500 XC SP Model #099SP5AS Rev. 02

Transcription

1 00 XC SP Model #0SPAS Rev. 0 PARTS MANUAL PN and MICROFICHE PN 0 /

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3 B BRAKE A C TABLE OF CONTENTS 00 XC SP 0SPAS Parts Manual CARBURETOR C- CHAINCASE B CONSOLE A COOLING SYSTEM B COOLING SYSTEM (S# 0XXXX)... B CRANKCASE C CYLINDER (S# 0XXXX) C0 DECALS A DRIVE CLUTCH B DRIVE TRAIN B DRIVEN CLUTCH C D ENGINE MOUNTING C EXHAUST SYSTEM C FOX SHOCK - FRONT TRACK C FOX SHOCK - IFS C FOX SHOCK - REAR TRACK C FRONT SUSPENSION B FRONT SUSPENSION B FRONT TORQUE ARM B H HOOD A-0 E F H HOOD - FOAM/FOIL A M MAGNETO D N NOSEPAN A- O OIL TANK/AIR BOX C PART NUMBER INDEX D- PISTON and CRANKSHAFT C RAIL MOUNTING (SUSPENSION).... B0 REAR TORQUE ARM B RECOIL STARTER D SEAT and GAS TANK A SKI B STEERING B STEERING - HANDLEBAR B SUSPENSION B TOOL KIT D TUNNEL A W WATER PUMP/OIL 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. P R S T

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 Bearing Drive Chain Length Drive Shaft Sprocket Reverse Transmission Sprocket Ratio Type - Dipstick DRIVE CLUTCH Center Distance (in.) Clutch Offset (in.) Clutch Type Clutch Weight Diameter Ring Gear Spider Spring Color Stationary 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.) 00 XC SP SPECIFICATIONS GRAPHICS Liquid Cooled Hydraulic Disc / Piston. N/A Sealed Ball 0P T- Accessory :0 Top Mount-Dipstick / P- 0-. Accessory Cast Dark Blue Standard Yes 0. R Gold SN0--A 0W 0.x 00 Mikuni TM Rack Liquid Iron Lined RPM CDI Yes RNC Champion.0 Backrest Pad Color Belly Pan Color Clutch Guard Color Drive Clutch Cover Color Front Shock Color Front Springs Color Grab Bars Color Handlebar Cover Handlebar Grips Color Headlight Pod Color Hi-Fax Color Hood Color Snowflap Color Radius Rods Color Rear Rack (Cargo) Color Rear Idler Wheel Color Rail Color Seat Color/Welt Color Ski Color Trailing Arm Color Tunnel Color Tunnel Stripe Color Windshield (Size & Color) Windshield Base Color LIGHTS/BATTERY Headlight Type Headlight (watts) Brake Light (watts) Tail Light (watts) Indicator Light TRACK Track Construction Track Length Overall (in.) Track Pattern Lug Height Track Width (in.) SUSPENSION Front Type Front Travel (in.) Radius Rods (Adj. or Lub.) IFS Shock/Spring Adjustment Torsion Bar Rear Type Qty. Bogie Wheels Qty. Rear Idlers 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./Angle N/A Black Unpainted Unpainted White Racing Red N/A Black Molded Black Black White Black Metallic Black/Silver Logo Black N/A Racing Red Unpainted Black/Black Black Black Black Bright Red Mid Height/Smoke/Flared Black Halogen High x./low Oil/Brake/Temp/Acc/Hi Beam Polyester-C Lightening New Block. XC-0. Adjustable Fox IFP / XTRA-0 Quick Adjustable Quick Adjustable 0. Fox IFP Fox IFP 0# Torsion. sq./ 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 00 XC SP 0SPAS & 0 0

6 TUNNEL 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Rivet Guard, Chaincase Rivet Bracket, Muffler Support (See Exhaust Sys. Pg. C, Ref. ) 0-0 Bulkhead, CRC 0-0 Bracket, Gas Tank 0 Rivet Rivet 00 Snap, Male Asm., Tunnel (Incl.,0,) 0-0 Strap, Gas Tank Nut, Nylok Cooler, Wear Strip (See Cooling System Pg. B, Ref.0) Rivet Rivet -0 Panel, Tunnel Back Rivet 0 Snowflap 0 Bumper, Rear 0 0 Screw 0 Washer, Lock 0 Washer, Flat -00 Cap, Bumper 000 Reflector, Red Rivet Extrusion, Clutch Guard 0 0 Footrest, LH Footrest, RH -0-0 Brace, Footrest, LH Brace, Footrest, RH Support, Tunnel, LH Support, Tunnel, RH Bracket, Suspension, Rear, LH Bracket, Suspension, Rear, RH 00 Nut, Speed Bolt, Carriage -0-0 Bracket, Front Susp. Mounting, LH Bracket, Front Susp. Mounting, RH 00 Cushion, Tank Rivet Guard, Adaptor, Drive 00 Plug, Hole 00 Plug, Hole / A

7 SEAT and GAS TANK 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Cap, Fuel Asm., Seat Cushion (Incl. -,0-,) Cover, Seat Clip Rivet 000 Grommet, Relatch, Bottom 00 Grommet, Relatch, Top 00 Relatch, Twist Lock w/hole Rivet Nut, Nylok 0 0 Washer, Dish, Toothed 000 Bulb, Taillight 0 Lens 0 Screw 000 Bulb, Brakelight Housing, Taillight Bolt 0 Harness, Taillight Foam, Seat Pad 0 Cushion, Tank Hold Down 0 0 Pickup, Fuel w/filter 000 Ring, Compression 000- AR Line, Fuel 0 Fitting, Outlet, Double, 0 Degree 0000 Clamp, Hose, Red AR Line, Fuel 000 Spring, Tank, Front 0 Asm., Fuel Tank (Incl.0-,) 00 Fitting, Outlet, 0 Degree 0 Spring, Vent Hose Protector / A

8 NOSEPAN 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0-0 Brace, Hinge 0 Washer, Lock 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, Bumper, Formed, LH Extrusion, Bumper, Formed, RH -0 Brace, Pan, Lower Bolt Bumper, Front Nut, Nylok Rivet Brace, Pan, Upper 0 Washer Screw / A

9 NOSEPAN 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Tape, Foil 0 Tape, Foil 0 Tape, Foil 00-0 Tape, Foil 0 Tape, Foil 0 Tape, Foil 0 Tape, Foil Tape, Foil Tape, Foil Tape, Foil 0 Rivet 000 Decal - Suspension and Set-Up Clip, Belt Retainer 00 Pin, Clutch Guard 0 Asm., Clutch Guard (Incl. Decals) 00 Decal - Engine & Clutch Rivet Rivet 00 0 Plug, Hole ( Hole) Plug, Hole (. Hole) 0 0 Nosepan Nosepan NOTE: For units starting with serial number 0xxxx. 0 Plug, Hole Plate, Backer 00 Plug, Hole Rivet / A

10 HOOD 00 XC SP 0SPAS 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 - Asm., Hood (Incl. Foam/Foil) Screw Clip, U-Type Bolt, Tee, Adjuster 00 Spring, Headlight Adjust Foam, Headlight Seal 000 Knob, Headlight Adjust 0 Washer 00 0 Hinge, Upper, LH Hinge, Upper, RH Plate, Bolt Screw 0 Bolt, Carriage 0 Nut 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 0 Screen, Front / A

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

12 DECALS 00 XC SP 0SPAS RH 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 00 Kit - Hood Decals, 00 XC SP (Incl.,,,,0,,,,) 00 Kit - Decal Application Solution (For Seat Decals) 000 Decal - Position Sensitive 00 Decal - Track/Seat, English/French 0 Decal - Seat, POLARIS, Flags 0 Decal - NO PASSENGER Warning, English/French 0 Decal - Hood Center, INDY SP 0 Decal - Hood Center, POLARIS 0 Decal - CRC 0 Decal - Hood Side, XC, RH 00 Decal - XC-0, RH 0 0 Decal - 00 HIGH PERFORMANCE TWIN, RH 00 Decal - Warning/Caution, French 0 Decal - Warning/Caution, English 0 Decal - HIGH PERFORMANCE TWIN 00, LH 0 Decal - XC-0, LH 0 Decal - Hood Side, XC, LH / A

13 HOOD - FOAM/FOIL 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description -0 Screen, Hood, RH Screw 00 Clip, U-Type 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 / A

14 CONSOLE 00 XC SP 0SPAS Footrest 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw Spacer 00 Regulator, LR Nut, Nylok 00 Socket 000 Housing 000 Housing 000 Housing Harness, Wire, Main Harness, Ignition Jumper NOTE: For units starting with serial number 0xxxx Decal - Console, Ignition 0 Washer Screw 00 Kit - Ignition Switch 00 Cable, Choke (Incl.,0) 0 Kit - Choke Lever 000 Cable Tie Washer 0 Rivet 0 Guide, Recoil 0 Nut, Choke 0 Key, Ignition 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 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Cover Screws 0 Kit - Cover Asm. (Incl.,) Gasket 00 Kit - Spring, Parking Lever 000 Asm., Master Cylinder (Incl.,,,,0,) Screw 0 Kit - Lever & Pivot Pin Screw 0 00 Kit - Body/Reservoir Clamp Switch, Brakelight 0 0 Kit - Cartridge Asm. 00 Asm., Control, LH Button, Switch, HI/LO, LH Control 0 Kit - Pivot Pin 0 Kit - Parking Lever & Spring (Incl. ) 0 0 Line, Brake Line, Brake NOTE: For units starting with serial number 0xxxx. 00 Kit - Clip, Spring (Qty. ) 0 Inlet 0 00 Kit - Cooler, Water Kit - Gasket, Brake Cooler 0 Screw (Pkg. of ) 0 Bolt 0 Washer, Spring Lock 0 Washer 0-0 Bracket, Rope Guide 0 Guide, Rope NOTE: For units starting with serial number 0xxxx. Guide, Rope Rivet, Pop 0 Bracket, Caliper 0 Piston & Seal (Incl. ) 00 Kit - Seal Kit - Heavy Duty Brake Pad, Type (Incl. ) 0 0 Asm., Brake Caliper (Incl.,,0) Asm., Brake Caliper (Incl.,,0) NOTE: For units starting with serial number 0xxxx. / A

16 B FRONT SUSPENSION 00 XC SP 0SPAS

17 FRONT SUSPENSION 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Strap, Spacer, Bottom 0 Nut, FLEXLOC 0 Washer Bolt Nut, Nylok 0 Nut, FLEXLOC -0 Bar, Sway 0 Bushing, Sway Bar Rivet 0 0 Nut, FLEXLOC 0 Arm, Steering, LH Arm, Steering, RH Washer Rivet 00 Bearing, Spherical 0 Ring, Retainer Foam, Trailing Arm Mount 0 Washer Bolt Arm, Trailing, LH (Incl.,) Arm, Trailing, RH (Incl.,) 0 Slide, Sway Bar Stop, Steering, LH Stop, Steering, RH 0 Bushing, Flange 0 Bushing 0 Bushing, Flange 00-0 Spindle 000 Fitting, Lubrication 00 Bushing 00 Fitting, Lubrication Bolt 0 Bolt 00 Bushing Washer Bushing, Radius Rod, Outer Fox Shock, IFS (See Fox Shock - IFS Pg. C) Retainer, Spring, Slotted Spring, Compression 000 Rod End, RH 0 Nut, Jam 0-0 Rod, Radius, Upper 0-0 Rod, Radius, Lower Nut, Jam 0 00 Rod End Rivet Brace, Pan, Lower (See Nosepan Pg. A, Ref. ) Bolt Bracket, Radius Rod, Lower 0-0 Brace, Bulkhead, Front / B

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

19 COOLING SYSTEM 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Cap, Pressure, lb. (See Oil Tank/Air Box Pg.C, Ref. ) 000- AR Line, Fuel Tank, Oil/Coolant (See Oil Tank/Air Box Pg. C, Ref. ) Hose, Engine Out/Brake Cooler 00 Clamp, Hose 0 Hose, Brake Cooler/Wear Strip 00 Clamp, Hose Hose, Rear Wear Strip Cooler Cooler, Wear Strip 0 Rivet 0 Exchanger, Close-Off 00 Clamp Rivet 0 Hose, Close-Off/Wear Strip Cooler Hose, Bypass Out/Tee In Hose, Tee Out/Tee In 000 Clamp, Hose 0 Spring, Hose Retainer Hose, Tee Out/Pump In 0 00 Connector, Tee Hose, Tee/Center Cooler Hose, Tee/Bottle / B

20 COOLING SYSTEM (S# 0XXXX) 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description Cap, Pressure, lb. (See Oil Tank/Air Box Pg.C, Ref. ) 000- AR Line, Fuel Tank, Oil/Coolant (See Oil Tank/Air Box Pg. C, Ref. ) Hose, Engine Out/Brake Cooler 00 Clamp, Hose 0 Hose, Brake Cooler/Wear Strip 0 Hose, Close-Off/Wear Strip Cooler 00 Clamp, Hose Hose, Rear Wear Strip Cooler 0 Cooler, Wear Strip Rivet 0 Exchanger, Close-Off 00 Clamp Rivet 0 Spring, Hose Retainer Hose, Tee/Pump 00 Connector, Tee Hose, Tee/Center Cooler Hose, Tee/Bottle / B

21 STEERING - HANDLEBAR 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Grip, Handlebar Pin, Retaining 0 Washer 00 Ring, Retaining 0 00 Lever, Throttle Lever, w/heater Block, Throttle 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, Cap 0 0 Grip Heater, Hi/Lo/Med Screw 0 Nut, Nylok Nut, Nylok -0 Post, Steering Screw Screw Holder, Wire 00 Ring, Retaining Screw, Set 0 00 Switch, Auxiliary Shut-Off / B

22 0 STEERING 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut Washer 0 Washer, Thrust 0 Bearing, Ball 0 Nut, FLEXLOC 0 Asm., Pitman Arm (Incl.,) 00 End, Rod, Hi-Angle 0 Nut 0 Rod, Drag Link 0 Nut, LH 0 Nut, Nylok 00 Fitting, Lubrication 00 End, Rod, LH 0 Bolt Retainer, Bolt Rivet Hoop, Steering Bolt, Carriage Cable Tie Clip, Cable Retaining NOTE: For units starting with serial number 0xxxx. B 0 0 Nut, FLEXLOC Rivet 0 Stop, Torque 0 Nut 00 Stop, Torque, Coarse Bolt, Carriage Boot, Tie Rod, CRC -0 Plate, Boot Rivet, Pop 0 Screw 0 00 Plug 00-0 Rod, Tie Bolt Nut, FLEXLOC 00 Bushing 0 Asm., Idler Arm (Incl.,) 00 Tube, Spacer 0 O-Ring Washer Screw 0 Rack, Steering /

23 CHAINCASE 00 XC SP 0SPAS 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 0 Ring, Retaining 0 Sprocket, T, /W Asm., Tightener Replacement (Includes the following) Bearing, Chaincase Block, Tightener Wheel, Idler Washer, Thrust Pin, Chain Tightener 0 Washer, Spring 0 Nut, FLEXLOC 0 Pin, Cotter 0 Gasket, Chaincase 0 Cover, Chaincase Screw 0 Screw Washer, Spring 0 0 Sprocket, T, /W Sprocket, 0T, /W NOTE: For units starting with serial number 0xxxx. 0 Chain, 0P, /W Nut, Nylok 0 0 Plug Chaincase Screw / B

24 DRIVE TRAIN 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer AR Washer 00 Spacer, Input Shaft Driven Clutch (See Driven Clutch Pg. C, Ref. ) 0 Belt, Drive Bolt, Carriage AR Bushing 0 AR Bushing 0 Flangette w/grease Fitting 0 Gasket, Jackshaft Key Bearing, Jackshaft Flangette 0 Washer Nut, Nylok 0 Jackshaft (Incl.,) 0 Ring, Retaining 0 Disc, Brake 0 00 Sleeve, Seal 0 O-Ring Nut, Flange 0 Washer Dipstick 0 O-Ring Screw Cover, Chaincase, Cast (See Chaincase Pg. B, Ref. ) Bolt, Carriage 0 Drive Shaft (Incl. 0,,) 0 0 Flangette w/screws Bearing, Drive Shaft 00 Bushing, Speedometer, Metal Flangette 00 Key, Speedometer, Square 00 Gasket, Drive Adaptor 0 Adaptor, Drive w/fitting / B

25 RAIL MOUNTING (SUSPENSION) 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description 0- Asm., Bogie Wheel (Incl. -) Insert, Bearing ( per Wheel) 0 Bearing, Roller ( per Wheel) 0 Ring, Retaining ( per Wheel) Rivet, Pop 00 Cover, Rail Tip Nut, Nylok 0 Bumper, Suspension Angle, Reinforcement Nut, Nylok 0 Nut, FLEXLOC Nut, Nylok 0 Bracket, Rail Reinforcement 0 Bumper, Suspension Angle, Reinforcement Screw Mount, Bumper 0 Bumper, Pivot Arm Bolt 00 Nut 00 Block, Idler Bolt Adjusting 0 Asm., Rail, Xtra-0, LH (Incl.,,,,) Asm., Rail, Xtra-0, RH (Incl.,,,,) NOTE: When ordering a rail assembly for units with serial numbers starting with 0xxxx, you must order Kit - Rail Assembly PN 0. 0 Rivet, Flat Bolt Washer Bushing Rivet 0 Spacer, Bogie Wheel Roller, Spring Spacer 00 Bracket, Bogie Wheel 0 0 Washer Washer 0 Washer Screw 0 Screw 0 Washer, Lock Screw Spacer Screw / B0

26 SUSPENSION 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Lock 0 Washer Bracket, Shaft Support Nut, FLEXLOC Washer, Flat Bolt Washer, Belle Asm., Idler Wheel Ring, Retaining Bearing 0 Spacer, Idler Bushing 0 Wheel, Idler Spacer, Idler, Center 00 Shaft Screw 0 Hi-Fax 0 Shaft 0-0 Arm, Pivot, Rear 00 Fitting, Lubrication 0 00 Shaft 00 Shaft, Pivot Arm 0 Track Clip, Slide Clip, Guide / B

27 FRONT TORQUE ARM 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Lock Washer 000 Shaft 0-0 Arm, Front Torque Nut Washer 00 Fitting, Lubrication 0000 Bolt, Eye 0 0 Retainer, Spring Shield, Spring Shock, Front Track (See Fox Shock - Rear Track Pg. C For Details) 00 Retainer, Spring, Slotted 00-0 Spring, Compression 0 Nut, FLEXLOC 0 Spacer 00 Bushing Nut, FLEXLOC Washer 0 Washer Screw 0-0 Arm, Shock Screw Shaft (See Suspension Pg. B, Ref. ) Shaft (See Suspension Pg. B, Ref. 0) Spacer 0 Bushing Asm., Bogie Wheel (See Rail Mounting - Suspension Pg. B0, Ref. ) Screw 0 Screw 0 Strap, Limiter, Front Shaft, Pivot Arm (See Suspension Pg. B, Ref. ) Nut, Nylok Bolt, Carriage / B

28 REAR TORQUE ARM 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Spring Lock Washer 0 Shaft, Torque Arm, Rear, Upper 0-0 Arm,Torque, Rear Nut, FLEXLOC Bolt, Carriage Shaft, Torque Arm, Rear, Lower 0000 Bolt, Eye 0 00 Fitting, Lubrication Nut, Nylok Screw 00 Clip, Push-On Roller, Spring Collar, Bearing Lock Screw, Set Washer Wheel, Carrier Bearing ( Per Wheel) Ring, Retaining ( Per Wheel) B Spring, Torsion, LH (./ Degree) Optional Spring, Torsion, RH (./ Degree) Optional Spring, Torsion, LH (./ Degree) Standard Spring, Torsion, RH (./ Degree) Standard Spring, Torsion, LH (./ Degree) Optional Spring, Torsion, RH (./ Degree) Optional 0 00 Sleeve, Torsion Spring Washer 0 Strap, Limiter, Rear 0 Screw 00 Bushing Washer Spacer 0-0 Shock Rod Bolt 0 Shock, Rear Track, X-0, Fox, P/S 0 00 Bushing 0 Bolt /

29 DRIVE CLUTCH 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer, Spring Lock Bearing, Cover 0 Ring, Retaining, Cover 0 Spring, Clutch, Dark Blue 0 Washer, Multilube Roller & Bushing 0 Button, Guide Weight/Bushing, Pin, Weight, Hardened 0 Bearing, Sleeve 00 Insert, Moveable 0 Nut, FLEXLOC AR AR AR AR Spacer (.00mm) Spacer (.0mm) Spacer (.0mm) Spacer (.00mm) 00 Nut, Jam 00 Pin, Roller 00 Kit - Shim, Drive Clutch 0 Asm., Drive Clutch, Basic (Incl. All Less,) Kit - Clutch Update (Incl.,,) / B

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

31 FOX SHOCK - IFS 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Fox Shock, IFS 00 Kit - Piston Valving 00 Bushing 0 Ring, Spring Preload Adjustment 0 Bumper, Jounce 00 Retainer, Spring, Slotted Asm., Bearing O-Ring, Outer O-Ring, Inner Wiper, Outer Wiper, Inner Screw Ball 0000 Bearing, Bushing 0000 O-Ring 000 Piston, IFP Screw O-Ring 0 00 Sleeve, Steel, Body End Asm., Air Valve Air Valve Housing w/rubber Pellet Screw O-Ring 0000 O-Ring 000 Body Cap 000 Nut 000 Bushing, Back-Up 0000 Ring, Piston 000 Plate, Top-Out 00 Eyelet, Billet (. ) / C

32 FOX SHOCK - FRONT TRACK 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Shock, Front Track 00 Bushing 000 Sleeve 00 Body Cap 0000 O-Ring 000 Piston, Floating 000 Nut 000 Bushing, Backup 000 Plate, Top-Out 00 Eyelet, Base 0 00 Shaft 00 Kit - Piston Valving 0000 Ring, Piston 00 Retainer, Spring 0000 O-Ring 0000 Bearing 000 O-Ring 000 Screw 000 O-Ring 0000 O-Ring Wiper, Inner 000 Wiper, Outer 0000 Screw 000 Ball 00 Bushing / C

33 FOX SHOCK - REAR TRACK 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Shock, Rear Track 00 O-Ring Piston, IFP Screw O-Ring 00 Asm., Bearing 00 Eyelet 00 Shaft 000 Plate, Top-Out 00 Collar 0000 Ring, Piston 000 Bushing, Backup Nut, Lock 00 Sleeve, Bypass 000 Ring, Rebound, Blue C 00 Body 0000 O-Ring Asm., Air Valve Screw O-Ring 00 Body Cap 00 Sleeve 00 Bushing 000 O-Ring O-Ring 000 Wiper, Inner 000 Wiper, Outer 0000 Screw 000 Ball /

34 ENGINE MOUNTING 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw 00 Washer 00 Spark Plug, RNC, Champion 00 0 Engine, SN0-- 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. Engine, SN0--A NOTE: For units starting with serial number 0xxxx. Handle, Recoil 00 Nut, FLEXLOC 0 Washer, Flat 00 Mount, Engine 0 Nut 0 Strap, Engine Mount, LH Strap, Engine Mount, RH Washer Screw 00 Mount, Engine Nut, Nylok 0000 Clamp, Hose 0 Pump, Fuel AR Line, Fuel 0 Valve, Fuel Shut-Off 0 Filter, Fuel NOTE: For units starting with serial number 0xxxx Clamp, Hose 00 AR Line, Fuel 00 Cable, Throttle / C

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

36 EXHAUST SYSTEM 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Rivet Shield, Heat NOTE: For units starting with serial number 0xxxx. Rivet 0-0 Bracket, Resonator Rivet Asm., Tuned Pipe (Incl. ) Cover, Pipe, Top Cover, Pipe, Bottom Matte, Sound 0 Spring, Exhaust Resonator Resonator NOTE: For units starting with serial number 0xxxx. Boot, Exhaust, Outlet 0 Screw Gasket, Exhaust 0-0 Manifold 00 Seal, Exhaust Rivet Bracket, Muffler, Front AR Washer 0 Dampener, Vibration Clamp (. x.0) Clamp (. x.) Clamp (. x.) Clamp (. x.) / C

37 CRANKCASE 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Clamp Stud Stud 0 Asm., Crankcase (Incl.,,-0) 0 Plug Screw Screw Screw Screw 0 00 Pin, Dowel Seal 0 Reed Valve Stuffer, Reed Adaptor, Carb 00 Clamp, Hose Screw / C

38 CYLINDER 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Screw Screw Washer, Flat 0 Sensor, Temperature 00 Cover, Thermostat O-Ring 0-00 Cover, Head O-Ring 0 Seal, Head Cover, Rubber 00 Head, Cylinder O-Ring O-Ring 0 Nut, Flange 00 Cylinder Gasket, Cylinder Base 0 Fitting 0 Thermostat Screw / C

39 CYLINDER (S# 0XXXX) 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Screw Washer, Flat Screw 0 Cover, Thermostat O-Ring Cover, Head O-Ring Seal, Head Cover, Rubber 0 00 Head, Cylinder O-Ring O-Ring 0 Nut, Flange 0 Cylinder Gasket, Cylinder Base 0 Sensor, Temperature 0 Thermostat Screw / C0

40 WATER PUMP/OIL PUMP 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Seal 00 Seal 00 Washer, Flat 0 Impeller, Water Pump Washer 0 Nut, Nylok 0 Gasket, Water Pump Cover 00 0 Cover, Water Pump Cover, Water Pump NOTE: For units starting with serial number 0xxxx. Screw 0 Washer, Thrust Driveshaft, Water/Oil Pump O-Ring 00 Bearing, Pump Shaft, Flanged Gasket O-Ring NOTE: For units starting with serial number 0xxxx. 00 Pump, Oil, Outlet Screw / C

41 PISTON and CRANKSHAFT 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Circlip, Piston 0 Pin, Piston Kit - Piston Rings (Standard) Kit - Piston Rings (.mm/.00 O/S) Kit - Piston Rings (.0mm/.00 O/S) Kit - Piston (Incl. -) Kit - Piston (.mm/.00 O/S) Kit - Piston (.0mm/.00 O/S) Washer Bearing 0 Bearing 0 Kit - Rod, Connecting (Incl.,,) Washer 0 Crankweb, Center 0 Bearing, Sealed Gear, Pump Drive Shaft, Pump Drive 0 Ring, Snap Key, Woodruff 0 Bearing 0 Asm., Crankshaft (Incl.,,-,,) 0 Bearing 0/ C

42 CARBURETOR 00 XC SP 0SPAS Ref. Part Qty. Description Ref. Part Qty. Description Asm., Carburetor, Rack, mm 0 Screw 0 Cap, Top 0 Gasket 0 Screw 0 Packing 0 Clip 0 Ring 0 Plate 0 E-Ring 0 0 Cap, Rubber 00 Holder, Guide 0 Spring 0 Plunger 00 Valve, Piston 0 Needle, Jet (J-FH0-) 0 Packing 0 E-Ring 0 Plate 0 0 Lever, LH Lever, RH 0 0 Ring 0 Screw, LH 00 Screw, RH 00 O-Ring, Air Funnel 0 Funnel 0 Screw 0 Jet, Pilot Air (PAJ) (0.) 00 Pin 00 0 Jet, Main (0) Jet, Main (0) NOTE: For units starting with serial number 0xxxx. 0 Nipple 0 0 O-Ring 0 Screw 0 Body, Float 0 O-Ring 0 Float 0 Jet, Starter 00 Jet, Pilot () 0 Washer 0 Spring 0 Asm., Adjuster 0 0 Packing 000 Valve, Check, 0 Degree 0/ C

43 CARBURETOR 00 XC SP 0SPAS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bolt 0 Lever 0 Screw 00 Ring 0 Spring 0 Screw 0 Adjuster 0 Spring 0 Bracket 0 00 Screw 00 Screw 0 Spring 0 Ring 0 Lever 0 Shaft 0 Screw 00 Bracket 0 Hose 0 Packing, Starter Shaft 0 0 Spring, Starter Shaft 00 Shaft 0 Ring 0 E-Ring 0 Lever, Starter 0 Nipple, Fuel Inlet 00 Clamp, Hose 00- AR Fuel Line Plug, Trap / C

44 MAGNETO 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw 00 Pulley, Starting 0 Nut, Hex 0 Washer 00 Flywheel 000 Stator 0 Grommet Washer. Lock 0 Washer Screw 0 Kit - CDI (Incl. Nyogel & Decal) 0 00 Cap, Spark Plug 00-0 Wire, Ignition / D

45 RECOIL STARTER 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Recoil (Incl. -,,) 00 Nut 00 Plate, Friction 00 Spring, Friction 00 Ratchet 00 Spring, Return D 00 Reel 000 Spring, Spiral 00 Bushing, Rope 0 Screw 0 Housing, Recoil Starter 00 Rope, Starter /

46 TOOL KIT 00 XC SP 0SPAS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Tool (Incl. -)assembler Screwdriver Wrench Box Wrench, Special Manual, Owner s, Snowmobile Supplement, O/M, 00 XC SP 0 Roll, Tool D 00 Strap, Emergency Starter 0 Screw 0 Cover, Tool Box 0 Foam, Tool Box 0 0 Box, Tool 0-0 Bracket, Tool Box /

47 PART NUMBER INDEX 00 XC SP 0SPAS Part Ref. Grid Part Ref. Grid Part Ref. Grid A A A A B B A A A A A A A A A A B B C D C C C C C C C C B B B C B B C... C... C C... C C... C... C C... C C... C C C... C... C C... C 0... C C... C... C C... C... C C... C C... C 0... C C... C... C C... C... C C... C C... C... C C 0... 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 B B B B B B B B B B B B B D B B B B D B A A A A A A A A A A B A A B A A C... C A A A C C D B C C C C A A A A A A A A C A C C C C A A A A B A A C A C B 0... B B... B

48 PART NUMBER INDEX 00 XC SP 0SPAS Part Ref. Grid Part Ref. Grid Part Ref. Grid C A C C C A A A A A A D A B C C C C C D D D D D D D D D D 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 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 B B B B B B B B A A A A A A A A A C B B0.. B B C B D B B C B C B B B B C B C C D D A A A A A C D A0.. A A A A A D B C C.. C B B B B C B B B B B B.. B B C B... C C C C B B B B B B B B B C C

49 PART NUMBER INDEX 00 XC SP 0SPAS Part Ref. Grid Part Ref. Grid Part Ref. Grid B C B B C C C C C B B C B B B B A A B B A A B0.. B A B A B B A C B C A D B B B C C B A A A A B B B C A A A B A A C C A A A C C B A A A A A A B A A A A A A A A B A C A B B B B B B B B B B A... A... C A A C A B B A... A C B A B B C B C C C C.. C D B B B B... B C C.. C0 D B B... B B... B C C.. C C A B... B C.. C B B B B C C.. C A B B B B A A B C D D A B B A B B C B A B A A C A A B C B B C C B B B B C C C C A A

50 PART NUMBER INDEX 00 XC SP 0SPAS Part Ref. Grid Part Ref. Grid Part Ref. Grid A A A A B B B B B B B B B B A A A B B B B B B D B C C C C C C A A A A A B D B B A A C C C.. C C A C A A A A A A A B A A A A C B C C C B B.. B A B C B B B... B B B B B B B A C C B C A C A A C C C A B... B B C A C C C C C A B B B B B C C A C C A A A C C A A A D A A A A A A A A A A A C A... C A A D B C A B A A A... A B.. B.. B 0.. B A C.. C A A A B B B... B B... B B... B B C C B A C A C C A A... B C C C A B B A A

51 PART NUMBER INDEX 00 XC SP 0SPAS Part Ref. Grid Part Ref. Grid Part Ref. Grid D A C A A... A C A B B A B B A... C B B.. B B B.. B B B B B B B B B B A C A A A.. B A A B B B B... B B B0.. B B B B B.. B B B B B A B B B.. C0... C C.. C0.. C C D C B B C B.. B.. B C.. C C D C B D C C B B C C B B A.. A0.. A.. A C C C B A C B B C A A... B 0... B A... A... A 0... A... B.. B C B B B... B.. B B B B... B.. B D B... B B 0.. B0.. B.. B.. B B B B B.. B B... C B B B B B B B C D C C.. C C B A C B.. B.. B.. A A... A.. B B B B.. B B B B B B C B.. B B B B A 0.. B0.. B... C B... B B B C C B.. B

52 PART NUMBER INDEX 00 XC SP 0SPAS Part Ref. Grid Part Ref. Grid Part Ref. Grid B.. B... C C A D B A B D D B C C.. C C C B B... B C... C A A... A... A C B B B... B... B B B B A A A B A A A A A... A... C A... A B... B A A 0... A A B A... B A A 0.. A A... C B B B A A B B B A.. A A 0... B... B... B... C... C A... B B... C A A B C A A A A C C B B B B B B C B C B B0.. B.. B C B C A A A... B... B... C A... C C C D D D

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55 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

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

57 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

58 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

59

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