sportsman 500 ho, rse, duse, 2002 parts manual

PARTS MANUAL PN 9916743 and MICROFICHE PN 9918266 5/02E 2001 Polaris Sales Inc.

SPORTSMAN 500 HOModel #A02CH50AAModel #A02CH50ABModel #A02CH50AEModel #A02CH50AK

SPORTSMAN 500 RSEModel #A02CH50AC

SPORTSMAN 500 DUSEModel #A02CH50AD

WORKER 500Model #A02CH50EB

SPORTSMAN XModel #A02CH50AJ

Rev. 04

DESERT SPORTSMAN 500Model #A02CH50FA

SPORTSMAN 500 HO FREEDOMModel #A02CH50AL

SPORTSMAN 500 PSE HOModel #A02CH50AM

SPORTSMAN 500Model #A02CH50AN

2Thispage left intentionallyblank.

TABLE OF CONTENTSSPORTSMAN 500 A02CH50(AA)(AB)(AE)(AK) and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 RSE A02CH50AC

and SPORTSMAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and and SPORTSMAN 500 PSE HO A02CH50AM andSPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB

Parts Manual

AA-ARM / STRUT MOUNTING C4. . . . . . . . . . . .AIR BOX B1. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D9-10. . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C7. . . . . . . . . . . . . . . . . . . . .CONTROLS -

MASTER CYLINDER/BRAKE LINE B8. . . . .CONTROLS - THROTTLE ASM./CABLE B12. . . .COOLING SYSTEM A10. . . . . . . . . . . . . . . . . . .CRANKCASE D3. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D4. . . . . . . . . . . . .CYLINDER D5-6. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A9. . . . . . . . . . . . . . . . . . . . . . . . . . .DECALS (AJ) E5. . . . . . . . . . . . . . . . . . . . . . . .DECALS (AL) E6. . . . . . . . . . . . . . . . . . . . . . . .DECALS (AM) E7. . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C5. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C6. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL / TAILLIGHT C8. . . . . . . . . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A11. . . . . . . . . . . . . . . . . . .

FFOOT BRAKE B11. . . . . . . . . . . . . . . . . . . . . . .FRAME MOUNTING C3. . . . . . . . . . . . . . . . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C13. . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A7-8. . .FRONT STRUT B5. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B6. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP E2. . . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C12. . . . . . . . . . . . . . . . . . . .

GGEARCASE (Cases and Snorkel) C14. . . . . . . . . .

GEARCASE (Internal Components ) D1-2. . . . . . . .

HHANDLEBAR and HEADLIGHT POD B13-14. . . . . . .

IINTAKE and EXHAUST D7. . . . . . . . . . . . . . . . .

MMAGNETO D14. . . . . . . . . . . . . . . . . . . . . . . . . .MULTI MOUNT WINCH (AJ) E4. . . . . . . . . . . . .

OOIL FILTER D13. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D12. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK (If Built Before 1/02/02) C2. . . . . . . . .OIL TANK (If Built After 1/02/02) E8. . . . . . . . . . .

PPROP SHAFT B3. . . . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE/FOOT PEDAL B9-10. . . . . . . . . . . .REAR CAB and SEAT A3-4. . . . . . . . . . . . . . . . .REAR DRIVE SHAFT B4. . . . . . . . . . . . . . . . . .REAR RACK MOUNTING A6. . . . . . . . . . . . . . .REAR SUSPENSION C9-10. . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE C11. . . . . . . . . . . . . . . . . .RECOIL STARTER D8. . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR E1. . . . . . . . . . . . . . . . . . .STEERING POST C1. . . . . . . . . . . . . . . . . . . . .

TTOOL KIT E3. . . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D11. . . . . . . . . . . . . . . . . . . . . . .

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 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN

and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB

2

7

3

6

910

14

13

15

16

17

36

12

19

20

21

32

3840

41

1

37

34

11

22

23

4

35

18

3

2730

28

29

27

8

2625

24

3133

6

2739

25

26

E 2001 Polaris Sales Inc.

5

A4

REAR CAB and SEATSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


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 7661645 10 Rivet, T-Lock2 7511930 2 Bolt3 7555792 4 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-359

5432117-1365433282-283A5433941-315A5432117-0535432117-3415432117-3175432117-1775432117-3335434393-375A

1111111111

Cab, Rear, Olive Green Metallic (AA)Cab, Rear, Porsche Red (AB)(EB)Cab, Rear, Mossy Oak (AC)Cab, Rear, Wetlands Camo (AD)Cab, Rear, Yellow (AE)Cab, Rear, Sonic Blue (AJ)(AL)Cab, Rear, Gun Metal (AK)Cab, Rear, Black Metallic (AM)Cab, Rear, Sterling Spruce (AN)Cab, Rear, Camo (FA)

6 7541925 4 Nut, Nylok7 5224592 1 Retainer, Seat Latch8 5811308 1 Foil, Tape, Rear Cab9 7512242 4 Screw10 7555859 4 Washer, Flat11 7512085 2 Screw12 5431786 1 Box, Tool13 7621403 2 Rivet14 5211033 2 Bracket, Lever Retainer15 1040387 1 Latch, Seat16 7041370 1 Spring, Latch17 2682441-316

2682441-070

268301726831042681747-3162682958-070

2683018268310558111045811105

11

1111

1111

Asm., Seat, Delta Marsh (AD)Asm., Seat, Black(AA)(AB)(AC)(EB)(AK)(FA)(AN)Asm., Seat (AJ)Asm., Seat (AL)(AM)Covering, Seat, Delta Marsh (AD)Covering, Seat, Black(AA)(AB)(AC)(EB)(AN)Covering, Seat (AJ)Cover, Seat (AL)(AM)Foil, Seat Base, LargeFoil, Seat Base, Small

18 5412067 8 Bumper, Rubber19 7517375 2 Screw20 5431787 1 Cover, Tool Box21 5410896 1 Cap, Drain22 7661638 6 Rivet23 5246103-067 1 Guard, Clutch24 ------ -- -- -- -- 1 Front Housing

(See Front Housing Pg. C13 for Details)25 7552603 7 Washer, Spring Lock26 7512492 7 Screw27 7542122 28 Nut, Nylok28 5432280 2 Spacer, Footwell29 7517377 4 Screw30 1013325-067

1013729-06711

Frame, Main (If built before 9/03/01)Frame, Main (If built after 9/03/01)

31 7078261 1 Decal, Hitch32 7517376 8 Screw33 5432221-070

5433219-07011

Footwell, Black, LHFootwell, Black, RH

34 5811111 1 Foil, Foam, Rear Fender35 5811106 2 Foil, Rear Cab, Front36 7079902 1 Decal, Carb/Filter Information37 5811087 1 Foil, Foam38 7512232 12 Screw39 7517685 2 Screw40 7670057 12 Nut, U-Type Speed41 5431796-070

5431797-07011

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

5/02

A5

FRONT CABSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


6

7

5

8

10

15

32

1112

1716

18 8

1

4

4

9

4

1413


1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5810996

5812329

1

1

Foil, Foam, Side Panel(If built before 6/18/01)Foil, Foam, Side Panel(If built after 6/18/01)

3 2632289-3592632289-1362632317-2832632288-3152632289-0532632289-3412632289-3172632289-1772632289-3332632481-3752620085-3592620085-1362632065-2832632272-3152620085-0532620085-3412620085-3172620085-1772620085-3332632480-375

11111111111111111111

Panel/Foil, Olive Green, LH (AA)Panel/Foil, Porsche Red, LH (AB)(EB)Panel/Foil, Mossy Oak, LH (AC)Panel/Foil, Wetlands Camo, LH (AD)Panel/Foil, Yellow, LH (AE)Panel/Foil, Sonic Blue, LH (AJ)(AL)Panel/Foil, Gun Metal, LH (AK)Panel/Foil, Black Metallic, LH (AM)Panel/Foil, Sterling Spruce, LH (AN)Panel/Foil, C.E.W. Camo, LH (FA)Panel/Foil, Olive Green, RH (AA)Panel/Foil, Porsche Red, RH (AB)(EB)Panel/Foil, Mossy Oak, RH (AC)Panel/Foil, Wetlands Camo, RH (AD)Panel/Foil, Yellow, RH (AE)Panel/Foil, Sonic Blue, RH (AJ)(AL)Panel/Foil, Gun Metal, RH (AK)Panel/Foil, Black Metallic, RH (AM)Panel/Foil, Sterling Spruce, RH (AN)Panel/Foil, C.E.W. Camo, RH (FA)

4 7512232 10 Screw5 2632299-359

2632299-1362632306-2832632271-3152632299-0532632299-3412632299-3172632479-3752632299-2882632299-1772632299-333

11111111111

Cab, Front, Olive Green Metallic (AA)Cab, Front, Porsche Red (AB)(EB)Cab, Front, Mossy Oak (AC)Cab, Front, Wetlands Camo (AD)Cab, Front, Yellow (AE)Cab, Front, Sonic Blue (AJ)Cab, Front, Gun Metal (AK)Cab, Front, Camo (FA)Cab, Front, Blazing Red (AL)Cab, Front, Black Metallic (AM)Cab, Front, Sterling Spruce (AN)

6 5432088-3595432088-1365433290-283A5433944-315A5432088-0535432088-3415432088-3175434395-375A5432088-2885432088-1775432088-333

11111111111

Cover, Front, Olive Green Metallic (AA)Cover, Front, Porsche Red (AB)(EB)Cover, Front, Mossy Oak (AC)Cover, Front, Wetlands Camo (AD)Cover, Front, Yellow (AE)Cover, Front, Sonic Blue (AJ)Cover, Front, Gun Metal (AK)Cover, Front, C.E.W. Camo (FA)Cover, Front, Blazing Red (AL)Cover, Front, Black Metallic (AM)Cover, Front, Sterling Spruce (AN)

7 7670085 2 Clip, Spring8 7670057 10 Nut, U-Type Speed9 7517312 2 Screw10 7670135 4 Nut, Speed11 7555931 2 Washer, Flat12 7542122 2 Nut, Nylok13 7621509 3 Rivet, Plasti Loc14 5244913-067

5244914-06711

Guard, Splash, LHGuard, Splash, RH

15 5431798-0705431799-070

11

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

16 7541925 2 Nut, Nylok17 7555792 2 Washer18 7512085 2 Screw

5/02

A6

REAR RACK MOUNTINGSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


4

3

2

9

10

11

1312

12

5

14

1

15

3

8

7

5

6

1617

14

(After 4/19/02)


1 2871501

2871501-156

1

1

Kit, Rack Extender, Rear(Incl. 15)(AC)(AD)(FA)(AL)Kit, Rack Extender, Rear (Incl. 15)(AM)

2 7517686 2 Screw3 7517685 4 Screw4 2670174-070 1 Asm., Rack, Rear, w/Warning Decal5 7542324 8 Nut, Nylok (If built before 9/03/01)6 5243378-067

1013913-15611

Bumper, Rear (AC)(AD)(FA)(AL)Bumper, Rear (AM)

7 5433305 4 Cap (AC)(AD)(FA)(AL)(AM)8 7515321 4 Bolt (AC)(AD)(FA)(AL)(AM)9 7670096 2 Nut, Chimney10 1040524-067

1040525-067

1

1

Mount, Front, Rear Rack, LH(If built before 9/03/01)Mount, Front, Rear Rack, RH(If built between 9/03/01 and 2/19/02))

11 5333332-067 4 Spacer (If built before 9/03/01)12 7558402 8 Washer, Flat (If built before 9/03/01)13 7515385 4 Screw (If built before 9/03/01)14 1012894-067

1040490-067

1013724-067

1

1

1

Support, Rear Rack(AC)(AD)(FA)(AL)(AM)Support, Rear Rack(AA)(AB)(AE)(EB)(AJ)(AK)(AN)(If built before 2/19/02)Support, Rear Rack(AA)(AB)(AE)(EB)(AJ)(AK)(AN)(If built after 2/19/02)

15 7517208 6 Screw16 5334092 2 Spacer (If built after 9/03/01)17 7517983 2 Screw (If built after 9/03/01)

2/02

A7

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


21

22

23

1024

25

20

7

6

9

1819

26

28

27

36

37

3

5

8

5

1

7

5

34

2

4

30

2934

35

8

A02CH50AJ and A02CH50AL

3233

31

1

3

4

5

5

5

77 1010

A02CH50FA Only

2 12

1311

14

15

1617

23

26

After 12/12/01

A8

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN



1 1040526-067

2871499-156

1

1

Extender, Front Rack, Low(AC)(AD)(FA)Kit, Extender, Front Rack, Low (AM)

2 7517685 4 Screw3 2670180-070 1 Asm., Front Rack

(Incl. Warning Decal)4 7517208 4 Screw5 7515399 8 Screw6 2200775 1 Kit, Front Rack Mount7 7542324 4 Nut, Nylok8 7555954 4 Washer9 5432155-070 1 Bumper10 7558402 4 Washer, Flat11 5432387 4 Insert (FA)12 7556175 2 Washer (FA)13 1013461-067 1 Support, Front Rack (FA)14 5434001-070 1 Bumper (FA)15 7515306 4 Screw (FA)16 5434002-067 1 Panel (FA)17 7512093 2 Screw (FA)18 7515391 2 Screw19 7515390 2 Screw20 1013744-067

1013746-06711

Support, Front Rack, LHSupport, Front Rack, RH

21 7512232 4 Screw22 2431014

24310154030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

23 7512329 4 Bolt24 5810467 1 Plug, Frame25 5244729-067

5244730-06711

Extension, Frame, LHExtension, Frame, RH

26 5244731-0671013772-067

11

Guard, Brush (If built before 12/12/01)Guard, Brush (If built after 12/12/01)

27 7621330 7 Rivet (If built before 12/12/01)28 5240591-067 1 Grill, Brush Guard

(If built before 12/12/01)29 5433305 4 Cap, End, Bumper (AC)(AD)(AL)(AM)30 5243377-067

5243377-15611

Bumper, Front (AC)(AD)(AL)Bumper, Front (AM)

31 7515547 2 Screw (AJ)(AL)32 5211633-067 1 Plate, Back Mount (AJ)(AL)33 5241224-067 1 Hitch, U-Bolt (AJ)(AL)34 7512097 6 Screw35 7556034 6 Washer36 7670094 6 Nut, U-Type37 5433923

543392411

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

5/02

A9

DECALSSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-

MAN 500 DUSE A02CH50AD and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB

RH

LH

15

18

63254

21

922

19

7

12

1

16

20

17

1

18

8

141310

23

11

(Decal Pg. for AJ see Pg. E5)(Decal Pg. for AL see Pg. E6)

(Decal Pg. for AM see Pg. E7)


1 7170021 1 Decal, Warning, Front and Rear Rack2 7078443

707845271705937170594

2

211

Decal, POLARIS(AA)(AB)(AC)(AD)(EB)(AK)(FA)Decal, POLARIS (AE)Decal, POLARIS, Side Panel, LH (AN)Decal, POLARIS, Side Panel, RH (AN)

3 7078253 2 Decal, Age Warning4 7079780 1 Decal, Warning, Switch, AWD5 7078003 1 Decal, Headlight Adjustment6 7079920

7079979707992170799177079931707951370795147170062

22222112

Decal, Tank Side (AA)(AN)Decal, Tank Side (AB)Decal, Tank Side (AC)(AD)Decal, Tank Side (AE)Decal, Tank Side (EB)Decal, Tank Side, LH (AK)Decal, Tank Side, RH (AK)Decal, Tank Side, (FA)

7 7078465 1 Logo, Polaris Star8 7079773

7079916

1

1

Decal, POLARIS(AA)(AB)(AC)(AD)(EB)(AK)(FA)(AN)Decal, POLARIS (AE)

9 7078045 1 Decal, Liquid Cooled, Radiator10 7170018

717001911

Decal, RSE Legend, Pod (AC)Decal, DUSE Legend, Pod (AD)

11 7079520 1 Decal, Ignition12 7079604 1 Decal, Warning, Override, AWD13 7079977 1 Decal, IRS, Rear14 7079959

7079960

1

1

Decal, POLARIS, Rear (AA)(AB)(AC)(AD)(EB)(AK)(FA)Decal, POLARIS, Rear (AE)

15 7079927 2 Decal, Red Reflector16 7077920 1 Decal, Passenger Warning17 7079084 1 Decal, Tire Pressure18 7079928

7079929707991870799197079961707996270795157079516

11111111

Decal, 4x4, LH (AA)(AE)(AN)Decal, 4x4, RH (AA)(AE)(AN)Decal, 4x4, LH (AB)(EB)Decal, 4x4, RH (AB)(EB)Decal, 4x4, LH (AC)(AD)(FA)Decal, 4x4, RH (AC)(AD)(FA)Decal, 4X4 ISD, LH (AK)Decal, 4X4 ISD, RH (AK)

19 7079085 1 Decal, Discretionary Warning20 7079083 1 Decal, Warning, General, CPSC21 7079926 2 Decal, Amber Reflector22 7078577 1 Decal, Drain Recoil23 7077749 1 Decal, Warning, Park Lock (EB Only)

5/02

A10

COOLING SYSTEMSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


36

2

13

12

33 32

19

39

25

11

37

40

41

38

3

2123

22

28

10

27

17

24

30

29

26

14

168

14

11

7

8

4

5

9

1

31

35

30

34

6

15

18

20

20


1 7080807 1 Clamp, Hose2 1240044 1 Cap, Pressure3 5433364 1 Filler, Coolant4 5243505 1 Bracket, Filler, Coolant5 7661637 3 Rivet6 5433948 1 Flexguard7 5411783 1 Hose, Engine, Upper8 7080827 2 Clamp, 19 7512232 2 Screw10 5411632 1 Hose, Filler Neck11 7080826 2 Clamp12 7517659 4 Screw13 2410123 1 Asm., Fan and Motor14 7670111 4 U-Clip15 7547069 2 Nutsert16 3110032 2 Mount, Rubber17 5020572 2 Spacer18 7080492 1 Cable Tie19 5433059 1 Shroud, Fan20 7512084 2 Screw21 4010161 1 Sensor, Thermal

22 1240045 1 Radiator23 7552801 2 Washer, Spring Lock24 7512240 2 Screw25 5433317 1 Cover, Radiator26 5410607 4 O-Ring27 7052296 1 Valve, Radiator/Coller Drain28 5410584 2 Bushing, Mount29 5243503-067 1 Bracket, Radiator, Lower30 7517386 3 Screw31 7080890 1 Tie, Panel32 5411782 1 Hose, Engine, Lower33 5521550 1 Guard, Hose34 7080851 1 Clamp, Hose35 7080696 1 Clamp, Hose36 5430743 1 Cap, Overflow, Drilled37 5810279 1 Gasket, Overflow Cap38 5433774 1 Plug, Cap39 5431673 1 Tank, Surge40 8450003-1525 1 Line, Fuel41 7052065 1 Fitting, Barbed, 90 Degree

5/02

A11

EXHAUST SYSTEMSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


10

14

5

8

3

1

9

11

2

6

8

4

5

5

9

8

9

32

1

13

13

12

12

15

16

15

16

7


1 7542324 3 Nut, Nylok2 7555716 3 Washer, Flat3 5410436 3 Washer, Rubber4 7555863 2 Washer5 5010192 3 Bushing6 5241663 1 Bracket, Silencer, Frame7 7512329 2 Bolt8 5410241 3 Dampener, Vibration

9 7515316 3 Bolt, Carriage10 1261042-029 1 Silencer, Exhaust11 7512666 1 Bolt12 5243518 2 Seal, Exhaust13 7041804 4 Spring, Exhaust14 1261040-029 1 Pipe, Exhaust15 5241678 2 Shield, Heat, Exhaust16 7515106 4 Screw

5/02

A12

FUEL TANKSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


20

5

15 12

9

18

17

1

23

19

14

16

7

4

13

8

6

14

10

11


1 5433687 1 Cap, Gas Tank2 5812123 1 Gasket, Fuel Cap3 5812210 1 Seal, Foam4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7512247 2 Bolt7 7552801 2 Washer, Spring Lock8 7558301 2 Washer, Flat9 5222154-067

5222155-067

5246069-067

5246070-067

1

1

1

1

Bracket, Mounting, Rear, LH(If built before 7/23/01)Bracket, Mounting, Rear, RH(If built before 7/23/01Bracket, Mounting, Rear, LH(If built after 7/23/01)Bracket, Mounting, Rear, RH(If built after 7/23/01

10 7547069 2 Nutsert11 5810317 1 Pad, Fuel Tank Bracket (FA)12 7052150 1 Fitting, Fuel Outlet, Main13 8450040-600 AR Line, Fuel14 7080003 4 Clamp, Hose, Red15 7052149 1 Fitting, Fuel Outlet, Reserve16 7517505 1 Screw17 5432559 1 Knob, Fuel Valve18 5432733 1 Nut, Fuel Valve19 7052161 1 Valve, 3-Way20 2520144 1 Asm., Fuel Tank (Incl. 12,15)

5/02

A13

ENGINE MOUNTINGSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


17

25

3815

39

31

28

26

1619

8

33

4

34

3

6

10

23

29

9

14

11

13

27

2021

24

1822

7

30

12

22

2

1

5

4

5

1011

7

1817

22

19

373635

3222

A14

ENGINE MOUNTINGSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN



1 7517756 2 Screw2 5243829 1 Strap, Fuel Pump3 7546601 2 Nut, Nylok4 8450040-600 AR Line, Fuel5 7080003 8 Clamp, Hose, Red6 2530009 1 Filter7 8360009-600 AR Line, Fuel8 7051011 1 Valve, Check9 8450003-1525 AR Line, Fuel10 3110071 2 Mount, Rubber11 7552605 2 Washer, Split Lock12 7542105 2 Nut13 5245055 1 Strap, Carburetor Mount14 7547069 2 Nutsert15 4010132 1 Cable, Ground, Engine16 5241453 1 Mount, Engine, Top17 7552901 2 Washer, Spring Lock18 7512315 2 Bolt19 3110044 2 Mount, Rubber, Top20 7080539 1 Clamp, Nylon21 7621462 1 Rivet22 7547108 8 Nut, Flange Lock

23 5224658-067 1 Strap, Frame Support24 4010095 1 Cable, Black, Battery/Engine25 4010093 1 Cable, Solenoid/Starter26 5410421 1 Boot, Clutch Intake27 7080511 1 Clamp, Narrow Band28 3110046 2 Mount, Rubber, Front29 7555815 2 Washer30 3084205 1 Screw and Washer31 7081008 1 Cable, Choke32 5245043 1 Bracket, Torque Stop33 7515417 2 Screw34 5241150 1 Mount, Engine, Front35 3080285 2 Nut36 3080530 2 Washer, Lock37 1261043-029 1 Manifold38 3085822 1 Engine, Short Block (EH50PLE013)

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

39 7080967 1 Cable, Throttle

5/02

B1

AIR BOXSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1

4

22

21

11

5

24

26

8

12

27

7

10

2

25

9

3

29

30

6

1416

15

23

13

2818

15

13

3

1920

17


1 5811633 1 Filter, Precleaner Sleeve2 7080595 1 Filter, Air Intake3 7080413 2 Clamp, Narrow Band4 5432601 1 Collar, Carburetor Inlet5 5432868 1 Cover, Air Box6 7517541 4 Screw7 5433293 1 Duct, Air Inlet8 5811626 1 Seal, Foam9 ------ -- -- -- -- 1 Duct, Clutch Air Inlet (See Clutch Cov-

er Pg. C7, Ref. 23)10 5411422 1 Gasket, Intake11 5811482 1 Seal, Air Box Cover12 5433387 1 Box, Air13 7080699 4 Clamp, Hose14 8450073-600 AR Line, Breather15 7080544 2 Clamp, Hose

16 2530029 1 Filter, Breather17 7080913 1 P-Clamp18 5411858 AR Hose, Breather19 5412004 1 Boot, Carb20 7080511 1 Clamp, Narrow21 5432858 1 Duct, Carburetor Inlet22 5830128 1 Gasket, Carburetor Inlet Duct23 5411668 1 Line, Breather24 5432377 1 Plug, Trap25 8450059-150 AR Line, Fuel26 7080650 1 Clamp, Hose27 5811650 1 Foil, Air Box28 7558301 2 Washer, Flat29 7515179 2 Screw30 5242044 6 Clip, Air Box

9/01

B2

DRIVE SHAFTSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


12

6

7

8 9

11

3 51

2 4 10


1 1380114 1 Asm., Drive Shaft w/Sleeve (NEA)2 5222299 1 Sleeve, Drive Shaft Seal3 3260121 1 Clamp, Band4 7670092 1 Circlip5 2201015 1 Kit, Replacement Boot6 1380060 1 Shaft, Replacement (Incl. 4)

7 1380061 1 Cardan, Replacement (Incl. 4,6,8,9)8 3260104 1 Kit, Cross and Bearing9 3260101 1 Yoke, Splined10 7661913 2 Pin, Spring11 3260123 1 Clamp, Band12 2200960 2 Kit, Drive Shaft w/Sleeve

4/01

B3

PROP SHAFTSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1 23

46

5


1380115 1 Shaft, Prop1 3260133 1 Yoke, Gear Case, Front2 3260104 2 Kit, Cross and Bearing3 3260136 1 Shaft, Prop

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

4/01

B4

REAR DRIVE SHAFTSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


8756

24

10

31

9

24


1380142 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)

4/01

B5

FRONT STRUTSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1

2

35

67

9

10

4

1112

13

15

16

8

14

17

18

19

21

4

20

2223

24

252627

1112

4


1 5411608 2 Bumper2 7041761 2 Strut, Front3 5211115 2 Washer4 7558402 10 Washer, Flat5 7080367 2 Clamp, Cable6 7542324 4 Nut, Nylok7 7512365 4 Screw8 7552901 4 Washer, Spring Lock9 5810439 2 Retainer, Casting Wire, Strut10 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B7)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 1820950

1820951

1

1

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

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

(See Drive Shaft Pg. B2, Ref. 12)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, Nylok

4/01

B6

FRONT WHEELSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


10 11 12 14

12

34

5

79

8

15

1625

24 7

17 18 2021

23

136

6

22

19


1 7512325 8 Bolt2 5243676 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub, Elec./Mech.6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 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 Spacer14 3250030 2 Cam

15 7052045 2 Plug, Magnetic Drain16 5410947

541195222

Tire, 25x8-12 (AA)(AB)(AE)(EB)Tire, 25x8-12(AC)(AD)(AJ)(AK)(FA)(AL)(AM)(AN)

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, Flange Lock24 1520269-117

1520269-0671520519

221

Rim, Front, Black (AA)(AB)(AE)(EB)Rim, Front, Black (AC)(AD)(FA)Rim, Chrome (AJ)(AK)(AL)(AM)(AN)

25 1525017 2 Valve, Rim2/02

B7

FRONT BRAKESPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


12 3

4

56

7 8

9

10

11

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

1910549 1 Asm., Brake Caliper, LH(Incl. 1-7,9,10)

1910550 1 Asm., Brake Caliper, RH(Incl. 1-7,9,10)

1 7515489 1 Screw, Socket Set2 5132960

51329611930642

111

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

3 5410494 1 Boot, Pin Seal

4 1930665 1 Kit, Piston and Seal (Incl. 5-7)5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)7 5132294 1 Piston, Brake, Long8 2201398 1 Kit, Front Brake Pad9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 7080352 1 Screw, Bleeder

4/01

B8

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


14

18

8

11

12

13

13

15

1617

3

910

19

2

1

7

6

5

4


2010196 1 Asm., Master Cylinder1 5411297 1 Boot, Brake Line, Rubber2 5410988 2 Seal3 4110164 1 Switch4 2201834 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)5 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)6 2201833 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)7 2201835 1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)8 1910478 1 Line, Brake, Stainless Steel

9 7621462 2 Rivet10 7080539 2 Clamp, Nylon11 8360031-30 1 Conduit12 1910474 1 Line, Brake, Left Front13 7080138 8 Cable Tie14 7512024 2 Screw15 8360011-38 1 Tubing, Convoluted16 1910475 1 Line, Brake, Right Front17 7052292 1 Fitting, Cross18 1910470 1 Line, Brake, Stainless Steel19 1910499 1 Bolt, Banjo

4/01

B9

REAR BRAKE/FOOT PEDALSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


10

7

8

9

11

12

13

1415

1617

18

19

212223 11

1415

12

3

4

5

6

20

B10

REAR BRAKE/FOOT PEDALSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN



1 7515497 2 Screw2 7552603 2 Washer, Spring Lock3 7555806 2 Washer, Flat4 1910553

2201399220118022014282201467

11121

Asm., Caliper, Brake, RearKit, Brake Pad (Incl. Spacer and Pin)Kit, SealKit, Bleeder ReplacementPiston, Caliper, Rear

5 1910479 1 Line, Brake6 ------ -- -- -- -- 1 Line, Brake, Stainless Steel

(See Controls-Master Cylinder BrakeLine Pg. B8,Ref. 8)

7 7512240 1 Bolt8 1930854 1 Reservoir, Brake, Rear9 7542153 1 Nut, Nylok, Flanged10 1910315 1 Hose, Reservoir

11 7080003 2 Clamp, Hose12 7542122 2 Nut, Nylok13 7041750 1 Spring14 7555919 2 Washer15 5431107 2 Bushing, Pivot, Pedal16 1910280-067 1 Rod, Brake17 7661401 1 Pin, Cotter18 1910301 1 Master Cylinder, Brake, Rear19 7512247 2 Bolt20 1910439 1 Disc, Brake (EB)21 1910440 1 Disc, Brake

(AA)(AB)(AC)(AD)(AE)(AJ)(AK)(FA)(AM)(AN)

22 7571620 1 Washer, Spring23 7547046 1 Nut, Nylok, Thin

2/02

B11

FOOT BRAKEWORKER 500 A02CH50EB

2

11

5

12

13

9

14

43

16

10

1

7

6

815

8

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

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

1 7512126 1 Bolt2 1040732-067 1 Bracket, Park Brake3 7661205 1 Pin, Cotter4 7555827 2 Washer5 5211914 1 Handle, Park Lock6 7555931 1 Washer, Flat7 7542103 1 Nut, FLEXLOC8 7556063 2 Washer, Wave

9 5224875 1 Spring, Return10 7558707 1 Bushing11 5242749 1 Pawl, Park Lock12 5224871 1 Linkage, Park Lock13 7080644 1 Clevis, Threaded14 7661843 1 Pin, Clevis15 7661011 1 Pin, Cotter16 7661203 1 Pin, Cotter

4/01

B12

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


3

1

8

5

4

2

6

7


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

Mounting Pg. A14, Ref. 39)

5 2010205 1 Asm., Throttle Control6 5245134 1 Bracket, Throttle Stop (EB)7 7517910 1 Screw (EB)8 2010191 1 Asm., Throttle Clamp

4/01

B13

HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


33

89

10

15

41

1

2

3 13

5

6

7

11

14

16

17

20

2425

2928

38

36

35

3436

30

22

27

4

4

23

37

21

26

1819

12

40

31

39

32

B14

HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN

and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EBPart 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 32803633280378

32803773280358

11

11

Speedometer (AA)(AB)(AE)Speedometer(AC)(AD)(AJ)AK)(AL)(AM)(AN)Speedometer, Kilo (EB)Speedometer, Kilo (FA)

2 40103154010416

13

Panel, Indicator LightBulb

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

Throttle Asm./Cable Pg. B12, Ref. 5)6 5242987-067 1 Tube, Handlebar7 2200774

5630616

1

2

Kit, Handlebar Block(Incl. Blocks and 7,11,29)Block, Handlebar Retainer

8 7541933 2 Nut, Brass9 7555868 2 Washer, Lock10 7558212 2 Washer, Flat11 7515189 4 Screw12 3280291 1 Clamp, Speedometer13 5433763-359

5433763-1365433975-283A5433972-315A5433763-0535433763-3415433763-3175434398-375A5433763-2885433763-1775433763-333

11111111111

Pod, Headlight, Upper (AA)Pod, Headlight, Upper (AB)(EB)Pod, Headlight, Upper (AC)Pod, Headlight, Upper (AD)Pod, Headlight, Upper (AE)Pod, Headlight, Upper (AJ)Pod, Headlight, Upper (AK)Pod, Headlight, Upper (FA)Pod, Headlight, Upper (AL)Pod, Headlight, Upper (AM)Pod, Headlight, Upper (AN)

14 ------ -- -- -- -- 1 Asm., Master Cylinder(See Controls - Master Cylinder/BrakeLine Pg. B8 for details)

15 5433903 1 Spacer, Switch, LH16 4010422 1 Switch, Handlebar, H/L/O/Rev./OR17 5433834-070 2 Grip, Handlebar18 5432952 1 Plug, Hole

19 7517625 1 Screw, Set20 5244969-067 1 Bracket, Pod Mounting21 7517317 2 Screw22 4032079 1 Knob, Adjusting23 5411120 1 Boot, Headlight24 4032077 1 Collar, Locking25 2410268

40320754010253

111

Asm., HeadlampLens and ReflectorBulb, Headlight, Halogen

26 4032078 1 Rod, Adjusting27 5410163 2 O-Ring28 7081008 1 Cable, Choke29 7542122 4 Nut, Nylok30 7670089 2 Nut, U-Type31 4010283 1 Receptacle, Pod Mount, 12V32 5411744 1 Cap, Rubber33 7080631 1 Clip, Cable Retaining34 7522021 2 Screw35 5433762-070

5433762-17711

Pod, Headlight, LowerPod, Headlight, Lower (AM)

36 40103904010278

4010321

11

1

Switch, Ignition (Incl. Key)Blank, Key, Series 2000, 6700, 6800.NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Blank, 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.

37 5433534 1 Cover, Key38 7080922 1 Nut, Choke39 4010298 1 Sensor, Hall Effect40 5132382 1 Cap, Hall Sensor41 7517658 1 Screw

5/02

C1

STEERING POSTSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


41

53

2

6

9

11

7

10

8

3

6

7

112


1 7542324 4 Nut, Nylok2 7080424 1 Fitting, Lubrication3 5433866 2 Bushing, Steering, Upper4 1821112-067 1 Post, Steering5 5132679

5222999-067

1

1

Bracket, Steering Post(If built before 1/01/02)Bracket, Steering Post(If built after 1/01/02)

6 75123777515321

44

Bolt, Carriage (If built before 1/01/02)Bolt (If built after 1/01/02)

7 7556162 2 Bushing8 5222393 1 Flangette9 3514352 1 Bearing10 7547158 1 Nut11 7661633 1 Pin, Cotter12 7558402 2 Washer, Flat

2/02

C2

OIL TANK (If Built Before 1/02/02)SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


15

1

2

4

8

10

6

7

11

12

23

1718

19

2021

22

14

5

3

9

9

16

9

To Top Oil Pump Fitting on Engine

To Lower Oil Pump Fitting on Engine

To Airbox

1413

8

(Oil Tank built after 1/02/02 See Pg. E8)


1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7052163 1 Fitting5 5411668 1 Line, Breather6 5434574 1 Dipstick7 5410889 1 O-Ring8 7517102 2 Bolt, Banjo9 7555896 4 Washer, Copper10 7052109 1 Tube, Banjo Return11 7052133 1 Tube, Banjo Intake12 2530020 1 Screen, Oil Filter

13 7542122 2 Nut, Nylok14 7558301 2 Washer, Flat15 5131255 1 Tank, Oil, RH16 5411042 1 Grommet17 5410828 2 Grommet, Mounting, Reservoir18 5333204 2 Bushing19 7512130 2 Screw20 7051524 1 Plug, Magnetic21 5850135 1 Washer, Nylon22 7515158 9 Screw23 5131785 1 Tank, Oil, LH

8/01

C3

FRAME MOUNTINGSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1

3

4

7

8

2

10

113

6

7

5

9


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

(See Gear Selector Pg. C12, Ref. 17)

7 7517386 5 Screw8 7512144 1 Screw9 ------ -- -- -- -- 4 Nut, FLEXLOC

(See Gear Selector Pg. C12, Ref. 14)10 5131277 1 Arm, Shift11 7661103 2 Pin, Cotter

4/01

C4

A-ARM / STRUT MOUNTINGSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1 3

45

67

9

2

11

1213

26

14

15

171618

20

24

25

2322

21

2728

28 27

2221

19

29

13

8

10

E 2001 Polaris Sales Inc.


1 7542403 2 Nut, FLEXLOC2 1820805 2 Asm., Tie Rod3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End, RH5 7542711 2 Nut, Jam6 5020926 2 Tie Rod7 7547028 2 Nut, Jam, LH8 7517909 2 Bolt9 7061054 2 Rod End, LH10 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 Joint16 7512284 4 Screw

17 5410548 2 Boot, Rubber18 7542438 2 Nut, Castle19 5431837

543183811

Shield, CV Joint, LHShield, CV Joint, RH

20 7512084 6 Screw21 5433066

543455144

Bushing, A-Arm, LongBushing, A-Arm, Long (AL)

22 5020677 4 Bushing23 5020681 2 Shaft, A-Arm24 2201607

220160811

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

25 7080433 2 Fitting, Lubrication26 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B5, Ref. 16)27 7512492 4 Screw28 7552603 4 Washer, Spring Lock29 7515415 2 Screw

11/01

C5

DRIVE CLUTCHSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


17

11

10

9

12

5

6

1413

5

72

4

1615

31

18

8

11 10

9 12

56

14 13 5

4

16 15

19 20

25

A01CH50EB

A01CH50(AA)AB)(AC)(AD)(AE)(AJ)(AK)(AL)(AM)(AN)(FA)

21 22 23

24


1 1520231 1 Clutch, Drive, One Way2 7556204 1 Washer3 5631119 1 Spacer4 7541906 3 Nut, FLEXLOC5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 3585712 1 Bearing8 7547130 1 Nut, Jam9 3576510 1 Cover, Bearing10 7552801 6 Washer, Spring Lock11 7512176 6 Bolt12 7041157 1 Spring, Clutch13 1321457 3 Roller and Bushing14 5430945 6 Washer, Multilube15 7512266 3 Bolt, Shoulder

16 5630710 3 Weight, Shift, 10 WH17 1321706 1 Asm., Drive Clutch, Braking

(Incl. 1-11,13-15,18)18 7556202 1 Washer19 5210752

524298152107535210754

ARARARAR

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

20 3576504 1 Bearing, Moveable, 1/221 5430261 1 Bushing22 5210748 1 Washer23 7512566 1 Bolt24 7575202 1 Washer25 1321632 1 Asm., Drive Clutch

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

2/02

C6

DRIVEN CLUTCHSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


10

3

78

9

17

19

20

21

23

3

2

22

18

14

13

654

1

1516

11

12


1 5010409 1 Spacer, Driven2 7556120 AR Bushing3 1322184

1322182

1

1

Asm., Driven Clutch, Braking(Incl. 5-7,17-23)Asm., Driven Clutch (Incl.11,12,15-17,19-23)(EB)

4 75560137556203

11

Washer (If built before 3/20/01)Washer (If built after 3/20/01)

5 7556010 1 Bushing6 7710461 1 Ring, Retaining7 5220646 1 Washer, Domed8 7552901 1 Washer, Spring Lock9 7515327 1 Bolt10 3211069

321107711

Belt, DriveBelt, Drive (EB)

11 7511854 3 Bolt (EB)

12 5430766 3 Button, Ramp (EB)13 7517323 3 Screw14 1321977 3 Roller, Taper15 7555898

7556076ARAR

Washer (.020)(EB)Washer (.025)(EB)

16 7556804 AR Washer (.030)(EB)17 3585710

357650411

BearingBearing (EB)

18 5211115 1 Washer (Not EB)19 3576511 1 Bearing, Moveable, 120 7041635

704119811

SpringSpring (EB)

21 51316745132344

11

Ramp, StationaryRamp, Stationary (EB)

22 5210752 1 Spacer (EB)23 7710448 1 Ring, Retaining (EB)

8/01

C7

CLUTCH COVERSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


4

8

3

10

11

12

13

19

2021

23

22

14

1 2

5

9

7

17

18

16

6

14

14

15


1 1040519-067 1 Bracket, Clutch Cover, Rear2 7512240 2 Bolt3 5410489 1 Seal, Cover Case4 2201851 1 Kit, Inner Clutch Cover (Incl. 14)5 7555748 3 Washer, Rubber6 7552801 3 Washer, Spring Lock7 7512247 1 Bolt8 7512277 1 Bolt9 7512278 1 Screw10 5521578 1 Seal, Cover, Clutch, Outer11 5433451-070 1 Cover, Clutch, Outer12 7078689 1 Decal, Warning, Clutch Cover

13 70776667074782

11

Decal, Automatic/EBSDecal, Automatic Transmission (EB)

14 7512094 9 Screw15 7555935 2 Washer16 5411489 1 Boot, Duct17 7080761 2 Cable Tie18 5433980 1 Duct, Clutch Outlet19 ------ -- -- -- 3 Screw and Washer

(See Crankcase Pg. D3, Ref. 6)20 5242046-067 1 Bracket, Clutch Seal21 5410575 1 Seal, Cover Case22 7080511 1 Clamp, Narrow Band23 5432086 1 Duct, Air Inlet

5/02

C8

ELECTRICAL / TAILLIGHTSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1

2

4 5

6

78

910 13

12

11

2920

14

28

21

22

23

25

2630

12113837

32

31

35

34

36

20

33

3

16

1718

19

15

24

27


1 2460944 1 Harness, Main Wire2 2200593 1 Kit, Circuit Breaker, 20 AMP3 2201795 1 Kit, Circuit Breaker, 10 AMP4 2432034

2410320

1

1

Asm., Taillight w/Brake Light (Incl. 5-10)(If built before 2/01/02)Asm., Taillight 12V (Incl. 5-10)(If built after 2/01/02)

5 4032046 1 Lens, Taillight6 4032029 2 Screw, Taillight7 4030043 1 Bulb, Taillight8 4032045 1 Gasket, Taillight9 4032064 1 Backing, Taillight/Brake Light10 7670054 2 Nut, Speed11 7541925 4 Nut, Nylok12 7571602 4 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 7517386 1 Screw (EB)(FA)16 4010311 1 Switch, Horn (EB)(FA)17 4010310 1 Horn (EB)(FA)18 7512057 1 Screw (EB)(FA)

19 5810317 1 Pad, Fuel Tank Bracket (EB)(FA)20 4010094 1 Cable, Battery/Solenoid21 2200361 1 Kit, Battery Bolt, Short22 7010032 2 Hook, Battery Strap23 5410424 1 Strap, Battery Holddown24 2460837 1 Harness, Horn (EB)(FA)25 5432077 AR Tube, Battery Vent26 4140006 1 Battery27 2202147 1 Kit, Fusible Link28 5431769 1 Cover, Battery29 4010093 1 Cable, Solenoid/Starter30 7512007 2 Bolt31 5810455 2 Pad, Rack Mount32 5241416 1 Bracket, CDI33 7512024 1 Screw34 5131036 1 Sink, Heat35 4060173

401065711

Rectifier, Regulator (All models except EB)Rectifier, Regulator (EB Only)

36 7512018 3 Screw37 4020149 5 Clip, Rosebud38 7670109 2 Clip, Routing

5/02

C9

REAR SUSPENSIONSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


27

40

28

29

2624

36

10

219

18

11

34

33

32

35

17

3938

37

42

44

41

30

31

22

2

19

13

15

1

3 14

16

7

6

5

4

3

1

16

1415

9

99

10

10 1011

11

11

11

11

18

17

1032

20

18

35

98

6

54

9

58

8

1817

17

25

24

23

18

12

65

43

12 12

6

10

20

20

20

20

C10

REAR SUSPENSIONSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN



1 7512329 6 Bolt2 1580107-067 2 Arm, Stabilizer Bar3 7542324 6 Nut, Nylok4 7517231 4 Screw5 7555761 8 Washer, Flat6 5432598 8 Bushing, Stabilizer7 5020827 2 Rod, Linkage, Stabilizer8 5020826 6 Shaft, A-Arm, Short9 5433063

5434548

12

12

Bushing, A-Arm, Short(If built before 10/01/01)Bushing, A-Arm, Short(If built after 10/01/01)

10 5020677 12 Bushing11 7080433 12 Fitting, Lubrication12 7515472 6 Screw13 5334114-067 1 Bar, Stabilizer Tube14 7555939 4 Washer15 5433413

5434549

2

2

Bushing, Stabilizer Tube(If built before 10/10/01)Bushing, Stabilizer Tube(If built after 10/10/01)

16 7558402 8 Washer, Flat17 7512492 16 Screw18 7552603 16 Washer, Spring Lock19 1541322-067

1541802-067

1

1

Support, Stabilizer(If built before 10/08/01)Support, Stabilizer(If built after 10/08/01)

20 7542439 12 Nut, Nylok21 5242077-067 2 Bracket, A-Arm Pivot22 7515433 2 Screw23 7542321 2 Nut, Flange

24 7515321 4 Bolt25 5224667-067 1 Support, Transmission, Upper26 7552901 2 Washer, Spring Lock27 5630885 2 Retainer, Spring28 7041453-067

7041519-067

2

2

Spring, Compression, Rear(AA)(AB)(AC)(AD)(AE)(AJ)(AL)(AM)Spring, Compression, Rear (EB)

29 56310145433551

21

Cam, Adjusting, SpringSleeve, Shock Protector

30 7041959 2 Shock, Rear31 7515415 2 Screw32 5433066

5434551

4

4

Bushing, A-Arm, Long(If built before 10/01/01)Bushing, A-Arm, Long(If built after 10/01/01)

33 5020681 2 Shaft, A-Arm34 1012717-067

1012718-06711

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

35 5433065

5434550

8

8

Bushing, Control, Lower(If built before 10/01/01)Bushing, Control, Lower(If built after 10/01/01)

36 1040730-0671040731-067

11

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

37 5631141 4 Bushing, Bearing Carrier38 7555936 4 Washer39 7517297 4 Screw40 5433098-070

5433099-07011

Shield, Rear, LHShield, Rear, RH

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

2/02

C11

REAR WHEEL DRIVESPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


78

1011

1

12

6

9

2

3

5

4


1 7661404 2 Pin, Cotter2 7542459 8 Nut, Flange Lock3 5131649 2 Hub, Rear Wheel4 ------ -- -- -- -- 2 Carrier, Bearing, Wheel (See Rear

Suspension Pg. C10, Ref. 42)5 7710440 2 Ring, Retaining6 7515513 8 Stud7 5410948

541194922

Tire, 25x11-10 (AA)(AB)(AE)(EB)Tire, 25x11-12(AC)(AD)(AJ)(AK)(FA)(AL)(AM)(AN)

8 1525017 2 Valve, Rim9 1520217-117

1520457-0671520520

221

Rim, Rear, Silver (AA)(AB)(AE)(EB)Rim, Rear, Black (AC)(AD)(FA)Rim, Rear, Chrome(AJ)(AK)(AL)(AM)(AN)

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

2/02

C12

GEAR SELECTORSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


2

4

3

5

7

8

6

112310

22

1

13

21

9

12

1011

15

15

2019

17

17

14

14

18

16

14

14


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

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

4/01

C13

FRONT HOUSINGSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1 2

34 5

678

9 10

11 12

13

14

15

16

17

18

1920 21

22

2324

25

26

2728

1

2


1341323 1 Asm., Front Gearcase(Incl. 1-12,16-26)

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

14 8450003-1525 AR Line, Fuel15 7080307 1 Clamp, Hose16 3233524 1 Tube, Vent17 3233696 1 Gearcase18 3233725 1 Shaft, Output19 3233020 1 Bearing, Ball20 3233554 AR Shim21 3233693 1 O-Ring22 3233724 1 Cover, Output23 3233583 AR Shim24 3233582 1 Button, Thrust25 3233254 1 Washer, Plug26 3233253 1 Plug, Drain27 7512492 4 Screw28 7552603 4 Washer, Spring Lock

4/01

C14

GEARCASE (Cases and Snorkel)SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


14

4

30

28

3132

26

16

19

20

2123

2224

35

12

1213

38

6

9

3

137

115

34

5

33

29

10

17

25

15

18

8

7

15

27

36


-- -- -- -- -- -- -- 1 Asm., Gearcase (See Gearcase -Inter-nal Components Pg. D2 for Details)

1 3233256 2 Seal2 3233026 18 Screw3 3233636 1 Decal, Switch4 3233252 2 Screw5 3233248 3 Seal6 3233778 1 Gearcase, LH7 7052095 1 Fitting, 90 Degree8 8360009-600 AR Line, Fuel9 3233037 1 Vent, Tube10 3233475 1 Dipstick11 3233749 8 Screw12 3233617 1 Switch, 2 Position13 3233635 1 Switch, 3 Position14 3233442 2 Screw15 ------ -- -- -- -- 4 Washer (See Gearcase - Internal

Components Pg. D2, Ref. 2)16 3233352 1 Washer17 3233476 1 Gear, 31T, Snorkel18 ------ -- -- -- -- Bearing, Ball (See Gearcase -Internal

Components Pg. D2, Ref. 29)19 3233446 1 Shaft, Drive, Snorkel20 3233302 1 O-Ring

21 3233750 1 Tube, Snorkel22 3233305 1 Bearing, Ball23 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. 23 indicates choices, may also beused in combinations.

24 3233306 1 Ring, Retaining25 3233444 1 Lock, Bolt26 3233351 1 Bolt27 3233779 1 Spacer, Snorkel28 3233292 1 Bushing29 3233293 1 Seal30 3233291 2 Nut, FLEXLOC31 3233294 1 Stamping, Cover Plate32 3233295 4 Washer33 3233296 4 Screw34 3233777 1 Plug, Drain35 3233254 1 Washer36 7517844 1 Screw37 3233776 1 Gearcase, RH38 3233247 3 Pin, Dowel

4/01

D1

GEARCASE (Internal Components)SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1 23

4

5

1422 2019

21

28

1816 1315

12

2729

37

3432 31

42

40

41

10

4546

26

24

25

23

4

56

10

26

23

67

23

10

8

17

9

3536

30

4443

3938

33

21 21

15

15

11

27

11

D2

GEARCASE (Internal Components)SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN



1341360 1 Asm., Gearcase (Incl. 1-37 and all onGearcase (Cases and Snorkel) Pg. C14)

1 3233055 2 Nut2 3233054 6 Washer3 3233153 2 Bellcrank, HLR4 3233045 2 Ring, Retaining5 3233040 2 Washer6 3233548 2 O-Ring7 3233774 1 Shaft, Shift8 3233019 1 Bearing9 3233571 1 Shaft, Input, 31T, HCR10 3233018 3 Bearing11 3233176 2 Washer, Thrust12 3233744 1 Gear, 30T13 3233743 1 Engagement Dog, High14 3233664 1 Fork, Shift, H/R15 3233720 3 Ring, Retaining16 3233719 1 Sprocket, 24T17 3233036 1 Chain, Silent, 34P18 3233742 1 Shaft, Reverse, HCR19 3233775 1 Fork, Shift, Low20 3233661 1 Shaft, Shift21 3233718 3 Bearing, Needle22 3233745 1 Gear, 36T

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

4/01

D3

CRANKCASESPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


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 3085808 1 Asm., Crankcase

(Incl. 1,4,5,7,11,12,17,20,21,23)3 3084838 2 Pin, Straight4 3080676 1 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 3 Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3087154 1 Fitting, Oil Inlet10 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

1/02

D4

CRANKSHAFT and PISTONSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


21

22

8

12

15

14

7

10

19 16

11

20

9

3

13

4

17

23

18

2

1

4

65


1 308537930853803085381

111

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

2 308717030871713087172

111

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

3 ------ -- -- -- -- 1 Pin, Piston4 3085534 2 Clip5 3080676 1 Bearing, Ball6 3085815 1 Bearing, Ball7 3085812 1 Crankshaft 28 3085341 1 Pin, Crank9 3085813 1 Rod, Connecting10 3085400 1 Bearing, Large End11 3085024 1 Ball, Steel12 3085861

308594511

Asm., Crankshaft (Incl. 7-13,21)Crankshaft 1

13 3085852 1 Gear 1, Balancer14 3086837 1 Shaft, Balancer15 3240088

308489230848933084894

1111

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

16 308489530848963084897

111

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

17 3084882 1 Sprocket 118 3085528 1 Nut, Slit19 3083905 1 Nut, Lock20 3083904 1 Washer21 3085346 1 Pin, Dowel22 3081447 1 Key23 3240168 1 Key, Woodruff

9/01

D5

CYLINDERSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


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

D6

CYLINDERSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN



1 3084045 1 Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt, Allen4 3084857 2 Pin, Straight5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve, Black7 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 Valve, Brown15 3084875 4 Bolt, Cylinder Head16 3084860 1 Plug17 3084861 1 Gasket18 3084862 1 Plug, Blind19 3084215 2 Bolt, Flange

20 3085075 1 Gasket, Exhaust21 3085326 2 Stud22 3080285 2 Nut23 3080530 2 Washer, Lock24 3085854 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3084838 2 Pin, Straight29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3086811 1 Cylinder (Incl. 32)32 3084130 1 Pipe 2, Elbow33 3085370 1 Gasket, Cylinder34 3084868 1 Cover, Camshaft35 3086200 1 Gasket, Cover, Cam36 3085527 1 Cylinder Head (Incl. 4-6,14,16-18,21)37 3085371 1 Gasket, Head38 3085809 1 Adapter

4/01

D7

INTAKE and EXHAUSTSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


14

18

15

1617

25

26

13 12 11

10

6

98

22

7

19

8

21

24

4

3

21

5

20

27

23

89 6

9

1211

13


1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3086839 1 Spring, Tensioner4 3086813 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Intake Rocker Arm (Incl. 8,9)7 3084913 1 Asm., Exhaust Rocker Arm (Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3086893 4 Retainer, Spring13 3084906 4 Spring, Valve14 3085855 1 Camshaft (Incl. 15-18)

15 3086838 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3084914 1 Sprocket 220 3081657 3 Bolt and Washer21 3084916 1 Guide, Chain22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot, Lever24 3084917 1 Lever25 3085349 2 Valve, Intake26 3085412 2 Valve, Exhaust27 3084874 2 Bolt, Flange

4/01

D8

RECOIL STARTERSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


14

6

4

7

10

5

31 2

11

8

12

13

15

9

8

7


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

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084933 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3087163

308716411

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

15 3085083 1 Asm., Rope

9/01

D9

CARBURETORSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


18

2930

5

20

8

3

9

4

1

6

21

38

7

2324

41

44

4342

19

37

36

39

2

17

50

14

13

11

16 15

26

27

52

51

49

10

12

28

3534

333231

40

22

5348

47

45

46

25

12

15

D10

CARBURETORSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN



1 3130914 1 Cover, Diaphragm2 3130821 2 Screw3 3130911 1 Spring4 3130913 1 Ring5 3130908 1 E-Ring6 3130915 1 Ring7 3131292 1 Needle, Jet8 3130910 1 Diaphragm9 3130912 1 Valve, Piston10 3130932 1 Ring11 3130927 1 Spring12 3130933 4 Screw13 3130926 2 Washer14 3130925 1 Case15 3130515 2 Seal16 3130928 1 O-Ring17 3130619 1 Jet, Air18 3131289 1 Asm., Carburetor (Incl. 1-53)19 3131305 1 Jet, Needle20 3131290 1 Block, Jet21 3130916 1 O-Ring22 3131208 1 Cap23 3130593 1 Plunger24 3130538 1 Spring25 3130199 1 Holder, Guide26 3130517 1 Packing27 3130519 1 Cap

28 3130518 1 E-Ring29 3130906 2 Screw30 3130907 1 Valve, Throttle31 3130522 1 O-Ring32 3130523 1 Washer33 3130525 1 Spring34 3130934 1 Adjuster35 3131306 1 Jet, Pilot (#40)36 3130922 1 Valve, Needle37 3131293 1 Float38 3130917 1 Seal39 3130923 1 Body, Float40 3130935 1 Screw41 3130919 1 Ring42 3131304 1 Jet, Main (#152.5)43 3130239 1 O-Ring44 3131291 1 Screw, Guide45 3131295 1 Adjuster, Cable46 3131296 1 Washer47 3130010 1 Spring48 3130543 1 Guide, Cable49 3130931 1 Shaft, Throttle50 3130924 3 Screw51 3130930 1 Cover52 3131294 1 O-Ring53 3131242 1 Clip

4/01

D11

WATER PUMPSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


11

7

83

3

2

1

9

12

13

4

10

65


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

8 3086840 1 Gasket, Water Pump9 3085077 1 Nut, Self Lock10 3083138 1 Gasket11 3084935 1 Impeller12 3084942 1 Washer, Seal13 3084877 4 Bolt, Flange

4/01

D12

OIL PUMPSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


4

1

10

32

11

12

15

87

6

13

14

5

16

17

9

18


1 3084946 1 Case 2, Oil Pump2 3084949 1 Rotor, Outer Feed3 3084948 1 Rotor, Inner Feed4 3085817

308494511

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

5 3085535 1 Screw6 3084955 2 Pin, Dowel7 3084954 2 Pin, Dowel8 3084953 1 Washer9 3084962 3 Bolt and Washer10 3084947 1 Case 3, Oil Pump

11 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Strainer, Oil14 3084205 3 Screw and Washer15 3085818 1 Shaft, Pump16 3087173 1 Gear, Pump 217 3084959

30849603084961

ARARAR

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

18 3085820 2 Bolt, Flange

9/01

D13

OIL FILTERSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1

4

5

3

3

3

2

2

2

2

2


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

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

4/01

D14

MAGNETOSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


196

5

89

1011

12

13

4

7

1

2

15

18

3

1416

17


1 30852273085228

11

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

2 3084980 1 Cap, Spark Plug3 3084997 1 Plug, Spark, BKR6E4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3086980

3087167

3086981

1

1

1

Asm., Plate (Incl. 5,6,8-12,14)(through S# 02-22573)Asm., Plate (Incl. 5,6,8-12,14)(S# 02-22574 and higher)Plate

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3086984

308716811

Stator (Incl. 13)(through S# 02-22573)Stator (Incl. 13)(S# 02-22574 and higher)

10 3086985 3 Screw and Washer11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3081256 1 Screw and Washer15 3087029

308716911

CDI System (through S# 02-22573)CDI System (S# 02-22574 and higher)

16 3083073 2 Nut17 3080077 2 Washer, Spring18 3085521 1 Switch, Magnetic19 3086983

308716611

Flywheel/Ring Gear (through S# 02-22573)Flywheel/Ring Gear (S# 02-22574 and higher)

11/01

E1

STARTING MOTORSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


1

10

12

2

6

11

5

4

18

13

17

16

15

14

78

9

32

12


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 3087030 1 Asm., Gear Shaft (Incl. 13-17)

4/01

E2

FUEL PUMPSPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTS-MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN


5

2

4 3

3

5

1

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

sportsman 500 ho, rse, duse, 2002 parts manual

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