SPORTSMAN 500 HO/INT`L Model #A05MH50AB

PARTS MANUAL PN 9919416 and MICROFICHE PN 9919417 7/04
SPORTSMAN 500 HO/INT’L
Model #A05MH50AB
Model #A05MH50AC
Model #A05MH50AG
Model #A05MH50AH
Model #A05MH50FB
E 2004 Polaris Sales Inc.
TABLE OF CONTENTS
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
A
H
A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
B
BRAKE LINES, FRONT . . . . . . . . . . . . . . . . . B6
BUMPER MOUNTING . . . . . . . . . . . . . . . . . A7-8
C
CALIPER, REAR . . . . . . . . . . . . . . . . . . . . .
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS - THROTTLE ASM./CABLE . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT and PISTON . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
B7
D7-8
C9
B4
B9
A11
D4
D6
D5
D
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT, FRONT . . . . . . . . . . . . . . . . .
DRIVE SHAFT, REAR . . . . . . . . . . . . . . . . .
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . .
A10
C7
B10
B11
C8
E
ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . C13
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A13-14
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A12
F
FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . .
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .
FRONT HOUSING . . . . . . . . . . . . . . . . . . . .
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .
B8
B5
A5
D3
D11
B2
G
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C6
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . D1-2
H
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . C1-2
HEADLIGHT POD . . . . . . . . . . . . . . . . . . . . . C1-2
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . C3
I
INTAKE and EXHAUST . . . . . . . . . . . . . . . . . D9
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . E2
MASTER CYLINDER, REAR . . . . . . . . . . . . B8
O
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D13
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D12
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
P
PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B12
R
RACK MOUNTING FRONT . . . . . . . . . . . . .
REAR CAB and SEAT . . . . . . . . . . . . . . . . .
REAR RACK MOUNTING . . . . . . . . . . . . . . .
REAR SUSPENSION . . . . . . . . . . . . . . . . . .
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . .
RECOIL STARTER . . . . . . . . . . . . . . . . . . . .
A8
A3-4
A6
C11-12
C10
D14
S
STARTING MOTOR . . . . . . . . . . . . . . . . . . .
STEERING POST . . . . . . . . . . . . . . . . . . . . .
STORAGE BOX, REAR . . . . . . . . . . . . . . . .
STORAGE, FRONT . . . . . . . . . . . . . . . . . . .
STRUT MOUNTING . . . . . . . . . . . . . . . . . . .
STRUT, FRONT . . . . . . . . . . . . . . . . . . . . . .
E1
C5
A9
A7
C4
B13
T
TAILLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . C3
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
TRANSMISSION MOUNTING . . . . . . . . . . . . C14
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D10
WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . . B14
WORKLAMPS . . . . . . . . . . . . . . . . . . . . . . . C3
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
REAR CAB and SEAT
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
5
3
6
E 2004 Polaris Sales Inc.
2
4
12
25
7
24
8
23 22
9
21
26
20
13
10
11
12
12
13
14
15
19
16
17
18
Rear Cab Foil
View From Bottom
A3
REAR CAB and SEAT
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
7512095
7555798
7512026
7556034
7511930
5246076
7555792
7541925
5435363-400
5435363-293
5435664-455
5435363-341
7558403
7170911
7661855
5435354-070
5435355-070
Qty. Description
Ref. Part No.
2
2
3
3
2
1
4
2
1
1
1
1
2
1
14
1
1
14
15
16
17
18
19
20
21
22
23
24
Screw
Washer
Screw
Washer
Bolt
Retainer, Seat Latch
Washer
Nut, Nylok
Cab, Rear, Camo Green Metallic (AH)
Cab, Rear, Indy Red (AB)(FB)
Cab, Rear, New Break Up (AC)
Cab, Rear, Sonic Blue (AG)
Washer (AC)
Decal, Hitch
Rivet
Footwell, Black, LH
Footwell, Black, RH
7517230
7542122
5812703
5812702
5812701
1014536-067
7621403
5211033
7041370
1040387
2683433-070
2683434-070
2683661-070
25 7079902
26 5412623
Qty. Description
8
8
2
1
1
1
2
2
1
1
1
1
1
1
2
Screw
Nut, Nylok
Foil, Rear Cab, Front, Top
Foil, Rear, Cab, Front, Bottom
Foil, Cab, Rear
Frame, Main, Black
Rivet
Bracket, Lever Retainer
Spring, Latch
Latch, Seat
Asm., Seat, Black
Covering, Seat, Black
Asm., Seat, Black (AC)
Decal, Carb/Filter Information
Grommet
7/04
A4
FRONT CAB
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
E 2004 Polaris Sales Inc.
5
13
2
4
3
12
14
13
5
6
7
10
11
8
8
9
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 5435352-400
5435352-293
5435352-341
5435668-455
2 2632864-400
2632864-293
2632864-341
2632975-455
3 7670057
4 7517219
5 5435353-177
2632936-177
5435353-070
2632936-070
5435915-455
2633048-455
Qty. Description
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
Cover, Front, Camo Green Met (AH)
Cover, Front, Indy Red (AB)(FB)
Cover, Front, Sonic Blue (AG)
Cover, Front, New Break Up (AC)
Cab, Front, Camo Green Met (AH)
Cab, Front, Indy Red (AB)(FB)
Cab, Front, Sonic Blue (AG)
Cab, Front, New Break Up (AC)
Nut, U-Type Speed
Screw
Panel, Side, LH, Black (AG)(AH)
Asm., Panel/Foil, RH, Black (AG)(AH)
Panel, Side, LH, Black (AB)(FB)
Asm., Panel/Foil, RH, Black (AB)(FB)
Panel, Side, LH, New Break Up (AC)
Asm., Panel/Foil, RH, NBU (AC)
Ref. Part No.
6
7
8
9
10
11
12
13
14
5812615
7080756
7517386
5248100
7546601
5246872
7661855
7512026
7556034
Qty. Description
1
1
4
1
2
1
2
8
4
Foil, Side Panel, RH
Clip
Screw
Guard, Splash, RH
Nut, Nylok
Guard, Splash, LH/Pump Mount
Rivet
Screw
Washer
7/04
A5
REAR RACK MOUNTING
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
1
19
2
4
18
3
5
6
12
7
8
15
9
10
11
12
17
13
14
16
15
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
7517230
7517983
5248469-418
7518418
1014768-418
7517208
2632867-070
8 7518213
9 5435959
10 7555843
Qty. Description
4
2
1
2
1
6
1
Screw
Screw
Channel, Rear Rack, Black
Screw
Extender, Rear Rack (AC)
Screw (AC)
Asm., Rack, Rear, Black
(Incl. Warning Decal and Reflectors)
2 Screw
2 Spacer
2 Washer, Flat
Ref. Part No.
11
12
13
14
15
16
7542324
5248471-418
5334092
1014668-067
7518341
-------
17 7542343
18 7542153
19 7518424
Qty. Description
2
2
2
1
4
1
Nut, Nylok
Channel, Rear Rack, Front, Black
Spacer
Support, Rear Rack, Black
Bolt, Flange
Bracket, Silencer, Frame (See Exhaust System Pg. A12, Ref. 6)
4 Nut, Flange
4 Nut, Nylok, Flange
2 Screw
8/04
A6
FRONT STORAGE and BUMPER MOUNTING
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
4
2
3
33
32
1
31
5
3
30
34
35
29
1
2
6
7
9
28
8
26
27
25
11
10
11
13
24
23
13
22
21
14
15
20
12
16
18
17
A7
19
FRONT RACK and BUMPER MOUNTING
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 7515399
2 1014591-067
1014592-067
3 7518341
4 5810467
5 7542343
6 1014636-067
7 5435629
8 5812778
9 7081241
7081242
10 7512076
11 5334257
12 7661855
13 5434314
5434315
14 5412504
15 5435046
16 5247507-067
17 7518046
Qty. Description
6
1
1
2
1
8
1
1
1
1
1
4
2
6
1
1
4
1
1
4
Screw
Support, Front Rack, LH
Support, Front Rack, RH
Screw, Flange
Plug, Frame
Nut, Nylok, Flange
Guard, Brush
Cover, Radiator
Seal, Radiator Cover
Latch, LH
Latch, RH
Screw
Latch, Wire
Rivet
Shield, Side, Radiator, LH
Shield, Side, Radiator, RH
Grommet
Cover, Radiator
Grill, Brush Guard
Screw
Ref. Part No.
Qty. Description
18 5435701
5435702
19 5435357-070
20 7518383
21 7518382
22 7556341
23 2632865-070
1
1
1
2
4
4
1
24
25
26
27
28
29
30
31
32
33
34
35
1
3
2
4
4
1
1
2
8
8
2
1
1202838
5412352
5435628
7555960
7517208
5521693
5435362-070
5247653-418
7542122
7518427
5134576
5521706
Cover, Bumper, LH
Cover, Bumper, RH
Panel
Screw
Screw
Washer, Flat
Asm., Bumper, Front, Black
(Incl. Warning Decal)
Asm., Box, Lower, Front
Plug
Cover, Strut
Washer, Flat
Screw, Flange
Seal
Cover, Box, Front
Channel, Lid, Front
Nut, Nylok
Screw
Pin
Seal, Lid/Bumper
7/04
A8
REAR STORAGE BOX
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
E 2004 Polaris Sales Inc.
2
3
7
4
8
5
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5435605
7081205
5435368
5521694
Qty. Description
1
1
1
1
Ref. Part No.
Box, Upper
Latch
Cover
Seal
5
6
7
8
5810455
5435630
5412352
7661855
Qty. Description
2
1
1
2
Pad
Box, Lower
Plug
Rivet
7/04
A9
DECALS
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
3
2
4
5
6
7
1
8
3
E 2004 Polaris Sales Inc.
12
13
10
9
RH
15
14
16
11
17
18
LH
9
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
7172689
7173013
7172572
7172707
7172708
7172893
7172894
7172559
7172704
7172710
7172896
7172897
7079780
7171067
Qty. Description
2
1
2
1
1
1
1
1
1
1
1
1
1
1
Decal, Reflector, Red
Urocal, 50th Anniversary
Decal, Warning, Front and Rear Rack
Decal, Rear Cab, “AWD”, LH
Decal, Rear Cab, “AWD”, RH
Decal, Rear Cab, “AWD”, LH (AC)
Decal, Rear Cab, “AWD”, RH (AC)
Decal, Age Warning, 16, ATV
Decal, “SPORTSMAN”, LH
Decal, “SPORTSMAN”, RH
Decal, “SPORTSMAN 500”, LH (AC)
Decal, “SPORTSMAN 500”, RH (AC)
Decal, Warning, AWD Switch, White
Decal, Front Cover, “New Break Up” (AC)
Ref. Part No.
9 7172687
7172688
10 7172562
11 7078465
12 7079672
13 7172564
14 7172711
7172712
15 7172560
16 7172561
17 7172566
18 7172748
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH
Decal, Drain Recoil
Logo, Polaris Star
Decal, Foot Brake
Decal, Warning, Override, AWD
Decal, Tankside, “500”, LH (Not on AC)
Decal, Tankside, “500”, RH (Not on AC)
Decal, Warning, General, CPSC
Decal, Discretional Warning
Decal, Passenger Warning
Decal, Tire Pressure/Load
7/04
A10
COOLING SYSTEM
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
8
1
25
2
24
23
10
5
3
26
5
6
4
22
27
21
20
6
7
8
19
6
18
19
E 2004 Polaris Sales Inc.
17
9
10
13
11
12
16
14
15
12
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
7517975
2410383
1240044
5412402
7512084
7080826
5412405
7080696
5412404
5521550
7080851
7517386
7080138
7080492
Qty. Description
4
1
1
1
4
4
1
2
1
2
1
3
1
1
Screw
Asm., Fan and Motor
Cap, Pressure
Neck, Filler
Screw
Clamp
Hose, Filler Neck
Clamp
Hose, Engine, Lower
Guard, Hose, Plastic
Clamp, Hose
Screw
Cable Tie
Cable Tie
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
5247047-067
5410584
7515179
1240152
5411975
8450003-1525
7052065
5431673
5433774
5810279
5430743
5412403
5246754-067
Qty. Description
1
2
2
1
2
1
1
1
1
1
1
1
1
Bracket, Radiator, Lower
Bushing, Mount, Lower
Screw
Radiator
Asm., Grommet and Insert
Line, Fuel
Fitting, Barbed, 90 Degree
Tank, Surge
Plug, Cap
Gasket, Overflow Cap
Cap, Overflow, Drilled
Hose, Engine, Upper
Bracket, Radiator, Lower
7/04
A11
EXHAUST SYSTEM
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
6
5
4
3
2
1
7
E 2004 Polaris Sales Inc.
8
13
14
12
9
15
11
10
4
17
8
12
16
7
5
2
1
3
12
13 14
18
17
12
15
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
7542324
7555716
5410436
7555863
5010192
5241663
5412508
7515316
1261042-029
Qty. Description
3
3
3
3
3
1
3
3
1
Nut, Nylok
Washer, Flat
Washer, Rubber
Washer
Bushing
Bracket, Silencer, Frame
Dampener, Vibration
Bolt, Carriage
Silencer, Exhaust
Ref. Part No.
10
11
12
13
14
15
16
17
18
7512666
7556230
7041804
7515197
7555935
5248727
1261246-029
5243518
1261043-029
Qty. Description
1
1
4
4
4
2
1
2
1
Bolt
Washer, Clean Out
Spring, Exhaust
Screw
Washer
Shield, Heat, Exhaust
Pipe, Exhaust
Seal, Exhaust
Manifold
9/04
A12
ENGINE MOUNTING
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
32
33
E 2004 Polaris Sales Inc.
32
35
32
1
3
32
2
32
33
4
32
34
5
8
33
6
9
10
7
14
9
20
31
30
11
29
12
13
28
27
26
25
24
23
22
16
14
17 18
15
14
21
14
20
19
14
A13
ENGINE MOUNTING
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
Qty. Description
1
2
3
4
5
6
7
8
8450003-1525
5247155
3084205
7542105
7558203
3110050
7542143
-------
AR
1
2
2
2
2
2
1
9
10
11
12
13
14
15
16
17
18
19
20
8360009-600
7051011
5412487
7080511
4010895
7547263
5224658-067
3110046
7555815
7555797
5245043
3110044
AR
1
1
1
1
8
1
2
2
2
1
2
Line, Fuel
Strap, Carburetor Mount
Screw and Washer
Nut
Washer
Mount, Carb
Insert
Asm., Carburetor
(See Carburetor Pg. D8, Ref. 21)
Line, Fuel
Valve, Check Vent
Boot, Clutch Intake
Clamp, Narrow Band
Cable, Black, Frame/Engine
Nut, Flange Lock
Strap, Frame Support
Mount, Rubber, Front
Washer
Washer
Bracket, Torque Stop
Mount, Rubber, Top
Ref. Part No.
21 5241150
22 7518415
23 TBA
24
25
26
27
28
29
30
31
32
33
34
35
5430261
7575202
7512566
5210748
3082038
5241453
7552901
7512315
7080003
8450103
2530009
8450040-600
Qty. Description
1 Mount, Engine, Front
2 Screw
1 Engine, Short Block (EH50PLE135)
NOTE: The Short Block assembly
contains a crankcase assembly, cylinder & cylinder head assembly and a
piston & crankshaft assembly. Prior
authorization is required for warranty
consideration.
1 Bushing
1 Washer, Interlock
1 Bolt
1 Washer, Flat
1 Asm., Bolt and Washer
1 Mount, Engine, Top
2 Washer, Spring Lock
2 Bolt
8 Clamp, Hose, Red
AR Line, Fuel
1 Filter
AR Line, Fuel
7/04
A14
AIR BOX
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
8
6
E 2004 Polaris Sales Inc.
9
7
5
10
1
4
2
3
11
6
12
13
26
12
14
25
12
24
15
23
22
21
17
19
16
12
18
20
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
5811633
7080595
7080413
5811482
5432868
5242044
5411422
7517317
5433293
5811626
5433387
7080699
8450073-600
Qty. Description
1
1
2
1
1
6
1
4
1
1
1
4
AR
Filter, Precleaner Sleeve
Filter, Air Intake
Clamp, Narrow Band
Seal, Air Box Cover
Cover, Air Box
Clip, Air Box
Gasket, Intake
Screw
Duct, Air Inlet
Seal, Foam
Box, Air
Clamp, Hose
Line, Breather
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
7080913
5411858
7080694
2530029
5412284
5433847
5411668
5432377
8450059-150
7080650
5811650
7558301
7515179
Qty. Description
1
1
1
1
1
1
1
1
AR
1
1
2
2
P-Clamp
Hose, Breather
Clamp
Filter, Breather
Boot, Carburetor
Sleeve
Line, Breather
Plug, Trap
Line, Fuel
Clamp, Hose
Foil, Air Box
Washer, Flat
Screw
7/04
B1
FUEL TANK
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
9
E 2004 Polaris Sales Inc.
1
8
10
11
2
6
4
3
12
13
7
5
14
15
16
22
21
20
17
18
19
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 7517685
2 5247184
5247185
3 5812265
4 8360009-600
5 5431053
6 5433687
7 5812123
8 7052159
9 5432559
10 7517505
11 5432733
Qty. Description
2
1
1
1
AR
1
1
1
1
1
1
1
Screw
Bracket, Fuel Cover Mount, LH
Bracket, Fuel Cover Mount, RH
Seal, Foam
Line, Fuel
Vent, Tank
Cap, Gas Tank
Gasket, Fuel Cap
Valve, On/Off
Knob, Fuel Valve
Screw
Nut, Fuel Valve
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
22
7080003
8450103
7080492
7518257
2410554
5810858
7052363
7515136
5812005
5812004
2520403
Qty. Description
4
AR
1
5
1
1
1
2
1
1
1
Clamp, Hose, Red
Line, Fuel
Cable Tie
Screw
Sender, Fuel
Gasket
Fitting, Fuel Outlet
Screw
Foil, Tank
Foil, Tank
Asm., Fuel Tank w/Sender (Incl. 15-21)
7/04
B2
OIL TANK
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
E 2004 Polaris Sales Inc.
2
3
4
14
15
12
13
2
18
16
17
5
6
15
7
8
9
14
11
10
12
13
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
5411668
7080699
5434574
8450073-34
7080474
8450096-25
7512017
7080693
7081026
Qty. Description
1
2
1
1
2
1
1
1
1
Line, Breather
Clamp
Dipstick
Hose, Breather
Clamp
Line
Screw
Clamp
Clamp
Ref. Part No.
10
11
12
13
14
15
16
17
18
7052326
5412507
5333204
5410828
7512242
7558301
7051524
5850135
1261176
Qty. Description
1
1
2
2
2
2
1
1
1
Screen, Oil Filter, 90 Degree
Grommet
Bushing, Mounting
Grommet
Screw
Washer, Flat
Plug
Washer, Nylon
Tank, Oil
7/04
B3
CONTROLS
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
1
2
3
4
6
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
2010238
1 7517899
2 2202725
3 2201836
Qty. Description
Ref. Part No.
1 Asm., Master Cylinder
2 Screw, Torx
1 Kit, Master Cylinder Cap
(Incl. Cap, Screws, Sight, Gasket)
1 Kit, Master Cylinder Park Brake Lever
(Incl. Lever, Spring)
4 2201833
5 2202410
6 2201835
Qty. Description
1 Kit, Master Cylinder Clamp
(Incl. Clamp, Screws)
1 Kit, Piston
(Incl. Piston, Seals, Boot, Spring)
1 Kit, Master Cylinder Lever
(Incl. Pin, Lever, Clip)
7/04
B4
FRONT BRAKE
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
2
3
E 2004 Polaris Sales Inc.
11
4
5
6
7
8
10
9
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
1910841
1910842
7515489
5134639
5134640
1930642
5410494
1930665
Qty. Description
1
1
1
1
1
1
1
1
Asm., Brake Caliper, LH (Incl. 1-7,9,10)
Asm., Brake Caliper, RH (Incl. 1-7,9,10)
Screw, Socket Set
Caliper, Brake, LH
Caliper, Brake, RH
Kit, Front Brake Boot
Boot, Pin Seal
Kit, Piston and Seal (Incl. 6-7)
Ref. Part No.
5
6
7
8
9
10
11
5410780
5410779
5132294
2202412
1910411
5410495
7080352
Qty. Description
1
1
1
1
1
1
1
Ring, Molded Square (.103 x .134)
Ring, Molded Square (.094)
Piston, Brake, Long
Kit, Front Brake Pad
Mount, Caliper
Boot, Bushing
Screw, Bleeder
7/04
B5
FRONT BRAKE LINES
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
1
2
3
3
4
10
9
8
5
6
2
7
2
1
1
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
5410988
1910499
1910883
7052292
1910839
Qty. Description
6
3
1
1
1
Seal
Bolt, Banjo
Line, Brake, Stainless Steel
Fitting, Cross
Line, Brake, Right Front Stainless Steel
Ref. Part No.
6
7
8
9
10
8360031-34
7080138
1910838
7512024
4110164
Qty. Description
1
4
1
2
1
Conduit
Cable Tie
Line, Brake, Left Front w/Fittings
Screw
Switch
7/04
B6
REAR CALIPER
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
2
E 2004 Polaris Sales Inc.
1
3
4, 5
3
5
5
3
4, 5
6
7
1, 3
1
1, 3, 7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1910690
1 2201873
2 1910538
3 2201870
Qty. Description
1
1
2
1
Ref. Part No.
Asm., Caliper
Kit, Anvil Body
Fitting, Bleed, Compact
Kit, Slide Bolt
4
5
6
7
2201872
2201869
1910529
2202414
Qty. Description
1
1
1
1
Kit, Seal
Kit, Piston and Seal
Bracket, Caliper
Kit, Brake Pad
3/04
B7
REAR MASTER CYLINDER/FOOT PEDAL
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
6
E 2004 Polaris Sales Inc.
5
3
11
12
7
4
13
2
14
10
8
1
2
9
4
25
27
26
15
16
18
17
20
22
23
21
21
20
19
24
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
2202708
2202660
1910690
5410988
1910760
1910499
7670126
7517756
7080138
7512024
7080499
7080003
7542153
1930854
7512240
Qty. Description
1
1
1
4
1
2
1
1
3
1
1
2
1
1
1
Kit, Brake Line, Rear (Incl. 16)
Kit, Brake Line, Rear (Incl. 3)
Asm., Caliper
Seal
Line, Brake, Caliper, Rear
Bolt, Banjo
Clip, Retaining
Screw
Cable Tie
Screw
Clamp
Clamp, Hose
Nut
Reservoir, Brake, Rear
Screw
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
1910315
7042291
1910765
1910790
7512122
7041750
7555919
5433189
7512247
1910814-067
7661401
7512365
7552901
7558402
Qty. Description
1
1
1
1
2
1
2
2
2
1
1
2
2
2
Hose, Reservoir
Spring, Park Lockout
Line, Rear Brake
Master Cylinder, Brake, Rear
Nut, Nylok
Spring
Washer
Bushing, Pivot, Pedal
Screw
Pedal, Brake
Pin, Cotter
Screw
Washer, Spring Lock
Washer, Flat
7/04
B8
CONTROLS - THROTTLE ASM./CABLE
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
E 2004 Polaris Sales Inc.
2
3
4
5
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5410193
5434113
5411439
7081181
Qty. Description
1
1
1
1
Ref. Part No.
O-Ring
Cover
O-Ring
Cable, Throttle
5 2010230
2010250
6 2010191
Qty. Description
1 Asm., Throttle Control, AWD
(Incl. 6)(If built before 10/04/04)
1 Asm., Throttle Control, AWD
(Incl. 6)(If built after 10/04/04)
1 Asm., Throttle Clamp
7/04
B9
FRONT DRIVE SHAFT
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
2
3
4
5
1
3
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1380234
1 7670092
2 1590395
3 7710557
Qty. Description
2
2
2
2
Asm., Drive Shaft, Front
Circlip
Joint (CV, Inner)
Circlip
Ref. Part No.
4 2202826
5 2201015
6 1590396
Qty. Description
2 Kit, Boot
(Inner)(Incl. Clamps and Grease)
1 Kit, Boot
(Outer)(Incl. Clamps and Grease)
1 Joint, CV (Outer)
7/04
B10
REAR DRIVE SHAFT
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
1
2
3
4
4
5
10
6
2
7
8
9
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1380240
1
2
3
4
1590325
1350044
1350046
1350045
Qty. Description
2 Asm., Drive Shaft, Rear
(Incl. 1-8)(If built after 11/24/03)
1 CV Joint
2 Clamp, Large
1 Grease, 30g
2 Boot
Ref. Part No.
5
6
7
8
9
10
1350043
1350047
1590281
1350042
2201374
2201373
Qty. Description
2
1
1
1
1
1
Clamp, Small
Grease, 50g
Joint, Plunging
Ring, Spring
Kit, Boot (Gear Side)
Kit, Boot (Wheel Side)
7/04
B11
PROP SHAFT
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
3
E 2004 Polaris Sales Inc.
4
5
2
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1380233
1 3260133
2 2202015
3 3260131
Qty. Description
1
1
2
1
Asm., Shaft, Prop, Front
Yoke, Gear Case, Front
Kit, Cross and Bearing
Yoke, Prop Shaft, Transmission
Ref. Part No.
4 7080424
5 5411092
6 7661913
Qty. Description
1 Fitting, Lubrication
1 O-Ring
1 Pin, Spring
7/04
B12
FRONT STRUT
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
16
5
1
2
6
3
7
22
4
8
21
17
11
20
19
18
9
16
11
13
14
15
11
10
12
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7547104
7555749
5810291
5432872
5132062
5432871
5243364
7042299-067
5412665
7515339
7558402
5134154
5134155
Qty. Description
2
2
2
2
2
2
2
2
2
4
10
1
1
Nut, Nylok
Washer
Spacer, Rubber
Ball, Pivot, Top
Spacer
Ball, Pivot, Bottom
Retainer, Spring
Spring, Compression
Bumper
Bolt
Washer, Flat
Hubstrut, LH
Hubstrut, RH
Ref. Part No.
Qty. Description
13
14
15
16
17
7710507
3514342
7080306
7542324
-------
2
2
2
4
1
18
19
20
21
22
7552901
7512365
7080367
5211115
7041762
4
4
2
2
2
Ring, Retaining
Bearing, Hubstrut
Fitting, Lubrication
Nut, Nylok
Asm., Front Brake Caliper, LH
(See Front Brake Pg. B5 for Details)
Washer, Spring Lock
Screw
Clamp, Rubber Coated
Washer
Strut, Front
9/04
B13
FRONT WHEEL
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
8
9
7
E 2004 Polaris Sales Inc.
6
4
2
5
3
10
1
12
11
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 5412660
5412516
2 1520269-067
1520269-486
3 5411164
4 7661401
5 7556004
6 5134310
Qty. Description
2
2
2
2
2
2
2
2
Tire, Front, 26x8R12
Tire, Front, 25x8-12 (FB)
Rim, Front, Black (AH)(AC)
Rim, Front, Silver (AB)(AG)(FB)
Cover, Dust
Pin, Cotter
Washer
Hub
Ref. Part No.
7
8
9
10
11
12
7515513
5244314
7512325
7542810
1525017
7547237
Qty. Description
8
2
8
2
2
8
Stud
Disc, Brake
Bolt
Nut, Slotted
Valve, Rim
Nut
7/04
B14
HANDLEBAR and HEADLIGHT POD
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
E 2004 Polaris Sales Inc.
2
30
6
31
32
3
29
28
35
4
6
5
33
8
7
9
27
34
26
10
13
25
22
11
24
23
12
14
15
16
21
20
17
15
19
18
C1
HANDLEBAR and HEADLIGHT POD
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 4011074
2 5435364-400
5435364-293
5435364-341
5435680-455
3 5434380
4 3280431
3280435
5 5412138
6 7511881
7 ------8
9
10
11
12
13
14
15
5843350
4122550
7080138
7670127
5410163
7080922
5433534
4011002
4010278
4010321
Qty. Description
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
2
1
1
1
1
1
Switch, Worklight
Pod, Headlight, Upper (AH)
Pod, Headlight, Upper (AB)(FB)
Pod, Headlight, Upper (AG)
Pod, Headlight, Upper (AC)
Bezel
Cluster
Cluster (FB)
Mount, Rubber
Screw
Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B9, Ref. 5)
Knob, Adjusting
Rod, Adjusting
Cable Tie
Clip, Screw
O-Ring
Nut, Choke
Cover, Key
Switch, Key, 3 Position (Incl. Key)
Blank, Key, Series 2000, 6700, 6800
Blank, Key, Series 2200, 2300, 2700,
2800 NOTE: Your key can be duplicated only by obtaining a key blank
from Polaris and having it cut by mating it with your existing key.
Ref. Part No.
Qty. Description
16 5435365-177
5435365-070
17 7517658
18 5132382
19 4010298
20 7542122
21 7081176
22 4010638
23 7517317
24 5244969-067
25 5631516
26 5631517
27 - - - - - - -
1
1
1
1
1
4
1
1
2
1
28
29
30
31
32
33
34
35
1
1
2
1
1
1
4
1
1
5432952
7517625
5433834-070
4010592
5433903
5242987-067
7515189
2410429
4831060
1
1
Pod, Headlight, Lower
Pod, Headlight, Lower (AC)
Screw
Cap
Sensor
Nut, Nylok
Cable, Choke
Receptacle, Pod Mount, 12V
Screw
Bracket, Pod Mounting
Block, Handlebar
Block, Handlebar, Pegged
Asm., Master Cylinder
(See Controls Pg. B4 for Details)
Plug
Screw, Set
Grip, Handlebar
Switch, Handlebar, Hi/Lo/Off
Spacer, Switch, LH
Tube, Handlebar
Screw
Asm., Headlamp
Bulb, Headlight
7/04
C2
TAILLAMPS/WORKLAMPS/HEADLIGHTS
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH
E 2004 Polaris Sales Inc.
1
8
10
7
9
2
6
5
4
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 2410427
2410428
2 7670054
3 7517561
4 7670112
5 2410425
2410426
Qty. Description
1
1
4
2
2
1
1
Asm., Tail/Worklamp, LH
Asm., Tail/Worklamp, RH
Nut, Speed
Screw
U-Nut
Asm., Headlight, LH
Asm., Headlight, RH
Ref. Part No.
6
7
8
9
10
4011066
4011102
4011065
4011101
4011064
Qty. Description
2
2
2
2
2
Bulb, Bumperlight
Socket, Worklight
Bulb, Worklight
Socket, Taillight
Bulb, Tail/Stop
7/04
C3
A-ARM/STRUT MOUNTING
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
24
1
2
E 2004 Polaris Sales Inc.
25
26
28
3
4
26
28
5
25
24
23
27
22
6
7
21
8
9
10
18
11
19
20
17
12
8
14
13
15
16
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 ------2
3
4
5
6
7
8
9
10
11
12
13
7080927
5211121
5410548
7512284
2202906
2202907
7542438
7661203
5435028-070
5435029-070
7512084
7517909
7556099
7547177
Qty. Description
1 Asm., Hubstrut
(See Front Strut Pg. B13, Ref. 12)
2 Joint, Ball
2 Bracket, Ball Joint
2 Boot, Rubber
4 Screw
1 Kit, A-Frame, LH (Incl. 8,24,25,27,28)
1 Kit, A-Frame, RH (Incl. 8,24,25,27,28)
2 Nut, Castle
4 Pin, Cotter
1 Shield, CV Joint, LH
1 Shield, CV Joint, RH
6 Screw
2 Bolt
4 Washer, Flat
2 Nut
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
5411920
7061054
7547028
5134242
7542711
7061034
5411291
1821498
7515415
7542439
7512492
7552603
7555832
5133806
5434551
Qty. Description
1
2
2
2
2
2
2
2
2
2
4
4
4
2
4
Boot, Seal, Rod End
Rod End, LH
Nut, Jam, LH
Tie Rod
Nut
Rod End
Boot, Seal, Rod End
Asm., Tie Rod (Incl. 20-15)
Screw
Nut, FLEXLOC
Screw
Washer, Spring Lock
Washer
Shaft, A-Arm
Bushing, A-Arm, Long
7/04
C4
STEERING POST
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
2
E 2004 Polaris Sales Inc.
1
3
10
3
4
5
6
7
1
5
10
8
9
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
7517428
5246732
5433866
1822630-067
7556162
Qty.
4
1
2
1
2
Description
Ref. Part No.
Bolt, Carriage
Bracket, Steering Post, Upper
Bushing, Steering, Upper
Post, Steering
Bushing
6
7
8
9
10
5222393
3514352
7547158
7661633
7542343
Qty.
1
1
1
1
4
Description
Flangette
Bearing
Nut
Pin, Cotter
Nut, Nylok, Flange
7/04
C5
GEAR SELECTOR
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
2
E 2004 Polaris Sales Inc.
3
4
9
11
10
5
4
6
8
5
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
5412003
7512024
5411007
7515175
7542122
1822730
Qty. Description
1
1
1
2
2
1
Cover
Screw
Knob, Gear Selector
Screw
Nut, Nylok
Asm., Linkage
Ref. Part No.
7
8
9
10
11
1013315-067
7542324
8360012-10
5435042
7518342
Qty. Description
1
2
1
2
2
Selector, Gear
Nut, Nylok
Trim, Edge
Mount, Gear Selector
Screw
7/04
C6
DRIVE CLUTCH
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
5
E 2003 Polaris Sales Inc.
1
6
4
2
7
3
8
9
16
11
14 13
15
10
5
12
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1321706
1
2
3
4
5
6
7
1520231
7556202
5631119
7541906
5431936
5020422
3585712
Qty. Description
1 Asm., Drive Clutch, Braking
(Incl. 1-10,12-14,16)
1 Clutch, Drive, One Way
1 Washer, Brass
1 Spacer
3 Nut, FLEXLOC
6 Button, Clutch, Stemless
3 Pin, Roller
1 Bearing
Ref. Part No.
8
9
10
11
12
13
14
15
16
7547130
3576510
7518062
7041157
1321457
5430945
7512266
5630710
7556204
Qty. Description
1
1
6
1
3
6
3
3
1
Nut, Jam
Cover, Bearing
Screw
Spring, Clutch
Roller and Bushing
Washer, Multilube
Bolt, Shoulder
Weight, Shift, 10 WH
Washer, PTFE
7/04
C7
DRIVEN CLUTCH
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2003 Polaris Sales Inc.
2
1
8
9
10
4
7
11
12
5
6
13
14
15
16
13
3
17
8
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 7556120
2 1322408
3
4
5
6
7
8
7556203
7552901
7515327
5220646
3211095
7710448
Qty. Description
AR Bushing
1 Asm., Driven Clutch, EBS
(Incl. 4-6,8-14,17)
1 Washer
1 Washer, Spring Lock
1 Bolt
1 Washer, Domed
1 Belt, Drive, EBS
2 Ring, Retaining
Ref. Part No.
9
10
11
12
13
14
15
16
17
5210752
5131674
7041635
5211115
3576511
3585710
7517323
1321977
5247804
Qty. Description
1
1
1
1
3
1
3
3
1
Spacer
Ramp, Stationary, Braking
Spring, Driven
Washer
Bearing, Moveable
Bearing
Screw
Roller, Taper
Plate, Driven Clutch, EBS
7/04
C8
CLUTCH COVER
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
9
7
10
8
11
6
10
4
5
12
3
1
13
2
14
15
E 2004 Polaris Sales Inc.
16
17
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
2201954
7517599
7080511
5435236
5521578
5434255-070
5410542
5434264
5411489
Qty. Description
1
5
1
1
1
1
1
1
1
Kit, Inner Clutch Cover (Incl. 14)
Asm., Bolt/Washer
Clamp, Narrow Band
Duct, Clutch Air Inlet
Seal, Cover, Clutch
Cover, Clutch, Outer
O-Ring
Plug, Drain
Boot, Duct
Ref. Part No.
10
11
12
13
14
15
7080707
5435235
7172747
7172563
7512094
-------
16 5242046
17 5410575
Qty. Description
2
1
1
1
9
3
Clamp, Narrow Band
Duct, Clutch Outlet
Decal, “Automatic Transmission”, EBS
Decal, Warning, Clutch Cover
Screw
Screw and Washer
(See Crankcase Pg. D4, Ref. 6)
1 Bracket, Clutch, Seal
1 Seal, Cover Case
7/04
C9
REAR WHEEL DRIVE
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
12
11
10
E 2004 Polaris Sales Inc.
9
8
13
6
7
5
4
3
2
1
15
14
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 5412661
5412753
2 1520457-067
1520457-486
3 5411164
4 7543005
5 5244635
6 7661404
7 7555796
Qty. Description
2
2
2
2
2
2
2
2
4
Tire, Rear, 26x11R12
Tire, Rear, 25x10-12 (FB)
Rim, Rear, Black (AH)(AC)
Rim, Rear, Silver (AB)(AG)(FB)
Cover, Dust, Hub
Nut, Castle
Disc, Brake, Rear
Pin, Cotter
Washer, Cone
Ref. Part No.
8
9
10
11
12
5134311
7515513
7710440
3585502
-------
13 7512325
14 1525017
15 7547237
Qty. Description
2
8
2
2
2
Hub, Rear Wheel
Stud
Ring, Retaining
Bearing
Carrier, Bearing, Wheel (See Rear
Suspension Pg. C12, Ref. 11)
8 Screw
2 Valve, Rim
8 Nut, Flange
7/04
C10
REAR SUSPENSION
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
4
3
2
7
1
4
5
18
3
35
37
6
8
18
36
2
9
30
29
8
26
28
32
28
18
22
29
21
31
30
8
7
20
E 2004 Polaris Sales Inc.
11
12
13
14
19
15
16
18
17
C11
24
25
27
8
9
18
26
34
33
10
36
35
23
REAR SUSPENSION
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
7518341
7542343
7555939
5434549
5334114-067
1580107-067
7517231
7555761
5432598
5020827
5134206
5631142
5434550
7552614
7555740
7517873
7515415
7542439
7043100
5630551
7043091-067
Qty. Description
6
6
2
2
1
2
4
8
8
2
2
4
8
4
4
4
2
10
2
2
2
Bolt, Flange
Nut, Nylok
Washer
Bushing, Stabilizer Tube
Bar, Stabilizer Tube
Arm, Stabilizer Bar
Screw
Washer, Flat
Bushing, Stabilizer
Rod, Linkage, Stabilizer
Carrier, Wheel Bearing
Bushing, Bearing Carrier
Bushing, Control, Lower
Washer, Lock
Washer, Flat
Bolt
Screw
Nut, Nylok
Shock, Rear
Cam, Adjusting, Spring
Spring, Compression, Rear
Ref. Part No.
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
5630885
7515433
5247345
7518364
5020826
1014868-293
1014869-293
1014868-067
1014869-067
5434551
7552603
7512492
1014174-293
1014175-293
1014174-067
1014175-067
7512084
5435008-067
5435009-067
5133806
7515472
5434548
1541802-067
Qty. Description
2
2
2
4
6
1
1
1
1
4
4
4
1
1
1
1
4
1
1
2
6
12
1
Retainer, Spring
Screw
Bracket, A-Arm Pivot
Screw
Shaft, A-Arm, Short
Arm, Control, Upper, LH
Arm, Control, Upper, RH
Arm, Control, Upper, LH (AC)
Arm, Control, Upper, RH (AC)
Bushing, A-Arm, Long
Washer, Spring Lock
Screw
Arm, Control, Lower, LH
Arm, Control, Lower, RH
Arm, Control, Lower, LH (AC)
Arm, Control, Lower, RH (AC)
Screw
Shield, Rear, LH
Shield, Rear, RH
Shaft, A-Arm
Screw
Bushing, A-Arm, Short
Support, Stabilizer
7/04
C12
ELECTRICAL/TAILLIGHT
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
19
1
18
17
16
20
2
19
3
21
22
14
24
4
5
15
23
27
26
25
13
6
11
7
12
E 2004 Polaris Sales Inc.
8
10
11
9
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 5431769
2 2202848
2200361
3 4011138
4140006
4 4011139
5 5810290
6 7512232
7 2410535
8 2410466
9 4010924
10 4011110
11 7512024
12 5246747
13 5810317
Qty. Description
1
1
1
1
1
1
3
1
1
1
1
1
4
1
1
Cover, Battery
Kit, Battery Bolt, Short
Kit, Battery Bolt, Short (FB)
Battery
Battery (FB)
Cable, Battery/Frame
Pad, Battery
Screw
Harness, Winch
Harness, Main
Module, Resistor
Module, Controller
Screw
Bracket, CDI
Pad, Rack Mount
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
7541925
7512007
7080138
4020139
7080965
7010032
5412499
7552801
7547283
7512027
4010094
4010093
7518287
4011072
Qty. Description
1
1
12
3
3
2
1
2
2
2
1
1
2
1
Nut, Nylok
Screw
Cable Tie
Clip, Rosebud
Mount, Cable Tie
Hook, Battery Strap
Strap, Battery Holddown
Washer, Spring Lock
Nut
Screw
Cable, Battery/Solenoid
Cable, Solenoid/Starter
Nut
Switch, Magnetic
7/04
C13
TRANSMISSION MOUNTING
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
E 2004 Polaris Sales Inc.
7
9
2
8
7
6
5
4
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
7518365
7517180
7518364
7080307
8450003
Qty. Description
3
3
4
1
AR
Screw
Nut, Flange
Screw, Flange
Clamp
Line
Ref. Part No.
6
7
8
9
7515382
7542343
7515398
5221624-067
Qty. Description
1
3
2
1
Screw
Nut, Flange
Screw, Flange
Support, Transmission
7/04
C14
GEARCASE
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
24
7
25
23
E 2004 Polaris Sales Inc.
18
21
22
20
19
27
18
26
17
15
12 13
16
14
31
11
32
8
65 64
67
68
63
62
61
2
24
60
45
41 44
50
59
58
69
72
74
71
80
56
70
73
75
57
73
74
75
71
76
70
77
78
79
D1
55
54
53
51
52
38
47
48
46
16
27
40
43
14
46
37
39
41
42
35
33
6
66
34
34
9
3 5
1 2 4
35
35
10
7
36
29
28
30
49
GEARCASE
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1341450
3233906
3233826
3233827
3233829
3233869
3233831
3233878
3233832
3233524
3234059
3234066
3234065
3234064
3233364
3234063
3234086
3234062
3233268
3234058
3234057
3233247
3234056
3233846
3234087
3233874
3233749
3233018
3234061
3234060
3233699
3234080
3234088
3233915
3233851
3233718
3233176
3234067
3234068
3233855
3234070
Qty. Description
1
1
8
1
1
1
1
2
1
1
1
1
1
1
2
1
5
1
2
1
1
2
1
22
2
1
2
2
1
1
1
1
1
1
2
3
1
1
1
1
1
Asm., Gearcase
Bellcrank
Screw
Cover, Gear
Pawl, Detent
O-Ring
Shaft, Shift
Seal, Triple Lip
Gear, 31T
Tube, Vent
Gearcase, RH
Shaft, Center Drive
Bearing, Ball
Spacer
Ring, Retaining
Cover, Bearing
Screw
Gear, Output, 91T
Bearing, Ball
Sprocket, 59T
Chain
Pin, Dowel
Gearcase, LH
Screw
Plug
Seal, Dual Lip
Screw
Bearing
Deflector, Oil
Sprocket, 19T
Ring, Retaining
Drum, Shift
Baffle, Oil
Plate, Park
Washer
Bearing, Needle
Washer, Thrust
Ring, Retaining
Gear, 28T
Washer
Dog, Engagement
Ref. Part No.
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
3233850
3233854
3234071
3233852
3234069
3234074
3233019
3234075
3233036
3233357
3234092
3234076
3233788
3233106
3233305
3234085
3234084
3233265
3234083
3233917
3233839
3233548
3234081
3234082
3233076
3233830
3233961
3233834
3233835
3234091
3234077
3234073
3234089
3234078
3234090
3233432
3233433
3233434
3233431
3234079
Qty. Description
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
2
2
2
1
1
1
1
Ring, Retaining
Sprocket, 24T
Shaft, Reverse, 26T
Gear, 33T
Dog, Engagement
Bearing, Ball
Bearing
Asm., Input Shaft
Chain, Silent
Spacer
Ring, Retaining
O-Ring
Seal, Triple Lip
Ring, Snap
Bearing, Ball
Tube, Snorkel
O-Ring
Bearing, Ball
Shaft, Snorkel
Asm., Park Lockout
Gear, 16T
O-Ring
Disc, Lockout
Star, Detent
O-Ring
Spring, Compression
Nut, Lock
Ring, Retaining
Switch
Washer
Fork, Shift
Collar, Shift
Spring, Compression
Spring, Compression
Ring, Retaining
Pin, Dowel
Shoe, Chain Tensioner
Cam, Chain Tensioner
Spring, Torsion
Rail, Shift Shaft
5/03
D2
FRONT HOUSING
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
1
2
3
4
16
14
5
7
6
15
2
28
13
8
15
12
9
27
11
5
16
10
26
25
20
19
18
17
21
4
24
22
23
15
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
Qty. Description
1341497
3233955
1 3234163
2 3234159
1
1
1
1
3
4
5
6
7
8
3234161
3233926
3233953
3233928
3234166
3234167
1
2
1
1
1
1
9
10
11
12
13
------3233957
3234169
7080307
8450003
7512024
1
14
1
1
AR
1
Asm., Front Gearcase
Kit, Bolt
Screw, Set
Asm., Cover Plate
(Incl. Output Cover, Insert and Coil)
Shim, Armature Plate
Bearing, Roller Ball
Asm., Race/Output Hub (Incl. 25)
Pin, Dowel
Clutch Housing/Ring Gear
Asm., Roll Cage
(Incl. Spring and Roll Cage)
Spring
Kit, Roll
Bushing
Clamp
Line
Screw
Ref. Part No.
14 7080693
15 3233956
16
17
18
19
20
21
22
23
24
3233918
3233947
3234112
3233944
------------3233942
7518364
3233951
25
26
27
28
3233929
3234168
3234162
3234160
Qty. Description
1 Clamp
1 Kit, Minor Repair
(Incl. O-Rings and Seals)
11 Bolt
1 Cover, Input
1 Bearing, Roller Ball
1 Shaft, Pinion, 11T
1 Bushing
1 Gearcase, LH
1 Plug, Oil Fill
4 Screw, Flange
1 Asm., Drain Plug
(Incl. Plug and Washer)
1 Bearing, Needle, Roller Thrust
1 Asm., Clutch (Incl. 7-9)
1 Ring, Retaining, Internal
1 Plate Armature
7/04
D3
CRANKCASE
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
6
2
E 2004 Polaris Sales Inc.
7
5
3
8
2
1
4
9
10
23
22
15
21
16
20
18
5
14
13
12
11
17
19
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 3083669
2 3089240
3
4
5
6
7
8
9
10
11
3087266
3080676
3084840
3084205
3084839
3085525
3087154
3084842
3084845
Qty. Description
1 Bushing, Starter
1 Asm., Crankcase
(Incl. 1,4,5,7,8,15,16,17,20,21,23)
2 Pipe, Knock
1 Bearing, Ball
2 Pin, Dowel
3 Screw and Washer
1 Seal, Oil
1 Pipe, Air Breather
1 Fitting, Oil Inlet
1 Union
1 Plug
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
22
23
D4
3084846
3084844
3086810
3084834
3084835
3084841
3082956
3086749
3084837
3084836
3084847
3086838
Qty. Description
1
1
1
2
1
10
1
1
1
1
1
2
Gasket, Aluminum
Spring, One Way Valve
Valve, One Way
Bearing, Ball
Bearing, Ball
Bolt, Flange
Gasket
Plug
Seal, Mechanical
Seal, Oil
O-Ring
Pin, Dowel
8/04
CYLINDER
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
2
8
1
7
3
4
5
6
9
11
10
37
36
35
12
16
5
13
17
18
31
34
33
15
14
19
32
24
8
23
21
22
20
25
30
26
27
28
29
16
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
3084045
3081497
3081330
3084857
3084994
3084858
3084870
3084877
3084866
3084867
3085073
3085074
3084861
3084860
3084859
3084874
3084875
3085854
3084864
Qty. Description
1
1
2
2
4
2
1
10
1
1
1
1
1
1
2
10
4
1
1
Asm., Band, Adapter (Incl. 2)
Screw
Bolt, Socket Head
Pin, Straight
Guide, Valve
Seal, Intake Valve
Adapter, Water Out
Bolt, Flange
Adapter, Camshaft
O-Ring
Cover, Rocker
Gasket, Rocker Cover
Gasket
Plug
Seal, Exhaust Valve
Bolt, Flange
Bolt, Cylinder Head
Bolt, Rocker Shaft
Support, Valve Rocker Shaft
Ref. Part No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
D5
3084876
3084863
3080530
3087199
3085326
3087266
3084849
3084873
3089256
3086747
3085370
3084862
3089242
3085075
3086781
3085371
3085527
3085809
Qty. Description
4
1
2
2
2
2
1
4
1
1
1
1
1
1
2
1
1
1
Bolt
Support, Valve Rocker Shaft
Washer, Lock
Nut
Stud
Pipe, Knock
Union, Oil Pump
Bolt, Flange
Cylinder (Incl. 29)
Pipe, Elbow, 2
Gasket, Cylinder
Plug, Blind
Cover, Camshaft
Gasket, Exhaust
Bolt, Flange
Gasket, Head
Head, Cylinder (Incl. 4-6,13-15,24,31)
Adapter
8/04
CRANKSHAFT and PISTON
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
4
1
3
2
1
5
6
7
21
8
9
20
10
E 2004 Polaris Sales Inc.
11
12
15
19
16
18
13
17
14
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 3085534
2 ------3 3087221
3087222
3087223
4 3087224
3087225
3087226
5 3085815
6 3085812
7 3087090
8 3085813
9 3085343
10 3085024
11 3089570
3089678
Qty. Description
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Clip
Pin, Piston
Piston Set, Std (Incl. 1)
Piston Set, 0.25 mm O/S (Incl. 1)
Piston Set, 0.50 mm O/S (Incl. 1)
Ring Set, Piston, Std
Ring Set, Piston, 0.25 mm O/S
Ring Set, Piston, 0.50 mm O/S
Bearing, Ball
Crankshaft 2
Pin, Crank
Rod, Connecting
Bearing, Large End
Ball, Steel
Asm., Crankshaft (Incl. 6-12)
Crankshaft 1
Ref. Part No.
12 3089245
13 3086837
14 3084895
3084896
3084897
15 3240088
3084892
3084893
3084894
16 3084882
17 3085528
18 3086767
19 3083905
20 3081447
21 3240168
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Balancer, Gear 1
Shaft, Balancer
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
Spacer (0.6)
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
Sprocket 1
Nut, Slit
Washer
Nut, Lock
Key
Key, Woodruff
8/04
D6
CARBURETOR
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
2
22
E 2004 Polaris Sales Inc.
23
3
27
24
21
4
25
26
20
5
6
28
7
19
8
17
16
14
9
18
17 30
29
31
15
33
34
13
32
12
35
11
10
49
48
36
47
37
46
38
45
39
40
41
14
44
43
D7
42
CARBURETOR
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
3130914
3130821
3130911
3130913
3130908
3130915
3131292
3130910
3130912
3130543
3130931
3130932
3130927
3130933
3130926
3130925
3130515
3130928
3130619
3085698
3131567
3131305
3130909
3130916
3131395
Qty. Description
1
2
1
1
1
1
1
1
1
1
1
1
1
4
2
1
2
1
1
2
1
1
1
1
1
Cover, Diaphragm
Screw
Spring
Ring
E-Ring
Ring
Needle, Jet
Diaphragm
Valve, Piston
Guide, Cable
Shaft, Throttle
Ring
Spring
Screw
Washer
Case
Seal
O-Ring
Jet, Air
Screw and Washer
Asm., Carburetor (Incl. All less 20)
Jet, Needle
Block, Jet
O-Ring
Asm., Plunger
Ref. Part No.
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
3130538
3131396
3130519
3130518
------3131475
3130907
3130624
3131359
3130921
3130917
3130923
3130935
3130919
3130571
3130239
3130321
3131242
3131295
3131296
3130010
3130930
3130929
3130924
Qty. Description
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
Spring
Holder, Guide
Cap
E-Ring
Packing
Screw
Valve, Throttle, 120
Jet, Pilot, #40
Valve, Needle (1.5)
Float
Seal
Body, Float
Screw
Ring
Jet, Main #155
O-Ring
Screw, Guide
Clip
Adjuster, Cable
Washer
Spring
Cover
O-Ring
Screw
8/04
D8
INTAKE and EXHAUST
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
6
7
9
8
7
6
1
2
11
12
10
3
4
5
28
14
13
8
6
15
7
16
17
27
18
26
13
12
11
19
25
24
23
21
22
20
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3087129
3087130
3087131
3087132
3086493
3084912
3084911
3084910
3084909
3084913
3084908
3087203
3086892
3085855
Qty. Description
1
1
1
1
1
4
4
2
1
1
8
4
4
1
Plug
Gasket
Spring
Pin
Asm., Tensioner (Incl. 1-4)
Nut
Screw, Adjusting
Asm., Rocker Arm, Intake (Incl. 6,7)
Shaft, Rocker
Asm., Rocker Arm, Exhaust (Incl. 6,7)
Valve, Collet
Retainer, Spring
Spring, Valve
Camshaft (Incl. 15-18)
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
28
D9
3086838
3085348
3085076
3084899
3084914
3084916
3081657
3084915
3084924
3084917
3085349
3085412
3086448
3083361
Qty. Description
1
1
1
1
1
1
3
1
1
1
2
2
1
2
Pin, Dowel
Lever, Release
Spring, Return
Pin, Dowel
Sprocket 2
Guide, Chain
Bolt and Washer
Chain, Timing
Bolt, Pivot Lever
Lever
Valve, Intake
Valve, Exhaust
Gasket, Tensioner
Asm., Bolt and Washer
8/04
WATER PUMP
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
3
E 2004 Polaris Sales Inc.
4
1
2
1
6
9
8
5
7
10
11
7
12
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
3086774
3085857
3084940
3089246
3084942
3084935
Qty. Description
2
1
1
1
1
1
Clamp, Hose
Hose, Main
Thermostat
Asm., Thermo Sensor
Washer, Seal
Impeller
Ref. Part No.
7
8
9
10
11
12
7555998
3085077
3086840
3085351
3085359
3084877
Qty. Description
2
1
1
1
1
4
Washer, Flat
Nut, Self Lock
Gasket, Water Pump
Cover, Water Pump
Bolt, Flange
Bolt, Flange
8/04
D10
FUEL PUMP
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
2
3
2
4
1
4
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
3085275
1 3084999
2 3085356
Qty. Description
1 Asm., Fuel Pump (Incl. 1-4)
1 Screw and Washer
2 Screw and Washer
Ref. Part No.
3 3084591
4 3088170
Qty. Description
4 Screw & Washer
1 Diaphragm, Gasket Set
8/04
D11
OIL PUMP
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
E 2004 Polaris Sales Inc.
4
3
2
1
6
9
8
5
10
11
7
14
12
15
13
18
17
16
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
3084946
3084949
3084948
3088210
3087264
3084955
3085535
3084954
3084962
3087265
3084950
Qty. Description
1
1
1
1
1
2
1
2
3
1
1
Pump, Oil, Case 2
Rotor, Outer, Feed
Rotor, Inner, Feed
Asm., Oil Pump (Incl. 1-7,9-15)
Pump, Oil, Case 1
Pin, Dowel
Screw
Pin, Dowel
Bolt and Washer
Pump, Oil, Case 3
Rotor, Inner, Scav
Ref. Part No.
11
12
13
14
15
16
17
18
3084951
3084956
3084205
3084953
3085858
3087173
3085820
3084959
3084960
3084961
Qty. Description
1
1
3
1
1
1
2
AR
AR
AR
Rotor, Outer
Unit, Oil Strainer
Screw and Washer
Washer
Shaft, Pump
Gear, Pump, 2
Bolt, Flange
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
8/04
D12
OIL FILTER
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
2
3
2
5
3
2
2
3
4
E 2004 Polaris Sales Inc.
2
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 3084963
2 3084846
3 3086815
Qty. Description
1 Oil Filter
8 Gasket, Aluminum
4 Bolt, Banjo
Ref. Part No.
4 3084965
5 3084964
Qty. Description
1 Pipe, Oil Delivery 2
1 Pipe, Oil Delivery 1
8/04
D13
RECOIL STARTER
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
3
2
1
5
4
6
7
8
9
14
11
13
10
E 2004 Polaris Sales Inc.
8
12
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
3084822
3083463
3083378
3083379
3084744
3085266
3086749
3082956
Qty. Description
1
1
1
1
1
1
2
2
Reel
Spring, Return
Ratchet
Spring, Friction
Plate, Friction
Bolt and Washer
Plug
Gasket
Ref. Part No.
9
10
11
12
13
3083669
3083185
3084750
3084877
3087163
3087164
14 3085083
D14
Qty. Description
1
1
1
9
1
1
1
Bushing, Starter
Spring, Spiral
Bushing
Bolt, Flange
Asm., Recoil (Incl. 1-6,9-11,13,14)
Starter Case (Incl. 11)
Asm., Rope
8/04
STARTING MOTOR
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
3
4
2
E 2004 Polaris Sales Inc.
5
1
6
1
7
8
12
10
13
11
9
14
15
16
17
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
3084981
3084982
3088169
3083649
3084408
3085034
3082038
3085353
3085033
Qty. Description
1
1
1
2
3
1
2
1
1
Starting Motor (Incl. 1-5,7-10,12)
Washer Set
Brush, Carbon
Nut, Flange
O-Ring
Bracket, Rear
Bolt and Washer
Armature
Asm., Front Bracket (Incl. 9)
Ref. Part No.
9
10
11
12
13
14
15
16
17
3240114
3084983
3087030
3084405
7555908
3084412
3084411
3084410
3084409
Qty. Description
1
2
1
2
1
1
1
1
1
O-Ring
Asm., Bolt Set (Incl. 4)
Asm., Gear Shaft (Incl. 14-17)
Ring, Rubber
Washer, Thrust
Clip
Spring, Weight
Spring, Return
Clip
8/04
E1
MAGNETO
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
2
1
3
16
19
18 17
15
13
4
14
12
5
10
11
6
8
7
9
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
3089239
3084980
3070172
3084978
3084972
3089545
3089248
7 3081657
8 3084973
9 3089546
Qty.
1
1
1
1
1
1
1
5
1
1
Description
Coil, Ignition (Incl. 2)
Cap, Spark Plug
Plug, Spark, NGK BKR6E
O-Ring
Metal, Bearing
Asm., Plate (Incl. 5,8-15)
Plate
Bolt and Washer
Seal, Oil
Stator (Incl. 13)
Ref. Part No.
10
11
12
13
14
15
16
17
18
19
3089544
3089547
3084976
3089250
3089254
3081256
3089238
7547283
7552801
4010930
Qty.
1
3
2
1
1
1
1
2
2
1
Description
Flywheel w/Ring Gear
Screw and Washer
Screw and Washer
Band, Pulse
Coil, Pulser
Screw and Washer
CDI System
Nut
Washer, Spring Lock
Switch, Magnetic
8/04
E2
TOOL KIT
SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN
500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB
1
8
2
3
9
4
5
6
E 2004 Polaris Sales Inc.
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
3085383
2874924
1
2
3
4
2870725
3082657
3085001
3085002
Qty. Description
Ref. Part No.
1 Kit, Tool
(Incl. 2-8)(If built before 8/02/04)
1 Kit, Tool
(Incl. 2-8)(If built after 8/02/04)
1 Gauge, Tire Pressure
1 Screwdriver
1 Wrench, 8-10 Open
1 Wrench, 12-14 Open
5
6
7
8
3085568
3085569
2682572
2873647
2874858
9 9919412
E3
Qty. Description
1
1
1
1
1
1
Wrench, Box
Puller, Spark Plug (Wrench Handle)
Pouch, Tool Kit
Wrench, Torx (If built before 8/02/04)
Wrench, Torx (If built after 8/02/04)
Owner’s Manual, ‘05 Sportsmans,
4/5/6/700
7/04
PRINTED IN THE USA
PARTS MANUAL PN 9919416 and MICROFICHE PN 9919417 7/04