FREEDOM Model #W035297DA Model #W035297IA. E 2002 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /02

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1 FREEDOM Model #W0DA Model #W0IA E 00 Polaris Sales Inc. PARTS MANUAL PN 0 and MICROFICHE PN 0 /0

2 TABLE OF CONTENTS FREEDOM W0DA and FREEDOM W0IA Parts Manual BATTERY... BILGE PUMP... CARBURETOR... COOLING SYSTEM... CRANKCASE... CRANKSHAFT and PISTON... CYLINDER & MANIFOLD... DECALS... DRIVE SYSTEM... B C D E B B C B C C C A B ELECTRICAL BOX... B- ELECTRICAL BOX MOUNTING... B ENGINE AIR INTAKE/HULL AIR INLET... B ENGINE FOGGING SYSTEM... B ENGINE MOUNTING... B EXHAUST SYSTEM... B F FRONT STORAGE COMPARTMENT... A FUEL SYSTEM... A0 FUEL TANK... A FUEL/WATER SEPARATOR... B0 H HULL and BODY... A- M MAGNETO... OIL PUMP... OIL TANK... PROPULSION O P... S C C A SEAT... A SHROUD... A- STARTING MOTOR... C STEERING... A- TOOL KIT WATER INLET T... W... B C B The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

3 SHROUD FREEDOM W0DA and FREEDOM W0IA E 00 Polaris Sales Inc A

4 SHROUD FREEDOM W0DA and FREEDOM W0IA 0 Gauge, Fuel, Warning 0 Asm., Console Latch - Lid, Console 000 Spring, Torsion, Console 0 Seal 0 Nut Pad, Console 0 Nut, Nylok 0 Washer 0 Hook, Console Screw Screw 0 Washer, Lock Washer, Flat 00 Cable, Choke Grommet, Access 0 Nut, Nylok Rivet Bracket, Hood Post 0 Washer Nut Pin, Latch Grommet, Deck, Wire Harness 00 Cable Tie 00 Rivet Cover, Reverse Gasket - Shroud, Steering 0 Bumper, Door/Shroud 0 00 Knob 0000 Screw Washer, Lock Pin, Hinge Hinge, Console /0 A

5 HULL and BODY FREEDOM W0DA and FREEDOM W0IA A

6 HULL and BODY FREEDOM W0DA and FREEDOM W0IA - Pad, Boarding - - Pad, Footwell, Rear, LH Pad, Footwell, Rear, RH - - Pad, Footwell, Center, LH Pad, Footwell, Center, RH - - Pad, Footwell, Front, LH Pad, Footwell, Front, RH Screw 0 Washer 0 Nut, Nylok Screw Plate, Seat Tongue 0-00 Bumper, Front Rivet -00 Plug, Bumper, Rear Nut, Nylok Washer, Flat 0 Washer, Dish, Rubber 00 Strap, Bow 0 Screw Washer, Flat Rail, Rub, Side, LH Rail, Rub, Side, RH 0 Washer, Lock Nut Sponson, LH Sponson, RH Screw 0-00 Bolt, Carriage 0 Washer, Rubber Washer, Flat Pad, Heel, LH Pad, Heel, RH -00 Bumper, Rear 00 Plug, Bilge 0 Screw Hook, Tow Nut, Nylok Washer, Flat -00 Handle, Grab Nut 00 Plunger, Latch /0 A

7 FRONT STORAGE COMPARTMENT FREEDOM W0DA and FREEDOM W0IA 0 0 Latch, Hood Bumper, Door/Deck - Door, Compartment 0 Asm., Door Hinge Screw Washer, Flat 0 Nut, Nylok 0 Washer, Rubber 0 Washer 0 0 Screw Washer, Lock Seal, Door Rivet 00 Cable, Limiter, Hinge Plate, Fire Extinguisher Cover, Fire Extinguisher 00 Asm., Fire Extinguisher Container (Incl. and Container) Container, Fire Extinguisher 0 Rivet Seal, Bucket, Front 0 Bucket, Front Storage /0 A

8 DECALS FREEDOM W0DA and FREEDOM W0IA RH 0 LH 0 Kit, Decals Freedom 0 Decal, Warning, Rear Decal, Cover, Mirror, LH Decal, Cover, Mirror, RH 0 Decal, Fuel, Off/On 00 Decal, Fire Extinguisher 0 Logo, Polaris Star 0 0 Decal, Deck, Front, LH Decal, Deck, Front, RH 00 Decal, POLARIS 0 Decal, Refueling Warning 0 Decal, Spark Ign. Comp. w/canada A 0 0 Decal, POLARIS, LH 0 0 Decal, Deck, Rear, FREEDOM, LH Decal, Deck, Rear, FREEDOM, RH 0 Decal, NMMA, Passenger 0 Logo, Planet 0 Decal, Hood Center, Polaris 0 Decal, Gauge Cover 0 Decal, Warning 0 Decal, Caution, Capsize 0 Decal, Patent 0 Decal, Coast Guard, Exemption /0

9 FUEL TANK FREEDOM W0DA and FREEDOM W0IA Bracket, Strap 0 Washer, Lock Screw Hook, Strap, Narrow 0 Strap, Rubber Tank, Oil (See Oil Tank Pg. A, Ref. ) Hook, Strap 0 Strap, Battery Holddown 0 Cap, Fuel, Ratchet Chain, Bead, Cap Retainer Screw 00 Coupling, End, Fuel Cap Chain Inlet, Fuel A Seal, Fuel Inlet Nut, Fuel Inlet 00 Clamp, Hose Hose, Fuel Fill 00 Clamp 0 Asm., Fuel Sender 0 0 Rivet 0 Pad, Fuel Tank Stop Bracket, Fuel Tank Stop Pad, Fuel Tank Tank, Fuel Rivet 0 Seal, Fuel Cap /0

10 FUEL SYSTEM FREEDOM W0DA and FREEDOM W0IA 0 SEE NOTE BELOW NOTE: Fuel line from fuel/water separator connects to fuel sender fitting marked ON. 0 Screw 0 Washer, Flat -00 Knob, Fuel Valve, Black Nut, Fuel Valve 0 Valve, Fuel 00 Clamp, Hose 00 T-Clip 00 AR Line, Fuel 0 Fitting A Separator, Fuel/Water (See Fuel/Water Separator Pg. B0, Ref. ) 0 Fitting, Tee 0 Grommet, Vent 00 Cable Tie 00 Valve, Check 00 Cable Tie 0 Valve, Vacuum Check Asm., Fuel Sender (See Fuel Tank Pg. A, Ref. ) /0

11 SEAT FREEDOM W0DA and FREEDOM W0IA 0-0 Asm., Seat, Final (Incl. -) 0- - Asm., Seat, Main Cover, Seat, Main Asm., Seat, Rear Cover, Seat, Rear 0 Spacer Plate, Top, Seat Base Latch Handle, Seat Base Latch 00 Spring, Seat Base Latch A Plate, Seat Base Latch Plate, Bottom, Seat Base Latch Washer, Flat 0 Washer, Lock Screw 0 Rivet Plug, Nylon /0

12 OIL TANK FREEDOM W0DA and FREEDOM W0IA Coupling 000 Chain Rivet Screw Cap, Oil Tank 0 Rivet Inlet, Oil Gasket, Oil Inlet 00 Clamp, Hose 0 00 Elbow, 0 Degree 0 Sender, Low Oil Warning A 00 Cable Tie 000- Conduit 000 Clamp, Hose 0 AR Line, Fuel 00 Filter, Oil 00 Clamp, Hose 00-0 AR Line, Fuel Tank, Oil 0 0 Valve, Check, Vacuum 0 AR Line, Fuel Hose, Oil Fill /0

13 STEERING FREEDOM W0DA and FREEDOM W0IA 0 0 Screw Washer, Lock Washer, Flat 0-00 Pad, Handlebar, Top -00 Pad, Handlebar, Bottom 0 Screw 0 Clamp, Handlebar -00 Handle, Grab 0 Block, Throttle, Split 0 00 Cable, Throttle 00 Cable Tie 0 Switch, START/STOP/BILGE Button, Start/Stop, LH 00 Lanyard w/whistle 0-00 Handlebar w/grip A Column, Steering Housing, Steering Bearing, Steering Nut, Nylok Washer, Flat 0 Gasket, Steering Housing Screw Clamp, Throttle Block 0 Ring, Retaining 0 Washer, Flat 0 Lever, Throttle, Thumb 0 Pin, Retaining Rivet 00 Cable Tie 0 Pin, Roll /0

14 STEERING FREEDOM W0DA and FREEDOM W0IA Nut 0 Screw Washer, Flat 000 Rod End Nut, Nylok Seal, Rod 0 Ring, Stopper 0 Nut, Steering Cable (Special) 000 Cable, Steering 0 Washer, Flat 00 Nut, Jam 0 Seal, Rod 0 Screw Bolt Column, Steering Mount, Shroud, Steering 0 Nut, Nylok 0/0 A

15 DRIVE SYSTEM FREEDOM W0DA and FREEDOM W0IA 0 00 Asm., Drive Coupler 0 O-Ring Shroud, Coupler 00 Clamp, Hose 0 Bumper, Drive Shaft 0 Shaft, Drive 00 Fitting, Lubrication B 000 Seal, Bearing Asm., Bearing Housing (Incl., ) 0 0 Hose, Bearing Housing Fitting, Drive Shaft, Thru-Hull O-Ring Nut, Thru-Hull Bushing /0

16 PROPULSION FREEDOM W0DA and FREEDOM W0IA Nut, Nylok Bracket, Steering Cable Nut Stud, Pump Mounting Housing, Pump 0 O-Ring Pipe, Water, Engine 0 Stator, Pump 00 Spacer, Bearing 00 Bearing 0 00 Seal, Stator Bearing 00 Spacer, Impeller Impeller Extension, Pump 0 Screw 0 Anode, Zinc Stud, Mounting, Pump, Long Washer, Flat 0 Washer, Lock B Nut 0 0 O-Ring Seal, Tailcone Screen, Engine Inlet 0 Nozzle, Steering Screw 0 Collar 0 Washer, Lock Washer, Flat Bearing, Steering Nozzle Bolt 0 Nozzle, Stationary Wedge, Pump 0 Screw Cone, Pump 0 O-Ring Shaft, Stub 0 O-Ring /0

17 EXHAUST SYSTEM FREEDOM W0DA and FREEDOM W0IA Fitting, Inlet, Water Washer, Flat Washer, Lock Screw 00 Screw 00 Gasket, Exhaust 0- Asm., Exhaust Pipe 00 Clamp, Hose Hose, Pipe/Silencer 0 0 Strap, Rubber Pad, Foam Hook Screw Washer, Lock Washer, Flat B 0 Bumper, Rubber Cradle, Silencer 0-0 Silencer, Exhaust 00 Clamp, Hose 0 Hose Hose, Crossover 000 Clamp, Hose 0 Hose Resonator Hose, Exhaust Fitting, Exhaust 0 Seal Washer, Flat Screw /0

18 ENGINE MOUNTING FREEDOM W0DA and FREEDOM W0IA Asm., Temperature Switch Ground, Spark Plug 00 Decal, Spark Plug Screw Decal, Warning (See Cylinder and Manifold Pg. C, Ref. ) Spark Plug, NGK BPRES (See Cylinder and Manifold Pg. C, Ref. ) Washer, Flat - Plate, Front Mount - Plate, Rear Mount 0 0 Washer, Flat 0 Lock, Plate 0 Screw 0 Mount, Engine AR Shim, Engine Mount B 0 Washer, Flat 0 0 Washer, Lock Screw 00 Bracket, Rear Muffler Screw 0 Washer, Flat Nut, Nylok 0 Washer, Lock Bolt 00 Kit, Short Block NOTE: The Short Block assembly contains a crankcase assembly, cylinder, and cylinder head assembly. 0 Clip, Retainer 0 Bolt 00 Cable Tie /0

19 BATTERY FREEDOM W0DA and FREEDOM W0IA E 00 Polaris Sales Inc. 0 Screw Bracket, Battery Hold Down Cover, Battery 0 Grommet, Vent 00 Connector 00 Cable Tie AR Tube, Battery Vent Pad, Battery 000 Battery, Amp 0 00 Kit, Battery Bolt 00 Cable, Ground, Battery/Engine /0 B

20 COOLING SYSTEM FREEDOM W0DA and FREEDOM W0IA Clamp, Hose - Fitting, Thru-Hull Gasket - Conduit, Flex 0 Hose, Outlet, Pump Fitting, Tee 00 Clamp, Hose 0 Fitting, Screen, Exhaust Hose, Water 0 00 Fitting, Injector, Exhaust 00 Hose, Inlet 00 Cable Tie Screw Screw B 0- Asm., Exhaust Manifold Washer, Flat Washer, Lock 00 Screw 00 Fitting, Drain Exhaust 0 - Conduit, Flex Hose, Water Out Valve, Pop-Off 000 Thermostat, Degrees F. 0 Gasket, Thermostat Washer Cover, Thermostat, Machined 00 Spring, Compression 00 Seal, Thermostat Housing /0

21 WATER INLET FREEDOM W0DA and FREEDOM W0IA 0 0 Scoop, Inlet 00 Nut, Hex, Nylon Washer, Flat 0 Gasket, Pitot Washer, Flat 0 Screw, Nylon 0-0 Grate, Inlet Screw Screw 0 Screw 00- Plate, Ride 000 Insert, Sponson/Ride Plate /0 B

22 BILGE PUMP FREEDOM W0DA and FREEDOM W0IA 0 0 Elbow 00 Cable Tie 000- Hose, Water 00 Strap, Cable - Fitting, Water, Thru-Hull Gasket B Hose 00 Clamp 0 Asm., Bilge Pump 0 Washer, Flat 0 Screw /0

23 ENGINE AIR INTAKE/HULL AIR INLET FREEDOM W0DA and FREEDOM W0IA ENGINE AIR INTAKE 0 HULL AIR INLET -00 Plug, Intake Silencer 0 O-Ring Stud 00 Gasket, Carburetor, Upper Base, Intake Screw 0 Filter, Intake 0 Decal, POLARIS MARINE 00 B -00 Cover, Intake 0 0 Nut, Acorn 0 Rivet 0 Flange, Air Inlet Gasket 00 Clamp, Hose 0 Duct, Air Inlet 00 Cable Tie /0

24 FUEL/WATER SEPARATOR FREEDOM W0DA and FREEDOM W0IA Screw Washer, Lock 0 Washer, Rubber, Dish Spacer 00 Separator, Fuel/Water (Incl. -) B0 00 O-Ring 0 Element 0 Spring 00 Float /00

25 ELECTRICAL BOX FREEDOM W0DA and FREEDOM W0IA 0 Top View B

26 ELECTRICAL BOX FREEDOM W0DA and FREEDOM W0IA 0 Harness, Main 00 Cable Tie 00 Cable Tie 00 Cable Tie 0 Insulator Harness, Starter Relay, Bilge Screw Washer, Flat Plate, Stator 0 0 Decal, RESET ELEC SYSTEM O-Ring 00 Boot, Threaded 00 Cable, Battery/Solenoid 00 Cable, Solenoid/Starter 0 Harness,WireStator 0 Nut, Nylok Cover, Electrical Box Seal 00 Regulator, Button 0 0 Screw 0 Washer, Flat 0 Nut, Nylok 00 Asm., Grounding Strap w/fuses Controller, Ignition (See Magneto Pg. C, Ref. 0) 00 Anchor -. Conduit 00 Fuse, Amp 00 Fuse, / Amp 0 Harness, Jumper 0 Pin, Latch 0 Latch Screw 00 Plug, Wire Sealing 0 Cap Grommet, Solid Asm., Electrical Box, Ignition (Incl.,,,0) 0 Breaker, Circuit 0 Asm., Terminal Board Coil, Ignition (See Magneto Pg. C, Ref. ) 0 0 Bracket, Coil /0 B

27 ELECTRICAL BOX MOUNTING FREEDOM W0DA and FREEDOM W0IA Screw 0 Washer, Rubber Washer 0 Bracket, Electrical Box 0 Spacer 00 Driver, Lamp LR Burr Bumper 0 Anchor 0 0 Nut, Nylok 0 Rivet B 00 Strap, Cable 00 Relay Washer, Ext.., Lock Washer, Lock 0 Nut Insulator (See Electrical Box Pg. B, Ref. ) Washer, Flat Screw 0 Hook Strap /0

28 ENGINE FOGGING SYSTEM FREEDOM W0DA and FREEDOM W0IA 0 0 Kit, Engine Fogging 00 Cable Tie 00 Clamp, Hose 00 Clamp, Hose 0 Fitting, Tee 0 Decal, Engine Primer 00 AR Line, Oil 0 Primer, Engine, Fog Screw (See Fuel/Water Separator Pg. B0, Ref. ) Washer, Lock (See Fuel/Water Separator Pg. B0, Ref. ) Washer, Dish (See Fuel/Water Separator Pg. B0, Ref. ) B Separator, Fuel/Water (See Fuel/Water Separator Pg. B0, Ref. ) 0 Decal, Fogging Oil Only Washer, Flat Nut 00 Valve, Check, Vent 0 Fitting, 0 Degree Tank, Oil 0 Gasket, Overflow Cap Cap, Oil Bottle 0 0 Screw Bracket, Fog Bottle 0/

29 CRANKCASE FREEDOM W0DA and FREEDOM W0IA 0 0 Stud, Cylinder Flange 00 Kit, Asm., Crankcase (Incl. -,-) 00 Pin, Dowel 0 Fitting 0 Plug O-Ring Bushing Clamp, Stator Wires Screw 0 Bushing 0 Bushing C 0 Spring Screw 0 Screw 0 Asm., Flywheel Cover (Incl. ) 0 Gasket, Flywheel Cover Screw 00 Pin, Dowel 0 Asm., Flywheel Housing (Incl.,) 0 0 Plug Screw Screw /0

30 CYLINDER & MANIFOLD FREEDOM W0DA and FREEDOM W0IA Decal, Warning 0 Screw 00 Decal, Spark Plug 0 Plug, Pipe 00 Spark Plug, NGK BPRES Screw Screw 0 O-Ring 0 O-Ring 0 O-Ring 0 Nut 00 Cylinder 0 Screw C 0 Screw Bracket, Oil Pump Cable 0- Manifold, Intake 00 Gasket, Carb Stuffer, Reed Block 0 Asm., Valve, Reed 0 Gasket, Cylinder Base 0 Head, Cylinder Ring, Head 0-0 Cover, Head 00 Gasket, Water, Manifold 00- Asm., Manifold, Water /0

31 CRANKSHAFT and PISTON FREEDOM W0DA and FREEDOM W0IA Circlip, Piston 00 Pin, Piston 00 Kit, Piston Rings (Std.)( Rings) 00 Kit, Piston Rings (.mm OS) 00 Kit, Piston Rings (.0 mm OS) NOTE: If the number stamped on the head of piston reads ELKO a use the above kits. Kit, Piston Asm. (Std.)(Incl.,,) Kit, Piston Asm. (. mm OS)(Incl.,,) Kit, Piston Asm. (.0 mm OS)(Incl.,,) 00 Kit, Connecting Rod Assembly (Incl. -) 00 Bearing, Connecting Rod (0 mm) Washer, Thrust Pin, Crankshaft Bearing, Connecting Rod 0 0 Bearing, Ball Seal 0 O-Ring Collar, Crankshaft 0 Bushing 0 Crankweb, PTO 0 Crankweb, Center 0 Labyrinth Bearing, Ball 0 Crankweb, Mag. 0 Key, Woodruff 00 Seal Washer (See Magneto Pg. C, Ref. ) Nut, Pump Drive (See Magneto Pg. C, Ref. ) Coupler 0 Kit, Crankshaft, Cylinder (Incl. 0,-0,) 0/0 C

32 CARBURETOR FREEDOM W0DA and FREEDOM W0IA 0 Jet Block 0 Asm., Carburetor 00 Screw, Fuel Pump 00 Kit, Fuel Pump Body 00 Kit, Gasket, Fuel Pump 00 Gasket, Carburetor, Upper 00 Screen, Fuel Strainer 00 Kit, Accelerator Pump 00 Kit, Check Valve Mid Range 00 Kit, Needle Valve 00 Jet, Main, Keihin 0 00 Jet, Main, Keihin 00 Jet, Pilot, Keihin 00 Jet, Mid, Keihin C 00 Screw, Jet Block Cover 00 Cover, Jet Block 000 Kit, Diaphragm, Jet Block 00 Screw, Jet Block 00 Block, Jet 00 O-Ring, Jet Block 00 Collar 0 00 O-Ring, Valve Seat 00 Kit, Check Valve 00 Kit, Idler Mixture Screw 000 Cap, Limiter 00 Gasket, Lower 00 Kit, Idle Stop Screw /00

33 OIL PUMP FREEDOM W0DA and FREEDOM W0IA 00 Cable, Oil Pump 00- Line, Oil 000 Clamp, mm Washer 0 E-Ring O-Ring 0 Screw 00 Pump, Oil (Incl. ) 00 Retainer /0 C

34 MAGNETO FREEDOM W0DA and FREEDOM W0IA 0 00 Stator, Twin 0 00 CDI, Programmed (If built before 0 Screw //0) 000 CDI, Programmed (If built after 0 O-Ring //0) Holder, Magnet 00 Coil, Ignition 00 Asm., Flywheel 00 Clip 0 Kit, Timing Screws 00- Wire, Spark Plug 0 Washer 00- Wire, Spark Plug 0 Nut 00 Cable Tie 0 Harness, Wire 00 Cap, Spark Plug C /0

35 STARTING MOTOR FREEDOM W0DA and FREEDOM W0IA Starter, Long Stud 0 Bolt, Through 0 Screw 0 Spring, Brush 0 Asm., Brush (Incl. -) 00 O-Ring 0 Washer 0 Washer, Spring 0 Nut 00 Ring, Rubber 0 00 Asm., Rear Bracket 0 AR Washer, Thrust 0 Washer, Thrust C 00 Asm., Armature 00 Asm., Bendix (Incl. -) 00 Asm., Front Bracket 0 O-Ring 0 Washer 0 Ring, Snap 0 Stopper 0 0 Cover 0 Spring Bushing, Flanged 0 Washer, Thrust 0 Asm., Gear 00 Asm., Gear (Incl. -) /0

36 TOOL KIT FREEDOM W0DA and FREEDOM W0IA Asm.,ToolKit(Incl.-) Wrench, Spark Plug Wrench, Open End Screwdriver C Manual, Owners, 0 PWC 00 Pouch, Tool Kit 0 Wrench, Allen, Plated, / /0

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

38 Changed pages in 0 0 A cover toc x B C x x D E F G 0

VIRAGE Model #W005197D INT L VIRAGE Model #W005197I Rev. 01. E 2000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00

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