Diagram(s) and/or PartsList(s) · 2012-02-14 · 1996 BEARCAT 4X4 (96A4A-AP-1996) Page 2 of 96...

1996 BEARCAT 4X4 (96A4A-AP-1996) Page 1 of 96ACCESSORIES

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

www.mymowerparts.com

1996 BEARCAT 4X4 (96A4A-AP-1996) Page 2 of 96ACCESSORIES

Ref # Part Number Qty DescriptionS/P/F0436-013 Bag, Rack Utility - Front00436-012 Bag, Rack Utility - Rear00436-025 Blade, 48 in. Plow00436-010 Cover, Black and Green00436-011 Cover, Camoflage00436-047 Cover, Padded Bar - Black00436-046 Cover, Padded Bar - Green00436-035 Engine Block Heater0 S0436-023 Gun Scabbard02255-464 Manual, Parts02255-344 Manual, Operator02255-466 Manual, Service00436-050 Mounting Bracket, Gun Scabbard00436-051 Mounting Bracket, Portable Lights00436-008 Mounting Plate with Tow Loops00436-052 Plow Mounting Kit, Winch Lift00436-053 Plow Mounting Kit, Mechanical Lift00436-040 Portable Light, Spot0 /P0436-039 Portable Light, Work0 /P0436-014 Safety Flag0 /P0436-032 Tie Down, Black00436-031 Tie Down, Green00436-041 Tire Repair, Standard00436-042 Tire Repair, Deluxe00436-045 Tire Sealant0 S0436-034 Tool Holder0 S0436-024 Winch Kit00436-068 Winch Accessories Kit0



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 3 of 96AIR INTAKE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 4 of 96AIR INTAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0423-066 Clamp12 0470-305 Boot, Air Cleaner13 0423-018 Clamp24 0570-004 Cleaner, Air - Lower Assembly1 S5 0470-328 Baffle, Splash - Air Cleaner16 0470-324 Gasket, Air Cleaner17 0470-304 Snorkel, Air Cleaner1 S8 0470-307 Clamp, Air Cleaner69 0423-037 Spring, Air Cleaner6

10 0123-549 Screw, Machine4 /P11 0123-010 Nut, Expansion4 /P12 0410-004 Hose, Crankcase Vent113 0470-322 Filter, Air Cleaner (inc. 14)4 S14 0470-332 Sleeve, Filter215 0470-309 Valve, Air Cleaner1 S16 0470-310 Cap, Drain - Air Cleaner1 S17 0423-047 Clamp, Hose118 0423-045 Clamp, Hose - Spring219 0470-327 Support, Air Cleaner Flange220 0706-990 Tape, Foil (6 in. x 24 in.)AR /P/F



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 5 of 96BODY PANEL ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 6 of 96BODY PANEL ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0506-156 Panel, Fender - Front1 S2 0406-153 Cover, Radiator Access1 S/P3 0506-154 Flare - Front Right1 S3 0506-155 Flare - Front Left1 S4 0506-104 Rack - Front1 S5 0606-526 Yellow Reflector26 0623-269 Clip, Retaining87 0506-164 Panel, Side - Right17 0506-165 Panel, Side - Left18 0506-157 Panel, Fender - Rear19 0506-103 Rack - Rear1 S

10 0406-269 Wrap, Tube - Rear Rack111 0123-788 Tie, Cable7 /P12 0606-029 Red Reflector213 0406-082 Flare - Rear Right113 0406-083 Flare - Rear Left114 0406-086 Mud Flap - Right114 0406-087 Mud Flap - Left115 0423-046 Rivet, Plastic5416 0506-160 Fender Extension - Rear Right116 0506-161 Fender Extension - Rear Left117 0423-010 Washer, Body1418 8474-616 Screw, Machine1419 0423-060 Clip, Tinerman220 0623-302 Screw, Self-Tapping221 8409-020 Screw, Cap6 /P22 8408-812 Screw, Cap223 0423-031 Nut, Speed224 0123-010 Nut, Expansion2 /P25 0423-068 Screw, Machine226 0219-376 Tape, Foil0 /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 7 of 96CAM CHAIN ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 8 of 96CAM CHAIN ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-133 Chain, Cam12 3402-134 Guide, Chain13 3402-135 Tensioner, Chain14 3423-074 Bolt15 3003-188 Washer1 S/P6 3402-136 Adjuster, Tensioner - Assembly17 3402-137 Gasket18 3004-475 Bolt2 S9 3003-290 Gasket2 /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 9 of 96CAM SHAFT VALVE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 10 of 96CAM SHAFT VALVE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-130 Cam Shaft1 S2 3402-131 Sprocket13 3423-047 Pin14 3423-073 Washer15 3423-013 Bolt2 S6 3423-071 C-Ring1 /P7 3402-138 Arm, Valve Rocker (inc. 8-9)1 S8 3423-075 Screw, Cap29 3423-076 Nut2

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



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 11 of 96CARBURETOR



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 12 of 96CARBURETOR

Ref # Part Number Qty DescriptionS/P/F0470-317 Complete Assembly1 S

1 4505-001 Cover - Assembly12 4505-002 Spring23 4505-003 Ring14 4505-004 E-Ring1 S5 4505-005 Ring16 4505-020 Jet Needle 5D40-41 /P7 4505-007 Screw4 S8 4505-008 Diaphram1 S9 4505-009 Screw1

10 4505-010 Plunger - Assembly111 4505-011 O-Ring1 /P12 4505-012 Washer113 4505-013 Spring114 4505-014 Screw415 4505-016 Screw, Pilot1 /P16 4505-017 Jet, Pilot 40117 4505-019 Jet, Main 142.5118 4505-006 Needle Jet P-71 /P19 4505-021 Float - Assembly120 4505-022 Seat, Valve 2.0121 4505-044 O-Ring, Bowl122 4505-045 Filter123 4505-023 Chamber, Float124 4505-024 Jet, Pilot1 /P25 4505-025 Screw526 4505-026 Spring127 4505-027 Cable Adjust - Assembly128 4505-028 Cover129 4505-029 Washer130 4505-030 Screw131 4505-031 O-Ring132 4505-032 Guide, Cable133 4505-033 Washer234 4505-042 Screw135 4505-043 Clip1 S36 4505-035 Hose237 4505-036 Cap1 /P38 4505-037 Clip139 4505-039 Spring1 /P40 6505-153 Pin141 6505-006 Washer142 0487-001 Cable, Throttle143 0487-002 Cable, Choke1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 13 of 96CLUTCH ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 14 of 96CLUTCH ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-001 Housing, Starter Clutch1 S2 3446-003 Clutch, Primary Drive One Way13 3446-010 Shoe, Starter Clutch14 3423-081 Nut, Starter Clutch Shoe15 3423-032 Washer, Starter Shoe16 3423-122 Washer, Primary Driven17 3423-186 Washer, Primary Driven18 3446-002 Gear, Primary Driven - Assembly19 3446-004 Hub, Clutch Sleeve1

10 3423-079 Bolt, Clutch Spring411 3446-005 Spring, Clutch412 3446-006 Plate, Clutch Drive613 3446-007 Plate, Clutch Driven514 3446-008 Disk, Clutch Pressure115 3446-009 Plate, Clutch Release116 3423-080 Nut, Clutch Sleeve Hub117 3423-032 Washer, Sleeve Hub118 3446-011 Arm, Clutch Release119 3423-082 Bolt, Clutch (No. 1)120 3423-083 Bolt, Clutch (No. 2)221 3446-012 Guide, Release Roller122 3446-013 Roller, Clutch Release - Assembly1 S23 3423-125 Bolt, Clutch Release Arm1 S24 3008-014 Nut, Clutch Release (No. 2)125 3423-022 Nut, Clutch Release (No. 1)126 3423-027 Washer, Clutch (No.2)127 3402-186 Bearing, Clutch1 /P28 3004-366 Washer, Clutch (No. 1)1 S



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 15 of 96CONTROL SWITCH HOUSING ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 16 of 96CONTROL SWITCH HOUSING ASSEMBLY

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



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 17 of 96COOLING ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 18 of 96COOLING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0413-007 Screen, Radiator12 3002-964 Clamp, Wire2 /P3 8408-620 Screw, Cap24 0423-030 Grommet25 0423-036 Collar26 0610-016 Hose - 25 ft0 /P7 0413-002 Cap, Radiator1 S8 0413-001 Radiator -Assembly (inc. 1, 4, 7, 9-10, and

21)1

9 0423-062 O-Ring110 0430-001 Switch, Temperature Sensor1 S11 0214-015 Clamp, Hose612 0410-002 Hose, Coolant - Upper113 0413-006 Blade, Fan114 0413-004 Motor, Fan115 8474-516 Screw, Machine316 0410-001 Hose, Coolant - Lower117 0410-003 Hose, Coolant - Crossover118 8474-616 Screw, Machine819 0423-010 Washer, Shoulder820 0406-200 Panel, Fender - Inner221 0413-009 Screw, Thumb422 0423-031 Nut, Speed423 0423-056 Nut, Jam - Left124 8050-252 Washer125 0423-028 Bushing, Stem226 8477-616 Screw, Machine427 0123-788 Tie, Cable8 /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 19 of 96CRANK BALANCER ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 20 of 96CRANK BALANCER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-126 Balancer, Crank12 3402-050 Bearing23 3423-033 Washer14 3402-128 Gear, Driven15 3402-129 Race, Driven Gear Inner16 3423-041 Pin3 S7 3402-090 Spring68 3004-540 Key1 /P9 3423-107 Washer1

10 3423-200 Circlip1 /P11 3402-150 Gear, Oil Pump Drive112 3423-114 Pin1 /P13 3402-151 Spacer114 3423-025 Nut115 3423-029 Washer1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 21 of 96CRANKCASE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 22 of 96CRANKCASE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-104 Crankcase Set12 3423-088 Pin43 3423-091 Bolt3 S4 3423-092 Bolt6 S5 3423-094 Bolt26 0693-303 Bolt4 S7 3423-093 Bolt28 3423-095 Plug, Oil Gallery19 3402-011 Gasket1

10 3423-052 O-Ring111 3423-009 Bolt3 /P12 3423-024 Nut313 3004-278 Washer3 S/P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 23 of 96CRANKCASE COVER ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 24 of 96CRANKCASE COVER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-105 Cover, Clutch (inc. 2)1 S2 3402-112 Lens, Oil Inspection1 /P3 3402-108 Gasket14 3423-088 Pin25 0693-327 Bolt14 S6 3423-097 Bolt17 3003-290 Gasket1 /P8 3004-339 Plug, Oil Gallery1 S/P9 3402-009 Gasket1 /P

10 3402-042 Cap, Engine Oil Filler111 3423-055 O-Ring112 3402-100 Cap, Inspection113 3402-101 O-Ring114 3423-096 Screw, Cap2 S15 3402-037 Plug, Oil Pressure116 3402-012 Gasket117 3402-106 Cover Set, Transfer (inc. 18-19)118 3402-097 Jet, Oil Mission119 3423-051 O-Ring120 3402-109 Gasket1 S21 3423-120 Clip122 3423-098 Bolt13 S23 3423-092 Bolt1 S24 3003-290 Gasket1 /P25 3004-705 Plug, Oil Gallery2 S26 3003-188 Gasket2 S/P27 3402-038 Plug128 3402-013 Gasket1 /P29 3413-009 Union, Water Drain130 3413-008 Hose1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 25 of 96CRANKSHAFT ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 26 of 96CRANKSHAFT ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-115 Crankshaft - Assembly (inc. 2-7)12 3402-111 Rod, Connecting13 3402-116 Pin, Crank14 3402-064 Bearing15 3423-030 Washer26 3402-117 Crankshaft - Right17 3402-118 Crankshaft - Left18 3402-127 Gear, Balancer Drive19 3423-048 Pin1

10 3402-044 Bearing - Right111 3402-058 Bearing - Center112 3402-054 Bearing - Left113 3402-120 Retainer, Bearing - Right114 3423-017 Screw, Cap215 3402-188 Retainer, Oil Seal - Left1 /P16 3423-018 Screw, Cap317 3402-113 Piston118 3402-114 Ring Set, Piston119 3402-110 Pin120 3423-069 Circlip221 3402-189 Piston Set (OS:0.5 mm)1 S21 3402-190 Piston Set (OS:1.0 mm)122 3402-051 Bearing123 3402-070 Seal, Oil124 3402-119 Spacer1 S25 3423-063 O-Ring126 3436-007 Ring Set (+.20 in.)1 S27 3436-008 Ring Set (+.40 in.)1 S



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 27 of 96CYLINDER ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 28 of 96CYLINDER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-102 Cylinder12 3423-090 Bolt, Stud23 3004-488 Nut2 S/P4 3402-103 Gasket, Cylinder1 S5 3423-088 Pin26 3413-006 Union, Water Hose17 3423-121 Bolt1 S8 3423-058 O-Ring1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 29 of 96CYLINDER HEAD ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 30 of 96CYLINDER HEAD ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F3402-107 Complete Gasket Set1 S

1 3402-098 Head, Cylinder - Assembly (inc. 2-6)12 3402-099 Guide, Valve43 3423-068 Circlip44 3423-043 Pin2 /P5 3423-006 Bolt46 3008-376 Bolt2 S7 3402-163 Gasket, Cylinder Head18 3423-088 Pin29 3423-015 Bolt2

10 3423-016 Bolt211 3423-089 Bolt, Cylinder Head Stud2 S12 3423-087 Bolt, Cylinder Head Stud2 S13 3004-492 Bolt, Stud1 /P14 3423-007 Bolt2 S15 3004-376 Bolt4 S/P16 3004-488 Nut4 S/P17 3004-326 Nut1 S/P18 3003-290 Gasket4 /P19 3402-010 Gasket, Head Nut420 0217-705 Spark Plug (NGK CR8E)1 /P21 3402-100 Cap, Inspection222 3402-101 O-Ring223 3004-341 Bolt4 S/P24 3402-035 Plug, Cylinder Head125 3402-149 Pipe, Intake - Assembly (inc. 26)126 3423-062 O-Ring1 S27 3423-019 Screw, Cap228 3402-086 Clamp1 /P29 3004-341 Bolt2 S/P30 3413-005 Thermostat1 S31 3530-005 Switch, Water Temp - Assembly132 3413-004 Cover, Thermostat1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 31 of 96DECALS



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 32 of 96DECALS

Ref # Part Number Qty DescriptionS/P/F1 0411-006 Decal, Warning - Front Rack Load12 0411-018 Decal, "Bearcat" - Front13 0411-011 Decal, Caution - Electrical14 0411-045 Decal, Warning - Turn15 0411-008 Decal, Warning Reverse/Pre Ride1 /P6 0411-040 Decal, Warning - Age17 0411-010 Decal, Warning - General18 0411-014 Decal, "Bearcat" - Side Right18 0411-015 Decal, "Bearcat" - Side Left19 0411-012 Decal, Warning - Tire Pressure1

10 0411-003 N/A111 0411-007 Decal, Warning - Rear Rack Load112 0411-043 Decal, "Arctic Cat"1 /P13 0411-013 Decal, Warning - Towing114 0411-009 Decal, Hi/Low Range115 0411-003 Decal, Shift Pattern1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 33 of 96ELECTRICAL COMPONENTS ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 34 of 96ELECTRICAL COMPONENTS ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3530-001 Relay, Starter Motor - Assembly1 /P2 3423-020 Bolt2 /P3 3530-003 CDI Unit14 3530-004 Coil, Ignition - Assembly1 /P5 3430-007 Cap, Spark Plug1 /P6 3430-008 Seal, Spark Plug1 /P7 3430-009 Seal, High Tension Cord1 /P8 3530-008 Relay, Neutral Start - Assembly1 S9 8408-616 Screw, Cap2



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 35 of 96ENGINE AND EXHAUST



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 36 of 96ENGINE AND EXHAUST

Ref # Part Number Qty DescriptionS/P/F1 0512-001 Pipe, Exhaust12 8408-820 Screw, Cap2 /P3 3423-003 Screw, Cap3 S4 0423-050 Washer, Motor35 0423-042 Spacer, Engine1 S6 0462-001 Engine1 S7 8428-002 Nut, Lock38 0412-007 Seal, Exhaust1 /P9 8474-813 Nut, Jam1

10 8408-860 Screw, Cap111 8408-020 Screw, Cap412 0506-083 Bracket, Upper Motor113 0502-016 Lever, Shift1 S14 8408-620 Screw, Cap115 0412-003 Spacer, Exhaust316 0412-004 Bushing, Rubber317 0412-005 Muffler1 S18 8408-830 Screw, Cap319 0406-224 Cover, Exhaust120 8477-610 Screw, Machine421 8050-252 Washer322 0214-015 Clamp123 8053-211 Washer, Star4 S24 8424-602 Nut2 /P25 8408-640 Screw, Cap226 0107-630 Spacer2



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 37 of 96FRAME AND RELATED PARTS



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 38 of 96FRAME AND RELATED PARTS

Ref # Part Number Qty DescriptionS/P/F1 0409-001 Headlight22 8424-802 Nut63 0409-005 Bulb, Headlight24 8053-242 Washer, Lock2 /P5 8408-850 Screw, Cap26 0406-175 Screen, Bumper17 0406-261 Yoke, Headlight28 0406-262 Mount, Headlight2 S9 8409-020 Screw, Cap8 /P

10 0506-075 Bumper - Front1 S11 0506-066 Footrest - Right112 0506-067 Footrest - Left113 0123-950 Screw, Machine214 8408-816 Screw, Cap1015 0506-133 Frame116 0423-010 Washer, Shoulder1017 8474-616 Screw, Machine1018 0406-095 Panel, Belly1 S19 0506-079 Tube, Cross120 0406-130 Cap, Bumper2



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 39 of 96FRONT BEVEL GEAR ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 40 of 96FRONT BEVEL GEAR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3435-009 Flange, Gear (inc. 2-5)1 S2 3435-029 Collar, Gear13 3435-030 Plate, Oil Seal14 3423-034 Plate, Gear15 3423-060 O-Ring, Collar16 3435-014 Gear, Bevel17 3435-021 Housing, Bevel Gear18 3435-022 Shim Set, Housing19 3423-026 Nut, Gear1 S

10 3423-028 Washer, Bevel Gear111 3402-016 Spacer, Bevel Gear112 3402-065 Bearing113 3402-066 Bearing1 /P14 3423-064 O-Ring115 3402-072 Seal, Joint116 3423-175 Bolt, Housing1 S17 3435-018 Gear1 /P18 3435-017 Shim Set119 3435-020 Shim Set120 3402-059 Bearing121 3402-072 Seal - Left122 3402-185 Bearing - Left123 3435-013 Differential - Assembly124 3402-057 Bearing, Differential Case - Right125 3402-072 Seal, Output Oil126 3435-024 Housing (inc. 27)127 3402-084 Union, Breather128 3435-025 Case, Bearing129 3423-010 Bolt, Mounting2 /P30 3402-012 Gasket, Oil Drain Plug131 3402-013 Gasket, Oil Filler Plug1 /P32 3402-036 Plug, Oil Drain1 S33 3402-041 Plug, Oil Filler1 S34 3423-183 Plug135 3423-050 O-Ring136 3423-050 O-Ring137 3423-175 Bolt8 S38 3423-070 Ring, Driveshaft - Front239 3435-007 Coupling, Propeller Shaft140 3423-182 Bolt6 S41 3004-491 Nut6 S/P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 41 of 96FRONT SUSPENSION ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 42 of 96FRONT SUSPENSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0603-033 Retainer, Spring2 S2 0403-001 Shock Absorber - Front (inc. 3-4)23 0604-310 Bushing, Shock Absorber84 0403-028 Sleeve, Shock45 8478-013 Nut, Lock126 8409-040 Screw, Cap47 0403-002 Spring, Front28 0403-025 Collar, Spring2 /P9 0403-013 Washer, Spring2

10 0503-016 A-Arm, Upper Right - Ass'y (inc. two No. 11-12)

1 S

10 0503-017 A-Arm, Upper Left - Ass'y (inc. two No. 11-12)

1 S

11 0405-001 Ball Joint - Front4 S12 0423-009 Clip, Retaining2 /P13 0505-016 Knuckle - Assembly - Right (inc. 14-18)1 S13 0505-017 Knuckle - Assembly - Left (inc. 14-18)1 S14 0505-010 Knuckle, Steering - Right1 S14 0505-011 Knuckle, Steering - Left1 S15 0402-085 Bearing, Wheel Hub - Front2 S16 0423-034 Clip, Bearing217 0402-089 Seal, Wheel Bearing - Front218 0402-069 Seal, Wheel Bearing - Front219 8409-030 Screw, Cap420 8409-060 Screw, Cap821 0503-013 A-Arm, 4x4 Lower Left (inc. two No. 11-12)1 S21 0503-012 A-Arm, 4x4 Lower Right (inc. two No. 11-12)1 S22 0402-098 Axle, Drive - Front2 S23 0436-038 Repair Kit, Outer Boot - Front Axle224 0436-037 Repair Kit, Inner Boot - Front Axle225 0403-027 Retainer, Spring - Lower2



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 43 of 96FUEL TANK ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 44 of 96FUEL TANK ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0570-003 Tank, Fuel (inc. 2 and 6-9)1 S2 0470-315 Cap, Fuel Tank (inc. 3)1 S3 0470-316 Line, Fuel Cap Vent14 8408-650 Screw, Cap25 0623-184 Washer26 0406-169 Bushing, Fuel Tank Mount47 0406-170 Collar, Fuel Tank Mount28 0610-007 Line, Fuel1 /P9 0423-048 Clamp, Hose - Spring2

10 0 Gasket, Fuel1 F11 0470-314 Valve, Shut-Off (inc. 10)1 S12 8471-616 Screw, Cap213 0417-001 Pad, Fuel Tank4



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 45 of 96GEAR SHIFTING ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 46 of 96GEAR SHIFTING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-038 Fork, (No. 2)22 3446-039 Fork, (No. 3)13 3446-040 Fork, Reverse14 3446-052 Shaft, Gear Shift Fork25 3446-041 Cam, Gear Shift (inc. 6)16 3423-114 Pin, Gear Shift1 /P7 3446-042 Cam, Reverse Shift18 3446-049 Plate, Gear Shift Cam19 3446-050 Guide, Gear Shift Cam Plate1 S

10 3402-014 Spacer, Reverse Shift Cam111 3402-051 Bearing, Gear Shift Cam112 3004-376 Bolt, Gear Shift Cam Plate1 S/P13 3004-552 Screw, Cam Bearing Retainer2 S14 3423-135 Retainer, Bearing215 3446-043 Stopper, Gear Shift Cam116 3446-044 Stopper, Reverse Shift Cam117 3446-046 Housing, Reverse Cam Stopper118 3446-047 Spring, Shift Cam Stopper Arm119 3446-048 Support, Shift Cam Stopper120 3402-012 Gasket, Cam Stopper Housing121 3402-088 Spring, Reverse Cam Stopper122 3423-141 Washer, Gear Shift Cam123 3423-142 Washer, Cam Stopper Arm124 3004-488 Nut, Cam Stopper Arm Support1 S/P25 3446-053 Shaft, Gear Shift1 S26 3446-054 Spacer, Gear Shift Shaft127 3446-056 Stopper, Gear Shift Arm128 3402-068 Seal, Gear Shift Shaft Oil1 /P29 3402-076 Seal, Reverse Shift Oil130 3402-094 Spring, Gear Shift Return131 3446-055 Arm, Reverse Gear Shift132 3004-366 Washer, Gear Shift Cable Arm1 S33 3423-168 E Ring, Gear Shift Cable Arm1 S34 3423-166 Screw, Cap2 S35 3530-007 Base Assembly1 S36 3423-044 Contact, Neutral137 3423-059 O-Ring, Neutral138 3004-787 Clamp139 3004-761 Clamp140 3402-087 Spring141 3402-008 Hub, Gear Shift1 /P42 3402-093 Spring, Gear Shift143 0706-990 Tape, FoilAR /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 47 of 96HI/LO SHIFTER ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 48 of 96HI/LO SHIFTER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-045 Stopper, Driven Grear1 S2 3446-046 Housing, Shift Stop13 3446-051 Shaft, Fork14 3446-073 Fork, Shift15 3446-074 Cam, Shift16 3446-075 Spring27 3446-076 Shaft, Shift18 3446-077 Plate, Lever Stop19 3423-193 Circlip, Shaft - Left1 S/P

10 3446-078 Knob111 3402-012 Gasket, Cam Stop112 3402-071 Seal, Oil1 /P13 3402-089 Spring114 3004-377 Bolt, Stopper Plate2 S/P15 3423-156 Screw, Shift Knob1 S16 3423-157 Washer, Cam Stop117 3423-158 Washer, Shaft - Left1 /P18 3423-191 Circlip, Cam Spring1 /P19 3423-192 Circlip, Shift Lever2 /P20 3446-079 Lever, Shift - Assembly (inc. 21-26)1 S21 3446-106 Collar122 3423-152 Washer1 /P23 3423-153 E-Clip124 3446-107 Spring125 3423-154 Circlip126 3423-155 Washer127 3402-191 Spacer1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 49 of 96HYDRAULIC BRAKE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 50 of 96HYDRAULIC BRAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0402-053 Tube, Brake Line - Front12 0402-051 Hose, Brake - Front1 S3 0402-073 Block, Mounting24 0423-038 Bolt, Oil3 S5 0423-039 Washer, Crush66 0402-010 Caliper, Brake - Right (inc. 7-12)2 /P6 0402-011 Caliper, Brake - Front Left (inc. 7-12)1 /P7 0 Housing - Right2 F7 0 Housing - Left1 F8 0 Housing, Anvil3 F9 0117-868 Pin, Cotter3

10 0402-142 Pin, Hydraulic Brake Caliper311 0402-141 O-Ring, Hydraulic Brake Caliper612 0402-096 Pad, Hydraulic Brake6 S13 0402-054 Tube, Brake Line - Rear114 8408-625 Screw, Cap115 8408-820 Screw, Cap4 /P16 8408-825 Screw, Cap217 0402-052 Hose, Brake - Rear118 0402-115 Clip, Brake Line1 S19 0402-143 Cap, Bleeder Valve2 F20 8408-625 Screw, Cap121 8408-825 Screw, Cap222 8408-820 Screw, Cap4 /P23 0402-143 Cap, Bleeder Valve2 F



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 51 of 96HYDRAULIC BRAKE CONTROL ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 52 of 96HYDRAULIC BRAKE CONTROL ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0502-021 Brake, Lever - Assembly (inc. 2-14)1 S2 0402-049 Lever, Brake13 0623-430 Bolt, Lever Mounting1 /P4 0623-506 Screw, Cover - Master Cylinder25 0602-742 Cover, Master Cylinder16 0602-741 Gasket, Cover - Master Cylinder17 0602-740 Reservoir, Hydraulic Brake18 0602-587 O-Ring, Reservoir19 0 Master Cylinder1 F

10 0623-432 Screw, Reservoir Mount211 0623-056 Nut, Lock112 8052-212 Washer, Lock213 0623-629 Screw, Clamp2 S14 0602-907 Clamp115 0402-050 Hose, Master Cylinder1 S16 8408-625 Screw, Cap1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 53 of 96MAGNETO ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 54 of 96MAGNETO ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3430-011 Stator - Assembly1 /P2 3430-012 Rotor13 3423-162 Bolt, Magneto3 S4 0691-785 Key, Magneto15 3423-086 Nut, Magneto16 3423-005 Bolt2 /P7 3430-005 Clamp, Magneto (No. 1)18 3430-006 Clamp, Magneto (No. 2)19 3423-005 Bolt1 /P

10 3004-761 Clamp, Magneto (No. 3)1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 55 of 96MECHANICAL BRAKE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 56 of 96MECHANICAL BRAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0402-128 Caliper, Mechanical Brake - Ass'y (inc. 2-3)1 S2 0502-020 Pad Set1 /P3 0402-125 Pin, Actuator14 0402-116 Bracket, Spring Retaining15 0423-058 Screw, Socket Head26 0402-129 Spring, Mechanical Brake17 0124-057 E-Ring1 /P8 0487-004 Cable, Brake - Rear19 0423-049 Pin1

10 0117-868 Pin, Cotter111 0115-602 Spring, Brake Arm Return112 0423-064 Cap, Protector - Red113 0502-027 Brake, Parking1 S14 8408-616 Screw, Cap215 0670-183 O-Ring216 0502-024 Lever, Foot Brake1 S17 0423-027 Washer, Brake Lever118 0623-237 Ring, Snap1 /P19 0402-144 Spring, Foot Brake1 S



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 57 of 96OIL FILTER/PUMP ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 58 of 96OIL FILTER/PUMP ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-153 Pump, Engine Oil12 3402-152 Gear, Driven13 3423-046 Pin14 3423-115 Washer15 3423-184 Circlip1 S6 3423-113 Screw, Cap3 S/P7 3402-156 Strainer, Engine Oil18 3423-118 Screw, Cap29 3402-157 Cap, Oil Strainer1

10 3423-077 O-Ring111 3004-756 Bolt4 S12 3402-155 Filter, Engine Oil1 S13 3402-036 Plug, Drain1 S14 3402-012 Gasket115 3402-154 Valve, Oil Relief - Assembly116 3402-158 Union, Oil Filter1 S



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 59 of 96REAR AXLE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 60 of 96REAR AXLE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0502-018 Housing, Axle - Rear Right12 8409-030 Screw, Cap23 8409-025 Screw, Cap14 0402-145 Axle - Rear2 S5 0402-139 Gasket - Rear Axle16 3008-100 Bladder, Case17 0123-811 Tie, Cable18 8408-616 Screw, Cap29 0506-135 Hitch, Trailer1

10 8408-840 Screw, Cap211 0402-138 Gasket - Rear Axle112 0423-010 Washer, Shoulder113 0502-005 Housing, Axle - Rear Left1 S14 0402-068 Seal215 0423-033 C-Clip216 0402-003 Bearing, Wheel Hub - Rear217 8474-813 Nut, Jam218 0423-031 Nut, Speed219 0406-097 Panel, Gear Case - Rear120 8408-820 Screw, Cap1 /P21 8050-252 Washer1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 61 of 96REAR BEVEL GEAR ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 62 of 96REAR BEVEL GEAR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3435-051 Boot, Final Drive12 3435-006 Shaft, Rear Final1 S3 3435-008 Coupling, Rear1 S4 3435-012 Gear Set1 S5 3435-015 Stopper, Rear Final16 3435-016 Pin, Bearing Stopper17 3435-019 Shim Set1 /P8 3435-020 Shim Set19 3435-065 Shim Set1 /P

10 3435-023 Case111 3435-026 Case - Right1 S12 3435-027 Case - Left113 3435-028 Housing114 3423-025 Nut, Rear Drive Pinion115 3423-029 Washer, Drive Nut116 3423-171 Washer - Left117 3003-290 Gasket, Bearing Stopper Pin1 /P18 3402-012 Gasket, Oil Drain Plug119 3402-036 Plug, Oil Drain1 S20 3402-039 Plug, Gear Oil Filler121 3402-052 Bearing122 3402-056 Bearing1 S23 3402-059 Bearing - Right124 3402-061 Bearing, Final Drive Pilot125 3423-049 O-Ring, Bearing Case - Right1 S26 3423-057 O-Ring, Gear Oil Filler1 /P27 3423-065 O-Ring, Final Bearing Stopper128 3003-335 O-Ring, Bearing Case - Left1 /P29 3435-048 Seal, Final Driven1 S30 3402-073 Seal, Oil1 /P31 3402-074 Seal, Oil132 3402-075 Seal, Oil133 3004-786 Clamp - Right1 /P34 3402-092 Spring135 3004-279 Stud, Bolt4 S/P36 3004-301 Stud, Bolt - Left2 S37 3423-175 Bolt, Bearing - Right9 S38 3402-187 Bearing - Left1 /P39 3004-333 Nut, Rear Left Case2 S40 3423-176 Nut, Rear Final Housing4 S41 3423-194 Circlip Set1 S



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 63 of 96REAR SUSPENSION ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 64 of 96REAR SUSPENSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 8409-060 Screw, Cap32 8409-000 Screw, Cap23 0504-001 Arm, Swing34 8478-013 Nut, Hex95 8409-055 Screw, Cap16 0504-005 Arm, Swing17 0403-027 Retainer, Spring - Lower28 0404-001 Shock Absorber - Rear (inc. 9-10)29 0403-028 Sleeve, Shock4

10 0604-310 Bushing, Shock Absorber811 0603-033 Retainer, Spring2 S12 8409-040 Screw, Cap413 0404-006 Spring - Rear2 /P14 0403-025 Collar, Spring2 /P15 0403-013 Washer, Spring Adjustment2



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 65 of 96RECOIL STARTER ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 66 of 96RECOIL STARTER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3445-003 Starter, Recoil - Assembly (inc. 2-12)12 3445-004 Reel13 3445-005 Ratchet14 3445-014 Pin, Ratchet15 3445-007 Spring, Spiral16 3445-009 Spring, Friction17 3445-010 Shaft18 3445-012 Cover, Spring19 3445-008 Plate, Friction1

10 3445-006 Guide, Ratchet111 3004-488 Nut1 S/P12 3445-011 Rope - Assembly113 3445-013 Gasket1 /P14 3423-112 Bolt6 S15 3445-015 Cup, Starter116 3004-491 Nut1 S/P17 3423-053 O-Ring1 /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 67 of 96REVERSE SHIFT LEVER ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 68 of 96REVERSE SHIFT LEVER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 8402-830 Screw, Cap12 8050-252 Washer13 0402-103 Axle, Reverse Shifter14 0502-022 Lever, Reverse1 S5 0423-032 O-Ring26 0423-063 E-Ring27 0402-136 Spring, Reverse Lever1 S8 0409-008 Reverse Switch19 0402-130 Retainer, Switch1 S

10 0402-062 Knob, Reverse Shift Lever111 3423-168 E-Ring1 S12 0487-003 Cable, Shift113 3446-005 Arm, Reverse Gear Shift114 8408-616 Screw, Cap1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 69 of 96SEAT ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 70 of 96SEAT ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 5990-012 Seat - Assembly (inc. 2-11)1 S2 0506-054 Cover, Seat13 0506-056 Foam, Seat14 0506-167 Base, Seat - Assembly (inc. 5-10)15 0506-166 Base, Seat1 S6 8061-628 Rivet47 0506-147 Pin, Seat Base - Front1 S8 8060-630 Rivet49 0406-268 Plate, Seat Retainer2

10 8050-152 Washer411 0624-263 Staple5012 8050-217 Washer2 /P13 0406-199 Collar, Front Seat Base214 0406-171 Bumper, Seat Base - Front215 0623-404 Cap, Protector116 0406-103 Latch, Seat - Assembly1 S17 8477-616 Screw, Machine218 0406-172 Bumper, Seat Base - Center219 0406-270 Bumper, Seat Base - Center220 8408-620 Screw, Cap2



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 71 of 96SECONDARY DRIVE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 72 of 96SECONDARY DRIVE ASSEMBLY

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

10 3423-026 Nut1 S11 3423-028 Washer212 3435-003 Flange, Output Joint1 S13 3402-072 Seal, Oil214 3402-067 Bearing w/ Locating Ring and Pin2 S15 3402-017 Shim - 0.60 mm115 3402-018 Shim - 0.65 mm115 3402-019 Shim - 0.70 mm115 3402-020 Shim - 0.75 mm115 3402-021 Shim - 0.80 mm1 S15 3402-022 Shim - 0.85 mm115 3402-023 Shim - 0.90 mm115 3402-024 Shim - 0.95 mm115 3402-025 Shim - 1.00 mm1 S15 3402-028 Shim - 1.05 mm115 3402-029 Shim - 1.10 mm115 3402-030 Shim - 1.15 mm115 3402-031 Shim - 1.20 mm116 3446-037 Shaft - Rear117 3446-034 Gear1 S18 3402-062 Bearing w/Groove1 S19 3423-072 Ring, Bearing120 3423-137 Washer121 3423-136 Nut122 3446-036 Shaft - Front123 3435-001 Yoke, Drive Output (inc. 24-27)1 S24 3435-029 Collar, Yoke125 3423-060 O-Ring126 3435-030 Plate, Yoke Collar127 3423-035 Plate, Yoke Collar128 3423-026 Nut1 S29 3435-011 Joint Set, Universal (inc. 30)130 3423-067 Circlip431 3435-002 Yoke, Joint132 3435-005 Boot, Propeller Shaft1 /P33 3435-004 Shaft, Propeller134 3004-552 Screw, Cap1 S35 3423-135 Retainer2



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 73 of 96SECONDARY TRANSMISSION ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 74 of 96SECONDARY TRANSMISSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-065 Shaft, Output12 3446-066 Gear, Idle13 3446-072 Gear, Driven14 3423-150 Washer3 /P5 3446-069 Spacer1 S6 3446-070 Gear, (No. 2)17 3446-108 Dog, Select Sliding18 3423-036 Washer, (No. 1)19 3446-103 Bushing1

10 3402-046 Bearing, Driveshaft - Left111 3402-047 Bearing, Center Shaft - Left1 S12 3423-066 Circlip, (No. 1)1 /P13 3423-202 Washer, Gear (No. 2)1 S14 3446-068 Spacer115 3423-148 Spacer, Idle Gear116 3446-067 Gear, (No. 1)117 3446-069 Spacer, Drive1 S18 3402-045 Bearing Set - Left1 /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 75 of 96SPEEDOMETER DRIVE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 76 of 96SPEEDOMETER DRIVE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-031 Retainer, Bearing2 /P2 3402-009 Washer, Driven1 /P3 3004-552 Screw, Retainer2 S4 3402-077 Seal, Driven Gear15 3446-033 Gear1 S6 3446-035 Shim Set17 3423-023 Nut18 3423-032 Washer19 3423-146 Washer - Right1

10 3446-062 Spacer, Driven Gear1 S11 3423-143 Bolt, Gear1 S12 3423-145 Washer113 3423-056 O-Ring114 3423-144 Washer115 3004-507 Bolt, Gear2 S16 3402-055 Bearing Set - Right1 /P17 3446-057 Housing, Odometer Gear (inc. 18-21)118 3446-058 Sleeve119 3446-059 Gasket1 S20 3446-060 Gear, Drive121 3446-061 Gear, Driven1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 77 of 96STARTER CLUTCH ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 78 of 96STARTER CLUTCH ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-123 Limiter, Idle Gear - Assembly12 3402-125 Bushing23 3423-103 Washer2 /P4 3402-124 Gear, Starter Idle15 3423-042 Pin16 3402-122 Clutch, Starter - Set (inc. 7)1 S7 3402-063 Bearing18 3423-104 Washer19 3423-102 Bolt6 S



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 79 of 96STARTER MOTOR ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 80 of 96STARTER MOTOR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3545-001 Motor, Starter Assembly (inc. 2-9)1 S2 3008-094 Terminal Set, Brush1 /P3 3008-095 Holder Set, Brush1 /P4 3008-096 Spring, Brush45 3008-164 O-Ring16 3423-084 O-Ring17 3436-001 Washer Set18 3008-101 O-Ring2 S9 3423-085 Bolt2

10 3423-162 Bolt2 S11 3423-195 Nut1 /P12 3423-201 Circlip1 /P13 3402-043 Bearing, Pinion Shaft1 /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 81 of 96STEERING ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 82 of 96STEERING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0487-005 Cable, Speedometer12 8477-616 Screw, Machine33 0420-003 Speedometer1 S4 0423-052 Collar, Body35 3430-013 Switch, Ignition - Assembly (inc. 6)1 S6 3409-007 Key, Ignition - Blank1 /P7 0420-011 Bezel/Lens, Warning - Assembly18 0420-012 Bezel/Lens, Shifting - Assembly19 0405-019 Instrument Pod1

10 0420-013 Bulb, Light Bar911 0420-001 Light, Warning - Assembly112 0420-004 Light, Shift Indicator - Assembly113 0123-950 Screw, Self-Tapping414 8408-860 Screw, Cap615 0405-035 Cap, Steering Adjuster416 0506-139 Bracket, Key Switch1 S17 0505-007 Tube, Handlebar1 S18 0405-013 Grip, Handlebar2 S19 0705-064 Housing, Bearing - Upper1 /P20 0405-020 Bearing, Steering Post221 0605-171 Cap, Bearing - Steering122 0117-868 Pin, Cotter423 0505-012 Post, Steering124 8408-816 Screw, Cap225 0602-233 Flange, Bearing126 0107-223 Bearing - w/o Lock Collar1 S27 0123-570 Washer128 8409-020 Screw, Cap1 /P29 0423-014 Nut, Hex430 0505-001 Tie Rod, Assembly (inc. 31-35)1 /P31 8480-010 Nut, Hex2 S32 0405-011 Ball Joint, Tie Rod - Left2 S33 0405-010 Ball Joint, Tie Rod - Right2 S34 0423-013 Nut235 0405-032 Tie Rod236 0620-149 Bulb, Speedometer1 /P37 0420-014 Harness, Speedometer138 0420-018 Bracket, Speedometer139 0420-016 Mount, Rubber240 0420-017 Washer241 0420-015 Pin, Retainer2



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 83 of 96STORAGE BOX AND BATTERY ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 84 of 96STORAGE BOX AND BATTERY ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 8408-616 Screw, Cap12 0406-242 Strap, Battery13 0406-252 Pad, Battery - Upper24 0445-005 Battery - Assembly (inc. 5-7)1 S5 0645-045 Cap, Battery66 0645-152 Clamp, Hose17 0645-179 Hose, Battery Vent1 S8 0123-788 Tie, Cable0 /P9 0406-227 Pad, Battery - Lower1

10 0444-001 Kit, Tool1 S11 0423-052 Collar, Body112 0530-001 Fuse Box - Assembly (inc. 13-16)113 0430-005 Block, Fuse114 0430-006 Lid, Fuse Block115 0411-042 Decal, Fuse Block116 0630-057 Fuse, 10 AMP316 0630-058 Fuse, 15 AMP217 0623-121 Screw, Machine618 0506-102 Storage Box-Ass'y (inc. 19-23, (4) 24 &

25-27)1 /P

19 0406-257 Box, Tool1 S20 8050-152 Washer621 0406-208 Lid, Tool Box122 0773-401 Chain, Storage123 0623-620 Rivet224 0123-010 Nut, Expansion6 /P25 0673-973 Seal, Storage Cover126 0406-205 Ring, Mounting - Storage Box Lid1 /P27 8060-630 Rivet628 0219-376 Tape, Foil0 /P29 0423-044 Clamp, Tube4



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 85 of 96TAILLIGHT ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 86 of 96TAILLIGHT ASSEMBLY

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

1 0109-460 Bulb, Stop Taillight1 /P2 0409-011 Taillight w/Socket Assembly13 0409-012 Gasket, Taillight14 0409-007 Lens, Taillight15 0409-010 Screw, Taillight26 0623-302 Screw, Self-Tapping27 8053-212 Washer, Lock2 /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 87 of 96THROTTLE CASE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 88 of 96THROTTLE CASE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3509-002 Case, Throttle - Assembly (inc. 2-9)1 S2 3409-001 Lever13 3004-533 Bolt1 S/P4 3004-447 Washer, Lock1 /P5 3003-030 Washer1 /P6 3423-014 Screw, Cap17 3423-198 Nut18 3423-199 Screw, Cap29 3004-638 Screw, Cap1 /P



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 89 of 96TRANSMISSION ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 90 of 96TRANSMISSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3446-014 Shaft, Counter12 3446-016 Gear, 2nd Drive13 3446-017 Gear, 3rd Drive14 3446-018 Gear, 4th Drive15 3446-019 Gear, 5th Drive16 3446-020 Bushing, 5th Drive Gear17 3423-037 Washer, 5th Drive Gear18 3402-049 Bearing, Center Shaft - Right1 /P9 3402-081 Bushing, 4th Drive Gear1

10 3423-066 Circlip, 4th Drive1 /P11 3423-066 Circlip, 5th Drive1 /P12 3402-179 Bearing, Center Shaft113 3423-126 Washer, 2nd Drive1 /P14 3423-187 Washer, 4th Drive1 /P15 3423-187 Washer, 4th Drive1 /P16 3446-015 Shaft, Drive117 3446-021 Gear, 1st Driven1 S18 3446-022 Gear, 2nd Driven119 3446-023 Gear, 3rd Driven120 3446-024 Bushing, 3rd Driven121 3446-025 Gear, 4th Driven1 S22 3446-026 Gear, 5th Driven123 3446-029 Gear, Reverse Driven124 3446-030 Dog, Reverse125 3446-032 Bushing, Reverse Driven126 3423-038 Washer, 3rd Driven - Right127 3423-039 Washer, 3rd Driven - Left128 3423-040 Washer, 3rd Driven - Left129 3402-053 Bearing, Driveshaft130 3402-080 Bushing, 1st Driven1 S31 3402-082 Bushing, 2nd Driven132 3423-188 Circlip, 2nd Driven1 S33 3423-188 Circlip, 3rd Driven1 S34 3003-320 Bearing, Driveshaft - Right1 /P35 3423-129 Washer, Reverse Driven136 3423-130 Washer, 1st Driven - Left137 3423-131 Washer, 1st Driven - Right138 3003-605 Washer, 2nd Driven1 /P39 3423-189 Circlip, Reverse Driven1 S40 3446-027 Shaft, Reverse Idle141 3446-028 Gear, Reverse Idle142 3402-079 Bushing, Reverse Idle143 3423-126 Washer, Reverse Idle2 /P44 3423-190 Circlip, Reverse Idle1 S



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 91 of 96WATER PUMP ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 92 of 96WATER PUMP ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 3402-159 Case, Water Pump1 S2 3423-185 Bolt13 3003-188 Gasket1 S/P4 3423-078 O-Ring15 3004-507 Bolt2 S6 3423-119 Bolt1 S7 3413-003 Joint, Pump Drive1 S8 3413-002 Shaft, Water Pump w/Bearing19 3423-046 Pin1

10 3003-356 Seal, Pump Drive111 3003-466 Seal, Mechanical1 S12 3413-001 Impeller113 3003-426 Bolt114 3003-431 Washer1 /P15 3003-432 Gasket1



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 93 of 96WHEEL AND TIRE ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 94 of 96WHEEL AND TIRE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0402-007 Tire, Front22 0402-140 Cap, Valve Stem43 0402-064 Valve, Stem44 0402-005 Wheel - Front2 S5 0423-015 Nut, Hex46 0123-458 Pin, Cotter4 /P7 0423-021 Washer48 0402-099 Seal, Hub49 0402-088 Hub, Wheel - Front2 S

10 0402-009 Disc, Brake3 S11 0423-029 Screw, Machine1212 0402-080 Hub, Wheel - Rear2 S13 0402-006 Wheel - Rear214 0402-008 Tire - Rear215 0403-011 Cap, Wheel - Center4 S16 8409-020 Screw, Cap16 /P17 0402-074 Wheel and Tire Assy - RH (inc. 1, 4, and 16)1 F17 0402-075 Wheel and Tire Assy - LH (inc. 1, 4, and 16)1 F18 0402-076 Wheel and Tire Assy - RH (inc. 2, 3, 13, and

14)1 F

18 0402-077 Wheel and Tire Assy - LH (inc. 2, 3, 13, and 14)

1 F



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 95 of 96WIRING HARNESS ASSEMBLY



1996 BEARCAT 4X4 (96A4A-AP-1996) Page 96 of 96WIRING HARNESS ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0486-001 Harness, Main1 /P2 0445-003 Cable, Battery/Electric Start Relay1 /P3 0445-002 Cable, Battery/Ground14 0123-788 Tie, Cable0 /P5 0409-009 Switch, Brake - Assembly16 0530-002 Regulator, Voltage17 8408-630 Screw, Cap28 0402-130 Retainer, Switch1 S9 0445-004 Cable, Battery/Electric Start1

10 0445-001 Receptacle, 12V411 8060-430 Rivet2 /P12 0123-149 Washer2 /P13 0486-004 Harness, 12V Receptacle1



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