1992–2006 Argo Avenger, Conquest, Response, Bigfoot, Vanguard & Vanguard 2 ATV Service Manual Set (P/N 673-04-1)

This 1992–2006 Argo 6x6 and 8x8 ATV service manual set combines P/N 673-04-1, edition 05/06, integrated Avenger supplement material identified as 673-06, and the included Avenger/Frontier parking-brake service instructions.

• Engine and powerpack: Basic servicing and engine removal and installation for Briggs & Stratton Vanguard, Kawasaki FD620D, and Kohler Aegis applications.

• Clutch system: Variable speed torque converter service, driver and driven clutch disassembly, reassembly, inspection, and driven-clutch spring-load testing.

• Transmission repair: Gearbox and differential overhaul, shifter assembly service, component inspection, and separate procedures for the Avenger 34-100 series.

• Brakes and steering: Hydraulic caliper and master cylinder rebuilding, bleeding, mechanical Vanguard brake adjustment, steering-column service, and parking-brake repair.

• Axles and chains: Idler shaft alignment, axle bearing and seal replacement, bearing extensions, drive chains, and early and later chain tensioners.

• Electrical system: Starter removal and installation, brake cooling fan service, wiring diagrams, harness component views, and digital gauge calibration.

• Fuel system: Tank removal and installation, fuel-line inspection, and vented fuel-system checks, with separate Avenger and early Vanguard procedures.

Written for qualified technicians at authorized Argo dealers and distributors, this manual assumes familiarity with standard workshop practices.

Engine Service and FD620D Compatibility

The engine section covers routine maintenance and engine replacement; detailed internal engine work requires the separate engine manufacturer service manuals. The general reference pages include maintenance charts, SAE viscosity tables, and symptom/cause/corrective-action troubleshooting charts.

For the Kawasaki FD620D, the spark-plug discussion distinguishes early Conquest engines from vehicles beginning at CB17857 with engine specification HS12 or later. The longer revised plug can damage an earlier-spec engine.

Engine and frame removal require suitable lifting equipment. Follow the manual’s vehicle-support and electrical-isolation precautions.

Clutch and Transmission Overhaul

Driver-clutch procedures distinguish threaded-bushing and cap-screw spring covers. Driven-clutch coverage separates standard assemblies from the Avenger 127-136 design; the Clutch Weight Chart and 658-20 driven clutch service tool support this work.

Transmission procedures extend into sun gears, pinions, Oilite bushings, and housing and side-cover assemblies. The Transmission Component Changes chart helps match replacement shafts, brake discs, and covers to the vehicle’s production configuration before parts are ordered.

The 34-100 supplement also distinguishes input-shaft assemblies before and from transmission serial A5883.

Brake, Steering, and Axle Variations

Separate procedures address Grimeca and Knott hydraulic calipers and the Vanguard’s mechanical brakes. Supplement pages cover steering-shaft changes and Avenger/Frontier emergency and parking-brake caliper service.

Axle coverage distinguishes keyed and splined components, single- and dual-seal flanges, and bearing-extension arrangements. Frontier idler-shaft Diagrams C and D show retaining-ring locations; incorrect shaft alignment or chain tension can damage chains, sprockets, and the frame.

The chain-service instructions identify 658-08 modified chain-joining pliers. Flat rate schedules cover service jobs and accessory installation.

Electrical References and Frontier Coverage

Model-specific electrical references include Response V896-65, Conquest V899-37/V899-38, and Vanguard 2 V699-55 wiring diagrams with harness component views. Earlier Tecumseh and Magnum drawings provide electrical references without extending complete vehicle repair coverage to those models.

The 613-119 Digital Gauge Package calibration instructions cover Avenger and Frontier applications. Frontier coverage also includes listed specifications, idler-shaft installation, and parking-brake service; it is not a separate full Frontier workshop manual.

Body, Ducting, and Exhaust Work

Body procedures cover firewall and floorpan access, upper and lower body removal, and frame inspection. Ducting and exhaust sections distinguish Conquest arrangements from Briggs-powered models and include spark-arrestor maintenance.

Examples of Clutch and Brake Fastener Torques

These are a small selection of the component-specific fastener specifications in the manual.

The driver clutch assembly nut is listed at 100 ft-lb (135.6 N·m), a different fastening point from the clutch-to-engine mounting bolt. For the hydraulic calipers in the main brake section, caliper-to-transmission mounting bolts are listed at 45 ft-lb (61.0 N·m).

Text Search, Wiring Detail, and PDF Contents

Search and diagram detail: Main procedure text is searchable, while most wiring-diagram labels are embedded in images. There are no embedded PDF bookmarks. Small wiring labels require zooming.

The set is delivered as one printable, English-language 430-page PDF, with the following contents:

The cover, service guide, six supplement divider pages, and 13 blank or separator pages are already included in these counts.