XLT CLASSIC Model #099ED6AS Rev. 02

Transcription

1 XLT CLASSIC Model #0EDAS Rev. 0 PARTS MANUAL PN 0 and MICROFICHE PN 0 /

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3 B BATTERY BOX C BRAKE B CARBURETOR C CHAINCASE B CONTROLS B COOLING SYSTEM B CRANKCASE C CYLINDER C DECALS A DRIVE CLUTCH B DRIVE TRAIN B DRIVEN CLUTCH B ENGINE MOUNTING C- EXHAUST SYSTEM C FRONT SUSPENSION and SKI A- FRONT TORQUE ARM B FUEL PUMP C HOOD A0 HOOD/HEADLIGHT A C D E F H TABLE OF CONTENTS XLT CLASSIC 0EDAS Parts Manual I IGNITION and WIRE HARNESS B M MAGNETO C N NOSEPAN A- O OIL PUMP C OIL TANK/AIR BOX C PART NUMBER INDEX D- PISTON and CRANKSHAFT C REAR TORQUE ARM B RECOIL STARTER D SEAT and GAS TANK A STARTING MOTOR D STEERING B STEERING - HANDLEBAR B SUSPENSION B-0 TOOL KIT C TUNNEL A W WATER PUMP C0 The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. P R S T

4 XLT CLASSIC SPECIFICATIONS BRAKES ELECTRICAL Type CAPACITIES Coolant Capacity (qts.) Chaincase Oil Capacity (oz.) Dry Weight (lbs.) Fuel Tank Capacity (US/lmp. Gal.) Gearcase Oil Capacity (oz.) Height (in.) Length (Incl. skis) Oil Capacity (qts.) Ski Center Distance (in.) Ski Length (in.) Ski Width (in.) Width (in.) CHAINCASE Drive Chain Length Drive Shaft Sprocket Reverse Transmission Sprocket Ratio DRIVE CLUTCH Center Distance (in.) Clutch Offset (in.) Clutch Type Clutch Weight Ring Gear Spider Spring Color Hydraulic Disc / Piston 0./. N/A P (/) T- Standard : / P- 0MB Bushed Standard Cast Silver/Gold Headlight Type Headlight (watts) Brake Light (watts) Tail Light (watts) Indicator Light Thumbwarmer Handwarmers GRAPHICS Backrest Pad Color Belly Pan Color Front Shock Color Front Springs Color Handlebar Cover Headlight Pod Color Hood Color Hood Accent Colors Snow Flap Color Nosecone-Top/Bottom Color Rear Rack (Cargo) Color Rear Idler Wheel Color Seat Color Ski Color Tunnel Color Tunnel Stripe Color Windshield (Size & Color) Windshield Base Color Halogen High x./low Brake/Oil/Temp/Battery/ Hi-Beam Standard Hi/Low N/A Black Black Candy Apple Red Black Molded N/A Candy Apple Red Metallic Process Blue/Medium Blue/Bright Silver/ Black/White Black/Silver Logo N/A N/A Red Black Black Black Candy Apple Red/ Process Blue/Medium Blue/Black Std. Evolved/Smoke Black Band DRIVEN CLUTCH TRACK Covers Diameter (in.) Helix Angle Spring Position Spring Type Yes 0. Silver Track Construction Track Length Overall (in.) Track Pattern Track Width (in.) Lug Height Polyester Lightning. ENGINE SPECS SUSPENSION Engine Model Number Alternator Output Bore X Stroke (mm) Displacement (cc s) Carburetion/Throttle Body Carburetor Model Cooling Cylinders Cylinder Plating Electric Start Ignition Timing Dynamic Deg. BTDC Ignition Type Oil Injection Spark Plug Type (RFI) ECPL V 0W x0 Mikuni VMSS Slide Liquid N/A RPM CDI Yes RNC Champion Front Type Front Travel (in.) Radius Rods (Adj. or Lub.) Shock Torsion Bar Rear Type Front Torque Arm Limiter Rear Torque Arm Limiter Rear Travel (in.) Shock: Front Torque Arm Rear Torque Arm Springs: Front Torque Arm Rear Torque Arm Rear Torque Arm Spring Dia. X- 0.0 Upper Fixed Lower Adjustable Select w/thrd. Adj. / Xtra- Adjustable N/A. AFX Ryde AFX N/A Torsion/Coil Variable Rate Chrome Silicon.0 Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

5 POLARIS SNOWMOBILE PUBLICATION NUMBERS OWNER S MANUAL PARTS PARTS ASSEMBLY MODEL MODEL # & SUPPLEMENT MANUAL MICROFICHE INSTRUCTIONS XLT CLASSIC 0EDAS & 0 0

6 TUNNEL XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description 0 Bumper, Hood 0 Screw Rivet 0 Decal - Tunnel Strip, Top 00 Snap, Male 0 Rivet Nutsert Bracket, Suspension, Rear, LH Bracket, Suspension, Rear, RH Snow Flap 0 Rivet 0-0 Panel, Tunnel Back 0-0 Asm., Tunnel (Incl. -, and Heat Exchangers) -0 Bumper, Rear Nut, Nylok Screw 000 Reflector, Red Cap, Bumper 0 Washer 0 Bolt 0 Rivet Rivet 0-0 Console Mount, LH 0-0 Support, Bumper, Side Stop, Bumper Rivet, Pop 0 Footrest, LH Support, Tunnel, RH Support, Tunnel, LH Rivet, Pop -0 Plate, Suspension, Front, Outer 0 Guard, Adaptor, Drive Rivet Mount, Front Suspension, LH Mount, Front Suspension, RH Rivet 00 Plug, Hole 00 Bushing, Open/Close 00 Plug, Hole 0-0 Bulkhead -0 Bracket, Rope Guide Guide, Rope 0 0 Footrest, RH 0-0 Console Mount, RH / A

7 SEAT and GAS TANK XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Cap, Fuel Tank w/gasket 0 Grommet, Fuel Tank 000 Grommet, Relatch, Bottom, 00 Grommet, Relatch, Top, 00 Relatch, Twist Lock, w/hole Rivet 000 Bulb, Taillight 0 Lens 0 Screw Bulb, Brakelight Asm., Seat/Tank (Incl. -0,-,) Seat Covering 00 Hardware Package, Sending Unit 0 Sender, Fuel Level w/gasket 0 Flange, Fuel Tank Mounting 0 Harness, Taillight Washer 00 Clip, Dart Retainer, Weldnut Housing, Taillight 0 Cover, Taillight Protector 0 Rivet, Pop Screw Rivet, Pop 00 Fuel Pick-Up w/strainer 000 Ring, Compression 000- AR Line, Fuel Nut 00 Fitting, Outlet, Double AR Hose Clamp AR Line, Fuel 00 Fitting 00 Cable, Tank Retention / A

8 A NOSEPAN XLT CLASSIC 0EDAS

9 NOSEPAN XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Console Cover, Console 0 Rivet, Plastic Washer Screw Nut, Retainer Washer 0 Screw 0 Retainer, Hood Latch 0 Washer, Rubber Back Washer, Rubber 0 Screw Well Nut Bumper, Side Panel 0 Screw 0 Washer, Ext. Tooth 0 Nosepan - 0 Side Panel, LH Foam, Side Panel, LH Rivet, Pop 0 0 Bumper, Rubber Stop Washer 0 Washer Screw Rivet Rivet 0 0 Washer - Side Bumper, LH 00 Plug, Hole, Nosepan 0 Foil, Side Bumper, Lower 0 0 Foil, Side Panel, Lower 00 Foam, Foil, Side Panel, RH 000- Side Panel, w/foil, RH (Incl. 0-) 0 Foil, Side Panel, Upper 0 0 Foil, Side Panel, Top, Outer Foil, Side Panel, Top, Inner 0 Foil, Side Panel, Front Foil, Side Bumper, Upper 0 Foil, Side Bumper, Middle 000- Side Bumper w/foil, RH (Incl.,,) Foil, Pan Side, RH 0 Foil, Shock Tower, Lower RH Foil, Shock Tower, Top RH Foil, Shock Tower, RH Foil, Center Foil, Shock Tower, LH / A

10 NOSEPAN XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description 00-0 Brace, Hood Support - Cap, Bumper 0-0 Bumper, Front 0 Screw 0 Stud Plate 0 Bolt Nut, Flange 0-0 Hinge Mount 0-0 Hood Hinge 0 0 Bolt 0 Washer 0 Nut, FLEXLOC Bumper Support, RH Bumper Support, LH 0 Washer 0 Bracket, Side Panel, Plated, RH Nut, Retainer 0 Shield, Fastener Rivet Rivet, Pop 0 0 Dampener, Vibration AR Washer 0-0 Support, Muffler Rivet Rivet 0 Boot, Exhaust, Outlet 0-0 Bracket, Muffler, Rear Rivet Rivet 00 Clip, Half 0 Rivet, Pop 0 Rivet, Pop 00 Decal - Suspension Troubleshooting Clip, Belt Retainer 00 Decal - Engine & Clutch 00 Knob, Clutch Guard Bumper, Clutch Guard Knob 0 Guard, Clutch Rivet, Pop 0 Hinge, Clutch Guard 0 0 Mount, Clutch Guard, Front 0-0 Bracket, Side Panel, LH / A

11 HOOD XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description 0 Windshield, Standard, Smoke 0 Rivet, Plastic Nut Washer, Split Washer, Flat 00 Bracket, Speedo/Tach Housing, Instrument (Incl. Warning Decals) 00 Cushion, Rubber 00 Asm., Tachometer, (Incl.,,) 0 Knob, Trip Odometer 00 Asm., Speedometer, Backlit,, 00 MPH (Incl.,,,) 0 00 Cable, Speedometer 00 Cushion, Fuel Gauge, Rubber 0 Fuel Gauge,, Backlit 0 Spacer, Fuel Gauge Bracket 0 Bracket, Fuel Gauge, 0 Washer, Flat 0 Washer, Lock 0 Nut 00 0 Kit - Mirrors Screw Nut, Well 0 Tape, Foil 0 00 Screw 00 Retainer, Windshield Foam, Hood, LH Foam, Hood, RH Foil, Hood, RH 0 Foam, Hood, Center 00 Cable, Hood Retainer 0 Bolt 0 Nut, FLEXLOC - Hood (Incl. Foam & Foil) 0 Foil, Hood, Front 0 Foil, Hood, Center Harness, Headlight Fuse,. Amp 00 Cable Tie A0 /

12 HOOD/HEADLIGHT XLT CLASSIC 0EDAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Headlamp (Incl.,) 000 Bulb, Hi Beam 0 Bulb, Halogen 000 Fastener, U-Type Clip 00 Nut, U-Type Speed 0-0 Headlight Mount 0 Bolt Pivot, Headlight Bolt, Tee, Adjuster 0 00 Spring, Headlight Adjustment Bracket, Headlight Mount, RH Bracket, Headlight Mount, LH 0 Wire, Retainer, LH Wire, Retainer, RH Lens/Reflector, LH Lens/Reflector, RH A 0 Bushing 0 Rivet, Cherry Mate 0 Strap, Hood Latch Screw 0 Washer, Flat Nut, Nylok Knob, Headlight Adjustment Rivet 0-0 Screen, Hood, Upper 0-0 Screen, Hood, Center 00 Clip, U Type Speed 0-0 Screen, Hood, Lower 00-0 Screen, Front /

13 DECALS XLT CLASSIC 0EDAS RH 0 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Hood Decals, XLT Classic (Incl.,-,-,,) 00 Kit - Decal Application Solution (For Seat Decal) 0 Decal - XTRA 0- Decal - Bumper 00 Decal - Seat, POLARIS 0 Decal - Classic 0 Decal - Reverse 0 Decal - Reverse Shift 0 Decal - Hood Center, INDY 0 Decal - Classic 0 Decal - POLARIS, Hood Center 0 00 Decal - Hood Top, RH 0 Decal - Hood Side, XLT, RH 0 Decal - IFS XTRA, RH 0 Decal - Side Panel, Top, RH 0 Decal - Side Panel, Bottom, RH 00 Decal - Tunnel, RH 0 Decal - Caution, English 00 Decal - Warning 0 Decal - Warning, French 00 Decal - Track/Seat, LH/RH, Eng./Fr. 0 0 Decal - Tunnel, LH 0 Decal - Side Panel, Top, LH 0 Decal - Side Panel, Bottom, LH 0 Decal - Hood Side, XLT, LH 0 Decal - IFS XTRA, LH 0 Decal - Hood Top, LH / A

14 FRONT SUSPENSION and SKI XLT CLASSIC 0EDAS A

15 FRONT SUSPENSION and SKI XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Rivet -0 Brace, Bulkhead, Steering Strap, Spacer, Top Strap, Spacer, Bottom Bolt Bolt Nut, Nylok -0 Sway Bar 0 Bushing, Sway Bar 0 Rivet, Pop Rivet 0-0 Arm, Steering 0 Nut, FLEXLOC Slide, Sway Bar Washer 000 Bushing 0 Pivot, Rubber, Trailing Arm Bolt 0 0 Asm.,Trailing Arm, LH (Incl.,) Asm., Trailing Arm, RH (Incl.,) Stop, Steering, LH Stop, Steering, RH 0 Bushing, Flanged 0 Bushing 0 Bushing, Flanged 000 Fitting, Lubrication w/ball 00-0 Shaft, Spindle, Trailing Nut, Nylok Washer Ski, Plastic Washer 0 Bolt 0-0 Plate, Skag 0 Skag, Carbide,, 0 Degree Bolt Washer 0 Bolt Nut 0 Toe, Ski, Plastic 0 Pin, Cotter Nut 0-0 Support, Ski, Rubber Retainer, Ski, Rubber 0 Stop, Rubber 000 Retainer, Spring Body, Threaded Ring, Spring Preload, Adjustable 0-0 Spring, Compression 00 Retainer, Spring, Slotted, Cast 00 Bushing 00 Fitting, Lubrication Screw 0 Bushing, Pivot, Radius Rod, Outer 00 Bushing 0 Bushing, Pivot, / 00 Shock, Gas, Select, IFS Bolt 0 Radius Rod, Upper, Fixed 0 Bushing, Pivot, / -0 Radius Rod, Lower Nut, Jam 00 Rod End 0 0 Washer 0 Rivet 0 Nut, FLEXLOC 0 Nut, FLEXLOC -0 Bracket, Pan Support / A

16 STEERING - HANDLEBAR XLT CLASSIC 0EDAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Cover, Handlebar, Top 0 Rivet, Plastic 0 Switch, Handwarmer Hi/Lo (Incl. ) 00 Cap, Switch -0 Handlebar, Adjustable 00 Caplug Grip, Handlebar, Black 0 Heater, Grip Bolt Block, Handlebar, Upper 0-0 Block, Handlebar Nut, Nylok B 0 Screw Cover, Handlebar, Lower 0 Pin, Cotter 00 Cable, Reverse 0 Ring, Retaining Pin, Dowel Screw 0 Pin, Spring -0 Asm., Lever, Shift (Incl. 0) Screw -0 Bracket, Reverse Shift 0 Cover, Handlebar, Upper /

17 STEERING XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, FLEXLOC 0-0 Steering Hoop 000 Cable Tie, Releasable Screw -0 Steering Post Rivet 0 Nut, Nylok 0 Nut, FLEXLOC 00 Fitting, Lubrication 0 0 Bolt Center Steering (Incl.,) 00 Bushing Washer 0 Nut, FLEXLOC 00 Rod End, RH Nut, LH Rod, Drag Link 0 Nut, RH 00 Rod End, LH 0 0 Pin, Cotter 0 Bushing 0 0 Rivet -0 Plate, Boot Seal, LH Boot, Tie Rod, Extra, LH Washer, Wave Screw 0 Block, Steering 00 Clip, Rosebud Boot, Tie Rod, Extra, RH 0-0 Plate, Boot Seal, RH 00 Rod End, High Angle, RH 00-0 Rod, Tie AR Trim, Edge Bolt, Carriage Bolt, Carriage 00 Fitting, Lubrication 000 Rod End, High Angle, LH / B

18 CONTROLS XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Pin, Retaining 00 Ring, Retaining 00 0 Lever, Throttle w/warmer Lever, Throttle 0 Washer Block, Throttle/Brake 00 Switch, Auxiliary Shut-Off Washer Screw 00 Ring, Retaining 0 Screw Holder, Wire 0 Switch, Headlight, Hi/Lo Screw 00 Adaptor, Block 000 Asm., Master Cylinder (Incl. -,-) 00 Screw 0 Cover, Master Cylinder 0 Gasket, Master Cylinder Bolt, Brake Lever 0 Bushing 0 Lever, Brake 0 Spring, Park Brake Lever 00 Lever, Park Brake 000 Bushing, Park Brake Lever Screw Tag, Park Brake Warning 00 Strap, Park Brake Tag Nut, Nylok 0 O-Ring 0 00 Piston, Master Cylinder 0 Seal, U-Packing 0 Spring, Master Cylinder 0 Washer 0 Clamp, Master Cylinder 0 Bolt 0 Housing, Master Cylinder 0 Baffle, Master Cylinder 0 Washer, Baffle, Master Cylinder / B

19 IGNITION and WIRE HARNESS XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Ignition Key w/cap NOTE: When ordering ignition key PN 0 be sure to specify if for an A,B,C,D, or E switch. Letter code will be labeled on underside of switch body behind console. Key dot code found on key cap (i.e. one dot = A, two dots = B, etc.). 0 Nut, Ignition Switch 00 Decal - Ignition Switch 00 Kit - Ignition, E.S. w/key 00 Nut, Choke Slide 0 Washer, Lock 00 Kit - Choke Control 00 Cable, Choke Control (Incl. ) 0 Decal - Electric Start 0 00 Decal - POLARIS, Domed 0 Decal - No Passenger Warning 00 Harness, Wire, Handlebar 00 Housing, Circuit Receptacle 000 Housing, Circuit 00 Housing, Circuit 00 Harness, Main Wire B /

20 BRAKE XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer, Spring Lock 0 Washer 0 Bracket, Caliper 0 Piston and Seal (Incl. ) 00 Kit - Seal, Piston, Caliper 00 Kit - Clip, Spring (Qty. ) 0 Switch, Stoplight 00 Kit - Brake Pad (Incl. ) 0 0 Asm., Brake Caliper (Incl. -,) 0 Kit - Caliper (Incl.,,) 0 Line, Brake 0 Inlet / B

21 CHAINCASE XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Asm., Jackshaft (See Drive Train Pg. B, Ref. ) 000 Seal, Oil Bolt 0 Nut 0 Bearing w/seal 0 Ring, Retaining Washer 0 Sprocket, T, /W 0 Washer, Spring 0 Nut, FLEXLOC 0 Pin, Cotter Asm., Tightener Bearing, Chaincase Idler Block, Tightener Wheel, Idler Washer, Thrust Pin, Chain Tightener 0 Gasket, Chaincase Cover, Chaincase 0-0 Bracket, Cable Mount Screw 0 Washer, Wrought Bolt Bolt 0 00 Seal, Oil 0-0 Shaft, Shift 00 Spring, Reverse Cable Tension B 0 Clevis 0 Pin, Clevis 0 Pin, Cotter Pin, Dowel 0 Ring, Retaining Kit - Shift Fork/Shaft (Incl.,) Fork, Shift 0 O-Ring 0 Washer, Thrust 0 Gear, Pinion, Spur Sprocket, Pinion, T, / W Chain, P, /W 0 Shaft, Pinion 0 Screw Bracket, Chain Retention Screw Chaincase 0 Plug 0 Washer 0 Sprocket w/bearing, T, /W Bearing 00 Coupler, Drive Reverse Gear 0 Spring, Compression 0 Retainer, Drive Coupler 0 Washer, Spring Lock Bolt /

22 DRIVE TRAIN XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer, Flat AR Washer 00 Spacer, Input Shaft Asm., Driven Clutch (See Driven Clutch Pg. B, Ref. ) 0 AR Bushing 00 Flangette w/fitting Fitting, Lubrication 0 Gasket, Jackshaft Bolt, Carriage 0 00 Belt, Drive Key Bearing, Jackshaft Flangette 0 Washer Nut, Nylok 0 Asm., Jackshaft (Incl.,) 0 Ring, Retaining 0 Disc, Brake 00 Sleeve, Seal 0 0 O-Ring Dipstick 0 O-Ring Nut, Flanged Bolt, Carriage 0 Asm., Drive Shaft (Incl.,,) 00 Bushing, Speedometer Bearing, Drive Shaft 0 Flangette w/screws 00 Key, Square, Speedometer 0 Flangette 00 Gasket, Drive Adaptor 0 Adaptor, Drive w/zerk / B

23 COOLING SYSTEM XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok 0 Washer 0 Cap, Overflow Bottle, Drilled 0 Plug, Cap, Overflow 0 Gasket, Cap, Overflow 0 Bolt Bottle, Overflow w/fittings 0 Rivet Extrusion, Cooling, Center 0 00 Clamp, Hose, Silver 00 Clamp, Hose, Gray 0 Extrusion, Cooling, Side, LH Guard, Cooling Extrusion Hose, Side to Center, LH 0 Hose, Center to Pump Filler, Remote Coolant Bracket, Oil Tank B Cap, Pressure 00 Hose, Engine Out/Filler 0 00 Spring, Hose Retainer 00 Clamp, Hose Tubing, Convoluted 0 Hose, Crossover Tubing, Convoluted 00 Spring, Hose Retainer 0 Hose, Filler Out, RH 000 Clamp, Hose, Large Green 0 Foil, Tape 000- AR Line, Coolant 0 00 Check Valve 00 Clip, Rosebud 00 Filter, Coolant Extrusion, Cooling, Side, RH /

24 SUSPENSION XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Insert, Wheel ( Per Wheel) 0 Wheel (Incl. -) 0 Bearing, Roller ( Per Wheel) 0 Ring, Retaining ( Per Wheel) Bolt Washer Spacer 0 Spacer, Bogie Wheel Plate, Rail Support 0 Block, Spring Slider 0 Bracket, Bumper Support 0 Bumper, Jounce, Rail Nut, Nylok Nut, Nylok Bolt Mount, Bumper 0 Bumper, Pivot Arm 0 Nut, FLEXLOC 0 Bumper, Rear, Pivot Arm 0 Block, Pivot Arm Stop, Rear Asm., Rail, Xtra-, LH (Incl.,,,,,,) Asm., Rail, Xtra-, RH (Incl.,,,,,,) Screw 0 Rivet, Flat Head 00 Block, Idler Bolt Adjusting 00 Nut Bolt Nut, FLEXLOC 0 Bolt Rivet 0 Rivet Bolt 0 Washer, Spring Lock 0 Bolt Washer 00 Bushing Hi-Fax, White Screw Rivet, Pop Cover, Rail Tip 0 Nut, Nylok / B

25 SUSPENSION XLT CLASSIC 0EDAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt Washer, Belle 0- Wheel, Idler, Red Spacer, Idler Washer 0 Shaft Bushing 0 Wheel, Idler, Black Spacer, Idler, Long 0 00 Shaft, Idler Screw 0 Washer 0 Screw Boss, Bolt Head Screw 0 Washer, Lock 0 AR AR Track Clip, Slide Clip, Guide 0-0 Shaft, Limiter Strap 00 Fitting, Lubrication Shock, Pivot Arm 00 Shaft, Bracket, Rear Shock -0 Pivot Arm, Rear Nut, FLEXLOC / B0

26 FRONT TORQUE ARM XLT CLASSIC 0EDAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Washer, Lock 00 Shaft, Front Torque Arm, Upper 0-0 Front Torque Arm 0 Strap, Limiter Washer 0 Bolt 0 Nut, FLEXLOC Washer 0 00 Fitting, Lubrication 00 Shaft Rivet Bumper, Front Torque Arm Nut, Nylok / B

27 REAR TORQUE ARM XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Screw Washer, Lock Washer 00 Shaft, Rear Torque Arm, Upper Bolt Nut, FLEXLOC 00 Fitting, Lubrication Sleeve, Torsion Spring Spring, Torsion, LH, Std. (.0 Dia.) Spring, Torsion, RH, Std. (.0 Dia.) Spring, Torsion, LH, Firm, Opt. (. Dia.) Spring, Torsion, RH, Firm, Opt. (. Dia.) 0 Washer, Thrust Wheel Bearing Ring, Retaining 000 Collar, Bearing Lock Screw, Set 0-0 Rear Torque Arm 0 Nut, FLEXLOC, Thin 00 Shaft Screw 0 Shock, Rear Track -0 Retainer, Spring 0-0 Spring, Compression 0 0 Shield, Spring 00 Clip, Push-On 0 Roller, Spring, Adjustable 00 Retainer, Spring, Slotted 0 Bushing 0 Shield, Spring 0-0 Spring, Compression Ring, Spring Preload 000 Retainer, Spring, Body, Threaded 0-0 Rod, Shock 0 Washer 0 Spacer 0 Shock, Front Track, Adjustable Bolt / B

28 DRIVE CLUTCH XLT CLASSIC 0EDAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Kit - Clutch Rebuild (Incl. -,0,,) Bolt 0 Washer, Spring Lock Bearing, Cover 0 Ring, Retaining,Cover 0 Spring, Clutch, Silver/Gold 00 Pin, Roller 00 Kit - Shim, Drive Clutch 0 Button, Guide 00 Nut, Jam 0 0 Washer, Multilube Roller and Bushing AR AR AR AR Spacer (.00 ) Spacer (.0 ) Spacer (.0 ) Spacer (.00 ) Shift Weight, 0M-B 0 Pin, Weight 0 Bearing, Sleeve 00 Insert, Moveable 0 Gear, Ring Screw 0 Nut, FLEXLOC 0 Asm., Drive Clutch, ES, Basic (Incl. All Less,) / B

29 DRIVEN CLUTCH XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw 0 Plate, Driven 0 Ring, Retaining 0 Washer 0 Ramp, Driven, Degree 0 Key 0 Spring, Clutch, Silver 0 Bushing, Driven, Large DU 0 0 AR AR AR Washer (.0) Washer (.0) Washer (.0) 0 Washer 00 Pin, Driven, Adjustable Cam, Driven, Adjustable Bolt 00 Cap, Driven 0 Button, Ramp Asm., Driven Clutch, Adjustable (Incl. -) / B

30 ENGINE MOUNTING XLT CLASSIC 0EDAS C

31 ENGINE MOUNTING XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer, Lock 00 Washer, Clutch Retainer, Short 00 O-Ring, Clutch Bolt 00 Spacer, Clutch Bolt 000- Conduit, Convoluted 00 Spark Plug, RNC Champion 0 Engine, ECPL, Short Block NOTE: The Short Block Engine asm. contains a crankcase asm., cylinder and cylinder head asm., and a piston & crankshaft asm. Prior authorization required for warranty consideration. Well Nut 0 Washer, Flat Asm., Fuel Pump (See Fuel Pump Pg. C, Ref. ) Nut, Flange 0 Washer, Flat 00 Mount, Engine, Rubber 0 Nut, FLEXLOC 0 0 Plate, Engine, RH Plate, Engine, LH Washer 0 Washer, Spring Lock Bolt 0 00 Mount, Engine Washer, Flat 00 Nut, FLEXLOC Nut, Hex 00-0 Torque Limiter Rivet 00 Stop, Torque, Coarse Spacer Bolt 0 Washer 0 Handle, Recoil 0 Screw AR Line, Fuel 00 Cable, Throttle w/oil 00 Cable Tie AR Line, Fuel 0000 Clamp, Hose, Red 000 Filter, Fuel 00 Clamp 000 Valve, Fuel Shut-Off AR Hose / C

32 EXHAUST SYSTEM XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Spring, Exhaust 0-0 Resonator 00 Spring, Exhaust 0 Dampener, Vibration Gasket, Exhaust (See Cylinder Pg. C, Ref. ) 0-0 Manifold Washer, Lock (See Cylinder Pg. C, Ref. 0) Nut (See Cylinder Pg. C, Ref. ) AR Washer, Thrust Muffler / C

33 OIL TANK/AIR BOX XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description 0000 Sensor, Oil Level w/connector 0 Cap, Oil Tank 0 Gasket, Oil Cap 0 Washer 0 Bolt Oil Tank w/sending Unit Hole 000- AR Line, Fuel 000 Filter 00 Clamp, Hose, Yellow Clamp, Hose, Large Green 00 Fitting, Outlet, Single Nut, Nylok 00 Fitting, 0 Degree AR Fuel Line 00 Spring, Vent Hose Protector Bolt 0 Washer 0-0 Bracket, Air Silencer 0 Decal - Fuel Shut-Off 0 Rivet Well Nut 00 Plate, Silencer, Air 0 Decal - Cooling System 00 Clip, Rosebud 00 Air Duct Silencer, Air, Upper, Drilled 0 Decal - Caution, Air Box 00 Decal - Adjustable Driven Clutch 0 Decal - Greasing 0 Baffle 00 0 Clip, Silencer Bracket, Silencer, Intake -0 Bracket, Front Silencer Silencer, Intake, Drilled 0 Boot, Air Silencer / C

34 BATTERY BOX XLT CLASSIC 0EDAS 0 Back side of console shown 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Screw Nut, Nylok 00 Regulator, LR 00 Cable, Battery/Engine 00 Kit - Battery Bolt, Short 0 Washer 000 Battery 000 Cable, Battery/Solenoid 0 AR Tube, Battery Vent Strap, Battery Holddown 00 Pad, Battery 0-0 Battery Box Rivet 0 Washer 0 Washer 000 Wire, Jumper, Solenoid/Battery 0 Insulator, Cable 000 Cable, Solenoid/Starter AR Trim, Edge 0 00 Breaker, Circuit 000 Rectifier, LR- 00 Sink, Heat 0 Washer, Star 00 Bolt / C

35 TOOL KIT XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Tool (Incl. -) Screwdriver Wrench, 0- Spanner Box Wrench, Special Screwdriver, Flat, Shielded 00 Strap, Emergency Starter Manual, Owner s, Snowmobile Supplement, Owner s Manual, XLT Classic C 0 Cover, Tool Box 0 Foam, Tool Box 0 Screw 0 0 Tool Box 0 Tray, Tool Box Mount /

36 CRANKCASE XLT CLASSIC 0EDAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Nipple, Elbow 0 Stud 0 Grommet 0 Asm., Crankcase (Incl.,,,,0-) 0 Pipe, Pulse 000 Pin, Dowel C 0 Gasket, Aluminum 0 Bolt, Flange 00 Seal, Oil 0 00 Bolt and Washer 00 Bolt and Washer 0 Bolt and Washer /

37 CYLINDER XLT CLASSIC 0EDAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Flange Bolt 0 Flange Bolt 0 Thermo Switch (0 Degree C) 0 O-Ring, Head 0 Cylinder Head (PTO) 0 Cylinder Head (Center) 0 Gasket, Head 00 Cylinder (Incl.,) 0 Plug 0 0 Check Valve 0 Gasket, Cylinder 0 Asm., Band (Incl. ) 0 Screw, Pan Head Adapter 00 Bolt, Socket Head 0 O-Ring 0 Adapter (Incl. ) 0 Nut, Flange 0 Stud 0 Gasket, Exhaust Washer, Spring Lock 00 Nut 0 Cylinder Head (MAG) 0 O-Ring, Head Cover 0 Head Cover (Incl. ) 0 Pipe, Water 0 Dowel Pin / C

38 PISTON and CRANKSHAFT XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description Ring, Piston (Standard) Ring, Piston (0.mm/.00 O/S) Ring, Piston (0.0mm/.00 O/S) Piston (Standard) Piston (0.mm/.00 O/S) Piston (0.0mm/.00 O/S) 00 Pin, Piston 0 Clip, Piston Pin 00 Bearing, Small End 0 Rod, Connecting 0 Bearing, Large End 0 Crank Pin 0 Spacer, Crank Pin 0 0 Crank Pin 000 Key, Woodruff Asm., Crankshaft (Incl. -0,-) Crankshaft (MAG Side) Crankshaft (Center) (Incl. -0,,) Crankshaft (MAG Side) (Incl. 0) 0 0 Crankshaft (PTO Side) (Incl. ) 0 Crankshaft (PTO Side) 0 Bearing, Ball 00 Spacer 0 Bearing, Ball 0 Bearing, Ball 0 0 Washer 00 Nut / C

39 WATER PUMP XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description 0 O-Ring, Outlet 00 Pump Casing 00 Bolt and Washer 0 O-Ring 0 Asm., Water Pump (Incl.,,,) 0 Belt 0 Pulley, Drive 0 Screw and Washer / C0

40 CARBURETOR XLT CLASSIC 0EDAS Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Mixing Chamber Top 0 Spring, Throttle 00 Plate, Throttle 00 E-Ring, C-Ring 0 Jet Needle (DP-) 0 Throttle Valve (.) 0 Needle Jet Q- (0) 0 Cap 0 Cap, Plunger Spring, Plunger 0 Asm., Plunger 000 Spring, Throttle Adjuster 000 Screw, Throttle Stop 00 Screw, Air 00 Spring, Air Adjuster 00 Pilot Jet (#0) 00 Screw and Washer 00 Clamp, Hose 00 Clamp, Hose 0 Plug, Trap 00-0 Conduit, Convoluted 00- Fuel Line 00 Nipple 0 O-Ring 0 Main Jet (#0) 00 Washer 0 Asm., Carburetor (Incl. -,-) 00 Asm., Float 0 Cap Gasket, Float Chamber 00 Valve, Needle (.) 00 Packing, Needle Valve 00 Arm, Float 0 Pin, Float / C

41 FUEL PUMP XLT CLASSIC 0EDAS Ref. Part Qty. Description 0 Diaphragm, Gasket Set 00 Asm., Fuel Pump (Incl.,) 0 Screw and Washer / C

42 OIL PUMP XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Clamp, Hose 0 Vinyl Pipe (0mm) 0 Vinyl Pipe (0mm) 0 Screw, Air Vent 0 Band, Wire 0 Packing 0 Asm., Oil Pump (Incl.,,,-) 0 Vinyl Pipe (0mm) 0 Gear, Small 0 00 Spacer C 0 Bushing AR AR AR Spacer (.mm) Spacer (.mm) Spacer (.mm) 0 O-Ring 00 Nut 0 Washer, Spring 0 Lever, Control 0 Collar, Cam Shaft 0 Spring, Return 0 Screw and Washer /

43 MAGNETO XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Band, Wire 0 Screw and Washer 0 Clamp 0 Screw and Washer 0 Asm., Plate (Incl. -,) 0 Screw and Washer 00 Screw and Washer 0 Asm., Flywheel 0 Plate, Coil 0 00 Coupler, P 0 C.D.I. System 00 Cap, Spark Plug 0 Code 00 Bolt and Washer 00 Ignition Coil 0 Coupler, P 0 Grommet / C

44 RECOIL STARTER XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Pulley, Starting 0 Bolt and Washer 0 Nut, Flange 0 Plate, Friction 0 Spring, Friction 0 Ratchet 0 Spring, Return 0 Reel 0 Rope, Recoil 0 0 Spring, Spiral 00 Guide, Rope 0 Bolt 000 Washer, Spring Lock 00 Nut 00 Bolt and Washer 0 0 Recoil Starter (Incl. -,) Starter Case / D

45 STARTING MOTOR XLT CLASSIC 0EDAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Kit - Brush & Spring Asm., Brush & Screw Asm., Brush Bushing, Insulation Washer, Insulation Nut 00 Kit - Asm., Commutator Cap (Incl.) Nut Screw Bracket, Starter, Rear 00 Kit - Asm., Armature 00 Kit - Drive Hardware Washer, Curved Spring Washer, Thrust Spacer Spring, Antidrift Pinion, Stop Ring, Lock Cover, Dust D 00 Kit - Asm., Drive Cap 00 Kit - Asm., Drive Plate, Drive Pinion 0 Bracket, Starter, Front 0 Washer, Lock Bolt 0 Screw 00 Kit - Screw Bolt, Thru 0 Nut 000 Washer, Spring 0 Switch, Magnetic (Incl.,) 000 Motor-Starter, Domestic /

46 Part Ref. Grid C A A A A A A A B A A A A A C B A A A B A A A A A A A C C A C C B B B B B B B B B B B B A.. B B B B B B B B B B B B B A B B A A A A B B B B PART NUMBER INDEX XLT CLASSIC 0EDAS Part Ref. Grid B B B B B B B B B B C B B B B B D D D D D D D A B A A A C C B A B B A B A B B B C B C A A C A A A A A A A A C D A C A C D C D C C C C... D C D Part Ref. Grid C C C C C C C C C C C D C C D C D C C C C C C C C C C D C C D C C C C C C D D D D D C C D D C C C C C C C C C C C C C C D C C C C C C C C

47 Part Ref. Grid C C C C C C C C C C C C C C C C C C C C D C C C C C C C C C C C C C C C C D D C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C PART NUMBER INDEX XLT CLASSIC 0EDAS Part Ref. Grid C C C C C C C C C C C C C C C C B B B B B A B A A A A A A A A A A A A A A A A B.. B B B B B B B B A B A B B B B C C C C C B C B B... B... C B A A D Part Ref. Grid A B C C C A B B B B C D A A B C A B B B B B C C B B B B B B B B B B B B B B B B B B B B B B B B B B C A B B B B C C A A A B B A A B B B B

48 Part Ref. Grid A B A B B A B A B A A A B A A A A B A C A B C B A A A A A B B D B A B A A A D A C C B A B C B B B B B B B B C C A... C C B B B B B B B A C A PART NUMBER INDEX XLT CLASSIC 0EDAS Part Ref. Grid A A A B A B B B A B B A A A A B B B A B B A B B B B B C C B C A B B A B B B A C A A B B A C A A B A A A B B B A.. B A A A C C B B B A A B A D Part Ref. Grid C C A B A B A A A B A B B... C B B B B B B B B B B A.. B B C B C B A A A A A A A C B A A A A A A A A A B A A A A A A A B C A B B B B A B B B B

49 Part Ref. Grid A B B B A B C B C B C B B A B C C A A... C B A B B B B C C C A A A B A C C A B A A A A A A A A A A A A A A A B B A A A A A A A A... C A0... C A B C PART NUMBER INDEX XLT CLASSIC 0EDAS Part Ref. Grid B C A B 0... C A B A A A A A... B.. B0 0.. B.. B B B B A A A C.. C C C A A A A B... B B B B B A... B B B A B A A C C B A A B B... C A A A A C... C A... B... C A... B A B B B B B D Part Ref. Grid B A.. B B B... B B B B C B A C C A B.. B A B A B A B A A B B B A A B B B A B A.. B B B A B B B B D B D D A B B B B B B B B B A A0.. B A... C... C A... C A

50 Part Ref. Grid B... B A.. A... B... B... B 0... B... C A A A A... D A... B A B.. B B C A... B.. B B B.. B0.. B C B B A A... B A A B C B A... B A B C B B.. B0... D A... C... C... C B.. B B B B... C B B B A... B B B B B C PART NUMBER INDEX XLT CLASSIC 0EDAS Part Ref. Grid B A A A A B A... C A B B.. B A A 0... C A B B B B A B0... C B A... A 0.. A... C C B B B B B A... B B.. B C A... A.. A B... C A... B B B C B B B C A A A A A A A B A.. B A A A B A D Part Ref. Grid A A... A.. A... C A... A A A B B A.. A0... B A B B... B A B B A... A.. A... B... B... C 0... C A... A.. A B B B B A A B A B A C A A A B B B B B B B B B.. B B B A C... C C A... B... C A... C C A

51 Part Ref. Grid C C C PART NUMBER INDEX XLT CLASSIC 0EDAS Part Ref. Grid Part Ref. Grid D

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56 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN

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60 PRINTED IN THE USA PARTS MANUAL PN 0 and MICROFICHE PN 0 /