diagram(s) and/or partslist(s)€¦ · 42 0487-001 1 cable, throttle 43 0487-002 1 cable, choke 44...

1999 ATV 500 4X4 (99A4G-AP-1999) of 92AIR INTAKE ASSEMBLY

For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

1999 ATV 500 4X4 (99A4G-AP-1999) of 92AIR INTAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0423-066 Clamp12 0470-305 Boot, Air Cleaner13 0423-018 Clamp14 0470-337 Housing, Air Cleaner15 0623-301 Screw, Self-Tapping3 /P6 0470-343 Gasket, Air Cleaner17 0470-342 Snorkel, Air Cleaner1 S8 0470-307 Clamp, Air Cleaner49 0423-037 Spring, Air Cleaner4

10 0623-121 Screw, Machine411 0123-010 Nut, Expansion4 /P12 0410-004 Hose, Crankcase Vent113 0470-322 Filter, Air Cleaner (inc. 14)1 S14 0470-332 Sleeve, Filter115 0470-309 Valve, Air Cleaner1 S16 1673-272 Cap, Fitting - Air Cleaner1 /P17 0423-047 Clamp, Hose118 0423-045 Clamp, Hose - Spring219 0470-351 Support, Air Cleaner Flange220 0406-356 Plate, Heat - Air Intake121 0423-082 Clamp, Air Cleaner1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92BODY PANEL ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92BODY PANEL ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0506-392 Panel, Fender - Front (Green) (500)1 S1 0506-308 Panel, Fender - Front (Red) (500)1 S2 0506-145 Cover, Access (500)1 S2 0506-153 Cover, Access (Red)1 S3 0406-080 Flare - Front Right1 /P3 0406-081 Flare - Front Left1 /P4 0506-293 Rack - Front (500)1 /P5 0606-526 Reflector - Amber26 0623-269 Clip, Retaining87 0506-164 Panel, Side - Right (Green) (500)17 0506-242 Panel, Side - Right (Red)17 0506-165 Panel, Side - Left (Green) (500)17 0506-243 Panel, Side - Left (Red)18 0506-157 Panel, Fender - Rear (Green) (500)18 0506-307 Panel, Fender - Rear - Red19 0506-292 Rack - Rear (500)1 /P

10 0406-293 Wrap, Tube - Rear Rack111 0417-002 Foam, Access Panel112 0606-029 Reflector - Red213 0406-082 Flare, Rear Right113 0406-083 Flare, Rear Left114 0406-086 Mud Flap - Right114 0406-087 Mud Flap - Left115 0423-046 Rivet, Plastic5616 0406-084 Fender Extension - Rear Right116 0406-085 Fender Extension - Rear Left117 0423-010 Washer, Shoulder1618 0423-101 Screw, Body1619 0423-060 Clip, Tinerman220 0623-309 Screw, Self-Tapping221 8409-020 Screw, Cap6 /P22 8408-812 Screw, Cap223 0423-031 Nut, Speed224 0123-010 Nut, Expansion3 /P25 0423-068 Screw, Machine226 0623-184 Washer127 8477-616 Screw, Machine228 0406-297 Plate, Heat - Rear Panel129 0123-549 Screw, Machine1 /P30 8476-616 Screw, Machine1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CAM CHAIN ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CAM CHAIN ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-353 Chain, Cam (500)12 3402-355 Guide, Chain (500)13 3402-356 Tensioner, Chain (500)14 3423-074 Screw, Cap15 3003-188 Washer1 S/P6 3402-136 Adjuster, Tensioner - Assembly17 3402-137 Gasket18 3004-475 Screw, Cap2 S9 3003-290 Gasket2 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CAM SHAFT VALVE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CAM SHAFT VALVE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-027 Cam Shaft1 S2 3402-352 Sprocket (500)13 3423-047 Pin14 3423-073 Washer15 3423-013 Screw, Cap2 S6 3423-071 C-Ring1 /P7 3402-138 Arm, Valve Rocker (inc. 8-9)1 S8 3423-075 Screw, Cap29 3423-076 Nut2

10 3402-139 Arm, Valve Rocker (inc. 8-9)111 3402-148 Seat, Spring412 3402-078 Seal, Oil413 3402-140 Shaft, Rocker Arm114 3402-141 Shaft, Rocker Arm115 3423-031 Washer216 3402-040 Plug, Shaft2 /P17 3402-012 Gasket218 3402-142 Valve, Intake2 S19 3402-143 Valve, Exhaust220 3402-144 Spring, Valve - Set421 3402-146 Retainer, Spring4 S22 3402-147 Cotter, Valve8



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CARBURETOR



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CARBURETOR

Ref # Part Number Qty DescriptionS/P/F0470-361 Complete Assembly (500)1

1 4505-001 Cover Assembly12 4505-046 Spring (500)1 /P3 4505-003 Ring14 4505-004 E-Ring1 S5 4505-005 Ring16 4505-020 Jet Needle (500)1 /P7 4505-007 Screw4 S8 4505-008 Diaphram (500)1 S9 4505-009 Screw1

10 4505-010 Plunger Assembly (500)111 4505-011 O-Ring1 /P12 4505-012 Washer113 4505-013 Spring114 4505-014 Screw415 4505-016 Screw, Pilot (500)1 /P16 4505-098 Jet, Pilot 55 (500)117 4505-080 Jet, Main 150117 4505-047 Jet, Main 145118 4505-101 Needle Jet 0-4 (500)1 S18 4505-006 Needle Jet 0-4 (500)1 /P19 4505-021 Float Assembly120 4505-102 Seat, Valve 2.3121 4505-044 O-Ring, Bowl122 4505-045 Filter123 4505-049 Chamber, Float124 4505-038 Jet, Pilot - Air (500)1 S25 4505-025 Screw326 4505-026 Spring127 4505-027 Cable Adjust - Assembly128 4505-028 Cover129 4505-029 Washer130 4505-030 Screw131 4505-031 O-Ring132 4505-032 Guide, Cable133 4505-033 Washer234 4505-042 Screw135 4505-034 Clip1 /P36 4505-035 Hose237 4505-053 Clip238 4505-052 Hose1 S39 4505-039 Spring1 /P40 6505-153 Pin141 6505-006 Washer142 0487-001 Cable, Throttle143 0487-002 Cable, Choke144 6505-875 O-Ring1 /P45 4505-051 Screw, Cap346 4505-050 Cover Assembly, Primer1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CLUTCH ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CLUTCH ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-232 Housing, Starter Clutch (500)12 3446-003 Clutch, Primary Drive One Way13 3446-233 Shoe, Starter Clutch (500)14 3423-081 Nut, Starter Clutch Shoe15 3423-032 Washer, Starter Shoe16 3423-122 Washer, Primary Driven17 3423-350 Washer, Primary Driven (500)18 3446-002 Gear, Primary Driven - Assembly19 3446-004 Hub, Clutch Sleeve (500)1

10 3423-330 Screw, Cap, Clutch Spring411 3446-005 Spring, Clutch412 3446-006 Plate, Clutch Drive (500)613 3446-007 Plate, Clutch Driven (500)514 3446-008 Disk, Clutch Pressure115 3446-009 Plate, Clutch Release116 3423-080 Nut, Clutch Sleeve Hub117 3423-032 Washer, Sleeve Hub118 3446-011 Arm, Clutch Release119 3423-333 Bolt, Clutch Release (No. 1) (500)120 3423-083 Bolt, Clutch (No. 2)221 3446-214 Guide, Release Roller122 3446-013 Roller, Clutch Release - Assembly1 S23 3423-125 Bolt, Clutch Release Arm1 S24 3008-014 Nut, Clutch Release (No. 2)125 3423-022 Nut, Clutch Release (No. 1) (500)126 3423-027 Washer, Clutch (No. 2)127 3402-186 Bearing, Clutch1 /P28 3423-204 Washer, Clutch Release (No. 1) (500)1 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CONTROL SWITCH HOUSING ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CONTROL SWITCH HOUSING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3509-001 Switch, Handle - Assembly (inc. 2-5)1 S2 3409-009 Lever, Choke13 3409-010 Cover, Choke14 3423-196 Screw, Cap15 3423-197 Screw, Cap1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92COOLING ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92COOLING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0413-007 Screen, Radiator12 3002-964 Clamp, Wire2 /P3 8476-620 Screw, Cap24 0423-030 Grommet25 0423-036 Collar26 0610-016 Hose - 25 ft0 /P7 0413-002 Cap, Radiator1 S8 0413-001 Radiator Assembly (inc. 1, 4, 7, 9-10, 21, &

28)1

9 0423-062 O-Ring110 0430-010 Switch, Temperature Sensor1 /P11 0423-070 Clamp, Hose612 0410-002 Hose, Coolant - Upper113 0413-006 Blade, Fan114 0413-004 Motor, Fan115 8474-516 Screw, Machine316 0410-001 Hose, Coolant - Lower117 0410-003 Hose, Coolant - Crossover118 0423-101 Screw, Body419 0623-184 Washer220 0406-200 Panel, Fender - Inner221 0413-009 Screw, Thumb422 0423-031 Nut, Speed423 0423-056 Nut - Left124 8050-252 Washer125 0423-028 Bushing, Stem226 8477-616 Screw, Machine427 0123-788 Tie, Cable8 /P28 0 Radiator1 F



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CRANK BALANCER ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CRANK BALANCER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-350 Balancer, Crank (500)12 3402-050 Bearing23 3423-033 Washer14 3402-128 Gear, Driven15 3402-129 Race, Driven Gear - Inner16 3423-106 Pin3 /P7 3402-090 Spring68 3004-540 Key1 /P9 3423-107 Washer1

10 3423-200 Circlip1 /P11 3402-150 Gear, Oil Pump Drive (500)112 3423-114 Pin1 /P13 3402-151 Spacer114 3423-025 Nut, Lock115 3423-029 Washer1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CRANKCASE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CRANKCASE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-366 Crankcase Set (inc. 2-8, 10, 15, & 16) (500)1 S2 3423-088 Pin43 3423-091 Screw, Cap3 S4 3423-092 Screw, Cap7 S5 3423-094 Screw, Cap26 0693-303 Screw, Cap4 S7 3423-093 Screw, Cap28 3423-051 O-Ring (500)19 3402-011 Gasket1

10 3423-052 O-Ring (500)111 3423-009 Screw, Cap3 /P12 3423-024 Nut313 3004-278 Washer3 S/P14 3423-095 Plug, Oil Gallery115 3402-369 Jet, Piston Cooling (500)116 3004-552 Screw (500)1 S



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CRANKCASE COVER ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CRANKCASE COVER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-367 Cover, Clutch (inc. 2) (500)12 3402-112 Lens, Oil Inspection1 /P3 3402-108 Gasket14 3423-088 Pin45 0693-327 Screw, Cap14 S6 3423-097 Screw, Cap17 3003-290 Gasket1 /P8 3004-339 Plug, Oil Gallery1 S/P9 3003-290 Gasket1 /P

10 3402-042 Cap, Engine Oil Filler111 3423-055 O-Ring112 3402-363 Cap, Inspection (500)113 3402-101 O-Ring114 3423-096 Screw, Cap2 S15 3402-214 Plug, Oil Pressure (500)116 3402-012 Gasket117 3402-368 Cover Set, Transfer (inc. 18-19) (500)118 3402-097 Jet, Oil Mission119 3423-051 O-Ring120 3402-109 Gasket1 S21 3423-120 Clip122 3423-098 Screw, Cap13 S23 3423-092 Screw, Cap1 S24 3003-290 Gasket1 /P25 3423-348 Plug, Oil Gallery (500)226 3005-242 Gasket227 3402-041 Plug, Allen Head1 S28 3402-013 Gasket1 /P29 3413-009 Union, Water Drain130 3413-008 Hose1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CRANKSHAFT ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CRANKSHAFT ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-372 Crankshaft Assembly (inc. 2-9) (500)12 3402-376 Rod, Connecting (500)13 3402-377 Pin, Crank (500)14 3402-386 Bearing (500)1 S5 3423-351 Washer (500)26 3402-378 Crankshaft Set - Right (inc. 8-9 ) (500)17 3402-379 Crankshaft - Left (500)18 0 Gear, Balancer Drive1 F9 0 Pin1 F

10 3402-384 Bearing - Right (500)111 3402-058 Bearing - Center112 3402-054 Bearing - Left113 3402-120 Retainer, Bearing115 3402-188 Retainer, Oil Seal - Left1 /P16 3423-018 Screw, Cap317 3402-373 Piston (500)118 3402-374 Ring Set, Piston (500)119 3402-375 Pin (500)120 3423-344 Circlip (500)221 3402-431 Piston Assy (inc. 17, 18, and 20) (500)122 3402-051 Bearing123 3402-070 Seal, Oil124 3402-119 Spacer1 S25 3423-063 O-Ring126 3423-053 O-Ring1 /P27 3402-348 Spacer, Bearing - Left128 3004-491 Nut1 S/P29 3402-387 Seal, Oil130 3423-355 Circlip1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CYLINDER ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CYLINDER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-364 Cylinder (500)12 3423-090 Bolt, Stud23 3004-488 Nut2 S/P4 3402-365 Gasket, Cylinder (500)1 /P5 3423-088 Pin26 3413-006 Union, Water Hose17 3423-121 Screw, Cap1 S8 3423-058 O-Ring1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CYLINDER HEAD ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92CYLINDER HEAD ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F3402-370 Complete Gasket Set (500)1 S

1 3402-361 Head, Cylinder - Assembly (inc. 2-6) (500)12 3402-099 Guide, Valve43 3423-068 Circlip44 3423-043 Pin2 /P5 3423-006 Screw, Cap46 3008-376 Screw, Cap2 S7 3402-362 Gasket, Cylinder Head (500)18 3423-088 Pin29 3423-015 Screw, Cap2

10 3423-016 Screw, Cap211 3423-089 Screw, Cylinder Head Stud2 S12 3423-087 Screw, Cylinder Head Stud2 S13 3423-203 Bolt, Stud1 S/P14 3423-007 Screw, Cap2 S15 3004-376 Screw, Cap4 S/P16 3004-488 Nut4 S/P17 3004-326 Nut1 S/P18 3003-290 Gasket4 /P19 3402-010 Gasket, Head Nut420 0217-632 Spark Plug (NGK CR6E)121 3402-100 Cap, Inspection222 3402-101 O-Ring223 3004-341 Screw, Cap4 S/P24 3402-035 Plug, Cylinder Head125 3402-357 Pipe, Intake #1 - Assembly (500)125 3402-358 Pipe, Intake #2 - Assembly (500)126 3423-353 O-Ring (500)1 /P27 3423-347 Screw, Cap (500)228 3402-086 Clamp1 /P29 3004-341 Screw, Cap (500)1 S/P30 3413-012 Thermostat (500)131 3530-005 Switch, Water Temp - Assembly132 3413-004 Cover, Thermostat133 3423-354 Stud, Thermostat Cover134 3423-349 Nut135 3402-048 Plug, Frost1 F



1999 ATV 500 4X4 (99A4G-AP-1999) of 92DECALS



1999 ATV 500 4X4 (99A4G-AP-1999) of 92DECALS

Ref # Part Number Qty DescriptionS/P/F1 0411-006 Decal, Warning - Front Rack Load12 0411-120 Decal, Front (500)13 3611-002 Decal, "Made In U.S.A."14 0411-045 Decal, Warning - Turn15 0411-008 Decal, Warning Reverse/Pre-Ride1 /P6 0411-040 Decal, Warning - Age17 0411-010 Decal, Warning - General18 0411-112 Decal, Side Right (500)18 0411-113 Decal, Side Left (500)19 0411-180 Decal, Warning - Tire Pressure (500)1

10 0411-125 Decal, Fuel Valve (500)111 0411-007 Decal, Warning - Rear Rack Load112 0411-043 Decal, "Arctic Cat"1 /P13 0411-013 Decal, Warning - Towing114 0411-003 Decal, Shift Pattern115 0411-011 Decal, Caution - Electrical116 0411-009 Decal, Hi/Low Range1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92ENGINE AND EXHAUST



1999 ATV 500 4X4 (99A4G-AP-1999) of 92ENGINE AND EXHAUST

Ref # Part Number Qty DescriptionS/P/F1 0512-001 Pipe, Exhaust12 8408-820 Screw, Cap2 /P3 3423-009 Screw, Cap2 /P4 0423-050 Washer, Engine35 0423-042 Spacer, Engine1 S6 0462-011 Engine (500)1 S7 8428-002 Nut, Lock28 0412-007 Seal, Exhaust1 /P9 8424-802 Nut2

10 8408-860 Screw, Cap111 8408-816 Screw, Cap412 0506-083 Bracket, Upper Engine113 0502-016 Lever, Shift1 S14 8476-620 Screw, Cap115 0412-033 Bushing, Rubber316 0412-005 Muffler1 S17 0423-106 Screw, Cap318 0406-224 Cover, Exhaust119 8477-610 Screw, Machine420 0214-015 Clamp121 8053-211 Washer, Star4 S22 8424-602 Nut2 /P23 8476-640 Screw, Cap224 0107-630 Spacer225 0423-079 Clamp, Hose226 0406-298 Plate, Heat - Muffler1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92FRAME AND RELATED PARTS



1999 ATV 500 4X4 (99A4G-AP-1999) of 92FRAME AND RELATED PARTS

Ref # Part Number Qty DescriptionS/P/F1 0409-001 Headlight Assembly (inc. 3 and 13)22 8424-802 Nut63 0409-005 Bulb, Headlight24 8053-242 Washer, Lock2 /P5 8408-850 Screw, Cap26 0406-175 Screen, Bumper - Lower (500)17 0406-261 Yoke, Headlight28 0406-262 Mount, Headlight2 S9 8409-020 Screw, Cap (500)8 /P

10 0506-294 Guard, Brush (500)111 0506-176 Footrest - Right1 S12 0506-177 Footrest - Left1 S13 0123-590 Screw, Machine214 8408-816 Screw, Cap (500)1015 0506-133 Frame, Main116 0423-010 Washer, Shoulder1017 8474-616 Screw, Machine1018 0406-354 Panel, Belly1 /P19 0506-079 Tube, Cross - Bumper (500)120 0406-130 Cap, Bumper221 8408-820 Screw, Cap2 /P22 0506-149 Bracket, Differential123 8428-002 Nut, Lock124 3423-010 Screw, Cap1 /P25 0506-297 Channel, Bumper Mount (for Ref. No. 10)2 S/F26 8408-812 Screw, Cap (for Ref. No. 10)4 F



1999 ATV 500 4X4 (99A4G-AP-1999) of 92FRONT BEVEL GEAR ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92FRONT BEVEL GEAR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F3502-003 Complete Assembly1 S/P

1 3435-089 Flange, Gear (inc. 2-5)1 /P/F2 3435-029 Collar, Gear1 F3 3435-030 Plate, Oil Seal1 F4 3423-034 Plate, Gear1 F5 3423-060 O-Ring, Collar1 F6 3435-086 Gear, Bevel17 3435-021 Housing, Bevel Gear18 3435-022 Shim Set, Housing19 3423-178 Nut, Gear1 /P/F

10 3423-028 Washer, Bevel Gear1 F11 3402-016 Spacer, Bevel Gear112 3402-065 Bearing113 3402-066 Bearing1 /P14 3423-064 O-Ring115 3402-072 Seal, Joint116 3423-175 Bolt, Housing1 S17 3435-087 Gear118 3435-017 Shim Set119 3435-020 Shim Set120 3402-059 Bearing121 3402-072 Seal - Left122 3402-185 Bearing - Left123 3435-085 Differential - Assembly (500)124 3402-057 Bearing, Differential Case - Right125 3402-072 Seal, Output Oil126 3435-024 Housing (inc. 27)127 3402-084 Union, Breather128 3435-025 Case, Bearing129 3423-010 Bolt, Mounting2 /P30 3402-012 Gasket, Oil Drain Plug131 3402-013 Gasket, Oil Filler Plug1 /P32 3402-036 Plug, Oil Drain1 S33 3402-041 Plug, Oil Filler1 S34 3402-197 Plug135 3423-050 O-Ring136 3423-061 O-Ring137 3423-175 Screw, Cap8 S38 3423-070 Ring, Driveshaft - Front239 3435-007 Coupling, Propeller Shaft1 F40 3423-182 Screw, Cap6 S/F41 3004-491 Nut6 S/P/F42 0402-147 Bladder, Case1 S/F43 0123-811 Tie, Cable1 F44 8428-002 Nut, Lock1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92FRONT SUSPENSION ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92FRONT SUSPENSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0603-033 Retainer, Spring2 S2 0403-001 Shock Absorber - Front (inc. 3-4)23 0604-310 Bushing, Shock Absorber84 0403-028 Sleeve, Shock45 8428-002 Nut, Lock126 8409-040 Screw, Cap47 0403-002 Spring, Shock Absorber28 0403-025 Collar, Spring2 /P9 0403-013 Washer, Spring2

10 0503-026 A-Arm, Upper Right - Assembly (inc. one No. 11-12)

1 S/P

10 0503-027 A-Arm, Upper Left - Assembly (inc. one No. 11-12)

1 S/P

11 0405-001 Ball Joint - Front4 S12 0423-009 Clip, Ball Joint4 /P13 0505-026 Knuckle - Assembly - Right (inc. 14 and one

No. 15-18)1 S/P

13 0505-027 Knuckle - Assembly - Left (inc. 14 and one No. 15-18)

1 S/P

14 0505-024 Knuckle, Steering - Right1 S14 0505-025 Knuckle, Steering - Left1 S15 0402-275 Bearing, Wheel Hub - Front2 /P16 0423-034 Clip, Bearing217 0402-089 Seal, Wheel Bearing - Front218 0402-069 Seal, Wheel Bearing - Front219 8409-030 Screw, Cap420 8409-060 Screw, Cap821 0503-012 A-Arm, Lower Right (inc. one No. 11-12)1 S21 0503-013 A-Arm, Lower Left (inc. one No. 11-12)1 S22 0402-179 Axle, Drive - Front2 S23 0436-114 Repair Kit, Outer Boot - Front Axle2 S24 0436-113 Repair Kit, Inner Boot - Front Axle2 S25 0403-027 Retainer, Spring - Lower2



1999 ATV 500 4X4 (99A4G-AP-1999) of 92FUEL TANK ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92FUEL TANK ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0570-012 Tank, Fuel (inc. 2-3 and 8-12)1 S2 0470-315 Cap, Fuel Tank (inc. 3)1 S3 0470-316 Line, Fuel Cap Vent14 8476-650 Screw, Cap25 0623-184 Washer26 0406-169 Bushing, Fuel Tank Mount47 0406-170 Collar, Fuel Tank Mount28 0610-007 Line, Fuel0 /P9 0423-048 Clamp, Hose - Spring2

10 0 Gasket, Fuel1 F11 0470-363 Valve, Shut-Off (inc. 10)1 S12 8471-616 Screw, Cap213 0417-001 Pad, Fuel Tank4



1999 ATV 500 4X4 (99A4G-AP-1999) of 92GEAR SHIFTING ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92GEAR SHIFTING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-038 Fork, (No. 2)22 3446-039 Fork, (No. 3)13 3446-040 Fork, Reverse14 3446-052 Shaft, Gear Shift Fork25 3446-041 Cam, Gear Shift (inc. 6)16 3423-114 Pin, Gear Shift1 /P7 3446-241 Cam, Reverse Shift18 3446-049 Plate, Gear Shift Cam19 3446-050 Guide, Gear Shift Cam Plate1 S

10 3423-357 Washer, Reverse Shift Cam111 3402-051 Bearing, Gear Shift Cam112 3423-125 Bolt, Clutch Release Arm1 S13 3423-370 Screw, Cam Bearing Retainer214 3423-135 Retainer, Bearing215 3446-043 Stopper, Gear Shift Cam116 3446-117 Stopper, Reverse Shift Cam117 3446-164 Housing, Reverse Cam Stopper118 3446-047 Spring, Shift Cam Stopper Arm119 3446-048 Support, Shift Cam Stopper120 3402-012 Gasket, Cam Stopper Housing121 3402-088 Spring, Reverse Cam Stopper122 3423-141 Washer, Gear Shift Cam123 3423-142 Washer, Cam Stopper Arm124 3004-488 Nut, Cam Stopper Arm Support1 S/P25 3446-243 Shaft, Gear Shift (inc. 42)1 S26 3446-054 Spacer, Gear Shift Shaft127 3446-056 Stopper, Gear Shift Arm129 3402-076 Seal, Reverse Shift Oil130 3402-094 Spring, Gear Shift Return131 3446-055 Arm, Reverse Gear Shift132 3423-204 Washer, Gear Shift Cable Arm (500)1 /P33 3423-168 E Ring, Gear Shift Cable Arm1 S34 3423-166 Screw, Cap2 S35 3430-015 Base Assembly1 /P36 3423-044 Contact, Neutral137 3423-059 O-Ring, Neutral138 3004-787 Clamp139 3002-964 Clamp1 /P40 3402-087 Spring141 3402-008 Hub, Gear Shift1 /P42 3402-093 Spring, Gear Shift143 0706-990 Tape, Foil0 /P44 3423-358 Circlip, Reverse Shift Cam1 S45 3402-068 Seal, Gear Shift Shaft Oil (500)1 /P46 3402-385 Bearing, Gear Shift (500)1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92HI/LO SHIFTER ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92HI/LO SHIFTER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-242 Stopper, Shift Cam12 3446-046 Housing, Shift Stop13 3446-051 Shaft, Fork14 3446-073 Fork, Shift15 3446-250 Cam, Shift (500)16 3446-104 Spring17 3446-251 Shaft, Shift1 S8 3446-077 Plate, Lever Stop19 3446-105 Lever, Shift - Assembly (inc. 10-17)1 /P

10 3446-252 Rod, Sub111 3446-107 Spring112 3423-155 Washer113 3423-154 Circlip114 3423-205 Pin115 3446-106 Collar116 3423-152 Washer1 /P17 3423-153 E-Clip118 3446-078 Knob119 3402-191 Spacer120 3402-012 Gasket, Cam Stop121 3402-071 Seal, Oil1 /P22 3446-113 Spring123 3004-377 Bolt, Stopper Plate2 S/P24 3423-156 Screw, Shift Knob1 S25 3402-382 Washer, Cam Stop126 3423-158 Washer, Shaft - Left1 /P27 3423-191 Circlip, Cam Spring1 /P28 3423-192 Circlip, Shift Lever2 /P29 3423-193 Circlip, Shaft - Left1 S/P30 3446-261 Spacer Set (500)1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92HYDRAULIC BRAKE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92HYDRAULIC BRAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0402-053 Tube, Brake Line - Front12 0402-307 Hose, Brake - Front (500)13 0402-073 Block, Mounting24 0423-038 Bolt, Oil3 S5 0423-039 Washer, Crush66 0402-300 Caliper, Brake - Right Front (inc. 7-13 and

two No. 14-16)1 S

6 0402-301 Caliper, Brake - Left Front and Rear (inc. 7-13 and two No. 14-16)

2 S

7 0 Housing, Caliper3 F8 0402-164 O-Ring39 0117-868 Pin, Cotter3

10 0402-142 Pin, Hydraulic Brake Caliper311 0402-143 Cap, Bleeder Valve312 0402-096 Pad, Hydraulic Brake6 S13 0402-167 Valve, Bleeder314 0402-299 O-Ring, Hydraulic Brake Caliper615 0402-165 Washer616 0402-166 Screw, Socket Head6 S17 0402-184 Hose, Brake - Rear118 0402-115 Clip, Brake Line1 S19 0402-054 Tube, Brake Line - Rear120 8476-625 Screw, Cap121 8408-825 Screw, Cap422 8408-820 Screw, Cap2 /P23 0402-306 Switch, Brake Pressure (500)1 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92HYDRAULIC BRAKE CONTROL ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92HYDRAULIC BRAKE CONTROL ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0502-061 Brake, Lever - Assembly (inc. 2-14 and

17-20)1 S

2 0402-242 Lever, Brake1 S3 0623-430 Bolt, Lever Mounting1 /P4 0623-506 Screw, Cover - Master Cylinder25 0602-742 Cover, Master Cylinder16 0602-741 Gasket, Cover - Master Cylinder17 0602-740 Reservoir, Hydraulic Brake18 0602-587 O-Ring, Reservoir19 0 Master Cylinder1 F

10 0623-432 Screw, Reservoir Mount211 0623-056 Nut, Lock112 8052-212 Washer, Lock213 0623-613 Screw, Clamp2 /P14 0602-907 Clamp115 0402-050 Hose, Master Cylinder1 S16 8476-625 Screw, Cap117 0402-240 Lever, Brake Lock1 S18 0402-245 Spring119 0423-090 Nut, Press120 0402-246 Pin1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92MAGNETO ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92MAGNETO ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3430-011 Stator Assembly1 /P2 3430-012 Rotor13 3423-162 Bolt, Magneto3 S4 0691-785 Key, Magneto15 3423-086 Nut, Magneto16 3423-005 Screw, Cap3 /P7 3430-005 Clamp, Magneto (No. 1)18 3430-006 Clamp, Magneto (No. 2)19 3002-964 Clamp, Magneto (No. 3)1 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92MECHANICAL BRAKE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92MECHANICAL BRAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0502-048 Mechanical Brake Assembly (inc. 2-6)1 S2 0402-206 Arm, Inner13 0402-208 Pin, Arm24 0402-210 Pad, Mechanical Brake2 S5 0402-207 Arm, Outer16 0402-209 Spring, Arm27 0502-095 Lever, Foot Brake1 /P8 0487-006 Cable, Brake - Rear19 8408-820 Screw, Cap2 /P

10 0402-161 Spring, Foot Brake1 S/P11 0423-027 Washer, Brake Lever112 0623-237 Ring, Snap1 /P13 0502-056 Bracket, Brake Switch114 8476-616 Screw, Cap215 0670-183 O-Ring2



1999 ATV 500 4X4 (99A4G-AP-1999) of 92OIL FILTER/PUMP ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92OIL FILTER/PUMP ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-153 Pump, Engine Oil12 3402-026 Gear, Driven13 3423-046 Pin14 3423-115 Washer15 3423-184 Circlip1 S6 3423-113 Screw, Cap3 S/P7 3402-156 Strainer, Engine Oil18 0693-389 Screw, Cap2 S9 3402-157 Cap, Oil Strainer1

10 3423-077 O-Ring111 3004-756 Screw, Cap4 S12 0436-146 Filter, Engine Oil (500)1 S13 3402-036 Plug, Drain1 S14 3402-012 Gasket115 3402-359 Valve, Assembly - Oil Relief (500)116 3402-158 Union, Oil Filter1 S



1999 ATV 500 4X4 (99A4G-AP-1999) of 92REAR AXLE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92REAR AXLE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0502-080 Housing, Axle - Rear Right1 S2 8409-030 Screw, Cap33 8409-025 Screw, Cap14 0402-191 Axle - Rear25 0402-139 Gasket, Rear Axle16 0402-147 Bladder, Case1 S7 0123-811 Tie, Cable18 8476-616 Screw, Cap29 0506-135 Hitch, Trailer1

10 8408-840 Screw, Cap211 0402-138 Gasket, Rear Axle112 0423-010 Washer, Shoulder113 0502-081 Housing, Axle - Rear Left1 S14 0402-068 Seal215 0423-033 C-Clip216 0402-003 Bearing, Wheel Hub - Rear217 8424-802 Nut218 0423-031 Nut, Speed219 0406-097 Panel, Gear Case - Rear120 8408-816 Screw, Cap121 8050-252 Washer1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92REAR BEVEL GEAR ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92REAR BEVEL GEAR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F3402-005 Complete Assembly1

1 3435-051 Boot, Final Drive12 3435-081 Shaft, Rear Final1 /P3 3435-082 Coupling, Rear1 /P4 3435-083 Gear Set1 /P5 3435-015 Stopper, Rear Final16 3435-016 Pin, Bearing Stopper17 3435-019 Shim Set1 /P8 3435-020 Shim Set19 3435-065 Shim Set1 /P

10 3435-084 Case111 3435-026 Case - Right1 S12 3435-027 Case - Left113 3435-028 Housing114 3423-025 Nut, Rear Drive Pinion115 3423-029 Washer, Drive Nut116 3423-171 Washer - Left117 3003-290 Gasket, Bearing Stopper Pin1 /P18 3402-012 Gasket, Oil Drain Plug119 3402-036 Plug, Oil Drain1 S20 3402-039 Plug, Gear Oil Filler121 3402-052 Bearing122 3402-056 Bearing1 S23 3402-059 Bearing - Right124 3402-061 Bearing, Final Drive Pilot125 3423-173 O-Ring, Bearing Case - Right1 /P26 3423-057 O-Ring, Gear Oil Filler1 /P27 3423-065 O-Ring, Final Bearing Stopper128 3003-335 O-Ring, Bearing Case - Left1 /P29 3435-088 Seal, Final Driven1 /P30 3402-073 Seal, Oil1 /P31 3402-074 Seal, Oil132 3402-075 Seal, Oil133 3004-786 Clamp - Right1 /P34 3402-092 Spring135 3004-279 Stud, Bolt4 S/P36 3004-421 Stud, Bolt - Left2 S/P37 3423-175 Bolt, Bearing - Right9 S38 3402-187 Bearing - Left1 /P39 3004-326 Nut2 S/P40 3423-167 Nut, Rear Final Housing441 3423-194 Circlip Set1 S



1999 ATV 500 4X4 (99A4G-AP-1999) of 92REAR SUSPENSION ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92REAR SUSPENSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 8409-060 Screw, Cap22 8409-000 Screw, Cap23 0504-001 Arm, Swing34 8428-002 Nut, Lock85 8409-055 Screw, Cap16 0504-005 Arm, Swing17 0403-027 Retainer, Spring - Lower28 0404-001 Shock Absorber - Rear (inc. two No. 9 & four

No. 10)2

9 0403-028 Sleeve, Shock410 0604-310 Bushing, Shock Absorber811 0603-033 Retainer, Spring2 S12 8409-040 Screw, Cap413 0404-006 Spring, Shock Absorber2 /P14 0403-025 Collar, Spring2 /P15 0403-013 Washer, Spring Adjustment216 8422-002 Nut, Lock117 8409-065 Screw, Cap1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92RECOIL STARTER ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92RECOIL STARTER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3445-003 Starter, Recoil - Assembly (inc. 2-12)12 3445-004 Reel13 3445-016 Ratchet Assembly (inc. 4 and 6-10)14 0 Pin, Ratchet1 F5 3445-007 Spring, Spiral16 0 Spring, Friction1 F7 0 Shaft1 F8 0 Cover, Spring1 F9 0 Plate, Friction1 F

10 0 Guide, Ratchet1 F11 3004-488 Nut1 S/P12 3445-011 Rope Assembly113 3445-013 Gasket1 /P14 3423-112 Screw, Cap4 S15 3445-026 Cup, Starter (500)1 S16 3004-491 Nut1 S/P17 3423-053 O-Ring1 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92REVERSE SHIFT LEVER ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92REVERSE SHIFT LEVER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0402-239 Axle, Reverse Shift12 8476-616 Screw, Cap13 3446-055 Arm, Reverse Shift14 0502-059 Lever, Reverse1 S5 0423-096 O-Ring26 0423-063 E-Ring27 0402-136 Spring, Reverse Lever1 S8 0409-008 Reverse Switch19 0402-168 Retainer, Switch1 /P

10 0402-062 Knob, Reverse Shift Lever111 3423-168 E-Ring1 S12 0487-003 Cable, Shift1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92SEAT ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92SEAT ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 5990-176 Seat Assembly (inc. 2-8)1 /P2 0506-290 Cover, Seat13 0506-291 Foam, Seat14 0506-223 Base, Seat Assembly (inc. 5-7)1 /P5 0 Base, Seat1 F6 8061-628 Rivet47 0506-147 Pin, Seat Base - Front2 S8 0624-100 Staple09 0406-309 Grommet, Seat - Center2

10 8476-620 Screw, Cap211 0406-235 Spring, Seat Latch112 8050-217 Washer2 /P13 0406-199 Collar, Front Seat Base214 0406-171 Bumper, Seat Base - Front215 0623-404 Cap, Protector116 0406-103 Latch, Seat - Assembly1 S17 8477-616 Screw, Machine218 0411-182 Decal, Cold Start1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92SECONDARY DRIVE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92SECONDARY DRIVE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3435-010 Joint Assembly, Rear Output (inc. 2-8)12 3435-066 Boot, Joint - Set (inc. 3-7)13 3423-212 Band14 3435-067 Boot15 3423-211 Band16 3423-210 Ring, Snap17 3423-356 Seal, Plate18 0 Flange, Output1 F9 8408-820 Screw, Cap4 /P

10 3423-025 Nut111 3423-028 Washer212 3435-003 Flange, Output Joint1 S13 3402-072 Seal, Oil214 3402-067 Bearing w/ Locating Ring and Pin2 S15 3402-017 Shim - 0.60 mm115 3402-018 Shim - 0.65 mm115 3402-019 Shim - 0.70 mm115 3402-020 Shim - 0.75 mm115 3402-021 Shim - 0.80 mm1 S15 3402-022 Shim - 0.85 mm115 3402-023 Shim - 0.90 mm115 3402-024 Shim - 0.95 mm115 3402-025 Shim - 1.00 mm1 S15 3402-028 Shim - 1.05 mm115 3402-029 Shim - 1.10 mm115 3402-030 Shim - 1.15 mm115 3402-031 Shim - 1.20 mm116 3446-240 Shaft - Rear1 S17 3446-222 Gear1 /P18 3402-062 Bearing w/Groove1 S19 3423-072 Ring, Bearing120 3423-137 Washer121 3423-136 Nut122 3446-239 Shaft - Front123 3435-001 Yoke, Drive Output (inc. 24-27)1 S24 3435-029 Collar, Yoke125 3423-060 O-Ring126 3435-030 Plate, Yoke Collar127 3423-035 Plate, Yoke Collar128 3423-025 Nut129 3435-011 Joint Set, Universal (inc. 30)130 3423-067 Circlip431 3435-002 Yoke, Joint132 3435-005 Boot, Propeller Shaft1 /P33 3435-004 Shaft, Propeller134 3004-552 Screw, Cap1 S35 3423-135 Retainer2



1999 ATV 500 4X4 (99A4G-AP-1999) of 92SECONDARY TRANSMISSION ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92SECONDARY TRANSMISSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-262 Shaft, Output1 /P2 3446-066 Gear, Idle13 3446-072 Gear, Driven14 3402-391 Washer (500)2 S5 3402-015 Spacer, Drive16 3446-248 Gear No. 2 (500)27 3446-249 Dog, Select Sliding (500)18 3423-036 Washer19 3446-103 Bushing1

10 3402-046 Bearing, Driveshaft - Left111 3402-047 Bearing, Center Shaft - Left1 S12 3423-066 Circlip No. 11 /P13 3402-195 Washer, Gear No. 2 (500)114 3446-246 Spacer (500)115 3423-148 Spacer, Idle Gear116 3446-245 Gear No. 1 (500)117 3446-247 Bushing (500)118 3402-045 Bearing Set - Left1 /P19 3423-150 Washer1 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92SPEEDOMETER DRIVE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92SPEEDOMETER DRIVE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-031 Retainer, Bearing2 /P2 3402-009 Washer, Driven1 /P3 3423-370 Screw, Retainer24 3402-077 Seal, Driven Gear15 3446-221 Gear1 S6 3446-035 Shim Set17 3423-023 Nut18 3423-032 Washer19 3423-146 Washer - Right1

10 3446-114 Spacer, Driven Gear1 /P11 3423-143 Bolt, Gear1 S12 3423-145 Washer113 3423-056 O-Ring114 3423-144 Washer115 3423-346 Bolt, Gear2 S16 3402-180 Bearing Set - Right1 S17 3446-057 Housing, Odometer Gear118 3446-058 Sleeve119 3446-244 Gasket1 /P20 3446-060 Gear, Drive121 3446-061 Gear, Driven1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92STARTER CLUTCH ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92STARTER CLUTCH ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-123 Limiter, Assembly - Idle Gear (500)12 3402-125 Bushing23 3423-103 Washer2 /P4 3402-349 Gear, Starter Idle (500)15 3423-042 Pin16 3402-380 Clutch, Starter - Set (inc. 7)1 /P7 3402-063 Bearing18 3423-104 Washer19 3423-102 Screw, Cap6 S

10 3423-352 Spacer (500)1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92STARTER MOTOR ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92STARTER MOTOR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3545-014 Motor, Starter Assembly (inc. 2-9) (500)1 /P2 3008-094 Terminal Set, Brush1 /P3 3008-095 Holder Set, Brush1 /P4 3008-096 Spring, Brush45 3008-164 O-Ring16 3423-084 O-Ring17 3436-001 Washer Set18 3008-553 O-Ring2 /P9 3423-085 Screw, Cap2

10 3423-162 Screw, Cap2 S11 3423-195 Nut1 /P12 3423-201 Circlip1 /P13 3402-043 Bearing, Pinion Shaft1 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92STEERING ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92STEERING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0487-005 Cable, Speedometer12 8477-616 Screw, Machine33 0420-003 Speedometer (inc. 36-41)1 S4 0423-052 Collar, Body15 3430-013 Switch, Ignition - Assembly (inc. 6)1 S6 3409-007 Key, Ignition - Blank (C Series)1 /P6 3409-011 Key, Ignition - Blank (D Series)17 0420-011 Bezel/Lens, Warning - Assembly18 0420-012 Bezel/Lens, Shifting - Assembly19 0405-019 Instrument Pod1

10 0420-013 Bulb, Light Bar911 0420-001 Light, Warning - Assembly112 0420-004 Light, Shift Indicator - Assembly113 0123-950 Screw, Self-Tapping414 8408-860 Screw, Cap615 0405-035 Cap, Steering Adjuster416 0506-139 Bracket, Key Switch1 S17 0505-028 Tube, Handlebar1 S18 0405-039 Grip, Handlebar2 /P19 0605-171 Housing, Bearing - Lower120 0405-020 Bearing, Steering Post221 0705-064 Housing, Bearing - Upper1 /P22 0623-175 Pin, Cotter423 0505-012 Post, Steering124 8408-816 Screw, Cap225 0602-233 Flange, Bearing126 0405-052 Bearing - w/Inverted Oil Seal127 0423-073 Washer128 8409-020 Screw, Cap1 /P29 8422-002 Nut, Hex Castle430 0505-021 Tie Rod, Assembly (inc. 31-35)2 S31 8420-002 Nut - Right2 /P32 0405-040 Ball Joint, Tie Rod - Right2 S33 0405-041 Ball Joint, Tie Rod - Left2 S34 0423-013 Nut - Left235 0405-032 Tie Rod236 0620-149 Bulb, Speedometer1 /P37 0420-014 Harness, Speedometer138 0420-018 Bracket, Speedometer139 0420-016 Mount, Rubber240 0420-017 Washer241 0420-015 Pin, Retainer242 0423-067 Tube, Loom143 0409-013 Cover, Key144 8060-428 Rivet2



1999 ATV 500 4X4 (99A4G-AP-1999) of 92STORAGE BOX AND BATTERY ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92STORAGE BOX AND BATTERY ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 8476-616 Screw, Cap12 0506-178 Strap, Battery - w/Pads (inc. 3 and 11)13 0406-289 Pad, Battery - Upper Rear24 0445-005 Battery Assembly (inc. 5-7)1 S5 0645-045 Cap, Battery66 0645-152 Clamp, Hose17 0645-263 Hose, Battery Vent1 /P8 0123-903 Tie, Cable09 0406-227 Pad, Battery - Lower1

10 0444-079 Kit, Tool1 S/P11 0406-288 Pad, Battery - Upper Front112 0530-001 Fuse Box - Assembly (inc. 13-16)113 0 Block, Fuse1 F14 0 Lid, Fuse Block1 F15 0411-042 Decal, Fuse Block116 0630-057 Fuse, 10 AMP316 0630-058 Fuse, 15 AMP217 0123-549 Screw, Machine4 /P18 0506-102 Storage Box - Assembly (inc. 19-27)1 /P19 0406-257 Box, Tool1 S20 8050-152 Washer621 0406-208 Lid, Tool Box122 0773-401 Chain, Storage123 8061-223 Rivet2 /P24 0123-010 Nut, Expansion4 /P25 0673-973 Seal, Storage Cover126 0406-205 Ring, Mounting - Storage Box Lid1 /P27 8060-630 Rivet628 0623-301 Screw, Self-Tapping2 /P29 0423-044 Clamp, Tube4



1999 ATV 500 4X4 (99A4G-AP-1999) of 92TAILLIGHT ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92TAILLIGHT ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F0409-002 Complete Taillight Assembly1

1 0109-460 Bulb, Stop - Taillight1 /P2 0409-011 Taillight w/Socket Assembly13 0409-012 Gasket, Taillight14 0409-007 Lens, Taillight15 0409-010 Screw, Machine26 0623-301 Screw, Self-Tapping2 /P7 8053-212 Washer, Lock - External Tooth2 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92THROTTLE CASE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92THROTTLE CASE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3509-003 Case, Throttle - Assembly (inc. 2-9)1 /P2 3409-001 Lever13 3004-533 Screw, Cap1 S/P4 3004-447 Washer, Lock1 /P5 3003-030 Washer1 /P6 3423-014 Screw, Cap17 3423-327 Nut18 3423-199 Screw, Cap29 3004-638 Screw, Cap1 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92TRANSMISSION ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92TRANSMISSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-014 Shaft, Counter12 3446-016 Gear, 2nd Drive13 3446-215 Gear, 3rd Drive14 3446-018 Gear, 4th Drive15 3446-216 Gear, 5th Drive16 3446-020 Bushing, 5th Drive Gear17 3423-037 Washer, 5th Drive Gear18 3402-050 Bearing, Center Shaft - Right19 3402-081 Bushing, 4th Drive Gear1

10 3423-066 Circlip, 4th Drive2 /P11 3423-190 Circlip, Reverse Idle1 S12 3402-179 Bearing, Center Shaft113 3402-195 Shim114 3423-187 Washer, 4th Drive2 /P15 3423-126 Washer, Reverse Idle2 /P16 3446-234 Driveshaft (500)117 3446-235 Gear, 1st Driven (500)1 /P18 3446-022 Gear, 2nd Driven119 3446-218 Gear, 3rd Driven120 3446-024 Bushing, 3rd Driven121 3446-219 Gear, 4th Driven1 /P22 3446-220 Gear, 5th Driven123 3446-029 Gear, Reverse Driven124 3446-030 Dog, Reverse125 3446-032 Bushing, Reverse Driven126 3423-038 Washer, 3rd Driven - Right127 3423-039 Washer, 3rd Driven - Left128 3423-040 Washer, 3rd Driven - Left129 3402-336 Bearing, Driveshaft130 3402-080 Bushing, 1st Driven1 S31 3402-082 Bushing, 2nd Driven132 3423-188 Circlip, 2nd Driven2 S33 3446-238 Bushing, Reverse Idle134 3003-320 Bearing, Driveshaft - Right1 /P35 3402-335 Washer, Reverse Driven236 3446-237 Gear, Reverse Idle137 3423-131 Washer, 1st Driven - Right138 3402-383 Washer, 2nd Driven (500)139 3423-189 Circlip, Reverse Driven1 S40 3446-236 Shaft, Reverse Idle1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92WATER PUMP ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92WATER PUMP ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-354 Case, Water Pump (inc. 2-3) (500)1 /P2 3423-343 Screw, Cap (500)13 3003-188 Gasket1 S/P4 3423-078 O-Ring15 3004-507 Screw, Cap2 S6 3423-119 Screw, Cap1 S7 3413-011 Joint, Pump Drive (500)1 /P8 3413-002 Shaft, Water Pump w/Bearing19 3423-046 Pin1

10 3003-356 Seal, Pump Drive111 3402-360 Seal, Mechanical1 S12 3413-001 Impeller113 3003-426 Screw, Cap114 3003-431 Washer1 /P15 3003-432 Gasket1



1999 ATV 500 4X4 (99A4G-AP-1999) of 92WHEEL AND TIRE ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92WHEEL AND TIRE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3423-213 Nut, Hex42 0402-140 Cap, Valve Stem43 0402-064 Valve, Stem44 0402-215 Wheel - Front25 0402-277 Tire (500)46 0123-458 Pin, Cotter4 /P7 0423-080 Washer48 0402-181 Seal, Hub49 0502-041 Hub, Wheel - Front2 S

10 0402-009 Disc, Brake3 S11 0423-029 Screw, Machine1212 0502-042 Hub, Wheel - Rear2 S13 0402-311 Wheel - Rear (500)214 0402-277 Tire - Rear215 0403-035 Cap, Wheel - Center4 /P16 8409-020 Screw, Cap16 /P



1999 ATV 500 4X4 (99A4G-AP-1999) of 92WIRING HARNESS ASSEMBLY



1999 ATV 500 4X4 (99A4G-AP-1999) of 92WIRING HARNESS ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0486-020 Harness, Main (500)12 0486-029 Diode (500)13 0123-903 Tie, Cable04 8060-428 Rivet25 0445-001 Receptacle, 12V16 0123-149 Washer2 /P7 0486-004 Harness, 12V Receptacle18 0409-009 Switch, Brake - Assembly29 3430-008 Seal, Spark Plug1 /P

10 3430-007 Cap, Spark Plug1 /P11 3430-009 Seal, High Tension Cord1 /P12 8424-602 Nut2 /P13 0107-630 Spacer214 3530-004 Coil, Ignition - Assembly1 /P15 8476-640 Screw, Cap216 0423-075 Tie, Cable - Push Mount317 0423-065 Base, Wire Tie118 3430-037 Regulator, Voltage1 S19 8476-625 Screw, Cap220 8476-616 Screw, Cap221 3530-003 CDI Unit122 3530-008 Relay, Neutral Start - Assembly1 S23 3530-001 Relay, Starter Motor - Assembly (inc. 25)1 /P24 3423-020 Screw, Cap2 /P25 0630-098 Fuse, 30 Amp126 0445-003 Cable, Battery/Electric Start Relay1 /P27 0445-004 Cable, Battery/Electric Start128 0645-019 Boot, Terminal329 0445-002 Cable, Battery/Ground130 0402-168 Retainer, Switch1 /P



diagram(s) and/or partslist(s)€¦ · 42 0487-001 1 cable, throttle 43 0487-002 1 cable, choke 44...

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