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Download Craftsman A2006ABH4AUSG User's Manual
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® W or (Manual Transmission) Model Number A2006ABH4AUSR (Red) Model Number A2006ABH4AUSG (Green) Illustrated Parts Manual om 400 (VP) ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c ARCTIC CAT 2006 TABLE OF CONTENTS 2006 ATV 400 VP (Manual Transmission) Red (Model No. A2006ABH4AUSR) Green (Model No. A2006ABH4AUSG) W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m FRONT BODY PANEL ASSEMBLY......................................................................................................................... 1 REAR BODY PANEL ASSEMBLY ........................................................................................................................... 2 TAILLIGHT ASSEMBLY........................................................................................................................................... 3 DECALS ................................................................................................................................................................... 4 FRAME AND RELATED PARTS.............................................................................................................................. 5 SEAT 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 OIL COOLER ASSEMBLY ..................................................................................................................................... 20 FRONT DRIVE GEARCASE ASSEMBLY.............................................................................................................. 21 REAR DRIVE GEARCASE ASSEMBLY ................................................................................................................ 22 REAR AXLE ASSEMBLY....................................................................................................................................... 23 WIRING HARNESS ASSEMBLY ........................................................................................................................... 24 CARBURETOR ...................................................................................................................................................... 25 CYLINDER HEAD ASSEMBLY.............................................................................................................................. 26 CYLINDER ASSEMBLY......................................................................................................................................... 27 CRANKCASE ASSEMBLY..................................................................................................................................... 28 CRANKCASE 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 CLUTCH ASSEMBLY ............................................................................................................................................ 37 TRANSMISSION ASSEMBLY................................................................................................................................ 38 SECONDARY TRANSMISSION ASSEMBLY........................................................................................................ 39 SECONDARY DRIVE ASSEMBLY ........................................................................................................................ 40 GEAR SHIFTING ASSEMBLY ............................................................................................................................... 41 SECONDARY SHIFTING ASSEMBLY .................................................................................................................. 42 STARTER MOTOR ASSEMBLY............................................................................................................................ 43 MAGNETO ASSEMBLY......................................................................................................................................... 44 CONTROL SWITCH HOUSING ASSEMBLY ........................................................................................................ 45 THROTTLE CASE ASSEMBLY ............................................................................................................................. 46 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. ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 Printed June 2005 ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c om 2006 ATV 400 VP Manual Transmission FRONT BODY PANEL ASSEMBLY 0740-509 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 1 1 4 6 4 4 4 1 1 2 2 2 2 4 1 1 Rack - Front - Assembly (inc. 2-4) Decal, Warning - Front Rack Load Bushing, Rack Bushing, Rack Screw, Machine Spacer Grommet Panel, Fender - Front - Red Panel, Fender - Front - Green (Green) Screw, Shoulder Washer Nut, Lock Nut, Stamped Nut, Lock Decal, Reflector - Front - Right Decal, Reflector - Front - Left W or 9 10 11 12 13 14 1506-750 0411-576 0441-592 2406-014 8410-830 0423-463 0423-465 1506-819 1506-820 0423-355 8050-222 8424-602 0423-357 8432-802 1411-078 1411-079 Ref. Part No. Qty. Description 15 0623-362 4 Rivet, Plastic - Reinstallable 16 1406-867 1 Cover, Steering Post - Red 1406-970 1 Cover, Steering Post - Green (Green) 17 1406-956 1 Cover, Gas Tank - Red 1406-957 1 Cover, Gas Tank - Green (Green) 18 0623-544 2 Plug 19 0412-356 1 Shield, Heat - Fender - Front 20 1406-906 1 Panel, Splash - Right 1406-907 1 Panel, Splash - Left 21 0423-342 4 Screw, Self-Tapping 22 0423-101 3 Screw, Body 23 0123-788 AR Cable Tie - 7.5 in. 24 0470-404 1 Grommet, Fuel Shut-Off Valve Knob 1 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission REAR BODY PANEL ASSEMBLY 0740-305 Ref. Part No. Qty. Description Ref. Part No. 1 2 3 4 5 6 7 8 9 10 12 8050-222 2 Washer 13 8424-602 8 Nut, Lock 14 1411-080 1 Decal, Reflector - Rear - Right 1411-081 1 Decal, Reflector - Rear - Left 15 0423-540 16 Nut, Lock 16 0623-362 4 Rivet, Reinstallable 17 1406-950 1 Footwell - Right 1406-951 1 Footwell - Left 18 0423-419 12 Screw, Body 19 1506-125 2 Footpeg 20 0412-351 1 Shield, Heat 1506-753 1 0411-814 1 0411-648 1 0441-592 4 2406-014 8 8410-830 4 0423-463 4 0423-465 4 8432-802 4 1406-953 1 1406-954 1 11 0423-355 12 2 Rack - Rear - Assembly (inc. 2-5) Decal, “Arctic Cat” Decal, Warning - Rear Rack Load Bushing, Rack Bushing, Rack Screw, Machine Spacer Grommet Nut, Lock Panel, Fender - Rear - Red Panel, Fender - Rear - Green (Green) Screw, Shoulder Qty. Description W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission TAILLIGHT ASSEMBLY 0739-667 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 0623-301 6 8053-212 Qty. Description 1 Socket, Taillight 2 Screw, Self-Tapping 2 Washer, Lock - External Tooth 3 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission DECALS 0740-574 *Included on Front/Rear Fender Panels Ref. Part No. Qty. Description 1 1411-250 2 0411-835 3 1411-047 1411-048 4 1411-051 1411-052 5 0411-840 0411-839 6 0411-401 7 0411-966 8 1411-054 1411-055 1411-056 1411-057 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Decal, Warning - Reverse/Pre-Ride* Decal, Warning - Hill Decal, Instrument Pod Decal, Instrument Pod (Green) Decal, “Speedrack” Decal, “Speedrack” (Green) Decal, Front Decal, Front (Green) Decal, Warning - Age* Decal, Warning - Differential Lock Decal, Side - Upper Right Decal, Side - Upper Left Decal, Side - Upper Right (Green) Decal, Side - Upper Left (Green) Ref. Part No. 9 1411-060 1411-061 1411-062 1411-063 10 0411-430 11 0411-435 12 0411-267 13 0411-218 14 0411-965 Qty. Description 1 1 1 1 1 1 1 1 2 Decal, Side - Lower Right Decal, Side - Lower Left Decal, Side - Lower Right (Green) Decal, Side - Lower Left (Green) Decal, Warning - Tire Pressure Decal, Warning - Passenger Decal, Warning - Towing Decal, Warning - General* Decal, “Speedrack” W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission FRAME AND RELATED PARTS 0740-297 Ref. Part No. Qty. Description Ref. Part No. 1 1506-716 2 0509-027 0509-028 3 0409-073 4 0623-785 5 8050-217 6 0423-447 7 0423-514 8 0423-522 9 0423-513 10 8409-020 11 0506-653 1506-596 12 1506-686 1506-687 13 14 15 16 17 18 19 20 21 1 1 1 4 4 8 4 2 2 2 4 1 1 1 1 Frame, Main Headlight Assembly - Right (inc. 3) Headlight Assembly - Left (inc. 3) Bulb, Headlight Screw, Self-Tapping Washer Grommet Stud, Adjuster - Headlight Spring, Adjuster - Headlight Knob, Adjuster - Headlight Screw, Cap Channel, Bumper Mounting - Right Channel, Bumper Mounting - Left Bracket, Mounting - Bumper - Right Bracket, Mounting - Bumper - Left 22 23 24 25 8408-816 1506-800 2406-030 1506-067 0406-864 0423-101 8424-802 8409-016 1506-659 1506-660 1406-853 8408-002 1506-429 8408-025 Qty. Description 6 1 2 1 1 6 4 4 1 1 2 2 1 2 Screw, Cap Bumper, Front Cap, Tube Foam, Frame Panel, Belly Screw, Body Nut, Flange Screw, Cap Footrest - Right Footrest - Left Rod, Support Nut, Hex Brace, A-Arm Screw, Cap 5 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission SEAT ASSEMBLY 0739-690 Ref. Part No. Qty. Description 1 2 3 4 5 6 1506-937 1506-209 1506-208 2406-144 0406-879 1 1 1 1 2 Seat Assembly (inc. 2-9) Cover, Seat Foam, Seat Base, Seat Assembly (inc. 5-6) Bumper, Seat - Rear Ref. Part No. 6 7 8 9 Qty. Description 0406-877 4 Bumper, Seat - Front 0624-528 AR Staple 1406-592 1 Spring, Seat Latch 1506-156 1 Latch, Seat W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission 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 0505-072 0405-083 0423-013 0405-032 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 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission HANDLEBAR ASSEMBLY 0740-540 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 8 0505-418 0405-148 0405-149 8050-247 8477-845 0405-147 1506-578 3430-040 3409-007 3409-011 3409-012 3409-013 1 2 2 2 2 2 1 1 1 1 1 1 Tube, Handlebar - Black Plug, Handlebar End Cap, Handlebar Washer Screw, Machine Grip, Handlebar Bracket, Gauge - Black 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 11 12 13 14 15 16 17 0409-013 0423-535 0423-357 0405-192 0405-193 0405-198 0420-068 0420-066 0420-067 Qty. Description 1 2 4 1 1 1 1 1 1 Cover, Key Rivet, Plastic - Reinstallable Nut, Stamped Instrument Pod - Red Instrument Pod - Green (Green) Bezel, Lights - Instrument Pod Light, Indicator - “Temperature” Light, Indicator - “N” Light, Indicator - “R” ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c om 2006 ATV 400 VP Manual Transmission FRONT SUSPENSION ASSEMBLY 0740-243 *Not a Service Part Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 W or 10 11 12 13 14 1603-889 2 Retainer, Spring 0403-144 2 Shock Absorber - Front (inc. 3-4) 0604-310 8 Bushing, Shock Absorber 0403-028 4 Sleeve, Shock 0403-102 2 Cam, Spring Adjuster 0403-103 2 Spring, Shock Absorber 8409-040 4 Screw, Cap 8428-002 10 Nut, Lock 0503-192 1 A-Arm, Upper Right - Black (inc. 10-13) 0503-193 1 A-Arm, Upper Left - Black (inc. 10-13) 0403-081 4 Bushing 0403-080 2 Collar 0423-009 4 Clip, Ball Joint 0405-115 4 Ball Joint - Front 0503-292 1 A-Arm, Lower Right (inc. two No. 12-13) 0503-291 1 A-Arm, Lower Left (inc. two No. 12-13) Ref. Part No. 15 0505-460 0505-461 16 * * 17 1402-027 18 0423-423 19 8409-030 20 0423-334 21 8409-075 22 0502-814 23 1441-109 24 0436-276 25 0406-944 0406-927 26 0423-101 27 0441-587 Qty. Description 1 1 1 1 2 2 4 2 4 2 2 2 1 1 4 1 Knuckle - Assembly - Right (inc. 16-18) Knuckle - Assembly - Left (inc. 16-18) Knuckle, Steering - Right Knuckle, Steering - Left Bearing, Wheel Hub Ring, Retaining Screw, Cap Screw, Cap Screw, Cap Axle, Drive - Front (inc. 23-24) Clip, Retaining Repair Kit, Boot - Front Axle Guard, Boot - Axle - Right Guard, Boot - Axle - Left Screw, Body Wrench, Spanner 9 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission REAR SUSPENSION ASSEMBLY 0737-585 Ref. Part No. Qty. Description 1 2 3 4 5 6 10 8409-060 4 Screw, Cap 0423-335 2 Screw, Cap 0504-218 3 Arm, Swing 8428-002 10 Nut, Lock 0504-215 1 Arm, Swing 8409-040 4 Screw, Cap Ref. Part No. 7 8 9 10 11 12 0404-107 0604-310 0403-028 0403-102 1603-889 0404-108 Qty. Description 2 8 4 2 2 2 Shock Absorber - Rear (inc. 8-9) Bushing, Shock Absorber Sleeve, Shock Absorber Cam, Spring Adjuster Retainer, Spring - Upper Spring, Shock Absorber - Black W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission WHEEL AND TIRE ASSEMBLY 0740-518 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 7 0423-407 4 Pin, Cotter Ref. Part No. Qty. Description 8 0402-856 2 Wheel - Front - Gray 0402-989 2 Wheel - Rear - Gray 9 0423-408 16 Nut, Mounting - Wheel 10 1402-360 2 Tire - Front 1402-361 2 Tire - Rear 11 0402-064 4 Stem, Valve (inc. 12) 12 0402-140 4 Cap, Valve Stem 11 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission AUXILIARY BRAKE ASSEMBLY (Fully Bled Master Cylinder Replacement Kit p/n 0502-940) 0740-522 *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 0423-178 0423-413 0123-788 8408-625 8408-820 0502-602 0502-603 4 2 1 2 2 1 1 24 25 26 27 28 29 30 31 0502-606 0502-607 0502-609 0502-608 0502-605 0502-604 0502-873 8471-616 1 1 1 1 1 1 1 2 12 0502-789 1602-213 8050-252 8408-816 1402-407 1402-377 8050-217 0402-584 0502-941 * 0502-886 0502-877 8424-602 0423-608 8476-640 1402-418 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 Spacer Screw, Machine Hose, Brake - Rear Qty. Description Washer, Crush Bolt, Banjo Fitting Cable Tie - 7.5 in. Screw, Cap Screw, Cap Caliper, Brake (inc. 23-29) Housing, Caliper - Assembly - Right Front (inc. 24-26) Piston/Seal Set (inc. 25) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Bracket, Master Cylinder Screw, Machine W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission HYDRAULIC HAND BRAKE ASSEMBLY (Master Cylinder Rebuild Kit p/n 0502-704) 0740-525 Ref. Part No. Qty. Description 1 2 3 4 5 6 0502-914 0502-566 0502-868 0502-568 0502-869 0502-866 1 1 1 1 1 1 Brake Assembly (inc. 2-9) Screw, Reservoir Cover - Kit Cover, Reservoir - Kit Screw, Master Cylinder Clamp - Kit Clamp, Master Cylinder - Kit Lever Assembly - Kit (inc. 7-8) Ref. Part No. 7 8 9 10 11 0502-867 0502-580 0502-564 0423-178 0423-413 Qty. Description 1 1 1 2 1 Lock, Brake Lever - Kit Lever Pin - Kit Switch, Brake - Kit Washer, Crush Bolt, Banjo Fitting 13 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission HYDRAULIC BRAKE ASSEMBLY 0740-580 Ref. Part No. Qty. Description 1 2 3 4 5 0502-883 8476-625 0623-038 8408-820 0502-602 0502-610 6 0502-603 0502-611 14 1 1 1 6 1 2 Hose, Brake - Assembly Screw, Cap Nut, Hex Screw, Cap Caliper, Brake - Right Front (inc. 6-12) Caliper, Brake - Left Front and Right Rear (inc. 6-12) 1 Housing, Caliper - Assembly - Right Front (inc. 7-9) 2 Housing, Caliper - Assembly - Left Front and Right Rear (inc. 7-9) Ref. Part No. 7 8 9 10 11 12 13 14 0502-606 0502-607 0502-609 0502-608 0502-605 0502-604 0423-178 0423-413 Qty. Description 3 3 3 3 3 3 6 3 Piston/Seal Set (inc. 8) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Washer, Crush Bolt, Banjo Fitting W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission GAS TANK ASSEMBLY 0740-526 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 0570-109 0470-438 0109-733 0570-086 0470-416 0470-445 0470-364 1 1 1 1 1 1 1 Tank, Gas - Assembly (inc. 2-10) Cap, Gas Tank (inc. 3) Gasket, Tank Cap Gauge, Fuel w/Gasket (Press-Fit) Hose, Vent Valve, Fuel Shut-Off (inc. 7) Gasket, Fuel Shut-Off Valve Ref. Part No. 8 9 10 11 12 13 Qty. Description 0423-398 2 Nut, Lock 0423-152 2 Clamp, Hose - Spring 0610-007 AR Hose, Gasline - 25 ft 0470-408 1 Knob, Fuel Shut-Off Valve 0423-146 1 Screw, Fuel Shut-Off Valve Knob 0423-106 2 Screw, Gas Tank 15 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission REVERSE SHIFT LEVER ASSEMBLY 0740-535 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 1402-335 0423-357 0502-659 0502-410 8424-602 0423-182 0402-675 0502-760 1 1 1 4 1 1 1 2 1 1 Handle, Reverse Shift Lever Clip, Push Plate, Shift Nut, Stamped Lever, Shift Spring, Reverse Shift Lever Nut O-Ring Axle, Pivot Axle, Reverse Shift Lever - Black 0423-299 0423-087 8408-812 0502-589 1402-270 0623-294 0423-169 3423-204 0423-091 Qty. Description 2 1 1 1 1 2 1 1 1 O-Ring Washer Screw, Cap Linkage, Shift End, Rod Nut E-Ring Washer Bushing, Shift Linkage W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission AIR INTAKE ASSEMBLY 0740-792 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 0423-019 0470-467 0423-018 0470-446 0470-391 0470-343 0470-383 0470-307 0423-037 0623-121 0123-010 1 1 2 1 1 1 1 4 4 4 4 Clamp Boot, Air Intake Clamp Housing, Air Intake Filter, Air (inc. one No. 3) Gasket Snorkel Clamp Spring Screw, Machine Nut, Expansion 0470-351 0412-141 0470-442 0623-101 1673-272 0423-047 0423-045 0410-045 0470-470 0510-592 Qty. Description 2 1 1 1 1 1 2 1 1 1 Support, Air Intake Flange Shield, Heat Valve, Drain Clip, Routing - Snap-In Cap, Drain Tube Clamp, Hose Clamp, Hose - Spring Hose, Crankcase Vent Carburetor, CVK34-AE Hose, Carburetor Drain 17 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission 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 7 0645-263 Cover, Battery Pad, Battery 8 0645-151 Kit, Tool 9 0123-903 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 Clip, Routing - Snap-In W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission ENGINE AND EXHAUST 0740-536 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 0462-037 0423-405 0423-426 0423-042 8428-002 8408-816 1506-626 1506-625 8408-860 8424-802 0412-007 8408-820 0512-257 0423-317 0412-344 0512-263 0412-343 0612-188 0612-668 0412-340 0512-269 1 2 4 2 2 2 1 1 1 3 1 2 1 3 1 1 1 1 2 3 1 Engine Screw, Cap Washer, Engine Spacer, Engine Nut, Lock Screw, Cap Bracket, Engine - Right Bracket, Engine - Left Screw, Cap Nut Seal, Exhaust Screw, Cap Pipe, Exhaust - Assembly (inc. 13-16) Clamp, Hose Shield, Exhaust Pipe - Outer Pipe, Exhaust Shield, Exhaust Pipe - Inner Gasket, Exhaust Pipe Spring, Extension Bushing, Muffler Muffler - Assembly (inc. 21-23) Ref. Part No. Qty. Description 21 22 23 24 25 26 27 28 0412-313 0512-219 8408-616 0412-329 8477-610 0409-008 0402-991 1506-449 1 1 3 1 4 1 1 1 29 30 31 32 33 34 35 36 37 38 39 40 0423-361 0502-871 1402-284 8476-620 1602-213 0402-994 8422-002 1506-693 3402-013 3430-033 3402-556 3530-037 1 1 1 1 2 1 1 1 1 1 1 1 Gasket, Spark Arrester Spark Arrester, Assembly Screw, Cap Cover, Muffler Screw, Machine Switch, Reverse Retainer, Reverse Switch Bracket, Mounting - Reverse Switch (inc. 29) Screw, Machine Shifter, Toe - Assembly (inc. 31-32) Pad, Toe - Shift Lever Screw, Machine O-Ring Pin, Shift Lever Nut Bracket, Foot Shifter Gasket Switch, Cooling Fan Gasket Switch, Oil Light 19 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission OIL COOLER ASSEMBLY 0740-369 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 20 0413-118 1 Cooler, Oil - Assembly (inc. 2-9) 0413-053 1 Cooler, Oil 0413-007 1 Screen, Radiator 8475-512 12 Screw, Machine 0413-064 1 Shroud, Fan 0413-044 1 Fan, Cooling 0413-058 1 Plug, Drain 0413-059 1 O-Ring 0423-030 2 Grommet Ref. Part No. 10 11 12 13 14 15 16 17 18 0623-038 0423-484 0423-028 0423-098 0410-044 0410-013 0423-089 8471-616 0410-012 Qty. Description 2 2 2 4 2 1 2 4 1 Nut w/Washer Screw, Shoulder Bushing, Stem Clamp, Hose Hose, Oil Fitting, Oil O-Ring, Oil Fitting Screw, Cap Fitting, Oil - Angled W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission FRONT DRIVE GEARCASE ASSEMBLY 0740-537 Ref. Part No. Qty. Description 1 0502-817 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0502-386 0423-411 0402-985 0423-393 1402-046 0502-407 1402-011 0423-423 1402-043 0423-118 0502-529 0402-947 0423-417 0402-981 0402-982 0402-357 0502-783 19 0402-336 20 0402-327 21 0402-328 1 Gearcase, Front Drive - Assembly (inc. 2-34) 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 Bearing 11 Screw, Self-Tapping 1 Housing, Pinion 1 Gasket, Flange 1 Ring, Retaining 1 Collar, Shaft 1 Washer, Wave Spring 1 Collar, Lock 1 Gear, Pinion - Assembly - 10T (inc. 19-20) 1 Collar, Retaining 1 Bearing 1 Bearing Ref. Part No. Qty. Description 22 23 24 25 26 27 28 29 1 1 2 1 1 1 2 AR AR AR AR AR 1 1 1 1 1 1 1 2 4 2 1 30 31 32 33 34 35 36 37 38 39 40 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 0402-333 0423-154 1402-104 0423-315 0402-147 0423-404 0423-426 8428-002 0402-966 Housing, Gearcase Pin, Dowel Seal Plug, Magnetic (inc. 26) O-Ring O-Ring Bearing Shim Shim Shim Shim Shim Gear, Ring - 36T Cover, Gearcase Plug, Fill (inc. 33) O-Ring Fitting Clamp, Fitting Bladder, Gearcase Screw, Cap Washer Nut, Lock Boot, Shaft 21 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission REAR DRIVE GEARCASE ASSEMBLY 0740-538 Ref. Part No. Qty. Description 1 0502-822 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 22 0502-088 0502-239 0502-089 0402-321 0402-322 0402-323 0402-324 0402-325 0402-326 0402-328 1402-103 0402-331 0402-335 0402-851 0402-338 0402-381 0402-429 0402-430 0402-431 0402-432 0402-433 1 Gearcase, Rear Drive - Assembly (inc. 2-32) 1 Housing, Gearcase 1 Housing, Pinion 1 Cover, Gearcase 1 Ring, Retaining 1 Bearing 1 Seal 2 Bearing 2 Seal 1 Button, Thrust 1 Bearing, Needle 1 Fitting, 45° 1 Collar, Lock 1 Collar, Shaft 1 Shaft, Thrust 1 Spring, Compression 1 Gear, Ring - 36T AR Shim AR Shim AR Shim AR Shim AR Shim Ref. Part No. Qty. Description 19 0402-434 0402-435 0402-436 0402-437 0402-438 20 0423-111 21 0423-115 22 0423-118 23 0502-783 AR AR AR AR AR 1 6 6 1 24 25 26 27 28 29 30 31 32 33 34 0402-327 0402-336 0423-148 0423-149 0402-333 0423-154 0402-334 0423-153 0402-450 0402-147 0423-315 1 1 1 1 1 1 1 2 1 1 1 Shim Shim Shim Shim Shim Washer Screw, Self-Tapping Screw, Self-Tapping Gear, Pinion - Assembly - 10T (inc. 24-25) Bearing Collar, Retaining O-Ring O-Ring Plug, Fill (inc. 29) O-Ring, Fill Plug Plug, Drain (inc. one No. 31) O-Ring, Drain Plug Plug, Drain - Magnetic (inc. one No. 31) Bladder, Gearcase Clamp, Fitting W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission REAR AXLE ASSEMBLY 0740-539 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 0506-675 0423-116 0406-415 0423-101 0423-031 8477-616 0402-374 0502-090 0502-091 1 4 1 1 2 2 2 1 1 Hitch, Trailer Screw, Self-Tapping Panel, Gearcase Screw, Body Nut, Speed Screw, Machine Gasket, Axle Housing Housing, Axle - Right Housing, Axle - Left Ref. Part No. Qty. Description 9 0423-117 12 Screw, Self-Tapping 10 0423-119 2 O-Ring 11 1402-400 1 Axle - Right 1402-401 1 Axle - Left 12 0502-859 1 Housing, Bearing - Right 0502-681 1 Housing, Bearing - Left 13 1402-027 2 Bearing 14 0423-423 2 Ring, Retaining 23 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission WIRING HARNESS ASSEMBLY 0740-541 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 24 0486-181 1 Harness, Main (inc. 2-7 and two No. 8) 0486-164 1 Tether, Accessory Connector 0530-008 1 Cover, Fuse Block 0430-037 1 Holder, Fuse 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 0123-788 AR Cable Tie - 7.5 in. 0445-053 1 Cable, Electric Start Relay/Starter 0623-038 7 Nut w/Washer 0645-327 1 Boot, Terminal 0445-052 1 Cable, Battery/Electric Start Relay Ref. Part No. 13 14 15 16 17 18 19 20 21 22 23 24 25 26 0645-019 0445-036 8476-625 3402-683 3402-684 3402-682 3430-055 8476-620 3430-009 3430-007 3430-008 0445-054 0409-009 0402-991 Qty. Description 1 1 4 1 1 1 1 1 1 1 1 1 1 1 Boot, Terminal Solenoid Screw, Machine CDI Unit Cushion, CDI Regulator, Voltage Coil, Ignition - Assembly Screw, Machine Seal, High Tension Wire Cap, Spark Plug Seal, Spark Plug Cable, Battery/Ground Switch, Brake - Assembly Retainer, Brake Switch W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CARBURETOR CVK34-AE (Complete Assembly p/n 0470-470) 0740-480 *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 5507-001 5507-002 5507-085 5507-109 5507-005 5507-110 5507-007 5507-047 5507-043 5507-009 5507-041 5507-042 5507-044 5507-010 5507-179 5507-107 * 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 - 147** Main Jet - 145** Main Jet - 140** Slow Jet - 38 Starter Jet - 75 Valve, Float - Set (inc. 13) Clip Float Set (inc. 15) Pin, Float Screw, Pilot Air - Set (inc. 17-19) Spring Ref. Part No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 * * 5507-027 5507-028 5507-029 5507-115 5507-117 5507-180 5507-114 * 5507-050 5507-032 5507-031 * 5507-034 5507-035 5507-017 0487-021 5507-036 5507-037 0410-056 Qty. Description 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 4 1 1 1 1 Washer 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 25 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CYLINDER HEAD ASSEMBLY 0738-415 *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 3402-576 3402-099 3423-068 3423-043 3423-006 3402-577 3423-449 3003-290 3423-326 3423-007 3423-429 3423-439 3004-376 1 2 4 2 4 1 2 4 2 2 1 4 2 Head, Cylinder - Assembly (inc. 2-5) Guide, Valve Ring, Valve Guide Pin, Dowel Bolt Gasket, Cylinder Head Pin, Dowel Gasket Nut, Cylinder Head Bolt, Head Cover Bolt, Head Cover Washer, Cylinder Head Nut Bolt, Head Cover 3008-376 3423-453 3402-011 0217-708 3402-100 3402-101 3004-341 3402-035 3423-353 8476-620 0570-076 0423-317 3402-048 Qty. Description 1 1 1 1 2 2 4 1 1 2 1 1 1 Bolt, Head Cover Plug, Oil Gallery Gasket, Oil Gallery Plug Spark Plug (NGK CR7E) Cap, Inspection O-Ring Bolt, Inspection Cap Plug, Head O-Ring Screw Manifold, Intake Clamp Plug, Frost W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CYLINDER ASSEMBLY 0737-039 Ref. Part No. Qty. Description 1 2 3 4 5 3402-578 3423-384 3004-778 3423-431 3423-432 1 2 2 2 2 Cylinder Bolt, Stud Bolt, Stud Bolt Bolt Ref. Part No. 6 7 8 9 3423-427 3004-488 3402-579 3423-088 Qty. Description 2 4 1 2 Bolt Nut Gasket, Cylinder Pin, Dowel 27 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CRANKCASE ASSEMBLY 0739-903 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 28 3402-763 3004-880 3005-332 3005-410 3423-097 3423-091 3402-012 1 4 1 3 4 8 1 Crankcase Assembly (inc. 2-9) Bolt Bolt Bolt Bolt Bolt Gasket, Oil Pressure Plug Ref. Part No. 8 9 10 11 12 13 14 3402-214 3423-088 3004-552 3402-764 3402-691 3423-051 3402-582 Qty. Description 1 2 4 1 1 1 1 Plug, Oil Pressure Pin, Dowel Screw, Oil Guide Plate Plate, Oil Guide - Right Jet, Oil Gallery O-Ring, Oil Gallery Jet Plate, Oil Guide - Left W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CRANKCASE COVER ASSEMBLY 0737-722 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 3402-991 1 Cover, Clutch 3402-766 1 Gasket 3423-088 4 Pin, Dowel 3423-098 30 Bolt 3004-338 2 Plug, Oil Gallery 3003-290 2 Gasket 3402-100 1 Cap, Inspection 3402-101 1 O-Ring, Inspection Cap 3004-341 2 Bolt, Inspection Cap Ref. Part No. 10 11 12 13 14 15 16 17 18 3402-593 3423-055 3402-767 3402-768 3423-180 3402-013 3004-705 3402-444 3423-430 Qty. Description 1 1 1 1 1 1 1 1 1 Stick, Oil Level O-Ring, Oil Level Stick Cover, Magneto Gasket, Magneto Cover Plug Gasket Plug, Drain Gasket, Drain Plug Bolt 29 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CRANKSHAFT ASSEMBLY 0739-873 *Optional 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 30 3402-992 3402-597 3402-769 3402-571 3423-440 3402-993 3403-019 3402-698 3402-994 3423-768 3402-771 3402-216 1 1 1 1 2 1 1 1 2 1 1 1 Crankshaft Assembly (inc. 2-8) Rod, Connecting Pin, Crank Bearing Washer Crankshaft - Right Crankshaft - Left Gear, Crank Balancer Drive Bearing - Middle Spacer Circlip Bearing - Right 3402-594 3402-595 3436-015 3003-439 3402-596 3402-051 3423-063 3423-542 3402-070 3423-053 3402-188 3423-018 Qty. Description 1 1 1 2 1 1 1 1 1 1 1 3 Piston Ring, Piston - Set Piston Set (Oversized 0.50 mm)* Circlip Pin, Piston Bearing O-Ring Spacer Seal, Oil O-Ring Retainer, Crankshaft Oil Seal - Left Screw, Retainer W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission STARTER CLUTCH ASSEMBLY 0737-043 Ref. Part No. Qty. Description 1 2 3 4 3402-603 3402-124 3423-331 3423-397 1 1 1 1 Gear, Starter Idler - No. 1 Gear, Starter Idler - No. 2 Pin, Starter Idler Gear No. 1 Pin, Starter Idler Gear No. 2 Ref. Part No. 5 3402-690 6 3402-674 7 3423-102 Qty. Description 1 Clutch, Starter - Set (inc. 6) 1 Bearing 6 Bolt 31 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CRANK BALANCER ASSEMBLY 0737-728 Ref. Part No. Qty. Description 1 2 3 4 32 3402-605 3402-553 3402-772 3004-540 1 2 1 1 Balancer, Crank Bearing Gear, Driven - No. 1 Key Ref. Part No. 5 6 7 8 3402-617 3423-110 3423-555 3423-401 Qty. Description 1 1 1 1 Gear, Oil Pump Drive Pin, Drive Gear Bolt, Drive Gear Washer, Drive Gear W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CAMSHAFT/VALVE ASSEMBLY 0737-730 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 3402-989 3402-611 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 3402-140 3423-031 3402-012 3402-040 3402-141 3402-147 3423-541 3402-726 3402-078 3402-148 3402-725 3402-143 Qty. Description 1 2 2 2 1 8 4 4 4 4 2 2 Shaft, Rocker Arm Washer Gasket Plug, Shaft Shaft, Rocker Arm Cotter, Valve Retainer, Spring Spring, Valve Seal, Oil Seat, Spring Valve, Intake Valve, Exhaust 33 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CAM CHAIN ASSEMBLY 0737-051 Ref. Part No. Qty. Description 1 2 3 4 5 6 34 3402-281 3402-612 3402-613 3423-074 3402-436 3402-614 1 1 1 1 1 1 Chain, Cam Guide, Cam Chain Tensioner, Cam Chain Bolt Washer Adjuster, Tensioner - Assembly (inc. 7-9) Ref. Part No. 7 8 9 10 11 3423-484 3423-485 3423-286 3403-020 3004-512 Qty. Description 1 1 1 1 2 Spring Plug O-Ring Gasket, Adjuster Bolt W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission RECOIL STARTER ASSEMBLY 0737-034 Ref. Part No. Qty. Description 1 2 3 4 5 6 3445-003 3445-004 3445-007 3445-016 3445-005 3445-006 1 1 1 1 1 1 Starter, Recoil - Assembly (inc. 2-8) Reel Spring, Spiral Ratchet - Assembly (inc. 5-6) Ratchet Guide, Ratchet Ref. Part No. 7 8 9 10 11 3004-488 3445-011 3423-428 3445-029 3004-491 Qty. Description 1 1 4 1 1 Nut Rope Assembly Screw, Cap Cup, Starter Nut 35 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission OIL FILTER/PUMP ASSEMBLY 0737-035 Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 36 3402-619 3402-618 3423-046 3423-443 3423-184 3423-113 3402-156 0693-389 1 1 1 1 1 3 1 2 Pump, Oil Gear, Driven Pin Washer Circlip Screw Strainer, Oil Screw Ref. Part No. 9 10 11 12 13 14 15 16 3402-157 3423-077 3004-756 0812-005 3403-021 3402-012 3402-773 3005-206 Qty. Description 1 1 4 1 1 1 1 2 Cap, Oil Strainer O-Ring Screw, Cap Filter, Oil Plug, Drain Gasket, Drain Plug Valve, Oil Relief - Assembly Pin, Oil Pump W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CLUTCH ASSEMBLY 0739-874 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 3446-352 3446-003 3446-290 3423-409 3423-515 3423-516 3446-291 3446-004 3423-330 3423-517 3446-006 3446-007 3446-008 3446-009 1 1 1 1 1 1 1 1 4 4 6 5 1 1 Housing, Starter Clutch Clutch, Primary Drive One Way Shoe, Starter Clutch Nut, Starter Clutch Shoe Washer, Primary Driven Washer Gear, Primary Driven - Assembly Hub, Clutch Sleeve Screw, Cap - Clutch Spring Spring, Clutch Plate, Clutch Drive Plate, Clutch Driven Disc, Clutch Pressure Plate, Clutch Release 3423-080 3423-032 3446-292 3423-361 3423-083 3446-293 3446-294 3423-125 3008-014 3423-359 3423-027 3402-186 3423-360 3423-260 Qty. Description 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Nut, Clutch Sleeve Hub Washer, Sleeve Hub Arm, Clutch Release Bolt, Clutch Release - No. 1 Bolt, Clutch Release - No. 2 Guide, Release Roller Roller, Clutch Release - Assembly Bolt, Clutch Release Arm Nut, Clutch Release - No. 2 Nut, Clutch Release - No. 1 Washer, Clutch Release - No. 2 Bearing, Clutch Washer, Clutch Release - No. 1 Washer 37 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission TRANSMISSION ASSEMBLY 0737-733 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 3402-218 3446-297 3423-066 3423-036 3446-296 3446-145 3423-263 3446-141 3446-273 3446-146 3446-143 3423-266 3423-262 3446-147 3423-317 3446-142 3402-230 3402-775 0691-374 1 1 4 3 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 Bearing Dog, Reverse Circlip Washer, Lock Gear, Reverse Driven Bushing Washer Gear, 1st Driven Bushing Gear, 4th Driven Gear, 3rd Driven Washer, Lock Washer, Lock Gear, 5th Driven Washer Gear, 2nd Driven Bushing Driveshaft Bearing 3402-033 3446-031 3423-370 3446-295 3402-210 3446-139 3402-229 3423-279 3446-138 3423-261 3446-140 3446-137 3402-224 3402-209 3446-149 3402-228 3446-298 3423-518 Qty. Description 1 2 2 1 2 1 1 2 1 1 1 1 1 2 1 1 1 1 Plug, Countershaft Retainer, Bearing Screw Countershaft Washer Gear, 4th Drive Bushing Circlip Gear, 3rd Drive Washer Gear, 5th Drive Gear, 2nd Drive Bearing Washer Gear, Reverse Idle Bushing Shaft, Reverse Idle Circlip W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission SECONDARY TRANSMISSION ASSEMBLY 0740-284 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 3402-776 3446-300 3446-301 3423-036 3423-066 3446-249 3423-126 3446-302 3423-519 3402-979 3446-299 3402-205 3423-319 3402-217 1 1 1 1 1 1 2 1 1 1 1 1 1 1 Bearing Gear, Drive - No. 1 Bushing, Drive Gear No. 1 Washer Circlip Dog, Sliding Washer Gear, Drive - No. 2 Spacer, Drive Gear Bearing, Driveshaft Gear, Idle Spacer, Idle Gear Washer Bearing 3423-023 3005-372 3446-274 3446-035 3423-370 3446-031 3402-180 3446-403 3446-304 3402-045 3446-244 3446-260 3423-363 Qty. Description 1 1 1 1 2 2 1 1 1 1 1 1 2 Nut, Secondary Drive Gear Washer, Secondary Drive Gear Gear, Secondary Drive Shim, Secondary Drive Gear - Set Screw Retainer, Output Shaft Bearing Shaft, Output Gear, Driven Bearing Gasket, Speedometer Housing Retainer, Cover Plug Bolt, Retainer 39 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission SECONDARY DRIVE ASSEMBLY 0740-786 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 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 21 3402-067 22 3446-405 23 3403-015 24 3423-414 25 3435-051 26 1402-026 AR AR AR AR AR AR AR AR AR AR AR AR AR 1 1 1 3 1 1 40 3446-274 3446-035 3423-023 3005-372 3446-327 3402-562 3423-479 3423-025 3423-028 3402-742 3402-072 3402-558 3402-559 3423-520 3423-136 3446-222 3402-515 3423-072 3446-305 1 1 1 1 1 2 8 2 2 2 2 1 1 1 1 1 1 1 1 Gear, Secondary Drive Shim, Secondary Drive Gear - Set Nut Washer Yoke, Propeller Shaft - Front Joint, Universal - Set (inc. 7) Circlip Nut Washer Yoke, Drive Output Seal, Oil Bearing, Front Secondary Driven Shaft Shaft, Secondary Driven - Front Washer, Secondary Driven Gear Nut, Secondary Driven Gear Gear, Secondary Driven Bearing, Driven Gear C-Ring, Driven Bearing Shaft, Secondary Driven - Rear 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 Bearing, Rear Secondary Driven Shaft Yoke, Propeller Shaft Shaft, Propeller Bolt, Propeller Shaft Boot, Propeller Shaft Spring W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission GEAR SHIFTING ASSEMBLY 0737-745 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 3446-306 3446-155 3446-156 3402-643 3004-488 3423-142 3446-282 3446-048 3402-746 3423-141 3423-125 3446-309 3446-049 3423-045 3423-370 3423-135 1 1 1 1 1 1 1 1 1 1 1 1 1 5 2 2 Fork, Gear Shift - Reverse Fork, Gear Shift - No. 1 Fork, Gear Shift - No. 2 Shaft, Gear Shift Fork - No. 2 Nut Washer Spring, Gear Shift Cam Stopper Support, Gear Shift Cam Stopper Stopper, Gear Shift Cam Washer Bolt Guide, Gear Shift Plate, Gear Shift Cam (inc. 14) Pin Screw Retainer 3402-051 3446-308 3423-114 3402-087 3423-044 3446-313 3423-418 3446-157 3446-307 3446-310 3402-093 3446-056 3402-094 3446-054 3402-068 Qty. Description 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 Bearing, Gear Shift Cam Cam, Gear Shift (inc. 19) Pin Spring Contact Base, Neutral Switch Bolt Fork, Gear Shift - No. 3 Shaft, Gear Shift Fork - No. 1 Shaft, Gear Shift (inc. 27) Spring Stopper, Gear Shift Shaft Spring, Return Spacer, Gear Shift Shaft Seal, Oil 41 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission SECONDARY SHIFTING ASSEMBLY 0737-748 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 42 3446-314 3446-315 3423-524 3402-012 1691-043 3423-358 3446-322 3402-076 3402-434 3004-341 3423-527 3423-190 1 1 1 1 2 2 1 1 1 1 2 5 Stopper, Gear Shift Cam (inc. 2-3) Stopper Spring Gasket Washer Circlip Shaft, Gear Shift Seal, Oil Arm, Gear Shift Bolt, Gear Shift Arm Washer Circlip 3423-526 3446-325 3446-324 3446-323 3446-321 3402-381 3446-316 3423-533 3423-525 3446-320 3446-318 3446-317 Qty. Description 3 1 1 1 1 2 1 2 1 1 1 1 Spring Camshaft, Reverse Plate, Cam Lock Cam, Reverse Joint, Camshaft Washer Gear, Camshaft Washer Cam Camshaft Fork, Gear Shift Shaft, Gear Shift Fork W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission STARTER MOTOR ASSEMBLY 0737-056 Ref. Part No. Qty. Description 1 2 3 4 5 6 3545-016 3402-671 3402-672 3008-551 3008-164 3423-272 1 1 1 2 1 1 Motor, Starter - Assembly (inc. 2-10) Terminal Set, Brush Holder Set, Brush (inc. 4) Spring, Brush O-Ring O-Ring Ref. Part No. 7 8 9 10 11 12 3008-099 3423-497 3423-498 3423-496 3004-756 3423-195 Qty. Description 1 2 2 2 2 1 Washer Set O-Ring Through-Bolt (inc. 10) O-Ring Bolt Nut 43 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission MAGNETO ASSEMBLY 0737-033 Ref. Part No. Qty. Description 1 2 3 4 5 44 3430-053 3430-054 3004-756 0691-785 3423-086 1 1 3 1 1 Stator Assembly Rotor/Flywheel Bolt Key Nut Ref. Part No. 6 7 8 9 3423-005 3430-006 3430-005 3002-964 Qty. Description 3 1 1 1 Bolt Clamp Clamp Clamp, Wire W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission CONTROL SWITCH HOUSING ASSEMBLY 0738-416 Ref. Part No. Qty. Description 1 0509-013 2 3423-197 1 Switch, Control - Assembly (inc. 2-3) 1 Screw Ref. Part No. 3 3423-196 4 3409-019 Qty. Description 1 Screw 1 Cover, Choke Lever 45 W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 2006 ATV 400 VP Manual Transmission THROTTLE CASE ASSEMBLY 0737-633 Ref. Part No. Qty. Description 1 2 3 4 46 3509-003 3409-001 3004-533 3004-447 1 1 1 1 Case, Throttle - Assembly (inc. 2-8) Lever Screw, Cap Washer, Lock Ref. Part No. 5 6 7 8 3003-030 3423-014 3423-327 3423-199 Qty. Description 1 1 1 2 Washer Screw Nut Screw RELATED ITEMS 2006 ATV 400 VP (Manual Transmission) Red (Model No. A2006ABH4AUSR) Backrest Bag, Fender - Black Bag, Rack, Front - Black Bag, Rack, Rear - Black Basket, Open-End - Rear Brush Guard/Bumper, Front (4x4) Cargo Box Cargo Box Quick-Release Kit Cover, Black and Green Cover, Timber Camo Cover, Trailerable Engine Oil - 10W40 Engine Oil - 5W30 Engine Oil - Synthetic 0W40 Gear Lube (Diff) - 80W90 Gun Scabbard Gun Scabbard Mount Hand Guards - Black Hand/Thumb Warmers Illustrated Parts Manual License Plate Kit 2257-313 2257-299 0436-635 0436-228 0436-287 0436-296 0436-360 0436-822 0436-823 0436-636 0436-626 0436-762 0436-763 1402-028 0402-563 0436-297 0436-263 0436-382 0436-655 0436-623 Manuel d’utilisation (F) Operator’s Manual (E) 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 Blade, Carbon Fiber - 60 in. - Straight Plow Blade, Carbon Fiber - 60 in. - One-Way Plow, Push Frame Rack Basket (Front) Rack Extension, 4 in. (Front) Rack Extension, 8 in. (Rear) Tire, Titan AT589 (25x8-12, Mud & Snow) Tire, Titan AT589 (25x10-12, Mud & Snow) Tool Holder - Double Tool Holder - Single Torch Light Winch, 2500 lb Windshield, Clear w/Black Accent W or ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. co m 0436-768 0436-679 0436-660 0436-802 0436-811 0436-765 0436-454 0436-625 0436-777 0436-668 0436-776 0436-005 0436-003 0436-450 0436-007 0441-281 0436-706 0436-505 0436-352 2257-454 0436-787 Green (Model No. A2006ABH4AUSG) NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A p/n 2257- 454
