TABLE OF CONTENTS

ATV 300 2x4 ATV 300 4x4

(Model No. 98A4C-AP)

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. . . . . 15
. . . . . 1
. . . . . 28
. . . . . 27
. . . . . 20
. . . . . 31
. . . . . 40
. . . . . 23
. . . . . 24
. . . . . 25
. . . . . 22
. . . . . 21
. . . . . 3
. . . . . 36
. . . . . 37
. . . . . 19
. . . . . 17
. . . . . 4
. . . . . 7
. . . . . 13
. . . . . 35
. . . . . 12
. . . . . 11
. . . . . 39
. . . . . 10
. . . . . 18
. . . . . 30
. . . . . 8
. . . . . 29
Back Cover
. . . . . 14
. . . . . 5
. . . . . 34
. . . . . 33
. . . . . 16
. . . . . 26
. . . . . 38
. . . . . 6
. . . . . 2
. . . . . 41
. . . . . 32
. . . . . 9

W
or

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

AIR INTAKE ASSEMBLY . . . . . . . . . . . . . . . . .

BODY PANEL ASSEMBLY . . . . . . . . . . . . . . . .
CAM CHAIN ASSEMBLY . . . . . . . . . . . . . . . . .
CAM SHAFT VALVE ASSEMBLY . . . . . . . . . . . .
CARBURETOR . . . . . . . . . . . . . . . . . . . . . .
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . .
CONTROL SWITCH HOUSING ASSEMBLY . . . . . .
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . .
CRANKCASE COVER ASSEMBLY . . . . . . . . . . .
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . .
CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . .
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . .
DECALS . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL GEAR ASSEMBLY (4X4 ONLY) . . . .
DIFFERENTIAL LOCK ASSEMBLY (4X4 ONLY) . . . .
ELECTRICAL COMPONENTS . . . . . . . . . . . . . .
ENGINE AND RELATED PARTS . . . . . . . . . . . .
FRAME AND RELATED PARTS . . . . . . . . . . . . .
FRONT SUSPENSION ASSEMBLY . . . . . . . . . . .
FUEL TANK ASSEMBLY . . . . . . . . . . . . . . . . .
GEAR SHIFTING ASSEMBLY . . . . . . . . . . . . . .
HYDRAULIC BRAKE ASSEMBLY . . . . . . . . . . . .
HYDRAULIC BRAKE CONTROL ASSEMBLY . . . . . .
MAGNETO ASSEMBLY . . . . . . . . . . . . . . . . .
MECHANICAL BRAKE ASSEMBLY . . . . . . . . . . .
OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . .
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . .
REAR SUSPENSION ASSEMBLY . . . . . . . . . . . .
RECOIL STARTER ASSEMBLY . . . . . . . . . . . . .
RELATED ITEMS . . . . . . . . . . . . . . . . . . . . .
REVERSE SHIFT LEVER ASSEMBLY . . . . . . . . .
SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . .
SECONDARY GEAR/PROPELLER SHAFT ASSEMBLY
SECONDARY TRANSMISSION ASSEMBLY . . . . . .
SHIFTER ASSEMBLY . . . . . . . . . . . . . . . . . .
STARTER CLUTCH ASSEMBLY . . . . . . . . . . . .
STARTER MOTOR ASSEMBLY . . . . . . . . . . . . .
STEERING ASSEMBLY . . . . . . . . . . . . . . . . .
TAILLIGHT ASSEMBLY . . . . . . . . . . . . . . . . .
THROTTLE CASE ASSEMBLY . . . . . . . . . . . . .
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . .
WHEEL AND TIRE ASSEMBLY . . . . . . . . . . . . .

NOTE:

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om

(Model No. 98A2C-AP)

B3
A3
C2
C1
B8
C5
C14
B11
B12
B13
B10
B9
A5
C10
C11
B7
B5
A6
A9
B1
C9
A14
A13
C13
A12
B6
C4
A10
C3
D2
B2
A7
C8
C7
B4
B14
C12
A8
A4
D1
C6
A11

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
Arctic Cat Service Manuals. Underlined part numbers are new for the 1998 model.
year.

2001 Arctic Cat Inc.

Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

Printed September 2001

A1

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

BODY PANEL ASSEMBLY

0733-613 *Not Illustrated

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 0506-257 1
0506-239 1
2 0506-153 1
3 0506-274 1
0506-275 1
4 0506-191 1
5 0606-526 2
6 0623-269 8
7 0506-242 1
0506-243 1
8 0506-258 1
0506-245 1
9 0506-190 1
10 0406-293 1
11 0417-002 1
12 0606-029 2
13 0406-082 1
0406-083 1
14 0406-086 1
0406-087 1
15 0423-046 58
0423-046 10

16 0506-160
0506-161
0406-084
0406-085
17 0423-010
0423-010
18 8474-616
8474-616
19 0423-060
20 0623-309
21 8409-020
22 8408-812
23 0423-031
24 0123-010
25 0423-068
26 8477-610
27 8476-616
28 0406-374
29 0423-074
30 0506-272
0506-273
31 0623-362
32 0619-230

W
or

Panel, Fender - Front (4x4)

Panel, Fender - Front (2x4)
Cover, Access
Flare - Front Right (4x4)
Flare - Front Left (4x4)
Rack - Front
Reflector - Yellow
Clip, Retaining
Panel, Side - Right
Panel, Side - Left
Panel, Fender - Rear (4x4)
Panel, Fender - Rear (2x4)
Rack - Rear
Wrap, Tube - Rear Rack
Foam, Access Panel
Reflector - Red
Flare - Rear Right (4x4)
Flare - Rear Left (4x4)
Mud Flap - Right (4x4)
Mud Flap - Left (4x4)
Rivet, Plastic (4x4)
Rivet, Plastic (2x4)

A3

1
1
1
1
25
22
25
22
2
2
6
2
2
2
2
4
2
2
4
1
1
2
1

Fender Extension - Rear Right (4x4)

Fender Extension - Rear Left (4x4)
Fender Extension - Rear Right (2x4)
Fender Extension - Rear Left (2x4)
Washer, Body (4x4)
Washer, Body (2x4)
Screw, Machine (4x4)
Screw, Machine (2x4)
Clip, Tinerman
Screw, Self-Tapping
Screw, Cap
Screw, Cap
Nut, Speed
Nut, Expansion
Screw, Machine
Screw, Machine
Screw, Machine
Panel, Deflector
T-Nut
Flare - Front Right (2x4)
Flare - Front Left (2x4)
Rivet, Plastic
Foil, (3 in. x 24 in.)*

0732-336

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

TAILLIGHT
ASSEMBLY
(Complete Taillight Assembly p/n 0409-002)

Ref. Part No. Qty. Description

0109-460
0409-011
0409-012
0409-007

1
1
1
1

Bulb, Stop - Taillight

Taillight w/Socket-Assembly
Gasket, Taillight
Lens, Taillight

5 0409-010
6 0623-301
7 8053-212

W
or

1
2
3
4

Ref. Part No. Qty. Description

A4

2
2
2

Screw, Machine
Screw, Self-Tapping
Washer, Lock - External Tooth

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

DECALS

0733-614

Ref. Part No. Qty. Description

1
1
1
1
1
1
1
1
1
1
1
1

Decal, Warning - Front Rack Load

Decal, Front (4x4)
Decal, Front (2x4)
Decal, Made In U.S.A.
Decal, Warning - Turn
Decal, Warning Reverse/Pre Ride
Decal, Warning - Age
Decal, Warning - General
Decal, Side Right (4x4)
Decal, Side Left (4x4)
Decal, Side Right (2x4)
Decal, Side Left (2x4)

9 0411-096
0411-089
10 0411-086
11 0411-083
12 0411-043
13 0411-142
14 0411-090
0411-088
15 0411-145

1
1
1
1
1
1
1
1
1

Decal, Warning - Tire Pressure (4x4)

Decal, Warning - Tire Pressure (2x4)
Decal, Shift Pattern
Decal, Warning - Rear Rack Load
Decal, Arctic Cat
Decal, Warning - Towing
Decal, Hi/Low Range (4x4)
Decal, Hi/Low Range (2x4)
Decal, 2x4/4x4 Shift

W
or

1 0411-082
2 0411-109
0411-108
3 3611-002
4 0411-045
5 0411-008
6 0411-040
7 0411-010
8 0411-110
0411-111
0411-106
0411-107

Ref. Part No. Qty. Description

A5

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

FRAME AND RELATED PARTS

0733-713

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 0506-270 1
0506-188 1
2 0406-372 1
3 8476-616 2
4 0506-176 1
0506-217 1
5 8409-020 6
6 8408-816 8
7 0423-010 12
8 8474-616 12
9 0506-192 1
10 0406-354 1
11 0123-788 6
12 0406-175 1

13
14
15
16
17
18
19
20
21
22
23
24
25

W
or

Frame, Main (4x4)

Frame, Main (2x4)
Bracket, Body Holddown
Screw, Machine
Footrest - Right
Footrest - Left
Screw, Cap
Screw, Cap
Washer, Shoulder
Screw, Machine
Guard, Brush
Panel, Belly
Tie, Cable
Screen, Bumper - Lower

8424-802
8408-850
0406-262
0406-261
8053-242
0406-300
0409-001
0409-005
0123-950
0506-210
8408-820
0406-371
8471-610

A6

6
2
2
2
2
2
2
2
2
1
2
1
4

Nut
Screw, Cap
Mount, Headlight
Yoke, Headlight
Washer, Lock
Panel, Inner Fender
Headlight-Assembly (inc. 20-21)
Bulb, Headlight
Screw, Machine
Bracket, Differential (4x4)
Screw, Cap (4x4)
Cover, Front Driveshaft (4x4)
Screw, Cap (4x4)

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

SEAT ASSEMBLY

0733-618 * Not a Service Part

Ref. Part No. Qty. Description

5990-069 1
0506-054 1
0506-056 1
0506-223 1
*
1
8061-628 4
0506-147 1
0624-100 AR
0406-309 2

Seat Assembly (inc. 2-8)

Cover, Seat
Foam, Seat
Base, Seat - Assembly (inc. 5-7)
Base, Seat
Rivet
Pin, Seat Base - Front
Staple

10
11
12
13
14
15
16
17

8476-620
0406-235
8050-217
0406-199
0406-171
0623-404
0406-103
8476-616

2
1
2
2
2
1
1
2

Screw, Cap
Spring, Seat Latch
Washer
Collar, Front Seat Base
Bumper, Seat Base - Front
Cap, Protector
Latch, Seat - Assembly
Screw, Machine

Grommet, Seat - Center

W
or

1
2
3
4
5
6
7
8
9

Ref. Part No. Qty. Description

A7

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

STEERING ASSEMBLY

0733-616

Ref. Part No. Qty. Description

1
2
3
4
5
6

1
3
1
1
1
1
1
1
1
1
4
1
4
4
6
4
1
1

Cover, Key
Screw, Machine
Plug, Instrument Pod
Collar, Body
Switch, Ignition - Assembly (inc. 6)
Key, Ignition - Blank (C Series)
Key, Ignition - Blank (D Series)
Bezel/Lens, Warning - Assembly
Plate, Arctic Cat - Instrument Pod
Instrument Pod
Bulb, Light Bar
Light, Warning - Assembly
Nut
Screw, Self-Tapping
Screw, Cap
Cap, Steering Adjuster
Bracket, Key Switch
Tube, Handlebar

W
or

7
8
9
10
11
12
13
14
15
16
17

0409-013
8477-616
0405-042
0423-052
3409-003
3409-007
3409-011
0420-011
0405-036
0405-019
0420-013
0420-001
8422-002
0123-950
8408-860
0405-035
0506-139
0505-022

Ref. Part No. Qty. Description

18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

0405-039
0605-171
0405-020
0605-147
0623-175
0505-012
8408-816
0602-233
0602-808
0423-073
8409-020
0505-021
0405-032
8420-002
0405-041
0405-040
0423-013
8060-428

A8

2
1
2
1
4
1
2
1
1
1
1
2
2
2
2
2
2
2

Grip, Handlebar
Housing, Bearing - Lower
Bearing, Steering Post
Housing, Bearing - Upper
Pin, Cotter
Post, Steering
Screw, Cap
Flange, Bearing
Bearing
Washer
Screw, Cap
Tie Rod-Assembly (inc. 30-34)
Tie Rod
Nut - Right
Ball Joint, Tie Rod - Left
Ball Joint, Tie Rod - Right
Nut - Left
Rivet

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

FRONT SUSPENSION ASSEMBLY

0733-414

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 0603-033 2
2 0403-015 2
0403-036 2
3 0604-310 8
4 0403-028 4
5 8428-002 12
6 8409-040 4
7 0403-022 2
0403-037 2
8 0403-025 2
9 0403-013 2
10 0503-026 1
0503-027 1
11 0405-001 4
12 0423-009 4
13 0505-026 1
0505-027 1
14 0505-024 1
0505-025 1

15
16
17
18
19
20
21

W
or

Retainer, Spring
Shock Absorber - Front (inc. 3-4) (4x4)
Shock Absorber - Front (inc. 3-4) (2x4)
Bushing, Shock Absorber
Sleeve, Shock
Nut, Lock
Screw, Cap
Spring, Shock Absorber (4x4)
Spring, Shock Absorber (2x4)
Collar, Spring
Washer, Spring
A-Arm, Upper Right - Assembly (inc. 11-12)
A-Arm, Upper Left - Assembly (inc. 11-12)
Ball Joint - Front
Clip, Ball Joint
Knuckle - Assembly - Right (inc. 14-18)
Knuckle - Assembly - Left (inc. 14-18)
Knuckle, Steering - Right
Knuckle, Steering - Left

22
23
24
25
26

A9

0402-085
0423-034
0402-089
0402-069
8409-030
8409-060
0503-044
0503-045
0503-036
0503-037
0402-179
0402-249
0436-114
0436-113
0403-027
0402-183

2
2
2
2
4
8
1
1
1
1
1
1
2
2
2
2

Bearing, Wheel Hub - Front

Clip, Bearing
Seal, Wheel Bearing - Front
Seal, Wheel Bearing - Front
Screw, Cap
Screw, Cap
A-Arm, Lower Right (inc. 11-12) (4x4)
A-Arm, Lower Left (inc. 11-12) (4x4)
A-Arm, Lower Right (inc. 11-12) (2x4)
A-Arm, Lower Left (inc. 11-12) (2x4)
Axle, Drive - Front (RH) (4x4)
Axle, Drive - Front Short (LH) (4x4)
Repair Kit, Outer Boot - Front Axle (4x4)
Repair Kit, Inner Boot - Front Axle (4x4)
Retainer, Spring - Lower
Axle, Stub (2x4)

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

REAR SUSPENSION ASSEMBLY

0733-698

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1
2
3
4
5
6
7
8
9
10
11

14
15
16
17
18
19
20
21
22
23
24
25
26
27

Knuckle, Rear - Assembly (inc. 2)

Fitting, Grease

Collar, Suspension Bushing

Bushing, Suspension
Bearing, Wheel
Clip, Bearing
Seal
Seal
Axle, Drive
Arm, Rear - Upper
A-Arm, Rear - Lower Right
A-Arm, Rear - Lower Left
Shock Absorber - Rear
Sleeve, Shock

W
or

0504-032 2
0423-095 6
0403-038 6
0403-032 12
0402-085 2
0423-034 2
0402-089 2
0402-069 2
0402-171 2
0504-029 2
0504-030 1
0504-031 1
12 0404-014 2
13 0403-028 4

0604-310 8
0403-027 2
0403-013 2
0403-025 2
0603-033 2
0403-002 2
0423-087 2
8428-002 12
8409-040 2
8408-820 2
8409-000 6
8409-060 4
0436-113 2
0436-114 2

A10

Bushing, Shock Absorber

Retainer, Spring - Lower
Washer, Spring Adjust
Collar, Spring
Retainer, Spring
Spring, Suspension
Washer
Nut, Lock
Screw, Cap
Screw, Cap
Screw, Cap
Screw, Cap
Repair Kit, Inner Boot - Rear Axle
Repair Kit, Outer Boot - Rear Axle

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

WHEEL AND TIRE ASSEMBLY

0733-661

Ref. Part No. Qty. Description

1
2
3
4
5

4
4
4
2
2
2
4
4
4
2
2

Nut, Hex
Cap, Valve Stem
Valve, Stem
Wheel - Front
Tire - Front (4x4)
Tire - Front (2x4)
Pin, Cotter
Washer
Seal, Hub
Hub, Wheel - Front (4x4)
Hub, Wheel - Front (2x4)

10
11
12
13

0402-009 3
0423-029 12
0502-041 2
0402-262 2
0402-215 2
14 0402-153 2
15 0403-035 4
16 8409-020 16

Disc, Brake
Screw, Machine
Hub, Wheel - Rear
Wheel - Rear (4x4)
Wheel - Rear (2x4)
Tire - Rear
Cap, Wheel - Center
Screw, Cap

W
or

6
7
8
9

3423-213
0402-140
0402-064
0402-215
0402-252
0402-202
0123-458
0423-080
0402-181
0502-041
0502-040

Ref. Part No. Qty. Description

A11

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

MECHANICAL BRAKE ASSEMBLY

0733-691 *Not a Service Part

Ref. Part No. Qty. Description

0502-048
0402-206
0402-208
0402-210
0402-207
0402-209
*
0487-010

1
1
2
2
1
2
1
1

Mechanical Brake-Assembly (inc. 2-7)

Arm, Inner
Pin, Arm
Pad, Mechanical Brake
Arm, Outer
Spring, Arm
Housing, Mechanical Brake
Cable, Brake - Rear

9
10
11
12
13
14
15
16

8408-825
0402-161
0423-027
0623-237
0502-056
8476-616
0670-183
0502-024

W
or

1
2
3
4
5
6
7
8

Ref. Part No. Qty. Description

10

A12

2
1
1
1
1
2
2
1

Screw, Cap
Spring, Foot Brake
Washer, Brake Lever
Ring, Snap
Bracket, Brake Switch
Screw, Cap
O-Ring
Lever, Foot Brake

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

HYDRAULIC BRAKE CONTROL ASSEMBLY

0733-434 *Not a Service Part

Ref. Part No. Qty. Description

1 0502-061

0402-242
0623-430
0623-506
0602-742
0602-741
0602-740
0602-587
*
0623-432

1
1
2
1
1
1
1
1
2

Brake, Lever - Assembly

(inc. 2-14 and 17-20)
Lever, Brake
Bolt, Lever Mounting
Screw, Cover - Master Cylinder
Cover, Master Cylinder
Gasket, Cover - Master Cylinder
Reservoir, Hydraulic Brake
O-Ring, Reservoir
Master Cylinder
Screw, Reservoir Mount

11
12
13
14
15
16
17
18
19
20

0623-056
8052-212
0623-629
0602-907
0402-050
8476-625
0402-240
0402-245
0423-090
0402-246

1
2
2
1
1
1
1
1
1
1

Nut, Lock
Washer, Lock
Screw, Clamp
Clamp

Hose, Master Cylinder

Screw, Cap
Wedge, Parking Brake
Spring
Nut, Press
Pin

W
or

2
3
4
5
6
7
8
9
10

Ref. Part No. Qty. Description

A13

11

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

HYDRAULIC BRAKE ASSEMBLY

0733-624 * Not a Service Part

Ref. Part No. Qty. Description

1
2
3
4
5
6

0402-053
0402-051
0402-073
0423-038
0423-039
0402-010
0402-011
*
0402-164
0117-868
0402-142
0402-143

3
3
3
3
3

Tube, Brake Line - Front

Hose, Brake - Front
Block, Mounting
Bolt, Oil
Washer, Crush
Caliper, Brake - Right Front
(inc. 7-13 and two No. 14-16)
Caliper, Brake - Left Front and Rear
(inc. 7-13 and two No. 14-16)
Housing, Caliper
O-Ring
Pin, Cotter
Pin, Hydraulic Brake Caliper
Cap, Bleeder Valve

W
or

7
8
9
10
11

1
1
2
3
6
1

12

Ref. Part No. Qty. Description

12
13
14
15
16
17
18
19
20
21
22
23
24

0402-096
0402-167
0402-141
0402-165
0402-166
0402-254
0402-115
0402-170
8476-625
8408-825
0123-269
8476-612
0624-250

A14

6
3
6
6
6
1
1
1
1
6
1
1
1

Pad, Hydraulic Brake

Valve, Bleeder
O-Ring, Hydraulic Brake Caliper
Washer
Screw, Socket Head
Hose, Brake - Rear
Clip, Brake Line
Tube, Brake Line - Rear
Screw, Cap
Screw, Cap
Clamp, Cable
Screw, Machine
Nut

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

FUEL TANK ASSEMBLY

0733-834 * Not a Service Part

Ref. Part No. Qty. Description

0570-014
0470-315
0470-316
8476-650
0623-184
0406-169
0406-170

1
1
1
2
2
4
2

Tank, Fuel (inc. 2-3 and 6-12)

Cap, Fuel Tank (inc. 3)

Line, Fuel Cap Vent

Screw, Cap
Washer
Bushing, Fuel Tank Mount
Collar, Fuel Tank Mount

8
9
10
11
12
13

0610-007 AR
0423-048 2
*
1
0470-357 1
8471-616 2
0417-001 7

Line, Fuel
Clamp, Hose - Spring
Gasket, Fuel
Valve, Shut-Off (inc. 10)
Screw, Cap
Pad, Fuel Tank

W
or

1
2
3
4
5
6
7

Ref. Part No. Qty. Description

B1

13

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

REVERSE SHIFT LEVER ASSEMBLY

0733-716

Ref. Part No. Qty. Description

0402-239
0487-009
3423-168
0502-059
0423-096
0423-063

1
1
1
1
2
2

Axle, Reverse Shift

Cable, Shift
E-Ring
Lever, Reverse
O-Ring
E-Ring

7
8
9
10
11

0402-136
0409-008
0402-168
0402-062
3423-282

W
or

1
2
3
4
5
6

Ref. Part No. Qty. Description

14

B2

1
1
1
1
1

Spring, Reverse Lever

Reverse Switch
Retainer, Switch
Knob, Reverse Shift Lever
Clip, Cable

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

AIR INTAKE ASSEMBLY

0733-684

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 3570-001
2 3402-330
3 0470-355
0470-356
4 3402-331
5 8477-610
6 3423-329
7 3423-311
8 3423-313
9 3402-334
10 0470-349

11
12
13
14
15
16
17
18
19
20
21

Box, Air - Assembly (inc. 2 and 4-9)

Slider, Retainer - Filter

Filter, Air Cleaner
Sleeve, Filter
Cap
Screw, Cap
Joint
Clamp
Clip
Plug, Breather
Valve, Air Cleaner

0423-047
3470-004
0423-018
0470-347
0423-019
0570-019
0406-379
0406-379
0423-046
0444-072
8476-616

1
1
1
1
1
1
3
1
1
1
5

Clamp

Tube, Crankcase Breather

Clamp
Boot, Air Cleaner
Clamp
Snorkel, Air Intake
Washer, Lock
Strap, Tool Kit
Rivet, Plastic
Kit, Tool
Screw, Cap

W
or

1
1
1
1
1
2
1
2
3
1
1

B3

15

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

SHIFTER ASSEMBLY

0733-736

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1
2
3
4
5
6
7
8
9
10
11

12
13
14
15
16
17
18
19
20
21
22

1
2
1
1
2
2
2
2
1
2
1

Lever, Footshift
O-Ring
Axle, Footshift
Nut
Screw, Cap
Washer
Collar, HI/Lo Shift
Bushing, Hi/Lo Shift
Bushing, Shift
Washer
E-Ring, Gear Shift

0502-062
3487-001
0623-175
3423-282
0502-064
0487-012
0423-099
0487-014
0117-868
0423-052
8476-620

W
or

0436-178
0423-096
0402-214
8424-802
8476-630
8050-222
0402-256
0406-363
0423-091
8050-242
3423-168

16

B4

1
1
1
1
1
1
1
1
1
1
1

Linkage, Hi/Lo
Cable, Footshift
Pin, Cotter
Clip, Cable
Arm, 2x4/4x4 - Shift (4x4)
Cable, 2x4/4x4 - Shift (4x4)
Nut
Handle, Cable Shift
Pin, Cotter
Collar, Body
Screw, Cap (4x4)

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

ENGINE AND RELATED PARTS

0734-784

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 0462-009
0462-005
2 0506-301
3 0512-006
4 0423-092
5 8408-812
6 0512-004
7 0412-024
8 8053-211
9 8477-610
10 0412-023
11 0612-887
12 0412-031
13 8424-802
14 0123-321
15 0512-008
16 3402-300
17 0406-344

18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Engine (4x4)
Engine (2x4)
Frame, Sub (inc. 32)
Muffler
Clamp, Exhaust
Screw, Cap
Pipe, Exhaust
Cover, Exhaust - Rear
Washer, Lock
Screw, Cap
Cover, Exhaust
Gasket, Exhaust
Coupler, Exhaust
Nut
Spring, Extension
Pipe, Header
Seal, Exhaust Pipe
Panel, Belly - Subframe

W
or

1
1
1
1
1
2
1
1
4
4
1
2
1
2
3
1
1
1

B5

0423-010
8474-616
8409-020
8408-816
3402-264
3423-236
3402-263
8050-272
3423-235
8422-002
0402-231
0402-232
0406-320
0502-066
8422-202
3402-232

8
8
6
1
2
1
4
4
2
3
1
1
2
1
1
4

Washer, Shoulder
Screw, Cap
Screw, Cap
Screw, Cap
Mount, Motor
Screw, Cap
Mount, Motor
Washer
Screw, Cap
Nut
Spacer, Engine Mount - Long
Spacer, Engine Mount - Short
Cap, Subframe
Driveshaft (4x4)
Nut, Engine Mount - Front
Bushing

17

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

OIL COOLER ASSEMBLY

0733-727

Ref. Part No. Qty. Description

0413-011
0423-086
8476-620
8050-217
0423-036
0423-098

1
4
4
4
4
4

Cooler, Oil
Grommet
Screw, Cap
Washer
Collar
Clamp, Hose

7
8
9
10
11
12

0410-006
0410-007
8471-616
0423-089
0410-012
0410-013

W
or

1
2
3
4
5
6

Ref. Part No. Qty. Description

18

B6

1
1
4
2
1
1

Hose, Oil - Output

Hose, Oil - Input
Screw, Cap
O-Ring, Oil Fitting
Fitting, Oil - Angled
Fitting, Oil

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

ELECTRICAL COMPONENTS

0733-740

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

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

1
2
1
1
3
7
2
1
1
2
1
1
1
1
1
1

Harness, Main
Screw, Self-Tapping
Fuse Box Assembly
Decal, Fuse Box
Fuse, 10 AMP
Screw, Cap
Switch, Brake
Retainer, Switch
Coil, Ignition
Screw, Cap
Relay, Starter
CDI Unit
Regulator, Voltage
Bracket, Battery
Pad, Battery
Battery (inc. 17-19)

W
or

0486-008
0623-361
0530-003
0411-084
0630-057
8476-616
0409-009
0402-168
3530-012
8476-620
3530-013
3530-011
3530-014
0506-254
0406-380
0645-063

B7

0645-045 6
0645-152 1
0645-263 1
0123-788 AR
0445-010 1
0445-011 1
0445-012 1
0645-019 4
3430-009 1
3430-026 1
3430-007 1
3530-008 1
0486-012 1
0486-013 1
0624-250 2

Cap, Battery
Clamp, Hose
Hose, Battery Vent

Tie, Cable
Cable, Battery - Ground
Cable, Battery - Relay
Cable, Battery - Starter
Bolt, Terminal - Battery
Seal, High Tension Cord
Seal, Spark Plug
Cap, Spark Plug
Relay, Neutral Start
Harness, Neutral Jumper
Tube, Heat Spring
Nut, Starter Relay

19

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CARBURETOR

0733-773 *California Models Only

(Complete Assembly p/n 0470-348)

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

1
1
1
1
1
1
4
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1

Cover-Assembly
Spring
Ring
E-Ring
Ring
Jet Needle P-8M
Screw
Diaphram
Screw
Plunger Assembly
O-Ring
Washer
Spring
Screw
Screw, Pilot
Jet, Pilot 45
Jet, Main 137.5
Jet, Main 142.5*
Needle Jet 4D28-3
Float-Assembly
Seat, Valve 2.0 (With Needle)
O-Ring, Bowl

W
or

4505-001
4505-046
4505-003
4505-004
4505-005
4505-061
4505-007
4505-058
4505-009
4505-010
4505-011
4505-012
4505-013
4505-014
4505-016
4505-059
4505-060
4505-019
4505-057
4505-021
4505-022
4505-044

18
19
20
21

20

4505-045
4505-023
4505-024
4505-025
4505-026
4505-062
4505-028
4505-029
4505-030
4505-031
4505-032
4505-033
4505-042
4505-043
4505-035
4505-048
0487-008
4505-039
4505-040
6505-006
0487-007

B8

1
1
1
3
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1

Filter
Chamber, Float
Jet, Pilot - Air
Screw
Spring
Cable Adjust - Assembly
Cover
Washer
Screw
O-Ring
Guide, Cable
Washer
Screw
Clip
Hose
O-Ring
Cable, Choke
Spring
Pin
Washer
Cable, Throttle

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CYLINDER HEAD ASSEMBLY

0733-743

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1
2
3
4
5
6
7
8
9
10
11

12
13
14
15
16
17
18
19
20
21
22

1
2
2
2
7
3
1
2
2
3
1

Head, Cylinder - Assembly (inc. 2-6)

Guide, Valve
Ring, Valve Guide
Pin
Screw, Cap
Screw, Cap
Gasket, Cylinder Head
Pin
Gasket
Nut
Nut

3005-243
3003-032
0217-713
3402-249
3423-275
3402-213
3402-297
3423-276
3423-305
3402-086
3402-298

4
2
1
2
2
1
1
1
2
1
1

Gasket
Bolt, Stud
Spark Plug (NGK DR7EA)
Cap, Inspection
O-Ring
Plug, Head
Pipe, Intake
O-Ring
Screw, Cap
Clamp
Gasket, Intake Pipe

W
or

3402-246
3402-247
3423-068
3423-043
3004-426
3423-304
3402-248
3004-822
3003-290
3423-257
3004-326

B9

21

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CYLINDER ASSEMBLY

0733-744

Ref. Part No. Qty. Description

3402-251
3423-238
3423-239
3423-089
3423-237

1
2
2
2
2

Cylinder
Bolt, Stud
Bolt, Stud
Bolt, Stud
Bolt, Stud

6
7
8
9

3004-488
3402-252
3423-306
3005-226

W
or

1
2
3
4
5

Ref. Part No. Qty. Description

22

B10

4
1
2
1

Nut
Gasket, Cylinder
Pin
O-Ring

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CRANKCASE ASSEMBLY

0733-745

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 3402-314
3402-253
2 3423-088
3 3423-162
4 3423-098
5 3423-091
6 3423-307
7 3423-308
8 3423-094
9 3423-232
10 3423-234
11 3005-243

12
13
14
15
16
17
18
19
20
21
22
23

Crankcase Set (inc. 2-13) (4x4)

Crankcase Set (inc. 2-13) (2x4)
Pin
Screw, Cap
Screw, Cap
Screw, Cap
Screw, Cap
Screw, Cap
Screw, Cap
Screw, Cap
Screw, Cap
Gasket

3423-051
3402-245
3402-214
3402-012
3402-212
3423-274
3402-327
3402-011
3402-257
3402-250
3402-258
3423-271

1
1
1
1
1
1
1
1
1
1
1
1

O-Ring, Oil Gallery Jet

Jet, Oil Gallery
Plug
Gasket
Cap, Oil Filler
O-Ring
Plug, Oil Drain
Gasket
Pipe, Breather
Separator, Oil Breather
Plug, Reverse Switch Hole
O-Ring

W
or

1
1
2
2
4
2
3
4
4
1
1
1

B11

23

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CRANKCASE COVER ASSEMBLY

0733-746

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

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

1
1
1
4
2
8
9
2
1
2
2
1
1

Cover, Clutch (inc. 2)

Lens, Oil Inspection
Gasket
Pin
Screw, Cap
Screw, Cap
Screw, Cap
Screw, Cap
Gasket
Plug, Oil Gallery
Gasket
Switch, Oil Lamp
Gasket

3402-215
3423-274
3402-256
3402-262
3423-328
3004-339
3003-290
3004-756
3402-237
3423-308
3423-091
3430-029

W
or

3402-254
3402-112
3402-280
3423-088
3423-231
0693-327
3423-098
3423-307
3003-290
3004-705
3005-242
3430-019
3402-013

24

B12

1
1
1
1
1
1
1
1
2
1
2
1

Cap, Clutch Adjust

O-Ring
Cover, Transfer
Gasket, Transfer Cover
Screw, Cap
Plug, Oil Gallery
Gasket
Screw, Cap
Clamp, Breather Hose
Screw, Cap
Screw, Cap
Bracket, Shift Cable

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CRANKSHAFT ASSEMBLY

0733-747

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1
2
3
4
5
6
7
8
9
10
11

12
13
14
15

1
1
1
1
2
1
1
1
1
1
1

Crankshaft - Assembly (inc. 2-7)

Rod, Connecting
Pin, Crank
Bearing
Washer
Crankshaft - Right
Crankshaft - Left
Bearing - Right
Bearing - Middle
Bearing - Left
O-Ring

16
17
18
19

3402-301
3423-114
3402-265
3402-266
3436-009
3436-010
3402-267
3423-280
3402-227
3402-306
3402-307

1
1
1
1
1
1
1
2
1
1
1

Gear, Oil Pump Drive

Pin
Piston
Ring Set, Piston
Ring Set (+0.5 mm)
Ring Set (+1.0 mm)
Pin, Piston
Circlip
Seal, Oil
Piston Set (+0.5 mm)
Piston Set (+1.0 mm)

W
or

3402-269
3402-268
3402-270
3402-223
3005-241
3402-271
3402-272
3402-216
3402-221
3402-055
3423-053

B13

25

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

STARTER CLUTCH ASSEMBLY

0733-748

Ref. Part No. Qty. Description

1
1
1

Gear, Starter Idler

Pin
Spacer

4 3402-273
5 3402-222
6 3423-309

W
or

1 3402-274
2 3423-267
3 3402-145

Ref. Part No. Qty. Description

26

B14

1
1
3

Clutch Set, Starter (inc. 5)

Bearing

Screw, Cap

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CAM SHAFT VALVE ASSEMBLY

0733-749

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

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

1
1
1
1
2
1
2
2
2
2
2
4
1

Cam Shaft
Sprocket
Pin
Washer
Screw, Cap
C-Ring
Arm, Valve Rocker (inc. 8-9)
Screw, Cap
Nut
Seal, Oil
Seat, Spring
Cotter, Valve
Shaft, Decompression

W
or

3402-275
3402-326
3423-047
3423-284
3423-013
3423-071
3402-288
3423-287
3423-288
3402-226
3402-294
0693-281
3402-295

C1

3402-296 1
3402-225 1
3402-242 1
3004-326 1
3402-289 2
3423-052 2
3423-259 2
3003-290 2
3004-376 2
3402-290 1
3402-291 1
3402-292 2
3402-293 2

Lever, Decompression
Seal, Oil
Spring
Nut
Shaft, Rocker Arm
O-Ring
Washer
Gasket
Screw, Cap
Valve, Intake
Valve, Exhaust
Spring Set, Valve
Retainer, Spring

27

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CAM CHAIN ASSEMBLY

0733-750

Ref. Part No. Qty. Description

3402-281
3402-277
3402-282
3423-074
3003-188
3402-283

1
1
1
1
1
1

Chain, Cam
7 3402-284
Guide, Cam Chain
8 3402-285
9 3402-286
Tensioner, Cam Chain
Screw, Cap
10 3423-286
11 3402-287
Washer
Adjuster, Tensioner - Assembly (inc. 7-10) 12 3004-576

W
or

1
2
3
4
5
6

Ref. Part No. Qty. Description

28

C2

1
1
1
1
1
2

Spring
Plug
Bar
O-Ring

Gasket, Adjuster
Screw, Cap

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

RECOIL STARTER ASSEMBLY

0733-751

Ref. Part No. Qty. Description

3445-018
3445-019
3445-016
3445-007
3004-488
3445-020

1
1
1
1
1
1

Starter, Recoil - Assembly (inc. 2-6)

Reel
Ratchet - Assembly
Spring, Spiral
Nut
Rope-Assembly

7
8
9
10
11
12

3445-021
3423-112
3003-290
3445-022
3004-336
3004-362

1
6
1
1
1
1

Gasket, Recoil
Screw, Cap
Gasket
Cup, Starter
Nut
Washer, Lock

W
or

1
2
3
4
5
6

Ref. Part No. Qty. Description

C3

29

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

OIL PUMP ASSEMBLY

0733-752

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1
2
3
4
5
6
7
8
9
10
11

12
13
14
15
16
17
18
19
20
21
22

1
1
1
1
3
1
2
1
1
3
1

Pump, Engine Oil

Gear, Driven
Pin
Circlip
Screw, Cap
Strainer, Engine Oil
Screw, Cap
Cap, Oil Strainer
O-Ring
Screw, Cap
Plug, Drain

3402-012
3436-005
3423-270
3402-303
3004-705
3005-242
3423-277
3402-238
3423-314
3004-543
3423-315

W
or

3445-017
3402-302
3423-285
3423-168
3004-402
3402-304
0693-389
3402-305
3423-278
3004-507
3402-036

30

C4

1
1
1
1
1
1
1
1
2
1
3

Gasket
Filter, Engine Oil
O-Ring
Cap, Oil Filter
Plug, Oil Check
Gasket
O-Ring
Spring
Bolt, Stud
Bolt, Stud
Nut

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CLUTCH ASSEMBLY

0733-753

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

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

1
1
1
1
1
1
1
1
1
1
1
1
1
8
7
1

Gear, Primary Drive

Race, Inner
Clutch, One Way
Clutch-Assembly
Nut
Washer, Lock
Washer, Lock
Gear, Primary - Assembly
Spacer
Washer
Hub, Clutch
Nut
Washer
Plate, Drive
Plate, Driven
Disc, Pressure

W
or

3446-120
3446-129
3446-122
3446-128
3423-253
3423-032
3423-260
3446-121
3402-206
3402-211
3446-123
3423-254
3423-316
3446-124
3446-125
3446-126

C5

3402-239
3004-341
3446-127
3446-130
3402-043
3446-133
3446-131
3446-134
3423-248
3423-022
3446-132
3423-125
3423-245
0693-316
3003-290

4
4
1
1
1
1
1
1
1
1
1
1
3
3
3

Spring
Screw, Cap
Plate, Release
Piece, Push
Bearing
Guide, Ball - Outer
Guide, Ball - Inner
Ball, Release
Screw, Adjuster
Nut, Adjuster
Arm, Release
Screw, Cap
Screw, Cap
Nut
Seal, Cap Screw

31

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

TRANSMISSION ASSEMBLY

733-754A

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

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
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56

1
1
1
1
1
2
2
1
1
1
2
2
1
1
1
2
3
4
1
1
1
1
1
1
1
1
1
1

Shaft, Counter
Gear, 2nd Drive
Gear, 3rd Drive
Gear, 4th Drive
Bush
Washer
Circlip
Gear, 5th Drive
Washer
Bearing - Right
Retainer
Screw, Cap
Bearing, Middle
Driveshaft
Gear, 1st Driven
Bush
Washer, Lock
Circlip
Gear, 2nd Driven
Bush
Washer
Gear, 3rd Driven
Washer, Lock
Washer, Lock
Gear, 4th Driven
Gear, 5th Driven
Gear, Reverse Driven
Bush

W
or

3446-135
3446-137
3446-138
3446-139
3402-229
3402-210
3423-279
3446-140
3423-261
0691-374
3446-031
3004-552
3402-224
3446-136
3446-141
3446-144
3423-036
3423-066
3446-142
3402-230
3423-317
3446-143
3423-266
3423-262
3446-146
3446-147
3446-151
3446-145

32

3446-152 1
3423-263 1
3402-218 1
3402-220 1
3446-057 1
3446-059 1
3446-228 1
3423-336 1
3423-337 1
3446-114 1
3446-229 1
3423-144 1
3446-058 1
3402-077 1
3423-056 1
3423-143 1
3004-507 2
3402-009 1
3446-148 1
3446-149 1
3402-228 1
3446-150 1
3402-209 1
3402-255 1
3446-153 1
3423-231 2
0402-160 1
3446-231 1

C6

Dog
Washer
Bearing - Right
Bearing - Middle
Housing, Odometer Gear (4x4)
Gasket (4x4)
Gear, Odometer Drive (4x4)
Washer - Right (4x4)
Washer - Left (4x4)
Spacer (4x4)
Gear, Odometer Driven (4x4)
Washer (4x4)
Sleeve (4x4)
Seal, Oil (4x4)
O-Ring (4x4)
Screw, Cap (4x4)
Screw, Cap (4x4)
Washer (4x4)
Shaft, Reverse Idle
Gear, Reverse Idle
Bush
Spacer
Washer
Plug, Cover Hole (2x4)
Retainer, Cover Plug (2x4)
Bolt, Retainer (2x4)
Cap, Speedometer Drive
Gasket

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

SECONDARY TRANSMISSION ASSEMBLY

0733-755

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 3446-206
3446-179
2 3446-207
3446-184
3 3423-338
4 3423-298
5 3446-208
6 3446-209
7 3423-317
8 3423-318
9 3402-278
10 3004-209
11 3402-055
12 3446-031
13 3446-154
14 3004-552
15 0693-321
16 3446-181
17 3446-069
18 3423-036
19 3446-182
20 3446-183
21 3402-195

22
23
24
25
26
27
28
29
30
31
32
33

Shaft, Sub Transmission (4x4)

Shaft, Sub Transmission (2x4)
Gear, Driven (4x4)
Gear, Driven (2x4)
Washer - Right (4x4)
Washer - Left (4x4)
Gear, Driven (4x4)
Dog, Driven Gear (4x4)
Washer (4x4)
Circlip
Bearing - Right
Bearing - Left
Bearing - Middle
Retainer
Retainer
Screw, Cap
Screw, Cap
Gear, Drive
Bush
Washer
Gear, Drive
Dog, Drive Gear
Washer

W
or

1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
1

34
35
36
37
38
39
40
41
42
43

C7

3402-207 1
3423-066 1
3446-180 1
3402-205 1
3423-319 1
3003-261 1
3402-217 1
3446-185 1
3446-210 1
3446-168 1
3446-230 1
3446-211 1
3446-186 1
3446-187 1
3402-241 1
3423-141 1
3423-240 1
3423-268 1
3446-116 1
3423-125 1
3423-204 1
3423-168 1
3402-076 1

Spacer
Circlip
Gear, Idler
Washer
Washer
Bearing, Drive - Left
Bearing, Counter - Left
Fork
Fork (4x4)
Shaft
Shaft (4x4)
Cam, Sub Transmission Gear (4x4)
Cam, Sub Transmission Gear (2x4)
Stopper
Spring
Washer
Screw, Cap
Pin (4x4)
Arm
Screw, Cap
Washer
E-Ring
Seal, Oil

33

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

SECONDARY GEAR/PROPELLER SHAFT ASSEMBLY

0733-756

Ref. Part No. Qty. Description

3446-197
3446-035
3423-032
3423-254
3402-067
3402-062
3423-072
3446-199
3402-308
3402-017
3402-018
3402-019
3402-020
3402-021
3402-022
3402-023
3402-024
3402-025
3402-028
3402-029
3402-030
3402-031
10 3402-072

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Gear, Secondary Drive Bevel (4x4)

Shim Set, Secondary Drive Bevel (4x4)
Washer (4x4)
Nut (4x4)
Bearing, Front (4x4)
Bearing, Rear (4x4)
Ring (4x4)
Shaft, Secondary Output (4x4)
Shim, 25 x 34 x 0.50 mm (4x4)
Shim, 25 x 34 x 0.60 mm (4x4)
Shim, 25 x 34 x 0.65 mm (4x4)
Shim, 25 x 34 x 0.70 mm (4x4)
Shim, 25 x 34 x 0.75 mm (4x4)
Shim, 25 x 34 x 0.80 mm (4x4)
Shim, 25 x 34 x 0.85 mm (4x4)
Shim, 25 x 34 x 0.90 mm (4x4)
Shim, 25 x 34 x 0.95 mm (4x4)
Shim, 25 x 34 x 1 mm (4x4)
Shim, 25 x 34 x 1.05 mm (4x4)
Shim, 25 x 34 x 1.10 mm (4x4)
Shim, 25 x 34 x 1.15 mm (4x4)
Shim, 25 x 34 x 1.20 mm (4x4)
Seal, Oil

W
or

1
2
3
4
5
6
7
8
9

34

Ref. Part No. Qty. Description

11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

3423-340
3446-176
3446-175
3402-219
3402-072
3435-005
3435-002
3423-025
3423-028
3446-198
3423-281
3423-321
3435-007
3435-011
3423-067
3423-182
3004-491
3435-001

1
1
1
2
2
1
1
1
1
1
2
2
1
1
4
6
6
1

29
30
31
32

3423-060
3423-035
3435-029
3435-030

1
1
1
1

C8

Circlip (4x4)
Shaft, Rear Final Driven
Gear, Driven
Bearing
Seal, Oil
Boot (4x4)
Yoke, Propeller Shaft Joint (4x4)
Nut (4x4)
Washer (4x4)
Gear, Secondary Driven Bevel (4x4)
Ring
Circlip
Coupling (4x4)
Joint, Universal (inc. 25) (4x4)
Circlip
Screw, Cap (4x4)
Nut (4x4)
Yoke, Front Drive Output
(inc. 28-32) (4x4)
O-Ring
Plate
Collar
Plate, Oil Seal

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

GEAR SHIFTING ASSEMBLY

0733-757

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

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
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

1
1
1
1
1
1
1
1
1
6
1
1
1
2
1
1
1
1
1
1
1
1
1
1

Fork, Gear Shifting

Fork, Gear Shifting
Fork, Gear Shifting
Shaft
Fork, Gear Shifting
Shaft
Cam, Gear Shifting (inc. 8)
Pin
Retainer, Pin
Pin
Bearing
Retainer
Retainer
Screw, Cap
Stopper, Cam
Screw, Cap
Washer
Spring
Pin
Plate, Stopper
Screw, Cap
Pin
Cam, Reverse Shifting
Washer

W
or

3446-155
3446-156
3446-159
3446-167
3446-157
3446-051
3446-160
3423-114
3446-162
3423-045
3402-051
3446-163
3446-031
3004-552
3446-165
3423-240
3423-141
3402-240
3423-268
3446-166
3004-376
3005-206
3446-161
3423-322

C9

3446-164
3402-012
3446-169
3446-170
3402-312
3423-323
3446-171
3402-094
3446-172
3402-132
3423-233
3423-324
3402-076
3446-055
3446-115
3423-125
3423-228
3423-204
3423-168
3430-032
3423-273
3423-325
3423-044
3402-087

1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
2
1
1
2
1
1

Stopper, Cam
Gasket
Shaft, Gear Shifting
Arm, Gear Shifting (inc. 29-30)
Spring
E-Ring
Arm, Link
Spring
Stopper, Arm
Roller
Screw, Cap
Washer
Seal, Oil
Arm
Arm, Gear Shifting Cable
Screw, Cap
Screw, Cap
Washer
E-Ring
Base, Gear Shift-Assembly
O-Ring
Screw, Cap
Contact
Spring

35

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 4x4

0733-758 *Not in Assembly

DIFFERENTIAL
GEAR ASSEMBLY
Complete Assembly p/n 3502-001

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1
2
3
4
5
6
7
8
9
10
11
12
13

27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

Gear, Front Drive Bevel

Spacer
Bearing, Front
Bearing, Rear
Bearing
Case, Differential
Pinion, Differential Side
Gear, Right
Gear, Left
Shaft, Pinion
Hub
Shaft, Driven Output
Washer
Washer
Washer
Washer
Washer
Pin, Pinion Shaft
Screw, Cap
Housing, Differential Gear (inc. 19)
Union, Breather
Housing, Drive Bevel Gear
Washer
Shim Set, Front Drive Bevel Gear
Shim Set, Drive Gear Bearing
Shim Set, Front Drive Bevel Housing
O-Ring
O-Ring

W
or

3435-068 1
3402-016 1
3402-065 1
3402-066 1
3402-059 1
3435-076 1
3435-071 2
3435-072 1
3435-080 1
3435-073 1
3435-070 1
3435-074 1
3423-294 AR
3423-295 AR
3423-296 AR
3423-297 1
3423-293 2
3402-309 1
3423-309 6
3435-077 1
3402-084 1
3435-021 1
3423-317 1
3435-017 1
3435-020 1
3435-020 1
3423-064 1
3423-050 1

14
15
16
17
18
19
20
21
22
23
24
25
26

36

3435-078 1
3435-079 1
3402-185 1
3402-057 1
3402-072 3
3402-323 1
3423-010 2
3423-175 11
0693-327 2
3004-756 2
3005-206 2
3435-009 1
3423-034 1
3435-029 1
3435-030 1
3423-060 1
3423-178 1
3423-028 1
3402-036 1
3402-012 1
3402-038 1
3423-054 1
0402-147 1
0123-811 1
3435-075 1
3423-341 2
3423-070 2
3435-069 1

C10

Case, Driven Gear Bearing

Cover
Bearing, Left
Bearing, Right
Seal, Oil
Gasket, Case Cover
Screw, Cap
Screw, Cap
Screw, Cap
Screw, Cap
Pin
Flange, Drive Bevel Gear (inc. 39-42)
Plate
Collar
Plate, Oil Seal
O-Ring
Nut
Washer
Plug, Drain
Gasket
Plug, Filler
O-Ring
Bladder, Case*
Tie, Cable*
Dog
Nut
Circlip
Gear, Front Driven Bevel

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 4x4

DIFFERENTIAL LOCK ASSEMBLY

0733-759

Ref. Part No. Qty. Description

3446-205
3446-202
3446-203
3446-204
3402-311
3423-300

1
1
1
1
1
1

Fork, Differential Locking

Shaft, Fork
Cam, Differential Locking
Shaft, Cam
Spring
Washer, Right

7
8
9
10
11
12

3423-339
3402-076
3446-119
3446-046
3402-089
3402-012

1
1
1
1
1
1

Washer, Left
Seal, Oil
Stopper
Housing
Spring
Gasket

W
or

1
2
3
4
5
6

Ref. Part No. Qty. Description

C11

37

0733-760

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

STARTER
MOTOR ASSEMBLY
Complete Assembly p/n 3545-003

Ref. Part No. Qty. Description

3008-554
3008-550
3008-549
3008-164
3008-099
3008-551

1
1
1
3
1
2

Armature
Holder Set, Brush
Terminal Set, Brush (inc. 4)
O-Ring
Washer Set
Spring, Brush

7
8
9
10
11
12

3008-552
3423-289
3423-272
3008-553
3423-195
3004-756

W
or

1
2
3
4
5
6

Ref. Part No. Qty. Description

38

C12

1
2
1
2
1
2

Bracket, Front - Assembly

Bolt Set (inc. 4)
O-Ring
O-Ring
Nut
Screw, Cap

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

MAGNETO ASSEMBLY

0733-761

Ref. Part No. Qty. Description

3430-021
3430-022
3004-756
3423-326
3423-086

1
1
3
2
1

Stator - Assembly
Rotor
Bolt, Magneto
Screw, Cap
Nut, Magneto

6
7
8
9

3004-540
3430-023
3423-112
3430-036

1
1
1
1

Key
Plate
Screw, Cap
Sheet, Heat Protection

W
or

1
2
3
4
5

Ref. Part No. Qty. Description

C13

39

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

CONTROL SWITCH HOUSING ASSEMBLY

0732-323

Ref. Part No. Qty. Description

1
1
1

Switch, Handle - Assembly (inc. 2-5)

Lever, Choke
Cover, Choke

4 3423-196
5 3423-197

W
or

1 3409-002
2 3409-009
3 3409-010

Ref. Part No. Qty. Description

40

C14

1
1

Screw, Cap
Screw, Cap

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

om

300 2x4
300 4x4

THROTTLE CASE ASSEMBLY

0732-324

Ref. Part No. Qty. Description

3409-005
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
3004-638

1
1
2
1

Screw, Cap
Nut
Screw, Cap
Screw, Cap

W
or

1
2
3
4
5

Ref. Part No. Qty. Description

D1

41

Related Items
Model No. 98A2C-AP & 98A4C-AP

2255-676
2255-810
2255-811
0436-121
0436-051
0436-117
0436-093
0436-015
3436-005
0436-116
0436-040
0436-039
0436-014
0217-713
0436-129
0436-128
0436-032
0436-031
0436-101
0436-102
0436-042
0436-041
0436-045
0436-034
0436-068
0436-145

Manual, Operators
Manual, Service (2x4)
Manual, Service (4x4)
Mount, Gun Scabbard
Mounting Bracket, Portable Lights
Mounting Plate, Winch
Mud Flap Kit Front
Mud Flap Kit Rear (2x4)
Oil Filter
Plow Mounting Kit (4x4)
Portable Light, Spot
Portable Light, Work
Safety Flag
Spark Plug, NGK DR7EA
Speedometer Kit (2x4)
Speedometer Kit (4x4)
Tie Down, Black
Tie Down, Green
Tie Down, Ratchet Style Black
Tie Down, Ratchet Style Orange
Tire Repair, Deluxe
Tire Repair, Standard
Tire Sealant
Tool Holder
Winch Accessories Kit
Winch Kit

om

Air Filter
Accessory Plug Kit
Blade, 50 in. Snow Plow (4x4)
Boot Protector (4x4)
Brake Pads, Hyd
Brake Pads, Mech
Bulb, Headlight
Bulb, Stop/Taillight
Cargo Box
Cargo Trailer
Cleaner, Spray and Rinse
Cover, Camo
Cover, Gray
Cover, Black and Green
Decal Kit - French (2x4)
Decal Kit - French (4x4)
Engine Oil, 10W-40
Fan Kit
Fender Flare Kit Front (2x4)
Fender Flare Kit Rear (2x4)
Gasket Set
Gear Lube, 80W-90
Gun Scabbard
Handlebar Heater Kit
Lunch Pack, Camo
Lunch Pack, Black
Manual, Illustrated Parts

W
or

ld
of
80 P
0- ow
40 er
7- sp
72 or
18 ts.
c

0470-355
0436-016
0436-115
0436-151
0402-096
0402-210
0409-005
0109-460
0436-043
0436-139
0436-119
0436-011
0436-125
0436-010
0436-138
0436-137
0436-005
0436-127
0436-076
0436-077
3402-260
0436-006
0436-023
0436-049
0436-141
0436-122
2255-902

ARCTIC CAT
Printed in U.S.A.

D2

p/n 2255-902