Transcript
400 4x4 FIS
(Automatic Transmission) Model Model Model Model Model Model
Number Number Number Number Number Number
A2005ISH4BUSI A2005ISH4BUSH A2005ISH4BUSJ A2005ISH4BUSN A2005ISH4BUSM A2005ISH4BUSA
Illustrated Parts Manual
(Red) (Green) (Cat Green) (Red - LE) (Green - LE) (Cat Green - LE)
2005
TABLE OF CONTENTS 2005 ATV 400 FIS (Automatic Transmission) Red (Model No. A2005ISH4BUSI) Green (Model No. A2005ISH4BUSH) Cat Green (Model No. A2005ISH4BUSJ)
Red - LE (Model No. A2005ISH4BUSN) Green - LE (Model No. A2005ISH4BUSM) Cat Green - LE (Model No. A2005ISH4BUSA)
FRONT BODY PANEL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REAR BODY PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TAILLIGHT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRAME AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FRAME AND RELATED PARTS (LE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 WINCH ASSEMBLY (LE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 STEERING POST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HANDLEBAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FRONT SUSPENSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REAR SUSPENSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 WHEEL AND TIRE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WHEEL AND TIRE ASSEMBLY (LE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 AUXILIARY BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HYDRAULIC HAND BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 HYDRAULIC BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 GAS TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 REVERSE SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 AIR INTAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 STORAGE BOX AND BATTERY ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ENGINE AND EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 CASE/BELT COOLING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DRIVE TRAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FRONT DRIVE GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 REAR DRIVE GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 WIRING HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 CRANKCASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 CRANKSHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 STARTER CLUTCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 CRANK BALANCER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 CAMSHAFT/VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 CAM CHAIN ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 RECOIL STARTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 OIL FILTER/PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SECONDARY TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SECONDARY DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 GEAR SHIFTING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 STARTER MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 MAGNETO ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 CONTROL SWITCH HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 THROTTLE CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 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 2005 model year. 2004 Arctic Cat Inc. Printed June 2004 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
2005 ATV 400 FIS Automatic Transmission
FRONT BODY PANEL ASSEMBLY 0739-507
Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0541-267 1 Rack - Front - Assembly (inc. 2-4) 0411-576 1 Decal, Warning - Front Rack Load 0441-592 4 Bushing, Rack 0441-556 6 Bushing, Rack 8408-816 2 Screw, Cap 0423-360 2 Screw, Cap 0411-646 2 Decal, Reflector - Amber 1506-158 1 Flare - Front - Right 1506-159 1 Flare - Front - Left 0423-357 2 Nut, Stamped 1506-477 1 Panel, Fender - Front (inc. 11) 1506-476 1 Panel, Fender - Front (inc. 11) (Green) 1506-478 1 Panel, Fender - Front (inc. 11) (Cat Green) 1406-142 1 Cover, Access 1406-141 1 Cover, Access (Green) 1406-041 1 Cover, Access (Cat Green) 0423-101 AR Screw, Body 0423-031 2 Nut, Speed 8477-616 2 Screw, Machine 0423-342 6 Screw, Self-Tapping 0470-404 1 Grommet, Fuel Shut-Off Valve
Ref. Part No.
Qty. Description
17 0506-548 1 Panel, Side - Right 0506-243 1 Panel, Side - Left 0506-549 1 Panel, Side - Right (Green) 0506-673 1 Panel, Side - Left (Green) 0506-722 1 Panel, Side - Right (Cat Green) 0506-723 1 Panel, Side - Left (Cat Green) 18 0412-142 1 Shield, Heat 19 0123-010 2 Nut, Expansion 20 0423-356 2 Screw, Shoulder 21 0423-438 2 T-Nut w/Teeth 22 0623-362 2 Rivet, Reinstallable 23 1406-063 2 Panel, Fender - Inner - Upper 24 1406-481 2 Panel, Fender - Inner - Lower 25 0123-788 AR Cable Tie - 7.5 in. 26 1506-199 1 Panel, Kick - Right 1506-193 1 Panel, Kick - Left 27 0423-046 AR Rivet, Plastic 28 0423-361 4 Screw, Machine 29 0423-077 4 T-Nut w/Teeth 30 1506-194 2 Extension, Flare
1
2005 ATV 400 FIS Automatic Transmission
REAR BODY PANEL ASSEMBLY 0739-511
Ref. Part No. Qty. Description
Ref. Part No.
1 0541-268 1 Rack - Rear - Assembly (inc. 2-5) 0541-293 1 Rack - Rear - Assembly (inc. 2-5) (LE) 2 0411-814 1 Decal, “Arctic Cat” 0411-947 1 Decal, “Arctic Cat” (LE) 3 0411-648 1 Decal, Warning - Rear Rack Load 4 0441-592 4 Bushing, Rack 5 0441-556 8 Bushing, Rack 6 8409-020 4 Screw, Cap 7 0411-647 2 Decal, Reflector - Red 8 0423-101 AR Screw, Body 9 0423-046 AR Rivet, Plastic 10 1506-520 1 Panel, Fender - Rear 1506-519 1 Panel, Fender - Rear (Green) 1506-518 1 Panel, Fender - Rear (Cat Green) 11 1406-408 1 Shield, Fuse Block
12 13 14 15 16 17
2
18 19 20 21 22 23 24
1406-409 1406-410 0423-068 0412-124 0412-147 0506-552 0506-553 0423-342 0423-355 0423-438 1506-042 0406-085 0412-140 0623-309 0423-060
Qty. Description 2 2 2 1 1 1 1 6 2 2 1 1 1 2 2
Key, Fuse Block Shield Spring, Fuse Block Shield Screw, Machine Shield, Heat Shield, Heat Flare, Rear - Right Flare, Rear - Left Screw, Self-Tapping Screw, Shoulder T-Nut w/Teeth Fender Extension - Rear - Right Fender Extension - Rear - Left Shield, Heat Screw, Self-Tapping Clip, Tinerman
2005 ATV 400 FIS Automatic Transmission
TAILLIGHT ASSEMBLY (Complete Taillight Assembly p/n 0409-002) 0732-336
Ref. Part No. Qty. Description 1 2 3 4
0109-460 0409-058 0409-012 0409-007
1 1 1 1
Bulb, Stop/Taillight Taillight w/Socket Assembly Gasket, Taillight Lens Lens, Taillight
Ref. Part No. 5 0409-010 6 0623-301 7 8053-212
Qty. Description 2 Screw, Machine 2 Screw, Self-Tapping 2 Washer, Lock - External Tooth
3
2005 ATV 400 FIS Automatic Transmission
DECALS 0739-515
Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9
4
0411-008 0411-835 0411-426 0411-763 0411-435 0411-267 0411-218 0411-430 0411-774 0411-775 0411-776 0411-777 0411-778 0411-779
1 1 1 1 1 1 1 1 1 1 1 1 1 1
Decal, Warning - Reverse/Pre-Ride Decal, Warning - Turn Decal, Warning - Clutch Cover Decal, Warning - Differential Lock Decal, Passenger Decal, Warning - Towing Decal, Warning - General Decal, Warning - Tire Pressure Decal, Side - Right Decal, Side - Left Decal, Side - Right (Green) Decal, Side - Left (Green) Decal, Side - Right (Cat Green) Decal, Side - Left (Cat Green)
Ref. Part No. 10 0411-401 11 0411-771 0411-773 0411-772 12 0411-780 0411-782 0411-781 13 0411-965
Qty. Description 1 1 1 1 1 1 1 1
Decal, Warning - Age Decal, Front Decal, Front (Green) Decal, Front (Cat Green) Decal, Crest Decal, Crest (Green) Decal, Crest (Cat Green) Decal, “Speedrack”
2005 ATV 400 FIS Automatic Transmission
FRAME AND RELATED PARTS 0739-524
Ref. Part No. Qty. Description
Ref. Part No.
1 1506-465 2 0409-032 0409-031 3 0409-045 4 8410-860 5 0406-945 6 0423-375 7 8424-802 8 8409-020 9 0506-653 10 8408-812 11 0506-544 12 0406-130 13 0406-832
14 15 16 17
1 1 1 2 2 2 2 6 8 2 2 1 2 1
Frame, Main Headlight Assembly - Right (inc. 3-6) Headlight Assembly - Left (inc. 3-6) Bulb, Headlight Screw, Cap Bracket, Headlight Mounting Nut, Lock Nut, Flange Screw, Cap Channel, Bumper Mounting Screw, Cap Bumper Cap, Bumper Grille, Upper
18 19 20 21 22 23 24
Qty. Description
0423-361 2 Screw, Machine 1406-420 1 Grille, Bumper - Lower 8468-830 4 Screw, Machine 1441-006 1 Plate, Skid 1441-008 1 Plate, Skid (Green) 1441-007 1 Plate, Skid (Cat Green) 0423-101 AR Screw, Body 1406-030 1 Panel, Belly 8408-816 4 Screw, Cap 0506-534 1 Footrest - Right 0506-728 1 Footrest - Left 8424-602 2 Nut, Flange 1506-067 1 Foam, Frame 0406-289 1 Pad, Frame
5
2005 ATV 400 FIS Automatic Transmission
FRAME AND RELATED PARTS (LE) 0739-901
Ref. Part No. Qty. Description
Ref. Part No.
1 1506-465 2 0409-032 0409-031 3 0409-045 4 8410-860 5 0406-945 6 0423-375 7 8424-802 8 8409-020 9 0506-653 10 8408-812 11 0506-544 12 0406-130 13 0406-832 14 0541-290 15 0541-291 16 0441-517 17 8402-816 18 8451-152 19 8450-127 20 1441-132 21 8450-108 22 8451-121 23 8400-650
24 25 26 27
6
1 1 1 2 2 2 2 6 8 2 2 1 2 1 1 1 6 6 6 6 4 2 2 2
Frame, Main Headlight Assembly - Right (inc. 3-6) Headlight Assembly - Left (inc. 3-6) Bulb, Headlight Screw, Cap Bracket, Headlight Mounting Nut, Lock Nut, Flange Screw, Cap Channel, Bumper Mounting Screw, Cap Bumper Cap, Bumper Grille, Upper Plate, Bumper Tube Tube, Bumper Cap, Bumper Screw, Cap Washer, Lock Washer Spacer Washer Washer, Lock Screw, Cap
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
Qty. Description
8450-126 2 Washer 8451-151 2 Washer, Lock 8400-860 2 Screw, Cap 1441-006 1 Plate, Skid 1441-008 1 Plate, Skid (Green) 1441-007 1 Plate, Skid (Cat Green) 0423-101 AR Screw, Body 1406-030 1 Panel, Belly 1506-067 1 Foam, Frame 0406-289 1 Pad, Frame 8408-816 4 Screw, Cap 8424-602 2 Nut, Flange 0506-534 1 Footrest - Right 0506-728 1 Footrest - Left 0541-288 1 Bumper, Rear 8475-850 2 Screw, Machine 0541-313 2 Bracket, Clamp 8422-801 2 Nut, Lock 1441-134 2 Spacer 8406-020 2 Screw, Cap 0441-486 2 Support, Rear Bumper 8422-001 2 Nut, Lock 8406-040 2 Screw, Cap
2005 ATV 400 FIS Automatic Transmission
WINCH ASSEMBLY (LE) 0739-827
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
0441-490 0441-061 0441-426 0411-433 0441-465 8468-830 8051-246 8002-102 0441-403 0441-477 0441-478 0441-060 0409-066
1 1 1 1 1 2 4 4 1 1 1 6 1
Winch (inc. 2-3) Cable, Winch Hook, Winch Decal, Winch Plate, Winch Screw, Machine Washer, Lock Screw, Cap Roller, Winch Cable, Solenoid/Battery - Black Cable, Solenoid/Battery - Red Boot, Terminal Solenoid (inc. 14-15)
Qty. Description
8420-602 4 Nut 8451-122 4 Washer, Lock 0441-476 1 Cable, Winch/Solenoid - Yellow 0441-475 1 Cable, Winch/Solenoid - Blue 0123-788 AR Cable Tie - 7.5 in. 0409-044 1 Switch, Control 0509-010 1 Bracket, Mounting - Solenoid 0624-250 2 Nut, Lock 0409-034 1 Holder, Control Switch 0409-040 1 Cover, Switch 0423-382 1 Screw, Self-Tapping 0623-204 2 Screw, Machine 0417-001 1 Pad
7
2005 ATV 400 FIS Automatic Transmission
SEAT ASSEMBLY 0738-364
Ref. Part No. Qty. Description 1 2 3 4 5 6
8
0506-558 0506-556 0506-555 1406-060 0406-878 0406-877
1 1 1 1 1 2
Seat Assembly (inc. 2-8) Cover, Seat Foam, Seat Foam, Sound Base, Seat Assembly (inc. 6-7) Bumper, Seat - Front
Ref. Part No. 7 8 9 10 11 12
Qty. Description
0406-879 2 Bumper, Seat - Rear 0624-528 AR Staple 1406-087 1 Plate, Retainer 8060-284 1 Rivet 1406-371 1 Spring, Seat Latch 1506-217 1 Latch, Seat
2005 ATV 400 FIS Automatic Transmission
STEERING POST ASSEMBLY 0739-452
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 0505-431 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
9
2005 ATV 400 FIS Automatic Transmission
HANDLEBAR ASSEMBLY 0739-528
Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9
10
0505-448 0405-148 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 1506-423 11 0405-133 0405-132 0405-134 12 0623-362 13 0423-356 14 0420-052 15 8424-602 16 0423-448 17 0502-527 18 0502-613 19 0487-030
Qty. Description 1 1 1 1 4 1 1 1 2 1 1 1
Bracket, Mounting - Instrument Pod Instrument Pod Instrument Pod (Green) Instrument Pod (Cat Green) Rivet, Reinstallable Screw, Shoulder Gauge, Digital Nut, Flange Grommet Control, Differential Lock (inc. 18) Clamp, Differential Lock Control - Kit Cable, Differential Lock
2005 ATV 400 FIS Automatic Transmission
FRONT SUSPENSION ASSEMBLY 0739-603
Ref. Part No. Qty. Description 1 2 3 4 5 6
1603-889 2 Retainer, Spring 0403-127 2 Shock Absorber - Front (inc. 3-4) 0604-310 8 Bushing, Shock Absorber 0403-028 4 Sleeve, Shock 0403-102 2 Cam, Spring Adjuster 0403-129 2 Spring, Shock Absorber - Platinum 0403-128 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 0505-446 0505-447 18 0505-444 0505-445 19 1402-027 20 0423-423 21 8409-030 22 0423-334 23 8409-075 24 0502-542 0502-547 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 1 1 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, Drive - Front - Right (inc. 25-26) Axle, Drive - Front - Left (inc. 25-26) Clip, Retaining Repair Kit, Boot - Front Axle Guard, Boot - Axle - Right Guard, Boot - Axle - Left Guard, Boot - Axle - Right (Green) Guard, Boot - Axle - Left (Green) Guard, Boot - Axle - Right (Cat Green) Guard, Boot - Axle - Left (Cat Green) Screw, Body Wrench, Spanner
11
2005 ATV 400 FIS Automatic Transmission
REAR SUSPENSION ASSEMBLY 0739-532
Ref. Part No. Qty. Description 1 0504-312 0504-313 2 0504-311 0504-310 3 1402-027 4 0423-423 5 0403-038 6 0403-032 7 0504-326
1 1 1 1 2 2 4 8 1
0504-327
1
0504-320
1
0504-321
1
8 9 10 11 12
12
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. 2-6) Knuckle, Left Rear - Assembly (inc. 2-6) Knuckle - Right Knuckle - Left Bearing, Wheel Hub Ring, Retaining Collar, Suspension Bushing Bushing, Suspension A-Arm, Rear - Lower Right - Platinum (inc. 8-9) A-Arm, Rear - Lower Left - Platinum (inc. 8-9) A-Arm, Rear - Lower Right - Black (inc. 8-9) (Green) A-Arm, Rear - Lower Left - Black (inc. 8-9) (Green) Bushing Collar Nut, Lock Screw, Cap A-Arm, Rear - Upper Right - Platinum (inc. 8-9) A-Arm, Rear - Upper Left - Platinum (inc. 8-9) A-Arm, Rear - Upper Right - Black (inc. 8-9) (Green) A-Arm, Rear - Upper Left - Black (inc. 8-9) (Green)
Ref. Part No. 13 0441-754 0441-755 1441-004 1441-005 0441-758 0441-759 14 0423-101 15 1406-071 1406-072 16 0502-596 17 0441-400 18 0436-276 19 8409-075 20 1603-889 21 0404-074 0404-065 22 0404-072 23 0604-310 24 0403-028 25 0404-057 26 8409-040 27 0423-087 28 8408-820 29 0441-587
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, Drive (inc. 17-18) Clip, Retaining Repair Kit, Boot - Rear Axle Screw, Cap Retainer, Spring Spring, Suspension - Platinum Spring, Suspension - Black (Green) Shock Absorber - Rear (inc. 23-24) Bushing, Shock Absorber Sleeve, Shock Absorber Cam, Spring Adjuster Screw, Cap Washer Screw, Cap Wrench, Spanner
2005 ATV 400 FIS Automatic Transmission
WHEEL AND TIRE ASSEMBLY 0739-534
Ref. Part No. Qty. Description 1 2 3 4 5 6 7
0423-029 12 Screw, Machine 1402-225 3 Disc, Brake 0502-599 2 Hub, Wheel - Front (inc. 4) 0402-974 16 Stud, Wheel Hub 0423-407 4 Pin, Cotter 0423-394 4 Nut, Castle 1402-127 2 Wheel - Front - Platinum 0402-856 2 Wheel - Front - Gray (Green) 8 0423-408 16 Nut, Mounting - Wheel
Ref. Part No. 9 10 11 12
1402-100 0402-064 0402-140 0502-601 0502-599 13 1402-115 0402-858 14 1402-101
Qty. Description 2 4 4 1 1 2 2 2
Tire - Front Stem, Valve (inc. 11) Cap, Valve Stem Hub, Wheel - Rear - Left (inc. 4) Hub, Wheel - Rear - Right (inc. 4) Wheel - Rear - Platinum Wheel - Rear - Gray (Green) Tire - Rear
13
2005 ATV 400 FIS Automatic Transmission
WHEEL AND TIRE ASSEMBLY (LE) 0739-831
Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8
14
0423-029 12 Screw, Machine 1402-225 3 Disc, Brake 0502-599 2 Hub, Wheel - Front (inc. 4) 0402-974 16 Stud, Wheel Hub 0423-407 4 Pin, Cotter 0423-394 4 Nut, Castle 1402-286 2 Wheel - Front - Spoked 0423-408 16 Nut, Mounting - Wheel
Ref. Part No. 9 10 11 12
1402-100 0402-064 0402-140 0502-601 0502-599 13 1402-287 14 1402-101
Qty. Description 2 4 4 1 1 2 2
Tire - Front Stem, Valve (inc. 11) Cap, Valve Stem Hub, Wheel - Rear - Left (inc. 4) Hub, Wheel - Rear - Right (inc. 4) Wheel - Rear - Spoked Tire - Rear
2005 ATV 400 FIS Automatic Transmission
AUXILIARY BRAKE ASSEMBLY 0739-535 *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 25 26 27 28 29 30 31 32 33 34 35 36 37
0502-645 1602-213 0502-651 8422-002 0402-872 0402-575 0402-583 0402-584 0502-665 0402-580 0402-592 * 1402-277 1402-278 0423-525 1402-266 1402-257 8424-602 1506-521
1 2 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 1
Lever, Brake O-Ring Spring, Brake Lever Nut Axle, Brake Lever Pin, Clevis Washer Pin, Cotter Brake Assembly (inc. 10-17) Actuator, Push Rod Nut, Jam Master Cylinder Fitting, Banjo Bolt, Banjo Fitting Clamp, Hose Hose, Brake Reservoir Reservoir, Brake Nut, Flanged Bracket, Mounting - Reservoir
Qty. Description
8476-616 2 1402-200 1 0423-413 2 0423-178 4 8408-825 4 0502-457 1 * 1 0402-495 1 1402-126 2 0423-495 1 0402-493 1 1402-123 1 1402-125 2 0402-980 2 * 1 * 1 * 1 0123-788 AR
Screw, Machine Hose, Brake Bolt, Banjo Fitting Washer, Crush Screw, Cap Caliper, Brake (inc. 26-36) Housing, Caliper Pin, Brake Caliper Pad, Brake Pin, Cotter Cap, Bleed Valve Valve, Bleed Piston O-Ring, Brake Caliper O-Ring Plug Ring, Retaining Cable Tie - 7.5 in.
15
2005 ATV 400 FIS Automatic Transmission
HYDRAULIC HAND BRAKE ASSEMBLY 0738-331
Ref. Part No. Qty. Description 1 2 3 4 5 6
16
0502-620 0502-566 0502-565 0502-568 0502-567 0502-633
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
0502-634 0502-635 0502-580 0502-564 1402-212
Qty. Description 1 1 1 1 1
Lever Assembly - Kit (inc. 8-9) Lock, Brake Lever - Kit Lever Pin - Kit Switch, Brake - Kit Brakeline, Hydraulic
2005 ATV 400 FIS Automatic Transmission
HYDRAULIC BRAKE ASSEMBLY 0739-253
Ref. Part No. Qty. Description 1 8476-625 2 1402-231 1402-232 3 1402-086 4 1402-031 5 8408-820 6 0502-602 0502-610 7 0502-603 0502-611
1 1 1 1 1 6 1 2
Screw, Cap Hose, Brake - Front - Right Hose, Brake - Front - Left Block, Junction Plug Screw, Cap Caliper, Brake - Right Front (inc. 7-13) Caliper, Brake - Left Front and Right Rear (inc. 7-13) 1 Housing, Caliper - Assembly - Right Front (inc. 8-10) 2 Housing, Caliper - Assembly - Left Front and Right Rear (inc. 8-10)
Ref. Part No. 8 9 10 11 12 13 14 15 16
0502-606 0502-607 0502-609 0502-608 0502-605 0502-604 0423-178 0423-413 1402-204
Qty. Description 3 3 3 3 3 3 6 3 1
Piston/Seal Set (inc. 9) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Washer, Crush Bolt, Banjo Fitting Hose, Brake - Rear
17
2005 ATV 400 FIS Automatic Transmission
GAS TANK ASSEMBLY 0736-991
Ref. Part No. Qty. Description 1 2 3 4 5 6 7
18
0570-066 1 0470-438 1 0109-733 1 0570-086 1 0423-398 2 0470-416 1 0610-007 AR
Tank, Gas - Assembly (inc. 2-10) Cap, Gas Tank (inc. 3) Gasket, Tank Cap Gauge, Fuel w/Gasket (Press-Fit) Nut, Lock Hose, Vent Hose, Gasline - 25 ft
Ref. Part No. 8 9 10 11 12 13
0423-152 0470-445 0470-364 0470-408 0423-146 0423-130
Qty. Description 2 1 1 1 1 2
Clamp, Hose - Spring Valve, Fuel Shut-Off (inc. 10) Gasket, Fuel Shut-Off Valve Knob, Fuel Shut-Off Valve Screw, Fuel Shut-Off Valve Knob Screw, Gas Tank
2005 ATV 400 FIS Automatic Transmission
REVERSE SHIFT LEVER ASSEMBLY 0739-838
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
8424-602 8408-812 0502-187 0502-185 0423-299 0423-182 0423-087 0502-410 0402-675 0402-843 0423-345
1 1 1 1 2 2 1 1 1 1 1
Nut Screw, Cap Axle, Reverse Shift Lever Lever, Reverse Shift O-Ring O-Ring Washer Spring, Reverse Shift Lever Axle, Pivot Handle, Reverse Shift Lever Clip, Push
0502-668 1402-270 0623-294 0423-091 3423-204 0423-169 0402-685 0406-943 0423-371 0623-309
Qty. Description 1 1 2 1 1 1 1 1 3 1
Linkage, Shift End, Rod Nut Bushing, Shift Linkage Washer E-Ring Plate, Shift Shield, Linkage Screw, Machine Screw, Self-Tapping
19
2005 ATV 400 FIS Automatic Transmission
AIR INTAKE ASSEMBLY 0738-385
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
0423-019 0470-467 0423-018 0470-446 0470-391 0470-343 0470-383 0470-307 0423-037 0623-121
1 1 2 1 1 1 1 4 4 4
Clamp Boot, Air Intake Clamp Housing, Air Intake Filter, Air Gasket Snorkel Clamp Spring Screw, Machine
0123-010 0470-351 0412-141 0470-442 0623-101 1673-272 0423-047 0423-045 0410-045
Qty. Description 4 2 1 1 1 1 1 2 1
Nut, Expansion Support, Air Intake Flange Shield, Heat Valve, Drain Clip, Retaining Cap, Drain Tube Clamp, Hose Clamp, Hose - Spring Hose, Crankcase Vent
2005 ATV 400 FIS Automatic Transmission
STORAGE BOX AND BATTERY ASSEMBLY 0737-887
Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8
0506-178 0406-288 0406-289 0745-045 0645-045 0645-152 0645-263 0645-151
1 1 1 1 6 1 1 1
Strap, Battery w/Pads (inc. 2-3) Pad, Battery - Upper Front Pad, Battery - Upper Rear Battery Assembly (inc. 5-8) Cap, Battery Clamp, Hose Hose, Battery Vent Label, Warning - Battery
Ref. Part No. 9 10 11 12 13 14 15 16
0406-227 0444-122 0423-456 0123-903 0506-797 1406-140 1406-078 0623-797
Qty. Description 1 1 1 2 1 1 1 4
Pad, Battery - Lower Kit, Tool Screw, Thumb Cable Tie - 11.5 in. Storage Box - Assembly (inc. 14) Shield, Heat Cover, Storage Box Screw, Self-Tapping
21
2005 ATV 400 FIS Automatic Transmission
ENGINE AND EXHAUST 0739-572
Ref. Part No. Qty. Description
Ref. Part No.
1 0462-036 2 1506-201 1506-202 3 8424-802 4 8408-816 5 0506-892 6 8408-860 7 0423-405 8 0423-426 9 0423-042 10 8428-002 11 0412-007 12 8408-820
13 14 15 16 17 18 19 20 21 22 23 24 25
22
1 1 1 3 4 1 1 3 4 2 3 1 2
Engine Bracket, Engine - Right Bracket, Engine - Left Nut Screw, Cap Bracket, Engine - Upper Screw, Cap Screw, Cap Washer, Engine Spacer, Engine Nut, Lock Seal, Exhaust Screw, Cap
0512-178 0412-220 8477-610 0412-215 0612-188 0612-668 0512-139 0412-218 3402-013 3430-033 3530-037 3402-556 0412-224
Qty. Description 1 1 8 4 1 2 1 1 1 1 1 1 1
Pipe, Exhaust Cover, Exhaust Pipe - Front Screw, Machine Bushing, Exhaust Gasket, Exhaust Spring, Exhaust Muffler Cover, Muffler Gasket, Switch Switch, Cooling Fan Switch, Oil Light Gasket, Switch Cover, Exhaust Pipe - Rear
2005 ATV 400 FIS Automatic Transmission
OIL COOLER ASSEMBLY 0739-573
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
0413-052 0413-053 0413-007 0413-009 0413-064 8475-512 0413-044 0413-058 0413-059 0423-030
1 1 1 4 1 8 1 1 1 2
Cooler, Oil - Assembly (inc. 2-10) Cooler, Oil Screen, Oil Cooler Screw, Thumb Shroud, Fan Screw, Machine Fan, Cooling Plug, Drain O-Ring Grommet
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
23
2005 ATV 400 FIS Automatic Transmission
CASE/BELT COOLING ASSEMBLY 0737-586
Ref. Part No. Qty. Description 1 2 3 4
24
0413-107 0623-301 3402-449 0413-060
1 1 2 1
Duct, Belt Cooling - Rear Screw, Self-Tapping Clamp, Boot Boot, Duct - Rear
Ref. Part No. 5 6 7 8
0423-380 0413-048 0413-042 0123-788
Qty. Description 2 1 1 2
Clamp, Boot Boot, Duct - Front Duct, Belt Cooling - Front Cable Tie - 7.5 in.
2005 ATV 400 FIS Automatic Transmission
DRIVE TRAIN ASSEMBLY 0739-591
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
0402-147 0423-315 8428-002 0423-426 0423-404 0502-442 0402-966 0502-500 0423-396 0502-642
2 4 4 8 4 1 1 1 3 1
Bladder, Gearcase Clamp, Fitting Nut, Lock Washer Screw, Cap Gearcase, Front Boot, Shaft Plate, Cable Screw, Self-Tapping Gearcase, Rear
Qty. Description
0410-049 AR Hose, Vent 0623-101 1 Clip, Routing - Snap-In 0470-462 1 Fitting, Vent 0673-618 2 Bumper, Propeller Shaft 0402-963 1 Shaft, Propeller 0423-393 2 Clamp, Boot 0402-954 1 Boot 0402-950 1 Flange, Output 8408-820 4 Screw, Cap
25
2005 ATV 400 FIS Automatic Transmission
FRONT DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n 0502-442) 0739-579
Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32
26
0502-386 0423-411 0402-985 0423-393 1402-046 0502-407 1402-011 0423-423 0502-347 0502-579 0423-498 0423-396 1402-043 0423-118 0502-528 0402-947 0402-997 0402-998 0402-417 0423-402 0423-147 0402-999 0423-417 0402-357 0402-413 0502-123 0402-336 0402-327 0402-424 0402-425 0402-426 0402-427 0402-428 0402-328 0402-411 0502-514
1 1 1 1 1 1 1 1 1 1 1 3 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 AR AR AR AR AR 1 1 1
Shaft, Propeller - Assembly (inc. 2-6)
Clamp, Boot Boot, Propeller Shaft Clamp, Boot Shaft, Output Shaft, Input
Seal Ring, Retaining Bracket, Actuator Actuator (inc. 11) O-Ring Screw, Self-Tapping Bearing Screw, Self-Tapping Housing, Pinion Gasket, Flange Shaft, Selector Fork, Selector Shaft, Shuttle Ring, Retaining O-Ring Spring, Return Ring, Retaining Collar, Lock Coupler, Drive Gear, Pinion - Assembly - 10T (inc. 27-29) Collar, Retaining Bearing Shim Shim Shim Shim Shim Bearing Pin, Dowel Housing, Gearcase
Ref. Part No. 33 34 35 36 37
Qty. Description
40
1402-210 0423-153 0423-149 0402-393 0402-405 0402-406 0402-407 0402-408 0402-409 0502-411 1402-074 1402-075 1402-076 1402-077 1402-078 0502-434
1 2 1 1 AR AR AR AR AR 1 AR AR AR AR AR 1
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59
1402-053 0502-413 1402-079 1402-042 1402-054 1402-058 1402-057 1402-104 0402-419 1402-063 1402-055 1402-056 0423-133 0423-132 0423-424 1402-211 0402-394 0402-333 0423-154
1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1
38 39
Plug, Magnetic (inc. one No. 34) O-Ring O-Ring Bearing Shim Shim Shim Shim Shim Gear, Ring - 36T Shim Shim Shim Shim Shim Cover, Gearcase (inc. one No. 34, 41-56, and one No. 57) Bearing Flange, Bearing Pin, Parallel Collar, Sliding Fork Ring, Retaining Spring Fitting Switch, Indicator Spring Shaft, Lock Seal O-Ring Washer Ring, Retaining Plug, Oil Level (inc. one No. 34) Seal Plug, Fill (inc. 59) O-Ring
2005 ATV 400 FIS Automatic Transmission
REAR DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n 0502-642) 0739-580
Ref. Part No. Qty. Description 1 2 3 4 5
6 7
8 9 10 11 12 13 14
0502-352 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
1 2 2 1 AR AR AR AR AR 1 AR AR AR AR AR 1 1 1 1 1 11 1
Housing, Gearcase Bearing Seal Gear, Ring - 36T Shim Shim Shim Shim Shim Button, Thrust Shim Shim Shim Shim Shim O-Ring Cover, Gearcase Plug, Fill (inc. 11) O-Ring Fitting Screw, Self-Tapping Plug, Magnetic (inc. 15)
Ref. Part No.
Qty. Description
15 16 17 18
1 1 1 AR AR AR AR AR 1 1 1 1 1 1 1 1 1 1 1 1 1
19 20 21 22 23 24 25 26 27 28 29 30 31
0423-153 0402-328 0502-123 0402-424 0402-425 0402-426 0402-427 0402-428 0402-327 0402-336 0402-411 0402-331 0402-982 0402-981 0402-947 0502-529 0423-417 1402-043 0423-423 1402-011 0502-407
O-Ring Bearing Gear, Pinion - Assembly - 10T (inc. 18-20) Shim Shim Shim Shim Shim Bearing Collar, Retaining Pin, Dowel Collar, Lock Washer, Wave Collar, Shaft Gasket, Flange Housing, Pinion Ring, Retaining Bearing Ring, Retaining Seal Shaft, Input
27
2005 ATV 400 FIS Automatic Transmission
WIRING HARNESS ASSEMBLY 0739-840
Ref. Part No. Qty. Description
Ref. Part No.
1 0486-155 1 Harness, Main (inc. 2-7 and two No. 8) 2 0530-008 1 Cover, Fuse Block 3 0430-032 4 Fuse - 10 Amp 0430-031 3 Fuse - 15 Amp 0430-030 2 Fuse - 30 Amp 4 0430-033 3 Relay 5 0430-034 3 Diode 6 0430-037 1 Holder, Fuse 7 0411-828 1 Decal, Fuse Block 8 0123-788 AR Cable Tie - 7.5 in. 9 0645-327 1 Boot, Terminal 10 0445-042 1 Cable, Solenoid/Starter 11 0445-036 1 Solenoid 12 0623-038 4 Nut w/Washer 13 0445-038 1 Cable, Battery/Solenoid (inc. one No. 14) 14 0645-019 2 Boot, Terminal 15 0445-037 1 Cable, Battery/Ground 16 0409-009 1 Switch, Brake - Assembly
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
28
Qty. Description
0402-991 1 0506-985 1 8476-616 1 3402-683 1 8476-625 3 3402-682 1 0486-148 1 0445-022 1 0445-034 1 0509-011 1 3430-055 1 3430-009 1 3430-007 1 3430-008 1 8424-602 1 8476-620 1 0123-903 AR
Retainer, Switch Bracket, CDI Screw, Machine CDI Unit Screw, Machine Regulator, Voltage Harness, Adapter - Electric Choke Receptacle, 12V (inc. 25) Nut, Retainer Diode Assembly Coil, Ignition - Assembly Seal, High Tension Wire Cap, Spark Plug Seal, Spark Plug Nut, Flange Screw, Machine Cable Tie - 11.5 in.
2005 ATV 400 FIS Automatic Transmission
CARBURETOR (Complete Assembly p/n 0470-470) 0739-656 *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 5507-085 5507-109 5507-005 5507-110 5507-007 5507-047 5507-043 5507-009 5507-041 5507-042 5507-044 5507-010 5507-097 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 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 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 5507-180 5507-114 5507-065 5507-067 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
O-Ring Screw, Idle Adjust Washer Spring Plate Screw Choke, Electric Cover, Electric Choke Chamber, Float - Assembly (inc. 28-34) O-Ring, Float Chamber Screw, Drain Spring Diaphragm Assembly Housing, Pump U-Ring Screw Screw Cable, Throttle Cover Screw Hose, Vent
29
2005 ATV 400 FIS Automatic Transmission
CYLINDER HEAD ASSEMBLY 0738-415 *Not Illustrated
Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13
30
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
Ref. Part No. 14 15 16 17 18 19 20 21 22 23 24 25 *
3008-376 3423-453 3402-011 0217-708 3402-100 3402-101 3004-341 3402-035 3423-353 8476-620 0570-076 0423-066 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, Machine Manifold, Intake Clamp Plug, Frost
2005 ATV 400 FIS Automatic 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 2 1 2
Bolt Nut Gasket, Cylinder Pin, Dowel
31
2005 ATV 400 FIS Automatic Transmission
CRANKCASE ASSEMBLY 0739-843
Ref. Part No. Qty. Description 1 2 3 4 5 6
32
3402-580 3004-880 3005-332 3005-410 3402-012 3402-214
1 4 1 3 1 1
Crankcase Assembly (inc. 2-9) Bolt Bolt Bolt Gasket, Oil Pressure Plug Plug, Oil Pressure
Ref. Part No. 7 8 9 10 11 12
Qty. Description
3423-088 2 Pin, Dowel 3423-091 10 Bolt 3423-097 3 Bolt 3402-581 1 Plate, Oil Guide - Right 3004-552 4 Screw, Oil Guide Plate 3402-582 1 Plate, Oil Guide - Left
2005 ATV 400 FIS Automatic Transmission
CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY 0739-844
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
3402-583 1 Cover, Clutch 3402-589 1 Gasket 3423-088 6 Pin, Dowel 3423-098 26 Bolt 3423-392 1 Bolt 3003-290 1 Gasket 3402-586 1 Cover, V-Belt 3402-591 1 Gasket, V-Belt Cover 0693-327 14 Bolt 3004-552 3 Screw 3402-996 1 Plate, Air Intake 3402-444 1 Gasket, Drain Plug
3004-705 3402-041 3402-013 3402-585 3402-590 3004-705 3402-444 3402-593 3423-055 3423-307 3423-430
Qty. Description 1 1 1 1 1 1 1 1 1 2 1
Plug, Drain Plug Gasket Cover, Magneto Gasket, Magneto Cover Plug, Oil Gallery Gasket Stick, Oil Level O-Ring, Oil Level Stick Bolt Bolt
33
2005 ATV 400 FIS Automatic Transmission
CRANKSHAFT ASSEMBLY 0739-845 *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
34
3402-978 3402-597 3402-599 3402-571 3423-440 3402-600 3402-601 3402-698 3402-055 3402-566 3402-573 3402-602
1 1 1 1 2 1 1 1 1 1 1 1
Crankshaft Assembly (inc. 2-8) Rod, Connecting Pin, Crank Bearing Washer Crankshaft - Right Crankshaft - Left Gear, Crank Balancer Drive Bearing - Right Bearing - Middle Seal, Crankshaft Oil Retainer, Crankshaft Oil Seal - Middle
3423-018 3402-051 3423-063 3402-119 3402-070 3423-053 3402-188 3402-594 3402-595 3003-439 3402-596 3436-015
Qty. Description 6 1 1 1 1 1 1 1 1 2 1 1
Screw, Retainer Bearing O-Ring Spacer Seal, Oil O-Ring Retainer, Crankshaft Oil Seal - Left Piston Ring, Piston - Set Circlip Pin, Piston Piston Set (Oversized 0.50 mm)*
2005 ATV 400 FIS Automatic 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
35
2005 ATV 400 FIS Automatic Transmission
CRANK BALANCER ASSEMBLY 0739-846
Ref. Part No. Qty. Description 1 2 3 4
36
3402-605 3402-553 3004-540 3402-772
1 2 1 1
Balancer, Crank Bearing Key Gear, Driven
Ref. Part No. 5 6 7 8
3402-617 3423-110 3423-401 3423-555
Qty. Description 1 1 1 1
Gear, Oil Pump Drive Pin, Drive Gear Washer, Drive Gear Bolt, Drive Gear
2005 ATV 400 FIS Automatic Transmission
CAMSHAFT/VALVE ASSEMBLY 0739-847
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
3402-148 3402-078 3402-140 3402-141 3423-031 3423-111 3402-012 3402-725 3402-143 3402-726 3402-541 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
37
2005 ATV 400 FIS Automatic Transmission
CAM CHAIN ASSEMBLY 0737-051
Ref. Part No. Qty. Description 1 2 3 4 5 6
38
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 3402-287 3004-512
Qty. Description 1 1 1 1 2
Spring Plug O-Ring Gasket, Adjuster Bolt
2005 ATV 400 FIS Automatic 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
39
2005 ATV 400 FIS Automatic Transmission
OIL FILTER/PUMP ASSEMBLY 0737-035
Ref. Part No. Qty. Description 1 2 3 4 5 6 7 8
40
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 0436-146 3402-728 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
2005 ATV 400 FIS Automatic Transmission
TRANSMISSION ASSEMBLY 0737-052
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
3402-622 3402-623 3402-624 3402-625 3402-626 3402-627 3423-486 3423-487 3402-629 3402-477 3402-478 3402-630 3402-631 3402-481 3423-489 3402-632
1 1 2 1 1 1 1 2 2 3 3 1 1 4 1 1
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
3402-633 3423-437 3402-664 3402-620 3402-621 3402-977 3402-574 3423-505 3446-003 3446-278 3446-031 3423-435 3402-567 3402-693 3423-353 3423-501
Qty. Description 8 2 1 1 1 1 1 1 1 1 2 2 1 1 1 1
Roller, Movable Drive Face Nut V-Belt Housing, Clutch Spacer, Fixed Drive Face Seal, Clutch Housing Seal, Clutch Housing Circlip Clutch, One Way Shoe, Clutch - Assembly Retainer, Bearing Screw, Bearing Retainer Bearing Bearing O-Ring Nut
41
2005 ATV 400 FIS Automatic Transmission
SECONDARY TRANSMISSION ASSEMBLY 0739-848
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
42
3402-195 3402-503 3446-103 3402-634 3423-442 3402-500 3402-499 3402-665 3003-261 3402-045 3402-636 3423-066 3423-263 3402-494 3402-498 3402-635 3402-668 3402-496 3423-448 3402-495 3402-667 3004-209
2 1 1 1 1 1 1 1 1 2 1 3 3 3 3 1 1 1 2 1 1 1
Washer, Reverse Idle Gear Gear, Reverse Idle Bushing, Reverse Idle Gear Shaft, Reverse Idle Spacer, Reverse Idle Gear Seal, Driveshaft Bearing, Driveshaft Driveshaft Bearing, Driveshaft - Left Bearing, Shaft Dog, Reverse Driven Gear Circlip Washer Bushing Bearing Gear, Reverse Driven Gear, Driven - Low Dog, Sliding Washer Gear, Driven - High Countershaft Bearing, Shaft
3402-669 3423-191 3402-055 3423-370 3446-031 3402-666 3423-494 3446-244 3446-400 3006-322 3446-402 3423-617 3402-837 3423-767 3402-980 3423-766 3446-401 3003-290 3423-307 3402-981 3423-226
Qty. Description 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1
Gear, Drive - No. 2 Circlip Bearing, Output Shaft Screw, Bearing Retainer Retainer, Bearing Shaft, Output Spacer, Output Shaft Gasket, Housing Housing, Speedometer Sensor Seal, Shaft Shaft, Output Washer Rotor Washer Bearing O-Ring Cover, Speedometer Sensor Housing Gasket Bolt Sensor, Speedometer Bolt
2005 ATV 400 FIS Automatic Transmission
SECONDARY DRIVE ASSEMBLY 0739-850
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 3423-072 1 19 3402-639 1 20 3402-017 AR 3402-018 AR 3402-019 AR 3402-020 AR 3402-021 AR 3402-022 AR 3402-023 AR 3402-024 AR 3402-025 AR 3402-028 AR 3402-029 AR 3402-030 AR 3402-031 AR 21 3402-067 1 22 3402-514 1
3402-637 3446-035 3423-023 3005-372 3446-327 3402-562 3423-479 3423-025 3423-028 3402-742 3402-072 3402-558 3402-694 3423-137 3423-136 3402-638 3402-515
1 1 1 1 1 1 4 2 1 1 2 1 1 1 1 1 1
Gear, Secondary Drive Shim, Secondary Drive Gear - Set Nut Washer Yoke, Propeller Shaft Joint, Universal - Set (inc. 7) Circlip Nut Washer Yoke, Drive Output - Front 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
Qty. Description 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 Flange, Output Joint - Rear
43
2005 ATV 400 FIS Automatic Transmission
GEAR SHIFTING ASSEMBLY 0737-055
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
44
3402-640 3446-043 3446-283 3446-048 3402-642 3402-643 3402-644 3446-073 3004-787 3402-670 3446-281 3423-438 1691-043 3423-446 3402-076 3423-416 3004-376
1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1
Cam, Reverse Stopper, Cam Spring, Cam Stopper Support, Cam Stopper Plate, Gear Shift Cam Shaft, Shift Fork Shaft, Sub-Gear Shift Fork, Shift Clamp, Wire Cam, Gear Shift Shaft, Gear Shift Washer, Cam Stopper Spring Washer, Sub-Gear Shift Shaft Washer, Gear Shift Cam Plate Seal, Sub-Gear Shift Shaft C-Ring, Cam Bolt, Gear Shift Cam Plate
3423-141 3004-488 3423-358 3446-280 3423-044 3402-382 3423-191 3402-195 3423-421 3402-434 3423-204 3004-341 3423-153 3402-997 3423-418 3402-087
Qty. Description 1 1 2 2 2 2 4 1 1 1 1 1 1 1 2 2
Washer, Cam Stopper Nut, Cam Stopper Spring Circlip, Sub-Gear Shift Shaft Spring, Cam Contact Washer, Cam Spring Circlip, Cam Spring Washer, Shift Shaft Washer, Shift Shaft Arm, Select Washer, Select Arm Bolt, Select Arm E-Ring Base, Gear Shift - Assembly Bolt Spring
2005 ATV 400 FIS Automatic 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 4 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
45
2005 ATV 400 FIS Automatic Transmission
MAGNETO ASSEMBLY 0737-033
Ref. Part No. Qty. Description 1 2 3 4 5
46
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
2005 ATV 400 FIS Automatic Transmission
CONTROL SWITCH HOUSING ASSEMBLY 0739-980
Ref. Part No. Qty. Description 1 0509-014 2 0409-027
1 Switch, Control - Assembly (inc. 2-3) 1 Screw
Ref. Part No. 3 0409-028 4 3409-019
Qty. Description 1 Screw, Cap 1 Cover, Choke Lever
47
2005 ATV 400 FIS Automatic Transmission
THROTTLE CASE ASSEMBLY 0738-414
Ref. Part No. Qty. Description 1 2 3 4 5
48
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 w/Switch
RELATED ITEMS 2005 ATV 400 FIS (Automatic Transmission) Red (Model No. A2005ISH4BUSI) Green (Model No. A2005ISH4BUSH) Cat Green (Model No. A2005ISH4BUSJ)
0436-479 0436-548 0436-679 0436-336 0436-480 0436-640 0436-462 0436-616 0436-464 0436-454 0436-625 0436-459 0436-460 0436-652 0436-476 0436-477 0436-381 0436-339 0436-005 0436-003 0436-466 0436-538 0436-007 0436-501 0436-627 0436-706 0436-505 0436-352 0436-639 0436-463
Articulating Spool Mount Articulating Spool Receiver Mount Adapter Bag, Fender - Black Bag, Rack, Front - Black Bar, Utility/Gun Rack Brush Guard/Bumper Bucket Holder Bumper (Rear) Camp Stove Cradle Cargo Box Cargo Box Quick-Release Kit Carryall (9 x 12) Carryall (11 x 17) Carryall (14 x 27) Chain Saw Lock Cord Reel Cover, Black and Green Cover, Timber Camo Engine Oil - 10W40 Engine Oil - 5W30 Fender Box Gear Cradle Gear Lube (Diff) - 80W90 Grease, High-Performance Gun Scabbard Kit Gun Scabbard Mount Hand Guards - Black Hand/Thumb Warmers Ice Auger Holder Light Bar
Red - LE (Model No. A2005ISH4BUSN) Green - LE (Model No. A2005ISH4BUSM) Cat Green - LE (Model No. A2005ISH4BUSA)
2257-176 2257-034 2257-172 0436-626 0436-649 0436-648 0436-579 0436-580 0436-578 0436-511 0436-386 0436-228 0436-287 0436-296 0436-360 0436-356 0436-471 0436-624 0436-508 0436-465 1402-028 0402-563 0436-478 0436-297 0436-263 0436-468 0436-699 0436-361 0436-507 0436-470
Manual, Illustrated Parts Manual, Operator’s (E) Manuel d’utilisation (F) Rack Basket Rack Extension, 4 in. (Front) Rack Extension, 8 in. (Rear) Rapid Blind (Break-Up) Rapid Blind (Shadow Grass) Rapid Shack (Blue Ice) Rod Holder - Adjustable Snowplow Attachment Kit Snowplow Blade, 50 in. - Straight Snowplow Blade, 50 in. - One-Way Snowplow Blade, 60 in. - Straight Snowplow Blade, 60 in. - One-Way Snowplow, Push Frame Speedclamp, Double Sprayer System Sprayer Boom (120 in.) Table, Expansion Tire, Titan AT589 (25x8-12, Mud & Snow) Tire, Titan AT589 (25x10-12, Mud & Snow) Tool Caddy Tool Holder - Double Tool Holder - Single Tree Stand/Bow Case Holder Winch, 2500 lb Winch Mounting Kit Windshield, Clear w/Black 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 2257-176
