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Download Arctic Cat A2006TBM4BUSR User's Manual
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500 TRV (Automatic Transmission) ® Model Number A2006TBM4BUSR (Red) Model Number A2006TBM4BUSG (Green) Model Number A2006TBM4BUSZ (Cat Green) Illustrated Parts Manual ARCTIC CAT 2006 TABLE OF CONTENTS 2006 500 TRV Red (Model No. A2006TBM4BUSR) Green (Model No. A2006TBM4BUSG) Cat Green (Model No. A2006TBM4BUSZ) FRONT BODY PANEL ASSEMBLY ..................................................................................................................... 1 REAR BODY PANEL ASSEMBLY ........................................................................................................................ 2 TAILLIGHT ASSEMBLY ....................................................................................................................................... 3 DECALS................................................................................................................................................................. 4 FRAME AND RELATED PARTS .......................................................................................................................... 5 SEAT AND BACKREST ASSEMBLY ................................................................................................................... 6 STEERING POST ASSEMBLY ............................................................................................................................ 7 HANDLEBAR ASSEMBLY .................................................................................................................................... 8 FRONT SUSPENSION ASSEMBLY ..................................................................................................................... 9 REAR SUSPENSION ASSEMBLY ..................................................................................................................... 10 WHEEL AND TIRE ASSEMBLY ......................................................................................................................... 11 AUXILIARY BRAKE ASSEMBLY ........................................................................................................................ 12 HYDRAULIC HAND BRAKE ASSEMBLY ........................................................................................................... 13 HYDRAULIC BRAKE ASSEMBLY ...................................................................................................................... 14 GAS TANK ASSEMBLY ..................................................................................................................................... 15 REVERSE SHIFT LEVER ASSEMBLY .............................................................................................................. 16 AIR INTAKE ASSEMBLY .................................................................................................................................... 17 BATTERY ASSEMBLY ....................................................................................................................................... 18 ENGINE AND EXHAUST .................................................................................................................................... 19 COOLING ASSEMBLY ....................................................................................................................................... 20 CASE/BELT COOLING ASSEMBLY .................................................................................................................. 21 FRONT DRIVE GEARCASE ASSEMBLY .......................................................................................................... 22 REAR DRIVE GEARCASE ASSEMBLY ............................................................................................................. 23 WIRING HARNESS ASSEMBLY ........................................................................................................................ 24 CARBURETOR ................................................................................................................................................... 25 CYLINDER HEAD ASSEMBLY .......................................................................................................................... 26 CYLINDER ASSEMBLY ..................................................................................................................................... 27 CRANKCASE ASSEMBLY ................................................................................................................................. 28 CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY ........................................................................................... 29 CRANKSHAFT ASSEMBLY ............................................................................................................................... 30 STARTER CLUTCH ASSEMBLY ....................................................................................................................... 31 CRANK BALANCER ASSEMBLY ....................................................................................................................... 32 CAMSHAFT/VALVE ASSEMBLY ....................................................................................................................... 33 CAM CHAIN ASSEMBLY ................................................................................................................................... 34 RECOIL STARTER ASSEMBLY ........................................................................................................................ 35 OIL FILTER/PUMP ASSEMBLY ......................................................................................................................... 36 WATER PUMP ASSEMBLY ............................................................................................................................... 37 TRANSMISSION ASSEMBLY ............................................................................................................................ 38 SECONDARY TRANSMISSION ASSEMBLY ..................................................................................................... 39 SECONDARY DRIVE ASSEMBLY ..................................................................................................................... 40 GEAR SHIFTING ASSEMBLY ............................................................................................................................ 41 STARTER MOTOR ASSEMBLY ........................................................................................................................ 42 MAGNETO ASSEMBLY ..................................................................................................................................... 43 CONTROL SWITCH HOUSING ASSEMBLY ..................................................................................................... 44 THROTTLE CASE ASSEMBLY .......................................................................................................................... 45 RELATED ITEMS ..................................................................................................................................Back Cover NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not to be used for assembly. For assembly procedures, use an Arctic Cat Service Manual. Underlined part numbers are new for the 2006 model year. 2005 Arctic Cat Inc. Printed August 2005 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 2006 500 TRV FRONT BODY PANEL ASSEMBLY 0739-662 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 15 16 17 18 19 11 12 13 14 0541-272 1 Rack - Front - Assembly (inc. 2-5) 0411-576 1 Decal, Warning - Front Rack Load 2406-014 6 Bushing, Rack 0441-592 4 Bushing, Rack 1441-049 2 Plug, Rack 8410-830 4 Screw, Machine 0423-463 4 Spacer 0423-465 4 Grommet 8432-802 4 Nut, Lock 1406-614 1 Panel, Fender - Front 1406-613 1 Panel, Fender - Front (Green) 1406-615 1 Panel, Fender - Front (Cat Green) 1406-358 1 Cover, Access 0423-535 2 Rivet, Reinstallable 0623-362 10 Rivet, Reinstallable 1406-484 1 Cover, Steering Post 20 21 22 23 24 25 26 27 Qty. Description 0470-513 1 Cover, Storage Box 1406-573 1 Box, Storage 0470-514 1 Lid, Storage Box 1406-599 1 Latch, Storage Box 1406-313 1 Panel, Side - Right 1406-314 1 Panel, Side - Left 1406-354 1 Panel, Splash - Right 1406-355 1 Panel, Splash - Left 0423-342 4 Screw, Self-Tapping 0423-101 5 Screw, Body 0123-788 AR Cable Tie - 7.5 in. 0411-818 1 Decal, Reflector - Front - Right 0411-819 1 Decal, Reflector - Front - Left 0423-355 2 Screw, Shoulder 8050-222 2 Washer 8424-602 2 Nut, Lock 1 2006 500 TRV REAR BODY PANEL ASSEMBLY 0740-915 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 14 2506-092 1 Bracket, Rear Fender - Right 2506-093 1 Bracket, Rear Fender - Left 15 0423-087 2 Washer 16 0423-540 34 Nut, Lock 17 0423-419 22 Screw, Machine 18 2406-042 1 Footwell, Rear - Right 2406-043 1 Footwell, Rear - Left 19 1506-813 1 Footwell - Right 1506-814 1 Footwell - Left 20 0423-355 8 Screw, Shoulder 21 1506-125 4 Footpeg 22 0623-362 2 Rivet, Reinstallable 23 0423-101 2 Screw, Body 24 8477-620 2 Screw, Machine 25 0623-184 2 Washer 26 8424-602 2 Nut, Hex 1506-873 1441-317 0541-448 0423-635 0423-036 0423-636 0441-592 8410-830 0423-463 0423-465 8432-802 2406-038 2406-039 2406-040 13 0411-820 0411-821 2 1 2 2 2 2 2 4 4 4 4 4 1 1 1 1 1 Rack, Rear - Assembly (inc. 2-7) Cap, Vinyl Pin - Assembly (inc. 4) Pin, Roll Collar Spring Bushing, Rack Screw, Machine Spacer Grommet Nut, Lock Panel, Fender - Red Panel, Fender - Green (Green) Panel, Fender - Cat Green (Cat Green) Decal, Reflector - Right Decal, Reflector - Left Qty. Description 2006 500 TRV TAILLIGHT ASSEMBLY 0739-987 Ref. Part No. Qty. Description 1 0509-022 2 0509-025 3 0409-056 1 Taillight Assembly (inc. 2-4) 1 Housing, Taillight 1 Bulb, Taillight Ref. Part No. 4 0409-057 5 1406-790 6 0423-534 Qty. Description 1 Socket, Taillight 4 Pad, Taillight 2 Grommet 3 2006 500 TRV DECALS 0740-925 *Included on Front/Rear Fender Panels Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 4 1411-250 0411-894 0411-426 1411-074 1411-075 1411-076 1411-077 0411-833 0411-832 1411-258 1411-259 1411-260 1411-261 1411-256 1411-257 1411-014 1411-015 1411-016 1411-017 1411-018 1411-019 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Decal, Warning - Reverse/Pre-Ride* Decal, Warning - Hill Decal, Warning - Clutch Cover Decal, Instrument Pod Decal, Instrument Pod (Green) Decal, Instrument Pod (Cat Green) Decal, Warning - Towing Decal, Passenger Decal, Warning - Tire Pressure Decal, Side - Lower Right Decal, Side - Lower Left Decal, Side - Lower Right (Green) Decal, Side - Lower Left (Green) Decal, Side - Lower Right (Cat Green) Decal, Side - Lower Left (Cat Green) Decal, Side - Upper Right Decal, Side - Upper Left Decal, Side - Upper Right (Green) Decal, Side - Upper Left (Green) Decal, Side - Upper Right (Cat Green) Decal, Side - Upper Left (Cat Green) Ref. Part No. 10 0411-753 11 1411-050 12 0411-840 0411-839 0411-841 13 1411-264 1411-266 1411-262 14 1411-251 15 1411-269 Qty. Description 1 1 1 1 1 2 2 2 1 1 Decal, Warning - Age/General* Decal, “Speedrack” Decal, Front Decal, Front (Green) Decal, Front (Cat Green) Decal, Graphic - TRV Decal, Graphic - TRV (Green) Decal, Graphic - TRV (Cat Green) Decal, Warning - Seat/Passenger Decal, Warning - Passenger 2006 500 TRV FRAME AND RELATED PARTS 0740-926 Ref. Part No. Qty. Description Ref. Part No. 1 1506-864 1 2 0509-034 1 0509-035 1 3 0409-055 4 4 0623-785 4 5 8050-217 8 6 0423-447 4 7 0423-514 2 8 0423-522 2 9 0423-513 2 10 8409-020 4 11 0506-653 1 1506-596 1 12 1506-562 1 1506-563 1 13 8408-816 11 14 15 16 17 18 19 20 21 22 23 24 25 Frame, Main Headlight Assembly - Right (inc. 3) Headlight Assembly - Left (inc. 3) Bulb, Headlight Screw, Self-Tapping Washer Grommet Stud, Adjuster - Headlight Spring, Adjuster Knob, Adjuster Screw, Cap Channel, Bumper Mounting - Right Channel, Bumper Mounting - Left Bracket, Mounting - Bumper - Right Bracket, Mounting - Bumper - Left Screw, Cap Qty. Description 1506-855 1 Bumper 1406-360 1 Grille, Bumper 0423-419 2 Screw, Machine 0423-101 16 Screw, Body 8428-002 2 Nut, Lock 1506-429 1 Brace, A-Arm 8409-025 2 Screw, Cap 2406-091 1 Panel, Belly 0406-289 1 Pad, Frame 8424-802 8 Nut, Flange 8409-016 4 Screw, Cap 1506-846 1 Footrest - Right 1506-847 1 Footrest - Left 26 1506-994 1 Strap, Footrest - Right 1506-995 1 Strap, Footrest - Left 27 1506-548 1 Channel, Shock Support 5 2006 500 TRV SEAT AND BACKREST ASSEMBLY 0740-930 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 1506-937 1 Seat Assembly (inc. 2-9) 1506-209 1 Cover, Seat 1506-208 1 Foam, Seat 2406-144 1 Base, Seat - Assembly (inc. 5-6) 0406-879 2 Bumper, Seat - Rear 0406-877 4 Bumper, Seat - Front 0624-528 AR Staple 1406-592 1 Spring, Seat Latch 1506-156 1 Latch, Seat 1506-938 1 Seat, Passenger - Assembly (inc. 11-20) 2506-064 1 Seat, Passenger - Sub-Assembly (inc. 7 and 12-14) 12 1506-816 1 Foam, Seat - Passenger 6 18 19 20 21 22 23 24 1506-815 2406-110 2406-044 1506-932 2406-112 2406-113 0423-362 8432-802 0624-250 1506-939 1506-818 1506-817 8408-816 Qty. Description 1 1 1 1 1 1 6 6 4 1 1 1 4 Cover, Seat - Passenger Base, Seat - Inner Base, Seat - Passenger Bracket, Seat Support - Assembly Handhold, Passenger - Right Handhold, Passenger - Left Screw Nut, Hex Nut, Lock Backrest Assembly (inc. 22-23) Foam, Backrest Cover, Backrest Screw 2006 500 TRV STEERING POST ASSEMBLY 0739-774 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 8408-860 0405-035 0423-505 0405-166 0405-138 0405-139 0505-451 8408-816 0602-233 0405-052 4 4 2 1 1 1 1 2 1 1 Screw, Cap Cap, Steering Adjuster Screw, Shoulder Cap, Housing Housing, Lower Housing, Upper Post, Steering Screw, Cap Flange, Bearing Bearing w/Inverted Oil Seal 0423-073 8409-020 0505-408 0405-083 0423-013 0405-107 8420-002 0405-082 0423-157 0623-175 Qty. Description 1 1 2 2 2 2 2 2 4 4 Washer Screw, Cap Tie Rod - Assembly (inc. 14-18) Ball Joint, Tie Rod - Left Nut - Left Tie Rod Nut - Right Ball Joint, Tie Rod - Right Nut, Top Lock Pin, Cotter 7 2006 500 TRV HANDLEBAR ASSEMBLY 0740-932 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 8 0505-418 0405-218 0405-149 8050-247 8477-845 0405-147 0409-013 3430-040 3409-007 3409-011 3409-012 3409-013 1 2 2 2 2 2 1 1 1 1 1 1 Tube, Handlebar Plug, Handlebar End Cap, Handlebar Washer Screw, Machine Grip, Handlebar Cover, Key Switch, Ignition - Assembly (inc. 9) Key, Ignition - Blank (C Series) Key, Ignition - Blank (D Series) Key, Ignition - Blank (E Series) Key, Ignition - Blank (F Series) Ref. Part No. 10 1506-578 11 0405-188 0405-189 0405-190 12 0423-535 13 0420-065 14 0520-015 15 0423-493 16 0641-897 Qty. Description 1 1 1 1 2 1 1 2 1 Bracket, Mounting - Instrument Pod Instrument Pod Instrument Pod (Green) Instrument Pod (Cat Green) Rivet, Reinstallable Clamp Gauge, LCD Nut, Hex Outlet, Accessory - 12V 2006 500 TRV FRONT SUSPENSION ASSEMBLY 0739-603 *Not a Service Part Ref. Part No. Qty. Description 1 2 3 4 5 6 1603-889 2 Retainer, Spring 0403-137 2 Shock Absorber - Front (inc. 3-4) 0604-310 8 Bushing, Shock Absorber 0403-028 4 Sleeve, Shock 0403-102 2 Cam, Spring Adjuster 0503-318 2 Spring, Shock Absorber - Platinum 0503-317 2 Spring, Shock Absorber - Black (Green) 7 8409-040 4 Screw, Cap 8 8428-002 10 Nut, Lock 9 0503-272 1 A-Arm, Upper Right - Platinum (inc. 10-13) 0503-273 1 A-Arm, Upper Left - Platinum (inc. 10-13) 0503-196 1 A-Arm, Upper Right - Black (inc. 10-13) (Green) 0503-197 1 A-Arm, Upper Left - Black (inc. 10-13) (Green) 10 0403-081 4 Bushing 11 0403-080 2 Collar 12 0423-009 4 Clip, Ball Joint 13 0405-115 4 Ball Joint - Front 14 0503-268 1 A-Arm, Lower Right - Platinum (inc. 12-13 and 15-16) 0503-269 1 A-Arm, Lower Left - Platinum (inc. 12-13 and 15-16) 0503-220 1 A-Arm, Lower Right - Black (inc. 12-13 and 15-16) (Green) 0503-221 1 A-Arm, Lower Left - Black (inc. 12-13 and 15-16) (Green) Ref. Part No. 15 0403-115 16 0403-114 17 0505-460 0505-461 18 * * 19 1402-027 20 0423-423 21 8409-030 22 0423-334 23 8409-075 24 0502-812 25 0441-400 26 0436-276 27 0441-752 0441-753 1441-002 1441-003 0441-756 0441-757 28 0423-101 29 0441-587 Qty. Description 8 4 1 1 1 1 2 2 4 2 4 2 2 2 1 1 1 1 1 1 4 1 Bushing Collar Knuckle - Assembly - Right (inc. 18-20) Knuckle - Assembly - Left (inc. 18-20) Knuckle, Steering - Right Knuckle, Steering - Left Bearing, Wheel Hub Ring, Retaining Screw, Cap Screw, Cap Screw, Cap Axle - Front (inc. 25-26) Clip, Retaining Repair Kit, Boot - Front Guard, Boot - Right Guard, Boot - Left Guard, Boot - Right (Green) Guard, Boot - Left (Green) Guard, Boot - Right (Cat Green) Guard, Boot - Left (Cat Green) Screw, Body Wrench, Spanner 9 2006 500 TRV REAR SUSPENSION ASSEMBLY 0740-933 Ref. Part No. Qty. Description 1 0504-372 0504-373 2 1402-027 3 0423-423 4 0403-038 5 0403-032 6 0504-326 1 1 2 2 4 8 1 0504-327 1 0504-320 1 0504-321 1 7 8 9 10 11 10 0403-115 16 0403-114 8 8428-002 14 8409-000 4 0504-330 1 0504-331 1 0504-318 1 0504-319 1 Knuckle, Right Rear - Assembly (inc. 2-5) Knuckle, Left Rear - Assembly (inc. 2-5) Bearing, Wheel Hub Ring, Retaining Collar, Suspension Bushing Bushing, Suspension A-Arm, Rear - Lower Right - Platinum (inc. 7-8) A-Arm, Rear - Lower Left - Platinum (inc. 7-8) A-Arm, Rear - Lower Right - Black (inc. 7-8) (Green) A-Arm, Rear - Lower Left - Black (inc. 7-8) (Green) Bushing Collar Nut, Lock Screw, Cap A-Arm, Rear - Upper Right - Platinum (inc. 7-8) A-Arm, Rear - Upper Left - Platinum (inc. 7-8) A-Arm, Rear - Upper Right - Black (inc. 7-8) (Green) A-Arm, Rear - Upper Left - Black (inc. 7-8) (Green) Ref. Part No. 12 0441-754 0441-755 1441-004 1441-005 0441-758 0441-759 13 0423-101 14 1406-071 1406-072 15 0502-811 16 0441-400 17 0436-276 18 8409-075 19 1603-889 20 0404-127 0404-126 21 0404-099 22 0604-310 23 0403-028 24 0404-057 25 8409-050 26 0423-087 27 8408-820 28 0441-875 Qty. Description 1 1 1 1 1 1 6 1 1 2 2 2 8 2 2 2 2 8 2 2 2 2 2 1 Guard, Boot - Right Guard, Boot - Left Guard, Boot - Right (Green) Guard, Boot - Left (Green) Guard, Boot - Right (Cat Green) Guard, Boot - Left (Cat Green) Screw, Body Guard, Boot - Right Guard, Boot - Left Axle (inc. 16-17) Clip, Retaining Repair Kit, Boot - Rear Screw, Cap Retainer, Spring Spring, Suspension - Platinum Spring, Suspension - Black (Green) Shock Absorber - Rear (inc. 22-23) Bushing, Shock Absorber Sleeve, Shock Absorber Cam, Spring Adjuster Screw, Cap Washer Screw, Cap Wrench, Spanner 2006 500 TRV WHEEL AND TIRE ASSEMBLY 0740-358 Ref. Part No. Qty. Description 1 2 3 4 5 0423-557 12 Screw, Shoulder w/Loctite 1402-225 3 Disc, Brake 0502-599 2 Hub, Wheel - Front (inc. 4) 0402-974 16 Stud, Wheel Hub 0502-601 1 Hub, Wheel - Rear - Left (inc. 4) 0502-599 1 Hub, Wheel - Rear - Right (inc. 4) 6 0423-607 4 Nut, Castle Flange 7 0423-407 4 Pin, Cotter 8 1402-127 2 Wheel - Front - Platinum 1402-115 2 Wheel - Rear - Platinum 0402-856 2 Wheel - Front - Gray (Green) 0402-858 2 Wheel - Rear - Gray (Green) Ref. Part No. Qty. Description 9 0423-408 16 Nut, Mounting - Wheel 10 1402-100 2 Tire - Front 1402-137 2 Tire - Rear 11 0402-064 4 Stem, Valve (inc. 12) 12 0402-140 4 Cap, Valve Stem 11 2006 500 TRV AUXILIARY BRAKE ASSEMBLY (Fully Bled Master Cylinder Replacement Kit p/n 0502-939) 0740-359 *Not a Service Part Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 0423-178 0423-413 0502-840 8408-625 0502-785 8408-820 0502-602 0502-603 4 2 1 2 1 2 1 1 25 26 27 28 29 30 0502-606 0502-607 0502-609 0502-608 0502-605 0502-875 1 1 1 1 1 1 12 0502-805 1602-213 8050-252 8408-816 0502-807 1402-377 8050-217 0402-584 0502-881 * 0502-880 0502-877 0623-038 8476-616 0123-788 1402-417 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Lever, Brake O-Ring Washer Screw, Cap Spring, Brake Lever Pin, Clevis Washer Pin, Cotter Brake Assembly (inc. 10-12) Master Cylinder Hose, Brake Reservoir Reservoir, Brake Nut, Flanged Screw, Machine Cable Tie - 7.5 in. Hose, Brake Qty. Description Washer, Crush Bolt, Banjo Fitting Bracket, Switch Screw, Cap Spring, Brake Switch Screw, Cap Caliper, Brake (inc. 24-30) Housing, Caliper - Assembly Right Front (inc. 25-27) Piston/Seal Set (inc. 26) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set 2006 500 TRV HYDRAULIC HAND BRAKE ASSEMBLY 0739-479 Ref. Part No. Qty. Description 1 2 3 4 5 6 0502-914 0502-566 0502-868 0502-568 0502-869 0502-704 1 1 1 1 1 1 Brake Assembly (inc. 2-10) Screw, Reservoir Cover - Kit Cover, Reservoir - Kit Screw, Master Cylinder Clamp - Kit Clamp, Master Cylinder - Kit Master Cylinder Assembly - Kit Ref. Part No. 7 8 9 10 11 12 0502-866 0502-867 0502-580 0502-564 0423-178 0423-413 Qty. Description 1 1 1 1 2 1 Lever Assembly - Kit (inc. 8-9) Lock, Brake Lever - Kit Lever Pin - Kit Switch, Brake - Kit Washer, Crush Bolt, Banjo Fitting 13 2006 500 TRV HYDRAULIC BRAKE ASSEMBLY 0740-935 Ref. Part No. Qty. Description 1 2 3 4 0502-628 8476-625 8408-820 0502-602 0502-610 5 0502-603 0502-611 14 1 1 6 1 2 Hose, Brake - Assembly Screw, Cap Screw, Cap Caliper, Brake - Right Front (inc. 5-11) Caliper, Brake - Left Front and Right Rear (inc. 5-11) 1 Housing, Caliper - Assembly Right Front (inc. 6-8) 2 Housing, Caliper - Assembly Left Front and Right Rear (inc. 6-8) Ref. Part No. 6 7 8 9 10 11 12 13 0502-606 0502-607 0502-609 0502-608 0502-605 0502-875 0423-178 0423-413 Qty. Description 3 3 3 3 3 3 6 3 Piston/Seal Set (inc. 7) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Washer, Crush Bolt, Banjo Fitting 2006 500 TRV GAS TANK ASSEMBLY 0740-936 Ref. Part No. Qty. Description Ref. Part No. 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 0570-111 0470-438 0109-733 0570-114 0423-603 0470-475 0470-521 1623-158 0470-567 0570-131 8476-650 8427-602 0570-132 1 1 1 1 1 1 1 4 1 1 2 2 1 Tank, Gas - Assembly (inc. 2-13) Cap, Gas Tank (inc. 3) Gasket, Gas Tank Cap Sensor, Fuel Level (inc. 5-7) Clamp, Hose Filter, Fuel Seal, Fuel Level Sensor Screw, Self-Tapping Plate, Mounting - Fuel Level Sensor Strap, Gas Tank Mounting Screw, Machine Nut Strap, Gas Tank Mounting Qty. Description 0423-461 4 Clamp, Hose 0410-070 AR Hose, Gasline - 25 ft 1623-233 6 Clamp, Hose 0470-527 1 Fitting, Straight 0470-519 1 Pump, Fuel 8476-620 2 Screw, Machine 0623-038 2 Nut, Lock 0470-479 1 Shield, Heat 0470-474 1 Shield, Heat 0623-797 5 Screw, Self-Tapping 0470-536 2 Clip, Gas Tank Mounting 0423-609 2 Screw, Gas Tank Mounting 15 2006 500 TRV REVERSE SHIFT LEVER ASSEMBLY 0739-701 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 16 0402-843 0423-345 1402-110 0423-357 0502-659 0502-410 0502-742 8424-602 0423-182 0402-675 1 1 1 4 1 1 1 1 2 1 Knob, Reverse Shift Lever Clip, Push Plate, Shift Nut, Stamped Lever, Reverse Shift Spring, Reverse Shift Lever Shaft, Shift Lever Nut O-Ring Axle, Pivot 0423-299 8408-812 0423-087 0623-294 1402-270 0502-989 0423-091 8050-242 0423-169 Qty. Description 2 1 1 2 1 1 1 1 1 O-Ring Screw, Cap Washer Nut End, Rod Linkage, Shift Bushing, Shift Linkage Washer E-Ring 2006 500 TRV AIR INTAKE ASSEMBLY 0740-791 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 0413-091 0413-093 0470-442 0423-551 0470-529 1406-747 0623-362 0423-342 0423-454 0470-515 0423-455 1 1 2 2 1 1 2 6 2 1 4 Diverter, Air - Top Diverter, Air - Bottom Valve, Drain Clamp, Boot Boot, Air Intake Shroud, Splash Rivet, Reinstallable Screw, Self-Tapping Clip, Mounting - Air Intake Housing, Air Intake Clip, Spring 0470-525 0423-554 0470-516 0470-494 0470-554 0410-079 0423-045 0423-019 0470-533 0510-592 Qty. Description 1 1 1 1 1 1 2 1 1 1 Boot, Carburetor Clamp, Boot Screen, Air Filter Filter, Air Cover, Air Intake Hose, Vent - Crankcase Clamp, Hose Clamp, Boot Carburetor, CVK36-AE Hose, Carburetor Drain 17 2006 500 TRV BATTERY ASSEMBLY 0740-445 *Not Illustrated Ref. Part No. Qty. Description 1 2 3 * 4 5 18 5990-839 1406-507 0406-288 0444-122 0745-045 0645-045 1 1 2 1 1 6 Ref. Part No. Battery Cover/Tool Tray Assembly (inc. 2-3) 6 0645-152 Cover, Battery 7 0645-263 Pad, Battery 8 0645-151 9 0123-903 Kit, Tool Battery Assembly (inc. 5-8) 10 8476-616 Cap, Battery 11 0623-101 Qty. Description 1 1 1 4 2 1 Clamp, Hose Hose, Battery Vent Label, Warning - Battery Cable Tie - 11.5 in. Screw, Machine Routing Clip, Snap-In 2006 500 TRV ENGINE AND EXHAUST 0740-958 Ref. Part No. Qty. Description Ref. Part No. 1 0462-029 1 Engine 2 1506-740 1 Bracket, Engine Mounting - Right 1506-741 1 Bracket, Engine Mounting - Left 3 0423-405 2 Screw, Cap 4 0423-042 2 Spacer 5 8428-002 2 Nut, Lock 6 2406-065 4 Mount, Rubber - Engine 7 8408-820 10 Screw, Cap 8 8408-012 4 Screw, Cap 9 8432-802 8 Nut 10 0512-276 1 Pipe, Exhaust - Assembly (inc. 11-16) 11 0412-355 1 Shield, Exhaust Pipe 12 0412-354 1 Shield, Exhaust Pipe 13 0412-349 1 Shield, Exhaust Pipe 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0412-348 0512-278 0423-317 0412-007 0412-256 0612-668 0412-215 1506-732 0512-306 8408-616 0512-219 0412-313 0412-373 8477-610 Qty. Description 1 1 4 1 1 2 3 1 1 3 1 1 1 3 Shield, Exhaust Pipe Pipe, Exhaust Hose Clamp Seal, Exhaust Seal, Exhaust Spring, Extension Bushing, Exhaust Pipe Channel, Muffler Support Muffler - Assembly (inc. 23-25) Screw, Cap Arrester, Spark - Assembly Gasket, Spark Arrester Cover, Muffler Screw, Machine 19 2006 500 TRV COOLING ASSEMBLY 0740-446 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 20 0413-117 1 Radiator Assembly (inc. 2-13) 0413-043 1 Radiator 0413-007 1 Screen, Radiator 0413-002 1 Cap, Radiator 0423-030 2 Grommet 0610-016 AR Hose - 25 ft 0413-046 1 Shroud, Fan 0413-123 1 Fan, Cooling 8475-512 12 Screw, Machine 0423-351 1 Clamp, Wire 0123-397 1 Clamp, Cable 0413-045 0423-390 0423-484 0623-038 0423-028 0410-002 0410-022 0410-041 0423-496 0623-751 Qty. Description 1 1 2 2 2 1 1 1 6 1 Sender, Temperature - Coolant O-Ring Screw, Shoulder Nut w/Washer Bushing, Stem Hose, Coolant - Upper Hose, Coolant - Crossover Hose, Coolant - Lower Clamp, Hose Cable Tie 2006 500 TRV CASE/BELT COOLING ASSEMBLY 0740-881 Ref. Part No. Qty. Description 1 2 3 4 5 6 0423-342 0423-551 0413-092 0513-010 0470-442 0413-049 3 3 1 1 2 1 Screw, Self-Tapping Clamp, Boot Boot, Air-In Duct, Belt Cooling - Front Valve, Drain Boot, Duct - Front Ref. Part No. 7 8 9 10 11 12 3402-449 0413-055 0423-380 0413-106 0623-301 0123-903 Qty. Description 2 1 1 1 1 1 Clamp, Boot Boot, Duct - Rear Clamp, Duct Duct, Belt Cooling - Rear Screw, Self-Tapping Cable Tie - 11.5 in. 21 2006 500 TRV FRONT DRIVE GEARCASE ASSEMBLY 0740-941 Ref. Part No. Qty. Description 1 0502-816 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 22 0502-385 0423-411 0402-985 0423-393 1402-045 0502-407 1402-011 0423-423 0502-347 1402-043 0423-118 0502-528 0402-947 0423-417 0502-296 0423-498 0402-997 0402-998 0402-417 0423-402 0423-147 0402-999 0402-413 0402-357 0502-783 1 Gearcase, Front Drive - Assembly (inc. 2-43) 1 Shaft, Propeller - Assembly (inc. 3-7) 1 Clamp, Boot 1 Boot, Propeller Shaft 1 Clamp, Boot 1 Shaft, Output 1 Shaft, Input 1 Seal 1 Ring, Retaining 1 Bracket, Actuator 1 Bearing 11 Screw, Self-Tapping 1 Housing, Pinion 1 Gasket, Flange 1 Ring, Retaining 1 Actuator (inc. one No. 17) 2 O-Ring 1 Shaft, Selector 1 Fork, Selector 1 Shaft, Shuttle 1 Ring, Retaining 1 O-Ring 1 Spring, Return 1 Coupler, Drive 1 Collar, Lock 1 Gear, Pinion - Assembly - 10T (inc. 27-28) Ref. Part No. Qty. Description 27 28 29 30 31 32 33 34 35 36 37 1 1 1 1 1 2 1 1 1 2 AR AR AR AR AR 1 1 1 1 1 3 1 1 2 4 2 1 38 39 40 41 42 43 44 45 46 47 48 49 0402-336 0402-327 0402-328 0502-120 0402-411 0402-394 0402-450 0423-153 0423-149 0402-393 0402-405 0402-406 0402-407 0402-408 0402-409 0502-779 0502-121 1402-104 0402-333 0423-154 0423-396 0423-315 0402-147 0423-404 0423-426 8428-002 0402-966 Collar, Retaining Bearing Bearing Housing, Gearcase Pin, Dowel Seal Plug, Magnetic (inc. 34) O-Ring O-Ring Bearing Shim Shim Shim Shim Shim Gear, Ring - 36T Cover, Gearcase Fitting Plug, Fill (inc. 42) O-Ring Screw, Self-Tapping Clamp, Fitting Bladder, Gearcase Screw, Cap Washer Nut, Lock Boot, Shaft 2006 500 TRV REAR DRIVE GEARCASE ASSEMBLY 0740-972 Ref. Part No. Qty. Description 1 0502-820 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0502-622 0402-393 0402-394 1402-032 0402-405 0402-406 0402-407 0402-408 0402-409 0402-326 0402-429 0402-430 0402-431 0402-432 0402-433 0423-149 0502-346 0402-333 0423-154 1402-102 0423-118 0402-450 0423-153 0402-328 0402-411 0502-783 1 Gearcase, Rear Drive - Assembly (inc. 231) 1 Housing, Gearcase 2 Bearing 2 Seal 1 Gear, Ring - 36T AR Shim AR Shim AR Shim AR Shim AR Shim 1 Button, Thrust AR Shim AR Shim AR Shim AR Shim AR Shim 1 O-Ring 1 Cover, Gearcase 1 Plug, Fill (inc. 12) 1 O-Ring 1 Fitting 11 Screw, Self-Tapping 1 Plug, Magnetic (inc. 16) 1 O-Ring 1 Bearing 1 Pin, Dowel 1 Gear, Pinion - Assembly - 10T (inc. 2021) Ref. Part No. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 Qty. Description 0402-327 1 Bearing 0402-336 1 Collar, Retaining 0402-331 1 Collar, Lock 0402-982 1 Washer, Wave 0402-981 1 Collar, Shaft 0402-947 1 Gasket, Flange 0502-529 1 Housing, Pinion 0423-417 1 Ring, Retaining 1402-043 1 Bearing 0423-423 1 Ring, Retaining 1402-011 1 Seal 0502-407 1 Shaft, Input 0423-393 2 Clamp, Boot 0402-985 2 Boot 0423-411 2 Clamp, Boot 0673-618 2 Bumper, Propeller Shaft 1402-092 1 Shaft, Propeller 0402-950 1 Flange, Output 8408-820 4 Screw, Cap 0423-404 2 Screw, Cap 0423-426 6 Washer 8428-002 2 Nut, Lock 0423-315 3 Clamp, Fitting 0410-049 AR Hose, Vent 0470-462 1 Fitting, Vent 0623-101 1 Clip, Routing - Snap-In 0402-147 1 Bladder, Gearcase 1402-026 1 Spring 23 2006 500 TRV WIRING HARNESS ASSEMBLY 0740-942 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 24 0486-192 1 Harness, Main (inc. 2-8 and two No. 9) 0530-008 1 Cover, Fuse Block 0430-037 1 Holder, Fuse 0430-034 3 Diode 0430-033 2 Relay 0430-032 4 Fuse - 10 Amp 0430-031 3 Fuse - 15 Amp 0430-030 2 Fuse - 30 Amp 0411-838 1 Decal, Fuse Block 0486-164 1 Tether, Accessory Connector 0123-788 AR Cable Tie - 7.5 in. 0445-044 1 Cable, Solenoid/Starter 0623-038 8 Nut w/Washer 0645-327 1 Boot, Terminal 0445-046 1 Cable, Battery/Solenoid 0645-019 1 Boot, Terminal Ref. Part No. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 8476-625 0445-036 0412-291 1406-600 0123-010 0623-121 3530-039 0409-072 3530-028 0445-045 3530-027 3430-009 3430-007 3430-008 8476-620 Qty. Description 4 1 1 1 4 4 1 1 1 1 1 1 1 1 2 Screw, Machine Relay Assembly - Starter Shield, Heat Tray, Electrical Nut, Expansion Screw, Machine CDI Unit Switch, Brake - Assembly Regulator, Voltage Cable, Battery/Ground Coil, Ignition - Assembly Seal, High Tension Wire Cap, Spark Plug Seal, Spark Plug Screw, Machine 2006 500 TRV CARBURETOR CVK36-AE (Complete Carburetor Assembly p/n 0470-533) 0740-600 *Not a Service Part **Optional Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 5507-001 5507-002 5507-173 5507-099 5507-005 5507-184 5507-007 5507-174 5507-043 5507-009 5507-044 5507-086 5507-101 5507-112 5507-183 * 5507-039 * 5507-111 * * 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Cover, Top Screw, Top Cover Spring Piston, Vacuum Seat, Spring Jet Needle Needle Jet Holder, Needle Jet Main Jet - 142 Main Jet - 150** Main Jet - 140** Main Jet - 148** Slow Jet - 40 Starter Jet - 85 Valve, Float - Set (inc. 13) Clip Float Set (inc. 15) Pin, Float Screw, Pilot Air - Set (inc. 17-19) Spring Washer Ref. Part No. 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 * 5507-027 5507-028 5507-029 5507-115 5507-117 5507-113 5507-114 5507-181 5507-050 5507-032 5507-031 * 5507-034 5507-035 5507-017 0487-021 5507-036 5507-037 0410-056 0423-317 Qty. Description 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 4 1 1 1 1 1 O-Ring Screw, Idle Adjust Washer Spring Plate Screw Choke, Electric Cover, Electric Choke Chamber, Float - Assembly (inc. 28-33) Screw, Drain Spring Diaphragm Assembly Housing, Pump U-Ring Screw Screw Cable, Throttle Cover Screw Hose, Vent Clamp, Hose 25 2006 500 TRV CYLINDER HEAD ASSEMBLY 0739-959 *Not Illustrated Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 * 26 3402-098 3423-043 3402-099 3423-006 3008-376 3402-362 3423-088 3423-015 3423-016 3423-089 3423-087 3423-203 3423-007 3004-376 3004-488 3004-326 1 2 4 4 2 1 2 2 2 2 2 1 2 4 5 1 Head, Cylinder - Assembly (inc. 2-5) Pin, Dowel Guide, Valve Screw, Cap Screw, Cap Gasket, Cylinder Head Pin, Dowel Screw, Cap Screw, Cap Bolt, Stud Bolt, Stud Bolt, Stud Screw, Cap Screw, Cap Nut Nut 3003-290 3402-010 0217-632 3402-100 3402-101 3004-341 3423-383 3402-035 0570-092 0470-531 8476-620 0423-317 3530-038 3413-004 3413-012 3402-048 Qty. Description 4 4 1 2 2 5 1 1 1 1 2 1 1 1 1 1 Gasket Gasket, Head Nut Spark Plug (NGK CR6E) Cap, Inspection O-Ring Screw, Cap Bolt, Stud Plug, Cylinder Head Manifold, Intake O-Ring Screw, Machine Clamp Switch, Water Temperature - Assembly Cover, Thermostat Thermostat Plug, Frost 2006 500 TRV CYLINDER ASSEMBLY 0732-301 Ref. Part No. Qty. Description 1 2 3 4 3402-707 3423-384 3004-488 3402-365 1 2 2 1 Cylinder Bolt, Stud Nut Gasket, Cylinder Ref. Part No. 5 6 7 8 3423-088 3413-013 3423-121 3423-058 Qty. Description 2 1 1 1 Pin, Dowel Union, Water Hose Screw, Cap O-Ring 27 2006 500 TRV CRANKCASE ASSEMBLY 0737-757 Ref. Part No. Qty. Description 1 3402-708 2 3 4 5 6 7 8 9 10 11 28 3423-088 3004-822 3423-091 3423-119 3423-092 3004-880 3005-332 3423-385 3402-436 3423-386 1 Crankcase Assembly (inc. two No. 2 and 3-14) 4 Pin, Dowel 1 Pin, Dowel 4 Bolt 3 Bolt 3 Bolt 4 Bolt 1 Bolt 1 Bolt 2 Gasket 1 Plug Ref. Part No. 12 13 14 15 16 17 18 19 20 21 22 3423-387 3423-388 3423-508 3402-439 3423-506 3402-437 3423-389 3402-214 3402-012 3402-438 3423-055 Qty. Description 1 1 1 1 3 1 1 1 1 1 1 Bolt Bolt Bolt Housing, Secondary Shaft Bearing Bolt Pipe, Breather Bolt, Breather Pipe Plug, Oil Pressure Gasket, Oil Pressure Plug Stick, Oil Level O-Ring, Oil Level Stick 2006 500 TRV CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY 0737-759 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 3402-710 3402-711 3402-712 3402-713 3423-435 3423-088 3402-443 3402-444 3004-705 3402-709 3402-441 1 1 2 1 7 6 1 1 1 1 1 Cover, V-Belt Damper, V-Belt Cover Damper, V-Belt Cover Plate, V-Belt Cover Screw Pin, Dowel Gasket, V-Belt Cover Gasket, Drain Plug Plug, Drain Cover, Clutch Gasket, Clutch Cover Qty. Description 3402-445 1 Plate, Air Intake 3402-699 1 Cushion, Air Intake Plate 3402-714 1 Cover, Magneto 3402-715 1 Gasket, Magneto Cover 3402-041 1 Plug, Oil Filler 3402-013 1 Gasket, Oil Filler Plug 3423-098 26 Bolt 3423-092 2 Bolt 3004-756 2 Bolt 3423-091 14 Bolt 3423-119 2 Bolt 29 2006 500 TRV CRANKSHAFT ASSEMBLY 0737-077 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 30 3403-018 3402-376 3402-377 3402-717 3423-351 3403-025 3402-705 3402-058 1 1 1 1 2 1 1 1 Crankshaft Assembly (inc. 2-7) Rod, Connecting Pin, Crank Bearing Washer Crankshaft - Right Crankshaft - Left Bearing - Right Ref. Part No. 9 10 11 12 13 14 15 16 3402-054 3402-188 3402-788 3402-719 3402-720 3423-344 3402-375 3423-018 Qty. Description 1 1 1 1 1 2 1 3 Bearing - Left Retainer, Oil Seal - Left Piston Set (inc. 12-14) Piston Ring, Piston - Set Circlip, Piston Pin Pin, Piston Screw 2006 500 TRV STARTER CLUTCH ASSEMBLY 0735-612 Ref. Part No. Qty. Description 1 2 3 4 5 3402-813 3423-331 3402-349 3423-396 3423-397 1 1 1 1 1 Gear, Starter Idler - No. 1 Pin Gear, Starter Idler - No. 2 Spacer, Starter Idler Gear No. 2 Pin Ref. Part No. 6 7 8 9 3402-457 3402-063 3423-104 3423-509 Qty. Description 1 1 1 6 Clutch, Starter - Set (inc. 7) Bearing Washer Screw, Cap 31 2006 500 TRV CRANK BALANCER ASSEMBLY 0737-762 Ref. Part No. Qty. Description 1 2 3 4 5 32 3423-555 3423-401 3402-390 3423-110 3402-461 1 1 1 1 1 Bolt Washer Gear, Oil Pump Drive Pin Spacer Ref. Part No. 6 7 8 9 3402-050 3402-814 3004-540 3402-458 Qty. Description 2 1 1 1 Bearing Gear, Driven Key Balancer, Crank 2006 500 TRV CAMSHAFT/VALVE ASSEMBLY 0737-800 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 3402-723 3402-352 3423-047 3423-073 3423-013 3423-071 3402-805 8 3423-075 9 3423-076 10 3402-139 1 1 1 1 2 1 1 Camshaft Sprocket Pin Washer Bolt C-Ring Arm, Valve Rocker - Intake (inc. two No. 8-9) 4 Screw 4 Nut 1 Arm, Valve Rocker - Exhaust (inc. two No. 8-9) Ref. Part No. 11 12 13 14 15 16 17 18 19 20 21 22 3402-148 3402-078 3402-140 3402-141 3423-031 3402-040 3402-012 3402-725 3402-143 3402-726 3423-541 3402-147 Qty. Description 4 4 1 1 2 2 2 2 2 4 4 8 Seat, Spring Seal, Oil Shaft, Rocker Arm Shaft, Rocker Arm Washer Plug, Shaft Gasket Valve, Intake Valve, Exhaust Spring, Valve Retainer, Spring Cotter, Valve 33 2006 500 TRV CAM CHAIN ASSEMBLY 0732-308 Ref. Part No. Qty. Description 1 2 3 4 5 34 3402-353 3402-355 3402-356 3423-074 3003-188 1 1 1 1 1 Chain, Cam Guide, Chain Tensioner, Chain Bolt Washer Ref. Part No. 6 7 8 9 3402-136 3402-137 3004-475 3003-290 Qty. Description 1 1 2 2 Adjuster, Tensioner - Assembly Gasket Screw, Cap Gasket 2006 500 TRV RECOIL STARTER ASSEMBLY 0737-764 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 3445-003 3445-011 3445-007 3445-004 3445-016 3004-488 3423-428 1 1 1 1 1 1 4 Starter, Recoil - Assembly (inc. 2-6) Rope Assembly Spring, Spiral Reel Ratchet Assembly Nut Screw, Cap Ref. Part No. 8 9 10 11 12 13 14 3004-491 3445-029 3423-053 3423-063 3402-119 3402-070 3402-051 Qty. Description 1 1 1 1 1 1 1 Nut Cup, Starter O-Ring O-Ring Spacer Seal, Oil Bearing 35 2006 500 TRV OIL FILTER/PUMP ASSEMBLY 0737-765 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 36 3402-727 3402-463 3423-046 3423-443 3423-184 3423-510 3402-156 0693-389 1 1 1 1 1 3 1 2 Pump, Oil Gear, Driven Pin Washer Circlip Screw, Cap Strainer, Oil Screw, Cap Ref. Part No. 9 10 11 12 13 14 15 16 3402-157 3423-077 3004-756 0812-005 3403-021 3402-012 3402-154 3402-158 Qty. Description 1 1 4 1 1 1 1 1 Cap, Oil Strainer O-Ring Screw, Cap Filter, Oil Plug, Drain Gasket, Drain Plug Valve, Oil Relief - Assembly Union, Oil Filter 2006 500 TRV WATER PUMP ASSEMBLY 0737-766 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 3402-464 3423-343 3003-188 3423-402 3413-014 3005-909 3402-465 3003-615 3423-403 3423-404 3003-484 1 1 1 1 1 1 1 1 1 1 2 Pump, Water - Assembly (inc. 2-11) Screw, Cap Gasket O-Ring Impeller/Shaft Seal, Mechanical Seal, Oil Bearing E-Ring O-Ring Screw 3423-308 3402-026 3402-466 3423-046 3423-184 3402-467 3423-405 3402-390 3423-110 3423-189 Qty. Description 2 1 1 1 2 1 1 1 1 1 Screw, Cap Gear, Driven Shaft, Driven Gear Pin, Driven Gear Circlip, Driven Gear Bearing, Shaft Circlip, Shaft Bearing Gear, Water Pump Drive Pin, Drive Gear Circlip, Drive Gear 37 2006 500 TRV TRANSMISSION ASSEMBLY 0737-771 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 38 3402-750 3402-751 3402-470 3402-471 3402-752 3402-753 3402-474 3402-475 3402-476 3402-477 3402-478 3402-755 3402-756 3402-481 3423-406 3402-482 3402-483 1 1 2 1 1 1 1 2 2 4 4 1 1 4 1 1 8 Face, Fixed Drive Face, Movable Drive Seal, Movable Drive Face Spacer, Movable Drive Face Face, Fixed Driven Face, Movable Driven Spring, Movable Driven Face O-Ring, Movable Driven Face Seal, Movable Driven Face Pin, Movable Driven Face Spacer, Movable Driven Face Plate, Movable Drive Face Sleeve, Movable Driven Face Damper, Movable Drive Face Nut, Driven Pulley Holder, Movable Driven Face Spring Roller, Movable Drive Face 3423-514 3402-757 3402-758 3402-544 3402-808 3402-488 3446-003 3402-760 3446-031 3423-435 3402-567 3402-729 3423-353 3402-761 3423-501 3402-730 3423-018 Qty. Description 2 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 2 Nut V-Belt Housing, Clutch Spacer, Fixed Drive Face Seal, Clutch Housing - Center Seal, Clutch Housing - Left Clutch, One-Way Shoe, Clutch - Assembly Retainer, Bearing Screw, Bearing Retainer Bearing Bearing O-Ring Seal, Clutch Housing - Right Nut Retainer, Bearing Screw 2006 500 TRV SECONDARY TRANSMISSION ASSEMBLY 0738-929 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 3402-045 3402-381 3402-497 3423-066 3402-821 3402-825 3423-263 3402-494 3402-498 3402-822 3423-266 3402-820 3423-262 3402-668 3423-554 3402-824 3402-733 3423-412 3402-836 3423-518 3402-837 3423-556 2 1 1 2 1 1 2 3 3 1 1 1 1 1 2 1 1 1 1 1 1 1 Bearing, Shaft Washer, Drive Gear No. 2 - Right Gear, Drive - No. 2 Circlip Dog, Reverse Driven Gear Spacer, Reverse Driven Gear Washer Bushing Bearing Gear, Reverse Driven Washer, Lock Countershaft Washer, Lock Gear, Driven - Low Washer, Driven Gear Dog, Sliding Gear, Driven - High Washer, Drive Gear - Left Seal, Countershaft - Left Circlip Rotor Washer 3423-557 3446-289 3006-547 3446-355 3003-290 3423-091 3402-838 3423-226 3402-735 3402-835 3402-502 3402-534 3446-031 3423-435 3402-537 3402-499 3402-731 3003-261 3402-195 3402-503 3446-103 3402-507 Qty. Description 1 1 2 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 2 1 1 1 Circlip Gasket Pin Housing, Speedometer Sensor Gasket Bolt Sensor, Speedometer Bolt Bearing, Shaft Shaft, Output Bearing, Output Shaft Gear, Driven - No. 2 Retainer, Bearing Screw, Bearing Retainer Seal, Driveshaft - Left Bearing, Driveshaft - Right Driveshaft Bearing, Driveshaft - Left Washer, Reverse Idle Gear Gear, Reverse Idle Bushing, Reverse Idle Gear Shaft, Reverse Idle 39 2006 500 TRV SECONDARY DRIVE ASSEMBLY 0740-798 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 40 3402-327 3402-562 3423-479 3423-025 3423-028 3402-742 3402-743 3402-072 3402-067 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 1 1 4 2 2 1 1 2 2 AR AR AR AR AR AR AR AR AR AR AR AR AR Yoke, Propeller Shaft Joint Joint, Universal - Set (inc. 3) Circlip Nut, Rear Output Joint Washer, Rear Output Flange Yoke, Drive Output - Front (inc. 7) Plate, Output Yoke Seal, Oil - Driven Shaft Bearing, Driven Shaft Shim, 25 x 34 x 0.60 mm Shim, 25 x 34 x 0.65 mm Shim, 25 x 34 x 0.70 mm Shim, 25 x 34 x 0.75 mm Shim, 25 x 34 x 0.80 mm Shim, 25 x 34 x 0.85 mm Shim, 25 x 34 x 0.90 mm Shim, 25 x 34 x 0.95 mm Shim, 25 x 34 x 1.00 mm Shim, 25 x 34 x 1.05 mm Shim, 25 x 34 x 1.10 mm Shim, 25 x 34 x 1.15 mm Shim, 25 x 34 x 1.20 mm 3402-740 3446-035 3402-738 3005-372 3423-023 3402-515 3402-739 3423-340 3423-072 3423-415 3402-513 3402-514 1402-026 Qty. Description 1 1 1 1 1 1 1 2 1 1 1 1 1 Shaft, Secondary Driven - Front Shim, Secondary Drive Gear - Set Gear, Secondary Drive Washer Nut Bearing, Driven Gear Gear, Secondary Driven Circlip, Secondary Driven Gear Ring, Driven Bearing Washer, Driven Shaft Shaft, Secondary Driven - Rear Flange, Output Joint - Rear Spring 2006 500 TRV GEAR SHIFTING ASSEMBLY 0737-777 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 3423-418 3530-042 3423-044 3402-087 3423-421 3423-191 3402-826 3423-114 3402-382 3446-280 3402-827 3423-416 3446-353 3402-828 3402-381 3423-446 2 1 2 2 1 4 1 1 2 2 1 1 2 1 2 1 Bolt Base, Gear Shift - Assembly Contact Spring Washer, Shift Shaft Circlip, Cam Spring Shaft, Gear Shift (inc. 8) Pin Washer, Cam Spring Spring, Cam Cam, Reverse C-Ring, Cam Fork, Shift Cam, Gear Shift Washer, Shift Shaft Washer, Gear Shift Cam Plate 3402-642 3004-376 3423-358 3402-747 1691-043 3402-076 3402-434 3004-341 3423-141 3402-746 3446-048 3423-511 3423-438 3004-488 3446-266 3402-829 Qty. Description 1 1 2 1 2 1 1 1 1 2 1 1 2 1 1 1 Plate, Gear Shift Cam Bolt, Gear Shift Cam Plate Circlip, Sub-Gear Shift Shaft Shaft, Sub-Gear Shift Washer, Sub-Gear Shift Shaft Seal, Sub-Gear Shift Shaft Arm, Select Bolt, Select Arm Washer, Cam Stopper Stopper, Cam Support, Cam Stopper Spring, Cam Stopper Washer, Cam Stopper Spring Nut, Cam Stopper Spring Shaft, Shift Fork Bearing 41 2006 500 TRV STARTER MOTOR ASSEMBLY 0737-779 Ref. Part No. Qty. Description 1 2 3 4 5 6 42 3545-015 3008-094 3008-095 3008-096 3008-164 3423-084 1 1 1 4 1 1 Motor, Starter - Assembly (inc. 2-9) Terminal Set, Brush Holder Set, Brush Spring, Brush O-Ring O-Ring Ref. Part No. 7 8 9 10 11 3436-001 3008-553 3423-085 3423-162 3423-195 Qty. Description 1 2 2 2 1 Washer Set O-Ring Through-Bolt Screw, Cap Nut 2006 500 TRV MAGNETO ASSEMBLY 0737-780 Ref. Part No. Qty. Description 1 2 3 4 3430-058 3430-046 3423-162 0691-785 1 1 3 1 Stator Assembly Rotor/Flywheel Bolt Key Ref. Part No. 5 6 7 8 3423-086 3423-005 3430-006 3430-005 Qty. Description 1 3 1 1 Nut Bolt Clamp - No. 1 Clamp - No. 2 43 2006 500 TRV CONTROL SWITCH HOUSING ASSEMBLY 0739-980 Ref. Part No. Qty. Description 1 0509-014 2 0409-027 44 1 Switch, Control - Assembly (inc. 2-3) 1 Screw Ref. Part No. 3 0409-028 4 3409-019 Qty. Description 1 Screw 1 Cover, Choke Lever 2006 500 TRV THROTTLE CASE ASSEMBLY 0738-414 Ref. Part No. Qty. Description 1 2 3 4 5 0509-012 3409-001 3004-533 3004-447 3003-030 1 1 1 1 1 Case, Throttle - Assembly (inc. 2-9) Lever Screw, Cap Washer, Lock Washer Ref. Part No. 6 7 8 9 3423-014 3423-327 3423-199 0409-048 Qty. Description 1 1 2 1 Screw Nut Screw Cover, Throttle Case w/Switch 45 RELATED ITEMS 2006 500 TRV Red (Model No. A2006TBM4BUSR) Green (Model No. A2006TBM4BUSG) Cat Green (Model No. A2006TBM4BUSZ) 0436-660 0436-480 0436-619 0436-757 0436-827 0436-459 0436-460 0436-462 0436-477 0436-726 0436-087 0436-035 0436-466 0436-538 0436-501 0436-464 0436-828 0436-352 0436-463 0436-516 0436-040 0436-039 0436-122 2257-465 Bag, Rack, Front, Black Bar, Utility Brush Guard/Bumper - Deluxe Bumper - Rear Cargo Box Carryall (9 x 12) Carryall (11 x 17) Carryall (10 D) Cord Reel Cover, Trailerable Electrical Plug Engine Block Heater Fender Box Gear Cradle Grease, High-Performance Grill Cradle Gun Holder - Pro-Grip Hand/Thumb Warmers Light Bar Light Mount, Portable - Cargo Box Light, Portable - Spotlight Light, Portable - Work Lunch Pack, Black Manual, Illustrated Parts 2257-300 2257-314 0652-024 0436-635 0436-228 0436-287 0436-296 0436-360 0436-636 0436-626 0436-798 0436-026 0436-027 1402-028 0402-563 0436-656 0436-655 0436-703 0436-623 0436-470 Manual, Operator’s (E) Manuel d’utilisation (F) Paint, Metal - Black Plow Attachment Kit Plow Blade, 50 in. - Straight Plow Blade, 50 in. - One-Way Plow Blade, 60 in. - Straight Plow Blade, 60 in. - One-Way Plow, Push Frame Rack Basket Rack - Rear Tire Chains, Size B (24 in. and 25 in. Tires) Tire Chains, Size C (25 in. and 26 in. Tires) Tire, Titan AT589 (25x8-12, Mud & Snow) Tire, Titan AT589 (25x10-12, Mud & Snow) Winch Accessories Kit Winch Kit, 2500 lb Windshield, Clear Windshield, Clear w/Accent Workbase (8 in.) NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A. p/n 2257-465
