sportsman 500 model #a99ch50aa model #a99ch50ab worker 500...

78
PARTS MANUAL PN 991491 1 and MICROFICHE PN 9915651 1/99 SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 Model #A99CH50EA Model #A99CH50EB Rev . 01 1999

Upload: lamnguyet

Post on 07-May-2018

240 views

Category:

Documents


9 download

TRANSCRIPT

Page 1: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

PARTS MANUAL PN 9914911 and MICROFICHE PN 9915651 1/99

SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB

WORKER 500Model #A99CH50EAModel #A99CH50EB

Rev. 01

����

Page 2: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

�� ���� �� �� ���� ���� ��� ��

Page 3: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

TABLE OF CONTENTSSPORTSMAN 500 A99CH50(AA)(AB)

and WORKER 500 A99CH50(EA)(EB)

Parts Manual

AA–ARM/STRUT MOUNTING C3. . . . . . . . . AIR BOX B3. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D11-12. . . . . . . . . . . . . . . . . . . . . CLUTCH COVER C6. . . . . . . . . . . . . . . . . . . CONTROLS – MASTER CYLINDER/

BRAKE LINE B11. . . . . . . . . . . . . . . . . . . CONTROLS – THROTTLE ASM./

CABLE B10. . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM A12. . . . . . . . . . . . . . . . . CRANKCASE D6. . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT and PISTON D9. . . . . . . . . CV JOINT – BTB B4. . . . . . . . . . . . . . . . . . . CYLINDER D7-8. . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A10-11. . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH C4. . . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH C5. . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C7. . . . . . . . . . . ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . EXHAUST SYSTEM B1. . . . . . . . . . . . . . . . .

FFOOT BRAKE C13. . . . . . . . . . . . . . . . . . . . . . FRAME MOUNTING C2. . . . . . . . . . . . . . . . FRONT BRAKE B9. . . . . . . . . . . . . . . . . . . . FRONT CAB A7. . . . . . . . . . . . . . . . . . . . . . . FRONT HOUSING C14-D1. . . . . . . . . . . . . . . . . . FRONT RACK and

BUMPER MOUNTING A9. . . . . . . . . . . FRONT STRUT B7. . . . . . . . . . . . . . . . . . . . . FRONT WHEEL B8. . . . . . . . . . . . . . . . . . . . FUEL PUMP E5. . . . . . . . . . . . . . . . . . . . . . . FUEL TANK B2. . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR D5. . . . . . . . . . . . . . . . . . GEARCASE

(CASES and SNORKEL) D2. . . . . . . . . GEARCASE

(INTERNAL COMPONENTS) D3-4. . . . .

HHANDLEBAR and

HEADLIGHT POD B13-14. . . . . . . . . . . . . . .

IINTAKE and EXHAUST D10. . . . . . . . . . . . .

MMAGNETO E3. . . . . . . . . . . . . . . . . . . . . . . . .

OOIL FILTER E2. . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP E1. . . . . . . . . . . . . . . . . . . . . . . . . OIL TANK C1. . . . . . . . . . . . . . . . . . . . . . . . . .

PPART NUMBER INDEX E7-13. . . . . . . . . . . . . . PROP SHAFT B6. . . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE/FOOT PEDAL C11-12. . . . . . . . REAR CAB and SEA T A5-6. . . . . . . . . . . . . . REAR DRIVE SHAFT B5. . . . . . . . . . . . . . . REAR RACK MOUNTING A8. . . . . . . . . . . . REAR SUSPENSION C9-10. . . . . . . . . . . . . . . . REAR WHEEL DRIVE C8. . . . . . . . . . . . . . . RECOIL STARTER D13. . . . . . . . . . . . . . . . . .

SSTARTING MOTOR E4. . . . . . . . . . . . . . . . . STEERING POST B12. . . . . . . . . . . . . . . . . . .

TTOOL KIT E6. . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D14. . . . . . . . . . . . . . . . . . . . . .

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

Page 4: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

1999 SPORTSMAN 500 and WORKER 500 SPECIFICA TIONS

BRAKESType/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

2.255.25

32N/AN/A

290

18035

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/A11478134

71050.50

46

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 Sump92x75

49910:2 Full Stroke

Liquid250W

Standard1/BST34(CV type)

152.540

Q-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

6.69/15.17/13.34/1

2:13-16:1

N/AN/A

Shaft

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, Front

Spring, Rear

Gen IVN/AN/A

(A99CH50(AA)(EA)) Olive Green(A99CH50(AB)(EB)) Porsche Red(A99CH50(AA)(EA)) Olive Green

(A99CH50(AB)(EB)) Porsche RedBlack

Semi Flat Black(A99CH50(AA)(EA)) Black

(A99CH50(AB)(EB)) Porsche RedBlack

(A99CH50(AA)(EA)) Olive Green/Black

(A99CH50(AB)(EB)) PorscheRed/Black

BlackBlack

(A99CH50(AA)(EA)) Black(A99CH50(AB)(EB)) Aluminum

Black(A99CH50(AA)(EA)) Olive Green

(A99CH50(AB)(EB)) Porsche Red(A99CH50(AA)(EA)) Black(A99CH50(AB)(EB)) Blue

(A99CH50(AA)(EA)) Black(A99CH50(AB)(EB)) Blue

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 Strut6.25

Independent9.5

2 - 2″ Bore Gas BagCAM

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

Goodyear25x8x12

25x11x10N/A

55

N/A

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its productswithout notice.

Page 5: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

1999 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUAL

SUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Sportsman 500 A99CH50(AA)(AB) 9914905 9914910 9914911 9915651 9914913

Worker 500 A99CH50(EA)(EB) 9914905 9914910 9914911 9915651 9914913

Page 6: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A5

REAR CAB and SEATSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

2

8

3

7

5

1011

15

14

16

17

18

4241

13

20

22

23

37

6

4446

47

1

43

39

12

24

25

4

40

19

3

3134

32

33

31

9

2827

26

35

36

2930

38

21

7

3145

Page 7: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A6

REAR CAB and SEATSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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 5411042 1 Grommet6 5432117-191

5432117-136

1

1

Cab, Rear, Olive Green(A99CH50(AA)(EA))Cab, Rear, Porsche Red(A99CH50(AB)(EB))

7 7541925 4 Nut, Nylok8 5224592 1 Retainer, Seat Latch9 5811308 1 Foil, Tape, Rear Cab

10 7512242 4 Screw11 7555859 4 Washer12 7512085 2 Screw13 5431786 1 Box, Tool14 7621403 2 Rivet15 5211033 2 Bracket, Lever Retainer16 1040387 1 Latch, Seat17 7041370 1 Spring, Latch18 2682441-070

2681747-07058111045811105

1111

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

19 5410414 8 Bumper, Rubber20 7512130 2 Screw21 7555748 2 Washer22 5431787 1 Cover, Tool Box23 5410896 1 Cap, Drain

24 7661638 6 Rivet25 5242953-067 1 Guard, Clutch26 ––––––– 1 Front Housing (See Front Housing

Pg. C14 and Pg. D1 for Details)27 7552603 4 Washer28 7512492 4 Bolt29 7080653 1 Clamp, Hose30 7512024 1 Screw31 7542122 28 Nut, Nylok32 5432280 2 Spacer, Footwell33 7517377 4 Screw34 1012796-067 1 Frame, Main35 5410770 2 Grommet36 7078261 1 Decal - Hitch37 7517376 8 Screw38 5432221-070

5433219-07011

Footwell, Black, LHFootwell, Black, RH

39 5811111 1 Foil, Foam, Rear Fender40 5811106 2 Foil, Rear Cab, Front41 7073761 1 Decal - Carburetor Information42 7077446 1 Decal - Filter Element43 5811087 1 Foil, Foam44 7512232 10 Screw45 7515194 2 Screw46 7670057 12 Nut, U-Type Speed47 5431796

543179711

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

1/99

Page 8: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A7

FRONT CABSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

5

6

7

8

910

11

32

21

20

4

1819

1312

14

1516

8

1

17

4

4

22

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

1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5810996 1 Foil, Foam, Side Panel3 5431809-191

2620085-191

5431809-136

2620085-136

1

1

1

1

Panel, Side, Green, LH(A99CH50(AA)(EA))Panel, Side, w/Foil, Green, RH(A99CH50(AA)(EA))Panel, Side, Red, LH,(A99CH50(AB)(EB))Panel, Side, Red, w/Foil, RH (A99CH50(AB)(EB))

4 7512232 10 Screw5 5432088-191

5432088-136

1

1

Cover, Front, Olive Green(A99CH50(AA)(EA))Cover, Front, Red(A99CH50(AB)(EB))

6 7670085 2 Clip, Spring7 2631987-191

2631987-136

1

1

Cab, Front, Olive Green w/Warning-Decals (A99CH50(AA)(EA))Cab, Front, Red w/Warning Decals(A99CH50(AB)(EB))

8 7670057 10 Nut, U-Type Speed9 7670009 2 Nut, Push-on

10 7661645 4 Rivet, T-Lock11 5431798

543179911

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

12 7541925 2 Nut, Nylok13 7555792 2 Washer14 7512085 2 Screw15 7080693 1 Clamp, Hose16 8450073-600 AR Line, Breather17 7512017 1 Screw18 7555931 2 Washer19 7542122 2 Nut20 5811489 2 Shield, Deflector21 7670088 4 Clip, Dart22 7517312 2 Screw

1/99

Page 9: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A8

REAR RACK MOUNTINGSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

5

4

2

3

9

1110

12

14

1513

13

11

7

1

6

8

3

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

1 2871501 1 Kit - Rack Extender, Rear (Incl. 6)2 7515193 2 Screw3 7515194 4 Screw4 2670174 1 Asm., Rack, Rear

(Incl. Ref. 5 and Warning Decal)5 2670070 2 Reflector, Red6 7517208 6 Screw7 1040490-067 1 Support, Rear Rack8 5241663-067 1 Bracket, Silencer, Frame

9 7512329 4 Bolt10 7670096 2 Nut, Chimney11 7542343 8 Nut, Nylok12 1040524-067

1040525-06711

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

13 7558402 2 Washer14 5333332-067 4 Spacer15 7515385 4 Screw

10/98

Page 10: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A9

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

13

14

15

1617

18

12

6

5

8

910

19

20

21

23

24

25

2

3

4

11

4

7

1

27

6

26

22

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

1 7515194 4 Screw2 2670180 1 Asm., Front Rack

(Incl. Ref. 3 and Warning Decal)3 2670071 2 Reflector, Amber4 7515399 8 Screw5 2200775 1 Kit - Front Rack Mount6 7542324 4 Nut, Nylok7 7558403 2 Washer8 5432155-070 1 Bumper9 7515391 2 Screw

10 7515390 2 Screw11 7555954 4 Washer12 1040554-067

1040555-06711

Support, Front Rack, LHSupport, Front Rack, RH

13 7512232 4 Screw14 2431014

24310154030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

15 7515384 2 Bolt16 7558402 4 Washer17 5810467 1 Plug, Frame18 5241398-067

5241399-06711

Extension, Frame, LHExtension, Frame, RH

19 5241583-067 1 Guard, Brush20 5240591-067 1 Grill, Guard, Brush21 7621330 7 Rivet22 5241224-067 1 Hitch, U-Bolt23 7670094 6 Nut, U-Type24 7512097 6 Screw25 5431814

543181511

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

26 7515547 2 Screw27 5211633-067 1 Plate, Back Mount

10/98

Page 11: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A10

DECALSSPORTSMAN 500 A99CH50AA and WORKER 500 A99CH50EA

1 2 546 7 8

10

1314

15

9

8

18 1920

6

23

521

22

24

17

LH

RH

3

12

11

1

3

16

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

1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution3 7077660 2 Decal - “EBS DUAL SENSING”4 7078026 1 Decal - Side Panel, RH

(A99CH50AA)5 7077665 2 Decal - “4x4 Ind. Shaft Drive”6 7076502

7078055

2

2

Decal - “SPORTSMAN”(A99CH50AA)Decal - “WORKER”(A99CH50EA)

7 7078024 1 Decal - Tank Side, RH8 7076501 2 Decal - ‘‘POLARIS”9 7078003 1 Decal - Headlight Adjustment

10 7074935 1 Decal - Warning, AWD Switch11 7077765 1 Decal - “POLARIS” Domed

12 7077663 1 Decal - “500”13 7078045 1 Decal - “LIQUID COOLED”14 7078354 1 Decal - Discretionary Warning15 7075741 1 Decal - Drain Recoil16 7077749 1 Decal - Park Brake Lock

(A99CH50EA)17 7076202 1 Decal - CE Regulation18 7076273 1 Decal - Override Switch, AWD19 7078023 1 Decal - Tank Side, LH20 7078253 1 Decal - Age Warning, ATV21 7077920 1 Decal - Passenger Warning22 7075834 1 Decal - Tire Pressure23 7078025 1 Decal - Side Panel, LH

(A99CH50AA)24 7077919 1 Decal - Warning, General, CPSC

1/99

Page 12: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A11

DECALSSPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EB

8

22

2

25

7

13

18

10

23

20

15

6

21

11

24

1

6

14

12

19

3

3

17

16

1

LH

RH

9

4 5

5

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

1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution3 7077660 2 Decal - “EBS DUAL SENSING”4 7078026 1 Decal - Side Panel, RH5 7077665 2 Decal - “4x4 Ind. Shaft Drive”6 7076502

7078055

2

2

Decal - “SPORTSMAN”(A99CH50AB)Decal - “WORKER”(A99CH50EB)

7 7078253 1 Decal - Age Warning8 7076501 2 Decal - “POLARIS”9 7078003 1 Decal - Headlight Adjust

10 7074935 1 Decal - Warning, AWD Switch11 7078028 1 Decal - Tank Side, RH12 7078045 1 Decal - “LIQUID COOLED”

13 7078354 1 Decal - Discretionary Warning14 7075741 1 Decal - Drain Recoil15 7076483 1 Decal - Demand 4 Drive16 7077749 1 Decal - Park Brake Lock

(A99CH50EB)17 7077663 1 Decal - “500”18 7077765 1 Decal - “POLARIS” Domed19 7076202 1 Decal - CE Regulation20 7076273 1 Decal - Override Switch, AWD21 7078027 1 Decal - Tank Side, LH22 7077920 1 Decal - Passenger Warning23 7075834 1 Decal - Tire Pressure24 7078025 1 Decal - Side Panel, LH25 7077919 1 Decal - Warning, General, CPSC

1/99

Page 13: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A12

COOLING SYSTEMSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

41

8

1918

1716

9

10

12

11

13

1

28

30

31

3233

27

29

3

6

26

23

22

7

15

25

20

21

9

24

5

14

2

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

1 7080614 3 Clamp, Hose, Worm Gear2 7080696 1 Clamp, Hose, Worm Gear3 5411410 1 Hose, Water4 5411072 1 Hose, Lower Engine5 7080492 1 Cable Tie6 4010202 1 Switch, Thermal, Fan7 2511189 1 Cap, Pressure8 1240015 1 Radiator, U-Flow9 7552605 2 Washer

10 7512113 2 Bolt11 5410607 4 O-Ring12 5431760 1 Cover, Radiator w/Mesh13 5410584 2 Bushing, Mount, Lower Radiator14 7052181 1 Valve, Drain Cock15 5432593 1 Shroud, Fan, ATV16 5020572 2 Spacer, Mount, Radiator17 3110032 2 Mount, Rubber, Radiator

18 7558301 2 Washer19 7542122 2 Nut, Nylok20 7547004 3 Nut21 7558201 3 Washer22 4170013 1 Motor, Fan23 5241355-067 1 Bracket, Cooling Fan24 7512232 4 Screw25 7517475 3 Screw26 5242550 1 Blade, Fan27 5430743 1 Cap, Overflow, Drilled28 5810279 1 Gasket, Cap, Overflow29 5431895 1 Plug, Cap30 5431673 1 Tank, Surge31 8450003-1525 1 Line, Fuel32 7052065 1 Fitting, Barbed, 90 Degree33 7512084 2 Screw

10/98

Page 14: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A13

ENGINE MOUNTINGSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

18

28

44

46

39

42

21

11

33

6

3029

34

23

19

7

2

31

4140

43

27

32

45

38

3

36

4

37

1

47

12

13

26

22

2

1010

38

1412

1413

16

19

87

9

2425

35

17

39

15

20

19

19

19

5

Page 15: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

A14

ENGINE MOUNTINGSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

1 7546601 2 Nut, Nylok2 7080003 8 Clamp, Hose, Red3 5811490 1 Hose, 1.75” Long4 8450040-600 AR Line, Fuel5 8450083-46 1 Line, Fuel, Impulse6 ––––––– 1 Asm., Carburetor

(See Carburetor Pg. D12, Ref. 47)7 7080413 1 Clamp, Narrow Band8 5410995 1 Boot, Carburetor9 7080511 1 Clamp, Narrow Band

10 8450003-1525 AR Line, Fuel11 7052075 1 Fitting, Tee12 3110032 2 Mount, Rubber13 7552605 4 Washer14 7542105 4 Nut15 –––––– 1 Screw and Washer

(See Crankcase Pg. D6, Ref. 6)16 5211626-067 1 Strap, Carburetor Mount17 7512315 2 Bolt18 7552901 2 Washer19 7542403 6 Nut, FLEXLOC20 7080694 1 Clamp, Spring Hose21 ––––––– AR Hose, Breather

(See Air Box Pg. B3, Ref. 17)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, Clutch Retainer30 5430261 1 Bushing31 5410421 1 Boot, Clutch Intake32 ––––––– 1 Asm., Drive Clutch, Braking

(See Drive Clutch Pg. C4, Ref. 16)33 ––––––– 2 Screw and Washer

(See Crankcase Pg. D6, Ref. 6)34 ––––––– 1 Bracket, Retainer, Seal

(See Clutch Cover Pg. C6, Ref. 23)35 7080474 2 Clamp, Hose36 7515417 2 Bolt37 5241150-067 1 Mount, Engine, Front38 3110044 2 Mount, Rubber, Top39 7555801 2 Washer, Wrought40 ––––––– 2 Nut (See Cylinder Pg. D8, Ref. 22)41 ––––––– 2 Washer

(See Cylinder Pg. D8, Ref. 23)42 1260771-029 1 Manifold, Black43 ––––––– 1 Gasket, Exhaust

(See Cylinder Pg. D8, Ref. 20)44 3085556 1 Engine, EH50PLE09 - Short Block

NOTE: The Short Block assemblycontains a crankcase assembly,cylinder & cylinder head assemblyand a piston & crankshaft assem-bly. Prior authorization is requiredfor warranty consideration.

45 5241453-067 1 Mount, Engine, Top46 4010132 1 Cable, Ground, Engine47 2530009 1 Filter

1/99

Page 16: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B1

EXHAUST SYSTEMSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

11

11

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

1 7542324 3 Nut, Nylok2 7555716 3 Washer3 5410436 3 Washer4 7555863 2 Bushing5 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

Page 17: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B2

FUEL TANKSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

21

5

16 13

9

19

18

1

10

2

12

3

20

15

17

7

4

14

8

6

15

11

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

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 2 Bolt7 7552801 2 Washer8 7558301 2 Washer9 5222154-067

5222155-06711

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

10 5332457 2 Spacer

11 7542143 2 Insert12 5810317 2 Pad, Bracket, Fuel Tank13 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, Fuel, 3-Way21 2520144 1 Asm., Fuel Tank (Incl. 13,16)

10/98

Page 18: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B3

AIR BOXSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

4

19

18

11

5

21

23

8

12

24

7

10

2

22

9

3

26

27

6

14

1615

20

13

2517

15

13

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

1 5811137 1 Foam, Filter2 7080595 1 Filter, Air Intake3 7080413 1 Clamp4 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 Inlet

10 5411422 1 Gasket, Intake11 5811482 1 Seal, Air Box Cover12 5432774 1 Box, Air13 7080699 2 Clamp14 8450073-600 AR Line, Fuel

15 7080544 2 Clamp16 2530029 1 Filter, Breather17 5411477 AR Hose, Breather18 5432858 1 Duct, Carburetor Inlet19 5830128 1 Gasket, Carburetor Inlet Duct20 5411668 1 Line, Breather21 5432377 1 Plug, Trap22 8450059-150 AR Line, Fuel23 7080650 1 Clamp, Hose24 5811650 1 Foil25 7558301 2 Washer26 7515179 2 Screw27 5242044 6 Clip, Air Box

1/99

Page 19: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B4

CV JOINT - BTBSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

BTB

101

2 3 4 5 6

7

8 9

12

11

13

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

1 1380119 2 Asm., CV Housing w/Sleeve2 5222299 1 Sleeve, Seal, Drive Shaft3 3260115 1 Clamp, CV Joint, Large4 7670091 1 Circlip5 5411106 1 Boot, CV6 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, Splined

10 7661913 3 Pin, Spring11 7080627 1 Clamp, Band, Small12 2200773 1 Kit - Boot Replacement, CV Joint

(Incl. 3,5,11)13 2200961 1 Kit - Drive Shaft w/Sleeve BTB

10/98

Page 20: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B5

REAR DRIVE SHAFTSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

875 62

4

10

31

9

24

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

1380142 2 Asm., Drive Shaft, Rear (Incl. 1-8)1 1590280 1 CV Joint2 1350044 2 Clamp, Large3 1350046 1 Grease, Outer, 30g4 1350045 2 Boot5 1350043 2 Clamp, Small

6 1350047 1 Grease, Inner, 50g7 1590281 1 Joint, Plunging8 1350042 1 Ring, Spring9 2201374 1 Kit - Boot (Gear Side)

10 2201373 1 Kit - Boot (Wheel Side)

10/98

Page 21: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B6

PROP SHAFTSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1 23

45

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

1380115 1 Shaft, Prop1 3260133 1 Yoke, Gear Case, Front2 ––––––– 2 Kit - Cross and Bearing

(See CV Joint Pg. B4, Ref. 8)

3 3260136 1 Shaft, Prop4 3260131 1 Yoke, Prop Shaft, Transmission5 5411092 1 O-Ring

10/98

Page 22: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B7

FRONT STRUTSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

2

35

67

9

10

4

11

12

13

15

16

8

14

17

18

19

21

4

20

2223

24

25

26

27

1112

4

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

1 54114685411608

22

Bumper, Strut (For Strut 7041755)Bumper, Strut (For Strut 7041761)

2 70417557041761

22

Strut, Front, ArvinStrut, Front, Sachs

3 5211115 2 Washer, Spring Retainer4 7558402 10 Washer5 7080573 2 Clamp, Rubber Coated6 7542303 4 Nut, FLEXLOC7 7512365 4 Bolt8 7552901 4 Washer9 5810439 2 Retainer, Casting Wire, Strut

10 –––––––– 1 Asm., Front Brake Caliper, RH (SeeFront Brake Pg. B9 for Details)

11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Cup, Tapered Roller13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 2201311

2201312

1

1

Asm., Hubstrut, Heavy, LH (32mm)(Incl. 9,12-15,23)Asm., Hubstrut, Heavy, RH (32mm)(Incl. 9,12-15,23)

17 7041375-067 2 Spring, Coil18 5220602

524336422

Retainer, Spring (For Strut 7041755)Retainer, Spring (For Strut 7041761)

19 5430807 2 Ball, Pivot, Bottom20 7515339 4 Bolt21 5130668

513206222

Spacer (For Strut 7041755)Spacer (For Strut 7041761)

22 ––––––– 1 Kit - Drive Shaft w/Sleeve BTB (SeeCV Joint - BTB Pg. B4, Ref. 13)

23 3610028 2 Seal, Hubstrut24 5430806 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7542507

75471042 Nut, FLEXLOC (For Strut 7041755)

Nut, Nylok (For Strut 7041761)

1/99

Page 23: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B8

FRONT WHEELSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

10 11 12 14

1 2

34

5

79

8

15

1625

24 7

1718 20

21

23

13

6

6

22

19

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

1 7512325 8 Bolt2 5242935 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub, Elec./Mech.6 3554506 4 Bearing, Roller Cone, Tapered7 3554507 4 Bearing, Roller Cup, Tapered8 7515523 8 Stud9 1520243 2 Asm., Hub w/Bearing Race

(Incl. 3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter13 1321814 2 Spacer

14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5410947 2 Tire (25x8-12)17 7556004 2 Washer18 7542810 2 Nut, Slotted19 7661401 2 Pin, Cotter20 5410470 2 O-Ring21 5432611 2 Cap, Hub22 7512027 6 Screw23 7542459 8 Nut, Lock24 1520269-067

1520269-117

2

2

Rim, Front, Black(A99CH50(AA)(EA))Rim, Front, Aluminum(A99CH50(AB)(EB))

25 1525017 2 Valve, Rim

1/99

Page 24: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B9

FRONT BRAKESPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

2 3

9

10

12

11

131415

4

5 6 78

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

1910234 1 Asm., Front Brake Caliper, LH(Incl. 1-8,10,11)

1910310 1 Asm., Front Brake Caliper, RH(Incl. 1-8,10,11)

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 Insulator Seal(Incl. 5-8)

5 5410779 1 Square Ring, Molded (.094)6 5410780 1 Square Ring, Molded (.103 x .134)7 5020506 1 Piston, Caliper

8 5910026 1 Insulator, Caliper9 2200465

22009012201149

111

Kit - Front Brake Pad, General DutyKit - Front Brake Pad, Severe DutyKit - Front Brake Pad, Soft Duty

10 1910299 1 Mount, Caliper11 5410495 1 Boot, Bushing12 5410494 1 Boot, Pin Seal13 ––––––– 4 Washer

(See Front Strut Pg.B7, Ref. 4)14 ––––––– 4 Washer

(See Front Strut Pg. B7, Ref. 8)15 ––––––– 4 Bolt

(See Front Strut Pg. B7, Ref. 7)

1/99

Page 25: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B10

CONTROLS – THROTTLE ASM./CABLESPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

5

2

4

3

6

1

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

1 5410193 1 O-Ring2 5432721 1 Cover3 5411439 1 O-Ring

4 7080709 1 Cable, Throttle Control5 2010188 1 Asm., Throttle Control (Incl. 2,3,6)6 2010191 1 Asm., Throttle Clamp

1/99

Page 26: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B11

CONTROLS – MASTER CYLINDER/BRAKE LINESPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

2

3

5

10

6

4

12

1

11

13

23

27

17

20

2122

22

24

2526

16

1819

28

15

14

9

8

7

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

2050078

2200809

1

1

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 Bolt, Lever13 ––––––– 1 Ring, Square, Reservoir

14 5411297 1 Boot, Brake Line, Rubber15 5410988 2 Seal16 4110164 1 Switch, Brake Line17 ––––––– 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 Strap, Black, Weather Resistant23 7512024 2 Screw24 8360031-38 1 Conduit25 1930753 1 Line, Brake, Right Front w/Fittings26 7052129 1 Fitting, Inverted Flare Cross27 1930817 1 Line, Brake, Hyd., Pod28 1930674 1 Bolt, Banjo

10/98

Page 27: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B12

STEERING POSTSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

16

1514

2

3

4

13

10

56

7

11

6

6

9

12

7

8

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

1 1843051 1 Asm., Steering Post (Incl. 5,13)2 5431573 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 5431572 1 Bushing, Steering, Console15 5222999-067 1 Bracket, Steering Bushing, Upper16 7542324 2 Nut, Nylok

10/98

Page 28: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B13

HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

34

9

40

1011

19

41

1

2

3

15

6

7

8

12

14

18

17

20

21

2526

3029

39

37

36

35

3731

23

28

4

4

5

24

38

3233

22

27

16

17

42

13

Page 29: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

B14

HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

1 32802903280312

11

Speedometer, 3″ (Sportsman)Speedo, Kilometer (Worker)

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./CablePg. B10, 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 Nut10 7555868 2 Washer11 7558212 2 Washer12 7515189 4 Screw13 3280291 1 Clamp, Speedometer14 ––––––– 1 Asm., Master Cylinder

(See Controls - Master Cylinder/Brake Line Pg. B11 for details)

15 5433042-191

5433042-136

1

1

Pod, Headlight, Upper(A99CH50(AA)(EA))Pod, Headlight, Upper(A99CH50(AB)(EB))

16 5432952 1 Plug17 7517625 1 Screw18 4110243 1 Switch, Handlebar, LH

19 5432926 1 Spacer, Switch20 5431030 2 Grip, Handlebar21 5240586-067 1 Bracket, Pod Mounting22 7517317 2 Screw23 4032079 1 Knob, Adjusting24 5411120 1 Boot, Headlight25 4032077 1 Collar, Locking26 4032075

287044811

Lens and ReflectorBulb, Headlight, Halogen

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

220018811

Cable, Choke Control w/AdjusterKit - Choke Lever

30 7542122 4 Nut, Nylok31 7670089 2 Nut, U-Type32 2410025 1 Plug, Power, 12V33 7621334 2 Rivet, Bulbex34 7080631 1 Clip, Cable Retaining35 7522021 2 Screw36 5432314-070 1 Pod, Headlight, Lower37 4110209 1 Switch, Ignition (Incl. Key) NOTE:

Ignition Key may be ordered by us-ing the four digit number on the key.

38 5431964 1 Cover, Key39 7080229 1 Nut, Choke Slide40 4040081 1 Sensor, Speedometer41 7515181 1 Bolt42 7558203 1 Washer

1/99

Page 30: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C1

OIL TANKSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

23

1

2

4

10

9

6

7

11

12

15

17

18

19

2021

22

14

5

3

8

8

16

8

To Top Oil Pump Fitting on Engine

To Lower Oil Pump Fitting on Engine

To Airbox

1413

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

1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7052163 1 Fitting5 5411349 AR Line, Breather6 5432289 1 Dipstick7 5410889 1 O-Ring8 7555896 4 Washer9 7052109 1 Tube, Banjo Return

10 7517102 1 Bolt, Banjo11 7052133 1 Tube, Banjo Intake12 2530020 1 Screen, Oil Filter

13 7542122 2 Nut, Nylok14 7558301 2 Washer15 5131785 1 Tank, Oil, LH16 5411042 1 Grommet17 5410828 2 Grommet, Mounting, Reservoir18 5333204 2 Bushing19 7512130 2 Bolt20 7051524 1 Plug, Mag.21 5850135 1 Washer22 7515158 9 Screw23 5131255 1 Tank, Oil, RH

10/98

Page 31: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C2

FRAME MOUNTINGSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

2

3

64

7

8

9

10

11

12

6

2

5

4

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

1 7661013 2 Pin, Clevis2 5431107 2 Bushing3 5020850 1 Tube, Pivot4 7542122 2 Nut, Nylok5 ––––––– 2 Rod End, LH (See Gear Selector

Pg. D5, Ref. 18)6 7558301 2 Washer

7 7515181 2 Bolt8 7512249 1 Bolt9 7512144 1 Screw

10 1040494-067 1 Pivot, Shift11 5131277 1 Arm, Shift12 7661103 2 Pin, Cotter

10/98

Page 32: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C3

A-ARM/STRUT MOUNTINGSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1 45

6

7

89

3

10

1112

13

14

15

171618

20

24

25

2322

21

2627

27 26

2221

19

29 28

2

12

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

1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820567 2 Asm., Tie Rod (Incl. 4-9)4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End, RH6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061033 2 Rod End w/Fitting, LH

10 7555806 4 Washer11 7546904 2 Nut12 7661203 4 Pin, Cotter13 –––––––– 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B7, Ref. 16)14 7080673 2 Joint, Ball15 5211121 2 Bracket, Ball Joint

16 7512284 4 Bolt17 5410548 2 Boot, Rubber18 7542438 2 Nut, Castle19 5431837

543183811

Shield, CV Joint, LHShield, CV Joint, RH

20 7512084 6 Screw21 5431596 4 Bushing, A-Arm, Long22 5020677 4 Bushing23 5020964 2 Shaft, A-Arm24 2200736

220073711

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

25 7080433 2 Fitting, Lubrication26 7512492 4 Bolt27 7552603 4 Washer28 7517527 1 Bolt29 7515415 1 Bolt

10/98

Page 33: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C4

DRIVE CLUTCHSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

16

109

8

11

5

6

13

12

5

72

4

1514

31

17

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

1 1520231 1 Clutch, One Way Drive2 7556009 1 Washer3 5131646 1 Sleeve, Spacer4 7541906 3 Nut, FLEXLOC5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 3585712 1 Bearing8 3576510 1 Cover, Bearing9 7552801 6 Washer

10 7512176 6 Bolt11 7041157 1 Spring, Clutch12 1321457 3 Roller and Bushing13 5430945 6 Washer, Multilube14 7512266 3 Bolt, Shoulder15 5630513 3 Weight, Shift, 10 MH16 1321706 1 Asm., Drive Clutch, Braking

(Incl. All Less 11,15)17 7556008 1 Washer

1/99

Page 34: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C5

DRIVEN CLUTCHSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WOR -

KER 500 A99CH50EB

9

2

67

8

12

14

15

16

18

2

1

17

13

11

10

543

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

1 7556401 AR Bushing2 1322190 1 Asm., Driven Clutch, Braking

(Incl. 4-6,12-18)3 7556013 1 Washer4 7556010 1 Bushing5 7710461 1 Ring, Retaining6 5220646 1 Washer, Domed7 7552901 1 Washer8 7515382 1 Bolt9 3211069 1 Belt, Drive

10 7517323 3 Screw11 3250039 3 Roller, Taper, Engine Brake12 3585710 1 Bearing, Moveable, 1/2”13 5211115 1 Washer14 3576511 1 Bearing, Moveable, 1”15 7041636 1 Spring, Clutch16 5131674 1 Ramp, Stationary17 5210752 1 Spacer18 7710448 1 Ring, Retaining

1/99

Page 35: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C6

CLUTCH COVERSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

4

8

3

10

1113

14

15

16

12

22

2324

29

28

17

2627

25

1 2

20

5

9

7

19

20

21

18

6

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

1 1040519-067 1 Bracket, Clutch Cover, Rear2 7512240 2 Bolt3 5410489 1 Seal, Cover Case4 2201160 1 Kit - Inner Clutch Cover

(Incl. 13,17,25)5 7555748 3 Washer6 7552605 3 Washer7 7512247 1 Bolt8 7512277 1 Bolt9 7512278 1 Bolt

10 5521301 1 Seal, Cover, Clutch11 5432849 1 Cover, Clutch12 7670051 1 Clip, Cover, Clutch13 7512093 5 Screw14 7074946 1 Decal - Clutch Cover15 7077377 1 Decal - Engine/Clutch Modification

16 7077666 1 Decal - “Automatic/EBS” Clutch17 7512094 2 Screw18 5411489 1 Boot, Clutch Intake19 7080761 2 Cable Tie20 7512232 2 Screw21 5432947 1 Duct, Air Outlet22 –––––– 3 Screw and Washer

(See Crankcase Pg. D6, Ref. 6)23 5240409-067 1 Bracket, Retainer, Seal24 5410575 1 Seal, Cover Case25 7512095 1 Screw26 5241156-067 1 Bracket, Cover, Clutch27 7555935 1 Washer28 7080511 1 Clamp, Narrow Band29 ––––––– 1 Duct, Air Inlet

(See Air Box Pg. B3, Ref. 7)

10/98

Page 36: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C7

ELECTRICAL/TAILLIGHTSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

2

3 4

5

67

89 12

11

10

2315

13

14

22

1617

18

19

20

2124

111036

35

31

25

34

33

32

29

3028

32

15

27

26

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

1 2460661 1 Harness, Main Wire2 2200593 1 Kit - Circuit Breaker, 20 AMP3 2432034 1 Asm., Taillight w/Brake Light

(Incl. 4-9)4 4032046 1 Lens, Taillight5 4032029 2 Screw, Taillight6 4030043 1 Bulb, Taillight7 4032045 1 Gasket, Taillight8 4032064 1 Backing, Taillight/Brake Light9 7670054 2 Nut, Speed

10 7541925 4 Nut, Nylok11 7571602 4 Washer12 7512027 2 Screw13 5810290 3 Pad, Battery14 7072606 1 Decal - Battery15 4010094 1 Cable, Battery/Solenoid16 2200361 1 Kit - Battery Bolt, Short17 4010095 1 Cable, Battery/Engine18 7010032 2 Hook, Battery Strap

19 5410424 1 Strap, Battery Holddown20 5432077 AR Tube, Vent, Battery21 4140006 1 Battery22 5431769 1 Cover, Battery23 4010093 1 Cable, Solenoid/Starter24 7512007 2 Bolt25 5810455 2 Pad, Rack Mount26 2460760 1 Harness, Jumper, AWD w/Diode27 7080138 3 Cable Tie28 7080492 1 Cable Tie, 11”29 2460442 1 Pigtail, Power30 2410022 1 Plug, Power, 12V31 5241416 1 Bracket, CDI32 7512018 3 Screw33 5131036 1 Sink, Heat34 4060173 1 Regulator35 4020149 6 Clip, Rosebud36 7670109 2 Clip, Routing

10/98

Page 37: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C8

REAR WHEEL DRIVESPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

78

1011

1

12

6

9

2

3

5

4

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

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

Suspension Pg. C10, Ref. 43)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(A99CH50(AA)(EA))Rim, Rear, Aluminum(A99CH50(AB)(EB))

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

10/98

Page 38: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C9

REAR SUSPENSIONSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

27

41

28

29

26

24

37

10

219

18

11

34

33

32

36

17

4039

38

43

45

42

30

31

22

2

19

13

15

1

3 14

16

7

6

5

4

3

1

16

1415

9

99

10

10 10

11

11

11

11

11

2020

18

17

1032

35

18

36

98

20

6

54

9

20

5

8

8

1817

17

25

24

23

18

12

65

44

12 12

6

10

Page 39: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C10

REAR SUSPENSIONSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

1 7512329 6 Bolt2 1580107-067 2 Arm, Stabilizer Bar3 7542303 6 Nut, FLEXLOC4 7517231 4 Screw5 7555761 8 Washer6 5432598 8 Bushing, Stabilizer7 5020827 2 Rod, Linkage, Stabilizer8 5020826 6 Shaft, A-Arm, Short9 5432091 12 Bushing, A-Arm, Short

10 5020677 12 Bushing11 7080433 12 Fitting, Lubrication12 7515472 6 Bolt13 5333393-067 1 Bar, Stabilizer Tube14 7555939 4 Washer15 5432169 2 Bushing, Stabilizer Tube16 7558402 8 Washer17 7512492 12 Bolt18 7552603 12 Washer19 1541322-067 1 Support, Stabilizer20 7542403 8 Nut, FLEXLOC21 5242077-067 2 Bracket, A-Arm Pivot22 7515433 2 Bolt23 7542321 2 Nut, Flange24 7515321 4 Bolt25 5224667-067 1 Support, Transmission

26 7552901 2 Washer27 5630885 2 Retainer, Spring28 7041453-067

7041519-067

2

2

Spring, Compression, Rear (Sportsman)Spring, Compression, Rear (Worker)

29 5630551 2 Cam, Adjusting, Spring30 7041770 2 Shock, Rear31 7515415 2 Bolt32 5431596 4 Bushing, A-Arm, Long33 5020964 2 Shaft, A-Arm34 1012717-067

1012718-06711

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

35 7542439 2 Nut, Nylok36 5432092 8 Bushing, Control, Lower37 1040730-067

1040731-06711

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

38 5131883 4 Bushing, Bearing Carrier39 7555936 4 Washer40 7517297 4 Screw41 5433098

543309911

Shield, LHShield, RH

42 7512084 4 Screw43 5131738 2 Carrier, Bearing, Wheel44 3585502 2 Bearing, Carrier, Wheel45 7080586 2 Fitting, Lubrication

10/98

Page 40: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C11

REAR BRAKE/FOOT PEDALSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

10

7

8

9

11

12

13

1415

1617

18

19

202122 11

1415

12

3

4

5

6

Page 41: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C12

REAR BRAKE/FOOT PEDALSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

1 7515497 2 Bolt2 7552603 2 Washer3 7555806 2 Washer4 1930818

191033922010932201180193086022014282201467

1111121

Caliper, BrakeSpacer, Brake PadKit - Brake PadKit - Brake SealPinKit - Bleeder ReplacementPiston, Caliper, Rear

5 1930853 1 Line, Rear Brake6 1910305 1 Line, Brake, Caliper w/Fittings7 7512111 1 Bolt8 1930854 1 Reservoir, Brake, Rear9 7542153 1 Nut

10 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 1910188 1 Disc, Brake21 7571620 1 Washer22 7547046 1 Nut

1/99

Page 42: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C13

FOOT BRAKEWORKER 500 A99C H50EA and WORKER 500 A99CH50EB

2

11

5

12

13

9

14

43

16

10

1

7

6

815

8

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

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

9 5224875 1 Spring, Return10 7558707 1 Bushing11 5242749 1 Pawl, Parking Brake12 5224871 1 Linkage, Parking13 7080644 1 Clevis, Threaded14 7661843 1 Pin, Clevis15 7661011 1 Pin, Cotter16 7661203 1 Pin, Cotter

10/98

Page 43: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

C14

FRONT HOUSINGSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

12

34

56

78

1011

12

12 1819

16

20 21

22

2324

27

28

291

9

15

1725

26

1413

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

1341257 1 Asm., Front Gearcase(Incl. All Less 13,14)NOTE: Usedon Machines built before 9-14-98.

1 3233248 2 Seal2 3233315 1 O-Ring3 3233316 1 Cover, Input, Front Housing4 3233019 1 Bearing, Ball5 3233306 2 Ring, Retaining6 3233020 1 Bearing, Ball7 3233489 1 Shaft, Input, Front Housing8 3233479 1 Bushing9 3233480 1 Washer

10 3233319 1 Seal11 3233320 1 Ring, Retaining12 3233321 2 Screw13 7080307 2 Clamp

14 8360009-600 AR Line, Vent15 3233037 1 Tube, Vent16 3233481 1 Housing, Front, Gearcase17 3233463 1 Rivet18 3233254 1 Washer19 3233253 1 Plug, Drain20 3233324 1 Washer21 3233325 1 Plug22 3233326 1 Bearing, Needle23 3233327 1 Shaft, Output, Front Housing24 3233328 1 Gear, 31T, Spiral Bevel25 3233346 1 Washer, Thrust26 3233347 1 Washer, Thrust27 3233329 1 Bearing, Ball28 3233330 1 Cover, Output, Front Housing29 3233331 1 O-Ring

1/99

Page 44: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D1

FRONT HOUSINGSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1 21

201918

17

16

1211

9 10

87

65

43

24

25

2322

12

2

15

13

14

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

1341276 1 Asm., Front Gearcase (Incl. 1-12,15-25)NOTE: Used onMachines Built After 9-14-98

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing7 3233698 1 Pinion, Input8 3233697 1 Bushing9 3233319 1 Seal, Oil

10 3233541 1 Bushing11 3233324 1 Washer12 3233325 1 Plug

13 7080409 2 Clamp14 8450003-1525 AR Line15 3233524 1 Tube, Vent16 3233696 1 Gearcase, Front Housing17 3233710 1 SubAsm., Output Shaft, Front

Housing18 3233020 1 Bearing, Ball19 3233554 AR Shim20 3233693 1 O-Ring21 3233692 1 Cover, Output, Front Housing22 3233583 AR Shim23 3233702 1 Button, Thrust24 3233253 1 Plug, Drain25 3233254 1 Washer

1/99

Page 45: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D2

GEARCASE (Cases and Snorkel)SPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

12

4

27 24

2829

23

13

16

17

1820

1921

32

12

1011

34

6

7

3

133

95

31

5

30

25

8

14

2226

15

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

––––––– 1 Asm., Gearcase (See Gearcase-Internal Components Pg. D4 for-Details)

1 3233256 2 Seal2 3233252 2 Screw3 3233636 1 Decal - Switch4 3233026 18 Screw5 3233248 3 Seal6 3233671 1 Gearcase, LH7 3233037 1 Vent8 3233475 1 Dipstick9 3233616 1 Screw

10 3233617 1 Switch, 2 Position11 3233635 1 Switch, 3 Position12 3233442 2 Screw13 3233352 1 Washer14 3233476 1 Gear, 31T, Extended15 ––––––– Bearing, Ball (See Gearcase -Inter-

nal Components Pg. D4, Ref. 34)16 3233446 1 Shaft, Drive, Snorkel17 3233302 1 O-Ring18 3233303 1 Snorkel

19 3233305 1 Bearing, Ball20 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. 20 indicates choices, may alsobe used in combinations.

21 3233306 1 Ring, Retaining22 3233444 1 Lock, Bolt23 3233351 1 Bolt24 3233292 1 Bushing25 3233293 1 Seal26 ––––––– 4 Washer (See Gearcase - Internal-

Components Pg. D4, Ref. 10)27 3233291 2 Nut, FLEXLOC28 3233294 1 Stamping, Cover Plate29 3233295 4 Washer30 3233296 4 Screw31 3233253 1 Plug, Drain32 3233254 1 Washer33 3233672 1 Gearcase, RH34 3233247 3 Pin, Dowel

10/98

Page 46: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D3

GEARCASE (Internal Components)SPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

11

109

87

14

33

32

5

13

3123

30

29

28

27

2425

2221

2019

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

Page 47: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D4

GEARCASE (Internal Components)SPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

1341277 1 Asm., Gearcase(Incl. 1-51 and all on Gearcase -Cases and Snorkel Pg. D2)

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, HLR

10 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 3233485 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

10/98

Page 48: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D5

GEAR SELECTORSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

20

18

1516

19

2

3

4

5

7

8

910

11 12

13

14

25 24

23

6

18

17

2115

1

22

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

1341275 1 Asm., Gear Selector(Incl. 1-14,22-25)

1 3233195 1 Knob, HLR2 7512024 1 Screw3 3233131 1 Strap, Wire4 3233132 1 Clamp5 3233368 1 Boot, Gear Selector6 3233498 5 Screw7 3233213 1 Cover, Gear Selector8 3233227 1 Handle9 3233063 1 Cup, Bearing

10 3233083 1 Spring, Centering11 3233062 1 Pin, Stop12 3233069 2 Spring, Detent

13 3233060 2 Bullet, Detent14 3233495 1 Grommet15 7061014 2 Rod End, RH16 7546702 2 Nut, LH17 5020823 1 Rod, Shift Linkage, Hi-Range18 7061013 2 Rod End, LH19 7546707 4 Nut, FLEXLOC20 5020824 1 Rod, Shift Linkage, Low-Range21 7546701 2 Nut, RH22 3233076 2 O-Ring23 3233638 1 Slide, Low24 3233637 1 Slide, High/Reverse25 3233343 1 Body, Gear Selector

10/98

Page 49: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D6

CRANKCASESPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

2

4

10

11

2

19

20

1

22

7

5

16

3

1817

9

1514

1213

21

6

5

8

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

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

(Incl. 1,4,5,7,8,10,11,16,19,20,22)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 Union

10 3084834 2 Bearing, Ball11 3084835 1 Bearing, Ball

12 3084845 1 Plug13 3084846 1 Gasket, Aluminum14 3084844 1 Spring, Valve, One Way15 3084843 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

10/98

Page 50: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D7

CYLINDERSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

Page 51: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D8

CYLINDERSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

1 3083166 1 Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt4 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, Flange

10 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, Flange20 3085075 1 Gasket, Exhaust

21 3085326 2 Stud22 3080285 2 Nut23 3080530 2 Washer24 3084880 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 3085634 1 Cylinder (Incl. 32)32 3084130 1 Pipe 2, Elbow33 3085370 1 Gasket, Cylinder34 3084868 1 Cover, Camshaft35 3084869 1 Gasket, Cover, Cam36 3085527 1 Cylinder Head

(Incl. 4-6,14,16-18,21)37 3085371 1 Gasket, Head38 3084879 1 Adapter

10/98

Page 52: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D9

CRANKSHAFT and PISTONSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

19

20

6

10

14

12

5

8

18 13

9

17

7

2

11

1

15

21

16

3

4

1

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

1 3085534 2 Clip2 3085533 1 Pin, Piston3 3085866

30858673085868

111

Piston Set (Std)(Incl. 1-3) Piston Set (0.25 O/S)(Incl. 1-3)Piston Set (0.50 O/S)(Incl. 1-3)

4 308537930853803085381

111

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

5 3085374 1 Crankshaft 26 3085341 1 Pin, Crank7 3085376 1 Rod, Connecting8 3085400 1 Bearing, Large End9 3085024 1 Ball, Steel

10 30853993085373

11

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

10/98

Page 53: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D10

INTAKE and EXHAUSTSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

13 14

18

15

16

17

25

26

13 12 11

10

6

98

22

7

19

8

20

24

4

3

2

1

5

21

27

23

89 6

9

1211

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

1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3084919 1 Spring, Tensioner4 3084918 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Rocker Arm, Intake (Incl. 8,9)7 3084913 1 Asm., Rocker Arm, Exhaust

(Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting

10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3084907 4 Retainer, Spring13 3084906 4 Spring, Valve

14 3084898 1 Camshaft (Incl. 15-18)15 3080103 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3084914 1 Sprocket 220 3084916 1 Guide, Chain21 3081657 3 Bolt and Washer22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot, Lever24 3084917 1 Lever25 3085349 2 Valve, Intake26 3084905 2 Valve, Exhaust27 3084874 2 Bolt, Flange

10/98

Page 54: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D11

CARBURETORSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

47

37

34

9

50

5

49

12

4

6

4142

38

36

1235

131214

15

21

19

27

30

29

26

1110

3

22

20

16

24

18

25

40

23

51

4445

87

46

39

33

32

31

28

17

48

43

Page 55: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D12

CARBURETORSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

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

1 3130507 1 Ring2 3130508 1 E-Ring3 3130963 1 Needle, Jet (J8-4HB41)4 3130752 1 Ring5 3130732 1 Diaphragm6 3130960 1 Jet, Needle (Q-0)7 3130541 2 Screw8 3130540 2 Washer9 3130504 1 Asm., Jet Block

10 3130014 1 Washer11 3130570 1 Jet, Main (#152.5)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 Body, Float21 3130521 1 Screw22 3130529 1 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 3130959 1 Asm., Carburetor

(Incl. 1-38,43-51)48 3084205 2 Screw and Washer49 3130505 1 Spring50 3130503 1 Cover51 3130592 4 Screw

10/98

Page 56: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D13

RECOIL STARTERSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

14

6

4

7

10

5

31 2

11

8

12

13

15

9

8

7

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

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 Bush, Starter10 3083185 1 Spring, Power11 3084750 1 Bush12 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 Rope

10/98

Page 57: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

D14

WATER PUMPSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

11

7

83

3

2

1

9

12

13

4

10

65

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

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 Lock

10 3083138 1 Gasket11 3084935 1 Impeller12 3084942 1 Washer, Seal13 3084877 4 Bolt, Flange

10/98

Page 58: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

E1

OIL PUMPSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

4

1

10

3

2

11

12

15

87

6

13

14

5

1617

9

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

1 3084946 1 Case 2, Oil Pump2 3084949 1 Rotor, Outer (Feed)3 3084948 1 Rotor, Inner (Feed)4 3084944

3084945

1

1

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, Inner (Scav)12 3084951 1 Rotor, Outer13 3084956 1 Oil Strainer Unit14 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)

10/98

Page 59: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

E2

OIL FILTERSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

4

5

3

3

3

2

2

2

2

2

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

1 3084963 1 Filter, Oil2 3084846 8 Gasket, Aluminum3 3084966 4 Bolt, Banjo

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

10/98

Page 60: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

E3

MAGNETOSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

206

5

8

9

10

11

12

13 14

4

7

1

2

16

19

3

1517

18

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

1 30852273085228

11

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

2 3084980 1 Cap, Plug, Spark3 3070175 1 Plug, Spark4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3085559

308556011

Asm., Plate (Incl. 5,6,8-12,14,15)Plate

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3085561 1 Stator (Incl. 13)

10 3085563 3 Screw and Washer11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3084977 1 Clamp15 3081256 3 Screw and Washer16 3085639 1 CDI System17 3083073 2 Nut18 3080077 2 Washer19 3085521 1 Switch, Magnetic20 3085558 1 Flywheel w/Ring Gear

10/98

Page 61: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

E4

STARTING MOTORSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

10

12

2

6

11

5

4

18

13

17

16

15

14

78

9

32

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

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

Page 62: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

E5

FUEL PUMPSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

5

2

4 3

3

5

1

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

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

Page 63: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

E6

TOOL KITSPORTSMAN 500 A99CH50AA and SPORTSMAN 500 A99CH50AB and WORKER 500 A99CH50EA and WORKER

500 A99CH50EB

1

3

6

2

8

4

5

10

7

9

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

1 2870694 1 Asm., Tool Kit (Incl. 2-6)2 2870725 1 Gauge, Tire Pressure3 3083843 1 Screwdriver4 3083612 1 Wrench, Box, Special5 3083613 1 Wrench, 10-12 Spanner6 2690016 1 Pouch, Tool Kit

7 2871515 1 Lube, U-Joint, 3 oz., Case8 9914905

991491011

Owner’s Manual, ‘99 ATVSupplement, Owner’s Manual ’99Sportsman 500

9 2871095-067 1 Wrench, Spanner, Cam10 2460442 1 Pigtail, Power

10/98

Page 64: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

SPORTSMAN 500 A99CH50(AA)(AB) and WORKER 500 A99CH50(EA)(EB)

E7

1012717-067 34 C10. . . . 1012718-067 34 C10. . . . 1012796-067 34 A6. . . . . 1040387 16 A6. . . . . . . . . 1040490-067 7 A8. . . . . . 1040494-067 10 C2. . . . . 1040519-067 1 C6. . . . . . 1040524-067 12 A8. . . . . 1040525-067 12 A8. . . . . 1040554-067 12 A9. . . . . 1040555-067 12 A9. . . . . 1040730-067 37 C10. . . . 1040731-067 37 C10. . . . 1040732-067 2 C13. . . . . 1240015 8 A12. . . . . . . . . 1260715-029 9 B1. . . . . . 1260716-029 15 B1. . . . . 1260771-029 42 A14. . . . 1321457 12 C4. . . . . . . . . 1321706 16 C4. . . . . . . . . 1321814 13 B8. . . . . . . . . 1322190 2 C5. . . . . . . . . . 1341257 C14. . . . . . . . . . . . 1341275 D5. . . . . . . . . . . . . 1341276 D1. . . . . . . . . . . . . 1341277 D4. . . . . . . . . . . . . 1350042 8 B5. . . . . . . . . . 1350043 5 B5. . . . . . . . . . 1350044 2 B5. . . . . . . . . . 1350045 4 B5. . . . . . . . . . 1350046 3 B5. . . . . . . . . . 1350047 6 B5. . . . . . . . . . 1380092 7 B4. . . . . . . . . . 1380094 6 B4. . . . . . . . . . 1380115 B6. . . . . . . . . . . . . 1380119 1 B4. . . . . . . . . . 1380142 B5. . . . . . . . . . . . . 1520217-067 9 C8. . . . . . 1520217-117 9 C8. . . . . . 1520231 1 C4. . . . . . . . . . 1520243 9 B8. . . . . . . . . . 1520269-067 24 B8. . . . . 1520269-117 24 B8. . . . . 1520281 5 B8. . . . . . . . . . 1525017 25 B8. . . . . . . . . .

8 C8. . . 1541322-067 19 C10. . . . 1580107-067 2 C10. . . . . 1590280 1 B5. . . . . . . . . . 1590281 7 B5. . . . . . . . . . 1820567 3 C3. . . . . . . . . . 1843051 1 B12. . . . . . . . . 1910188 20 C12. . . . . . . . 1910234 B9. . . . . . . . . . . . . 1910280-067 16 C12. . . . 1910299 10 B9. . . . . . . . . 1910301 18 C12. . . . . . . . 1910305 6 C12. . . . . . . . . 1910310 B9. . . . . . . . . . . . . 1910315 10 C12. . . . . . . . 1910339 4 C12. . . . . . . . . 1930642 3 B9. . . . . . . . . .

1930665 4 B9. . . . . . . . . . 1930674 28 B11. . . . . . . . 1930752 21 B11. . . . . . . . 1930753 25 B11. . . . . . . . 1930792 11 B11. . . . . . . . 1930795 3 B11. . . . . . . . . 1930796 2 B11. . . . . . . . . 1930797 1 B11. . . . . . . . . 1930799 5 B11. . . . . . . . . 1930804 6 B11. . . . . . . . . 1930805 12 B11. . . . . . . . 1930806 10 B11. . . . . . . . 1930817 27 B11. . . . . . . . 1930818 4 C12. . . . . . . . . 1930853 5 C12. . . . . . . . . 1930854 8 C12. . . . . . . . . 1930860 4 C12. . . . . . . . . 2010188 5 B10. . . . . . . . . 2010191 6 B10. . . . . . . . . 2050078 B11. . . . . . . . . . . . 2200188 29 B14. . . . . . . . 2200361 16 C7. . . . . . . . . 2200465 9 B9. . . . . . . . . . 2200593 2 C7. . . . . . . . . . 2200736 24 C3. . . . . . . . . 2200737 24 C3. . . . . . . . . 2200771 8 B4. . . . . . . . . . 2200773 12 B4. . . . . . . . . 2200774 8 B14. . . . . . . . . 2200775 5 A9. . . . . . . . . . 2200808 4 B11. . . . . . . . . 2200809 B11. . . . . . . . . . . . 2200901 9 B9. . . . . . . . . . 2200961 13 B4. . . . . . . . . 2201034 7 B11. . . . . . . . . 2201090 9 B11. . . . . . . . . 2201093 4 C12. . . . . . . . . 2201149 9 B9. . . . . . . . . . 2201160 4 C6. . . . . . . . . . 2201180 4 C12. . . . . . . . . 2201311 16 B7. . . . . . . . . 2201312 16 B7. . . . . . . . . 2201373 10 B5. . . . . . . . . 2201374 9 B5. . . . . . . . . . 2201428 4 C12. . . . . . . . . 2201467 4 C12. . . . . . . . . 2410022 30 C7. . . . . . . . . 2410025 32 B14. . . . . . . . 2410133 15 B7. . . . . . . . . 2431014 14 A9. . . . . . . . . 2431015 14 A9. . . . . . . . . 2432034 3 C7. . . . . . . . . . 2460442 10 E6. . . . . . . . . .

29 C7. . . 2460661 1 C7. . . . . . . . . . 2460668 5 B14. . . . . . . . . 2460760 26 C7. . . . . . . . . 2511189 7 A12. . . . . . . . . . 2520144 21 B2. . . . . . . . . 2530009 47 A14. . . . . . . . 2530020 12 C1. . . . . . . . . 2530029 16 B3. . . . . . . . .

2620085-136 3 A7. . . . . . 2620085-191 3 A7. . . . . . 2631987-136 7 A7. . . . . . 2631987-191 7 A7. . . . . . 2670070 5 A8. . . . . . . . . . 2670071 3 A9. . . . . . . . . . 2670174 4 A8. . . . . . . . . . 2670180 2 A9. . . . . . . . . . 2681747-070 18 A6. . . . . 2682441-070 18 A6. . . . . 2690016 6 E6. . . . . . . . . . 2870448 26 B14. . . . . . . . 2870694 1 E6. . . . . . . . . . 2870725 2 E6. . . . . . . . . . 2871095-067 9 E6. . . . . . 2871501 1 A8. . . . . . . . . . 2871515 7 E6. . . . . . . . . . 3070175 3 E3. . . . . . . . . . 3080077 18 E3. . . . . . . . . 3080103 22 D6. . . . . . . . . .

15 D10. . 3080130 21 D9. . . . . . . . . 3080285 22 D8. . . . . . . . . 3080530 23 D8. . . . . . . . . 3080676 4 D6. . . . . . . . . . 3081256 15 E3. . . . . . . . . 3081330 3 D8. . . . . . . . . . 3081447 20 D9. . . . . . . . . 3081497 2 D8. . . . . . . . . . 3081657 21 D10. . . . . . . . .

7 E3. . . 3082038 7 E4. . . . . . . . . . 3082758 6 D14. . . . . . . . . 3082956 17 D6. . . . . . . . . .

8 D13. . 3083073 17 E3. . . . . . . . . 3083138 10 D14. . . . . . . . 3083166 1 D8. . . . . . . . . . 3083185 10 D13. . . . . . . . 3083378 3 D13. . . . . . . . . 3083379 4 D13. . . . . . . . . 3083453 18 D6. . . . . . . . . .

7 D13. . 3083463 2 D13. . . . . . . . . 3083612 4 E6. . . . . . . . . . 3083613 5 E6. . . . . . . . . . 3083649 5 E4. . . . . . . . . . 3083669 1 D6. . . . . . . . . . .

9 D13. . 3083737 13 E4. . . . . . . . . 3083843 3 E6. . . . . . . . . . 3083904 17 D9. . . . . . . . . 3083905 18 D9. . . . . . . . . 3084130 32 D8. . . . . . . . . 3084191 3 D14. . . . . . . . . 3084205 6 D6. . . . . . . . . . .

48 D12. . 14 E1. . .

3084215 19 D8. . . . . . . . . 3084405 12 E4. . . . . . . . . 3084406 4 E4. . . . . . . . . . 3084408 6 E4. . . . . . . . . . 3084409 17 E4. . . . . . . . .

Page 65: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

SPORTSMAN 500 A99CH50(AA)(AB) and WORKER 500 A99CH50(EA)(EB)

E8

3084410 16 E4. . . . . . . . . 3084411 15 E4. . . . . . . . . 3084412 14 E4. . . . . . . . . 3084591 4 E5. . . . . . . . . . 3084744 5 D13. . . . . . . . . 3084750 11 D13. . . . . . . . 3084822 1 D13. . . . . . . . . 3084834 10 D6. . . . . . . . . 3084835 11 D6. . . . . . . . . 3084836 20 D6. . . . . . . . . 3084837 19 D6. . . . . . . . . 3084838 3 D6. . . . . . . . . . .

28 D8. . . 3084839 7 D6. . . . . . . . . . 3084840 5 D6. . . . . . . . . . 3084841 16 D6. . . . . . . . . 3084842 9 D6. . . . . . . . . . 3084843 15 D6. . . . . . . . . 3084844 14 D6. . . . . . . . . 3084845 12 D6. . . . . . . . . .

1 D10. . 3084846 13 D6. . . . . . . . . .

2 E2. . . 3084847 21 D6. . . . . . . . . 3084849 29 D8. . . . . . . . . 3084857 4 D8. . . . . . . . . . 3084858 6 D8. . . . . . . . . . 3084859 14 D8. . . . . . . . . 3084860 16 D8. . . . . . . . . 3084861 17 D8. . . . . . . . . 3084862 18 D8. . . . . . . . . 3084863 27 D8. . . . . . . . . 3084864 26 D8. . . . . . . . . 3084866 10 D8. . . . . . . . . 3084867 7 D8. . . . . . . . . . 3084868 34 D8. . . . . . . . . 3084869 35 D8. . . . . . . . . 3084873 30 D8. . . . . . . . . 3084874 13 D8. . . . . . . . . .

27 D10. . 3084875 15 D8. . . . . . . . . 3084876 25 D8. . . . . . . . . 3084877 9 D8. . . . . . . . . . .

13 D13. . 13 D14. .

3084879 38 D8. . . . . . . . . 3084880 24 D8. . . . . . . . . 3084882 15 D9. . . . . . . . . 3084892 14 D9. . . . . . . . . 3084893 14 D9. . . . . . . . . 3084894 14 D9. . . . . . . . . 3084895 13 D9. . . . . . . . . 3084896 13 D9. . . . . . . . . 3084897 13 D9. . . . . . . . . 3084898 14 D10. . . . . . . . 3084899 18 D10. . . . . . . . 3084905 26 D10. . . . . . . . 3084906 13 D10. . . . . . . . 3084907 12 D10. . . . . . . . 3084908 11 D10. . . . . . . . 3084909 10 D10. . . . . . . . 3084910 6 D10. . . . . . . . .

3084911 9 D10. . . . . . . . . 3084912 8 D10. . . . . . . . . 3084913 7 D10. . . . . . . . . 3084914 19 D10. . . . . . . . 3084915 22 D10. . . . . . . . 3084916 20 D10. . . . . . . . 3084917 24 D10. . . . . . . . 3084918 4 D10. . . . . . . . . 3084919 3 D10. . . . . . . . . 3084920 2 D10. . . . . . . . . 3084922 5 D10. . . . . . . . . 3084924 23 D10. . . . . . . . 3084933 12 D13. . . . . . . . 3084935 11 D14. . . . . . . . 3084937 8 D14. . . . . . . . . 3084940 1 D14. . . . . . . . . 3084942 12 D14. . . . . . . . 3084944 4 E1. . . . . . . . . . 3084945 4 E1. . . . . . . . . . 3084946 1 E1. . . . . . . . . . 3084947 10 E1. . . . . . . . . 3084948 3 E1. . . . . . . . . . 3084949 2 E1. . . . . . . . . . 3084950 11 E1. . . . . . . . . 3084951 12 E1. . . . . . . . . 3084952 15 E1. . . . . . . . . 3084953 8 E1. . . . . . . . . . 3084954 7 E1. . . . . . . . . . 3084955 6 E1. . . . . . . . . . 3084956 13 E1. . . . . . . . . 3084958 16 E1. . . . . . . . . 3084959 17 E1. . . . . . . . . 3084960 17 E1. . . . . . . . . 3084961 17 E1. . . . . . . . . 3084962 9 E1. . . . . . . . . . 3084963 1 E2. . . . . . . . . . 3084964 4 E2. . . . . . . . . . 3084966 3 E2. . . . . . . . . . 3084972 5 E3. . . . . . . . . . 3084973 8 E3. . . . . . . . . . 3084976 12 E3. . . . . . . . . 3084977 14 E3. . . . . . . . . 3084978 4 E3. . . . . . . . . . 3084980 2 E3. . . . . . . . . . 3084981 1 E4. . . . . . . . . . 3084982 2 E4. . . . . . . . . . 3084983 11 E4. . . . . . . . . 3084994 5 D8. . . . . . . . . . 3084998 5 E5. . . . . . . . . . 3084999 2 E5. . . . . . . . . . 3085024 9 D9. . . . . . . . . . 3085033 9 E4. . . . . . . . . . 3085034 8 E4. . . . . . . . . . 3085072 8 D8. . . . . . . . . . 3085073 12 D8. . . . . . . . . 3085074 11 D8. . . . . . . . . 3085075 20 D8. . . . . . . . . 3085076 17 D10. . . . . . . . 3085077 9 D14. . . . . . . . . 3085083 15 D13. . . . . . . . 3085227 1 E3. . . . . . . . . . 3085228 1 E3. . . . . . . . . .

3085266 6 D13. . . . . . . . . 3085275 1 E5. . . . . . . . . . 3085326 21 D8. . . . . . . . . 3085341 6 D9. . . . . . . . . . 3085346 19 D9. . . . . . . . . 3085348 16 D10. . . . . . . . 3085349 25 D10. . . . . . . . 3085351 7 D14. . . . . . . . . 3085352 2 D14. . . . . . . . . 3085353 3 E4. . . . . . . . . . 3085356 3 E5. . . . . . . . . . 3085359 5 D14. . . . . . . . . 3085360 13 E3. . . . . . . . . 3085370 33 D8. . . . . . . . . 3085371 37 D8. . . . . . . . . 3085373 10 D9. . . . . . . . . 3085374 5 D9. . . . . . . . . . 3085376 7 D9. . . . . . . . . . 3085379 4 D9. . . . . . . . . . 3085380 4 D9. . . . . . . . . . 3085381 4 D9. . . . . . . . . . 3085394 18 E4. . . . . . . . . 3085399 10 D9. . . . . . . . . 3085400 8 D9. . . . . . . . . . 3085404 12 D9. . . . . . . . . 3085521 19 E3. . . . . . . . . 3085525 8 D6. . . . . . . . . . 3085527 36 D8. . . . . . . . . 3085528 16 D9. . . . . . . . . 3085533 2 D9. . . . . . . . . . 3085534 1 D9. . . . . . . . . . 3085535 5 E1. . . . . . . . . . 3085554 11 E3. . . . . . . . . 3085556 44 A14. . . . . . . . 3085558 20 E3. . . . . . . . . 3085559 6 E3. . . . . . . . . . 3085560 6 E3. . . . . . . . . . 3085561 9 E3. . . . . . . . . . 3085563 10 E3. . . . . . . . . 3085633 2 D6. . . . . . . . . . 3085634 31 D8. . . . . . . . . 3085638 5 E2. . . . . . . . . . 3085639 16 E3. . . . . . . . . 3085652 14 D13. . . . . . . . 3085653 14 D13. . . . . . . . 3085852 11 D9. . . . . . . . . 3085857 4 D14. . . . . . . . . 3085866 3 D9. . . . . . . . . . 3085867 3 D9. . . . . . . . . . 3085868 3 D9. . . . . . . . . . 3110032 17 A12. . . . . . . . .

12 A14. . 3110044 38 A14. . . . . . . . 3110046 23 A14. . . . . . . . 3130014 10 D12. . . . . . . . 3130199 43 D12. . . . . . . . 3130361 16 D12. . . . . . . . 3130501 37 D12. . . . . . . . 3130502 34 D12. . . . . . . . 3130503 50 D12. . . . . . . . 3130504 9 D12. . . . . . . . . 3130505 49 D12. . . . . . . . 3130507 1 D12. . . . . . . . .

Page 66: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

SPORTSMAN 500 A99CH50(AA)(AB) and WORKER 500 A99CH50(EA)(EB)

E9

3130508 2 D12. . . . . . . . . 3130511 41 D12. . . . . . . . 3130512 42 D12. . . . . . . . 3130513 38 D12. . . . . . . . 3130514 36 D12. . . . . . . . 3130515 12 D12. . . . . . . . 3130517 13 D12. . . . . . . . 3130518 14 D12. . . . . . . . 3130519 15 D12. . . . . . . . 3130520 19 D12. . . . . . . . 3130521 21 D12. . . . . . . . 3130522 27 D12. . . . . . . . 3130523 28 D12. . . . . . . . 3130524 30 D12. . . . . . . . 3130525 29 D12. . . . . . . . 3130529 22 D12. . . . . . . . 3130532 18 D12. . . . . . . . 3130533 25 D12. . . . . . . . 3130535 40 D12. . . . . . . . 3130538 44 D12. . . . . . . . 3130540 8 D12. . . . . . . . . 3130541 7 D12. . . . . . . . . 3130543 39 D12. . . . . . . . 3130544 33 D12. . . . . . . . 3130545 32 D12. . . . . . . . 3130546 31 D12. . . . . . . . 3130570 11 D12. . . . . . . . 3130589 35 D12. . . . . . . . 3130590 20 D12. . . . . . . . 3130591 23 D12. . . . . . . . 3130592 51 D12. . . . . . . . 3130593 45 D12. . . . . . . . 3130594 17 D12. . . . . . . . 3130624 26 D12. . . . . . . . 3130625 46 D12. . . . . . . . 3130668 24 D12. . . . . . . . 3130732 5 D12. . . . . . . . . 3130752 4 D12. . . . . . . . . 3130959 47 D12. . . . . . . . 3130960 6 D12. . . . . . . . . 3130963 3 D12. . . . . . . . . 3211069 9 C5. . . . . . . . . . 3233007 33 D4. . . . . . . . . 3233009 31 D4. . . . . . . . . 3233010 23 D4. . . . . . . . . 3233012 26 D4. . . . . . . . . 3233014 27 D4. . . . . . . . . 3233017 21 D4. . . . . . . . . 3233018 4 D4. . . . . . . . . . 3233019 4 C14. . . . . . . . . .

1 D4. . . 3233020 6 C14. . . . . . . . . .

18 D1. . . 34 D4. . .

3233026 4 D2. . . . . . . . . . 3233029 25 D4. . . . . . . . . 3233033 15 D4. . . . . . . . . 3233036 3 D4. . . . . . . . . . 3233037 15 C14. . . . . . . . .

7 D2. . . 3233040 7 D4. . . . . . . . . . 3233045 8 D4. . . . . . . . . .

3233054 10 D4. . . . . . . . . 3233055 11 D4. . . . . . . . . 3233060 13 D5. . . . . . . . . 3233062 11 D5. . . . . . . . . 3233063 9 D5. . . . . . . . . . 3233069 12 D5. . . . . . . . . 3233076 22 D5. . . . . . . . . 3233083 10 D5. . . . . . . . . 3233131 3 D5. . . . . . . . . . 3233132 4 D5. . . . . . . . . . 3233153 9 D4. . . . . . . . . . 3233176 20 D4. . . . . . . . . 3233177 19 D4. . . . . . . . . 3233189 18 D4. . . . . . . . . 3233195 1 D5. . . . . . . . . . 3233213 7 D5. . . . . . . . . . 3233227 8 D5. . . . . . . . . . 3233247 34 D2. . . . . . . . . 3233248 1 C14. . . . . . . . . .

2 D1. . . 5 D2. . .

3233252 1 D1. . . . . . . . . . . 2 D2. . .

3233253 19 C14. . . . . . . . . 24 D1. . . 31 D2. . .

3233254 18 C14. . . . . . . . . 25 D1. . . 32 D2. . .

3233256 1 D2. . . . . . . . . . 3233262 37 D4. . . . . . . . . 3233263 39 D4. . . . . . . . . 3233265 41 D4. . . . . . . . . 3233268 49 D4. . . . . . . . . 3233282 43 D4. . . . . . . . . 3233291 27 D2. . . . . . . . . 3233292 24 D2. . . . . . . . . 3233293 25 D2. . . . . . . . . 3233294 28 D2. . . . . . . . . 3233295 29 D2. . . . . . . . . 3233296 30 D2. . . . . . . . . 3233302 17 D2. . . . . . . . . 3233303 18 D2. . . . . . . . . 3233305 19 D2. . . . . . . . . 3233306 5 C14. . . . . . . . . .

21 D2. . . 3233308 16 D4. . . . . . . . . 3233309 17 D4. . . . . . . . . 3233315 2 C14. . . . . . . . . 3233316 3 C14. . . . . . . . . 3233319 10 C14. . . . . . . . .

9 D1. . . 3233320 11 C14. . . . . . . . 3233321 12 C14. . . . . . . . 3233324 20 C14. . . . . . . . .

11 D1. . . 3233325 21 C14. . . . . . . . .

12 D1. . . 3233326 22 C14. . . . . . . . 3233327 23 C14. . . . . . . . 3233328 24 C14. . . . . . . . 3233329 27 C14. . . . . . . .

3233330 28 C14. . . . . . . . 3233331 29 C14. . . . . . . . 3233343 25 D5. . . . . . . . . 3233346 25 C14. . . . . . . . 3233347 26 C14. . . . . . . . 3233351 23 D2. . . . . . . . . 3233352 13 D2. . . . . . . . . 3233353 20 D2. . . . . . . . . 3233354 20 D2. . . . . . . . . 3233355 20 D2. . . . . . . . . 3233356 20 D2. . . . . . . . . 3233357 20 D2. . . . . . . . . 3233360 36 D4. . . . . . . . . 3233361 2 D4. . . . . . . . . . 3233362 29 D4. . . . . . . . . 3233364 40 D4. . . . . . . . . 3233365 42 D4. . . . . . . . . 3233368 5 D5. . . . . . . . . . 3233430 51 D4. . . . . . . . . 3233431 48 D4. . . . . . . . . 3233432 47 D4. . . . . . . . . 3233433 46 D4. . . . . . . . . 3233434 45 D4. . . . . . . . . 3233442 12 D2. . . . . . . . . 3233444 22 D2. . . . . . . . . 3233446 16 D2. . . . . . . . . 3233463 17 C14. . . . . . . . 3233475 8 D2. . . . . . . . . . 3233476 14 D2. . . . . . . . . 3233479 8 C14. . . . . . . . . 3233480 9 C14. . . . . . . . . 3233481 16 C14. . . . . . . . 3233485 35 D4. . . . . . . . . 3233489 7 C14. . . . . . . . . 3233495 14 D5. . . . . . . . . 3233498 6 D5. . . . . . . . . . 3233524 15 D1. . . . . . . . . 3233532 28 D4. . . . . . . . . 3233541 10 D1. . . . . . . . . 3233548 6 D4. . . . . . . . . . 3233554 19 D1. . . . . . . . . 3233583 22 D1. . . . . . . . . 3233589 6 D1. . . . . . . . . . 3233616 9 D2. . . . . . . . . . 3233617 10 D2. . . . . . . . . 3233635 11 D2. . . . . . . . . 3233636 3 D2. . . . . . . . . . 3233637 24 D5. . . . . . . . . 3233638 23 D5. . . . . . . . . 3233661 5 D4. . . . . . . . . . 3233662 12 D4. . . . . . . . . 3233663 13 D4. . . . . . . . . 3233664 14 D4. . . . . . . . . 3233665 32 D4. . . . . . . . . 3233666 30 D4. . . . . . . . . 3233667 24 D4. . . . . . . . . 3233668 22 D4. . . . . . . . . 3233669 44 D4. . . . . . . . . 3233670 50 D4. . . . . . . . . 3233671 6 D2. . . . . . . . . . 3233672 33 D2. . . . . . . . . 3233692 21 D1. . . . . . . . . 3233693 20 D1. . . . . . . . .

Page 67: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

SPORTSMAN 500 A99CH50(AA)(AB) and WORKER 500 A99CH50(EA)(EB)

E10

3233696 16 D1. . . . . . . . . 3233697 8 D1. . . . . . . . . . 3233698 7 D1. . . . . . . . . . 3233699 5 D1. . . . . . . . . . 3233700 4 D1. . . . . . . . . . 3233701 3 D1. . . . . . . . . . 3233702 23 D1. . . . . . . . . 3233710 17 D1. . . . . . . . . 3240088 14 D9. . . . . . . . . 3240114 10 E4. . . . . . . . . 3250010 11 B8. . . . . . . . . 3250028 10 B8. . . . . . . . . 3250030 14 B8. . . . . . . . . 3250032 12 B8. . . . . . . . . 3250039 11 C5. . . . . . . . . 3260115 3 B4. . . . . . . . . . 3260130 9 B4. . . . . . . . . . 3260131 4 B6. . . . . . . . . . 3260133 1 B6. . . . . . . . . . 3260136 3 B6. . . . . . . . . . 3280290 1 B14. . . . . . . . . 3280291 13 B14. . . . . . . . 3280312 1 B14. . . . . . . . . 3554506 6 B8. . . . . . . . . . 3554507 12 B7. . . . . . . . . .

7 B8. . . 3554509 11 B7. . . . . . . . . 3576510 8 C4. . . . . . . . . . 3576511 14 C5. . . . . . . . . 3585502 44 C10. . . . . . . . 3585710 12 C5. . . . . . . . . 3585712 7 C4. . . . . . . . . . 3610019 3 B8. . . . . . . . . . 3610028 23 B7. . . . . . . . . 4010093 23 C7. . . . . . . . . 4010094 15 C7. . . . . . . . . 4010095 17 C7. . . . . . . . . 4010132 46 A14. . . . . . . . 4010202 6 A12. . . . . . . . . 4020149 35 C7. . . . . . . . . 4030043 6 C7. . . . . . . . . . 4030059 14 A9. . . . . . . . . 4032029 5 C7. . . . . . . . . . 4032045 7 C7. . . . . . . . . . 4032046 4 C7. . . . . . . . . . 4032064 8 C7. . . . . . . . . . 4032075 26 B14. . . . . . . . 4032077 25 B14. . . . . . . . 4032078 27 B14. . . . . . . . 4032079 23 B14. . . . . . . . 4040053 2 B14. . . . . . . . . 4040054 2 B14. . . . . . . . . 4040081 40 B14. . . . . . . . 4060173 34 C7. . . . . . . . . 4110164 16 B11. . . . . . . . 4110209 37 B14. . . . . . . . 4110243 18 B14. . . . . . . . 4140006 21 C7. . . . . . . . . 4170013 22 A12. . . . . . . . 5010192 5 B1. . . . . . . . . . 5020422 6 C4. . . . . . . . . . 5020506 7 B9. . . . . . . . . .

5020572 16 A12. . . . . . . . 5020677 22 C3. . . . . . . . . .

10 C10. . 5020823 17 D5. . . . . . . . . 5020824 20 D5. . . . . . . . . 5020826 8 C10. . . . . . . . . 5020827 7 C10. . . . . . . . . 5020850 3 C2. . . . . . . . . . 5020926 7 C3. . . . . . . . . . 5020964 23 C3. . . . . . . . . .

33 C10. . 5130668 21 B7. . . . . . . . . 5131036 33 C7. . . . . . . . . 5131115 3 B9. . . . . . . . . . . 5131116 3 B9. . . . . . . . . . . 5131255 23 C1. . . . . . . . . 5131277 11 C2. . . . . . . . . 5131646 3 C4. . . . . . . . . . 5131649 3 C8. . . . . . . . . . 5131674 16 C5. . . . . . . . . 5131738 43 C10. . . . . . . . 5131785 15 C1. . . . . . . . . 5131883 38 C10. . . . . . . . 5132062 21 B7. . . . . . . . . 5210748 29 A14. . . . . . . . 5210752 17 C5. . . . . . . . . 5211033 15 A6. . . . . . . . . 5211115 3 B7. . . . . . . . . . . .

13 C5. . . 5211121 15 C3. . . . . . . . . . 5211148 4 B8. . . . . . . . . . . 5211523 2 C1. . . . . . . . . . 5211626-067 16 A14. . . . 5211633-067 27 A9. . . . . 5211914 5 C13. . . . . . . . . 5220602 18 B7. . . . . . . . . 5220646 6 C5. . . . . . . . . . 5222154-067 9 B2. . . . . . 5222155-067 9 B2. . . . . . 5222193 13 B7. . . . . . . . . 5222299 2 B4. . . . . . . . . . 5222999-067 15 B12. . . . 5224592 8 A6. . . . . . . . . . 5224658-067 26 A14. . . . 5224667-067 25 C10. . . . 5224871 12 C13. . . . . . . . 5224875 9 C13. . . . . . . . . 5240409-067 23 C6. . . . . 5240586-067 21 B14. . . . 5240591-067 20 A9. . . . . 5240898 16 B1. . . . . . . . . 5241150-067 37 A14. . . . 5241156-067 26 C6. . . . . 5241224-067 22 A9. . . . . 5241355-067 23 A12. . . . 5241398-067 18 A9. . . . . 5241399-067 18 A9. . . . . 5241416 31 C7. . . . . . . . . 5241453-067 45 A14. . . . 5241583-067 19 A9. . . . . 5241663-067 8 A8. . . . . . 5241678 14 B1. . . . . . . . .

5242044 27 B3. . . . . . . . . 5242077-067 21 C10. . . . 5242550 26 A12. . . . . . . . 5242749 11 C13. . . . . . . . 5242935 2 B8. . . . . . . . . . 5242953-067 25 A6. . . . . 5242987-067 7 B14. . . . . 5243364 18 B7. . . . . . . . . 5332457 10 B2. . . . . . . . . 5333204 18 C1. . . . . . . . . 5333332-067 14 A8. . . . . 5333367 2 C3. . . . . . . . . . 5333393-067 13 C10. . . . 5410163 28 B14. . . . . . . . 5410193 1 B10. . . . . . . . . 5410241 7 B1. . . . . . . . . . 5410414 19 A6. . . . . . . . . 5410421 31 A14. . . . . . . . 5410424 19 C7. . . . . . . . . 5410436 3 B1. . . . . . . . . . 5410470 20 B8. . . . . . . . . 5410489 3 C6. . . . . . . . . . 5410494 12 B9. . . . . . . . . 5410495 11 B9. . . . . . . . . 5410548 17 C3. . . . . . . . . 5410575 24 C6. . . . . . . . . 5410584 13 A12. . . . . . . . 5410607 11 A12. . . . . . . . 5410770 35 A6. . . . . . . . . 5410772 7 B12. . . . . . . . . 5410779 5 B9. . . . . . . . . . 5410780 6 B9. . . . . . . . . . 5410828 17 C1. . . . . . . . . 5410889 7 C1. . . . . . . . . . 5410896 23 A6. . . . . . . . . 5410947 16 B8. . . . . . . . . 5410948 7 C8. . . . . . . . . . 5410988 15 B11. . . . . . . . 5410995 8 A14. . . . . . . . . 5411042 5 A6. . . . . . . . . . .

16 C1. . . 5411072 4 A12. . . . . . . . . 5411092 5 B6. . . . . . . . . . 5411106 5 B4. . . . . . . . . . . 5411120 24 B14. . . . . . . . . 5411164 12 C8. . . . . . . . . . 5411291 4 C3. . . . . . . . . . 5411297 14 B11. . . . . . . . 5411349 5 C1. . . . . . . . . . 5411410 3 A12. . . . . . . . . 5411422 10 B3. . . . . . . . . 5411439 3 B10. . . . . . . . . 5411468 1 B7. . . . . . . . . . 5411477 17 B3. . . . . . . . . 5411489 18 C6. . . . . . . . . 5411608 1 B7. . . . . . . . . . 5411668 20 B3. . . . . . . . . 5430261 30 A14. . . . . . . . 5430725 1 B2. . . . . . . . . . 5430743 27 A12. . . . . . . . 5430806 24 B7. . . . . . . . . 5430807 19 B7. . . . . . . . . 5430945 13 C4. . . . . . . . .

Page 68: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

SPORTSMAN 500 A99CH50(AA)(AB) and WORKER 500 A99CH50(EA)(EB)

E11

5430967 2 B14. . . . . . . . . 5431030 20 B14. . . . . . . . 5431053 5 B2. . . . . . . . . . 5431107 2 C2. . . . . . . . . . .

15 C12. . 5431570 11 B12. . . . . . . . 5431571 8 B12. . . . . . . . . 5431572 14 B12. . . . . . . . 5431573 2 B12. . . . . . . . . 5431574 5 B12. . . . . . . . . 5431596 21 C3. . . . . . . . . .

32 C10. . 5431673 30 A12. . . . . . . . 5431760 12 A12. . . . . . . . 5431769 22 C7. . . . . . . . . 5431786 13 A6. . . . . . . . . 5431787 22 A6. . . . . . . . . 5431796 47 A6. . . . . . . . . 5431797 47 A6. . . . . . . . . 5431798 11 A7. . . . . . . . . 5431799 11 A7. . . . . . . . . 5431809-136 3 A7. . . . . . 5431809-191 3 A7. . . . . . 5431814 25 A9. . . . . . . . . 5431815 25 A9. . . . . . . . . 5431837 19 C3. . . . . . . . . 5431838 19 C3. . . . . . . . . 5431895 29 A12. . . . . . . . 5431936 5 C4. . . . . . . . . . 5431964 38 B14. . . . . . . . 5432077 20 C7. . . . . . . . . 5432086 9 B3. . . . . . . . . . 5432088-136 5 A7. . . . . . 5432088-191 5 A7. . . . . . 5432091 9 C10. . . . . . . . . 5432092 36 C10. . . . . . . . 5432117-136 6 A6. . . . . . 5432117-191 6 A6. . . . . . 5432155-070 8 A9. . . . . . 5432169 15 C10. . . . . . . . 5432221-070 38 A6. . . . . 5432280 32 A6. . . . . . . . . 5432289 6 C1. . . . . . . . . . 5432314-070 36 B14. . . . 5432377 21 B3. . . . . . . . . 5432559 18 B2. . . . . . . . . 5432593 15 A12. . . . . . . . 5432598 6 C10. . . . . . . . . 5432601 4 B3. . . . . . . . . . 5432611 21 B8. . . . . . . . . 5432721 2 B10. . . . . . . . . 5432733 19 B2. . . . . . . . . 5432774 12 B3. . . . . . . . . 5432849 11 C6. . . . . . . . . 5432858 18 B3. . . . . . . . . 5432868 5 B3. . . . . . . . . . 5432926 19 B14. . . . . . . . 5432947 21 C6. . . . . . . . . 5432952 16 B14. . . . . . . . 5433042-136 15 B14. . . . 5433042-191 15 B14. . . . 5433098 41 C10. . . . . . . .

5433099 41 C10. . . . . . . . 5433219-070 38 A6. . . . . 5433293 7 B3. . . . . . . . . . 5521301 10 C6. . . . . . . . . 5630513 15 C4. . . . . . . . . 5630551 29 C10. . . . . . . . 5630616-067 8 B14. . . . . 5630885 27 C10. . . . . . . . 5810144 2 B2. . . . . . . . . . 5810279 28 A12. . . . . . . . 5810290 13 C7. . . . . . . . . 5810291 25 B7. . . . . . . . . 5810317 12 B2. . . . . . . . . 5810439 9 B7. . . . . . . . . . 5810455 25 C7. . . . . . . . . 5810467 17 A9. . . . . . . . . 5810996 2 A7. . . . . . . . . . 5811087 43 A6. . . . . . . . . 5811104 18 A6. . . . . . . . . . 5811105 18 A6. . . . . . . . . . 5811106 40 A6. . . . . . . . . . 5811107 4 A6. . . . . . . . . . . 5811111 39 A6. . . . . . . . . . 5811137 1 B3. . . . . . . . . . . 5811308 9 A6. . . . . . . . . . 5811310 3 B2. . . . . . . . . . 5811482 11 B3. . . . . . . . . 5811489 20 A7. . . . . . . . . 5811490 3 A14. . . . . . . . . 5811491 1 A7. . . . . . . . . . 5811626 8 B3. . . . . . . . . . 5811650 24 B3. . . . . . . . . 5830053 3 C1. . . . . . . . . . 5830128 19 B3. . . . . . . . . 5850135 21 C1. . . . . . . . . 5910026 8 B9. . . . . . . . . . 7010032 18 C7. . . . . . . . . 7041157 11 C4. . . . . . . . . 7041370 17 A6. . . . . . . . . 7041375-067 17 B7. . . . . 7041453-067 28 C10. . . . 7041519-067 28 C10. . . . 7041636 15 C5. . . . . . . . . 7041750 13 C12. . . . . . . . 7041755 2 B7. . . . . . . . . . 7041761 2 B7. . . . . . . . . . 7041770 30 C10. . . . . . . . 7042031 11 B1. . . . . . . . . 7051524 20 C1. . . . . . . . . 7052045 15 B8. . . . . . . . . 7052065 32 A12. . . . . . . . 7052075 11 A14. . . . . . . . 7052109 9 C1. . . . . . . . . . 7052129 26 B11. . . . . . . . 7052133 11 C1. . . . . . . . . 7052149 16 B2. . . . . . . . . 7052150 13 B2. . . . . . . . . 7052161 20 B2. . . . . . . . . 7052163 4 C1. . . . . . . . . . 7052181 14 A12. . . . . . . . 7061013 18 D5. . . . . . . . . 7061014 15 D5. . . . . . . . .

7061033 9 C3. . . . . . . . . . 7061034 5 C3. . . . . . . . . . 7072606 14 C7. . . . . . . . . 7073761 41 A6. . . . . . . . . 7074110 2 A10. . . . . . . . .

2 A11. . 7074935 10 A10. . . . . . . .

10 A11. . 7074946 14 C6. . . . . . . . . 7074954 1 A10. . . . . . . . .

1 A11. . 7075741 15 A10. . . . . . . . .

14 A11. . 7075834 22 A10. . . . . . . . .

23 A11. . 7076202 17 A10. . . . . . . . .

19 A11. . 7076273 18 A10. . . . . . . . .

20 A11. . 7076483 15 A11. . . . . . . . 7076501 8 A10. . . . . . . . .

8 A11. . 7076502 6 A10. . . . . . . . .

6 A11. . 7077377 15 C6. . . . . . . . . 7077446 42 A6. . . . . . . . . 7077660 3 A10. . . . . . . . .

3 A11. . 7077663 12 A10. . . . . . . . .

17 A11. . 7077665 5 A10. . . . . . . . .

5 A11. . 7077666 16 C6. . . . . . . . . 7077749 16 A10. . . . . . . .

16 A11. . 7077765 11 A10. . . . . . . . .

18 A11. . 7077919 24 A10. . . . . . . . .

25 A11. . 7077920 21 A10. . . . . . . . .

22 A11. . 7078003 9 A10. . . . . . . . .

9 A11. . 7078023 19 A10. . . . . . . . 7078024 7 A10. . . . . . . . . 7078025 23 A10. . . . . . . . .

24 A11. . 7078026 4 A10. . . . . . . . .

4 A11. . 7078027 21 A11. . . . . . . . 7078028 11 A11. . . . . . . . 7078045 13 A10. . . . . . . . .

12 A11. . 7078055 6 A10. . . . . . . . .

6 A11. . 7078253 20 A10. . . . . . . . .

7 A11. . 7078261 36 A6. . . . . . . . . 7078354 14 A10. . . . . . . . .

13 A11. . 7080003 2 A14. . . . . . . . . .

15 B2. . . 11 C12. .

Page 69: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

SPORTSMAN 500 A99CH50(AA)(AB) and WORKER 500 A99CH50(EA)(EB)

E12

7080138 22 B11. . . . . . . . . 27 C7. . .

7080229 39 B14. . . . . . . . 7080306 14 B7. . . . . . . . . 7080307 13 C14. . . . . . . . 7080352 1 B9. . . . . . . . . . 7080409 13 D1. . . . . . . . . 7080413 7 A14. . . . . . . . . .

3 B3. . . 7080424 3 B12. . . . . . . . . 7080433 13 B12. . . . . . . . .

25 C3. . . 11 C10. .

7080474 35 A14. . . . . . . . 7080492 5 A12. . . . . . . . . .

28 C7. . . 7080511 9 A14. . . . . . . . . .

28 C6. . . 7080539 24 A14. . . . . . . . .

19 B11. . 7080544 15 B3. . . . . . . . . 7080573 5 B7. . . . . . . . . . 7080586 45 C10. . . . . . . . 7080595 2 B3. . . . . . . . . . 7080614 1 A12. . . . . . . . . 7080627 11 B4. . . . . . . . . 7080631 34 B14. . . . . . . . 7080644 13 C13. . . . . . . . 7080650 23 B3. . . . . . . . . 7080653 29 A6. . . . . . . . . 7080673 14 C3. . . . . . . . . 7080693 15 A7. . . . . . . . . 7080694 20 A14. . . . . . . . 7080696 2 A12. . . . . . . . . 7080699 13 B3. . . . . . . . . 7080709 4 B10. . . . . . . . . 7080726 29 B14. . . . . . . . 7080761 19 C6. . . . . . . . . 7511848 1 C1. . . . . . . . . . 7511881 3 B14. . . . . . . . . 7511930 2 A6. . . . . . . . . . 7512007 24 C7. . . . . . . . . 7512017 17 A7. . . . . . . . . 7512018 32 C7. . . . . . . . . 7512024 30 A6. . . . . . . . . .

23 B11. . 2 D5. . .

7512027 22 B8. . . . . . . . . . 12 C7. . .

7512084 33 A12. . . . . . . . . 20 C3. . . 42 C10. .

7512085 12 A6. . . . . . . . . . 14 A7. . .

7512093 13 C6. . . . . . . . . 7512094 17 C6. . . . . . . . . 7512095 25 C6. . . . . . . . . 7512097 24 A9. . . . . . . . . 7512111 7 C12. . . . . . . . . . 7512113 10 A12. . . . . . . . 7512126 1 C13. . . . . . . . .

7512130 20 A6. . . . . . . . . . 19 C1. . .

7512144 9 C2. . . . . . . . . . 7512176 10 C4. . . . . . . . . 7512232 44 A6. . . . . . . . . .

4 A7. . . 13 A9. . . 24 A12. . 20 C6. . .

7512240 2 C6. . . . . . . . . . 7512242 10 A6. . . . . . . . . 7512247 7 C6. . . . . . . . . . .

19 C12. . 7512249 8 C2. . . . . . . . . . 7512266 14 C4. . . . . . . . . 7512277 8 C6. . . . . . . . . . 7512278 9 C6. . . . . . . . . . 7512284 16 C3. . . . . . . . . 7512315 17 A14. . . . . . . . 7512325 1 B8. . . . . . . . . . 7512329 9 A8. . . . . . . . . . .

1 C10. . 7512365 7 B7. . . . . . . . . . 7512492 28 A6. . . . . . . . . .

26 C3. . . 17 C10. .

7512566 27 A14. . . . . . . . 7512666 10 B1. . . . . . . . . 7515158 22 C1. . . . . . . . . 7515179 26 B3. . . . . . . . . 7515181 41 B14. . . . . . . . .

7 C2. . . 7515189 12 B14. . . . . . . . 7515193 2 A8. . . . . . . . . . 7515194 45 A6. . . . . . . . . .

3 A8. . . 1 A9. . .

7515197 12 B1. . . . . . . . . 7515316 8 B1. . . . . . . . . . 7515321 4 B12. . . . . . . . . .

24 C10. . 7515339 20 B7. . . . . . . . . 7515382 8 C5. . . . . . . . . . 7515384 15 A9. . . . . . . . . 7515385 15 A8. . . . . . . . . 7515390 10 A9. . . . . . . . . 7515391 9 A9. . . . . . . . . . 7515399 4 A9. . . . . . . . . . 7515415 29 C3. . . . . . . . . .

31 C10. . 7515417 36 A14. . . . . . . . 7515433 22 C10. . . . . . . . 7515472 12 C10. . . . . . . . 7515489 2 B9. . . . . . . . . . 7515497 1 C12. . . . . . . . . 7515513 6 C8. . . . . . . . . . 7515523 8 B8. . . . . . . . . . 7515547 26 A9. . . . . . . . . 7517102 10 C1. . . . . . . . . 7517208 6 A8. . . . . . . . . . 7517231 4 C10. . . . . . . . . 7517297 40 C10. . . . . . . .

7517312 22 A7. . . . . . . . . 7517317 22 B14. . . . . . . . 7517323 10 C5. . . . . . . . . 7517376 37 A6. . . . . . . . . 7517377 33 A6. . . . . . . . . 7517451 6 B2. . . . . . . . . . 7517475 25 A12. . . . . . . . 7517505 17 B2. . . . . . . . . 7517527 28 C3. . . . . . . . . 7517541 6 B3. . . . . . . . . . 7517625 17 B14. . . . . . . . 7522021 35 B14. . . . . . . . 7541906 4 C4. . . . . . . . . . 7541925 7 A6. . . . . . . . . . .

12 A7. . . 10 C7. . .

7541933 9 B14. . . . . . . . . 7542103 7 C13. . . . . . . . . 7542105 14 A14. . . . . . . . 7542122 31 A6. . . . . . . . . .

19 A7. . . 19 A12. . 30 B14. . 13 C1. . .

4 C2. . . 12 C12. .

7542143 11 B2. . . . . . . . . 7542153 9 C12. . . . . . . . . 7542303 6 B7. . . . . . . . . . .

3 C10. . 7542321 23 C10. . . . . . . . 7542324 6 A9. . . . . . . . . . .

1 B1. . . 16 B12. .

7542343 11 A8. . . . . . . . . 7542403 19 A14. . . . . . . . .

1 C3. . . 20 C10. .

7542438 18 C3. . . . . . . . . 7542439 35 C10. . . . . . . . 7542459 23 B8. . . . . . . . . .

2 C8. . . 7542507 27 B7. . . . . . . . . 7542711 6 C3. . . . . . . . . . 7542810 18 B8. . . . . . . . . 7543005 11 C8. . . . . . . . . 7543203 9 B12. . . . . . . . . 7546601 1 A14. . . . . . . . . 7546701 21 D5. . . . . . . . . 7546702 16 D5. . . . . . . . . 7546707 19 D5. . . . . . . . . 7546904 11 C3. . . . . . . . . 7547004 20 A12. . . . . . . . 7547028 8 C3. . . . . . . . . . 7547046 22 C12. . . . . . . . 7547104 27 B7. . . . . . . . . 7552603 27 A6. . . . . . . . . .

27 C3. . . 18 C10. .

2 C12. . 7552605 9 A12. . . . . . . . . .

13 A14. . 6 C6. . .

Page 70: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

SPORTSMAN 500 A99CH50(AA)(AB) and WORKER 500 A99CH50(EA)(EB)

E13

7552801 7 B2. . . . . . . . . . . 9 C4. . .

7552901 18 A14. . . . . . . . . 8 B7. . . 7 C5. . .

26 C10. . 38 D4. . .

7555716 2 B1. . . . . . . . . . 7555748 21 A6. . . . . . . . . .

5 C6. . . 7555749 26 B7. . . . . . . . . 7555761 5 C10. . . . . . . . . 7555792 3 A6. . . . . . . . . . .

13 A7. . . 7555796 10 C8. . . . . . . . . 7555801 39 A14. . . . . . . . 7555806 10 C3. . . . . . . . . .

3 C12. . 7555815 22 A14. . . . . . . . 7555827 4 C13. . . . . . . . . 7555859 11 A6. . . . . . . . . 7555863 4 B1. . . . . . . . . . 7555868 10 B14. . . . . . . . 7555878 6 B12. . . . . . . . . 7555896 8 C1. . . . . . . . . . 7555919 14 C12. . . . . . . . 7555931 18 A7. . . . . . . . . .

6 C13. . 7555935 13 B1. . . . . . . . . .

27 C6. . . 7555936 39 C10. . . . . . . . 7555939 14 C10. . . . . . . . 7555954 11 A9. . . . . . . . . 7556004 17 B8. . . . . . . . . 7556008 17 C4. . . . . . . . . 7556009 2 C4. . . . . . . . . . 7556010 4 C5. . . . . . . . . .

7556013 3 C5. . . . . . . . . . 7556063 8 C13. . . . . . . . . 7556401 1 C5. . . . . . . . . . 7558201 21 A12. . . . . . . . 7558203 42 B14. . . . . . . . 7558212 11 B14. . . . . . . . 7558301 18 A12. . . . . . . . .

8 B2. . . 25 B3. . . 14 C1. . .

6 C2. . . 7558402 13 A8. . . . . . . . . .

16 A9. . . 4 B7. . .

16 C10. . 7558403 7 A9. . . . . . . . . . 7558707 10 C13. . . . . . . . 7571602 11 C7. . . . . . . . . 7571620 21 C12. . . . . . . . 7575202 28 A14. . . . . . . . 7621330 21 A9. . . . . . . . . 7621334 33 B14. . . . . . . . 7621403 14 A6. . . . . . . . . 7621462 25 A14. . . . . . . . .

18 B11. . 7661011 15 C13. . . . . . . . 7661013 1 C2. . . . . . . . . . 7661103 12 C2. . . . . . . . . 7661203 12 C3. . . . . . . . . .

16 C13. . 7661205 3 C13. . . . . . . . . 7661401 19 B8. . . . . . . . . .

17 C12. . 7661404 1 C8. . . . . . . . . . 7661632 12 B12. . . . . . . . 7661633 10 B12. . . . . . . .

7661638 24 A6. . . . . . . . . 7661645 1 A6. . . . . . . . . . .

10 A7. . . 7661843 14 C13. . . . . . . . 7661913 10 B4. . . . . . . . . 7670009 9 A7. . . . . . . . . . 7670051 12 C6. . . . . . . . . 7670054 9 C7. . . . . . . . . . 7670057 46 A6. . . . . . . . . .

8 A7. . . 7670085 6 A7. . . . . . . . . . 7670086 4 B14. . . . . . . . . 7670088 21 A7. . . . . . . . . 7670089 31 B14. . . . . . . . 7670091 4 B4. . . . . . . . . . 7670094 23 A9. . . . . . . . . 7670096 10 A8. . . . . . . . . 7670109 36 C7. . . . . . . . . 7710440 5 C8. . . . . . . . . . 7710448 18 C5. . . . . . . . . 7710461 5 C5. . . . . . . . . . 8360009-600 4 B2. . . . . . .

14 C14. . 8360031-30 20 B11. . . . . 8360031-38 24 B11. . . . . 8450003-1525 31 A12. . . .

10 A14. . 14 D1. . .

8450040-600 4 A14. . . . . . 14 B2. . .

8450059-150 22 B3. . . . . 8450073-600 16 A7. . . . . .

14 B3. . . 8450083-46 5 A14. . . . . . 9914905 8 E6. . . . . . . . . . 9914910 8 E6. . . . . . . . . .

Page 71: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

In order to better serve you, this postage-paid mailer isprovided for your convenience to report an error orrelay a suggestion relative to any Polaris Publication.

POLARIS PUBLICATIONS REPORT

Publication No.

Machine

Publ. Date Page

Report of ErrorSuggestion

Name

Company

Address

City, State, Zip

Phone No. Date Thank you for your help!

9912263

4/94 Rev. 04

– Mailing Instructions –Please fold the top portion down first then fold the bottom portion up second so the

open edge is located at the top. Tape the open edge.

or FAX your report to:218-463-4580

( )

Page 72: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

FIRST CLASS PERMIT NO. 22 ROSEAU, MINNESOTA

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BE ADDRESSEE

POLARIS SALES INC.301 5TH AVE. S.W.ROSEAU, MN 56751

ATTN: TECHNICAL PUBLICATIONS

NO POSTAGENECESSARY IF

MAILEDIN THE UNITED

STATES

Page 73: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

In order to better serve you, this postage-paid mailer isprovided for your convenience to report an error orrelay a suggestion relative to any Polaris Publication.

POLARIS PUBLICATIONS REPORT

Publication No.

Machine

Publ. Date Page

Report of ErrorSuggestion

Name

Company

Address

City, State, Zip

Phone No. Date Thank you for your help!

9912263

4/94 Rev. 04

– Mailing Instructions –Please fold the top portion down first then fold the bottom portion up second so the

open edge is located at the top. Tape the open edge.

or FAX your report to:218-463-4580

( )

Page 74: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

FIRST CLASS PERMIT NO. 22 ROSEAU, MINNESOTA

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BE ADDRESSEE

POLARIS SALES INC.301 5TH AVE. S.W.ROSEAU, MN 56751

ATTN: TECHNICAL PUBLICATIONS

NO POSTAGENECESSARY IF

MAILEDIN THE UNITED

STATES

Page 75: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

In order to better serve you, this postage-paid mailer isprovided for your convenience to report an error orrelay a suggestion relative to any Polaris Publication.

POLARIS PUBLICATIONS REPORT

Publication No.

Machine

Publ. Date Page

Report of ErrorSuggestion

Name

Company

Address

City, State, Zip

Phone No. Date Thank you for your help!

9912263

4/94 Rev. 04

– Mailing Instructions –Please fold the top portion down first then fold the bottom portion up second so the

open edge is located at the top. Tape the open edge.

or FAX your report to:218-463-4580

( )

Page 76: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

FIRST CLASS PERMIT NO. 22 ROSEAU, MINNESOTA

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BE ADDRESSEE

POLARIS SALES INC.301 5TH AVE. S.W.ROSEAU, MN 56751

ATTN: TECHNICAL PUBLICATIONS

NO POSTAGENECESSARY IF

MAILEDIN THE UNITED

STATES

Page 77: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

�� ���� �� �� ���� ���� ��� ��

Page 78: SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 ...pi54.com/corp/manuals/Parts/9914911r01.pdf · parts manual pn 9914911 and microfiche pn 9915651 1/99 sportsman 500 model

PRINTED IN THE USA PARTS MANUAL PN 9914911 and MICROFICHE PN 99145651 1/99