Parts Catalog Rev. 01 Parts Manual RANGER 700 EFI 6X6 R06RF68AA. Copyright 2006 Printed 07/06/06 * * * MILITARY USE ONLY * * *

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1 *D o no ww t C w. op m yilit M ar ili ya ta tv ry pa U rts se.c O om nl y Parts Catalog * RANGER 700 EFI 6X6 R06RF68AA 9905 Rev. 0 Parts Manual Read the Operator's manual entirely. When you see this symbol, the subsequent instructions and warnings are serious - follow without exception. Your life and the lives of others depend on it! Copyright 006 Printed Cover photo may show optional equipment not supplied with standard unit.

2 Table of Contents Illustrated Parts Lists... A-ARM, FRONT/STRUT MOUNTING... A-ARMS, MID DRIVE...6 AIR BOX...8 ASM., BOX...0 BOX MOUNTING... BRAKE CALIPER, FRONT... BRAKE LINES/MASTER CYLINDER...6 BRAKE, FOOT...8 CHASSIS/BODY...0 CLUTCH COVER... COOLING SYSTEM... CRANKCASE...6 CRANKSHAFT...8 DASH INSTRUMENTS and CONTROLS...30 DECALS...3 DIPSTICK and OIL FILTER...3 DRIVE CLUTCH...36 DRIVEN CLUTCH...38 DRIVESHAFT, FRONT...0 DRIVESHAFT, MID... ELECTRICAL/BATTERY... ENGINE and CLUTCH AIR INTAKE...6 ENGINE MOUNTING...8 EXHAUST SYSTEM...50 FRAME, CAB...5 FUEL INJECTOR...5 FUEL SYSTEM...56 GEAR SELECTOR...58 GEARCASE...60 GEARCASE, INTERNAL...6 GEARCASE, MID...6 GEARCASE, OUTPUT SHAFT...66 GEARCASE, REAR...68 HOOD...70 HOUSING, FRONT...7 HOUSING, MID...7 INTAKE...76 MAGNETO...78 MANIFOLD and THERMOSTAT...80 MOLDINGS...8 OIL PUMP and WATER PUMP...8 PARK BRAKE...86 PARK BRAKE PEDAL...88 PISTON and CYLINDER...90 PROP SHAFT, FRONT...9 PROP SHAFT, REAR...9 SEAT/SEAT BASE...96 SHOCK, REAR...98 STARTING MOTOR...00 STEERING...0 STRUT, FRONT...0 SWING ARM...06 Copyright 006. All rights reserved. TAILGATE...08 THROTTLE...0 THROTTLE BODY MOUNTING... TOOL KIT... TRANSMISSION MOUNTING...6 WHEEL, FRONT...8 WHEEL, REAR...0 Part Number Index... Part Description Index...5 Polaris Industries provides this publication as is without warranty of any kind, either expressed or implied. While every precaution has been taken in the preparation of this manual, Polaris assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. Polaris reserves the right to revise and improve its products as it sees fit. This publication describes the state of this product at the time of its publication, and may not reflect the product in the future. The illustrations in this manual are not intended for safe and proper assembly or disassembly of equipment. The illustrations are intended for ordering parts only. Polaris is registered trademark. All other brands and product names are trademarks or registered trademarks of their respective holders. Printed in the United States of America. Parts Catalog 9905 Rev. 0

3 Alphabetized Table of Contents A A-ARM, FRONT/STRUT MOUNTING... A-ARMS, MID DRIVE...6 AIR BOX...8 ASM., BOX...0 B BOX MOUNTING... BRAKE CALIPER, FRONT... BRAKE LINES/MASTER CYLINDER...6 BRAKE, FOOT...8 C CHASSIS/BODY...0 CLUTCH COVER... COOLING SYSTEM... CRANKCASE...6 CRANKSHAFT...8 D DASH INSTRUMENTS and CONTROLS...30 DECALS...3 DIPSTICK and OIL FILTER...3 DRIVE CLUTCH...36 DRIVEN CLUTCH...38 DRIVESHAFT, FRONT...0 DRIVESHAFT, MID... E ELECTRICAL/BATTERY... ENGINE and CLUTCH AIR INTAKE...6 ENGINE MOUNTING...8 EXHAUST SYSTEM...50 F FRAME, CAB...5 FUEL INJECTOR...5 FUEL SYSTEM...56 G GEAR SELECTOR...58 GEARCASE...60 GEARCASE, INTERNAL...6 GEARCASE, MID...6 GEARCASE, OUTPUT SHAFT...66 GEARCASE, REAR...68 H HOOD...70 HOUSING, FRONT...7 HOUSING, MID...7 I INTAKE...76 M MAGNETO...78 MANIFOLD and THERMOSTAT...80 MOLDINGS...8 O OIL PUMP and WATER PUMP...8 P PARK BRAKE...86 PARK BRAKE PEDAL...88 PISTON and CYLINDER...90 PROP SHAFT, FRONT...9 PROP SHAFT, REAR...9 S SEAT/SEAT BASE...96 SHOCK, REAR...98 STARTING MOTOR...00 STEERING...0 STRUT, FRONT...0 SWING ARM...06 T TAILGATE...08 THROTTLE...0 THROTTLE BODY MOUNTING... TOOL KIT... TRANSMISSION MOUNTING...6 W WHEEL, FRONT...8 WHEEL, REAR...0 Parts Catalog 9905 Rev. 0 3

4 Polaris A-ARM, FRONT/STRUT MOUNTING Illustrated Parts Lists Applies to R06RF68AA [ C0] Parts Catalog 9905 Rev. 0

5 Illustrated Parts Lists A-ARM, FRONT/STRUT MOUNTING Polaris Applies to R06RF68AA [ C0] Ref Part No Qty 8 6 Part Description Nut, Nylok Nut, Nylok Bushing, A-Arm, Short Shaft, A-Arm, Short A-Frame, Black, LH A-Frame, Black, RH ASM., HUBSTRUT Joint, Ball Bracket, Ball Joint Boot, Rubber Bolt Nut, Castle Pin, Cotter Shield, CV Front, Black, LH Shield, CV Front, Black, RH Notes [If built before //06] [If built after //06] [If built before //06] [If built after //06] [See Strut, Front Pg. B9, Ref. ] Parts Catalog 9905 Rev. 0 5

6 Polaris A-ARMS, MID DRIVE Illustrated Parts Lists Applies to R06RF68AA [ B] 6 Parts Catalog 9905 Rev. 0

7 Illustrated Parts Lists A-ARMS, MID DRIVE Polaris Applies to R06RF68AA [ B] Ref Part No Qty Part Description Nut, Nylok Shaft, A-Arm, Short Bushing, A-Arm, Short Shaft, A-Arm, Upper, Black A-Arm, Mid Axle, Upper, Black Nut, Nylok Nut, Nylok Retainer, Shock Spring, Middle Axle, Black Washer Shock, Middle Axle Hub, Wheel, Rear Ring, Retaining Bearing, Carrier, Wheel Carrier, Bearing, Wheel, LH Carrier, Bearing, Wheel Shaft, A-Arm, Lower A-Arm, Mid Axle, Lower, Black Notes [If built before //06] [If built after //06] [If built before //06] [If built before //06] [If built after //06] [If built before //06] [If built after //06] [RH] [If built before //06] [If built after //06] Parts Catalog 9905 Rev. 0 7

8 Polaris AIR BOX Illustrated Parts Lists Applies to R06RF68AA [ C3] 8 Parts Catalog 9905 Rev. 0

9 Illustrated Parts Lists AIR BOX Polaris Applies to R06RF68AA [ C3] Ref Part No Qty Part Description Hose, Breather Clamp, Hose, Spring Clamp, Narrow Band Clamp, Narrow Band Boot, Air Box Sensor, T Map Clamp, Narrow Band O-Ring, Air Box Fitting Tube, Straight Outlet Box, Air Intake Box, Air Intake Clip, Cover Clip, Cover Filter, Air Intake Filter, Air Intake Seal, Cover Seal, Cover Cover Cover Clamp Cap, End Notes [If built before 0/3/05] [If built after 0/3/05] (If built before /0/05) (If built before /0/05) (If built before /0/05) (If built after /0/05) (If built before /0/05) (If built after /0/05) (If built before /0/05) (If built after /0/05) (If built before /0/05) (If built after /0/05) (If built before /0/05) (If built after /0/05) Parts Catalog 9905 Rev. 0 9

10 Polaris ASM., BOX Illustrated Parts Lists Applies to R06RF68AA [ A] 0 Parts Catalog 9905 Rev. 0

11 Illustrated Parts Lists ASM., BOX Polaris Applies to R06RF68AA [ A] Ref Part No Qty 0 0 Part Description Panel, Box, Long, Green, RH Asm., Taillight, RH Bulb, Taillight Ring, Tie Down Latch, Slam, Tailgate Nut, Nylok Bolt Support, Tailgate, Black Asm., Taillight, LH Bulb, Taillight Bumper Recess Panel, Box, Short, Green, LH Box, Short, Black Nut, Flange Seal, Foam Panel, Box, Front Asm., Box, Short, Green Notes [Incl. All] Parts Catalog 9905 Rev. 0

12 Polaris BOX MOUNTING Illustrated Parts Lists Applies to R06RF68AA [ A0] Parts Catalog 9905 Rev. 0

13 Illustrated Parts Lists BOX MOUNTING Polaris Applies to R06RF68AA [ A0] Ref Part No Qty Part Description Washer Box, Support, Black Latch, Box, Black Spring Pin, Clevis Shock, Dump Box Pin, Hitch Nut, Flange Washer Bushing, Box, Latch Rivet Bumper, Box Base Shield, Heat, Exhaust Harness, Cargo Box Clip, Routing Pin, Box Hinge, Black Notes [Incl. 8] Parts Catalog 9905 Rev. 0 3

14 Polaris BRAKE CALIPER, FRONT Illustrated Parts Lists Applies to R06RF68AA [ C05] Parts Catalog 9905 Rev. 0

15 Illustrated Parts Lists BRAKE CALIPER, FRONT Polaris Applies to R06RF68AA [ C05] Ref Part No Qty Part Description, Bleeder Caliper, Brake, LH Caliper, Brake, RH Kit, Front Brake Boot Seal, Caliper, Inner Seal, Caliper, Outer Piston, Brake Boot, Pin Seal Boot, Pin Seal Asm., Caliper, Mount Kit, Brake Pad, Assembly Boot, Bushing Boot, Bushing, Socket Set Asm., Caliper, Brake, LH Asm., Caliper, Brake, RH Notes (If built before 0/7/05) (If built after 0/7/05) (If built before 0/7/05) (If built after 0/7/05) Parts Catalog 9905 Rev. 0 5

16 Polaris BRAKE LINES/MASTER CYLINDER Illustrated Parts Lists Applies to R06RF68AA [ C0] 6 Parts Catalog 9905 Rev. 0

17 Illustrated Parts Lists BRAKE LINES/MASTER CYLINDER Polaris Applies to R06RF68AA [ C0] Ref Part No Qty 7 Part Description Line, Brake, Rear, LH Fitting, Tee, Brake Asm., Master Cylinder Line, Brake, Master Cylinder, Front Line, Brake, Front, Left Fitting, Cross, Brake Switch, Stoplight Line, Brake, Front, Right Bolt, Banjo Seal Line, Brake, Master Cylinder, Rear Clip Clip, Rosebud Line, Brake, Rear, RH Bolt, Banjo Cable Tie Notes Parts Catalog 9905 Rev. 0 7

18 Polaris BRAKE, FOOT Illustrated Parts Lists Applies to R06RF68AA [ C03] 8 Parts Catalog 9905 Rev. 0

19 Illustrated Parts Lists BRAKE, FOOT Polaris Applies to R06RF68AA [ C03] Ref Part No Qty Part Description Nut, Nylok Nut, Nylok Bushing, Pedal Pivot Tube, Brake Pedal Bushing Pin, Clevis Pin, Clip Pedal, Brake, Black Notes Parts Catalog 9905 Rev. 0 9

20 Polaris CHASSIS/BODY Illustrated Parts Lists Applies to R06RF68AA [ A05] 0 Parts Catalog 9905 Rev. 0

21 Illustrated Parts Lists CHASSIS/BODY Polaris Applies to R06RF68AA [ A05] Ref Part No Qty AR Part Description BASE, CAB/SEAT Support, Floor, Black, RH Support, Floor, Black, RH Nut, Flange Bolt Trim, Edge Support, Cab, Front, Black Support, Cab, Front, Black Nut, Nylok Pad, Rack Mount Cap, Bumper Plate, Grille, Bumper, Top, Black Plate, Grille, Bumper, Upper, Black Bumper, Black Cup, Hood Latch Rivet Decal, Reflector, Amber Support, Floor, Black, LH Frame, Main, Black U-Bolt Nut, Nylok Extension, Frame, Black Notes [If built before //05] [If built after //05] [See Seat/Seat Base Pg. A, Ref. ] [If built before //05] [If built after //05] (If built before 8/9/05) (If built after 8/9/05) Parts Catalog 9905 Rev. 0

22 Polaris CLUTCH COVER Illustrated Parts Lists Applies to R06RF68AA [ D0] Parts Catalog 9905 Rev. 0

23 Illustrated Parts Lists CLUTCH COVER Polaris Applies to R06RF68AA [ D0] Ref Part No Qty Part Description Asm., Cover, Clutch, Inner Washer Duct, Clutch, Air Outlet Clamp, Narrow Band Hose, Clutch Air Outlet Cover, Clutch, Outer, Black Decal, Warning, Clutch Cover Seal, Cover, Clutch, Outer Bracket, Clutch Seal Seal, Cover, Clutch, Inner Notes [Incl. 0,3] Parts Catalog 9905 Rev. 0 3

24 Polaris COOLING SYSTEM Illustrated Parts Lists Applies to R06RF68AA [ A] Parts Catalog 9905 Rev. 0

25 Illustrated Parts Lists COOLING SYSTEM Polaris Applies to R06RF68AA [ A] Ref Part No Qty AR Part Description Clamp, Hose Asm., Hose, Engine Outlet Cable Tie Mount, Cable Tie Clamp, Spring Band Connector, Barbed Hose, Radiator, Inlet Hose, Radiator, Outlet Edge, Trim Cap, Pressure Radiator, Flat Bushing, Mount, Lower Radiator Nut, Flanged, Nylok Asm., Grommet and Insert Bolt Valve, Plastic Radiator/Cooler Drain Shroud, Fan Clip, U Cable Tie Line, Fuel Fitting Bracket, Surge Tank Tank, Surge Plug, Cap Cap, Overflow Gasket Asm., Fan w/washer Clamp, Double Hose Hose, Engine Inlet Conduit, Flex Sheath, Reflect Notes Parts Catalog 9905 Rev. 0 5

26 Polaris CRANKCASE Illustrated Parts Lists Applies to R06RF68AA [ D0] 6 Parts Catalog 9905 Rev. 0

27 Illustrated Parts Lists CRANKCASE Polaris Applies to R06RF68AA [ D0] Ref Part No Qty Part Description Plug Dowel Plug Kit, Crankcase Pin, Dowel Bolt Asm., Oil Pickup Seal, O-Ring Plug Ring, Retaining Washer, Copper Plug, Socket Plate, Baffle Plate, Thrust Washer, Spring Kit, Gear Set Kit, Camshaft Notes Parts Catalog 9905 Rev. 0 7

28 Polaris CRANKSHAFT Illustrated Parts Lists Applies to R06RF68AA [ D] 8 Parts Catalog 9905 Rev. 0

29 Illustrated Parts Lists CRANKSHAFT Polaris Applies to R06RF68AA [ D] Ref Part No Qty Part Description Bearing Shaft, Balance Key, Woodruff Kit, Gear Set Washer Bearing Key, Woodruff Kit, Crankshaft Bearing, Ball Bushing Bearing, Ball Seal Notes Parts Catalog 9905 Rev. 0 9

30 Polaris DASH INSTRUMENTS and CONTROLS Illustrated Parts Lists Applies to R06RF68AA [ A07] 30 Parts Catalog 9905 Rev. 0

31 Illustrated Parts Lists DASH INSTRUMENTS and CONTROLS Polaris Applies to R06RF68AA [ A07] Ref Part No Qty 6 Part Description Panel, Indicator Bulb Hourmeter Plug, Hole, Rocker Switch Switch, AWD Switch, Headlight Receptacle, Pod Mount, V Plug, Indicator Light Indicator, Diagnostics Light Switch, Key Harness, Headlite/Hood Harness, Dash Notes Parts Catalog 9905 Rev. 0 3

32 Polaris DECALS Illustrated Parts Lists Applies to R06RF68AA [ A3] 3 Parts Catalog 9905 Rev. 0

33 Illustrated Parts Lists DECALS Polaris Applies to R06RF68AA [ A3] Ref Part No Qty Part Description Decal, Warning, Cab Frame/Seat Belt Decal, Filter Cleaning, Twin EFI Decal, Warning, Cont/Pass/Tire Pressure Decal, Box, "RANGER 6X6", LH Decal, Box, "RANGER 6X6", RH Decal, "POLARIS", Tailgate Decal, Reflector, Red Decal, Hitch Decal, Polaris Star Decal, 700 TWIN EFI, Hood, LH Decal, 700 TWIN EFI, Hood, RH Decal, Warning, Discretionary Decal, "APPLY BRAKE" Decal, Caution, "SHIFT AT IDLE" Plate, HWSR Notes Parts Catalog 9905 Rev. 0 33

34 Polaris DIPSTICK and OIL FILTER Illustrated Parts Lists Applies to R06RF68AA [ E0] 3 Parts Catalog 9905 Rev. 0

35 Illustrated Parts Lists DIPSTICK and OIL FILTER Polaris Applies to R06RF68AA [ E0] Ref Part No Qty Part Description Asm., Dipstick Tube, Oil Fill Washer Spring, Pressure Relief Pin, Dowel Clamp O-Ring Plug, Socket Nipple, Oil Filter Filter, Oil Notes Parts Catalog 9905 Rev. 0 35

36 Polaris DRIVE CLUTCH Illustrated Parts Lists Applies to R06RF68AA [ C] 36 Parts Catalog 9905 Rev. 0

37 Illustrated Parts Lists DRIVE CLUTCH Polaris Applies to R06RF68AA [ C] Ref Part No Qty AR AR AR AR Part Description Bearing, Cover Spring, Clutch Washer Asm., Roller and Bushing Button, Clutch Spacer,.00 Spacer,.05 Spacer,.03 Spacer,.050 Weight, Shift, 0-60 Bolt, Shoulder Nut, FLEXLOC Bearing, Moveable, / Inch Pin, Roller Asm., Drive Clutch, Wide Notes [Incl. All Less 3,8] Parts Catalog 9905 Rev. 0 37

38 Polaris DRIVEN CLUTCH Illustrated Parts Lists Applies to R06RF68AA [ C] 38 Parts Catalog 9905 Rev. 0

39 Illustrated Parts Lists DRIVEN CLUTCH Polaris Applies to R06RF68AA [ C] Ref Part No Qty AR Part Description Belt, Drive, EBS Bushing Asm., Driven Clutch Washer, Domed Washer, Spring Lock Bolt Retainer, Spring, Outer Spring, Compression Retainer, Spring, Inner Ring, Retaining Notes [3 Max] [Incl. 7-0] Parts Catalog 9905 Rev. 0 39

40 Polaris DRIVESHAFT, FRONT Illustrated Parts Lists Applies to R06RF68AA [ B06] 0 Parts Catalog 9905 Rev. 0

41 Illustrated Parts Lists DRIVESHAFT, FRONT Polaris Applies to R06RF68AA [ B06] Ref Part No Qty Part Description Circlip, Driveshaft Joint, CV Clip Kit, Boot Shaft, Axle Kit, Boot Joint, CV Asm., Driveshaft, Front Notes [Incl. Clamps and Grease] Parts Catalog 9905 Rev. 0

42 Polaris DRIVESHAFT, MID Illustrated Parts Lists Applies to R06RF68AA [ B] Parts Catalog 9905 Rev. 0

43 Illustrated Parts Lists DRIVESHAFT, MID Polaris Applies to R06RF68AA [ B] Ref Part No Qty Part Description Retainer Ring Boot Kit, Wheel Side Large Clamp Grease Boot Small Clamp Asm., Driveshaft, Mid Notes Parts Catalog 9905 Rev. 0 3

44 Polaris ELECTRICAL/BATTERY Illustrated Parts Lists Applies to R06RF68AA [ B05] Parts Catalog 9905 Rev. 0

45 Illustrated Parts Lists ELECTRICAL/BATTERY Polaris Applies to R06RF68AA [ B05] Ref Part No Qty Part Description Harness, Chassis Clip, Rosebud Cable Tie Cable Tie Wire, Spark Plug, 9.5cm Wire, Spark Plug, 59.3cm Coil, EFI Spacer Spacer Nut ECM Pad, Rack Mount Box, Battery Bracket, Battery Strap Bracket, Battery Strap Kit, Battery Bolt Kit, Battery Bolt Strap, Ground Block, Terminal Washer, Lock Nut, Hex Module, 700 ECM Cable, Red Solenoid, Starter Nut, Hex Battery, Top Mount Notes [If built before //05] [If built after //05] (If built before //06) (If built after //06) (If built before //06) (If built before 9/9/05) (If built after 9/9/05) Parts Catalog 9905 Rev. 0 5

46 Polaris ENGINE and CLUTCH AIR INTAKE Illustrated Parts Lists Applies to R06RF68AA [ C] 6 Parts Catalog 9905 Rev. 0

47 Illustrated Parts Lists ENGINE and CLUTCH AIR INTAKE Polaris Applies to R06RF68AA [ C] Ref Part No Qty 7 5 Part Description Filter, Intake Box, Air Baffeling Clamp, Hose Hose, Air Box, Front Clamp, Narrow Band Duct, Air Intake Cable Tie Hose, Air Box, Rear Nut, Nylok Hanger, Air Cleaner BOX, AIR INTAKE Hose, Clutch, Intake, Rear Clamp, Narrow Band Hose, Clutch, Intake, Front Notes [See Air Box Pg. C3, Ref. ] Parts Catalog 9905 Rev. 0 7

48 Polaris ENGINE MOUNTING Illustrated Parts Lists Applies to R06RF68AA [ B0] 8 Parts Catalog 9905 Rev. 0

49 Illustrated Parts Lists ENGINE MOUNTING Polaris Applies to R06RF68AA [ B0] Ref Part No Qty AR 8 Part Description Bracket, Motor Mount, Top Washer, Flat Mount, Rubber, Top Bracket, Engine Mount, Top Nut Cable, Battery, Ground Cable, Solenoid/Starter Kit, Short Block Mount, Engine, Lower, Front, Black Mount, Torque Stop Nut Mount, Engine, Transmission, Black Mount, Rubber, Rear Washer, Flat Notes NOTE:The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization required for warranty consideration. Parts Catalog 9905 Rev. 0 9

50 Polaris EXHAUST SYSTEM Illustrated Parts Lists Applies to R06RF68AA [ B03] 50 Parts Catalog 9905 Rev. 0

51 Illustrated Parts Lists EXHAUST SYSTEM Polaris Applies to R06RF68AA [ B03] Ref Part No Qty 8 8 Part Description Bolt Dampener Vibration Bushing Washer, Rubber Nut, Nylok Washer Bushing Silencer, Black Spring Seal, Exhaust Nutsert Nut, Hex Mount, Torque Stop Shield, Heat, Top Washer Bracket, Exhaust, Mount, Black Shield Shield, Exhaust, Manifold Gasket Manifold, Black Seal, Exhaust Tube, Exhaust, Black Spring Spring Washer Bolt Notes Parts Catalog 9905 Rev. 0 5

52 Polaris FRAME, CAB Illustrated Parts Lists Applies to R06RF68AA [ A03] 5 Parts Catalog 9905 Rev. 0

53 Illustrated Parts Lists FRAME, CAB Polaris Applies to R06RF68AA [ A03] Ref Part No Qty Part Description Bolt Frame, Cab, Front, Black, RH Bolt Nut, Nylok Nut, Nylok Asm., Frame, Cab, Right, Rear, Black Headrest, Black Bracket, Cab Frame, Cntr, Black Asm., Frame, Cab, Left, Rear, Black Frame, Cab, Front, Black, LH Notes [Incl. Warning Decals] [Incl. Warning Decals] Parts Catalog 9905 Rev. 0 53

54 Polaris FUEL INJECTOR Illustrated Parts Lists Applies to R06RF68AA [ E03] 5 Parts Catalog 9905 Rev. 0

55 Illustrated Parts Lists FUEL INJECTOR Polaris Applies to R06RF68AA [ E03] Ref Part No Qty Part Description Asm., Fuel Injector Fuel, Rail Dual Point Asm., and Washer Notes Parts Catalog 9905 Rev. 0 55

56 Polaris FUEL SYSTEM Illustrated Parts Lists Applies to R06RF68AA [ B0] 56 Parts Catalog 9905 Rev. 0

57 Illustrated Parts Lists FUEL SYSTEM Polaris Applies to R06RF68AA [ B0] Ref Part No Qty 6 AR 3 0 Part Description Cap, Gas w/ Gauge Asm., Fuel Tank Line, Fuel Foil, Tank Conduit, Flex tube Asm., Fuel Line Clip, Routing Bracket, Fuel Tank Bracket, Fuel Tank Notes [Incl. 3] [If built before //05] [If built before //05] [If built before //05] Parts Catalog 9905 Rev. 0 57

58 Polaris GEAR SELECTOR Illustrated Parts Lists Applies to R06RF68AA [ D08] 58 Parts Catalog 9905 Rev. 0

59 Illustrated Parts Lists GEAR SELECTOR Polaris Applies to R06RF68AA [ D08] Ref Part No Qty Part Description Cover, Shifter Knob, Shifter Nut, Nylok Bearing, Shifter Nut, Nylok Cable, Shifter Washer Clip, Pin Clip, Rosebud Grommet Gear Shift Grommet, Gear Shift Plug Bolt, Shoulder Washer, Flat Washer, Wave Spring Lever, Shifter Notes [x][6x6] Parts Catalog 9905 Rev. 0 59

60 Polaris GEARCASE Illustrated Parts Lists Applies to R06RF68AA [ D0] 60 Parts Catalog 9905 Rev. 0

61 Illustrated Parts Lists GEARCASE Polaris Applies to R06RF68AA [ D0] Ref Part No Qty 8 5 Part Description Nut, Lock Cover O-Ring Pawl, Detent Label, Oil Fill/Level Check Plug, Hex, Hollow w/o-ring Seal Shaft, Shift Gear, 3T Gearcase, Main Tube, Vent Pin, Dowel Gearcase, LH Seal, Dual Lip Bracket, Transmission Mount Gear, 6T Disc, Lockout Star, Detent O-Ring Spring, Compression Switch Ring, Retaining Bellcrank Asm., Gearcase Notes Parts Catalog 9905 Rev. 0 6

62 Polaris GEARCASE, INTERNAL Illustrated Parts Lists Applies to R06RF68AA [ D05] 6 Parts Catalog 9905 Rev. 0

63 Illustrated Parts Lists GEARCASE, INTERNAL Polaris Applies to R06RF68AA [ D05] Ref Part No Qty Part Description Bearing Chain, Silent Shaft, Input Bearing Drum, Shift Shaft O-Ring Fork, Shift Rail, Shift Shaft Spring, Wave Engagement Dog Ring, Retaining Washer Gear, 33T Bearing, Needle Shaft, Reverse Sprocket, T Washer Gear, 3T Gear, 7T Gear, 60T Cover, Bearing, Center Drive Ring, Snap Spacer Bearing, Ball Asm., Lapped Bevel, Gear Set Bearing, Needle Washer Asm., Gearcase Notes [Incl. Ref. from Gearcase, Output Shaft Pg. D6] Parts Catalog 9905 Rev. 0 63

64 Polaris GEARCASE, MID Illustrated Parts Lists Applies to R06RF68AA [ D07] 6 Parts Catalog 9905 Rev. 0

65 Illustrated Parts Lists GEARCASE, MID Polaris Applies to R06RF68AA [ D07] Ref Part No Qty Part Description Plug, Drain Seal Tube, Vent Cover, Output Shim Bearing, Ball Gear, Ring 37T Shaft, Output Bearing, Ball Spring, Wave O-Ring Pipe, Knock Seal, Triple Lip Ring, Retaining Washer, Thrust Bushing Gearcase, R Ring, Spring Bushing Pinion, 0T Gear, 6T Output Bearing, Ball Bracket, Caliper Mount Bolt Seal, Triple Lip Cover, Input Gear, 6T Input Shaft, Output Asm., Mid Gearcase Notes Parts Catalog 9905 Rev. 0 65

66 Polaris GEARCASE, OUTPUT SHAFT Illustrated Parts Lists Applies to R06RF68AA [ D06] 66 Parts Catalog 9905 Rev. 0

67 Illustrated Parts Lists GEARCASE, OUTPUT SHAFT Polaris Applies to R06RF68AA [ D06] Ref Part No Qty AR AR 5 Part Description Bearing Washer, Thrust Sprocket, 9T Asm., Lapped Bevel, Gear Set Shaft, Output, Main, Rear Button, Thrust Shim Shim Cover, Output, Front Seal Shaft, Output, Front Chain, Silent Sprocket, T Bushing Asm., Gearcase Notes [Incl. Ref. 6 from Gearcase, Internal Pg. D5] Parts Catalog 9905 Rev. 0 67

68 Polaris GEARCASE, REAR Illustrated Parts Lists Applies to R06RF68AA [ D0] 68 Parts Catalog 9905 Rev. 0

69 Illustrated Parts Lists GEARCASE, REAR Polaris Applies to R06RF68AA [ D0] Ref Part No Qty AR AR Part Description Seal, Triple Lip Cover, Input O-Ring Bearing, Ball Pinion, 0T Bushing Seal Case, Front Pipe, Knock O-Ring Spring, Wave Bearing, Ball Shaft, Output Gear, Ring 37T Bearing, Ball Plug, Expansion Tube, Vent Clamp, Hose Line, Fuel Clip Plug, Drain Cover, Output Shim Asm., Rear Gearcase Notes Parts Catalog 9905 Rev. 0 69

70 Polaris HOOD Illustrated Parts Lists Applies to R06RF68AA [ A08] 70 Parts Catalog 9905 Rev. 0

71 Illustrated Parts Lists HOOD Polaris Applies to R06RF68AA [ A08] Ref Part No Qty Part Description Asm., Hinge Hood, Green Grommet, Rubber Mount Plate, Catch Pin, Catch Seal, Glove Box Cover, Glove Box, Green Dash, Green Holder, Cup Nut, U-Type Nut, Nylok Washer Box, Storage Pin Liner, Hood Clip, Dart Bracket, Headlight Asm., Headlight Bulb, Headlight O-Ring Washer, Flat Strap, Hood Latch Grille, Hood, Black Clip, Wire Washer Notes Parts Catalog 9905 Rev. 0 7

72 Polaris HOUSING, FRONT Illustrated Parts Lists Applies to R06RF68AA [ D03] 7 Parts Catalog 9905 Rev. 0

73 Illustrated Parts Lists HOUSING, FRONT Polaris Applies to R06RF68AA [ D03] Ref Part No Qty AR Part Description, Set Asm., Cover Plate Button, Thrust Plate, Thrust Shim, Armature Plate Bearing, Roller Ball Asm., Race/Output Hub Pin, Dowel Clutch Housing/Ring Gear Kit, Roll Asm., Roll Cage Spring Bushing Fitting, Vent Line, Fuel Clip, Rosebud Clamp, Hose Kit, Seal Kit Cover, Input Bearing, Roller Ball Shaft, Pinion, T BUSHING GEARCASE, LH Plug, Oil Fill, Flange Asm., Drain Plug Bearing, Needle, Roller Thrust Ring, Retaining Plate, Armature Asm., Front Gearcase Asm., Gearcase Asm., Clutch Notes [Incl. Output Cover, Insert and Coil] [Incl. 7] [Incl. Spring and Roll Cage] [6x6] [Incl. O-Rings and Seals] [Incl. Plug and Washer] [Incl. 3,,3] [Incl. 9-] Parts Catalog 9905 Rev. 0 73

74 Polaris HOUSING, MID Illustrated Parts Lists Applies to R06RF68AA [ B0] 7 Parts Catalog 9905 Rev. 0

75 Illustrated Parts Lists HOUSING, MID Polaris Applies to R06RF68AA [ B0] Ref Part No Qty AR Part Description Clamp, Hose Line, Fuel T-Fitting Asm., Mid Gearcase Asm., Gear Coupler, Mid Drive Pin, Spring Notes Parts Catalog 9905 Rev. 0 75

76 Polaris INTAKE Illustrated Parts Lists Applies to R06RF68AA [ D] 76 Parts Catalog 9905 Rev. 0

77 Illustrated Parts Lists INTAKE Polaris Applies to R06RF68AA [ D] Ref Part No Qty 6 8 Part Description Bolt Asm., Arm, Rocker Retainer, Spring Retainer, Lock Spring, Valve Seat, Valve Spring Seal, Valve Guide Head, Cylinder Valve, Exhaust Valve, Intake Notes Parts Catalog 9905 Rev. 0 77

78 Polaris MAGNETO Illustrated Parts Lists Applies to R06RF68AA [ E0] 78 Parts Catalog 9905 Rev. 0

79 Illustrated Parts Lists MAGNETO Polaris Applies to R06RF68AA [ E0] Ref Part No Qty 3 Part Description Seal, Flanged Seal, Oil Asm., Engine Cover Stator Washer O-Ring Asm., Cover, Stator Asm., Cover, Stator Nut Flywheel Bracket, Stator, Wire Holddown Notes [If built before 3/3/06] [If built after 3/3//06] Parts Catalog 9905 Rev. 0 79

80 Polaris MANIFOLD and THERMOSTAT Illustrated Parts Lists Applies to R06RF68AA [ D09] 80 Parts Catalog 9905 Rev. 0

81 Illustrated Parts Lists MANIFOLD and THERMOSTAT Polaris Applies to R06RF68AA [ D09] Ref Part No Qty Part Description Sensor, Thermister O-Ring Thermostat w/bypass Cover, Thermostat Washer, Flat Notes Parts Catalog 9905 Rev. 0 8

82 Polaris MOLDINGS Illustrated Parts Lists Applies to R06RF68AA [ A06] 8 Parts Catalog 9905 Rev. 0

83 Illustrated Parts Lists MOLDINGS Polaris Applies to R06RF68AA [ A06] Ref Part No Qty Part Description Cover, Drive Shaft, Floor Asm., Main Floor Grommet, Choke Hole Foam, Foil, Floor Foil, Heat Shield, Floor Foam, Foil, Floor Foil, Floor, Horizontal Foil, Floor, Vertical Asm., Floor, Dog House Cover Floor, Dog House Cover Foil, Heat Shield Foam, Foil, Access Panel Fender, Rear, Black, LH Fender, Front, Black, LH Washer Nut, Nylok Washer Plate, Skid Panel, Wheel Well, LH Panel, Wheel Well, RH Fender, Front, Black, RH Nut, Speed Fender, Rear, Black, RH Nut, U-Type Notes [Incl., and Foil] [Incl. ] Parts Catalog 9905 Rev. 0 83

84 Polaris OIL PUMP and WATER PUMP Illustrated Parts Lists Applies to R06RF68AA [ E0] 8 Parts Catalog 9905 Rev. 0

85 Illustrated Parts Lists OIL PUMP and WATER PUMP Polaris Applies to R06RF68AA [ E0] Ref Part No Qty 5 Part Description Asm., Gerotor Housing, Oil Pump Bearing, Ball Ring, Retaining Shaft, Oil/Water Pump GEAR, DRIVEN, WATER/OIL Gasket, Cover, Mag Impeller, Water Pump Washer, Flat Nut, Hex, Nylok Seal, Water Pump Seal, Water Pump Cover, Water Pump Kit, Oil Pump Notes [Incl. -6] Parts Catalog 9905 Rev. 0 85

86 Polaris PARK BRAKE Illustrated Parts Lists Applies to R06RF68AA [ C06] 86 Parts Catalog 9905 Rev. 0

87 Illustrated Parts Lists PARK BRAKE Polaris Applies to R06RF68AA [ C06] Ref Part No Qty Part Description Asm., Park Brake Washer, Wrought Clip, Pin Cable, Brake, Parking Pin, Clevis Asm., Caliper, Park Brake Kit, Brake Pad Kit, Brake Pad and Shims Disk, Brake Kit, Mount Kit, Complete Notes Parts Catalog 9905 Rev. 0 87

88 Polaris PARK BRAKE PEDAL Illustrated Parts Lists Applies to R06RF68AA [ C07] 88 Parts Catalog 9905 Rev. 0

89 Illustrated Parts Lists PARK BRAKE PEDAL Polaris Applies to R06RF68AA [ C07] Ref Part No Qty Part Description Mount, Park Brake, Black Pin, Cotter Washer Spring, Lever Return Bushing, Pedal Pivot Washer Lever, Park, Black Spring, Catch, Parking Brake Latch, Park Brake Washer Pin, Clip Grommet Nut Handle Rod, Handle, Park Release Pin, Clevis Switch, Sensor, Park Brake Notes Parts Catalog 9905 Rev. 0 89

90 Polaris PISTON and CYLINDER Illustrated Parts Lists Applies to R06RF68AA [ D] 90 Parts Catalog 9905 Rev. 0

91 Illustrated Parts Lists PISTON and CYLINDER Polaris Applies to R06RF68AA [ D] Ref Part No Qty Part Description Gasket, Head Dowel Plug Circlip PIN, PISTON Kit, Piston Ring Gasket, Base Lifter, Valve Kit, Cylinder Pushrod Kit, Piston Notes [Incl. 3] [Incl. -6] Parts Catalog 9905 Rev. 0 9

92 Polaris PROP SHAFT, FRONT Illustrated Parts Lists Applies to R06RF68AA [ B08] 9 Parts Catalog 9905 Rev. 0

93 Illustrated Parts Lists PROP SHAFT, FRONT Polaris Applies to R06RF68AA [ B08] Ref Part No Qty Part Description Pin, Spring Yoke, Gear Case, Front Kit, Cross and Bearing Shaft, Prop Yoke, Prop Shaft, Transmission Fitting, Lubrication O-Ring Asm., Shaft, Prop Front Notes Parts Catalog 9905 Rev. 0 93

94 Polaris PROP SHAFT, REAR Illustrated Parts Lists Applies to R06RF68AA [ B07] 9 Parts Catalog 9905 Rev. 0

95 Illustrated Parts Lists PROP SHAFT, REAR Polaris Applies to R06RF68AA [ B07] Ref Part No Qty Part Description Pin, Spring Disc, Brake Yoke, Flanged Kit, Cross and Bearing Shaft, Prop Yoke Fitting, Lubrication O-Ring Asm., Prop Shaft, Rear Notes Parts Catalog 9905 Rev. 0 95

96 Polaris SEAT/SEAT BASE Illustrated Parts Lists Applies to R06RF68AA [ A0] 96 Parts Catalog 9905 Rev. 0

97 Illustrated Parts Lists SEAT/SEAT BASE Polaris Applies to R06RF68AA [ A0] Ref Part No Qty 8 8 Part Description Nut Asm., Seat, Back Asm., Seat, Bottom Black Nut, Nylok Washer, Flat Pin, Seat Latch Rivet Tab, Seat Mount Foil Foil, Seat Base, Cab/Seat, Black Grommet Asm., Seat Belt Bolt Nut, Nylok Asm., Seat Belt, Center Notes [Incl. 5-9] Parts Catalog 9905 Rev. 0 97

98 Polaris SHOCK, REAR Illustrated Parts Lists Applies to R06RF68AA [ C0] 98 Parts Catalog 9905 Rev. 0

99 Illustrated Parts Lists SHOCK, REAR Polaris Applies to R06RF68AA [ C0] Ref Part No Qty Part Description Nut, Nylok Retainer, Shock Spring, Black Cam, Adjusting, Spring Shock, Rear Notes Parts Catalog 9905 Rev. 0 99

100 Polaris STARTING MOTOR Illustrated Parts Lists Applies to R06RF68AA [ E05] 00 Parts Catalog 9905 Rev. 0

101 Illustrated Parts Lists STARTING MOTOR Polaris Applies to R06RF68AA [ E05] Ref Part No Qty Part Description Bolt Starter Asm., Bendix Washer Nut Washer, Lock Notes Parts Catalog 9905 Rev. 0 0

102 Polaris STEERING Illustrated Parts Lists Applies to R06RF68AA [ B] 0 Parts Catalog 9905 Rev. 0

103 Illustrated Parts Lists STEERING Polaris Applies to R06RF68AA [ B] Ref Part No Qty 3 5 Part Description Boot, Seal, Rod End Rod End Nut, Jam, LH TIE ROD, INNER Clamp, Boot, Small Boot, Passenger, Side Rack Clamp, Boot, Large Bolt Bolt Washer, Spring Lock Bushing, Shaft, Steering Washer, Wave Wheel, Steering Nut Cap, Steering Wheel Bushing Shaft, Steering, Upper Shaft, Steering w/joints, Lower Nut, Nylok Nut, Nylok Boot, Driver Side, Rack Bolt Washer Nut Pin, Cotter Asm., Gear Box, Steering Bolt Notes Parts Catalog 9905 Rev. 0 03

104 Polaris STRUT, FRONT Illustrated Parts Lists Applies to R06RF68AA [ B09] 0 Parts Catalog 9905 Rev. 0

105 Illustrated Parts Lists STRUT, FRONT Polaris Applies to R06RF68AA [ B09] Ref Part No Qty 0 Part Description Nut Washer Spacer, Rubber Ball, Pivot, Top Spacer Ball, Pivot, Bottom Retainer, Spring Spring, Compression, Black Bumper Strut, Front Washer Clamp, Cable Nut, Nylok, Cap Washer, Spring Lock Washer, Flat ASM., FRONT BRAKE CALIPER, RH Fitting, Lubrication w/ball Check Ring, Retaining Bearing, Hubstrut Asm., Hubstrut, LH Asm., Hubstrut, RH Bolt Notes [See Brake Caliper, Front Pg. C5 for Details] [mm][incl.,3,6,9,0,] [mm][incl.,3,6,9,0,] Parts Catalog 9905 Rev. 0 05

106 Polaris SWING ARM Illustrated Parts Lists Applies to R06RF68AA [ C09] 06 Parts Catalog 9905 Rev. 0

107 Illustrated Parts Lists SWING ARM Polaris Applies to R06RF68AA [ C09] Ref Part No Qty Part Description Ring, Retaining Bearing, Carrier, Wheel Tube, Axle, Black, RH Bolt O-Ring Asm., Drive Shaft, Axle, LH Asm., Drive Shaft, Axle, RH Tube, Axle, Black, LH Nut, Nylok Washer, Flat Arm, Swing, Black U-Bolt Bracket, Bolt Lock Nut, Nylon, Flanged Bolt, Swing Arm, Pivot Bushing, Swing Arm Pivot, LH Bushing, Swing Arm, LH Fitting, Lubrication Nut, Hex, Jam Washer, Flat ASM., GEARCASE, REAR Plate, Differential, Skid, Black Bushing, Swing Arm, RH Bushing, Swing Arm Pivot, RH Washer, Spring Lock Washer, Flat Notes [See Gearcase, Rear Pg. D for Details] [Rear Caliper Attach] [Rear Caliper Attach] [Rear Caliper Attach] Parts Catalog 9905 Rev. 0 07

108 Polaris TAILGATE Illustrated Parts Lists Applies to R06RF68AA [ A] 08 Parts Catalog 9905 Rev. 0

109 Illustrated Parts Lists TAILGATE Polaris Applies to R06RF68AA [ A] Ref Part No Qty Part Description Cap, Tailgate Panel, Outer, Green Latch, Paddle Washer, Wave Rod Bracket, Tailgate Nut, Nylok Washer, Flat Bolt Cable, Tailgate Tube, Tailgate Panel, Inner Pin, Hitch Washer Asm., Tailgate, Green Asm., Tailgate, Solar Red Asm., Tailgate, Black Notes [AA] [AA] [AB] [AC][AD][AE][AF] Parts Catalog 9905 Rev. 0 09

110 Polaris THROTTLE Illustrated Parts Lists Applies to R06RF68AA [ C0] 0 Parts Catalog 9905 Rev. 0

111 Illustrated Parts Lists THROTTLE Polaris Applies to R06RF68AA [ C0] Ref Part No Qty Part Description Cable, Throttle FRAME, MAIN Block, Pivot, Throttle Washer Pin, Clip Pedal, Throttle Throttle, Black Spring, Throttle Spring, Throttle Nutsert, Hex Notes Parts Catalog 9905 Rev. 0

112 Polaris THROTTLE BODY MOUNTING Illustrated Parts Lists Applies to R06RF68AA [ D3] Parts Catalog 9905 Rev. 0

113 Illustrated Parts Lists THROTTLE BODY MOUNTING Polaris Applies to R06RF68AA [ D3] Ref Part No Qty 7 Part Description Cover, Valve Asm., Reed w/gasket Plate, Breather Gasket, Breather Cover, Breather Plug, Spark, Champion RC7YC3 Adapter Clamp, Hose Asm., Body, Throttle Clamp, Hose Tubing Valve, Check Sensor, Crank Position Seal, Valve Cover Notes Parts Catalog 9905 Rev. 0 3

114 Polaris TOOL KIT Illustrated Parts Lists Applies to R06RF68AA [ E06] Parts Catalog 9905 Rev. 0

115 Illustrated Parts Lists TOOL KIT Polaris Applies to R06RF68AA [ E06] Ref Part No Qty Part Description Gauge, Tire Pressure SCREWDRIVER WRENCH, OPEN 8-0 Wrench, Open - SOCKET, SPARK PLUG HANDLE, SPARK PLUG SOCKET Pouch, Tool Kit Manual, Owner's, '06 Ranger 700 x/6x6 Wrench, Torx, T-7 Wrench, Spanner, Cam Kit, Tool Notes [Incl. -7,9] Parts Catalog 9905 Rev. 0 5

116 Polaris TRANSMISSION MOUNTING Illustrated Parts Lists Applies to R06RF68AA [ B0] 6 Parts Catalog 9905 Rev. 0

117 Illustrated Parts Lists TRANSMISSION MOUNTING Polaris Applies to R06RF68AA [ B0] Ref Part No Qty 6 AR Part Description Bolt Nut Asm., Main Gearcase Clamp, Hose Line, Fuel Clip, Rosebud Clip Nut, Flange Bracket, Transmission Mount, Rear Nut Bracket Mount, Transmission Engine, Black Notes Parts Catalog 9905 Rev. 0 7

118 Polaris WHEEL, FRONT Illustrated Parts Lists Applies to R06RF68AA [ B3] 8 Parts Catalog 9905 Rev. 0

119 Illustrated Parts Lists WHEEL, FRONT Polaris Applies to R06RF68AA [ B3] Ref Part No Qty Part Description Bolt Disc, Brake, Front Stud Hub, Wheel Rim, Front, Black Tire, Front, 5x0- Washer, Flat Nut, Flanged Washer Nut, Slotted Cover, Hub, Dust Pin, Cotter Valve, Rim Notes Parts Catalog 9905 Rev. 0 9

120 Polaris WHEEL, REAR Illustrated Parts Lists Applies to R06RF68AA [ C08] 0 Parts Catalog 9905 Rev. 0

121 Illustrated Parts Lists WHEEL, REAR Polaris Applies to R06RF68AA [ C08] Ref Part No Qty Part Description Cover, Dust, Hub Pin, Cotter Washer, Cone Rim, Rear, Black Hub, Rear Wheel Disc, Brake, Rear Bolt Tire, Rear, 5x- Stud Valve, Rim Washer, Flat Nut, Flanged Nut, Castle Notes Parts Catalog 9905 Rev. 0

122 Part Number Index The Part Number Index is a numeric index of all part numbers included in this manual. The index shows what page(s) the part is used on. Part Number Page ,, 7, 73, 85, 9, 03, 05, 07,, , , 63, 67, , Part Number Page , , , Part Number Page , , , , , , , , , , , , , , Part Number Page , , , , , , , Parts Catalog 9905 Rev. 0

123 Part Number Index (continued) Part Number Page , 73, , 59, , , , Part Number Page , , Part Number Page , Part Number Page , , , , 5, , 73, 75, , 95, Parts Catalog 9905 Rev. 0 3

PARTS MANUAL PN and MICROFICHE PN /04. SPORTSMAN MV7 Model #A05MH68AP. E 2004 Polaris Sales Inc.

PARTS MANUAL PN and MICROFICHE PN /04. SPORTSMAN MV7 Model #A05MH68AP. E 2004 Polaris Sales Inc. PARTS MANUAL PN 0 and MICROFICHE PN 0/0 SPORTSMAN MV Model #A0MHAP E 00 Polaris Sales Inc. This page left blank intentionally. A A -ARM MOUNTING... AIR BOX... TABLE OF CONTENTS Parts Manual C B B BRAKE