BAD BOY 0NSLAUGHT 647971-B Service Manual

ATV Vehicle

SERVICE PARTS MANUAL

647971-B ISSUED AUGUST 2015

REVISED JANUARY 2016

SERVICE PARTS MANUAL GASOLINE POWERED ATV

ONSLAUGHT

STARTING MODEL YEAR 2017 CALIFORNIA Proposition 65 Warning WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth defects and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes and particulates, all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specifications. Such modifications can cause serious personal injury or death. E-Z-GO Division of Textron Inc. prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

TSV reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold previously.

The information contained in this manual may be revised periodically by TSV, and therefore is subject to change without notice.

TSV DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.

These are the original instructions as defined by 2006/42/EC.

TO CONTACT US: Textron Specialized Vehicles 1451 Marvin Griffin Road Augusta, Georgia, USA 30906-3852

647971 Service Parts Manual

Page i

NOTES The use of non Original Equipment Manufacturer (OEM) parts may void the warranty.

Overfilling of batteries may void the warranty.

BATTERY PROLONGED STORAGE All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75° F (-60° C).

As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals.

BATTERY DISPOSAL Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acidresistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information.

Page ii

647971 Service Parts Manual

TABLE OF CONTENTS SECTION

Page No.

ENGINE ASSEMBLY (100 FBG-KDEU) ..............................................................................................................A - 1 INTAKE SYSTEM (101 FBG-KDEU) ...................................................................................................................B - 1 CYLINDER HEAD ASSEMBLY (102 FBG-KDEU).............................................................................................. C - 1 CYLINDER (103 FBG-KDEU) ............................................................................................................................. D - 1 TRANSMISSION SYSTEM ASSEMBLY (104 FBG-KDEU).................................................................................E - 1 LEFT CRANKCASE COVER (105/10501 FBG-KDEU) ....................................................................................... F - 1 RIGHT CRANKCASE COVER (106 FBG-KDEU)............................................................................................... G - 1 CRANKCASE (107 FBG-KDEU)......................................................................................................................... H - 1 THROTTLE BODY (108 FBG-KDEU) .................................................................................................................. J - 1 CRANKSHAFT (109 FBG-KDEU)........................................................................................................................K - 1 STARTING SYSTEM - FLYWHEEL MAGNETO - ECU (110 FBG-KDEU).......................................................... L - 1 L CRANKCASE (111/112 FBG-KDEU)............................................................................................................... M - 1 FRONT DIFFERENTIAL ASSEMBLY (LOCK) (113 FBG-KDEU)....................................................................... N - 1 REAR DIFFERENTIAL ASSEMBLY (114 FBG-KDEU) .......................................................................................P - 1 CVT (115 FBG-KDEU) ........................................................................................................................................ R - 1 MUFFLER ASSEMBLY (116 FBG-KDEU)...........................................................................................................S - 1 AIR CLEANER ASSEMBLY (117 FBG-KDEU).................................................................................................... T - 1 RADIATOR AND COOLING FAN (118 FBG-KDEU) .......................................................................................... U - 1 WIRING HARNESS AND LOCK ASSEMBLY (119 FBG-KDEU).........................................................................V - 1 BATTERY - HORN - RELAY - RECTIFIER (120 FBG-KDEU)............................................................................W - 1 BOX HOLDER (121 FBG-KDEU).........................................................................................................................X - 1 ENGINE BUFFER (122 FBG-KDEU) ...................................................................................................................Y - 1 SERVO MOTOR (123 FBG-KDEU) ..................................................................................................................... Z - 1 EPS ASSEMBLY (124 FBG-KDEU).................................................................................................................. AA - 1 SPEEDOMETER (201 FBG-KDEU).................................................................................................................. AB - 1 HEAD LAMP (202/2101 FBG-KDEU) ............................................................................................................... AC - 1 REAR LAMP ASSEMBLY (203 FBG-KDEU) .................................................................................................... AD - 1 FRAME (204 FBG-KDEU)................................................................................................................................. AE - 1 REAR SUSPENSION (205 FBG-KDEU)........................................................................................................... AF - 1 BUMPER BRACKET (206 FBG-KDEU)............................................................................................................ AG - 1

647971 Service Parts Manual

Page iii

TABLE OF CONTENTS SECTION

Page No.

FUEL TANK AND FUEL SYSTEM (207/20701 FBG-KDEU)............................................................................ AH - 1 SHIFT LEVER (208 FBG-KDEU)....................................................................................................................... AJ - 1 BRAKE PEDAL (209 FBG-KDEU) .................................................................................................................... AK - 1 FRONT AND REAR BRAKES (210/217 FBG-KDEU) .......................................................................................AL - 1 FRONT SUSPENSION .....................................................................................................................................AM - 1 STEERING KNUCKLE (212 FBG-KDEU)......................................................................................................... AN - 1 FRONT AND REAR WHEELS (213/219 FBG-KDEU) ...................................................................................... AP - 1 STEERING SHAFT (214/21401 FBG-KDEU)................................................................................................... AR - 1 HANDLEBAR (215 FBG-KDEU) ....................................................................................................................... AS - 1 MASTER CYLINDER (216 FBG-KDEU)........................................................................................................... AT - 1 REAR AXLE (218 FBG-KDEU) ......................................................................................................................... AU - 1 FRONT BUMPER (220 FBG-KDEU) ................................................................................................................ AV - 1 FRONT BODY - FOOTBOARD - REAR BODY (221/222/223 FBF-KDEU)..................................................... AW - 1 SEAT SET (224 FBG-KDEU)............................................................................................................................ AX - 1 LABELS (225 FBG-KDEU) ............................................................................................................................... AY - 1 CARRIER - BUMPER OPTION (226 FBG-KDEU) ........................................................................................... AZ - 1

Page iv

647971 Service Parts Manual

NOTES

647971 Service Parts Manual

Page v

ENGINE ASSEMBLY

Page A-1

Service PartsParts Manual 647971 Service Manual

ENGINE ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

TBG520198E-1 PEDAL BOX ASSEMBLY (PDS) (INCLUDES ITEMS 2 - 34) .........................

1

1A

TBG520198EP ENGINE ASSEMBLY (4X4 for EPS) ...............................................................

1

2

926144

1

MAINTENANCE TOOL PACKAGE ......................................................

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page A-2

INTAKE SYSTEM

Page B-1

Service PartsParts Manual 647971 Service Manual

INTAKE SYSTEM THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

925502

CVT INLET BOX ..................................................................................

1

2

924689

BELT COOLING DUCT, FRONT NO. 2...........................................................

1

3

924714

CLAMP............................................................................................................

1

4

924672

COOLING DUCT CONNECTOR, FRONT ......................................................

1

4A

927103

COOLING DUCT CONNECTOR, FRONT (for EPS) ......................................

1

5

924720

CLAMP............................................................................................................

1

6

924695

BELT COOLING DUCT, FRONT NO. 1...........................................................

1

6A

927102

BELT COOLING DUCT, FRONT (for EPS) .....................................................

1

7

924717

CLAMP............................................................................................................

1

8

924696

COOLING DUCT CONNECTOR, FRONT ......................................................

1

9

924719

CLAMP............................................................................................................

1

10

R66001

CLAMP............................................................................................................

1

11

924097

COOLING DUCT CONNECTOR, REAR.........................................................

1

12

925258

CLAMP............................................................................................................

1

13

D9900063

BELT COOLING DUCT, REAR .......................................................................

1

14

GA551SC09

FLANGE BOLT, M6X20...................................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page B-2

CYLINDER HEAD ASSEMBLY

Page C-1

Service PartsParts Manual 647971 Service Manual

CYLINDER HEAD ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927327

CYLINDER HEAD ASSEMBLY ............................................................

1

1-1

927328

COMPLETE CYLINDER HEAD ...........................................................

1

1-10

S95808

STUD, M8X38 ......................................................................................

2

1-1-1

927109

SCREW................................................................................................

1

1-2

924020

INTAKE VALVE ....................................................................................

2

1-3

924021

EXHAUST VALVE ................................................................................

2

1-4

924023

LOWER CUP .......................................................................................

4

1-5

924024

VALVE STEM SEAL .............................................................................

4

1-6

924025

INNER VALVE SPRING .......................................................................

4

1-7

924026

OUTER VALVE SPRING......................................................................

4

1-8

924027

UPPER CUP ........................................................................................

4

1-9

400093

VALVE COTTER ..................................................................................

8

2

926100

INTAKE PIPE .......................................................................................

1

3

S20614

FLANGE BOLT, M6X60........................................................................

2

4

927325

FLANGE BOLT, M8X60........................................................................

2

5

S06501

ADJUSTING BOLT...............................................................................

4

6

N03501

HEX NUT .............................................................................................

4

7

S99605

BOLT, M6X12 .......................................................................................

2

8

924031

FIXING PLATE .....................................................................................

1

9

924036

TIMING SPROCKET, 34T GB-69.........................................................

1

10

924994

CAM SHAFT SET.................................................................................

1

11

924032

C RING.................................................................................................

1

12

924033

EXHAUST VALVE ROCKER ARM .......................................................

1

13

924034

INTAKE VALVE ROCKER ARM ...........................................................

1

14

927333

ROCKER ARM AXLE PIN ....................................................................

2

15

924016

CYLINDER HEAD GASKET ................................................................

1

16

924017

CYLINDER HEAD COVER ..................................................................

1

17

924019

BOLT, M7X31 .......................................................................................

2

18

924297

GASKET...............................................................................................

1

19

924018

BOLT, M7X23.5 ....................................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page C-2

CYLINDER HEAD ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

20

S96806

CAM CHAIN TENSIONER BOLT.........................................................

1

21

W99818

GASKET...............................................................................................

1

23

926101

RUBBER TUBE....................................................................................

1

24

926103

O-RING ................................................................................................

1

25

924090

SPARK PLUG (NGK CR7E).................................................................

1

26

P40803

DOWEL PIN .........................................................................................

4

27

N10801

FLANGE NUT, M8................................................................................

2

28

S20616

FLANGE BOLT, M6X40........................................................................

2

29

R66004

CLAMP.................................................................................................

2

30

S95807

STUD ...................................................................................................

2

31

926143

THERMOSTAT COVER .......................................................................

1

32

925115

WASHER .............................................................................................

1

33

S96605

FLANGE BOLT.....................................................................................

1

34

S24616

FLANGE BOLT, M6X20........................................................................

4

35

924294

THERMOSTAT.....................................................................................

1

37

S77601

FLANGE BOLT.....................................................................................

1

38

926024Y

FUEL INJECTOR .................................................................................

1

39

926153

FUEL RAIL ...........................................................................................

1

40

S24604

FLANGE BOLT, M6X12........................................................................

1

41

926030

INJECTOR CLIP ..................................................................................

1

22

36

Page C-3

Service PartsParts Manual 647971 Service Manual

CYLINDER HEAD ASSEMBLY

Notes:

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page C-4

CYLINDER HEAD ASSEMBLY

Page D-1

Service PartsParts Manual 647971 Service Manual

CYLINDER HEAD ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

925338

CYLINDER GASKET, 0.25t..................................................................

1

2

D9900009

STUD ...................................................................................................

2

3

P40301

DOWEL PIN .........................................................................................

4

4

S95607

STUD ...................................................................................................

2

5

926124

CYLINDER (ALLOY) ............................................................................

1

6

GA504NT01

FLANGE NUT, M6................................................................................

2

7

D9900011

STUD ...................................................................................................

2

8

910178

CYLINDER HEAD GASKET ................................................................

1

9

924013

GASKET...............................................................................................

1

10

924014

TENSIONER ADJUSTER ASSEMBLY.................................................

1

11

S24603

FLANGE BOLT, M6X16........................................................................

2

12

926022Y

COOLANT TEMPERATURE SENSOR................................................

1

13

924038

CAM CHAIN TENSIONER ..............................................................................

1

14

D9900013

CAM CHAIN GUIDE.............................................................................

1

15

D9900014

TIMING CHAIN ....................................................................................

1

16

924666

WATER PUMP .....................................................................................

1

17

R66701

CLIP .....................................................................................................

2

19

W99010

WASHER, Ø10.5XØ22X3.5t ...........................................................................

4

20

924833

P CLIP..................................................................................................

1

21

925148

Y CLIP..................................................................................................

1

22

S20617

FLANGE BOLT, M6X25........................................................................

2

23

S24604

FLANGE BOLT, M6X12........................................................................

2

18

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page D-2

TRANSMISSION SYSTEM ASSEMBLY

Page E-1

Service PartsParts Manual 647971 Service Manual

TRANSMISSION SYSTEM ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

924218

SEC DRIVEN OUTPUT SHAFT, FRONT.............................................

1

2

924205

SEC DRIVEN OUTPUT SHAFT, REAR ...............................................

1

3

927154

UNIVERSAL JOINT ASSEMBLY..........................................................

1

3-1

925494

GREASE NIPPLE ................................................................................

1

4

927154

UNIVERSAL JOINT ASSEMBLY..........................................................

1

4-1

925494

GREASE NIPPLE ................................................................................

1

5

924214

SEC DRIVEN GEAR BEARING, MDL .................................................

1

6

924228

SEC DRIVEN OUTPUT SHAFT BEARING, FRONT ...........................

3

7

924229

DRIVEN SHAFT OIL SEAL, FRONT....................................................

2

8

W99826

WASHER, Ø18XØ30X3t ......................................................................

2

9

927128

DRIVE OUTPUT YOKE, FRONT .........................................................

2

10

N33804

HEX NUT, M18X1.5 .............................................................................

2

11

W99509

SHIM, SEC DRIVEN SHAFT Ø25XØ34X0.05t ....................................

1

11A

W99510

SHIM, SEC DRIVEN SHAFT Ø25XØ34X0.1t ......................................

1

11B

W99511

SHIM, SEC DRIVEN SHAFT Ø25XØ34X0.3t ......................................

1

11C

W99512

SHIM, SEC DRIVEN SHAFT Ø25XØ34X0.5t ......................................

1

11D

W99517

SHIM, REVERSE SHAFT ....................................................................

1

12

924217

SEC DRIVEN BEARING RING, MDL...................................................

1

13

924204

SEC DRIVE BEVEL GEAR, 21T ..........................................................

1

14

W99305

WASHER..............................................................................................

1

15

N33802

NUT......................................................................................................

1

16

925346

PROPELLER SHAFT, REAR ...............................................................

1

18

925345

PROPELLER SHAFT...........................................................................

1

19

S21007

BOLT, M10X1.25X20............................................................................

14

20

925334

SPRING ...............................................................................................

1

21

925333

SPRING ...............................................................................................

1

17

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page E-2

LEFT CRANKCASE COVER

Page F-1

Service PartsParts Manual 647971 Service Manual

LEFT CRANKCASE COVER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

BEARING, Ø20XØ52X15................................................................................

1

BEARING, Ø25XØ47X8.......................................................................

1

924184 924070 924073 924072 924071 924075 924074

OIL SEAL, Ø25XØ36X6 ..................................................................................

1

SPACER...............................................................................................

O-RING, Ø2.5XØ43.5 ..........................................................................

CRANKCASE COVER RETAINER ......................................................

O-RING, Ø2.4XØ14.8 ..........................................................................

1 1 1 1

9

924707

SPACER..........................................................................................................

1

10

N10203 924708 S24616 924154 W99823

NUT.................................................................................................................

1

CAP......................................................................................................

FLANGE BOLT, M6X20........................................................................

OIL PRESSURE VALVE.......................................................................

WASHER..............................................................................................

1 3 1 1

1 2 3 4 5 6 7 8

11 12 13 14

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page F-2

LEFT CRANKCASE COVER

Page F-3

Service PartsParts Manual 647971 Service Manual

LEFT CRANKCASE COVER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM 1 2 3 4 5 6 7 8 8-1 9 10 11 12 13 14 15 16 17 18 19 20 21

PART NO.

DESCRIPTION

QTY.

400157 924376 924197 S95604 924240 924764 S21604 927324

OIL LEVEL GAUGE ASSEMBLY..........................................................

SPEEDOMETER GEAR ASSEMBLY...................................................

SPEEDOMETER GEAR ASSEMBLY GASKET ...................................

BOLT ....................................................................................................

OIL SEAL, Ø12XØ22X9 .......................................................................

GEAR POSITION ARM ........................................................................

FLANGE BOLT, M6X1.0X20 ................................................................

WATER PUMP, COMPLETE ................................................................

1 1 1 2 1 2 1 1

924362 S24626 W99620 924339 W99821 GA504SC12 S24602 S20813 S24625 GA504NT01 514410 927314 R36501 GA510SR02

O-RING ................................................................................................

FLANGE BOLT, M6X48........................................................................

WASHER, TDC Ø16.2XØ22.5X2t........................................................

SCREW................................................................................................

WASHER..............................................................................................

FLANGE BOLT, M8X12........................................................................

FLANGE BOLT, M6X50........................................................................

FLANGE BOLT.....................................................................................

FLANGE BOLT.....................................................................................

FLANGE NUT, M6................................................................................

CLAMP.................................................................................................

HOSE ...................................................................................................

CLIP .....................................................................................................

CLAMP, L200 .......................................................................................

2 2 1 1 1 1 12 1 2 2 2 1 1 2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page F-4

RIGHT CRANKCASE COVER

Page G-1

Service PartsParts Manual 647971 Service Manual

RIGHT CRANKCASE COVER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

924337

BREATHER PIPE.................................................................................

1

2

924047

OIL GUIDE PLATE ...............................................................................

1

3

S24604

FLANGE BOLT, M6X12...................................................................................

3

4

GA504PN02

DOWEL PIN, 6.5X9X10 .......................................................................

2

5

D9900064

ENGINE OIL PUMP .............................................................................

1

6

GA502SC01

BOLT, M6X25 .......................................................................................

3

7

924147

WASHER, DRIVEN GEAR...................................................................

3

8

924148

DOWEL PIN .........................................................................................

1

9

D9900065

DRIVEN GEAR ....................................................................................

1

10

924149

C RING.................................................................................................

1

11

924150

ENGINE OIL STRAINER......................................................................

1

12

S43501

BOLT ....................................................................................................

2

13

924152

O-RING ................................................................................................

1

14

924151

OIL STRAINER CAP.......................................................................................

1

15

S24605

FLANGE BOLT, M6X25........................................................................

4

16

W99303

DRAIN PLUG WASHER.......................................................................

1

17

924326

DRAIN PLUG BOLT .............................................................................

1

18

S21810

FLANGE BOLT.....................................................................................

4

19

S21811

FLANGE BOLT.....................................................................................

3

20

S24602

FLANGE BOLT, M6X50........................................................................

7

21

924168

O-RING, Ø30XØ44X7..........................................................................

1

22

924179

BEARING, Ø30XØ62X23.8..................................................................

1

23

924184

BEARING, Ø20XØ52X15.....................................................................

1

24

925024

BEARING .............................................................................................

1

25

927315

BEARING .............................................................................................

1

26

924118

DOWEL PIN .........................................................................................

1

27

924117

DRIVEN GEAR ....................................................................................

1

28

W99011

GASKET, 2.5t .......................................................................................

1

29

S21007

BOLT, M10X1.25X20............................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page G-2

THROTTLE BODY

Page J-1

Service PartsParts Manual 647971 Service Manual

THROTTLE BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

926031Y

THROTTLE BODY, COMPLETE..........................................................

1

1-1

927942

THROTTLE BODY (TPS).....................................................................

1

1-2

927945

TEMPERATURE - MANIFOLD AIR PRESSURE (T-MAP) ..................

1

1-3

927946

BOLT (T-MAP)......................................................................................

1

1-4

927943

IDLE SPEED CONTROL (ISC) ............................................................

1

1-5

927944

BOLT (ISC)...........................................................................................

2

2

926114

SEAL ....................................................................................................

1

3

926113

QUADRANT COVER ...........................................................................

1

4

S70403

SOCKET HEAD SCREW, M4X8 ..........................................................

4

5

925697

CABLE STUD.......................................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page J-2

CRANKCASE

Page H-1

Service PartsParts Manual 647971 Service Manual

CRANKCASE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927321

CRANKCASE.......................................................................................

1

2

927323

CRANKCASE COVER, LH ..................................................................

1

2A

927322

CRANKCASE COVER, LH (for EPS)...................................................

1

3

927060

CRANKCASE COVER, RH..................................................................

1

4

925147BL

CLUTCH COVER (BLACK)..................................................................

1

5

924185

BEARING CHUCK ...............................................................................

2

6

S46603

SCREW................................................................................................

2

7

S24627

FLANGE BOLT, M6X74........................................................................

1

8

P40301

DOWEL PIN .........................................................................................

6

9

S24610

FLANGE BOLT, M6X40........................................................................

26

10

924051

CLUTCH COVER GASKET .................................................................

1

11

W99821

WASHER..............................................................................................

1

12

GA504SC12

FLANGE BOLT, M8X12........................................................................

1

13

924166

BEARING, 12X32X10 ..........................................................................

1

14

R01901

C RING.................................................................................................

1

15

925115

WASHER..............................................................................................

1

16

924055

GASKET...............................................................................................

1

17

924808

GASKET...............................................................................................

1

18

S24626

FLANGE BOLT, M6X8..........................................................................

2

19

GA504WS04

SPRING WASHER...............................................................................

2

20

927034

HEAT INSULATION..............................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page H-2

CRANKSHAFT

Page K-1

Service PartsParts Manual 647971 Service Manual

CRANKSHAFT THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927068YA

CRANKSHAFT SET .............................................................................

1

2

927316

DRIVEN GEAR ASSEMBLY.................................................................

1

4

925764

FIXED SHAFT......................................................................................

1

4-1

925234

KEY 25X14X4 ......................................................................................

1

5

927302A

PISTON SET........................................................................................

1

6

927064

PISTON RING SET ........................................................................................

1

3

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page K-2

STARTING SYSTEM - FLYWHEEL MAGNETO - ECU

Page L-1

Service PartsParts Manual 647971 Service Manual

STARTING SYSTEM - FLYWHEEL MAGNETO - ECU THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

925668

CLUTCH ASSEMBLY (STARTING) ................................................................

1

2

926023YC

ECU.................................................................................................................

1

3

926029M

HIGH TENSION LINE IGNITION ASSEMBLY .....................................

1

3-1

926752

SPARK PLUG ATTACHMENT.........................................................................

1

4

S70402

SOCKET HEAD SCREW, M4X25...................................................................

2

5

S70607

SOCKET HEAD SCREW, M6X20...................................................................

4

6

926714A

FLYWHEEL MAGNETO ASSEMBLY ...................................................

1

6-1

926715

ROTOR ASSEMBLY ............................................................................

1

6-2

926716A

STATOR ASSEMBLY ...........................................................................

1

6-2-1

925809

FIXING PLATE .....................................................................................

1

6-2-2

S99616

FLANGE BOLT, M6X36........................................................................

3

6-2A

927756A

STATOR ASSEMBLY ......................................................................................

1

6A

927755A

FLYWHEEL MAGNETO ASSEMBLY ...................................................

1

7

S70811

BOLT, M8X20 ..................................................................................................

6

9

924937

CLAMP............................................................................................................

1

10

S13502

CROSS RECESSED PAN HEAD SCREW, M5X10........................................

3

11

924470E

START MOTOR ASSEMBLY................................................................

1

11-1

P30405

PIN .......................................................................................................

1

11-2 1 1-3

925302

GEAR ...................................................................................................

1

R00201

SNAP RING, C TYPE .....................................................................................

1

12

S24607

FLANGE BOLT, M6X32...................................................................................

2

13

926748

GEAR SENSOR ASSEMBLY...............................................................

1

13-1

924246

CONTACT PIN, GEAR SELECT SWITCH...........................................

2

13-2

925858

SPRING, GEAR SELECT SWITCH ................................................................

2

14

S79501

SOCKET HEAD SCREW, M5X16...................................................................

2

15

D9900040

KEY .................................................................................................................

1

16

N10803

FLANGE NUT .................................................................................................

1

17

924282

NO. 2 CLAMP .................................................................................................

1

18

514410

CLAMP.................................................................................................

3

8

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page L-2

L CRANKCASE

Page M-1

Service PartsParts Manual 647971 Service Manual

L CRANKCASE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

D9900066

WATER PUMP SPROCKET ...........................................................................

1

2

W99412

GASKET, 14X32X1 .........................................................................................

1

3

W99430

WASHER, 12.3X22X1t....................................................................................

1

4

924393

WATER PUMP RETAINER .............................................................................

1

5

S70602

HEX SOCKET SCREW, M6X1.0X25 ..............................................................

2

6

W99616

GASKET..........................................................................................................

1

7

924231

GEAR SHAFT CAM STOPPER ......................................................................

1

8

924233

SET SCREW, GEAR CAM STOP ...................................................................

1

9

924232

SPRING ..........................................................................................................

1

10

W99617

SPRING ABATEMENT WASHER ...................................................................

1

11

N10601

FLANGE NUT, M6...........................................................................................

1

12

924374

OIL FILTER STUD...........................................................................................

1

13

924153

ENGINE OIL FILTER............................................................................

1

14

924048

OIL GUIDE PLATE ..........................................................................................

1

15

S24604

FLANGE BOLT, M6X12...................................................................................

1

16

924112

PIN (NO. 2 STARTING IDLER) .......................................................................

1

17

924110

GEAR ..............................................................................................................

1

18

924111

PIN (NO. 1 STARTING IDLER) .......................................................................

1

19

924835

STARTING IDLER GEAR ...............................................................................

1

20

925690

COMPLETE SHIFT CAMSHAFT ....................................................................

1

21

W99218

WASHER ........................................................................................................

2

22

R00703

C RING............................................................................................................

2

23

924236

SECONDARY DIAL POLE ..............................................................................

1

24

W99303

DRAIN PLUG WASHER .................................................................................

1

26

S24627

FLANGE BOLT, M6X74...................................................................................

3

27

S21812

FLANGE BOLT, M8X97.5................................................................................

1

28

S24602

FLANGE BOLT, M6X50...................................................................................

3

29

924739

BUSHING........................................................................................................

1

30

925826A

COMPLETE OIL PRESSURE SENSOR..............................................

1

30-1

925826

OIL PRESSURE SENSOR...................................................................

1

30-2

W99020

WASHER..............................................................................................

1

25

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page M-2

L CRANKCASE

Page M-3

Service PartsParts Manual 647971 Service Manual

L CRANKCASE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927315

BEARING ........................................................................................................

1

2

924163

BEARING ........................................................................................................

1

3

924068

OIL SEAL, Ø34XØ52X6 ..................................................................................

1

4

925664

CRANKCASE RETAINER, LH ........................................................................

1

5

S46601

SCREW...........................................................................................................

3

6

P30303

DOWEL PIN ....................................................................................................

1

7

D9900071

WATER PUMP CHAIN WHEEL ......................................................................

1

8

924351

WATER PUMP CHAIN ....................................................................................

1

9

924718

WASHER ........................................................................................................

1

10

924366

WASHER ........................................................................................................

1

11

924235

FORK POLE....................................................................................................

1

12

924237

FORK ..............................................................................................................

1

13

924364

THRUST BEARING .............................................................................

1

14

924701

GEAR SHIFT CAM ASSEMBLY...........................................................

1

14-1

R00206

C CLIP.............................................................................................................

5

15

R00206

C CLIP.............................................................................................................

1

16

W99517

REVERSE SHAFT SHIM ................................................................................

1

17

924186

REVERSE GEAR SHAFT ...............................................................................

1

18

924636

REVERSE GEAR FORK.................................................................................

1

19

R00501

C CLIP.............................................................................................................

1

20

W99709

WASHER, Ø17XØ30X1t .................................................................................

3

21

924643

BEARING, Ø17X24X15 ..................................................................................

1

22

925052

IDLER GEAR (28T).........................................................................................

1

23

924182

BEARING, Ø25X52X15 ..................................................................................

1

24

924185

BEARING CHUCK ..........................................................................................

2

25

924699

FORK SPRING ...............................................................................................

1

26

925165

COMPLETE TRANSMISSION GEAR (31T) ...................................................

1

27

925051

GEAR (19T) ....................................................................................................

1

28

924180

BEARING, Ø20X47X14 ..................................................................................

1

29

925558

TRANSMISSION SHAFT (26T) ......................................................................

1

30

925057

OUTPUT COUNTER-SHAFT ASSEMBLY (42T) ............................................

1

31

W99012

WASHER ........................................................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page M-4

L CRANKCASE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

32

924066

BEARING, Ø35XØ72X17 ................................................................................

1

33

W99413

SHIM 24X48X1T ..................................................................................

2

33A

W99414

SHIM 24X48X0.5T ...............................................................................

1

33B

W99415

SHIM 24X48X0.3T ...............................................................................

1

33C

W99417

SHIM 24X48X0.05T .............................................................................

1

34

924203

SEC DRIVE BEVEL GEAR (17T) ....................................................................

1

35

W99304

SHIM ....................................................................................................

1

36

N33803

HEX NUT .............................................................................................

1

37

P40301

DOWEL PIN .........................................................................................

2

38

924645

DOWEL PIN .........................................................................................

1

39

924149

C RING ................................................................................................

1

40

924700

FORK SPRING ....................................................................................

1

41

W99015

WASHER .............................................................................................

2

42

925695

RETAINING PLATE..............................................................................

1

43

W99437

WASHER, 0.2t .................................................................................................

1

45

S46603

SCREW ...........................................................................................................

2

46

925746

O-RING ................................................................................................

1

44

Page M-5

Service PartsParts Manual 647971 Service Manual

L CRANKCASE

Notes:

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page M-6

FRONT DIFFERENTIAL (LOCK)

Page N-1

Service PartsParts Manual 647971 Service Manual

FRONT DIFFERENTIAL (LOCK) THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

924984B

FRONT DIFFERENTIAL ASSEMBLY (LOCK) .....................................

1

1-1

925496

UNIVERSAL JOINT ASSEMBLY..........................................................

1

1-2

924380

OIL SEAL, Ø52xØ73x14 ......................................................................

1

1-3

R01301

CLIP .....................................................................................................

1

1-4

924606

CLIP .....................................................................................................

1

1-6

925703A

DRIVE PINION INCLUDING BEARING...............................................

1

1-7

924384

BEARING, Ø15XØ21X12.....................................................................

1

1-8

924867

GEAR BOX ..........................................................................................

1

1-9

P40102

DOWEL PIN .........................................................................................

2

1-10

924886

LOCK SLEEVE (19T)...........................................................................

1

1-11

925337

BEARING .............................................................................................

3

1-1-1

925494

GREASE NIPPLE ................................................................................

1

1-12

925460

FRONT DRIVE HOUSING ...................................................................

1

1-13

GA556WS04

SPRING WASHER, 8.2X3.2X2t ...........................................................

14

1-14

S70810

SOCKET HEAD SCREW, M8X1.25X36 ..............................................

8

1-15

925010

OIL SEAL .............................................................................................

2

1-16

924982

STEEL ROPE BRACKET.....................................................................

1

1-17

924339

SCREW................................................................................................

1

1-18

W99620

WASHER, TDC Ø16.2XØ22.5X2t........................................................

1

1-19

925353

SPRING ...............................................................................................

1

1-20

924887

SHIFT FORK........................................................................................

1

1-21

924970

SHIFT SPRING ....................................................................................

1

1-22

924871

SHIFT ROD..........................................................................................

1

1-23

924971

WASHER, 1t.........................................................................................

2

1-24

R10702

E RING.................................................................................................

3

1-25

W99307

SHIM, 0.1t ............................................................................................

2

1-25A W99308

SHIM, 0.3t ............................................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page N-2

FRONT DIFFERENTIAL (LOCK) THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1-26

924983

LIMITED SLIP GEAR ASSEMBLY .......................................................

1

1-27

924261

EXHAUST PIPE BREATHER...............................................................

1

1-28

R40802

CLIP .....................................................................................................

1

1-29

924264

BREATHER CASE ...............................................................................

1

1-30

S70809

SOCKET HEAD SCREW, M8X1.25X40 ..............................................

6

1-31

S21815

FLANGE BOLT, M8X1.25X50 ..............................................................

2

1-32

924611

SHIFT BRACKET ASSEMBLY.............................................................

1

1-33

W99218

WASHER .............................................................................................

4

1-34

925673

RETURN SPRING ...............................................................................

1

1-37

924381

OIL SEAL, Ø45XØ68X12.....................................................................

1

1-38

927078

SHIFT ROD..........................................................................................

1

1-39

927106

SHIFT FORK........................................................................................

1

1-40

924970

SHIFT SPRING ....................................................................................

1

1-41

924981

FRONT DRIVE COVER .......................................................................

1

1-42

P40301

DOWEL PIN .........................................................................................

2

1-43

924382

BEARING, Ø45XØ68X12 ....................................................................

1

1-44

R00105

CLIP .....................................................................................................

1

1-45

924398

SHIFT SLEEVE (14T) ..........................................................................

1

1-46

924326

DRAIN PLUG BOLT .............................................................................

1

1-47

W99303

DRAIN PLUG WASHER ......................................................................

1

1-49

925354

SPRING ...............................................................................................

1

1-50

S20623

BOLT, M6X14 .......................................................................................

1

1-51

W99621

WASHER, Ø635XØ13.2X1.3t ..............................................................

1

2

S20019

FLANGE BOLT, M10X1.25

3

GA551NT01

SELF LOCK NUT, M10X1.25 ..........................................................................

1

4

925442Y

TRANSMISSION SHAFT (R) (BLACK)................................................

1

4-1

927278

TRANSMISSION SHAFT BOOT SET..................................................

1

4-2

925685

C CLIP .............................................................................................................

1

Page N-3

Service PartsParts Manual 647971 Service Manual

FRONT DIFFERENTIAL (LOCK) THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

5

925441Y

TRANSMISSION SHAFT (L)................................................................

1

5-1

927278

TRANSMISSION SHAFT BOOT SET ..................................................

1

5-2

925685

C CLIP.............................................................................................................

1

6

924224

PROPELLER SHAFT BOOT................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page N-4

REAR DIFFERENTIAL

Page P-1

Service PartsParts Manual 647971 Service Manual

REAR DIFFERENTIAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

925700A

REAR DIFFERENTIAL ASSEMBLY.....................................................

1

1-1

925792A

RR FINAL DRIVE HOUSING SET .......................................................

1

1-10

925452

FINAL DRIVEN GEAR .........................................................................

1

1-11

W99531

SHIM, Ø45.5XØ54X0.5t.......................................................................

1

1-11A

W99529

SHIM, Ø45.5XØ54X0.1t.......................................................................

2

1-11B

W99530

SHIM, Ø45.5XØ54X0.05t.....................................................................

1

1-12

924268

BEARING, Ø45XØ75X16.....................................................................

1

1-13

925642

REAR FINAL DRIVEN CASE, RH........................................................

1

1-14

S21813

SCREW................................................................................................

9

1-15

924275

OIL SEAL, Ø42XØ62X9 .......................................................................

1

1-16

924963

JOINT PLATE (L) .................................................................................

1

1-17

S21004

FLANGE BOLT.....................................................................................

4

1-18

S21010

BOLT ....................................................................................................

10

1-19

W10203

SPRING WASHER...............................................................................

4

1-3

924273

O-RING, Ø3.1X75.4 .............................................................................

1

1-4

924252

REAR FINAL DRIVE JOINT.................................................................

1

1-5

924769

BREATHER PIPE.................................................................................

1

1-6

R40002

CLIP .....................................................................................................

1

1-7

924966

JOINT PLATE (R).................................................................................

1

1-8

924271

O-RING, Ø2.3XØ158.3 ........................................................................

1

1-9

W99427

SHIM, Ø40XØ50X0.5t..........................................................................

1

1-9A

W99425

SHIM, Ø40XØ50X0.1t..........................................................................

2

1-9B

W99426

SHIM, Ø40XØ50X0.1t..........................................................................

1

2

925443Y

REAR TRANSMISSION SHAFT (L).....................................................

1

2-1

927279

TRANSMISSION SHAFT BOOT SET ..................................................

1

2-2

925250

C CLIP..................................................................................................

1

3

925444Y

REAR TRANSMISSION SHAFT (R) ....................................................

1

3-1

927279

TRANSMISSION SHAFT BOOT SET ..................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page P-2

REAR DIFFERENTIAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

3-2

925250

C CLIP..................................................................................................

1

4

925449

O-RING, Ø3XØ30.2 .............................................................................

2

1-1-1

513426Y

BRAKE DISC, 180mm .........................................................................

1

1-1-10 W99710

WASHER .............................................................................................

1

N33701

NUT......................................................................................................

1

1-1-12 925617

DUST GUARD COVER........................................................................

1

1-1-2

S72005

SOCKET HEAD SCREW, M10 ............................................................

4

1-1-3

925792

RR FINAL DRIVE HOUSING ...............................................................

1

1-1-4

924964

REAR FINAL DRIVE SHAFT ...............................................................

1

1-1-5

925001

BEARING .............................................................................................

1

1-1-6

924968

O-RING ................................................................................................

1

1-1-7

R01802

C CLIP..................................................................................................

1

1-1-8

924969

OIL SEAL .............................................................................................

1

1-1-9

924965

LOCK SEAT .........................................................................................

1

1-2

926139A

REAR FINAL GEAR CASE SET ..........................................................

1

1-2-1

924261

BREATHER EXHAUST PIPE...............................................................

1

1-2-11

925355

BEARING, Ø28XØ68X18 ....................................................................

1

1-2-12 924255

SNAP RING .....................................................................................................

1

1-2-13 924254

SNAP RING .........................................................................................

1

1-2-14 S95003

STUD ...................................................................................................

4

1-2-15 N10001

NUT......................................................................................................

4

1-2-2

W99620

WASHER, TDC Ø16.2XØ22.5X2t........................................................

2

1-2-3 1-2-4

924339 924274

SCREW................................................................................................

OIL SEAL, Ø38XØ54X6.......................................................................

2 1

1-2-5

S21605

WASHER, Ø6.5XØ13.2X1.3t ...............................................................

1

1-2-6

W99621

FLANGE BOLT, M6x10 ........................................................................

1

1-2-7

924270

BEARING, Ø40XØ50X20 ....................................................................

1

1-2-8

924269

BEARING, Ø20XØ28X23 ....................................................................

1

1-1-11

Page P-3

Service PartsParts Manual 647971 Service Manual

REAR DIFFERENTIAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM 1-2-9

PART NO.

925450

DESCRIPTION

QTY.

GEAR (UMBRELLA) ............................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page P-4

CVT

Page R-1

Service PartsParts Manual 647971 Service Manual

CVT THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927061

FIXED DRIVE FACE ............................................................................

1

2

927082

MOVABLE DRIVE ASSEMBLY SHEAVE .............................................

1

2-1

924512

MOVABLE DRIVE FACE PLATE..........................................................

1

2-2

925343

MOVABLE DRIVE SHEAVE SPACER .................................................

1

2-3

492860A

COMPLETE MOVABLE DRIVE SHEAVE ROLLER (15G)(8 PIECE) ..

1

2-4

490687

SLIDING PAD.......................................................................................

4

2-5

924510

OIL SEAL .............................................................................................

2

3

924161A

V/S BELT..............................................................................................

1

4

924521

SPACER...............................................................................................

1

5

924162

OIL SEAL ........................................................................................................

1

6

924163

BEARING ........................................................................................................

1

7

924525

CLUTCH HOUSING ASSEMBLY....................................................................

1

8

N33805

NUT.................................................................................................................

1

9

927160

UNIDIRECTIONAL CLUTCH ..........................................................................

1

10

D9900072

CLUTCH ASSEMBLY...........................................................................

1

10-1

492184

WASHER ........................................................................................................

1

11

D9900018

DRIVEN PULLEY ASSEMBLY ........................................................................

1

12

924520

O-RING ...........................................................................................................

1

13

924523

NUT.................................................................................................................

2

14

925733

AIR DEFLECTOR ...........................................................................................

1

15

927047

AIR COWLING ................................................................................................

1

16

S24616

FLANGE BOLT, M6X20...................................................................................

2

17

W99616

GASKET...............................................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page R-2

MUFFLER ASSEMBLY

Page S-1

Service PartsParts Manual 647971 Service Manual

MUFFLER ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

926156

MUFFLER ASSEMBLY ........................................................................

1

1-1

927190

COMPLETE MUFFLER BODY ............................................................

1

1-10

925599

SCREW, MUFFLER COVERS.............................................................

16

1-11

925320

SPRING ...............................................................................................

2

1-1-1

923288

SPARK ARRESTER.............................................................................

2

1-12

925704

EXHAUST PIPE PROTECTOR............................................................

1

1-1-2

927189

SOCKET HEAD SCREW, m6X12 ........................................................

6

1-13

926158

BOLT ....................................................................................................

2

1-2

925612

EXHAUST PIPE ...................................................................................

1

1-3

925555

PLUMBAGO GASKET .........................................................................

2

1-4

925556

CLAMP.................................................................................................

1

1-5

925222

MUFFLER PROTECTOR.....................................................................

1

1-6

925567

EXHAUST PIPE PROTECTOR............................................................

1

1-7

925548

MUFFLER PROTECTOR.....................................................................

1

1-8

925298

EXHAUST PIPE PROTECTOR............................................................

1

1-9

W99506

WASHER ........................................................................................................

2

2

GA556WS04

SPRING WASHER, 8.2X3.2X2t ......................................................................

2

3

925198

EXHAUST PIPE GASKET ..............................................................................

1

4

N10801

FLANGE NUT, 8mm........................................................................................

2

5

S20814

FLANGE BOLT, M8X1.25X20 ..............................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page S-2

AIR CLEANER ASSEMBLY

Page T-1

Service PartsParts Manual 647971 Service Manual

AIR CLEANER ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

926111A

AIR CLEANER ASSEMBLY .................................................................

1

1-1

925003A

AIR CLEANER COVER SET ...............................................................

1

1-10

925121

TUBE....................................................................................................

1

1-11

R36401

CLIP .....................................................................................................

1

1-2

GA557SC12

PAN HEAD SCREW, M5X10 ...............................................................

1

1-3

923278

S CLIP..................................................................................................

4

1-4

R40101

HOSE CLAMP BATTEN.......................................................................

2

1-5

924733

TWO THROUGH-HOLE.......................................................................

2

1-6

926120

CLIP .....................................................................................................

1

1-7

R66802

CLIP .....................................................................................................

1

1-8

925281

HEAT INSULATION..............................................................................

1

1-9

925041

FILTER ............................................................................................................

1

2

924691A

AIR CLEANER BRACKET ...................................................................

1

2-1

924743

HEAT INSULATION.........................................................................................

1

3

W99605

WASHER ........................................................................................................

3

4

R40501

CLIP ................................................................................................................

1

5

R40201

CLIP ................................................................................................................

1

6

924692

TWO INTAKE DUCTS, LH ..............................................................................

1

7

S20603

FLANGE BOLT, M6X12...................................................................................

5

8

924684

SPECIAL NUT......................................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page T-2

RADIATOR AND COOLING FAN

Page U-1

Service PartsParts Manual 647971 Service Manual

RADIATOR AND COOLING FAN THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

926129A

RADIATOR ASSEMBLY .......................................................................

1

1-1

926129

COMPLETE RADIATOR ......................................................................

1

1-10

S20611

HEX HEAD BOLT, M6X20....................................................................

4

1-1-1

924798

RADIATOR CAP ASSEMBLY...............................................................

1

1-2

924670

RADIATOR PROTECTOR ...................................................................

1

1-3

924940

COOLING FAN ASSEMBLY.................................................................

1

1-4

925435

TAPING SCREW..................................................................................

1

1-5

GA555SC05

OUTLET BOLT, M6X1.0X16.................................................................

4

1-6

D9900054

COOLING FAN COVER.......................................................................

1

1-7

S21605

FLANGE BOLT, M6X10...................................................................................

4

2

924638

RADIATOR BRACKET ....................................................................................

1

3

924741

BRACKET .......................................................................................................

2

4

S20814

FLANGE BOLT, M8X1.25X20 .........................................................................

1

5

S21008

BOLT, M10X20 ................................................................................................

2

6

W99806

WASHER, 8.5X16X2.......................................................................................

1

7

402129

RUBBER WASHER ........................................................................................

4

8

924355

OUTLET HOSE...............................................................................................

1

9

924354

INLET HOSE...................................................................................................

1

10

R66701

CLIP ................................................................................................................

3

11

R66301

CLIP ................................................................................................................

1

12

924641

RESERVOIR ASSEMBLY ...............................................................................

1

13

924681

RECIRCULATION HOSE................................................................................

1

14

W99010

WASHER, Ø10.5XØ22X3.5t ...........................................................................

2

15

GA555SC05

OUTLET BOLT, M6X1.0X16 ...........................................................................

2

16

925175

HOSE ..............................................................................................................

1

17

924642

COMPLETE THERMOSTAT ...........................................................................

1

18

R40201

CLIP ................................................................................................................

5

19

GA510SR01

CLAMP L150...................................................................................................

2

20

925265

HOSE ...................................................................................................

1

21

925048

ENGINE OIL PIPE (L) ..........................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page U-2

RADIATOR AND COOLING FAN THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

21-1

927263

PROTECTION TUBE (L), 835mm ...................................................................

1

22

925049

ENGINE OIL PIPE (R) .........................................................................

1

22-1

927264

PROTECTION TUBE (R), 955mm...................................................................

1

23

925082

OIL RADIATOR PROTECTOR ........................................................................

1

24

924722

OIL RADIATOR ASSEMBLY............................................................................

1

25

924710

O-RING, Ø2.4XÕ12.3......................................................................................

4

26

S70609

SOCKET HEAD SCREW, M6X16 ...................................................................

4

27

S21605

FLANGE BOLT, M6X10 ...................................................................................

4

28

S20603

FLANGE BOLT, M6X12 ...................................................................................

4

29

S95602

STUD, M6X18 .................................................................................................

4

30

GA504WS04

SPRING WASHER ..........................................................................................

4

31

N10605

NUT .................................................................................................................

4

33

400535

CLAMP, L300...................................................................................................

2

34

925350

P CLIP .............................................................................................................

1

35

925085

BRACKET ............................................................................................

1

32

Page U-3

Service PartsParts Manual 647971 Service Manual

RADIATOR AND COOLING FAN

Notes:

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page U-4

WIRING HARNESS AND LOCK ASSEMBLY

Page V-1

Service PartsParts Manual 647971 Service Manual

WIRING HARNESS AND LOCK ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927973

WIRING HARNESS .............................................................................

1

1A

927976

WIRING HARNESS (for EPS).........................................................................

1

2

923437

REED ...................................................................................................

1

3

927763U

LOCK ASSEMBLY................................................................................

1

3-1

924448-S

LOCK ...................................................................................................

2

3-1-1

925711

FIXED FILM .........................................................................................

1

3-2

924424-S

IGNITION SWITCH LOCK SET ...........................................................

1

3-3

440744-S

SEAT LOCK SET ............................................................................................

1

4

S96601

SPECIAL SCREW...........................................................................................

2

5

926717

TILT SW ..........................................................................................................

1

6

S70607

SOCKET HEAD SCREW, M6X20...................................................................

2

7

923423

BLANK KEY, RH .............................................................................................

1

8

923424

BLANK KEY, LH ..............................................................................................

1

9

926713

FUSE WIRING HARNESS...................................................................

1

9-1

926708

MINI FUSE, 10A...................................................................................

6

9-2

926709

MINI FUSE, 15A...................................................................................

2

9-3

926710

MINI FUSE, 20A...................................................................................

2

9-4

927782

MINI RELAY ....................................................................................................

3

10

GA510SR01

CLAMP, L150 ..................................................................................................

4

11

GA510SR02

CLAMP, L200 ..................................................................................................

3

12

400535

CLAMP, L300 ..................................................................................................

6

13

926711

FUSE BOX BRACKET ....................................................................................

2

14

S79501

SOCKET HEAD SCREW, M5X16...................................................................

2

15

927905

COUPLER.......................................................................................................

5

16

514410

CLAMP............................................................................................................

2

17

925475

BRACKET .......................................................................................................

1

18

927735

FUSE WIRING HARNESS (GEP) (for EPS) ........................................

1

18-1

927761

FUSE, 40A (for EPS)............................................................................

1

18-2

927762

FUSE, 30A (for EPS) .............................................................................

2

19

N10601

FLANGE NUT, 6mm........................................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page V-2

WIRING HARNESS AND LOCK ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

20

S70609

SOCKET HEAD SCREW, M6X16 ...................................................................

2

21

GA510SR02

CLAMP, L200 .......................................................................................

2

Page V-3

Service PartsParts Manual 647971 Service Manual

WIRING HARNESS AND LOCK ASSEMBLY

Notes:

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page V-4

BATTERY - HORN - RELAY - RECTIFIER

Page W-1

Service PartsParts Manual 647971 Service Manual

BATTERY - HORN - RELAY - RECTIFIER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

552856

PULSE REGULATOR .....................................................................................

1

2

925873

POWER SOURCE ...............................................................................

2

2-1

925874

RUBBER CAP.................................................................................................

1

3

926743

GEAR SHIFT CONTROLLER .........................................................................

1

4

925816

CABLE (NEGATIVE) .......................................................................................

1

5

924464

CUSHION........................................................................................................

1

6

927801

STARTING TERMINAL CABLE ......................................................................

1

7

924423A

12V 18AH BATTERY.......................................................................................

1

9

926747

RECTIFIER (6 SCR) .......................................................................................

1

9A

927872

EPS RECTIFIER ASSEMBLY ..............................................................

1

10

929718

STARTING MOTOR RELAY.................................................................

1

10-1

552813

FUSE, 30A ......................................................................................................

1

11

S70609

SOCKET HEAD SCREW, M6X16...................................................................

2

927826

RECTIFIER INPUT TERMINAL ADAPTER..........................................

1

8

12 13 14

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page W-2

BOX HOLDER

Page X-1

Service PartsParts Manual 647971 Service Manual

BOX HOLDER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

GA5100004A

RELAY..................................................................................................

2

1-1

924453

RUBBER BUSHING.............................................................................

1

2

441066

RELAY (20A, NC).................................................................................

1

2-1

924453

RUBBER BUSHING.............................................................................

1

4

925802

TOOL BAG111

5

924934

BRACKET ............................................................................................

1

6

S24603

FLANGE BOLT, M6X16........................................................................

1

7

926719

DIAGNOSTIC TOOL ............................................................................

1

3

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page X-2

ENGINE BUFFER

Page Y-1

Service PartsParts Manual 647971 Service Manual

ENGINE BUFFER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

N10804

NUT, M8X1.25.................................................................................................

6

2

S20009

HEX HEAD BOLT, M10X1.25X48 ...................................................................

1

3

S20011

BOLT, M10X1.25X205.....................................................................................

1

4

925255

CAKE BUSHING .............................................................................................

3

5

925263

BRACKET (L)..................................................................................................

1

6

925283

BRACKET .......................................................................................................

1

7

GA551NT01

SELF LOCKING NUT, M10X1.25....................................................................

3

8

925235

BUSHING........................................................................................................

1

9

W99011

GASKET, 2.5t ..................................................................................................

1

10

925245

BRACKET .......................................................................................................

1

11

925256

CAKE ANCHOR ..............................................................................................

1

12

S20044

BOLT, M10X1.25X310.....................................................................................

1

13

S20020

FLANGE BOLT, M10X186.5............................................................................

1

14

925264

BRACKET (R) .................................................................................................

1

15

925696

BUSHING.............................................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page Y-2

SERVO MOTOR

Page Z-1

Service PartsParts Manual 647971 Service Manual

SERVO MOTOR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

925167

SERVO MOTOR ASSEMBLY ..............................................................

1

2

926720

LOCK CONTROLLER..........................................................................

1

3

925866

LOCK SWITCH ....................................................................................

1

4

513077

TRANSFER SHIFT CABLE..................................................................

1

5

513078

TRANSFER SHIFT CABLE (LOCK) ....................................................

1

6

W99433

WASHER..............................................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page Z-2

EPS ASSEMBLY

Page AA-1

Service PartsParts Manual 647971 Service Manual

EPS ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927823

EPS GEAR BOX ..................................................................................

1

1-1

925996

O-RING ................................................................................................

1

1-2

925993

SPACER...............................................................................................

1

1-3

925994

COUPLER.......................................................................................................

1

2

925908

CONTROLLER.....................................................................................

1

2-1

927856

SIGNAL WIRING..................................................................................

1

2-2

927857

POWER WIRING ............................................................................................

1

3

925911

MOTOR...........................................................................................................

1

4

S20802

FLANGE BOLT, M8X30...................................................................................

3

5

S70811

BOLT, M8X20 ..................................................................................................

3

6

S20817

FLANGE BOLT, M8X16........................................................................

4

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AA-2

SPEEDOMETER

Page AB-1

Service PartsParts Manual 647971 Service Manual

SPEEDOMETER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927956A

SPEEDOMETER ASSEMBLY..............................................................

1

1-1

926741

LOW-VOLTAGE CONTROLLER..........................................................

1

1A

927958A

SPEEDOMETER ASSEMBLY (for EPS) .........................................................

1

2

GA510SR02

CLAMP, L200 ..................................................................................................

4

3

512658

SPEED SENSOR............................................................................................

1

4

GA552WS05

WASHER, 5.2X10X0.8....................................................................................

2

5

W10501

SPRING WASHER..........................................................................................

2

6

GA552NT05

FLANGE NUT, M5...........................................................................................

2

7

S57501

OVAL HEAD FLANGE SCREW, M5X16 .........................................................

4

8

GA555SC05

OUTLET BOLT, M6X1.0X16 ...........................................................................

6

9

513102

SPEEDOMETER COVER...............................................................................

1

10

512662

UPPER BRACKET ASSEMBLY ......................................................................

1

11

512636

LOWER BRACKET ASSEMBLY ..........................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AB-2

HEAD LAMP

Page AC-1

Service PartsParts Manual 647971 Service Manual

HEAD LAMP THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

927979

DIPPED-BEAM HEAD LAMP ASSEMBLY, LH.....................................

1

1-1

910564

FIXED SEAT, LH ..................................................................................

1

1-2

929723

BULB, 60W ..........................................................................................

1

1-3

910566

ADJUST SEAT .....................................................................................

1

1-4

S47602

ROUND HEAD SCREW, M5X16

1-5

927981

DIPPED-BEAM HEAD LAMP...............................................................

1

2

927980

DIPPED-BEAM HEAD LAMP ASSEMBLY, RH ....................................

1

2-1

910565

FIXED SEAT, RH.............................................................................................

1

3

927977

COMPLETE MAIN-BEAM HEAD LAMP ASSEMBLY, LH ....................

1

3-1

929722

FIXED SEAT.........................................................................................

1

3-2

929723

BULB, 60W ..........................................................................................

1

3-3

927983

ADJUST SEAT .....................................................................................

1

3-4

S47602

ROUND HEAD SCREW, M5X16 .........................................................

2

3-5

927982

MAIN-BEAM HEAD LAMP ..............................................................................

1

4

927978

COMPLETE MAIN-BEAM HEAD LAMP ASSEMBLY, RH....................

1

4-1

929703

FIXED SEAT ...................................................................................................

1

5

S70504

SCREW...........................................................................................................

8

6

S50501

OVAL HEAD SCREW, M5X12 .............................................................

4

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AC-2

HEAD LAMP

Page AC-3

Service PartsParts Manual 647971 Service Manual

HEAD LAMP THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

511723

HEAD LAMP ASSEMBLY #3 (OPTION) ..............................................

1

1-1

GA5520019

BULB, 12V, 35/35W .............................................................................

1

1-2

513921

MOUNTING STAY................................................................................

1

1-3

514076

COMPLETE SOCKET..........................................................................

1

1-4

400517

BULB, 12V, 5W ...............................................................................................

1

2

513103

FRONT HANDLEBAR COVER ............................................................

1

2A

513103V

FRONT HANDLEBAR COVER (CAMO) .........................................................

1

3

513107

REAR HANDLEBAR COVER .........................................................................

1

4

512666

BRACKET .......................................................................................................

1

5

GA555SC02

PAN HEAD SCREW........................................................................................

1

6

511722

BRACKET .......................................................................................................

1

7

GA552SC11

TAPPING SCREW, M4X16 .............................................................................

6

8

GA552WS05

WASHER, 5.2X10X0.8....................................................................................

1

9

W10501

SPRING WASHER..........................................................................................

1

10

S13502

CROSS RECESSED PAN HEAD SCREW, M5X10........................................

1

11

S57501

OVAL HEAD FLANGE SCREW, M5X16 .........................................................

2

12

GA555SC05

OUTLET BOLT, M6X1.0X16.................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AC-4

REAR LAMP ASSEMBLY

Page AD-1

Service PartsParts Manual 647971 Service Manual

REAR LAMP ASSEMBLY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

511810Y

REAR LAMP ASSEMBLY.....................................................................

2

1-1

GF5180002

12V BULB, P21/5W..............................................................................

2

1-2

514035Y

REAR LAMP WIRING SET ..................................................................

2

1-3

514036Y

COMPLETE REAR LAMP...............................................................................

2

2

S50506

TAPPING SCREW ..........................................................................................

6

3

GA510SR01

CLAMP, L150 .......................................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AD-2

FRAME

Page AE-1

Service PartsParts Manual 647971 Service Manual

FRAME THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

514927

MAIN FRAME.......................................................................................

1

1A

514930

MAIN FRAME (for EPS)..................................................................................

1

2

511925A

FRONT PROTECTOR (PLASTIC) (OPTION).................................................

1

3

511926

REAR PROTECTOR (PLASTIC) (OPTION) ...................................................

1

4

514963

FRONT INTERNAL FENDER, LH...................................................................

1

5

511994

FRONT INTERNAL FENDER, RH ..................................................................

1

6

511986

PROTECTOR COVER (OPTION)...................................................................

1

7

511990

BRACKET .......................................................................................................

1

8

516048

BRACKET ............................................................................................

1

8A

516046

BRACKET (for EPS) .......................................................................................

1

9

511950

FRONT SEAT STEADY ..................................................................................

1

10

511953

STEERING LOCK PIN ....................................................................................

1

11

511946

STEERING LOCK SPRING ............................................................................

1

12

S20004

FLANGE BOLT, M10X30.................................................................................

1

13

GA501NT01

FLANGE NUT, M10.........................................................................................

1

14

GA555SC05

OUTLET BOLT, M6X1.0X16 ...........................................................................

2

15

S25602

BOLT, M6X16 ..................................................................................................

13

16

GA554BS02

SPACER..........................................................................................................

2

17

S07601

FLANGE BOLT, M6X16 (DARK GREEN) .......................................................

10

18

S21008

BOLT, M10X20 ................................................................................................

4

19

GA556WS06

SPRING WASHER, 10.2X3.7X2.5t .................................................................

6

20

511992

BRACKET .......................................................................................................

1

21

S20017

FLANGE BOLT, M10X50.................................................................................

2

22

GA555SC05

OUTLET BOLT, M6X1.0X16 ...........................................................................

1

23

511995

ENHANCING PLATE ...........................................................................

1

26

515897

EPS BRACKET (for EPS) ...............................................................................

1

27

S20814

FLANGE BOLT, M8X1.25X20 (for EPS) .........................................................

4

28

GA556WS04

SPRING WASHER, 8.2X3.2X2t (for EPS) ......................................................

4

29

516049

BRACKET (for EPS) .......................................................................................

1

30

S20817

FLANGE BOLT, M8X16 (for EPS)........................................................

1

24 25

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AE-2

REAR SUSPENSION

Page AF-1

Service PartsParts Manual 647971 Service Manual

REAR SUSPENSION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

511643

UPPER ARM SET, LH REAR (RH FOR CARGO BED MODEL ONLY)

1

2

511644

UPPER ARM SET, RH REAR (LH FOR CARGO BED MODEL ONLY)

1

3

511657

LOWER ARM SET, LH REAR ..............................................................

1

4

511658

LOWER ARM SET, RH REAR .............................................................

1

5

511640

TORSION BAR ....................................................................................

1

6

511642

TORSION BAR FIX BRACKET ............................................................

2

7

511655

UNIVERSAL ROD RR..........................................................................

2

8

S20017

FLANGE BOLT, M10X60......................................................................

2

9

516371

COVER PROTECTOR, LH ..................................................................

1

10

516372

COVER PROTECTOR, RH..................................................................

2

11

511675

SHOCK ABSORBER, REAR................................................................

2

12

511641

RUBBER ..............................................................................................

2

13

S20009

HEX HEAD BOLT, M10X1.25X48 ........................................................

4

14

GA551NT01

SELF LOCK NUT, M10-1.25 ................................................................

18

15

GA556WS04

SPRING WASHER, 8.2X3.2X2t ...........................................................

4

16

S21809

BOLT, M8X1.25X18..............................................................................

4

17

S20017

FLANGE BOLT, M10X60......................................................................

6

18

W99005

WASHER, 2t.........................................................................................

2

19

S20038

FLANGE BOLT, M10X1.25X123 ..........................................................

2

20

S20039

FLANGE BOLT, M10X1.25X100 ..........................................................

2

21

S07601

FLANGE BOLT, M6X16 (DARK GREEN) ............................................

6

22

S21013

FLANGE BOLT, M10X65......................................................................

2

23

511697A

COMPLETE ALLOY A-ARM PROTECTION, LH .................................

1

23-1 S20603

FLANGE BOLT, M6X12........................................................................

4

23-2 GA555WS02

WASHER..............................................................................................

4

24

COMPLETE ALLOY A-ARM PROTECTION, RH .................................

1

24-1 S20603

FLANGE BOLT, M6X12........................................................................

4

24-2 GA555WS02

WASHER..............................................................................................

4

511698A

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AF-2

BUMPER BRACKET

Page AG-1

Service PartsParts Manual 647971 Service Manual

BUMPER BRACKET THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

514937

VENTILATION BOARD BRACKET ......................................................

1

2

512014

FRONT BUMPER BRACKET...............................................................

1

3

512055

FOOT BOARD BRACKET, LH .............................................................

1

4

512056

FOOT BOARD BRACKET, RH.............................................................

1

5

516080

REAR HAND HOLD ........................................................................................

1

6

S20814

FLANGE BOLT, M8X1.25X20 .........................................................................

6

7

S21809

BOLT, M8X1.25X18.........................................................................................

2

8

GA556WS04

SPRING WASHER, 8.2X3.2X2t ......................................................................

2

9

512024

BRACKET .......................................................................................................

1

10

GA556WS06

SPRING WASHER, 10.2X3.7X2.5t .................................................................

2

11

S21008

BOLT, M10X20 ................................................................................................

4

12

512017

REAR BUMPER BRACKET, LH......................................................................

1

13

512018

REAR BUMPER BRACKET, RH .....................................................................

1

14

S20807

OUTLET BOLT, M8X1.25X12 .........................................................................

2

15

S20004

FLANGE BOLT, M10X30.................................................................................

4

16

512042

SUPPORTING ROD .......................................................................................

2

17

N02601

NUT, M6 ..........................................................................................................

2

18

N10604

SELF LOCK NUT, M6 .....................................................................................

2

19

516047

BRACKET (for EPS) .......................................................................................

1

20

S20817

FLANGE BOLT, M8X16 (for EPS)........................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AG-2

FUEL TANK AND FUEL SYSTEM

Page AH-1

Service PartsParts Manual 647971 Service Manual

FUEL TANK AND FUEL SYSTEM THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

516167

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

1

2

927966

FUEL LEVEL GAUGE ASSEMBLY .................................................................

1

3

516109

FRONT SEAT BRACKET................................................................................

1

4

512120

CUSHION........................................................................................................

2

5

518103

SPACER..........................................................................................................

4

6

516135

FUEL TANK BRACKET ...................................................................................

1

7

512125

FUEL TANK GASKET .....................................................................................

1

8

514410

CLAMP............................................................................................................

2

9

S45502

OVAL HEAD SCREW......................................................................................

4

10

GA556SC01

FLANGE BOLT,M6X1X12 ...............................................................................

4

11

S20802

FLANGE BOLT, M8X30...................................................................................

4

12

S79602

SOCKET HEAD SCREW, M6X16...................................................................

6

13

W99005

WASHER, 2t ...................................................................................................

2

15

516172

VENT HOSE ...................................................................................................

1

16

516173

VENT HOSE ...................................................................................................

1

17

516170

VENT HOSE ...................................................................................................

1

18

516175

VENT HOSE ...................................................................................................

1

19

512135

THREE WAY TUBE UNIT ...............................................................................

1

20

516111

VALVE .............................................................................................................

1

21

516114

RUBBER BUSHING........................................................................................

1

22

S21605

FLANGE BOLT, M6X10...................................................................................

1

23

R40002

CLIP ................................................................................................................

4

24

R40201

CLIP ................................................................................................................

2

25

R40301

CLIP ................................................................................................................

2

26

516137

ISOLATOR ......................................................................................................

1

27

516160

OIL SEAL ........................................................................................................

1

28

414146

SPRING ..........................................................................................................

1

29

516159

FUEL FILLER NECK.......................................................................................

1

30

516192

FUEL CAP.......................................................................................................

1

31

GA510SR01

CLAMP, L150 .......................................................................................

1

14

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AH-2

FUEL TANK AND FUEL SYSTEM

Page AH-3

Service PartsParts Manual 647971 Service Manual

FUEL TANK AND FUEL SYSTEM THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

926026M

FUEL PUMP ASSEMBLY.....................................................................

1

2

926119

RUBBER SLEEVE ..........................................................................................

2

3

926706

FUEL FILTER ..................................................................................................

2

4

926025M

FUEL PRESSURE REGULATOR ASSEMBLY ...............................................

1

5

926118

CLIP ................................................................................................................

2

6

S20611

HEX HEAD BOLT, M6X20...............................................................................

2

7

GA555SC05

OUTLET BOLT, M6X1.0X16 ...........................................................................

2

8

926121

CLAMP............................................................................................................

1

R40601

CLIP ................................................................................................................

1

R40301

CLIP ................................................................................................................

7

14

R60207

CLIP ................................................................................................................

2

15

516144

HOSE ..............................................................................................................

1

16

R60206

CLIP ................................................................................................................

1

17

516145

HOSE ..............................................................................................................

1

18

R60204

CLIP ................................................................................................................

1\3

19

516146

HOSE ..............................................................................................................

1

20

R60203

CLIP ................................................................................................................

1

22

512137

SPRING, 250L ................................................................................................

1

23

S21605

FLANGE BOLT, M6X10...................................................................................

2

24

414146

SPRING ..........................................................................................................

2

25

514476

CLAMP............................................................................................................

2

26

516161

HOSE (A) ........................................................................................................

1

27

516162

HOSE (B) ........................................................................................................

1

28

516165

VENT HOSE ...................................................................................................

1

29

516163

HOSE (C) ........................................................................................................

2

30

516164

HOSE (D) ........................................................................................................

1

31

512135

THREE WAY TUBE UNIT ...............................................................................

2

9 10 11 12 13

21

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AH-4

FUEL TANK AND FUEL SYSTEM THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

32

GA510SR01

CLAMP, L150...................................................................................................

1

33

R40201

CLIP.................................................................................................................

2

34

R40002

CLIP .....................................................................................................

1

Page AH-5

Service PartsParts Manual 647971 Service Manual

QTY.

FUEL TANK AND FUEL SYSTEM

Notes:

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AH-6

SHIFT LEVER

Page AJ-1

Service PartsParts Manual 647971 Service Manual

SHIFT LEVER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

514224

SHIFT LEVER KNOB......................................................................................

1

2

514202

SHIFT LEVER PULL ROD ASSEMBLY ..........................................................

1

3

514217

LEVER ASSEMBLY..............................................................................

1

3-1

514211

SPRING ..........................................................................................................

1

4

514212

SHIFT LEVER CONNECTING ROD (UPPER) ...............................................

1

5

514221Y

SHIFT LEVER CONNECTING ROD SPINDLE ..............................................

1

6

514213

SHIFT LEVER CONNECTING ROD (LOWER) ..............................................

1

7

514219

SPRING ..........................................................................................................

1

8

S07506

SCREW WITH WASHER, M5X8.....................................................................

1

9

S21809

BOLT, M8X1.25X18.........................................................................................

6

10

N01802

NUT.................................................................................................................

4

11

W40801

LOCK WASHER...................................................................................

4

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AJ-2

BRAKE PEDAL

Page AK-1

Service PartsParts Manual 647971 Service Manual

BRAKE PEDAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

514118

BRAKE PEDAL ...............................................................................................

1

2

514103

O-RING ...........................................................................................................

2

3

W99824

WASHER, 8.5 .................................................................................................

1

4

S20817

FLANGE BOLT, M8X16...................................................................................

1

5

W99702

WASHER ........................................................................................................

1

6

514136

SPRING ..........................................................................................................

1

7

514115

MASTER CYLINDER ASSEMBLY ..................................................................

1

8

GA556WS04

SPRING WASHER, 8.2X3.CX2t .....................................................................

4

9

S20804

FLANGE BOLT................................................................................................

2

10

S20814

FLANGE BOLT, M8X1.25X20 .........................................................................

2

11

514121

MASTER CYLINDER BRACKET ....................................................................

1

13

P31701

PIN, .................................................................................................................

1

14

P10102

PIN, 1.5X20.....................................................................................................

1

16

S96604

GREASE NIPPLE ...........................................................................................

1

17

S20617

FLANGE BOLT, M6X25...................................................................................

1

18

W99810

WASHER ........................................................................................................

1

19

516307

COVER PROTECTOR, RH.............................................................................

1

20

516063

BRACKET, UPPER .........................................................................................

1

21

516064

BRACKET, LOWER ........................................................................................

1

22

S07601

FLANGE BOLT, M6X16 (DARK GREEN) ............................................

2

12

15

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AK-2

FRONT AND REAR BRAKES

*6328 &6%/)7

Page AL-1

Service PartsParts Manual 647971 Service Manual

FRONT AND REAR BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

511213

FRONT BRAKE MANIFOLD ...........................................................................

1

2

514330YA

BRAKE HOSE ASSEMBLY..................................................................

1

2-1 GA559WS04

WASHER, 10.2X15X1.2t......................................................................

4

2-2 S21001

OIL BOLT, M10X1.25X22 .....................................................................

2

3

BRAKE HOSE ASSEMBLY..................................................................

1

3-1 GA559WS04

WASHER, 10.2X15X1.2t......................................................................

4

3-2 S21001

OIL BOLT, M10X1.25X22 .....................................................................

2

4

516510

BRAKE HOSE ASSEMBLY..................................................................

1

4-1 GA559WS04

WASHER, 10.2X15X1.2t......................................................................

4

4-2 S21001

OIL BOLT, M10X1.25X22 .....................................................................

2

5

513522

BRACKET ............................................................................................

1

6

GA557SC1

HEX HEAD BOLT, M6X10....................................................................

2

7

S24610

FLANGE BOLT, M6X40........................................................................

2

513538YA

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AL-2

FRONT AND REAR BRAKES

6)%6 &6%/)7

Page AL-3

Service PartsParts Manual 647971 Service Manual

FRONT AND REAR BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

DESCRIPTION

QTY.

516508

REAR BRAKE MANIFOLD .............................................................................

1

3

511012

BRAKE HOSE ASSEMBLY..................................................................

1

3-1

GA559WS04

WASHER, 10.2X15X1.2t......................................................................

4

3-2

S21001

OIL BOLT, M10X1.25X22 .....................................................................

2

4

511011

BRAKE HOSE ASSEMBLY ..................................................................

1

4-1

GA559WS04

WASHER, 10.2X15X1.2t......................................................................

4

4-2

S21001

OIL BOLT, M10X1.25X22 .....................................................................

2

5

514341YA

BRAKE HOSE ASSEMBLY..................................................................

1

5-1

GA559WS04

WASHER, 10.2X15X1.2t......................................................................

4

5-2

S21001

OIL BOLT, M10X1.25X22 .....................................................................

2

6

W10601

SPRING WASHER, 6.2X11.5X1t ....................................................................

2

7

S24610

FLANGE BOLT, M6X40...................................................................................

2

8

514365

OIL BRAKE SWITCH, 450L .................................................................

1

1

PART NO.

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AL-4

FRONT SUSPENSION

Page AM-1

Service PartsParts Manual 647971 Service Manual

FRONT SUSPENSION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

511107

UPPER FRONT ARM SET, LH ............................................................

1

1A

511105

UPPER FRONT ARM SET, LH (for EPS)........................................................

1

2

511108

UPPER FRONT ARM SET, RH ............................................................

1

2A

511106

UPPER FRONT ARM SET, RH (for EPS) .......................................................

1

3

511128

LOWER FRONT ARM SET, LH............................................................

1

3A

511130

LOWER FRONT ARM SET, LH (for EPS).......................................................

1

4

511129

LOWER FRONT ARM SET, RH ...........................................................

1

4A

511131

LOWER FRONT ARM SET, RH (for EPS) ......................................................

1

5

516306

COVER PROTECTOR, LH .............................................................................

1

6

516307

COVER PROTECTOR, RH.............................................................................

1

7

513329

CLAMP, LH......................................................................................................

2

8

513330

CLAMP, RH .....................................................................................................

2

9

516346

FRONT SHOCK ABSORBER .........................................................................

2

10

S20009

HEX HEAD BOLT, M10X1.25X48 ...................................................................

4

11

S20017

FLANGE BOLT, M10X60.................................................................................

8

12

S21605

FLANGE BOLT, M6X10...................................................................................

4

13

S07601

FLANGE BOLT, M6X16 (DARK GREEN) .......................................................

6

14

GA551NT01

SELF LOCK NUT, M10X1.25 ..........................................................................

10

15

511951

STEEL PROTECTOR .....................................................................................

1

16

513370A

COMPLETE ORNAMENTAL COVER, LH ...........................................

1

16-1 513363

ANCHOR PLATE .................................................................................

1

16-2 S20603

FLANGE BOLT, M6X12........................................................................

3

16-3 GA555WS02

WASHER ........................................................................................................

3

COMPLETE ORNAMENTAL COVER, RH...........................................

1

17-1 513363

ANCHOR PLATE .................................................................................

1

17-2 S20603

FLANGE BOLT, M6X12........................................................................

3

17-3 GA555WS02

WASHER..............................................................................................

3

17

513371A

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AM-2

STEERING KNUCKLE

Page AN-1

Service PartsParts Manual 647971 Service Manual

STEERING KNUCKLE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

516388A

STEERING KNUCKLE ASSEMBLY, LH...............................................

1

1-1

516388

STEERING KNUCKLE, LH ..................................................................

1

1-2

513325

OUTER OIL SEAL................................................................................

1

1-3

513350

BEARING .............................................................................................

2

1-4

513324

SPACER...............................................................................................

1

1-5

513367

INNER OIL SEAL ............................................................................................

1

2

516389A

STEERING KNUCKLE ASSEMBLY, RH ..............................................

1

2-1

516389

STEERING KNUCKLE, RH..................................................................

1

2-2

513325

OUTER OIL SEAL................................................................................

1

2-3

513350

BEARING .............................................................................................

2

2-4

513324

SPACER...............................................................................................

1

2-5

513367

INNER OIL SEAL ............................................................................................

1

3

512959

FRONT WHEEL HUB......................................................................................

2

4

513420Y

BRAKE DISC, 200mm ....................................................................................

2

5

S72005

SOCKET HEAD SCREW, M10 .......................................................................

8

6

GA555SC02

PAN HEAD SCREW........................................................................................

6

7

512944

PROTECTIVE COVER ...................................................................................

2

8

GA556WS04

SPRING WASHER, 8.2X3.2X2t ......................................................................

4

9

N13202

NUT, M12X1.25...............................................................................................

4

10

W99229

WASHER, 2t ...................................................................................................

4

11

GA551PN04

COTTER PIN ..................................................................................................

4

12

S21809

BOLT, M8X1.25X18.........................................................................................

4

13

513564

FRONT CALIPER ASSEMBLY, LH ......................................................

1

13-1 515402

PAD ......................................................................................................

1

13-2 515172

PIN ..................................................................................................................

2

513565

FRONT CALIPER ASSEMBLY, RH......................................................

1

14-1 515402

PAD ......................................................................................................

1

14-2 515172

PIN .......................................................................................................

2

14

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AN-2

FRONT AND REAR WHEELS

*6328 ;,))0

Page AP-1

Service PartsParts Manual 647971 Service Manual

FRONT AND REAR WHEELS THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

512920MBY

COMPLETE RIM, 12" MATTE BLACK STEEL.....................................

2

1A

512954MBY

COMPLETE RIM, 14" MATTE BLACK STEEL.....................................

2

1B

512953MBY

COMPLETE RIM, 14" MATTE BLACK ALUMINUM.............................

2

2

512942Y

TIRE, AT 25X8-12 (INNOVA) ...............................................................

2

2A

512979Y

TIRE, AT 26X8R-12..............................................................................

2

3

512906

VALVE STEM ..................................................................................................

2

4

N05003

NUT.................................................................................................................

8

5

W99830

WASHER ........................................................................................................

2

6

N13801

NUT.................................................................................................................

2

7

515172

RUBBER CAP.................................................................................................

2

8

P10204

PIN .......................................................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AP-2

FRONT AND REAR WHEELS

6)%6 ;,))0

Page AP-3

Service PartsParts Manual 647971 Service Manual

FRONT AND REAR WHEELS THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

513435MBY

COMPLETE RIM, 12" MATTE BLACK STEEL.....................................

2

1A

513437MBY

COMPLETE RIM, 14" MATTE BLACK STEEL.....................................

2

1B

513436MBY

COMPLETE RIM, 14" MATTE BLACK ALUMINUM.............................

2

2

513421Y

TIRE, AT 25X10-12 (INNOVA) .............................................................

2

2A

512980Y

TIRE, AT 26X10R-12............................................................................

2

3

513429

REAR WHEEL HUB .............................................................................

2

4

512906

VALVE STEM ..................................................................................................

2

5

N05003

NUT.................................................................................................................

8

6

W99830

WASHER ........................................................................................................

2

7

N13801

NUT.................................................................................................................

2

8

512996

RUBBER CAP.................................................................................................

2

9

P10204

PIN .......................................................................................................

2

10

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AP-4

STEERING SHAFT

Page AR-1

Service PartsParts Manual 647971 Service Manual

STEERING SHAFT THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

512732

STEERING SHAFT .........................................................................................

1

2

S21814

BOLT, M8X80 ..................................................................................................

2

3

512724

STEERING SHAFT BRACKET .......................................................................

2

4

512723

SPACER..........................................................................................................

2

5

512725

STEERING SHAFT SLEEVE BUSHING..............................................

1

6

512745

STEERING TIE ROD ASSEMBLY .......................................................

2

6-1

515292

LINKAGE ROD.....................................................................................

1

6-2

516040

BALL JOINT (1)....................................................................................

1

6-3

516039

BALL JOINT (2)...............................................................................................

1

7

N13001

NUT, M10X1.25...............................................................................................

4

8

GA551PN04

COTTER PIN ..................................................................................................

4

9

W99220

WASHER ........................................................................................................

4

10

512726

STEERING SHAFT DUST SEAL ....................................................................

1

11

512728

BUSHING........................................................................................................

1

12

512722

O-RING ...........................................................................................................

1

13

512727

LOWER STEERING DUST SEAL...................................................................

1

14

W99409

WASHER, Ø14.5XØ26X2t ..............................................................................

1

15

N25401

NUT, M14 .............................................................................................

1

16

P10301

PIN .......................................................................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AR-2

STEERING SHAFT

78))6-2+ 7,%*8 JSV )47

Page AR-3

Service PartsParts Manual 647971 Service Manual

STEERING SHAFT THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

512739

STEERING SHAFT (for EPS) .........................................................................

1

2

512725

STEERING SHAFT SLEEVE BUSHING.........................................................

1

3

512724

STEERING SHAFT BRACKET .......................................................................

2

4

512754

SPACER..........................................................................................................

2

5

S21814

BOLT, M8X80 ..................................................................................................

2

6

S20824

BOLT, M8X25 ..................................................................................................

1

7

R65602

CLAMP............................................................................................................

1

8

512753

DUST COVER.................................................................................................

1

9

400535

CLAMP, L300 ..................................................................................................

1

10

R00209

SNAP RING, C TYPE .....................................................................................

1

11

N50501

SLOTTED NUT ...............................................................................................

1

12

512746

DUST CAP ......................................................................................................

1

13

W99225

WASHER, 4t ...................................................................................................

1

14

R01902

C CLIP.............................................................................................................

1

15

513350

BEARING ........................................................................................................

2

16

512747

BEARING BASE .............................................................................................

1

17

512750

DUST SEAL ....................................................................................................

1

18

512741

LOWER STEERING ARM PLATE...................................................................

1

19

512745

STEERING TIE ROD ASSEMBLY .......................................................

2

19-1 515292

LINKAGE ROD.....................................................................................

1

19-2 516040

BALL JOINT (1)....................................................................................

1

19-3 516039

BALL JOINT (2)....................................................................................

1

20

N13001

NUT, M10X1.25...............................................................................................

4

21

W99220

WASHER ........................................................................................................

4

22

GA551PN04

COTTER PIN ..................................................................................................

4

23

S21809

BOLT, MIX1.25X18...............................................................................

3

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AR-4

HANDLEBAR

Page AS-1

Service PartsParts Manual 647971 Service Manual

HANDLEBAR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

513081

HANDLEBAR ASSEMBLY ..............................................................................

1

2

S20809

FLANGE BOLT, M8X55...................................................................................

4

3

513030

UPPER HANDLEBAR BRACKET...................................................................

2

4

513031

LOWER HANDLEBAR BRACKET ..................................................................

2

5

401827

GRIP ...............................................................................................................

2

6

401801

COLLAR..........................................................................................................

2

7

513044

GRIP END.......................................................................................................

2

8

S70611

SOCKET HEAD SCREW, M6X50...................................................................

2

9

513083

THROTTLE CABLE ........................................................................................

1

10

410151A

REAR VIEW MIRROR SET (OPTION) ................................................

1

10-1 410152A

REAR VIEW MIRROR, LH (OPTION)..................................................

1

10-2 410153A

REAR VIEW MIRROR, RH (OPTION) ............................................................

1

11 12

GA510SR01

CLAMP, L150 ..................................................................................................

4

13

513109

HAND GUARD, LH (OPTION) ........................................................................

1

14

513113

HAND GUARD BRACKET, LH (OPTION).......................................................

1

15

513049

SPACER, LH (OPTION)..................................................................................

1

16

513110

HAND GUARD, RH (OPTION)........................................................................

1

17

513117

HAND GUARD BRACKET, RH (OPTION) ......................................................

1

18

513048

SPACER, RH (OPTION) .................................................................................

1

19

S50501

OVAL HEAD SCREW, M5X12 (OPTION) ............................................

4

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AS-2

MASTER CYLINDER

Page AT-1

Service PartsParts Manual 647971 Service Manual

MASTER CYLINDER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

DESCRIPTION

QTY.

511013

MASTER CYLINDER ASSEMBLY, LH .................................................

1

1-1 511014

LEVER .................................................................................................

1

2

927757

SWITCH ASSEMBLY, LH ................................................................................

1

3

513220

OVERRIDE SWITCH ...........................................................................

1

1

PART NO.

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AT-2

REAR AXLE

Page AU-1

Service PartsParts Manual 647971 Service Manual

REAR AXLE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

512851A

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

2

1-1

512851

REAR AXLE HOUSING .......................................................................

1

1-2

925001

BEARING .............................................................................................

2

1-3

512861

SPACER...............................................................................................

1

1-4

R01601

C CLIP..................................................................................................

1

1-5

512860

OIL SEAL, INSIDE ...............................................................................

1

1-6

512713

GREASE CAP, 15.5 .............................................................................

4

1-7

512862

OIL SEAL, OUTSIDE ......................................................................................

1

2

514374

REAR CALIPER...................................................................................

1

2-1

514089

PAD .................................................................................................................

1

3

W99005

WASHER, 2t ...................................................................................................

2

4

GA556WS06

SPRING WASHER, 10.2X3.7X2.5t .................................................................

2

5

S20004

FLANGE BOLT, M10X30......................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AU-2

FRONT BUMPER

Page AV-1

Service PartsParts Manual 647971 Service Manual

FRONT BUMPER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

514500E

FRONT BUMPER ...........................................................................................

1

2

512444

FRONT AIR INLET GRILL...............................................................................

1

3

514501

FRONT SHOCK MOUNT, LH..........................................................................

1

4

514502

FRONT SHOCK MOUNT, RH .........................................................................

1

5

514521

FRONT LOWER LEG SHIELD (STEEL).........................................................

1

6

W99219

WASHER ........................................................................................................

4

7

S21008

BOLT, M10X20 ................................................................................................

4

8

S25602

BOLT, M6X16 ..................................................................................................

8

9

S50501

OVAL HEAD SCREW, M5X12 ........................................................................

4

10

S57501

OVAL FLANGE HEAD SCREW, M5X16 .........................................................

4

11

514510

FRONT SIDE REFLECTOR ASSEMBLY........................................................

2

12

514508

REFLECTOR BRACKET, LH ..........................................................................

1

13

514509

REFLECTOR BRACKET, RH...............................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AV-2

BODY

*6328 &3(=

Page AW-1

Service PartsParts Manual 647971 Service Manual

BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

512465

FRONT BODY COVER ........................................................................

1

1A

512465V

FRONT BODY COVER (CAMO OPTION) ...........................................

1

2

512465V

FRONT FENDER SIDE RAIL, LH ...................................................................

1

3

512462

FRONT FENDER SIDE RAIL, RH ..................................................................

1

4

512421

GLOVE COMPARTMENT, LH..............................................................

1

4A

512421V

GLOVE COMPARTMENT, LH (CAMO OPTION)............................................

1

5

512422

GLOVE COMPARTMENT, RH .............................................................

1

5A

512422V

GLOVE, COMPARTMENT, RH (CAMO OPTION) ..........................................

1

6

512425

CARRIER COVER ..........................................................................................

4

7

512424

RESERVOIR COVER ..........................................................................

1

7A

512424V

RESERVOIR COVER (CAMO OPTION) ........................................................

1

8

512484A

HEADLAMP FENDER, LH ...................................................................

1

8-1

514649

ALUMINUM FOIL LABEL ................................................................................

2

9

512485A

HEADLAMP FENDER, RH ..................................................................

1

9-1

514649

ALUMINUM FOIL LABEL ................................................................................

2

10

511794

BRACKET, MAIN-BEAM HEADLAMP ............................................................

4

11

511795

BRACKET, LOW-BEAM HEADLAMP .............................................................

4

14

512436

WATERPROOF BAND....................................................................................

2

15

S25602

BOLT, M6X16 ..................................................................................................

6

16

512430

RUBBER PLUG (OPTION) .............................................................................

1

17

S72605

HEX HEAD BOLT, M6X16 (SILVER WHITE) ..................................................

10

18

GA552SC11

TAPPING SCREW, M4X16 .............................................................................

6

19

N32601

SPRING NUT ..................................................................................................

18

20

GA552NT01

SPRING NUT, M4 ...........................................................................................

4

21

S50401

TAPPING SCREW, M4X12 .............................................................................

2

22

512423

WATERPROOF BAND....................................................................................

2

23

454016

RUBBER PLUG ..............................................................................................

2

12 13

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AW-2

BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

24

512439

WATERPROOF BAND ....................................................................................

2

25

GA555WS02

WASHER .........................................................................................................

10

26

N10603

SPRING NUT, M6............................................................................................

10

27

512434

RUBBER PLUG (OPTION)..............................................................................

1

28

W99605

WASHER .........................................................................................................

10

29

S41502

BOLT, M5X16 ..................................................................................................

8

30

N32501

SPRING NUT, M5............................................................................................

8

31

S57501

OVAL FLANGE HEAD SCREW, M5X16 ..............................................

6

Page AW-3

Service PartsParts Manual 647971 Service Manual

BODY

Notes:

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AW-4

BODY

*338&3%6(

Page AW-5

Service PartsParts Manual 647971 Service Manual

BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

512524B

FOOTBOARD, LH...........................................................................................

1

2

512571A

FOOTBOARD, RH ..........................................................................................

1

3

512544A

COMPLETE OIL LEVEL CHECKING COVER .....................................

1

3-1

512543

RUBBER PLUG ..............................................................................................

2

5

512589

SIDE COVER, LH ................................................................................

1

5A

512589V

SIDE COVER, LH (CAMO OPTION) ..............................................................

1

6

512590

SIDE COVER, RH................................................................................

1

6A

512590V

SIDE COVER, RH (CAMO OPTION)..............................................................

1

7

512526

SIDE COVER BRACKET, LH..........................................................................

1

8

512527

SIDE COVER BRACKET, RH .........................................................................

1

9

GA556SC01

FLANGE BOLT, M6X1.J0X12 .........................................................................

2

10

512505

UPPER FUEL TANK COVER...............................................................

1

UPPER FUEL TANK COVER (CAMO OPTION).............................................

1

512535

GEAR CHANGE INDICATOR SUPPORT............................................

1

11-1 515124

PROTECTOR..................................................................................................

1

S25602

BOLT, M6X16 ..................................................................................................

6

15

S72605

HEX HEAD BOLT, M6X16 (SILVER WHITE) ..................................................

22

16

GA555WS02

WASHER ........................................................................................................

24

17

S50501

OVAL HEAD SCREW, M5X12 ........................................................................

2

18

S50509

TAPPING SCREW, M5X16 .............................................................................

2

19

N32601

SPRING NUT ..................................................................................................

2

20

S72603

HEX HEAD BOLT, M6X12....................................................................

2

4

10A 512505V 11

12 13 14

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AW-6

BODY

6)%6 &3(=

Page AW-7

Service PartsParts Manual 647971 Service Manual

BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

514498G

COMPLETE REAR BODY COVER .....................................................

1

1-1

514460

HEAT INSULATION..............................................................................

1

1-2

514461

HEAT INSULATION..............................................................................

1

1A

514498VG

COMPLETE REAR BODY COVER (CAMO OPTION) ...................................

1

2

514446B

REAR FENDER SIDE RAIL, LH

3

514447B

REAR FENDER SIDE RAIL, RH.....................................................................

1

4

514403K

REAR BUMPER..............................................................................................

1

5

511802

REAR REFLECTOR ASSEMBLY.........................................................

2

6

514413

BATTERY PLATE............................................................................................

1

7

512425

CARRIER COVER ..........................................................................................

2

8

514405

REAR BODY COVER BRACKET ...................................................................

1

9

W99605

WASHER..............................................................................................

12

10

GA554NT04

FLANGE NUT, M6X1.0 ...................................................................................

6

11

GA555SC05

OUTLET BOLT, M6X1.0X16 ...........................................................................

2

12

S57501

OVAL FLANGE HEAD SCREW, M5X16 .........................................................

4

13

GA552SC11

TAPPING SCREW, M4X16 .............................................................................

8

15

N32601

SPRING NUT ..................................................................................................

12

16

N10603

SPRING NUT, M6 ...........................................................................................

8

17

S20814

FLANGE BOLT, MIX1.25X20 ..........................................................................

2

18

S25602

BOLT, M6X16 ..................................................................................................

1

19

S07601

FLANGE BOLT, M6X16 (DARK GREEN) .......................................................

4

20

514410

CLAMP............................................................................................................

2

21

514411

CONNECTOR .................................................................................................

2

23

S72605

HEX HEAD BOLT, M6X16 (SILVER WHITE) ..................................................

10

24

GA555WS02

WASHER ........................................................................................................

10

25

514418

COVER ...........................................................................................................

1

26

512466

PLATE, LH ......................................................................................................

1

27

512467

PLATE, RH...........................................................................................

1

14

22

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AW-8

BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

28

S72601

HEX HEAD BOLT, M6X20 ...............................................................................

2

29

S20611

HEX HEAD BOLT, M6X20 ...............................................................................

4

30

514467

DRAIN HOSE ..................................................................................................

1

31

R40002

CLIP.................................................................................................................

1

32

GA510SR02

CLAMP, L200...................................................................................................

1

33

GA510SR01

CLAMP, L150...................................................................................................

2

34

514407

REFLECTOR BRACKET, LH...........................................................................

1

35

514408

REFLECTOR BRACKET, RH ..........................................................................

1

36

514489

REAR SIDE REFLECTOR ASSEMBLY...........................................................

2

37

514474

TURN SIGNAL LAMP BALATA COVER ..............................................

2

Page AW-9

Service PartsParts Manual 647971 Service Manual

BODY

Notes:

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AW-

SEAT

Page AX-1

Service PartsParts Manual 647971 Service Manual

SEAT THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

512317

SEAT SET, BLACK...............................................................................

1

1-1

515019

FRONT RUBBER DAMPER ................................................................

2

1-2

515022

REAR RUBBER DAMPER...................................................................

2

1-3

515020

HOOK...................................................................................................

1

1A

512321BL

TWO LEVER SEAT SET, BLACK (OPTION) ..................................................

1

2

511933

SEAT LOCK SET .................................................................................

1

3

512337

SEAT CABLE LOCK SET................................................................................

1

4

S21605

FLANGE BOLT, M6X10........................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AX-2

LABELS

Page AY-1

Service PartsParts Manual 647971 Service Manual

LABELS THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

518277

FRONT CARRIER LABEL...............................................................................

1

2

518278

REAR CARRIER LABEL.................................................................................

1

3

513667

WARNING LABEL...........................................................................................

1

4

517253

12" TIRE PRESSURE LABEL..............................................................

1

4A

518290

14" TIRE PRESSURE LABEL.........................................................................

1

5

517246

SHIFT RANGE LABEL....................................................................................

1

6

513661

D.C. ELECTRIC SOURCE LABEL..................................................................

1

7

513663

INFORMATION LABEL ........................................................................

1

8

514661

TOWING CAPACITY LABEL...........................................................................

1

9

513665

AGE 16 LABEL ...............................................................................................

1

10

514625

ENGINE OIL CHECK LABEL ..........................................................................

1

11

514626

CLIMBING HILLS LABEL................................................................................

1

12

513602

WARNING LABEL...........................................................................................

1

13

516753

LOCK (MODE) LABEL ....................................................................................

1

14

518289

SOLO SEAT LABEL ........................................................................................

1

15

518295

GEAR SHIFT WARNING LABEL (1) ...............................................................

1

16

518296

GEAR SHIFT WARNING LABEL (2) ...............................................................

1

17

517255

ENGINE OIL GRADE LABEL...............................................................

1

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AY-2

CARRIER AND BUMPER OPTION

Page AZ-1

Service PartsParts Manual 647971 Service Manual

CARRIER AND BUMPER OPTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

DESCRIPTION

QTY.

1

515063A

COMPLETE FRONT CARRIER...........................................................

1

1-1

S20024

BOLT ....................................................................................................

2

1-2

512027

BRACKET ............................................................................................

2

1-3

S20002

FLANGE BOLT, M10X1.25..............................................................................

2

2

516085A

COMPLETE REAR CARRIER .............................................................

1

2-1

513943

BRACKET ............................................................................................

1

2-2

GA504SC12

FLANGE BOLT, M8X12........................................................................

2

2-3

S21809

BOLT, M8X1.25X18.........................................................................................

4

3

514079A

COMPLETE REAR BUMPER, STEEL.................................................

1

3-1

S21809

BOLT, M8X1.25X18..............................................................................

2

3-2

512020

PLUG ..............................................................................................................

4

4

515045A

COMPLETE FRONT BUMPER, STEEL ..............................................

1

4-1

S21809

BOLT, M8X1.25X18..............................................................................

2

4-2

512027

BRACKET ............................................................................................

2

4-3

S20018

BOLT ....................................................................................................

2

Service Parts Manual Service Parts Manual 647971 Service Parts Manual

Page AZ-2

CARRIER AND BUMPER OPTION

Notes:

Page AZ-3

Service PartsParts Manual 647971 Service Manual

Textron Specialized Vehicles 1451 Marvin Griffin Road, Augusta, Georgia 30906-3852 USA

Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Parts & Accessories Department or at www.shopezgo.com.

Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc., Technical Communications Department