Sabercat 700 EFI EXT2
Transcription
Illustrated Parts Manual 2 0 0 5 Sabercat 700 EFI EXT TM Overseas, red Model Number S2005SCFXEOSR TABLE OF CONTENTS 2005 Sabercat 700 EFI EXT Model No. S2005SCFXEOSR - EXT Red SKI AND SPINDLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 A-ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SHOCK ABSORBER AND SWAY BAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FRONT SUSPENSION SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STEERING POST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TIE ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HANDLEBAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HYDRAULIC BRAKE CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DRIVE/DROPCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DRIVE/REVERSE DROPCASE ASSEMBLY (LX/EXT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DROPCASE AND CHAIN TENSION ASSEMBLY (LX/EXT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REVERSE SHIFT LEVER ASSEMBLY (LX/EXT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SLIDE RAIL AND TRACK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 IDLER WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION FRONT ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION FRONT ARM SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION REAR ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION REAR ARM SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 17 18 19 20 FRONT FRAME AND FOOTREST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 HOOD AND WINDSHIELD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES (LX/EXT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CONSOLE AND SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 BELLY PAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 BELT GUARD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 GAS TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SEAT AND STORAGE BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY (EXT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 COOLING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ENGINE AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 EXHAUST ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FLEX-DRIVE STARTER MOTOR ASSEMBLY (LX/EXT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 BATTERY, SOLENOID, AND CABLES (LX/EXT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 AIR SILENCER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 CYLINDER AND HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 PISTON AND CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 REED VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 THROTTLE BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 WATER PUMP AND THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 SERVOMOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 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. ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 Printed July 2004 2005 Sabercat 700 EFI SKI AND SPINDLE ASSEMBLY 0739-677 1 1703-109 2 0603-624 3 2603-456 2603-457 4 1703-503 5 0603-621 6 1703-432 2 2 1 1 2 4 1 1703-433 1 0603-158 0603-083 1623-010 0603-647 8005-584 0623-796 1603-203 4 4 2 4 2 2 6 7 8 9 10 11 12 13 Ski, Plastic - Black Handle, Plastic - Black Wearbar - Right Wearbar - Left Saddle, Ski - Black (inc. 5) Insert, Ski Saddle Spindle, Steering - Right - Black (inc. 7-14) Spindle, Steering - Left - Black (inc. 7-14) Bearing Bearing Fitting, Grease Insert, Spindle Screw, Cap Ring, Retaining Washer, Thrust 14 1703-659 15 0603-034 16 6611-258 2 2 2 Arm, Steering Axle, Spindle Decal, “AWS” - Spindle 17 18 19 20 21 22 23 24 25 26 27 28 2 4 4 2 2 2 4 2 8 2 2 4 Cap, Spindle Nut, Lock Screw, Machine Damper, Ski Screw, Cap Pin, Cotter Washer Nut, Lock Nut, Lock Screw, Cap Screw, Cap Nut, Lock 0623-831 8048-366 8017-581 0603-036 0623-552 0123-458 0623-728 0123-296 8047-486 8020-135 8020-143 8048-426 1 2005 Sabercat 700 EFI A-ARM ASSEMBLY 0739-674 1 1703-734 1703-735 2 1603-895 3 1703-426 4 0603-083 5 0623-952 6 0623-664 7 1603-563 8 8048-486 2 1 1 8 2 8 2 4 2 8 A-Arm, Lower - Right - Black (inc. 2) A-Arm, Lower - Left - Black (inc. 2) Bearing A-Arm, Upper - Black (inc. 4) Bearing Screw, Cap Washer Axle, Inner - Upper Arm Nut, Lock 9 10 11 12 13 14 15 16 0603-864 8020-230 2603-179 2606-886 1623-009 8040-546 1603-616 8026-232 2 4 4 1 2 2 4 2 Tube, Axle Screw, Cap Axle, Inner - Lower Arm Brace, Lower A-Arm Screw, Cap Nut, Lock Axle, Powder Metal Screw, Cap 2005 Sabercat 700 EFI SHOCK ABSORBER AND SWAY BAR ASSEMBLY 0739-678 1 2 3 4 5 6 7 8 1703-795 1603-890 8048-486 1603-023 0623-991 8020-232 0603-648 2 2 8 4 2 2 2 Shock, Ski Retainer, Spring Nut, Lock Sleeve, Shock Washer Screw, Cap Spacer, Shock Mount 2603-304 2 Spring, Compression - Silver 9 10 11 12 13 14 15 16 1703-616 1603-211 2603-307 8020-226 8020-225 1603-002 8048-426 8002-137 1 2 2 2 2 2 4 4 Sway Bar Bearing Arm, Sway Bar Screw, Cap Screw, Cap Link, Sway Bar Nut, Lock Screw, Cap 3 2005 Sabercat 700 EFI FRONT SUSPENSION SHOCK ABSORBER (Complete Shock Absorber p/n 1703-795) 0738-644 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 2603-262 1603-501 2603-461 0603-991 1703-452 1604-271 1603-996 1604-274 1604-272 2603-055 2603-065 2603-075 2603-095 2603-124 2603-047 2603-052 2603-132 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 Body, Shock Eyelet, Shock Rod, Shock Bumper, Shock Cap, Shock (inc. 6) O-Ring Piston, 0.120 in. - Orifice Strap, Piston - Teflon Washer, Top Out Valve, 0.800 x 0.010 in. Valve, 0.900 x 0.010 in. Valve, 1.000 x 0.010 in. Valve, 1.100 x 0.010 in. Valve, 1.250 x 0.008 in. Valve, 0.700 x 0.015 in. Valve, 0.800 x 0.006 in. Valve, 1.300 x 0.006 in. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 2603-122 2 2603-062 1 2603-125 1 1604-273 1 0623-696 1 1603-911 1 0704-791 1 2604-153 1 2604-152 1 2603-012 1 1603-209 2 1603-914 2 0624-433 1 2604-649 1 2604-162 1 0603-955 2 2639-151 AR Valve, 1.250 x 0.006 in. Valve, 0.900 x 0.006 in. Valve, 1.250 x 0.010 in. Washer, Backup Nut, Lock Nut, Adjuster Piston, Floating (inc. 25-26) Strap, Piston - Teflon O-Ring Sleeve, Protector Sleeve, Eyelet Bushing, Shock Screw, Valve Valve, Pressure (inc. 32) O-Ring, Valve Bushing, Shock Oil, Gas Shock - 6 qt Case 2005 Sabercat 700 EFI STEERING POST ASSEMBLY 0738-711 1 2 3 4 5 6 7 8 9 10 11 12 8002-137 0605-506 0605-507 8048-426 0705-844 0605-576 4 2 1 4 1 2 Screw, Cap Cap, Adjusting Block Block, Adjusting Nut, Lock Post, Steering Block, Mounting - Steering Post 0705-934 0623-779 8017-581 8048-366 8040-426 8004-225 1 2 2 4 2 1 Plate, Retaining (inc. 8) Insert Screw, Machine Nut, Lock Nut, Lock Screw, Cap 13 14 15 16 17 18 19 20 21 22 23 24 0623-025 0623-044 0705-947 8017-402 0605-504 0623-294 0605-672 0123-917 0605-511 0630-149 0623-902 0630-146 3 2 1 2 1 1 1 1 1 1 2 1 Nut, Lock Washer Stop, Steering Post Screw, Machine Ball Joint, Tie Rod - Right Nut, Hex - Right Tube, Tie Rod Nut, Hex - Left Ball Joint, Tie Rod - Left Module, Control - Remote Starter Screw, Machine Control, Remote 5 2005 Sabercat 700 EFI TIE ROD ASSEMBLY 0739-679 1 2 3 4 5 6 7 8 9 6 0705-397 0623-954 0623-955 0605-635 0623-956 8005-584 1705-045 0605-607 1623-176 1 4 2 2 2 2 1 2 2 Shaft, Steering Washer, Thrust Washer, Thrust Arm, Shaft Snap Ring Screw, Cap Shaft, Idler Ball Joint, Tie Rod - Left Screw, Cap 10 11 12 13 14 15 16 17 18 0605-673 0123-917 0623-294 0605-608 0623-957 0605-605 0605-312 0605-606 1606-079 2 3 3 2 2 1 1 1 2 Tube, Tie Rod - Spindle Nut, Hex - Left Nut, Hex - Right Ball Joint, Tie Rod - Right Screw, Cap Ball Joint, Tie Rod - Left Tube, Tie Rod Ball Joint, Tie Rod - Right Plug 2005 Sabercat 700 EFI CONTROL ASSEMBLY 0739-778 *Not a Service Part 1 0609-632 2 3 4 5 6 7 8 9 10 11 12 13 0609-576 0609-611 0609-615 0609-612 0609-633 0609-604 0609-501 0609-036 0609-040 0609-577 0609-565 1639-963 1 1 1 1 2 1 4 2 2 1 1 1 1 Control, Throttle - Assembly (inc. 2-6 and two No. 7) Control, Housing Half (inc. 3-5) Clip, Retaining Plate Screw, Self-Tapping Control, Switch Half Screw, Machine Seal, Throttle Lever Washer E-Ring Axle, Lever - Throttle Lever, Throttle Tool, Removal - Kit - Throttle Cable 14 0609-667 15 0617-248 16 0609-628 17 18 19 20 21 22 23 24 25 26 1 1 1 Element, Thumbwarmer Pad, Insulator Control, Stop Switch/Warmer - Assembly (inc. two No. 7 and 17-24) 0609-636 1 Control, Warmer Half (inc. 18-21) 0609-605 1 Screw, Machine 0609-573 1 Knob, Handwarmer 0609-606 1 Screw, Machine 0609-572 1 Knob, Thumbwarmer 0609-635 1 Control, Stop Switch Half (inc. 23-24) 0609-607 2 Screw, Machine * 1 Switch, Stop 0123-788 AR Cable Tie - 8 in. 0687-155 1 Cable, Throttle 7 2005 Sabercat 700 EFI HANDLEBAR ASSEMBLY 0739-680 1 0705-846 2 1606-442 3 0609-668 0609-670 8 1 2 1 1 Handlebar Grip, Handlebar Element, Handwarmer - Right Element, Handwarmer - Left 4 0605-611 5 0705-954 1 1 Pad, Handlebar Wrap, Handlebar Pad 2005 Sabercat 700 EFI HYDRAULIC BRAKE CONTROL ASSEMBLY 0738-179 *Not a Service Part **Not Illustrated 1 2 3 4 5 6 7 8 9 1602-364 1602-363 1623-027 0623-056 0602-740 0602-741 0602-742 0623-506 0623-613 1 1 1 1 1 1 1 2 2 Brake Assembly (inc. 2-14) Lever, Brake Screw, Lever Mounting Nut, Lock Reservoir Gasket, Cover Cover, Reservoir Screw, Cover Screw, Machine 10 11 12 13 14 ** 15 16 17 0602-587 1 O-Ring * 1 Master Cylinder 8052-212 2 Washer, Lock - Internal Tooth 0623-432 2 Screw, Master Cylinder Mounting 0602-907 1 Clamp, Master Cylinder 0638-315 AR Fluid, Brake - High Temperature 0609-629 1 Switch, Dimmer/Brakelight 0609-637 1 Spring Assembly, Dimmer/Brakelight 1602-488 1 Brakeline, Hydraulic 9 2005 Sabercat 700 EFI DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES 0739-675 *Not a Service Part 1 0728-114 1 Track Drive Assembly (inc. 2-6) 2 1602-510 2 Sprocket, Drive 3 1602-551 1 Driveshaft 4 0702-412 1 Plate, Flange 5 1602-374 1 Bearing, 1 in. w/o Lock Collar 6 0630-167 1 Magnet 7 0630-166 1 Regulator, Voltage 8 8048-426 3 Nut, Lock 9 8020-315 2 Screw, Cap 10 0623-912 AR Washer 11 1602-205 1 Disc, Brake 12 0101-076 1 Key 13 0702-506 1 Shaft, Driven (inc. 14-16) 14 0602-598 1 Key 15 1602-233 1 Bearing, 1 in. w/o Lock Collar 16 1602-367 1 Spacer 17 0623-118 AR Washer 0623-119 AR Washer 10 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 0648-042 1 Shaft, Stub 0616-032 2 O-Ring 0726-182 1 Clutch, Driven 0123-053 AR Washer 0123-694 AR Washer 0123-019 1 Washer 8002-139 1 Screw, Cap 0602-829 1 Caliper, Brake Assembly (inc. 26-36) 8005-677 2 Screw, Cap 8050-272 2 Washer 0602-590 1 Fitting, Adapter * 1 Housing 0602-729 1 O-Ring, Housing 0602-583 2 O-Ring 0602-708 2 Piston 0602-707 1 Screw, Bleed - Assembly * 1 Housing 0702-229 1 Pad, Brake - Set (inc. 36) 0602-706 1 Pin, Retaining 2005 Sabercat 700 EFI DRIVE/REVERSE DROPCASE ASSEMBLY 0738-683 *Not a Service Part 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 12 0702-633 1 Sprocket Assembly - 40T (inc. 2-8) * 0602-144 0602-133 0602-138 0623-182 0123-430 0602-016 0602-012 1602-042 1602-048 0702-048 0602-023 0602-022 0602-024 8002-231 1602-046 8050-272 0702-372 8070-153 0602-028 1 1 3 3 6 6 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Sprocket Retainer, Spring Pin, Slip Spring, Compression Screw, Cap Nut, Lock Bearing Spacer, Shaft Chain - 72P Extension, Driveshaft Gear, Reverse - 55T (inc. 13-15) Washer, Thrust Bearing, Thrust Ring, Retaining Screw, Cap Washer, Tab Lock Washer Retainer, Shaft (inc. 20) Pin, Spring Spring, Return 22 23 24 25 26 0602-872 0702-365 1602-045 0602-366 1 1 1 1 Shaft, Reverse Idler, Reverse - Assembly - 19T (inc. 24) Bearing Aligner, Idler - Pin 0702-322 1 Idler, Reverse - 24T (inc. 27) 0602-205 0602-215 1602-044 8020-130 8041-426 1602-052 0107-003 1602-521 8040-426 1 3 1 1 3 1 2 2 3 Bearing, Caged Spacer, Reverse Idler Washer, Thrust Screw, Cap Nut, Lock Bearing, 7/8 in. Seal, O-Ring Plate, Flange Nut, Lock 0602-455 1 Sprocket - 22T 37 0623-231 38 0623-465 39 1602-051 1 1 1 Washer, Spring Nut, Lock Bearing, 1 in. 27 28 29 30 31 32 33 34 35 36 2005 Sabercat 700 EFI DROPCASE AND CHAIN TENSION ASSEMBLY 0739-863 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 0702-417 1 Dropcase w/Studs (inc. 2-5) 0623-317 3 Stud, Ribbed 0607-025 9 O-Ring, Stud 0623-117 2 Bolt, Ribbed 0123-523 4 Bolt, Ribbed 8047-426 7 Nut, Lock 1623-121 1 Bolt, Carriage 8011-139 2 Bolt, Carriage 8050-252 AR Washer 0623-293 2 Plug, Drain 1602-213 3 O-Ring 0602-479 1 Plug, Drain - Magnetic 0602-746 1 Housing, Screw - Chain Adjuster 0602-645 1 Cover, Adjuster Housing 0602-803 1 Spring, Power - Adjuster Shaft 0623-526 3 Screw, Self-Tapping 1602-536 1 Shaft, Chain Adjuster 0602-748 1 Screw, Chain Adjuster 0602-801 1 O-Ring, Cover - Chain Adjuster 0602-901 1 Spring, Compression 0602-804 1 Rivet, Button Head 0623-541 1 Screw, Machine 1602-221 1 Cover, Dropcase 0702-291 1 Shaft, Shift Fork 25 26 27 28 29 30 31 32 33 34 35 36 37 38 0602-021 0623-542 1602-151 0623-081 0602-085 0602-437 8020-134 1602-533 0702-537 0623-765 0623-914 0605-014 0623-122 1 1 1 6 1 1 5 1 1 1 1 1 2 Seal, O-Ring Pin, Spring Cover, Oil Vent Screw, Self-Tapping Fork, Shift Seal, Dropcase Screw, Cap Stick, Oil Level Tube, Oil Level Stick Screw, Self-Tapping Screw, Self-Tapping O-Ring, Oil Level Stick Tube Nut, Lock 0602-466 1 Bracket, Chain Backing 39 40 41 42 43 44 45 46 8002-045 0602-681 8050-222 0602-675 0623-525 0702-129 0602-383 0602-676 1 1 1 1 2 1 1 1 Screw, Cap Nut, Roller Arm Washer Arm, Chain Roller Washer Roller, Chain Tightener (inc. 45) Bearing, Chain Tightener Shaft, Chain Roller 13 2005 Sabercat 700 EFI REVERSE SHIFT LEVER ASSEMBLY 0738-714 *Not a Service Part **Included in Kit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1602-429 0623-641 0117-868 8002-137 0702-500 0602-844 0602-853 8050-247 8053-242 8002-140 0630-013 0630-011 0630-010 1 1 1 1 1 2 1 2 1 1 1 1 1 Lever Pin, Clevis Pin, Cotter Screw, Cap Shift Pivot (inc. 6) Bushing Axle Washer Washer, Lock - External Tooth Screw, Cap Boot, Switch Switch, Alarm Alarm, Reverse (inc. 14) (Optional Kit p/n 3639-013) 14 15 16 17 18 19 20 21 22 23 24 25 0630-017 1 8040-426 2 0702-499 1 0602-305 1 0623-260 1 * 1 0123-144 1 0602-322 1 8002-132 1 5611-483 1 0686-120 1 0123-788 AR Ring, Retaining Nut, Lock Linkage, Shifting - Assembly (inc. 17-21) Rod End - Left Nut, Jam - Left Rod, Linkage Nut, Jam - Right Rod End - Right Screw, Cap Decal, Warning - General/Brake/Reverse** Harness** Cable Tie - 7.5 in. 2005 Sabercat 700 EFI OS SLIDE RAIL AND TRACK ASSEMBLY ) 0739-683 1 2 3 4 5 6 7 8 9 10 11 12 2604-746 2 Rail, Formed 0604-930 5 Axle, Inner 1623-248 10 Screw, Cap 2604-281 1 Spacer 8002-043 2 Screw, Cap 8050-217 4 Washer 2604-842 2 End Cap, Slide Rail 8047-366 8 Nut, Lock 0123-859 2 Screw, Machine 2604-537 2 Wearstrip, Slide Rail 0123-767 2 Rivet, Solid 0123-766 2 Nut, Push 13 14 15 16 17 18 19 20 21 22 23 0104-631 2 8020-132 4 2604-593 4 8048-426 4 8017-405 2 1604-607 2 8041-246 2 0704-352 2 8002-042 4 1602-750 1 1602-134 38 Pad, Shock Screw, Cap Bracket, Mounting - Front Arm Nut, Lock Screw, Machine Pad, Shock Nut, Lock Adjuster, Track Screw, Cap Track Assembly (inc. 23) Clip, Guide 15 2005 Sabercat 700 EFI OS IDLER WHEEL ASSEMBLY 0739-830 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 16 8020-232 6 Screw, Cap 0623-664 8 Washer 1604-837 6 Wheel, Idler (inc. 4-5) 1604-847 10 Bearing, Wheel 0623-946 10 Ring, Retaining 2604-579 6 Block, Mounting - Idler Wheel 8048-486 14 Nut, Lock 8020-224 6 Screw, Cap 1623-037 2 Screw, Cap 8050-272 2 Washer 1604-793 2 Spacer 0623-912 2 Washer 1604-792 1 Axle, Steel 8047-490 2 Nut, Lock 1604-209 1 Axle, Steel 0704-994 1 Pivot, Shock (inc. 17-19) 1623-010 1 Fitting, Grease 1623-011 1 Washer, Grease Fitting 0603-083 2 Bearing 20 21 22 23 24 25 26 27 28 29 30 31 32 33 2604-109 2604-378 2604-515 8050-282 8020-229 2604-874 1604-810 1604-839 2604-881 2604-635 2604-760 1623-249 1604-952 2 2 2 2 2 1 1 2 2 2 2 2 2 Spacer Block, Slide Slide, Spring Washer Screw, Cap Axle, Rear Spacer Wheel, Idler (inc. 4-5) Bushing, Adjuster Bushing, Adjuster Wheel, Idler (inc. 4-5) Screw, Cap Cap, Idler Wheel 0704-854 34 8051-277 35 8042-486 36 0623-123 2 2 2 Spacer (EXT) Washer, Lock Nut 2 Screw, Cap 2005 Sabercat 700 EFI OS REAR SUSPENSION FRONT ARM ASSEMBLY 0739-744 1 2 3 4 5 6 7 8 9 1704-312 0604-889 8047-490 8002-228 0104-629 8020-228 8002-041 0623-875 1 8 2 2 4 2 2 6 Arm, Front Suspension (inc. 2) Bushing Nut, Lock Screw, Cap Spacer, Front Arm Screw, Cap Screw, Cap Washer 2604-836 10 8047-366 2 4 Strap, Limiter Nut, Lock 11 12 13 14 15 16 17 18 19 20 8002-045 0623-044 8040-486 1704-116 1603-890 8020-227 1603-531 8048-486 0704-523 0604-790 2 2 2 1 1 1 1 1 1 1 Screw, Cap Washer Nut, Lock Shock Absorber, Front Arm Retainer, Spring Screw, Cap Axle, Shock Nut, Lock Spring, Compression Cover, Shock 17 2005 Sabercat 700 EFI OS REAR SUSPENSION FRONT ARM SHOCK ABSORBER (Complete Shock Absorber p/n 1704-116) 0738-660 1 2 3 4 5 6 7 8 9 10 11 12 13 18 1604-796 2604-365 1703-453 1604-271 1604-272 2603-055 2603-065 2603-075 2603-096 2603-136 2603-125 2603-095 0603-953 1 1 1 1 1 2 2 2 1 1 1 1 1 Eyelet, Shock Rod, Shock Cap, Shock (inc. 4) O-Ring Washer, Top Out Valve, 0.800 x 0.010 in. Valve, 0.900 x 0.010 in. Valve, 1.000 x 0.010 in. Valve, 1.100 x 0.012 in. Valve, 1.300 x 0.012 in. Valve, 1.250 x 0.010 in. Valve, 1.100 x 0.010 in. Piston, 0.093 in. - Orifice 14 15 16 17 18 19 20 21 22 23 24 25 26 1604-274 1 1604-273 1 0623-696 1 2604-596 1 1603-911 1 0704-791 1 2604-153 1 2604-152 1 0624-546 1 0704-796 1 2604-162 1 2604-156 1 2639-151 AR Strap, Piston - Teflon Washer, Backup Nut, Lock Body, Shock Nut, Spring Adjuster Piston, Floating (inc. 20-21) Strap, Piston - Teflon O-Ring Screw, Machine Valve, Pressure (inc. 24) O-Ring, Valve Sleeve, Shock Eyelet Oil, Gas Shock - 6 qt Case 2005 Sabercat 700 EFI OS REAR SUSPENSION REAR ARM ASSEMBLY 0739-687 1 2 3 4 5 6 7 8 9 10 11 12 13 1704-005 1604-100 2604-147 1623-010 1704-019 1623-011 8047-490 2604-664 2604-663 8050-272 1623-037 1623-086 1 2 2 3 1 1 1 2 1 1 1 1 Arm, Idler (inc. 2-3 and two No. 4) Bushing, Flared Bearing Fitting, Grease Arm, Rear (inc. one No. 4 and 6) Washer, Grease Fitting Nut, Lock Bushing, Rear Arm Tube, Axle Washer Screw, Cap Screw, Cap 8048-486 14 2604-370 15 1604-204 1604-205 16 0623-138 17 2604-143 2 1 1 1 2 2 Nut, Lock Axle, Steel Block, Spring Adjuster - Right Block, Spring Adjuster - Left Ring, Retaining Wheel, Idler (inc. 18-19) 18 19 20 21 0107-598 0123-798 2604-379 0704-926 0704-927 2 2 2 1 1 Bearing Ring, Retaining Sleeve, Spring Spring, Suspension - Right Spring, Suspension - Left 0623-044 8051-277 8002-226 2604-139 1623-219 0704-361 2604-531 1604-139 4 2 3 1 1 2 4 3 Washer Washer, Lock Screw, Cap Axle, Inner Carriage Screw, Cap Link, Rear Shock Axle, Link Sleeve, Shock 8041-486 2 Nut, Lock 1623-219 32 1704-117 1 1 Screw, Cap Shock Absorber - Rear Arm 22 23 24 25 26 27 28 29 30 31 19 2005 Sabercat 700 EFI OS REAR SUSPENSION REAR ARM SHOCK ABSORBER (Complete Shock Absorber p/n 1704-117) 0738-688 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 20 2604-598 1603-503 2604-599 1703-452 1604-271 1603-314 1604-274 1604-272 2603-065 2603-075 2603-095 2603-125 2603-040 2603-094 2603-135 2603-126 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 2 Body, Shock Eyelet, Shock Rod, Shock Cap, Shock (inc. 5) O-Ring Piston, 0.039 in. - Orifice Strap, Piston - Teflon Washer, Top Out Valve, 0.900 x 0.010 in. Valve, 1.000 x 0.010 in. Valve, 1.100 x 0.010 in. Valve, 1.250 x 0.010 in. Valve, 0.700 x 0.004 in. Valve, 1.100 x 0.008 in. Valve, 1.300 x 0.010 in. Valve, 1.250 x 0.012 in. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 2603-096 1 2603-076 1 2603-055 1 1604-273 1 0623-696 1 0704-791 1 2604-153 1 2604-152 1 2604-164 2 1604-397 2 0704-796 1 2604-162 1 0624-546 1 1604-262 2 2639-151 AR Valve, 1.100 x 0.012 in. Valve, 1.000 x 0.012 in. Valve, 0.800 x 0.010 in. Washer, Backup Nut, Lock Piston, Floating (inc. 23-24) Strap, Piston - Teflon O-Ring Bushing, Shock Sleeve, Eyelet Valve, Pressure (inc. 28) O-Ring Screw, Valve Bushing, Shock Oil, Gas Shock - 6 qt Case 2005 Sabercat 700 EFI FRONT FRAME AND FOOTREST ASSEMBLY 0739-703 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0707-819 1 Chassis - Assembly (inc. 2-8) 1623-019 2 Bolt, Carriage - Ribbed 1623-020 2 Bolt, Carriage - Ribbed 1623-212 1 Bolt, Carriage - Ribbed 0675-161 4 Bearing 0607-657 6 Bushing, Lower A-Arm Mount 0607-656 2 Bushing, Upper A-Arm Mount 1623-010 2 Fitting, Grease 2706-806 1 Brace, Side Plate 8017-580 9 Screw, Machine 0608-364 1 Mount, Engine 0623-943 4 Washer, Cup 8048-366 14 Nut, Lock 2706-552 1 Guard, Hose 1623-115 1 Screw 8017-579 4 Screw, Machine 2706-153 1 Support, Side Plate 8060-706 2 Rivet 2706-550 1 Footrest - Right 2706-551 1 Footrest - Left 20 0623-282 AR Rivet 21 2706-151 2 Plate, Backing 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 0623-341 6 Rivet 0706-371 AR Trim 0708-433 1 Bracket, Bearing Support (inc. 25) 0623-117 3 Bolt, Stud - Ribbed 0623-190 1 Screw, Self-Tapping 3606-178 2 Bumper 1623-130 6 Rivet 2706-517 1 Tube, Belt Guard 0607-725 1 Plate, Backing 1623-167 1 Bolt, Carriage - Ribbed 1623-018 2 Screw, Self-Tapping 2706-843 1 Brace, Side Plate 2606-939 1 Plate, Mounting - Torque Bumper - Engine 0704-352 1 Mount, Torque Bumper - Engine 0608-396 1 Bumper, Torque - Engine 8042-486 1 Nut 8002-042 2 Screw, Cap 1623-171 1 Clip 0608-432 1 Guide, Rope 8017-400 1 Screw, Machine 8041-246 1 Nut, Lock 21 2005 Sabercat 700 EFI HOOD AND WINDSHIELD ASSEMBLY 0739-704 1 2 1718-723 1718-663 1 1 Hood w/Decals - Red (inc. 2-9) Hood w/o Decals - Red (inc. 3-5) 3 5611-483 1 Decal, Warning - General and Brake 4 5 6 1623-026 0623-847 6611-236 6611-237 2 2 1 1 Pin, Clevis Clip, Hairpin Decal, Hood - Lower Right Decal, Hood - Lower Left 9 10 3611-611 1718-665 1 1 Decal, “Made In U.S.A.” - Domed Cover, Hood - Black (inc. 11-15) 11 12 2706-031 6611-242 1 1 Cover, Hood w/o Decals - Black Decal, Cover - Center 13 6611-244 6611-245 1 1 Decal, Cover - Right Decal, Cover - Left 14 6611-243 1 Decal, Cover - Front 15 16 17 18 19 20 21 22 23 2606-007 2606-801 3606-150 0623-302 2606-726 1623-052 0623-544 2639-477 1 2 1 4 2 2 2 2 Foil, Protective O-Ring Screen, Hood Screw, Self-Tapping Cable, Hood U-Nut Plug Kit, Mirror (inc. six No. 23-25) 0623-902 10 Screw, Machine 0124-054 10 Snap Cap w/Washer 26 0623-845 3606-562 10 1 Nut, Expansion Windshield 27 28 29 0616-032 0617-466 0123-394 4 1 14 O-Ring Foam, Hood Clip, Retaining - Foam 24 7 6611-238 6611-239 1 1 Decal, Hood - Upper Right Decal, Hood - Upper Left 8 6611-240 6611-241 1 1 Decal, Console - Right Decal, Console - Left 22 25 2005 Sabercat 700 EFI HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES 0739-705 1 2 3 4 1686-053 1 Harness, Main 1686-065 1 Harness, Hood 0123-788 AR Cable Tie - 8 in. 0609-530 1 Lens/Reflector - Headlight - Right (inc. 5) 0609-531 1 Lens/Reflector - Headlight - Left (inc. 5) 5 0609-251 4 Bulb, Headlight 6 0623-360 2 Spring, Adjuster 7 8 9 10 11 12 1623-025 1623-137 1623-024 0620-292 0620-281 0620-280 2 2 2 1 1 4 Insert Clip, Hairpin Screw, Adjuster Tachometer/Speedometer (inc. 11-12) Bracket, Retaining Nut w/Washer 23 2005 Sabercat 700 EFI HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES (LX/EXT) 0739-707 1 1686-018 1686-051 2 0630-100 3 0623-589 4 1686-065 5 0609-530 0609-531 6 0609-251 24 1 1 1 1 1 1 1 4 Harness, Main (inc. 2) Harness, Main (inc. 2) (EXT) Fuse, 7.5 Amp Clip, Retaining Harness, Hood Lens/Reflector - Headlight - Right (inc. 6) Lens/Reflector - Headlight - Left (inc. 6) Bulb, Headlight 7 8 9 10 11 12 13 14 1623-025 2 0623-360 2 1623-024 2 1623-137 2 0620-292 1 0620-281 1 0620-280 4 0123-788 AR Insert Spring, Adjuster Screw, Adjuster Clip, Hairpin Tachometer/Speedometer (inc. 12-13) Bracket, Retaining Nut w/Washer Cable Tie - 8 in. 2005 Sabercat 700 EFI CONSOLE AND SWITCH ASSEMBLY 0739-708 1 2706-252 2 1623-129 3 0609-449 4 * 5 0609-113 1 5 Console Screw, Self-Tapping 1 1 1 Switch, Ignition (inc. 4) Key Nut, Retaining 6 7 8 9 10 11 0123-899 0609-450 1612-287 0630-148 3606-355 1623-184 1 1 2 1 1 1 Washer, Ignition Switch Spacer, Ignition Switch Bumper, Molded Switch, Hood Spacer T-Nut *Key is coded to switch; see dealer to determine part number. 25 2005 Sabercat 700 EFI BELLY PAN ASSEMBLY 0739-709 1 2 3 4 5 6 7 8 9 10 11 2606-646 1 Belly Pan - Right - Black 2606-647 1 Belly Pan - Left - Black 0617-443 1 Foam, Belly Pan 8061-708 12 Rivet 2606-650 1 Panel, Access - Drive Clutch - Black 0606-526 2 Reflector, Front - Amber 0623-269 4 Clip, Retaining 8017-581 8 Screw, Machine 8050-217 8 Washer 8040-366 4 Nut, Lock 3606-578 12 1623-031 13 0623-797 14 15 16 17 18 19 20 21 22 26 1 6 8 Belly Pan, Center - Red Screw, Self-Tapping Screw, Self-Tapping 3606-579 1 Bumper, Front - Red 0623-784 18 Screw, Self-Tapping 2606-911 1 Screen, Center Belly Pan 1623-030 2 Nut, Speed 3606-050 1 Pin, Resonator Mounting 1612-603 1 Seal, Exhaust 8061-508 8 Rivet 1612-686 1 Deflector, Exhaust 8061-710 2 Rivet 23 2606-624 24 6611-246 6611-247 2 1 1 Strap, Hold-Down Decal, Belly Pan - Upper Right Decal, Belly Pan - Upper Left 25 6611-252 6611-253 1 1 Decal, Belly Pan - Vent - Rear - Right Decal, Belly Pan - Vent - Rear - Left 26 6611-250 6611-251 1 1 Decal, Belly Pan - Vent - Front - Right Decal, Belly Pan - Vent - Front - Left 27 6611-248 6611-249 1 1 Decal, Belly Pan - Front - Right Decal, Belly Pan - Front - Left 2005 Sabercat 700 EFI BELT GUARD ASSEMBLY 738-734A 1 2 3 4 5 6 7 0607-822 0623-855 0607-659 1611-565 3611-969 8048-366 8040-426 1 1 1 1 1 1 1 Guard, Belt Screw, Shoulder Strap, Hold-Down Decal, Warning - Belt Guard Decal, “ACT - Roller Driven Clutch” Nut, Lock Nut, Lock 8 9 10 11 12 13 8050-252 1623-046 8017-672 0617-450 5611-862 6611-512 1 1 1 1 1 1 Washer Washer, Rubber Screw, Machine Foam, Belt Guard Decal, Spring Adjustment Decal, Clutching Chart 27 2005 Sabercat 700 EFI GAS TANK ASSEMBLY 0738-828 1 2 3 4 0770-628 1670-447 1670-511 1670-523 1 1 1 1 5 0623-427 4 28 Tank, Gas (inc. 2-4) Cap, Gas Tank (inc. 3) Seal, Tank Cap Gauge, Fuel - Assembly w/Gasket (Press-Fit) U-Nut 6 7 8 9 10 8048-366 8011-041 0123-765 8041-366 5611-861 9 2 4 2 1 Nut, Flange Bolt, Carriage Washer, Cup Nut, Lock Decal, Caution - Remote Start 2005 Sabercat 700 EFI FUEL PUMP ASSEMBLY 0738-987 1 2 3 4 5 6 7 8 9 10 1670-421 1670-412 1670-536 1670-532 1670-533 1670-535 1670-476 1670-475 1670-534 1670-479 1 2 1 1 1 1 1 1 1 1 Pump, Fuel - Assembly (inc. 2-13) Screw Regulator, Pressure O-Ring, Regulator O-Ring, Regulator Grommet O-Ring Nut, Fuel Pump Fitting Grommet Washer, Sealing - Threaded 11 12 13 14 15 16 17 18 19 1670-478 1 Washer 1670-477 1 Nut, Mounting 1670-579 1 Retainer, Wire 0610-563 4 Clamp, Hose 0610-075 AR Hose, Gasline - 10 ft 1670-618 1 Pickup, Fuel 1670-617 1 Pickup, Fuel 0623-373 2 Clamp, Hose 0716-558 AR Conduit, Flexible - 10 ft 29 2005 Sabercat 700 EFI SEAT AND STORAGE BOX ASSEMBLY 0739-721 1 7998-106 1 Complete Seat Assembly (inc. 2-9) 2 2706-721 1 Cover, Seat (inc. 3) 3 4 5 6 7 8 30 3606-369 1 Wire, Seat 0717-176 1 Foam, Seat 0624-528 AR Staple 3606-056 1 Base, Seat 3606-248 1 Panel, Seat 1623-177 2 Clip, Retaining 9 10 11 12 13 14 15 1623-158 1623-138 8017-667 3606-074 3606-072 3606-357 6611-256 6611-257 3 2 2 1 1 2 1 1 Screw, Self-Tapping Latch, Seat Screw, Machine Box, Storage (inc. 13-14) Cover, Storage Box Strap, Hold-Down Decal, Storage Box - Right Decal, Storage Box - Left 2005 Sabercat 700 EFI TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY 0739-730 *Optional 1 1718-569 2 2706-556 Tunnel Assembly (inc. 2-4) Bracket, Suspension Mounting Right - Rear 2706-557 1 Bracket, Suspension Mounting Left - Rear 3 2706-264 1 Plate, Backing - Right 2706-263 1 Plate, Backing - Left 4 0123-418 AR Rivet 0623-806 AR Rivet 8060-506 AR Rivet* 5 1623-022 6 Screw, Self-Tapping 6 2606-007 3 Foil, Protective 7 8060-504 9 Rivet 8 2606-938 1 Protector, Wiring Harness 9 8017-399 2 Screw, Machine 10 8040-246 2 Nut, Lock 11 0617-455 1 Foam, Rear Heat Exchanger 12 0623-204 2 Screw, Machine 13 0609-229 1 Lens, Taillight 14 0609-230 1 Taillight w/Socket Assembly 15 0609-638 1 Housing, Taillight 32 1 1 16 17 18 19 20 21 22 23 24 25 26 27 28 29 0109-460 1623-023 1623-109 3606-453 0617-496 8048-366 8017-581 1623-242 8017-577 0623-363 3606-333 5611-852 5611-853 6611-012 6611-013 30 6611-260 1 2 4 1 1 2 2 2 1 1 1 1 1 1 1 2 Bulb, Taillight Nut, Speed Screw, Self-Tapping Bumper, Rear (inc. 20) Foam, Rear Heat Exchanger Nut, Lock Screw, Machine Washer Screw, Machine Nut, Speed Snowflap w/Decals (inc. 27-28) Decal, Warning - Towing (French) Decal, Warning - Towing (English) Decal, Reflector - Red - Right Decal, Reflector - Red - Left Decal, “EXT” - Tunnel 31 3606-223 32 3002-964 33 1623-061 2 1 2 Strap, Hold-Down - Storage Box Clamp, Wire Screw, Self-Tapping 2005 Sabercat 700 EFI COOLING ASSEMBLY 0739-731 1 2706-565 1 Heat Exchanger - Left Tube 2 2706-564 1 Heat Exchanger - Right Tube 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2706-522 1623-229 0610-567 8041-246 8017-397 8060-504 1623-405 1623-061 3606-349 0606-268 0123-788 0623-063 0610-538 0610-015 0610-016 1 7 2 2 2 6 4 2 1 1 AR 1 AR AR AR Heat Exchanger, Rear Clamp, Hose Hose, Coolant - Rear Heat Exchanger Nut, Lock Screw, Machine Rivet Rivet Screw, Self-Tapping Tank, Coolant Cap, Filler Neck Cable Tie - 8 in. Clamp, Hose Hose, Vent - 25 ft Hose, Vent - 100 ft Hose, Vent - 25 ft 17 18 19 20 21 22 8048-366 1623-092 0610-571 0610-573 1623-048 0610-648 1 2 1 1 1 1 23 1623-186 24 0610-570 1 1 25 26 27 28 29 30 1 1 1 3 1 1 3606-354 0623-166 1623-187 0623-540 0124-045 0406-288 Nut, Lock Clamp, Hose Hose, Coolant - Right Tube/Coolant Tank Hose, Coolant - Coolant Tank/Engine Clamp, Hose Hose, Coolant - Engine/Front Heat Exchanger Clamp, Hose Hose, Coolant - Front Heat Exchanger/ Left Tube Protector, Hose Rivet Clamp, Hose Cable Tie - Triple Clamp, Hose Pad 33 2005 Sabercat 700 EFI ENGINE AND RELATED PARTS 0739-725 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 34 0662-407 1 Engine, AD70L3 w/o EFI Components 0636-363 1 Handle, Recoil 0606-885 1 Cap, Recoil Handle 0608-388 1 Bracket, Engine Mounting - Right 8020-136 1 Screw, Cap 8408-820 6 Screw, Cap 8048-426 4 Nut, Lock 0623-987 3 Washer 1670-328 1 Foil, Protective 0623-373 5 Clamp, Hose 0610-076 AR Hose, Coolant - 10 ft 0610-581 3 Clamp, Hose 1670-596 1 Y-Fitting 0619-776 AR Conduit, Flexible - 5 ft 0708-431 1 Bracket, Engine Mounting - Left (inc. 16 and one No. 17) 16 17 18 19 0608-400 0623-765 0608-407 0608-397 1 3 1 1 Bumper, Torque Screw, Self-Tapping Plate, Reinforcement Plate, Reinforcement 22 23 24 25 26 27 28 29 0725-396 0627-035 0623-210 0623-804 0608-396 8042-486 0608-394 8020-220 1 1 1 1 1 1 1 1 Clutch, Drive Belt, Drive Washer, High Collar Bolt, Clutch Bumper, Torque - Engine Nut Tube, Torque Bumper Screw, Cap 2005 Sabercat 700 EFI EXHAUST ASSEMBLY 0739-723 1 1712-114 1 2 1712-115 1 3 0624-526 AR 0624-541 AR 4 1612-178 3 5 1612-590 1 6 1612-574 1 7 1612-804 1 8 1612-805 1 Chamber, Expansion - Assembly (inc. 2-8) Chamber, Expansion Tie, Perforated Band - 5 ft Tie, Perforated Band - 25 ft Spring, Exhaust Packing, Expansion Chamber - Upper Cover, Expansion Chamber - Upper Cover, Expansion Chamber - Lower Packing, Expansion Chamber - Lower 9 10 11 12 13 14 15 16 1712-104 0612-820 1612-014 1612-323 1712-022 0612-471 1612-685 0612-668 1 3 1 1 1 5 1 1 Manifold, Exhaust Spring, Exhaust Gasket, Exhaust Gasket, Exhaust - Tailpipe Resonator Spring, Extension Brace, Resonator Spring, Extension 35 2005 Sabercat 700 EFI FLEX-DRIVE STARTER MOTOR ASSEMBLY 0739-718 *Not a Service Part 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 36 0745-143 0645-296 0645-131 0645-293 0645-297 0645-313 0645-275 0645-128 0623-093 * 0745-207 8048-426 8048-366 0745-260 8011-039 8020-040 1623-080 0745-221 1 1 1 1 1 1 1 2 2 1 1 2 4 1 1 1 1 1 (Optional Kit p/n 3639-966) Motor, Starter (inc. 2-10) Armature Assembly (inc. 3-4) Washer, Wave Washer, Thrust Cap, Drive Cap, Commutator (inc. 7) Kit, Brush and Spring Through-Bolt Bolt, Ribbed Case, Starter Motor Bracket, Mounting - Starter Motor Nut, Lock Nut, Lock Bracket, Mounting - Starter Motor Bolt, Carriage Screw, Cap Clamp, Flex-Drive Shaft Shaft, Flex-Drive (inc. 19) 19 0623-891 20 0745-208 4 1 21 22 23 24 0645-382 0645-429 0745-165 0745-170 2 2 1 1 25 26 27 28 29 30 31 32 33 0745-224 0645-380 0645-186 8026-131 0645-367 1623-128 0123-053 1686-124 8053-212 1 1 1 2 1 6 2 1 1 Screw, Set - Socket Bracket, Pinion Drive - Assembly (inc. 21-27) Ring, Snap Washer, Thrust Bracket, Pinion Drive Drive, Pinion - Flex-Drive Shaft (inc. 25-27) Kit, Pinion Drive Assembly (inc. 26-27) Pinion Drive Assembly Pinion Stopper Assembly Screw, Cap Ring Gear Screw, Machine - Socket Head Washer Wire, Ground Washer, Lock - External Tooth 2005 Sabercat 700 EFI BATTERY, SOLENOID, AND CABLES 0739-694 *Included in Kit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0745-059 1 Battery (inc. 2-6) 0645-246 6 Cap, Battery 0645-152 1 Clamp, Hose 0645-263 1 Hose, Battery Vent 0645-151 1 Decal, Warning - Battery 0645-082 AR Wrap, Heat - Battery 0645-457 1 Cable, Battery/Solenoid (inc. 8-9) 0645-019 1 Boot, Terminal - Battery 0645-327 1 Boot, Terminal - Solenoid 0645-136 1 Cable, Battery/Ground 0745-250 1 Tray, Battery 0645-243 1 Strap, Battery - Top 0645-311 1 Strap, Battery - Side 0623-325 1 Nut, Wing 8050-217 1 Washer 8048-366 5 Nut, Lock 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 8011-039 0745-220 0745-204 0445-036 0623-038 8020-043 0645-467 1686-117 0630-002 0123-811 0609-449 ** 0609-113 0123-899 0623-589 8047-366 2 1 1 1 2 2 1 1 1 2 1 1 1 1 1 2 Bolt, Carriage Shield, Heat Bracket, Mounting - Battery Tray Solenoid Nut w/Washer Screw, Cap Cable, Solenoid/Starter Harness, Electric Start (inc. 25-26)* Diode, Charging Cable Tie - 4 in. Switch, Ignition (inc. 28)* Key* Nut, Retaining* Washer, Ignition Switch* Clip, Retaining* Nut, Lock **Key is coded to switch; see dealer to determine part number. 37 2005 Sabercat 700 EFI AIR SILENCER ASSEMBLY 0738-749 1 2 3 4 5 6 7 38 0770-620 1670-473 1670-621 1670-514 1623-132 1623-031 3606-146 1 1 1 1 2 1 1 Silencer, Air - Assembly (inc. 2-3) Intake, Air Silencer, Air Connector, Air-Intake Clamp, Air-Intake Connector Screw, Self-Tapping Hold-Down, Air Silencer 8 9 10 11 12 13 1623-204 1670-584 0623-165 5611-619 3611-403 3002-964 2 1 2 1 1 1 Screw, Self-Tapping Boot, Air Silencer Clip, Retaining Decal, ECU Decal, Fuel Designation Clamp, Wire 2005 Sabercat 700 EFI OIL TANK ASSEMBLY 0739-691 1 2 3 4 5 6 7 8 9 1670-673 1670-325 1670-324 0609-683 0609-639 0609-237 1670-365 0109-733 4611-532 1 1 1 1 1 1 1 1 1 Tank, Oil (inc. 2-3) Grommet Fitting, Elbow Sensor, Low Oil - Assembly (inc. 5-6) Switch, Oil Sensor w/Harness Seal, Grommet - Oil Sensor Cap, Oil Tank (inc. 8) Seal, Cap - Oil Tank Decal, Oil Tank 10 0623-063 1 11 0610-015 AR 0610-016 AR 12 0123-903 1 13 2606-129 1 14 8017-584 2 15 8048-366 2 16 0124-045 1 17 0716-558 AR Clamp, Hose Hose, Oil - 100 ft Hose, Oil - 25 ft Cable Tie - 11.5 in. Cover, Servomotor Screw, Cap Nut, Lock Clamp, Hose Loom, Protective - 10 ft 39 2005 Sabercat 700 EFI Cam Arm Kit - p/n 3639-599 (inc. 3-5 and 7-8) Uncalibrated Drive Clutch - p/n 0746-134 DRIVE CLUTCH (Assembly p/n 0725-396) 0738-469 1 2 3 4 5 6 0646-362 0746-131 0646-372 0646-344 1602-692 0746-671 0746-694 0746-702 7 1623-183 40 1 1 6 3 6 3 3 3 3 Sheave, Stationary Sheave, Movable (inc. 3) Bearing Pin, Cam Arm O-Ring Arm, Cam (inc. 7) Arm, Cam (inc. 7) (5-9,000 ft Alt.) Arm, Cam (inc. 7) (Over 9,000 ft Alt.) Screw, Set 8 8048-366 9 0646-265 0646-266 10 0746-115 11 0646-229 12 0646-140 13 0746-113 14 8051-212 15 1623-085 3 2 1 1 1 1 1 6 6 Nut, Lock Washer, Spacer Washer, Spacer Spider Assembly Spring, Drive Clutch - Yellow/White Nut Cover Washer, Lock - Spring Screw, Machine 2005 Sabercat 700 EFI DRIVEN CLUTCH (Assembly p/n 0726-182) 0737-913 1 0748-023 2 0648-009 3 0148-198 0148-199 4 0748-588 5 0648-002 0148-222 1 2 2 2 1 1 1 Sheave, Movable (inc. one No. 2) Bearing Washer, Thrust: 0.030 in. Washer, Thrust: 0.060 in. Sheave, Stationary Bracket, Torque - 53° Bracket, Torque - 51° (Over 5,000 ft Alt.) 6 8051-152 7 8005-404 8 0748-025 3 3 1 Washer, Lock Screw, Socket Head Spring, Driven Clutch - Cat Green 9 0748-589 10 8070-224 11 0648-097 12 0648-431 0648-082 13 0648-079 14 8040-426 15 0148-224 16 0148-225 17 0623-914 1 Plate, Roller - Assembly (inc. one No. 2 and 10-13) 3 Pin, Spring 3 Pin, Cam Roller 3 Washer, Spring 3 Washer, Thrust - Cam Roller 3 Roller, Cam 3 Nut, Lock 1 Cover, Movable Sheave 1 Cover, Stationary Sheave 12 Screw, Self-Tapping 41 2005 Sabercat 700 EFI CYLINDER AND HEAD ASSEMBLY 0739-379 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 42 3006-491 1 Head, Cylinder 0217-709 2 Plug, Spark (BR9EYA) 3006-544 1 Bolt 3006-496 1 Hook, Engine 3006-538 12 Bolt 3003-227 12 O-Ring 3003-335 2 O-Ring 3006-490 2 O-Ring 3005-747 1 Holder, Exhaust Valve Cable 3004-491 4 Nut 3004-279 6 Bolt, Stud 3004-326 6 Nut 3006-516 2 Gasket, Exhaust 3006-492 2 Cylinder 3006-493 1 Gasket, Cylinder 3004-975 4 Pin, Dowel 3005-847 4 Bolt, Stud 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 3006-494 3006-321 3006-329 3006-495 3005-860 3006-484 3005-983 3006-436 3006-425 3004-442 3005-226 3005-744 3005-808 3006-689 3006-322 3005-846 2 4 2 2 2 2 2 2 2 4 2 4 1 2 2 4 Valve, Exhaust Pin, Exhaust Valve Dowel Gasket, Exhaust Valve Plate, Exhaust Valve Stopper, Exhaust Valve Spring Pin, Exhaust Valve Stopper Gasket, Exhaust Valve Cover Cover, Exhaust Valve Bolt O-Ring Bolt Clamp Cable, Exhaust Valve Seal, Oil Bolt 2005 Sabercat 700 EFI CRANKCASE ASSEMBLY 0739-363 1 2 3 4 5 6 3006-924 1 Crankcase (inc. 2-7) 3006-488 10 Bolt 3004-376 1 Bolt 3006-650 1 Bolt 3004-442 1 Bolt 3003-647 1 Bushing 7 8 9 10 11 3005-206 3006-549 3006-498 3006-547 3006-548 2 2 1 2 2 Pin, Dowel Bolt Case, Magneto Pin, Dowel Bolt 43 2005 Sabercat 700 EFI PISTON AND CRANKSHAFT 0739-361 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 44 3006-499 3006-500 3005-304 3006-501 3008-500 3008-503 3006-718 3005-308 3004-147 3008-504 3006-489 3006-551 3008-495 3006-503 3006-719 3004-372 3006-505 2 2 4 2 4 2 1 2 2 2 1 1 2 1 2 6 1 Piston Set (inc. 2-3) Ring Set, Piston Circlip, Piston Pin, Piston Washer Bearing Crankshaft Assembly (inc. 8-24) Connecting Rod Washer, Crank Pin Bearing Bearing Washer Bearing Shim Crankshaft - Right Balancer, Crankshaft Screw Wheel, Crankshaft 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3005-508 3008-421 3006-508 3006-519 3006-504 3006-506 3006-540 3006-552 3003-759 3003-658 3003-359 3004-540 3003-367 3005-909 3004-760 3006-520 3423-300 2 2 2 1 1 1 1 1 1 4 1 1 1 1 1 1 1 Ring, Middle Crank Seal Bearing Race, Middle Crank Seal Gear, Oil Pump Drive Crankshaft - Middle Crankshaft - Left Bearing Spacer, Oil Seal Seal, Oil Pin, Alignment C-Ring Key Seal, Oil Seal, Mechanical - Water Pump Seal, Water/Oil Pump Gear, Driven - Oil Pump Shim, Oil Pump Shaft 2005 Sabercat 700 EFI REED VALVE ASSEMBLY 0739-369 1 2 3 4 5 3006-510 2 Valve, Reed - Assembly (inc. 2-4) 3006-553 4 Stopper 3005-878 4 Valve, Reed 3004-506 16 Screw 3005-879 2 Gasket, Reed Valve 6 7 8 9 3006-527 2 Pipe, Intake 3004-463 2 Clamp 3004-376 12 Bolt 3002-964 1 Clamp, Wire 45 2005 Sabercat 700 EFI THROTTLE BODY ASSEMBLY 0739-367 1 3006-720 3006-721 3006-722 2 3006-517 3 3006-059 3006-060 3006-061 46 1 1 1 1 2 2 2 Body, Throttle - Assembly O (inc. 2-7) Body, Throttle - Assembly Q (inc. 2-7) Body, Throttle - Assembly V (inc. 2-7) Pipe, Delivery Injector, Fuel - Assembly O Injector, Fuel - Assembly Q Injector, Fuel - Assembly V 4 5 6 7 3423-166 3006-723 3004-193 3005-692 4 1 2 1 8 3006-514 1 Screw Hose Clamp, Hose O-Ring Set (inc. All Throttle Body O-Rings) Rod, Control - Oil Pump 2005 Sabercat 700 EFI OIL PUMP 0739-371 1 2 3 4 5 6 7 3006-724 3008-030 3005-884 3005-126 3003-661 3402-009 3004-346 1 1 1 1 1 8 4 Pump, Oil O-Ring Retainer, Oil Pump Input Shaft O-Ring Union Gasket Bolt 8 9 10 11 12 13 14 3008-037 3005-357 3003-217 3004-893 3008-035 3005-032 3005-696 6 1 3 2 2 2 1 Clamp, Hose Hose Valve, Check Bolt Hose, Oil Protector, Hose Clamp 47 2005 Sabercat 700 EFI WATER PUMP AND THERMOSTAT 0739-372 1 2 3 4 5 6 7 48 3006-942 3006-356 3005-899 3005-697 3003-426 3003-431 3003-432 1 1 2 1 1 1 1 Cover, Water Pump O-Ring, Water Pump Cover Pin, Dowel Impeller, Water Pump Bolt Washer Gasket 8 9 10 11 12 13 14 3004-009 3006-521 3006-324 3004-341 3006-914 3006-913 3004-512 4 1 2 6 1 1 3 Circlip Hose, Water Inlet Clamp Bolt Cap, Thermostat Thermostat Bolt 2005 Sabercat 700 EFI RECOIL STARTER 0739-364 *Not a Service Part 1 2 3 4 5 6 7 3006-915 3003-179 3002-921 3006-457 * * * 1 1 1 1 1 1 1 Starter Assembly (inc. 2-10) Roller, Starter Spring Ratchet Set (inc. 5-7) Spring, Friction Washer Spring, Return 8 9 10 11 12 13 3006-475 3006-456 3006-889 3004-383 3006-522 3004-705 1 1 1 4 1 3 Plate, Friction Nut Rope, Starter Screw, Cap Pulley, Starter Screw, Cap 49 2005 Sabercat 700 EFI MAGNETO 0739-373 1 2 3 4 5 6 7 50 3004-378 3006-524 3006-943 3004-338 3006-523 3005-524 3005-987 4 1 1 1 1 3 1 Bolt Base, Stator - Plate Stator Bolt Rotor/Flywheel Bolt Washer 8 9 10 11 12 13 14 3004-362 3006-476 3004-706 3003-972 3006-453 3005-960 3005-775 1 1 3 1 1 1 1 Washer, Lock Bolt Screw Clamp, Sensor Sensor, Ignition Timing Plate, Stator Lead Wire Grommet, Stator Lead Wire 2005 Sabercat 700 EFI ELECTRICAL 0739-412 1 2 3 4 5 6 3006-692 3006-367 3005-387 3006-728 3006-725 3005-233 1 2 1 1 1 1 Coil, Ignition - Assembly Cap, Spark Plug Clamp Sensor, Temperature Sensor, Coolant Washer, Coolant Sensor 7 3006-932 3006-933 3006-934 8 3005-908 9 3005-237 1 1 1 1 1 ECU O ECU Q ECU V Cap, Rubber Cable Tie 51 2005 Sabercat 700 EFI SERVOMOTOR ASSEMBLY 0739-377 1 3006-699 2 3005-661 52 1 1 Servomotor Pulley, Controller 3 3006-700 1 Nut RELATED ITEMS 2005 Sabercat 700 EFI (Model No. S2005SCFXEOSR - EXT Red) 3639-558 3639-559 Altitude Kit (5-9000 ft) - EXT Altitude Kit (Over 9000 ft) - EXT 3639-020 Cover, Machine (Storage) - EXT 3639-656 Cover, Machine (Deluxe) - EXT 2257-231 3639-718 0639-456 Handbook, Safety (E/F) Handlebar Bag Handlebar Muffs 2257-085 Manual, Operator’s (E/F) 0652-100 0652-024 Paint, Hood - Black (1/2 oz) Paint, Metal - Black 2639-582 3639-700 3639-596 3639-715 3639-692 Skid Plate (Black) Tank Jacket - Gray Trim Trunk Liner Bag Windshield, Storage Bag Windshield, High NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A p/n 2257-121 Overseas Edition
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