ARCTIC CAT 400 500 4X4 ATV Replacement Parts Manual 1998
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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
Arctic Cat Service Manuals. Underlined part numbers are new for the 1998 model
year.
NOTE:
© 2001 Arctic Cat Inc. Printed September 2001
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AIR INTAKE ASSEMBLY .............................. 15 .... B3
BODY PANEL ASSEMBLY .............................. 1 .... A3
CAM CHAIN ASSEMBLY .............................. 30 .... C4
CAM SHAFT VALVE ASSEMBLY ......................... 29 .... C3
CARBURETOR ................................... 21 .... B9
CLUTCH ASSEMBLY ................................ 34 .... C8
CONTROL SWITCH HOUSING ASSEMBLY .................... 46 .... D6
COOLING ASSEMBLY ............................... 18 .... B6
CRANK BALANCER ASSEMBLY .......................... 28 .... C2
CRANKCASE ASSEMBLY ............................. 24 .... B12
CRANKCASE COVER ASSEMBLY ........................ 25 .... B13
CRANKSHAFT ASSEMBLY ............................ 26 .... B14
CYLINDER ASSEMBLY .............................. 23 .... B11
CYLINDER HEAD ASSEMBLY ........................... 22 .... B10
DECALS ........................................ 3 .... A5
ELECTRICAL COMPONENTS ASSEMBLY .................... 45 .... D5
ENGINE AND EXHAUST .............................. 17 .... B5
FRAME AND RELATED PARTS ........................... 4 .... A6
FRONT BEVEL GEAR ASSEMBLY ........................ 41 .... D1
FRONT SUSPENSION ASSEMBLY ......................... 7 .... A9
FUEL TANK ASSEMBLY .............................. 13 .... B1
GEAR SHIFTING ASSEMBLY ........................... 39 .... C13
HI/LOW SHIFTER ASSEMBLY ........................... 40 .... C14
HYDRAULIC BRAKE ASSEMBLY ......................... 12 .... A14
HYDRAULIC BRAKE CONTROL ASSEMBLY ................... 11 .... A13
MAGNETO ASSEMBLY .............................. 44 .... D4
MECHANICAL BRAKE ASSEMBLY ........................ 10 .... A12
OIL FILTER/PUMP ASSEMBLY .......................... 32 .... C6
REAR AXLE ASSEMBLY .............................. 19 .... B7
REAR BEVEL GEAR ASSEMBLY ......................... 42 .... D2
REAR SUSPENSION ASSEMBLY .......................... 8 .... A10
RECOIL STARTER ASSEMBLY .......................... 31 .... C5
RELATED ITEMS ............................. Back Cover .... D8
REVERSE SHIFT LEVER ASSEMBLY ....................... 14 .... B2
SEAT ASSEMBLY .................................. 5 .... A7
SECONDARY DRIVE ASSEMBLY ......................... 38 .... C12
SECONDARY TRANSMISSION ASSEMBLY ................... 36 .... C10
SPEEDOMETER DRIVE ASSEMBLY ....................... 37 .... C11
STARTER CLUTCH ASSEMBLY .......................... 27 .... C1
STARTER MOTOR ASSEMBLY .......................... 43 .... D3
STEERING ASSEMBLY ............................... 6 .... A8
STORAGE BOX AND BATTERY ASSEMBLY ................... 16 .... B4
TAILLIGHT ASSEMBLY ............................... 2 .... A4
THROTTLE CASE ASSEMBLY ........................... 47 .... D7
TRANSMISSION ASSEMBLY ........................... 35 .... C9
WATER PUMP ASSEMBLY ............................ 33 .... C7
WHEEL AND TIRE ASSEMBLY ........................... 9 .... A11
WIRING HARNESS ASSEMBLY .......................... 20 .... B8
TABLE OF CONTENTS
ATV 400 4x4 & 500 4x4
(Model No. 98A4E-AP & 98A4G-AP)
A1
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BODY PANEL ASSEMBLY
0734-275
1 0506-277 1 Panel, Fender - Front (400)
0506-156 1 Panel, Fender - Front (500)
2 0506-265 1 Cover, Access (400)
0506-145 1 Cover, Access (500)
3 0406-080 1 Flare - Front Right
0406-081 1 Flare - Front Left
4 0506-191 1 Rack - Front (400)
0506-104 1 Rack - Front (500)
5 0606-526 2 Reflector - Yellow
6 0623-269 8 Clip, Retaining
7 0506-268 1 Panel, Side - Right (400)
0506-164 1 Panel, Side - Right (500)
0506-269 1 Panel, Side - Left (400)
0506-165 1 Panel, Side - Left (500)
8 0506-267 1 Panel, Fender - Rear (400)
0506-157 1 Panel, Fender - Rear (500)
9 0506-190 1 Rack - Rear (400)
0506-103 1 Rack - Rear (500)
10 0406-293 1 Wrap, Tube - Rear Rack
11 0417-002 1 Foam, Access Panel
12 0606-029 2 Reflector - Red
13 0406-082 1 Flare, Rear Right
0406-083 1 Flare, Rear Left
14 0406-086 1 Mud Flap - Right
0406-087 1 Mud Flap - Left
15 0423-046 56 Rivet, Plastic
16 0406-084 1 Fender Extension - Rear Right
0406-085 1 Fender Extension - Rear Left
17 0423-010 16 Washer, Body
18 8474-616 16 Screw, Machine
19 0423-060 2 Clip, Tinerman
20 0623-309 2 Screw, Self-Tapping
21 8409-020 6 Screw, Cap
22 8408-812 2 Screw, Cap
23 0423-031 2 Nut, Speed
24 0123-010 3 Nut, Expansion
25 0423-068 2 Screw, Machine
26 0623-184 1 Washer
27 8477-616 2 Screw, Machine
28 0406-297 1 Plate, Heat - Rear Panel
29 0123-549 1 Screw, Machine
30 8476-616 1 Screw, Machine
A3
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
1
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TAILLIGHT ASSEMBLY
(Complete Taillight Assembly p/n 0409-002)
0732-336
1 0109-460 1 Bulb, Stop - Taillight
2 0409-011 1 Taillight w/Socket Assembly
3 0409-012 1 Gasket, Taillight
4 0409-007 1 Lens, Taillight
5 0409-010 2 Screw, Machine
6 0623-301 2 Screw, Self-Tapping
7 8053-212 2 Washer, Lock - External Tooth
A4
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
2
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DECALS
0734-277
1 0411-006 1 Decal, Warning - Front Rack Load
2 0411-116 1 Decal, Front (400)
0411-120 1 Decal, Front (500)
3 3611-002 1 Decal, “Made In U.S.A.”
4 0411-045 1 Decal, Warning - Turn
5 0411-008 1 Decal, Warning Reverse/Pre-Ride
6 0411-040 1 Decal, Warning - Age
7 0411-010 1 Decal, Warning - General
8 0411-114 1 Decal, Side Right (400)
0411-115 1 Decal, Side Left (400)
0411-112 1 Decal, Side Right (500)
0411-113 1 Decal, Side Left (500)
9 0411-012 1 Decal, Warning - Tire Pressure (400)
0411-097 1 Decal, Warning - Tire Pressure (500)
10 0411-127 1 Decal, Fuel Valve (400)
0411-125 1 Decal, Fuel Valve (500)
11 0411-007 1 Decal, Warning - Rear Rack Load
12 0411-043 1 Decal, “Arctic Cat”
13 0411-013 1 Decal, Warning - Towing
14 0411-003 1 Decal, Shift Pattern
15 0411-011 1 Decal, Caution - Electrical
16 0411-009 1 Decal, Hi/Low Range
A5
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
3
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FRAME AND RELATED PARTS
0733-396
1 0409-001 2 Headlight Assembly (inc. 3 and 13)
2 8424-802 6 Nut
3 0409-005 2 Bulb, Headlight
4 8053-242 2 Washer, Lock
5 8408-850 2 Screw, Cap
6 0406-390 1 Screen, Bumper - Lower (400)
0406-175 1 Screen, Bumper - Lower (500)
7 0406-261 2 Yoke, Headlight
8 0406-262 2 Mount, Headlight
9 8409-020 6 Screw, Cap (400)
8409-020 8 Screw, Cap (500)
10 0506-192 1 Guard, Brush (400)
0506-186 1 Guard, Brush (500)
11 0506-176 1 Footrest - Right
12 0506-177 1 Footrest - Left
13 0123-590 2 Screw, Machine
14 8408-816 8 Screw, Cap (400)
8408-816 10 Screw, Cap (500)
15 0506-133 1 Frame, Main
16 0423-010 10 Washer, Shoulder
17 8474-616 10 Screw, Machine
18 0406-354 1 Panel, Belly
19 0506-079 1 Tube, Cross - Bumper (500)
20 0406-130 2 Cap, Bumper
21 8408-820 2 Screw, Cap
22 0506-149 1 Bracket, Differential
23 8428-002 1 Nut, Lock
24 3423-010 1 Screw, Cap
A6
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
4
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SEAT ASSEMBLY
0734-278 * Not a Service Part
1 5990-069 1 Seat Assembly (inc. 2-8)
2 0506-054 1 Cover, Seat
3 0506-056 1 Foam, Seat
4 0506-223 1 Base, Seat Assembly (inc. 5-7)
5 * 1 Base, Seat
6 8061-628 4 Rivet
7 0506-147 2 Pin, Seat Base - Front
8 0624-100 AR Staple
9 0406-309 2 Grommet, Seat - Center
10 8476-620 2 Screw, Cap
11 0406-235 1 Spring, Seat Latch
12 8050-217 2 Washer
13 0406-199 2 Collar, Front Seat Base
14 0406-171 2 Bumper, Seat Base - Front
15 0623-404 1 Cap, Protector
16 0406-103 1 Latch, Seat - Assembly
17 8477-616 2 Screw, Machine
A7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
5
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STEERING ASSEMBLY
0734-279
1 0487-005 1 Cable, Speedometer
2 8477-616 3 Screw, Machine
3 0420-003 1 Speedometer (inc. 36-41)
4 0423-052 1 Collar, Body
5 3430-013 1 Switch, Ignition - Assembly (inc. 6)
6 3409-007 1 Key, Ignition - Blank (C Series)
3409-011 1 Key, Ignition - Blank (D Series)
7 0420-011 1 Bezel/Lens, Warning - Assembly
8 0420-012 1 Bezel/Lens, Shifting - Assembly
9 0405-019 1 Instrument Pod
10 0420-013 9 Bulb, Light Bar
11 0420-001 1 Light, Warning - Assembly
12 0420-004 1 Light, Shift Indicator - Assembly
13 0123-950 4 Screw, Self-Tapping
14 8408-860 6 Screw, Cap
15 0405-035 4 Cap, Steering Adjuster
16 0506-139 1 Bracket, Key Switch
17 0505-028 1 Tube, Handlebar
18 0405-039 2 Grip, Handlebar
19 0605-171 1 Housing, Bearing - Lower
20 0405-020 2 Bearing, Steering Post
21 0705-064 1 Housing, Bearing - Upper
22 0623-175 4 Pin, Cotter
23 0505-012 1 Post, Steering
24 8408-816 2 Screw, Cap
25 0602-233 1 Flange, Bearing
26 0107-223 1 Bearing - w/Inverted Oil Seal
27 0423-073 1 Washer
28 8409-020 1 Screw, Cap
29 8422-002 4 Nut, Hex Castle
30 0505-021 2 Tie Rod, Assembly (inc. 31-35)
31 8420-002 2 Nut
32 0405-040 2 Ball Joint, Tie Rod - Right
33 0405-041 2 Ball Joint, Tie Rod - Left
34 0423-013 2 Nut - Left
35 0405-032 2 Tie Rod
36 0620-149 1 Bulb, Speedometer
37 0420-014 1 Harness, Speedometer
38 0420-018 1 Bracket, Speedometer
39 0420-016 2 Mount, Rubber
40 0420-017 2 Washer
41 0420-015 2 Pin, Retainer
42 0423-067 1 Tube, Loom
43 0409-013 1 Cover, Key
44 8060-428 2 Rivet
A8
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
6
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FRONT SUSPENSION ASSEMBLY
0732-344
1 0603-033 2 Retainer, Spring
2 0403-001 2 Shock Absorber - Front (inc. 3-4)
3 0604-310 8 Bushing, Shock Absorber
4 0403-028 4 Sleeve, Shock
5 8428-002 12 Nut, Lock
6 8409-040 4 Screw, Cap
7 0403-002 2 Spring, Shock Absorber
8 0403-025 2 Collar, Spring
9 0403-013 2 Washer, Spring
10 0503-026 1 A-Arm, Upper Right - Assembly (inc. one
No. 11-12)
0503-027 1 A-Arm, Upper Left - Assembly (inc. one
No. 11-12)
11 0405-001 4 Ball Joint - Front
12 0423-009 4 Clip, Ball Joint
13 0505-026 1 Knuckle - Assembly - Right (inc. 14 and
one No. 15-18)
0505-027 1 Knuckle - Assembly - Left (inc. 14 and
one No. 15-18)
14 0505-024 1 Knuckle, Steering - Right
0505-025 1 Knuckle, Steering - Left
15 0402-275 2 Bearing, Wheel Hub - Front
16 0423-034 2 Clip, Bearing
17 0402-089 2 Seal, Wheel Bearing - Front
18 0402-069 2 Seal, Wheel Bearing - Front
19 8409-030 4 Screw, Cap
20 8409-060 8 Screw, Cap
21 0503-012 1 A-Arm, Lower Right (inc. one No. 11-12)
0503-013 1 A-Arm, Lower Left (inc. one No. 11-12)
22 0402-179 2 Axle, Drive - Front
23 0436-114 2 Repair Kit, Outer Boot - Front Axle
24 0436-113 2 Repair Kit, Inner Boot - Front Axle
25 0403-027 2 Retainer, Spring - Lower
A9
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
7
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REAR SUSPENSION ASSEMBLY
0733-399
1 8409-060 2 Screw, Cap
2 8409-000 2 Screw, Cap
3 0504-001 3 Arm, Swing
4 8428-002 8 Nut, Lock
5 8409-055 1 Screw, Cap
6 0504-005 1 Arm, Swing
7 0403-027 2 Retainer, Spring - Lower
8 0404-001 2 Shock Absorber - Rear (inc. two No. 9
and four No. 10)
9 0403-028 4 Sleeve, Shock
10 0604-310 8 Bushing, Shock Absorber
11 0603-033 2 Retainer, Spring
12 8409-040 4 Screw, Cap
13 0404-006 2 Spring, Shock Absorber
14 0403-025 2 Collar, Spring
15 0403-013 2 Washer, Spring Adjustment
16 8422-002 1 Nut, Lock
17 8409-065 1 Screw, Cap
A10
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
8
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WHEEL AND TIRE ASSEMBLY
0733-366
1 3423-213 4 Nut, Hex
2 0402-140 4 Cap, Valve Stem
3 0402-064 4 Valve, Stem
4 0402-215 2 Wheel - Front
5 0402-176 2 Tire - Front (400)
0402-153 2 Tire - Front (500)
6 0123-458 4 Pin, Cotter
7 0423-080 4 Washer
8 0402-181 4 Seal, Hub
9 0502-041 2 Hub, Wheel - Front
10 0402-009 3 Disc, Brake
11 0423-029 12 Screw, Machine
12 0502-042 2 Hub, Wheel - Rear
13 0402-224 2 Wheel - Rear
14 0402-153 2 Tire - Rear
15 0403-035 4 Cap, Wheel - Center
16 8409-020 16 Screw, Cap
A11
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1998 400 4x4
1998 500 4x4
9
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800-407-7218
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