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
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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
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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
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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
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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
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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
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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
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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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HYDRAULIC BRAKE ASSEMBLY
0740-580
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0502-883 1 Hose, Brake - Assembly
2 8476-625 1 Screw, Cap
3 0623-038 1 Nut, Hex
4 8408-820 6 Screw, Cap
5 0502-602 1 Caliper, Brake - Right Front (inc. 6-12)
0502-610 2 Caliper, Brake - Left Front and Right Rear
(inc. 6-12)
6 0502-603 1 Housing, Caliper - Assembly - Right Front
(inc. 7-9)
0502-611 2 Housing, Caliper - Assembly - Left Front
and Right Rear (inc. 7-9)
7 0502-606 3 Piston/Seal Set (inc. 8)
8 0502-607 3 Seal Set
9 0502-609 3 Valve, B leed
10 0502-608 3 O-Ring, Guide - Set
11 0502-605 3 Bracket Assembly
12 0502-604 3 Pad, Brake - Set
13 0423-178 6 Washer, Crush
14 0423-413 3 Bolt, Banjo Fitting
14
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GAS TANK ASSEMBLY
0740-526
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0570-109 1 Tank, Gas - Assembly (inc. 2-10)
2 0470-438 1 Cap, Gas Tank (inc. 3)
3 0109-733 1 Gasket, Tank Cap
4 0570-086 1 Gauge, Fuel w/Gasket (Press-Fit)
5 0470-416 1 Hose, Vent
6 0470-445 1 Valve, Fuel Shut-Off (inc. 7)
7 0470-364 1 Gasket, Fuel Shut-Off Valve
8 0423-398 2 Nut, Lock
9 0423-152 2 Clamp, Hose - Spring
10 0610-007 AR Hose, Gasline - 25 ft
11 0470-408 1 Knob, Fuel Shut-Off Valve
12 0423-146 1 Screw, Fuel Shut-Off Valve Knob
13 0423-106 2 Screw, Gas Tank
15
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REVERSE SHIFT LEVER ASSEMBLY
0740-535
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0402-843 1 Handle, Reverse Shift Lever
2 0423-345 1 Clip, Push
3 1402-335 1 Plate, Shift
4 0423-357 4 Nut, Stamped
5 0502-659 1 Lever, Shift
6 0502-410 1 Spring, Reverse Shift Lever
7 8424-602 1 Nut
8 0423-182 2 O-Ring
9 0402-675 1 Axle, Pivot
10 0502-760
1 Axle, Reverse Shift Lever - Black
11 0423-299 2 O-Ring
12 0423-087 1 Washer
13 8408-812 1 Screw, Cap
14 0502-589 1 Linkage, Shift
15 1402-270 1 End, Rod
16 0623-294 2 Nut
17 0423-169 1 E-Ring
18 3423-204 1 Washer
19 0423-091 1 Bushing, Shift Linkage
16
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AIR INTAKE ASSEMBLY
0740-792
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0423-019 1 Clamp
2 0470-467 1 Boot, Air Intake
3 0423-018 2 Clamp
4 0470-446 1 Housing, Air Intake
5 0470-391 1 Filter, Air (inc. one No. 3)
6 0470-343 1 Gasket
7 0470-383 1 Snorkel
8 0470-307 4 Clamp
9 0423-037 4 Spring
10 0623-121 4 Screw, Machine
11 0123-010 4 Nut, Expansion
12 0470-351 2 Support, Air Intake Flange
13 0412-141 1 Shield, Heat
14 0470-442 1 Valve, Drain
15 0623-101 1 Clip, Routing - Snap-In
16 1673-272 1 Cap, Drain Tube
17 0423-047 1 Clamp, Hose
18 0423-045 2 Clamp, Hose - Spring
19 0410-045 1 Hose, Crankcase Vent
20 0470-470 1 Carburetor, CVK34-AE
21 0510-592 1 Hose, Carburetor Drain
17
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BATTERY ASSEMBLY
0740-445 *Not Illustrated
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5990-839 1 Battery Cover/Tool Tray Assembly (inc. 2-3)
2 1406-507 1 Cover, Battery
3 0406-288 2 Pad, Battery
* 0444-122 1 Kit, Tool
4 0745-045 1 Battery Assembly (inc. 5-8)
5 0645-045 6 Cap, Battery
6 0645-152 1 Clamp, Hose
7 0645-263 1 Hose, Battery Vent
8 0645-151 1 Label, Warning - Battery
9 0123-903 4 Cable Tie - 11.5 in.
10 8476-616 2 Screw, Machine
11 0623-101 1 Clip, Routing - Snap-In
18
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ENGINE AND EXHAUST
0740-536
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0462-037 1 Engine
2 0423-405 2 Screw, Cap
3 0423-426 4 Washer, Engine
4 0423-042 2 Spacer, Engine
5 8428-002 2 Nut, Lock
6 8408-816 2 Screw, Cap
7 1506-626 1 Bracket, Engine - Right
1506-625 1 Bracket, Engine - Left
8 8408-860 1 Screw, Cap
9 8424-802 3 Nut
10 0412-007 1 Seal, Exhaust
11 8408-820 2 Screw, Cap
12 0512-257
13 0423-317 3 Clamp, Hose
14 0412-344 1 Shield, Exhaust Pipe - Outer
15 0512-263
16 0412-343
17 0612-188 1 Gasket, Exhaust Pipe
18 0612-668 2 Spring, Extension
19 0412-340 3 Bushing, Muffler
20 0512-269
1 Pipe, Exhaust - Assembly (inc. 13-16)
1 Pipe, Exhaust
1 Shield, Exhaust Pipe - Inner
1 Muffler - Assembly (inc. 21-23)
21 0412-313 1 Gasket, Spark Arrester
22 0512-219
23 8408-616
24 0412-329
25 8477-610 4 Screw, Machine
26 0409-008 1 Switch, Reverse
27 0402-991 1 Retainer, Reverse Switch
28 1506-449 1 Bracket, Mounting - Reverse Switch
29 0423-361 1 Screw, Machine
30 0502-871
31 1402-284 1 Pad, Toe - Shift Lever
32 8476-620 1 Screw, Machine
33 1602-213 2 O-Ring
34 0402-994 1 Pin, Shift Lever
35 8422-002 1 Nut
36 1506-693
37 3402-013 1 Gasket
38 3430-033 1 Switch, Cooling Fan
39 3402-556 1 Gasket
40 3530-037 1 Switch, Oil Light
1 Spark Arrester, Assembly
3 Screw, Cap
1 Cover, Muffler
(inc. 29)
1 Shifter, Toe - Assembly (inc. 31-32)
1 Bracket, Foot Shifter
19
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OIL COOLER ASSEMBLY
0740-369
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0413-118 1 Cooler, Oil - Assembly (inc. 2-9)
2 0413-053 1 Cooler, Oil
3 0413-007 1 Screen, Radiator
4 8475-512 12 Screw, Machine
5 0413-064 1 Shroud, Fan
6 0413-044 1 Fan, Cooling
7 0413-058 1 Plug, Drain
8 0413-059 1 O-Ring
9 0423-030 2 Grommet
10 0623-038 2 Nut w/Washer
11 0423-484 2 Screw, Shoulder
12 0423-028 2 Bushing, Stem
13 0423-098 4 Clamp, Hose
14 0410-044 2 Hose, Oil
15 0410-013 1 Fitting, Oil
16 0423-089 2 O-Ring, Oil Fitting
17 8471-616 4 Screw, Cap
18 0410-012 1 Fitting, Oil - Angled
20
2006 ATV 400 VP Manual Transmission
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800-407-7218
FRONT DRIVE GEARCASE ASSEMBLY
0740-537
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0502-817 1 Gearcase, Front Drive - Assembly
2 0502-386 1 Shaft, Propeller - Assembly (inc. 3-7)
3 0423-411 1 Clamp, Boot
4 0402-985 1 Boot, Propeller Shaft
5 0423-393 1 Clamp, Boot
6 1402-046 1 Shaft, Output
7 0502-407 1 Shaft, Input
8 1402-011 1 Seal
9 0423-423 1 Ring, Retaining
10 1402-043 1 Bearing
11 0423-118 11 Screw, Self-Tapping
12 0502-529 1 Housing, Pinion
13 0402-947 1 Gasket, Flange
14 0423-417 1 Ring, Retaining
15 0402-981 1 Collar, Shaft
16 0402-982 1 Washer, Wave Spr ing
17 0402-357 1 Collar, Lock
18 0502-783
19 0402-336 1 Collar, Retaining
20 0402-327 1 Bearing
21 0402-328 1 Bearing
(inc. 2-34)
1 Gear, Pinion - Assembly - 10T
(inc. 19-20)
22 0502-120 1 Housing, Gearcase
23 0402-411 1 Pin, Dowel
24 0402-394 2 Seal
25 0402-450 1 Plug, Magnetic (inc. 26)
26 0423-153 1 O-Ring
27 0423-149 1 O-Ring
28 0402-393 2 Bearing
29 0402-405 AR Shim
0402-406 AR Shim
0402-407 AR Shim
0402-408 AR Shim
0402-409 AR Shim
30 0502-779
31 0502-121 1 Cover, Gearcase
32 0402-333 1 Plug, Fill (inc. 33)
33 0423-154 1 O-Ring
34 1402-104 1 Fitting
35 0423-315 1 Clamp, Fitting
36 0402-147 1 Bladder, Gearcase
37 0423-404 2 Screw, Cap
38 0423-426 4 Washer
39 8428-002 2 Nut, Lock
40 0402-966 1 Boot, Shaft
1 Gear, Ring - 36T
21
2006 ATV 400 VP Manual Transmission
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REAR DRIVE GEARCASE ASSEMBLY
0740-538
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0502-822 1 Gearcase, Rear Drive - Assembly
(inc. 2-32)
2 0502-088 1 Housing, Gearcase
3 0502-239 1 Housing, Pinion
4 0502-089 1 Cover, Gearcase
5 0402-321 1 Ring, Retaining
6 0402-322 1 Bearing
7 0402-323 1 Seal
8 0402-324 2 Bearing
9 0402-325 2 Seal
10 0402-326 1 Button, Thrust
11 0402-328 1 Bearing, Needle
12 1402-103 1 Fitting, 45°
13 0402-331 1 Collar, Lock
14 0402-335 1 Collar, Shaft
15 0402-851 1 Shaft, Thrust
16 0402-338 1 Spring, Compression
17 0402-381 1 Gear, Ring - 36T
18 0402-429 AR Shim
0402-430 AR Shim
0402-431 AR Shim
0402-432 AR Shim
0402-433 AR Shim
19 0402-434 AR Shim
0402-435 AR Shim
0402-436 AR Shim
0402-437 AR Shim
0402-438 AR Shim
20 0423-111 1 Washer
21 0423-115 6 Screw, Self-Tapping
22 0423-118 6 Screw, Self-Tapping
23 0502-783
24 0402-327 1 Bearing
25 0402-336 1 Collar, Retaining
26 0423-148 1 O-Ring
27 0423-149 1 O-Ring
28 0402-333 1 Plug, Fill (inc. 29)
29 0423-154 1 O-Ring, Fill Plug
30 0402-334 1 Plug, Drain (inc. one No. 31)
31 0423-153 2 O-Ring, Drain Plug
32 0402-450 1 Plug, Drain - Magnetic (inc. one No. 31)
33 0402-147 1 Bladder, Gearcase
34 0423-315 1 Clamp, Fitting
1 Gear, Pinion - Assembly - 10T
(inc. 24-25)
22
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REAR AXLE ASSEMBLY
0740-539
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0506-675 1 Hitch, Trailer
2 0423-116 4 Screw, Self-Tapping
3 0406-415 1 Panel, Gearcase
4 0423-101 1 Screw, Body
5 0423-031 2 Nut, Speed
6 8477-616 2 Screw, Machine
7 0402-374 2 Gasket, Axle Housing
8 0502-090 1 Housing, Axle - Right
0502-091 1 Housing, Axle - Left
9 0423-117 12 Screw, Self-Tapping
10 0423-119 2 O-Ring
11 1402-400
1402-401
12 0502-859
0502-681 1 Housing, Bearing - Left
13 1402-027 2 Bearing
14 0423-423 2 Ring, Retaining
1 Axle - Right
1 Axle - Left
1 Housing, Bearing - Right
23
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800-407-7218
WIRING HARNESS ASSEMBLY
0740-541
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0486-181 1 Harness, Main (inc. 2-7 and two No. 8)
2 0486-164 1 Tether, Accessory Connector
3 0530-008 1 Cover, Fuse Block
4 0430-037 1 Holder, Fuse
5 0430-033 2 Relay
6 0430-032 4 Fuse - 10 Amp
0430-031 3 Fuse - 15 Amp
0430-030 2 Fuse - 30 Amp
7 0411-838 1 Decal, Fuse Block
8 0123-788 AR Cable Tie - 7.5 in.
9 0445-053
10 0623-038 7 Nut w/Washer
11 0645-327 1 Boot, Terminal
12 0445-052
1 Cable, Electric Start Relay/Starter
1 Cable, Battery/Electric Start Relay
13 0645-019 1 Boot, Terminal
14 0445-036 1 Solenoid
15 8476-625 4 Screw, Machine
16 3402-683 1 CDI Unit
17 3402-684 1 Cushion, CDI
18 3402-682 1 Regulator, Voltage
19 3430-055 1 Coil, Ignition - Assembly
20 8476-620 1 Screw, Machine
21 3430-009 1 Seal, High Tension Wire
22 3430-007 1 Cap, Spark Plug
23 3430-008 1 Seal, Spark Plug
24 0445-054 1 Cable, Battery/Ground
25 0409-009 1 Switch, Brake - Assembly
26 0402-991 1 Retainer, Brake Switch
24
2006 ATV 400 VP Manual Transmission
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CARBURETOR
0740-480 *Not a Service Part **Optional
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5507-001 1 Cover, Top
2 5507-002 4 Screw, Top Cover
3 5507-085 1 Spring
4 5507-109 1 Piston, Vacuum
5 5507-005 1 Seat, Spring
6 5507-110 1 Jet Needle
7 5507-007 1 Needle Jet
8 5507-047 1 Holder, Needle Jet
9 5507-043 1 Main Jet - 142
5507-009 1 Main Jet - 150**
5507-041 1 Main Jet - 147**
5507-042 1 Main Jet - 145**
5507-044 1 Main Jet - 140**
10 5507-010 1 Slow Jet - 38
11 5507-179 1 Starter Jet - 75
12 5507-107 1 Valve, Float - Set (inc. 13)
13 * 1 Clip
14 5507-039 1 Float Set (inc. 15)
15 * 1 Pin, Float
16 5507-111 1 Screw, Pilot Air - Set (inc. 17-19)
17 * 1 Spring
CVK34-AE (Complete Assembly p/n 0470-470)
18 * 1 Washer
19 * 1 O-Ring
20 5507-027 1 Screw, Idle Adjust
21 5507-028 1 Washer
22 5507-029 1 Spring
23 5507-115 1 Plate
24 5507-117 1 Screw
25 5507-180 1 Choke, Electric
26 5507-114 1 Cover, Electric Choke
27 * 1 Chamber, Float - Assembly (inc. 28-33)
28 5507-050 1 Screw, Drain
29 5507-032 1 Spring
30 5507-031 1 Diaphragm Assembly
31 * 1 Housing, Pump
32 5507-034 1 U-Ring
33 5507-035 3 Screw
34 5507-017 4 Screw
35 0487-021 1 Cable, Throttle
36 5507-036 1 Cover
37 5507-037 1 Screw
38 0410-056 1 Hose, Vent
25
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
CYLINDER HEAD ASSEMBLY
0738-415 *Not Illustrated
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-576 1 Head, Cylinder - Assembly (inc. 2-5)
2 3402-099 2 Guide, Valve
3 3423-068 4 Ring, Valve Guide
4 3423-043 2 Pin, Dowel
5 3423-006 4 Bolt
6 3402-577 1 Gasket, Cylinder Head
7 3423-449 2 Pin, Dowel
8 3003-290 4 Gasket
9 3423-326 2 Nut, Cylinder Head
10 3423-007 2 Bolt, Head Cover
11 3423-429 1 Bolt, Head Cover
12 3423-439 4 Washer, Cylinder Head Nut
13 3004-376 2 Bolt, Head Cover
14 3008-376 1 Bolt, Head Cover
15 3423-453 1 Plug, Oil Gallery
16 3402-011 1 Gasket, Oil Gallery Plug
17 0217-708 1 Spark Plug (NGK CR7E)
18 3402-100 2 Cap, Inspection
19 3402-101 2 O-Ring
20 3004-341 4 Bolt, Inspection Cap
21 3402-035 1 Plug, Head
22 3423-353 1 O-Ring
23 8476-620 2 Screw
24 0570-076 1 Manifold, Intake
25 0423-317 1 Clamp
* 3402-048 1 Plug, Frost
26
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
CYLINDER ASSEMBLY
0737-039
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-578 1 Cylinder
2 3423-384 2 Bolt, Stud
3 3004-778 2 Bolt, Stud
4 3423-431 2 Bolt
5 3423-432 2 Bolt
6 3423-427 2 Bolt
7 3004-488 4 Nut
8 3402-579 1 Gasket, Cylinder
9 3423-088 2 Pin, Dowel
27
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
CRANKCASE ASSEMBLY
0739-903
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-763 1 Crankcase Assembly (inc. 2-9)
2 3004-880 4 Bolt
3 3005-332 1 Bolt
4 3005-410 3 Bolt
5 3423-097 4 Bolt
6 3423-091 8 Bolt
7 3402-012 1 Gasket, Oil Pressure Plug
8 3402-214 1 Plug, Oil Pressure
9 3423-088 2 Pin, Dowel
10 3004-552 4 Screw, Oil Guide Plate
11 3402-764 1 Plate, Oil Guide - Right
12 3402-691 1 Jet, Oil Gallery
13 3423-051 1 O-Ring, Oil Gallery Jet
14 3402-582 1 Plate, Oil Guide - Left
28
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
CRANKCASE COVER ASSEMBLY
0737-722
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-991 1 Cover, Clutch
2 3402-766 1 Gasket
3 3423-088 4 Pin, Dowel
4 3423-098 30 Bolt
5 3004-338 2 Plug, Oil Gallery
6 3003-290 2 Gasket
7 3402-100 1 Cap, Inspection
8 3402-101 1 O-Ring, Inspection Cap
9 3004-341 2 Bolt, Inspection Cap
10 3402-593 1 Stick, Oil Level
11 3423-055 1 O-Ring, Oil Level Stick
12 3402-767 1 Cover, Magneto
13 3402-768 1 Gasket, Magneto Cover
14 3423-180 1 Plug
15 3402-013 1 Gasket
16 3004-705 1 Plug, Drain
17 3402-444 1 Gasket, Drain Plug
18 3423-430 1 Bolt
29
2006 ATV 400 VP Manual Transmission
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800-407-7218
CRANKSHAFT ASSEMBLY
0739-873 *Optional
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-992 1 Crankshaft Assembly (inc. 2-8)
2 3402-597 1 Rod, Connecting
3 3402-769 1 Pin, Crank
4 3402-571 1 Bearing
5 3423-440 2 Washer
6 3402-993 1 Crankshaft - Right
7 3403-019 1 Crankshaft - Left
8 3402-698 1 Gear, Crank Balancer Drive
9 3402-994 2 Bearing - Middle
10 3423-768 1 Spacer
11 3402-771 1 Circlip
12 3402-216 1 Bearing - Right
13 3402-594 1 Piston
14 3402-595 1 Ring, Piston - Set
15 3436-015 1 Piston Set (Oversized 0.50 mm)*
16 3003-439 2 Circlip
17 3402-596 1 Pin, Piston
18 3402-051 1 Bearing
19 3423-063 1 O-Ring
20 3423-542 1 Spacer
21 3402-070 1 Seal, Oil
22 3423-053 1 O-Ring
23 3402-188 1 Retainer, Crankshaft Oil Seal - Left
24 3423-018 3 Screw, Retainer
30
2006 ATV 400 VP Manual Transmission
World of Powersports.com
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STARTER CLUTCH ASSEMBLY
0737-043
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-603 1 Gear, Starter Idler - No. 1
2 3402-124 1 Gear, Starter Idler - No. 2
3 3423-331 1 Pin, Starter Idler Gear No. 1
4 3423-397 1 Pin, Starter Idler Gear No. 2
5 3402-690 1 Clutch, Starter - Set (inc. 6)
6 3402-674 1 Bearing
7 3423-102 6 Bolt
31
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
CRANK BALANCER ASSEMBLY
0737-728
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-605 1 Balancer, Crank
2 3402-553 2 Bearing
3 3402-772 1 Gear, Driven - No. 1
4 3004-540 1 Key
5 3402-617 1 Gear, Oil Pump Drive
6 3423-110 1 Pin, Drive Gear
7 3423-555 1 Bolt, Drive Gear
8 3423-401 1 Washer, Drive Gear
32
2006 ATV 400 VP Manual Transmission
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CAMSHAFT/VALVE ASSEMBLY
0737-730
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-989 1 Camshaft
2 3402-611 1 Sprocket
3 3423-047 1 Pin
4 3423-073 1 Washer
5 3423-013 2 Bolt
6 3423-071 1 C-Ring
7 3402-805 1 Arm, Valve Rocker - Intake
(inc. two No. 8-9)
8 3423-075 4 Screw
9 3423-076 4 Nut
10 3402-139 1 Arm, Valve Rocker - Exhaust
(inc. two No. 8-9)
11 3402-140 1 Shaft, Rocker Arm
12 3423-031 2 Washer
13 3402-012 2 Gasket
14 3402-040 2 Plug, Shaft
15 3402-141 1 Shaft, Rocker Arm
16 3402-147 8 Cotter, Valve
17 3423-541 4 Retainer, Spring
18 3402-726 4 Spring, Valve
19 3402-078 4 Seal, Oil
20 3402-148 4 Seat, Spring
21 3402-725 2 Valve, Intake
22 3402-143 2 Valve, Exhaust
33
2006 ATV 400 VP Manual Transmission
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CAM CHAIN ASSEMBLY
0737-051
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-281 1 Chain, Cam
2 3402-612 1 Guide, Cam Chain
3 3402-613 1 Tensioner, Cam Chain
4 3423-074 1 Bolt
5 3402-436 1 Washer
6 3402-614 1 Adjuster, Tensioner - Assembly (inc. 7-9)
7 3423-484 1 Spring
8 3423-485 1 Plug
9 3423-286 1 O-Ring
10 3403-020 1 Gasket, Adjuster
11 3004-512 2 Bolt
34
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
RECOIL STARTER ASSEMBLY
0737-034
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3445-003 1 Starter, Recoil - Assembly (inc. 2-8)
2 3445-004 1 Reel
3 3445-007 1 Spring, Spiral
4 3445-016 1 Ratchet - Assembly (inc. 5-6)
5 3445-005 1 Ratchet
6 3445-006 1 Guide, Ratchet
7 3004-488 1 Nut
8 3445-011 1 Rope Assembly
9 3423-428 4 Screw, Cap
10 3445-029 1 Cup, Starter
11 3004-491 1 Nut
35
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
OIL FILTER/PUMP ASSEMBLY
0737-035
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-619 1 Pump, Oil
2 3402-618 1 Gear, Driven
3 3423-046 1 Pin
4 3423-443 1 Washer
5 3423-184 1 Circlip
6 3423-113 3 Screw
7 3402-156 1 Strainer, Oil
8 0693-389 2 Screw
9 3402-157 1 Cap, Oil Strainer
10 3423-077 1 O-Ring
11 3004-756 4 Screw, Cap
12 0812-005 1 Filter, Oil
13 3403-021 1 Plug, Drain
14 3402-012 1 Gasket, Drain Plug
15 3402-773 1 Valve, Oil Relief - Assembly
16 3005-206 2 Pin, Oil Pump
36
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
CLUTCH ASSEMBLY
0739-874
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3446-352 1 Housing, Starter Clutch
2 3446-003 1 Clutch, Primary Drive One Way
3 3446-290 1 Shoe, Starter Clutch
4 3423-409 1 Nut, Starter Clutch Shoe
5 3423-515 1 Washer, Primary Driven
6 3423-516 1 Washer
7 3446-291 1 Gear, Primary Driven - Assembly
8 3446-004 1 Hub, Clutch Sleeve
9 3423-330 4 Screw, Cap - Clutch Spring
10 3423-517 4 Spring, Clutch
11 3446-006 6 Plate, Clutch Drive
12 3446-007 5 Plate, Clutch Driven
13 3446-008 1 Disc, Clutch Pressure
14 3446-009 1 Plate, Clutch Release
15 3423-080 1 Nut, Clutch Sleeve Hub
16 3423-032 1 Washer, Sleeve Hub
17 3446-292 1 Arm, Clutch Release
18 3423-361 1 Bolt, Clutch Release - No. 1
19 3423-083 1 Bolt, Clutch Release - No. 2
20 3446-293 1 Guide, Release Roller
21 3446-294 1 Roller, Clutch Release - Assembly
22 3423-125 1 Bolt, Clutch Release Arm
23 3008-014 1 Nut, Clutch Release - No. 2
24 3423-359 1 Nut, Clutch Release - No. 1
25 3423-027 1 Washer, Clutch Release - No. 2
26 3402-186 1 Bearing, Clutch
27 3423-360 1 Washer, Clutch Release - No. 1
28 3423-260 1 Washer
37
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
TRANSMISSION ASSEMBLY
0737-733
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-218 1 Bearing
2 3446-297 1 Dog, Reverse
3 3423-066 4 Circlip
4 3423-036 3 Washer, Lock
5 3446-296 1 Gear, Reverse Driven
6 3446-145 1 Bushing
7 3423-263 1 Washer
8 3446-141 1 Gear, 1st Driven
9 3446-273 2 Bushing
10 3446-146 1 Gear, 4th Driven
11 3446-143 1 Gear, 3rd Driven
12 3423-266 1 Washer, Lock
13 3423-262 1 Washer, Lock
14 3446-147 1 Gear, 5th Driven
15 3423-317 1 Washer
16 3446-142 1 Gear, 2nd Driven
17 3402-230 1 Bushing
18 3402-775 1 Driveshaft
19 0691-374 1 Bearing
20 3402-033 1 Plug, Countershaft
21 3446-031 2 Retainer, Bearing
22 3423-370 2 Screw
23 3446-295 1 Countershaft
24 3402-210 2 Washer
25 3446-139 1 Gear, 4th Drive
26 3402-229 1 Bushing
27 3423-279 2 Circlip
28 3446-138 1 Gear, 3rd Drive
29 3423-261 1 Washer
30 3446-140 1 Gear, 5th Drive
31 3446-137 1 Gear, 2nd Drive
32 3402-224 1 Bearing
33 3402-209 2 Washer
34 3446-149 1 Gear, Reverse Idle
35 3402-228 1 Bushing
36 3446-298 1 Shaft, Reverse Idle
37 3423-518 1 Circlip
38
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
SECONDARY TRANSMISSION ASSEMBLY
0740-284
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3402-776 1 Bearing
2 3446-300 1 Gear, Drive - No. 1
3 3446-301 1 Bushing, Drive Gear No. 1
4 3423-036 1 Washer
5 3423-066 1 Circlip
6 3446-249 1 Dog, Sliding
7 3423-126 2 Washer
8 3446-302 1 Gear, Drive - No. 2
9 3423-519 1 Spacer, Drive Gear
10 3402-979 1 Bearing, Driveshaft
11 3446-299 1 Gear, Idle
12 3402-205 1 Spacer, Idle Gear
13 3423-319 1 Washer
14 3402-217 1 Bearing
15 3423-023 1 Nut, Secondary Drive Gear
16 3005-372 1 Washer, Secondary Drive Gear
17 3446-274 1 Gear, Secondary Drive
18 3446-035 1 Shim, Secondary Drive Gear - Set
19 3423-370 2 Screw
20 3446-031 2 Retainer, Output Shaft
21 3402-180 1 Bearing
22 3446-403 1 Shaft, Output
23 3446-304 1 Gear, Driven
24 3402-045 1 Bearing
25 3446-244 1 Gasket, Speedometer Housing
26 3446-260 1 Retainer, Cover Plug
27 3423-363 2 Bolt, Retainer
39
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
SECONDARY DRIVE ASSEMBLY
0740-786
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3446-274 1 Gear, Secondary Drive
2 3446-035 1 Shim, Secondary Drive Gear - Set
3 3423-023 1 Nut
4 3005-372 1 Washer
5 3446-327 1 Yoke, Propeller Shaft - Front
6 3402-562 2 Joint, Universal - Set (inc. 7)
7 3423-479 8 Circlip
8 3423-025 2 Nut
9 3423-028 2 Washer
10 3402-742 2 Yoke, Drive Output
11 3402-072 2 Seal, Oil
12 3402-558 1 Bearing, Front Secondary Driven Shaft
13 3402-559 1 Shaft, Secondary Driven - Front
14 3423-520 1 Washer, Secondary Driven Gear
15 3423-136 1 Nut, Secondary Driven Gear
16 3446-222 1 Gear, Secondary Driven
17 3402-515 1 Bearing, Driven Gear
18 3423-072 1 C-Ring, Driven Bearing
19 3446-305 1 Shaft, Secondary Driven - Rear
20 3402-017 AR Shim, 25 x 34 x 0.60 mm
3402-018 AR Shim, 25 x 34 x 0.65 mm
3402-019 AR Shim, 25 x 34 x 0.70 mm
3402-020 AR Shim, 25 x 34 x 0.75 mm
3402-021 AR Shim, 25 x 34 x 0.80 mm
3402-022 AR Shim, 25 x 34 x 0.85 mm
3402-023 AR Shim, 25 x 34 x 0.90 mm
3402-024 AR Shim, 25 x 34 x 0.95 mm
3402-025 AR Shim, 25 x 34 x 1.00 mm
3402-028 AR Shim, 25 x 34 x 1.05 mm
3402-029 AR Shim, 25 x 34 x 1.10 mm
3402-030 AR Shim, 25 x 34 x 1.15 mm
3402-031 AR Shim, 25 x 34 x 1.20 mm
21 3402-067 1 Bearing, Rear Secondary Driven Shaft
22 3446-405 1 Yoke, Propeller Shaft
23 3403-015 1 Shaft, Propeller
24 3423-414 3 Bolt, Propeller Shaft
25 3435-051 1 Boot, Propeller Shaft
26 1402-026 1 Spring
40
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
GEAR SHIFTING ASSEMBLY
0737-745
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3446-306 1 Fork, Gear Shift - Reverse
2 3446-155 1 Fork, Gear Shift - No. 1
3 3446-156 1 Fork, Gear Shift - No. 2
4 3402-643 1 Shaft, Gear Shift Fork - No. 2
5 3004-488 1 Nut
6 3423-142 1 Washer
7 3446-282 1 Spring, Gear Shift Cam Stopper
8 3446-048 1 Support, Gear Shift Cam Stopper
9 3402-746 1 Stopper, Gear Shift Cam
10 3423-141 1 Washer
11 3423-125 1 Bolt
12 3446-309 1 Guide, Gear Shift
13 3446-049 1 Plate, Gear Shift Cam (inc. 14)
14 3423-045 5 Pin
15 3423-370 2 Screw
16 3423-135 2 Retainer
17 3402-051 1 Bearing, Gear Shift Cam
18 3446-308 1 Cam, Gear Shift (inc. 19)
19 3423-114 1 Pin
20 3402-087 2 Spring
21 3423-044 2 Contact
22 3446-313 1 Base, Neutral Switch
23 3423-418 2 Bolt
24 3446-157 1 Fork, Gear Shift - No. 3
25 3446-307 1 Shaft, Gear Shift Fork - No. 1
26 3446-310 1 Shaft, Gear Shift (inc. 27)
27 3402-093 1 Spring
28 3446-056 1 Stopper, Gear Shift Shaft
29 3402-094 1 Spring, Return
30 3446-054 1 Spacer, Gear Shift Shaft
31 3402-068 1 Seal, Oil
41
2006 ATV 400 VP Manual Transmission
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800-407-7218
SECONDARY SHIFTING ASSEMBLY
0737-748
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3446-314 1 Stopper, Gear Shift Cam (inc. 2-3)
2 3446-315 1 Stopper
3 3423-524 1 Spring
4 3402-012 1 Gasket
5 1691-043 2 Washer
6 3423-358 2 Circlip
7 3446-322 1 Shaft, Gear Shift
8 3402-076 1 Seal, Oil
9 3402-434 1 Arm, Gear Shift
10 3004-341 1 Bolt, Gear Shift Arm
11 3423-527 2 Washer
12 3423-190 5 Circlip
13 3423-526 3 Spring
14 3446-325 1 Camshaft, Reverse
15 3446-324 1 Plate, Cam Lock
16 3446-323 1 Cam, Reverse
17 3446-321 1 Joint, Camshaft
18 3402-381 2 Washer
19 3446-316 1 Gear, Camshaft
20 3423-533 2 Washer
21 3423-525 1 Cam
22 3446-320 1 Camshaft
23 3446-318 1 Fork, Gear Shift
24 3446-317 1 Shaft, Gear Shift Fork
42
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
STARTER MOTOR ASSEMBLY
0737-056
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3545-016 1 Motor, Starter - Assembly (inc. 2-10)
2 3402-671 1 Terminal Set, Brush
3 3402-672 1 Holder Set, Brush (inc. 4)
4 3008-551 2 Spring, Brush
5 3008-164 1 O-Ring
6 3423-272 1 O-Ring
7 3008-099 1 Washer Set
8 3423-497 2 O-Ring
9 3423-498 2 Through-Bolt (inc. 10)
10 3423-496 2 O-Ring
11 3004-756 2 Bolt
12 3423-195 1 Nut
43
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
MAGNETO ASSEMBLY
0737-033
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3430-053 1 Stator Assembly
2 3430-054 1 Rotor/Flywheel
3 3004-756 3 Bolt
4 0691-785 1 Key
5 3423-086 1 Nut
6 3423-005 3 Bolt
7 3430-006 1 Clamp
8 3430-005 1 Clamp
9 3002-964 1 Clamp, Wire
44
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
CONTROL SWITCH HOUSING ASSEMBLY
0738-416
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0509-013 1 Switch, Control - Assembly (inc. 2-3)
2 3423-197 1 Screw
3 3423-196 1 Screw
4 3409-019 1 Cover, Choke Lever
45
2006 ATV 400 VP Manual Transmission
World of Powersports.com
800-407-7218
THROTTLE CASE ASSEMBLY
0737-633
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3509-003 1 Case, Throttle - Assembly (inc. 2-8)
2 3409-001 1 Lever
3 3004-533 1 Screw, Cap
4 3004-447 1 Washer, Lock
5 3003-030 1 Washer
6 3423-014 1 Screw
7 3423-327 1 Nut
8 3423-199 2 Screw
46
RELATED ITEMS
World of Powersports.com
800-407-7218
2006 ATV 400 VP (Manual Transmission)
Red (Model No. A2006ABH4AUSR) Green (Model No. A2006ABH4AUSG)
0436-768 Backrest
0436-679 Bag, Fender - Black
0436-660 Bag, Rack, Front - Black
0436-802 Bag, Rack, Rear - Black
0436-811 Basket, Open-End - Rear
0436-765 Brush Guard/Bumper, Front (4x4)
0436-454 Cargo Box
0436-625 Cargo Box Quick-Release Kit
0436-777 Cover, Black and Green
0436-668 Cover, Timber Camo
0436-776 Cover, Trailerable
0436-005 Engine Oil - 10W40
0436-003 Engine Oil - 5W30
0436-450 Engine Oil - Synthetic 0W40
0436-007 Gear Lube (Diff) - 80W90
0441-281 Gun Scabbard
0436-706 Gun Scabbard Mount
0436-505 Hand Guards - Black
0436-352 Hand/Thumb Warmers
2257-454 Illustrated Parts Manual
0436-787 License Plate Kit
NOTE: For a complete list of related items, refer to the current accessory catalog.
2257-313 Manuel d’utilisation (F)
2257-299 Operator’s Manual (E)
0436-635 Plow Attachment Kit
0436-228 Plow Blade, 50 in. - Straight
0436-287 Plow Blade, 50 in. - One-Way
0436-296 Plow Blade, 60 in. - Straight
0436-360 Plow Blade, 60 in. - One-Way
0436-822 Plow Blade, Carbon Fiber - 60 in. - Straight
0436-823 Plow Blade, Carbon Fiber - 60 in. - One-Way
0436-636 Plow, Push Frame
0436-626 Rack Basket (Front)
0436-762 Rack Extension, 4 in. (Front)
0436-763 Rack Extension, 8 in. (Rear)
1402-028 Tire, Titan AT589 (25x8-12, Mud & Snow)
0402-563 Tire, Titan AT589 (25x10-12, Mud & Snow)
0436-297 Tool Holder - Double
0436-263 Tool Holder - Single
0436-382 Torch Light
0436-655 Winch, 2500 lb
0436-623 Windshield, Clear w/Black Accent
Printed in U.S.A p/n 2257- 454
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