FREEDOM

Model #W035297DA
Model #W035297IA

E 2002 Polaris Sales Inc. PARTS MANUAL PN 9918097 and MICROFICHE PN 9918098 9/02
 TABLE OF CONTENTS
FREEDOM W035297DA and FREEDOM W035297IA
Parts Manual

B FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . A10

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . A9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . B5
FUEL/WATER SEPARATOR . . . . . . . . . . . . . B10
BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . B8
C H
HULL and BODY . . . . . . . . . . . . . . . . . . . . . A5-6
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . C4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . B6 M
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . C1 MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . C6
CRANKSHAFT and PISTON . . . . . . . . . . . . . C3 O
CYLINDER & MANIFOLD . . . . . . . . . . . . . . . C2 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . C5
D OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . A12
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A8 P
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . B1 PROPULSION . . . . . . . . . . . . . . . . . . . . . . . B2
E S
ELECTRICAL BOX . . . . . . . . . . . . . . . . . . . . B11-12 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
ELECTRICAL BOX MOUNTING . . . . . . . . . . B13 SHROUD . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
ENGINE AIR INTAKE/HULL AIR INLET . . . . B9 STARTING MOTOR . . . . . . . . . . . . . . . . . . . C7
ENGINE FOGGING SYSTEM . . . . . . . . . . . . B14 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . A13-14
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . B4 T
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . B3 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . C8
F W
FRONT STORAGE COMPARTMENT . . . . . . A7 WATER INLET . . . . . . . . . . . . . . . . . . . . . . . B7

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
 SHROUD
FREEDOM W035297DA and FREEDOM W035297IA

E 2002 Polaris Sales Inc.

34

3
33
4 32

5 12

6 14 31

7
30
8 29
9 12
10 11 28
13
14

14 26 25 24
27 23
22
15
21
16 14

18 20
12
17
19
14
17
14
17

A3
 SHROUD
FREEDOM W035297DA and FREEDOM W035297IA
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 3280445 1 Gauge, Fuel, Warning 18 7621491 4 Rivet
2 2653011 1 Asm., Console Latch 19 5434684 1 Bracket, Hood Post
3 5434564-1129 1 Lid, Console 20 7555835 2 Washer
4 7042007 1 Spring, Torsion, Console 21 7547187 1 Nut
5 5521630 1 Seal 22 5132781 1 Pin, Latch
6 7546705 2 Nut 23 5411664 1 Grommet, Deck, Wire Harness
7 5812235 1 Pad, Console 24 7080138 1 Cable Tie
8 7546704 2 Nut, Nylok 25 7661040 8 Rivet
9 7556094 2 Washer 26 5812357 1 Cover, Reverse
10 5245455 1 Hook, Console 27 5811982 1 Gasket
11 7517669 2 Screw 28 5434562-1129 1 Shroud, Steering
12 7517668 6 Screw 29 5812076 1 Bumper, Door/Shroud
13 7556055 2 Washer, Lock 30 7081037 1 Knob
14 7555831 12 Washer, Flat 31 2080005 1 Screw
15 7081056 1 Cable, Choke 32 7552613 2 Washer, Lock
16 5411674 1 Grommet, Access 33 5333698 1 Pin, Hinge
17 7546804 5 Nut, Nylok 34 5433384 1 Hinge, Console
9/02

A4
 HULL and BODY
FREEDOM W035297DA and FREEDOM W035297IA

36
3

35 4
33 5
5
34 6
31

33 8
6 6
6 32
7 9
7
6
12 11 7
30 29 28

27

13

12 26

25 10
24

11
12
21 20
22 18 19
23 14 18
17
13
14
15
16

A5
 HULL and BODY
FREEDOM W035297DA and FREEDOM W035297IA
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 5812376-318 1 Pad, Boarding 19 5521568-070 1 Rail, Rub, Side, LH
2 5812374-318 1 Pad, Footwell, Rear, LH 5521569-070 1 Rail, Rub, Side, RH
5812375-318 1 Pad, Footwell, Rear, RH 20 7571625 1 Washer, Lock
3 5812372-318 1 Pad, Footwell, Center, LH 21 7547214 1 Nut
5812373-318 1 Pad, Footwell, Center, RH 22 5432274-070 1 Sponson, LH
4 5812433-318 1 Pad, Footwell, Front, LH 5432275-070 1 Sponson, RH
5812434-318 1 Pad, Footwell, Front, RH 23 7515198 12 Screw
5 7517644 6 Screw 24 7517320-070 2 Bolt, Carriage
6 7556094 14 Washer 25 5811440 12 Washer, Rubber
7 7546704 8 Nut, Nylok 26 7555836 2 Washer, Flat
8 7517798 2 Screw 27 5811918 1 Pad, Heel, LH
9 5433671 1 Plate, Seat Tongue 5811919 1 Pad, Heel, RH
10 5411758-070 1 Bumper, Front 28 5433531-070 1 Bumper, Rear
11 7621511 31 Rivet 29 1060125 2 Plug, Bilge
12 5431994-070 29 Plug, Bumper, Rear 30 7511882 4 Screw
13 7542133 4 Nut, Nylok 31 2632218 1 Hook, Tow
14 7555839 14 Washer, Flat 32 7542455 1 Nut, Nylok
15 7555870 2 Washer, Dish, Rubber 33 7555846 2 Washer, Flat
16 2670150 1 Strap, Bow 34 5433474-070 1 Handle, Grab
17 7517330 1 Screw 35 7542454 1 Nut
18 7556232 2 Washer, Flat 36 5020753 1 Plunger, Latch
9/02

A6
 FRONT STORAGE COMPARTMENT
FREEDOM W035297DA and FREEDOM W035297IA

1
2

2
6
12 11
10
4
13 5
15 9 5

14 7
6
8
16
7
17

18

18
20
19

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 2632297 1 Latch, Hood 12 5521565 1 Seal, Door
2 5521617 2 Bumper, Door/Deck 13 7621235 4 Rivet
3 5433999-1129 1 Door, Compartment 14 7080853 2 Cable, Limiter, Hinge
4 1013825 1 Asm., Door Hinge 15 5211548 1 Plate, Fire Extinguisher
5 7517644 5 Screw 16 5431842 1 Cover, Fire Extinguisher
6 7555839 6 Washer, Flat 17 1060114 1 Asm., Fire Extinguisher Container
7 7546704 5 Nut, Nylok (Incl. 16 and Container)
5431841 1 Container, Fire Extinguisher
8 5811440 1 Washer, Rubber
18 7621480 4 Rivet
9 7555890 4 Washer
19 5411865 1 Seal, Bucket, Front
10 7516805 4 Screw
20 5433464 1 Bucket, Front Storage
11 7552613 4 Washer, Lock
9/02

A7
 DECALS
FREEDOM W035297DA and FREEDOM W035297IA

1
2 3
4

14
13
12

5
RH

11
10

9 8
7
6
15
16

17

18
19 LH

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

2202386 1 Kit, Decals Freedom 10 7170766 2 Decal, “POLARIS”, LH

1 7079126 1 Decal, Warning, Rear 11 7170764 1 Decal, Deck, Rear, “FREEDOM”, LH
2 7170105 1 Decal, Cover, Mirror, LH 7170765 1 Decal, Deck, Rear, “FREEDOM”, RH
7170106 1 Decal, Cover, Mirror, RH 12 7170788 1 Decal, NMMA, 3 Passenger
3 7077479 1 Decal, Fuel, Off/On 13 7079171 1 Logo, Planet
4 7078260 1 Decal, Fire Extinguisher 14 7170445 1 Decal, Hood Center, “Polaris”
5 7078465 1 Logo, Polaris Star 15 7170768 1 Decal, Gauge Cover
6 7170762 1 Decal, Deck, Front, LH 16 7079127 1 Decal, Warning
7170763 1 Decal, Deck, Front, RH 17 7073865 1 Decal, Caution, Capsize
7 7170102 2 Decal, “POLARIS” 18 7170888 1 Decal, Patent
8 7170215 1 Decal, Refueling Warning 19 7077812 1 Decal, Coast Guard, Exemption
9 7079125 1 Decal, Spark Ign. Comp. w/Canada
9/02

A8
 FUEL TANK
FREEDOM W035297DA and FREEDOM W035297IA
7 4

8
6
5
3
3 4
2
2 4

1
1
10
12 11
16 14 13 9
16 15
17

26 25
19 18
3
2
3

2 22
20

21
21
20
22

23
23

24

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 5244279 6 Bracket, Strap 14 5811492 1 Seal, Fuel Inlet
2 7552610 8 Washer, Lock 15 5433621 1 Nut, Fuel Inlet
3 7515361 8 Screw 16 7080766 2 Clamp, Hose
4 5243775 9 Hook, Strap, Narrow 17 5411757 1 Hose, Fuel Fill
5 5430621 3 Strap, Rubber 18 7080451 1 Clamp
6 ------- 1 Tank, Oil 19 2410124 1 Asm., Fuel Sender
(See Oil Tank Pg. A12, Ref. 19) 20 7621407 2 Rivet
7 5243776 3 Hook, Strap 21 5812206 2 Pad, Fuel Tank Stop
8 5410424 3 Strap, Battery Holddown 22 5244758 2 Bracket, Fuel Tank Stop
9 2520177 1 Cap, Fuel, Ratchet 23 5812152 2 Pad, Fuel Tank
10 7080710 1 Chain, Bead, Cap Retainer 24 5434914 1 Tank, Fuel
11 7511873 1 Screw 25 7621229 1 Rivet
12 7080442 2 Coupling, End, Fuel Cap Chain 26 5411305 1 Seal, Fuel Cap
13 5433553 1 Inlet, Fuel
9/02

A9
 FUEL SYSTEM
FREEDOM W035297DA and FREEDOM W035297IA
12

13

14
1
8 15
2
6 8 15 16
3 10 11
6
4
6

8
6

7 8 SEE NOTE
BELOW 17
6

9
6
6

NOTE: Fuel line from fuel/water

separator connects to fuel sender
fitting marked “ON.”

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 7516302 1 Screw 10 - - - - - - - 1 Separator, Fuel/Water (See Fuel/Water
2 7555840 1 Washer, Flat Separator Pg. B10, Ref. 5)
3 5432836-070 1 Knob, Fuel Valve, Black 11 7052111 1 Fitting, Tee
4 5431451 1 Nut, Fuel Valve 12 5410682 1 Grommet, Vent
5 7052159 1 Valve, Fuel 13 7080483 1 Cable Tie
6 7080476 17 Clamp, Hose 14 7051015 1 Valve, Check
7 7080482 1 T-Clip 15 7080138 2 Cable Tie
8 8450104 AR Line, Fuel 16 7052118 1 Valve, Vacuum Check
9 7052329 1 Fitting 17 ------- 1 Asm., Fuel Sender
(See Fuel Tank Pg. A9, Ref. 19)
9 /02

A10
 SEAT
FREEDOM W035297DA and FREEDOM W035297IA

4
5
6
1 12 7
8
9
13
10
11

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2683181-320 1 Asm., Seat, Final (Incl. 1-13) 7 5211314 1 Plate, Seat Base Latch
1 2683022-415 1 Asm., Seat, Main 8 5431357 1 Plate, Bottom, Seat Base Latch
2682665-415 1 Cover, Seat, Main 9 7555839 2 Washer, Flat
2 2683021-320 1 Asm., Seat, Rear 10 7555838 2 Washer, Lock
2682663-320 1 Cover, Seat, Rear
11 7516814 2 Screw
3 7556091 2 Spacer
12 7661044 2 Rivet
4 5431359 1 Plate, Top, Seat Base Latch
13 5432798 1 Plug, Nylon
5 5431358 1 Handle, Seat Base Latch
6 7042036 1 Spring, Seat Base Latch
9/02

A11
 OIL TANK
FREEDOM W035297DA and FREEDOM W035297IA

1
5
2
3
4
6
7 1

9 22

11 10
12 21 12 20

19

17
18
17
12
13 16
14
15
14

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 7080442 2 Coupling 12 7080138 4 Cable Tie
2 7080710 1 Chain 13 4010051-36 1 Conduit
3 7621229 1 Rivet 14 7080307 2 Clamp, Hose
4 7517241 1 Screw 15 5521609 AR Line, Fuel
5 5432843 1 Cap, Oil Tank 16 2530015 1 Filter, Oil
6 7661042 4 Rivet 17 7080474 2 Clamp, Hose
7 5433914 1 Inlet, Oil 18 8450059-150 AR Line, Fuel
8 5811554 1 Gasket, Oil Inlet 19 5434871 1 Tank, Oil
9 7080481 2 Clamp, Hose 20 7052118 1 Valve, Check, Vacuum
10 7052130 1 Elbow, 90 Degree 21 5521608 AR Line, Fuel
11 2410295 1 Sender, Low Oil Warning 22 5411756 1 Hose, Oil Fill
9/02

A12
 STEERING
FREEDOM W035297DA and FREEDOM W035297IA

5
3 6 7
11
2
8
1 29
12
28
27 9 13
10
26
25 14

24 15
23 22
21 6

16
20

17
19
18

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 7517717 6 Screw 15 5133395 1 Column, Steering
2 7552613 6 Washer, Lock 16 5433136 1 Housing, Steering
3 7555836 6 Washer, Flat 17 5433135 4 Bearing, Steering
4 5433901-070 1 Pad, Handlebar, Top 18 7542335 4 Nut, Nylok
5 5433899-070 1 Pad, Handlebar, Bottom 19 7555831 4 Washer, Flat
6 7517660 8 Screw 20 5811551 1 Gasket, Steering Housing
7 5631017 1 Clamp, Handlebar 21 7517787 4 Screw
8 5433355-070 1 Handle, Grab 22 5433737 1 Clamp, Throttle Block
9 5433081 1 Block, Throttle, Split 23 7710426 1 Ring, Retaining
10 7081065 1 Cable, Throttle 24 7555840 1 Washer, Flat
11 7080138 1 Cable Tie 25 5433079 1 Lever, Throttle, Thumb
12 2410168 1 Switch, START/STOP/BILGE 26 7661053 1 Pin, Retaining
5434236 1 Button, Start/Stop, LH 27 7621478 2 Rivet
13 7080675 1 Lanyard w/Whistle 28 7080483 1 Cable Tie
14 1820994-070 1 Handlebar w/Grip 29 7661099 1 Pin, Roll
9/02

A13
 STEERING
FREEDOM W035297DA and FREEDOM W035297IA

2
3
1 4

5
10
6
4
7 5
1
8
9
13
15
14 12
3 6
11
10 10
11
16

3
17

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 7542150 2 Nut 10 7555856 2 Washer, Flat
2 7515120 1 Screw 11 7547001 2 Nut, Jam
3 7555839 5 Washer, Flat 12 5412206 1 Seal, Rod
4 7060170 2 Rod End 13 7518026 1 Screw
5 7542133 2 Nut, Nylok 14 7516717 2 Bolt
6 5411818 1 Seal, Rod 15 5133395 1 Column, Steering
7 1860117 1 Ring, Stopper 16 1821244 1 Mount, Shroud, Steering
8 1860114 1 Nut, Steering Cable (Special) 17 7546704 2 Nut, Nylok
9 7081080 1 Cable, Steering
10/02

A14
 DRIVE SYSTEM
FREEDOM W035297DA and FREEDOM W035297IA

2
3

5 4

5
8
4
9
8
10

11
12
13

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1060119 1 Asm., Drive Coupler 8 3610040 2 Seal, Bearing
2 5410735 1 O-Ring 9 1341145 1 Asm., Bearing Housing (Incl. 7, 8)
3 5432129 1 Shroud, Coupler 10 5411027 1 Hose, Bearing Housing
4 7080481 3 Clamp, Hose 11 5432298 1 Fitting, Drive Shaft, Thru-Hull
5 5410663 2 Bumper, Drive Shaft 12 5411174 1 O-Ring
6 6230253 1 Shaft, Drive 13 5431985 1 Nut, Thru-Hull Bushing
7 7080629 1 Fitting, Lubrication
8/01

B1
 PROPULSION
FREEDOM W035297DA and FREEDOM W035297IA

5 7

6
8
5
9
10 24
11
4
23
12
3
2
13 25
1
3
22 28
17 14 26
15
27
29
21
3 30
16
32 31
19 18 1 17 20
33
17
34
35
36
9

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 7542455 3 Nut, Nylok 19 7542454 1 Nut

2 5244556 1 Bracket, Steering Cable Nut 20 5410817 1 O-Ring
3 5132355 3 Stud, Pump Mounting 21 5811984 1 Seal, Tailcone
4 5131573 1 Housing, Pump 22 5431523 1 Screen, Engine Inlet
5 5410735 2 O-Ring 23 5130999 1 Nozzle, Steering
6 5432269 1 Pipe, Water, Engine 24 7515366 2 Screw
7 5130983 1 Stator, Pump 25 5130938 2 Collar
8 5010294 1 Spacer, Bearing 26 7552610 4 Washer, Lock
9 3514008 2 Bearing 27 7555835 4 Washer, Flat
10 3610043 2 Seal, Stator Bearing 28 5431518 2 Bearing, Steering Nozzle
11 5010295 1 Spacer, Impeller 29 7515389 4 Bolt
12 5132372 1 Impeller 30 5131569 1 Nozzle, Stationary
13 5131196 1 Extension, Pump 31 5432841 1 Wedge, Pump
14 7522019 1 Screw 32 7512064 3 Screw
15 5630598 1 Anode, Zinc 33 5431519 1 Cone, Pump
16 5132111 1 Stud, Mounting, Pump, Long 34 5410819 1 O-Ring
17 7555966 3 Washer, Flat 35 5132674 1 Shaft, Stub
18 7552607 1 Washer, Lock 36 5410818 1 O-Ring
9/02

B2
 EXHAUST SYSTEM
FREEDOM W035297DA and FREEDOM W035297IA

1 4
5
3
2 3
2

7 6

21

24
23
9
22
8 20 19

22

11 10 25
19
12 14 26
13
13 14
14 15 28 27
16 29
15

17 18

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 5020668 1 Fitting, Inlet, Water 16 5410414 2 Bumper, Rubber
2 7555856 4 Washer, Flat 17 5222696 1 Cradle, Silencer
3 7552611 4 Washer, Lock 18 1260581-067 1 Silencer, Exhaust
4 7517268 2 Screw 19 7080445 3 Clamp, Hose
5 7517004 2 Screw 20 5412331 1 Hose
6 5830051 1 Gasket, Exhaust 21 5434652 1 Hose, Crossover
7 1261023-399 1 Asm., Exhaust Pipe 22 7080907 3 Clamp, Hose
8 7080446 2 Clamp, Hose 23 5412061 1 Hose
9 5411165 1 Hose, Pipe/Silencer 24 5433632 1 Resonator 3
10 5430621 1 Strap, Rubber 25 5411951 1 Hose, Exhaust
11 5811342 1 Pad, Foam 26 5132446 1 Fitting, Exhaust
12 5243775 2 Hook 27 5810529 1 Seal
13 7515127 2 Screw 28 7555836 4 Washer, Flat
14 7555838 6 Washer, Lock 29 7515116 4 Screw
15 7555839 2 Washer, Flat
9/02

B3
 ENGINE MOUNTING
FREEDOM W035297DA and FREEDOM W035297IA

3 4
1

2
5
27

26
25 6

24

23
22
21
20
19
16
15 7
18
8
17 7
9
16
14
15
10
11
13 12

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2410187 1 Asm., Temperature Switch 15 7555835 10Washer, Flat
2 5242488 1 Ground, Spark Plug 16 7552610 10Washer, Lock
3 7077026 1 Decal, Spark Plug 17 7517627 8Screw
4 7515149 2 Screw 18 1060142 1Bracket, Rear Muffler
5 ------- 1 Decal, Warning (See Cylinder and 19 7515357 2Screw
Manifold Pg. C2, Ref. 1) 20 7555848 4Washer, Flat
6 ------- 2 Spark Plug, NGK BPR8ES (See Cylin- 21 7542725 4Nut, Nylok
der and Manifold Pg. C2, Ref. 5)
22 7556055 1Washer, Lock
7 7556184 4 Washer, Flat
23 7517497 1Bolt
8 5631166-329 1 Plate, Front Mount
24 2202071 1Kit, Short Block NOTE: The Short
9 5631167-329 1 Plate, Rear Mount Block assembly contains a crankcase
10 7556170 4 Washer, Flat assembly, cylinder, and cylinder head
11 5245460 2 Lock, Plate assembly.
12 7517330 4 Screw 25 5240876 1 Clip, Retainer
13 3021254 4 Mount, Engine 26 7516603 1 Bolt
14 5211727 AR Shim, Engine Mount 27 7080138 1 Cable Tie
9/02

B4
 BATTERY
FREEDOM W035297DA and FREEDOM W035297IA

E 2002 Polaris Sales Inc.

3
6
5
4

11 10

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 7515192 2 Screw 7 5432121 AR Tube, Battery Vent
2 5211676 1 Bracket, Battery Hold Down 8 5812116 1 Pad, Battery
3 5432413 1 Cover, Battery 9 4140009 1 Battery, 19 Amp
4 5410682 1 Grommet, Vent 10 2200619 2 Kit, Battery Bolt
5 7052078 1 Connector 11 4010118 1 Cable, Ground, Battery/Engine
6 7080483 2 Cable Tie
9/02

B5
 COOLING SYSTEM
FREEDOM W035297DA and FREEDOM W035297IA

1
2 3
9

4 7 8
7
1 10
5 1 1

6
7 1 11

9
4 12
20
13
19
21 14

15
1 7
16
17
18
28
22
23
27 24
25
26

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 7080475 6 Clamp, Hose 15 1260694-329 1 Asm., Exhaust Manifold
2 5431444-133 1 Fitting, Thru-Hull 16 7555856 1 Washer, Flat
3 5811317 1 Gasket 17 7552611 1 Washer, Lock
4 5521287-45 2 Conduit, Flex 18 7517004 1 Screw
5 5411049 1 Hose, Outlet, Pump 19 5020746 1 Fitting, Drain Exhaust
6 5431784 1 Fitting, Tee 20 5521398-13 1 Conduit, Flex
7 7080476 4 Clamp, Hose 21 5411479 1 Hose, Water Out
8 7052128 1 Fitting, Screen, Exhaust 22 5432799 1 Valve, Pop-Off
9 8450054-100 1 Hose, Water 23 7051008 1 Thermostat, 143 Degrees F.
10 5020747 1 Fitting, Injector, Exhaust 24 5412014 1 Gasket, Thermostat
11 5411050 1 Hose, Inlet 25 7556174 1 Washer
12 7080138 8 Cable Tie 26 5631136 1 Cover, Thermostat, Machined
13 7516727 2 Screw 27 7041310 1 Spring, Compression
14 7516725 4 Screw 28 5410860 1 Seal, Thermostat Housing
8/01

B6
 WATER INLET
FREEDOM W035297DA and FREEDOM W035297IA

2
1
3

4
5

12

8
11
9

10

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 5133650 1 Scoop, Inlet 7 5630542-067 1 Grate, Inlet
2 7547003 1 Nut, Hex, Nylon 8 7515155 1 Screw
3 7555873 1 Washer, Flat 9 7517267 8 Screw
4 5810879 2 Gasket, Pitot 10 7515126 2 Screw
5 7555848 1 Washer, Flat 11 5631080-329 1 Plate, Ride
6 7518085 1 Screw, Nylon 12 7010083 8 Insert, Sponson/Ride Plate
9/02

B7
 BILGE PUMP
FREEDOM W035297DA and FREEDOM W035297IA

1
2
4
3

2
2
5
6

11
9

10

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 7052141 1 Elbow 7 5411595 1 Hose

2 7080138 3 Cable Tie 8 7080475 1 Clamp
3 8450050-26 1 Hose, Water 9 2410169 1 Asm., Bilge Pump
4 7080598 1 Strap, Cable 10 7555837 2 Washer, Flat
5 5431444-133 1 Fitting, Water, Thru-Hull 11 7512056 2 Screw
6 5811317 1 Gasket
9/02

B8
 ENGINE AIR INTAKE/HULL AIR INLET
FREEDOM W035297DA and FREEDOM W035297IA

ENGINE AIR INTAKE HULL AIR INLET

1

2 10 11

12

9
13

8
14

15

16

6
3

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 5432138-070 1 Plug, Intake Silencer 9 5434114-070 1 Cover, Intake

2 5410589 1 O-Ring 10 7546708 2 Nut, Acorn
3 5133129 2 Stud 11 7661042 6 Rivet
4 5830062 1 Gasket, Carburetor, Upper 12 5433220 2 Flange, Air Inlet
5 5631118 1 Base, Intake 13 5411545 2 Gasket
6 7517799 2 Screw 14 7080439 2 Clamp, Hose
7 2520185 1 Filter, Intake 15 5433082 2 Duct, Air Inlet
8 7170225 1 Decal, “POLARIS MARINE 700” 16 7080492 4 Cable Tie
8/01

B9
 FUEL/WATER SEPARATOR
FREEDOM W035297DA and FREEDOM W035297IA

2
3
4
3

6 5

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 7517798 2 Screw 6 3240209 1 O-Ring
2 7552613 2 Washer, Lock 7 3240239 1 Element
3 7555870 4 Washer, Rubber, Dish 8 3240238 1 Spring
4 5132374 2 Spacer 9 3240240 1 Float
5 3240220 1 Separator, Fuel/Water (Incl. 6-9)
7/00

B10
 ELECTRICAL BOX
FREEDOM W035297DA and FREEDOM W035297IA

10

9 Top View
8
1 7

6
11
12

5 13
14
2 15

3 16

4
17

18
19
20
21
2
22 20
22
40
39
23

24
38

26 37
25

27 28 29 36

30 35
31
34

21 32 33

B11
 ELECTRICAL BOX
FREEDOM W035297DA and FREEDOM W035297IA
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 2461107 1 Harness, Main 22 7547061 3 Nut, Nylok
2 7080138 11 Cable Tie 23 2410250 1 Asm., Grounding Strap w/Fuses
3 7080483 4 Cable Tie 24 - - - - - - - 1 Controller, Ignition
4 7080492 1 Cable Tie (See Magneto Pg. C6, Ref. 10)
5 5410346 3 Insulator 25 7080464 7 Anchor
6 2461113 1 Harness, Starter Relay, Bilge 26 5521286-2.5 6 Conduit
7 7515113 2 Screw 27 4060161 1 Fuse, 3 Amp
8 7555836 2 Washer, Flat 28 4060111 1 Fuse, 1/4 Amp
9 5432574 1 Plate, Stator 29 2460928 1 Harness, Jumper
10 7073734 1 Decal, “RESET ELEC SYSTEM” 30 5333544 4 Pin, Latch
11 5411491 1 O-Ring 31 5432503 4 Latch
12 7080461 1 Boot, Threaded 32 7517825 4 Screw
13 4010669 1 Cable, Battery/Solenoid 33 4010261 1 Plug, Wire Sealing
14 4010237 1 Cable, Solenoid/Starter 34 5432502 1 Cap
15 2460718 1 Harness, 8 Wire Stator 35 5411235 1 Grommet, Solid
16 7547059 4 Nut, Nylok 36 2632137 1 Asm., Electrical Box, Ignition
(Incl. 17,18,31,30)
17 5433119 1 Cover, Electrical Box
37 2434011 1 Breaker, Circuit
18 5432569 1 Seal
38 2410297 1 Asm., Terminal Board
19 4010648 1 Regulator, 1 Button
39 - - - - - - - 1 Coil, Ignition
20 7512042 3 Screw (See Magneto Pg. C6, Ref. 11)
21 7555837 10 Washer, Flat 40 5244370 1 Bracket, Coil
9/02

B12
 ELECTRICAL BOX MOUNTING
FREEDOM W035297DA and FREEDOM W035297IA

1
2
3
6

7 3
5 10
4

11

20
21
10

12

13
14
15
16
17

18 19

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 7517798 2 Screw 12 7080598 2 Strap, Cable

2 5811440 2 Washer, Rubber 13 4010826 1 Relay
3 7555839 4 Washer 14 7556261 2 Washer, Ext.., Lock
4 5246640 1 Bracket, Electrical Box 15 7552613 2 Washer, Lock
5 7556091 2 Spacer 16 7546705 2 Nut
6 4010615 1 Driver, Lamp LR 85 17 ------- 1 Insulator
7 7556218 2 Burr (See Electrical Box Pg. B12, Ref. 5)
8 5521616 1 Bumper 18 7555836 2 Washer, Flat
9 5246708 1 Anchor 19 7517717 2 Screw
10 7546704 4 Nut, Nylok 20 5243775 4 Hook
11 7661042 2 Rivet 21 5411456 2 Strap
9/02

B13
 ENGINE FOGGING SYSTEM
FREEDOM W0335297DA and FREEDOM W0335297IA

9
7 10

1 6 21

2
11
20

3
4 6
3

12
19

18
5 2 13
14
17
15

16

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
2872635 1 Kit, Engine Fogging 11 - - - - - - - 1 Separator, Fuel/Water (See Fuel/Water
1 7080138 4 Cable Tie Separator Pg. B10, Ref. 5)
2 7080484 2 Clamp, Hose 12 7075732 1 Decal, ‘‘Fogging Oil Only”
3 7080476 2 Clamp, Hose 13 7555837 2 Washer, Flat
4 7052139 1 Fitting, Tee 14 7541931 2 Nut
5 7075738 1 Decal, Engine Primer 15 7052047 1 Valve, Check, Vent
6 8450062 AR Line, Oil 16 7052138 2 Fitting, 90 Degree
7 3160114 1 Primer, Engine, Fog 17 5432362 1 Tank, Oil
8 ------- 2 Screw (See Fuel/Water Separator Pg. 18 5810279 1 Gasket, Overflow Cap
B10, Ref. 1) 19 5432359 1 Cap, Oil Bottle
9 ------- 2 Washer, Lock (See Fuel/Water Sepa- 20 7512045 2 Screw
rator Pg. B10, Ref. 2) 21 5244295 1 Bracket, Fog Bottle
10 - - - - - - - 2 Washer, Dish (See Fuel/Water Separa-
tor Pg. B10, Ref. 3)
10/99

B14
 CRANKCASE
FREEDOM W035297DA and FREEDOM W035297IA

13

1 11 12
10
5
14
6
7 8 9
2

15

4 16
3 17

18

19

20

21
22

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 5131677 8 Stud, Cylinder Flange 12 7041457 1 Spring
2 2201804 1 Kit, Asm., Crankcase (Incl. 1-4,21-22) 13 7517676 6 Screw
3 7663001 2 Pin, Dowel 14 7516806 1 Screw
4 7052145 1 Fitting 15 1201923 1 Asm., Flywheel Cover (Incl. 11)
5 5433820 1 Plug 16 5811550 1 Gasket, Flywheel Cover
6 5411564 1 O-Ring 17 7516723 4 Screw
7 3514378 1 Bushing 18 7663002 3 Pin, Dowel
8 5243231 1 Clamp, Stator Wires 19 1201938 1 Asm., Flywheel Housing (Incl. 7,18)
9 7517431 1 Screw 20 7051529 2 Plug
10 3574214 1 Bushing 21 7516725 4 Screw
11 3569806 1 Bushing 22 7516913 2 Screw
8/01

C1
 CYLINDER & MANIFOLD
FREEDOM W035297DA and FREEDOM W035297IA

1
2
25
3
24

4
5

6 23

7 22

21
8

9
10
17
19
16 15
11 18
14
20
12

14 13

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7075383 1 Decal, Warning 14 7516807 8 Screw
2 7516806 4 Screw 15 5241134 1 Bracket, Oil Pump Cable
3 7077026 1 Decal, Spark Plug 16 5630656-329 1 Manifold, Intake
4 7051527 1 Plug, Pipe 17 5830043 1 Gasket, Carb
5 3070174 2 Spark Plug, NGK BPR8ES 18 5433151 2 Stuffer, Reed Block
6 7516722 8 Screw 19 1201825 2 Asm., Valve, Reed
7 7517352 12 Screw 20 5811784 2 Gasket, Cylinder Base
8 5410917 2 O-Ring 21 3021117 2 Head, Cylinder
9 5410932 2 O-Ring 22 5241944 2 Ring, Head
10 5412232 2 O-Ring 23 5630527-093 2 Cover, Head
11 7547021 8 Nut 24 5830061 2 Gasket, Water, Manifold
12 3021019 2 Cylinder 25 1202061-329 1 Asm., Manifold, Water
13 7517306 2 Screw
9/02

C2
 CRANKSHAFT and PISTON
FREEDOM W035297DA and FREEDOM W035297IA

2 4
1

5
10
6
23 24
5 22
7
9 8 21
14
20
10
19
11
18
10 16
12 17
13 15 25
14

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 3022950 4 Circlip, Piston 12 5410613 1 O-Ring
2 3021091 2 Pin, Piston 13 5131195 1 Collar, Crankshaft
3 2200918 1 Kit, Piston Rings (Std.)(2 Rings) 14 7555905 2 Bushing
2200917 1 Kit, Piston Rings (.25mm OS) 15 5131083 1 Crankweb, PTO
2200916 1 Kit, Piston Rings (.50 mm OS) NOTE: If the
number stamped on the head of piston 16 5131084 2 Crankweb, Center
reads ELKO 2194a use the above 3 kits. 17 5131086 1 Labyrinth
4 2201626 1 Kit, Piston Asm. (Std.)(Incl.1,2,3) 18 3514318 1 Bearing, Ball
2201627 1 Kit, Piston Asm. (.25 mm OS)(Incl.1,2,3)
2201628 1 Kit, Piston Asm. (.50 mm OS)(Incl.1,2,3) 19 5131085 1 Crankweb, Mag.
5 2201022 1 Kit, Connecting Rod Assembly (Incl. 7-9) 20 7721117 1 Key, Woodruff
6 3584001 2 Bearing, Connecting Rod (20 mm) 21 3610044 1 Seal
7 ------- 4 Washer, Thrust 22 ------- 1 Washer (See Magneto Pg. C6, Ref. 7)
8 ------- 2 Pin, Crankshaft 23 ------- 1 Nut, Pump Drive
9 ------- 2 Bearing, Connecting Rod (See Magneto Pg. C6, Ref. 8)
10 3585503 4 Bearing, Ball 24 5432576 1 Coupler
11 5411937 2 Seal 25 2201242 1 Kit, Crankshaft, 2 Cylinder
(Incl. 10,14-20,)
10/02

C3
 CARBURETOR
FREEDOM W035297DA and FREEDOM W035297IA

11 12

10

9
Jet Block

13
7

6 14

4 5 15
16
20
17
21 18
19

22
3
23
2

1
25

24

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
1253368 1 Asm., Carburetor 13 3050135 8 Screw, Jet Block Cover
1 3050136 4 Screw, Fuel Pump 14 3050139 2 Cover, Jet Block
2 2200687 1 Kit, Fuel Pump Body 15 2200730 1 Kit, Diaphragm, Jet Block
3 2200686 1 Kit, Gasket, Fuel Pump 16 3050137 1 Screw, Jet Block
4 5830062 1 Gasket, Carburetor, Upper 17 3050282 2 Block, Jet
5 3050144 2 Screen, Fuel Strainer 18 3050147 2 O-Ring, Jet Block
6 2201309 1 Kit, Accelerator Pump 19 3050138 2 Collar
7 2200685 1 Kit, Check Valve Mid Range 20 3050148 4 O-Ring, Valve Seat
8 2200733 1 Kit, Needle Valve 21 2200688 2 Kit, Check Valve
9 3050117 1 Jet, Main, Keihin 22 2200689 2 Kit, Idler Mixture Screw
10 3050189 1 Jet, Main, Keihin 23 3050140 2 Cap, Limiter
11 3050125 1 Jet, Pilot, Keihin 24 5830043 2 Gasket, Lower
12 3050119 1 Jet, Mid, Keihin 25 2200731 1 Kit, Idle Stop Screw
7/00

C4
 OIL PUMP
FREEDOM W035297DA and FREEDOM W035297IA

1
2

5
4

9
8

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 7081022 1 Cable, Oil Pump 6 5411293 1 O-Ring
2 8450061-54 2 Line, Oil 7 7516605 2 Screw
3 7080603 4 Clamp, 7 mm 8 2540073 1 Pump, Oil (Incl. 6)
4 7555944 1 Washer 9 7080654 2 Retainer
5 7710427 1 E-Ring
8/01

C5
 MAGNETO
FREEDOM W035297DA and FREEDOM W035297IA

4
15
16

5 7
8

6 9
14

13

12

11

10

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 4010172 1 Stator, Twin 10 4010568 1 CDI, Programmed (If built before
2 7517620 3 Screw 9/25/02)
4010803 1 CDI, Programmed (If built after
3 5411320 1 O-Ring 9/25/02)
4 5432282 1 Holder, Magnet 11 4010175 1 Coil, Ignition
5 4010569 1 Asm., Flywheel 12 7080471 1 Clip
6 2201228 1 Kit, Timing Screws 13 4010173-42 1 Wire, Spark Plug
7 7555907 1 Washer 14 4010173-56 1 Wire, Spark Plug
8 7546909 1 Nut 15 7080483 2 Cable Tie
9 2460718 1 Harness, 8 Wire 16 4020155 2 Cap, Spark Plug
11/02

C6
 STARTING MOTOR
FREEDOM W035297DA and FREEDOM W035297IA
1

3 5
6 7
8

10
9

12
11

13

9
14

17

25
16
15
24
21
23 20
22 19
18
17
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
4010675 1 Starter, Long Stud 13 3240205 1 Asm., Armature
1 3240113 2 Bolt, Through 14 4060119 1 Asm., Bendix (Incl. 17-25)
2 7516807 2 Screw 15 3240206 1 Asm., Front Bracket
3 3240111 4 Spring, Brush 16 3240114 1 O-Ring
4 3240115 1 Asm., Brush (Incl. 3-8) 17 3083737 1 Washer
5 3084408 1 O-Ring 18 3240126 1 Ring, Snap
6 3240119 1 Washer 19 3240125 1 Stopper
7 3240117 1 Washer, Spring 20 3240123 1 Cover
8 3240116 1 Nut 21 7041457 1 Spring
9 3084405 2 Ring, Rubber 22 3574214 1 Bushing, Flanged
10 3240207 1 Asm., Rear Bracket 23 7555908 1 Washer, Thrust
11 3240118 AR Washer, Thrust 24 3240122 1 Asm., Gear
12 3240112 1 Washer, Thrust 25 3240120 1 Asm., Gear (Incl. 17-24)
8/01

C7
 TOOL KIT
FREEDOM W035297DA and FREEDOM W035297IA

1
2 3

5
6

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
2872114 1 Asm., Tool Kit (Incl. 1-6) 4 9918123 1 Manual, Owners, ’03 PWC
1 ------- 1 Wrench, Spark Plug 5 2690016 1 Pouch, Tool Kit
2 ------- 1 Wrench, Open End 6 2871109 1 Wrench, Allen, Plated, 3/16
3 ------- 1 Screwdriver
9/02

C8
PRINTED IN THE USA PARTS MANUAL PN 9918097 and MICROFICHE PN 9918098 9/02
Changed pages in 9918097
1 2 3 4 5 6 7 8 9 10 11 12 13 14

A cover toc x

C x x

1 2 3 4 5 6 7 8 9 10 11 12 13 14