38
PARTS MANUAL PN 9915619 and MICROFICHE PN 9915620 10/99 120 XCR Model #S00WB1AS

120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

  • Upload
    hangoc

  • View
    224

  • Download
    1

Embed Size (px)

Citation preview

Page 1: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓPARTS MANUAL PN 9915619 and MICROFICHE PN 9915620 10/99

120 XCRModel #S00WB1AS

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ

Page 2: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

�������������� ����������������

Page 3: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

TABLE OF CONTENTS120 XCR S00WB1AS

Parts ManualC

CARBURETOR B8. . . . . . . . . . . . . . . . . CLUTCH B2. . . . . . . . . . . . . . . . . . . . . . CRANKCASE B4. . . . . . . . . . . . . . . . . .

DDECALS A9. . . . . . . . . . . . . . . . . . . . . . DRIVE TRAIN B1. . . . . . . . . . . . . . . . . . .

EELECTRIC DEVICE B10. . . . . . . . . . . . . . ELECTRICAL AND CONSOLE A10. . . . . . ENGINE MOUNTING B3. . . . . . . . . . . . .

FFRONT SUSPENSION and

STEERING A12. . . . . . . . . . . . . . . . . .

HHANDLEBAR and CONTROLS A11. . . . . . HOOD A8. . . . . . . . . . . . . . . . . . . . . . . .

IINTAKE / EXHAUST B9. . . . . . . . . . . . . .

NNOSEPAN A7. . . . . . . . . . . . . . . . . . . . .

PPART NUMBER INDEX B12-14. . . . . . . . . . . . PISTON and CRANKSHAFT B5. . . . . . . .

RREAR SUSPENSION A13. . . . . . . . . . . . . RECOIL STARTER / BLOWER

HOUSING B6. . . . . . . . . . . . . . . . . .

SSEAT and GAS TANK A6. . . . . . . . . . . . SKI A14. . . . . . . . . . . . . . . . . . . . . . . . . . SPEED CONTROL / GOVERNOR B7. . . .

TTOOL KIT B11. . . . . . . . . . . . . . . . . . . . . TUNNEL A5. . . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for as-sembly.

Page 4: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

2000 120 XCR SPECIFICATIONSBRAKES

Type Mechanical Band

CAPACITIESDry Weight (lbs.)Fuel Tank Capacity (US/lmp. Gal.)Height (in.)Length (Incl. skis)Oil Capacity (leters)Ski Center Distance (in.)Ski Length (in.)Ski Width (in.)Width (in.) Compressed

140.53174.630

24.54

34

CHAINCASEDrive Chain LengthDrive Shaft SprocketSprocket Ratio

74P4T-2

10:42

DRIVE CLUTCHCenter Distance (in.)Clutch TypeClutch WeightSpring Color

11.75Centrifical

56–58 gramsRed

ENGINE SPECSEngine Model NumberAlternator OutputBore X Stroke (mm)Displacement (cc’s)Carburetion/Throttle BodyCarburetor ModelCoolingCylindersCylinder PlatingIgnition TypeSpark Plug Type (RFI)

EH122PM010 Fuji, 4HP12V 50W 2P

60x43121

1 MikuniBV 15/18

Centrifugal Fan1

Iron LinerTransistor

BR6ES

ELECTRICALHeadlight TypeHeadlight (watts)

Halogen35W

GRAPHICSBelly Pan ColorFront Shock ColorFront Springs ColorHandlebar CoverHood ColorHood Accent Colors

Snow Flap ColorRear Idler Wheel ColorSki ColorSeat ColorTunnel ColorWindshield (Size/Color)

RedBlack

RedBlack

RedStratus Blue/Black/Screamin Yellow/Process

Blue/Violet “C”/WhiteBlack

RedBlackBlack

UnpaintedMini Flared/Clear

TRACKTrack ConstructionTrack LengthTrack PatternTrack Width (in.)Lug Height

Polyester-C68.04

Tri-Star Clipped10

.71″

SUSPENSIONFront TypeRadius Rods (Adj. or Lub.)IFS Shocks/Spring Adj.Rear TypeFront Torque Arm LimiterRear Torque Arm LimiterRear Travel (in.)Springs:

Rear Torque ArmRear Torque Arm Spring

30 IFSFixed Length

Arvin/FixedSingle Arm Torsion

StandardStandard

6.9

Torsion.406/6

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products withoutnotice.

Page 5: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

2000 POLARIS SNOWMOBILE PUBLICATION NUMBERS

MODEL MODEL #OWNER’S MANUAL& SUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

120 XCR S00WB1AS 9915612& ––––––– 9915619 9915620 9915621

Page 6: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A5

TUNNEL120 XCR S00WB1AS

18

4

1

16

3

17

2

6

7

89

15

14

13

10

5

111

1

1

1

3

1

5 12

1

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7661637 54 Rivet2 5243862-067 1 Bracket, Pan Support, Rear3 5243997-067

5243998-06711

Stop, Foot, LHStop, Foot, RH

4 1013045 1 Asm., Tunnel (incl. 11,16)5 7621467 14 Rivet6 2872428 1 Flag7 5244025-067 1 Bracket, Flag Mount8 7575202 1 Washer9 7542432 1 Nut, Jam

10 7512068 2 Screw

11 5243861 1 Bumper, Rear12 5244387 1 Bracket, Tunnel, Rear13 5433494 1 Flap, Snow14 2670133 2 Reflector, Red15 5433319

543332011

Skirt, Snow, LHSkirt, Snow, RH

16 5243867-0675243868-067

11

Pad, Suspension, LHPad, Suspension, RH

17 5243972-067 1 Guard, Sprocket18 1013046-067 1 Bulkhead

9/99

Page 7: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A6

SEAT and GAS TANK120 XCR S00WB1AS

1

8

1619

9

15

10

17

2524

18

2021

23

5

23

4

7

12

11

22

5

5

5

12

13

14

11

ÄÄÄÄÄÄÄÄÄÄÄÄ6

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 26825332682534

11

Cover, SeatCushion, Seat

2 2872427 1 Taillight w/Harness3 7512091 2 Screw4 7670094 2 Nut, U-Type5 7621467 4 Rivet6 5810290 4 Pad7 5433150 2 Strap, Air Box, Top8 2520171 1 Asm., Gas Tank (Incl. 9,10,15,16,)9 7052243 1 Pick-Up, Fuel

10 7080402 2 Ring, Compression11 8350018-600 AR Line, Fuel12 7080307 4 Clamp, Hose, Large Green13 7052249 1 Valve, Fuel, 90 Degree

14 4010051-06 AR Conduit, Convoluted15 7052259 1 Fitting, 90 Degree16 7052028 1 Grommet, Tank Fitting17 8350019-600 AR Line, Fuel18 8450061-600 AR Line, Fuel19 7052095 1 Fitting, 90 Degree20 2632154 1 Console21 5243049 1 Guide, Recoil22 7078317 1 Decal - Fuel Shut-Off23 7621330 2 Rivet24 7515148 2 Screw25 5430725

581014411

Cap, Gas TankGasket, Fuel Cap

9/99

Page 8: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A7

NOSEPAN120 XCR S00WB1AS

8

14

12

13

3

5

11

4

2

6

7

4

4

4

1

10

3

1

9

4

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7670102 2 Clip2 5243896

524389711

Bracket, Hinge LHBracket, Hinge RH

3 7542122 6 Nut, Nylok4 7621467 18 Rivet5 2670134 2 Reflector, Amber6 7512283 2 Screw7 7670057 2 Nut, U-Type Speed

8 1013048-067 1 Guard, Clutch9 7661637 1 Rivet

10 7078389 1 Decal - Engine and Clutch11 5433526-293 1 Nosepan12 5244079

524408011

Brace, Bumper, Front, LHBrace, Bumper, Front, RH

13 7515166 6 Screw14 5433536-070 1 Bumper, Front

9/99

Page 9: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A8

HOOD120 XCR S00WB1AS

5

9

14

13

15

67

16

3

10

1

2

4

812

11

6

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5433477 1 Windshield2 5410970 4 Retainer, Windshield3 4010341 1 Headlight, Single Beam4 7517703 2 Bolt, Carriage5 5433525-293 1 Hood6 7541925 3 Nut, Nylok7 7558201 2 Washer, Flat8 7515159 2 Bolt

9 52440235244024

11

Bracket, Hinge Support, LHBracket, Hinge Support, RH

10 5333835 2 Spacer, Hood Hinge11 7558302 2 Washer12 7542122 2 Nut, Nylok13 7621467 2 Rivet14 7080861 1 Cable, Hood15 7511989 1 Bolt16 7670102 3 Clip

9/99

Page 10: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A9

DECALS120 XCR S00WB1AS

10

2

7

6

4

3

11

8

15

13

9 12

5

1

14

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

2201588 1 Kit - Hood Decals, “00 120 XCR (Incl. 1-4,6,7,10,11)

1 7078518 1 Decal - “POLARIS”, Hood Center2 7078517 1 Decal - “Indy SP”, Flags, Hood Center3 7078524 1 Decal - Headlight Insert4 7078523 1 Decal - Headlight, Reflective5 7078529 1 Decal - “POLARIS” Flags, Seat6 7078521

707852211

Decal - “XCR”, Hood Side, LHDecal - “XCR”, Hood Side, RH

7 70785197078520

11

Decal - “120”, LHDecal - “120”, RH

8 7078386 1 Decal - “INDY EDGE”, LH9 7078527 1 Decal - Warning, French, LH

10 7078315 1 Logo - 45th Anniversary11 7078525 1 Decal - Dash, Gauges12 7078528 1 Decal - Warning, English, RH13 7078385 1 Decal - No Passenger, Seat14 7078698 1 Decal - Ignition15 7078387 1 Decal - “EDGE INDY”, RH

9/99

Page 11: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A10

ELECTRICAL AND CONSOLE120 XCR S00WB1AS

1

2

3

9

45

6

8

7

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5410378 1 Key, Ignition2 7542807 1 Nut, Ignition3 4110038 1 Switch, Ignition4 7080891 1 Band, Tether, Wrist5 4010357 1 Switch, Tether w/Disc

6 4010308 1 Regulator/Limiter, RPM7 7541925 2 Nut, Nylok8 7512091 2 Screw9 7080864 1 Cable, Choke

9/99

Page 12: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A11

HANDLEBAR and CONTROLS120 XCR S00WB1AS

24

23

9

3

5

13 22

25

1

4

12

1011

6

7

148

1918

21

16

17

2

5

5

14

13

20

15

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7661624 1 Pin, Retaining2 7710503 1 Ring, Retaining3 5433527 1 Lever, Throttle4 7710401 1 Ring, Retaining5 7511848 10 Screw6 2682537 1 Pad, Handlebar7 5811884 1 Foam, Handlebar Pad8 1820773-067 1 Post, Steering9 5430604 2 Block, Adaptor

10 5433622 1 Insert, Brake/Throttle Block11 7661617 1 Rivet12 5433528 1 Lever, Brake13 7512465 2 Screw, Socket Set

14 5433476 2 Grip, Handlebar15 7080860 1 Cable, Throttle16 1013096-067

1013097-06711

Brace, Steering Post, LHBrace, Steering Post, RH

17 7621467 2 Rivet18 5433416 1 Bushing, Steering, Upper19 5244048 1 Bracket, Steering Post20 7670102 1 Clip21 7542122 2 Nut, Nylok22 7555727 1 Washer23 5431592 2 Block, Throttle/Brake24 4110106 1 Switch, Auxiliary Shut-Off25 7555730 AR Washer

7/99

Page 13: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A12

FRONT SUSPENSION and STEERING120 XCR S00WB1AS

1

2

35

7

8

69

30

1011

12

1415

13

1617

18

19

21

2324

22

20

29

6

1112

13

13

8

713

24 23

10

4

28

28

31

25

27

27

26

26

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7080433 3 Fitting, Lubrication2 7542122 6 Nut, Nylok3 7558301 4 Washer, Flat4 1820802-067 1 Bracket, Radius Rod5 7512263 2 Bolt, Carriage6 7515534 4 Screw7 7542451 4 Nut, Nylok8 7558403 4 Washer9 1820767 2 Tie Rod, Plated

10 7517745 4 Bolt, Shoulder11 7556160 4 Washer12 5433624 8 Bushing, Shock Mount13 7542324 6 Nut, Nylok14 5433481 2 Cap, Spindle15 1820764 2 Spindle16 5433593 2 Bushing, Eurothane

17 5132329 2 Bushing18 7512310 2 Bolt19 1820774-293

1820775-29311

Arm, Trailing, LHArm, Trailing, RH

20 7555734 8 Washer, Flat21 3514343 4 Bushing22 7512329 4 Bolt23 5333834 8 Spacer24 5433547 16 Bushing, Radius Rod25 1820780-293 4 Rod, Radius26 7555725 8 Washer27 7542344 4 Nut, Nylok28 5244330-067 2 Support, Radius Rod29 7512193 4 Bolt, Carriage30 1820768-293 2 Asm., Shock31 7517778 4 Bolt

9/99

Page 14: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A13

REAR SUSPENSION120 XCR S00WB1AS

16

14

27

29

11

1512

26

30 2221

9

25

3637

33

31

2324

10

35

2

54

3

1

13

17

20

32

6

28

34

388

19

7

2324

25

7

7

3331 8

9

1

2

18

4 5

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5333826 2 Spacer, Carrier Wheel2 1541403 2 Asm., Carrier Wheel (Incl. 5,4)3 5132254 1 Shaft, Carrier4 7710444 4 Ring, Retaining5 3514012 4 Bearing6 5811954 1 Strap, Limiter, Rear7 7517744 4 Screw8 7555960 2 Washer, Flat9 7542344 2 Nut, Thin

10 7555726 2 Washer, Flat11 7517227 2 Screw12 7621512 4 Rivet13 5132253 1 Shaft, Idler, Rear14 5241628 2 Bracket, Idler Adjustable15 7542451 3 Nut, Nylok16 1541415

154141611

Asm., Rail, LHAsm., Rail, RH

17 5333836 2 Spacer, Idler18 1590279-293 2 Asm. Wheel (Incl. 4,5)19 7571629 2 Washer

20 7512492 2 Screw21 7512312 2 Bolt22 5433623-070 2 Block, Toe23 7515317 4 Bolt24 7552901 4 Washer, Split Lock25 7555958 6 Washer, Flat26 7661621 2 Rivet27 5521529 2 Hi-Fax28 5521499 2 Bumper, Jounce, Front29 7515199 2 Screw30 7670068 2 Nut, Push-On31 5132256 2 Shaft, Lower32 5811953 1 Strap, Limiter, Front33 5132257 2 Shaft, Torque Arm, Upper34 7041844-067

7041845-06711

Spring, Torsion, LHSpring, Torsion, RH

35 5433507 2 Sleeve, Torsion Spring36 1541398-067 1 Arm, Torque37 7080424 2 Fitting, Lubrication38 7512307 1 Screw

9/99

Page 15: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

A14

SKI120 XCR S00WB1AS

6

8

54

1

3

7

2

9

5

5

2

5

10

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5132285 2 Tube, Spacer2 7542324 6 Nut, Nylok3 5243980 2 Bracket, Ski Stop4 5132284 2 Bushing, Spacer5 5132328 8 Bushing

6 5433495-070 2 Ski, Plastic7 7515385 2 Screw8 1820766 2 Skag9 7558402 2 Washer, Flat

10 7661915 2 Pin, Spring

7/99

Page 16: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B1

DRIVE TRAIN120 XCR S00WB1AS

11

8

4

6

53

2

7

10

1

12

4

5

1

3

12

9

4

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7517736 4 Bolt, Carriage2 5244302 1 Flangette3 3514338 2 Bearing w/Screw Set4 7661913 3 Pin, Spring5 5433455 2 Sprocket6 6230172 1 Shaft, Drive

7 5222393 1 Flangette8 3221116 1 Chain, Roller #409 3221122 1 Link, Connecting

10 5411751-070 1 Track11 1013095 1 Sprocket, 42T12 7542344 4 Nut, Nylok

7/99

Page 17: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B2

CLUTCH120 XCR S00WB1AS

2

15

5

16

3

14

7

6

9

10

8

1112

4

13

717

1

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7080859 1 Cable, Brake2 1013151 1 Mount, Brake/Tensioner3 7041853 1 Spring, Brake Release4 5132476

751225711

Pin , Brake CableScrew, Socket Set

5 5243864 1 Band, Brake (Incl. 4)6 7555734 1 Washer, Flat7 7542324 2 Nut, Nylok8 5132462 1 Spacer, Clutch, End

9 1321860 1 Clutch, Drive10 5132324 1 Spacer, Clutch, Outer11 7517780 1 Bolt, Zerk12 7556138 2 Washer, Fiber13 7517810 3 Screw14 7515394 1 Bolt, Carriage15 5132601 1 Bushing, Tensioner16 5433672 1 Pulley, Idler17 7555770 1 Washer

11/99

Page 18: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B3

ENGINE MOUNTING120 XCR S00WB1AS

9

1

3

2

8

6

7

6

6

7

5

4

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7078526 1 Decal - Engine Cover, “POLARIS XCR”2 3070185 1 Plug, Spark NGKBR6ES3 1211677 1 Engine, EH122PM0104 1013075-067 1 Strap, Engine

5 7517810 4 Screw

6 7555954 6 Washer7 7512329 4 Bolt8 7542324 2 Nut, Nylok9 2460782 1 Harness, Main Wire

9/99

Page 19: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B4

CRANKCASE120 XCR S00WB1AS

10

12

27

222324

22

36

3031

32

1

33

3

2

26

34

25

7

8

9

29

35

2120

16

11

4

5

64

23

913

1415

1328

1918

17

For Serial #’s 99535-99562

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3083568 4 Bolt, Flange2 3086527 1 Cover, Rocker3 3086528 1 Gasket, Rocker Cover4 3086531 2 Gasket, Breather Cover5 3086530 1 Plate, Breather6 3086529 1 Cover, Breather7 3086532 1 Pipe, Rubber8 3086125 2 Bolt, Flange9 3083054 2 Pin, Dowel

10 3086946 1 Asm., Crankcase (Inc. 9,10,11,27,29)11 3086510 1 Seal, Oil12 7052266 1 Fitting13 7080003 2 Clamp, Hose, Red14 8450040-600 AR Line, Fuel15 7661037 1 Pin16 7556152 1 Seal, Bonded17 7052115 1 Plug18 7052278 1 Fitting

19 7541748 1 Nut20 3086518 1 Sleeve, Governor21 3086517 1 Gear, Governor22 3086519 2 Gauge, Oil23 3086520 2 Gasket24 3086966 1 Cover, Main Bearing (Inc. 25,27,28)25 3086516 1 Seal, Oil26 3086522 8 Bolt and Washer27 3080108 2 Bearing28 3086947 1 Bearing, Ball29 3086511 2 Pipe30 3082934 1 Stud31 3086513 1 Stud32 3086535 2 Guide, Valve33 3086526 4 Bolt, Flange34 3086524 1 Head, Cylinder (Incl. 35,30,31,32)35 3086512 2 Stud36 3086525 1 Gasket, Head

9/99

Page 20: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B5

PISTON and CRANKSHAFT120 XCR S00WB1AS

1

2

2

3

5

6

8

9

7

12

10

5

4

11

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 308655030865513086552

111

Ring, Piston Set (Standard)Ring, Piston Set (0.25mm O/S)Ring, Piston Set (0.50mm O/S)

2 3086553 2 Clip3 3086546 1 Pin, Piston4 3086969

30869703086971

111

Piston (Standard)(Incl. 2)Piston (0.25mm O/S)(Incl. 2)Piston (0.50mm O/S)(Incl. 2)

5 3086544 1 Asm., Connecting Rod (Incl. 9)

6 3240294 1 Nut7 3086540 1 Washer, Spring8 3086949 1 Crankshaft9 3086545 2 Bolt

10 308653730865383086539

111

Spacer (0.6mm)Spacer (0.8mm)Spacer (1.0mm)

11 3086535 1 Gear, Crankshaft12 3086536 1 Key, Woodruff

9/99

Page 21: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B6

RECOIL STARTER / BLOWER HOUSING120 XCR S00WB1AS

1

2

56

3

8

9

18

17

10

16

13

7

1415

1

1211

19

4

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3083568 5 Bolt, Flange2 3086622 1 Cover, Head3 3086638 1 Label, Caution4 3086960 1 Decal - Warning5 3086957 1 Housing, Blower6 7078526 1 Decal - Engine Cover “POLARIS XCR”7 3085359 4 Bolt, Flange8 3086958 1 Asm., Recoil Starter (Incl. 7-15)9 3086625 1 Spring, Spiral

10 3086626 1 Reel

11 3086865 2 Spring, Return12 3086629 2 Ratchet13 3086632 1 Guide, Ratchet14 3086634 1 Screw, Set15 3086959 1 Pulley, Starter16 3086630 1 Spring, Friction17 2870621 1 Rope, Recoil18 3086628 1 Knob, Starter19 3086866 1 Cap, Knob

9/99

Page 22: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B7

SPEED CONTROL / GOVERNOR120 XCR S00WB1AS

1

2

224

6

8

10

5

7

11

13

16

17

1920

12

18

9

14

15

3

3

21

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3084566 1 Bolt, Flange2 3086605 1 Plate, Stop3 3086954 2 Washer, Friction4 3086609 1 Screw5 3086606 1 Spring, Idle Set6 3086604 1 Knob7 3081497 1 Screw8 3083073 1 Nut9 3081600 1 Screw

10 3086973 1 Bracket, Wire11 3086599 1 Spring, Governor

12 3086597 1 Spring, Rod13 3086596 1 Rod, Governor14 3086862 1 Bracket, Return Spring15 3086956 1 Spring, Return16 3086594 1 Lever, Governor17 3086598 1 Nut18 3082038 1 Bolt and Washer19 3086053 2 Clip20 3086595 1 Shaft, Governor21 3086955 1 Spacer22 3086944 1 Asm., Speed Control (Incl. 6)

11/99

Page 23: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B8

CARBURETOR120 XCR S00WB1AS

14

2

1

34

56

8

9

15

20

24

10

23

21

22

25

19

181716

5 7

11

1213

3

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3086962 1 Shaft, Throttle2 3086654 1 Valve, Throttle3 3086963 4 Screw4 3086658 1 Adjuster5 3086672 2 Spring6 3086671 1 Screw, Adjust7 3086875 1 Screw8 3086657 1 Jet, Pilot9 3086659 1 Lever, Choke

10 3086964 1 Valve, Choke11 3086876 1 Ring12 3086874 1 Spring, Return13 3086873 1 Ring

14 3086664 1 Pin15 3086669 1 Nozzle, Main16 3086675 1 Holder, Guide17 3086670 1 Jet, Main18 3086667 1 Packing, Chamber19 3086663 1 Needle20 3086674 1 Spring21 3086666 1 Packing22 3086662 1 Bolt23 3086665 1 Chamberbody, Float24 3086668 1 Float25 3086652 1 Asm., Carburetor (Incl. 2-22)

9/99

Page 24: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B9

INTAKE / EXHAUST120 XCR S00WB1AS

8

27

29

34

19

22

20

26

16

23

4

37

1112

1314

15

28

9

17

10

1

24

25

35

36

2

3

21

38

33

2

13736

383

7

8

31

18

2130

3231

3029

5

6

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3086570 2 Bolt, Pivot2 3086569 2 Arm, Rocker3 3084912 2 Nut4 3086951 1 Gasket, Insulator5 3086861 1 Bracket, Choke6 3086583 1 Gasket, Air Cleaner7 3086581 1 Cleaner, Air8 3083856 2 Nut, Flange9 3086591 1 Bolt, Flange

10 3086590 1 Gasket11 3086967 1 Pipe, Intake (Incl. 12)12 3086968 2 Stud13 3086589 1 Gasket14 3086588 1 Insulator15 3086592 1 Gasket16 3086565 1 Valve, Intake17 3086566 1 Valve, Exhaust18 7556144 1 Washer, Fiber19 3110050 1 Mount, Carburetor

20 7555954 2 Washer21 7542101 2 Nut22 3086562 2 Tappet23 3086557 1 Lever, Release24 3086559 1 Ring, Snap25 3086558 1 Pin, Spring26 3086554 1 Camshaft (Incl. 23,24,25)27 3086972 1 Asm., Muffler28 3086576 4 Bolt, Tapping29 3086575 2 Nut30 7552901 2 Washer, Spring Lock31 3086574 2 Gasket32 7512310 2 Bolt33 1261014-029 1 Headpipe34 3086568 2 Rod, Push35 3086571 1 Plate, Guide36 3086563 2 Spring, Valve37 3086564 2 Retainer, Spring38 3086567 4 Valve, Collet

11/99

Page 25: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B10

ELECTRIC DEVICE120 XCR S00WB1AS

4

2

6

9

11

17

8

3

5

10

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 3086694 1 Cap, Spark Plug2 3086965 1 Coil, Ignition3 3083730 2 Bolt and Washer4 3086677 1 Flywheel5 3085697 4 Screw and Washer6 3086682 1 Coil, Charge

7 3086688 1 Clamp8 3086720 1 Clamp9 3086687 1 Grommet

10 3085359 1 Bolt, Flange11 3086692 1 Plug, Spark

9/99

Page 26: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

B11

TOOL KIT120 XCR S00WB1AS

1

2

3

4

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

3083409 1 Kit - Tool (Incl 1-3)1 ––––––– 1 Screwdriver2 ––––––– 1 Wrench, 10-12 Spanner

3 ––––––– 1 Box Wrench, Special4 9915612 1 Manual, Owners “00 120 XCR”

7/99

Page 27: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

120 XCR S00WB1AS

C12

1013045 4 A5. . . . . . . . . . 1013046-067 18 A5. . . . . 1013048-067 8 A7. . . . . . 1013075-067 4 B3. . . . . . 1013095 11 B1. . . . . . . . . 1013096-067 16 A11. . . . 1013097-067 16 A11. . . . 1013151 2 B2. . . . . . . . . . 1211677 3 B3. . . . . . . . . . 1261014-029 33 B9. . . . . 1321860 9 B2. . . . . . . . . . 1541398-067 36 A13. . . . 1541403 2 A13. . . . . . . . . 1541415 16 A13. . . . . . . . 1541416 16 A13. . . . . . . . 1590279-293 18 A13. . . . 1820764 15 A12. . . . . . . . 1820766 8 A14. . . . . . . . . 1820767 9 A12. . . . . . . . . 1820768-293 30 A12. . . . 1820773-067 8 A11. . . . . 1820774-293 19 A12. . . . 1820775-293 19 A12. . . . 1820780-293 25 A12. . . . 1820802-067 4 A12. . . . . 2201588 A9. . . . . . . . . . . . . 2460782 9 B3. . . . . . . . . . 2520171 8 A6. . . . . . . . . . 2632154 20 A6. . . . . . . . . 2670133 14 A5. . . . . . . . . 2670134 5 A7. . . . . . . . . . 2682533 1 A6. . . . . . . . . . 2682534 1 A6. . . . . . . . . . 2682537 6 A11. . . . . . . . . 2870621 17 B6. . . . . . . . . 2872427 2 A6. . . . . . . . . . 2872428 6 A5. . . . . . . . . . 3070185 2 B3. . . . . . . . . . 3080108 27 B4. . . . . . . . . 3081497 7 B7. . . . . . . . . . 3081600 9 B7. . . . . . . . . . 3082038 18 B7. . . . . . . . . 3082934 30 B4. . . . . . . . . 3083054 9 B4. . . . . . . . . . 3083073 8 B7. . . . . . . . . . 3083409 B11. . . . . . . . . . . . 3083568 1 B4. . . . . . . . . .

1 B6. . . 3083730 3 B10. . . . . . . . . 3083856 8 B9. . . . . . . . . .

3084566 1 B7. . . . . . . . . . 3084912 3 B9. . . . . . . . . . 3085359 7 B6. . . . . . . . . .

10 B10. . 3085697 5 B10. . . . . . . . . 3086053 19 B7. . . . . . . . . 3086125 8 B4. . . . . . . . . . 3086510 11 B4. . . . . . . . . 3086511 29 B4. . . . . . . . . 3086512 35 B4. . . . . . . . . 3086513 31 B4. . . . . . . . . 3086516 25 B4. . . . . . . . . 3086517 21 B4. . . . . . . . . 3086518 20 B4. . . . . . . . . 3086519 22 B4. . . . . . . . . 3086520 23 B4. . . . . . . . . 3086522 26 B4. . . . . . . . . 3086524 34 B4. . . . . . . . . 3086525 36 B4. . . . . . . . . 3086526 33 B4. . . . . . . . . 3086527 2 B4. . . . . . . . . . 3086528 3 B4. . . . . . . . . . 3086529 6 B4. . . . . . . . . . 3086530 5 B4. . . . . . . . . . 3086531 4 B4. . . . . . . . . . 3086532 7 B4. . . . . . . . . . 3086535 32 B4. . . . . . . . .

11 B5. . . 3086536 12 B5. . . . . . . . . 3086537 10 B5. . . . . . . . . 3086538 10 B5. . . . . . . . . 3086539 10 B5. . . . . . . . . 3086540 7 B5. . . . . . . . . . 3086544 5 B5. . . . . . . . . . 3086545 9 B5. . . . . . . . . . 3086546 3 B5. . . . . . . . . . 3086550 1 B5. . . . . . . . . . 3086551 1 B5. . . . . . . . . . 3086552 1 B5. . . . . . . . . . 3086553 2 B5. . . . . . . . . . 3086554 26 B9. . . . . . . . . 3086557 23 B9. . . . . . . . . 3086558 25 B9. . . . . . . . . 3086559 24 B9. . . . . . . . . 3086562 22 B9. . . . . . . . . 3086563 36 B9. . . . . . . . . 3086564 37 B9. . . . . . . . . 3086565 16 B9. . . . . . . . . 3086566 17 B9. . . . . . . . . 3086567 38 B9. . . . . . . . .

3086568 34 B9. . . . . . . . . 3086569 2 B9. . . . . . . . . . 3086570 1 B9. . . . . . . . . . 3086571 35 B9. . . . . . . . . 3086574 31 B9. . . . . . . . . 3086575 29 B9. . . . . . . . . 3086576 28 B9. . . . . . . . . 3086581 7 B9. . . . . . . . . . 3086583 6 B9. . . . . . . . . . 3086588 14 B9. . . . . . . . . 3086589 13 B9. . . . . . . . . 3086590 10 B9. . . . . . . . . 3086591 9 B9. . . . . . . . . . 3086592 15 B9. . . . . . . . . 3086594 16 B7. . . . . . . . . 3086595 20 B7. . . . . . . . . 3086596 13 B7. . . . . . . . . 3086597 12 B7. . . . . . . . . 3086598 17 B7. . . . . . . . . 3086599 11 B7. . . . . . . . . 3086604 6 B7. . . . . . . . . . 3086605 2 B7. . . . . . . . . . 3086606 5 B7. . . . . . . . . . 3086609 4 B7. . . . . . . . . . 3086622 2 B6. . . . . . . . . . 3086625 9 B6. . . . . . . . . . 3086626 10 B6. . . . . . . . . 3086628 18 B6. . . . . . . . . 3086629 12 B6. . . . . . . . . 3086630 16 B6. . . . . . . . . 3086632 13 B6. . . . . . . . . 3086634 14 B6. . . . . . . . . 3086638 3 B6. . . . . . . . . . 3086652 25 B8. . . . . . . . . 3086654 2 B8. . . . . . . . . . 3086657 8 B8. . . . . . . . . . 3086658 4 B8. . . . . . . . . . 3086659 9 B8. . . . . . . . . . 3086662 22 B8. . . . . . . . . 3086663 19 B8. . . . . . . . . 3086664 14 B8. . . . . . . . . 3086665 23 B8. . . . . . . . . 3086666 21 B8. . . . . . . . . 3086667 18 B8. . . . . . . . . 3086668 24 B8. . . . . . . . . 3086669 15 B8. . . . . . . . . 3086670 17 B8. . . . . . . . . 3086671 6 B8. . . . . . . . . . 3086672 5 B8. . . . . . . . . . 3086674 20 B8. . . . . . . . . 3086675 16 B8. . . . . . . . .

Page 28: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

120 XCR S00WB1AS

C13

3086677 4 B10. . . . . . . . . 3086682 6 B10. . . . . . . . . 3086687 9 B10. . . . . . . . . 3086688 7 B10. . . . . . . . . 3086692 11 B10. . . . . . . . 3086694 1 B10. . . . . . . . . 3086720 8 B10. . . . . . . . . 3086861 5 B9. . . . . . . . . . 3086862 14 B7. . . . . . . . . 3086865 11 B6. . . . . . . . . 3086866 19 B6. . . . . . . . . 3086873 13 B8. . . . . . . . . 3086874 12 B8. . . . . . . . . 3086875 7 B8. . . . . . . . . . 3086876 11 B8. . . . . . . . . 3086944 22 B7. . . . . . . . . 3086946 10 B4. . . . . . . . . 3086947 28 B4. . . . . . . . . 3086949 8 B5. . . . . . . . . . 3086951 4 B9. . . . . . . . . . 3086954 3 B7. . . . . . . . . . 3086955 21 B7. . . . . . . . . 3086956 15 B7. . . . . . . . . 3086957 5 B6. . . . . . . . . . 3086958 8 B6. . . . . . . . . . 3086959 15 B6. . . . . . . . . 3086960 4 B6. . . . . . . . . . 3086962 1 B8. . . . . . . . . . 3086963 3 B8. . . . . . . . . . 3086964 10 B8. . . . . . . . . 3086965 2 B10. . . . . . . . . 3086966 24 B4. . . . . . . . . 3086967 11 B9. . . . . . . . . 3086968 12 B9. . . . . . . . . 3086969 4 B5. . . . . . . . . . 3086970 4 B5. . . . . . . . . . 3086971 4 B5. . . . . . . . . . 3086972 27 B9. . . . . . . . . 3086973 10 B7. . . . . . . . . 3110050 19 B9. . . . . . . . . 3221116 8 B1. . . . . . . . . . 3221122 9 B1. . . . . . . . . . 3240294 6 B5. . . . . . . . . . 3514012 5 A13. . . . . . . . . 3514338 3 B1. . . . . . . . . . 3514343 21 A12. . . . . . . . 4010051-06 14 A6. . . . . . 4010308 6 A10. . . . . . . . . 4010341 3 A8. . . . . . . . . . 4010357 5 A10. . . . . . . . .

4110038 3 A10. . . . . . . . . 4110106 24 A11. . . . . . . . 5132253 13 A13. . . . . . . . 5132254 3 A13. . . . . . . . . 5132256 31 A13. . . . . . . . 5132257 33 A13. . . . . . . . 5132284 4 A14. . . . . . . . . 5132285 1 A14. . . . . . . . . 5132324 10 B2. . . . . . . . . 5132328 5 A14. . . . . . . . . 5132329 17 A12. . . . . . . . 5132462 8 B2. . . . . . . . . . 5132476 4 B2. . . . . . . . . . 5132601 15 B2. . . . . . . . . 5222393 7 B1. . . . . . . . . . 5241628 14 A13. . . . . . . . 5243049 21 A6. . . . . . . . . 5243861 11 A5. . . . . . . . . 5243862-067 2 A5. . . . . . 5243864 5 B2. . . . . . . . . . 5243867-067 16 A5. . . . . 5243868-067 16 A5. . . . . 5243896 2 A7. . . . . . . . . . 5243897 2 A7. . . . . . . . . . 5243972-067 17 A5. . . . . 5243980 3 A14. . . . . . . . . 5243997-067 3 A5. . . . . . 5243998-067 3 A5. . . . . . 5244023 9 A8. . . . . . . . . . 5244024 9 A8. . . . . . . . . . 5244025-067 7 A5. . . . . . 5244048 19 A11. . . . . . . . 5244079 12 A7. . . . . . . . . 5244080 12 A7. . . . . . . . . 5244302 2 B1. . . . . . . . . . 5244330-067 28 A12. . . . 5244387 12 A5. . . . . . . . . 5333826 1 A13. . . . . . . . . 5333834 23 A12. . . . . . . . 5333835 10 A8. . . . . . . . . 5333836 17 A13. . . . . . . . 5410378 1 A10. . . . . . . . . 5410970 2 A8. . . . . . . . . . 5411751-070 10 B1. . . . . 5430604 9 A11. . . . . . . . . 5430725 25 A6. . . . . . . . . 5431592 23 A11. . . . . . . . 5433150 7 A6. . . . . . . . . . 5433319 15 A5. . . . . . . . . 5433320 15 A5. . . . . . . . .

5433416 18 A11. . . . . . . . 5433455 5 B1. . . . . . . . . . 5433476 14 A11. . . . . . . . 5433477 1 A8. . . . . . . . . . 5433481 14 A12. . . . . . . . 5433494 13 A5. . . . . . . . . 5433495-070 6 A14. . . . . 5433507 35 A13. . . . . . . . 5433525-293 5 A8. . . . . . 5433526-293 11 A7. . . . . 5433527 3 A11. . . . . . . . . 5433528 12 A11. . . . . . . . 5433536-070 14 A7. . . . . 5433547 24 A12. . . . . . . . 5433593 16 A12. . . . . . . . 5433622 10 A11. . . . . . . . 5433623-070 22 A13. . . . 5433624 12 A12. . . . . . . . 5433672 16 B2. . . . . . . . . 5521499 28 A13. . . . . . . . 5521529 27 A13. . . . . . . . 5810144 25 A6. . . . . . . . . 5810290 6 A6. . . . . . . . . . 5811884 7 A11. . . . . . . . . 5811953 32 A13. . . . . . . . 5811954 6 A13. . . . . . . . . 6230172 6 B1. . . . . . . . . . 7041844-067 34 A13. . . . 7041845-067 34 A13. . . . 7041853 3 B2. . . . . . . . . . 7052028 16 A6. . . . . . . . . 7052095 19 A6. . . . . . . . . 7052115 17 B4. . . . . . . . . 7052243 9 A6. . . . . . . . . . 7052249 13 A6. . . . . . . . . 7052259 15 A6. . . . . . . . . 7052266 12 B4. . . . . . . . . 7052278 18 B4. . . . . . . . . 7078315 10 A9. . . . . . . . . 7078317 22 A6. . . . . . . . . 7078385 13 A9. . . . . . . . . 7078386 8 A9. . . . . . . . . . 7078387 15 A9. . . . . . . . . 7078389 10 A7. . . . . . . . . 7078517 2 A9. . . . . . . . . . 7078518 1 A9. . . . . . . . . . 7078519 7 A9. . . . . . . . . . 7078520 7 A9. . . . . . . . . . 7078521 6 A9. . . . . . . . . . 7078522 6 A9. . . . . . . . . . 7078523 4 A9. . . . . . . . . .

Page 29: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

120 XCR S00WB1AS

C14

7078524 3 A9. . . . . . . . . . 7078525 11 A9. . . . . . . . . 7078526 1 B3. . . . . . . . . .

6 B6. . . 7078527 9 A9. . . . . . . . . . 7078528 12 A9. . . . . . . . . 7078529 5 A9. . . . . . . . . . 7078698 14 A9. . . . . . . . . 7080003 13 B4. . . . . . . . . 7080307 12 A6. . . . . . . . . 7080402 10 A6. . . . . . . . . 7080424 37 A13. . . . . . . . 7080433 1 A12. . . . . . . . . 7080859 1 B2. . . . . . . . . . 7080860 15 A11. . . . . . . . 7080861 14 A8. . . . . . . . . 7080864 9 A10. . . . . . . . . 7080891 4 A10. . . . . . . . . 7511848 5 A11. . . . . . . . . 7511989 15 A8. . . . . . . . . 7512068 10 A5. . . . . . . . . 7512091 3 A6. . . . . . . . . .

8 A10. . 7512193 29 A12. . . . . . . . 7512257 4 B2. . . . . . . . . . 7512263 5 A12. . . . . . . . . 7512283 6 A7. . . . . . . . . . 7512307 38 A13. . . . . . . . 7512310 18 A12. . . . . . . .

32 B9. . . 7512312 21 A13. . . . . . . . 7512329 22 A12. . . . . . . .

7 B3. . . 7512465 13 A11. . . . . . . . 7512492 20 A13. . . . . . . . 7515148 24 A6. . . . . . . . . 7515159 8 A8. . . . . . . . . . 7515166 13 A7. . . . . . . . . 7515199 29 A13. . . . . . . . 7515317 23 A13. . . . . . . . 7515385 7 A14. . . . . . . . . 7515394 14 B2. . . . . . . . .

7515534 6 A12. . . . . . . . . 7517227 11 A13. . . . . . . . 7517703 4 A8. . . . . . . . . . 7517736 1 B1. . . . . . . . . . 7517744 7 A13. . . . . . . . . 7517745 10 A12. . . . . . . . 7517778 31 A12. . . . . . . . 7517780 11 B2. . . . . . . . . 7517810 13 B2. . . . . . . . .

5 B3. . . 7541748 19 B4. . . . . . . . . 7541925 6 A8. . . . . . . . . .

7 A10. . 7542101 21 B9. . . . . . . . . 7542122 3 A7. . . . . . . . . .

12 A8. . . 21 A11. . 2 A12. .

7542324 13 A12. . . . . . . . 2 A14. . 7 B2. . . 8 B3. . .

7542344 27 A12. . . . . . . . 9 A13. .

12 B1. . . 7542432 9 A5. . . . . . . . . . 7542451 7 A12. . . . . . . . .

15 A13. . 7542807 2 A10. . . . . . . . . 7552901 24 A13. . . . . . . .

30 B9. . . 7555725 26 A12. . . . . . . . 7555726 10 A13. . . . . . . . 7555727 22 A11. . . . . . . . 7555730 25 A11. . . . . . . . 7555734 20 A12. . . . . . . .

6 B2. . . 7555770 17 B2. . . . . . . . . 7555954 6 B3. . . . . . . . . .

20 B9. . . 7555958 25 A13. . . . . . . .

7555960 8 A13. . . . . . . . . 7556138 12 B2. . . . . . . . . 7556144 18 B9. . . . . . . . . 7556152 16 B4. . . . . . . . . 7556160 11 A12. . . . . . . . 7558201 7 A8. . . . . . . . . . 7558301 3 A12. . . . . . . . . 7558302 11 A8. . . . . . . . . 7558402 9 A14. . . . . . . . . 7558403 8 A12. . . . . . . . . 7571629 19 A13. . . . . . . . 7575202 8 A5. . . . . . . . . . 7621330 23 A6. . . . . . . . . 7621467 5 A5. . . . . . . . . .

5 A6. . . 4 A7. . .

13 A8. . . 17 A11. .

7621512 12 A13. . . . . . . . 7661037 15 B4. . . . . . . . . 7661617 11 A11. . . . . . . . 7661621 26 A13. . . . . . . . 7661624 1 A11. . . . . . . . . 7661637 1 A5. . . . . . . . . .

9 A7. . . 7661913 4 B1. . . . . . . . . . 7661915 10 A14. . . . . . . . 7670057 7 A7. . . . . . . . . . 7670068 30 A13. . . . . . . . 7670094 4 A6. . . . . . . . . . 7670102 1 A7. . . . . . . . . .

16 A8. . . 20 A11. .

7710401 4 A11. . . . . . . . . 7710444 4 A13. . . . . . . . . 7710503 2 A11. . . . . . . . . 8350018-600 11 A6. . . . . 8350019-600 17 A6. . . . . 8450040-600 14 B4. . . . . 8450061-600 18 A6. . . . . 9915612 4 B11. . . . . . . . .

Page 30: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

�������������� ����������������

Page 31: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

In order to better serve you, this postage-paid mailer isprovided for your convenience to report an error orrelay a suggestion relative to any Polaris Publication.

POLARIS PUBLICATIONS REPORT

Publication No.

Machine

Publ. Date Page

Report of ErrorSuggestion

Name

Company

Address

City, State, Zip

Phone No. Date Thank you for your help!

9912263

4/94 Rev. 04

– Mailing Instructions –Please fold the top portion down first then fold the bottom portion up second so the

open edge is located at the top. Tape the open edge.

or FAX your report to:218-463-4580

( )

Page 32: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

FIRST CLASS PERMIT NO. 22 ROSEAU, MINNESOTA

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BE ADDRESSEE

POLARIS SALES INC.301 5TH AVE. S.W.ROSEAU, MN 56751

ATTN: TECHNICAL PUBLICATIONS

NO POSTAGENECESSARY IF

MAILEDIN THE UNITED

STATES

Page 33: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

In order to better serve you, this postage-paid mailer isprovided for your convenience to report an error orrelay a suggestion relative to any Polaris Publication.

POLARIS PUBLICATIONS REPORT

Publication No.

Machine

Publ. Date Page

Report of ErrorSuggestion

Name

Company

Address

City, State, Zip

Phone No. Date Thank you for your help!

9912263

4/94 Rev. 04

– Mailing Instructions –Please fold the top portion down first then fold the bottom portion up second so the

open edge is located at the top. Tape the open edge.

or FAX your report to:218-463-4580

( )

Page 34: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

FIRST CLASS PERMIT NO. 22 ROSEAU, MINNESOTA

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BE ADDRESSEE

POLARIS SALES INC.301 5TH AVE. S.W.ROSEAU, MN 56751

ATTN: TECHNICAL PUBLICATIONS

NO POSTAGENECESSARY IF

MAILEDIN THE UNITED

STATES

Page 35: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

In order to better serve you, this postage-paid mailer isprovided for your convenience to report an error orrelay a suggestion relative to any Polaris Publication.

POLARIS PUBLICATIONS REPORT

Publication No.

Machine

Publ. Date Page

Report of ErrorSuggestion

Name

Company

Address

City, State, Zip

Phone No. Date Thank you for your help!

9912263

4/94 Rev. 04

– Mailing Instructions –Please fold the top portion down first then fold the bottom portion up second so the

open edge is located at the top. Tape the open edge.

or FAX your report to:218-463-4580

( )

Page 36: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

FIRST CLASS PERMIT NO. 22 ROSEAU, MINNESOTA

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BE ADDRESSEE

POLARIS SALES INC.301 5TH AVE. S.W.ROSEAU, MN 56751

ATTN: TECHNICAL PUBLICATIONS

NO POSTAGENECESSARY IF

MAILEDIN THE UNITED

STATES

Page 37: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

�������������� ����������������

Page 38: 120 XCR Model #S00WB1AS - pi54.compi54.com/corp/manuals/Parts/9915619.pdf · 4 34 CHAINCASE Drive Chain ... Bore X Stroke (mm) Displacement (cc’s) ... Cooling Cylinders Cylinder

PRINTED IN THE USA PARTS MANUAL PN 9915619 and MICROFICHE PN 9915620 10/99