Illustrated Parts Manual
Transcription
Illustrated Parts Manual
ARCTIC CAT ® Illustrated Parts Manual Prowler/Prowler XT Model Number U2007P1S4BUSR (Red) Model Number U2007P1S4BUSG (Green) Model Number U2007P1S4BUSZ (Cat Green) Model Number U2007P2S4BUSR (Red - XT) Model Number U2007P2S4BUSG (Green - XT) Model Number U2007P2S4BUSZ (Cat Green - XT) MORE TO GO ON.™ TABLE OF CONTENTS 2007 Prowler/Prowler XT Red (Model No. U2007P1S4BUSR) Green (Model No. U2007P1S4BUSG) Cat Green (Model No. U2007P1S4BUSZ) Red - XT (Model No. U2007P2S4BUSR) Green - XT (Model No. U2007P2S4BUSG) Cat Green - XT (Model No. U2007P2S4BUSZ) FRONT BODY PANEL ASSEMBLY .................................................................................................................................. 1 REAR BODY PANEL AND CARGO BOX ASSEMBLY ..................................................................................................... 2 TAILGATE ASSEMBLY ..................................................................................................................................................... 3 DECALS ............................................................................................................................................................................. 4 DECALS (XT) ..................................................................................................................................................................... 5 FRAME AND RELATED PARTS ....................................................................................................................................... 6 FRAME AND RELATED PARTS (XT) ............................................................................................................................... 7 CANOPY AND TAILLIGHT ASSEMBLY ............................................................................................................................ 8 TILT FRAME ASSEMBLY .................................................................................................................................................. 9 SEAT, BATTERY, AND TOOL KIT ASSEMBLY .............................................................................................................. 10 DASH ASSEMBLY ........................................................................................................................................................... 11 DASH ASSEMBLY (XT) ................................................................................................................................................... 12 STEERING POST ASSEMBLY ....................................................................................................................................... 13 FRONT SUSPENSION ASSEMBLY ................................................................................................................................ 14 FRONT SUSPENSION ASSEMBLY (XT) ........................................................................................................................ 15 REAR SUSPENSION ASSEMBLY .................................................................................................................................. 16 REAR SUSPENSION ASSEMBLY (XT) .......................................................................................................................... 17 SWAY BAR ASSEMBLY (XT) .......................................................................................................................................... 18 WHEEL AND TIRE ASSEMBLY ...................................................................................................................................... 19 WHEEL AND TIRE ASSEMBLY (XT) .............................................................................................................................. 20 REAR AND PARKING BRAKE ASSEMBLY .................................................................................................................... 21 HYDRAULIC BRAKE ASSEMBLY ................................................................................................................................... 22 ACCELERATOR ASSEMBLY .......................................................................................................................................... 23 GAS TANK ASSEMBLY .................................................................................................................................................. 24 SHIFTING ASSEMBLY .................................................................................................................................................... 25 AIR INTAKE ASSEMBLY ................................................................................................................................................. 26 ENGINE AND EXHAUST ................................................................................................................................................. 27 COOLING ASSEMBLY .................................................................................................................................................... 28 DRIVE TRAIN ASSEMBLY .............................................................................................................................................. 29 FRONT DRIVE GEARCASE ASSEMBLY ....................................................................................................................... 30 FRONT DRIVE GEARCASE ASSEMBLY (XT) ............................................................................................................... 31 REAR DRIVE GEARCASE ASSEMBLY .......................................................................................................................... 32 WIRING HARNESS ASSEMBLY ..................................................................................................................................... 33 WIRING HARNESS ASSEMBLY (XT) ............................................................................................................................. 34 CARBURETOR ................................................................................................................................................................ 35 CYLINDER HEAD ASSEMBLY ....................................................................................................................................... 36 CYLINDER ASSEMBLY .................................................................................................................................................. 37 CRANKCASE ASSEMBLY .............................................................................................................................................. 38 CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY ....................................................................................................... 39 CRANKSHAFT ASSEMBLY ............................................................................................................................................ 40 STARTER CLUTCH ASSEMBLY .................................................................................................................................... 41 CRANK BALANCER ASSEMBLY .................................................................................................................................... 42 CAMSHAFT/VALVE ASSEMBLY .................................................................................................................................... 43 CAM CHAIN ASSEMBLY ................................................................................................................................................ 44 MAGNETO COVER ASSEMBLY ..................................................................................................................................... 45 OIL FILTER/PUMP ASSEMBLY ...................................................................................................................................... 46 WATER PUMP ASSEMBLY ............................................................................................................................................ 47 TRANSMISSION ASSEMBLY ......................................................................................................................................... 48 SECONDARY TRANSMISSION ASSEMBLY ................................................................................................................. 49 GEAR SHIFTING ASSEMBLY ......................................................................................................................................... 50 SECONDARY DRIVE ASSEMBLY .................................................................................................................................. 51 STARTER MOTOR ASSEMBLY ..................................................................................................................................... 52 MAGNETO ASSEMBLY .................................................................................................................................................. 53 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 2007 model year. 2006 Arctic Cat Inc. Printed June 2006 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 2007 Prowler/Prowler XT FRONT BODY PANEL ASSEMBLY 0741-714 1 1406-758 1 Hood 1406-732 1 Hood (Green) 1406-759 1 Hood(Cat Green) 2 2606-624 2 Strap, Hold-Down 3 1406-733 1 Screen, Grille 4 0123-987 8 Clip, U 5 1506-798 2 Bracket, Hood 6 8408-020 4 Screw, Cap 7 0423-157 4 Nut, Top-Lock 8 1406-915 1 Pin, Hood 9 1406-792 1 Fender, Front - Right 1406-791 1 Fender, Front - Left 1406-730 1 Fender, Front - Right (Green) 1406-731 1 Fender, Front - Left (Green) 1406-798 1 Fender, Front - Right (Cat Green) 1406-797 1 Fender, Front - Left (Cat Green) 10 1623-066 2 Nut, Lock 11 0623-855 2 Screw, Dome-Head Shoulder 12 8050-217 10 Washer 13 0623-784 10 Screw, Self-Tapping 14 1506-715 1 Storage, Under-Hood - Assembly (inc. 15-18) 15 1406-945 1 Box, Storage - Under-Hood 16 1406-944 1 Cover, Access - Master Cylinder 17 1406-946 1 Seal, Storage Box 18 0470-442 1 Valve, Air Cleaner 19 0423-545 12 Screw, Body 20 1406-632 1 Panel, Fender - Inner - Left 1406-633 1 Panel, Fender - Inner - Right 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 8468-620 6 Screw, Machine 0423-577 15 Clip, U 1406-634 1 Floor 0423-342 3 Screw, Self-Tapping 1406-854 1 Base, Seat - Right 1406-869 1 Base, Seat - Left 1406-649 1 Console, Center 1406-825 1 Gate, Shift 0409-069 1 Panel, Switch-Mount 0409-070 2 Plug, Switch Hole 0409-071 1 Switch, Reverse Override 1411-195 1 Decal, Shift-Gate 0411-818 1 Decal, Reflector - Front - Right 0411-819 1 Decal, Reflector - Front - Left 0423-540 1 Nut 2506-066 1 Bracket, Support - Right 2506-067 1 Bracket, Support - Left 0423-447 6 Grommet 8476-620 8 Screw, Machine 8476-616 2 Screw, Machine 8424-602 2 Nut, Flange 0509-034 1 Headlight Assembly - Right (inc. 40) 0509-035 1 Headlight Assembly - Left (inc. 40) 0409-055 4 Bulb, Headlight 0623-785 4 Screw, Self-Tapping 0423-514 2 Stud, Adjuster - Headlight 0423-522 2 Spring, Adjuster 0423-513 2 Knob, Adjuster 1 2007 Prowler/Prowler XT REAR BODY PANEL AND CARGO BOX ASSEMBLY 0741-710R 1 2406-417 1 Box, Rear Cargo 2 2406-070 1 Panel, Splash - Rear - Right 2406-071 1 Panel, Splash - Rear - Left 3 0423-101 12 Screw, Body 4 0423-403 2 Clamp, Tube 5 8424-602 10 Nut, Hex 6 0623-784 18 Screw, Self-Tapping 7 1406-796 1 Fender, Rear - Lower - Right 1406-795 1 Fender, Rear - Lower - Left 1406-810 1 Fender, Rear - Lower - Right (Green) 1406-809 1 Fender, Rear - Lower - Left (Green) 1406-802 1 Fender, Rear - Lower - Right (Cat Green) 1406-801 1 Fender, Rear - Lower - Left (Cat Green) 8 8476-616 2 Screw, Machine 9 0423-577 4 Clip, U 10 1406-794 1 Fender, Rear - Upper - Right 1406-793 1 Fender, Rear - Upper - Left 1406-728 1 Fender, Rear - Upper - Right (Green) 1406-729 1 Fender, Rear - Upper - Left (Green) 1406-800 1 Fender, Rear - Upper - Right (Cat Green) 1406-799 1 Fender, Rear - Upper - Left (Cat Green) 2 11 1406-762 1 Panel, Box - Right 1406-761 1 Panel, Box - Left 12 1411-128 1 Decal, Reflector - Rear - Right 1411-129 1 Decal, Reflector - Rear - Left 13 1506-776 1 Bracket, Fender Support - Right 1506-777 1 Bracket, Fender Support - Left 14 0423-342 28 Screw, Self-Tapping 15 2506-035 1 Striker, Tailgate - Left 2506-034 1 Striker, Tailgate - Right 16 8474-630 8 Screw, Machine 17 0423-623 8 Bolt, Carriage 18 1506-933 8 Plate, Retainer 19 8424-802 8 Nut, Hex 20 1506-539 1 Bracket, Tailgate 21 0624-250 2 Nut, Lock 22 8050-217 6 Washer 23 0412-391 1 Shield, Heat - Rear Cargo Box 24 0412-392 1 Shield, Heat - Rear Splash Panel - Right 25 8476-620 2 Screw, Machine 2007 Prowler/Prowler XT TAILGATE ASSEMBLY (Complete Tailgate Assembly p/n 2506-205) 0741-711 1 2 3 4 5 6 1506-704 2506-056 1406-706 2406-369 2406-365 1406-927 1 1 4 1 1 1 Brace, Tailgate Latch, Tailgate - Assembly Bushing Panel, Tailgate - Outer Panel, Tailgate - Inner Shaft, Pivot - Tailgate 7 8 9 10 11 0623-784 12 Screw, Self-Tapping 0423-101 4 Screw, Body 8050-217 2 Washer 0487-045 2 Cable, Tailgate 8476-625 2 Screw 3 2007 Prowler/Prowler XT DECALS 0741-715 1 1411-382 1411-383 1411-384 2 1411-119 3 1411-123 4 1411-157 5 1411-120 6 1411-126 7 1411-125 8 1411-458 1411-459 1411-462 1411-463 1411-464 1411-465 4 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 Decal, Center Decal, Center (Green) Decal, Center (Cat Green) Decal, Warning - Cargo Decal, Warning - Towing - Rear Decal, Box - “Arctic Cat” Decal, Warning - Pinch Point Decal, Warning - Console Decal, Warning - Dash Decal, “650 H1” - Right Decal, “650 H1” - Left Decal, “650 H1” - Right (Green) Decal, “650 H1” - Left (Green) Decal, “650 H1” - Right (Cat Green) Decal, “650 H1” - Left (Cat Green) 9 1411-202 1411-145 1411-155 10 1411-122 11 1411-295 12 1411-330 1 1 1 1 1 1 Decal, Front - “Arctic Cat” Decal, Front - “Arctic Cat” (Green) Decal, Front - “Arctic Cat” (Cat Green) Decal, Warning - Towing - Front Decal, Warning - Canopy Decal, Brake Release 2007 Prowler/Prowler XT DECALS (XT) 0741-716 1 1411-457 1411-460 1411-461 2 1411-124 3 1411-119 4 1411-123 5 1411-157 6 1411-120 7 1411-126 8 1411-125 9 1411-458 1411-459 1411-462 1411-463 1411-464 1411-465 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 Decal, Center Decal, Center (Green) Decal, Center (Cat Green) Decal, Warning - Differential Lock Decal, Warning - Cargo Decal, Warning - Towing - Rear Decal, Box - “Arctic Cat” Decal, Warning - Pinch Point Decal, Warning - Console Decal, Warning - Dash Decal, “650 H1” - Right Decal, “650 H1” - Left Decal, “650 H1” - Right (Green) Decal, “650 H1” - Left (Green) Decal, “650 H1” - Right (Cat Green) Decal, “650 H1” - Left (Cat Green) 10 1411-202 1411-145 1411-155 11 1411-122 12 1411-295 13 1411-330 1 1 1 1 1 1 Decal, Front - “Arctic Cat” Decal, Front - “Arctic Cat” (Green) Decal, Front - “Arctic Cat” (Cat Green) Decal, Warning - Towing - Front Decal, Warning - Canopy Decal, Brake Release 5 2007 Prowler/Prowler XT FRAME AND RELATED PARTS 0741-725 1 2 3 4 5 6 7 8 9 10 11 12 13 6 2506-202 1 Frame, Main 1506-453 1 Bumper 8409-020 2 Screw, Cap 8428-002 2 Nut, Flange Lock 8476-820 4 Screw, Machine 1506-797 1 Bracket, Steering Support - Right 0502-853 1 Bracket, Steering Support - Left 0423-642 12 Screw, Machine 8408-820 6 Screw, Machine 2506-220 1 Support, Steering 8424-802 6 Nut, Flange Lock 8408-870 6 Screw, Cap 1506-844 1 Bracket, Seat - Support - Front Right 1506-845 1 Bracket, Seat - Support - Front Left 8427-802 12 Nut, Flange Lock 14 15 16 17 18 19 20 21 22 23 24 25 26 27 1506-842 2 Bracket, Seat - Support - Rear 8408-850 6 Screw, Cap 0423-577 4 Clip, U 8476-616 4 Screw, Machine 1506-835 1 Support, Canopy 2506-304 1 Support, Overhead - Right 2506-305 1 Support, Overhead - Left 0623-544 16 Plug 1406-883 2 Pad, Armrest 1406-720 1 Panel, Belly 0423-545 20 Screw, Body 1406-721 2 Panel, Belly - Side 0123-788 AR Cable Tie 1406-753 1 Shield, Heat 0623-784 5 Screw, Self-Tapping 2007 Prowler/Prowler XT FRAME AND RELATED PARTS (XT) 0741-726 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2506-202 1 Frame, Main 1506-453 1 Bumper 8409-020 2 Screw, Cap 8428-002 2 Nut, Flange Lock 8476-820 4 Screw, Machine 1506-797 1 Bracket, Steering Support - Right 0502-853 1 Bracket, Steering Support - Left 0423-642 12 Screw, Machine 8408-820 6 Screw, Machine 2506-220 1 Support, Steering 8424-802 10 Nut, Flange Lock 8408-870 6 Screw, Cap 1506-844 1 Bracket, Seat - Support - Front Right 1506-845 1 Bracket, Seat - Support - Front Left 8427-802 12 Nut, Flange Lock 1506-842 2 Bracket, Seat - Support - Rear 8408-850 6 Screw, Cap 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 0423-577 4 Clip, U 8476-616 4 Screw, Machine 1506-835 1 Support, Canopy 2506-304 1 Support, Overhead - Right 2506-305 1 Support, Overhead - Left 0623-544 16 Plug 1406-883 2 Pad, Armrest 1406-720 1 Panel, Belly 0423-545 20 Screw, Body 1406-721 2 Panel, Belly - Side 0123-788 AR Cable Tie 1506-672 1 Bumper 0423-505 4 Screw, Shoulder 8050-342 8 Washer 8051-277 4 Washer, Spring Lock 1406-753 1 Shield, Heat 0623-784 5 Screw, Self-Tapping 7 2007 Prowler/Prowler XT CANOPY AND TAILLIGHT ASSEMBLY (Complete Canopy Assembly p/n 1506-794) 0740-381 1 2 3 4 5 6 7 8 9 8 1506-680 1 1506-713 1 0423-361 8 1506-665 1 0423-642 8 1506-795 2 1406-884 2 1506-722 2 0623-544 10 Tube, Canopy - Rear Support, Canopy Screw, Machine Tube, Canopy - Front Screw, Machine Pad, Headrest - Assembly (inc. 7-9) Pad, Headrest Mount, Headrest Plug 10 11 12 13 14 15 16 17 0423-419 18 Screw, Machine 0423-577 2 Clip, U-Nut 2406-069 1 Bracket, Taillight Mounting 0623-301 2 Screw, Self-Tapping 0509-022 1 Taillight Assembly (inc. 15-17) 0509-025 1 Housing, Taillight 0409-056 1 Bulb, Taillight 0409-057 1 Socket, Taillight 2007 Prowler/Prowler XT TILT FRAME ASSEMBLY 0741-740 1 2 3 4 5 6 7 8 1506-669 1406-736 1406-674 8408-840 2506-197 8424-802 0423-628 8424-602 1 2 4 2 1 2 4 2 Latch, Tilt Box Grip, Latch Rod Bushing, Pivot Screw, Cap Frame, Box Nut, Flange Grommet Nut, Flange 9 10 11 12 13 14 15 16 8050-217 0423-355 2506-194 0423-505 0405-166 0405-138 0405-139 1612-178 2 2 1 4 2 2 2 1 Washer Screw, Shoulder Support, Lift Screw, Shoulder Cap, Housing Housing, Lower Housing, Upper Spring 9 2007 Prowler/Prowler XT SEAT, BATTERY, AND TOOL KIT ASSEMBLY 0740-365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 10 1506-925 1506-763 8468-620 0406-877 8468-820 2706-164 0423-559 2606-854 0423-073 0623-038 0423-120 1506-852 0745-059 0645-246 2 2 4 8 8 2 2 2 4 4 2 1 1 6 Seat Plate, Base - Seat Screw, Machine Bumper, Seat Screw, Machine Latch - Assembly Stud, Latch - Seat Lever, Release - Seat Latch Washer Nut, Hex Nut, Wheel Base, Seat/Tools - Assembly Battery - Assembly (inc. 14-17) Cap, Battery 15 16 17 18 19 20 21 22 23 24 25 26 27 28 0645-151 0645-152 0645-263 0406-380 0406-227 1506-841 1506-840 8424-602 8476-616 0423-456 1506-839 1506-853 8408-025 8428-002 1 1 1 1 2 1 1 8 8 1 1 2 4 4 Label, Warning - Battery Clamp, Hose Hose, Battery Vent Pad, Battery Pad, Battery Box, Battery Panel, Electrical Nut, Flange Screw, Machine Screw, Thumb Cover, Battery Box Belt, Seat Screw, Cap Nut 2007 Prowler/Prowler XT DASH ASSEMBLY 0741-741 1 2 3 4 5 6 7 8 9 10 11 2406-505 1 Panel, Dash 1406-727 1 Pod, Instrument 0405-214 1 Bezel, Lights - Instrument Pod 0420-068 1 Light, Indicator - Temperature 0420-066 1 Light, Indicator - “N” 0420-067 1 Light, Indicator - “R” 0423-357 4 Nut, Stamped 0423-342 10 Screw, Self-Tapping 0623-784 6 Screw, Self-Tapping 0641-897 2 Outlet, Accessory - 12V 0430-040 1 Switch, Ignition (inc. 12-14) 12 0430-050 13 0430-042 0430-043 14 0430-054 15 0423-541 16 1406-789 17 0409-069 18 0409-067 19 0409-074 20 0409-070 21 2506-192 1 1 1 1 1 1 1 1 1 1 1 Nut, Flange - Key Switch Key, Ignition Series (Y) Key, Ignition Series (Z) Cover, Key Grommet, Latch - Glove Box Cover, Glove Box Panel, Switch-Mount Switch - Lights Switch, 2WD/4WD Plug, Switch-Hole Bracket, Support - Lower Dash 11 2007 Prowler/Prowler XT DASH ASSEMBLY (XT) 0741-704 1 2 3 4 5 6 7 8 9 10 12 2406-505 1 Panel, Dash 1406-727 1 Pod, Instrument 0520-013 1 Gauge, A/D LCD 0423-342 10 Screw, Self-Tapping 0623-784 6 Screw, Self-Tapping 0420-065 1 Clamp, Plastic - LCD Gauge 0423-493 2 Nut, Hex 0641-897 2 Outlet, Accessory - 12V 0409-069 1 Panel, Switch-Mount 0409-067 1 Switch - Lights 11 12 13 14 15 16 17 18 19 0409-074 0502-905 0430-040 0430-050 0430-042 0430-043 0430-054 1406-789 0423-541 2506-192 1 1 1 1 1 1 1 1 1 1 Switch, 2WD/4WD Lever, Differential Lock - Assembly Switch, Ignition (inc. 14-16) Nut, Flange - Key Switch Key, Ignition Series (Y) Key, Ignition Series (Z) Cover, Key Cover, Glove Box Grommet, Latch - Glove Box Bracket, Support - Lower Dash 2007 Prowler/Prowler XT STEERING POST ASSEMBLY 0741-747 1 2 3 4 5 6 7 8 9 10 11 12 0502-884 0405-239 1670-477 0828-071 0423-558 0405-155 0405-160 0423-613 0405-205 0405-246 0423-622 0405-245 1 1 1 2 2 2 1 3 2 1 2 2 Wheel, Steering - Assembly (inc. 2) Cover, Steering Wheel Nut, Hex Washer Washer Bushing, Steering Shaft, Steering Wheel Screw, Self-Tapping End - Tie Rod Housing, Rack and Pinion (inc. 11-17) Nut, Hex Tie Rod 13 14 15 16 17 18 19 20 21 22 23 24 0405-216 0405-206 0405-236 0405-237 0405-238 0423-072 0623-175 0423-655 0405-156 8409-050 0623-728 8424-002 2 2 2 2 2 2 2 2 1 2 2 2 Boot, Rack Spacer, Rack Clamp, Tie Rod End Clamp, Boot Bushing Nut Pin, Cotter Bolt Shaft, Lower Steering - Assembly Screw, Cap Washer Nut, Flange 13 2007 Prowler/Prowler XT FRONT SUSPENSION ASSEMBLY 0741-745 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 14 1603-889 2 Retainer, Spring 0403-161 2 Spring, Shock Absorber - Black 0403-102 2 Cam, Spring Adjuster 0403-147 2 Shock Absorber - Front (inc. 5-6) 0603-955 8 Bushing 1603-209 4 Sleeve 0404-116 4 Sleeve, Shock 0441-587 1 Wrench, Spanner 8409-040 4 Screw, Cap 8428-002 10 Nut, Lock 0503-196 1 A-Arm, Upper Right - Black (inc. 12-15) 0503-197 1 A-Arm, Upper Left - Black (inc. 12-15) 0403-081 4 Bushing 0403-080 2 Collar 0423-009 4 Clip, Ball Joint 0405-115 4 Ball Joint 16 0503-252 1 0503-253 1 0403-115 0403-114 0423-723 8409-075 0505-480 0505-481 1402-027 0423-423 8409-030 0502-733 1441-109 0436-276 8 4 2 4 1 1 2 2 4 2 2 2 17 18 19 20 21 22 23 24 25 26 27 A-Arm, Lower Right - Black (inc. 14-15 and 17-18) A-Arm, Lower Left - Black (inc. 14-15 and 17-18) Bushing Collar Screw, Cap Screw, Cap Knuckle - Assembly - Right (inc. 22-23) Knuckle - Assembly - Left (inc. 22-23) Bearing, Wheel Hub Ring, Retaining Screw, Cap Axle - Front (inc. 26-27) Clip, Retaining Repair Kit, Boot - Front Axle 2007 Prowler/Prowler XT FRONT SUSPENSION ASSEMBLY (XT) 0741-748 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1603-889 2 Retainer, Spring 0403-161 2 Spring, Shock Absorber - Platinum 0403-102 2 Cam, Spring Adjuster 0403-147 2 Shock Absorber - Front (inc. 5-6) 0603-955 8 Bushing 1603-209 4 Sleeve 0404-116 4 Sleeve, Shock 0441-587 1 Wrench, Spanner 8409-040 4 Screw, Cap 8428-002 10 Nut, Lock 0503-196 1 A-Arm, Upper Right - Black (inc. 12-15) 0503-197 1 A-Arm, Upper Left - Black (inc. 12-15) 0403-081 4 Bushing 0403-080 2 Collar 0423-009 4 Clip, Ball Joint 0405-115 4 Ball Joint 0503-334 1 A-Arm, Lower Right - Black (inc. 14-15 and 17-18) 0503-335 1 A-Arm, Lower Left - Black (inc. 14-15 and 17-18) 17 18 19 20 21 22 23 24 25 26 27 28 29 0403-115 0403-114 0423-723 8409-075 0505-480 0505-481 1402-027 0423-423 8409-030 0502-733 0502-734 1441-109 0436-276 0441-752 0441-753 1441-002 1441-003 0441-756 0441-757 0423-545 8 4 2 4 1 1 2 2 4 1 1 2 2 1 1 1 1 1 1 4 Bushing Collar Screw, Cap Screw, Cap Knuckle - Assembly - Right (inc. 22-23) Knuckle - Assembly - Left (inc. 22-23) Bearing, Wheel Hub Ring, Retaining Screw, Cap Axle - Front - Left (inc. 26-27) Axle - Front - Right (inc. 26-27) Clip, Retaining Repair Kit, Boot - Front Axle 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 15 2007 Prowler/Prowler XT REAR SUSPENSION ASSEMBLY 0741-749 1 2 3 4 5 6 7 8 9 Knuckle, Rear - Assembly (inc. 2-5) Bearing, Wheel Hub Ring, Retaining Collar, Suspension Bushing Bushing, Suspension Axle, Drive (inc. 7-8) Clip, Retaining Repair Kit, Boot - Rear Axle A-Arm, Rear - Lower Right - Black (inc. 10-11) 0504-481 1 A-Arm, Rear - Lower Left - Black (inc. 10-11) 10 0403-115 16 Bushing 11 0403-114 8 Collar 12 0504-358 1 A-Arm, Rear - Upper Right - Black (inc. 10-11) 0504-359 1 A-Arm, Rear - Upper Left - Black (inc. 10-11) 16 0504-389 1402-027 0423-423 0403-038 0403-032 0502-740 0441-893 0436-276 0504-480 2 2 2 4 8 2 2 2 1 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 8409-000 4 Screw, Cap 8428-002 14 Nut, Lock 8409-075 8 Screw, Cap 1603-889 2 Retainer, Spring 0404-117 2 Spring, Suspension - Black 0404-057 2 Cam, Spring Adjuster 0441-587 1 Wrench, Spanner 0404-115 2 Shock Absorber - Rear (inc. 21-23) 0603-955 8 Bushing 1603-219 2 Sleeve, Shock 1603-209 2 Sleeve 0423-087 2 Washer 8408-820 2 Screw, Cap 0404-116 2 Sleeve, Shock Absorber 8409-040 2 Screw, Cap 2007 Prowler/Prowler XT REAR SUSPENSION ASSEMBLY (XT) 0741-750 1 2 3 4 5 6 7 8 9 0504-389 1402-027 0423-423 0403-038 0403-032 0502-740 0441-893 0436-276 0504-464 2 2 2 4 8 2 2 2 1 Knuckle, Rear - Assembly (inc. 2-5) Bearing, Wheel Hub Ring, Retaining Collar, Suspension Bushing Bushing, Suspension Axle, Drive (inc. 7-8) Clip, Retaining Repair Kit, Boot - Rear Axle A-Arm, Rear - Lower Right - Black (inc. 10-11) 0504-465 1 A-Arm, Rear - Lower Left - Black (inc. 10-11) 10 0403-115 16 Bushing 11 0403-114 8 Collar 12 0504-358 1 A-Arm, Rear - Upper Right - Black (inc. 10-11) 0504-359 1 A-Arm, Rear - Upper Left - Black (inc. 10-11) 13 8409-000 4 Screw, Cap 14 8428-002 14 Nut, Lock 15 16 17 18 19 20 21 22 23 24 25 26 27 28 8409-075 1603-889 0404-117 0404-057 0441-587 0404-115 0603-955 1603-219 1603-209 0423-087 8408-820 0404-116 8409-040 0441-754 0441-755 1441-004 1441-005 0441-758 0441-759 29 0423-545 8 2 2 2 1 2 8 2 2 2 2 2 2 1 1 1 1 1 1 4 Screw, Cap Retainer, Spring Spring, Suspension - Black Cam, Spring Adjuster Wrench, Spanner Shock Absorber - Rear (inc. 21-23) Bushing Sleeve, Shock Sleeve Washer Screw, Cap Sleeve, Shock Absorber Screw, Cap 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 17 2007 Prowler/Prowler XT SWAY BAR ASSEMBLY (XT) 0740-634 1 2 3 4 5 18 0404-110 0404-135 0404-094 0404-095 8409-016 1 2 2 2 4 Bar, Sway - Assembly Clamp, Sway Bar Bushing Bushing, Sway Bar - Upper Bushing, Sway Bar - Lower Screw, Cap 6 7 8 9 10 8422-002 0423-335 0423-073 1402-434 0423-620 2 2 8 8 2 Nut Screw, Cap Washer Bushing, Sway Bar Spacer, Sway Bar 2007 Prowler/Prowler XT WHEEL AND TIRE ASSEMBLY 0741-724 1 0423-557 8 Screw, Machine 2 1402-455 2 Disc, Brake 3 0502-980 2 Hub, Wheel - Front (inc. 4) 0503-322 2 Hub, Wheel - Rear (inc. 4) 4 0402-974 16 Stud, Wheel Hub 5 0423-407 4 Pin, Cotter 6 0423-607 4 Nut, Castle 7 1402-511 2 Wheel - Front - Gray 8 9 10 11 12 13 14 0423-408 16 Nut, Mounting - Wheel 1402-392 2 Tire - Front 0402-064 4 Stem, Valve (inc. 11) 0402-140 4 Cap, Valve Stem 1402-514 2 Wheel - Rear - Gray 1402-393 2 Tire - Rear 0403-181 4 Cap, Wheel 19 2007 Prowler/Prowler XT WHEEL AND TIRE ASSEMBLY (XT) 0740-489 1 0423-557 8 Screw, Machine 2 1402-455 2 Disc, Brake 3 0502-980 2 Hub, Wheel - Front (inc. 4) 0503-322 2 Hub, Wheel - Rear (inc. 4) 4 0402-974 16 Stud, Wheel Hub 5 0423-407 4 Pin, Cotter 6 0423-607 4 Nut, Castle 20 7 8 9 10 11 12 13 1402-449 2 Wheel - Front - Black 0423-618 16 Nut, Mounting - Wheel - Chrome 1402-392 2 Tire - Front 0402-064 4 Stem, Valve (inc. 11) 0402-140 4 Cap, Valve Stem 1402-452 2 Wheel - Rear - Black 1402-393 2 Tire - Rear 2007 Prowler/Prowler XT REAR AND PARKING BRAKE ASSEMBLY 0741-751 *Not a Service Part 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1402-324 0423-557 1502-143 0502-988 1502-160 0502-985 * 0502-609 * 0502-605 * 0502-875 1502-161 0487-036 1502-146 1 5 1 1 1 1 1 1 2 1 2 2 1 1 1 Rotor Screw, Shoulder Brake - Assembly (inc. 4-13) Nut Lever, Actuator Spring Housing, Caliper Valve, Bleed O-Ring, Brake Caliper Bracket Assembly Piston Pad, Brake Spring, Anti-Rattle Cable, Parking Brake Brake, Parking - Assembly 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1502-026 0423-668 1502-029 0423-667 1502-030 0487-043 0623-044 8424-602 1502-024 8408-816 8424-802 1402-388 0423-178 0423-413 8408-835 1 2 1 2 1 1 1 1 1 3 3 1 4 2 2 Spring E-Clip Pin E-Clip Pin Cable, Brake Release Washer Nut Handle, Parking Brake Screw, Cap Nut, Hex Hose, Brake Washer, Crush Bolt, Banjo-Fitting Screw, Cap 21 2007 Prowler/Prowler XT HYDRAULIC BRAKE ASSEMBLY 0740-514 1 0502-786 2 3 4 5 6 7 8 9 10 11 12 13 14 15 22 0405-225 0402-592 1402-520 1402-377 8050-217 0402-584 8424-802 8408-860 0423-178 0423-610 0423-413 1402-389 1402-290 0502-958 0502-959 1 1 2 1 1 1 1 2 2 7 1 2 1 1 1 1 Cylinder, Master Brake - Assembly (inc. 2-4) Cap, Brake Fluid Reservoir Nut, Clevis Clevis Pin, Clevis Washer Pin, Cotter Nut Screw, Cap Washer, Crush Bolt, Double Banjo-Fitting Bolt, Banjo-Fitting Hose, Brake - Front Hose, Brake - Front Right Caliper, Brake - Front Right (inc. 16-22) Caliper, Brake - Front Left (inc. 16-22) 16 0502-603 1 0502-611 1 0502-606 0502-607 0502-609 0502-608 0502-960 0502-875 8408-825 0502-785 0409-072 1502-042 1602-213 8428-002 2 2 2 2 2 2 4 1 1 1 2 1 17 18 19 20 21 22 23 24 25 26 27 28 Housing, Caliper - Assembly - Front Right (inc. 17-19) Housing, Caliper - Assembly - Front Left (inc. 17-19) Piston/Seal Set (inc. 18) Seal Set Valve, Bleed O-Ring, Guide - Set Bracket Assembly Pad, Brake - Set Screw, Cap Spring, Brake Switch Switch, Brake - Assembly Lever, Brake O-Ring Nut 2007 Prowler/Prowler XT ACCELERATOR ASSEMBLY 0740-496 1 2 3 4 5 0502-974 0405-233 0402-872 1602-213 8422-002 1 1 1 2 1 Pedal, Accelerator Spring Axle O-Ring Nut 6 7 8 9 10 8471-616 0502-991 0623-038 0502-990 0487-048 2 1 2 1 1 Screw, Machine Bracket, Accelerator Pedal Nut, Hex w/Washer Bracket, Cable - Throttle Cable, Throttle 23 2007 Prowler/Prowler XT GAS TANK ASSEMBLY 0741-746 1 0570-117 1 Tank, Gas - Assembly (inc. 2-8) 0570-097 1 Tank, Gas - Assembly (inc. 2-8) (XT) 2 0470-575 1 Cap, Gas Tank w/Gauge 0470-541 1 Cap, Gas Tank (XT) 3 0570-118 1 Sensor, Fuel Level (inc. 4-6) 0570-100 1 Sensor, Fuel Level (inc. 4-6) (XT) 4 0470-521 1 Seal, Fuel Level Sensor 5 0470-475 1 Filter, Fuel 6 0423-603 1 Clamp, Hose 7 1623-158 4 Screw, Plastite 8 0470-639 1 Plate, Mounting - Fuel Level Sensor 9 0423-688 4 Clamp, Hose 10 0410-070 AR Hose, Gasline - 25 ft 11 1623-406 3 Clip, Routing 12 0423-670 4 Clamp, Hose 24 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0470-527 8476-620 0470-519 0623-038 8476-625 0470-544 0623-784 0570-127 0570-128 8427-602 8476-650 0423-357 1406-886 0123-788 0123-811 1 2 1 4 2 1 2 1 1 1 1 4 1 1 1 Fitting, Straight Screw, Machine Pump, Fuel Nut, Lock Screw, Machine Bracket, Gas Tank Mount Screw, Self-Tapping Strap, Gas Tank Strap, Gas Tank Nut, Hex Screw, Machine Nut, Stamped Inset, Gas Tank Cap Cable Tie - 7.5 in. Cable Tie - 4 in. 2007 Prowler/Prowler XT SHIFTING ASSEMBLY 0741-696 1 2 3 4 5 6 7 8 9 1506-525 8476-616 0423-577 1402-275 1506-811 0423-505 8424-802 1402-269 1506-810 1 8 4 2 1 1 2 1 1 Mount, Shift Screw, Machine Clip, U Retainer, Shift Linkage Axle, Shift Screw, Shoulder Nut, Flange Spring, Shift Lever, Shift 10 11 12 13 14 15 16 17 18 1402-566 0623-269 0541-527 0123-144 0423-686 0423-091 0623-094 0124-057 8408-825 1 1 1 1 1 1 1 1 1 Knob, Shift Clip, Retainer Linkage, Shift Nut, Jam Rod End Bushing, Shift Washer E-Ring Screw, Cap 25 2007 Prowler/Prowler XT AIR INTAKE ASSEMBLY 0741-729 1 2 3 4 5 6 7 8 9 10 11 12 13 26 0470-554 1 0470-663 1 0470-516 1 0470-540 1 0423-455 4 0470-442 3 0423-554 1 0470-525 1 0423-380 1 0470-571 1 0510-593 1 1506-801 1 0423-342 12 Cover, Air Intake Filter, Air Screen, Air Filter Housing, Air Intake Clip, Spring Valve, Drain Clamp, Boot Boot, Carburetor Clamp, Boot Carburetor, CVK36-AE Hose, Carburetor Drain Bracket, Mount - Air Intake Screw, Self-Tapping 14 15 16 17 18 19 20 21 22 23 24 25 26 0623-784 0423-551 0413-098 0413-101 0413-085 0413-100 0413-049 0413-108 0413-109 0423-550 0410-087 0423-045 0123-788 4 7 2 1 1 1 1 1 1 3 1 2 2 Screw, Self-Tapping Clamp, Plastic Boot, Air Duct Plenum, Air-In/Out Boot, Air-In Duct, Air-In Boot, Duct Duct, Air-Out Boot, Air-Out Clamp Hose, Vent - Crankcase Clamp, Hose Cable Tie - 7.5 in. 2007 Prowler/Prowler XT ENGINE AND EXHAUST 0740-392 1 2 3 4 5 6 7 8 9 10 11 0800-027 0412-338 0512-189 0612-668 0412-256 0512-191 0412-313 0512-219 8408-616 0412-215 1411-176 1 1 1 2 1 1 1 1 3 2 1 Engine Gasket, Exhaust Pipe Pipe, Exhaust Spring Seal, Exhaust Muffler - Assembly (inc. 7-9) Gasket, Spark Arrester Spark Arrester Assembly Screw, Cap Bushing, Exhaust Pipe Decal - “Duramatic” 12 1411-177 13 1506-998 1506-999 14 0423-537 15 0423-042 16 8424-002 17 0408-014 18 8408-820 19 8428-002 20 0411-426 1 1 1 2 3 8 4 2 2 1 Decal - “USA” Bracket, Engine - Right Bracket, Engine - Left Bolt Spacer, Engine Mount Nut Mount, Engine Screw, Cap Nut Decal, Warning - Clutch Cover 27 2007 Prowler/Prowler XT COOLING ASSEMBLY 0741-753 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 28 0413-116 1 Radiator - Assembly (inc. 2-14) 0413-043 1 Radiator 0413-002 1 Cap, Radiator 0423-030 2 Grommet 0610-016 AR Hose - 25 ft 0423-351 1 Clamp, Wire 8475-512 12 Screw, Machine 0413-007 1 Screen, Radiator 0423-390 1 O-Ring 0413-045 1 Sensor, Temperature - Coolant 0413-122 1 Cooler, Oil 0413-124 1 Shroud, Fan 0413-123 1 Fan, Cooling 0123-397 1 Clamp, Cable 0623-038 2 Nut w/Washer 0423-484 2 Screw, Shoulder 0423-028 2 Bushing, Stem 18 19 20 21 22 23 24 25 26 27 28 29 0423-496 10 Clamp, Hose 0410-092 1 Hose, Coolant - Upper Radiator 0410-089 1 Pipe, Coolant - Upper 0410-091 1 Hose, Coolant - Upper Engine 0410-094 1 Hose, Coolant - Lower Radiator 0410-090 1 Pipe, Coolant - Lower 0410-093 1 Hose, Coolant - Lower Engine 0410-095 1 Hose, Coolant - Rear 0423-594 2 Clamp, Pipe - Coolant 0623-784 2 Screw, Self-Tapping 0123-903 5 Cable Tie - 11.5 in. 0410-097 1 Hose, Oil - Lower 0410-098 1 Hose, Oil - Upper 30 0623-028 6 Clamp 31 0406-288 2 Pad 32 0623-751 2 Cable Tie, Reuseable 2007 Prowler/Prowler XT DRIVE TRAIN ASSEMBLY 0741-756 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1502-128 1 Gearcase, Rear (inc. 2-6) 1502-124 1 Shaft, Input - Assembly (inc. 3) 1402-322 1 Cover, End 0402-944 1 Joint, Universal - Set (inc. 5) 0423-395 4 Retainer 0502-331 1 Yoke, Propeller Shaft 8409-025 3 Screw, Cap 0502-857 1 Shaft, Drive - Rear 0402-966 1 Boot, Shaft 0423-315 2 Clamp, Hose 0410-070 AR Hose, Vent - 25 ft 0123-788 1 Tie, Cable 0623-101 1 Clip, Routing - Snap-In 0423-155 2 Clamp, Hose 0470-462 1 Fitting, Vent 0402-147 2 Bladder, Gearcase 17 18 19 20 21 22 23 24 25 26 27 28 29 30 8408-820 4 Screw, Cap 0402-950 1 Flange, Output 0423-393 2 Clamp, Boot 0402-985 2 Boot, Coupler 0423-411 2 Clamp, Boot 0673-618 2 Bumper, Driveshaft 1402-271 1 Shaft, Propeller 1502-129 1 Gearcase, Front 1502-127 1 Gearcase, Front (XT) 8428-002 4 Nut, Lock 0423-426 12 Washer 0423-404 4 Screw, Cap 0502-942 1 Plate, Cable (XT) 0423-396 2 Screw, Self-Tapping (XT) 0487-037 1 Cable (XT) 29 2007 Prowler/Prowler XT FRONT DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n 1502-129) 0741-757 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 30 0502-548 1402-441 1402-442 0402-393 0402-405 0402-406 0402-407 0402-408 0402-409 0502-778 0423-149 1502-130 0402-333 0423-154 0402-450 0423-153 0423-118 0402-328 0502-649 0402-327 0402-336 1 2 1 2 AR AR AR AR AR 1 1 1 1 1 1 1 11 1 1 1 1 Housing, Gearcase Seal Fitting Bearing Shim - 1.3 Shim - 1.4 Shim - 1.5 Shim - 1.6 Shim - 1.7 Gear, Front - Assembly - 36T O-Ring Cover, Gearcase Plug, Level (inc. 10) O-Ring Plug, Drain (inc. 12) O-Ring Screw, Self-Tapping Bearing, Needle Gear, Pinion - Assembly - 9T (inc. 16-17) Bearing Collar, Retaining 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 0402-357 0402-413 0423-417 0402-947 0402-411 0502-528 1402-043 0423-423 0502-347 1402-011 1502-085 0402-997 0402-998 0402-417 0423-402 0423-147 0402-999 0502-296 0423-498 0423-396 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 Collar, Lock Coupler, Drive Ring, Retaining Gasket Pin, Dowel Housing, Pinion Bearing Ring, Retaining Bracket, Actuator Seal Shaft, Input - Assembly Shaft, Selector Fork, Selector Shaft, Shuttle Ring, Retaining O-Ring Spring, Return Actuator (inc. one No. 36) O-Ring Screw, Self-Tapping 2007 Prowler/Prowler XT FRONT DRIVE GEARCASE ASSEMBLY (XT) (Complete Assembly p/n 1502-127) 0741-758 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 0502-548 1402-441 1402-442 0402-393 0402-405 0402-406 0402-407 0402-408 0402-409 0502-650 0423-149 1402-074 1402-075 1402-076 1402-077 1402-078 0502-736 1402-053 0502-413 1402-079 1402-042 1402-054 1402-058 1402-057 1402-055 1402-063 0402-419 0423-133 0402-333 0423-154 1 2 1 1 AR AR AR AR AR 1 1 AR AR AR AR AR 1 1 1 1 1 1 2 1 1 1 1 1 1 1 Housing, Gearcase Seal Fitting Bearing Shim - 1.3 Shim - 1.4 Shim - 1.5 Shim - 1.6 Shim - 1.7 Gear, Front - Assembly - 36T O-Ring Shim Shim Shim Shim Shim Cover, Gearcase (inc. one No. 2 and 10-25) Bearing Flange, Bearing Pin Collar, Sliding Fork Ring, Retaining Spring Shaft, Lock Spring Switch, Indicator O-Ring Plug, Level (inc. 22) O-Ring 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 0423-132 1 Washer 0423-424 1 Ring, Retaining 1402-056 1 Seal 0423-118 11 Screw, Self-Tapping 1402-210 1 Plug, Drain (inc. 28) 0423-153 1 O-Ring 0402-328 1 Bearing, Needle 0502-649 1 Gear, Pinion - Assembly - 9T (inc. 31-32) 0402-327 1 Bearing 0402-336 1 Collar, Retaining 0402-357 1 Collar, Lock 0402-413 1 Coupler, Drive 0423-417 1 Ring, Retaining 0402-947 1 Gasket 0402-411 1 Pin, Dowel 0502-952 1 Housing, Pinion 1402-043 1 Bearing 0423-423 1 Ring, Retaining 0502-347 1 Bracket, Actuator 1402-011 1 Seal 1502-085 1 Shaft, Input - Assembly 0402-997 1 Shaft, Selector 0402-998 1 Fork, Selector 0402-417 1 Shaft, Shuttle 0423-402 1 Ring, Retaining 0423-147 1 O-Ring 0402-999 1 Spring, Return 0502-579 1 Actuator (inc. one No. 51) 0423-498 2 O-Ring 0423-396 3 Screw, Self-Tapping 31 2007 Prowler/Prowler XT REAR DRIVE GEARCASE ASSEMBLY (Complete Assembly p/n 1502-128) 0740-421 1 0502-548 1 2 1402-442 2 3 0402-405 AR 0402-406 AR 0402-407 AR 0402-408 AR 0402-409 AR 4 1402-441 2 5 0402-393 2 6 0423-149 1 7 1402-245 1 8 0502-741 1 9 0402-333 1 10 0423-154 1 11 0402-450 1 12 0423-153 1 13 0423-118 11 14 0402-429 AR 0402-430 AR 0402-431 AR 0402-432 AR 0402-433 AR 32 Housing, Gearcase Fitting, 90° Shim Shim Shim Shim Shim Seal Bearing O-Ring Gear, Rear - 36T Cover, Gearcase Plug, Fill (inc. 10) O-Ring Plug, Magnetic (inc. 12) O-Ring Screw, Self-Tapping Shim Shim Shim Shim Shim 15 16 17 18 19 20 21 22 23 24 25 26 27 28 0402-326 0402-411 0402-328 0502-649 0402-327 0402-336 0402-357 0423-633 0423-546 0402-947 0502-746 0402-324 0402-347 1402-314 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Button, Thrust Pin, Dowel Bearing Gear, Pinion - Assembly - 9T (inc. 19-20) Bearing Collar, Retaining Collar, Lock O-Ring Ring, Retaining Gasket Housing, Pinion Bearing Ring, Retaining Seal 2007 Prowler/Prowler XT WIRING HARNESS ASSEMBLY 0741-700 1 2 3 4 5 6 7 8 9 10 11 12 0486-220 1 Harness, Main (inc. 2-8) 0486-164 1 Tether, Accessory Connector 0530-008 1 Cover, Fuse Block 0430-037 1 Holder, Fuse 0430-034 1 Diode 0430-033 1 Relay - 10 Amp 0430-045 3 Relay - 20 Amp 0430-032 4 Fuse - 10 Amp 0430-031 5 Fuse - 15 Amp 0430-030 2 Fuse - 30 Amp 1411-576 1 Decal, Fuse Block 0123-788 AR Cable Tie - 7.5 in. 0824-037 1 Regulator, Voltage 8476-625 4 Screw, Machine 8424-602 2 Nut, Hex 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0824-041 0445-058 0623-038 0445-061 0645-327 0445-049 0645-019 0486-221 0824-036 0824-021 8476-620 0409-009 0402-991 0445-050 0486-176 1 1 8 1 1 1 2 1 1 1 2 1 1 1 1 CDI Unit Solenoid Nut w/Washer Cable, Solenoid/Starter Boot, Terminal Cable, Battery/Solenoid (inc. one No. 19) Boot, Terminal Harness, Console Coil, Ignition - Assembly Cap, Spark Plug Screw, Machine Switch, Brake - Assembly Retainer, Brake Switch Cable, Battery/Engine Harness Adapter, Taillight 33 2007 Prowler/Prowler XT WIRING HARNESS ASSEMBLY (XT) 0741-703 1 2 3 4 5 6 7 8 9 10 11 12 34 0486-218 1 Harness, Main (inc. 2-8) 0486-164 1 Tether, Accessory Connector 0530-008 1 Cover, Fuse Block 0430-037 1 Holder, Fuse 0430-034 1 Diode 0430-033 1 Relay - 10 Amp 0430-045 3 Relay - 20 Amp 0430-032 4 Fuse - 10 Amp 0430-031 5 Fuse - 15 Amp 0430-030 2 Fuse - 30 Amp 1411-576 1 Decal, Fuse Block 0123-788 AR Cable Tie - 7.5 in. 0824-037 1 Regulator, Voltage 8476-625 4 Screw, Machine 8424-602 2 Nut, Hex 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0824-041 0445-058 0623-038 0445-061 0645-327 0445-049 0645-019 0486-224 0824-036 0824-021 8476-620 0409-009 0402-991 0445-050 0486-176 1 1 8 1 1 1 2 1 1 1 2 1 1 1 1 CDI Unit Solenoid Nut w/Washer Cable, Solenoid/Starter Boot, Terminal Cable, Battery/Solenoid (inc. one No. 19) Boot, Terminal Harness, Console Coil, Ignition - Assembly Cap, Spark Plug Screw, Machine Switch, Brake - Assembly Retainer, Brake Switch Cable, Battery/Engine Harness Adapter, Taillight 2007 Prowler/Prowler XT CARBURETOR CVK36-AE (Complete Assembly p/n 0470-571) 0741-115 *Not a Service Part **Optional 1 2 3 4 5 6 7 8 9 10 11 12 13 14 5507-001 5507-002 5507-066 5507-099 5507-005 5507-201 5507-007 5507-047 5507-075 5507-072 5507-073 5507-074 5507-076 5507-057 5507-043 5507-042 5507-041 5507-009 5507-077 5507-078 5507-101 5507-112 5507-183 * 5507-039 1 4 1 1 1 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 - 132 Main Jet - 125** Main Jet - 128** Main Jet - 130** Main Jet - 138** Main Jet - 135** Main Jet - 142** Main Jet - 145** Main Jet - 148** Main Jet - 150** Main Jet - 152** Main Jet - 155** Slow Jet Starter Jet - 85 Valve, Float - Set (inc. 13) Clip Float Set (inc. 15) 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 * 5507-111 * * * 5507-027 5507-028 5507-029 5507-115 5507-117 5507-204 5507-114 5507-203 5507-050 5507-032 5507-202 5507-033 5507-034 5507-035 5507-067 5507-017 5507-037 5507-036 0410-056 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 4 1 1 1 Pin, Float Screw, Pilot - Set (inc. 17-19) Spring Washer O-Ring Screw, Idle Adjust Washer Spring Plate Screw Choke, Electric Cover, Electric Choke Chamber, Float - Assembly (inc. 28-34) Screw, Drain Spring Diaphragm Assembly - Pump Housing Housing, Pump U-Ring Screw O-Ring, Float Chamber Screw Screw Cover Hose, Vent 35 2007 Prowler/Prowler XT CYLINDER HEAD ASSEMBLY 0741-101 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 36 0808-047 0808-002 0829-001 0826-001 0826-002 0830-085 0829-002 0808-037 0827-030 0827-002 0827-031 0826-005 0826-006 8424-604 8424-804 1 4 2 4 2 1 2 4 2 2 1 2 4 5 1 Head, Cylinder - Assembly (inc. 2-4) Guide, Valve Dowel, Sleeve Screw, Cap Screw, Cap Gasket, Cylinder Head Pin, Dowel Screw, Cap Bolt, Stud Bolt, Stud Bolt, Stud Screw, Cap Screw, Cap Nut Nut 16 17 18 19 20 21 22 23 24 25 26 27 28 29 0830-107 0830-147 0217-727 0808-003 0830-004 0826-007 0808-077 0570-115 0830-090 0826-008 0423-317 0808-007 0808-008 0808-078 4 4 1 2 2 5 1 1 1 2 1 1 1 1 Gasket - Seal, Fastener Washer, Crush Spark Plug (RG6YC) Cap, Inspection O-Ring Screw, Cap Plug, Cylinder Head Pipe, Intake - Assembly O-Ring Screw, Machine Clamp, Intake Pipe Switch, Water Temperature - Assembly Cover, Thermostat Thermostat 2007 Prowler/Prowler XT CYLINDER ASSEMBLY 0739-929 1 2 3 4 0804-016 0827-002 8424-604 0830-084 1 2 2 1 Cylinder Bolt, Stud Nut Gasket, Base 5 6 7 8 0829-002 0804-002 8468-612 0830-007 2 1 1 1 Pin, Dowel Union, Water Hose Screw, Machine O-Ring 37 2007 Prowler/Prowler XT CRANKCASE ASSEMBLY 0739-931 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 38 0801-056 8412-850 0801-002 0832-003 0832-005 0832-013 0832-014 0832-002 0832-012 0832-015 0822-052 0826-100 0822-010 0801-028 0812-008 0830-035 0829-002 0829-003 8468-645 1 4 2 1 2 1 2 1 1 1 1 2 2 1 1 1 5 1 4 Crankcase Assembly (inc. 2-16) Screw, Cap Plug Bearing Bearing Bearing Bearing Bearing Bearing Bearing Seal, Countershaft Screw, Cap Retainer, Bearing Pipe, Breather Union, Oil Filter Seal, Driveshaft Pin, Dowel Pin, Dowel Screw, Machine 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 8468-655 8468-675 8412-860 0826-017 0830-008 0826-019 0826-018 8468-695 0801-006 0826-105 0801-069 0826-038 0812-028 0812-025 0801-073 0830-010 8468-680 0812-026 3 2 1 1 2 1 1 1 1 3 1 1 2 2 1 1 1 4 Screw, Machine Screw, Machine Screw, Cap Screw, Cap Gasket Screw, Cap Screw, Cap Screw, Machine Housing, Secondary Shaft Bearing Bolt Pipe, Breather Bolt, Breather Pipe Fitting, Oil Cooler Bolt, Oil Cooler Fitting Stick, Oil Level O-Ring, Oil Level Stick Screw, Machine Gasket 2007 Prowler/Prowler XT CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY 0741-709 1 2 3 4 5 6 7 8 9 10 0806-014 0829-002 0830-013 8408-812 0830-012 0806-013 0826-029 0806-048 0830-116 0830-128 1 4 1 1 1 1 3 1 1 1 Cover, V-Belt Pin, Dowel Washer, Crush Screw, Cap Gasket, V-Belt Cover Cover, Clutch Screw, Machine Seal, Air Intake Gasket, Clutch Cover Gasket, Magneto Cover 11 12 13 14 15 16 17 18 19 0806-021 1 Cover, Magneto - Assembly 0806-022 1 Plug 0830-015 1 Washer, Crush 3002-964 1 Clamp, Wire 8468-645 14 Screw, Machine 8468-655 2 Screw, Machine 8468-625 2 Screw, Machine 8468-640 26 Screw, Machine 8468-675 2 Screw, Machine 39 2007 Prowler/Prowler XT CRANKSHAFT ASSEMBLY 0739-932 1 0805-032 2 0805-035 3 0805-011 40 1 1 1 Crankshaft Assembly Piston Set (inc. 3-6) Ring, Piston - Set 4 0831-001 5 0805-010 6 0805-012 2 1 1 Circlip, Piston Pin Piston Pin, Piston 2007 Prowler/Prowler XT STARTER CLUTCH ASSEMBLY 0739-940 1 2 3 4 5 0815-001 0829-031 0815-002 0815-003 0829-032 1 1 1 1 1 Gear, Starter Idler - No. 1 Shaft, Starter Gear Gear, Starter Idler - No. 2 Spacer, Starter Idler Gear No. 2 Shaft, Starter Gear 6 7 8 9 10 0815-004 0832-004 0802-035 0826-069 0828-002 1 1 1 6 1 Gear, Starter Clutch (inc. 7) Bearing Clutch, Starter Screw, Machine Washer 41 2007 Prowler/Prowler XT CRANK BALANCER ASSEMBLY 0739-941 1 2 3 4 42 0826-033 0828-003 0811-003 0829-007 1 1 1 1 Screw, Cap Washer Gear, Oil Pump Drive Pin, Dowel 5 6 7 8 0811-004 0811-002 0829-006 0811-017 1 1 1 1 Spacer Gear, Driven Key Balancer, Crank 2007 Prowler/Prowler XT CAMSHAFT/VALVE ASSEMBLY 0739-942 1 2 3 4 5 6 7 0809-116 0809-002 0829-008 0828-004 0826-034 0809-003 0809-134 1 1 1 1 2 1 1 8 0809-033 9 0827-007 10 0809-136 4 4 1 Camshaft Sprocket Pin Washer Bolt C-Ring Arm, Valve Rocker - Intake (inc. two No. 8-9) Screw Nut Arm, Valve Rocker - Exhaust (inc. two No. 8-9) 11 12 13 14 15 16 17 18 19 20 0809-006 0830-016 0809-007 0809-008 0831-066 0809-014 0809-039 0809-040 0809-138 0809-013 4 4 1 1 2 8 2 2 4 4 Seat, Spring - Valve Seal, Oil Shaft, Rocker Arm - Intake Shaft, Rocker Arm - Exhaust Plug, Shaft Keeper, Valve Valve, Intake Valve, Exhaust Spring, Valve Retainer, Spring 43 2007 Prowler/Prowler XT CAM CHAIN ASSEMBLY 0732-308 1 2 3 4 5 44 0810-001 0810-002 0810-003 0826-036 0830-025 1 1 1 1 1 Chain, Cam Guide, Chain Tensioner, Chain Bolt Washer 6 7 8 9 0810-004 0830-018 8468-625 0830-107 1 1 2 2 Adjuster, Tensioner - Assembly Gasket Screw, Machine Gasket 2007 Prowler/Prowler XT MAGNETO COVER ASSEMBLY 0741-730 *Optional 1 0820-034 0820-062 2 0826-038 3 0827-008 4 0820-061 5 0830-108 1 1 4 1 1 1 Cover, Magneto* Cover, Magneto Screw, Machine Nut Spacer O-Ring 6 7 8 9 10 11 0826-031 0805-008 0830-021 0820-007 0830-022 0832-006 3 1 1 1 1 1 Screw Retainer, Oil Seal O-Ring Spacer Seal, Oil Bearing 45 2007 Prowler/Prowler XT OIL FILTER/PUMP ASSEMBLY 0741-719 1 2 3 4 5 6 7 46 0812-023 0812-002 0829-009 0828-007 0831-002 0826-039 0812-003 1 1 1 1 1 3 1 Pump, Oil Gear, Driven Pin Washer Circlip Screw, Cap Strainer, Oil 8 9 10 11 12 13 14 0826-040 0812-029 0812-053 8468-625 0812-007 0812-006 0830-017 2 1 1 4 1 1 1 Screw, Machine Filter, Oil Cap, Oil Strainer Screw, Machine Valve, Oil-Relief - Assembly Plug, Drain Gasket, Drain Plug 2007 Prowler/Prowler XT WATER PUMP ASSEMBLY 0739-945 1 2 3 4 5 6 0813-001 8468-665 0813-004 0813-005 0829-009 0831-002 1 2 1 1 1 2 Pump, Water - Assembly Screw, Machine Gear, Driven Shaft, Driven Gear Pin, Driven Gear Circlip, Driven Gear 7 8 9 10 11 0832-008 0831-004 0811-003 0829-007 0831-005 1 1 1 1 1 Bearing, Shaft Circlip, Shaft Bearing Gear, Water Pump Drive Pin, Drive Gear Circlip, Drive Gear 47 2007 Prowler/Prowler XT TRANSMISSION ASSEMBLY 0741-159 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 48 0823-254 0823-176 0823-177 0832-010 0823-016 0823-020 0826-031 0827-010 0823-008 0823-010 0823-159 0823-013 0823-149 0823-012 0823-156 0823-131 1 3 3 1 1 1 2 1 1 4 1 1 1 8 1 1 Pulley, Driven - Assembly (inc. 2-3 and 30) Shoe, Cam Screw, Cam Bearing Seal, Clutch Housing - Right Retainer, Bearing Screw Nut Plate, Movable Drive Face Damper, Movable Drive Face Face, Movable Drive Belt, Drive Spacer, Movable Drive Face Roller, Movable Drive Face Face, Fixed Drive Shroud, Drive Face 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 0623-914 0823-015 0470-531 0830-034 0823-096 0832-009 0826-029 0822-010 0828-075 0823-017 0827-011 0823-018 0823-098 0823-178 0828-076 6 1 1 1 1 1 2 2 1 1 1 1 1 1 1 Screw, Self-Tapping Spacer, Fixed Drive Face O-Ring Seal, Clutch Housing - Right Housing, Clutch Bearing Screw, Bearing Retainer Retainer, Bearing Shim Seal, Clutch Housing - Left Nut Clutch, One-Way Clutch, Centrifugal - 6 Plate Nut, Driven Pulley Shim 2007 Prowler/Prowler XT SECONDARY TRANSMISSION ASSEMBLY 0739-954 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0822-048 0822-008 0822-014 0831-011 0822-045 0828-008 0822-013 0832-011 0822-005 0828-014 0828-015 0822-004 0822-046 0822-003 0822-007 0822-006 0828-011 0828-010 0831-039 1 1 1 2 1 2 1 3 3 1 1 1 2 1 1 1 1 1 1 Countershaft Assembly (inc. 2-16) Gear, Drive - No. 2 Dog, Reverse Driven Gear Circlip Spacer, Reverse Driven Gear Washer Gear, Reverse Driven Bearing Bushing Washer, Lock Washer, Lock Gear, Driven - Low Washer, Driven Gear Countershaft Dog, Sliding Gear, Driven - High Washer, Drive Gear - Left Washer, Drive Gear - Right Ring, Retaining 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 0828-069 0822-050 0831-040 0830-129 0829-023 0822-049 0824-015 8468-620 8468-645 0830-107 0822-009 0822-037 0832-014 0822-001 0828-016 0822-011 0822-012 0822-015 1 1 1 1 2 1 1 1 2 2 1 1 1 1 2 1 1 1 Washer, Thrust Trigger, Speedometer Sensor Ring, Retaining Gasket Pin, Dowel Housing, Speedometer Sensor Sensor, Speedometer Screw, Machine Screw, Machine Seal, Fastener Gear, Driven - No. 2 Shaft, Output Bearing Driveshaft Washer, Reverse Idle Gear Gear, Reverse Idle Bushing, Reverse Idle Gear Shaft, Reverse Idle 49 2007 Prowler/Prowler XT GEAR SHIFTING ASSEMBLY 0739-957 1 2 3 4 5 6 7 8 9 10 11 12 13 50 8470-520 0818-049 0818-013 0818-017 0828-040 0818-046 0828-067 0832-034 0828-037 0818-005 0826-006 0828-036 0831-010 2 1 2 2 1 1 2 1 1 1 1 2 2 Screw, Machine Base, Gear Shift - Assembly Contact Spring Washer, Shift Shaft Shaft, Gear Shift - Assembly Washer, Shift Shaft Bearing Washer, Gear Shift Cam Plate Plate, Gear Shift Cam Bolt, Gear Shift Cam Plate Washer, Sub-Gear Shift Shaft Circlip, Sub-Gear Shift Shaft 14 15 16 17 18 19 20 21 22 23 24 25 0818-007 0830-044 0818-014 8468-620 0828-038 0818-002 0818-004 0818-028 0828-035 8424-602 0818-072 0818-006 1 1 1 1 1 1 1 1 1 1 2 1 Shaft, Sub-Gear Shift Seal, Sub-Gear Shift Shaft Arm, Select Screw, Machine Washer, Cam Stopper Stopper, Cam Support, Cam Stopper Spring, Cam Stopper Washer, Cam Stopper Spring Nut, Cam Stopper Spring Fork, Shift Shaft, Shift Fork 2007 Prowler/Prowler XT SECONDARY DRIVE ASSEMBLY 0739-956 1 2 3 4 5 6 7 8 9 0502-829 1402-462 0423-395 0827-013 0828-020 0502-828 0830-043 0832-017 0828-021 0828-022 0828-023 0828-024 0828-025 0828-026 0828-027 0828-028 0828-029 10 0819-003 1 1 4 2 2 1 2 2 AR AR AR AR AR AR AR AR AR 1 Yoke, Propeller Shaft Joint Joint, Universal - Set (inc. 3) Retainer, Universal Joint Nut, Rear Output Joint Washer, Rear Output Flange Yoke, Drive Output - Front Seal, Oil - Driven Shaft Bearing, Driven Shaft Shim, 25 x 34 x 0.25 mm Shim, 25 x 34 x 0.30 mm Shim, 25 x 34 x 0.70 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 Shaft, Secondary Driven - Front 11 0828-030 0828-031 0828-032 0828-033 0828-018 0828-062 0828-063 0828-064 0828-065 12 0819-001 13 0828-019 14 0827-012 15 0832-016 16 0819-002 17 0831-008 18 0819-011 19 0819-053 20 0819-005 AR AR AR AR AR AR AR AR AR 1 1 1 1 1 1 1 1 1 Shim, 24 x 34 x 0.25 mm Shim, 24 x 34 x 0.30 mm Shim, 24 x 34 x 0.35 mm Shim, 24 x 34 x 0.90 mm Shim, 24 x 34 x 0.95 mm Shim, 24 x 34 x 1.00 mm Shim, 24 x 34 x 1.05 mm Shim, 24 x 34 x 1.10 mm Shim, 24 x 34 x 1.15 mm Gear, Secondary Drive Washer Nut Bearing, Driven Gear Gear, Secondary Driven Circlip, Secondary Driven Gear Ring, Driven Bearing Shaft, Secondary Driven - Rear Flange, Output Joint - Rear 51 2007 Prowler/Prowler XT STARTER MOTOR ASSEMBLY 0739-958 1 0825-001 2 8468-630 52 1 2 Motor, Starter - Assembly Screw, Machine 3 0623-038 1 Nut w/Washer 2007 Prowler/Prowler XT MAGNETO ASSEMBLY 0737-780 1 2 3 4 0802-037 0802-036 0826-102 0829-012 1 1 3 1 Stator - Assembly Rotor/Flywheel Screw, Machine Key 5 6 7 8 0827-014 8470-510 0802-015 0802-016 1 3 1 1 Nut Screw, Machine Clamp - No. 1 Clamp - No. 2 53 RELATED ITEMS 2007 Prowler/Prowler XT Red (Model No. U2007P1S4BUSR) Green (Model No. U2007P1S4BUSG) Cat Green (Model No. U2007P1S4BUSZ) 0436-801 0436-772 0436-820 0436-818 0436-817 0436-816 0436-839 0436-815 0436-983 0436-984 0436-990 0436-968 0436-969 0436-970 0436-035 0436-976 0436-800 0436-608 0436-716 0436-715 2257-692 Box Lift, Electric Bumper, Brushguard Cab Enclosure - Complete Cab Enclosure Doors Cab Enclosure Rear Panel Cab Enclosure Roof Cab Enclosure Support - Roof/Windshield Cab Enclosure Windshield Cab, Soft - Black Cab, Soft - Max-4 Cover, Tonneau Cover, Trailerable Covers, Fender - Max-4 Covers, Seat - Max-4 Engine Heater Gun Scabbard, Dual Gun Scabbard Mount Hitch Hitch Ball (1 7/8 in.) Hitch Ball (2 in.) Manual, Illustrated Parts Red - XT (Model No. U2007P2S4BUSR) Green - XT (Model No. U2007P2S4BUSG) Cat Green - XT (Model No. U2007P2S4BUSZ) 2257-615 2257-616 0436-831 0436-830 0436-832 0436-985 0436-819 0436-796 0436-988 0436-987 0436-989 0436-836 0436-973 0436-974 0436-972 0436-971 0436-821 0436-799 0436-975 0436-920 Manual, Operator’s (E) Manuel d’utilisation (F) Mower - Finish (42 in.) Mower - Finish (63 in.) Mower - Rough-Cut (42 in.) Nerf Bars Plow Kit - 72 in. Rail, SpeedRack Mount Rails, Box Shield, Operator Side Guards Sprayer - 45 gal. Top, Soft - Max-4 Top, Soft - Black V-Bag - Black V-Bag - Max-4 Winch, 3000 lb Windshield Windshield - Polycarbonate Windshield Wiper Kit NOTE: For a complete list of related items, refer to the current accessory catalog. Printed in U.S.A p/n 2257-692
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