Download - pi54.com › corp › manuals › Parts › 9918835.pdf 550 CLASSIC Model #S04ND5BSTABLE OF CONTENTS 550ClassicS04ND5BS PartsManual A AIRBOX B14 B BATTERY BOX C1 BLOWER HOUSING C8

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


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



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



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



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



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



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



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



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



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



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


A14

FRONT SUSPENSION550 CLASSIC S04ND5BS


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


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


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




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



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




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




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




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




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.



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




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




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




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




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



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




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


14


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




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




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


11



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




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




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




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




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


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


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



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


10



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.



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



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

Changed

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34

56

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1112

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Acover

toc

Bx

C D E F G

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Download - pi54.com › corp › manuals › Parts › 9918835.pdf 550 CLASSIC Model #S04ND5BSTABLE OF CONTENTS 550ClassicS04ND5BS PartsManual A AIRBOX B14 B BATTERY BOX C1 BLOWER HOUSING C8

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