700 Diesel EGR Street Legal MY08 04

2008
700 DIESEL EFT
MODEL NUMBER A2008TBT4DETI (RED)

MODEL NUMBER A2008TBT4DETM (GREEN)
(VADA7D4AV80X10001 - VADA7D4AV80X10493)
MO R E TO GO ON.
TM
TABLE OF CONTENTS
2008 ATV 700 Diesel EFT
Red (Model No. A2008TBT4DETI)
Green (Model No. A2008TBT4DETM)
FRONT RACK AND HEADLIGHT ASSEMBLIES .................................................................................................... 1
REAR RACK AND FOOTWELL ASSEMBLIES ....................................................................................................... 2
FRAME AND RELATED PARTS ............................................................................................................................. 3
WINCH ASSEMBLY ................................................................................................................................................ 4
LICENSE PLATE HOLDER ASSEMBLY ................................................................................................................. 5
SEAT AND BACKREST ASSEMBLY ...................................................................................................................... 6
STEERING POST ASSEMBLY ............................................................................................................................... 7
HANDLEBAR ASSEMBLY ....................................................................................................................................... 8
FRONT SUSPENSION ASSEMBLY ........................................................................................................................ 9
REAR SUSPENSION ASSEMBLY ........................................................................................................................ 10
WHEEL AND TIRE ASSEMBLY ............................................................................................................................ 11
AUXILIARY BRAKE ASSEMBLY ........................................................................................................................... 12
PARKING BRAKE ASSEMBLY ............................................................................................................................. 13
HYDRAULIC HAND BRAKE ASSEMBLY .............................................................................................................. 14
HYDRAULIC BRAKE ASSEMBLY ......................................................................................................................... 15
FUEL TANK ASSEMBLY ....................................................................................................................................... 16
SHIFT LEVER ASSEMBLY ................................................................................................................................... 17
AIR INTAKE ASSEMBLY ....................................................................................................................................... 18
BATTERY ASSEMBLY .......................................................................................................................................... 19
ENGINE AND EXHAUST ....................................................................................................................................... 20
COOLING ASSEMBLY .......................................................................................................................................... 21
CASE/BELT COOLING ASSEMBLY ..................................................................................................................... 22
DRIVE TRAIN ASSEMBLY .................................................................................................................................... 23
FRONT DRIVE GEARCASE ASSEMBLY ............................................................................................................. 24
REAR DRIVE GEARCASE ASSEMBLY ................................................................................................................ 25
WIRING HARNESS ASSEMBLY ........................................................................................................................... 26
CLUTCHES AND V-BELT ASSEMBLIES .............................................................................................................. 27
TRANSMISSION RIGHT-SIDE ASSEMBLY .......................................................................................................... 28
TRANSMISSION LEFT-SIDE ASSEMBLY ....................................................................................................... 29,30
CRANKSHAFT ASSEMBLY .................................................................................................................................. 31
PISTON SET AND CONNECTING ROD ASSEMBLY ........................................................................................... 32
FLYWHEEL AND CROWN GEAR ASSEMBLY ..................................................................................................... 33
DRIVE PULLEY AND ALTERNATOR BELT ASSEMBLY ..................................................................................... 34
CRANKCASE, CRANKSHAFT SUPPORT, AND OIL FILTER ASSEMBLIES ...................................................... 35
CYLINDER HEAD AND PRECOMBUSTION CHAMBER ASSEMBLY ................................................................. 36
PTO VACUUM PUMP ASSEMBLY ....................................................................................................................... 37
ROCKER ARM COVER AND BREATHER SYSTEM ASSEMBLIES .................................................................... 38
FUEL SYSTEM INJECTION PUMP ASSEMBLY .................................................................................................. 39
CAMSHAFT AND FUEL PUMP DRIVE ECCENTRIC ........................................................................................... 40
CAM PULLEYS, TIMING BELT, AND SPEED GOVERNOR ASSEMBLY ............................................................ 41
ROCKER ARM, VALVES, AND OIL SWITCH ASSEMBLIES ............................................................................... 42
EXHAUST MANIFOLD ASSEMBLY ...................................................................................................................... 43
EGR SYSTEM ASSEMBLY ................................................................................................................................... 44
THERMOSTAT, WATER INLET FLANGE, AND OIL LEVEL STICK ASSEMBLIES ............................................. 45
OIL PUMP ASSEMBLY ......................................................................................................................................... 46
OIL PAN ASSEMBLY ............................................................................................................................................ 47
THROTTLE CONTROL AND LOCKED TORQUE DEVICE ASSEMBLIES ........................................................... 48
FUEL FILTER, ELECTRO-VALVE, AND HOSES ASSEMBLY ............................................................................. 49
FUEL FEED PUMP AND PUSH ROD ASSEMBLIES ............................................................................................ 50
WATER PUMP ASSEMBLY .................................................................................................................................. 51
INTAKE MANIFOLD AND THROTTLE CONTROL ASSEMBLY ........................................................................... 52
EXTERNAL ALTERNATOR ASSEMBLY ............................................................................................................... 53
STARTER MOTOR ASSEMBLY ........................................................................................................................... 54
BELT GUARD ASSEMBLY .................................................................................................................................... 55
CONTROL SWITCH HOUSING ASSEMBLY ........................................................................................................ 56
THROTTLE CASE ASSEMBLY ............................................................................................................................. 57
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 2008 model year. For a complete list of related items, refer to the current accessory catalog.
2008 Arctic Cat Inc.
Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Printed April 2008
FRONT RACK AND HEADLIGHT ASSEMBLIES

0743-336
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
0541-272 1 Rack - Front - Assembly (inc. 2-5)

0411-576 1 Decal, Warning - Front Rack Load
2406-014 6 Bushing, Rack
1441-049 2 Plug, Rack
8410-830 4 Screw, Cap
0423-669 4 Spacer
0423-465 4 Grommet
8432-802 4 Nut, Lock
0423-654 2 Screw, Shoulder
8050-222 2 Washer
0423-540 2 Nut, Lock
0423-535 2 Rivet, Reinstallable
1406-358 1 Cover, Access
0623-362 12 Rivet, Reinstallable
1406-484 1 Cover, Steering Post
0470-513 1 Cover, Storage Box
2506-234 1 Lid, Storage Box w/Latch (inc. 19-20)
0470-514 1 Lid, Storage Box
1406-599 1 Latch, Storage Box
2406-404 1 Panel, Side - Lower - Right
2406-405 1 Panel, Side - Lower - Left
22 0423-101 5 Screw, Body
23 2506-434 1 Panel, Splash - Right
2506-383 1 Panel, Splash - Left
24 0423-342 2 Screw, Self-Tapping

25 0123-788 AR Tie, Cable - 7.5 in.
26 0509-036 1 Headlight Assembly - Right (inc. 27-33)
0509-037 1 Headlight Assembly - Left (inc. 27-33)
27 0409-096 2 Bulb, Headlight
28 0409-097 2 Retainer, Spring
29 0409-098 2 Boot, Rubber
30 0409-099 2 Bulb, Turn Signal
31 0409-100 2 Socket, Turn Signal Bulb
32 0409-102 2 Socket, Position Bulb
33 0409-101 2 Bulb, Position
34 0423-514 2 Stud, Adjuster - Headlight
35 0423-522 2 Spring, Adjuster
36 0423-513 2 Knob, Adjuster
37 0623-785 4 Screw, Self-Tapping
38 8050-217 8 Washer
39 0423-447 4 Grommet
40 1411-725 1 Decal, Front
41 1411-634 1 Decal, Side - Upper Right
1411-635 1 Decal, Side - Upper Left
42 2506-934 1 Panel, Fender - Front - Red
2506-936 1 Panel, Fender - Front - Green (Green)
43 0411-818 1 Decal, Reflector - Right
0411-819 1 Decal, Reflector - Left
44 1411-050 1 Decal, Speedrack
REAR RACK AND FOOTWELL ASSEMBLIES

0743-337
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2506-221 1 Rack - Rear - Assembly (inc. 2-6)

0541-504 2 Pin - Assembly (inc. 3-5)
0423-635 2 Pin, Roll
0423-677 2 Collar
0423-636 2 Spring
8410-835 4 Screw, Cap
0423-669 4 Spacer
0423-465 4 Grommet
8432-802 4 Nut, Lock
0423-087 2 Washer
2506-092 1 Bracket, Rear Fender - Right
2506-093 1 Bracket, Rear Fender - Left
8050-222 2 Washer
0423-540 34 Nut, Lock
0423-101 2 Screw, Body
0423-419 20 Screw, Machine
2406-042 1 Footwell, Rear - Right
2406-043 1 Footwell, Rear - Left
2506-193 1 Footwell - Right
2406-471 1 Footwell - Left
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1506-125
8477-620
0423-719
2406-531
0405-261
8050-282
8409-020
3313-392
3313-393
3313-506
3303-849
3313-509
3313-507
0409-112
0409-113
8476-516
3304-061
2506-952
2506-954
1411-592
1411-593
0411-832
4
2
2
1
1
1
1
1
1
2
2
1
1
1
1
6
6
1
1
1
1
1
Footpeg
Screw, Machine
Screw, Self-Tapping
Panel, Splash
Bushing, Splash Panel
Washer
Screw, Cap
Taillight Assembly - Right (inc. 29-31)
Taillight Assembly - Left (inc. 29-31)
Bulb, Turn Signal
Bulb, Taillight
Socket, Taillight - Assembly - Right
Socket, Taillight - Assembly - Left
Bezel, Taillight - Right
Bezel, Taillight - Left
Screw, Machine
Nut, U-Clip
Panel, Fender - Rear - Red
Panel, Fender - Rear - Green (Green)
Decal, Reflector - Rear - Right
Decal, Reflector - Rear - Left
Decal, Warning - Tire Pressure
FRAME AND RELATED PARTS

0743-346
1 2506-966 1 Frame, Main

2 8409-020 4 Screw, Cap
3 2506-813 1 Channel, Bumper Mounting - Right
2506-285 1 Channel, Bumper Mounting - Left
4 1506-562 1 Bracket, Mounting - Bumper - Right
1506-563 1 Bracket, Mounting - Bumper - Left
5 8408-816 11 Screw, Cap
6 1506-855 1 Bumper
7 1406-360 1 Grille, Bumper
8 0423-419 2 Screw, Machine
9 0423-101 12 Screw, Body
10 0423-744 2 Nut, Lock
11 1506-429 1 Brace, A-Arm
12 8409-025 2 Screw, Cap
13 2406-253 1 Panel, Belly
14 0406-289 2 Pad, Frame
15 8424-802
16 8409-016
17 1506-848
1506-849
18 2406-216
2406-217
19 2506-447
20 8477-616
21 0623-038
22 2406-321
23 0430-053
24 0541-714
25 0436-715
26 0423-693
27 0423-690
28 1411-077
4
3
1
1
1
1
1
3
3
1
1
1
1
1
1
1
Nut, Flange
Screw, Cap
Footrest - Right
Footrest - Left
Strap, Footrest - Right
Strap, Footrest - Left
Channel, Shock Support
Screw, Machine
Nut w/Washer
Bracket, Mounting - Horn
Horn, Electric - 12V
Mount, Ball Hitch
Kit, Ball Hitch
Bolt
Nut, Lock
Decal, Warning - Towing
WINCH ASSEMBLY
0743-257
1
2
3
4
5
6
7
8
9
10
11
12
13
1441-657 1 Winch (inc. 2-3)

0441-061 1 Cable, Winch
1411-826 1 Decal, Warning
8051-246 4 Washer, Lock
8408-820 4 Screw, Cap
0441-426 1 Hook, Winch w/Strap - Assembly (inc. 7-9)
1441-131 1 Hook, Winch w/Strap
1441-130 1 Pin
1441-129 1 Cotter Pin
0441-403 1 Roller, Winch
0123-788 AR Tie, Cable - 7.5 in.
0445-068 1 Cable, Winch/Solenoid - Yellow
14
15
16
17
18
19
20
21
22
23
24
25
26
0445-069
0623-038
1441-112
1441-113
0441-060
0409-066
8476-625
0505-552
0505-551
8050-093
8009-243
0853-212
0486-276
1
8
1
1
3
1
2
1
1
2
2
1
1
Cable, Winch/Solenoid - Blue

Nut w/Washer
Cable, Solenoid/Battery - Black
Cable, Solenoid/Battery - Red
Boot, Terminal
Solenoid
Screw, Machine
Switch, Winch - Assembly (inc. 22-26)
Bracket, Winch Switch
Washer, Lock - Internal Tooth
Screw, Machine
Washer, Lock - External Tooth
Harness, Adapter - Solenoid
LICENSE PLATE HOLDER ASSEMBLY

0743-236 *Not a Service Part
1 2506-914
2 3304-772
3
*
4 3303-847
1
1
2
1
Holder, License Plate

Light, License Plate (inc. 3-4)
Screw, Self-Tapping
Bulb
5
6
7
8
0123-950
8432-802
8050-247
8408-820
2
2
2
2
Screw, Self-Tapping
Nut, Lock
Washer
Screw, Machine
SEAT AND BACKREST ASSEMBLY

0743-271
1
2
3
4
5
6
7
8
9
10
1506-937 1 Seat Assembly (inc. 2-9)

1506-209 1 Cover, Seat
1506-208 1 Foam, Seat
2406-144 1 Base, Seat - Assembly (inc. 5-6)
0406-879 2 Bumper, Seat - Rear
0406-877 4 Bumper, Seat - Front
0624-528 AR Staple
1406-592 1 Spring, Seat Latch
1506-156 1 Latch, Seat
1506-938 1 Seat, Passenger - Assembly
(inc. 7 and 11-21)
11 2506-064 1 Seat, Passenger - Sub-Assembly
(inc. 7 and 12-14)
12 1506-816 1 Foam, Seat - Passenger
13 1506-815 1 Cover, Seat - Passenger
14
15
16
17
18
19
20
21
22
23
24
25
26
2406-110
2406-044
0411-814
1506-932
2406-112
2406-113
0423-362
8432-802
8427-602
1506-939
1506-818
1506-817
8408-816
0441-587
1
1
1
1
1
1
6
6
4
1
1
1
4
1
Base, Seat - Inner

Base, Seat - Passenger
Decal, Arctic Cat - White
Bracket, Seat Support - Assembly
Handhold, Passenger - Right
Handhold, Passenger - Left
Screw
Nut, Hex
Nut, Lock
Backrest Assembly (inc. 23-24)
Foam, Backrest
Cover, Backrest
Screw
Wrench, Spanner
STEERING POST ASSEMBLY

1
2
3
4
5
6
7
8
9
10
11
12
13
14
8408-860
0405-035
0423-505
0505-484
0405-138
0405-139
0505-451
8408-820
2406-355
2506-173
2406-354
2406-349
0602-233
0405-052
4
4
2
1
1
1
1
2
1
1
1
1
1
1
Screw, Cap
Cap, Steering Adjuster
Screw, Shoulder
Cap, Housing
Housing, Lower
Housing, Upper
Post, Steering
Screw, Cap
Lock, Steering - Assembly (inc. 10-12)
Latch
Lock
Bracket, Mounting - Lock
Flange, Bearing
Bearing w/Inverted Oil Seal
15
16
17
18
0423-073
8409-020
0505-499
0505-511
1
1
2
2
19
*
20 0423-013
21 0405-281
22 0505-510
2
2
2
2
23
*
24 8420-002
25 0423-157
26 0623-175
2
2
4
4
Washer
Screw, Cap
Tie Rod - Assembly (inc. 18-24)
End, Tie Rod - Left-Hand Thread - Kit
(inc. 19-20 and two No. 25-26)
End, Tie Rod - Left-Hand Thread
Nut - Left-Hand Thread
Tie Rod
End, Tie Rod - Right-Hand Thread - Kit
(inc. 23-24 and two No. 25-26)
End, Tie Rod - Right-Hand Thread
Nut - Right-Hand Thread
Nut, Lock
Pin, Cotter
HANDLEBAR ASSEMBLY
0743-350
1
2
3
4
5
6
7
8
9
10
11
12
13
0505-522
0405-218
0405-149
8050-247
8477-845
0405-147
0430-069
0430-050
0430-042
0430-043
0430-054
0505-500
0505-501
0641-897
0520-033
1
2
2
2
2
2
1
1
1
1
1
1
1
1
1
Tube, Handlebar
Plug, Handlebar
End Cap, Handlebar
Washer
Screw, Machine
Grip, Handlebar
Switch, Ignition - Assembly (inc. 8-10)
Nut, Flange - Ignition Switch
Key, Ignition (Y Series - Left-Side Cut)
Key, Ignition (Z Series - Right-Side Cut)
Cover, Key
Instrument Pod
Instrument Pod (Green)
Outlet, Accessory - 12V
Gauge, LCD
14
15
16
17
18
19
20
21
22
23
24
25
26
27
0420-074
0420-075
2506-470
0423-535
0420-065
0423-493
2406-630
2406-631
1411-865
0502-527
0502-613
0487-050
0487-044
1411-610
1411-847
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
Light, Indicator - Glow Plug

Light, Indicator - Battery
Bracket, Mounting - Instrument Pod
Rivet, Reinstallable
Clamp, Plastic
Nut w/Washer
Mirror - Right
Mirror - Left
Decal, Warning - Brake Lever Lock
Control, Differential Lock (inc. 23)
Clamp, Differential Lock Control - Kit
Cable, Differential Lock
Cable, Throttle
Decal, Instrument Pod
Decal, Warning - Differential Lock
FRONT SUSPENSION ASSEMBLY

0743-294
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0403-176 2 Shock Absorber - Front (inc. 2)

0403-182 4 Bushing, Double-Bonded
0403-102 2 Cam, Spring Adjuster
0403-174 2 Spring, Shock Absorber - Platinum
1603-889 2 Retainer, Spring
8409-040 4 Screw, Cap
0423-744 10 Nut, Lock
0503-272 1 A-Arm, Upper Right - Platinum (inc. 9-12)
0503-273 1 A-Arm, Upper Left - Platinum (inc. 9-12)
0403-081 4 Bushing
0403-080 2 Collar
0423-009 4 Clip, Ball Joint
0405-115 4 Ball Joint - Front
0503-342 1 A-Arm, Lower Right - Platinum
(inc. 14-15 and two No. 11-12)
0503-343 1 A-Arm, Lower Left - Platinum
(inc. 14-15 and two No. 11-12)
0403-115 8 Bushing
15 0403-114
16 0505-460
0505-461
17 1402-027
18 0423-423
19 8409-030
20 0423-334
21 8409-075
22 0502-813
0502-812
23 1441-109
24 0436-276
25 0441-752
0441-753
1441-002
1441-003
26 0423-545
4
1
1
2
2
4
2
4
1
1
2
2
1
1
1
1
4
Collar
Knuckle - Assembly - Right (inc. 17-18)
Knuckle - Assembly - Left (inc. 17-18)
Bearing, Wheel Hub
Ring, Retaining
Screw, Cap
Screw, Cap
Screw, Cap
Axle, Drive - Front - Left (inc. 23-24)
Axle, Drive - Front - Right (inc. 23-24)
Clip, Retaining
Repair Kit, Boot
Guard, Boot - Right - Red
Guard, Boot - Left - Red
Guard, Boot - Right - Green (Green)
Guard, Boot - Left - Green (Green)
Screw, Body
REAR SUSPENSION ASSEMBLY

0743-295
1 0504-374
0504-373
2 1402-027
3 0423-423
4 0403-038
5 0403-032
6 0504-440
Knuckle - Assembly - Right (inc. 2-5)

Knuckle - Assembly - Left (inc. 2-5)
Bearing, Wheel Hub
Ring, Retaining
Collar, Suspension Bushing
Bushing, Suspension
A-Arm, Rear - Lower Right - Platinum
(inc. 7-8)
0504-441 1 A-Arm, Rear - Lower Left - Platinum
(inc. 7-8)
7 0403-115 16 Bushing
8 0403-114 8 Collar
9 0423-744 14 Nut, Lock
10 8409-000 4 Screw, Cap
11 0504-476 1 A-Arm, Rear - Upper Right - Platinum
(inc. 7-8)
0504-477 1 A-Arm, Rear - Upper Left - Platinum
(inc. 7-8)
12 0441-754 1 Guard, Boot - Right - Red
0441-755 1 Guard, Boot - Left - Red
1441-004 1 Guard, Boot - Right - Green (Green)
1441-005 1 Guard, Boot - Left - Green (Green)
10
1
1
2
2
4
8
1
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
0423-545
8409-075
0502-811
0441-893
0436-276
0123-788
1603-889
0404-145
0404-057
0404-147
0403-182
0603-955
1603-219
0423-087
8408-820
8409-050
4
8
2
2
2
2
2
2
2
2
2
4
2
2
2
2
Screw, Body
Screw, Cap
Axle, Drive - Rear (inc. 16-17)
Clip, Retaining
Repair Kit, Boot
Tie, Cable
Retainer, Spring
Spring, Suspension - Platinum
Cam, Spring Adjuster
Shock Absorber - Rear (inc. 23-25)
Bushing, Double-Bonded
Bushing, Shock Absorber
Sleeve, Shock Absorber
Washer
Screw, Cap
Screw, Cap
WHEEL AND TIRE ASSEMBLY

0743-260
1
2
3
4
5
0423-557 12 Screw, Shoulder w/Loctite

1436-164 3 Disc, Brake
0502-599 2 Hub, Wheel - Front (inc. 4)
0402-974 16 Stud, Wheel Hub
0502-601 1 Hub, Wheel - Rear - Left (inc. 4)
0502-599 1 Hub, Wheel - Rear - Right (inc. 4)
6 0423-607 4 Nut, Castle
7 0423-407 4 Pin, Cotter
8 1402-127 2 Wheel - Front - Platinum

1402-115 2 Wheel - Rear - Platinum
9 0423-408 16 Nut, Mounting - Wheel
10 1402-100 2 Tire - Front
1402-137 2 Tire - Rear
11 0402-064 4 Stem, Valve (inc. 12)
12 0402-140 4 Cap, Valve Stem
11
AUXILIARY BRAKE ASSEMBLY

0743-389
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
12
1502-063 1 Lever, Brake

1602-213 2 O-Ring
8050-252 1 Washer
8408-816 1 Screw, Cap
0502-807 1 Spring, Brake Lever
0502-785 1 Spring, Brake Switch
1502-147 1 Master Cylinder
1402-592 1 Hose, Brake
0423-178 7 Washer, Crush
0423-413 2 Bolt, Banjo-Fitting
0423-610 1 Bolt, Banjo-Fitting - Double
1402-594 1 Hose, Brake
1502-115 2 Clip, Brake Hose
0123-788 AR Tie, Cable - 7.5 in.
1436-163 1 Caliper, Brake (inc. 16-23)
16 1436-161
17
18
19
20
21
22
23
24
25
26
27
28
1
1
1
1
1
1
2
1
2
1
1
1
0502-606
0502-607
0502-609
0502-608
0502-605
1436-165
8408-821
0502-840
8408-625
1402-377
0117-868
8050-217
Housing, Caliper - Assembly - Left Rear

(inc. 17-19 and 23)
Piston/Seal Set (inc. 18)
Seal Set
Valve, Bleed
O-Ring, Guide - Set
Bracket Assembly
Pad, Brake - Set
Screw, Cap
Bracket, Switch
Screw, Cap
Pin, Clevis
Pin, Cotter
Washer
PARKING BRAKE ASSEMBLY

0743-214
1
2
3
4
5
1502-150
1502-429
1502-432
1502-430
1502-431
1
1
1
1
1
Lever, Parking Brake - Assembly (inc. 2-5)

Kit, Parking Brake Lever Assembly
Kit, Handlebar Clamp
Kit, Thumb Nut Adjuster
Kit, Parking Brake Lever Lock
6
7
8
9
10
0487-055
1502-176
1402-602
8408-826
0402-379
1
1
2
2
1
Cable, Brake - Rear

Mechanical Brake Assembly
Pad, Brake
Screw, Cap
Wire Form, Cable
13
HYDRAULIC HAND BRAKE ASSEMBLY

0741-458
1
2
3
4
5
6
14
0502-914
0502-566
0502-868
0502-568
0502-869
0502-704
1
1
1
1
1
1
Brake Assembly (inc. 2-10)

Screw, Reservoir Cover
Cover, Reservoir
Screw, Master Cylinder Clamp
Clamp, Master Cylinder
Master Cylinder Assembly
7
8
9
10
11
12
0502-866
0502-867
0502-580
0502-564
0423-178
0423-413
1
1
1
1
2
1
Lever Assembly (inc. 8-9)

Lock, Brake Lever - Kit
Lever Pin - Kit
Switch, Brake
Washer, Crush
Bolt, Banjo-Fitting
HYDRAULIC BRAKE ASSEMBLY

0743-262
1
2
3
4
1502-148
8476-625
1623-589
1436-162
1
1
4
1
1436-163
5 1436-160
1436-161
Hose, Brake - Assembly

Screw, Cap
Screw, Cap
Caliper, Brake - Right Front
(inc. 5-11 and two No. 3)
Caliper, Brake - Left Front
Housing, Caliper - Assembly - Right Front
Housing, Caliper - Assembly - Left Front
6
7
8
9
10
11
12
13
14
0502-606
0502-607
0502-609
0502-608
0502-605
1436-165
0423-178
0423-413
0623-038
2
2
2
2
2
2
2
1
1
Piston/Seal Set (inc. 7)

Seal Set
Valve, Bleed
O-Ring, Guide - Set
Bracket Assembly
Pad, Brake - Set
Washer, Crush
Bolt, Banjo-Fitting
Nut, Lock
15
FUEL TANK ASSEMBLY

0742-733
1
2
3
4
5
6
7
8
9
16
0570-214 1 Tank, Fuel - Assembly (inc. 2-6)

0470-653 1 Cap, Fuel Tank
0570-228 1 Sensor, Fuel Level (inc. 4)
0470-521 1 Seal, Fuel Level Sensor
0470-639 1 Plate, Mounting - Fuel Level Sensor
1623-158 4 Screw, Plastite
0423-689 2 Clamp, Hose
0410-143 AR Hose, Fuel - 25 ft
10
11
12
13
14
15
16
17
18

0109-332 1 Fitting, T
0423-835 1 Clamp
0423-732 2 Screw, Mounting - Fuel Tank
0423-460 2 Grommet
0470-715 1 Shield, Fuel Tank
0623-797 4 Screw, Self-Tapping
SHIFT LEVER ASSEMBLY

0742-734
1
2
3
4
5
6
7
8
9
10
11
0402-843
0423-345
1402-576
0423-357
0502-659
0402-678
1502-012
8424-602
0423-182
0402-675
0423-299
1
1
1
4
1
1
1
1
2
1
2
Knob, Shift Lever

Clip, Push
Plate, Shift
Nut, Stamped
Lever, Shift
Spring, Shift Lever
Axle, Shift Lever
Nut
O-Ring
Axle, Pivot
O-Ring
12
13
14
15
16
17
18
19
20
21
8408-812
0423-087
8424-802
1402-621
0423-091
0623-094
0423-169
1502-226
0123-917
0623-294
1
1
1
1
2
2
2
1
1
1
Screw, Cap
Washer
Nut, Hex
Pin, Mounting - Shift Linkage
Bushing, Shift Linkage
Washer
E-Ring
Linkage, Shift - Assembly (inc. 20-21)
Nut, Hex - Left-Hand Thread
Nut, Hex - Right-Hand Thread
17
AIR INTAKE ASSEMBLY

0741-964
1
2
3
4
5
6
7
8
9
18
0413-091
0413-093
2406-509
0623-362
0423-832
0470-618
0423-066
0470-621
0470-617
1
1
1
2
2
1
2
1
1
Diverter, Air - Top

Diverter, Air - Bottom
Shroud, Splash
Clamp, Boot
Duct, Air Intake
Clamp, Boot
Duct, Engine Intake
Filter, Air - Assembly (inc. 10-13)
10
11
12
13
14
15
16
17
0470-627
0470-619
0470-620
0470-628
8476-620
8050-222
2506-082
8476-616
1
1
1
1
2
2
1
4
Cap, Air Filter

Element, Air Filter - Main
Element, Air Filter - Safety
Bracket, Mounting - Air Filter Element
Screw, Bracket
Washer
Bracket, Mounting - Air Filter
Screw, Machine
BATTERY ASSEMBLY
0743-352 *Not Illustrated
1
2
3
*
4
5
5991-395
2406-815
0406-288
0444-122
8476-620
0623-325
1
1
2
1
2
1
Battery Cover/Tool Tray Assembly (inc. 2-3) 6 8050-217

7 0645-243
Cover, Battery
8 0406-289
Pad, Battery
9 0645-311
Kit, Tool
10 0645-432
Screw, Machine
11 1411-508
Nut, Wing
1
1
1
1
1
1
Washer
Strap, Battery - Top
Pad, Battery
Strap, Battery - Side
Battery
Decal, Storage
19
ENGINE AND EXHAUST

0743-423
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
0462-047
2406-323
8468-820
8422-002
2506-186
8408-816
0423-736
0423-687
0412-387
0512-322
0412-386
0412-385
0512-321
0423-317
0612-668
0412-375
1506-732
0412-215
0512-306
1
3
2
3
1
5
1
2
1
1
1
1
1
4
2
1
1
3
1
Engine
Mount, Engine - Rubber
Screw, Cap
Nut, Lock
Mounting, Bracket - Engine
Screw, Cap
Screw, Cap
Nut
Gasket, Exhaust Manifold
Pipe, Exhaust - Assembly (inc. 11-14)
Shield, Exhaust Pipe - Lower
Shield, Exhaust Pipe - Upper
Pipe, Exhaust
Hose Clamp
Spring
Seal, Exhaust
Channel, Muffler Support (inc. one No. 18)
Bushing
Muffler (inc. 20-22)
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
0412-313 1 Gasket, Spark Arrester

0512-219 1 Arrester, Spark
8408-616 3 Screw, Cap
0412-373 1 Cover, Muffler
1502-365 1 Gearcase - Assembly
2506-190 1 Bracket, Mounting - Engine - Right
2506-191 1 Bracket, Mounting - Engine - Left
8408-820 10 Screw, Cap
2506-061 3 Washer, Engine Mount
8408-055 3 Screw, Cap
0408-015 1 Plate, Mounting - Engine/Transmission
8409-030 2 Screw, Cap
0423-685 2 Screw, Cap
2506-189 1 Bracket, Mounting - Engine - Front
2406-322 1 Mount, Engine - Rubber
0423-737 1 Nut
0423-073 1 Washer, Flat
COOLING ASSEMBLY
0742-736
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0413-143
0413-180
0413-181
0423-030
0413-182
0423-577
8476-616
0413-183
8424-602
0413-168
1602-213
0423-028
0623-038
0423-484
1
1
1
2
1
4
4
1
4
1
1
2
2
2
Radiator Assembly (inc. 2-11)

Radiator
Screen, Radiator
Grommet
Shroud, Fan
Clip, U-Nut
Screw
Fan, Cooling
Nut, Hex
Switch, Cooling Fan
O-Ring
Bushing, Stem
Nut w/Washer
Screw, Shoulder
15
16
17
18
19
20
21
22
23
24
25
26
27
28

0410-106 1 Hose, Coolant
0413-086 1 Tank, Coolant Overflow
0623-316 1 Tie, Cable
0610-011 AR Hose - 25 ft
0413-087 1 Stopper, Coolant Tank
0610-016 AR Hose - 25 ft
0413-002 1 Cap, Radiator
0413-193 1 Tank, Coolant Fill
1623-093 3 Clamp
0410-121 1 Hose, Coolant - Coupler
0410-107 1 Hose, Coolant
0123-788 2 Tie, Cable
21
CASE/BELT COOLING ASSEMBLY

0741-991
1
2
3
4
5
6
7
8
9
10
11
12
13
22
0413-132
0423-551
0423-342
0413-141
8475-512
8424-502
0423-018
0413-133
0423-550
1502-157
0830-013
8408-812
1402-528
1
1
3
1
2
2
1
1
2
1
1
1
1
Duct, Belt Cooling - Front

Clamp, Plastic
Screw, Self-Tapping
Fan, Belt Cooling
Screw, Machine
Nut, Hex
Clamp, Boot
Boot, Belt Cooling - Inlet
Clamp, Plastic
Cover, Clutch
Washer, Crush
Screw, Cap
Gasket, V-Belt Cover
14
15
16
17
18
19
20
21
22
23
24
25
26
0829-002 2 Dowel, Split

1402-527 1 Cover, Clutch
1402-526 1 Gasket, Gearcase
1402-524 1 Gasket, Clutch Cover
0413-134 1 Boot, Belt Cooling - Outlet
0423-019 1 Clamp, Boot
0470-442 1 Valve, Drain
0413-106 1 Duct, Belt Cooling - Rear
0623-316 1 Tie, Cable
DRIVE TRAIN ASSEMBLY

0742-251
1
2
3
4
5
6
7
8
9
10
11
12
1402-620 2 Bladder, Gearcase

0423-315 4 Clamp, Fitting
0423-744 4 Nut, Lock
0423-426 10 Washer
0423-404 4 Screw, Cap
1502-244 1 Gearcase, Front
0402-966 1 Boot, Shaft
0502-500 1 Plate, Cable
1502-079 1 Gearcase, Rear
0410-048 AR Hose, Vent
0123-788 1 Tie, Cable
13
14
15
16
17
18
19
20
21
22
23
0470-462
0423-393
0402-985
0423-411
0673-618
1402-507
8408-820
0402-950
1402-026
0502-976
8409-025
1
2
2
2
2
1
4
1
1
1
3
Fitting, Vent Hose

Clamp, Boot
Boot
Clamp, Boot
Bumper, Propeller Shaft
Shaft, Propeller
Screw, Cap
Flange, Output
Spring
Shaft, Propeller
Screw, Cap
23
FRONT DRIVE GEARCASE ASSEMBLY

(Complete Assembly p/n 1502-244)
0742-249
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
24
1402-369 1 Yoke, Flange

1402-164 1 Joint, Universal - Set (inc. 3)
0423-450 4 Retainer
0502-517 1 Yoke, Front End - Assembly
1402-011 1 Seal
0423-423 1 Ring, Retaining
0502-579 1 Actuator (inc. one No. 8)
0423-498 2 O-Ring
0502-347 1 Bracket, Actuator
1402-043 1 Bearing
0502-528 1 Housing, Pinion
0402-947 1 Gasket, Flange
0402-997 1 Shaft, Selector
0402-998 1 Fork, Selector
0402-417 1 Shaft, Shuttle
0423-147 1 O-Ring
0402-999 1 Spring, Return
0402-413 1 Coupler, Drive
0402-357 1 Collar, Lock
0502-783 1 Gear, Pinion - Assembly - 10T (inc. 25-26)
0402-336 1 Collar, Retaining
0402-327 1 Bearing
0402-328 1 Bearing
0502-514 1 Housing, Gearcase
0402-411 1 Pin, Dowel
1402-441 2 Seal
1402-210 1 Plug, Magnetic (inc. one No. 32)
0423-153 2 O-Ring
0423-149 1 O-Ring
34 0402-393 1
35 0402-405 AR
0402-406 AR
0402-407 AR
0402-408 AR
0402-409 AR
36 1502-234 1
37 1402-074 AR
1402-075 AR
1402-076 AR
1402-077 AR
1402-078 AR
38 1502-097 1
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
1402-053
0502-413
1402-079
1402-042
1402-054
1402-058
1402-057
1402-104
0402-419
1402-063
1402-055
1402-056
0423-133
0423-132
0423-424
1402-211
0402-333
0423-154
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Bearing
Shim
Shim
Shim
Shim
Shim
Gear, Ring - 36T
Shim
Shim
Shim
Shim
Shim
Cover, Gearcase (inc. one No. 30, one No.
32, and 39-54)
Bearing
Flange, Bearing
Pin, Parallel
Collar, Sliding
Fork
Ring, Retaining
Spring
Fitting
Switch, Indicator
Spring
Shaft, Lock
Seal
O-Ring
Washer
Ring, Retaining
Plug, Oil Level (inc. one No. 32)
Plug, Fill (inc. 56)
O-Ring
REAR DRIVE GEARCASE ASSEMBLY

(Complete Assembly p/n 1502-079)
0741-524
1
2
3
4
5
6
7
8
9
10
11
12
0502-622
0402-393
1402-441
1402-032
0402-405
0402-406
0402-407
0402-408
0402-409
0402-326
0402-429
0402-430
0402-431
0402-432
0402-433
0423-149
1502-082
0402-333
0423-154
1402-102
1
2
2
1
AR
AR
AR
AR
AR
1
AR
AR
AR
AR
AR
1
1
1
1
1
Housing, Gearcase
Bearing
Seal
Gear, Ring - 36T
Shim
Shim
Shim
Shim
Shim
Button, Thrust
Shim
Shim
Shim
Shim
Shim
O-Ring
Cover, Gearcase
O-Ring
Fitting
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

0402-450 1 Plug, Magnetic (inc. one No. 15)
0423-153 2 O-Ring
0402-328 1 Bearing
0502-783 1 Gear, Pinion - Assembly - 10T (inc. 18-19)
0402-327 1 Bearing
0402-336 1 Collar, Retaining
0402-411 1 Pin, Dowel
0402-331 1 Collar, Lock
0402-982 1 Washer, Wave
0402-981 1 Collar, Shaft
0402-947 1 Gasket, Flange
0502-529 1 Housing, Pinion
1402-043 1 Bearing
1402-011 1 Seal
1502-085 1 Shaft, Input
1402-211 1 Plug, Oil Level (inc. one No. 15)
25
WIRING HARNESS ASSEMBLY

0743-354
1
2
3
4
5
6
7
8
9
10
11
12
13
26
0486-272 1 Harness, Main (inc. 2-8)

0486-164 1 Tether, Accessory Connector
0530-008 1 Cover, Fuse Block
0430-037 1 Holder, Fuse
0430-033 1 Relay (5-Pin) - 20 Amp
0430-045 3 Relay (4-Pin) - 20 Amp
0430-032 4 Fuse - 10 Amp
0430-031 4 Fuse - 15 Amp
0430-030 2 Fuse - 30 Amp
1411-381 1 Decal, Fuse Block
0430-049 1 Flasher (3-Pin)
0123-788 AR Tie, Cable - 7.5 in.
0409-089 1 Switch, Brake - Assembly
0445-060 1 Cable, Battery/Ground
0445-058 1 Solenoid
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
0623-038
0645-327
0445-059
0645-019
2406-388
8476-620
0623-362
0423-371
8424-502
3206-311
3206-307
3206-306
3206-308
3206-309
0445-067
4
1
1
2
1
2
4
1
1
1
1
2
2
2
1
Nut w/Washer
Boot, Terminal
Cable, Battery - Assembly
Boot, Terminal
Tray, Electrical
Screw, Machine
Screw, Machine
Nut, Hex
Relay, Glow Plug
Wire, Glow Plug
Plug, Glow
Nut
Washer
Boot, Terminal
CLUTCHES AND V-BELT ASSEMBLIES

0742-008
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1502-073
1502-208
0423-752
1402-632
0423-751
1402-630
0423-750
0423-749
1402-631
1402-629
0828-020
0827-013
1402-564
1502-072
1
1
3
3
1
1
1
1
1
1
1
1
1
1
Pulley, Driven - Assembly (inc 2-10)

Face, Driven - Movable (inc. 3-4)
Screw, Cam
Shoe, Cam
Ring, Retaining
Cam
Spring
Shim
Key
Face, Driven - Fixed
Washer
Nut, Driven Pulley
V-Belt
Pulley, Drive - Assembly (inc. 15-26)
15
16
17
18
19
20
21
22
23
24
25
26
27
28
0423-747
0423-746
1502-207
1402-628
1402-625
1502-205
1402-627
1402-626
0423-745
1402-624
1402-623
1502-206
0423-733
0423-673
1
1
1
3
1
6
6
6
1
1
1
1
1
1
Nut, Hex
Washer, Lock
Plate, Movable Drive Face
Damper, Movable Drive Face
Face, Drive - Movable
Block, Weight - Assembly (inc. 21-22)
Weight
Block, Weight
Spring
Stopper
Seat, Spring
Face, Drive - Fixed
Washer
Bolt, Hex
27
TRANSMISSION RIGHT-SIDE ASSEMBLY

0741-915
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
28
1502-364
8408-830
0801-006
0829-002
0832-050
0828-016
1402-737
0822-012
0822-011
0829-003
0822-067
0832-015
0402-347
1402-559
0828-062
0828-063
0828-064
0828-065
0819-001
0828-019
0827-012
0832-049
1402-553
1
3
1
2
1
2
1
1
1
2
1
1
1
1
AR
AR
AR
AR
1
1
1
1
1
Housing, Gearcase - Set

Screw, Cap
Housing, Secondary Output Shaft Bearing
Dowel, Split
Bearing, Secondary Output Shaft
Washer, Thrust
Shaft, Reverse Idle
Bushing, Reverse Idle Gear
Gear, Reverse Idle
Dowel, Split
Shaft, Output - Secondary
Bearing, Output - Secondary Shaft
Ring, Retaining
Gear, Driven - No. 2 (42T)
Shim, 24 x 48 x 1.00
Shim, 24 x 48 x 1.05
Shim, 24 x 48 x 1.10
Shim, 24 x 48 x 1.15
Gear, Secondary Drive
Washer, Thrust
Nut, Hex
Bearing
Shaft, Input
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
0832-048
0830-035
8470-520
0409-090
0423-714
8405-640
8405-855
0828-040
0818-046
0831-011
0828-039
0818-012
0818-027
0818-011
0818-009
0818-010
0829-011
0818-017
0818-013
0828-067
0832-034
0828-037
1402-605
1
1
2
1
1
7
4
1
1
4
2
2
1
1
1
1
1
2
2
2
1
1
1
Bearing, Driveshaft
Seal, Driveshaft
Screw, Machine
Switch, Gear Shift Position
O-Ring
Screw, Cap
Screw, Cap
Washer
Shaft, Gear Shift - Assembly (inc. 30-37)
Ring, Retaining
Washer
Spring, Cam - Gear Shift
Cam, Reverse - Gear Shift
C-Ring
Cam, Forward - Gear Shift
Shaft, Gear Shift
Pin, Dowel
Spring, Gear Shift Contact
Contact, Gear Shift
Washer, Thrust Bearing
Bearing, Thrust - Roller
Washer
Gasket
TRANSMISSION LEFT-SIDE ASSEMBLY

0741-914
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
0832-050
0828-010
1402-558
1502-149
0831-011
0822-014
0822-045
0828-008
0822-013
0832-011
0822-005
0828-015
0828-014
0822-004
0822-046
0822-003
0822-007
0822-006
0828-011
0818-072
0818-006
0822-052
0831-040
0822-050
0828-069
0831-039
0830-129
0829-023
0822-049
0830-107
8468-645
2
1
1
1
2
1
1
2
1
3
3
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
2
1
2
2
Bearing
Washer, Thrust - Secondary Transmission
Gear, Drive - No. 2 (18T)
Countershaft (inc. 5-18)
Ring, Retaining
Dog, Reverse Gear
Insert, Gear
Washer, Secondary Transmission
Gear, Reverse Driven
Bearing
Bushing
Washer, Lock - Secondary Transmission
Washer, Secondary Transmission
Gear, Driven - Low (40T)
Shim, Drive Gear Spacer
Countershaft
Dog, Sliding Driven Gear - High/Low
Gear, Driven - High (30T)
Washer
Fork, Shift
Shaft, Shift Fork
Seal, Countershaft - Right
Ring, External Retaining
Trigger, Speedometer Sensor
Washer, Thrust
Ring, External Retaining
Gasket, Odometer Drive
Pin, Solid Dowel
Housing, Speedometer Sensor
Seal, Fastener
Screw, Machine
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
0824-042
8468-620
0828-038
0818-002
0818-004
0818-028
0828-035
8424-602
1402-556
0828-036
0831-010
0818-007
1402-557
1502-009
8405-620
0830-044
0818-014
0818-005
0826-006
0812-006
0830-017
1402-102
0402-333
0423-154
0819-063
1402-164
0423-450
0827-013
1
1
1
1
1
1
1
1
1
2
2
1
1
1
6
1
1
1
1
1
1
1
1
1
1
1
4
2
Sensor, Speedometer
Screw, Machine
Washer
Stopper, Swing Arm - Cam Assembly
Support, Cam Stopper
Spring, Torsion - Cam Arm
Washer
Nut, Hex Flange
Stop, Spring - Selector
Washer
Ring, Retaining
Shaft, Sub - Gear Shift
Gasket, Cover - Selector
Cover, Selector - Gearcase
Screw, Cap
Seal, Sub - Gear Shift
Arm, Selector
Plate, Gear Shift Cam
Screw, Cap
Plug, Drain - Magnetic
Gasket, Compression
Fitting, 90
O-Ring
Yoke, Propeller Shaft
Joint, Universal - Set (inc. 58)
Ring, Retaining - Universal Joint
Nut, Hex
(Continued on Page 30)
29
TRANSMISSION LEFT-SIDE ASSEMBLY

(Continued)
0741-914
60
61
62
63
64
65
66
67
68
30
0828-020
0819-061
0830-043
0832-017
0828-026
1402-554
0819-002
1402-555
0832-016
2
1
2
1
1
1
1
1
1
Washer
Yoke, Drive Output - Front Assembly
Seal, Oil - Driven Shaft
Bearing, Driven Shaft
Shim, 25 x 34 x 1.00
Shaft, Output - Secondary
Gear, Secondary Driven
Sleeve, Bearing - Output Shaft
Bearing, Driven Gear
69
70
71
72
73
74
75
76
0819-011
0819-005
0470-689
2506-388
0423-465
2506-445
0423-715
0423-396
1
1
1
1
1
1
1
2
Ring, Driven Bearing

Flange, Output Joint - Assembly
Level Stick, Lubricant
Tube, Level Stick
Grommet
Bracket, Level Stick Tube
O-Ring
Screw, Self-Tapping
CRANKSHAFT ASSEMBLY
0741-807
1 3206-019
2 3206-020
3 3206-018
1
2
1
Crankshaft Assembly (inc. 2-5)

Plug
Key
4 3206-022
5 3206-021
1
1
Pin
Key
31
PISTON SET AND CONNECTING ROD ASSEMBLY

0741-808
1 3206-026
3206-027
3206-028
2 3206-023
3206-024
3206-025
3 3206-030
32
2
2
2
2
2
2
2
Piston - Set (inc. 2-4)

Piston - Set (+0.50 mm)
Piston - Set (+1.00 mm)
Ring - Set
Ring - Set (+0.50 mm)
Ring - Set (+1.00 mm)
Piston Pin
4
5
6
7
8
3206-031
3206-035
3206-029
3206-036
3206-032
3206-033
3206-034
4
2
2
4
2
2
2
Circlip
Connecting Rod (inc. 6-7)
Bushing
Bolt
Bushing
Bushing (-0.25 mm)
Bushing (-0.50 mm)
FLYWHEEL AND CROWN GEAR ASSEMBLY

0741-809
1 3206-040
2 3206-037
1
1
Flywheel (inc. 2)
Gear, Crown
3 8409-040
4 1402-560
5
1
Bolt
Axle, Stub
33
DRIVE PULLEY AND ALTERNATOR BELT ASSEMBLY

0741-810
1 3206-042
2 3206-044
34
1
1
Belt
Pulley
3 3206-043
4 3206-041
4
1
Screw
Screw
CRANKCASE, CRANKSHAFT SUPPORT, AND OIL FILTER ASSEMBLIES

1
2
3
4
5
6
7
8
9
10
11
12
13
3206-046
*
*
*
3206-054
3206-049
3206-045
3206-058
3206-047
3206-048
3206-053
3206-358
3206-055
3206-056
3206-057
1
1
1
1
4
6
4
1
1
2
2
1
3
3
3
Crankcase (inc. 2-6, two No. 7, and 8-10)

Housing - Front
Housing - Center
Housing - Rear
Gasket
Screw
Sleeve
Pin, Tapered
Plug
Plug
Pin, Lock
Gasket
Bearing
Bearing (-0.25 mm)
Bearing (-0.50 mm)
14 3206-050
3206-051
3206-052
15 3206-206
16 3206-207
17 3206-193
18 3206-194
19 3206-090
20 3206-091
21 3206-088
22 3206-377
23 3206-359
2
2
2
1
1
1
1
1
1
6
1
1
Washer
Washer (+0.10 mm)
Washer (+0.20 mm)
Gasket
Plug
Connector, Oil Filter
Cartridge, Oil Filter
Flange, Engine (inc. 20-21)
Ring
Screw
Sensor, Engine Coolant Temperature
Gasket
35
CYLINDER HEAD AND PRECOMBUSTION CHAMBER ASSEMBLY

0741-814
1
2
3
4
5
6
7
8
9
10
11
3206-063
3206-065
3206-148
3206-147
3206-149
3206-076
3206-275
3206-074
3206-075
3206-077
3206-061
3206-062
12 3206-073
36
1
1
4
4
4
1
1
1
1
1
4
4
2
Cylinder Head (inc. 2-14)

Plug
Retainer
Spring, Valve
Washer
O-Ring
Plug
Retainer
Washer
Bolt
Guide, Valve
Guide, Valve (+0.50 mm)
Seat, Exhaust Valve
13
14
15
16
17
18
19
20
21
22
3206-152
3206-072
3206-066
3206-064
3206-069
3206-070
3206-071
3206-068
3206-079
3206-067
3206-078
3206-376
4
2
6
6
1
1
1
2
2
2
2
2
Retainer, Valve
Seat, Intake Valve
Screw
Washer
Gasket, Head - 1.56-1.64 (1 small hole)
Gasket, Head - 1.66-1.74 (2 small holes)
Gasket, Head - 1.76-1.84 (3 small holes)
Chamber, Precombustion
Spacer
Nut, Locking
Bolt
Brace, Lifting
PTO VACUUM PUMP ASSEMBLY

0743-402
1
2
3
4
5
3206-313
3206-336
3206-088
3206-337
3206-338
1
1
3
1
1
O-Ring
Flange, Vacuum Pump
Screw
Gasket
Pump, Vacuum
6
7
8
9
3206-339
3206-342
3206-340
3206-341
3
2
1
1
Screw
Clamp
Hose, Union
Union
37
ROCKER ARM COVER AND BREATHER SYSTEM ASSEMBLIES

0741-815
1
2
3
4
5
6
7
38
3206-081
3206-087
3206-080
3206-086
3206-084
3206-085
3206-083
1
1
1
1
1
1
2
Cap, Oil Filler (inc. 2)

O-Ring
Cover, Rocker Arm
Gasket
Connection
Separator
Screw
8
9
10
11
12
13
14
3206-370
3206-200
3206-205
3206-202
3206-201
3206-203
3206-204
8
4
1
1
1
1
1
Screw
Clamp
Hose, Connection
Hose, Drain
Valve, Suction
Tube, Valve
Clamp
FUEL SYSTEM INJECTION PUMP ASSEMBLY

1
2
3
4
5
6
7
8
9
10
11
3206-092
3206-093
3206-095
3206-094
3206-098
3206-126
3206-103
3206-104
3206-105
3206-106
3206-107
3206-108
3206-109
3206-110
3206-111
3206-112
3206-113
*
3206-114
3206-115
3206-125
1
4
4
1
2
2
2
2
2
2
2
2
2
2
2
2
2
1
2
2
2
Pipe, Delivery (inc. 2-4)

Screw
Seal, Ring
Seal, Delivery Pipe
Valve, Bleed
Gasket
Spacer - 2.00
Spacer - 1.90
Spacer - 1.80
Spacer - 1.70
Spacer - 1.60
Spacer - 1.50
Spacer - 1.40
Spacer - 1.30
Spacer - 1.20
Spacer - 1.10
Spacer - 1.00
Spring, Pressure
Drive Rod
Spacer
O-Ring
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
3206-123
3206-245
3206-102
3206-097
3206-133
3206-122
3206-124
3206-059
3206-116
3206-099
3206-117
3206-245
*
3206-118
3206-119
3206-120
3206-101
*
3206-121
*
3206-127
2
4
2
4
2
2
2
2
2
2
2
2
1
1
2
8
2
1
2
1
1
Nozzle
Nut
Pump, Injection - Nozzle
Stud
Tappet
O-Ring
Gasket, Copper
Arrester, Spark
Filler
Spring, Valve
Gasket, Valve
Valve, Delivery
Plunger, Injection
O-Ring
Sleeve
Screw
Spring, Tappet
Push Rod
Circlip
Retainer, Lower
Plate, Locking
39
CAMSHAFT AND FUEL PUMP DRIVE ECCENTRIC

0743-405
1 3206-129
2 3206-131
40
1
1
Camshaft
Cam
3 3206-128
4 3206-374
1
1
Sleeve
Screw
CAM PULLEYS, TIMING BELT, AND SPEED GOVERNOR ASSEMBLY

0741-816
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
3206-153
3206-154
3206-156
3206-155
3206-159
3206-158
3206-157
3206-142
3206-160
3206-209
3206-208
3206-088
3206-211
3206-210
3206-212
3206-166
3206-213
3206-214
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
3
1
1
Pulley, Cam Driven

Belt, Timing
Washer
Screw
Pulley
Stud
Washer
Nut
Pulley, Cam Drive
Camshaft Support (inc. 11-16)
Ring, Seal
Screw
Bearing, Ball
Seal, Oil
Plate
Screw
Flyweight - Assembly
Sleeve, Control (inc. 19)
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
3206-216
3206-217
3206-215
3206-218
3206-220
3206-219
3206-221
3206-223
3206-222
3206-225
3206-228
3206-224
3206-226
3206-229
3206-227
3206-232
3206-231
3206-230
1
1
1
1
1
1
2
2
1
2
1
1
1
1
1
1
1
1
Sleeve
Roller, Thrust (inc. 21)
Washer, Thrust
Rail, Injection Pump (inc. 23-26)
Plate
Plate
Screw
Washer
Spring, Fuel
Screw
Lever, Governor - Assembly (inc. 30-33)
Pin, Lever
Seal
Sleeve
Journal
Nut
Screw
Device, Min-Max
41
ROCKER ARM, VALVES, AND OIL SWITCH ASSEMBLIES

0741-819
1
2
3
4
5
6
7
8
9
10
11
42
3206-135
3206-141
3206-137
3206-136
3206-134
3206-140
3206-139
3206-138
3206-144
3206-146
3206-145
1
2
4
4
4
2
2
2
1
2
1
Arm, Rocker - Assembly (inc. 2-11)

Support
Nut
Screw
Arm, Rocker - Intake/Exhaust
Arm, Rocker - Injection Pump
Nut
Screw
Shaft, Rocker Arm
Plug
Pin, Lock
12
13
14
15
16
17
18
19
20
21
3206-064
3206-142
3206-143
3206-313
3206-314
3206-082
3206-305
3206-304
3206-150
3206-151
3
3
3
1
1
3
1
1
2
2
Washer
Nut
Stud, Bolt
O-Ring
Flange
Screw
Elbow, Pipe
Switch, Oil
Valve, Exhaust
Valve, Intake
EXHAUST MANIFOLD ASSEMBLY

0743-414
1 3206-373
2 3206-292
3 3206-293
1
4
6
Manifold, Exhaust w/Front Outlet

Stud
Nut
4 3206-297
5 3206-291
2
2
Stud
Gasket, Exhaust Manifold
43
EGR SYSTEM ASSEMBLY

1
2
3
4
5
6
7
8
9
10
44
3206-343
3206-348
3206-339
3206-352
3206-346
3206-293
3206-345
3206-344
3206-351
3206-349
1
2
2
1
2
2
1
1
2
1
Valve, EGR
Gasket, EGR Valve
Screw
Clamp
Screw
Nut
Pipe, Union
Ring, Seal
Hose, Union
Hose, Union
11
12
13
14
15
16
17
18
19
3206-350
3206-267
3206-353
3206-356
3206-347
3206-354
3206-325
3206-355
*
3
1
1
1
1
1
1
1
1
Clamp
Screw
Spacer
Spacer
Bracket
Sheathing, Rubber
Clamp
Spacer
Screw
THERMOSTAT, WATER INLET FLANGE, AND OIL LEVEL STICK ASSEMBLIES

0743-415
1
2
3
4
5
6
7
8
3206-262
3206-169
3206-259
3206-260
3206-261
3206-263
3206-206
3206-265
1
2
1
1
1
1
1
1
9 3206-266
10 3206-264
2
1
Thermostat - Assembly (inc. 2-8)

Screw
Cover, Thermostat
O-Ring
Thermostat
Body, Thermostat - Assembly
Gasket
Sensor/Thermistor, Engine Coolant
Temperature
Screw
Gasket
11
12
13
14
15
16
17
18
19
20
3206-268
3206-372
3206-200
0410-111
3206-190
3206-267
3206-197
3206-198
3206-195
3206-196
1
1
2
1
2
2
1
2
1
1
Gasket
Flange
Clamp
Hose
Clamp
Screw
Stick, Oil Level (inc. 18)
Seal
O-Ring
Guard, Oil Level Stick
45
OIL PUMP ASSEMBLY

1
2
3
4
5
6
7
46
3206-171
3206-167
3206-163
3206-162
3206-164
3206-165
3206-172
1
1
1
1
1
1
1
Pump, Oil (inc. 2-10)

Rotor, Oil Pump - Assembly
Plug
Gasket
Spring, Pressure Valve
Rod, Drive
O-Ring
8
9
10
11
12
13
14
*
3206-166
3206-371
3206-168
3206-169
3206-161
3206-174
1
3
1
1
6
1
2
Plate
Screw
Gasket
Bolt
Screw
Ring, Seal
Screw
OIL PAN ASSEMBLY

1
2
3
4
5
6
7
8
9
3206-179
*
3206-183
*
*
3206-176
3206-177
3206-175
3206-178
1
1
4
1
1
1
1
1
2
Pan, Oil - Assembly (inc. 2-5)

Pipe, Oil - Intake
Screw
Pipe, Oil - Return
Pan, Oil
Seal, Oil
Seal, Oil
Gasket
Stud, Hollow
10
11
12
13
14
15
16
17
18
3206-191 2 Washer
3206-190 2 Clamp
3206-088 20 Screw
3206-186 1 Gasket
3206-187 1 Gasket
3206-188 1 Cover, Oil Pan
3206-189 20 Screw
3206-181 1 Gasket, Copper
3206-182 1 Plug
47
THROTTLE CONTROL AND LOCKED TORQUE DEVICE ASSEMBLIES

1
2
3
4
5
6
7
8
9
10
11
12
48
3206-236
*
3206-235
3206-364
3206-007
3206-362
3206-238
3206-363
3206-243
3206-237
3206-238
3206-239
1
1
1
1
1
1
1
1
1
2
2
1
Device, Locked Torque (inc. 2-3)

Nut
Gasket
Gasket, Copper
Gasket, Copper
Screw
Washer
Sensor, Cam
Circlip
Nut
Washer
Rod, Tie
13
14
15
16
17
18
19
20
21
22
23
24
3206-241
3206-242
3206-360
3206-246
3206-240
3206-365
3206-366
3206-367
3206-378
3206-368
3206-369
3206-370
1
1
1
1
2
2
1
1
1
1
1
1
Lever, Throttle Control

Circlip
Pin
Seal, Oil
Bolt
Washer
Safety Plate
Valve, Vacuum
Bolt
Screw
Support
Screw
FUEL FILTER, ELECTRO-VALVE, AND HOSES ASSEMBLY

0742-741
1
2
3
4
5
6
7
8
9
10
3206-335
3206-010
3206-002
3206-003
3206-004
3206-006
3206-007
3206-008
3206-015
3206-001
1
4
1
1
6
1
2
1
1
1
Hose, Fuel
Washer, Crush
Electro-Valve
Cap, Filler
Washer, Crush
Bolt, Banjo-Fitting
Gasket
Banjo Fitting
Hose, Fuel
Fuel Filter - Assembly (inc. 11)
11
12
13
14
15
16
17
18
19
3206-012
3206-013
3206-011
3206-005
3206-009
8432-802
8408-825
0124-045
0423-670
1
1
1
1
2
2
2
1
1
Fuel Filter
Hose, Fuel
Bolt, Banjo-Fitting
Bolt, Banjo-Fitting w/Valve
Bolt, Banjo-Fitting
Nut, Lock
Screw, Cap
Clamp, Hose
Clamp, Hose
49
FUEL FEED PUMP AND PUSH ROD ASSEMBLIES

0741-841
1
2
3
4
5
50
3206-009
3206-010
3206-245
3206-234
3206-254
2
4
2
2
2
Bolt, Banjo-Fitting
Washer, Crush
Nut
Washer
Stud
6
7
8
9
3206-255
3206-257
3206-256
3206-258
1
1
1
1
Pump
Rod, Push
O-Ring
Banjo Fitting
WATER PUMP ASSEMBLY

0741-827
1 3206-271
2 3206-273
1
2
Pump, Water - Assembly

Screw
3 3206-274
4 3206-272
2
1
Screw
Gasket
51
INTAKE MANIFOLD AND THROTTLE CONTROL ASSEMBLY

0743-418
1
2
3
4
5
6
7
8
9
10
52
3206-276
3206-278
3206-277
3206-286
3206-283
3206-284
3206-285
3206-280
3206-279
3206-288
3
1
1
1
1
1
1
1
1
1
Screw
Manifold, Intake
Gasket, Intake Manifold
Lever, Internal
Spring, Recovery
Sleeve
Screw
Screw
Screw
Pin
11
12
13
14
15
16
17
18
19
20
3206-287
3206-242
3206-281
3206-357
3206-289
3206-169
3206-234
3206-266
3206-137
3206-282
1
1
1
1
1
2
2
4
1
1
Lever, External
Circlip
O-Ring
Flange, Intake
Gasket
Screw
Washer
Screw
Nut
Bolt
EXTERNAL ALTERNATOR ASSEMBLY

0743-419
1
2
3
4
5
6
3206-303
3206-300
3206-142
3206-298
3206-301
3206-302
1
1
1
2
1
1
Alternator
Support, Alternator
Nut
Washer
Bolt
Washer
7
8
9
10
11
3206-266
3206-299
3206-137
3206-324
3206-325
3
1
1
1
1
Screw
Bolt
Nut
Wire w/Diode
Clamp
53
STARTER MOTOR ASSEMBLY

0741-838
1 3206-319
2 3206-322
3 3206-321
54
1
1
1
Motor, Starter
Washer, Lock
Nut
4 8409-025
5 1402-525
2
1
Screw, Cap
Gasket, Starter Motor
BELT GUARD ASSEMBLY

0743-420
1 3206-315
2 3206-043
3 3206-189
1
3
1
Guard, Belt
Screw
Screw
4 3206-316
5 3206-317
1
1
Plug
Gasket
55
CONTROL SWITCH HOUSING ASSEMBLY

0743-239
1 0409-081
56
Switch, Control - Assembly
2 3409-019
Cover, Switch Housing
THROTTLE CASE ASSEMBLY

0738-414
1
2
3
4
5
0509-012
3409-001
3004-533
3004-447
3003-030
1
1
1
1
1
Case, Throttle - Assembly (inc. 2-9)

Lever
Screw, Cap
Washer, Lock
Washer
6
7
8
9
3423-014
3423-327
3423-199
0409-048
1
1
2
1
Screw
Nut
Screw
Cover, Throttle Case w/Switch
57
Printed in U.S.A.
p/n 2258-438

700 Diesel EGR Street Legal MY08 04

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700 Diesel EGR Street Legal MY08 04

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2008

700 DIESEL EFT

MODEL NUMBER A2008TBT4DETI (RED)

Printed April 2008

2008 ATV 700 Diesel EFT

FRONT RACK AND HEADLIGHT ASSEMBLIES

0541-272 1 Rack - Front - Assembly (inc. 2-5)

24 0423-342 2 Screw, Self-Tapping

2008 ATV 700 Diesel EFT

REAR RACK AND FOOTWELL ASSEMBLIES

2506-221 1 Rack - Rear - Assembly (inc. 2-6)

2008 ATV 700 Diesel EFT

FRAME AND RELATED PARTS

1 2506-966 1 Frame, Main

2008 ATV 700 Diesel EFT

1441-657 1 Winch (inc. 2-3)

Cable, Winch/Solenoid - Blue

2008 ATV 700 Diesel EFT

LICENSE PLATE HOLDER ASSEMBLY

Holder, License Plate

2008 ATV 700 Diesel EFT

SEAT AND BACKREST ASSEMBLY

1506-937 1 Seat Assembly (inc. 2-9)

Base, Seat - Inner

2008 ATV 700 Diesel EFT

STEERING POST ASSEMBLY

2008 ATV 700 Diesel EFT

Light, Indicator - Glow Plug

2008 ATV 700 Diesel EFT

FRONT SUSPENSION ASSEMBLY

0403-176 2 Shock Absorber - Front (inc. 2)

2008 ATV 700 Diesel EFT

REAR SUSPENSION ASSEMBLY

Knuckle - Assembly - Right (inc. 2-5)

2008 ATV 700 Diesel EFT

WHEEL AND TIRE ASSEMBLY

0423-557 12 Screw, Shoulder w/Loctite

8 1402-127 2 Wheel - Front - Platinum

2008 ATV 700 Diesel EFT

AUXILIARY BRAKE ASSEMBLY

1502-063 1 Lever, Brake

Housing, Caliper - Assembly - Left Rear

2008 ATV 700 Diesel EFT

PARKING BRAKE ASSEMBLY

Lever, Parking Brake - Assembly (inc. 2-5)

Cable, Brake - Rear

2008 ATV 700 Diesel EFT

HYDRAULIC HAND BRAKE ASSEMBLY

Brake Assembly (inc. 2-10)

Lever Assembly (inc. 8-9)

2008 ATV 700 Diesel EFT

HYDRAULIC BRAKE ASSEMBLY

Hose, Brake - Assembly

Piston/Seal Set (inc. 7)

2008 ATV 700 Diesel EFT

FUEL TANK ASSEMBLY

0570-214 1 Tank, Fuel - Assembly (inc. 2-6)

0423-688 3 Clamp, Hose

2008 ATV 700 Diesel EFT

SHIFT LEVER ASSEMBLY

Knob, Shift Lever

2008 ATV 700 Diesel EFT

AIR INTAKE ASSEMBLY

Diverter, Air - Top