2005 Carryall 295 / XRT 1500 (Gas & Diesel) - Bennett Golf Cars

2005XRT 1500/Carryall 294Illustrated Parts ListGasoline and Diesel VehiclesManual Number 102680304Edition Code 0105L0310K

USING THE ILLUSTRATED PARTS LISTý WARNING• This manual is to be used only for identification and ordering of service parts. Be sure to read and usethe maintenance and service manual before attempting any vehicle repairs.This manual covers all XRT 1500 and Carryall 294 vehicles.The manual is divided into 15 sections. Sections 1 through 14 pertain to service parts for the vehicles, and Section15 pertains to tools that are used on all Club Car products.Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Tableof Contents lists section numbers, and under them, the individual page titles and numbers to be found in thatsection. The index can be used to find specific parts and assemblies. The index is divided into numerical andalphabetical listings with the page numbers in italic text.There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is anillustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon.The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (correspondingto the numbers on the illustration), part descriptions, and quantity of parts used.Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by thenumbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indentedto level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the partquantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. Apart that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion ofthe vehicle illustrated on that particular spread.HOW TO ORDER PARTSReplacement parts and accessories can be obtained from our network of authorized dealers and distributors. Youcan obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting ourweb site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts andTechnical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3887.P. O. Box 204658Augusta, Georgia 30917-4658 USATelephone 706-863-3000Service Parts Fax 706-855-7413www.clubcar.com

NOTE:This illustrated parts list represents the most current information at the time of publication. Club Car, Inc. iscontinually working to further improve its vehicles and other products. These improvements may affect theparts used to service the vehicle. Any modification and/or significant change in specifications will be forwardedto all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions ofthis illustrated parts list.Club Car, Inc. reserves the right to change specifications and designs at any time without notice and withoutthe obligation of making changes to units previously sold.Copyright © 2007 Club Car, Inc.Club Car is a registered trademark of Club Car, Inc.This manual effective August 2, 2004.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

CONTENTSSECTION 1 – BODY AND TRIMFront Body Trim, Gasoline Vehicles ......................................................................................................................................... 1-3Front Body Trim, Diesel Vehicles .............................................................................................................................................. 1-5Front Body Components ............................................................................................................................................................. 1-7Front Seats and Cup Holder ....................................................................................................................................................... 1-9ROPS .................................................................................................................................................................................................... 1-11Tilt Bed and Hinge .......................................................................................................................................................................... 1-13Electric Bed Lift ................................................................................................................................................................................ 1-15Rear Body Trim ................................................................................................................................................................................ 1-17Cargo Box (Steel) ............................................................................................................................................................................ 1-19SECTION 2 – WHEELS AND TIRESWheels and Tires ............................................................................................................................................................................. 2-3SECTION 3 – DECALSSafety Decals, Gasoline Vehicles ............................................................................................................................................... 3-3Safety Decals, Gasoline Vehicles, Continued ....................................................................................................................... 3-5Safety Decals, Diesel Vehicles .................................................................................................................................................... 3-7Safety Decals, Diesel Vehicles, Continued ............................................................................................................................. 3-9Badging Decals, XRT 1500 Vehicles ......................................................................................................................................... 3-11Badging Decals, Carryall 294 Vehicles .................................................................................................................................... 3-13SECTION 4 – BRAKE SYSTEMSFront Brake Assembly ................................................................................................................................................................... 4-3Rear Brake Assembly ..................................................................................................................................................................... 4-5Master Cylinder ............................................................................................................................................................................... 4-7Hydraulic Brake Lines and Clips ................................................................................................................................................ 4-9Park Brake Assembly with Pulley System .............................................................................................................................. 4-11Park Brake Assembly with Bellcrank System ........................................................................................................................ 4-13SECTION 5 – PEDAL GROUPAccelerator Pedal Assembly ....................................................................................................................................................... 5-3Brake Pedal Assembly ................................................................................................................................................................... 5-5Park Brake Pedal Assembly ......................................................................................................................................................... 5-7Park Brake Pedal Assembly with Bellcrank System ............................................................................................................ 5-92005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1

CONTENTSSECTION 6 – STEERING AND SUSPENSIONSteering Column ............................................................................................................................................................................. 6-3Steering Gear Assembly ............................................................................................................................................................... 6-5Front Suspension – A-Arms ......................................................................................................................................................... 6-7Front Suspension (Standard) ...................................................................................................................................................... 6-9Front Suspension (High-Capacity Option) ............................................................................................................................. 6-11Rear Suspension (Standard) ........................................................................................................................................................ 6-13Rear Suspension (High-Capacity Option) ............................................................................................................................... 6-15SECTION 7 – ELECTRICAL SYSTEMWiring – Gasoline Vehicles Built Before November 19, 2005 .......................................................................................... 7-5Wiring – Gasoline Vehicles Built After November 19, 2005 ............................................................................................. 7-9Wiring – Diesel Vehicles ................................................................................................................................................................ 7-13Headlights ......................................................................................................................................................................................... 7-15Electrical Component Box, Gasoline Vehicles ...................................................................................................................... 7-17Electrical Component Box, Diesel Vehicles ........................................................................................................................... 7-19Electrical Components, Instrument Panel, Gasoline Vehicles ........................................................................................ 7-21Electrical Components, Instrument Panel, Diesel Vehicles .............................................................................................. 7-23Battery – Gasoline Vehicles ......................................................................................................................................................... 7-25Battery – Diesel Vehicles .............................................................................................................................................................. 7-27SECTION 8 – DIESEL ENGINE – CLOSED BREATHERKubota D722 Diesel Engine Mounting .................................................................................................................................... 8-3Crankcase ........................................................................................................................................................................................... 8-5Oil Pan ................................................................................................................................................................................................. 8-7Cylinder Head ................................................................................................................................................................................... 8-9Gear Case ........................................................................................................................................................................................... 8-11Head Cover ........................................................................................................................................................................................ 8-13Dipstick and Guide ......................................................................................................................................................................... 8-15Oil Pump ............................................................................................................................................................................................. 8-17Main Bearing Case .......................................................................................................................................................................... 8-19Camshaft and Idle Gear ................................................................................................................................................................ 8-21Piston and Crankshaft ................................................................................................................................................................... 8-23Flywheel ............................................................................................................................................................................................. 8-25Shaft ..................................................................................................................................................................................................... 8-27Idle Apparatus .................................................................................................................................................................................. 8-29Stop Solenoid ................................................................................................................................................................................... 8-3140-Amp Alternator ......................................................................................................................................................................... 8-33Page 22005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

CONTENTS60-Amp Alternator ......................................................................................................................................................................... 8-35Injection Pump ................................................................................................................................................................................ 8-37Speed Control Plate ....................................................................................................................................................................... 8-39Nozzle Holders and Glow Plugs ................................................................................................................................................ 8-41Governor Components ................................................................................................................................................................ 8-43Starter ................................................................................................................................................................................................. 8-45Valves and Rocker Arms ............................................................................................................................................................... 8-47Diesel Inlet Manifold ..................................................................................................................................................................... 8-49Exhaust Manifold ............................................................................................................................................................................ 8-51Gasket Kits ......................................................................................................................................................................................... 8-53Piston Kit ............................................................................................................................................................................................ 8-55SECTION 9 – HONDA GX620 GASOLINE ENGINEHonda GX620 Gasoline Engine Mounting ............................................................................................................................ 9-3Shrouds and Brackets ................................................................................................................................................................... 9-5Ignition Components and Flywheel ........................................................................................................................................ 9-7Oil Circulation .................................................................................................................................................................................. 9-9Cylinder Head .................................................................................................................................................................................. 9-11Crankcase and Crankshaft ........................................................................................................................................................... 9-13Oil Filter Adapter and Voltage Regulator .............................................................................................................................. 9-15SECTION 10 – FUEL, INTAKE, AND GOVERNOR SYSTEMFuel System – Gasoline Vehicles ............................................................................................................................................... 10-3Fuel Tank – Gasoline Vehicles .................................................................................................................................................... 10-5Fuel System – Diesel Vehicles .................................................................................................................................................... 10-7Fuel Tank – Diesel Vehicles ......................................................................................................................................................... 10-9Carburetor Assembly, Honda Gasoline Vehicles ................................................................................................................. 10-11Carburetor Installation – Honda Gasoline Vehicles ........................................................................................................... 10-13Governor and Accelerator Cables, Gasoline Vehicles ....................................................................................................... 10-15Choke Cable, Gasoline Vehicles ................................................................................................................................................ 10-17Accelerator Cable, Diesel Vehicles ........................................................................................................................................... 10-19Governor Cover – Gasoline Vehicles ....................................................................................................................................... 10-21Governor System – Gasoline Vehicles .................................................................................................................................... 10-23Intake Duct and Air Box Assembly – Honda Gasoline Vehicles ..................................................................................... 10-25Intake Duct and Air Box Assembly – Diesel Vehicles ......................................................................................................... 10-27SECTION 11 – EXHAUST SYSTEMExhaust System, Gasoline Vehicles .......................................................................................................................................... 11-3Exhaust System, Diesel Vehicles ............................................................................................................................................... 11-52005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 3

CONTENTSSECTION 12 – CLUTCHESClutch Cover (Standard) ............................................................................................................................................................... 12-3Clutch Cover (Sealed) .................................................................................................................................................................... 12-5Drive Belt ............................................................................................................................................................................................ 12-7Drive Clutch – Gasoline Vehicles ............................................................................................................................................... 12-9Drive Clutch – Diesel Vehicles .................................................................................................................................................... 12-11Driven Clutch .................................................................................................................................................................................... 12-13SECTION 13 – DRIVETRAIN COMPONENTSFront Differential Mounting and Half Shafts ......................................................................................................................... 13-3Front Differential (Output Components) ............................................................................................................................... 13-5Front Differential (Input Components) ................................................................................................................................... 13-7Prop Shafts ........................................................................................................................................................................................ 13-9Forward/Reverse Shifter Assembly .......................................................................................................................................... 13-11Transmission ..................................................................................................................................................................................... 13-13Transmission, Continued ............................................................................................................................................................. 13-15Transmission Shift Shaft and Bell Crank (Style A) ................................................................................................................ 13-17Transmission Shift Shaft and Bell Crank (Style B) ............................................................................................................... 13-19Transmission, Continued ............................................................................................................................................................. 13-21Transmission Cable ........................................................................................................................................................................ 13-23Rear Differential ............................................................................................................................................................................... 13-25Rear Differential, Continued ....................................................................................................................................................... 13-27SECTION 14 – RADIATOR AND COOLANT SYSTEM (DIESEL VEHICLES)Radiator .............................................................................................................................................................................................. 14-3Coolant Expansion Tank ............................................................................................................................................................... 14-5Coolant Pipes and Hoses .............................................................................................................................................................. 14-7Water Flange and Thermostat .................................................................................................................................................... 14-9Water Pump ...................................................................................................................................................................................... 14-11Block Coolant Pipe .......................................................................................................................................................................... 14-13SECTION 15 – MAINTENANCE AND SERVICE TOOLSMaintenance and Service Tools ................................................................................................................................................. 15-3Maintenance and Service Tools, Continued ......................................................................................................................... 15-5Maintenance and Service Tools, Continued ......................................................................................................................... 15-7Maintenance and Service Tools, Continued ......................................................................................................................... 15-9Maintenance and Service Tools, Continued ......................................................................................................................... 15-11Page 42005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

CONTENTSSECTION i – INDEX2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 5

BODY AND TRIM1GED

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ITEM PART NO. DESCRIPTION1 2 3 4FRONT BODY TRIM, GASOLINE VEHICLES1 1014306 Washer, 1/4" Type B Flat .......................................................................................................................... 72 102021502 Fender, Left Front ....................................................................................................................................... 13 102021602 Fender, Right Front .................................................................................................................................... 14 102021802 Dashboard with Access Hole ................................................................................................................. 15 N/A Cap, 1/4" Plastic Screw Head ................................................................................................................. 56 N/A Washer, 1/4 Id Scalloped Plast ............................................................................................................... 57 102289002 Screw, M8 X 1.25 X 30 Tri, Blk ................................................................................................................. 48 102298130 Bolt, Flange Head, M8 X 30.0 ................................................................................................................. 49 102410603 P-Clamp, Insulated .312 In ...................................................................................................................... 110 102418501 Weldment, Support, ROPS ...................................................................................................................... 111 N/A Plate, Brush Mount .................................................................................................................................... 112 102429301 Grill, Flat ......................................................................................................................................................... 113 102432001 Mat, Floor ...................................................................................................................................................... 114 102459710 Cowl, Machined, Dark Green ................................................................................................................. 115 N/A Cowl, Machined, Dark Gray .................................................................................................................... 116 102459715 Cowl, Machined, Red ................................................................................................................................ 117 102459716 Cowl, Machined, White ............................................................................................................................ 118 102459718 Cowl, Machined, Camo ............................................................................................................................ 119 N/A Support, Access Panel, Dash .................................................................................................................. 120 102491501 Washer Hard,m10 ...................................................................................................................................... 421 N/A Rivet, .125" Dia, .311" Panel .................................................................................................................... 522 102617201 Nut Flg M10 X 1.5 Mech Def .................................................................................................................. 423 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 424 102628601 Screw, 1/4-20 X 1.0 Pn Hd Torx .............................................................................................................. 1325 102760501 Panel, Access, Dash ................................................................................................................................... 126 102760701 Cam Lock Body ........................................................................................................................................... 127 102760801 Latch, Cam, Access Panel ........................................................................................................................ 128 102778001 Asm, Brush Guard ...................................................................................................................................... 129 102967901 Rivet, Removable, Tuflok 1/4" ................................................................................................................ 1530 96715552 Bolt, M10 X 1.50 X 65 ................................................................................................................................ 4QTY1GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-3

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ITEM PART NO. DESCRIPTION1 2 3 4FRONT BODY TRIM, DIESEL VEHICLES1 1014306 Washer, 1/4" Type B Flat .......................................................................................................................... 72 102021502 Fender, Left Front ....................................................................................................................................... 13 102021602 Fender, Right Front .................................................................................................................................... 14 102021802 Dashboard with Access Hole ................................................................................................................. 15 N/A Cap, 1/4" Plastic Screw Head ................................................................................................................. 56 N/A Washer, 1/4 Id Scalloped Plast ............................................................................................................... 57 102289002 Screw, M8 X 1.25 X 30 Tri, Blk ................................................................................................................. 48 102298130 Bolt, Flange Head, M8 X 30.0 ................................................................................................................. 49 102410603 P-Clamp, Insulated .312 In ...................................................................................................................... 110 102418501 Weldment, Support, ROPS ...................................................................................................................... 111 N/A Plate, Brush Mount .................................................................................................................................... 112 102432001 Mat, Floor ...................................................................................................................................................... 113 102459710 Cowl, Machined, Dark Green ................................................................................................................. 114 N/A Cowl, Machined, Dark Gray .................................................................................................................... 115 102459715 Cowl, Machined, Red ................................................................................................................................ 116 102459716 Cowl, Machined, White ............................................................................................................................ 117 102459718 Cowl, Machined, Camo ............................................................................................................................ 118 N/A Support, Access Panel, Dash .................................................................................................................. 119 102491501 Washer Hard,m10 ...................................................................................................................................... 420 N/A Rivet, .125" Dia, .311" Panel .................................................................................................................... 521 102617201 Nut Flg M10 X 1.5 Mech Def .................................................................................................................. 422 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 423 102628601 Screw, 1/4-20 X 1.0 Pn Hd Torx .............................................................................................................. 1324 102760501 Panel, Access, Dash ................................................................................................................................... 125 102760701 Cam Lock Body ........................................................................................................................................... 126 102760801 Latch, Cam, Access Panel ........................................................................................................................ 127 102778001 Asm, Brush Guard ...................................................................................................................................... 128 102831601 Guard, Radiator ........................................................................................................................................... 129 102967901 Rivet, Removable, Tuflok 1/4" ................................................................................................................ 1530 8248 Screw, 1/4-20 X 0.75 Truss-Head Machine ........................................................................................ 4QTY1GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-5

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ITEM PART NO. DESCRIPTION1 2 3 4FRONT BODY COMPONENTS1 1016967 Blind Rivet, Push Type .............................................................................................................................. 82 102289001 Screw, M8X1.25X30, Hex ......................................................................................................................... 13 **** Weldment, Dash, Front ............................................................................................................................ 14 102437201 Guard, Splash .............................................................................................................................................. 15 102491301 Bolt, M10x1.50x100 (Black) .................................................................................................................... 46 102491501 Washer Hard,m10 ...................................................................................................................................... 77 102617201 Nut Flg M10 X 1.5 Mech Def .................................................................................................................. 118 **** Bracket, Support, Steering ...................................................................................................................... 19 96715552 Bolt, M10 X 1.50 X 65 ................................................................................................................................ 7QTY1GED**** Special order item available upon request.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-7


ITEM PART NO. DESCRIPTION1 2 3 4FRONT SEATS AND CUP HOLDER1 1014471 Tape, Vinyl Foam 1/8" x 3/4" * ................................................................................................................ 22 102425401 Closeout, Driver Side ................................................................................................................................ 13 N/A Closeout, Passenger Side ........................................................................................................................ 14 102442001 Pan, Center, Closeout ................................................................................................................................ 15 102473701 Asm, Bucket Seat Adjustable (includes items 6 through 18) ..................................................... 16 1011652 Hinge Plate ............................................................................................................................................. 27 102047001 Rivet, 1/4 X .438 Blind ......................................................................................................................... 48 102059401 Screw, 6m-1.00 X 10mm Hex Head ................................................................................................ 19 102061101 Seat Holder Cup .................................................................................................................................... 110 102298130 Bolt, Flange Head, M8 X 30.0 ............................................................................................................ 411 102298401 Nut,m8,all Metal Lock ......................................................................................................................... 412 102456001 Pan, Seat, Driver Asm .......................................................................................................................... 113 102458901 Decal, Hot Surface Warning .............................................................................................................. 114 102473501 Adjuster, Forward/Aft .......................................................................................................................... 115 102473601 Adjuster, Slider ...................................................................................................................................... 116 102475901 Washer, Bell ............................................................................................................................................. 417 103267001 Seat, Bucket, Gray ................................................................................................................................. 118 451 Lockwasher, 1/4 Helical Split ............................................................................................................ 119 N/A Assembly, Bucket Seat w/Spacers (includes items 20 through 29) ......................................... 120 1011652 Hinge Plate ............................................................................................................................................. 221 1012830 Screw, M8-125 X 22 Hex-Head ......................................................................................................... 422 1013734 Lockwasher, 8mm Split ...................................................................................................................... 423 102023703 Pan, Seat, Passenger ............................................................................................................................ 124 102047001 Rivet, 1/4 X .438 Blind ......................................................................................................................... 425 102059401 Screw, 6m-1.00 X 10mm Hex Head ................................................................................................ 126 102061101 Seat Holder Cup .................................................................................................................................... 127 102458901 Decal, Hot Surface Warning .............................................................................................................. 128 103267001 Seat, Bucket, Gray ................................................................................................................................. 129 451 Lockwasher, 1/4 Helical Split ............................................................................................................ 130 N/A Console, Center, Drink Holder ............................................................................................................... 131 102967901 Rivet, Removable, Tuflok 1/4" ................................................................................................................ 4QTY1GED* Note: Item not shown.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-9

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ITEM PART NO. DESCRIPTION1 2 3 4ROPS1 101887601 Locknut, M6-1.00 Nylon Insert .............................................................................................................. 22 102059001 Seat Holder Base ........................................................................................................................................ 23 102418401 Weldment, Top, ROPS (includes items 4 through 6) ...................................................................... 14 102459401 Decal, Young Driver Warning ........................................................................................................... 15 102621101 Decal, ROPS Certification/Warning ................................................................................................ 16 N/A Weldment, ROPS, Top, Unlabeled ................................................................................................... 17 102418501 Weldment, Support, ROPS ...................................................................................................................... 18 102447601 Buckle, Seat Belt with Sleeve ................................................................................................................. 29 102447602 Retractor, Seat Belt .................................................................................................................................... 210 102482201 Kit, ROPS (includes items 11 through 15) .......................................................................................... 111 102419901 Tube, Support, Front, ROPS .............................................................................................................. 212 102420001 Tube, Support, Rear, ROPS ................................................................................................................ 213 102718001 Bolt, M10 X 55, Zn-Ni (Black) ............................................................................................................ 814 102718101 Washer, Hard, M10, Zn-Ni/Blk .......................................................................................................... 1615 N/A Nut, Hex Cap, M10, Zn-Ni/Blk ........................................................................................................... 816 102491301 Bolt, M10x1.50x100 (Black) .................................................................................................................... 417 102491501 Washer Hard,m10 ...................................................................................................................................... 418 102617201 Nut Flg M10 X 1.5 Mech Def .................................................................................................................. 419 102670601 Bracket, Seatbelt, Bolt-On ....................................................................................................................... 120 102671201 Screw,m12x1.75x30 Thd Form Blk ....................................................................................................... 421 102718101 Washer, Hard, M10, Zn-Ni/Blk ................................................................................................................ 822 N/A Nut, Hex Cap, M10, Zn-Ni/Blk ................................................................................................................ 223 102732401 Bolt, M10 X 45, Zn-Ni (Black) .................................................................................................................. 224 102739201 Barrier, Heat, Neoprene ........................................................................................................................... 125 102886101 Weldment, Supp, Seat, Rops .................................................................................................................. 126 332 Washer, 1/4 Type A Narrow Flat ............................................................................................................ 227 96742515 Bolt, M6 X 1 X 45 ......................................................................................................................................... 2QTY1GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-11

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ITEM PART NO. DESCRIPTION1 2 3 4TILT BED AND HINGE1 1012303 Bushing, Steel .............................................................................................................................................. 22 1015356 Hinge .............................................................................................................................................................. 23 1015583 Bushing, Urethane ..................................................................................................................................... 24 102065901 Locknut, 3/8-16 Flanged Dimple .......................................................................................................... 45 102066001 Washer, 3/8 Type B Hard Flat ................................................................................................................. 46 102171504 Assembly, Tilt Bed, Electric Lift (includes items 7 through 14) .................................................. 17 1010435 Bolt, Carriage, 5/16-18 X 1.00 ........................................................................................................... 48 1014471 Tape, Vinyl Foam 1/8" x 3/4" * .......................................................................................................... A/R9 N/A Plate, Floor Bed ..................................................................................................................................... 110 N/A Frame Assembly .................................................................................................................................... A/R11 1015399 Screw, 5/16-18 X 0.88 Torx Truss-Head ......................................................................................... 412 102725801 Foam, Barrier, Heat, Bed, Frt ............................................................................................................. 113 102725901 Foam, Barrier, Heat, Bed, Rail ............................................................................................................ 114 7473 Locknut, 5/16-18 Nylon Insert ......................................................................................................... 815 102614101 Plate, Back ..................................................................................................................................................... 216 7561 Bolt, 3/8-16 X 3.00 Hex Head ................................................................................................................. 417 8754 Locknut, 3/8-16 Hex .................................................................................................................................. 218 8755 Screw, 3/8-16 X 3.375 Hex Cap .............................................................................................................. 2QTY1GED* Note: Item not shown.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-13

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ITEM PART NO. DESCRIPTION1 2 3 4ELECTRIC BED LIFT1 1010200 Bolt, 3/8-16 X 4.25 Hex Head ................................................................................................................. 12 1016603 Bushing Long .............................................................................................................................................. 23 1017162 Actuator Assembly, Electric .................................................................................................................... 14 1017167 Actuator Adapter ....................................................................................................................................... 15 1017774 Body Spacer ................................................................................................................................................. 86 102066001 Washer, 3/8 Type B Hard Flat ................................................................................................................. 87 102426601 Bumper, Bed, Mtg, Front .......................................................................................................................... 28 102465701 Weldment, Bracket, Actuator ................................................................................................................. 19 102614101 Plate, Back ..................................................................................................................................................... 110 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 211 102629001 Tie Wrap, 8.00" With Mount .................................................................................................................... 212 102673901 Wire Harness, Electric Lift ........................................................................................................................ 113 357 Washer, Lock, Hel Sp 3/8 Reg ................................................................................................................. 214 8754 Locknut, 3/8-16 Hex .................................................................................................................................. 915 8755 Screw, 3/8-16 X 3.375 Hex Cap .............................................................................................................. 616 8990 Tie Wrap, 8" Nylon ..................................................................................................................................... 5QTY1GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-15


ITEM PART NO. DESCRIPTION1 2 3 4REAR BODY TRIM1 1012769 Screw, M6-1.00 X 25mm Hex Cap ........................................................................................................ 22 1014306 Washer, 1/4" Type B Flat .......................................................................................................................... 83 1014321 Screw, #10 Truss-Head Torx .................................................................................................................... 24 101438702 Corner Cap AWD ........................................................................................................................................ 25 102251601 Fender, Right Rear ..................................................................................................................................... 16 102251701 Fender, Left Rear ......................................................................................................................................... 17 102454001 Assembly, Panel (Passenger Side) ........................................................................................................ 18 102454101 Assembly, Panel (Driver Side) ................................................................................................................ 19 102454201 Panel, Front .................................................................................................................................................. 110 102466201 Bezel, Fuel Fill .............................................................................................................................................. 111 102491701 Well Nut 1/4-20 ........................................................................................................................................... 1412 102621501 Nut Flg, M6 X 1.0 Nylon ........................................................................................................................... 213 102684501 Washer, M12 Hard Regular ..................................................................................................................... 214 8251 Screw, 1/4-20 X 1.0 Truss-Head Machine ........................................................................................... 14QTY1GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-17


ITEM PART NO. DESCRIPTION1 2 3 4CARGO BOX (STEEL)1 N/A Instl, Steel Box, XRT (includes items 2 through 27) ........................................................................ 12 1010435 Bolt, Carriage, 5/16-18 X 1.00 ........................................................................................................... 133 1010436 Bumper, Rubber .................................................................................................................................... 44 1014306 Washer, 1/4" Type B Flat ..................................................................................................................... 45 1014415 Screw, 1/4-20 X 0.75 Torx Truss-Head ........................................................................................... 86 1014537 Stud, Self-Clinching Flush Head ...................................................................................................... 47 1015399 Screw, 5/16-18 X 0.88 Torx Truss-Head ......................................................................................... 188 101894304 Box Bed Tailgate Angle ....................................................................................................................... 19 101963401 Locknut, 5/16-18 Hex Flange ........................................................................................................... 410 102221301 Front Panel Weldment ........................................................................................................................ 111 102221401 Left Panel Weldment ........................................................................................................................... 112 102221501 Right Panel Weldment ........................................................................................................................ 113 102221701 Front Corner Cap .................................................................................................................................. 214 102222001 Slam Latch ............................................................................................................................................... 215 102239901 Washer, Rubber, 3/8 ............................................................................................................................. 416 102614401 Assembly, Tailgate (includes items 17 through 24) ................................................................. 117 1013366 Hair Pin Clip ...................................................................................................................................... 418 1014415 Screw, 1/4-20 X 0.75 Torx Truss-Head ..................................................................................... 419 N/A Tailgate, Weldment ........................................................................................................................ 120 102221801 Tether Assembly ............................................................................................................................. 221 102222101 Spring Latch Left ............................................................................................................................ 122 102222201 Spring Latch Right ......................................................................................................................... 123 102673201 Decal, Club Car Tailgate ............................................................................................................... 124 8233 Locknut, 1/4-20 Nylon Insert ..................................................................................................... 425 332 Washer, 1/4 Type A Narrow Flat ...................................................................................................... 426 7473 Locknut, 5/16-18 Nylon Insert ......................................................................................................... 3127 8233 Locknut, 1/4-20 Nylon Insert ............................................................................................................ 4QTY1GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 1-19

1GED

WHEELS AND TIRES2GED


ITEM PART NO. DESCRIPTION1 2 3 4WHEELS AND TIRES1 102021406 Gray Tire Assembly, HDAT, 8-Inch (includes items 2 through 4) ............................................... 22 102021305 HDAT Tire, 8" ........................................................................................................................................... 13 102374801 Wheel, Indus Spider, Gray .................................................................................................................. 14 7310 Valve Stem .............................................................................................................................................. 15 102021407 Gray Tire Assembly, HDAT 10.5-Inch (includes items 6 through 8) .......................................... 26 102021302 Tire, HDAT ................................................................................................................................................ 17 102374801 Wheel, Indus Spider, Gray .................................................................................................................. 18 7310 Valve Stem .............................................................................................................................................. 19 102021408 Gray Tire Assembly, AT489 LH (includes items 10 through 12) ................................................. 210 102021306 Tire, AT489 ............................................................................................................................................... 111 102374801 Wheel, Indus Spider, Gray .................................................................................................................. 112 7310 Valve Stem .............................................................................................................................................. 113 102021409 Gray Tire Assembly, AT489 RH (includes items 14 through 16) ................................................. 214 102021306 Tire, AT489 ............................................................................................................................................... 115 102374801 Wheel, Indus Spider, Gray .................................................................................................................. 116 7310 Valve Stem .............................................................................................................................................. 117 102736901 Nut, Lug, 1/2-20 SAE J2283 .................................................................................................................... 16QTY2GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 2-3

2GED

DECALS3GED


ITEM PART NO. DESCRIPTION1 2 3 4SAFETY DECALS, GASOLINE VEHICLES1 1011553 Decal, Trailer Hitch ..................................................................................................................................... 12 101553901 Decal, Bed Load Warning ........................................................................................................................ 13 101609401 Decal, Crush Area Warning ..................................................................................................................... 24 102224001 Decal, Rotating Parts Warning .............................................................................................................. 15 102455201 Decal, Instrument Panel Warning, Gasoline Vehicle ..................................................................... 16 102459301 Decal, Bed Crush Area Warning ............................................................................................................ 17 102459401 Decal, Young Driver Warning ................................................................................................................ 18 N/A Decal, Vehicle Loading, High-Capacity .............................................................................................. 19 102621101 Decal, ROPS Certification/Warning ..................................................................................................... 110 N/A Decal, Vehicle Loading, Standard Capacity ...................................................................................... 1QTY3GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 3-3


ITEM PART NO. DESCRIPTIONSAFETY DECALS, GASOLINE VEHICLES, CONTINUED1 2 3 41 101547601 Decal, Gasoline Explosion/Fire Warning ............................................................................................ 12 102231601 Decal, Winch Cable Fracture Warning ................................................................................................ 13 N/A Decal, Operating Instructions, Gasoline ............................................................................................ 14 102458901 Decal, Hot Surface Warning ................................................................................................................... 35 102459101 Decal, Frame Ground Warning .............................................................................................................. 16 102459501 Decal, Rotating Parts and Hot Exhaust Warning ............................................................................ 1QTY3GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 3-5


ITEM PART NO. DESCRIPTION1 2 3 4SAFETY DECALS, DIESEL VEHICLES1 1011553 Decal, Trailer Hitch ..................................................................................................................................... 12 101553901 Decal, Bed Load Warning ........................................................................................................................ 13 101609401 Decal, Crush Area Warning ..................................................................................................................... 24 102224001 Decal, Rotating Parts Warning .............................................................................................................. 15 N/A Decal, Warning, Diesel ............................................................................................................................. 16 102458801 Decal, Diesel Fuel Only ............................................................................................................................. 17 102459301 Decal, Bed Crush Area Warning ............................................................................................................ 18 102459401 Decal, Young Driver Warning ................................................................................................................ 19 N/A Decal, Vehicle Loading, High-Capacity .............................................................................................. 110 102621101 Decal, ROPS Certification/Warning ..................................................................................................... 111 N/A Decal, Vehicle Loading, Standard Capacity ...................................................................................... 1QTY3GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 3-7


ITEM PART NO. DESCRIPTIONSAFETY DECALS, DIESEL VEHICLES, CONTINUED1 2 3 41 102231601 Decal, Winch Cable Fracture Warning ................................................................................................ 12 102455101 Decal, Operating Instructions, Diesel ................................................................................................. 13 102458901 Decal, Hot Surface Warning ................................................................................................................... 54 102459001 Decal, Hot Manifold Warning ................................................................................................................ 15 102459101 Decal, Frame Ground Warning .............................................................................................................. 16 102459201 Decal, Diesel Explosion/Fire Warning ................................................................................................. 17 102459501 Decal, Rotating Parts and Hot Exhaust Warning ............................................................................ 18 102460201 Decal, Rotating Parts Warning .............................................................................................................. 1QTY3GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 3-9

3GED15 2 3 7 46000011-001Page 3-102005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4BADGING DECALS, XRT 1500 VEHICLES1 102046501 Decal, XRT Front ......................................................................................................................................... 12 102622701 Decal, XRT 1500 (driver-side) ................................................................................................................. 13 102622801 Decal, XRT 1500 (passenger-side) ........................................................................................................ 14 102623301 Decal, 4x4 ...................................................................................................................................................... 25 102623501 Decal, Diesel ................................................................................................................................................ 26 102673201 Decal, Club Car Tailgate ........................................................................................................................... 17 102673301 Decal, High-Capacity (optional accessory) ....................................................................................... 2QTY3GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 3-11

3GED15 2 3 7 46000011-002Page 3-122005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4BADGING DECALS, CARRYALL 294 VEHICLES1 102046501 Decal, XRT Front ......................................................................................................................................... 12 102622901 Decal, Carryall 294 (driver-side) ............................................................................................................ 13 102623001 Decal, Carryall 294 (passenger-side) ................................................................................................... 14 102623301 Decal, 4x4 ...................................................................................................................................................... 25 102623501 Decal, Diesel ................................................................................................................................................ 26 102673201 Decal, Club Car Tailgate ........................................................................................................................... 17 102673301 Decal, High-Capacity (optional accessory) ....................................................................................... 2QTY3GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 3-13

3GED

BRAKE SYSTEMS4GED


ITEM PART NO. DESCRIPTION1 2 3 4FRONT BRAKE ASSEMBLY1 102367601 Brake Caliper, Front, with Brake Pads .................................................................................................. 22 102488001 Bolt, Banjo, M10x1x19 .............................................................................................................................. 23 102491601 Washer, Copper, M10 Crush ................................................................................................................... 44 102493301 Bolt Flange Head, 3/8-24x.750 with Loctite ..................................................................................... 45 102714001 Service Kit, Brake Pad (4 Pads) ............................................................................................................... 16 103418801 Pin, Slide, 7/16 ............................................................................................................................................. 2QTY4GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 4-3


ITEM PART NO. DESCRIPTION1 2 3 4REAR BRAKE ASSEMBLY1 102399201 Caliper, Brake, Hydro-Mechanical, LH ................................................................................................. 12 102399202 Caliper, Brake, Hydro-Mechanical, RH ................................................................................................ 13 102488001 Bolt, Banjo, M10x1x19 .............................................................................................................................. 24 102491601 Washer, Copper, M10 Crush ................................................................................................................... 45 102493301 Bolt Flange Head, 3/8-24x.750 with Loctite ..................................................................................... 46 102714001 Service Kit, Brake Pad (4 Pads) ............................................................................................................... 17 103418701 Spring, Brake Caliper Return .................................................................................................................. 18 103418801 Pin, Slide, 7/16 ............................................................................................................................................. 2QTY4GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 4-5


ITEM PART NO. DESCRIPTION1 2 3 4MASTER CYLINDER1 101082903 Clevis Pin, 5/16 X 1 ..................................................................................................................................... 12 1014306 Washer, 1/4" Type B Flat .......................................................................................................................... 13 101887601 Locknut, M6-1.00 Nylon Insert .............................................................................................................. 14 102176901 Pin, Rue .......................................................................................................................................................... 15 102402801 Cylinder, Master, Tandem ........................................................................................................................ 16 102402901 Assembly, Reservoir, Remote (includes items 7 and 8) ................................................................ 17 102051401 Filler Cap Asm ........................................................................................................................................ 18 N/A Reservoir, Brake Fluid, Without Cap ............................................................................................... 19 102541465 Bolt, M 6 X 1.0 X 65 Hex, Flange, Head, Black ................................................................................... 110 102618401 Bolt Flanged Head, M8 X 1.25 X 35 ...................................................................................................... 211 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 212 102715701 Line, Reservoir, Brake ................................................................................................................................ 2QTY4GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 4-7

4GE3D89422104161551141412713000015-001Page 4-82005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4HYDRAULIC BRAKE LINES AND CLIPS1 101887601 Locknut, M6-1.00 Nylon Insert .............................................................................................................. 12 102296140 Bolt, Flanged Head, M6x1.0x40 ............................................................................................................ 33 102296401 Nut-m6x1.0 Flng All Mtl Lock ................................................................................................................ 24 102296716 Screw, M6 X 16 Tt Hx Fl Hd ..................................................................................................................... 75 102407801 Assembly, Brake Line, Rear ..................................................................................................................... 16 102407901 Assembly, Brakeline, Front (includes item 7) ................................................................................... 17 102410603 P-Clamp, Insulated .312 In ................................................................................................................. 18 102474101 Bracket, Brake Line, Left ........................................................................................................................... 19 102474102 Bracket, Brake Line, Right ........................................................................................................................ 110 102474301 Bracket, Tee, Brakeline .............................................................................................................................. 111 102475701 Clip, Brake Line ............................................................................................................................................ 612 102689001 Bracket, Line, Hydraulic ........................................................................................................................... 213 102689101 Brkt, Line, Hyd, Shk Mnt, Drv ................................................................................................................. 114 102689102 Brkt, Line, Hyd, Shk Mnt, Pass ................................................................................................................ 115 8639 Tie Wrap, 11" Nylon ................................................................................................................................... 1QTY4GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 4-9

4GE62172173D3610151611189145 12481137000087-001Page 4-102005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4PARK BRAKE ASSEMBLY WITH PULLEY SYSTEM1 1011779 E-Clip, 1/2 ...................................................................................................................................................... 22 1012438 Locknut, #10-24 Nylon Insert ................................................................................................................ 123 101260202 Screw, #10-24 X 3/4 Socket-Head ........................................................................................................ 124 1013531 Spring, Brake Return ................................................................................................................................. 15 N/A Equalizer Bracket ........................................................................................................................................ 16 N/A Pulley, 2-Inch Flat Mount ........................................................................................................................ 37 102442701 Cable, Brake, Parking, Left ....................................................................................................................... 18 102442801 Cable, Brake, Parking, Right .................................................................................................................... 19 102618301 Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... 110 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 111 102770001 Brake Cable, Park, Kit, Front (includes items 12 through 16) ..................................................... 112 1010521 Nut, 5/16-24 Hex ................................................................................................................................... 113 102052801 Nut, 5/16-24 Hex Cone ....................................................................................................................... 114 N/A Cable, Brake, Parking, Front .............................................................................................................. 115 N/A Ring, Retaining, External, 9mm ....................................................................................................... 116 1241 Washer, 5/16 Type A Flat .................................................................................................................... 117 183 Washer, #10 Type A Flat ........................................................................................................................... 1218 8639 Tie Wrap, 11" Nylon ................................................................................................................................... 2QTY4GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 4-11

4GED6113512 314210 74118000533-003Page 4-122005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTIONPARK BRAKE ASSEMBLY WITH BELLCRANK SYSTEM1 2 3 41 1011779 E-Clip, 1/2 ...................................................................................................................................................... 22 1013531 Spring, Brake Return ................................................................................................................................. 13 N/A Equalizer Bracket ........................................................................................................................................ 14 102618301 Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... 15 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 16 102712601 Cable, Crank, Bell, Front ........................................................................................................................... 17 102763301 Cable, Noncoated, Pbrake, Left ............................................................................................................. 18 102763401 Cable, Noncoated, Pbrake, Rght ........................................................................................................... 19 102770301 Kit, Cable, Brake, Crank, Fr (includes items 10 through 13) ........................................................ 110 1010521 Nut, 5/16-24 Hex ................................................................................................................................... 111 102052801 Nut, 5/16-24 Hex Cone ....................................................................................................................... 112 N/A Cable, Crank, Bell, Main ...................................................................................................................... 113 1035 Cotter Pin, 3/32 x 1 ............................................................................................................................... 114 8639 Tie Wrap, 11" Nylon ................................................................................................................................... 2QTY4GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 4-13

4GED

PEDAL GROUP5GED


ITEM PART NO. DESCRIPTION1 2 3 4ACCELERATOR PEDAL ASSEMBLY1 102489901 Asm, Pedal, Accelerator (includes items 2 through 17) ................................................................ 12 102296401 Nut-m6x1.0 Flng All Mtl Lock ........................................................................................................... 33 N/A Pullrod, Spring, Compression ........................................................................................................... 14 102442901 Bushing, Greaseless ............................................................................................................................. 45 N/A Spring, Comp, Pedal, Pullrod ............................................................................................................ 16 N/A Washer, Retaining Spring, 7mm ...................................................................................................... 27 N/A Guide, Cable, Accelerator .................................................................................................................. 18 N/A Weldment, Bracket, Pedal .................................................................................................................. 19 N/A Weldment, Lever, Motion, Lost ........................................................................................................ 110 N/A Spring, Torsion ....................................................................................................................................... 111 N/A Spring, Stop, Pedal ............................................................................................................................... 112 N/A Bolt, Stop, Pedal .................................................................................................................................... 113 N/A Pad, Grip Tape, Accelerator ............................................................................................................... 114 N/A Weldment, Pedal, Accelerator .......................................................................................................... 115 102618101 Nut M6x1 Mech Def Center .............................................................................................................. 116 103273101 Bolt, Shoulder, M8 X 70, Hc ............................................................................................................... 117 96706825 Bolt, M6 X 1 X 70 ................................................................................................................................... 218 102618301 Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... 219 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 2QTY5GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 5-3


ITEM PART NO. DESCRIPTION1 2 3 4BRAKE PEDAL ASSEMBLY1 102380601 Bracket, Pedal, Brake ................................................................................................................................. 12 102618101 Nut M6x1 Mech Def Center .................................................................................................................... 13 102618301 Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... 24 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 25 N/A Asm, Pedal, Brake, Hung (includes items 6 and 7) ......................................................................... 16 102442901 Bushing, Greaseless ............................................................................................................................. 27 102626201 Weldment, Pedal, Brake, Hung ........................................................................................................ 18 103273101 Bolt, Shoulder, M8 X 70, Hc .................................................................................................................... 1QTY5GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 5-5


ITEM PART NO. DESCRIPTION1 2 3 4PARK BRAKE PEDAL ASSEMBLY1 N/A Pedal Asm, Brake, Park (includes items 2 and 3) ............................................................................. 12 102758701 Kit, Handle, Brake, Park ....................................................................................................................... 13 N/A Pedal, Brake, Park .................................................................................................................................. 14 102618301 Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... 35 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 36 102892401 Asm, Pedal, Brake, Hard (includes items 7 and 8) ........................................................................... 17 N/A Pedal, Brake, Park .................................................................................................................................. 18 102896601 Handle, Release, Park Brake .............................................................................................................. 1QTY5GEDNote: Item 1 has been discontinued. Use item 6 for replacement of thecomplete assembly.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 5-7

5G1013ED119161817112815231571445000086-003Page 5-82005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

PARK BRAKE PEDAL ASSEMBLY WITH BELLCRANK SYSTEMITEM PART NO. DESCRIPTION1 2 3 41 N/A Pedal Asm, Brake, Park (includes items 2 and 3) ............................................................................. 12 102758701 Kit, Handle, Brake, Park ....................................................................................................................... 13 N/A Pedal, Brake, Park .................................................................................................................................. 14 102618301 Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... 35 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 36 102751501 Asm, Sub, Bracket, Park Brake (includes items 7 through 15) .................................................... 17 102323501 Washer, Flat, 3/8, Blk Fin ..................................................................................................................... 28 102716001 Cable, Crank, Bell .................................................................................................................................. 19 102741501 Bolt Flg, M8x1.25 X 35, Gr10.9 ......................................................................................................... 210 102741601 Nut Flg M8 X 1.25 Gr 10 ...................................................................................................................... 211 102751301 Asm, Bellcrank, Upper ......................................................................................................................... 112 N/A Asm, Bellcrank, Lower ......................................................................................................................... 113 103305001 Brkt, Bellcrank, Prk Brk, Awd ............................................................................................................. 114 103305101 Spacer, Pivot, Park Brk, Awd .............................................................................................................. 215 1035 Cotter Pin, 3/32 x 1 ............................................................................................................................... 216 102892401 Asm, Pedal, Brake, Hard (includes items 17 and 18) ...................................................................... 117 N/A Pedal, Brake, Park .................................................................................................................................. 118 102896601 Handle, Release, Park Brake .............................................................................................................. 1QTY5GEDNote: Item 1 has been discontinued. Use item 16 for replacement of thecomplete assembly.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 5-9

5GED

STEERING AND SUSPENSION6GED


ITEM PART NO. DESCRIPTION1 2 3 4STEERING COLUMN1 102290120 Bolt, M10 X 20 Hex Washer Hd .............................................................................................................. 12 102298130 Bolt, Flange Head, M8 X 30.0 ................................................................................................................. 13 102363802 Steering Wheel, Viper, Hex Hub ............................................................................................................ 14 102364201 Steering Column (includes items 5 through 8) ............................................................................... 15 102298130 Bolt, Flange Head, M8 X 30.0 ............................................................................................................ 16 102571301 Shroud, Steering Column .................................................................................................................. 17 N/A Knuckle, Steering, Slider .................................................................................................................... 18 N/A Column, Steering without Knuckle and Shroud ....................................................................... 19 102367101 Cap, Steering Wheel, Viper ..................................................................................................................... 110 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 3QTY6GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 6-3

6G2E18 34116 78 1315169 10 5 1412D21TYPICAL4 PLACES17TYPICAL2 PLACESTYPICAL2 PLACES221TYPICAL2 PLACES1920TYPICAL2 PLACES000071-002Page 6-42005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4STEERING GEAR ASSEMBLY1 1013042 Nut, 12mm Hex ........................................................................................................................................... 22 102010102 Steering Rack (includes items 3 through 18) ................................................................................... 13 1013035 Bellows, Long ......................................................................................................................................... 24 1013042 Nut, 12mm Hex ..................................................................................................................................... 25 1013044 Rack Screw Locknut ............................................................................................................................. 16 1013051 Snap Ring ................................................................................................................................................ 17 1013052 Seal, Steering Pinion Dust ................................................................................................................. 18 101879401 Bearing, Ball ............................................................................................................................................ 19 101879701 Support Yoke ......................................................................................................................................... 110 101879801 Rack Guide Pressure Spring .............................................................................................................. 111 101879901 Ring, Stop, C-Type ................................................................................................................................ 112 101880201 Inner Ball Joint Asm ............................................................................................................................. 213 N/A Pinion, Steering ..................................................................................................................................... 114 N/A Bearing, Lower Pinion ......................................................................................................................... 115 N/A Screw, Rack Guide ................................................................................................................................ 116 N/A Housing, Steering Gear ...................................................................................................................... 117 N/A Rack, Steering ........................................................................................................................................ 118 8990 Tie Wrap, 8" Nylon ................................................................................................................................ 219 102022601 End, Tie Rod M12 X 1.25 .......................................................................................................................... 220 102022901 Locknut, M12-1.25 Nylon ........................................................................................................................ 221 102449901 Link, Drag ...................................................................................................................................................... 222 102687801 Bolt, Flange Head, M10x 1.5 X 40 with Loctite ................................................................................ 4QTY6GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 6-5

6G9E1215 13 11 1410242D2237 4 6 851722242416242024241 2312318192021251921000074-001Page 6-62005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4FRONT SUSPENSION – A-ARMS1 102022901 Locknut, M12-1.25 Nylon ........................................................................................................................ 22 102368501 Sub-assembly, A-Arm, Upper, LH (includes items 3 through 8) ................................................ 13 102296140 Bolt, Flanged Head, M6x1.0x40 ....................................................................................................... 14 102296401 Nut-m6x1.0 Flng All Mtl Lock ........................................................................................................... 15 102361901 Joint, Ball ................................................................................................................................................. 16 102368801 A-Arm, Upper, Left ............................................................................................................................... 17 102474101 Bracket, Brake Line, Left ..................................................................................................................... 18 102722301 Ring, Retaining, Ext, 1-1/4" ................................................................................................................ 19 102368502 Sub-assembly, A-Arm, Upper, RH (includes items 10 through 15) ........................................... 110 102296140 Bolt, Flanged Head, M6x1.0x40 ....................................................................................................... 111 102296401 Nut-m6x1.0 Flng All Mtl Lock ........................................................................................................... 112 102361901 Joint, Ball ................................................................................................................................................. 113 102368802 A-Arm, Upper, Right ............................................................................................................................ 114 102474102 Bracket, Brake Line, Right .................................................................................................................. 115 102722301 Ring, Retaining, Ext, 1-1/4" ................................................................................................................ 116 102408401 Bushing, A-Arm ........................................................................................................................................... 817 102437001 Sleeve, Upper .............................................................................................................................................. 418 102437101 Sleeve, Lower ............................................................................................................................................... 219 102446901 Arm, Lower ................................................................................................................................................... 220 102469901 Bushing, Lower Arm .................................................................................................................................. 421 102490801 Bolt, Flange Head, M12x 1.75x 30 with Loctite ............................................................................... 422 102616301 Bolt, Flange Head, M12 X 1.75 X 70 ..................................................................................................... 423 102617701 Nut, Square, M12x 1.75 ............................................................................................................................ 424 102620501 Nut Flg, M12x1.75, Nylon Gr 10 ............................................................................................................ 625 103256701 Bolt Flg, M12 X 1.75 X 200 10. ................................................................................................................ 2QTY6GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 6-7


ITEM PART NO. DESCRIPTION1 2 3 4FRONT SUSPENSION (STANDARD)1 102298240 Bolt, Flange Head, M8-1.25 X 40 ........................................................................................................... 42 102394002 Shock, Coil Over, Front Hd ...................................................................................................................... 23 102616301 Bolt, Flange Head, M12 X 1.75 X 70 ..................................................................................................... 24 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 45 102620501 Nut Flg, M12x1.75, Nylon Gr 10 ............................................................................................................ 2QTY6GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 6-9

6GE587131418D2161171149811109111512 64 15 -143000072-002Page 6-102005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTIONFRONT SUSPENSION (HIGH-CAPACITY OPTION)1 2 3 41 102298240 Bolt, Flange Head, M8-1.25 X 40 ........................................................................................................... 42 102394002 Shock, Coil Over, Front Hd ...................................................................................................................... 23 102468802 Kit, Anti-Sway Bar (includes items 4 through 15) ........................................................................... 14 1016183 Screw, 3/8-16 X 7.00 Hex Cap ........................................................................................................... 25 102298130 Bolt, Flange Head, M8 X 30.0 ............................................................................................................ 46 102298240 Bolt, Flange Head, M8-1.25 X 40 ..................................................................................................... 47 102446601 Bushing, Anti-Sway Bar, 1-1/8 .......................................................................................................... 28 102464601 Bar, Sway, Formed ................................................................................................................................ 19 102470101 Bushing, Link .......................................................................................................................................... 810 102470501 Sleeve, Link ............................................................................................................................................. 211 102470601 Washer, Cup, Bushing ......................................................................................................................... 812 102477201 Mount, Link ............................................................................................................................................. 213 102495001 Bracket, Anti-Sway Bar ........................................................................................................................ 214 102618601 Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... 815 8754 Locknut, 3/8-16 Hex ............................................................................................................................ 216 102616301 Bolt, Flange Head, M12 X 1.75 X 70 ..................................................................................................... 217 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 418 102620501 Nut Flg, M12x1.75, Nylon Gr 10 ............................................................................................................ 2QTY6GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 6-11


ITEM PART NO. DESCRIPTION1 2 3 4REAR SUSPENSION (STANDARD)1 1015597 Fitting, 1/4-28 Thread-Forming Grease .............................................................................................. 22 102365601 Shock, Coil Over Rear ............................................................................................................................... 23 102393501 Weldment, Receiver, Rear ....................................................................................................................... 14 102616301 Bolt, Flange Head, M12 X 1.75 X 70 ..................................................................................................... 45 102619801 Washer, Strip, Swingarm .......................................................................................................................... 26 102620401 Bolt Flanged Head, M12 X 1.75 X 50 ................................................................................................... 87 102620501 Nut Flg, M12x1.75, Nylon Gr 10 ............................................................................................................ 68 N/A Sub Asm Swingarm (includes items 9 through 11) ....................................................................... 29 102398901 Bushing, Pivot, Urethane ................................................................................................................... 210 102477001 Bushing, Teflon ...................................................................................................................................... 211 103282301 Swingarm, Rear, Awd .......................................................................................................................... 112 N/A Insert, Flanged, H-Bracket ....................................................................................................................... 413 102682901 Pin, Swingarm, Weldment ...................................................................................................................... 214 102684501 Washer, M12 Hard Regular ..................................................................................................................... 1015 102685601 Nut Flg M12 X 1.75 Cl10 .......................................................................................................................... 816 102689101 Brkt, Line, Hyd, Shk Mnt, Drv ................................................................................................................. 117 102689102 Brkt, Line, Hyd, Shk Mnt, Pass ................................................................................................................ 118 102737101 Cotter, Rue Ring, 1/2" ................................................................................................................................ 2QTY6GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 6-13


ITEM PART NO. DESCRIPTION1 2 3 4REAR SUSPENSION (HIGH-CAPACITY OPTION)1 1015597 Fitting, 1/4-28 Thread-Forming Grease .............................................................................................. 22 102365602 Shock, Coil Over, Rear HD ....................................................................................................................... 23 102393501 Weldment, Receiver, Rear ....................................................................................................................... 14 102616301 Bolt, Flange Head, M12 X 1.75 X 70 ..................................................................................................... 45 102619801 Washer, Strip, Swingarm .......................................................................................................................... 26 102620401 Bolt Flanged Head, M12 X 1.75 X 50 ................................................................................................... 87 102620501 Nut Flg, M12x1.75, Nylon Gr 10 ............................................................................................................ 68 N/A Sub Asm Swingarm (includes items 9 through 11) ....................................................................... 29 102398901 Bushing, Pivot, Urethane ................................................................................................................... 210 102477001 Bushing, Teflon ...................................................................................................................................... 211 103282301 Swingarm, Rear, Awd .......................................................................................................................... 112 N/A Insert, Flanged, H-Bracket ....................................................................................................................... 413 102682901 Pin, Swingarm, Weldment ...................................................................................................................... 214 102684501 Washer, M12 Hard Regular ..................................................................................................................... 1015 102685601 Nut Flg M12 X 1.75 Cl10 .......................................................................................................................... 816 102689101 Brkt, Line, Hyd, Shk Mnt, Drv ................................................................................................................. 117 102689102 Brkt, Line, Hyd, Shk Mnt, Pass ................................................................................................................ 118 102737101 Cotter, Rue Ring, 1/2" ................................................................................................................................ 2QTY6GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 6-15

6GED

ELECTRICAL SYSTEM7GED

7GE16_BRN(W05)D16_BLU(W01)16_BLU(W03)LIGHT SWITCH14_YEL(W07)16_BLU(W09)BRAKE SWITCH14_YEL(W76)16_BLU(W04)BUZZER18_RED_WHT_STP(W16)16_BLK(W13)18_BLK(W15)REVERSE SWITCHOIL LIGHT16_BLK(W14)18_BLK_WHT_STP(W17)FUEL/HR METER123418_RED(W59)18_BLU(W53)18_PUR(W49)18_BLK(W22)18_WHT(W18)18_ORG(W20)18_BLK(W23)18_BLK(W24)DIODE 218_YEL(W40) 18_YEL(W41)18_BLK(W21)18_BLK(W31)DIODE 118_BLK(W32)KEY SWITCHM-M+SLB16_GRN(W43)18_PUR(W47)18_PUR(W48)DIODE 318_YEL(W45)16_RED(W37)18_PINK(W63)START RELAYNC18_LHT_GRN(W44)NOFRONT DIFFERENTIAL18_GRAY(W34)18_GRAY(W35)16_BLK(W36)18_GRAY(W33)18_BLK(W60)18_PUR(W51)DIFF RELAYNC18_PUR(W50)NOPOWER POINT18_PUR(W52)18_BLK(W61)14_RED(W66)ACC RELAYNCNO14_RED(W74)16_ORG_WHT_STP(W46)18_BLK(W62)DIODE 418_BLK(W64)18_BLK(W65)DIODE 512_BLK(W75)000001-002Page 7-22005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

14_BLU(W26)14_BLU(W25)18_RED(W83)18_RED(W77)18_RED(W78)16_YEL(W12)16_PINK(W06)16_PINK(W68)18_YEL(W10)18_WHT(W11)BRKRIGHTLEFTTLGNDREGULATOR7GEDFUEL SENDERWHTWHT/BLUBLK/YELBLKGRAYGRAY14_RED(W28)14_RED(W27)STATOR14_BLU(W08)18_YEL(W54)14_BLK(W69)18_YEL(W39)FUEL SOLENOID18_BLK(W21)16_BLK(W67)18_YEL(W55)16_BLK_WHT_STP(W19)16_BLK_WHT_STP(W79)OIL PRESSURE SWITCH18_WHT_BLK_STP(W38)10_RED(W73)IG14_RED16_RED(W30)16_GRN(W42)18_GRN(W57)16_GRN(W58)STARTER14_RED(W29)DIODE 6DIODE 7ENGINE GROUND18_BLK(W71)18_BLK(W70)6_BLK(W82)6_RED(W80)6_BLK(W81)+ -12_BLK(W72)FRAME GROUND14_RED18_BLK_WHT_STP(W02)20A 10A 5A 25ANEUTRAL SWITCH18_BLK(W56)14_RED14_BLKBED LIFT SWITCH14_RED14_YEL14_RED14_RED14_YELBED LIFTMOTORCIRCUIT BREAKER000001-0022005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-3

7GEDSee previous two pages for illustration.Page 7-42005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

WIRING – GASOLINE VEHICLES BUILT BEFORE NOVEMBER 19,2005ITEM PART NO. DESCRIPTION1 2 3 41 102435301 Wire Harness, Awd, Gas ........................................................................................................................... 1QTY7GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-5

7GE16_BRN(W05)D16_BLU(W01)16_BLU(W03)LIGHT SWITCH14_YEL(W07)16_BLU(W09)BRAKE SWITCH14_YEL(W76)16_BLU(W04)BUZZER18_RED_WHT_STP(W16)16_BLK(W13)18_BLK(W15)REVERSE SWITCHOIL LIGHT16_BLK(W14)18_BLK_WHT_STP(W17)FUEL/HR METER123418_RED(W59)18_BLU(W53)18_PUR(W49)18_BLK(W22)18_WHT(W18)18_ORG(W20)18_BLK(W23)18_BLK(W24)DIODE 218_YEL(W40) 18_YEL(W41)18_BLK(W21)18_BLK(W31)DIODE 118_BLK(W32)KEY SWITCHM-M+SLB16_GRN(W43)16_PUR(W47)18_PUR(W48)DIODE 318_YEL(W45)16_RED(W37)16_PUR_WHT(W27)18_PINK(W63)START RELAYNC18_LHT_GRN(W44)NOFRONT DIFFERENTIAL18_GRAY(W34)18_GRAY(W35)16_BLK(W36)18_GRAY(W33)18_BLK(W60)18_PUR(W51)DIFF RELAYNC18_PUR(W50)NOPOWER POINT18_PUR(W52)18_BLK(W61)14_RED(W66)ACC RELAYNCNO14_RED(W74)16_ORG_WHT_STP(W46)18_BLK(W62)DIODE 418_BLK(W64)18_BLK(W65)DIODE 512_BLK(W75)000001-002Page 7-62005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

14_BLU(W26)14_BLU(W25)18_RED(W83)18_RED(W77)18_RED(W78)16_YEL(W12)16_PINK(W06)16_PINK(W68)18_YEL(W10)18_WHT(W11)BRKRIGHTLEFTTLGNDREGULATOR7GEDFUEL SENDER14_RED(W28)16_PUR_WHT(W27)WHTWHT/BLUBLK/YELBLKGRAYGRAYSTATOR14_BLU(W08)18_YEL(W54)14_BLK(W69)18_YEL(W39)FUEL SOLENOID18_BLK(W21)16_BLK(W67)18_YEL(W55)16_BLK_WHT_STP(W19)16_BLK_WHT_STP(W79)OIL PRESSURE SWITCH18_WHT_BLK_STP(W38)IG14_RED16_RED(W30)16_GRN(W42)18_GRN(W57)10_RED(W73)16_GRN(W58)STARTER14_RED(W29)DIODE 6DIODE 7ENGINE GROUND18_BLK(W71)18_BLK(W70)6_BLK(W82)6_RED(W80)6_BLK(W81)+ -12_BLK(W72)FRAME GROUND14_RED18_BLK_WHT_STP(W02)20A 10A 5A 25ANEUTRAL SWITCH18_BLK(W56)14_RED14_BLKBED LIFT SWITCH14_RED14_YEL14_RED14_RED14_YELBED LIFTMOTORCIRCUIT BREAKER000001-0032005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-7


WIRING – GASOLINE VEHICLES BUILT AFTER NOVEMBER 19,2005ITEM PART NO. DESCRIPTION1 2 3 41 102435301 Wire Harness, Awd, Gas ........................................................................................................................... 1QTY7GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-9

7GE16_BRN_WHT_STP(W67)18_BRN(W77)16_BRN(W05)D16_BLU(W01)16_BLU(W03)LIGHT SWITCH14_YEL(W07)16_BLU(W09)BRAKE SWITCH14_YEL(W68)BUZZER18_RED_WHT_STP(W16)REVERSE SWITCH18_ORG(W20)16_BLU(W04)16_BLK(W13)WATER TEMP LIGHT18_GRN_WHT_STP(W38)18_PUR(W30)OIL LIGHT16_BLK(W14)18_BLK(W15)18_PUR(W49)18_BLK_WHT_STP(W17)FUEL/HR METER123418_RED(W59)18_BLU(W53)18_BLK(W22)18_WHT(W18)18_BLK(W23)18_BLK(W21)18_BLK(W31)Diode 118_BLK(W32)18_BLK(W55)KEY SWITCHB+AC18_PUR(W29)12_RED(W25)12_BLU(W26)16_RED_WHT_STP(W37)FRONT DIFFERENTIAL14_BLK(W71)18_GRAY(W35)Diode 216_BLK(W36)IG1IG2STPRGR12_BLU(W27)18_RED(W24)18_LHT_GRN(W44)18_GRAY(W33)18_GRAY(W34)POWER POINTFAN18_BLU(W56)16_ORG_WHT_STP(W46)14_BLU(W66)14_BLU(W69)18_BLK(W60)18_BLK(W61)Diode 312_BLK(W84)Diode 4000002-002Page 7-102005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

718_RED(W88)18_RED(W87)18_RED(W89)16_YEL(W12)16_PINK(W06)18_WHT(W11)14_BLU(W08)16_PINK(W51)18_YEL(W10)BRKRIGHTLEFTTAILGND18_YEL_BLK_STP(W39)THERMOSTATLIGHTTHERMOSTATFANGLOW PLUGGEDFUEL SENDER18_GRAY(W40)FUEL PUMPFUEL SOLENOIDHOLD COILFUEL SOLENOIDPULL COIL16_BLK_WHT_STP(W19)16_BLK_WHT_STP(W90)FUEL SOLENOID COMMONOIL PRESSURE SWITCH18_GRAY(W41)14_BLK(W54)10_RED(W47)50A BREAKER14_BLU(W43)ALTERNATORB+IGL18_ORG(W83)18_PUR(W50)18_YEL(W81)18_PUR(W48)18_GRAY(W52)18_PUR_WHT(W80)16_BLK(W63)12_BLU(W28)16_GRN(W42)18_GRN(W57)10_RED(W45)16_GRN(W58)STARTER12_RED(W02)Diode 5Diode 6START RELAYNCNODIFF RELAYNCNO10_RED(W73)18_BLK(W82)18_BLK(W70)6_BLK(W93)6_RED(W91)6_BLK(W92)+ __ENGINEGROUND14_RED16_GRN_WHT_STP(W76)14_YEL(W74)FAN RELAYNCNO14_YEL(W75)20A 30A 5A 30A12_BLK(W72)14_REDCIRCUIT BREAKER14_RED(W86)ACC RELAYNCNO14_RED(W85)18_BLK(W78)FRAMEGROUND14_RED14_YEL14_RED18_BLK(W64)18_BLK(W65)18_BLK(W62)18_BLK_WHT_STP(W79)NEUTRAL SWITCH14_BLK14_REDBED LIFT SWITCH14_RED14_YELBED LIFTMOTOR000002-0022005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-11


ITEM PART NO. DESCRIPTIONQTY1 2 3 4WIRING – DIESEL VEHICLES1 102444201 Wire Harness, Awd, Diesel ....................................................................................................................... 17GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-13


ITEM PART NO. DESCRIPTION1 2 3 4HEADLIGHTS1 101988001 Headlight Assembly, Driver-Side Single Beam (includes items 2 through 10) .................... 12 1013461 Screw, #10-16 Hex-Head Hi-Lo ........................................................................................................ 23 1016880 Headlight Bezel, Left ........................................................................................................................... 14 1017 Nut, #10-24 Stainless-Steel Hex Machine .................................................................................... 25 1017062 Turn Signal Lens Assy .......................................................................................................................... 16 1017064 Mounting Bracket ................................................................................................................................. 27 1017065 Retainer, Headlight .............................................................................................................................. 18 101987901 Connector Harness Assembly, Headlight .................................................................................... 19 101988101 Bulb, Headlight ...................................................................................................................................... 110 101988201 Lens, Headlight ..................................................................................................................................... 111 101988002 Headlight Assy, Passenger-Side Single Beam (includes items 12 through 20) .................... 112 1013461 Screw, #10-16 Hex-Head Hi-Lo ........................................................................................................ 213 1016879 Headlight Bezel, Right ........................................................................................................................ 114 1017 Nut, #10-24 Stainless-Steel Hex Machine .................................................................................... 215 1017062 Turn Signal Lens Assy .......................................................................................................................... 116 1017064 Mounting Bracket ................................................................................................................................. 217 1017065 Retainer, Headlight .............................................................................................................................. 118 101987901 Connector Harness Assembly, Headlight .................................................................................... 119 101988101 Bulb, Headlight ...................................................................................................................................... 120 101988201 Lens, Headlight ..................................................................................................................................... 1QTY7GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-15


ELECTRICAL COMPONENT BOX, GASOLINE VEHICLESITEM PART NO. DESCRIPTION1 2 3 41 1012295 Fuse, 10-Amp ............................................................................................................................................... 22 N/A Screw, 1/4-20 X .88 Hex Hd Cap ............................................................................................................ 13 1015741 Fuse Block ..................................................................................................................................................... 14 102420201 Relay, Mini ISO, SPDT ................................................................................................................................ 25 **** Connector, Relay ........................................................................................................................................ 36 102420401 Plate, Electrical ............................................................................................................................................ 17 102420501 Cover, Electrical .......................................................................................................................................... 18 102447901 Fastener, Push-in ........................................................................................................................................ 79 102448001 Rivet, Drive ................................................................................................................................................... 210 102492201 Fuse, 25-Amp ............................................................................................................................................... 211 1108 Locknut, 1/4-20 Dimpled ........................................................................................................................ 212 332 Washer, 1/4 Type A Narrow Flat ............................................................................................................ 1QTY7GED**** Special order item available upon request.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-17


ITEM PART NO. DESCRIPTIONELECTRICAL COMPONENT BOX, DIESEL VEHICLES1 2 3 41 1012295 Fuse, 10-Amp ............................................................................................................................................... 12 N/A Screw, 1/4-20 X .88 Hex Hd Cap ............................................................................................................ 13 1015741 Fuse Block ..................................................................................................................................................... 14 102420201 Relay, Mini ISO, SPDT ................................................................................................................................ 35 **** Connector, Relay ........................................................................................................................................ 46 102420401 Plate, Electrical ............................................................................................................................................ 17 102420501 Cover, Electrical .......................................................................................................................................... 18 102447901 Fastener, Push-in ........................................................................................................................................ 89 102448001 Rivet, Drive ................................................................................................................................................... 210 102492201 Fuse, 25-Amp ............................................................................................................................................... 111 102492301 Fuse, 30-Amp ............................................................................................................................................... 212 1108 Locknut, 1/4-20 Dimpled ........................................................................................................................ 213 332 Washer, 1/4 Type A Narrow Flat ............................................................................................................ 1QTY7GED**** Special order item available upon request.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-19


ELECTRICAL COMPONENTS, INSTRUMENT PANEL, GASOLINEVEHICLESITEM PART NO. DESCRIPTION1 2 3 41 1013857 Knob, Light Switch .................................................................................................................................... 12 1014557 Washer, 7/16 Flat ........................................................................................................................................ 13 1015636 Toggle Switch (includes item 4) ............................................................................................................ 14 N/A Nut, Toggle Switch ............................................................................................................................... 15 1016630 Light, Oil ........................................................................................................................................................ 16 102044702 Key Switch 12v Key Start ......................................................................................................................... 17 102044801 Key Set ........................................................................................................................................................... 18 N/A Connector, 5 Way, Female ....................................................................................................................... 19 102051601 Spacer, Keyswitch ...................................................................................................................................... 110 102051701 Nut, Key Switch ........................................................................................................................................... 111 102051901 Switch, Light ................................................................................................................................................ 112 102198001 Receptacle, Accessory .............................................................................................................................. 113 102739901 Panel, Instrument - Gas ............................................................................................................................ 114 102967901 Rivet, Removable, Tuflok 1/4" ................................................................................................................ 715 103348101 Gauge Fuel-hour Sep Gnd ...................................................................................................................... 116 103348201 Clip, Meter, Round ..................................................................................................................................... 1QTY7GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-21


ELECTRICAL COMPONENTS, INSTRUMENT PANEL, DIESELVEHICLESITEM PART NO. DESCRIPTION1 2 3 41 1013857 Knob, Light Switch .................................................................................................................................... 12 1014557 Washer, 7/16 Flat ........................................................................................................................................ 13 1015636 Toggle Switch (includes item 4) ............................................................................................................ 14 N/A Nut, Toggle Switch ............................................................................................................................... 15 1016630 Light, Oil ........................................................................................................................................................ 16 102051901 Switch, Light ................................................................................................................................................ 17 102198001 Receptacle, Accessory .............................................................................................................................. 18 102375401 Light, Indicator, Coolant Temp .............................................................................................................. 19 N/A Connector, 6 Way, 56 Series ................................................................................................................... 110 102457301 Switch, Key (includes items 11 through 13) ..................................................................................... 111 102731701 Key Set (1 pair) ....................................................................................................................................... 112 N/A Nut, Key Switch ..................................................................................................................................... 113 N/A Switch, Key without Nut .................................................................................................................... 114 102739902 Panel, Instrument - Diesel ....................................................................................................................... 115 102967901 Rivet, Removable, Tuflok 1/4" ................................................................................................................ 716 103348101 Gauge Fuel-hour Sep Gnd ...................................................................................................................... 117 103348201 Clip, Meter, Round ..................................................................................................................................... 1QTY7GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-23


ITEM PART NO. DESCRIPTION1 2 3 4BATTERY – GASOLINE VEHICLES1 1010934 Screw, 5/16-18 X 1.00 Hex Cap .............................................................................................................. 12 1012328 Battery, 12-Volt ........................................................................................................................................... 13 1014375 Screw, 3/8-16 X 0.50 Stainless Steel Hex-Head ............................................................................... 24 101898001 Clamp, Battery ............................................................................................................................................. 15 102355301 Lockwasher, 3/8 Stainless Stl ................................................................................................................. 26 102442201 Asm, #6 Red Wire ....................................................................................................................................... 17 102442301 Asm, #6 Blk Wire ......................................................................................................................................... 18 102442401 Asm, #6 Blk Wire ......................................................................................................................................... 19 102490301 Bolt, M6 X 1 X 16 Loctite .......................................................................................................................... 110 1241 Washer, 5/16 Type A Flat ......................................................................................................................... 111 7473 Locknut, 5/16-18 Nylon Insert ............................................................................................................... 1QTY7GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-25


ITEM PART NO. DESCRIPTION1 2 3 4BATTERY – DIESEL VEHICLES1 1010934 Screw, 5/16-18 X 1.00 Hex Cap .............................................................................................................. 12 1012328 Battery, 12-Volt ........................................................................................................................................... 13 1014375 Screw, 3/8-16 X 0.50 Stainless Steel Hex-Head ............................................................................... 24 101898001 Clamp, Battery ............................................................................................................................................. 15 102355301 Lockwasher, 3/8 Stainless Stl ................................................................................................................. 26 102442201 Asm, #6 Red Wire ....................................................................................................................................... 17 102448401 Wire Asm, #6 Blk, Awd, 350 .................................................................................................................... 18 102448501 Wire Asm, #6 Blk, Awd, 325 .................................................................................................................... 19 102498201 Bolt, M10 X 1.25 X 25 Loctite ................................................................................................................. 110 1241 Washer, 5/16 Type A Flat ......................................................................................................................... 111 7473 Locknut, 5/16-18 Nylon Insert ............................................................................................................... 1QTY7GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 7-27

7GED

DIESEL ENGINE – CLOSED BREATHER8GED


ITEM PART NO. DESCRIPTION1 2 3 4KUBOTA D722 DIESEL ENGINE MOUNTING1 1012769 Screw, M6-1.00 X 25mm Hex Cap ........................................................................................................ 32 101833101 Stud, M8-1.25 X 50 mm Two-Ended .................................................................................................... 13 101833201 Stud, M8-1.25 X 60mm Two-Ended ..................................................................................................... 14 102298401 Nut,m8,all Metal Lock ............................................................................................................................... 75 102370101 Spacer, Engine, Diesel .............................................................................................................................. 16 102370501 Isolator Ring and Bushing ....................................................................................................................... 47 102370601 Washer, Snubbing, Ring N Bush ........................................................................................................... 48 102382401 Bracket, FNR Trans Cable ......................................................................................................................... 19 102410603 P-Clamp, Insulated .312 In ...................................................................................................................... 110 N/A Plate, Engine Mounting, Weld, Left-Hand ......................................................................................... 111 102414801 Plate, Engine Mounting, Weld, Right-Hand ...................................................................................... 112 102462301 Hose, Vent, Transmission ......................................................................................................................... 113 102462501 Cover, CVT Inner, Diesel ........................................................................................................................... 114 102465901 Shaft, CVT Adapter .................................................................................................................................... 115 102490101 Bolt, M10 X 1.5 X 20 Loctite .................................................................................................................... 416 102490201 Bolt, M8 X 1.25 X 25 Loctite .................................................................................................................... 717 102490501 Bolt, M10 X 1.5 X 100 Loctite ................................................................................................................. 118 102494401 Bracket, Transmission Mounting .......................................................................................................... 219 102498201 Bolt, M10 X 1.25 X 25 Loctite ................................................................................................................. 820 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 121 102621301 Bolt, M8 X 1.25 X 40 with Loctite .......................................................................................................... 322 102621501 Nut Flg, M6 X 1.0 Nylon ........................................................................................................................... 323 102670701 Nut Flg M10 X 1.5 Nylon .......................................................................................................................... 124 102934601 Engine, Kubota, D722, with Closed Breather, 60a .......................................................................... 125 96701412 Washer, M12 Hard ...................................................................................................................................... 426 N/A Locknut, M12x1.75 Nylon Insert ........................................................................................................... 427 96704721 Bolt, M12 X 1.75 X 90 ................................................................................................................................ 428 96718978 Bolt, M8 X 1.25 X 80 ................................................................................................................................... 129 96741038 Washer, M8 Hard ........................................................................................................................................ 1030 96741046 Washer, M10 Hard ...................................................................................................................................... 12QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-3

8GE415D13161211111423519216181711109122067282 15 -1000039-001Page 8-42005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4CRANKCASE1 102600001 Engine Block (includes items 2 through 15) .................................................................................... 12 N/A Pin, Pipe, Dia 8 X 14 .............................................................................................................................. 23 N/A Pin, Straight, Dia 5 X 10 ...................................................................................................................... 24 N/A Pin, Pipe, Dia 7 X 14 .............................................................................................................................. 15 N/A Pin, Straight, Dia 8 X 16 ...................................................................................................................... 26 102600701 Plug, 1/8" ................................................................................................................................................. 37 102600801 Plug, 3/32" ............................................................................................................................................... 58 102601001 Plug, 1/4" ................................................................................................................................................. 19 N/A Pin, Pipe, Dia 8 X 11 .............................................................................................................................. 210 102726201 Cap, Sealing, Small ............................................................................................................................... 311 102726301 Cap, Sealing, Med ................................................................................................................................. 512 102726401 Cap, Sealing, Large ............................................................................................................................... 213 N/A Cover, Fuel Camshaft ........................................................................................................................... 114 N/A Plug, Expansion ..................................................................................................................................... 115 N/A Block, Engine .......................................................................................................................................... 116 102600301 O Ring, 8 X 7 ................................................................................................................................................. 117 102601401 Cock, Drain ................................................................................................................................................... 118 102631601 Bolt, M6 X 1 X 20 ......................................................................................................................................... 219 N/A Plate, Engine Block .................................................................................................................................... 120 102730801 Switch, Oil Pressure ................................................................................................................................... 121 N/A Gasket, Fuel Pump, D722 ........................................................................................................................ 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-5


ITEM PART NO. DESCRIPTION1 2 3 4OIL PAN1 N/A Bolt, M6 X 1 X 14 ......................................................................................................................................... 222 102606901 Bolt, M8 X 1.25 X 15 ................................................................................................................................... 13 102607001 Oil Pan ............................................................................................................................................................ 14 102607201 Plug, Drain, M12 X 14 ............................................................................................................................... 15 102607301 Gasket, 20 X 13 ............................................................................................................................................ 16 102607401 Filter, Oil, Pick Up ........................................................................................................................................ 17 102654601 O Ring, 20 X 17 ............................................................................................................................................ 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-7

8GED11102127631345199 13 -8000041-002Page 8-82005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4CYLINDER HEAD1 102600301 O Ring, 8 X 7 ................................................................................................................................................. 12 102652801 Bolt, Cylinder Head .................................................................................................................................... 143 N/A Hook, Engine ............................................................................................................................................... 24 102654101 Gasket, Cylinder Head .............................................................................................................................. 15 N/A Spring, Start ................................................................................................................................................. 16 N/A Bolt, Engine Hook ...................................................................................................................................... 27 N/A Stay, Cylinder Head ................................................................................................................................... 18 102798001 Head, Cylinder, Complete (includes items 9 through 13) ............................................................ 19 102600801 Plug, 3/32" ............................................................................................................................................... 110 N/A Guide, Exhaust Valve ........................................................................................................................... 311 N/A Guide, Inlet Valve .................................................................................................................................. 312 N/A Cap, Sealing, Head ............................................................................................................................... 113 N/A Cap, Sealing, Head, Top ...................................................................................................................... 2QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-9


ITEM PART NO. DESCRIPTION1 2 3 4GEAR CASE1 N/A O Ring, 18 X 13 ............................................................................................................................................ 32 N/A Spring, Valve ................................................................................................................................................ 13 N/A Ball, Valve ...................................................................................................................................................... 14 N/A Seat, Valve ..................................................................................................................................................... 15 N/A Joint, Pipe ..................................................................................................................................................... 16 N/A Washer, Plain, Special ............................................................................................................................... 17 N/A Bolt, M6 X 1 X 60 ......................................................................................................................................... 28 102602701 Seal, Oil .......................................................................................................................................................... 19 N/A Bolt, D722, Front Case .............................................................................................................................. 910 N/A Bolt, D722 Intake Manfld Lower ........................................................................................................... 111 102703301 Filter, Engine Oil, D722 ............................................................................................................................. 112 N/A Bolt, Gearcase, Top .................................................................................................................................... 213 N/A Bolt, Gearcase, Lower ............................................................................................................................... 114 102729301 Gasket, Gearcase, D722 ........................................................................................................................... 115 102798101 Case, Gear (includes items 16 through 19) ....................................................................................... 116 102601001 Plug, 1/4" ................................................................................................................................................. 217 N/A Screw, Breather ..................................................................................................................................... 218 N/A Case, Gear ................................................................................................................................................ 119 N/A Stay, Spring ............................................................................................................................................. 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-11


ITEM PART NO. DESCRIPTION1 2 3 4HEAD COVER1 102644001 O Ring, 30 X 36 ............................................................................................................................................ 12 102644101 Plug, Oil Filler ............................................................................................................................................... 13 102798401 Assembly, Cylinder Head Cover (includes items 4 through 10) ................................................ 14 N/A Pipe, Water Return, D722 ................................................................................................................... 15 102798501 Gasket, Cylinder Head Cover ............................................................................................................ 16 N/A Shield, Breather ..................................................................................................................................... 17 N/A Valve, Breather ....................................................................................................................................... 18 N/A Cover, Breather ...................................................................................................................................... 19 N/A Screw, Breather ..................................................................................................................................... 410 N/A Cover, Cylinder Head ........................................................................................................................... 111 102798701 Bolt, Cylinder Head Cover ....................................................................................................................... 412 N/A Tube, Breather ............................................................................................................................................. 113 N/A Clamp, Breather Tube ............................................................................................................................... 2QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-13


ITEM PART NO. DESCRIPTION1 2 3 4DIPSTICK AND GUIDE1 102606701 Gauge, Oil ..................................................................................................................................................... 12 102727701 Guide, Oil Gauge ........................................................................................................................................ 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-15


ITEM PART NO. DESCRIPTION1 2 3 4OIL PUMP1 N/A Nut, Flange, D722 Oil Pump ................................................................................................................... 12 N/A Gear, Oil Pump Drive ................................................................................................................................. 13 N/A Key, Feather, 8x4 ......................................................................................................................................... 14 102606501 Assy, Pump, Oil ........................................................................................................................................... 15 N/A Gasket, Oil Pump ........................................................................................................................................ 16 102727901 Bolt, Oil Pump ............................................................................................................................................. 3QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-17


ITEM PART NO. DESCRIPTION1 2 3 4MAIN BEARING CASE1 N/A Gasket, Bearing Case ................................................................................................................................ 12 N/A Gasket, Cover ............................................................................................................................................... 13 N/A Bolt, M6 X 1 X 20 ......................................................................................................................................... 84 N/A Bolt, M6 X 1 X 22 ......................................................................................................................................... 85 N/A Bolt, Bearing Case, Top ............................................................................................................................. 66 102609101 Assy Case, Main Brg, First ........................................................................................................................ 17 102609301 Assy Case, Main Brg, Sec .......................................................................................................................... 18 N/A Bolt, Bearing Case, Bottom ..................................................................................................................... 29 102609601 Assy Case, Main Brg, Third ...................................................................................................................... 110 N/A Assy, Cover, Bearing Case (includes items 11 and 12) .................................................................. 111 N/A Cover, Bearing Case ............................................................................................................................. 112 102608501 Seal, Oil ..................................................................................................................................................... 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-19


ITEM PART NO. DESCRIPTION1 2 3 4CAMSHAFT AND IDLE GEAR1 N/A Bolt, D722, Cam End ................................................................................................................................. 22 N/A Gear, Idle (includes items 3 and 4) ....................................................................................................... 13 N/A Bushing, D722 Idle Gear ..................................................................................................................... 14 N/A Gear, Idle .................................................................................................................................................. 15 N/A Shaft, Idle Gear ............................................................................................................................................ 16 N/A Bolt, M6 X 1 X 14 ......................................................................................................................................... 37 N/A Ring, Snap ..................................................................................................................................................... 18 102605401 Push Rod ....................................................................................................................................................... 69 102605501 Tappet ............................................................................................................................................................ 610 102605801 Assy Camshaft, Long (includes items 11 through 15) .................................................................. 111 102605601 Key, Feather, Long Camshaft ............................................................................................................ 112 N/A Gear, Cam ................................................................................................................................................ 113 N/A Stopper, Camshaft ................................................................................................................................ 114 N/A Camshaft ................................................................................................................................................. 115 N/A Ball, Check ............................................................................................................................................... 116 N/A Collar, Idle Gear ........................................................................................................................................... 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-21

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ITEM PART NO. DESCRIPTION1 2 3 4PISTON AND CRANKSHAFT1 N/A Key, Feather, Short Camshaft ................................................................................................................. 12 102607601 Assy Piston Ring, D722 Std ..................................................................................................................... 33 102607602 Assy Piston Ring, D722 +.025 ................................................................................................................ 34 102607801 Assy, Connecting Rod (includes items 5 through 10) ................................................................... 35 102607901 Bolt, Connecting Rod .......................................................................................................................... 66 102630701 Metal, Crank, Rod, D722, Std ............................................................................................................ 37 N/A Metal, Crank, Rod, D722, .020 .......................................................................................................... 38 N/A Metal, Crank, Rod, D722, .040 .......................................................................................................... 39 102732201 Bushing, Piston Pin, D722 .................................................................................................................. 310 N/A Rod, Connecting ................................................................................................................................... 111 102608101 Sleeve, Crankshaft ..................................................................................................................................... 112 102608801 Metal,crank, O Side, Std ........................................................................................................................... 213 N/A Metal,crank, O Side, +.020 ...................................................................................................................... 214 N/A Metal,crank, O Side, +.040 ...................................................................................................................... 215 102608804 Metal,crank, I Side, Std ............................................................................................................................. 216 N/A Metal,crank, I Side, +.020 ........................................................................................................................ 217 N/A Metal,crank, I Side, +.040 ........................................................................................................................ 218 102609001 Metal, Crank, Main, Rear Std .................................................................................................................. 119 N/A Metal, Crank, Main, Rear -.020 ............................................................................................................... 120 N/A Metal, Crank, Main, Rear -.040 ............................................................................................................... 121 102609801 Metal, Crank, Main, Mid Std ................................................................................................................... 422 N/A Metal, Crank, Main, Mid +.020 ............................................................................................................... 223 N/A Metal, Crank, Main, Mid +.040 ............................................................................................................... 224 102610001 Crankshaft (includes items 25 and 26) ............................................................................................... 125 N/A Ball, Crankshaft ...................................................................................................................................... 326 N/A Crankshaft ............................................................................................................................................... 127 102630001 Metal, Crank, D722, Frnt, Std ................................................................................................................. 128 N/A Metal, Crank, 722, Frnt, -.020 ................................................................................................................. 129 N/A Metal, Crank, 722, Frnt, -.040 ................................................................................................................. 130 N/A Gear, Crank ................................................................................................................................................... 131 N/A Slinger, Oil ..................................................................................................................................................... 132 N/A O Ring, 23 X 26 ............................................................................................................................................ 133 N/A Collar, Crankshaft ....................................................................................................................................... 134 102630901 Circlip, Piston Pin ........................................................................................................................................ 635 102631001 Pin, Piston ..................................................................................................................................................... 336 102728101 Piston, D722, Std ........................................................................................................................................ 337 102728102 Piston, D722, +0.25 .................................................................................................................................... 3QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-23


ITEM PART NO. DESCRIPTION1 2 3 4FLYWHEEL1 N/A Plate, Rear End ............................................................................................................................................ 12 102647801 Flywheel (includes items 3 and 4) ........................................................................................................ 13 N/A Gear, Ring, D722 .................................................................................................................................... 14 N/A Flywheel ................................................................................................................................................... 15 N/A Bolt, Flange Head, M10 X 1.5 X 25 ....................................................................................................... 56 102728301 Bolt, End Plate ............................................................................................................................................. 10QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-25


ITEM PART NO. DESCRIPTION1 2 3 4SHAFT1 N/A Bolt, D722, Cam End ................................................................................................................................. 22 N/A Circlip, External ........................................................................................................................................... 13 102604801 Stopper, Fuel, C/shaft ............................................................................................................................... 14 N/A Assy, Fuel Camshaft (includes items 5 through 13) ....................................................................... 15 N/A Gear, Injection Pump ........................................................................................................................... 16 N/A Ball, Injection Pump ............................................................................................................................. 87 N/A Sleeve, Governor ................................................................................................................................... 18 N/A Ball, Governor ........................................................................................................................................ 329 N/A Case, Governor Ball .............................................................................................................................. 110 N/A Circlip ........................................................................................................................................................ 111 N/A Bearing, Ball ............................................................................................................................................ 112 N/A Key, Feather, Short Camshaft ........................................................................................................... 113 N/A Camshaft, Fuel, Short .......................................................................................................................... 114 N/A Bearing, Ball ................................................................................................................................................. 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-27


ITEM PART NO. DESCRIPTION1 2 3 4IDLE APPARATUS1 102635301 Gasket, 6 X 10 .............................................................................................................................................. 12 102635701 Cap, Bolt Assy .............................................................................................................................................. 13 102637001 Nut, Lock, Special ....................................................................................................................................... 14 102637101 Nut, Special .................................................................................................................................................. 15 102728601 Assy, Idle Apparatus (includes items 6 through 11) ...................................................................... 16 N/A Nut, M8, D722 Idle App, Specl ......................................................................................................... 17 N/A Nut, M8, D722 Idle App ...................................................................................................................... 18 102635901 Assy, Bolt, Adjusting (includes items 9 and 10) ......................................................................... 19 N/A Spring, Idle Apparatus .................................................................................................................. 110 N/A Stud, Idle Adjustment ................................................................................................................... 111 N/A Gasket, Idle Apparatus, Rear ............................................................................................................. 212 102728901 Gasket, Idle Apparatus, Front ................................................................................................................ 113 102799501 Bolt, Idle Adjusting .................................................................................................................................... 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-29


ITEM PART NO. DESCRIPTION1 2 3 4STOP SOLENOID1 102640601 Washer, Spring, M6, D722 ....................................................................................................................... 22 N/A Bolt, Solenoid, Stop, D722 ...................................................................................................................... 23 102799601 Solenoid, Stop ............................................................................................................................................. 14 102799701 Stay, Stop Solenoid ................................................................................................................................... 15 102799801 O-Ring, Stop Solenoid .............................................................................................................................. 16 N/A Bolt, Stop Solenoid .................................................................................................................................... 2QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-31


ITEM PART NO. DESCRIPTION1 2 3 440-AMP ALTERNATOR1 102601101 V-Belt .............................................................................................................................................................. 12 102630601 Pulley, Fan Drive ......................................................................................................................................... 13 102631601 Bolt, M6 X 1 X 20 ......................................................................................................................................... 24 102647701 Nut, M8, Plate .............................................................................................................................................. 15 N/A Pulley, Water Pump ................................................................................................................................... 16 102730001 Alternator, 40-Amp .................................................................................................................................... 17 102730101 Stay, Alternator Assy, D722 ..................................................................................................................... 18 102730201 Collar, Alternator Assy, D722 .................................................................................................................. 19 102730301 Cover, Alternator Assy, D722 .................................................................................................................. 110 N/A Bolt, Alt, D722, Adjuster ........................................................................................................................... 111 N/A Bolt, Alt, D722, Drive Pulley .................................................................................................................... 112 N/A Bolt, D722, Drive Pulley ........................................................................................................................... 413 102732501 Washer, Spring, D722, Starter ................................................................................................................ 114 102800701 Bolt, Alternator, Lower ............................................................................................................................. 115 102801001 Washer, Alternator, Upper ...................................................................................................................... 2QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-33


ITEM PART NO. DESCRIPTION1 2 3 460-AMP ALTERNATOR1 102630601 Pulley, Fan Drive ......................................................................................................................................... 12 102631601 Bolt, M6 X 1 X 20 ......................................................................................................................................... 23 102647701 Nut, M8, Plate .............................................................................................................................................. 14 N/A Pulley, Water Pump ................................................................................................................................... 15 102730201 Collar, Alternator Assy, D722 .................................................................................................................. 16 N/A Bolt, Alt, D722, Adjuster ........................................................................................................................... 17 N/A Bolt, Alt, D722, Drive Pulley .................................................................................................................... 18 N/A Bolt, D722, Drive Pulley ........................................................................................................................... 49 102732501 Washer, Spring, D722, Starter ................................................................................................................ 110 102800701 Bolt, Alternator, Lower ............................................................................................................................. 111 102801001 Washer, Alternator, Upper ...................................................................................................................... 212 102934701 Alternator, 60 Amp .................................................................................................................................... 113 102934801 Brkt, Alt, D722, 60 Amp ............................................................................................................................ 114 102934901 Belt, Acc Drive, D722, 60 Amp ............................................................................................................... 115 103239901 Guard, Acc Belt ............................................................................................................................................ 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-35


ITEM PART NO. DESCRIPTION1 2 3 4INJECTION PUMP1 N/A Bolt, Hex-Head, M5 X 0.75 X ................................................................................................................... 22 102640601 Washer, Spring, M6, D722 ....................................................................................................................... 43 N/A Nut, Special .................................................................................................................................................. 24 102640901 Shim, Injection Pump, 0.20 mm ............................................................................................................ A/R5 102641001 Shim, Injection Pump, 0.25 mm ............................................................................................................ A/R6 N/A Shim, Injection Pump, 0.30 mm ............................................................................................................ A/R7 N/A Stud, M5 X 25 ............................................................................................................................................... 28 102800101 Assembly, Fuel Injection Pump (includes items 9 through 11) ................................................. 19 N/A Screw, Hollow, D722, Inj Pump ........................................................................................................ 110 N/A Joint, Eye .................................................................................................................................................. 111 N/A Pump, Injection ..................................................................................................................................... 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-37


ITEM PART NO. DESCRIPTION1 2 3 4SPEED CONTROL PLATE1 102634501 Gasket, Control Plate ................................................................................................................................ 12 N/A Bolt, M6 X 1 X 30 ......................................................................................................................................... 23 102635301 Gasket, 6 X 10 .............................................................................................................................................. 24 N/A Bolt, D722 Intake Manfld Lower ........................................................................................................... 25 102800401 Assembly, Speed Plate (includes items 6 through 19) ................................................................. 16 N/A Lever, Engine Stop ................................................................................................................................ 17 N/A Nut, Speed Control .............................................................................................................................. 18 N/A Lever, Speed Control ........................................................................................................................... 19 102634001 O Ring, 19 X 16 ...................................................................................................................................... 110 102634101 Plate, Speed Control ............................................................................................................................ 111 N/A O Ring, 9 X 7 ........................................................................................................................................... 112 N/A Collar, Lever ............................................................................................................................................ 113 N/A Spring, Return ........................................................................................................................................ 114 N/A Cap, Speed Cntrl Plate Rtrn ............................................................................................................... 115 N/A Pin, Spring, Speed Plate ..................................................................................................................... 116 N/A Nut, Speed Control .............................................................................................................................. 217 N/A Bolt, Speed Control .............................................................................................................................. 218 N/A Lever, Governor ..................................................................................................................................... 119 N/A Shaft, Governor Lever ......................................................................................................................... 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-39


ITEM PART NO. DESCRIPTION1 2 3 4NOZZLE HOLDERS AND GLOW PLUGS1 102605701 Assy Pipe, D722 Fuel Over Flow ............................................................................................................ 12 102635301 Gasket, 6 X 10 .............................................................................................................................................. 13 102642401 Cord, Glow Plug .......................................................................................................................................... 14 102642501 Nut, Flange,m4 ............................................................................................................................................ 35 102642601 Glow Plug ..................................................................................................................................................... 36 N/A Screw, Washer ............................................................................................................................................. 27 N/A Clamp, Pipe, Top ......................................................................................................................................... 28 102643001 Pipe, Injection, Left .................................................................................................................................... 19 102643101 Pipe, Injection, Right ................................................................................................................................. 110 102643201 Pipe, Injection, Middle ............................................................................................................................. 111 N/A Clamp, Pipe, Bottom ................................................................................................................................. 212 102643401 Assy Pipe, Over Flow (includes items 13 and 14) ........................................................................... 113 N/A Clip, Pipe, Return .................................................................................................................................. 214 N/A Hose, Overflow ...................................................................................................................................... 115 102643701 Screw, Air Bleeder ...................................................................................................................................... 116 102729701 Kit, Holder, Nozzle (includes items 17 through 19) ....................................................................... 317 102641501 Assembly, Nozzle Holder ................................................................................................................... 318 102642701 Seal, Heat ................................................................................................................................................. 319 102643601 Gasket, Nozzle ....................................................................................................................................... 3QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-41


ITEM PART NO. DESCRIPTION1 2 3 4GOVERNOR COMPONENTS1 102635101 Spring, Governor ........................................................................................................................................ 12 N/A Bolt, M5 X 0.75 X 25 .................................................................................................................................. 23 102800201 Spring, Start ................................................................................................................................................. 14 N/A Assembly, Governor Fork (includes items 5 through 9) ............................................................... 15 N/A Holder, Fork Lever ................................................................................................................................ 16 N/A Bolt, M5 X 0.75 X 11 ............................................................................................................................ 17 N/A Washer, Spring, M5 .............................................................................................................................. 18 N/A Lever, Fork, Middle, D722 CB ............................................................................................................ 19 N/A Assembly, Governor Fork Level, Lower, D722 CB (includes items 10 through 12) ........ 110 N/A Pin, Spring ......................................................................................................................................... 111 N/A Shaft, Fork Lever ............................................................................................................................. 112 N/A Lever, Fork, End, D722 CB ............................................................................................................ 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-43


ITEM PART NO. DESCRIPTION1 2 3 4STARTER1 102645501 Nut, D722, Starter ...................................................................................................................................... 22 102647701 Nut, M8, Plate .............................................................................................................................................. 23 102648401 Bolt, M8 X 1.25 X 28 ................................................................................................................................... 24 102648501 Motor, Starter .............................................................................................................................................. 15 102732501 Washer, Spring, D722, Starter ................................................................................................................ 4QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-45


ITEM PART NO. DESCRIPTION1 2 3 4VALVES AND ROCKER ARMS1 N/A Bolt, M6 X 1 X 8 ........................................................................................................................................... 22 N/A Washer, D722, Plain, Rocker ................................................................................................................... 23 N/A Washer, Rocker Arm .................................................................................................................................. 24 N/A Pin, Spring, D722, Rocker ........................................................................................................................ 15 N/A Assy Rocker Arm (includes items 6 through 8) ............................................................................... 66 N/A Nut, M6 ..................................................................................................................................................... 67 N/A Screw-Adjusting .................................................................................................................................... 68 N/A Arm, Rocker ............................................................................................................................................ 19 N/A Shaft, Rocker Arm ...................................................................................................................................... 110 N/A Spring, Rocker Arm ................................................................................................................................... 211 N/A Collet, Valve Spring, Set ........................................................................................................................... 612 N/A Cap, Valve, D722 ......................................................................................................................................... 613 102653101 Spring, Valve ................................................................................................................................................ 614 102653201 Retainer, Spring .......................................................................................................................................... 615 102653301 Seal, Valve Stem .......................................................................................................................................... 616 102653601 Valve, Exhaust .............................................................................................................................................. 317 102653701 Valve, Inlet .................................................................................................................................................... 318 N/A Bracket, Rocker Arm, D722 Closed-Breather .................................................................................... 319 102801201 Bolt, Rocker Arm ......................................................................................................................................... 3QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-47


ITEM PART NO. DESCRIPTION1 2 3 4DIESEL INLET MANIFOLD1 N/A Bolt, M6 X 1 X 45 ......................................................................................................................................... 32 N/A Bolt, D722 Intake Manfld Lower ........................................................................................................... 23 N/A Assembly, Intake Manifold (includes items 4 through 6) ............................................................ 14 102646001 Gasket, Intake Manifold ..................................................................................................................... 15 N/A Pipe, Breather ......................................................................................................................................... 16 N/A Manifold, Intake .................................................................................................................................... 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-49


ITEM PART NO. DESCRIPTION1 2 3 4EXHAUST MANIFOLD1 N/A Cover, Heat Proof ....................................................................................................................................... 12 N/A Stud, M6 X 26 ............................................................................................................................................... 33 102646601 Gasket, Ex-manifold .................................................................................................................................. 14 N/A Nut, Flange, M6, Ubs ................................................................................................................................. 35 N/A Bolt, Flange Head, M6 X 1 X 16 ............................................................................................................. 36 102731501 Manifold, Exhaust, D722 .......................................................................................................................... 17 102731601 Bolt, D722, Exhst Manfld Cover ............................................................................................................. 2QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-51


ITEM PART NO. DESCRIPTION1 2 3 4GASKET KITS1 102731801 Kit, Gasket Upper, D722 (includes items 2 through 13) ............................................................... 12 102422301 Gasket, Exhaust Diesel ........................................................................................................................ 13 102600301 O Ring, 8 X 7 ........................................................................................................................................... 14 102633401 Gasket, Thermostat .............................................................................................................................. 15 102635301 Gasket, 6 X 10 ......................................................................................................................................... 36 102644001 O Ring, 30 X 36 ...................................................................................................................................... 17 102644501 Gasket, Head Cover .............................................................................................................................. 18 102646001 Gasket, Intake Manifold ..................................................................................................................... 19 102646601 Gasket, Ex-manifold ............................................................................................................................. 110 102653301 Seal, Valve Stem .................................................................................................................................... 611 102654101 Gasket, Cylinder Head ......................................................................................................................... 112 102654701 Gasket, Water Flange .......................................................................................................................... 113 102798501 Gasket, Cylinder Head Cover ............................................................................................................ 114 102731901 Kit, Gasket Lower, D722 (includes items 15 through 27) ............................................................. 115 N/A O Ring, 18 X 13 ...................................................................................................................................... 316 N/A Gasket, Oil Pump .................................................................................................................................. 117 N/A Gasket, Bearing Case ........................................................................................................................... 118 N/A Gasket, Cover ......................................................................................................................................... 119 N/A O Ring, 23 X 26 ...................................................................................................................................... 120 102632701 Gasket, Water Pump, D722 ............................................................................................................... 121 102634001 O Ring, 19 X 16 ...................................................................................................................................... 122 N/A O Ring, 9 X 7 ........................................................................................................................................... 123 102634501 Gasket, Control Plate ........................................................................................................................... 124 102654601 O Ring, 20 X 17 ...................................................................................................................................... 125 N/A Gasket, Idle Apparatus, Rear ............................................................................................................. 226 102729301 Gasket, Gearcase, D722 ...................................................................................................................... 127 N/A Gasket, Fuel Pump, D722 ................................................................................................................... 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-53


ITEM PART NO. DESCRIPTION1 2 3 4PISTON KIT1 102732001 Kit, Piston Rebuild, D722 (includes items 2 through 6) ................................................................ 12 102607601 Assy Piston Ring, D722 Std ................................................................................................................ 13 102630901 Circlip, Piston Pin .................................................................................................................................. 24 102631001 Pin, Piston ................................................................................................................................................ 15 102728101 Piston, D722, Std ................................................................................................................................... 16 102732201 Bushing, Piston Pin, D722 .................................................................................................................. 1QTY8GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 8-55

8GED

HONDA GX620 GASOLINE ENGINE9GED


ITEM PART NO. DESCRIPTION1 2 3 4HONDA GX620 GASOLINE ENGINE MOUNTING1 1012769 Screw, M6-1.00 X 25mm Hex Cap ........................................................................................................ 32 102298401 Nut,m8,all Metal Lock ............................................................................................................................... 23 102370501 Isolator Ring and Bushing ....................................................................................................................... 44 102370601 Washer, Snubbing, Ring N Bush ........................................................................................................... 45 102382401 Bracket, FNR Trans Cable ......................................................................................................................... 16 102410603 P-Clamp, Insulated .312 In ...................................................................................................................... 17 N/A Plate, Eng Mtg, Weld, Honda ................................................................................................................. 18 102462301 Hose, Vent, Transmission ......................................................................................................................... 19 102462502 Cover, CVT Inner, Honda .......................................................................................................................... 110 102490101 Bolt, M10 X 1.5 X 20 Loctite .................................................................................................................... 411 102490201 Bolt, M8 X 1.25 X 25 Loctite .................................................................................................................... 612 102490501 Bolt, M10 X 1.5 X 100 Loctite ................................................................................................................. 113 102494401 Bracket, Transmission Mounting .......................................................................................................... 214 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 115 102621501 Nut Flg, M6 X 1.0 Nylon ........................................................................................................................... 316 102670701 Nut Flg M10 X 1.5 Nylon .......................................................................................................................... 517 103252201 Engine, Honda, No Acr ............................................................................................................................. 118 96701412 Washer, M12 Hard ...................................................................................................................................... 419 N/A Locknut, M12x1.75 Nylon Insert ........................................................................................................... 420 96704721 Bolt, M12 X 1.75 X 90 ................................................................................................................................ 421 96704960 Bolt, M10 X 1.5 X 60 ................................................................................................................................... 422 96718978 Bolt, M8 X 1.25 X 80 ................................................................................................................................... 123 96741038 Washer, M8 Hard ........................................................................................................................................ 624 96741046 Washer, M10 Hard ...................................................................................................................................... 9QTY9GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 9-3


ITEM PART NO. DESCRIPTION1 2 3 4SHROUDS AND BRACKETS1 102657501 Bolt, Flange Head, M6 X 11 X 4 ............................................................................................................. 22 102666201 Cap Assy, Noise Suppressor ................................................................................................................... 23 102666801 Cover, Fan, Bright Red .............................................................................................................................. 14 102666901 Nut, Flange, M6 ........................................................................................................................................... 45 102667001 Fan, Cooling ................................................................................................................................................. 16 102667101 Holder, Screen Grid ................................................................................................................................... 17 102667201 Bolt, Flange Head, M8 X 1.25 X 16 ....................................................................................................... 38 102667301 Bolt, Flange Head, M6 X 1 X 12 ............................................................................................................. 39 102667401 Grid Screen, PTO ......................................................................................................................................... 110 N/A Plate, R Side .................................................................................................................................................. 111 102667601 Shroud, R ....................................................................................................................................................... 112 N/A Shroud, Head ............................................................................................................................................... 213 N/A Hanger, Engine ........................................................................................................................................... 214 N/A Bolt, Flange Head, M8 X 1.25 X 20 ....................................................................................................... 215 N/A Shroud, L ....................................................................................................................................................... 116 N/A Bolt, Flange Head, M6 X 1 X 12 ............................................................................................................. 617 N/A Plate, Left Side ............................................................................................................................................. 118 N/A Nut, Square, 5mm ...................................................................................................................................... 2QTY9GEDNote: The part number for a complete engine is 102402701.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 9-5


ITEM PART NO. DESCRIPTION1 2 3 4IGNITION COMPONENTS AND FLYWHEEL1 102655301 Stud, Engine ................................................................................................................................................. 22 102661901 Bolt, Flange Head, M6 X 1 X 32 ............................................................................................................. 93 102664601 Flywheel ........................................................................................................................................................ 14 N/A Washer, M20 ................................................................................................................................................. 15 N/A Nut, Flange, M20 ........................................................................................................................................ 16 102664901 Key, Special Woodruff, 25 X 18 .............................................................................................................. 17 102665001 Coil Assy, Charge, 12-Volt, 20-Amp ...................................................................................................... 18 N/A Pin, Dowel, 10x12 ....................................................................................................................................... 29 102665301 Diode Assembly ......................................................................................................................................... 110 N/A Bolt, Flange Head, M6 X 1 X 8 ................................................................................................................ 111 N/A Grommet, Tool ............................................................................................................................................ 112 102665601 Motor, Starter .............................................................................................................................................. 113 N/A Bolt, Flange Head, M8 X 1.25 X 110 ..................................................................................................... 214 102665901 Coil Assy, R, Ignition .................................................................................................................................. 215 102666001 Coil Assy, L, Ignition .................................................................................................................................. 216 102666201 Cap Assy, Noise Suppressor ................................................................................................................... 217 N/A Clamp, Wire .................................................................................................................................................. 118 102831201 Switch, Oil Pressure ................................................................................................................................... 119 AM1232301 Spark Plug, BPR2ES .................................................................................................................................... 2QTY9GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 9-7

9G1114 13E10D15112232243 8 7 6952162120191817000022-001Page 9-82005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4OIL CIRCULATION1 102658001 Gasket, Case Cover .................................................................................................................................... 12 102658101 Cover Assembly, Crankcase (includes items 3 through 9) .......................................................... 13 N/A Governor Assembly ............................................................................................................................. 14 N/A Washer, Plain, M6 .................................................................................................................................. 15 102724301 Seal, Oil, 38 X 58 X 9 ............................................................................................................................. 16 N/A Slider, Governor .................................................................................................................................... 17 102724501 Washer, 6 X 16 ........................................................................................................................................ 18 N/A Clip, Governor ........................................................................................................................................ 19 N/A Cover, Crankcase ................................................................................................................................... 110 102658201 Dipstick, Oil .................................................................................................................................................. 111 102658301 Cap, Oil Filler ................................................................................................................................................ 112 N/A Pin A, Dowel, 8 X 14 ................................................................................................................................... 213 102658501 Washer, Drain Plug, M14 .......................................................................................................................... 114 102658601 Bolt, Drain Plug , M14 ............................................................................................................................... 115 102658701 Bolt, Flange Head, M8 X 1.25 X 50 ...................................................................................................... 916 102658901 Cover, Oil Filter ............................................................................................................................................ 117 102659001 Cover Assembly, Oil Pump ...................................................................................................................... 118 102659101 Rotor, Oil Pump, Outer ............................................................................................................................. 119 102659201 Spring, Relief Valve .................................................................................................................................... 120 N/A Ball, Steel , 3/8, #12 .................................................................................................................................... 121 N/A Bolt, Socket .................................................................................................................................................. 222 N/A Bolt, Flange Head, M6 X 1 X 20 ............................................................................................................. 323 102724701 Screen, Oil Filter .......................................................................................................................................... 1QTY9GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 9-9


ITEM PART NO. DESCRIPTION1 2 3 4CYLINDER HEAD1 102657601 Gasket, Intake Manifold ........................................................................................................................... 22 N/A Manifold, Inlet ............................................................................................................................................. 13 N/A Bolt, Socket, M8 X 1.25 X 45 ................................................................................................................... 44 102662101 Cover, Head .................................................................................................................................................. 15 N/A Cover, Head Filler ....................................................................................................................................... 16 102662201 Gasket, Cylinder Head Cover ................................................................................................................. 27 N/A Bolt, Head Cover ......................................................................................................................................... 28 N/A Washer, Head Cover .................................................................................................................................. 29 N/A Bolt, Flange Head, M10 X 1.5 X 80 ....................................................................................................... 810 N/A Bolt, Stud, M8x22 ....................................................................................................................................... 411 N/A Cylinder Head, #2 ....................................................................................................................................... 112 N/A Cylinder Head, #1 ....................................................................................................................................... 113 102662901 Plate, Push Rod Guide .............................................................................................................................. 214 N/A Pivot, Rocker Arm ....................................................................................................................................... 415 102663101 Arm, Valve Rocker ...................................................................................................................................... 416 102663201 Bolt, Pivot, M8 ............................................................................................................................................. 417 102663301 Nut, Pivot Adj ............................................................................................................................................... 418 102663401 Valve, Ex ......................................................................................................................................................... 219 102663501 Valve, In ......................................................................................................................................................... 220 102663801 Rod, Push ...................................................................................................................................................... 421 102663901 Retainer, In Valve Spring .......................................................................................................................... 222 102664001 Spring, Valve ................................................................................................................................................ 423 102664101 Seal, Valve Stem .......................................................................................................................................... 224 102664301 Gasket, Cylinder Head .............................................................................................................................. 225 N/A Pin A, Dowel ,12 X 20 ................................................................................................................................ 426 N/A Retainer, Ex Valve Spring ......................................................................................................................... 227 102722801 Seat, Valve Spring ...................................................................................................................................... 228 102722901 Rotator, Valve ............................................................................................................................................... 229 AM1232301 Spark Plug, BPR2ES .................................................................................................................................... 2QTY9GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 9-11

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ITEM PART NO. DESCRIPTION1 2 3 4CRANKCASE AND CRANKSHAFT1 102659801 Crankshaft .................................................................................................................................................... 12 102659901 Camshaft Assembly .................................................................................................................................. 13 102660001 Lifter Assembly, Valve ............................................................................................................................... 14 N/A Bearing, Radial Ball, 6003 ........................................................................................................................ 15 N/A Bolt, Flange Head, M5 X 1 X 16 ............................................................................................................. 16 N/A Bolt, Flange Head, M6 X 1 X 25 ............................................................................................................ 17 102660401 Piston, Std ..................................................................................................................................................... 28 N/A Piston, Over-Sized 0.25 ............................................................................................................................ 29 N/A Piston, Over-Sized 0.50 ............................................................................................................................ 210 102660404 Piston, 0.75 ................................................................................................................................................... 211 102660501 Rod Assy., Connecting (includes items 12 through 14) ............................................................... 212 N/A Bolt, Connecting Rod, 6 X 37 ............................................................................................................ 213 N/A Connecting Rod .................................................................................................................................... 114 N/A Cap, Connecting Rod .......................................................................................................................... 115 102660601 Clip, Piston Pin, 18mm ............................................................................................................................. 416 102660701 Pin, Piston ..................................................................................................................................................... 217 102660801 Ring Set, Piston, Std .................................................................................................................................. 218 N/A Ring Set, Piston, OS 0.25 .......................................................................................................................... 219 102660803 Ring Set, Piston, OS 0.50 .......................................................................................................................... 220 N/A Ring Set, Piston, OS 0.75 .......................................................................................................................... 221 102661001 Washer, Plain, M8 ....................................................................................................................................... 322 N/A Pin, Lock, 8 Mm ........................................................................................................................................... 223 N/A Bearing, Needle, 8 X 12.7 X 11 ............................................................................................................... 124 N/A Oil Seal, 8 X 14 X 5 ...................................................................................................................................... 125 N/A Bearing, Needle, 8 X 12 X 10 .................................................................................................................. 126 102661401 Oil Seal, 38 X 58 X 9 ................................................................................................................................... 127 N/A Shaft, Governor Arm ................................................................................................................................. 128 N/A Cover, Breather ........................................................................................................................................... 129 102661701 Gasket, Breather Cover ............................................................................................................................ 130 102661801 Valve, Breather ............................................................................................................................................ 131 102661901 Bolt, Flange Head, M6 X 1 X 32 ............................................................................................................. 232 102664901 Key, Special Woodruff, 25 X 18 .............................................................................................................. 133 N/A Clamp, Wire .................................................................................................................................................. 134 N/A Pin A, Dowel ................................................................................................................................................. 135 N/A Bolt, Flange Head, 6 X 16 ......................................................................................................................... 1QTY9GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 9-13


ITEM PART NO. DESCRIPTIONOIL FILTER ADAPTER AND VOLTAGE REGULATOR1 2 3 41 102289001 Screw, M8X1.25X30, Hex ......................................................................................................................... 32 102331401 Regulator, Voltage ..................................................................................................................................... 13 102371401 Bracket, Oil Filter Mount .......................................................................................................................... 14 102434801 Adapter, 90, 5/16 Tube ............................................................................................................................. 15 102443501 Hose, 3/8, Remote Oil, Honda ............................................................................................................... 16 102443601 Clamp, Hose ................................................................................................................................................. 47 102457501 Adapter, 90, 3/8 Tube ............................................................................................................................... 18 102457601 Hose, 5/16, Remote Oil, Honda ............................................................................................................. 19 102475301 Nipple, M20, Remote Oil ......................................................................................................................... 110 102490401 O-ring 11.8 X 2.4 ......................................................................................................................................... 211 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 212 102670801 Screw, M6 X 1 X 25 Thd Form ................................................................................................................ 513 102710301 Plate, Fuel/Oil System ............................................................................................................................... 114 102721901 Adapter, 3/8 Hose ...................................................................................................................................... 115 102722001 Adapter, 5/16 Hose .................................................................................................................................... 116 102827901 Filter, Oil, Honda Service ......................................................................................................................... 117 102849401 Adapter, Oil Filter, Honda Eng ............................................................................................................... 118 96705587 Bolt, M8 X 1.25 X 30 ................................................................................................................................... 2QTY9GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 9-15

9GED

FUEL, INTAKE, AND GOVERNORSYSTEM10GED


ITEM PART NO. DESCRIPTION1 2 3 4FUEL SYSTEM – GASOLINE VEHICLES1 1013746 Clamp, 0.301 ID Hose ................................................................................................................................ 22 101587703 Hose, Fuel, Vent, 22" Long ...................................................................................................................... 13 101824401 Vent Barb ...................................................................................................................................................... 14 102298401 Nut,m8,all Metal Lock ............................................................................................................................... 15 102411202 Clamp, Hose, Ctb 13mm .......................................................................................................................... 26 102426301 Strap, Tank, Fuel .......................................................................................................................................... 17 N/A Clip, Tube, B10 ............................................................................................................................................. 18 102657301 Filter, Fuel ...................................................................................................................................................... 19 103307901 Hose, Tank To Filter, Fh680d ................................................................................................................... 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-3


ITEM PART NO. DESCRIPTION1 2 3 4FUEL TANK – GASOLINE VEHICLES1 102952102 Asm, Tank, Fuel, Gas, 4x4 (includes items 2 through 14) ............................................................. 12 1013461 Screw, #10-16 Hex-Head Hi-Lo ........................................................................................................ 53 1013462 Sending Unit, Fuel Level * ................................................................................................................. 14 1015139 Insulation Grommet ............................................................................................................................ 15 1015143 Vent, Fuel Tank ...................................................................................................................................... 16 1016 Washer, #10 Split Lock ........................................................................................................................ 17 N/A Wire Asm, Blk, 170mm ........................................................................................................................ 18 N/A Wire Asm, Org, 170mm ....................................................................................................................... 19 102522001 Gasket, Rubber ...................................................................................................................................... 110 102670901 Valve, Pickup Tube, Fuel ..................................................................................................................... 111 102751601 Cap, Fuel Tank, Gasoline .................................................................................................................... 112 N/A Tank, Fuel, Gas, 4x4 .............................................................................................................................. 113 183 Washer, #10 Type A Flat ...................................................................................................................... 114 8797 Nut, #10-32 Brass Hex ......................................................................................................................... 1QTY10GED* Note: Must replace fuel sending unit gasket when servicing thiscomponent.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-5

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ITEM PART NO. DESCRIPTION1 2 3 4FUEL SYSTEM – DIESEL VEHICLES1 101313402 Clamp, Green Hose .................................................................................................................................... 12 1013746 Clamp, 0.301 ID Hose ................................................................................................................................ 23 101587703 Hose, Fuel, Vent, 22" Long ...................................................................................................................... 14 101824401 Vent Barb ...................................................................................................................................................... 15 102289001 Screw, M8X1.25X30, Hex ......................................................................................................................... 56 102296716 Screw, M6 X 16 Tt Hx Fl Hd ..................................................................................................................... 17 102410602 P-Clamp, Insulated 1.75 In ...................................................................................................................... 18 102410801 Pump, Diesel Fuel Electric ....................................................................................................................... 19 102411202 Clamp, Hose, Ctb 13mm .......................................................................................................................... 210 102411203 Clamp, Hose, Ctb 14mm .......................................................................................................................... 611 102426301 Strap, Tank, Fuel .......................................................................................................................................... 112 102430001 Hose, Tank To Prefilter Diesel ................................................................................................................. 113 102430101 Hose, Fuel Prefilter To Pump .................................................................................................................. 114 102430201 Hose, Fuel Pump To Filter ........................................................................................................................ 115 102430301 Hose, Fuel Filter To Eng ............................................................................................................................ 116 102430401 Hose, Fuel Return ....................................................................................................................................... 117 102434601 Filter Assy, Fuel ............................................................................................................................................ 118 102434701 Filter, Fuel ...................................................................................................................................................... 119 102434801 Adapter, 90, 5/16 Tube ............................................................................................................................. 220 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 321 102710301 Plate, Fuel/Oil System ............................................................................................................................... 122 96705587 Bolt, M8 X 1.25 X 30 ................................................................................................................................... 2QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-7


ITEM PART NO. DESCRIPTION1 2 3 4FUEL TANK – DIESEL VEHICLES1 102952101 Asm, Tank, Fuel, Diesel, 4x4 (includes items 2 through 16) ........................................................ 12 1013461 Screw, #10-16 Hex-Head Hi-Lo ........................................................................................................ 53 1013462 Sending Unit, Fuel Level * ................................................................................................................. 14 1015139 Insulation Grommet ............................................................................................................................ 15 1015143 Vent, Fuel Tank ...................................................................................................................................... 16 1016 Washer, #10 Split Lock ........................................................................................................................ 17 N/A Wire Asm, Blk, 170mm ........................................................................................................................ 18 N/A Wire Asm, Org, 170mm ....................................................................................................................... 19 102406701 Bushing, Line, Return .......................................................................................................................... 210 102406801 Elbow, 90 Barbed .................................................................................................................................. 111 102478501 Pickup Tube, Fuel .................................................................................................................................. 112 102494701 Cap, Fuel (Diesel) .................................................................................................................................. 113 102522001 Gasket, Rubber ...................................................................................................................................... 114 N/A Tank, Fuel, Diesel, 4x4 ......................................................................................................................... 115 183 Washer, #10 Type A Flat ...................................................................................................................... 116 8797 Nut, #10-32 Brass Hex ......................................................................................................................... 1QTY10GED* Note: Must replace fuel sending unit gasket when servicing thiscomponent.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-9


CARBURETOR ASSEMBLY, HONDA GASOLINE VEHICLESITEM PART NO. DESCRIPTION1 2 3 41 103201601 Carburetor, Seal Shaft (includes items 2 through 13) ................................................................... 12 102623802 Jet, GX620, #102 (8000 ft. and higher (2438 m and higher)) ................................................ 13 102623805 Jet, GX620, #105 (5000-8000 ft. (1524-2438 m)) ....................................................................... 14 102623808 Jet, GX620, #108 (0-5000 ft. (0-1524 m)) ...................................................................................... 15 102655401 Nozzle, Main ........................................................................................................................................... 16 102655501 Float Set ................................................................................................................................................... 17 102655601 Gasket Set ............................................................................................................................................... 18 102655701 Screw Set, Drain .................................................................................................................................... 19 102655801 Screw-Washer, M4 X 14 ...................................................................................................................... 410 102655901 Valve Assy., Solenoid ........................................................................................................................... 111 102656001 Screw-Washer, M5 X 12 ...................................................................................................................... 212 102724101 Screw Set, Left ....................................................................................................................................... 113 102724201 Screw Set, Right .................................................................................................................................... 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-11


CARBURETOR INSTALLATION – HONDA GASOLINE VEHICLESITEM PART NO. DESCRIPTION1 2 3 41 N/A Bracket, Choke Cable ................................................................................................................................ 12 102462601 Insert, Adapter, Carburetor ..................................................................................................................... 23 102493001 Gasket, Adapter, Carburetor .................................................................................................................. 14 102617301 Screw Tapping, M5 X 0.8x10 .................................................................................................................. 25 102620801 Adapter, Intake Honda GX620 ............................................................................................................... 16 102656101 Clip, Breather Tube .................................................................................................................................... 17 N/A Grommet, Reserve Tank .......................................................................................................................... 18 102656301 Bolt, Flange Head, M6 X 1 X 120 ........................................................................................................... 29 102656402 Pump Assy., Fuel, Sup ............................................................................................................................... 110 N/A Tube, Breather ............................................................................................................................................. 111 102656601 Stay, Fuel Pump .......................................................................................................................................... 112 102656701 Gasket, Carburetor .................................................................................................................................... 213 102656801 Insulator, Carburetor ................................................................................................................................. 114 N/A Srew-Washer, M6 X 16 .............................................................................................................................. 215 N/A Tube B, Fuel .................................................................................................................................................. 116 102657101 Tube, Diaphragm ....................................................................................................................................... 117 N/A Clip, Tube, B10 ............................................................................................................................................. 318 102657301 Filter, Fuel ...................................................................................................................................................... 119 N/A Clip, Wire Harness ...................................................................................................................................... 120 102657501 Bolt, Flange Head, M6 X 11 X 4 ............................................................................................................. 221 102657601 Gasket, Intake Manifold ........................................................................................................................... 222 N/A Manifold, Inlet ............................................................................................................................................. 123 N/A Bolt, Socket, M8 X 1.25 X 45 ................................................................................................................... 424 102710501 Spring, Continuity, Solenoid .................................................................................................................. 125 102725401 Tube A, Fuel .................................................................................................................................................. 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-13


GOVERNOR AND ACCELERATOR CABLES, GASOLINE VEHICLESITEM PART NO. DESCRIPTION1 2 3 41 102475701 Clip, Brake Line ............................................................................................................................................ 22 102498701 Cable, Accelerator, GX620 ....................................................................................................................... 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-15


ITEM PART NO. DESCRIPTION1 2 3 4CHOKE CABLE, GASOLINE VEHICLES1 102475701 Clip, Brake Line ............................................................................................................................................ 22 102826101 Cable, Choke ................................................................................................................................................ 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-17


ITEM PART NO. DESCRIPTION1 2 3 4ACCELERATOR CABLE, DIESEL VEHICLES1 102475701 Clip, Brake Line ............................................................................................................................................ 22 102498801 Cable, Accelerator, Diesel ........................................................................................................................ 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-19


ITEM PART NO. DESCRIPTION1 2 3 4GOVERNOR COVER – GASOLINE VEHICLES1 102451001 Cover, Engine, Honda ............................................................................................................................... 12 102498101 Bolt, M8 X 1.25 X 20 ................................................................................................................................... 23 102707101 Grommet, Split, 50 Durometer .............................................................................................................. 24 N/A Bolt, M5 X .8 X 20 ........................................................................................................................................ 2QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-21


ITEM PART NO. DESCRIPTION1 2 3 4GOVERNOR SYSTEM – GASOLINE VEHICLES1 1014007 Washer, 1/4 Flat .......................................................................................................................................... 22 101886101 Screw, 1/4-20 X 1.00 Square-Head ...................................................................................................... 23 102296716 Screw, M6 X 16 Tt Hx Fl Hd ..................................................................................................................... 34 102423701 Cable, Engine Governor ........................................................................................................................... 15 102433101 Bracket, Governor, Arm, Trans ............................................................................................................... 16 102433501 Wire, Governor ............................................................................................................................................ 17 N/A Bracket, Governor, Trans Cable ............................................................................................................. 18 102452301 Adjuster, Spring, Idle ................................................................................................................................. 19 102454801 Bracket, Arm, Gov, Engine ....................................................................................................................... 110 102454901 Bracket, Cable, Gov, Engine .................................................................................................................... 111 102457001 Spring ............................................................................................................................................................. 112 102457101 Spring, Carb ................................................................................................................................................. 113 102457201 Spring, Compression, Adj, Idle .............................................................................................................. 114 102490101 Bolt, M10 X 1.5 X 20 Loctite .................................................................................................................... 215 102499601 Guard, Governor, Ground Speed .......................................................................................................... 116 102616801 Bolt, M4 X .7 X 60 ........................................................................................................................................ 117 102616901 Nut Flg, M4 X 0.7 Mech Def .................................................................................................................... 118 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 119 8233 Locknut, 1/4-20 Nylon Insert ................................................................................................................. 220 N/A Washer, M4 ................................................................................................................................................... 121 96718978 Bolt, M8 X 1.25 X 80 ................................................................................................................................... 122 96741038 Washer, M8 Hard ........................................................................................................................................ 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-23

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ITEM PART NO. DESCRIPTION1 2 3 4INTAKE DUCT AND AIR BOX ASSEMBLY –HONDA GASOLINE VEHICLES1 102378901 Hose, Intake, GX620 .................................................................................................................................. 12 102395601 Hose, Intake, Primary ................................................................................................................................ 13 102411210 Clamp, Hose, Ctb 64mm .......................................................................................................................... 44 102541465 Bolt, M 6 X 1.0 X 65 Hex, Flange, Head, Black ................................................................................... 25 102621201 Bolt Flanged Head, M8 X1.25x 16 with Loctite ............................................................................... 26 102621501 Nut Flg, M6 X 1.0 Nylon ........................................................................................................................... 27 N/A Weldment, Support, Air Cleaner .......................................................................................................... 18 102810701 Filter, Air, Canister, W/labe (includes items 9 through 12) ......................................................... 19 102498601 Element, Filter, Air, 5 In ....................................................................................................................... 110 102725501 Valve, Evacuator, Filter Air ................................................................................................................. 111 102725601 Cap, Latch Lock, Filter, Air .................................................................................................................. 112 N/A Body, Canister, Filter, Air ..................................................................................................................... 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-25


INTAKE DUCT AND AIR BOX ASSEMBLY – DIESEL VEHICLESITEM PART NO. DESCRIPTION1 2 3 41 102379001 Hose, Intake, D722 ..................................................................................................................................... 12 102395601 Hose, Intake, Primary ................................................................................................................................ 13 102411209 Clamp, Hose, Ctb 55mm .......................................................................................................................... 14 102411210 Clamp, Hose, Ctb 64mm .......................................................................................................................... 35 102541465 Bolt, M 6 X 1.0 X 65 Hex, Flange, Head, Black ................................................................................... 26 102621201 Bolt Flanged Head, M8 X1.25x 16 with Loctite ............................................................................... 27 102621501 Nut Flg, M6 X 1.0 Nylon ........................................................................................................................... 28 N/A Weldment, Support, Air Cleaner .......................................................................................................... 19 102810701 Filter, Air, Canister, W/labe (includes items 10 through 13) ....................................................... 110 102498601 Element, Filter, Air, 5 In ....................................................................................................................... 111 102725501 Valve, Evacuator, Filter Air ................................................................................................................. 112 102725601 Cap, Latch Lock, Filter, Air .................................................................................................................. 113 N/A Body, Canister, Filter, Air ..................................................................................................................... 1QTY10GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 10-27

10GED

EXHAUST SYSTEM11GED


ITEM PART NO. DESCRIPTION1 2 3 4EXHAUST SYSTEM, GASOLINE VEHICLES1 102409401 Pipe, Exhaust Intermediate .................................................................................................................... 12 102409501 Spring, Exhaust ........................................................................................................................................... 43 102409601 Header, Exhaust, Gas ................................................................................................................................ 14 102621201 Bolt Flanged Head, M8 X1.25x 16 with Loctite ............................................................................... 25 102812801 Asm, Muffler, AWD Homologation (includes items 6 through 8) ............................................. 16 102409501 Spring, Exhaust ...................................................................................................................................... 47 N/A Muffler ...................................................................................................................................................... 18 N/A Bracket, Muffler ..................................................................................................................................... 19 102834901 Gasket, Exhaust, Gx620 ............................................................................................................................ 210 96704416 Nut Flg, M8 X 1.25 Serrated .................................................................................................................... 4QTY11GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 11-3


ITEM PART NO. DESCRIPTION1 2 3 4EXHAUST SYSTEM, DIESEL VEHICLES1 102298401 Nut,m8,all Metal Lock ............................................................................................................................... 32 102409301 Pipe, Exhaust Diesel Main ....................................................................................................................... 13 102409401 Pipe, Exhaust Intermediate .................................................................................................................... 14 102409501 Spring, Exhaust ........................................................................................................................................... 45 102422301 Gasket, Exhaust Diesel ............................................................................................................................. 16 102621201 Bolt Flanged Head, M8 X1.25x 16 with Loctite ............................................................................... 27 102621301 Bolt, M8 X 1.25 X 40 with Loctite .......................................................................................................... 38 102628101 Shield, Diesel Exhaust .............................................................................................................................. 19 102731601 Bolt, D722, Exhst Manfld Cover ............................................................................................................. 110 102812801 Asm, Muffler, AWD Homologation (includes items 11 through 13) ........................................ 111 102409501 Spring, Exhaust ...................................................................................................................................... 412 N/A Muffler ...................................................................................................................................................... 113 N/A Bracket, Muffler ..................................................................................................................................... 1QTY11GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 11-5

11GED

CLUTCHES12GED


ITEM PART NO. DESCRIPTION1 2 3 4CLUTCH COVER (STANDARD)1 102296716 Screw, M6 X 16 Tt Hx Fl Hd ..................................................................................................................... 72 102411210 Clamp, Hose, Ctb 64mm .......................................................................................................................... 13 N/A Cover, Cvt, Open ......................................................................................................................................... 14 103320601 Hose, Outlet, Cvt ........................................................................................................................................ 1QTY12GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 12-3


ITEM PART NO. DESCRIPTION1 2 3 4CLUTCH COVER (SEALED)1 102616003 Kit, Sealed CVT Cover (includes items 2 through 11) .................................................................... 12 101856102 Screw, 1/4-15 X 1.50 Hi-lo Hex ......................................................................................................... 33 102296716 Screw, M6 X 16 Tt Hx Fl Hd ................................................................................................................ 74 102411210 Clamp, Hose, Ctb 64mm .................................................................................................................... 35 102414501 Cover, CVT Outer .................................................................................................................................. 16 102481001 Hose, Inlet, Cover, CVT ........................................................................................................................ 17 102481201 Bracket, Inlet, Cover, CVT ................................................................................................................... 18 102481301 Gasket, Cover, CVT ............................................................................................................................... 19 102616101 Cap, Inlet, Cover, CVT .......................................................................................................................... 110 102628001 Filter, Inlet, Cover, CVT ........................................................................................................................ 111 103320601 Hose, Outlet, Cvt ................................................................................................................................... 1QTY12GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 12-5


ITEM PART NO. DESCRIPTIONQTY1 2 3 4DRIVE BELT1 102374901 Belt, Drive ...................................................................................................................................................... 112GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 12-7

12GED116124 105141719222313151878169201214 23 -23000007-003Page 12-82005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4DRIVE CLUTCH – GASOLINE VEHICLES1 102385601 Washer, Stepped ........................................................................................................................................ 12 102490001 Bolt, M10x1.25x200 Loctite .................................................................................................................... 13 103185401 Clutch, 4x4, Gas, W/cover (includes items 4 through 23) ............................................................ 14 102690501 Screw, Shlder Hex, .312 X 1.75 ......................................................................................................... 25 102690701 Nut, Lock Hex, 1/14-20, Flexlc .......................................................................................................... 26 102691001 Sub Assy, Wt Clutch, Gas .................................................................................................................... 27 102691401 Spring, Compression, Primary ......................................................................................................... 18 N/A Washer, Lock, H-Spring, 1/4 .............................................................................................................. 49 102691701 Screw, Cap, Hex Hd, 1/4 X 1.25 ........................................................................................................ 410 102691801 Shim, 1.63 X 1.33 ................................................................................................................................... A/R11 N/A Subassembly, Drive Clutch ............................................................................................................... 112 N/A Subassembly, Moveable, Drive Clutch .......................................................................................... 113 N/A Spider Subassembly (Gasoline) (includes items 14 through 20) ......................................... 114 102690201 Pin, Spring Slotted,1.25 X 1.0 ..................................................................................................... 215 102690301 Pin, Dowel, .375 X 1.50 ................................................................................................................. 216 102690501 Screw, Shlder Hex, .312 X 1.75 ................................................................................................... 217 102690701 Nut, Lock Hex, 1/14-20, Flexlc .................................................................................................... 218 102691901 Roller, Torque, Gas .......................................................................................................................... 419 N/A Spider, Drive Clutch ....................................................................................................................... 120 102839401 Sub Assy, Roller Weight ................................................................................................................ 221 N/A Cover, Drive Clutch .............................................................................................................................. 122 103185801 Cover, Clutch, 4x4 ................................................................................................................................. 123 103185901 Gasket, Cover, Clutch, 4x4 ................................................................................................................. 1QTY12GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 12-9


ITEM PART NO. DESCRIPTION1 2 3 4DRIVE CLUTCH – DIESEL VEHICLES1 102385601 Washer, Stepped ........................................................................................................................................ 12 102616501 Bolt, M10 X 1.5 X 160 ................................................................................................................................ 13 103185501 Clutch, 4x4, Diesel, W/cover (includes items 4 through 23) ....................................................... 14 102690501 Screw, Shlder Hex, .312 X 1.75 ......................................................................................................... 25 102690701 Nut, Lock Hex, 1/14-20, Flexlc .......................................................................................................... 26 102690801 Sub Assy, Wt Clutch, Diesel ............................................................................................................... 27 102691401 Spring, Compression, Primary ......................................................................................................... 18 N/A Washer, Lock, H-Spring, 1/4 .............................................................................................................. 49 102691701 Screw, Cap, Hex Hd, 1/4 X 1.25 ........................................................................................................ 410 102691801 Shim, 1.63 X 1.33 ................................................................................................................................... A/R11 N/A Subassembly, Drive Clutch ............................................................................................................... 112 N/A Subassembly, Moveable, Drive Clutch .......................................................................................... 113 N/A Subassembly, Spider Utility, Diesel (includes items 14 through 20) .................................. 114 102690201 Pin, Spring Slotted,1.25 X 1.0 ..................................................................................................... 215 102690301 Pin, Dowel, .375 X 1.50 ................................................................................................................. 216 102690401 Roller, Torque, Diesel ..................................................................................................................... 417 102690501 Screw, Shlder Hex, .312 X 1.75 ................................................................................................... 218 102690701 Nut, Lock Hex, 1/14-20, Flexlc .................................................................................................... 219 N/A Spider, Drive Clutch ....................................................................................................................... 120 102839401 Sub Assy, Roller Weight ................................................................................................................ 221 N/A Cover, Drive Clutch .............................................................................................................................. 122 103185801 Cover, Clutch, 4x4 ................................................................................................................................. 123 103185901 Gasket, Cover, Clutch, 4x4 ................................................................................................................. 1QTY12GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 12-11


ITEM PART NO. DESCRIPTION1 2 3 4DRIVEN CLUTCH1 102369901 CVT, Secondary (includes items 2 through 8) .................................................................................. 12 102695401 Washer, Thrust, 1.53 X 1.92 ............................................................................................................... 13 N/A Sheave, Driven Clutch ......................................................................................................................... 14 102695601 Retainer, Spring, Inner ........................................................................................................................ 15 102695701 Spring, Compression, Secondary .................................................................................................... 16 102695801 Retainer, Spring, Outer ....................................................................................................................... 17 102695901 Ring, Retaining, External .................................................................................................................... 18 N/A Driven Clutch Base Sheave ............................................................................................................... 19 102385701 Washer, Stepped ........................................................................................................................................ 110 102490501 Bolt, M10 X 1.5 X 100 Loctite ................................................................................................................. 1QTY12GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 12-13

12GED

DRIVETRAIN COMPONENTS13GED


FRONT DIFFERENTIAL MOUNTING AND HALF SHAFTSITEM PART NO. DESCRIPTION1 2 3 41 102274101 Center Cap, Rubber ................................................................................................................................... 22 102381701 Spacer Block, Diff ....................................................................................................................................... 13 102436001 Upright Sub-Assembly, LH (includes items 4 through 11) .......................................................... 14 102022901 Locknut, M12-1.25 Nylon .................................................................................................................. 15 102368201 Bearing ..................................................................................................................................................... 16 N/A Upright, Left ........................................................................................................................................... 17 102374701 Internal Retaining Ring, 80mm Bore ............................................................................................. 18 102376601 Assy, Rotor, Brake, Front (includes items 9 and 10) .................................................................. 19 N/A Rotor, Brake, Front .......................................................................................................................... 110 102475801 Stud, Wheel Lug .............................................................................................................................. 411 102479001 Asm, Adjuster, Slide (includes items 12 through 14) ............................................................... 112 102361901 Joint, Ball ........................................................................................................................................... 113 102447001 Slide, Adjuster .................................................................................................................................. 114 102722301 Ring, Retaining, Ext, 1-1/4" ......................................................................................................... 115 102436101 Upright Sub-Assembly, RH (includes items 16 through 23) ....................................................... 116 102022901 Locknut, M12-1.25 Nylon .................................................................................................................. 117 102368201 Bearing ..................................................................................................................................................... 118 N/A Upright, Right ........................................................................................................................................ 119 102374701 Internal Retaining Ring, 80mm Bore ............................................................................................. 120 102376601 Assy, Rotor, Brake, Front (includes items 21 and 22) ................................................................ 121 N/A Rotor, Brake, Front .......................................................................................................................... 122 102475801 Stud, Wheel Lug .............................................................................................................................. 423 102479001 Asm, Adjuster, Slide (includes items 24 through 26) ............................................................... 124 102361901 Joint, Ball ........................................................................................................................................... 125 102447001 Slide, Adjuster .................................................................................................................................. 126 102722301 Ring, Retaining, Ext, 1-1/4" ......................................................................................................... 127 102462401 Hose, Vent, Front Diff ................................................................................................................................ 128 102491001 Bolt Flanged Head, 3/8-16x1.0 with Loctite ..................................................................................... 229 102491101 Bolt Flanged Head, 3/8-16x1.500 with Loctite ................................................................................ 230 102617501 Nut Flg, M22 X 1.5 Mech Def .................................................................................................................. 231 102617801 Washer Hard, M22 ...................................................................................................................................... 232 102711601 Bolt, Flange Head, M10 X 1.5 X 25 ....................................................................................................... 433 102865201 Shaft, Half ..................................................................................................................................................... 234 103244701 Asm, Mount, Diff Plate ............................................................................................................................. 1QTY13GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-3

13GE8 7 6 923 10 11 12 134 5D3334323526282729313021222024252335171518141619403638 3937000010-001Page 13-42005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTIONFRONT DIFFERENTIAL (OUTPUT COMPONENTS)1 2 3 41 102371801 Differential, Front * (includes items 2 through 40) ........................................................................ 12 102438201 Kit, Assy, Output Cover Plate (includes items 3 through 13) ................................................ 13 N/A Set Screw, #10-24 UNC-3A with Patch .................................................................................... 14 102439101 Thrust Button ................................................................................................................................... 15 102439201 Thrust Plate ...................................................................................................................................... 16 N/A Mate-N-Lock Pin ............................................................................................................................. 27 N/A Mate-N-Lock Housing ................................................................................................................... 18 N/A Oil Seal ............................................................................................................................................... 19 N/A Grommet ........................................................................................................................................... 110 N/A Plate, Output Cover ....................................................................................................................... 111 N/A O-Ring ................................................................................................................................................ 112 N/A Coil, Pocket Insert ........................................................................................................................... 113 N/A Coil with Press-Fit Bobbin ........................................................................................................... 114 102438301 Kit, Assy, Race Output Hub (includes items 15 through 19) ................................................. 115 N/A Pin, Dowel ......................................................................................................................................... 116 102439501 Bearing, Needle .............................................................................................................................. 117 N/A Race/Output Hub, Male ............................................................................................................... 118 N/A Bushing, PermiGlide ...................................................................................................................... 119 N/A Race/Output Hub, Female .......................................................................................................... 120 102438401 Kit, Assy, Clutch (includes items 21 through 23) ....................................................................... 121 102439601 Clutch Hsg/Ring Gear, Machined ............................................................................................. 122 102439801 Kit, Roller (contains 14 rollers) ................................................................................................... 123 102439901 Kit, Assy, Roll Cage (includes items 24 and 25) .................................................................... 124 N/A Kit, H-Clip Spring (contains 14 clips) ................................................................................. 125 N/A Roll Cage, Plastic ....................................................................................................................... 126 102438501 Kit, Bolt (contains 7 bolts) .................................................................................................................. 127 102438601 Kit, Minor Repair (includes items 28 through 31) ..................................................................... 128 N/A Oil Seal ............................................................................................................................................... 129 N/A O-Ring ................................................................................................................................................ 130 N/A O-Ring ................................................................................................................................................ 131 N/A Oil Seal, Triple-Lipped .................................................................................................................. 132 102438701 Retaining, Ring Internal ...................................................................................................................... 133 102438801 Plate, Armature ..................................................................................................................................... 134 102438901 Shim, Armature, Plate ......................................................................................................................... 135 102439301 Bearing, Ball ............................................................................................................................................ 1236 102440101 Kit, Assy, Drain Plug (includes items 37 and 38) ........................................................................ 137 N/A Plug, Oil Drain .................................................................................................................................. 138 N/A Washer, Nylon, 0.625 x 0.382 x 0.06 ......................................................................................... 139 102440301 Plug, Oil Fill ............................................................................................................................................. 140 N/A Bushing, Self-Lubricating, 80 x 85 x 20 ......................................................................................... 1QTY13GED* Note: This assembly also contains components listed on the following twopages.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-5


ITEM PART NO. DESCRIPTION1 2 3 4FRONT DIFFERENTIAL (INPUT COMPONENTS)1 102440201 Kit, Assy, Input Cover Plate (includes items 2 through 4) ............................................................ 12 102440601 Cover, Input, Machined ...................................................................................................................... 13 N/A O-Ring ....................................................................................................................................................... 14 N/A Oil Seal, Triple-Lipped ......................................................................................................................... 15 102440401 Shaft, Pinion, Machined ........................................................................................................................... 16 102440501 Bearing, Ball ................................................................................................................................................. 17 N/A Bushing, Plain 16 Id X 15 Wide .............................................................................................................. 1QTY13GEDNote: This page contains a list of components internal to the frontdifferential. See the previous pages for other front differential components.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-7


ITEM PART NO. DESCRIPTION1 2 3 4PROP SHAFTS1 N/A Inst, Prop Shafts, Awd (includes items 2 through 4) ..................................................................... 12 102371701 Prop Shaft, Front ................................................................................................................................... 13 102372101 Prop Shaft, Rear ..................................................................................................................................... 14 95293643 Pin, Spring, 5/16 X 1-1/2 Hd .............................................................................................................. 2QTY13GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-9


ITEM PART NO. DESCRIPTION1 2 3 4FORWARD/REVERSE SHIFTER ASSEMBLY1 102470801 Asm, FNR (includes items 2 through 19) ........................................................................................... 12 1014727 Washer, #4 Nylon Flat .......................................................................................................................... 23 1014808 Switch, Limit ........................................................................................................................................... 14 1016851 Buzzer, Reverse (9-48 VDC) ............................................................................................................... 15 1016896 Screw, #4-40 X 1.125 Hx Hd Mch .................................................................................................... 26 102298401 Nut,m8,all Metal Lock ......................................................................................................................... 37 N/A Weldment, FNR Shifter ....................................................................................................................... 18 102375901 Bushing, Fnr ........................................................................................................................................... 19 102376001 Knob, Fnr ................................................................................................................................................ 110 N/A Weldment, FNR Shifter Bracket ....................................................................................................... 111 N/A Rivet, Micro Tuflok ................................................................................................................................ 212 102615701 Stud, Ball, .346 Dia ................................................................................................................................ 113 102616701 Locknut, M10x1.5 Nylon Insert ........................................................................................................ 114 102618301 Bolt Flanged Head, M8 X 1.25 X 65 ................................................................................................ 315 102684501 Washer, M12 Hard Regular ................................................................................................................ 216 102684601 Shoulder Bolt,m12 X 20 M10 Thd ................................................................................................... 117 8057 Nut, #4-40 Hex Machine ..................................................................................................................... 218 8058 Lockwasher, #4 Helical Split .............................................................................................................. 219 8717 Locknut, 1/4-28 Nylon Insert ............................................................................................................ 1QTY13GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-11


ITEM PART NO. DESCRIPTION1 2 3 4TRANSMISSION1 102369401 Transmission, Parallel Shaft * (includes items 2 through 18) ..................................................... 12 102693301 Screw,hex Flange, M8 X 35 ................................................................................................................ 113 102764201 Asm, Gear Case, Rear (includes items 4 through 9) .................................................................. 14 102694201 Plug, Square Skt, 1/12-14, Ptf ..................................................................................................... 15 N/A Oil, Deflector .................................................................................................................................... 16 N/A Gearcase, Rear ................................................................................................................................. 17 N/A Vent, Trans ........................................................................................................................................ 18 N/A Screw, Tapping # 10-24 X .375 ................................................................................................... 19 102699401 Seal, Triple, 25 X 35 X 7.8 ............................................................................................................. 210 102764301 Asm, Gear Case, Front (includes items 11 through 17) ........................................................... 111 102693401 Plug,3/8-16, Hex Flange ............................................................................................................... 112 102693501 Washer, .625 X .382 X .60 ............................................................................................................. 113 102694201 Plug, Square Skt, 1/12-14, Ptf ..................................................................................................... 114 102696101 Pin, Dowel, 6 X 20 ........................................................................................................................... 215 N/A Gearcase, Front ............................................................................................................................... 116 102699401 Seal, Triple, 25 X 35 X 7.8 ............................................................................................................. 117 102721501 Seal, Dual-Lip ................................................................................................................................... 118 102765201 Kit, Reverse Gear Repair (includes items 19 through 28) ....................................................... 119 102696201 Ring, Retaining, Basic External .................................................................................................. 220 N/A Washer, Thrust, 1.007 X .062 ....................................................................................................... 121 N/A Washer, 26.231 X 39.167 X 1.57 ................................................................................................. 122 102696801 Bearing, Ball ...................................................................................................................................... 123 102696901 Bearing, Ball ...................................................................................................................................... 124 102697101 Bearing, Needle .............................................................................................................................. 225 N/A Sprocket, 19-Tooth ......................................................................................................................... 126 N/A Sprocket, 51-Tooth ......................................................................................................................... 127 N/A Chain, .375p, .75 Wide, 60ptch .................................................................................................. 128 102699701 Ring, Retaining, E-Ring ................................................................................................................. 2QTY13GED* Note: This assembly also contains components listed on the following fourpages.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-13

13GED1113 14 12 1521678910543000016-008Page 13-142005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4TRANSMISSION, CONTINUED1 102697501 Dog, Engagement ...................................................................................................................................... 12 102698701 Shaft, Intermediate ................................................................................................................................... 13 102764901 Kit, Forward Gear Repair (includes items 4 through 10) .............................................................. 14 102696201 Ring, Retaining, Basic External ......................................................................................................... 25 N/A Washer, Thrust, 1.007 X .062 ............................................................................................................. 26 102696801 Bearing, Ball ............................................................................................................................................ 17 102696901 Bearing, Ball ............................................................................................................................................ 18 102697101 Bearing, Needle ..................................................................................................................................... 29 N/A Gear, Helical 58-Tooth ......................................................................................................................... 110 N/A Gear, Helical 34-Tooth ......................................................................................................................... 111 102765101 Kit, Neutral Switch Repair (includes items 12 through 15) ......................................................... 112 N/A Spring, .484 X .340 X 1.076 ................................................................................................................ 113 N/A Guide, Detent Bullet ............................................................................................................................ 114 N/A Bullet, Detent ......................................................................................................................................... 115 N/A Switch, Indicator, Pollak ..................................................................................................................... 1QTY13GEDNote: This page contains a list of components internal to the transmission.See the previous pages for other transmission components.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-15


TRANSMISSION SHIFT SHAFT AND BELL CRANK (STYLE A)ITEM PART NO. DESCRIPTION1 2 3 41 102765001 Kit, Trans Shift Shaft Repair (includes items 2 through 6) ........................................................... 12 102696001 Nut, Lock Hex, Nylon, 5/16-24 ......................................................................................................... 13 N/A Ring, Retaining, External 9/16 .......................................................................................................... 14 N/A Washer, Flat, .58 X 1.08 X .05 ............................................................................................................. 15 N/A Weldment, Shift, Shaft ........................................................................................................................ 16 102699601 Seal, Dul Lip, .88 X .56 X .19 ............................................................................................................... 17 103294301 Kit, Bellcrank, D Shape, Clamp (includes items 8 through 11) ................................................... 18 1010177 Bolt, 3/8-16 X 2.00 Hex Head ............................................................................................................ 19 N/A Asm, Bellcrank, D Shape, Clamp ..................................................................................................... 110 334 Washer, 3/8 Type A Flat ...................................................................................................................... 111 8754 Locknut, 3/8-16 Hex ............................................................................................................................ 1QTY13GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-17


TRANSMISSION SHIFT SHAFT AND BELL CRANK (STYLE B)ITEM PART NO. DESCRIPTION1 2 3 41 102696001 Nut, Lock Hex, Nylon, 5/16-24 ............................................................................................................... 12 N/A Ring, Retaining, External 9/16 ............................................................................................................... 13 N/A Washer, Flat, .58 X 1.08 X .05 .................................................................................................................. 14 102699601 Seal, Dul Lip, .88 X .56 X .19 .................................................................................................................... 15 103239501 Bellcrank, Alum ........................................................................................................................................... 16 103239801 Shaft, Shift .................................................................................................................................................... 1QTY13GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-19


ITEM PART NO. DESCRIPTION1 2 3 4TRANSMISSION, CONTINUED1 102697801 Fork, Transmission ..................................................................................................................................... 12 102698801 Shaft, Output ............................................................................................................................................... 13 102699501 Plug, 19mm .................................................................................................................................................. 14 102764701 Kit, Input Shaft Repair (includes items 5 through 13) ................................................................... 15 102696201 Ring, Retaining, Basic External ......................................................................................................... 16 102696901 Bearing, Ball ............................................................................................................................................ 27 102697001 Bearing, Ball ............................................................................................................................................ 18 N/A Gear, Helical 90-Tooth ......................................................................................................................... 19 N/A Shaft, Input ............................................................................................................................................. 110 N/A Gear, Helical, 31-tooth ........................................................................................................................ 111 102699701 Ring, Retaining, E-Ring ....................................................................................................................... 112 N/A Sub Assy, Fly Weight ............................................................................................................................ 113 N/A Sub Assy, Governor Spool ................................................................................................................. 114 102764801 Kit, Governor Shaft Repair (includes items 15 through 17) ........................................................ 215 102700001 Ring, Retaining ...................................................................................................................................... 116 N/A Assy, Governor Arm ............................................................................................................................. 117 102721501 Seal, Dual-Lip ......................................................................................................................................... 1QTY13GEDNote: This page contains a list of components internal to the transmission.See the previous pages for other transmission components.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-21

13GE437D216561 5000032-001Page 13-222005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4TRANSMISSION CABLE1 1011084 Nut, 1/4-28 Hex Jam ................................................................................................................................. 22 1012769 Screw, M6-1.00 X 25mm Hex Cap ........................................................................................................ 33 102382401 Bracket, FNR Trans Cable ......................................................................................................................... 14 102475701 Clip, Brake Line ............................................................................................................................................ 25 102495801 Cable, Transmission Shift ........................................................................................................................ 16 102615801 Joint, Ball, .346 Dia ..................................................................................................................................... 27 102621501 Nut Flg, M6 X 1.0 Nylon ........................................................................................................................... 3QTY13GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-23


ITEM PART NO. DESCRIPTION1 2 3 4REAR DIFFERENTIAL1 102831501 Axle, Rear, Guard Mounts (Complete Assembly) (includes items 2 through 19) ................ 12 102276001 Locking Cap, Nut .................................................................................................................................. 23 102376602 Assy, Rotor, Brake, Rear ....................................................................................................................... 24 102449101 Gearcase, Lower, Machined .............................................................................................................. 15 102463501 Axle, Right-hand ................................................................................................................................... 16 102463601 Axle, Left-Hand ...................................................................................................................................... 17 102672101 Washer,counterbored 51 X 30 ......................................................................................................... 28 102672201 Washer, Bellevle, 1.063 X .043 .......................................................................................................... 129 102672301 Washer, Belleville, 49 X 4 .................................................................................................................... 210 102672401 Nut, Hex, M20 X 1.5 , Modified ........................................................................................................ 211 N/A Screw, M10 X 25 .................................................................................................................................... 812 102693301 Screw,hex Flange, M8 X 35 ................................................................................................................ 913 102693401 Plug,3/8-16, Hex Flange ..................................................................................................................... 114 102693501 Washer, .625 X .382 X .60 ................................................................................................................... 115 102694201 Plug, Square Skt, 1/12-14, Ptf ........................................................................................................... 116 102694301 Bellows, Vent, Upper Housing ......................................................................................................... 117 102694401 Clamp, Hose, Dw-9.5 ........................................................................................................................... 118 102694701 Screw, Hex Fl, M12 X 1.75 X 30 ......................................................................................................... 1219 102694801 Pin, Cotter, 5/32 X 1.25 ........................................................................................................................ 2QTY13GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-25


ITEM PART NO. DESCRIPTION1 2 3 4REAR DIFFERENTIAL, CONTINUED1 102765301 Asm, Gearcase, Upper (includes items 2 and 3) .............................................................................. 12 N/A Gearcase, Upper, Machined .............................................................................................................. 13 102694001 Vent, Top, Upper Housing ................................................................................................................. 14 102765401 Asm, Axle Tube, RH (includes items 5 through 7) .......................................................................... 15 N/A Weldment, Axle Tube Rh ................................................................................................................... 16 102463801 Ring, Retaining, Internal ..................................................................................................................... 17 102464301 Bearing ..................................................................................................................................................... 18 102765501 Asm, Axle Tube, LH (includes items 9 through 11) ........................................................................ 19 N/A Weldment, Axle Tube Lh .................................................................................................................... 110 102463801 Ring, Retaining, Internal ..................................................................................................................... 111 102464301 Bearing ..................................................................................................................................................... 112 102765801 Kit, Rear Axle Gear Repair (includes items 13 through 17) ......................................................... 113 102464201 Bearing, Ball ............................................................................................................................................ 114 102464401 Seal, Dual-Lip 25x 62x 7tc .................................................................................................................. 115 102464501 Seal, Dual-Lip 30x 62x 8tc .................................................................................................................. 216 N/A Gear, Ring, 33-Tooth ............................................................................................................................ 117 N/A Asm, Pinion W/ Bearings (includes items 18 through 23) ..................................................... 118 N/A Pinion, I0t Machined ..................................................................................................................... 119 102463901 Ring, Retaining, External ............................................................................................................. 120 102464001 Bearing, Ball ...................................................................................................................................... 121 102464101 Bearing, Needle, Drawn Shell .................................................................................................... 122 102693601 Washer, 2.625 X 2.367 X .06 ........................................................................................................ 123 102694502 Shim, 1.50 X 1.189 X .008 ............................................................................................................. 124 102961501 Asm, Differential & Carrier (includes items 25 through 30) ........................................................ 125 102464201 Bearing, Ball ............................................................................................................................................ 126 102464401 Seal, Dual-Lip 25x 62x 7tc .................................................................................................................. 127 102464501 Seal, Dual-Lip 30x 62x 8tc .................................................................................................................. 228 102961301 Housing, Differential, Mach .............................................................................................................. 129 102961401 Pin, Dowel, 4 X 35 ................................................................................................................................. 130 102961601 Asm, Locker, Nongrease/Spacers .................................................................................................... 1QTY13GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 13-27

13GED

RADIATOR AND COOLANT SYSTEM(DIESEL VEHICLES)14GED


ITEM PART NO. DESCRIPTION1 2 3 4RADIATOR1 1014471 Tape, Vinyl Foam 1/8" x 3/4" * ................................................................................................................ A/R2 102289001 Screw, M8X1.25X30, Hex ......................................................................................................................... 23 102377801 Hose, Coolant Lower Pipe ....................................................................................................................... 14 102377901 Hose, Coolant Lower Rad ........................................................................................................................ 15 102380301 Tee, Coolant Fill ........................................................................................................................................... 16 102410301 Exchanger, Engine Coolant (includes items 7 through 9) ........................................................... 17 102737301 Cap, Radiator .......................................................................................................................................... 18 N/A Drain Cock, Radiator ............................................................................................................................ 19 N/A Radiator .................................................................................................................................................... 110 102411207 Clamp, Hose, Ctb 35mm .......................................................................................................................... 211 102411208 Clamp, Hose, Ctb 38mm .......................................................................................................................... 112 102411301 Nut, Self Retaining ..................................................................................................................................... 413 102436701 Fan, Cooling 12 In Elect ........................................................................................................................... 114 102452101 Guard, Radiator, Top ................................................................................................................................. 115 102490301 Bolt, M6 X 1 X 16 Loctite .......................................................................................................................... 816 N/A Bracket, Upper Radiator Mount ............................................................................................................ 217 102498101 Bolt, M8 X 1.25 X 20 ................................................................................................................................... 218 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 219 102684401 Bumper, 13mm Stud ................................................................................................................................. 220 102685001 Isolator, Twin-Stud ..................................................................................................................................... 221 102855501 Shroud, Radiator Fan ................................................................................................................................ 122 96704416 Nut Flg, M8 X 1.25 Serrated .................................................................................................................... 223 96705199 Washer, M6 ................................................................................................................................................... 424 96741038 Washer, M8 Hard ........................................................................................................................................ 2QTY14GED* Note: Item not shown.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 14-3


ITEM PART NO. DESCRIPTION1 2 3 4COOLANT EXPANSION TANK1 102289001 Screw, M8X1.25X30, Hex ......................................................................................................................... 22 102460801 Bracket, Coolant Bottle ............................................................................................................................ 13 N/A Asm, Tank, Expansion (includes items 4 through 11) ................................................................... 14 102411204 Clamp, Hose, CTB 15mm ................................................................................................................... 45 102411205 Clamp, Hose, CTB 22mm ................................................................................................................... 16 N/A Fitting, Tee ............................................................................................................................................... 17 102427501 Cap, Radiator .......................................................................................................................................... 18 102434501 Tank, Expansion .................................................................................................................................... 19 N/A Hose, Tee To Vent Tube, Coolnt ....................................................................................................... 110 102807601 Hose, Clnt, 5/8 Sae J20r3 Bulk .......................................................................................................... A/R11 N/A Hose, Clnt 5/16 Sae J20r3 Bulk ........................................................................................................ A/RQTY14GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 14-5


ITEM PART NO. DESCRIPTION1 2 3 4COOLANT PIPES AND HOSES1 102377501 Hose, Coolant Upper Rad ........................................................................................................................ 12 102377601 Hose, Coolant Lower Eng ........................................................................................................................ 13 102411204 Clamp, Hose, CTB 15mm ......................................................................................................................... 44 102411205 Clamp, Hose, CTB 22mm ......................................................................................................................... 15 102411206 Clamp, Hose, Ctb 30mm .......................................................................................................................... 16 102411207 Clamp, Hose, Ctb 35mm .......................................................................................................................... 57 102411208 Clamp, Hose, Ctb 38mm .......................................................................................................................... 18 102427601 Clamp, Bar ..................................................................................................................................................... 19 102435001 Hose, Vent Tube To Eng, Coolnt ............................................................................................................ 110 102458901 Decal, Hot Surface Warning ................................................................................................................... 211 102480501 Hose, Coolant, Return, Engine ............................................................................................................... 112 102618301 Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... 213 102618601 Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 314 102628701 Weldment, Group, Coolant Pipe (includes items 15 through 19) ............................................. 115 N/A Pipe, Coolant Upper ............................................................................................................................ 116 N/A Pipe, Coolant Lower ............................................................................................................................. 117 N/A Tab, Rear Mntg, Coolant Pipe ........................................................................................................... 218 N/A Pipe, Vent, Coolant ............................................................................................................................... 119 N/A Tab, Cooling Pipe Mount ................................................................................................................... 120 96747126 Bolt, M8 X 1.25 X 130 ................................................................................................................................ 1QTY14GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 14-7


ITEM PART NO. DESCRIPTION1 2 3 4WATER FLANGE AND THERMOSTAT1 102410001 Sensor, Coolant Temp ............................................................................................................................... 12 102631301 Cover, Thermostat ..................................................................................................................................... 13 102631401 Assy, Thermostat ....................................................................................................................................... 14 102631601 Bolt, M6 X 1 X 20 ......................................................................................................................................... 25 N/A Band, Pipe ..................................................................................................................................................... 26 102633201 Flange, Water (includes items 7 and 8) .............................................................................................. 17 N/A Pipe, Water Return, D722 ................................................................................................................... 18 N/A Flange, Water ......................................................................................................................................... 19 102633401 Gasket, Thermostat ................................................................................................................................... 110 102654701 Gasket, Water Flange ................................................................................................................................ 111 N/A Bolt, Alt, D722, Stay Lower ...................................................................................................................... 112 102731001 Pipe, Water Return, D722 ........................................................................................................................ 113 N/A Bolt, D722, Thermostat Cover ............................................................................................................... 2QTY14GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 14-9


ITEM PART NO. DESCRIPTION1 2 3 4WATER PUMP1 N/A Bolt, M6 X 1 X 22 ......................................................................................................................................... 42 102632701 Gasket, Water Pump, D722 ..................................................................................................................... 13 102731201 Water Pump Assembly ............................................................................................................................. 1QTY14GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 14-11


ITEM PART NO. DESCRIPTION1 2 3 4BLOCK COOLANT PIPE1 102631701 Band, Pipe, with Nut ................................................................................................................................. 22 102631801 Pipe, Water, Bent ........................................................................................................................................ 13 N/A Nut, Flange, M6 ........................................................................................................................................... 14 N/A Pipe, Water, Bent ........................................................................................................................................ 15 N/A Stud, M6 X 15 ............................................................................................................................................... 1QTY14GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 14-13

14GED

MAINTENANCE AND SERVICE TOOLS15GED

15GED1 2 34 567 89141510 11121316 171819Page 15-22005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTION1 2 3 4MAINTENANCE AND SERVICE TOOLSThe following tool list includes all tools available from Club Car formaintenance and service procedures for gasoline, electric, and/ordiesel vehicles, both past and present models. Be sure to carefullyexamine the tool list for applicability to your vehicle before ordering.QTYDIESEL1 101871001 Accelerator Pedal Adjustment Tool ....................................................................... 1 12 101813202 Adhesive, Guide Ring, 3-Gram Tube ..................................................................... 13 101641202 Arbor ................................................................................................................................ 14 101831901 Battery Discharge Machine, 36/48 Volt ................................................................ 15 1014305 Battery Terminal Protector Spray ........................................................................... 1 1 16 1011767 Battery Thermometer ................................................................................................. 1 1 17 1016417 Bearing and Oil Seal Remover Assembly ............................................................ 1 1 18 1016416 Bearing Driver Set ........................................................................................................ 1 1 19 1012811 Bearing Puller ................................................................................................................ 1 1 110 1012812 Bearing Puller Wedge Attachment ........................................................................ 1 1 111 1013582 Brake Adjustment Tool (used only on vehicles withmanually adjusted mechanical brakes) ............................................................... 1 112 102555501 Brake Cable Release Tool ........................................................................................... 1 1 113 102249901 Brake Pedal Adjustment Tool Kit (used for the Carryall ElectricIndustrial Truck only) (includes items 14 and 15).............................................. 114 **** Brake Pedal Adjustment Tool ............................................................................. 115 **** Brake Pedal Tension Tool ..................................................................................... 116 101887101 Calibration Test Module ............................................................................................ 117 101808401 Cam Installation Tool .................................................................................................. 118 102562401 Charger Bezel Tool ....................................................................................................... 119 102686101 Clutch Removal Tool (for 4x4 vehicles) ................................................................. 1 1QTYGASQTYELEC15GEDPlease refer to the maintenance and service manualfor proper tool application.**** Special order item available upon request2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 15-3

DISPLAY FUNCTIONS:PRESS AND HOLDBUTTON TO SHOWFUNCTION NUMBER.RELEASE BUTTON TOSHOW FUNCTION VALUE.Func1 - Battery voltage.Func2 - Energy units removed since last charge cycle.Func3 - Total accumulated energy units removed.Func4 - Last charge termination type (1 = Incomplete,2 = DVDT, 4 = Normal, 8 = Max. timer).RPOWERONOFFPART #1707515GEDWARNING21 22 23 24 2526 272028 29303132COMMUNICATIONDISPLAY MODULEClub Car33 34 35 363738 39 4041 42 43Page 15-42005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTIONMAINTENANCE AND SERVICE TOOLS, CONTINUED1 2 3 4QTYDIESEL20 1014510 Clutch Tool Kit (includes items 21 - 27) ................................................................ 121 1014498 Clutch Alignment Tool (for pre-unitized transaxlevehicles built prior to 1997 model year) ........................................................ 122 1014496 Drive Clutch Puller (for Kawasaki engines only) .......................................... 123 1014497 Drive Clutch Hub Puller (for Kawasaki engines only) ................................ 124 1014508 Driven Clutch Cam Puller (for Kawasaki engines only) ............................. 125 1014507 Driven Clutch Puller Plug (for Kawasaki engines only) ............................. 126 1015524 Drive Clutch Holder Tool Assembly (for Kawasaki engines only) .......... 127 101809101 Press Weldment (for Kawasaki engines only) ............................................... 128 102601501 Drive ClutchFixed Sheave Tool(for 4x4 vehicles) ........................................................................................................... 1 129 102603501 Driven Clutch Spring Compression Base (for use with items 30and 31) (for 4x4 vehicles) ........................................................................................... 1 130 102605201 Driven Clutch Spring Compression Collar (for use with items 29and 31) (for 4x4 vehicles) ........................................................................................... 1 131 102606101 Driven Clutch Spring Compression Nut (for use with items 29and 30) (for 4x4 vehicles) ........................................................................................... 1 132 102607501 Drive Clutch Spider Removal Tool(for 4x4 vehicles) ........................................................................................................... 1 133 101831801 Communication Display Module ........................................................................... 134 101641002 Compression Gauge and Adapter ......................................................................... 135 1011273 Continuity Tester .......................................................................................................... 1 136 102773801 Cutter, Valve Seat, #122 .............................................................................................. 137 102773901 Cutter, Valve Seat #115 ............................................................................................... 138 102774101 Wrench, T, #505.............................................................................................................. 139 102774101 Adapter, T-Wrench........................................................................................................ 140 102675401 Cutter, Valve Seat, 60 Degree (requires item 51)(for Honda GX620 Gasoline Engines) ................................................................... 141 102774201 Pilot, 6.6 MM ................................................................................................................... 142 102774301 Pilot, 6.62 MM................................................................................................................. 143 102774401 Pilot, 6.65 MM................................................................................................................. 1QTYGASQTYELEC15GEDPlease refer to the maintenance and service manualfor proper tool application.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 15-5

LiquidGasket15GED44 45464748 495051555657235452 535859 60 61Page 15-62005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTIONMAINTENANCE AND SERVICE TOOLS, CONTINUED1 2 3 4QTYDIESEL44 1012151 Dry Moly Lubricant ...................................................................................................... 1 1 145 1016627 Flywheel Puller Kit (for Kawasaki Engines) ......................................................... 146 102669901 Gauge, Carburetor Float Level(for Honda GX620 Gasoline Engines) ................................................................... 147 1016418 Gear Yoke ........................................................................................................................ 1 1 148 101933101 Governor Shaft Installation Tool (for Kawasaki Engine Vehicles) ............... 149 102169401 Hydraulic Brake Adjuster (for Turf/CA 272/472, Pioneer/XRT 1200,Bobcat 2100, HUV 4213) ............................................................................................ 150 1011478 Hydrometer .................................................................................................................... 1 1 151 1013593 Internal Retaining Ring Pliers .................................................................................. 1 1 152 102248803 IQ Display Module (IQDM) Kit (IQ System and IQ Plus vehicles) ................. 1(includes items 54 and 55)53 102248804 IQ Display Module (IQDM-P) Kit (IQ System and IQ Plus vehicles).............. 1(includes items 54 and 55)54 102251501 Adaptor, Cable ......................................................................................................... 155 102241502 IQDM Series 2 Cable .............................................................................................. 156 102241501 IQDM Series 1 Cable (replacement) ...................................................................... 157 101928701 Liquid Gasket (transaxle case) ................................................................................. 1 1 158 102243402 Moly-Teflon Lubricant (4-oz. (113-gram) tube) ................................................. 159 101997201 Paint, Touch-Up – Beige* .......................................................................................... 1 159 101997207 Paint, Touch-Up – Black* ........................................................................................... 1 159 101997212 Paint, Touch-Up – Burgundy* .................................................................................. 1 159 101997211 Paint, Touch-Up – Classic Blue (Navy)* ................................................................. 1 159 101997205 Paint, Touch-Up – Dark Gray* .................................................................................. 1 1 159 101997209 Paint, Touch-Up – Dark Green* ............................................................................... 1 1 159 101997204 Paint, Touch-Up – Gray* ............................................................................................. 1 1 159 101997203 Paint, Touch-Up – Red* .............................................................................................. 1 1 159 101997206 Paint, Touch-Up – Royal Blue (Pacific Blue)* ....................................................... 1 159 101997202 Paint, Touch-Up – White* .......................................................................................... 1 1 160 102562301 Paint, Precedent Underbody – Gray....................................................................... 1 161 102587201 Paint Pen, Touch-Up, Precedent Underbody – Black ....................................... 1 1QTYGASQTYELEC15GEDPlease refer to the maintenance and service manualfor proper tool application.* Item 59 is not for use on Surlyn ® body material, which is usedon Precedent vehicles.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 15-7

Inspect• Brakes• Park Brake• Steering• Accelerator• F & R Selector• Reverse Buzzer• Key Switch• Speeds• Tires• Bag Straps and BucklesGOODOther Mechanical Problems• Unusual Noise• Will Not Run• Stopped on Course• Other:•••Damage• Right Side• Left Side• Front• Rear• Other: ______________CleanlinessNEED(S)ATTENTIONNo DamageNEED(S)ATTENTION• Seats• Floor Mat• Dash Compartments• Bag Well• Beverage Holders• Overall Appearance: ___________________Date: _____________ Inspected By: _________________Car No. ___________(Over)CCI 101823115GED62 63646566Safety FirstNever use a vehicle that is unsafe.Inspect each day.6768 69 707172AM10753ONOFFSTRSPKMAXMINGASDSLGAS/DIESELTACHOMETER737475 7677 83848586Page 15-82005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTIONMAINTENANCE AND SERVICE TOOLS, CONTINUED1 2 3 4QTYDIESEL62 1016414 Piston Ring Compressor Kit (FE290, FE350 and FE400 engines) ................. 163 1016415 Piston Ring Pliers (for Kawasaki Engines) ............................................................ 164 102668801 Puller, Special Use (for Kubota D722 Diesel Engines) ..................................... 165 1012549 Retaining Ring Pliers, 45° External ......................................................................... 1 1 166 1012560 Retaining Ring Pliers, 90° Internal .......................................................................... 1 1 167 101823101 Safety First Card (50 per pack) ................................................................................. 1 1 168 1012809 Seal Puller ....................................................................................................................... 1 1 169 102330901 Spanner Wrench (for coil over shock frontsuspension vehicles only) ......................................................................................... 1 170 1014264 Steering Column Bearing Press Tool ..................................................................... 1 171 1014259 Steering Column Retaining Ring Tool .................................................................. 1 172 102061201 Steering Wheel Puller Tool ....................................................................................... 1 1 173 AM10753 Tachometer (includes gasoline engine pick up lead only) ........................... 1 174 AM10771 Tachometer Diesel Probe (for use with item 73) .............................................. 175 1014162 Transaxle Axle Seal Tool ............................................................................................. 176 1014161 Transaxle Pinion Seal Tool ......................................................................................... 177 1014115 Transmission Tool Kit .................................................................................................. 178 101611003 Tune-Up Kit, All OHV (for FE290, FE350, FE400 only) (includesair filter, spark plug, oil filter, fuel filters) (not shown) .................................... 179 AM11804 Tune-Up Kit, Gx620 (for Honda Engines) (includes air filter,spark plug, oil filter, fuel filters) (not shown) ...................................................... 180 AM11805 Tune-Up Kit, D722 (for Kubota Engines) (includes air filter,oil filter, fuel filters, water separator filter) (not shown) ................................. 181 AM1220301 Tune-Up Kit, Precedent (for FE290/350 Engines) (includes airfilter, spark plug, oil filter, fuel filters) (not shown) ........................................... 182 AM1232401 Tune-Up Kit, FH680D (for Kawasaki V-Twin Engines) (includes oilfilter, fuel filter, air filter, and spark plugs) (not shown)................................... 183 1016413 Valve Clearance Adjuster Screw Holder (for FE290 engines only) ............. 184 102674601 Valve Guide Driver(for Honda GX620 Gasoline Engines) ................................................................... 185 101641201 Valve Guide Reamer (FE290, FE350, and FE400 only)...................................... 186 102674401 Valve Guide Reamer, 6.6 mm(for Honda GX620 Gasoline Engines) ................................................................... 1QTYGASQTYELEC15GED2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 15-9

2200m200202000kMAX1000 ---750V200k100020k2k200500FUSED2002002m20m200m15GED454587888990- +WAVETEK5XLVOFFVAV! COM!200nA9192 93949596Page 15-102005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

ITEM PART NO. DESCRIPTIONMAINTENANCE AND SERVICE TOOLS, CONTINUED1 2 3 4QTYDIESEL87 1016552 Valve Seat Cutter Guide ............................................................................................. 188 1016551 Valve Seat Cutter T-Wrench ...................................................................................... 189 1016553 Valve Seat Cutter, 45° (32 mm diameter) (for FE290 engines only) ........... 190 1016554 Valve Seat Cutter, 45°/30° (35 mm diameter) .................................................... 191 101641101 Valve Spring Compressor .......................................................................................... 192 1011480 Volt Ohm Meter ............................................................................................................ 1 1 193 102570401 Tool, Tensioning, Starter Generator (For Precedent vehicles) ...................... 194 103601401 Puller, Drive Clutch, XRT 950*................................................................................... 195 103601701 Tool, Disassembly, Driven Clutch, XRT 950 .......................................................... 196 103600501 Screw, Driven Clutch Disassembly, M6, XRT 950 ............................................... 1QTYGASQTYELEC15GED*Note: The XRT 950 Drive Clutch Puller requires the use of Screw,Driven Clutch Disassembly, CCI Part Number 103600501.2005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page 15-11

INDEXPart Number and PageAM10753 15-9AM10771 15-9AM1232301 9-7, 9-11183 4-11, 10-5, 10-9332 1-11, 1-19, 7-17, 7-19334 13-17357 1-15451 1-91016 10-5, 10-91017 7-151035 4-13, 5-91108 7-17, 7-191241 4-11, 7-25, 7-277310 2-37473 1-13, 1-19, 7-25, 7-277561 1-138057 13-118058 13-118233 1-19, 10-238248 1-58251 1-178639 4-9, 4-11, 4-138717 13-118754 1-13, 1-15, 6-11, 13-178755 1-13, 1-158797 10-5, 10-98990 1-15, 6-51010177 13-171010200 1-151010435 1-13, 1-191010436 1-191010521 4-11, 4-13101082903 4-71010934 7-25, 7-271011084 13-231011273 15-51011478 15-71011480 15-111011553 3-3, 3-71011652 1-91011767 15-31011779 4-11, 4-131012151 15-71012295 7-17, 7-191012303 1-131012328 7-25, 7-271012438 4-111012549 15-91012560 15-9101260202 4-111012769 1-17, 8-3, 9-3, 13-231012809 15-91012811 15-31012812 15-31012830 1-91013035 6-51013042 6-51013044 6-51013051 6-51013052 6-5101313402 10-71013366 1-191013461 7-15, 10-5, 10-91013462 10-5, 10-91013531 4-11, 4-131013582 15-31013593 15-71013734 1-91013746 10-3, 10-71013857 7-21, 7-231014007 10-231014115 15-91014161 15-91014162 15-91014259 15-91014264 15-91014305 15-31014306 1-3, 1-5, 1-17, 1-19, 4-71014321 1-171014375 7-25, 7-27101438702 1-171014415 1-191014471 1-9, 1-13, 14-31014496 15-51014497 15-51014498 15-51014507 15-51014508 15-51014510 15-51014537 1-191014557 7-21, 7-231014727 13-111014808 13-111015139 10-5, 10-91015143 10-5, 10-91015356 1-131015399 1-13, 1-19101547601 3-51015524 15-5101553901 3-3, 3-71015583 1-131015597 6-13, 6-151015636 7-21, 7-231015741 7-17, 7-19101587703 10-3, 10-7101609401 3-3, 3-7101611003 15-91016183 6-11101641002 15-5101641101 15-11101641201 15-9101641202 15-31016413 15-91016414 15-91016415 15-91016416 15-31016417 15-31016418 15-71016551 15-111016552 15-111016553 15-111016554 15-111016603 1-151016627 15-71016630 7-21, 7-231016851 13-111016879 7-151016880 7-151016896 13-111016967 1-71017062 7-151017064 7-151017065 7-151017162 1-151017167 1-151017774 1-15101808401 15-3101809101 15-5101813202 15-3101823101 15-9101824401 10-3, 10-7101831801 15-5101831901 15-3101833101 8-3101833201 8-3101856102 12-5101871001 15-3101879401 6-5101879701 6-5101879801 6-5101879901 6-5101880201 6-5101886101 10-23101887101 15-3101887601 1-11, 4-7, 4-9101894304 1-19101898001 7-25, 7-27101928701 15-7101933101 15-7101963401 1-19101972001 15-7101972002 15-7101972003 15-7101972004 15-7101972005 15-7101972006 15-72005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page i-1

INDEX101972007 15-7101972009 15-7101972011 15-7101972012 15-7101987901 7-15101988001 7-15101988002 7-15101988101 7-15101988201 7-15102010102 6-5102021302 2-3102021305 2-3102021306 2-3102021406 2-3102021407 2-3102021408 2-3102021409 2-3102021502 1-3, 1-5102021602 1-3, 1-5102021802 1-3, 1-5102022601 6-5102022901 6-5, 6-7, 13-3102023703 1-9102044702 7-21102044801 7-21102046501 3-11, 3-13102047001 1-9102051401 4-7102051601 7-21102051701 7-21102051901 7-21, 7-23102052801 4-11, 4-13102059001 1-11102059401 1-9102061101 1-9102061201 15-9102065901 1-13102066001 1-13, 1-15102169401 15-7102171504 1-13102176901 4-7102198001 7-21, 7-23102221301 1-19102221401 1-19102221501 1-19102221701 1-19102221801 1-19102222001 1-19102222101 1-19102222201 1-19102224001 3-3, 3-7102231601 3-5, 3-9102239901 1-19102241501 15-7102241502 15-7102243402 15-7102248803 15-7102249901 15-3102251501 15-7102251601 1-17102251701 1-17102274101 13-3102276001 13-25102289001 1-7, 9-15, 10-7, 14-3, 14-5102289002 1-3, 1-5102290120 6-3102296140 4-9, 6-7102296401 4-9, 5-3, 6-7102296716 4-9, 10-7, 10-23, 12-3, 12-5102298130 1-3, 1-5, 1-9, 6-3, 6-11102298240 6-9, 6-11102298401 1-9, 8-3, 9-3, 10-3, 11-5, 13-11102323501 5-9102330901 15-9102331401 9-15102355301 7-25, 7-27102361901 6-7, 13-3102363802 6-3102364201 6-3102365601 6-13102365602 6-15102367101 6-3102367601 4-3102368201 13-3102368501 6-7102368502 6-7102368801 6-7102368802 6-7102369401 13-13102369901 12-13102370101 8-3102370501 8-3, 9-3102370601 8-3, 9-3102371401 9-15102371701 13-9102371801 13-5102372101 13-9102374701 13-3102374801 2-3102374901 12-7102375401 7-23102375901 13-11102376001 13-11102376601 13-3102376602 13-25102377501 14-7102377601 14-7102377801 14-3102377901 14-3102378901 10-25102379001 10-27102380301 14-3102380601 5-5102381701 13-3102382401 8-3, 9-3, 13-23102385601 12-9, 12-11102385701 12-13102393501 6-13, 6-15102394002 6-9, 6-11102395601 10-25, 10-27102398901 6-13, 6-15102399201 4-5102399202 4-5102402801 4-7102402901 4-7102406701 10-9102406801 10-9102407801 4-9102407901 4-9102408401 6-7102409301 11-5102409401 11-3, 11-5102409501 11-3, 11-5102409601 11-3102410001 14-9102410301 14-3102410602 10-7102410603 1-3, 1-5, 4-9, 8-3, 9-3102410801 10-7102411202 10-3, 10-7102411203 10-7102411204 14-5, 14-7102411205 14-5, 14-7102411206 14-7102411207 14-3, 14-7102411208 14-3, 14-7102411209 10-27102411210 10-25, 10-27, 12-3, 12-5102411301 14-3102414501 12-5102414801 8-3102418401 1-11102418501 1-3, 1-5, 1-11102419901 1-11102420001 1-11102420201 7-17, 7-19102420401 7-17, 7-19102420501 7-17, 7-19102422301 8-53, 11-5102423701 10-23102425401 1-9102426301 10-3, 10-7102426601 1-15102427501 14-5102427601 14-7102429301 1-3102430001 10-7102430101 10-7Page i-22005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

INDEX102430201 10-7102430301 10-7102430401 10-7102432001 1-3, 1-5102433101 10-23102433501 10-23102434501 14-5102434601 10-7102434701 10-7102434801 9-15, 10-7102435001 14-7102435301 7-5, 7-9102436001 13-3102436101 13-3102436701 14-3102437001 6-7102437101 6-7102437201 1-7102438201 13-5102438301 13-5102438401 13-5102438501 13-5102438601 13-5102438701 13-5102438801 13-5102438901 13-5102439101 13-5102439201 13-5102439301 13-5102439501 13-5102439601 13-5102439801 13-5102439901 13-5102440101 13-5102440201 13-7102440301 13-5102440401 13-7102440501 13-7102440601 13-7102442001 1-9102442201 7-25, 7-27102442301 7-25102442401 7-25102442701 4-11102442801 4-11102442901 5-3, 5-5102443501 9-15102443601 9-15102444201 7-13102446601 6-11102446901 6-7102447001 13-3102447601 1-11102447602 1-11102447901 7-17, 7-19102448001 7-17, 7-19102448401 7-27102448501 7-27102449101 13-25102449901 6-5102451001 10-21102452101 14-3102452301 10-23102454001 1-17102454101 1-17102454201 1-17102454801 10-23102454901 10-23102455101 3-9102455201 3-3102456001 1-9102457001 10-23102457101 10-23102457201 10-23102457301 7-23102457501 9-15102457601 9-15102458801 3-7102458901 1-9, 3-5, 3-9, 14-7102459001 3-9102459101 3-5, 3-9102459201 3-9102459301 3-3, 3-7102459401 1-11, 3-3, 3-7102459501 3-5, 3-9102459710 1-3, 1-5102459715 1-3, 1-5102459716 1-3, 1-5102459718 1-3, 1-5102460201 3-9102460801 14-5102462301 8-3, 9-3102462401 13-3102462501 8-3102462502 9-3102462601 10-13102463501 13-25102463601 13-25102463801 13-27102463901 13-27102464001 13-27102464101 13-27102464201 13-27102464301 13-27102464401 13-27102464501 13-27102464601 6-11102465701 1-15102465901 8-3102466201 1-17102468802 6-11102469901 6-7102470101 6-11102470501 6-11102470601 6-11102470801 13-11102473501 1-9102473601 1-9102473701 1-9102474101 4-9, 6-7102474102 4-9, 6-7102474301 4-9102475301 9-15102475701 4-9, 10-15, 10-17, 10-19, 13-23102475801 13-3102475901 1-9102477001 6-13, 6-15102477201 6-11102478501 10-9102479001 13-3102480501 14-7102481001 12-5102481201 12-5102481301 12-5102482201 1-11102488001 4-3, 4-5102489901 5-3102490001 12-9102490101 8-3, 9-3, 10-23102490201 8-3, 9-3102490301 7-25, 14-3102490401 9-15102490501 8-3, 9-3, 12-13102490801 6-7102491001 13-3102491101 13-3102491301 1-7, 1-11102491501 1-3, 1-5, 1-7, 1-11102491601 4-3, 4-5102491701 1-17102492201 7-17, 7-19102492301 7-19102493001 10-13102493301 4-3, 4-5102494401 8-3, 9-3102494701 10-9102495001 6-11102495801 13-23102498101 10-21, 14-3102498201 7-27, 8-3102498601 10-25, 10-27102498701 10-15102498801 10-19102499601 10-23102522001 10-5, 10-9102541465 4-7, 10-25, 10-27102555501 15-3102562401 15-32005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page i-3

INDEX102570401 15-11102571301 6-3102600001 8-5102600301 8-5, 8-9, 8-53102600701 8-5102600801 8-5, 8-9102601001 8-5, 8-11102601101 8-33102601401 8-5102601501 15-5102602701 8-11102603501 15-5102604801 8-27102605201 15-5102605401 8-21102605501 8-21102605601 8-21102605701 8-41102605801 8-21102606101 15-5102606501 8-17102606701 8-15102606901 8-7102607001 8-7102607201 8-7102607301 8-7102607401 8-7102607501 15-5102607601 8-23, 8-55102607602 8-23102607801 8-23102607901 8-23102608101 8-23102608501 8-19102608801 8-23102608804 8-23102609001 8-23102609101 8-19102609301 8-19102609601 8-19102609801 8-23102610001 8-23102614101 1-13, 1-15102614401 1-19102615701 13-11102615801 13-23102616003 12-5102616101 12-5102616301 6-7, 6-9, 6-11, 6-13, 6-15102616501 12-11102616701 13-11102616801 10-23102616901 10-23102617201 1-3, 1-5, 1-7, 1-11102617301 10-13102617501 13-3102617701 6-7102617801 13-3102618101 5-3, 5-5102618301 4-11, 4-13, 5-3, 5-5, 5-7, 5-9, 13-11,14-7102618401 4-7102618601 1-3, 1-5, 1-15, 4-7, 4-11, 4-13, 5-3,5-5, 5-7, 5-9, 6-3, 6-9, 6-11, 8-3, 9-3, 9-15,10-7, 10-23, 14-3, 14-7102619801 6-13, 6-15102620401 6-13, 6-15102620501 6-7, 6-9, 6-11, 6-13, 6-15102620801 10-13102621101 1-11, 3-3, 3-7102621201 10-25, 10-27, 11-3, 11-5102621301 8-3, 11-5102621501 1-17, 8-3, 9-3, 10-25, 10-27, 13-23102622701 3-11102622801 3-11102622901 3-13102623001 3-13102623301 3-11, 3-13102623501 3-11, 3-13102623802 10-11102623805 10-11102623808 10-11102626201 5-5102628001 12-5102628101 11-5102628601 1-3, 1-5102628701 14-7102629001 1-15102630001 8-23102630601 8-33, 8-35102630701 8-23102630901 8-23, 8-55102631001 8-23, 8-55102631301 14-9102631401 14-9102631601 8-5, 8-33, 8-35, 14-9102631701 14-13102631801 14-13102632701 8-53, 14-11102633201 14-9102633401 8-53, 14-9102634001 8-39, 8-53102634101 8-39102634501 8-39, 8-53102635101 8-43102635301 8-29, 8-39, 8-41, 8-53102635701 8-29102635901 8-29102637001 8-29102637101 8-29102640601 8-31, 8-37102640901 8-37102641001 8-37102641501 8-41102642401 8-41102642501 8-41102642601 8-41102642701 8-41102643001 8-41102643101 8-41102643201 8-41102643401 8-41102643601 8-41102643701 8-41102644001 8-13, 8-53102644101 8-13102644501 8-53102645501 8-45102646001 8-49, 8-53102646601 8-51, 8-53102647701 8-33, 8-35, 8-45102647801 8-25102648401 8-45102648501 8-45102652801 8-9102653101 8-47102653201 8-47102653301 8-47, 8-53102653601 8-47102653701 8-47102654101 8-9, 8-53102654601 8-7, 8-53102654701 8-53, 14-9102655301 9-7102655401 10-11102655501 10-11102655601 10-11102655701 10-11102655801 10-11102655901 10-11102656001 10-11102656101 10-13102656301 10-13102656402 10-13102656601 10-13102656701 10-13102656801 10-13102657101 10-13102657301 10-3, 10-13102657501 9-5, 10-13102657601 9-11, 10-13102658001 9-9102658101 9-9102658201 9-9102658301 9-9102658501 9-9102658601 9-9102658701 9-9Page i-42005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

INDEX102658901 9-9102659001 9-9102659101 9-9102659201 9-9102659801 9-13102659901 9-13102660001 9-13102660401 9-13102660404 9-13102660501 9-13102660601 9-13102660701 9-13102660801 9-13102660803 9-13102661001 9-13102661401 9-13102661701 9-13102661801 9-13102661901 9-7, 9-13102662101 9-11102662201 9-11102662901 9-11102663101 9-11102663201 9-11102663301 9-11102663401 9-11102663501 9-11102663801 9-11102663901 9-11102664001 9-11102664101 9-11102664301 9-11102664601 9-7102664901 9-7, 9-13102665001 9-7102665301 9-7102665601 9-7102665901 9-7102666001 9-7102666201 9-5, 9-7102666801 9-5102666901 9-5102667001 9-5102667101 9-5102667201 9-5102667301 9-5102667401 9-5102667601 9-5102668801 15-9102669901 15-7102670601 1-11102670701 8-3, 9-3102670801 9-15102670901 10-5102671201 1-11102672101 13-25102672201 13-25102672301 13-25102672401 13-25102673201 1-19, 3-11, 3-13102673301 3-11, 3-13102673901 1-15102674001 15-5102674101 15-5102674201 15-5102674401 15-9102674601 15-9102675001 15-5102675101 15-5102675201 15-5102675301 15-5102675401 15-5102682901 6-13, 6-15102684401 14-3102684501 1-17, 6-13, 6-15, 13-11102684601 13-11102685001 14-3102685601 6-13, 6-15102686101 15-3102687801 6-5102689001 4-9102689101 4-9, 6-13, 6-15102689102 4-9, 6-13, 6-15102690201 12-9, 12-11102690301 12-9, 12-11102690401 12-11102690501 12-9, 12-11102690701 12-9, 12-11102690801 12-11102691001 12-9102691401 12-9, 12-11102691701 12-9, 12-11102691801 12-9, 12-11102691901 12-9102693301 13-13, 13-25102693401 13-13, 13-25102693501 13-13, 13-25102693601 13-27102694001 13-27102694201 13-13, 13-25102694301 13-25102694401 13-25102694502 13-27102694701 13-25102694801 13-25102695401 12-13102695601 12-13102695701 12-13102695801 12-13102695901 12-13102696001 13-17, 13-19102696101 13-13102696201 13-13, 13-15, 13-21102696801 13-13, 13-15102696901 13-13, 13-15, 13-21102697001 13-21102697101 13-13, 13-15102697501 13-15102697801 13-21102698701 13-15102698801 13-21102699401 13-13102699501 13-21102699601 13-17, 13-19102699701 13-13, 13-21102700001 13-21102703301 8-11102707101 10-21102710301 9-15, 10-7102710501 10-13102711601 13-3102712601 4-13102714001 4-3, 4-5102715701 4-7102716001 5-9102718001 1-11102718101 1-11102721501 13-13, 13-21102721901 9-15102722001 9-15102722301 6-7, 13-3102722801 9-11102722901 9-11102724101 10-11102724201 10-11102724301 9-9102724501 9-9102724701 9-9102725401 10-13102725501 10-25, 10-27102725601 10-25, 10-27102725801 1-13102725901 1-13102726201 8-5102726301 8-5102726401 8-5102727701 8-15102727901 8-17102728101 8-23, 8-55102728102 8-23102728301 8-25102728601 8-29102728901 8-29102729301 8-11, 8-53102729701 8-41102730001 8-33102730101 8-33102730201 8-33, 8-352005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page i-5

INDEX102730301 8-33102730801 8-5102731001 14-9102731201 14-11102731501 8-51102731601 8-51, 11-5102731701 7-23102731801 8-53102731901 8-53102732001 8-55102732201 8-23, 8-55102732401 1-11102732501 8-33, 8-35, 8-45102736901 2-3102737101 6-13, 6-15102737301 14-3102739201 1-11102739901 7-21102739902 7-23102741501 5-9102741601 5-9102751301 5-9102751501 5-9102751601 10-5102758701 5-7, 5-9102760501 1-3, 1-5102760701 1-3, 1-5102760801 1-3, 1-5102763301 4-13102763401 4-13102764201 13-13102764301 13-13102764701 13-21102764801 13-21102764901 13-15102765001 13-17102765101 13-15102765201 13-13102765301 13-27102765401 13-27102765501 13-27102765801 13-27102770001 4-11102770301 4-13102778001 1-3, 1-5102798001 8-9102798101 8-11102798401 8-13102798501 8-13, 8-53102798701 8-13102799501 8-29102799601 8-31102799701 8-31102799801 8-31102800101 8-37102800201 8-43102800401 8-39102800701 8-33, 8-35102801001 8-33, 8-35102801201 8-47102807601 14-5102810701 10-25, 10-27102812801 11-3, 11-5102826101 10-17102827901 9-15102831201 9-7102831501 13-25102831601 1-5102834901 11-3102839401 12-9, 12-11102849401 9-15102855501 14-3102865201 13-3102886101 1-11102892401 5-7, 5-9102896601 5-7, 5-9102934601 8-3102934701 8-35102934801 8-35102934901 8-35102952101 10-9102952102 10-5102961301 13-27102961401 13-27102961501 13-27102961601 13-27102967901 1-3, 1-5, 1-9, 7-21, 7-23103185401 12-9103185501 12-11103185801 12-9, 12-11103185901 12-9, 12-11103201601 10-11103239501 13-19103239801 13-19103239901 8-35103244701 13-3103252201 9-3103256701 6-7103267001 1-9103273101 5-3, 5-5103282301 6-13, 6-15103294301 13-17103305001 5-9103305101 5-9103307901 10-3103320601 12-3, 12-5103348101 7-21, 7-23103348201 7-21, 7-23103418701 4-5103418801 4-3, 4-595293643 13-996701412 8-3, 9-396704416 11-3, 14-396704721 8-3, 9-396704960 9-396705199 14-396705587 9-15, 10-796706825 5-396715552 1-3, 1-796718978 8-3, 9-3, 10-2396741038 8-3, 9-3, 10-23, 14-396741046 8-3, 9-396742515 1-1196747126 14-7AA-arm 6-7absorber, shock 6-9, 6-11accelerator cable 10-15, 10-19accelerator pedal 5-3accelerator pedal adjustment tool 15-3accessory receptacle 7-21, 7-23actuator 1-15adapteractuator 1-15cable (IQDM) 15-7hose 9-15intake, engine 10-13tube 9-15, 10-7adapter, oil filter 9-15adhesive, guide ring 15-3adjusterhydraulic brake 15-7adjuster, forward/aft 1-9adjuster, slide 13-3adjuster, slider 1-9adjuster, spring 10-23air clean support 10-25, 10-27air filter 10-25, 10-27air filter canister 10-25, 10-27air filter evacuator 10-25, 10-27alternator 8-33, 8-35alternator belt 8-35arbor 15-3armA- 6-7governor 13-21lower 6-7rocker 8-47valve rocker 9-11arm, swing 6-13, 6-15assemblyaccelerator pedal 5-3adjusting bolt 8-29alternator 8-33bearing case cover 8-19brake line 4-9brake pedal 5-5, 5-7, 5-9Page i-62005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

INDEXbrake rotor 13-3, 13-25bucket seat 1-9camshaft 8-21, 9-13case, main bearing 8-19connecting rod 8-23, 9-13crankcase cover 9-9cylinder head cover 8-13drain cock 8-5filler cap 4-7forward/reverse 13-11fuel camshaft 8-27fuel cap 10-9fuel filter 10-7fuel injection pump 8-37fuel pump 10-7, 10-13fuel tank vent 10-5, 10-9gear case 13-13, 13-27governor 9-9governor arm 13-21governor fork 8-43governor fork lever 8-43headlight 7-15headlight harness 7-15hinge, tilt bed 1-13idle apparatus 8-29inner ball joint 6-5intake manifold 8-49muffler 13-3nozzle holder 8-41oil pump 8-17oil pump cover 9-9overflow pipe 8-41park brake pedal 5-7, 5-9pinion 13-27piston ring 8-23, 8-55reservoir, remote 4-7rocker arm 8-47slide adjuster 13-3speed plate 8-39tailgate 1-19tank, coolant expansion 14-5tether 1-19thermostat 14-9tilt bed 1-13tire 2-3turn signal lens 7-15valve, lifter 9-13valve, solenoid 10-11water pump 14-11wire 7-25, 7-27, 10-5, 10-9assembly, sub-A-arm, upper 6-7fly weight 13-21front differential upright 13-3gear case 13-13governor spool 13-21moveable drive clutch 12-9, 12-11spider 12-9, 12-11stationary 12-9, 12-11swingarm 6-13, 6-15weight clutch 12-9, 12-11axle 13-25axle tube 13-27axle, rear, guard mounts 13-25Bballcheck 8-21crankshaft 8-23governor 8-27injection pump 8-27steel 9-9valve 8-11ball joint 6-7, 13-3, 13-23ball stud 13-11band, pipe 14-9, 14-13banjo bolt 4-3, 4-5bar clamp 14-7bar, sway 6-11barb, vent 10-3, 10-7barrier, heat 1-11base, seat holder 1-11battery clamp 7-25, 7-27battery discharge machine 15-3battery terminal protector spray 15-3battery thermometer 15-3battery, 12-volt 7-25, 7-27bearing 13-27ball (steering pinion) 6-5lower pinion 6-5needle 9-13, 13-5, 13-13, 13-15, 13-27radial ball 9-13bearing and oil seal remover 15-3bearing case cover 8-19bearing case, main 8-19bearing driver set 15-3bearing puller 15-3bearing puller wedge 15-3bed floor plate 1-13bed, tilt 1-13bell crank kit 4-13bellcrank 5-9, 13-17, 13-19bellows 6-5, 13-25belt guard 8-35belt, alternator 8-35belt, drive 12-7belt, V- 8-33bezel, fuel fill 1-17bezel, headlight 7-15block, differential spacer 13-3block, engine 8-5block, fuse 7-17, 7-19bobbin, coil with press fit 13-5body, front 1-3, 1-5boltadjusting 8-29banjo 4-3, 4-5drain plug 9-9boxcargo 1-19bracketactuator 1-15anti-sway bar 6-11brake line 4-9, 6-7brake pedal 5-5choke cable 10-13coolant bottle 14-5cover inlet 12-5equalizer 4-11, 4-13governor arm 10-23governor cable 10-23headlight mounting 7-15hydraulic line 4-9, 6-13, 6-15muffler 11-3, 11-5oil filter mount 9-15park brake 5-9radiator mount, upper 14-3rocker arm 8-47seatbelt 1-11steering support 1-7transmission cable 8-3, 9-3, 13-23transmission mounting 8-3, 9-3brake adjustment tool 15-3brake cable 4-13brake cable release tool 15-3brake caliper 4-3, 4-5brake caliper return spring 4-5brake fluid reservoir 4-7brake line 4-9brake pad service kit 4-3, 4-5brake pedal 5-5, 5-7, 5-9brake pedal adjustment tool 15-3brake pedal tension tool 15-3brake return spring 4-11, 4-13brake rotor 13-3, 13-25brake, park, cable pulley kit 4-11breather cover 8-13breather shield 8-13breather tube 8-13, 10-13breather valve 8-13, 9-13brush guard 1-3, 1-5bucket seat 1-9buckle, seatbelt 1-11bulb, headlight 7-15bullet, detent 13-15bumperbed 1-15front 1-3, 1-52005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page i-7

INDEXrubber 1-19stud 14-3bushing 1-15A-arm 6-7anti-sway bar 6-11arm, lower 6-7flanged bronze 8-21forward/reverse 13-11greaseless 5-3, 5-5link 6-11Permiglide 13-5piston pin 8-23, 8-55pivot, urethane 6-13, 6-15plain 13-7return line 10-9self-lubricating 13-5steel 1-13teflon 6-13, 6-15urethane 1-13button, thrust 13-5buzzer, reverse 13-11Ccableaccelerator 10-15, 10-19bell crank 4-13, 5-9brake 4-13choke 10-17governor 10-23IQDM 15-7park brake 4-11transmission 13-23cage, roll 13-5calibration test module 15-3caliper, brake 4-3, 4-5cam installation tool 15-3camshaft 8-21, 9-13camshaft, fuel 8-27canister, air filter 10-25, 10-27capair filter 10-25, 10-27bolt assembly 8-29connecting rod 9-13filler 4-7fuel 10-9fuel tank 10-5inlet 12-5noise suppressor 9-5, 9-7oil filler 9-9pressure 14-5radiator 14-3rubber 13-3sealing 8-5, 8-9spark plug 9-5, 9-7speed control plate 8-39steering wheel 6-3valve 8-47cap, front corner 1-19carburetor air vent tube 10-3, 10-7carburetor float level tool 15-7carburetor, Honda 10-11card, safety first 15-9cargo box 1-19casegear 8-11, 13-13, 13-25, 13-27governor ball 8-27main bearing 8-19case cover, bearing 8-19chain, transmission 13-13charge coil 9-7charger bezel tool 15-3choke cable 10-17clampbar 14-7battery 7-25, 7-27breather tube 8-13hose 10-3, 10-7p- (fuel filter) 1-3, 1-5, 4-9, 8-3, 9-3, 10-7pipe 8-41wire 9-7, 9-13clevis pin 4-7cliphair pin 1-19clip, brake line 4-9, 10-15, 10-17, 10-19, 13-23clip, breather tube 10-13clip, governor 9-9clip, meter 7-21, 7-23clip, piston pin 9-13clip, return pipe 8-41clip, tube 10-3, 10-13clip, wire harness 10-13closeout 1-9clutch 12-13clutch alignment tool 15-5clutch cover 12-9, 12-11clutch housing 13-5clutch removal tool 15-3clutch tool kit 15-5clutch, diesel 12-11clutch, gas 12-9coilcharge 9-7ignition 9-7pocket insert 13-5coil with press-fit bobbin 13-5collar, alternator assembly 8-33, 8-35collar, crankshaft 8-23collar, idle gear 8-21collar, lever 8-39collet 8-47column, steering 6-3communication display module 15-5compression gauge 15-5compressor, piston ring 15-9compressor, valve spring 15-11connecting rod 8-23, 9-13connector, relay 7-17, 7-19console, drink holder 1-9continuity tester 15-5coolant exchanger 14-3coolant expansion tank 14-5coolant fill tee 14-3coolant lamp sensor 14-9coolant pipe 14-7coolant pipe mounting tab 14-7coolant temperature indicator light 7-23cooling fan 9-5, 14-3cord, glow plug 8-41corner cap 1-19cotter, rue ring 6-13, 6-15cover 9-9alternator assembly 8-33bearing case 8-19breather 8-13, 9-13clutch 12-9, 12-11crankcase 9-9CVT 8-3, 9-3, 12-3, 12-5, 12-9, 12-11cylinder head 8-13electrical 7-17, 7-19engine 10-21fan 9-5fuel camshaft 8-5head 9-11head filler 9-11heat proof 8-51input 13-7oil filter 9-9oil pump 9-9thermostat 14-9cover plate, output 13-5cover, steering column 6-3cowl 1-3, 1-5cowl support, ROPS 1-3, 1-5, 1-11crank 8-23crankcase 9-9crankcase cover 9-9crankshaft 8-23, 9-13C-type stop ring 6-5cup holder, seat 1-9cutter, valve seat 15-5, 15-11CVT 12-13CVT cover 12-3CVT cover kit, sealed 12-5CVT cover kit, unsealed 12-5cylinder head 8-9, 9-11cylinder head cover 8-13cylinder, master 4-7Page i-82005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

INDEXDdash, front 1-7dashboard 1-3, 1-5decal4x4 3-11, 3-13bed load warning 3-3, 3-7Carryall 294 3-13Club Car 3-11, 3-13Club Car tailgate 1-19, 3-11, 3-13crush area warning 3-3, 3-7diesel 3-11, 3-13diesel fuel only 3-7driver/passenger 3-5, 3-9ground warning 3-5, 3-9high capacity 3-11, 3-13hot manifold warning 3-9hot surface warning 1-9, 3-5, 3-9, 14-7operating instructions 3-5, 3-9ROPS certification 1-11, 3-3, 3-7rotating parts 3-3, 3-7rotating parts and hot manifold 3-5, 3-9rotating parts warning 3-9trailer hitch 3-3, 3-7under 16 warning 1-11, 3-3, 3-7vehicle loading 3-3, 3-7warning, diesel 3-7warning, gas 3-3winch cable warning 3-5, 3-9XRT 1500 3-11deflector oil 13-13diaphragm tube 10-13diesel tachometer probe 15-9differential housing 13-27differential, front 13-5diode, engine stop 9-7dipstick, oil 9-9disc 4-11dowel pin 13-5drag link 6-5drain cock 8-5drink holder console 1-9drive belt 12-7drive clutch fixed sheave tool 15-5drive clutch holder tool 15-5drive clutch hub puller 15-5drive clutch puller 15-5drive clutch spider removal tool 15-5drive clutch, moveable 12-9, 12-11drive shaft 13-9driven clutch base sheave 12-13driven clutch cam puller 15-5driven clutch puller plug 15-5driven clutch spring compression base tool15-5driven clutch spring compression collar tool15-5driven clutch spring compression nut tool15-5dry moly lubricant 15-7EE-clip 4-11, 4-13elbow 10-9end, tie rod 6-5engine block 8-5engine, diesel, Kubota D722 with closedbreather 8-3engine, Honda 9-3equalizer 4-11, 4-13exchanger, engine coolant 14-3exhaust header 11-3exhaust valve 8-47, 9-11expansion tank, coolant 14-5Ffan shroud 14-3fan, cooling 9-5, 14-3fastener, push-in 7-17, 7-19fender, front 1-3, 1-5fender, rear 1-17filler cap 4-7filterair 10-25, 10-27fuel 10-3, 10-7, 10-13inlet cover 12-5oil 8-7, 8-11, 9-15filter, air, canister 10-25, 10-27fitting, thread-forming grease 6-13, 6-15flange, water 14-9float set 10-11floor mat 1-3, 1-5floor plate, bed 1-13fly weight 13-21flywheel 8-25, 9-7flywheel puller 15-7FNR shifter bracket 8-3, 9-3, 13-23fork, transmission 13-21forward/reverse assembly 13-11Forward/Reverse shifter 13-11frame, tilt bed 1-13front body 1-3, 1-5front differential 13-5fuel camshaft 8-27fuel cap 10-9fuel filter 10-3, 10-7, 10-13fuel gauge sending unit 10-5, 10-9fuel injection pump 8-37fuel pickup tube 10-9fuel pump 10-7, 10-13fuel tank (diesel) 10-9fuel tank (gasoline) 10-5fuel tank cap 10-5fuel tank strap 10-3, 10-7fuel tank vent 10-5, 10-9fuel tank, diesel 10-9fuel tank, gas 10-5fuel tube 10-13fuel-hour gauge 7-21, 7-23fuse10-amp 7-17, 7-1925-amp 7-17, 7-1930-amp 7-19fuse block 7-17, 7-19Ggasketbearing case 8-19, 8-53breather cover 9-13carburetor 10-13carburetor adapter 10-13carburetor bowl 10-11case cover 9-9clutch cover 12-9, 12-11control plate 8-39, 8-53cover 8-19, 8-53, 12-5cylinder head 8-9, 8-53, 9-11cylinder head cover 8-13, 8-53, 9-11drain plug 8-7exhaust 8-53, 11-3, 11-5ex-manifold 8-51, 8-53fuel pump 8-5, 8-53gearcase 8-11, 8-53head cover 8-53head cover nut 8-29, 8-39, 8-41, 8-53idle apparatus 8-29, 8-53intake manifold 8-49, 8-53, 9-11, 10-13liquid 15-7nozzle 8-41oil pump 8-17, 8-53sending unit 10-5, 10-9thermostat 8-53, 14-9water flange 8-53, 14-9water pump 8-53, 14-11gauge, compression 15-5gauge, fuel-hour 7-21, 7-23gauge, oil 8-15gearcam 8-21case 8-11, 13-13, 13-25, 13-27crank 8-23helical 13-15, 13-21idle 8-21injection pump 8-27oil pump drive 8-17ring 8-25, 13-5, 13-27gear ring engagement 13-15gear yoke 15-7glow plug 8-412005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page i-9

INDEXglow plug cord 8-41governor 9-9governor arm 13-21governor cable 10-23governor fork lever 8-43governor guard 10-23governor lever 8-39governor shaft installation tool 15-7governor spool 13-21governor wire 10-23grid, screen 9-5grill 1-3grip tape, accelerator pad 5-3grommet 10-5, 10-9, 10-13, 13-5grommet tool 9-7guardgovernor 10-23radiator 14-3splash 1-7guard, belt 8-35guard, brush 1-3, 1-5guideaccelerator cable 5-3detent bullet 13-15exhaust valve 8-9inlet valve 8-9oil gauge 8-15valve seat cutter 15-11guide ring adhesive 15-3Hhair pin clip 1-19half shaft 13-3handle, park brake 5-7, 5-9hanger, engine 9-5harness, wire 7-5, 7-9, 7-13head, cylinder 8-9, 9-11header, exhaust 11-3headlight assembly 7-15headlight bulb 7-15headlight harness 7-15headlight retainer 7-15heat barrier 1-11heat seal 8-41helical gear 13-15, 13-21hinge plate 1-9hinge, tilt bed 1-13holderdrink 1-9fork lever 8-43screen grid 9-5Honda engine 9-3hook, engine 8-9hose 14-5coolant 14-3, 14-7fuel filter 10-7fuel pump 10-7fuel return 10-7inlet cover 12-5intake 10-25, 10-27oil, remote 9-15overflow 8-41vent 8-3, 9-3, 13-3, 14-5, 14-7hose, outlet 12-3, 12-5housingclutch 13-5differential 13-27Mate-N-Lock 13-5steering gear 6-5hub 4-11hub, race/output 13-5hydraulic brake adjuster 15-7hydrometer 15-7Iidle apparatus 8-29idle gear 8-21ignition coil 9-7injection pump gear 8-27inlet valve 8-47, 9-11insert, carburetor adapter 10-13insulator, carburetor 10-13intake adapter, engine 10-13intake manifold 8-49internal retaining ring pliers 15-7IQ display module (IQDM) 15-7isolator ring and bushing 8-3, 9-3isolator, twin stud 14-3Jjet, main 10-11jointball 6-7, 13-3, 13-23eye 8-37pipe 8-11Kkeyfeather 8-17, 8-21, 8-23, 8-27pair 7-23woodruff 9-7, 9-13key (pair) 7-21key switch 7-21, 7-23key switch spacer 7-21keyswitch nut 7-21kitanti-sway 6-11bolt 13-5brake pad service 4-3, 4-5brake pedal adjustment tool 15-3clutch 13-5cover plate, input 13-7cover plate, output 13-5drain plug 13-5forward gear repair 13-15gasket 8-53governor shaft repair 13-21H-clip spring 13-5input shaft repair 13-21IQ display module (IQDM) 15-7neutral switch repair 13-15nozzle holder 8-41park brake handle 5-7, 5-9piston rebuild 8-55race output hub 13-5rear axle gear repair 13-27repair, minor 13-5reverse gear repair 13-13roll cage 13-5roller 13-5ROPS 1-11transmission shift shaft repair 13-17tune-up 15-9knob, forward/reverse 13-11knob, light switch 7-21, 7-23knuckle, slider steering 6-3Llatch, access panel 1-3, 1-5latch, slam 1-19latch, spring 1-19lens, headlight 7-15leverengine stop 8-39fork 8-43governor 8-39lost motion 5-3speed control 8-39lightoil 7-21, 7-23light switch 7-21, 7-23light switch knob 7-21, 7-23light, coolant temperature indicator 7-23limit switch 13-11line, brake reservoir 4-7link, drag 6-5liquid gasket 15-7low oil warning light 7-21, 7-23lubricant, dry moly 15-7lubricant, moly-teflon 15-7Mmain jet 10-11manifoldexhaust 8-51inlet 9-11, 10-13Page i-102005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

INDEXintake 8-49mat, floor 1-3, 1-5Mate-N-Lock housing 13-5Mate-N-Lock pin 13-5meter clip 7-21, 7-23meter, volt ohm 15-11modulecalibration test 15-3communication display 15-5moly-teflon lubricant 15-7motorstarter 8-45, 9-7mount, link 6-11moveable drive clutch 12-9, 12-11muffler 11-3, 11-5, 13-3Nnipple, remote oil 9-15noise suppressor cap 9-5, 9-7nongrease/spacers locker 13-27nozzle holder 8-41nozzle, main 10-11nut, keyswitch 7-21nut, toggle switch 7-21, 7-23Ooil deflector 13-13oil dipstick 9-9oil filter 8-7, 8-11, 9-15oil filter screen 9-9oil pan 8-7oil pressure switch 8-5, 9-7oil pump 8-17oil pump drive gear 8-17oil seal 8-11, 8-19, 9-9, 9-13, 13-5, 13-7oil slinger 8-23oil warning light, low 7-21, 7-23O-ring 8-5, 8-7, 8-9, 8-11, 8-13, 8-23, 8-31, 8-39,8-53, 9-15, 13-5, 13-7overflow pipe 8-41Ppaint, touch-up 15-7pancenter 1-9oil 8-7seat 1-9panelaccess 1-3, 1-5left 1-19right 1-19side 1-17panel, front 1-17, 1-19park brake cable 4-11park brake pedal 5-7, 5-9p-clamp (fuel filter) 1-3, 1-5, 4-9, 8-3, 9-3, 10-7pedal, accelerator 5-3pedal, brake 5-5, 5-7, 5-9pin, clevis 4-7pin, dowel 13-5pin, Mate-N-Lock 13-5pin, piston 8-23, 8-55, 9-13pin, slide, caliper slide pin 4-3, 4-5pinion 13-27pinion, steering 6-5pipebreather 8-49coolant 14-7exhaust 11-3, 11-5injection 8-41overflow 8-41water 14-13water return 8-13, 14-9pipe band 14-9, 14-13pipe clamp 8-41pipe, coolant 14-7piston 8-23, 8-55, 9-13piston pin 8-23, 8-55, 9-13piston ring 8-23, 8-55piston ring compressor 15-9piston ring pliers 15-9piston ring set 9-13pivot, rocker arm 9-11platearmature 13-5back 1-13, 1-15brush mount 1-3, 1-5cover, output 13-5electrical 7-17, 7-19engine block 8-5engine mounting 8-3, 9-3engine, left side 9-5fuel/oil 9-15, 10-7hinge 1-9push rod guide 9-11shroud 8-25, 9-5speed 8-39speed control 8-39thrust 13-5pliersinternal retaining ring 15-7piston ring 15-9retaining ring 15-9plugdrain 8-7driven clutch puller 15-5engine block 8-5, 8-9, 8-11, 13-13, 13-25expansion 8-5gearcase 13-13, 13-25glow 8-41oil drain 13-5oil fill 13-5oil filler 8-13plug, spark 9-7, 9-11press weldment 15-5prop shaft 13-9protector spray, battery terminal 15-3pullerbearing 15-3clutch 15-3drive clutch 15-5drive clutch hub 15-5driven clutch cam 15-5flywheel 15-7seal 15-9special use tool 15-9pulleyfan drive 8-33, 8-35mount 4-11water pump 8-33, 8-35pulley, brake, park, cable, kit 4-11pullrod, compression spring 5-3pumpfuel 10-7, 10-13fuel injection 8-37oil 8-17water 14-11push rod 8-21, 9-11Rrack guide pressure spring 6-5rack, steering 6-5radiator 14-3radiator cap 14-3radiator guard 1-5, 14-3radiator pipe 14-7reamer, valve guide 15-9receiver, rear 6-13, 6-15receptacle, accessory 7-21, 7-23regulator, voltage 9-15relay 7-17, 7-19relay connector 7-17, 7-19remover, bearing and oil seal 15-3reservoir, brake fluid 4-7reservoir, remote 4-7retainerheadlight 7-15spring (driven clutch) 12-13valve spring 8-47, 9-11retaining ring 13-3retaining ring pliers 15-9retractor, seat belt 1-11reverse buzzer 13-11ringpiston 8-23, 8-55snap 6-5ring gear 8-25, 13-5, 13-272005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page i-11

INDEXring set, piston 9-13ring, C-type stop 6-5ring, retaining 13-3ring, retaining, ext 6-7, 13-3rivet, blind push 1-7rocker arm 8-47rocker arm pivot 9-11rodconnecting 8-23, 9-13crank crank rod 8-23push 8-21, 9-11roll cage 13-5roller weight 12-9, 12-11roller, torque 12-9, 12-11ROPS certification decal 1-11, 3-3, 3-7ROPS cowl support 1-3, 1-5, 1-11ROPS kit 1-11ROPS support tube 1-11ROPS top 1-11ROPS weldment 1-11rotator, valve 9-11rotor, brake 13-3, 13-25rotor, oil pump 9-9rubber bumper 1-19Ssafety first card 15-9screen grid 9-5screen, oil filter 9-9screw, valve clearance adjuster 15-9sealdual lip 13-13, 13-17, 13-19, 13-21, 13-27heat 8-41oil 8-11, 8-19, 9-9, 9-13, 13-5, 13-7steering pinion dust 6-5triple lip 13-13valve stem 8-47, 8-53, 9-11seal puller 15-9seatbucket 1-9valve 8-11valve spring 9-11seat belt retractor 1-11seat holder base 1-11seat, bucket 1-9seatbelt buckle 1-11sending unit, fuel gauge 10-5, 10-9sensor, coolant lamp 14-9service kit, brake pad 4-3, 4-5shaftCVT adapter 8-3drive 13-9fork lever 8-43governor arm 9-13governor lever 8-39idle gear 8-21input 13-21intermediate 13-15output 13-21pinion 13-7prop 13-9rock arm 8-47shift 13-19shaft shift 13-17shaft, half 13-3sheave, drive clutch base 12-13sheave, driven clutch 12-13shield, breather 8-13shield, exhaust 11-5shift, shaft 13-17shim 12-9, 12-11, 13-27shim, armature plate 13-5shim, injection pump 8-37shock absorber 6-9, 6-11, 6-13, 6-15shroud 9-5head 9-5shroud, fan 14-3slam latch 1-19sleevecrankshaft 8-23governor 8-27link 6-11lower suspension 6-7upper suspension 6-7slide pin 4-3, 4-5slide, adjuster 13-3slider, governor 9-9slinger, oil 8-23snap ring 6-5solenoid, stop 8-31spacerengine 8-3key switch 7-21spacer block, differential 13-3spanner wrench 15-9spark plug 9-7, 9-11spark plug cap 9-5, 9-7speed plate 8-39spider 12-9, 12-11splash guard 1-7spray, battery terminal protector 15-3springaccess panel 1-3, 1-5brake caliper return 4-5brake return 4-11, 4-13carburetor 10-23choke spring 10-23compression 10-23, 12-9, 12-11, 12-13continuity 10-13detent bullet 13-15exhaust 11-3, 11-5governor 8-43governor idle 10-23idle apparatus 8-29pedal 5-3pedal stop 5-3rack guide pressure 6-5relief valve 9-9return 8-39rocker arm 8-47start 8-9, 8-43torsion 5-3valve 8-11, 8-47, 9-11spring latch 1-19sprocket 13-13start spring 8-43starter motor 8-45, 9-7stayalternator assembly 8-33cylinder head 8-9fuel pump 10-13spring 8-11stop solenoid 8-31steel bushing 1-13steering column 6-3steering column bearing press tool 15-9steering column cover 6-3steering column retaining ring tool 15-9steering gear housing 6-5steering pinion dust seal 6-5steering rack 6-5steering wheel 6-3steering wheel puller tool 15-9stem, valve 2-3stop solenoid stay 8-31stopper, camshaft 8-21stopper, fuel camshaft 8-27strap, fuel tank 10-3, 10-7stud 8-3, 8-37, 8-51, 14-13engine 9-7idle adjustment 8-29self-clinching 1-19stud, ball 13-11support yoke (steering) 6-5support, access panel 1-3, 1-5sway bar 6-11swingarm 6-13, 6-15switchindicator (transmission) 13-15key 7-21, 7-23light 7-21, 7-23limit 13-11oil pressure 8-5, 9-7toggle 7-21, 7-23T12-volt battery 7-25, 7-27tab, coolant pipe mounting 14-7Page i-122005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List

INDEXtachometer 15-9tachometer probe, diesel 15-9tailgate 1-19tailgate angle 1-19tankcoolant expansion 14-5tank, fuel 10-5, 10-9tank, fuel (diesel) 10-9tank, fuel (gasoline) 10-5tape, grip, accelerator pad 5-3tape, vinyl foam 1-9, 1-13, 14-3tappet 8-21tee, coolant fill 14-3temperature indicator light, coolant 7-23tester, continuity 15-5tether 1-19thermometer, battery 15-3thermostat 14-9thread-forming grease fitting 6-13, 6-15thrust button 13-5thrust plate 13-5tie rod end 6-5tie wrap 1-15, 4-9, 4-11, 4-13, 6-5tilt bed 1-13tilt bed frame 1-13tire 2-3toggle switch 7-21, 7-23toolaccelerator pedal adjustment 15-3belt tensioning, starter/generator 15-11brake adjustment 15-3brake cable release 15-3brake pedal adjustment 15-3brake pedal tension 15-3cam installation 15-3carburetor float level 15-7charger bezel 15-3clutch alignment 15-5cT-wrench 15-5drive clutch fixed sheave 15-5drive clutch holder 15-5drive clutch spider removal 15-5driven clutch spring compression base15-5driven clutch spring compression collar15-5driven clutch spring compression nut 15-5governor shaft installation 15-7grommet 9-7puller, special use 15-9steering column bearing press 15-9steering column retaining ring 15-9steering wheel puller 15-9transaxle axle seal 15-9transaxle pinion seal 15-9transmission 15-9valve guide driver 15-9valve seat cutter 15-5tool kit, clutch 15-5top, ROPS 1-11torque converter 12-13torque roller 12-9, 12-11touch-up paint 15-7transaxle axle seal tool 15-9transaxle housing 13-27transaxle pinion seal tool 15-9transmission cable 13-23transmission cable bracket 8-3, 9-3, 13-23transmission chain 13-13transmission fork 13-21transmission tool 15-9transmission, parallel shaft 13-13tubeaxle 13-27breather 8-13, 10-13carburetor air vent 10-3, 10-7diaphragm 10-13fuel 10-13fuel pickup 10-9ROPS support 1-11tune-up kit 15-9turn signal lens 7-15T-wrench tool 15-5Uupright, front differential 13-3urethane bushing 1-13Vvalve 10-25, 10-27breather 8-13, 9-13exhaust 8-47, 9-11fuel pickup tube 10-5inlet 8-47, 9-11lifter 9-13rocker arm 9-11rotator 9-11seat 8-11solenoid 10-11spring seat 9-11valve clearance adjuster screw 15-9valve guide driver tool 15-9valve guide reamer 15-9valve seat cutter 15-5, 15-11valve seat cutter guide 15-11valve seat cutter tool 15-5valve seat t-wrench 15-11valve spring compressor 15-11valve stem 2-3V-belt 8-33vent barb 10-3, 10-7vent, housing, upper 13-27vent, transmission 13-13volt ohm meter 15-11voltage regulator 9-15Wwarning light, low oil 7-21, 7-23water flange 14-9water pump 14-11wedge, bearing puller 15-3weight clutch 12-9, 12-11weldmentpress 15-5weldment, accelerator pedal 5-3weldment, accelerator pedal bracket 5-3weldment, actuator bracket 1-15weldment, air cleaner support 10-25, 10-27weldment, brake pedal 5-5weldment, coolant pipe 14-7weldment, cowl support, ROPS 1-3, 1-5, 1-11weldment, dash, front 1-7weldment, Forward/Reverse shifter 13-11weldment, Forward/Reverse shifter bracket13-11weldment, lever, lost motion 5-3weldment, receiver 6-13, 6-15weldment, shaft shift 13-17weldment, tilt bed frame 1-13weldment, top, ROPS 1-11wheel 2-3wheel, steering 6-3wire assembly 7-25, 7-27, 10-5, 10-9wire harness 7-5, 7-9, 7-13wire harness, electric lift 1-15wire, governor 10-23wrap, tie 1-15, 4-9, 4-11, 4-13, 6-5wrench, spanner 15-9Yyoke, gear 15-7yoke, support (steering) 6-52005 XRT 1500/Carryall 294 Gasoline and Diesel Vehicle Illustrated Parts List Page i-13

Club Car, Inc.P.O. Box 204658Augusta, GA 30917-4658USAWeb www.clubcar.comPhone 1.706.863.30001.800.ClubCarInt’l +1 706.863.3000Fax 1.706.863.5808

2005 Carryall 295 / XRT 1500 (Gas & Diesel) - Bennett Golf Cars

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