SUPER SPORT Model #099SB5BS Rev. 02

Transcription

1 SUPER SPORT Model #0SBBS Rev. 0 PARTS MANUAL PN and MICROFICHE PN 0 /

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3 A AIR BOX C B BLOWER HOUSING & RECOIL STARTER C BRAKE A CARBURETOR C CHAINCASE B CONSOLE A CRANKCASE C CYLINDER C DECALS A DRIVE CLUTCH B DRIVE TRAIN B DRIVEN CLUTCH B ENGINE MOUNTING C EXHAUST SYSTEM B FRONT SUSPENSION and SKI B- FRONT TORQUE ARM B FUEL PUMP C C D E F TABLE OF CONTENTS Parts Manual HOOD A- HOOD - FOAM/FOIL A M MAGNETO C N NOSEPAN A- H O OIL PUMP C OIL TANK B P PART NUMBER INDEX C-D PISTON and CRANKSHAFT C RAIL MOUNTING (SUSPENSION).... B REAR TORQUE ARM B R SEAT and GAS TANK A STEERING B STEERING - HANDLEBAR B SUSPENSION (TRAIL) B TOOL 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. S T

4 SUPER SPORT 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.) Compressed 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 (Touring) 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) Hydraulic Disc / Piston N/A./. N/A. 0. P / T () Accessory : / P- -0 Accessory Cast Dark Blue Yes. Silver ECPM0 V 0W x Mikuni VMSS Slide Fan Air Iron Liner RPM CDI Yes NGK BRES Headlight Type Headlight (watts) Indicator Light Handwarmer Thumbwarmer GRAPHICS Backrest Pad Color Belly Pan Color Front Shock Color Front Springs Color Grab Bar 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 Ski Color Tunnel Color Tunnel Stripe Color Windshield (Size/Color) Windshield Base Color TRACK Track Construction Track Length Overall Track Pattern Track Width Lug Height SUSPENSION Front Type Front Travel (in.) Radius Rods (Adj. or Fixed) IFS Shocks/Spring Adj. Torsion Bar/Type Rear Type Front Torque Arm Limiter Rear Torque Arm Limiter Rear Travel (in.) (Rear Idler) Shock: Front Track Rear Track Springs: Front Torque Arm Rear Torque Arm Rear Torque Arm Spring Dia. Halogen High x./low 0 Hi-Beam/Oil/Brake/Accessory Standard Standard N/A Black Black Violet N/A Black Molded Black Bright White Metallic Screamin Yellow/Black/Turquoise/New Purple C /Orange Black/Silver Logo N/A N/A Violet C Black Black Turquoise/Orange/ Screamin Yellow Flared/Smoke Black Band Polyester Lightning Bolt. X- IFS Fixed Upper Nitrex/Thread Adjust / Std. XTRA Quick Adjustable Quick Adjustable. Nitrex Select 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 0 0

6 TUNNEL Bulkhead Rivet Rivet 00 Snap, Male -0 Tunnel Rivet Panel, Tunnel Back Rivet Snow Flap 0 Bumper, Rear 0 Bolt 0 Washer, Spring Lock 0 Washer, Flat -00 Cap, Bumper 0 Reflector, Red -0-0 Bracket, Suspension, Rear, LH Bracket, Suspension, Rear, RH 0 0 Rivet Extrusion, Clutch Guard Footrest, LH Footrest, RH Support, Tunnel, LH Support, Tunnel, RH -0-0 Pad, Susp. Mounting, Front, LH Pad, Susp. Mounting, Front, RH 0 Decal - Tunnel Strip, Top Rivet Guard, Adaptor, Drive 00 Plug, Hole 00 Plug, Hole / A

7 SEAT and GAS TANK 0 0 Cap, Fuel w/gauge Gasket, Gas Cap 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 000 Bulb, Brakelight 0 0 Cushion, Seat (Incl. -,0-,,0) Cover, Seat 0 Harness, Taillight Washer Rivet Retainer, Weld Nut Housing, Taillight Cover, Taillight Protector Rivet Screw 0 Rivet 00 Fuel Pick-Up w/strainer 000 Ring, Compression 000- AR Line, Fuel 0 Fitting, Outlet, Double, 0 Degree 000 Clamp, Hose, Green, Large AR Line, Fuel Nut, Nylok AR Fuel Line 00 Fitting, 0 Degree 0 00 Cable, Tank Retention / A

8 NOSEPAN Brace, Hinge 0 Washer, Spring Lock Bolt 0 Rivet Nut Guide, Hood, RH Guide, Hood, LH 0 Rivet 0 Strap, Hood Latch Brace, Pan, LH Brace, Pan, RH Rivet Cap, Bumper, LH Cap, Bumper, RH Screw 00 Plug, Hole Extrusion, Bumper, Formed, LH Extrusion, Bumper, Formed, RH Plug, Hole 0 Plug, Hole Bolt, Carriage -0 Brace, Pan, Lower Bumper, Front 0 Nut, Nylok Screw Rivet 0 Washer 0-0 Brace, Pan, Upper / A

9 NOSEPAN 0 0 Tape, Foil Tape, Foil Tape, Foil Tape, Foil Tape, Foil Tape, Foil Tape, Foil 0 Rivet 0 Decal - Engine and Clutch, French Duct, Air Outlet 00 Pin, Clutch Guard 0 Decal - Engine and Clutch, English Asm., Clutch Guard (Incl. Decals) Rivet Rivet Rivet Plate, Air Deflect 00 Clip, U-Type Louver 0 Plate, Backer 0 Plug, Hole Nosepan -0 Screen, Nosepan, Front Cover, Nosepan, Front Rivet 0 Washer / A

10 HOOD Mount, Headlight Screw 00 Nut, U-Type Speed 0 Asm., Headlamp (Incl. Bulbs) 000 Bulb, High Beam 0 Bulb, Halogen Lens/Reflector, LH Lens/Reflector, RH 0- Asm., Hood (Incl. Foam/Foil) Screw 000 Clip, U-Type Bolt, Tee, Adjuster 0 Spring, Headlight Adjust Foam, Headlight Seal 000 Knob, Headlight Adjust 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 Windshield, Flared/Smoke, 0 Rivet 0 Nut 0 Washer, Split Lock 0 Washer 0 Bracket, Speedo/Tach 0 Housing, Instrument (Incl. Warning Decals) 00 Cushion, Rubber Tachometer Bulb, Replacement 0 Knob, Trip Odometer Speedometer Bulb, Replacement 0 Cable, Speedometer Foam, Pre-Filter A 00 Cable Tie 0 Harness, Headlight Screw Rivet 0 Cup, Hood Latch 0 Retainer 0 Washer Clip, Pigtail 0 Rivet 00 Cable, Hood Rivet Deflector, Air, Hood Foam, Hood Air Deflector Rivet /

12 HOOD - FOAM/FOIL -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, Hood, RH Foil/Foam, Hood 0 Foam, Hood, LH Foam, Hood, Center -0 Cover, Louver, LH / A

13 DECALS RH LH 0 Kit - Hood Decals, Super Sport (Incl.-,,,,,,) 00 Kit - Decal Application Solution (For Seat and Handlebar Decals) 0 Decal - No Passenger Warning 0 Decal - Hood Center, INDY 00 Decal - Hood Center, POLARIS 0 Decal - IFS XTRA, RH 0 Decal - Hood Side, 0, RH 0 Decal - Super Sport, RH 0 0 Decal - Tunnel, RH Decal - Tunnel, LH 0 Decal - Seat, POLARIS 0 Decal - XTRA- 00 Decal - Dash Warning, French, RH 0 Decal - Dash Warning, English, LH 00 Decal - Track/Seat, English/French 0 Decal - Super Sport, LH 0 Decal - IFS XTRA, LH 0 Decal - Hood Side, 0, LH / A

14 CONSOLE Footrest 0 0 Screw Spacer 00 Regulator, LR Nut, Nylok 00 Housing, Connector 00 Housing, Connector w/tab 0 Socket 000 Housing 000 Terminal, Ring 000 Housing 00 Harness, Wire, Main 0 Decal - Console, Ignition 0 Washer Screw 00 Kit - Ignition Switch 000 Cable, Choke (Incl.,) Lever, Choke (Incl. Pin) 000 Cable Tie, Releasable Washer 0 Rivet 0 Guide, Recoil Washer, Lock Nut, Choke Cap w/key NOTE: When ordering ignition key PN 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 0 Console / A

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

16 FRONT SUSPENSION and SKI B

17 FRONT SUSPENSION and SKI Rivet -0 Brace, Bulkhead Strap, Spacer, Bottom Strap, Spacer, Top Bolt 0 Nut, FLEXLOC Bolt Nut, Nylok 0 Shock 00 Retainer, Slotted 0-0 Spring, Compression Ring, Spring Preload 000 Retainer, Spring, Body, Threaded -0 Bar, Sway Bushing, Sway Bar Rivet 0-0 Arm, Steering Bolt Washer 0 0 Nut, FLEXLOC Rivet Washer 0 Bushing Pivot, Rubber Bolt 0 0 Asm., Trailing Arm, LH (Incl.,) Asm., Trailing Arm, RH (Incl.,) Slide, Sway Bar Stop, Steering, LH Stop, Steering, RH 0 Bushing, Flange 0 0 Bushing 0 Bushing, Flange 000 Fitting, Lubrication 0-0 Shaft, Spindle Stop, Rubber Nut, Nylok 00-0 Ski Bolt 0-0 Skag, Carbide -0 Plate, Skag 0 Nut 0 Pin, Cotter 0 Bushing, Ski Pivot 00 Fitting, Lubrication Bushing, Radius Rod Pivot 0 Bushing -0 Radius Rod, Lower Nut, Jam 00 Rod End Bracket, Radius Rod, Lower 0 Brace, Pan, Lower (See Nosepan Pg. A, Ref. ) Bolt 0 Nut, FLEXLOC Bushing, Pivot, / Rod, Radius, Upper, Fixed Bushing, Pivot, / / B

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

19 STEERING Rivet -0 Plate, Boot, Seal, RH Boot, Tie Rod, RH Rod End, LH Rod End, RH 0 Nut, FLEXLOC 0 Nut, LH Nut, RH Rod, Drag Link 0 Bolt 0 Nut, FLEXLOC 000 Cable Tie -0 Hoop, Steering 00 Fitting, Lubrication Bolt, Carriage Rivet Nut, FLEXLOC Bolt, Carriage B -0 Plate, Boot, Seal, LH 00-0 Tie Rod Rod End, RH Rod End, LH 0 Rivet Boot, Tie Rod, LH 00 Clip, Rosebud 0 Block, Steering Screw Washer, Wave 0 Bushing Bushing Washer 0 Pin, Cotter 0 0 Nut, FLEXLOC Steering, Center (Incl.,) 00 Fitting, Lubrication /

20 CHAINCASE 0 00 Seal, Oil 0 Nut Bolt 0 Bearing 0 Ring, Retaining Asm., Tightener Bearing, Chaincase Idler Block, Tightener Wheel, Idler Washer, Thrust Pin, Chain Tightener Sprocket, T, /W 0 Washer, Spring Nut, FLEXLOC 0 Pin, Cotter Gasket, Chaincase 0 Cover, Chaincase Bolt 0 Bolt Washer, Spring Connector 0 Chain, Silent, P, /W Sprocket, T, /W Nut, Nylok 0 Plug (Incl. O-Ring) 0 Chaincase, Vented Screw / B

21 DRIVE TRAIN Bolt 0 Washer AR Washer 00 Spacer, Input Shaft Driven Clutch (See Driven Clutch Pg. B For Details) 0 Belt, Drive Bolt, Carriage 0 AR Bushing Flangette w/grease Zerk Gasket, Jackshaft Key Bearing, Jackshaft Flangette 0 Washer Nut, Nylok 0-0 Asm., Jackshaft (Incl.,) Ring, Retaining, Round Sect., Disc, Brake, Slotted 00 Sleeve, Seal 0 O-Ring Dipstick O-Ring Nut, Flange Cover, Chaincase (See Chaincase Pg. B, Ref. ) Bolt, Carriage 0 Asm., Drive Shaft (Incl.,,) 00 Bushing, Metal, Speedometer Bearing, Drive Shaft Flangette w/screws 0 00 Key, Square, Speedometer Flangette 00 Gasket, Drive Adaptor 0 Adaptor, Drive w/ Zerk / B

22 SUSPENSION 0 0 Screw 0 Washer, Spring Lock 0 Washer Bracket, Shaft Support Nut, FLEXLOC Bolt Washer, Belle 0- Idler Wheel, Violet C Spacer, Idler Bushing 0 0 Idler Wheel, Black Bearing Ring, Retaining Spacer, Idler, Long 00 Shaft Screw Hi-Fax, White 0 Track Clip, Slide Clip, Guide 00 Shaft, Pivot Arm 00 Shaft 0 Shaft 0 Washer, Flat 00 Fitting, Lubrication 0-0 Arm, Pivot, Rear / B

23 RAIL MOUNTING (SUSPENSION) 0 0 Nut, Nylok Bumper, Suspension Angle, Reinforcement Nut, Nylok Nut, FLEXLOC Nut, Nylok 0 Bracket, Rail Reinforcement Bumper, Suspension Angle, Reinforcement Mount, Bumper Screw Bumper, Pivot Arm Bolt 00 Nut, Tensioner Adjusting 0 Block, Idler Bolt Adjusting Rail, LH, Xtra- (Incl.,,,) Rail, RH, Xtra- (Incl.,,,) 0 Rivet, Flat Rivet 0 Spacer, Bogie Wheel Washer 0 Asm., Bogie Wheel (Incl. -) 0 Spacer Bolt 0 Bolt Bolt Washer, Flat Spacer 0 Roller, Spring 0 Bracket, Bogie Wheel 0 Washer Spacer 0 0 Washer, Lock Screw Screw Cover, Rail Tip Rivet Insert, Bearing ( per Wheel) 0 Bearing, Roller ( per Wheel) 0 Ring, Retaining ( per Wheel) / B

24 FRONT TORQUE ARM 0 0 Screw 0 Washer, Lock Washer, Flat 0 Shaft, Mounting 0-0 Arm, Front Torque Nut Washer 00 Fitting, Lubrication 000 Bolt, Eye -0 Retainer, Spring 0 Shield, Spring 0 Shock, Front Track 00 Retainer, Spring, Slotted 0-0 Spring, Compression Nut, FLEXLOC 0 00 Bushing (. ) Bushing (. ) Washer B 0-0 Arm, Shock Screw 0 Screw Shaft (See Suspension Pg. B, Ref. ) Shaft (See Suspension Pg. B, Ref. ) Spacer 0 Bushing 0 Asm., Bogie Wheel Screw Screw Strap, Limiter, Front Shaft, Pivot Arm (See Suspension Pg. B, Ref. ) 0 Nut Bolt, Carriage /

25 REAR TORQUE ARM 0 0 Screw 0 Washer, Lock Washer, Flat 00 Shaft, Torque, Rear, Upper -0 Arm, Rear Torque 00 Fitting, Lubrication Nut, FLEXLOC Bolt, Carriage Shaft, Torque Arm, Lower Rear 000 Bolt, Eye Nut, Nylok Roller, Spring Adjustment 00 Clip, Push-On Screw 00 Collar, Bearing Lock Screw, Set Washer Asm., Wheel Bearing ( Per Wheel) Ring, Retaining ( Per Wheel) Spring, Susp., Rear, LH, Standard (.0/ Degree) Spring, Susp., Rear, RH, Standard (.0/ Degree) Spring, Susp., Rear, LH, Optional (./ Degree) Spring, Susp., Rear, RH, Optional (./ Degree) Spring, Susp., Rear, LH, Optional (./ Degree) Spring, Susp., Rear, RH, Optional (./ Degree) 0 Sleeve, Torsion Spring Washer Strap, Limiter, Rear Bolt 00 Bushing Washer Spacer -0 Rod, Shock Screw 0 Bushing 0 Screw 0 Shock, Gas, Rear, Adjustable / B

26 DRIVE CLUTCH 00 Kit - Clutch Rebuild (Incl. -,-,,) Bolt 0 Washer, Spring Lock Cover, Bearing, Garmax Ring, Retaining,Cover 0 Spring, Clutch, Dark Blue 00 Pin, Roller 00 Kit - Shim, Drive Clutch 0 Button, Guide 00 Nut, Jam 0 Washer, Multilube Asm., Roller and Bushing AR Spacer (.00 ) AR Spacer (.0 ) AR Spacer (.0 ) AR Spacer (.00 ) Nut, FLEXLOC Asm., Weight/Bushing, Bushed (-0) Pin, Weight 0 Bearing, Sleeve 0 Insert, Moveable Asm., Drive Clutch, Basic (Incl. All Less,) / B

27 DRIVEN CLUTCH 0 Screw Plate, Driven, Vented 0 Ring, Retaining 0 Washer Ramp, Driven, Degree Key 0 Spring, Driven Clutch, Silver/Blue 0 Bushing, Driven, Large DU AR Washer (.0) Washer 00 Pin, Driven, Adjustable Cam, Driven, Adjustable Bolt Cap, Driven, Vented 0 Button, Ramp Asm., Driven Clutch, Degree (Incl. -) / B

28 EXHAUST SYSTEM Cover, Megaphone, Top Cover, Megaphone, Bottom Matte, Sound Clamp (. x.) Clamp (. x.) Clamp (. x.) Asm., Muffler (Incl.,) Muffler Bolt 0 Washer, Lock Washer Shield, Muffler Rivet -0 Bracket, Tuned Pipe/Chassis AR Washer Dampener, Vibration 0 Boot, Exhaust Hat, Exhaust Rivet Washer 00 Clamp Screw 0-0 Manifold Gasket, Exhaust (See Cylinder Pg. C, Ref. ) 0 0 Cover, Manifold Matte, Sound 0 Spring, Exhaust / B

29 OIL TANK Tank, Oil 0 Decal - Fuel Shut Off Screw 0 Washer 00 Nut, Chimney Sensor, Oil Level Cap, Oil Tank Valve, Fuel Shut-Off (See Engine Mounting Pg. C, Ref. ) Asm., Fuel Pump (See Engine Mounting Pg. C, Ref. Screw 00 Grommet 00 Fitting, 0 Degree 00 Clip, Twist Lock Rivet Bolt 0 Bracket, Mount, Fuel Pump Nut, Nylok Bracket, Oil Tank 00 Clip, Rosebud Clamp 000- AR Line, Oil 000 Filter, Oil / B

30 AIR BOX Boot, Carb 0 Fitting 0 Foam, Airbox, Chimney Mesh, Wire, Formed Retainer, Tab Top, Silencer 00 Decal - Adjustable Driven Clutch 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 Rivet / C

31 ENGINE MOUNTING Bolt 0 Washer, Lock 0 Washer, Clutch Retainer 0 O-Ring, Clutch Bolt 00 Spacer, Clutch Bolt 00 Spark Plug, NGK BRES 0 Engine, ECPM0-Short Block NOTE: The short block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization required for warranty consideration. Recoil Handle Spacer, Engine 00 Nut, FLEXLOC, Thin Washer 0 Mount, Engine, Rubber 00 Plate, Mount, Motor Washer, Spring Lock Screw 0 Nut, FLEXLOC Washer 0 Mount, Engine Asm., Fuel Pump (See Fuel Pump Pg. C, Ref. ) Clamp, Hose, Red AR Line, Fuel 0 Valve, Fuel Shut-Off 000 Filter, Fuel 00 Clamp 00 Cable Tie 00 Cable, Throttle Control / C

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

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

34 PISTON and CRANKSHAFT 0 0 Clip, Piston Pin 00 Bearing, End, Large 0 Bearing, End, Small Ring, Piston (Standard) Ring, Piston (0.mm/.0 O/S) Ring, Piston (0.0mm/.00 O/S) Piston (Standard) Piston (0.m/.0 O/S) Piston (0.0m/.00 O/S) 0 Pin, Piston 0 Spacer, Crank Pin 0 Crank Pin 00 Rod, Connecting 0 Bearing, Ball C 0 Spacer 0 Bearing, Ball 0 Crankshaft (PTO Side) 0 Bearing, Ball 00 Gear, Drive, Oil Pump 0 Crankshaft (Incl.,,) 0 0 Asm., Crankshaft (Incl. -,,-) Crankshaft (MAG Side) 0 Bearing, Ball 00 Washer, Spring 0 00 Nut 00 Key /

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

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

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

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

39 MAGNETO 0 Screw and Washer 0 Asm., Flywheel 00 0 Asm., Magneto Stator 0 Screw and Washer 00 Cap, Spark Plug 0 Cap, Spark Plug 00 Nut, Rubber 000 CDI System 00 Bolt, Flange 00 Coil, Ignition 0 Bolt, Flange / C

40 TOOL KIT 0 Kit - Tool (Incl. -) Screwdriver Wrench, - Spanner Box Wrench, Special 0 Manual, Owner s, Snowmobile Supplement, Owner s Manual, Super Sport 00 Pouch, Tool Kit 00 Strap, Emergency Starter 0 Cover, Tool Box Foam, Tool Box 0 Screw 0 Box, Tool 0-0 Bracket, Tool Box / C

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

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

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

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

48 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

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 /