2004 switchback

7/29/2019 2004 Switchback

1/66

600 SWITCHBACK F/OModel #S04NS6ES

Model #S04NS6ESA

Model #S04NS6ESB

E 2003 Polaris Sales Inc.

PARTS MANUAL PN 9918837 and MICROFICHE PN 9918838 3/03

700 SWITCHBACK F/OModel #S04NS7CS

Model #S04NS7CSA

Model #S04NS7CSB800 SWITCHBACK F/O

Model #S04NS8CSModel #S04NS8CSAModel #S04NS8CSB


2/66

This page left blank intentionally.


3/66

TABLE OF CONTENTS600SWITCHBACKF/O S04NS6ESand 600SWITCHBACKSTOCK AS04NS6ESAand600 SWITCHBACKSTOCKB S04NS6ESBand 700SWITCHBACKF/O S04NS7CSand 700SWITCH-

BACK STOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCH-BACK STOCK B S04NS8CSB

Parts Manual

AAIRBOX C2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

BBATTERY BOX C9. . . . . . . . . . . . . . . . . . . . . . .

BRAKE A13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR (600) C13-14. . . . . . . . . . . . . . . . . .

CARBURETOR (700) D8-9. . . . . . . . . . . . . . . . . .

CARBURETOR (800) E1-2. . . . . . . . . . . . . . . . . .

CHAINCASE B11. . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS A3-4. . . . . . . . . . . . . . . . . . . . . . . . . . .CONSOLE A12. . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM A14. . . . . . . . . . . . . . . . . . .

CRANKCASE (600) C10. . . . . . . . . . . . . . . . . . . .

CRANKCASE (700) D4. . . . . . . . . . . . . . . . . . . .

CRANKCASE (800) D12. . . . . . . . . . . . . . . . . . . .

CYLINDER (600) C11. . . . . . . . . . . . . . . . . . . . .

CYLINDER (700) D5. . . . . . . . . . . . . . . . . . . . .

CYLINDER (800) D13. . . . . . . . . . . . . . . . . . . . .

DDECALS A11. . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CLUTCH (Electric Start Models) B13. . . . .

DRIVE CLUTCH (Manual Start Models) B14. . . . .DRIVE TRAIN B12. . . . . . . . . . . . . . . . . . . . . . . .

DRIVEN CLUTCH C1. . . . . . . . . . . . . . . . . . . . .

EENGINE MOUNTING (600) C7. . . . . . . . . . . . . .

ENGINE MOUNTING (700)(800) C8. . . . . . . . . .

EXHAUST SYSTEM C3. . . . . . . . . . . . . . . . . . .

GGAS TANK A5. . . . . . . . . . . . . . . . . . . . . . . . . .

HHANDLEBAR B4-6. . . . . . . . . . . . . . . . . . . . . . . .

HOOD A8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOOD FOIL/FOAM A10. . . . . . . . . . . . . . . . . . . .

MMAGNETO (600) D2. . . . . . . . . . . . . . . . . . . . .

MMAGNETO (700) D10. . . . . . . . . . . . . . . . . . . . .

MAGNETO (800) E4. . . . . . . . . . . . . . . . . . . . .

NNOSEPAN A6-7. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL TANK C2. . . . . . . . . . . . . . . . . . . . . . . . . . .

PPISTON and CRANKSHAFT (600) D1. . . . . . . . .

PISTON and CRANKSHAFT (700) D7. . . . . . . . .PISTON and CRANKSHAFT (800) E3. . . . . . . . .

RRAIL MOUNTING SUSPENSION B8. . . . . . . . .

RECOIL STARTER (600) D3. . . . . . . . . . . . . . . .

RECOIL STARTER (700) D11. . . . . . . . . . . . . . . .

RECOIL STARTER (800) E5. . . . . . . . . . . . . . . .

SSEAT A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHOCK (FRONT TRACK) C5. . . . . . . . . . . . . . .

SHOCK (IFS) C4. . . . . . . . . . . . . . . . . . . . . . . .

SHOCK (REAR TRACK) C6. . . . . . . . . . . . . . . .SKI B3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING MOTOR (600) E6. . . . . . . . . . . . . . .

STARTING MOTOR (700)(800) E7. . . . . . . . . . .

STEERING B6. . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING B4-5. . . . . . . . . . . . . . . . . . . . . . . . .

SUSPENSION B7. . . . . . . . . . . . . . . . . . . . . . .

SUSPENSION, FRONT B1-2. . . . . . . . . . . . . . . .

TTOOL KIT E8. . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE ARM, FRONT B9. . . . . . . . . . . . . . . .

TORQUE ARM, REAR B10. . . . . . . . . . . . . . . . .

WWATER PUMP/OIL PUMP (600) C12. . . . . . . . . .

WATER PUMP/OIL PUMP (700) D6. . . . . . . . . .

WATER PUMP/OIL PUMP (800) D14. . . . . . . . . .

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


4/66A3

CHASSIS600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

23

4

1516

1813

14

14

12

1417

56

E 2003 Polaris Sales Inc.

9

7

8

11

7

1

10

20

21

1919

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 1014160-309 1 Asm., Chassis

2 30211043110078

11

Stop, Torque (600)Stop, Torque (700)(800)

3 7542404 1 Nut

4 1013379

1013377

1

1

Stop, Torque (600)

Stop, Torque (700)(800)5 7517854 2 Screw

6 7517632 1 Screw

7 7621432 7 Rivet

8 5245202 1 Bracket, Oil Tank

9 5246177 1 Bracket, Air Box

10 7080592 2 Caplug

11 22020592202598

11

Kit, Trailing Arm Mount, LHKit, Trailing Arm Mount, RH

12 5433150 2 Strap, Airbox, Top

13 52454575245458

11

Mount, Console, Toe Clip, LHMount, Console, Toe Clip, RH

14 7661637 80 Rivet

15 5246310

5246311

1

1

Support, Footrest, LH

Support, Footrest, RH16 52452885242740

11

Footrest, LHFootrest, RH

17 5221583 1 Guard, Adapter Drive

18 7080416 2 Plug, Hole

19 7661130 15 Rivet

20 7081076 2 Plug, Hole

21 5132292 1 Bulkhead, Front

3/03


5/66A4

CHASSIS600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

13

25

1819

20

2417

5

22

27

14

10

17

1816

15

1 2

3

4

6 89

1112

21

26

23

28

29

21

7



1 4030043 1 Bulb, Taillight

2 4032014 1 Lens, Red

3 7518019 2 Screw

4 4032015 1 Gasket, Lens

5 2410307 1 Asm., Taillight (Incl. 1-4)

6 7515140 2 Screw

7 2202379 1 Kit, Close Off (Incl. Close Off & Rivets)

8 7552801 2 Washer, Spring Lock

9 7556033 2 Washer

10 7512113

75528017558301

4

44

Bolt

Washer, Spring LockWasher, Flat

11 3021186 2 Mount, Rubber, Carburetor

12 7555916 2 Washer, Nylon

13 2632460-309 1 Asm., Bumper, Rear

14 7081039 2 Bushing, Snap

15 7512094 4 Screw

16 7558301 4 Washer, Flat

17 7517686 4 Screw

18 70796677079668

11

Decal, Reflector, Red, LHDecal, Reflector, Red, RH

19 5434097-3885434098-388

11

Skirt, Snow, LH, Flame YellowSkirt, Snow, RH, Flame Yellow

20 51330585133059

11

Rack, FrontRack, Rear

21 7661637 7 Rivet

22 52457267661079

13

Guard, Wire, Taillight (Incl. Rivets)Rivet

23 2461065 1 Jumper, Seat, Taillight

24 7621418 5 Rivet25 5434356-1106 1 Flap, Snow, Black w/Chrome

26 5812229 1 Support, Snow Flap

27 541203354120745412134

211

Protector, Bed, Front/RearProtector, Bed, LHProtector, Bed, RH

28 5812360 1 Gasket, Seat Base, 1/4 Inch

29 5812290 2 Gasket, Seat Base

3/03


6/66A5

SEAT AND GAS TANK600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

2

6

5

1

17

12

1614

19

15

13 14

11

7

9

104

8

20

3

18



1 2520323 1 Cap w/Gauge, Fuel

2 26832952683299

11

Asm., Seat Switchback (Incl. 3,6)(600)Asm., Seat Switchback (Incl.3,6)(700)(800)

3 26832982683301

11

Asm., Cover, Switchback (600)Asm., Cover, Switchback (700)(800)


5 7517219 2 Screw6 2461064 1 Harness, Taillight

7 7542122 2 Nut, Nylok


9 7670021 2 Nut, Speed

10 7512193 2 Bolt, Carriage

11 5810947 2 Foam, Seal, Rear Cooler

12 7052269 1 Fitting

13 5432981 1 Grommet

14 7080768 2 Ring, Compression

15 8350020-600 AR Fuel Line

16 7052215 1 Pickup w/Mesh, Fuel

17 2520262 1 Asm., Fuel Tank

18 7080804 2 Cable Tie, Releaseable

19 7052095 1 Fitting, 90 Degree

20 8450061-600 AR Fuel Line

3/03


7/66A6

NOSEPAN600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

1

2

11

10

19

18

15

28

14

27

12

1813

1

2322

21

84

6

9

7

6

1

17

3

3

29

7

5

5

24

20

26

25

16



1 7661637 12 Rivet

2 5243992-067 1 Hinge, Pivot, Lower, RH

3 7621431 2 Rivet

4 1821108-067 1 Tower, Shock, RH

5 7661130 6 Rivet

6 7517935 4 Screw

7 7556153 4 Washer

8 1821107-067 1 Tower, Shock, LH

9 7547180 4 Nut, Flange

10 5244049-067 1 Bracket, Support, Radius Rod

11 5244050 1 Brace, Pan, Lower

12 5243991-067 1 Hinge, Pivot, Lower, LH

13 7542153 2 Nut, Flanged, Nylok

14 5433518-070 1 Asm., Bumper, Front, Black

15 7512163 2 Bolt

16 7621472 3 Rivet

17 5245853 1 Shield, Exhaust, Heat, Extended

18 7621467 20 Rivet

19 5434345-293 1 Nosepan, High Shocks, Indy Red

20 5434346 1 Cover, Shock Tower, LH

21 7542122 4 Nut, Nylok

22 7555827 4 Washer

23 7515166 4 Screw

24 54343475812271

11

Cover, Shock Tower, RHFoil, Shock Tower Cover

25 7621418 1 Rivet

26 7621485 8 Rivet

27 7517312 4 Screw


29 52448885244889

11

Guide, Hood, LHGuide, Hood, RH

3/03


8/66A7

NOSEPAN600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

9

58

10

11

16

1213

15

18

19

20

24

31

21

22

6

7

17

14



1 7670130 3 Clip, Speed, U-Type

2 5811948 1 Foil

3 7080963 1 Retainer, J-Clip4 7621435 1 Rivet

5 5812020 1 Foil, Tape, Nosepan

6 5810949 1 Foil, Tape

7 5812036 1 Foil, Nosepan

8 5812019 1 Foil, Tape, Nosepan, Lower, RH

9 5812018 1 Foil, Tape, Nosepan, Upper, RH

10 7621402 5 Rivet

11 5222769 1 Clip, Belt Retainer

12 1013069 1 Asm., Guard, Clutch

13 7080698 1 Pin, Clutch Cover

14 5812352 1 Pad, Clutch Guard15 7075350 1 Decal, Engine and Clutch

16 7621429 2 Rivet

17 7170043 1 Decal, Troubleshoot ing

18 2670134 2 Asm., Reflector, Amber

19 5433926 1 Plug, Nosepan, Oblong

20 5211722 1 Plate, Backer, Clutch Guard

21 4020139 1 Clip, Rosebud

22 7670131 2 Plug, Nylon

2/02


9/66A8

HOOD600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

1

4

6

7

8

9

10

11

12

16

19

20

2319

20

18

21

17

21

18 17

21

15

5

21 14

3

13

22

2



1 2632521-177 1 Asm., Hood, Black

2 7080138 1 Cable Tie

3 2461015 1 Harness, Headlight

4 2410132 1 Asm. Headlamp (Incl. Bulbs)

5 5812450 1 Seal, Headlight, One Piece

6 2870448 2 Bulb, Headlight7 4032063 2 Retainer, Headlamp Bulb

8 7517872 1 Bolt, Tee Adjuster

9 7041954 1 Spring, Headlight Adjust

10 7080887 1 Knob, Headlight Adjust, Locking

11 5811793 2 Foam, Prefilter

12 263249158123245811948

111

Asm., Plenum w/FoilFoil, PlenumFoil

13 7170040 1 Decal, Suspension Set-Up

14 5433660 1 Cover, Access, Headl ight

15 7512068 10 Screw

16 5243567-067 1 Hinge, Upper, LH

17 7512240 4 Bolt

18 7558301 4 Washer, Flat19 7512113 2 Bolt

20 5332403 2 Spacer

21 7542122 6 Nut, Nylok

22 7080367 1 Clamp, Cable

23 5243568-067 1 Hinge, Upper, RH

3/03


10/66A9

HOOD600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

1

2

3

45

6

7

89

10

11

7

89

16

17

14

15

13

12

13



1 7621509 3 Rivet, Plastic Lock

2 5435041 1 Windshield, Smoke, Flared, 13 Inch

3 5410970 4 Retainer, Windshield4 2874394

28744014030015

113

Asm., Tachometer (600)Asm., Tachometer, DET (700)(800)Bulb, Replacement

5 3280209 2 Cushion, Rubber

6 3280210 2 Bracket, Speedometer/Tachometer


8 3280156 4 Washer, Split Lock

9 3280158 4 Nut

10 3280186 1 Knob, Trip Odometer

11 32804114030015 14 Asm., SpeedometerBulb, Replacement

12 3280385 1 Cable, Speedometer

13 4010589 3 Clip, Plastic, Dart Nylon

14 7512018 2 Screw

15 7541925 2 Nut, Nylok

16 7080521 2 Cable, Hood Retainer

17 7661637 2 Rivet

3/03


11/66A10

HOOD FOIL/FOAM600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

8

7

9

11

4

13

21

VIEW LOOKING AT HOOD FROM UNDERNEATH

14

6

12

3

5

10

1 1

1

1



1 7661142 8 Rivet

2 5434196-070 1 Closure, Hood, Side, RH, Black

3 5434197-070 1 Backer, Hood Closure, Upper, Black

4 5434198-070 1 Closure, Hood, Upper, Black

5 5246028 1 Retainer, Closure, Upper

6 5812270 1 F oam, Hood, Rear, LH

7 5812286 1 F oam, Hood, Front, LH

8 5812007 1 Foam, Hood Center

9 5812017 1 F oil, Tape, Hood, RH

10 5246029 1 Retainer, Closure, Lower

11 5434199-070 1 Closure, Hood, Lower, Black

12 5434201-070 1 Backer, Hood Closure, Lower, Black

13 5434195-070 1 Closure, Hood, Side, LH, Black

14 5434223-070 1 Closure, Hood, Upper, LH, Black

7/01


12/66A11

DECALS600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

21

19

24

27

1

11

5

15

16

22

9

23

14

26

2

6

13

3

1718

25

47

10

8

20

12



1 7079886 1 Decal, Warning, English

2 7170112 1 Decal, Warning, Elec./Rev./Opt.

3 7078716 1 Decal, Electric Start, Domed

4 7171496 1 Decal, Dash5 7079887 1 Decal, Warning, French

6 7170061 1 Decal, Choke

7 717150771715087171505717150671715097171510

111111

Decal, Hood Top, 600, LHDecal, Hood Top, 600, RHDecal, Hood Top, 700, LHDecal, Hood Top, 700, RHDecal, Hood Top, 800, LHDecal, Hood Top, 800, RH

8 71713897171387

11

Urocal, Hood Center, Switchback (Blue)Urocal, Hood Center, Switchback (Red)

9 71713957171499

11

Decal, Hood Center, Switchback (Blue)Decal, Hood Center, Switchback (Red)

10 22025672202568

2202569

11

1

Decal, Kit, Hood, 04 600 Switchback (Incl.4,7-9,12,14-16,20-22,27)Decal, Kit, Hood, 04 700 Switchback (Incl.4,7-9,12,14-16,20-22,27)Decal, Kit, Hood, 04 800 Switchback (Incl.4,7-9,12,14-16,20-22,27)

11 7075438 1 Decal, Warning, No Passenger

12 7170608 1 Urocal, Perc

13 7079509 1 Decal, Ignition, TPS

14 7171394 1 Decal, Hood Center, Louver

15 7171195 1 Urocal, POLARIS

16 71715017171502

11

Decal, Hood Side, Front, LHDecal, Hood Side, Front, RH

17 71715177171518 11 Decal, Pan, Front, LHDecal, Pan, Front, RH

18 71701437170144

11

Decal, Trailing Arm, Edge IFS, LHDecal, Trailing Arm, Edge IFS, RH

19 71714977171498

11

Decal, Pan, Rear, LHDecal, Pan, Rear, RH

20 71713887171516

22

Urocal, Switchback (Red)Urocal, Switchback (Blue)

21 7171511717151271713897171390

1111

Decal, Hood Side, Switchback, LH (Red)Decal, Hood Side, Switchback, RH (Red)Decal, Hood Side, Switchback, LH (Blue)Decal, Hood Side, Switchback, RH (Blue)

22 71712737171274

11

Decal, Hood Top, POLARIS, LHDecal, Hood Top, POLARIS, RH

23 7171513717151471713917171392

1111

Decal, Tunnel, 144, LH (Red)Decal, Tunnel, 144, RH (Red)Decal, Tunnel, 144, LH (Blue)Decal, Tunnel, 144, RH (Blue)

24 71714247171393

22

Decal, Seat, Switchback, POLARIS (Red)Decal, Seat, Switchback, POLARIS (Blue)

25 7078321 1 Decal, Max. 15 LBS. (7KG.)

26 7076360 1 Decal, Track, Seat, LH/RH, English/French

27 71715037171504

11

Decal, Headlight, LHDecal, Headlight, RH

3/03


13/66A12

CONSOLE600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

16

18

19

12

6

13

11

98

20

3

4

1

5

15

17

10

2

7

14

4

3

2

Standard

Electric Start

1



1 75120317517263

22

Screw (Standard)Screw (Electric Start)

2 7555746 2 Washer

3 40107934010794

11

Regulator, AC, 14.3v (Standard)Regulator, AC/DC, 14.3v (Electric Start)

4 7541925 1 Nut, Nylok

5 5434134 1 Console, RMK

6 2201614 1 Ki t - Ignit ion Switch, ES, Fuel

7 7670090 2 Clip, Plast ic, Dart, Nylon

8 5432943 1 Lever, Choke (Incl. Pin)

9 7080946 1 Cable, Choke, Rack (Incl. 8,11)

10 7515199 2 Screw

11 5432944 1 Nut, Choke, w/Notch

12 7547035 1 Nut, Ignition

13 5410611 1 Cap w/Key NOTE: When orderingigni-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.).

14 7080138 4 Cable Tie

15 4010192 7 Socket

16 4010193 2 Housing, Connector

17 4020092 1 Terminal, Ring

18 2461146 1 Harness, Main

19 4020057 1 Housing

20 4020063 1 Housing

7/02


14/66A13

BRAKE600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

19

1

2

3

16

15

13

6

12118

4

5

9

147

10

25

17

18

20

21

22

23

24



1 2201254 1 Kit, Cover Screw

2 2201255 1 Kit, Cover Assembly (Incl . 1,3)

3 -- -- -- -- -- -- -- 1 Gasket

4 2201250 1 K it, Park Lever Spring

5 2010219 1 Asm., Master Cylinder(Incl. 2,4,8,11,12,15)

6 7517441 2 Screw

7 7512078 1 Screw

8 2201943 1 Kit, Lever9 7517566 1 Screw

10 2201945 1 Kit, Snap Ring

11 22021464010157

11

Kit, Asm Master CylinderSwitch, Brake Light

12 2201944 1 Kit, Cartridge Subassembly

13 2010206 1 Asm., Control, LH

14 5433291 1 Button, Switch, HI/LO, LH Control

15 2201946 1 Kit , Pivot Pin, w/Snap Ring

16 2201251 1 Kit, Park Lever and Spring (Incl. 4)

17 2202202 1 Kit, Brake Pad, Type 81

18 22022072202204

11

Kit, Piston/SealKit, Seal

19 2202201 1 Kit, Brake Caliper Asm. (Incl. 17,18,23)

20 7556160 2 Washer21 7552603 2 Washer, Spring Lock

22 7515534 2 Screw

23 2202206 1 Kit, Pin Retaining

24 2202205 1 Kit, Bleeder Fitting

25 1910613 1 Line, Brake

8/02


15/66A14

COOLING SYSTEM600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

9

14

7

1

1

1

6

6

6

6

2

3

8 10

11

1517

4

6

6

24

18

20

2122

10

1312

23

16

Brake5

1

19



1 7080844 7 Clamp, Springband

2 54124325412244

11

Hose, Bypass/Brake Cooler (600)Hose, Engine Out/Brake Cooler(700)(800)

3 5412351 1 Hose, Gripper/Brake Cooler

4 54124335412341

11

Hose, Center Out Bottle In (600)Hose, Center Out/Bottle In (700)(800)

5 7080138 1 Cable Tie6 7080841 8 Clamp, Springband

7 12401041240105

11

Gripper/De-Icer, LHGripper/De-Icer, RH

8 5412205 2 Hose, Gripper/Rear Closeoff

9 1240150 1 Exchanger, Closeoff, Rear

10 7661637 22 Rivet

11 5412083 1 Hose, Gripper/Center Cooler

12 5521602 1 Tubing, Convoluted

13 5810291 1 Spacer, Rubber

14 2520292 1 Cooler, Bulkhead

15 5412236 1 Hose, Front Cooler/Engine Out

16 7080560 2 Clamp, Hose

17 54122375412160

11

Hose, Bottle to Engine (600)Hose, Pump/Bottle (700)(800)

18 70809087080951

11

Clamp, Hose (600)Clamp, Hose (700)(800)

19 7555859 1 Washer, Flat (600)

20 2520312 1 Bottle, Coolant

21 2511270 1 Cap, Pressure

22 7170063 1 Decal, Water Bottle Cap

23 7080761 1 Cable Tie

24 8450003-1525 1 Fuel Line

3/03


16/66B1

FRONT SUSPENSION600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

10

14

15

19

20

5

26 27

24

28

23

21

29

30

31

32

33

34

35

36

37

38

39

44

43

46

40

9

49

7

1

8

10

10

19

11 10

10

18

22

12

25

5

18

4

13

16

17

48

47

3

6

22

404142

45

2

2


17/66B2

FRONT SUSPENSION600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB



1 7517980 2 Bolt

2 7556212 4 Washer

3 5132454 2 Bushing, Spacer

4 7061081 2 Rod End, Radius LH5 7547066 4 Nut, Nylon

6 7547117 2 Nut, Jam, LH

7 5133487-385 2 Tube, Radius Rod, Upper, Cld Slv

8 7542520 2 Nut, Jam

9 7061061 2 R od End, Radius

10 7542439 10 Nut, Nylok

11 7515433 2 Screw

12 5630580 2 Retainer, Spring, Slotted

13 7515415 2 Screw

14 7041576-067 2 Spring, Compression

15 7042147 2 Shock, IFS, Arvin, IFP

16 5431734 2 Ring, Spring Preload

17 1500063 2 Retainer, Spring, Body, Threaded

18 7517583 4 Screw

19 7555832 4 Washer

20 5133060 2 Arm, Steering

21 7061086 2 Rod End, RH


23 1821201-3851821202-385

11

Asm., Trailing Arm, Slv, LH (Incl. 26,27)Asm., Trailing Arm, Slv, RH (Incl. 26,27)


25 5132364 2 Cup, Mount, Trail ing Arm

26 7061042 2 Bearing, Spherical

27 7710437 2 Ring, Retaining

28 7512099 2 Screw29 3573909 2 Bushing, Flange

30 7080433 2 Fit ting, Lubrication

31 5433814 2 Bushing, Torsion Bar

32 7621452 6 Rivet

33 5246343-067 1 Bar, Torsion

34 5434371 2 Slide, Torsion Bar

35 7556509 2 Bushing

36 3574208 2 Bushing, Flanged

37 6230225-067 2 Shaft w/Steering Stop, Spindle

38 7080306 2 Fitting, Lubrication, w/Ball

39 5010158 2 Bushing

40 7547216 4 Nut, Nylon

41 7556213 2 Washer

42 7517906 2 Bolt

43 7542711 4 Nut, Jam

44 7061052 2 Rod End, Radius, RH, Lower

45 7556153 2 Washer

46 5133555 2 Tube, Radius Rod, Lower

47 7547028 2 Nut, Jam

48 7061087 2 Rod End, Radius, LH, Lower

49 7518041 2 Bolt

3/03


18/66B3

SKI600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

11

13

12

3

1415

4

1

2

5

8

3

9

107

6

6



1 7542321 2 Nut, Flange

2 7542122 2 Nut, Nylok

3 7558301 4 Washer, Flat4 5434618-293

5434618-10722

Toe, Ski, Plastic, RedToe, Ski, Plastic, Med. Blue

5 7542439 2 Nut, Nylok

6 7556130 4 Washer, Belle

7 5132637 4 Bushing, Plastic Ski

8 5412018 2 Stop, Ski Rubber

9 7542324 8 Nut, Nylok


11 1821335--0701821336--070 11 Asm., Ski, LH (Incl. 7)Asm., Ski, RH (Incl. 7)

12 7517968 2 Screw

13 2874334 2 Kit, Skag, Carbide 4-Inch, 60 Degree(2 per Kit)

14 7518047 2 Bolt

15 7518070 2 Screw

3/03


19/66B4

STEERING - HANDLEBAR600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

16

1

23

45

6

7

8 9

10

11

12

13

14

2221

20

17 18

19

24

252627

2829

30

15

23



1 7661624 1 Pin, Retaining


3 54329702010171

11

Lever, ThrottleAsm., Lever w/Heater, Hi/Lo

4 5431592 1 Block, Throttle/Brake

5 5433345 1 Adaptor, Block, Throttle

6 54341455434146

11

Collar, Console, LHCollar, Console, RH

7 7670106 2 Nut, Push-On

8 5434179 1 Emblem, Star

9 5243396-070 1 Bar, Mountain

10 7547107 2 Nut, Jam

11 7542344 2 Nut, Nylok

12 5433330 1 Cover, Handlebar

13 5433160-070 2 Slide, Handlebar Cover

14 4010287 2 Dart, Clip, Nylon

15 7517238 4 Screw

16 5412195 2 Grip, Handlebar, Short, Cut

17 1253274-070 2 Asm., Handlebar Hook (Black)

18 7517834 2 Screw, Socket Head

19 2461027 2 Heater, Grip, Lo/Med/Hi, Short

20 -------------- 1 Asm., Control, LH(See Brake Pg. A13, Ref. 13)

21 1821231-067 1 Handlebar

22 5630187-067 2 Block, Handlebar23 7542122 4 Nut, Nylok

24 7511848 8 Screw

25 5432261 1 Holder, Wire


27 7512465 1 Screw, Set

28 7555727 1 Washer

29 4110106 1 Switch, Auxil iary Shut-Off, Closed

30 7555730 2 Washer

3/03


20/66B5


S04NS8CSB

810

13

3

11

2

5

3

1

11

14

12

9

7

7

4

15

6

21

7



1 51336487080510

22

Bracket, Steering PostFitting, Zerk

2 5432785 4 Bushing, Steering Post3 7542324 4 Nut, Nylok

4 5245373 1 Bracket, Console, Front Neck

5 1821060-067 1 Post, Steering


7 4020139 4 Clip, Rosebud

8 54335325433533

11

Boot, Tie Rod, LHBoot, Tie Rod, RH

9 5 244470 2 Plate, Tie Rod Boot

10 7621433 6 Rivet

11 7517579 4 Bolt, Carriage12 7542343 4 Nut

13 1013444-067 1 Hoop, Steering


15 7547030 2 Palnut

3/03


21/66B6


S04NS8CSB

9

2

845

3

1

14

11

15

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



1 7061086 2 Rod End, RH

2 7542401 4 Nut

3 5334147 2 Tie Rod4 7542424 4 Nut, LH

5 7061085 2 Rod End, LH

6 7061076 2 Rod End, RH

7 5333772 1 Rod, Steering Rack

8 5333773-067 1 Rod, Draglink

9 7542439 8 Nut, Nylok

10 7061075 2 Rod End, LH

11 5132106 4 Bushing, Reducer12 1820957 1 Asm., Pitman Arm (Incl. 11,13,15)

13 5133423 2 Spacer, Tube, Pitman/Idler Arms

14 7512435 2 Screw

15 3514320 4 Bearing, Ball

16 1820959 1 Asm., Idler Arm (Incl. 11,13,15)

11/01


22/66B7

SUSPENSION600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

78

910

13141 28

16

23

17

3

4

5

27

31

29

5

6

15

19 21

22

1112

26

25

24

1

12925

23

27

19

4

18

20

2

4

15

30

30

43

4




2 7547217 1 Nut, Nylok

3 7542439 2 Nut, Nylok


5 1590303-1071590303-293

22

Asm., Wheel, Idler Blue (Incl. 11,12)Asm., Wheel, Idler Red (Incl. 11,12)

6 5432535 4 Spacer, Idler

7 7555918 1 Bushing

8 1594087 1 Asm., Wheel

9 5333285 1 Spacer, Idler, Long

10 5020744 1 Shaft, Idler

11 3514384 2 Bearing


13 7556130 2 Washer, Belle

14 7517731 2 Bolt

15 7517921 2 Screw

16 7517996 1 Screw

17 5412168 1 Track

18 7517857 2 Screw


20 7556042 2 Washer

21 7517247 2 Screw

22 5020868 1 Shaft

23 5334062 2 Spacer, Shock Centering

24 5133188 1 Shaft

25 7555832 2 Washer

26 7556210 2 Washer

27 7080424 2 Fitting, Lubrication

28 1541635-067 1 Arm, Pivot, Shock

29 5334042 2 Tube


31 1541832-067 1 Arm, Pivot, Rear

3/03


23/66B8

RAIL MOUNTING SUSPENSION600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

21

2324

17 19

6

18

20

2715

2928

131

34

9

1011

7

4 1410

11

13

21

21

5 7

414

1530

3132

1011

3

16

8

14

12

164

5

4

13

722

2

233

25

26

15


Ref. Part No. Qty. Description Ref. Part No. Qty. Description1 7512007 2 Bolt

2 7555792 4 Washer

3 7510504 4 Screw


5 55214985432946

44

Bumper, Jounce, RearLiner, Bumper

6 15418351541836

11

Asm., Rail, LH (Incl. 1-6,19,20,33,34)Asm., Rail, RH (Incl. 1-6,19,20,33,34)

7 7542324 12 Nut, Nylok

8 5245411 2 Bracket, Rai l Reinforcement

9 7542439 4 Nut, Nylok

10 7515346 6 Screw11 7556179 6 Washer, Spring

12 1590317 2 Asm., Bogie Wheel

13 7515317 6 Bolt

14 5631065 6 Block, Wheel Mount

15 7555983 6 Washer

16 7541925 4 Nut, Nylok

17 7517227 2 Screw

18 7542404 2 Nut

19 5130530 2 Block, Idler Bolt Adjust

20 7621501 4 Rivet

21 1590318-1071590318-293

44

Asm., Wheel, Scrolled Blue (Incl. 23,24)Asm., Wheel, Scrolled Red (Incl. 23,24)

22 7510504 4 Screw

23 3514303 4 B earing (1 Per Wheel)

24 7718407 4 Ring, Retaining (1 Per Wheel)

25 7661123 2 Pin, Clevis

26 7661644 2 Pin, Hitch

27 7515438 2 Screw

28 5434334

76611237661644

2

22

Guide, Spring, Square

Pin, ClevisPin, Hitch

29 5333948 2 Spacer

30 7661845 2 Rivet

31 5521632 2 Hi-Fax

32 7515199 2 Screw

33 7541925 2 Nut, Nylok

34 5434355 2 Cap, Rail Tip

3/03


24/66B9

FRONT TORQUE ARM600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

1

5

4

2

10

14

11 9

3

18

15

12

13

13

16

678

1213

1513

17



1 7042084524506754335037042050-0675630580

11111

Shock, Front TrackRetainer, Spring, Gab, PlatedShield, SpringSpring, CompressionRetainer, Spring, Slotted

2 7512410 1 Screw

3 7080424 1 Fitting, Lubrication

4 5334026 1 Shaft

5 1541613-385 1 Arm, Torque, Front, Cld Slv

6 7517435 2 Screw



9 5020908 1 Shaft

10 7512329 2 Bolt

11 5333522 2 Bushing

12 7517313 4 Screw


14 5812282 2 Strap, Limiter

15 7542344 4 Nut, Nylok

16 7542324 2 Nut, Nylok

17 7080510 1 Fitting, Zerk

18 7542411 2 Nut, FLEXLOC

3/03


25/66B10

REAR TORQUE ARM600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

11

87

1213

17 16

15

24

14

59

23

10

1

21

20

25

4

18

18

22

19

19

19

19

23

22

6

25

20

6

6



1 7517435 2 Screw



4 5133165 1 Shaft

5 1541615-3857080424

12

Arm, Torque, Rear, Cld SlvFitting, Lubrication


7 7547217 1 Nut, Nylok


9 7512410 1 Screw

10 5434337 1 Sleeve, Torsion Spring

11 5333997 1 Shaft

12 5432983 2 Roller, Spring, Adjustable, Square

13 7080394 2 Clip, Push-On

14 7517908 1 Screw

15 1541285 2 Asm., Carrier Wheel w/Collar,

16 7556301 2 Bushing

17 7042068-0677042069-0677042079-0677042080-067

7042081-0677042082-067

1111

11

Spring, Torsion, LH, STD (.359/47)Spring, Torsion, RH, STD (.359/47)Spring, Torsion, LH, Opt. (.375/47)Spring, Torsion, RH, Opt. (.375/47)

Spring, Torsion, LH, Opt. (.347/47)Spring, Torsion, RH, Opt. (.347/47)

18 7515496 2 Bolt

19 7555795 4 Washer, Wave

20 5133101 2 Bushing

21 1541631-067 1 Rod, Shock

22 5132391 2 Bushing

23 5333905 1 Sleeve

24 7042176 1 Shock, Track, Rear

25 5010422 2 Bushing

3/03


26/66B11

CHAINCASE600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

13

2

57

8

4

9

1110

12 1314

1516

18

17

6

21

1

75

22

20

19



1 3610030 2 Seal, Oil

2 7542404 1 Nut

3 7515459 1 Screw

4 13322665630123

35530027558702

11

12

Asm., Tightener, SlidingWheel, Idler

Bearing, Chaincase IdlerWasher, Thrust


6 13321435410675

12

Asm., Dipstick (Incl. O-Ring)O-Ring


8 32210983221099

11

Sprocket, 22T, 3/4W (600)Sprocket, 23T, 3/4W (700)(800)

9 7571620 1 Washer, Spring

10 7661203 1 Pin, Cotter

11 7547202 1 Nut, Insert

12 5411497 1 Gasket, Chaincase, O-Ring

13 5631354 1 Cover, Chaincase

14 7512242 5 Screw

15 7517979 1 Screw

16 7571618 1 Washer, Spring

17 32220993222108

11

Sprocket, 40T (600)Sprocket, 39T (700)(800)

18 3221109 1 Chain, 74P, 3/4W

19 7542451 1 Nut, Nylok

20 7052115 1 Plug

21 5134085 1 Chaincase

22 7515477 1 Screw

3/03


27/66B12

DRIVE TRAIN600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

12

34

5

6

9

16

12

14

15

1110

18

1920

21 222927

3031

3233

23

13

17

28

8

26

2310

2221

7

25

24



1 7515369 1 Screw


3 7555734 AR Washer, Flat

4 5020913 1 Spacer

5 -------------- 1 Asm., Driven Clutch(See Driven Clutch Pg. C1, Ref. 15)

6 3211080 1 Belt, Drive

7 7555917 1 Washer

8 7555864 AR Washer

9 7556509 AR Bushing10 7542324 6 Nut, Nylok


12 52413597080561

11

Flangette w/Grease ZerkFitting, Lub/Vent

13 5811095 1 Gasket, Jackshaft

14 3514525 2 Bearing

15 5222751 1 Flangette


17 7721128 1 Key

18 1332220 1 Asm., Jackshaft (Incl. 14,19)


20 1910403 1 Asm., Brake Disc

21 5020588 2 Sleeve, Seal

22 5410613 2 O-Ring

23 7542423 3 Nut, Flange

24 7558403 1 Washer

25 7518002 1 Screw


27 1590346 1 Asm., Drive Shaft (Incl. 28,29)

28 1012945 1 Asm., Flangette w/Screws

29 3280019 1 Bushing, Speedometer, Metal

30 5243529 1 Flangette, Offset, w/Hole

31 3280017 1 Key, Speedometer, Square

32 5830012 1 Gasket, Drive Adaptor

33 3280116 1 Adaptor w/Zerk, Drive

3/03


28/66B13

DRIVE CLUTCH (ELECTRIC START MODELS)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

1

2

34

5

6

78

9

10

11

12

1314

15

16

17

18

19

20

9



1 7512265 6 Bolt


3 35765163514347

11

Bearing, Cover (600)(700)Bearing, Cover (800)

4 7710417 1 Ring, Retaining, Cover

5 7042083 1 Spring, Clutch, Black/Green

6 5020425 1 Nut, Jam

7 5430945 6 Washer, Multilube

8 1321622 3 Asm., Roller and Bushing

9 5430445 6 Button, Guide

10 52107545210753524298152107525132542

ARARARARAR

Spacer (.050)Spacer (.032)Spacer (.025)Spacer (.020)Spacer, Clutch, Drive (.130)(800)

11 132158713215851321584

333

Asm., Weight/Bushing 10-60 (600)Asm., Weight/Bushing 10-64 (700)Asm., Weight/Bushing 10-66 (800)

12 7515105 3 Pin, Weight

13 3576502 1 Bearing, Sleeve

14 5010188 1 Insert, Moveable

15 5131062 1 Gear, Ring

16 7515351 6 Screw


18 1321932

1321931

1322022

1

1

1

Asm., Drive Clutch ES Basic 118(Incl. All Less 5,11)(600)Asm., Drive Clutch ES Basic 117(Incl. All Less 5,11)(700)Asm., Drive Clutch ES Basic 125(Incl. All Less 5,11)(800)

19 2200387 1 K it, Drive Clutch Shim

20 51330795133054

33

Pin, Roller (600)(700)Pin, Roller (800)

3/03


29/66B14

DRIVE CLUTCH (MANUAL START MODELS)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

12

3 4

5 910

6

7 8

17

6

15

11 12

16

1314

18



1 7512265 6 Bolt


3 35765163514347

11

Bearing, Cover (600)(700)Bearing, Cover (800)

4 7710417 1 Ring, Retaining, Cover

5 7042083 1 Spring, Clutch, Black/Green

6 54304455434188

66

Button, Guide (700)Button, Guide (800)

7 5430945 6 Washer, Multilube

8 1321622 3 Asm., Roller and Bushing

9 51330795133054

33

Pin, Roller (600)(700)Pin, Roller (800)

10 2200387 1 Kit, Drive Clutch Shim

11 132158713215851321584

333

Asm., Weight/Bushing, 10-60 (600)Asm., Weight/Bushing, 10-64 (700)Asm., Weight/Bushing, 10-66 (800)

12 7515105 3 Pin, Hardened Weight

13 3576502 1 Bearing, Sleeve

14 5010188 1 Insert, Moveable

15 521075452107535242981

5210752

ARARAR

AR

Spacer (.050)Spacer (.032)Spacer (.025)

Spacer (.020)16 7541906 3 Nut, FLEXLOC

17 5020425 1 Nut, Jam

18 1321928

1321810

1321880

1

1

1

Asm., Drive Clutch, Basic 114(Less 5,11)(600)Asm., Drive Clutch, Basic 102(Less 5,11)(700)Asm., Drive Clutch, Basic 108(Less 5,11)(800)

3/03


30/66C1

DRIVEN CLUTCH600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

1

2

1

3

4

5 6

6

7

78

8

9

10

1112 13

14

15



1 7518023 12 Screw

2 5246216 1 P late, Windage

3 3 233996 8 Screw, Cap4 5134095

513413211

Ramp, Driven, 56/42-.36 (600)Ramp, Driven, 58/42--.36 (700)(800)


6 5434534 2 Roller

7 7556226 1 Washer, Thrust


9 7042198 1 Spring, Driven Clutch, Blk/Red


11 3234033 1 Spacer12 7518024 1 Screw


14 5246217 1 Plate, Windage

15 1322321 1 Asm., Driven Clutch, 211 (Incl.1,2,5-9,11-15)

3/03


31/66C2

OIL TANK / AIRBOX600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

10

14

13

12

23

811

15

29

27

3

5

7

28

25

26

25

E 2003 Polaris Sales Inc.1

2

2021

16

4

18

6

19

9

172224



1 5434089 1 Cover, Tool Box

2 5812209 1 Foam, Tool Box

3 7512297 1 Screw

4 7542122 1 Nut, Nylok

5 12535391261127

11

Asm., Oil Tank w/Sender (Incl. 1,27)Oil Bottle/Tool Box w/Mount

6 7512095 2 Screw

7 -------------- 1 Kit, CDI (See Magneto, Pg. D10, Ref.19)

8 7052127 2 Fitting

9 7670102 1 Clip, Silencer

10 5811983 1 Foam, Air Box, Chimney11 7075351 1 Decal, Caut ion, Air Box

12 5433150 1 S trap, Air Box, Top

13 1253498

1253501

1

1

Asm., Air Silencer (Incl. 23 & De-cals)(600)Asm., Air Silencer (Incl. 23 & De-cals)(700)(800)

14 7171037 1 Decal, Belt Removal

15 7073426 1 Decal, Greasing

16 7547103 2 Nut


18 -------------- 1 Coil, Ignition (See Magneto, Pg. D10,Ref. 17)

19 7080471 1 Clip, Ignition Cable

20 7552604 2 Washer

21 7517610 2 Screw

22 7077026 1 Decal Spark Plug

23 54121695412157

22

Boot, Carburetor (600)Boot, Carburetor (700)(800)

24 7511862 2 Screw25 7080307 2 Clamp, Hose

26 8450003-1525 AR Fuel Line

27 4010660 1 Sender, Oil , w/Front Terminals

28 7052305 1 Grommet, Oil Sender

29 1240094 1 Cap, Oil, Vented

3/03


32/66C3

EXHAUST SYSTEM600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

6

11

12

13

19

16

18

15

4

2

2

14

17

1

2

2

5

7

9

3

3

8

10



1 1261296-029 1 Bracket, Chassis/Resonator

2 7041687 7 Spring, Exhaust

3 70416877042029

44

Spring, Exhaust (600)Spring, Exhaust (700)(800)

4 1261130-0291261177-029

11

Resonator (600)(700)Resonator (800)

5 7555904 1 Washer

6 5411684 1 Boot, Exhaust, Outlet

7 7621467 2 Rivet

8 7542321 2 Nut, Flange9 5243929 1 Deflector, Snow, Exhaust


11 58118385811799

22

Gasket, Exhaust (600)Gasket, Exhaust (700)(800)

12 1261046-0291261124-029

11

Manifold (600)Manifold (700)(800)

13 7517322 6 Screw

14 3610046 1 Seal, Exhaust, Socket

15 7556004 AR Washer

16 5411576 1 Dampener, Vibration, w/Ribs

17 7080811708081270808137080740

7080741

7080742

1121

1

2

Clamp, Worm Drive (.44 x 6.50) (600)Clamp, Worm Drive (.44 x 3.75) (600)Clamp, Worm Drive (.44 x 4.25) (600)Clamp, Worm Drive (.44 x 3.69)(700)(800)Clamp, Worm Drive (.44 x 4.25)(700)(800)Clamp, Worm Drive (.44 x 6.38)(700)(800)

18 1261152

1261151-029524439852443995830207583019812611231261122-0295245929524593058302155830216

1

11111111111

Asm., Tuned Pipe (Incl. 17) (600)

Pipe, Tuned (600)Cover, Tuned Pipe, Top (600)Cover, Tuned Pipe, Bottom (600)Matte, Sound Top (600)Matte, Sound (600)Asm., Tuned Pipe (Incl. 17)(700)(800)Pipe, Tuned (700)(800)Cover, Tuned Pipe, Top (700)(800)Cover, Tuned Pipe, Bottom (700)(800)Matte, Sound Top (700)(800)Matte, Sound Bottom (700)(800)

19 7661637 8 Rivet

3/03


33/66C4

SHOCK (IFS)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

8

4

6

14

10

15

2

11

12

9

7

16

5

3

3

13

1



1 7042147 2 Shock, IFS

2 1700036 2 Bushing

3 1700079 1 Sleeve4 1 700033 1 Nut, Spring Retainer

5 1700072 2 Bushing

6 1700042 1 Bumper, Comp.

7 1700007 1 Asm., Cylinder Head

8 1700057 1 Nut

9 1700056 1 Screw, Valve

10 17000761700047

11

Asm., Pressure ValvePressure Valve O-Ring

11 170002317000321700048

111

IFPIFP, Band, WearIFP, O-Ring

12 1700108170003117000771700078

1111

Banded, PistonPiston, Band, WearWasher, Top-outWasher, Back-up

13 1700194 1 Shaft

14 1700022 1 Seal, Cap

15 1700021 1 Seal, Rod

16 1700010 1 Mount, Upper

2/02


34/66C5

SHOCK (FRONT TRACK)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

11

10

8

12

4

6

13

15

9

2

3

7

5

14

1



1 7042084 1 Shock, Front Track, IFP

2 1700074 2 Bushing

3 1700161 1 Sleeve

4 1 700033 1 Nut, Spring Retainer

5 1700036 2 Bushing

6 1700157 1 Sleeve

7 1700156 1 Asm., Cylinder Head

8 1700057 1 Nut

9 1700056 1 Screw, Valve

10 17000761700047

11

Asm., Pressure ValvePressure Valve O-Ring

11 170002317000321700048

111

IFPIFP, Band, WearIFP, O-Ring

12 1700103

170003117000771700078

1

111

Banded, Piston

Piston, Band, WearWasher, Top-outWasher, Back-up

13 1700051 1 Cylinder, Head O-Ring

14 1700182 1 Shaft


8/01


35/66C6

SHOCK (REAR TRACK)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

11

10

2

3

5

6

12

8

7

9

17

16

15

14

18

13

19

20

4

1



1 7042177 1 Shock, Rear Track


3 1700220 1 Shaft

4 1700162 1 Isolator

5 1700197 2 Clamp, Hose

6 1700198 1 Body, Reservoir

7 1700201 1 Washer, Copper

8 1700200 1 Bolt, Banjo

9 1700202 1 Hose, Pressure

10 1700069 1 Sleeve

11 1700073 2 Bushing

12 1700199 1 Body

13 1700205 1 Asm., Valve Body

14 1700054 1 IFP, Screw, Bleed

15 1700204 1 IFP, O-Ring

16 1700203 1 IFP

17 17001641700217

11

End Cap, Reservoir w/ValveCap, End, Reservoir

18 17002181700065

11

Valve, Pressure w/ScrewMale Adapter

19 17001561700051

11

Asm., Cylinder HeadCylinder, Head O-Ring

20 1700110 1 Banded Piston3/03


36/66C7

ENGINE MOUNTING (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

1 23

4

5 6

7 8

9

1011

12

13

14

15

16

1718

1920

21

2526

27

2829

30

3132

33

13

2120

30

29

30

29

30

2223

24

34


Ref. Part No. Qty. Description Ref. Part No. Qty. Description1 7517501 1 Screw

2 7556003 1 Washer

3 5131872 1 Washer, Clutch Retainer

4 2202256 1 Kit, Short Block NOTE: The ShortBlock assembly contains a crankcaseassembly, cylinder and cylinder headassembly, and a piston and crankshaftassembly. Prior authorizat ion is re-quired for warranty consideration.

5 3070190 2 Spark Plug, RN57YCC, Champion

6 5521398-13 1 Conduit


8 7710427 1 E-Ring9 5811485 1 Foil, Tape

10 5431499-070 1 Handle, Recoil

11 7542451 2 Nut, Nylok


13 52454655246382

11

Strap, Engine Mount, LHStrap, Engine Mount, RH

14 3021290 1 Mount, Engine

15 7512539 4 Screw


17 7547180 1 Nut, Flanged


19 5245044 1 Bracket, Engine Mount, RH



22 1014392 1 Brkt, Pump, Fuel

23 5410012 1 Plug, Rubber

24 7542122 2 Nut, Nylok

25 1013397 1 Bracket, Engine Mount, LH

26 7517854 3 Screw


28 7081128 1 Cable, Throttle

29 8350017-600 AR Line, Fuel

30 7080003 8 Clamp, Hose

31 1253424 1 Asm., Valve, Fuel, Plast ic

32 2520275 1 Pump, Fuel

33 8450040-600 AR Line, Fuel

34 8360052-25 1 Tubing, Convoluted

3/03


37/66C8

ENGINE MOUNTING (700)(800)700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACK STOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK

STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B S04NS8CSB

11

12

5

4

9

12

14

18

26

29

30

32

3

15

27 10

25

27

7 8

23

17

1912

1819

24

1819

28

28

28

6

16

13

31

27

28

13

2021

22



1 7517501 1 Screw

2 7556003 1 Washer3 5131872

513244111

Washer, Clutch Retainer (700)Washer, Clutch Retainer (800)

4 2202512

2202518

1

1

Kit, Short Block, S707003 NOTE: TheShort Block assembly contains acrankcase assembly, cylinder andcylinder head assembly, and a pistonand crankshaft assembly. Priorauthorizat ion is required for warrantyconsideration. (700)Kit, Short Block, S707003 NOTE: TheShort Block assembly contains acrankcase assembly, cylinder andcylinder head assembly, and a pistonand crankshaft assembly. Prior

authorizat ion is required for warrantyconsideration. (800)

5 3070190 2 Spark Plug, RN57YCC, Champion

6 5521398-13 1 Conduit


8 7710427 1 E-Ring

9 5431499-070 1 Handle, Recoil

10 7542451 2 Nut, Nylok


12 5245462

5246381

1

1

Strap, Engine Mount, LH

Strap, Engine Mount, RH13 3021220 2 Mount, Engine

14 7512539 4 Screw


16 7547180 1 Nut, Flanged, Nylon

17 5245044 1 Bracket, Engine Mount, RH



20 1014392 1 Brkt, Pump, Fuel

21 5410012 1 Plug, Rubber

22 7542122 2 Nut, Nylok

23 1013397 1 Bracket, Engine Mount, LH

24 7517854 3 Screw25 3021206 2 Mount, Engine

26 7081083 1 Cable, Throttle

27 8350017-600 AR Line, Fuel

28 7080003 8 Clamp, Hose

29 1253424 1 Asm., Valve, Fuel Plastic

30 2520275 1 Pump, Fuel

31 8360052-15 1 Tubing, Convoluted

32 8450040-600 AR Line, Fuel

3/03


38/66C9

BATTERY BOX600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB and 700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACKSTOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB and 800 SWITCHBACK F/O S04NS8CS and 800 SWITCHBACK STOCK A S04NS8CSA and 800 SWITCHBACK STOCK B

S04NS8CSB

1

2

3

10

4

5

6

8

2021

9

15

12

11

17

19

13

18

7

14

16



1 5810290 3 Pad, Battery

2 2450020 1 Asm., Strap, Battery Hold-Down

3 5432077 AR Tube, Vent

4 4140006 1 Battery

5 4010114 1 Cable, Battery

6 2200361 1 Kit, Battery Bolt, Short

7 4010107 1 Cable, Solenoid/Starter

8 -------------- 1 Switch, Magnetic(See Starting Motor Pg. E7, Ref. 18)

9 5410346 2 Insulator, Cable

10 2460393 1 Asm., Cable, Battery/Solenoid

11 4010108 1 Wire, Jumper, Solenoid/Battery

12 2434008 1 Breaker, Circuit

13 7541925 2 Nut, Nylok

14 7542122 2 Nut, Nylok

15 1013679-067 1 Box, Battery

16 5810129 1 Foil, Tape

17 7621467 1 Rivet

18 1013385 1 Plate, Stud, Battery Box

19 7511930 2 Bolt

20 -------------- 2 Washer, Spring(See Starting Motor Pg. E7, Ref. 17)

21 -- -- -- -- -- -- -- 2 Nut(See Starting Motor Pg. E7, Ref. 16)

3/03


39/66C10

CRANKCASE (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

1

2 3

4

5

67

8

324

99

8

10

11

12

13

14

15

16

17

18

19

2021

22

23



1 7080681 2 Clamp, Hose

2 7051020 2 Valve, Check

3 7080603 2 Clamp

4 8450061-600 AR Line, Oil

5 5132196 4 Stud, Cylinder

6 5132197 4 Stud, Cylinder

7 8360056-25 1 Tubing, Convoluted8 2202312 1 Kit - Crankcase (Incl. 5,6,10-16)

9 5411394 2 Seal, Flanged w/Standoff

10 7051529 2 Plug

11 7517785 2 Bolt

12 7517784 8 Bolt

13 7516825 1 Screw

14 7517786 4 Bolt

15 7517577 1 Screw

16 7663001 2 Pin, Dowel


18 5010390 1 Bearing, Pump Shaft

19 1201825 2 Asm., Reed Valve20 5433151 2 Stuffer, Reed Block

21 1253423 2 Adaptor, Carb

22 7516822 12 Screw

23 7080654 1 Retainer

3/03


40/66C11

CYLINDER (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

1

2

34

5

67

89

10

1112

13

14

1516

17

18

1920

2122 23

24

25

27

28

29

26



1 4010398 1 Sensor, Temperature

2 7517533 12 Screw

3 7517679 1 Screw


5 5631391 1 Cover, Thermostat

6 5411521 1 O-Ring

7 5631425-366 1 Cover, Head

8 5411411 2 O-Ring9 5411465 1 Seal, Rubber Head

10 3021322 1 Head, Cylinder

11 5410932 2 O-Ring

12 5411359 2 O-Ring

13 7547013 8 Nut

14 5133380 2 Valve, Guillotine

15 5812350 2 Gasket, Base to Cyl. Exh. Valve

16 1202216 2 Asm., Base Exh. Valve Dome

17 5132950 2 Washer, Bellows, Exh., Valve, Dome

18 5412147 2 Bellows, Exhaust Valve

19 5631381 2 Cap/Nut, Bellows, Exh., Valve, Dome

20 7041786-03 2 Spring, Comp

21 1202640 2 Asm., EV Housing w/Bushing

22 7516820 4 Screw

23 7517932 4 Screw24 3021333 2 Cylinder

25 5811916 2 Gasket, Cylinder Base

26 7052234 1 Fitting

27 7052258 1 Thermostat, w/o Bypass

28 7517950 1 Screw

29 7516822 1 Screw

3/03


41/66C12

WATER PUMP/OIL PUMP (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

12

3 4

56

7

8

9

10

11

12

10

13

1415

1816

17

1716



1 5411197 1 Seal

2 3610067 1 Seal, Waterpump


4 5432330 1 Impeller, Water Pump


6 7546804 1 Nut, Nylok

7 5811601 1 Gasket, Water Pump Cover

8 5630920 1 Cover, Water Pump, Hi Flow

9 7516822 9 Screw


11 5131855 1 Driveshaft, Water/Oi l Pump

12 5411196 1 O-Ring

13 5010391 1 Bearing, Pump Shaft, Flanged

14 5811789 1 Gasket, Oil Pump

15 2540105 1 Asm., Pump, Oil

16 8450061--600 AR Line--Oil

17 7080603 4 Clamp

18 7517277 2 Screw

3/03


42/66C13

CARBURETOR (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

1

2 234

5

6

7

8910

11

12

13

14

1516

17

8 910

76

1819

20 21

22

23

24

2526

272829

3031

32

33

3435 36

37

38

39

4041

424243 44 45

46

47

48

49

50



1 1253505 1 Asm., Carburetor

2 3130951 4 Screw

3 3130872 2 Cap, Top

4 3130871 2 Gasket

5 3130844 2 Screw

6 3130846 4 Washer, Packing

7 3130856 4 Clip8 3130845 8 Ring

9 3130857 4 Plate

10 3130847 4 E-Ring

11 3130831 2 Cap, Rubber, Starter

12 3130830 2 Holder, Guide, Starter

13 3130829 2 Spring, Starter

14 3130828 2 Asm., Plunger

15 3130940 2 Valve, Piston (1.5)

16 3131377 2 Needle, Jet (9DGI01-60)

17 3130867 2 Packing

18 3130868 2 E-Ring

19 3130843 2 Plate

20 31308553130849

11

Asm., Lever, LHAsm., Lever, RH

21 3130848 1 Ring

22 3130854 1 Screw, LH

23 3130850 1 Screw, RH

24 3130825 8 Screw, Air Funnel

25 3131335 2 Asm., Funnel

26 3131356 2 O-Ring, Air Funnel, Long

27 3130808 1 Pin

28 3131371 1 Spring

29 3130142 2 Jet, Main (420)

30 3131372 1 Washer

31 3130522 1 O--Ring

32 3131336 2 Screw, Air33 3130859 2 Asm., Float

34 3131248 2 Bolt, Drain

35 3130863 2 O-Ring, Drain Screw

36 3130824 2 Screw, Float Bowl

37 3130858 2 Body, Float

38 3130861 2 O-Ring, Float Bowl

39 3130860 2 Screw, Valve Seat

40 3130069 2 Jet, Pilot (50)

41 3130768 2 Jet, Starter (140)

42 3130837 4 Washer

43 3130836 2 Spring

44 3130987 2 Adjuster

45 3130986 1 Cap

46 3131010 2 Screw (MAG Side)

47 3131009 1 Asm., Sensor, Throttle Position (MAGSide)

48 3130479 2 Cap

49 3130835 2 Packing

50 7051020 2 Valve, Check, 90 Degree

3/03


43/66C14

CARBURETOR (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

1

1

2

3

4

5

6

7

8

91011

12 1314

1516

1718

1819

203

2

18

2122

23

24

25

21

26

25

27



1 3130834 2 Bolt

2 3130832 2 Lever, Starter

3 3130833 3 Screw, Starter

4 3140032 1 Ring

5 3130817 1 Spring

6 3130816 1 Screw

7 3131285 1 Adjuster8 3131284 1 Spring

9 3131380 1 Bracket

10 3130810 1 Screw

11 3130809 1 Screw

12 3130950 1 Spring

13 3130853 1 Ring

14 3131370 1 Asm., Shaft

15 3130821 2 Screw

16 3130820 1 Bracket

17 3131137 2 Hose, Vent

18 3130842 3 Packing, Starter Shaft

19 3130841 1 Spring, Starter Shaft

20 3130840 1 Shaft

21 3130852 2 Ring22 3130839 1 E-Ring

23 3130819 1 Lever, Starter

24 3131374 1 Asm., Nipple

25 7080003 4 Clamp, Hose

26 8350017-600 AR Line, Fuel

27 5431893 2 Plug, Trap

3/03


44/66D1

PISTON and CRANKSHAFT (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

1

2

3

2

45

4

6

7

8

9

10

11

12

13

7

9



1 2201256 2 Kit - Piston Rings

2 3022950 4 Circlip, Piston

3 2202258 2 Kit - Piston (Incl. 1,2,13)

4 3514365 2 Bearing

5 2201132 1 Kit - Asm., Connecting Rod




9 5411394 2 Seal, Flanged, w/Standoff

10 5131373 1 Gear, Pump Drive

11 2202257 1 Kit - Crankshaft (Incl. 6-10)

12 7721117 1 Key, Woodruff

13 -------------- 2 Pin, Piston

3/03


45/66D2

MAGNETO (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

1

23

4

5

6

789

10

1112

13

14



1 7517278 6 Screw

2 3040161 1 Pul ley, Starting, Recoil

3 7546909 1 Nut, Hex

4 7555907 1 Washer

5 4010677 1 Flywheel, Ignition

6 4060222 1 Stator, Ignition


8 7555969 3 Washer, Lock

9 7517314 3 Screw

10 2202528 1 Kit - CDI (Incl. Nyogel and Decal)

11 4010811 1 Harness, Ignition

12 4060229 1 Coil, Ignition

13 4010124-305 2 Wire, Ignition

14 4020159 2 Cap, Spark Plug

3/03


46/66D3

RECOIL STARTER (600)600 SWITCHBACK F/O S04NS6ES and 600 SWITCHBACK STOCK A S04NS6ESA and 600 SWITCHBACK STOCK B S04NS6ESB

2

8

11

12

1

3

4

5 6

7

9

10



1 1202298 1 Asm., Recoil Electric Reverse (Incl.2-8,11,12)

2 3040163 1 Nut, Fastening

3 3040164 1 Plate, Friction

4 3040167 1 Spring, Friction5 5246108 1 Ratchet, Pawl Electric Reverse

6 3040166 1 Spring, Return

7 3040168 1 Reel

8 3040170 1 Spring, Spiral

9 3040171 1 Bushing, Rope Slide, Recoil

10 7516827 6 Screw

11 5630645 1 Housing, Recoil, Starter

12 3040169 1 Rope, Starter

3/03


47/66D4

CRANKCASE (700)700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACK STOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB

1

5

21

2019

6

3

7

8

9

11

10

12

16

14

15

5

19

2

13

18

4

17

32



1 5131677 8 Stud, Cylinder, Flange

2 8450061-600 AR Line, Fuel

3 7080603 2 Clamp

4 7051020 1 Valve, Check

5 2202233 1 Kit - Crankcase (Incl. 1,5,14,15,18)

6 5411125 2 O-Ring

7 5630610 1 Manifold, Water ,Inlet

8 5243431 2 Retainer, Inlet Water, Manifold

9 7516736 2 Screw

10 8450068-04 1 Hose

11 7080560 2 Clamp, Hose

12 5411394 1 Seal, Flanged w/Standoff

13 7051529 2 Plug

14 7516919 2 Screw

15 7516732 4 Screw



18 7663001 2 Pin, Dowel


20 7052160 1 Valve, Check, Oil Pump

21 7517319 1 Screw

3/02


48/66D5

CYLINDER (700)700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACK STOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB

1213

14

167

19

15

9

21

11

1

3235

20

33

5

3

4

6

2

18

17

10

8

36

37

38

22

2324

25

2627

28

29

30 31

31 30

2928

27

2625

2423

22

38

3940

34



1 7080681 2 Clamp, Hose

2 7517398 12 Screw

3 7080683 3 Clamp, Hose

4 1253327 2 Adapter, Carb

5 5433151 2 Stuffer, Reed Block

6 1201825 2 Asm., Reed Valve

7 5411521 1 O-Ring

8 7052258 1 Thermostat w/o Bypass

9 5631391 1 Cover, Thermostat

10 7517950 1 Screw


12 7517679 1 Screw, Bleed

13 7517534 12 Screw14 7516822 1 Screw

15 4010398 1 Sensor, Temperature

16 5631426-366 1 Cover, Head

17 5411294 1 Seal, Rubber, Head

18 5410917 2 O-Ring

19 3021424 1 Head, Cylinder

20 5412232 2 O-Ring

21 5410932 2 O-Ring

22 5133743 2 Valve, Guillotine

23 5812350 2 Gasket, Base to Cyl. Exh. Valve

24 1202216 2 Asm., Base Exh. Valve Dome

25 5132950 2 Washer, Bellows, Exh., Valve, Dome

26 5412399 2 Bellows, Exhaust Valve

27 5631381 2 Cap/Nut Bellows, Exh., Valve, Dome

28 7041786-08 2 Spring, Comp

29 1202640 2 Asm., EV Housing w/Bushing

30 7516820 4 Screw

31 7517932 4 Screw

32 3021367 2 Cylinder

33 5812362 2 Gasket, Cylinder Base

34 24103697517262 11 Sensor, DetonationScrew

35 7547013 8 Nut

36 5521398-96 AR Conduit

37 5411536 1 Hose, Bypass

38 7081030 2 Clamp, Bypass

39 7052234 1 Fitting

40 7080654 1 Retainer

3/03


49/66D6

WATER PUMP/OIL PUMP (700)700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACK STOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB

1

10

2

3

67

8 9

11

12

14

4

5

13

19

20

18

17

15

16



1 3021044 1 Pulley, Waterpump, Driven


3 5132273 1 Shaft, Waterpump

4 -------------- 1 Housing, Ignition(See Magneto, (700) Pg. D10, Ref. 13)

5 3610044 1 Seal

6 3610067 1 Seal, Waterpump


8 5432330 1 Impeller, Waterpump


10 7546804 1 Nut, Nylok

11 5811627 1 Gasket, Waterpump Cover

12 5631280 1 Cover, Waterpump


14 7516822 5 Screw15 -------------- 1 Housing, Ignition

(See Magneto, (700) Pg. D10, Ref. 13)

16 7516823 6 Screw

17 8450061-82 AR Line, Fuel

18 7080603 4 Clamp

19 2540102 1 Asm., Pump, Oil

20 7516607 2 Screw

3/03


50/66D7

PISTON and CRANKSHAFT (700)700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACK STOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB

1

2

3

4

5

9

7

8

11

12

1

9

5

6

13

109



1 3022950 4 Circlip, Piston

2 -------------- 2 Pin, Piston

3 2200895 2 K it - Piston Rings

4 2202237 2 Kit - Asm., Piston (Incl. 1,2,3)5 3584001 2 Bearing

6 2201953 2 K it - Connecting Rod(Incl. Rod, Pin, Bearing, Washers)

7 7721117 1 Key, Woodruff

8 7555905 1 Bushing


10 3514318 1 Bearing, Ball11 5131899 1 Spacer, Crankshaft


13 2201848 1 Kit - Crankshaft (Incl. 8-12)

3/02


51/66D8

CARBURETOR (700)700 SWITCHBACK F/O S04NS7CS and 700 SWITCHBACK STOCK A S04NS7CSA and 700 SWITCHBACK STOCK B S04NS7CSB

10

21

23

23

4

26

251718

1615

39

4027

3433

22

37

32

36

9

7

206

8

5

19

47

10

69

8

7

11

12

13

43

41 42

48

14

2004 switchback

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