sportsman 500 model #a00ch50(aa)(ab)(ae) …pi54.com/corp/manuals/parts/9915480r05.pdf · recoil...

PARTS MANUAL PN 9915480 and MICROFICHE PN 9916574 6/00

SPORTSMAN 500Model #A00CH50(AA)(AB)(AE)

(AF)(AH)(AK)(AL)SPORTSMAN 500 RSE

Model #A00CH50(AC)(AJ)WORKER 500

Model #A00CH50(EB)Rev. 05

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSSPORTSMAN500A00CH50(AA)(AB)(AE)(AF)(AH)(AK)andSPORTSMAN500RSEA00CH50(AC)(AJ)

and WORKER 500 A00CH50(EB)Parts Manual

AA-ARM/STRUT MOUNTING C4. . . . . . . . . . . . .AIR BOX B4. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D13-14. . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C7. . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER CYLINDER/BRAKE

LINE B12. . . . . . . . . . . . . . . . . . . . . . . . . .CONTROLS - THROTTLE ASM./CABLE B11. . .COOLING SYSTEM A13. . . . . . . . . . . . . . . . . . .CRANKCASE D8. . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D11. . . . . . . . . . . . .CV JOINT - BTB B5. . . . . . . . . . . . . . . . . . . . .CYLINDER D9-10. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A11-12. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C5. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C6. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C8. . . . . . . . . . . . . . .ENGINE MOUNTING B1-2. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A14. . . . . . . . . . . . . . . . . . .

FFOOT BRAKE E9. . . . . . . . . . . . . . . . . . . . . . .FRAME MOUNTING C3. . . . . . . . . . . . . . . . . . .FRONT BRAKE B10. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A7. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING D1-2. . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A9-10. . .FRONT STRUT B8. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B9. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP E7. . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B3. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C14. . . . . . . . . . . . . . . . . . . .

GGEARCASE (Cases and Snorkel) D7. . . . . . . .GEARCASE (INTERNAL COMPONENTS) D3-4. . .

HHANDLEBAR and HEADLIGHT POD C1-2. . . . . .

IINTAKE and EXHAUST D12. . . . . . . . . . . . . . . .

MMAGNETO E5. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL COOLING D5-6. . . . . . . . . . . . . . . . . . . . . . .OIL FILTER E4. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP E3. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK B14. . . . . . . . . . . . . . . . . . . . . . . . . .

PPROP SHAFT B7. . . . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE/FOOT PEDAL C11-12. . . . . . . . . . . .REAR CAB and SEAT A5-6. . . . . . . . . . . . . . . . .REAR DRIVE SHAFT B6. . . . . . . . . . . . . . . . .REAR RACK MOUNTING A8. . . . . . . . . . . . . . .REAR SUSPENSION C9-10. . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE C13. . . . . . . . . . . . . . . . .RECOIL STARTER E1. . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR E6. . . . . . . . . . . . . . . . . . .STEERING POST B13. . . . . . . . . . . . . . . . . . . . .

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

WWATER PUMP E2. . . . . . . . . . . . . . . . . . . . . . .

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

(AA) refers to Model #A00CH50AA and (AF) refers to Model #A00CH50AF, Olive Green. (AB) refers to Model#A00CH50AB and (AH) refers to Model #A00CH50AH, Porsche Red. (AC) refers to Model #A00CH50AC and (AJ) refersto Model #A00CH50AJ, Camo. (AE) refers to Model #A00CH50AE and (AK) refers to Model #A00CH50AK, Medium Yel-low. (EB) Refers To Model #A00CH50EB, Red.

2000 SPORTSMAN 500 SPECIFICATIONSBRAKES

Type/BrakesType/Brakes - AuxiliaryPark Brake

Hydraulic DiscMechanical

Hydraulic Lock, All Wheel

CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallons)Gearcase Oil (ounces)Engine Counter Balance 10W30Oil (quarts) InjectorOil (quarts) Engine OW40Rack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

2.255.2532N/AN/A29018035

Standard1225

DRIVE TRAINType Engine Braking

DRIVE CLUTCHCenter Distance (inches)Clutch Offset (inches)Clutch WeightSpring Color

101/2

10MH(50g)Blue/Green

DRIVEN CLUTCHHelix AngleSpring Position

Compound (EBS)N/A

DIMENSIONAL FEATURES

Approx. Turning RadiusBox, ToolBox (cubic feet)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (lbs. dry)Wheel Base (inches)Width (inches)

65�6x7x14

N/A11478134697

50.5046

ENGINEEngine Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCoolingAlternator OutputElec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayAir Screw/Pilot ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

EH50PLE094 Cycle, Single Cyl.

Dry Sump92x75499

10:2 Full StrokeLiquid250W

Standard1/BST34(CV type)

152.540Q-0N/A

2 5/8 Turn4HB41-3

CDI30 @ 3500

.028NGK BKR5EUSFS Appr.

GEARCASETransmissionShift TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain Type

PRDSide Lever

6.69/15.17/13.34/12:1

3-16:1N/AN/AShaft

GRAPHICSBody StyleBumper Caps/Polyprop.Cargo Box or BedFender, Front

Fender, Rear

FootwellFrame/SteelFront Cover

Handlebar Cover w/DecalHeadlight/Dash Pod

Rack, FrontRack, RearRims

Seat VinylSide Panel

Spring, FrontSpring, Rear

Gen IV(AE)(AK) Medium Yellow(AE)(AK) Medium Yellow(AA)(AF) Olive Green

(AB)(AH)(EB) Porsche Red(AE)(AK) Medium Yellow

(AL) Gun Metal(AC)(AJ) Camo

(AA)(AF) Olive Green(AB)(AH)(EB) Porsche Red(AE)(AK) Medium Yellow

(AL) Gun Metal50(AC)(AJ) Camo

BlackSemi Flat Black(AA)(AF) Black



Black(AA)(AF) Olive Green/Black

(AB)(AH)(EB) PorscheRed/Black(AE)(AK) Medium Yellow/Blk


BlackBlack

(AA)(AE)(AF)(AK)(AC)(AJ) Black(AB)(AH)(EB)(AL) Aluminum

Black(AA)(AF) Olive Green



BlackBlack

ELECTRICALHeadlight - Handlebar (watts)Headlight - Front Hood (watts)Headlight - Grill (watts)Taillights (watts)Brake Light (watts)Indicator Bulb

1 Single Beam, 60WN/A

2 Single Beam, 27W8.26W26.9W1.0W

SUSPENSIONFront Type -

Front Travel (inches)Rear Type -

Rear Travel (inches)ShockAdjustment

MacPherson Strut6.7

Independent9.5

2 - 1 3/8” Bore Gas BagCAM

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

Goodyear25x8x1225x11x10

N/A55

N/A

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

2000 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUAL

SUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Sportsman 500 A00CH50(AA)(AB)(AE)(AF)(AH)(AK)(AL)

9915299 9915476 9915480 9916574 9915512

Sportsman 500 RSE A00CH50(AC)(AJ) 9915299 9915753 9915480 9916574 9915512

Worker 500 A00CH50(EB) 9915299 9915476 9915480 9916574 9915512

A5

REAR CAB and SEATSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN

500 A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB

2

7

3

6

910

14

13

15

16

17

3938

12

19

21

23

34

5

4142

43

1

40

36

11

24

25

4

37

18

3

2932

30

31

29

8

2827

26

3335

20

6

29

27

28

22

E 2000 Polaris Sales Inc.

A6

REAR CAB and SEATSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


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

1 7661645 10 Rivet, T-Lock2 7511930 2 Bolt3 7555792 4 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-191

5432117-1365432117-0535433282-2835432117-317

11111

Cab, Rear, Olive Green (AA)(AF)Cab, Rear, Porsche Red (AB)(AH)(EB)Cab, Rear, Med Yellow (AE)(AK)Cab, Rear, Camo (AC)(AJ)Cab, Rear, Gun Metal Gray (AL)

6 7541925 4 Nut, Nylok7 5224592 1 Retainer, Seat Latch8 5811308 1 Foil, Tape, Rear Cab9 7512242 4 Screw10 7555859 4 Washer, Flat11 7512085 2 Screw12 5433640 1 Box, Tool13 7621403 2 Rivet14 5211033 2 Bracket, Lever Retainer15 1040387 1 Latch, Seat16 7041370 1 Spring, Latch17 2682441-070

2681747-07058111045811105

1111

SeatCovering, SeatFoil, Seat Base, LargeFoil, Seat Base, Small

18 5410414 8 Bumper, Rubber19 7512130 2 Screw20 7555748 2 Washer

21 5431787 1 Cover, Tool Box22 7052095 2 Fitting, 90 Degree23 5410896 1 Cap, Drain24 7661638 6 Rivet25 5242953-067 1 Guard, Clutch26 ------ -- -- -- -- 1 Front Housing

(See Front Housing Pg. D1 for Details)27 7552603 7 Washer, Spring Lock28 7512492 7 Screw29 7542122 28 Nut, Nylok30 5432280 2 Spacer, Footwell31 7517377 4 Screw32 1012979-067

1013359-06711

Frame, Main (If built before 3/13/00)Frame, Main (If built after 3/13/00)

33 7078261 1 Decal - Hitch34 7517376 8 Screw35 5432221-070

5433219-07011

Footwell, Black, LHFootwell, Black, RH

36 5811111 1 Foil, Foam, Rear Fender37 5811106 2 Foil, Rear Cab, Front38 7073761 1 Decal - Carburetor Information39 7077446 1 Decal - Filter Element40 5811087 1 Foil, Foam41 7512232 12 Screw42 7670057 12 Nut, U-Type Speed43 5431796-070

5431797-07011

Guard, Mud, Rear, LHGuard, Mud, Rear, RH

6/00

A7

FRONT CABSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


3

4

2

5

8

7

17

2021

10 9

1516

19

18

23

1112

522

1

1

6

1

13

14


1 7512232 10 Screw2 2631987-191

2631987-136

2631987-0532632064-283

2632306-283

2632299-317

1

1

11

1

1

Cab, Front, Olive Green w/WarningDecals (AA)(AF)Cab, Front, Red w/Warning Decals(AB)(AH)(EB)Cab, Front, Med Yellow (AE)(AK)Cab, Front, Camo(AC)(AJ)(If built before 5/15/00)Cab, Front, Camo(AC)(AJ)(If built after 5/15/00)Cab, Front, Gun Metel Gray (AL)

3 5432088-1915432088-1365432088-0535432088-3175433290-283

11111

Cover, Frt., Olive Green (AA)(AF)Cover, Front, Red (AB)(AH)(EB)Cover, Frt., Med Yellow (AE)(AK)Cover, Frt. Gun Metal Gray (AL)Cover, Front, Camo (AC)(AJ)

4 7670085 2 Clip, Spring5 7670057 10 Nut, U-Type Speed6 7517312 2 Screw7 7661645 4 Rivet, T-Lock8 7670068 2 Nut, Push-on9 5811917 2 Shield, Deflector10 7670090 3 Clip, Plastic Dart11 7670109 1 Clip, Routing

12 5411778 AR Line, Breather13 5244913-067

5244914-06711

Guard, Splash, LHGuard, Splash, RH

14 7517685 1 Screw15 7555931 2 Washer, Flat16 7542122 2 Nut, Nylok17 5431798-070

5431799-07011

Guard, Mud, Front, LHGuard, Mud, Front, RH

18 7541925 2 Nut, Nylok19 7555792 2 Washer20 5431809-053

2620085-0535431809-1912620085-1915431809-1362620085-1362632289-3172620085-3172632286-2832632317-2832632065-283

11111111111

Panel, Side, Yellow LH (AE)(AK)Panel/Foil, Yellow, RH (AE)(AK)Panel, Side, Green, LH (AA)(AF)Panel/Foil, Green, RH (AA)(AF)Panel, Side, Red, LH (AB)(AH)(EB)Panel/Foil, Red, RH (AB)(AH)(EB)Panel/Foam, Gun Metal Gray, LH (AL)Panel/Foil, Gun Metal Gray, RH (AL)PanelFoam, Camo, LH (AC)PanelFoam, Camo, LH (AJ)Panel/Foil, Camo, RH (AC)(AJ)

21 5810996 1 Foil, Foam, Side Panel22 5811491 1 Foil, Side Panel, Gen. IV, RH23 7512085 2 Screw

10/00

A8

REAR RACK MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


5

4

23

9

1112

13 14

1510

10

11

7

1

6

8

2

16

18

17

11

910

10


1 2871501 1 Kit - Rack Extender, Rear (Incl. 6)2 7517685 4 Screw3 7517686 2 Screw4 2670174-070 1 Asm., Rack, Rear

(Incl. Ref. 5 and Warning Decal)5 2670070 2 Reflector, Red6 7517208 6 Screw7 1040490-067

1012894-067

1

1

Support, Rear Rack(AA)(AB)(AE)(AF)(AH)(AK)(EB)(AL)Support, Rear Rack (AC)(AJ)

8 5241663-067 1 Bracket, Silencer, Frame

9 7512329 4 Bolt10 7558402 10 Washer, Flat11 7542324 8 Nut, Nylok12 7670096 2 Nut, Chimney13 1040524-067

1040525-06711

Mount, Front, Rear Rack, LHMount, Front, Rear Rack, RH

14 5333332-067 4 Spacer15 7515385 4 Screw16 7515321 4 Screw17 5243378-067 1 Bumper, Rear (AC)(AJ)18 5433305 4 Cap, Bumper, End (AD)(AJ)(AL)

10/00

A9

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


15

16

17

1819

20

14

8

7

10

1112

21

23

22

27

28

3

4

6

13

6

9

1

8

6

26

2

5

25

24

A10

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN



1 1040526-067 1 Extender, Rack, Front, Low (AC)(AJ)2 7517685 4 Screw3 2670180 1 Asm., Front Rack

(Incl. Ref. 4 and Warning Decal)4 2670071 2 Reflector, Amber5 7517208 4 Screw (AC)(AJ)6 7515399 8 Screw7 2200775 1 Kit - Mount, Front Rack8 7542324 4 Nut, Nylok9 7558403 2 Washer10 5432155-070 1 Bumper11 7515391 2 Screw12 7515390 2 Screw13 7555954 4 Washer14 1013210-067

1013211-06711

Support, Front Rack, LHSupport, Front Rack, RH

15 7512232 4 Screw

16 243101424310154030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

17 7515382 2 Bolt18 7558402 4 Washer19 5810467 1 Plug, Frame20 5244623-067

5244624-06711

Extension, Frame, LHExtension, Frame, RH

21 5241583-067 1 Guard, Brush22 7621330 7 Rivet23 5240591-067 1 Grill, Guard, Brush24 5433305 4 Cap, End, Bumper (AC)(AJ)25 5243377-067 1 Bumper, Front (AC)(AJ)26 7512097 6 Screw27 7670094 6 Nut, U-Type28 5433315

543331611

Shield, Side, Radiator, LHShield, Side, Radiator, RH

1/00

A11

DECALSSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500

A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500 A00CH50AL and WORKER 500 A00CH50EB

265

7

111213

8

5

15

1716

18 19

20

LH

RH

4

109

144

31


1 7079110 1 Decal - Warning, Rear Rack2 7074110 1 Decal - Load Distribution3 7077749 1 Decal - Park Brake Warning (EB)4 7078455

707845670787747078775

1111

Decal - “4X4 ISD”, LH (AA)(AB)(AF)(AH)Decal - “4X4 ISD”, RH (AA)(AB)(AF)(AH)Decal - “4X4 ISD”, LH (AE)(AK)(AL)Decal - “4X4 ISD”, RH (AE)(AK)(AL)

5 7078452

7078433

2

2

Decal - ‘‘POLARIS”, Side Panel(AA)(AB))(AE)(AF)(AH(AK)(EB)Decal - ‘‘POLARIS”, Side Panel (AL)

6 707845970787777078513

111

Decal - Tank Side, RH (AA)(AB)(AF)(AH)Decal - Tank Side, RH (AE)(AK)Decal - “WORKER”, Tank Side, RH (EB)

7 7074935

7079213

1

1

Decal - Warning, AWD Switch(AA)(AB))(AE)(AF)(AH(AK)(EB)Decal - Warning, AWD Switch (AL)

8 7078003 1 Decal - Headlight Adjustment9 7078315

7078465

1

1

Logo, “45th Anniversary”(If built before 12/31/99)Logo, Polaris Star (AF)(AH)(AL)

10 7078449

7078859

1

1

Decal - “500 L/C 4 Stroke”(AA)(AB)(AF)(AH)Decal - “500 L/C 4 Stroke” (AE)(AK)(AL)

11 7074220 1 Decal - “Macpherson Strut”12 7078354

7079085

1

1

Decal - Discretionary Warning(AA)(AB))(AE)(AF)(AH(AK)(EB)Decal - Discretionary Warning (AL)

13 7078577 1 Decal - Drain Recoil14 7079102 2 Decal - Rack/Warning15 7079604 1 Decal - Warning, Override, AWD16 7078253 1 Decal - Age Warning, ATV17 7078458

70787767078512

111

Decal - Tank Side, LH (AA)(AB)(AF)(AH)Decal - Tank Side, LH (AE)(AK)(AL)Decal - “WORKER”, Tank Side, LH (EB)

18 7077920 1 Decal - Passenger Warning19 7075834

7079084

1

1

Decal - Tire Pressure(AA)(AB))(AE)(AF)(AH(AK)(EB)Decal - Tire Pressure (AL)

20 7077919

7079083

1

1

Decal - Warning, General, CPSC(AA)(AB))(AE)(AF)(AH(AK)(EB)Decal - Warning, General, CPSC (AL)

10/00

A12

DECALSSPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE A00CH50AJ

RH

LH

12 3

456 7

8

9

10

111213

14

15

18 1917

16


1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution3 7078049 1 Decal - “EBS Dual Sensing”, RH4 7078050 2 Decal - “4X4 Indy Shaft Drive”5 7078051 2 Decal - “SPORTSMAN”6 7078253 1 Decal - Age Warning7 7078047 2 Decal - “POLARIS”8 7078003 1 Decal - Headlight Adjust9 7074935 1 Decal -Warning AWD Switch10 7078046 1 Decal - “Remington Special Edition”11 7078045 1 Decal - “Liquid Cooled”, Radiator

12 7078354 1 Decal - Discretionary Warning13 7078577 1 Decal - Drain Recoil14 7078315

7078465

1

1

Logo, 45th Anniversary(If built before 12/31/99)Logo, Polaris Star(If built after 12/31/99)

15 7076273 1 Decal - Override Switch, AWD16 7077919 1 Decal - Warning, General, CPSC17 7078048 1 Decal - “EBS Dual Sensing”, LH18 7077920 1 Decal - Passenger Warning19 7079084 1 Decal - Tire Pressure/Load

10/00

A13

COOLING SYSTEMSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


36

2

13

12

3231

19

39

24

11

37

40

419

38

3

20

16

2221

27

10

26

18

23

28

25

14

178

14

11

7

8

4

5

1

30

34

29

33

6

15

35

29

9


1 7080807 1 Clamp, Hose2 1240044 1 Cap, Pressure3 5433364 1 Filler, Coolant4 5243505-067 1 Bracket, Filler, Coolant5 7661638 3 Rivet6 5433707 1 Flexguard7 5411783 1 Hose, Engine, Upper8 7080827 2 Clamp, 1”9 7512084 4 Screw10 5411632 1 Hose, Filler Neck11 7080826 2 Clamp12 7517659 4 Screw13 2410123 1 Asm., Fan and Motor14 7670111 4 U-Clip15 7080492 1 Cable Tie16 7547069 2 Nutsert17 3110032 2 Mount, Rubber18 5020572 2 Spacer19 5433059 1 Shroud, Fan20 4010161 1 Sensor, Thermal21 1240045 1 Radiator

22 7552605 2 Washer, Split Lock23 7512113 2 Screw24 5433317 1 Cover, Radiator25 5410607 4 O-Ring26 7052244 1 Valve, Drain27 5410584 2 Bushing, Mount28 5243503-067 1 Bracket, Radiator, Lower29 7517386 3 Screw30 7080890 1 Tie, Panel31 5411782 1 Hose, Engine, Lower32 5521550 1 Plastic, Guard, Hose33 7080851 1 Clamp, Hose34 7080696 1 Clamp, Hose35 4010369 1 Breaker, Circuit, Fan36 5430743 1 Cap, Overflow, Drilled37 5810279 1 Gasket, Overflow Cap38 5433774 1 Plug, Cap39 5431673 1 Tank, Surge40 8450003-1525 1 Line, Fuel41 7052065 1 Fitting, Barbed, 90 Degree

9/00

A14

EXHAUST SYSTEMSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


14

9

15

5

14

7

3

1

8

13

10

2

12

6

12

7

4

5

16

5

8

1312

7

8

32

1

1111


1 7542324 3 Nut, Nylok2 7555716 3 Washer, Flat3 5410436 3 Washer, Rubber4 7555863 2 Washer5 5010192 3 Bushing6 ------ -- -- -- 1 Bracket, Silencer, Frame (See Rear

Rack Mounting Pg. A8, Ref. 8)7 5410241 3 Dampener, Vibration8 7515316 3 Bolt, Carriage

9 1260715-029 1 Silencer, Exhaust10 7512666 1 Bolt11 7042031 4 Spring, Exhaust12 7515197 4 Screw13 7555935 4 Washer14 5241678 2 Shield, Heat, Exhaust15 1260716-029 1 Pipe, Exhaust16 5240898 1 Seal, Exhaust

10/98

B1

ENGINE MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


18

28

44

47

39

42

21

10

33

5

3029

34

23

2

31

4140

43

27

32

45

38

3

36

4

37

1

48

11

26

22

2

99

38

1311

1312

15

76

8

2425

35

17

39

14

20

19

16

46

4

8

19

19

19

19

2

B2

ENGINE MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN



1 7546601 2 Nut, Nylok2 7080003 8 Clamp, Hose, Red3 5811490 1 Hose, 1.75” Long4 8450040-600 AR Line, Fuel5 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D14, Ref. 47)6 7080413 1 Clamp, Narrow Band7 5410995 1 Boot, Carburetor8 7080511 2 Clamp, Narrow Band9 8450003-1525 AR Line, Fuel10 7052075 1 Fitting, Tee11 3110032 2 Mount, Rubber12 7552605 2 Washer, Split Lock13 7547069 2 Nutsert14 ------ -- -- -- 1 Screw and Washer

(See Carburetor Pg. D14, Ref. 48)15 5211626-067 1 Strap, Carburetor Mount16 8360009-600 AR Line, Fuel17 7512315 2 Bolt18 7552901 2 Washer, Spring Lock19 7547108 8 Nut, Flange Lock20 7080694 1 Clamp, Spring Hose21 ------ -- -- -- -- AR Hose, Breather

(See Air Box Pg. B4, Ref. 16)22 7555815 2 Washer23 3110046 2 Mount, Rubber, Front24 7080539 1 Clamp, Nylon25 7621462 1 Rivet26 5224658-067 1 Strap, Frame Support27 7512566 1 Bolt

28 7575202 1 Washer, Interlock29 5210748 1 Washer, Flat30 5430261 1 Bushing31 5410421 1 Boot, Clutch Intake32 ------ -- -- -- -- 1 Asm., Drive Clutch, Braking

(See Drive Clutch Pg. C5, Ref. 17)33 ------ -- -- -- -- 2 Screw and Washer

(See Crankcase Pg. D8, Ref. 6)34 ------ -- -- -- -- 1 Bracket, Retainer, Seal

(See Clutch Cover Pg. C7, Ref. 24)35 7080474 2 Clamp, Hose36 7515417 2 Screw37 5241150-067 1 Mount, Engine, Front38 3110044 2 Mount, Rubber, Top39 7555801 2 Washer, Wrought40 ------ -- -- -- -- 2 Nut (See Cylinder Pg. D10, Ref. 22)41 ------ -- -- -- -- 2 Washer

(See Cylinder Pg. D10, Ref. 23)42 1260771-029 1 Manifold, Black43 ------ -- -- -- -- 1 Gasket, Exhaust

(See Cylinder Pg. D10, Ref. 20)44 3085556 1 Engine, Short Block (EH50PLE09)

NOTE: The Short Block assemblycontains a crankcase assembly, cylin-der & cylinder head assembly and apiston & crankshaft assembly. Priorauthorization is required for warrantyconsideration.

45 5241453-067 1 Mount, Engine, Top46 7512232 1 Screw47 4010132 1 Cable, Ground, Engine48 2530009 1 Filter

1/00

B3

FUEL TANKSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


21

5

16 13

9

19

18

1

10

2

12

3

20

15

17

7

4

14

8

6

15

11


1 5430725 1 Cap, Gas Tank2 5810144 1 Gasket, Fuel Cap3 5811310 1 Seal, Foam4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7517451

751224722

Bolt (AA)(AB)Screw (AF)(AH)(AK)(AJ)

7 7552801 2 Washer, Spring Lock8 7558301 2 Washer, Flat9 5222154-067

5222155-06711

Bracket, Mounting, Rear, LHBracket, Mounting, Rear, RH

10 5332457 2 Spacer (AA)(AB)

11 7547069 2 Nutsert12 5810317 2 Pad, Fuel Tank Bracket13 7052150 1 Fitting, Fuel Outlet, Main14 8450040-600 AR Line, Fuel15 7080003 4 Clamp, Hose, Red16 7052149 1 Fitting, Fuel Outlet, Reserve17 7517505 1 Screw18 5432559 1 Knob, Fuel Valve19 5432733 1 Nut, Fuel Valve20 7052161 1 Valve, 3-Way21 2520144 1 Asm., Fuel Tank (Incl. 13,16)

1/00

B4

AIR BOXSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1

4

18

17

11

5

20

22

8

12

23

7

10

2

21

9

3

25

26

6

14

15

19

13

2416

13

13

13


1 5811633 1 Filter, Precleaner Sleeve2 7080595 1 Filter, Air Intake3 7080413 1 Clamp, Narrow Band4 5432601 1 Collar, Carburetor Inlet5 5432868 1 Cover, Air Box6 7517541 4 Screw7 5433293 1 Duct, Air Inlet8 5811626 1 Seal, Foam9 5432086 1 Duct, Clutch Air Inlet10 5411422 1 Gasket, Intake11 5811482 1 Seal, Air Box Cover12 5432774 1 Box, Air13 7080699 4 Clamp, Hose

14 8450073-600 AR Line, Breather15 2530029 1 Filter, Breather16 5411847 AR Hose, Breather17 5432858 1 Duct, Carburetor Inlet18 5830128 1 Gasket, Carburetor Inlet Duct19 5411668 1 Line, Breather20 5432377 1 Plug, Trap21 8450059-150 AR Line, Fuel22 7080650 1 Clamp, Hose23 5811650 1 Foil, Air Box24 7558301 2 Washer, Flat25 7515179 2 Screw26 5242044 6 Clip, Air Box

3/00

B5

CV JOINT - BTBSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


BTB

1012 3 4 5 6

7

8 9

12

11

13


1 1380119 2 Asm., CV Housing w/Sleeve2 5222299 1 Sleeve, Drive Shaft Seal3 3260115 1 Clamp, CV Joint, Large4 7670091 1 Circlip5 5411106 1 Boot, CV Joint6 1380094 1 Shaft Replacement (Incl. 4)7 1380092 1 Cardan Replacement (Incl. 4,6,8,9)

8 2200771 1 Kit - Cross and Bearing9 3260130 1 Yoke, Splined10 7661913 3 Pin, Spring11 7080627 1 Clamp, Small Band12 2200773 1 Kit - Boot Replacement (Incl. 3,5,11)13 2200961 1 Kit - Drive Shaft w/Sleeve BTB

10/98

B6

REAR DRIVE SHAFTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


986 72 5

11

31

10

254


1380142 2 Asm., Drive Shaft, Rear (Incl. 1-9)1 1590280 1 CV Joint2 1350044 2 Clamp, Large3 1350046 1 Grease, 30g4 7710505 1 Ring, Retaining5 1350045 2 Boot

6 1350043 2 Clamp, Small7 1350047 1 Grease, 50g8 1590281 1 Joint, Plunging9 1350042 1 Ring, Spring10 2201374 1 Kit - Boot (Gear Side)11 2201373 1 Kit - Boot (Wheel Side)

3/00

B7

PROP SHAFTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


2 34

56

1


1380146 1 Shaft, Prop1 7661913 1 Pin2 3260133 1 Yoke, Gear Case, Front3 ------ -- -- -- -- 2 Kit - Cross and Bearing

(See CV Joint - BTB Pg. B5, Ref. 8)

4 3260136 1 Shaft, Prop5 3260131 1 Yoke, Prop Shaft, Transmission6 5411092 1 O-Ring

2/00

B8

FRONT STRUTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1

2

35

67

9

10

4

1112

13

15

16

8

14

17

18

19

21

4

20

2223

24

252627

1112

4


1 5411608 2 Bumper2 7041761 2 Strut, Front3 5211115 2 Washer4 7558402 10 Washer, Flat5 7080573 2 Clamp, Rubber Coated6 7542324 4 Nut, Nylok7 7512365 4 Screw8 7552901 4 Washer, Spring Lock9 5810439 2 Retainer, Casting Wire, Strut10 ------ -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B10 for Details)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 2201311

2201312

1

1

Asm., Hubstrut, Heavy, LH(42mm)(Incl. 9,12-15,23)Asm., Hubstrut, Heavy, RH(42mm)(Incl. 9,12-15,23)

17 7041375-067 2 Spring, Compression18 5243364 2 Retainer, Spring19 5432871 2 Ball, Pivot, Bottom20 7515339 4 Bolt21 5132062 2 Spacer22 ------ -- -- -- -- 1 Kit - Drive Shaft w/Sleeve BTB

(See CV Joint - BTB Pg. B5, Ref. 13)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, Nylok

6/00

B9

FRONT WHEELSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


9 10 11 13

1

26

23

4

68

7

14

1524

23 6

16 17 1920

22

12

5

5

21

18

25


1 7512325 8 Bolt2 3610019 2 Seal, Front Hub3 5211148 2 Plate, Armature4 1520281 2 Clutch, Front Hub, Elec./Mech.5 3554506 4 Bearing, Tapered Roller Cone6 3554507 4 Bearing, Tapered Roller Cup7 7515523 8 Stud8 1520243 2 Asm., Hub w/Bearing Race (Incl. 2,6,7)9 3250028 2 Cage, Roll10 3250010 12 Roll11 3250032 2 Spring, Garter12 1321814 2 Spacer13 3250030 2 Cam14 7052045 2 Plug, Magnetic Drain

15 5410947 2 Tire (25x8-12)16 7556004 2 Washer17 7542810 2 Nut, Slotted18 7661401 2 Pin, Cotter19 5410470 2 O-Ring20 5432611 2 Cap, Hub21 7512027 6 Screw22 7542459 8 Nut23 1520269-067

1520269-117

2

2

Rim, Front, Black(AA)(AC)(AE)(AF)(AK)(AJ)Rim, Front, Aluminum (AB)(AH)(AL)(EB)

24 1525017 2 Valve, Rim25 5243676 2 Disc, Brake (AF)(AH)(AK)(AL)(AJ)(EB)26 5242935 2 Disc, Brake (AA)(AB)(AC)(AE)

6/00

B10

FRONT BRAKESPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1

2 3

8

9

11

10

121314

4

5 6 7


1910309

1910310

1910427

1910428

1

1

1

1

Asm., Front Brake Caliper, LH(Incl. 1-7,9,10)(AA)(AB)(AC)(AE)Asm., Front Brake Caliper, RH(Incl. 1-7,9,10)(AA)(AB)(AC)(AE)Asm., Front Brake Caliper, LH (Incl.1-7,9,10)(AF)(AH)(AK)(AJ)(AL)(EB)Asm., Front Brake Caliper, RH (Incl.1-7,9,10)(AF)(AH)(AK)(AJ)(AL)(EB)

1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 5131115

51311161930642

111

Caliper, Brake, LHCaliper, Brake, RHKit - Front Brake Boot

4 1930665 1 Kit - Piston and Seal(Incl. 5-7)5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)7 5132294 1 Piston, Brake, Long

8 2200465

2200901

22011492201398

1

1

11

Kit - Front Brake Pad, General Duty(AA)(AB)(AC)(AE)Kit - Front Brake Pad, Severe Duty(AA)(AB)(AC)(AE)Kit - Front Brake Pad (AA)(AB)(AC)(AE)Kit - Front Brake Pad(AF)(AH)(AK)(AJ)(AL)(EB)

9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 5410494 1 Boot, Pin Seal12 ------ -- -- -- -- 4 Washer

(See Front Strut Pg.B8, Ref. 4)13 ------ -- -- -- -- 4 Washer

(See Front Strut Pg. B8, Ref. 8)14 ------ -- -- -- -- 4 Screw

(See Front Strut Pg. B8, Ref. 7)

6/00

B11

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


5

2

4

3

6

1


1 5410193 1 O-Ring2 5433806 1 Cover3 5411439 1 O-Ring

4 7080709 1 Cable, Throttle5 2010188 1 Asm., Throttle Control (Incl. 2,3,6)6 2010191 1 Asm., Throttle Clamp

1/00

B12

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


2

3

5

10

6

4

12

1

11

13

23

27

17

20

2122

22

25

24

2616

1819

28

15

14

9

8

7


20500782200809

11

Asm., Master Cylinder (Incl. 13)Kit - Master Cylinder Reservoir(Incl. 1-3,13)

1 1930797 2 Bolt, Cap2 1930796 1 Cap, Reservoir3 1930795 1 Diaphragm4 2200808 1 Kit - Master Cylinder Clamp5 1930799 1 Asm., Piston Master Cylinder6 1930804 1 Rivet7 2201034 1 Kit - Brake Lever w/Parking Latch

(Incl. 6-9)8 ------ -- -- -- -- 1 Spring, Flat9 2201090 1 Kit - Park Brake Lever (Incl. 6,8)10 1930806 1 Nut11 1930792 2 Bolt, Reservoir12 1930805 1 Bolt13 ------ -- -- -- -- 1 Ring, Square, Reservoir

14 5411297 1 Boot, Rubber Brake Line15 5410988 2 Seal16 4110164 1 Switch17 ------ -- -- -- -- 1 Line, Rear Brake (See Rear Brake/

Foot Pedal Pg. C12, Ref. 5)18 7621462 2 Rivet19 7080539 2 Clamp, Nylon20 8360031-30 1 Conduit21 1930752 1 Line, Brake, Left Front w/Fittings22 7080138 8 Cable Tie23 7512024 2 Screw24 1930753 1 Line, Brake, Right Front w/Fittings25 8360011-38 1 Tubing, Convoluted26 7052129 1 Fitting, Inverted Flare Cross27 1930817 1 Line, Brake, Pod28 1930674 1 Bolt, Banjo

4/99

B13

STEERING POSTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1

16

1514

2

3

4

13

10

567

11

6

6

9

12

7

8


1 1843051 1 Asm., Steering Post (Incl. 5,13)2 5433415 1 Bushing, Steering, Console3 7080424 1 Fitting, Lubrication4 7515321 2 Bolt5 5431574 1 Plug, Grease, Steering6 7555878 3 Washer7 5410772 2 O-Ring8 5431571 1 Spacer, Steering Post

9 7543203 1 Nut10 7661633 1 Pin, Cotter11 5431570 1 Bushing, Steering, Lower12 7661632 2 Rivet13 7080433 1 Fitting, Lubrication14 5433416 1 Bushing, Steering, Upper15 5222999-067 1 Bracket, Steering Bushing, Upper16 7542324 2 Nut, Nylok

1/00

B14

OIL TANKSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


15

1

2

4

8

10

6

7

11

12

23

1718

19

2021

22

14

5

3

9

9

16

9

To Top Oil Pump Fitting on Engine

To Lower Oil Pump Fitting on Engine

To Airbox

1413

8


1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7052163 1 Fitting5 5411668 1 Line, Breather6 5432289 1 Dipstick7 5410889 1 O-Ring8 7517102 2 Bolt, Banjo9 7555896 4 Washer, Copper10 7052109 1 Tube, Banjo Return11 7052133 1 Tube, Banjo Intake12 2530020 1 Screen, Oil Filter

13 7542122 2 Nut, Nylok14 7558301 2 Washer, Flat15 5131785 1 Tank, Oil, LH16 5411042 1 Grommet17 5410828 2 Grommet, Mounting, Reservoir18 5333204 2 Bushing19 7512130 2 Screw20 7051524 1 Plug, Magnetic21 5850135 1 Washer22 7515158 9 Screw23 5131255 1 Tank, Oil, RH

11/02

C1

HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500

A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB

35

9

42

1011

16

44

1

2

3 14

6

7

8

12

15

17

18

21

2526

3029

41

37

36

3831

23

28

4

4

5

24

39

3233

22

27

1920

13

43

34

40

C2

HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500



1 32802903280312

11

SpeedometerSpeedometer, Kilometers (EB)

2 543096740400534040054

111

Plug, IndicatorIndicator, Hot TemperatureIndicator, Neutral/Reverse

3 7511881 3 Screw4 7670086 3 Nut, U-Type5 2460668 1 Harness, Headlight Pod6 ------ -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B11, Ref. 5)7 5242987-067 1 Tube, Handlebar8 2200774

5630616-067

1

2

Kit - Handlebar Block(Incl. Blocks and 8,12,30)Block, Handlebar Retainer

9 7541933 2 Nut, Brass10 7555868 2 Washer, Lock11 7558212 2 Washer, Flat12 7515189 4 Screw13 3280291 1 Clamp, Speedometer14 5433042-053

5433042-1915433042-1365433042-3175433289-283

11111

Pod, Headlight, Upper (AE)(AK)Pod, Headlight, Upper (AA)(AF)Pod, Headlight, Upper (AB)(AH)(EB)Pod, Headlingt, Upper (AL)Pod, Headlight, Upper (AC)(AJ)

15 ------ -- -- -- -- 1 Asm., Master Cylinder(See Controls - Master Cylinder/BrakeLine Pg. B12 for details)

16 5432926 1 Spacer, Switch17 4010262 1 Switch, Handlebar18 5431030 2 Grip, Handlebar19 5432952 1 Plug20 7517625 1 Screw, Set21 5240586-067 1 Bracket, Pod Mounting22 7517317 2 Screw23 4032079 1 Knob, Adjusting24 5411120 1 Boot, Headlight

25 4032077 1 Collar, Locking26 4032075

287044811

Lens and ReflectorBulb, Headlight, Halogen

27 4032078 1 Rod, Adjusting28 5410163 2 O-Ring29 7080726

220018811

Cable, Choke w/AdjusterKit - Choke Control

30 7542122 4 Nut, Nylok31 7670089 2 Nut, U-Type32 2410025 1 Plug, Power, 12V (If built before 9/27/99)33 7621334 2 Rivet, Bulbex34 4010283 1 Receptacle, Pod Mount, 12V

(If built after 9/27/99)35 7080631 1 Clip, Cable Retaining36 7522021 2 Screw37 5432314-070

5433366-070

5433706-283

5431811-070

1

1

1

1

Pod, Headlight, Lower (If built before9/27/99)(AA)(AB)Pod, Headlight, Lower(If built between 9/27/99 and 4/24/00)(AA)(AB)(AE)(AF)(AH)(AK)(AL)(EB)Pod, Headlight, Lower (If built between9/27/99 and 4/24/00)(AC)(AJ)Pod, Headlight, Lower (If built after4/24/00)(AC)(AJ)(AF)(AH)

38 41102644010278

4010321

11

1

Switch, Ignition (Incl. Key)Key, Blank, Series 2000, 6700, 6800.NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Key, Blank, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

39 5433534 1 Cover, Key40 5433733 1 Nut, Ignition41 7080229 1 Nut, Choke Slide42 4040081

401029811

Sensor (If built before 8/09/99)Sensor (If built after 8/09/99)(Incl. 43)

43 5132382 1 Cap (If built after 8/09/99)44 7517658 1 Screw

10/00

C3

FRAME MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


1

3

4

7

8

2

10

113

6

7

5

9


1 7661013 2 Pin, Clevis2 1040494-067 1 Pivot, Shift3 5431107 2 Bushing4 5020850 1 Tube, Pivot5 7542122 1 Nut, Nylok6 ------ -- -- -- -- 2 Rod End, LH

(See Gear Selector Pg. C14, Ref. 17)

7 7517386 4 Screw8 7512144 1 Screw9 ------ -- -- -- -- 4 Nut, FLEXLOC

(See Gear Selector Pg. C14, Ref. 14)10 5131277 1 Arm, Shift11 7661103 2 Pin, Cotter

4/99

C4

A-ARM/STRUT MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


1

4

56

7

89

3

12

1314

27

15

16

181719

21

25

26

2423

22

2829

29 28

2322

20

31 30

2

14

9

11

10


1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820567

1820805

2

2

Asm., Tie Rod(Incl. 4-9)(If Built before 8/16/99)Asm., Tie Rod(Incl. 4-9)(If Built after 8/16/99)

4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061033

706105422

Rod End, LH (If Built before 8/16/99)Rod End, LH (If Built after 8/16/99)

10 5411920 1 Boot, Seal, Rod End11 7517674 2 Bolt (If Built after 8/16/99)12 7555806

755609944

Washer, Flat (If Built before 8/16/99)Washer, Flat (If Built after 8/16/99)

13 7546904 2 Nut14 7661203 4 Pin, Cotter15 7080927 2 Joint, Ball

16 5211121 2 Bracket, Ball Joint17 7512284 4 Screw18 5410548 2 Boot, Rubber19 7542438 2 Nut, Castle20 5431837

543183811

Shield, CV Joint, LHShield, CV Joint, RH

21 7512084 6 Screw22 5433066 4 Bushing, A-Arm, Long23 5020677 4 Bushing24 5020681 2 Shaft, A-Arm25 2201607

220160811

Kit - A-Frame, LHKit - A-Frame, RH

26 7080433 2 Fitting, Lubrication27 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B8, Ref. 16)28 7512492 4 Screw29 7552603 4 Washer, Spring Lock30 7517527 1 Bolt31 7515415 1 Screw

10/00

C5

DRIVE CLUTCHSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


17

11

10

9

12

5

6

1413

5

72

4

1615

31

18

8

11 10

9 12

56

14 13 5

4

16 15

19 20

21A00CH50EB

A00CH50(AA)AB)(AE)(AF)(AH)(AK)(AL)(AC)(AJ)


1 1520231 1 Clutch, One Way Drive2 7556009 1 Washer3 5631119 1 Spacer4 7541906 3 Nut, FLEXLOC5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 3585712 1 Bearing8 7547130 1 Nut, Jam9 3576510 1 Cover, Bearing10 7552801 6 Washer, Spring Lock11 7512176 6 Bolt12 7041157 1 Spring, Clutch13 1321457 3 Roller and Bushing

14 5430945 6 Washer, Multilube15 7512266 3 Bolt, Shoulder16 5630513 3 Weight, Shift, 10 MH17 1321706 1 Asm., Drive Clutch, Braking (Incl.

1-11,13-15,18)(AA)AB)(AE)(AF)(AH)(AK)(AL)(AC)(AJ)

18 7556008 1 Washer19 5210752

524298152107535210754

ARARARAR

Spacer (.020”)Spacer (.025”)Spacer (.032”)Spacer (.050”)

20 3576504 1 Bearing, Moveable, 12”21 1321632 1 Asm., Drive Clutch

(Incl. 4-6,10-16,19,20)(EB)

6/00

C6

DRIVEN CLUTCHSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


6

5

23

4

16

14

1312

11

987

5

1

15

10

1

34

13

109

21718

1920

20

A00CH50EB

A00CH50AAA00CH50ABA00CH50AEA00CH50AFA00CH50AHA00CH50AKA00CH50ALA00CH50ACA00CH50AJ 21

22

2425

26

2723


1 7556120 AR Bushing2 5220646 1 Washer, Domed3 7552901 1 Washer, Spring Lock4 7515382 1 Bolt5 1322182 1 Asm., Driven Clutch, 3 Angle, Heavy

(Incl. 7-16)(EB)6 3211077 1 Belt, Drive7 5430766 3 Button, Ramp8 7511854 3 Bolt9 7710448 1 Ring, Retaining10 5210752 1 Spacer11 5132344

513144711

Ramp, Stationary (If built before 4/01/00)Ramp, Stationary (If built after 4/01/00)

12 7041198 1 Spring, Clutch13 3576511 1 Bearing, Moveable (1”)14 3576504 1 Bearing, Moveable (1/2”)

15 7556804 AR Washer (.030”)16 7555898

7556076ARAR

Washer, Spacer (.020”)Washer, Spacer (.025”)

17 7556013 1 Washer18 7556010 1 Bushing19 7710461 1 Ring, Retaining20 1322190 1 Asm., Driven Clutch, Braking (Incl.

2,9,10,13,18,19,24-27)(AA)(AB)(AE)(AF)(AH)(AK)(AC)(AJ)

21 3211069 1 Belt, Drive22 7517323 3 Screw23 1321977 1 Roller, Taper24 3585710 1 Bearing25 5211115 1 Washer26 7041636 1 Spring27 5131674 1 Ramp, Stationary

10/00

C7

CLUTCH COVERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


4

8

3

10

1113

14

15

16

12

23

2425

29

28

18

2717

26

1 2

21

5

9

7

20

21

22

19

6

1317


1 1040519-067 1 Bracket, Clutch Cover, Rear2 7512240 2 Bolt3 5410489

541190111

Seal, Cover Case (If built before 3/13/00)Seal, Cover Case (If fuilt after 3/13/00)

4 2201160 1 Kit - Inner Clutch Cover (Incl. 13,18,26)5 7555748 3 Washer6 7552605 3 Washer, Split Lock7 7512247 1 Bolt8 7512277 1 Bolt9 7512278 1 Screw10 5521301 1 Seal, Cover, Clutch11 5433540

5433451-070

1

1

Cover, Clutch, Outer(If built before 3/13/00)Cover, Clutch, Outer(If built after 3/13/00)

12 7670051 1 Clip, Clutch Cover13 7512093 5 Screw (If built before 3/13/00)(Use

7512094 if built after 3/13/00)14 7074946

7078689

1

1

Decal - Warning, Clutch Cover(If built before 10/04/99)Decal - Warning, Clutch Cover(If built after 10/04/99)

15 7077377 1 Decal - Engine/Clutch Modification(If built before 10/04/99)

16 7077666 1 Decal - “Automatic/EBS”, Clutch17 7555935 2 Washer18 7512094 2 Screw (If built before 3/13/00)(Use

7512278 if built after 3/13/00)19 5411489 1 Boot, Duct20 7080761 2 Cable Tie21 7512232 2 Screw22 5432947

5433980

1

1

Duct, Clutch Outlet(If built before 3/01/00)Duct, Clutch Outlet(If built after 3/01/00)

23 ------ -- -- -- 3 Screw and Washer(See Crankcase Pg. D8, Ref. 6)

24 5240409-067 1 Bracket, Retainer, Seal25 5410575 1 Seal, Cover Case26 7512095 1 Screw27 5241156-067 1 Bracket, Cover, Clutch28 7080511 1 Clamp, Narrow Band29 ------ -- -- -- -- 1 Duct, Air Inlet

(See Air Box Pg. B4, Ref. 9)6/00

C8

ELECTRICAL/TAILLIGHTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


1

2

4 5

6

78

910 13

12

11

2315

14

22

161718

19

20

2124

121132

31

26

25

29

28

30

15

27

3


1 2460784 1 Harness, Main2 2200593 1 Kit - Circuit Breaker, 20 AMP3 2201795 1 Kit - Circuit Breaker, 10 AMP4 2432034 1 Asm., Taillight w/Brake Light (Incl.

5-10)5 4032046 1 Lens, Taillight6 4032029 2 Screw, Taillight7 4030043 1 Bulb, Taillight8 4032045 1 Gasket, Taillight9 4032064 1 Backing, Taillight/Brake Light10 7670054 2 Nut, Speed11 7541925 4 Nut, Nylok12 7571602 4 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 4010094 1 Cable, Battery/Solenoid16 2200361 1 Kit - Battery Bolt, Short

17 4010095 1 Cable, Battery/Engine18 7010032 2 Hook, Battery Strap19 5410424 1 Strap, Battery Holddown20 5432077 AR Tube, Battery Vent21 4140006 1 Battery22 5431769 1 Cover, Battery23 4010093 1 Cable, Solenoid/Starter24 7512007 2 Bolt25 5810455 2 Pad, Rack Mount26 5241416 1 Bracket, CDI27 7512024 1 Screw28 5131036 1 Sink, Heat29 4060173 1 Regulator30 7512018 3 Screw31 4020149 5 Clip, Rosebud32 7670109 2 Clip, Routing

1/00

C9

REAR SUSPENSIONSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


27

40

28

29

2624

36

10

219

18

11

34

33

32

35

17

3938

37

42

44

41

30

31

22

2

19

13

15

1

3 14

16

7

6

5

4

3

1

16

1415

9

99

10

10 1011

11

11

11

11

2020

18

17

1032

18

35

98

20

6

54

9

20

5

8

8

1817

17

25

24

23

18

12

65

43

12 12

6

1020

C10

REAR SUSPENSIONSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500



1 7512329 6 Bolt2 1580107-067 2 Arm, Stabilizer Bar3 7542324 6 Nut, Nylok4 7517231 4 Screw5 7555761 8 Washer, Flat6 5432598 8 Bushing, Stabilizer7 5020827 2 Rod, Linkage, Stabilizer8 5020826 6 Shaft, A-Arm, Short9 5433063 12 Bushing, A-Arm, Short10 5020677 12 Bushing11 7080433 12 Fitting, Lubrication12 7515472 6 Screw13 5333393-067 1 Bar, Stabilizer Tube14 7555939 4 Washer15 5433413 2 Bushing, Stabilizer Tube16 7558402 8 Washer, Flat17 7512492 16 Screw18 7552603 16 Washer, Spring Lock19 1541322-067 1 Support, Stabilizer20 7542439 8 Nut, Nylok21 5242077-067 2 Bracket, A-Arm Pivot22 7515433 2 Screw23 7542321 2 Nut, Flange24 7515321 4 Bolt

25 5224667-067 1 Support, Transmission26 7552901 2 Washer, Spring Lock27 5630885 2 Retainer, Spring28 7041453-067

7041519-06722

Spring, Compression, RearSpring, Compression, Rear (EB)

29 5630551 2 Cam, Adjusting, Spring30 7041770 2 Shock, Rear31 7515415 2 Screw32 5433066 4 Bushing, A-Arm, Long33 5020681 2 Shaft, A-Arm34 1012717-067

1012718-06711

Arm, Control, Lower, LHArm, Control, Lower, RH

35 5433065 8 Bushing, Control, Lower36 1040730-067

1040731-06711

Arm, Control, Upper, LHArm, Control, Upper, RH

37 5131883 4 Bushing, Bearing Carrier38 7555936 4 Washer39 7517297 4 Screw40 5433098-070

5433099-07011

Shield, LHShield, RH

41 7512084 4 Screw42 5131738 2 Carrier, Wheel Bearing43 3585502 2 Bearing, Wheel Carrier44 7080586 2 Fitting, Lubrication

6/00

C11

REAR BRAKE/FOOT PEDALSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


10

7

8

9

11

12

13

1415

1617

18

19

222324 11

1415

12

3

4

5

6

21

20

C12

REAR BRAKE/FOOT PEDALSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500



1 7515497 2 Screw2 7552603 2 Washer, Spring Lock3 7555806 2 Washer, Flat4 1910366

1910441

2201093

191033919308602201399

220118022014282201181

11

1

111

121

Asm., Caliper, Rear (AA)(AB)(AC)(AE)Asm., Caliper, Rear(AF)(AH)(AK)(AJ)(AL)(EB)Kit - Brake Pad (Incl. Spacer and Pin)(AA)(AB)(AC)(AE)SpacerPinKit - Brake Pad (Incl. Spacer and Pin)(AF)(AH)(AK)(AJ)(EB)Kit - Brake SealKit - Bleeder ReplacementPiston, Stepped Bore

5 1930853 1 Line, Rear Brake6 1910305 1 Line, Brake, Caliper w/Fittings7 7512111 1 Bolt8 1930854 1 Reservoir, Brake, Rear

9 7542153 1 Nut10 1910315 1 Hose, Reservoir11 7080003 2 Clamp, Hose12 7542122 2 Nut, Nylok13 7041750 1 Spring14 7555919 2 Washer15 5431107 2 Bushing, Pivot, Pedal16 1910280-067 1 Rod, Brake17 7661401 1 Pin, Cotter18 1910301 1 Master Cylinder, Brake, Rear19 7512247 2 Bolt20 1910439 1 Disc, Brake (EB)21 1910440 1 Disc, Brake (AF)(AH)(AK)(AJ)(AL)22 1910188 1 Disc, Brake (AA)(AB)(AC)(AE)23 7571620 1 Washer, Spring24 7547046 1 Nut, Nylok

6/00

C13

REAR WHEEL DRIVESPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


78

1011

1

12

6

9

2

3

5

4


1 7661404 2 Pin, Cotter2 7542459 8 Nut3 5131649 2 Hub, Rear Wheel4 ------ -- -- -- -- 2 Carrier, Bearing, Wheel (See Rear

Suspension Pg. C10, Ref. 42)5 7710440 2 Ring, Retaining6 7515513 8 Stud7 5410948 2 Tire, 25x11-10, Tracker P

8 1525017 2 Valve, Rim9 1520217-067

1520217-117

2

2

Rim, Rear, Black(AA)(AC)(AE)(AF)(AK)Rim, Rear, Aluminum (AB)(AH)(AL)(EB)

10 7555796 4 Washer, Cone11 7543005 2 Nut, Castle12 5411164 2 Cover, Dust, Hub

6/00

C14

GEAR SELECTORSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500


2

4

3

5

7

8

6

112310

22

1

13

21

9

12

1011

15

15

2019

17

17

14

14

18

16

14

14


1341271 1 Asm., Gear Selector (Incl. 1-13,21-23)1 3233195 1 Asm., Knob2 7512024 1 Screw3 3233649 4 Screw4 3233131 1 Strap, Wire5 3233648 1 Cover, Gear Selector Boot6 3233658 1 Handle, Gear Selector7 3233646 1 Sphere, Plastic8 3233754 1 Pin, Groove9 3233644 1 Pin, Dowel10 3233642 2 Spring, Detent11 3233060 2 Bullet, Detent

12 3233076 2 O-Ring13 3233639 1 Slide, Low14 7546707 4 Nut, FLEXLOC15 7061014 2 Rod End, RH16 7546701 2 Nut, RH17 7061013 2 Rod End, LH18 5020824 1 Rod, Shift Linkage, Low-Range19 5020823 1 Rod, Shift Linkage, Hi-Range20 7546702 2 Nut, LH21 3233640 1 Slide, High/Reverse22 3233641 1 Body, Gear Selector23 3233643 1 Spring, Centering

9/00

D1

FRONT HOUSINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN

500 A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 A00CH50AJ and WORKER 500 A00CH50EB

1 222120

19

18

17

1211

9 10

87

65

43

25

26

2423

12

2

16

14

15

13


1341276 1 Asm., Front Gearcase(Incl. 1-12,16-26)(If Built before 8/16/99)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing, Ball7 3233698 1 Pinion, Input8 3233541 1 Bushing9 3233319 1 Seal10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug, Oil Fill13 7080307 1 Clamp, Hose

14 7080756 1 Clip, Snap-In15 8450003-1525 AR Line, Fuel16 3233524 1 Tube, Vent17 3233696 1 Gearcase18 3233710

32336943233695

111

SubAsm., Output Shaft, Front HousingShaft, OutputGear, 29T

19 3233020 1 Bearing20 3233554 AR Shim21 3233693 1 O-Ring22 3233692 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233702 1 Button, Thrust25 3233253 1 Plug, Drain26 3233254 1 Washer

9/99

D2

FRONT HOUSINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1 2

34 5

678

9 10

11 12

13

14

15

16

17

18

1920 21

22

2324

25

26

2728

1

2


1341323 1 Asm., Front Gearcase(Incl. 1-12,16-26)(If Built after 8/16/99)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Front Housing Input4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing, Ball7 3233726 1 Pinion, Input8 3233541 1 Bushing9 3233319 1 Seal10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug, Oil Fill13 7080756 1 Clip, Snap In

14 8450003-1525 AR Line, Fuel15 7080307 1 Clamp16 3233524 1 Tube, Vent17 3233696 1 Gearcase18 3233725 1 Shaft, Output19 3233020 1 Bearing, Ball20 3233554 AR Shim21 3233693 1 O-Ring22 3233724 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233582 1 Button, Thrust25 3233254 1 Washer, Plug26 3233253 1 Plug, Drain27 7512492 4 Screw28 7552603 4 Washer

7/99

D3

GEARCASE (Internal Components)SPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500

A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 A00CH50AJ

11109

87

14

3332

5

13

3123

30

29

2827

2425

22212019

34

36

39

41

42

51

47

48

4

26

43

44

15

1817

11

109

8

76

26

23

4

15

16

6

12

16

4

1

3

2

3837

35

50

49 4645

40

D4

GEARCASE (Internal Components)SPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500

A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 A00CH50AJ


1341310 1 Asm., Gearcase (Incl. 1-36 and all onGearcase (Cases and Snorkel) Pg. D7)(If built before 9/10/99)

1 3233019 1 Bearing2 3233361 1 Shaft, Input, 31T, HCR3 3233036 1 Chain, Silent, 34P4 3233018 3 Bearing5 3233661 1 Shaft, Shift6 3233548 2 O-Ring7 3233040 2 Washer8 3233045 2 Ring, Retaining9 3233153 2 Bellcrank, HLR10 3233054 6 Washer11 3233055 2 Nut12 3233662 1 Shaft, Shift13 3233663 1 Fork, Shift, Low14 3233664 1 Fork, Shift, H/R15 3233033 2 Screw16 3233308 2 Pin, Interlock17 3233309 1 Bracket, Interlock18 3233189 1 Spring, Interlock19 3233177 1 Ring, Retaining20 3233176 1 Washer, Thrust21 3233017 1 Bearing, Needle22 3233668 1 Gear, 30T23 3233010 2 Washer24 3233667 1 Engagement Dog

25 3233029 1 Ring, Retaining26 3233012 2 Washer27 3233014 1 Bearing, Needle28 3233532 1 Sprocket, 24T29 3233362 1 Shaft, Reverse, HCR30 3233666 1 Engagement Dog, Low31 3233009 1 Bearing, Needle32 3233665 1 Gear, 33T33 3233007 2 Washer34 3233020 2 Bearing, Ball35 3233715 1 Shaft, Center Drive36 3233360 1 Gear, Output, 100T, HCR37 3233262 4 Screw38 7552901 4 Washer39 3233263 1 Cover, Bearing, Center Drive40 3233364 1 Ring, Retaining41 3233265 1 Bearing42 3233365 1 Pinion, 16T, Spiral Bevel43 3233282 2 Screw44 3233669 1 Deflector, Oil45 3233434 1 Chain Tensioner, Cam46 3233433 1 Chain Tensioner, Shoe47 3233432 2 Pin, Dowel48 3233431 1 Spring, Torsion49 3233268 2 Bearing50 3233670 1 Sprocket, 60T51 3233430 1 Chain, Silent

4/99

D5

GEARCASE (INTERNAL COMPONENTS)SPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1 2

3456

78 9

10

23456

11121314151617

1018

1920

2122

2324

15

15

1110

25

26

27 28 29 30

3132333435

23

21 21 27

36

37

383940

4142

4344

4546

26

D6

GEARCASE (INTERNAL COMPONENTS)SPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN



1341332 1 Asm., Gearcase (Incl. 1-37 and all onGearcase (Cases and Snorkel) Pg. D7)(If built after 9/10/99)

1 3233055 2 Nut2 3233054 6 Washer3 3233153 2 Bellcrank, HLR4 3233045 2 Ring, Retaining5 3233040 2 Washer6 3233548 2 O-Ring7 3233662 1 Shaft, Shift8 3233019 1 Bearing9 3233361 1 Shaft, Input, 31T, HCR10 3233018 3 Bearing11 3233176 1 Washer, Thrust12 3233744 1 Gear, 30T13 3233743 1 Engagement Dog, High14 3233664 1 Fork, Shift, H/R15 3233720 3 Ring, Retaining16 3233719 1 Sprocket, 24T17 3233036 1 Chain, Silent, 34P18 3233742 1 Shaft, Reverse, HCR19 3233663 1 Fork, Shift, Low20 3233661 1 Shaft, Shift21 3233718 3 Bearing, Needle22 3233731 1 Gear, 33T

23 3233308 2 Pin, Interlock24 3233189 1 Spring, Interlock25 3233309 1 Bracket, Interlock26 3233747 2 Screw27 3233177 1 Ring, Retaining28 3233732 1 Engagement Dog, Low29 3233020 2 Bearing, Ball30 3233715 1 Shaft, Center Drive31 3233365 1 Pinion, 16T, Spiral Bevel32 3233265 1 Bearing33 3233364 1 Ring, Retaining34 3233263 1 Cover, Bearing, Center Drive35 7552901 4 Washer36 3233262 4 Screw37 3233360 1 Gear, Output, 100T, HCR38 3233434 1 Chain Tensioner, Cam39 3233433 1 Chain Tensioner, Shoe40 3233432 2 Pin, Dowel41 3233431 1 Spring, Torsion42 3233430 1 Chain, Silent43 3233268 2 Bearing44 3233670 1 Sprocket, 60T45 3233282 2 Screw46 3233669 1 Deflector, Oil

1/00

D7

GEARCASE (Cases and Snorkel)SPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


14

4

29 26

3031

25

15

18

19

2022

2123

34

12

1213

36

6

9

3

135

115

33

5

32

27

10

16

2428

17

8

7


-- -- -- -- -- -- -- 1 Asm., Gearcase (See Gearcase -Inter-nal Components Pg. D4 for Details)

1 3233256 2 Seal2 3233026 18 Screw3 3233636 1 Decal - Switch4 3233252 2 Screw5 3233248 3 Seal6 3233716 1 Gearcase, LH7 7052095 1 Fitting, 90 Degree8 8360009-600 AR Line, Fuel9 3233037 1 Vent, Tube10 3233475 1 Dipstick11 3233691 8 Screw12 3233617 1 Switch, 2 Position13 3233635 1 Switch, 3 Position14 3233442 2 Screw15 3233352 1 Washer16 3233476 1 Gear, 31T, Snorkel17 ------ -- -- -- -- Bearing, Ball (See Gearcase -Internal

Components Pg. D4, Ref. 34)18 3233446 1 Shaft, Drive, Snorkel19 3233302 1 O-Ring20 3233303 1 Snorkel

21 3233305 1 Bearing, Ball22 3233353

3233354323335532333563233357

11111

Spacer (1.180x.995x.010)Spacer (1.180x.995x.025)Spacer (1.180x.995x.040)Spacer (1.180x.995x.005)Spacer (1.180x.995x.008) NOTE:Ref. 22 indicates choices, may also beused in combinations.

23 3233306 1 Ring, Retaining24 3233444 1 Lock, Bolt25 3233351 1 Bolt26 3233292 1 Bushing27 3233293 1 Seal28 ------ -- -- -- -- 4 Washer (See Gearcase - Internal

Components Pg. D4, Ref. 10)29 3233291 2 Nut, FLEXLOC30 3233294 1 Stamping, Cover Plate31 3233295 4 Washer32 3233296 4 Screw33 3233253 1 Plug, Drain34 3233254 1 Washer35 3233672 1 Gearcase, RH36 3233247 3 Pin, Dowel

4/99

D8

CRANKCASESPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


2

4

10

11

2

19

20

1

22

7

5

16

3

1817

9

1514

1213

21

6

5

8


1 3083669 1 Bushing, Starter2 3085633 1 Asm., Crankcase

(Incl. 1,4,5,7,10,11,16,19,20,22)3 3084838 2 Pin, Straight4 3080676 3 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 5 Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3084842 2 Union10 3084834 2 Bearing, Ball11 3084835 1 Bearing, Ball

12 3084845 1 Plug13 3084846 1 Gasket, Aluminum14 3084844 1 Spring, Valve, One Way15 3086810 1 Valve, One Way16 3084841 10 Bolt, Flange17 3082956 1 Gasket18 3083453 1 Plug19 3084837 1 Seal, Mechanical20 3084836 1 Seal, Oil21 3084847 1 O-Ring22 3080103 2 Pin, Dowel

4/99

D9

CYLINDERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


2

20

38

2223

21

12

5

4

37

107

34

9

25

29

1617

3

6

18

27

1

26

13

35

28

33

31

32

8

11

30

36

14

24

15

19

5

36

36

13

9

18

D10

CYLINDERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN



1 3083166 1 Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt, Allen4 3084857 2 Pin, Straight5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve7 3084867 1 O-Ring8 3085072 1 Adapter, Water Out9 3084877 10 Bolt, Flange10 3084866 1 Adapter, Camshaft11 3085074 1 Gasket, Rocker Cover12 3085073 1 Cover, Rocker13 3084874 10 Bolt, Flange14 3084859 2 Seal, Exhaust Valve15 3084875 4 Bolt, Cylinder Head16 3084860 1 Plug17 3084861 1 Gasket18 3084862 1 Plug, Blind19 3084215 2 Bolt, Flange

20 3085075 1 Gasket, Exhaust21 3085326 2 Stud22 3080285 2 Nut23 3080530 2 Washer, Lock24 3085854 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3084838 2 Pin, Straight29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3086811 1 Cylinder (Incl. 32)32 3084130 1 Pipe 2, Elbow33 3085370 1 Gasket, Cylinder34 3084868 1 Cover, Camshaft35 3086200 1 Gasket, Cover, Cam36 3085527 1 Cylinder Head (Incl. 4-6,14,16-18,21)37 3085371 1 Gasket, Head38 3084879 1 Adapter

4/99

D11

CRANKSHAFT and PISTONSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


19

20

6

10

1412

5

8

18 13

9

17

7

3

11

4

15

21

16

2

1

4


1 308537930853803085381

111

Piston Ring Set (Std)Piston Ring Set (0.25 O/S)Piston Ring Set (0.50 O/S)

2 308586630858673085868

111

Piston Set (Std) (Incl. 2-4)Piston Set (0.25 O/S) (Incl. 2-4)Piston Set (0.50 O/S) (Incl. 2-4)

3 ------ -- -- -- -- 1 Pin, Piston4 3085534 2 Clip5 3085374 1 Crankshaft 26 3085341 1 Pin, Crank7 3085376 1 Rod, Connecting8 3085400 1 Bearing, Large End9 3085024 1 Ball, Steel10 3085399

308537311

Asm., Crankshaft (Incl. 5-11,19)Crankshaft 1

11 3085852 1 Gear 1, Balancer

12 3085404 1 Shaft, Balancer13 3084895

30848963084897

111

Spacer (0.8)Spacer (1.0)Spacer (1.2)

14 3240088308489230848933084894

1111

Spacer (0.6)Spacer (0.8)Spacer (1.0)Spacer (1.2)

15 3084882 1 Sprocket 116 3085528 1 Nut, Slit17 3083904 1 Washer18 3083905 1 Nut, Lock19 3085346 1 Pin, Dowel20 3081447 1 Key21 3080130 1 Key, Woodruff

4/99

D12

INTAKE and EXHAUSTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


14

18

15

1617

25

26

13 12 11

10

6

98

22

7

19

8

21

24

4

3

21

5

20

27

23

89 6

9

1211

13


1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3086814 1 Spring, Tensioner4 3086813 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Intake Rocker Arm (Incl. 8,9)7 3084913 1 Asm., Exhaust Rocker Arm (Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3084907 4 Retainer, Spring13 3084906 4 Spring, Valve14 3086212 1 Camshaft (Incl. 15-18)

15 3086838 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3084914 1 Sprocket 220 3081657 3 Bolt and Washer21 3084916 1 Guide, Chain22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot, Lever24 3084917 1 Lever25 3085349 2 Valve, Intake26 3084905 2 Valve, Exhaust27 3084874 2 Bolt, Flange

6/99

D13

CARBURETORSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


47

37

34

9

50

5

49

12

4

6

4142

38

36

1235

1312

1415

21

19

27

30

29

26

1110

3

22

20

16

24

18

25

40

23

51

4445

87

46

39

3332

31

28

17

48

43

D14

CARBURETORSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN



1 3130507 1 Ring2 3130508 1 E-Ring3 3130962 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3130960 1 Jet, Needle (Q-0)7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3130571 1 Jet, Main (#155)12 3130515 2 Seal13 3130517 1 Packing14 3130518 1 E-Ring15 3130519 1 Cap16 3130361 1 Pin, Float17 3130594 1 Plate18 3130532 1 O-Ring19 3130520 4 Screw20 3130590 1 Asm., Float Body21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 1 Screw24 3130668 1 Valve, Needle (1.5)25 3130533 1 O-Ring26 3130624 1 Jet, Pilot (#40)

27 3130522 1 O-Ring28 3130523 1 Washer29 3130525 1 Spring30 3130524 1 Adjuster31 3130546 1 Screw, Adjust32 3130545 1 Ring33 3130544 1 Spring34 3130502 1 Valve, Throttle (100)35 3130589 1 Spring36 3130514 1 Ring37 3130501 2 Screw38 3130513 1 Asm., Throttle Shaft39 3130543 1 Guide, Cable40 3130535 4 Screw41 3130511 1 Cover42 3130512 1 O-Ring43 3130199 1 Holder, Guide44 3130538 1 Spring45 3130593 1 Asm., Plunger46 3130625 1 Jet, Air (#160)47 3131200 1 Asm., Carburetor (Incl. 1-38,43-51)48 3084205 2 Screw and Washer49 3130505 1 Spring50 3130503 1 Asm., Cover51 3130592 4 Screw

4/99

E1

RECOIL STARTERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


14

6

4

7

10

5

31 2

11

8

12

13

15

9

8

7


1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Bolt and Washer7 3083453 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084933 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3085652

308565311

Asm., Recoil (Incl. 1-6,9-11,14,15)Starter Case (Incl. 11)

15 3085083 1 Asm., Rope

4/99

E2

WATER PUMPSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


11

7

83

3

2

1

9

12

13

4

10

65


1 3084940 1 Thermostat2 3085352 1 Switch, Thermostat3 3084191 2 Clamp, Hose4 3085857 1 Hose, Main5 3085359 1 Bolt, Flange6 3082758 1 Gasket, Aluminum7 3085351 1 Cover, Water Pump

8 3084937 1 Gasket, Water Pump9 3085077 1 Nut, Self Lock10 3083138 1 Gasket11 3084935 1 Impeller12 3084942 1 Washer, Seal13 3084877 4 Bolt, Flange

7/98

E3

OIL PUMPSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


4

1

10

32

11

12

15

87

6

13

14

5

1617

9


1 3084946 1 Case 2, Oil Pump2 3084949 1 Rotor, Outer Feed3 3084948 1 Rotor, Inner Feed4 3084944

308494511

Asm., Oil Pump (Incl. 1-8,10-15)Case 1, Oil Pump

5 3085535 1 Screw6 3084955 2 Pin, Dowel7 3084954 2 Pin, Dowel8 3084953 1 Washer9 3084962 3 Bolt and Washer

10 3084947 1 Case 3, Oil Pump11 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Strainer, Oil14 3084205 3 Screw and Washer15 3084952 1 Shaft, Pump16 3084958 1 Gear, Pump 217 3084959

30849603084961

ARARAR

Spacer (0.8)Spacer (1.0)Spacer (1.2)

7/98

E4

OIL FILTERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1

4

5

3

3

3

2

2

2

2

2


1 3084963 1 Filter, Oil2 3084846 8 Gasket, Aluminum3 3086815 4 Bolt, Banjo

4 3084964 1 Pipe 1, Oil Delivery5 3085638 1 Pipe 2, Oil Delivery

4/99

E5

MAGNETOSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


206

5

89

1011

12

13 14

4

7

1

2

16

19

3

1517

18


1 30852273085228

11

Asm., Ignition Coil (Incl. 1,2)Coil, Ignition

2 3084980 1 Cap, Plug, Spark3 3070175 1 Plug, Spark4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3086820

30855603086980

3086981

1

11

1

Asm., Plate (Incl. 5,6,8-12,14,15)(Up to S#00-29083)Plate (Up to S#00-29083)Asm., Plate (Incl. 5,6,8-12,14,15)(S#00-29083 & after)Plate (S#00-29083 & after)

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3086821

308698411

Stator (Incl. 13)(Up to S#00-29083)Stator (Incl. 13)(S#00-29083 & after)

10 30855633086985

33

Screw and Washer (Up to S#00-29083)Screw and Washer (S#00-29083 & after)

11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3084977 1 Clamp15 3081256 3 Screw and Washer16 3085639

308698211

CDI System (Up to S#00-29083)CDI System (S#00-29083 & after)

17 3083073 2 Nut18 3080077 2 Washer, Spring19 3085521 1 Switch, Magnetic20 3086819

308698311

Flywheel w/Ring Gear (Up to S#00-29083)Flywheel w/Ring Gear (S#00-29083 & after)

12/99

E6

STARTING MOTORSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1

10

12

2

6

11

5

4

18

13

17

16

15

14

78

9

32


1 3084981 1 Motor, Starting (Incl. 2-6,8-12)2 3084982 1 Washer Set3 3085353 1 Armature4 3084406 1 Brush5 3083649 2 Nut, Flange6 3084408 3 O-Ring7 3082038 2 Bolt and Washer8 3085034 1 Bracket, Rear9 3085033 1 Bracket, Front (Incl. 10)

10 3240114 1 O-Ring11 3084983 2 Asm., Set Bolt (Incl. 6)12 3084405 2 Ring, Rubber13 3083737 1 Washer, Gear Shaft14 3084412 1 Clip15 3084411 1 Spring, Weight16 3084410 1 Spring, Return17 3084409 1 Clip18 3085394 1 Asm., Gear Shaft (Incl. 13-17)

10/98

E7

FUEL PUMPSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


5

2

4 3

3

5

1


1 3085275 1 Asm., Fuel Pump (Incl. 2-5)2 3084999 1 Screw and Washer3 3085356 2 Screw and Washer

4 3084591 4 Screw and Washer5 3084998 1 Diaphragm Gasket Set

10/98

E8

TOOL KITSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN


1

3

8

2

9

4

510

6

7


1 3085383 1 Asm., Tool Kit (Incl.2 -8)2 2870725 1 Gauge, Tire Pressure3 3082657 1 Screwdriver4 3085001 1 Wrench, 10-12 Open5 3085002 1 Wrench, 12-14 Open6 3085568 1 Wrench, Box, 125mm7 3085569 1 Puller, Spark Plug (Wrench Handle)

8 2682572 1 Pouch, Tool Kit9 9915299

9915476

9915753

11

1

Owner’s Manual, ‘00 ATVSupplement, Owner’s Manual ’00Sportsman 500(AA)(AB)(AE)(AF)(AH)(AK)(AL)(EB)Supplement, Owner’s Manual ’00Sportsman 500 RSE (AC)(AJ)

10 2871095-067 1 Wrench, Spanner, Cam

6/00

E9

FOOT BRAKEWORKER 500 A00CH50EB

2

11

5

12

13

9

14

43

16

10

1

7

6

815

8


1 7512126 1 Bolt2 1040732-067 1 Bracket3 7661205 1 Pin, Cotter4 7555827 2 Washer5 5211914 1 Handle, Parking Brake6 7555931 1 Washer, Flat7 7542103 1 Nut, FLEXLOC8 7556063 2 Washer, Wave

9 5224875 1 Spring, Return10 7558707 1 Bushing11 5242749 1 Pawl, Parking Brake12 5224871 1 Linkage, Parking Lock13 7080644 1 Clevis, Threaded14 7661843 1 Pin, Clevis15 7661011 1 Pin, Cotter16 7661203 1 Pin, Cotter

10/98

PRINTED IN THE USA PARTS MANUAL PN 9915480 and MICROFICHE PN 9916574 6/00

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