2004 Polaris Parts Manual

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

14

1516

18

2025

21

26

1

22

2827

9


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


1

3

2

4

56

78

9

10

11 12 14

1516

13

17

18

22

21 2019



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


2

3 56

8 9

1011

13

12

1415

1617

18

1

4

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

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


12

3

4

56

7

8

9

2

10




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


8

4

18

19

17

13

2

6

1415

7

5

10

11

20

16

3

1

12

9

5




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


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



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


9

5 8

10

11

16

12 13

15

18

19

20

3 4

21

17

21

14

7

6




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


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



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


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



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


8

7

9

11

4

13

21

VIEW LOOKING AT HOOD FROM UNDERNEATH

14

6

12

3

5

101 1

1

1



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


5

6

43

8

1

97

2

16

1312

14

27

26

25

22

15

28

21

19

18

17

1011

20


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



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


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


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



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


6

9

10

11

1314

3

8

52

1

7

4

5

23

12



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


1

23

3

1

45

6

7

8

91011

12

12

13

1315

11

14




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


1

1

2

3 45

6

7

8

9

10

11

12

13

14

1516

17

187

19

2021

2223

242526

27

28




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


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.



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


2021

22

18

17

19

25

24

1

2

3

16

15

13

6

12118

4

5

9

14

10

7

23




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


13

2

68

95

10

1211

13 1415

1617

19

18

7

22

1

86

20

23

21

4

4




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


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



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


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


5

M-12

M-12



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


2

1

6

1211

54

3

18

17

10

16

88

16

9

1513

14

7

15

16 17




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


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



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


15

16

1714

11

6

8

7

12

9

10


13

5

3

1 24

2

2

4 2



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


12

34

5

67 8

9

10

1112

1314

15

16

17

18

19

9




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


1

2

1

34

5 6

6

7

78

8

910

1112 13

14




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


5

910

1516

14

20

19

18

8

31

4

11

12

2

1713

7


612


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


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


1



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


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


17



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


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




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


1

2

3

10

4

5

6

8

2021

915

12

11

16

19

13

18

7

14

17




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


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


600

700/800

15

19

16


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


29



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



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




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




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




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




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




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




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



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




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




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




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




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




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


6



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




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


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


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




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




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




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




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




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




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


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




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


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


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




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




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




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




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




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



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


1

2

3

64

5

7


8

9


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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Documents

2004 Polaris Parts Manual