sportsman 500 - the quad connection 2004/2004... · e 2003 polaris sales inc. parts manual pn...

E 2003 Polaris Sales Inc.

PARTS MANUAL PN 9918728 and MICROFICHE PN 9918729 8/03

SPORTSMAN 500Model #A04CH50AOModel #A04CH50AQModel #A04CH50ARModel #A04CH50ASModel #A04CH50ATModel #A04CH50AVModel #A04CH50AW

Rev. 01

TABLE OF CONTENTSSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500

A04CH50AS and SPORTSMAN 500 A04CH50AT and SPORTSMAN 500 A04CH50AV and SPORTSMAN 500 A04CH50AW

Parts Manual

AA--ARM C3. . . . . . . . . . . . . . . . . . . . . . . . . . . .AIR BOX B2. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBUMPER MOUNTING A7-8. . . . . . . . . . . . . . . . .

CCALIPER, REAR B9. . . . . . . . . . . . . . . . . . . . .CARBURETOR D5-6. . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C8. . . . . . . . . . . . . . . . . . . . .CONTROLS -- MASTER

CYLINDER/BRAKE LINE B5. . . . . . . . . . . .CONTROLS -- THROTTLE ASM./CABLE B6. . . .COOLING SYSTEM A12. . . . . . . . . . . . . . . . . . .CRANKCASE D2. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D7. . . . . . . . . . . . .CYLINDER D3-4. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A10-11. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C6. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT B10. . . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C7. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL / TAILLIGHT C11. . . . . . . . . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM B1. . . . . . . . . . . . . . . . . . .

FFOOT PEDAL B8. . . . . . . . . . . . . . . . . . . . . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING D1. . . . . . . . . . . . . . . . . . . .FUEL PUMP E1. . . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B3. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C5. . . . . . . . . . . . . . . . . . . .GEARCASE C13-14. . . . . . . . . . . . . . . . . . . . . . . . .

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

IINTAKE and EXHAUST D8. . . . . . . . . . . . . . . . .

MMAGNETO D13. . . . . . . . . . . . . . . . . . . . . . . . . .MASTER CYLINDER, REAR B8. . . . . . . . . . . .

OOIL FILTER D12. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D11. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK B4. . . . . . . . . . . . . . . . . . . . . . . . . . .

PPROP SHAFT B12. . . . . . . . . . . . . . . . . . . . . . .

RRACK MOUNTING, FRONT A7-8. . . . . . . . . . . . .REAR CAB and SEAT A3-4. . . . . . . . . . . . . . . . .REAR DRIVE SHAFT B11. . . . . . . . . . . . . . . . . .REAR RACK MOUNTING A6. . . . . . . . . . . . . . .REAR SUSPENSION C9-10. . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE C12. . . . . . . . . . . . . . . . . .RECOIL STARTER D9. . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR D14. . . . . . . . . . . . . . . . . . .STEERING POST C4. . . . . . . . . . . . . . . . . . . . .STRUT MOUNTING C3. . . . . . . . . . . . . . . . . . .STRUT, FRONT B13. . . . . . . . . . . . . . . . . . . . . .

TTOOL KIT E2. . . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D10. . . . . . . . . . . . . . . . . . . . . . .WHEEL, FRONT B14. . . . . . . . . . . . . . . . . . . . . .WINCH ASM. A9. . . . . . . . . . . . . . . . . . . . . . . .

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

A3

REAR CAB and SEATSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and

SPORTSMAN 500 A04CH50AT and SPORTSMAN 500 A04CH50AV and SPORTSMAN 500 A04CH50AW

1

6

2

5

89

14

13

15

16

17

32

12

19

28

34

35

36

33

30

11

3

31

18

2

20 26

24

25

20

7

2322

21

2729

5

20

2223


4

10

A4

REAR CAB and SEATSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


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

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

1 7511930 2 Bolt2 7555792 4 Washer3 5811107 1 Foil, Rear Cab, Rear4 5432117-400

5435164-4555435164-4565432117-0535432117-3415432117-288

111111

Cab, Rear, Camo Green Metallic (AQ)Cab, Rear, Break-Up (AT)(AO)Cab, Rear, Shadowgrass (AV)Cab, Rear, Med Yellow (AR)Cab, Rear, Sonic Blue Met (AS)Cab, Rear, Blazing Red (AW)

5 7541925 4 Nut, Nylok6 5224592 1 Retainer, Seat Latch7 5811308 1 Foil, Tape, Rear Cab8 7512242 4 Screw9 7555859 4 Washer, Flat10 7556034 4 Washer11 7512085 2 Screw12 5431786 1 Box, Tool13 7621403 2 Rivet14 5211033 2 Bracket, Lever Retainer15 1040387 1 Latch, Seat (If built before 7/14/03)16 7041370 1 Spring, Latch17 2683222-070

2683437-0702683418-0702682958-070

1111

Asm., Seat, Black (If built before 7/14/03)Asm., Seat, Black (If built after 7/14/03)Asm., Seat, Black w/Gold Polaris (AT)(AV)Covering, Seat, Black

18 5412067 8 Bumper, Rubber (If built before 7/14/03)19 5431787 1 Cover, Tool Box20 7542122 8 Nut, Nylok21 ------ -- -- -- -- 1 Front Housing

(See Front Housing Pg. D1 for Details)22 7552603 7 Washer, Spring Lock23 7512492 7 Screw24 5432280 2 Spacer, Footwell25 7517377 4 Screw26 1014189-067 1 Frame, Main, Black27 7170911 1 Decal, Hitch28 7517376 8 Screw29 5432221-070

5433219-07011

Footwell, Black, LHFootwell, Black, RH

30 5811111 1 Foil, Foam, Rear Fender31 5811106 2 Foil, Rear Cab, Front32 7079902 1 Decal, Carb/Filter Information33 5811087 1 Foil, Foam34 7512232 22 Screw35 7670057 22 Nut, U-Type Speed36 5434704-070

5434705-07011

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

8/03

A5

FRONT CABSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


6

7

5

9

12

17

32

15

2221

23

9

1

4

4

13

4

18

14

20

16E 2003 Polaris Sales Inc.

10

19

8

11

11

11

11



1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5812329

581232611

Foil, Side Panel, RH (AQ)(AR)(AS)(AW)Foil, Side Panel, RH (AT)(AV)(AO)

3 2635322-4002632471-4005435335-4552632819-4555435335-4562632819-4562635322-0532632471-0532635322-3412632471-3412635322-2882632471-288

111111111111

Panel, Side, Camo Green Met, LH (AQ)Panel/Foil, Camo Green Met, RH (AQ)Panel, Side, Break-Up, LH (AT)(AO)Panel/Foil, Break-Up, RH (AT)(AO)Panel, Side, Shadowgrass, LH (AV)Panel/Foil, Shadowgrass, RH (AV)Panel, Side, Med Yellow, LH (AR)Panel/Foil, Med Yellow, RH (AR)Panel, Side, Sonic Blue Met, LH (AS)Panel/Foil, Sonic Blue Met, RH (AS)Panel, Side, Red, LH (AW)Panel/Foil, Red, RH (AW)

4 7517312 2 Screw5 2632748-400

2632818-4552632818-4562632748-0532632748-3412632748-288

111111

Cab, Front, Camo Green Met (AQ)Cab, Front, Break-Up (AT)(AO)Cab, Front, Shadowgrass (AV)Cab, Front, Med Yellow (AR)Cab, Front, Sonic Blue Met (AS)Cab, Front, Red (AW)

6 5432088-4005435166-4555435166-4565435110-0535435110-3415435110-288

111111

Cover, Front, Camo Green Met (AQ)Cover, Front, Break-Up (AT)(AO)Cover, Front, Shadowgrass (AV)Cover, Front, Med Yellow (AR)Cover, Front, Sonic Blue Met (AS)Cover, Front, Blazing Red (AW)

7 7670085 2 Clip, Spring8 7512240 2 Bolt9 7670057 10 Nut, U-Type Speed10 5246872 1 Guard, Splash, LH/Pump Mount11 7546601 5 Nut, Nylok12 7670135 4 Nut, Speed13 7512232 10 Screw14 7670156 2 Clip, Retainer15 7556034 2 Washer16 7555859 2 Washer, Flat17 5434702-070

5434703-07011

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

18 5246021-067 1 Guard, Splash, RH19 7517386 1 Screw20 7515158 2 Screw21 7541925 2 Nut, Nylok22 7555792 2 Washer23 7512085 2 Screw

8/03

A6

REAR RACK MOUNTINGSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


1

23

5

8

9710

11

12

6

2

7

4


4



1 1040510-418 1 Extender, Rack, Rear (AT)(AV)(AO)2 7517983 2 Screw3 7517685 2 Screw4 7555916 2 Washer, Nylon5 2632669-070

2632837-070

1

1

Asm., Rack, Rear (Incl. Warning Decal)(If built before 2/03/03)Asm., Rack, Rear (Incl. Warning Decal)(If built after 2/03/03)

6 5334092 2 Spacer7 7558402 8 Washer, Flat8 7512329 4 Bolt9 ---- -- -- -- -- -- 1 Bracket, Silencer, Frame

(See Exhaust System Pg. B1, Ref. 6)10 7542324 4 Nut, Nylok11 1013724-067 1 Support, Rear Rack12 7517208 6 Screw (AT)(AV)(AO)

8/03

A7

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


27

6

21

7

26

9

10

14

5

20

4

24

13

17

16

23

15

11

14

23

238

7

18

21

7

7

8

27

12

25

22

19

8


3

1

2

7

A8

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and




1 1013972-4181013972-067

11

Extention, Front Rack (AT)(AV)Extention, Front Rack (AO)

2 7081085 2 Plug, Barbed (AT)(AV)(AO)3 7517208 4 Screw4 7517685 4 Screw5 5434697-070

5435240-070

1

1

Rack, Front, Black(If built before 2/03/03)Rack, Front, Black (If built after 2/03/03)

6 24310174030059

22

HeadlightBulb, Replacement, 27W

7 7558402 10 Washer, Flat8 7542324 8 Nut, Nylok (Qty. 12 for AT, AV, AO)9 2632758-070 1 Asm., Bumper, Front, Black

(Incl. Warning Decal)10 7515306 4 Screw11 5434699-070 1 Panel12 7512094 2 Screw13 1013366-067 1 Guard, Brush

14 54343145434315

11

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

15 5412504 4 Grommet16 5435046 1 Cover, Radiator17 5247507-067 1 Grill, Brush Guard18 7522021 4 Screw19 7670094 6 Nut, U-Type20 7512097 6 Screw21 7512329 2 Screw22 7171474

717147511

Decal, Reflector, Amber, LHDecal, Reflector, Amber, RH

23 7515399 4 Screw24 1014020-067 1 Support, Front Rack25 5810467 1 Plug, Frame26 1014261-067

1014262-06711

Support, Front Rack, LHSupport, Front Rack, RH

27 7512232 6 Screw

8/03

A9

WINCH ASM.SPORTSMAN 500 A04CH50AT and SPORTSMAN 500 A04CH50AV

E 2003 Polaris Sales Inc. 7

27 20

25

20

20

20

26

17

21

2413

17

7

7

77

7

22

12

18

23

11

14

15

16

1

3

2

4

19

9

5

10

8

6

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 2410423 1 Asm., Winch Switch2 7518304 2 Screw3 5247139 1 Plate, Switch Mount4 5133010 2 Spacer, Master Cylinder Clamp5 7512247 2 Bolt6 2202254 1 Contactor7 7558402 10 Washer, Flat8 7512329 1 Bolt9 5247570 1 Bracket, Contactor10 7542122 2 Nut, Nylok11 2202253 1 Asm., Hook, Warn Winch12 2202643 1 Asm., Winch, Warn w/Cable13 5247568 1 Plate, Fairlead Mount14 2871462 1 Roller, Fairlead, Warn Winch

15 7515494 2 Screw16 7542451 2 Nut, Nylok17 7512392 4 Screw18 2461220 1 Harness, Front19 2461218 1 Harness, Main20 7542324 10 Nut, Nylok21 5434698-070 1 Bumper, Front22 2431017 2 Asm., Headlight, Bottom Mount23 1014020-067 1 Support, Rack, Front24 5247569 1 Plate Mount25 7515321 4 Bolt26 7515317 4 Screw27 7552901 4 Washer, Spring Lock

5/03

A10

DECALSSPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and SPORTSMAN 500 A04CH50AW

RH

LH

14

2

11

4365

20

8

18

7

10

1

16

19

17

1

915

1312



1 7170021 2 Decal, Warning, Front and Rear Rack2 7170999

717195311

Decal, “4x4”, Side Panel, Lower, LHDecal, “4x4”, Side Panel, Lower, RH

3 71709977170998

11

Decal, Side Panel, Middle, LHDecal, Side Panel, Middle, RH

4 7078253 2 Decal, Age Warning5 7079780 1 Decal, Warning, Switch, AWD6 7078003 1 Decal, Headlight Adjustment7 7078465 1 Logo, Polaris Star8 7078577 1 Decal, Drain Recoil9 7079773

707991611

Decal, “POLARIS” (AQ)(AS)(AW)Decal, “POLARIS” (AR)

10 7079604 1 Decal, Warning, Override, AWD

11 71710027171003

11

Decal, Tank Side, LHDecal, Tank Side, RH

12 71709957170996

11

Decal, Side Panel, Top, LHDecal, Side Panel, Top, RH

13 7079977 1 Decal, IRS, Rear14 7170991 2 Decal, Red Reflector15 7079959

707996011

Decal, “POLARIS”, Rear (AQ)(AS)(AW)Decal, “POLARIS”, Rear (AR)

16 7077920 1 Decal, Passenger Warning17 7079084 1 Decal, Tire Pressure18 7171383 1 Decal, Discretionary Warning19 7079083 1 Decal, Warning, General, CPSC20 7171474

717147511


8/03

A11

DECALSSPORTSMAN 500 A04CH50AT and SPORTSMAN 500 A04CH50AV and SPORTSMAN 500 A04CH50AO


3

21 20

19

6

7

10

18

13

12

5

17

16

8

1415

4

11

2

1

9

2



1 7170991 2 Decal, Reflector, Red2 7170021 2 Decal, Warning, Rack, Front/Rear3 7078253 1 Decal, Age Warning, 16 ATV4 7171478

717147911

Decal, “SPORTSMAN 500”, LHDecal, “SPORTSMAN 500”, RH

5 7079780 1 Decal, Switch Warning, AWD6 7078003 1 Decal, Headlight Adjustment7 7078465 1 Logo, Polaris Star8 7171067 1 Decal “NEW BREAK UP”, Front Cover9 7171474

717147511


10 7078577 1 Decal, Drain Recoil11 7171879

707977311

Decal, “POLARIS”, Front Cover (AT)(AV)Decal, “POLARIS”, Front Cover (AO)

12 7079672 1 Decal, Foot Brake13 7079604 1 Decal, Override Warning, AWD14 7171482

717148311

Decal, Side Panel, LHDecal, Side Panel, RH

15 71714867171487

11

Decal, “4x4”, Side Panel, LHDecal, “4x4”, Side Panel, RH

16 7079977 1 Decal, IRS, Rear17 7172066

707995911

Decal, “POLARIS”, Rear, Gold (AT)(AV)Decal, “POLARIS”, Rear, Gold (AO)

18 7079084 1 Decal, Tire Pressure/Load19 7077920 1 Decal, Passenger Warning20 7171383 1 Decal, Discretionary Warning21 7079083 1 Decal, General Warning

8/03

A12

COOLING SYSTEMSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


19

2

3

11

13

6

16

1

18

15

14

17

5

9

24

10

20

22

12

4

7

21

8


23

11

13

11

11

3



1 7517975 4 Screw2 2410383 1 Asm., Fan and Motor3 5521550 2 Guard, Hose, Plastic4 5412403 1 Hose, Engine, Upper5 1240152 1 Radiator6 5246754-067 1 Bracket, Radiator, Lower7 7515179 2 Screw8 5247047-067 1 Bracket, Radiator, Lower9 7517386 2 Screw10 5410584 2 Bushing, Mount, Lower11 7547197 4 Clamp12 7080851 1 Clamp, Hose

13 7512084 2 Screw14 7052065 1 Fitting, Barbed, 90 Degree15 8450003-1525 1 Line, Fuel16 5431673 1 Tank, Surge17 5433774 1 Plug, Cap18 5810279 1 Gasket, Overflow Cap19 5430743 1 Cap, Overflow, Drilled20 5412404 1 Hose, Engine, Lower21 5412405 1 Hose, Filler Neck22 5412402 1 Neck, Filler23 1240044 1 Cap, Pressure24 5411975 2 Asm., Grommet and Insert

5/03

A13

ENGINE MOUNTINGSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


13

23

36

37

29

25

24

1215

5

31

1

32

3

19

26

6

20

1617

22

1418

4

27

18

2

1

2

4

1413

18

15

353433

3018

87

10

28

9

11


2021

A14

ENGINE MOUNTINGSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and




1 8450040-600 AR Line, Fuel2 7080003 8 Clamp, Hose, Red3 2530009 1 Filter4 8360009-600 AR Line, Fuel5 7051011 1 Valve, Check6 8450003-1525 AR Line, Fuel7 5247155 1 Strap, Carburetor Mount8 7542105 2 Nut9 7558203 2 Washer10 7542143 2 Insert11 3110050 2 Mount, Carb12 5241453 1 Mount, Engine, Top13 7552901 2 Washer, Spring Lock14 7512315 2 Bolt15 3110044 2 Mount, Rubber, Top16 7080539 1 Clamp, Nylon17 7621462 1 Rivet18 7547108 8 Nut, Flange Lock19 5224658-067 1 Strap, Frame Support20 7080511 2 Clamp, Narrow Band21 5410421

5412487

1

1

Boot, Clutch Intake(If built before 8/04/03)Boot, Clutch Intake (If built after 8/04/03)

22 4010895 1 Cable, Black, Frame/Engine23 4010093 1 Cable, Solenoid/Starter24 5410421 1 Boot, Clutch Intake25 3110046 2 Mount, Rubber, Front26 7555815 2 Washer27 3084205 1 Screw and Washer28 3082038 1 Bolt and Washer29 7081008 1 Cable, Choke30 5245043 1 Bracket, Torque Stop31 7515417 2 Screw32 5241150 1 Mount, Engine, Front33 3080285 2 Nut34 3080530 2 Washer, Lock35 1261043-029 1 Manifold36 3085822 1 Engine, Short Block EH50PL NOTE:

The Short Block assembly contains acrankcase assembly, cylinder & cylin-der head assembly and a piston &crankshaft assembly. Prior authoriza-tion is required for warranty consider-ation.

37 7080967 1 Cable, Throttle

12/02

B1

EXHAUST SYSTEMSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


10

18

5

8

3

1

9

12

2

6

8

4

5

5

9

8

9

32

1

14

14

13

13

17

15

17

15

7

19

16


11



1 7542324 3 Nut, Nylok2 7555716 3 Washer, Flat3 5410436 3 Washer, Rubber4 7555863 2 Washer5 5010192 3 Bushing6 5241663 1 Bracket, Silencer, Frame7 7515316 2 Bolt, Carriage8 5410241 3 Dampener, Vibration9 7515316 3 Bolt, Carriage10 1261042-029 1 Silencer, Exhaust

11 7556230 1 Washer12 7512666 1 Bolt13 5243518 2 Seal, Exhaust14 7041804 4 Spring, Exhaust15 7515197 4 Screw16 7555935 4 Washer17 5241678 2 Shield, Heat, Exhaust18 1261246-029 1 Pipe, Exhaust19 ------ -- -- -- -- 1 Manifold (See Engine Mounting Pg.

A14, Ref. 35)

8/03

B2

AIR BOXSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


1

19

9

4

22

24

7

10

25

6

8

2

23

3

27

28

5

1214

13

21

11

2616

13

11

3

1718

15


20



1 5811633 1 Filter, Precleaner Sleeve2 7080595 1 Filter, Air Intake3 7080413 2 Clamp, Narrow Band4 5432868 1 Cover, Air Box5 7517317 4 Screw6 5433293 1 Duct, Air Inlet7 5811626 1 Seal, Foam8 5411422 1 Gasket, Intake9 5811482 1 Seal, Air Box Cover10 5433387 1 Box, Air11 7080699 4 Clamp, Hose12 8450073-600 AR Line, Breather13 7080544 2 Clamp, Hose14 2530029 1 Filter, Breather15 7080913 1 P-Clamp

16 5411858 AR Hose, Breather17 5412004 1 Boot, Carb18 7080511 1 Clamp, Narrow19 5412284 1 Boot, Carb20 5433847 1 Sleeve21 5411858 1 Hose, Breather22 5432377

543529911

Plug, Trap (If built before 7/21/03)Plug, Trap (If built after 7/21/03)

23 8450059-150 AR Line, Fuel24 7080694 1 Clamp, Hose25 5811650 1 Foil, Air Box26 7558301 2 Washer, Flat27 7515179 2 Screw28 5242044 6 Clip, Air Box

8/03

B3

FUEL TANKSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


17

7

11

6

1514

1

2

3

16

10

13

4

9

5

1012


8

18

21

20

19



1 54336875435324

11

Cap, Gas Tank (If built before 7/01/03)Cap, Gas Tank (If built after 7/01/03)

2 5812123 1 Gasket, Fuel Cap3 5812265 1 Seal, Foam4 8360009-600 AR Line, Fuel5 7517685 2 Screw6 5247184

524718511

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

7 5431053 1 Vent, Tank8 5812004 1 Foil, Tank9 8450103 AR Hose, Fuel10 7080003 4 Clamp, Hose, Red

11 7052346 1 Fitting, Fuel Outlet, Reserve12 7052028 1 Grommet13 7517505 1 Screw14 5432559 1 Knob, Fuel Valve15 5432733 1 Nut, Fuel Valve16 7052159 1 Valve, On/Off17 2520339 1 Asm., Fuel Tank w/Sender

(Incl. 7,8,11,12,18-21)18 5812005 1 Foil, Tank19 5810858 1 Gasket20 2410289 1 Sender, Fuel21 7512056 5 Screw

8/03

B4

OIL TANKSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


14

65

7

1312

10

1 2

8

34

9 9

6521

3

3

11




1 7512242 2 Screw2 7558301 2 Washer, Flat3 7080699 4 Clamp4 5411668 1 Line, Breather5 5410828

541250722

Grommet (If built before 8/18/03)Grommet (If built after 8/18/03)

6 5333204 2 Bushing, Mounting7 5434574 1 Dipstick

8 7081026 2 Clamp9 8450096-25 1 Line10 7052326 1 Screen, Oil Filter, 90 Degree11 5411042 1 Grommet12 7051524 1 Plug13 5850135 1 Washer, Nylon14 1261176 1 Tank, Oil

8/03

B5

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


13

16

9

10

11

12

12

14

153

17

2

1

5

7

6

4

10

8




1 5411297 1 Boot, Brake Line, Rubber2 5410988 2 Seal3 4110164 1 Switch4 2201834 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)5 2201835 1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)6 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)7 2201833

7518304

1

2

Kit, Master Cylinder Clamp(Incl. Clamp, Screws)Bolt (AT)(AV)(See Winch Asm., Pg. A9, Ref. 2)

8 2010196 1 Asm., Master Cylinder9 ------ -- -- -- -- 1 Line, Brake, Rear Caliper

(See Rear Caliper Pg. B9, Ref. 1)10 8360052-34 2 Conduit11 1910474 1 Line, Brake, Left Front w/Fittings12 7080138 8 Cable Tie13 7512024 2 Screw14 1910475 1 Line, Brake, Right Front Stainless Steel15 7052292 1 Fitting, Cross16 1910470 1 Line, Brake, Stainless Steel17 1910499 1 Bolt, Banjo

5/03

B6

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


3

1

7

5

4

2


6



1 5434113 1 Cover2 5410193 1 O-Ring3 5411439 1 O-Ring4 ------ -- -- -- -- 1 Cable, Throttle Control (See Engine

Mounting Pg. A14, Ref. 37)

5 20102302010234

11

Asm., Throttle Control (Incl. 7)Asm., Throttle Control, Thumb(Incl. 6,7)(AT)(AV))

6 2410420 1 Asm., Thumb Warmer (AT)(AV)7 2010191 1 Asm., Throttle Clamp

8/03

B7

FRONT BRAKESPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


12 3

45

6

7 8

9

10

11



19106811910682

11

Asm., Brake Caliper, LH (Incl. 1-7,9,10)Asm., Brake Caliper, RH (Incl. 1-7,9,10)

1 7515489 1 Screw, Socket Set2 5133407

51334081930642

111

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

3 5410494 1 Boot, Pin Seal4 1930665 1 Kit, Piston and Seal (Incl. 5-7)

5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)7 5132294 1 Piston, Brake, Long8 2202414 1 Kit, Brake Pad Asm.9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 7080352 1 Screw, Bleeder

9/02

B8

REAR MASTER CYLINDER/FOOT PEDALSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


5

2 3

4

108

9

67

11

13

15

14

16

4

9

1

8


12



1 7512240 1 Screw2 1930854 1 Reservoir, Brake, Rear3 7542153 1 Nut4 7080003 2 Clamp, Hose5 1910315 1 Hose, Reservoir6 1910736-067 1 Pedal, Brake7 7661401 1 Pin, Cotter8 7555919 2 Washer9 5431107

5433189

2

2

Bushing, Pivot, Pedal(If built before 5/01/03)Bushing, Pivot, Pedal(If built after 5/01/03)

10 7041750 1 Spring11 1910301 1 Master Cylinder, Brake, Rear12 7042291 1 Spring, Park Lockout13 7512247 2 Screw14 5410988 2 Seal15 1910499 1 Bolt, Banjo16 1910765 1 Line, Rear Brake

8/03

B9

REAR CALIPERSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


7 8 9

10

11

6

112

15,

17

16

14

12,

12

12,

12

15,

17

16

16

16

14

14

14

14,

3

42

5

13




1910690 1 Asm., Caliper1 1910760 1 Line, Brake, Rear, Caliper2 7517756 1 Screw3 7670126 1 Clip, Retaining, Dual4 7621462 1 Rivet5 7080960 1 Clamp, Nylon6 1910765 1 Line, Brake, Rear, Master Cylinder7 7512365 2 Screw8 7552901 2 Washer, Spring Lock

9 7558402 2 Washer, Flat10 ------ -- -- -- -- 2 Carrier, Bearing11 1910529 1 Bracket, Caliper12 2201873 1 Kit, Anvil Body13 1910538 2 Fitting, Bleed, Compact14 2201870 1 Kit, Slide Bolt15 2201872 1 Kit, Seal16 2201869 1 Kit, Piston and Seal17 2202414 1 Kit, Brake Pad

5/03

B10

DRIVE SHAFTSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


321 4

65




1380218 1 Asm., Front Drive Shaft1 3260133 1 Yoke, Splined2 2202015 1 Kit, Cross and Bearing3 1380223 1 Shaft, Replacement

4 2201015 1 Kit, Replacement Boot5 7670092 1 Circlip6 1380190 1 Joint, CV w/Sleeve

5/03

B11

REAR DRIVE SHAFTSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


875 62

4

10

31

9

24




1380197 2 Asm., Drive Shaft, Rear (Incl. 1-8)1 1590280 1 CV Joint2 1350044 2 Clamp, Large3 1350046 1 Grease, 30g4 1350045 2 Boot5 1350043 2 Clamp, Small

6 1350047 1 Grease, 50g7 1590281 1 Joint, Plunging8 1350042 1 Ring, Spring9 2201374 1 Kit, Boot (Gear Side)10 2201373 1 Kit, Boot (Wheel Side)

6/02

B12

PROP SHAFTSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


2

13

4 65E 2003 Polaris Sales Inc.



1380233 1 Shaft, Prop, Front1 3260133 1 Yoke, Gear Case, Front2 2202015 2 Kit, Cross and Bearing3 1380233 1 Shaft, Prop

4 3260131 1 Yoke, Prop Shaft, Transmission5 7080424 1 Fitting, Lubrication6 5411092 1 O-Ring

5/03

B13

FRONT STRUTSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


1

2

3

4

5

6

7

8

910

11 1213

14

15

1610

10

17

1819

20

21

22

18




1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872

543527422

Ball, Pivot, Top (If built before 10/01/03)Ball, Pivot, Top (If built after 10/01/03)

5 5132062 2 Spacer6 5432871

5435275

2

2

Ball, Pivot, Bottom(If built before 10/01/03)Ball, Pivot, Bottom(If built after 10/01/03)

7 5243364 2 Retainer, Spring8 7041375-067

7042312-0677042054-067

222

Spring, Comp. (If built before 8/01/03)Spring, Comp. (If built after 8/01/03)Spring, Compression (AT)(AV)

9 7515339 4 Bolt10 7558402 10 Washer, Flat

11 51323015132302

11

Hubstrut, LHHubstrut, RH

12 3514342 2 Bearing, Hubstrut13 7710507 2 Ring, Retaining14 ------ -- -- -- -- 1 Asm., Front Brake Caliper, LH

(See Front Brake Pg. B7 for Details)15 7080306 2 Fitting, Lubrication16 7552901 4 Washer, Spring Lock17 7512365 4 Screw18 7542324 4 Nut, Nylok19 7080367 2 Clamp, Rubber Coated20 5211115 2 Washer21 7041761 2 Strut, Front22 5411608 2 Bumper

8/03

B14

FRONT WHEELSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


1

2 3

4

5

6

7

8

9

10

11

12




1 7512325 8 Bolt2 5244314 2 Disc, Brake3 7515513 8 Stud4 5133360 2 Hub5 1520563-067

1520696-4551520696-4561520563-3851520587

22222

Rim, Front, Black (AQ)(AO)Rim, Front, Break-Up (AT)Rim, Front, Shadowgrass (AV)Rim, Front, Cloud Silver (AR)(AS)Rim, Front, Chrome (AW)

6 54119525412396

22

Tire, Front, 25x8-12Tire, Front, 25x8-12 (AR)(AS)

7 7547237 8 Nut8 7556004 2 Washer9 7542810 2 Nut, Slotted10 5411164 2 Cover, Dust11 7661401 2 Pin, Cotter12 1525017 2 Valve, Rim

5/03

C1

HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


28

5

9

33

2

1

7

3736

17

8

15

10

11

18

22

26 24

34

29

27

29

20

2330

19

21

1314

3132

4

35

25


12

16

3

6

C2

HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and




1 5434380 1 Bezel2 3280431 1 Cluster3 4010964 1 Switch, Thumb Warmer, Hi/Lo4 5412138 1 Mount, Rubber5 7511881 3 Screw6 4010963 1 Switch, Hand Warmer, Hi/Lo7 5434706-400

5435330-4555435330-4565434706-0535434706-3415434706-2885435239-455

1111111

Pod, Headlight, Upper (AQ)Pod, Headlight, Upper (AT)Pod, Headlight, Upper (AV)Pod, Headlight, Upper (AL)Pod, Headlight, Upper (AS)Pod, Headlight, Upper (AW)Pod, Headlight, Upper (AO)

8 7517238 4 Screw9 5433903 1 Spacer, Switch, LH10 4010592 1 Switch, Handlebar, Hi/Lo/Off11 5433834-070 2 Grip, Handlebar12 2461213 1 Harness, Wire, Warmers13 5432952 1 Plug14 7517625 1 Screw, Set15 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls - Master Cylinder/BrakeLine Pg. B5 for details)

16 2410418 2 Asm., Hand Warmer17 5631146

56311475631517

5631516

1

11

1

Block, Handlebar, Pegged(If built before 9/29/03)Block, Handlebar (If built before 9/29/03)Block, Handlebar, Pegged(If built after 9/29/03)Block, Handlebar (If built after 9/29/03)

18 5244969-067 1 Bracket, Pod Mounting19 7517317 2 Screw20 4032079 1 Knob, Adjusting21 4032078 1 Rod, Adjusting22 2410268

401025311

Asm., HeadlampBulb, Headlight

23 5410163 2 O-Ring24 ------ -- -- -- -- 1 Cable, Choke (See Engine Mounting

Pg. A14, Ref. 29)25 4010638 1 Receptacle, Pod Mount, 12V26 7542122 4 Nut, Nylok27 5433762-070 1 Pod, Headlight28 7080631 1 Clip, Cable Retaining29 4011002

40102784010321

111

Switch, Key, 3 Position (Incl. Key)Blank, Key, Series 2000, 6700, 6800Blank, Key, Series 2200, 2300, 2700,2800 NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

30 5433534 1 Cover, Key31 5132382 1 Cap32 4010298 1 Sensor33 7517658 1 Screw34 7080922 1 Nut, Choke35 7670127 1 Clip, Screw36 5242987-067 1 Tube, Handlebar37 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B6, Ref. 5)8/03

C3

A-ARM/STRUT MOUNTINGSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


13

45

6

78

2

11

12

13

1814

15

1716

2122

20

2419

2526

26 25

19

23

27

13

9

10



1 7542439 2 Nut, FLEXLOC2 1820805 2 Asm., Tie Rod (Incl. 3-8)3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End5 7542711 2 Nut6 5020926 2 Tie Rod7 7547028 2 Nut, Jam, LH8 7061054 2 Rod End, LH9 7517909 2 Bolt10 5411920 1 Boot, Seal, Rod End11 7556099 4 Washer, Flat12 7547177 2 Nut13 7661203 4 Pin, Cotter14 7080927 2 Joint, Ball15 5211121 2 Bracket, Ball Joint

16 7512284 4 Screw17 5410548 2 Boot, Rubber18 ------ -- -- -- -- 1 Asm., Hubstrut

(See Front Strut Pg. B13, Ref. 11)19 5434551 4 Bushing, A-Arm, Long20 2202274

220227511

Kit, A-Frame, LH (Incl. 13,19,24,25,26)Kit, A-Frame, RH (Incl. 13,19,24,25,26)

21 7542438 2 Nut, Castle22 7512084 6 Screw23 5435028-070

5435029-07011

Shield, CV Joint, LHShield, CV Joint, RH

24 5133806 2 Shaft, A-Arm25 7512492 4 Screw26 7571611 4 Washer, Spring Lock27 7515415 2 Screw

5/03

C4

STEERING POSTSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


31

4

2

5

8

10

6

9

7

2

5

6

111



1 7542324 4 Nut, Nylok2 5433866 2 Bushing, Steering, Upper3 1013920-067 1 Post, Steering4 5246732 1 Bracket, Steering Post5 7517428 4 Bolt, Carriage6 7556162 2 Bushing

7 5222393 1 Flangette8 3514352 1 Bearing9 7547158 1 Nut10 7661633 1 Pin, Cotter11 7558402 2 Washer, Flat

12/02

C5

GEAR SELECTORSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


1

2

3

8

10

4

6

11

6

7

5

9

9

5




1 5412003 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector4 5435042 2 Mount, Gear Selector5 7515175 2 Screw6 7542122 2 Nut, Nylok

7 1821462 1 Asm., Linkage8 7542324 2 Nut, Nylok9 7555770 2 Washer10 1013315-067 1 Selector, Gear11 7515306 2 Screw

5/03

C6

DRIVE CLUTCHSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


11

10

9

12

5

6

1413

5

72

4

1615

31

17

8



1321706 1 Asm., Drive Clutch, Braking(Incl. 1-11,13-15,17)

1 1520231 1 Clutch, Drive, One Way2 7556202 1 Washer, Brass3 5631119 1 Spacer4 7541906 3 Nut, FLEXLOC5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 3585712 1 Bearing8 7547130 1 Nut, Jam

9 3576510 1 Cover, Bearing10 7552801 6 Washer, Spring Lock11 7512176 6 Bolt12 7041157 1 Spring, Clutch13 1321457 3 Roller and Bushing14 5430945 6 Washer, Multilube15 7512266 3 Bolt, Shoulder16 5630710 3 Weight, Shift, 10 WH17 7556204 1 Washer, PTFE

9/02

C7

DRIVEN CLUTCHSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


10

3

78

9

13

15

16

17

3

2

14

12

11

654

1



1 5210752 1 Spacer, Driven2 7556120 AR Bushing3 1322184

1322408

1

1

Asm., Driven Clutch, Braking(Incl. 5-7,13-17)(If built before 7/01/03)Asm., Driven Clutch(Incl. 5-7,13-17)(If built after 7/01/03)

4 7556203 1 Washer5 7556010 1 Bushing (If built before 7/01/03)6 7710461

771044811

Ring, Retaining (If built before 7/01/03)Ring, Retaining (If built after 7/01/03)

7 5220646 1 Washer, Domed

8 7552901 1 Washer, Spring Lock9 7515327 1 Bolt10 3211095 1 Belt, Drive11 7517323 3 Screw12 1321977 3 Roller, Taper13 3585710 1 Bearing14 5211115 1 Washer15 3576511 1 Bearing, Moveable, 1 Inch16 7041635 1 Spring17 5131674 1 Ramp, Stationary

8/03

C8

CLUTCH COVERSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


1

3 4

9 8

1314

15

17

16

5

2

1112

10

5

5

6 7




1 2201851 1 Kit, Inner Clutch Cover (Incl. 5)2 7517599 5 Asm. Bolt/Washer3 5521578 1 Seal, Cover, Clutch4 5434255-070 1 Cover, Clutch, Outer5 7512094 9 Screw6 5410542 1 O-Ring7 5434264 1 Plug, Drain8 7074782 1 Decal, “Automatic Transmission”9 7078689 1 Decal, Warning, Clutch Cover

10 5411489 1 Boot, Duct11 7080707 2 Clamp, Narrow Band12 5435235 1 Duct, Clutch Outlet13 ------ -- -- -- -- 3 Screw and Washer

(See Crankcase Pg. D2, Ref. 6)14 5242046 1 Bracket, Clutch, Seal15 5410575 1 Seal, Cover Case16 7080511 1 Clamp, Narrow Band17 5435236 1 Duct, Clutch Air Inlet

5/03

C9

REAR SUSPENSIONSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


27

41

28

29

25

36

209

16

34

3332

35

15

4038

37

4342

30

31

232

17

11

13

1

3 12

14

7

6

5

4

3

1

14

1213

9

99

16

15

32

1835

98

6

54

9

58

8

1615

26

24

10

65

44

10 10

6

18

18

18

18

39


2219

21

C10

REAR SUSPENSIONSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and




1 7512329 6 Bolt2 1580107-067 2 Arm, Stabilizer Bar3 7542324 6 Nut, Nylok4 7517231 4 Screw5 7555761 8 Washer, Flat6 5432598

5435323

8

8

Bushing, Stabilizer Link(If built before 8/11/03)Bushing, Stabilizer Link(If built after 8/11/03)

7 5020827 2 Rod, Linkage, Stabilizer8 5020826 6 Shaft, A-Arm, Short9 5434548 12 Bushing, A-Arm, Short10 7515472 6 Screw11 5334114-067 1 Bar, Stabilizer Tube12 7555939 4 Washer13 5434549 2 Bushing, Stabilizer Tube14 7558402 8 Washer, Flat15 7512492 14 Screw16 7552603 14 Washer, Spring Lock17 1541802-067 1 Support, Stabilizer18 7542439 12 Nut, Nylok19 7517878 2 Screw20 5242077-067

5247345

2

2

Bracket, A-Arm Pivot(If built before 5/05/03)Bracket, A-Arm Pivot(If built after 5/05/03)

21 7547008 2 Nut22 7517844 1 Screw23 7515433 2 Screw24 7542321 2 Nut, Flange25 7515321 4 Bolt26 5221624-067 1 Support, Transmission, Upper

27 5630885 2 Retainer, Spring28 7041453-067

7042311-067

2

2

Spring, Compression, Rear(If built before 6/16/03)Spring, Compression, Rear(If built after 6/16/03)

29 56310145433551

21

Cam, Adjusting, SpringSleeve, Shock Protector

30 7041959 2 Shock, Rear31 7515415 2 Screw32 5434551 4 Bushing, A-Arm, Long33 5133806 2 Shaft, A-Arm34 1014174-067

1014175-0671014174-293

1014175-293

111

1

Arm, Control, Lower, LH (AO)(AT)(AV)Arm, Control, Lower, RH (AO)(AT)(AV)Arm, Control, Lower, LH(AQ)(AR)(AS)(AW)Arm, Control, Lower, RH(AQ)(AR)(AS)(AW)

35 5434550 8 Bushing, Control, Lower36 1014320-067

1014321-0671014320-293

1014321-293

111

1

Arm, Control, Upper, LH (AO)(AT)(AV)Arm, Control, Upper, RH (AO)(AT)(AV)Arm, Control, Upper, LH(AQ)(AR)(AS)(AW)Arm, Control, Upper, RH(AQ)(AR)(AS)(AW)

37 5631142 4 Bushing, Bearing Carrier38 7552614 4 Washer, Lock39 7555740 4 Washer, Flat40 7517873 4 Bolt41 5435008-070

5435009-07011

Shield, Rear, LHShield, Rear, RH

42 7512084 4 Screw43 5133663

513366411

Carrier, Wheel Bearing, LHCarrier, Wheel Bearing (RH)

44 3585502 2 Bearing, Wheel Carrier

8/03

C11

ELECTRICAL / TAILLIGHTSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


23

5 6

7

89

1011 14

13

12

22

15 17

18

19

2023

1231 30

26

24

16

27

1

21

4

E 2003 Polaris Sales Inc.2829

25


1 2201795 1 Kit, Circuit Breaker, 10 AMP2 2461192 1 Harness, Main3 2200593 1 Kit, Circuit Breaker, 20 AMP4 4010924 1 Module, Resistor5 2410320 1 Asm., Taillight 12V (Incl. 6-11)6 4032046 1 Lens, Taillight7 4032029 2 Screw, Taillight8 4030043 1 Bulb, Taillight9 4032045 1 Gasket, Taillight10 4032064 1 Backing, Taillight/Brake Light11 7670054 2 Nut, Speed12 7541925 4 Nut, Nylok13 7571602 2 Washer14 7512027 2 Screw15 5810290 3 Pad, Battery16 4010094 1 Cable, Battery/Solenoid (AQ)17 2200361 1 Kit, Battery Bolt, Short

18 7010032 2 Hook, Battery Strap19 5410424

5412499

1

1

Strap, Battery Holddown(If built before 8/18/03)Strap, Battery Holddown(If built after 8/18/03)

20 4010774 1 Battery21 2202147 1 Kit, Fusible Link22 4010093 1 Cable, Solenoid/Starter23 7512007 2 Bolt24 5810455 1 Pad, Rack Mount25 4010970 1 Module, Load Shed (AT)(AV)26 5246747 1 Bracket, CDI27 7512024 4 Screw28 4010937 1 Module, Controller29 7512024 2 Screw30 4020149 5 Clip, Rosebud31 7670109 2 Clip, Routing

8/03

C12

REAR WHEEL DRIVESPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


11

13

3

15

2

1

12

4

14

5

7

9

8

6

10




1 5411164 2 Cover, Dust, Hub2 7661404 2 Pin, Cotter3 7555796 4 Washer, Cone4 1520564-067

1520564-3851520695-4551520695-4561520588

22222

Rim, Rear, Black (AQ)(AO)Rim, Rear, Cloud Silver (AR)(AS)Rim, Rear, Break-Up (AT)Rim, Rear, Shadowgrass (AV)Rim, Rear, Chrome (AW)

5 51333615134311

22

Hub, Rear Wheel (If built before 9/29/03)Hub, Rear Wheel (If built after 9/29/03)

6 5244635 2 Disc, Brake, Rear

7 7710440 2 Ring, Retaining8 3585502 2 Bearing9 5133664 2 Carrier, Bearing, Wheel10 7512325 8 Screw11 5411949

541245122

Tire, 25x11-12 (AO)(AQ)(AT)(AV)(AW)Tire,25x11-12 (AR)(AS)

12 7515513 8 Stud13 1525017 2 Valve, Rim14 7547237 8 Nut, Flange15 7543005 2 Nut, Castle

8/03

C13

GEARCASESPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


27

29

1042

12

73

30

3432

24

9

7

14

36

25

4943

38

52

35

44 46

11

22

26

28

23

13

19

17

2

21

15

48

47

37

67

1

71

74

7275

18

69

3

68

66

45

6

8

77

62

6463 59

60

6558

57

78

16

50

41

40

54

45

53

39

80

56

76

79

61

31

20

33

70


55

51

18

7 24

1614

27

46

2

35

3534

41

74

71

73

75

70

C14

GEARCASESPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and




1341450 1 Asm., Gearcase1 3233906 1 Bellcrank2 3233826 8 Screw3 3233827 1 Cover, Gear4 3233829 1 Pawl, Detent5 3233869 1 O-Ring6 3233831 1 Shaft, Shift7 3233878 2 Seal, Triple Lip8 3233832 1 Gear, 31T9 3233524 1 Tube, Vent10 3234059 1 Gearcase, RH11 3234066 1 Shaft, Center Drive12 3234065 1 Bearing, Ball13 3234064 1 Spacer14 3233364 2 Ring, Retaining15 3234063 1 Cover, Bearing16 3234086 5 Screw17 3234062 1 Gear, Output, 91T18 3233268 2 Bearing, Ball19 3234058 1 Sprocket, 59T20 3234057 1 Chain21 3233247 2 Pin, Dowel22 3234056 1 Gearcase, LH23 3233846 22 Screw24 3234087 2 Plug25 3233874 1 Seal, Dual Lip26 3233749 2 Screw27 3233018 2 Bearing28 3234061 1 Deflector, Oil29 3234060 1 Sprocket, 19T30 3233699 1 Ring, Retaining31 3234080 1 Drum, Shift32 3234088 1 Baffle, Oil33 3233915 1 Plate, Park34 3233851 2 Washer35 3233718 3 Bearing, Needle36 3233176 1 Washer, Thrust37 3234067 1 Ring, Retaining38 3234068 1 Gear, 28T39 3233855 1 Washer40 3234070 1 Dog, Engagement

41 3233850 2 Ring, Retaining42 3233854 1 Sprocket, 24T43 3234071 1 Shaft, Reverse, 26T44 3233852 1 Gear, 33T45 3234069 1 Dog, Engagement46 3234074 2 Bearing, Ball47 3233019 1 Bearing48 3234075 1 Asm., Input Shaft49 3233036 1 Chain, Silent50 3233357 1 Spacer51 3234092 1 Ring, Retaining52 3234076 1 O-Ring53 3233788 1 Seal, Triple Lip54 3233106 1 Ring, Snap55 3233305 1 Bearing, Ball56 3234085 1 Tube, Snorkel57 3234084 1 O-Ring58 3233265 1 Bearing, Ball59 3234083 1 Shaft, Snorkel60 3233917 1 Asm., Park Lockout61 3233839 1 Gear, 16T62 3233548 1 O-Ring63 3234081 1 Disc, Lockout64 3234082 1 Star, Detent65 3233076 1 O-Ring66 3233830 1 Spring, Compression67 3233961 1 Nut, Lock68 3233834 1 Ring, Retaining69 3233835 1 Switch70 3234091 2 Washer71 3234077 2 Fork, Shift72 3234073 1 Collar, Shift73 3234089 2 Spring, Compression74 3234078 2 Spring, Compression75 3234090 2 Ring, Retaining76 3233432 2 Pin, Dowel77 3233433 1 Shoe, Chain Tensioner78 3233434 1 Cam, Chain Tensioner79 3233431 1 Spring, Torsion80 3234079 1 Rail, Shift Shaft

5/03

D1

FRONT HOUSINGSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


2

14

56

78

9 1011

12

1315

1617

1819

20

2122

23

26

15

6

24

14

14

7


2

1

3 4

25



1341344

1341497

3233950

1

1

1

Asm., Front Gearcase(If built before 7/14/03)Asm., Front Gearcase(If built after 7/14/03)Asm., Gearcase (Incl. 13,19,20)

3233955 1 Kit, Bolt1 3234163 1 Screw, Set (1341497)2 3233998

3234159

1

1

Asm., Cover Plate (Incl. Output Cover,Insert and Coil)(1341344)Asm., Cover Plate (Incl. Output Cover,Insert and Coil)(1341497)

3 3234164 1 Button, Thrust (1341497)4 3234165 1 Plate, Thrust (1341497)5 3233925

323416111

Kit, Shim Set (Incl. Shims)(1341344)Shim, Armature Plate (1341497)

6 3233926 2 Bearing, Roller Ball7 3233953 1 Asm., Race/Output Hub (Incl. 23)8 3233928 1 Pin, Dowel9 3233932 1 Bearing, Roller Ball (1341344)10 3233933

323416611

Clutch Housing/Ring Gear (1341344)Clutch Housing/Ring Gear (1341497)

11 3234167

------ -- -- -- --

1

1

Asm., Roll Cage(Incl. Spring and Roll Cage)Spring

12 3233957 14 Kit, Roll13 ------ -- -- -- --

323416911

Bushing (1341344)Bushing (1341497)

14 3233956 1 Kit, Minor Repair(Incl. O-Rings and Seals)

15 3233918 11 Bolt16 3233947 1 Cover, Input17 3234112 1 Bearing, Roller Ball18 3233944 1 Shaft, Pinion, 11T19 ------ -- -- -- -- 1 Bushing20 ------ -- -- -- -- 1 Gearcase, LH21 3233942 1 Plug, Oil Fill22 3233951 1 Asm., Drain Plug

(Incl. Plug and Washer)23 3233929 1 Bearing, Needle, Roller Thrust24 3233954

323416811

Asm., Clutch (Incl. 9-12)(1341344)Asm., Clutch (Incl. 10-12)(1341497)

25 3234162 1 Ring, Retaining, Internal26 3233924

323416011

Plate, Armature (1341344)Plate, Armature (1341497)

8/03

D2

CRANKCASESPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


2

4

11

12

2

20

21

1

23

7

5

17

3

1918

10

1615

1314

22

6

5

8

9




1 3083669 1 Bushing, Starter2 3089240 1 Asm., Crankcase

(Incl. 1,4,5,7,8,11,12,17,20,21,23)3 3087266 2 Pipe, Knock4 3080676 1 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 3 Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3087154 1 Union10 3084842 1 Union11 3084834 2 Bearing, Ball

12 3084835 1 Bearing, Ball13 3084845 1 Plug14 3084846 1 Gasket, Aluminum15 3084844 1 Spring, Valve, One Way16 3086810 1 Valve, One Way17 3084841 10 Bolt, Flange18 3082956 1 Gasket19 3083453 1 Plug20 3084837 1 Seal, Mechanical21 3084836 1 Seal, Oil22 3084847 1 O-Ring23 3080103 2 Pin, Dowel

5/03

D3

CYLINDERSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


2

20

37

232221

12

5

4

36

107

34

9

25

29

1617

3

6

18

27

1

26

13

28

33

31

32

8

11

30

35

14

24

15

19

5

35

35

13

9

18


D4

CYLINDERSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and




1 3084045 1 Asm., 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, Flange10 3084866 1 Adapter, Camshaft11 3085074 1 Gasket, Rocker Cover12 3085073 1 Cover, Rocker13 3084874 10 Bolt, Flange14 3084859 2 Seal, Exhaust Valve15 3084875 4 Bolt, Cylinder Head16 3084860 1 Plug17 3084861 1 Gasket18 3084862 1 Plug, Blind19 3084215 2 Bolt, Flange

20 3085075 1 Gasket, Exhaust21 3085326 2 Stud22 3080530 2 Washer, Lock23 3087199 2 Nut24 3085854 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3087266 2 Pipe, Knock29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3089256 1 Cylinder (Incl. 32)32 3084130 1 Pipe 2, Elbow33 3085370 1 Gasket, Cylinder34 3089242 1 Cover, Camshaft35 3085527 1 Head, Cylinder (Incl. 4-6,14,16-18,21)36 3085371 1 Gasket, Head37 3085809 1 Adapter

5/03

D5

CARBURETORSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


14

31

21

2

8

3

9

5

6

20

36

34

11

4

29

13

28

29

2726

37

32

4438

7

49

47

16

33

48

22

46

40

1

2423

30

17

10

12

45

41

35

2519

15

14

42

43

39


18

D6

CARBURETORSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and




1 3130821 2 Screw2 3130914 1 Cover, Diaphragm3 3130911 1 Spring4 3130913 1 Ring5 3130908 1 E-Ring6 3130915 1 Ring7 3131292 1 Needle, Jet8 3130910 1 Diaphragm9 3130912 1 Valve, Piston10 3130543 1 Guide, Cable11 3130931 1 Asm., Throttle Shaft12 3130932 1 Ring13 3130927 1 Spring14 3130933 4 Screw15 3130926 2 Washer16 3130925 1 Case17 3130619 1 Jet, Air18 3085698 2 Screw and Washer19 3131567 1 Asm., Carburetor (Incl. All less 18)20 3131305 1 Jet, Needle21 3131290 1 Block, Jet22 3130916 1 O-Ring23 3130593 1 Asm., Plunger24 3130538 1 Spring25 3130199 1 Cap, Plunger

26 3130519 1 Cap27 3130518 1 E-Ring28 3130517 1 Packing29 3130515 2 Seal30 3131475 2 Screw31 3130907 1 Valve, Throttle, #12032 3131306 1 Jet, Pilot (#40)33 3131359 1 Valve, Needle (1.5)34 3130928 1 O-Ring35 3131294 1 O-Ring36 3130930 1 Cover37 3130924 3 Screw38 3130010 1 Spring39 3131296 1 Washer40 3131295 1 Asm., Adjuster, Cable41 3131242 1 Clip42 3131291 1 Screw, Guide43 3130239 1 O-Ring44 3131308 1 Jet, Main, #15545 3130919 1 Ring46 3130935 1 Screw47 3130923 1 Asm., Float Body48 3130917 1 Seal49 3131293 1 Asm., Float

5/03

D7

CRANKSHAFT and PISTONSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


19

20

6

10

1412

5

8

18 13

9

17

7

11

1

15

21

16

2

3

1

4




1 3085534 2 Clip2 3087221

30872223087223

111

Asm., Piston Set (Std) (Incl. 1)Asm., Piston Set (0.25 O/S) (Incl. 1)Asm., Piston Set (0.50 O/S) (Incl. 1)

3 308722430872253087226

111

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

4 3085815 2 Bearing, Ball5 3085812 1 Crankshaft 26 3085341 1 Pin, Crank7 3085813 1 Rod, Connecting8 3085400 1 Bearing, End, Large9 3085024 1 Ball, Steel10 3089257

308925811

Asm., Crankshaft (Incl. 4-11,19)Crankshaft 1

11 3089245 1 Balancer, Gear 1

12 3086837 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 3086838 1 Pin, Dowel20 3081447 1 Key21 3240168 1 Key, Woodruff

5/03

D8

INTAKE and EXHAUSTSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


15

19

16

1718

26

27

1413 12

11

7

109

23

8

20

9

22

25

5

3

21

6

21

28

24

910

7

10

13

12

14


4



1 3087129 1 Plug2 3087130 1 Gasket3 3087131 1 Spring4 3087132 1 Pin5 3086493 1 Asm., Tensioner (Incl. 1-4)6 3086448 1 Gasket, Tensioner7 3084910 2 Asm., Rocker Arm, Intake (Incl. 9,10)8 3084913 1 Asm., Rocker Arm, Exhaust (Incl. 9,10)9 3084912 4 Nut10 3084911 4 Screw, Adjusting11 3084909 1 Shaft, Rocker12 3084908 8 Collet, Valve13 3087203 4 Retainer, Spring14 3084906 4 Spring, Valve

15 3085855 1 Camshaft (Incl. 15-19)16 3086838 1 Pin, Dowel17 3085348 1 Lever, Release18 3085076 1 Spring, Return19 3084899 1 Pin, Dowel20 3084914 1 Sprocket 221 3081657 3 Bolt and Washer22 3084916 1 Guide, Chain23 3084915 1 Chain, Timing24 3084924 1 Bolt, Pivot25 3084917 1 Lever26 3085349 2 Valve, Intake27 3085412 2 Valve, Exhaust28 3083361 2 Asm. Bolt and Washer

5/03

D9

RECOIL STARTERSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


13

6

4

7

10

5

31 2

11

8

12

14

9

8

7




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

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084877 9 Bolt, Flange13 3087163

308716411

Asm., Recoil (Incl. 1-6,9-11,13,14)Starter Case (Incl. 11)

14 3085083 1 Asm., Rope

6/02

D10

WATER PUMPSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


411

7

12

12

2

1

6

3

8

13

510

9




1 3084940 1 Thermostat2 3089246 1 Asm., Thermo Sensor3 3084942 1 Washer, Seal4 3084935 1 Impeller5 3083138 1 Gasket, Aluminum6 3085077 1 Nut, Self Lock7 3086840 1 Gasket, Water Pump

8 3084877 4 Bolt, Flange9 3085359 1 Bolt, Flange10 3082758 1 Gasket, Aluminum11 3085351 1 Cover, Water Pump12 3084191 2 Clamp, Hose13 3085857 1 Hose, Main

5/03

D11

OIL PUMPSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


4

1

10

3

2

11

17

15

87

6

13

14

5

16

18

9

12




1 3084946 1 Pump, Oil, Case 22 3084949 1 Rotor, Outer (Feed)3 3084948 1 Rotor, Inner (Feed)4 3085817

308494511

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

5 3085535 1 Screw6 3088156 2 Pin, Dowel7 3088155 2 Pin, Dowel8 3084953 1 Washer9 3084962 3 Bolt and Washer10 3084947 1 Pump, Oil, Case 3

11 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Unit, Oil Strainer14 3084205 3 Screw and Washer15 3085858 1 Shaft, Pump16 3087173 1 Gear 2, Pump17 3085820 2 Bolt, Flange18 3084959

30849603084961

ARARAR

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

12/02

D12

OIL FILTERSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


1

4

5

3

3

3

2

2

2

2

2




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

4 3084964 1 Pipe, Oil Delivery 15 3085638 1 Pipe, Oil Delivery 2

4/01

D13

MAGNETOSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


10

6

5

8

9

11

13

12

14

4

7

1

2

16 3

15


19 1718



1 30892393084979

11

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

2 3084980 1 Cap, Spark Plug3 3084997 1 Plug, Spark4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3089253

308924811

Asm., Plate (Incl. 5,8-15)Plate

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3089249 1 Stator (Incl. 13)

10 3089247 1 Flywheel w/Ring Gear11 3089251 3 Screw and Washer12 3084976 2 Screw and Washer13 3089250 1 Band, Pulse14 3089254 1 Coil, Pulser15 3081256 1 Screw and Washer16 3089238 1 CDI System17 7542105 2 Nut18 7552801 2 Washer, Spring Lock19 4010930 1 Switch, Magnetic

5/03

D14

STARTING MOTORSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


9

12

1

4

10

3

2

11 13

17

16

15

14

56

8

7




3084981 1 Asm., Starting Motor (Incl. 1-4,6-10,12)1 3088163 1 Washer Set2 3088169 1 Brush Set, Carbon3 3088166 2 Nut, Flange4 3088165 3 O-Ring5 3082038 2 Bolt and Washer6 3085034 1 Asm., Bracket, Rear7 3088168 1 Asm., Armature8 3088160 1 Asm., Bracket, Front

9 3088161 1 O-Ring10 3088164 2 Asm., Bolt Set (Incl. 4)11 3089255 1 Asm., Gear Shaft (Incl. 14-17)12 3088162 2 Ring, Rubber13 3083737 1 Washer, Gear Shaft14 3084412 1 Clip15 3084411 1 Spring, Weight16 3084410 1 Spring, Return17 3084409 1 Clip

5/03

E1

FUEL PUMPSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


4

1

3 2

2

4




3085275 1 Asm., Fuel Pump (Incl. 1-4)1 3088171 1 Screw and Washer2 3088173 2 Screw and Washer

3 3084591 4 Screw and Washer4 3088170 1 Diaphragm, Gasket Set

8/03

E2

TOOL KITSPORTSMAN 500 A04CH50AO and SPORTSMAN 500 A04CH50AQ and SPORTSMAN 500 A04CH50AR and SPORTSMAN 500 A04CH50AS and


2

7

110

3

4

5

6 8

9



3085383 1 Kit, Tool (Incl. 1-9)1 2870725 1 Gauge, Tire Pressure2 3082657 1 Screwdriver3 3085001 1 Wrench, 8-10 Open4 3085002 1 Wrench, 12-14 Open5 3085568 1 Wrench, Box6 3085569 1 Puller, Spark Plug (Wrench Handle)

7 2682572 1 Pouch, Tool Kit8 2871095 1 Wrench, Spanner, Cam9 2873647 1 Wrench, Torx10 9918724

991898311

Owner’s Manual, ’04.5 SportsmansInstructions, Hand/Thumb Warmer Op-eration (AT)(AV)

8/03

PRINTED IN THE USA PARTS MANUAL PN 9918728 and MICROFICHE PN 9918729 8/03

Changed

pages

in9918728

12

34

56

78

910

1112

1314

Acover

toc

B C D Ex

x

F G

12

34

56

78

910

1112

1314

sportsman 500 - the quad connection 2004/2004... · e 2003 polaris sales inc. parts manual pn...

Documents