WATER MANIFOLD..................................................... 37 RECOIL STARTER.................................................................. 38 MAGNETO........................................................................ 39 ELECTRICAL...................................................................... 40 ALTERNATE CARBURETOR PARTS................................................... 41 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. 2004 Arctic Cat Inc. Printed October 2004 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
SKI AND SPINDLE ASSEMBLY 0740-020 1 2603-458 2 Ski, Plastic - Black 2 2603-397 4 Insert, Ski 3 0703-871 2 Wearbar 4 8047-486 8 Nut, Lock 5 2603-394 2 Handle, Plastic - Black 6 8047-366 4 Nut, Lock 7 8017-587 2 Screw, Machine 8 8017-584 2 Screw, Machine 9 0623-776 2 Screw, Cap 10 0123-458 2 Pin, Cotter 11 0623-728 4 Washer 12 0123-296 2 Nut, Lock 13 1703-921 2 Damper, Ski 14 0603-034 2 Axle, Spindle 15 1703-630 1 Spindle, Steering - Right - Platinum (inc. 16-23) 1703-631 1 Spindle, Steering - Left - Platinum (inc. 16-23) 16 0603-647 4 Insert, Spindle 17 1623-010 2 Fitting, Grease 18 0603-083 4 Bearing 19 0603-158 4 Bearing 20 1603-203 6 Washer, Thrust 21 8005-584 2 Screw, Cap 22 1703-413 2 Arm, Steering 23 0623-796 2 Ring, Retaining 24 0623-831 2 Cap, Spindle 25 1603-908 4 Spacer 26 6611-455 2 Decal, AWS - Spindle 6611-456 2 Decal, AWS - Spindle (Black) 1
A-ARM ASSEMBLY 0739-803 1 1703-253 2 A-Arm, Lower - Platinum (inc. 2) 2 1603-895 8 Bearing 3 1703-256 2 A-Arm, Upper - Platinum (inc. 4) 4 1603-915 8 Bearing 5 0623-952 2 Screw, Cap 6 0623-664 4 Washer 7 1603-563 2 Axle, Inner - Upper Arm 8 8047-486 10 Nut, Lock 9 0603-864 2 Tube, Axle 10 8020-230 4 Screw, Cap 11 2606-886 1 Brace, Lower A-Arm 12 2603-179 4 Axle, Inner - Lower Arm 13 8026-236 2 Screw, Cap 14 8026-232 2 Screw, Cap 15 0603-639 2 Tube, Axle 16 1603-244 4 Axle, Powder Metal 2
0740-200 FRONT SUSPENSION SHOCK ABSORBER ASSEMBLY 1 1603-889 2 Retainer, Spring 2 1703-787 2 Spring, Compression - Green 1703-786 2 Spring, Compression - Red (Black) 3 2603-533 2 Sleeve, Wear 4 2603-532 2 Retainer, Spring - Lower 5 8047-486 4 Nut, Lock 6 0623-991 2 Washer 7 1603-023 4 Sleeve, Shock 8 2603-385 2 Shock, Ski (inc. 9-10) 9 0603-955 8 Bushing, Shock 10 1603-209 4 Sleeve, Shock 11 0603-648 2 Spacer, Shock Mount 12 8020-232 2 Screw, Cap 3
STEERING POST ASSEMBLY 0740-202 1 8002-138 4 Screw, Cap 2 0605-506 2 Cap, Adjusting Block 3 0605-507 1 Block, Adjusting 4 1705-023 1 Post, Steering 5 8047-426 6 Nut, Lock 6 0605-576 2 Block, Mounting - Steering Post 7 1705-050 1 Stop, Steering Post 8 8047-366 2 Nut, Lock 9 0623-044 2 Washer 10 0623-025 3 Nut, Lock 11 8004-225 1 Screw, Cap 12 0605-504 1 Ball Joint, Tie Rod - Right 13 0623-294 1 Nut, Hex - Right 14 0605-726 1 Tube, Tie Rod 15 0123-917 1 Nut, Hex - Left 16 0605-511 1 Ball Joint, Tie Rod - Left 17 3606-749 1 Panel, Close-Out 18 1623-353 3 Screw, Self-Tapping 19 0705-994 1 Support, Steering 20 0623-454 3 Clip, Retaining 21 1623-406 3 Clip, Routing 22 0623-942 2 Washer 23 8020-137 4 Screw, Cap 24 1623-407 1 Clip, Routing 25 0623-677 1 Cable Tie, Push-Mount 4
TIE ROD ASSEMBLY 0739-808 1 0705-397 1 Shaft, Steering 2 0623-954 4 Washer, Thrust 3 0623-955 2 Washer, Thrust 4 0605-635 2 Arm, Shaft 5 0623-956 2 Snap Ring 6 8005-584 2 Screw, Cap 7 1705-045 1 Shaft, Idler 8 0605-607 2 Ball Joint, Tie Rod - Left 9 1623-176 2 Screw, Cap 10 0605-680 2 Tube, Tie Rod - Spindle 11 0123-917 3 Nut, Hex - Left 12 0623-294 3 Nut, Hex - Right 13 0605-608 2 Ball Joint, Tie Rod - Right 14 0623-957 2 Screw, Cap 15 0605-605 1 Ball Joint, Tie Rod - Left 16 0605-312 1 Tube, Tie Rod 17 0605-606 1 Ball Joint, Tie Rod - Right 18 1606-079 2 Plug 5
HANDLEBAR AND CONTROLS 0740-203 1 0609-675 1 Control - Assembly (inc. 2-10) 2 0609-674 1 Control, Throttle - Stop Switch Half 3 0609-673 1 Control, Throttle - Thumbwarmer Assembly (inc. 4-10) 4 0609-495 1 Control, Throttle - Thumbwarmer Half w/o Components 5 0609-497 1 Plug, Rubber 6 0609-498 1 Clip, Retaining - Throttle Cable 7 0609-496 1 Plate, Cover 8 0609-312 7 Screw, Self-Tapping 9 0609-672 1 Switch, Thumbwarmer Assembly (inc. three No. 8 and 10) 10 0609-378 1 Plate, Cover 11 0609-492 2 Screw, Machine 12 0609-317 1 Axle, Lever - Throttle 13 0609-036 2 Washer 14 0609-501 2 Washer, Shoulder - Throttle 15 0609-368 1 Lever, Throttle 16 0609-040 1 Ring, Retaining 17 0705-387 1 Handlebar Assembly 18 0605-556 1 End Cap, Throttle - Right 19 0605-557 1 End Cap, Brake - Left 20 1606-442 2 Grip, Handlebar 21 0609-681 2 Element, Handwarmer 22 0617-248 1 Pad, Insulator 23 0609-680 1 Element, Thumbwarmer 24 0623-262 1 Clip, Wire 25 0687-177 1 Cable, Throttle (inc. 26) 26 0623-464 2 Nut, Locking 27 0123-788 AR Cable Tie - 8 in. 28 1639-963 1 Tool, Removal - Kit - Throttle Cable 29 0124-056 1 Washer 30 0124-057 1 E-Ring 31 0705-905 1 Wrap, Handlebar 32 1686-204 1 Harness, Adapter 6
0737-603 *Not a Service Part **Not Illustrated HYDRAULIC BRAKE CONTROL ASSEMBLY 1 1602-590 1 Brake Assembly (inc. 2-14) 2 1602-712 1 Lever, Brake 3 0623-430 1 Screw, Lever Mounting 4 0623-056 1 Nut, Lock 5 0602-740 1 Reservoir 6 0602-741 1 Gasket, Cover 7 0602-742 1 Cover, Reservoir 8 0623-506 2 Screw, Cover 9 0623-613 2 Screw, Machine 10 0602-587 1 O-Ring 11 * 1 Master Cylinder 12 8052-212 2 Washer, Lock - Internal Tooth 13 0623-432 2 Screw, Master Cylinder Mounting 14 0602-907 1 Clamp, Master Cylinder ** 0638-315 AR Fluid, Brake - High Temperature 15 0609-679 1 Control, Dimmer - Assembly (inc. 16-21) 16 0609-322 1 Housing, Dimmer Control 17 0609-267 1 Switch, Dimmer and Brake - Assembly 18 0609-474 1 Knob, Dimmer Switch 19 0609-678 1 Switch, Handwarmer - Assembly (inc. 20 and three No. 21) 20 0609-378 1 Plate, Cover 21 0609-312 7 Screw, Self-Tapping 22 1602-588 1 Brakeline, Hydraulic 7
DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES 0739-815 *Not a Service Part 1 0728-113 1 Track Drive Assembly (inc. 2-4) 2 1602-592 2 Sprocket, Drive 3 1602-760 1 Driveshaft 4 1602-315 1 Collar 5 1602-791 1 Insert, Driveshaft 6 1602-497 1 Spacer, Brake Caliper 7 1602-656 1 Disc, Brake 8 1623-445 1 Washer, Copper 9 1623-376 1 Screw, Cap 10 1602-355 1 Nut, Retaining 11 0702-648 1 Plate, Mounting - Gearcase 12 1623-355 6 Nut, Push 13 0702-667 1 Gearcase Assembly 14 8047-426 11 Nut, Lock 15 0648-442 AR Washer 0648-443 AR Washer 16 0726-189 1 Clutch, Driven 17 1623-072 1 Washer 18 1623-275 1 Screw, Cap 19 0648-714 AR Washer 0648-715 AR Washer 0648-716 AR Washer 20 0648-441 1 O-Ring 21 0648-741 1 Adjuster, Sheave 22 0702-652 1 Caliper, Brake - Assembly (inc. 23-39) 23 1623-360 5 Bolt, Carriage - Ribbed 24 1602-671 4 Screw, Cap 25 0402-165 4 Washer 26 * 1 Housing 27 0602-729 1 O-Ring, Housing 28 1602-464 1 Pin, Retaining - Brake Pad 29 1602-461 2 Piston 30 1602-669 2 O-Ring 31 0702-563 1 Pad, Brake - Set (inc. 32-33) 32 1602-466 4 Clip, Anti-Rattle 33 1602-467 1 Clip, Hairpin 34 1602-458 1 Fitting, Bleed 35 0602-590 1 Fitting, Adapter 36 * 1 Housing 37 1602-462 2 Bearing 38 1602-463 2 Sleeve, Driveshaft 39 1602-456 1 Ring, Retaining 40 0648-441 AR O-Ring 8
0739-741 *Not Illustrated GEARCASE ASSEMBLY (Complete Gearcase Assembly p/n 0702-667) 1 0702-660 1 Gearcase (inc. 2-6) 2 1602-344 1 Seal, Oil 3 1602-345 2 Pin, Dowel 4 1602-766 1 Seal, Oil 5 1602-213 1 O-Ring 6 0623-293 1 Plug, Gearcase 7 0630-176 1 Sensor, Speedometer 8 1623-343 1 Clip, Retaining 9 0702-675 1 Gear, Ring - 76T (inc. 10-11) 10 1602-318 1 Bearing 11 1602-745 1 Retainer, Magnet 12 0702-688 1 Shaft, Input - 57T (inc. one No. 13) 13 1602-340 2 Bearing 14 1602-349 1 Gear, Planetary - 5 Pinion 15 1602-731 1 Ring, Retaining - Planetary Gear 16 0702-712 1 Gear, Transfer - 63T/34T (inc. one No. 13 and 17) 17 1602-348 1 Bearing 18 0702-684 1 Cover, Gearcase (inc. 19-20) 19 1602-341 1 Bearing 20 1602-342 1 Seal, Oil 21 1623-075 11 Screw, Machine * 4639-025 AR Fluid, Gearcase - Case 9
0739-821 SLIDE RAIL AND TRACK ASSEMBLY (Complete Skid Frame Assembly p/n 1704-336; p/n 1704-386 Black) 1 2604-730 2 Rail, Formed - Stamped 2 0604-426 2 Support, Rail 3 2604-659 2 Spacer 4 2604-660 1 Spacer 5 8002-043 2 Screw, Cap 6 8050-217 4 Washer 7 2604-724 2 End Cap, Slide Rail 8 8047-366 8 Nut, Lock 9 0123-859 2 Screw, Machine 10 2604-745 2 Wearstrip, Slide Rail 11 8020-134 4 Screw, Cap 12 8060-633 4 Rivet, Solid 13 0604-918 2 Pad, Shock 14 0604-967 4 Bracket, Retaining 15 2604-733 2 Insert, Rail 16 0604-930 2 Axle, Aluminum 17 8020-222 4 Screw, Cap 18 8041-246 2 Nut, Lock 19 1604-607 2 Pad, Shock 20 8017-405 2 Screw, Machine 21 0704-352 2 Adjuster, Track 22 8002-042 4 Screw, Cap 23 1602-607 1 Track Assembly (inc. 24) 24 1602-907 48 Clip, Guide 10
IDLER WHEEL ASSEMBLY 0739-826 1 0623-527 1 Screw, Cap 2 0623-439 1 Washer 3 1604-792 1 Axle 4 0623-912 2 Washer 5 1604-793 2 Spacer, Front Arm Shock 6 8048-486 5 Nut, Lock 7 2604-579 2 Block, Mounting - Idler Wheel 8 2604-751 2 Wheel, Idler - Green (inc. 9-10) 2604-749 2 Wheel, Idler - Red (inc. 9-10) (Black) 9 1604-847 5 Bearing 10 0623-946 5 Ring, Retaining 11 8020-232 2 Screw, Cap 12 0623-664 4 Washer 13 8020-229 2 Screw, Cap 14 8050-282 2 Washer 15 2604-515 2 Slide, Spring 16 2604-378 2 Block, Slide 17 1623-037 1 Screw, Cap 18 0623-044 1 Washer 19 1604-213 2 Spacer 20 0623-675 4 Washer 21 1604-684 2 Wheel, Idler (inc. 22-25) 22 1604-773 2 Insert, Wheel - Outside 23 0107-598 2 Bearing 24 0123-798 2 Ring, Retaining 25 1604-772 2 Insert, Wheel - Inside 26 1604-209 1 Axle, Inner 27 1704-016 1 Pivot, Shock (inc. 28-29) 28 1623-010 1 Fitting, Grease 29 1623-011 1 Washer, Grease Fitting 30 0603-105 1 Spacer 31 8047-490 1 Nut, Lock 32 0623-921 1 Washer 33 1604-940 1 Spacer, Rear Wheel 34 2604-283 1 Axle, Rear Wheel 35 2604-524 1 Wheel, Idler (inc. 9-10) 36 2604-260 3 Bushing, Adjuster 37 0704-854 2 Spacer 38 8051-277 2 Washer, Lock 39 8042-486 2 Nut 40 0623-123 2 Screw, Cap 41 2604-827 2 Wheel, Idler - Green (inc. 9-10) 2604-828 2 Wheel, Idler - Red (inc. 9-10) (Black) 42 8020-223 2 Screw, Cap 43 1604-952 2 Cap, Idler Wheel 11
REAR SUSPENSION FRONT ARM ASSEMBLY 0740-205 1 1704-246 1 Arm, Front Suspension - Platinum (inc. 2-5) 2 1623-011 1 Washer, Grease Fitting 3 1623-010 3 Fitting, Grease - Self-Tapping 4 0604-889 4 Bushing, Front Arm 5 2604-128 2 Bushing, Front Arm 6 2604-591 1 Axle, Aluminum 7 1604-162 2 Axle, Inner Carriage 8 8020-223 2 Screw, Cap 9 8020-229 2 Screw, Cap 10 0114-197 2 Washer 11 8047-486 2 Nut, Lock 12 1623-044 2 Knob, Adjuster 13 0623-184 8 Washer 14 2604-657 2 Strap, Limiter 15 0623-325 2 Nut, Wing 16 8047-366 2 Nut, Lock 17 8002-043 2 Screw, Cap 18 0604-590 1 Cover, Shock 19 1704-259 1 Spring, Compression 20 8048-486 1 Nut, Lock 21 1603-889 1 Retainer, Spring 22 1603-531 1 Axle, Serrated 23 8020-226 1 Screw, Cap 24 2604-741 1 Shock Absorber, Front Arm 25 2603-532 1 Retainer, Spring - Lower 26 2603-534 1 Sleeve, Wear 12
REAR SUSPENSION REAR ARM ASSEMBLY 0739-842 1 0704-783 1 Arm, Idler - Platinum (inc. 2 and one No. 3-4) 2 2604-128 2 Bushing, Flared 3 1623-011 2 Washer, Grease Fitting 4 1623-010 2 Fitting, Grease - Self-Tapping 5 1704-001 1 Arm, Rear - Platinum (inc. one No. 3-4) 6 1623-037 1 Screw, Cap 7 0623-439 1 Washer 8 2604-664 2 Bushing, Rear Arm 9 2604-663 1 Tube, Axle 10 8047-490 1 Nut, Lock 11 8020-220 2 Screw, Cap 12 2604-176 1 Axle, Aluminum 13 1604-204 1 Block, Spring Adjuster - Right 1604-205 1 Block, Spring Adjuster - Left 14 0623-138 2 Ring, Retaining 15 2604-764 4 Sleeve, Spring 16 1704-352 1 Spring, Suspension - Right 1704-353 1 Spring, Suspension - Left 17 1604-690 2 Wheel, Idler (inc. 18-19) 18 0107-598 2 Bearing 19 0123-798 2 Ring, Retaining 20 1604-507 2 Spacer, Pivot - Idler Arm 21 1604-181 2 Axle, Powder Metal 22 1604-187 2 Washer, Pivot - Idler Arm 23 0704-981 2 Arm, Pivot Idler (inc. 24-26) 24 1604-202 4 Bushing, Flared 25 8020-138 4 Screw, Cap 26 8048-426 4 Nut, Lock 27 1623-166 2 Screw, Cap 28 8020-233 2 Screw, Cap 29 1604-498 4 Axle, Link - Flanged 30 0704-350 2 Link, Rear Shock 31 1604-139 3 Sleeve, Shock 32 8041-486 2 Nut, Lock 33 8048-486 1 Nut, Lock 34 8020-226 1 Screw, Cap 35 2604-161 1 Shock Absorber - Rear Arm 13
FRONT FRAME AND FOOTREST ASSEMBLY 0740-233 1 0707-988 1 Chassis - Assembly (inc. 2-8) 2 1623-359 2 Bolt, Carriage - Ribbed 3 1623-019 2 Bolt, Carriage - Ribbed 4 0675-161 4 Bearing 5 0607-656 2 Bushing, Upper A-Arm Mount 6 0607-657 6 Bushing, Lower A-Arm Mount 7 1623-010 2 Fitting, Grease 8 0623-581 9 Insert 9 1623-171 1 Clip 10 8020-040 4 Screw, Machine 11 8020-131 5 Screw, Cap 12 3606-416 1 Brace, Side Plate - Right 13 0608-364 1 Mount, Engine 14 3606-761 1 Protector, Main Harness 15 1623-353 3 Screw, Self-Tapping 16 1623-204 1 Screw, Self-Tapping 17 0608-449 1 Guide, Rope 18 8041-426 1 Nut, Lock 19 2706-685 2 Tube, Support - Footrest 20 3606-775 2 Guard, Support Tube 21 8017-581 2 Screw, Machine 22 1623-371 2 Screw, Tube 23 2706-580 2 Plate, Backing 24 8060-686 AR Rivet 25 2706-816 1 Footrest - Right (inc. 26-28) 2706-817 1 Footrest - Left (inc. 26-29) 26 8060-484 AR Rivet 27 1623-417 2 Grommet 28 3606-837 2 Plate, Retaining 29 0607-835 1 Plate, Mounting - Belt Guard 30 1623-264 AR Rivet 31 3606-904 1 Bracket, Support - Footrest - Right 3606-905 1 Bracket, Support - Footrest - Left 32 3606-907 1 Bracket, Support - Footrest - Lower Left 33 2706-629 1 Brace, Side Plate - Left 34 1623-406 4 Clip, Routing 35 0623-454 1 Clip, Routing 36 0623-677 3 Cable Tie, Push-Mount 14
HOOD AND WINDSHIELD ASSEMBLY 0740-206 1 1718-741 1 Hood w/decals - Green (inc. 2-11) 1718-740 1 Hood w/decals - Black (inc. 2-11) (Black) 2 1718-678 1 Hood w/o Decals - Green (inc. 3-6) 1718-598 1 Hood w/o Decals - Black (inc. 3-6) (Black) 3 1623-026 2 Pin, Clevis 4 0623-847 2 Clip, Hairpin 5 6611-143 1 Decal, Caution 6 6611-144 1 Decal, Warning - English 6611-145 1 Decal, Warning - French 7 3611-611 1 Decal, Made In U.S.A. - Domed 8 6611-462 1 Decal, Hood - Lower Right 6611-463 1 Decal, Hood - Lower Left 6611-472 1 Decal, Hood - Lower Right (Black) 6611-473 1 Decal, Hood - Lower Left (Black) 9 6611-460 1 Decal, Hood - Vent - Upper Right 6611-461 1 Decal, Hood - Vent - Upper Left 6611-470 1 Decal, Hood - Vent - Upper Right (Black) 6611-471 1 Decal, Hood - Vent - Upper Left (Black) 10 6611-458 1 Decal, Hood - Vent - Lower Right 6611-459 1 Decal, Hood - Vent - Lower Left 6611-468 1 Decal, Hood - Vent - Lower Right (Black) 6611-469 1 Decal, Hood - Vent - Lower Left (Black) 11 6611-502 1 Decal, Hood - Center 6611-503 1 Decal, Hood - Center (Black) 12 2706-793 1 Screen, Vent - Center 13 2706-794 1 Screen, Vent - Front - Right 2706-795 1 Screen, Vent - Front - Left 14 2706-796 1 Screen, Vent - Rear - Right 2706-797 1 Screen, Vent - Rear - Left 15 0123-394 38 Clip, Retaining 16 0617-490 1 Foam, Hood - Right 0617-491 1 Foam, Hood - Left 17 0617-489 1 Foam, Hood - Rear 18 0623-302 4 Screw, Self-Tapping 19 2606-726 2 Cable, Hood 20 1623-052 2 U-Nut 21 0623-362 4 Rivet, Reinstallable 22 3606-868 1 Windshield 23 0616-032 2 O-Ring 24 3606-428 1 Bezel, Intake - Right 3606-429 1 Bezel, Intake - Left 25 0617-486 1 Foam, Intake Bezel - Right 0617-487 1 Foam, Intake Bezel - Left 15
0740-208 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES 1 1686-024 1 Harness, Main 2 1686-069 1 Harness, Hood 3 0123-788 AR Cable Tie - 8 in. 4 0609-694 1 Lens/Reflector - Headlight - Right (inc. 5-6) 0609-695 1 Lens/Reflector - Headlight - Left (inc. 5-6) 5 0609-251 2 Bulb, Headlight 6 0609-693 2 Bulb, Headlight 7 1623-025 2 Insert 8 0623-360 2 Spring, Adjuster 9 1623-024 2 Screw, Adjuster 10 1623-137 2 Clip, Hairpin 11 1623-272 2 Clip - Right 1623-273 2 Clip - Left 12 0620-292 1 Tachometer/Speedometer (inc. 13-14) 13 0620-281 1 Bracket, Retaining 14 0620-280 4 Nut w/washer 15 0617-501 2 Foam, Hood/Headlight 16 8047-366 1 Nut, Lock 17 0630-181 1 Regulator, Voltage 18 1686-003 1 Harness, Extension - Taillight 19 0686-858 1 Harness, Adapter 16
CONSOLE AND SWITCH ASSEMBLY 0740-214 1 3606-443 1 Console 2 8017-425 7 Screw, Machine 3 8017-427 4 Screw, Machine 4 8041-246 4 Nut, Lock 5 0609-651 1 Switch, Ignition (inc. 6) 6 * 1 Key 7 0609-113 1 Nut, Retaining 8 0123-899 1 Washer, Ignition Switch 9 0609-450 1 Spacer, Ignition Switch 10 7611-099 1 Decal, Console 11 0687-179 1 Cable, Choke (inc. 12) 12 0687-132 1 Nut, Retainer * Key is coded to switch; see dealer to determine part number. 17
BELLY PAN ASSEMBLY 0739-494 1 2706-628 1 Belly Pan - Right - Black 2706-815 1 Belly Pan - Left - Black 2 3606-426 1 Panel, Access - Right 3606-427 1 Panel, Access - Left 3 0617-502 1 Foam, Side Panel - Right 0617-503 1 Foam, Side Panel - Left 4 0123-394 11 Clip, Retaining 5 3606-867 1 Belly Pan, Center - Black 6 4606-040 1 Bumper, Front - Black 7 2606-911 1 Screen, Belly Pan - Center 8 0623-784 10 Screw, Self-Tapping 9 0623-797 34 Screw, Self-Tapping 10 1612-853 1 Shield, Heat 11 1612-861 1 Deflector, Exhaust 12 0623-778 14 Rivet 13 1623-030 2 Nut, Speed 14 8017-581 4 Screw, Machine 15 8050-217 8 Washer 16 8047-366 4 Nut, Lock 17 0619-206 AR Tape, Foil 18 2606-624 2 Strap, Hold-Down 19 6611-485 1 Decal, Belly Pan - Right 6611-484 1 Decal, Belly Pan - Left 6611-487 1 Decal, Belly Pan - Right (Black) 6611-486 1 Decal, Belly Pan - Left (Black) 20 6611-635 1 Decal, Clutching 21 6611-514 1 Decal, Reflector - Amber - Right 6611-515 1 Decal, Reflector - Amber - Left 22 0607-447 2 Cable 23 0605-283 2 Clip, Hairpin 24 8061-426 2 Rivet 18
BELT GUARD ASSEMBLY 0740-235 1 0707-963 1 Guard, Belt 2 1611-565 1 Decal, Warning - Belt Guard 3 3611-969 1 Decal, ACT - Roller Driven Clutch 4 0707-582 1 Retainer, Drive Belt 5 0617-497 1 Foam, Belt Guard 6 0607-836 1 Bracket, Mounting 7 8061-506 4 Rivet 8 1611-582 1 Decal, Caution - Jetting/Storage 19
GAS TANK ASSEMBLY 0740-207 1 0770-707 1 Tank, Gas (inc. 2-11) 2 1670-725 1 Gauge, Fuel - Assembly w/gasket (Press-Fit) 3 1670-447 1 Cap, Gas Tank (inc. 4) 4 1670-511 1 Seal, Tank Cap 5 0605-769 1 Plate, Mounting - Steering Post 6 1623-408 2 Washer, Rubber 7 1623-355 2 Nut, Push 8 0510-358 1 Strainer 9 6101-001 AR Hose, Gasline - 100 ft 6101-009 AR Hose, Gasline - 50 ft 10 0670-289 AR Tape, Teflon 11 1670-321 1 Outlet, Tank 12 8061-628 1 Rivet 13 3606-173 1 Strap, Hold-down - Coolant Tank 14 8047-366 2 Nut, Lock 15 0123-765 2 Washer, Cup 16 1623-077 2 Nut 17 8017-582 2 Screw, Machine 20
SEAT ASSEMBLY 0739-789 1 7998-027 1 Complete Seat Assembly (inc. 2-9) 7998-137 1 Complete Seat Assembly (inc. 2-9) (Black) 2 2706-687 1 Cover, Seat 2706-739 1 Cover, Seat (Black) 3 0624-528 AR Staple, Seat Cover 4 2706-647 1 Foam, Seat Cushion 5 3606-430 1 Seat-Base 6 1623-393 2 Clip, Retaining - Seat-Base 7 8061-506 1 Rivet 8 3606-813 1 Strap, Hold-Down - Seat Pad 9 8050-127 1 Washer 10 1623-198 2 Stud, Latch - Seat-Base 11 0423-178 2 Washer, Crush 12 8048-426 2 Nut, Lock 13 7998-026 1 Pad, Seat (inc. 14-17) 14 2706-698 1 Foam, Seat Pad 15 2706-697 1 Cover, Seat Pad (inc. 16-17) 16 1623-348 2 Clip, Retaining - Strap 17 1623-347 3 Clip, Hold-Down - Seat Pad 21
TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY 0739-505 *Optional 1 1718-820 1 Tunnel Assembly (inc. 2-9) 2 0707-989 1 Tunnel, Front (inc. 3-4) 3 1623-127 2 Insert 4 1623-070 1 Stud, Self-Clinching 5 1718-817 1 Tunnel, Rear (inc. 6) 6 0623-582 2 Insert 7 2706-456 1 Bracket, Suspension Mounting - Right - Rear 2706-457 1 Bracket, Suspension Mounting - Left - Rear 8 8060-686 AR Rivet 9 8060-484 18 Rivet 10 3606-530 1 Roll, Tunnel - Right 3606-531 1 Roll, Tunnel - Left 11 0123-418 AR Rivet 8060-486 AR Rivet* 12 0623-562 1 Plug, Hole 13 1623-045 2 Spacer 14 8017-406 2 Screw, Machine 15 3606-584 2 Rack 16 8017-577 10 Screw, Machine 17 3606-585 1 Pad, Rubber 18 0623-363 1 Nut, Speed 19 0509-022 1 Taillight Assembly (inc. 20-22) 20 0509-025 1 Housing, Taillight 21 0409-057 1 Socket, Taillight 22 0409-056 1 Bulb, Taillight 23 0623-257 2 Screw, Self-Tapping 24 8050-127 2 Washer 25 3606-747 1 Housing, Taillight Mounting 26 8017-617 1 Screw, Machine 27 3606-431 1 Bumper, Rear 28 5611-853 1 Decal, Warning - Towing (English) 29 5611-852 1 Decal, Warning - Towing (French) 30 8017-607 2 Screw, Machine 31 6611-012 1 Decal, Reflector - Red - Right 6611-013 1 Decal, Reflector - Red - Left 32 8017-581 4 Screw, Machine 33 3606-763 1 Snowflap 3606-764 1 Snowflap (Black) 34 3606-776 1 Support, Snowflap 35 0623-184 4 Washer 36 8047-366 4 Nut, Lock 37 1623-022 4 Screw, Self-Tapping 38 6611-491 1 Decal, 141 - Right 6611-490 1 Decal, 141 - Left 6611-497 1 Decal, 141 - Right (Black) 6611-496 1 Decal, 141 - Left (Black) 39 6611-524 1 Decal, Tunnel 6611-525 1 Decal, Tunnel (Black) 40 3606-849 2 Deflector, Snow 41 8050-157 4 Washer 22
COOLING ASSEMBLY 0739-574 1 2706-656 1 Heat Exchanger - Rear 2 8060-686 7 Rivet 3 1623-349 7 Clamp, Hose 4 0610-552 3 Hose, Coolant 5 3606-564 2 Protector, Hose - Rear 6 8060-484 AR Rivet 8060-488 AR Rivet 7 3606-518 1 Heat Exchanger - Right 8 3606-519 1 Heat Exchanger - Left 9 3606-565 1 Protector, Hose - Front 10 1623-229 2 Clamp, Hose 11 0610-625 1 Hose, Coolant Tank/Engine 12 1623-322 2 Clamp, Hose 13 2706-791 1 Tank, Coolant 14 0610-553 1 Hose, Coolant Tank/Right Heat Exchanger 15 2611-758 1 Decal, Fill Level - Coolant Tank 16 0610-016 AR Hose, Vent - 25 ft 0610-015 AR Hose, Vent - 100 ft 17 0606-268 1 Cap, Filler Neck 18 1623-234 1 Clamp, Hose 19 0610-538 AR Hose, Coolant - 25 ft 20 0623-063 1 Clamp, Hose 21 0123-788 1 Cable Tie - 7.5 in. 22 1623-350 1 Clamp, Hose 23 0610-626 1 Hose, Coolant - Engine/Front Heat Exchanger 24 1619-038 1 Protector, Hose - 7 in. 25 4606-102 1 Pad, Support - Coolant Bottle 23
ENGINE AND RELATED PARTS 0740-209 1 0662-415 1 Engine, AW50L4 2 0636-363 1 Handle, Recoil 3 0606-885 1 Cap, Recoil Handle 4 0708-461 1 Bracket, Engine Mounting - Right 5 8413-830 2 Screw, Cap 6 8020-136 1 Screw, Cap 7 8047-426 3 Nut, Lock 8 0623-677 2 Cable Tie - Push-Mount 9 1670-328 1 Foil, Protective 10 0623-373 3 Clamp, Hose 11 0610-076 AR Hose, Coolant - 10 ft 12 0610-581 3 Clamp, Hose 13 1670-596 1 Y-Fitting 14 0623-987 2 Washer 15 0708-442 1 Bracket, Engine Mounting - Left (inc. 16 and two No. 17) 16 0608-430 1 Spacer, Torque Bumper 17 1623-128 8 Screw, Self-Tapping 18 0608-433 1 Bumper, Torque 19 8413-825 4 Screw, Cap 20 0645-443 1 Damper, Clutch 21 0725-469 1 Clutch, Drive 22 0627-036 1 Belt, Drive 23 0623-210 1 Washer, High Collar 24 0623-804 1 Bolt, Clutch 25 8050-252 4 Washer 26 0619-619 1 Conduit, Flexible - 4 in. 27 0619-994 1 Conduit, Flexible (3/4 in. ID) - 6 in. 24
EXHAUST ASSEMBLY 0740-210 1 1712-125 1 Chamber, Expansion - Assembly (inc. 2-8) 2 1712-124 1 Chamber, Expansion 3 0624-526 AR Tie, Perforated Band - 5 ft 0624-541 AR Tie, Perforated Band - 25 ft 4 1612-178 3 Spring, Exhaust 5 1612-693 1 Packing, Expansion Chamber - Upper 6 1612-696 1 Cover, Expansion Chamber - Upper 7 1612-695 1 Cover, Expansion Chamber - Lower 8 1612-694 1 Packing, Expansion Chamber - Lower 9 1712-041 1 Manifold, Exhaust 10 0612-820 3 Spring, Exhaust 11 1612-014 1 Gasket, Exhaust 12 0612-693 1 Gasket, Exhaust - Tailpipe 13 1712-146 1 Resonator 14 0612-471 3 Spring, Extension 15 1623-374 1 Pin, Mounting - Resonator 16 1623-375 1 Grommet 17 1623-379 1 Clip, Hairpin 18 1612-873 2 Grommet 19 1612-927 1 Washer, Tab 20 8047-486 1 Nut, Lock 25
AIR INTAKE ASSEMBLY 0740-143 1 0617-500 2 Foam, Air Intake 2 8017-581 2 Screw, Machine 3 3606-480 1 Intake, Air - Right 4 1623-137 1 Clip, Hairpin 5 1623-409 2 Nut, Push 6 0623-184 2 Washer 7 8047-366 2 Nut, Lock 8 0623-600 1 Plug 9 0617-488 1 Foam, Air Intake 10 3606-811 1 Foil, Protective 11 3606-779 1 Foil, Protective 12 0623-165 6 Clip, Retaining 13 1670-517 1 Screen, Vent 14 0617-499 1 Seal, Air Intake 15 3606-481 1 Intake, Air - Left 26
AIR SILENCER, CARBURETOR, AND FUEL PUMP ASSEMBLY 0740-211 1 0770-611 1 Silencer, Air - Assembly (inc. 2-3) 2 1670-473 1 Intake, Air 3 1670-616 1 Silencer, Air 4 1670-514 1 Connector, Air-Intake 5 1623-132 2 Clamp, Air-Intake Connector 6 1623-031 1 Screw, Self-Tapping 7 3606-146 1 Hold-Down, Air Silencer 8 1623-204 2 Screw, Self-Tapping 9 1670-640 1 Boot, Air Silencer 10 0770-708 2 Carburetor, VM34-613 0770-697 2 Carburetor, VM34-612 (International) 11 0623-652 2 Clamp, Hose 12 0610-442 2 Hose, Drain 13 8017-582 2 Screw, Machine 14 1670-537 1 Pump, Fuel 15 8047-366 2 Nut, Lock 16 0610-629 AR Hose, Gasline - 100 ft 0610-628 AR Hose, Gasline - 25 ft 17 0716-507 AR Protector, Hose 18 1623-234 5 Clamp, Hose 19 0610-007 AR Hose, Impulse 20 1623-233 4 Clamp, Hose 21 6101-001 AR Hose, Gasline - 100 ft 6101-009 AR Hose, Gasline - 50 ft 22 0623-677 1 Cable Tie - Push-Mount 23 3002-964 1 Clamp, Wire 24 1623-171 1 Clip, Snap 25 0617-485 2 Foam, Air Silencer 26 1623-336 2 Clip, Hose 27 1670-166 1 Filter, Fuel 28 0123-811 2 Cable Tie - 4 in. 27
OIL TANK ASSEMBLY 0740-066 1 1670-604 1 Tank, Oil 2 1670-325 1 Grommet 3 1670-481 1 Fitting, Elbow 4 0609-503 1 Sensor, Low Oil - Assembly (inc. 5-6) 5 0609-518 1 Switch, Oil Sensor w/harness 6 0609-237 1 Seal, Grommet - Oil Sensor 7 1670-365 1 Cap, Oil Tank (inc. 8) 8 0109-733 1 Seal, Cap - Oil Tank 9 4611-564 1 Decal, Oil Tank 10 0124-045 2 Clamp, Hose 11 0610-015 AR Hose, Oil - 100 ft 0610-016 AR Hose, Oil - 25 ft 12 1623-256 1 Grommet 13 3606-982 1 Shield, Heat 14 8050-157 2 Washer 15 8017-395 2 Screw, Machine 16 8017-577 3 Screw, Machine 17 0123-811 1 Cable Tie - 4 in. 28
Cam Arm Kit - p/n 3639-599 (inc. 3-5 and 7-8) Uncalibrated Drive Clutch - p/n 0746-149 0738-469 DRIVE CLUTCH (Assembly p/n 0725-469*) 1 0646-374 1 Sheave, Stationary 2 0746-142 1 Sheave, Movable (inc. 3) 3 0646-372 6 Bearing 4 0646-747 3 Pin, Cam Arm 5 1602-692 6 O-Ring 6 0746-744 3 Arm, Cam (inc. 7)* 0746-702 3 Arm, Cam (0-3,000 ft Alt.) (inc. 7) 0746-662 3 Arm, Cam (3-6,000 ft Alt.) (inc. 7) 0746-713 3 Arm, Cam (Over 9,000 ft Alt.) (inc. 7) 7 1623-183 3 Screw, Set 8 8048-366 3 Nut, Lock 9 0646-377 1 Spacer 10 0746-115 1 Spider Assembly 11 0646-147 1 Spring, Drive Clutch - Yellow/White* 0646-149 1 Spring, Drive Clutch - Red (0-6,000 ft Alt.) 12 0646-140 1 Nut 13 0746-113 1 Cover 14 8051-212 6 Washer, Lock - Spring 15 1623-085 6 Screw, Machine * Drive Clutch (p/n 0725-469) is calibrated to 6-9,000 ft Alt. 29
0739-053 DRIVEN CLUTCH (Assembly p/n 0726-189) 1 0748-595 1 Cover, Torque Bracket (inc. 2-3) 2 0648-433 1 Ring, Snap 3 0648-009 1 Bearing 4 1623-074 3 Screw, Machine 5 0648-439 1 Adjuster, Spring 6 0648-693 1 Spring, Driven Clutch - White 7 0648-720 1 Spacer 8 0648-448 1 Bracket, Torque 36 9 0748-614 1 Sheave, Stationary (inc. 10-12) 10 0648-097 6 Pin, Cam Roller 11 0648-139 6 Roller, Cam 12 8070-224 6 Pin, Spring 13 0648-688 1 Retainer, Torque Bracket 14 0748-591 1 Sheave, Movable 15 1623-258 6 Screw, Machine 16 0648-437 1 Seat, Spring 30
CARBURETOR VM34-613 (Complete Assembly p/n 0770-708); VM34-612 (Complete Assembly p/n 0770-697 - International) 0738-474 *Not a Service Part 1 * 1 Mixing Body Assembly 2 6505-188 1 Cap, Starter Plunger 3 6505-033 1 Spring, Starter Plunger 4 6506-389 1 Starter Plunger 5 6505-021 1 Spring, Throttle Stop Screw 6 6505-022 1 Screw, Throttle Stop 7 6505-020 1 Spring, Pilot Air Screw 8 6505-019 1 Screw, Pilot Air 9 6505-047 1 Pilot Jet 40 6505-029 1 Pilot Jet 35 (International and 0-3,000 ft Alt. STD) 10 6505-620 1 Ring, Baffle 11 6505-068 1 Main Jet 250** 6505-290 1 Main Jet 290** (International) 12 6505-558 1 Top, Mixing Body 13 6506-393 1 Spring, Piston Valve 14 6505-630 1 Plate 15 0770-037 1 Block, Magnet 16 6505-559 1 Screw w/washer 17 6505-610 1 E-Clip 18 6505-437 1 Washer, E-Clip 19 6506-297 1 Jet Needle 6DF7-2 6506-297 1 Jet Needle 6DF7-3 (International and 0-3,000 ft Alt. STD) 20 6505-561 1 Piston Valve CA 3.0 21 6506-376 1 Needle Jet P-4 (480) 22 0623-137 2 Screw, Self-Tapping 23 0630-076 1 Switch, Magnetic - Carburetor 24 6505-186 1 Plate 25 6505-036 1 Screw w/spring Washer 26 6505-024 1 Washer 27 6505-160 1 Needle Valve Assembly 1.5 28 6505-153 1 Pin, Float Arm 29 6505-027 1 Arm, Float 30 6505-010 2 Cap 31 6505-009 2 Float 32 6505-030 1 Gasket, Float Chamber 33 6506-377 1 Chamber, Float 34 6505-608 2 Plate, Hose 35 6505-629 2 Hose 36 6505-014 4 Screw w/spring Washer 37 6505-622 1 O-Ring 38 6505-617 1 Screw, Drain 39 6505-569 1 Cap 40 6505-607 1 Washer **Alternate Carburetor Parts on page 41 31
CYLINDER AND HEAD ASSEMBLY 0739-389 1 3006-744 1 Head, Cylinder 2 0217-709 2 Plug, Spark (BR9EYA) 3 3006-419 2 Bolt 4 3006-420 2 O-Ring 5 3004-459 12 Bolt 6 3003-227 12 O-Ring 7 3003-224 2 O-Ring 8 3003-226 2 O-Ring 9 3004-326 6 Nut 10 3004-491 8 Nut 11 3004-975 4 Pin, Dowel 12 3006-743 8 Bolt, Stud 13 3006-748 2 Gasket, Exhaust 14 3006-745 2 Cylinder 15 3006-423 1 Gasket, Cylinder 16 3004-279 6 Bolt, Stud 32
CRANKCASE ASSEMBLY 0739-390 1 3006-912 1 Crankcase (inc. 2-7) 2 3006-483 10 Bolt 3 3004-341 1 Bolt 4 3423-393 1 Bolt 5 0693-303 4 Bolt 6 3003-647 1 Bushing 7 3005-206 2 Pin, Dowel 8 0630-140 1 Switch, Temperature 33
PISTON AND CRANKSHAFT 0739-391 1 3006-746 2 Piston Set (inc. 2-3) 2 3005-828 2 Ring Set, Piston 3 3005-304 4 Circlip, Piston 4 3005-816 2 Pin, Piston 5 3008-500 4 Washer 6 3008-503 2 Bearing 7 3006-428 1 Crankshaft Assembly (inc. 8-25) 8 3005-492 2 Connecting Rod 9 3005-494 2 Washer, Crank Pin Bearing 10 3005-505 2 Bearing 11 3005-502 2 Washer 12 3005-507 1 Bearing 13 3005-603 1 Shim 14 3006-346 1 Crankshaft - Right 15 3005-500 2 Balancer, Crankshaft 16 3004-372 6 Screw 17 3006-348 1 Wheel, Crankshaft 18 3005-508 2 Ring, Middle Crank Seal 19 3005-503 1 Bearing 20 3005-597 2 Race, Middle Crank Seal 21 3006-353 1 Gear, Oil Pump Drive 22 3005-504 1 Bearing 23 3006-347 1 Crankshaft - Middle 24 3006-349 1 Crankshaft - Left 25 3006-540 1 Bearing 26 3003-658 4 Pin, Alignment 27 3003-759 1 Seal, Oil 28 3008-525 1 Seal, Oil 29 3010-070 1 Key 30 3003-359 1 C-Ring 31 3005-909 1 Seal, Mechanical - Water Pump 32 3004-760 1 Seal, Water/Oil Pump 33 3006-354 1 Gear, Driven - Oil Pump 34 3005-049 1 Shim, Oil Pump Shaft 34
REED VALVE ASSEMBLY 0739-392 1 3005-876 2 Valve, Reed - Assembly (inc. 2-4) 2 3005-877 4 Stopper 3 3005-878 4 Valve, Reed 4 3004-506 16 Screw 5 3005-879 2 Gasket, Reed Valve 6 3006-747 2 Pipe, Intake 7 3004-212 2 Clamp 8 3004-341 12 Bolt 9 3002-964 1 Clamp, Wire 10 3006-485 1 Bracket, Oil Pump Cable 35
OIL PUMP 0740-232 1 3006-976 1 Pump, Oil 2 3006-085 2 Bolt 3 3008-030 1 O-Ring 4 3004-804 1 Retainer, Oil Pump Input Shaft 5 3005-126 1 O-Ring 6 3004-805 1 Valve, Check 7 3402-009 2 Gasket 8 3004-346 1 Bolt 9 3008-037 6 Clamp, Hose 10 3005-357 1 Hose 11 3008-035 2 Hose, Oil 12 3005-696 1 Clamp 36
WATER PUMP/WATER MANIFOLD 0739-398 1 3006-942 1 Cover, Water Pump 2 3004-341 6 Bolt 3 3006-356 1 O-Ring, Water Pump Cover 4 3005-899 2 Pin, Dowel 5 3003-426 1 Bolt 6 3003-432 1 Gasket 7 3003-431 1 Washer 8 3006-324 2 Clamp 9 3005-697 1 Impeller, Water Pump 10 3004-009 1 Circlip 11 3006-360 1 Hose, Water Inlet 12 3006-914 1 Cap, Thermostat 13 3006-913 1 Thermostat 14 3004-512 3 Bolt 37
RECOIL STARTER 0739-364 *Not a Service Part 1 3006-915 1 Starter Assembly (inc. 2-10) 2 3003-179 1 Roller, Starter 3 3002-921 1 Spring 4 3006-457 1 Ratchet Set (inc. 5-7) 5 * 1 Spring, Friction 6 * 1 Washer 7 * 1 Spring, Return 8 3006-475 1 Plate, Friction 9 3006-456 1 Nut 10 3006-889 1 Rope, Starter 11 3004-383 4 Screw, Cap 12 3003-929 1 Pulley, Starter 13 3004-705 3 Screw, Cap 38
MAGNETO 0739-402 1 3004-378 4 Bolt 2 3006-364 1 Base, Stator - Plate 3 3006-750 1 Stator 4 3005-433 3 Bolt 5 3004-338 1 Bolt 6 3006-751 1 Rotor/Flywheel 7 3005-987 1 Washer 8 3004-362 1 Washer, Lock 9 3006-476 1 Bolt 10 3004-706 2 Screw 11 3005-889 1 Sensor, Ignition Timing 12 3005-960 1 Plate, Stator Lead Wire 13 3005-775 1 Grommet, Stator Lead Wire 39
ELECTRICAL 0739-403 1 3006-752 1 CDI Unit 2 3003-474 1 Cover, Connector 3 3006-692 1 Coil, Ignition 4 3006-367 2 Cap, Spark Plug 5 3005-387 1 Clamp 40
MAIN JETS AVAILABLE JET P/N JET P/N 120 6505-270 420 6505-125 130 6505-216 430 6505-146 140 6505-217 440 6505-126 150 6505-168 450 6505-147 160 6505-064 460 6505-127 170 6505-065 470 6505-148 180 6505-056 480 6505-149 190 6505-066 490 6505-150 200 6505-144 500 6505-151 210 6505-145 510N 6506-378 220 6505-137 520 6505-530 230 6505-067 520N 6506-379 240 6505-079 530 6505-170 250 6505-068 530N 6506-380 260 6505-017 540 6505-531 270 6505-069 540N 6506-381 280 6505-080 550N 6506-382 290 6505-123 560 6505-172 300 6505-128 560N 6506-383 310 6505-136 580 6505-211 320 6505-074 590 6505-173 330 6505-070 600 6505-532 340 6505-076 620 6505-174 350 6505-071 640 6505-533 360 6505-038 650 6505-534 370 6505-072 660 6505-535 380 6505-077 680 6505-169 390 6505-078 700 6505-536 400 6505-124 710 6505-537 410 6505-212 720 6505-538 PISTON VALVES AVAILABLE (VM-Style) SLIDE CARBURETOR SIZE (mm) * For models with carburetor switch. THROTTLE VALVES AVAILABLE (TM-Style) SLIDE CARBURETOR P/N SIZE (mm) ALTERNATE CARBURETOR PARTS P/N 2.0 28-30 6505-048 3.0 28-30 6505-161 3.0 30 6505-510 3.5 30 6505-528 1.5 32-34 6505-256 2.5 32-34 6505-246 3.0 32-34 6505-439 3.5 32-34 6505-248 2.5 34 6505-500 2.5 34 6505-614* 3.0 34 6505-507 3.0 34 6505-561* 2.0 36 6505-877 3.0 36 6505-592* 2.5 38 6505-254 3.0 38 6506-643 3.5 38 6505-436 3.5 38 6505-525 3.5 38 6505-526 3.5 38 6505-554 3.5 38 6505-613* 4.0 38 6505-504 3.5 40 6505-575* 1.0 40-44 6505-092 2.0 40-44 6505-179 2.5 40-44 6505-570 3.5 40-44 6505-548 3.0 40-44 6506-809 3.5 40-44 6505-813* 2.0 38 6506-119 3.0 38 6506-120 3.0 38 6506-232 3.5 38 6506-210 2.5 40 6506-273 NEEDLE JETS AVAILABLE(VM-Style) NEEDLE JET P/N NEEDLE JET P/N O-6 (480) 6505-931 Q-2 (480) 6505-641 O-8 (182) 6505-181 Q-3 (480) 6505-599 O-8 (480) 6505-824 Q-4 (166) 6505-214 P-0 (159) 6505-155 Q-4 (480) 6505-636 P-0 (166) 6505-007 Q-5 (159) 6505-119 P-0 (169) 6505-051 Q-5 (166) 6505-520 P-0 (480) 6505-598 Q-5 (480) 6505-580 P-2 (480) 6505-595 Q-6 (166) 6505-506 P-4 (159) 6505-221 Q-8 (480) 6506-112 P-4 (166) 6505-502 R-0 (166) 6505-505 P-4 (480) 6505-540 Z-4 (224) 6505-808 P-4 (169) 6505-164 Z-5 (224) 6505-541 P-5 (480) 6505-542 Z-6 (224) 6505-597 P-6 (159) 6505-247 Z-8 (224) 6505-572 P-6 (166) 6505-268 Z-9 (224) 6505-618 P-6 (480) 6505-539 AA-0 (224) 6505-544 P-6 (251) 6505-235 AA-1 (224) 6505-609 P-8 (159) 6505-298 AA-2 (224) 6505-545 P-8 (166) 6505-433 AA-3 (224) 6505-604 P-8 (480) 6505-543 AA-4 (224) 6505-605 Q-0 (159) 6505-260 AA-5 (224) 6505-099 Q-0 (166) 6505-190 AA-8 (224) 6505-571 Q-0 (480) 6505-529 BB-0 (224) 6505-182 Q-2 (166) 6505-508 BB-5 (224) 6505-180 JET NEEDLES AVAILABLE JET P/N JET P/N NEEDLE (VM-Style) NEEDLE (TM-Style) 6CH3 6505-519 9CFH1-56 6506-116 6DH2 6505-252 9DH2-59 6506-110 6DH3 6505-509 9DH5-61 6506-114 6DH4 6505-003 9DEH1-55 6506-118 6DH7 6505-215 9DEH2-57 6506-115 6DH8 6505-236 9EGY01-57 6506-192 6DF7 6506-297 9EH09 6506-173 7DJ2 6505-549 9EH2-57 6506-111 7DH2 6505-097 9EH6-60 6506-117 7DH5 6505-814 9EJ1-60 6506-384 9EH7-62 6506-113 9DFH2-58 6506-200 9DFH2-59 6506-201 9DFH3-56 6506-186 9DEH3 6506-182 9DFH1-56 6506-221 9DFH-59 6506-304 9EH6-59 6506-228 9DH9-54 6506-272 9EH6-58 6506-290 9DFH4-60 6506-260 9EFH9-60 6506-374 INLET NEEDLE ASSEMBLIES AVAILABLE (VM-Style) SEAT DIA. CARB. SIZE (mm) P/N 1.5 mm (Steel) 28, 30, 32, 34 6505-026 1.5 mm (Viton) 28, 30, 32, 34 6505-160 1.5 mm (Steel) 28 34 GVM 6505-245 1.5 mm (Steel) 36, 38, 40, 44 6505-103 1.5 mm (Viton) 36, 38, 40, 44 6505-171 1.8 mm (Viton) 36, 38, 40, 44 6505-175 2.0 mm (Viton) 36, 38, 40, 44 6505-176 INLET NEEDLE ASSEMBLIES AVAILABLE (TM-Style) SEAT DIA. CARB. SIZE (MM) P/N 1.5 mm (Steel) 38 6506-121 1.8 mm (Steel) 38 6506-144 PILOT JETS AVAILABLE JET NO. P/N JET NO. P/N 17.5 6505-218 35 6505-029 20 6505-138 40 6505-047 22.5 6505-310 45 6505-278 25 6505-075 50 6505-262 27.5 6505-503 52.5 6505-261 30 6505-073 55 6505-255 41
RELATED ITEMS 2005 M5 (Model No. S2005M5CICUSG) (Model No. S2005M5CICUSB) (Model No. S2005M5CICOSG - International) 3639-982 Altitude Kit (0-3000 ft) 3639-983 Altitude Kit (3-6000 ft) 3639-984 Altitude Kit (Over 9000 ft) 3639-087 Avalanche Probe 3639-657 Cover, Machine (Deluxe) 3639-669 Cover, Machine (Premium) 3639-539 Gasket Set 2257-231 Handbook, Safety (E/F) 0639-456 Handlebar Muffs 3639-719 Handlebar Bag 3639-734 Hitch, Pivot 2257-141 Manual, Illustrated Parts 2257-085 Manual, Operator s (E/F) 0652-115 Paint, Hood - Green (1/2 oz) 0652-100 Paint, Hood - Black (1/2 oz) 0652-024 Paint, Metal - Black 3639-725 Rack Bag 3639-579 Rack Strap 3639-597 Seat Liner Bag 3639-588 Shovel, Snow w/saw (Deluxe) 3639-838 Skid Plate - Black 4639-029 Tank Pads 4639-140 Tether Switch 3639-755 Windscreen, Low - Chrome 3639-767 Windshield, Mid - Smoke 1639-396 Windshiled, Flair Bag 1639-397 Windshield, Storage Bag NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A p/n 2257-141