XPRESS 300 Model #A99CA28CA Rev. 01

Transcription

1 XPRESS 00 Model #ACACA Rev. 0 PARTS MANUAL PN and MICROFICHE PN /

2

3 TABLE OF CONTENTS Parts Manual A ARM/STRUT MOUNTING B0 AIR BOX B CARBURETOR D CLUTCH COVER B CONTROLS - MASTER CYLINDER/BRAKE LINE B CONTROLS - THROTTLE ASM./CABLE B COOLING SYSTEM A CRANKCASE and CYLINDER C-0 CRANKSHAFT and PISTON C DECALS A DRIVE CLUTCH B DRIVEN CLUTCH B ELECTRICAL/TAILLIGHT C ENGINE MOUNTING A0 EXHAUST SYSTEM A FRONT BRAKE B FRONT CAB A FRONT RACK and BUMPER MOUNTING A FRONT WHEEL B FUEL TANK A A C D E F G GEAR SELECTOR C GEARCASE C- GEARCASE/BRAKE and CHAIN COVER MOUNTING C H HANDLEBAR B K KIT - CLAMP B M MAGNETO C O OIL PUMP C OIL TANK B P PART NUMBER INDEX D- REAR BRAKE C REAR CAB and SEAT A- REAR RACK MOUNTING A REAR WHEEL DRIVE C RECOIL STARTER C STARTING MOTOR C STEERING POST B STRUT B SWING ARM/SHOCK MOUNTING.... B T TOOL KIT D 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 Type - Front Type - Rear Type - Auxiliary Type - Parking BRAKES 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, Cargo Bed Box, Tool (cubic inches) Box (cubic feet) Ground Clearance (inches) Height (inches) Length (inches) Seat Height (inches) Weight (dry) Wheel Base (inches) Width (inches) GEARCASE Trans. Number and Type 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 Chain Adjustment TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center Wheel Bolt Pattern - Center XPRESS 00 SPECIFICATIONS ENGINE Hydraulic Disc Hydraulic Disc Mechanical Hydraulic Lock, All Wheel N/A 0 N/A N/A Standard 0 PVT 0 / (G) g Blue/Green Compound - 0 N/A N/A.... PRD Side Lever./././ N/A / P N/A N/A 0 O-Ring Eccentric Goodyear xx0 xx0 N/A N/A N/A 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 Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust GRAPHICS Body Style Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front/HDPE Fender, Rear/HDPE Frame/Steel Front Cover Grips/TPR Handlebar Cover w/decal Headlight Pod Mud Flaps/EVA Rack, Front/Steel Rack, Rear/Steel Rims/Steel Radiator Structure Color Seat Vinyl Side Panel Spring, Front/Steel Spring, Rear/Steel Tool Box Lettering w/letter Color Tank Cover LIGHTS/BATTERY Headlight (watts) Taillight (watts) Brake Light (watts) Other (Grill Mntd. Lights) Indicator Bulb Battery SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Adjustment ECPFE0 Cycle,Oil Injection.x./ Effective Air w/fan Assist 0W Standard /VM0SS 0 0- ().0. DP- NGKBRES USFS Appr. Gen IV N/A N/A Bonnie Blue Bonnie Blue Black Bonnie Blue Black Black Black Black Black Black Aluminum N/A Light Gray Bonnie Blue Bonnie Blue Bonnie Blue N/A N/A N/A V/. W V/. W, V 0/0W V/.0W V AH MacPherson Strut. Progressive Rate Swing Arm. Bore Gas Bag CAM 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 XPRESS 00 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER S MANUAL OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Xpress 00 ACACA 0

6 FRONT CAB Ref. Part Qty. Description Ref. Part Qty. Description Foil, Side Panel, RH 0 Foil, Foam, Side Panel 00- Asm., Panel/Foil, RH, Bonnie Blue, (Incl. Foil & Foam) - Panel, Side, RH, Bonnie Blue 0- Panel, Side, LH, Bonnie Blue Screw 0 Screw 0- Cover, Front, Bonnie Blue 00 Clip, Spring 0- Asm., Cab, Front (Bonnie Blue) (Incl. Warning Decals) A Nut, U-Type Speed 000 Nut, Push-On Rivet, T-Lock 0 Decal - Drain Recoil Nut, Nylok Washer Washer Nut, Nylok 00 Clip, Dart 0 Shield, Deflector Guard, Mud, Front, RH Guard, Mud, Front, LH /

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

8 REAR CAB and SEAT A

9 REAR CAB and SEAT Ref. Part Qty. Description Ref. Part Qty. Description 0 Rivet, T-Lock 0 Foil, Rear Cab, Rear 0 Decal - Carb Information Nut, Nylok Retainer, Seat Latch Screw Washer, Flat Washer 0 Screw 0 Box, Tool Screw, Special 0 Rivet, Pop 0 Bracket, Lever Retainer 00 Seat Latch 00 Spring, Latch Bumper, Rubber Cover, Tool Box 0 Cap, Drain Asm., Seat, Light Gray (Incl. -) Cover, Seat, Light Gray (w/label) Foil, Seat Base, Large Foil, Seat Base, Small Guard, Clutch, Outer Rivet 0-0 Guard, Rock Screw 00-0 Frame Nut Screw Tab, Airbox Mount 0 Foil, Footwell, Rib 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 0 Bolt - Cab, Rear, Bonnie Blue Foil, Foam, Rear Fender 0 Foil, Rear Cab, Front 0 Foil, Foam 0 Decal - Filter Element / A

10 FRONT RACK and BUMPER MOUNTING 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Harness, Headlight 00 Reflector, Amber 00 Asm., Rack, Front (Incl. Reflector & Decal) Screw Screw 00 Mount, Front Rack 00-0 Support, Front Rack, LH -00 Panel, Grill Screw 0-00 Bumper, Front Screw 00-0 Bumper Mount 0 Screw Nut, Nylok 00-0 Support, Front Rack, RH Support, Front Rack, LH Support, Front Rack, RH A Screw Bolt 0 Washer Headlight, 0/0 Watt, LH Headlight, 0/0 Watt, RH Bulb, 0/0 Watt Replacement -0-0 Extension, Frame, RH Extension, Frame, LH 0 Plug, Frame Nut, Nylok Brush Guard -0 Hitch, U-Bolt -0 Plate, Back Mount Screw 0 Decal - Caution, Rotating Fan (Located On Left Side) /

11 ENGINE MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description 00 Mount, Motor 00 Insulator, Mount, Motor AR Washer Bolt 0 Washer, Spring Lock Nut, FLEXLOC 0 Washer, Flat 00 Thermostat, Cooling Fan -0 Mount, Engine, Top 0 0 Nut, FLEXLOC Screw 0 Fitting, Vent 00 Cable, Ground/Engine Bolt 0 Washer, Lock 0 Washer 0 Bushing Asm., Drive Clutch, ATV-0 (See Drive Clutch Pg. B, Ref. ) Bolt Mount, Lower Engine 0 Nut, FLEXLOC 00 Spark Plug, NGK BRES A0 Cable, Solenoid/Starter (See Electrical/Taillight Pg. C, Ref. ) 00 Clamp, Narrow Band 0 Boot, Clutch Intake 00 Washer, Spring 0 Screw -0 Mount, Engine, Front 00 Engine, ECPFE0-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 Hose, Formed (See Fuel Tank Pg. A, Ref. ) /

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

13 DECALS RH 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 00 Decal - Load Distribution 0 Decal - Rack/Warning 0 Decal Decal - XPRESS 0 Decal - Tank Side, RH 0 Decal - POLARIS 0 Decal - Discretionary Warning 0 Decal - Side Panel, RH 0 Decal - Recoil Drain 0 00 Decal - CE Regulation 0 Decal - POLARIS, Domed 00 Decal - Tank Side, LH 0 Decal - Override Switch 0 Decal - Age Warning, ATV 00 Decal - Passenger Warning 0 Decal - Tire Pressure 0 Decal - Warning, General 0 Decal - Side Panel, LH / A

14 EXHAUST SYSTEM 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok Washer 00 Bushing 0 Dampener, Vibration 00 Support, Muffler 0 Nut 0 Washer, Rubber Screw Bolt Bracket, Muffler Support Bolt, Clean Out 00 Plug, Clean Out 00 Spring, Exhaust 00-0 Exhaust 00 Spring, Exhaust 0-0 Headpipe 0-0 Manifold Washer, Spring (See Crankcase and Cylinder Pg. C0, Ref. ) Nut (See Crankcase and Cylinder Pg. C0, Ref. ) 0 Tab, Spring / A

15 FUEL TANK 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, Gas Tank 0 Bolt -0-0 Screw Filter Clamp, Hose Bracket, Fuel Cover Mount Rear, LH Bracket, Fuel Cover Mount Rear, RH 0 A AR Fuel Line 0-0 Bracket, Tank Mount, Rear Nut, Nylok 00 AR Pad, Fuel, Bulk 0 Fitting, 0 Degree, Fuel Outlet, Main 0 Fitting, 0 Deg., Fuel Outlet, Reserve Hose, Formed 00 Clamp, Hose 0 0 Valve, Fuel, Way Nut, Fuel Valve Knob, Fuel Valve 0 Screw /

16 OIL TANK 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Cap, Oil Tank 0 Gasket, Oil Cap 0 Grommet Tank, Oil AR Line, Fuel 00 Fitting 0 Rivet, Pop 0 Sensor, Oil Level 00 Mount, Tie Anchor 0 Screw 0 Fitting 00 Strap, Tyton 000- AR Line, Fuel 000 Clamp, Hose, Large Green 000 Filter, Fuel 00 Clamp, Hose, Yellow AR Line, Fuel 00 Pad, Fuel, Bulk / 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 Screw 0 Washer, Wrought 000 Nut Box, Air Intake (Incl. ) 0 Valve, Umbrella 0 0 Bushing, Molded Bolt, Carriage B 000 Clamp 00 Clamp Boot, Carburetor 00 Tape, Foil, Air Box 000 Palnut 00 Filter, Air Intake 00 Seal, Air Intake Cover 0 Cover, Air Intake 0 00 Retainer, Air Intake Cover Nut, Wing /

18 STRUT 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 0-0 Spring, Coil, Front Shock Bumper, Strut B 0 0 Strut, Front 00 Clamp, Rubber Coated 0 Nut, FLEXLOC 0 Washer 000 Fitting, Lubrication Bolt 0 00 Support, Strut & Spindle, LH Support, Strut & Spindle, RH Washer, Spring Retainer /

19 FRONT WHEEL 0 Ref. Part Qty. Description Ref. Part Qty. Description Support, Strut & Spindle (See Strut Pg. B, Ref. ) 000 Seal, Front Hub Bearing, Ball Brake Disc 00 Hub, Wheel 00 Tire, Front (x-0) 0- Rim, Front 0 Valve, Rim 00 Spacer, Hub, Front 0 Washer Nut, Castle 0 Pin, Cotter 0 Cap, Hub 00 O-Ring Nut, Flanged Stud Bolt / B

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

21 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 0 Asm., Piston, Master Cylinder 00 Rivet 00 Kit Brake Lever, w/park Brake Latch (Incl.,,,0) Spring, Flat 00 Nut Kit - Park Brake Lever (Incl.,,0) 0 Bolt, Master Cylinder Reservoir 00 Bolt, Lever Ring, Square, Master Cylinder Reservoir Boot, Brake Line 0 Seal 0 Line, Brake 0 Switch 0 Line, Brake, Rear w/fittings Rivet, Pop 0 00 Clamp, Nylon 00-0 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, Cross 0 Bolt, Banjo / B

22 CONTROLS THROTTLE ASM./CABLE 0 Ref. Part Qty. Description Ref. Part Qty. Description 000 Screw 0 Decal - Throttle 0000 Cap 000 Packing 00 Asm., Throttle Control (Incl. -0) 000 Holder 000 Screw 000 Bolt 000 Plate 0 00 Switch, ETC 00 Cable, Throttle Control / 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. -) 0 Kit - Front Brake Boot 00 Screw, Bleeder Screw, Socket Set Caliper, Brake, LH Caliper, Brake, RH 0 Square Ring, Molded (.0) 00 Square Ring, Molded (.0) 000 Piston, Caliper 00 Insulator, Caliper 0 Kit - Piston and Insulator Seal (Incl. -) 00 Kit - General Duty Brake Pad, Front (Complete set of pads) 000 Kit - Severe Duty Brake Pad, Front (Complete set of pads) 0 Kit - Brake Pads, Soft, Front 0 00 Mount, Caliper 0 Boot, Bushing 0 Boot, Pin Seal 0 Washer 0 Washer, Spring Lock Bolt / B

24 STEERING POST 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Steering Post (Incl.,) 00 Clip, Tinnerman Bushing, Steering, Console 00 Fitting, Lubrication Bolt 000 Clamp, Wire Routing Bushing 0 O-Ring Spacer, Steering Post 0 Pin, Cotter 0 Nut 0 Bushing, Steering, Lower Rivet Plug, Grease, Steering 00 Fitting, Lubrication Bushing, Steering, Console -0 Bracket, Upper Steering Bushing Nut, Nylok / B

25 A ARM/STRUT MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, FLEXLOC Bushing Boot, Seal, Rod End 00 Rod End, RH Nut 00 Tie Rod 0 Nut, LH 00 Rod End, LH w/fitting 0 Asm., Tie Rod w/fitting (Incl. -) 0 0 Washer 0 Nut 0 Cotter Pin 0 Bracket, Ball Joint Bolt Nut, Castle 0 Boot, Rubber 00 Ball Joint Asm., Hubstrut (See Strut Pg. B, Ref. ) Bushing, A-Arm, Long 0 00 Bushing 00 Fitting, Lubrication Kit, A-Frame, LH (Incl. -,,) Kit, A-Frame, RH (Incl. -,,) 00 Shaft, A-Arm Bolt 0 Washer, Spring Lock Bolt / B0

26 SWING ARM/SHOCK MOUNTING Ref. Part Qty. Description Ref. Part Qty. Description 0 Bolt, Shoulder 0 Plate, Bolt Lock 0 Adapter, Spring Seat 00-0 Spring, Rear Compression Nut, Nylok Screw Retainer, Shock 0 Shock, Rear 0 Sleeve, Spring Protector 0 0 Cam, Adjusting, Spring 0 Bushing, Thrust, Steel Bushing, Thrust, Urethane Washer, Flat 0 Nut, Nylok Bushing, Pivot (See Gearcase Pg. C, Ref. ) 00 Bushing, Swing Arm Extended Bushing, Swing Arm B 00 Fitting, Lubrication, Degree 0 Bolt, Shoulder 0 0 Guide, Chain Rivet, Pop 0 Decal - Lubrication 0 Washer 0 Screw Bushing 0 Chain Guard 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 /

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

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

29 CLUTCH COVER Ref. Part Qty. Description Ref. Part Qty. Description 0 Seal, Cover Case Washer Screw 0 Seal, Clutch Cover Cover, Clutch, Outer 00 Clip, Clutch Cover 0 Screw 0 Decal - Clutch Cover 0 Decal - Engine/Clutch Modification 0 0 Decal - Automatic Transmission 0 Screw 00 Cable Tie 0 Boot, Clutch Intake Screw 0 Clip, Retainer, Oil Line 00 Clamp, Narrow Band Duct, Inlet Down Tube Tape, Foil 00 Boot, Intake 0 Duct, Inlet Top 0 Screw 000 Kit - Cover, Clutch, Inner (Incl.,,,,) Washer, Nylon -0 Bracket, Clutch Cover Washer Duct, Air Outlet -0 Bracket, Retainer, Seal 0 Seal, Cover Case 0 Screw 0 Rivet, Pop Screw and Washer (See Crankcase and Cylinder Pg. C0, Ref. ) / B

30 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, Rear Caliper 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 Asm., Output Shaft Bearing (Incl. ) 0 Brake Disc 00 Seal, Brake Nut 000 Fitting, Lubrication 0 AR 0 AR AR Bolt, Carriage 0 Ring, Retaining 0 Sprocket, T 0 0 Nut, FLEXLOC Screw 0 Nut Screw 0 Washer, Flat Shim - Bearing (.00) Shim - Bearing (.00) Shim - Bearing (.00) Note: Use shims only with OutputShaft Bearing PN 0 / C

31 REAR BRAKE 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Screw, Bleeder 0 Pin, Brake Caliper, Brake, Rear Kit - General Duty Brake Pad, Rear (Complete set of pads) Kit - Severe Duty Brake Pad, Rear (Complete set of pads) Kit - Brake Pad, Soft, Rear Kit - Piston and Seal (Incl. -) 0 Square Ring, Molded (. Sq.) 0 Square Ring, Molded (.0 Sq.) 00 Piston, Caliper 0 Spring, Anti-Rattle, Rear Brake 0 0 O-Ring 0 Spring, Compression, Brake 00 Pin, Brake Caliper 000 Gasket, Brake C 0 Ramp, Moveable, Brake 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, Thrust 0 Pin, Cotter /

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

33 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 Lens, Taillight 00 Screw 000 Bulb 00 Gasket, Taillight 00 Backing, Taillight/Brake Light 00 Nut, Speed 0 Nut, Nylok 0 Washer, Star 0 Screw 00 Pad, Battery 00 Kit - Battery Bolt, Short C 0 Insulator, Cable 000 Cable, Battery/Engine 000 Hook, Battery Strap 0 Strap, Battery Holddown 0 AR Tube, Battery Vent Battery Cover, Battery 000 Cable, Battery/Solenoid 00 Cable, Solenoid/Starter 00 Bolt 00 Rectifier, LR- 0 Screw 000 Limiter, RPM, LR Rivet 000 Board, Terminal /

34 GEARCASE C

35 GEARCASE Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gearcase (Incl. -) Seal 0 Stud 0 Bushing, Pivot 0 0 Screw 00 Gearcase, LH 0 Pipe, Knock 0 Shift Fork, Low 0 Shift Fork, High/Reverse 0 Shift Shaft, Low, HLR 0 O-Ring 00 Washer 0 Ring, Retaining Bell Crank 0 Washer 0 Nut, FLEXLOC 0 Shift Shaft, High/Reverse 0 Pin, Interlock 00 Bracket, Interlock 0 Spring 0 0 Bearing, Ball 0 Screw Shaft, Input, HLR 0 Bearing 00 Washer, Thrust Gear, T 00 Bearing, Needle 00 Washer, Thrust Engagement Dog, Low, HLR Shaft, Reverse, HLR 0 0 Washer, Thrust 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 Tube Dipstick Plug, Oil Drain 0 Washer 00 Gearcase, RH 0 Oil Deflector 00 Bearing 0 Shaft, Output, HLR 0 Gear, T 00 Bushing, Speedo / C

36 GEAR SELECTOR Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gear Selector (Incl. -,-,-) Asm., Knob 0 Screw Clamp Clamp Boot, Gear Selector 0 Mount, Tie Anchor Cover, Gear Selector Spring, Holding Handle 0 0 Cup, Bearing 0 Spring, Centering 0 Pin, Dowel 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 0 00 Rod, Shift Linkage 000 Rod, Shift Linkage 0 Nut, RH Slide, High/Reverse 0 Nut, FLEXLOC 0 O-Ring 0 Slide, Low Body, Gear Selector Screw 00 Pin, Dowel 0 0 Butterfly, Interlock Screw / C

37 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 0 Crankshaft Gear Key, Woodruff 00 Washer 00 Nut, Lock 00 Asm., Crankshaft (Incl.-,,,,) 00 Crankshaft 00 Crankshaft 0 0 AR AR Spacer (0.mm) Spacer (0.mm) 0 Crank Pin, PTO Side 00 Rod, Connecting C /

38 CRANKCASE and CYLINDER C

39 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 / C0

40 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 C 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 /

41 STARTING MOTOR 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, Flange 00 Brush 0 Asm., Starting Motor (Incl. -,,,-,0-) 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 C 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-) /

42 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 C 0 Bolt 0 Plate, Friction 0 0 Spring, Friction 0 Reel 00 Asm., Rope 0 Spring, Return 0 Ratchet /

43 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 C 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) /

44 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 /

45 TOOL KIT Ref. Part Qty. Description Ref. Part Qty. Description 00 Tool Kit Pouch 0 Wrench, Box, Special 0 Wrench, 0- Spanner 0 Screwdriver 0 Tire Pressure Gauge 0 Asm., Tool Kit (Incl. -) 0 Manual, Owners, ATV Supplement, Owner s Manual, Xpress 00 / D

46 Part Ref. Grid A A A A A A C A A A A A A A A A A A B B B C C C B C B... C B C B B B C C B B B B B B B B B B B B B B B B B B B B PART NUMBER INDEX Part XPRESS 00 ACAC D Ref. Grid B B B B B B... B B B C C C C B B B B C B B B C B B B B C A A C B C A A A0 0.. A... B A A A A A A A A D D A C C C C C C C0 Part Ref. Grid C C C C C C C C C C C C C0.. C C C C C C C C C C C C C C C C C C C C C C C C D D C C C C C C C D C C C C C C C C C

47 Part Ref. Grid C C D 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 A 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 NUMBER INDEX Part XPRESS 00 ACAC 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 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 Part Ref. Grid D D D D D D D B C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C

48 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 C C C C C B C B.. B B B C B C... C C C C A A C C A C C C C B B C C C B PART NUMBER INDEX Part XPRESS 00 ACAC D Ref. Grid B B B B C A A C C B B C B C C B B C C C B B C C B B B B B B C B A B.. B B B C A C B B C C A C B B A B B A A A B Part Ref. Grid B A B B B C C B A B A B A A A A C A A A A B B A B A C A C A0.. B C A B C B B B B B B B C B B B C C B B B A B B B B

49 Part Ref. Grid C A B B B A A B B B A B B B B B B B B A C B B B B B B B B C A A A A B B A A A A A A A B B B B B C B B B A B A PART NUMBER INDEX Part XPRESS 00 ACAC D Ref. Grid B A A B A A B B B B C B C C B A C B B B B A A A A A A A A A B A A A A A C B C B B B C A B B B A... C A A A A B B Part Ref. Grid A A B A A C C B B B B A A A B B B A B A C A A A.. A A A A A B A A A A A A A A A A0.. A B B B B B B... C 0... C B B... C B B B B

50 Part Ref. Grid B.. B B A B A0 B B B B B B B B B B B A A C B... B... C... C C B A... A B B B A A C B A... A... A.. A0.. A.. A.. B A B B B B A B B A A B A B PART NUMBER INDEX Part XPRESS 00 ACAC D Ref. Grid A C B B C C A A A... A B A A0... B B C B A A A A B B C C C B C C B C A B B A B A A A A A0.. B A... A 0... C A... A... A.. A... B B C A B B Part Ref. Grid A.. A.. A... B A A0.. B C C A B B... C C B B B B B B C C B C C C B A B B0... C B A0... B.. B... C A A B C B B C A... A C A0 0.. B0... C A C C A B B B

51 Part Ref. Grid B C A B B B B B B A B A... A... B... B.. B... C C A C A PART NUMBER INDEX Part XPRESS 00 ACAC Ref. Grid B B B B C C C B B B A 0.. B A... A C A B C A... A B Part Ref. Grid B C A A A C C B A0.. A... B A... B B B B A0.. A B D D D

52

53 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

54 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

55 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0

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

57 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0

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

59

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