Polaris victory kingpin_parts_manual_2004

E 2003 Polaris Sales Inc.

PARTS MANUAL PN 9918956 and MICROFICHE PN 9918957 9/03

KINGPINt

Model #V04CB16CA/CB/CC/CD/CF/CK/CL/CMModel #V04CB16DA/DB/DC/DD/DF/DK/DL/DMModel #V04CB16LA/LB/LC/LD/LF/LK/LL/LMModel #V04CB16UA/UB/UC/UD/UF/UK/UL/UM

TABLE OF CONTENTSKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN

V04CB16CL and KINGPIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DFand KINGPIN V04CB16DK and KINGPIN V04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPINV04CB16LD and KINGPIN V04CB16LF and KINGPIN V04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB

and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN V04CB16UF and KINGPIN V04CB16UK and KINGPIN V04CB16UL and KINGPIN V04CB16UM

AAIR BOX B12. . . . . . . . . . . . . . . . . . . . . . . .

BBATTERY BOX C1. . . . . . . . . . . . . . . . . . . .BRAKE A7. . . . . . . . . . . . . . . . . . . . . . . . .BRAKE, FRONT B10. . . . . . . . . . . . . . . . . . .BRAKE, REAR B11. . . . . . . . . . . . . . . . . . . .

CCAM and VALVE COVERS D3. . . . . . . . . . .CAMCHAIN and TENSIONER D2. . . . . . . . .CLUTCH LEVER ASM. B14. . . . . . . . . . . . . .CRANKCASE C12. . . . . . . . . . . . . . . . . . . . .CRANKCASE BEARINGS C13. . . . . . . . . . . .CRANKSHAFT C11. . . . . . . . . . . . . . . . . . . .CYLINDER and HEAD C14. . . . . . . . . . . . . . .

DDECALS C3. . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH D10. . . . . . . . . . . . . . . . . . .

EECM/BATTERY BOX C1. . . . . . . . . . . . . . . .ELECTRICAL C5. . . . . . . . . . . . . . . . . . . . .ENGINE MOUNTING C10. . . . . . . . . . . . . . . .EVAP SYSTEM D12. . . . . . . . . . . . . . . . . . . .EXHAUST SYSTEM C8. . . . . . . . . . . . . . . .

FFENDER, FRONT A12. . . . . . . . . . . . . . . . .FENDER, REAR B8. . . . . . . . . . . . . . . . . .FLOORBOARD, LH A6. . . . . . . . . . . . . . . . .FLOORBOARD, PASSENGER A5. . . . . . . .FLOORBOARD, RH A7. . . . . . . . . . . . . . . .FOOTPEG, LH A6. . . . . . . . . . . . . . . . . . . .FOOTPEG, RH A7. . . . . . . . . . . . . . . . . . . .FOOTPEGS, PASSENGER A5. . . . . . . . . . .FRAME, MAIN A3. . . . . . . . . . . . . . . . . . . .FRONT FORKS and CLAMP ASM. A10. . . . . .FUEL SYSTEM A11. . . . . . . . . . . . . . . . . . . .FUSE BOX MOUNT C2. . . . . . . . . . . . . . . .

HHANDLE BAR A8. . . . . . . . . . . . . . . . . . . . .HANDLEBAR MOUNTING A9. . . . . . . . . . . .

HHEADLIGHT B6. . . . . . . . . . . . . . . . . . . . . .

IIGNITION ASM. C6. . . . . . . . . . . . . . . . . . .

OOIL COOLING C7. . . . . . . . . . . . . . . . . . . .OIL PUMP D5. . . . . . . . . . . . . . . . . . . . . . .OIL PUMP MOUNTING D4. . . . . . . . . . . . . .OWNER’S MANUAL D13. . . . . . . . . . . . . . . .

PPRIMARY COVER D7. . . . . . . . . . . . . . . . .PRIMARY DRIVE D6. . . . . . . . . . . . . . . . . .

SSADDLEBAG ASM. B9. . . . . . . . . . . . . . . . .SEAT AND BACKREST C4. . . . . . . . . . . . . .SHIFTER A6. . . . . . . . . . . . . . . . . . . . . . . .SHIFT FORKS/DRUM D8. . . . . . . . . . . . . . .SHOCK, REAR B13. . . . . . . . . . . . . . . . . . .SIDE COVER, LH C1. . . . . . . . . . . . . . . . . .SIDE COVER, RH C2. . . . . . . . . . . . . . . . . .SPEEDOMETER B5. . . . . . . . . . . . . . . . . . .SPROCKET, DRIVE, FRONT C9. . . . . . . . . .STARTER MOTOR D11. . . . . . . . . . . . . . . . .SUSPENSION, REAR A4. . . . . . . . . . . . . . .SWING ARM A4. . . . . . . . . . . . . . . . . . . . .

TTAILLIGHT B8. . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION D9. . . . . . . . . . . . . . . . . . .TURN SIGNALS A12. . . . . . . . . . . . . . . . . . .

VVALVE TRAIN D1. . . . . . . . . . . . . . . . . . . . .

WWHEEL, FRONT (BILLET) A14. . . . . . . . . . . .WHEEL, FRONT (CAST) B1. . . . . . . . . . . . .WHEEL, FRONT (SPOKED) A13. . . . . . . . . .WHEEL, REAR (BILLET) B3. . . . . . . . . . . . .WHEEL, REAR (CAST) B4. . . . . . . . . . . . . .WHEEL, REAR (SPOKED) B2. . . . . . . . . . .WINDSHIELD B7. . . . . . . . . . . . . . . . . . . . .

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

A3

MAIN FRAMEKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN

V04CB16UF and KINGPIN V04CB16UK and KINGPIN V04CB16UL and KINGPIN V04CB16UM

8

4

9

1

6

5

3

2

7

10

E 2003 Polaris Sales Inc.Kingpin is a Trademarkof Polaris Industries

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 1014399-0671014399-385

11

Frame, Main, BlackFrame, Main, Silver

2 7517404 1 Screw3 7547039 1 Nut4 7042047 1 Spring, Side Stand5 1013062 1 Stand, Side (Incl. 2,3,6-8)6 5411745 1 Pad, Side Stand

7 7556121 2 Washer, Flat8 7661064 2 Rivet9 1014401-067

1014401-38511

Cradle, LH, BlackCradle, LH, Silver

10 1013888-0671013888-385

11

Cradle, RH, BlackCradle, RH, Silver

9/03

A4

SWING ARM and REAR SUSPENSIONKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


4 53

26

11

7

10

8

9

14

1922

13

21

23 24

25

26

28

3231

29

1816

17

22

22

25

23

19

19

1

13

5

30

2012

12

21


15

26

27

Kingpin is a Trademarkof Polaris Industries



1 5434637 2 Cap2 7547048 1 Nut, FLEXLOC3 7556236 2 Washer, Flat4 5133475 1 Bushing5 3610096 2 Seal6 3514413 1 Bearing7 1014408-156

1014408-38511

Asm., Swing Arm w/Bearings, ChromeAsm., Swing Arm w/Bearings, Silver

8 7670149 1 Ring, Retaining9 1013916 1 Shaft, Swing Arm Pivot10 3514414 2 Bearing, Ball11 5631478 1 Bushing12 3610095 4 Seal13 3514411 2 Bearing, Needle14 5134101 1 Bushing15 7710544 1 Ring, Retaining16 7518206 1 Screw

17 7556155 1 Washer, Flat18 ------ -- -- -- -- 1 Asm., Shock

(See Rear Shock Pg. B13 for Details)19 7547268 4 Nut, Nylok20 5133473 1 Bushing, Suspension, Short21 7517946 3 Screw22 7556260 4 Washer, Flat23 5247519 2 Link, Suspension Strap24 5134080-067 1 Link, Suspension Pivot25 3514459 2 Bearing26 5134096 2 Bushing, Suspension, Plain Bearing27 3514412 1 Bearing, Needle28 7518202 2 Screw29 7518032 2 Screw30 7663008 2 Dowel31 5134079-067 1 Mount, Minor Pivot32 7517827 2 Screw

6/03

A5

PASSENGER FOOTPEGS/FLOORBOARDSKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


12

10

45

6

9 8

7

4

5

6

10

54

2

19

8

3


17

12

11

1316

15

14

8

11

17

13 16

12

8Kingpin is a Trademarkof Polaris Industries



1 51335405133526

11

Footpeg, Clear, LHFootpeg, Clear, RH

2 5412261 2 Pad, Footpeg, Rear3 7518149 1 Screw4 7518142 4 Screw5 7556245 5 Washer, Flat6 1014126-385

1014127-38511

Mount, Footpeg, Passenger, Silver, LHMount, Footpeg, Passenger, Silver, RH

7 5246787 1 Bracket, Exhaust, Upper8 7710545 2 Ring, Retaining9 7661168 2 Pin, Pivot

10 7556274 2 Washer, Footpeg, Pivot11 5412450 2 Pad, Passenger Floorboard12 5134049-425 1 Floorboard, Passenger, Bur13 7661172 2 Pin, Pivot14 7042255 2 Spring, Compression15 5133944 2 Ball, Floorboard, Detent16 5247353 2 Plate, Floorboard, Detent17 1014283-067

1014284-0671014283-3851014284-385

1111

Floorboard, Passenger, Black, LHFloorboard, Passenger, Black, RHFloorboard, Passenger, Silver, LHFloorboard, Passenger, Silver, RH

9/03

A6

L.H. FOOTPEG/FLOORBOARD/SHIFTERKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


13

12

1817

21

2221

4

1920

5

6 7

15

9

1816 17

14

13

1516

1211

8

3

10


25

27 2624

Floorboard

Footpeg

20

67

54

119

21

23 28




1 77104997710508

11

Ring, Retaining, External (Footpeg)Ring, Retaining, External (Floorboard)

2 7556075 1 Washer, Flat3 3514335 1 Bearing, Shift Pedal4 7547230 1 Nut5 1013957

101424611

Asm., Shifter Linkage (Footpeg)Asm., Shifter Linkage (Floorboard)

6 5133530 1 Lever, Shifter7 7518141 2 Screw8 7556273 1 Washer, Wave9 7661167 1 Pin, Pivot10 7710545 1 Ring, Retaining11 7556241 1 Washer, Flat12 5412256

541245611

Pad, FootpegPad, Floorboard, Driver

13 51335405134061-425

11

Footpeg, CC, LHFloorboard, Driver

14 5133539 1 Feeler, Footpeg15 7518101 1 Screw

16 7556234 2 Washer, Flat17 7518146 1 Screw18 5133527-385

5133527-0675133863-3855133863-067

1111

Support, Footpeg, Silver, LHSupport, Footpeg, Black, LHSupport, Floorboard, Silver, LHSupport, Floorboard, Black, LH

19 75181477518329

11

Screw (Footpeg)Screw (Floorboard)

20 54113645412493

12

Pad, Shift Pedal (Footpeg)Pad, Shifter (Floorboard)

21 5133528-3855133528-1565134179-410

111

Pedal, Shift Lever, Silver (Footpeg)Pedal, Shift Lever, Chrome (Footpeg)Pedal, Shifter Lever (Floorboard)

22 7547039 1 Nut23 1014589 1 Shaft, Shift Lever24 7556322 1 Washer, Wave25 7661095 1 Pin, Floorboard Support26 7041623 1 Spring, Support, Floorboard27 7661094 1 Pin, Cotter28 3514470 2 Bushing, Shift, Rear

9/03

A7

R.H. FOOTPEG/FLOORBOARD/BRAKEKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN



Footpeg

10

98

67

16

2 34

1113141215

1

1

5

2524

11

17

18

19

20

27

15

26

13 21

122223




1 7547039 2 Nut2 7710499 2 Ring, Retaining, External3 7556075 2 Washer, Flat4 3514335 2 Bearing, Shift Pedal5 5133525-385

5133525-15611

Pedal, Brake Lever, SilverPedal, Brake Lever, Chrome

6 7661167 1 Pin, Pivot7 7710545 2 Ring, Retaining8 7556241 2 Washer, Flat9 5412256 2 Pad, Footpeg10 5133526 1 Footpeg, CC, RH11 5133539 1 Feeler, Footpeg12 7518146 1 Screw13 7518101 1 Screw14 7556234 2 Washer, Flat

15 5133529-3855133864-385

11

Support, Footpeg, Silver, RHSupport, Floorboard, RH

16 7556273 2 Washer, Wave17 5412256 1 Pad, Footpeg18 5134178-410 1 Pedal, Brake Lever19 7517715 1 Screw, Brake Pivot20 5020904 2 Bushing, Pedal21 7517410 2 Screw22 7661094 1 Pin, Cotter23 7661095 1 Pin, Floorboard Support24 5134061-425 1 Floorboard, Driver, Bur25 5412456 1 Pad, Floorboard26 5134199-385 1 Support, Brake Pedal27 7041623 1 Spring, Floorboard Support

9/03

A8

HANDLEBARKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


2220

21 17

13

7

65

1114

2

19 18

8

12

16

LH RH

9

43

10

3

9

16

1515


11




2010224 1 Asm., Throttle Cable (Incl. 10,11,14)1 5432692

543271511

Cap, Handlebar End, LHCap, Handlebar End, RH

2 5411256 1 Grip, Handlebar, LH3 2632829

263283011

Mirror, LHMirror, RH

4 ------ -- -- -- -- 1 Asm., Clutch Lever (See Clutch LeverAsm. Pg. B14 for Details)

5 53341245334359

11

HandlebarHandlebar, Pull Back

6 ------ -- -- -- -- 1 Asm., Master Cylinder, Front Brake(See Front Brake Pg. B10, Ref. 3)

7 40107734010699

11

Switch, Hand Control, Chrome, RHSwitch, Hand Control, Silver, RH

8 5411255 1 Grip, Throttle, Handlebar9 7517366 4 Screw

10 7081131 1 Cable, Throttle, Pull11 7081130 1 Cable, Throttle, Push12 7517420 1 Screw13 5242448 1 Retainer, Throttle Cable14 5433039 2 Clip, Throttle Cable15 5521655 2 Shrink, Heat16 5433140 2 Dart, Handlebar17 7081115 2 Strap, Retainer18 7517272 2 Screw19 5246529 1 Bracket, Clutch Cable20 5433071 1 Bushing, Clutch Cable, Upper21 7080716 1 Cable, Fast Idle22 4010933

401077511

Switch, Hand Control, Chrome, LHSwitch, Hand Control, Silver, LH

6/03

A9

HANDLEBAR MOUNTINGKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

2

3

4

5

67

89

6




1 5133512-4115133512-156

22

Riser, CapRiser, Cap, Chrome

2 7518143 2 Screw3 7518142 2 Screw4 1821325-411

1821325-15622

Asm., Riser, Handlebar (Incl. 5)Asm., Riser, Handlebar, Chrome (Incl. 5)

5 7518082 2 Stud6 5412272 4 Isolator, Handlebar7 5134129 2 Sleeve, Isolator, Handlebar8 7556260 2 Washer, Flat9 7547268 2 Nut, Nylok

6/03

A10

FRONT FORKS and CLAMP ASM.KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


2

3

4 5

10

8

9

6

11

137

12

15

14

16

18

17


1

1


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 7517361 10 Screw2 2202686 2 Kit, Bearing Seal3 5412473 1 Cap, Steering Stem4 1821378-411 1 Asm., Bracket, Lower5 3514416 1 Bearing, Needle6 3514417 2 Bearing, Needle7 5134094 2 Nut, Steering Head8 2410330

2461094401076054352095435210

11611

Asm., Indicator LightsHarness, Indicator LightsBulb, Wedge BaseHousing, Indicator Light (Oil,Turn,Fuel)Housing, Indicator Light (Neut.,Hi,Eng.)

9 1821379-411 1 Asm., Bracket, Upper10 7556246 1 Washer11 5134148 1 Nut, Top, Triple Clamp12 5132481-156 2 Cap

13 22027035412560

22

Kit, Cap, Fork Tube (Incl. O-Ring)O-Ring

14 7042330 2 Spring, Fork15 5134364 2 Spacer16 5134362 1 Tube, Outer17 2202684

2202685------ -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- ---- -- -- -- -- -- --

211111111

Kit, Cartridge Asm.Kit, Cartridge HardwareCartridgeRetainer, SpringNut, JamGuide, SpringBoltWasherClip, Retaining

18 2202682-4112202682-1562202683-4112202683-156

1111

Kit, Inner Tube, LH (Alum)(Incl. 1)Kit, Inner Tube, LH (Chrome)(Incl. 1)Kit, Inner Tube, RH (Alum)(Incl. 1)Kit, Inner Tube, RH (Chrome)(Incl. 1)

9/03

A11

FUEL SYSTEMKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


11

21

86

2219

426

25

10

2317

16

14

20

1312

7

3

28

1

9

2

5

15

3

4

5

24

33

30

3132

34

35

36

37

38


27

1818

39

29




1 7518086 3 Screw2 1014108-266

------ -- -- -- ---341------ -- -- -- ---342------ -- -- -- ---381------ -- -- -- ---1172------ -- -- -- ---1173------ -- -- -- ---1174------ -- -- -- ---1175

11111111

Tank, Fuel, BlackBlueRedPurple ThunderCruiser Black/Bronze MistBronze Mist/Pearl WhiteBlue Tribal FadePurple Thunder/Silver/Tribal

3 7517525 3 Screw4 5134160 3 Bushing5 5412480 6 Bushing, Flange6 5412414

541241511

Cover, Mount, LHCover, Mount, RH

7 5412071 2 O-Ring8 5133613 1 Plug9 7710515 1 Ring, Retaining10 5412096 1 Grommet11 5412095 1 Grommet12 7556193 1 Washer13 7556192 1 Washer14 7547186 1 Nut15 5412093 1 Grommet16 5411869 1 O-Ring17 5412332 1 Hose18 7081151 2 Clamp, Hose

19 2520251 1 Fitting20 7556131 1 Washer21 5412094 1 Grommet22 5434782 1 Line23 5434781 1 Line, Water Vent24 2520322 1 Asm., Fuel Line, Filter25 2520284 1 Pump, Fuel26 7547233 1 U-Nut27 7556260 1 Washer, Flat28 7517845 1 Screw29 ------ -- -- -- -- 1 Asm., Ignition Switch/Fuel Cap

(See Ignition Asm. Pg. C6, Ref. 5)30 1253363

541188611

Asm., Throttle BodyCap, Fitting

31 5412259 2 O-Ring32 1253335 1 Adapter, Throttle Body33 7080894 4 Clamp, Hose34 5411942 1 Hose35 7517405 2 Screw36 1253405

150019824

Injector, FuelO-Ring

37 7670129 2 Clip, Injector Clocking38 2520207 1 Asm., Fuel Rail39 ------ -- -- -- -- 1 Harness, Jumper, Fuel Injector

(See Electrical Pg. C5, Ref. 25)9/03

A12

FRONT FENDER and TURN SIGNALSKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


3 41

6

5

2

12

11

7

13

2


89

7

10




1 7517429 2 Screw2 5134083 4 Sleeve, Turn Signal Mount3 5412453

541245411

Mount, Front, LHMount, Front, RH

4 241040224104034010742

111

Signal, Turn, LHSignal, Turn, RHBulb, Single Filament, 10W

5 7710495 2 Nut6 7517739 2 Screw7 7518142 4 Screw8 7517893 4 Screw

9 52470135247014

11

Guard, Fork, LHGuard, Fork, RH

10 5247015 1 Trim, Fender, Front11 5434552 2 Reflector, Amber12 1013831-266

------ -- -- -- ---341------ -- -- -- ---342------ -- -- -- ---381------ -- -- -- ---1172------ -- -- -- ---1173------ -- -- -- ---1174------ -- -- -- ---1175

11111111

Asm., Fender, Front, BlackBlueRedPurple ThunderCruiser Black/Bronze MistBronze Mist/Pearl WhiteBlue Tribal FadePurple Thunder/Silver/Tribal

13 7547076 4 Nut9/03

A13

FRONT WHEEL (SPOKED)KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


8

4

7

1

11

3

6

15

5

14 10

9

16

7

6

12

2


13




1 5133593 1 Axle, Front2 7517517 4 Screw3 5631479 1 Spacer, Bearing, LH4 5631481 1 Spacer, Bearing, LH5 7517936 1 Screw6 3610094 2 Seal7 3514405 2 Bearing, Ball8 5334135 1 Spacer, Bearing9 7710526 1 Ring, Retaining10 7518297 6 Screw

11 1910623 1 Rotor, Brake12 1520618 AR Weight, Balance13 7079024 Decal, Rim, Laced14 1520614

5133869581246553340215334023

1

112020

Asm., Wheel, Front (Incl. 6,7,8,9, Rim,Hub, Flap, and Spokes)RimFlap, RimSpoke, OuterSpoke, Inner

15 1821320 1 Tube, Tire, Inner16 5412372 1 Tire, Front

9/03

A14

FRONT WHEEL (BILLET)KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

3

45

97

15

6 8

13

14

11

10

12

97

2




1 5133593 1 Axle, Front2 7517517 4 Screw3 5631479 1 Spacer, Bearing, LH4 5631481 1 Spacer, Bearing, LH5 7517936 1 Screw6 5334135 1 Spacer7 3514405 2 Bearing, Ball8 7710526 1 Ring, Retaining

9 3610094 2 Seal10 1910623 1 Rotor, Brake11 7518297 6 Screw12 1520618 AR Weight, Balance13 1520232 1 Valve, Rim14 5412372 1 Tire, Front15 1520617 1 Asm., Wheel, Front (Incl. 6-9,13)

9/03

B1

FRONT WHEEL (CAST)KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN



1

2

3

45

6 7 8

9

10

111213

14

15

9

7




1 5133593 1 Axle, Front2 7517517 4 Screw3 5631479 1 Spacer, Bearing, LH4 5631481 1 Spacer, Bearing, LH5 7517936 1 Screw6 5334135 1 Spacer7 3514405 2 Bearing, Ball8 7710526 1 Ring, Retaining

9 3610094 2 Seal10 1910623 1 Rotor, Brake11 7518297 6 Screw12 1520618 AR Weight, Balance13 1520232 1 Valve, Rim14 5412372 1 Tire, Front15 1520630 1 Asm., Wheel, Front (Incl. 6-9,13)

9/03

B2

REAR WHEEL (SPOKED)KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


11

3

25

8

17

6 9

13

15

16

4

18

10

7

12

1

1920

2

3

1110

14




1 1014470 1 Shaft, Spindle, Wheel, Rear2 7518178 2 Screw3 5133481 2 Mount, Axle Adjustment4 5631480 1 Spacer, RH5 5631479 1 Spacer, Bearing, LH6 7518044 5 Screw7 7556234 5 Washer, Flat8 1341448 1 Asm., Sprocket, 64T9 1520615

51336775812233533402153340235132870

111202040

Asm., Wheel (Incl. 10-14)RimFlap, RimSpoke, OuterSpoke, InnerNipple, Spoke

10 3610094 2 Seal11 3514405 2 Bearing, Ball12 5334138 1 Spacer, Bearing13 7710526 1 Ring, Retaining14 1520618 AR Weight, Balance15 1910623 1 Rotor, Brake16 7518297 6 Screw17 5412373 1 Tire, Rear18 1821398 1 Tube, Tire, Inner19 7547226 1 Nut, Hex, Fujilok20 5245087-236 1 Washer, Indicator, Axle

9/03

B3

REAR WHEEL (BILLET)KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


2

45 6

17

13

7

3

8 9

10

11

1415

16

181920

1

12

54

17

16




1 7518044 5 Screw2 7556234 5 Washer, Flat3 1341448 1 Asm., Sprocket, 64T4 3610094 2 Seal5 3514405 2 Bearing, Ball6 1520616 1 Asm., Wheel, Billet, Rear

(Incl. 4-8,12,13)7 5334138 1 Spacer8 7710526 1 Ring, Retaining9 1910623 1 Rotor, Brake, Floating10 7518297 6 Screw

11 5412373 1 Tire, Rear12 1520618 AR Weight, Balance13 1520232 1 Valve, Rim14 7547226 1 Nut, Hex, Fujilok15 5245087-236 1 Washer, Indicator, Axle16 7518178 2 Screw17 5133481 2 Mount, Axle, Adjustment18 5631479 1 Spacer, Bearing, LH19 5631480 1 Spacer, RH20 1014470 1 Shaft, Spindle

9/03

B4

REAR WHEEL (CAST)KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN



1 2 3

45

6

78 9

10

11

1213

1415

16

17181920

54

16

17




1 7518044 5 Screw2 7556234 5 Washer, Flat3 1341448 1 Asm., Sprocket, 64T4 3610094 2 Seal5 3514405 2 Bearing, Ball6 1520632 1 Asm., Wheel, Cast, Rear

(Incl. 4-8,12,13)7 5334138 1 Spacer8 7710526 1 Ring, Retaining9 1910623 1 Rotor, Brake, Floating10 7518297 6 Screw

11 5412373 1 Tire, Rear12 1520618 AR Weight, Balance13 1520232 1 Valve, Rim14 7547226 1 Nut, Hex, Fujilok15 5245087-236 1 Washer, Indicator, Axle16 7518178 2 Screw17 5133481 2 Mount, Axle, Adjustment18 5631479 1 Spacer, Bearing, LH19 5631480 1 Spacer, RH20 1014470 1 Shaft, Spindle

9/03

B5

SPEEDOMETERKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

23 4

98

5

10

7

3

6




1 328040532804424030050

111

Speedometer (MPH)Speedometer (KPH)Bulb, Dash

2 5246295 1 Bracket, Mount3 1014059-067

1014060-06711

Wire, Loom, LHWire, Loom, RH

4 7518140 2 Screw

5 5246297 1 Cover, Speedometer6 7556239 2 Washer, Cup7 7518141 2 Screw8 5133550 2 Sleeve9 5412201 2 Grommet10 5412199 2 Mount, Isolator

9/03

B6

HEADLIGHTKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


19

16

13

10

12

9

22

15

21

18

14

17

1820

1 3

11

2


6

8

5

7

2

4




1 2410339 1 Housing, HID/Halogen2 4010805 1 Bulb, Halogen, H8 (High Beam)3 4010776 1 Bulb, HID4 7080792 1 Strap, Cable Tie5 7547118 3 Nut6 4010777 1 Ballast, HID7 7621403 2 Rivet8 1014219 1 Mount, HID9 5246268 1 Ring, Headlight, Bezel10 2410348 1 Housing, Dual Halogen11 4010804 1 Bulb, Halogen, H11 (Low Beam)

12 5246396 1 Ring, Headlight Bulb Mount13 1014391 1 Bucket, Headlight14 5412231 1 Grommet15 7518145 1 Screw16 1013850 1 Mount, Headlight17 7547189 1 Nut18 5412273 2 Isolator, Headlight19 5134111 1 Sleeve20 7547268 1 Nut, Nylok21 7547126 1 Nut, Nylok22 7518064 1 Screw

9/03

B7

WINDSHIELDKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN



1

3

8

18217

13

11

12

14

15

5

76

9

4

16

2

5

4

9

13

9

11

10




263283426327132632833

111

Asm., Windshield, LowAsm., Windshield, MedAsm., Windshield, Tall

1 7079671 1 Badge, Windshield Stamp2 7518229 10 Bolt, Carriage3 5246994 1 Bracket, Windshield, Front, Top4 5812464 2 Pad, Windshield5 5133932 10 Spacer, Windshield6 5434963

543474111

Windshield, MidWindshield, Tall

7 5246997 1 Bracket, Windshield, Rear, Top8 7556254 4 Washer ,Flat

9 7547115 2 Nut, Acorn10 1014276 1 Asm., Windshield Clamp11 7517523 2 Screw12 5246998

524699911

Bracket, Windshield, Rear, LHBracket, Windshield, Rear, RH

13 7556291 8 Washer, Flat14 7079506 1 Decal, Warning/Caution/Cleaning15 7547184 4 Nut, Acorn16 1014278

101427911

Asm., Deflector, Lower, LHAsm., Deflector, Lower, RH

17 5246995 1 Bracket, Windshield, Front, LH18 5246996 1 Bracket, Windshield, Front, RH

9/03

B8

REAR FENDER and TAILLIGHTKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


2

3

7

20

23

1

21

22

25

19

11

12

8

18

1617

10

15

5


13

29

26

28

18

24

30

2

27

46

9

14




1 5247016 1 Trim, Fender, Rear2 7517704 5 Screw3 2410286 1 Taillight4 7518308 2 Screw5 5812521 1 Pad, License Plate Mount6 7547106 3 Nut, Nylok7 2670070 1 Reflector, Red8 5247445 1 Bracket, License Plate9 7517494 3 Screw, Buttonhead10 7517406 2 Screw11 5411323 2 Bumper, Grommet12 2410407 1 Light, License Plate13 5812520 1 Spacer, License Plate14 5134403 2 Spacer15 7547115 2 Nut, Acorn16 5247446 1 Bracket, License Plate17 7547264 2 Nut, Acorn18 5433921 2 Reflector, Round, Red19 2632828 1 Asm., Reflector (Incl. 7,18)

20 2461125 1 Harness, Rear21 7080737 3 Clip, Electrical22 1014214-266

------ -- -- -- ---341------ -- -- -- ---342------ -- -- -- ---381------ -- -- -- ---1172------ -- -- -- ---1173------ -- -- -- ---1174------ -- -- -- ---1175

11111111

Asm., Fender, Rear, BlackBlueRedPurple ThunderCruiser Black/Bronze MistBronze Mist/Pearl WhiteBlue Tribal FadePurple Thunder/Silver/Tribal

23 56313195631320

11

Cover, Rail, LHCover, Rail, RH

24 7518084 4 Screw25 5247476-067 1 Bracket, Taillight Shield26 5433140 2 Dart27 7081040 4 Rivet28 2410404

241040511

Signal, Rear, LH (Incl. 30)Signal, Rear, RH (Incl. 30)

29 5247156-067 1 Bracket, Fender, Brace30 7517405 2 Screw

9/03

B9

SADDLEBAG ASM.KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN



1

6

5

2

4

3

3

3

1

7

7




1 7547249 6 U-Nut2 7518143 4 Screw3 7556045 6 Washer, Flat4 7517523 2 Screw

5 1014649 1 Asm., Saddlebag6 1014388-385

1014389-38511

Support, Bag, LHSupport, Bag, RH

7 7517410 6 Screw

9/03

B10

FRONT BRAKEKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


132

4

2

5

5

9

9

6

8

7

10


11




1 5131657 1 Lever, Hand Brake, Front2 2201215 1 Kit, Lever Hardware (Incl. Pin and Nut)3 2010217

2201182

41102422201218

11

11

Asm., Master Cyl., Front Brake, SilverKit, Sight Hardware(Incl. O-Ring, Sight and Clip)Switch, StopKit, Pushrod Hardware(Incl. Pushrod and Boot)

4 2202309 1 Kit, Cap Hardware (Incl. Membrane,Screws, Cap and Diaphragm)

5 1930848 3 Bolt, Banjo

6 19107251910731

11

Hose, Brake, FrontHose, Brake, Front, Pull Back

7 7517990 2 Screw8 1910726

220117322011762202492

1111

Asm., Front Caliper, LHKit, Bleeder Screw, BootKit, Pins, Clips, SpringKit, Front Brake Pads (2 Per)

9 7556028 4 Washer, Banjo, Copper10 7517704 2 Screw11 2202310 1 Kit, Clamp Hardware

(Incl. Clamp and Screws)9/03

B11

REAR BRAKEKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

1913

12

10

9

8

6

2

9

17

15

5

16

7

14 1312

18E 2003 Polaris Sales Inc.

11

3 4

3




1 19106192202491220117322011742201175

11111

Asm., Caliper, RearKit, Brake PadKit, Bleeder Screw, BootKit, Boots, Caliper, RearKit, Pin, Retainer, Spring, Clip

2 19107461910794

11

Asm., Brake Hose, Rear (Footpeg)Asm., Brake, Hose, Rear (Floorboard)

3 7517704 2 Screw4 7080983 1 Clamp5 5433140 1 Dart6 7517405 1 Screw7 7556064 1 Washer, Flat8 1930882 1 Reservoir9 7080904 2 Clamp, Hose10 1910656

191079611

Hose, Reservoir (Footpeg)Hose, Reservoir (Floorboard)

11 7080138 1 Cable Tie12 1930848 2 Bolt13 7556028 4 Washer, Banjo, Copper14 7511841

751739122

Screw (Footpeg)Screw (Floorboard)

15 19106201910762

11

Cylinder, Master, Rear (Footpeg)Cylinder, Master, Rear (Floorboard)

16 70421867042288

11

Spring, Ext., Brake Return (Footpeg)Spring, Ext., Brake Pedal (Floorboard)

17 ------ -- -- -- -- 1 Pedal, Brake Lever (See R.H. Foot-peg/Floorboard/Brake Pg. A7, Ref. 5)

18 7080945708101470811137081114

3333

Clip, Brake Line (Black)Clip, Brake Line (Black)Clip, Brake Line, SilverClip, Brake Line, Silver

19 4010372 1 Switch, Pressure

9/03

B12

AIR BOXKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

2

4

6

257

11

1920

23

8

21

3

12

9

524

2218

10

13

1415

17 16

15


1




1 7517842 7 Screw2 5433466 1 Cover, Airbox3 5811867 1 Seal, Airbox Cover4 7517885 4 Screw, Button Head5 7556121 4 Washer, Flat6 ---- -- -- -- -- -- 1 Sensor, MAP

(See Electrical Pg. C5, Ref. 10)7 5433471 1 Tube, Intake, RH8 5433470 1 Tube, Intake, LH9 5434070 1 Hose, Breather10 7080782 1 Clamp, Breather Hose11 5811908 1 Gasket, Airbox12 1253363 1 Asm., Throttle Body13 5412259 2 O-Ring

14 1253335 1 Adapter, Throttle Body15 7517259 4 Screw16 7080656 2 Clamp, Narrow Band17 7516610 2 Screw18 5432302 1 Clip, Retainer19 5811869 1 Bumper, Rubber20 7080858 1 Filter, Air21 5433469 1 Cover, Air Filter22 7517816 2 Screw23 5811866 1 Seal, Filter, Access Hatch24 1013720 1 Airbox25 ------ -- -- -- -- 1 Sensor, Air Temperature

(See Electrical Pg. C5, Ref. 6)

6/03

B13

REAR SHOCKKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


2

1

1




1541999 1 Asm., Rear Shock, KYB1 2202501 1 Kit, Preload Ring, Retainer2 7042329 1 Spring, Compression

9/03

B14

CLUTCH LEVER ASM.KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


12

7

6

9

4

11

5

8

10

3

1413

21




1322064 1 Asm., Clutch Bracket/Lever, Silver(Incl. 4-7)

1 7710495 1 Nut2 7080998 1 Clamp, Vinyl Coated3 7081120 1 Cable, Clutch4 5133537 1 Pin, Clutch Lever5 5433164 1 Washer, Clutch Lever6 5133535 1 Bracket, Clutch/Mirror

7 5131562 1 Lever, Hand, Clutch, LH8 7517506 2 Screw9 5133536 1 Cap, Clutch/Mirror, Bracket, Silver10 7547092 1 Nut, Nylok11 5243113 1 Clip, Clutch, Micro12 4110257 1 Switch, Clutch13 5433071 1 Bushing, Clutch Cable, Upper14 5433070 2 Clip, Clutch, Fast Idle Cables

4/03

C1

ECM/BATTERY BOX/LH SIDE COVERKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


21

7

20

9

14

15

11

1312

10

8

4

1

6

18

3

7

8

11

22

2

1617

5


11

19

2




1 2461214 1 Cable, Battery, Positive2 5411570 2 Boot, Battery Cable, Red Positive3 2201357 1 Kit, Battery Bolt4 4010466 1 Battery5 7080138 2 Strap (8 Inch)6 2461006 1 Harness, Charging7 7517438 2 Screw8 5433833 3 Grommet, Side Cover9 1014477-067

581029013

Box, BatteryPad, Battery

10 7670141 4 Clip, Plastic11 7710495 4 Nut12 5412322 2 Grommet13 1014071 1 Cover, Battery14 5334217 1 Wrench, Cruiser, Phillips

15 5434595-266------ -- -- -- ---341------ -- -- -- ---342------ -- -- -- ---381------ -- -- -- ---1172------ -- -- -- ---1173------ -- -- -- ---1174------ -- -- -- ---1175

11111111

Cover, Side, LH, BlackBlueRedPurple ThunderCruiser Black/Bronze MistBronze Mist/Pearl WhiteBlue Tribal FadePurple Thunder/Silver/Tribal

16 5412343 1 Boot, Terminal Insulator, Black17 7547091 1 Nut, FLEXLOC18 2461106 1 Cable, Starter19 7547270 2 Nut20 ------ -- -- -- -- 1 Solenoid, Starter

(See Electrical Pg. C5, Ref. 5)21 4010916 1 ECM, Programmed NOTE: Refer to

Victory Diagnostic Software UsersGuide for appropriate calibration in-structions.

22 7080756 1 Clip, Snap-In9/03

C2

FUSE BOX MOUNT/RH SIDE COVERKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


45

9

6

3

7

8

2

1

7

76

3

3




1 7670142 8 Clip, Dart2 5435254 1 Flap, Debris3 7081040 4 Rivet4 2410332 1 Breaker, Circuit5 4010778 1 Boot6 7517704 2 Screw7 5433833 3 Grommet

8 5434596-266------ -- -- -- ---341------ -- -- -- ---342------ -- -- -- ---381------ -- -- -- ---1172------ -- -- -- ---1173------ -- -- -- ---1174------ -- -- -- ---1175

11111111

Cover, Side, RH, BlackBlueRedPurple ThunderCruiser Black/Bronze MistBronze Mist/Pearl WhiteBlue Tribal FadePurple Thunder/Silver/Tribal

9 1014042-067 1 Mount, Fuse Box9/03

C3

DECALSKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


2

1

3




1 7079205 1 Decal, Warning, Operate, Fuel (Bilingual)2 7170334

717033511

Badge, Tank, LHBadge, Tank, RH

3 7079796 1 Decal, Patent Pending (Bilingual)9/03

C4

SEAT AND BACKRESTKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN



12

3 4 5

6

7

8

910

1112

14

13




1 7517782 2 Screw2 7556253 2 Spacer, Backrest3 2683426 1 Asm., Backrest Touring4 2683257

268324011

Asm., Passenger Seat (Non-Touring)Asm., Seat, Touring

5 5412067 2 Bumper, Rubber6 2683237 1 Asm., Drivers Seat7 7517753 2 Screw

8 2683260 1 Strap, Hold Down9 7661834 8 Rivet10 7518043 4 Screw11 5247432-329 1 Bracket, Pillion Support12 7517886 4 Screw13 7518270 2 Screw14 1014264 1 Backrest, Touring

9/03

C5

ELECTRICALKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1 2 6

8

9

10

12

75

16

1618

3

24

23

21

4

14

13

13

11 25

2017 19

15


22




1 4110235 1 Switch, Neutral Indicator2 4010649 1 Switch, Oil Pressure3 2410358 4 Diode4 2410338 1 Relay, Flasher5 4010947 1 Solenoid, Starter6 4040077 1 Sensor, Air Temperature7 4010225

150020111

Sensor, Throttle PositionO-Ring

8 41102177517272

11

Sensor, Crankshaft PositionScrew

9 4040076 1 Sensor, Engine Temperature10 4040078 1 Sensor, MAP11 7518141 1 Screw12 4010766 1 Sensor, Vehicle Speed13 7517272 3 Screw

14 7518140 1 Screw15 2461180 1 Harness, Main Wire16 4010948 4 Relay, Micro17 2410280 5 Fuse, 15 Amp.18 2434016 1 Fuse, 10 Amp.19 7170962 1 Decal, Fuse Box20 7171031 1 Decal, Fuse Box Removal21 2410337

241042111

Regulator, Voltage (Black)Regulator, Voltage, Silver

22 7080492 1 Cable Tie23 7517739 2 Screw24 1013510

101449211

Bracket, Voltage Regulator (Black)Bracket, Voltage Regulator, Silver

25 2461135 1 Harness, Jumper, Fuel Injector

6/03

C6

IGNITION ASM.KINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


3

2

8

9

1

7

4

10

11

6

7

7

5

12E 2003 Polaris Sales Inc.

11




1 7081033 2 Cable Tie2 5132791 1 Spacer3 2410266

4010530

1

1

Asm., Ignition Coil(Incl. Coil and Spark Plug Wires)Coil, Ignition

4 7517973 1 Screw5 4010685 1 Asm., Ignition Switch/Fuel Cap

NOTE: Fuel Cap also shown on FuelSystem Pg. A11, Ref. 29)

6 4110239 1 Key, Blank7 7517704 4 Screw8 5245658-067

5245658-38511

Bracket, Ignition, BlackBracket, Ignition, Silver

9 5245659 1 Cover, Ignition/Coil10 7670136 3 Clip, Tinnerman11 7080756 4 Clip, Snap In12 4010531 2 Lead, Spark Plug Wire

9/03

C7

OIL COOLINGKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


9

3

5

611

1

2

4

10

12

137 8

14

15

1920

21

1716

18

13

18

16 17

1617




1 7170617 1 Badge, Oil Line Cover2 5245659 1 Cover, Ignition/Coil3 5412364 3 Isolator, Cover Mount4 5334192 1 Line, Inlet5 7080906 1 Cable Tie6 5412188 1 Mount, Rubber7 7547115 1 Nut, Acorn8 7517384 1 Screw9 1013984 1 Plate, Nut10 1240142-385

1240142-06711

Bracket, Oil Cooler, SilverBracket, Oil Cooler, Black

11 7517839 2 Screw

12 1240145-3851240145-067

11

Cooler, Oil, SilverCooler, Oil, Black

13 5412105 2 Isolator, Cooler14 5412027 1 O-Ring15 5334191 1 Line, Outlet16 7556113 4 Washer, Flat17 5411356 4 O-Ring18 7517405 3 Screw19 7547076 1 Nut20 4010739 1 Horn, Disk21 5133647 1 Spacer, Horn

9/03

C8

EXHAUST SYSTEMKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


12

1

13

3

5

2

11

84

7

6

109

7

3

6 7

6

10

8

2

2

3




1 12612911261293

11

Asm., Muffler, Rear, 49 StatesAsm., Muffler, RH, California

2 7517523 5 Screw3 7556245 5 Washer, Flat4 1014127-385 1 Footpeg, Passenger, Silver, RH5 5246787-236 1 Bracket, Exhaust, Upper6 5811770 3 Gasket, Exhaust7 7081028 3 Clamp, Muffler8 7546805 4 Nut

9 1261261126108712612607081156

1112

Asm., Manifold w/Heat ShieldManifold, Exhaust, RearShield, Heat, U-TubeClamp, Heat Shield

10 5246008 2 Gasket, Exhaust Sealing11 1261089 1 Asm., Header Pipe12 ------ -- -- -- -- 1 Cradle, RH

(See Main Frame Pg.A3, Ref. 10)13 1261290

126129211

Asm., Muffler Front, 49 StatesAsm., Muffler, LH, California

9/03

C9

FRONT DRIVE SPROCKETKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1312

1415

1617

2

1

19

11

6

9

5

10

8

4

4

7

3

18

5

18

3




1 3211088 1 Belt, Drive2 5246487 1 Guard, Belt, Upper3 5412265 3 Grommet4 5134082 3 Sleeve5 7518141 3 Screw6 7517301 3 Screw7 7661156 3 Spacer8 5412070 3 Isolator9 5133266 1 Cover, Sprocket10 5412260 1 Gasket, Sprocket Cover

11 7517272 2 Screw12 5244114 1 Washer, Lock, Plate13 7547209 1 Nut14 5133262 1 Sprocket, Drive, 30T15 3610057 1 Seal16 5133394 1 Sleeve, Seal17 3610091 1 O-Ring18 7517704 2 Screw19 1013965-067 1 Guard, Belt, Lower

6/03

C10

ENGINE MOUNTINGKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


4

1

6

8

2

7 6

24

5

5 5


3

10

9

9

9

9

11




1 7517365 4 Screw2 7518053 8 Screw3 7556305 4 Washer, Flat4 7518125 2 Screw5 7556287 4 Washer, Flat6 7547232 2 Nut7 5133599-236

5133599-40822

Mount, Engine, Front, SilverMount, Engine, Front, Black

8 5246366-2365246366-408

22

Bracket, Engine Mount, Rear, SilverBracket, Engine Mount, Rear, Black

9 7518099 4 Screw10 5133693 1 Dowel11 ------ -- -- -- -- 1 Mount, Minor Pivot

(See Swing Arm and Rear SuspensionPg. A4 for Details)

6/03

C11

CRANKSHAFTKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


4

4

2

2 3

3

5

9

8

6

108

7

1

1

12

11

5




1 2202393 2 Kit, Piston Ring(Incl. Top, Middle, Bottom Rings)

2 3021419 2 Asm., Piston(Incl. Piston, Rings, Clips, Pin)

3 5131860 2 Pin, Wrist4 7710479 4 Ring, Retaining5 3021196 2 Asm., Connecting Rod (Incl. 12)6 5133674 1 Shaft, Balance

7 7661045 1 Pin, Solid8 7721122 2 Key9 3021274 1 Asm., Crankshaft (Incl. 8,10)10 7052320 1 Plug11 3514390-067

3514390-1593514390-027

444

Bearing, Rod, BlackBearing, Rod, OrangeBearing, Rod, Blue

12 7517937 4 Screw6/03

C12

CRANKCASEKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


5

1

4

2

1

11

3

1

2

2

2

2

4

4

2

31




1202542

1202688

1

1

Asm., Crankcase(Incl. 1,3,5 and Bearings)Asm., Crankcase, (Silver)(Incl. 1,3,5 and Bearings)

1 7663008 6 Dowel

2 7517409 9 Screw3 7663005 2 Dowel4 7517719 10 Screw5 7663007 2 Dowel

6/03

C13

CRANKCASE BEARINGSKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


234

5

25

19

24

236

7

8

13

9 10

11

12

14

15

1718

20

22

3

3

21

1

16




1 5132270 1 Fitting, Breather2 5131792 1 Plate, Breather Baffle3 7517255 9 Screw4 3514421 1 Bearing5 5211817 1 Plate, Bearing Retaining (Main)6 5211774 1 Plate, Bearing Retaining7 3513524 1 Bearing, Ball, Double Row8 3513512 1 Bearing, Ball9 3514404 1 Bearing, Ball10 5211773 1 Plate, Retaining, Bearing (Balance)11 7517598 3 Screw12 5132139 1 Adaptor, Shift Shaft13 7661101 1 Pin, Solid

14 3513518 1 Bearing, Ball15 3514313 1 Bearing, Ball16 9810050 1 Caplug17 5131793 1 Plate, Reed Valve18 5131791 1 Plate, Reed Backer19 7517276 2 Screw20 3513511 1 Bearing, Ball21 5244477 1 Plate, Bearing22 7517797 2 Screw23 3514426 1 Bearing, Ball24 7661020 1 Pin, Solid25 3584007 1 Bearing

6/03

C14

CYLINDER and HEADKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


13

4

129

10

11

1

2

15

5

16

7

8

6

3

17

3

14

2202191 - Gasket Kit, Top End2202192 - Gasket Kit, Complete, V92C




1 7547017 8 Nut2 7555986 8 Washer, Flat3 5132040 4 Stud, Exhaust Mount4 5244363 2 Gasket, Head5 7663008 4 Dowel6 5830225 2 Gasket, Tensioner7 3021374 2 Tensioner, Camchain8 7518236 4 Screw9 5244365 2 Gasket, Base10 5132597 8 Stud, Cylinder Mounting

11 5132633 4 Stud, Cylinder Mounting12 5132410

5132410-38522

CylinderCylinder, Silver

13 3021128302149030211293021491

1111

Head, Cylinder, Front (Incl. 16,17)Head, Cylinder, Front, Silver (Incl. 16,17)Head, Cylinder, Rear (Incl. 16,17)Head, Cylinder, Rear, Silver (Incl. 16,17)

14 7556043 4 Washer, Flat15 7547014 4 Nut16 3021154 8 Guide, Valve17 7052315 2 Plug, Pipe

6/03

D1

VALVE TRAINKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

2

7

16

15

11

12

13

14

3

5

6

9

8

10

4




1 3021169 2 Asm., Rocker Arm, Exhaust2 3021189 4 Asm., Rocker Shaft3 5133625 2 Spacer, Rocker Arm4 3021168 4 Asm., Rocker Arm Intake5 7547080 12 Nut6 7556211 12 Washer, Flat7 3021162

302116611

Camshaft, FrontCamshaft, Rear

8 5132593 12 Stud

9 30211773021178

11

Asm., Cam Carrier, FrontAsm., Carrier, Rear

10 7663008 4 Dowel11 7010081 16 Keeper, Valve12 3021153 8 Cap, Valve13 7041892 8 Spring, Valve14 3610078 8 Seal, Valve Stem15 3021151 4 Valve, Intake16 3021357 4 Valve, Exhaust

2/03

D2

CAMCHAIN and TENSIONERKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

1

2

2

3

3

4

4

5

5

6

6

89

910

107




1 7517286 2 Bolt2 3060009 2 Guide, Rotating Camchain3 7516409 2 Bolt4 7517257 4 Screw5 3222091 2 Sprocket, 38T, Camshaft

6 3221145 2 Chain, Camshaft7 5010430 1 Adaptor, Cam Chain Guide8 3060011 1 Spacer9 3060008 2 Guide, Fixed Camchain10 7517271 2 Bolt

8/02

D3

CAM and VALVE COVERSKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


3

67

7

5

9

8

4

5

2

1




1 52459615134062

11

Cover, Cam Drive CapCover, Cam Drive, Ness

2 7517259 6 Screw3 5133265 1 Cover, Cam Drive4 5830224 1 Gasket, Cam Cover

5 5830202 2 Gasket, Valve Cover6 5133970 1 Cover, Valve, Rear7 7517301 20 Screw8 3070197 2 Plug, Spark, NGK CPR6EB99 5133969 1 Cover, Valve, Front

6/03

D4

OIL PUMP MOUNTINGKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


3

4

5

6

9

11

87

12

16

13

13

1

2

1414

10

6


15




1 5434349 1 Dipstick, Oil Fill2 5411331 1 O-Ring3 2540086 1 Filter, Oil4 2540115 1 Nipple5 5133043 1 Body, Oil Pump6 7517256 3 Screw7 3221082 1 Sprocket, 19T8 7556054 1 Washer, Flat

9 7517257 1 Screw10 5412002 2 O-Ring11 3221144 1 Chain12 2540076 1 Tube, Oil, Filter/Crankcase13 5411231 3 O-Ring14 7556026 3 Washer15 7517406 1 Screw16 2540095 1 Tube, Oil, Outlet

4/03

D5

OIL PUMPKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


5

2

96

121

11

7

14

10

13

4

3

8




1 5133039 1 Cap, Oil Pump2 2540091 1 Gerotor, Lubrication3 7661128 2 Pin4 7663007 2 Dowel5 2540088 1 Asm., Regulator Valve6 5133043 1 Body, Pump7 2540092 1 Gerotor, Cooling

8 2540080 1 Jet, Oil9 7663014 2 Dowel10 5133040 1 Base11 2540096 1 Asm., Regulator Valve12 3610081 1 Seal, Oil Inlet13 2540090 1 Asm., Inlet Screen14 2540089 1 Shaft, Oil Pump

4/03

D6

PRIMARY DRIVEKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


56

7 8 9

10

12

24 2322

151617

19202118

12

3

4

1314

11




1 6230238 1 Gear, Split, Drive2 7042096 4 Spring, Split Gear3 6230239 1 Gear, Split, Backlash4 7710529 1 Ring, Retaining5 1341414 1 Asm., Split Gear, 37T (Incl. 1-4)6 6230212 1 Gear, Compensator7 5133045 1 Sleeve, Compensator8 5133044 1 Slider, Compensator9 7042019 4 Spring, Belleville Compensator10 5133085 1 Retainer, Compensator11 7556166 1 Washer, Split Lock12 7547019 1 Nut

13 7518008 1 Bolt, Oil Jet14 7555987 1 Washer, Flat15 7517882 6 Screw16 3021211 1 Flywheel17 3021197 1 Adaptor, Flywheel18 7721122 1 Key, Woodruff19 7710490 1 Ring, Retaining, 35 Degree20 7556237 1 Washer, Flat21 1013722 1 Asm., Crankshaft Gear Starter Drive22 4060156 1 Clutch, Starter Drive23 7517260 5 Screw24 6230240 1 Gear, Crankshaft

11/02

D7

PRIMARY COVERKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

2

6

811

12

7

1716

15

14

4

3

5

1314

9 10




1 58302235830227

11

Gasket, Primary CoverKit, Gasket, Beaded Paper

2 3021305 1 Asm. Primary Cover, Chrome (Incl. 3,4,5)3 3512106 1 Bearing, Needle4 3552105 2 Bearing, Needle5 3610059 2 Seal6 1013770 1 Pinion, Clutch7 7517499 1 Screw8 5412230 1 O-Ring9 5246387 1 Plate, Cap Seal

10 7517483 3 Screw11 5245960

513406311

Cover, Primary Cap, ChromeCover, Primary, Ness

12 7517754 2 Screw13 7517301 1 Screw14 7517261 16 Screw15 4010436 1 Stator16 7517515 1 Screw17 5245036 1 Bracket, Stator Wire

6/03

D8

SHIFT FORKS/DRUMKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


12

3

6

87

5

4

9

10

1213

2

11

16 1514




1 5133255 2 Fork, Shift, Mainshaft2 5132177 2 Rail, Shift3 5133256 1 Fork, Shift, Countershaft4 5812232 1 Washer, Copper5 7052306 1 Plug, Socket6 1341415

35135187661023

1

12

Asm., Shifter Drum(Incl. Bearing, Drum, Pins)Bearing, BallPin, Solid

7 7556154 1 Washer, Flat

8 ---- -- -- -- -- -- 1 Switch, Neutral Indicator(See Electrical Pg. C5, Ref. 1)

9 7041583 1 Spring10 1341416 1 Asm., Shifter Ratchet (Incl. 9)11 7710534 1 Ring, Retaining12 7517384 1 Screw13 5133254 1 Star, Shifter14 7517965 1 Screw15 1341402 1 Asm., Roller Follower16 7042087 1 Spring, Tension

2/03

D9

TRANSMISSIONKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1

9

2

4

3

6

10

11

12

13

8

7

2

2

4

6

2

2

2

4

4

4

14

6

6

2

1718

19

4

5

16 15




1 1341452 1 Asm., Countershaft (Incl. 2-9)2 7710525 8 Ring, Retaining3 6230234 1 Gear, Common, Countershaft, 34T4 5246272 6 Washer, Thrust5 6230264 1 Gear, 4th Countershaft, 31T6 3584006 4 Bearing, Roller7 6230263 1 Gear, Countershaft, 3rd, 28T8 6230257 1 Gear 2nd Countershaft, 24T9 6230259 1 Shaft, Counter10 1341451 1 Asm., Mainshaft (Incl. 2,4,6,11-14)

11 6230228 1 Shaft, Main12 6230260 1 Gear, 1st Mainshaft, 38T13 6230258 1 Gear, 2nd Mainshaft, 33T14 6230261 2 Gear, 3rd Mainshaft, 29T15 6230262 1 Gear, 4th Mainshaft, 26T16 7710535 1 Ring, Retaining17 3514401 1 Bearing, Roller18 3514359 1 Bearing, Needle19 1341411 1 Asm., Clutchshaft, 5th (Incl. 17,18)

9/02

D10

DRIVE CLUTCHKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1 2 5 9 12 1310

16

1819 2017

2325

22

3 4 14 15

2124

876

26

11


2728




1 7670122 1 Clip, External2 1341438 1 Asm., Gear/Basket3 3514358 1 Bearing, Ball4 7670123 1 Circlip, Internal5 5133313 1 Hub, Clutch6 5246074 1 Seat, Judder Spring7 7042123 1 Spring, Diaphragm, Judder8 5246077 1 Plate, Friction Judder9 3230546 9 Plate, Separator10 5246481 8 Plate, Friction11 3230545 1 Plate, Friction Clutch12 5132703 1 Plate, Pressure13 7042099 1 Spring, Clutch, Diaphragm14 7710510 1 Ring, Snap15 7670124 1 Circlip, Internal

16 13220611321899

11

Asm., ClutchAsm., Clutch Pack (Incl. 9,10,11)

17 5131658 1 Washer18 7547019 1 Nut19 1341427 1 Asm., Rack Insert (Incl. 22,23,24)20 7710506 1 Circlip21 7710532 1 Ring, Retaining22 5132553 1 Insert, Pressure Plate23 3514356 1 Bearing, Ball24 7670128 1 Circlip, Internal25 6230245 1 Rack, Clutch26 7556166 1 Washer, Lock27 7517587 1 Screw28 7556139 1 Washer, Flat

4/03

D11

STARTER MOTORKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


5 4

67

9

10

11 12

1 2

8

3




1 7517409 1 Screw2 7663005 2 Dowel3 5412175 1 O-Ring4 4060155

401095611

StarterStarter, Silver

5 7517719 1 Screw6 3230544 1 Clutch, Torque Limiting

7 3513518 1 Bearing, Ball8 5412292 1 O-Ring9 5132276

513311911

Cap, BearingCap, Bearing, Silver

10 7517272 2 Screw11 6230246 1 Gear, Idler12 5020905 1 Shaft, Idler, Mounting

6/03

D12

EVAP SYSTEMKINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPIN V04CB16LK and KINGPIN V04CB16LL and KING-

PIN V04CB16LM

12

6 11

78

13

1

4

9

10

3

5

2

1




1 7080138 2 Cable Tie2 7547121 2 Nut3 7517839 1 Screw4 7080756 1 Clip, Snap-In5 7517881 1 Screw6 5246644 1 Bracket, EVAP Canister7 5434835 1 Line, Water Vent

8 5434837 1 Line, Fuel9 7080924 1 Tiewrap10 7080932 1 Filter, Vent Line11 5411870 1 Hose, Vent12 2520192 1 Filter13 5434838 1 Line, Purge

11/02

D13

OWNER’S MANUALKINGPIN V04CB16CA and KINGPIN V04CB16CB and KINGPIN V04CB16CC and KINGPIN V04CB16CD and KINGPIN V04CB16CF and KINGPIN V04CB16CK and KINGPIN V04CB16CL and KING-PIN V04CB16CM and KINGPIN V04CB16DA and KINGPIN V04CB16DB and KINGPIN V04CB16DC and KINGPIN V04CB16DD and KINGPIN V04CB16DF and KINGPIN V04CB16DK and KINGPINV04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPINV04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM and KINGPIN V04CB16UA and KINGPIN V04CB16UB and KINGPIN V04CB16UC and KINGPIN V04CB16UD and KINGPIN


1




1 99191679919168

11

Manual, Owner’s, ’04 KingpinManual, Owner’s, ’04 Kingpin, Cana-da, Bilingual

9/03

This page left blank intentionally.

PRINTED IN THE USA PARTS MANUAL PN 9918956 and MICROFICHE PN 9918957 9/03

Polaris victory kingpin_parts_manual_2004

Automotive

Transcript of Polaris victory kingpin_parts_manual_2004