Arctic Cat Bearcat 454 4x4 Atc Replacement Parts Manual 1997

BEARCAT ATV 4x4 (Model No. 97A4A & 97A4B)

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 15 . . . . . 1 . . . . 30 . . . . 29 . . . . 21 . . . . 34 . . . . 46 . . . . 18 . . . . 28 . . . . 24 . . . . 25 . . . . 26 . . . . 23 . . . . 22 . . . . . 3 . . . . 45 . . . . 17 . . . . . 4 . . . . 41 . . . . . 7 . . . . 13 . . . . 39 . . . . 40 . . . . 12 . . . . 11 . . . . 44 . . . . 10 . . . . 32 . . . . 19 . . . . 42 . . . . . 8 . . . . 31 Back Cover . . . . 14 . . . . . 5 . . . . 38 . . . . 36 . . . . 37 . . . . 27 . . . . 43 . . . . . 6 . . . . 16 . . . . . 2 . . . . 47 . . . . 35 . . . . 33 . . . . . 9 . . . . 20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W or

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

B4 A4 C5 C4 B10 . C9 . D7 . B7 . C3 B13 B14 . C1 B12 B11 . A6 . D6 . B6 . A7 . D2 A10 . B2 C14 . D1 . B1 A14 . D5 A13 . C7 . B8 . D3 A11 . C6 . D9 . B3 . A8 C13 C11 C12 . C2 . D4 . A9 . B5 . A5 . D8 C10 . C8 A12 . B9

om

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 .

COOLING ASSEMBLY . . . . . . . . . . . .

CRANK BALANCER ASSEMBLY . . . . . . .

CRANKCASE ASSEMBLY . . . . . . . . . .

CRANKCASE COVER ASSEMBLY . . . . .

CRANKSHAFT ASSEMBLY . . . . . . . . .

CYLINDER ASSEMBLY . . . . . . . . . . .

CYLINDER HEAD ASSEMBLY . . . . . . . .

DECALS . . . . . . . . . . . . . . . . . . . .

ELECTRICAL COMPONENTS ASSEMBLY .

ENGINE AND EXHAUST . . . . . . . . . . .

FRAME AND RELATED PARTS . . . . . . .

FRONT BEVEL GEAR ASSEMBLY . . . . .

FRONT SUSPENSION ASSEMBLY . . . . .

FUEL TANK ASSEMBLY . . . . . . . . . . .

GEAR SHIFTING ASSEMBLY . . . . . . . .

HI/LOW SHIFTER ASSEMBLY . . . . . . . .

HYDRAULIC BRAKE ASSEMBLY . . . . . .

HYDRAULIC BRAKE CONTROL ASSEMBLY MAGNETO ASSEMBLY . . . . . . . . . . .

MECHANICAL BRAKE ASSEMBLY . . . . .

OIL FILTER/PUMP ASSEMBLY . . . . . . .

REAR AXLE ASSEMBLY . . . . . . . . . . .

REAR BEVEL GEAR ASSEMBLY . . . . . .

REAR SUSPENSION ASSEMBLY . . . . . .

RECOIL STARTER ASSEMBLY . . . . . . .

RELATED ITEMS . . . . . . . . . . . . . . .

REVERSE SHIFT LEVER ASSEMBLY . . . .

SEAT ASSEMBLY . . . . . . . . . . . . . .

SECONDARY DRIVE ASSEMBLY . . . . . .

SECONDARY TRANSMISSION ASSEMBLY SPEEDOMETER DRIVE ASSEMBLY . . . .

STARTER CLUTCH ASSEMBLY . . . . . . .

STARTER MOTOR ASSEMBLY . . . . . . .

STEERING ASSEMBLY . . . . . . . . . . .

STORAGE BOX AND BATTERY ASSEMBLY TAILLIGHT ASSEMBLY . . . . . . . . . . .

THROTTLE CASE ASSEMBLY . . . . . . . .

TRANSMISSION ASSEMBLY . . . . . . . .

WATER PUMP ASSEMBLY . . . . . . . . .

WHEEL AND TIRE ASSEMBLY . . . . . . .

WIRING HARNESS ASSEMBLY . . . . . . .

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 Arctic Cat Service Manuals.

Underlined part numbers are new for the 1997 model year.

© 2001 Arctic Cat Inc. ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

Printed September 2001

A1

0733-362

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

om

BEARCAT ATV 4X4

BODY PANEL ASSEMBLY (*4x4 Models Serial # . . .08001 and above)

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 0506-156 2 0506-179 3 0506-154 0506-155 4 0506-104 5 0606-526 6 0623-269 7 0506-164 0506-165 8 0506-157 9 0506-103 10 0406-269 11 0123-788 12 0606-029 13 0406-082 0406-083 14 0406-086 0406-087

15 0423-046 16 0506-160 0506-161 17 0423-010 18 8474-616 19 0423-060 20 0423-068 21 8409-020 22 8408-812 23 0423-031 24 0123-010 25 0423-068 26 0706-990 27 0123-010 28 0406-297 29 0123-549

Panel, Fender - Front Cover, Radiator Access Flare - Front Right Flare - Front Left Rack - Front Yellow Reflector Clip, Retaining Panel, Side - Right Panel, Side - Left Panel, Fender - Rear Rack - Rear Wrap, Tube - Rear Rack Tie, Cable Red Reflector Flare - Rear Right Flare - Rear Left Mud Flap - Right Mud Flap - Left

W or

1 1 1 1 1 2 8 1 1 1 1 1 7 2 1 1 1 1

A4

54 1 1 13 13 2 2 6 2 2 2 2 AR 1 1 1

Rivet, Plastic Fender Extension - Rear Right Fender Extension - Rear Left Washer, Body Screw, Machine Clip, Tinerman Screw, Self-Tapping Screw, Cap Screw, Cap Nut, Speed Nut, Expansion Screw, Machine Tape, Foil Nut, Expansion* Plate, Heat - Rear Panel* Screw, Machine*

1

0732-336

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

om

BEARCAT ATV 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 0623-574 7 8053-212

W or

1 2 3 4

Ref. Part No. Qty. Description

2

A5

2 2 2

Screw, Machine Screw, Self-Tapping Washer, Lock

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

om

BEARCAT ATV 4X4

DECALS

0732-340

Ref. Part No. Qty. Description 0411-006 0411-018 0411-011 0411-045 0411-008 0411-040 0411-010 0411-014 0411-015

1 1 1 1 1 1 1 1 1

Decal, Warning - Front Rack Load Decal, “Bearcat” - Front Decal, Caution - Electrical Decal, Warning - Turn Decal, Warning Reverse/Pre Ride Decal, Warning - Age Decal, Warning - General Decal, “Bearcat” - Side Right Decal, “Bearcat” - Side Left

9 10 11 12 13 14

0411-012 0411-003 0411-007 0411-043 0411-013 0411-009

1 1 1 1 1 1

Decal, Warning - Tire Pressure Decal, Shift Pattern Decal, Warning - Rear Rack Load Decal, “Arctic Cat” Decal, Warning - Towing Decal, Hi/Low Range

W or

1 2 3 4 5 6 7 8

Ref. Part No. Qty. Description

A6

3

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

om

BEARCAT ATV 4X4

FRAME AND RELATED PARTS

0732-335

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

2 6 2 2 2 1 2 2 8 1 1 1

Headlight Nut, Lock Bulb, Headlight Washer, Lock Screw, Cap Screen, Bumper Yoke, Headlight Mount, Headlight Screw, Cap Bumper - Front Footrest - Right Footrest - Left

0123-590 2 8408-816 10 0506-133 1 0423-010 10 8474-616 10 0406-095 1 0506-079 1 0406-130 2 8408-820 2 0506-149 1 3423-010 1 8428-002 1

W or

0409-001 8424-802 0409-005 8053-242 8408-850 0406-175 0406-261 0406-262 8409-020 0506-075 0506-066 0506-067

4

A7

Screw, Machine Screw, Cap Frame Washer, Shoulder Screw, Machine Panel, Belly Tube, Cross Cap, Bumper Screw, Cap Bracket, Front Gear Case Screw, Cap Nut, Lock

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

om

BEARCAT ATV 4X4

SEAT ASSEMBLY

0732-342

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

1 1 1 1 1 4 1 4 2 4

Seat - Assembly (inc. 2-11)

³ Cover, Seat ³ Foam, Seat ³ Base, Seat - Assembly (inc. 5-10) ³ ³ Base, Seat ³ ³ Rivet ³ ³ Pin, Seat Base - Front ³ ³ Rivet ³ ³ Plate, Seat Retainer ³ ³ Washer

0624-263 AR 8050-217 2 0406-199 2 0406-171 2 0623-404 1 0406-103 1 8477-616 2 0406-270 2 0406-172 2 8408-620 2

³ Staple

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

W or

5990-012 0506-054 0506-056 0506-167 0506-166 8061-628 0506-147 8060-630 0406-268 8050-152

A8

5

0733-363

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

om

BEARCAT ATV 4X4

STEERING ASSEMBLY (*4x4 Models Serial # . . .08001 and above)

Ref. Part No. Qty. Description 1 2 3 4 5 6

1 3 1 3 1 1 1 1 1 1 9 1 1 4 6 4 1 1 2 1 2 1 4

Cable, Speedometer Screw, Machine Speedometer (inc. 36-41) Collar, Body Switch, Ignition - Assembly (inc. 6) ³ Key, Ignition - Blank (C Series) ³ Key, Ignition - Blank (D Series) Bezel/Lens, Warning - Assembly Bezel/Lens, Shifting - Assembly Instrument Pod Bulb, Light Bar Light, Warning - Assembly Light, Shift Indicator - Assembly Screw, Self-Tapping Screw, Cap Cap, Steering Adjuster Bracket, Key Switch Tube, Handlebar Grip, Handlebar Housing, Bearing - Lower Bearing, Steering Post Housing, Bearing - Upper Pin, Cotter

W or

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

0487-005 8477-616 0420-003 0423-052 3430-013 3409-007 3409-011 0420-011 0420-012 0405-019 0420-013 0420-001 0420-004 0123-950 8408-860 0405-035 0506-139 0505-007 0405-039 0605-171 0405-020 0705-064 0117-868

6

Ref. Part No. Qty. Description 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

0505-012 8408-816 0602-233 0107-223 0423-073 8409-020 0423-014 0505-001 8420-002 0405-011 0405-010 0423-013 0405-032 0620-149 0420-014 0420-018 0420-016 0420-017 0420-015 0423-072 0423-014 43 0409-013

A9

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

Post, Steering Screw, Cap Flange, Bearing Bearing - w/o Lock Collar Washer Screw, Cap Nut, Hex Castle Tie Rod, Assembly (inc. 31-35) ³ Nut ³ Ball Joint, Tie Rod - Left ³ Ball Joint, Tie Rod - Right ³ Nut ³ Tie Rod Bulb, Speedometer Harness, Speedometer Bracket, Speedometer Mount, Rubber Washer Pin, Retainer Nut, Hex Castle Nut, Hex Castle* Cover, Key*

0732-344

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

om

BEARCAT ATV 4X4

FRONT(*4x4 SUSPENSION ASSEMBLY Models Serial # . . .08001 and above)

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 2 3 4 5 6 7 8 9 10

13 0505-016

1

0505-017

1

14 0505-010 0505-011 15 0402-085 16 0423-034 17 0402-089 18 0402-069 19 8409-030 20 8409-060 21 0503-013

1 1 2 2 2 2 4 8 1

0503-012

1

0402-098 0436-038 0436-037 0403-027

2 2 2 2

0603-033 2 0403-001 2 0604-310 8 0403-028 4 8424-802 12 8409-040 4 0403-002 2 0403-025 2 0403-013 2 0503-016 1 1

W or

0503-017

Retainer, Spring Shock Absorber - Front (inc. 3-4) ³ Bushing, Shock Absorber ³ Sleeve, Shock Nut, Lock Screw, Cap Spring, Shock Absorber Collar, Spring Washer, Spring A-Arm, Upper Right - Assembly (inc. one No. 11-12) A-Arm, Upper Left - Assembly (inc. one No. 11-12) A-Arm, Upper Right - Assembly (inc. one No. 11-12)* A-Arm, Upper Left - Assembly (inc. one No. 11-12)* ³ Ball Joint - Front ³ Clip, Ball Joint

0503-026

1

0503-027

1

11 0405-001 12 0423-009

4 2

22 23 24 25

A10

Knuckle - Assembly - Right (inc. 14 and one No. 15-18) Knuckle - Assembly - Left (inc. 14 and one No. 15-18) ³ Knuckle, Steering - Right ³ Knuckle, Steering - Left ³ Bearing, Wheel Hub - Front ³ Clip, Bearing ³ Seal, Wheel Bearing - Front ³ Seal, Wheel Bearing - Front Screw, Cap Screw, Cap A-Arm, 4x4 Lower Left (inc. one No. 11-12) A-Arm, 4x4 Lower Right (inc. one No. 11-12) Axle, Drive - Front Repair Kit, Outer Boot - Front Axle Repair Kit, Inner Boot - Front Axle Retainer, Spring - Lower

7

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

om

BEARCAT ATV 4X4

REAR SUSPENSION ASSEMBLY

0732-345

Ref. Part No. Qty. Description 8409-060 8409-000 0504-001 8428-002 8409-055 0504-005 0403-027 0404-001

3 2 3 8 1 1 2 2

Screw, Cap Screw, Cap Arm, Swing Nut, Lock Screw, Cap Arm, Swing Retainer, Spring - Lower Shock Absorber - Rear (inc. two No. 9 and four No. 10)

9 10 11 12 13 14 15 16

0403-028 0604-310 0603-033 8409-040 0404-006 0403-025 0403-013 8422-002

W or

1 2 3 4 5 6 7 8

Ref. Part No. Qty. Description

8

A11

4 8 2 4 2 2 2 1

³ Sleeve, Shock ³ Bushing, Shock Absorber Retainer, Spring Screw, Cap Spring, Shock Absorber Collar, Spring Washer, Spring Adjustment Nut, Lock

0733-366

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

om

BEARCAT ATV 4X4

WHEEL AND TIRE ASSEMBLY (*4x4 Models Serial # . . .08001 and above)

Ref. Part No. Qty. Description 0423-015 0402-140 0402-064 0402-005 0402-007 0402-176 6 0123-458 7 0423-021 8 0402-099

4 4 4 2 2 2 4 4 4

Nut, Hex Cap, Valve Stem Valve, Stem Wheel - Front Tire - Front Tire - Front* Pin, Cotter Washer Seal, Hub

9 10 11 12 13 14

0402-088 2 0402-009 3 0423-029 12 0402-080 2 0402-006 2 0402-008 2 0402-153 2 15 0403-011 4 16 8409-020 16

Hub, Wheel - Front Disc, Brake Screw, Machine Hub, Wheel - Rear Wheel - Rear Tire - Rear Tire - Rear* Cap, Wheel - Center Screw, Cap

W or

1 2 3 4 5

Ref. Part No. Qty. Description

A12

9

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

om

BEARCAT ATV 4X4

MECHANICAL BRAKE ASSEMBLY

0732-337

Ref. Part No. Qty. Description 1 0436-099 2 0402-128 0402-125 0502-020 0423-058 0402-129 0402-116 0487-004 0423-049 0117-868

³ Caliper, Mechanical Brake - Assembly

Mechanical Brake Assembly (inc. 2-7)

1 1 2 1 1 1 1 1

(inc. 2-4) ³ ³ Pin, Actuator ³ ³ Pad Set ³ Screw, Socket Head ³ Spring, Mechanical Brake ³ Bracket, Spring Retaining Cable, Brake - Rear Pin Pin, Cotter

11 12 13 14 15 16 17 18 19 20

0115-602 0423-064 0502-035 8408-616 0670-183 0502-024 0423-027 0623-237 0402-161 0124-057

W or

3 4 5 6 7 8 9 10

1 1

Ref. Part No. Qty. Description

10

A13

1 1 1 2 2 1 1 1 1 1

Spring, Brake Arm Return Cap, Protector - Red Brake, Parking Screw, Cap O-Ring Lever, Foot Brake Washer, Brake Lever Ring, Snap Spring, Foot Brake E-Ring

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

om

BEARCAT ATV 4X4

HYDRAULIC BRAKE CONTROL ASSEMBLY

0732-338 *Not a Service Part

Ref. Part No. Qty. Description 0502-021 0402-049 0623-430 0623-506 0602-742 0602-741 0602-740 0602-587

1 1 1 2 1 1 1 1

Brake, Lever - Assembly (inc. 2-14) ³ Lever, Brake ³ Bolt, Lever Mounting ³ Screw, Cover - Master Cylinder ³ Cover, Master Cylinder ³ Gasket, Cover - Master Cylinder ³ Reservoir, Hydraulic Brake ³ O-Ring, Reservoir

9 10 11 12 13 14 15 16

* 0623-432 0623-056 8052-212 0623-613 0602-907 0402-050 8408-625

1 2 1 2 2 1 1 1

³ Master Cylinder ³ Screw, Reservoir Mount ³ Nut, Lock ³ Washer, Lock ³ Screw, Clamp ³ Clamp Hose, Master Cylinder Screw, Cap

W or

1 2 3 4 5 6 7 8

Ref. Part No. Qty. Description

A14

11

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

om

BEARCAT ATV 4X4

HYDRAULIC BRAKE ASSEMBLY

0732-339 * 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

1

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) ³ Housing, Caliper ³ O-Ring ³ Pin, Cotter ³ Pin, Hydraulic Brake Caliper

11 12 13 14 15 16 17 18 19 20 21 22

0402-143 0502-019 0402-167 0402-141 0402-165 0402-166 0402-052 0402-115 0402-054 8408-625 8408-825 8408-820

W or

7 * 8 0402-164 9 0117-868 10 0402-142

1 1 2 3 6 1

Ref. Part No. Qty. Description

12

B1

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

³ Cap, Bleeder Valve ³ Pad, Hydraulic Brake - Set ³ Valve, Bleeder ³ O-Ring, Hydraulic Brake Caliper ³ Washer ³ Screw, Socket Head Hose, Brake - Rear Clip, Brake Line Tube, Brake Line - Rear Screw, Cap Screw, Cap Screw, Cap

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

om

BEARCAT ATV 4X4

FUEL TANK ASSEMBLY

0732-346 * Not a Service Part

Ref. Part No. Qty. Description 0570-003 1 0470-315 1 0470-316 AR 8408-650 2 0623-184 2 0406-169 4 0406-170 2

Tank, Fuel (inc. 2 and 6-9) ³ Cap, Fuel Tank (inc. 3) 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 0470-314 1 8471-616 2 0417-001 4

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

B2

13

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

om

BEARCAT ATV 4X4

REVERSE SHIFT LEVER ASSEMBLY

0732-334

Ref. Part No. Qty. Description 8477-830 8050-252 0402-103 0502-022 0423-069 0423-063 0402-136

1 1 1 1 2 2 1

Screw, Cap Washer Axle, Reverse Shifter Lever, Reverse O-Ring E-Ring Spring, Reverse Lever

8 9 10 11 12 13 14

0409-008 0402-130 0402-062 3423-168 0487-003 3446-055 8408-616

W or

1 2 3 4 5 6 7

Ref. Part No. Qty. Description

14

B3

1 1 1 1 1 1 1

Reverse Switch Retainer, Switch Knob, Reverse Shift Lever E-Ring Cable, Shift Arm, Reverse Gear Shift Screw, Cap

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

om

BEARCAT ATV 4X4

AIR INTAKE ASSEMBLY (*4x4 Models Serial # . . .08001 and above)

0732-810 ** Not Illustrated

Ref. Part No. Qty. Description 1 2 3 4 5 6 7

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

Clamp Boot, Air Cleaner Clamp Cleaner, Air - Lower Assembly Baffle, Splash - Air Cleaner Gasket, Air Cleaner Snorkel, Air Cleaner Snorkel, Air Cleaner* Clamp, Air Cleaner Spring, Air Cleaner Screw, Machine Nut, Expansion Hose, Crankcase Vent Filter, Air Cleaner (inc. 14)

W or

8 9 10 11 12 13

0423-066 0470-305 0423-018 0570-007 0470-328 0470-324 0470-334 0470-342 0470-307 0423-037 0123-549 0123-010 0410-004 0470-322

Ref. Part No. Qty. Description 14 0470-332 2 15 0470-309 1 16 0470-333 1 1673-272 1 17 0423-071 1 18 0423-045 2 19 0470-327 2 20 0706-990 AR 21 0423-018 1 0423-082 1 22 0406-296 1 23 0123-549 3 24 0123-010 3 25 0406-297 1

B4

³ Sleeve, Filter

Valve, Air Cleaner Cap, Drain - Air Cleaner Cap, Fitting - Air Cleaner* Clamp, Hose Clamp, Hose - Spring Support, Air Cleaner Flange Tape, Foil Clamp, Air Cleaner Clamp, Air Cleaner* Plate, Heat - Air Intake* Screw, Machine* Nut, Expansion* Plate, Heat**

15

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

om

BEARCAT ATV 4X4

STORAGE BOX AND BATTERY ASSEMBLY (**4x4 Models Serial # . . .08001 and above)

0732-811 * Not a Service Part

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 0623-121 18 0506-102

Screw, Cap Strap, Battery - w/Pads (inc. 3 and 11) ³ Pad, Battery - Upper Front Battery - Assembly (inc. 5-7) ³ Cap, Battery ³ Clamp, Hose ³ Hose, Battery Vent Tie, Cable Pad, Battery - Lower Kit, Tool Pad, Batter - Upper Rear Fuse Box - Assembly (inc. 13-16) ³ Block, Fuse ³ Lid, Fuse Block ³ Decal, Fuse Block ³ Fuse, 10 AMP ³ Fuse, 15 AMP

W or

8408-616 1 0506-178 1 0406-289 2 0445-005 1 0645-045 6 0645-152 1 0645-179 1 0123-788 AR 0406-227 1 0444-001 1 0406-288 2 0530-001 1 * 1 * 1 0411-042 1 0630-057 3 0630-058 2

16

19 20 21 22 23 24 25 26 27 28 29 30

4 1

0406-257 1 8050-152 6 0406-208 1 0773-401 1 0623-620 2 0123-010 6 0673-973 1 0406-205 1 8060-630 6 0706-990 AR 0423-044 4 0623-549 2 0623-121 2

B5

Screw, Machine Storage Box - Assembly (inc. 19-23 and four No. 24 and 25-27) ³ Box, Tool ³ Washer ³ Lid, Tool Box ³ Chain, Storage ³ Rivet ³ Nut, Expansion ³ Seal, Storage Cover ³ Ring, Mounting - Storage Box Lid ³ Rivet Tape, Foil Clamp, Tube Screw, Machine Screw, Machine**

0733-371

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

om

BEARCAT ATV 4X4

ENGINE AND EXHAUST (*4x4 Models Serial # . . .08001 and above)

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

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

Pipe, Exhaust Screw, Cap Screw, Cap Washer, Motor Spacer, Engine Engine Nut, Lock Seal, Exhaust Nut, Jam Screw, Cap Screw, Cap Bracket, Upper Motor Lever, Shift Screw, Cap

W or

0512-001 8408-820 3423-003 0423-050 0423-042 0462-003 8428-002 0412-007 8424-802 8408-860 8409-020 0506-083 0502-016 8408-620

B6

0412-003 0412-004 0412-005 8408-830 0406-224 8477-610 8050-252 0214-015 8053-211 8424-602 8408-640 0107-630 0423-079 0406-298

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

Spacer, Exhaust Bushing, Rubber Muffler Screw, Cap Cover, Exhaust Screw, Machine Washer Clamp Washer, Star Nut Screw, Cap Spacer Clamp, Hose* Plate, Heat - Muffler*

17

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

om

BEARCAT ATV 4X4

COOLING ASSEMBLY

0732-738

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8

0423-062 0430-001 0423-070 0410-002 0413-006

1 1 6 1 1

Screen, Radiator Clamp, Wire Screw, Cap Grommet Collar Hose - 25 ft Cap, Radiator Radiator - Assembly (inc. 1, 4, 9-10 and 21) ³ O-Ring ³ Switch, Temperature Sensor Clamp, Hose Hose, Coolant - Upper Blade, Fan

W or

9 10 11 12 13

0413-007 1 3002-964 2 8408-620 2 0423-030 2 0423-036 2 0610-016 AR 0413-002 1 0413-001 1

18

Ref. Part No. Qty. Description 14 15 16 17 18 19 20 21 22 23 24 25 26 27

0413-004 8474-516 0410-001 0410-003 8474-616 0423-010 0406-200 0413-009 0423-031 0423-056 8050-252 0423-028 8477-616 0123-788

B7

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

Motor, Fan Screw, Machine Hose, Coolant - Lower Hose, Coolant - Crossover Screw, Machine Washer, Shoulder Panel, Fender - Inner Screw, Thumb Nut, Speed Nut, Jam - Left Washer Bushing, Stem Screw, Machine Tie, Cable

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

om

BEARCAT ATV 4X4

REAR AXLE ASSEMBLY

0732-350

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

1 2 1 2 1 1 1 2 1 2 1

Housing, Axle - Rear Right Screw, Cap Screw, Cap Axle - Rear Gasket, Rear Axle Bladder, Case Tie, Cable Screw, Cap Hitch, Trailer Screw, Cap Gasket, Rear Axle

0423-010 0502-005 0402-068 0423-033 0402-003 8428-002 0423-031 0406-097 8408-820 8050-252

1 1 2 2 2 2 2 1 1 1

Washer, Shoulder Housing, Axle - Rear Left Seal C-Clip Bearing, Wheel Hub - Rear Nut, Jam Nut, Speed Panel, Gear Case - Rear Screw, Cap Washer

W or

0502-018 8409-030 8409-025 0402-145 0402-139 3008-100 0123-811 8408-616 0506-135 8408-840 0402-138

B8

19

733-409A

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

om

BEARCAT ATV 4X4

WIRING HARNESS ASSEMBLY (*4x4 Models Serial # . . .08001 and above)

Ref. Part No. Qty. Description

Harness, Main Harness, Main* Cable, Battery/Electric Start Relay Cable, Battery/Ground Tie, Cable Switch, Brake - Assembly Regulator, Voltage Regulator, Voltage* Screw, Cap Retainer, Switch

9 0445-004 10 0445-001 11 8060-430 8060-426 12 0123-149 13 0486-004 14 0423-067 15 0423-065 16 0623-454

W or

1 0486-001 1 0486-007 1 2 0445-003 1 3 0445-002 1 4 0123-788 AR 5 0409-009 1 6 0530-002 1 3430-016 1 7 8408-620 2 8 0402-130 1

Ref. Part No. Qty. Description

20

B9

1 4 2 2 2 1 1 2 1

Cable, Battery/Electric Start Receptacle, 12V Rivet Rivet* Washer Harness, 12V Receptacle Tube, Loom Base, Wire Tie Clip, Snap In

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

om

BEARCAT ATV 4X4

CARBURETOR

0732-351

(*4x4 Models Serial # . . .08001 and above)(Complete Assembly p/n 0470-317, 0470-340*)

Ref. Part No. Qty. Description

Ref. Part No. Qty. Description

1 4505-001 2 4505-002 4505-046 3 4505-003 4 4505-004 5 4505-005 6 4505-020 7 4505-007 8 4505-008 9 4505-009 10 4505-010 11 4505-011 12 4505-012 13 4505-013 14 4505-014 15 4505-016 16 4505-017 17 4505-019 4505-047 18 4505-006 19 4505-021 20 4505-022 21 4505-044

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Cover - Assembly Spring Spring* Ring E-Ring Ring Jet Needle 5D40-4 Screw Diaphram Screw Plunger - Assembly O-Ring Washer Spring Screw Screw, Pilot Jet, Pilot 40 Jet, Main 142.5 Jet, Main 152.5* Needle Jet P-7 Float - Assembly Seat, Valve 2.0 (With Needle) O-Ring, Bowl

W or

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

B10

4505-045 4505-023 4505-038 4505-025 4505-026 4505-027 4505-028 4505-029 4505-030 4505-031 4505-032 4505-033 4505-042 4505-034 4505-035 4505-036 4505-037 4505-039 6505-153 6505-006 0487-001 0487-002

1 1 1 3 1 1 1 1 1 1 1 2 1 1 2 1 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 Cap Clip Spring Pin Washer Cable, Throttle Cable, Choke

21

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

om

BEARCAT ATV 4X4

CYLINDER HEAD ASSEMBLY (Complete Gasket Set p/n 3402-107)

0732-300 *Not Illustrated

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

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

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

³ Guide, Valve ³ Circlip ³ Pin ³ Screw, Cap ³ Screw, Cap

Gasket, Cylinder Head Pin Screw, Cap Screw, Cap Screw, Cylinder Head Stud Screw, Cylinder Head Stud Bolt, Stud Screw, Cap Screw, Cap Nut Nut

W or

3402-098 3402-099 3423-068 3423-043 3423-006 3008-376 3402-163 3423-088 3423-015 3423-016 3423-089 3423-087 3423-203 3423-007 3004-376 3004-488 3004-326

22

3003-290 3402-010 0217-705 3402-100 3402-101 3004-341 3402-035 3402-149 3423-062 3423-019 3402-086 3004-341 3413-005 3530-005 3413-004 3402-048

B11

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

Gasket Gasket, Head Nut Spark Plug (NGK CR8E) Cap, Inspection O-Ring Screw, Cap Plug, Cylinder Head Pipe, Intake - Assembly (inc. 26) ³ O-Ring Screw, Cap Clamp Screw, Cap Thermostat Switch, Water Temp - Assembly Cover, Thermostat Plug, Frost*

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

om

BEARCAT ATV 4X4

CYLINDER ASSEMBLY

0732-301

Ref. Part No. Qty. Description 3402-102 3423-090 3004-488 3402-103

1 2 2 1

Cylinder Bolt, Stud Nut Gasket, Cylinder

5 6 7 8

3423-088 3413-006 3423-121 3423-058

2 1 1 1

Pin Union, Water Hose Bolt O-Ring

W or

1 2 3 4

Ref. Part No. Qty. Description

B12

23

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

om

BEARCAT ATV 4X4

CRANKCASE ASSEMBLY

0732-302

Ref. Part No. Qty. Description 3402-198 3423-088 3423-091 3423-092 3423-094 0693-303 3423-093

1 4 3 6 2 4 2

Crankcase Set (inc. 2-7)

³ Pin ³ Screw, Cap ³ Screw, Cap ³ Screw, Cap ³ Screw, Cap ³ Screw, Cap

8 9 10 11 12 13

3423-095 3402-011 3423-052 3423-009 3423-024 3004-278

W or

1 2 3 4 5 6 7

Ref. Part No. Qty. Description

24

B13

1 1 1 3 3 3

Plug, Oil Gallery Gasket O-Ring Screw, Cap Nut Washer

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

om

BEARCAT ATV 4X4

CRANKCASE COVER ASSEMBLY

0732-303 *Engine Serial No. M403-100043 and later

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

Cover, Clutch (inc. 2)

³ Lens, Oil Inspection

Gasket Pin Screw, Cap Screw, Cap Gasket Plug, Oil Gallery Gasket Cap, Engine Oil Filler O-Ring Cap, Inspection O-Ring Screw, Cap Plug, Oil Pressure Gasket

W or

3402-199 1 3402-112 1 3402-108 1 3423-088 2 0693-327 14 3423-097 1 3003-290 1 3004-339 1 3402-009 1 3402-042 1 3423-055 1 3402-100 1 3402-101 1 3423-096 2 3402-037 1 3402-012 1

3402-106 1 3402-097 1 3423-051 1 3402-109 1 3423-120 1 3423-098 13 3423-092 1 3003-290 1 3004-705 2 3003-188 2 3402-038 1 3402-192 1 28 3402-013 1 29 3413-009 1 30 3413-008 1

B14

Cover Set, Transfer (inc. 18-19)

³ Jet, Oil Mission ³ O-Ring

Gasket Clip Screw, Cap Screw, Cap Gasket Plug, Oil Gallery Gasket Plug, Hex Head Plug, Allen Head* Gasket Union, Water Drain Hose

25

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

om

BEARCAT ATV 4X4

CRANKSHAFT ASSEMBLY

0732-304 * Not a Service Part ** Not Illustrated

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 3423-018 17 3402-113 18 3402-114 3436-007 3436-008 19 3402-110 20 3423-069 21 3436-002 3436-003 22 3402-051 23 3402-070 24 3402-119 25 3423-063 26 3436-007 27 3436-008

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

Crankshaft - Assembly (inc. 2-7) ³ Rod, Connecting ³ Pin, Crank ³ Bearing ³ Washer ³ Crankshaft Set - Right (inc. 8-9) ³ Crankshaft - Left Gear, Balancer Drive Pin Bearing - Right Bearing - Center Bearing - Left Retainer, Bearing - Right Screw, Cap Retainer, Oil Seal - Left

W or

3402-115 3402-111 3402-116 3402-064 3423-030 3402-193 3402-118 * * 3402-044 3402-058 3402-054 3402-120 3423-017 3402-188

26

C1

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

Screw, Cap Piston Ring Set, Piston Ring Set (+0.020 in.)

Ring Set (+0.040 in.)

Pin Circlip Piston Set (+0.020 in.)

Piston Set (+0.040 in.)

Bearing Seal, Oil Spacer O-Ring Ring Set (+0.020 in.) ** Ring Set (+0.040 in.) **

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

om

BEARCAT ATV 4X4

STARTER CLUTCH ASSEMBLY

0732-305

Ref. Part No. Qty. Description 3402-123 3402-125 3423-103 3402-124 3423-042

1 2 2 1 1

Limiter, Idle Gear - Assembly Bushing Washer Gear, Starter Idle Pin

6 7 8 9

3402-122 3402-063 3423-104 3423-102

1 1 1 6

Clutch, Starter - Set (inc. 7)

³ Bearing

Washer Screw, Cap

W or

1 2 3 4 5

Ref. Part No. Qty. Description

C2

27

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

om

BEARCAT ATV 4X4

CRANK BALANCER ASSEMBLY

0732-306

Ref. Part No. Qty. Description 3402-126 3402-050 3423-033 3402-128 3402-129 3423-106 3402-090 3004-540

1 2 1 1 1 3 6 1

Balancer, Crank Bearing Washer Gear, Driven Race, Driven Gear Inner Pin Spring Key

9 10 11 12 13 14 15

3423-107 3423-200 3402-150 3423-114 3402-151 3423-025 3423-029

W or

1 2 3 4 5 6 7 8

Ref. Part No. Qty. Description

28

C3

1 1 1 1 1 1 1

Washer Circlip Gear, Oil Pump Drive Pin Spacer Nut Washer

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

om

BEARCAT ATV 4X4

CAM SHAFT VALVE ASSEMBLY

0732-307

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 2 1 1 2 2 1 4

Cam Shaft Sprocket Pin Washer Screw, Cap C-Ring Arm, Valve Rocker (inc. 8-9) ³ Screw, Cap ³ Nut Arm, Valve Rocker (inc. 8-9) Seat, Spring

3402-078 3402-140 3402-141 3423-031 3402-040 3402-012 3402-142 3402-143 3402-144 3402-146 3402-147

4 1 1 2 2 2 2 2 4 4 8

Seal, Oil Shaft, Rocker Arm Shaft, Rocker Arm Washer Plug, Shaft Gasket Valve, Intake Valve, Exhaust Spring, Valve - Set Retainer, Spring Cotter, Valve

W or

3402-130 3402-131 3423-047 3423-073 3423-013 3423-071 3402-138 3423-075 3423-076 3402-139 3402-148

C4

29

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

om

BEARCAT ATV 4X4

CAM CHAIN ASSEMBLY

0732-308

Ref. Part No. Qty. Description 3402-133 3402-134 3402-135 3423-074 3003-188

1 1 1 1 1

Chain, Cam Guide, Chain Tensioner, Chain Screw, Cap Washer

6 7 8 9

3402-136 3402-137 3004-475 3003-290

W or

1 2 3 4 5

Ref. Part No. Qty. Description

30

C5

1 1 2 2

Adjuster, Tensioner - Assembly Gasket Screw, Cap Gasket

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

om

BEARCAT ATV 4X4

RECOIL STARTER ASSEMBLY

0732-309 * Not a Service Part

Ref. Part No. Qty. Description 3445-003 3445-004 3445-016 * 3445-007 * * * *

1 1 1 1 1 1 1 1 1

Starter, Recoil - Assembly (inc. 2-12)

³ Reel ³ Ratchet Assembly (inc. 4 and 6-10) ³ ³ Pin, Ratchet ³ Spring, Spiral ³ Spring, Friction ³ Shaft ³ Cover, Spring ³ Plate, Friction

10 11 12 13 14 15 16 17

* 3004-488 3445-011 3445-013 3423-112 3445-015 3004-491 3423-053

1 1 1 1 6 1 1 1

³ Guide, Ratchet ³ Nut ³ Rope - Assembly Gasket Screw, Cap Cup, Starter Nut O-Ring

W or

1 2 3 4 5 6 7 8 9

Ref. Part No. Qty. Description

C6

31

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

om

BEARCAT ATV 4X4

OIL FILTER/PUMP ASSEMBLY

0732-310 * Engine Serial No. M403-100043 and later

Ref. Part No. Qty. Description 3402-153 3402-152 3423-046 3423-115 3423-184 3423-113 3402-156 3423-118 0693-389

1 1 1 1 1 3 1 2 2

Pump, Engine Oil Gear, Driven Pin Washer Circlip Screw, Cap Strainer, Engine Oil Screw, Cap Screw, Cap*

9 10 11 12 13 14 15 16

3402-157 3423-077 3004-756 0436-001 3402-036 3402-012 3402-154 3402-158

W or

1 2 3 4 5 6 7 8

Ref. Part No. Qty. Description

32

C7

1 1 4 1 1 1 1 1

Cap, Oil Strainer O-Ring Screw, Cap Filter, Engine Oil Plug, Drain Gasket Valve, Oil Relief - Assembly Union, Oil Filter

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

om

BEARCAT ATV 4X4

WATER PUMP ASSEMBLY

0732-311

Ref. Part No. Qty. Description 3402-159 3423-185 3003-188 3423-078 3004-507 3423-119 3413-003 3413-002

1 1 1 1 2 1 1 1

Case, Water Pump (inc. 2-3)

³ Screw, Cap ³ Gasket

O-Ring Screw, Cap Screw, Cap Joint, Pump Drive Shaft, Water Pump w/Bearing

9 10 11 12 13 14 15

3423-046 3003-356 3003-466 3413-001 3003-426 3003-431 3003-432

1 1 1 1 1 1 1

Pin Seal, Pump Drive Seal, Mechanical Impeller Screw, Cap Washer Gasket

W or

1 2 3 4 5 6 7 8

Ref. Part No. Qty. Description

C8

33

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

om

BEARCAT ATV 4X4

CLUTCH ASSEMBLY

0732-312

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

1 1 1 1 1 1 1 1 1 4 4 6 5 1

Housing, Starter Clutch Clutch, Primary Drive One Way Shoe, Starter Clutch Nut, Starter Clutch Shoe Washer, Starter Shoe Washer, Primary Driven Washer, Primary Driven Gear, Primary Driven - Assembly Hub, Clutch Sleeve Screw, Cap, Clutch Spring Spring, Clutch Plate, Clutch Drive Plate, Clutch Driven Disk, Clutch Pressure

W or

3446-001 3446-003 3446-010 3423-081 3423-032 3423-122 3423-186 3446-002 3446-004 3423-079 3446-005 3446-006 3446-007 3446-008

34

3446-009 3423-080 3423-032 3446-011 3423-082 3423-083 3446-012 3446-013 3423-125 3008-014 3423-022 3423-027 3402-186 3423-204

C9

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

Plate, Clutch Release Nut, Clutch Sleeve Hub Washer, Sleeve Hub Arm, Clutch Release Bolt, Clutch (No. 1) Bolt, Clutch (No. 2) Guide, Release Roller Roller, Clutch Release - Assembly Bolt, Clutch Release Arm Nut, Clutch Release (No. 2) Nut, Clutch Release (No. 1) Washer, Clutch (No. 2) Bearing, Clutch Washer, Clutch (No. 1)

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

om

BEARCAT ATV 4X4

TRANSMISSION ASSEMBLY

0732-313

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

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

Shaft, Counter Gear, 2nd Drive Gear, 3rd Drive Gear, 4th Drive Gear, 5th Drive Bushing, 5th Drive Gear Washer, 5th Drive Gear Bearing, Center Shaft - Right Bushing, 4th Drive Gear Circlip, 4th Drive Circlip, Reverse Idle Bearing, Center Shaft Washer, 2nd Drive Washer, 4th Drive Washer, Reverse Idle Shaft, Drive Gear, 1st Driven Gear, 2nd Driven Gear, 3rd Driven Bushing, 3rd Driven Gear, 4th Driven

W or

3446-014 3446-016 3446-017 3446-018 3446-019 3446-020 3423-037 3402-049 3402-081 3423-066 3423-190 3402-179 3423-126 3423-187 3423-126 3446-015 3446-021 3446-022 3446-023 3446-024 3446-025

C10

3446-026 3446-029 3446-030 3446-032 3423-038 3423-039 3423-040 3402-053 3402-080 3402-082 3423-188 3402-079 3003-320 3423-129 3423-130 3423-131 3003-605 3423-189 3446-027 3446-028

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

Gear, 5th Driven Gear, Reverse Driven Dog, Reverse Bushing, Reverse Driven Washer, 3rd Driven - Right Washer, 3rd Driven - Left Washer, 3rd Driven - Left Bearing, Driveshaft Bushing, 1st Driven Bushing, 2nd Driven Circlip, 2nd Driven Bushing, Reverse Idle Bearing, Driveshaft - Right Washer, Reverse Driven Washer, 1st Driven - Left Washer, 1st Driven - Right Washer, 2nd Driven Circlip, Reverse Driven Shaft, Reverse Idle Gear, Reverse Idle

35

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

om

BEARCAT ATV 4X4

SECONDARY TRANSMISSION ASSEMBLY

0732-314

Ref. Part No. Qty. Description 3446-065 3446-066 3446-072 3423-150 3402-015 3446-070 3446-108 3423-036 3446-103

1 1 1 3 1 1 1 1 1

Shaft, Output Gear, Idle Gear, Driven Washer Spacer Gear, (No. 2) Dog, Select Sliding Washer Bushing

10 11 12 13 14 15 16 17 18

3402-046 3402-047 3423-066 3423-126 3446-068 3423-148 3446-067 3446-069 3402-045

W or

1 2 3 4 5 6 7 8 9

Ref. Part No. Qty. Description

36

C11

1 1 1 1 1 1 1 1 1

Bearing, Driveshaft - Left Bearing, Center Shaft - Left Circlip, (No. 1) Washer, Gear (No. 2) Spacer Spacer, Idle Gear Gear, (No. 1) Spacer, Drive Bearing Set - Left

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

om

BEARCAT ATV 4X4

SPEEDOMETER DRIVE ASSEMBLY

0732-459

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

2 1 2 1 1 1 1 1 1 1 1

Retainer, Bearing Washer, Driven Screw, Retainer Seal, Driven Gear Gear Shim Set Nut Washer Washer - Right Spacer, Driven Gear Bolt, Gear

3423-145 3423-056 3423-144 3004-507 3402-055 3446-057 3446-058 3446-059 3446-060 3446-061

1 1 1 2 1 1 1 1 1 1

Washer O-Ring Washer Bolt, Gear Bearing Set - Right Housing, Odometer Gear (inc. 18-21) Sleeve Gasket Gear, Drive Gear, Driven

W or

3446-031 3402-009 3004-552 3402-077 3446-033 3446-035 3423-023 3423-051 3423-146 3446-062 3423-143

C12

37

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

om

BEARCAT ATV 4X4

SECONDARY DRIVE ASSEMBLY

0732-315

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

Yoke, Drive Output (inc. 2-5)

³ Collar, Yoke ³ Plate, Yoke Collar ³ Plate, Yoke Collar ³ O-Ring, Yoke Collar

Yoke, Joint Shaft, Propeller Boot, Propeller Shaft Gear Shaft - Front Shaft - Rear Flange, Output Joint Joint Assembly, Rear Output Nut, Front Drive Bevel Gear Nut Washer, Rear Output Flange Shim, 25 x 34 x 0.6 mm Shim, 25 x 34 x 0.65 mm Shim, 25 x 34 x 0.700 mm Shim, 25 x 34 x 0.75 mm Shim, 25 x 34 x 0.80 mm Shim, 25 x 34 x 0.85 mm Shim, 25 x 34 x 0.90 mm Shim, 25 x 34 x 0.95 mm Shim, 25 x 34 x 1 mm Shim, 25 x 34 x 1.05 mm Shim, 25 x 34 x 1.10 mm Shim, 25 x 34 x 1.15 mm Shim, 25 x 34 x 1.20 mm

3402-062 3402-067 3435-011 3423-067 3402-072 3423-072 3423-137 3423-025 3004-552

W or

3435-001 3435-029 3435-030 3423-035 3423-060 3435-002 3435-004 3435-005 3446-034 3446-036 3446-037 3435-003 3435-010 3423-178 3423-136 3423-028 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

38

C13

1 2 1 4 2 1 1 1 1

Bearing w/Groove Bearing w/ Locating Ring and Pin Joint Set, Universal (inc. 21) ³ Circlip Seal, Oil Ring, Bearing Washer Nut Screw, Cap

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

om

BEARCAT ATV 4X4

GEAR SHIFTING ASSEMBLY

0732-316

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

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

Fork, (No. 2) Fork, (No. 3) Fork, Reverse Shaft, Gear Shift Fork Cam, Gear Shift (inc. 6) ³ Pin, Gear Shift Cam, Reverse Shift Plate, Gear Shift Cam Guide, Gear Shift Cam Plate Spacer, Reverse Shift Cam Bearing, Gear Shift Cam Bolt, Clutch Release Arm Screw, Cam Bearing Retainer Retainer, Bearing Stopper, Gear Shift Cam Stopper, Reverse Shift Cam Housing, Reverse Cam Stopper Spring, Shift Cam Stopper Arm Support, Shift Cam Stopper Gasket, Cam Stopper Housing Spring, Reverse Cam Stopper Washer, Gear Shift Cam

W or

3446-038 3446-039 3446-040 3446-052 3446-041 3423-114 3446-042 3446-049 3446-050 3402-014 3402-051 3423-125 3004-552 3423-135 3446-043 3446-044 3446-046 3446-047 3446-048 3402-012 3402-088 3423-141

C14

3423-142 1 3004-488 1 3446-053 1 3446-054 1 3446-056 1 3402-068 1 3402-076 1 3402-094 1 3446-055 1 3423-204 1 3423-168 1 3423-166 2 3530-007 1 3423-044 1 3423-059 1 3004-787 1 3004-761 1 3402-087 1 3402-008 1 3402-093 1 0706-990 AR

Washer, Cam Stopper Arm Nut, Cam Stopper Arm Support Shaft, Gear Shift Spacer, Gear Shift Shaft Stopper, Gear Shift Arm Seal, Gear Shift Shaft Oil Seal, Reverse Shift Oil Spring, Gear Shift Return Arm, Reverse Gear Shift Washer, Gear Shift Cable Arm E Ring, Gear Shift Cable Arm Screw, Cap Base Assembly Contact, Neutral O-Ring, Neutral Clamp Clamp Spring Hub, Gear Shift Spring, Gear Shift Tape, Foil

39

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

om

BEARCAT ATV 4X4

HI/LOW SHIFTER ASSEMBLY

0732-317

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

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

Stopper, Driven Gear Housing, Shift Stop Shaft, Fork Fork, Shift Cam, Shift Spring Shaft, Shift Plate, Lever Stop Circlip, Shaft - Left Knob Gasket, Cam Stop Seal, Oil Spring Bolt, Stopper Plate

W or

3446-045 3446-046 3446-051 3446-073 3446-074 3446-075 3446-076 3446-077 3423-193 3446-078 3402-012 3402-071 3446-113 3004-377

40

3423-156 3423-157 3423-158 3423-191 3423-192 3446-079 3446-106 3423-152 3423-153 3402-091 3423-154 3423-155 3402-191 3446-112

D1

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

Screw, Shift Knob Washer, Cam Stop Washer, Shaft - Left Circlip, Cam Spring Circlip, Shift Lever Lever, Shift - Assembly (inc. 21-26) ³ Collar ³ Washer ³ E-Clip ³ Spring ³ Circlip ³ Washer Spacer Spacer Set

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

om

BEARCAT ATV 4X4

FRONT BEVEL GEAR ASSEMBLY

0732-318

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

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

Flange, Gear (inc. 2-5)

³ Collar, Gear ³ Plate, Oil Seal ³ Plate, Gear ³ O-Ring, Collar

Gear, Bevel Housing, Bevel Gear Shim Set, Housing Nut, Gear Washer, Bevel Gear Spacer, Bevel Gear Bearing Bearing O-Ring Seal, Joint Bolt, Housing Gear Shim Set Shim Set Bearing Seal - Left

W or

3435-009 3435-029 3435-030 3423-034 3423-060 3435-014 3435-021 3435-022 3423-178 3423-028 3402-016 3402-066 3402-065 3423-064 3402-072 3423-175 3435-018 3435-017 3435-020 3402-059 3402-072

D2

3402-185 3435-013 3402-057 3402-072 3435-024 3402-084 3435-025 3423-010 3402-012 3402-013 3402-036 3402-041 3402-197 3423-050 3423-061 3423-175 3423-070 3435-007 3423-182 3004-491

1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 8 2 1 6 6

Bearing - Left Differential - Assembly Bearing, Differential Case - Right Seal, Output Oil Housing (inc. 27) ³ Union, Breather Case, Bearing Bolt, Mounting Gasket, Oil Drain Plug Gasket, Oil Filler Plug Plug, Oil Drain Plug, Oil Filler Plug O-Ring O-Ring Screw, Cap Ring, Driveshaft - Front Coupling, Propeller Shaft Screw, Cap Nut

41

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

om

BEARCAT ATV 4X4

REAR BEVEL GEAR ASSEMBLY

0732-319

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

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

Boot, Final Drive Shaft, Rear Final Coupling, Rear Gear Set Stopper, Rear Final Pin, Bearing Stopper Shim Set Shim Set Shim Set Case Case - Right Case - Left Housing Nut, Rear Drive Pinion Washer, Drive Nut Washer - Left Gasket, Bearing Stopper Pin Gasket, Oil Drain Plug Plug, Oil Drain Plug, Gear Oil Filler Bearing

W or

3435-051 3435-006 3435-008 3435-012 3435-015 3435-016 3435-019 3435-020 3435-065 3435-023 3435-026 3435-027 3435-028 3423-025 3423-029 3423-171 3003-290 3402-012 3402-036 3402-039 3402-052

42

3402-056 3402-059 3402-061 3423-173 3423-057 3423-065 3003-335 3435-048 3402-073 3402-074 3402-075 3004-786 3402-092 3004-279 3004-301 3423-175 3402-187 3004-326 3423-206 3423-194

D3

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

Bearing Bearing - Right Bearing, Final Drive Pilot O-Ring, Bearing Case - Right O-Ring, Gear Oil Filler O-Ring, Final Bearing Stopper O-Ring, Bearing Case - Left Seal, Final Driven Seal, Oil Seal, Oil Seal, Oil Clamp - Right Spring Stud, Bolt Stud, Bolt - Left Bolt, Bearing - Right Bearing - Left Nut Nut, Rear Final Housing Circlip Set

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

om

BEARCAT ATV 4X4

STARTER MOTOR ASSEMBLY

0732-320

Ref. Part No. Qty. Description 3545-001 3008-094 3008-095 3008-096 3008-164 3423-084 3436-001

1 1 1 4 1 1 1

Motor, Starter Assembly (inc. 2-9)

³ Terminal Set, Brush ³ Holder Set, Brush ³ Spring, Brush ³ O-Ring ³ O-Ring ³ Washer Set

8 9 10 11 12 13

3008-101 3423-085 3423-162 3423-195 3423-201 3402-043

2 2 2 1 1 1

³ O-Ring ³ Screw, Cap

Screw, Cap Nut Circlip Bearing, Pinion Shaft

W or

1 2 3 4 5 6 7

Ref. Part No. Qty. Description

D4

43

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

om

BEARCAT ATV 4X4

MAGNETO ASSEMBLY

0732-321

Ref. Part No. Qty. Description 3430-011 3430-012 3423-162 0691-785 3423-086

1 1 3 1 1

Stator - Assembly Rotor Bolt, Magneto Key, Magneto Nut, Magneto

6 7 8 9

3423-005 3430-005 3430-006 3004-761

W or

1 2 3 4 5

Ref. Part No. Qty. Description

44

D5

3 1 1 1

Screw, Cap Clamp, Magneto (No. 1) Clamp, Magneto (No. 2) Clamp, Magneto (No. 3)

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

om

BEARCAT ATV 4X4

ELECTRICAL COMPONENTS ASSEMBLY

0732-322

Ref. Part No. Qty. Description 3530-001 3423-020 3530-003 3530-004 3430-007

1 2 1 1 1

Relay, Starter Motor - Assembly Screw, Cap CDI Unit Coil, Ignition - Assembly Cap, Spark Plug

6 7 8 9

3430-008 3430-009 3530-008 8408-616

1 1 1 2

Seal, Spark Plug Seal, High Tension Cord Relay, Neutral Start - Assembly Screw, Cap

W or

1 2 3 4 5

Ref. Part No. Qty. Description

D6

45

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

om

BEARCAT ATV 4X4

CONTROL SWITCH HOUSING ASSEMBLY

0732-323

Ref. Part No. Qty. Description 1 1 1

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

続 Lever, Choke 続 Cover, Choke

4 3423-196 5 3423-197

W or

1 3509-001 2 3409-009 3 3409-010

Ref. Part No. Qty. Description

46

D7

1 1

続 Screw, Cap 続 Screw, Cap

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

om

BEARCAT ATV 4X4

THROTTLE CASE ASSEMBLY

0732-324

Ref. Part No. Qty. Description 3509-002 3409-001 3004-533 3004-447 3003-030

1 1 1 1 1

Case, Throttle - Assembly (inc. 2-9)

³ Lever ³ Screw, Cap ³ Washer, Lock ³ Washer

6 7 8 9

3423-014 3423-198 3423-199 3004-638

1 1 2 1

³ Screw, Cap ³ Nut ³ Screw, Cap ³ Screw, Cap

W or

1 2 3 4 5

Ref. Part No. Qty. Description

D8

47

Related Items Model No. 97A4A & 97 A4B

0436-008 0436-052 0436-053 0217-708 0436-040 0436-039 0436-014 0436-032 0436-031 0436-041 0436-042 0436-045 0436-034 0436-024 0436-068

Mounting Plate with Tow Loops Plow Mounting Kit, Winch Lift Plow Mounting Kit, Mechanical Lift Plug, Spark - CR7E Portable Light, Spot Portable Light, Work Safety Flag Tie Down, Black Tie Down, Green Tire Repair, Standard Tire Repair, Deluxe Tire Sealant Tool Holder Winch Kit Winch Accessories Kit

om

Bag, Rack Utility - Front Bag, Rack Utility - Rear Blade, 48 in. Plow Cover, Black and Green Cover, Camoflage Cover, Padded Bar - Black Cover, Padded Bar - Green Engine Block Heater Gasket Set Gun Scabbard Manual, Illustrated Parts Manual, Operator’s Manual, Service Microfiche, Parts Mounting Bracket, Gun Scabbard Mounting Bracket, Portable Lights

W or

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

0436-013 0436-012 0436-025 0436-010 0436-011 0436-047 0436-046 0436-035 3402-107 0436-023 2255-731 2255-520 2255-576 2255-580 0436-050 0436-051

ARCTIC CAT Printed in U.S.A.

D9

®

p/n 2255-731