PARTS MANUAL PN and MICROFICHE PN /03. FRONTIER CLASSIC Model #S04ND7DS Model #S04ND7DSA. E 2003 Polaris Sales Inc.

Transcription

1 PARTS MANUAL PN and MICROFICHE PN /0 FRONTIER CLASSIC Model #S0NDDS Model #S0NDDSA E 00 Polaris Sales Inc.

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3 TABLE OF CONTENTS FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA Parts Manual AIR BOX... C BATTERY BOX... C BRAKE... B CHAINCASE... B0 CHASSIS... A CONSOLE... A COOLING SYSTEM... B CRANKCASE... C CRANKSHAFT... C CYLINDER... D CYLINDER HEAD... D DECALS... A DRIVE CLUTCH... C DRIVE TRAIN... B DRIVEN CLUTCH... C ELECTRIC MODULE (M -0)(ACE)... C ELECTRICAL... C ENGINE MOUNTING... C EXHAUST... D EXHAUST SYSTEM... C0 FOIL/FOAM... A FRONT SUSPENSION... B- FRONT TORQUE ARM (M -0)... B FUEL SYSTEM... D GAS TANK... A HANDLEBAR... B A B C D E F G H HOOD... A0- INTAKE H... I M MAGNETO... N D D NOSEPAN... A- OIL DIPSTICK and FILTER... OIL PUMP... PISTON O P... RAIL MOUNTING (M -0)... REAR SUSPENSION (M -0)... REAR TORQUE ARM (M -0)... RECOIL ASM.... R S D D C B B C D SEAT... A SEAT, ADJUSTABLE... A- SENSORS/SWITCHES/ELECTRICAL... C SHIFT (Reverse Models)... B SHOCK (Front Track)(M -0)... C SHOCK (REAR TRACK)(M -0 ACE)... C SHOCK (REAR TRACK)(M -0)... C SKI... B STARTING MOTOR... D STEERING... B- TOOL KIT... WATER PUMP T W... D D The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

4 CHASSIS FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA 0 E 00 Polaris Sales Inc Asm., Chassis 00 Clamp, Hose Rivet Stop, Torque 0 Mount, Engine, Rear, RH Nut, Nylok 00 Nut, Speed 0 Bolt, Carriage 0 Rivet 0 Mount, Engine, Rear, LH 0 Screw 0 Asm., Bracket, Coil w/nuts 0 Gasket, Seat Base Screw 0 Gasket, Seat Base 0 Backer, Snow Flap Rivet Rivet Screw 0 Washer, Spring Lock 0 0 Washer, Flat -0 Asm., Bumper, Rear -0 Flap, Snow, Long, Black w/chrome A 0 0 Asm., Reflector, Red Asm.,Skirt,Snow/Reflector,LH(Incl.) Asm.,Skirt,Snow/Reflector,RH(Incl.) 0 Strap -0-0 Mount, Toe Clip, Console, LH Mount, Toe Clip, Console, RH -0 Brace, Tunnel Roll, BLK -0-0 Brace, Lower, Tunnel, LH Brace, Lower, Tunnel, RH Support, Footrest, LH Support, Footrest, RH Footrest, LH Footrest, RH Guard, Adapter, Drive 00 Plug, Barbed Grommet, M-0 ACE Pad, Suspension, Front, LH Pad, Suspension, Front, RH 00 0 Kit, Trailing Arm Mount, LH Kit, Trailing Arm Mount, RH 00 Plug, Hole 00 Bushing, Open/Close Rivet Bulkhead, Front 00 Clamp, Nylon /0

5 SEAT FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 0 Asm., Seat (Blue Diamond) Asm., Cover, Seat (Blue Diamond) 000 Grommet, Relatch, Bottom 00 Grommet, Relatch, Top 00 Relatch w/hole, Twist Lock Rivet Housing, Taillight Bulb, Taillight Bulb, Brakelight 0 Lens 0 Screw Rivet 0 Nut, Seat 0 Washer, Flat Screw 0 Harness, Taillight /0 A

6 SEAT, ADJUSTABLE FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc A

7 SEAT, ADJUSTABLE FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA -00 Asm., Seat Bucket Plate, Adjustable Seat 0 Ring, Retaining Cap, Plunger, Seat Base Plunger, Seat Bucket Base, Plunger Cover, Trunk Latch, Trunk 0 Lock, Bracket 0 0 Screw 0 Lock, Adjustable Seat (Incl. ) 000 Key, Adjustable Seat w/keys NOTE: When ordering Key PN 000 be sure to specify dash number as found on Key or Lock Bezel (-0 through -0) 0 0 Asm., Taillight, LH Asm., Taillight, RH 00 Bulb, Taillight 00 Socket, Bulb Nut, Seat Rivet Washer, Belleville Screw 0-00 Trunk, Bottom, BLK Screw Washer 0 Screw, Trunk Lock 0 Washer, Trunk Lock 00 Nut, Trunk Lock Bracket, Pushlock Harness, Taillight 0 Asm., Seat, Adjustable (Blue Diamond) Asm., Seat Cover, Adjustable Seat (Blue Diamond) Flange, Trunk 0 0 Spring, Compression, Lock 0 Spring, Compression, Plunger /0 A

8 GAS TANK FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Cable Tie AR Line, Oil -00 Asm., Cap, Fuel 00 Fitting, 0 Degree 0 Asm., Tank, Fuel (Incl. ) Nut, Nylok 0 Washer, Flat 00 Nut, Speed Bolt, Carriage 0 0 Foam, Seal 00- AR Line, Fuel 00- Tubing, Convoluted 00 Clamp, Hose, Screw Type Pump, Fuel Kit, Fuel Tank Gasket (Incl. Screws) /0 A

9 NOSEPAN FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 0 Rivet -0 Hinge, Pivot, Lower, RH Mount, Upper, Shock, RH 0 Foam, Seal 0 Nut, Flanged, Nylon Screw Mount, Upper Shock, LH Washer Rivet 0 Rivet Rivet 0-0 Bracket, Radius Rod Support 00 Brace, Pan, Lower -0 Hinge, Pivot, Lower, LH Nut, Flanged, Nylok -00 Asm., Bumper, Front Bolt Rivet Shield, Exhaust, Heat, Extended 0-00 Nosepan, Black Nut, Nylok Washer Screw Screw 0 Washer, Spring Lock Guide, Hood, LH Guide, Hood, RH /0 A

10 NOSEPAN FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Plug, Nylon 0 Foil, Nosepan Foil, Nosepan, Shock Tower Foil, Nosepan, Upper, RH 0 Tape, Foil, Nosepan, Lower, RH 0 Foil, Tape 00 Foil, Tape, Nosepan 00 J-Clip, Retainer Rivet 0 Foil Rivet Clip, Retainer, Belt 00 Asm., Clutch Guard A 00 Pin, Clutch Guard Pad, Clutch Guard 00 Decal, Engine and Clutch Rivet 00 0 Decal, Troubleshooting, M-0, Decal, Troubleshooting, M-0 ACE 0 Rivet 0 0 Asm., Reflector, Amber 0 Plug, Hole Plug, Nosepan, Oblong 00 Clip, Routing Plate, Backer, Clutch Guard /0

11 HOOD FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Asm., Hood, Blue Diamond Metallic Harness, Headlight 0 Asm. Headlamp (Incl. Bulbs) 0 Seal, Headlight, One Piece 0 Bulb 00 Retainer, Headlamp Bulb Bolt, Tee Adjuster 0 Spring, Headlight Adjust 00 Knob, Headlight Adjust, Locking Asm., Mirror, LH Asm., Mirror, RH Washer, Flat Nut, Nylok Foam, Prefilter 0 Asm., Plenum/Foil (Incl. -) Plenum, Intake, Hood A0 0 0 Decal, Suspension Set-Up, M-0 Decal, Suspension Set-Up, M-0 ACE 0 Cover, Access, Headlight 0 0 Screw Foil Foil, Plenum Foil Foil, Plenum, LH, Inner 0-0 Hinge, Upper, LH 0 Bolt 0 Washer, Flat Bolt 0 Spacer Nut, Nylok -0 Hinge, Upper, RH /0

12 E 00 Polaris Sales Inc. HOOD FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA Rivet, Plastic, Lock 0 Windshield, Inch 00 Retainer, Windshield 0 Washer, Flat Nut Washer, Lock 0 Washer, Flat 0 Clamp, Back 0 Cushion, Rubber 0 00 Asm., Gauge, Ride Control (M-0 ACE)(Incl.,) 00 Cushion, Rubber 000 Kit, Tachometer (Incl. -) Bulb, Taillight 0 Knob, Trip Odometer Asm., Speedometer Bulb, Taillight A 00 Bracket, Speedometer/Tachometer 0 Nut, Nylok 0 Cable, Speedometer (w/foil) Asm., Fuel Gauge Fuse 00 Cushion, Rubber, Fuel Gauge 0 0 Spacer, Fuel Gauge Bracket 0 Bracket, Fuel Gauge 0 Washer, Flat 0 Washer, Split Lock 0 Nut, Hex 00 Clip, Rosebud 0 Screw Nut, Nylok 00 Cable, Hood Retainer Rivet /0

13 FOIL/FOAM FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. Rivet -00 Closure, Hood, Upper, LH Foil, Tape, Hood, Front Foil, Tape, Hood, Rear 0 Foam, Hood, Rear, LH Foam, Hood, Front, LH Foam, Hood, Center w/channel /0 A

14 DECALS FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Kit, Decal, Hood 0 Frontier Classic 0 Decal, Hood Top, POLARIS, LH (Incl.,-,,,) 0 Decal, Hood Top, POLARIS, RH 00 Kit, Decal Application Solution 00 Decal, Track/Seat, LH/RH, English/French (For Seat Decals) Decal, Seat, POLARIS (Adj. Blue) 0 Decal, Warning, French 0 Decal, Seat, Classic POLARIS (Std. Blue) 0 Decal, Electric Start, Domed Decal, Tunnel, M-0 BY FAST, LH 0 Decal, Warning, English Decal, Tunnel, M-0 BY FAST, RH 00 Decal, Ignition 0 Decal, Tunnel, M-0 ACE, LH 0 Decal, Warning/Rev/Elec. Rev. Opt. 0 Decal, Tunnel, M-0 ACE, RH 0 Decal, Warning, NO PASSENGER Urocal, Classic Decal, Hood Center, Classic Decal, Hood Side, Classic, LH Decal, Hood Side, Classic, RH 00 Urocal, Hood Center, Classic 0 Decal, Pan, LH Decal, Hood Top, FRONTIER CYCLE, LH 0 Decal, Pan, RH Decal, Hood Top, FRONTIER CYCLE, RH 0 0 Decal, Trailing Arm, EDGE IFS, LH 0 Urocal, FRONTIER, CYCLE 0 Decal, Trailing Arm, EDGE IFS, RH Decal, Headlight, LH Urocal, POLARIS Decal, Headlight, RH A /0

15 CONSOLE FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 Screw 0 0 Asm., Console w/foil Foil, Console Side Foil, Console, Louver 0 Decal, No Passenger, Warning 00 Kit, Ignition Switch 00 Decal, Ignition 000 Clip, Plastic, Dart, Nylon 00 Receptacle, Pod Mount 0 Nut, Ignition 0 Cap w/key NOTE: When ordering ignition key PN 0 be sure to specify if for an A,B,C,D, or E switch. Letter code will be labeled on underside of switch body behind console. Key dot code found on key cap (i.e. one dot = A, two dots= B, etc.). 0 Plug, Recoil 00 Cable Tie 0 00 Harness, Fusible Link Relay, Sealed 0 Harness, Main 000 Housing, Pack 00 Housing, Connector Nut, Nylok 00 Screw 00 Control, M-0, ACE /0 A

16 FRONT SUSPENSION FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc B

17 FRONT SUSPENSION FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA 0 Bolt 0 Bushing, Radius Rod, Pivot, Inner Bushing, Shoulder 0 Nut, Nylon 0- Rod, Radius, Upper, Cloud Silver 0 Nut, Jam Nut, Nylok Screw 0 Shock, ifs, Nitrex 0 Ring, Spring Preload, Adjust 00 Retainer, Spring, Slotted 00- Spring, Compression, Cloud Silver 000 Retainer, Spring, Body, Threaded Screw Washer Arm, Steering Washer, Flat - - Asm., Trailing Arm, Cloud Silver, LH (Incl.,) Asm., Trailing Arm, Cloud Silver, RH (Incl.,) 0 Washer, Flat 0 Cup, Mount, Trailing Arm 00 Bearing, Spherical 0 Ring, Retainer 0 Screw 00 Rod End, RH 0 Bushing, Flange 00 Fitting, Lubrication Bushing, Torsion Bar Rivet -0 Bar, Torsion 0 Slide, Torsion Bar 0 Bushing 0 Bushing, Flanged 0-0 Shaft, Spindle, w/steer Stop 000 Fitting, Lubrication, w/ball 00 Bushing 000 Rod End, Radius Nut, Jam 0- Rod, Radius, Lower, Cloud Silver 0 Nut, Nylon 0 00 Rod End, Radius 0 Bushing, Shoulder Bolt /0 B

18 BRAKE FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Kit, Cover Screws 0 Kit, Cover Assembly (Incl.,) Gasket 00 Kit, Park Lever Spring Screw 0 Screw 0 Kit, Lever Screw 0 Kit, Snap Ring Kit, Asm., Master Cylinder, (Incl. -) Switch, Brake Light 0 Kit, Cartridge Subassembly Asm., Control, LH Asm., Control, LH w/shock Adjust B Button, Switch, HI/LO, LH Control 0 Kit, Pivot Pin w/snap Ring 0 Kit, Park Lever and Spring (Incl. ) 00 Line, Brake 00 Kit, Brake Pad, Type Kit, Piston/Seal Kit, Seal 0 Kit, Asm., Brake Caliper (Incl.,) 0 0 Washer 0 Washer, Spring Lock Screw 00 Kit, Pin Retaining 00 Kit, Bleeder Fitting /0

19 SKI FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 Nut, Flange Nut, Nylok Washer - Toe, Ski, Plastic, Cloud Silver 0 Washer, Belle Bushing 0 Stop, Ski, Rubber Nut, Nylok Washer, Flat Asm., Ski Screw Kit, Skag, Dual Bolt 0 Screw /0 B

20 STEERING FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 0 Pin, Retaining 00 Ring, Retaining 0 00 Lever, Throttle Asm., Lever w/heater, HI/LO Block, Throttle/Brake Grip, Handlebar 0 Plug, Overflow Adaptor, Block, Throttle -0 Handlebar Screw 0 Collar, Console, LH Collar, Console, RH 00 Nut, Push-On Emblem, Star -00 Cover, Handlebar 0-00 Slide, Handlebar Cover 00 Clip, Dart, Nylon Asm., Control, LH (See Brake Pg. B, Ref. ) 0-0 Block, Handlebar -0 Post, Steering Nut, Nylok 0 0 Heater, Grip, Lo/Med/Hi 00 Cable, Throttle Screw Holder, Wire 00 Ring, Retaining Screw, Set Washer 00 Switch, Auxiliary Shut-Off 0 Washer /0 B

21 HANDLEBAR FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 Bolt, Carriage 0-0 Hoop, Steering Nut, Flange 00 Clip, Rosebud Bolt, Carriage Rivet 0 Plate, Tie Rod Boot Boot, Tie Rod, LH Boot, Tie Rod, RH 00 Nut, Pal 0 0 Washer, Flat Nut, Nylok 000 Bracket, Steering Post Fitting, Zerk Bushing, Steering Post Bushing, Steering Post 000 Bracket, Steering Post Fitting, Zerk Bracket, Console, Front Neck /0 B

22 STEERING FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Rod End, RH 0 Nut Tie Rod Nut, LH 00 Rod End, LH 00 Rod End, RH Rod, Steering Rack -0 Rod, Draglink B Nut, Nylok 0 00 Rod End, LH 0 Bushing, Reducer 0 Asm., Pitman Arm (Incl.,,) Spacer, Tube Pitman/Idler Arm Screw 0 Bearing, Ball 0 Asm., Idler Arm (Incl.,,) /0

23 COOLING SYSTEM FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 0 Hose, Bottle/Engine In 0000 Clamp, Hose Line, Fuel 0 Bottle, Coolant 0 Cap, Pressure 00 Decal, Water Bottle Cap 000- Line, Fuel 00 Clamp, Springband Hose, Wear Strip/Bottle 0 Rivet 00 Clamp, Springband 0 Hose, Cooling B 0 Exchanger, Rear Seal, Rear Cooler Rivet 0 Cooler, Wear Strip 0 Cooler, Center, Outlet Rivet Hose, Wear Strip/Center Cooler 0 Bracket, Coolant Bottle 00 Cable Tie Tubing, Convoluted Hose, Engine Out/Cooler /0

24 SHIFT FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 0 Handle, Reverse Rivet 00 Pin, Cotter Nut, Nylok Bushing Washer, Wave Nut, Nylok Nut 00 Rod End, RH 0 Bolt Rod, Threaded 0 Nut, Jam Screw 0 Washer, Flat 000 Rod End, LH Actuator, Shift Pin, Clevis 0 Bracket, Shift Lever Guide /0 B

25 CHAINCASE FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Seal, Oil 0 Nut Screw Asm., Tightener, Chain, Quiet 0 Bearing, Ball 0 Ring, Retaining Asm., Dipstick 0 Sprocket, T, /W 0 Washer, Spring 0 0 Nut, Nylok 0 Pin, Cotter 0 Asm., Sprocket, Pinion, T, /W Bearing, Needle 0 0 Asm., Pinion Gear, Spur Bearing, Needle Pin, Dowel Kit, Shift Fork/Shaft (Incl.,) Fork, Shift Gasket, Chaincase O-Ring Cover, Chaincase Screw 00 Seal, Oil 0 0 Ring, Retaining -0 Shaft, Shift Washer, Thrust 0 Chain, P, /W 0 Shaft, Pinion, w/wrench Flats Screw Asm., Jackshaft (See Drive Train Pg. B, Ref. ) 0 Chaincase 0 Plug Bracket, Chain Retention 0 0 Screw Washer 0 Asm., Sprocket, T, /W Bearing, Needle 00 Coupler, Drive 0 Asm., Gear, Reverse 0 Spring, Compression 0 Retainer, Drive Coupler 0 Washer, Spring Lock Screw 0 Screw /0 B0

26 DRIVE TRAIN FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA 0 E 00 Polaris Sales Inc Bolt 0 Washer, Flat AR Washer, Flat 00 Spacer, Input Shaft Asm., Driven Clutch, R (See Driven Clutch Pg. C for Details) 0 Belt, Drive AR Washer AR Washer 0 AR Bushing 0 Nut, Nylok 0 Washer, Flat 00 Flangette w/grease Zerk Fitting, Lubrication 0 Gasket, Jackshaft Bearing Flangette Bolt, Carriage Key Asm., Jackshaft (Incl.,) 0 Ring, Retaining 0 0 Disc, Brake 00 Sleeve, Seal 0 O-Ring Bolt, Carriage Nut, Flange 0 Washer 00 Screw 00 Asm., Drive Shaft (Incl.,,) 0 Asm., Flangette w/screws 00 Bushing, Metal, Speedometer 0 Flangette, Offset, w/hole 00 Key, Square, Speedometer 00 Gasket, Drive Adaptor 0 00 Adaptor w/zerk, Drive Fitting, Lubrication /0 B

27 RAIL MOUNTING (M-0) FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA 0 E 00 Polaris Sales Inc Asm., Rail, M-0, LH Nut, Tension Adjust (Incl. -,,,0,0,) 0 Rivet -0 Asm., Rail, M-0, RH (Incl. -,,,0,0,) 0 Block, Idler Bolt Adjust 0-0 Asm., Rail, M-0, ACE, LH Guide, Slider, LH (Incl. -,,,0,0,) Guide, Slider, RH 0-0 Asm., Rail, M-0, ACE, RH 0 Plate, Coupler Block (Incl. -,,,0,0,) Nut, Nylok Washer Cap, Rail Tip Nut, Nylok (Qty. 0 for ACE) 0 Washer, Flat (Qty. for ACE) Block, Rail Support Rivet Plate, Rail Support 0 Ring, Retaining ( per Wheel) 0 0 Bearing ( per Wheel) 0- Asm., Wheel, Scrolled, Bright Silver Metallic (Incl.,0) Washer, Flat Bumper, Rail Jounce (M-0) Bumper (M-0 ACE) Liner, Bumper (M-0 ACE) 00 Nut (M-0 ACE) 00 Clip, J, Retainer (M-0 ACE) Screw (M-0 Only) Screw B 0 Bolt 0 Block, Slider, Long, M-0, LH Block, Slide, Long, M-0, RH Block, Shock Pivot Threaded (M-0 Only) Bolt (M-0 Only) 0 Nut (M-0 Only) 00 Spacer (M-0 Only) Screw (M-0 ACE) 0 00 Bolt (M-0) Screw (M-0 ACE) Clamp, Reservoir, M-0 (Only) Bolt (M-0 Only) Washer, Spring Bolt Bolt 0 Block, Wheel Mount, LWT Hi-Fax Screw Screw /0

28 REAR SUSPENSION (M-0) FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Nut, Nylok 0 Washer, Flat 0 Nut, Nylok Spacer, Idler Bushing Spacer, Idler, Long 00 Asm., Idler Wheel 00 Shaft, Idler 00- Asm., Idler Wheel, Scrolled, Silver 0 0 Washer, Belle Bolt Screw Screw Screw (M-0 Only) 0 Washer, Spring Lock (Qty. ACE) 0 Washer (Qty. ACE) Block, Shock Pivot Adjust (M-0 Only) 0 Ring, Retaining Bearing 0 Screw Screw 0 AR Track Inch, Mod Lightning Track Inch, Shockwave Clip Guide 0 Spacer, Shock Centering (Qty. ACE) 0 O-Ring O-Ring (ACE) Shaft, Tapered (Qty. ACE) Mount, Limiter Strap Lower, Attachment 0 Bushing 0 Spacer, Bogie, Inner 0- Asm., Wheel, Bright Silver Metallic 0 0 Shaft 0 Washer, Flat -0 Tube B /0

29 FRONT TORQUE ARM (M-0) FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Screw Washer, Lock Washer, Flat Spacer, Upper, Front Torque Arm Screw, Socket Set Shaft, Upper, Front Torque Arm -0-0 Arm, Torque, M-0, Black Arm, Torque M-0 ACE, Black Nut, Nylok Screw 00 Fitting, Lubrication 0 00 Cable Tie (ACE) Shaft, Front Torque Arm, Lower, Pivot Spacer, Front Torque Arm, Lower B 0 Sleeve, ACE Wire 0 Shock, Front Track, M Shaft, Tapered (See Rear Suspension, M-0 Pg. B, Ref. ) 0-0 Spring, Compression, Black 00 Retainer, Spring, Slotted 0 Sleeve Nut, Nylok 0 Washer, Flat Bolt, Carriage Screw 0 Strap, Limiter Nut, Nylok, Thin /0

30 REAR TORQUE ARM (M-0) FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description Shaft, Upper Torque Arm -0-0 Arm, Torque, M-0 Arm, Torque, M-0 ACE Nut, Nylok Screw 00 Fitting, Lubrication 0 Shaft< Rear Torque Arm, Lower 0 Decal, M-0, Fox Asm., Wheel, Off-Set Bearing Ring, Retaining Collar, Bearing Lock, Rear Screw, Socket Set 0 Washer, Flat Washer, Lock Screw, Socket Head Shaft, Tapered (See Rear Suspension M-0 Pg. B, Ref. ) 0 0 Shock, Rear Track (See Shock, Rear Track, M-0 Pg. C for Details) Shock, Rear Track (See Shock, Rear Track, M-0 ACE Pg. C for Details) 0 Sleeve Cap, Ice (M-0) C 00 Retainer, Spring Slotted (M-0) Nut, Preload (M-0) 0-0 Spring, Shock, Rear, M-0 0 Bushing, Overload Depressor 0 Retainer, Spring, Rear 0-0 Spring, Overload, Rear, M-0 Ring, Adjuster (M-0) Nut, Ring Adjuster (M-0) Sleeve, Overload Depressor (M-0) Retainer, Spring, Lower, M-0 ACE 00-0 Spring, Compression (M-0 ACE) Bushing, Nylon (M-0 ACE) Pad, Rubber (M-0 ACE) 0 0 Clamp, Hose (M-0 ACE) Retainer, Spring, Upper, M-0 ACE 00-0 Spring, Compression (M-0 ACE) Bushing, Overload Depressor, M-0 ACE Retainer, Spring, Preload Adjust (M-0 ACE) Collar, Spring, Preload Adjust (M-0 ACE) 00-0 Spring, Compression (M-0 ACE) Cover, M-0 (ACE) Collar, Spring, Slotted (M-0 ACE) /0

31 SHOCK (FRONT TRACK) (M-0) FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Shock, Front Track, M-0 (Incl. All) 00 Asm., Body Cap 000 O-Ring 00 Piston, Floating 000 Plate, Backup 000 Plate, Top-Out 00 Shaft 00 Bumper 00 Eyelet 000 Sleeve Bushing 00 Nut, Adjusting, Front Shock 00 Asm., Bearing, FIST (Incl. -0) 0000 O-Ring 00 O-Ring 00 Ring, Snap 00 Scraper, FIST 00 O-Ring 00 U-Cup 000 O-Ring 0 00 Bearing 0000 Bearing 00 Kit, Piston Valving 000 Nut, Lock 00 Body 0000 O-Ring 0000 Bearing 000 O-Ring 000 Screw 00 Bearing /0 C

32 SHOCK (REAR TRACK)(M-0 ACE) FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 Shock, Rear Track (Incl. All) 00 Asm., Reservoir (Incl. -) 000 Seal, O-Ring 00 Piston, Floating 000 Hose 00 Asm., Cap, Reservoir 0000 O-Ring 00 Reservoir 000 Asm., Cap, Reservoir 000 O-Ring 000 Asm., Air Valve 0 00 Asm., Bearing, FIST (Incl. -) 0000 O-Ring 00 O-Ring 00 Ring, Snap 00 Scraper, FIST 00 O-Ring C 00 U-Cup 000 O-Ring 00 Bearing 00 Bearing 0 00 Asm., Cap, Body 000 O-Ring 00 Body 000 Nut, Lock 000 Plate, Backup 0000 Bearing 000 Plate, Top-Out 00 Shaft 00 Eyelet 0 Bumper, Jounce Bushing 000 Sleeve /0

33 SHOCK (REAR TRACK)(M-0) FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA 0 0 E 00 Polaris Sales Inc. 0 0 Shock, Rear Track, M-0 (Incl. All) 00 Asm., Reservoir (Incl. -) 000 Seal, O-Ring 00 Piston, Floating 00 Hose 00 Asm., Cap, Reservoir 0000 O-Ring 00 Reservoir 000 Asm., Cap, Reservoir 000 O-Ring 000 Asm., Air Valve 0 00 Asm., Bearing, FIST (Incl. -) 0000 O-Ring 00 O-Ring 00 Ring, Snap 00 Scraper, FIST 00 O-Ring C 00 U-Cup 000 O-Ring 00 Bearing 00 Bearing 0 00 Asm., Cap, Body 000 O-Ring 00 Body 000 Nut, Lock 000 Plate, Backup 0000 Bearing 000 Plate, Top-Out 00 Shaft 00 Eyelet 000 Sleeve Bushing 0 Bumper, Jounce /0

34 DRIVE CLUTCH FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Asm., Drive Clutch, Basic 0 0 Bearing, Sleeve (Incl. All Less,) 00 Insert, Moveable 0 Kit, Wide Roller Spider Rebuild (Incl. -,0,) 0 Nut, FLEXLOC Bolt 0 Washer, Spring Lock Bearing, Cover 0 Ring, Retaining, Cover 00 Spring, Clutch, Yellow 0 Washer, Multilube Asm., Roller and Bushing 0 Button, Guide Asm., Weight/Bushing, Pin, Weight, Hardened AR AR AR AR Spacer,.00 Spacer,.0 Spacer,.0 Spacer, Nut, Jam 0 Pin, Roller 00 Kit, Drive Clutch Shim 0 Screw 00 Washer, Bevel 0 Washer, Clutch Retainer /0 C

35 DRIVEN CLUTCH FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 Asm., Driven Clutch, Basic 0 (Incl. All Less,,0,) 0 Screw Plate, Driven, Vented 0 Bushing, Driven, Large 0 0 AR AR AR AR Washer,.00 Washer,.00 Washer,.0 Washer,.0 00 Pin, Adjustable Driven Cap, Driven, Vented Bolt Cam, Adjustable Driven 0 Button, Ramp 0 0 Spring, Clutch, Silver 0 Key Ramp, Driven, R 0 Washer 0 Ring, Retaining /0 C

36 ELECTRIC MODULE (M-0)(ACE) FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Bushing 0 O-Ring 0 Bushing, Flange Shaft, Screw Bearing, Raceway O-Ring Asm., Casting (Incl.,0,,) Gear, T Gear, T 0 00 Fitting, Lubrication 0 Screw Bearing 0 Bearing Grommet Plate, Grommet 0 Screw 0 Washer, Thrust Gear, Bevel, Large Gear, Bevel, Small 0 Screw Seal, Cover Cover, Motor Pin, Drivlok Plate, Support, Motor 00 Cable Tie 00 Motor 0 Screw 00 Nut, Nylok 0 Washer 0 0 Washer, Spring Lock 000 Potentiometer, M-0 ACE 00 Screw 00 Screw Spacer 0 Harness, Wire (Incl. ) Bearing, Thrust 0 Screw, Set Screw Clevis 0 Nut, Nylok /0 C

37 BATTERY BOX/ELECTRICAL FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc On Bulkhead Screw Nut, Spring Nylok 0 Washer, Lock 0 Nut 0 Asm., Starter Solenoid (Incl.,) 00 Relay 00 Switch, Alternator Control 00 Switch, Roll Over Bolt, Carriage 0 00 Nut, Speed 0 Screw Foam, Battery Box Spacer Retainer, Battery 000 Cable, Battery/Solenoid 0 Cable, Insulator Nut, Flanged, Nylok 00 Pad, Battery Cover, Battery Box C 00 Kit, Battery Bolt Cable, Starter 000 Battery, Top Mount, 0 AMP 0 Tube, Battery Vent 0-0 Box, Battery Pad, Battery, Side Pad, Battery Sink, Heat Regulator 00 Rectifier, Regulator 0 Screw 0 Asm., Bracket, Battery Box w/studs Edge, Trim Rivet Washer 00 Module, Load Shed, LR 0 Asm., Bracket, ECU w/studs 00 ECU Calibration /0

38 AIR BOX FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA 0 E 00 Polaris Sales Inc. 0 Hose, Breather 00 Clamp, Narrow Band Boot, Carb Adapter 0 Screw Foam, Airbox, Chimney 0 Decal, Caution, Air Box 0 Asm., Air Silencer Nut, Well 0 Washer, External Tooth 0 Screw 0 Decal, Greasing 00 Decal, Adjustable Driven Clutch 0 Bracket, Fuel, Filter Pad, Foam Rivet 00 Clamp, Hose 0 Fitting 00 Clamp, Spring Hose /0 C

39 EXHAUST SYSTEM FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0-0 Bracket, Chassis/Resonator Rivet -0 Resonator 0 Spring, Exhaust Gasket, Exhaust 0 Washer Boot, Outlet, Exhaust Rivet Screw 0 Manifold 0 Spring, Exhaust 00 Seal, Exhaust, Socket Pipe, Head 000 Sensor, Oxygen /0 C0

40 SENSORS/SWITCHES/ELECTRICAL FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Sensor, Thermister 000 Heater, Frost Plug Screw 00 Switch, Oil Pressure 0 Insulator, Cable 0 Sensor, Crank Position Screw 00 Cable, Inch, Red, Solenoid/Starter 000- Conduit, Convoluted 0 00 Cable, Inch, Black, Engine/Ground /0 C

41 ENGINE MOUNTING FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Kit, Short Block NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston and crankshaft assembly. Prior authorization is required for warranty consideration. 0 Nut, FLEXLOC Washer, Flat 0 Mount, Engine Washer, Flat 0 Nut, Flanged, Nylon 0 Screw 0 Washer, Spring Lock 0 Bracket, Engine Mount, Front 0 00 Nut, FLEXLOC 0 Mount, Engine Strap, Engine Mount, Rear Washer 0/0 C

42 CRANKCASE FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA 0 E 00 Polaris Sales Inc. 0 Seal, Flange 0 Bearing, Ball Bushing Bearing, Ball 0 Kit, Crankcase (Incl.,-) 0 Nipple, Oil Filter Lifter, Valve Screw 00 Washer, Bevel 0 0 Spring, Pressure Relief Pin, Dowel Bearing, Journal Balance Shaft 0 Ring, Retaining Seal, Oil Gasket, Cover C 0 Asm., Cover, Engine, Magneto 0 Screw 0 Seal, Flanged 0 Bearing, Main Journal 0 Screw Screw 00 Pin, Dowel 00 Plug, Socket Washer, Copper 0 Baffle, Oil 0 Screw 0 Bolt 00 Asm., Oil Pickup 0 Seal, O-Ring /0

43 CRANKSHAFT and PISTON FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 0 Kit, Piston (Incl.,,) 0 Circlip, Piston 0 Pin, Piston 0 Kit, Piston Rings 0 Kit, Crankshaft (Incl. )(See Crankcase Pg. C, Ref.,,,) 0 Gear, Crankshaft Key, Woodruff Screw Washer, Retaining Kit, Gear Set (Incl.,)(See Intake & Exhaust Pg. D, Ref. ) 0 Key, Woodruff Shaft, Balance /0 C

44 CYLINDER and CYLINDER HEAD FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 Screw Cover, Crankcase Breather 0 Breather, Valve Screw 0 Asm., Rocker Cover Seal, O-Ring 0 Screw 00 Asm., Cylinder Head D Gasket, Cylinder Head 0 00 Asm., Cylinder Gasket, Cylinder Base Screw 0 Cover, Thermostat w/o Bypass O-Ring 0 Thermostat 0 Fitting, 0 Degree /0

45 INTAKE and EXHAUST FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Asm., Rocker Arm 0 Pushrod 0 Kit, Camshaft Plate, Thrust Screw 0 Kit, Gear Set 0 Spring, Compression Washer, Spring D Screw 0 Valve, Exhaust Valve, Intake Seal, Valve Guide 0 Spring, Valve Retainer, Spring 00 Retainer, Lock, Valve Stem /0

46 OIL DIPSTICK and FILTER FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 Asm., Dipstick 0 Asm., Tube, Oil Filler Screw D 0 Seal, O-Ring 0 Clamp, Oil Fill Tube 000 Filter, Oil /0

47 OIL PUMP/WATER PUMP FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Asm., Gerotor Housing, Oil Pump 0 Screw Shaft, Oil/Water Pump 0 Bearing, Ball Kit, Gear Set (See Intake & Exhaust Pg. D, Ref. ) 00 Seal, Water Pump D Impeller, Water Pump 0 Screw 0 Washer, Flat 0 Nut, Hex, Nylok 000 Asm., Cover Waterpump Bracket, Cover, Water Pump Screw 0 Seal, O-Ring /0

48 MAGNETO FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 Screw 00 Coil, EFI Spacer, Coil 00 Wire, Spark Plug 000- Conduit, Convoluted 00 Flywheel Screw 00 Stator 00 Plug, Spark, Champion, RCYC 0 0 Screw Stator, Bracket, Wire, Hold, Down /0 D

49 RECOIL ASM. FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. 0 0 Screw 0 Plate, Friction 0 Ratchet Reel, Recoil 0 Spring, Power 0 Handle, Recoil 0 Rope, Starter Recoil Housing 00 Bushing, Rope Slide, Recoil Housing, Recoil, Upper 0 00 Bushing 0 Spring, Return 0 Spring, Friction D 0 Asm., Recoil Housing (Incl. -) Screw 0 Screw Washer, Flat 0 Screw 0 Asm., Housing Recoil, Lower Screw 0 00 Pulley, Starting Recoil 0 Washer 0 Nut, Hex O-Ring 0 Plug, Hole, Timing, Nylon /0

50 STARTING MOTOR FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. Screw 00 Clamp, Hose 00 Starter 0 Washer, Thrust 00 Asm., Bendix Washer, Lock 0 Nut /0 D

51 FUEL SYSTEM FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc Rail, Fuel 0 Screw 00 Clamp, Hose, Screw Type 00- AR Line, Fuel 0 Filter, Fuel 00 Cable Tie 0 00 Asm., Throttle Body Sensor, Throttle Position Heater, Wax 0 00 Asm., Fuel Injector O-Ring 00 Clamp 0 0 Adapter, Throttle Body Manifold, Intake Gasket, Intake Screw /0 D

52 TOOL KIT FRONTIER CLASSIC S0NDDS and FRONTIER CLASSIC S0NDDSA E 00 Polaris Sales Inc. Kit, Tool (Incl. -) Screw Driver Wrench, 0- Spanner Box Wrench, Special Wrench, Box End D 0 Wrench, M-0 Adjust Wrench, Spanner, M-0 ACE DVD, 0 Snow, Suspension/Maintenance Manual, Owner s, 0 Frontier Touring/Classic 0 Roll, Tool 00 Strap, Emergency Starter /0

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54 PRINTEDINTHEUSA PARTS MANUAL PN and MICROFICHE PN /0