Arctic Cat A2006TBM4BUSR User Manual
500 TRV
(Automatic Transmission)
ARCTIC CAT
Illustrated Parts Manual
2006
2006
500 TRV
(Automatic Transmission)
®
Model Number A2006TBM4BUSR (Red)
Model Number A2006TBM4BUSG (Green)
Model Number A2006TBM4BUSZ (Cat Green)
Illustrated Parts Manual
TABLE OF CONTENTS
2006 500 TRV
Red (Model No. A2006TBM4BUSR) Green (Model No. A2006TBM4BUSG)
Cat Green (Model No. A2006TBM4BUSZ)
FRONT BODY PANEL ASSEMBLY ..................................................................................................................... 1
REAR BODY PANEL ASSEMBLY ........................................................................................................................ 2
TAILLIGHT ASSEMBLY ....................................................................................................................................... 3
DECALS................................................................................................................................................................. 4
FRAME AND RELATED PARTS .......................................................................................................................... 5
SEAT AND BACKREST ASSEMBLY ................................................................................................................... 6
STEERING POST ASSEMBLY ............................................................................................................................ 7
HANDLEBAR ASSEMBLY .................................................................................................................................... 8
FRONT SUSPENSION ASSEMBLY ..................................................................................................................... 9
REAR SUSPENSION ASSEMBLY ..................................................................................................................... 10
WHEEL AND TIRE ASSEMBLY ......................................................................................................................... 11
AUXILIARY BRAKE ASSEMBLY ........................................................................................................................ 12
HYDRAULIC HAND BRAKE ASSEMBLY ........................................................................................................... 13
HYDRAULIC BRAKE ASSEMBLY ...................................................................................................................... 14
GAS TANK ASSEMBLY .............................................................................................................
REVERSE SHIFT LEVER ASSEMBLY .............................................................................................................. 16
AIR INTAKE ASSEMBLY .................................................................................................................................... 17
BATTERY ASSEMBLY ....................................................................................................................................... 18
ENGINE AND EXHAUST .................................................................................................................................... 19
COOLING ASSEMBLY ....................................................................................................................................... 20
CASE/BELT COOLING ASSEMBLY .................................................................................................................. 21
FRONT DRIVE GEARCASE ASSEMBLY .......................................................................................................... 22
REAR DRIVE GEARCASE ASSEMBLY ............................................................................................................. 23
WIRING HARNESS ASSEMBLY ........................................................................................................................ 24
CARBURETOR ................................................................................................................................................... 25
CYLINDER HEAD ASSEMBLY .......................................................................................................................... 26
CYLINDER ASSEMBLY ..................................................................................................................................... 27
CRANKCASE ASSEMBLY ................................................................................................................................. 28
CLUTCH/V-BELT/MAGNETO COVER ASSEMBLY ...........................................................................................29
CRANKSHAFT ASSEMBLY ............................................................................................................................... 30
STARTER CLUTCH ASSEMBLY ....................................................................................................................... 31
CRANK BALANCER ASSEMBLY ....................................................................................................................... 32
CAMSHAFT/VALVE ASSEMBLY ....................................................................................................................... 33
CAM CHAIN ASSEMBLY ............................................................................................................
RECOIL STARTER ASSEMBLY ........................................................................................................................ 35
OIL FILTER/PUMP ASSEMBLY ......................................................................................................................... 36
WATER PUMP ASSEMBLY ............................................................................................................................... 37
TRANSMISSION ASSEMBLY ............................................................................................................................ 38
SECONDARY TRANSMISSION ASSEMBLY ..................................................................................................... 39
SECONDARY DRIVE ASSEMBLY ..................................................................................................................... 40
GEAR SHIFTING ASSEMBLY ............................................................................................................................ 41
STARTER MOTOR ASSEMBLY ........................................................................................................................ 42
MAGNETO ASSEMBLY ..................................................................................................................................... 43
CONTROL SWITCH HOUSING ASSEMBLY ..................................................................................................... 44
THROTTLE CASE ASSEMBLY .......................................................................................................................... 45
RELATED ITEMS ..................................................................................................................................Back Cover
........................ 15
....................... 34
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 2006 model year.
2005 Arctic Cat Inc. Printed August 2005
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
2006 500 TRV
FRONT BODY PANEL ASSEMBLY
0739-662
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0541-272 1 Rack - Front - Assembly (inc. 2-5)
2 0411-576 1 Decal, Warning - Front Rack Load
3 2406-014 6 Bushing, Rack
4 0441-592 4 Bushing, Rack
5 1441-049 2 Plug, Rack
6 8410-830
7 0423-463 4 Spacer
8 0423-465 4 Grommet
9 8432-802 4 Nut, Lock
10 1406-614 1 Panel, Fender - Front
1406-613 1 Panel, Fender - Front (Green)
1406-615 1 Panel, Fender - Front (Cat Green)
11 1406-358 1 Cover, Access
12 0423-535 2 Rivet, Reinstallable
13 0623-362 10 Rivet, Reinstallable
14 1406-484 1 Cover, Steering Post
4 Screw, Machine
15 0470-513 1 Cover, Storage Box
16 1406-573 1 Box, Storage
17 0470-514 1 Lid, Storage Box
18 1406-599 1 Latch, Storage Box
19 1406-313 1 Panel, Side - Right
1406-314 1 Panel, Side - Left
20 1406-354 1 Panel, Splash - Right
1406-355 1 Panel, Splash - Left
21 0423-342 4 Screw, Self-Tapping
22 0423-101 5 Screw, Body
23 0123-788 AR Cable Tie - 7.5 in.
24 0411-818 1 Decal, Reflector - Front - Right
0411-819 1 Decal, Reflector - Front - Left
25 0423-355 2 Screw, Shoulder
26 8050-222 2 Washer
27 8424-602 2 Nut, Lock
1
2006 500 TRV
REAR BODY PANEL ASSEMBLY
0740-915
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1506-873 1 Rack, Rear - Assembly (inc. 2-7)
2 1441-317 2 Cap, Vinyl
3 0541-448 2 Pin - Assembly (inc. 4)
4 0423-635 2 Pin, Roll
5 0423-036 2 Collar
6 0423-636 2 Spring
7 0441-592 4 Bushing, Rack
8 8410-830 4 Screw, Machine
9 0423-463 4 Spacer
10 0423-465 4 Grommet
11 8432-802 4 Nut, Lock
12 2406-038 1 Panel, Fender - Red
2406-039 1 Panel, Fender - Green (Green)
2406-040 1 Panel, Fender - Cat Green (Cat Green)
13 0411-820 1 Decal, Reflector - Right
0411-821 1 Decal, Reflector - Left
14 2506-092
2506-093
15 0423-087 2 Washer
16 0423-540 34 Nut, Lock
17 0423-419 22 Screw, Machine
18 2406-042 1 Footwell, Rear - Right
2406-043 1 Footwell, Rear - Left
19 1506-813 1 Footwell - Right
1506-814 1 Footwell - Left
20 0423-355 8 Screw, Shoulder
21 1506-125 4 Footpeg
22 0623-362 2 Rivet, Reinstallable
23 0423-101 2 Screw, Body
24 8477-620 2 Screw, Machine
25 0623-184 2 Washer
26 8424-602 2 Nut, Hex
1 Bracket, Rear Fender - Right
1 Bracket, Rear Fender - Left
2
2006 500 TRV
TAILLIGHT ASSEMBLY
0739-987
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0509-022 1 Taillight Assembly (inc. 2-4)
2 0509-025 1 Housing, Taillight
3 0409-056 1 Bulb, Taillight
4 0409-057 1 Socket, Taillight
5 1406-790 4 Pad, Taillight
6 0423-534 2 Grommet
3
2006 500 TRV
DECALS
0740-925 *Included on Front/Rear Fender Panels
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1411-250 1 Decal, Warning - Reverse/Pre-Ride*
2 0411-894 1 Decal, Warning - Hill
3 0411-426 1 Decal, Warning - Clutch Cover
4 1411-074
1411-075
1411-076
5 1411-077
6 0411-833 1 Decal, Passenger
7 0411-832 1 Decal, Warning - Tire Pressure
8 1411-258
1411-259
1411-260
1411-261
1411-256
1411-257
9 1411-014
1411-015
1411-016
1411-017
1411-018
1411-019
1 Decal, Instrument Pod
1 Decal, Instrument Pod (Green)
1 Decal, Instrument Pod (Cat Green)
1 Decal, Warning - Towing
1 Decal, Side - Lower Right
1 Decal, Side - Lower Left
1 Decal, Side - Lower Right (Green)
1 Decal, Side - Lower Left (Green)
1 Decal, Side - Lower Right (Cat Green)
1 Decal, Side - Lower Left (Cat Green)
1 Decal, Side - Upper Right
1 Decal, Side - Upper Left
1 Decal, Side - Upper Right (Green)
1 Decal, Side - Upper Left (Green)
1 Decal, Side - Upper Right (Cat Green)
1 Decal, Side - Upper Left (Cat Green)
10 0411-753 1 Decal, Warning - Age/General*
11 1411-050
12 0411-840 1 Decal, Front
0411-839 1 Decal, Front (Green)
0411-841 1 Decal, Front (Cat Green)
13 1411-264
1411-266
1411-262
14 1411-251
15 1411-269
1 Decal, “Speedrack”
2 Decal, Graphic - TRV
2 Decal, Graphic - TRV (Green)
2 Decal, Graphic - TRV (Cat Green)
1 Decal, Warning - Seat/Passenger
1 Decal, Warning - Passenger
4
2006 500 TRV
FRAME AND RELATED PARTS
0740-926
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1506-864 1 Frame, Main
2 0509-034
0509-035
3 0409-055 4 Bulb, Headlight
4 0623-785 4 Screw, Self-Tapping
5 8050-217 8 Washer
6 0423-447 4 Grommet
7 0423-514 2 Stud, Adjuster - Headlight
8 0423-522 2 Spring, Adjuster
9 0423-513 2 Knob, Adjuster
10 8409-020 4 Screw, Cap
11 0506-653 1 Channel, Bumper Mounting - Right
1506-596 1 Channel, Bumper Mounting - Left
12 1506-562 1 Bracket, Mounting - Bumper - Right
1506-563 1 Bracket, Mounting - Bumper - Left
13 8408-816 11 Screw, Cap
1 Headlight Assembly - Right (inc. 3)
1 Headlight Assembly - Left (inc. 3)
14 1506-855
15 1406-360 1 Grille, Bumper
16 0423-419 2 Screw, Machine
17 0423-101 16 Screw, Body
18 8428-002 2 Nut, Lock
19 1506-429 1 Brace, A-Arm
20 8409-025 2 Screw, Cap
21 2406-091
22 0406-289 1 Pad, Frame
23 8424-802 8 Nut, Flange
24 8409-016 4 Screw, Cap
25 1506-846
1506-847
26 1506-994
1506-995
27 1506-548 1 Channel, Shock Support
1 Bumper
1 Panel, Belly
1 Footrest - Right
1 Footrest - Left
1 Strap, Footrest - Right
1 Strap, Footrest - Left
5
2006 500 TRV
SEAT AND BACKREST ASSEMBLY
0740-930
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1506-937 1 Seat Assembly (inc. 2-9)
2 1506-209 1 Cover, Seat
3 1506-208 1 Foam, Seat
4 2406-144
5 0406-879 2 Bumper, Seat - Rear
6 0406-877 4 Bumper, Seat - Front
7 0624-528 AR Staple
8 1406-592 1 Spring, Seat Latch
9 1506-156 1 Latch, Seat
10 1506-938
11 2506-064
12 1506-816
1 Base, Seat - Assembly (inc. 5-6)
1 Seat, Passenger - Assembly (inc. 11-20)
1 Seat, Passenger - Sub-Assembly
(inc. 7 and 12-14)
1 Foam, Seat - Passenger
13 1506-815
14 2406-110
15 2406-044
16 1506-932
17 2406-112
2406-113
18 0423-362 6 Screw
19 8432-802 6 Nut, Hex
20 0624-250 4 Nut, Lock
21 1506-939
22 1506-818
23 1506-817
24 8408-816 4 Screw
1 Cover, Seat - Passenger
1 Base, Seat - Inner
1 Base, Seat - Passenger
1 Bracket, Seat Support - Assembly
1 Handhold, Passenger - Right
1 Handhold, Passenger - Left
1 Backrest Assembly (inc. 22-23)
1 Foam, Backrest
1 Cover, Backrest
6
2006 500 TRV
STEERING POST ASSEMBLY
0739-774
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 8408-860 4 Screw, Cap
2 0405-035 4 Cap, Steering Adjuster
3 0423-505 2Screw, Shoulder
4 0405-166
5 0405-138
6 0405-139
7 0505-451 1 Post, Steering
8 8408-816 2 Screw, Cap
9 0602-233 1 Flange, Bearing
10 0405-052 1 Bearing w/Inverted Oil Seal
1 Cap, Housing
1 Housing, Lower
1 Housing, Upper
11 0423-073 1 Washer
12 8409-020 1 Screw, Cap
13 0505-408 2 Tie Rod - Assembly (inc. 14-18)
14 0405-083 2 Ball Joint, Tie Rod - Left
15 0423-013 2 Nut - Left
16 0405-107 2 Tie Rod
17 8420-002 2 Nut - Right
18 0405-082 2 Ball Joint, Tie Rod - Right
19 0423-157 4 Nut, Top Lock
20 0623-175 4 Pin, Cotter
7
2006 500 TRV
HANDLEBAR ASSEMBLY
0740-932
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0505-418 1 Tube, Handlebar
2 0405-218 2 Plug, Handlebar
3 0405-149 2 End Cap, Handlebar
4 8050-247 2 Washer
5 8477-845 2 Screw, Machine
6 0405-147 2 Grip, Handlebar
7 0409-013 1 Cover, Key
8 3430-040 1 Switch, Ignition - Assembly (inc. 9)
9 3409-007 1 Key, Ignition - Blank (C Series)
3409-011 1 Key, Ignition - Blank (D Series)
3409-012 1 Key, Ignition - Blank (E Series)
3409-013 1 Key, Ignition - Blank (F Series)
10 1506-578 1 Bracket, Mounting - Instrument Pod
11 0405-188
0405-189
0405-190
12 0423-535 2 Rivet, Reinstallable
13 0420-065 1 Clamp
14 0520-015
15 0423-493 2 Nut, Hex
16 0641-897 1 Outlet, Accessory - 12V
1 Instrument Pod
1 Instrument Pod (Green)
1 Instrument Pod (Cat Green)
1 Gauge, LCD
8
2006 500 TRV
FRONT SUSPENSION ASSEMBLY
0739-603 *Not a Service Part
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1603-889 2 Retainer, Spring
2 0403-137 2 Shock Absorber - Front (inc. 3-4)
3 0604-310 8 Bushing, Shock Absorber
4 0403-028 4 Sleeve, Shock
5 0403-102 2 Cam, Spring Adjuster
6 0503-318
0503-317
7 8409-040 4 Screw, Cap
8 8428-002 10 Nut, Lock
9 0503-272 1 A-Arm, Upper Right - Platinum
0503-273 1 A-Arm, Upper Left - Platinum (inc. 10-13)
0503-196 1 A-Arm, Upper Right - Black (inc. 10-13)
0503-197 1 A-Arm, Upper Left - Black (inc. 10-13)
10 0403-081 4 Bushing
11 0403-080 2 Collar
12 0423-009 4 Clip, Ball Joint
13 0405-115 4 Ball Joint - Front
14 0503-268 1 A-Arm, Lower Right - Platinum
0503-269 1 A-Arm, Lower Left - Platinum
0503-220 1 A-Arm, Lower Right - Black
0503-221 1 A-Arm, Lower Left - Black
2 Spring, Shock Absorber - Platinum
2 Spring, Shock Absorber - Black (Green)
(inc. 10-13)
(Green)
(Green)
(inc. 12-13 and 15-16)
(inc. 12-13 and 15-16)
(inc. 12-13 and 15-16) (Green)
(inc. 12-13 and 15-16) (Green)
15 0403-115 8 Bushing
16 0403-114 4 Collar
17 0505-460
0505-461
18 * 1 Knuckle, Steering - Right
*1 Knuckle, Steering - Left
19 1402-027 2 Bearing, Wheel Hub
20 0423-423 2 Ring, Retaining
21 8409-030 4 Screw, Cap
22 0423-334 2 Screw, Cap
23 8409-075 4 Screw, Cap
24 0502-812
25 0441-400 2 Clip, Retaining
26 0436-276 2 Repair Kit, Boot - Front
27 0441-752 1 Guard, Boot - Right
0441-753 1 Guard, Boot - Left
1441-002 1 Guard, Boot - Right (Green)
1441-003 1 Guard, Boot - Left (Green)
0441-756 1 Guard, Boot - Right (Cat Green)
0441-757 1 Guard, Boot - Left (Cat Green)
28 0423-101 4 Screw, Body
29 0441-587 1 Wrench, Spanner
1 Knuckle - Assembly - Right (inc. 18-20)
1 Knuckle - Assembly - Left (inc. 18-20)
2 Axle - Front (inc. 25-26)
9
2006 500 TRV
REAR SUSPENSION ASSEMBLY
0740-933
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0504-372 1 Knuckle, Right Rear - Assembly (inc. 2-5)
0504-373 1 Knuckle, Left Rear - Assembly (inc. 2-5)
2 1402-027 2 Bearing, Wheel Hub
3 0423-423 2 Ring, Retaining
4 0403-038 4 Collar, Suspension Bushing
5 0403-032 8 Bushing, Suspension
6 0504-326 1 A-Arm, Rear - Lower Right - Platinum
(inc. 7-8)
0504-327 1 A-Arm, Rear - Lower Left - Platinum
(inc. 7-8)
0504-320 1 A-Arm, Rear - Lower Right - Black
(inc. 7-8) (Green)
0504-321 1 A-Arm, Rear - Lower Left - Black
(inc. 7-8) (Green)
7 0403-115 16 Bushing
8 0403-114 8 Collar
9 8428-002 14 Nut, Lock
10 8409-000 4 Screw, Cap
11 0504-330 1 A-Arm, Rear - Upper Right - Platinum
(inc. 7-8)
0504-331 1 A-Arm, Rear - Upper Left - Platinum
(inc. 7-8)
0504-318 1 A-Arm, Rear - Upper Right - Black
(inc. 7-8) (Green)
0504-319 1 A-Arm, Rear - Upper Left - Black
(inc. 7-8) (Green)
12 0441-754 1 Guard, Boot - Right
0441-755 1 Guard, Boot - Left
1441-004 1 Guard, Boot - Right (Green)
1441-005 1 Guard, Boot - Left (Green)
0441-758 1 Guard, Boot - Right (Cat Green)
0441-759 1 Guard, Boot - Left (Cat Green)
13 0423-101 6 Screw, Body
14 1406-071 1 Guard, Boot - Right
1406-072 1 Guard, Boot - Left
15 0502-811
16 0441-400 2 Clip, Retaining
17 0436-276 2 Repair Kit, Boot - Rear
18 8409-075 8 Screw, Cap
19 1603-889 2 Retainer, Spring
20 0404-127
0404-126
21 0404-099 2 Shock Absorber - Rear (inc. 22-23)
22 0604-310 8 Bushing, Shock Absorber
23 0403-028 2 Sleeve, Shock Absorber
24 0404-057 2 Cam, Spring Adjuster
25 8409-050 2 Screw, Cap
26 0423-087 2 Washer
27 8408-820 2 Screw, Cap
28 0441-875
2 Axle (inc. 16-17)
2 Spring, Suspension - Platinum
2 Spring, Suspension - Black (Green)
1 Wrench, Spanner
10
2006 500 TRV
WHEEL AND TIRE ASSEMBLY
0740-358
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0423-557 12 Screw, Shoulder w/Loctite
2 1402-225 3 Disc, Brake
3 0502-599 2 Hub, Wheel - Front (inc. 4)
4 0402-974 16 Stud, Wheel Hub
5 0502-601 1 Hub, Wheel - Rear - Left (inc. 4)
0502-599 1 Hub, Wheel - Rear - Right (inc. 4)
6 0423-607
7 0423-407 4 Pin, Cotter
8 1402-127 2 Wheel - Front - Platinum
1402-115 2 Wheel - Rear - Platinum
0402-856 2 Wheel - Front - Gray (Green)
0402-858 2 Wheel - Rear - Gray (Green)
4 Nut, Castle Flange
9 0423-408 16 Nut, Mounting - Wheel
10 1402-100 2 Tire - Front
1402-137 2 Tire - Rear
11 0402-064 4 Stem, Valve (inc. 12)
12 0402-140 4 Cap, Valve Stem
11
2006 500 TRV
AUXILIARY BRAKE ASSEMBLY
0740-359 *Not a Service Part
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0502-805 1Lever, Brake
2 1602-213 2 O-Ring
3 8050-252 1 Washer
4 8408-816 1 Screw, Cap
5 0502-807 1 Spring, Brake Lever
6 1402-377 1 Pin, Clevis
7 8050-217 1 Washer
8 0402-584 1 Pin, Cotter
9 0502-881
10 * 1 Master Cylinder
11 0502-880
12 0502-877
13 0623-038 1 Nut, Flanged
14 8476-616 1 Screw, Machine
15 0123-788 1 Cable Tie - 7.5 in.
16 1402-417
1 Brake Assembly (inc. 10-12)
1 Hose, Brake Reservoir
1 Reservoir, Brake
1 Hose, Brake
(Fully Bled Master Cylinder Replacement Kit p/n 0502-939)
17 0423-178 4 Washer, Crush
18 0423-413 2 Bolt, Banjo Fitting
19 0502-840
20 8408-625 2 Screw, Cap
21 0502-785 1 Spring, Brake Switch
22 8408-820 2 Screw, Cap
23 0502-602 1 Caliper, Brake (inc. 24-30)
24 0502-603 1 Housing, Caliper - Assembly -
25 0502-606 1 Piston/Seal Set (inc. 26)
26 0502-607 1 Seal Set
27 0502-609 1 Val ve, Bleed
28 0502-608 1 O-Ring, Guide - Set
29 0502-605 1 Bracket Assembly
30 0502-875
1 Bracket, Switch
Right Front (inc. 25-27)
1 Pad, Brake - Set
12
2006 500 TRV
HYDRAULIC HAND BRAKE ASSEMBLY
0739-479
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0502-914 1 Brake Assembly (inc. 2-10)
2 0502-566 1 Screw, Reservoir Cover - Kit
3 0502-868 1 Cover, Reservoir - Kit
4 0502-568 1 Screw, Master Cylinder Clamp - Kit
5 0502-869 1 Clamp, Master Cylinder - Kit
6 0502-704 1 Master Cylinder Assembly - Kit
7 0502-866 1 Lever Assembly - Kit (inc. 8-9)
8 0502-867
9 0502-580 1 Lever Pin - Kit
10 0502-564 1 Switch, Brake - Kit
11 0423-178 2 Washer, Crush
12 0423-413 1 Bolt, Banjo Fitting
1 Lock, Brake Lever - Kit
13
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