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550 CLASSICModel #S04ND5BS
E 2003 Polaris Sales Inc.
PARTS MANUAL PN 9918835 and MICROFICHE PN 9918836 3/03
TABLE OF CONTENTS550 Classic S04ND5BS
Parts Manual
AAIRBOX B14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
BBATTERY BOX C1. . . . . . . . . . . . . . . . . . . . . . .BLOWER HOUSING C8. . . . . . . . . . . . . . . . . . .BRAKE B5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCARBURETOR C9. . . . . . . . . . . . . . . . . . . . . . .CHAINCASE B11. . . . . . . . . . . . . . . . . . . . . . . .CHASSIS A3. . . . . . . . . . . . . . . . . . . . . . . . . . .CONSOLE A12. . . . . . . . . . . . . . . . . . . . . . . . . .CRANKCASE C5. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT C7. . . . . . . . . . . . . . . . . . . . . . .CYLINDER C6. . . . . . . . . . . . . . . . . . . . . . . . . .
DDECALS A11. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B12. . . . . . . . . . . . . . . . . . . . . .DRIVE TRAIN C2. . . . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH B13. . . . . . . . . . . . . . . . . . . . .
EENGINE MOUNTING C4. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM C3. . . . . . . . . . . . . . . . . . .
FFRONT SUSPENSION A13-14. . . . . . . . . . . . . . . . .FRONT TORQUE ARM B8. . . . . . . . . . . . . . . . .FUEL PUMP C10. . . . . . . . . . . . . . . . . . . . . . . . .
GGAS TANK A5. . . . . . . . . . . . . . . . . . . . . . . . . .
HHANDLEBAR B3. . . . . . . . . . . . . . . . . . . . . . . .HOOD A8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .HOOD FOAM/FOIL A10. . . . . . . . . . . . . . . . . . . .
MMAGNETO C12. . . . . . . . . . . . . . . . . . . . . . . . . .
NNOSEPAN A6-7. . . . . . . . . . . . . . . . . . . . . . . . . .
OOIL PUMP C11. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK B14. . . . . . . . . . . . . . . . . . . . . . . . . . .
PPISTON C7. . . . . . . . . . . . . . . . . . . . . . . . . . .
RRAIL MOUNTING B6. . . . . . . . . . . . . . . . . . . . .REAR SUSPENSION B7. . . . . . . . . . . . . . . . . .REAR TORQUE ARM B9. . . . . . . . . . . . . . . . . .RECOIL STARTER C8. . . . . . . . . . . . . . . . . . . .
SSEAT A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SHOCK (REAR TRACK) B10. . . . . . . . . . . . . . . .SKI B1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR C13. . . . . . . . . . . . . . . . . . .STEERING B2-4. . . . . . . . . . . . . . . . . . . . . . . . . .
TTOOL KIT C14. . . . . . . . . . . . . . . . . . . . . . . . . . .
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
A3
CHASSIS550 CLASSIC S04ND5BS
34
5 18
14 1516 17
19
2120
22
26
28
31
24
24
27
1
25
1824
24
23
30 24
7
6
E 2003 Polaris Sales Inc.
29
32
34
2
33
1
9
10
11
10
8
12 13
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 7621432 19 Rivet2 5246330 1 Bracket, Oil Tank/Hose Support3 3021104 1 Stop, Torque4 7542404 1 Nut5 1013399 1 Stop, Torque6 7517632 1 Screw7 7517854 2 Screw8 1014086--067 1 Asm., Chassis, Edge, Natural
(Incl. 26-29,34)9 5246177 1 Brkt Airbox Edge10 7080934 6 Caplug11 7080592 2 Caplug12 5812290 2 Gasket, Seat Base13 5812360 1 Gasket, Seat Base, 1/4 Inch14 7512232 6 Bolt15 7552801 6 Washer, Spring Lock16 7558301 6 Washer, Flat17 2632165-309 1 Bumper, Rear, Unpainted18 7621472 13 Rivet19 5433961--1106 1 Flap, Snow, Short, Black/Chrome
20 7517441 4 Screw21 2670133 1 Asm., Reflector, Red22 2632443-070
2632444-07011
Asm., Snowskirt, Refl., LHAsm., Snowskirt, Refl., RH
23 5245118-067 1 Brace, Tunnel Roll24 7661637 74 Rivet25 5433150 2 Strap, Airbox Top26 5246310--067
5246311--06711
Support, Footrest, LHSupport, Footrest, RH
27 5245457--0675245458--067
11
Mount, Console, Toe Clip, LHMount, Console, Toe Clip, RH
28 5245288--0675247205--067
11
Footrest, LHFootrest, RH
29 22020592202598
11
Kit, Trailing Arm Mount, LHKit, Trailing Arm Mount, RH
30 5246066 1 Guard, Belt31 7080416 2 Plug, Hole32 7661130 15 Rivet33 7081076 2 Plug, Hole34 5132292 1 Bulkhead, Front
3/03
A4
SEAT550 CLASSIC S04ND5BS
1
14
67
13
2
3 54
8
12
11
9
10
10
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 26832322683233
11
Asm., Seat, (Incl. 1,6,14)Cover, Seat
2 7080550 1 Grommet, Relatch, Bottom3 7080549 1 Grommet, Relatch, Top4 7080548 1 Relatch w/Hole, Twist Lock5 7621337 2 Rivet6 5433341
40300244030045
121
Housing, TaillightBulb, TaillightBulb, Brakelight
7 5430423 1 Lens8 7511840 4 Screw9 7555727 3 Washer10 7621319 7 Rivet11 5631194 2 Nut, Seat12 7558301 2 Washer, Flat13 7517219 2 Screw14 2460399 1 Harness, Taillight
3/03
A5
GAS TANK550 CLASSIC S04ND5BS
1
2
3
4
5
6
7
89
10
11
12
13
14
15
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2520323 1 Cap w/Gauge, Fuel2 7542122 2 Nut, Nylok3 7555960 2 Washer, Flat4 7670021 2 Nut Speed5 7512193 2 Bolt Carriage6 5810947 2 Foam, Seal, Rear Cooler7 7052301 1 Pickup, Fuel, w/Filter8 7080402 2 Ring, Compression
9 7052028 1 Grommet, Flanged10 7052321 1 Fitting, Straight11 8350019-600 AR Line, Fuel12 2520276 1 Asm., Fuel Tank (Incl. 7-13)13 7052095 1 Fitting, 90 Degree14 8450061-600 AR Line, Fuel15 7080804 2 Cable Tie, Releasable
3/03
A6
NOSEPAN550 CLASSIC S04ND5BS
12
12
11
19
8
16
24
15
23
13
814
22 2120
7
3 6
5
6
1
25
1817
910
4
4
8
1
1
1
1
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7661637 12 Rivet2 5243992-067 1 Hinge, Pivot, Lower, RH3 5243978 1 Mount, Shock, Upper, RH4 5810947 1 Foam, Seal, Rear Cooler5 7547180 4 Nut, Flanged6 7517935 4 Screw7 5243977 1 Mount, Shock, Upper, 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, Pivot, Lower, LH
14 7542153 2 Nut, Flanged, Nylok15 5433518-070 1 Asm., Bumper, Front Black16 7512163 2 Bolt17 7621472 3 Rivet18 5245853 1 Shield, Exhaust, Heat, Extended19 5434343--070 1 Nosepan, Black20 7542122 4 Nut, Nylok21 7555827 4 Washer22 7515166 4 Screw23 7517312 4 Screw24 7552801 4 Washer, Spring Lock25 5244888
524488911
Guide, Hood, LHGuide, Hood, RH
3/03
A7
NOSEPAN550 CLASSIC S04ND5BS
18
14
21
1516
20
22
23
24
19
3
1
2
4
13
11
12
5
6
87
9
10
17
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7670130 3 Clip, Speed, U-Type2 7080963 1 J-Clip, Retainer3 5811948 1 Foil4 7621462 1 Rivet5 5812020 2 Foil, Tape, Nosepan6 5811458 1 Foil, Tape7 5812040 1 Foil, Nosepan, Front8 5812067 1 Foil, Tape, Top, Shock9 5812039 1 Foil, Nosepan, Shock Tower10 5812068 1 Foil, Tape11 5812018 1 Foil, Tape, Nosepan, Upper, RH12 5812019 1 Foil, Tape, Nosepan, Lower, RH
13 5812353 1 Foam14 5434531 1 Duct, Engine Air Outlet15 1013069 1 Asm., Guard, Clutch16 7080698 1 Pin, Clutch Guard17 5812352 1 Pad, Clutch Guard18 7621485 3 Rivet19 7079297 1 Decal, Warning Engine and Clutch20 7170046 1 Decal, Troubleshooting, Edge, PPS21 7621402 5 Rivet22 2670134 2 Asm., Reflector, Amber23 5433926 1 Plug, Hole, Oblong24 5211722 1 Plate, Backer, Clutch Guard
3/03
A8
HOOD550 CLASSIC S04ND5BS
1
3
5
6
7
8
9
10
1115
18
19
2118
19
17
20
16
20
17 16
20
14
4
20 13
2
12
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2632783-447 1 Asm., Hood, Edge, Fan, Blue2 2461015 1 Harness, Headlight, E/R3 2410132 1 Asm. Headlamp (Incl. Bulbs)4 5812450 1 Seal, Headlight, One Piece5 2870448 2 Bulb6 4032063 2 Retainer, Headlamp Bulb7 7517872 1 Bolt, Tee Adjuster8 7041954 1 Spring, Headlight Adjust9 7080887 1 Knob, Headlight Adjust, Locking10 5811793 2 Foam, Prefilter11 2632491
58123245811948
111
Asm., Plenum w/FoilFoil, PlenumFoil
12 7170740 1 Decal, Suspension Set-Up13 5433660 1 Cover, Access, Headlight14 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 5243568-067 1 Hinge, Upper, RH
3/03
A9
HOOD550 CLASSIC S04ND5BS
1
2
3
9
8
13
10
11
12
20
21
18
19
17
14
17
15
6
5
4
16
7
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7621509 3 Rivet2 5435045 1 Windshield, Smoke, 15-Inch3 5410970 4 Retainer, Windshield4 7670133 1 Retainer, Bolt, Lamp5 4010687 1 Indicator Reverse6 5434081 1 Plug, Dash, w/Hole7 2461031 1 Harness, Jumper Reverse Light8 3280210 1 Bracket, Speedometer/Tachometer9 3280209 1 Cushion, Rubber10 3280186 1 Knob, Trip Odometer11 3280411
403001514
Asm., SpeedometerBulb, Replacement
12 3280157 2 Washer, Flat
13 7546703 2 Nut, Nylok14 3280385 1 Cable, Speedometer15 7080138 3 Cable Tie16 2632246--070
2632247--07075560887546703
1166
Asm., Mirror, Edge, LHAsm., Mirror, Edge, RHWasher, FlatNut Nylok
17 4010589 2 Clip, Plastic, Dart, Nylon18 7512018 2 Screw19 7541925 2 Nut, Nylok20 7080521 2 Cable, Hood Retainer21 7661637 2 Rivet
3/03
A10
HOOD FOAM/FOIL550 CLASSIC S04ND5BS
32
5
1
4
VIEW FROM UNDER HOOD
10
6
7
12
11
8
9
13
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5243465-067 1 Screen, Nostril Hood, RH2 5243463-067 1 Screen, Louver Hood, Rear3 5243462-067 1 Screen, Louver Hood, Front4 7621334 7 Rivet5 5243464-067 1 Screen, Nostril Hood, LH6 5812424 1 Foil, Hood, Louver, RH7 5812061 1 Foil, Tape
8 5812107 1 Foil, Hood, Edge, RH9 5812106 1 Foil, Hood, Edge, RH10 5810345 1 Foil, Tape11 5812270 1 Foam, Hood, Rear, LH12 5812286 1 Foam, Hood, Front, LH13 5812007 1 Foam, Hood, Center, Edge
3/03
A11
DECALS550 CLASSIC S04ND5BS
67 10
11
14
15
16
17
1819
32
21
1
22
20
12
4
5
8
13
9
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7079886 1 Decal, Warning, English2 7078716 1 Decal, Electric Start, Domed3 7079887 1 Decal, Warning, French4 2202541
2200891
1
1
Kit, Decal, Hood ’04 550 Classic(Incl. 2,5-10,13,14,17,20)Kit, Decal Application Solution(For Seat Decals)
5 7171090 1 Urocal, Hood Center, “Classic”6 7171136 1 Decal, Hood Center, “Classic”7 7171155
717115611
Decal, Hood Top, “550”, LHDecal, Hood Top, “550”, RH
8 7171154 2 Urocal, “550”9 7171143
717114411
Decal, Headlight, LHDecal, Headlight, RH
10 7171123 2 Urocal, “POLARIS”
11 7076360 1 Decal, Track/Seat, LH/RH, English/French12 7171099 2 Decal, Seat, “Classic POLARIS”13 7171116 2 Urocal, “Classic”14 7171141
717114211
Decal, Hood Side, “Classic”, LHDecal, Hood Side, “Classic”, RH
15 71710977171098
11
Decal, Pan, LHDecal, Pan, RH
16 71701437170144
11
Decal, Trailing Arm, “Edge IFS”, LHDecal, Trailing Arm, “Edge IFS”, RH
17 7171195 1 Urocal, “POLARIS”18 7170061 1 Decal, Choke19 7075438 1 Decal, Warning, “NO PASSENGER”20 7170608 1 Urocal, “Perc”21 7170112 1 Decal, Warning/Rev/Elec. Rev. Opt.22 7170039 1 Decal, Ignition
3/03
A12
CONSOLE550 CLASSIC S04ND5BS
5
9 10
1516
14
21
20
18
8
31
4
12
6
7
11
2
17
13
19
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7541925 2 Nut, Nylok2 7555746 2 Washer3 4010794 1 Regulator, AC/DC 14.3V4 7517263 2 Screw5 4010193 2 Housing, Connector6 4010192 7 Socket7 4020092 1 Terminal, Ring8 4020063 1 Housing9 2461148 1 Harness, Main10 4020057 1 Housing11 7515199 2 Screw12 5434483--070 1 Console w/ACC13 4010638 1 Receptacle Pod Mnt
14 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 Control (Incl. Pin)19 7571610 1 Washer20 7080290 1 Cable, Choke Control (Incl. 21,18)21 7080229 1 Nut, Choke, Slide
3/03
A13
FRONT SUSPENSION550 CLASSIC S04ND5BS
12
11
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
7
7
2 1417
10
17
20
4
14
9
13
8
8
7
7
E 2003 Polaris Sales Inc.
A14
FRONT SUSPENSION550 CLASSIC S04ND5BS
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517980 2 Bolt2 5434036 8 Bushing, Radius Rod, Pivot, Inner3 5132779 2 Bushing, Shoulder4 7547066 4 Nut, Nylok5 1820679-385 2 Rod, Radius, Upper, Cld. Silver6 7542520 2 Nut, Jam7 7542439 12 Nut, Nylok8 7515433 4 Screw9 1500063 2 Retainer, Spring, Body, Threaded10 5630580 2 Retainer, Spring, Slotted11 7041932 2 Shock, IFS12 7041551--067 2 Spring, Compression, IFS, Black13 5431734 2 Ring, Spring, Preload14 7517583 6 Screw15 7555832 4 Washer16 5132728 2 Arm, Steering17 7555797 4 Washer, Flat18 1821165-385
1821166-38511
Asm., Trailing Arm, Cld Slv, LH (Incl. 21,22)Asm., Trailing Arm, Cld Slv, RH (Incl. 21,22)
19 7555820 2 Washer, Flat20 5132364 2 Cup, Mount, Trailing Arm21 7061042 2 Bearing, Spherical
22 7710437 2 Ring, Retaining23 7512099 2 Screw24 7061057 2 Rod End, RH25 3573909 2 Bushing, Flange26 7080433 2 Fitting, Lubrication27 5433234 2 Bushing, Torsion Bar28 7621452 6 Rivet29 5244415-067 1 Bar, Torsion30 5434369 2 Slide, Torsion Bar31 7556509 2 Bushing32 3574208 2 Bushing, Flanged33 6230225-067 2 Shaft, Spindle, w/Steering 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, Cld. Silver39 7547065 2 Nut, Nylon40 7061061 2 Rod End, Radius41 5132780 2 Bushing, Shoulder42 7512684 2 Bolt
5/02
B1
SKI550 CLASSIC S04ND5BS
6
9
10
11
1314
3
8
52
1
7
4
5
23
12
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1 7542321 2 Nut, Flange2 7542439 4 Nut, Nylok3 7555832 4 Washer, Belle4 5434165-385 2 Toe, Ski, Plastic, Cloud Silver5 7556130 4 Washer, Belle6 5132637 4 Bushing, Plastic Ski7 5412018 2 Stop, Ski Rubber
8 7542324 8 Nut, Nylok9 7556175 8 Washer, Flat10 1820929-070 2 Asm., Comp. Ski, Blank11 7517968 2 Screw12 2874752 2 Kit, Skag, Dual, 4 Inch, 60 Degree13 7515514 2 Bolt14 7515307 2 Screw
4/03
B2
STEERING550 CLASSIC S04ND5BS
8
6
2
11
10
1
45
7
3
14
9
12
1312
13
3
1
11
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517579 4 Bolt, Carriage2 1013776-067 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 5245354 1 Bracket, Console, Front Neck
2/03
B3
HANDLEBAR550 CLASSIC S04ND5BS
234
26
1
1
7
7
6 8
9
10
1112
13
1415
16
18
19
2021
17
2223
27
25
24
5
28
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5432634 2 Grip, Handlebar2 7661624 1 Pin, Retaining3 7710503 1 Ring, Retaining4 5432970
201017111
Lever, ThrottleAsm., Lever w/Heater, HI/LO
5 4110106 1 Switch, Auxiliary Shut-Off, Closed6 5433345 1 Adaptor, Block, Throttle7 5431096 2 Plug, Overflow8 5243355-067 1 Handlebar9 7517238 4 Screw10 5434488 1 Collar, Console, RH11 7670106 2 Nut, Push-On12 5434179 1 Emblem, Star13 5433159-070 1 Cover, Handlebar14 5433160-070 2 Slide, Handlebar Cover
15 4010287 2 Dart, Clip, Nylon16 5434487 1 Collar, Console, LH17 2460677 2 Heater, Grip, Lo/Med/Hi18 ------ -- -- -- -- 1 Asm., Control, LH
(See Brake Pg.B5 Ref. 12)19 5630187-067 2 Block, Handlebar20 1820965-067 1 Post, Steering21 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
2/03
B4
STEERING550 CLASSIC S04ND5BS
9
2
84 5
3
1
14
1115
12
13
16
7
1
2
2
2
9
9
9
4
4
5
10
3
13
15
15
11
11
1114
15
9
66
10
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1 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, Draglink
9 7542439 8 Nut, Nylok10 7061075 2 Rod End, LH11 5132106 4 Bushing, Reducer12 1820957 1 Asm., Pitman Arm (Incl. 11,13,15)13 5133423 2 Spacer, Tube Pitman/Idler Arms14 7512435 2 Screw15 3514320 4 Bearing, Ball16 1820959 1 Asm., Idler Arm (Incl. 11,13,15)
3/02
B5
BRAKE550 CLASSIC S04ND5BS
2019
18
2423
2116
1
2
3
15
14
12
6
11
5
8
4
9
13
10
7
22
17
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2201254 1 Kit, Cover Screws2 2201255 1 Kit, Cover Assembly (Incl. 1,3)3 ------ -- -- -- -- 1 Gasket4 2201250 1 Kit, Park Lever Spring5 2202146
4010157
1
1
Kit, Asm., Master Cylinder, Hayes(Incl. 1-11)Switch, Brake Light
6 7517441 2 Screw7 7512078 1 Screw8 2201943 1 Kit, Lever9 7517566 1 Screw10 2201945 1 Kit, Snap Ring11 2201944 1 Kit, Cartridge Subassembly12 2010206 1 Asm., Control, LH, E/R, Basic
13 5433291 1 Button, Switch, HI/LO, LH Control14 2201946 1 Kit, Pivot Pin15 2201251 1 Kit, Park Lever and Spring (Incl. 4)16 1910607 1 Line, Brake17 2202205 1 Kit, Bleeder Fitting18 7515534 2 Screw19 7552603 2 Washer, Spring Lock20 7556160 2 Washer21 2202198 1 Kit, Asm., Brake Caliper (Incl.
17,22,23,24)22 2202206 1 Kit, Pin Retaining23 2202202 1 Kit, Brake Pad, Type 8124 2202207
220220411
Kit, Piston/SealKit, Seal
7/03
B6
RAIL MOUNTING550 CLASSIC S04ND5BS
1
2 3
4 5
6 7 89
1011 12 13
14
1516
1718
1920
2122
23
2425
2627
28
2930
31
32
33
3435
4
9 4 711
7
1
30
26
2728
247
1
25
5
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1 1590275-244 4 Asm., Wheel, Scrolled, Silver Metallic2 7718407 4 Ring, Retaining (1 per Wheel)3 3514303 4 Bearing (1 per Wheel)4 7541925 6 Nut, Nylok5 7555792 4 Washer6 5434374 2 Cap, Rail Tip7 7555783 8 Washer, Flat8 5521499 2 Bumper, Jounce, Front9 7542324 8 Nut, Nylok10 7661845 2 Rivet11 7542439 6 Nut, Nylok12 5244677 2 Bracket, Rail Reinforcement13 5432946 2 Liner, Bumper14 5521498 2 Bumper, Jounce, Rear15 7515537 4 Bolt16 5131113 4 Mount, Bumper17 5410925 4 Bumper, Pivot Arm18 5244371 2 Spacer
19 5132444 2 Block, Idler Bolt Adjusting20 7621501 4 Rivet21 7547156 2 Nut, Jam22 7517773 2 Screw23 1541755
154175611
Asm., Rail, LH (Incl. 6,8,14,17,19)Asm., Rail, RH (Incl. 6,8,14,17,19)
24 7510504 4 Screw25 5631065 4 Block, Wheel, Mount26 7515346 4 Screw27 7556179 4 Washer, Spring28 7515317 4 Bolt29 7515438 2 Screw30 7555983 4 Washer31 5333948 2 Spacer32 5433959 2 Roller, Spring, Square33 5521571 2 Hi-Fax34 7511975 2 Screw35 7515199 2 Screw
5/02
B7
REAR SUSPENSION550 CLASSIC S04ND5BS
12 3
4 5
67
8
9
10
11
12
1314
151617
18
19
2021
22
23
25
26
24
21
1
1
6
6
5
5
14
23
15165
20
19
4
24
5
5
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1 7542439 4 Nut, Nylok2 5133233 1 Bushing3 1541477-067 1 Arm, Pivot, Shock4 7515417 2 Screw5 7555806 8 Washer, Flat6 5432535 4 Spacer, Idler7 7555918 1 Bushing8 1594087 1 Asm., Wheel9 5333285 1 Spacer, Idler, Long10 5020744 1 Shaft, Idler11 1590303-244
77104443514384
222
Asm., Idler Wheel, Slv MtRing, RetainingBearing
12 7556130 2 Washer, Belle13 7517731 2 Bolt
14 7517921 2 Screw15 7517247 4 Screw16 7552603 4 Washer, Spring Lock17 5411057
52228401
ARTrack (.82 inch)Clip, Guide
18 5020723 1 Shaft, Pivot Arm19 1541485 2 Asm., Wheel, w/Hole20 7556301 2 Bushing21 1541711-067 1 Mount, Shock22 5132490 1 Shaft23 7555893 2 Washer, Flat24 7080424 2 Fitting, Lubrication25 5333404 1 Shaft26 1541707-067 1 Arm, Pivot, Rear
3/03
B8
FRONT TORQUE ARM (EDGE)550 CLASSIC S04ND5BS
123 4 5
6
7
8
910
11
12
14
16
17
18
1920
22
23
2425
26
19
2324
24
25
21
15
13
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517435 2 Screw2 7552603 2 Washer, Spring Lock3 7555893 2 Washer, Flat4 5132067 1 Shaft, FTA, Upper5 1541779-067 1 Arm, Torque, Front, Black6 7080510 1 Fitting, Zerk, 90 Degree7 7542439 1 Nut, Nylok8 5333905 1 Sleeve9 7041939 1 Shock, Front Track10 5630580 1 Retainer, Spring, Slotted11 5430671 1 Shield, Spring12 7041253-067 1 Spring, Comp13 5245067 1 Retainer, Spring
14 5333906 1 Sleeve15 5210953 1 Retainer, Spring16 7515415 1 Screw17 7080424 2 Fitting, Lubrication18 5133308 2 Shaft, w/O-Ring19 7556156 6 Washer20 7547066 2 Nut, Nylon21 5412022 2 O-Ring22 7512597 2 Bolt23 7517313 4 Screw24 7556175 8 Washer, Flat25 7542344 4 Nut, Nylok26 5412140 2 Strap, Limiter, Front
3/02
B9
REAR TORQUE ARM550 CLASSIC S04ND5BS
13
4
6
7
8 910
1112
1415
16
1718
19
20
2122
2324
25
26
2728
29
30
3132
33
13
813
8
24 2513
2425
2
5E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty.. Description Ref. Part No. Qty.. Description
1 1541969-067 1 Arm, Torque, Rear, Black2 7542411 1 Nut, Flexloc3 7512410 1 Screw4 5333758 2 Shaft, Arm5 7555945 2 Washer, Thrust6 3514331 4 Bushing, Arm7 7515415 2 Screw8 7555806 5 Washer, Flat9 7555893 2 Washer, Flat10 7552603 2 Washer, Spring Lock11 7517435 2 Screw12 1541967 2 Asm., Rear Torque Arm (Incl. 6)13 7542439 4 Nut, Nylok14 5132388 2 Spacer, Wheel15 1590343 2 Asm., Carrier Wheel16 7555787 2 Washer, Thrust17 5431923 2 Sleeve, Torsion Spring18 5432983 2 Roller, Spring, Adjustable, Square19 7080394 2 Clip, Push-On
20 7041942-0677041943-0677041629-0677041630-0677041940-0677041941-067
111111
Spring, Torsion, LH (Opt)(.375/77)Spring, Torsion, RH (Opt)(.375/77)Spring, Torsion, Soft, LH (Std)(.359/77)Spring, Torsion, Soft, RH (Std)(.359/77)Spring, Torsion, Firm, LH (Opt)(.405/77)Spring, Torsion, Firm, RH (Opt)(.405/77)
21 7517232 1 Screw22 5333873 1 Shaft23 7515514 1 Bolt24 7555795 3 Washer25 5132391 3 Bushing26 1541479-067 2 Rod, Shock27 7517851 1 Screw28 5132390 1 Bushing, Nut29 5333907 1 Sleeve30 7080424 1 Fitting, Lubrication31 5333904 1 Spacer32 7042129 1 Shock, PPS33 5010422 1 Bushing
3/03
B10
SHOCK (REAR TRACK)550 CLASSIC S04ND5BS
2
3
4
5
6
7
8
9
10
11
12 1314 15 16
17
18
1920
21
22
2324
25
2726 28
18
2423
29
1
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7042129 1 Shock, Rear Track, PPS (Incl. All)2 1500295
150002211
ScrewO-Ring
3 150048115000061500003
111
Asm., Floating PistonBearing, ExternalO-Ring
4 1500306 1 Valve, Check5 1500331 1 Asm., Body, Inner6 1500016 1 Nut, Lock7 1500015 1 Plate, Backup8 1500489
150000211
PistonBearing, Piston
9 1500487 1 Shaft10 1500302 1 Eyelet11 1500483 1 O-Ring12 1500485 1 Scraper, F.I.S.T.13 1500266 1 U-Cup14 1500484 1 O-Ring
15 1500486 1 Ring, Snap, Internal16 1500295
150002211
ScrewO-Ring
17 1500482 1 Asm., Bearing F.I.S.T.(Incl. 11-16,18-20)
18 1500228 1 O-Ring19 1500127 1 O-Ring20 1500488 1 Bearing21 1500459 1 O-Ring22 1500228 2 O-Ring23 1500097 2 Ring, Retaining, Wire24 1500336 2 Collar, Alum25 1500480 1 Asm., Body (Incl. 2)26 1500311 1 Sleeve .56 ID27 1500307 2 Bushing28 5333907 1 Sleeve .385 ID29 5010422 1 Bushing .385 ID
3/02
B11
CHAINCASE550 CLASSIC S04ND5BS
1 32
57
84
9
1110
12 1314
1516
18
17
6
20
1
75
21
19
22
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3610030 2 Seal, Oil2 7542404 1 Nut3 7515459 1 Screw4 1332266
563012335530027558702
1112
Asm., Tightener, SlidingWheel, IdlerBearing, Chaincase IdlerWasher, Thrust
5 3514309 2 Bearing, Ball6 1332143
541067512
Asm., Dipstick (Incl. O-Ring)O-Ring
7 7718406 2 Ring, Retaining8 3221095 1 Sprocket, 19T, 3/4W9 7571620 1 Washer, Spring10 7661203 1 Pin, Cotter
11 7547202 1 Nut12 5411497 1 Gasket, Chaincase O-Ring13 5631354 1 Cover, Chaincase14 7512242 5 Screw15 7517979 1 Screw16 7571618 1 Washer, Spring17 3222108 1 Sprocket, 39T18 3221110 1 Chain, 72P, 3/4W19 7052115 1 Plug20 5134085 1 Chaincase21 7515477 1 Screw, Carriage22 7542451 1 Nut, Nylok
2/03
B12
DRIVE CLUTCH550 CLASSIC S04ND5BS
12
34
5
67 8
9
10
1112
1314
15
16
17
18
19
20
9
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512265 6 Bolt2 7552801 6 Washer, Spring Lock3 3576516 1 Bearing, Cover4 7710417 1 Ring, Retaining, Cover5 7041781 1 Spring, Clutch, Dark Blue/White6 5020425 1 Nut, Jam7 5430945 6 Washer, Multilube8 1321622 3 Asm., Roller and Bushing9 5430445 6 Button, Guide10 5210754
5210753524298152107525132542
ARARARARAR
Spacer (.050)Spacer (.032)Spacer (.025)Spacer (.020)Spacer (.130)
11 1321586 3 Asm., Weight/Bushing (10-62)12 7515105 3 Pin, Weight, Hardened13 3576502 1 Bearing, Sleeve14 5010188 1 Insert, Moveable15 5133649 1 Gear, Ring16 7515351 6 Screw17 7541906 3 Nut, FLEXLOC18 1322316 1 Asm., Drive Clutch ES Basic 126
(Incl. All Less 5,11)19 2200387 1 Kit, Drive Clutch Shim20 5133079 3 Pin, Roller
4/02
B13
DRIVEN CLUTCH550 CLASSIC S04ND5BS
1
2
1
34
5 6
6
7
78
8
910
1112 13
14
15
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7518023 12 Screw2 5246216 1 Plate, Windage3 3233996 8 Screw4 5133887 1 Ramp, Driven5 7710522 1 Ring, Retaining6 5434534 2 Roller7 7556226 1 Washer, Thrust8 7710523 2 Ring, Retaining
9 7042137 1 Spring, Driven Clutch, Red/Blue10 7556227 1 Washer, Thrust11 3234033 1 Spacer12 7518024 1 Screw13 7542103 1 Nut, FLEXLOC14 5246217 1 Plate, Windage15 1322321 1 Asm., Driven Clutch, Basic, 211
(Incl. 1,2,5-9,11-15)
2/03
B14
OIL TANK / AIRBOX550 CLASSIC S04ND5BS
11
16
15
13
20
21
12
1429
25
3
5
9
7
26
2324
23
E 2003 Polaris Sales Inc.1
2
4 8
4
62728
10
1718
196
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. Qty. Description Ref. Part No. Qty. Description
1 5434089 1 Cover, Tool Box2 5812209 1 Foam, Tool Box3 7512297 1 Screw4 7542122 3 Nut, Nylok5 1253453
126119911
Asm., Oil Tank w/Sender (Incl. 1,25)Oil Bottle/Tool Box w/Mnt
6 7555932 4 Washer, Nylon7 ------ -- -- -- -- 1 Asm., Fuel Pump
(See Fuel Pump Pg. C10, Ref. 3)8 7512095 2 Screw9 ------ -- -- -- -- 1 System, CDI
(See Magneto Pg. C12, Ref. 9)10 7670102 1 Clip Silencer Box11 5811882 1 Foam, Air Box, Chimney12 7075351 1 Decal, Caution, Air Box13 5433150 1 Strap, Air Box, Top14 7073426 1 Decal, Greasing
15 1253499 1 Asm., Air Silencer w/ER(Incl. 20 & Decals)
16 7171037 1 Decal, Belt Removal, Team, E/R17 7547103 2 Nut18 7552604 2 Washer19 7517610 2 Screw20 5412189 2 Boot, Carburetor21 7052127 2 Fitting, Hose22 4010051-30 AR Tubing, Convoluted23 7080307 2 Clamp, Hose24 8450003-1525 AR Line, Fuel25 4010660 1 Sender, Oil w/Front Terminals26 7052305 1 Grommet, Oil Sender27 7555859 2 Washer, Flat28 7512163 2 Bolt29 1240094 1 Cap, Oil, Vented
3/03
C1
BATTERY BOX550 CLASSIC S04ND5BS
1
2
3
10
4
5
6
820
21
9
15
12
11
17
19
13
18
7
14
16
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5810290 3 Pad, Battery2 2450020 1 Asm., Strap, Battery Hold-Down3 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 Pg. C13, Ref. 19)9 5410346 2 Insulator, Cable10 2460393 1 Asm., Cable, Battery/Solenoid11 4010108 1 Wire, Jumper, Solenoid/Battery
12 2434008 1 Breaker, Circuit13 7541925 2 Nut, Nylok14 7542122 2 Nut, Nylok15 1013679-067 1 Box, Battery16 5810129 1 Foil, Tape17 7621467 1 Rivet18 1013385 1 Plate, Stud, Battery Box19 7511930 2 Bolt20 ------ -- -- -- -- 2 Washer, Spring
(See Starting Motor Pg. C13, Ref. 18)21 ------ -- -- -- -- 2 Nut
(See Starting Motor Pg. C13, Ref. 17)
3/02
C2
DRIVE TRAIN550 CLASSIC S04ND5BS
12
3 4 5
6
9
16
1114
15
10
13
18
1920
22 232725
2829
3031
24
12
17
26
8
2124
13
2322
7
21
E 2003 Polaris Sales Inc.
14
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7515369 1 Screw2 7555701 1 Washer, Flat3 7555734 AR Washer, Flat4 5020913 1 Spacer5 ------ -- -- -- -- 1 Asm., Driven Clutch
(See Driven Clutch Pg. B13, Ref. 15)6 3211078 1 Belt, Drive7 7555917 1 Washer8 7555864 AR Washer9 7556509 AR Bushing10 7558402 3 Washer, Flat11 5241359
708056111
Flangette w/Grease ZerkFitting, Lubrication
12 5811095 1 Gasket, Jackshaft13 7542324 6 Nut, Nylok14 3514525 2 Bearing15 5222751 1 Flangette
16 7512377 3 Bolt, Carriage17 7721116 1 Key18 1332220 1 Asm., Jackshaft (Incl. 14,19)19 7710422 1 Ring, Retaining20 1910612 1 Disc, Brake21 7515428 3 Bolt, Carriage22 5020588 2 Sleeve, Seal23 5410613 2 O-Ring24 7542423 3 Nut, Flange25 1590340 1 Asm., Drive Shaft (Incl. 26,27)26 1012945 1 Asm., Flangette w/Screws27 3280019 1 Bushing, Speedometer, Metal28 5243529 1 Flangette, Offset, w/Hole29 3280017 1 Key, Speedometer, Square30 5830012 1 Gasket, Drive Adaptor31 3280116 1 Adaptor w/Zerk, Drive
5/03
C3
EXHAUST SYSTEM550 CLASSIC S04ND5BS
1
2
34
56
7
8
9
10
11
12
13
14
15
16
17
18
3
3
10
3
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1261296-029 1 Bracket, Chassis/Resonator2 3610047 1 Seal, Exhaust3 7041687 8 Spring, Exhaust4 1261130-029 1 Resonator5 7555904 1 Washer6 5411684 1 Boot, Exhaust Outlet7 7621467 1 Rivet8 3085714 2 Gasket, Exhaust9 1260981-029 1 Manifold
10 7517555 6 Screw11 7517935 1 Screw12 7547180 1 Nut, Flanged, Nylon13 5245498 1 Bracket, Chassis Pipe14 7556004 AR Washer15 5411576 1 Dampener, Vibration w/Ribs16 1261228-029 1 Asm., Tuned Pipe17 7042029 2 Spring, Exhaust18 7661637 8 Rivet
3/03
C4
ENGINE MOUNTING550 CLASSIC S04ND5BS
12 3
7
8
9
16
12
13
28
29
31
45
32
32
14
11
22
10
25
25
25
25
25
25
26
26
26
25
30
23
21
2120
20
20
21
24
19
17
17
6
18
18
1314
15
112627
10
1616
15
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517776 1 Screw2 7575202 1 Washer3 5010287 1 Washer, Clutch Retainer, Short4 5410507 2 O-Ring, Clutch Bolt5 5020513 1 Spacer, Clutch Bolt6 7080290 1 Cable, Choke Control7 3070163 2 Spark Plug, NGK BR9ES8 3088822 1 Engine, Short Block NOTE: The
Short Block assembly contains acrankcase assembly, cylinder and cylin-der head assembly, and a piston andcrankshaft assembly. Prior authoriza-tion is required for warranty consider-ation.
9 5431499-070 1 Handle, Recoil10 7542451 2 Nut, Nylok11 7555893 2 Washer, Flat12 5246193 1 Strap, Engine Mount, RH13 3021220 2 Mount, Engine14 5245117 2 Spacer, Engine Mount
15 7547180 2 Nut, Flanged, Nylon16 7517399 4 Screw17 3021206 2 Mount, Engine18 7517854 3 Screw19 5245044 1 Bracket, Engine Mount, RH20 7555806 4 Washer, Flat21 7547008 4 Nut, FLEXLOC, Thin22 5245466 1 Strap, Engine Mount, LH23 5245020 2 Spacer, Engine24 1013397 1 Bracket, Engine Mount, LH25 7080307 8 Clamp, Hose26 8350018-600 AR Line, Fuel27 7052248 1 Valve, Fuel Plastic, Inline28 ------ -- -- -- -- 1 Asm., Fuel Pump
(See Fuel Pump Pg. C10, Ref. 3)29 7081172 1 Cable, Throttle30 8360052-305 1 Tubing, Convoluted31 8450040-600 AR Line, Fuel32 7080003 2 Clamp, Hose
4/03
C5
CRANKCASE550 CLASSIC S04ND5BS
2
310
8
7
9
4
65
1
1
E 2003 Polaris Sales Inc.
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. Qty. Description Ref. Part No. Qty. Description
1 3085713 8 Stud2 3089225 1 Asm., Crankcase(Incl. 1-4,8,9)3 3083798 1 Pipe, Pulse4 3080103 2 Pin, Dowel5 3083568 2 Bolt, Flange6 3082758 2 Gasket, Aluminum
7 3085664 1 Seal, Oil8 3084225 4 Asm., Bolt and Washer9 3084670 10 Asm., Bolt and Washer10 3085241 1 Seal, Oil11 3085462 1 Nipple
4/03
C6
CYLINDER550 CLASSIC S04ND5BS
6
14
15
2
3
18
16
7
8
17
5
4
11
12
9
1310
1
1
4
58
11
1213
9
10
7
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084271 12 Bolt, Flange2 3088215 1 Cylinder Head3 3085704 1 Gasket, Head4 3085714 2 Gasket, Exhaust5 3082911 8 Nut, Flange6 3085692 1 Cover, Cylinder Baffle7 3088214
308922622
Cylinder Unit (If built to 4/1/03)Cylinder Unit (If built from 4/1/03)
8 3085666 2 Gasket, Cylinder9 3081497 2 Screw
10 3085619 2 O-Ring11 3081330 4 Bolt, Allen12 3085670 2 Adaptor (Incl. 10)13 3083166 2 Asm., Band, Adaptor (Incl. 9)14 3085717 4 Asm., Screw and Washer15 3086387 2 Stopper16 3085715 2 Valve17 3086386 2 Asm., Reed Valve18 3086388 2 Plate
2/03
C7
PISTON and CRANKSHAFT550 CLASSIC S04ND5BS
1
1
1
2
3
3
4
4
7
7
7
7
6
5
58
8
11
1213
20
1918
15
16
2
10
9
14
9
6
17
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084167 4 Clip, Piston Pin2 3086988
30869893086990
444
Ring, Piston (Standard)Ring, Piston (0.25 O/S)Ring, Piston (0.50 O/S)
3 308821630882173088218
222
Piston, Set (Standard)Piston, Set (0.25 O/S)Piston, Set (0.50 O/S)
4 3083838 2 Pin, Piston5 3083216 2 Bearing, End, Small6 3240083 2 Rod, Connecting7 3083277 4 Spacer, Crank Pin8 3086390 2 Bearing, End, Large9 3083456 2 Crank Pin No. 2
10 3085754 1 Bearing, Ball11 3085677 1 Spacer12 3085753 1 Bearing, Ball13 3088199 1 Crankshaft 3 (PTO Side)14 3084586 2 Bearing, Ball15 3085674 1 Crankshaft 2 (Incl. 9)16 3088198
308717711
Asm., Crankshaft (Incl. 7-6,10,14-15)Crankshaft (MAG Side)
17 3084681 1 Bearing, Ball18 3083093 1 Nut19 3083094 1 Washer, Spring20 3080130 1 Key, Woodruff
2/03
C8
BLOWER HOUSING & RECOIL STARTER550 CLASSIC S04ND5BS
1
8
23
7
11
25
21
20 9
6
10
2413
26
14151617
1819
3
5
6
7
9
22
2
4
12
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3086991 1 Baffle, Cylinder, 12 7079511 1 Decal, “POLARIS”, Engine Shroud3 3084566 4 Bolt, Flange4 7079510 1 Decal, “550”, Engine Shroud5 3085693 2 Bolt, Flange6 3085690 2 Cap, Cylinder Baffle7 3085694 4 Bolt, Flange8 3085691 1 Cylinder Baffle 29 3083550 5 Asm., Bolt and Washer10 3087206
308718011
Starter, Recoil (Incl. 13-19,26)Case, Starter
11 3086792 1 Plug, Rubber12 3082030 1 Bolt and Washer13 3083376 1 Spring, Spiral
14 3083377 1 Asm., Reel15 3083463 1 Spring, Return16 3087207 1 Ratchet17 3083379 1 Spring, Friction18 3083464 1 Plate, Friction19 3083381 1 Nut, Flange20 3087181 1 Pulley, Starter21 3087020 1 Housing, Blower22 3084857 2 Pin, Straight23 3084823 1 Band, Wire24 3084225 5 Asm., Bolt and Washer25 3085688 3 Asm., Bolt and Washer26 3085723 AR Rope, Starter
2/03
C9
CARBURETOR550 CLASSIC S04ND5BS
29
1
2
334
4
33
32
5
6
7
98
1112
132526
2728 24
2223
1918
2014
21
31
1516
17
30
10
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3130877 1 Asm., Top, Mixing Chamber2 3130439 1 Spring, Throttle3 3130879 1 Plate, Throttle4 3131416 1 Needle, Jet (6BGY33)5 3130199 1 Cap, Plunger6 3130884 1 Spring, Plunger7 3130328 1 Asm., Plunger8 3130010 1 Spring, Throttle Adjuster9 3130437 1 Screw, Throttle Stop10 3131288 1 Hose11 3130011 1 Screw, Air12 3130012 1 Spring, Screw, Throttle Stop13 3130067 1 Pilot Jet (#40)14 3130025 4 Asm., Screw and Washer15 7080003 4 Clamp, Hose, Red16 5431893 1 Plug, Trap17 8350017-600 AR Line, Fuel18 5020476 1 Fitting, Sediment19 3130239 1 O-Ring
20 31301303130131
11
Main Jet (#270)(Mag)Main Jet (#280)(PTO)
21 3130014 1 Washer22 3130430 2 Asm., Float23 3130237 2 Cap24 3130020 1 Gasket, Float Chamber25 3131146 1 Needle Valve (1.5)26 3130017 1 Packing, Needle Valve27 3130018 1 Arm, Float28 3130361 1 Pin, Float29 3131520
3131521
1
1
Asm., Carburetor(MAG)(Incl. 1-14,18-34)Asm., Carburetor(PTO)(Incl. 1-14,18-34)
30 3083337 1 Asm., Valve, Check31 3130479 1 Cap32 3130894 1 Needle Jet (Q-2) 48033 3130372 1 Throttle Valve (3.0)34 3130508 1 E-Ring
2/03
C10
FUEL PUMP550 CLASSIC S04ND5BS
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
1 3084591 4 Screw2 3084590 1 Diaphragm, Gasket Set3 3085490 1 Asm., Fuel Pump (Incl. 1-2)
9/02
1
3
2
2
E 2003 Polaris Sales Inc.
C11
OIL PUMP550 CLASSIC S04ND5BS
4
11
1
1
56
8
91011
1213 14
15
17
1819
16
E 2003 Polaris Sales Inc.1
2
3 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 3083141 6 Clamp, Hose2 3087114 1 Tube3 3087113 1 Rubber Pipe4 3085157 1 Vinyl Pipe 25 3083125 1 Screw, Air Vent6 3083126 1 Packing7 3087185 1 Vinyl Pipe8 3089223 1 Asm., Oil Pump (Incl. 3-13,19)9 3089228 1 Spring, Return10 3083445 1 Collar, Cam Shaft11 3089227 1 Lever, Control
12 3083121 1 Washer, Spring13 3083120 1 Nut14 3083783 2 Screw and Washer15 3083131 1 Gear, Small16 3083130 1 Spacer17 3083353 1 Bushing, Oil Pump18 3083671
30836723083673
ARARAR
Spacer 1 (.15)Spacer 2 (.3)Spacer 3 (.6)
19 3083127 1 O-Ring
4/03
C12
MAGNETO550 CLASSIC S04ND5BS
7
8
9
3
2
1
4
6
5
11
12
E 2003 Polaris Sales Inc.
10
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 3085698 2 Asm., Screw and Washer2 3087213 1 Asm., Flywheel3 3087212 1 Asm., Stator4 3085697 3 Asm., Screw and Washer5 3085935 2 Cap, Spark Plug6 3086976 2 Cap, Spark Plug7 3087219 1 Harness Unit
8 3088219
3089229
1
1
Asm., CDI System(Incl.7,9)(If built to 4/1/03)Asm., CDI System(Incl.7,9)(If built from 4/1/03)
9 30882203089230
11
Unit, CDI System (If built to 4/1/03)Unit, CDI System (If built from 4/1/03)
10 2461060 1 Jumper, Stubber (E/S Only)11 3087214
308721611
Asm., Coil, Ignition (Incl. 6)Coil, Ignition
12 3084177 2 Bolt, Flange4/03
C13
STARTING MOTOR550 CLASSIC S04ND5BS
4
1314
5
15
12
62
9
7
11
8
16
19
18
178
10
31E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542103 1 Nut, Flexloc2 2200759
------ -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- --
112111
Kit, Brush & SpringAsm., Brush & ScrewAsm., BrushBushing, InsulationWasher, InsulationNut
3 2200758 1 Kit, Asm., Commutator Cap (Incl. 2)4 7542153 2 Nut, Flanged, Flexloc5 7516815 2 Screw6 5240956 1 Bracket, Starter, Rear7 2200756 1 Kit, Asm., Armature8 2200755
------ -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- --
11111111
Kit, Drive HardwareWasher, Curved SpringWasher, ThrustSpacerSpring, AntidriftPinion, StopRing, LockCover, Dust
9 2200757 1 Kit, Asm., Drive Cap10 4170006 1 Motor, Starter, Domestic11 2200754
------ -- -- -- ---- -- -- -- -- -- --
111
Kit, Asm., DrivePlate, DrivePinion
12 5241271 1 Bracket, Starter, Front13 7552603 2 Washer, Spring Lock14 7512492 2 Screw15 7516730 2 Screw16 2200753
------ -- -- -- --12
Kit, ScrewBolt, Thru
17 3082939 4 Nut18 3080077 4 Washer, Spring19 4010930 1 Switch, Magnetic (Incl. 17,18)
4/03
C14
TOOL KIT550 CLASSIC S04ND5BS
2
3
4
9
8
5
67
1
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083409 1 Kit, Tool (Incl. 2-5)2 ------ -- -- -- -- 1 Screwdriver3 ------ -- -- -- -- 1 Wrench, 9/16 x 1/2 Open End4 ------ -- -- -- -- 1 Box Wrench, Special5 5910082 1 Wrench, Box End, 9/16 x 5/86 9918079 1 Video, Suspension Setup (Edge)
7 2874113 1 Tool, Belt Removal8 2872012 1 Tool, Scissor Stop Wrench (Edge)9 9918199
9918201
1
1
Manual, Owner’s, ’04 Edge 121 InchTrackSupplement, Owner’s Manual, ’04 550Classic
3/03
PRINTED IN THE USA PARTS MANUAL PN 9918835 AND MICROFICHE PN 9918836 3/03
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