98 arctic cat 300 2x4 parts list

TABLE OF CONTENTS ATV 300 2x4 ATV 300 4x4(Model No. 98A2C-AP) (Model No. 98A4C-AP)

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

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

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

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

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

The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not to be used for assembly. For assembly procedures, use Arctic Cat Service Manuals. Underlined part numbers are new for the 1998 model. year. Printed September 2001

A1

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300 2x4 300 4x4

0733-613 *Not Illustrated

Ref. Part No. Qty. Description 1 0506-257 1 0506-239 1 2 0506-153 1 3 0506-274 1 0506-275 1 4 0506-191 1 5 0606-526 2 6 0623-269 8 7 0506-242 1 0506-243 1 8 0506-258 1 0506-245 1 9 0506-190 1 10 0406-293 1 11 0417-002 1 12 0606-029 2 13 0406-082 1 0406-083 1 14 0406-086 1 0406-087 1 15 0423-046 58 0423-046 10

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cBODY PANEL ASSEMBLY16 0506-160 0506-161 0406-084 0406-085 17 0423-010 0423-010 18 8474-616 8474-616 19 0423-060 20 0623-309 21 8409-020 22 8408-812 23 0423-031 24 0123-010 25 0423-068 26 8477-610 27 8476-616 28 0406-374 29 0423-074 30 0506-272 0506-273 31 0623-362 32 0619-230 1 1 1 1 25 22 25 22 2 2 6 2 2 2 2 4 2 2 4 1 1 2 1 Ref. Part No. Qty. Description Panel, Fender - Front (4x4) Panel, Fender - Front (2x4) Cover, Access Flare - Front Right (4x4) Flare - Front Left (4x4) Rack - Front Reflector - Yellow Clip, Retaining Panel, Side - Right Panel, Side - Left Panel, Fender - Rear (4x4) Panel, Fender - Rear (2x4) Rack - Rear Wrap, Tube - Rear Rack Foam, Access Panel Reflector - Red Flare - Rear Right (4x4) Flare - Rear Left (4x4) Mud Flap - Right (4x4) Mud Flap - Left (4x4) Rivet, Plastic (4x4) Rivet, Plastic (2x4)

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

A3

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300 2x4 300 4x4

0732-336

Ref. Part No. Qty. Description 1 2 3 4 0109-460 0409-011 0409-012 0409-007 1 1 1 1

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2

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cTAILLIGHT ASSEMBLY (Complete Taillight Assembly p/n 0409-002)5 0409-010 6 0623-301 7 8053-212 2 2 2 Ref. Part No. Qty. Description Bulb, Stop - Taillight Taillight w/Socket-Assembly Gasket, Taillight Lens, Taillight

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

A4

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300 2x4 300 4x4

0733-614

Ref. Part No. Qty. Description 1 0411-082 2 0411-109 0411-108 3 3611-002 4 0411-045 5 0411-008 6 0411-040 7 0411-010 8 0411-110 0411-111 0411-106 0411-107 1 1 1 1 1 1 1 1 1 1 1 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cDECALSRef. Part No. Qty. Description 9 0411-096 0411-089 10 0411-086 11 0411-083 12 0411-043 13 0411-142 14 0411-090 0411-088 15 0411-145 1 1 1 1 1 1 1 1 1 Decal, Warning - Front Rack Load Decal, Front (4x4) Decal, Front (2x4) Decal, Made In U.S.A. Decal, Warning - Turn Decal, Warning Reverse/Pre Ride Decal, Warning - Age Decal, Warning - General Decal, Side Right (4x4) Decal, Side Left (4x4) Decal, Side Right (2x4) Decal, Side Left (2x4)

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

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om3

300 2x4 300 4x4

0733-713

Ref. Part No. Qty. Description 1 0506-270 1 0506-188 1 2 0406-372 1 3 8476-616 2 4 0506-176 1 0506-217 1 5 8409-020 6 6 8408-816 8 7 0423-010 12 8 8474-616 12 9 0506-192 1 10 0406-354 1 11 0123-788 6 12 0406-175 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cFRAME AND RELATED PARTS13 14 15 16 17 18 19 20 21 22 23 24 25 8424-802 8408-850 0406-262 0406-261 8053-242 0406-300 0409-001 0409-005 0123-950 0506-210 8408-820 0406-371 8471-610 6 2 2 2 2 2 2 2 2 1 2 1 4 Ref. Part No. Qty. Description Frame, Main (4x4) Frame, Main (2x4) Bracket, Body Holddown Screw, Machine Footrest - Right Footrest - Left Screw, Cap Screw, Cap Washer, Shoulder Screw, Machine Guard, Brush Panel, Belly Tie, Cable Screen, Bumper - Lower

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

A6

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300 2x4 300 4x4

0733-618 * Not a Service Part

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 5990-069 1 0506-054 1 0506-056 1 0506-223 1 * 1 8061-628 4 0506-147 1 0624-100 AR 0406-309 2

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cSEAT ASSEMBLY10 11 12 13 14 15 16 17 8476-620 0406-235 8050-217 0406-199 0406-171 0623-404 0406-103 8476-616 Ref. Part No. Qty. Description 2 1 2 2 2 1 1 2

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

Seat Assembly (inc. 2-8)

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

A7

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300 2x4 300 4x4

0733-616

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0409-013 8477-616 0405-042 0423-052 3409-003 3409-007 3409-011 0420-011 0405-036 0405-019 0420-013 0420-001 8422-002 0123-950 8408-860 0405-035 0506-139 0505-022 1 3 1 1 1 1 1 1 1 1 4 1 4 4 6 4 1 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cSTEERING ASSEMBLY18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 0405-039 0605-171 0405-020 0605-147 0623-175 0505-012 8408-816 0602-233 0602-808 0423-073 8409-020 0505-021 0405-032 8420-002 0405-041 0405-040 0423-013 8060-428 2 1 2 1 4 1 2 1 1 1 1 2 2 2 2 2 2 2 Ref. Part No. Qty. Description Cover, Key Screw, Machine Plug, Instrument Pod Collar, Body Switch, Ignition - Assembly (inc. 6) Key, Ignition - Blank (C Series) Key, Ignition - Blank (D Series) Bezel/Lens, Warning - Assembly Plate, Arctic Cat - Instrument Pod Instrument Pod Bulb, Light Bar Light, Warning - Assembly Nut Screw, Self-Tapping Screw, Cap Cap, Steering Adjuster Bracket, Key Switch Tube, Handlebar

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

A8

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300 2x4 300 4x4

0733-414

Ref. Part No. Qty. Description 1 0603-033 2 2 0403-015 2 0403-036 2 3 0604-310 8 4 0403-028 4 5 8428-002 12 6 8409-040 4 7 0403-022 2 0403-037 2 8 0403-025 2 9 0403-013 2 10 0503-026 1 0503-027 1 11 0405-001 4 12 0423-009 4 13 0505-026 1 0505-027 1 14 0505-024 1 0505-025 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cFRONT SUSPENSION ASSEMBLY15 16 17 18 19 20 21 0402-085 0423-034 0402-089 0402-069 8409-030 8409-060 0503-044 0503-045 0503-036 0503-037 0402-179 0402-249 0436-114 0436-113 0403-027 0402-183 2 2 2 2 4 8 1 1 1 1 1 1 2 2 2 2 Ref. Part No. Qty. Description Retainer, Spring Shock Absorber - Front (inc. 3-4) (4x4) Shock Absorber - Front (inc. 3-4) (2x4) Bushing, Shock Absorber Sleeve, Shock Nut, Lock Screw, Cap Spring, Shock Absorber (4x4) Spring, Shock Absorber (2x4) Collar, Spring Washer, Spring A-Arm, Upper Right - Assembly (inc. 11-12) A-Arm, Upper Left - Assembly (inc. 11-12) Ball Joint - Front Clip, Ball Joint Knuckle - Assembly - Right (inc. 14-18) Knuckle - Assembly - Left (inc. 14-18) Knuckle, Steering - Right Knuckle, Steering - Left 22 23 24 25 26

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

A9

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300 2x4 300 4x4

0733-698

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 0504-032 2 0423-095 6 0403-038 6 0403-032 12 0402-085 2 0423-034 2 0402-089 2 0402-069 2 0402-171 2 0504-029 2 0504-030 1 0504-031 1 12 0404-014 2 13 0403-028 4

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cREAR SUSPENSION ASSEMBLYRef. Part No. Qty. Description 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0604-310 8 0403-027 2 0403-013 2 0403-025 2 0603-033 2 0403-002 2 0423-087 2 8428-002 12 8409-040 2 8408-820 2 8409-000 6 8409-060 4 0436-113 2 0436-114 2

Fitting, Grease

Knuckle, Rear - Assembly (inc. 2)

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

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

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300 2x4 300 4x4

0733-661

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 3423-213 0402-140 0402-064 0402-215 0402-252 0402-202 0123-458 0423-080 0402-181 0502-041 0502-040 4 4 4 2 2 2 4 4 4 2 2

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cWHEEL AND TIRE ASSEMBLY10 11 12 13 0402-009 3 0423-029 12 0502-041 2 0402-262 2 0402-215 2 14 0402-153 2 15 0403-035 4 16 8409-020 16 Ref. Part No. Qty. Description Nut, Hex Cap, Valve Stem Valve, Stem Wheel - Front Tire - Front (4x4) Tire - Front (2x4) Pin, Cotter Washer Seal, Hub Hub, Wheel - Front (4x4) Hub, Wheel - Front (2x4)

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

A11

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300 2x4 300 4x4

0733-691 *Not a Service Part

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 0502-048 0402-206 0402-208 0402-210 0402-207 0402-209 * 0487-010 1 1 2 2 1 2 1 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cMECHANICAL BRAKE ASSEMBLYRef. Part No. Qty. Description 9 10 11 12 13 14 15 16 8408-825 0402-161 0423-027 0623-237 0502-056 8476-616 0670-183 0502-024 2 1 1 1 1 2 2 1 Mechanical Brake-Assembly (inc. 2-7) Arm, Inner Pin, Arm Pad, Mechanical Brake Arm, Outer Spring, Arm Housing, Mechanical Brake Cable, Brake - Rear

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

A12

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300 2x4 300 4x4

0733-434 *Not a Service Part

Ref. Part No. Qty. Description 1 0502-061 2 3 4 5 6 7 8 9 10 1

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

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cRef. Part No. Qty. Description 11 12 13 14 15 16 17 18 19 20 0623-056 8052-212 0623-629 0602-907 0402-050 8476-625 0402-240 0402-245 0423-090 0402-246 1 2 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 Brake, Lever - Assembly (inc. 2-14 and 17-20) Lever, Brake Bolt, Lever Mounting Screw, Cover - Master Cylinder Cover, Master Cylinder Gasket, Cover - Master Cylinder Reservoir, Hydraulic Brake O-Ring, Reservoir Master Cylinder Screw, Reservoir Mount

HYDRAULIC BRAKE CONTROL ASSEMBLY Nut, Lock Washer, Lock Screw, Clamp Clamp

Hose, Master Cylinder Screw, Cap Wedge, Parking Brake Spring Nut, Press Pin

A13

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300 2x4 300 4x4


Ref. Part No. Qty. Description 1 2 3 4 5 6 0402-053 0402-051 0402-073 0423-038 0423-039 0402-010 0402-011 7 8 9 10 11 * 0402-164 0117-868 0402-142 0402-143 1 1 2 3 6 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cHYDRAULIC BRAKE ASSEMBLYRef. Part No. Qty. Description 12 13 14 15 16 17 18 19 20 21 22 23 24 0402-096 0402-167 0402-141 0402-165 0402-166 0402-254 0402-115 0402-170 8476-625 8408-825 0123-269 8476-612 0624-250 6 3 6 6 6 1 1 1 1 6 1 1 1 2 3 3 3 3 3 Tube, Brake Line - Front Hose, Brake - Front Block, Mounting Bolt, Oil Washer, Crush Caliper, Brake - Right Front (inc. 7-13 and two No. 14-16) Caliper, Brake - Left Front and Rear (inc. 7-13 and two No. 14-16) Housing, Caliper O-Ring Pin, Cotter Pin, Hydraulic Brake Caliper Cap, Bleeder Valve

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

A14

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300 2x4 300 4x4


Ref. Part No. Qty. Description 1 2 3 4 5 6 7 0570-014 0470-315 0470-316 8476-650 0623-184 0406-169 0406-170 1 1 1 2 2 4 2

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cFUEL TANK ASSEMBLY8 9 10 11 12 13 0610-007 AR 0423-048 2 * 1 0470-357 1 8471-616 2 0417-001 7 Ref. Part No. Qty. Description

Cap, Fuel Tank (inc. 3) Line, Fuel Cap Vent

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

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

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

B1

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300 2x4 300 4x4

0733-716

Ref. Part No. Qty. Description 1 2 3 4 5 6 0402-239 0487-009 3423-168 0502-059 0423-096 0423-063 1 1 1 1 2 2

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cREVERSE SHIFT LEVER ASSEMBLYRef. Part No. Qty. Description 7 8 9 10 11 0402-136 0409-008 0402-168 0402-062 3423-282 1 1 1 1 1 Axle, Reverse Shift Cable, Shift E-Ring Lever, Reverse O-Ring E-Ring

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

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300 2x4 300 4x4

0733-684

Ref. Part No. Qty. Description 1 3570-001 2 3402-330 3 0470-355 0470-356 4 3402-331 5 8477-610 6 3423-329 7 3423-311 8 3423-313 9 3402-334 10 0470-349 1 1 1 1 1 2 1 2 3 1 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cAIR INTAKE ASSEMBLY11 12 13 14 15 16 17 18 19 20 21 0423-047 3470-004 0423-018 0470-347 0423-019 0570-019 0406-379 0406-379 0423-046 0444-072 8476-616 1 1 1 1 1 1 3 1 1 1 5 Ref. Part No. Qty. Description

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

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

Clamp

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

B3

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300 2x4 300 4x4

0733-736

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 0436-178 0423-096 0402-214 8424-802 8476-630 8050-222 0402-256 0406-363 0423-091 8050-242 3423-168 1 2 1 1 2 2 2 2 1 2 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cSHIFTER ASSEMBLY12 13 14 15 16 17 18 19 20 21 22 0502-062 3487-001 0623-175 3423-282 0502-064 0487-012 0423-099 0487-014 0117-868 0423-052 8476-620 1 1 1 1 1 1 1 1 1 1 1 Ref. Part No. Qty. Description Lever, Footshift O-Ring Axle, Footshift Nut Screw, Cap Washer Collar, HI/Lo Shift Bushing, Hi/Lo Shift Bushing, Shift Washer E-Ring, Gear Shift

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

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300 2x4 300 4x4

0734-784

Ref. Part No. Qty. Description 1 0462-009 0462-005 2 0506-301 3 0512-006 4 0423-092 5 8408-812 6 0512-004 7 0412-024 8 8053-211 9 8477-610 10 0412-023 11 0612-887 12 0412-031 13 8424-802 14 0123-321 15 0512-008 16 3402-300 17 0406-344 1 1 1 1 1 2 1 1 4 4 1 2 1 2 3 1 1 1

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ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cENGINE AND RELATED PARTS18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 0423-010 8474-616 8409-020 8408-816 3402-264 3423-236 3402-263 8050-272 3423-235 8422-002 0402-231 0402-232 0406-320 0502-066 8422-202 3402-232 8 8 6 1 2 1 4 4 2 3 1 1 2 1 1 4 Ref. Part No. Qty. Description Engine (4x4) Engine (2x4) Frame, Sub (inc. 32) Muffler Clamp, Exhaust Screw, Cap Pipe, Exhaust Cover, Exhaust - Rear Washer, Lock Screw, Cap Cover, Exhaust Gasket, Exhaust Coupler, Exhaust Nut Spring, Extension Pipe, Header Seal, Exhaust Pipe Panel, Belly - Subframe

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

B5

om17

300 2x4 300 4x4

0733-727


W or

18

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cOIL COOLER ASSEMBLY7 8 9 10 11 12 0410-006 0410-007 8471-616 0423-089 0410-012 0410-013 1 1 4 2 1 1 Ref. Part No. Qty. Description Cooler, Oil Grommet Screw, Cap Washer Collar Clamp, Hose Hose, Oil - Output Hose, Oil - Input Screw, Cap O-Ring, Oil Fitting Fitting, Oil - Angled Fitting, Oil

B6

om

300 2x4 300 4x4

0733-740

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0486-008 0623-361 0530-003 0411-084 0630-057 8476-616 0409-009 0402-168 3530-012 8476-620 3530-013 3530-011 3530-014 0506-254 0406-380 0645-063 1 2 1 1 3 7 2 1 1 2 1 1 1 1 1 1

W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cELECTRICAL COMPONENTS17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 0645-045 6 0645-152 1 0645-263 1 0123-788 AR 0445-010 1 0445-011 1 0445-012 1 0645-019 4 3430-009 1 3430-026 1 3430-007 1 3530-008 1 0486-012 1 0486-013 1 0624-250 2 Ref. Part No. Qty. Description Harness, Main Screw, Self-Tapping Fuse Box Assembly Decal, Fuse Box Fuse, 10 AMP Screw, Cap Switch, Brake Retainer, Switch Coil, Ignition Screw, Cap Relay, Starter CDI Unit Regulator, Voltage Bracket, Battery Pad, Battery Battery (inc. 17-19)

Cap, Battery Clamp, Hose Hose, Battery Vent

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

B7

om19

300 2x4 300 4x4

0733-773 *California Models Only

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 4505-001 4505-046 4505-003 4505-004 4505-005 4505-061 4505-007 4505-058 4505-009 4505-010 4505-011 4505-012 4505-013 4505-014 4505-016 4505-059 4505-060 4505-019 4505-057 4505-021 4505-022 4505-044 1 1 1 1 1 1 4 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1

W or

20

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c(Complete Assembly p/n 0470-348) 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 4505-045 4505-023 4505-024 4505-025 4505-026 4505-062 4505-028 4505-029 4505-030 4505-031 4505-032 4505-033 4505-042 4505-043 4505-035 4505-048 0487-008 4505-039 4505-040 6505-006 0487-007

CARBURETOR

Ref. Part No. Qty. Description 1 1 1 3 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1

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

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

B8

om

300 2x4 300 4x4

0733-743


W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cCYLINDER HEAD ASSEMBLY12 13 14 15 16 17 18 19 20 21 22 3005-243 3003-032 0217-713 3402-249 3423-275 3402-213 3402-297 3423-276 3423-305 3402-086 3402-298 4 2 1 2 2 1 1 1 2 1 1 Ref. Part No. Qty. Description Head, Cylinder - Assembly (inc. 2-6) Guide, Valve Ring, Valve Guide Pin Screw, Cap Screw, Cap Gasket, Cylinder Head Pin Gasket Nut Nut

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

B9

om21

300 2x4 300 4x4

0733-744

Ref. Part No. Qty. Description 1 2 3 4 5 3402-251 3423-238 3423-239 3423-089 3423-237 1 2 2 2 2 Cylinder Bolt, Stud Bolt, Stud Bolt, Stud Bolt, Stud

W or

22

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cCYLINDER ASSEMBLY6 7 8 9 3004-488 3402-252 3423-306 3005-226 4 1 2 1 Ref. Part No. Qty. Description Nut Gasket, Cylinder Pin O-Ring

B10

om

300 2x4 300 4x4

0733-745

Ref. Part No. Qty. Description 1 3402-314 3402-253 2 3423-088 3 3423-162 4 3423-098 5 3423-091 6 3423-307 7 3423-308 8 3423-094 9 3423-232 10 3423-234 11 3005-243 1 1 2 2 4 2 3 4 4 1 1 1

W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cCRANKCASE ASSEMBLY12 13 14 15 16 17 18 19 20 21 22 23 3423-051 3402-245 3402-214 3402-012 3402-212 3423-274 3402-327 3402-011 3402-257 3402-250 3402-258 3423-271 1 1 1 1 1 1 1 1 1 1 1 1 Ref. Part No. Qty. Description Crankcase Set (inc. 2-13) (4x4) Crankcase Set (inc. 2-13) (2x4) Pin Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Screw, Cap Gasket

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

B11

om23

300 2x4 300 4x4

0733-746

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 3402-254 3402-112 3402-280 3423-088 3423-231 0693-327 3423-098 3423-307 3003-290 3004-705 3005-242 3430-019 3402-013 1 1 1 4 2 8 9 2 1 2 2 1 1

W or

24

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cCRANKCASE COVER ASSEMBLYRef. Part No. Qty. Description 14 15 16 17 18 19 20 21 22 23 24 25 3402-215 3423-274 3402-256 3402-262 3423-328 3004-339 3003-290 3004-756 3402-237 3423-308 3423-091 3430-029 1 1 1 1 1 1 1 1 2 1 2 1 Cover, Clutch (inc. 2) Lens, Oil Inspection Gasket Pin Screw, Cap Screw, Cap Screw, Cap Screw, Cap Gasket Plug, Oil Gallery Gasket Switch, Oil Lamp Gasket

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

B12

om

300 2x4 300 4x4

0733-747


W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cCRANKSHAFT ASSEMBLY12 13 14 15 16 17 18 19 3402-301 3423-114 3402-265 3402-266 3436-009 3436-010 3402-267 3423-280 3402-227 3402-306 3402-307 1 1 1 1 1 1 1 2 1 1 1 Ref. Part No. Qty. Description Crankshaft - Assembly (inc. 2-7) Rod, Connecting Pin, Crank Bearing Washer Crankshaft - Right Crankshaft - Left Bearing - Right Bearing - Middle Bearing - Left O-Ring

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

B13

om25

300 2x4 300 4x4

0733-748

Ref. Part No. Qty. Description 1 3402-274 2 3423-267 3 3402-145 1 1 1

W or

26

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cSTARTER CLUTCH ASSEMBLY4 3402-273 5 3402-222 6 3423-309 1 1 3 Ref. Part No. Qty. Description Gear, Starter Idler Pin Spacer

Bearing

Clutch Set, Starter (inc. 5) Screw, Cap

B14

om

300 2x4 300 4x4

0733-749

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 3402-275 3402-326 3423-047 3423-284 3423-013 3423-071 3402-288 3423-287 3423-288 3402-226 3402-294 0693-281 3402-295 1 1 1 1 2 1 2 2 2 2 2 4 1

W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cCAM SHAFT VALVE ASSEMBLY14 15 16 17 18 19 20 21 22 23 24 25 26 3402-296 1 3402-225 1 3402-242 1 3004-326 1 3402-289 2 3423-052 2 3423-259 2 3003-290 2 3004-376 2 3402-290 1 3402-291 1 3402-292 2 3402-293 2 Ref. Part No. Qty. Description Cam Shaft Sprocket Pin Washer Screw, Cap C-Ring Arm, Valve Rocker (inc. 8-9) Screw, Cap Nut Seal, Oil Seat, Spring Cotter, Valve Shaft, Decompression

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

C1

om27

300 2x4 300 4x4

0733-750


W or

28

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cCAM CHAIN ASSEMBLY1 1 1 1 1 2 Ref. Part No. Qty. Description Chain, Cam 7 3402-284 Guide, Cam Chain 8 3402-285 9 3402-286 Tensioner, Cam Chain Screw, Cap 10 3423-286 11 3402-287 Washer Adjuster, Tensioner - Assembly (inc. 7-10) 12 3004-576

Spring Plug Bar O-Ring

Gasket, Adjuster Screw, Cap

C2

om

300 2x4 300 4x4

0733-751


W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cRECOIL STARTER ASSEMBLY7 8 9 10 11 12 3445-021 3423-112 3003-290 3445-022 3004-336 3004-362 1 6 1 1 1 1 Ref. Part No. Qty. Description Starter, Recoil - Assembly (inc. 2-6) Reel Ratchet - Assembly Spring, Spiral Nut Rope-Assembly

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

C3

om29

300 2x4 300 4x4

0733-752


W or

30

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cOIL PUMP ASSEMBLY12 13 14 15 16 17 18 19 20 21 22 3402-012 3436-005 3423-270 3402-303 3004-705 3005-242 3423-277 3402-238 3423-314 3004-543 3423-315 1 1 1 1 1 1 1 1 2 1 3 Ref. Part No. Qty. Description Pump, Engine Oil Gear, Driven Pin Circlip Screw, Cap Strainer, Engine Oil Screw, Cap Cap, Oil Strainer O-Ring Screw, Cap Plug, Drain Gasket Filter, Engine Oil O-Ring Cap, Oil Filter Plug, Oil Check Gasket O-Ring Spring Bolt, Stud Bolt, Stud Nut

C4

om

300 2x4 300 4x4

0733-753

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 3446-120 3446-129 3446-122 3446-128 3423-253 3423-032 3423-260 3446-121 3402-206 3402-211 3446-123 3423-254 3423-316 3446-124 3446-125 3446-126 1 1 1 1 1 1 1 1 1 1 1 1 1 8 7 1

W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cCLUTCH ASSEMBLY17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3402-239 3004-341 3446-127 3446-130 3402-043 3446-133 3446-131 3446-134 3423-248 3423-022 3446-132 3423-125 3423-245 0693-316 3003-290 4 4 1 1 1 1 1 1 1 1 1 1 3 3 3 Ref. Part No. Qty. Description Gear, Primary Drive Race, Inner Clutch, One Way Clutch-Assembly Nut Washer, Lock Washer, Lock Gear, Primary - Assembly Spacer Washer Hub, Clutch Nut Washer Plate, Drive Plate, Driven Disc, Pressure

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

C5

om31

300 2x4 300 4x4

733-754A

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 3446-135 3446-137 3446-138 3446-139 3402-229 3402-210 3423-279 3446-140 3423-261 0691-374 3446-031 3004-552 3402-224 3446-136 3446-141 3446-144 3423-036 3423-066 3446-142 3402-230 3423-317 3446-143 3423-266 3423-262 3446-146 3446-147 3446-151 3446-145 1 1 1 1 1 2 2 1 1 1 2 2 1 1 1 2 3 4 1 1 1 1 1 1 1 1 1 1

W or

32

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cTRANSMISSION ASSEMBLY29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 3446-152 1 3423-263 1 3402-218 1 3402-220 1 3446-057 1 3446-059 1 3446-228 1 3423-336 1 3423-337 1 3446-114 1 3446-229 1 3423-144 1 3446-058 1 3402-077 1 3423-056 1 3423-143 1 3004-507 2 3402-009 1 3446-148 1 3446-149 1 3402-228 1 3446-150 1 3402-209 1 3402-255 1 3446-153 1 3423-231 2 0402-160 1 3446-231 1 Ref. Part No. Qty. Description Shaft, Counter Gear, 2nd Drive Gear, 3rd Drive Gear, 4th Drive Bush Washer Circlip Gear, 5th Drive Washer Bearing - Right Retainer Screw, Cap Bearing, Middle Driveshaft Gear, 1st Driven Bush Washer, Lock Circlip Gear, 2nd Driven Bush Washer Gear, 3rd Driven Washer, Lock Washer, Lock Gear, 4th Driven Gear, 5th Driven Gear, Reverse Driven Bush

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

C6

om

300 2x4 300 4x4

0733-755

Ref. Part No. Qty. Description 1 3446-206 3446-179 2 3446-207 3446-184 3 3423-338 4 3423-298 5 3446-208 6 3446-209 7 3423-317 8 3423-318 9 3402-278 10 3004-209 11 3402-055 12 3446-031 13 3446-154 14 3004-552 15 0693-321 16 3446-181 17 3446-069 18 3423-036 19 3446-182 20 3446-183 21 3402-195 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1

W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cRef. Part No. Qty. Description 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 3402-207 1 3423-066 1 3446-180 1 3402-205 1 3423-319 1 3003-261 1 3402-217 1 3446-185 1 3446-210 1 3446-168 1 3446-230 1 3446-211 1 3446-186 1 3446-187 1 3402-241 1 3423-141 1 3423-240 1 3423-268 1 3446-116 1 3423-125 1 3423-204 1 3423-168 1 3402-076 1 Shaft, Sub Transmission (4x4) Shaft, Sub Transmission (2x4) Gear, Driven (4x4) Gear, Driven (2x4) Washer - Right (4x4) Washer - Left (4x4) Gear, Driven (4x4) Dog, Driven Gear (4x4) Washer (4x4) Circlip Bearing - Right Bearing - Left Bearing - Middle Retainer Retainer Screw, Cap Screw, Cap Gear, Drive Bush Washer Gear, Drive Dog, Drive Gear Washer

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

C7

om33

300 2x4 300 4x4

SECONDARY GEAR/PROPELLER SHAFT ASSEMBLY0733-756

Ref. Part No. Qty. Description 3446-197 3446-035 3423-032 3423-254 3402-067 3402-062 3423-072 3446-199 3402-308 3402-017 3402-018 3402-019 3402-020 3402-021 3402-022 3402-023 3402-024 3402-025 3402-028 3402-029 3402-030 3402-031 10 3402-072 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

W or

34

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cRef. Part No. Qty. Description 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 3423-340 3446-176 3446-175 3402-219 3402-072 3435-005 3435-002 3423-025 3423-028 3446-198 3423-281 3423-321 3435-007 3435-011 3423-067 3423-182 3004-491 3435-001 3423-060 3423-035 3435-029 3435-030 1 1 1 2 2 1 1 1 1 1 2 2 1 1 4 6 6 1 1 1 1 1 Gear, Secondary Drive Bevel (4x4) Shim Set, Secondary Drive Bevel (4x4) Washer (4x4) Nut (4x4) Bearing, Front (4x4) Bearing, Rear (4x4) Ring (4x4) Shaft, Secondary Output (4x4) Shim, 25 x 34 x 0.50 mm (4x4) Shim, 25 x 34 x 0.60 mm (4x4) Shim, 25 x 34 x 0.65 mm (4x4) Shim, 25 x 34 x 0.70 mm (4x4) Shim, 25 x 34 x 0.75 mm (4x4) Shim, 25 x 34 x 0.80 mm (4x4) Shim, 25 x 34 x 0.85 mm (4x4) Shim, 25 x 34 x 0.90 mm (4x4) Shim, 25 x 34 x 0.95 mm (4x4) Shim, 25 x 34 x 1 mm (4x4) Shim, 25 x 34 x 1.05 mm (4x4) Shim, 25 x 34 x 1.10 mm (4x4) Shim, 25 x 34 x 1.15 mm (4x4) Shim, 25 x 34 x 1.20 mm (4x4) Seal, Oil

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

C8

om

300 2x4 300 4x4

0733-757

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3446-155 3446-156 3446-159 3446-167 3446-157 3446-051 3446-160 3423-114 3446-162 3423-045 3402-051 3446-163 3446-031 3004-552 3446-165 3423-240 3423-141 3402-240 3423-268 3446-166 3004-376 3005-206 3446-161 3423-322 1 1 1 1 1 1 1 1 1 6 1 1 1 2 1 1 1 1 1 1 1 1 1 1

W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cGEAR SHIFTING ASSEMBLY25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 3446-164 3402-012 3446-169 3446-170 3402-312 3423-323 3446-171 3402-094 3446-172 3402-132 3423-233 3423-324 3402-076 3446-055 3446-115 3423-125 3423-228 3423-204 3423-168 3430-032 3423-273 3423-325 3423-044 3402-087 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 1 1 2 1 1 Ref. Part No. Qty. Description Fork, Gear Shifting Fork, Gear Shifting Fork, Gear Shifting Shaft Fork, Gear Shifting Shaft Cam, Gear Shifting (inc. 8) Pin Retainer, Pin Pin Bearing Retainer Retainer Screw, Cap Stopper, Cam Screw, Cap Washer Spring Pin Plate, Stopper Screw, Cap Pin Cam, Reverse Shifting Washer

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

C9

om35

300 4x4

0733-758 *Not in Assembly

Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 3435-068 1 3402-016 1 3402-065 1 3402-066 1 3402-059 1 3435-076 1 3435-071 2 3435-072 1 3435-080 1 3435-073 1 3435-070 1 3435-074 1 3423-294 AR 3423-295 AR 3423-296 AR 3423-297 1 3423-293 2 3402-309 1 3423-309 6 3435-077 1 3402-084 1 3435-021 1 3423-317 1 3435-017 1 3435-020 1 3435-020 1 3423-064 1 3423-050 1

W or

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

36

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cDIFFERENTIAL GEAR ASSEMBLY Complete Assembly p/n 3502-001Ref. Part No. Qty. Description 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 3435-078 1 3435-079 1 3402-185 1 3402-057 1 3402-072 3 3402-323 1 3423-010 2 3423-175 11 0693-327 2 3004-756 2 3005-206 2 3435-009 1 3423-034 1 3435-029 1 3435-030 1 3423-060 1 3423-178 1 3423-028 1 3402-036 1 3402-012 1 3402-038 1 3423-054 1 0402-147 1 0123-811 1 3435-075 1 3423-341 2 3423-070 2 3435-069 1 Gear, Front Drive Bevel Spacer Bearing, Front Bearing, Rear Bearing Case, Differential Pinion, Differential Side Gear, Right Gear, Left Shaft, Pinion Hub Shaft, Driven Output Washer Washer Washer Washer Washer Pin, Pinion Shaft Screw, Cap Housing, Differential Gear (inc. 19) Union, Breather Housing, Drive Bevel Gear Washer Shim Set, Front Drive Bevel Gear Shim Set, Drive Gear Bearing Shim Set, Front Drive Bevel Housing O-Ring O-Ring

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

C10

om

300 4x4

0733-759


W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cDIFFERENTIAL LOCK ASSEMBLY7 8 9 10 11 12 3423-339 3402-076 3446-119 3446-046 3402-089 3402-012 1 1 1 1 1 1 Ref. Part No. Qty. Description Fork, Differential Locking Shaft, Fork Cam, Differential Locking Shaft, Cam Spring Washer, Right Washer, Left Seal, Oil Stopper Housing Spring Gasket

C11

om37

300 2x4 300 4x4

0733-760


W or

38

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cSTARTER MOTOR 3545-003 ASSEMBLY Complete Assembly p/n7 8 9 10 11 12 3008-552 3423-289 3423-272 3008-553 3423-195 3004-756 1 2 1 2 1 2 Ref. Part No. Qty. Description Armature Holder Set, Brush Terminal Set, Brush (inc. 4) O-Ring Washer Set Spring, Brush

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

C12

om

300 2x4 300 4x4

0733-761

Ref. Part No. Qty. Description 1 2 3 4 5 3430-021 3430-022 3004-756 3423-326 3423-086 1 1 3 2 1

W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cMAGNETO ASSEMBLY6 7 8 9 3004-540 3430-023 3423-112 3430-036 1 1 1 1 Ref. Part No. Qty. Description Stator - Assembly Rotor Bolt, Magneto Screw, Cap Nut, Magneto

Key Plate Screw, Cap Sheet, Heat Protection

C13

om39

300 2x4 300 4x4

0732-323

Ref. Part No. Qty. Description 1 3409-002 2 3409-009 3 3409-010 1 1 1

W or

40

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cRef. Part No. Qty. Description 4 3423-196 5 3423-197 1 1 Switch, Handle - Assembly (inc. 2-5) Lever, Choke Cover, Choke

CONTROL SWITCH HOUSING ASSEMBLY Screw, Cap Screw, Cap

C14

om

300 2x4 300 4x4

0732-324

Ref. Part No. Qty. Description 1 2 3 4 5 3409-005 3409-001 3004-533 3004-447 3003-030 1 1 1 1 1

W or

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cTHROTTLE CASE ASSEMBLY6 7 8 9 3423-014 3423-327 3423-199 3004-638 1 1 2 1 Ref. Part No. Qty. Description

Lever Screw, Cap Washer, Lock Washer

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

Screw, Cap Nut Screw, Cap Screw, Cap

D1

om41

Related ItemsModel No. 98A2C-AP & 98A4C-AP

W or

Printed in U.S.A.

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. cARCTIC CATD2

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

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

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

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

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p/n 2255-902

98 arctic cat 300 2x4 parts list

Documents

left 4x4 decal

right 4x4 decal

cylinder assembly

assembly procedures

crankshaft assembly

steering assembly

left 2x4 decal

right 2x4 decal