PARTS MANUAL PN and MICROFICHE PN /03. OCTANE Model #W045402DA. E 2003 Polaris Sales Inc.
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1 PARTS MANUAL PN 0 and MICROFICHE PN 00 /0 OCTANE Model #W00DA E 00 Polaris Sales Inc.
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3 TABLE OF CONTENTS OCTANE W00DA Parts Manual BATTERY BOX... BILGE PUMP... CARBURETOR... COOLING... CRANKCASE... CRANKSHAFT and PISTON... CYLINDER & MANIFOLD... DECALS... DRIVE SYSTEM... B C D E A B B B B B0 B A A0 ELECTRICAL BOX... B- ENGINE HOOD... A ENGINE MOUNT... A EXHAUST... A FLAME ARRESTOR... FUEL SYSTEM VENTING... FUEL TANK... F M MAGNETO... PROPULSION P... STARTING MOTOR... STEERING... STEERING HANDLEPOLE... TOOL KIT... TRIM AND BUMPERS... WATER INLET S T W... B A A B A B A A B A B The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
4 TRIM AND BUMPERS OCTANE W00DA E 00 Polaris Sales Inc. -00 Pad, Footwell, Cap, Starboard -00 Pad, Footwell, Cap, Port 0-00 Pad, Footwell, Tray -00 Pad, Footwell, Port, Side A 0-00 Pad, Footwell, Front 00 Eyes, Bow 0 Rail, Rub 0-00 Pad, Footwell, Starboard, Side /0
5 ENGINE HOOD OCTANE W00DA 0 E 00 Polaris Sales Inc. Screw 0 Bracket, Hood Latch Receiver Washer, Flat 0 Nut, Nylok 0 Pad, Handlepole 0 0 Hood Seal, Hood Pad, Handlepole (Incl. Cover) Pad, Cover, Handlepole 00 Cable Tie A Grommet, Deck, Wire Harness 0 0 Screw Washer, Lock 0 Bracket, Front Hood Latch Washer 0 Nut, Nylok Tube, Air Vent, Hood 00 Asm., Latch, Adjustable /0
6 DECALS OCTANE W00DA 0 E 00 Polaris Sales Inc. 0 Decal, POLARIS, Compartment Door 0 00 Decal, Top Graphic, Port Decal, Top Graphic, Starboard 0 Decal, Warning, Gas and Oil 0 Decal, Nose Graphic, Port 0 Decal, Nose Graphic, Starboard 0 Decal, Side Name, POLARIS 0 0 Decal, Mainside, Port Decal, Mainside, Starboard A 0 Decal, Spark Ignition Complies w/canada 00 Decal, Warning, View 0 0 Decal, Capacity 0 Decal, Warning 0 Decal, Caution, Capsize Decal, Competition Only /0
7 FUEL TANK OCTANE W00DA E 00 Polaris Sales Inc. 0 0 D-Hook 0 Strap, Rubber 0 Asm., Sender, Pickup 00 Clamp, Hose Hose, Inlet Nut, Inlet Seal, Inlet Rivet 000 Chain, Bead, Cap Retainer 0 Screw 00 Coupling, End, Cap Chain 0 Asm., Cap, Ratchet 0 Seal, Cap A Inlet 00 Clamp, Hose 0 Tank, Fuel Bracket, Strap 0 Pad, Tank 0 Pad, Tank, Rear 0 Washer Washer, Lock 0 Screw 00 Clamp, Hose 00 AR Line, Fuel 000 Filter, Fuel /0
8 FUEL SYSTEM VENTING OCTANE W00DA E 00 Polaris Sales Inc. 0 Grommet, Vent 00 Cable Tie 00 Cable Tie 00 Valve, Check, Relief 00 Clamp, Hose A 0 Valve, Vacuum Check 00 AR Line, Fuel 00 T-Clip 0 T-Fitting /0
9 STEERING OCTANE W00DA 0 0 E 00 Polaris Sales Inc Asm., Steering (Incl.,-,-) Screw Nut, Nylok Grip, Handlepole 0 Washer, Flat Pin, Retaining Block, Throttle, Split Nut, Lock Pad, Handlebar 0 Crossbrace, Handlebar 00 Cable Tie Clamp, Handlebar 0 Handlebar 00 Switch, Stop 00 Lanyard w/whistle 0 Screw Clamp, Handlebar Nut, Nylok A Washer 0 Bearing, Cup, Sealed 0 Screw Bushing 0 0 Nut, Hex, Nylok Plate, Cover, Steering Plate, Mount, Steering Shaft, Steering Washer, Flat Turnplate, Steering 0 Screw 000 Cable, Throttle 00 Asm., Switch, Start Bracket, Starter Button 0 0 Screw Clamp, Slip Throttle Block 0 Ring, Retaining 0 Lever, Throttle Control, Finger /0
10 STEERING HANDLEPOLE OCTANE W00DA E 00 Polaris Sales Inc. 0 0 Screw Washer 000 Rod End 0 Nut 00 Cable, Steering 0 Nut, Nylok -00 Asm., Handlepole 0 Bushing, Handlepole 0 Spring, Handlepole 0 0 Bolt, Handlepole Washer, Flat 0 Screw 0 Washer, Lock A Bracket, Handlepole Nut 0 Nut, Steering Cable Nozzle, Steering 0 Screw Washer, Lock 0 Screw Bracket, Steering Cable 0 Clip, Latch Handle Pole Washer, Handle Pole Latch Latch, Handle Pole Pin, Latch Handle Pole /0
11 DRIVE SYSTEM OCTANE W00DA E 00 Polaris Sales Inc Impeller (See Propulsion Pg. A, Ref. ) Screw Washer, Lock Shroud, Coupler 0 Bumper, Drive Shaft 0 Shaft, Drive Coupler, Drive Shaft 0 Cushion, Rubber, Drive A0 Coupler, PTO 0 Screw 0 Washer, Lock Washer, Flat 0 0 Asm., Bearing Housing, Driveshaft Bearing Seal, Bearing, Carrier Pin, Dowel Ring, Retaining /0
12 PROPULSION OCTANE W00DA E 00 Polaris Sales Inc Asm., Pump (Incl.,,,,,) Screw 0 Collar, Steering Nozzle Nozzle, Steering Nozzle, Exit Sleeve, Exit Nozzle Cone, Pump, Stator 0 O-Ring 0 O-Ring 00 Bearing Stator, Pump 0 00 Spacer, Bearing 00 Spacer, Impeller A Impeller Seal, Impeller/Shaft Housing, Pump Seal, Pump, Intake 00 Seal, Bearing, Stator 0 Washer, Lock Screw Washer, Flat 0 Shaft, Stub O-Ring, Cone Pump, Stator 0 Screw, Tailcone 0 Bolt, Pump /0
13 EXHAUST OCTANE W00DA E 00 Polaris Sales Inc Screw Headpipe, Exhaust Kit, Exhaust (Incl. ) 0 Clamp, Coupler, Exhaust Hose, Coupler, Exhaust 0 Chamber, Exhaust 00 Clamp, Hose Hose Waterbox, Exhaust 0 D-Hook 0 Strap, Rubber 0 Screw Washer, Lock Washer A Bracket, Strap Pad, Waterbox Tube, Exhaust, Extension Gasket, Outlet Outlet, Exhaust 0 Rivet 0 Gasket, Exhaust Plate, Adapter 0 Gasket, Manifold/Adaptor Manifold, Exhaust 0 Gasket, Manifold/Headpipe 0 Screw, Socket Head 0 Screw 0 Washer, Lock /0
14 ENGINE MOUNT OCTANE W00DA E 00 Polaris Sales Inc. 0 0 Kit, Short Block Decal, Emission, Exempt Screw 0 Washer, Lock Washer Shim, Slotted A Mount, Motor 0 Washer, Flat 0 Screw 0 Bedplate, Engine Washer, Flat Bolt /0
15 BATTERY BOX OCTANE W00DA E 00 Polaris Sales Inc Cover, Battery 0 Grommet, Vent 00 Connector 00 Cable Tie Tube, Battery Vent Bracket, Strap Screw Washer A Pad, Battery 0 Tray, Battery D Hook 0 Strap, Rubber, Battery 000 Battery, Marine 00 Cable, Ground, Battery/Engine 00 Kit, Battery Bolt /0
16 COOLING OCTANE W00DA E 00 Polaris Sales Inc. 0 0 Fitting, 0 Degree 00 Clamp, Hose AR Line, Fuel Tube, Inlet 0 T-Fitting B 0 Fitting, Water Fitting, Flange 00 Gasket, Water, Manifold Washer, Lock 0 0 Screw /0
17 WATER INLET OCTANE W00DA E 00 Polaris Sales Inc. Plate, Ride Scoop, Inlet Grate, Inlet 0 Screw, Grate, Inlet B Screw Washer, Lock 0 Screw 0 Screw /0
18 BILGE PUMP OCTANE W00DA E 00 Polaris Sales Inc. Gasket - Fitting, Thru Hull, 0 Degree 00 Cable Tie B 0 Asm., Bilge w/connector Harness, Bilge 00 Clamp, Hose Hose /0
19 FLAME ARRESTOR OCTANE W00DA E 00 Polaris Sales Inc Screw 0000 Knob 00 Cable, Choke B 00 Clamp, Hose 000 Arrestor, Flame /0
20 ELECTRICAL BOX OCTANE W00DA 0 Top View E 00 Polaris Sales Inc B
21 ELECTRICAL BOX OCTANE W00DA 0 Harness, Circuit Breaker/Solenoid 0 Harness, Start/Stop Controls 00 Anchor, Cable Tie 00 Cable Tie 0 Insulator, Cable 0 Nut Washer, Lock 00 Solenoid, Starter, Waterproof 0 Nut, Nylok 0 Strap, Battery Holddown D-Hook 00 Fuse, Amp 00 Fuse, / Amp 0 Harness, Jumper Screw Washer Bracket, E-Box 0 Latch, Electrical Box Pin, Latch, Electrical Box 0 00 Controller, Ignition 00 Asm., Strap Grounding w/fuses 0 Nut, Nylok Washer, Flat 0 Screw 00 Regulator 00 Cable, Battery/Solenoid 00 Cable, Solenoid/Starter O-Ring 00 Boot, Threaded 0 Bolt Washer, Flat Plate, Stator 0 Decal, Electrical Box Reset 0 Harness,WireStator Cover, Electrical Box Seal, Plastic, Electrical Box 0 Bracket, Coil 00 Coil, Ignition 00 Asm., Terminal Board 0 0 Breaker, Circuit Asm., Electrical Box, Ignition (Incl.,,,) Grommet, Solid 0 Cap, Grommet, Electrical Box /0 B
22 TOOL KIT OCTANE W00DA E 00 Polaris Sales Inc. Asm.,ToolKit(Incl.-) Socket, Spark Plug Wrench, Open End Screwdriver, Standard/Phillips 00 Pouch, Tool Kit B 0 Wrench, Allen, Plated, / 00 Asm., Fire Extinguisher Container Cover, Fire Extinguisher Container, Fire Extinguisher Manual, Owners, 0 PWC /0
23 CRANKCASE OCTANE W00DA E 00 Polaris Sales Inc. 0 0 Stud, Cylinder Flange 00 Kit, Crankcase (Incl. -,-) 00 Pin, Dowel 0 Fitting, Straight O-Ring 0 Plug, Hole, Timing Bushing Bushing 0 Washer, Thrust 0 0 Spring 0 Gasket, Flywheel Cover 0 Bushing B Screw 0 Cover, Oil Pump Mount 0 Screw Gasket, Oil Pump 0 Screw 0 Asm., Flywheel Cover (Incl. ) Screw 0 00 Pin, Dowel 0 Asm., Flywheel Housing (Incl.,0) 0 Plug Screw Screw /0
24 CYLINDER & MANIFOLD OCTANE W00DA E 00 Polaris Sales Inc Plug, Spark Bolt 0-0 Cover, Head Screw 0 O-Ring Ring, Head 0 Head, Cylinder O-Ring O-Ring 0 0 Nut 00 Cylinder B Gasket, Cylinder Base 0 Asm., Valve, Reed Stuffer, Reed Block Screw 0 Screw 0- Manifold, Intake 00 Gasket, Carb 00 Gasket, Carb, Upper 0 0 Adaptor, Flame Arrestor 0 Screw /0
25 CRANKSHAFT and PISTON OCTANE W00DA E 00 Polaris Sales Inc Kit, Crankshaft (Incl. 0,-0) 00 Circlip, Piston 00 Pin, Piston Kit, Piston Rings, Std. ( Rings) Kit, Piston Rings,.mm OS Kit, Piston Rings,.0 mm OS Kit, Piston, Std. (Incl.-) Kit, Piston,. mm OS (Incl.-) Kit, Piston,.0 mm OS (Incl.-) 00 Kit, Connecting Rod (Incl. -) Bearing, Connecting Rod (0 mm) Washer, Thrust Pin, Crankshaft Bearing, Connecting Rod 0 0 Bearing, Ball B0 0 Seal, Flange 0 O-Ring Collar, Crankshaft 0 Bushing Crankweb, PTO Crankweb, Center 0 Labyrinth Bearing, Ball Crankweb, Magneto 0 Key, Woodruff 00 Seal Washer (See Magneto Pg. B, Ref. ) Nut, Hex (See Magneto Pg. B, Ref. ) 0/0
26 CARBURETOR OCTANE W00DA E 00 Polaris Sales Inc. 0 Fig Asm., Carb 00 Kit, Carb Rebuild (Incl. 0,) 00 Screw, Fuel Pump 00 Kit, Fuel Pump Body 00 Kit, Gasket, Fuel Pump 00 Hose, Fuel 00 Cable Tie 00 Jet, Block, Rear 00 Joint, Connecting 00 Tube, Rubber 00 Screen, Fuel Strainer 0 00 Kit, Needle Valve ( Per Carb) 00 Jet, Main (Per Carb) #0 00 Jet, Pilot,# 00 Screw, Jet Block Cover 00 Cover, Jet Block 000 Kit, Diaphragm, Jet Block (Per Carb) B 00 Screw, Jet Block 00 O-Ring, Jet Block 00 Collar 00 O-Ring, Valve Seat 0 00 Kit, Check Valve ( Per Carb) 000 Cap, Limiter 000 Kit, Main Mixture Screw ( Per Carb) 00 Kit, Idle Stop Screw 00 E-Clip 00 Washer, Plain 00 Lever, Synchronizing 00 Washer, Lock 00 Nut, Throttle Shaft 00 Kit, Synchronizing Screw Plate, Connecting 00 Screw, Connecting Plate /0
27 MAGNETO OCTANE W00DA E 00 Polaris Sales Inc Asm., Wire, Spark Plug Asm., Wire, Spark Plug 0 Nut, Hex 0 Washer 00 Asm., Flywheel B 0 Screw 00 Asm., Stator Screw Clamp, Stator Wire /0
28 STARTING MOTOR OCTANE W00DA E 00 Polaris Sales Inc Starter, Long Stud 0 Asm., Brush (Incl. -) 00 Asm., Bendix (Incl. -) 0 Bolt, Through 0 Screw 0 Spring, Brush 00 O-Ring 0 Washer 0 Washer, Spring 0 Nut 00 Ring, Rubber 00 Asm., Rear Bracket 0 0 AR Washer, Thrust B 0 Washer, Thrust 00 Asm., Armature 00 Asm., Front Bracket 0 O-Ring 0 Washer 0 Ring, Snap 0 Stopper 0 Cover 0 Spring 0 Bushing, Flanged 0 Washer, Thrust 0 Asm., Gear 00 Asm., Gear (Incl. -) /0
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30 PRINTED IN THE USA PARTS MANUAL PN 0 and MICROFICHE PN 00 /0
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Illustration A Crankcase, Cylinder Illustration A Crankcase, Cylinder Ref.Nr. Item code Quantity Description 1 1113 020 2107 1 Crankcase (1,2,4,5,7,8) 2-11 1 1113 020 2108 1 Crankcase (3,6) 2-11 2 1113
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Illustration A Crankcase Illustration A Crankcase Ref.Nr. Item code Quantity Description 1 1124 020 2116 1 Crankcase 2-15 2 0000 988 5215 1 Connector 3 9371 470 2610 2 Cylindrical pin 5x18 4 1120 162 5200
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Illustration A Crankcase, Crankshaft Illustration A Crankcase, Crankshaft Ref.Nr. Item code Quantity Description 1 1117 020 2106 1 Crankcase 2-9 2 9022 341 1050 4 Spline screw IS-M5x25 3 0000 988 5211
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XPEDITION 325 Model #A00CK32AA Rev. 01. E 2000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00
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