Pantera 550 Model Number S2005PTCCAUSB 0

Illustrated

Parts

Manual

Pantera 550Model Number S2005PTCCAUSB 2

005

®

2004 Arc®™ Trad

TABLE OF CONTENTS2005 Pantera 550

(Model No. S2005PTCCAUSB)

SKI AND SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2SHOCK ABSORBER AND SWAY BAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3STEERING POST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TIE ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5HANDLEBAR AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6HYDRAULIC BRAKE CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DRIVE/REVERSE DROPCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9DROPCASE AND CHAIN TENSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10REVERSE SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11SLIDE RAIL AND TRACK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12IDLER WHEEL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13REAR SUSPENSION FRONT ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14REAR SUSPENSION REAR ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15FRONT FRAME AND FOOTREST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16HOOD AND WINDSHIELD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . 18CONSOLE AND SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19BELLY PAN AND FRONT BUMPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20BELT GUARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21GAS TANK AND SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22BACKREST AND TAILLIGHT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23TUNNEL AND REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24COOLING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25ENGINE AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26EXHAUST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27FLEX-DRIVE STARTER MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28BATTERY, SOLENOID, AND CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29CARBURETOR AND FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30AIR SILENCER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35CYLINDER AND HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37PISTON AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39WATER PUMP/WATER MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43ALTERNATE CARBURETOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44RELATED ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not to be used for assembly. For assembly procedures, use an Arctic Cat Service Manual. Underlined part numbers are new for the 2005 model year.

tic Cat Inc. Printed June 2004emarks of Arctic Cat Inc., Thief River Falls, MN 56701

2005 Pantera 550

SKI AND SPINDLE ASSEMBLY0739-521

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

1 0703-595 2 Ski, Plastic2 0603-624 2 Handle, Plastic - Black3 1703-003 2 Wearbar4 0703-596 2 Saddle, Ski (inc. 5)5 0603-621 4 Insert, Ski Saddle6 0703-648 1 Spindle, Steering - Right - Black (inc. 7-9)

0703-649 1 Spindle, Steering - Left - Black (inc. 7-9)7 0603-647 8 Insert, Spindle8 0623-010 2 Fitting, Grease9 0603-158 4 Bearing

10 0623-831 2 Cap, Spindle11 6611-160 1 Decal, “AWS” - Spindle - Right

6611-161 1 Decal, “AWS” - Spindle - Left

1111111122222

2 0603-034 2 Axle, Spindle3 0603-036 2 Damper4 0123-296 2 Nut, Lock5 0623-728 4 Washer6 0123-458 2 Pin, Cotter7 0623-552 2 Screw, Cap8 0603-616 4 Spacer9 8047-486 8 Nut, Lock0 8048-366 4 Nut, Lock1 8017-581 4 Screw, Machine2 8020-135 2 Screw, Cap3 8020-143 2 Screw, Cap4 8048-426 4 Nut, Lock

1

2005 Pantera 550

A-ARM ASSEMBLY0738-350


1 0703-532 1 Arm, Lower - Right - Black (inc. 2 and 4)0703-533 1 Arm, Lower - Left - Black (inc. 2 and 4)

2 0603-158 4 Bearing3 0703-535 2 Arm, Upper - Black (inc. 4)4 0603-083 12 Bearing5 0623-509 2 Screw, Cap6 0623-664 2 Washer7 1603-244 4 Axle, Powder Metal8 0603-692 2 Tube, Axle

1111111

2

9 8048-486 6 Nut, Lock0 0623-508 2 Screw, Cap1 0623-663 2 Washer2 1603-397 4 Axle, Non-Serrated3 0603-693 2 Tube, Axle4 8048-546 2 Nut, Lock5 0603-830 4 Axle, Spindle Mount6 8026-234 4 Screw, Cap

2005 Pantera 550

SHOCK ABSORBER AND SWAY BAR ASSEMBLY0738-667


1 1603-175 2 Shock, Front Suspension (inc. 2-3)2 0604-309 2 Sleeve, Shock3 0604-310 8 Bushing, Shock4 0603-259 2 Nut, Retainer - Spring5 0603-147 2 Sleeve, Threaded6 1703-660 2 Spring, Compression - Blue7 1603-889 2 Retainer, Spring8 8020-226 4 Screw, Cap9 8048-486 8 Nut, Lock

10 8020-234 2 Screw, Cap

1111111112

1 0603-854 2 Spacer, Shock Mount - Front2 1604-184 2 Axle, Lower Shock Mount3 0603-855 2 Spacer, Shock Mount - Rear4 1703-618 1 Sway Bar5 0603-151 2 Bearing, Sway Bar6 2603-307 2 Arm, Sway Bar7 8002-137 4 Screw, Cap8 8048-426 4 Nut, Lock9 1603-414 2 Link, Sway Bar0 8020-225 2 Screw, Cap

3

2005 Pantera 550

STEERING POST ASSEMBLY0738-352


1 0705-837 1 Post, Steering2 8002-137 4 Screw, Cap3 0605-506 2 Cap, Adjusting Block4 0605-507 1 Block, Adjusting5 8048-426 6 Nut, Lock6 0623-814 2 Screw, Cap7 0605-406 1 Cap, Bearing Housing8 0405-020 2 Bearing, Half9 0605-147 1 Housing, Bearing

10 8048-366 2 Nut, Lock

111111111

4

1 0623-025 2 Nut, Lock2 0623-044 2 Washer3 0705-407 1 Plate, Backing4 8020-130 2 Screw, Cap5 0605-423 1 Ball Joint, Steering - Left6 0123-917 1 Nut, Hex - Left7 0605-626 1 Tube, Tie Rod8 0623-294 1 Nut, Hex - Right9 0605-504 1 Ball Joint, Tie Rod - Right

2005 Pantera 550

TIE ROD ASSEMBLY0738-354


1 0705-370 1 Drag Link (inc. 2)2 0605-541 2 Bearing3 1705-058 1 Arm, Steering - Assembly4 0605-540 4 Insert5 1705-060 1 Arm, Steering - Idler - Assembly6 8020-234 2 Screw, Cap7 8048-486 2 Nut, Lock8 0623-920 2 Screw, Cap9 0605-522 2 Axle, Drag Link

10 8050-272 2 Washer11 8048-426 2 Nut, Lock

1111111122

2 8004-226 3 Screw, Cap3 0623-044 3 Washer4 0623-025 5 Nut, Lock5 8050-277 4 Washer6 0605-014 2 O-Ring7 0605-504 2 Ball Joint, Tie Rod - Right8 0623-294 2 Nut, Hex - Right9 0605-352 2 Tube, Tie Rod - Spindle0 0123-917 2 Nut, Hex - Left1 0605-511 2 Ball Joint, Steering - Left

5

2005 Pantera 550

HANDLEBAR AND CONTROLS0739-689


1 0609-482 1 Control, Throttle (High/Low) (inc. 2-10)2 0609-493 1 Control, Throttle - Stop Switch Half3 0609-500 1 Control, Throttle - Thumbwarmer

Assembly (High/Low) (inc. 4-10)4 0609-495 1 Control, Throttle - Thumbwarmer Half

(High/Low) w/o Components5 0609-497 1 Plug, Rubber6 0609-498 1 Clip, Retaining - Throttle Cable7 0609-496 1 Plate, Cover8 0609-312 7 Screw, Self-Tapping9 0609-382 1 Switch, Thumbwarmer Assembly

(High/Low) (inc. three No. 8 and 10)10 0609-378 1 Plate, Cover11 0609-492 2 Screw, Machine12 0609-317 1 Axle, Lever - Throttle13 0609-036 2 Washer14 0609-501 2 Washer, Shoulder - Throttle

1111122222222223

6

5 0609-324 1 Lever, Throttle6 0609-040 1 Ring, Retaining7 0705-361 1 Handlebar8 2606-084 2 Grip, Handlebar9 0616-995 1 Pad, Handlebar0 0623-128 4 Screw, Self-Tapping1 0609-375 2 Element, Handwarmer2 1639-963 1 Tool, Removal - Kit - Throttle Cable3 0609-689 1 Element, Thumbwarmer4 0617-248 1 Pad, Insulator5 0623-262 1 Clip, Wire6 0687-060 1 Cable, Throttle (inc. 27)7 0623-464 2 Nut, Locking - Throttle Cable8 0124-056 1 Washer9 0124-057 1 E-Ring0 0123-788 AR Cable Tie - 8 in.

2005 Pantera 550

HYDRAULIC BRAKE CONTROL ASSEMBLY0737-603 *Not a Service Part **Not Illustrated


1 0602-943 1 Brake Assembly (inc. 2-14)2 1602-740 1 Lever, Brake3 0623-430 1 Screw, Lever Mounting4 0623-056 1 Nut, Lock5 0602-740 1 Reservoir6 0602-741 1 Gasket, Cover7 0602-742 1 Cover, Reservoir8 0623-506 2 Screw, Cover9 0623-613 2 Screw, Machine

10 0602-587 1 O-Ring11 * 1 Master Cylinder12 8052-212 2 Washer, Lock - Internal Tooth

11

11111

222

3 0623-432 2 Screw, Master Cylinder Mounting4 0602-907 1 Clamp, Master Cylinder** 0638-315 AR Fluid, Brake - High Temperature5 0609-406 1 Control, Dimmer - Assembly (inc. 16-21)6 0609-322 1 Housing, Dimmer Control7 0609-267 1 Switch, Dimmer and Brake - Assembly8 0609-474 1 Knob, Dimmer Switch9 0609-383 1 Switch, HI/LO Handwarmer - Assembly

(inc. 20 and three No. 21)0 0609-378 1 Plate, Cover1 0609-312 7 Screw, Self-Tapping2 0602-944 1 Brakeline, Hydraulic

7

2005 Pantera 550

DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES0738-482 *Not a Service Part


1 0728-105 1 Track Drive Assembly (inc. 2-4)2 1602-507 2 Sprocket, Drive3 0602-487 1 Driveshaft4 0120-247 1 Bushing, Drive5 0702-476 1 Plate, Flange - Bearing Assembly (inc. 6-9)6 0602-198 2 Plate, Flange7 8011-130 3 Bolt, Carriage8 1602-375 1 Bearing, 1 in. w/Lock Collar -

Re-Lubricative9 0623-810 3 Ring, Solder

10 8048-426 5 Nut, Lock11 0602-154 1 Cable, Adapter12 0720-005 1 Adapter, Drive (inc. 13)13 0104-062 1 Fitting, Grease14 8020-315 2 Screw, Cap15 1602-205 1 Disc, Brake16 0602-598 1 Key17 0702-266 1 Shaft, Driven18 0101-076 1 Key19 8020-132 2 Screw, Cap20 1602-099 1 Bearing, 1 in. w/Lock Collar -

Re-Lubricative

22

222222233333333334

8

1 0602-892 1 Plate, Flange2 0623-118 AR Washer

0623-119 AR Washer3 0648-066 1 Shaft, Stub4 0726-162 1 Clutch, Driven5 0123-053 AR Washer6 0123-578 AR Washer7 0123-019 1 Washer8 8020-142 1 Screw, Cap9 0602-829 1 Caliper, Brake Assembly (inc. 30-40)0 * 1 Housing1 * 1 Housing2 8005-677 2 Screw, Cap3 0602-707 1 Screw, Bleed - Assembly4 0702-229 1 Pad, Brake - Set (inc. 35)5 0602-706 1 Pin, Retaining6 0602-729 1 O-Ring, Housing7 0602-583 2 O-Ring8 0602-708 2 Piston9 8050-272 2 Washer0 0602-590 1 Fitting, Adapter

2005 Pantera 550

DRIVE/REVERSE DROPCASE ASSEMBLY0738-421 *Not a Service Part


1 0702-170 1 Sprocket Assembly - 39T (inc. 2-8)2 * 1 Sprocket3 0602-144 1 Retainer, Spring4 0602-133 3 Pin, Slip5 0602-138 3 Spring, Compression6 0623-182 6 Screw, Cap7 0123-430 6 Nut, Lock8 0602-016 1 Bearing9 0602-012 1 Spacer, Shaft

10 1602-041 1 Chain - 70P11 1602-048 1 Extension, Driveshaft12 0702-048 1 Gear, Reverse - 55T (inc. 13-15)13 0602-023 2 Washer, Thrust14 0602-022 1 Bearing, Thrust15 0602-024 1 Ring, Retaining16 8002-231 1 Screw, Cap17 1602-046 1 Washer, Tab Lock18 8050-272 1 Washer19 0702-372 1 Retainer, Shaft (inc. 20)20 8070-153 1 Pin, Spring

2222222223333333333

1 0602-028 1 Spring, Return2 0602-215 1 Spacer, Reverse Idler3 0602-094 1 Shaft, Reverse4 0702-260 1 Idler, Reverse - Assembly - 24T (inc. 25)5 0602-018 1 Bearing6 0602-366 1 Aligner, Idler - Pin7 0702-366 1 Idler, Reverse - Assembly - 19T (inc. 28)8 1602-045 1 Bearing9 1602-044 1 Washer, Thrust0 8020-130 1 Screw, Cap1 1602-521 2 Plate, Flange2 1602-052 1 Bearing, 7/8 in.3 0107-003 2 O-Ring4 8041-426 3 Nut, Lock5 0602-444 1 Sprocket - 19T6 0623-231 1 Washer, Spring7 0623-465 1 Nut, Lock8 1602-051 1 Bearing, 1 in.9 8040-426 3 Nut, Lock

9

2005 Pantera 550

DROPCASE AND CHAIN TENSION ASSEMBLY0739-522


1 0702-417 1 Dropcase w/Studs (inc. 2-5)2 0623-317 3 Stud, Ribbed3 0607-025 9 O-Ring, Stud4 0623-117 2 Bolt, Ribbed5 0123-523 4 Bolt, Ribbed6 8047-426 7 Nut, Lock7 8020-135 1 Screw, Cap8 8011-139 2 Bolt, Carriage9 8050-252 AR Washer

10 1623-121 1 Bolt, Carriage11 0602-479 1 Plug, Drain - Magnetic12 1602-213 3 O-Ring13 0602-876 1 Adapter, Manual Adjust14 0623-905 1 Seal, Manual Adjust15 8050-272 1 Washer16 0123-150 1 Nut17 1602-101 1 Adjuster, Chain18 0616-964 1 Guard, Dropcase19 8011-135 1 Bolt, Carriage20 8048-366 1 Nut, Lock21 0702-553 1 Bracket, Chain Backing22 8020-134 5 Screw, Cap

2222222333333333344444

10

3 1602-222 1 Cover, Dropcase4 0702-350 1 Shaft, Shift Fork5 0602-021 1 Seal, O-Ring6 0623-542 1 Pin, Spring7 1602-151 1 Cover, Oil Vent8 0623-081 6 Screw, Self-Tapping9 0602-085 1 Fork, Shift0 0602-437 1 Seal, Dropcase1 0623-293 2 Plug, Drain2 0623-914 1 Screw, Self-Tapping3 0605-014 1 O-Ring, Oil Level Stick Tube4 1602-107 1 Stick, Oil Level5 1602-106 1 Tube, Oil Level Stick6 0602-676 1 Shaft, Chain Roller7 0623-525 2 Washer8 0702-129 1 Roller, Chain Tightener (inc. 39)9 0602-383 1 Bearing, Chain Tightener0 0602-681 1 Nut, Roller Arm1 8050-222 1 Washer2 0623-122 1 Nut, Lock3 0602-675 1 Arm, Chain Roller4 8002-045 1 Screw, Cap

2005 Pantera 550

REVERSE SHIFT LEVER ASSEMBLY0739-453 *Not a Service Part


1 0602-978 1 Lever2 0623-641 1 Pin, Clevis3 0117-868 1 Pin, Cotter4 8002-137 1 Screw, Cap5 0702-632 1 Shift Pivot6 0602-853 1 Axle7 8050-247 2 Washer8 8053-242 1 Washer, Lock - External Tooth9 8002-140 1 Screw, Cap

10 0702-465 1 Bracket, Reverse Switch11 0630-011 1 Switch, Alarm

11111111222

2 0630-013 1 Boot, Switch3 0630-010 1 Alarm, Reverse (inc. 14)4 0630-017 1 Ring, Retaining5 8002-132 1 Screw, Cap6 8040-426 2 Nut, Lock7 0702-347 1 Linkage, Shifting - Assembly (inc. 18-22)8 0602-305 1 Rod End - Left9 0623-260 1 Nut, Jam - Left0 * 1 Rod, Linkage1 0123-144 1 Nut, Jam - Right2 0602-322 1 Rod End - Right

11

2005 Pantera 550

SLIDE RAIL AND TRACK ASSEMBLY(Complete Skid Frame Assembly p/n 7998-477)

0739-484


1 2604-712 2 Rail, Formed2 0604-426 2 Support, Rail3 8047-366 8 Nut, Lock4 8050-217 4 Washer5 2604-842 2 End Cap, Slide Rail6 8002-043 2 Screw, Cap7 0123-859 2 Screw, Machine8 2604-257 2 Wearstrip, Slide Rail - Black9 8020-134 4 Screw, Cap

10 8060-633 4 Rivet, Solid11 0604-967 4 Bracket, Retaining12 0604-918 2 Pad, Shock13 8048-426 4 Nut, Lock14 0704-395 2 Bracket, Mounting - Front Arm15 8020-132 4 Screw, Cap16 8020-227 2 Screw, Cap

1112222222222333

12

7 1604-413 2 Block, Spring Tension8 8048-486 2 Nut, Lock9 8041-246 2 Nut, Lock0 1604-429 2 Pad, Shock1 8017-405 2 Screw, Machine2 2604-562 2 Stop, Rear Arm3 8020-222 2 Screw, Cap4 8005-676 2 Screw, Cap5 0623-044 2 Washer6 2604-545 2 Block, Rear Arm Coupler7 2604-046 2 Bushing, Rear Arm Coupler Block8 8041-486 2 Nut, Lock9 8002-042 4 Screw, Cap0 0704-352 2 Adjuster, Track1 1602-476 1 Track Assembly (inc. 32)2 0602-488 54 Clip, Guide

2005 Pantera 550

IDLER WHEEL ASSEMBLY0739-485


1 8020-232 4 Screw, Cap2 0623-664 4 Washer3 2604-196 2 Wheel, Idler (inc. 4-5)4 1604-847 7 Bearing5 0623-946 7 Ring, Retaining6 2604-579 2 Block, Mounting - Idler Wheel7 8020-224 2 Screw, Cap8 8048-486 6 Nut, Lock9 1604-952 4 Cap, Idler Wheel

10 1623-037 2 Screw, Cap11 0623-044 2 Washer12 2604-738 2 Block, Mounting - Idler Wheel13 1604-837 2 Wheel, Idler (inc. 4-5)14 1704-235 1 Bracket, Mounting - Front Shock15 2604-737 1 Axle, Steel16 8047-490 2 Nut, Lock17 1704-016 1 Pivot, Shock (inc. 18-19)18 1623-010 1 Fitting, Grease19 1623-011 1 Washer, Grease Fitting20 1604-209 1 Axle, Steel21 0603-105 1 Spacer22 1604-213 4 Spacer23 0623-675 8 Washer24 1604-684 4 Wheel, Idler (inc. 25-28)25 1604-773 4 Insert, Wheel - Outside

222233333333334444444444

6 0107-598 4 Bearing7 0123-798 4 Ring, Retaining8 1604-772 4 Insert, Wheel - Inside9 0604-930 1 Axle0 1604-214 1 Spacer1 8020-223 4 Screw, Cap2 2604-283 1 Axle, Rear Wheel3 0623-921 1 Washer4 1604-940 1 Spacer5 1604-838 1 Wheel, Idler (inc. 4-5)6 2604-260 3 Bushing, Adjuster7 8042-486 2 Nut8 0623-123 2 Screw, Cap9 2604-251 2 Wheel, Idler (inc. 4-5)0 1704-279 2 Spring, Overload Assembly (inc. 41-44)1 2604-788 2 Block, Wear2 0623-121 2 Screw, Machine3 8041-276 2 Nut, Lock4 1604-412 4 Clip, Retaining5 0623-746 4 Washer6 0604-739 2 Bushing, Overload Spring7 1604-430 2 Spacer, Spring Slide8 2604-516 2 Slide, Spring9 8050-282 2 Washer

13

2005 Pantera 550

REAR SUSPENSION FRONT ARM ASSEMBLY0739-434


1 1704-335 1 Arm, Front Suspension (inc. 2-4)2 1623-010 2 Fitting, Grease3 0104-386 2 Bushing, Front Arm4 0603-083 2 Bearing5 0604-194 1 Tube, Axle6 0603-061 2 Axle, Serrated7 0623-664 1 Washer8 1623-037 1 Screw, Cap9 8047-490 1 Nut, Lock

10 1604-369 1 Shock Absorber, Front Arm11 1604-384 2 Bushing, Shock12 1604-329 1 Axle, Pivot - Shock13 8020-228 1 Screw, Cap14 8048-486 1 Nut, Lock15 8020-226 1 Screw, Cap

111122222222223

14

6 0603-030 1 Axle, Serrated7 8041-486 1 Nut, Lock8 1603-889 1 Retainer, Spring9 0603-147 1 Sleeve, Threaded0 0603-259 1 Nut, Retainer - Spring1 0603-860 1 Spring, Compression2 0604-590 1 Cover, Shock3 2604-305 2 Strap, Limiter4 8047-366 4 Nut, Lock5 0623-184 8 Washer6 8002-043 4 Screw, Cap7 0114-163 1 Axle, Inner Carriage8 0623-044 2 Washer9 8051-277 2 Washer, Lock0 8002-224 2 Screw, Cap

2005 Pantera 550

REAR SUSPENSION REAR ARM ASSEMBLY0739-927


1 1704-012 1 Arm, Idler (inc. 2 and one No. 3)2 1604-100 2 Bushing3 1623-010 2 Fitting, Grease4 1704-019 1 Arm, Rear (inc. one No. 3 and 5)5 1623-011 1 Washer, Grease Fitting6 8047-490 1 Nut, Lock7 2604-664 2 Bushing, Rear Arm8 2604-663 1 Axle, Inner9 1623-037 1 Screw, Cap

10 8050-272 1 Washer11 8020-220 2 Screw, Cap12 1604-208 1 Axle, Aluminum13 1604-204 1 Block, Spring Adjuster - Right

1604-205 1 Block, Spring Adjuster - Left14 0623-138 2 Ring, Retainer15 0114-254 2 Sleeve, Spring16 1704-146 1 Spring, Suspension - Right

1704-147 1 Spring, Suspension - Left17 2604-699 2 Wheel, Idler (inc. 18-19)18 0107-598 2 Bearing19 0123-798 2 Ring, Retaining

22222222223333333333

0 1604-507 2 Spacer, Pivot Idler Arm1 1604-181 2 Axle, Powder Metal2 1604-187 2 Washer, Pivot Idler Arm3 0704-981 2 Arm, Pivot Idler (inc. 24-26)4 1604-202 4 Bushing, Flared5 8020-138 4 Screw, Cap6 8048-426 4 Nut, Lock7 0623-044 2 Washer8 8051-277 2 Washer, Lock9 8002-224 2 Screw, Cap0 0623-793 2 Screw, Cap1 1604-498 4 Axle, Link - Flanged2 0704-928 2 Link, Inner Carriage3 0704-854 1 Spacer, Shock Link4 8048-486 2 Nut, Lock5 8020-226 1 Screw, Cap6 8041-486 1 Nut, Lock7 2604-637 1 Shock Absorber - Rear Arm (inc. 38-39)8 1604-185 2 Sleeve, Shock9 0604-310 4 Bushing, Shock

15

2005 Pantera 550

FRONT FRAME AND FOOTREST ASSEMBLY0739-523


1 0707-617 1 Chassis Assembly (inc. 2-6)2 0623-699 3 Insert3 0623-582 2 Insert4 0607-420 4 Insert, Lower A-Arm Mount5 0607-421 4 Insert, Upper A-Arm Mount6 0623-581 1 Insert7 2606-732 1 Belly Pan - Center - Pewter8 1623-129 30 Screw, Self-Tapping9 0623-784 7 Screw, Self-Tapping

10 0705-866 1 Support, Steering (inc. 11)11 0623-779 2 Insert12 8019-614 4 Screw, Machine13 8020-040 2 Screw, Cap14 8048-366 6 Nut, Lock

111

11222

2222

16

5 0623-297 3 Screw, Self-Tapping6 1706-099 1 Cup, Recoil Rope7 1706-884 1 Footrest - Right - Black

2706-113 1 Footrest - Left - Black8 0623-166 AR Rivet9 0623-282 10 Rivet0 0623-341 8 Rivet1 2706-110 2 Plate, Backing - Footrest2 1706-886 1 Plate, Backing - Right - Black

1706-887 1 Plate, Backing - Left - Black3 0705-173 1 Bracket, Mounting - Guard4 8060-506 2 Rivet5 3002-964 1 Clamp, Wire6 0623-228 1 Mount, Cable Tie

2005 Pantera 550

HOOD AND WINDSHIELD ASSEMBLY0739-525


1 1718-744 1 Hood w/Decals (inc. 2-16)2 1718-634 1 Hood w/o Decals (inc. 3-12)3 0717-148 1 Foam, Hood - Upper Middle - Right

0717-149 1 Foam, Hood - Upper Middle - Left4 0717-146 1 Foam, Hood - Upper Right

0717-147 1 Foam, Hood - Upper Left5 0717-138 1 Foam, Hood - Middle6 0717-140 1 Foam, Hood - Rear - Right

0717-141 1 Foam, Hood - Rear - Left7 3611-485 1 Decal, Warning - General and Brake8 3611-970 1 Decal, Caution - Engine/Battery/Fuel9 3611-580 1 Decal, Reverse

10 1606-938 1 Foil, Hood - Right1606-939 1 Foil, Hood - Left

11 2606-614 1 Hinge, Hood12 0623-797 5 Screw, Self-Tapping13 6611-173 1 Decal, Hood - Crest14 6611-166 1 Decal, Hood - Lower Right

6611-167 1 Decal, Hood - Lower Left

1

1111222222222233

5 6611-162 1 Decal, Hood - Upper Right6611-163 1 Decal, Hood - Upper Left

6 6611-171 1 Decal, “Arctic Cat” - Hood7 2606-247 1 Cable, Hood8 0623-805 1 Clip, Hairpin9 0623-057 1 Screw, Self-Tapping0 1606-067 2 Strap, Hold-Down1 2639-477 2 Mirror - Kit (inc. six No. 22-24)2 0623-902 10 Screw, Machine3 0124-054 10 Snap Cap w/Washer4 0623-845 10 Nut, Expansion5 2606-366 1 Windshield6 0616-032 4 O-Ring7 1623-016 2 Screw, Machine8 2706-409 1 Screen, Vent - Hood - Upper Left - Black9 2706-407 1 Screen, Vent - Hood - Left - Black0 2706-408 1 Screen, Vent - Hood - Right - Black1 0123-394 16 Clip, Retaining

17

2005 Pantera 550

HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES0739-529 *Included in Hood w/Decals


1 0620-238 1 Speedometer (inc. 2-4 and one No. 5)2 0620-073 1 Knob, Tripmeter3 0620-151 1 Harness, Bulb - Speedometer (inc. 4

and one No. 5)4 0620-149 3 Bulb, Indicator 5 0230-020 3 Bulb, Instrument6 0620-236 1 Tachometer (inc. 7 and one No. 5)7 0620-215 1 Harness, Tachometer (inc. one No. 5)8 0620-135 2 Ring, Rubber Cushion 9 0620-134 2 Ring, Retaining Bracket

10 0623-038 4 Nut w/Washer 11 8050-212 4 Washer12 0123-788 AR Cable Tie - 8 in.13 0620-269 1 Cable, Speedometer14 1686-089 1 Harness, Main (inc. 15)15 0630-100 1 Fuse, 7.5 Amp16 0686-588 1 Harness, Hood17 0620-240 1 Gauge, Fuel (inc. 18-22 and one No. 5)18 0620-218 1 Harness, Fuel Gauge (inc. 19 and

one No. 5)

1222222222233333333

18

9 0630-025 1 Fuse, 0.5 Amp0 8050-122 2 Washer1 8051-122 2 Washer, Lock2 0623-839 2 Nut3 0620-139 1 Ring, Rubber Cushion4 0620-138 1 Ring, Retaining Bracket5 0623-757 1 Nut, U6 0609-250 1 Lens/Reflector - Headlight7 0609-251 2 Bulb, Headlight - High Beam8 0609-252 1 Bulb, Headlight - Low Beam9 0623-467 1 Screw, Thumb0 0623-466 1 Spring, Adjuster1 0623-847 2 Clip, Hairpin2 8020-045 1 Screw, Cap3 0630-105 1 Regulator, Voltage4 8048-366 1 Nut, Lock5 6611-169 1 Decal, Instrument - Hood*6 3611-611 1 Decal, “Made In U.S.A.” - Domed*7 0623-589 1 Clip, Retaining

2005 Pantera 550

CONSOLE AND SWITCH ASSEMBLY0738-511


1 1606-614 1 Console2 1606-105 1 Door, Console3 0609-449 1 Switch, Ignition (inc. 4)4 * 2 Key5 0609-450 1 Spacer, Ignition Switch6 0123-899 1 Washer, Lock - Internal Tooth7 2611-744 1 Decal, Console - Right

11111

8 0609-113 1 Nut, Retaining9 0687-007 1 Cable, Choke (inc. 10-11)0 0636-062 1 Kit, Choke Lever1 0623-054 1 Nut, Choke2 0641-158 1 Outlet, Accessory3 3611-405 1 Decal, Console - Left4 1623-175 4 Screw, Self-Tapping

*Key is coded to switch; see dealer to determine part number.

19

2005 Pantera 550

BELLY PAN AND FRONT BUMPER ASSEMBLY0739-530


1 2706-894 1 Belly Pan - Right - Silver2 2706-663 1 Belly Pan - Left - Silver3 0623-378 2 Screw, Self-Tapping4 3606-532 1 Louver, Air-Intake - Right - Silver

3606-533 1 Louver, Air-Intake - Left - Silver5 8061-508 9 Rivet6 0617-315 1 Foam, Belly Pan - Left7 0623-647 2 Screw, Self-Tapping8 0623-184 2 Washer9 0623-269 4 Clip, Retaining

10 0606-526 2 Reflector, Front - Amber11 3606-630 1 Panel, Clutch Access - Silver12 0623-784 4 Screw, Self-Tapping13 3002-964 1 Clamp, Wire14 0123-149 4 Washer15 0623-427 2 Nut, U

111122

22222222

20

6 2606-737 1 Bumper, Front - Pewter7 8020-040 4 Screw, Cap8 8048-366 6 Nut, Lock9 1623-129 16 Screw, Self-Tapping0 0623-564 8 Screw, Self-Tapping1 0605-332 1 Boot, Steering - Right

0605-333 1 Boot, Steering - Left2 0619-206 AR Tape, Foil3 0712-881 1 Ring, Exhaust Outlet - Upper4 0612-470 1 Boot, Exhaust5 0712-880 1 Ring, Exhaust Outlet - Lower6 0712-879 1 Deflector, Exhaust7 8020-039 2 Screw, Cap8 8060-508 8 Rivet9 0123-788 1 Cable Tie - 7.5 in.

2005 Pantera 550

BELT GUARD ASSEMBLY0739-936


1 0707-628 1 Belt Guard Assembly (inc. 2-4)2 0607-549 1 Bushing, Belt Guard3 0607-550 1 Plate, Bushing - Belt Guard4 8060-504 2 Rivet5 3611-969 1 Decal, “ACT - Roller Driven Clutch”6 0607-447 1 Cable7 0605-283 1 Clip, Hairpin8 0636-659 1 Holder, Drive Belt (inc. 9)9 8060-706 2 Rivet

11111111

0 1611-582 1 Decal, Caution - Jetting/Storage1 1611-565 1 Decal, Warning - Belt Guard2 8020-050 1 Screw, Cap3 0607-094 2 Insert, Hinge4 8048-366 1 Nut, Lock5 0707-707 1 Bracket, Belt Guard6 3002-964 1 Clamp, Wire7 8061-508 4 Rivet

21

2005 Pantera 550

GAS TANK AND SEAT ASSEMBLY0739-533


1 1718-752 1 Complete Seat Assembly - Front (inc. 2-18 and one No. 19)

2 0770-655 1 Tank, Gas/Seat-Base (inc. 3-10)3 0670-042 1 Outlet, Tank4 6101-001 AR Hose, Gasline - 100 ft

6101-009 AR Hose, Gasline - 50 ft5 0510-358 1 Strainer, Gas Tank6 1670-494 1 Vent, Gas Tank7 1670-325 1 Grommet8 0670-289 AR Tape, Teflon9 0670-341 1 Cap, Gas Tank (inc. 10)

10 0109-733 1 Seal, Tank Cap11 1606-612 1 Insert, Seat Foam12 1706-158 1 Foam, Seat Cushion - Front13 2606-133 1 Insert, Seat Foam14 0623-309 6 Screw, Self-Tapping15 8050-217 2 Washer16 0624-528 AR Staple, Seat Cover17 2606-943 1 Wire, Seat18 2706-659 1 Cover, Seat - Front (inc. one No. 19)19 3606-363 2 Wire, Seat20 1718-753 1 Complete Seat Assembly - Passenger

(inc.16, one No. 19, and 21-30)21 2606-066 1 Seat-Base - Passenger22 2606-188 1 Bracket, Hold-Down - Seat - Right

2606-189 1 Bracket, Hold-Down - Seat - Left23 0623-853 12 Rivet

22222

233333333

3

34444444

22

4 2606-161 1 Plate, Strike5 0623-778 4 Rivet6 0617-098 1 Foam, Seat-Base/Taillight7 1606-191 1 Extension, Toolbox8 2706-660 1 Cover, Seat - Passenger

(inc. one No. 19)9 1706-159 1 Foam, Seat - Passenger0 2606-942 1 Wire, Seat1 2706-130 1 Bracket, Retainer - Latch2 8060-706 2 Rivet3 2606-159 1 Handle, Backrest - Latch4 2606-154 2 Spring, Compression5 8017-580 2 Screw, Machine6 8050-222 2 Washer7 2606-268 1 Guard, Seat - Right

2606-269 1 Guard, Seat - Left8 2706-134 1 Bracket, Hold-Down - Receiver - Right

2706-135 1 Bracket, Hold-Down - Receiver - Left9 0623-582 2 Insert0 2606-180 1 Pad, Rubber1 0624-312 5 Screw, Machine2 0623-371 5 Washer, Nylon3 0620-255 1 Sender, Fuel Level (inc. 44)4 0670-474 1 Gasket, Fuel Level Sender5 1623-233 1 Clamp, Hose6 0623-101 1 Clip, Routing - Snap-In

2005 Pantera 550

BACKREST AND TAILLIGHT ASSEMBLY0739-536


1 2706-658 1 Backrest w/Cover (inc. 2-3)2 2706-657 1 Cover, Backrest3 0114-163 1 Axle, Backrest4 0723-003 2 Washer, Cup5 0616-547 2 Block, Tension - Backrest6 0623-566 2 Screw, Machine7 2706-126 1 Arm, Adjuster - Backrest - Right

2706-127 1 Arm, Adjuster - Backrest - Left8 1606-903 2 Spacer, Backrest Adjuster9 8017-582 14 Screw, Machine

10 0609-093 4 Screw, Retaining11 0609-090 1 Lens, Taillight12 0609-092 1 Gasket, Taillight Lens13 0109-460 1 Bulb, Stop/Taillight14 0609-091 1 Housing, Taillight w/Socket15 1606-689 1 Cover, Taillight16 8050-212 2 Washer17 0623-038 2 Nut w/Washer18 1706-230 1 Bracket, Mounting - Rack/Taillight19 4611-043 1 Decal, Warning - Latch/Payload (French)20 4611-042 1 Decal, Warning - Latch/Payload (English)21 8017-580 4 Screw, Machine22 8048-366 4 Nut, Lock23 0609-370 1 Switch, Handwarmer - Passenger24 1606-682 1 Bracket, Backrest/Rack - Right25 8020-042 8 Screw, Cap26 0686-702 1 Harness, Handwarmer - Passenger - Right

2223333333333444444

4444

5

7 0686-701 1 Harness, Handwarmer - Passenger - Left8 8050-217 2 Washer9 2706-128 2 Retainer, Handhold0 1606-683 1 Bracket, Backrest/Rack - Left1 0623-826 4 E-Ring2 2706-129 2 Retainer, Handhold - Passenger3 1606-819 2 Lever, Quick-Release - Backrest4 0623-842 2 Washer5 0623-838 2 Washer, Friction6 0606-029 2 Reflector, Rear - Red7 0623-269 4 Clip, Retaining8 1606-772 2 Retainer, Handgrip - Passenger9 0623-727 6 Screw, Self-Tapping0 0670-183 2 O-Ring1 0609-476 2 Element, Handwarmer - Passenger2 1606-771 2 Handgrip, Passenger Handhold3 1606-688 2 Lever, Quick-Release - Handhold4 0623-837 2 Washer, Friction5 1606-684 1 Handhold, Passenger - Right

1606-685 1 Handhold, Passenger - Left6 0623-850 2 T-Nut7 0623-378 4 Screw, Self-Tapping8 0123-802 4 Washer9 1606-238 1 Deflector, Wind - Right

1606-239 1 Deflector, Wind - Left0 0123-987 2 Clip, Retaining

23

2005 Pantera 550

TUNNEL AND REAR BUMPER0739-627 *Optional


1 1718-542 1 Tunnel Assembly (inc. 2-3)2 1706-032 1 Bracket, Suspension Mounting - Right

1706-033 1 Bracket, Suspension Mounting - Left3 0623-072 AR Rivet, Solid

0123-418 AR Rivet, Solid8060-506 AR Rivet*

4 2706-116 2 Plate, Suspension Mounting - Front5 2706-118 1 Roll, Tunnel - Right

2706-119 1 Roll, Tunnel - Left6 8060-506 19 Rivet7 2706-386 1 Footrest, Rear - Right

2706-387 1 Footrest, Rear - Left8 0707-704 1 Bracket, Main Harness Protector9 0623-166 2 Rivet

10 3002-964 1 Clamp

1111111112222

24

1 0623-562 2 Plug, Hole2 1606-200 1 Bumper, Rear3 0623-771 4 Nut, U4 0623-427 2 Nut, U5 5611-852 1 Decal, Warning - Towing (French)6 5611-853 1 Decal, Warning - Towing (English)7 8017-580 1 Screw, Machine8 8017-579 2 Screw, Machine9 0623-184 2 Washer0 8048-366 3 Nut, Lock1 8050-217 1 Washer2 1606-507 1 Snowflap, Reverse3 6611-174 1 Decal, Tunnel - Right

6611-175 1 Decal, Tunnel - Left

2005 Pantera 550

COOLING ASSEMBLY0738-529


1 1606-396 1 Tank, Coolant2 0606-268 1 Cap, Filler Neck3 2611-758 1 Decal, Fill Level - Coolant Tank4 0623-761 1 Clamp, Coolant Tank5 6101-001 AR Hose, Vent - 100 ft

6101-009 AR Hose, Vent - 50 ft6 8017-580 1 Screw, Machine7 8048-366 1 Nut, Lock8 0623-736 8 Clamp, Hose

11

11

11

9 0610-378 1 Hose, Coolant - Engine/Coolant Tank0 0623-540 2 Cable Tie - Triple1 0610-336 1 Hose, Coolant - Engine/Front Heat

Exchanger2 0610-379 1 Hose, Coolant Tank/Rear Heat Exchanger3 0610-244 1 Hose, Coolant - Front Heat Exchanger/

Rear Heat Exchanger4 1706-919 1 Heat Exchanger, Rear5 8060-706 36 Rivet

25

2005 Pantera 550

ENGINE AND RELATED PARTS

0738-530


1 0662-393 1 Engine, ACB55L62 0708-114 1 Bracket, Engine Mounting - Right - Front3 8013-132 6 Screw, Cap4 8051-242 6 Washer, Lock5 8050-242 6 Washer6 8020-220 2 Screw, Cap7 0608-217 3 Mount, Engine8 8020-135 1 Screw, Cap9 0745-135 1 Bracket, Engine Mounting - Left - Front

10 8048-486 6 Nut, Lock11 0608-118 1 Mount, Engine - Double Male12 0708-070 1 Bracket, Engine Mounting - Right - Rear13 0636-363 1 Handle, Recoil14 0606-885 1 Cap, Recoil Handle15 0608-235 1 Bracket, Engine Mounting - Left - Rear16 0623-095 2 Screw, Machine

11

1222222222233

26

7 8020-224 3 Screw, Cap8 0708-140 1 Bracket, Engine Mounting/Bearing Support

(inc. 19-20)9 1623-010 1 Fitting, Grease0 0623-904 1 Cap, Grease Fitting1 8020-040 1 Screw, Cap2 8048-366 1 Nut, Lock3 8020-225 1 Screw, Cap4 0608-299 1 Bumper, Torque - Engine5 8042-516 2 Nut6 8050-282 2 Washer7 8051-277 1 Washer, Lock8 0725-301 1 Clutch, Drive9 0627-021 1 Belt, Drive0 0623-210 1 Washer, High Collar1 0623-804 1 Bolt, Clutch

2005 Pantera 550

EXHAUST ASSEMBLY0738-537


1 0712-720 1 Chamber, Expansion - Assembly2 0612-027 1 Spring, Extension3 0612-131 1 Gasket, Exhaust4 1712-058 1 Manifold, Exhaust5 0612-188 1 Gasket, Exhaust6 0712-885 1 Resonator7 0712-330 1 Bracket, Support - Expansion Chamber8 0623-856 2 Screw, Machine - Hex Shoulder9 0612-107 2 Bushing, Resonator - Rubber

10 8048-366 2 Nut, Lock

111111111

1 0612-820 3 Spring, Exhaust2 0623-765 1 Screw, Self-Tapping3 0612-111 1 Bumper, Rubber4 0712-906 1 Bracket, Mounting - Resonator5 0612-471 4 Spring, Exhaust6 8020-040 2 Screw, Cap7 0712-903 1 Bracket8 8053-212 1 Washer, Lock - External Tooth9 0686-126 1 Harness, Engine/Ground

27

2005 Pantera 550

FLEX-DRIVE STARTER MOTOR ASSEMBLY0738-538 *Not a Service Part


1 0745-143 1 Motor, Starter (inc. 2-10)2 0645-296 1 Armature Assembly (inc. 3-4)3 0645-131 1 Washer, Wave4 0645-293 1 Washer, Thrust5 0645-297 1 Cap, Drive6 0645-313 1 Cap, Commutator (inc. 7)7 0645-275 1 Kit, Brush and Spring8 0645-128 2 Through-Bolt9 0623-093 2 Bolt, Ribbed

10 * 1 Case, Starter Motor11 0708-135 1 Bracket, Mounting - Starter Motor12 0623-890 2 Screw, Self-Tapping13 8048-426 2 Nut, Lock14 8020-224 1 Screw, Cap15 0745-153 1 Shield, Heat16 8048-366 1 Nut, Lock17 0623-892 1 Screw, Self-Tapping

11222222222233333

28

8 0623-404 1 Cap, Protector9 0745-156 1 Shaft, Flex-Drive (inc. 20)0 0623-891 4 Screw, Set1 0745-135 1 Bracket, Engine Mounting - Left Front2 0645-256 2 Ring, Snap3 0645-254 3 Washer, Thrust4 0645-255 1 Washer, Wave5 0745-253 1 Drive, Pinion - Flex-Drive Shaft (inc. 26-28)6 0745-224 1 Kit, Pinion Drive Assembly (inc. 27-28)7 0645-380 1 Pinion Drive Assembly8 0645-186 1 Pinion Stopper Assembly9 0645-329 1 Ring Gear0 1623-128 6 Screw, Machine - Socket Head1 8005-584 1 Screw, Cap2 8051-242 1 Washer, Lock3 0623-140 2 Washer4 1623-080 1 Clamp, Flex-Drive Shaft

2005 Pantera 550

BATTERY, SOLENOID, AND CABLES0738-544


1 0745-047 1 Battery (inc. 2-6)2 0645-045 6 Cap, Battery3 0645-152 1 Clamp, Hose4 0645-263 1 Hose, Battery Vent5 0645-151 1 Decal, Warning - Battery6 0645-082 AR Wrap, Heat - Battery7 0645-161 1 Cable, Battery/Solenoid (inc. 8-9)8 0645-019 1 Boot, Terminal - Battery9 0645-327 1 Boot, Terminal - Solenoid

10 0645-318 1 Cable, Battery/Ground11 0645-115 1 Cable, Solenoid/Starter12 0645-196 1 Solenoid (inc. 13-16)13 8051-242 2 Washer, Lock14 8043-452 2 Nut15 8051-152 2 Washer, Lock

111122222222

2

6 8042-272 2 Nut7 0745-144 1 Tray, Battery8 0645-245 1 Strap, Battery - Side9 0645-243 1 Strap, Battery - Top0 0623-325 1 Nut, Wing1 8050-217 1 Washer2 8048-366 6 Nut, Lock3 0623-122 1 Nut, Lock4 0716-391 AR Conduit, Flexible5 0645-181 1 Tube, Heat Protection6 0623-144 1 Cable Tie - 17.5 in.7 8020-040 AR Screw, Cap

8020-045 AR Screw, Cap8 0123-788 AR Cable Tie - 8 in.

29

2005 Pantera 550

CARBURETOR AND FUEL PUMP ASSEMBLY0739-539


1 0770-379 2 Carburetor - VM38-4242 0623-652 2 Clamp, Hose3 0610-442 2 Hose, Drain4 0670-197 2 Flange, Carburetor (inc. 5-6)5 0670-199 2 Clamp (inc. 6)6 0670-209 2 Spacer, Clamp7 1670-402 2 Boot, Carburetor8 0670-144 1 Valve, Fuel Shut-Off (inc. 9-10)9 0623-287 1 Nut

10 0623-288 1 Washer11 0770-614 1 Bracket, Mounting - Fuel Shut-Off Valve12 8017-402 4 Screw, Machine13 6101-001 AR Hose, Gasline - 100 ft

6101-009 AR Hose, Gasline - 50 ft

111111222222

30

4 0510-335 1 Filter, Fuel5 0610-007 AR Hose, Impulse - 25 ft6 0670-311 1 Pump, Fuel7 8017-577 1 Screw, Machine8 8051-212 1 Washer, Lock9 0123-811 3 Cable Tie - 4 in.0 0770-693 1 Plate, Mounting (inc. 21)1 1623-127 6 Insert2 8017-406 2 Screw, Machine3 0107-630 2 Spacer, Fuel Pump4 0716-558 1 Conduit, Flexible - 10 ft5 1623-233 10 Clamp, Hose

2005 Pantera 550

AIR SILENCER ASSEMBLY0739-540


1 0770-439 1 Silencer, Air - Assembly (inc. 2)2 0623-627 1 Insert, Threaded3 0617-254 1 Foam, Air Silencer - Front4 0617-252 1 Foam, Air Silencer - Back Magneto5 0617-253 1 Foam, Air Silencer - Back PTO6 1670-197 1 Cover, Air Silencer7 0617-393 1 Foam, Air Silencer - Cover8 0623-727 3 Screw, Self-Tapping9 1670-049 1 Cover, Tool Tray

10 0617-411 1 Foam, Tool Tray11 0623-780 2 Screw, Machine - Hex Shoulder12 4611-029 1 Decal, Fuel Shut-Off Valve

11111112222

3 1606-038 2 Bumper, Air Silencer4 0623-403 1 Clamp, Push-Mount5 1670-062 1 Resonator, Q-Wave6 6611-443 1 Decal, Jet Chart7 0617-245 1 Seal, Air Silencer/Plenum8 0617-270 2 Foam, Plenum - Intake9 8020-039 9 Screw, Cap0 1670-327 1 Plenum, Air Silencer1 8020-040 1 Screw, Cap2 8048-366 10 Nut, Lock3 0707-705 1 Bracket, Guide - Harness/Rope

31

2005 Pantera 550

OIL TANK ASSEMBLY0739-449


1 1670-026 1 Tank, Oil2 0609-503 1 Sensor, Low Oil - Assembly (inc. 3-4)3 0609-518 1 Switch, Oil Sensor w/Harness4 0609-237 1 Seal, Grommet - Oil Sensor5 1670-365 1 Cap, Tank (inc. 6)6 0109-733 1 Seal, Tank Cap7 1611-564 1 Decal, Oil Tank8 8017-580 1 Screw, Machine

1111

11

32

9 8048-366 1 Nut, Lock0 0670-289 AR Tape, Teflon1 0670-733 1 Outlet, Oil Tank2 1623-351 2 Clamp, Hose3 6101-001 AR Hose, Oil Line - 100 ft

6101-009 AR Hose, Oil Line - 50 ft4 0716-558 AR Conduit, Flexible - 10 ft5 1670-234 1 Foil, Protective

2005 Pantera 550

DRIVE CLUTCH(Assembly p/n 0725-301)

0737-832

Cam Arm Kit - p/n 1639-030 (inc. 5, 6, 8, and 9)Uncalibrated Drive Clutch - p/n 0746-103


1 0646-325 1 Sheave, Stationary2 0746-074 1 Sheave, Movable3 0746-086 1 Cover4 0646-140 1 Nut5 0646-295 3 Pin, Cam Arm6 0623-392 3 Nut, Lock7 0746-527 3 Arm, Cam (inc. 8)

0746-538 3 Arm, Cam (inc. 8) (5-9,000 ft Alt.)0746-523 3 Arm, Cam (inc. 8) (Over 9,000 ft Alt.)

11111

8 0646-160 3 Bearing, Cam Arm9 0646-101 6 Washer, Cam Arm0 0646-265 3 Washer, Spacer1 0746-118 1 Spider Assembly2 8051-212 9 Washer, Lock3 0623-596 9 Screw, Machine4 0646-149 1 Spring, Drive Clutch - Red

0646-147 1 Spring, Drive Clutch - Yellow/Green (Over 5,000 ft Alt.)

33

2005 Pantera 550

DRIVEN CLUTCH(Assembly p/n 0726-162)

0738-405


1 0748-023 1 Sheave, Movable (inc. one No. 2)2 0648-009 2 Bearing3 0148-199 2 Washer, Thrust: 0.060 in.

0148-198 1 Washer, Thrust: 0.030 in.4 0748-021 1 Sheave, Stationary5 0648-014 1 Bracket, Torque 49°

0648-025 1 Bracket, Torque 47° (Over 9,000 ft Alt.)6 8051-152 3 Washer, Lock7 8005-404 3 Screw, Cap

11111

34

8 0148-227 1 Spring, Driven Clutch - Yellow9 0748-018 1 Plate, Roller - Assembly (inc. one No. 2

and 10-13)0 8070-224 3 Pin, Spring1 0648-097 3 Pin, Cam Roller2 0648-082 3 Washer, Thrust - Cam Roller3 0648-079 3 Roller, Cam4 8048-426 3 Nut, Lock

2005 Pantera 550

CARBURETORVM38-424 (Complete Carburetor p/n 0770-379)

0738-549 *Not a Service Part


1 * 1 Mixing Body Assembly2 6505-188 1 Cap, Starter Plunger3 6505-193 1 Washer4 6505-033 1 Spring5 6505-035 1 Plunger, Starter6 6505-101 1 Screw, Throttle Stop7 6505-021 1 Spring, Throttle Stop Screw8 6505-020 1 Spring, Pilot Air Screw9 6505-019 1 Screw, Pilot Air

10 6505-047 1 Pilot Jet 4011 6505-199 1 Guide, Screw12 6505-620 1 Ring, Baffle13 6505-076 1 Main Jet 340**14 6505-582 1 Top, Mixing Chamber15 6505-584 1 Spring, Piston Valve16 6505-588 1 Plate17 0770-045 1 Block, Magnet18 6505-591 1 Screw, Machine19 6505-610 1 E-Clip20 6505-437 2 Washer, E-Clip21 6505-236 1 Jet Needle 6DH8-3

22

222222333333333344

2 6505-643 1 Piston Valve CA 3.03 6505-595 1 Needle Jet P-2 (480)

6505-598 1 Needle Jet P-0 (480) (Over 5,000 ft Alt.)4 0623-137 2 Screw, Cap5 0630-076 1 Switch, Magnetic - Carburetor6 6505-400 1 Screw, Machine7 6505-399 1 Washer8 6505-612 1 Washer9 6505-102 2 Washer, Valve Seat0 6505-171 1 Needle Valve Assembly 1.51 6505-153 1 Pin, Float Arm2 6505-638 1 Arm, Float3 6505-010 2 Cap4 6505-640 2 Float5 6505-197 1 Gasket, Float Chamber6 6505-637 1 Chamber, Float7 6505-094 2 Plate, Hose8 6505-280 2 Tube, Air Vent9 6505-195 4 Screw w/Spring Washer0 6505-622 1 O-Ring1 6505-617 1 Plug, Drain

**Alternate Carburetor Parts on page 44

35

2005 Pantera 550

CYLINDER AND HEAD ASSEMBLY0737-702


1 3003-762 2 Head, Cylinder2 3003-765 2 O-Ring, Head - Outer3 3003-227 12 O-Ring, Head Bolt4 3003-764 2 O-Ring, Head - Inner5 3004-370 12 Bolt, Head6 0217-709 2 Plug, Spark (BR9EYA)7 3003-926 2 Cylinder (inc. 8)8 3003-597 2 Fitting, Oil9 3003-763 2 Gasket, Cylinder

10 3005-207 8 Bolt, Stud - Cylinder

111111111

36

1 3004-989 8 Nut2 3004-362 8 Washer, Lock3 3004-278 8 Washer4 3004-279 4 Bolt, Stud5 3004-334 8 Nut6 3004-280 8 Washer, Lock7 3423-204 4 Washer8 3003-503 2 Gasket, Exhaust9 3004-301 4 Bolt, Stud

2005 Pantera 550

CRANKCASE ASSEMBLY0737-705


1 3002-276 2 Gasket2 3002-040 1 Union, Hose3 3005-406 1 Crankcase Assembly (inc. 4-9) 4 3003-646 2 Pin, Dowel5 3004-442 2 Bolt6 3004-444 2 Bolt7 3004-881 8 Bolt8 3004-880 2 Bolt

111111

9 3003-647 1 Bushing, Oil Pump Shaft0 3004-775 1 Plate, Oil Seal1 3004-377 4 Bolt2 3006-440 1 Cover, Sensor Opening3 0623-352 2 Screw, Cap4 8051-152 2 Washer, Lock5 3006-634 1 Plug, Crankcase

37

2005 Pantera 550

PISTON AND CRANKSHAFT0735-044 *Not a Service Part


1 * 2 Piston2 3006-686 2 Ring Assembly3 3003-767 2 Pin, Piston4 3003-433 2 Bearing, Piston Pin5 3003-439 4 Circlip, Piston Pin6 3005-209 4 Washer, Piston Pin Bearing7 3005-752 1 Crankshaft Assembly (inc. 8-22 and 24-25)8 3005-112 2 Rod, Connecting9 3003-784 2 Bearing

10 3003-812 1 Crankshaft - Right11 3005-753 1 Crankshaft - Center12 3005-232 1 Wheel, Crank13 3005-231 1 Crankshaft - Left14 3003-815 2 Balancer, Crankshaft15 3004-372 8 Screw, Machine16 3004-698 2 Race, Middle Seal17 3003-817 2 Ring

11222222222233333

38

8 3005-202 1 Gear, Oil Pump Drive9 3005-210 1 Bearing, Crankshaft - Right0 3003-164 2 Bearing, Crankshaft - Center1 3003-782 2 Washer2 3003-805 1 Bearing, Crankshaft - Left3 3004-540 1 Key4 3003-783 1 Washer5 3003-933 1 Washer, Crank Pin6 3005-188 1 Seal, Oil - Right7 3003-759 1 Seal, Oil - Left8 3003-216 1 C-Ring9 3003-658 4 Pin, Alignment0 3005-324 1 Gear, Driven - Oil Pump1 3005-049 1 Shim, Oil Pump Shaft2 3005-909 1 Seal, Mechanical Water Pump3 3004-760 1 Seal, Water/Oil Pump4 3006-685 2 Piston Assembly (inc. 1-2 and 5)

2005 Pantera 550

OIL PUMP0728-134


1 3004-394 1 Oil Pump Assembly2 3004-349 1 Gasket, Oil Pump3 3004-373 2 Screw4 3008-035 2 Hose, Oil Pump5 3008-037 4 Clip, Hose6 3003-661 1 Union, Gear Lube

111

7 3005-357 1 Hose, Oil Pump8 3004-763 1 Retainer, Oil Pump9 3004-286 1 Gasket, Retainer0 3003-217 3 Valve, Check1 3004-346 4 Bolt, Union2 3402-009 8 Gasket, Check Valve

39

2005 Pantera 550

WATER PUMP/WATER MANIFOLD0736-190


1 3005-519 1 Case, Water Pump2 3003-702 2 Screw, Case3 3002-012 2 Pin, Case4 3003-372 1 O-Ring, Case5 3003-432 1 Washer6 3005-697 1 Impeller7 3003-426 1 Bolt8 3003-431 1 Washer9 3003-618 1 Drain

10 3005-226 1 O-Ring, Drain11 3004-472 1 Washer, Lock12 3004-417 1 Washer

11111112222

40

3 3004-402 3 Screw4 0630-140 1 Sensor, Heat5 3004-509 1 Thermostat6 3003-924 1 Cap, Thermostat7 3004-376 3 Bolt8 3004-777 1 Manifold, Thermostat9 3004-260 2 Gasket, Thermostat Manifold0 3004-369 4 Bolt1 3003-495 1 Gasket, Thermostat2 0623-285 1 Cable Tie - Double Loop3 3004-009 1 Circlip

2005 Pantera 550

RECOIL STARTER0737-558 *Not a Service Part


1 3006-915 1 Starter Assembly (inc. 2-10)2 3003-179 1 Roller, Starter3 3002-921 1 Spring4 3006-457 1 Ratchet Set (inc. 5-7)5 * 1 Spring, Friction6 * 1 Washer7 * 1 Spring, Return

1111

8 3006-475 1 Plate, Friction9 3006-456 1 Nut0 3006-889 1 Rope, Starter1 3004-383 4 Screw, Cap2 3003-929 1 Pulley, Starter3 3004-338 3 Bolt

41

2005 Pantera 550

MAGNETO0736-621


1 3004-833 1 Stator Assembly (inc. 2-6)2 3003-013 1 Coil, Lighting3 3004-445 3 Screw4 3004-344 5 Washer, Lock5 3004-834 1 Coil Set, Primary6 3004-476 2 Screw

111

42

7 3003-795 1 Grommet8 3004-893 2 Bolt9 3005-950 1 Rotor/Flywheel0 3005-175 1 Washer1 3004-345 1 Washer, Lock2 0691-370 1 Nut

2005 Pantera 550

ELECTRICAL0735-864


1 3005-408 1 CDI Unit2 3005-409 1 Coil, Ignition3 3003-737 2 Cap, Spark Plug

4 3003-474 1 Cover, Connector5 3005-387 1 Clamp

43

44

ALTERNATE CARBURETOR PARTS

* For models with carburetor switch.

MAIN JETS AVAILABLEJET P/N JET P/N120 6505-270 420 6505-125130 6505-216 430 6505-146140 6505-217 440 6505-126150 6505-168 450 6505-147160 6505-064 460 6505-127170 6505-065 470 6505-148180 6505-056 480 6505-149190 6505-066 490 6505-150200 6505-144 500 6505-151210 6505-145 510N 6506-378220 6505-137 520 6505-530230 6505-067 520N 6506-379240 6505-079 530 6505-170250 6505-068 530N 6506-380260 6505-017 540 6505-531270 6505-069 540N 6506-381280 6505-080 550N 6506-382290 6505-123 560 6505-172300 6505-128 560N 6506-383310 6505-136 580 6505-211320 6505-074 590 6505-173330 6505-070 600 6505-532340 6505-076 620 6505-174350 6505-071 640 6505-533360 6505-038 650 6505-534370 6505-072 660 6505-535380 6505-077 680 6505-169390 6505-078 700 6505-536400 6505-124 710 6505-537410 6505-212 720 6505-538

PISTON VALVES AVAILABLE(VM-Style)

SLIDE CARBURETOR SIZE (mm)

P/N

2.0 28-30 6505-0483.0 28-30 6505-1613.0 30 6505-5103.5 30 6505-5281.5 32-34 6505-2562.5 32-34 6505-2463.0 32-34 6505-4393.5 32-34 6505-2482.5 34 6505-5002.5 34 6505-614*3.0 34 6505-5073.0 34 6505-561*2.0 36 6505-8773.0 36 6505-592*2.5 38 6505-2543.0 38 6506-6433.5 38 6505-4363.5 38 6505-5253.5 38 6505-5263.5 38 6505-5543.5 38 6505-613*4.0 38 6505-5043.5 40 6505-575*1.0 40-44 6505-0922.0 40-44 6505-1792.5 40-44 6505-5703.5 40-44 6505-5483.0 40-44 6506-8093.5 40-44 6505-813*

THROTTLE VALVES AVAILABLE(TM-Style)

SLIDE CARBURETOR SIZE (mm)

P/N

2.0 38 6506-1193.0 38 6506-1203.0 38 6506-2323.5 38 6506-2102.5 40 6506-273

NEEDLE JETS AVAILABLE(VM-Style)NEEDLE

JETP/N NEEDLE

JETP/N

O-6 (480) 6505-931 Q-2 (480) 6505-641O-8 (182) 6505-181 Q-3 (480) 6505-599O-8 (480) 6505-824 Q-4 (166) 6505-214P-0 (159) 6505-155 Q-4 (480) 6505-636P-0 (166) 6505-007 Q-5 (159) 6505-119P-0 (169) 6505-051 Q-5 (166) 6505-520P-0 (480) 6505-598 Q-5 (480) 6505-580P-2 (480) 6505-595 Q-6 (166) 6505-506P-4 (159) 6505-221 Q-8 (480) 6506-112P-4 (166) 6505-502 R-0 (166) 6505-505P-4 (480) 6505-540 Z-4 (224) 6505-808P-4 (169) 6505-164 Z-5 (224) 6505-541P-5 (480) 6505-542 Z-6 (224) 6505-597P-6 (159) 6505-247 Z-8 (224) 6505-572P-6 (166) 6505-268 Z-9 (224) 6505-618P-6 (480) 6505-539 AA-0 (224) 6505-544P-6 (251) 6505-235 AA-1 (224) 6505-609P-8 (159) 6505-298 AA-2 (224) 6505-545P-8 (166) 6505-433 AA-3 (224) 6505-604P-8 (480) 6505-543 AA-4 (224) 6505-605Q-0 (159) 6505-260 AA-5 (224) 6505-099Q-0 (166) 6505-190 AA-8 (224) 6505-571Q-0 (480) 6505-529 BB-0 (224) 6505-182Q-2 (166) 6505-508 BB-5 (224) 6505-180

JET NEEDLES AVAILABLEJET

NEEDLE(VM-Style)

P/N JET NEEDLE

(TM-Style)

P/N

6CH3 6505-519 9CFH1-56 6506-1166DH2 6505-252 9DH2-59 6506-1106DH3 6505-509 9DH5-61 6506-1146DH4 6505-003 9DEH1-55 6506-1186DH7 6505-215 9DEH2-57 6506-1156DH8 6505-236 9EGY01-57 6506-1926DF7 6506-297 9EH09 6506-1737DJ2 6505-549 9EH2-57 6506-1117DH2 6505-097 9EH6-60 6506-117

9EJ1-60 6506-3847DH5 6505-814 9EH7-62 6506-113

9DFH2-58 6506-2009DFH2-59 6506-2019DFH3-56 6506-186

9DEH3 6506-1829DFH1-56 6506-2219DFH-59 6506-3049EH6-59 6506-2289DH9-54 6506-2729EH6-58 6506-290

9DFH4-60 6506-2609EFH9-60 6506-374

INLET NEEDLE ASSEMBLIES AVAILABLE(VM-Style)

SEAT DIA. CARB. SIZE (mm)

P/N

1.5 mm (Steel) 28, 30, 32, 34 6505-0261.5 mm (Viton) 28, 30, 32, 34 6505-1601.5 mm (Steel) 28 — 34 GVM 6505-2451.5 mm (Steel) 36, 38, 40, 44 6505-1031.5 mm (Viton) 36, 38, 40, 44 6505-1711.8 mm (Viton) 36, 38, 40, 44 6505-1752.0 mm (Viton) 36, 38, 40, 44 6505-176

INLET NEEDLE ASSEMBLIES AVAILABLE (TM-Style)

SEAT DIA. CARB. SIZE (MM)

P/N

1.5 mm (Steel) 38 6506-1211.8 mm (Steel) 38 6506-144

PILOT JETS AVAILABLEJET NO. P/N JET NO. P/N

17.5 6505-218 35 6505-02920 6505-138 40 6505-047

22.5 6505-310 45 6505-27825 6505-075 50 6505-262

27.5 6505-503 52.5 6505-26130 6505-073 55 6505-255

2639-517 Altitude Kit (5-9000 ft) 2257-085 Manual, Operator’s (E/F)

RELATED ITEMS2005 Pantera 550

(Model No. S2005PTCCAUSB)

2639-518 Altitude Kit (Over 9000 ft)3639-020 Cover, Machine (Storage)3639-660 Cover, Machine (Deluxe)0636-812 Gasket Set1639-217 Gauge Kit, Temperature2257-231 Handbook, Safety (E/F)3639-721 Handlebar Bag0639-456 Handlebar Muffs1639-607 Hitch, Pivot2257-114 Manual, Illustrated Parts

0652-100 Paint, Hood - Black (1/2 oz)0652-024 Paint, Metal - Black3639-714 Saddlebags1639-417 Skid Plate - Black0703-193 Sway Bar - Heavy Duty3639-908 Tank Jacket3639-726 Touring Gear Bag3639-961 Windshield Flair Bags (Pair)3639-962 Windshield Storage Bag - Top

NOTE: For a complete list of related items, refer to the current accessory catalog.

Printed in U.S.A. p/n 2257-114

Pantera 550 Model Number S2005PTCCAUSB 0

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