500 RMK Model #099ER4BS Rev. 02

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1 00 RMK Model #0ERBS Rev. 0 PARTS MANUAL PN and MICROFICHE PN 0 /

3 A ACCS SYSTEM C B BRAKE B0 C CARBURETOR C CHAINCASE B CONTROLS B COOLING SYSTEM B CRANKCASE C CYLINDER C D DECALS A DRIVE CLUTCH C DRIVE TRAIN B DRIVEN CLUTCH C E ENGINE MOUNTING C EXHAUST SYSTEM C F FLYWHEEL D FRONT SUSPENSION B- FRONT TORQUE ARM B FUEL PUMP C H HOOD A HOOD - HEADLIGHT A TABLE OF CONTENTS 00 RMK 0ERBS Parts Manual I IGNITION and WIRE HARNESS A M MAGNETO D N NOSEPAN A-0 O OIL PUMP C OIL TANK / AIR BOX C P PART NUMBER INDEX D- PISTON and CRANKSHAFT C0 R RAIL MOUNTING (SUSPENSION).... B REAR TORQUE ARM B RECOIL STARTER D S SEAT and GAS TANK A SKI B STEERING B STEERING - HANDLEBAR B SUSPENSION B T TOOL KIT C TUNNEL A TUNNEL A W WATER PUMP C The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

4 Type BRAKES CAPACITIES Coolant Capacity (qts.) Chaincase Oil Capacity (oz.) Dry Weight (lbs.) Fuel Tank Capacity (US/lmp. Gal.) Gearcase Oil Capacity (oz.) Height (in.) Length (Incl. skis) Oil Capacity (qts.) Ski Center Distance (in.) Ski Length (in.) Ski Width (in.) Width (in.) CHAINCASE Drive Chain Length Drive Shaft Sprocket Reverse Transmission Sprocket Ratio DRIVE CLUTCH Center Distance (in.) Clutch Offset (in.) Clutch Type Clutch Weight Ring Gear Spider Spring Color DRIVEN CLUTCH Covers Diameter (in.) Helix Angle Spring Position Spring Type ENGINE SPECS Engine Model Number Alternator Output Bore X Stroke (mm) Displacement (cc s) Carburetion/Throttle Body Carburetor Model Cooling Cylinders Cylinder Plating Electric Start Ignition Timing Dynamic Deg. BTDC Ignition Type Oil Injection Spark Plug Type (RFI) 00 RMK SPECIFICATIONS GRAPHICS Liquid Cooled Hydraulic Disc / Piston./. N/A 0.. P (/) T- Wide Accessory : / P- 0MR Accessory Cast Dark Blue No 0. Red EC0PL V 00W P x0 Mikuni ACCS VMSS Slide Liquid N/A 000 RPM CDI Yes RNC Champion Backrest Pad Color Belly Pan Color Front Shock Color Front Springs Color Grab Bars Color Handlebar Cover Headlight Pod Color Hood Color Hood Accent Colors Snow Flap Color Nosecone, Top/Bottom Color Rear Rack (Cargo) Color Rear Idler Wheel Color Rail Color Seat Color Ski Color Tunnel Color Tunnel Stripe Color Windshield (Size & Color) Windshield Base Color ELECTRICAL Headlight Type Headlight (watts) Indicator Light Thumbwarmer Handwarmers TRACK Track Construction Track Length Overall (in.) Track Pattern Track Width (in.) Lug Height SUSPENSION Front Type Front Travel (in.) Radius Rods (Adj. or Lub.) Shock Torsion Bar/Type Rear Type Front Torque Arm Limiter Rear Torque Arm Limiter Rear Travel (in.) Shock: Front Track Rear Track Springs: Front Torque Arm Rear Torque Arm Rear Torque Arm Spring Dia. N/A Black Black Medium Blue N/A Black Molded N/A Black Metallic Bright Red/Fire Red/ Medium Blue/White/ Process Blue/Bright Silver Black/Silver Logo N/A N/A Medium Blue Unpainted Black Black Composite Black Bright Red/Fire Red/ Medium Blue/White STD Evolved/Smoke/Flared Black Band/No Flags Halogen High x./low 0 Oil/Brake/Temp/Hi Beam STD Hi/Low Polyester. Deep Lug. RMK. Adjustable Nitro/Threaded Adj. / XTRA-0 Quick Adjustable Quick Adjustable. Nitrex Cell Indy Select Chrome Silicon/Variable Torsion. SQ Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

5 POLARIS SNOWMOBILE PUBLICATION NUMBERS OWNER S MANUAL PARTS PARTS ASSEMBLY MODEL MODEL # & SUPPLEMENT MANUAL MICROFICHE INSTRUCTIONS 00 RMK 0ERBS & 0

6 A TUNNEL 00 RMK 0ERBS 0 0 0

7 TUNNEL 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description 0 Bumper, Hood 0-0 Console Mount, RH 0 Screw Rivet Guide, Rope Rivet 0-0 Tunnel, Liquid, Xtra-0 (Incl.,,) 00-0 Panel, Tunnel Back Rivet 0 Rivet 0 Snow Flap, Xtra-0 0 Bolt 0 Washer, Spring Lock 0 Washer, Flat 00 Bumper, Rear Screw 000 Reflector, Red Cap, Bumper Rivet Snow Skirt, LH Snow Skirt, RH 0 Rivet Screw Nut, Nylok 0-0 Console Mount, LH 0-0 Support, Bumper, Side Stop, Bumper 0 0 Footrest, LH Footrest, RH Rivet Guard, Adapter 0 00 Plug, Hole 00 Plug, Hole 0-0 Bulkhead -0 Bracket, Rope Guide Rivet 00 Snap, Male Pad, Front, Susp. Mounting, LH Pad, Front, Susp. Mounting, RH Bracket, Suspension, Rear, LH Bracket, Suspension, Rear, RH 0 Screw / A

8 SEAT and GAS TANK 00 RMK 0ERBS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Cap, Gas w/gauge Gasket, Gas Cap 0 Grommet, Fuel Tank Asm., Seat, Long (Incl. --,-) Seat Covering, Long 000 Bulb, Taillight 0 Lens 0 Screw 000 Bulb, Brakelight Washer 00 Dart Clip 0 Retainer, Weld Nut Housing, Taillight Cover, Taillight Protector 0 Rivet Screw Rivet 00 Fuel Pick-Up w/strainer 000 Ring, Compression 000- AR Fuel Line 0 Fitting, Outlet, Double Clamp, Hose, Red AR Fuel Line AR Fuel Line 00 Cable, Tank Retention 00 Fitting, 0 Degree Nut 0 Harness, Taillight / A

9 NOSEPAN 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description 00-0 Brace, Hood Support - Cap, Bumper 0-0 Bumper, Front 0 Screw 0 Stud Plate 0 Bolt Nut, Flange 0-0 Hinge Mount 0-0 Hood Hinge 0 0 Bolt 0 Washer 0 Nut, FLEXLOC Bumper Support, RH Bumper Support, LH 0 Washer Washer 0 Bracket, Side Panel, Plated, RH Nut, Retainer 0 Shield, Fastener Rivet 0 Rivet Rivet 0 Dampener, Vibration AR Washer 0-0 Support, Muffler, Front Rivet 00 Boot, Exhaust 0-0 Bracket, Muffler Support, Rear Rivet Rivet 0 00 Clip, Half Rivet 0 Rivet 0 Decal - Suspension Troubleshooting, X-0 Clip, Belt Retainer 00 Decal - Engine & Clutch 00 Knob, Clutch Guard Bumper, Clutch Guard Knob 0 Guard, Clutch Rivet 0 0 Hinge, Clutch Guard 0 Mount, Clutch Guard, Front 0-0 Bracket, Side Panel, LH / A

10 A NOSEPAN 00 RMK 0ERBS

11 NOSEPAN 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description 0 Foil, Lower, Side Bumper 000- Foil, Side Bumper, RH, Black (Incl.,,,) 0 Foil, Middle, Side Bumper Foil, Upper, Side Bumper 0 Foil, Side Panel, Front 0 0 Foil, Side Panel, Top, Outer Foil, Side Panel, Top, Inner 0 Foil, Side Panel, Upper 0 Foil, Side Panel, Lower 00 Foil, Foam, Side Panel, RH Foil, Side Panel, RH (Incl. -0) Console, Basic Cover, Console 0 Rivet Washer Screw Nut, Retainer Washer 0 Screw 0 Retainer, Hood Latch 0 Washer, Rubber Back Washer, Rubber 0 Screw Well Nut Bumper, Side Panel 0 Screw 0 Washer, Ext. Tooth Nosepan - 0 Side Panel, LH Foam, Side Panel, LH Rivet 0 0 Bumper, Rubber Stop Washer Screw Rivet Rivet 0 Washer - Side Bumper, LH 00 Plug, Nosepan Hole 00 Foil, Side, LH 0 Foil, Center 0 0 Foil, Front, Pan, RH Foil, Front, RH, Pan Foil, Pan, Side, RH 0 Foil, Upper, RH, Pan Foil, Lower, RH, Pan Foil, Shock Tower, Lower RH Foil, Shock Tower, Top RH Foil, Shock Tower, RH Foil, Center Foil, Shock Tower, LH / A0

12 HOOD 00 RMK 0ERBS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Rivet Windshield, Flared, Smoke Nut Washer, Split Lock Washer, Flat 00 Bracket, Speedo/Tach Instrument Housing (Incl. Warning Decals) 00 Cushion, Rubber, Tach/Speedo Tachometer, Backlit, Pulse (Incl.,,) Bulb, Replacement 0 Knob, Trip Odometer Speedometer, Backlit (Incl.,,,) Bulb, Replacement 0 00 Cable, Speedometer 0 Harness, Headlight 00 Cable Tie 00 Screw 0 Foil Tape 00 Retainer - Windshield Foam, Hood, LH Foam, Hood, RH Foil, Hood, RH 0 Foam, Hood, Center 00 Cable, Hood Retainer 0 Bolt 0 0 Nut, FLEXLOC - Hood (Incl. Foam & Foil) 0 Foil, Hood, Front 0 Foil, Hood, Center / A

13 HOOD - HEADLIGHT 00 RMK 0ERBS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 000 Bulb, Hi-Beam 0 Bulb, Headlight, Halogen 000 Fastener, Clip, U-Type 00 Headlamp (Incl.,) Bolt, Tee, Adjuster 00 Spring, Headlight Adjustment Bracket, Headlight Mount, RH Bracket, Headlight Mount, LH Pivot, Headlight 00 Nut, Speed, U-Type Mount, Headlight 0 Screw 0 Wire, Retainer, LH Wire, Retainer, RH Lens, Reflector, LH Lens, Reflector, RH 0 Bushing 0 Rivet 0 Strap, Hood Latch Screw 0 Washer, Flat Nut, Nylok Knob, Headlight Adjustment Rivet 0-0 Screen, Hood, Upper 0-0 Screen, Hood, Center 00 Clip, Speed, U-Type 0-0 Screen, Lower 00-0 Screen, Front / A

14 DECALS 00 RMK 0ERBS RH 0 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Hood Decal, 00 RMK, (Incl. -,-,,) 00 Kit - Decal Application Solution (For Seat Decal) 0 Decal - Close-Off, RMK 0 Decal - XTRA 0 0- Decal - Bumper, Bright Red 00 Decal - Seat, POLARIS 0 Decal - INDY 00, RH 0 Decal - Hood Center, ACCS 0 Decal - Hood Center, POLARIS 00 Decal - Hood Top, RH 0 Decal - Hood Side, RH 0 00 Decal - IFS XTRA, RH 0 Decal - Side Panel, Top, RH 0 Decal - Side Panel, Bottom, RH 0 Decal - Tunnel, RH 0 Decal - Warning, English 00 Decal - Warning 000 Decal - Rear Suspension Set-up 0 Decal - Warning, French 0 Decal - 00 INDY, LH 00 Decal - Track/Seat, LH/RH, English/ French 0 0 Decal - Tunnel, LH 0 Decal - Side Panel, Top, LH 0 Decal - Side Panel, Bottom, LH 0 Decal - IFS XTRA, LH 0 Decal - Hood Side, LH 00 Decal - Hood Top, LH / A

15 IGNITION and WIRE HARNESS 00 RMK 0ERBS 0 Back side of console shown Ref. Part Qty. Description Ref. Part Qty. Description 00 Decal - POLARIS, Domed 0 Decal - No Passenger Warning 0 Ignition Key w/cap 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 labelled on underside of switch body behind console. Key dot code found on key cap (i.e. one dot = A, two dots = B, etc.). 00 Kit - Ignition Switch 0 Nut, Ignition 00 Decal - Ignition 000 Cable, Choke Control (Incl. ) 00 Kit - Choke Control 0 Washer, Lock 0 00 Nut, Choke Slide 00 Socket, Housing 000 Housing, Circuit 00 Housing, Circuit Receptacle 00 Harness, Wire, Handlebar 0 Harness, Main Wire 00 Regulator, LR 00 Screw Nut, Nylok / A

16 B FRONT SUSPENSION 00 RMK 0ERBS

17 FRONT SUSPENSION 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description Rivet -0 Brace, Bulkhead Strap, Spacer, Bottom Strap, Spacer, Top Screw Screw Bolt Nut, Nylok -0 Bar, Sway 0 Bushing, Sway Bar Rivet 0-0 Arm, Steering 0 Nut, FLEXLOC Slide, Sway Bar Rivet Washer 000 Bushing 0 Pivot, Trailing Arm, Rubber Screw Trailing Arm, LH (Incl.,) Trailing Arm, RH (Incl.,) Stop, Steering, LH Stop, Steering, RH 0 Bushing, Flange 0 Bushing 0 Bushing, Flange 000 Fitting, Lubrication 00-0 Shaft, Spindle 00 Bushing 000 Retainer, Spring Body, Threaded Ring, Spring Preload, Adjustable Spring, Compression 00 Retainer, Spring, Slotted 00 Fitting, Lubrication Screw Bushing, Pivot, Radius Rod, Outer Washer 0 Bushing, Pivot, / 0 Shock, IFS 0 Bushing, Pivot, / 00 Bushing 0 0 Radius Rod, Upper, Fixed (Incl.,) -0 Radius Rod, Lower Nut, Jam 00 Rod End, RH -0 Bracket, Pan Support 0 Washer 0 Rivet 0 Nut, FLEXLOC 0 Nut, FLEXLOC / B

18 SKI 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Toe, Ski Nut Nut, FLEXLOC Washer Washer Nut 0 Pin, Cotter Block, Rubber Stop 0 Stop, Rubber 0-0 Support, Ski Rubber Nut, Nylok Washer 0 Ski w/short Saddle Kit - Skag, Carbide,, 0 Degree Screw Bolt 0 Screw / B

19 STEERING - HANDLEBAR 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Cover, Reverse Lever Screw 0 Cover, Handlebar, Upper 0 Switch, Handwarmer, Hi/Lo (Incl. ) 00 Cap, Switch 0 Cover, Handlebar, Top 0 Rivet -0 Handlebar, Adjustable 00 Caplug 0 Grip, Handlebar, Black 0 Grip Heater, Hi/Lo Screw 0-0 Block, Handlebar, Upper 0-0 Block, Handlebar Nut, Nylok Cover, Handlebar, Lower 0 Screw / B

20 STEERING 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description 00 Rod End, LH 0 Nut, FLEXLOC 0 Nut, LH Nut, RH Rod, Drag Link 00 Rod End, RH -0 Steering Post Screw 000 Cable Tie 0-0 Steering Hoop 0 0 Nut, FLEXLOC 0 Nut, Nylok 00 Fitting, Lubrication Center Steering (Incl. ) Bolt Rivet Bolt 0 0 Rivet Rod End, LH Rod End, RH -0 Plate, Boot Seal, LH 0 Boot, Tie Rod, LH Boot, Tie Rod, RH 00-0 Tie Rod 00 Clip, Rosebud 00 Fitting, Lubrication 0 Block, Center Steering Screw Washer, Wave 0 Bushing -0 Plate, Boot Seal, RH Screw 0 00 Bushing Washer 0 Nut, FLEXLOC 0 Pin, Cotter / B

21 COOLING SYSTEM 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok 0 Washer 0 Cap, Overflow Bottle 0 Plug, Overflow Bottle 0 Gasket, Cap 0 Bolt Bottle, Overflow w/fittings 00 Clamp, Hose, Grey Rivet 0 Cooling Extrusion, Center 00 Clamp, Hose, Silver Side Cooling Extrusion, LH Side Cooling Extrusion, RH Guard, Cooling Extrusion Hose, Side to Center 0 Hose, Crossover Tubing, Convoluted 00 Spring, Hose Retainer 0 Hose, Pump/Center Extrusion Bracket, Coolant Tank 0 Tubing, Convoluted 00 Clamp, Hose, Black 0 Hose, Filler, RH Extrusion 00 Hose, Engine To Filler Neck Screw Filler, Remote Coolant Cap, Pressure 000 Clamp, Hose, Large Green 000- Line, Fuel 00 Valve, Check 0 00 Filter, Coolant 00 Clip, Rosebud / B

22 CONTROLS 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description Pin, Retaining 0 Washer 00 Ring, Retaining 00 0 Lever, Heater, Standard Lever, Throttle Block, Throttle/Brake 00 Switch, Auxiliary Shut-Off Washer Screw Screw 0 00 Ring, Retaining Holder, Wire Screw 0 Switch, Headlight, Hi/Lo 00 Adaptor, Block 000 Master Cylinder (Incl. -0,-) 00 Screw 0 Cover, Master Cylinder 0 Gasket, Master Cylinder Bolt, Brake Lever 0 Bushing 0 Spring, Park Brake Lever 00 Lever, Park Brake 000 Bushing, Park Brake Lever Screw Tag, Park Brake Warning 00 Strap, Park Brake Tag Nut, Nylok 0 Lever, Brake 0 O-Ring 0 00 Piston, Master Cylinder 0 Seal, U-Pack 0 Spring, Master Cylinder 0 Washer 0 Clamp, Master Cylinder 0 Screw 0 Housing, Master Cylinder 0 Baffle, Master Cylinder 0 Washer, Baffle, Master Cylinder / B

23 CHAINCASE 00 RMK 0ERBS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 000 Seal, Oil Screw 0 Nut 0 Bearing, Ball 0 Ring, Retaining Tightener, Gearcase Bearing, Chaincase Idler Block, Tightener Wheel, Idler Washer, Thrust Pin, Chain Tightener 0 Sprocket, T, /W 0 Washer, Spring Nut, FLEXLOC 0 0 Pin, Cotter 0 Gasket, Chaincase 0 Cover, Chaincase, Cast Screw 0 Bolt Washer, Spring 0 Chain, Silent, P, /W Nut, Nylok 0 Sprocket, T, /W 0 Plug 0 Chaincase w/ratchet Mount Screw / B

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

25 BRAKE 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer, Spring Lock 0 Washer 0 Bracket, Caliper 0 Piston and Seal (Incl. ) 00 Kit - Seal, Piston, Caliper 00 Kit - Clip, Spring (Qty. ) 0 Switch, Stoplight 00 Kit - Brake Pads, Top Mounting (Incl. ) 0 0 Brake Caliper (Incl. -,) 0 Kit - Caliper (Incl.,,) 0 Line, Brake 0 Inlet / B0

26 SUSPENSION 00 RMK 0ERBS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Lock 0 Washer Bracket, Shaft Support Nut, FLEXLOC Bolt Washer, Belle 0-0 Idler Wheel, Blue Spacer, Idler 0 Bushing 0 Idler Wheel, Black Spacer, Idler, Long 00 Shaft Screw Screw (See Rail Mntng Pg. B, Ref. ) Hi-Fax Cover, Rail Tip (See Rail Mntng Pg. B, Ref. ) Rivet, Pop (See Rail Mntng Pg. B, Ref. ) 0 0 AR AR Track Clip, Slide Clip, Guide 0 00 Shaft, Pivot Arm 00 Shaft Nut (See Rail Mntng Pg. B, Ref. ) 0 Shaft 00-0 Pivot Arm, Shock 00 Fitting, Lubrication Screw Washer -0 Pivot Arm, Rear / B

27 RAIL MOUNTING (SUSPENSION) 00 RMK 0ERBS 0 LH Shown 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Bogie Wheel (Incl. -) Insert, Bearing ( per Wheel) 0 Bearing, Roller ( per Wheel) 0 Ring, Retaining ( per Wheel) 0 Bumper, Suspension Angle, Reinforcement, Bumper Screw Mount, Bumper 0 Bumper, Pivot Arm Bolt 0 00 Nut, Tensioner Adjusting 00 Block, Adjusting, Idler Bolt 0 0 Rail, RH, Xtra-0 (Incl.,,,,,) Rail, LH, Xtra 0 (Incl.,,,,,) 0 Rivet Nut, FLEXLOC 0 Roller, Spring Washer Spacer Bolt 0 Bolt 0 0 Spacer, Bogie Wheel Rivet Screw Cover, Rail Tip Rivet Nut 0 Bumper, Suspension Angle, Reinforcement, Bumper Nut Plate, Rail Support Nut / B

28 FRONT TORQUE ARM 00 RMK 0ERBS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Lock Washer 0 Shaft 0-0 Torque Arm, Front, Xtra-0, Blk Washer Nut, Nylok 0 Shield, Spring 0 Shock, Front Track 0 00 Retainer, Spring, Slotted 0-0 Spring, Compression -0 Retainer, Spring 0000 Bolt, Eye 00 Fitting, Lubrication Rivet Protector, Track, LH Protector, Track, RH B Shaft (See Suspension Pg. B, Ref. ) Spacer 0 Bushing 0 Asm., Bogie Wheel (See Rail Mounting Pg. B, Ref.) Shaft (See Suspension Pg. B, Ref. ) Screw Nut, FLEXLOC Screw 0 Strap, Limiter, Front Shaft, Pivot Arm (See Suspension Pg. B, Ref. 0) Nut Bolt /

29 REAR TORQUE ARM 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Lock Washer 0 Shaft, Torque, Upper, Rear 0-0 Torque Arm, Rear 00 Fitting, Lubrication Nut, FLEXLOC Bolt Shaft Bolt, Eye Nut, Nylok Screw Spring, Torsion, LH (./ Degree) Optional Spring, Torsion, RH (./ Degree) Optional Spring, Torsion, LH (.0/ Degree) Optional Spring, Torsion, RH (.0/ Degree) Optional Spring, Torsion, LH (./ Degree) Standard Spring, Torsion, RH (./ Degree) Standard B Collar, Bearing Lock Screw, Set 0 Wheel Washer 00 Sleeve, Torsion Spring 00 Clip, Push-On 0 Roller, Spring Adjustment Washer 0 Strap, Limiter, Rear 0 Bolt Washer 00 Bushing Spacer 0-0 Shock, Rod Screw 00 Bushing 0 0 Screw 0 Shock, Rear, Adjustable /

30 DRIVE CLUTCH 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Kit - Clutch Update (Incl. -,,,) Bolt 0 Washer, Spring Lock Bearing, Cover, Garmax 0 Ring, Retaining 0 Spring, Clutch, Dark Blue 00 Nut, Jam 0 Washer, Multilube Roller and Bushing 0 Button, Guide AR AR AR Spacer (.00 ) Spacer (.0 ) Spacer (.00 ) 0 Weight/Bushing (0M-R) 0 Pin, Weight, Hardened 0 Bearing, Sleeve 00 Insert, Moveable 0 Nut, FLEXLOC 00 Pin, Roller 00 Kit - Drive Clutch Shim Asm., Drive Clutch, Basic (Less,) / C

31 DRIVEN CLUTCH 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw 0 Plate, Driven 0 Ring, Retaining 0 Washer 0 Ramp, Driven, Degree 0 Key 0 Spring, Clutch, Red 0 Bushing, Driven, Large DU 0 0 AR AR AR Washer (.0) Washer (.0) Washer (.0) 0 Washer 00 Pin, Driven, Adjustable Cam, Driven, Adjustable Screw 00 Cap, Driven 0 Button, Ramp Driven Clutch, Adjustable, Degree (Incl. -) / C

32 EXHAUST SYSTEM 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 00-0 Muffler 0 Spring, Exhaust Nut (See Cylinder Pg. C, Ref. ) Washer, Lock (See Cylinder Pg. C, Ref. ) 00-0 Manifold Gasket, Exhaust (See Cylinder Pg. C, Ref. ) 00 Spring, Exhaust 0 Nut, FLEXLOC 0 Washer 0-0 Deflector, Exhaust Bolt / C

33 OIL TANK / AIR BOX 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description 0000 Sensor, Oil Level w/connectors 0 Cap, Oil Tank 0 Gasket, Oil Cap 0 Washer 0 Bolt 000- AR Line, Fuel 000 Filter 000 Clamp, Hose, Large Green AR Conduit, Convoluted 0 00 Fitting, Outlet, Single Oil Tank w/sending Unit Hole Nut, Nylok 00 Fitting, AR Line, Vent Screw 0 Washer 0 Decal - Fuel Shut-Off -0 Bracket, Air Silencer Rivet 0 00 Plate, Silencer, Air Fuel Pump (See Fuel Pump Pg. C, Ref. ) Washer, Flat Nut, Well 00 Clip, Rosebud 0 Decal - Cooling System Silencer, Air, Upper, ACCS 00 Air Duct 0 Decal - Caution, Air Box 0 Decal - Greasing 0 00 Decal - Adjustable Driven Clutch 00 0 Clip, Silencer Baffle Bracket, Silencer, Intake Silencer, Intake, Drilled 00 Boot, Air Silencer / C

34 ACCS SYSTEM 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 AR Rubber Pipe (.x.) (mm) 0 T-Nipple, Air Vent 0 Rubber Pipe (.x0.) (mm) 0 ACCS Body Fuel Line Foam, Filter ACCS 00 Cable Tie C Conduit, Convoluted 0 Grommet 0 Nut, Well Washer 0 Washer Screw /

35 ENGINE MOUNTING 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description Screw 0 Washer, Lock 00 Washer, Clutch Retainer 00 O-Ring, Clutch Bolt 00 Spacer, Clutch Bolt 00 Spark Plug, RNC Champion 0 Engine, EC0PL-Short Block NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization is required for warranty consideration. Recoil Handle 0 Screw 0 0 Washer, Flat 00 Engine Mount, Rubber Tube, Spacer Nut, Flange Plate, Engine Mount 0 Washer, Spring Lock Screw 00 Mount, Engine 00 Nut, FLEXLOC Nut 0 00 Limiter, Torque 00 Stop, Torque Washer 0 Nut, FLEXLOC AR Line, Fuel Clamp, Hose, Red Fuel Pump (See Fuel Pump Pg. C, Ref. ) 0 Filter, Fuel 00 Clamp 000 Valve, Fuel Shut-Off AR Tubing, Convoluted 00 Cable Tie 00 Cable, Throttle Control w/oil / C

36 TOOL KIT 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Tool (Incl. -) Screwdriver Wrench, 0- Spanner Box Wrenches, Special Screwdriver, Flat, Shielded Manual, Owner s, Snowmobile Supplement, Owner s Manual, 00 RMK 00 Strap, Emergency Starter 0 Cover, Tool Box 0 Foam, Tool Box 0 Screw 0 0 Tool Box AR Edge Trim 0 Tray, Tool Box Mount / C

37 CRANKCASE 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Pipe, Pulse 0 Stud 0 Grommet 0 Asm., Crankcase (Incl.,,,-) 000 Pin, Dowel 0 Bolt, Flange 0 Gasket, Aluminum 00 Seal, Oil (MAG Side) 00 Bolt and Washer 0 00 Bolt and Washer 00 Bolt and Washer 000 Seal, Oil (PTO Side) / C

38 CYLINDER 00 RMK 0ERBS 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bolt, Flange 0 Cylinder Head (Incl. 0) 0 Gasket, Aluminum 0 Plug 00 Nut 000 Washer, Lock 0 Gasket, Exhaust 000 Pin, Dowel 0 Stud 0 0 Cylinder (Incl.,0) 0 Nut, Flange 0 Gasket, Cylinder 0 Check Valve 0 Asm., Band, Adaptor (Incl. ) 0 Screw 00 Adapter (Incl. ) 0 O-Ring 00 Bolt 0 Switch, Thermo (0 Degree) 0 0 Pipe, Water 0 Gasket, Head / C

39 PISTON and CRANKSHAFT 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description Ring, Piston (Standard) Ring, Piston (0.mm/.00 O/S) Ring, Piston (0.0mm/.00 O/S) Piston (Std) Piston (0.mm/.00 O/S) Piston (0.0mm/.00 O/S) 0 Pin, Piston 0 Clip, Piston Pin 0 Spacer, Crank Pin 0 Crank Pin (mm) 0 Bearing, Large End 0 Bearing, Small End 0 Rod, Connecting 0 0 Crank Pin (mm) 00 Bearing, Ball 00 Spacer 00 Bearing, Ball 00 Crankshaft (PTO Side) 0 Key 00 0 Asm., Crankshaft (Incl. -,-,,,0) Crankshaft (MAG Side) 0 Bearing, Ball 00 Washer, Spring 00 Nut 0 0 Crankshaft (Center) (Incl.,0) 0 Gear, Drive, Oil Pump / C0

40 WATER PUMP 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw and Washer 0 O-Ring 0 Pump Casing 00 Bolt and Washer 0 Gasket, Water Pump 0 Asm., Water Pump (Incl. -,) 0 Belt 0 Pulley, Drive / C

41 FUEL PUMP 00 RMK 0ERBS Ref. Part Qty. Description 0 Asm., Fuel Pump (Incl.,) 0 Diaphragm, Gasket Set 0 Screw and Washer / C

42 CARBURETOR 00 RMK 0ERBS Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Mixing Chamber, Top (Incl. Gasket) 0 Spring 00 Plate 00 E-Ring 0 Jet Needle (FJ-) 0 Throttle Valve (.) 0 Needle Jet P-0 (0) 0 Cap 0 Float Pin 0 00 Float Arm 00 Packing, Needle Valve 00 Needle Valve (.) 000 Gasket, Float Chamber 0 Cap 00 Asm., Float 0 0 Asm., Carburetor (MAG) (Incl. -0,-) Asm., Carburetor (PTO) (Incl. -0,-) 00 Washer 0 Main Jet (#0) 0 O-Ring 0 00 Nipple 00 Clamp, Hose Plug, Trap 00- AR Line, Fuel 00 Clamp, Hose 00 Screw and Washer 000 Pilot Jet (#) 00 Spring, Air Adjuster 00 Air Screw 000 Throttle Stop Screw Spring, Throttle Adjuster 0 Asm., Plunger 000 Plunger Spring 0 Plunger Cap / C

43 OIL PUMP 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Clamp, Hose 0 Pipe, Vinyl 0 Screw, Air Vent 0 Packing 00 Asm., Oil Pump (Incl. -0,) 0 Spring, Return 0 Collar, Cam Shaft 00 Lever, Control 0 Washer, Spring 0 00 Nut 0 Screw and Washer 0 Gear, Small 00 Spacer 0 Bushing AR AR AR 0 O-Ring Spacer (.mm) Spacer (.mm) Spacer (.mm) / C

44 MAGNETO 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 P Coupler 0 Grommet 0 Harness, Wire (Incl. ) 00 Screw and Washer 0 Clamp 0 0 Asm., Plate (Incl. -,0,,) Plate 0 Stator 0 Screw and Washer 0 Flywheel 0 0 Screw and Washer 0 Coil, Exciter 0 Screw and Washer 0 Coupler, P Male 00 Cap, Resistor Plug 00 Coil, Ignition 0 Screw and Washer 00 Nut, Rubber / D

45 RECOIL STARTER 00 RMK 0ERBS 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Pulley, Starting 0 Bolt and Washer 0 Nut, Flange 0 Plate, Friction 0 Spring, Friction 0 0 Asm., Recoil Starter (Incl. -,-) Starter Case Complete 0 Clamp 0 Bolt and Washer 00 Guide, Rope 0 0 Spring, Spiral 0 Rope, Starter 0 Reel 0 Spring, Return 0 Ratchet / D

46 PART NUMBER INDEX 00 RMK 0ERBS Part Ref. Grid Part Ref. Grid Part Ref. Grid A A A A A A A A A A A B A A B A A C A A C C C A C C C C B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B A C A A C B B B A A B A A A A B A B B B C C B A A C A A A A A A A A A D B C C C... C C C C D C D C C C D D D C C C C C D C C C0 D C D C C C C C C C C C C C C C D C C D C C C C C C D D D D D D D D C C C D D D D C C C C C C C C C C D C C C D D D D C C C C C

47 PART NUMBER INDEX 00 RMK 0ERBS Part Ref. Grid Part Ref. Grid Part Ref. Grid C D C D D D C C C C C C C C C D C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C B B B B B B A B A A A A A A A A B B B B B B C B B C C B C... C A D A B... B... C A A.. A A A A B C A B B B B B B C C B D B B B C C C C B B C B B B B B B B B C B B B B C B B A C C C C C B B B B B B B.. B A B A B B A B B C A A A A A B C A C A A B A A

48 PART NUMBER INDEX 00 RMK 0ERBS Part Ref. Grid Part Ref. Grid Part Ref. Grid A A B B A A B A B C B B B B C B B B B B B B B B C B B B B B B C C A A C B B A B B B A A A A B B A C B B B B B B B B A B B B A B A C C B B B C C B C A C B A B B B A C A B B B A C A A B B A A A B B B B A A A C A B A A A B B A B A C A B C B A B B B B D C B B B B B B B B B B B B 0.. B B C B A B A A A A A A A A A A A C A A A A A A A A A B B A A A A A A A A A C B C B B 0.. B B C B B A B

49 PART NUMBER INDEX 00 RMK 0ERBS Part Ref. Grid Part Ref. Grid Part Ref. Grid C B B B B B B B B B C B C A B C C A... C B A B B B B B C C C A A A A C C A A A A A A A A A A A A A A A A A A A A A A A A A A... C A... C A A C A B B... C A B A A A B... B.. B.. B.. B B B C A A A C.. C C C A B B B B B A... B B B A B A A C A C A... B A A A A A C C... C A... B... C A... B A0 D B C B B B A.. B B... B.. B.. B B B B C B C B C B B B B C A C A A B B A B B B B B B.. B B B.. B B B B B B B B A B B B.. B.. B B B B B A A... C A0... C

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

51 PART NUMBER INDEX 00 RMK 0ERBS Part Ref. Grid Part Ref. Grid Part Ref. Grid A... C C C D

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

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

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

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

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

60 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...