550 CLASSIC EDGE Model #S03ND5BS. E 2002 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /02

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1 0 CLASSIC EDGE Model #S0NDBS E 00 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /0

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3 TABLE OF CONTENTS 0 Classic S0NDBS Parts Manual A AIRBOX... B B BATTERY BOX... B BLOWER HOUSING... C BRAKE... B C CARBURETOR... C CHAINCASE... B0 CHASSIS... A CONSOLE... A CRANKCASE... C CRANKSHAFT... C CYLINDER... C D DECALS - EDGE... A0 DRIVE CLUTCH (Electric Start Models)... B DRIVE TRAIN... C DRIVEN CLUTCH... B ENGINE MOUNTING... C EXHAUST SYSTEM... C FRONT SUSPENSION... A- FRONT TORQUE ARM... B FUEL PUMP... C E F H HOOD... A- HOOD FOAM/FOIL... A M MAGNETO... C N NOSEPAN... A- O OIL PUMP... OIL TANK... PISTON P... R RAIL MOUNTING (EDGE)... REAR SUSPENSION (EDGE)... REAR TORQUE ARM (EDGE)... RECOIL STARTER... S C0 B C B B B C SEAT and GAS TANK... A SHOCK (REAR TRACK)(EDGE)... B SKI... A STARTING MOTOR... C STEERING... B STEERING - HANDLEBAR... B- T TOOL KIT... 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 CHASSIS 0 Classic S0NDBS E 00 Polaris Sales Inc Asm., Chassis, Edge, Natural Rivet 0 Bracket, Oil Tank/Hose Support 00 Stop, Torque 0 Nut 0 Stop, Torque Screw Screw 00 Caplug 00 Caplug 0 0 Bolt 0 Washer, Spring Lock 0 Washer, Flat -0 Bumper, Rear, Unpainted Rivet -0 Flap, Snow, Black/Chrome Screw 0 Reflector, Red Skirt, Snow, LH Skirt, Snow, RH -0 Brace, Tunnel Roll 0 Rivet 0 Strap Pad, Clutch Guard Support, Footrest, LH Support, Footrest, RH -0-0 Mount, Console, Toe Clip, LH Mount, Console, Toe Clip, RH Footrest, LH Footrest, RH Kit, Trailing Arm Mount, LH Kit, Trailing Arm Mount, RH Guard, Belt 00 Plug, Hole 0 Rivet 0 00 Plug, Hole Bulkhead, Front Brkt Airbox Edge /0 A

5 SEAT AND GAS TANK 0 Classic S0NDBS Cap w/gauge, Fuel 0 0 Asm.,Seat,(Incl.,,) Cover, Seat 000 Bulb, Taillight 000 Bulb, Brakelight 0 Lens 0 Screw Housing, Taillight Washer Rivet 0 Nut, Seat 0 Washer, Flat Screw Patch Gasket, Wire Harness 0 Harness, Taillight Nut, Nylok 0 Washer, Flat 00 Nut Speed Bolt Carriage 0 0 Foam, Seal 00 Pickup, Fuel 000 Ring, Compression 00 Grommet AR Line, Fuel 000 Clamp, Hose 0 Fitting, Straight AR Line, Fuel 0 Asm., Fuel Tank (Incl. -) 00 Fitting, 0 Degree AR Line, Fuel 000 Cable Tie, Releasable /0 A

6 NOSEPAN 0 Classic S0NDBS 0 0 Rivet -0 Hinge, Pivot, Lower, RH Mount, Shock, Upper, RH 0 Foam, Seal 0 Nut, Flanged Screw Mount, Shock, Upper, LH Rivet Rivet 0 Rivet 0-0 Bracket, Radius Rod Support 00 Brace, Pan, Lower -0 Hinge, Pivot, Lower, LH Nut, Nylok -00 Bumper, Front Black Bolt Rivet Shield, Heat -00 Nosepan, Black 0 Nut, Nylok Washer Screw Screw 0 Washer, Spring Lock Guide, Hood, LH Guide, Hood, RH /0 A

7 NOSEPAN 0 Classic S0NDBS Clip, Speed, U-Type 00 J-Clip, Retainer Foil Rivet 00 Tape, Foil Tape, Foil 00 Foil, Nosepan, Front 0 Tape, Foil 0 Foil, Nosepan 0 0 Tape, Foil Foam 0 Rivet Duct, Engine Air Outlet 00 Guard, Clutch 00 Pin, Clutch Guard Rivet 0 Decal, Engine and Clutch 00 Decal, Troubleshooting, Edge, PPS 0 Reflector, Amber 0 Plug, Hole, Oblong Plate, Backer /0 A

8 HOOD 0 Classic S0NDBS Asm., Hood, Slvr 0 Harness, Headlight 0 Asm. Headlamp (Incl. Bulbs) Foam, Seal, Headlight, Top 0 Bulb, Headlight 00 Retainer, Headlamp Bulb Foam, Seal, Headlight, Bottom Bolt, Tee Adjust 0 Spring, Headlight Adjust 0 00 Knob, Headlight Adjust Foam, Prefilter Plenum w/foil, Intake, Hood Foil, Plenum Foil, Tape 00 Decal, Suspension Set-Up 0 Cover, Access, Headlight 0 0 Screw -0 Hinge, Upper, LH 0 Bolt 0 Washer, Flat Bolt 0 0 Spacer Nut, Nylok -0 Hinge, Upper, RH /0 A

9 HOOD 0 Classic S0NDBS Rivet Windshield, Smoke, -inch 00 Retainer, Windshield 0 Retainer 00 Indicator Reverse 0 Plug Dash 0 Harness, Jumper Reverse Light 00 Bracket, Speedometer/Tachometer 00 Cushion, Rubber 0 0 Knob, Trip Odometer Asm., Speedometer Bulb, Replacement 0 Washer, Flat 0 Washer, Split Lock 0 Nut 0 Cable, Speedometer 00 Cable Tie Asm Mirror Edge LH Asm Mirror Edge RH Washer Nut Nylok 00 Clip, Rosebud 0 Screw 0 Nut, Nylok 00 Cable, Hood Retainer Rivet /0 A

10 HOOD FOAM/FOIL 0 Classic S0NDBS 0 VIEW FROM UNDER HOOD -0 Screen, Nostril Hood, RH -0 Screen, Louver Hood, Rear -0 Screen, Louver Hood, Front Rivet -0 Screen, Nostril Hood, LH 0 Foil, Hood, Edge, RH 0 Foil, Hood, Edge, RH 0 Foam, Hood, Rear, LH Foam, Hood, Front, LH 0 00 Foam, Hood, Center, Edge /0 A

11 DECALS - EDGE 0 Classic S0NDBS 0 0 Kit, Hood Decal, 0 0 Classic 0 0 Decal, Pan, LH (Incl.,-,,,,) 00 Decal, Pan, RH 00 Kit, Decal Application Solution 0 (For Seat Decals) 0 0 Decal, Warning, English 0 Decal, Electric Start, Domed 0 Decal, Warning, French 0 0 Decal, Hood Center, Classic Urocal, Hood Center, 0 Classic 0 Urocal, Decal, Fan Cooled Twin, LH Decal, Fan Cooled Twin, RH 0 0 Decal, Hood Top, Polaris, LH Decal, Hood Top, Polaris, RH 00 Decal, Track/Seat/LH/RH/Eng/Fr 0 Decal, Classic Polaris Decal, Hood Side, Classic, LH Decal, Hood Side, Classic, RH Urocal, Classic Decal, Hood Side, Front, LH Decal, Hood Side, Front, RH 0 0 Decal, Trailing Arm, Edge IFS, LH Decal, Trailing Arm, Edge IFS, RH 0 Decal, Hood Center, Polaris 00 Decal, Choke 0 Decal, Warning, NO PASSENGER 00 Urocal, Perc 0 Decal, Warning/Rev/Elec. Rev. Opt. 00 Decal, Ignition /0 A0

12 A FRONT SUSPENSION 0 Classic S0NDBS

13 FRONT SUSPENSION 0 Classic S0NDBS 0 Bolt 0 Bushing, Radius Rod, Pivot, Inner Bushing, Shoulder 0 Nut, Nylok 0-0 Rod, Radius, Upper, Black 0 Nut, Jam Nut, Nylok Screw 000 Retainer Spring 0 00 Retainer, Spring, Slotted 0 Shock, Select 0-0 Spring, Compression Black Ring Spring Preload Screw Washer Arm, Steering Washer, Flat - - Asm., Trailing Arm, Cld Slv, LH (Incl.,) Asm., Trailing Arm, Cld Slv, RH (Incl.,) 0 Washer, Flat 0 Cup, Mount, Trailing Arm 00 Bearing, Spherical 0 Ring, Retaining 0 Screw 00 Rod End, RH 0 Bushing 00 Fitting, Lubrication Bushing, Torsion Bar Rivet -0 Bar, Torsion 0 Slide, Torsion Bar 0 Bushing 0 Bushing, Flanged 0-0 Shaft, Spindle 000 Fitting, Lubrication 00 Bushing 000 Rod End Nut, Jam 0-0 Rod, Radius, Lower, Black 0 Nut, Nylok 0 00 Rod End 0 Bushing, Shoulder Bolt /0 A

14 CONSOLE 0 Classic S0NDBS 0 0 Nut, Nylok Washer 00 Regulator, AC/DC.V Screw 00 Housing, Connector 00 Socket 000 Terminal, Ring 000 Housing Harness, Main Wire Housing 00 Receptacle Pod Mnt 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 00 Nut, Choke 0 Washer Screw 000 Cable, Choke (Incl.,) 00 Kit, Choke Control (Incl. Pin) 00 Clip 0 00 Kit, Ignition Switch -00 Console w/acc /0 A

15 SKI 0 Classic S0NDBS 0 Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description Nut, Flange Nut, Nylok Washer -00 Toe, Ski, Plastic, Black 0 Washer Bushing 0 Stop, Rubber Nut, Nylok (Qty.. for Dual, Qty.. for Std.) Washer, Flat (Qty. for Dual, Qty.. for Std.) Ski Screw 0 Kit, Skag, Dual, Inch, 0 Degree Screw 0 Screw /0 A

16 B STEERING/HANDLEBAR 0 Classic S0NDBS

17 STEERING/HANDLEBAR 0 Classic S0NDBS Ref. Part No. Qty.. Description Ref. Part No. 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 Collar, RH 00 Nut, Push-On Emblem, Star -00 Cover, Handlebar 0-00 Slide, Handlebar Cover 00 Clip, Dart Collar, LH Asm., Control, LH (See Brake Pg. B, Ref. ) 0-0 Block, Handlebar 0-0 Post, Steering 0 Nut, Nylok Bolt, Carriage 0 Heater, Grip, Lo/Med/Hi 0-0 Hoop, Steering (Edge) 00 Clip, Rosebud Bolt, Carriage Nut Rivet 0 Plate, Tie Rod Boot Boot, Tie Rod, LH Boot, Tie Rod, RH 0 00 Palnut 0 Washer, Flat Nut, Nylok Bushing 000 Bracket, Steering Post Fitting, Lubrication Bracket, Console Support Screw Holder, Wire 00 Ring, Retaining Screw, Set 0 Washer 00 Switch, Auxiliary Shut-Off 0 Washer /0 B

18 STEERING 0 Classic S0NDBS 0 0 Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description 00 Rod End, RH 0 Nut Tie Rod Nut, LH 00 Rod End, LH 00 Rod End, RH Rod, Steering Rack -0 Rod, Draglink Nut, Nylok 0 00 Rod End, LH 0 Bushing, Reducer 0 Asm., Pitman Arm (Incl.,,) Tube, Spacer Screw 0 Bearing, Ball 0 Asm., Idler Arm (Incl.,,) /0 B

19 BRAKE 0 Classic S0NDBS 0 0 Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description 0 Kit, Cover Screw 0 Kit, Cover Assembly (Incl.,) Gasket 00 Kit, Park Lever Spring 00 Asm., Master Cylinder (Incl.,,,,,) Screw 0 Screw 0 Kit, Lever Screw 0 0 Kit - Snap Ring 0 00 Kit, Asm., Master Cylinder Switch, Brake Light 0 Kit, Cartridge Subassembly 000 Asm., Control, LH E/R Button, Switch, HI/LO, LH Control 0 Kit, Pivot Pin 0 Kit, Park Lever and Spring (Incl. ) 00 Asm., Brake Caliper (Incl.,,) 0 Line, Brake 00 Kit, Clip Spring (Qty.. ) 0 0 Inlet Bolt 0 Washer, Spring Lock 0 Washer, Wrought 0 Bracket, Caliper 0 Piston and Seal (Incl. ) 00 Kit, Seal 00 Kit, Heavy Duty Brake Pad, Type (Incl. ) /0 B

20 RAIL MOUNTING (EDGE) 0 Classic S0NDBS Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description 0- Asm., Wheel, Slv Mt 0 Ring, Retaining ( per Wheel) 0 Bearing ( per Wheel) Nut, Nylok Washer Cap, Rail Tip Washer, Flat Bumper, Front Nut, Nylok 0 Rivet Nut, Nylok Bracket, Rail Reinforcement Liner, Bumper Bumper, Rear Screw Mount, Bumper 0 Bumper, Pivot Arm Spacer Block, Idler Bolt Adjusting 0 0 Rivet Nut, Jam Screw Asm., Rail, LH (Incl.,,,,) Asm., Rail, RH (Incl.,,,,) 00 Screw 0 Mount, Wheel Screw Washer, Spring Screw Bolt 0 Washer Spacer Roller, Spring Hi-Fax, White Bolt Screw /0 B

21 REAR SUSPENSION (EDGE) 0 Classic S0NDBS Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description Nut, Nylok Bushing -0 Arm, Pivot, Shock Screw 0 Washer, Flat Spacer, Idler Bushing 0 Wheel Spacer, Idler, Long 0 00 Shaft, Idler 00-0 Asm., Idler Wheel, Slv Mt Ring, Retaining Bearing 0 Washer, Belle Bolt Screw Screw 0 Washer, Spring Lock 0 Track (. inch) Clip, Guide Clip, Guide 00 Shaft, Pivot Arm Asm., Wheel 0 0 Bushing -0 Mount, Shock 0 Shaft Washer, Flat 0 Shaft 0-0 Arm, Pivot, Rear 00 Fitting, Lubrication /0 B

22 FRONT TORQUE ARM (EDGE) 0 Classic S0NDBS 0 0 Screw 0 Washer, Spring Lock Washer, Flat 0 Shaft -0 Arm, Torque, Front, Black 000 Fitting, 0 Degree Nut, Nylok 0 Sleeve 0 Shock, Front Track 0 00 Retainer, Spring, Slotted 0 Shield, Spring 0-0 Spring 0 Retainer, Spring 0 Sleeve 0 Retainer, Spring Screw 00 Fitting, Lubrication 0 Shaft Washer 0 0 Nut, Nylok 0 O-Ring Screw Screw Washer, Flat Nut, Nylok 0 Strap, Limiter /0 B

23 REAR TORQUE ARM (EDGE) 0 Classic S0NDBS 0 0 Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description -0 Arm, Torque, Rear, Black Nut, Flange 0 Screw Shaft, Arm Washer Bushing Screw 0 Washer, Flat Washer, Flat 0 0 Washer, Spring Lock Screw Asm., Rear Torque Arm (Incl. ) Nut, Nylok Spacer, Wheel 0 Asm., Wheel Washer, Thrust Sleeve, Torsion Spring Roller, Spring, Adjustable 00 Clip, Push-On Screw Shaft Bolt Washer Bushing -0 Rod, Shock Bolt 0 Bushing, Nut 0 Sleeve 0 00 Fitting, Lubrication 0 Spacer 0 Shock, PPS 00 Bushing Spring, Torsion, LH (Opt)(./) Spring, Torsion, RH (Opt)(./) Spring, Torsion, Soft, LH (Std)(./) Spring, Torsion, Soft, RH (Std)(./) Spring, Torsion, Firm, LH (Opt)(.0/) Spring, Torsion, Firm, RH (Opt)(.0/) /0 B

24 SHOCK (REAR TRACK) 0 Classic S0NDBS Shock, Rear Track, PPS Screw O-Ring Asm., Floating Piston Bearing, External O-Ring 000 Valve, Check 00 Body, Internal 000 Nut, Lock 000 Plate, Backup Piston Bearing, Piston 00 Shaft 000 Eyelet 0 00 O-Ring 00 Scraper, F.I.S.T. 00 U-Cup 00 O-Ring 00 Ring, Snap, Internal Screw O-Ring 00 Asm., Bearing (Incl. 0-,-) 00 O-Ring 00 O-Ring 00 Bearing 0 00 O-Ring 00 O-Ring 000 Ring, Retaining, Wire 00 Collar 000 Asm., Body (Incl. ) 00 Sleeve. ID 000 Bushing 0 Sleeve. ID 00 Bushing. ID /0 B

25 CHAINCASE 0 Classic S0NDBS Seal, Oil Screw Nut, Nylok Nut, Chain Adjuster 0 Screw 0 Bearing 0 Ring, Retaining Asm., Gearcase Tightener Bearing, Chaincase Idler Wheel, Idler Washer, Thrust Pin, Chain Tightener Block, Tightener 0 Sprocket, T, /W 0 0 Washer, Spring 0 Pin, Cotter Nut, FLEXLOC Gasket, Chaincase Cover, Chaincase Screw 0 Dipstick Screw Washer, Spring 0 Sprocket, T, /W 0 0 Chain, P, /W 0 Plug Chaincase /0 B0

26 DRIVE CLUTCH (ELECTRIC START MODELS) 0 Classic S0NDBS 0 0 Bolt 0 Washer, Spring Lock Bearing, Cover 0 Ring, Retaining, Cover 0 Spring, Clutch, Dark Blue/White 00 Nut, Jam 0 Washer, Multilube Asm., Roller and Bushing 0 Button, Guide AR AR AR AR AR Spacer (.00 ) Spacer (.0 ) Spacer (.0 ) Spacer (.00 ) Spacer (.0 ) Asm., Weight/Bushing (0-) 0 Pin, Weight 0 Bearing, Sleeve 00 Insert, Moveable Gear, Ring Screw 0 Nut, FLEXLOC Asm., Drive Clutch ES Basic (Incl. All Less,) 00 Kit, Drive Clutch Shim 0 0 Pin, Roller /0 B

27 DRIVEN CLUTCH 0 Classic S0NDBS Screw Plate, Driven, Vented Key 0 Bushing, Driven, Large DU 0 0 AR AR AR AR Washer (.0) Washer (.0) Washer (.0) Washer (.00) 00 Pin, Driven Cap, Driven, Vented Bolt Cam, Driven 0 0 Asm., Driven Clutch, Basic, 0 0 Roller Driven Pin Roller Driven Shim 00 Spring, Clutch, Green/Black Spacer Ramp, Driven, Roller D 0 Washer 0 Ring, Retaining /0 B

28 OIL TANK / AIRBOX 0 Classic S0NDBS E 00 Polaris Sales Inc Cover, Tool Box 0 Foam, Tool Box Screw Nut, Nylok Asm., Oil Tank (Incl.,) Tank, Oil Washer, Nylon Asm., Fuel Pump (See Fuel Pump Pg. C, Ref. ) 0 Screw System, CDI (See Magneto Pg. C, Ref. ) 0 00 Clip Silencer Foam, Air Box, Chimney 0 Decal, Caution, Air Box 0 Strap, Air Box, Top 0 Decal, Greasing Asm., Air Silencer (Incl. 0 & Decals) 0 Decal, E/R 0 Nut Well 0 Washer 0 Screw 0 Boot, Carburetor 0 Fitting 000 Clamp, Hose 000- AR Hose 000 Sender, Oil 00 Grommet, Oil Sender Washer, Flat Bolt 00 Cap, Oil /0 B

29 BATTERY BOX 0 Classic S0NDBS Pad, Battery 000 Strap, Battery Hold-Down 0 AR Tube, Vent 000 Battery 00 Cable, Battery 00 Kit, Battery Bolt 000 Cable, Solenoid/Starter Switch, Magnetic (See Starting Motor Pg. C, Ref. ) 0 Insulator, Cable 0 0 Cable, Battery/Solenoid 000 Wire, Jumper, Solenoid/Battery 00 Breaker, Circuit Nut, Nylok Nut, Nylok 0-0 Box, Battery Rivet 0 Plate, Stud 0 Bolt Washer, Spring (See Starting Motor Pg. C, Ref. ) Nut (See Starting Motor Pg. C, Ref. ) /0 B

30 DRIVE TRAIN 0 Classic S0NDBS Screw 0 Washer, Flat AR Washer, Flat 00 Spacer, Input Shaft Asm., Driven Clutch (See Driven Clutch Pg. B, Ref. 0) 0 Belt, Drive Washer AR Washer 0 AR Bushing 0 0 Washer, Flat 00 Flangette w/grease Fitting Fitting, Lubrication 0 Gasket, Jackshaft Nut, Nylok Bearing Flangette Bolt, Carriage Key 0 Asm., Jackshaft (Incl.,) 0 Ring, Retaining 0 0 Disc, Brake Nut 00 Sleeve, Seal 0 O-Ring Bolt, Carriage 00 Asm., Drive Shaft (Incl.,) 0 Asm., Flangette w/screws 00 Bushing, Speedometer, Metal Flangette 00 Key, Speedometer, Square 0 00 Gasket, Drive Adaptor 0 Adaptor w/zerk, Drive /0 C

31 EXHAUST SYSTEM 0 Classic S0NDBS Muffler (Tuned Pipe) 0 Spring, Exhaust 0 Retainer, Spring Screw 0 Washer, Spring Lock Washer, Flat Shield, Muffler 0 Boot, Exhaust Gasket, Exhaust (See Cylinder Pg. C, Ref. ) Manifold Screw 0 Nut, Flanged Dampener, Vibration Screw /0 C

32 ENGINE MOUNTING 0 Classic S0NDBS Screw 0 Washer 00 Washer, Clutch Retainer, Short 00 O-Ring, Clutch Bolt 00 Spacer, Clutch Bolt 000 Cable, Choke Control 00 Spark Plug, NGK BRES 0 Engine, Short Block ( ECPM00 SB) 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. -00 Handle, Recoil 0 Nut, Nylok Washer, Flat Strap, Engine Mount, LH Strap, Engine Mount, RH 00 Mount, Engine Spacer, Engine Mount Screw 00 Mount, Engine Screw 0 Bracket, Engine Mounting, RH 0 0 Washer, Flat 00 Nut, FLEXLOC, Thin 0 Nut, Flanged 0 Bracket, Engine Mounting, LH 00 Spacer, Engine 00 Cable, Throttle 00-0 Tubing, Convoluted AR Line, Fuel 0000 Clamp, Hose 000 Clamp, Hose AR Line, Fuel Asm., Fuel Pump (See Fuel Pump Pg. C, Ref. ) 0 Valve, Fuel Shut-Off /0 C

33 CRANKCASE 0 Classic S0NDBS 0 0 Stud 00 Asm., Crankcase (Incl. -,,) 0 Pipe, Pulse 000 Pin, Dowel 0 Bolt, Flange 0 Gasket, Aluminum 0 Seal, Oil 0 Bolt and Washer 00 0 Bolt and Washer 0 0 Seal, Oil / C

34 CYLINDER 0 Classic S0NDBS Bolt, Flange 00 Cylinder Head 00 Gasket, Head 0 Gasket, Exhaust 0 Nut, Flange 0 Cover, Cylinder Baffle 0 Cylinder Unit 0 Gasket, Cylinder 0 Screw 0 0 O-Ring 00 Bolt 00 Adaptor (Incl. 0) 0 Band, Adaptor (Incl. ) 0 Screw and Washer 0 Stopper 0 Valve 0 Asm., Reed Valve 0 Plate /00 C

35 PISTON and CRANKSHAFT 0 Classic S0NDBS Clip, Piston Pin 00 Bearing, End, Large 0 Bearing, End, Small Ring, Piston (Standard) Ring, Piston (0.mm/.00 O/S) Ring, Piston (0.0mm/.00 O/S) Piston, Set (Standard) Piston, Set (0.m/.00 O/S) Piston, Set (0.0m/.00 O/S) 0 Pin, Piston 0 Spacer, Crank Pin 0 Crank Pin No. 00 Rod, Connecting 0 0 Bearing, Ball 0 Spacer 0 Bearing, Ball 0 Crankshaft (PTO Side) 0 Bearing, Ball 0 Crankshaft (Incl. ) 0 0 Asm., Crankshaft (Incl. -,0,-) Crankshaft (MAG Side) 0 Bearing, Ball 00 Nut 00 Washer, Spring Key /0 C

36 BLOWER HOUSING & RECOIL STARTER 0 Classic S0NDBS Baffle, Cylinder, 0 Decal, POLARIS, Engine Shroud 0 Bolt, Flange 00 Decal, 0, Engine Shroud 0 Bolt, Flange 00 Cap, Cylinder Baffle 0 Bolt, Flange 0 Cylinder Baffle 00 Bolt and Washer Starter, Recoil (Incl. 0,-,) Case, Starter 0 Plug, Rubber 000 Bolt and Washer 0 Spring, Spiral 0 Reel 0 Spring, Return 00 Ratchet 0 Spring, Friction 0 Plate, Friction 0 Nut, Flange 0 0 Pulley, Starting 000 Housing, Blower 0 Pin, Straight 0 Band, Wire 0 Bolt and Washer 0 Bolt and Washer 0 AR Rope, Starter /0 C

37 CARBURETOR 0 Classic S0NDBS Top 0 Spring, Throttle 0 Plate, Throttle Needle, Jet (BGY-) 0 Cap, Plunger 0 Spring, Plunger 0 Plunger 000 Spring, Throttle Adjuster 0 Screw, Throttle Stop 0 Hose 00 Screw, Air 00 Spring, Screw, Throttle Stop 00 Pilot Jet (#) 00 Screw and Washer 00 Fitting, Sediment 0 O-Ring 0 Main Jet (#0) 00 Washer 00 Float 0 0 Cap 000 Gasket, Float Chamber Needle Valve (.) 00 Packing, Needle Valve 00 Arm, Float 0 Pin, Float Asm., Carburetor (Incl. -) 0 Valve, Check 0 Cap 0 Needle Jet (Q-) Throttle Valve (.0) 00 E-Ring /0 C

38 FUEL PUMP 0 Classic S0NDBS Ref. Part No. Qty. Description 0 Screw 00 Asm., Fuel Pump (Incl. -) 00 Diaphragm, Gasket Set / C

39 OIL PUMP 0 Classic S0NDBS 0 0 Vinyl Pipe 0 Clamp, Hose 0 Screw, Air Vent 0 Packing 00 Asm., Oil Pump (Incl. -0,) 00 Spring, Return 0 Collar, Cam Shaft 00 Lever, Control 0 Washer, Spring 0 00 Nut 0 Screw and Washer 0 Gear, Small 00 Spacer 0 Bushing, Oil Pump AR AR AR 0 O-Ring Spacer (.mm) Spacer (.mm) Spacer (.mm) /0 C0

40 STARTING MOTOR 0 Classic S0NDBS Kit, Brush & Spring Asm., Brush & Screw Asm., Brush Bushing, Insulation Washer, Insulation Nut 00 Kit, Commutator Cap (Incl. ) Nut Screw 0 Bracket, Starter, Rear 00 Kit, Armature Kit, Drive Hardware Washer, Curved Spring Washer, Thrust Spacer Spring, Antidrift Pinion, Stop Ring, Lock Cover, Dust 00 Kit, Drive Cap 000 Motor, Starter, Domestic Kit, Drive Plate, Drive Pinion Bracket, Starter, Front 0 Washer, Spring Lock Screw 0 Screw Kit, Screw Bolt, Thru 0 Nut 000 Washer, Spring 0 Switch, Magnetic (Incl.,) 0 Nut /0 C

41 MAGNETO 0 Classic S0NDBS 0 0 Screw and Washer 0 Asm., Flywheel 0 Stator 0 Screw and Washer 0 Cap, Spark Plug 0 Cap, Spark Plug 0 Harness Unit 0 CDI System Comp (Includes and ) 0 CDI System 0 00 Jumper Stubber E/R w/es 0 Coil, Ignition /0 C

42 TOOL KIT 0 Classic S0NDBS 0 00 Kit, Tool (Incl. -) Screwdriver Wrench, / x / Open End Box Wrench, Special 00 Wrench, Box End, / x / 00 Wrench, / x / Open End 0 Video, Suspension Setup Screw 0 Tool, Scissor Stop Wrench (Edge) 00 Strap, Emergency Starter (Manual Start) 0 Manual, Owner s, 0 Snowmobile Supplement, Owner s Manual, 0 0 Classic /0 C

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44 PRINTED IN THE USA PARTS MANUAL PN AND MICROFICHE PN /0

SUPERSPORT EDGE Model #S01NB5BS Model #S01NB5BSA Rev. 03. E 2000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00

SUPERSPORT EDGE Model #S01NB5BS Model #S01NB5BSA Rev. 03. E 2000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00 SUPERSPORT EDGE Model #S0NBBS Model #S0NBBSA Rev. 0 E 000 Polaris Sales Inc. PARTS MANUAL PN 0 and MICROFICHE PN 0/00 TABLE OF CONTENTS SUPERSPORT S0NBBS and SUPERSPORT S0NBBSA Parts Manual AIR BOX A...