RANGER 2X4 SERIES 11 RANGER 4X4 SERIES 11 RANGER …pi54.com/corp/manuals/Parts/9918179r02.pdf ·...

RANGER 2X4 SERIES 11Model #A11RB42AA

RANGER 4X4 SERIES 11Model #A11RD50AAModel #A11RD50AB

RANGER 6X6 SERIES 11Model #A11RF50AA

E 2003 Polaris Sales Inc.

PARTS MANUAL PN 9918179 and MICROFICHE PN 9918180 7/03

Rev. 02

TABLE OF CONTENTSRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11

A11RD50AB and RANGER 6X6 SERIES 11 A11RF50AA

Parts Manual

AA--ARM B13. . . . . . . . . . . . . . . . . . . . . . . . . . . .AIR BOX C11. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBATTERY B3. . . . . . . . . . . . . . . . . . . . . . . . . . .BODY A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .BRAKE CALIPER, FRONT C3. . . . . . . . . . . . . .BRAKE CALIPERS, REAR C5. . . . . . . . . . . . . .BRAKE LINES C2. . . . . . . . . . . . . . . . . . . . . . .BRAKE, FOOT C1. . . . . . . . . . . . . . . . . . . . . .BRUSH/HEADLIGHT GUARD E11. . . . . . . . . . . .

CCAB FRAME A3. . . . . . . . . . . . . . . . . . . . . . . .CARBURETOR D13-14. . . . . . . . . . . . . . . . . . . . . . .CHASSIS A4. . . . . . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C13. . . . . . . . . . . . . . . . . . . . .CONTROLS A6. . . . . . . . . . . . . . . . . . . . . . . . .COOLING SYSTEM A10. . . . . . . . . . . . . . . . . . .CRANKCASE E1. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT E2. . . . . . . . . . . . . . . . . . . . . . .CYLINDER D11-12. . . . . . . . . . . . . . . . . . . . . . . . . .

DDASH INSTRUMENTS A6. . . . . . . . . . . . . . . . .DECALS A9. . . . . . . . . . . . . . . . . . . . . . . . . . .DIFFERENTIAL LOCK D10. . . . . . . . . . . . . . . . .DRIVE CLUTCH C9. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT, FRONT B4. . . . . . . . . . . . . . . . .DRIVEN CLUTCH C10. . . . . . . . . . . . . . . . . . . . .DUMP BOX A8. . . . . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL B3. . . . . . . . . . . . . . . . . . . . . . . .ENGINE AND CLUTCH AIR INTAKE C12. . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . . .EXHAUST E3. . . . . . . . . . . . . . . . . . . . . . . . . .EXHAUST SYSTEM B1. . . . . . . . . . . . . . . . . . .

FFLYWHEEL COVER E4. . . . . . . . . . . . . . . . . . .FRONT HOUSING D2. . . . . . . . . . . . . . . . . . . .FUEL SYSTEM A11. . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR/DIFFERENTIAL LOCK D10. . .GEARCASE (2X4) D3-4. . . . . . . . . . . . . . . . . . . .GEARCASE (4X4) D5-6. . . . . . . . . . . . . . . . . . . .

GGEARCASE (6X6) D7-8. . . . . . . . . . . . . . . . . . . .GEARCASE, MID D9. . . . . . . . . . . . . . . . . . . . .

HHOOD A7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IINTAKE E3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MMAGNETO E8. . . . . . . . . . . . . . . . . . . . . . . . . .MASTER CYLINDER C2. . . . . . . . . . . . . . . . . .MID DRIVE A--ARMS B10. . . . . . . . . . . . . . . . . .MID DRIVESHAFT B9. . . . . . . . . . . . . . . . . . . .MID HOUSING B8. . . . . . . . . . . . . . . . . . . . . . .MOLDINGS A5. . . . . . . . . . . . . . . . . . . . . . . . .

OOIL FILTER E7. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP E6. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . . . .

PPARK BRAKE LOCK C4. . . . . . . . . . . . . . . . . . .PISTON E2. . . . . . . . . . . . . . . . . . . . . . . . . . . .PROP SHAFT, FRONT B6. . . . . . . . . . . . . . . . .PROP SHAFT, REAR B5. . . . . . . . . . . . . . . . . .

RREAR GEARCASE (2X4, 4X4) C14. . . . . . . . . . . .REAR GEARCASE (6X6) D1. . . . . . . . . . . . . . .REAR WHEEL DRIVE C6. . . . . . . . . . . . . . . . . .

SSHOCK, REAR C8. . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR E9. . . . . . . . . . . . . . . . . . .STEERING B12. . . . . . . . . . . . . . . . . . . . . . . . . .STRUT MOUNTING B13. . . . . . . . . . . . . . . . . . .STRUT, FRONT B7. . . . . . . . . . . . . . . . . . . . . .SWING ARM C7. . . . . . . . . . . . . . . . . . . . . . . .

TTHROTTLE B14. . . . . . . . . . . . . . . . . . . . . . . . .TOOL KIT E10. . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION MOUNTING B2. . . . . . . . . . . .

WWATER PUMP E5. . . . . . . . . . . . . . . . . . . . . . .WHEEL, FRONT B11. . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3

CAB FRAMERANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB

and RANGER 6X6 SERIES 11 A11RF50AA

34

5

67

2

8

1013

14

25

24

22

26

27

12

23

15

212019

1718 28

16


36

5

25 2622

9

9

11

9

1

9

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 1014047-0671014047-418

11

Frame, Cab, Right, Front (AA)Frame, Cab, Right, Front (AB)

2 5434879-3175434879-070

22

Headrest (AA)Headrest (AB)

3 5243093-067 2 Tube,Coupler, Top, Rear4 1013717

1013335-418

1

1

Frame, Cab, Right, Rear(Incl. Warning Decals)(AA)Frame, Cab, Right, Rear (AB)

5 7517230 12 Screw6 5243092-067 2 Tube, Coupler, Center, Rear7 7661637 40 Rivet8 1013716

1013334--418

1

1

Frame, Cab, Left, Rear(Incl. Warning Decals)(AA)Frame, Cab, Left, Rear (AB)

9 7542324 12 Nut, Nylok10 7515339 2 Screw11 7515319 2 Screw12 1014046-067

1014046-41811

Frame, Cab, Left, Front (AA)Frame, Cab, Left, Front (AB)

13 7670096 8 Nut, Chimney

14 2683124-3172683124-455

11

Seat, Back (AA)Seat, Back (AB)

15 5244844-0675244844-418

11

Tube, Frame, Top, Front (AA)Tube, Frame, Top, Front (AB)

16 5812295 4 Foil17 7555734 2 Washer, Flat18 5910096 2 Pin, Seat Latch19 7621479 4 Rivet20 5245676 2 Tab, Seat Mount21 2682638-317

2682638-45511

Seat, Bottom (Incl. 9,16-20)(AA)Seat, Bottom (Incl. 9,16-20)(AB)

22 7512539 4 Screw23 7515321 6 Screw24 2632422 1 Asm., Seat Belt, Center25 2632421 2 Asm., Seat Belt26 7542525 4 Nut, Nylok27 1013336-067 1 Base, Cab/Seat28 5411042 2 Grommet

5/03

A4

CHASSIS/BODYRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


41

25

6

9

10

7 8

11

15

16

18

202526

23

24

3

13

14

31

19

5

5

52

1

5

18

13

3

24 22 21

17

27

27

29

12

1314

14

14

28

30


(See Brush/Headlight Guard Pg. E11for A11RD50AB Bumper and Guard)



1 7515522 4 Screw2 7542449 4 Nut3 7517583 2 Screw4 1013374-067 1 Support, Floor, RH5 7515399 18 Screw6 ------ -- -- -- -- 1 Base, Cab/Seat

(See Cab Frame Pg. A3, Ref. 27)7 7670090 20 Clip, Dart8 5434028 2 Panel, Seat Frame9 7542451 8 Nut, Nylok10 5245209 4 U-Bolt11 1013931-067

1014048-06711

Frame, Main (2x4, 4x4)Frame, Main (6x6)

12 1013747-067 1 Extension, Frame (6x6)13 7515415 14 Screw (Qty 14 for 6x6, Qty 4 for 2x4, 4x4)14 7542439 16 Nut, Nylok15 5246110-067 1 Bracket, Oil Tank

16 1013373-067 1 Support, Floor, LH17 7547182 3 Nut, Insert18 5434191 2 Cap, Bumper19 7079924 2 Decal, Reflector, Amber20 1014004-067 1 Bumper (AA)21 7621334 4 Rivet22 5430733 2 Cup, Hood Latch23 7515547 3 Screw24 7517685 6 Screw25 5245329-067 1 Plate, Grill, Bumper, Upper (AA)26 5245626-067 1 Plate, Grill, Bumper, Top (AA)27 7555801 4 Washer, Wrought28 5810317 1 Pad29 7512399 2 Screw30 8360012-06 1 Trim, Edge31 1013930-067 1 Support, Cab, Front

5/03

A5

MOLDINGSRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


23

9

86

4

10

1

12

2

13

22

15 14

18 161719

21

1

1

1

10

1

114

15

11

101

1

57

3

19

20




1 7517685 49 Screw2 5433827-070 1 Fender, Rear, RH3 7670145 11 Nut, U-Type4 5434004 1 Floor, Drive Shaft, Cover5 5812222 1 Foil6 5812243 1 Foil, Floor7 5812296 1 Foil8 5812242 1 Foil, Heat Shield9 2632478 1 Cover, Dog House (Incl. 7,8)10 7670057 8 Nut, U-Type Speed11 7670090 8 Clip, Dart12 5433826-070 1 Fender, Rear, LH13 5434747

5434747-070

5435106-070

5435177-070

11

1

1

Fender, Front, LH (If built before 12/01/02)Fender, Front, LH(If built 12/01/02 to 1/01/03)Fender, Front, LH(If built 1/01/03 to 5/01/03)Fender, Front, LH (If built after 5/01/03)

14 7555935 6 Washer15 7542122 6 Nut, Nylok16 7517386 12 Screw

(Qty 12 for 2x4, 4x4, Qty 15 for 6x6)17 7556065 12 Washer

(Qty 12 for 2x4, 4x4, Qty 15 for 6x6)18 5812176

581233311

Plate, Skid (2x4, 4x4)Plate, Skid (6x6)

19 7512084 16 Screw20 5434903 2 Panel, Wheel Well21 5434807

543480811

Panel, Wheel Well, LHPanel, Wheel Well, RH

22 54347485434748-070

5435107-070

5435178-070

11

1

1

Fender, Front, RH (If built before 12/01/02)Fender, Front, RH(If built 12/01/02 to 1/01/03)Fender, Front, RH(If built 1/01/03 to 5/01/03)Fender, Front, RH (If built after 5/01/03)

23 2632625 1 Floor, Main (Incl. Foil)7/03

A6

DASH INSTRUMENTS AND CONTROLSRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


76

21

5

3

4

12

10

9

811




1 4010797 1 Panel, Indicator2 4010460 1 Hourmeter3 4010525 1 Switch, Headlight4 4010601 1 Switch, AWD (4x4)5 5434192 1 Plug, Hole6 4010390 1 Switch, Ignition

7 4010638 1 Receptacle, 12V8 7080922 1 Nut, Choke9 7080937 1 Cable, Choke10 2461058 1 Harness, Dash11 2201795 1 Kit, Circuit Breaker, Fan12 2460978 1 Harness, Headlight

6/02

A7

HOODRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


20

323

24

13

2

25

10

18

26

1716

19

2221

27

3 31

11

56 7 8

94

12

1415




1 7518158 8 Screw2 5434057 2 Hinge3 7517685 16 Screw4 5410774 1 Grommet5 7512026 3 Screw6 5910119 1 Plate7 5246693 1 Pin, Catch8 5521623

552166711

Seal, Glove Box (If built before 4/07/03)Seal, Glove Box (If built after 4/07/03)

9 5434719-1955435116-455

11

Cover, Glove Box (AA)Cover, Glove Box (AB)

10 5434657-1955435109-1955435117-455

111

Dash (If built before 1/01/03)(AA)Dash (If built after 1/01/03)(AA)Dash (AB)

11 5434763 2 Holder, Cup12 7621479 4 Rivet13 5434658-195

5435118-45511

Hood (AA)Hood (AB)

14 7670157 2 U-Nut (If built after 1/01/03)15 7517561 2 Screw (If built after 1/01/03)16 7542122 2 Nut, Nylok17 7555935 2 Washer18 5410370 2 Strap, Hood Latch19 7517230 2 Screw20 5434746 1 Liner, Hood21 4032094 4 Spring, Adjust22 7518156 4 Screw, Adjust23 7670090 4 Clip, Dart24 2410275

401068122

Asm., HeadlightBulb, Headlight

25 7670134 2 Clip, Wire26 7518157 2 Screw27 5412148 2 Grommet

7/03

A8

DUMP BOXRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


17

11

6

13

4

36

10

9

5

14

1

3

1238

2

28

7

8

16

2523

15

18

37

19

2032

29

31

31

33 34

163

33

21

13

3

12

14

17

30

6

24

21 22

22

15

8

35

21

27 26

5

33




1 7515177 2 Screw2 7555960

755585922

Washer, Flat (2x4, 4x4)Washer, Flat (6x6)

3 7517561 20 Screw4 5244068-067 1 Cover, Tailgate5 5433656 2 Latch6 5132810 2 Shaft, Latch7 7556143 2 Washer, Rubber w/Metal Back8 7661644 6 Pin, Hitch9 5433655 1 Latch, Paddle10 5433951 1 Tailgate11 5132811 1 Rod, Hinge12 7517742 2 Screw13 5243304 2 Bracket, Box Latch14 7081001 2 Cable, Tailgate15 7517938 2 Screw16 7517790 4 Screw17 2410322

401034022

Asm., Taillight w/Brake LightBulb

18 5411009 2 Plug19 7079925 2 Decal, Reflector, Red20 1013511-067 2 Pin, Hinge21 7517386 8 Screw22 7661037 4 Pin, Clevis

23 7041996 2 Shock, Dump Box24 7670116 6 Clip, Routing (Qty 5 for 6x6)25 1014139-067

1014138-06711

Base, Box (2x4, 4x4)Base, Box (6x6)

26 5412321 2 Bumper27 7621418 4 Rivet28 7547089 12 Nut, Flange Lock

(Qty 12 for 2x4, 4x4, Qty 15 for 6x6)29 7041687 2 Spring, Exhaust30 7515319 4 Screw31 5434226 8 Bushing32 1013571-067

1013814-06711

Latch, Box (2x4, 4x4)Latch, Box (6x6)

33 75557707558402

44

Washer (If built before 1/01/03)Washer, Flat (If built after 1/01/03)

34 7542324 4 Nut, Nylok35 5246389 1 Shield, Exhaust36 5434578-070

5434579-0705434870-0705434639-070

1111

Box (2x4)Box (4x4)(AA)Box (4x4)(AB)Box (6x6)

37 7556157 12 Washer(Qty 12 for 2x4, 4x4, Qty 15 for 6x6)

38 7517959 12 Screw(Qty 12 for 2x4, 4x4, Qty 15 for 6x6)

7/03

A9

DECALSRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


2

6

43

10

5

1

7

12 9 8


11

1



1 7079425 2 Decal, Warning, Cab Frame/Seat Belt(Qty. 1 for AB)

2 7079902 1 Decal, 4 Stroke, Carb/Filter Info3 7079424

717057411

Decal, Tire Pressure/Load (2x4, 4x4)Decal, Tire Pressure/Load (6x6)

4 7079397707939971709817170516

2222

Decal, Box Side, “2X4”Decal, Box Side, “4X4” (AA)Decal, Box Side, “4X4” (AB)Decal, Box Side, “6X6”

5 70794287171061

11

Decal, Tailgate, “POLARIS” (AA)Decal, Tailgate, “POLARIS” (AB)

6 7170014 1 Decal, Hitch7 7079735 1 Decal, Lock/Unlock Diff (2x4, 4x4)8 7170544 1 Decal, Caution, “SHIFT AT IDLE”9 7170532

717073911

Decal, “APPLY BRAKE” (AA)Decal, “APPLY BRAKE” (AB)

10 7170583 1 Decal, Warning, Discretionary11 7171067 1 Decal, Front Cover, “NEW BREAK-UP”

(AB)12 7079402

717073911

Decal, Hood, “POLARIS” (AA)Decal, Hood, “POLARIS” (AB)

5/03

A10

COOLING SYSTEMRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


293031

32

34353637

1

12

2

811

1314

10

28

27

1918

20 21

22

25 23

24

1

11

8

8

8

8

8

26

9

63

4 5

15 17

16

33

7




1 7080614 2 Clamp, Hose2 5411978 1 Hose, Engine Outlet3 7080138 1 Cable Tie4 7080965 3 Mount, Cable Tie5 7670102 1 Clip6 4020149 1 Clip, Rosebud7 4020139 1 Clip, Rosebud8 7080826 6 Clamp9 5521324 1 Tubing, Convoluted10 5411977 1 Hose, Radiator, Inlet11 7052092 2 Connector, Barbed12 5411980 1 Hose, Engine Inlet13 7080898 1 Clamp14 7517386 1 Screw15 7547220 4 Screw, w/Washer16 2410340 1 Asm., Fan17 5434696 1 Shroud18 7512163 2 Screw19 5411975 2 Asm., Grommet

20 7542153 2 Nut, Flanged21 1240093 1 Cap, Pressure22 1240140 1 Radiator23 5410584 2 Bushing24 7052296 1 Valve, Plastic Radiator/Cooler Drain25 4010161 1 Sensor, Thermal26 7547197 4 Clip, U27 7518067 4 Screw28 5411979 1 Hose, Radiator, Outlet29 7080761 7 Cable Tie30 8450003-55 AR Line, Fuel31 7052065 1 Fitting32 7512084 4 Screw33 5246873 1 Bracket, Tank34 5431673 1 Tank, Surge35 5433774 1 Plug36 5810279 1 Gasket37 5430743 1 Cap

1/03

A11

FUEL SYSTEMRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


3

21

1918

9

17

16

15

10

1112

14

21

20

2324

13

9

3

2

2

12

7

8

6

4

5

2

25

22

3

26




1 7052259 1 Fitting2 7080003 6 Clamp, Hose3 8450103 AR Line, Fuel4 7052028 1 Grommet5 8350019-45 AR Tubing6 7080402 2 Ring, Compression7 7052301 1 Pick-Up, Fuel8 1240119 1 Cap, Gas Tank w/Gauge9 7542324 3 Nut, Nylok10 5433861 1 Tank, Fuel11 5812230 1 Pad, Bottom12 7512399 3 Screw13 1013487-067 1 Support, Tank

14 7515398 1 Screw15 5812252 1 Foil, Tank16 8360009-50 AR Line17 7052095 1 Fitting, 90 Degree18 5812231 2 Pad, Top19 1013471-067 2 Strap, Tank20 4010658 1 Pump, Fuel21 7080138 1 Cable Tie22 8360054-56 1 Conduit, Hite MP23 7517685 2 Screw24 7542122 2 Nut, Nylok25 2530009 1 Filter26 7670109 3 Clip, Routing

1/03

A12

OIL TANKRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


4

89

3

1718

15

2

2

1

1

16

14

13

89

10

5

7

7

11

6

6

12

12




1 7512163 2 Bolt2 7558301 2 Washer, Flat3 5434307 1 Dipstick4 1261175 1 Tank, Oil5 5412303

541236611

Line, Breather (If built before 7/15/02)Line, Breather (If built after 7/15/02)

6 7080761 1 Cable Tie7 7542122 2 Nut, Nylok8 5333204 2 Bushing, Mounting9 5410828 2 Grommet, Reservoir Mounting

10 7080699 1 Clamp, Hose, Spring11 8450073-55 AR Line, Breather12 7080474 2 Clamp13 8450096-51 AR Line14 7081026 1 Clamp, Hose15 7052326 1 Screen, Oil Filter, 90 Degree16 5411042 1 Grommet17 5850135 1 Washer, Nylon18 7051524 1 Plug

1/03

A13

ENGINE MOUNTINGRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


26

19

3

12

24

25

15

14

16

4

22

20

28

118

652

13

1

23

21

9

18

7

10

3

9

15

12

12

12

12

13

17

27


A14

ENGINE MOUNTINGRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB

and RANGER 6X6 SERIES 11 A11RF50AAPart numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.


1 7515399 4 Screw2 5244244-067 1 Bracket, Motor Mount, Top3 8450003-1525 AR Line4 7052075 1 Fitting, Tee5 5245206-067 1 Bracket, Carburetor6 3084205 2 Screw and Washer7 7517386 2 Screw8 5245024-067 1 Bracket, Dampner9 7542153 4 Nut10 3021398 2 Mount, Rubber11 8360009-100 AR Line12 7547108 8 Nut, Flange Lock13 3110044 2 Mount, Rubber14 7512315 2 Screw15 7552901 2 Washer, Spring Lock16 5241453 1 Mount, Engine, Top17 4010539 1 Cable, Sol/Starter18 7555815 2 Washer19 3021119 2 Mount, Rubber, Rear

20 1013134-067 1 Mount, Engine, Rear21 5430261 1 Bushing22 5210748 1 Washer, Flat23 7575202 1 Washer, Interlock24 7512566 1 Screw25 7515417 2 Screw26 5244245-067 1 Bracket, Motor Mount, Front27 3085556

3087023

1

1

Engine, Short Block (EH50PLE15)(4x4, 6x6) NOTE: The Short Block as-sembly contains a crankcase assem-bly, cylinder and cylinder head assem-bly, and a piston & crankshaft assem-bly. Prior authorization required forwarranty consideration.Engine, Short Block (EH42PLE07)(2x4) NOTE: The Short Block assem-bly contains a crankcase assembly,cylinder and cylinder head assembly,and a piston & crankshaft assembly.Prior authorization required for warran-ty consideration.

28 4010605 1 Cable, Battery/Frame/Engine

1/03

B1

EXHAUST SYSTEMRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


14

32

20

5

22

67

8

16

17

18

19

2324

2526

5

20

14

14

15

9

12

10

27

21

13

11E 2003 Polaris Sales Inc.



1 1261082-029 1 Silencer2 5410436 2 Washer, Rubber3 7555716 2 Washer, Flat4 7542324 2 Nut, Nylok5 7041804 5 Spring, Exhaust6 7547101 1 Nutsert7 7542301 1 Nut8 3110064 1 Mount, Torque Stop9 5246454 1 Shield, Side10 7515197 4 Screw11 7555935 4 Washer12 5246455 1 Shield, Top13 7517386 2 Screw14 2632609

52456445246388

111

Asm. Shield ExhaustShield, LHShield, RH

15 7661637 6 Rivet16 3085075 1 Gasket17 1261043-029 1 Manifold18 3080530 2 Washer, Lock19 3080285 2 Nut20 5243518 2 Seal, Exhaust21 7515399 1 Screw22 1261230-029 1 Pipe, Exhaust23 5010192 2 Bushing24 7555863 2 Washer25 5410241 2 Dampener26 7515316 2 Bolt, Carriage27 7512666 1 Bolt

1/03

B2

TRANSMISSION MOUNTINGRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


20

12

3

4

5

1213

14

19

18

6

4

4

3

53

18

7

811

10

9

15

416

17




1 7515522 2 Screw2 7552603 2 Washer, Spring Lock3 7555976 4 Washer, Flat (Qty 4 for 6x6, Qty 6 for

2x4, 4x4)4 7547108 6 Nut, Flange Lock5 7515417 2 Screw6 ------ -- -- -- -- 1 Asm., Main Gearcase7 7080307 1 Clamp8 8450003-1525 AR Line9 7670102 1 Clip10 7511840 1 Screw (2x4, 4x4)11 7080525 1 T-Clip (2x4, 4x4)

12 7515398 2 Screw13 7542321 2 Nut, Flanged14 5244599-067

5247348

5246084-067

1

1

1

Bracket, Mount, Rear (2x4, 4x4)(If built before 2/03/03)Bracket, Mount, Rear (2x4, 4x4)(If built after 2/03/03)Bracket, Mount, Rear (6x6)

15 3234043 2 Nut16 3234045 2 Spacer17 3234042 2 Screw18 7517289 4 Screw19 5246954 1 Bracket, Transmission Mount20 1013134-067 1 Mount, Engine, Rear

3/03

B3

ELECTRICAL/BATTERYRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


20

19

13

17

6 9

24

4

1

15

12

105

22

2 25

28

26

2327

18

3

12

1

8

14

16

11

7

21

1




1 7512018 8 Screw2 4010740 1 Cutoff, 12VDC3 4010606 1 Switch, Hub Safety4 4060191

4010670

1

1

Rectifier, Regulator, LR-390 (2x4 If builtbefore 8/9/02)Rectifier, Regulator, LR-390 (2x4 If builtafter 8/9/02, 4x4)(6x6)

5 5133190 1 Sink, Heat6 7670109 5 Clip, Routing7 4020139 3 Clip, Rosebud (Qty 4 for 6x6)8 7080138 2 Cable Tie (2x4, 4x4)9 4020149 4 Clip, Rosebud10 7080761 5 Cable Tie (Qty 2 for 6x6)11 7670116 1 Clip, Routing (2x4, 4x4)12 7517386 5 Screw13 4010605 1 Cable, Battery/Engine/Frame14 2202172 1 Kit - Battery Bolt15 4010541 1 Cable, Battery/Solenoid

16 4010630 1 Battery17 5432077

543503011

Tube, Battery Vent (If built before 9/16/02)Tube, Battery Vent (If built after 9/16/02)

18 7555859 4 Washer, Flat19 5434037 1 Box, Battery20 2461082

246102822005934010781

1121

Harness (2x4, 4x4)Harness (6x6)Kit - Circuit Breaker, 20 AMPDiode

21 7512084 2 Screw22 5245617 1 Bracket, Electrical Cover23 3087198 1 Switch, Magnetic24 5246747 1 Bracket, CDI25 7512024 1 Screw26 3085639

308716911

CDI System (2x4)CDI System (4x4)(6x6)

27 ------ -- -- -- -- 1 Bracket, Oil Tank(See Chassis/Body Pg. A4, Ref. 15)

28 3085227 1 Coil, Ignition3/03

B4

FRONT DRIVE SHAFTRANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB and RANGER 6X6 SERIES 11 A11RF50AA

4

5

3

21

6




1 7670092 2 C-Clip2 1590327 2 Joint, CV3 2201015 2 Kit, Boot (Incl. Clamps and Grease)4 1380187

138023122

Shaft (Incl. 5)(Use w/1380178)Shaft (Incl. 5)(Use w/1380230)

5 32601042202015

22

Kit, Cross and Bearing (Use w/1380178)Kit, Cross and Bearing, Nongrease(Use w/1380230)

6 1380178

1380230

2

2

Asm., Drive Shaft(If built before 5/06/03)Asm., Drive Shaft(If built after 5/06/03)

7/03

B5

REAR PROP SHAFTRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


23

45 7

1

6

8




1 7661913 1 Pin, Spring2 1350039 1 Yoke, Prop Shaft, Rear3 3260104

2202015

2

2

Kit, Cross and Bearing(Use w/1380180)Kit, Cross and Bearing(Use w/1380193)

4 1380184 1 Shaft, Prop

5 3260131 1 Yoke, Prop Shaft, Transmission6 7080424 1 Fitting, Lubrication7 5411092 1 O-Ring8 1380180

1380193

1

1

Asm., Prop Shaft, Rear(If built before 9/11/02)Asm., Prop Shaft, Rear(If built after 9/11/02)

1/03

B6

FRONT PROP SHAFTRANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB and RANGER 6X6 SERIES 11 A11RF50AA

1

2 34

56 7

8




1 7661913 1 Pin, Spring2 3260133 1 Yoke, Gear Case, Front3 3260104

220201522

Kit, Cross and Bearing (Use w/1380177)Kit, Cross and Bearing (Use w/1380194)

4 1380182 1 Shaft, Prop5 3260131 1 Yoke, Prop Shaft, Transmission

6 7080424 1 Fitting, Lubrication7 5411092 1 O-Ring8 1380177

1380194

1

1

Asm., Shaft, Prop(If built before 9/11/02)Asm., Shaft, Prop(If built after 9/11/02)

1/03

B7

FRONT STRUTRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


9

10

11 12 13

14

18

2021

15

178

7

6

5

22

4

3

2

1

16

1316

16

19




1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Ball, Pivot, Top5 5132062 2 Spacer6 5432871 2 Ball, Pivot, Bottom7 5243364 2 Retainer, Spring8 7041985-067 2 Spring, Compression9 5411608 2 Bumper10 7041784 2 Strut, Front11 5211115 2 Washer12 7080367 2 Clamp13 7542324 4 Nut, Nylok

14 7512365 4 Screw15 7552901 4 Washer, Spring Lock16 7558402 10 Washer, Flat17 7080306 2 Fitting, Lubrication18 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Caliper Pg. C3 forDetails)

19 7710507 2 Ring, Retaining20 3514342 2 Bearing21 1820899

1820901

1

1

Asm., Hubstrut, LH(42mm)(Incl. 12,13,16,19,20,22)Asm., Hubstrut, RH(42mm)(Incl. 12,13,16,19,20,22)

22 7515339 4 Bolt

5/01

B8

MID HOUSINGRANGER 6X6 SERIES 11 A11RF50AA

1

1

1

2

2

2

3

3

10

5

4

6

9

7

8




1 7080307 1 Clamp, Hose2 8450003-1525 AR Line, Fuel3 7052075 2 T-Fitting4 1341405 1 Asm., Mid Gearcase5 7661029 2 Pin, Spring

6 ------ -- -- -- -- 2 Asm., Driveshaft, Mid (See Mid Drive-shaft Pg. B9 for Details)

7 7552603 4 Washer, Spring Lock8 7512492 4 Screw9 1380192 1 Coupler10 7661913 1 Pin, Spring

1/02

B9

MID DRIVESHAFTRANGER 6X6 SERIES 11 A11RF50AA

9

1 365 5 7

82 4 2




1 1350067 1 Yoke, Wheel End2 1590257 2 Joint3 1350092 1 Yoke, Tube and Sleeve4 7080424 1 Fitting, Lubrication5 5241755 2 Clamp, Boot

6 5411161 1 Boot7 1350069 1 Yoke, Shaft8 1350071 1 Yoke9 1380161 2 Asm., Driveshaft, Mid (Incl. All)

1/02

B10

MID DRIVE A-ARMSRANGER 6X6 SERIES 11 A11RF50AA

26

31

4

2

2021

2524

15

14

23

22

11

12

13

18

16

19

17

6

9

7

10

5

82

1

1514

1213

11

21 24

2




1 5434548 12 Bushing2 7542439 10 Nut, Nylok3 5020826 6 Shaft4 7515472 6 Screw5 7515433 2 Screw6 5241147 2 Retainer7 7042169-067 2 Spring8 7556142 2 Washer9 7042078 2 Shock, Mid10 7515415 2 Screw11 7517873 4 Screw12 7552614 4 Washer, Spring Lock13 7555740 4 Washer

14 5631142 4 Bushing15 5434550 8 Bushing, Control, Lower16 5131649 2 Hub17 7710440 2 Ring, Retaining18 3585502 2 Bearing19 5133663 2 Carrier20 1014058-067 2 A-Arm, Mid, Lower21 5132532 4 Bushing22 7553101 4 Washer, Spring Lock23 7512589 4 Screw24 5434547 4 Bushing25 5133676 2 Shaft26 1014063-067 2 A-Arm, Mid, Upper

6/02

B11

FRONT WHEELRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1

2

4

3

6

12

5

8

9

7

11

10

13




1 7512325 8 Bolt2 5244314 2 Disc, Brake3 7515523

751551388

Stud (If built before 10/07/02)Stud (If built after 10/07/02)

4 5131935 2 Hub, Wheel5 1520349-067

1520696-45522

Rim, Front, Black (AA)Rim, Front, Black (AB)

6 54113975412302

22

Tire (25x10-12)(AA)Tire (25x10-12)(AB)

7 7542459 8 Nut, Flange Lock8 7556004 2 Washer9 7542810 2 Nut, Slotted10 5411164 2 Cover, Dust11 7661401 2 Pin, Cotter12 1525017 2 Valve, Rim13 1821088 2 Spindle (2x4)

5/03

B12

STEERINGRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


2827

20

11 12

13

17

10

22

15

14

8

23

3029

24

6

4

2

5

7

3

1

25

26

13

7

5

4

3

21

19

16

18

9

21




1 5411920 2 Boot2 7061054 2 Rod End3 7547028 2 Nut, Jam4 1821006 2 Tie Rod5 7080978 2 Clamp, Small6 5412013 1 Boot, Passenger Side7 7080979 2 Clamp, Large8 7515382 3 Screw9 7080884 1 J-Clip (2x4, 4x4)(If built before 1/01/03)10 7515434 1 Screw11 7517924 1 Screw12 7552902 1 Washer, Spring Lock13 5434106 2 Bushing, Shaft, Steering14 7547188 1 Nut15 5434768 1 Cap

16 7078465 1 Logo, Polaris Star17 1821334 1 Wheel, Steering18 7556063 2 Washer, Wave19 7556301 1 Bushing20 1821018 1 Shaft, Steering, Upper21 1821019 1 Shaft, Steering w/Joints, Lower22 7542439 1 Nut, Nylok23 7542324 5 Nut, Nylok24 5412012 1 Boot, Driver Side25 7517909 2 Screw26 7556099 4 Washer, Flat27 7547177 2 Nut28 7661203 2 Pin, Cotter29 1820921 1 Box, Steering30 7512371 2 Screw

3/03

B13

A-ARM/STRUT MOUNTINGRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


12

6

7

8

910

1114

3

15

12

45

13

2 1

45




1 7512589 4 Screw2 7553101 4 Washer, Spring Lock3 1541884-067

1541885-0671541882-0671541883-067

1111

A-Frame, LH (2x4)A-Frame, RH (2x4)A-Frame, LH (4x4)(6x6)A-Frame, RH (4x4)(6x6)

4 5132532 4 Bushing5 5434547 4 Bushing, A-Arm6 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B7, Ref. 21)7 7080927 2 Joint, Ball8 5211121 2 Bracket, Ball Joint9 5410548 2 Boot, Rubber

10 7512284 4 Screw11 7542438 2 Nut, Castle12 7661203 2 Pin, Cotter13 5433927-070

5433928-070

5435028-070

5435029-070

1

1

1

1

Shield, CV Joint, LH (4x4)(6x6)(If built before 11/18/02)Shield, CV Joint, RH (4x4)(6x6)(If built before 11/18/02)Shield, CV Joint, LH (4x4)(6x6)(If built after 11/18/02)Shield, CV Joint, RH (4x4)(6x6)(If built after 11/18/02)

14 7512084 6 Screw (4x4)(6x6)15 5133676 2 Shaft, A-Arm

1/03

B14

THROTTLERANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1

2

7

34

5

6

8

9




1 7080938 1 Cable, Throttle2 ------ -- -- -- 1 Frame, Main3 5434327 1 Block, Pivot4 7555954 1 Washer5 7661011 1 Pin, Cotter

6 7515102 4 Screw7 1013557-067 1 Throttle8 7042004 1 Spring9 7547069 4 Nutsert

1/02

C1

FOOT BRAKERANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


8

5

46

37

4

9


1

2



1 7512310 2 Screw2 7542324 2 Nut, Nylok3 7542439 1 Nut, Nylok4 5431107

543318922

Bushing (If built before 6/02/03)Bushing (If built after 6/02/03)

5 5334030 1 Tube6 7515417 1 Screw7 5910110 1 Pin, Clevis8 1013521-067 1 Pedal, Brake9 7661140 1 Pin, Clip

7/03

C2

BRAKE LINES/MASTER CYLINDERRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


3

5

8

4

1

13

10

7

2

9 119

12

6

10

14

15

16




1 1910493 1 Line, Rear, LH2 7052293 1 Fitting, Tee3 1910447 1 Asm., Master Cylinder4 1910486 1 Line, Brake, M/C, Front5 1910484 1 Line, Brake, Front, Left6 7052316 1 Fitting, Cross, Brake7 4110164 1 Switch8 1910485 1 Line, Brake, Front, Right9 7512025 4 Screw

10 1910594 2 Bolt, Banjo11 5410988 4 Seal12 1910487

191057211

Line, Brake, M/C, Rear (2x4, 4x4)Line, Brake, M/C, Rear (6x6)

13 1910494 1 Line, Rear, RH14 7080138 1 Cable Tie15 7670102 4 Clip16 4020139 1 Clip, Rosebud

7/03

C3

FRONT BRAKE CALIPERRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1

10

2

87

6

9

34

5

11




1 7080352 1 Screw, Bleeder2 5132830

51328311930642

111

Caliper, Brake, LHCaliper, Brake, RHKit - Front Brake Boot

3 5412010 1 Seal, Caliper, Inner4 5412011 1 Seal, Caliper, Outer5 5132829 1 Piston, Brake

6 5410494 1 Boot, Pin Seal7 1910513 1 Mount, Caliper, Front8 2202413 2 Kit, Brake Pad Asm.9 5410495 1 Boot, Bushing10 7515489 1 Screw, Socket Set11 1910640

191064111

Asm., Front Brake Caliper, LHAsm., Front Brake Caliper, RH

1/03

C4

PARK BRAKE LOCKRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


20

4

10

5

13

14

22

21

9

8

17

23

1112

18

29

36

3028

26

27

25

15

16

17

14

2526

1

72

19

24




1 70810107081018

11

Cable, Park Brake, Main (2x4, 4x4)Cable, Park Brake, Main (6x6)

2 5245209 1 U-Bolt3 7542451 2 Nut, Nylok4 ------ -- -- -- -- 1 Mount, Parking Brake5 5133067 1 Rod, Parking Brake6 5410437 1 Grommet7 7546701 1 Nut8 7081013 1 Handle, Parking Brake9 7042057 1 Spring, Catch, Parking Brake10 ------ -- -- -- -- 1 Catch, Parking Brake11 7558201 1 Washer, Flat12 7661103 1 Pin, Cotter13 ------ -- -- -- -- 1 Plate, Catch, Parking Brake14 ------ -- -- -- -- 2 Bushing15 7558302 1 Washer

16 7661140 1 Pin, Clip17 ------ -- -- -- -- 2 Washer18 ------ -- -- -- -- 1 Pin, Cotter19 7080138 1 Cable Tie20 ------ -- -- -- -- 1 Lever, Parking Brake21 7042056 1 Spring, Parking Brake22 ------ -- -- -- -- 1 Pin, Clevis23 ------ -- -- -- -- 1 Washer24 1910604 1 Asm., Parking Brake

(Incl. 4,5-10,13,14,17-20,22,23)25 7542122 2 Nut, Nylok26 7512287 2 Bolt, Brake Lever27 7517386 7 Screw28 7081012 1 Cable, Park Brake, LH29 2632418 1 Asm., Equilizer and Pin30 7081011 1 Cable, Park Brake, RH

5/03

C5

REAR BRAKE CALIPERSRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


5

4

3

1

28

19

16

20

22

14

139

23

11

25

24

6

7

12

15

21

17

18

14

10




1 5133195 1 Plunger2 7556205 1 Washer, Flat, Plunger3 1910581 1 Spring, Compression4 5412127 2 O-Ring5 1910638

1910639

1910645

1910646

1

1

1

1

Asm., Caliper, Rear, LH(Incl. 5-25)(2x4, 4x4)Asm., Caliper, Rear, RH(Incl. 5-25)(2x4,4x4)Asm., Caliper, Rear, LH(Incl. 5-25)(6x6)Asm., Caliper, Rear, RH(Incl. 5-25)(6x6)

6 7080352 1 Screw, Bleeder7 7515489 1 Screw8 7517963 3 Screw9 7556206 1 Washer, Flat10 7552605 2 Washer, Lock11 7517964 1 Screw12 7542105 1 Nut

13 5133196 1 Lever, Brake Actuator14 5410494 2 Boot, Pin Seal15 5245793

524579411

Bracket, Housing, LHBracket, Housing, RH

16 5830214 1 Gasket17 5133199

513320111

Insert, Ball Track, LHInsert, Ball Track, RH

18 51332025133203

11

Actuator, LHActuator, RH

19 3514375 3 Ball20 5411596

541201011

Seal, Caliper, Inner (2x4, 4x4)Seal, Caliper, Inner (6x6)

21 51324055132829

11

Piston, Brake (2x4, 4x4)Piston, Brake (6x6)

22 54115975412011

11

Seal, Caliper, Outer (2x4, 4x4Seal, Caliper, Outer (6x6)

23 5410495 1 Boot, Bushing24 2202413 2 Kit, Brake Pad25 1910513 2 Mount, Caliper

1/03

C6

REAR WHEEL DRIVERANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


8

10

3

12

2

1

9

4

11

5

6

7




1 5411164 2 Cover, Dust, Hub (Use Qty 4 for 6x6)2 7661404 2 Pin, Cotter (Use Qty 4 for 6x6)3 7555796 2 Washer, Cone (Use Qty 6 for 6x6)4 1520483-067

1520695-45522

Rim, Rear (AA)(Use Qty 4 for 6x6)Rim, Rear (AB)

5 5133361 2 Hub, Rear Wheel (Use Qty 4 for 6x6)6 5244635 2 Disc, Brake, Rear (Use Qty 4 for 6x6)

7 7512325 8 Screw (Use Qty 16 for 6x6)8 5412008

541230122

Tire, 25x11-12 (AA)(Use Qty 4 for 6x6)Tire, 25x11-12 (AB)

9 7515513 8 Stud (Use Qty 16 for 6x6)10 1525017 2 Valve, Rim (Use Qty 4 for 6x6)11 7542459 8 Nut, Flange Lock (Use Qty 16 for 6x6)12 7543005 2 Nut, Castle (Use Qty 4 for 6x6)

5/03

C7

SWING ARMRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


12

9

3 7

8 21

27

4 5

18

24

1319

23

20

10

21

11

22

17

25

12

54

17

5

54

4

6

6

26

1615

14

2829

30




1 7710440 2 Ring, Retaining2 3585502 2 Bearing, Wheel3 1013293-067 1 Tube, Axle, RH4 7517585 8 Screw5 7553201 8 Washer, Split Lock

(If built before 7/07/03)6 5410772 2 O-Ring7 1380213 1 Axle, LH8 1380214 1 Axle, RH9 1013292-067 1 Tube, Axle, LH10 7542525 8 Nut, Nylok11 7555984 8 Washer, Flat12 1013295-067 1 Arm, Swing13 5245127 4 U-Bolt14 5246229 2 Bracket, Bolt Lock15 7512490 2 Screw

16 7547180 2 Nut, Nylon, Flanged17 5131697 2 Bolt, Swing Arm, Pivot18 5133166 1 Bushing, Pivot, LH19 5434545 1 Bushing, Swing Arm, LH20 7080424 2 Fitting, Lubrication21 7547082 1 Nut, Jam22 7556035 1 Washer, Flat23 5434546 2 Bushing, Swing Arm, RH24 5133167 1 Bushing, Pivot, RH25 ------ -- -- -- -- 1 Asm., Gearcase, Rear (See Rear

Gearcase Pg. C14 for Details)26 5811716 2 Pad, Rubber27 5245665-067 1 Plate, Skid28 7558402 4 Washer, Flat29 7552901 4 Washer, Lock30 7517445 4 Screw

7/03

C8

REAR SHOCKRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1

2

3

4

5

6

7

2




1 7517583 2 Screw2 7542439 4 Nut, Nylok3 5241147 2 Retainer, Spring4 7041955-067 2 Spring

5 5630551 2 Cam, Adjusting6 7041956 2 Shock, Rear7 7515415 2 Screw

3/02

C9

DRIVE CLUTCHRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


12 3

6

12

4 5 6

7

11

10

89

13




1 7518062 6 Screw2 3576510 1 Bearing, Cover3 7041157 1 Spring, Clutch4 5430945 6 Washer, Multilube5 1321457 3 Asm., Roller and Bushing6 5431936 6 Button, Guide, Stemless7 5210752

524298152107535210754

ARARARAR

Spacer (.020)Spacer (.025)Spacer (.032)Spacer (.050)

8 563071156305135630514

333

Weight, Shift 10 BH (2x4)Weight, Shift 10 MH (4x4)Weight, Shift G (6x6)

9 7512266 3 Bolt, Shoulder10 7541906 3 Nut, FLEXLOC11 3576504 1 Bearing, Moveable, 1/2 Inch12 5020422 3 Pin, Roller13 1321976 1 Asm., Drive Clutch, Wide

(Incl. All Less 3,8)

1/03

C10

DRIVEN CLUTCHRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1

3

45

6

7

10

11

12

13

15

1617

3

2

9

14

8




1 3211077 1 Belt, Drive2 7556120 AR Bushing (3 Max)3 1321874

13218481322072

111

Asm., Driven Clutch (Incl. 7-17)(2x4)Asm., Driven Clutch (Incl. 7-17)(4x4)Asm., Driven Clutch (Incl. 7-17)(6x6)

4 5220646 1 Washer, Domed5 7552901 1 Washer, Spring Lock6 7515382 1 Bolt7 7555898 AR Washer (.020)8 7556076 AR Washer (.025)9 7556804 AR Washer (.030)

10 3576504 1 Bearing, Moveable, 1/2 Inch11 3576511 1 Bearing, Moveable, 1 Inch12 7041782

704149911

Spring, Clutch (2x4, 4x4)Spring, Clutch, Silver (6x6)

13 51323445131446

11

Ramp, Stationary (2x4, 6x6)Ramp, Stationary (4x4)

14 52441165210752

11

Spacer (2x4)Spacer (4x4, 6x6)

15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

6/02

C11

AIR BOXRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB



8

13

9

7

14

10

12

11

34

62

2

5

1

15



1 8450073-100 AR Line2 7080699 2 Clamp, Hose3 7080913 1 P-Clamp4 2530029 1 Filter, Breather5 5411921 1 Hose, Breather6 7080694 1 Clamp, Hose7 5434060 1 Box, Air8 5412015 1 O-Ring

9 5434058 1 Tube, Outlet10 7052164 2 Fitting, 90 Degree11 7670132 2 Clip12 7080981 1 Filter13 5434059 1 Cover, Air Box14 5812196 1 Seal, Cover15 1253433 1 Asm., Air Cleaner (Incl. 7-14)

1/03

C12

ENGINE AND CLUTCH AIR INTAKERANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1 13

1615

17

1211

10

36

4

8

1920

18

53

14

33

3

1

21

2

7

39

17




1 5812253 2 Filter2 5434323 1 Box, Air Baffeling, Engine3 7080451 6 Clamp, Hose4 1910482 1 Hose, Air Box, Front5 5434291 1 Duct, Intake, Engine6 7080761 1 Cable Tie (2x4, 4x4)7 7080560 1 Clamp, Hose8 1910483 1 Hose, Air Box, Rear9 5810290 1 Pad, Battery10 7542324 1 Nut, Nylok11 7515398 1 Screw

12 7512399 2 Screw13 1240101-067 1 Hanger, Air Cleaner14 ------ -- -- -- -- 1 Box, Air (See Air Box Pg. C11, Ref. 7)15 7080413 1 Clamp, Narrow Band16 5411976 1 Boot, Air Box17 7080656 2 Clamp, Narrow Band18 1910491 1 Hose, Clutch, Rear19 5434054 1 Duct, Air Intake20 1910490 1 Hose, Clutch, Front21 5434141 1 Box, Air Baffeling

1/03

C13

CLUTCH COVERRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1

10

8

9

12

13

7

11

32

5

4

6 5

7




1 5434234 1 Cover, Clutch, Inner2 7555748 5 Washer3 7517312 5 Screw4 5434247 1 Duct, Clutch Outlet5 7080707 2 Clamp, Narrow Band6 5411489 1 Boot, Duct7 7512094 9 Screw

8 5433451-070 1 Cover, Clutch, Outer9 7078689 1 Decal, Warning, Clutch Cover10 5521578 1 Seal, Cover, Clutch, Outer11 3084205 3 Screw and Washer12 5242046 1 Bracket, Seal13 5410575 1 Seal, Cover Case

6/02

C14

REAR GEARCASE (2X4, 4X4)RANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB

35

1

23

45

6

7 89

34

11 12

41

40

13

14

15 16

39

1718

38

19

37 36

2930

252627

21 2820

24

10

35

7

34

12

3231

23

22

33

42




1 3233785 1 Seal2 3233800 1 Cover, Input3 3233801 1 O-Ring4 3233589 1 Bearing, Ball5 3233802 1 Pinion, 10T6 3233577 1 Bushing7 3233803 2 Seal8 3233804 1 Case, Front9 3233529 1 Pipe, Knock10 3234017 1 O-Ring11 3233806 1 Bearing, Ball12 3233807 2 Ring, Retaining13 3233810 1 Housing, Differential Lock14 3234022 1 Gear, 14T, RH15 3234023 1 Gear, 14T, LH16 3233813 1 Gear, Ring 37T17 3233815 1 Collar, Spined18 3233378 1 Washer, Thrust19 3233268 1 Bearing, Ball20 3233822 1 Actuator, Cam21 3233820 1 Spring, Torsion

22 7555923 1 Washer23 7661140 1 Pin, Clip24 3233823 1 Seal25 3233818 1 Actuator26 5410440 1 O-Ring27 3233819 1 Ring, Retaining28 3233821 1 Ring, Retaining29 3233817 1 Cover, Output30 3233524 1 Tube, Vent31 7670102 3 Clip32 8450003 AR Line, Vent33 7080307 1 Clamp, Hose34 3233805 2 Plug, Drain35 3233252 12 Screw36 3233816 1 Dog, Engagement37 3233581 AR Shim38 3233377 1 Ring, Retaining39 3233814 8 Screw, Cap40 3233809 2 Pinion, Differential, 10T41 3233808 1 Pin, Differential Pinion42 1341442 1 Asm., Rear Gearcase

6/02

D1

REAR GEARCASE (6X6)RANGER 6X6 SERIES 11 A11RF50AA

1

23

4

5

6

7 89

10

1112

1314

15 16

17

19

20

23

21

22

22 24

7

21

18

25




1 3233785 1 Seal2 3233800 1 Cover, Input3 3233801 1 O-Ring4 3233589 1 Bearing, Ball5 3233802 1 Pinion, 10T6 3233577 1 Bushing7 3233803 2 Seal8 3233804 1 Case, Front9 3233529 1 Pipe, Knock10 3234017 1 O-Ring11 3233987 1 Spring, Wave12 3233806 1 Bearing, Ball13 3234021 1 Shaft, Output

14 3233985 1 Gear, Ring 37T15 3233268 1 Bearing, Ball16 3233995 1 Plug, Expansion17 3233524 1 Tube, Vent18 7080307 1 Clamp, Hose19 8450003 AR Line, Vent20 7670102 3 Clip21 3233805 2 Plug, Drain22 3233252 12 Screw23 3233817 1 Cover, Output24 3233581 AR Shim25 1341441 1 Asm., Rear Gearcase

1/03

D2

FRONT HOUSINGRANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB and RANGER 6X6 SERIES 11 A11RF50AA

2

1

34

56

7 89

10

11

12

13

1516

1718

192021

22

2324

25

26

28

16

11

4

14

29

27

1

1

1

5




1 3233956 1 Kit, Minor Repair(Incl. O-Rings and Seals)

2 3233998 1 Asm., Cover Plate(Incl. Output Cover, Insert and Coil)

3 3233925 1 Kit, Shim Set (Incl. Shims)4 3233926 2 Bearing, Roller Ball5 3233953 1 Asm., Race/Output Hub (Incl. 26)6 3233928 1 Pin, Dowel7 3233932 1 Bearing, Roller Ball8 3233933 1 Clutch Housing/Ring Gear9 3233949

3233935

1

1

Asm., Roll Cage(Incl. Spring and Roll Cage)Spring

10 3233957 14 Kit, Roll11 3233934 2 Ring, Retaining12 ------ -- -- -- -- 1 Bushing13 8450003-1525 AR Line, Fuel14 4020139 1 Clip, Rosebud

15 7080307 1 Clamp, Hose16 3233955 11 Kit, Bolt17 3233947 1 Cover, Input18 3233945 1 Bearing, Roller Ball19 3233944 1 Shaft, Pinion, 11T20 ------ -- -- -- -- 1 Bushing21 ------ -- -- -- -- 1 Gearcase, LH22 3233942 1 Plug, Oil Fill23 7552603 4 Washer, Spring Lock24 7512492 4 Screw25 3233951 1 Asm., Drain Plug

(Incl. Plug and Washer)26 3233929 1 Bearing, Needle, Roller Thrust27 3233954 1 Asm., Clutch (Incl. 7-11)28 3233924 1 Plate Armature29 1341344

3233950

1

1

Asm., Front Gearcase(Incl. 2-12,19-22,25-28)Gearcase (Incl. 12,20,21)

1/03

D3

GEARCASE (2X4)RANGER 2X4 SERIES 11 A11RB42AA

12 3

45 6

78

9

10

11

12

1314

1516 17

181920

21

22 23

28

28

13

13

22

13

19

1911

29

29

30

3132

333134 35

3637

38 39 4033 31

32 31 4136 42

43

4445

4647

495051

52 53 54

5556

57

58596061

626364

65

66

6768

6970

7172

7374

48

24

2726

25

75


D4

GEARCASE (2X4)RANGER 2X4 SERIES 11 A11RB42AA



1 3233054 1 Washer, Flat (If built before 7/08/02)2 3233826 5 Screw3 3233827 1 Cover4 3233829 1 Pawl, Detent5 3233828 1 O-Ring6 3233831 1 Shaft, Shift7 3233842 1 Seal8 3233832 1 Gear, 31T9 3233833

323404611

Gearcase, Main (If built before 7/08/02)Gearcase, Main (If built after 7/08/02)

10 3233524 1 Tube, Vent11 3233529 4 Pipe, Knock12 3233841 1 Drum, Shift13 3233018 4 Bearing, Ball14 3233036 1 Chain, Silent15 3233861 1 Gear, 15T (If built before 7/08/02)16 3233862 1 Sprocket, 16T (If built before 7/08/02)17 3233864 1 Gear, 31T (If built before 7/08/02)18 3233863 1 Shaft, Input (If built before 7/08/02)19 3233019 3 Bearing, Ball20 3233889 1 Asm., Input Shaft (Incl. 15-18)21 3233865 1 Cover, Main, LH22 3233846 17 Screw (Qty. 15 after 7/08/02)23 3233866 1 Seal24 3234042 2 Screw (If built after 7/08/02)25 3234044 1 Bracket, Trans Mount

(If built after 7/08/02)26 3234045 2 Spacer (If built after 7/08/02)27 3234043 2 Nut, Lock (If built after 7/08/02)28 3233859 2 Pin, Dowel29 3233858 2 Fork30 3233860 1 Rail, Shift Shaft31 3233875 4 Dog, Engagement32 3233849 2 Spring, Wave33 3233850 2 Ring, Retaining34 3233851 1 Washer35 3233852 1 Gear, 33T36 3233718 2 Bearing, Needle37 3233892 1 Shaft, Reverse38 3233103 1 Bearing, Needle39 3233854

323389311

Sprocket, 24T (If built before 7/08/02)Sprocket, 24T (If built after 7/08/02)

40 3233894 1 Washer41 3233855 1 Washer42 3233856 1 Gear, 30T43 3233857 1 Gear, 37T44 3233847 1 Gear, 47T45 3233608 4 Screw46 3233609 1 Cover, Bearing47 3233106 1 Ring, Retaining48 3233357 1 Spacer (If built after 7/08/02)49 3233607 1 Bearing, Ball50 3233606 1 Shaft, 10T51 3233619 1 Washer, Thrust52 3233582 1 Button, Thrust53 3233583 AR Shim54 3233713 1 Gearcase, Cover, Front55 3233777 1 Plug56 3233254 1 Washer57 3233611 AR Shim58 3233622 1 Shaft, Output, Rear59 3233621 1 Gear, 31T60 3233747 2 Screw (If built before 7/08/02)61 3233712 1 Deflector, Oil (If built before 7/08/02)62 3233840 1 O-Ring63 3233839 1 Gear, 16T64 3233838 1 Disc, Lockout65 3233837 1 Detent, Star66 3233836 1 O-Ring67 3233711 1 Plug, Oil Fill68 3233324 1 Washer69 3233830 1 Spring, Compression70 3233835 1 Switch71 3233834 1 Ring, Retaining72 7547144 1 Nut, Nylok (If built before 7/08/02)73 3233825 1 Bellcrank74 3233055

323396111

Nut, FLEXLOC (If built before 7/08/02)Nut, Lock (If built after 7/08/02)

75 1341367

1341463

1

1

Asm., Main Gearcase(If built before 7/08/02)Asm., Main Gearcase(If built after 7/08/02)

11/02

D5

GEARCASE (4X4)RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB

1

71

2 34

68

5 6 8

61

7069

67 666564

63

9

6215

10

22

7

1446

47

58

48

15

4952

6059

57

5051

5354

56

14

7

55

4544

424140

39

11

2627

11

28293031

3233 34

353637 38

23

24

25

12

13

16

17

26

282627 26

31

11

15

2423

11

14

43

18

2120

19

72


D6

GEARCASE (4X4)RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB



1 3233961 1 Nut2 3233826 5 Screw3 3233827 1 Cover4 3233829 1 Pawl, Detent5 3233828 1 O-Ring6 3233831 1 Shaft, Shift7 3233842 2 Seal8 3233832 1 Gear, 31T9 3233711 1 Plug, Oil Fill10 3233524 1 Tube, Vent11 3233018 4 Bearing12 3233036 1 Chain, Silent13 3233889 1 Shaft, Input14 3233019 4 Bearing15 3233529 4 Pipe, Knock16 3233865 1 Cover, LH17 3233866 1 Seal18 3234042 2 Screw (If built after 7/08/02)19 3234044 1 Bracket, Trans Mount

(If built after 7/08/02)20 3234045 2 Spacer (If built after 7/08/02)21 3234043 2 Nut, Lock (If built after 7/08/02)22 3233841 1 Drum, Shift23 3233858 2 Fork, Shift24 3233859 2 Pin, Dowel25 3233860 1 Rail, Shift Shaft26 3233875 4 Engagement Dog27 3233849 2 Spring, Wave28 3233850 2 Ring, Retaining29 3233851 1 Washer30 3233852 1 Gear, 33T31 3233718 2 Bearing, Needle32 3233892 1 Shaft, Reverse33 3233103 1 Bearing, Needle34 3233893 1 Sprocket, 24T35 3233894 1 Washer36 3233855 1 Washer37 3233856 1 Gear, 30T

38 3233857 1 Gear, 37T39 3233847 1 Gear, 47T40 3233608 4 Screw41 3233609 1 Cover, Bearing42 3233106 1 Ring, Retaining43 3233357 1 Spacer44 3233607 1 Bearing, Ball45 3233606 1 Shaft, Pinion, 10T46 3233619 1 Washer, Thrust47 3233843 1 Sprocket, 19T48 3233621 1 Gear, 31T49 3233622 1 Shaft, Output, Main, Rear50 3233582 1 Button, Thrust51 3233583 AR Shim52 3233611 AR Shim53 3233845 1 Cover, Output, Front54 3233846 17 Screw, Tapping (Qty. 15 after 7/08/02)55 3233777 1 Plug56 3233254 1 Washer57 3233625 1 Shaft, Output, Main, Front58 3233408 1 Chain, Silent59 3233844 1 Sprocket, 22/22T60 3233552 1 Bushing61 3233833

323404611


62 3233324 1 Washer63 3233840 1 O-Ring64 3233839 1 Gear, 16T65 3233838 1 Disc, Lockout66 3233837 1 Star, Detent67 3233836 1 O-Ring68 3233830 1 Spring, Compression69 3233835 1 Switch70 3233834 1 Ring, Retaining71 3233825 1 Bellcrank72 1341355

1341464

1

1

Asm., Main Gearcase(If built before 7/08/02)Asm., Main Gearcase(If built after 7/08/02)

11/02

D7

GEARCASE (6X6)RANGER 6X6 SERIES 11 A11RF50AA

12 3

45 6

78 9

10

1112

13

14

1516

17

222324

25

2423

11 2627 26

28293031

3233 34

35282627 26

313637 38

11

11

3940

4142

4344

45

15 1446

4748

49 5051

7

52 5354

5556

14

57

58

59601561

62

6364

65

666768

6970

71

18

2120

19

72


D8

GEARCASE (6X6)RANGER 6X6 SERIES 11 A11RF50AA



1 3233961 1 Nut2 3233826 5 Screw3 3233827 1 Cover4 3233829 1 Pawl, Detent5 3233828 1 O-Ring6 3233831 1 Shaft, Shift7 3233842 2 Seal8 3233832 1 Gear, 31T9 3233711 1 Plug, Oil Fill10 3233524 1 Tube, Vent11 3233018 4 Bearing12 3233036 1 Chain, Silent13 3233889 1 Shaft, Input14 3233019 4 Bearing15 3233529 4 Pipe, Knock16 3233865 1 Cover, LH17 3233866 1 Seal18 3234042 2 Screw (If built after 7/08/02)19 3234044 1 Bracket, Trans Mount

(If built after 7/08/02)20 3234045 2 Spacer (If built after 7/08/02)21 3234043 2 Nut, Lock (If built after 7/08/02)22 3233841 1 Drum, Shift23 3233858 2 Fork, Shift24 3233859 2 Pin, Dowel25 3233860 1 Rail, Shift Shaft26 3233875 4 Engagement Dog27 3233849 2 Spring, Wave28 3233850 2 Ring, Retaining29 3233851 1 Washer30 3233852 1 Gear, 33T31 3233718 2 Bearing, Needle32 3233892 1 Shaft, Reverse33 3233103 1 Bearing, Needle34 3233893 1 Sprocket, 24T35 3233894 1 Washer36 3233855 1 Washer37 3233856 1 Gear, 30T

38 3233857 1 Gear, 37T39 3233847 1 Gear, 47T40 3233608 4 Screw41 3233609 1 Cover, Bearing42 3233106 1 Ring, Retaining43 3233357 1 Spacer44 3233607 1 Bearing, Ball45 3233606 1 Shaft, Pinion, 10T46 3233619 1 Washer, Thrust47 3233843 1 Sprocket, 19T48 3233621 1 Gear, 31T49 3233911 1 Shaft, Output, Main, Rear50 3233582 1 Button, Thrust51 3233583 AR Shim52 3233611 AR Shim53 3233845 1 Cover, Output, Front54 3233846 17 Screw, Tapping (Qty. 15 after 7/08/02)55 3233777 1 Plug56 3233254 1 Washer57 3233625 1 Shaft, Output, Main, Front58 3233408 1 Chain, Silent59 3233844 1 Sprocket, 22/22T60 3233552 1 Bushing61 3233833

323404611


62 3233324 1 Washer63 3233840 1 O-Ring64 3233839 1 Gear, 16T65 3233838 1 Disc, Lockout66 3233837 1 Star, Detent67 3233836 1 O-Ring68 3233830 1 Spring, Compression69 3233835 1 Switch70 3233834 1 Ring, Retaining71 3233825 1 Bellcrank72 1341426

1341465

1

1

Asm., Gearcase(If built before 7/08/02)Asm., Gearcase(If built after 7/08/02)

11/02

D9

MID GEARCASERANGER 6X6 SERIES 11 A11RF50AA

23

4

56

7

89

10 11

12 13

1415 16

17 18

1920

2122

23

24

25 26

3

13

2

215

16

17

1

1

27




1 3233252 15 Screw2 3233805 3 Plug3 3233803 2 Seal4 3233524 1 Tube, Vent5 3233982 1 Cover, Output6 3233581 1 Shim7 3233268 1 Bearing, Ball8 3233985 1 Gear, Ring 37T9 3233986 1 Shaft, Output10 3233806 1 Bearing, Ball11 3233987 1 Spring, Wave12 3233988 1 O-Ring13 3233529 4 Pipe, Knock14 3233788 1 Seal, Triple Lip

15 3233306 2 Ring, Retaining16 3234050 2 Washer, Thrust17 3233989 2 Bushing18 3233983 1 Gearcase, R1119 3233292 1 Bushing20 3233990 1 Pinion, 10T21 3233991 1 Gear, 26T Output22 3233589 1 Bearing, Ball23 3233992 1 Shaft, Output24 3233993 1 Gear, 26T Input25 3233984 1 Cover, Input26 3233785 1 Seal, Triple Lip27 1341405 1 Asm., Mid Gearcase

1/03

D10

GEAR SELECTOR/DIFFERENTIAL LOCKRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


18

10

21

23

20

1222

17

9

11

1516

4

3 5

8

24

21

6

20

2

14

13

7

2x4 and 4x4 ONLY

19

7




1 2250044 1 Pin, Hitch (2X4, 4X4)2 7555919 2 Washer (2X4, 4X4)3 5431107

5433189

2

2

Bushing, Pedal Pivot(2X4, 4X4)(If built before 6/02/03)Bushing, Pedal Pivot(2X4, 4X4)(If built after 6/02/03)

4 1013584 1 Lock, Differential (2X4, 4X4)5 7042029 1 Spring (2X4, 4X4)6 7558302 3 Washer (2X4, 4X4)7 7661140 2 Clip (2X4, 4X4)8 7080939 1 Cable, Differential (2X4, 4X4)9 7542344 1 Nut, Nylok10 5132928 1 Bearing, Shifter11 7547144 1 Nut, Nylok

12 7081005 1 Cable, Shifter13 7555923 2 Washer (2X4, 4X4)14 4020149 1 Clip (6X6)15 7555795 1 Washer, Wave16 7555976 1 Washer, Cone17 7517745 1 Bolt, Shoulder18 1541628 1 Shifter19 5412294 1 Plug (6x6 Only)20 5412154 2 Grommet (Qty. 1 for 6x6)21 5411007 1 Knob, Shifter22 7517756 1 Screw23 5412079 1 Cover24 7081016 1 Knob, Differential Lock (2X4, 4X4)

7/03

D11

CYLINDERRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


2

22

40

252423

14

5

4

39

127

36

9

27

31

1819

3

6

20

29

1

28

15

37

30

35

33

34

8

13

32

38

16

26

17

21

5

38

38

15

9

1011


D12

CYLINDERRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB



1 3083166 1 Asm., Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt4 3084857 2 Pin, Straight5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve7 3084867 1 O-Ring8 3085072

3088208

1

1

Adapter, Water Out(If built before 8/9/02)Adapter, Water Out(If built after 8/9/02)

9 3084877 10 Bolt, Flange10 3085359 1 Bolt, Flange (If built after 8/9/02)(2x4)11 3082758 1 Gasket, Aluminum

(If built after 8/9/02)(2x4)12 3084866 1 Adapter, Camshaft13 3085074 1 Gasket, Rocker Cover14 3085073 1 Cover, Rocker15 3084874 10 Bolt, Flange16 3084859 2 Seal, Exhaust Valve17 3084875 4 Bolt, Cylinder Head18 3084860 1 Plug19 3084861 1 Gasket20 3084862 1 Plug, Blind21 3084215 2 Bolt, Flange

22 3085075 1 Gasket, Exhaust23 3085326 2 Stud24 3080530 2 Washer, Lock25 3080285

308719922

Nut (If built before 8/9/02 in 2x4)Nut (If built after 8/9/02 in 2X4)(4x4)(6x6)

26 3085854 1 Bolt, Rocker Shaft27 3084876 4 Bolt28 3084864 1 Support, Valve Rocker Shaft (PTO)29 3084863 1 Support, Valve Rocker Shaft (MAG)30 3084838

3087266

2

2

Pin, Straight(If built before 8/9/02 in 2x4)Pipe Knock(If built after 8/9/02 in 2X4)(4x4)(6x6)

31 3084849 1 Union, Oil Pump32 3084873 4 Bolt, Flange33 3087062

308681111

Cylinder (Incl. 34)(2x4)Cylinder (Incl. 34)(4x4,6x6)

34 3084130 1 Pipe 2, Elbow35 3085370 1 Gasket, Cylinder36 3088717 1 Cover, Camshaft37 3086200 1 Gasket, Cover, Cam38 3085527 1 Head, Cylinder (Incl. 4-6,16,18-20,23)39 3085337

308537111

Gasket, Head (2x4)Gasket, Head (4x4)(6x6)

40 3084879 1 Adapter

1/03

D13

CARBURETORRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


33

24

21

2829

25

23

622

56

43

16

14

8

21

17

15

7

10

13

9

27

12

3132

26

20

18

11

34

30

18

20 4x4 and 6x6 only


19

D14

CARBURETORRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB



1 3130014 1 Washer2 3130563

3131472

3131426

11

1

Jet, Main (#135)(2x4)Jet, Main (#142.5)(4x4)(6x6)(If built before 1/03)Jet, Main (#135)(4x4)(6x6)(If built after 1/03)

3 3130519 1 Cap4 3130518 1 E-Ring5 3130517 1 Packing6 3130515 2 Seal7 3130361 1 Pin, Float8 3130526

313142111

Jet, Pilot (#42.5)(2x4)Jet, Pilot (#42.5)(4x4)(6x6)

9 3130533 1 O-Ring10 3131361 1 Valve, Needle11 3130594 1 Plate12 3130591 1 Screw13 3130532 1 O-Ring14 3130520 4 Screw15 3131212 1 Asm., Float Body16 3130521 1 Screw17 3130529 1 Asm., Float18 3130546

3131423

1

1

Screw, Adjust(If built before 8/9/02 in 2X4)Screw, Adjust(If built after 8/9/02 in 2X4)(4x4)(6x6)

19 3130545 1 Ring (If built before 8/09/02)20 3130544

313083611

Spring (If built before 8/9/02 in 2X4)Spring (If built after 8/9/02 in 2X4)(4x4)(6x6)

21 3130502 1 Valve, Throttle (100)22 3130589 1 Spring23 3130514 1 Ring24 3130501 2 Screw25 3130513 1 Asm., Throttle Shaft26 3130543 1 Guide, Cable27 3130535 4 Screw28 3130511 1 Cover29 3130512 1 O-Ring (If built before 1/03)30 3130199 1 Cap, Plunger31 3130538 1 Spring32 3130593 1 Asm., Plunger33 3131362

3131519

3131441

1

1

1

Asm., Carburetor (If built before8/9/02)(2x4)(Incl. All Less 26-29)Asm., Carburetor (If built after8/9/02)(2x4)(Incl. All Less 26-29)Asm., Carburetor(4x4)(6x6)(Incl. All Less 26-29)

34 3084205 2 Screw and Washer

4/03

E1

CRANKCASERANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


2

4

11

12

2

20

21

1

23

75

17

3

19 18

9

1615

1314

22

6

5

8

10




1 3083669 1 Bushing, Starter2 3085633

3085808

1

1

Asm., Crankcase(If built before 8/9/02 in 2X4)(Incl. 1,4,5,7,8,11,12,17,20,21,22)Asm., Crankcase(If built after 8/9/02 in 2X4)(4x4)(6x6)(Incl. 1,4,5,7,8,11,12,17,20,21,22)

3 3084838

3087266

2

2

Pin, Straight(If built before 8/9/02 in 2x4)Pin, Knock(If built after 8/9/02 in 2x4)(4x4)(6x6)

4 3080676 3 Bearing, Ball (Qty 1 if built after 1/03)5 3084840 2 Pin, Dowel6 3084205 3 Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3087154 1 Fitting, Oil Inlet (4x4)(6x6)

10 3084842 1 Union11 3084834 2 Bearing, Ball12 3084835 1 Bearing, Ball13 3084845 1 Plug14 3084846 1 Gasket, Aluminum15 3084844 1 Spring, Valve, One Way16 3086810 1 Valve, One Way17 3084841 10 Bolt, Flange18 3082956 1 Gasket19 3083453 1 Plug20 3084837 1 Seal, Mechanical21 3084836 1 Seal, Oil22 3084847 1 O-Ring23 3080103 2 Pin, Dowel

1/03

E2

CRANKSHAFT and PISTONRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


19

20

72114 12

6

9

17

1310

18

8

11

1

1522

16

2

3

1

23

5 4


Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3085534 2 Clip2 3086207

3087230

3086208

3087231

3086209

3087232

3087221

3087222

3087223

1

1

1

1

1

1

1

1

1

Asm., Piston Set(Std)(Incl. 1)(If built before 8/9/02)(2x4)Asm., Piston Set(Std)(Incl. 1)(If built after 8/9/02)(2x4)Asm., Piston Set (0.25 O/S)(Incl. 1)(If built before 8/9/02)(2x4)Asm., Piston Set (0.25 O/S)(Incl. 1)(If built after 8/9/02)(2x4)Asm., Piston Set (0.50 O/S)(Incl. 1)(If built before 8/9/02)(2x4)Asm., Piston Set (0.50 O/S)(Incl. 1)(If built after 8/9/02)(2x4)Asm., Piston Set (Std)(Incl. 1)(4x4)(6x6)Asm., Piston Set (0.25 O/S)(Incl. 1)(4x4)(6x6)Asm., Piston Set (0.50 O/S)(Incl. 1)(4x4)(6x6)

3 3086488

3087233

3086489

3087234

3086490

3087235

308722430872253087226

1

1

1

1

1

1

111

Piston Ring Set (Std)(If built before 8/9/02)(2x4)Piston Ring Set (Std)(If built after 8/9/02)(2x4)Piston Ring Set (0.25 O/S)(If built before 8/9/02)(2x4)Piston Ring Set (0.25 O/S)(If built after 8/9/02)(2x4)Piston Ring Set (0.50 O/S)(If built before 8/9/02)(2X4)Piston Ring Set (0.50 O/S)(If built after 8/9/02)(2X4)Piston Ring Set (Std)(4x4)(6x6)Piston Ring Set (0.25 O/S)(4x4)(6x6)Piston Ring Set (0.50 O/S)(4x4)(6x6)

4 3080676 1 Bearing, Ball (4x4)(6x6)5 3085815 1 Bearing, Ball (4x4)(6x6)6 3085340

3087229

30887193085812

1

1

11

Crankshaft 2(If built before 8/9/02)(2x4)Crankshaft 2 (If built between 8/9/02 and1/03)(2X4)Crankshaft 2 (If built after 1/03)(2x4)Crankshaft 2 (4x4)(6x6)

7 3085341 1 Pin, Crank8 3086206

308537611

Rod, Connecting (2x4)Rod, Connecting (4x4)(6x6)

9 3085400 1 Bearing, End, Large10 3085024 1 Ball, Steel11 3085852 1 Gear 1, Balancer12 3085404 1 Shaft, Balancer13 3084895

30848963084897

111

Spacer (0.8)Spacer (1.0)Spacer (1.2)

14 3240088308489230848933084894

1111

Spacer (0.6)Spacer (0.8)Spacer (1.0)Spacer (1.2)

15 3084882 1 Sprocket 116 3085528 1 Nut, Slit17 3083905 1 Nut, Lock18 3083904 1 Washer19 3085346 1 Pin, Dowel20 3081447 1 Key21 3084881

3087228

308533930888173087227

3085373

1

1

111

1

Asm., Crankshaft (Incl. 6-11,19)(If built before 8/9/02 in 2X4)Asm., Crankshaft (Incl. 6-11,19)(If built after 8/9/02 in 2X4)Crankshaft 1 (If built before 1/03 in 2x4)Crankshaft 1 (If built after 1/03 in 2x4)Asm., Crankshaft(Incl. 6-11,19)(4x4)(6x6)Crankshaft 1 (4x4)(6x6)

22 3080130 1 Key, Woodruff23 3085344 2 Spacer (If built before 1/03)(2x4)

1/03

E3

INTAKE and EXHAUSTRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


14

18

15

1617

25

26

13 12 11

106

98

22

7

19

8

21

24

4

3

21

5

20

27

23

8

9

69

1211

13




1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3086839 1 Spring, Tensioner4 3086813 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Rocker Arm, Intake (Incl. 8,9)7 3084913 1 Asm., Rocker Arm, Exhaust (Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3087203

3086893

4

4

Retainer, Spring (If built before 8/09/02and after 1/03 in 2x4)(4x4)(6x6)Retainer, Spring (If built after 8/09/02and before 1/03 in 2x4)

13 3084906 4 Spring, Valve

14 3086212 1 Camshaft (Incl. 15-18)15 3086838 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3084914 1 Sprocket 220 3081657 3 Bolt and Washer21 3084916 1 Guide, Chain22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot24 3084917 1 Lever25 3085349 2 Valve, Intake26 3085412 2 Valve, Exhaust27 3084874 2 Bolt, Flange

1/03

E4

FLYWHEEL COVERRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


6

1

2

4

1

2 3

5




1 3083453 2 Plug2 3082956 2 Gasket3 3083669 1 Bushing, Starter4 3084877 9 Bolt, Flange

5 3084933 1 Gasket (If built before 8/9/02)(2x4)6 3087146

3087200

1

1

Cover, Flywheel (Incl. 3)(If built before 8/9/02 in 2x4)Cover, Flywheel (Incl. 3)(If built after 8/9/02 in 2x4)(4x4)(6x6)

1/03

E5

WATER PUMPRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


11

7

8

3

3

2

1

9

12

13

4

10

65




1 3084940 1 Thermostat2 3085352 1 Switch, Thermostat3 3084191 2 Clamp, Hose4 3085857 1 Hose, Main5 3085359 1 Bolt, Flange6 3082758 1 Gasket, Aluminum7 3085351 1 Cover, Water Pump

8 3086840 1 Gasket, Water Pump9 3085077 1 Nut, Self Lock10 3083138 1 Gasket, Aluminum11 3084935 1 Impeller12 3084942 1 Washer, Seal13 3084877 4 Bolt, Flange

7/00

E6

OIL PUMPRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


4

1

10

3

2

11

15

87

6

13

14

5

16

17

9

12




1 3084946 1 Pump, Oil, Case 22 3084949 1 Rotor, Outer (Feed)3 3084948 1 Rotor, Inner (Feed)4 3084944

308494511

Asm., Oil Pump (Incl. 1-8,10-15)Pump, Oil, Case 1

5 3085535 1 Screw6 3084955

308815622

Pin, Dowel (If built before 1/03)Pin, Dowel (If built after 1/03)

7 30849543088155

22

Pin, Dowel (If built before 1/03)Pin, Dowel (If built after 1/03)

8 3084953 1 Washer

9 3084962 3 Bolt and Washer10 3084947 1 Pump, Oil, Case 311 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Unit, Oil Strainer14 3084205 3 Screw and Washer15 3084952 1 Shaft, Pump16 3084958 1 Gear 2, Pump17 3084959

30849603084961

ARARAR

Spacer (0.8)Spacer (1.0)Spacer (1.2)

1/03

E7

OIL FILTERRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1

4

5

3

3

3

2

2

2

2

2




1 3084963 1 Filter, Oil2 3084846 8 Gasket, Aluminum3 3086815 4 Bolt, Banjo

4 3084964 1 Pipe, Oil Delivery 15 3085638 1 Pipe, Oil Delivery 2

7/00

E8

MAGNETORANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


17 6

5

8

9

1011

1213

4

7

1 2

15

3

14

16

18

15

161920

21




1 30849793085228

3085227

11

1

Coil, Ignition (If built before 8/9/02 in 2x4)Coil, Ignition (If built after 8/9/02 in 2x4)(4x4)(6x6)Asm., Ignition Coil (Incl. 1,2)(4x4)(6x6)

2 3084980 1 Cap, Spark Plug3 3070175 1 Plug, Spark, BKR5E4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3086859

3087167

30849713086981

1

1

11

Asm., Plate (Incl. 5,6,8-14)(If built before 8/9/02 in 2x4)Asm., Plate (Incl. 5,6,8-14)(If built after 8/9/02 in 2x4)(4x4)(6x6)Plate (If built before 8/9/02 in 2x4)Plate (If built after 8/9/02 in 2x4)(4x4)(6x6)

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3086860

308716811

Stator (Incl. 13)(If built before 8/9/02 in 2x4)Stator (Incl. 13)(If built after 8/9/02 in 2x4)(4x4)(6x6)

10 3081342

3086985

3

3

Screw and Washer(If built before 8/9/02 in 2x4)Screw and Washer(If built after 8/9/02 in 2x4)(4x4)(6x6)

11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3081256 1 Screw and Washer15 3085639

3087169

3087201

11

1

CDI System (If built before 8/9/02 in 2x4)CDI System (If built after 8/9/02 in 2x4)(If built after 1/03 in 4x4 and 6x6)CDI System(If built before 1/03 in 4x4 and 6x6)

16 3085521

3087198

1

1

Switch, Magnetic(If built before 8/9/02 in 2x4)Switch, Magnetic(If built after 8/9/02 in 2x4)(4x4)(6x6)

17 3086857

3087166

1

1

Flywheel w/Ring Gear(If built before 8/9/02 in 2x4)Flywheel w/Ring Gear(If built after 8/9/02 in 2x4)(4x4)(6x6)

18 3085359 2 Bolt, Flange (Use w/3087198)19 3084977 1 Clamp (If built before 8/9/02)(2x4)20 3083073 2 Nut (If built before 8/9/02)(2x4)21 3080077 2 Washer, Spring (If built before 8/9/02)(2x4)

1/03

E9

STARTING MOTORRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


10

13

2

5

11

4

3

12 14

18

17

16

15

67

9

8

1




1 3084981 1 Asm., Starting Motor (Incl. 2-5,7-11,13)2 3084982

308816311

Washer Set (If built before 1/03)Washer Set (If built after 1/03)

3 30844063088169

11

Brush Set, Carbon (If built before 1/03)Brush Set, Carbon (If built after 1/03)

4 30836493088166

22

Nut, Flange (If built before 1/03)Nut, Flange (If built after 1/03)

5 30844083088165

33

O-Ring (If built before 1/03)O-Ring (If built after 1/03)

6 3082038 2 Bolt and Washer7 3085034 1 Asm., Bracket, Rear8 3085353

308816811

Asm., Armature (If built before 1/03)Asm., Armature (If built after 1/03)

9 30850333088160

11

Asm., Bracket, Front (If built before 1/03)Asm., Bracket, Front (If built after 1/03

10 32401143088161

11

O-Ring (If built before 1/03)O-Ring (If built after 1/03)

11 30849833088164

22

Asm., Set Bolt (Incl. 5)(If built before 1/03)Asm., Set Bolt (Incl. 5)(If built after 1/03)

12 3087030 1 Asm., Gear Shaft (Incl. 14-18)13 3084405

308816222

Ring, Rubber (If built before 1/03)Ring, Rubber (If built after 1/03)

14 3083737 1 Washer, Gear Shaft15 3084412 1 Clip16 3084411 1 Spring, Weight17 3084410 1 Spring, Return18 3084409 1 Clip

1/03

E10

TOOL KITRANGER 2X4 SERIES 11 A11RB42AA and RANGER 4X4 SERIES 11 A11RD50AA and RANGER 4X4 SERIES 11 A11RD50AB


1

3

8

2

9

4

5

6

7

10




1 3085383 1 Kit, Tool (Incl. 3-8)2 2870725 1 Gauge, Tire Pressure3 3082657 1 Screwdriver4 3085001 1 Wrench, 8-10 Open5 3085002 1 Wrench, 12-14 Open

6 3085568 1 Wrench, Box7 3085569 1 Puller, Spark Plug (Wrench Handle)8 2682572 1 Pouch, Tool Kit9 9918186 1 Owner’s Manual10 2871348 1 Wrench, Open 1/2-9/16

1/03

E11

BRUSH/HEADLIGHT GUARDRANGER 4X4 SERIES 11 A11RD50AB

8

6

7

3

5

10

1

4

9

2

4

210

1

1

1

(See Chassis/Body Pg. A4 for A11RD50AA Bumper)


9



1 7515307 8 Screw (AB)2 1013785-418 2 Guard, Headlight (AB)3 1013789-418 1 Guard, Brush, FBW (AB)4 7517428 6 Screw (AB)5 1013866-418

1013867-41811

Mount, Brush Guard, LH (AB)Mount, Brush Guard, RH (AB)

6 5245329-418 1 Plate, Grill, Upper, FBW (AB)7 5245626-418 1 Plate, Grill, Top, FBW (AB)8 1014004-418 1 Bumper, FBW (AB)9 7542423 14 Nut, Flange (AB)10 7080523 2 Knob, Guard (AB)

7/03

PARTS MANUAL PN 9918179 and MICROFICHE PN 9918180 7/03PRINTED IN THE USA

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Date post:	14-Feb-2019
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