800 XCR Model #S00SB8AS Rev. 01

Transcription

1 00 XCR Model #S00SBAS Rev. 0 PARTS MANUAL PN 0 and MICROFICHE PN 0/

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3 BRAKE B A CARBURETOR D- CHAINCASE B CONSOLE A COOLING SYSTEM B CRANKCASE C CYLINDER C-0 DECALS A DRIVE CLUTCH C DRIVE TRAIN B DRIVEN CLUTCH C ENGINE MOUNTING C- EXHAUST SYSTEM C FOX SHOCK - FRONT TRACK B FOX SHOCK - GAS, REAR TRACK C FOX SHOCK - IFS B FRONT SUSPENSION B- FRONT TORQUE ARM B FUEL PUMP D HOOD A-0 HOOD - FOAM/FOIL A C D E F H TABLE OF CONTENTS Parts Manual MAGNETO D N NOSEPAN A- OIL PUMP C OIL TANK / AIR BOX C PART NUMBER INDEX D- PISTON and CRANKSHAFT C RAIL MOUNTING (SUSPENSION) B REAR TORQUE ARM B RECOIL STARTER C SEAT and GAS TANK A SKI B STEERING B STEERING - HANDLEBAR B SUSPENSION B0 TOOL KIT/BOX D TUNNEL A WATER PUMP M O P R S T W 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 XCR SPECIFICATIONS 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) Polaris HPB Liquid Cooled, / Piston./. N/A P (/) T- N/A : / P- 0-0 N/A Wide Almond Yes 0. R- Silver/Blue ECPL0 V 0W x Mikuni Rack TM Flatside w/tps Liquid Nicasil RPM Digital CDI w/tps Yes RNC Champion Backrest Pad Color Belly Pan Color Front Shock Color Front Springs Color Handlebar Cover Headlight Pod Color Hood Color Hood Accent Colors GRAPHICS 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 Headlight Type Headlight (watts) Indicator Light Thumbwarmer Handwarmers ELECTRICAL 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.) Shock Torsion Bar Rear Type Front/Rear Torque Arm Limiter Rear Travel (in.) Shock: Front Track Rear Track Springs: Front Torque Arm Rear Torque Arm Rear Torque Arm Spring Dia. N/A Black Gold Indy Red Black Black Black Screamin Yellow/Blk/White/Br. Red/ Black Fine Fade/Slate Metallic/Vlt.-C Black N/A N/A Indy Red Black High Gloss Black Br. Red/Screamin Yellow/Vlt.-C/Br. Silver/ Black/Slate Metallic/Blk Fine Fade Mid Flared Smoke Black Band Halogen X High 0/Low 0 Temp/Oil/Brake/Acc/Hi Beam/Premium Standard Hi/Low Standard Polyester Shock Wave/. XC-0 0 Adjustable FOX IFP/Thread Adjust / XTRA-0 Race Quick Adjustable 0. FOX IFP FOX IFP Variable 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.

5 000 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 Rivet Guard, Chaincase Rivet Bulkhead, CRC 00-0 Asm., Tunnel (Incl. 0,,) Rivet Rivet Rivet 0 Snowflap 0-0 Panel, Tunnel Back 0 Bumper, Rear -00 Cap, Bumper 0 Washer, Flat 0 Washer, Spring Lock 0 Screw Rivet -0-0 Bracket, Suspension, Rear, LH Bracket, Suspension, Rear, RH Bracket, Front Pad Mounting, LH Bracket, Front Pad Mounting, RH Extrusion, Clutch Guard Footrest, LH Footrest, RH Support, Tunnel, LH Support, Tunnel, RH -0-0 Brace, Footrest/Trailing Arm, LH Brace, Footrest/Trailing Arm, RH Rivet Guard, Adaptor, Drive 00 Plug, Hole Plug, Hole Plug, Hole / A

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

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

9 NOSEPAN 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Tape, Foil 0 Tape, Foil 0 Tape, Foil 00-0 Tape, Foil Foil 000 Patch, Heat Resistant 00- Tape, Foil Foil, Heatshield, Pan 0 Rivet 0 00 Decal - Troubleshooting, XTRA-0 Clip, Belt Retainer 00 Pin, Clutch Guard 0 Asm., Clutch Guard (Incl. Decals) 00 Decal - Engine and Clutch Rivet Rivet 00 Clip, Dart 0 Plug, Hole Nosepan 0 Plate, Backer 00 Plug, Hole Rivet / A

10 HOOD 0 0 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, Headlight 0 Bulb, Halogen 000 Fastener, U-Type Clip Lens/Reflector, LH Lens/Reflector, RH - Asm., Hood (Incl. Foam/Foil) 0 Cover, Access Headlight Screw 00 Knob, Headlight Adjust 00 0 Hinge, Upper, LH Hinge, Upper, RH Plate, Bolt Screw 0 Bolt, Carriage Nut, Nylok Plate, Hinge, Lower Brace, Hood, Upper 0 Brace, Hood, Lower Rivet 0 Spring, Extension 00 Ring, Spring Attachment 00 Clamp, Retainer Screw Screen, Front Foam, Headlight Seal 00 Spring, Headlight Adjust Bolt, Tee, Adjuster / A

11 HOOD Ref. Part Qty. Description Ref. Part Qty. Description Windshield,, Flared, Smoke 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 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 0 Bracket, Fuel Gauge, A0 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 00 Clip, Routing 0 Rivet Clip, Pigtail 0 Washer Cable, Hood, LH Cable, Hood, RH 0 0 Rivet Rivet Duct, Air, Hood /

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

13 DECALS LH 0 RH Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Hood Decals, XCR (Incl.,,,,,,,,) 00 Kit - Decal Application Solution (For Seat Decals) 00 Decal - Hood Center, POLARIS 0 Decal - Hood Center, INDY 00 Decal - Warning/Caution, French 0 Decal - Warning/Caution, English 0 Decal - Seat, POLARIS, Flags 0 Decal - XTRA 0 0 Decal - Tunnel, LH 0 Decal - 00 XCR, LH 0 Decal - Hood Side, LH 0 0 Decal - XC-0, LH 0 Decal - NO PASSENGER Warning, English/French 00 Decal - Track/Seat, English/French 0 Decal - Tunnel, RH 00 Decal - XCR 00, RH 0 Decal - Hood Side, RH 0 Decal - XC-0, RH 0 Decal - Suspension Set-Up / A

14 CONSOLE 0 Footrest 0 ON/ Prem. ON/ Reg. Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw Spacer 00 Regulator, LR Nut, Nylok 00 Housing, Connector 00 Socket 00 Cable Tie 000 Terminal, Ring 000 Housing 0 0 Harness, Main Wire 00 Decal - Ignition, Off/Prem./Reg. Screw 0 Kit - Ignition Switch 00 Cable, Choke (Incl.,) 00 Kit - Choke Control Washer 000 Cable Tie 0 Rivet 0 Guide, Recoil 0 0 Washer, Lock 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 0 Console / A

15 BRAKE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Cover Screw 0 Kit - Cover Asm. (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 Asm. 00 Asm., Control, LH Button, Switch, HI/LO, LH Control 0 Kit - Pivot Pin 0 Kit - Parking Lever and Spring (Incl. ) 0 Asm., Brake Caliper (Incl.,,) 0 Line, Brake 00 Kit - Clip, Spring (Qty. ) 0 Inlet 0 00 Kit - Cooler, Water Kit - Gasket, Brake Cooler 0 0 Screw (Pkg. of ) Bolt 0 Washer, Spring Lock 0 Washer, Flat 0 Guide, Rope 0 Bracket, Caliper 0 Piston and Seal (Incl. ) 00 Kit - Seal 00 Switch, Brake Light 0 Kit - Heavy Duty Brake Pad, Type Small (Incl. ) 00 Kit - Heavy Duty Brake Pad, Type Large (Incl. ) / A

16 B FRONT SUSPENSION

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

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

19 STEERING Ref. Part Qty. Description Ref. Part Qty. Description Rack 0 O-Ring, Teflon 00 Tube, Spacer 0 Asm., Idler Arm (Incl.,) 0 Nut, FLEXLOC 0 Nut, FLEXLOC Washer 0 Bushing 00 Fitting, Lubrication 0 00 Spacer Arm, Pitman (Incl.,) 00 Rod End, RH 0 Nut Rod, Link, Drag Nut, LH 00 Rod End, LH 0 Bolt 00 Fitting, Lubrication 0 Nut, FLEXLOC Post, Steering 000 Cable Tie Screw 0 Nut, FLEXLOC B Rivet 00-0 Hoop, Steering Bolt, Carriage 0-0 Support, Plate Bearing Washer Rivet 0 0 Bracket, Torque Stop Nut 00 Stop, Torque Boot, Tie Rod -0 Plate, Boot Rivet 00 Clip, Rosebud 0 Screw 0 Washer, Thrust Bolt 0 Screw Nut, FLEXLOC 00 Rod End, LH Tie Rod Bolt, Carriage Bracket, Bolt Retaining /

20 STEERING - HANDLEBAR 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Grip, Handlebar Pin, Retaining 00 Ring, Retaining 0 00 Lever, Throttle Lever, w/heater Block, Throttle/Brake Adaptor, Block Screw 00 Nut, Push-On Emblem, STAR 0 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. A, Ref. ) 0 Plug, Overflow 0 Heater, Grip, Lo/Med/Hi Screw 0 0 Nut, FLEXLOC Nut, Nylok 0-0 Post, Steering Screw Screw Holder, Wire 00 Ring, Retaining Screw, Set 00 Switch, Auxiliary Shut-Off 0 Washer / B

21 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 0 Sprocket, T, /W Asm., Tightener Bearing, Chaincase Idler Wheel, Idler Washer, Thrust Pin, Chain Tightener 0 Washer, Spring 0 Nut, FLEXLOC 0 Pin, Cotter 0 Gasket, Chaincase 0 Cover, Chaincase Screw 0 Bolt Washer, Spring Chain, 0P, /W Nut, Nylok 0 Sprocket, T, /W 0 0 Plug Chaincase Screw / B

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

23 0 COOLING SYSTEM Ref. Part Qty. Description Ref. Part Qty. Description Screw Washer, Flat 0 Plug, Thermo 0 Gasket 0 Sensor, Water Temp. 00 Autostat, 0 Degree 0 Housing, Thermostat Hose, Stat Out/Brake In 0 Hose, Brake Cooler, -Way Line, Fuel 0 Cap, Pressure Bolt 0 Washer 00 Nut, Chimney Tank, Coolant 00 Clip, Rosebud 00 Clamp, Springband 0 Rivet Bracket, Tank, Surge 0 00 Spring, Hose Retainer 0 Hose, Footrest/Tee, RH 00 Cooler, Side, RH 00 Clamp, Springband Hose, Strip Cooler/Tank 00 Cooler, Wear Strip Hose, Rear Wear Strip Cooler 00 Cooler, Side, LH Guard, Cooling, LH Guard, Side Cooler, RH 00 Clamp, Hose 0 0 Exchanger, Close-Off 0 Hose, Front Cooler/LH Footrest 0 Hose, Crossover 00 Clamp, Springband 0 Hose, Tee/RH Wearstrip Hose, Center Cooler, Top Surge 00 Clamp, Springband Tubing, Convoluted 00 Connector Hose, Coolant 0 Hose, Stat Out/Tank In Hose, Engine Out/Stat In 000 Gasket, Thermostat 0 Cap/Thermostat, Housing 0 Washer, Spring Lock Screw B /

24 RAIL MOUNTING (SUSPENSION) Ref. Part Qty. Description Ref. Part Qty. Description 0- Asm., Bogie Wheel, Red (Incl. -) Insert, Wheel ( per Wheel) 0 Bearing, Roller ( per Wheel) 0 Ring, Retaining ( per Wheel) Rivet 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, Adjusting, Idler Bolt 0 0 Rivet B Bolt Washer, Flat Spacer Rivet 0 Spacer, Bogie Wheel Roller, Spring Spacer 00 Bracket, Bogie Wheel 0 Washer Flat 0 0 Washer Washer, Flat Screw 0 Bolt 0 Washer, Split Lock Screw Spacer Screw Asm., Rail, Xtra-0, LH (Incl.,,,,) Asm., Rail, Xtra-0, RH (Incl.,,,,) /

25 SUSPENSION Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Spring Lock 0 Washer, Flat Bracket, Shaft Support Nut, FLEXLOC Washer, Flat Bolt Washer, Belle Spacer, Idler Bushing Asm., Idler Wheel, Indy Red Ring, Retaining Bearing 0 Wheel 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 / B0

26 FRONT TORQUE ARM Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Spring Lock Washer, Flat 0 Shaft 0-0 Arm, Torque, Front Nut, Nylok Washer, Flat 00 Fitting, Lubrication 0000 Bolt, Eye 0 0 Ring, Retaining 0 Shield, Spring Shock, Front Track (See Fox Shock - Front Track Pg. B For Details) 00 Retainer, Spring, Slotted 0-0 Spring, Compression 0 Nut, FLEXLOC 0 Spacer 00 Bushing Nut, FLEXLOC B Washer, Wave 0 Screw 0-0 Arm, Shock Screw Shaft (See Suspension Pg. B0, Ref. ) Shaft (See Suspension Pg. B0, Ref. 0) Spacer 0 Bushing 0 Asm., Wheel Screw Screw 0 Strap, Limiter, Front Shaft, Arm, Pivot (See Suspension Pg. B0, Ref. ) Nut, Nylok Bolt, Carriage /

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

28 FOX SHOCK - FRONT TRACK 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Shock, Front Track 00 Bushing 000 Bushing 00 Cap, Body 0000 O-Ring 00 Piston, Floating 000 Nut, Lock 000 Plate, Backup 000 Plate, Top-Out 00 Asm., Bearing 0 00 Bushing 00 Eyelet 00 Shaft 00 Kit - Piston Valving 0000 Bearing, Piston 00 Ring, Spring Preload 00 Body 0000 O-Ring 0000 Bearing 000 O-Ring 0 00 Screw 000 Screw 000 O-Ring 0000 O-Ring 000 Shaft, U-Cup 000 Wiper, Shaft 0000 Screw 000 Ball / B

29 FOX SHOCK - IFS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Shock - Gas, IFP, IFS 00 Bushing (.0) 0 Ring, Adjusting, Spring Preload 0 Bumper, Jounce 00 Retainer, Spring, Slotted Asm., Bearing O-Ring, Outer O-Ring, Inner Wiper, Shaft Shaft, U-Cup Screw Ball 0000 Bearing 0000 O-Ring 00 Piston, Floating 00 Screw 0 00 Sleeve Asm., Air Valve Screw O-Ring 0000 O-Ring 00 Asm., Body Cap 000 Nut, Lock 000 Plate, Back-Up 0000 Bearing, Piston 000 Plate, Top-Out 00 Eyelet / B

30 FOX SHOCK - GAS, REAR TRACK 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Shock, Rear Track, Fox (Incl. -) 00 Bushing 000 Asm.,Air Valve 000 Screw 00 Bushing 0000 O-Ring 00 Piston, Floating 0000 Bearing 0000 O-Ring 000 Plate, Backup O-Ring 000 Shaft, U-Cup 000 Wiper, Shaft C 000 Eyelet 00 Bearing 0000 O-Ring 000 Plate, Top-Out 0000 Bearing, Piston 000 Nut, Lock 000 O-Ring Screw 000 O-Ring 00 Cap, Body 000 Body 000 Shaft /

31 DRIVE CLUTCH 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Wide Roller Spider Rebuild (Incl. -,,,) Bolt 0 Washer, Spring Lock Cover, Bearing 0 Ring, Retaining, Cover 0 Spring, Clutch, Almond 00 Nut, Jam 0 Washer, Multilube Roller and Bushing 0 Button, Guide AR AR AR AR Spacer (.00 ) Spacer (.0 ) Spacer (.0 ) Spacer (.00 ) Weight/Bushing (0-0) 0 Pin, Hardened Weight 00 Insert, Moveable 0 Bearing, Sleeve 0 Nut, FLEXLOC 00 Pin, Roller 00 Kit - Drive Clutch Shim 0 Asm., Drive Clutch (Incl. All Less,) / C

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

33 EXHAUST SYSTEM 0 0 Ref. Part Qty. Description Ref. Part Qty. Description -0 Bracket, Resonator, Front Rivet -0 Bracket, Resonator, Rear Rivet 0 Spring, Resonator 0-0 Resonator 00-0 Stinger Outlet Rivet Rivet 0 0 Support, Pipe Gasket, Exhaust (See Cylinder Pg. C0, Ref. ) Washer (See Cylinder Pg. C0, Ref. ) Bolt (See Cylinder Pg. C0, Ref. ) 0 Spring 00 Pipe, Tuned, PTO 0 Pipe, Tuned, Center 0 Pipe, Tuned, MAG 00 Seal, Exhaust Socket, Rear 00 Seal, Exhaust Socket, Front Pipe, Head, MAG 0-0 Pipe, Head, Center 0-0 Pipe, Head, PTO / C

34 ENGINE MOUNTING 0 0 C

35 ENGINE MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw 00 Washer Washer, Clutch Retainer Asm., Drive Clutch (See Drive Clutch Pg. C, Ref. ) 00 Cable, Throttle 00 Plug, Spark, RNC, Champion 00 Engine, Short Block (ECPL0) 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 00-0 AR Conduit 0 00 Cable Tie 0 Hose, Water Trap, Degree Plug, Trap 0000 Clamp, Hose 00 Clamp, Hose 0 Valve, Fuel Shut-Off 00 AR Tubing 00 AR Tubing AR Line, Fuel Plate, Engine, LH 0 00 Cable Tie 00 Nut, FLEXLOC Washer, Flat 00 Mount, Stud, Engine Washer, Flat Bolt 0 Washer, Spring Lock Washer, Flat Plate, Engine, RH 00 Mount, Engine / C

36 OIL TANK / AIR BOX Ref. Part Qty. Description Ref. Part Qty. Description Foam, Intake 0 Inlet, Plenum Plenum 0 Decal - Fuel Shut-Off Bracket, Fuel Shut-Off Valve, Screw Washer, Flat Nut, Well 0 Washer, Tooth, External 0 Screw 0 Fitting Boot Bracket, Air Box Rivet Box, Air, Bottom 0 Seal, Plenum 0 Boot, Cone, Outlet 0 Decal - Air Box Caution 00 Decal - Adjustable Driven Clutch 0 0 Decal - Greasing 0 Washer, Flat Bolt C Screw 0 Washer, Flat 0 Gasket, Oil Cap 0 Cap, Oil Tank 0 Sensor, Oil Level 00 Nut, Chimney 00 Fitting, 0 Degree AR Line, Fuel 0 Decal - Low Oil Level 0 Bushing 0 Bracket, Oil Tank Bolt 00 Fitting, / Outlet Line, Oil 000 Filter 000- AR Line, Fuel 0 Bracket, Oil Tank 0 00 Clamp, Hose 000 Clamp, Hose, Green, Large 0000 Clamp, Hose, Red 00 Clamp, Hose Tank, Oil w/send Unit Hole /

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

38 C CYLINDER

39 CYLINDER Ref. Part Qty. Description Ref. Part Qty. Description 000 Bolt and Washer 0 Manifold, Outlet 00 Plug, Vent, Air 0 Gasket, Aluminum 0 Gasket, Manifold 0 Cover, Head 0 Bolt, Flange 0 Bolt, Flange 00 O-Ring 0 0 O-Ring 00 Head, Cylinder 000 Pin, Dowel 0 O-Ring 0 Nut, Flange 0 Gasket, Exhaust 00 Bolt 000 Washer 0 Cylinder (Incl. ) 0 Gasket, Cylinder 0 0 Gasket, Cover, Inlet 0 Cover, Inlet 0 O-Ring 0 Bolt, Flange 0 Adjuster, Spring 0 O-Ring 0 Bolt, Flange 00 Cover, Valve, Exhaust 00 Spring, Valve, Exhaust 0 Cap, Valve, Exhaust 0 0 Bolt 0 Bellows, Valve, Exhaust 0 Washer 0 Housing, Valve, Exhaust (Incl. ) 0 Pin, Dowel 0 Gasket, Valve, Exhaust 0 Valve, Exhaust 0 Screw and Washer 0 Stopper 0 Valve 0 0 Asm., Reed Valve (Incl.-) 0 Stuffer, Valve, Reed 0 Adapter 0 Gasket 0 Valve, Check 0 Bolt 0 Bolt, Flange 0 Nut, Flange 0 Screw 0 Asm., Band (Incl. ) / C0

40 PISTON and CRANKSHAFT Ref. Part Qty. Description Ref. Part Qty. Description 0 Piston Set 0 Clip, Piston Pin 00 Ring, Piston 0 Pin, Piston 00 Spacer, Pin, Crank 00 Rod, Connecting 0 Bearing, End, Small 0 Bearing, End, Large 0 Pin, Crank 0 0 Pin, Crank 000 Key, Woodruff 0 Asm., Crankshaft (Incl.,,-0,,-) 0 Crankshaft C 00 Nut 0 Washer 00 Bearing 0 Bearing 0 Spacer 0 Bearing 0 Crankshaft, Center (Incl.,,-0,,0) 0 Crankshaft, Mag (Incl. 0) 0 0 Crankshaft, PTO (Incl. ) 0 Crankshaft /

41 RECOIL STARTER 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw, Set 00 Washer 0 Spring, Spiral 0 Mark, Timing 000 Bolt and Washer Guide, Rope 0 Bolt and Washer 0 Spring, Return 0 0 Ratchet Starter, Recoil (Incl. -,-,,0) Case, Starter C 00 Bush 0 Spring, Friction 0 Plate, Friction 0 Washer 0 Bolt and Washer 0 Bolt and Washer 00 Washer 0 Pulley, Starting 0 Reel 0 0 Rope, Starter /

42 WATER PUMP 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 000 Pin, Dowel 0 Bolt, Flange 0 Pin, Dowel 0 Bearing 0 Shaft, Pump, Water 0 O-Ring 0 Bearing 0 Bolt, Flange 00 Bolt and Washer 0 0 Gasket 00 Bolt 0 Asm., Water Pump (Incl.,-,-,-) 0 Casing, Pump (Incl. ) 0 Gasket, Aluminum 00 Plug, Vent, Air 0 0 Screw and Washer 0 Impeller 0 Plate, Sealing 0 Seal, Mechanical 0 Pump, Water (Incl.,,,,) 0 0 Gasket, Pump, Water / C

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

44 CARBURETOR PTO Side 0 Center 0 MAG Side Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Carburetor (Incl. - and all of Carburetor Pg. D) 0 Screw 0 Lever Asm., Mixing Body 0 Lever, Starter 0 Screw (Center Side) 00 Bracket (Center Side) 0 Screw (Center Side) 0 Spring (Center Side) 0 Screw, Adjust (Center Side) 0 0 Spring (Center Side) 0 Bracket (Center Side) 00 Screw (Center Side) 0 Spring 0 Ring 00 Asm., Shaft w/throttle Lever 00 Screw (Center Side) 00 Ring 00 E-Ring 0 Spring 0 Asm., Mixing Body 0 Packing 0 Shaft Asm., Mixing Body 00 Asm., Nipple 00 Bolt / D

45 CARBURETOR Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw 0 Cap, Top 0 Gasket Asm., Mixing Body 0 Asm., Plunger 0 Spring 00 Holder, Guide 0 Cap 0 E-Ring 0 0 Plate 0 Clip 0 Washer 0 Ring 00 0 Screw (Center and MAG Side) Screw (PTO Side) 0 Ring (Center and MAG Side) 0 0 Asm., Lever (PTO and MAG Side) Asm., Lever (Center Side) 00 Ring (PTO Side) 0 E-Ring 0 Screw 0 0 Plate 0 Packing 00 Needle, Jet (DH0--) 00 Asm, Sensor (MAG Side) D 00 Screw (MAG Side) 0 Cap 00 Asm., Piston Valve 0 Spring 0 Cap 0 Adjuster 0 0 Washer 0 Packing 0 Jet, Pilot (#0) 0 Jet, Main (#) 0 Asm., Float 0 O-Ring 0 Body, Float 0 O-Ring 0 Screw 0 Nipple 0 00 Screw 0 Jet, Main (#0) 0 Washer 0 Jet Screw Asm., Funnel 00 O-Ring Hose (PTO Side) Hose (Center and MAG Side) /

46 MAGNETO Ref. Part Qty. Description Ref. Part Qty. Description 0 Band 0 Screw and Washer 0 Screw and Washer 0 Screw and Washer 0 Asm., Plate (Incl. -,,) Stator 00 Screw and Washer D 00 Asm., Flywheel 0 CDI System 00 Cap, Plug, Spark 0 0 Coil, Ignition 0 Nut, Flange 0 Plate, Coil, Ignition 0 Bolt, Flange /

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

48 TOOL KIT/BOX Ref. Part Qty. Description Ref. Part Qty. Description 00 Kit - Tool (Incl. -) Screwdriver Wrench, 0- Spanner Box Wrench, Special 0 Wrench, Scissor Stop Manual, Owners, 00 Snowmobile Supplement, Owner s Manual, XCR 0 Roll, Tool 00 Strap, Emergency Starter / D

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

50 Part Ref. Grid C A A A A A D A C B D C C C C.. C0.. C C0.. C C D C C C C0... C.. C C C C C C C C C C C C C C C C C C C0.. C C C C C C D C C C C PART NUMBER INDEX Part Ref. Grid C C C C C C C C0... D D C C0... D C C C C C C C C C D C C C C C C0.. C C C D C C C C C C C C C C C C C D D C C C C C C C C D Part Ref. Grid C C C C C C C C C C D C C C C C C D D C C C C B C C C C C C C C C C C C C D C C C C C C C C C C C C C C C C C C C

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

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

53 Part Ref. Grid B B B B B B A A B A B B A A B B B B B B.. B.. B B C A A B C B B A A A C A A A A A A A B B A B B.. B B B A C C B B B B PART NUMBER INDEX Part Ref. Grid B B B C C A A B B C B B B A... C C B C A A C B B B B B B C C C A C A A A A A A A A A A A A A A A A C A A A C... C A0.. A D0 Part Ref. Grid A C D B C A B A A... A B B... B.. B0.. B 0.. B C C A... C C A A A A A B A C A A A A... B B B B B A A B B A A A A C A A C A A... B B C B

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

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

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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

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60 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

61 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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64 PRINTED IN THE USA PARTS MANUAL PN 0 and MICROFICHE PN 0/