Craftsman A2006ABH4AUSR, A2006ABH4AUSG User Manual
400 (VP)
(Manual Transmission)
ARCTIC CAT
Illustrated Parts Manual
2006
World of Powersports.com
800-407-7218
2006
400 (VP)
(Manual Transmission)
®
Model Number A2006ABH4AUSR (Red)
Model Number A2006ABH4AUSG (Green)
Illustrated Parts Manual
TABLE OF CONTENTS
World of Powersports.com
800-407-7218
2006 ATV 400 VP (Manual Transmission)
Red (Model No. A2006ABH4AUSR) Green (Model No. A2006ABH4AUSG)
FRONT BODY PANEL ASSEMBLY......................................................................................................................... 1
REAR BODY PANEL ASSEMBLY ........................................................................................................................... 2
TAILLIGHT ASSEMBLY........................................................................................................................................... 3
DECALS ................................................................................................................................................................... 4
FRAME AND RELATED PARTS.............................................................................................................................. 5
SEAT 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......................................................................................................................................... 15
REVERSE SHIFT LEVER ASSEMBLY.................................................................................................................. 16
AIR INTAKE ASSEMBLY ....................................................................................................................................... 17
BATTERY ASSEMBLY .......................................................................................................................................... 18
ENGINE AND EXHAUST ....................................................................................................................................... 19
OIL COOLER ASSEMBLY ..................................................................................................................................... 20
FRONT DRIVE GEARCASE ASSEMBLY.............................................................................................................. 21
REAR DRIVE GEARCASE ASSEMBLY ................................................................................................................ 22
REAR AXLE ASSEMBLY....................................................................................................................................... 23
WIRING HARNESS ASSEMBLY ........................................................................................................................... 24
CARBURETOR ...................................................................................................................................................... 25
CYLINDER HEAD ASSEMBLY.............................................................................................................................. 26
CYLINDER ASSEMBLY......................................................................................................................................... 27
CRANKCASE ASSEMBLY..................................................................................................................................... 28
CRANKCASE COVER ASSEMBLY.......................................................................................................
CRANKSHAFT ASSEMBLY................................................................................................................................... 30
STARTER CLUTCH ASSEMBLY........................................................................................................................... 31
CRANK BALANCER ASSEMBLY .......................................................................................................................... 32
CAMSHAFT/VALVE ASSEMBLY........................................................................................................................... 33
CAM CHAIN ASSEMBLY....................................................................................................................................... 34
RECOIL STARTER ASSEMBLY............................................................................................................................ 35
OIL FILTER/PUMP ASSEMBLY ............................................................................................................................ 36
CLUTCH ASSEMBLY ............................................................................................................................................ 37
TRANSMISSION ASSEMBLY................................................................................................................................ 38
SECONDARY TRANSMISSION ASSEMBLY........................................................................................................ 39
SECONDARY DRIVE ASSEMBLY ........................................................................................................................ 40
GEAR SHIFTING ASSEMBLY ............................................................................................................................... 41
SECONDARY SHIFTING ASSEMBLY ....................................................................................................
STARTER MOTOR ASSEMBLY............................................................................................................................ 43
MAGNETO ASSEMBLY......................................................................................................................................... 44
CONTROL SWITCH HOUSING ASSEMBLY ........................................................................................................ 45
THROTTLE CASE ASSEMBLY ............................................................................................................................. 46
RELATED ITEMS.................................................................................................................................... Back Cover
................ 29
.............. 42
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
2005 Arctic Cat Inc. Printed June 2005
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
for the 2006 model year.
2006 ATV 400 VP Manual Transmission
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FRONT BODY PANEL ASSEMBLY
0740-509
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1506-750 1 Rack - Front - Assembly (inc. 2-4)
2 0411-576 1 Decal, Warning - Front Rack Load
3 0441-592 4 Bushing, Rack
4 2406-014
5 8410-830 4 Screw, Machine
6 0423-463 4 Spacer
7 0423-465 4 Grommet
8 1506-819
1506-820
9 0423-355 2 Screw, Shoulder
10 8050-222 2 Washer
11 8424-602 2 Nut, Lock
12 0423-357 2 Nut, Stamped
13 8432-802 4 Nut, Lock
14 1411-078
1411-079
6 Bushing, Rack
1 Panel, Fender - Front - Red
1 Panel, Fender - Front - Green (Green)
1 Decal, Reflector - Front - Right
1 Decal, Reflector - Front - Left
15 0623-362 4 Rivet, Plastic - Reinstallable
16 1406-867 1 Cover, Steering Post - Red
1406-970
17 1406-956
1406-957
18 0623-544 2 Plug
19 0412-356
20 1406-906
1406-907
21 0423-342 4 Screw, Self-Tapping
22 0423-101 3 Screw, Body
23 0123-788 AR Cable Tie - 7.5 in.
24 0470-404 1 Grommet, Fuel Shut-Off Valve Knob
1 Cover, Steering Post - Green (Green)
1 Cover, Gas Tank - Red
1 Cover, Gas Tank - Green (Green)
1 Shield, Heat - Fender - Front
1 Panel, Splash - Right
1 Panel, Splash - Left
1
2006 ATV 400 VP Manual Transmission
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REAR BODY PANEL ASSEMBLY
0740-305
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1506-753 1 Rack - Rear - Assembly (inc. 2-5)
2 0411-814 1 Decal, “Arctic Cat”
3 0411-648 1 Decal, Warning - Rear Rack Load
4 0441-592 4 Bushing, Rack
5 2406-014 8 Bushing, Rack
6 8410-830 4 Screw, Machine
7 0423-463 4 Spacer
8 0423-465 4 Grommet
9 8432-802 4 Nut, Lock
10 1406-953
1406-954
11 0423-355 12 Screw, Shoulder
1 Panel, Fender - Rear - Red
1 Panel, Fender - Rear - Green (Green)
12 8050-222 2 Washer
13 8424-602 8 Nut, Lock
14 1411-080
1411-081
15 0423-540 16 Nut, Lock
16 0623-362 4 Rivet, Reinstallable
17 1406-950
1406-951
18 0423-419 12 Screw, Body
19 1506-125 2 Footpeg
20 0412-351
1 Decal, Reflector - Rear - Right
1 Decal, Reflector - Rear - Left
1 Footwell - Right
1 Footwell - Left
1 Shield, Heat
2
2006 ATV 400 VP Manual Transmission
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TAILLIGHT ASSEMBLY
0739-667
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 0623-301 2 Screw, Self-Tapping
6 8053-212 2 Washer, Lock - External Tooth
3
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DECALS
0740-574 *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 0411-835 1 Decal, Warning - Hill
3 1411-047 1 Decal, Instrument Pod
1411-048
4 1411-051
1411-052
5 0411-840 1 Decal, Front
0411-839 1 Decal, Front (Green)
6 0411-401 1 Decal, Warning - Age*
7 0411-966 1 Decal, Warning - Differential Lock
8 1411-054
1411-055
1411-056
1411-057
1 Decal, Instrument Pod (Green)
1 Decal, “Speedrack”
1 Decal, “Speedrack” (Green)
1 Decal, Side - Upper Right
1 Decal, Side - Upper Left
1 Decal, Side - Upper Right (Green)
1 Decal, Side - Upper Left (Green)
9 1411-060
1411-061
1411-062
1411-063
10 0411-430 1 Decal, Warning - Tire Pressure
11 0411-435 1 Decal, Warning - Passenger
12 0411-267 1 Decal, Warning - Towing
13 0411-218 1 Decal, Warning - General*
14 0411-965 2 Decal, “Speedrack”
1 Decal, Side - Lower Right
1 Decal, Side - Lower Left
1 Decal, Side - Lower Right (Green)
1 Decal, Side - Lower Left (Green)
4
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FRAME AND RELATED PARTS
0740-297
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1506-716 1 Frame, Main
2 0509-027
0509-028
3 0409-073
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 - Headlight
9 0423-513 2 Knob, Adjuster - Headlight
10 8409-020 4 Screw, Cap
11 0506-653 1 Channel, Bumper Mounting - Right
1506-596 1 Channel, Bumper Mounting - Left
12 1506-686 1 Bracket, Mounting - Bumper - Right
1506-687 1 Bracket, Mounting - Bumper - Left
1 Headlight Assembly - Right (inc. 3)
1 Headlight Assembly - Left (inc. 3)
4 Bulb, Headlight
13 8408-816 6 Screw, Cap
14 1506-800 1 Bumper, Front
15 2406-030
16 1506-067 1 Foam, Frame
17 0406-864 1 Panel, Belly
18 0423-101 6 Screw, Body
19 8424-802 4 Nut, Flange
20 8409-016 4 Screw, Cap
21 1506-659
1506-660
22 1406-853
23 8408-002 2 Nut, Hex
24 1506-429 1 Brace, A-Arm
25 8408-025 2 Screw, Cap
2 Cap, Tube
1 Footrest - Right
1 Footrest - Left
2 Rod, Support
5
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SEAT ASSEMBLY
0739-690
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
1 Base, Seat Assembly (inc. 5-6)
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
6
2006 ATV 400 VP Manual Transmission
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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 2 Screw, Shoulder
4 0405-166 1 Cap, Housing
5 0405-138 1 Housing, Lower
6 0405-139 1 Housing, Upper
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
11 0423-073 1 Washer
12 8409-020 1 Screw, Cap
13 0505-072 2 Tie Rod - Assembly (inc. 14-18)
14 0405-083 2 Ball Joint, Tie Rod - Left
15 0423-013 2 Nut - Left
16 0405-032 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
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HANDLEBAR ASSEMBLY
0740-540
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0505-418 1 Tube, Handlebar - Black
2 0405-148 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 1506-578 1 Bracket, Gauge - Black
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 0409-013 1 Cover, Key
11 0423-535 2 Rivet, Plastic - Reinstallable
12 0423-357 4 Nut, Stamped
13 0405-192
0405-193
14 0405-198
15 0420-068
16 0420-066
17 0420-067
1 Instrument Pod - Red
1 Instrument Pod - Green (Green)
1 Bezel, Lights - Instrument Pod
1 Light, Indicator - “Temperature”
1 Light, Indicator - “N”
1 Light, Indicator - “R”
8
2006 ATV 400 VP Manual Transmission
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FRONT SUSPENSION ASSEMBLY
0740-243 *Not a Service Part
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1603-889 2 Retainer, Spring
2 0403-144
3 0604-310 8 Bushing, Shock Absorber
4 0403-028 4 Sleeve, Shock
5 0403-102 2 Cam, Spring Adjuster
6 0403-103 2 Spring, Shock Absorber
7 8409-040 4 Screw, Cap
8 8428-002 10 Nut, Lock
9 0503-192 1 A-Arm, Upper Right - Black (inc. 10-13)
0503-193 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 0503-292
0503-291
2 Shock Absorber - Front (inc. 3-4)
1 A-Arm, Lower Right (inc. two No. 12-13)
1 A-Arm, Lower Left (inc. two No. 12-13)
15 0505-460
0505-461
16 * 1 Knuckle, Steering - Right
*1 Knuckle, Steering - Left
17 1402-027 2 Bearing, Wheel Hub
18 0423-423 2 Ring, Retaining
19 8409-030 4 Screw, Cap
20 0423-334 2 Screw, Cap
21 8409-075 4 Screw, Cap
22 0502-814
23 1441-109 2 Clip, Retaining
24 0436-276 2 Repair Kit, Boot - Front Axle
25 0406-944 1 Guard, Boot - Axle - Right
0406-927 1 Guard, Boot - Axle - Left
26 0423-101 4 Screw, Body
27 0441-587 1 Wrench, Spanner
1 Knuckle - Assembly - Right (inc. 16-18)
1 Knuckle - Assembly - Left (inc. 16-18)
2 Axle, Drive - Front (inc. 23-24)
9
2006 ATV 400 VP Manual Transmission
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REAR SUSPENSION ASSEMBLY
0737-585
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 8409-060 4 Screw, Cap
2 0423-335 2 Screw, Cap
3 0504-218 3 Arm, Swing
4 8428-002 10 Nut, Lock
5 0504-215 1 Arm, Swing
6 8409-040 4 Screw, Cap
7 0404-107 2 Shock Absorber - Rear (inc. 8-9)
8 0604-310 8 Bushing, Shock Absorber
9 0403-028 4 Sleeve, Shock Absorber
10 0403-102 2 Cam, Spring Adjuster
11 1603-889 2 Retainer, Spring - Upper
12 0404-108
2 Spring, Shock Absorber - Black
10
2006 ATV 400 VP Manual Transmission
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WHEEL AND TIRE ASSEMBLY
0740-518
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
4 Nut, Castle
8 0402-856 2 Wheel - Front - Gray
0402-989 2 Wheel - Rear - Gray
9 0423-408 16 Nut, Mounting - Wheel
10 1402-360 2 Tire - Front
1402-361 2 Tire - Rear
11 0402-064 4 Stem, Valve (inc. 12)
12 0402-140 4 Cap, Valve Stem
11
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AUXILIARY BRAKE ASSEMBLY
0740-522 *Not a Service Part
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0502-789 1Lever, Brake
2 1602-213 2 O-Ring
3 8050-252 1 Washer
4 8408-816 1 Screw, Cap
5 1402-407 1 Spring, Brake Lever
6 1402-377 1 Pin, Clevis
7 8050-217 1 Washer
8 0402-584 1 Pin, Cotter
9 0502-941
10 * 1 Master Cylinder
11 0502-886
12 0502-877
13 8424-602 1 Nut, Flanged
14 0423-608 1 Spacer
15 8476-640 1 Screw, Machine
16 1402-418
1 Brake Assembly (inc. 10-12)
1 Hose, Brake Reservoir
1 Reservoir, Brake
1 Hose, Brake - Rear
(Fully Bled Master Cylinder Replacement Kit p/n 0502-940)
17 0423-178 4 Washer, Crush
18 0423-413 2 Bolt, Banjo Fitting
19 0123-788 1 Cable Tie - 7.5 in.
20 8408-625 2 Screw, Cap
21 8408-820 2 Screw, Cap
22 0502-602 1 Caliper, Brake (inc. 23-29)
23 0502-603 1 Housing, Caliper - Assembly - Right Front
24 0502-606 1 Piston/Seal Set (inc. 25)
25 0502-607 1 Seal Set
26 0502-609 1 Valve, B leed
27 0502-608 1 O-Ring, Guide - Set
28 0502-605 1 Bracket Assembly
29 0502-604 1 Pad, Brake - Set
30 0502-873
31 8471-616 2 Screw, Machine
1 Bracket, Master Cylinder
(inc. 24-26)
12
2006 ATV 400 VP Manual Transmission
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HYDRAULIC HAND BRAKE ASSEMBLY
0740-525
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0502-914 1 Brake Assembly (inc. 2-9)
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 0502-866
1 Lever Assembly - Kit (inc. 7-8)
(Master Cylinder Rebuild Kit p/n 0502-704)
7 0502-867
8 0502-580 1 Lever Pin - Kit
9 0502-564 1 Switch, Brake - Kit
10 0423-178 2 Washer, Crush
11 0423-413 1 Bolt, Banjo Fitting
1 Lock, Brake Lever - Kit
13
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