XCF SP Model #099SX4FS Rev. 01

Transcription

1 XCF SP Model #0SXFS Rev. 0 PARTS MANUAL PN and MICROFICHE PN 0 /

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3 B BLOWER HOUSING and RECOIL STARTER C BRAKE A C CARBURETOR C CHAINCASE B CONSOLE A CRANKCASE C CYLINDER C D DECALS A DRIVE CLUTCH B DRIVE TRAIN B DRIVEN CLUTCH B E ENGINE MOUNTING C EXHAUST SYSTEM B F FRONT SUSPENSION and SKI B- FRONT TORQUE ARM B0 FUEL PUMP C TABLE OF CONTENTS Parts Manual H HOOD A-0 HOOD - FOAM/FOIL A M MAGNETO C0 N NOSEPAN A- O OIL PUMP C OIL TANK/AIR BOX C P PART NUMBER INDEX C-D PISTON and CRANKSHAFT C R RAIL MOUNTING (SUSPENSION).... B REAR TORQUE ARM B S SEAT and GAS TANK A SKI B STEERING B STEERING - HANDLEBAR B SUSPENSION B T TOOL KIT/BOX C TUNNEL A The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

4 Type BRAKES CAPACITIES Coolant Capacity (qts.) Chaincase Oil Capacity (oz.) Dry Weight (lbs.) Fuel Tank Capacity (US 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 DRIVEN CLUTCH Covers Diameter (in.) Helix Angle Spring Position Spring Type ENGINE SPECS 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) XCF SP SPECIFICATIONS GRAPHICS Hydraulic Disc. / Piston NA. N/A P / T() Accessory 0/0 / P- 0-AL Accessory Cast Dark Blue Yes 0. Silver ECPM00 V 0W.x Mikuni VMAL Slide Fan Air NICASEL RPM CDI Yes NGK BRES Backrest Pad Color Belly Pan Color Front Shock Color Front Springs Color Grab Bars Color Handlebar Cover Headlight Pod Color Hood Color Hood Accent Colors Rear Rack (Cargo) Color Rear Idler Wheel Color Ski Color Snow Flap Color Tunnel Color Tunnel Stripe Color Windshield (Size & Color) Windshield Base Color LIGHTS/BATTERY Headlight Type Headlight (watts) Indicator Light Thumbwarmer Handwarmers TRACK Track Construction Track Length Overall (in.) Track Pattern Track Width (in.) Lug Height SUSPENSION Front Type Front Travel (in.) Radius Rods (Adj. or Lub.) IFS Shock/Spring Adjustment 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. N/A Black Black Bright Red N/A Black Molded Black Indy Red Fire Red/Process Blue New Purple C /Black Screamin Yellow N/A Indy Red Black Black/Silver Logo Black Fire Red/Bright White/Black /Smoke/Flared Black Band Halogen High x0 & Low 0 Hi-Beam/Oil/Brake/Accessory Standard Standard Polyester Lightning Bolt (New). X-0 CRC Adjustable Select/Threaded Adj. / Std. XTRA-0 Quick Adjustable Quick Adjustable 0. Ryde FX Ryde AFX Coil Torsion.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 & 0

6 TUNNEL 0 0 Ref. Part Qty. Description Ref. Part Qty. Description -0 Support, Muffler Rivet Rivet Rivet 00 Snap, Male 0 Rivet 0 0 Rivet 0-0 Panel, Tunnel Back 0 Snowflap 0 Rivet 0-0 Bumper, Rear 0 Reflector, Red -00 Cap, Bumper 0 Washer 0 Washer 0 Bolt Extrusion, Clutch Guard 0 0 Footrest, LH Footrest, RH Tunnel Support, LH Tunnel Support, RH Pad, Suspension, Rear, LH Pad, Suspension, Rear, RH Pad, Front Suspension Mount., LH Pad, Front Suspension Mount., RH 00 Cushion, Tank 0-0 Asm., Tunnel (Incl.,0,) 00-0 Bulkhead, CRC Guard, Adaptor Drive 00 Plug, Hole 00 Plug, Hole / A

7 SEAT and GAS TANK 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Cap, Fuel Asm., Seat Cushion (Incl. -,) Cover, Seat 000 Grommet, Relatch, Bottom 00 Grommet, Relatch, Top 00 Relatch, Twist Lock w/hole Rivet 000 Bulb, Taillight 000 Bulb, Brakelight 0 Lens 0 0 Screw Housing, Taillight Rivet Retainer, Tool Pouch Clip 0 Washer 0 Screw 0 0 Harness, Taillight Jumper, Seat, Taillight Nut, Nylok 00 Nut, Speed Bolt, Carriage AR Line 0000 Clamp, Hose, Red 0 Fitting, Tank Outlet 00 Grommet, Tank Fitting 000 Ring, Compression 000- AR Line, Fuel 0 Pickup, Fuel w/filter 00 Asm., Fuel Tank (Incl. -) 00 Fitting, 0 Degree 0 Spring, Vent Hose Protector / A

8 NOSEPAN Ref. Part Qty. Description Ref. Part Qty. Description 0-0 Brace, Hinge 0 Washer Bolt 0 Rivet 0 Nut Guide, Hood, LH Guide, Hood, RH 0 Rivet 00 Strap, Hood Latch Brace, Pan, LH Brace, Pan, RH 0 Rivet Cap, Bumper, LH Cap, Bumper, RH Screw 00 Plug, Hole Extrusion, Formed Bumper, LH Extrusion, Formed Bumper, RH 0 Plug, Hole 00 Plug, Hole Bolt, Carriage -0 Brace, Pan, Lower Bumper, Front 0 Nut, Nylok Screw 0 Washer Rivet 00 Clip, Rosebud 0-0 Brace, Pan, Upper / A

9 NOSEPAN 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Tape, Foil 0 Tape, Foil Tape, Foil 0 Tape, Foil 0 Tape, Foil 0 Tape, Foil 0 Tape, Foil 0 Rivet 0 Decal - Engine and Clutch, French 0 Duct, Air Outlet 00 Pin, Clutch Cover 0 Decal - Engine and Clutch, English 0 Guard, Clutch Rivet Rivet 00 Clip, U-Type Louver Plate, Backer 00 Plug, Hole 0 Nosepan Screen, Nosepan, Front Cover, Nosepan, Front Rivet 0 Washer Rivet / A

10 HOOD Ref. Part Qty. Description Ref. Part Qty. Description 0-0 Mount, Headlight 0 Screw 00 Nut, U-Type Speed 0 Asm., Headlamp (Incl. Bulbs) 00 Bulb, High Beam 0 Bulb, Headlight Lens/Reflector, LH Lens/Reflector, RH 0- Asm., Hood (Incl. Foam/Foil)(SVC) Screw Clip, U-Type Bolt, Tee, Adjuster 00 Spring, Headlight Adjust Foam, Headlight Seal 000 Knob, Headlight Adjust 00 0 Hinge, Upper, LH Hinge, Upper, RH Plate, Bolt Screw 0 Bolt, Carriage Nut, Nylok 0 Plate, Hinge, Lower -0 Shim, Hinge, Lower Brace, Hood, Upper Brace, Hood, Lower Rivet 0 Spring, Extension 00 Ring, Spring Attachment 00 Clamp, Retainer Screw Screen, Front / A

11 HOOD 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Windshield, Flared/Smoke 0 Rivet 0 Nut 0 Washer 0 Washer 00 Bracket, Speedo/Tach 0 Housing, Instrument (Incl. Warning Decals) 00 Cushion, Rubber 00 Tachometer 0 Knob, Trip Odometer 00 Speedometer 0 0 Cable, Speedometer Foam, Pre-Filter 00 Cable Tie 0 Harness, Headlight Screw Rivet 0 Cup, Hood Latch 00 Retainer Washer Clip, Pigtail 0 Rivet 00 Cable, Hood 0 Rivet 0 Washer Deflector, Air, Hood Foam, Air Deflector Hood 0 Rivet / A0

12 HOOD - FOAM/FOIL 0 Ref. Part Qty. Description Ref. Part Qty. Description -0 Screen, Hood, RH Screw 000 Clip, U-Type 0 Foil, Hood Tab, Reinforcement Foil, Tape, Upper Louver, RH Foil, Tape Foil, Hood, RH Foil/Foam, Hood, RH 0 Foam, Hood, LH 0 Foam, Hood, Center -0 Cover, Louver FC, LH / A

13 DECALS RH 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Hood Decals, XCF (Incl.,,,,0,,,,) 00 Kit - Decal Application Solution (For Seat Decals) 0 Decal - XTRA 0 00 Decal - Track/Seat, English/French 0 Decal - POLARIS Flags, Seat 0 Decal - NO PASSENGER Warning, English/French 0 Decal - Hood Center, INDY SP 00 Decal - Hood Center, POLARIS 0 Decal - CRC 0 Decal - Hood Side, XCF, RH 0 Decal - IFS XTRA, RH 0 00 Decal - INDY HIGH PERFORMANCE FAN, RH 0 Decal - Tunnel, RH 0 Decal - Rear Suspension Setup, X-0 00 Decal - Warning/Caution, French 0 Decal - Warning/Caution, English 0 Decal - Tunnel, LH 0 Decal - HIGH PERFORMANCE FAN INDY, LH 0 Decal - IFS XTRA, LH 0 Decal - Hood Side, XCF, LH / A

14 CONSOLE Footrest 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw Spacer 00 Regulator, LR Nut, Nylok 00 Housing, Connector 00 Housing, Connector 00 Socket 000 Housing 000 Terminal, Ring Housing 0 Harness, Wire 0 Decal - Console, Ignition 0 Washer Screw 000 Switch, Ignition Washer 000 Cable, Choke Control (Incl.,) 0 Kit - Choke Lever (Incl. Pin) 000 Cable Tie, Releasable 0 0 Rivet 0 Guide, Recoil 0 Washer Nut, Choke 0 Cap w/key 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 Console / A

15 BRAKE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Cover Screws 0 Kit - Cover Assembly (Incl.,) Gasket 00 Kit - Parking Lever Spring 000 Asm., Master Cylinder (Incl.,,,,0,) Screw 0 Kit - Lever and Pivot Pin Screw 0 00 Kit - Body/Reservoir Clamp Switch, Brakelight 0 0 Kit - Cartridge Assembly 00 Control, LH Button, Switch, HI/LO, LH Control 0 Kit - Pivot Pin 0 Kit - Parking Lever and Spring (Incl. ) 00 Asm., Brake System (Incl.,,) 0 Line, Brake 00 Kit - Clip, Spring (Qty. ) 0 Inlet Bolt 0 0 Washer 0 Washer 0 Guide, Rope 0 Bracket, Caliper 0 Piston and Seal (Incl. ) 00 Kit - Seal 0 00 Kit - Heavy Duty Brake Pad, Type (Incl. ) Kit - Brake Pad, Type / A

16 B FRONT SUSPENSION

17 FRONT SUSPENSION Ref. Part Qty. Description Ref. Part Qty. Description Rivet -0 Brace, Bulkhead, Front Strap, Spacer, Bottom 0 Nut, FLEXLOC 0 Washer Screw Nut, Nylok -0 Bar, Sway Bushing 0 Rivet Arm, Steering, LH Arm, Steering, RH 0 Nut, FLEXLOC Rivet Washer 000 Bushing 0 Pivot, Rubber Screw Trailing Arm, LH (Incl.,) Trailing Arm, RH (Incl.,) Slide, Sway Bar Stop, Steering, LH Stop, Steering, RH 0 Bushing, Flanged 0 Bushing 0 Bushing, Flanged 00-0 Spindle 000 Fitting, Lubrication 00 Bushing 00 Fitting, Lubrication Screw Screw 0 00 Bushing Washer Bushing, Radius Rod, Outer -0 Rod, Radius, Lower Nut, Jam 00 Rod End Screw Bracket, Radius Rod, Bottom 0 Nut, FLEXLOC 000 Rod End 0 0 Nut -0 Rod, Radius, Upper 0 Shock, Gas IFS Select 00 Retainer, Slotted 0-0 Spring, Compression Ring, Spring Preload 000 Retainer, Threaded / B

18 SKI 0 Ref. Part Qty. Description Ref. Part Qty. Description Nut, Flange Nut Washer 0-00 Toe, Ski Plastic 0 Pin, Cotter Nut -0 Saddle 0 Stop, Rubber Retainer, Ski, Rubber 0-0 Support, Ski, Rubber Nut, Nylok Washer Ski, Plastic Kit - Carbide,, 0 Degree Screw Screw 0 Screw / B

19 STEERING - HANDLEBAR Ref. Part Qty. Description Ref. Part Qty. Description Grip, Handlebar 0 Washer Pin, Retaining 00 Ring, Retaining 0 00 Lever, Throttle Lever w/heater Block, Throttle/Brake Adaptor, Block Screw 00 Nut, Push-On 0 0 Emblem, POLARIS Cover, Handlebar 0 Slide, Cover, LH Slide, Cover, RH Screw Washer 0 Nut 0-0 Block, Handlebar -0 Handlebar Asm., Control, LH (See Brake Pg. A, Ref. ) 0 Plug 0 0 Heater, Grip, Hi/Lo/Med Screw Bracket, Steering Hoop/Fuel Tank 0 Nut, FLEXLOC Nut, Nylok 0-0 Post, Steering Screw Screw Holder, Wire 00 Ring, Retaining 0 Screw, Set 00 Switch, Auxiliary Shut-Off / B

20 STEERING Ref. Part Qty. Description Ref. Part Qty. Description Rack, Steering 0 O-Ring 00 Tube, Spacer 0 Asm., Pitman Arm (Incl.,) 0 Nut, FLEXLOC 0 Bushing Washer 0 Nut, FLEXLOC 00 Rod End, RH 0 0 Nut, RH 0 Bolt 00 Spacer 00 Fitting, Lubrication 0 Asm., Idler Arm (Incl.,) 00 Rod, Drag Link Nut, LH 00 Rod End, LH 00 Fitting, Lubrication 0 Nut, FLEXLOC 0 Post, Steering (See Steering/Handlebar Pg. B, Ref. ) Bolt, Carriage 0 Stop, Torque Rivet 000 Cable Tie 0-0 Hoop, Steering 0 Nut, FLEXLOC Bolt, Carriage 0 Nut 00 Stop, Torque, Coarse 0-0 Plate, Boot Rivet Boot, Tie Rod 00 Rod End, RH 00-0 Tie Rod Screw 0 Washer Nut, FLEXLOC Bolt Washer 0 Screw / B

21 CHAINCASE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Jackshaft (See Drive Train Pg. B, Ref. ) Screw 0 Nut 0 Bearing 0 Ring, Retaining 0 Sprocket, 0T, Spline (/W) Washer Nut, FLEXLOC Asm., Tightener Repl. (Incl. following) Bearing, Chaincase Wheel, Idler Washer Pin, Chain Tightener 0 0 Pin, Cotter 0 Gasket, Chaincase 0 Cover, Chaincase, Cast Screw 0 Screw Washer 0 Sprocket, 0T (/W) Chain, P (/W) Nut, Nylok 0 Plug 0 Chaincase w/ratchet Mount Screw 000 Seal, Oil / B

22 DRIVE TRAIN Ref. Part Qty. Description Ref. Part Qty. Description 0 Bolt 0 Washer AR Washer 00 Spacer, Input Shaft Asm., Driven Clutch (See Driven Clutch Pg. B, Ref. ) 0 Belt, Drive Bolt, Carriage 0 AR Bushing Flangette w/grease Fitting 0 0 Gasket Key Bearing Flangette 0 Washer Nut, Nylok 0 Asm., Jackshaft (Incl.,) 0 Ring, Retaining, Round Sect., B 0 Disc, Brake 00 Sleeve, Seal 0 0 O-Ring Dipstick 0 O-Ring Chaincase, Top Mount (See Chaincase Pg. B, Ref. 0) Nut, Flange Bolt, Carriage 0 Asm., Drive Shaft (Incl.,,) 0 Flangette w/screws Bearing 00 Bushing, Metal Speedometer 0 Flangette 00 Gasket, Drive Adaptor 0 Adaptor, Drive w/zerk 00 Key, Square Speedometer /

23 SUSPENSION Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer 0 Washer Bracket, Shaft Support Nut Bolt Washer 0- Wheel, Idler, Indy Red Spacer, Idler 0 Bushing 0 Wheel Spacer, Idler, Center 00 Shaft, Idler Screw Hi-Fax, White 0 0 AR AR Track Clip, Slide Clip, Guide 00 Shaft, Pivot Arm 00 Shaft Washer 0 0 Shaft 0-0 Arm, Pivot, Rear 00 Fitting, Lubrication / B

24 RAIL MOUNTING (SUSPENSION) Ref. Part Qty. Description Ref. Part Qty. Description Rivet Cover, Rail Tip Nut, Nylok 0 Bumper, Suspension Angle, Reinforcement Nut, Nylok Nut, FLEXLOC Nut, Nylok 0 Bracket, Rail Reinforcement 0 Bumper, Suspension Angle, Reinforcement 0 Screw Mount, Bumper 0 Bumper, Pivot Arm Bolt 00 Nut, Tensioner, Adj. Asm., Rail, RH Xtra-0, LH (Incl.,,,,,,) Asm., Rail, LH Xtra-0, RH (Incl.,,,,,,) 0 Rivet 00 Block, Idler, Adjustable Rivet 0 Spacer, Wheel, Bogie 0 Washer 0- Wheel, Bogie, Indy Red (Incl. -) Spacer Bolt 0 Bolt Screw Washer Spacer 0 Roller, Spring 0 Washer 0 Spacer 0 Washer Screw 00 Bracket, Wheel, Bogie Screw Insert, Wheel ( per Wheel) 0 Ring, Retaining ( per Wheel) 0 Bearing ( per Wheel) / B

25 FRONT TORQUE ARM Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer Washer 0 Shaft 0-0 Arm, Torque, Front Nut, Nylok Washer 00 Fitting, Lubrication 0000 Bolt, Eye 0 Nut, Nylok -0 Retainer, Spring 0 Shield, Spring 0 Shock, Track, Front 00 Retainer, Slotted 0-0 Spring, Compression Nut, FLEXLOC 0 Spacer 00 Bushing Washer Arm, Shock Screw Screw Shaft (See Suspension Pg. B, Ref. 0) Spacer 0 Bushing Wheel, Bogie (See Rail Mounting Suspension Pg. B, Ref. ) Shaft (See Suspension Pg. B, Ref. ) Screw 0 Strap, Limiter, Front 0 Shaft, Pivot Arm (See Suspension Pg. B, Ref. ) Bolt, Carriage / B0

26 REAR TORQUE ARM Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer Washer 00 Shaft, Rear Torque, Upper -0 Arm, Torque, Rear Nut, FLEXLOC Shaft Bolt, Carriage 0000 Bolt, Eye 0 00 Fitting, Lubrication Nut, Nylok Roller, Spring Adjustment 00 Clip, Push-On Screw 000 Collar, Bearing Lock Screw, Set Asm., Wheel Bearing (Per Wheel) Ring, Retaining ( Per Wheel) Washer Spring, Susp., Rear, LH (.0) Std. Spring, Susp., Rear, RH (.0) Std. Spring, Susp., Rear, LH (.) Opt. Spring, Susp., Rear, RH (.) Opt. Spring, Susp., Rear, LH (.) Opt. Spring, Susp., Rear, RH (.) Opt. 0 Sleeve, Torsion Spring Washer 0 Strap, Limiter, Rear 0 Bolt 00 Bushing Washer Spacer 0-0 Rod, Shock Screw 00 Bushing 0 0 Screw 0 Shock, Track, Rear / B

27 DRIVE CLUTCH 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Kit - Rebuild (Incl. -,,,) Bolt 0 Washer Cover, Bearing 0 Ring, Retaining, Cover 0 Spring, Clutch, Dark Blue 00 Nut 0 Washer, Multilube Roller and Bushing 0 Button, Guide B AR AR AR AR Spacer (.00 mm) Spacer (.0 mm) Spacer (.0 mm) Spacer (.00 mm) Weight/Bushing (0A-L) 0 Pin, Weight, Hardened 0 Bearing, Sleeve 00 Insert, Moveable 0 Nut, FLEXLOC 00 Pin, Roller 00 Kit - Drive Clutch Shim Asm., Drive Clutch Basic (Less and ) /

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

29 EXHAUST SYSTEM 0 Ref. Part Qty. Description Ref. Part Qty. Description 0-0 Muffler (Tuned Pipe) 0 Spring, Exhaust Rivet -0 Bracket, Tuned Pipe/Chassis AR Washer 0 Dampener, Vibration 00 Boot, Exhaust Hat, Exhaust Rivet 0 Washer 00 Clamp, Hose Gasket, Exhaust (See Cylinder Pg. C, Ref. ) 0-0 Manifold Screw 0 Cover, Manifold Matte, Sound / B

30 ENGINE MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer 00 Washer, Clutch Retainer, Short 00 O-Ring, Clutch Bolt 00 Spacer, Clutch Bolt 00 Spark Plug, NGK BRES 0 Engine, ECPM00-Short Block NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston and crankshaft asm. Prior authorization is required for warranty consideration. Spacer 00 Nut, FLEXLOC 0 Washer 00 Mount, Engine, -Tab 0 Nut 00 Plate, Motor Mount 0 Washer Screw Washer 00 Mount, Engine Handle, Recoil 00 Cable, Throttle 0 00 Cable Tie 0000 Clamp, Hose, Red AR Line, Fuel Asm., Fuel Pump (See Fuel Pump Pg. C, Ref. ) 0 Valve, Fuel Shut-Off / C

31 OIL TANK/AIR BOX Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer 00 Nut 0 Sensor, Oil Level Cap, Oil, Vented Tank, Oil 0 Decal - Fuel Shut Off Valve, Fuel Shut-Off (See Engine Mounting Pg. C, Ref.) Pump, Fuel (See Fuel Pump Pg. C, Ref.) 0 Screw 00 Grommet 00 Fitting, 0 Degree 00 Clip, Twist Lock Rivet Screw 0 Bracket, Fuel Pump Mount Nut, Nylok Bracket, Oil/Coolant Tank 00 Clip, Rosebud Clamp, Hose, Large Green 000- AR Line 000 Filter Boot, Carb 0 Fitting 0 Foam, Airbox, Chimney Mesh, Wire, Formed 0 Retainer, Tab Top, Silencer 00 Decal - Adjustable Driven Clutch 0 0 Decal - Caution, Air Box 0 Decal - Greasing Foam, Airbox, Internal 0 Plate, Silencer, Intake 0 Plate, Silencer, Intake, Vertical Silencer, Intake, Drilled Strap, Tie Down Bracket, Silencer Mount / C

32 CRANKCASE 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Stud 0 Pipe (Pulse) 00 Asm., Crankcase (Incl. -,,) 000 Pin, Dowel 0 Bolt, Flange 0 Gasket, Aluminum 0 Seal, Oil 0 Bolt and Washer 00 0 Bolt and Washer 0 0 Seal, Oil / C

33 CYLINDER 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bolt, Flanged 0 Head, Cylinder 0 Gasket, Head 0 Gasket, Exhaust 0 Cylinder Unit 0 Nut, Flange 0 Cover, Baffle, Cylinder 0 Gasket 00 Bolt 0 0 O-Ring 00 Adaptor (Incl. 0) 0 Screw 0 Asm., Band (Incl. ) 0 Screw and Washer 0 Stopper 0 Valve 0 Asm., Valve, Reed (Incl. -) 0 Plate / C

34 PISTON and CRANKSHAFT 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Clip, Piston Pin 0 Ring, Piston (Standard) 0 Piston (Incl. )(Standard) 0 Pin, Piston 0 Spacer, Crank Pin 00 Rod, Connecting 0 Bearing, Small End 00 Bearing, Large End 0 Crank Pin Key 00 Nut 00 Washer, Spring 0 Bearing, Ball 0 0 Asm., Crankshaft (Incl. -,,,-0) Crankshaft (Mag End) 0 Crankshaft (Incl. ) 0 Bearing, Ball 0 Crankshaft (PTO End) 0 Bearing, Ball 0 Spacer 0 0 Bearing, Ball / C

35 BLOWER HOUSING and RECOIL STARTER 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Plug, Heat Valve 0 Baffle, Cylinder 0 Decal - Polaris Engine Shroud 0 Bolt, Flange 0 Decal - 0 Engine Shroud 0 Bolt, Flange 00 Cap, Baffle, Cylinder 0 Bolt, Flange 0 Baffle, Cylinder 0 0 Clamp 00 Bolt and Washer 0 Rope, Recoil 0 Bolt and Washer 0 Bolt and Washer C 0 Band, Wire 0 Housing, Blower 0 Pin, Straight 0 Pulley, Starting 0 Nut, Flange 0 0 Plate, Friction 0 Spring, Friction 0 Ratchet 0 Spring, Return 0 Reel 0 Spring, Spiral 0 0 Recoil Starter (Incl.,-) Starter Case /

36 CARBURETOR 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Mixing Chamber Top (Incl. Gasket) 0 Spring, Throttle 0 Plate, Throttle 000 E-Ring 0 Needle, Jet (DH0-) 0 Valve, Throttle (.0) Jet, Needle Q- 0 Cap 0 Hose 0 0 Valve, Check 0 Asm., Carburetor (Incl. -,-) Asm., Carburetor (PTO)(Incl. -,-) Packing, Needle Valve 0 Valve, Needle (.) 0 Pin, Float 0 Float 0 Gasket, Float Chamber 0 Cap C 0 Float 0 Ring Jet, Main (#0)(Mag) Jet, Main (#0)(PTO) 0 O-Ring 00 Nipple 00- AR Line, Fuel Plug, Trap 00 Clamp, Hose 00 Clamp, Hose 00 Screw and Washer 00 Jet, Pilot (#) 000 Spring, Throttle, Adjuster 0 0 Screw, Throttle Stop 00 Screw, Air 00 Spring, Air Adjuster 0 Asm., Plunger 000 Spring, Plunger 0 Cap, Plunger /

37 FUEL PUMP Ref. Part Qty. Description 0 Screw 00 Diaphragm, Gasket Set 00 Asm., Fuel Pump (Incl.,) / C

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

39 MAGNETO 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw and Washer 0 Stator 0 Asm., Flywheel 00 Bolt, Flange 0 CDI System 00 Nut, Rubber 0 Cap, Spark Plug 0 Screw and Washer 00 Cap, Spark Plug 0 00 Coil, Ignition Complete 0 Bolt, Flange / C0

40 TOOL KIT/BOX Ref. Part Qty. Description Ref. Part Qty. Description 00 Kit - Tool (Incl. -) Screwdriver Wrench, 0- Spanner Box Wrench, Special Screwdriver, Flat, Shielded 00 Strap, Emergency Starter 00 Pouch, Tool Kit Manual, Owners, Snowmobile Supplement, Owner s Manual, XCF SP / C

41 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid A B A A A A A A B A A A A B A 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 B B B B B A A A A A A B A B B A A A A A A A A A A A A A A A A A A B A A A A C A C A A A A A A C A B 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 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 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 C C C C C C C

42 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid C C C C C C C C C C C C C C C C B 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 B B B B C B B B A A A A A A A A A B.. B B B B B B B B B B B B A A A A A A A A A... C C A A A B C B B B C B B B B B B B B C C B0.. B B B B B B B B B B B B B B B B C B C B B B B A A B B A A B... B B A B B B A B A A B A A B B B B B C B B B A B A C C B A A A A A A B A A A A B B B A A C B A A C A

43 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid A A B B B B B B B B B B B B B A A A B B C A B B A... A B B A B B C B C B B A B C A B B B A B B B B B B C B B B A A C B A B B B B B B B B C A A A A C A A B B B B B B A A A A A C A B B B B B B.. B A A A A A A B B B C A C A A A A A A A A A A A A B B C C B B0 C B B A B B B B B B B B B B B A B B A A A... C A B C C C A A B B B B B C C C A A A A A C A A A A A A A A A A A C C A A A A A A... C

44 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid A C A A C A B C A B A A A... A B... B... B.. B0 0.. B B A C C A A A B C A C A... B A B B A A A B A A... A B B A B B A... C B B.. B0.. B B... B B B B B B B B B B A B A A A... B A A B B B B 0... B B B B B B B0.. B B B A B B B B B B.. B0.. B C B B B B B A.. A0.. A.. A C C B B A B C B B A A... B... B A 0... A... A... B D B... C B B B... B.. B0.. B B B B... B B... B B... B... B.. B0.. B B B B B... B B B B B B B B B C C B A B.. B0.. B 0.. A A... A.. B C B B B0.. B B... B B B B B B B B0.. B B A... B

45 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid B... B B B B B... B 0... C B A.. A C B A B0.. B B B B... B B A A0 0.. B A... A... A C B B... B A B B B C A A B A A A A... A.. A A... A A A 0... B B B A A 0.. A0.. B A B A B A A B B B A A... B... B... C A... B A A B A A.. A A A C B B B B B B B B.. B B B A... C A... C C C C D

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47 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0

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49 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0

50 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

51 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0

52 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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54 PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN 0 /