ARGO. CONQUEST 6x6 PARTS MANUAL. From Serial #

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1 ARGO CONQUEST 6x6 PARTS MANUAL From Serial # Manual No /2006 3C Printed in Canada

2 Foreword ODG has prepared this parts manual for the CONQUEST 6x6 model to assist both qualified mechanics and vehicle owners in ordering correct, quality replacement ARGO parts. Proper and regular service, and replacing old, worn or broken parts with the correct ARGO replacement parts, are both essential to prolonging the life of the ARGO. Please refer to this parts manual before ordering any replacement part. All information contained in this CONQUEST 6x6 Parts Manual is based on the latest product specification available at time of printing. If your CONQUEST 6x6 differs from the specifications contained in this manual, contact Ontario Drive & Gear Limited for information. ODG reserves the right to alter specifications on the CONQUEST 6x6 model at any time, without obligation or prior notification. Reproduction of this CONQUEST 6x6 Parts Manual, in whole or in part, is prohibited without prior written permission from. Vehicle Identification CONQUEST 6x6 - Serial Nos. A14916 Explanation of Parts Manual Format Ref Part No. Description Qty - Reference number between assembly diagram and component parts list - Argo replacement part number for identification and re-ordering - Part description for identification and re-ordering - Indicates the quantity of a part used in an Assembly i

Using the Parts Manual 1. Find the major vehicle assembly in the Table of Contents on this page, and turn to that section. 2. Locate the part in the illustration that you wish to order. 3.

3 Using the Parts Manual 1. Find the major vehicle assembly in the Table of Contents on this page, and turn to that section. 2. Locate the part in the illustration that you wish to order. 3. Refer to the parts list in that section. 4. Find the correct part number (Part No.), part description (Description) and correct quantity (Qty). 5. Use only this information to order ARGO replacement parts. DO NOT attempt to order a replacement part by reference number or page number. Table of Contents Foreword... i Model Identification... i Using the Parts Manual... ii 1.0 Transmission Intake and Exhaust System Clutch System Power Pack Assembly Steering & Brake System CE Kit Vehicle Body & Firewall Frame & Drive System Fuel & Seat System Roll Bar System Alternator Kit Electrical System...19 ii

4 1.0 Transmission 1

5 1.0 Transmission Ref. Qty. Part # Description M Transmission Asm - M, does not include Refs 38,52,53 & 56, uses Refs 5a & 8a G Transmission Asm - G, does not include Refs 38,52,53 & 56, uses Refs 5b & 8b Cover, Transmission Housing, Transmission Shaft, Input - 13/21T A Gear, Idler - 13T (incl. Ref 51) 5a Gear, Helical - 24T - M 5b Gear, Helical - 21T - G Shaft, Spline Gear, Double - 26/33T 8a Gear Plate - 73T - M 8b Gear Plate - 76T - G Bushing, Oilite - ½ x 3/ Gear, Planet - 12T Gear, Sun - 21T Shaft, Output Shifter Asm. 14a Washer, Shim.040 Thk 14b Washer, Shim.020 Thk Retaining Ring Bearing, Ball 6204Z-C Bearing, Ball 6206-C3 18 as req Washer, Shim 2.06x2.42x Retaining Ring Seal, Oil WBS 30x62x Retaining Ring Pin, Dowel ½ x Plug Plate Ball, Steel 6mm Rc Spring, Compression - 7/32x Seal, Oil WBS 30x72x Retaining Ring Retaining Ring Bearing, Ball NSE C Washer, Shim 2.25x2.81x Bearing, Ball 6207-C SHCS 5/16-18x1.0 Bare Bearing, Ball 6005-C Retaining Ring Cage Lever, Shift Gasket, Cover - 1/64" Thk Plug, Magnetic 3/8-18 NPT Holder, Shift Lever Pin, Spring 5/32x O-Ring Bushing, Oilite - ½ x Pin, Dowel 1/4 x 7/ Dipstick, with breather HHCS 5/16-18x1.0 GR5 Zn Lockwasher 5/ Washer.64 x.875 x.10 Zn Shift Yoke Bearing, Drawn Cup Needle HHCS 1/4-20x1.25 GR5 Zn Locknut, Nylon 1/4-20 Zn 54 See Section 4.0 Power Pack Assembly FHSC 5/16-18x1.0 GR8 Zn Knob, Shift 2

6 2.0 Intake and Exhaust System Ref. Qty. Part # Description Ref. Qty. Part # Description Duct, Intake PHMS, PHIL 1/4-20 x 1.0 Zn Seal, Radiator LG Seal, Radiator LG Washer, Fender 1/4 B x 1.25 OD Rivet 3/16 x 5/8 - Black Washer, Fibre - W-77F Support, Exhaust Duct Gasket Lockwasher 5/16 Hi-Collar Bare SHCS M8 x1,25 x 20mm Zn Muffler, Kawasaki V-Twin Spring, Extension- 7/16 x Pipe, Muffler Tail - Kawasaki Shield, Heat - Kawi Muffler Screw, IHWH T/C Slot 1/4-20 x 1/ Duct, Exhaust - Kawasaki Washer.19x.50x.08 Zn Spark Arrester Tube, Tailpipe Outlet Screw IHWH #8 x 3/ Blower Fan HHCS, #10-24 x 1/ Washer,.19 x.50 x Lockwasher #10 Int. Tooth Locknut, Nylon 1/4-20 Zn HHCS 1/4-20 x 3/4 Gr2 Zn Locknut, 2-way 1/4-20 Zn Lockwasher, #8 External Tooth Adpt. & Mounting Kit - includes the following: 1 Mounting Bracket 1 Nut, # Lockwasher, 3/16" 1 Screw, #10-32 x 2" 2 Nut, 1/ Lockwasher, 1/4" 2 Screw, 1/4-20 x 5/8" 1 Adaptor, 3" dia Brake Cool Air Duct Clamp, Gear 3.50" HF Hose, Intake - 3" dia. x 29" Terminal, Male # Terminal, Female #

7 3.0 Clutch System Ref. Qty. Part # Description Clutch, Driver - Keyed (incl. Refs 2 to 14) Pulley, Half - Fixed Pulley, Half - Sliding 4 1 V09 Plate, Spring Guide 5 1 V Spring Lockwasher SHCS Washer, Zc Nut (A) Cap Cover, Spring 12 3 C24-L1 Spring, Anti-noise 13 3 C13-266T Weight, 260g Block, Red 15 1 V08C Retaining Ring Clutch, Driven - Model B (incl. Refs 28 to 37) 28 1 ASK-5 Key 1/4x1/4x5/ ASR-6 Retaining Ring 30 as req ASA-1-S Spacer.025" Thick 30a as req ASA-1 Spacer.050" Thick 31 1 AFK OD01 Pulley, Half - Fixed 32 1 AMC-2-250OD01 Pulley, Half -Sliding incl. Refs. 33, 34 & ANS-2-T Shoe, Cam Bushing, Super Oilite Pin, Spring 5/32x ACS Spring, Blue 37 1 AFC-4-C3D4 Cam Retaining Ring 4

8 4.0 Power Pack Assembly 5

9 Ref. Qty. Part # Description 1 1 FD620D-JS12 Engine - Kawasaki, (incl. Refs. 2, 3, 4, 6, 8, 41) Sparkplug, BPR4ES Element, Air Filter - Foam Element, Air Filter - Paper Key 1/4x1/4x Gasket, Drain Plug 7 See Section 3.0 Clutch System Filter, Oil SHCS M10x1,5x90mm Lockwasher, Hi-Collar -M HHCS 5/16-18x3.25 Gr5 Zn HHCS 5/16-18x1.25 Gr5 Zn Locknut, Nylon 5/16-18 Zn Spacer-5/16 IDx7/16 OD x 13/32 Lg Washer.40x1.37x.12 Zn SHCS M8x1,25x20mm Zn Lockwasher 5/16 Zn Spacer 19 See Section 2.0 Intake & Exhaust System HHCS 5/8-11x10.0 Gr5 Zn Locknut, Nylon 5/8-11 Zn Washer, Square -.64 ID Washer 5/16 SAE Zn HHCS 5/8-11x7.5 Gr5 Zn Frame, Powerpack - Conq HHCS 1/2-13x6.5 Gr5 Zn Lockwasher 1/ Nut, Fin Hex 1/2-13 Zn 29 See Section 1.0 Transmission Washer, Square Lock.64ID HHCS 3/8-16x3.0 Gr5 Full Thread HHCS 3/8-16x1.25 Gr5 Zn Lockwasher 3/8 Split Ring Zn Drive Belt 35 See Section 3.0 Clutch System 4.0 Power Pack Assembly Ref. Qty. Part # Description Key 1/4x1/4x Brake Disc #50-2x13T 38 as req Washer, Shim 1 idx.5x.010 (right hand disc only) 39 as req Washer 1.03x1.37x.06 Zn 40 to 41 See Section 5.0 Steering & Brake System HHCS 3/8-16x1.0 Gr5 Zn Washer 3/8 Zn Washer.40x1.37x.12 Hi- Carbon Cable Asm, Choke - Conq Nut, Jam 3/8-24 UNF Zn Lockwasher 3/8 Int. Tooth Guard, Belt Protect Vinyl Trim - 1.5" Vinyl Trim " HHCS 5/16-18x2.75 Gr5 Zn Cable Asm, Throttle Shift Gate, Transmission HHCS 5/16-8x3/4 Gr5 Zn Spring, Extension SHCS 3/8-16x1.25 Zn Washer 3/8 SAE Gr8-Dich Clip, Retainer Tie Wrap - 5.5" - Black 60 See Section 5.0 Steering & Brake System HHCS 3/8-24x1.25 Gr5 Zn Washer.34 x.70 x.06 Zn 6

10 5.0 Steering & Brake System 7

11 Ref. Qty. Part # Description Frame Assembly, Steering Column Handlebar Assembly Master Cylinder, Grimeca - R Master Cylinder, Grimeca - L Shaft, Steering - Argo /PI Pin, Spring 1/4 x Washer,.39 x.94 x.13 Zn Di-chr Locknut, Nylon 3/8-16 Zn Arm, Steering Clamp, Lower Handlebar Clamp, Upper Handlebar Ring, Retaining SH-0075PA Bushing, Oilite - 3/4 x 1/ Key, 3/16 x 3/16 x Retainer, Handbrake Cable SHCS, 1/4-20 x 1.0 Zn Locknut, Nylon 1/4-20 Zn HHCS, 1/4-20 x 4.0 Gr5 Zn Washer,.28 x.62 x.04 Zn Collar Lever Assembly, Handbrake, Spring Cable Assembly, Handbrake Grip, Molded Throttle Twist Grip Cable Asm., Throttle Tie Wrap Black O-Ring Kit, Knott Caliper 29 2 Seal, Piston 30 2 Seal, Rubber 31 2x Plug, Rubber Pad Set (4), Brake - Non-Asbestos 33 2x Pin, Cotter 1/8 x 3.00 Zn 34 2x Piston, Knott Caliper 35 2x Hose Asm, Hydraulic-310mm BHCS, 1/4-20 x 1.0, Plated Caliper, Hydraulic Brake - L, w/o pads Caliper, Hydraulic Brake - R, w/o pads 5.0 Steering & Brake System Ref. Qty. Part # Description 39 2x Washer,.34x.70x.06 Zn 40 2x Screw, Bleeding, Knott Caliper 41 2x SHCS 5/16-18 x 2.75 Zn 42 2x Nut, Fin Hex 5/16-18 Zn 43 2x FHMS M5 x 0,8 x 6mm 44 2x Cover 45 2x Cover, Rubber 47 2x Spring, Comp x 49.3mm 48 2x1 Seal, Primary, 19mm (See Ref. 55) 49 2x Piston 19mm dia. 50 2x1 Seal, Secondary, 19mm (See Ref. 55) 51 2x1 Boot, Rubber (See Ref. 55) SHSS 10-24x1/4 Knurl Cup PT, PL 53 2x Washer, Copper 2.3 x 10.0 x x Bolt, Banjo M10 x 1,0 x 21,0 Zn 55 2x O-Ring Kit, Master Cylinder - Grimeca (incl. Ref. 48, 50 & 51) Pin, Female Nut, Fin Hex 1/4-20 Zn Fin, Male Bolt, Banjo Washer, Copper - 2,3 x 10,0 x 16, Fluid, Brake-Silicon Dot L 8

12 6.0 CE Kit (Opt.) 9

13 6.0 CE Kit (Opt.) Ref. Qty. Part # Description Plate, Capacity-Land/Water Rivet, Alum. 3/32x3/ T/S Pan HD Phil #10x3/4 A Zn Button, Horn Fuse, 10A 2-Prong (ATO10) Wire Harness, Horn Washer.28x.62x.04 Zn Screw, IHWH T/C Slot 1/4-20x1/ Horn, Electric HHCS 5/16-18x1.0 Gr5 Zn Locknut, Nylon 5/16-18 Zn Washer.34x.70x.06 Zn Spring, Comp. 0.53x HHCS 5/16-24x3.75 Gr8 Zn HHCS 5/16-24x2.75 Gr8 Zn HHCS 5/16-18x2.75 Gr5 Zn HHCS 5/16-18x2.25 Gr5 Zn Washer.34x1.00x.06 Zn Ball, Steel 1/4 Chrome steel Cam, Parking Brake Spacer, Left Spacer, Right Caliper, Parking Brake Caliper, Parking Brake - Notch Bracket, Caliper Shim Rod Ball Joint, 5/ Locknut, 2-Way 5/16-24 Zn Nut, Jam 5/16-24 Zn Pin, Cotter 3/32x.750 Zn Pin, Roll.250 DIA. x.88 Lg Locknut, Nylon 5/16-24 Zn Screw, Shoulder 5/16 x 3/8 Lg Spring Shaft ASM, Left Shaft ASM, Right Brake Plate, Mtg - Lock Lever Lever Asm - Lock Lever ASM, Parking Brake Plug, End - Black Washer.19x.50x.08 Zn Rivet - 3/16x5/8 Black Clip, Coated Retaining Ring TY-18ST PD Clip, Retainer Screw, IHWH T/C Slot 1/4-20x3/ Spacer 5/16 IDx7/16 ODx13/32 Lg HHCS 5/16-18x3.25 Gr5 Zn Label Stock " Wide Plate, Serial Number - Blank - Must be stamped with vehicle serial # provided by owner Duct, Brake Cooling 10

14 7.0 Vehicle Body & Firewall 11

15 7.0 Vehicle Body & Firewall Ref. Qty. Part # Description Ref. Qty. Part # Description Body & Hood, Upper - Conquest Replacement, specify colour (incl. Ref 5, 11, 12, 13, 14, 15 & 38) Body, Lower - Ext d 6x6, specify colour Plug, Nylon - Black Bumper, Vinyl - 6x Hood Kit (specify colour) (incl. Ref 6,8,9,10,19,23,24 & 27) HHCS 10-24x1/2 Zn Clip, Hood Rivet 3/16 x 5/8 - Black Wing Stud Grommet, Alum Hood Frame Assembly Rivet 1/8 x 7/ Spring Plate Spring Screw, IHWH T/C Slot 1/4-20x1/ Brace, Dash Vinyl Trim, 84" Vinyl Trim, 28" Lockwasher #10 Int. Tooth Zn Skid Plate - Ext d 6x Collar, Magna Grip Pin, Magna Grip A Pin, Hinge B Knuckle, Hinge T-Nut 1/4-20 Zn Rivet, Alum - 3/32x3/ Rivet 3/16 x 1 - Black Nameplate, Conquest Nameplate, ARGO T/S Pan HD Phil #10x5/8 A Zn RM Firewall (incl. 9,10,26,32,51) Label, Warning - HOT Reflector, Red Floor Pan, Front (specify colour) Floor Pan, Rear 6x6 (specify colour) Washer.19x.50x.08 Zn Vinyl Strip 1/2"x1/4"x37.5' Washer.19x.50x.04 Zn Clip, Hitch Pin Zn Plug, Drain 5/8" x 13/32" Nut, Fin. Hex 3/8-16 Zn Support, Adjustable C/Bolt 3/8-16x3/4 GR2 Zn Lockwasher 3/8 Zn Pin, Lynch HHCS 3/8-24x1.5 GR5 Zn Locknut, Nylon 3/8-24 Zn Hitch Assembly 50 1 Vehicle ID Plate Shifting Plate Plate, Keyswitch Floor Pan Plate Operation Plate Fuel Plate Plate, Capacity - Land/ Water 58 1 U.S. Plate, Non U.S. Argos only Plate, Capacity - 6x Dash Handle, incl Plug cap, avail. only with Locknut, Nylon #10-24 Zn Bumper, Rubber PHMS 10-24x3/4 Zn Rivet, 5/32 x 9/16 - Black Screen, Intake - Conquest Screen, Exhaust - Conquest Tube, Hitch - Insert Pin, Top Link 12

16 8.0 Frame and Drive System 13

17 8.0 Frame and Drive System Ref. Qty. Part # Description Frame Asm - 6x Gasket, Bearing Extension Locknut, Nylon 3/8-16 Zn Washer.40x1.37x.12 Hi-Carbon Bearing, Ball a Bearing, Ball Lockwasher 3/8 Zn C/Bolt 3/8-16x1.0 Gr5 Zn Flange - 4-hole Gasket,Outer Bearing Flange Flange Greaseable - 4 Hole Seal, Oil 1.25x1.75x Seal, Oil 1.25x1.874x Flange Assem, Outer (incl. Refs. 11 & 12) C/Bolt 3/8-16x1.75 Gr5 Zn C/Bolt 3/8-16x6.5 Zn Bearing Extension (uses Refs. 17 & 18) Washer 7/16 SAE Zn HHCS 7/16-20x2.5 Gr5 Zn 19 5x Stud, Wheel 7/16-20 x #B Axle Assembly - Front (incl. Ref. 19) Axle Assembly - Mid (incl. Ref. 19) Shaft, Idler - 11T Frame Assembly, Battery Sprocket, Double - 24T Sprocket - S60x19T SHSS 5/16-18x3/8 1/2 DOG, PL Chain, Idler RC50-2 x 40P (incl. Ref 53) Insert, 1/ HHCS 3/8-16 x 1.0 2B Gr8 Zn HHCS 3/8-16x.75 Gr5 Zn Washer 3/8 SAE Zn HHCS 3/8-16x1.5 Gr5 Zn C/Bolt 3/8-16x1.25 Gr5 Zn Rivet 1/8 x 7/ Spring Link, Half - RC60-1 (opt.) Flange, Greaseable - 90 Degree Chain RC50-2x42P - Front (incl. Ref 53) Chain RC50-2x76P - Mid (incl. Ref 53) Chain RC60-1x88P - Rear (incl. Ref 54) 46 5x Nut, Wheel 7/16-20 Zn Valve, Tire C Rim - 10x9 - Charcoal Tire, Goodyear Rawhide III 25x Pin, Cotter 1/8 x 1.50 Zn 53 1x Con. Link, RC50-2 H.D. 54 1x Con. Link, RC60-1 H.D Spring Torsion x Slider Block - 1/2" Shaft Tensioner Asm, Chain Spring, Torsion -.76 x Retaining Ring Slide, Chain - 2" Slide, Chain Spring Clip - RC 50 Closed Spring Clip - RC 60 Closed 14

18 9.0 Fuel & Seat Systems 15

19 9.0 Fuel & Seat Systems Ref. Qty. Part # Description Handrail Assembly Lockwasher 1/ PHMS, Phil 1/4-20x1.25 Zn Back Pad Asm Seat, Bench Angle, Left Angle, Right PHMS, Phil 1/4-20 x 1.50 Zn HHCS 1/4-20x3/4 Gr2 Zn Lockwasher 1/ Frame Asm, Seat Clamp, Hose, 9/16" - Black Washer.19x.50x.08 Zn Tool Box Pickup Assembly, Fuel (See Ref. 19) Tank, Fuel - 32 litre (incl. Ref. 18) Clamp, Hose, 1/2" - Black Fuel Hose - 110" Fuel Filter Clamp, Gear 2.25" HF Hose, Filler Neck Asm, Fuel Cap, Fuel Hose, Vent - 93" 6x Male Connector, 1/4" Clamp, Nylon Wire - 14" ID HHCS 1/4-20x3/4 Gr2 Zn Locknut, Nylon #10-24 Zn Clamp, Nylon Wire - 12" ID Washer.28x.62x.04 Zn Rivet 3/16x1 - Black Foam Cushion Nut, Locking PAL 1/2-20 Zn RHMS 10-24x1.50 Zn Washer.21x1.0x.06 Zn Pump, Fuel Locknut, Nylon 1/4-20 Zn 16

20 10.0 Roll Bar System Ref. Qty. Part # Description Roll Bar, Welded Assembly Brace, Rear Plate, Attachment Plate, Angle - Rear Brace HDW Hardware Kit HHCS 5/16-18x1.0 Gr5 Zn HHCS 5/16-18x1.25 Gr HHCS 5/16-18x1.5 Gr Washer,.34x1.02x Washer,.34x.70x.06 Zn Washer,.43x1.02x.09 Zn HHCS 5/16-18x3/4 Gr5 Zn HHCS 3/8-16x2.5 Gr5 Zn Locknut, Nylon 5/16-18 Zn Locknut, Nylon 3/8-16 Zn Seat Belt Assembly c/w Label Anchor, Seat - Belt 17

21 11.0 Alternator Kit Ref. Qty. Part # Description Alternator - 40 amp Bottom Bracket Pulley V-Belt, 3/8" x 19" Wire Harness Top Bracket HDW Hardware Kit comprised of: Tie Wrap - 5.5" - Black Lockwasher 1/4" Split-ring Zn Lockwasher 5/16" Split-ring Zn Flat Washer.34 x.70 x.06 Zn Lockwasher 7/16" Split-ring Zn HHCS M8 x 1.25 x 25mm HHCS M8 x 1.25 x 60mm Zn HHCS M10 x 1.50 x 50mm Zn HHCS M8 x 1.25 x 35mm Gr 5 Zn RHMS 1/4-20 x 3" Phil Zn Nut, Hex M10 x 1.50 Zn Nut, Hex M6 x 1.0 Zn Insulator, Terminal (6ga.) Block, Adjuster 18

22 12.0 Electrical System 19

23 12.0 Electrical System Ref. Qty. Part # Description Key, Molded Switch, Light Wire Harness - Conquest (incl. Fuse Holders) Knob, Light Lockwasher 7/16 External Tooth Battery, Exide Wire, Ground - 14" Bracket, Battery Retaining Locknut, Nylon 5/16-18 Zn Tie Wrap, 5.5" - Black Rivet 3/16x5/8 - Black 11a Rivet 3/16x1 - Black Clamp, Nylon Wire-1/2" ID Cover, Nut Clamp, Nylon - 1" ID Label, Fuse Panel - Kawasaki (located on Guard, Belt Protect - see pg. 5) Terminal Strip, Ground Hourmeter Voltmeter Gauge, Water Temperature Light, Indicator Light Kit, # Locknut, Nylon 1/4-20 Zn Regulator, Voltage PHMS, PHIL 1/4-20x1.0 Zn Rivet 1/8x7/ Heat Shrink, 2 x ½ Terminal, Male # Terminal Insulator (2 ga.) Cap, Battery Terminal Fuse, 20A 2 prong (AT020) Fuse, 15A 2 prong (AT015) Locknut, Nylon #10-24 Zn Fuse, 10A 2 prong (AT010) PHMS #10-24x3/4 Zn Terminal, Battery Post Headlamp Asm (incl. Refs. 71 & 78) Bulb, Headlight - Halogen Fuse, 30A 2 prong (AT030) Block - Fuse, 8 position (4 fuse) Terminal - Fuse, quad Terminal - Fuse, triple Terminal - Fuse, single RB Bezel, Rubber Headlamp Switch, Ignition Nut, flanged, plastic #4 Phil Drive Oval Head Screw, Black Wire Harness, 12V Acc. Outlet Outlet, 12VDC 20

24 ARGO Products Manufactured by: 220 Bergey Court New Hamburg, Ontario Canada N3A 2J5 Phone: (519) Fax: (519) ODG Dedicated to quality and performance

CONDOR SPARE PARTS LIST RATCHET DRIVE CODE 511R ISSUE 09/02/00

CONDOR SPARE PARTS LIST RATCHET DRIVE CODE 511R ISSUE 09/02/00 CONDOR RATCHET DRIVE CODE R SPARE PARTS LIST FROM SERIAL NO: R000 ISSUE 0/0/00 MANUAL PART NO: REV(..) - PARTS LIST - MAINFRAME ASSEMBLY - 0 Cutterhead Attachment DETAIL 'A'. 0 0 0 0 SEE DETAIL 'A'. 0