XPLORER 300 Model #A99CC28CA Rev. 01

Transcription

1 XPLORER 00 Model #ACCCA Rev. 0 PARTS MANUAL PN and MICROFICHE PN /

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3 TABLE OF CONTENTS Xplorer 00 ACCCA Parts Manual A-ARM/STRUT MOUNTING B AIR BOX B CARBURETOR D CENTER TIGHTENER C CLUTCH COVER C CONTROLS - MASTER CYLINDER/BRAKE LINE B0 CONTROLS - THROTTLE ASM./CABLE B COOLING SYSTEM A CRANKCASE and CYLINDER C- CRANKSHAFT and PISTON D CV JOINT - BTB B A C D DECALS A DRIVE CLUTCH C DRIVEN CLUTCH C ELECTRICAL/TAILLIGHT C ENGINE MOUNTING A EXHAUST SYSTEM A FRONT BRAKE B FRONT CAB A FRONT DRIVE B FRONT RACK and BUMPER MNTING A0 FRONT STRUT B FRONT TIGHTENER B FRONT WHEEL B E F F FUEL TANK A GEAR SELECTOR C0 GEARCASE C- GEARCASE/BRAKE and CHAIN COVER MOUNTING C G H HANDLEBAR B M MAGNETO D OIL PUMP D OIL TANK B P PART NUMBER INDEX D- O REAR BRAKE C REAR CAB and SEAT A- REAR RACK MOUNTING A REAR WHEEL DRIVE C RECOIL STARTER D STARTING MOTOR D STEERING POST B SWING ARM/SHOCK MOUNTING.... B T TOOL KIT C R S The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

4 BRAKES Type/Brakes Type/Brakes - Auxiliary Park Brake CAPACITIES Coolant Capacity (quarts) Fuel Tank (gallon) Gearcase Oil (ounces) Engine Counter Balance 0W0 Oil (quarts) Injector Oil (quarts) Engine OW0 Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight Type DRIVE TRAIN DRIVE CLUTCH Center Distance (inches) Clutch Offset (inches) Clutch Weight Spring Color DRIVEN CLUTCH Helix Angle Spring Position DIMENSIONAL FEATURES Approx. Turning Radius Box, Tool Box (cubic feet) Ground Clearance (inches) Height (inches) Length (inches) Seat Height (inches) Weight (dry) Wheel Base (inches) Width (inches) ENGINE Engine Model Number Engine Type Bore & Stroke (mm) Displacement (cc s) Compression Ratio Cooling Alternator Output Elec. Start w/recoil Back Up Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Air Screw/Pilot Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust XPLORER 00 SPECIFICATIONS Hydraulic Disc Mechanical Standard N/A 0 N/A N/A Standard 0 PVT 0 / g Blue/Green Compound - xx N/A.. ECPFE0 Cycle, Oil Inj..x.: Effective Air w/fan Assist 0W Standard /VM0SS 0 O-().0. Turn DP NGK BRES USFS Appr. GEARCASE Transmission Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type GRAPHICS Body Style Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover w/decal Headlight/Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Tank Cover Tool Box Cover w/lettering Color LIGHTS Headlight (watts) Taillight (watts) Brake Light (watts) Other (Grill Mntd. Lights) Indicator Bulb SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Adjustment TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center (x) PRD Side Lever./././ / P /0 P / 0P N/A 0 O-Ring Gen IV N/A N/A EB Green EB Green Black Semi Flat Black EB Green Black Black Black Black Aluminum Burnished Brown EB Green Fire Red Fire Red N/A N/A N/A N/A V/.W V/.W, V 0/0W V/.0W MacPherson Strut. MONO. CAM Titan x-0 x-0 N/A N/A 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 XPLORER 00 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER S MANUAL OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Xplorer 00 ACCCA 0 0

6 REAR CAB and SEAT A

7 REAR CAB and SEAT Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok Retainer, Seat Latch Screw Washer, Flat 0 Screw Box, Tool Screw 0 Rivet, Pop 0 Bracket, Lever Retainer 0 00 Latch, Seat 00 Spring, Latch Asm., Seat, Burnished Brown (Incl. -) Covering, Seat, Burnished Brown Foil, Seat Base, Large Foil, Seat Base, Small 0 Bumper, Rubber Cover, Tool Box 0 Cap, Drain Tab, Air Box Mount 0-0 Guard, Clutch Rivet 0-0 Guard, Rock 0 Screw 00-0 Frame Nut, Nylok 00 Plug, Hole, Rubber Screw 0 Foil, Footwell, Ribbed 0 Foil, Rear Cab, Front Washer 0 Decal - Filter Element 0 Foil, Foam 0 0 Decal - Carb Information 0 Foil, Rear Cab, Rear Foil, Foam, Rear Fender Foil, Footwell, Slotted Footwell, RH, Black Footwell, LH, Black 0 Foil, Footwell 00 Nut, U Type, Speed Guard, Mud, Rear, RH Guard, Mud, Rear, LH - Cab, Rear, EB Green 0 Bolt 0 0 Rivet, T-Lock / A

8 FRONT CAB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Foil, Side Panel, RH 0 Foil, Foam, Side Panel Asm., Panel/Foil, RH, EB Green (Incl. Foil & Foam) Panel, Side, LH, EB Green Screw 0 Screw 0- Cover, Front, EB Green 00 Clip, Spring, Trim 0- Asm., Cab, Front, Service, EB Green (Incl. Warning Decals) 00 0 Nut, U Type Speed 0 Rivet, T-Lock 000 Nut, Push On 000 Clamp, Wire Routing 0 Decal - Caution, Rotating Fan Shield, Deflector 00 Clip, Dart Nut, Nylok Washer, Flat Guard, Mud, Front, RH Guard, Mud, Front, LH Nut, Nylok 0 Washer Decal - Drain Recoil (See Decal Pg. A, Ref. ) / A

9 REAR RACK MOUNTING 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Screw 0 Asm., Rack, Rear (Incl. & Warning Decal) 000 Reflector, Red Support, Rear Rack Screw Screw A Nut, Flange, Nylok 00 Nut, Chimney 0-0 Spacer 0 Washer Screw Mount, Front, Rear Rack, LH Mount, Front, Rear Rack, RH /

10 DECALS RH 0 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 0 Decal - Rack/Warning 00 Decal - Load Distribution 0 Decal - x 0 Decal - 00 Side Panel 0 Decal - X 0 Decal - POLARIS 0 Decal - Warning, AWD Switch 0 Decal - Tank Side, RH 0 Decal - Discretionary Warning 0 0 Decal - Side Panel, RH 0 Decal - Recoil Drain A 0 Decal - Demand--Drive 0 Decal - POLARIS, Domed 0 Decal - Override Switch, AWD 0 Decal - Tank Side, LH 0 Decal - Age Warning 00 Decal - Passenger Warning 00 Decal - Tire Pressure 0 Decal - Side Panel, LH 0 0 Decal - Warning, General, CPSC 00 Decal - MacPherson Strut /

11 FRONT RACK and BUMPER MOUNTING 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Harness, Headlight, Hi/Lo Headlight, Side, RH Headlight, Side, LH Bulb, Replacement Screw Screw 00 Reflector, Amber 00 Asm., Rack, Front (Incl. & Decal) Screw 00 Kit - Front Rack Mount Nut, Nylok 0-00 Bumper 0 Washer Screw 0 Screw A0 Washer Support, Rack, Front, LH Support, Rack, Front, RH Bolt 0 Washer -0-0 Extension, Frame, LH Extension, Frame, RH 0 Rivet, Pop Grill, Brush Guard -0 Hitch, U-Bolt -0 Guard, Brush Screw -0 Plate, Back Mount 0 Plug, Frame /

12 ENGINE MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description 00 Mount, Motor 00 Insulator, Mount, Motor 00 Cable, Ground/Engine Bolt 0 Washer, Spring Lock -0 Mount, Engine, Top Nut, FLEXLOC 00 Thermostat, Cooling Fan 0 Nut, FLEXLOC 0 0 Fitting, Vent Bolt 0 Washer, Lock 0 Washer, Clutch Retainer 0 Bushing Asm., Drive Clutch, ATV-0 (See Drive Clutch Pg. C, Ref. ) Bolt 00-0 Mount, Lower Engine 0 Washer, Flat 0 Nut, FLEXLOC 0 00 Spark Plug, NGK BRES Cable, Solenoid Starter (See Electrical/Taillight Pg. C, Ref. ) 00 Clamp, Narrow Band 0 Boot, Clutch Intake AR Washer 00 Washer, Spring Lock 0 Screw -0 Mount, Engine, Front 00 Engine, ECPF0-Short Block NOTE: The Short Block assembly contains a crankcase assembly, cylinder & cylinder head assembly and a piston & crankshaft assembly. Prior authorization required for warranty consideration Clamp, Hose, Red AR Line, Fuel 00 Check Valve, Vent 000 Fitting, Tee AR Line, Fuel -0 Mount, Rear 00 Mount, Engine, Rubber 000 Filter AR Hose, Fuel (See Fuel Tank Pg. A, Ref. ) / A

13 COOLING SYSTEM Ref. Part Qty. Description Ref. Part Qty. Description Blade, Fan 00 Nut, Nylok 0 Washer 00-0 Mount, Fan Screw 00 Motor, Fan, Air Cooled Bolt Nut, Nylok / A

14 EXHAUST SYSTEM 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok Washer 00 Bushing 0 Dampener, Vibration 00 Mount, Torque Stop 0 Nut Screw 0-0 Bracket, Muffler Support 0 Washer, Rubber 0 Bolt Bolt 00 Plug, Clean Out 00 Spring, Exhaust 00-0 Exhaust 00 Spring, Exhaust 0-0 Headpipe Tab, Spring 0-0 Manifold Washer, Spring (See Crankcase and Cylinder Pg. C, Ref. ) 0 Nut (See Crankcase and Cylinder Pg. C, Ref. ) / A

15 FUEL TANK 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Tank, Fuel (Incl.,,) 0 Seal, Foam 0 Gasket, Fuel Cap 0 Cap, Fuel Tank AR Hose, Gas Tank Vent 0 Vent, Tank 0 Bolt -0-0 Bracket, Mount, Cover, Rear, LH Bracket, Mount, Cover, Rear, RH Screw Filter AR Line, Fuel 0000 Clamp, Hose, Red 0-0 Bracket, Tank Mount, Rear Nut, Nylok Hose, Fuel 00 AR Pad, Fuel, Bulk 0 Fitting, 0 Degree, Fuel Outlet, Main 0 Fitting, 0 Deg., Fuel Outlet, Reserve 0 Valve, Way 0 Nut, Fuel Valve Knob, Fuel Valve 0 Screw / A

16 OIL TANK 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Cap, Oil Tank 0 Gasket, Oil Cap 0 Grommet, Oil Tank 00 Fitting AR Line, Fuel 0 Sensor, Oil Level 0 Rivet, Pop Tank, Oil, Drilled 00 Mount, Tie Anchor 0 Screw 0 Fitting 00 Clamp, Hose 000- AR Line, Fuel 000 Clamp, Hose, Large Green 000 Filter 00 Clamp, Hose, Yellow AR Line, Fuel 00 Pad / B

17 AIR BOX 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Filter, Foam 0 Seal, Foam Box, Air Silencer 00 Boot, Air Silencer 00 Filter, Air Intake Screw 0 Washer 000 Nut, Speed, U -Clip Box, Air Intake (Incl. ) 0 0 Valve, Umbrella 0 Bushing, Molded B Bolt, Carriage 00 Clamp, Band, Narrow 0 Boot, Carburetor 000 Clamp 00 Tape, Foil, Air Box 000 Palnut 00 Seal, Air Intake Cover 0 Cover, Air Intake 0 00 Retainer, Cover, Air Intake Nut, Wing /

18 FRONT DRIVE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, FLEXLOC Washer 00 Clip, Christmas Tree Bolt Nut Spacer, Front Eccentric Asm., Front Tightener (See Front Tightener Pg. B For Details) 0 Screw Clamp, Front Eccentric 0 0 Washer Bolt Screw 0 Link, Connector 0-0 Asm., Chain, P (Incl. ) Screw 0 Decal - Front Chain Tension Guard, Front Chain 0 Foil, Chain Guard Asm., Center Tightener (See Center Tightener Pg. C For Details) Asm., Chain, 0P (Incl. ) / B

19 FRONT TIGHTENER Ref. Part Qty. Description Ref. Part Qty. Description 0 Sprocket, T 00 Eccentric, Front 000 Fitting, Lubrication 00 Shaft, Output 0 Bearing, Open 00 Seal, Tightener 0 O-Ring 00 Spacer, Front Tightener 00 Asm., Front Tightener (Incl. -) / B

20 CV JOINT - BTB BTB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., CV Housing w/sleeve Sleeve, Drive Shaft Seal 0 Clamp, Large, CV Joint 00 Circlip 0 Boot, CV Joint 00 Shaft (Incl. ) 00 Cardan (Incl.,,,) 00 Kit - Cross and Bearing 00 Yoke, Splined 0 Pin, Spring 0 Washer, Spring 00 Clamp, Band, Small 00 Kit - Repl. Boot, CV Joint (Incl.,,) 00 Kit - Drive Shaft w/sleeve BTB / B

21 FRONT STRUT 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, FLEXLOC Washer 0 Spacer, Rubber 00 Pivot, Ball Top 00 Pivot, Ball Bottom 0 Spacer, Threaded 00 Retainer, Spring, Top Bumper, Strut 0 Strut, Front 0 Washer 00 Clamp, Rubber Coated 0 Nut, FLEXLOC Bolt 0 Washer, Spring Lock 0 Washer 0 Retainer, Strut Casting Wire Asm., Front Brake Caliper (See Front BrakePg. B for Details) 0 Bearing, Tapered Roller 0 Bearing, Tapered Roller Cup 0 Sleeve, Hubstrut Seal 00 Coil, Magnetic 000 Fitting, Lubrication 0 0 Asm., Hubstrut, Service, LH, mm, Heavy (Incl.,-,) Asm., Hubstrut, Service, RH, mm, Heavy (Incl.,-,) 00 Seal, Hubstrut Asm., Drive Shaft, Long (See CV Joint - BTB Pg. B, Ref. ) Bolt 0-0 Spring, Coil / B

22 FRONT WHEEL 0 DETAIL A A 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt Disc, Brake 00 Seal, Front Hub Plate, Armature 0 Asm. Clutch, Front Hub, Elec./Mech., Heavy (Splined Drive Shaft) 0 Bearing, Tapered Roller Cone 0 Bearing, Tapered Roller Cup Stud 0 Asm. Hub w/bearing Race (Incl.,,) 0 00 Cage, Roll 000 Roll 00 Spring, Garter Spacer (Splined Drive Shaft) 000 Cam (Splined Drive Shaft) 00 Plug, Magnetic Drain Tire (x-0) 00 Washer 0 Nut 0 Pin, Cotter 0 00 O-Ring Cap, Hub 0 Screw Nut, Lock 0- Rim, Front 0 Valve, Rim / B

23 FRONT BRAKE 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Front Brake Caliper, LH (Incl. -) 0 Asm., Front Brake Caliper, RH (Incl. -) 00 Screw, Bleeder Screw, Socket Set Caliper, Brake, LH Caliper, Brake, RH 0 Kit - Boot, Front Brake 0 Kit - Piston and Insulator Seal (Incl. -) 0 Ring, Square (.0) 00 Ring, Square (.0 x.) 000 Piston, Caliper 00 Insulator, Caliper Kit - Severe Duty Brake Pad, Front (Complete set of pads) Kit - General Duty Brake Pad, Front Kit - Brake Pad, Soft, Front 0 00 Mount, Caliper 0 Boot, Bushing 0 Boot, Pin Seal Washer (See Front Strut Pg. B, Ref. ) Washer, Spring Lock (See Front Strut Pg. B, Ref. ) Bolt (See Front Strut Pg. B, Ref. ) / B

24 CONTROLS THROTTLE ASM./CABLE 0 Ref. Part Qty. Description Ref. Part Qty. Description 000 Screw, Button Head 0 Decal - Throttle 0000 Cap 000 Packing 00 Asm., Throttle Control (Incl. -) 0 Switch, Demand Drive 000 Bulb, Demand Drive Indicator 000 Holder 000 Screw Bolt 000 Plate 00 Switch, ETC 00 Cable, Throttle Control / B

25 CONTROLS - MASTER CYLINDER/BRAKE LINE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Master Cylinder (Incl. -) Kit - Master Cylinder Reservoir (Incl. -,) 0 Bolt, Cap 0 Cap, Reservoir 0 Diaphragm 000 Kit - Clamp, Master Cylinder 0 Asm., Piston, Master Cylinder 00 Rivet, Park Brake 00 Kit - Brake Lever, w/pkg. Brake Latch (Incl.,,0) Spring, Flat 00 Nut Kit - Park Brake Lever (Incl.,) 0 Bolt, Master Cylinder Reservoir 00 Bolt 0 Ring, Square, Master Cylinder Boot, Brake Line, Rubber 0 Seal 0 Switch 0 Line, Brake Rivet, Pop 00 Clamp, Nylon Cable Conduit, 0cm 0 Line, Brake, Left Front w/fittings 00 Cable Tie 0 Screw 00- Conduit, cm 0 Line, Brake, Right Front w/fittings 00 Fitting, Inverted Flare Cross 0 Line, Brake 0 Bolt, Banjo, Brake / B0

26 HANDLEBAR 0 0 Ref. Part Qty. Description Ref. Part Qty. Description -00 Cover, Logo 0 Screw -00 Panel, Instrument Screw -0 Bracket, Instrument Panel Asm., Master Cylinder (See Control - Master Cyl./Brake Line Pg. B0 for Details) Cable, Choke Control Kit - Choke Lever Spacer 0 Switch, Handlebar, Hi/Low/Off, LH 0 00 Grip, Handlebar 000 Screw -0 Tube, Handlebar B 0 Block, Handlebar Nut, Nylok 00 Clip, Cable Retaining Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B, Ref. ) 0 Harness, Control Panel 000 Indicator, Neutral/Reverse 000 Indicator, Low Oil/High Beam 0 0 Plug, Indicator Hole 0 Switch, Ignition (Incl. Key) Note: Ignition Key may be ordered by using the four digit number on the key. Cover, Key 00 Nut, Choke Slide /

27 STEERING POST 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Steering Post (Incl.,) Nut, Nylok -0 Bracket, Upper Steering Bushing Bushing, Steering Console 00 Fitting, Lubrication Plug, Grease, Steering Rivet 0 Bushing, Steering, Lower Bushing 0 Pin, Cotter 0 Nut, Hex, Slotted Spacer, Steering Post 0 O-Ring Bolt 00 Fitting, Lubrication Bushing, Steering Console / B

28 A ARM/STRUT MOUNTING 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, FLEXLOC Bushing 0 Washer Screw Bolt & Washer 0 Asm., Tie Rod (Incl. -) Boot, Seal, Rod End 00 Rod End, RH Nut, RH 0 00 Rod, Tie 0 Nut, LH 00 Rod End, LH 0 Nut 0 Pin, Cotter Asm., Hubstrut, Service (See Front Strut Pg. B, Ref. ) 00 Ball Joint, High Angle Bracket, Ball Joint Bolt 0 Boot, Rubber 0 Nut, Castle 0 Screw 0 Shield, CV Joint, RH Shield, CV Joint, LH Bushing, A-Arm Long 00 Bushing 00 Shaft, A-Arm Kit - A-Frame, LH (Incl.,,,-) Kit - A-Frame, RH (Incl.,,,-) 00 Fitting, Lubrication Screw 0 Washer, Spring Lock 0/ B

29 SWING ARM/SHOCK MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description 0 Bolt, Shoulder 0 Plate, Bolt Lock 0 Cam, Adjustment, Spring 0 Adaptor, Spring Seat 0 Sleeve, Spring Protector 00-0 Spring, Compression Nut, Nylok Screw Retainer, Shock 0 0 Shock, Rear 0 Bushing, Thrust Bushing, Thrust Washer 0 Nut, Nylok Bushing, Pivot (See Steering Post Pg. C, Ref. ) 0 Bolt, Shoulder 00 Bushing, Swing Arm Extended B 00 Fitting, Lubricated, Degree Bushing, Swing Arm 0 0 Decal - Lubrication Rivet, Pop 0 Guide, Chain 0 Screw Bushing 0 Guard, Chain 0 Washer Nut 000 Asm., Swing Arm (Incl.,) Washer 0 0 Nut, FLEXLOC 0 Decal - Chain Free Play 0 Decal - Hitch 00 Kit - Hitch (Incl. -) Bolt Screw /

30 TOOL KIT Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Tool Kit (Incl. -) 00 Pouch, Tool Kit 0 Wrench, Box, Special 0 Wrench, 0- Spanner 0 Screwdriver 0 Gauge, Tire Pressure 0 Manual, Owners, ATV Supplement, Manual, Owners, Xplorer 00 / C

31 CENTER TIGHTENER 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Center Tightener (Incl.,,-,-) 00 Shaft, Center Tightener, Short 00 Seal, Tightener, WD 0 Sprocket, T, Splined Washer Washer, Dish Lock Screw 0 Bearing, Tapered Roller Cone 0 Bearing, Tapered Roller Cup 0 Asm., Eccentric, Center w/cup Fitting, Lube w/ball 0 O-Ring 00 Spacer, Tapered 0 Sprocket, T Washer 0 Nut 0 Pin, Cotter / C

32 DRIVE CLUTCH 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer, Spring Lock 0 Washer, Multilube Asm., Roller and Bushing Button, Clutch, Stemless 0 Weight, Shift (G) Bolt, Shoulder 0 Nut, FLEXLOC 0 Bearing, Moveable, / AR AR AR AR Spacer (.00) Spacer (.0) Spacer (.0) Spacer (.00) 00 Pin, Roller 0 Spring, Clutch 0 Bearing, Cover Asm., Drive Clutch, ATV-0 (Less,) / C

33 DRIVEN CLUTCH 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bushing 0 AR Bushing 0 Belt, Drive Asm., Driven Clutch, Angle, Heavy (Incl. -) 0 Washer, Domed 0 Washer, Spring Lock Bolt AR Washer (.00) 0 AR Washer 0 0 AR Washer (.0) Bearing, Moveable 0 Spring, Clutch Ramp, Stationary 0 Spacer 0 Ring, Retaining Bolt 0 Button, Ramp / C

34 CLUTCH COVER Ref. Part Qty. Description Ref. Part Qty. Description 0 Seal, Cover Case Bolt and Washer 0 Seal, Clutch Cover Cover, Clutch, Outer 00 Clip, Clutch Cover 0 Screw 0 Decal - Clutch Cover 0 Decal - Engine/Clutch Modification 0 Decal - Automatic Transmission 0 0 Screw 00 Cable Tie 0 Boot, Clutch Intake Screw 0 Clip, Retainer, Oil Line 00 Clamp, Band, Narrow Duct, Inlet Down Tube Tape, Foil 00 Boot, Intake Duct, Inlet Top 0 0 Screw Duct, Air Outlet 000 Kit - Clutch Cover, Inner (Incl.,0,,,) Washer, Nylon -0 Bracket, Clutch Cover Washer 0 Screw -0 Bracket, Retainer Seal 0 Seal, Cover Case Rivet 0 Screw and Washer (See Crankcase and Cyl. Pg. C, Ref. ) / C

35 GEARCASE/BRAKE and CHAIN COVER MOUNTING 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer, Spring Lock 0 Washer 0 Decal - Brake Shield 0-0 Shield, Caliper, Rear 0 Asm., Brake Caliper, Rear Plate, Bolt Lock (See Swing Arm/ Shock Mounting Pg. B, Ref. ) 0 Washer, Spring Lock Bolt 0 Bolt, Shoulder(See Swing Arm/ Shock Mounting Pg. B, Ref. ) 0 Kit - Relube Bearing (Incl.,-) 0 Washer Bolt 0 Sprocket, T 0 Ring, Retaining 0 Disc, Brake Nut 00 Fitting, Lubrication Bolt, Carriage 0 0 Ring, Retaining 0 Sprocket, T, Splined 0 Nut, FLEXLOC Screw 0 Nut Screw 0 Washer 00 Seal, Brake 0 Bearing, Needle Housing, Bearing, Output Shaft / C

36 REAR BRAKE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Screw, Bleeder 0 Pin, Brake 0 Asm., Brake Caliper, Rear (Incl. -,-) Caliper, Brake, Rear Kit - Severe Duty Brake Pad, Rear Kit - General Duty Brake Pad, Rear 00 Kit - Piston and Seal (Incl. -) 0 Ring, Square (. 0 Ring, Square (.0 ) 00 Piston, Brake 0 Spring, Anti-Rattle 0 0 O-Ring 0 Spring, Compression, Brake 00 Pin, Brake Caliper 000 Gasket, Brake 0 Ramp, Moveable, Brake C 0 Ramp, Stationary Brake Screw 00 Seal, Brake Arm, Brake Caliper Washer 0 Nut Screw 0 Pin, Cotter Washer Rod, Brake 00-0 Foot Brake 00 Spring, Exhaust 0 Bushing, Pedal Pivot Washer 0 Pin, Cotter /

37 REAR WHEEL DRIVE Ref. Part Qty. Description Ref. Part Qty. Description Washer 00 Nut, Jam, Rear Axle Bolt 00 Kit - Mach., Hub (Incl. -,,) 00 Retainer, Bolt, Pushnut Tire (x-0) 0 Valve, Rim 0 Link, Connector Washer, Flat 0 Nut, Wheel Washer, Cone 00 Nut, Castle 0 Pin, Cotter Hub, Dust Cover 0-0 Drive Chain, P Nut, Nylok C -0 Guard, Sprocket, T 0 Spacer, Sprocket Guard 0 Sprocket, Rear, 0T 0 0 Bolt Stud 00 Asm., Hub Sprocket (Incl. ) 0 O-Ring 00 Seal, Rear Axle 0 Bearing, Rear Axle 000 Tube, Bearing Spacer 000 Fitting, Lubrication 0 Housing, Axle 000 Spacer, Bearing 0 00 Ring, Retaining 00 Axle, Rear 0- Rim, Rear /

38 ELECTRICAL/TAILLIGHT Ref. Part Qty. Description Ref. Part Qty. Description 0 Harness, Main Wire 00 Kit - Circuit Breaker, 0 AMP 0 Asm., Taillight w/brake Light (Incl. -) 00 Screw, Taillight 00 Lens, Taillight 000 Bulb, Taillight 00 Gasket, Taillight 00 Backing, Taillight/Brake Light 00 Nut, Speed 0 Nut, Nylok 0 Washer 0 Screw 00 Pad, Battery 00 Kit - Battery Bolt (Short) 000 Cable, Battery/Engine C 000 Hook, Battery Strap 0 Strap, Battery Holddown 0 AR Tube, Battery Vent 000 Battery 0 Cover, Battery 000 Cable, Battery/Solenoid 00 Cable, Solenoid/Starter 000 Board, Terminal Rivet Ignition Coil Complete (See Magneto Pg. D, Ref. ) 0 Screw 000 Limiter, Reverse Speed 00 Rectifier, Regulator, LR - 00 Bolt /

39 GEAR SELECTOR 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gear Selector (Incl. -,-,-) Asm., Knob 0 Screw Clamp Clamp Boot, Gear Selector Cover, Gear Selector Spring, Holding Sub Asm., Handle 0 Cup, Bearing 0 0 Spring, Centering 0 Pin, Stop 0 Spring, Detent 00 Bullet, Detent Switch, Gear Selector 00 Strap, Wire 00 Rod End, mm, RH 00 Rod End, mm, LH 0 Nut, LH 00 Rod, Shift Linkage Rod, Shift Linkage 0 Nut, RH 0 Nut, FLEXLOC Asm., Slide, High/Reverse Asm., Slide, Low Body, Gear Selector Screw 00 Pin, Interlock 0 Butterfly, Interlock 0 Screw / C0

40 GEARCASE C

41 GEARCASE Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gearcase (Incl. -) 00 Gearcase, LH 0 0 Screw Seal 0 Bushing, Pivot 0 Stud 0 Pipe, Knock 0 Shift Rail, Low 0 Shift Rail, High/Reverse 0 Shaft, Low Shift 0 O-Ring 00 Washer 0 Ring, Retaining Bell Crank 0 Washer 0 Nut 0 Shaft, High/Reverse Shift 0 Pin 00 Bracket 0 Spring 0 0 Bearing 0 Screw Shaft, Input 0 Bearing 00 Washer Gear, T 00 Bearing, Needle 00 Washer Engagement Dog, Low Shaft, Reverse 0 0 Washer Sprocket, T 0 Chain, Silent P (W) 0 Bearing, Needle 0 Ring, Retaining Engagement Dog, High/Reverse Gear, T 0 Bearing, Needle Washer, Thrust Ring, Retaining 0 0 Vent Line, Vent Dipstick Plug 0 Washer 00 Gearcase, RH 0 Oil Deflector 00 Bearing Shaft, Output 0 Gear, T 0 00 Bushing, Speedo / C

42 CRANKCASE and CYLINDER C

43 CRANKCASE and CYLINDER Ref. Part Qty. Description Ref. Part Qty. Description 00 Head, Cylinder 00 Fin Damper 00 Nut, Flange 0 Fin Damper B 0 Fin Damper A 00 Gasket, Head 00 Stud 0 O-Ring 00 Adapter, Carburetor (Incl. ) 0 00 Bolt, Socket Head 0 Screw, Pan Head 0 Asm., Band (Incl. ) 0 Seal, Oil 000 Pin, Dowel 00 Grommet 000 Bracket, Wire 00 Bolt and Washer 0 Asm., Crankcase (Incl.,,0-,,) 0 Gasket, Starter 0 0 Gasket 0 Plug, Drain 0 Bearing, Ball 0 Spacer 0 Bearing, Ball 00 Bolt and Washer 0 Bolt and Washer 0 Screw and Washer 0 Seal, Oil (PTO) 0 Stud 0 0 Gasket, Cylinder 0 Nut, Flange 0 Fin Damper 0 Cylinder (Incl.,,) 0 Stud 0 Gasket, Exhaust 000 Washer, Spring 00 Nut 0 Stud / C

44 CRANKSHAFT and PISTON 0 Ref. Part Qty. Description Ref. Part Qty. Description Piston Ring (Std) Piston Ring (.00 /0.mm O/S) Piston Ring (.00 /0.0mm O/S) Asm., Piston (Std) Asm., Piston (.00 /0.mm O/S) Asm., Piston (.00 /0.0mm O/S) 0 Pin, Piston 0 Clip, Piston Pin 0 Bearing, Small End 00 Bearing, Large End 00 Spacer, Crank Pin 00 Bearing, Ball D 0 Crankshaft Gear Key, Woodruff 00 Washer 00 Nut, Lock Asm., Crankshaft (Incl.-,,,,) Crankshaft 00 Crankshaft 0 0 AR AR Spacer (0.mm) Spacer (0.mm) 0 Crank Pin, PTO Side 00 Rod, Connecting /

45 MAGNETO 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw and Washer 0 Clamp 0 0 Asm., Plate (Incl. -,,,-) Plate, Coil 0 Screw and Washer 00 Cap, Spark Plug 0 Stator 0 Screw and Washer 0 Flywheel, w/ring Gear 0 Coil, Exciting D 0 0 Screw and Washer 0 Grommet 0 Harness, Wire (Incl.,) 00 Screw and Washer 00 Coupler, P 00 Nut 000 Washer, Spring 0 Switch, Magnetic 00 C.D.I. System 0 Coil, Ignition /

46 STARTING MOTOR 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, Flange 00 Brush 0 0 Asm., Starting Motor (Incl. -,,,-,0-) Asm., Starter (Incl.,,,,,,-) 00 Ring, Rubber 00 Cover, Rear 0 Gasket, Aluminum 0 Bolt 00 O-Ring 00 Through Bolt 0 00 Bracket 0 Bolt and Washer 0 Washer Set 00 Asm., Armature (Incl.,) 0 O-Ring 0 Bearing, Ball 0 O-Ring 00 Cover, Front (Incl. ) 0 Washer, Gear Shaft 00 Bolt and Washer 0 00 Clip 00 Spring, Return 0 Spring, Weight 0 Clip 0 Asm., Gear Shaft (Incl.,0-) / D

47 RECOIL STARTER 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Spring, Spiral 00 Bush 0 Plug 0 Gasket Asm., Recoil Starter (Incl.,,,-) Starter Case 0 Bolt and Washer 0 Bolt, Flange 0 Bolt 0 Plate, Friction 0 0 Spring, Friction 0 Reel 00 Asm., Rope 0 Spring, Return 0 Ratchet / D

48 OIL PUMP 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bolt 0 Washer 0 Check Valve 0 Clamp, Hose 0 Vinyl Pipe (0mm) 0 Screw, Air Vent 0 Packing 0 Asm., Oil Pump (Incl. -,-,0) 0 Cap 0 0 Collar, Camshaft 0 0 Spring & Lever Lever, Control 0 Washer, Spring 00 Nut 0 Screw and Washer 0 Spacer 0 Small Gear 0 O-Ring 0 Bush, Oil Pump AR AR AR 0 0 O-Ring Spacer (0.mm) Spacer (0.mm) Spacer (0.mm) / D

49 CARBURETOR Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Top (Incl. Gasket) 0 Spring, Throttle 000 Plate, Throttle 000 E-Ring 0 Jet Needle (DP-) 0 Washer 00 Throttle Valve (.0) 00 Needle Jet (0-) 0 Asm., Carburetor (Incl. -0) 0 00 Packing, Needle Valve 0 Pin, Float 00 Arm, Float 00 Needle Valve (.) 000 Packing, Float Chamber 0 Cap D 00 Float 0 Float Chamber 0 Main Jet (#) 0 O-Ring 0 0 Bolt, Banjo 00 Screw and Washer 00 Washer, Main Jet 00 Pilot Jet (#0) 00 Spring, Air Adjuster 00 Screw, Air 0 Screw, Throttle Stop 000 Spring, Throttle Adjuster 0 Plunger, Starter 000 Spring, Plunger 0 0 Cap, Plunger /

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

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

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

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

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

55 PART NUMBER INDEX Part Ref. Grid Part Ref. Grid Part Ref. Grid C B C C A 0... A C A.. B... C C A C C A B B.. B C B C A C C A C B C C C A B A.. A0... B.. B... C A C B C A A C A B B B B C B... C C C B B A... C A 0... A C B A C C A... A B B C A A B A B C C C C A.. A... B.. C A... B B B B A.. A B C C 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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59 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

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

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

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