CLASSIC TOURING Model #S00ST4BS Rev. 01

Transcription

1 CLASSIC TOURING Model #S00STBS Rev. 0 PARTS MANUAL PN and MICROFICHE PN 0/

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3 TABLE OF CONTENTS Parts Manual B M BACKREST A- MAGNETO D BATTERY BOX C N BRAKE B NOSEPAN A-0 C O CARBURETOR C OIL PUMP C CHAINCASE B0 OIL TANK / AIR BOX C CONSOLE B P COOLING SYSTEM B CRANKCASE C PART NUMBER INDEX D- CYLINDER C PISTON and CRANKSHAFT C0 D R REAR TORQUE ARM C DECALS A RECOIL STARTER D DRIVE CLUTCH C REVERSE LINKAGE B DRIVE TRAIN B DRIVEN CLUTCH C S E SEAT and GAS TANK A SKI B ENGINE MOUNTING B STARTING MOTOR D EXHAUST SYSTEM C STEERING B F STEERING - HANDLEBAR B FRONT SUSPENSION B- SUSPENSION B- FRONT TORQUE ARM C T FUEL PUMP C TOOL KIT D H TUNNEL A HOOD A- W HOOD - FOAM/FOIL A WATER PUMP C 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/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 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) Spark Plug Gap (in.) 000 CLASSIC TOURING SPECIFICATIONS GRAPHICS Hydraulic Disc./. N/A qt. oz.. 0. P T () Standard /0 / P- 0MB Bushed Standard Cast Gold Yes N/A Silver EC0PL0 V 00W x0 Mikuni VMSS Slide Liquid Iron Liner RPM CDI Yes RNC Champion.0/.0 Backrest Pad Color Belly Pan Color Front Shock Color Front Springs Color Rear Springs Color Grab Bars 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 Colors Windshield (Size/Color) Windshield Base Color Headlight Type Headlight (watts) Indicator Light Thumbwarmer Handwarmers ELECTRICAL 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 Shocks/Spring Adj. Torsion Bar/Type Rear Type Front Torque Arm Limiter Rear Torque Arm Limiter Rear Travel (in.) Shock: Front Track Rear Track Springs: Front Torque Arm Rear Torque Arm Rear Torq. Arm Spring Dia. Black Black Black Candy Apple Red Black Black Black Molded Black Candy Apple Red Metalic Lt. Gold/Fire Red/Sandstone Metallic/Black/White Black/Silver Logo N/A N/A Candy Apple Red Black Black Composite High Gloss Black Lt. Gold/Fire Read/C. A. Red Metallic/Sandstone Metallic/Black Flared Clear Black Band Halogen High x0/low 0 Brake/Oil/Temp/Hi Beam Standard Hi/Low/Med. Polyester. Lightning. X-. Fixed Upper Select/Thrd Adj. / XTRA Standard N/A 0. Select Select N/A Torsion/Coil./ 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.

5 000 POLARIS SNOWMOBILE PUBLICATION NUMBERS OWNER S MANUAL PARTS PARTS ASSEMBLY MODEL MODEL # & SUPPLEMENT MANUAL MICROFICHE INSTRUCTIONS &

6 TUNNEL Ref. Part Qty. Description Ref. Part Qty. Description 0 Rivet Rivet 00 Snap, Male Brace, Tunnel, Lower, LH Brace, Tunnel, Lower, RH Pad, Rear Suspension, LH Pad, Rear Suspension, RH 0-0 Plate, Tunnel Support 0-0 Bracket, U-Tensioner Rivet -0 Flap, Snow 0 Rivet 0 Bumper, Rear 0-0 Panel, Tunnel Close-Off Rivet 0 Screw 0 Washer, Spring Lock 0 Washer, Flat -00 Cap, Bumper Skirt, Snow, Touring, LH Skirt, Snow, Touring, RH Rivet 0 0 Screw 0 Footrest w/pad, LH 0 Footrest w/pad, RH 0 Pad, Footrest Grip Edge, Tunnel, LH, Black Edge, Tunnel, RH, Black 0 Rivet Extrusion, Clutch Guard 0 0 Footrest, LH Footrest, RH Rivet 00-0 Tunnel (Incl. Heat Exchangers) -0 Plate, Suspension, Front, Outer Rivet Guard, Adaptor, Drive Rivet 0-0 Bulkhead 00 Plug, Hole 00 Plug, Hole Mount, Front Suspension, LH Mount, Front Suspension, RH / A

7 SEAT and GAS TANK Ref. Part Qty. Description Ref. Part Qty. Description 0 Cap, Fuel Tank w/gasket Gasket, Gas Cap 0 Grommet, Fuel Tank Asm., Seat Cushion (Incl.,-,-,,) Cover, Seat 00 Reflector, Seat, Center 0 Nut, Nylon Nut, Nylok 0-0 Bracket, Seat Mount Rivet Housing, Lens, LH Housing, Lens, RH 0 0 Screw 00 Screw 0 0 Lens, LH Lens, RH 000 Bulb, Brakelight 0 0 Screw 00 Bulb, Taillight Screw A 0 Nut, Well Screw 0 Pickup, Fuel w/filter Ring, Compression 00- AR Tubing 0 Flange, Fuel Tank Mounting Washer 00 Fitting, Outlet, Double 000 Clamp, Hose AR Tubing 00 Fitting, 0 Degree AR Line, Fuel 00 Cable, Tank Retention 0 00 Package, Sending Unit Hardware 0 Sender, Fuel Level w/gasket 0 Harness, Taillight Retainer, Tool Clip Pouch Rivet 0 Washer /

8 BACKREST A

9 BACKREST Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Backrest Cushion Adjustment, Cushion (Incl. -,,,0) Washer, Wave 0 Bracket, Mounting Screw Key, Square 0 Rotor 00 Ring, Retaining Washer, Flat Spring Knob, Adjustment 0 0 Screw Nut, Nylok Housing, Backrest Adjustment, LH Housing, Backrest Adjustment, RH 00 Cable, Actuator 0 Asm., Backrest Adjuster (Incl. -) 0 Spring, Locking 00 0 Pawl, Master Locking, LH Pawl, Locking, RH 0 Sector, Engagement 000 Pin, Sector Bolt Lever, Locking Screw, Cap 0 Bolt 00 Stud, Limiter 0 Gear, Stationary -0 Tube, Backrest Mounting 00 Cable Tie Cover, Cable Washer, Thrust 0 Spring, Torsion, Preload 0-0 Cover, Spring 0 Nut, Acorn 0 Screw Washer, Flat Handle, Grab, LH Handle, Grab, RH 0 Grip, Passenger w/heater Tape, Foam 0 0 Deflector, Air, LH Deflector, Air, RH Rivet 0 Asm., Grab Handle Knob (Incl. 0-) Knob, Backrest Bolt Spacer, Adjustment Knob 00 Caplug Nut, Nylok 00 Nut, Pal Bolt, Carriage Frame, Main, LH Frame, Main, RH Key, Hi-Pro Rivet 0 0 Housing, Switch 0 Harness, Heater Switch 0 Decal - High/Off/Low Screw 0 Cushion, Backrest w/light Screw Rivet Cover, Backrest Taillight, Backrest Bulb, Replacement / A

10 NOSEPAN Ref. Part Qty. Description Ref. Part Qty. Description 0-0 Brace, Hinge 0 Washer, Spring Lock Bolt 0 Rivet 0 Nut, FLEXLOC 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 A Screw 00 Plug, Hole Extrusion, Bumper, Formed, LH Extrusion, Bumper, Formed, RH 00 Clip, Routing Bolt -0 Brace, Pan, Lower Rivet Bumper, Front 0 Nut, Nylok Screw 0 Washer, Flat 0 Brace, Pan, Upper /

11 NOSEPAN 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Tape, Foil 0 Tape, Foil 0 Tape, Foil 0 Tape, Foil 0 Tape, Foil Tape, Foil 0 Tape, Foil 0 Rivet 0 Decal - Troubleshooting, XTRA- 0 Clip, Belt Retainer 00 Pin, Clutch Guard 0 Asm., Clutch Guard 00 Decal - Engine and Clutch Rivet Rivet Nosepan 0 Plug, Hole Plate, Backer 00 Bushing, Open/Close 0 00 Plug, Hole Rivet / A0

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

13 HOOD Ref. Part Qty. Description Ref. Part Qty. Description Windshield,, Flared, Clear 0 Rivet, Plastic 0 Nut 0 Washer, Split Lock 0 Washer, Flat 00 Bracket, Speedometer/Tachometer 0 Housing, Instrument (Incl. Warning Decals) 00 Cushion, Rubber Tachometer, Pulse Bulb, Replacement 0 Knob, Trip Odometer Speedometer Bulb, Replacement 0 0 Cable, Speedometer 0 00 Gauge, Fuel,, Backlit Fuse 00 Cushion, Fuel Gauge 0 Spacer, Fuel Gauge Bracket A 0 Bracket, Fuel Gauge, 0 Washer, Flat 0 Nut 0 Washer, Split Lock Foam, Pre-Filter 00 Cable Tie 0 0 Harness, Headlight Rivet 0 Cup, Hood Latch Screw 00 Retainer Rivet Clip, Pigtail 0 Washer 00 Cable, Hood 0 Rivet 0 0 Screw Deflector, Air /

14 HOOD - FOAM/FOIL 0 Ref. Part Qty. Description Ref. Part Qty. Description -0 Screen, Hood, RH Screw 000 Fastener, U-Type Clip 0 Foil, Hood Tab Screen, Hood, Front, Upper, LH Screen, Hood, Front, Upper, RH Foil, Tape, Upper Louver, RH Foil, Tape Screen, Hood, Front, Lower, LH Screen, Hood, Front, Lower, RH Foil, Hood, RH 0 Foil, Hood, RH Foil/Foam, Hood Rivet 0 Foam, Hood, LH 0 Foam, Hood, Center -0 Screen, Hood, LH 0/ A

15 DECALS RH 0 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Hood Decals, 00 Classic Touring (Incl. -,,0,-) 00 Kit - Decal Application Solution (For Seat and Backrest Decals) 0 Decal - POLARIS, Seat 0 Logo - th Anniversary 00 Decal - One Passenger 00 Decal - Warning/Caution, French 0 Decal - Warning/Caution, English 0 Decal - Hood Center, INDY 00 Decal - POLARIS, Hood Center 0 0 Decal - Trailing Arm, INDY, LH Decal - Trailing Arm, INDY, RH 0 00 Decal - Hood Side, 00 Classic, LH Decal - Hood Side, Classic 00, RH Decal - Hood Side, Touring, LH Decal - Hood Side, Touring, RH 0 Decal - Tunnel, RH 0 Decal - XTRA- 00 Decal - POLARIS, Backrest 00 Decal - Track/Seat, LH/RH, Eng./Fr. 0 Decal - Reverse Caution, RH 00 Decal - Reverse Warning, LH 0 Decal - Electric Start 0 Decal - Tunnel, LH / A

16 CONSOLE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Housing, Connector 00 Housing, Connector 00 Socket 000 Housing 000 Terminal, Ring 000 Housing 0 Harness, Main 0 Decal - Console, Ignition Screw 0 00 Kit - Ignition Switch 000 Cable, Choke Control (Incl.,0) 00 Kit - Choke Control (Incl. Pin) 000 Cable Tie Washer, Nylon 0 Rivet 0 Nut, Sleeve Type 0 Guide, Recoil 00 Asm., V Power Plug (Incl. ) 0 Washer, Lock 0 00 Nut, Choke Slide 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 / B

17 BRAKE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Cover Screw 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 - Clamp Body/Reservoir Switch, Brakelight 0 0 Kit - Cartridge Assembly 00 Asm., Control, LH 0 Kit - Pivot Pin 0 Kit - Parking Lever and Spring (Incl. ) 0 Line, Brake 00 Kit - Clip, Spring (Qty. ) 0 Inlet Bolt 0 Washer, Spring Lock 0 Washer, Flat 0 0 Bracket, Caliper 0 Piston and Seal (Incl. ) 00 Kit - Seal, Piston, Caliper 0 Kit - Brake Pad, Type Heavy Duty, Small (Incl. ) 00 Kit - Brake Pad, Type, Heavy Duty, Large (Incl. ) 0 Asm., Brake Caliper (Incl.,,) / B

18 FRONT SUSPENSION B

19 FRONT SUSPENSION Ref. Part Qty. Description Ref. Part Qty. Description Rivet Brace, Bulkhead Strap, Spacer, Bottom Strap, Spacer, Top Screw 0 Nut, FLEXLOC Screw Nut, Nylok 00 Shock 0 00 Retainer, Slotted 0-0 Spring, Compression Ring, Spring Preload 000 Retainer, Spring, Body, Threaded -0 Bar, Sway 0 Bushing, Sway Bar Rivet 0-0 Arm, Steering Screw 0 Bushing, Pivot, / 0 Screw Washer 0 Nut, FLEXLOC Rivet Washer 000 Bushing 0 Pivot, Rubber Screw 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 Bushing 0 Bushing, Flange 000 Fitting, Lubrication 00-0 Shaft, Spindle 00 Bushing 00 Fitting, Lubrication Bushing, Radius Rod Pivot 00 Bushing 0-0 Rod, Radius, Lower Nut, Jam 00 Rod End Bracket, Radius Rod, Lower Brace, Pan, Lower (See Nosepan Pg. A, Ref. ) Bolt 0 Nut, FLEXLOC 0 Bushing, Pivot, / 0 Rod, Radius, Upper, Fixed / B

20 SKI 0 Ref. Part Qty. Description Ref. Part Qty. Description 0-00 Toe, Ski, Plastic 0 Pin, Cotter Nut Washer 0 Stop, Rubber Retainer, Ski, Rubber -0 Support, Ski, Rubber Washer, Flat Nut, Nylok Ski Screw 0-0 Plate, Skag 0 Kit - Skag,, 0 Degree (Pair) Bolt 0 Screw Nut, FLEXLOC Nut, Flange / B

21 STEERING Ref. Part Qty. Description Ref. Part Qty. Description 0 0 Rivet 0 Bolt 00 Fitting, Lubrication 00 Clip, Rosebud 00 Bushing Washer 0 Nut, FLEXLOC 0 Pin, Cotter Rod End, LH Rod End, RH 0 0 Nut, FLEXLOC 0 Nut, LH Nut, RH Rod, Drag Link 00 Cable Tie Post, Steering (See Steering/Handlebar Pg. B, Ref. ) 000 Cable Tie 0-0 Hoop, Steering, Short 0 Nut, FLEXLOC Bolt, Carriage Rivet 0 0 Nut, FLEXLOC Bolt, Carriage Boot, Tie Rod, LH Boot, Tie Rod, RH Rod End, LH Rod End, RH -0 Plate, Boot Seal, LH 00-0 Tie Rod 0 Block, Steering Screw Washer, Wave 0 Bushing 0-0 Plate, Boot Seal Asm., Center Steering (Incl.,) / B

22 STEERING - HANDLEBAR 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Grip, Handlebar Pin, Retaining 0 Washer 00 Ring, Retaining 00 Lever, Easy Throttle Lever w/heater Block, Throttle Adaptor, Block Screw Boot, Handlebar 0 00 Nut, Push-On Emblem, Star Cover, Handlebar 0 Slide, Cover, LH Slide, Cover, RH 00 Clip, Dart Washer 0-0 Block, Handlebar -0 Handlebar Asm., Control, LH (See Brake Pg. B, Ref. ) 0 Plug, Overflow 0 0 Heater, Grip, Lo/Med/Hi Screw -0 Bracket, Tank Retention 0 Nut, FLEXLOC Nut, Nylok 00-0 Post, Steering Screw 00 Ring, Retaining Screw, Set 0 Switch, Auxiliary Shut-Off / B

23 COOLING SYSTEM Ref. Part Qty. Description Ref. Part Qty. Description 00 Nut, Chimney 0 Washer 0 Cap, Overflow 0 Plug, Overflow 0 Gasket, Overflow Cap Bolt Bottle, Overflow w/fittings 00 Clamp, Springband Rivet 0 Extrusion, Cooling, Center 00 Clamp, Springband Cooler, Side, LH Cooler, Side, RH Guard, Cooling Extrusion Hose, Side to Center, LH 0 Hose, Crossover 0 Hose, Pump/Center Extrusion B Bracket, Oil Tank Tubing, Convoluted 00 Trim, Edge 0 00 Clamp, Springband 0 Hose, Filler, Extrusion, RH 00 Hose, Engine Out/Filler Filler, Remote Coolant Screw Nut, Nylok Cap, Pressure Tubing, Convoluted 00 Spring, Hose Retainer 000 Clamp, Hose Line, Fuel 00 Valve, Check 00 Filter, Coolant 00 Clip, Rosebud /

24 ENGINE MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer 00 Washer, Clutch Retainer 00 O-Ring, Clutch Bolt 00 Spacer, Clutch Bolt 000- AR Conduit, Convoluted 00 Spark Plug, RNC Champion 00 Engine, Short Block (EC0PL0) 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. Handle, Recoil 0 0 Screw 0 Washer, Flat Mount, Rubber Engine Tube, Spacer Mount, Rubber Engine Nut, Flange Plate, Motor Mount 0 Washer, Spring Lock Screw 00 Mount, Engine 0 00 Nut, FLEXLOC, Thin Nut 00 Limiter, Torque 00 Stop, Torque Washer, Flat 000 Clamp, Hose 0 Nut, FLEXLOC AR Tubing Asm., Fuel Pump, Non-Asbestos (See Fuel Pump Pg. C, Ref. ) 0000 Clamp, Hose, Red AR Line, Fuel 000 AR Conduit, Convoluted 00 Cable Tie 00 Cable, Throttle Control w/oil 000 Valve, Fuel Shut-Off B /

25 CHAINCASE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Jackshaft (See Drive Train Pg. B, Ref. ) 000 Seal, Oil Screw 0 Nut 0 Bearing, Ball 0 Ring, Retaining Washer 0 Sprocket, T, /W 0 Washer, Spring 0 Nut, FLEXLOC 0 Pin, Cotter Asm., Tightener Bearing, Chaincase Idler Wheel, Idler Washer, Thrust Pin, Chain Tightener 0 Gasket, Chaincase Cover, Chaincase 0 Washer Screw Screw 00 Seal, Oil -0 Shaft, Shift 0 Pin, Dowel 0 0 Ring, Retaining Kit - Shift Fork/Shaft (Incl.,0) Fork, Shift 0 O-Ring Washer, Thrust 0 0 Gear, Pinion, Spur Bearing, Needle Chain, P, /W 0 Sprocket, Pinion Bearing, Needle 0 Shaft, Pinion 0 Screw 0 Bracket, Chain Retention Screw Chaincase 0 Plug Washer Sprocket, T, /W 00 Coupler, Drive Gear, Reverse 0 Spring, Compression 0 Retainer, Drive Coupler 0 0 Washer, Spring Lock Screw 0 / B0

26 REVERSE LINKAGE 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Lever, Shift Pin, Clevis Actuator, Shift 00 Washer, Wave 0 Bolt, Shoulder 0 Nut Screw 00 Rod, Threaded Nut Rod End Screw 0 Nut, Jam 00 Rod End, LH 0 Screw 0 Washer, Flat 0 Nut, FLEXLOC Bracket, Shift Actuator 00 Pin, Cotter / B

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

28 SUSPENSION Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Spring Lock 0 Ring, Retaining 0 Wheel, Bogie 0-0 Shaft, Tensioner Nut, FLEXLOC Washer, Flat 0 Washer, Flat Washer, Belle 0 0- Wheel, Idler, Candy Apple Red Spacer, Idler Bushing 0 Asm., Wheel Spacer, Idler, Long 00 Shaft, Idler Screw Screw 0 Bushing Spacer 0 00 Shaft, Pivot Arm Asm., Wheel, Bogie (See Suspension Pg. B, Ref. ) Spacer Boss, Bolt Head 0 Screw 0 AR AR Track Clip, Slide Clip, Guide 00 Fitting, Lubrication 0-0 Shaft, Limiter Strap 0-0 Shock, Pivot Arm 0 Shaft 0 00 Shaft, Shock Bracket, Rear -0 Arm, Pivot, Rear / B

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

30 FRONT TORQUE ARM 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Washer, Lock 00 Shaft, Front, Upper 0-0 Arm, Torque, Front 0 Strap, Limiter Washer, Flat 0 Bolt 0 Nut, FLEXLOC Washer, Flat 0 00 Fitting, Lubrication 00 Shaft Rivet Bumper, Front Torque Arm Nut, Nylok / C

31 REAR TORQUE ARM Ref. Part Qty. Description Ref. Part Qty. Description Screw Washer, Lock Washer, Flat 00 Shaft, Rear Torque Arm, Upper Screw Nut, FLEXLOC 00 Fitting, Lubrication Sleeve, Torsion Spring 0-0 Spring, Torsion, LH, Standard (./ Degree) 0-0 Spring, Torsion, RH, Standard (./ Degree) 00-0 Spring, Torsion, LH, Optional (./ Degree) 00-0 Spring, Torsion, RH, Optional (./ Degree) 0-0 Spring, Torsion, LH, Optional (.0/ Degree) 0-0 Spring, Torsion, RH, Optional (.0/ Degree) 0 Washer, Thrust Asm., Wheel Bearing Ring, Retaining 000 Collar, Bearing Lock Screw 0-0 Arm, Rear Torque 0 Nut, FLEXLOC, Thin 00 Shaft Screw 0 Shock, Gas, Rear Track 0-0 Spring, Compression 0 Shield, Spring 0 00 Clip, Push-On 0 Roller, Spring Adjust 00 Retainer, Spring, Slotted 0 Bushing 0-0 Rod, Shock, Xtra Spring, Compression Ring, Spring Preload, Adjusting 000 Retainer, Spring, Body, Threaded Washer, Wave 0 Shock, Front Track 0 0 Spacer Screw / C

32 BATTERY BOX 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw Spacer, Regulator 00 Regulator, LR 000 Rectifier, LR-, LR- Nut, Nylok 00 Pad, Battery 000 Strap, Battery Hold-Down 0 AR Tube, Vent 0 Cable, Battery/Solenoid Battery 00 Cable, Battery 00 Kit - Battery Bolt Switch, Magnetic (See Starting Motor Pg. D, Ref. ) C Washer, Spring (See Starting Motor Pg. D, Ref. ) Nut (See Starting Motor Pg. D, Ref. ) 0 Washer, External Tooth 0 Insulator, Cable 000 Cable Rivet Box, Battery 0 Screw 00 Breaker, Circuit 000 Wire, Jumper, Solenoid/Battery 0 Washer, Flat /

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

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

35 EXHAUST SYSTEM 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00-0 Muffler 0 Spring, Exhaust Nut (See Cylinder Pg. C, Ref. ) Washer, Lock (See Cylinder Pg. C, Ref. ) 00-0 Manifold Gasket, Exhaust (See Cylinder Pg. C, Ref. ) 00 Spring, Exhaust Rivet -0 Bracket, Muffler, Rear 0 Dampener, Vibration w/ribs 00 AR Washer Hat, Exhaust 00 Boot, Exhaust Washer, Flat Rivet Rivet Rivet 0-0 Support, Muffler / C

36 OIL TANK / AIR BOX Ref. Part Qty. Description Ref. Part Qty. Description 0000 Sensor, Oil Lever w/connectors 0 Cap, Oil Tank 0 Gasket, Oil Cap 0 Washer Bolt 000- AR Line, Fuel 000 Filter 000 Conduit, Convoluted 000 Clamp, Hose, Large Green 0 00 Fitting, Outlet, Single Asm., Fuel Pump Non-Asbestos (See Fuel Pump Pg. C, Ref. ) Screw Screw 0 Washer 0 Decal - Fuel Shut-Off -0 Bracket, Silencer/Remote Filler Nut, Well Rivet C Washer, Flat 0 00 Plate, Silencer, Air AR Line, Fuel 00 Fitting 00 Boot Silencer, Intake, Drilled Bracket, Silencer, Intake 0 Baffle 00 0 Clip, Silencer 00 Decal - Adjustable Driven Clutch 0 Decal - Greasing 0 0 Decal - Caution, Air Box Foam, Airbox Chimney 00 Clip, Rosebud Cover, Silencer 0 Decal - Cooling System Tank, Oil 00 Nut, Chimney 00 Fitting, 0 Degree /

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

38 CYLINDER 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bolt, Flange 0 Head, Cylinder (Incl. 0) 0 Plug 0 Gasket, Aluminum 00 Nut 000 Washer, Lock 0 Gasket, Exhaust 000 Pin, Dowel 0 Stud 0 0 Cylinder (Incl.,) 0 Nut, Flange 0 Gasket, Cylinder 0 Valve, Check 0 Asm., Adaptor Band (Incl. ) 0 Screw 00 Adaptor (Incl. ) 0 O-Ring 00 Bolt, Allen 0 Switch, Thermo (0 Degree C) 0 0 Pipe, Water 0 Gasket, Head / C

39 PISTON and CRANKSHAFT 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Clip, Piston Pin 0 Ring, Piston (Standard) 0 Ring, Piston (0.mm/.00 O/S) 0 Ring, Piston (0.0mm/.00 O/S) Piston (Std) Piston (0.mm/.00 O/S) Piston (0.0mm/.00 O/S) 0 Pin, Piston 0 Spacer, Crank Pin 0 Pin, Crank, (mm) 0 Bearing, End, Large 0 Rod, Connecting 0 Bearing, Small End 0 0 Pin, Crank, (mm) 000 Key 00 Nut 00 Washer, Spring 0 Bearing, Ball 0 0 Asm., Crankshaft (Incl. -,0-) Crankshaft (Mag Side) 0 Crankshaft (Center)(Incl.,0) 0 Bearing, Ball 00 Crankshaft (PTO Side) 00 Bearing, Ball 0 00 Spacer 00 Bearing, Ball / C0

40 WATER PUMP Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw and Washer 0 O-Ring 0 Casing, Pump, 00 Bolt and Washer 0 Gasket, Water Pump 0 Asm., Water Pump (Incl. -,) 0 Belt 0 Pulley, Drive / C

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

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

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

44 MAGNETO 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Coupler, P 0 Grommet 0 Harness, Wire (Incl. ) 00 Screw and Washer 0 Clamp Stator 0 Screw and Washer Asm., Plate (Incl. -,0,,) Plate D 0 Flywheel 0 0 Screw and Washer 0 Coil, Exciter 0 Screw and Washer 0 Coupler, Male 00 Cap, Resistor Plug 00 Coil, Ignition 0 Screw and Washer 00 Nut, Rubber /

45 RECOIL STARTER 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Pulley, Starter 0 Bolt and Washer 0 Nut, Flange 0 Plate, Friction 0 Spring, Friction 0 0 Asm., Recoil Starter (Incl. -,-) Starter Case Complete 0 Clamp 0 Bolt and Washer 00 Guide, Rope 0 0 Spring, Spiral 0 Rope, Recoil 0 Reel 0 Spring, Return 0 Ratchet / D

46 STARTING MOTOR 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 - Commutator Cap (Incl. ) Nut Screw 0 Bracket, Starter, Rear 00 Kit - Armature 00 Kit - Drive Hardware Washer, Curved Spring Washer, Thrust Spacer Spring, Antidrift Pinion, Stop Ring, Lock Cover, Dust 00 Kit - Drive Cap 000 Motor, Starter, Domestic 0 00 Kit - Drive Plate, Drive Pinion Bracket, Starter, Front 0 Washer, Spring Lock Screw 0 Screw 00 Kit - Screw Bolt, Thru 0 Nut 000 Washer, Spring 0 Switch, Magnetic (Incl.,) / D

47 TOOL KIT Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Tool (Incl. -) Screw Driver Wrench, 0- Spanner Box Wrench, Special Box Wrench, Special Screwdriver, Shielded Supplement, Manual, Owner s, 000 Classic Touring Manual, Owner s, 000 Snowmobile 00 Pouch 00 Strap, Emergency Starter / D

48 PART NUMBER INDEX Part Ref. Grid A B A A A A A A A A A A A A A A A A B A A A A B A A A C A B A B A B B C C C C C C C C B B B B B B B B B C B C C B C B Part D Ref. Grid B B B C B B B B B B B B B B B B B B B B B B B B B B B C B C B B D D D D D D D A B B B B B B B B B A B A B A A C C C A Part Ref. Grid A B A A B B A B C B A A A A A A A D A D A D B B D C... C C C C C D D C C D D D C C C C C D D C C C D C C C C C C C C C C

49 PART NUMBER INDEX Part Ref. Grid D C D C D C C D C C C C D D D D D D D D C C C D D D D C C C C C C C C C D C C C D D D D C C C C C D C D D D C C C C C Part D Ref. Grid C C C C C C D C C C C C C C C C C C C C C C C B C C C C C C B 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 Part Ref. Grid C B B B B B B A A A A A A A A A A A A A A A A A B... C B B B B0.. B B C B C B C C B B B... C B C C B C B B B B B B B D B... B... C A

50 PART NUMBER INDEX Part Ref. Grid A.. A.. A A A A C C C A B C D B B C B B B C B B B B C C C B B B C B A C C C A B C B B B B B C C B B B A A A B B B B C C C Part D Ref. Grid C A B B B B C A A A A A B A A B A A B C B A B D A D B B B B A A B B B C B A B A A B A B A A A A A A C A A B A A A A C Part Ref. Grid C B B A A A B A B A B C A B B B C B B B B B A C A C C B B B B B B B A A B C B C A B B B B B B B B B B B C A B B C C A

51 PART NUMBER INDEX Part Ref. Grid B C C B... B B B C B B B B B... C A A C C C B A A A A A A B C A A A A A A A C A C B C A C B B B A A A A B B B B B A B B B B Part D Ref. Grid B B A B B B B A B A B B... C C B C A A A A A A B B A A A A A A A A C A A A A A B A C B B C A C C C C C A A C C C C C B B Part Ref. Grid C A A C B C A B C B C A... C B A B B B B B B B C C C A C C A A A B A A A A A A A A A A A A A A A A A A A A B A.. A... B A B B

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

53 PART NUMBER INDEX Part Ref. Grid B.. B B C B B B... B B B A B A A B B B B.. B... D C C... C A... A... C B B.. B B C B... B B B A.. B B B C A C C B.. B.. B B... B B... C B C B B B.. B C A B0 Part Ref. D0 Grid B A B B C C B C B B.. B C... C C C A... A A... B... C B B B C B B B A A B A A B A.. A B A A.. A0.. A A.. A0... C... C A A A B A... C A A.. A0.. A... C A B B B Part Ref. Grid A B A B B B B B A.. A A... A... B... B... B... C... C A... B... C B A A B A B A.. A C A B... C B A.. A B B C B B B A C B B... C C B A A A... B A B B... C B C

54 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid A... C D D D

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61

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