800 XCR Model #S03SB8AS Rev. 01. E 2002 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /03

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1 00 XCR Model #S0SBAS Rev. 0 PARTS MANUAL PN and MICROFICHE PN /0

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3 BRAKE B... CARBURETOR... D- CHAINCASE... B CONSOLE... A COOLING SYSTEM... A- CRANKCASE... C CYLINDER... C- DECALS... DRIVE CLUTCH... DRIVE TRAIN... DRIVEN CLUTCH... ENGINE MOUNTING... EXHAUST SYSTEM... FRONT SUSPENSION... FRONT SUSPENSION... FRONT TORQUE ARM... FUEL PUMP... C D E F H TABLE OF CONTENTS Parts Manual B A C B C C C B B B D HOOD... A- HOOD - FOAM/FOIL... A M MAGNETO... D NOSEPAN... A- OIL PUMP... OIL TANK / AIR BOX... P PISTON and CRANKSHAFT N O... RAIL MOUNTING (SUSPENSION)... REAR TORQUE ARM... RECOIL STARTER... S R C C C B B C SEAT and GAS TANK... A SHOCK, FOX - GAS, REAR TRACK... C SHOCK, RYDE FX, FRONT TRACK... B SHOCK, RYDE FX, IFS... C SKI... B STEERING... B- STEERING - HANDLEBAR... B SUSPENSION... T B TOOL KIT/BOX... TUNNEL... WATER PUMP W... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. D A C

4 TUNNEL 0 0 Rivet Guard, Chaincase Rivet -0 Bulkhead, CRC Grommet -0 Asm., Tunnel (Incl. ) Rivet Rivet - Snowflap -0 Panel, Tunnel Back 0-0 Bumper, Rear -00 Cap, Bumper 0 Washer, Flat 0 Washer, Spring Lock 0 Screw Rivet 00 Snap Pad, Clutch Guard Footrest, LH Footrest, RH Support, Tunnel, LH Support, Tunnel, RH -0-0 Brace, Footrest/Trailing Arm, LH Brace, Footrest/Trailing Arm, RH Guard, Adaptor, Drive 00 Plug, Hole Plug, Hole Plug, Hole /0 A

5 SEAT and GAS TANK 0 A Asm., Seat (Incl. -,-,,) Cover Cap, Fuel Tank Gasket Grommet, Fuel Tank 000 Grommet, Relatch, Inch Bottom 00 Grommet, Relatch, Inch Top Rivet 00 Relatch w/hole, Twist Lock, Inch 0 Nut, Nylon 00 Reflector, Seat, Center 00 Screw -0 Bracket, Seat Mount Washer Rivet Housing, Lens, LH Housing, Lens, RH 000 Bulb, Brakelight 0 0 Lens, LH Lens, RH 0 Screw Retainer, Clip, Tool Pouch Rivet 0 00 Bulb, Taillight Screw Nut, Well 0 Washer Screw 0 Harness, Taillight 0 Pickup w/mesh, Fuel 00 Ring, Compression AR Tubing 0 Flange, Mounting, Fuel Tank 0 Nut, Nylok Grommet 0 Fitting 00 Clamp, Hose AR Tubing 00 Fitting, 0 Degree AR Line, Fuel 00 Cable, Tank Retention 0 Package, Sending Unit Hardware 00 Sender, Fuel Level /0

6 NOSEPAN Brace, Hinge 0 Washer Bolt Retainer, Wire Harness 0 Rivet Nut, FLEXLOC Guide, Hood, LH Guide, Hood, RH 0 Rivet 0 Strap, Hood Latch Brace, Pan, LH Brace, Pan, RH Rivet Cap, Bumper, LH Cap, Bumper, RH Screw 00 Plug, Hole Extrusion, Bumper, Formed, LH Extrusion, Bumper, Formed, RH 00 Clip, Rosebud Bolt -0 Brace, Pan, Lower Rivet 0 Rivet -00 Bumper, Front Nut, Nylok Screw 0 Brace, Pan, Upper /0 A

7 NOSEPAN 0 Foil 0 Tape, Foil Tape, Foil Tape, Foil 00-0 Tape, Foil Foil, Pan, RH 000 Patch, Heat Resistant 0 Rivet 0 Decal, Troubleshooting, XTRA- Clip, Belt Retainer 00 Pin, Clutch Guard Asm., Clutch Guard (Incl. Decals) 00 Decal, Engine and Clutch Rivet Rivet 00 Clip, Dart Plug, Hole Nosepan Plate, Backer 0 0 Plug, Hole Rivet /0 A

8 HOOD 0 0 A

9 HOOD Windshield, Inch, Flared, Smoke 0 Rivet, Plastic 0 Nut 0 Washer, Split Lock 0 Washer, Flat 0 Bracket, Speedometer/Tachometer Foam, Pre-Filter Cover, Intake 0 Spacer, Fuel Gauge Bracket Housing (Incl. Warning Decals) 00 Cushion, Rubber Tachometer Bulb, Replacement 0 Knob, Trip Odometer Speedometer Bulb, Replacement 0 0 Cable, Speedometer Foil, Tape 0 00 Gauge, Fuel, Inch, Backlit Fuse 00 Cushion, Fuel Gauge 0 Bracket, Fuel Gauge, Inch 0 Washer, Flat 0 Nut 0 Washer, Split Lock 0 00 Cable Tie 0 Harness, Headlight Rivet 0 Cup, Hood Latch Screw 0 Retainer 00 Rosebud Rivet Clip, Pigtail 0 Washer Cable, Hood, LH Cable, Hood, RH 0 Rivet -0 Tubing, Convoluted Duct,Air,Hood /0 A

10 HOOD Mount, Headlight Screw 00 Nut, U-Type Speed 0 Asm., Headlamp (Incl. Bulbs) 0 Bulb, Headlight 0 Bulb, Halogen 000 Fastener, U-Type Clip Lens/Reflector, LH Lens/Reflector, RH Seal, Reflector, SRP - Asm., Hood (Incl. Foam/Foil) Cover, Access Headlight 0 Rivet, Plastic Lock Screw 00 Knob, Headlight Adjust 0 Hinge, Upper, LH Hinge, Upper, RH Plate, Bolt Screw Bolt, Carriage Nut, Nylok 0 Plate, Hinge, Lower Brace, Hood, Upper Brace, Hood, Lower Rivet 0 Spring, Extension 00 Ring, Spring Attachment 00 Clamp, Retainer Screw Screen, Front Foam, Headlight Seal 0 Foam, Headlight Seal 00 Spring, Headlight Adjust Bolt, Tee, Adjuster /0 A

11 HOOD - FOAM/FOIL 00 Foil, Heat Shield, Hood Foam, Hood, Center Foil, Hood Tab Foil, Front, LH Foam, Hood, LH -0 Screen, Hood, RH Screw 000 Fastener, U-Type Clip -0-0 Screen, Hood, Front, Upper, LH Screen, Hood, Front, Upper, RH -0-0 Screen, Hood, Front, Lower, LH Screen, Hood, Front, Lower, RH Rivet -0 Screen, Hood, LH /0 A

12 DECALS 0 Kit, Hood Decals, 0 00 XCR (Incl.,,,) 00 Kit, Decal Application Solution (For Seat Decals) 00 Decal, Hood Center, POLARIS Decal, Hood Center, XCR Decal, Suspension Set-Up Decal, Seat, POLARIS, LH Decal, Seat, POLARIS, RH 00 Decal, Track/Seat, English/French Decal, Pan, Variable Exhaust System, LH Decal, Pan, Variable Exhaust System, RH Decal, 00 Triple Cylinder, LH Decal, Triple Cylinder 00, RH Decal, Hood Side, XCR, LH Decal, Hood Side, XCR, RH 0 Decal, Trailing Arm, INDY, LH Decal, Trailing Arm, INDY, RH 0 Decal, NO PASSENGER Warning, English/French, LH/RH Decal, Warning, English/French /0 A

13 CONSOLE Footrest 0 ON/ Prem. ON/ Reg. 0 Screw Spacer 00 Regulator, LR Nut, Nylok 0 Housing, Connector 0 Socket 00 Cable Tie 000 Terminal, Ring 000 Housing Harness, Main Wire 0 Decal, Choke 00 Decal, Ignition, OFF/PREM/REG Screw 0 Kit, Ignition Switch 00 Cable, Choke (Incl.,) 0 Kit, Choke Control Washer 000 Cable Tie 0 Rivet 0 0 Guide, Recoil Nut, Choke Cap w/key NOTE: When ordering ignition key PN 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 0 Console /0 A

14 COOLING SYSTEM A

15 COOLING SYSTEM Screw Washer, Flat 0 Plug, Thermo 0 Gasket 0 Sensor, Water Temperature 0 Autostat, 0 Degree 0 Housing, Thermostat Hose, Stat Out/Brake In Hose, Brake Cooler, -Way 000- Line, Fuel 0 Cap, Pressure Bolt 0 Washer 00 Nut, Chimney Tank, Coolant 00 Clip, Rosebud 00 Clamp, Springband Rivet Bracket, Tank, Surge 0 0 Spring, Hose Retainer Hose, Footrest/Tee, RH 00 Cooler, Side, RH Hose, Strip Cooler/Tank 00 Cooler, Wear Strip Rivet Hose, Cooler, Rear Wear Strip 00 Cooler, Side, LH Guard, Cooling, LH Guard, Side Cooler, RH 00 Clamp, Hose 0 00 Clamp, Springband Hose, Tee/RH Wear Strip 00 Clamp, Springband 0 Exchanger, Close-Off Hose, Crossover Hose, Front Cooler/LH Footrest Hose, Center Cooler/Top Surge 00 Clamp, Springband Tubing, Convoluted 00 Cable Tie, Inch 0 00 Connector Hose, Coolant Hose, Stat Out/Tank In 00 Clamp Hose, Engine Out/Stat In 000 Gasket, Thermostat 0 Cap, Housing, Thermostat 0 Washer, Spring Lock Screw /0 A

16 BRAKE Kit, Cover Screw 0 Kit, Cover Assembly (Incl.,) Gasket 00 Kit, Park Lever Spring 0 Asm., Master Cylinder (Incl.,,,,,) Screw 0 Kit, Lever Screw 0 Kit, Snap Ring 0 0 Kit, Asm., Master Cylinder Switch, Brakelight 0 Kit, Cartridge Subassembly 0 Asm., Control, LH Button, Switch, HI/LO, LH Control 0 Kit, Pivot Pin 0 Kit, Park Lever and Spring (Incl. ) Asm., Brake Caliper (Incl.,,0) 0 Line, Brake 00 Kit, Clip, Spring (Qty. ) 0 Inlet Kit, Cooler, Water Kit, Gasket, Brake Cooler 0 Screw (Pkg. of ) Bolt 0 Washer, Spring Lock 0 Washer, Flat Guide, Rope 0 Bracket, Caliper 0 Piston and Seal (Incl. ) 00 Kit, Seal 0 Switch, Brake Light 0 00 Kit, Heavy Duty Brake Pad, Type Large (Incl. ) /0 B

17 SKI Nut, Flange Nut, FLEXLOC Washer - Toe, Ski, Screamin Yellow 0 Pin, Cotter Nut 0 Stop, Rubber Retainer, Ski, Rubber -0 Support, Ski, Rubber Nut, Nylok 0 Washer, Flat 0-00 Ski Kit, Skag, Inch, 0 Degree Screw Screw 0 Screw /0 B

18 FRONT SUSPENSION B

19 FRONT SUSPENSION Strap, Spacer, Bottom 0 Nut, FLEXLOC 0 Washer, Thrust Screw Nut, Nylok 0 Nut, Nylon 00-0 Bar, Torsion 0 Bushing, Sway Bar Rivet 0 Nut, FLEXLOC 0 Arm, Steering, LH Arm, Steering, RH Washer, Flat Rivet 0 Bearing, Spherical Ring, Retainer Bolt 0 Washer, Wrought - - Kit, Trailing Arm, LH, Screamin Yellow (Incl.,) Kit, Trailing Arm, RH, Screamin Yellow (Incl.,) Slide, Sway Bar Stop, Steering, LH, Screamin Yellow Stop, Steering, RH, Screamin Yellow 0 Bushing, Flange 0 Bushing 0 Bushing, Flange 00-0 Shaft, Spindle 000 Fitting, Lubrication 0 Bushing 00 Fitting, Lubrication Screw Screw 0 0 Bushing Washer Bushing, Radius Rod, Outer Shock, IFS Retainer, Spring, Slotted Spring, Compression 0 Rod End 0 Nut, Jam - Rod, Radius, Upper, Screamin Yellow - Rod, Radius, Lower, Screamin Yellow Nut, Jam 0 Rod End 0 Rivet Bolt Bracket, Radius Rod, Lower 0 Nut, FLEXLOC -0 Brace, Bulkhead, Front /0 B

20 STEERING B

21 STEERING 0 Rack 0 O-Ring, Teflon 0 Tube, Spacer 0 Asm., Idler Arm (Incl.,) 0 Nut, FLEXLOC 0 Nut, FLEXLOC Washer 0 Bushing 00 Fitting, Lubrication 0 Spacer Asm., Pitman Arm (Incl.,) 00 Rod End, RH 0 Nut Rod, Link, Drag Nut, LH 00 Rod End, LH 0 Bolt 00 Fitting, Lubrication 0 Nut, FLEXLOC Cable Tie Rivet 0-0 Hoop, Steering Nut, FLEXLOC Bolt, Carriage -0 Plate, Bearing Support Washer Rivet Bracket, Torque Stop Nut 0 0 Stop, Torque Boot, Tie Rod -0 Plate, Boot Rivet 00 Clip, Rosebud 0 Screw 0 Washer, Thrust Bolt Screw Nut, FLEXLOC 0 00 Rod End, LH 000 Tie Rod Bolt, Carriage Bracket, Bolt Retaining /0 B

22 STEERING - HANDLEBAR 0 Grip, Handlebar Pin, Retaining 0 Ring, Retaining 0 0 Lever, Throttle Lever w/heater Block, Throttle/Brake Adaptor, Block Screw 0 Nut, Push-On Emblem, Star -00 Cover, Handlebar 0-00 Slide, Cover 0 Clip, Dart 0-0 Block, Handlebar -0 Handlebar Asm., Control, LH (See Brake Pg. B, Ref. ) Plug, Overflow 0 Heater, Grip, Lo/Med/Hi Screw Nut, FLEXLOC 0 Nut, Nylok 0-0 Post, Steering Screw Holder, Wire 0 Ring, Retaining Screw, Set Washer Switch, Auxiliary Shut-Off 0 Washer /0 B

23 CHAINCASE Asm., Jackshaft (See Drive Train Pg. B, Ref. ) 00 Seal, Oil Screw 0 Nut 0 Bearing, Ball 0 Ring, Retaining Sprocket, T, /W Asm., Tightener Bearing, Chaincase Idler Wheel, Idler Washer, Thrust Pin, Chain Tightener Tightener, Block 0 Washer, Spring B Nut, FLEXLOC 0 Pin, Cotter 0 Gasket, Chaincase 0 Cover, Chaincase Screw Bolt Washer, Spring Chain, 0P, /W Nut, Nylok Sprocket, T, /W 0 0 Plug Chaincase Screw /0

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

25 RAIL MOUNTING (SUSPENSION) Asm., Bogie Wheel, Red (Incl. -) Insert, Wheel ( per Wheel) 0 Bearing, Roller ( per Wheel) 0 Ring, Retaining ( per Wheel) Rivet 00 Cover, Rail Tip Nut, Nylok Bumper, Suspension Angle, Reinforcement Nut, Nylok Nut, FLEXLOC Nut, Nylok Bracket, Rail Reinforcement Bumper, Suspension Angle, Reinforcement Screw Mount, Bumper Bumper, Pivot Arm Bolt 00 Nut 00 Block, Adjusting, Idler Bolt 0 0 Rivet Bolt Washer, Flat Spacer Rivet 0 Spacer, Bogie Wheel Roller, Spring Spacer 00 Bracket, Bogie Wheel 0 Washer Flat 0 0 Washer Washer, Flat Screw 0 Bolt 0 Washer, Split Lock Screw Spacer Screw Asm., Rail, Xtra-, LH (Incl.,,,,) Asm., Rail, Xtra-, RH (Incl.,,,,) /0 B

26 SUSPENSION 0 Screw 0 Washer, Spring Lock Washer Bracket, Shaft Support Nut, FLEXLOC 0 Washer, Flat Washer, Flat Bolt 0 Washer 0-0 Spacer, Idler Bushing Asm., Idler Wheel, Indy Red Ring, Retaining Bearing 0 Wheel Spacer, Idler, Center 00 Shaft Screw 0 Hi-Fax 0 Shaft 0-0 Arm, Pivot, Rear 0 00 Fitting, Lubrication 00 Shaft 00 Shaft, Pivot Arm 0 Track Clip, Slide Clip, Guide /0 B

27 FRONT TORQUE ARM 0 0 Screw 0 Washer, Spring Lock Washer, Flat 0 Shaft -0 Arm, Torque, Front 0 Shield, Spring Nut, Nylok Washer, Flat 00 Fitting, Lubrication 000 Bolt, Eye 00 Bushing 0 Spacer 0 Nut, FLEXLOC 0-0 Spring, Compression 00 Retainer, Spring, Slotted 0 Shock, Front Track Nut, FLEXLOC Washer, Wave Screw 0-0 Arm, Shock Screw Shaft (See Suspension Pg. B, Ref. ) Shaft (See Suspension Pg. B, Ref. ) Spacer 0 Bushing 0 Asm., Wheel Screw Screw Strap, Limiter, Front Shaft, Arm, Pivot (See Suspension Pg. B, Ref. ) Nut, Nylok Bolt, Carriage /0 B

28 REAR TORQUE ARM 0 0 Screw 0 Washer, Spring Lock Washer, Flat Shaft, Rear Torque Arm, Upper 0-0 Arm, Torque, Rear Nut, FLEXLOC Bolt, Carriage Shaft 000 Bolt, Eye 00 Fitting, Lubrication Nut, Nylok Screw 00 Clip, Push-On Roller, Spring Collar, Bearing Lock Screw, Set Asm., Wheel Bearing ( Per Wheel) Ring, Retaining ( Per Wheel) Washer, Thrust Spring, Torsion, LH, Opt. (./) Spring, Torsion, RH, Opt. (./) Spring, Torsion, LH, Std. (./) Spring, Torsion, RH, Std. (./) Spring, Torsion, LH, Opt. (./) Spring, Torsion, RH, Opt. (./) 0 00 Sleeve, Torsion Spring Washer, Flat Strap, Limiter, Rear Screw 00 Bushing Washer, Wave Spacer -0 Rod, Shock Screw 0 Shock, Rear Track, X- 0 0 Bushing Bolt /0 B

29 RYDE FX SHOCK - FRONT TRACK 0 Shock, Front Track, RYDE FX 00 Screw, Valve Asm., Pressure Valve O-Ring IFP Band, Wear, IFP O-Ring 0 Body 00 Nut Subassembly, Piston Band, Wear Washer, Top-Out Washer, Back-Up 0 Asm., Cylinder Head 00 O-Ring 0 Shaft 00 Mount, Upper 0 Sleeve 00 Bushing 00 Nut, Retainer, Spring /0 B

30 RYDE FX SHOCK - IFS 0 Shock, Gas, IFP, IFS, RYDE FX IFP Band, Wear, IFP O-Ring, IFP Subassembly, Piston Band, Wear Washer, Top-Out Washer, Back-Up 0 Body 000 Asm., Cylinder Head 00 Mount, Upper 00 Seal, Rod 00 Seal, Cap 00 Shaft 00 Nut Asm., Pressure Valve O-Ring 00 Screw, Valve 00 Sleeve 00 Bushing 00 Bumper 00 Nut, Retainer, Spring 00 Bushing /0 C

31 FOX SHOCK - GAS, REAR TRACK 0 0 Shock, Rear Track, Fox (Incl. All) 00 Bushing 000 Asm.,Air Valve 000 Screw 00 Bushing 00 O-Ring 00 Piston, Floating 0000 Bearing 0000 O-Ring 000 Plate, Backup 000 O-Ring 000 Shaft, U-Cup 000 Wiper, Shaft 000 Shaft 000 Eyelet 00 Bearing 0000 O-Ring 000 Plate, Top-Out 0000 Bearing, Piston 000 Nut, Lock Body 000 O-Ring 000 Screw 000 O-Ring 00 Cap, Body /0 C

32 DRIVE CLUTCH 0 Kit, Wide Roller Spider Rebuild (Incl. -,,,) Bolt 0 Washer, Spring Lock Cover, Bearing Ring, Retaining, Cover 0 Spring, Clutch, Almond 00 Nut, Jam 0 Washer, Multilube Roller and Bushing 0 Button, Guide AR AR AR AR Spacer (.00) Spacer (.0) Spacer (.0) Spacer (.00) Weight/Bushing (-0) Pin, Weight, Hardened 0 Insert, Moveable 0 Bearing, Sleeve Nut, FLEXLOC 00 Pin, Roller 00 Kit, Drive Clutch Shim Asm., Drive Clutch, Basic (Incl. All Less,) /0 C

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

34 EXHAUST SYSTEM 0-0 Bracket, Resonator, Front Rivet -0 Bracket, Resonator, Rear Rivet 0 Spring, Resonator 0-0 Resonator 0-0 Outlet, Stinger Rivet Rivet Support, Pipe 0 Seal, Exhaust, Socket, Rear 0 Spring 0 Seal, Exhaust, Socket, Front 0-0 Pipe, Head, MAG 0-0 Pipe, Head, Center 0-0 Pipe, Head, PTO Gasket, Exhaust (See Cylinder Pg. C, Ref. ) Washer (See Cylinder Pg. C, Ref. ) Bolt (See Cylinder Pg. C, Ref. ) Pipe, Tuned, PTO Cover, Pipe, Half, A, PTO Cover, Pipe Half, B, PTO Matte, Pipe, Half Band, Muffler, Inch Dia. Pipe, Tuned, Center Cover, Pipe, Half, A, Center Cover, Pipe, Half, B, Center Matte, Pipe, Half Band, Muffler, Inch Dia. Pipe, Tuned, MAG Cover,Pipe,Half,rd,A,MAG Cover,Pipe,Half,rd,B,MAG Cover, Pipe, Half, nd, A, MAG Cover, Pipe, Half, nd, B, MAG Matte, Pipe, Half nd, A, MAG Matte,Pipe,Half,rd,MAG Matte, Pipe, Half, nd, B, MAG Band, Muffler, Inch Dia. /0 C

35 ENGINE MOUNTING Screw 00 Washer Washer, Clutch Retainer Asm., Drive Clutch (See Drive Clutch Pg. C, Ref. ) 00 Cable, Throttle 00 Plug, Spark, RNC, Champion 00 Engine, Short Block ECPL0 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. 00 Cable Tie -00 Handle, Recoil 00-0 AR Conduit Hose, Water Trap, Degree Plug, Trap 0000 Clamp, Hose 0 Mount, Engine Plate, Engine, RH Washer, Flat Washer, Spring Lock Bolt 00 Nut, FLEXLOC 0 Washer, Flat Washer, Flat 0 Mount, Stud, Engine Plate, Engine, LH 00 Cable Tie 00 Clamp, Hose 0 Valve, Fuel Shut-Off AR Tubing AR Tubing AR Line, Fuel /0 C

36 OIL TANK / AIR BOX Foam, Intake Inlet, Plenum Plenum 0 Decal, Fuel Shut-Off Bracket, Shut-Off Valve Screw Washer, Flat Nut, Well 0 Washer, Tooth, External Screw 0 Fitting Boot Bracket, Air Box Rivet Box, Air, Bottom Seal, Plenum Boot, Cone, Outlet 0 Decal, Air Box Caution 00 Decal, Adjustable Driven Clutch 0 0 Decal, Greasing 0 Washer, Flat Bolt Screw 0 Washer, Flat Gasket, Oil Cap 0 Cap, Oil Tank Sensor, Oil Level 00 Nut, Chimney 00 Fitting, 0 Degree AR Line, Fuel 0 Decal, Low Oil Level 0 Bushing 0 Bracket, Oil Tank Bolt 0 Fitting, / Inch Outlet Line, Oil 000 Filter 000- AR Line, Fuel 0 Bracket, Oil Tank 0 00 Clamp, Hose 000 Clamp, Hose 0000 Clamp, Hose 00 Clamp, Hose Tank w/sending Unit Hole, Oil /0 C

37 CRANKCASE 0 Nipple, Elbow 0 Asm., Crankcase (Incl. -,-,) 0 Stud 00 Pin, Dowel 0 Seal, Oil 0 Gasket 0 Bolt, Flange 00 Bolt and Washer 00 Bolt and Washer 0 Bolt and Washer 0 Pipe 00 Bolt and Washer 0 Stud 0 Seal, Oil 0 Pipe /0 C

38 CYLINDER C

39 CYLINDER 00 Bolt and Washer 0 Manifold, Outlet 00 Plug, Vent, Air 0 Gasket, Aluminum 0 Gasket, Manifold 0 Cover, Head 0 Bolt, Flange 0 Bolt, Flange 0 O-Ring 0 O-Ring 00 Head, Cylinder 00 Pin, Dowel 0 O-Ring 0 Nut, Flange 0 Gasket, Exhaust 00 Bolt 000 Washer 0 Cylinder (Incl. ) 0 Gasket, Cylinder 0 0 Gasket, Cover, Inlet 0 Cover, Inlet 0 O-Ring 0 Bolt, Flange 0 Adjuster, Spring 0 O-Ring 0 Bolt, Flange 00 Cover, Valve, Exhaust 00 Spring, Valve, Exhaust 0 Cap, Valve, Exhaust 0 0 Bolt 0 Bellows, Valve, Exhaust 0 Washer 0 Housing, Valve, Exhaust (Incl. ) 0 Pin, Dowel 0 Gasket, Valve, Exhaust 0 Valve, Exhaust 0 Screw and Washer 0 Stopper 0 Valve 0 0 Asm., Reed Valve (Incl.-) 0 Stuffer, Valve, Reed 0 Adapter 0 Gasket 0 Valve, Check 0 Bolt 0 Bolt, Flange 0 Nut, Flange 0 Screw 0 Asm., Band (Incl. ) /0 C

40 PISTON and CRANKSHAFT 0 0 Piston Set 0 Clip, Piston Pin 00 Ring, Piston 0 Pin, Piston 00 Spacer, Pin, Crank 00 Rod, Connecting 0 Bearing, End, Small 0 Bearing, End, Large 0 Pin, Crank 0 Pin, Crank 000 Key, Woodruff 0 0 Asm., Crankshaft (Incl.,,-,,-) Crankshaft 00 Nut 0 Washer 00 Bearing 0 Bearing 0 Spacer 0 Bearing 0 0 Crankshaft, Center (Incl.,,-,,0) Crankshaft, Mag (Incl. ) 0 0 Crankshaft, PTO (Incl. ) 0 Crankshaft /0 C

41 RECOIL STARTER 0 0 Screw, Set 00 Washer 0 Spring, Spiral 0 Mark, Timing 00 Bolt and Washer 0 0 Starter, Recoil (Incl. -,-,,0) Case, Starter 0 Guide, Rope 0 Bolt and Washer 0 Spring, Return 0 Ratchet 00 Bush 0 Spring, Friction 0 Plate, Friction 0 Washer 0 Bolt and Washer 0 Bolt and Washer 00 Washer 0 Pulley, Starting 0 Reel 0 0 Rope, Starter /0 C

42 WATER PUMP 0 00 Pin, Dowel 0 0 Bolt, Flange 0 Pin, Dowel 0 0 Bearing 0 Shaft, Pump, Water 0 O-Ring 0 Bearing 0 Bolt, Flange 00 Bolt and Washer 0 Gasket 00 Bolt Asm., Water Pump (Incl.,-,-,-) Casing, Pump (Incl. ) 0 Gasket, Aluminum 00 Plug, Vent, Air 0 Screw and Washer 0 Impeller 0 Plate, Sealing 0 Seal, Mechanical 0 Pump, Water (Incl.,,,,) 0 0 Gasket, Pump, Water /0 C

43 OIL PUMP 0 0 Clamp, Hose 0 Pipe, Rubber 0 Connector, T-Type 0 Pipe, Vinyl 0 Pipe, Vinyl 00 Asm., Oil Pump (Incl. -) 0 Spring, Return 0 Screw and Washer 0 Collar, Cam Shaft 00 Lever, Control 0 Washer, Spring 00 Nut 0 Packing 0 Screw, Air Vent 0 O-Ring AR AR AR Spacer (.mm) Spacer (.mm) Spacer (.mm) 0 Bush 00 Spacer 0 Gear, Small 0 0 Pipe, Vinyl /0 C

44 CARBURETOR D

45 CARBURETOR 0 Screw 0 Cap, Top 0 Gasket Asm., Mixing Body 0 Asm., Plunger 0 Spring 00 Holder, Guide 0 Cap 0 E-Ring 0 Plate 0 Clip 0 Washer 0 Ring 00 0 Screw (Center and MAG Side) Screw (PTO Side) 0 Ring (Center and MAG Side) 0 0 Asm., Lever (PTO and MAG Side) Asm., Lever (Center Side) 00 Ring (PTO Side) 0 E-Ring 0 Screw 0 0 Plate 0 Packing 0 Needle, Jet (DH0--) 0 Asm, Sensor (MAG Side) Screw (MAG Side) 0 Cap 0 Asm., Piston Valve 0 Spring 0 Cap 0 Adjuster 0 0 Washer 0 Packing 0 Jet, Pilot (#0) 0 Jet, Main (#) 0 Asm., Float 0 O-Ring 0 Body, Float 0 O-Ring 0 Screw 0 Nipple 0 00 Screw 0 Jet, Main (#0) 0 Washer 0 Jet 0 Hose (PTO Side) Hose (Center and MAG Side) 0 Screw Asm., Funnel 00 O-Ring /0 D

46 CARBURETOR PTO Side Center 0 MAG Side Asm., Carburetor (Incl. - and all of Carburetor Pg. D) 0 Screw 0 Lever Asm., Mixing Body 0 Lever, Starter 0 Screw (Center Side) 00 Bracket (Center Side) 0 Screw (Center Side) 0 Spring (Center Side) 0 Screw, Adjust (Center Side) 0 Spring (Center Side) 0 Bracket (Center Side) 0 Screw (Center Side) 0 Spring 0 Ring 0 Asm., Shaft w/throttle Lever 00 Screw (Center Side) 0 Ring 00 E-Ring 0 Spring Asm., Mixing Body 0 Packing Shaft Asm., Mixing Body 0 Asm., Nipple 0 Bolt /0 D

47 MAGNETO 0 Band 0 Screw and Washer 0 Screw and Washer 0 Screw and Washer Asm., Plate (Incl. -,,) Stator 00 Screw and Washer 00 Asm., Flywheel 0 CDI System 00 Cap, Plug, Spark 0 Coil, Ignition 0 Nut, Flange 0 Plate, Coil, Ignition 0 Bolt, Flange /0 D

48 FUEL PUMP Ref. Part No. Qty. Description 0 Asm., Fuel Pump (Incl.,) 0 Diaphragm, Set, Gasket 0 Screw and Washer /0 D

49 TOOL KIT/BOX 00 Kit, Tool (Incl. -) Screwdriver Wrench, - Spanner Box Wrench, Special 0 Wrench, Scissor Stop Manual, Owners, 0 Snowmobile Supplement, Owner s Manual, 0 00 XCR 0 Roll, Tool 00 Strap, Emergency Starter /0 D

50 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...