2004 Polaris Parts Manual

PARTS MANUAL PN 9918845 and MICROFICHE PN 9918846 4/03600 CLASSIC EDGE TOURING/INT’L Model #S04NT6ES Model #S04NT6EE 700 CLASSIC EDGE TOURING/INT’L Model #S04NT7CS Model #S04NT7CE 800 CLASSIC EDGE TOURING/INT’L Model #S04NT8CS Model #S04NT8CE Rev. 01 E 2003 Polaris Sales Inc. TABLE OF CONTENTS 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 Parts Manual A H B HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . B5 HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-11 C MAGNETO (600) . . . . . . . . . . . . . . . . . . . . . D3 MAGNETO (700) . . . . . . . . . . . . . . . . . . . . . D11 MAGNETO (800) . . . . . . . . . . . . . . . . . . . . . E5 AIRBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4 BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . C6 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7 BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . A6 CARBURETOR (600) . . . . . . . . . . . . . . . . . . CARBURETOR (700) . . . . . . . . . . . . . . . . . . CARBURETOR (800) . . . . . . . . . . . . . . . . . . CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . CRANKCASE (600) . . . . . . . . . . . . . . . . . . . . CRANKCASE (700) . . . . . . . . . . . . . . . . . . . . CRANKCASE (800) . . . . . . . . . . . . . . . . . . . . CYLINDER (600) . . . . . . . . . . . . . . . . . . . . . CYLINDER (700) . . . . . . . . . . . . . . . . . . . . . CYLINDER (800) . . . . . . . . . . . . . . . . . . . . . C14- D1 D9-10 E2-3 A5 B8 A3 C2 C3 C11 D5 D13 C12 D6 D14 DECALS - EDGE . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . A13-14 B14 C5 C1 D E ELECTRIC MODULE (M-- 12)(ACE) . . . . . . . . ENGINE MOUNTING (600) . . . . . . . . . . . . . . ENGINE MOUNTING (700)(800) . . . . . . . . . . EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . C10 C8 C9 C7 FLAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOIL/FOAM . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SUSPENSION . . . . . . . . . . . . . . . . . FRONT TORQUE ARM . . . . . . . . . . . . . . . . . A6 A12 B1-2 B11 F G GAS TANK . . . . . . . . . . . . . . . . . . . . . . . . . . A7 M N NOSEPAN . . . . . . . . . . . . . . . . . . . . . . . . . . A8-9 O OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . C4 P PISTON and CRANKSHAFT (600) . . . . . . . . . D2 PISTON and CRANKSHAFT (700) . . . . . . . . . D8 PISTON and CRANKSHAFT (800) . . . . . . . . . E4 R RAIL MOUNTING . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION . . . . . . . . . . . . . . . . . . REAR TORQUE ARM . . . . . . . . . . . . . . . . . . REAR TRACK SHOCK . . . . . . . . . . . . . . . . . RECOIL STARTER (600) . . . . . . . . . . . . . . . . RECOIL STARTER (700) . . . . . . . . . . . . . . . . RECOIL STARTER (800) . . . . . . . . . . . . . . . . B9 B10 B12 B13 D4 D12 E6 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SKI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR (600) . . . . . . . . . . . . . . . STARTING MOTOR (700)(800) . . . . . . . . . . . STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . A4 B3 E7 E8 B4-6 S T TAILLIGHT ASM. . . . . . . . . . . . . . . . . . . . . . A5 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E9 W WATER 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. CHASSIS 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 10 E 2003 Polaris Sales Inc. 11 12 10 6 7 9 8 1 3 2 10 5 14 4 17 26 27 25 10 10 21 24 28 13 10 15 16 18 19 10 20 23 10 10 22 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. 1 3021104 3110078 2 7542404 3 1013379 1013377 4 7517632 5 1014451-309 6 5245202 7 7621432 8 5246177 9 7081076 10 7661637 11 5246278-067 12 5246439-067 13 5246275-067 5246276-067 14 1013857 1013858 Qty. 1 1 1 1 1 1 1 1 6 1 2 64 4 2 1 1 1 Description Stop, Torque (600) Stop, Torque (700)(800) Nut Stop, Torque (600) Stop, Torque (700)(800) Screw Chassis, Touring, Natural Bracket, Oil Bottle Rivet Bracket, Airbox Plug, Hole Rivet Hook, Cargo Hook, Cargo, Front Bracket, Lower, Accessory Attach, LH Bracket, Lower, Accessory Attach, RH Asm., Footrest, Passenger, LH (Incl. 15,16) 1 Asm., Footrest, Passenger, RH (Incl. 15,16) Ref. Part No. 15 5246435 16 7512076 17 1240133 1240134 18 5433150 19 5245457 5245458 20 5246310 5246311 21 7081085 22 5245288 5247205 23 5812437 24 2202059 2202598 25 5221583 26 7080416 27 7661637 28 5132292 Qty. 2 12 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 15 1 Description Mount, Passenger Footrest Screw Cooler, Running Board, LH Cooler, Running Board, RH Strap, Airbox Top Mount, Console, Toe Clip, LH Mount, Console, Toe Clip, RH Support, Footrest, LH Support, Footrest, RH Plug, Barbed Footrest, LH Footrest, RH Foam, Tool w/Adhesive Kit, Mount, Trailing Arm, LH Kit, Mount, Trailing Arm, RH Guard, Adapter Drive Plug, Hole Rivet Bulkhead, Front 4/03 A3 Tour. Wind. Grab Handle Rivet Tube... Torsion 1 Plate. Touring 1 Asm. Seat 4/03 A4 .. Seat Latch. Pssngr. Seat 1 Spring. Seat Cover. Description 1 1 2 2 2 1 1 2 6 1 2 2 4 2 Handle. refer to PartSmart. Seat. Passenger Plug. Overflow Grip. RH Asm.. which is updated monthly. Part No. RH Heater. Seat. Seat. 2-9) 3 Screw 1 Latch. Base. Edge. Passenger Asm. Grab Handle Ref. Primary (Incl. 11 1013963-067 1013964-067 12 2461199 13 5431096 14 5412306 15 2683161 2683162 16 2632756 17 7661637 18 1014499 19 7517219 20 7558301 21 7621319 22 5631194 Qty. 3-9) 1 Asm. Flat Rivet Nut. Mount.. Tour.... LH Handle. LH 1 Plate. Grip. Handlebar. Mount. Grab. Base. Secondary 1 Asm. Touring (Incl. Passenger. To ensure that correct parts are received. Deflector. Ref. Grab Handle Screw Washer. 3 4 1 5 7 8 22 9 21 20 19 6 18 11 12 13 14 10 17 16 15 Part numbers may have changed since this microfiche was issued. Wind.SEAT 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 E 2003 Polaris Sales Inc. Grab. 2683071 1 2683323 2683324 2 2683326 2683327 3 2683325 4 5 6 7 7512026 1013935 7042246 5247090 5247091 8 7621485 9 7512098 10 5434660 Qty. Seat. Passenger 1 Asm. LH Asm. Description 1 Asm. Knob. Edge Touring 1 Asm. Seat Cover. Deflector. Passenger.. RH 6 Rivet 3 Screw 2 Bushing. Part No. Latch. Latch. .. 2410324-070 1 2 3 4 5 6 7 8 9 2461178 2461144 2632641 5246525 7081093 4010873 7512076 4010767 4010764 Qty. 10-13) 1 Harness. RH Screw Bail. Snow. 3 5 6 13 4 12 10 1 11 8 9 2 7 15 16 14 17 18 Part numbers may have changed since this microfiche was issued. Taillight. Taillight Ref. which is updated monthly. Taillight 1 Harness. Reflector. Snow..CARGO BOX/TAILLIGHT ASM. Trunk Lock 1 Lock. LH Skirt. 4) 1 Pawl. Description 6 6 1 1 1 2 1 2 1 1 12 Nut. Trunk Lock Rivet Skirt. Bulb 2 Bulb. Ring w/Key 14 Screw 2 Socket.. Edge. Trunk (Incl. Ref. To ensure that correct parts are received. 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 E 2003 Polaris Sales Inc. Part No. Edge. 10 11 12 13 14 15 16 17 18 7546703 7556088 ------2410327 2410328 7517560 5246523 7661637 5434583-070 5434584-070 7621467 Qty. Cover. Part No. Flat Housing. Edge Touring (Incl.. Description 1 Asm. Taillight Asm. LH Asm. Reflector. Trunk (Incl. refer to PartSmart. 6) 1 Asm. Nylok Washer. Passenger Heater Switch 1 Asm. RH Rivet 4/03 A5 . 4 1 2 3 7 6 5 2 8 9 10 Part numbers may have changed since this microfiche was issued. Ref. Natural Bolt Ref. Hitch/Flap Rivet Hitch Asm. RMK. Description 6 6 5 1 1 Washer.BUMPER/HITCH/FLAP 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 E 2003 Polaris Sales Inc. 1 2 3 4 5 5246282 7661637 1013859-067 2632576-309 7512240 Qty. Spring Lock Washer. refer to PartSmart. Rear Bumper. 6 7 8 9 10 7552801 7558301 7621418 5434356-1106 5812229 Qty. Touring. Flat Rivet Flap. Part No. Description 1 10 1 1 6 Bracket. Black w/Chrome Support. which is updated monthly. Part No. Snow. To ensure that correct parts are received.. Snow Flap 4/03 A6 . GAS TANK 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 1 4 3 20 E 2003 Polaris Sales Inc. 5 19 6 18 17 7 16 8 15 5 14 9 13 12 10 11 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. 1 2 3 4 5 6 7 8 9 10 11 7080804 7052095 8450061-600 2511195-070 5810512 7542122 7555960 5810947 5246436-067 7555843 7670021 7515203 Qty. 2 1 AR 1 1 4 2 2 1 2 2 2 Description Ref. Part No. Cable Tie, Releasable Fitting, 90 Degree Line, Fuel Asm., Cap, Fuel Gasket, Fuel Cap Nut, Nylok Washer, Flat Foam, Seal, Rear, Cooler Bracket, Gastank Washer, Flat Nut, Speed Bolt, Carriage 12 13 14 15 16 17 18 7512247 7052215 7080768 8350020-160 5432981 7052269 2520288 19 2410352 20 2410232 Qty. Description 2 1 2 AR 1 1 1 Bolt Pickup Fuel, w/Mesh Ring, Compression Line, Fuel Grommet Fitting Asm., Fuel Tank, Edge, Touring (Incl. 2, 13-20) 1 Sender, Fuel, LH 1 Package, Hardware, Sending Unit (Incl. Gasket and Screws) 4/03 A7 NOSEPAN 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 4 E 2003 Polaris Sales Inc. 6 3 4 5 7 1 2 1 1 1 6 11 13 10 1 12 22 9 8 21 20 25 24 23 19 8 17 8 14 15 18 17 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. 1 2 3 4 5 6 7 8 9 10 11 12 13 7661637 5243992-067 5243978 5810947 7547180 7517935 5243977 7621467 7621431 7661136 5244049-067 5244050 5243991-067 Qty. 14 1 1 1 4 4 1 21 2 6 1 1 1 Description Ref. Part No. Rivet Hinge, Lower, Pivot, RH Mount, Upper, Shock, RH Foam, Seal, Rear Cooler Nut, Flanged, Nylon Screw Mount, Upper, Shock, LH Rivet Rivet Rivet Bracket, Radius Rod Support Brace, Pan, Lower Hinge, Lower, Pivot, LH 14 15 16 17 18 19 20 21 22 23 24 25 7542153 5433518-070 7512163 7621472 5245853 5434343-397 7542122 7555827 7515166 7517312 7552801 5244888 5244889 Qty. 2 1 2 3 1 1 4 4 4 4 4 1 1 Description Nut, Nylok, Flanged Asm., Bumper, Front Edge, Black Bolt Rivet Shield, Exhaust, Heat, Extended Nosepan, Stone Silver Nut, Nylok Washer Screw Screw Washer, Spring Lock Guide, Hood, Edge, LH Guide, Hood, Edge, RH 4/03 A8 NOSEPAN 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 E 2003 Polaris Sales Inc. 7 12 11 3 5 4 6 13 8 14 9 2 15 10 1 16 17 18 19 21 20 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 2 7080963 7621462 3 5811948 4 7621462 5 5812020 6 5810949 7 5812036 8 5812019 9 5812018 10 7621402 3 1 1 1 1 1 1 1 1 1 5 11 12 13 14 15 16 17 18 19 20 21 1 1 1 1 1 2 1 2 1 1 1 Clip, Speed, U-Type Retainer, J-Clip Rivet Foil Rivet Tape, Foil, Nosepan Foil, Tape Foil, Nosepan Foil, Tape, Nosepan, Lower, RH Foil Tape, Nosepan, Upper, RH Rivet 5222769 1013069 7080698 5812352 7075350 7621429 7170742 2670134 5433926 5211722 4020139 Clip, Belt Retainer Asm., Clutch, Guard Pin, Clutch Guard Pad, Clutch Guard Decal, Engine and Clutch Rivet Decal, Troubleshooting, Edge Tour Asm., Reflector, Amber Plug, Nosepan, Oblong Plate, Backer, Clutch Guard Clip, Rosebud 9/02 A9 Plenum Foil Foil. Headlight Adjust Knob. Headlight. LH Bolt Washer.. Headlight Retainer. Suspension Set-Up (600)(700) Decal. Edge Foil 12 7171810 7170741 13 5433660 14 7512068 15 5243567-067 16 7512240 17 7558301 18 7512113 19 5332403 20 7542122 21 7080367 22 5243568-067 Qty. which is updated monthly. Plenum. Headlight. Headlamp Bulb Bolt. Flat Bolt Spacer Nut. Edge. 6 2 1 7 8 9 16 18 10 17 22 20 21 20 11 15 19 20 13 12 19 18 17 16 14 Part numbers may have changed since this microfiche was issued. Bulbs) Seal. Upper. Edge. Tee Adjust Spring. Asm. refer to PartSmart. One Piece Bulb.. 1 1 1 1 1 2 2 1 1 1 2 1 1 1 Description Ref. Ref. Hood.HOOD 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 4 5 3 E 2003 Polaris Sales Inc. To ensure that correct parts are received. Part No. 1 2632521-177 2632521-341 2 2461015 3 2410132 4 5812450 5 2870448 6 4032063 7 7517872 8 7041954 9 7080887 10 5811793 11 2632491 5812324 5811948 Qty. Suspension Set-Up (800) Cover. Headlamp (Incl.. Headlight. Prefilter Asm. Headlight Adjust. Cable Hinge. 1 1 1 10 1 4 4 2 2 6 1 1 Description Decal. Black Asm. E/R Asm. Access Screw Hinge. Nylok Clamp. Locking Foam. Hood. Sonic Blue Harness.. Edge. Part No. Upper. RH 5/03 A10 . which is updated monthly. 1 4 1 1 1 2 1 2 2 2 1 1 1 6 6 3 2 2 2 2 Description Asm. Part No. 6. Rubber Asm. 9-13)(600) Kit. Fuel Gauge Washer.HOOD 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 800 Only 2 14 13 8 1 7 3 5 15 16 12 6 4 9 11 10 17 E 2003 Polaris Sales Inc. 9-13)(700)(800) Bulb. To ensure that correct parts are received. Mirror. Flat Bracket. Windshield Nut Washer. Split Lock Washer. LH Asm. Lock Back. Nylok Clip. Replacement Knob. 1 2 3 4 5 6 7 8 7621509 5435044 5410970 7541933 7555868 3280322 3280323 3280404 3 1 4 2 2 1 1 1 9 10 11 12 13 14 3280158 3280156 3280157 3280210 3280209 2874394 4 4 4 2 2 1 2874401 1 4030015 15 3280186 3 1 Description Ref. Ref. Speedometer/Tachometer Cushion. Head (Incl. Part No. Rubber Kit. Hood Retainer Rivet 4/03 A11 . Flat Nut. 17 Inch Retainer. Rubber. Fuel Gauge Fuse Cushion. Tachometer w/Rev (Incl. Flat Washer. refer to PartSmart.. Fuel Gauge Bracket Bracket.. Hex Cable. Nylok Cable. Gauge.070 7556088 7546703 26 4010589 27 7512018 28 7541925 29 7080521 30 7661637 Qty. Fuel Gauge Spacer. Trip Odometer 16 3280411 4030015 17 3280410 4060139 18 3280230 19 3280228 20 3280229 21 3280231 22 3280233 23 3280232 24 3280385 25 2632246-. Split Lock Nut. Rosebud Screw Nut. 9 24 11 10 21 18 19 20 23 22 25 26 27 28 26 29 30 Part numbers may have changed since this microfiche was issued. Speedometer Bulb. Qty.. Clamp. Mirror. Rivet Windshield.. Tachometer w/DET (Incl. Speedometer Asm. Ride Control. Replacement Asm. Gauge Cushion.. RH Washer.7) Nut Washer.070 2632247-. which is updated monthly. RH Retainer. LH. Lower. Rear. Hood. Tape.FOIL/FOAM 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 1 14 E 2003 Polaris Sales Inc. Side. Upper. Hood Closure. Hood. Part No. Closure. 1 1 13 2 12 11 10 1 3 1 4 5 VIEW LOOKING AT HOOD FROM UNDERNEATH 6 9 7 8 Part numbers may have changed since this microfiche was issued. Hood. Black Closure. RH. Lower Closure. To ensure that correct parts are received. Black Closure. Black Backer. Upper. 8 1 1 1 1 1 1 Description Ref. Rivet Closure. Part No. Ref. LH Foam. Upper Foam. Hood. Hood. Hood. Black Retainer. Closure. Hood. refer to PartSmart. 1 1 1 1 1 1 1 Description Foam. LH. Hood Center Foil. Lower. Black Closure. Hood Closure. Front. Black 3/02 A12 . LH 8 9 10 11 12 13 14 5812007 5812017 5246029 5434199-070 5434201-070 5434195-070 5434223-070 Qty. Side. Upper. 1 2 3 4 5 6 7 7661142 5434196-070 5434197-070 5434198-070 5246028 5812270 5812286 Qty. Black Backer. Hood. 9 8 7 6 5 11 13 15 10 27 28 12 14 16 26 25 17 23 18 22 21 20 19 A13 24 .DECALS 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 1 2 3 4 E 2003 Polaris Sales Inc. 16-18. EDGE TOURING 1 Decal. Rear. “800” 1 Decal.7. Part No. “EDGE TOURING”. LH (700) 1 Decal. Rear 1 Decal. Hood Center “EDGE TOURING” 1 Decal. “LIBERTY 700”. which is updated monthly.20. Ref. “PERC” 1 Decal. Domed 1 Decal.23. ’04 600 Edge Touring (Incl. RH (700) 2 Urocal. Description 1 Kit. Reflector.21. ’04 700 Edge Touring (Incl. Hood Side.21. Hood Side.3. “Max. Hood Decal. Front 1 Urocal. Part No. Hood Side. RH 1 Decal. Snowskirt. Snowskirt.” 1 Urocal.3.RH 2 Urocal. Snowskirt.20. Electric Start. “EDGE IFS”. 2. 19 7171213 1 Decal. Pan. LH 1 Decal. LH 1 Decal. “LIBERTY 600”.10. Pan. “POLARIS”.28) 1 Kit. LH (700) 1 Decal. English/French. RH (600) 1 Decal.16-18. Hood Decal. Snowskirt. 1 Decal. Warning. Trailing Arm. “POLARIS” 1 Decal. Trailing Arm. Hood Decal. Warning/Rev/Elec. RH (600)(800) 1 Decal. Hood Side. Pan. Edge Tour. RH (600)(800) 1 Decal. Rev. “LIBERTY 800”.14-18. Hood Top.23. Opt.RH 2 Urocal. TPS 2 Urocal. ’04 800 Edge Touring (Incl. English 1 Decal. “Pssngr. “EDGE IFS”. Hood Top.28) 1 Decal. “ACE”.20. Ignition. 30 Lbs. Warning.21. Qty. LH 1 Decal. 2. Reflector. Reflector. LH (600)(800) 1 Decal. Dash 1 Decal. “POLARIS” Ref. Warning. “LIBERTY 800”. Snowskirt. “EDGE TOURING”. Rear.3.11. Track/Seat. RH (700) 1 Decal. Snowskirt. RH 7171214 20 21 22 23 24 25 26 27 28 7171407 7171408 7171216 7171209 7171210 7171211 7171212 7171405 7171406 7171207 7171208 7171199 7171409 7171410 7171197 7171198 7171355 7171356 7170603 7170604 7171135 7170607 7076360 7171201 7171202 Description 4/03 A14 . 2202588 2202589 2202590 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 7079886 7171221 7078716 7079887 7170061 7075439 7170608 7170112 7079509 7171219 7171203 7171204 7171324 7171403 7171404 7171220 7171205 7171206 7171217 7171215 7171218 7171195 Qty.23. “700” 1 Decal. To ensure that correct parts are received. LH (800) 1 Decal. LH 1 Decal. Pan. refer to PartSmart. 2. LH (700) 1 Decal. “EDGE IFS”. (14 KG)” 1 Decal. LH 1 Decal. LH 1 Decal. “EDGE IFS”. LH 1 Decal. RH (700) 1 Decal. LH (600) 1 Decal.DECALS 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 Part numbers may have changed since this microfiche was issued.12. French 1 Decal. RH 1 Decal.7. “ACE”. Hood Center. Hood Center “EDGE TOURING” 1 Urocal. Trailing Arm.13. “LIBERTY 700”. RH (800) 1 Decal. LH (600)(800) 1 Decal. “LIBERTY 600”. Choke 1 Decal. LH/RH 1 Decal.28) 1 Kit. RH 1 Decal. Trailing Arm. RH 2 Urocal. “POLARIS”. “600” 1 Decal.7. 8 7 11 12 1 2 3 4 8 10 9 13 7 4 5 14 6 2 14 41 20 15 17 15 42 21 22 7 16 7 19 18 7 17 40 39 25 38 24 23 26 27 37 31 28 32 14 7 36 29 33 34 35 B1 30 .FRONT SUSPENSION 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 E 2003 Polaris Sales Inc. Mount. Part No.FRONT SUSPENSION 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 Part numbers may have changed since this microfiche was issued. Trailing Arm Bearing. Jam Rod. Qty. 2 8 2 4 2 2 12 4 2 2 2 2 2 2 2 6 4 2 4 1 Description Bolt Bushing. Threaded Screw Washer Arm. RH (Incl.22) 2 Washer. which is updated monthly. Radius. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 2 2 2 2 2 2 2 2 6 1 2 2 2 2 2 2 2 2 2 2 2 2 2 5132364 7061042 7710437 7512099 7061057 3573909 7080433 5433814 7621452 5244557-067 5434371 7556509 3574208 6230225-067 7080306 5010158 7061060 7542711 1820677-385 7547065 7061061 5132780 7512684 Description Cup. Compression Indy Blue Retainer. Adjust Retainer. Spring Slotted Spring. Cloud. w/Steer Stop Fitting.. Flat Asm. Radius Nut. Radius. Spring. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 7517980 5434036 5132779 7547066 1820679-385 7542520 7542439 7515433 7041918 5431734 5630580 7042074-067 7042074-385 7042074-312 1500063 7517583 7555832 5132728 7555797 1821165-385 1821166-385 19 7555820 Qty. Radius Rod. Shoulder Bolt 4/03 B2 . Nylok Screw Shock. Lubrication. RH Bushing. Black Spring. Cloud Silver Nut. Gas Ring. Body. Upper. Torsion Bar Bushing Bushing. Pivot. Spherical Ring. Lubrication Bushing. Cloud Silver. refer to PartSmart. Flat Ref. Trailing Arm. Compression. Flanged Shaft. To ensure that correct parts are received. Nylon Rod. Part No. 21.22) 1 Asm. 21. Compression. LH (Incl. Flange Fitting. Steering Washer. Spindle. Radius Bushing. Spring Preload. Shoulder Nut. Nylon Rod End.. Cloud Silver Spring. Cloud Silver. Lower. Torsion Bar Rivet Bar. Silver Nut. Inner Bushing. Jam Nut. Ref. w/Ball Bushing Rod End. Torsion Slide. Retainer Screw Rod End. Trailing Arm. 60 Degree 2 Bolt 2 Screw 9/02 B3 . Ref. Anti. refer to PartSmart. Black Washer. Dart Dual. To ensure that correct parts are received. Nylok Washer Toe. Description 8 2 2 2 Washer. Ski. 4 Inch. Nylok 9 10 11 12 7556175 1820929-070 7517968 2874752 13 7515514 14 7515307 Qty. which is updated monthly.. Part No. Plastic Ski Stop. Flat Asm. 1 2 3 4 5 6 7 8 7542321 7542439 7555832 5434165-070 7556130 5132637 5412018 7542324 Qty. Plastic.SKI 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 7 E 2003 Polaris Sales Inc. 8 9 4 6 2 5 10 1 2 3 5 11 14 3 13 12 Part numbers may have changed since this microfiche was issued. Ski Rubber Nut. Skag. 2 4 4 2 4 2 2 8 Description Ref. Part No. Comp Ski Screw Kit. Belle Bushing. Flange Nut. Nut. which is updated monthly. Description 2 2 4 2 2 4 1 1 Palnut Washer. Black Bracket. Flat Nut. Description 4 1 4 4 4 6 2 1 1 Bolt. Tie Rod. Ref. Carriage Nut.STEERING 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 E 2003 Polaris Sales Inc. LH Boot. RH Ref. Rosebud Bolt. Steering Clip. Console. Steering Post Fitting. Front Neck 4/03 B4 . Carriage Hoop. Zerk Bushing. refer to PartSmart. To ensure that correct parts are received. Steering Post Post. 1 2 3 4 5 6 7 8 7517579 1013804-067 4020139 7512377 7542343 7621433 5244470 5433532 5433533 Qty. Steering. Part No. Flanged Rivet Plate. 9 10 11 12 7547030 7558402 7542324 5133648 7080510 13 5432785 14 1820965-067 15 5245354 Qty. Tie Rod Boot Boot. Tie Rod. Nylok Bracket. 11 1 12 13 15 14 12 3 13 2 3 4 5 11 10 9 1 8 6 7 Part numbers may have changed since this microfiche was issued. Part No. Retaining Ring.. 12 2 1 3 4 5 8 6 28 27 26 25 24 13 11 7 14 10 15 16 9 17 23 7 22 18 19 20 21 1 Part numbers may have changed since this microfiche was issued. LH 2 Heater... LH (See Brake Pg. Handlebar Cover Dart. Retaining Lever. Description 2 1 1 1 1 1 1 2 1 4 1 2 1 1 2 2 Grip. Throttle Plug. Auxiliary Shut-Off. Ref. Control. Clip. 13) 2 Block. Part No. Handlebar Slide. Lever w/Heater.. Overflow Handlebar Screw Collar. HI/LO Switch. To ensure that correct parts are received... Throttle/Brake 1 Ring. Description 1 Collar. Handlebar 1 Post. Grip. 16 5434487 17 2460677 18 .. Wire 1 Washer 1 Screw. which is updated monthly. Star Cover. Nylon Ref. Nylok 8 Screw 1 Holder. B4.. Push-On Emblem. Set 1 Block. Part No. Console. Console. Throttle Asm. Block. Closed Adaptor. Handlebar Pin..HANDLEBAR 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 E 2003 Polaris Sales Inc. Lo/Med/Hi 1 Asm. refer to PartSmart. Black (See Steering Pg.19 5630187-067 20 .. Steering.. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 5432634 7661624 7710503 5432970 2010171 4110106 5433345 5431096 5243355-067 7517238 5434488 7670106 5434179 5433159-070 5433160-070 4010287 Qty. RH Nut. Ref. B7 Ref. 14) 4 Nut. Retaining 2 Washer 4/03 B5 ..21 22 23 24 25 26 27 28 7542122 7511848 5432261 7555727 7512465 5431592 7710401 7555730 Qty. Part No.16) 4/03 B6 .STEERING 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 E 2003 Polaris Sales Inc. which is updated monthly.16) 2 Spacer. Description 1 Post. RH Rod..11 12 13 14 15 16 17 7061075 5132106 1820957 5133423 7512435 3514320 1820959 Qty. RH Nut Rod. Ref.. B4. 1 2 3 4 5 6 7 8 9 7061057 7542401 5333949 7542424 7061055 7061076 5333772 5333773-067 7542439 Qty. Steering.. Reducer 1 Asm. Ref. Black (See Steering Pg. Part No. To ensure that correct parts are received. Rod End. Nylok 10 . LH Rod End.. refer to PartSmart. Tie Nut. 10 9 2 5 4 1 2 6 3 7 9 12 4 11 9 5 4 16 11 9 17 3 16 14 12 6 8 2 12 16 15 13 9 2 14 16 1 12 15 Part numbers may have changed since this microfiche was issued. 14) 2 Rod End. Pitman Arm (Incl. Ball 1 Asm... 12. 12. Steering Rack Rod. 2 4 2 4 2 2 1 1 8 Description Ref. LH 4 Bushing. LH Rod End..14. Tube Pitman/Idler Arms 2 Screw 4 Bearing.14. Draglink Nut. Idler Arm (Incl. . Asm.23) Washer Washer. Control. Brake. 17. Brake Caliper (Incl. Seal Kit. Kit. Cartridge Subassembly Asm. LH E/R (600)(700) Asm.. Edge. 1 1 1 1 1 1 1 2 2 2 1 1 1 Description Button. Bleeder Fitting Line. Master Cylinder Switch. HI/LO. Park Lever Spring Asm.11.. Piston/Seal Kit. Part No. Lever Screw Kit. LH E/R (800) 14 15 16 17 18 19 20 21 22 23 24 25 5433291 2201946 2201251 2202202 2202207 2202204 2202201 7556160 7552603 7515534 2202206 2202205 1910607 Qty. To ensure that correct parts are received. Switch.BRAKE 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 E 2003 Polaris Sales Inc. Snap Ring Kit. refer to PartSmart.15) Screw Screw Kit.4. Pin Retaining Kit.3) Gasket Kit. which is updated monthly. Cover Screw Kit. 2. 1 2 3 4 5 Qty. Asm. w/Snap Ring Kit.8. Type 81 Kit. Brake Pad. Braided 4/03 B7 .18. Part No. Brake Light Kit. LH Control Kit.12. Park Lever and Spring (Incl. 1 17 2 18 3 25 16 4 24 6 19 15 5 23 7 14 13 21 20 22 9 8 11 12 10 Part numbers may have changed since this microfiche was issued. 4) Kit. Control. Spring Lock Screw Kit.. 1. Throttle. 2201254 2201255 ------2201250 2010219 1 1 1 1 1 7517441 7512078 2201943 7517566 2201945 2202146 4010157 12 2201944 13 2010206 2010208 2 1 1 1 1 1 1 1 1 1 6 7 8 9 10 11 Description Ref. Cover Assembly (Incl.. Master Cylinder (Incl. Ref. Pivot Pin. Sliding Bearing. Seal. refer to PartSmart. which is updated monthly. Chaincase. 41T (600) Sprocket. Retaining Sprocket. 1 2 3 7 4 6 5 8 9 10 11 12 23 13 14 15 1 4 20 22 21 6 8 19 18 17 16 Part numbers may have changed since this microfiche was issued. Tightener. 21T (600) Sprocket. Cotter 12 13 14 15 16 17 18 19 20 21 22 23 7547202 5411497 5631354 7512242 7517979 7571618 3222101 3222099 3221109 7542451 7052115 5134085 7515477 Qty. Chaincase Screw Screw Washer. 74P.. Dowel Asm. Dipstick O-Ring Ring. Part No.CHAINCASE 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 E 2003 Polaris Sales Inc. 40T (700)(800) Chain. 1 2 3 4 5 6 7 8 9 10 11 3610030 7542404 7515459 7661826 1332266 3514309 1332143 5410675 7718406 3221097 3221098 7571620 7661203 Qty. Oil Nut Screw Pin. Spring Sprocket. To ensure that correct parts are received. Spring Pin. 1 1 1 5 1 1 1 1 1 2 1 1 1 Description Nut Gasket. 3/4W Nut. 2 1 1 2 1 2 1 1 2 1 1 1 1 Description Ref. O-Ring Cover. Part No. 22T (700)(800) Washer. Ball Asm.. Nylok Plug Chaincase Screw 4/03 B8 . Ref. 2 2 2 6 1 1 1 1 2 2 2 2 4 6 6 4 2 2 2 2 2 Description Nut. 1-3.17. Flat Block. Rail. Description 1 Asm. Flat 2 Bolt 2 Washer.. Spring 6 Asm. Rail Tip 2 Block.RAIL MOUNTING 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 16 E 2003 Polaris Sales Inc.16. Wheel. Slider.14. Nylok 4 Washer 2 Cap. Retaining (1 per Wheel) Bearing (1 per Wheel) Screw Rivet Bolt Screw Hi-Fax Screw 5/03 B9 . To ensure that correct parts are received. LWT 8 Washer. Idler Bolt Adjust Ref.30) 2 Plate. Coupler Block Bolt Block.34) 6 Nut. Shock Pivot Threaded Screw Ring. Scrolled. Flat 2 Bumper 2 Liner.. Silver (Incl. 5 7 9 8 15 1 13 10 14 5 11 12 19 24 26 25 23 27 22 8 28 12 1 2 5 6 3 2 4 32 5 18 31 11 17 20 21 9 35 12 2 34 36 33 9 8 7 30 9 29 Part numbers may have changed since this microfiche was issued.17.. RH (Incl. which is updated monthly. Slide. Slider. Jam Screw Plate. M-12 LH (Incl. LH Block. RH Bolt Nut Washer. Wheel Mount. Long. RH Guide. Rail Support 12 Nut. Part No. 1542004 1542005 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7541925 7555792 5434374 5132577 7542324 7558402 7515382 7556179 1590318-244 5244651 7515317 5631065 7555783 5412336 5432946 15 7512392 16 7621501 17 5132444 Qty. 29. Slider. Rail Support 4 Bolt 6 Block.16. Bumper 2 Screw 4 Rivet 2 Block. Long. M-12..31.34) 1 Asm. Rail. Nylok 8 Washer. 1-3. LH Guide. Ref..14. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 7547156 7517773 5245045 7512310 5434885 5434886 5631188 5631189 7515511 7542404 7555806 5132584 7515346 7718407 3514303 7510504 7661845 7512329 7511975 5521632 7515199 Qty. Part No.31. refer to PartSmart. Shockwave Clip. Guide Fitting. Spring Lock (M-12)(Qty 2 for Ace) 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 7556042 5132583 5434897 5010332 7555976 7515538 3514384 7710444 7517996 7518005 5412342 5241473 5241474 7080424 1012267 1541797 5334042 5133093 7558402 5333477 Qty. Shock Pivot Adjust (M-12) Guide. which is updated monthly. Shock Centering (M-12) Shaft. refer to PartSmart. Lower Washer. Ref. Flat Bushing (M-12) O-Ring (M-12) Spacer. To ensure that correct parts are received. Belle Bolt Screw Screw Screw Washer. Retaining Screw Screw Track. Long Shaft. Idler. Arm Tube Shaft. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 7547217 7556216 7556401 5411092 5333902 5132793 7555806 7542439 7547064 5432535 7555918 1594087 5333285 5020744 1590303-244 7556130 7517731 7517896 7517821 7517856 7552603 Qty.. Flat Bolt Bearing Ring. Square Bushing Washer. Nut. Rear Torque Arm.... Part No. Flat Nut. Wheel Spacer.REAR SUSPENSION 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 10 E 2003 Polaris Sales Inc. Flat Tube 4/03 B10 . Idler Bushing Asm. Nylok Washer. 4 3 5 8 9 6 13 7 38 M-12 14 10 39 15 38 37 1 12 11 16 17 2 18 7 35 2 34 36 2 24 25 33 32 22 21 31 23 22 21 26 M-12 19 20 27 15 28 30 29 Part numbers may have changed since this microfiche was issued. Spring. Idler Wheel. Silver Metallic Washer. 1 3 2 2 2 1 6 3 1 4 1 2 1 1 2 2 2 1 1 2 4 Description Ref. Idler Asm. Limiter Strap Shock Pivot. Lubrication Shaft. Tapered (M-12) Washer. 4 2 2 2 1 1 2 2 1 2 1 AR AR 1 1 1 1 1 2 1 Description Washer (M-12)(Qty 2 for Ace) Block. Nylok Spacer. Part No. Slide Clip. Nylok Nut. . Nylok Washer. Ref. Flat Washer. Limiter (800) 4/03 B11 . 24) 10 . Ref. To ensure that correct parts are received. Torque.. Part No. w/o O-Ring 2 Bumper.. Part No. Front. B10. Flat 4 Bolt 2 Strap. Front. 3 4 5 1 2 16 17 6 16 7 8 15 8 18 9 15 16 13 14 10 12 17 11 Part numbers may have changed since this microfiche was issued. Description 1 Bolt (See Rear Suspension Pg.. Cloud Silver Shaft. B10. Front Torque Arm.. Arm... 1 1 2 2 2 2 2 3 2 Description Ref. which is updated monthly.FRONT TORQUE ARM 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 E 2003 Polaris Sales Inc. Lubrication Guide. Torque Arm 4 Rivet 4 Nut. Ref. Upper Washer. 1 2 3 4 5 6 7 8 9 1541816-385 5020812 7555984 7552614 7517815 7542439 7555743 7080424 ------- Qty. Nylok 8 Washer. Limiter (600)(700) 1 Strap. Lock Screw Nut. Flat Fitting. refer to PartSmart.11 12 13 14 15 16 17 18 5412022 5133531 5432166 7621418 7542324 7556175 7512310 5412225 5412512 Qty. 27) 2 O-Ring 2 Shaft. Spring Square (See Rear Suspension Pg. Nylon Clip. . Spring Retainer. B10..405/77. Front Track Retainer. Spring Shield. Ref. Lock Ref. Qty. 4 5 6 2 7 8 9 1 23 2 11 35 12 10 13 14 15 16 34 26 7 33 22 32 31 25 30 2 28 26 29 17 23 18 21 20 24 19 27 29 28 Part numbers may have changed since this microfiche was issued.405/77. Upper Sleeve. B10. Bearing Lock Screw. To ensure that correct parts are received. Spring Preload. 37) Fitting. Retaining Washer. LH Spring. Adjust Spring. Torsion. Part No. Tapered (See Rear Suspension Pg.. FLEXLOC.. Compression Shield. Rear. 1541798-385 7542411 7042141 5132064 5434921 5333905 7515433 7042161 3514450 ------- 1 1 1 1 1 1 2 1 1 1 11 5133484 12 5434627 13 7042240-067 7042241-067 14 7556296 15 1590355 3514330 7710486 16 7556303 17 7552614 1 1 1 1 2 2 2 2 2 2 Description Arm. Compression Bearing Shaft. Square Rod. Torque. 18 7517815 19 7555984 20 5134207 7512257 21 . 6) Shaft. Part No. Adjust. Spring. . Cloud Silver Nut. Wave Washer. Shock Screw Washer. Wheel. Torsion Spring Spring. Socket Head Washer. RH Washer Asm. Spring Slotted 4/03 B12 . Wave Spacer Shock. Torsion. Rear Torque Arm. Spring Ring. Rear. Lower (See Rear Suspension Pg.- 2 2 2 2 1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 2 2 2 2 1 2 2 1 1 1 1 1 1 7080424 3514441 7080394 5432983 1541821 7517378 7555795 5333028 7041486 1500091 5431734 7041404-067 5410874 5020618 Description Screw. 1 2 3 4 5 6 7 8 9 10 Qty... which is updated monthly. Flat Collar. Track Retainer.. Socket Set Shaft. Spring Sleeve Screw Spring.REAR TORQUE ARM 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 3 E 2003 Polaris Sales Inc. Lubrication Bushing. refer to PartSmart. Push-On Roller. Rear Torque Arm.. Ref. Offset Bearing Ring. Thin Shock. Ref.. Cylinder Head Asm. Ref. refer to PartSmart. Part No.REAR TRACK SHOCK 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 4 2 3 5 2 4 1 2 6 E 2003 Polaris Sales Inc. 7 8 9 10 11 15 12 13 17 14 16 Part numbers may have changed since this microfiche was issued. Top-Out Washer. Pressure Valve O-Ring. Flange (Ace) Bushing (M-12) Bearing Screw. Part No. 7042141 5133403 5411092 5133402 7556401 3514450 1700056 1700184 1700047 8 1700033 9 1700216 1 2 3 4 5 6 7 Qty. Cylinder Head Bumper Mount. Pressure Valve Nut. which is updated monthly. M-12 Bushing (Ace) O-Ring Bushing. Back-Up O-Ring. Rear Track.. Upper Shaft Sleeve Bushing 4/03 B13 .. To ensure that correct parts are received. Description 1 1 2 1 2 1 1 1 1 1 1 Shock. Description 1 1 1 1 1 1 1 1 1 1 2 Asm. Spring Retainer Nut Ref. Valve Asm. Piston Band.. 10 1700100 1700031 1700077 1700078 11 1700051 12 1700156 13 1700042 14 1700011 15 1700215 16 1700069 17 1700075 Qty. Wear Washer. Black/Green 1 Nut.11)(800) 6 Bolt 6 Washer. Description 1 Asm. Roller (800) 4/03 B14 .050) Spacer (. All Less 5. Drive Clutch ES Basic 118 (Incl. Clutch. Drive Clutch Shim Pin. refer to PartSmart.. 1 2 3 4 5 7 6 8 9 11 12 10 19 18 9 13 14 17 15 16 Part numbers may have changed since this microfiche was issued. Part No.130)(800) Asm. Retaining.032) Spacer (. Sleeve Insert. Ref. Roller (600)(700) Pin. Clutch. Moveable Gear.025) Spacer (. Ring Screw Nut. Drive Clutch ES Basic 125 (Incl. Weight/Bushing 10-64 (700)(800) Pin. To ensure that correct parts are received.020) Spacer. Weight Bearing. Spring Lock 1 Bearing.. Multilube 3 Asm. All Less 5.. Cover 1 Spring. Jam 6 Washer.. Drive (. Part No.11)(600) 1 Asm. AR AR AR AR AR 3 3 3 1 1 1 6 3 1 3 3 Description Spacer (. Cover (800) 1 Ring..DRIVE CLUTCH 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 E 2003 Polaris Sales Inc. All Less 5. Roller and Bushing 6 Button.. Cover (600)(700) 1 Bearing. Drive Clutch ES Basic 117 (Incl. Guide Ref. 1321932 1321931 1322022 1 7512265 2 7552801 3 3576516 3514347 4 7710417 5 7042083 6 5020425 7 5430945 8 1321622 9 5430445 Qty.11)(700) 1 Asm. which is updated monthly. 10 5210754 5210753 5242981 5210752 5132542 11 1321586 1321585 12 7515105 13 3576502 14 5010188 15 5131062 16 7515351 17 7541906 18 2200387 19 5133079 5133054 Qty. FLEXLOC Kit. Weight/Bushing 10-62 (600) Asm. refer to PartSmart. Driven 60/42-. Description 1 Asm. Windage 5/03 C1 . Retaining 2 Roller Ref.65 (800) 1 Ring. 3 4 5 6 7 8 9 10 6 8 7 11 12 13 14 1 Part numbers may have changed since this microfiche was issued. Driven Clutch. 1322321 1 2 3 4 7518023 5246216 3233996 5134095 5134226 5134204 5 7710522 6 5434534 Qty. Windage 8 Screw.36 ER (600) 1 Ramp. Driven Clutch.DRIVEN CLUTCH 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 1 2 E 2003 Polaris Sales Inc. Thrust 2 E-Ring. Basic 211 (Incl. Description 1 Washer. Part No.. Cap 1 Ramp. 7 7556226 8 7710523 9 7042165 10 11 12 13 14 7042167 7556227 3234033 7518024 7542103 5246217 Qty. Ref. Retaining 1 Spring. Driven Clutch. Thrust 1 Spacer 1 Screw 1 Nut.11-14) 12 Screw 1 Plate. To ensure that correct parts are received. Red/Silver (800) 1 Washer. FLEXLOC 1 Plate. Part No. which is updated monthly. 5-9. Driven 56/42-. Driven 64/44-. Red/Green (600)(700) 1 Spring.75 ER (700) 1 Ramp. Description 1 Receptacle.D. Letter code will be labeled on underside of switch body behind console. Ignition 1 Kit. Ref. refer to PartSmart. two dots= B.C. 13 14 15 16 17 12 1 2 18 19 11 3 20 4 5 6 7 12 8 9 10 Part numbers may have changed since this microfiche was issued. 1 Circuit Housing Harness. 18. Pod Mount 1 Cap w/Key NOTE: When ordering ignition key PN 5410611 be sure to specify if for an A. Nylon 1 Kit. 2 2 1 1 2 2 7 1 1 1 1 1 2 Description Ref. etc. Rectifier (800) Screw Housing. or E switch.3V (600)(700) Regulator.070 12 7515199 Qty.20) 1 Nut. Choke Control (Incl. 1 Nut. Choke Slide 4/03 C2 . 1 7541925 2 7555746 3 4010794 4010730 4 7517263 5 4010193 6 4010192 7 4020153 8 4020063 9 2461149 10 4020057 11 5434483-. Ignition Switch 2 Clip. one dot = A.B. Plastic Dart. Main.). Part No. Part No.CONSOLE 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 E 2003 Polaris Sales Inc. Nut. To ensure that correct parts are received. TPS ER Housing Console w/ACC Screw 13 4010638 14 5410611 15 16 17 18 19 20 7547035 2200358 7670088 2200188 7080290 7080229 Qty. Connector Socket Housing.e. which is updated monthly. AC/DC 14. Key dot code found on key cap (i. Choke Control 1 Cable. Nylok Washer Regulator. Springband 1 Cooler. Hose Bottle. Ref. 8 6 9 6 1 2 1 19 4 5 6 10 1 18 17 16 1 15 6 7 3 Brake 23 20 21 22 10 6 6 14 13 12 11 Part numbers may have changed since this microfiche was issued. Bulkhead Hose. Pressure Decal. Convoluted Spacer. Part No. Gripper/Center Cooler Ref. Side Cooler/Rear Cooler 1 Exchanger. Front Cooler/Engine Out Clamp. To ensure that correct parts are received. LH 1 Cooler. 12 13 14 15 16 17 18 19 20 21 22 23 5521602 5810291 2520292 5412236 7080560 5412237 5412160 7080951 2520312 2511270 7170063 8450003-1525 7080761 Qty. Brake Cooler/Gripper 1 Hose. Pump/Bottle (700)(800) Clamp.COOLING SYSTEM 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 E 2003 Polaris Sales Inc. Hose Hose. Rear 18 Rivet 1 Hose. RH 2 Hose. Center Out/Bottle In (700)(800) 1 Cable Tie 8 Clamp. Rubber Cooler. Description 1 1 1 1 1 1 1 1 1 1 1 1 1 Tubing. Running Board. Center Out/Bottle In (600) 1 Hose. Bottle to Engine (600) Hose. Engine Out/Brake Cooler (700)(800) 1 Hose. Bypass/Brake Cooler (600) 1 Hose. which is updated monthly. Springband 1 Hose. 1 7080844 2 5412432 5412244 3 5412351 4 5412433 5412341 5 7080138 6 7080841 7 1240133 1240134 8 5412255 9 1240150 10 7661637 11 5412083 Qty. Coolant Cap. Running Board. Closeoff. Part No. Water Bottle Cap Line. Description 7 Clamp. refer to PartSmart. Fuel Cable Tie 4/03 C3 . Greasing Asm.OIL TANK / AIRBOX 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 E 2003 Polaris Sales Inc. 19) Fitting Clip. Ignition (See Magneto (700). Air Silencer (Incl. To ensure that correct parts are received. D11. Pg. w/Front Terminals Grommet. 23 & Decals)(600) Asm. Oil Tank w/Sender (Incl. Well Washer. 17) Clip. 1 2 3 4 5 5434089 5812209 7512297 7542122 1253453 1261199 6 7512095 7 ------8 9 10 11 12 13 14 Qty.26) Oil Bottle/Tool Box w/Mnt Screw Kit. 1. 23 & Decals)(700)(800) Ref. Air Box. Pg. Chimney Decal. Nylon Coil. which is updated monthly. refer to PartSmart. Description 1 1 1 1 1 1 2 1 7052127 7670102 5811983 7075351 5433150 7073426 1253498 2 1 1 1 1 1 1 1253501 1 Cover. Carburetor (600) Boot. Tool Box Screw Nut. Description 1 2 2 1 1 2 2 2 2 2 2 AR 1 1 1 1 Decal. Vented 4/03 C4 . D11.. Hose Line. Silencer Foam. Carburetor (700)(800) Clamp. Top Decal. 15 16 17 18 7171037 7547103 7555932 ------- 19 20 21 22 23 7080471 7552604 7517610 7511862 5412169 5412157 7080307 8450003-1525 4010660 7052305 7079003 1240094 24 25 26 27 28 29 Qty. VES Cap. Oil Sender Decal. Part No. Air Silencer (Incl. Oil. Oil. Fuel Sender. Ignition Cable Washer Screw Screw (700)(800) Boot. Ref. Air Box. Air Box Strap. CDI (See Magneto (700). 1 10 2 6 3 7 4 29 8 12 11 9 13 14 5 15 28 23 27 22 26 17 24 21 25 20 16 18 19 24 Part numbers may have changed since this microfiche was issued.. Part No.. Tool Box Foam. E/R Belt Removal Nut. Caution. Ref. Oil. Ref. Nylok Asm. Ref. To ensure that correct parts are received. w/Hole Key. Jackshaft Nut. Flangette w/Screws Bushing. Carriage Asm. 1 1 1 1 3 2 2 1 1 2 1 1 1 1 1 1 1 Description Key Asm. Brake Nut. Speedometer. Lubrication Gasket. Part No.. C1 for Details) Belt. refer to PartSmart. Flanged Sleeve. 2 3 7 4 5 8 9 10 14 15 11 6 17 12 13 16 18 13 33 32 31 30 29 20 19 14 28 21 22 23 27 24 22 23 26 25 21 Part numbers may have changed since this microfiche was issued. Drive Adaptor Adaptor w/Zerk. Drive Washer Washer Bushing Washer.. Metal Flangette. 1 2 3 4 5 7515369 7555701 7555734 5020913 ------- 1 1 AR 1 1 6 7 8 9 10 11 3211080 7555917 7555864 7556509 7558402 5241359 7080561 5811095 7542324 3514525 5222751 7512377 1 1 AR AR 3 1 1 1 6 2 1 3 12 13 14 15 16 Description Ref. Driven Clutch (See Driven Clutch Pg. 28.. Drive Shaft (Incl. Jackshaft (Incl. Seal O-Ring Washer Screw Bolt. Qty. Retaining Kit. Speedometer. 14. Disc. Carriage 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 7721128 1332220 7710422 2202493 7542423 5020588 5410613 7558403 7518002 7515428 1590366 1012945 3280019 5243529 3280017 5830012 3280116 Qty. Square Gasket. which is updated monthly. Part No. Flat Washer.DRIVE TRAIN 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 1 E 2003 Polaris Sales Inc. Screw Washer. Drive 4/03 C5 .29) Asm.. Nylok Bearing Flangette Bolt. Offset. Flat Spacer Asm. Flat Flangette w/Grease Fitting Fitting.19) Ring. Ref. Solenoid/Battery Breaker. 14) 4/03 C6 . Ref. Circuit 13 7541925 14 7542122 15 1013256-067 1013679-067 16 7621467 17 5810129 18 1013385 19 7511930 20 ..21 . E8. 15) 2 Nut (See Starting Motor (700)(800) Pg.. Vent Battery Cable.. Magnetic (See Starting Motor (700)(800) Pg.. Ref.. Battery (700)(800) Rivet Foil Tape Plate. Stud. Part No. Battery/Solenoid Wire.BATTERY BOX 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 13 12 14 11 E 2003 Polaris Sales Inc. which is updated monthly. Battery. To ensure that correct parts are received. Spring (See Starting Motor (700)(800) Pg. Cable Asm.- Qty. Solenoid/Starter Switch. Battery Asm. Battery Box Bolt Washer. E8. refer to PartSmart.. Part No. Jumper. Description 2 2 1 1 1 1 1 2 2 Nut... E8. 10 15 9 8 7 21 20 6 19 18 5 1 4 17 16 2 3 Part numbers may have changed since this microfiche was issued. Battery Bolt Cable. Battery (600) Box. Cable. Battery Kit. 1 2 3 4 5 6 7 8 5810290 2450020 5432077 4140006 4010114 2200361 4010107 ------- 3 1 AR 1 1 1 1 1 9 10 11 12 5410346 2460393 4010108 2434008 2 1 1 1 Description Ref. Nylok Box.. Nylok Nut... Ref. Battery Hold-Down Strap Tube. Qty.. 16) Insulator. Pad. Chassis/Resonator Spring. Top (600) 1 Cover. Exhaust (600) Gasket. Exhaust.25)(700)(800) 2 Clamp Worm Driven (. Exhaust Washer Boot. Top (600) 1 Matte.69)(700)(800) 1 Clamp Worm Driven (. Bottom (700)(800) 8 Rivet 4/03 C7 . Tuned Pipe. Carriage Gasket. Tuned Pipe (700)(800) 1 Cover. Vibration w/Ribs (700)(800) 2 Clamp Worm Driven (. Description 1 4 1 1 7 1 1 1 2 1 2 2 2 1 1 6 1 1 1 1 Bracket.44 x 4.38)(700)(800) 1 Asm. Sound.44 x 3. Top (700)(800) 1 Matte. Vibration (600) 1 Dampener. Socket Screw Nut. To ensure that correct parts are received. Flanged. 2 3 22 21 4 20 5 4 2 7 6 8 9 600 19 700/800 15 18 19 17 4 11 13 15 10 12 16 4 16 14 13 Part numbers may have changed since this microfiche was issued. Top (700)(800) 1 Cover. Ref. Tuned Pipe. Exhaust (700)(800) Manifold (600) Manifold (700)(800) Screw Seal. which is updated monthly. Flange Deflector. 18 7556004 19 5433576 5411576 20 7080811 7080812 7080813 7080740 7080741 7080742 21 1261007 5244398 5244399 5830207 5830198 1261123 5245929 5245930 5830215 5830216 22 7661637 Qty.. Part No.25)(600) 1 Clamp Worm Driven (.44 x 3. Exhaust Resonator (600)(700) Resonator (800) Spring. 1 1261296-029 2 7042029 3 1261130-029 1261177-029 4 7041687 5 7555904 6 5411684 7 7621467 8 7542321 9 5243929 10 7512394 11 5811838 5811799 12 1261046-029 1261124-029 13 7517322 14 3610046 15 7517935 16 7547180 17 5245498 Qty.. Nylon Bracket. Exhaust Outlet Rivet Nut. Snow Exhaust Bolt. Bottom (700)(800) 1 Matte. Sound. Tuned Pipe. refer to PartSmart. Tuned Pipe (600) 1 Cover. Sound.75)(600) 1 Clamp Worm Driven (.44 x 4. Part No.50)(600) 1 Clamp Worm Driven (. Chassis/Pipe (700)(800) Ref. Description 1 Washer 1 Dampener.44 x 6. Tuned Pipe.EXHAUST 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 1 E 2003 Polaris Sales Inc. Sound (600) 1 Asm. Bottom (600) 1 Matte.44 x 6. 1 2 3 4 Qty. Tape Handle. Retaining Foil. Fuel Tubing. Engine Ref. Engine RH Mount. Engine Mount. Description 7517501 7556003 5131872 2202515 1 1 1 1 3070190 5521398-13 7555944 7710427 5811485 5431499-070 7542451 7555893 5245465 5246382 14 3021220 2 1 1 1 1 1 2 2 1 1 2 5 6 7 8 9 10 11 12 13 Screw Washer Washer. Valve. Ref. Nylon Bracket. Throttle Line.. Flat Nut. Short Block NOTE: The Short Block assembly contains a crankcase assembly.ENGINE MOUNTING (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE 5 E 2003 Polaris Sales Inc. 6 4 1 2 3 7 8 9 29 13 28 29 33 32 29 29 31 10 27 28 26 14 25 24 29 13 14 17 30 28 11 12 23 16 15 19 22 20 20 21 19 18 Part numbers may have changed since this microfiche was issued. Rubber Hole Nut. Spark Plug. Fuel Line. RH Washer. Flat Strap. Fuel Clamp. LH Screw Mount. which is updated monthly. Fuel. Part No. Spring Lock Nut. Champion Conduit Washer. RN57YCC. Nylon E-Ring. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 7512539 7553101 7547180 5245044 7555806 7547008 1014392 5410012 7542122 1013397 7517854 3021206 7080867 8350017-600 7080003 1253424 2520275 8450040-600 8360052-25 Qty. Prior authorization is required for warranty consideration. Plastic Pump. Engine Mount. To ensure that correct parts are received. FLEXLOC Bracket. Description 4 4 1 1 4 4 1 1 2 1 3 2 1 AR 8 1 1 AR 1 Screw Washer. Fuel Plug. Pump. Engine Cable. Part No. Recoil Nut. and a piston and crankshaft assembly. Engine Mount. refer to PartSmart. Nylok Washer. Convoluted 4/03 C8 . Nylok Bracket. Flanged. Hose Asm. LH Strap. Clutch Retainer Kit. cylinder and cylinder head assembly. Valve. cylinder and cylinder head assembly. Engine Mount. Champion Conduit Washer. RH Washer. Short Block. Engine Mount. Flanged. refer to PartSmart. Engine Mount. RN57YCC. Rubber Hole Nut. Pump. 1 7517501 2 7556003 3 5131872 5132441 4 2202512 2202518 5 6 7 8 9 10 11 12 3070190 5521398-13 7555944 7710427 5431499-070 7542451 7555893 5245462 5246381 13 3021220 Qty. Short Block. Spark Plug. Qty. Part No. Fuel Tubing. Engine Ref. S70704 (700) Kit. Retaining Handle. which is updated monthly. Fuel Plug. RH Mount. Engine Mount. Plastic Pump. Part No. LH Screw Mount. Fuel Clamp. Description 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 4 4 1 1 4 4 1 1 2 1 3 2 1 AR 8 1 1 2 AR 7512539 7553101 7547180 5245044 7555806 7547008 1014392 5410012 7542122 1013397 7517854 3021206 7081051 8350017-600 7080003 1253424 2520275 8360052-15 8450040-600 Screw Washer. Fuel 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 5 E 2003 Polaris Sales Inc. S80704 (800) NOTE: The Short Block assembly contains a crankcase assembly. Prior authorization is required for warranty consideration. Ref. Flat Strap. Throttle Line. Fuel. Engine Cable. FLEXLOC Bracket. and a piston and crankshaft assembly. Clutch Retainer (800) Kit. Flat Nut.. Clutch Retainer (700) Washer. Nylok Bracket. Convoluted Line. 6 4 1 2 3 7 8 28 32 27 28 31 26 27 28 30 31 27 12 13 16 24 23 22 10 11 25 29 28 9 12 19 18 13 15 21 19 20 14 18 19 18 17 Part numbers may have changed since this microfiche was issued. Hose Asm. LH Strap. Recoil Nut. Spring Lock Nut. To ensure that correct parts are received. Description 1 1 1 1 1 1 2 1 1 1 1 2 2 1 1 2 Screw Washer Washer. Nylon Bracket. Nylon E-Ring. Nylok Washer. Thrust Gear. 12T Gear. Raceway O-Ring Asm. Description 1 1 1 1 1 1 2 2 6 6 1 4 2 2 1 1 1 1 1 1 1 Seal. Part No. Nylok 11/02 C10 . Plastic. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 5434293 5434292 7661161 5246536 7080138 4010596 7518087 7547004 7556042 7552603 4010780 7518006 7518005 5133351 2461104 5133155 3514387 7518037 7515438 5133325 7542439 Qty. 18 8 9 2 3 4 5 10 41 16 11 12 13 16 6 14 15 23 25 26 28 27 36 34 38 40 24 16 29 30 37 20 17 7 1 19 35 29 30 33 31 32 39 Part numbers may have changed since this microfiche was issued. Ref. Grommet Screw Washer. Plastic. Casting (Incl. Screw Bearing. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5133403 5411092 5133402 5133159 3514388 5412229 1541692 5133155 5434728 5434727 7080424 7518088 3514385 3514403 5434492 5222998 7511866 7556201 3221135 3221136 7518152 Qty. Small Screw Ref. refer to PartSmart. Wire Plate.12. Bevel. Thrust Screw. Drivlok Plate. Lubrication Screw Bearing Bearing Grommet. Part No. 32T Fitting. Spring Lock Potentiometer Screw Screw Spacer Harness.10.ELECTRIC MODULE (M-12)(ACE) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE 16 22 21 E 2003 Polaris Sales Inc.. To ensure that correct parts are received. Flange Shaft. Description 1 2 1 1 2 1 1 1 1 1 1 2 1 1 1 1 10 1 1 1 1 Bushing O-Ring Bushing.36) Housing Gear. 6. Nylok Washer Washer. Bevel. Large Gear. Wire Housing Bearing. Motor Cable Tie Motor Screw Nut. Set Screw Clevis Nut. Support. which is updated monthly. Cover Cover.13. Motor Pin. Reed Valve Valve. 1 2 3 4 5 6 7 8 9 10 11 12 7080681 7516822 7080654 1253423 5433151 1201825 7051020 7080603 8450061-600 5132196 5132197 8360056-25 Qty. Dowel Fitting. Description 1 2 2 2 8 1 4 1 2 1 1 Kit. Hose Screw Retainer Adaptor.CRANKCASE (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE 10 1 9 7 8 8 7 9 2 3 12 4 5 11 13 6 E 2003 Polaris Sales Inc. 10. 13 14 15 16 17 18 19 20 21 22 23 2202519 5411394 7051529 7517785 7517784 7516825 7517786 7517577 7663001 7052322 5010390 Qty.11. Oil Stud. Cylinder Tubing. which is updated monthly. Convoluted Ref. Reed Block Asm. To ensure that correct parts are received. Flanged w/Standoff Plug Bolt Bolt Screw Bolt Screw Pin. 14 14 13 23 22 21 15 20 16 19 18 17 Part numbers may have changed since this microfiche was issued. Part No. Pump Shaft 4/03 C11 . Cylinder Stud. Check Clamp Line.15-21) Seal. 45 Degree Bearing.. Part No. refer to PartSmart. Crankcase (Incl. Carburetor Stuffer. Ref. Description 2 12 1 2 2 2 2 2 AR 4 4 1 Clamp. Green/White Asm.. which is updated monthly. Temperature Screw Screw Washer. Cylinder Base Fitting Thermostat. Dome Spring. Qty. Exhaust Valve Cap/Nut. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 4010398 7517533 7517679 7555998 5631391 5411521 5631425-366 5411411 5411465 3021322 5410932 5411359 7547013 5133380 5812350 Qty. 5 6 21 7 8 19 9 26 20 18 17 10 11 22 23 15 12 16 14 13 24 25 Part numbers may have changed since this microfiche was issued. EV Housing w/Bushing Screw Screw Cylinder Gasket. Base to Cylinder Exhaust Valve Ref. Exhaust. Thermostat O-Ring Cover. Guillotine Gasket. Ref. Cylinder O-Ring O-Ring Nut Valve. Description 1 12 1 1 1 1 1 2 1 1 2 2 8 2 2 Sensor. Bellows. Bellows. refer to PartSmart. Valve. Flat Cover. Part No.. Head O-Ring Seal. Rubber Head Head. Dome Bellows.CYLINDER (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE 1 2 3 4 29 28 27 E 2003 Polaris Sales Inc. w/o Bypass Screw Screw 4/03 C12 . Base Exhaust Valve Dome Washer. Description 16 17 18 19 1202216 5132950 5412399 5631381 2 2 2 2 20 21 22 23 24 25 26 27 28 29 7041786-03 1202640 7516820 7517932 3021333 5811916 7052234 7052258 7517950 7516822 2 2 4 4 2 2 1 1 1 1 Asm. Valve. Exhaust. Comp. To ensure that correct parts are received. 10 11 12 13 14 15 16 17 18 7555977 5133688 5411196 5010391 5811789 2540117 7080603 8450061-.600 7517277 Qty. Oil Pump Asm.. 1 2 3 4 5 6 7 8 9 5411197 3610067 7556006 5432330 7555874 7546804 5811601 5630920 7516822 Qty. Thrust Gear. Water Pump. Pump Shaft. Part No. Oil Screw 4/03 C13 . 1 7 2 3 4 5 8 6 17 18 16 15 9 14 13 12 10 11 17 10 16 Part numbers may have changed since this microfiche was issued. Water Pump Cover Cover. which is updated monthly. Part No. Flat Nut. Waterpump Washer. To ensure that correct parts are received. Flanged Gasket. Flat Impeller. Water Pump Washer.WATER PUMP/OIL PUMP (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE E 2003 Polaris Sales Inc. Oil Clamp Line. Description 2 1 1 1 1 1 4 AR 2 Washer. Nylok Gasket. refer to PartSmart. Ref. Cross Shaft O-Ring Bearing. Hex. Description 1 1 1 1 1 1 1 1 9 Seal Seal. Pump. Hi Flow Screw Ref. Part No. Starter Asm...5) Needle... Packing Clip Ring Plate E-Ring Cap. Drain O-Ring. Float Bolt. Piston (1. Float Bowl Screw. To ensure that correct parts are received. 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 3131356 3130808 3131371 3130142 3131372 3130522 3131336 3130859 3131248 3130863 3130824 3130858 3130861 3130860 3130069 3130768 3130837 3130836 3130987 3130986 3131010 3131009 3130479 3130835 7051020 Qty. Check. Description 2 1 1 2 1 1 2 2 2 2 2 2 2 2 2 2 4 2 2 1 2 1 2 2 2 O-Ring. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1253505 3130951 3130872 3130871 3130844 3130846 3130856 3130845 3130857 3130847 3130831 3130830 3130829 3130828 3130940 3131377 3130867 3130868 3130843 3130855 3130849 3130848 3130854 3130850 3130825 3131335 Qty. Pilot (50) Jet. Starter Spring. Plunger Valve. Ref. Drain Screw Screw. Lever. Carburetor Screw Cap. Part No... Air Funnel Asm. which is updated monthly. LH Asm. LH Screw. Starter (140) Washer Spring Adjuster Cap Screw (MAG Side) Asm. Air Asm. 90 Degree 3/03 C14 . Float Bowl Body. Valve Seat Jet. RH Ring Screw.. Air Funnel. Lever. Rubber.Ring Screw. Sensor. Description 1 4 2 2 2 4 4 8 4 4 2 2 2 2 2 2 2 2 2 1 1 1 1 1 8 2 Asm. Top Gasket Screw Washer. Starter Holder. Jet (9DGI01-60) Packing E-Ring Plate Asm. Guide. RH Screw. Float O-Ring. Throttle Position (MAG) Cap Packing Valve.CARBURETOR (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE 1 2 3 22 4 5 6 9 8 7 10 11 E 2003 Polaris Sales Inc. Funnel Ref. 1 14 49 21 20 19 18 24 17 6 5 16 7 8 9 15 41 42 41 40 39 27 28 31 30 12 13 48 47 25 26 23 46 29 45 43 44 32 38 37 36 33 35 34 Part numbers may have changed since this microfiche was issued. refer to PartSmart. Long Pin Spring Jet. Main (420) Washer O-. Starter Screw. Starter Asm. Starter Shaft Shaft Ring E-Ring Lever. Trap 3/03 D1 . Description 2 1 2 3 1 1 2 1 1 1 4 AR 2 Screw Bracket Hose. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3130834 3130832 3130833 3140032 3130817 3130816 3131285 3131284 3131380 3130810 3130809 3130950 3130853 3131370 Qty.CARBURETOR (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE E 2003 Polaris Sales Inc. 7 6 5 8 11 4 1 3 9 10 15 12 13 16 14 2 1 18 22 21 3 21 20 18 23 17 2 25 26 19 18 24 25 27 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received. Ref. Starter Shaft Spring. refer to PartSmart. Description 2 2 3 1 1 1 1 1 1 1 1 1 1 1 Bolt Lever.. Fuel Plug. Hose Line. Vent Packing. 15 16 17 18 19 20 21 22 23 24 25 26 27 3130821 3130820 3131137 3130842 3130841 3130840 3130852 3130839 3130819 3131374 7080003 8350017-600 5431893 Qty. Shaft Ref. which is updated monthly. Part No. Starter Ring Spring Screw Adjuster Spring Bracket Screw Screw Spring Ring Asm. Part No.. Nipple Clamp. Asm. Piston (Incl. which is updated monthly.12) Bearing Kit. Description 2 1 2 1 1 2 Bearing. Ball Ref. Part No. Woodruff Pin. Flanged. Piston 3/03 D2 . Connecting Rod Bearing.PISTON and CRANKSHAFT (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE E 2003 Polaris Sales Inc. refer to PartSmart. Ref. Pump Drive Key. 1 2 3 4 5 6 2202520 2201256 3022950 2202258 3514365 2201132 3513508 Qty. w/Standoff Gear.2. Part No. 6-10) Kit. To ensure that correct parts are received. Piston Rings Circlip. Ball Bearing. Piston Kit.. 1 2 3 9 4 12 4 5 8 7 6 2 11 7 9 10 Part numbers may have changed since this microfiche was issued. Ball Seal. Description 1 2 4 2 2 1 2 Kit. 1. 7 8 9 10 11 12 3585503 3514310 5411394 5131373 7721117 ------- Qty. Crankshaft (Incl. CDI (Incl.MAGNETO (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE 6 E 2003 Polaris Sales Inc. Ignition Stator. Starting. Part No. Flat Ref. Part No. Ignition Coil. 5 4 2 3 1 9 8 7 10 14 12 11 13 Part numbers may have changed since this microfiche was issued. Ignition Washer. To ensure that correct parts are received. refer to PartSmart. Hex Washer Flywheel. Description 6 1 1 1 1 1 3 Screw Pulley. Spark Plug 3/03 D3 . Ref. Ignition Wire. which is updated monthly. Recoil Nut. 8 9 10 11 12 13 14 7555969 7517314 2202528 4010811 4060229 4010124-305 4020159 Qty. Nyogel and Decal) Harness. Lock Screw Kit. Description 3 3 1 1 1 2 2 Washer. 1 2 3 4 5 6 7 7517278 3040161 7546909 7555907 4010677 4060222 7555970 Qty. Ignition Cap. Recoil Screw Housing. Part No. Rope Slide. Recoil. 1202298 1 2 3 4 5 3040163 3040164 3040167 5246108 3040166 Qty. Return Ref. Fastening 1 Plate. Friction 1 Ratchet. refer to PartSmart. Pawl Electric Reverse 1 Spring. Part No. Friction 1 Spring. 8 9 7 6 10 4 5 3 11 2 1 Part numbers may have changed since this microfiche was issued. Starter Rope.10. 1-7.11) 1 Nut. Description 1 Asm. Ref. Description 1 1 1 6 1 1 Reel Spring. Recoil Electric Reverse (Incl. Spiral Bushing. To ensure that correct parts are received. which is updated monthly..RECOIL STARTER (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE E 2003 Polaris Sales Inc. Starter 3/03 D4 . 6 7 8 9 10 11 3040168 3040170 3040171 7516827 5630645 3040169 Qty. Water . 45 Degree Pin. Description Ref.18) O-Ring Manifold.CRANKCASE (700) 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE E 2003 Polaris Sales Inc. 1. 1 2 3 4 5 6 7 8 9 10 11 8 AR 2 1 1 2 1 2 2 1 2 12 13 14 15 16 17 18 19 20 21 5131677 8450061-600 7080603 7051020 2202233 5411125 5630610 5243431 7516736 8450068-04 7080560 Stud. Ref. Check Kit. Oil Pump Screw 3/02 D5 . Dowel Washer. Hose 5411394 7051529 7516919 7516732 7710441 7052322 7663001 7555998 7052160 7517319 Qty. Cylinder. Check. Part No. Part No.Inlet Retainer. Description 1 2 2 4 1 1 2 2 1 1 Seal.15. Manifold Screw Hose Clamp.14.5. To ensure that correct parts are received. which is updated monthly. Crankcase (Incl. refer to PartSmart. Flange Line. Qty. 1 2 3 4 7 6 8 5 9 21 19 10 20 19 11 3 2 18 12 5 13 17 14 15 16 Part numbers may have changed since this microfiche was issued. Fuel Clamp Valve. Flat Valve. Inlet Water. Flanged w/Standoff Plug Screw Screw Ring. Retaining Fitting. Temperature Cover. Detonation Screw Nut Conduit. EV Housing w/Bushing Screw Screw Cylinder w/Decom Gasket. Valve. Thermostat Screw Washer. Rubber. Flex Hose. which is updated monthly. Reed Block Asm. Qty. Flat Screw. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 7080681 7517398 7080683 1253327 5433151 1201825 5411521 7052258 5631391 7517950 7555998 7517679 7517534 7516822 4010398 5631426-366 5411294 5410917 3021424 5412232 5410932 Qty. Exhaust.. Reed Valve O-Ring Thermostat w/o Bypass Cover. refer to PartSmart. Exhaust Valve Cap/Nut Bellows. Part No. Exhaust. 14 5 29 17 6 26 18 19 40 20 39 38 23 22 27 21 28 31 30 29 25 26 32 35 28 25 24 38 37 27 30 31 22 24 23 33 36 34 Part numbers may have changed since this microfiche was issued. Base Exhaust Valve Dome Washer. Cylinder Base Sensor.CYLINDER (700) 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE 12 11 10 13 9 8 1 2 15 16 7 3 4 E 2003 Polaris Sales Inc.. Hose Screw Clamp.. Head Seal. Base to Cylinder Exhaust Valve Asm. Cylinder O-Ring O-Ring Ref. Bypass Clamp. Description 22 23 24 25 26 27 28 29 30 31 32 33 34 2 2 2 2 2 2 2 2 4 4 2 2 1 1 8 AR 1 2 1 1 35 36 37 38 39 40 5133743 5812350 1202216 5132950 5412399 5631381 7041786-08 1202640 7516820 7517932 3021367 5812362 2410369 7517262 7547013 5521398-96 5411536 7081030 7052234 7080654 Valve. Guillotine Gasket. Description 2 12 3 2 2 2 1 1 1 1 1 1 12 1 1 1 1 2 1 2 2 Clamp. To ensure that correct parts are received. Bleed Screw Screw Sensor. Hose Adapter. Bellows. Bypass Fitting Retainer 3/03 D6 . Dome Spring. Carburetor Stuffer. Comp Green/Yellow Asm. Valve. Part No. Ref. Head O-Ring Head. Dome Bellows. Ref. 13) Seal Seal. Part No. 90 Degree Screw Asm. D11. Hex. Waterpump Washer. Description 1 2 3 4 3021044 3514311 5132273 ------- 1 2 1 1 5 6 7 8 9 10 3610044 3610067 7556006 5432330 7555874 7546804 1 1 1 1 1 1 Pulley. D11. Oil Screw 3/03 D7 . Waterpump. Pump. Idler (See Magneto. Ignition/WP. Flat Nut. Fuel Clamp Asm. Cover Bead Cover. Waterpump Asm. w/o NTP Fitting. Ignition/WP. Ball Shaft. Idler (See Magneto. Ref. To ensure that correct parts are received. Waterpump Washer. Ref. 13) Screw Line.. Nylok Ref. Flat Impeller. Part No.. refer to PartSmart. Waterpump. Description 1 1 1 5 1 6 AR 4 1 2 Gasket. (700) Pg. 13 12 11 5 8 6 9 10 7 4 15 2 3 16 1 17 18 19 20 Part numbers may have changed since this microfiche was issued. 11 12 13 14 15 5811627 5631280 7052221 7516822 ------- 16 17 18 19 20 7516823 8450061-82 7080603 2540102 7516607 Qty. Qty. Housing. Driven Bearing. (700) Pg.WATER PUMP/OIL PUMP (700) 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE 14 E 2003 Polaris Sales Inc. Housing. Waterpump.. which is updated monthly. Piston Pin.. To ensure that correct parts are received.2. Part No. Piston (Incl. which is updated monthly. 3 1 4 2 5 1 6 8 7 5 9 9 11 10 9 12 Part numbers may have changed since this microfiche was issued.3) Bearing Kit. Ball Bearing. Pin.PISTON and CRANKSHAFT (700) 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE E 2003 Polaris Sales Inc. Ball Spacer. Connecting Rod w/Burr Pin (Incl. Washers) Ref. 7 8 9 10 11 12 7721117 7555905 3585503 3514318 5131899 3514310 Qty. 1 2 3 4 5 6 2201848 3022950 ------2200895 2202237 3584001 2201953 Qty. 1. Description 1 1 4 1 1 1 Key. refer to PartSmart. Piston Kit. 8-12) Circlip. Part No. Piston Rings Kit. Ball 3/02 D8 . Bearing. Crankshaft Bearing. Rod. Asm. Woodruff Bushing Bearing. Crankshaft (Incl. Description 1 4 2 2 2 2 2 Kit. Ref. . 2 3 4 5 9 10 11 8 48 22 19 18 6 20 24 17 6 5 16 7 7 14 12 21 8 9 23 30 13 47 46 25 40 41 40 42 43 39 38 26 15 45 29 27 28 44 31 37 36 35 32 33 34 Part numbers may have changed since this microfiche was issued. Sensor Throttle Position (MAG) Cap Packing Valve. Jet Packing E-Ring Plate Asm. Starter (145) Washer Spring Adjuster Cap Screw (MAG) Asm.. Description 1 4 2 2 2 4 4 8 4 4 2 2 2 2 2 2 2 2 2 1 1 1 1 1 8 Asm. 90 Degree 3/03 D9 . Drain Screw Screw. Starter Holder. Ref. To ensure that correct parts are received. Starter Asm. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 3131439 3131356 3130147 3131336 3131371 3131372 3130522 3131231 3131248 3130863 3130824 3130858 3130861 3130860 3130068 3130769 3130837 3130836 3130987 3130986 3131010 3131009 3130479 3130835 7051020 Qty. LH Asm.0) Needle. Valve Seat Jet. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1253506 3130951 3130872 3130871 3130844 3130846 3130856 3130845 3130857 3130847 3130831 3130830 3130829 3130828 3131252 3131415 3130867 3130868 3130843 3130855 3130849 3130848 3130854 3130850 3130825 Qty. Air Funnel Ref. refer to PartSmart. Plunger Valve. Float Bolt. Rubber. Pilot (45) Jet. Lever. Lever. Check. Long Jet. Float Bowl Screw. Float O-Ring. RH Screw..CARBURETOR (700) 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE 1 E 2003 Polaris Sales Inc. Funnel O-Ring. Float Bowl Body. Part No. RH Ring Screw. LH Screw. Carburetor Screw Cap. Piston (2.. Guide. Top Gasket Screw Washer.. Main (470) Screw.. Drain O-Ring. Description 2 2 2 2 1 1 1 2 2 2 2 2 2 2 2 2 4 2 2 1 2 1 2 2 2 Asm. Packing Clip Ring Plate E-Ring Cap. which is updated monthly. Air Funnel. Air Spring Washer O-Ring Asm. Starter Spring.. Part No. Part No. Part No. Bolt Lever. Lever) 15 16 17 18 19 20 21 22 23 24 25 26 27 3130821 3130820 3131137 3130842 3130841 3131233 3131232 3130839 3130819 3131350 7080003 8350017-600 5431893 Qty. Starter Ring Spring Screw Adjuster Spring Bracket Screw Screw Spring Ring Asm. 2 1 2 3 1 1 2 1 1 1 4 AR 2 Description Screw Bracket Hose. Ref. 2 2 3 1 1 1 1 1 1 1 1 1 1 1 Description Ref. To ensure that correct parts are received. Nipple Clamp. Starter Screw. refer to PartSmart.. Starter Shaft Shaft Ring E-Ring Lever.. Shaft (Incl. which is updated monthly. Hose Line. Starter Shaft Spring. 7 6 5 8 9 11 4 1 3 15 10 12 13 16 14 2 1 17 18 22 21 21 20 23 25 26 3 18 19 18 17 2 24 25 27 Part numbers may have changed since this microfiche was issued. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3130834 3130832 3130833 3140032 3130817 3130816 3131285 3131284 3130815 3130810 3130809 3130950 3130853 3131369 Qty. Trap 5/01 D10 .CARBURETOR (700) 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE E 2003 Polaris Sales Inc. Starter Asm. Vent Packing. Fuel Plug. Part No. Spark Plug Decal.T. Water Pump Drive Nut. To ensure that correct parts are received. Waterpump Belt Pulley. Ignition/WP. 19. Ignition Ref. which is updated monthly. Qty. D. Housing.. Hex Washer Flywheel. Flat Stator. Ignition Coil. Part No. Stator Wires Cap. Starting. Ignition Kit. Ignition Screw Washer. Nyogel & Decal) Decal. 1 2 3 4 5 6 7 8 9 10 11 7516823 3021144 2201821 5630824 7546909 7555907 4010677 7517246 7555969 7555970 4010297 Qty. Spark Plug Wire. CDI (Incl. Description 6 1 1 1 1 1 1 3 3 3 1 Screw Pulley. Recoil Kit. 12 11 9 10 8 7 4 5 14 6 15 3 16 20 2 19 1 17 18 Part numbers may have changed since this microfiche was issued. Lock Washer. (700) 6/03 D11 .MAGNETO (700) 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE 13 E 2003 Polaris Sales Inc.E. refer to PartSmart. Idler Grommet. Description 12 13 14 15 16 17 18 19 4 1 1 2 AR 1 1 1 1 1 7516734 1202161 5411178 4020155 4010124-305 4060229 4010872 2202525 7077026 20 7170413 Screw Asm. Ref. Ignition Harness. 1-10. Pawl Electric Reverse 1 Spring. Fastening 1 Plate. Recoil E/R.13 & Starting Pulley) 1 Nut.. Recoil Screw Shield. Ref. 8 9 6 2 3 4 7 10 5 11 9 1 12 13 Part numbers may have changed since this microfiche was issued. Spiral Housing. refer to PartSmart. Description 1 Asm. Friction 1 Spring. Rope Slide. Part No. To ensure that correct parts are received. Return 1 Reel Ref. Description 1 1 2 1 6 1 1 Spring. which is updated monthly. 1202408 1 2 3 4 5 6 3040163 3040164 3040167 5246108 3040166 3040168 Qty.RECOIL STARTER (700) 700 CLASSIC EDGE TOURING S04NT7CS and 700 CLASSIC EDGE TOURING INT’L S04NT7CE E 2003 Polaris Sales Inc. 7 8 9 10 11 12 13 3040170 3040160 7661148 3040171 7516823 5246218 3040169 Qty. Friction 1 Ratchet. Recoil Rope Rope. Part No. Shield (Incl. Recoil Rivet Bushing. Starter 3/02 D12 . Cylinder. 1. w/Standoff Plug Ref. refer to PartSmart. Fuel Clamp Washer. Part No. Part No. Crankcase (Incl. Check. Ref.14. Retaining Fitting Pin. Description 2 4 1 1 2 AR 1 2 1 1 Screw Screw Ring. Description 8 1 1 2 1 2 2 1 2 1 2 Stud.18) O-Ring Manifold. Inlet Retainer.5. Flange. Flat Valve. 1 5 4 6 2 3 7 21 19 20 8 19 18 9 17 16 10 3 11 15 12 14 13 Part numbers may have changed since this microfiche was issued. Inlet Water.CRANKCASE (800) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE E 2003 Polaris Sales Inc. Water. Oil Pump Screw 3/02 D13 . 1 2 3 4 5 6 7 8 9 10 11 5131677 7051020 2202336 5411125 5630610 5243431 7516736 8450068-04 7080560 5411394 7051529 Qty. Dowel Line. Check Kit. which is updated monthly. Flange Valve. Hose Seal. 12 13 14 15 16 17 18 19 20 21 7516919 7516732 7710441 7052322 7663001 8450061-600 7080603 7555998 7052160 7517319 Qty. To ensure that correct parts are received.15. Manifold Screw Hose Clamp. To ensure that correct parts are received. 14 9 4 5 15 8 6 16 7 31 17 18 27 19 40 25 20 39 38 21 32 30 28 29 26 24 23 22 37 36 33 34 35 Part numbers may have changed since this microfiche was issued. Temperature Cover. Valve. Base Exhaust Valve Dome Washer. Part No. Exhaust Valve Cap/Nut Bellows. Comp Pink/Yellow Asm. Head O-Ring Head. Reed Valve O-Ring Thermostat w/o Bypass Cover. Dome Spring.. Part No. Dome Bellows. EV Housing w/Bushing Screw Screw Gasket. Hose Screw Clamp. Valve. Exhaust. Head Seal. Ref. Thermostat Screw Washer. Rubber.. Bleed Screw Screw Sensor. Carburetor Stuffer. Flex Hose. Detonation Screw Conduit. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 7080681 7517398 7080683 1253327 5433151 1201825 5411521 7052258 5631391 7517950 7555998 7517679 7517534 7516822 4010398 5631427-329 5411294 5410917 3021426 5412232 5411675 Qty. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3021339 5133775 5812350 1202216 5132950 5412399 5631381 7041786-11 1202640 7516820 7517932 5812363 7547013 2410369 7517262 5521398-96 5411536 7081030 7052234 7080654 Qty. refer to PartSmart. Exhaust. Bypass Clamp.. Flat Screw. which is updated monthly. Reed Block Asm. Description 2 2 2 2 2 2 2 2 2 4 4 2 8 1 1 AR 1 4 1 1 Cylinder Valve. Guillotine Gasket. Base to Cylinder Exhaust Valve Asm. Cylinder Base Nut Sensor. Bypass Fitting Retainer 10/02 D14 . Bellows.CYLINDER (800) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE 13 1 2 12 11 10 3 E 2003 Polaris Sales Inc. Hose Adapter. Cylinder O-Ring O-Ring Ref. Description 2 12 3 2 2 2 1 1 1 1 1 1 12 1 1 1 1 2 1 2 2 Clamp. w/o NTP Fitting. Nylok Ref. 13) Seal Seal. Housing. Description 1 2 3 4 3021044 3514311 5132273 ------- 1 2 1 1 5 6 7 8 9 10 3610044 3610067 7556006 5432330 7555874 7546804 1 1 1 1 1 1 Pulley. Ignition/WP. Ignition/WP. Hex. Waterpump. Waterpump. Driven Bearing... Waterpump Washer. Description 1 1 1 5 1 6 AR 4 1 2 Gasket. Flat Nut. Waterpump Asm. (800) Pg. Idler (See Magneto. Ref. Flat Impeller. Cover Bead Cover. 11 12 13 14 15 5811627 5631280 7052221 7516822 ------- 16 17 18 19 20 7516823 8450061-600 7080603 2540102 7516607 Qty. refer to PartSmart. Part No. Ball Shaft. Qty. Fuel Clamp Asm. (800) Pg. To ensure that correct parts are received. 13) Screw Line. E5. 90 Degree Screw Asm. which is updated monthly. E5.WATER PUMP/OIL PUMP (800) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE 14 E 2003 Polaris Sales Inc. Pump. Idler (See Magneto. Waterpump. Part No. Ref. Waterpump Washer. Oil Screw 3/02 E1 .. Housing. 13 12 11 5 8 9 10 4 6 7 2 1 2 15 3 16 17 18 20 19 Part numbers may have changed since this microfiche was issued. Ref. 90 Degree 3/03 E2 . Float O-Ring... Rubber.CARBURETOR (800) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE 1 2 3 22 5 10 11 8 48 21 4 9 E 2003 Polaris Sales Inc. which is updated monthly. Valve Seat Bolt.. Drain O-Ring. Pilot (45) Jet. 1 6 7 7 14 12 13 19 18 17 6 5 16 8 45 46 20 24 25 26 40 41 40 39 38 30 9 15 47 29 23 27 28 42 44 43 37 31 36 35 32 33 34 Part numbers may have changed since this microfiche was issued. RH Ring Screw. Part No. Main (470) Screw. RH Screw. Lever. Float Bowl Body. Drain Screw Screw.0) Needle.. Jet Packing E-Ring Plate Asm. Ref. Float Jet. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1253504 3130951 3130872 3130871 3130844 3130846 3130856 3130845 3130857 3130847 3130831 3130830 3130829 3130828 3131252 3131438 3130867 3130868 3130843 3130855 3130849 3130848 3130854 3130850 3130825 Qty. Check.. Packing Clip Ring Plate E-Ring Cap. Starter (145) Washer Spring Adjuster Cap Screw (MAG) Asm. Carburetor Screw Cap.. Description 2 2 1 2 1 1 1 2 2 2 2 2 2 2 2 2 4 2 2 1 2 1 2 2 2 Asm. Float Bowl Asm. LH Asm.. To ensure that correct parts are received. Long Spring Screw. LH Screw. Air Funnel Ref. Part No. refer to PartSmart. Air O-Ring Washer Jet. Lever. Starter Holder. Air Funnel. Piston (2. Top Gasket Screw Washer. Guide. Starter Asm. Sensor Throttle Position (MAG) Cap Packing Valve. Funnel O-Ring. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 3131439 3131356 3131371 3131336 3130522 3131372 3130147 3130860 3131248 3130863 3130824 3130858 3130861 3131231 3130068 3130769 3130837 3130836 3130987 3130986 3131010 3131009 3130479 3130835 7051020 Qty. Description 1 4 2 2 2 4 4 8 4 4 2 2 2 2 2 2 2 2 2 1 1 1 1 1 8 Asm. Starter Spring. Plunger Valve. which is updated monthly. To ensure that correct parts are received. 7 6 5 8 11 4 1 9 10 15 12 13 3 16 14 2 1 18 22 21 3 20 18 19 18 17 21 2 27 25 24 23 26 Part numbers may have changed since this microfiche was issued. Lever) Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3130834 3130832 3130833 3140032 3130817 3130816 3131285 3131284 3130815 3130810 3130809 3130950 3130853 3131369 Qty. Fuel Plug. Trap Clamp. Part No.Shaft (Incl.. refer to PartSmart. Starter Ring Spring Screw Adjuster Spring Bracket Screw Screw Spring Ring Asm. Ref. Hose 3/02 E3 . Nipple Line. Description 2 2 3 1 1 1 1 1 1 1 1 1 1 1 Bolt Lever. 15 16 17 18 19 20 21 22 23 24 25 26 27 3130821 3130820 3131137 3130842 3130841 3131233 3131232 3130839 3130819 3131350 8350017-600 5431893 7080003 Qty.. Vent Packing. Description 2 1 2 3 1 1 2 1 1 1 AR 2 4 Screw Bracket Hose. Starter Shaft Spring.CARBURETOR (800) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE E 2003 Polaris Sales Inc. Starter Screw. Part No. Starter Asm. Starter Shaft Shaft Ring E-Ring Lever. 1 2 3 4 5 6 2201842 3021179 ------2201631 2202337 3514357 2201557 Qty. Woodruff Bushing Bearing. Crankshaft (Incl. Part No. Ball Bearing. To ensure that correct parts are received. Piston (Incl. Crankshaft Bearing. Rod. Bearing. Piston Rings Kit.2. Washers) Ref. Ball 3/02 E4 . which is updated monthly. Ref.PISTON and CRANKSHAFT (800) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE 3 1 2 E 2003 Polaris Sales Inc. Pin. refer to PartSmart. Description 1 4 2 2 2 2 2 Kit. Piston Pin. Connecting Rod (Incl. 7 8 9 10 11 12 7721117 7555905 3585503 3514318 5131899 3514310 Qty. Ball Spacer. Description 1 1 4 1 1 1 Key. 8-12) Circlip. 4 5 1 8 6 7 9 9 11 10 9 12 Part numbers may have changed since this microfiche was issued. Part No. Asm.. Piston Kit.3) Bearing Kit. 1. Lock Washer. Water Pump Drive Nut. which is updated monthly. To ensure that correct parts are received. 11 9 10 8 7 4 5 14 6 15 3 16 2 20 1 19 17 18 Part numbers may have changed since this microfiche was issued. Part No.. Spark Plug Decal. 19. Description 6 1 1 1 1 1 1 3 3 3 1 Screw Pulley. Starting. Ignition Screw Washer. Description 4 1 1 2 AR 1 1 1 1 1 Screw Asm. Spark Plug Wire. Hex Washer Flywheel.MAGNETO (800) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE 13 12 E 2003 Polaris Sales Inc. Idler Grommet. Part No. Ignition Ref. refer to PartSmart. 12 13 14 15 16 17 18 19 7516734 1202161 5411178 4020155 4010124-305 4060229 4010872 2202522 7077026 20 7170413 Qty. Recoil Kit. Ignition Harness. Ignition Kit. Flat Stator. Ignition/WP. Ref.E. Stator Wires Cap. (800) 6/03 E5 . Housing. 1 2 3 4 5 6 7 8 9 10 11 7517998 3021144 2201821 5630824 7546909 7555907 4010677 7517246 7555969 7555970 4010297 Qty. CDI (Incl. Ignition Coil. D.T. Waterpump Belt Pulley. Nyogel & Decal) Decal. Part No. Recoil Screw Shield.RECOIL STARTER (800) 800 CLASSIC EDGE TOURING S04NT8CS and 800 CLASSIC EDGE TOURING INT’L S04NT8CE 9 8 E 2003 Polaris Sales Inc. 1-10. which is updated monthly. Recoil E/R. Starter 3/02 E6 . Description 1 Asm. Rope Slide.. Ref. Part No. Description 1 1 2 1 6 1 1 Spring. Friction 1 Ratchet. Friction 1 Spring. Return 1 Reel Ref. To ensure that correct parts are received. 7 8 9 10 11 12 13 3040170 3040160 7661148 3040171 7517998 5246218 3040169 Qty. Spiral Housing. Pawl Electric Reverse 1 Spring. Shield (Incl. Recoil Rivet Bushing.13 & Starting Pulley) 1 Nut. refer to PartSmart. 1202408 1 2 3 4 5 6 3040163 3040164 3040167 5246108 3040166 3040168 Qty. 4 2 3 6 7 10 5 11 9 1 12 13 Part numbers may have changed since this microfiche was issued. Fastening 1 Plate. Recoil Rope Rope. Nylok Screw 3/03 E7 . Spring Switch. Description 1 1 2 2 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 Motor. Brush & Spring Asm. 4 3 2 5 1 6 7 8 9 16 17 7 15 14 13 10 11 12 Part numbers may have changed since this microfiche was issued. Part No. Asm. which is updated monthly. Curved Spring Washer. Asm. Drive Hardware Washer.STARTING MOTOR (600) 600 CLASSIC EDGE TOURING S04NT6ES and 600 CLASSIC EDGE TOURING INT’L S04NT6EE E 2003 Polaris Sales Inc. Brush Bushing. Ref.. Drive Cap Kit.. Stop Ring. Lock Cover. 1. Drive Plate. Armature Kit.. Flat Screw Bracket.. Description 1 1 1 1 2 2 1 2 2 1 2 3 Kit. Asm. Spring Lock Bracket. Starter. Insulation Washer. FLEXLOC Kit. Insulation Nut Kit. Antidrift Pinion. Starter Kit.2) Nut. Brush & Screw Asm. 5) Nut Washer... Front Washer. To ensure that correct parts are received. Dust Ref. Commutator Cap (Incl. Starter. Drive Pinion Screw Washer. 1 2 3 4 5 6 7 4170006 2200758 3082939 3080077 3083211 7542103 2200759 ------------------------------2200756 2200755 ------------------------------------------- Qty. refer to PartSmart. 8 2200757 9 2200754 ------------10 7512492 11 7552603 12 5245467 13 7555843 14 7517322 15 5244250 16 7542153 17 7516823 Qty. Thrust Spacer Spring. Flanged. Asm. Rear Nut. Magnetic (Incl. Part No. Part No. Dust Kit.. Drive Cap Kit. Screw Bolt. 14... Drive Plate. 2200758 4170006 7542103 2200759 ------------------------------7542153 7517957 5245780 5245781 7552603 7512492 2200756 1 1 1 1 1 2 1 1 1 2 4 1 1 2 2 1 1 2 3 4 5 6 7 8 9 Description Kit. To ensure that correct parts are received. Asm. Starter. Part No. Ref.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 E 2003 Polaris Sales Inc. Domestic Nut. Spring Switch. 10 2200755 ------------------------------------------11 2200757 12 2200754 ------------13 2200753 ------14 3082939 15 3080077 16 3083211 Qty. Big Block Washer. Starter. Insulation Washer.. refer to PartSmart. Curved Spring Washer. 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 Description Kit. 1 2 16 15 3 14 9 4 10 13 11 5 12 10 4 8 6 7 Part numbers may have changed since this microfiche was issued. Drive Hardware Washer. Stop Ring. Flexloc Kit. Antidrift Pinion. Thrust Spacer Spring. Lock Cover.. Armature Ref. Brush Bushing. Flanged. Spring Lock Screw Kit. Commutator Cap (Incl. 2) Motor. Asm. Rear Bracket. Magnetic (Incl.15) 5/01 E8 . Nylok Screw Bracket. Asm. Thru Nut Washer. Asm.. Brush & Spring Asm. Insulation Nut Nut. Drive Pinion Kit. Starter. Qty. which is updated monthly. Brush & Screw Asm. Part No. Description 1 1 1 1 1 1 Ref. ’04 700 Classic Touring 1 Supplement. Screwdriver. Kit. Belt Removal 1 Tool. which is updated monthly. Flat. 1-3) Screwdriver Wrench. To ensure that correct parts are received. Owner’s Manual. Owner’s. ’04 600 Classic Touring 1 Supplement. Emergency Starter 1 Tool. Shielded 4/03 E9 . Tool (Incl. Ref. 2 9 8 7 3 6 4 5 Part numbers may have changed since this microfiche was issued. Suspension Setup 6 9918226 9918281 9918283 9918378 7 7080287 8 2874113 9 2871845 Qty. ’04 800 Classic Touring 1 Strap. 5/8 x 8/16 Video.TOOL KIT 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 1 E 2003 Polaris Sales Inc. 9/16 Inch x 1/2 Inch Open End Box Wrench. Owner’s Manual. Description 1 Manual. 1 2 3 4 5 2873520 ------------------------9918079 Qty. Owner’s Manual. Part No. refer to PartSmart. Special Wrench. Box End. ’04 Snowmobile Tour Family 1 Supplement. PRINTED IN THE USA PARTS MANUAL PN 9918845 AND MICROFICHE PN 9918846 4/03 . G F E D C B A 1 cover 1 2 toc 2 3 3 4 4 Changed pages in 9918845 5 x 5 6 6 7 7 8 8 9 9 10 10 11 x 11 12 12 13 13 14 14 .