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  • 550 CLASSIC Model #S04ND5BS

    E 2003 Polaris Sales Inc.

    PARTS MANUAL PN 9918835 and MICROFICHE PN 9918836 3/03

  • TABLE OF CONTENTS 550 Classic S04ND5BS

    Parts Manual

    A AIRBOX B14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

    B BATTERY BOX C1. . . . . . . . . . . . . . . . . . . . . . . BLOWER HOUSING C8. . . . . . . . . . . . . . . . . . . BRAKE B5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

    C CARBURETOR C9. . . . . . . . . . . . . . . . . . . . . . . CHAINCASE B11. . . . . . . . . . . . . . . . . . . . . . . . CHASSIS A3. . . . . . . . . . . . . . . . . . . . . . . . . . . CONSOLE A12. . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE C5. . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT C7. . . . . . . . . . . . . . . . . . . . . . . CYLINDER C6. . . . . . . . . . . . . . . . . . . . . . . . . .

    D DECALS A11. . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH B12. . . . . . . . . . . . . . . . . . . . . . DRIVE TRAIN C2. . . . . . . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH B13. . . . . . . . . . . . . . . . . . . . .

    E ENGINE MOUNTING C4. . . . . . . . . . . . . . . . . . EXHAUST SYSTEM C3. . . . . . . . . . . . . . . . . . .

    F FRONT SUSPENSION A13-14. . . . . . . . . . . . . . . . . FRONT TORQUE ARM B8. . . . . . . . . . . . . . . . . FUEL PUMP C10. . . . . . . . . . . . . . . . . . . . . . . . .

    G GAS TANK A5. . . . . . . . . . . . . . . . . . . . . . . . . .

    H HANDLEBAR B3. . . . . . . . . . . . . . . . . . . . . . . . HOOD A8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOOD FOAM/FOIL A10. . . . . . . . . . . . . . . . . . . .

    M MAGNETO C12. . . . . . . . . . . . . . . . . . . . . . . . . .

    N NOSEPAN A6-7. . . . . . . . . . . . . . . . . . . . . . . . . .

    O OIL PUMP C11. . . . . . . . . . . . . . . . . . . . . . . . . . OIL TANK B14. . . . . . . . . . . . . . . . . . . . . . . . . . .

    P PISTON C7. . . . . . . . . . . . . . . . . . . . . . . . . . .

    R RAIL MOUNTING B6. . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION B7. . . . . . . . . . . . . . . . . . REAR TORQUE ARM B9. . . . . . . . . . . . . . . . . . RECOIL STARTER C8. . . . . . . . . . . . . . . . . . . .

    S SEAT A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHOCK (REAR TRACK) B10. . . . . . . . . . . . . . . . SKI B1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR C13. . . . . . . . . . . . . . . . . . . STEERING B2-4. . . . . . . . . . . . . . . . . . . . . . . . . .

    T TOOL 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

    CHASSIS 550 CLASSIC S04ND5BS

    3 4

    5 18

    14 15 16 17

    19

    21 20

    22

    26

    28

    31

    24

    24

    27

    1

    25

    18 24

    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 Rivet 2 5246330 1 Bracket, Oil Tank/Hose Support 3 3021104 1 Stop, Torque 4 7542404 1 Nut 5 1013399 1 Stop, Torque 6 7517632 1 Screw 7 7517854 2 Screw 8 1014086--067 1 Asm., Chassis, Edge, Natural

    (Incl. 26-29,34) 9 5246177 1 Brkt Airbox Edge 10 7080934 6 Caplug 11 7080592 2 Caplug 12 5812290 2 Gasket, Seat Base 13 5812360 1 Gasket, Seat Base, 1/4 Inch 14 7512232 6 Bolt 15 7552801 6 Washer, Spring Lock 16 7558301 6 Washer, Flat 17 2632165-309 1 Bumper, Rear, Unpainted 18 7621472 13 Rivet 19 5433961--1106 1 Flap, Snow, Short, Black/Chrome

    20 7517441 4 Screw 21 2670133 1 Asm., Reflector, Red 22 2632443-070

    2632444-070 1 1

    Asm., Snowskirt, Refl., LH Asm., Snowskirt, Refl., RH

    23 5245118-067 1 Brace, Tunnel Roll 24 7661637 74 Rivet 25 5433150 2 Strap, Airbox Top 26 5246310--067

    5246311--067 1 1

    Support, Footrest, LH Support, Footrest, RH

    27 5245457--067 5245458--067

    1 1

    Mount, Console, Toe Clip, LH Mount, Console, Toe Clip, RH

    28 5245288--067 5247205--067

    1 1

    Footrest, LH Footrest, RH

    29 2202059 2202598

    1 1

    Kit, Trailing Arm Mount, LH Kit, Trailing Arm Mount, RH

    30 5246066 1 Guard, Belt 31 7080416 2 Plug, Hole 32 7661130 15 Rivet 33 7081076 2 Plug, Hole 34 5132292 1 Bulkhead, Front

    3/03

  • A4

    SEAT 550 CLASSIC S04ND5BS

    1

    14

    6 7

    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 2683232 2683233

    1 1

    Asm., Seat, (Incl. 1,6,14) Cover, Seat

    2 7080550 1 Grommet, Relatch, Bottom 3 7080549 1 Grommet, Relatch, Top 4 7080548 1 Relatch w/Hole, Twist Lock 5 7621337 2 Rivet 6 5433341

    4030024 4030045

    1 2 1

    Housing, Taillight Bulb, Taillight Bulb, Brakelight

    7 5430423 1 Lens 8 7511840 4 Screw 9 7555727 3 Washer 10 7621319 7 Rivet 11 5631194 2 Nut, Seat 12 7558301 2 Washer, Flat 13 7517219 2 Screw 14 2460399 1 Harness, Taillight

    3/03

  • A5

    GAS TANK 550 CLASSIC S04ND5BS

    1

    2

    3

    4

    5

    6

    7

    8 9

    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, Fuel 2 7542122 2 Nut, Nylok 3 7555960 2 Washer, Flat 4 7670021 2 Nut Speed 5 7512193 2 Bolt Carriage 6 5810947 2 Foam, Seal, Rear Cooler 7 7052301 1 Pickup, Fuel, w/Filter 8 7080402 2 Ring, Compression

    9 7052028 1 Grommet, Flanged 10 7052321 1 Fitting, Straight 11 8350019-600 AR Line, Fuel 12 2520276 1 Asm., Fuel Tank (Incl. 7-13) 13 7052095 1 Fitting, 90 Degree 14 8450061-600 AR Line, Fuel 15 7080804 2 Cable Tie, Releasable

    3/03

  • A6

    NOSEPAN 550 CLASSIC S04ND5BS

    1 2

    12

    11

    19

    8

    16

    24

    15

    23

    13

    814

    22 21 20

    7

    3 6

    5

    6

    1

    25

    18 17

    9 10

    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 Rivet 2 5243992-067 1 Hinge, Pivot, Lower, RH 3 5243978 1 Mount, Shock, Upper, RH 4 5810947 1 Foam, Seal, Rear Cooler 5 7547180 4 Nut, Flanged 6 7517935 4 Screw 7 5243977 1 Mount, Shock, Upper, LH 8 7621467 21 Rivet 9 7621431 2 Rivet 10 7661136 6 Rivet 11 5244049-067 1 Bracket, Radius Rod Support 12 5244050 1 Brace, Pan, Lower 13 5243991-067 1 Hinge, Pivot, Lower, LH

    14 7542153 2 Nut, Flanged, Nylok 15 5433518-070 1 Asm., Bumper, Front Black 16 7512163 2 Bolt 17 7621472 3 Rivet 18 5245853 1 Shield, Exhaust, Heat, Extended 19 5434343--070 1 Nosepan, Black 20 7542122 4 Nut, Nylok 21 7555827 4 Washer 22 7515166 4 Screw 23 7517312 4 Screw 24 7552801 4 Washer, Spring Lock 25 5244888

    5244889 1 1

    Guide, Hood, LH Guide, Hood, RH

    3/03

  • A7

    NOSEPAN 550 CLASSIC S04ND5BS

    18

    14

    21

    15 16

    20

    22

    23

    24

    19

    3

    1

    2

    4

    13

    11

    12

    5

    6

    8 7

    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-Type 2 7080963 1 J-Clip, Retainer 3 5811948 1 Foil 4 7621462 1 Rivet 5 5812020 2 Foil, Tape, Nosepan 6 5811458 1 Foil, Tape 7 5812040 1 Foil, Nosepan, Front 8 5812067 1 Foil, Tape, Top, Shock 9 5812039 1 Foil, Nosepan, Shock Tower 10 5812068 1 Foil, Tape 11 5812018 1 Foil, Tape, Nosepan, Upper, RH 12 5812019 1 Foil, Tape, Nosepan, Lower, RH

    13 5812353 1 Foam 14 5434531 1 Duct, Engine Air Outlet 15 1013069 1 Asm., Guard, Clutch 16 7080698 1 Pin, Clutch Guard 17 5812352 1 Pad, Clutch Guard 18 7621485 3 Rivet 19 7079297 1 Decal, Warning Engine and Clutch 20 7170046 1 Decal, Troubleshooting, Edge, PPS 21 7621402 5 Rivet 22 2670134 2 Asm., Reflector, Amber 23 5433926 1 Plug, Hole, Oblong 24 5211722 1 Plate, Backer, Clutch Guard

    3/03

  • A8

    HOOD 550 CLASSIC S04ND5BS

    1

    3

    5

    6

    7

    8

    9

    10

    11 15

    18

    19

    2118

    19

    17

    20

    16

    20

    17 16

    20

    14

    4

    20 13

    2

    12

    E 2003 Polaris Sales Inc.

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