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E 2003 Polaris Sales Inc.
PARTS MANUAL PN 9918845 and MICROFICHE PN 9918846 4/03
600 CLASSIC EDGE TOURING/INT’LModel #S04NT6ESModel #S04NT6EE
700 CLASSIC EDGE TOURING/INT’LModel #S04NT7CSModel #S04NT7CE
800 CLASSIC EDGE TOURING/INT’LModel #S04NT8CSModel #S04NT8CE
Rev. 01
TABLE OF CONTENTS600CLASSIC EDGETOURINGS04NT6ES and 600CLASSIC EDGETOURING INT’L S04NT6EE and 700CLASSIC EDGETOURING S04NT7CS and 700CLASSIC
EDGE TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
Parts Manual
AAIRBOX C4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
BBATTERY BOX C6. . . . . . . . . . . . . . . . . . . . . . .BRAKE B7. . . . . . . . . . . . . . . . . . . . . . . . . . . .BUMPER A6. . . . . . . . . . . . . . . . . . . . . . . . . . .
CCARBURETOR (600) C14- D1. . . . . . . . . . . . . . . . . .CARBURETOR (700) D9-10. . . . . . . . . . . . . . . . . .CARBURETOR (800) E2-3. . . . . . . . . . . . . . . . . .CARGO BOX A5. . . . . . . . . . . . . . . . . . . . . . . .CHAINCASE B8. . . . . . . . . . . . . . . . . . . . . . . .CHASSIS A3. . . . . . . . . . . . . . . . . . . . . . . . . . .CONSOLE C2. . . . . . . . . . . . . . . . . . . . . . . . . .COOLING SYSTEM C3. . . . . . . . . . . . . . . . . . .CRANKCASE (600) C11. . . . . . . . . . . . . . . . . . . .CRANKCASE (700) D5. . . . . . . . . . . . . . . . . . . .CRANKCASE (800) D13. . . . . . . . . . . . . . . . . . . .CYLINDER (600) C12. . . . . . . . . . . . . . . . . . . . .CYLINDER (700) D6. . . . . . . . . . . . . . . . . . . . .CYLINDER (800) D14. . . . . . . . . . . . . . . . . . . . .
DDECALS -- EDGE A13-14. . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B14. . . . . . . . . . . . . . . . . . . . . .DRIVE TRAIN C5. . . . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C1. . . . . . . . . . . . . . . . . . . . .
EELECTRIC MODULE (M--12)(ACE) C10. . . . . . . .ENGINE MOUNTING (600) C8. . . . . . . . . . . . . .ENGINE MOUNTING (700)(800) C9. . . . . . . . . .EXHAUST C7. . . . . . . . . . . . . . . . . . . . . . . . . .
FFLAP A6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FOIL/FOAM A12. . . . . . . . . . . . . . . . . . . . . . . . .FRONT SUSPENSION B1-2. . . . . . . . . . . . . . . . .FRONT TORQUE ARM B11. . . . . . . . . . . . . . . . .
GGAS TANK A7. . . . . . . . . . . . . . . . . . . . . . . . . .
HHANDLEBAR B5. . . . . . . . . . . . . . . . . . . . . . . .HITCH A6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .HOOD A10-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MMAGNETO (600) D3. . . . . . . . . . . . . . . . . . . . .MAGNETO (700) D11. . . . . . . . . . . . . . . . . . . . .MAGNETO (800) E5. . . . . . . . . . . . . . . . . . . . .
NNOSEPAN A8-9. . . . . . . . . . . . . . . . . . . . . . . . . .
OOIL TANK C4. . . . . . . . . . . . . . . . . . . . . . . . . . .
PPISTON and CRANKSHAFT (600) D2. . . . . . . . .PISTON and CRANKSHAFT (700) D8. . . . . . . . .PISTON and CRANKSHAFT (800) E4. . . . . . . . .
RRAIL MOUNTING B9. . . . . . . . . . . . . . . . . . . . .REAR SUSPENSION B10. . . . . . . . . . . . . . . . . .REAR TORQUE ARM B12. . . . . . . . . . . . . . . . . .REAR TRACK SHOCK B13. . . . . . . . . . . . . . . . .RECOIL STARTER (600) D4. . . . . . . . . . . . . . . .RECOIL STARTER (700) D12. . . . . . . . . . . . . . . .RECOIL STARTER (800) E6. . . . . . . . . . . . . . . .
SSEAT A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SKI B3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR (600) E7. . . . . . . . . . . . . . .STARTING MOTOR (700)(800) E8. . . . . . . . . . .STEERING B4-6. . . . . . . . . . . . . . . . . . . . . . . . . .
TTAILLIGHT ASM. A5. . . . . . . . . . . . . . . . . . . . .TOOL KIT E9. . . . . . . . . . . . . . . . . . . . . . . . . . .
WWATER PUMP/OIL PUMP (600) C13. . . . . . . . . .WATER PUMP/OIL PUMP (700) D7. . . . . . . . . .WATER PUMP/OIL PUMP (800) E1. . . . . . . . . .
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
A3
CHASSIS600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
435
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1516
18
2025
21
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1
22
2827
9
E 2003 Polaris Sales Inc.
2
11
12
13
19
17
10
10
10
10
10 1010
10
10
23
6
8
24
7
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 30211043110078
11
Stop, Torque (600)Stop, Torque (700)(800)
2 7542404 1 Nut3 1013379
101337711
Stop, Torque (600)Stop, Torque (700)(800)
4 7517632 1 Screw5 1014451-309 1 Chassis, Touring, Natural6 5245202 1 Bracket, Oil Bottle7 7621432 6 Rivet8 5246177 1 Bracket, Airbox9 7081076 2 Plug, Hole10 7661637 64 Rivet11 5246278-067 4 Hook, Cargo12 5246439-067 2 Hook, Cargo, Front13 5246275-067
5246276-06711
Bracket, Lower, Accessory Attach, LHBracket, Lower, Accessory Attach, RH
14 1013857
1013858
1
1
Asm., Footrest, Passenger, LH(Incl. 15,16)Asm., Footrest, Passenger, RH(Incl. 15,16)
15 5246435 2 Mount, Passenger Footrest16 7512076 12 Screw17 1240133
124013411
Cooler, Running Board, LHCooler, Running Board, RH
18 5433150 2 Strap, Airbox Top19 5245457
524545811
Mount, Console, Toe Clip, LHMount, Console, Toe Clip, RH
20 52463105246311
11
Support, Footrest, LHSupport, Footrest, RH
21 7081085 1 Plug, Barbed22 5245288
524720511
Footrest, LHFootrest, RH
23 5812437 1 Foam, Tool w/Adhesive24 2202059
220259811
Kit, Mount, Trailing Arm, LHKit, Mount, Trailing Arm, RH
25 5221583 1 Guard, Adapter Drive26 7080416 2 Plug, Hole27 7661637 15 Rivet28 5132292 1 Bulkhead, Front
4/03
A4
SEAT600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
3
2
4
56
78
9
10
11 12 14
1516
13
17
18
22
21 2019
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2683071 1 Asm., Base, Seat, Passenger, Primary(Incl. 3-9)
1 26833232683324
11
Asm., Seat, Edge, TouringAsm., Seat Cover, Edge Touring
2 26833262683327
11
Asm., Base, Seat, Pssngr. SecondaryAsm., Seat Cover, Passenger
3 2683325 1 Asm., Seat, Passenger, Touring(Incl. 2-9)
4 7512026 3 Screw5 1013935 1 Latch, Seat6 7042246 1 Spring, Seat Latch, Torsion7 5247090
524709111
Plate, Latch, Mount, Tour, LHPlate, Latch, Mount, Tour, RH
8 7621485 6 Rivet9 7512098 3 Screw10 5434660 2 Bushing, Grab Handle
11 1013963-0671013964-067
11
Handle, Grab, LHHandle, Grab, RH
12 2461199 2 Heater, Grip, Passenger13 5431096 2 Plug, Overflow14 5412306 2 Grip, Handlebar, Passenger15 2683161
268316211
Asm., Deflector, Wind, LHAsm., Deflector, Wind, RH
16 2632756 2 Asm., Knob, Grab Handle17 7661637 6 Rivet18 1014499 1 Tube, Grab Handle19 7517219 2 Screw20 7558301 2 Washer, Flat21 7621319 4 Rivet22 5631194 2 Nut, Seat
4/03
A5
CARGO BOX/TAILLIGHT ASM.600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
2
3 56
8 9
1011
13
12
1415
1617
18
1
4
7
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2410324-070 1 Asm., Taillight, Edge Touring(Incl. 10-13)
1 2461178 1 Harness, Taillight2 2461144 1 Harness, Passenger Heater Switch3 2632641 1 Asm., Cover, Trunk (Incl. 4)4 5246525 1 Pawl, Trunk Lock5 7081093 1 Lock, Trunk (Incl. 6)6 4010873 1 Asm., Ring w/Key7 7512076 14 Screw8 4010767 2 Socket, Bulb9 4010764 2 Bulb, Taillight
10 7546703 6 Nut, Nylok11 7556088 6 Washer, Flat12 ------ -- -- -- -- 1 Housing, Taillight13 2410327
241032811
Asm., Reflector, LHAsm., Reflector, RH
14 7517560 2 Screw15 5246523 1 Bail, Trunk Lock16 7661637 2 Rivet17 5434583-070
5434584-07011
Skirt, Snow, Edge, LHSkirt, Snow, Edge, RH
18 7621467 12 Rivet
4/03
A6
BUMPER/HITCH/FLAP600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
12
3
4
56
7
8
9
2
10
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5246282 1 Bracket, Hitch/Flap2 7661637 10 Rivet3 1013859-067 1 Hitch4 2632576-309 1 Asm., Rear Bumper, Touring, Natural5 7512240 6 Bolt
6 7552801 6 Washer, Spring Lock7 7558301 6 Washer, Flat8 7621418 5 Rivet9 5434356-1106 1 Flap, Snow, RMK, Black w/Chrome10 5812229 1 Support, Snow Flap
4/03
A7
GAS TANK600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
8
4
18
19
17
13
2
6
1415
7
5
10
11
20
16
3
1
12
9
5
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080804 2 Cable Tie, Releasable2 7052095 1 Fitting, 90 Degree3 8450061-600 AR Line, Fuel4 2511195-070
581051211
Asm., Cap, FuelGasket, Fuel Cap
5 7542122 4 Nut, Nylok6 7555960 2 Washer, Flat7 5810947 2 Foam, Seal, Rear, Cooler8 5246436-067 1 Bracket, Gastank9 7555843 2 Washer, Flat10 7670021 2 Nut, Speed11 7515203 2 Bolt, Carriage
12 7512247 2 Bolt13 7052215 1 Pickup Fuel, w/Mesh14 7080768 2 Ring, Compression15 8350020-160 AR Line, Fuel16 5432981 1 Grommet17 7052269 1 Fitting18 2520288 1 Asm., Fuel Tank, Edge, Touring
(Incl. 2, 13-20)19 2410352 1 Sender, Fuel, LH20 2410232 1 Package, Hardware, Sending Unit
(Incl. Gasket and Screws)
4/03
A8
NOSEPAN600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
12
12
11
19
8
16
24
15
23
13
814
2221
20
7
36
5
6
18
17
17
25
1
910
4
4
8
1
1
1
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7661637 14 Rivet2 5243992-067 1 Hinge, Lower, Pivot, RH3 5243978 1 Mount, Upper, Shock, RH4 5810947 1 Foam, Seal, Rear Cooler5 7547180 4 Nut, Flanged, Nylon6 7517935 4 Screw7 5243977 1 Mount, Upper, Shock, LH8 7621467 21 Rivet9 7621431 2 Rivet10 7661136 6 Rivet11 5244049-067 1 Bracket, Radius Rod Support12 5244050 1 Brace, Pan, Lower13 5243991-067 1 Hinge, Lower, Pivot, LH
14 7542153 2 Nut, Nylok, Flanged15 5433518-070 1 Asm., Bumper, Front Edge, Black16 7512163 2 Bolt17 7621472 3 Rivet18 5245853 1 Shield, Exhaust, Heat, Extended19 5434343-397 1 Nosepan, Stone Silver20 7542122 4 Nut, Nylok21 7555827 4 Washer22 7515166 4 Screw23 7517312 4 Screw24 7552801 4 Washer, Spring Lock25 5244888
524488911
Guide, Hood, Edge, LHGuide, Hood, Edge, RH
4/03
A9
NOSEPAN600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
9
5 8
10
11
16
12 13
15
18
19
20
3 4
21
17
21
14
7
6
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7670130 3 Clip, Speed, U-Type2 7080963
762146211
Retainer, J-ClipRivet
3 5811948 1 Foil4 7621462 1 Rivet5 5812020 1 Tape, Foil, Nosepan6 5810949 1 Foil, Tape7 5812036 1 Foil, Nosepan8 5812019 1 Foil, Tape, Nosepan, Lower, RH9 5812018 1 Foil Tape, Nosepan, Upper, RH10 7621402 5 Rivet
11 5222769 1 Clip, Belt Retainer12 1013069 1 Asm., Clutch, Guard13 7080698 1 Pin, Clutch Guard14 5812352 1 Pad, Clutch Guard15 7075350 1 Decal, Engine and Clutch16 7621429 2 Rivet17 7170742 1 Decal, Troubleshooting, Edge Tour18 2670134 2 Asm., Reflector, Amber19 5433926 1 Plug, Nosepan, Oblong20 5211722 1 Plate, Backer, Clutch Guard21 4020139 1 Clip, Rosebud
9/02
A10
HOOD600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
3
5
6
7
8
9
10
1115
18
19
2218
19
17
20
16
20
17 16 14
4
20 13
2
12
21
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2632521-1772632521-341
11
Asm., Hood, Edge, BlackAsm., Hood, Edge, Sonic Blue
2 2461015 1 Harness, Headlight, Edge, E/R3 2410132 1 Asm., Headlamp (Incl. Bulbs)4 5812450 1 Seal, Headlight, One Piece5 2870448 2 Bulb, Headlight6 4032063 2 Retainer, Headlamp Bulb7 7517872 1 Bolt, Tee Adjust8 7041954 1 Spring, Headlight Adjust9 7080887 1 Knob, Headlight Adjust, Locking10 5811793 2 Foam, Prefilter11 2632491
58123245811948
111
Asm., Plenum FoilFoil, Plenum, EdgeFoil
12 71718107170741
11
Decal, Suspension Set-Up (600)(700)Decal, Suspension Set-Up (800)
13 5433660 1 Cover, Headlight, Access14 7512068 10 Screw15 5243567-067 1 Hinge, Upper, LH16 7512240 4 Bolt17 7558301 4 Washer, Flat18 7512113 2 Bolt19 5332403 2 Spacer20 7542122 6 Nut, Nylok21 7080367 1 Clamp, Cable22 5243568-067 1 Hinge, Upper, RH
5/03
A11
HOOD600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
3
1413
12
10
15
16
11
109
29
30
26
2120
18
17
19
2
11
9
27
28
26
2423 22
25
800 Only
456
78
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7621509 3 Rivet2 5435044 1 Windshield, 17 Inch3 5410970 4 Retainer, Windshield4 7541933 2 Nut5 7555868 2 Washer, Lock6 3280322 1 Back, Clamp, Gauge7 3280323 1 Cushion, Rubber8 3280404 1 Asm., Gauge, Ride Control, Head
(Incl. 6,7)9 3280158 4 Nut10 3280156 4 Washer, Split Lock11 3280157 4 Washer, Flat12 3280210 2 Bracket, Speedometer/Tachometer13 3280209 2 Cushion, Rubber14 2874394
2874401
4030015
1
1
3
Kit, Tachometer w/Rev(Incl. 9-13)(600)Kit, Tachometer w/DET(Incl. 9-13)(700)(800)Bulb, Replacement
15 3280186 1 Knob, Trip Odometer
16 32804114030015
14
Asm., SpeedometerBulb, Replacement
17 32804104060139
11
Asm., Fuel GaugeFuse
18 3280230 1 Cushion, Rubber, Fuel Gauge19 3280228 2 Spacer, Fuel Gauge Bracket20 3280229 1 Bracket, Fuel Gauge21 3280231 2 Washer, Flat22 3280233 2 Washer, Split Lock23 3280232 2 Nut, Hex24 3280385 1 Cable, Speedometer25 2632246--070
2632247--07075560887546703
1166
Asm., Mirror, LHAsm., Mirror, RHWasher, FlatNut, Nylok
26 4010589 3 Clip, Rosebud27 7512018 2 Screw28 7541925 2 Nut, Nylok29 7080521 2 Cable, Hood Retainer30 7661637 2 Rivet
4/03
A12
FOIL/FOAM600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
8
7
9
11
4
13
21
VIEW LOOKING AT HOOD FROM UNDERNEATH
14
6
12
3
5
101 1
1
1
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7661142 8 Rivet2 5434196-070 1 Closure, Hood, Side, RH, Black3 5434197-070 1 Backer, Hood Closure, Upper, Black4 5434198-070 1 Closure, Hood, Upper, Black5 5246028 1 Retainer, Closure, Upper6 5812270 1 Foam, Hood, Rear, LH7 5812286 1 Foam, Hood, Front, LH
8 5812007 1 Foam, Hood Center9 5812017 1 Foil, Tape, Hood, RH10 5246029 1 Retainer, Closure, Lower11 5434199-070 1 Closure, Hood, Lower, Black12 5434201-070 1 Backer, Hood Closure, Lower, Black13 5434195-070 1 Closure, Hood, Side, LH, Black14 5434223-070 1 Closure, Hood, Upper, LH, Black
3/02
A13
DECALS600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
5
6
43
8
1
97
2
16
1312
14
27
26
25
22
15
28
21
19
18
17
1011
20
E 2003 Polaris Sales Inc.
23 24
A14
DECALS600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2202588
2202589
2202590
1
1
1
Kit, Hood Decal, ’04 600 Edge Touring(Incl. 2,3,7,10,11,16-18,20,21,23,28)Kit, Hood Decal, ’04 700 Edge Touring(Incl. 2,3,7,12,13,16-18,20,21,23,28)Kit, Hood Decal, ’04 800 Edge Touring(Incl. 2,3,7,14-18,20,21,23,28)
1 7079886 1 Decal, Warning, English2 7171221 1 Decal, Dash3 7078716 1 Decal, Electric Start, Domed4 7079887 1 Decal, Warning, French5 7170061 1 Decal, Choke6 7075439 1 Decal, Warning, “Pssngr.”7 7170608 1 Urocal, “PERC”8 7170112 1 Decal, Warning/Rev/Elec. Rev. Opt.9 7079509 1 Decal, Ignition, TPS10 7171219 2 Urocal, “600”11 7171203
717120411
Decal, “LIBERTY 600”, LHDecal, “LIBERTY 600”,RH
12 7171324 2 Urocal, “700”13 7171403
717140411
Decal, “LIBERTY 700”, LHDecal, “LIBERTY 700”,RH
14 7171220 2 Urocal, “800”15 7171205
717120611
Decal, “LIBERTY 800”, LHDecal, “LIBERTY 800”, RH
16 71712177171215
11
Decal, Hood Center “EDGE TOURING”Urocal, Hood Center “EDGE TOURING”
17 7171218 1 Decal, Hood Center, Front18 7171195 1 Urocal, “POLARIS”
19 7171213
7171214
71714077171408
1
1
11
Decal, Trailing Arm, “EDGE IFS”, LH(600)(800)Decal, Trailing Arm, “EDGE IFS”, RH(600)(800)Decal, Trailing Arm, “EDGE IFS”, LH (700)Decal, Trailing Arm, “EDGE IFS”, RH (700)
20 7171216 2 Urocal, EDGE TOURING21 7171209
717121011
Decal, Hood Side, “EDGE TOURING”, LHDecal, Hood Side, “EDGE TOURING”, RH
22 7171211717121271714057171406
1111
Decal, Pan, LH (600)(800)Decal, Pan, RH (600)(800)Decal, Pan, LH (700)Decal, Pan, RH (700)
23 71712077171208
11
Decal, Hood Side, Rear, LHDecal, Hood Side, Rear, RH
24 7171199 2 Urocal, “POLARIS”25 7171409
71714107171197717119871713557171356
111111
Decal, Snowskirt, LH (700)Decal, Snowskirt, RH (700)Decal, Snowskirt, LH (600)Decal, Snowskirt, RH (600)Decal, Snowskirt, “ACE”, LH (800)Decal, Snowskirt, “ACE”, RH (800)
26 71706037170604
11
Decal, Reflector, LHDecal, Reflector, RH
27 717113571706077076360
111
Decal, “Max. 30 Lbs. (14 KG)”Decal, Reflector, Edge Tour, RearDecal, Track/Seat, English/French, LH/RH
28 71712017171202
11
Decal, Hood Top, “POLARIS”, LHDecal, Hood Top, “POLARIS”, RH
4/03
B1
FRONT SUSPENSION600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
7
12
9
15
16
4
21 22
19
23
18
2425
2627
28
29
30
31
32
33
34
35
1436
37
38
3940
2
4142
5
3
1
6
7
715
8
8
7
7
7
2 1417
11
17
20
4
14
1310
E 2003 Polaris Sales Inc.
B2
FRONT SUSPENSION600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517980 2 Bolt2 5434036 8 Bushing, Radius Rod, Pivot, Inner3 5132779 2 Bushing, Shoulder4 7547066 4 Nut, Nylon5 1820679-385 2 Rod, Radius, Upper, Cloud, Silver6 7542520 2 Nut, Jam7 7542439 12 Nut, Nylok8 7515433 4 Screw9 7041918 2 Shock, Gas10 5431734 2 Ring, Spring Preload, Adjust11 5630580 2 Retainer, Spring Slotted12 7042074-067
7042074-3857042074-312
222
Spring, Compression, BlackSpring, Compression, Cloud SilverSpring, Compression Indy Blue
13 1500063 2 Retainer, Spring, Body, Threaded14 7517583 6 Screw15 7555832 4 Washer16 5132728 2 Arm, Steering17 7555797 4 Washer, Flat18 1821165-385
1821166-385
1
1
Asm., Trailing Arm, Cloud Silver, LH(Incl. 21,22)Asm., Trailing Arm, Cloud Silver, RH(Incl. 21,22)
19 7555820 2 Washer, Flat
20 5132364 2 Cup, Mount, Trailing Arm21 7061042 2 Bearing, Spherical22 7710437 2 Ring, Retainer23 7512099 2 Screw24 7061057 2 Rod End, RH25 3573909 2 Bushing, Flange26 7080433 2 Fitting, Lubrication27 5433814 2 Bushing, Torsion Bar28 7621452 6 Rivet29 5244557-067 1 Bar, Torsion30 5434371 2 Slide, Torsion Bar31 7556509 2 Bushing32 3574208 2 Bushing, Flanged33 6230225-067 2 Shaft, Spindle, w/Steer Stop34 7080306 2 Fitting, Lubrication, w/Ball35 5010158 2 Bushing36 7061060 2 Rod End, Radius37 7542711 2 Nut, Jam38 1820677-385 2 Rod, Radius, Lower, Cloud Silver39 7547065 2 Nut, Nylon40 7061061 2 Rod End, Radius41 5132780 2 Bushing, Shoulder42 7512684 2 Bolt
4/03
B3
SKI600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
6
9
10
11
1314
3
8
52
1
7
4
5
23
12
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542321 2 Nut, Flange2 7542439 4 Nut, Nylok3 7555832 4 Washer4 5434165-070 2 Toe, Ski, Plastic, Black5 7556130 4 Washer, Belle6 5132637 2 Bushing, Plastic Ski7 5412018 2 Stop, Ski Rubber8 7542324 8 Nut, Nylok
9 7556175 8 Washer, Flat10 1820929-070 2 Asm., Comp Ski11 7517968 2 Screw12 2874752 2 Kit, Skag, Anti, Dart Dual, 4 Inch, 60De-
gree13 7515514 2 Bolt14 7515307 2 Screw
9/02
B4
STEERING600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
23
3
1
45
6
7
8
91011
12
12
13
1315
11
14
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517579 4 Bolt, Carriage2 1013804-067 1 Hoop, Steering3 4020139 4 Clip, Rosebud4 7512377 4 Bolt, Carriage5 7542343 4 Nut, Flanged6 7621433 6 Rivet7 5244470 2 Plate, Tie Rod Boot8 5433532
543353311
Boot, Tie Rod, LHBoot, Tie Rod, RH
9 7547030 2 Palnut10 7558402 2 Washer, Flat11 7542324 4 Nut, Nylok12 5133648
708051022
Bracket, Steering PostFitting, Zerk
13 5432785 4 Bushing, Steering Post14 1820965-067 1 Post, Steering, Black15 5245354 1 Bracket, Console, Front Neck
4/03
B5
HANDLEBAR600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
1
2
3 45
6
7
8
9
10
11
12
13
14
1516
17
187
19
2021
2223
242526
27
28
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5432634 2 Grip, Handlebar2 7661624 1 Pin, Retaining3 7710503 1 Ring, Retaining4 5432970
201017111
Lever, ThrottleAsm., Lever w/Heater, HI/LO
5 4110106 1 Switch, Auxiliary Shut-Off, Closed6 5433345 1 Adaptor, Block, Throttle7 5431096 2 Plug, Overflow8 5243355-067 1 Handlebar9 7517238 4 Screw10 5434488 1 Collar, Console, RH11 7670106 2 Nut, Push-On12 5434179 1 Emblem, Star13 5433159-070 1 Cover, Handlebar14 5433160-070 2 Slide, Handlebar Cover15 4010287 2 Dart, Clip, Nylon
16 5434487 1 Collar, Console, LH17 2460677 2 Heater, Grip, Lo/Med/Hi18 ------ -- -- -- -- 1 Asm., Control, LH
(See Brake Pg. B7 Ref. 13)19 5630187-067 2 Block, Handlebar20 ------ -- -- -- -- 1 Post, Steering, Black
(See Steering Pg. B4, Ref. 14)21 7542122 4 Nut, Nylok22 7511848 8 Screw23 5432261 1 Holder, Wire24 7555727 1 Washer25 7512465 1 Screw, Set26 5431592 1 Block, Throttle/Brake27 7710401 1 Ring, Retaining28 7555730 2 Washer
4/03
B6
STEERING600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
9
2
84 5
3
1
15
1216
13
14
17
7
1
2
2
2
9
9
9
4
4
5
11
3
14
16
16
12
12
1215
16
9
66
11
10E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7061057 2 Rod End, RH2 7542401 4 Nut3 5333949 2 Rod, Tie4 7542424 4 Nut, LH5 7061055 2 Rod End, LH6 7061076 2 Rod End, RH7 5333772 1 Rod, Steering Rack8 5333773-067 1 Rod, Draglink9 7542439 8 Nut, Nylok
10 ------ -- -- -- -- 1 Post, Steering, Black(See Steering Pg. B4, Ref. 14)
11 7061075 2 Rod End, LH12 5132106 4 Bushing, Reducer13 1820957 1 Asm., Pitman Arm (Incl. 12,14,16)14 5133423 2 Spacer, Tube Pitman/Idler Arms15 7512435 2 Screw16 3514320 4 Bearing, Ball17 1820959 1 Asm., Idler Arm (Incl. 12,14,16)
4/03
B7
BRAKE600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
2021
22
18
17
19
25
24
1
2
3
16
15
13
6
12118
4
5
9
14
10
7
23
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2201254 1 Kit, Cover Screw2 2201255 1 Kit, Cover Assembly (Incl. 1,3)3 ------ -- -- -- -- 1 Gasket4 2201250 1 Kit, Park Lever Spring5 2010219 1 Asm., Master Cylinder
(Incl. 2,4,8,11,12,15)6 7517441 2 Screw7 7512078 1 Screw8 2201943 1 Kit, Lever9 7517566 1 Screw10 2201945 1 Kit, Snap Ring11 2202146
401015711
Kit, Asm., Master CylinderSwitch, Brake Light
12 2201944 1 Kit, Cartridge Subassembly13 2010206
201020811
Asm., Control, LH E/R (600)(700)Asm., Throttle, Control, LH E/R (800)
14 5433291 1 Button, Switch, HI/LO, LH Control15 2201946 1 Kit, Pivot Pin, w/Snap Ring16 2201251 1 Kit, Park Lever and Spring (Incl. 4)17 2202202 1 Kit, Brake Pad, Type 8118 2202207
220220411
Kit, Piston/SealKit, Seal
19 2202201 1 Kit, Asm., Brake Caliper (Incl. 17,18,23)20 7556160 2 Washer21 7552603 2 Washer, Spring Lock22 7515534 2 Screw23 2202206 1 Kit, Pin Retaining24 2202205 1 Kit, Bleeder Fitting25 1910607 1 Line, Brake, Edge, Braided
4/03
B8
CHAINCASE600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
13
2
68
95
10
1211
13 1415
1617
19
18
7
22
1
86
20
23
21
4
4
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3610030 2 Seal, Oil2 7542404 1 Nut3 7515459 1 Screw4 7661826 2 Pin, Dowel5 1332266 1 Asm., Tightener, Sliding6 3514309 2 Bearing, Ball7 1332143
541067511
Asm., DipstickO-Ring
8 7718406 2 Ring, Retaining9 3221097
322109811
Sprocket, 21T (600)Sprocket, 22T (700)(800)
10 7571620 1 Washer, Spring11 7661203 1 Pin, Cotter
12 7547202 1 Nut13 5411497 1 Gasket, Chaincase, O-Ring14 5631354 1 Cover, Chaincase15 7512242 5 Screw16 7517979 1 Screw17 7571618 1 Washer, Spring18 3222101
322209911
Sprocket, 41T (600)Sprocket, 40T (700)(800)
19 3221109 1 Chain, 74P, 3/4W20 7542451 2 Nut, Nylok21 7052115 1 Plug22 5134085 1 Chaincase23 7515477 1 Screw
4/03
B9
RAIL MOUNTING600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1 3
131
5
6
4
10
2930
9
14
5
1918
16
17
23
20
2122
27
2425
31
32
12
3335
34
15
8 736
26
2
2
11 28
212
8
11
5
12
7 8
5
9
9
9
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1542004
1542005
1
1
Asm., Rail, M-12 LH(Incl. 1-3,14,16,17,31,34)Asm., Rail, M-12, RH(Incl. 1-3,14,16,17,31,34)
1 7541925 6 Nut, Nylok2 7555792 4 Washer3 5434374 2 Cap, Rail Tip4 5132577 2 Block, Rail Support5 7542324 12 Nut, Nylok6 7558402 8 Washer, Flat7 7515382 2 Bolt8 7556179 2 Washer, Spring9 1590318-244 6 Asm.,Wheel, Scrolled, Silver (Incl. 29,30)10 5244651 2 Plate, Rail Support11 7515317 4 Bolt12 5631065 6 Block, Wheel Mount, LWT13 7555783 8 Washer, Flat14 5412336
543294622
BumperLiner, Bumper
15 7512392 2 Screw16 7621501 4 Rivet17 5132444 2 Block, Idler Bolt Adjust
18 7547156 2 Nut, Jam19 7517773 2 Screw20 5245045 2 Plate, Coupler Block21 7512310 6 Bolt22 5434885
543488611
Block, Slider, Long, LHBlock, Slide, Long, RH
23 56311885631189
11
Guide, Slider, LHGuide, Slider, RH
24 7515511 2 Bolt25 7542404 2 Nut26 7555806 2 Washer, Flat27 5132584 2 Block, Shock Pivot Threaded28 7515346 4 Screw29 7718407 6 Ring, Retaining (1 per Wheel)30 3514303 6 Bearing (1 per Wheel)31 7510504 4 Screw32 7661845 2 Rivet33 7512329 2 Bolt34 7511975 2 Screw35 5521632 2 Hi-Fax36 7515199 2 Screw
5/03
B10
REAR SUSPENSION600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
8
10
11
14
12
15
1617
2829
6 13
32
9
3839
18
19
3121
4
20212223
22
7
7
3
34
35
33
36
2
2425
2627
1
2
2
30
1038
15
37
E 2003 Polaris Sales Inc.
5
M-12
M-12
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1 7547217 1 Nut, Nylok2 7556216 3 Washer, Flat3 7556401 2 Bushing (M-12)4 5411092 2 O-Ring (M-12)5 5333902 2 Spacer, Shock Centering (M-12)6 5132793 1 Shaft, Tapered (M-12)7 7555806 6 Washer, Flat8 7542439 3 Nut, Nylok9 7547064 1 Nut, Nylok10 5432535 4 Spacer, Idler11 7555918 1 Bushing12 1594087 2 Asm., Wheel13 5333285 1 Spacer, Idler, Long14 5020744 1 Shaft, Idler15 1590303-244 2 Asm., Idler Wheel, Silver Metallic16 7556130 2 Washer, Belle17 7517731 2 Bolt18 7517896 1 Screw19 7517821 1 Screw20 7517856 2 Screw21 7552603 4 Washer, Spring Lock
(M-12)(Qty 2 for Ace)
22 7556042 4 Washer (M-12)(Qty 2 for Ace)23 5132583 2 Block, Shock Pivot Adjust (M-12)24 5434897 2 Guide, Spring, Square25 5010332 2 Bushing26 7555976 1 Washer, Flat27 7515538 1 Bolt28 3514384 2 Bearing29 7710444 2 Ring, Retaining30 7517996 1 Screw31 7518005 2 Screw32 5412342
52414735241474
1ARAR
Track, ShockwaveClip, SlideClip, Guide
33 7080424 1 Fitting, Lubrication34 1012267 1 Shaft, Limiter Strap35 1541797 1 Shock Pivot, Arm36 5334042 1 Tube37 5133093 1 Shaft, Rear Torque Arm, Lower38 7558402 2 Washer, Flat39 5333477 1 Tube
4/03
B11
FRONT TORQUE ARM600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
2
1
6
1211
54
3
18
17
10
16
88
16
9
1513
14
7
15
16 17
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1 1541816-385 1 Arm, Torque, Front, Cloud Silver2 5020812 1 Shaft, Front Torque Arm, Upper3 7555984 2 Washer, Flat4 7552614 2 Washer, Lock5 7517815 2 Screw6 7542439 2 Nut, Nylok7 7555743 2 Washer, Flat8 7080424 3 Fitting, Lubrication9 ------ -- -- -- -- 2 Guide, Spring Square
(See Rear Suspension Pg. B10, Ref. 24)
10 ------ -- -- -- -- 1 Bolt(See Rear Suspension Pg. B10, Ref. 27)
11 5412022 2 O-Ring12 5133531 2 Shaft, w/o O-Ring13 5432166 2 Bumper, Front, Torque Arm14 7621418 4 Rivet15 7542324 4 Nut, Nylok16 7556175 8 Washer, Flat17 7512310 4 Bolt18 5412225
541251221
Strap, Limiter (600)(700)Strap, Limiter (800)
4/03
B12
REAR TORQUE ARM600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
11
1
2 7
22 21
15
2019
1718
10
12
30
35
3132
33
24
13
2334
4
27
26
5
8
25
9
3
2829
2
7
228 29
23
26
E 2003 Polaris Sales Inc. 6
14
16
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1 1541798-385 1 Arm, Torque, Rear, Cloud Silver2 7542411 1 Nut, FLEXLOC, Thin3 7042141 1 Shock, Rear, Track4 5132064 1 Retainer, Spring5 5434921 1 Shield, Spring6 5333905 1 Sleeve7 7515433 2 Screw8 7042161 1 Spring, Compression9 3514450 1 Bearing10 ------ -- -- -- -- 1 Shaft, Tapered
(See Rear Suspension Pg. B10, Ref. 6)11 5133484 1 Shaft, Rear Torque Arm, Upper12 5434627 1 Sleeve, Torsion Spring13 7042240-067
7042241-06711
Spring, Torsion, .405/77, LHSpring, Torsion, .405/77, RH
14 7556296 2 Washer15 1590355
35143307710486
222
Asm., Wheel, OffsetBearingRing, Retaining
16 7556303 2 Washer, Wave17 7552614 2 Washer, Lock
18 7517815 2 Screw, Socket Head19 7555984 2 Washer, Flat20 5134207
751225722
Collar, Bearing LockScrew, Socket Set
21 ------ -- -- -- -- 1 Shaft, Rear Torque Arm, Lower(See Rear Suspension Pg. B10, Ref. 37)
22 7080424 1 Fitting, Lubrication23 3514441 2 Bushing, Nylon24 7080394 2 Clip, Push-On25 5432983 2 Roller, Spring, Adjust, Square26 1541821 2 Rod, Shock27 7517378 1 Screw28 7555795 2 Washer, Wave29 5333028 2 Spacer30 7041486 1 Shock, Front Track31 1500091 1 Retainer, Spring32 5431734 1 Ring, Spring Preload, Adjust33 7041404-067 1 Spring, Compression34 5410874 1 Shield, Spring35 5020618 1 Retainer, Spring Slotted
4/03
B13
REAR TRACK SHOCK600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
15
16
1714
11
6
8
7
12
9
10
E 2003 Polaris Sales Inc.
13
5
3
1 24
2
2
4 2
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
7042141 1 Shock, Rear Track, M-121 5133403 1 Bushing (Ace)2 5411092 2 O-Ring3 5133402 1 Bushing, Flange (Ace)4 7556401 2 Bushing (M-12)5 3514450 1 Bearing6 1700056 1 Screw, Valve7 1700184
170004711
Asm., Pressure ValveO-Ring, Pressure Valve
8 1700033 1 Nut, Spring Retainer9 1700216 1 Nut
10 1700100170003117000771700078
1111
Asm., PistonBand, WearWasher, Top-OutWasher, Back-Up
11 1700051 1 O-Ring, Cylinder Head12 1700156 1 Asm., Cylinder Head13 1700042 1 Bumper14 1700011 1 Mount, Upper15 1700215 1 Shaft16 1700069 1 Sleeve17 1700075 2 Bushing
4/03
B14
DRIVE CLUTCH600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
12
34
5
67 8
9
10
1112
1314
15
16
17
18
19
9
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1321932
1321931
1322022
1
1
1
Asm., Drive Clutch ES Basic 118(Incl. All Less 5,11)(600)Asm., Drive Clutch ES Basic 117(Incl. All Less 5,11)(700)Asm., Drive Clutch ES Basic 125(Incl. All Less 5,11)(800)
1 7512265 6 Bolt2 7552801 6 Washer, Spring Lock3 3576516
351434711
Bearing, Cover (600)(700)Bearing, Cover (800)
4 7710417 1 Ring, Retaining, Cover5 7042083 1 Spring, Clutch, Black/Green6 5020425 1 Nut, Jam7 5430945 6 Washer, Multilube8 1321622 3 Asm., Roller and Bushing9 5430445 6 Button, Guide
10 52107545210753524298152107525132542
ARARARARAR
Spacer (.050)Spacer (.032)Spacer (.025)Spacer (.020)Spacer, Clutch, Drive (.130)(800)
11 13215861321585
33
Asm., Weight/Bushing 10-62 (600)Asm., Weight/Bushing 10-64 (700)(800)
12 7515105 3 Pin, Weight13 3576502 1 Bearing, Sleeve14 5010188 1 Insert, Moveable15 5131062 1 Gear, Ring16 7515351 6 Screw17 7541906 3 Nut, FLEXLOC18 2200387 1 Kit, Drive Clutch Shim19 5133079
513305433
Pin, Roller (600)(700)Pin, Roller (800)
4/03
C1
DRIVEN CLUTCH600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
2
1
34
5 6
6
7
78
8
910
1112 13
14
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1322321 1 Asm., Driven Clutch, Basic 211(Incl. 5-9,11-14)
1 7518023 12 Screw2 5246216 1 Plate, Windage3 3233996 8 Screw, Cap4 5134095
51342265134204
111
Ramp, Driven 56/42-.36 ER (600)Ramp, Driven 60/42-.75 ER (700)Ramp, Driven 64/44-.65 (800)
5 7710522 1 Ring, Retaining6 5434534 2 Roller
7 7556226 1 Washer, Thrust8 7710523 2 E-Ring, Retaining9 7042165
7042167
1
1
Spring, Driven Clutch, Red/Green(600)(700)Spring, Driven Clutch, Red/Silver (800)
10 7556227 1 Washer, Thrust11 3234033 1 Spacer12 7518024 1 Screw13 7542103 1 Nut, FLEXLOC14 5246217 1 Plate, Windage
5/03
C2
CONSOLE600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
5
910
1516
14
20
19
18
8
31
4
11
12
2
1713
7
E 2003 Polaris Sales Inc.
612
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7541925 2 Nut, Nylok2 7555746 2 Washer3 4010794
401073011
Regulator, AC/DC 14.3V (600)(700)Regulator, Rectifier (800)
4 7517263 2 Screw5 4010193 2 Housing, Connector6 4010192 7 Socket7 4020153 1 Housing, 1 Circuit8 4020063 1 Housing9 2461149 1 Harness, Main, TPS ER10 4020057 1 Housing11 5434483--070 1 Console w/ACC12 7515199 2 Screw
13 4010638 1 Receptacle, Pod Mount14 5410611 1 Cap w/Key NOTE: When ordering igni-
tion key PN 5410611 be sure to specifyif for an A,B,C,D, or E switch. Lettercode will be labeled on underside ofswitch body behind console. Key dotcode found on key cap (i.e. one dot = A,two dots= B, etc.).
15 7547035 1 Nut, Ignition16 2200358 1 Kit, Ignition Switch17 7670088 2 Clip, Plastic Dart, Nylon18 2200188 1 Kit, Choke Control19 7080290 1 Cable, Choke Control (Incl. 18,20)20 7080229 1 Nut, Choke Slide
4/03
C3
COOLING SYSTEM600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
9
14
7
1
1
1
6
6
6
6
2
3
810
11
1517
4
6
6
22
18
19
2021
10
1312
23
16
Brake5
E 2003 Polaris Sales Inc.
1
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080844 7 Clamp, Springband2 5412432
541224411
Hose, Bypass/Brake Cooler (600)Hose, Engine Out/Brake Cooler(700)(800)
3 5412351 1 Hose, Brake Cooler/Gripper4 5412433
541234111
Hose, Center Out/Bottle In (600)Hose, Center Out/Bottle In (700)(800)
5 7080138 1 Cable Tie6 7080841 8 Clamp, Springband7 1240133
124013411
Cooler, Running Board, LHCooler, Running Board, RH
8 5412255 2 Hose, Side Cooler/Rear Cooler9 1240150 1 Exchanger, Closeoff, Rear10 7661637 18 Rivet11 5412083 1 Hose, Gripper/Center Cooler
12 5521602 1 Tubing, Convoluted13 5810291 1 Spacer, Rubber14 2520292 1 Cooler, Bulkhead15 5412236 1 Hose, Front Cooler/Engine Out16 7080560 1 Clamp, Hose17 5412237
541216011
Hose, Bottle to Engine (600)Hose, Pump/Bottle (700)(800)
18 7080951 1 Clamp, Hose19 2520312 1 Bottle, Coolant20 2511270 1 Cap, Pressure21 7170063 1 Decal, Water Bottle Cap22 8450003-1525 1 Line, Fuel23 7080761 1 Cable Tie
4/03
C4
OIL TANK / AIRBOX600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
10
15
14
12
23
811
1329
26
3
5
7
27
2425
24
1
2
2021
16
4
18
6
19
9
22
28
E 2003 Polaris Sales Inc.
17
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5434089 1 Cover, Tool Box2 5812209 1 Foam, Tool Box3 7512297 1 Screw4 7542122 1 Nut, Nylok5 1253453
126119911
Asm., Oil Tank w/Sender (Incl. 1,26)Oil Bottle/Tool Box w/Mnt
6 7512095 2 Screw7 ------ -- -- -- -- 1 Kit, CDI
(See Magneto (700), Pg. D11, Ref. 19)8 7052127 2 Fitting9 7670102 1 Clip, Silencer10 5811983 1 Foam, Air Box, Chimney11 7075351 1 Decal, Caution, Air Box12 5433150 1 Strap, Air Box, Top13 7073426 1 Decal, Greasing14 1253498
1253501
1
1
Asm., Air Silencer(Incl. 23 & Decals)(600)Asm., Air Silencer(Incl. 23 & Decals)(700)(800)
15 7171037 1 Decal, E/R Belt Removal16 7547103 2 Nut, Well17 7555932 2 Washer, Nylon18 ------ -- -- -- -- 1 Coil, Ignition
(See Magneto (700), Pg. D11, Ref. 17)19 7080471 1 Clip, Ignition Cable20 7552604 2 Washer21 7517610 2 Screw22 7511862 2 Screw (700)(800)23 5412169
541215722
Boot, Carburetor (600)Boot, Carburetor (700)(800)
24 7080307 2 Clamp, Hose25 8450003-1525 AR Line, Fuel26 4010660 1 Sender, Oil, w/Front Terminals27 7052305 1 Grommet, Oil Sender28 7079003 1 Decal, Oil, VES29 1240094 1 Cap, Oil, Vented
4/03
C5
DRIVE TRAIN600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
12
3 45
6
9
16
1114
15
10
13
18
1920
222329
27
3031
3233
21
12
17
28
8
26
21
13
2322
7
25
24
14
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7515369 1 Screw2 7555701 1 Washer, Flat3 7555734 AR Washer, Flat4 5020913 1 Spacer5 ------ -- -- -- -- 1 Asm., Driven Clutch
(See Driven Clutch Pg. C1 for Details)6 3211080 1 Belt, Drive7 7555917 1 Washer8 7555864 AR Washer9 7556509 AR Bushing10 7558402 3 Washer, Flat11 5241359
708056111
Flangette w/Grease FittingFitting, Lubrication
12 5811095 1 Gasket, Jackshaft13 7542324 6 Nut, Nylok14 3514525 2 Bearing15 5222751 1 Flangette16 7512377 3 Bolt, Carriage
17 7721128 1 Key18 1332220 1 Asm., Jackshaft (Incl. 14,19)19 7710422 1 Ring, Retaining20 2202493 1 Kit, Disc, Brake21 7542423 3 Nut, Flanged22 5020588 2 Sleeve, Seal23 5410613 2 O-Ring24 7558403 1 Washer25 7518002 1 Screw26 7515428 2 Bolt, Carriage27 1590366 1 Asm., Drive Shaft (Incl. 28,29)28 1012945 1 Asm., Flangette w/Screws29 3280019 1 Bushing, Speedometer, Metal30 5243529 1 Flangette, Offset, w/Hole31 3280017 1 Key, Speedometer, Square32 5830012 1 Gasket, Drive Adaptor33 3280116 1 Adaptor w/Zerk, Drive
4/03
C6
BATTERY BOX600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
2
3
10
4
5
6
8
2021
915
12
11
16
19
13
18
7
14
17
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5810290 3 Pad, Battery2 2450020 1 Asm., Battery Hold-Down Strap3 5432077 AR Tube, Battery, Vent4 4140006 1 Battery5 4010114 1 Cable, Battery6 2200361 1 Kit, Battery Bolt7 4010107 1 Cable, Solenoid/Starter8 ------ -- -- -- -- 1 Switch, Magnetic
(See Starting Motor (700)(800) Pg. E8,Ref. 16)
9 5410346 2 Insulator, Cable10 2460393 1 Asm., Cable, Battery/Solenoid11 4010108 1 Wire, Jumper, Solenoid/Battery12 2434008 1 Breaker, Circuit
13 7541925 2 Nut, Nylok14 7542122 2 Nut, Nylok15 1013256-067
1013679-06711
Box, Battery (600)Box, Battery (700)(800)
16 7621467 1 Rivet17 5810129 1 Foil Tape18 1013385 1 Plate, Stud, Battery Box19 7511930 2 Bolt20 ------ -- -- -- -- 2 Washer, Spring
(See Starting Motor (700)(800) Pg. E8,Ref. 15)
21 ------ -- -- -- -- 2 Nut(See Starting Motor (700)(800) Pg. E8,Ref. 14)
4/03
C7
EXHAUST600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
3
6
12
11
14
19
21
1
20
4
4
4
4
22
15
16
13
13
5
7
2
17
18
2
9
10
8
E 2003 Polaris Sales Inc.
600
700/800
15
19
16
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1261296-029 1 Bracket, Chassis/Resonator2 7042029 4 Spring, Exhaust3 1261130-029
1261177-02911
Resonator (600)(700)Resonator (800)
4 7041687 7 Spring, Exhaust5 7555904 1 Washer6 5411684 1 Boot, Exhaust Outlet7 7621467 1 Rivet8 7542321 2 Nut, Flange9 5243929 1 Deflector, Snow Exhaust10 7512394 2 Bolt, Carriage11 5811838
581179922
Gasket, Exhaust (600)Gasket, Exhaust (700)(800)
12 1261046-0291261124-029
11
Manifold (600)Manifold (700)(800)
13 7517322 6 Screw14 3610046 1 Seal, Exhaust, Socket15 7517935 1 Screw16 7547180 1 Nut, Flanged, Nylon17 5245498 1 Bracket, Chassis/Pipe (700)(800)
18 7556004 1 Washer19 5433576
541157611
Dampener, Vibration (600)Dampener, Vibration w/Ribs(700)(800)
20 7080811708081270808137080740
7080741
7080742
2111
1
2
Clamp Worm Driven (.44 x 6.50)(600)Clamp Worm Driven (.44 x 3.75)(600)Clamp Worm Driven (.44 x 4.25)(600)Clamp Worm Driven(.44 x 3.69)(700)(800)Clamp Worm Driven(.44 x 4.25)(700)(800)Clamp Worm Driven(.44 x 6.38)(700)(800)
21 1261007524439852443995830207583019812611235245929524593058302155830216
1111111111
Asm., Tuned Pipe (600)Cover, Tuned Pipe, Top (600)Cover, Tuned Pipe, Bottom (600)Matte, Sound, Top (600)Matte, Sound (600)Asm., Tuned Pipe (700)(800)Cover, Tuned Pipe, Top (700)(800)Cover, Tuned Pipe, Bottom (700)(800)Matte, Sound, Top (700)(800)Matte, Sound, Bottom (700)(800)
22 7661637 8 Rivet4/03
C8
ENGINE MOUNTING (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
1 2 3
45 6
7 8
9
10 1112
13
15
16
1714
181920
2425
26
2728
29
3031
32
13
2019
29
28
29
2829
2122
23
33
14
E 2003 Polaris Sales Inc.
29
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517501 1 Screw2 7556003 1 Washer3 5131872 1 Washer, Clutch Retainer4 2202515 1 Kit, Short Block NOTE: The Short
Block assembly contains a crankcaseassembly, cylinder and cylinder headassembly, and a piston and crankshaftassembly. Prior authorization is re-quired for warranty consideration.
5 3070190 2 Spark Plug, RN57YCC, Champion6 5521398-13 1 Conduit7 7555944 1 Washer, Nylon8 7710427 1 E-Ring, Retaining9 5811485 1 Foil, Tape10 5431499-070 1 Handle, Recoil11 7542451 2 Nut, Nylok12 7555893 2 Washer, Flat13 5245465
524638211
Strap, Engine Mount, LHStrap, Engine RH
14 3021220 2 Mount, Engine
15 7512539 4 Screw16 7553101 4 Washer, Spring Lock17 7547180 1 Nut, Flanged, Nylon18 5245044 1 Bracket, Engine Mount, RH19 7555806 4 Washer, Flat20 7547008 4 Nut, FLEXLOC21 1014392 1 Bracket, Pump, Fuel22 5410012 1 Plug, Rubber Hole23 7542122 2 Nut, Nylok24 1013397 1 Bracket, Engine Mount, LH25 7517854 3 Screw26 3021206 2 Mount, Engine27 7080867 1 Cable, Throttle28 8350017-600 AR Line, Fuel29 7080003 8 Clamp, Hose30 1253424 1 Asm., Valve, Fuel, Plastic31 2520275 1 Pump, Fuel32 8450040-600 AR Line, Fuel33 8360052-25 1 Tubing, Convoluted
4/03
C9
ENGINE MOUNTING (700)(800)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800
CLASSIC EDGE TOURING INT’L S04NT8CE
11
12
54
9
12
14
18
26
2930
32
3
15
27 10
25
27
7 8
23
17
1912
1819
24
1819
28
28
28
6
1613
31
27
28
13
2021
22
31
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517501 1 Screw2 7556003 1 Washer3 5131872
513244111
Washer, Clutch Retainer (700)Washer, Clutch Retainer (800)
4 22025122202518
11
Kit, Short Block, S70704 (700)Kit, Short Block, S80704 (800) NOTE:The Short Block assembly contains acrankcase assembly, cylinder andcylinder head assembly, and a pistonand crankshaft assembly. Priorauthorization is required for warrantyconsideration.
5 3070190 2 Spark Plug, RN57YCC, Champion6 5521398-13 1 Conduit7 7555944 1 Washer, Nylon8 7710427 1 E-Ring, Retaining9 5431499-070 1 Handle, Recoil10 7542451 2 Nut, Nylok11 7555893 2 Washer, Flat12 5245462
524638111
Strap, Engine Mount, LHStrap, Engine Mount, RH
13 3021220 2 Mount, Engine
14 7512539 4 Screw15 7553101 4 Washer, Spring Lock16 7547180 1 Nut, Flanged, Nylon17 5245044 1 Bracket, Engine Mount, RH18 7555806 4 Washer, Flat19 7547008 4 Nut, FLEXLOC20 1014392 1 Bracket, Pump, Fuel21 5410012 1 Plug, Rubber Hole22 7542122 2 Nut, Nylok23 1013397 1 Bracket, Engine Mount, LH24 7517854 3 Screw25 3021206 2 Mount, Engine26 7081051 1 Cable, Throttle27 8350017-600 AR Line, Fuel28 7080003 8 Clamp, Hose29 1253424 1 Asm., Valve, Fuel, Plastic30 2520275 1 Pump, Fuel31 8360052-15 2 Tubing, Convoluted32 8450040-600 AR Line, Fuel
4/03
C10
ELECTRIC MODULE (M-12)(ACE)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
38
37
28
24
6
36
1514
16
40
4
22
16
5
7
89 10
12 13
171819
20
21
23
31
26
16
35
39
3
21
41 32
30
30
29
2934
33
27
11
16 25
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5133403 1 Bushing2 5411092 2 O-Ring3 5133402 1 Bushing, Flange4 5133159 1 Shaft, Screw5 3514388 2 Bearing, Raceway6 5412229 1 O-Ring7 1541692
513315511
Asm., Casting (Incl. 6,10,12,13,36)Housing
8 5434728 1 Gear, Plastic, 12T9 5434727 1 Gear, Plastic, 32T10 7080424 1 Fitting, Lubrication11 7518088 2 Screw12 3514385 1 Bearing13 3514403 1 Bearing14 5434492 1 Grommet, Wire15 5222998 1 Plate, Grommet16 7511866 10 Screw17 7556201 1 Washer, Thrust18 3221135 1 Gear, Bevel, Large19 3221136 1 Gear, Bevel, Small20 7518152 1 Screw
21 5434293 1 Seal, Cover22 5434292 1 Cover, Motor23 7661161 1 Pin, Drivlok24 5246536 1 Plate, Support, Motor25 7080138 1 Cable Tie26 4010596 1 Motor27 7518087 2 Screw28 7547004 2 Nut, Nylok29 7556042 6 Washer30 7552603 6 Washer, Spring Lock31 4010780 1 Potentiometer32 7518006 4 Screw33 7518005 2 Screw34 5133351 2 Spacer35 2461104 1 Harness, Wire36 5133155 1 Housing37 3514387 1 Bearing, Thrust38 7518037 1 Screw, Set39 7515438 1 Screw40 5133325 1 Clevis41 7542439 1 Nut, Nylok
11/02
C11
CRANKCASE (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
1
7 89
10
1112
13
879
1414
13
15
16
17
18
19
20
21
2223
6
54
2
3
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080681 2 Clamp, Hose2 7516822 12 Screw3 7080654 1 Retainer4 1253423 2 Adaptor, Carburetor5 5433151 2 Stuffer, Reed Block6 1201825 2 Asm., Reed Valve7 7051020 2 Valve, Check8 7080603 2 Clamp9 8450061-600 AR Line, Oil10 5132196 4 Stud, Cylinder11 5132197 4 Stud, Cylinder12 8360056-25 1 Tubing, Convoluted
13 2202519 1 Kit, Crankcase (Incl. 10,11,15-21)14 5411394 2 Seal, Flanged w/Standoff15 7051529 2 Plug16 7517785 2 Bolt17 7517784 8 Bolt18 7516825 1 Screw19 7517786 4 Bolt20 7517577 1 Screw21 7663001 2 Pin, Dowel22 7052322 1 Fitting, 45 Degree23 5010390 1 Bearing, Pump Shaft
4/03
C12
CYLINDER (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
12
34
5
6 7
89
10
1112
1314
1516
17
1819
20
2122 23
24
25
27
28
29
26
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 4010398 1 Sensor, Temperature2 7517533 12 Screw3 7517679 1 Screw4 7555998 1 Washer, Flat5 5631391 1 Cover, Thermostat6 5411521 1 O-Ring7 5631425-366 1 Cover, Head8 5411411 2 O-Ring9 5411465 1 Seal, Rubber Head10 3021322 1 Head, Cylinder11 5410932 2 O-Ring12 5411359 2 O-Ring13 7547013 8 Nut14 5133380 2 Valve, Guillotine15 5812350 2 Gasket, Base to Cylinder Exhaust Valve
16 1202216 2 Asm., Base Exhaust Valve Dome17 5132950 2 Washer, Bellows, Exhaust, Valve, Dome18 5412399 2 Bellows, Exhaust Valve19 5631381 2 Cap/Nut, Bellows, Exhaust, Valve,
Dome20 7041786-03 2 Spring, Comp, Green/White21 1202640 2 Asm., EV Housing w/Bushing22 7516820 4 Screw23 7517932 4 Screw24 3021333 2 Cylinder25 5811916 2 Gasket, Cylinder Base26 7052234 1 Fitting27 7052258 1 Thermostat, w/o Bypass28 7517950 1 Screw29 7516822 1 Screw
4/03
C13
WATER PUMP/OIL PUMP (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
1 23 4
5 6
7
8
9
10
11
12
10
13
1415
1817
16
1617
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5411197 1 Seal2 3610067 1 Seal, Waterpump3 7556006 1 Washer, Flat4 5432330 1 Impeller, Water Pump5 7555874 1 Washer, Flat6 7546804 1 Nut, Hex, Nylok7 5811601 1 Gasket, Water Pump Cover8 5630920 1 Cover, Water Pump, Hi Flow9 7516822 9 Screw
10 7555977 2 Washer, Thrust11 5133688 1 Gear, Cross Shaft12 5411196 1 O-Ring13 5010391 1 Bearing, Pump Shaft, Flanged14 5811789 1 Gasket, Oil Pump15 2540117 1 Asm., Pump, Oil16 7080603 4 Clamp17 8450061--600 AR Line, Oil18 7517277 2 Screw
4/03
C14
CARBURETOR (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
1 123
4
5 6
789
1011
1213
14 15
16
7 8 9
65
171819 20
21
22
23
24 25
2627
28
293031
32
33
34 35
36
3738
394041 4142
43 44
45
46
474849
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1253505 1 Asm., Carburetor1 3130951 4 Screw2 3130872 2 Cap, Top3 3130871 2 Gasket4 3130844 2 Screw5 3130846 4 Washer, Packing6 3130856 4 Clip7 3130845 8 Ring8 3130857 4 Plate9 3130847 4 E-Ring10 3130831 2 Cap, Rubber, Starter11 3130830 2 Holder, Guide, Starter12 3130829 2 Spring, Starter13 3130828 2 Asm., Plunger14 3130940 2 Valve, Piston (1.5)15 3131377 2 Needle, Jet (9DGI01-60)16 3130867 2 Packing17 3130868 2 E-Ring18 3130843 2 Plate19 3130855
313084911
Asm., Lever, LHAsm., Lever, RH
20 3130848 1 Ring21 3130854 1 Screw, LH22 3130850 1 Screw, RH23 3130825 8 Screw, Air Funnel24 3131335 2 Asm., Funnel
25 3131356 2 O-Ring, Air Funnel, Long26 3130808 1 Pin27 3131371 1 Spring28 3130142 2 Jet, Main (420)29 3131372 1 Washer30 3130522 1 O--Ring31 3131336 2 Screw, Air32 3130859 2 Asm., Float33 3131248 2 Bolt, Drain34 3130863 2 O-Ring, Drain Screw35 3130824 2 Screw, Float Bowl36 3130858 2 Body, Float37 3130861 2 O-Ring, Float Bowl38 3130860 2 Screw, Valve Seat39 3130069 2 Jet, Pilot (50)40 3130768 2 Jet, Starter (140)41 3130837 4 Washer42 3130836 2 Spring43 3130987 2 Adjuster44 3130986 1 Cap45 3131010 2 Screw (MAG Side)46 3131009 1 Asm., Sensor, Throttle Position (MAG)47 3130479 2 Cap48 3130835 2 Packing49 7051020 2 Valve, Check, 90 Degree
3/03
D1
CARBURETOR (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
1
1
2
3
4
56
7
8
91011
12 1314
1516
171818
19
203
2
1821
22
23
24
25
21
26
25
27
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3130834 2 Bolt2 3130832 2 Lever, Starter3 3130833 3 Screw, Starter4 3140032 1 Ring5 3130817 1 Spring6 3130816 1 Screw7 3131285 1 Adjuster8 3131284 1 Spring9 3131380 1 Bracket10 3130810 1 Screw11 3130809 1 Screw12 3130950 1 Spring13 3130853 1 Ring14 3131370 1 Asm., Shaft
15 3130821 2 Screw16 3130820 1 Bracket17 3131137 2 Hose, Vent18 3130842 3 Packing, Starter Shaft19 3130841 1 Spring, Starter Shaft20 3130840 1 Shaft21 3130852 2 Ring22 3130839 1 E-Ring23 3130819 1 Lever, Starter24 3131374 1 Asm., Nipple25 7080003 4 Clamp, Hose26 8350017-600 AR Line, Fuel27 5431893 2 Plug, Trap
3/03
D2
PISTON and CRANKSHAFT (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
1
2
3
2
45
4
6
7
89
10
11
12
7
9
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2202520 1 Kit, Crankshaft (Incl. 6-10)1 2201256 2 Kit, Piston Rings2 3022950 4 Circlip, Piston3 2202258 2 Kit, Piston (Incl. 1,2,12)4 3514365 2 Bearing5 2201132 1 Kit, Asm., Connecting Rod6 3513508 2 Bearing, Ball
7 3585503 2 Bearing, Ball8 3514310 1 Bearing, Ball9 5411394 2 Seal, Flanged, w/Standoff10 5131373 1 Gear, Pump Drive11 7721117 1 Key, Woodruff12 ------ -- -- -- -- 2 Pin, Piston
3/03
D3
MAGNETO (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
1
23
4
5
6
789
10
11 12
13
14
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517278 6 Screw2 3040161 1 Pulley, Starting, Recoil3 7546909 1 Nut, Hex4 7555907 1 Washer5 4010677 1 Flywheel, Ignition6 4060222 1 Stator, Ignition7 7555970 3 Washer, Flat
8 7555969 3 Washer, Lock9 7517314 3 Screw10 2202528 1 Kit, CDI (Incl. Nyogel and Decal)11 4010811 1 Harness, Ignition12 4060229 1 Coil, Ignition13 4010124-305 2 Wire, Ignition14 4020159 2 Cap, Spark Plug
3/03
D4
RECOIL STARTER (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
1
7
10
112
3
4 5
6
8
9
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1202298 1 Asm., Recoil Electric Reverse(Incl. 1-7,10,11)
1 3040163 1 Nut, Fastening2 3040164 1 Plate, Friction3 3040167 1 Spring, Friction4 5246108 1 Ratchet, Pawl Electric Reverse5 3040166 1 Spring, Return
6 3040168 1 Reel7 3040170 1 Spring, Spiral8 3040171 1 Bushing, Rope Slide, Recoil9 7516827 6 Screw10 5630645 1 Housing, Recoil, Starter11 3040169 1 Rope, Starter
3/03
D5
CRANKCASE (700)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE
1
5
21
2019
6
3
7
8
9
11
10
12
16
14
15
5
19
2
13
18
4
17
32
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5131677 8 Stud, Cylinder, Flange2 8450061-600 AR Line, Fuel3 7080603 2 Clamp4 7051020 1 Valve, Check5 2202233 1 Kit, Crankcase (Incl. 1,5,14,15,18)6 5411125 2 O-Ring7 5630610 1 Manifold, Water ,Inlet8 5243431 2 Retainer, Inlet Water, Manifold9 7516736 2 Screw10 8450068-04 1 Hose11 7080560 2 Clamp, Hose
12 5411394 1 Seal, Flanged w/Standoff13 7051529 2 Plug14 7516919 2 Screw15 7516732 4 Screw16 7710441 1 Ring, Retaining17 7052322 1 Fitting, 45 Degree18 7663001 2 Pin, Dowel19 7555998 2 Washer, Flat20 7052160 1 Valve, Check, Oil Pump21 7517319 1 Screw
3/02
D6
CYLINDER (700)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE
1213
14
167
19
15
9
21
11
1
3235
20
33
5
34
6
2
18
17
10
8
36
37
38
222324
25
2627
28
2930 31
31 3029
2827
2625
2423
22
383940
34
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080681 2 Clamp, Hose2 7517398 12 Screw3 7080683 3 Clamp, Hose4 1253327 2 Adapter, Carburetor5 5433151 2 Stuffer, Reed Block6 1201825 2 Asm., Reed Valve7 5411521 1 O-Ring8 7052258 1 Thermostat w/o Bypass9 5631391 1 Cover, Thermostat10 7517950 1 Screw11 7555998 1 Washer, Flat12 7517679 1 Screw, Bleed13 7517534 12 Screw14 7516822 1 Screw15 4010398 1 Sensor, Temperature16 5631426-366 1 Cover, Head17 5411294 1 Seal, Rubber, Head18 5410917 2 O-Ring19 3021424 1 Head, Cylinder20 5412232 2 O-Ring21 5410932 2 O-Ring
22 5133743 2 Valve, Guillotine23 5812350 2 Gasket, Base to Cylinder Exhaust Valve24 1202216 2 Asm., Base Exhaust Valve Dome25 5132950 2 Washer, Bellows, Exhaust, Valve, Dome26 5412399 2 Bellows, Exhaust Valve27 5631381 2 Cap/Nut Bellows, Exhaust, Valve, Dome28 7041786-08 2 Spring, Comp Green/Yellow29 1202640 2 Asm., EV Housing w/Bushing30 7516820 4 Screw31 7517932 4 Screw32 3021367 2 Cylinder w/Decom33 5812362 2 Gasket, Cylinder Base34 2410369
751726211
Sensor, DetonationScrew
35 7547013 8 Nut36 5521398-96 AR Conduit, Flex37 5411536 1 Hose, Bypass38 7081030 2 Clamp, Bypass39 7052234 1 Fitting40 7080654 1 Retainer
3/03
D7
WATER PUMP/OIL PUMP (700)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE
1
10
2
3
67
8 9
11
12
14
4
5
13
1920
18
17
15
16
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3021044 1 Pulley, Waterpump, Driven2 3514311 2 Bearing, Ball3 5132273 1 Shaft, Waterpump4 ------ -- -- -- -- 1 Asm., Housing, Ignition/WP, Idler
(See Magneto, (700) Pg. D11, Ref. 13)5 3610044 1 Seal6 3610067 1 Seal, Waterpump7 7556006 1 Washer, Flat8 5432330 1 Impeller, Waterpump9 7555874 1 Washer, Flat10 7546804 1 Nut, Hex, Nylok
11 5811627 1 Gasket, Waterpump, Cover Bead12 5631280 1 Cover, Waterpump, w/o NTP13 7052221 1 Fitting, 90 Degree14 7516822 5 Screw15 ------ -- -- -- -- 1 Asm., Housing, Ignition/WP, Idler
(See Magneto, (700) Pg. D11, Ref. 13)16 7516823 6 Screw17 8450061-82 AR Line, Fuel18 7080603 4 Clamp19 2540102 1 Asm., Pump, Oil20 7516607 2 Screw
3/03
D8
PISTON and CRANKSHAFT (700)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE
12
3
4
5
9
78
11
12
1
9
5
109
E 2003 Polaris Sales Inc.
6
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2201848 1 Kit, Crankshaft (Incl. 8-12)1 3022950 4 Circlip, Piston2 ------ -- -- -- -- 2 Pin, Piston3 2200895 2 Kit, Piston Rings4 2202237 2 Kit, Asm., Piston (Incl. 1,2,3)5 3584001 2 Bearing6 2201953 2 Kit, Connecting Rod w/Burr Pin
(Incl. Rod, Pin, Bearing, Washers)
7 7721117 1 Key, Woodruff8 7555905 1 Bushing9 3585503 4 Bearing, Ball10 3514318 1 Bearing, Ball11 5131899 1 Spacer, Crankshaft12 3514310 1 Bearing, Ball
3/02
D9
CARBURETOR (700)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE
9
20
22
1
23
2524
1617
1514 38
3926
3332
21
36
31
35
8
6
195
7
4
18
46
9
58
7
6
1011
12
42
40 41
47
13
23
34
2740
48
44
45
37
2829
30
43
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1253506 1 Asm., Carburetor1 3130951 4 Screw2 3130872 2 Cap, Top3 3130871 2 Gasket4 3130844 2 Screw5 3130846 4 Washer, Packing6 3130856 4 Clip7 3130845 8 Ring8 3130857 4 Plate9 3130847 4 E-Ring10 3130831 2 Cap, Rubber, Starter11 3130830 2 Holder, Guide, Starter12 3130829 2 Spring, Starter13 3130828 2 Asm., Plunger14 3131252 2 Valve, Piston (2.0)15 3131415 2 Needle, Jet16 3130867 2 Packing17 3130868 2 E-Ring18 3130843 2 Plate19 3130855
313084911
Asm., Lever, LHAsm., Lever, RH
20 3130848 1 Ring21 3130854 1 Screw, LH22 3130850 1 Screw, RH23 3130825 8 Screw, Air Funnel
24 3131439 2 Asm., Funnel25 3131356 2 O-Ring, Air Funnel, Long26 3130147 2 Jet, Main (470)27 3131336 2 Screw, Air28 3131371 1 Spring29 3131372 1 Washer30 3130522 1 O-Ring31 3131231 2 Asm., Float32 3131248 2 Bolt, Drain33 3130863 2 O-Ring, Drain Screw34 3130824 2 Screw, Float Bowl35 3130858 2 Body, Float36 3130861 2 O-Ring, Float Bowl37 3130860 2 Screw, Valve Seat38 3130068 2 Jet, Pilot (45)39 3130769 2 Jet, Starter (145)40 3130837 4 Washer41 3130836 2 Spring42 3130987 2 Adjuster43 3130986 1 Cap44 3131010 2 Screw (MAG)45 3131009 1 Asm., Sensor Throttle Position (MAG)46 3130479 2 Cap47 3130835 2 Packing48 7051020 2 Valve, Check, 90 Degree
3/03
D10
CARBURETOR (700)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE
1920
22 3
2
14
17
24
1516
23
56
9
12
7
8
1011
21
4
13
18
21
1818
17
3
2
1
1
25
25
26
27
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3130834 2 Bolt2 3130832 2 Lever, Starter3 3130833 3 Screw, Starter4 3140032 1 Ring5 3130817 1 Spring6 3130816 1 Screw7 3131285 1 Adjuster8 3131284 1 Spring9 3130815 1 Bracket10 3130810 1 Screw11 3130809 1 Screw12 3130950 1 Spring13 3130853 1 Ring14 3131369 1 Asm., Shaft (Incl. Lever)
15 3130821 2 Screw16 3130820 1 Bracket17 3131137 2 Hose, Vent18 3130842 3 Packing, Starter Shaft19 3130841 1 Spring, Starter Shaft20 3131233 1 Shaft21 3131232 2 Ring22 3130839 1 E-Ring23 3130819 1 Lever, Starter24 3131350 1 Asm., Nipple25 7080003 4 Clamp, Hose26 8350017-600 AR Line, Fuel27 5431893 2 Plug, Trap
5/01
D11
MAGNETO (700)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE
1
2
3
4 5
7
89
6
11
12
14
19
10
13
15
16
1718
20
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7516823 6 Screw2 3021144 1 Pulley, Starting, Recoil3 2201821 1 Kit, Waterpump Belt4 5630824 1 Pulley, Water Pump Drive5 7546909 1 Nut, Hex6 7555907 1 Washer7 4010677 1 Flywheel, Ignition8 7517246 3 Screw9 7555969 3 Washer, Lock10 7555970 3 Washer, Flat11 4010297 1 Stator, Ignition
12 7516734 4 Screw13 1202161 1 Asm., Housing, Ignition/WP, Idler14 5411178 1 Grommet, Stator Wires15 4020155 2 Cap, Spark Plug16 4010124-305 AR Wire, Ignition17 4060229 1 Coil, Ignition18 4010872 1 Harness, Ignition19 2202525
707702611
Kit, CDI (Incl. 19, Nyogel & Decal)Decal, Spark Plug
20 7170413 1 Decal, D.E.T. (700)
6/03
D12
RECOIL STARTER (700)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE
1
2 34
10
11
8
7
13
6
5
9
9
12
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1202408 1 Asm., Recoil E/R, Shield(Incl. 1-10,13 & Starting Pulley)
1 3040163 1 Nut, Fastening2 3040164 1 Plate, Friction3 3040167 1 Spring, Friction4 5246108 1 Ratchet, Pawl Electric Reverse5 3040166 1 Spring, Return6 3040168 1 Reel
7 3040170 1 Spring, Spiral8 3040160 1 Housing, Recoil9 7661148 2 Rivet10 3040171 1 Bushing, Rope Slide, Recoil11 7516823 6 Screw12 5246218 1 Shield, Recoil Rope13 3040169 1 Rope, Starter
3/02
D13
CRANKCASE (800)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
5
3
8
4
1
2
7
6
10
11
12
1314
15
1617
1819
20
21
9
3
19
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5131677 8 Stud, Cylinder, Flange2 7051020 1 Valve, Check3 2202336 1 Kit, Crankcase (Incl. 1,5,14,15,18)4 5411125 2 O-Ring5 5630610 1 Manifold, Water, Inlet6 5243431 2 Retainer, Inlet Water, Manifold7 7516736 2 Screw8 8450068-04 1 Hose9 7080560 2 Clamp, Hose10 5411394 1 Seal, Flange, w/Standoff11 7051529 2 Plug
12 7516919 2 Screw13 7516732 4 Screw14 7710441 1 Ring, Retaining15 7052322 1 Fitting16 7663001 2 Pin, Dowel17 8450061-600 AR Line, Fuel18 7080603 1 Clamp19 7555998 2 Washer, Flat20 7052160 1 Valve, Check, Oil Pump21 7517319 1 Screw
3/02
D14
CYLINDER (800)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
17
142
5
1516
48
76
1312
13
1110
9
18
19
20
21
22
2324
25 26
2728
29
3031 32
33343637
3839
40
35
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080681 2 Clamp, Hose2 7517398 12 Screw3 7080683 3 Clamp, Hose4 1253327 2 Adapter, Carburetor5 5433151 2 Stuffer, Reed Block6 1201825 2 Asm., Reed Valve7 5411521 1 O-Ring8 7052258 1 Thermostat w/o Bypass9 5631391 1 Cover, Thermostat10 7517950 1 Screw11 7555998 1 Washer, Flat12 7517679 1 Screw, Bleed13 7517534 12 Screw14 7516822 1 Screw15 4010398 1 Sensor, Temperature16 5631427-329 1 Cover, Head17 5411294 1 Seal, Rubber, Head18 5410917 2 O-Ring19 3021426 1 Head, Cylinder20 5412232 2 O-Ring21 5411675 2 O-Ring
22 3021339 2 Cylinder23 5133775 2 Valve, Guillotine24 5812350 2 Gasket, Base to Cylinder Exhaust Valve25 1202216 2 Asm., Base Exhaust Valve Dome26 5132950 2 Washer, Bellows, Exhaust, Valve, Dome27 5412399 2 Bellows, Exhaust Valve28 5631381 2 Cap/Nut Bellows, Exhaust, Valve, Dome29 7041786-11 2 Spring, Comp Pink/Yellow30 1202640 2 Asm., EV Housing w/Bushing31 7516820 4 Screw32 7517932 4 Screw33 5812363 2 Gasket, Cylinder Base34 7547013 8 Nut35 2410369
751726211
Sensor, DetonationScrew
36 5521398-96 AR Conduit, Flex37 5411536 1 Hose, Bypass38 7081030 4 Clamp, Bypass39 7052234 1 Fitting40 7080654 1 Retainer
10/02
E1
WATER PUMP/OIL PUMP (800)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
6
3
4
2
5
7
8 9
11
1213
14
1718
10
2
16
15
1920
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3021044 1 Pulley, Waterpump, Driven2 3514311 2 Bearing, Ball3 5132273 1 Shaft, Waterpump4 ------ -- -- -- -- 1 Asm., Housing, Ignition/WP, Idler
(See Magneto, (800) Pg. E5, Ref. 13)5 3610044 1 Seal6 3610067 1 Seal, Waterpump7 7556006 1 Washer, Flat8 5432330 1 Impeller, Waterpump9 7555874 1 Washer, Flat10 7546804 1 Nut, Hex, Nylok
11 5811627 1 Gasket, Waterpump, Cover Bead12 5631280 1 Cover, Waterpump, w/o NTP13 7052221 1 Fitting, 90 Degree14 7516822 5 Screw15 ------ -- -- -- -- 1 Asm., Housing, Ignition/WP, Idler
(See Magneto, (800) Pg. E5, Ref. 13)16 7516823 6 Screw17 8450061-600 AR Line, Fuel18 7080603 4 Clamp19 2540102 1 Asm., Pump, Oil20 7516607 2 Screw
3/02
E2
CARBURETOR (800)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
6
13
914710
8
4
15
2
11
12
16
3
5171819
7
1 1
65
89
20
21
22
26
2524
23 27 2829
30
31
3233 34
35
36
37
383940 41
4243
44
45
4647
48
40
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1253504 1 Asm., Carburetor1 3130951 4 Screw2 3130872 2 Cap, Top3 3130871 2 Gasket4 3130844 2 Screw5 3130846 4 Washer, Packing6 3130856 4 Clip7 3130845 8 Ring8 3130857 4 Plate9 3130847 4 E-Ring10 3130831 2 Cap, Rubber, Starter11 3130830 2 Holder, Guide, Starter12 3130829 2 Spring, Starter13 3130828 2 Asm., Plunger14 3131252 2 Valve, Piston (2.0)15 3131438 2 Needle, Jet16 3130867 2 Packing17 3130868 2 E-Ring18 3130843 2 Plate19 3130855
313084911
Asm., Lever, LHAsm., Lever, RH
20 3130848 1 Ring21 3130854 1 Screw, LH22 3130850 1 Screw, RH23 3130825 8 Screw, Air Funnel
24 3131439 2 Asm., Funnel25 3131356 2 O-Ring, Air Funnel, Long26 3131371 1 Spring27 3131336 2 Screw, Air28 3130522 1 O-Ring29 3131372 1 Washer30 3130147 1 Jet, Main (470)31 3130860 2 Screw, Valve Seat32 3131248 2 Bolt, Drain33 3130863 2 O-Ring, Drain Screw34 3130824 2 Screw, Float Bowl35 3130858 2 Body, Float36 3130861 2 O-Ring, Float Bowl37 3131231 2 Asm., Float38 3130068 2 Jet, Pilot (45)39 3130769 2 Jet, Starter (145)40 3130837 4 Washer41 3130836 2 Spring42 3130987 2 Adjuster43 3130986 1 Cap44 3131010 2 Screw (MAG)45 3131009 1 Asm., Sensor Throttle Position (MAG)46 3130479 2 Cap47 3130835 2 Packing48 7051020 2 Valve, Check, 90 Degree
3/03
E3
CARBURETOR (800)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
21
1917
20
18
4
23
1
22 3
7
11
8
910 16
12
515
1314
24
3
6
1
2
25
26
18
2
18
21
27
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3130834 2 Bolt2 3130832 2 Lever, Starter3 3130833 3 Screw, Starter4 3140032 1 Ring5 3130817 1 Spring6 3130816 1 Screw7 3131285 1 Adjuster8 3131284 1 Spring9 3130815 1 Bracket10 3130810 1 Screw11 3130809 1 Screw12 3130950 1 Spring13 3130853 1 Ring14 3131369 1 Asm.,Shaft (Incl. Lever)
15 3130821 2 Screw16 3130820 1 Bracket17 3131137 2 Hose, Vent18 3130842 3 Packing, Starter Shaft19 3130841 1 Spring, Starter Shaft20 3131233 1 Shaft21 3131232 2 Ring22 3130839 1 E-Ring23 3130819 1 Lever, Starter24 3131350 1 Asm., Nipple25 8350017-600 AR Line, Fuel26 5431893 2 Plug, Trap27 7080003 4 Clamp, Hose
3/02
E4
PISTON and CRANKSHAFT (800)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
3
5
4
11
12
7
10
8
9
1
2
6
1
9
9
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2201842 1 Kit, Crankshaft (Incl. 8-12)1 3021179 4 Circlip, Piston2 ------ -- -- -- -- 2 Pin, Piston3 2201631 2 Kit, Piston Rings4 2202337 2 Kit, Asm., Piston (Incl. 1,2,3)5 3514357 2 Bearing6 2201557 2 Kit, Connecting Rod
(Incl. Rod, Pin, Bearing, Washers)
7 7721117 1 Key, Woodruff8 7555905 1 Bushing9 3585503 4 Bearing, Ball10 3514318 1 Bearing, Ball11 5131899 1 Spacer, Crankshaft12 3514310 1 Bearing, Ball
3/02
E5
MAGNETO (800)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
3
8
64 5
7
2
910
11
12
13
14
15
16
17
18
19
20
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517998 6 Screw2 3021144 1 Pulley, Starting, Recoil3 2201821 1 Kit, Waterpump Belt4 5630824 1 Pulley, Water Pump Drive5 7546909 1 Nut, Hex6 7555907 1 Washer7 4010677 1 Flywheel, Ignition8 7517246 3 Screw9 7555969 3 Washer, Lock10 7555970 3 Washer, Flat11 4010297 1 Stator, Ignition
12 7516734 4 Screw13 1202161 1 Asm., Housing, Ignition/WP, Idler14 5411178 1 Grommet, Stator Wires15 4020155 2 Cap, Spark Plug16 4010124-305 AR Wire, Ignition17 4060229 1 Coil, Ignition18 4010872 1 Harness, Ignition19 2202522
707702611
Kit, CDI (Incl. 19, Nyogel & Decal)Decal, Spark Plug
20 7170413 1 Decal, D.E.T. (800)
6/03
E6
RECOIL STARTER (800)800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
11
76
4
8
532
13
10
1 9
9
12
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1202408 1 Asm., Recoil E/R, Shield(Incl. 1-10,13 & Starting Pulley)
1 3040163 1 Nut, Fastening2 3040164 1 Plate, Friction3 3040167 1 Spring, Friction4 5246108 1 Ratchet, Pawl Electric Reverse5 3040166 1 Spring, Return6 3040168 1 Reel
7 3040170 1 Spring, Spiral8 3040160 1 Housing, Recoil9 7661148 2 Rivet10 3040171 1 Bushing, Rope Slide, Recoil11 7517998 6 Screw12 5246218 1 Shield, Recoil Rope13 3040169 1 Rope, Starter
3/02
E7
STARTING MOTOR (600)600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE
15
1210
17
14
4
16
11
13
7
98
7
6
51
2
3
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
4170006 1 Motor, Starter2200758 1 Kit, Asm., Commutator Cap (Incl. 5)
1 3082939 2 Nut2 3080077 2 Washer, Spring3 3083211 1 Switch, Magnetic (Incl. 1,2)4 7542103 2 Nut, FLEXLOC5 2200759
------ -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- --
112111
Kit, Brush & SpringAsm., Brush & ScrewAsm., BrushBushing, InsulationWasher, InsulationNut
6 2200756 1 Kit, Asm., Armature7 2200755
------ -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- --
11111111
Kit, Drive HardwareWasher, Curved SpringWasher, ThrustSpacerSpring, AntidriftPinion, StopRing, LockCover, Dust
8 2200757 1 Kit, Asm., Drive Cap9 2200754
------ -- -- -- ---- -- -- -- -- -- --
111
Kit, Asm., DrivePlate, DrivePinion
10 7512492 2 Screw11 7552603 2 Washer, Spring Lock12 5245467 1 Bracket, Starter, Front13 7555843 2 Washer, Flat14 7517322 2 Screw15 5244250 1 Bracket, Starter, Rear16 7542153 2 Nut, Flanged, Nylok17 7516823 3 Screw
3/03
E8
STARTING MOTOR (700)(800)700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800
CLASSIC EDGE TOURING INT’L S04NT8CE
3
8
4
6
5
2
11
9
12
10
13
16
15
14
10
1
7
4
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2200758 1 Kit, Asm., Commutator Cap (Incl. 2)4170006 1 Motor, Starter, Domestic
1 7542103 1 Nut, Flexloc2 2200759
------ -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- --
112111
Kit, Brush & SpringAsm., Brush & ScrewAsm., BrushBushing, InsulationWasher, InsulationNut
3 7542153 2 Nut, Flanged, Nylok4 7517957 4 Screw5 5245780 1 Bracket, Starter, Rear6 5245781 1 Bracket, Starter, Big Block7 7552603 2 Washer, Spring Lock8 7512492 2 Screw9 2200756 1 Kit, Asm., Armature
10 2200755------ -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- --
11111111
Kit, Drive HardwareWasher, Curved SpringWasher, ThrustSpacerSpring, AntidriftPinion, StopRing, LockCover, Dust
11 2200757 1 Kit, Asm., Drive Cap12 2200754
------ -- -- -- ---- -- -- -- -- -- --
111
Kit, Asm., DrivePlate, DrivePinion
13 2200753------ -- -- -- --
12
Kit, ScrewBolt, Thru
14 3082939 2 Nut15 3080077 2 Washer, Spring16 3083211 1 Switch, Magnetic (Incl. 14,15)
5/01
E9
TOOL KIT600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE and 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE
TOURING INT’L S04NT7CE and 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE
1
2
3
64
5
7
E 2003 Polaris Sales Inc.
8
9
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2873520 1 Kit, Tool (Incl. 1-3)1 ------ -- -- -- -- 1 Screwdriver2 ------ -- -- -- -- 1 Wrench, 9/16 Inch x 1/2 Inch Open End3 ------ -- -- -- -- 1 Box Wrench, Special4 ---- -- -- -- -- -- 1 Wrench, Box End, 5/8 x 8/165 9918079 1 Video, Suspension Setup
6 9918226
9918281
9918283
9918378
1
1
1
1
Manual, Owner’s, ’04 SnowmobileTour FamilySupplement, Owner’s Manual, ’04 600Classic TouringSupplement, Owner’s Manual, ’04 700Classic TouringSupplement, Owner’s Manual, ’04 800Classic Touring
7 7080287 1 Strap, Emergency Starter8 2874113 1 Tool, Belt Removal9 2871845 1 Tool, Screwdriver, Flat, Shielded
4/03
PRINTED IN THE USA PARTS MANUAL PN 9918845 AND MICROFICHE PN 9918846 4/03
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