Polaris Kingpin Parts Manual and Microfiche PN 9918956 and 9918957Qty. Description1 Floorboard, Passenger, LH1 Floorboard, Passenger, RH2 Peg, Foot, Passenger4 ScrewRef. Part No.4 75562365 75561216 76610647 7556155Qty. Description4 Washer, Flat4 Washer, Flat4 Rivet4 Washer, FlatRef. Part No.8 75179469 754704810 754703911 7663008

PARTS MANUAL PN 9918956 and MICROFICHE PN 9918957 9/03

KINGPINt
Model #V04CB16CA/CB/CC/CD/CF/CK/CL/CM
Model #V04CB16DA/DB/DC/DD/DF/DK/DL/DM
Model #V04CB16LA/LB/LC/LD/LF/LK/LL/LM
Model #V04CB16UA/UB/UC/UD/UF/UK/UL/UM
E 2003 Polaris Sales Inc.

TABLE OF CONTENTS
KINGPIN 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 V04CB16DF
and KINGPIN V04CB16DK and KINGPIN V04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN
V04CB16LD 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

A

H

AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . B12

HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . B6

BATTERY BOX . . . . . . . . . . . . . . . . . . . .
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE, FRONT . . . . . . . . . . . . . . . . . . .
BRAKE, REAR . . . . . . . . . . . . . . . . . . . .

C1
A7
B10
B11

IGNITION ASM. . . . . . . . . . . . . . . . . . . . C6

CAM and VALVE COVERS . . . . . . . . . . .
CAMCHAIN and TENSIONER . . . . . . . . .
CLUTCH LEVER ASM. . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . .
CRANKCASE BEARINGS . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . .
CYLINDER and HEAD . . . . . . . . . . . . . . .

D3
D2
B14
C12
C13
C11
C14

B

C

D

DECALS . . . . . . . . . . . . . . . . . . . . . . . . C3
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . D10

E

ECM/BATTERY BOX . . . . . . . . . . . . . . . .
ELECTRICAL . . . . . . . . . . . . . . . . . . . . .
ENGINE MOUNTING . . . . . . . . . . . . . . . .
EVAP SYSTEM . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM . . . . . . . . . . . . . . . .

C1
C5
C10
D12
C8

FENDER, FRONT . . . . . . . . . . . . . . . . .
FENDER, REAR . . . . . . . . . . . . . . . . . .
FLOORBOARD, LH . . . . . . . . . . . . . . . . .
FLOORBOARD, PASSENGER . . . . . . . .
FLOORBOARD, RH . . . . . . . . . . . . . . . .
FOOTPEG, LH . . . . . . . . . . . . . . . . . . . .
FOOTPEG, RH . . . . . . . . . . . . . . . . . . . .
FOOTPEGS, PASSENGER . . . . . . . . . . .
FRAME, MAIN . . . . . . . . . . . . . . . . . . . .
FRONT FORKS and CLAMP ASM. . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . .
FUSE BOX MOUNT . . . . . . . . . . . . . . . .

A12
B8
A6
A5
A7
A6
A7
A5
A3
A10
A11
C2

F

H

HANDLE BAR . . . . . . . . . . . . . . . . . . . . . A8
HANDLEBAR MOUNTING . . . . . . . . . . . . A9

I

O

OIL COOLING . . . . . . . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP MOUNTING . . . . . . . . . . . . . .
OWNER’S MANUAL . . . . . . . . . . . . . . . .

C7
D5
D4
D13

P

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

S

SADDLEBAG ASM. . . . . . . . . . . . . . . . . .
SEAT AND BACKREST . . . . . . . . . . . . . .
SHIFTER . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT FORKS/DRUM . . . . . . . . . . . . . . .
SHOCK, REAR . . . . . . . . . . . . . . . . . . .
SIDE COVER, LH . . . . . . . . . . . . . . . . . .
SIDE COVER, RH . . . . . . . . . . . . . . . . . .
SPEEDOMETER . . . . . . . . . . . . . . . . . . .
SPROCKET, DRIVE, FRONT . . . . . . . . . .
STARTER MOTOR . . . . . . . . . . . . . . . . .
SUSPENSION, REAR . . . . . . . . . . . . . . .
SWING ARM . . . . . . . . . . . . . . . . . . . . .

B9
C4
A6
D8
B13
C1
C2
B5
C9
D11
A4
A4

T

TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . B8
TRANSMISSION . . . . . . . . . . . . . . . . . . . D9
TURN SIGNALS . . . . . . . . . . . . . . . . . . . A12

V

VALVE TRAIN . . . . . . . . . . . . . . . . . . . . . D1

W

WHEEL, FRONT (BILLET) . . . . . . . . . . . .
WHEEL, FRONT (CAST) . . . . . . . . . . . . .
WHEEL, FRONT (SPOKED) . . . . . . . . . .
WHEEL, REAR (BILLET) . . . . . . . . . . . . .
WHEEL, REAR (CAST) . . . . . . . . . . . . . .
WHEEL, REAR (SPOKED) . . . . . . . . . . .
WINDSHIELD . . . . . . . . . . . . . . . . . . . . .

A14
B1
A13
B3
B4
B2
B7

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

MAIN FRAME
KINGPIN 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 V04CB16DF and KINGPIN V04CB16DK and KINGPIN
V04CB16DL and KINGPIN V04CB16DM and KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD 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

Kingpin is a Trademark
of Polaris Industries

10

9

2

1

8

7

6

3
4

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.

1 1014399-067
1014399-385
2 7517404
3 7547039
4 7042047
5 1013062
6 5411745

Qty. Description

1
1
1
1
1
1
1

Frame, Main, Black
Frame, Main, Silver
Screw
Nut
Spring, Side Stand
Stand, Side (Incl. 2,3,6-8)
Pad, Side Stand

Ref. Part No.

7 7556121
8 7661064
9 1014401-067
1014401-385
10 1013888-067
1013888-385

Qty. Description

2
2
1
1
1
1

Washer, Flat
Rivet
Cradle, LH, Black
Cradle, LH, Silver
Cradle, RH, Black
Cradle, RH, Silver
9/03

A3

SWING ARM and REAR SUSPENSION

1
16

17 18

15

19

19

14

12

2

7

4 5

3

6

13
5

12
20

8

11
10

9

3

1

21

21

22

23

24


25

26

23
22

25

31

32

27

30
28

22

19

26
29
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

5434637
7547048
7556236
5133475
3610096
3514413
1014408-156
1014408-385
7670149
1013916
3514414
5631478
3610095
3514411
5134101
7710544
7518206

Qty. Description

2
1
2
1
2
1
1
1
1
1
2
1
4
2
1
1
1

Cap
Nut, FLEXLOC
Washer, Flat
Bushing
Seal
Bearing
Asm., Swing Arm w/Bearings, Chrome
Asm., Swing Arm w/Bearings, Silver
Ring, Retaining
Shaft, Swing Arm Pivot
Bearing, Ball
Bushing
Seal
Bearing, Needle
Bushing
Ring, Retaining
Screw

Ref. Part No.

17 7556155
18 - - - - - - 19
20
21
22
23
24
25
26
27
28
29
30
31
32

7547268
5133473
7517946
7556260
5247519
5134080-067
3514459
5134096
3514412
7518202
7518032
7663008
5134079-067
7517827

Qty. Description

1 Washer, Flat
1 Asm., Shock
(See Rear Shock Pg. B13 for Details)
4 Nut, Nylok
1 Bushing, Suspension, Short
3 Screw
4 Washer, Flat
2 Link, Suspension Strap
1 Link, Suspension Pivot
2 Bearing
2 Bushing, Suspension, Plain Bearing
1 Bearing, Needle
2 Screw
2 Screw
2 Dowel
1 Mount, Minor Pivot
2 Screw
6/03

A4

PASSENGER FOOTPEGS/FLOORBOARDS

4

1

2

3

4

5

5

6

7
10

11

9

8
6
5

8

12

13

14

4

2

16

15

17

1

9

8


8

10

11

17

13

16
12

Ref. Part No.

1 5133540
5133526
2 5412261
3 7518149
4 7518142
5 7556245
6 1014126-385
1014127-385
7 5246787
8 7710545
9 7661168

Qty. Description

1
1
2
1
4
5
1
1
1
2
2

Footpeg, Clear, LH
Footpeg, Clear, RH
Pad, Footpeg, Rear
Screw
Screw
Washer, Flat
Mount, Footpeg, Passenger, Silver, LH
Mount, Footpeg, Passenger, Silver, RH
Bracket, Exhaust, Upper
Ring, Retaining
Pin, Pivot

Ref. Part No.

10
11
12
13
14
15
16
17

7556274
5412450
5134049-425
7661172
7042255
5133944
5247353
1014283-067
1014284-067
1014283-385
1014284-385

Qty. Description

2
2
1
2
2
2
2
1
1
1
1

Washer, Footpeg, Pivot
Pad, Passenger Floorboard
Floorboard, Passenger, Bur
Pin, Pivot
Spring, Compression
Ball, Floorboard, Detent
Plate, Floorboard, Detent
Floorboard, Passenger, Black, LH
Floorboard, Passenger, Black, RH
Floorboard, Passenger, Silver, LH
Floorboard, Passenger, Silver, RH
9/03

A5

L.H. FOOTPEG/FLOORBOARD/SHIFTER

1 2

6
3

22

6

7

5

4

5

4

9

8

21
20

7

Footpeg
10

11

12

19

13

21
20

23

28

19
24

1
27 26

18

16 17

16

12

15
14

25
13
18

17

15

Floorboard

Ref. Part No.

1 7710499
7710508
2 7556075
3 3514335
4 7547230
5 1013957
1014246
6 5133530
7 7518141
8 7556273
9 7661167
10 7710545
11 7556241
12 5412256
5412456
13 5133540
5134061-425
14 5133539
15 7518101

Qty. Description

1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1

Ring, Retaining, External (Footpeg)
Ring, Retaining, External (Floorboard)
Washer, Flat
Bearing, Shift Pedal
Nut
Asm., Shifter Linkage (Footpeg)
Asm., Shifter Linkage (Floorboard)
Lever, Shifter
Screw
Washer, Wave
Pin, Pivot
Ring, Retaining
Washer, Flat
Pad, Footpeg
Pad, Floorboard, Driver
Footpeg, CC, LH
Floorboard, Driver
Feeler, Footpeg
Screw

Ref. Part No.

16 7556234
17 7518146
18 5133527-385
5133527-067
5133863-385
5133863-067
19 7518147
7518329
20 5411364
5412493
21 5133528-385
5133528-156
5134179-410
22 7547039
23 1014589
24 7556322
25 7661095
26 7041623
27 7661094
28 3514470

Qty. Description

2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2

Washer, Flat
Screw
Support, Footpeg, Silver, LH
Support, Footpeg, Black, LH
Support, Floorboard, Silver, LH
Support, Floorboard, Black, LH
Screw (Footpeg)
Screw (Floorboard)
Pad, Shift Pedal (Footpeg)
Pad, Shifter (Floorboard)
Pedal, Shift Lever, Silver (Footpeg)
Pedal, Shift Lever, Chrome (Footpeg)
Pedal, Shifter Lever (Floorboard)
Nut
Shaft, Shift Lever
Washer, Wave
Pin, Floorboard Support
Spring, Support, Floorboard
Pin, Cotter
Bushing, Shift, Rear
9/03

A6

R.H. FOOTPEG/FLOORBOARD/BRAKE

5
2

1

3

4

Footpeg

6
7
8

9

16
15

10
12

14 13

11

17
18

25

26
27

19

12
20

1
15

13

24

23
22

11

21

Ref. Part No.

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

7547039
7710499
7556075
3514335
5133525-385
5133525-156
7661167
7710545
7556241
5412256
5133526
5133539
7518146
7518101
7556234

Qty. Description

2
2
2
2
1
1
1
2
2
2
1
1
1
1
2

Nut
Ring, Retaining, External
Washer, Flat
Bearing, Shift Pedal
Pedal, Brake Lever, Silver
Pedal, Brake Lever, Chrome
Pin, Pivot
Ring, Retaining
Washer, Flat
Pad, Footpeg
Footpeg, CC, RH
Feeler, Footpeg
Screw
Screw
Washer, Flat

Ref. Part No.

15 5133529-385
5133864-385
16 7556273
17 5412256
18 5134178-410
19 7517715
20 5020904
21 7517410
22 7661094
23 7661095
24 5134061-425
25 5412456
26 5134199-385
27 7041623

Qty. Description

1
1
2
1
1
1
2
2
1
1
1
1
1
1

Support, Footpeg, Silver, RH
Support, Floorboard, RH
Washer, Wave
Pad, Footpeg
Pedal, Brake Lever
Screw, Brake Pivot
Bushing, Pedal
Screw
Pin, Cotter
Pin, Floorboard Support
Floorboard, Driver, Bur
Pad, Floorboard
Support, Brake Pedal
Spring, Floorboard Support
9/03

A7

HANDLEBAR

LH

1

4

3

2

6

5

21

20

19 18

8

1

16

15
22

7

3
16

9

RH

9

15

17

14

11

13

10

12

Ref. Part No.

Qty. Description

2010224
5432692
5432715
5411256
2632829
2632830
-------

1
1
1
1
1
1
1

5 5334124
5334359
6 -------

1
1
1

7 4010773
4010699
8 5411255
9 7517366

1
1
1
4

1
2
3
4

Asm., Throttle Cable (Incl. 10,11,14)
Cap, Handlebar End, LH
Cap, Handlebar End, RH
Grip, Handlebar, LH
Mirror, LH
Mirror, RH
Asm., Clutch Lever (See Clutch Lever
Asm. Pg. B14 for Details)
Handlebar
Handlebar, Pull Back
Asm., Master Cylinder, Front Brake
(See Front Brake Pg. B10, Ref. 3)
Switch, Hand Control, Chrome, RH
Switch, Hand Control, Silver, RH
Grip, Throttle, Handlebar
Screw

Ref. Part No.

10
11
12
13
14
15
16
17
18
19
20
21
22

7081131
7081130
7517420
5242448
5433039
5521655
5433140
7081115
7517272
5246529
5433071
7080716
4010933
4010775

Qty. Description

1
1
1
1
2
2
2
2
2
1
1
1
1
1

Cable, Throttle, Pull
Cable, Throttle, Push
Screw
Retainer, Throttle Cable
Clip, Throttle Cable
Shrink, Heat
Dart, Handlebar
Strap, Retainer
Screw
Bracket, Clutch Cable
Bushing, Clutch Cable, Upper
Cable, Fast Idle
Switch, Hand Control, Chrome, LH
Switch, Hand Control, Silver, LH
6/03

A8

HANDLEBAR MOUNTING

1

4
3
2


5
6
7
6
8
9

Ref. Part No.

1 5133512-411
5133512-156
2 7518143
3 7518142
4 1821325-411
1821325-156

Qty. Description

2
2
2
2
2
2

Ref. Part No.

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

5
6
7
8
9

7518082
5412272
5134129
7556260
7547268

Qty. Description

2
4
2
2
2

Stud
Isolator, Handlebar
Sleeve, Isolator, Handlebar
Washer, Flat
Nut, Nylok
6/03

A9

FRONT FORKS and CLAMP ASM.

11
10

9

12

8

13
4

6
5

7
14

1
15

3


16

2
17

1
18

Ref. Part No.

1
2
3
4
5
6
7
8

9
10
11
12

7517361
2202686
5412473
1821378-411
3514416
3514417
5134094
2410330
2461094
4010760
5435209
5435210
1821379-411
7556246
5134148
5132481-156

Qty. Description

Ref. Part No.

10
2
1
1
1
2
2
1
1
6
1
1
1
1
1
2

13 2202703
5412560
14 7042330
15 5134364
16 5134362
17 2202684
2202685
------------------------------------------18 2202682-411
2202682-156
2202683-411
2202683-156

Screw
Kit, Bearing Seal
Cap, Steering Stem
Asm., Bracket, Lower
Bearing, Needle
Bearing, Needle
Nut, Steering Head
Asm., Indicator Lights
Harness, Indicator Lights
Bulb, Wedge Base
Housing, Indicator Light (Oil,Turn,Fuel)
Housing, Indicator Light (Neut.,Hi,Eng.)
Asm., Bracket, Upper
Washer
Nut, Top, Triple Clamp
Cap

Qty. Description

2
2
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1

Kit, Cap, Fork Tube (Incl. O-Ring)
O-Ring
Spring, Fork
Spacer
Tube, Outer
Kit, Cartridge Asm.
Kit, Cartridge Hardware
Cartridge
Retainer, Spring
Nut, Jam
Guide, Spring
Bolt
Washer
Clip, Retaining
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

A10

FUEL SYSTEM

1

29
28

3

2

4
30

5
3

4 5
6

31
32

27
26
25

7
8
9

18

17

10
11
12
13
14
15
16

34

39
38

33

24

37

35
36

21

23

20
19

22

18

Ref. Part No.

1 7518086
2 1014108-266
- - - - - - - -341
- - - - - - - -342
- - - - - - - -381
- - - - - - - -1172
- - - - - - - -1173
- - - - - - - -1174
- - - - - - - -1175
3 7517525
4 5134160
5 5412480
6 5412414
5412415
7 5412071
8 5133613
9 7710515
10 5412096
11 5412095
12 7556193
13 7556192
14 7547186
15 5412093
16 5411869
17 5412332
18 7081151

Qty. Description

3
1
1
1
1
1
1
1
1
3
3
6
1
1
2
1
1
1
1
1
1
1
1
1
1
2

Screw
Tank, Fuel, Black
Blue
Red
Purple Thunder
Cruiser Black/Bronze Mist
Bronze Mist/Pearl White
Blue Tribal Fade
Purple Thunder/Silver/Tribal
Screw
Bushing
Bushing, Flange
Cover, Mount, LH
Cover, Mount, RH
O-Ring
Plug
Ring, Retaining
Grommet
Grommet
Washer
Washer
Nut
Grommet
O-Ring
Hose
Clamp, Hose

Ref. Part No.

19
20
21
22
23
24
25
26
27
28
29

Qty. Description

2520251
7556131
5412094
5434782
5434781
2520322
2520284
7547233
7556260
7517845
-------

1
1
1
1
1
1
1
1
1
1
1

30 1253363
5411886
31 5412259
32 1253335
33 7080894
34 5411942
35 7517405
36 1253405
1500198
37 7670129
38 2520207
39 - - - - - - -

1
1
2
1
4
1
2
2
4
2
1
1

Fitting
Washer
Grommet
Line
Line, Water Vent
Asm., Fuel Line, Filter
Pump, Fuel
U-Nut
Washer, Flat
Screw
Asm., Ignition Switch/Fuel Cap
(See Ignition Asm. Pg. C6, Ref. 5)
Asm., Throttle Body
Cap, Fitting
O-Ring
Adapter, Throttle Body
Clamp, Hose
Hose
Screw
Injector, Fuel
O-Ring
Clip, Injector Clocking
Asm., Fuel Rail
Harness, Jumper, Fuel Injector
(See Electrical Pg. C5, Ref. 25)
9/03

A11

FRONT FENDER and TURN SIGNALS

1

2

3

4

6
2

7

5
9

8

10
7

13
11

12

Ref. Part No.

1 7517429
2 5134083
3 5412453
5412454
4 2410402
2410403
4010742
5 7710495
6 7517739
7 7518142
8 7517893

Qty. Description

2
4
1
1
1
1
1
2
2
4
4

Screw
Sleeve, Turn Signal Mount
Mount, Front, LH
Mount, Front, RH
Signal, Turn, LH
Signal, Turn, RH
Bulb, Single Filament, 10W
Nut
Screw
Screw
Screw

Ref. Part No.

9 5247013
5247014
10 5247015
11 5434552
12 1013831-266
- - - - - - - -341
- - - - - - - -342
- - - - - - - -381
- - - - - - - -1172
- - - - - - - -1173
- - - - - - - -1174
- - - - - - - -1175
13 7547076

Qty. Description

1
1
1
2
1
1
1
1
1
1
1
1
4

Guard, Fork, LH
Guard, Fork, RH
Trim, Fender, Front
Reflector, Amber
Asm., Fender, Front, Black
Blue
Red
Purple Thunder
Blue Tribal Fade
Nut
9/03

A12

FRONT WHEEL (SPOKED)


1
3
4

2
6

5

7
8

7

9

6

16
15
14
13

11

12

10

Ref. Part No.

1
2
3
4
5
6
7
8
9
10

5133593
7517517
5631479
5631481
7517936
3610094
3514405
5334135
7710526
7518297

Qty. Description

1
4
1
1
1
2
2
1
1
6

Axle, Front
Screw
Spacer, Bearing, LH
Spacer, Bearing, LH
Screw
Seal
Bearing, Ball
Spacer, Bearing
Ring, Retaining
Screw

Ref. Part No.

11
12
13
14

1910623
1520618
7079024
1520614

5133869
5812465
5334021
5334023
15 1821320
16 5412372

Qty. Description

1 Rotor, Brake
AR Weight, Balance
Decal, Rim, Laced
1 Asm., Wheel, Front (Incl. 6,7,8,9, Rim,
Hub, Flap, and Spokes)
1 Rim
1 Flap, Rim
20 Spoke, Outer
20 Spoke, Inner
1 Tube, Tire, Inner
1 Tire, Front
9/03

A13

FRONT WHEEL (BILLET)


1
3
2

9

4

5

7
6

14

7 8

9

15
13

10
11

12

Ref. Part No.

1
2
3
4
5
6
7
8

5133593
7517517
5631479
5631481
7517936
5334135
3514405
7710526

Qty. Description

1
4
1
1
1
1
2
1

Axle, Front
Screw
Spacer, Bearing, LH
Spacer, Bearing, LH
Screw
Spacer
Bearing, Ball
Ring, Retaining

Ref. Part No.

9
10
11
12
13
14
15

3610094
1910623
7518297
1520618
1520232
5412372
1520617

Qty. Description

2
1
6
AR
1
1
1

Seal
Rotor, Brake
Screw
Weight, Balance
Valve, Rim
Tire, Front
Asm., Wheel, Front (Incl. 6-9,13)
9/03

A14

FRONT WHEEL (CAST)


1
15

3
2

9

4

5

7
6 7

14

13

8
9

10
11

12

Ref. Part No.

1
2
3
4
5
6
7
8

5133593
7517517
5631479
5631481
7517936
5334135
3514405
7710526

Qty. Description

1
4
1
1
1
1
2
1

Axle, Front
Screw
Spacer, Bearing, LH
Spacer, Bearing, LH
Screw
Spacer
Bearing, Ball
Ring, Retaining

Ref. Part No.

9
10
11
12
13
14
15

3610094
1910623
7518297
1520618
1520232
5412372
1520630

Qty. Description

2
1
6
AR
1
1
1

Seal
Rotor, Brake
Screw
Weight, Balance
Valve, Rim
Tire, Front
Asm., Wheel, Front (Incl. 6-9,13)
9/03

B1

REAR WHEEL (SPOKED)


10

11
12

3
1

6
4

7

8

11

13

10

9

5 3

2

14
15
2
20

16

19

18

17

Ref. Part No.

1
2
3
4
5
6
7
8
9

1014470
7518178
5133481
5631480
5631479
7518044
7556234
1341448
1520615
5133677
5812233
5334021
5334023
5132870

Qty. Description

1
2
2
1
1
5
5
1
1
1
1
20
20
40

Shaft, Spindle, Wheel, Rear
Screw
Mount, Axle Adjustment
Spacer, RH
Spacer, Bearing, LH
Screw
Washer, Flat
Asm., Sprocket, 64T
Asm., Wheel (Incl. 10-14)
Rim
Flap, Rim
Spoke, Outer
Spoke, Inner
Nipple, Spoke

Ref. Part No.

10
11
12
13
14
15
16
17
18
19
20

3610094
3514405
5334138
7710526
1520618
1910623
7518297
5412373
1821398
7547226
5245087-236

Qty. Description

2
2
1
1
AR
1
6
1
1
1
1

Seal
Bearing, Ball
Spacer, Bearing
Ring, Retaining
Weight, Balance
Rotor, Brake
Screw
Tire, Rear
Tube, Tire, Inner
Nut, Hex, Fujilok
Washer, Indicator, Axle

9/03

B2

REAR WHEEL (BILLET)

1

2

3
4

6

5

7

5

8
4

9
10


13

17
19

20
16

12

18 17

11

16
15

14

Ref. Part No.

Qty. Description

1
2
3
4
5
6

7518044
7556234
1341448
3610094
3514405
1520616

5
5
1
2
2
1

7
8
9
10

5334138
7710526
1910623
7518297

1
1
1
6

Screw
Washer, Flat
Asm., Sprocket, 64T
Seal
Bearing, Ball
Asm., Wheel, Billet, Rear
(Incl. 4-8,12,13)
Spacer
Ring, Retaining
Rotor, Brake, Floating
Screw

Ref. Part No.

11
12
13
14
15
16
17
18
19
20

5412373
1520618
1520232
7547226
5245087-236
7518178
5133481
5631479
5631480
1014470

Qty. Description

1
AR
1
1
1
2
2
1
1
1

Tire, Rear
Weight, Balance
Valve, Rim
Nut, Hex, Fujilok
Screw
Mount, Axle, Adjustment
Spacer, Bearing, LH
Spacer, RH
Shaft, Spindle
9/03

B3

REAR WHEEL (CAST)

1 2

3
4

6

5

7

5

8
4

9

10
13


17
19

20
16

12

18 17

11

16
15

14

Ref. Part No.

Qty. Description

1
2
3
4
5
6

7518044
7556234
1341448
3610094
3514405
1520632

5
5
1
2
2
1

7
8
9
10

5334138
7710526
1910623
7518297

1
1
1
6

Screw
Washer, Flat
Asm., Sprocket, 64T
Seal
Bearing, Ball
Asm., Wheel, Cast, Rear
(Incl. 4-8,12,13)
Spacer
Ring, Retaining
Rotor, Brake, Floating
Screw

Ref. Part No.

11
12
13
14
15
16
17
18
19
20

5412373
1520618
1520232
7547226
5245087-236
7518178
5133481
5631479
5631480
1014470

Qty. Description

1
AR
1
1
1
2
2
1
1
1

Tire, Rear
Weight, Balance
Valve, Rim
Nut, Hex, Fujilok
Screw
Mount, Axle, Adjustment
Spacer, Bearing, LH
Spacer, RH
Shaft, Spindle
9/03

B4

SPEEDOMETER

1

3
2

4

3

5

10
9
8
6
7

Ref. Part No.

1 3280405
3280442
4030050
2 5246295
3 1014059-067
1014060-067
4 7518140

Qty. Description

1
1
1
1
1
1
2

Speedometer (MPH)
Speedometer (KPH)
Bulb, Dash
Bracket, Mount
Wire, Loom, LH
Wire, Loom, RH
Screw

Ref. Part No.

5
6
7
8
9
10

5246297
7556239
7518141
5133550
5412201
5412199

Qty. Description

1
2
2
2
2
2

Cover, Speedometer
Washer, Cup
Screw
Sleeve
Grommet
Mount, Isolator
9/03

B5

HEADLIGHT

1

3

2

6

13
4

5

12

14

11

7
8
10
9

15
2

16
17

22

18
19

21

20

18

Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11

2410339
4010805
4010776
7080792
7547118
4010777
7621403
1014219
5246268
2410348
4010804

Qty. Description

1
1
1
1
3
1
2
1
1
1
1

Housing, HID/Halogen
Bulb, Halogen, H8 (High Beam)
Bulb, HID
Strap, Cable Tie
Nut
Ballast, HID
Rivet
Mount, HID
Ring, Headlight, Bezel
Housing, Dual Halogen
Bulb, Halogen, H11 (Low Beam)

Ref. Part No.

12
13
14
15
16
17
18
19
20
21
22

5246396
1014391
5412231
7518145
1013850
7547189
5412273
5134111
7547268
7547126
7518064

Qty. Description

1
1
1
1
1
1
2
1
1
1
1

Ring, Headlight Bulb Mount
Bucket, Headlight
Grommet
Screw
Mount, Headlight
Nut
Isolator, Headlight
Sleeve
Nut, Nylok
Nut, Nylok
Screw
9/03

B6

WINDSHIELD

7

6

9

8

4

10
9

4
2

5

13

3

12

11

14

1
5
11
18
2

17

9

15
16


13

Ref. Part No.

1
2
3
4
5
6
7
8

2632834
2632713
2632833
7079671
7518229
5246994
5812464
5133932
5434963
5434741
5246997
7556254

Qty. Description

1
1
1
1
10
1
2
10
1
1
1
4

Asm., Windshield, Low
Asm., Windshield, Med
Asm., Windshield, Tall
Badge, Windshield Stamp
Bolt, Carriage
Bracket, Windshield, Front, Top
Pad, Windshield
Spacer, Windshield
Windshield, Mid
Windshield, Tall
Bracket, Windshield, Rear, Top
Washer ,Flat

Ref. Part No.

9
10
11
12
13
14
15
16
17
18

7547115
1014276
7517523
5246998
5246999
7556291
7079506
7547184
1014278
1014279
5246995
5246996

Qty. Description

2
1
2
1
1
8
1
4
1
1
1
1

Nut, Acorn
Asm., Windshield Clamp
Screw
Bracket, Windshield, Rear, LH
Bracket, Windshield, Rear, RH
Washer, Flat
Decal, Warning/Caution/Cleaning
Nut, Acorn
Asm., Deflector, Lower, LH
Asm., Deflector, Lower, RH
Bracket, Windshield, Front, LH
Bracket, Windshield, Front, RH
9/03

B7

REAR FENDER and TAILLIGHT

18
12

13

17
16
15

14

21
19

20

18

22

11
10

9
8

23
6

7

5

4

3
24

25
26

2


27

1
29

2
28

30
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

5247016
7517704
2410286
7518308
5812521
7547106
2670070
5247445
7517494
7517406
5411323
2410407
5812520
5134403
7547115
5247446
7547264
5433921
2632828

Qty. Description

1
5
1
2
1
3
1
1
3
2
2
1
1
2
2
1
2
2
1

Trim, Fender, Rear
Screw
Taillight
Screw
Pad, License Plate Mount
Nut, Nylok
Reflector, Red
Bracket, License Plate
Screw, Buttonhead
Screw
Bumper, Grommet
Light, License Plate
Spacer, License Plate
Spacer
Nut, Acorn
Bracket, License Plate
Nut, Acorn
Reflector, Round, Red
Asm., Reflector (Incl. 7,18)

Ref. Part No.

20 2461125
21 7080737
22 1014214-266
- - - - - - - -341
- - - - - - - -342
- - - - - - - -381
- - - - - - - -1172
- - - - - - - -1173
- - - - - - - -1174
- - - - - - - -1175
23 5631319
5631320
24 7518084
25 5247476-067
26 5433140
27 7081040
28 2410404
2410405
29 5247156-067
30 7517405

Qty. Description

1
3
1
1
1
1
1
1
1
1
1
1
4
1
2
4
1
1
1
2

Harness, Rear
Clip, Electrical
Asm., Fender, Rear, Black
Blue
Red
Purple Thunder
Blue Tribal Fade
Cover, Rail, LH
Cover, Rail, RH
Screw
Bracket, Taillight Shield
Dart
Rivet
Signal, Rear, LH (Incl. 30)
Signal, Rear, RH (Incl. 30)
Bracket, Fender, Brace
Screw
9/03

B8

SADDLEBAG ASM.

1

2
3

5

4
6

3
1

7
3

7

Ref. Part No.

1
2
3
4

7547249
7518143
7556045
7517523

Qty. Description

6
4
6
2

Ref. Part No.

U-Nut
Screw
Washer, Flat
Screw

5 1014649
6 1014388-385
1014389-385
7 7517410

Qty. Description

1
1
1
6

Asm., Saddlebag
Support, Bag, LH
Support, Bag, RH
Screw
9/03

B9

FRONT BRAKE

4
3

2

1

5
2

11

9

6

10

5

7

9

8

Ref. Part No.

Qty. Description

1 5131657
2 2201215
3 2010217
2201182

1
1
1
1

4110242
2201218

1
1

4 2202309

1

5 1930848

3

Lever, Hand Brake, Front
Kit, Lever Hardware (Incl. Pin and Nut)
Asm., Master Cyl., Front Brake, Silver
Kit, Sight Hardware
(Incl. O-Ring, Sight and Clip)
Switch, Stop
Kit, Pushrod Hardware
(Incl. Pushrod and Boot)
Kit, Cap Hardware (Incl. Membrane,
Screws, Cap and Diaphragm)
Bolt, Banjo

Ref. Part No.

6 1910725
1910731
7 7517990
8 1910726
2201173
2201176
2202492
9 7556028
10 7517704
11 2202310

Qty. Description

1
1
2
1
1
1
1
4
2
1

Hose, Brake, Front
Hose, Brake, Front, Pull Back
Screw
Asm., Front Caliper, LH
Kit, Bleeder Screw, Boot
Kit, Pins, Clips, Spring
Kit, Front Brake Pads (2 Per)
Washer, Banjo, Copper
Screw
Kit, Clamp Hardware
(Incl. Clamp and Screws)
9/03

B10

REAR BRAKE

6

1
8

7

9
5
3 4

2

10

13
19

12
3


11

18

17
9
16

15
14

13

12

Ref. Part No.

1 1910619
2202491
2201173
2201174
2201175
2 1910746
1910794
3 7517704
4 7080983
5 5433140
6 7517405
7 7556064
8 1930882
9 7080904
10 1910656
1910796

Qty. Description

1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1

Asm., Caliper, Rear
Kit, Brake Pad
Kit, Bleeder Screw, Boot
Kit, Boots, Caliper, Rear
Kit, Pin, Retainer, Spring, Clip
Asm., Brake Hose, Rear (Footpeg)
Asm., Brake, Hose, Rear (Floorboard)
Screw
Clamp
Dart
Screw
Washer, Flat
Reservoir
Clamp, Hose
Hose, Reservoir (Footpeg)
Hose, Reservoir (Floorboard)

Ref. Part No.

Qty. Description

11
12
13
14

7080138
1930848
7556028
7511841
7517391
15 1910620
1910762
16 7042186
7042288
17 - - - - - - -

1
2
4
2
2
1
1
1
1
1

18 7080945
7081014
7081113
7081114
19 4010372

3
3
3
3
1

Cable Tie
Bolt
Washer, Banjo, Copper
Screw (Footpeg)
Screw (Floorboard)
Cylinder, Master, Rear (Footpeg)
Cylinder, Master, Rear (Floorboard)
Spring, Ext., Brake Return (Footpeg)
Spring, Ext., Brake Pedal (Floorboard)
Pedal, Brake Lever (See R.H. Footpeg/Floorboard/Brake Pg. A7, Ref. 5)
Clip, Brake Line (Black)
Clip, Brake Line (Black)
Clip, Brake Line, Silver
Clip, Brake Line, Silver
Switch, Pressure
9/03

B11

AIR BOX

1
2

3
25

7

4
5

24

6
23

8
1

9
22
18

20

11

19
12

21

13
15

15
17

14

16

10

Ref. Part No.

Qty. Description

1
2
3
4
5
6

7517842
5433466
5811867
7517885
7556121
-------

7
1
1
4
4
1

7
8
9
10
11
12
13

5433471
5433470
5434070
7080782
5811908
1253363
5412259

1
1
1
1
1
1
2

Screw
Cover, Airbox
Seal, Airbox Cover
Screw, Button Head
Washer, Flat
Sensor, MAP
Tube, Intake, RH
Tube, Intake, LH
Hose, Breather
Clamp, Breather Hose
Gasket, Airbox
Asm., Throttle Body
O-Ring

Ref. Part No.

14
15
16
17
18
19
20
21
22
23
24
25

1253335
7517259
7080656
7516610
5432302
5811869
7080858
5433469
7517816
5811866
1013720
-------

Qty. Description

1
4
2
2
1
1
1
1
2
1
1
1

Adapter, Throttle Body
Screw
Clamp, Narrow Band
Screw
Clip, Retainer
Bumper, Rubber
Filter, Air
Cover, Air Filter
Screw
Seal, Filter, Access Hatch
Airbox
Sensor, Air Temperature
6/03

B12

REAR SHOCK

1

2

1

Ref. Part No.

1541999
1 2202501
2 7042329

Qty. Description

Ref. Part No.

Qty. Description

1 Asm., Rear Shock, KYB
1 Kit, Preload Ring, Retainer
1 Spring, Compression
9/03

B13

CLUTCH LEVER ASM.

4

3

5
6

14

1

13
7

11

2
12

10
9
8


Ref. Part No.

1322064
1
2
3
4
5
6

7710495
7080998
7081120
5133537
5433164
5133535

Qty. Description

1 Asm., Clutch Bracket/Lever, Silver
(Incl. 4-7)
1 Nut
1 Clamp, Vinyl Coated
1 Cable, Clutch
1 Pin, Clutch Lever
1 Washer, Clutch Lever
1 Bracket, Clutch/Mirror

Ref. Part No.

7
8
9
10
11
12
13
14

5131562
7517506
5133536
7547092
5243113
4110257
5433071
5433070

Qty. Description

1
2
1
1
1
1
1
2

Lever, Hand, Clutch, LH
Screw
Cap, Clutch/Mirror, Bracket, Silver
Nut, Nylok
Clip, Clutch, Micro
Switch, Clutch
Bushing, Clutch Cable, Upper
Clip, Clutch, Fast Idle Cables
4/03

B14

ECM/BATTERY BOX/LH SIDE COVER


1
2
3

5

4
2
6
7
8

21
22
20

11

11
19

12
13

7
11

14
16

17

9
10

18

8

15

Ref. Part No.

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

2461214
5411570
2201357
4010466
7080138
2461006
7517438
5433833
1014477-067
5810290
7670141
7710495
5412322
1014071
5334217

Qty. Description

1
2
1
1
2
1
2
3
1
3
4
4
2
1
1

Cable, Battery, Positive
Boot, Battery Cable, Red Positive
Kit, Battery Bolt
Battery
Strap (8 Inch)
Harness, Charging
Screw
Grommet, Side Cover
Box, Battery
Pad, Battery
Clip, Plastic
Nut
Grommet
Cover, Battery
Wrench, Cruiser, Phillips

Ref. Part No.

15 5434595-266
- - - - - - - -341
- - - - - - - -342
- - - - - - - -381
- - - - - - - -1172
- - - - - - - -1173
- - - - - - - -1174
- - - - - - - -1175
16 5412343
17 7547091
18 2461106
19 7547270
20 - - - - - - 21 4010916

22 7080756

Qty. Description

1
1
1
1
1
1
1
1
1
1
1
2
1

Cover, Side, LH, Black
Blue
Red
Purple Thunder
Blue Tribal Fade
Boot, Terminal Insulator, Black
Nut, FLEXLOC
Cable, Starter
Nut
Solenoid, Starter
1 ECM, Programmed NOTE: Refer to
Victory Diagnostic Software Users
Guide for appropriate calibration instructions.
1 Clip, Snap-In
9/03

C1

FUSE BOX MOUNT/RH SIDE COVER

7

3

9
6
7

1

6
3

4

5

7 3

8

2

Ref. Part No.

1
2
3
4
5
6
7

7670142
5435254
7081040
2410332
4010778
7517704
5433833

Qty. Description

8
1
4
1
1
2
3

Ref. Part No.

Clip, Dart
Flap, Debris
Rivet
Breaker, Circuit
Boot
Screw
Grommet

8 5434596-266
- - - - - - - -341
- - - - - - - -342
- - - - - - - -381
- - - - - - - -1172
- - - - - - - -1173
- - - - - - - -1174
- - - - - - - -1175
9 1014042-067

Qty. Description

1
1
1
1
1
1
1
1
1

Cover, Side, RH, Black
Blue
Red
Purple Thunder
Blue Tribal Fade
Mount, Fuse Box
9/03

C2

DECALS


1
2

3

Ref. Part No.

1 7079205
2 7170334
7170335
3 7079796

Qty. Description

1
1
1
1

Ref. Part No.

Qty. Description

Decal, Warning, Operate, Fuel (Bilingual)
Badge, Tank, LH
Badge, Tank, RH
Decal, Patent Pending (Bilingual)
9/03

C3

SEAT AND BACKREST


3

6

4

7

5

2

1

8
14

9

13

10

11
12

Ref. Part No.

1
2
3
4

7517782
7556253
2683426
2683257
2683240
5 5412067
6 2683237
7 7517753

Qty. Description

2
2
1
1
1
2
1
2

Screw
Spacer, Backrest
Asm., Backrest Touring
Asm., Passenger Seat (Non-Touring)
Asm., Seat, Touring
Bumper, Rubber
Asm., Drivers Seat
Screw

Ref. Part No.

8
9
10
11
12
13
14

2683260
7661834
7518043
5247432-329
7517886
7518270
1014264

Qty. Description

1
8
4
1
4
2
1

Strap, Hold Down
Rivet
Screw
Bracket, Pillion Support
Screw
Screw
Backrest, Touring
9/03

C4

ELECTRICAL

1

5

4

3

2

7

6

9
10

8

15
14
12

25

11

13
24

16

23
22
21

13
18

17

16

20

19

Ref. Part No.

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

4110235
4010649
2410358
2410338
4010947
4040077
4010225
1500201
4110217
7517272
4040076
4040078
7518141
4010766
7517272

Qty. Description

1
1
4
1
1
1
1
1
1
1
1
1
1
1
3

Switch, Neutral Indicator
Switch, Oil Pressure
Diode
Relay, Flasher
Solenoid, Starter
Sensor, Air Temperature
Sensor, Throttle Position
O-Ring
Sensor, Crankshaft Position
Screw
Sensor, Engine Temperature
Sensor, MAP
Screw
Sensor, Vehicle Speed
Screw

Ref. Part No.

14
15
16
17
18
19
20
21
22
23
24
25

7518140
2461180
4010948
2410280
2434016
7170962
7171031
2410337
2410421
7080492
7517739
1013510
1014492
2461135

Qty. Description

1
1
4
5
1
1
1
1
1
1
2
1
1
1

Screw
Harness, Main Wire
Relay, Micro
Fuse, 15 Amp.
Fuse, 10 Amp.
Decal, Fuse Box
Decal, Fuse Box Removal
Regulator, Voltage (Black)
Regulator, Voltage, Silver
Cable Tie
Screw
Bracket, Voltage Regulator (Black)
Bracket, Voltage Regulator, Silver
Harness, Jumper, Fuel Injector
6/03

C5

IGNITION ASM.

1

2
3

12
4

7

5
11
9

10

11
7
8

6

7

Ref. Part No.

1 7081033
2 5132791
3 2410266
4010530
4 7517973
5 4010685

Qty. Description

2 Cable Tie
1 Spacer
1 Asm., Ignition Coil
(Incl. Coil and Spark Plug Wires)
1 Coil, Ignition
1 Screw
1 Asm., Ignition Switch/Fuel Cap
NOTE: Fuel Cap also shown on Fuel
System Pg. A11, Ref. 29)

Ref. Part No.

6 4110239
7 7517704
8 5245658-067
5245658-385
9 5245659
10 7670136
11 7080756
12 4010531

Qty. Description

1
4
1
1
1
3
4
2

Key, Blank
Screw
Bracket, Ignition, Black
Bracket, Ignition, Silver
Cover, Ignition/Coil
Clip, Tinnerman
Clip, Snap In
Lead, Spark Plug Wire
9/03

C6

OIL COOLING

10

9

5
6

11

13

8

7

4

12

3

2

16 17
1

14

16 17
18
13

15
18

21

20

16
17

19

Ref. Part No.

1
2
3
4
5
6
7
8
9
10

7170617
5245659
5412364
5334192
7080906
5412188
7547115
7517384
1013984
1240142-385
1240142-067
11 7517839

Qty. Description

1
1
3
1
1
1
1
1
1
1
1
2

Badge, Oil Line Cover
Cover, Ignition/Coil
Isolator, Cover Mount
Line, Inlet
Cable Tie
Mount, Rubber
Nut, Acorn
Screw
Plate, Nut
Bracket, Oil Cooler, Silver
Bracket, Oil Cooler, Black
Screw

Ref. Part No.

12 1240145-385
1240145-067
13 5412105
14 5412027
15 5334191
16 7556113
17 5411356
18 7517405
19 7547076
20 4010739
21 5133647

Qty. Description

1
1
2
1
1
4
4
3
1
1
1

Cooler, Oil, Silver
Cooler, Oil, Black
Isolator, Cooler
O-Ring
Line, Outlet
Washer, Flat
O-Ring
Screw
Nut
Horn, Disk
Spacer, Horn
9/03

C7

EXHAUST SYSTEM

1
2
3


4

2
3

6
5

8

9

7

10

6

10
7

6

8

7

13
3
2
12
11

Ref. Part No.

1 1261291
1261293
2 7517523
3 7556245
4 1014127-385
5 5246787-236
6 5811770
7 7081028
8 7546805

Qty. Description

1
1
5
5
1
1
3
3
4

Asm., Muffler, Rear, 49 States
Asm., Muffler, RH, California
Screw
Washer, Flat
Footpeg, Passenger, Silver, RH
Bracket, Exhaust, Upper
Gasket, Exhaust
Clamp, Muffler
Nut

Ref. Part No.

9 1261261
1261087
1261260
7081156
10 5246008
11 1261089
12 - - - - - - 13 1261290
1261292

Qty. Description

1
1
1
2
2
1
1

Asm., Manifold w/Heat Shield
Manifold, Exhaust, Rear
Shield, Heat, U-Tube
Clamp, Heat Shield
Gasket, Exhaust Sealing
Asm., Header Pipe
Cradle, RH
(See Main Frame Pg.A3, Ref. 10)
1 Asm., Muffler Front, 49 States
1 Asm., Muffler, LH, California
9/03

C8

FRONT DRIVE SPROCKET

1

2

3

4

5

5

4

3
15

16

17

14

9
6

7

13

12

10
11

8
18
19

18

Ref. Part No.

1
2
3
4
5
6
7
8
9
10

3211088
5246487
5412265
5134082
7518141
7517301
7661156
5412070
5133266
5412260

Qty. Description

1
1
3
3
3
3
3
3
1
1

Belt, Drive
Guard, Belt, Upper
Grommet
Sleeve
Screw
Screw
Spacer
Isolator
Cover, Sprocket
Gasket, Sprocket Cover

Ref. Part No.

11
12
13
14
15
16
17
18
19

7517272
5244114
7547209
5133262
3610057
5133394
3610091
7517704
1013965-067

Qty. Description

2
1
1
1
1
1
1
2
1

Screw
Washer, Lock, Plate
Nut
Sprocket, Drive, 30T
Seal
Sleeve, Seal
O-Ring
Screw
Guard, Belt, Lower
6/03

C9

ENGINE MOUNTING

2

1

4

8 5

6

4

7 5 6
5

3
2

11
9
9
10

9
9

Ref. Part No.

1
2
3
4
5
6
7

7517365
7518053
7556305
7518125
7556287
7547232
5133599-236
5133599-408

Qty. Description

4
8
4
2
4
2
2
2

Screw
Screw
Washer, Flat
Screw
Washer, Flat
Nut
Mount, Engine, Front, Silver
Mount, Engine, Front, Black

Ref. Part No.

8 5246366-236
5246366-408
9 7518099
10 5133693
11 - - - - - - -

Qty. Description

2
2
4
1
1

Bracket, Engine Mount, Rear, Silver
Bracket, Engine Mount, Rear, Black
Screw
Dowel
Mount, Minor Pivot
(See Swing Arm and Rear Suspension
Pg. A4 for Details)
6/03

C10

CRANKSHAFT

1

2

4

3

1
2

4

3

5

6

11
12

7

5

8

10
8
9

Ref. Part No.

1 2202393
2 3021419
3
4
5
6

5131860
7710479
3021196
5133674

Qty. Description

2 Kit, Piston Ring
(Incl. Top, Middle, Bottom Rings)
2 Asm., Piston
(Incl. Piston, Rings, Clips, Pin)
2 Pin, Wrist
4 Ring, Retaining
2 Asm., Connecting Rod (Incl. 12)
1 Shaft, Balance

Ref. Part No.

7
8
9
10
11

7661045
7721122
3021274
7052320
3514390-067
3514390-159
3514390-027
12 7517937

Qty. Description

1
2
1
1
4
4
4
4

Pin, Solid
Key
Asm., Crankshaft (Incl. 8,10)
Plug
Bearing, Rod, Black
Bearing, Rod, Orange
Bearing, Rod, Blue
Screw
6/03

C11

CRANKCASE

2

4

2

1

2

2

1

2

1
4

1

4

3
1

1

2
3
5

Ref. Part No.

1202542
1202688
1 7663008

Qty. Description

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

Ref. Part No.

2
3
4
5

7517409
7663005
7517719
7663007

Qty. Description

9
2
10
2

Screw
Dowel
Screw
Dowel
6/03

C12

CRANKCASE BEARINGS

1

2
3

4


5
3

25 24

3

6

23

7
8

22

21

19
20

18
17
9

16

10
11

13

15

12
14

Ref. Part No.

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

5132270
5131792
7517255
3514421
5211817
5211774
3513524
3513512
3514404
5211773
7517598
5132139
7661101

Qty. Description

1
1
9
1
1
1
1
1
1
1
3
1
1

Fitting, Breather
Plate, Breather Baffle
Screw
Bearing
Plate, Bearing Retaining (Main)
Plate, Bearing Retaining
Bearing, Ball, Double Row
Bearing, Ball
Bearing, Ball
Plate, Retaining, Bearing (Balance)
Screw
Adaptor, Shift Shaft
Pin, Solid

Ref. Part No.

14
15
16
17
18
19
20
21
22
23
24
25

3513518
3514313
9810050
5131793
5131791
7517276
3513511
5244477
7517797
3514426
7661020
3584007

Qty. Description

1
1
1
1
1
2
1
1
2
1
1
1

Bearing, Ball
Bearing, Ball
Caplug
Plate, Reed Valve
Plate, Reed Backer
Screw
Bearing, Ball
Plate, Bearing
Screw
Bearing, Ball
Pin, Solid
Bearing
6/03

C13

CYLINDER and HEAD

17

2202191 - Gasket Kit, Top End
2202192 - Gasket Kit, Complete, V92C

16

15
14

1
2

13

3

4
5

7

3

6

8
9

12
10
11

Ref. Part No.

1
2
3
4
5
6
7
8
9
10

7547017
7555986
5132040
5244363
7663008
5830225
3021374
7518236
5244365
5132597

Qty. Description

8
8
4
2
4
2
2
4
2
8

Nut
Washer, Flat
Stud, Exhaust Mount
Gasket, Head
Dowel
Gasket, Tensioner
Tensioner, Camchain
Screw
Gasket, Base
Stud, Cylinder Mounting

Ref. Part No.

11 5132633
12 5132410
5132410-385
13 3021128
3021490
3021129
3021491
14 7556043
15 7547014
16 3021154
17 7052315

Qty. Description

4
2
2
1
1
1
1
4
4
8
2

Stud, Cylinder Mounting
Cylinder
Cylinder, Silver
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)
Washer, Flat
Nut
Guide, Valve
Plug, Pipe
6/03

C14

VALVE TRAIN

5
6


7

1

2

8
3

4

9

11

10

12
13
14

16
15

Ref. Part No.

1
2
3
4
5
6
7

3021169
3021189
5133625
3021168
7547080
7556211
3021162
3021166
8 5132593

Qty. Description

2
4
2
4
12
12
1
1
12

Asm., Rocker Arm, Exhaust
Asm., Rocker Shaft
Spacer, Rocker Arm
Asm., Rocker Arm Intake
Nut
Washer, Flat
Camshaft, Front
Camshaft, Rear
Stud

Ref. Part No.

9 3021177
3021178
10 7663008
11 7010081
12 3021153
13 7041892
14 3610078
15 3021151
16 3021357

Qty. Description

1
1
4
16
8
8
8
4
4

Asm., Cam Carrier, Front
Asm., Carrier, Rear
Dowel
Keeper, Valve
Cap, Valve
Spring, Valve
Seal, Valve Stem
Valve, Intake
Valve, Exhaust
2/03

D1

CAMCHAIN and TENSIONER

5

6

4
6


3
2

3
2
1
1

10

9

8

7

9
10

4

5

Ref. Part No.

1
2
3
4
5

7517286
3060009
7516409
7517257
3222091

Qty. Description

2
2
2
4
2

Bolt
Guide, Rotating Camchain
Bolt
Screw
Sprocket, 38T, Camshaft

Ref. Part No.

6
7
8
9
10

3221145
5010430
3060011
3060008
7517271

Qty. Description

2
1
1
2
2

Chain, Camshaft
Adaptor, Cam Chain Guide
Spacer
Guide, Fixed Camchain
Bolt
8/02

D2

CAM and VALVE COVERS

7

8
7

6
9

5

5

4
2

3

1

Ref. Part No.

1 5245961
5134062
2 7517259
3 5133265
4 5830224

Qty. Description

1
1
6
1
1

Ref. Part No.

Cover, Cam Drive Cap
Cover, Cam Drive, Ness
Screw
Cover, Cam Drive
Gasket, Cam Cover

5
6
7
8
9

5830202
5133970
7517301
3070197
5133969

Qty. Description

2
1
20
2
1

Gasket, Valve Cover
Cover, Valve, Rear
Screw
Plug, Spark, NGK CPR6EB9
Cover, Valve, Front
6/03

D3

OIL PUMP MOUNTING

1
2
5

6

8

7

10

9

4
3

6

11

12

13
13

14

14
16

15

Ref. Part No.

1
2
3
4
5
6
7
8

5434349
5411331
2540086
2540115
5133043
7517256
3221082
7556054

Qty. Description

1
1
1
1
1
3
1
1

Dipstick, Oil Fill
O-Ring
Filter, Oil
Nipple
Body, Oil Pump
Screw
Sprocket, 19T
Washer, Flat

Ref. Part No.

9
10
11
12
13
14
15
16

7517257
5412002
3221144
2540076
5411231
7556026
7517406
2540095

Qty. Description

1
2
1
1
3
3
1
1

Screw
O-Ring
Chain
Tube, Oil, Filter/Crankcase
O-Ring
Washer
Screw
Tube, Oil, Outlet
4/03

D4

OIL PUMP

8


7
6

5

9

4
10

3

11

2

12

1
14

13

Ref. Part No.

1
2
3
4
5
6
7

5133039
2540091
7661128
7663007
2540088
5133043
2540092

Qty. Description

1
1
2
2
1
1
1

Cap, Oil Pump
Gerotor, Lubrication
Pin
Dowel
Asm., Regulator Valve
Body, Pump
Gerotor, Cooling

Ref. Part No.

8
9
10
11
12
13
14

2540080
7663014
5133040
2540096
3610081
2540090
2540089

Qty. Description

1
2
1
1
1
1
1

Jet, Oil
Dowel
Base
Asm., Regulator Valve
Seal, Oil Inlet
Asm., Inlet Screen
Shaft, Oil Pump
4/03

D5

PRIMARY DRIVE

1

2

3


4

5

6
9

8

7

10
11 12

24

23

22
21

20 19

18
17

16

15

14 13

Ref. Part No.

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

6230238
7042096
6230239
7710529
1341414
6230212
5133045
5133044
7042019
5133085
7556166
7547019

Qty. Description

1
4
1
1
1
1
1
1
4
1
1
1

Gear, Split, Drive
Spring, Split Gear
Gear, Split, Backlash
Ring, Retaining
Asm., Split Gear, 37T (Incl. 1-4)
Gear, Compensator
Sleeve, Compensator
Slider, Compensator
Spring, Belleville Compensator
Retainer, Compensator
Washer, Split Lock
Nut

Ref. Part No.

13
14
15
16
17
18
19
20
21
22
23
24

7518008
7555987
7517882
3021211
3021197
7721122
7710490
7556237
1013722
4060156
7517260
6230240

Qty. Description

1
1
6
1
1
1
1
1
1
1
5
1

Bolt, Oil Jet
Washer, Flat
Screw
Flywheel
Adaptor, Flywheel
Key, Woodruff
Ring, Retaining, 35 Degree
Washer, Flat
Asm., Crankshaft Gear Starter Drive
Clutch, Starter Drive
Screw
Gear, Crankshaft
11/02

D6

PRIMARY COVER

6
4 5

1

3

2

7 8


14

9 10

11
12

13

15

14
16

17

Ref. Part No.

1 5830223
5830227
2 3021305
3 3512106
4 3552105
5 3610059
6 1013770
7 7517499
8 5412230
9 5246387

Qty. Description

1
1
1
1
2
2
1
1
1
1

Gasket, Primary Cover
Kit, Gasket, Beaded Paper
Asm. Primary Cover, Chrome (Incl. 3,4,5)
Bearing, Needle
Bearing, Needle
Seal
Pinion, Clutch
Screw
O-Ring
Plate, Cap Seal

Ref. Part No.

10 7517483
11 5245960
5134063
12 7517754
13 7517301
14 7517261
15 4010436
16 7517515
17 5245036

Qty. Description

3
1
1
2
1
16
1
1
1

Screw
Cover, Primary Cap, Chrome
Cover, Primary, Ness
Screw
Screw
Screw
Stator
Screw
Bracket, Stator Wire
6/03

D7

SHIFT FORKS/DRUM


1

3

2
16 15

14

13 12

4

2

5
6

10
9

8

11

7

Ref. Part No.

1
2
3
4
5
6

5133255
5132177
5133256
5812232
7052306
1341415

3513518
7661023
7 7556154

Qty. Description

2
2
1
1
1
1

Fork, Shift, Mainshaft
Rail, Shift
Fork, Shift, Countershaft
Washer, Copper
Plug, Socket
Asm., Shifter Drum
(Incl. Bearing, Drum, Pins)
1 Bearing, Ball
2 Pin, Solid
1 Washer, Flat

Ref. Part No.

8 ------9
10
11
12
13
14
15
16

7041583
1341416
7710534
7517384
5133254
7517965
1341402
7042087

Qty. Description

1 Switch, Neutral Indicator
1 Spring
1 Asm., Shifter Ratchet (Incl. 9)
1 Ring, Retaining
1 Screw
1 Star, Shifter
1 Screw
1 Asm., Roller Follower
1 Spring, Tension
2/03

D8

TRANSMISSION


1
9
8
7
5

2

3

6

4

6

4

2

2

4

2
10

11
6
2 4
6
2
18 17

16

4

4

2

12

13

14

15

19

Ref. Part No.

1
2
3
4
5
6
7
8
9
10

1341452
7710525
6230234
5246272
6230264
3584006
6230263
6230257
6230259
1341451

Qty. Description

1
8
1
6
1
4
1
1
1
1

Asm., Countershaft (Incl. 2-9)
Ring, Retaining
Gear, Common, Countershaft, 34T
Washer, Thrust
Gear, 4th Countershaft, 31T
Bearing, Roller
Gear, Countershaft, 3rd, 28T
Gear 2nd Countershaft, 24T
Shaft, Counter
Asm., Mainshaft (Incl. 2,4,6,11-14)

Ref. Part No.

11
12
13
14
15
16
17
18
19

6230228
6230260
6230258
6230261
6230262
7710535
3514401
3514359
1341411

Qty. Description

1
1
1
2
1
1
1
1
1

Shaft, Main
Gear, 1st Mainshaft, 38T
Gear, 2nd Mainshaft, 33T
Gear, 3rd Mainshaft, 29T
Gear, 4th Mainshaft, 26T
Ring, Retaining
Bearing, Roller
Bearing, Needle
Asm., Clutchshaft, 5th (Incl. 17,18)
9/02

D9

DRIVE CLUTCH

1

2

4

3

5

6

8

7

11

9 10

16
17

12

19

18

13

14 15

20

26

28 27


25

24

21

23

22

Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

7670122
1341438
3514358
7670123
5133313
5246074
7042123
5246077
3230546
5246481
3230545
5132703
7042099
7710510
7670124

Qty. Description

1
1
1
1
1
1
1
1
9
8
1
1
1
1
1

Clip, External
Asm., Gear/Basket
Bearing, Ball
Circlip, Internal
Hub, Clutch
Seat, Judder Spring
Spring, Diaphragm, Judder
Plate, Friction Judder
Plate, Separator
Plate, Friction
Plate, Friction Clutch
Plate, Pressure
Spring, Clutch, Diaphragm
Ring, Snap
Circlip, Internal

Ref. Part No.

16 1322061
1321899
17 5131658
18 7547019
19 1341427
20 7710506
21 7710532
22 5132553
23 3514356
24 7670128
25 6230245
26 7556166
27 7517587
28 7556139

Qty. Description

1
1
1
1
1
1
1
1
1
1
1
1
1
1

Asm., Clutch
Asm., Clutch Pack (Incl. 9,10,11)
Washer
Nut
Asm., Rack Insert (Incl. 22,23,24)
Circlip
Ring, Retaining
Insert, Pressure Plate
Bearing, Ball
Circlip, Internal
Rack, Clutch
Washer, Lock
Screw
Washer, Flat
4/03

D10

STARTER MOTOR

1

2

3

5

4

11

6

7

12

10
8

9

Ref. Part No.

1
2
3
4

7517409
7663005
5412175
4060155
4010956
5 7517719
6 3230544

Qty. Description

1
2
1
1
1
1
1

Screw
Dowel
O-Ring
Starter
Starter, Silver
Screw
Clutch, Torque Limiting

Ref. Part No.

7 3513518
8 5412292
9 5132276
5133119
10 7517272
11 6230246
12 5020905

Qty. Description

1
1
1
1
2
1
1

Bearing, Ball
O-Ring
Cap, Bearing
Cap, Bearing, Silver
Screw
Gear, Idler
Shaft, Idler, Mounting
6/03

D11

EVAP SYSTEM
KINGPIN V04CB16LA and KINGPIN V04CB16LB and KINGPIN V04CB16LC and KINGPIN V04CB16LD and KINGPIN V04CB16LF and KINGPIN V04CB16LK and KINGPIN V04CB16LL and KINGPIN V04CB16LM

1


1

2
13

3

12
4
8

5

7

9
10

6

11

Ref. Part No.

1
2
3
4
5
6
7

7080138
7547121
7517839
7080756
7517881
5246644
5434835

Qty. Description

2
2
1
1
1
1
1

Cable Tie
Nut
Screw
Clip, Snap-In
Screw
Bracket, EVAP Canister
Line, Water Vent

Ref. Part No.

8
9
10
11
12
13

5434837
7080924
7080932
5411870
2520192
5434838

Qty. Description

1
1
1
1
1
1

Line, Fuel
Tiewrap
Filter, Vent Line
Hose, Vent
Filter
Line, Purge
11/02

D12

OWNER’S MANUAL


1

Ref. Part No.

1 9919167
9919168

Qty. Description

Ref. Part No.

Qty. Description

1 Manual, Owner’s, ’04 Kingpin
1 Manual, Owner’s, ’04 Kingpin, Canada, Bilingual
9/03

D13

This page left blank intentionally.

PRINTED IN THE USA

PARTS MANUAL PN 9918956 and MICROFICHE PN 9918957 9/03

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