1996 Arctic Cat Bearcat 454 4X4 ATV Parts Catalog
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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 Inc. Service Manuals.
Underlined part numbers are new for the 1996 model year.
© 2001 Arctic Cat Inc. Printed September 2001
®™ Trademarks of Arctco, Inc., Thief River Falls, MN 56701
NOTE:
TABLE OF CONTENTS
Model No. 96A4A-AP
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
HIGH/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 PUMP/ FILTER 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
A1
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BODY PANEL ASSEMBLY
0732-341
1 0506-156 1 Panel, Fender - Front
2 0406-153 1 Cover, Radiator Access
3 0506-154 1 Flare - Front Right
0506-155 1 Flare - Front Left
4 0506-104 1 Rack - Front
5 0606-526 2 Yellow Reflector
6 0623-269 8 Clip, Retaining
7 0506-164 1 Panel, Side - Right
0506-165 1 Panel, Side - Left
8 0506-157 1 Panel, Fender - Rear
9 0506-103 1 Rack - Rear
10 0406-269 1 Wrap, Tube - Rear Rack
11 0123-788 7 Tie, Cable
12 0606-029 2 Red Reflector
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 54 Rivet, Plastic
16 0506-160 1 Fender Extension - Rear Right
0506-161 1 Fender Extension - Rear Left
17 0423-010 14 Washer, Body
18 8474-616 14 Screw, Machine
19 0423-060 2 Clip, Tinerman
20 0623-302 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 2 Nut, Expansion
25 0423-068 2 Screw, Machine
26 0706-990 AR Tape, Foil
A3
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
BEARCAT 454 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, Taillight
6 0623-302 2 Screw, Self-Tapping
7 8053-212 2 Washer, Lock
A4
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
BEARCAT 454 4X4
2
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DECALS
0732-340
1 0411-006 1 Decal, Warning - Front Rack Load
2 0411-018 1 Decal, “Bearcat” - Front
3 0411-011 1 Decal, Caution - Electrical
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 0411-014 1 Decal, “Bearcat” - Side Right
0411-015 1 Decal, “Bearcat” - Side Left
9 0411-012 1 Decal, Warning - Tire Pressure
10 0411-003 1 Decal, Shift Pattern
11 0411-007 1 Decal, Warning - Rear Rack Load
12 0411-043 1 Decal, “Arctic Cat”
13 0411-013 1 Decal, Warning - Towing
14 0411-009 1 Decal, Hi/Low Range
A5
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
BEARCAT 454 4X4
3
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FRAME AND RELATED PARTS
0735-385
1 0409-001 2 Headlight
2 8474-813 6 Nut, Hex
3 0409-005 2 Bulb, Headlight
4 8053-242 2 Washer, Lock
5 8408-850 2 Screw, Cap
6 0406-175 1 Screen, Bumper
7 0406-261 2 Yoke, Headlight
8 0406-262 2 Mount, Headlight
9 8409-020 8 Screw, Cap
10 0506-075 1 Bumper - Front
11 0506-066 1 Footrest - Right
12 0506-067 1 Footrest - Left
13 0123-590 2 Screw, Machine
14 8408-816 10 Screw, Cap
15 0506-133 1 Frame
16 0423-010 10 Washer, Shoulder
17 8474-616 10 Screw, Machine
18 0406-095 1 Panel, Belly
19 0506-079 1 Tube, Cross
20 0406-130 2 Cap, Bumper
A6
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
BEARCAT 454 4X4
4
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SEAT ASSEMBLY
0732-342
1 5990-012 1 Seat - Assembly (inc. 2-11)
2 0506-054 1 Cover, Seat
3 0506-056 1 Foam, Seat
4 0506-167 1 Base, Seat - Assembly (inc. 5-10)
5 0506-166 1 Base, Seat
6 8061-628 4 Rivet
7 0506-147 1 Pin, Seat Base - Front
8 8060-630 4 Rivet
9 0406-268 2 Plate, Seat Retainer
10 8050-152 4 Washer
11 0624-263 50 Staple
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
18 0406-172 2 Bumper, Seat Base - Center
19 0406-270 2 Bumper, Seat Base - Center
20 8408-620 2 Screw, Cap
A7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
BEARCAT 454 4X4
5
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STEERING ASSEMBLY
0732-343
1 0487-005 1 Cable, Speedometer
2 8477-616 3 Screw, Machine
3 0420-003 1 Speedometer
4 0423-052 3 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 0505-007 1 Tube, Handlebar
18 0405-013 2 Grip, Handlebar
19 0705-064 1 Housing, Bearing - Upper
20 0405-020 2 Bearing, Steering Post
21 0605-171 1 Cap, Bearing - Steering
22 0117-868 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/o Lock Collar
27 0123-570 1 Washer
28 8409-020 1 Screw, Cap
29 0423-014 4 Nut, Hex Castle
30 0505-001 2 Tie Rod, Assembly (inc. 31-35)
31 8480-010 2 Nut, Hex
32 0405-011 2 Ball Joint, Tie Rod - Left
33 0405-010 2 Ball Joint, Tie Rod - Right
34 0423-013 2 Nut, Hex
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
A8
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
BEARCAT 454 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 8478-013 12 Nut, Lock
6 8409-040 4 Screw, Cap
7 0403-002 2 Spring, Front
8 0403-025 2 Collar, Spring
9 0403-013 2 Washer, Spring
10 0503-016 1 A-Arm, Upper Right - Assembly (inc. two
No. 11-12)
0503-017 1 A-Arm, Upper Left - Assembly (inc. two
No. 11-12)
11 0405-001 4 Ball Joint - Front
12 0423-009 2 Clip, Ball Joint
13 0505-016 1 Knuckle - Assembly - Right (inc. 14-18)
0505-017 1 Knuckle - Assembly - Left (inc. 14-18)
14 0505-010 1 Knuckle, Steering - Right
0505-011 1 Knuckle, Steering - Left
15 0402-085 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 0503-013 1 A-Arm, 4x4 Lower Left (inc. two
No. 11-12)
0503-012 1 A-Arm, 4x4 Lower Right (inc. two
No. 11-12)
22 0402-098 2 Axle, Drive - Front
23 0436-038 2 Repair Kit, Outer Boot - Front Axle
24 0436-037 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
BEARCAT 454 4X4
7
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REAR SUSPENSION ASSEMBLY
0732-345
1 8409-060 3 Screw, Cap
2 8409-000 2 Screw, Cap
3 0504-001 3 Arm, Swing
4 8478-013 9 Nut, Hex
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. 9-10)
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 - Rear
14 0403-025 2 Collar, Spring
15 0403-013 2 Washer, Spring Adjustment
A10
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
BEARCAT 454 4X4
8
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WHEEL AND TIRE ASSEMBLY
0735-756 * Not Illustrated
1 0402-007 2 Tire, Front
2 0402-140 4 Cap, Valve Stem
3 0402-064 4 Valve, Stem
4 0402-005 2 Wheel - Front
5 0423-015 4 Nut, Hex
6 0123-458 4 Pin, Cotter
7 0423-021 4 Washer
8 0402-099 4 Seal, Hub
9 0402-088 2 Hub, Wheel - Front
10 0402-009 3 Disc, Brake
11 0423-029 12 Screw, Machine
12 0402-080 2 Hub, Wheel - Rear
13 0402-006 2 Wheel - Rear
14 0402-008 2 Tire - Rear
15 0403-011 4 Cap, Wheel - Center
16 8409-020 16 Screw, Cap
17 0402-074 1 Wheel and Tire Assy - RH
(inc. 1, 4, and 16) *
0402-075 1 Wheel and Tire Assy - LH
(inc. 1, 4, and 16) *
18 0402-076 1 Wheel and Tire Assy - RH
(inc. 2, 3, 13, and 14) *
0402-077 1 Wheel and Tire Assy - LH
(inc. 2, 3, 13, and 14) *
A11
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
BEARCAT 454 4X4
9
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Print one or all pages of your manual
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