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2008 Crossfire™ 800 EFI

Illustrated Parts Manual MODEL MODEL MODEL MODEL

NUMBER NUMBER NUMBER NUMBER

S2008CFH36USB S2008CFHSPUSO S2008CFHNFUSB S2008CFHSPOSO (INTERNATIONAL)

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TABLE OF CONTENTS 2008 Crossfire 800 EFI (Model No. S2008CFH36USB) (Model No. S2008CFHNFUSB)

(Model No. S2008CFHSPUSO) (Model No. S2008CFHSPOSO) - Int.

SKI AND SPINDLE ASSEMBLY ........................................................................................................................................ 1 SKI AND SPINDLE ASSEMBLY (International Sno Pro) ................................................................................................... 2 SKI AND SPINDLE ASSEMBLY (Nightfire Sno Pro) ......................................................................................................... 3 A-ARM ASSEMBLY ........................................................................................................................................................... 4 SHOCK ABSORBER AND SWAY BAR ASSEMBLY ........................................................................................................ 5 SHOCK ABSORBER AND SWAY BAR ASSEMBLY (Sno Pro) ........................................................................................ 6 FRONT SUSPENSION SHOCK ABSORBER ................................................................................................................... 7 FRONT SUSPENSION SHOCK ABSORBER (Sno Pro) ................................................................................................... 8 STEERING POST ASSEMBLY ......................................................................................................................................... 9 TIE ROD ASSEMBLY ...................................................................................................................................................... 10 HANDLEBAR AND CONTROLS ..................................................................................................................................... 11 HYDRAULIC BRAKE CONTROL ASSEMBLY ................................................................................................................ 12 DRIVE TRAIN SHAFT AND BRAKE ASSEMBLIES ........................................................................................................ 13 GEARCASE ASSEMBLY ................................................................................................................................................. 14 SLIDE RAIL AND TRACK ASSEMBLY ........................................................................................................................... 15 IDLER WHEEL ASSEMBLY ............................................................................................................................................ 16 REAR SUSPENSION FRONT ARM ASSEMBLY ............................................................................................................ 17 REAR SUSPENSION FRONT ARM ASSEMBLY (Sno Pro) ........................................................................................... 18 REAR SUSPENSION FRONT ARM SHOCK ABSORBER ............................................................................................. 19 REAR SUSPENSION FRONT ARM SHOCK ABSORBER (Sno Pro) ............................................................................. 20 REAR SUSPENSION REAR ARM ASSEMBLY .............................................................................................................. 21 REAR SUSPENSION REAR ARM ASSEMBLY (Sno Pro) .............................................................................................. 22 REAR SUSPENSION REAR ARM SHOCK ABSORBER ................................................................................................ 23 REAR SUSPENSION REAR ARM SHOCK ABSORBER (Sno Pro) ............................................................................... 24 FRONT FRAME AND FOOTREST ASSEMBLY ............................................................................................................. 25 HOOD AND WINDSHIELD ASSEMBLY .......................................................................................................................... 26 HOOD AND WINDSHIELD ASSEMBLY (Nightfire Sno Pro) ........................................................................................... 27 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES ......................................................................................... 28 HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES (Sno Pro) ........................................................................ 29 CONSOLE AND SWITCH ASSEMBLY ........................................................................................................................... 30 BELLY PAN ASSEMBLY ................................................................................................................................................. 31 BELLY PAN ASSEMBLY (Sno Pro) ................................................................................................................................. 32 BELLY PAN ASSEMBLY (Nightfire Sno Pro) .................................................................................................................. 33 BELT GUARD ASSEMBLY .............................................................................................................................................. 34 GAS TANK ASSEMBLY .................................................................................................................................................. 35 FUEL PUMP ASSEMBLY ................................................................................................................................................ 36 SEAT ASSEMBLY ........................................................................................................................................................... 37 SEAT ASSEMBLY (Nightfire Sno Pro) ............................................................................................................................ 38 TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY ............................................................................................. 39 TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY (Nightfire Sno Pro) .............................................................. 40 COOLING ASSEMBLY .................................................................................................................................................... 41 ENGINE AND RELATED PARTS .................................................................................................................................... 42 EXHAUST ASSEMBLY .................................................................................................................................................... 43 AIR INTAKE ASSEMBLY ................................................................................................................................................. 44 AIR SILENCER ASSEMBLY ............................................................................................................................................ 45 OIL TANK ASSEMBLY .................................................................................................................................................... 46 DRIVE CLUTCH .............................................................................................................................................................. 47 DRIVEN CLUTCH ............................................................................................................................................................ 48 CYLINDER AND HEAD ASSEMBLY ............................................................................................................................... 49 CRANKCASE ASSEMBLY .............................................................................................................................................. 50 PISTON AND CRANKSHAFT .......................................................................................................................................... 51 REED VALVE ASSEMBLY .............................................................................................................................................. 52 THROTTLE BODY ASSEMBLY ...................................................................................................................................... 53 OIL PUMP ........................................................................................................................................................................ 54 WATER PUMP/WATER MANIFOLD ............................................................................................................................... 55 RECOIL STARTER .......................................................................................................................................................... 56 MAGNETO ....................................................................................................................................................................... 57 ELECTRICAL ................................................................................................................................................................... 58 SERVOMOTOR ASSEMBLY ........................................................................................................................................... 59 „ NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not to be used for assembly. For assembly procedures, use an Arctic Cat Service Manual. Underlined part numbers are new for the 2008 model year. For a complete list of related items, refer to the current accessory catalog. ©2007 Arctic Cat Inc. ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

Printed September 2007

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2008 Crossfire 800 EFI

SKI AND SPINDLE ASSEMBLY 0742-469

1 2603-599 2 2603-456 2603-457 3 8047-486 4 2603-598 5 8047-366 6 1623-689 7 1623-688 8 0623-776 9 0123-458 10 0623-728 11 2603-397 12 0123-296 13 2603-553

2 1 1 8 2 4 2 2 2 2 4 4 2 2

Ski, Plastic - Black Wearbar - Right Wearbar - Left Nut, Lock Handle, Plastic - Black Nut, Lock Screw, Cap Screw, Cap Screw, Cap Pin, Cotter Washer Insert, Ski Nut, Lock Damper, Ski

14 2703-246

1

2703-247

1

0603-647 1623-010 0603-083 0603-158 1603-908 2603-548 0623-831 8611-162 8611-163

4 2 4 4 4 2 2 1 1

15 16 17 18 19 20 21 22

Spindle, Steering - Right - Platinum (inc. 15-18) Spindle, Steering - Left - Platinum (inc. 15-18) ‹ Insert, Spindle ‹ Fitting, Grease ‹ Bearing ‹ Bearing Spacer Axle, Spindle Cap, Spindle Decal, Spindle - Right Decal, Spindle - Left

1

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2008 Crossfire 800 EFI

SKI AND SPINDLE ASSEMBLY (International Sno Pro) 0742-539

1 2 3 4 5 6 7 8 9 10 11 12 13

2

2603-586 0703-871 8047-486 2603-598 8047-366 1623-689 1623-688 0623-776 0123-458 0623-728 2603-397 0123-296 2603-553

2 2 8 2 4 2 2 2 2 4 4 2 2

Ski, Plastic - Black Wearbar Nut, Lock Handle, Plastic - Black Nut, Lock Screw, Cap Screw, Cap Screw, Cap Pin, Cotter Washer Insert, Ski Nut, Lock Damper, Ski

14 2703-246

1

2703-247

1

0603-647 1623-010 0603-083 0603-158 1603-908 2603-548 0623-831 8611-162 8611-163

4 2 4 4 4 2 2 1 1

15 16 17 18 19 20 21 22

Spindle, Steering - Right - Platinum (inc. 15-18) Spindle, Steering - Left - Platinum (inc. 15-18) ‹ Insert, Spindle ‹ Fitting, Grease ‹ Bearing ‹ Bearing Spacer Axle, Spindle Cap, Spindle Decal, Spindle - Right Decal, Spindle - Left

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2008 Crossfire 800 EFI

SKI AND SPINDLE ASSEMBLY (Nightfire Sno Pro) 0742-619

1 2603-599 2 2603-456 2603-457 3 8047-486 4 2603-598 5 8047-366 6 1623-689 7 1623-688 8 0623-776 9 0123-458 10 0623-728 11 2603-397

2 1 1 8 2 4 2 2 2 2 4 4

Ski, Plastic - Black Wearbar - Right Wearbar - Left Nut, Lock Handle, Plastic - Black Nut, Lock Screw, Cap Screw, Cap Screw, Cap Pin, Cotter Washer Insert, Ski

12 0123-296 13 2603-553 14 2703-356

2 2 1

2703-357 0603-647 1623-010 0603-083 0603-158 1603-908 2603-548 0623-831

1 4 2 4 4 4 2 2

15 16 17 18 19 20 21

Nut, Lock Damper, Ski Spindle, Steering - Right - Black (inc. 15-18) Spindle, Steering - Left - Black (inc. 15-18) ‹ Insert, Spindle ‹ Fitting, Grease ‹ Bearing ‹ Bearing Spacer Axle, Spindle Cap, Spindle

3

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2008 Crossfire 800 EFI

A-ARM ASSEMBLY 0742-470

4

1 2703-102 2703-103 2703-106

1 1 1

2703-107

1

2 1603-895 3 1703-094 1703-426

8 2 2

4 0603-083 5 0623-952

8 2

A-Arm, Lower - Right - Platinum (inc. 2) A-Arm, Lower - Left - Platinum (inc. 2) A-Arm, Lower - Right - Black (inc. 2) (Nightfire Sno Pro) A-Arm, Lower - Left - Black (inc. 2) (Nightfire Sno Pro) ‹ Bearing A-Arm, Upper - Platinum (inc. 4) A-Arm, Upper - Black (inc. 4) (Nightfire Sno Pro) ‹ Bearing Screw, Cap

6 7 8 9 10 11 12 13 14 15 16 17

0623-664 1603-563 8047-486 0603-864 8020-230 0623-044 2603-305 4606-402 1623-009 8040-546 1603-616 8026-232

2 2 8 2 4 4 4 2 2 2 4 2

Washer Axle, Inner - Upper Arm Nut, Lock Tube, Axle Screw, Cap Washer Axle, Inner - Lower Arm Brace, Lower A-Arm Screw, Cap Nut, Lock Axle, Powder Metal Screw, Cap

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2008 Crossfire 800 EFI

SHOCK ABSORBER AND SWAY BAR ASSEMBLY 0742-471

1 2 3 4 5 6 7 8

2703-008 1603-890 8047-486 1603-023 0623-991 8020-232 0603-648 2703-018

2 2 4 4 2 2 2 2

Shock, Ski Retainer, Spring Nut, Lock Sleeve, Shock Washer Screw, Cap Spacer, Shock Mount Spring, Compression - Orange

9 10 11 12 13 14 15 16

2703-094 2603-648 2703-096 8020-045 8047-366 2603-649 8047-426 1623-584

1 2 2 4 4 2 2 2

Sway Bar Bearing Arm, Sway Bar Screw, Cap Nut, Lock Link, Sway Bar Nut, Lock Bolt, Carriage

5

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2008 Crossfire 800 EFI

SHOCK ABSORBER AND SWAY BAR ASSEMBLY (Sno Pro) 0742-504

1 2 3 4 5 6 7 8

6

2703-138 2603-614 8047-486 1603-023 0623-991 8020-232 0603-648 2703-094

2 1 4 4 2 2 2 1

Shock, Ski Pump, Air - Shock Nut, Lock Sleeve, Shock Washer Screw, Cap Spacer, Shock Mount Sway Bar

9 10 11 12 13 14 15

2603-648 2703-096 8020-045 8047-366 2603-649 8047-426 1623-584

2 2 4 4 2 2 2

Bearing Arm, Sway Bar Screw, Cap Nut, Lock Link, Sway Bar Nut, Lock Bolt, Carriage

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2008 Crossfire 800 EFI

FRONT SUSPENSION SHOCK ABSORBER (Complete Shock Absorber p/n 2703-008) 0740-459

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

2603-262 1603-501 2603-461 0603-991 1703-452 1604-271 1604-272 2603-055 2603-065 2603-075 2603-095 2603-124 2603-047 2603-052 2603-132 1603-996

1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1

Body, Shock Eyelet, Shock Rod, Shock Bumper, Shock Cap, Shock (inc. 6) ‹ O-Ring Washer, Top Out Valve, 0.800 x 0.010 in. Valve, 0.900 x 0.010 in. Valve, 1.000 x 0.010 in. Valve, 1.100 x 0.010 in. Valve, 1.250 x 0.008 in. Valve, 0.700 x 0.015 in. Valve, 0.800 x 0.006 in. Valve, 1.300 x 0.006 in. Piston, 0.120 in. - Orifice

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1604-274 1 2603-125 1 0623-696 1 0704-791 1 2604-152 1 2604-153 1 2603-012 1 1603-911 1 1603-209 2 1603-914 2 0624-433 1 2604-649 1 2604-162 1 0603-955 2 4639-366 AR

Strap, Piston - Teflon Valve, 1.250 x 0.010 in. Nut, Lock Piston, Floating (inc. 21-22) ‹ O-Ring ‹ Strap, Piston - Teflon Sleeve, Protector Nut, Adjuster Sleeve, Eyelet Bushing, Shock Screw, Valve Valve, Pressure (inc. 29) ‹ O-Ring, Valve Bushing, Shock Oil, Gas Shock - 1 qt

7

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2008 Crossfire 800 EFI

FRONT SUSPENSION SHOCK ABSORBER (Sno Pro) (Complete Shock Absorber p/n 2703-138) 0742-028 *Not Illustrated

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

8

2603-327 2603-511 2603-418 0603-955 1603-209 2603-411 2603-415 2603-333 2604-796 1604-315 1603-940 0603-386 0603-540 0603-335 0603-338 0603-340 0603-343

1 1 1 4 2 1 1 1 1 1 1 1 2 2 1 1 2

Cap, Air Valve Valve, Air End Cap, Shock Bushing, Shock Sleeve, Shock Body, Shock - Upper Rod, Shock Bearing - Assembly Kit, Seal/Cap Rebuild Ball, Bleed Screw Bumper, Internal Washer, Top Out Valve, 0.800 x 0.010 in. Valve, 0.900 x 0.010 in. Valve, 1.000 x 0.008 in. Valve, 1.100 x 0.008 in.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 * *

0603-347 2 Valve, 1.250 x 0.010 in. 0603-331 1 Valve, 0.700 x 0.008 in. 0603-336 1 Valve, 0.900 x 0.006 in. 0603-349 1 Valve, 1.300 x 0.008 in. 2603-309 1 Piston, 0.093 in. - Orifice 0603-389 1 Washer, Backup 0603-301 1 Nut, Cap 2603-417 1 Piston, Floating 2603-413 1 Body, Shock - Lower 1604-428 1 Plug, Rubber - Valve 2603-338 1 Screw, Set 2603-337 1 Ball, Air Valve 2603-610 1 Decal, Shock 2603-613 1 Spacer 4639-368 AR Oil, Shock - 1 qt 4639-012 AR Fluid, Float Shock - 8 oz

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2008 Crossfire 800 EFI

STEERING POST ASSEMBLY 0742-479

1 2 3 4 5 6 7 8 9 10 11 12 13

8002-138 0605-506 0605-507 1705-253 8047-426 0605-576 0605-943 8060-888 0623-044 0623-025 8004-225 0605-504 0623-294

4 2 1 1 6 2 1 3 2 3 1 1 1

Screw, Cap Cap, Adjusting Block Block, Adjusting Post, Steering Nut, Lock Block, Mounting - Steering Post Stop, Steering Post Rivet Washer Nut, Lock Screw, Cap Ball Joint, Tie Rod - Right-Hand Thread Nut, Hex - Right-Hand Thread

14 15 16 17 18 19 20 21 22 23 24 25 26

0605-856 1 0123-917 1 0605-511 1 4606-756 1 1623-353 3 1705-244 1 0623-677 3 1623-406 4 8050-252 2 1623-482 4 0617-538 1 0123-788 1 0706-371 AR

Tube, Tie Rod Nut, Hex - Left-Hand Thread Ball Joint, Tie Rod - Left-Hand Thread Panel, Close-Out Screw, Self-Tapping Support, Steering Cable Tie, Push-Mount Clip, Retaining Washer Screw, Cap Foam, Steering Post Cable Tie Trim

9

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2008 Crossfire 800 EFI

TIE ROD ASSEMBLY 0742-434

1 2 3 4 5 6 7 8 9 10 11 12

10

1705-178 0623-954 0623-955 1705-218 1623-359 0623-956 2603-721 1705-224 0605-807 0623-987 8047-426 1705-184

1 4 2 1 2 2 2 1 2 2 2 1

Shaft, Steering Washer, Thrust Washer, Thrust Arm, Shaft - Right (inc. one No. 5) ‹ Bolt, Carriage Snap Ring Axle, Steering Link Link, Steering (inc. 9) ‹ Bearing Washer Nut, Lock Shaft, Idler

13 14 15 16 17 18 19 20 21 22 23

1705-219 8005-584 1623-394 0605-607 0123-917 0605-961 0623-294 8020-226 0605-788 8047-486 3606-799

1 2 2 2 2 2 2 2 2 2 2

Arm, Shaft - Left (inc. one No. 5) Screw, Cap Screw, Cap Ball Joint, Tie Rod - Left-Hand Thread Nut, Hex - Left-Hand Thread Tube, Tie Rod - Spindle Nut, Hex - Right-Hand Thread Screw, Cap Ball Joint, Tie Rod - Right-Hand Thread Nut, Lock Plug

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2008 Crossfire 800 EFI

HANDLEBAR AND CONTROLS 0742-437 *Included in Kit

1 2 3 4 5 6 7 8 9 10 11 12 13 14

0687-198 1 Cable, Throttle 0123-788 AR Cable Tie - 8 in. 4606-801 2 Grip, Handlebar 0609-824 1 Control, Throttle - Rear (inc. 5-10) 0609-859 1 ‹ Kit, Throttle Lever Mounting (inc. 6-9) * 1 ‹ ‹ Axle, Lever - Throttle * 2 ‹ ‹ Cap, Lever Axle * 1 ‹ ‹ Spacer, Lever Axle 0123-766 1 ‹ ‹ Nut, Push 0609-797 1 ‹ Lever, Throttle 0617-248 1 Pad, Insulator 0609-775 1 Element, Thumbwarmer 0609-595 1 Clip, Retaining 0609-842 1 Control, Throttle - Front

15 16 17 18 19 20 21 22 23 24 25 26 27

7611-770 0609-792 0609-793 0609-791 1705-127 1705-149 1686-452 0123-811 0609-811 0609-805 1623-242 1623-687 0609-822 0609-823

1 1 1 8 1 1 1 1 1 1 2 2 1 1

Decal, Reverse - Throttle Control Cover, Connector Screw, Self-Tapping Screw, Machine Handlebar Wrap, Handlebar Harness, Handlebar Cable Tie - 4 in. Control, Dimmer - Rear Control, Dimmer - Front Washer, Backing Screw, Machine Element, Handwarmer - Right Element, Handwarmer - Left

11

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2008 Crossfire 800 EFI

HYDRAULIC BRAKE CONTROL ASSEMBLY 0740-889 *Not Illustrated

1 2 3 4 5 6 7

12

1602-930 1602-929 1602-931 1602-932 1602-933 1602-934 1602-935

1 1 1 1 1 2 1

Brake Assembly (inc. 2-10) ‹ Master Cylinder - Assembly ‹ Lever, Brake (inc. 4) ‹ ‹ Lock, Brake Lever - Kit ‹ Cover, Reservoir ‹ Screw, Reservoir Cover - Kit ‹ Clamp, Brake

8 9 10 11 12 13 *

1602-936 2 1602-937 1 1602-938 1 0423-178 2 0423-413 1 2602-009 1 0436-908 AR

‹ Screw, Brake Clamp - Kit ‹ Pin, Brake Lever - Kit ‹ Switch, Brake Washer, Crush Bolt, Banjo-Fitting Brakeline, Hydraulic Fluid, Brake - Synthetic Race - 12 oz

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2008 Crossfire 800 EFI

DRIVE TRAIN SHAFT AND BRAKE ASSEMBLIES 0742-472 *Not a Service Part

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

1602-957 1623-461 1602-656 1602-497 0728-171 0702-940 1602-783 2602-065 1602-984 0702-882 1623-355 0702-956 8047-426 0726-276 0648-714 0648-715 0648-716 0648-762 0648-441 8050-277 8051-272 1623-572 1702-014 1623-360

1 1 1 1 1 1 2 1 1 1 8 1 13 1 AR AR AR 1 1 1 1 1 1 5

Nut, Retaining Screw, Cap Disc, Brake Spacer, Brake Caliper Track, Drive - Assembly (inc. 6-7) ‹ Driveshaft ‹ Sprocket, Drive Spacer Seal Plate, Mounting - Gearcase Nut, Push Gearcase Assembly Nut, Lock Clutch, Driven Washer Washer Washer Adjuster, Sheave O-Ring Washer Washer, Lock Screw, Cap Caliper, Brake - Assembly (inc. 22-40) ‹ Bolt, Carriage - Ribbed

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

* 1602-458 1602-461 1602-669 0702-563 1602-466 1602-467 1602-464 * 0602-729 0402-165 1602-671 1602-670 2602-132 2602-131 1602-463 1602-456 0602-590 4606-309 8468-617 1623-676 0630-207 8060-602 2602-076

1 1 2 2 1 4 1 1 1 1 4 2 2 2 2 2 1 1 1 1 1 1 1 1

‹ Housing ‹ Fitting, Bleed ‹ Piston ‹ O-Ring ‹ Pad, Brake - Set (inc. 28-29) ‹ ‹ Clip, Anti-Rattle ‹ ‹ Clip, Hairpin ‹ Pin, Retaining - Brake Pad ‹ Housing ‹ O-Ring, Housing ‹ Washer ‹ Screw, Cap ‹ Screw, Cap ‹ Spacer, Speedometer Bracket ‹ Bearing ‹ Sleeve, Driveshaft ‹ Ring, Retaining ‹ Fitting, Adapter Plate, Mounting - Speedometer Sensor Screw, Machine Clamp, Speedometer Sensor Sensor, Speedometer Rivet Shield, Bearing

13

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2008 Crossfire 800 EFI

GEARCASE ASSEMBLY (Complete Gearcase Assembly p/n 0702-956) 0742-439 *Not a Service Part **Not Illustrated

1 2 3 4

0702-951 1602-915 2602-172 0702-891

1 4 1 1

5 6 7 8 9 10 11 12 13 14 15 16 17 18

1602-916 0630-228 0423-538 0630-220 8468-536 1702-003 2602-013 2602-057 2602-007 2602-127 0702-910 2602-040 2602-064 *

1 1 1 1 3 1 2 2 1 2 1 1 1 1

14

Gearcase (inc. 2-3) ‹ Pin, Dowel ‹ Seal, Oil Bracket, Mounting - Reverse Actuator (inc. 5-6) ‹ Bearing ‹ Switch, Alarm Screw, Self-Tapping Actuator, Reverse Screw, Machine Fork, Shift - Assembly (inc. 11-13) ‹ Seal, Oil ‹ Ring, Retaining ‹ Arm, Shift Fork Block, Slider Slider Assembly (inc. 16-20) ‹ Ring, Retaining ‹ Washer, Thrust ‹ Shaft, Output (inc. 19)

19 * 20 2602-063 21 0702-848 22 23 24 25 26 27 28 29 30 31 32 33 34 35 **

1 1 1

‹ ‹ Bearing ‹ Slider Gear, Transfer - 60T/34T - Assembly (inc. 22-27 and one No. 28) 1602-842 1 ‹ Bearing 2602-058 1 ‹ Washer, Spacer 0702-867 1 ‹ Gear, Planetary - Assembly 1602-840 1 ‹ Bearing, Thrust 1602-841 1 ‹ Washer, Thrust 0702-847 1 ‹ Gear, Transfer (inc. one No. 28) 1602-981 2 ‹ ‹ Bearing 0702-691 1 Shaft, Input - 60T (inc. one No. 28) 0702-953 1 Cover, Gearcase (inc. 31-34) 2602-160 1 ‹ Seal, Oil 1602-982 1 ‹ Bearing 2602-099 2 ‹ Plug, Gearcase 1602-213 2 ‹ O-Ring 1623-683 13 Screw, Machine 4639-628 AR Fluid, Gearcase - 12 oz

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2008 Crossfire 800 EFI

SLIDE RAIL AND TRACK ASSEMBLY (Complete Skid Frame Assembly p/n 7999-236; p/n 7999-237 Sno Pro; p/n 7999-987 Nightfire Sno Pro) 0741-622

1 3604-009 1704-712 2 0604-930 0704-501 3 1623-248 4 2604-281 1704-077 5 8002-043 6 8050-217 7 2604-842 8 8047-366 9 0123-859 10 2604-257 11 8060-633 12 0604-918 13 0604-967 14 8020-132

2 2 2 2 4 1 1 2 4 2 8 2 2 8 4 8 4

Rail, Formed Rail, Formed (Nightfire Sno Pro) Axle, Inner Axle, Inner (Nightfire Sno Pro) Screw, Cap Spacer Spacer, (Nightfire Sno Pro) Screw, Cap Washer End Cap, Slide Rail Nut, Lock Screw, Machine Wearstrip, Slide Rail Rivet, Blind Pad, Shock Bracket, Retaining Screw, Cap

15 16 17 18 19 20 21 22 23 24 25 26 27

2604-593 8047-426 1623-427 2604-562 0704-352 0704-503 8002-042 8005-676 0623-044 2604-860 2604-046 8041-486 1602-997 2602-005

4 4 2 2 2 2 4 2 2 2 2 2 1 1

Bracket, Mounting - Front Arm Nut, Lock Screw, Cap Bushing, Stop - Rear Arm Adjuster, Track Adjuster, Track (Nightfire Sno Pro) Screw, Cap Screw, Cap Washer Block, Rear Arm Coupler Bushing, Coupler Block Nut, Lock Track Assembly (inc. 27) Track Assembly (inc. 27) (International Sno Pro) 2602-037 36 ‹ Clip, Guide

15

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2008 Crossfire 800 EFI

IDLER WHEEL ASSEMBLY 0741-625

1 8020-232 2 8050-282 3 3604-048 3604-386

Screw, Cap Washer Wheel, Idler - Orange (inc. 4-5) Wheel, Idler - Black (inc. 4-5) (Nightfire Sno Pro) 4 3604-033 4 ‹ Bearing 5 0623-946 4 ‹ Ring, Retaining 6 2604-579 4 Block, Mounting - Idler Wheel 7 8020-224 4 Screw, Cap 8 8047-486 10 Nut, Lock 9 1604-792 1 Axle 10 0623-912 2 Washer 11 1604-793 2 Spacer, Shock - Front Arm 1704-078 2 Spacer, Shock - Front Arm (Nightfire Sno Pro) 12 1623-037 2 Screw, Cap 13 8050-272 2 Washer 14 8047-490 2 Nut, Lock 15 3604-039 2 Wheel, Idler (inc. 4-5) 16 0604-912 2 Block, Slide 17 2604-515 2 Slide, Spring 18 8020-228 2 Screw, Cap 19 2604-109 2 Spacer 1704-713 2 Spacer (Nightfire Sno Pro) 20 1604-209 1 Axle 21 0704-994 1 Pivot, Rear Shock (inc. 22-24) 22 1623-010 1 ‹ Fitting, Grease 23 1623-011 1 ‹ Washer, Grease Fitting 24 0603-083 2 ‹ Bearing 25 1623-248 4 Screw, Cap

16

4 6 2 2

26 27 28 29 30 31

1604-684 0107-598 0123-798 1604-772 1604-773 1604-213 0704-499 0623-675 0604-930 1604-214 0704-500 1604-217 0604-144 0704-504 0604-968 1604-685 0604-937 0704-505 0623-220 8051-277 8042-486 0623-123 0604-936 3604-018 3604-387

2 6 6 4 4 2 2 4 1 1 1 1 1 1 6 2 2 2 2 2 2 2 2 2 2

46 1604-774 47 0123-570 48 0604-246

2 2 2

32 33 34 35 36 37 38 39 40 41 42 43 44 45

Wheel, Idler (inc. 27-30) ‹ Bearing ‹ Ring, Retaining ‹ Insert, Wheel - Inside ‹ Insert, Wheel - Outside Spacer Spacer (Nightfire Sno Pro) Washer Axle Spacer Spacer (Nightfire Sno Pro) Axle, Rear Spacer, Rear Wheel Spacer, Rear Wheel (Nightfire Sno Pro) Bushing, Spacer Wheel, Idler (inc. 27-30) Spacer, Rear Wheel Spacer, Rear Wheel (Nightfire Sno Pro) Washer Washer, Lock Nut Screw, Cap Bushing, Adjuster Wheel, Idler - Orange (inc. 4-5 and 46) Wheel, Idler - Black (inc. 4-5 and 46) (Nightfire Sno Pro) ‹ Insert, Wheel Washer Cap, Idler Wheel

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2008 Crossfire 800 EFI

REAR SUSPENSION FRONT ARM ASSEMBLY 0741-626

1 2 3 4 5 6 7 8 9 10 11

1704-401 0604-889 1623-010 8047-486 8020-228 0104-629 8020-229 1604-162 0114-197 0604-790 3604-025

1 8 2 4 2 2 2 2 2 1 2

Arm, Front Suspension (inc. 2-3) ‹ Bushing ‹ Fitting, Grease - Self-Tapping Nut, Lock Screw, Cap Spacer, Front Arm Screw, Cap Axle, Front Arm Washer Cover, Shock Strap, Limiter

12 13 14 15 16 17 18 19 20 21

8002-041 0623-875 8047-366 8002-045 8041-486 1603-890 1603-531 8020-226 1704-463 1704-461

2 6 4 2 1 1 1 1 1 1

Screw, Cap Washer Nut, Lock Screw, Cap Nut, Hex Retainer, Spring Axle, Shock Screw, Cap Shock Absorber, Front Arm Spring, Compression - Black

17

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2008 Crossfire 800 EFI

REAR SUSPENSION FRONT ARM ASSEMBLY (Sno Pro) 0740-982

1 2 3 4 5 6 7 8 9 10 11

18

1704-401 0604-889 1623-010 8047-486 8020-228 0104-629 8020-229 1604-162 0114-197 0604-790 3604-025

1 8 2 4 2 2 2 2 2 1 2

Arm, Front Suspension (inc. 2-3) ‹ Bushing ‹ Fitting, Grease - Self-Tapping Nut, Lock Screw, Cap Spacer, Front Arm Screw, Cap Axle, Front Arm Washer Cover, Shock Strap, Limiter

12 13 14 15 16 17 18 19 20 21

8002-041 0623-875 8047-366 8002-045 1704-482 1603-890 1603-531 8020-226 1704-491 8041-486

2 6 4 2 1 1 1 1 1 1

Screw, Cap Washer Nut, Lock Screw, Cap Shock Absorber, Front Arm Retainer, Spring Axle, Shock Screw, Cap Spring, Compression - Black Nut, Lock

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2008 Crossfire 800 EFI

REAR SUSPENSION FRONT ARM SHOCK ABSORBER (Complete Shock Absorber p/n 1704-463) 0740-461

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1604-796 2604-365 1703-453 1604-271 1604-272 2603-054 2603-064 2603-076 2603-096 2603-136 0603-953 1604-274 2603-125 2603-095 2603-075

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Eyelet, Shock Rod, Shock Cap, Shock (inc. 4) ‹ O-Ring Washer, Top Out Valve, 0.800 x 0.008 in. Valve, 0.900 x 0.008 in. Valve, 1.000 x 0.012 in. Valve, 1.100 x 0.012 in. Valve, 1.300 x 0.012 in. Piston, 0.093 in. - Orifice Strap, Piston - Teflon Valve, 1.250 x 0.010 in. Valve, 1.100 x 0.010 in. Valve, 1.000 x 0.010 in.

16 17 18 19 20 21 22 23 24 25 26 27 28 29

2603-065 1 2603-055 1 1604-273 1 0623-696 1 0704-791 1 2604-152 1 2604-153 1 1603-911 1 2604-596 1 2604-156 1 0704-796 1 2604-162 1 0624-546 1 4639-366 AR

Valve, 0.900 x 0.010 in. Valve, 0.800 x 0.010 in. Washer, Backup Nut, Lock Piston, Floating (inc. 21-22) ‹ O-Ring ‹ Strap, Piston - Teflon Nut, Spring Adjuster Body, Shock Sleeve, Shock Eyelet Valve, Pressure (inc. 27) ‹ O-Ring, Valve Screw, Valve Oil, Shock - 1 qt

19

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2008 Crossfire 800 EFI

REAR SUSPENSION FRONT ARM SHOCK ABSORBER (Sno Pro) (Complete Shock Absorber p/n 1704-482) 0740-983 *Not Illustrated

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

20

0604-625 2604-872 2604-812 2604-815 2603-194 0603-540 0603-880 0603-881 0603-888 0603-890 2604-412 0603-347 0603-336 0603-333 0603-301

1 1 1 1 1 2 1 1 1 1 1 1 1 1 1

Eyelet, Shock Rod, Shock Bearing - Assembly Kit, Seal/Rebuild Spacer Washer, Top Out Valve, 0.900 x 0.012 in. Valve, 1.000 x 0.012 in. Valve, 1.100 x 0.015 in. Valve, 1.300 x 0.015 in. Piston, 0.055 in. - Orifice Valve, 1.250 x 0.010 in. Valve, 0.900 x 0.006 in. Valve, 0.800 x 0.006 in. Nut, Lock

16 17 18 19 20 21 22 23 24 25 26 27 28 29 *

2604-816 1 1604-316 1 1604-425 1 2603-245 2 2603-246 1 2604-840 1 2604-841 1 2603-475 1 2604-873 1 2604-817 1 0703-341 1 1604-318 1 0624-097 1 2604-415 1 4639-368 AR

Piston, Floating Screw, Relief (inc. 18) ‹ O-Ring Ring, Retaining Guide, Spring Nut, Spring Adjuster Nut, Locking - Spring Adjuster Nut Decal, Shock Body, Shock End Cap, Shock - Assembly (inc. 26-27) ‹ Valve, Pressure (inc. 27) ‹ ‹ O-Ring Screw, Valve Sleeve, Shock Eyelet Oil, Shock - 1 qt

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2008 Crossfire 800 EFI

REAR SUSPENSION REAR ARM ASSEMBLY 0741-875

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1704-404 1604-100 1623-010 1704-019 1623-011 1623-037 8050-272 2604-664 2604-663 8047-490 1623-086 8047-486 2604-370 1604-204 1604-205 15 0623-138 16 3604-024 17 1704-044 1704-045

1 2 2 1 1 1 1 2 1 1 1 1 1 1 1 2 2 1 1

Arm, Idler - Black (inc. 2 and one No. 3) ‹ Bushing, Flared ‹ Fitting, Grease - Self-Tapping Arm, Rear - Black (inc. one No. 3 and 5) ‹ Washer, Grease Fitting Screw, Cap Washer Bushing, Rear Arm Axle, Rear Arm - Inner Nut, Lock Screw, Cap Nut, Lock Axle, Steel Block, Spring Adjuster - Right Block, Spring Adjuster - Left Ring, Retaining Sleeve, Spring Spring, Suspension - Right Spring, Suspension - Left

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

1604-690 0107-598 0123-798 2604-980 3604-158 1604-187 1704-522 3604-028 8020-138 8047-426 1623-166 0623-793 1604-498 1704-416 0604-298 8041-486 1604-139 8020-226 1704-117

2 2 2 2 2 2 2 2 4 4 2 2 4 2 1 3 2 1 1

Wheel, Idler (inc. 19-20) ‹ Bearing ‹ Ring, Retaining Spacer, Pivot - Idler Arm Axle, Powder Metal Washer, Pivot - Idler Arm Arm, Pivot Idler (inc. 25-27) ‹ Bushing, Flared ‹ Screw, Cap ‹ Nut, Lock Screw, Cap Screw, Cap Axle, Link - Flanged Link, Rear Shock - Black Spacer, Shock Link - Black Nut, Lock Sleeve, Shock Screw, Cap Shock Absorber - Rear Arm

21

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2008 Crossfire 800 EFI

REAR SUSPENSION REAR ARM ASSEMBLY (Sno Pro) 0741-874

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

22

1704-404 1604-100 1623-010 1704-019 1623-011 1623-037 8050-272 2604-664 2604-663 8047-490 1623-086 8047-486 2604-370 1604-204 1604-205 0623-138 3604-024 1704-044 1704-045 1604-690

1 2 2 1 1 1 1 2 1 1 1 1 1 1 1 2 2 1 1 2

Arm, Idler - Black (inc. 2 and one No. 3) ‹ Bushing, Flared ‹ Fitting, Grease - Self-Tapping Arm, Rear - Black (inc. one No. 3 and 5) ‹ Washer, Grease Fitting Screw, Cap Washer Bushing, Rear Arm Axle, Rear Arm - Inner Nut, Lock Screw, Cap Nut, Lock Axle, Steel Block, Spring Adjuster - Right Block, Spring Adjuster - Left Ring, Retaining Sleeve, Spring Spring, Suspension - Right Spring, Suspension - Left Wheel, Idler (inc. 19-20)

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

0107-598 0123-798 2604-980 3604-158 1604-187 1704-522 3604-028 8020-138 8048-426 1623-166 1623-219 1604-498 1704-416 0604-298 8041-486 1604-139 8020-226 1704-484 0623-044

2 2 2 2 2 2 2 4 4 2 2 4 2 1 3 2 1 1 4

‹ Bearing ‹ Ring, Retaining Spacer, Pivot - Idler Arm Axle, Powder Metal Washer, Pivot - Idler Arm Arm, Pivot Idler (inc. 25-27) ‹ Bushing, Flared ‹ Screw, Cap ‹ Nut, Lock Screw, Cap Screw, Cap Axle, Link - Flanged Link, Rear Shock - Black Spacer, Shock Link - Black Nut, Lock Sleeve, Shock Screw, Cap Shock Absorber - Rear Arm Washer

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2008 Crossfire 800 EFI

REAR SUSPENSION REAR ARM SHOCK ABSORBER (Complete Shock Absorber p/n 1704-117) 0738-688

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

2604-598 1603-503 2604-599 1703-452 1604-271 1603-314 1604-274 1604-272 2603-065 2603-075 2603-095 2603-125 2603-040 2603-094 2603-135 2603-126

1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 2

Body, Shock Eyelet, Shock Rod, Shock Cap, Shock (inc. 5) ‹ O-Ring Piston, 0.039 in. - Orifice Strap, Piston - Teflon Washer, Top Out Valve, 0.900 x 0.010 in. Valve, 1.000 x 0.010 in. Valve, 1.100 x 0.010 in. Valve, 1.250 x 0.010 in. Valve, 0.700 x 0.004 in. Valve, 1.100 x 0.008 in. Valve, 1.300 x 0.010 in. Valve, 1.250 x 0.012 in.

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

2603-096 1 2603-076 1 2603-055 1 1604-273 1 0623-696 1 0704-791 1 2604-153 1 2604-152 1 2604-164 2 1604-397 2 2604-649 1 2604-162 1 0624-433 1 1604-262 2 4639-366 AR

Valve, 1.100 x 0.012 in. Valve, 1.000 x 0.012 in. Valve, 0.800 x 0.010 in. Washer, Backup Nut, Lock Piston, Floating (inc. 23-24) ‹ Strap, Piston - Teflon ‹ O-Ring Bushing, Shock Sleeve, Eyelet Valve, Pressure (inc. 28) ‹ O-Ring Screw, Valve Bushing, Shock Oil, Shock - 1 qt

23

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2008 Crossfire 800 EFI

REAR SUSPENSION REAR ARM SHOCK ABSORBER (Sno Pro) (Complete Shock Absorber p/n 1704-484) 0740-988

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

24

0604-893 2604-223 1604-222 2604-622 2604-627 2604-880 2604-530 2603-466 0603-338 0603-341 0603-350 2604-647 2604-631 0603-337 2604-645 2604-633

1 2 4 1 1 1 1 1 1 1 1 1 5 1 1 1

Eyelet, Shock Sleeve, Eyelet Bushing, Shock Rod, Shock Bearing - Assembly Kit, Seal/Rebuild Screw Washer, Top Out Valve, Shock 0.900 x 0.010 in. Valve, Shock 1.000 x 0.010 in. Valve, Shock 1.300 x 0.010 in. Valve, Shock 1.425 x 0.010 in. Valve, Shock 1.600 x 0.010 in. Valve, Shock 0.900 x 0.008 in. Piston, 0.055 in. - Orifice Valve, Shock 1.425 x 0.015 in.

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

2604-632 1 0603-891 1 0603-882 1 0603-881 1 0603-886 1 0603-885 1 0603-389 1 0603-301 1 2604-886 1 2604-621 1 2604-889 1 0703-341 1 1604-318 1 0624-097 1 4639-368 AR

Valve, Shock 1.425 x 0.012 in. Valve, Shock 1.300 x 0.012 in. Valve, Shock 1.100 x 0.012 in. Valve, Shock 1.000 x 0.012 in. Valve, Shock 0.900 x 0.015 in. Valve, Shock 0.800 x 0.015 in. Washer, Backup Nut Piston, Floating Body, Shock Decal, Shock Valve, Pressure - Assembly (inc. 29) ‹ O-Ring Screw, Valve Oil, Shock - 1 qt

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2008 Crossfire 800 EFI

FRONT FRAME AND FOOTREST ASSEMBLY (Complete Chassis Assembly p/n 1707-227; p/n 1707-229 Nightfire Sno Pro) 0742-797

1 1707-178 1707-228 2 3 4 5 6 7 8 9 10 11 12

1623-359 1623-019 0675-161 0607-656 0607-657 1623-010 0623-581 1623-022 1623-480 1623-481 4606-200 3706-450

1 1 3 2 4 2 6 2 8 2 4 3 1 1

13 14 15 16 17 18 19 20

1623-561 1 4606-793 1 1623-353 3 1623-204 1 0608-449 1 8041-426 1 2706-580 2 8060-686 AR 8061-706 AR 21 4706-034 1 4706-035 1 4706-192 1 4706-193

1

22 8060-484 AR 8060-504 AR 23 3606-837 2

Chassis - Assembly (inc. 2-8) Chassis - Assembly - Black (inc. 2-8) (Nightfire Sno Pro) ‹ Bolt, Carriage - Ribbed ‹ Bolt, Carriage - Ribbed ‹ Bearing ‹ Bushing, Upper A-Arm Mount ‹ Bushing, Lower A-Arm Mount ‹ Fitting, Grease ‹ Insert Screw Screw, Cap Screw, Cap Brace, Side Plate - Right Brace, Side Plate - Right - Black (Nightfire Sno Pro) Screw, Cap Protector, Main Harness Screw, Self-Tapping Screw, Self-Tapping Guide, Rope Nut, Lock Plate, Backing Rivet Rivet (Nightfire Sno Pro) Footrest - Right (inc. 22-24 and 26) Footrest - Left (inc. 22-26) Footrest - Right - Black (inc. 22-24 and 26) (Nightfire Sno Pro) Footrest - Left - Black (inc. 22-26) (Nightfire Sno Pro) ‹ Rivet ‹ Rivet (Nightfire Sno Pro) ‹ Plate, Retaining

3706-335

2

‹ Plate, Retaining - Black (Nightfire Sno Pro) 24 1623-657 8 ‹ Insert 25 0607-835 1 ‹ Plate, Mounting - Belt Guard 26 1623-706 4 ‹ Stud, Captive 27 1623-529 2 Grommet 28 1623-264 8 Rivet 29 3606-904 1 Bracket, Support - Footrest - Right 4606-353 1 Bracket, Support - Footrest - Left 3706-336 1 Bracket, Support - Footrest - Right - Black (Nightfire Sno Pro) 3706-692 1 Bracket, Support - Footrest - Left - Black (Nightfire Sno Pro) 30 3706-673 1 Panel, Close-Out - Footrest (inc. two No. 24) 31 1623-498 12 Screw, Machine 32 4606-742 1 Bracket, Support - Footrest - Lower Right 4606-743 1 Bracket, Support - Footrest - Lower Left 3706-690 1 Bracket, Support - Footrest - Lower Right Black (Nightfire Sno Pro) 3706-691 1 Bracket, Support - Footrest - Lower Left Black (Nightfire Sno Pro) 33 4606-434 1 Cover, Footrest - Right 4606-435 1 Cover, Footrest - Left 34 1623-171 1 Clip 35 1623-717 4 Clip, Routing 36 1623-406 7 Clip, Routing 37 3706-921 1 Brace, Side Plate - Left 4706-153 1 Brace, Side Plate - Left - Black (Nightfire Sno Pro) 38 3706-613 1 Bracket, Mounting - Servomotor (inc. 39) 39 0706-371 AR ‹ Trim 40 5606-208 1 Clip, Servomotor 41 2606-129 1 Cover, Servomotor 42 8047-366 2 Nut, Lock

25

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2008 Crossfire 800 EFI

HOOD AND WINDSHIELD ASSEMBLY 0742-414

1 2718-264 2718-266

1 1

2 2718-146 2718-147

1 1

3 4 5 6

2 2 1 1 1 1 1 1 1 1 1 1 1 1

1623-026 0623-847 6611-143 6611-144 6611-145 7 8611-168 8611-169 8611-172 8611-173 8 8611-156 8611-157 8611-174 8611-175 9 8611-267

26

Hood w/Decals - Black (inc. 2-9) Hood w/Decals - Orange (inc. 2-9) (Sno Pro) ‹ Hood w/o Decals - Black (inc. 3-6) ‹ Hood w/o Decals - Orange (inc. 3-6) (Sno Pro) ‹ ‹ Pin, Clevis ‹ ‹ Clip, Hairpin ‹ ‹ Decal, Caution ‹ ‹ Decal, Warning - English ‹ ‹ Decal, Warning - French ‹ Decal, Hood - Lower Right ‹ Decal, Hood - Lower Left ‹ Decal, Hood - Lower Right (Sno Pro) ‹ Decal, Hood - Lower Left (Sno Pro) ‹ Decal, Hood - Forward Right ‹ Decal, Hood - Forward Left ‹ Decal, Hood - Forward Right (Sno Pro) ‹ Decal, Hood - Forward Left (Sno Pro) ‹ Decal, AirCat - Chrome

10 2706-793 1 Screen, Vent - Center 11 3706-260 1 Screen, Vent - Front - Right 3706-261 1 Screen, Vent - Front - Left 12 2706-796 1 Screen, Vent - Rear - Right 2706-797 1 Screen, Vent - Rear - Left 13 1623-694 38 Clip, Retaining 14 0617-510 1 Foam, Hood - Right 0617-545 1 Foam, Hood - Left 15 0617-489 1 Foam, Hood - Rear 16 0623-302 4 Screw, Self-Tapping 17 2606-726 2 Cable, Hood 18 1623-052 2 U-Nut 19 5606-080 1 Bezel, Intake - Right 5606-081 1 Bezel, Intake - Left 20 0617-486 1 Foam, Intake Bezel - Right 0617-487 1 Foam, Intake Bezel - Left 21 0623-362 6 Rivet, Reinstallable 22 4606-117 1 Windshield 3606-868 1 Windshield (Sno Pro) 23 0616-032 2 O-Ring

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2008 Crossfire 800 EFI

HOOD AND WINDSHIELD ASSEMBLY (Nightfire Sno Pro) 0742-824

1 2 3 4 5 6 7 8 9 10 11 12

2718-457 2718-146 1623-026 0623-847 6611-143 6611-144 6611-145 8611-314 8611-315 8611-306 8611-267 2706-793 3706-260 3706-261 2706-796 2706-797

1 1 2 2 1 1 1 1 1 2 1 1 1 1 1 1

Hood w/Decals - Black (inc. 2-9) ‹ Hood w/o Decals - Black (inc. 3-6) ‹ ‹ Pin, Clevis ‹ ‹ Clip, Hairpin ‹ ‹ Decal, Caution ‹ ‹ Decal, Warning - English ‹ ‹ Decal, Warning - French ‹ Decal, Hood - Lower Right ‹ Decal, Hood - Lower Left ‹ Decal, Hood - “Arctic Cat” ‹ Decal, AirCat - Chrome Screen, Vent - Center Screen, Vent - Front - Right Screen, Vent - Front - Left Screen, Vent - Rear - Right Screen, Vent - Rear - Left

13 1623-694 38 Clip, Retaining 14 0617-510 1 Foam, Hood - Right 0617-545 1 Foam, Hood - Left 15 0617-489 1 Foam, Hood - Rear 16 0623-302 4 Screw, Self-Tapping 17 2606-726 2 Cable, Hood 18 1623-052 2 U-Nut 19 5606-080 1 Bezel, Intake - Right 5606-081 1 Bezel, Intake - Left 20 0617-486 1 Foam, Intake Bezel - Right 0617-487 1 Foam, Intake Bezel - Left 21 0623-362 6 Rivet, Reinstallable 22 3606-868 1 Windshield 23 0616-032 2 O-Ring

27

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2008 Crossfire 800 EFI

HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES 0742-800

1 2 3 4 5 6 7 8 9 10 11

28

0620-318 0620-322 0423-493 0609-848 0609-849 0609-251 0609-693 1623-025 0623-360 1623-024 1623-137 1623-272 1623-273

1 1 2 1 1 2 2 2 2 2 2 2 2

Tachometer/Speedometer Bracket, Retaining Nut w/Washer Lens/Reflector - Headlight - Right (inc. 5-6) Lens/Reflector - Headlight - Left (inc. 5-6) ‹ Bulb, Headlight ‹ Bulb, Headlight Insert Spring, Adjuster Screw, Adjuster Clip, Hairpin Clip - Right Clip - Left

12 13 14 15 16 17 18 19 20 21 22 23 24

0617-501 2 Foam, Hood/Headlight 1686-396 1 Harness, Hood 1686-392 1 Harness, Main (inc. 15-17) 0630-024 1 ‹ Fuse, 15 Amp 0630-102 1 ‹ Cover, Fuse 0486-164 1 ‹ Tether, Accessory Connector 1686-160 1 Harness, Extension - Taillight 0123-788 AR Cable Tie - 8 in. 0630-010 1 Alarm, Reverse (inc. 21) 0630-017 1 ‹ Ring, Retaining 0630-245 1 Unit, Chassis Control 8047-366 2 Nut, Lock 8017-584 2 Screw, Cap

Arctic Cat Parts & Free Mechanical Advice | www.FunOutfitters.com | 1 866-531-0123

2008 Crossfire 800 EFI

HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES (Sno Pro) 0742-801

1 2 3 4 5 6 7 8 9 10 11

0620-319 0620-322 0423-493 0609-848 0609-849 0609-251 0609-693 1623-025 0623-360 1623-024 1623-137 1623-272 1623-273

1 1 2 1 1 2 2 2 2 2 2 2 2

Tachometer/Speedometer Bracket, Retaining Nut w/Washer Lens/Reflector - Headlight - Right (inc. 5-6) Lens/Reflector - Headlight - Left (inc. 5-6) ‹ Bulb, Headlight ‹ Bulb, Headlight Insert Spring, Adjuster Screw, Adjuster Clip, Hairpin Clip - Right Clip - Left

12 13 14 15 16 17 18 19 20 21 22 23 24

0617-501 2 Foam, Hood/Headlight 1686-396 1 Harness, Hood 1686-392 1 Harness, Main (inc. 15-17) 0630-024 1 ‹ Fuse, 15 Amp 0630-102 1 ‹ Cover, Fuse 0486-164 1 ‹ Tether, Accessory Connector 1686-160 1 Harness, Extension - Taillight 0123-788 AR Cable Tie - 8 in. 0630-010 1 Alarm, Reverse (inc. 21) 0630-017 1 ‹ Ring, Retaining 0630-245 1 Unit, Chassis Control 8047-366 2 Nut, Lock 8017-584 2 Screw, Cap

29

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2008 Crossfire 800 EFI

CONSOLE AND SWITCH ASSEMBLY 0742-452

1 2 3 4 5 6 7

30

3606-442 6611-581 8050-157 8041-246 0609-728 * 0609-113

1 1 4 4 1 1 1

Console Decal, Console Washer Nut, Lock Switch, Ignition (inc. 6) ‹ Key Nut, Retaining

8 0123-899 9 0609-450 10 8468-511

1 1 7

Washer, Ignition Switch Spacer, Ignition Switch Screw, Machine *Key is coded to switch; see dealer to determine part number.

Arctic Cat Parts & Free Mechanical Advice | www.FunOutfitters.com | 1 866-531-0123

2008 Crossfire 800 EFI

BELLY PAN ASSEMBLY 0742-408

1 3706-606 3706-429 2 4606-256 4606-257 3 1623-666 4 1623-546 5 0617-502 0617-503 6 1623-694 7 3606-867 8 4606-040 9 2606-911 10 0623-784 11 0623-797 12 1623-129 13 1612-853 14 1612-861 15 0623-778 16 1623-030

1 1 1 1 2 2 1 1 11 1 1 1 10 29 6 1 1 14 2

Belly Pan - Right - Black Belly Pan - Left - Black Panel, Access - Right - Black Panel, Access - Left - Black Screw, Retaining - Access Panel Pin, Retaining Foam, Side Panel - Right Foam, Side Panel - Left Clip, Retaining Belly Pan, Center - Black Bumper, Front - Black Screen, Belly Pan - Center Screw, Self-Tapping Screw, Self-Tapping Screw, Self-Tapping Shield, Heat Deflector, Exhaust - Outlet Rivet Nut, Speed

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

8017-581 8050-217 8047-366 8611-260 5606-052 4606-207 4606-208 0607-447 0605-283 8061-426 4606-417 0123-802 8061-628 4606-993 7611-160 7611-161 32 8611-158 8611-159 33 2606-624

4 4 4 1 1 1 1 2 2 2 1 5 7 1 1 1 1 1 2

Screw, Machine Washer Nut, Lock Decal, Clutching Foil, Protective - Access Panel Foil, Protective - Upper Foil, Protective - Lower Cable Clip, Hairpin Rivet Protector, Driven Clutch Washer Rivet Deflector, Driven Clutch Protector Decal, Reflector - Amber - Right Decal, Reflector - Amber - Left Decal, Access Panel - Right Decal, Access Panel - Left Strap, Hold-Down

31

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2008 Crossfire 800 EFI

BELLY PAN ASSEMBLY (Sno Pro) 0742-825

1 3706-606 3706-429 2 4606-256 4606-257 3 1623-666 4 1623-546 5 0617-502 0617-503 6 1623-694 7 3606-867 8 4606-040 9 2606-911 10 0623-784 11 0623-797 12 1623-129 13 1612-853 14 1612-861 15 0623-778 16 1623-030

32

1 1 1 1 2 2 1 1 11 1 1 1 10 29 6 1 1 14 2

Belly Pan - Right - Black Belly Pan - Left - Black Panel, Access - Right - Black Panel, Access - Left - Black Screw, Retaining - Access Panel Pin, Retaining Foam, Side Panel - Right Foam, Side Panel - Left Clip, Retaining Belly Pan, Center - Black Bumper, Front - Black Screen, Belly Pan - Center Screw, Self-Tapping Screw, Self-Tapping Screw, Self-Tapping Shield, Heat Deflector, Exhaust - Outlet Rivet Nut, Speed

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

8017-581 8050-217 8047-366 8611-260 5606-052 4606-207 4606-208 0607-447 0605-283 8061-426 4606-417 0123-802 8061-628 4606-993 7611-160 7611-161 32 8611-176 8611-177 33 2606-624

4 4 4 1 1 1 1 2 2 2 1 5 7 1 1 1 1 1 2

Screw, Machine Washer Nut, Lock Decal, Clutching Foil, Protective - Access Panel Foil, Protective - Upper Foil, Protective - Lower Cable Clip, Hairpin Rivet Protector, Driven Clutch Washer Rivet Deflector, Driven Clutch Protector Decal, Reflector - Amber - Right Decal, Reflector - Amber - Left Decal, Access Panel - Right Decal, Access Panel - Left Strap, Hold-Down

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2008 Crossfire 800 EFI

BELLY PAN ASSEMBLY (Nightfire Sno Pro) 0742-826

1 3706-606 3706-429 2 4606-256 4606-257 3 1623-666 4 1623-546 5 0617-502 0617-503 6 1623-694 7 3606-867 8 4606-040 9 2606-911 10 0623-784 11 0623-797 12 1623-129 13 1712-488 14 1712-489 15 0623-778

1 1 1 1 2 2 1 1 11 1 1 1 10 29 6 1 1 14

Belly Pan - Right - Black Belly Pan - Left - Black Panel, Access - Right - Black Panel, Access - Left - Black Screw, Retaining - Access Panel Pin, Retaining Foam, Side Panel - Right Foam, Side Panel - Left Clip, Retaining Belly Pan, Center - Black Bumper, Front - Black Screen, Belly Pan - Center Screw, Self-Tapping Screw, Self-Tapping Screw, Self-Tapping Shield, Heat Deflector, Exhaust - Outlet Rivet

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1623-030 8017-581 8050-217 8047-366 8611-260 5606-052 4606-207 4606-208 0607-447 0605-283 8061-426 4606-417 0123-802 8061-628 4606-993 7611-160 7611-161 32 2606-624

2 4 4 4 1 1 1 1 2 2 2 1 5 7 1 1 1 2

Nut, Speed Screw, Machine Washer Nut, Lock Decal, Clutching Foil, Protective - Access Panel Foil, Protective - Upper Foil, Protective - Lower Cable Clip, Hairpin Rivet Protector, Driven Clutch Washer Rivet Deflector, Driven Clutch Protector Decal, Reflector - Amber - Right Decal, Reflector - Amber - Left Strap, Hold-Down

33

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2008 Crossfire 800 EFI

BELT GUARD ASSEMBLY 0741-638

1 2 3 4

34

1707-094 1611-565 3611-969 0707-582

1 1 1 1

Guard, Belt Decal, Warning - Belt Guard Decal, “ACT - Roller Driven Clutch” Retainer, Drive Belt

5 0617-497 6 0607-836 7 8061-506

1 1 4

Foam, Belt Guard Bracket, Mounting Rivet

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2008 Crossfire 800 EFI

GAS TANK ASSEMBLY 0742-454

1 2 3 4 5 6

0770-810 1670-824 0470-400 1670-447 1670-511 1705-116

1 1 1 1 1 1

7 8 9 10

1623-447 1623-448 1623-483 1670-801

2 4 2 1

Tank, Gas (inc. 2-16) ‹ Gauge, Fuel w/Seal (inc. 3) ‹ ‹ Seal, Fuel Gauge ‹ Cap, Gas Tank (inc. 5) ‹ ‹ Seal, Gas Tank Cap ‹ Plate, Mounting - Steering Post (inc. 7 and two No. 8) ‹ ‹ Bolt, Carriage ‹ ‹ O-Ring ‹ Nut, Aluminum ‹ Neck, Gas Tank Extension

11 12 13 14 15 16 17 18 19 20

8061-630 3606-173 4606-160 8050-157 5606-107 5606-049 8047-366 0123-765 1623-077 8017-582

2 1 1 2 1 1 2 2 2 2

‹ Rivet ‹ Strap, Hold-Down - Coolant Tank ‹ Strap, Hold-Down - Spark Plug ‹ Washer ‹ Foil, Protective ‹ Foil, Protective Nut, Lock Washer, Cup Nut Screw, Machine

35

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2008 Crossfire 800 EFI

FUEL PUMP ASSEMBLY 0742-122

1 2 3 4 5 6 7 8 9 10 11

36

1670-851 1 1670-535 1 1670-476 1 1670-475 1 1670-534 1 1670-479 1 1670-478 1 1670-477 1 1670-579 1 0610-563 2 0610-691 AR

Pump, Fuel - Assembly (inc. 2-9) ‹ Grommet ‹ O-Ring ‹ Nut, Fuel Pump Fitting ‹ Grommet ‹ Washer, Sealing - Threaded ‹ Washer ‹ Nut, Mounting ‹ Retainer, Wire Clamp, Hose Hose, Gasline - 10 ft

12 13 14 15 16 17 18 19 20 21

1670-701 1 1670-706 6 1670-703 1 1670-705 1 1670-702 1 1670-619 1 1670-704 1 1670-618 1 0623-373 2 0716-507 AR

Pickup, Fuel Clamp, Hose Hose, Gasline Y-Fitting Hose, Gasline Pickup, Fuel Hose, Gasline Pickup, Fuel Clamp, Hose Conduit, Flexible

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2008 Crossfire 800 EFI

SEAT ASSEMBLY 0742-411 *Not Illustrated

1 2 3 4 5 6 7

7999-544 1 Complete Seat Assembly (inc. 2-8) 3706-889 1 ‹ Cover, Seat 0624-528 AR ‹ Staple, Seat Cover 3706-118 1 ‹ Foam, Seat Cushion 4606-128 1 ‹ Seat-Base 1623-393 2 ‹ Clip, Retaining - Seat-Base 0123-788 2 ‹ Cable Tie - 8 in.

8 9 10 11 12 13 *

0617-512 8047-426 1623-458 4606-322 8061-628 3706-033 3706-731

1 2 2 1 1 1 1

‹ Foam, Compartment - Seat Nut, Lock Stud, Latch - Seat-Base Cover, Latch - Seat - Right Rivet Retainer, Tool Kit Kit, Tool

37

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2008 Crossfire 800 EFI

SEAT ASSEMBLY (Nightfire Sno Pro) 0742-631 *Not Illustrated

1 2 3 4 5 6 7

38

7999-989 1 Complete Seat Assembly (inc. 2-8) 4706-150 1 ‹ Cover, Seat 0624-528 AR ‹ Staple, Seat Cover 3706-118 1 ‹ Foam, Seat Cushion 4606-128 1 ‹ Seat-Base 1623-393 2 ‹ Clip, Retaining - Seat-Base 0123-788 2 ‹ Cable Tie - 8 in.

8 9 10 11 12 13 *

0617-512 8047-426 1623-458 4606-322 8061-628 3706-033 3706-731

1 2 2 1 1 1 1

‹ Foam, Compartment - Seat Nut, Lock Stud, Latch - Seat-Base Cover, Latch - Seat - Right Rivet Retainer, Tool Kit Kit, Tool

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2008 Crossfire 800 EFI

TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY (Complete Chassis Assembly p/n 1707-227) 0742-633

1 2718-509

1

2 3 4 5 6 7

2718-507 1623-562 1623-657 2718-508 0623-582 3706-152

1 8 4 1 2 1

3706-153

1

8 8060-686 AR 9 8060-482 AR 10 5606-402 1 5606-403 1 11 8060-688 4 12 8060-484 10 13 4606-050 1 4606-051 1 14 1623-022 4 15 3606-584 2 16 1623-499 10 17 4606-149 1 18 0623-562 1 19 0509-022 1 20 0509-025 1

Tunnel Assembly (inc. 2-11 and seven No. 12) ‹ Tunnel, Front (inc. 3-4) ‹ ‹ Insert ‹ ‹ Insert ‹ Tunnel, Rear (inc. 6) ‹ ‹ Insert ‹ Bracket, Suspension Mounting - Right Rear ‹ Bracket, Suspension Mounting - Left Rear ‹ Rivet ‹ Rivet ‹ Bracket, Tunnel Support - Right ‹ Bracket, Tunnel Support - Left ‹ Rivet ‹ Rivet Roll, Tunnel - Right Roll, Tunnel - Left Screw, Self-Tapping Rack Screw, Machine Pad, Rubber Plug, Hole Taillight Assembly (inc. 20-22) ‹ Housing, Taillight

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

0409-057 0409-056 4606-382 3606-747 8050-127 0623-297 1623-513 3606-431 5611-853 5611-852 1623-501 8017-581 8611-010 8611-011 4606-227 3606-776 0623-184 8047-366 8060-486 3002-964 0123-788 1623-671 1623-045 8611-164 8611-165

1 1 1 1 2 2 1 1 1 1 2 4 1 1 1 1 4 4 1 1 1 8 8 1 1

‹ Socket, Taillight ‹ Bulb, Taillight Spacer, Taillight Housing, Taillight Mounting Washer Screw, Self-Tapping Screw, Machine Bumper, Rear Decal, Warning - Towing (English) Decal, Warning - Towing (French) Screw, Machine Screw, Machine Decal, Reflector - Red - Right Decal, Reflector - Red - Left Snowflap Support, Snowflap Washer Nut, Lock Rivet Clamp, Wire Cable Tie Screw, Machine Spacer Decal, Tunnel - Right Decal, Tunnel - Left

39

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2008 Crossfire 800 EFI

TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY (Nightfire Sno Pro) (Complete Chassis Assembly p/n 1707-229) 0742-637

1 2718-512

1

2 3 4 5 6 7

2718-510 1623-562 1623-657 2718-511 0623-582 3706-152

1 8 4 1 2 1

3706-153

1

8 8061-706 AR 9 8060-482 AR 10 4706-170 1 4706-171 1 11 8060-708 4 12 8060-504 10 13 4706-168 1 4706-169 1 14 1623-022 4 15 3606-584 2 16 1623-499 10 17 4606-149 1 18 0623-562 1 19 0509-022 1

40

Tunnel Assembly - Black (inc. 2-11 and seven No. 12) ‹ Tunnel, Front - Black (inc. 3-4) ‹ ‹ Insert ‹ ‹ Insert ‹ Tunnel, Rear - Black (inc. 6) ‹ ‹ Insert ‹ Bracket, Suspension Mounting - Right Rear ‹ Bracket, Suspension Mounting - Left Rear ‹ Rivet ‹ Rivet ‹ Bracket, Tunnel Support - Right - Black ‹ Bracket, Tunnel Support - Left - Black ‹ Rivet ‹ Rivet Roll, Tunnel - Right - Black Roll, Tunnel - Left - Black Screw, Self-Tapping Rack Screw, Machine Pad, Rubber Plug, Hole Taillight Assembly (inc. 20-22)

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

0509-025 0409-057 0409-056 4606-382 3606-747 8050-127 0623-297 1623-513 3606-431 5611-853 5611-852 1623-501 8017-581 8611-010 8611-011 5606-254 3606-776 0623-184 8047-366 8060-506 3002-964 0123-788 1623-671 1623-045 8611-307

1 1 1 1 1 2 2 1 1 1 1 2 4 1 1 1 1 4 4 1 1 1 8 8 2

‹ Housing, Taillight ‹ Socket, Taillight ‹ Bulb, Taillight Spacer, Taillight Housing, Taillight Mounting Washer Screw, Self-Tapping Screw, Machine Bumper, Rear Decal, Warning - Towing (English) Decal, Warning - Towing (French) Screw, Machine Screw, Machine Decal, Reflector - Red - Right Decal, Reflector - Red - Left Snowflap Support, Snowflap Washer Nut, Lock Rivet Clamp, Wire Cable Tie Screw, Machine Spacer Decal, Tunnel - “Sno Pro”

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2008 Crossfire 800 EFI

COOLING ASSEMBLY 0742-827

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

3706-390 1 Heat Exchanger - Rear (inc. 2-3) 0623-582 1 ‹ Insert 0617-509 1 ‹ Foam, Tunnel/Heat Exchanger 8060-686 20 Rivet 1623-349 6 Clamp, Hose 0610-552 2 Hose, Coolant 3606-564 2 Protector, Hose - Rear 8060-484 AR Rivet 8060-488 AR Rivet 4606-772 1 Heat Exchanger - Right 4606-773 1 Heat Exchanger - Left 4606-270 1 Protector, Hose - Front 0610-679 1 Hose, Coolant - Front Heat Exchanger 1623-656 2 Clamp, Hose 0610-659 1 Hose, Coolant - Tank/Right Heat Exchanger 1623-093 2 Clamp, Hose

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

3706-684 1 Tank, Coolant 4606-209 1 Cap, Filler Neck 5606-040 1 Shield, Heat - Coolant Tank 0123-903 2 Cable Tie - 11.5 in. 0124-045 1 Clamp, Hose 0610-538 AR Hose, Coolant - 25 ft 2604-539 AR Loom - 10 ft 1623-619 1 Clamp, Hose 0123-788 3 Cable Tie - 7.5 in. 4606-962 1 Pad, Heat Exchanger - Front 1619-109 2 Protector, Hose - 7 in. 0610-681 1 Hose, Coolant Tank/Engine 1623-230 1 Clamp, Screw 1623-322 1 Clamp, Hose 0610-705 1 Hose, Coolant - Engine/Front Heat Exchanger 31 0619-619 1 Conduit, Flexible - 4 in.

41

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2008 Crossfire 800 EFI

ENGINE AND RELATED PARTS 0742-805

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

42

0662-514 1 Engine, AB80L1 w/o EFI Components 0636-363 1 Handle, Recoil 0606-885 1 Cap, Recoil Handle 8020-136 2 Screw, Cap 0708-471 1 Mount, Engine - MAG 8047-426 5 Nut, Lock 1623-504 4 Screw, Cap 4606-425 1 Foil, Protective 0619-619 1 Conduit, Flexible - 4 in. 1619-131 1 Conduit, Flexible (3/4 in. ID) - 12 in. 0123-788 2 Cable Tie 0623-373 4 Clamp, Hose 0610-774 1 Hose, Coolant - MAG/Throttle Body 0619-776 AR Conduit, Flexible - 5 ft 0610-699 1 Hose, Coolant - PTO/Throttle Body 1623-659 2 Clamp, Push-Mount 0708-523 1 Bracket, Engine Mounting - Assembly (inc. one No. 4, one No. 6, and 18-19)

18 0708-519

1

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

1 1 2 1 2 1 1 4 1 1 1 1 1 1 1 1

0608-549 0608-507 1623-603 0708-507 8060-730 0608-565 0608-462 8408-821 0746-192 0627-046 0623-210 0623-804 0623-677 1619-221 1619-220 0623-144

‹ Bracket, Engine Mounting - Front Lower Right ‹ Bracket, Engine Mounting - Upper Right Cap, Mounting Bracket - Engine Screw, Cap Bracket, Engine Mounting - Left (inc. 23-24) ‹ Rivet ‹ Plate, Backing - Torque Bumper Bumper, Torque Screw, Cap Clutch, Drive - Uncalibrated Belt, Drive Washer, High Collar Bolt, Clutch Cable Tie, Push-Mount Conduit, High-Temperature Conduit, High-Temperature Cable Tie, 17.5 in.

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2008 Crossfire 800 EFI

EXHAUST ASSEMBLY 0742-165

1 1712-358 1 2 1712-357 1 3 0624-552 AR 0624-541 AR 4 1612-178 3 5 2612-174 1 6 2612-168

1

7 2612-169

1

8 2612-175

1

9 2612-257

4

Chamber, Expansion - Assembly (inc. 2-8) ‹ Chamber, Expansion ‹ Tie, Perforated Band - 5 ft ‹ Tie, Perforated Band - 25 ft ‹ Spring, Exhaust ‹ Packing, Expansion Chamber - Rear Upper ‹ Cover, Expansion Chamber - Rear Upper ‹ Cover, Expansion Chamber - Rear Lower ‹ Packing, Expansion Chamber - Rear Lower Spring, Exhaust

10 11 12 13 14 15 16 17 18 19 20 21 22

2612-059 1712-300 0612-471 1612-323 1712-144 1612-873 1612-927 1623-375 1623-569 1623-379 8047-486 0630-229 0123-788

1 1 3 1 1 2 1 1 1 1 1 1 1

Gasket, Exhaust Manifold, Exhaust Spring, Extension Gasket, Exhaust - Tailpipe Resonator Assembly Grommet Washer, Tab Grommet Pin, Mounting - Resonator Clip, Hairpin Nut, Lock Sensor, Exhaust Temperature Cable Tie

43

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2008 Crossfire 800 EFI

AIR INTAKE ASSEMBLY 0742-463

1 2 3 4 5 6 7 8 9 10

44

0617-500 8017-581 5606-048 1623-137 1623-409 0623-184 8047-366 0623-600 0617-488 3606-811

2 2 1 1 2 2 2 1 1 1

Foam, Air Intake Screw, Machine Intake, Air - Right Clip, Hairpin Nut, Push Washer Nut, Lock Plug Foam, Air Intake Foil, Protective

11 12 13 14 15 16

3606-779 0623-165 1670-517 0617-499 3606-481 5606-050 5606-051 17 5606-054 18 0623-778

1 6 1 1 1 1 1 1 2

Foil, Protective Clip, Retaining Screen, Vent Seal, Air Intake Intake, Air - Left Foil, Protective - Right Foil, Protective - Left Shield, Heat Rivet

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2008 Crossfire 800 EFI

AIR SILENCER ASSEMBLY 0742-820

1 2 3 4 5 6 7

0770-719 1670-473 1670-754 1670-514 1623-132 1623-031 3606-146

1 1 1 1 2 1 1

Silencer, Air - Assembly (inc. 2-3) ‹ Intake, Air ‹ Silencer, Air Connector, Air-Intake Clamp, Air-Intake Connector Screw, Self-Tapping Hold-Down, Air Silencer

8 9 10 11 12 13 14

1623-204 1670-613 0623-165 8611-251 3002-964 0617-485 0623-677

2 1 2 1 1 2 1

Screw, Plastite Boot, Air Silencer Clip, Retaining Decal, EFI Diagnostics Clamp, Wire Foam, Air Silencer Cable Tie, Push-Mount

45

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2008 Crossfire 800 EFI

OIL TANK ASSEMBLY 0742-640

1 2 3 4 5 6 7 8 9

46

1670-930 1670-325 1670-481 0609-503 0609-518 0609-237 1670-365 0109-733 4611-532

1 1 1 1 1 1 1 1 1

Tank, Oil Grommet Fitting, Oil Tank Sensor, Low Oil - Assembly (inc. 5-6) ‹ Switch, Oil Sensor w/Harness ‹ Seal, Grommet - Oil Sensor Cap, Oil Tank (inc. 8) ‹ Seal, Cap - Oil Tank Decal, Oil Tank

10 0124-045 2 11 0610-693 AR 0610-692 AR 12 1623-256 1 13 5606-372 1 14 1623-705 2 15 1623-499 3 16 0623-765 1

Clamp, Hose Hose, Oil - 100 ft Hose, Oil - 25 ft Grommet Shield, Heat Screw, Machine Screw, Machine Screw, Self-Tapping

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2008 Crossfire 800 EFI

Cam Arm Kit - p/n 4639-674 (inc. 5-8)

DRIVE CLUTCH (Uncalibrated Drive Clutch - p/n 0746-192) 0741-939

1 2 3 4

1623-442 8051-212 0646-229 0746-715 0746-672 0746-716 0746-703

6 6 1 3 3 3 3

Screw, Machine Washer Spring, Drive Clutch - Yellow/White Arm, Cam (inc. 5) Arm, Cam (inc. 5) (3-6,000 ft Alt.) Arm, Cam (inc. 5) (6-9,000 ft Alt.) Arm, Cam (inc. 5) (Over 9,000 ft Alt.)

5 6 7 8

1623-183 1602-692 0646-747 8048-366

3 6 3 3

‹ Screw, Set O-Ring Pin, Cam Arm Nut, Lock

47

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2008 Crossfire 800 EFI

DRIVEN CLUTCH (Assembly p/n 0726-276) 0741-790

1 0748-664 0748-662

1 1

2 3 4 5

1 1 2 1

48

0648-433 0648-009 0648-713 0648-774

Bracket, Torque 46°/40° (inc. 2-3) Bracket, Torque 36° (inc. 2-3) (Over 6,000 ft Alt.) ‹ Ring, Snap ‹ Bearing Seat, Spring - Driven Clutch Spring, Driven Clutch - Orange

6 7 8 9 10 11 12

0648-753 0648-453 0648-097 0648-139 8070-224 0648-650 1623-517

1 1 6 6 6 1 9

Spacer Seat, Spring Pin, Cam Roller Roller, Cam Pin, Spring Retainer, Torque Bracket Screw, Machine

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2008 Crossfire 800 EFI

CYLINDER AND HEAD ASSEMBLY 0742-050

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

3007-521 1 Head, Cylinder 3004-081 2 O-Ring 3003-227 14 O-Ring 3005-854 2 O-Ring 3006-538 14 Bolt 0217-709 4 Plug, Spark (BR9EYA) 3006-496 1 Hook, Engine 3007-432 1 Bolt 3007-522 2 Cylinder 3007-523 1 Gasket, Cylinder 3007-244 2 Gasket, Exhaust Valve Case 3006-436 2 Gasket, Exhaust Valve Cover 3005-983 2 Pin, Exhaust Valve 3007-524 2 Valve, Exhaust 3005-860 2 Stopper, Exhaust Valve 3006-495 2 Plate, Exhaust Valve 3006-425 2 Cover, Exhaust Valve

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

3006-321 3005-226 3006-322 3006-484 3007-433 3007-247 3007-248 3005-747 3007-525 3005-847 3005-808 3007-434 3004-975 3007-391 3007-536 3007-415 3007-390

4 2 2 2 4 1 1 1 4 4 1 4 4 4 2 8 8

Pin, Dowel O-Ring Seal, Oil Spring Bolt Cable, Exhaust Valve - MAG Cable, Exhaust Valve - PTO Holder, Exhaust Valve Cable Bolt Bolt, Stud Clamp, Exhaust Valve Cable Bolt Pin, Dowel Nut Gasket, Exhaust Bolt, Stud Nut

49

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2008 Crossfire 800 EFI

CRANKCASE ASSEMBLY 0742-053

1 2 3 4

50

3007-526 1 Crankcase (inc. 2-7) 3006-538 2 ‹ Bolt 3006-488 10 ‹ Bolt 3007-445 2 ‹ Bolt

5 3007-527 6 3003-647 7 3005-206

1 1 2

‹ Bolt ‹ Bushing ‹ Pin, Dowel

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2008 Crossfire 800 EFI

PISTON AND CRANKSHAFT 0742-055

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

3007-528 3006-394 3005-304 3006-501 3008-500 3008-503 3007-529 3007-530 3007-531 3007-437 3007-438 3006-506 3006-719 3006-508 3005-508

2 2 4 2 4 2 1 2 1 1 1 1 2 2 2

Piston Set (inc. 2-3) ‹ Ring Set, Piston ‹ Circlip, Piston Pin, Piston Washer Bearing Crankshaft Assembly (inc. 8-26) ‹ Connecting Rod ‹ Crankshaft - Right ‹ Crankshaft - Middle ‹ Wheel, Crankshaft ‹ Crankshaft - Left ‹ Balancer, Crankshaft ‹ Race, Middle Crank Seal ‹ Ring, Middle Crank Seal

16 17 18 19 20 21 22 23 24 25 26 27 28 29

3006-519 3004-147 3006-489 3008-495 3008-421 3007-532 3007-439 3006-551 3007-440 3007-533 3003-759 3003-359 3003-658 3006-552

1 2 2 2 2 2 1 1 6 1 1 1 4 1

‹ Gear, Oil Pump Drive ‹ Washer ‹ Washer ‹ Washer ‹ Bearing ‹ Bearing, Crankshaft Pin ‹ Bearing - Left ‹ Bearing - Right ‹ Screw ‹ Seal, Oil - Right ‹ Seal, Oil - Left C-Ring Pin, Alignment Spacer, Oil Seal

51

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2008 Crossfire 800 EFI

REED VALVE ASSEMBLY 0742-060

1 2 3 4 5

52

3007-534 2 Valve, Reed - Assembly (inc. 2-4) 3007-535 4 ‹ Stopper 3005-878 4 ‹ Valve, Reed 3004-506 16 ‹ Screw 3005-879 2 Gasket, Reed Valve

6 7 8 9

3006-527 2 Pipe, Intake 3402-455 2 Clamp 3007-380 12 Bolt 3002-964 1 Clamp, Wire

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2008 Crossfire 800 EFI

THROTTLE BODY ASSEMBLY 0742-062

1 3007-537 2 3006-059 3006-060 3006-061 3 3007-442 4 3005-692

1 2 2 2 1 1

Body, Throttle - Assembly (inc. 2-9) ‹ Injector, Fuel - Assembly O ‹ Injector, Fuel - Assembly Q ‹ Injector, Fuel - Assembly V ‹ Pipe, Delivery ‹ O-Ring - Set

5 6 7 8 9 10

3006-723 3004-193 3007-443 3006-939 3007-026 3007-538

1 2 4 1 2 1

‹ Hose ‹ Clip ‹ Screw ‹ Sensor, Throttle - Assembly ‹ Screw Rod, Oil Pump Control

53

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2008 Crossfire 800 EFI

OIL PUMP 0742-077

1 2 3 4 5 6 7 8

54

3007-539 3006-520 3005-884 3003-217 3005-032 3005-696 3402-009 3423-300

1 1 1 3 2 2 8 1

Pump, Oil Gear, Driven - Oil Pump Retainer, Oil Pump Input Shaft Valve, Check Protector Clamp Gasket Shim, Oil Pump Shaft

9 10 11 12 13 14 15 16

3008-030 3005-126 3008-035 3005-357 3008-037 3004-346 3003-661 3007-445

1 1 2 1 6 4 1 2

O-Ring O-Ring Hose, Oil Hose Clamp, Hose Bolt Union Bolt

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2008 Crossfire 800 EFI

WATER PUMP/WATER MANIFOLD 0742-079

1 2 3 4 5 6 7 8 9

3007-540 3007-541 3007-180 3005-697 3003-426 3003-431 3003-432 3007-542 3007-431

1 1 1 1 1 1 1 1 1

Case, Water Pump O-Ring, Water Pump Case Seal, Water Pump Impeller, Water Pump Bolt Washer Washer Hose, Water Inlet Seal, Oil

10 11 12 13 14 15 16 17 18

3004-786 3007-409 3005-899 3004-009 3007-041 3007-304 3007-543 3007-446 3007-306

2 7 2 1 1 1 1 3 1

Clamp Bolt Pin, Dowel Circlip Thermostat Cap, Thermostat Gasket, Thermostat Cap Bolt Bolt

55

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2008 Crossfire 800 EFI

RECOIL STARTER 0741-373

1 2 3 4 5

56

3007-307 3007-308 3007-309 3007-310 3007-311

1 1 1 1 1

Starter Assembly (inc. 2-6) ‹ Roller, Starter ‹ Ratchet Set ‹ Plate, Friction ‹ Bolt w/Washer

6 7 8 9 10

3007-312 3006-889 3007-544 3007-407 3423-346

1 1 1 3 5

‹ Spring Rope, Starter Pulley, Starter Screw, Cap Screw, Cap

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2008 Crossfire 800 EFI

MAGNETO 0742-081

1 2 3 4 5 6 7 8

3007-623 3007-315 3007-546 3007-317 3007-318 3005-960 3007-433 3005-775

1 1 1 1 1 1 5 1

Stator Rotor/Flywheel Base, Stator - Plate Sensor, Ignition Timing Sensor, Ignition Timing Plate, Stator Lead Wire Bolt Grommet, Stator Lead Wire

9 10 11 12 13 14 15

3006-476 3005-987 3007-371 3007-449 3007-450 3004-540 3007-547

1 1 1 4 3 1 1

Bolt Washer Bolt Bolt Bolt Key Grommet

57

Arctic Cat Parts & Free Mechanical Advice | www.FunOutfitters.com | 1 866-531-0123

2008 Crossfire 800 EFI

ELECTRICAL 0742-083

1 2 3 4 5 6

58

3007-548 3006-367 3005-387 3006-728 3006-725 3005-233

4 4 2 1 1 1

Coil, Ignition - Assembly Cap, Spark Plug Clip Sensor, Temperature Sensor, Coolant Washer, Coolant Sensor

7 3007-605 3007-606 3007-607 8 3005-237 9 3006-886 10 3007-549

1 1 1 1 1 1

ECU O ECU Q ECU V Cable Tie Sensor, Knock Plate, Knock Sensor Lock

Arctic Cat Parts & Free Mechanical Advice | www.FunOutfitters.com | 1 866-531-0123

2008 Crossfire 800 EFI

SERVOMOTOR ASSEMBLY 0739-377

1 3007-067 2 3005-661

1 1

Servomotor Pulley, Controller

3 3007-550

1

Nut

59

Printed in U.S.A.

p/n 2257-995

Arctic Cat Parts & Free Mechanical Advice | www.FunOutfitters.com | 1 866-531-0123