Diagram(s) and/or PartsList(s) · 2012. 2. 12. · 17 0423-361 8 Screw, Machine 18 0509-022 1...

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 1 of 86ACCELERATOR ASSEMBLY

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2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 2 of 86ACCELERATOR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 1502-590 Pedal, Accelerator12 0470-851 Spring13 0402-872 Axle14 1602-213 O-Ring2 /P5 8422-002 Nut, Lock16 8471-616 Screw, Machine27 0502-991 Bracket, Accelerator Pedal18 8427-602 Nut, Lock29 0487-066 Cable, Accelerator1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 3 of 86AIR INTAKE ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 4 of 86AIR INTAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0470-861 Cover, Air Intake12 0470-560 Screen, Air Filter13 0470-558 Filter, Air14 0470-728 Housing, Air Intake15 0423-455 Clip, Spring46 1623-287 Clamp, Hose17 0423-766 Cap, Drain18 0610-563 Clamp, Hose19 0470-863 Valve, Drain1

10 0423-342 Screw, Self-Tapping4 /P11 0430-055 Sensor, Air Temperature (inc. 12)112 5507-224 O-Ring113 0423-554 Clamp114 0413-225 Boot, Intake115 0423-019 Clamp616 0413-232 Duct, Intake117 0413-219 Duct, Intake118 0470-834 Filter, Intake119 2516-166 Bracket, Support120 0623-784 Screw, Self-Tapping821 8476-616 Screw, Machine222 2416-088 Boot, Air-In123 0413-237 Duct, Air-In124 0413-098 Boot, Air-In125 0413-236 Duct, Air-In126 0470-442 Valve, Drain2 /P27 0423-018 Clamp128 0413-233 Boot, Air-In129 0423-730 Clamp430 0413-234 Boot, Air-Out131 0423-550 Clamp232 0413-247 Duct, Air-Out133 0413-248 Boot, Air-Out134 0413-235 Duct, Air-Out135 0413-226 Duct, Air-Out136 0470-881 Fitting, Elbow137 1623-281 Clamp, Hose538 0410-187 Hose, Vent139 0470-857 Separator, Oil140 1441-822 Foil, Protective141 0410-221 Hose, Vent142 0410-220 Hose, Vent143 0412-576 Foil, Protective1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 5 of 86BATTERY AND STARTER MOTOR ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 6 of 86BATTERY AND STARTER MOTOR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0445-081 Battery (inc. 2-5)12 0645-588 Cap, Battery6 /P3 0645-152 Clamp, Hose14 0645-262 Hose, Vent15 0645-430 Decal, Warning26 8476-616 Screw, Machine47 2406-914 Box, Battery18 0470-854 Hold-Down, Battery Box - Right19 0470-855 Hold-Down, Battery Box - Left1

10 8424-602 Nut4 /P11 0423-577 Clip, U-Nut112 2406-949 Cover, Battery Box113 1441-624 Screw, Thumb114 0445-078 Cable, Battery/Solenoid115 0645-019 Boot, Terminal216 0623-038 Nut w/Washer517 0445-058 Solenoid1 /P18 8476-625 Screw, Machine419 0445-080 Cable, Solenoid/Starter120 0645-327 Boot, Terminal - Solenoid121 0445-079 Cable, Battery/Ground122 0825-015 Motor, Starter - Assembly1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 7 of 86CAM CHAIN ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 8 of 86CAM CHAIN ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0810-001 Chain, Cam22 0810-046 Guide, Chain23 0810-049 Tensioner, Chain24 0826-106 Pivot, Tensioner25 0810-004 Adjuster, Tensioner - Assembly26 0830-134 Gasket27 8468-620 Screw, Machine4 /P8 8400-610 Screw, Cap29 0828-129 Washer2

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 9 of 86CANOPY AND TAILLIGHT ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 10 of 86CANOPY AND TAILLIGHT ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 2516-108 Tube, Canopy - Front12 0423-886 Screw, Machine43 0423-903 T-Nut44 1436-314 Mirror, Rear-View - Kit (inc. 5-6)1 /P5 0423-896 Nut, Expansion26 0423-904 Screw, Machine27 0423-910 Screw, Machine208 2516-304 Support, Canopy19 2516-106 Tube, Canopy - Rear1

10 1411-864 Decal, Warning - Canopy111 0423-916 Screw, Machine412 8427-805 Nut, Lock413 1506-795 Pad, Headrest - Assembly (inc. 14-16)214 1406-884 Pad, Headrest215 1506-722 Mount, Headrest216 0623-544 Clip, Retaining1017 0423-361 Screw, Machine818 0509-022 Taillight Assembly (inc. 19-21)119 0509-025 Housing, Taillight120 0409-056 Bulb, Taillight121 0409-057 Socket, Taillight122 2406-069 Bracket, Taillight Mounting123 0623-301 Screw, Self-Tapping2 /P

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 11 of 86CARGO BOX AND TAILGATE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 2516-329 Tailgate Assembly (inc. 2-9)12 2406-365 Panel, Tailgate - Inner1 /P3 1406-927 Shaft, Pivot - Tailgate14 0623-784 Screw, Self-Tapping205 1506-704 Brace, Tailgate16 0423-101 Screw, Shoulder107 2506-056 Latch, Tailgate - Assembly18 1406-706 Bushing49 2516-208 Panel, Tailgate - Outer1

10 2411-005 Decal, Tailgate - "Arctic Cat"111 8476-625 Screw, Machine212 0487-045 Cable, Tailgate213 8050-217 Washer6 /P14 2516-335 Box, Cargo115 0417-006 Strip, Foam216 0417-011 Foam, Cargo Box217 0417-010 Foam, Cargo Box218 0423-623 Bolt, Carriage819 1506-933 Plate, Retainer820 8424-802 Nut1421 8474-630 Screw, Machine622 1506-539 Bracket, Tailgate123 2506-664 Striker, Tailgate - Right123 2506-665 Striker, Tailgate - Left1 /P24 8424-602 Nut4 /P25 0624-250 Nut, Lock226 8476-620 Screw, Machine227 1411-119 Decal, Warning - Cargo128 2411-070 Decal, Rail229 2516-330 Rail, Cargo Box - Right129 2516-241 Rail, Cargo Box - Left130 8410-832 Screw, Cap831 0423-907 Washer432 2416-086 Spring133 0423-540 Nut, Lock134 2516-178 Bracket, Cargo Box Latch1 /P35 8476-616 Screw, Machine136 2516-188 Fender, Rear - Assembly - Upper Right (inc.

37-38)1

36 2516-189 Fender, Rear - Assembly - Upper Left (inc. 37-39)

37 0417-007 Strip, Foam238 0417-008 Pad, Foam239 2516-037 Ring, Trim140 1411-120 Decal, Warning - Pinch Point241 2411-066 Decal, Rear Fender - Right141 2411-067 Decal, Rear Fender - Left142 2516-204 Panel, Box - Right142 2516-205 Panel, Box - Left143 1411-128 Decal, Reflector - Right143 1411-129 Decal, Reflector - Left144 0423-342 Screw, Self-Tapping28 /P

Ref # Part Number Qty DescriptionS/P/F45 2411-064 Decal, Box - "Arctic Cat" - Right145 2411-065 Decal, Box - "Arctic Cat" - Left146 1506-776 Bracket, Fender Support - Right146 2506-927 Bracket, Fender Support - Left1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 14 of 86CLUTCH SIDE ENGINE COVERS

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 15 of 86CLUTCH SIDE ENGINE COVERS

Ref # Part Number Qty DescriptionS/P/F1 0806-112 Cover, Outside1 /P2 0830-137 Gasket, Cover13 0806-110 Cover, Inside14 0806-109 Cover, Clutch15 0830-133 Gasket, Clutch Cover16 8468-616 Screw, Machine97 8468-630 Screw, Machine218 0829-001 Pin, Dowel6 S9 0830-013 Washer, Crush1

10 8408-812 Screw, Cap1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 16 of 86CONSOLE AND FLOOR PANEL ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 17 of 86CONSOLE AND FLOOR PANEL ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 2516-456 Panel, Fender - Inner12 0423-577 Clip, U-Nut143 0623-784 Screw, Self-Tapping244 2406-635 Panel, Splash - Inner Fender15 0623-362 Rivet, Reinstallable46 2506-066 Bracket, Support - Right16 2506-067 Bracket, Support - Left17 0423-447 Grommet48 2516-184 Fender, Front - Right18 2516-185 Fender, Front - Left19 0623-855 Screw, Shoulder2

10 8050-217 Washer2 /P11 8048-366 Nut, Lock212 2411-062 Decal, Front Fender - Right112 2411-063 Decal, Front Fender - Left113 2516-313 Bracket, Support114 8476-616 Screw, Machine615 2416-081 Console - Front116 2416-109 Insert, Cupholder117 2416-111 Net, Storage118 0417-019 Foam, Console119 0417-018 Foam, Console120 8468-625 Screw, Machine1221 8468-670 Screw, Machine222 2416-085 Floor123 0423-545 Screw, Shoulder8 /P24 1402-793 Slide, Shift Gate125 1402-794 Slide, Shift126 1502-520 Gate, Shift (inc. 27)127 1411-985 Decal, Shift Gate128 0423-342 Screw, Self-Tapping3 /P29 0409-069 Panel, Switch-Mount130 0409-071 Switch, Reverse Override131 0409-070 Plug, Switch-Hole232 2411-095 Decal, Warning - Console133 2411-094 Decal, Warning - Brake Lever134 2406-951 Console, Center135 2406-960 Boot, Parking Brake Lever136 2516-196 Fender, Rear - Lower - Right136 2516-197 Fender, Rear - Lower - Left137 2516-326 Bracket, Fender Support - Lower238 2416-018 Panel, Splash - Right138 2416-019 Panel, Splash - Left139 8424-602 Nut2 /P40 0423-577 Clip, U-Nut4 F40 0423-466 Clip, U-Nut4 F41 0423-101 Screw, Shoulder4 F41 0423-545 Screw, Shoulder4 /P/F

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 18 of 86COOLING ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 19 of 86COOLING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0513-036 Radiator Assembly (inc. 2-13)12 0413-241 Cooler, Oil13 0413-216 Radiator14 0413-255 Cap, Radiator1 /P5 1623-637 Clip, U-Nut46 0413-195 Plug, Drain17 1602-213 O-Ring1 /P8 0413-217 Bracket, Mounting - Fan19 0413-123 Fan, Cooling1 /P

10 8470-510 Screw, Machine1211 0610-011 Hose - 25 ftAR /P12 0423-351 Clamp, Routing113 0423-030 Grommet214 0423-484 Screw, Shoulder215 0623-038 Nut w/Washer216 0423-028 Bushing, Stem217 0423-632 Clamp, Hose418 0410-183 Hose, Oil Cooler - In119 0410-184 Hose, Oil Cooler - Out120 0423-496 Clamp, Hose1521 0410-094 Hose, Coolant - Radiator/Coolant Pipe122 0410-177 Pipe, Coolant123 0623-784 Screw, Self-Tapping124 0423-594 Clamp, Routing325 0410-180 Hose, Coolant - Coolant Pipe/Water Pump126 0410-116 Hose, Coolant - Crossover127 0410-115 Hose, Coolant - Crossover128 0410-191 Hose, Coolant - Cylinder/Thermostat129 0410-190 Hose, Coolant - Cylinder/Thermostat130 8470-520 Screw, Machine431 0808-092 Cover, Thermostat132 0830-173 O-Ring133 0808-093 Thermostat134 0808-124 Sensor, Engine Coolant Temperature135 0808-189 Housing, Thermostat136 0410-189 Hose, Coolant - Thermostat/Coolant Pipe137 0410-178 Pipe, Coolant w/Bleed Valve138 0423-984 Screw, Bleed1 S39 0423-921 O-Ring140 0410-092 Hose, Coolant - Coolant Pipe/Radiator141 0410-199 Bracket, Mounting - Overflow Bottle142 0423-577 Clip, U-Nut343 8476-616 Screw, Machine344 0413-086 Bottle, Overflow145 0413-087 Plug146 0124-045 Clamp, Hose1 /P47 0623-751 Cable Tie - 11.75 in.AR48 0623-316 Tie, Cable - 14 in.AR49 1623-093 Clamp, Hose1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 20 of 86CRANKCASE ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 21 of 86CRANKCASE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0801-172 Crankcase - Assembly (inc. 2-13)12 0830-035 Seal, Driveshaft13 0832-048 Bearing1 /P4 0832-042 Bearing1 /P5 0832-050 Bearing2 /P6 0832-049 Bearing1 /P7 0832-055 Bearing - Assembly (inc. 8)18 0832-057 Bearing19 0801-002 Plug, Engine Case2

10 0822-052 Seal, Countershaft - Right111 0829-003 Pin, Dowel212 0829-002 Pin, Dowel213 0812-008 Union, Oil Filter114 0812-029 Filter, Oil1 S15 0830-172 O-Ring116 0812-060 Fitting, Oil117 8468-620 Screw, Machine2 /P18 0623-914 Screw, Self-Tapping219 0812-079 Plate, Oil Sump120 0812-052 Valve, Oil-Relief - Assembly121 0830-162 O-Ring, Oil Filler Cover122 0812-081 Cover, Oil Filler123 8468-616 Screw, Machine324 0801-179 Stick, Oil Level125 0830-010 O-Ring126 0812-078 Fitting, Oil - Threaded127 0830-191 Gasket, Breather128 0829-001 Pin, Dowel2 S29 0832-084 Bearing130 0831-086 Circlip131 0801-193 Cover, Breather132 8468-625 Screw, Machine533 8468-630 Screw, Machine234 8412-875 Screw, Cap135 8468-660 Screw, Machine836 8468-640 Screw, Machine237 8412-830 Screw, Cap338 8412-860 Screw, Cap1039 8412-850 Screw, Cap1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 22 of 86CRANKSHAFT AND PISTON ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 23 of 86CRANKSHAFT AND PISTON ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0805-299 Piston Set - Assembly (inc. 2-4)2 /P2 0805-164 Ring, Piston - Set23 0805-199 Circlip, Piston Pin44 0805-198 Pin, Piston25 0805-200 Crankshaft - Assembly1 S6 0805-273 Washer, Thrust1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 24 of 86CYLINDER ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 25 of 86CYLINDER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0830-209 Gasket, Head2 /P2 0804-031 Cylinder23 0829-002 Pin, Dowel84 0827-002 Bolt, Stud45 0827-018 Bolt, Stud46 8424-604 Nut87 0830-193 Gasket, Base28 0804-037 Plug, Cylinder19 0830-007 O-Ring2

10 0804-046 Union, Coolant Hose111 8468-612 Screw, Machine212 0804-030 Union, Coolant Hose113 8468-630 Screw, Machine214 0801-174 Cover, Breather115 0830-134 Gasket1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 26 of 86CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 27 of 86CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0808-135 Head, Cylinder - Assembly (inc. 2-17)2 S2 0829-001 Pin, Dowel4 S3 0826-001 Screw, Cap84 0809-202 Arm, Valve Rocker - Intake (inc. two No. 5-6)2 S5 0809-033 Screw, Adjuster8 S6 0827-007 Nut87 0809-205 Arm, Valve Rocker - Exhaust (inc. two No.

5-6)2 S

8 0809-008 Shaft, Rocker Arm - Exhaust29 0809-007 Shaft, Rocker Arm - Intake2

10 0809-014 Cotter, Valve1611 0809-013 Retainer, Spring812 0809-138 Spring, Valve8 S13 0830-016 Seal, Oil8 S14 0809-006 Seat, Spring - Valve815 0809-040 Valve, Exhaust4 S16 0809-039 Valve, Intake4 S17 0831-041 Plug, Shaft418 0809-246 Camshaft, Front Cylinder1 /P18 0809-248 Camshaft, Rear Cylinder1 /P19 0809-002 Sprocket220 0826-034 Screw, Cap421 0828-004 Plate, Retainer222 0829-008 Pin, Dowel223 0809-003 C-Ring224 0808-077 Plug, Cylinder Head225 0826-007 Screw, Cap1226 0808-003 Cap, Inspection427 0830-167 O-Ring4 /P28 0808-090 Screw, Cap829 0830-147 Washer8 /P30 0830-107 Gasket831 0826-002 Screw, Cap432 0826-005 Screw, Cap433 0826-006 Screw, Cap434 0217-799 Spark Plug2 /P/F35 0830-120 Seal236 0808-008 Cover, Thermostat237 0827-062 Bolt, Stud238 8424-804 Nut239 0827-030 Bolt, Stud440 8424-604 Nut4

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 28 of 86DASH ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 29 of 86DASH ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 2406-779 Panel, Dash12 0623-784 Screw, Self-TappingAR3 1623-697 Plug14 0423-419 Screw, Machine35 1411-904 Decal, Starting16 1411-124 Decal, Warning - Differential Lock17 0641-897 Outlet, Accessory - 12V2 /P8 0430-089 Switch, Ignition (inc. 9-11)1 /P9 0430-050 Nut, Flange - Ignition Switch1

10 0430-042 Key, Ignition - Series (Y Series - Left-Side Cut)

10 0430-043 Key, Ignition - Series (Z Series - Right-Side Cut)

11 0430-054 Cover, Key112 0420-076 Light, Indicator113 0409-069 Panel, Switch-Mount114 0409-067 Switch, Light115 0409-061 Switch, 2WD/4WD/Differential Lock116 0409-070 Plug, Switch Hole117 0423-541 Grommet, Latch - Glove Box118 2516-723 Cover, Glove Box (inc. 19)1 S19 2411-142 Decal, Warning - Passenger1 S20 1406-727 Pod, Instrument121 1411-125 Decal, Warning - Dash122 0423-342 Screw, Self-Tapping6 /P23 0520-047 Gauge, Analog/LCD1 F23 0520-075 Gauge, Analog/LCD1 F24 0420-065 Bracket, Retaining1 /P25 0423-493 Nut w/Washer226 1623-031 Screw, Self-TappingAR27 0623-228 SpacerAR

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 30 of 86DRIVE TRAIN ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 31 of 86DRIVE TRAIN ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 1402-620 Bladder, Gearcase2 /P2 0423-670 Clamp, Hose43 8428-002 Nut, Lock44 0423-426 Washer85 0423-404 Screw, Cap46 1502-558 Gearcase, Front17 1402-795 Driveshaft, Front18 8409-025 Screw, Cap39 0402-966 Boot, Shaft1

10 1502-404 Gearcase, Rear111 0410-070 Hose, Vent - 25 ftAR /P12 0419-392 Conduit, Flexible - 3 ftAR13 0470-702 Fitting, Vent1 /P14 1402-203 O-Ring115 1502-560 Driveshaft, Rear - Assembly (inc. 16-20)116 0502-522 Yoke, Slip117 0402-944 Joint, Universal (inc. 18)2 /P18 0423-395 Ring, Retaining819 1502-561 Driveshaft, Rear120 1402-689 Yoke, Flange121 8408-820 Screw, Cap4 /P22 0123-788 Tie, Cable - 8 in.AR /P

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 32 of 86ENGINE AND EXHAUST

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 33 of 86ENGINE AND EXHAUST

Ref # Part Number Qty DescriptionS/P/F1 0800-095 Engine, A950GH2 (inc. 2-3)12 0801-128 Spacer, Engine Mount13 0801-091 Mount, Engine44 0423-426 Washer25 0423-734 Screw, Cap16 0423-451 Screw, Cap17 8428-002 Nut, Lock28 0411-426 Decal, Warning - Clutch Cover19 0412-338 Gasket, Exhaust Pipe2 /P

10 8408-820 Screw, Cap4 /P11 0512-517 Pipe, Exhaust - Front1 /P12 0512-528 Shield, Exhaust Pipe - Upper113 0512-529 Shield, Exhaust Pipe - Lower114 8408-616 Screw, Cap915 8050-222 Washer6 /P16 0423-909 Isolator617 0423-908 Isolator618 0512-519 Pipe, Exhaust - Rear1 /P19 0412-543 Shield, Exhaust Pipe - Rear120 0412-561 Shield, Heat121 8476-616 Screw, Machine422 0423-577 Clip, U-Nut423 0612-668 Spring, Extension6 /P24 0412-375 Seal, Exhaust Pipe2 /P25 0512-500 Muffler - Assembly (inc. 26-27 and three No.

26 0412-313 Gasket, Spark Arrester127 0512-219 Arrester, Spark - Assembly1 /P28 8476-612 Screw, Machine629 0412-553 Bracket, Muffler Support230 0412-544 Bushing431 0412-551 Cover, Muffler1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 34 of 86FRAME AND RELATED PARTS

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 35 of 86FRAME AND RELATED PARTS

Ref # Part Number Qty DescriptionS/P/F1 2516-225 Frame, Main (inc. 2)12 0406-879 Bumper, Seat13 8408-820 Screw, Cap8 /P4 2516-556 Bracket, Mounting - Bumper15 8409-020 Screw, Cap2 /P6 8427-002 Nut, Lock27 0505-625 Support, Steering18 0423-817 Screw, Machine129 8476-820 Screw, Machine2

10 1506-797 Bracket, Steering Support - Right110 0502-853 Bracket, Steering Support - Left111 8424-802 Nut612 8408-870 Screw, Cap613 1506-844 Bracket, Seat Support - Front - Right113 1506-845 Bracket, Seat Support - Front - Left114 8427-802 Nut, Lock1615 1506-842 Bracket, Seat Support - Rear216 0423-577 Clip, U-Nut1217 8408-850 Screw, Cap618 8476-616 Screw, Machine419 2506-638 Support, Canopy120 2516-102 Support, Overhead - Right120 2516-103 Support, Overhead - Left121 2416-076 Plate, Skid - Center122 0423-545 Screw, Shoulder20 /P23 1406-721 Panel, Belly - Side224 1441-442 Insert825 2516-596 Plate, Skid - Right Side125 2516-597 Plate, Skid - Left Side126 8477-616 Screw, Machine1227 2506-779 Bumper128 8408-860 Screw, Cap429 2406-713 Fascia, Bumper - Front130 1411-122 Decal, Warning - Towing - Front131 1411-123 Decal, Warning - Towing - Rear1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 36 of 86FRONT BRAKE ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 37 of 86FRONT BRAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0502-786 Cylinder, Master Brake - Assembly (inc. 2-4)12 0405-225 Cap, Reservoir13 0402-592 Nut24 1402-520 Clevis15 1402-377 Pin, Clevis16 8050-217 Washer1 /P7 0117-868 Pin, Cotter18 8424-802 Nut29 8408-860 Screw, Cap2

10 0423-178 Washer, Crush711 0423-610 Bolt, Banjo-Fitting - Double112 0423-413 Bolt, Banjo-Fitting213 1402-389 Hose, Brake - Front114 1402-290 Hose, Brake - Front Right115 1502-730 Caliper, Brake - Front Right (inc. 16-22)1 /P15 1502-731 Caliper, Brake - Front Left (inc. 16-22)1 /P16 1436-160 Housing, Caliper - Assembly - Front Right

(inc. 17-19)1 /P

16 1436-161 Housing, Caliper - Assembly - Front Left (inc. 17-19)

17 0502-606 Piston/Seal Set (inc. 18)218 0502-607 Seal Set219 0502-609 Valve, Bleed2 /P20 0502-608 O-Ring, Guide - Set221 0502-690 Bracket Assembly222 1502-694 Pad, Brake - Set2 S23 8408-826 Screw, Cap424 0502-785 Spring, Brake Switch125 0409-089 Switch, Brake - Assembly126 1502-692 Lever, Brake127 1602-213 O-Ring2 /P28 8427-002 Nut, Lock1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 38 of 86FRONT DRIVE GEARCASE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1502-558 Complete Front Drive Gearcase Assembly1

1 1502-559 Shaft, Coupler - Assembly (inc. 2-5)12 0502-331 Coupler, Driveshaft13 0402-944 Joint, Universal (inc. 4)1 /P4 0423-395 Ring, Retaining45 0502-518 Yoke, Slip16 1402-011 Seal17 0423-423 Ring, Retaining18 1502-237 Bracket, Actuator19 0502-585 Actuator (inc. 10)1 S

10 1402-981 O-Ring111 0423-892 O-Ring1 /P12 0423-396 Screw, Self-Tapping313 1402-043 Bearing114 0423-118 Screw, Self-Tapping1115 0502-528 Housing, Pinion1 /P16 0402-947 Gasket117 0423-417 Ring, Retaining118 0402-997 Shaft, Selector119 0423-402 Ring, Retaining120 0402-998 Fork, Selector121 0402-417 Shaft, Shuttle122 0423-147 O-Ring123 0402-999 Spring, Return124 0402-413 Coupler, Drive125 0402-357 Collar, Lock126 0502-784 Gear, Pinion - Assembly - 11T (inc. 27-28)127 0402-336 Collar, Retaining128 0402-327 Bearing129 0502-514 Housing, Gearcase130 0402-328 Bearing131 0402-411 Pin, Dowel132 1402-210 Plug, Magnetic (inc. one No. 33)1 /P33 0423-153 O-Ring234 0423-149 O-Ring135 0402-393 Bearing136 0402-405 Shim, 41 x 49 x 1.3 mmAR36 0402-406 Shim, 41 x 49 x 1.4 mmAR36 0402-407 Shim, 41 x 49 x 1.5 mmAR36 0402-408 Shim, 41 x 49 x 1.6 mmAR36 0402-409 Shim, 41 x 49 x 1.7 mmAR37 1502-554 Gear, Ring - 34T1 /P38 1402-074 Shim, 61 x 69 x 1.3 mmAR38 1402-075 Shim, 61 x 69 x 1.4 mmAR38 1402-076 Shim, 61 x 69 x 1.5 mmAR38 1402-077 Shim, 61 x 69 x 1.6 mmAR38 1402-078 Shim, 61 x 69 x 1.7 mmAR39 1502-580 Cover, Gearcase (inc. one No. 33, 40-51, and

one No. 52)1

40 1402-053 Bearing141 0502-413 Flange, Bearing142 1402-079 Pin, Alignment1

Ref # Part Number Qty DescriptionS/P/F43 1402-042 Collar, Sliding144 1402-054 Fork145 1402-058 Ring, Retaining246 1402-057 Spring147 1402-063 Spring148 1402-656 Shaft, Lock149 1402-103 Fitting150 1402-211 Plug, Oil Level (inc. one No. 33)151 1402-056 Seal152 1402-713 Seal2 S53 0402-333 Plug, Fill (inc. 54)1 /P54 0423-154 O-Ring1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 41 of 86FRONT SUSPENSION ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 42 of 86FRONT SUSPENSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0423-920 Retainer, Spring22 0503-398 Spring, Suspension23 0403-215 Shock Absorber (inc. 4)24 0423-917 Sleeve, Shock - Threaded25 0423-919 Nut, Spring Retainer26 8409-055 Screw, Cap47 8428-002 Nut, Lock128 0503-432 A-Arm, Upper Right (inc. 9-12)18 0503-433 A-Arm, Upper Left (inc. 9-12)19 0403-208 Bushing16 /P

10 0403-214 Axle8 /P11 0423-009 Ring, Retaining4 /P12 0405-115 Ball Joint4 /P13 0423-946 Screw, Self-Tapping414 1502-594 Clamp, Routing215 8409-075 Screw, Cap816 0503-376 A-Arm, Lower Right (inc. 9-12)1 /P16 0503-377 A-Arm, Lower Left (inc. 9-12)1 /P17 1406-034 Guard, Boot - Right117 1406-035 Guard, Boot - Left118 0423-545 Screw, Shoulder4 /P19 1502-347 Axle - Front - Right (inc. 20-21)1 S19 1502-348 Axle - Front - Locking - Left (inc. 20-21)1 /P20 0423-844 Ring, Retaining2 /P21 1436-207 Repair Kit, Boot - Front Axle2 /P22 0505-580 Knuckle - Assembly - Right (inc. 23-24)1 /P22 0505-581 Knuckle - Assembly - Left (inc. 23-24)1 /P23 1402-809 Bearing2 /P24 0423-423 Ring, Retaining225 8409-030 Screw, Cap4

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 43 of 86GAS TANK ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 44 of 86GAS TANK ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0570-309 Tank, Gas - Assembly (inc. 2-5)12 0470-541 Cap, Gas Tank (inc. 3)1 /P3 1670-228 Gasket, Gas Tank Cap14 0423-898 Screw, Self-Tapping65 2670-042 Plate, Retaining16 0570-334 Pump, Fuel - Assembly (inc. 7)1 /P7 0470-838 Seal18 0570-293 Hose, Gasline19 0123-788 Tie, Cable - 8 in.AR /P

10 1406-886 Insert, Gas Tank Cap111 0423-357 Nut, Stamped412 0470-829 Bracket, Hold-Down - Right113 0623-784 Screw, Self-Tapping214 0470-830 Bracket, Hold-Down - Left115 8476-650 Screw, Machine116 8427-602 Nut, Lock117 8476-620 Screw, Machine218 0470-544 Bracket, Hold-Down - Front119 0623-038 Nut w/Washer220 0423-688 Clamp, Hose121 0410-070 Hose, Gasline - 25 ftAR /P

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 45 of 86GEAR SHIFTING ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 46 of 86GEAR SHIFTING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 8470-516 Screw, Machine22 0409-091 Switch, Gear Position13 0818-013 Contact24 0818-017 Spring25 0828-040 Washer16 0818-046 Shaft, Gear Shift - Assembly17 0828-095 Washer, Thrust28 0832-052 Bearing, Thrust1 /P9 0818-055 Cam, Gear Shift1

10 0826-006 Screw, Cap111 0828-036 Washer112 0831-010 Ring, Retaining113 0818-095 Shaft, Sub-Gear Shift114 0818-014 Arm, Shift115 8468-620 Screw, Machine1 /P16 0828-038 Washer117 0818-002 Stopper, Cam118 0818-004 Support, Cam Stopper119 0818-090 Spring120 0828-035 Washer121 8424-602 Nut1 /P22 0818-072 Fork, Shift2 /P23 0818-006 Shaft, Shift Fork1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 47 of 86HOOD AND HEADLIGHT ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 48 of 86HOOD AND HEADLIGHT ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 2516-302 Hood - Assembly (inc. 2)12 0411-818 Decal, Reflector - Right12 0411-819 Decal, Reflector - Left13 1406-733 Screen, Grille1 /P4 0123-987 Clip, U85 2516-606 Bracket, Hood26 2506-868 Shim, HoodAR7 8408-820 Screw, Cap4 /P8 8427-802 Nut, Lock49 1406-915 Pin, Hood1

10 2606-624 Strap, Hold-Down211 0417-013 Trim, Hood/Dash112 2516-276 Scoop, Hood113 2411-001 Decal, Hood - "1000 EFI"214 1411-789 Decal, Hood115 2411-058 Decal, Hood - Right115 2411-059 Decal, Hood - Left116 2411-068 Decal, Hood - "Prowler XTZ" - Right116 2411-069 Decal, Hood - "Prowler XTZ" - Left117 2411-060 Decal, Hood - Right117 2411-061 Decal, Hood - Left118 0417-014 Trim, Dash SupportAR19 2516-224 Storage, Under-Hood - Assembly (inc. 20-23)1 S/P20 2416-041 Box, Storage121 1406-944 Cover, Access - Master Cylinder122 1406-946 Seal, Storage Box123 0470-442 Valve, Drain1 /P24 8476-616 Screw, Machine225 8424-602 Nut2 /P26 0423-545 Screw, Shoulder4 /P27 0509-044 Headlight Assembly - Right (inc. 28)1 /P27 0509-035 Headlight Assembly - Left (inc. 28)128 0409-055 Bulb, Headlight429 0423-514 Stud, Adjuster230 0423-522 Spring, Adjuster231 0423-513 Knob, Adjuster232 0623-785 Screw, Self-Tapping433 8050-217 Washer8 /P34 0423-447 Grommet4

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 49 of 86MAGNETO ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 50 of 86MAGNETO ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0802-042 Rotor/Flywheel12 0829-012 Key13 0827-010 Nut14 0826-102 Screw, Machine35 0802-041 Stator - Assembly16 0831-064 Clamp17 8470-510 Screw, Machine4

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 51 of 86MAGNETO SIDE ENGINE COVERS

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 52 of 86MAGNETO SIDE ENGINE COVERS

Ref # Part Number Qty DescriptionS/P/F1 0806-107 Cover, Magneto12 0830-132 Gasket, Magneto Cover13 0832-010 Bearing14 0826-155 Plug, Check15 0830-015 Washer, Crush16 0830-176 Seal, Cap1 /P7 0806-066 Cap, Magneto Cover18 8468-650 Screw, Machine49 8468-695 Screw, Machine1

10 8468-665 Screw, Machine3

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 53 of 86OIL PUMP ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 54 of 86OIL PUMP ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0812-041 Gerotor - Set12 0829-009 Pin, Dowel23 0812-048 O-Ring14 0812-040 Housing, Oil Pump15 8468-625 Screw, Machine26 0812-047 Seal, Oil Pump17 0828-007 Shim1 /P8 0812-046 Shaft, Oil Pump19 0812-045 Gear, Driven1

10 0831-002 Ring, Retaining111 0812-057 Strainer, Oil1 /P12 0826-040 Screw, Machine213 0812-053 Cap, Oil Strainer114 8468-625 Screw, Machine415 0812-006 Plug, Drain116 0830-017 Gasket, Drain Plug1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 55 of 86REAR AND PARKING BRAKE ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 56 of 86REAR AND PARKING BRAKE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 1502-726 Caliper, Brake - Right (inc. 2-8)1 S1 1502-727 Caliper, Brake - Left (inc. 2-8)1 S2 1436-160 Housing, Caliper - Assembly - Right (inc. 3-5)1 /P2 1436-161 Housing, Caliper - Assembly - Left (inc. 3-5)1 /P3 0502-606 Piston/Seal Set (inc. 4)24 0502-607 Seal Set25 0502-609 Valve, Bleed2 /P6 0502-608 O-Ring, Guide - Set27 0502-605 Bracket Assembly28 1502-694 Pad, Brake - Set2 S9 8408-821 Screw, Cap4 /P

10 1402-845 Hose, Brake111 8476-620 Screw, Machine112 0623-038 Nut w/Washer113 0423-413 Bolt, Banjo-Fitting314 0423-178 Washer, Crush615 1402-914 Disc, Brake1 /P16 0423-557 Screw, Shoulder517 1502-581 Caliper, Parking Brake (inc. 18)118 1502-582 Pad, Brake - Set119 8408-825 Screw, Cap220 1502-579 Bracket, Mounting - Cable121 8408-836 Screw, Cap122 8432-802 Nut, Lock223 0487-061 Cable, Parking Brake124 0423-894 Pin, Retaining - Assembly (inc. 25-27)225 0423-989 Pin226 0423-990 Washer227 0423-991 Pin, Cotter228 1502-497 Lever, Parking Brake - Assembly (inc. 29-30)129 0409-131 Switch, Limiter130 0423-992 Screw, Machine131 8468-820 Screw, Machine232 8408-841 Screw, Cap1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 57 of 86REAR DRIVE GEARCASE ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 58 of 86REAR DRIVE GEARCASE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1502-404 Complete Rear Drive Gearcase Assembly1

1 1502-587 Housing, Gearcase12 0402-393 Bearing23 1402-713 Seal2 S4 1402-033 Gear, Ring - 34T15 0402-405 ShimAR5 0402-406 ShimAR5 0402-407 ShimAR5 0402-408 ShimAR5 0402-409 ShimAR6 0402-326 Button, Thrust17 0402-429 ShimAR7 0402-430 ShimAR7 0402-431 ShimAR7 0402-432 ShimAR7 0402-433 ShimAR8 0423-149 O-Ring19 1502-588 Cover, Gearcase1

10 0402-333 Plug, Fill (inc. 11)1 /P11 0423-154 O-Ring112 1402-442 Fitting113 0423-118 Screw, Self-Tapping814 1402-210 Plug, Magnetic (inc. 15)1 /P15 0423-153 O-Ring116 0402-947 Gasket117 0402-411 Pin, Dowel118 0402-328 Bearing119 0502-784 Gear, Pinion - Assembly - 11T (inc. 20-21)120 0402-327 Bearing121 0402-336 Collar, Retaining122 0402-357 Collar, Lock123 0423-834 Screw, Self-Tapping324 1502-563 Shaft, Input (inc. 25-32)125 1502-564 Cartridge, Clutch - Assembly1 /P26 0423-799 Ring, Retaining - External127 1402-682 Basket, Clutch128 0423-798 Ring, Retaining - Internal129 1402-678 Bearing, Flange130 1402-677 Bearing131 1402-687 Seal132 1502-565 Housing, Input1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 59 of 86REAR SUSPENSION ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 60 of 86REAR SUSPENSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0423-920 Retainer, Spring22 0504-612 Spring, Suspension23 0404-182 Shock Absorber (inc. 4)24 0423-917 Sleeve, Shock - Threaded25 0423-919 Nut, Spring Adjuster26 8409-060 Screw, Cap47 8428-002 Nut, Lock168 0504-598 A-Arm, Rear - Upper Right (inc. 9-10)18 0504-599 A-Arm, Rear - Upper Left (inc. 9-10)19 0403-208 Bushing16 /P

10 0403-214 Axle8 /P11 0504-592 A-Arm, Rear - Lower Right (inc. 9-10)111 0504-593 A-Arm, Rear - Lower Left (inc. 9-10)112 8409-000 Screw, Cap413 8409-075 Screw, Cap814 0504-613 Knuckle, Rear - Assembly (inc. 15-18)215 1402-809 Bearing2 /P16 0423-423 Ring, Retaining217 0403-213 Axle4 /P18 0403-206 Bushing8 /P19 1406-068 Guard, Boot - Right119 1406-069 Guard, Boot - Left120 0423-545 Screw, Shoulder4 /P21 1502-668 Axle, Drive (inc. 22-23)2 S22 1436-228 Repair Kit, Boot - Rear Axle2 /P23 1402-890 Clip, Retaining2

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 61 of 86SEAT ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 62 of 86SEAT ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 1506-925 Seat, Low-Back22 2506-780 Plate, Base - Seat2 /P3 0406-877 Bumper, Seat8 /P4 8468-820 Screw, Machine85 8468-620 Screw, Machine4 /P6 2706-164 Latch - Assembly (inc. 7)2 /P7 2606-854 Lever, Release - Seat Latch2 S8 0623-038 Nut w/Washer49 0423-559 Stud, Latch - Seat2

10 0423-073 Washer411 8424-002 Nut212 8408-020 Screw, Cap613 2516-325 Belt, Seat214 8427-002 Nut, Lock615 2406-910 Base, Seat - Right115 2406-911 Base, Seat - Left116 0444-122 Tool Kit - Assembly1 S/P17 8477-620 Screw, Machine818 2516-094 Panel, Seat - Assembly (inc. 19-23 and five

No. 24)1

19 2516-146 Panel, Seat - Front Right119 2516-147 Panel, Seat - Front Left120 0623-544 Clip, Retaining1121 2406-912 Panel, Seat - Rear Right121 2406-913 Panel, Seat - Rear Left122 2406-915 Seal, Seat Panel123 0423-577 Clip, U-Nut524 8476-620 Screw, Machine1325 0623-784 Screw, Self-Tapping226 2416-091 Cover, Access - Air Filter227 2416-148 Cover, Seat Belt - Right127 2416-149 Cover, Seat Belt - Left128 0423-915 Screw, Shoulder - Assembly (inc. 29-31)229 0 Screw, Shoulder2 F30 0 Washer2 F31 0 Nut, Lock2 F32 0412-560 Foil, Protective1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 63 of 86SECONDARY DRIVE ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 64 of 86SECONDARY DRIVE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0502-829 Yoke, Drive Output12 0402-944 Joint, Universal - Set (inc. 3)1 /P3 0423-395 Ring, Retaining44 0827-013 Nut25 0828-020 Washer26 0502-828 Yoke, Propeller Shaft Joint17 0830-043 Seal, Oil28 0832-017 Bearing29 0828-021 Shim, 25 x 34 x 0.25 mmAR9 0828-022 Shim, 25 x 34 x 0.30 mmAR9 0828-023 Shim, 25 x 34 x 0.70 mmAR9 0828-024 Shim, 25 x 34 x 0.90 mmAR9 0828-025 Shim, 25 x 34 x 0.95 mmAR9 0828-026 Shim, 25 x 34 x 1.00 mmAR9 0828-027 Shim, 25 x 34 x 1.05 mmAR9 0828-028 Shim, 25 x 34 x 1.10 mmAR9 0828-029 Shim, 25 x 34 x 1.15 mmAR

10 0819-089 Shaft, Secondary Driven - Front1 /P11 0832-016 Bearing, Driven Gear112 0822-106 Gear, Secondary Driven113 0819-011 Ring, Driven Bearing114 0819-053 Shaft, Secondary Driven - Rear115 0819-005 Flange, Output Joint116 0822-108 Gear, Secondary Drive117 0828-119 Shim, 30 x 48 x 0.25 mmAR17 0828-120 Shim, 30 x 48 x 0.30 mmAR17 0828-121 Shim, 30 x 48 x 0.35 mmAR17 0828-122 Shim, 30 x 48 x 0.90 mmAR17 0828-123 Shim, 30 x 48 x 0.95 mmAR17 0828-124 Shim, 30 x 48 x 1.00 mmAR17 0828-125 Shim, 30 x 48 x 1.05 mmAR17 0828-126 Shim, 30 x 48 x 1.10 mmAR17 0828-127 Shim, 30 x 48 x 1.15 mmAR18 0832-083 Bearing1 /P19 0827-060 Nut120 0832-050 Bearing1 /P

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 65 of 86SECONDARY TRANSMISSION ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 66 of 86SECONDARY TRANSMISSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0822-091 Countershaft Assembly (inc. 2-15)1 /P2 0822-014 Gear Select, Reverse13 0831-011 Ring, Retaining24 0822-045 Spacer, Reverse Driven Gear15 0828-008 Washer26 0822-013 Gear, Reverse Driven17 0832-011 Bearing38 0822-005 Bushing39 0828-014 Washer, Lock1

10 0828-015 Washer, Lock111 0822-004 Gear, Driven - Low112 0822-046 Washer, Driven Gear213 0822-003 Countershaft114 0822-007 Gear Select, Sliding115 0822-006 Gear, Driven - High116 0822-089 Gear, Drive117 0828-019 Washer, Thrust118 0828-011 Washer119 0831-040 Ring, Retaining120 0822-050 Trigger, Speedometer Sensor121 0828-069 Washer, Thrust122 0831-039 Ring, Retaining123 0829-001 Pin, Dowel2 S24 0830-194 Gasket125 0806-105 Housing, Speedometer Sensor126 0830-044 Seal127 8468-630 Screw, Machine228 0824-042 Sensor, Speedometer1 /P29 8468-620 Screw, Machine1 /P30 0822-001 Driveshaft131 0828-016 Washer, Thrust232 0822-011 Gear, Reverse Idle133 0822-012 Bushing134 0822-015 Shaft, Reverse Idle1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 67 of 86SHIFTER ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 68 of 86SHIFTER ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 1502-516 Mount, Shift12 8476-620 Screw, Machine43 0423-577 Clip, U-Nut44 8477-616 Screw, Machine85 1402-275 Retainer, Shift Linkage26 0623-038 Nut w/Washer27 1402-854 End Cap, Shift Knob18 1402-844 Knob, Shift19 0423-885 Nut1

10 1502-510 Lever, Shift111 1402-880 Spring112 0423-505 Screw, Shoulder113 1502-666 Axle, Shift114 8424-802 Nut115 0487-063 Cable, Shift116 0423-356 Screw, Shoulder117 0623-094 Washer118 8427-602 Nut, Lock119 2516-609 Bracket, Shift Cable120 8468-635 Screw, Machine221 0124-057 E-Ring1 /P

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 69 of 86STARTER CLUTCH ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 70 of 86STARTER CLUTCH ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0815-026 Gear, Starter Idler - No. 112 0829-031 Shaft, Starter Gear1 /P3 0815-002 Gear, Starter Idler - No. 214 0815-003 Spacer, Starter Idler Gear No. 215 0829-032 Shaft, Starter Gear1 /P6 0815-004 Gear, Starter Clutch (inc. 7)17 0832-079 Bearing1 /P8 0802-035 Clutch, Starter19 0826-069 Screw, Cap6

10 0828-113 Washer, Wave1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 71 of 86STEERING ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 72 of 86STEERING ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0505-603 Wheel, Steering - Assembly (inc. 2-3)1 /P2 0505-574 Cap, Steering Wheel (inc. 3)13 1411-953 Decal, Steering Wheel14 0423-884 Nut15 1602-467 Clip, Hairpin16 0828-071 Washer27 0423-558 Washer28 0405-155 Bushing29 0405-321 Shaft, Upper Steering1 /P

10 0423-655 Screw, Cap211 0405-156 Shaft, Lower Steering - Assembly112 8409-050 Screw, Cap213 0623-728 Washer214 8424-002 Nut215 0505-650 Housing, Rack and Pinion (inc. 16-23)1 /P16 0405-238 Bushing217 0405-216 Boot218 0405-236 Clamp219 0505-638 Tie Rod - Assembly (inc. 20-23)2 /P20 0405-237 Clamp221 0505-640 Nut2 /P22 0505-639 End, Tie Rod (inc. 23)2 S23 0623-175 Pin, Cotter224 0423-072 Nut2

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 73 of 86SWAY BAR ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 74 of 86SWAY BAR ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0404-110 Bar, Sway12 0404-135 Clamp, Sway Bar Bushing23 0404-094 Bushing, Sway Bar - Upper24 0404-095 Bushing, Sway Bar - Lower25 8409-016 Screw, Cap46 8422-002 Nut, Lock27 0423-335 Screw, Cap28 0423-073 Washer89 1402-434 Bushing8

10 0423-620 Spacer2

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 75 of 86THROTTLE BODY ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 76 of 86THROTTLE BODY ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0470-686 Throttle - Assembly (inc. 2-14)12 5507-117 Screw, Machine2 /P3 5507-227 Bracket, MAP Sensor14 0430-073 Sensor, MAP15 5507-232 O-Ring, MAP Sensor16 5507-231 Screw, Machine17 0430-072 Sensor, Throttle Position18 5507-234 O-Ring, Throttle Position Sensor19 5507-229 Plate, ISC Valve1

10 5507-233 O-Ring, ISC Valve111 0430-074 Valve, ISC112 5507-235 O-Ring113 5507-223 Cover114 5507-037 Screw, Machine1 /P15 0570-319 Manifold, Intake - Assembly (inc. 16-25)116 0423-371 Screw, Machine217 0470-893 Rail, Fuel - Front Cylinder118 0470-767 O-Ring, Fuel Injector219 0470-688 Injector, Fuel220 0470-768 Ring, Seal - Fuel Injector221 0570-140 Manifold, Intake222 0423-066 Clamp423 0470-660 Boot, Intake - Manifold224 0570-156 Plenum, Intake125 0470-764 Rail, Fuel - Rear Cylinder126 0830-090 O-Ring227 0826-008 Screw, Machine628 3002-964 Clamp, Wire1 /P

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 77 of 86TILT FRAME ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 78 of 86TILT FRAME ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 2506-919 Rod, Cargo Box Latch12 1406-736 Grip, Latch Rod13 1406-674 Bushing, Pivot44 8408-840 Screw, Cap25 2516-334 Frame, Box16 8427-802 Nut, Lock27 0423-628 Grommet48 8427-602 Nut, Lock29 2416-086 Spring1

10 0423-356 Screw, Shoulder211 2506-194 Support, Lift112 0423-505 Screw, Shoulder413 0405-166 Cap, Housing214 0405-138 Housing, Lower215 0405-139 Housing, Upper2

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 79 of 86TRANSMISSION ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 80 of 86TRANSMISSION ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0823-157 Pulley, Driven - Assembly (inc. 2-4)1 S/P2 0823-176 Shoe, Cam3 /P3 0823-177 Screw, Machine34 0823-178 Nut, Driven Pulley15 0832-010 Bearing16 0830-176 Seal1 /P7 0823-020 Retainer, Bearing18 0826-031 Screw, Machine29 0827-010 Nut1

10 0828-106 Washer111 0823-008 Plate, Movable Drive Face112 0823-010 Damper, Movable Drive Face413 0823-265 Spacer, Movable Drive Face114 0823-170 Roller, Movable Drive Face8 /P15 0823-159 Face, Movable Drive116 0823-231 Belt, Drive117 0823-156 Face, Fixed Drive1 /P18 0823-015 Spacer, Fixed Drive Face119 0470-531 O-Ring120 0830-188 Seal, Clutch Housing - Right1 /P21 0832-047 Bearing1 S22 0823-261 Housing, Clutch1 S/P23 0826-029 Screw, Machine224 0822-010 Retainer, Bearing2 /P25 0830-189 Seal, Clutch Housing - Left1 /P26 0827-011 Nut127 0823-018 Clutch, One-Way128 0823-098 Clutch, Centrifugal - 6 Plate1 S

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 81 of 86WATER PUMP ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 82 of 86WATER PUMP ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0813-056 Pump, Water - Assembly (inc. 2)1 /P2 0830-029 O-Ring13 8468-650 Screw, Machine24 0832-084 Bearing15 0831-086 Circlip16 0813-041 Shaft, Driven Gear17 0831-010 Ring, Retaining28 0813-043 Gear, Driven19 0829-009 Pin, Dowel1

10 0831-002 Ring, Retaining111 0832-046 Bearing2 /P12 0813-028 Spacer, Idler - Water Pump113 0813-026 Shaft, Water Pump Idler Gear114 0831-004 Ring, Retaining115 0813-027 Gear, Idler - Water Pump - Drive116 0831-040 Ring, Retaining1

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 83 of 86WHEEL AND TIRE ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 84 of 86WHEEL AND TIRE ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0423-557 Screw, Shoulder162 1402-455 Disc, Brake - Front2 S2 1436-164 Disc, Brake - Rear2 /P3 1502-433 Hub, Wheel - Front (inc. 4)2 /P3 1502-437 Hub, Wheel - Rear (inc. 4)24 0402-974 Stud, Wheel Hub16 /P5 0423-407 Pin, Cotter46 0423-607 Nut, Castle47 1402-732 Wheel - Front28 0423-618 Nut, Lug169 1402-790 Tire - Front2

10 0402-064 Stem, Valve (inc. 11)411 0402-140 Cap, Valve Stem412 1402-733 Wheel - Rear2 S13 1402-791 Tire - Rear214 1402-736 Cap, Wheel4

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 85 of 86WIRING HARNESS ASSEMBLY

2010 PROWLER 1000 XTZ 4X4 METALLIC CAT GREEN (Engine Serial Number 0950T80010060 and Up) (U2010P4W4EUSA)Page 86 of 86WIRING HARNESS ASSEMBLY

Ref # Part Number Qty DescriptionS/P/F1 0486-344 Harness, Main (inc. 2-9)12 0486-164 Tether, Accessory Connector13 0430-085 Cover, Fuse Block14 0430-037 Holder, Fuse15 0430-034 Diode16 0430-045 Relay (4-Pin) - 20 Amp5 /P7 0430-032 Fuse - 10 Amp57 0430-031 Fuse - 15 Amp47 0430-030 Fuse - 30 Amp28 2411-080 Decal, Fuse Block19 0430-086 Seal1

10 8424-602 Nut2 /P11 0824-037 Regulator, Voltage1 /P12 8476-625 Screw, Machine313 0623-038 Nut w/Washer414 8476-620 Screw, Machine315 0824-043 Coil, Ignition - Assembly216 0824-049 Cap, Spark Plug2 /P17 0123-903 Tie, Cable - 11.5 in.AR18 0530-025 ECU119 0430-059 Cushion, ECU120 0409-064 Switch, Tilt Sensor121 8468-425 Screw, Machine222 0123-802 Washer223 0423-493 Nut w/Washer224 0486-290 Harness, Console125 0423-075 Tie, Cable - Push-MountAR26 0123-788 Tie, Cable - 8 in.AR /P27 0486-176 Harness, Adapter - Taillight128 0123-269 Clamp, RoutingAR

Diagram(s) and/or PartsList(s) · 2012. 2. 12. · 17 0423-361 8 Screw, Machine 18 0509-022 1...

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