600 XC SP EDGE Model #S00NP6ES

Transcription

1 00 XC SP EDGE Model #S00NPES PARTS MANUAL PN and MICROFICHE PN /

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3 A AIR BOX C B BRAKE A C TABLE OF CONTENTS Parts Manual CARBURETOR C- CHAINCASE B CHASSIS A CONSOLE A COOLING SYSTEM B CRANKCASE C CYLINDER C D DECALS A DRIVE CLUTCH C DRIVE TRAIN B DRIVEN CLUTCH C ENGINE MOUNTING C EXHAUST C FOIL/FOAM A FOX SHOCK - FRONT TRACK C FOX SHOCK - IFS B FOX SHOCK - REAR TRACK C FRONT SUSPENSION B- E F F FRONT TORQUE ARM B H HOOD A-0 M MAGNETO C N NOSEPAN A- PART NUMBER INDEX D- PISTON and CRANKSHAFT C P R 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 T TOOL KIT D W WATER PUMP/OIL PUMP C0 The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. S

4 BRAKES XC SP EDGE SPECIFICATIONS GRAPHICS Type Liquid Cooled Hydraulic Disc / Piston CAPACITIES Coolant Capacity (qts.) Chaincase Oil Capacity (oz.) Dry Weight (lbs.) lbs. Fuel Tank Capacity (US/lmp. Gal.) Gearcase Oil Capacity (oz.) Height (in.)(aprox) Length (Incl. skis) Oil Capacity (qts.) Ski Center Distance (in.) Ski Length (in.) Ski Width (in.) Width (in.) Compressed CHAINCASE Drive Chain Length Drive Shaft Sprocket Reverse Transmission Sprocket Ratio DRIVE CLUTCH Center Distance (in.) Clutch Offset (in.) Clutch Type Clutch Weight Ring Gear Spider(Roller Width) 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 Type Oil Injection Spark Plug Type (RFI). N/A. 0. P (/) T- Wide Accessory :. / P- 0- N/A Cast Dark Blue/White Yes 0. R Silver/Blue S0--PO-A EV V 0W. x 00 Mikuni TM Liquid Nicasil N/A Digital CDI Yes RNYC Champion Backrest Pad Color Belly Pan Color Front Shock Color Front Springs Color Grab Bars Color Handlebar Cover Headlight Pod Color Hood Color Hood Accent Colors Snowflap Color Rear Rack (Cargo) Color Rear Idler Wheel Color Ski Color Tunnel Color Tunnel Stripe Color Windshield (Size & Color) Windshield Base Color ELECTRICAL Headlight Type Headlight (watts)/voltage Thumbwarmer Handwarmers 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 Fixed) IFS Shock/Spring Adj. Torsion Bar/Type Rear Type Front Torque Arm Limiter Rear Torque Arm Limiter Rear Travel (in.)(reader Idler) Shock: Front Track Rear Track Springs: Front Torque Arm Rear Torque Arm Rear Torque Arm Spring Dia./Angle N/A Indy Red Gold Fox Indy Red N/A Black N/A Indy Red Process Blue/Stratus Blue/Screamin Yellow/Black/White/Indy Red Black/Silver Logo N/A Indy Red Black Unpainted Stratus Blue/Indy Red/Process Blue/White/Black Flared Smoke Black Band Halogen High x 0/Low Std. HI/LO Std. Multi Range Prem/Oil/Brake/Temp/Hi Beam Polyester Shock Wave 0. Edge 0. Adjustable Fox IFP Adjust/Spring Dual Rate / Edge Quick Adjustable N/A. Fox IFP Fox Position Sensitive Chrome Silicon/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 SNOWMOBILE PUBLICATION NUMBERS MODEL MODEL # OWNER S MANUAL PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS 0

6 CHASSIS 0 Fuel Pump Ref. Part Qty. Description Ref. Part Qty. Description 00 Asm., Chassis Rivet 0 Bracket, Jackshaft Shield 00 Stop, Torque 0 Nut 00 Stop, Torque Rivet 0 Bolt 0 Washer, Spring Lock 0 Washer, Flat 0-0 Bumper, Rear -0 Flap, Snow 0 Screw 0 Reflector, Red 0 Skirt, Snow, LH Skirt, Snow, RH A Rivet Extrusion, Clutch Guard 0 Mount, Console, LH Mount, Console, RH Footrest, Toe Clip, Upper, LH Footrest, Toe Clip, Upper, RH 0 Strap 0 Rivet Support, Footrest, LH Support, Footrest, RH 0 Footrest, LH Footrest, RH 00 Plug, Hole Bolt, Carriage 00 Nut, Speed Washer, Nylon Nut, Nylok /

7 SEAT AND GAS TANK Ref. Part Qty. Description Ref. Part Qty. Description 00 Cap, Fuel Asm., Seat (Incl. -,) Cover, Seat Cover 000 Grommet, Relatch, Bottom 00 Grommet, Relatch, Top 00 Relatch, Twist Lock w/hole Rivet 000 Bulb, Taillight 000 Bulb, Brakelight 0 Lens 0 0 Screw Housing, Taillight Retainer, Tool Pouch Clip Rivet Nut, Weld 0 Washer, Flat Screw A 0 Harness, Taillight Nut, Nylok 0 Washer, Flat 0 00 Nut, Speed Bolt, Carriage 00 Cushion, Tank AR Line, Fuel 0000 Clamp, Hose, Red 0 Fitting, 0 Degree 00 Grommet, Flanged 000 Ring, Compression AR Line, Fuel 0 Pickup, Fuel w/filter 0 0 Asm., Fuel Tank (Incl. -) 00 Fitting, 0 Degree 00 AR Line, Fuel 000 Cable Tie /

8 NOSEPAN 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Rivet -0 Hinge, Pivot, Lower, RH -0 Mount, Shock, Upper, RH Nut, Nylok Washer 0 Screw Rivet -0 Mount, Shock, Upper, LH 0-0 Bracket, Radius Rod Support 0 0 Washer 00 Brace, Pan, Lower -0 Hinge, Pivot, Lower, LH Nut, Nylok -00 Bumper, Front Bolt Rivet Shield, Heat Rivet 0 Nosepan 0 Nut, Nylok Washer Screw Rivet Rivet Screw 0 Washer, Spring Lock / A

9 NOSEPAN 0 Ref. Part Qty. Description Ref. Part Qty. Description Foil 00 Tape, Foil 0 Foil, Nosepan 0 Tape, Foil 0 Tape, Foil 0 Rivet Clip, Belt Retainer 00 Guard, Clutch 00 Pin, Clutch Cover 0 00 Decal - Engine and Clutch Rivet 0 Reflector, Amber Plug, Hole Plate, Backer / A

10 HOOD Ref. Part Qty. Description Ref. Part Qty. Description - Asm., Hood (Incl. Foam and Foil) 0 Harness, Headlight 0 Asm. Headlamp (Incl. Bulbs) Seal, Headlight 0 Bulb, Headlight 00 Retainer, Headlamp Bulb Bolt, Adjust Tee 0 Spring, Headlight Adjust 00 Cable Tie 0 00 Knob, Headlight Adjust Foam, Prefilter Plenum, Hood Intake 0 Cover, Headlight Access 0 0 Screw -0 Hinge, Upper, LH Nut, Nylok 0 Washer, Flat Bolt 0 Spacer 0 0 Bolt -0 Hinge, Upper, RH / A

11 HOOD 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Rivet Windshield, Smoke, Flared 00 Retainer, Windshield Asm., Tachometer Bulb, Replacement 00 Cushion, Rubber 00 Bracket, Speedometer/Tachometer 0 Washer, Flat 0 Washer, Split Lock 0 Nut 0 0 Knob, Trip Odometer Asm., Speedometer Bulb, Replacement 0 Cable, Speedometer 00 Clip, Rosebud 0 Screw Nut, Nylok 00 Cable, Hood Retainer Rivet 00 Clip, Rosebud / A0

12 DECALS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Hood Decals, XC SP EDGE (Incl. -,-) 00 Kit - Decal Application Solution (For Seat Decals) 00 Decal - Track/Seat, English/French 00 Decal - POLARIS, Seat 0 Decal - NO PASSENGER 00 Decal - VARIABLE EXHAUST SYSTEM 00 Decal - SP, Flags, Hood Center 00 Decal - POLARIS, Hood Center 0 Decal - INDY, Trailing Arm, RH 0 Decal - XC, Hood Top, LH 0 Decal - 00, Hood Side, RH 0 00 Decal - Warning, English 0 Decal - Caution, English/French 00 Decal - Warning, French 0 0 Decal - Tunnel EDGE, LH Decal - Tunnel EDGE, RH 0 Decal - 00, Hood Side, LH 0 Decal - INDY, Trailing Arm, LH / A

13 FOIL/FOAM Ref. Part Qty. Description Ref. Part Qty. Description -0 Screen, Nostril Hood, RH -0 Screen, Louver Hood, Front 000 Fastener, U-Clip -0 Screen, Louver Hood, Rear -0 Screen, Nostril Hood, LH 0 Foil, Hood, RH 00 Foam, Hood, LH 00 Foam, Hood Center / A

14 CONSOLE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw Washer 000 Regulator Nut, Nylok 00 Cable Tie Console 0 Kit - Ignition Switch 00 Clip, Speed Lever, Choke (Incl. Pin) 0 00 Cable, Choke (Incl.,) 0 Guide, Recoil Screw 0 Rivet Nut, Choke 0 Nut, Ignition 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.). 00 Housing, Connector 00 Housing, Connector 00 Socket Housing 000 Terminal, Ring 000 Housing 0 Harness, Main Wire / A

15 BRAKE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Cover Screws 0 Kit - Cover Assembly (Incl.,) Gasket 00 Kit - Parking Lever Spring 000 Asm., Master Cylinder (Incl.,,,,0,) Screw 0 Kit - Lever and Pivot Pin Screw 0 00 Kit - Clamp Body/Reservoir Switch, Brake Light 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, Wrought 0 Guide, Rope 0 Bracket, Caliper 0 Piston and Seal (Incl. ) 00 Kit - Seal 00 Kit - Heavy Duty Brake Pad, Type (Incl. ) A /

16 FRONT SUSPENSION B

17 FRONT SUSPENSION Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Bushing Bushing, Pivot, Outer Washer, Flat 0 Nut 0-0 Rod, Radius, Upper 0 Nut, Jam Nut, Nylok Screw 0 00 Retainer, Slotted Spring 0-0 Spring 0 Shock, Gas, IFP Washer Arm, Steering Washer, Flat 0 Nut, Nylok 0 Washer, Flat 00 Bearing, Spherical 0 Ring, Retaining 0 0 Screw 0-0- Asm., Trailing Arm, LH (Incl.,) Asm., Trailing Arm, RH (Incl.,) 00 Rod End 0 Bushing 00 Fitting, Lubrication Bushing, Torsion Bar Rivet -0 Bar, Torsion Slide, Torsion Bar 0 Bushing 0 0 Bushing, Flanged 00-0 Shaft, Spindle 000 Fitting, Lubrication 00 Bushing Screw 000 Rod End Nut 0-0 Rod, Radius, Lower 0 Nut, FLEXLOC 00 Rod End 0 Washer 0 Bushing Bolt / B

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

19 COOLING SYSTEM 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 000- Line, Fuel 0 Cap, Pressure 00 Clamp, Springband Hose, Strip Cooler/Brake Rivet 00 Wear Strip Hose, Crossover, Wear Strip Protector, Hose Hose, Center/Strip Cooler 0 Rivet Rivet 0 Cooler, Center Hose, Bypass Out/Tee In Tubing, Convoluted 000 Clamp, Hose 000 Clamp, Hose 0 Hose, Tee 00 Connector, Tee Hose 0 00 Connector, Tee 00 Clamp, Springband Hose, Engine Out/Brake Cooler Hose, Bottle to Tee / B

20 STEERING HANDLEBAR B

21 STEERING HANDLEBAR Ref. Part Qty. Description Ref. Part Qty. Description Pin, Retaining 00 Ring, Retaining 0 00 Lever, Throttle Lever w/heater Block, Throttle/Brake Grip, Handlebar 0 Plug, Overflow Adaptor, Block -0 Handlebar Screw 0 00 Nut, Push-On Emblem, Star Cover, Handlebar 0 Slide, Handlebar Cover, LH Slide, Handlebar Cover, RH 00 Clip, Dart Asm., Control, LH (See Brake Pg. A, Ref. ) 0-0 Block, Handlebar -0 Post, Steering Nut, Nylok Bolt, Carriage 0 0 Heater, Grip, Lo/Med/Hi 00-0 Hoop, Steering 00 Clip, Rosebud Bolt, Carriage Nut Rivet 0 Plate, Tie Rod Boot Boot, Tie Rod, LH Boot, Tie Rod, RH 0 Washer, Flat Nut, Nylok 0 00 Bracket, Steering Post Fitting, Lubrication Bushing Screw Holder, Wire 00 Ring, Retaining Screw, Set Washer 00 Switch, Auxiliary Shut-Off 0 Washer / B

22 STEERING 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Rod End, RH 0 Nut 0-0 Tie Rod Nut, LH 00 Rod End, LH 00 Rod End< RH Rod, Steering Rack -0 Rod, Draglink Nut, Nylok Rod End, LH 0 Bushing, Reducer 0 Asm., Pitman Arm (Incl.,,) Tube Screw 0 Bearing, Ball 0 Asm., Idler Arm (Incl.,,) / B

23 CHAINCASE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 000 Seal, Oil Nut 0 Screw 0 Bearing, Ball 0 Ring, Retaining Asm., Tightener Bearing, Chaincase Idler Wheel, Idler Washer, Thrust Pin, Chain Tightener 0 Sprocket, T, /W 0 Washer, Spring 0 Pin, Cotter 0 Nut, FLEXLOC Gasket, Chaincase Cover, Chaincase Screw Dipstick 0 Screw Washer, Spring 0 Sprocket, T, /W 0 Chain, P, /W 0 Plug 0 Chaincase / B

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

25 RAIL MOUNTING (SUSPENSION) Ref. Part Qty. Description Ref. Part Qty. Description 0- Asm., Wheel (Incl.,) 0 Ring, Retaining ( per Wheel) 0 Bearing ( per Wheel) Nut, Nylok Washer, Flat Cap, Rail Tip Bumper, Front Nut, Nylok Rivet 0 Nut, Nylok Bracket, Rail Reinforcement Liner, Bumper Bumper, Rear Screw Mount, Bumper 0 Bumper, Pivot Arm Spacer Block, Idler Bolt Adjusting 0 Rivet 0 Nut Screw 0 Asm., Rail, LH (Incl.,,,,) Asm., Rail, RH (Incl.,,,,) 00 Screw Screw 0 Washer, Flat Screw Mount, Wheel Screw Washer, Flat 0 0 Washer, Flat Spacer Washer Spring, Roller, Square, X-0 Hifax 0 Bolt Screw / B0

26 SUSPENSION Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok 0 Bushing -0 Arm, Shock Pivot Screw 0 Washer, Flat Spacer, Idler Bushing 0 Wheel Spacer, Idler, Center 0 0 Shaft, Idler Washer Bolt Screw Asm., Idler Wheel Ring, Retaining Bearing B Washer, Flat Screw 0 Washer, Spring Lock Track Clip, Slide Clip, Guide 00 Shaft, Pivot Arm 0 Asm., Wheel 0 Bushing -0 Mount, Shock 0 Shaft Washer, Flat 0 Shaft -0 Arm, Pivot, Rear 00 Fitting, Lubrication /

27 FRONT TORQUE ARM 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Spring Lock Washer, Flat 0 Shaft -0 Arm, Torque, Front 00 Fitting, Lubrication Nut, Nylok 0 Shock, Front Track 00 Retainer, Slotted Spring 0 0 Shield, Spring 0-0 Spring Screw Nut, Nylok 0 Washer, Flat Shaft Washer 0 Nut, Nylok Screw Screw 0 Nut, Nylok Strap, Limiter 0000 Bolt, Eye Bolt, Carriage / B

28 REAR TORQUE ARM Ref. Part Qty. Description Ref. Part Qty. Description -0 Arm, Torque, Rear Nut, FLEXLOC 0 Screw Shaft, Arm Bushing Screw 0 Washer, Flat Washer, Flat 0 Washer, Spring Lock 0 Screw Asm., Rear Torque Arm (Incl. ) Nut, Nylok Spacer 0 Asm., Wheel Washer, Thrust 00 Sleeve, Torsion Spring Roller, Spring, Adjustable 00 Clip, Push On B Screw 0 Shaft 0-0 Spring, Torsion,./, LH (Std) 00-0 Spring, Torsion,./, RH (Std) 0-0 Spring, Torsion,./, LH (Opt) 0-0 Spring, Torsion,./, RH (Opt) 0-0 Spring, Torsion,.0/, LH (Opt) 0-0 Spring, Torsion,.0/, RH (Opt) 0-0 Spring, Torsion,./, LH (Opt) 0-0 Spring, Torsion,./, RH (Opt) Bolt Washer, Wave Bushing -0 Rod, Shock Bolt 0 Bushing, Nut 0 Shock 00 Bushing 0 0 Spacer 00 Fitting, Lubrication /

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

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

31 FOX SHOCK - REAR TRACK 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Shock, Rear Track 000 Cap, Air Valve 000 Valve, Air 000 Screw 000 O-Ring 000 Valve, Check, Black 00 Asm., Bearing 000 Eyelet 00 Shaft 000 Plate, Top-Out 0000 Bearing, Piston 000 Plate, Backup Nut, Lock 00 Body, Internal 00 Body, Outer 0000 Bearing, External 00 Piston, Floating 000 Screw 000 O-Ring 00 Screw w/o-ring 00 Sleeve 00 Sleeve 000 Bushing 000 O-Ring U-Cup 000 Wiper, Shaft 0000 Screw 000 Ball / C

32 DRIVE CLUTCH 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/White 0 Button, Guide 0 Washer, Multilube Asm., Roller and Bushing 00 Pin, Roller 0 00 Kit - Drive Clutch Shim Weight/Bushing, 0-0 Pin, Hardened Weight 0 Bearing, Sleeve 00 Insert, Moveable AR AR AR AR Spacer (.00mm) Spacer (.0mm) Spacer (.0mm) Spacer (.00mm) 0 Nut, FLEXLOC 00 Nut, Jam 0 Asm., Drive Clutch, Basic 0 (Less,) / C

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

34 AIR BOX Ref. Part Qty. Description Ref. Part Qty. Description Foam, Air Box, Chimney Duct, Air Inlet 00 Decal - Adjustable Driven Clutch 0 Decal - Greasing Cover, Air Box 0 Nut Washer, Nylon 0 Screw 0 Washer 0 Foam, Air Box, Plate Plate, Intake Cap, Oil, Vented Plate, Carburetor Adaptor 0 Boot, Carburetor Mount 00 Fastener, Dart Type 00 Box, Air, Oil/Coolant Rivet 000 Clamp, Hose 000- AR Line, Fuel 0 00 Fitting, Oil Sender 0 Grommet, Oil Sender 0 Decal - Surge Tank FULL COLD 00 Bracket, CDI 0 Screw Washer Nut, Nylok 0 Strap, Air Box, Top Tube, Intake, Outer 0 Decal - Caution, Air Box Clip, Plastic / C

35 EXHAUST 0 Ref. Part Qty. Description Ref. Part Qty. Description 00-0 Bracket, Chassis/Resonator 00-0 Resonator 0 0 Spring, Exhaust Boot, Exhaust Outlet Gasket, Exhaust 0-0 Manifold Screw 00 Seal, Exhaust Nut, Nylok 0 Washer Dampener, Vibration 0 Screw 00 Clamp 00 Clamp 00 Clamp Rivet Asm., Tuned Pipe Cover, Tuned Pipe, Top Cover, Tuned Pipe, Bottom Matte, Sound, Top Matte, Sound, Bottom / C

36 ENGINE MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw 00 Washer Washer 000 Spark Plug, RNYC, Champion 0 Engine (S0--P0) NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston and crankshaft assembly. Prior authorization is required for warranty consideration. 0 Decal - Fuel Shut-Off Handle, Recoil Shim 0 Nut, FLEXLOC 0 Washer, Flat Strap, Engine Mount, LH Strap, Engine Mount, RH 00 Mount, Engine Rivet 00 Nut, Plate Screw 00 Mount, Engine, Tab Nut, Nylok 00 Cable, Throttle 0000 Clamp, Hose AR Line, Fuel 0 Pump, Fuel 000 Clamp, Hose 000- AR Line, Fuel AR Line, Fuel 0 Valve, Fuel AR Line, Fuel / C

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

38 CYLINDER Ref. Part Qty. Description Ref. Part Qty. Description 00 Sensor, Temperature Screw 0 Washer Screw Washer, Flat 0 Cover, Thermostat O-Ring 0-0 Cover, Head O-Ring 0 Seal, Rubber Head Cover 00 Head, Cylinder 0 O-Ring O-Ring 0 Nut 0 Gasket 0 Housing w/bushing Screw Gasket, Housing C Adapter 0 0 Washer 0 Cap 00 Cover, Exhaust Valve 0 Bolt, Flange 0 O-Ring 0 Adjuster, Spring 00-0 Spring 0 Bellows, Exhaust Valve Screw 0 Valve, Guillotine 0 00 Cylinder Gasket, Cylinder Base 0 Thermostat Screw Screw 0 Fitting /

39 WATER PUMP/OIL PUMP 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Seal 00 Seal 00 Washer, Flat 0 Impeller, Water Pump Washer, Flat 0 Nut, Nylok 0 Gasket, Water Pump Cover 00 Cover, Water Pump Screw 0 Washer, Thrust Driveshaft, Water/Oil Pump O-Ring 00 Bearing, Pump Shaft, Flanged Gasket 00 Pump, Oil Screw / C0

40 CARBURETOR Ref. Part Qty. Description Ref. Part Qty. Description Asm., Carburetor 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-EFH-0-) 0 Packing 0 E-Ring 0 Plate 0 0 Lever, LH Lever, RH 0 0 Ring C 0 Screw, LH 00 Screw, RH 00 O-Ring, Air Funnel 0 Funnel 0 Screw 0 Jet, Pilot Air (PAJ)(.) 00 Pin 0 Jet, Main (0) 0 Nipple 0 0 O-Ring 0 Screw 0 Body, Float 0 O-Ring 0 Float 00 Jet, Pilot (0) 0 Jet, Starter () 0 Washer 0 Spring 0 Asm., Adjuster 0 0 Cap 0 Packing 000 Valve, Check, 0 Degrees /

41 CARBURETOR 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 0000 Clamp, Hose AR Line, Fuel Plug, Trap 0/ C

42 PISTON and CRANKSHAFT 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Piston Rings 00 Circlip, Piston 0 Kit - Piston (Incl.,,) 0 Bearing 0 Bearing, Ball 0 Bearing, Ball 0 Bearing, Ball Seal, Flanged Gear, Pump Drive 0 0 Kit - Crankshaft (Incl. -) Key, Woodruff Pin, Piston / C

43 MAGNETO 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw 00 Pulley, Starting 0 Nut, Hex 0 Washer 00 Flywheel 00 Stator 0 Washer, Flat Washer, Lock Screw 0 0 Kit - CDI (Incl. Nyogel and Decal) 00 Cap, Spark Plug 00-0 Wire, Ignition 00 Coil, Ignition / C

44 RECOIL STARTER 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 00 Rope /

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

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

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

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

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

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

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

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