Sportsman 500 HO, RSE, DUSE, 2002 Parts Manual

SPORTSMAN 500 HO
Model #A02CH50AA
Model #A02CH50AB
Model #A02CH50AE
Model #A02CH50AK
SPORTSMAN 500 RSE
Model #A02CH50AC
SPORTSMAN 500 DUSE
Model #A02CH50AD
SPORTSMAN X
Model #A02CH50AJ
SPORTSMAN 500 HO FREEDOM
Model #A02CH50AL
SPORTSMAN 500 PSE HO
Model #A02CH50AM
SPORTSMAN 500
Model #A02CH50AN
DESERT SPORTSMAN 500
Model #A02CH50FA
WORKER 500
Rev. 04
Model #A02CH50EB
E 2001 Polaris Sales Inc.
PARTS MANUAL PN 9916743 and MICROFICHE PN 9918266 5/02
This page left intentionally blank.
TABLE OF CONTENTS
SPORTSMAN 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 and
SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB
Parts Manual
GEARCASE (Internal Components ) . . . . . . . . D1-2
A-ARM / STRUT MOUNTING . . . . . . . . . . . . C4

AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .
CONTROLS MASTER CYLINDER/BRAKE LINE . . . . .
CONTROLS - THROTTLE ASM./CABLE . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT and PISTON . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .
DECALS (AJ) . . . . . . . . . . . . . . . . . . . . . . . .
DECALS (AL) . . . . . . . . . . . . . . . . . . . . . . . .
DECALS (AM) . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . .
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . .
D9-10
C7
B8
B12
A10
D3
D4
D5-6
A9
E5
E6
E7
C5
C6
ELECTRICAL / TAILLIGHT . . . . . . . . . . . . . . C8
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A13-14
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A11
FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . .
FRAME MOUNTING . . . . . . . . . . . . . . . . . . .
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .
FRONT HOUSING . . . . . . . . . . . . . . . . . . . .
FRONT RACK and BUMPER MOUNTING . . .
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .
B11
C3
A5
C13
A7-8
B5
B6
E2
A12
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C12
H
HANDLEBAR and HEADLIGHT POD . . . . . . . B13-14
I
INTAKE and EXHAUST . . . . . . . . . . . . . . . . . D7
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . D14
MULTI MOUNT WINCH (AJ) . . . . . . . . . . . . . E4
O
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL TANK (If Built Before 1/02/02) . . . . . . . . .
OIL TANK (If Built After 1/02/02) . . . . . . . . . . .
D13
D12
C2
E8
P
PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B3
REAR BRAKE/FOOT PEDAL . . . . . . . . . . . .

REAR CAB and SEAT . . . . . . . . . . . . . . . . .
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . .
REAR RACK MOUNTING . . . . . . . . . . . . . . .
REAR SUSPENSION . . . . . . . . . . . . . . . . . .
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . .
RECOIL STARTER . . . . . . . . . . . . . . . . . . . .
B9-10
A3-4
B4
A6
C9-10
C11
D8
S
STARTING MOTOR . . . . . . . . . . . . . . . . . . . E1
STEERING POST . . . . . . . . . . . . . . . . . . . . . C1
T
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D11
GEARCASE (Cases and Snorkel) . . . . . . . . . . C14

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 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTSMAN 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
15
14
7
8
17
19
10
3
2
36
20
37
41
35
21
22
34
27
39
38
40
18
12
11
16
13
33
23
31
32
25
27 26
30
29
24
28
27
25
26
A3
REAR CAB and SEAT

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.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Qty. Description
Ref. Part No.
7661645
7511930
7555792
5811107
5432117-359
5432117-136
5433282-283A
5433941-315A
5432117-053
5432117-341
5432117-317
5432117-177
5432117-333
5434393-375A
7541925
5224592
5811308
7512242
7555859
7512085
5431786
7621403
5211033
1040387
7041370
2682441-316
2682441-070
10
2
4
1
1
1
1
1
1
1
1
1
1
1
4
1
1
4
4
2
1
2
2
1
1
1
1
18
19
20
21
22
23
24
5412067
7517375
5431787
5410896
7661638
5246103-067
-------
8
2
1
1
6
1
1
25
26
27
28
29
30
2683017
2683104
2681747-316
2682958-070
1
1
1
1
7552603
7512492
7542122
5432280
7517377
1013325-067
1013729-067
7078261
7517376
5432221-070
5433219-070
5811111
5811106
7079902
5811087
7512232
7517685
7670057
5431796-070
5431797-070
7
7
28
2
4
1
1
1
8
1
1
1
2
1
1
12
2
12
1
1
2683018
2683105
5811104
5811105
1
1
1
1
Rivet, T-Lock
Bolt
Washer
Foil, Rear Cab, Rear
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)
Nut, Nylok
Retainer, Seat Latch
Foil, Tape, Rear Cab
Screw
Washer, Flat
Screw
Box, Tool
Rivet
Bracket, Lever Retainer
Latch, Seat
Spring, Latch
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, Large
Foil, Seat Base, Small
31
32
33
34
35
36
37
38
39
40
41
Qty. Description
Bumper, Rubber
Screw
Cover, Tool Box
Cap, Drain
Rivet
Guard, Clutch
Front Housing
(See Front Housing Pg. C13 for Details)
Washer, Spring Lock
Screw
Nut, Nylok
Spacer, Footwell
Screw
Frame, Main (If built before 9/03/01)
Frame, Main (If built after 9/03/01)
Decal, Hitch
Screw
Footwell, Black, LH
Footwell, Black, RH
Foil, Foam, Rear Fender
Foil, Rear Cab, Front
Decal, Carb/Filter Information
Foil, Foam
Screw
Screw
Nut, U-Type Speed
Guard, Mud, Rear, LH
Guard, Mud, Rear, RH
5/02
A4
FRONT CAB
7
8
18
17
13
14
10
16
15
12 11
Ref. Part No.
1 5811491
2 5810996
5812329
3 2632289-359
2632289-136
2632317-283
2632288-315
2632289-053
2632289-341
2632289-317
2632289-177
2632289-333
2632481-375
2620085-359
2620085-136
2632065-283
2632272-315
2620085-053
2620085-341
2620085-317
2620085-177
2620085-333
2632480-375
4 7512232
5 2632299-359
2632299-136
2632306-283
2632271-315
2632299-053
2632299-341
2632299-317
2632479-375
2632299-288
2632299-177
2632299-333
Qty. Description
1 Foil, Side Panel, Gen. IV, RH

1 Foil, Foam, Side Panel
(If built before 6/18/01)
1 Foil, Foam, Side Panel
(If built after 6/18/01)
1 Panel/Foil, Olive Green, LH (AA)
1 Panel/Foil, Porsche Red, LH (AB)(EB)
1 Panel/Foil, Mossy Oak, LH (AC)
1 Panel/Foil, Wetlands Camo, LH (AD)
1 Panel/Foil, Yellow, LH (AE)
1 Panel/Foil, Sonic Blue, LH (AJ)(AL)
1 Panel/Foil, Gun Metal, LH (AK)
1 Panel/Foil, Black Metallic, LH (AM)
1 Panel/Foil, Sterling Spruce, LH (AN)
1 Panel/Foil, C.E.W. Camo, LH (FA)
1 Panel/Foil, Olive Green, RH (AA)
1 Panel/Foil, Porsche Red, RH (AB)(EB)
1 Panel/Foil, Mossy Oak, RH (AC)
1 Panel/Foil, Wetlands Camo, RH (AD)
1 Panel/Foil, Yellow, RH (AE)
1 Panel/Foil, Sonic Blue, RH (AJ)(AL)
1 Panel/Foil, Gun Metal, RH (AK)
1 Panel/Foil, Black Metallic, RH (AM)
1 Panel/Foil, Sterling Spruce, RH (AN)
1 Panel/Foil, C.E.W. Camo, RH (FA)
10 Screw
1 Cab, Front, Olive Green Metallic (AA)
1 Cab, Front, Porsche Red (AB)(EB)
1 Cab, Front, Mossy Oak (AC)
1 Cab, Front, Wetlands Camo (AD)
1 Cab, Front, Yellow (AE)
1 Cab, Front, Sonic Blue (AJ)
1 Cab, Front, Gun Metal (AK)
1 Cab, Front, Camo (FA)
1 Cab, Front, Blazing Red (AL)
1 Cab, Front, Black Metallic (AM)
1 Cab, Front, Sterling Spruce (AN)
Ref. Part No.
6 5432088-359
5432088-136
5433290-283A
5433944-315A
5432088-053
5432088-341
5432088-317
5434395-375A
5432088-288
5432088-177
5432088-333
7 7670085
8 7670057
9 7517312
10 7670135
11 7555931
12 7542122
13 7621509
14 5244913-067
5244914-067
15 5431798-070
5431799-070
16 7541925
17 7555792
18 7512085
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
2
10
2
4
2
2
3
1
1
1
1
2
2
2
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)
Clip, Spring
Nut, U-Type Speed
Screw
Nut, Speed
Washer, Flat
Nut, Nylok
Rivet, Plasti Loc
Guard, Splash, LH
Guard, Splash, RH
Guard, Mud, Front, LH
Guard, Mud, Front, RH
Nut, Nylok
Washer
Screw
5/02
A5
REAR RACK MOUNTING

2
3
4
15
14
(After 4/19/02)
17
16
14
5
6
9
7
12
11
12 13
10
8
Ref. Part No.
1 2871501
2
3
4
5
6
7
8
9
10
2871501-156
7517686
7517685
2670174-070
7542324
5243378-067
1013913-156
5433305
7515321
7670096
1040524-067
1040525-067
Qty. Description
1 Kit, Rack Extender, Rear

(Incl. 15)(AC)(AD)(FA)(AL)
1 Kit, Rack Extender, Rear (Incl. 15)(AM)
2 Screw
4 Screw
1 Asm., Rack, Rear, w/Warning Decal
8 Nut, Nylok (If built before 9/03/01)
1 Bumper, Rear (AC)(AD)(FA)(AL)
1 Bumper, Rear (AM)
4 Cap (AC)(AD)(FA)(AL)(AM)
4 Bolt (AC)(AD)(FA)(AL)(AM)
2 Nut, Chimney
1 Mount, Front, Rear Rack, LH
1 Mount, Front, Rear Rack, RH
(If built between 9/03/01 and 2/19/02))
Ref. Part No.
11
12
13
14
Qty. Description
5333332-067
7558402
7515385
1012894-067
4
8
4
1
1040490-067
1013724-067
15 7517208
16 5334092
17 7517983
6
2
2
Spacer (If built before 9/03/01)

Washer, Flat (If built before 9/03/01)
Screw (If built before 9/03/01)
Support, Rear Rack
(AC)(AD)(FA)(AL)(AM)
Support, Rear Rack
(AA)(AB)(AE)(EB)(AJ)(AK)(AN)
Support, Rear Rack
(AA)(AB)(AE)(EB)(AJ)(AK)(AN)
Screw
Spacer (If built after 9/03/01)
Screw (If built after 9/03/01)
2/02
A6
FRONT RACK and BUMPER MOUNTING

3
1
12
4
A02CH50FA Only
2
5
11
13
5
14
6
7
5
10 15
4
8
22
21
10
9
17
20
23
8 19 18
10
24
25
26
26
27
After 12/12/01
28
37
34
29
36
A02CH50AJ and A02CH50AL
30
31 32
34
35
A7
23
33
16
FRONT RACK and BUMPER MOUNTING

Ref. Part No.
1 1040526-067
2871499-156
2 7517685
3 2670180-070
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
7517208
7515399
2200775
7542324
7555954
5432155-070
7558402
5432387
7556175
1013461-067
5434001-070
7515306
5434002-067
7512093
7515391
7515390
1013744-067
1013746-067
Qty. Description
1 Extender, Front Rack, Low

(AC)(AD)(FA)
1 Kit, Extender, Front Rack, Low (AM)
4 Screw
1 Asm., Front Rack
(Incl. Warning Decal)
4 Screw
8 Screw
1 Kit, Front Rack Mount
4 Nut, Nylok
4 Washer
1 Bumper
4 Washer, Flat
4 Insert (FA)
2 Washer (FA)
1 Support, Front Rack (FA)
1 Bumper (FA)
4 Screw (FA)
1 Panel (FA)
2 Screw (FA)
2 Screw
2 Screw
1 Support, Front Rack, LH
1 Support, Front Rack, RH
Ref. Part No.
Qty. Description
21 7512232
22 2431014
2431015
4030059
23 7512329
24 5810467
25 5244729-067
5244730-067
26 5244731-067
1013772-067
27 7621330
28 5240591-067
4
1
1
2
4
1
1
1
1
1
7
1
29 5433305
30 5243377-067
5243377-156
31 7515547
32 5211633-067
33 5241224-067
34 7512097
35 7556034
36 7670094
37 5433923
5433924
4
1
1
2
1
1
6
6
6
1
1
Screw
Headlight, LH
Headlight, RH
Bulb, Replacement, 27W
Bolt
Plug, Frame
Extension, Frame, LH
Extension, Frame, RH
Guard, Brush (If built before 12/12/01)
Guard, Brush (If built after 12/12/01)
Rivet (If built before 12/12/01)
Grill, Brush Guard
Cap, End, Bumper (AC)(AD)(AL)(AM)
Bumper, Front (AC)(AD)(AL)
Bumper, Front (AM)
Screw (AJ)(AL)
Plate, Back Mount (AJ)(AL)
Hitch, U-Bolt (AJ)(AL)
Screw
Washer
Nut, U-Type
Shield, Side, Radiator, LH
Shield, Side, Radiator, RH
5/02
A8
DECALS
SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTSMAN 500 DUSE A02CH50AD and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB
4 5
6
7
(Decal Pg. for AJ see Pg. E5)

(Decal Pg. for AL see Pg. E6)
23
18
(Decal Pg. for AM see Pg. E7)
10
22
11
12
13
14
RH
16
15
17
21
20
19
18
LH
Ref. Part No.
1 7170021
2 7078443
3
4
5
6
7
8
7078452
7170593
7170594
7078253
7079780
7078003
7079920
7079979
7079921
7079917
7079931
7079513
7079514
7170062
7078465
7079773
7079916
9 7078045
10 7170018
7170019
Qty. Description
1 Decal, Warning, Front and Rear Rack

2 Decal, POLARIS
(AA)(AB)(AC)(AD)(EB)(AK)(FA)
2 Decal, POLARIS (AE)
1 Decal, POLARIS, Side Panel, LH (AN)
1 Decal, POLARIS, Side Panel, RH (AN)
2 Decal, Age Warning
1 Decal, Warning, Switch, AWD
1 Decal, Headlight Adjustment
2 Decal, Tank Side (AA)(AN)
2 Decal, Tank Side (AB)
2 Decal, Tank Side (AC)(AD)
2 Decal, Tank Side (AE)
2 Decal, Tank Side (EB)
1 Decal, Tank Side, LH (AK)
1 Decal, Tank Side, RH (AK)
2 Decal, Tank Side, (FA)
1 Logo, Polaris Star
1 Decal, POLARIS
(AA)(AB)(AC)(AD)(EB)(AK)(FA)(AN)
1 Decal, POLARIS (AE)
1 Decal, Liquid Cooled, Radiator
1 Decal, RSE Legend, Pod (AC)
1 Decal, DUSE Legend, Pod (AD)
Ref. Part No.
11
12
13
14
15
16
17
18
19
20
21
22
23
Qty. Description
7079520
7079604
7079977
7079959
1
1
1
1
7079960
7079927
7077920
7079084
7079928
7079929
7079918
7079919
7079961
7079962
7079515
7079516
7079085
7079083
7079926
7078577
7077749
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
Decal, Ignition
Decal, Warning, Override, AWD
Decal, IRS, Rear
Decal, POLARIS, Rear (AA)(AB)(AC)
(AD)(EB)(AK)(FA)
Decal, POLARIS, Rear (AE)
Decal, Red Reflector
Decal, Passenger Warning
Decal, Tire Pressure
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)
Decal, Discretionary Warning
Decal, Warning, General, CPSC
Decal, Amber Reflector
Decal, Drain Recoil
Decal, Warning, Park Lock (EB Only)
5/02
A9
COOLING SYSTEM
2
3
15
9
10
16
17
11
13
20
19
14
22
21
12
36
18
37
38
30
11
33
27
28
32
34
20
25
14
35
39
23 24
26
29
31
30
40
41
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
7080807
1240044
5433364
5243505
7661637
5433948
5411783
7080827
7512232
5411632
7080826
7517659
2410123
7670111
7547069
3110032
5020572
7080492
5433059
7512084
4010161
Qty. Description
1
1
1
1
3
1
1
2
2
1
2
4
1
4
2
2
2
1
1
2
1
Clamp, Hose
Cap, Pressure
Filler, Coolant
Bracket, Filler, Coolant
Rivet
Flexguard
Hose, Engine, Upper
Clamp, 1
Screw
Hose, Filler Neck
Clamp
Screw
Asm., Fan and Motor
U-Clip
Nutsert
Mount, Rubber
Spacer
Cable Tie
Shroud, Fan
Screw
Sensor, Thermal
Ref. Part No.
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
1240045
7552801
7512240
5433317
5410607
7052296
5410584
5243503-067
7517386
7080890
5411782
5521550
7080851
7080696
5430743
5810279
5433774
5431673
8450003-1525
7052065
Qty. Description
1
2
2
1
4
1
2
1
3
1
1
1
1
1
1
1
1
1
1
1
Radiator
Washer, Spring Lock
Screw
Cover, Radiator
O-Ring
Valve, Radiator/Coller Drain
Bushing, Mount
Bracket, Radiator, Lower
Screw
Tie, Panel
Hose, Engine, Lower
Guard, Hose
Clamp, Hose
Clamp, Hose
Cap, Overflow, Drilled
Gasket, Overflow Cap
Plug, Cap
Tank, Surge
Line, Fuel
Fitting, Barbed, 90 Degree
5/02
A10
EXHAUST SYSTEM
1
2
3
4
5
6
8
5
8
9
16
10
15
11
12
13
8
14
13
12
15
16
Ref. Part No.
1
2
3
4
5
6
7
8
7542324
7555716
5410436
7555863
5010192
5241663
7512329
5410241
Qty. Description
3
3
3
2
3
1
2
3
Nut, Nylok
Washer, Flat
Washer, Rubber
Washer
Bushing
Bracket, Silencer, Frame
Bolt
Dampener, Vibration
Ref. Part No.
9
10
11
12
13
14
15
16
7515316
1261042-029
7512666
5243518
7041804
1261040-029
5241678
7515106
Qty. Description
3
1
1
2
4
1
2
4
Bolt, Carriage
Silencer, Exhaust
Bolt
Seal, Exhaust
Spring, Exhaust
Pipe, Exhaust
Shield, Heat, Exhaust
Screw
5/02
A11
FUEL TANK
1
2
6
5
7
8
20
19
18
10
17
16
14
15
12
11
14
13
Ref. Part No.
1
2
3
4
5
6
7
8
9
5433687
5812123
5812210
8360009-600
5431053
7512247
7552801
7558301
5222154-067
5222155-067
5246069-067
5246070-067
Qty. Description
1
1
1
AR
1
2
2
2
1
Cap, Gas Tank

Gasket, Fuel Cap
Seal, Foam
Line, Fuel
Vent, Tank
Bolt
Washer, Spring Lock
Washer, Flat
Bracket, Mounting, Rear, LH
1 Bracket, Mounting, Rear, RH
(If built before 7/23/01
1 Bracket, Mounting, Rear, LH
1 Bracket, Mounting, Rear, RH
(If built after 7/23/01
Ref. Part No.
10
11
12
13
14
15
16
17
18
19
20
7547069
5810317
7052150
8450040-600
7080003
7052149
7517505
5432559
5432733
7052161
2520144
Qty. Description
2
1
1
AR
4
1
1
1
1
1
1
Nutsert
Pad, Fuel Tank Bracket (FA)
Fitting, Fuel Outlet, Main
Line, Fuel
Clamp, Hose, Red
Fitting, Fuel Outlet, Reserve
Screw
Knob, Fuel Valve
Nut, Fuel Valve
Valve, 3-Way
Asm., Fuel Tank (Incl. 12,15)
5/02
A12
ENGINE MOUNTING
9
3
11
7
8
6
5
39
14
15
37
18
13
10
11
19
22
20
17 18
34
24
33
23
27
30
32
22
25
31
22
17
16
22
19
10
38
35 36
12
29
28
A13
26
21
ENGINE MOUNTING
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
7517756
5243829
7546601
8450040-600
7080003
2530009
8360009-600
7051011
8450003-1525
3110071
7552605
7542105
5245055
7547069
4010132
5241453
7552901
7512315
3110044
7080539
7621462
7547108
Qty. Description
2
1
2
AR
8
1
AR
1
AR
2
2
2
1
2
1
1
2
2
2
1
1
8
Screw
Strap, Fuel Pump
Nut, Nylok
Line, Fuel
Clamp, Hose, Red
Filter
Line, Fuel
Valve, Check
Line, Fuel
Mount, Rubber
Washer, Split Lock
Nut
Strap, Carburetor Mount
Nutsert
Cable, Ground, Engine
Mount, Engine, Top
Washer, Spring Lock
Bolt
Mount, Rubber, Top
Clamp, Nylon
Rivet
Nut, Flange Lock
Ref. Part No.
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
5224658-067
4010095
4010093
5410421
7080511
3110046
7555815
3084205
7081008
5245043
7515417
5241150
3080285
3080530
1261043-029
3085822
39 7080967
Qty. Description
1
1
1
1
1
2
2
1
1
1
2
1
2
2
1
1
Strap, Frame Support

Cable, Black, Battery/Engine
Cable, Solenoid/Starter
Boot, Clutch Intake
Clamp, Narrow Band
Mount, Rubber, Front
Washer
Screw and Washer
Cable, Choke
Bracket, Torque Stop
Screw
Mount, Engine, Front
Nut
Washer, Lock
Manifold
Engine, Short Block (EH50PLE013)
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 Cable, Throttle
5/02
A14
AIR BOX
SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A02CH50AK and SPORTSMAN 500 RSE A02CH50AC and SPORTSMAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN
7
5
9
3
10
11
12
13
30
14
15
17
16
29
15
28
27
18
22
26
21
13
25
23
20
24
19
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
5811633
7080595
7080413
5432601
5432868
7517541
5433293
5811626
------5411422
5811482
5433387
7080699
8450073-600
7080544
Qty. Description
1
1
2
1
1
4
1
1
1
1
1
1
4
AR
2
Filter, Precleaner Sleeve

Filter, Air Intake
Clamp, Narrow Band
Collar, Carburetor Inlet
Cover, Air Box
Screw
Duct, Air Inlet
Seal, Foam
Duct, Clutch Air Inlet (See Clutch Cover Pg. C7, Ref. 23)
Gasket, Intake
Seal, Air Box Cover
Box, Air
Clamp, Hose
Line, Breather
Clamp, Hose
Ref. Part No.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
2530029
7080913
5411858
5412004
7080511
5432858
5830128
5411668
5432377
8450059-150
7080650
5811650
7558301
7515179
5242044
Qty. Description
1
1
AR
1
1
1
1
1
1
AR
1
1
2
2
6
Filter, Breather
P-Clamp
Hose, Breather
Boot, Carb
Clamp, Narrow
Duct, Carburetor Inlet
Gasket, Carburetor Inlet Duct
Line, Breather
Plug, Trap
Line, Fuel
Clamp, Hose
Foil, Air Box
Washer, Flat
Screw
Clip, Air Box
9/01
B1
DRIVE SHAFT
10
11
12
Ref. Part No.
1
2
3
4
5
6
1380114
5222299
3260121
7670092
2201015
1380060
Qty. Description
1
1
1
1
1
1
Asm., Drive Shaft w/Sleeve (NEA)

Sleeve, Drive Shaft Seal
Clamp, Band
Circlip
Kit, Replacement Boot
Shaft, Replacement (Incl. 4)
Ref. Part No.
7
8
9
10
11
12
1380061
3260104
3260101
7661913
3260123
2200960
Qty. Description
1
1
1
2
1
2
Cardan, Replacement (Incl. 4,6,8,9)

Kit, Cross and Bearing
Yoke, Splined
Pin, Spring
Clamp, Band
Kit, Drive Shaft w/Sleeve
4/01
B2
PROP SHAFT
Ref. Part No.
1380115
1 3260133
2 3260104
3 3260136
Qty. Description
1
1
2
1
Ref. Part No.
Shaft, Prop
Yoke, Gear Case, Front
Kit, Cross and Bearing
Shaft, Prop
4 3260131
5 7080424
6 5411092
Qty. Description
1 Yoke, Prop Shaft, Transmission

1 Fitting, Lubrication
1 O-Ring
4/01
B3
REAR DRIVE SHAFT

10
Ref. Part No.
1
2
3
4
5
1380142
1590280
1350044
1350046
1350045
1350043
Qty. Description
2
1
2
1
2
2
Asm., Drive Shaft, Rear (Incl. 1-8)

CV Joint
Clamp, Large
Grease, 30g
Boot
Clamp, Small
Ref. Part No.
6
7
8
9
10
1350047
1590281
1350042
2201374
2201373
Qty. Description
1
1
1
1
1
Grease, 50g
Joint, Plunging
Ring, Spring
Kit, Boot (Gear Side)
Kit, Boot (Wheel Side)
4/01
B4
FRONT STRUT
27
26
25
24
22
20
23
11
21
12
19
10
14
18
13
12
15
17
11
16
Ref. Part No.
Qty. Description
1
2
3
4
5
6
7
8
9
10
5411608
7041761
5211115
7558402
7080367
7542324
7512365
7552901
5810439
--------
2
2
2
10
2
4
4
4
2
1
11
12
13
14
15
3554509
3554507
5222193
7080306
2410133
4
4
2
2
2
Bumper
Strut, Front
Washer
Washer, Flat
Clamp, Cable
Nut, Nylok
Screw
Washer, Spring Lock
Retainer, Casting Wire, Strut
Asm., Front Brake Caliper, RH
(See Front Brake Pg. B7)
Bearing, Tapered Roller
Bearing, Tapered Roller Cup
Sleeve, Hubstrut Seal
Fitting, Lubrication
Coil, Magnetic
Ref. Part No.
16 1820950
1820951
17
18
19
20
21
22
7041375-067
5243364
5432871
7515339
5132062
-------
23
24
25
26
27
3610028
5432872
5810291
7555749
7547104
Qty. Description
1 Asm., Hubstrut, Heavy, LH

(42mm)(Incl. 9,12-15,23)
1 Asm., Hubstrut, Heavy, RH
(42mm)(Incl. 9,12-15,23)
2 Spring, Compression
2 Retainer, Spring
2 Ball, Pivot, Bottom
4 Bolt
2 Spacer
1 Kit, Drive Shaft w/Sleeve
(See Drive Shaft Pg. B2, Ref. 12)
2 Seal, Hubstrut
2 Ball, Pivot, Top
2 Spacer, Rubber
2 Washer
2 Nut, Nylok
4/01
B5
FRONT WHEEL
11
10
12 13
14
15
16
25
24
17
19
18
20
21
23
22
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
7512325
5243676
3610019
5211148
1520281
3554506
3554507
7515523
1520243
3250028
3250010
3250032
1321814
3250030
Qty. Description
8
2
2
2
2
4
4
8
2
2
12
2
2
2
Bolt
Disc, Brake
Seal, Front Hub
Plate, Armature
Clutch, Front Hub, Elec./Mech.
Bearing, Tapered Roller Cone
Bearing, Tapered Roller Cup
Stud
Asm., Hub w/Bearing Race (Incl. 3,7,8)
Cage, Roll
Roll
Spring, Garter
Spacer
Cam
Ref. Part No.
15 7052045
16 5410947
5411952
17
18
19
20
21
22
23
24
7556004
7542810
7661401
5410470
5432611
7512027
7542459
1520269-117
1520269-067
1520519
25 1525017
Qty. Description
2 Plug, Magnetic Drain

2 Tire, 25x8-12 (AA)(AB)(AE)(EB)
2 Tire, 25x8-12
(AC)(AD)(AJ)(AK)(FA)(AL)(AM)(AN)
2 Washer
2 Nut, Slotted
2 Pin, Cotter
2 O-Ring
2 Cap, Hub
6 Screw
8 Nut, Flange Lock
2 Rim, Front, Black (AA)(AB)(AE)(EB)
2 Rim, Front, Black (AC)(AD)(FA)
1 Rim, Chrome (AJ)(AK)(AL)(AM)(AN)
2 Valve, Rim
2/02
B6
FRONT BRAKE
11
6
7
10
Ref. Part No.
1910549
1910550
1 7515489
2 5132960
5132961
1930642
3 5410494
Qty. Description
1 Asm., Brake Caliper, LH

(Incl. 1-7,9,10)
1 Asm., Brake Caliper, RH
(Incl. 1-7,9,10)
1 Screw, Socket Set
1 Caliper, Brake, LH
1 Caliper, Brake, RH
1 Kit, Front Brake Boot
1 Boot, Pin Seal
Ref. Part No.
4
5
6
7
8
9
10
11
1930665
5410779
5410780
5132294
2201398
1910411
5410495
7080352
Qty. Description
1
1
1
1
1
1
1
1
Kit, Piston and Seal (Incl. 5-7)

Ring, Molded Square (.094)
Ring, Molded Square (.103 x .134)
Piston, Brake, Long
Kit, Front Brake Pad
Mount, Caliper
Boot, Bushing
Screw, Bleeder
4/01
B7
CONTROLS - MASTER CYLINDER/BRAKE LINE

1
2
4
5
19
18
6
3
16
17
8
13
11
15
9
10
12
14
13
Ref. Part No.
Qty. Description
2010196
5411297
5410988
4110164
2201834
1
1
2
1
1
5 2201836
6 2201833
7 2201835
8 1910478
1
2
3
4
Asm., Master Cylinder

Boot, Brake Line, Rubber
Seal
Switch
Kit, Master Cylinder Cap
(Incl. Cap, Screws, Sight, Gasket)
Kit, Master Cylinder Park Brake Lever
(Incl. Lever, Spring)
Kit, Master Cylinder Clamp
(Incl. Clamp, Screws)
Kit, Master Cylinder Lever
(Incl. Pin, Lever, Clip)
Line, Brake, Stainless Steel
Ref. Part No.
9
10
11
12
13
14
15
16
17
18
19
7621462
7080539
8360031-30
1910474
7080138
7512024
8360011-38
1910475
7052292
1910470
1910499
Qty. Description
2
2
1
1
8
2
1
1
1
1
1
Rivet
Clamp, Nylon
Conduit
Line, Brake, Left Front
Cable Tie
Screw
Tubing, Convoluted
Line, Brake, Right Front
Fitting, Cross
Bolt, Banjo
4/01
B8
REAR BRAKE/FOOT PEDAL

8
9
11
10
23
22
21
11
12
20
19
18
13
15
17
B9
14
15
16
14
REAR BRAKE/FOOT PEDAL

Ref. Part No.
1
2
3
4
7515497
7552603
7555806
1910553
2201399
2201180
2201428
2201467
5 1910479
6 ------7
8
9
10
7512240
1930854
7542153
1910315
Qty. Description
2
2
2
1
1
1
2
1
1
1
1
1
1
1
Screw
Washer, Spring Lock
Washer, Flat
Asm., Caliper, Brake, Rear
Kit, Brake Pad (Incl. Spacer and Pin)
Kit, Seal
Kit, Bleeder Replacement
Piston, Caliper, Rear
Line, Brake
(See Controls-Master Cylinder Brake
Line Pg. B8,Ref. 8)
Bolt
Reservoir, Brake, Rear
Nut, Nylok, Flanged
Hose, Reservoir
Ref. Part No.
11
12
13
14
15
16
17
18
19
20
21
7080003
7542122
7041750
7555919
5431107
1910280-067
7661401
1910301
7512247
1910439
1910440
22 7571620
23 7547046
Qty. Description
2
2
1
2
2
1
1
1
2
1
1
Clamp, Hose
Nut, Nylok
Spring
Washer
Bushing, Pivot, Pedal
Rod, Brake
Pin, Cotter
Master Cylinder, Brake, Rear
Bolt
Disc, Brake (EB)
Disc, Brake
(AA)(AB)(AC)(AD)(AE)(AJ)(AK)(FA)
(AM)(AN)
1 Washer, Spring
1 Nut, Nylok, Thin
2/02
B10
FOOT BRAKE
WORKER 500 A02CH50EB
2
5
3
16
13
14
12
6
7
15
11
9
10
Ref. Part No.
1
2
3
4
5
6
7
8
7512126
1040732-067
7661205
7555827
5211914
7555931
7542103
7556063
Qty. Description
1
1
1
2
1
1
1
2
Bolt
Bracket, Park Brake
Pin, Cotter
Washer
Handle, Park Lock
Washer, Flat
Nut, FLEXLOC
Washer, Wave
Ref. Part No.
9
10
11
12
13
14
15
16
5224875
7558707
5242749
5224871
7080644
7661843
7661011
7661203
Qty. Description
1
1
1
1
1
1
1
1
Spring, Return
Bushing
Pawl, Park Lock
Linkage, Park Lock
Clevis, Threaded
Pin, Clevis
Pin, Cotter
Pin, Cotter
4/01
B11
CONTROLS - THROTTLE ASM./CABLE

1
2
6
7
Ref. Part No.
1
2
3
4
5434113
5410193
5411439
-------
Qty. Description
1
1
1
1
Cover
O-Ring
O-Ring
Cable, Throttle Control (See Engine
Mounting Pg. A14, Ref. 39)
Ref. Part No.
5
6
7
8
2010205
5245134
7517910
2010191
Qty. Description
1
1
1
1
Asm., Throttle Control

Bracket, Throttle Stop (EB)
Screw (EB)
Asm., Throttle Clamp
4/01
B12
HANDLEBAR and HEADLIGHT POD

1
2
17
3
13
16
15
12
10
19
18
14
11
8
6
7
5
4
20
21
22
40
39
23
24
38
37
26
36
27
29
41
30
35
36
B13
28
34
33
31
32
25
HANDLEBAR and HEADLIGHT POD

Ref. Part No.
1 3280363
3280378
2
3
4
5
3280377
3280358
4010315
4010416
7511881
7670086
------
6 5242987-067
7 2200774
5630616
7541933
7555868
7558212
7515189
3280291
5433763-359
5433763-136
5433975-283A
5433972-315A
5433763-053
5433763-341
5433763-317
5434398-375A
5433763-288
5433763-177
5433763-333
14 - - - - - - 8
9
10
11
12
13
15
16
17
18
5433903
4010422
5433834-070
5432952
Qty. Description
1 Speedometer (AA)(AB)(AE)
1 Speedometer
(AC)(AD)(AJ)AK)(AL)(AM)(AN)
1 Speedometer, Kilo (EB)
1 Speedometer, Kilo (FA)
1 Panel, Indicator Light
3 Bulb
3 Screw
3 Nut, U-Type
1 Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B12, Ref. 5)
1 Tube, Handlebar
1 Kit, Handlebar Block
(Incl. Blocks and 7,11,29)
2 Block, Handlebar Retainer
2 Nut, Brass
2 Washer, Lock
2 Washer, Flat
4 Screw
1 Clamp, Speedometer
1 Pod, Headlight, Upper (AA)
1 Pod, Headlight, Upper (AB)(EB)
1 Pod, Headlight, Upper (AC)
1 Pod, Headlight, Upper (AD)
1 Pod, Headlight, Upper (AE)
1 Pod, Headlight, Upper (AJ)
1 Pod, Headlight, Upper (AK)
1 Pod, Headlight, Upper (FA)
1 Pod, Headlight, Upper (AL)
1 Pod, Headlight, Upper (AM)
1 Pod, Headlight, Upper (AN)
1 Asm., Master Cylinder
(See Controls - Master Cylinder/Brake
Line Pg. B8 for details)
1 Spacer, Switch, LH
1 Switch, Handlebar, H/L/O/Rev./OR
2 Grip, Handlebar
1 Plug, Hole
Ref. Part No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Qty. Description
7517625
5244969-067
7517317
4032079
5411120
4032077
2410268
4032075
4010253
4032078
5410163
7081008
7542122
7670089
4010283
5411744
7080631
7522021
5433762-070
5433762-177
4010390
4010278
1
1
2
1
1
1
1
1
1
1
2
1
4
2
1
1
1
2
1
1
1
1
4010321
5433534
7080922
4010298
5132382
7517658
1
1
1
1
1
Screw, Set
Bracket, Pod Mounting
Screw
Knob, Adjusting
Boot, Headlight
Collar, Locking
Asm., Headlamp
Lens and Reflector
Bulb, Headlight, Halogen
Rod, Adjusting
O-Ring
Cable, Choke
Nut, Nylok
Nut, U-Type
Receptacle, Pod Mount, 12V
Cap, Rubber
Clip, Cable Retaining
Screw
Pod, Headlight, Lower
Pod, Headlight, Lower (AM)
Switch, Ignition (Incl. Key)
Blank, Key, Series 2000, 6700, 6800.
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.
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.
Cover, Key
Nut, Choke
Sensor, Hall Effect
Cap, Hall Sensor
Screw
5/02
B14
STEERING POST
2
4
3
5
6
12
1
7
8
9
11
7
10
Ref. Part No.
1
2
3
4
5
7542324
7080424
5433866
1821112-067
5132679
5222999-067
Qty.
4
1
2
1
1
Description
Nut, Nylok
Bushing, Steering, Upper
Post, Steering
Bracket, Steering Post
1 Bracket, Steering Post
Ref. Part No.
Qty.
6 7512377
7515321
7 7556162
8 5222393
9 3514352
10 7547158
11 7661633
12 7558402
4
4
2
1
1
1
1
2
Description
Bolt, Carriage (If built before 1/01/02)

Bolt (If built after 1/01/02)
Bushing
Flangette
Bearing
Nut
Pin, Cotter
Washer, Flat
2/02
C1
OIL TANK (If Built Before 1/02/02)

To Airbox
5
4
8
2
10
1
To Lower Oil Pump Fitting on Engine
23
8
11
9
22
12
15
21
14
20
9
To Top Oil Pump Fitting on Engine
13
(Oil Tank built after 1/02/02 See Pg. E8)

17
18
19
14
16
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7511848
5211523
5830053
7052163
5411668
5434574
5410889
7517102
7555896
7052109
7052133
2530020
Qty. Description
2
1
1
1
1
1
1
2
4
1
1
1
Screw
Plate, Vent, Oil Tank
Gasket, Oil Reservoir
Fitting
Line, Breather
Dipstick
O-Ring
Bolt, Banjo
Washer, Copper
Tube, Banjo Return
Tube, Banjo Intake
Screen, Oil Filter
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
7542122
7558301
5131255
5411042
5410828
5333204
7512130
7051524
5850135
7515158
5131785
Qty. Description
2
2
1
1
2
2
2
1
1
9
1
Nut, Nylok
Washer, Flat
Tank, Oil, RH
Grommet
Grommet, Mounting, Reservoir
Bushing
Screw
Plug, Magnetic
Washer, Nylon
Screw
Tank, Oil, LH
8/01
C2
FRAME MOUNTING
1
4
3
2
10
11
3
8
Ref. Part No.
1
2
3
4
5
6
7661013
1040494-067
5431107
5020850
7542122
-------
Qty. Description
2
1
2
1
1
2
Pin, Clevis
Pivot, Shift
Bushing
Tube, Pivot
Nut, Nylok
Rod End, LH
(See Gear Selector Pg. C12, Ref. 17)
Ref. Part No.
7 7517386
8 7512144
9 ------10 5131277
11 7661103
Qty. Description
5 Screw
1 Screw
4 Nut, FLEXLOC
(See Gear Selector Pg. C12, Ref. 14)
1 Arm, Shift
2 Pin, Cotter
4/01
C3
A-ARM / STRUT MOUNTING

4
5
6
2
7
9
29
10
11
28 27
12
13
27
28
22
21
26
14
25
21
22
15
23 24
18
19
17
16
13
20
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
7542403
1820805
5411291
7061034
7542711
5020926
7547028
7517909
7061054
5411920
7556099
7547177
7661203
7080927
5211121
7512284
Qty. Description
2
2
2
2
2
2
2
2
2
1
4
2
4
2
2
4
Nut, FLEXLOC
Asm., Tie Rod
Boot, Seal, Rod End
Rod End, RH
Nut, Jam
Tie Rod
Nut, Jam, LH
Bolt
Rod End, LH
Boot, Seal, Rod End
Washer, Flat
Nut
Pin, Cotter
Joint, Ball
Bracket, Ball Joint
Screw
Ref. Part No.
17 5410548
18 7542438
19 5431837
5431838
20 7512084
21 5433066
5434551
22 5020677
23 5020681
24 2201607
2201608
25 7080433
26 - - - - - - - 27 7512492
28 7552603
29 7515415
Qty. Description
2
2
1
1
6
4
4
4
2
1
1
2
1
Boot, Rubber
Nut, Castle
Shield, CV Joint, LH
Shield, CV Joint, RH
Screw
Bushing, A-Arm, Long
Bushing, A-Arm, Long (AL)
Bushing
Shaft, A-Arm
Kit, A-Frame, LH
Kit, A-Frame, RH
Asm., Heavy Hubstrut
(See Front Strut Pg. B5, Ref. 16)
4 Screw
4 Washer, Spring Lock
2 Screw
11/01
C4
DRIVE CLUTCH
5
6
4
1
9
10
18
12
15 14
16
11
5
13
17
A01CH50(AA)AB)(AC)(AD)(AE)(AJ)(AK)(AL)(AM)(AN)(FA)
14
11 10
13
15
16
5
19
20
21 22
12
5
23
24
25
A01CH50EB
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1520231
7556204
5631119
7541906
5431936
5020422
3585712
7547130
3576510
7552801
7512176
7041157
1321457
5430945
7512266
Qty. Description
1
1
1
3
6
3
1
1
1
6
6
1
3
6
3
Clutch, Drive, One Way

Washer
Spacer
Nut, FLEXLOC
Button, Clutch, Stemless
Pin, Roller
Bearing
Nut, Jam
Cover, Bearing
Washer, Spring Lock
Bolt
Spring, Clutch
Roller and Bushing
Washer, Multilube
Bolt, Shoulder
Ref. Part No.
16 5630710
17 1321706
18 7556202
19 5210752
5242981
5210753
5210754
20 3576504
21 5430261
22 5210748
23 7512566
24 7575202
25 1321632
Qty. Description
3 Weight, Shift, 10 WH
1 Asm., Drive Clutch, Braking
(Incl. 1-11,13-15,18)
1 Washer
AR Spacer (.020)
AR Spacer (.025)
AR Spacer (.032)
AR Spacer (.050)
1 Bearing, Moveable, 1/2
1 Bushing
1 Washer
1 Bolt
1 Washer
1 Asm., Drive Clutch
(Incl. 4-6,10-16,19,20)(EB)
2/02
C5
DRIVEN CLUTCH
2
11
12
4
10
23
22
13
21
14
20
19
18
17
16
15
Ref. Part No.
1 5010409
2 7556120
3 1322184
1322182
4 7556013
7556203
5 7556010
6 7710461
7 5220646
8 7552901
9 7515327
10 3211069
3211077
11 7511854
Qty. Description
1 Spacer, Driven
AR Bushing
1 Asm., Driven Clutch, Braking
(Incl. 5-7,17-23)
1 Asm., Driven Clutch (Incl.
11,12,15-17,19-23)(EB)
1 Washer (If built before 3/20/01)
1 Washer (If built after 3/20/01)
1 Bushing
1 Ring, Retaining
1 Washer, Domed
1 Washer, Spring Lock
1 Bolt
1 Belt, Drive
1 Belt, Drive (EB)
3 Bolt (EB)
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
22
23
5430766
7517323
1321977
7555898
7556076
7556804
3585710
3576504
5211115
3576511
7041635
7041198
5131674
5132344
5210752
7710448
Qty. Description
3
3
3
AR
AR
AR
1
1
1
1
1
1
1
1
1
1
Button, Ramp (EB)

Screw
Roller, Taper
Washer (.020)(EB)
Washer (.025)(EB)
Washer (.030)(EB)
Bearing
Bearing (EB)
Washer (Not EB)
Bearing, Moveable, 1
Spring
Spring (EB)
Ramp, Stationary
Ramp, Stationary (EB)
Spacer (EB)
Ring, Retaining (EB)
8/01
C6
CLUTCH COVER
7
11
3
8 9
14
10
23
22
12
19
21
20
18
16
14
15 14
13
17
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
1040519-067
7512240
5410489
2201851
7555748
7552801
7512247
7512277
7512278
5521578
5433451-070
7078689
Qty. Description
1
2
1
1
3
3
1
1
1
1
1
1
Bracket, Clutch Cover, Rear

Bolt
Seal, Cover Case
Kit, Inner Clutch Cover (Incl. 14)
Washer, Rubber
Washer, Spring Lock
Bolt
Bolt
Screw
Seal, Cover, Clutch, Outer
Cover, Clutch, Outer
Decal, Warning, Clutch Cover
Ref. Part No.
Qty. Description
13 7077666
7074782
14 7512094
15 7555935
16 5411489
17 7080761
18 5433980
19 - - - - - -
1
1
9
2
1
2
1
3
20
21
22
23
1
1
1
1
5242046-067
5410575
7080511
5432086
Decal, Automatic/EBS
Decal, Automatic Transmission (EB)
Screw
Washer
Boot, Duct
Cable Tie
Duct, Clutch Outlet
Screw and Washer
(See Crankcase Pg. D3, Ref. 6)
Bracket, Clutch Seal
Seal, Cover Case
Clamp, Narrow Band
Duct, Air Inlet
5/02
C7
ELECTRICAL / TAILLIGHT
15
16
5
1
3
10
7
8
20
14
21
22
13
23
12
11
24
11
12
25
20
37
36
19
38
18
17
29
30
28
26
27
35
34
31
33
32
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Qty. Description
2460944
2200593
2201795
2432034
1
1
1
1
2410320
4032046
4032029
4030043
4032045
4032064
7670054
7541925
7571602
7512027
5810290
7517386
4010311
4010310
7512057
1
2
1
1
1
2
4
4
2
3
1
1
1
1
Harness, Main Wire

Kit, Circuit Breaker, 20 AMP
Kit, Circuit Breaker, 10 AMP
Asm., Taillight w/Brake Light (Incl. 5-10)
Asm., Taillight 12V (Incl. 5-10)
Lens, Taillight
Screw, Taillight
Bulb, Taillight
Gasket, Taillight
Backing, Taillight/Brake Light
Nut, Speed
Nut, Nylok
Washer
Screw
Pad, Battery
Screw (EB)(FA)
Switch, Horn (EB)(FA)
Horn (EB)(FA)
Screw (EB)(FA)
Ref. Part No.
Qty. Description
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
1
1
1
2
1
1
AR
1
1
1
1
2
2
1
1
1
1
1
3
5
2
5810317
4010094
2200361
7010032
5410424
2460837
5432077
4140006
2202147
5431769
4010093
7512007
5810455
5241416
7512024
5131036
4060173
4010657
36 7512018
37 4020149
38 7670109
Pad, Fuel Tank Bracket (EB)(FA)

Cable, Battery/Solenoid
Kit, Battery Bolt, Short
Hook, Battery Strap
Strap, Battery Holddown
Harness, Horn (EB)(FA)
Tube, Battery Vent
Battery
Kit, Fusible Link
Cover, Battery
Cable, Solenoid/Starter
Bolt
Pad, Rack Mount
Bracket, CDI
Screw
Sink, Heat
Rectifier, Regulator (All models except EB)
Rectifier, Regulator (EB Only)
Screw
Clip, Rosebud
Clip, Routing
5/02
C8
REAR SUSPENSION
1
16
11
4
5
2
3
6
5
15
14
16
3
11
15
14
18
19
20
13 12
10
12
11
10
20
20
17
9
11
10
20
10
35
22
18
25
24
10
18
34
11
33
20
31
5
4
18
11
35
37
43
24
10
26
17
27
28
32
6
9
21
18
32
36
44
12
17
5
6 8
9
23
17
38
42
41
40
C9
39
29
30
REAR SUSPENSION
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
7512329
1580107-067
7542324
7517231
7555761
5432598
5020827
5020826
5433063
6
2
6
4
8
8
2
6
12
5434548
12
5020677
7080433
7515472
5334114-067
7555939
5433413
12
12
6
1
4
2
5434549
16
17
18
19
20
21
22
23
Qty. Description
7558402
7512492
7552603
1541322-067
8
16
16
1
1541802-067
7542439
5242077-067
7515433
7542321
12
2
2
2
Bolt
Arm, Stabilizer Bar
Nut, Nylok
Screw
Washer, Flat
Bushing, Stabilizer
Rod, Linkage, Stabilizer
Shaft, A-Arm, Short
Bushing, A-Arm, Short
Bushing, A-Arm, Short
Bushing
Screw
Bar, Stabilizer Tube
Washer
Bushing, Stabilizer Tube
Bushing, Stabilizer Tube
Washer, Flat
Screw
Washer, Spring Lock
Support, Stabilizer
Support, Stabilizer
Nut, Nylok
Bracket, A-Arm Pivot
Screw
Nut, Flange
Ref. Part No.
24
25
26
27
28
Qty. Description
7515321
5224667-067
7552901
5630885
7041453-067
4
1
2
2
2
7041519-067
29 5631014
5433551
30 7041959
31 7515415
32 5433066
2
2
1
2
2
4
5434551
33 5020681
34 1012717-067
1012718-067
35 5433065
2
1
1
8
5434550
36 1040730-067
1040731-067
37 5631141
38 7555936
39 7517297
40 5433098-070
5433099-070
41 7512084
42 5131738
43 3585502
44 7080586
1
1
4
4
4
1
1
4
2
2
2
Bolt
Support, Transmission, Upper
Washer, Spring Lock
Retainer, Spring
Spring, Compression, Rear
(AA)(AB)(AC)(AD)(AE)(AJ)(AL)(AM)
Spring, Compression, Rear (EB)
Cam, Adjusting, Spring
Sleeve, Shock Protector
Shock, Rear
Screw
Shaft, A-Arm
Arm, Control, Lower, LH
Arm, Control, Lower, RH
Bushing, Control, Lower
Bushing, Control, Lower
Arm, Control, Upper, LH
Arm, Control, Upper, RH
Bushing, Bearing Carrier
Washer
Screw
Shield, Rear, LH
Shield, Rear, RH
Screw
Carrier, Wheel Bearing
Bearing, Wheel Carrier
2/02
C10
REAR WHEEL DRIVE

4
5
6
1
11
10
9
7
12
Ref. Part No.
1
2
3
4
Qty. Description
7661404
7542459
5131649
-------
2
8
2
2
5 7710440
6 7515513
7 5410948
5411949
2
8
2
2
Pin, Cotter
Nut, Flange Lock
Hub, Rear Wheel
Carrier, Bearing, Wheel (See Rear
Suspension Pg. C10, Ref. 42)
Ring, Retaining
Stud
Tire, 25x11-10 (AA)(AB)(AE)(EB)
Tire, 25x11-12
(AC)(AD)(AJ)(AK)(FA)(AL)(AM)(AN)
Ref. Part No.
8 1525017
9 1520217-117
1520457-067
1520520
10 7555796
11 7543005
12 5411164
Qty. Description
2
2
2
1
Valve, Rim
Rim, Rear, Silver (AA)(AB)(AE)(EB)
Rim, Rear, Black (AC)(AD)(FA)
Rim, Rear, Chrome
(AJ)(AK)(AL)(AM)(AN)
4 Washer, Cone
2 Nut, Castle
2 Cover, Dust, Hub
2/02
C11
GEAR SELECTOR
1
2
3
4
6
23
10
11
8
22
9
10
11
15
21
20
19
17
14
14
12
13
18
14
15 16
17
14
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
1341271
3233195
7512024
3233649
3233131
3233648
3233658
3233646
3233754
3233644
3233642
3233060
Qty. Description
1
1
1
4
1
1
1
1
1
1
2
2
Asm., Gear Selector (Incl. 1-13,21-23)

Asm., Knob
Screw
Screw
Strap, Wire
Cover, Gear Selector Boot
Handle, Gear Selector
Sphere, Plastic
Pin, Groove
Pin, Dowel
Spring, Detent
Bullet, Detent
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
22
23
3233076
3233639
7546707
7061014
7546701
7061013
5020824
5020823
7546702
3233640
3233641
3233643
Qty. Description
2
1
4
2
2
2
1
1
2
1
1
1
O-Ring
Slide, Low
Nut, FLEXLOC
Rod End, RH
Nut, RH
Rod End, LH
Rod, Shift Linkage, Low-Range
Rod, Shift Linkage, Hi-Range
Nut, LH
Slide, High/Reverse
Body, Gear Selector
Spring, Centering
4/01
C12
FRONT HOUSING
13
14
15
11 12
16
9 10
17
8
6
3
1
18
19
25
28
27
20
26
21
22
2
1
24
23
Ref. Part No.
1341323
1
2
3
4
5
6
7
8
9
10
11
12
13
3233252
3233248
3233701
3233700
3233699
3233589
3233726
3233541
3233319
3233697
3233324
3233711
7080756
Qty. Description
1 Asm., Front Gearcase

(Incl. 1-12,16-26)
12 Screw
2 Seal
1 Cover, Front Housing Input
1 O-Ring
1 Ring, Retaining
1 Bearing, Ball
1 Pinion, Input
1 Bushing
1 Seal
1 Bushing
1 Washer
1 Plug, Oil Fill
1 Clip, Snap In
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
8450003-1525
7080307
3233524
3233696
3233725
3233020
3233554
3233693
3233724
3233583
3233582
3233254
3233253
7512492
7552603
Qty. Description
AR
1
1
1
1
1
AR
1
1
AR
1
1
1
4
4
Line, Fuel
Clamp, Hose
Tube, Vent
Gearcase
Shaft, Output
Bearing, Ball
Shim
O-Ring
Cover, Output
Shim
Button, Thrust
Washer, Plug
Plug, Drain
Screw
Washer, Spring Lock
4/01
C13
GEARCASE (Cases and Snorkel)

7
3
10
6
8
21
11
14
5
23 24
20
12
13
22
19
18
17
16
15
27
38
35
37
36
34
31
32
33
26
28
25
29
30 15
1
Ref. Part No.
------1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
3233256
3233026
3233636
3233252
3233248
3233778
7052095
8360009-600
3233037
3233475
3233749
3233617
3233635
3233442
-------
16 3233352
17 3233476
18 - - - - - - 19 3233446
20 3233302
Qty. Description
1 Asm., Gearcase (See Gearcase -Internal Components Pg. D2 for Details)

2 Seal
18 Screw
1 Decal, Switch
2 Screw
3 Seal
1 Gearcase, LH
1 Fitting, 90 Degree
AR Line, Fuel
1 Vent, Tube
1 Dipstick
8 Screw
1 Switch, 2 Position
1 Switch, 3 Position
2 Screw
4 Washer (See Gearcase - Internal
Components Pg. D2, Ref. 2)
1 Washer
1 Gear, 31T, Snorkel
Bearing, Ball (See Gearcase -Internal
Components Pg. D2, Ref. 29)
1 Shaft, Drive, Snorkel
1 O-Ring
Ref. Part No.
Qty. Description
21 3233750
22 3233305
23 3233353
3233354
3233355
3233356
3233357
1
1
1
1
1
1
1
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
1
1
1
1
1
1
2
1
4
4
1
1
1
1
3
3233306
3233444
3233351
3233779
3233292
3233293
3233291
3233294
3233295
3233296
3233777
3233254
7517844
3233776
3233247
Tube, Snorkel
Bearing, Ball
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 be
used in combinations.
Ring, Retaining
Lock, Bolt
Bolt
Spacer, Snorkel
Bushing
Seal
Nut, FLEXLOC
Stamping, Cover Plate
Washer
Screw
Plug, Drain
Washer
Screw
Gearcase, RH
Pin, Dowel
4/01
C14
GEARCASE (Internal Components)

1
2
3
4
5
3
4
5
6
7
6
17
19
24
10
23
11
22
21
10
15 20
16
18
15
12
13
14
25
27
23
28 29
26
42
21
30
41
36
35
34
33
15
21
32
31
11
10
27
37
40
39
38
45
26
43
44
D1
46
GEARCASE (Internal Components)

Ref. Part No.
1341360
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
3233055
3233054
3233153
3233045
3233040
3233548
3233774
3233019
3233571
3233018
3233176
3233744
3233743
3233664
3233720
3233719
3233036
3233742
3233775
3233661
3233718
3233745
Qty. Description
1 Asm., Gearcase (Incl. 1-37 and all on

Gearcase (Cases and Snorkel) Pg. C14)
2 Nut
6 Washer
2 Bellcrank, HLR
2 Ring, Retaining
2 Washer
2 O-Ring
1 Shaft, Shift
1 Bearing
1 Shaft, Input, 31T, HCR
3 Bearing
2 Washer, Thrust
1 Gear, 30T
1 Engagement Dog, High
1 Fork, Shift, H/R
3 Ring, Retaining
1 Sprocket, 24T
1 Chain, Silent, 34P
1 Shaft, Reverse, HCR
1 Fork, Shift, Low
1 Shaft, Shift
3 Bearing, Needle
1 Gear, 36T
Ref. Part No.
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
3233308
3233189
3233309
3233747
3233177
3233732
3233020
3233715
3233365
3233265
3233364
3233263
7552901
3233262
3233360
3233434
3233433
3233432
3233431
3233430
3233268
3233670
3233282
3233669
Qty. Description
2
1
1
2
1
1
2
1
1
1
1
1
4
4
1
1
1
2
1
1
2
1
2
1
Pin, Interlock
Spring, Interlock
Bracket, Interlock
Screw
Ring, Retaining
Engagement Dog, Low
Bearing, Ball
Shaft, Center Drive
Pinion, 16T, Spiral Bevel
Bearing
Ring, Retaining
Cover, Bearing, Center Drive
Washer
Screw
Gear, Output, 100T, HCR
Chain Tensioner, Cam
Chain Tensioner, Shoe
Pin, Dowel
Spring, Torsion
Chain, Silent
Bearing
Sprocket, 60T
Screw
Deflector, Oil
4/01
D2
CRANKCASE
7
5
9
10
23
11
12
22
21
20
19
18
15
17
14
13
16
Ref. Part No.
1 3083669
2 3085808
3
4
5
6
7
8
9
10
11
3084838
3080676
3084840
3084205
3084839
3085525
3087154
3084842
3084834
Qty. Description
1 Bushing, Starter
1 Asm., Crankcase
(Incl. 1,4,5,7,11,12,17,20,21,23)
2 Pin, Straight
1 Bearing, Ball
2 Pin, Dowel
3 Screw and Washer
1 Seal, Oil
1 Pipe, Air Breather
1 Fitting, Oil Inlet
1 Union
2 Bearing, Ball
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
22
23
3084835
3084845
3084846
3084844
3086810
3084841
3082956
3083453
3084837
3084836
3084847
3080103
Qty. Description
1
1
1
1
1
10
1
1
1
1
1
2
Bearing, Ball
Plug
Gasket, Aluminum
Spring, Valve, One Way
Valve, One Way
Bolt, Flange
Gasket
Plug
Seal, Mechanical
Seal, Oil
O-Ring
Pin, Dowel
1/02
D3
CRANKSHAFT and PISTON

1
4
2
3
4
6
23
9
10
22
11
12
21
13
14
19
15
20
18
17
16
Ref. Part No.
1 3085379
3085380
3085381
2 3087170
3087171
3087172
3 ------4 3085534
5 3080676
6 3085815
7 3085812
8 3085341
9 3085813
10 3085400
11 3085024
12 3085861
3085945
Qty. Description
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
Piston Ring Set (Std)

Piston Ring Set (0.25 O/S)
Piston Ring Set (0.50 O/S)
Piston Set (Std) (Incl. 2-4)
Piston Set (0.25 O/S) (Incl. 2-4)
Piston Set (0.50 O/S) (Incl. 2-4)
Pin, Piston
Clip
Bearing, Ball
Bearing, Ball
Crankshaft 2
Pin, Crank
Rod, Connecting
Bearing, Large End
Ball, Steel
Asm., Crankshaft (Incl. 7-13,21)
Crankshaft 1
Ref. Part No.
13 3085852
14 3086837
15 3240088
3084892
3084893
3084894
16 3084895
3084896
3084897
17 3084882
18 3085528
19 3083905
20 3083904
21 3085346
22 3081447
23 3240168
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Gear 1, Balancer
Shaft, Balancer
Spacer (0.6)
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
Sprocket 1
Nut, Slit
Nut, Lock
Washer
Pin, Dowel
Key
Key, Woodruff
9/01
D4
CYLINDER
1
3
4
10
12
38
11
36
36
37
13
5
17
36
35
16
14
15
18
19
24
20
23
22
34
21
27
26
28
29
18
33
30
31
32
13
D5
25
CYLINDER
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
3084045
3081497
3081330
3084857
3084994
3084858
3084867
3085072
3084877
3084866
3085074
3085073
3084874
3084859
3084875
3084860
3084861
3084862
19 3084215
Qty. Description
1
1
2
2
4
2
1
1
10
1
1
1
10
2
4
1
1
1
2
Band, Adapter (Incl. 2)

Screw
Bolt, Allen
Pin, Straight
Guide, Valve
Seal, Intake Valve, Black
O-Ring
Adapter, Water Out
Bolt, Flange
Adapter, Camshaft
Gasket, Rocker Cover
Cover, Rocker
Bolt, Flange
Seal, Exhaust Valve, Brown
Bolt, Cylinder Head
Plug
Gasket
Plug, Blind
Bolt, Flange
Ref. Part No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
3085075
3085326
3080285
3080530
3085854
3084876
3084864
3084863
3084838
3084849
3084873
3086811
3084130
3085370
3084868
3086200
3085527
3085371
3085809
Qty. Description
1
2
2
2
1
4
1
1
2
1
4
1
1
1
1
1
1
1
1
Gasket, Exhaust
Stud
Nut
Washer, Lock
Bolt, Rocker Shaft
Bolt
Support, Valve Rocker Shaft (PTO)
Support, Valve Rocker Shaft (MAG)
Pin, Straight
Union, Oil Pump
Bolt, Flange
Cylinder (Incl. 32)
Pipe 2, Elbow
Gasket, Cylinder
Cover, Camshaft
Gasket, Cover, Cam
Cylinder Head (Incl. 4-6,14,16-18,21)
Gasket, Head
Adapter
4/01
D6
INTAKE and EXHAUST

8
8
10
6
1
11
12
2
3
4
27
14
13
7
15
16
17
26
18
13 12
11
25
24
23
20
21
19
22
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3084845
3084920
3086839
3086813
3084922
3084910
3084913
3084912
3084911
3084909
3084908
3086893
3084906
3085855
Qty. Description
1
1
1
1
1
2
1
4
4
1
8
4
4
1
Plug
Gasket, Plug
Spring, Tensioner
Asm., Tensioner (Incl. 1-3)
Gasket, Tensioner
Asm., Intake Rocker Arm (Incl. 8,9)
Asm., Exhaust Rocker Arm (Incl. 8,9)
Nut
Screw, Adjusting
Shaft, Rocker
Collet, Valve
Retainer, Spring
Spring, Valve
Camshaft (Incl. 15-18)
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
3086838
3085348
3085076
3084899
3084914
3081657
3084916
3084915
3084924
3084917
3085349
3085412
3084874
Qty. Description
1
1
1
1
1
3
1
1
1
1
2
2
2
Pin, Dowel
Lever, Release
Spring, Return
Pin, Dowel
Sprocket 2
Bolt and Washer
Guide, Chain
Chain, Timing
Bolt, Pivot, Lever
Lever
Valve, Intake
Valve, Exhaust
Bolt, Flange
4/01
D7
RECOIL STARTER
7
8
9
15
11
10
12
14
13
7
Ref. Part No.
1
2
3
4
5
6
7
8
3084822
3083463
3083378
3083379
3084744
3085266
3083453
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
14
3083669
3083185
3084750
3084933
3084877
3087163
3087164
15 3085083
Qty. Description
1
1
1
1
9
1
1
1
Bushing, Starter
Spring, Spiral
Bushing
Gasket, Recoil
Bolt, Flange
Asm., Recoil (Incl. 1-6,9-11,14,15)
Starter Case (Incl. 11)
Asm., Rope
9/01
D8
CARBURETOR
1
19
20
3
21
22
24
23
18
4
5
6
25
17
27
26
8
15
14
9
12
28
29
15
16
13
36 35
11
30
31
32
33
34
10
37
49
50
52
51
38
53
48
39
40
47
41
12
46
42
43
45
44
D9
CARBURETOR
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
3130914
3130821
3130911
3130913
3130908
3130915
3131292
3130910
3130912
3130932
3130927
3130933
3130926
3130925
3130515
3130928
3130619
3131289
3131305
3131290
3130916
3131208
3130593
3130538
3130199
3130517
3130519
Qty. Description
1
2
1
1
1
1
1
1
1
1
1
4
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Cover, Diaphragm
Screw
Spring
Ring
E-Ring
Ring
Needle, Jet
Diaphragm
Valve, Piston
Ring
Spring
Screw
Washer
Case
Seal
O-Ring
Jet, Air
Asm., Carburetor (Incl. 1-53)
Jet, Needle
Block, Jet
O-Ring
Cap
Plunger
Spring
Holder, Guide
Packing
Cap
Ref. Part No.
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
3130518
3130906
3130907
3130522
3130523
3130525
3130934
3131306
3130922
3131293
3130917
3130923
3130935
3130919
3131304
3130239
3131291
3131295
3131296
3130010
3130543
3130931
3130924
3130930
3131294
3131242
Qty. Description
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
E-Ring
Screw
Valve, Throttle
O-Ring
Washer
Spring
Adjuster
Jet, Pilot (#40)
Valve, Needle
Float
Seal
Body, Float
Screw
Ring
Jet, Main (#152.5)
O-Ring
Screw, Guide
Adjuster, Cable
Washer
Spring
Guide, Cable
Shaft, Throttle
Screw
Cover
O-Ring
Clip
4/01
D10
WATER PUMP
4
3
11
8
9
12
10
7
5
13
Ref. Part No.
1
2
3
4
5
6
7
3084940
3085352
3084191
3085857
3085359
3082758
3085351
Qty. Description
1
1
2
1
1
1
1
Thermostat
Switch, Thermostat
Clamp, Hose
Hose, Main
Bolt, Flange
Gasket, Aluminum
Cover, Water Pump
Ref. Part No.
8
9
10
11
12
13
3086840
3085077
3083138
3084935
3084942
3084877
Qty. Description
1
1
1
1
1
4
Gasket, Water Pump

Nut, Self Lock
Gasket
Impeller
Washer, Seal
Bolt, Flange
4/01
D11
OIL PUMP
1
5
10
9
11
6
7
12
18
13
15
14
17
16
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
3084946
3084949
3084948
3085817
3084945
3085535
3084955
3084954
3084953
3084962
3084947
Qty. Description
1
1
1
1
1
1
2
2
1
3
1
Case 2, Oil Pump

Rotor, Outer Feed
Rotor, Inner Feed
Asm., Oil Pump (Incl. 1-8,10-15)
Case 1, Oil Pump
Screw
Pin, Dowel
Pin, Dowel
Washer
Bolt and Washer
Case 3, Oil Pump
Ref. Part No.
11
12
13
14
15
16
17
3084950
3084951
3084956
3084205
3085818
3087173
3084959
3084960
3084961
18 3085820
Qty. Description
1
1
1
3
1
1
AR
AR
AR
2
Rotor, Inner
Rotor, Outer
Strainer, Oil
Screw and Washer
Shaft, Pump
Gear, Pump 2
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
Bolt, Flange
9/01
D12
OIL FILTER
2
4
3
2
3
5
Ref. Part No.
1 3084963
2 3084846
3 3086815
Qty. Description
1 Filter, Oil
8 Gasket, Aluminum
4 Bolt, Banjo
Ref. Part No.
4 3084964
5 3085638
Qty. Description
1 Pipe 1, Oil Delivery

1 Pipe 2, Oil Delivery
4/01
D13
MAGNETO
15
16
17
18
14
13
12
19
10
11
6
7
9
Ref. Part No.
Qty. Description
1 3085227
3085228
2 3084980
3 3084997
4 3084978
5 3084972
6 3086980
1
1
1
1
1
1
1
3087167
3086981
7 3081657
8 3084973
9 3086984
3087168
1
5
1
1
1
Asm., Ignition Coil (Incl. 1,2)

Coil, Ignition
Cap, Spark Plug
Plug, Spark, BKR6E
O-Ring
Metal, Bearing
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
Bolt and Washer
Seal, Oil
Stator (Incl. 13)(through S# 02-22573)
Stator (Incl. 13)(S# 02-22574 and higher)
Ref. Part No.
10
11
12
13
14
15
16
17
18
19
3086985
3085554
3084976
3085360
3081256
3087029
3087169
3083073
3080077
3085521
3086983
3087166
Qty. Description
3
1
2
1
1
1
1
2
2
1
1
1
Screw and Washer

Band, Pulse
Screw and Washer
Coil, Pulser
Screw and Washer
CDI System (through S# 02-22573)
CDI System (S# 02-22574 and higher)
Nut
Washer, Spring
Switch, Magnetic
Flywheel/Ring Gear (through S# 02-22573)
Flywheel/Ring Gear (S# 02-22574 and higher)
11/01
D14
STARTING MOTOR
8
2
1
12
12
13
14
11
15
10
16
18
17
Ref. Part No.
1
2
3
4
5
6
7
8
9
3084981
3084982
3085353
3084406
3083649
3084408
3082038
3085034
3085033
Qty. Description
1
1
1
1
2
3
2
1
1
Motor, Starting (Incl. 2-6,8-12)

Washer Set
Armature
Brush
Nut, Flange
O-Ring
Bolt and Washer
Bracket, Rear
Bracket, Front (Incl. 10)
Ref. Part No.
10
11
12
13
14
15
16
17
18
3240114
3084983
3084405
3083737
3084412
3084411
3084410
3084409
3087030
Qty. Description
1
2
2
1
1
1
1
1
1
O-Ring
Asm., Set Bolt (Incl. 6)
Ring, Rubber
Washer, Gear Shaft
Clip
Spring, Weight
Spring, Return
Clip
Asm., Gear Shaft (Incl. 13-17)
4/01
E1
FUEL PUMP
4
3
2
1
Ref. Part No.
1 3085275
2 3084999
3 3085000
Qty. Description
Ref. Part No.
1 Asm., Fuel Pump (Incl. 2-5)

1 Screw and Washer
2 Screw and Washer
4 3084591
5 3084998
Qty. Description
4 Screw and Washer

1 Diaphragm, Gasket Set
4/01
E2
TOOL KIT
4
10
1
6
Ref. Part No.
1
2
3
4
5
6
7
8
3085383
2870725
3082657
3085001
3085002
3085568
3085569
2682572
Qty. Description
1
1
1
1
1
1
1
1
Kit, Tool (Incl. 2-8)

Gauge, Tire Pressure
Screwdriver
Wrench, 8-10 Open
Wrench, 12-14 Open
Wrench, Box
Puller, Spark Plug (Wrench Handle)
Pouch, Tool Kit
Ref. Part No.
9 2871095
10 9916632
9916742
9916815
9917483
9917113
E3
Qty. Description
1 Wrench, Spanner, Cam

(AC,AD models Only)
1 Owners Manual, 02 ATV
1 Supplement, Owners Manual, 02
Sportsman 500
(AA)(AB)(AE)(AK)(AL)(AM)(AN)
Sportsman 500 RSE/DUSE
(AC)(AD)(FA)
Sportsman X (AJ)
1 Supplement, Owners Manual, 02 Worker 500 (EB)
5/02
MULTI MOUNT WINCH

SPORTSMAN X A02CH50AJ
3
4
17
16
9
13
14
10
11
12 3
15
Ref. Part No.
1
2
3
4
5
6
7
8
9
2202140
7515319
7541602
1541536-067
7661114
2460916
1541637-067
2202139
7670096
Qty. Description
1
4
4
1
4
1
1
1
4
Kit, Winch Remote Holster Wire

Bolt
Nut
Mount, Receiver, Rear
Pin
Harness, Battery
Plate, Rear
Kit, Winch Contractor and Bracket
Nut, Chimney
Ref. Part No.
10
11
12
13
14
15
16
17
7517208
7515180
1541636-067
1541537-067
2202142
7517914
1541535-067
2460929
Qty. Description
4
4
1
1
1
4
1
1
Screw
Screw
Plate, Front
Mount, Receiver, Front
Kit, Winch Asm., 2500 LB Cable
Bolt
Mount, Winch
Harness, Main
8/01
E4
DECALS
SPORTSMAN X A02CH50AJ
8
9
(Decal Pg. for AA,AB,AE,AC,AD,AN,FA,EB see Pg. A9)

(Decal Pg for AL see Pg. E6)
RH
13
12
16
10
11
18
17
19
15
2
20
21
14
1
LH
23
22
11
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
7079927
7170021
7170135
7170211
7170212
7079928
7079929
7078253
7079780
7078003
7170209
7170210
7078045
7079926
Qty. Description
2
2
2
1
1
1
1
1
1
1
1
1
1
2
Decal, Reflector, Red

Decal, Warning, Rack, Front/Rear
Decal, POLARIS, Seat
Decal, True on Demand 4X4, LH
Decal, True on Demand 4X4, RH
Decal, 4X4, LH
Decal, 4X4, RH
Decal, Age Warning, 16
Decal, Warning, AWD Switch
Decal, Headlight Adjustment
Decal, Tank Side, LH
Decal, Tank Side, RH
Decal, Liquid Cooled, Radiator
Decal, Reflector, Amber
Ref. Part No.
Qty. Description
12 7170277
7170278
13 7078577
14 7170213
1
1
1
1
15
16
17
18
19
20
21
22
23
1
1
1
1
1
1
1
1
1
7170214
7079520
7079604
7079977
7077920
7079084
7079959
7079085
7079083
Decal, POLARIS, Side Panel, Tip, LH

Decal, POLARIS, Side Panel, Tip, RH
Decal, Drain Recoil
Decal, HIGH OUTPUT 500, Front
Cover
Decal, Headlight Pod
Decal, Ignition
Decal, IRS, Rear
Decal, Tire Pressure/Load
Decal, POLARIS, Rear
Decal, Warning, General
8/01
E5
DECALS
SPORTSMAN 500 HO FREEDOM A02CH50AL
7 8

12
11
10
13
15
16
17
19
18
20
21
22
14
1
24
23
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
7079927
7170021
7077202
7079774
7078253
7079776
7079780
7078003
7079926
7078045
7170491
7170492
12 7078577
Qty. Description
2
2
2
2
1
2
1
1
2
1
1
1
1

Decal, Warning, Front and Rear Rack
Decal, POLARIS, Seat
Urocal, 4X4 True on Demand
Decal, Age Warning
Urocal, Sportsman
Decal, Warning, Switch, AWD
Decal, Amber Reflector
Decal, 500, Flag, Side Panel, LH
Decal, 500, Flag, Side Panel, RH
Decal, Drain Recoil
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
24
7079773
7078465
7170472
7079520
7079604
7170489
7170490
7079977
7077920
7079084
7079959
7079085
7079083
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
1
Decal, POLARIS, Front Cover

Logo, Polaris Star
Urocal, Freedom Series
Decal, Ignition
Decal, Tank Side, Flag, LH
Decal, Tank Side, Flag, RH
Decal, IRS, Rear
Decal, Warning, General, CPSC
11/01
E6
DECALS
SPORTSMAN 500 PSE HO A02CH50AM
2
8
9

10

(Decal Pg. for AL see Pg. E6)
11
14
16
12
15
13
17
18 19
20
21
2
22
23
24
25
Ref. Part No.
1 7179927
2 7170021
3 7170557
7170558
4 7079774
5 7078253
6 7079780
7 7078003
8 7170561
7170584
9 7170555
7170556
10 7078465
11 7079773
12 7078045
Qty. Description
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1

Decal, Warning, Front/Rear Rack
Decal, Side Panel, LH
Decal, Side Panel, RH
Urocal, 4X4, ON DEMAND TRUE
Decal, Age Warning, 16
Decal, Warning, AWD Switch
Decal, 43, LH
Decal, 43, RH
Decal, P.S.E. Tank Side, LH
Decal, P.S.E. Tank Side, RH
Logo, Polaris Star
Decal, POLARIS, Front Cover
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
24
25
7179926
7078577
7170554
7079520
7079604
7079776
7170559
7170560
7079977
7079959
7077920
7079084
7079085
7079083
Qty. Description
2
1
1
1
1
2
1
1
1
1
1
1
1
1
Decal, Reflector, Amber

Decal, Drain Recoil
Logo, Seq. Petty Special Edition
Decal, Ignition
Urocal, SPORTSMAN
Decal, 500 HO, Side Panel, LH
Decal, 500 HO, Side Panel, RH
Decal, IRS, Rear
Decal, General Warning
2/02
E7
OIL TANK (If Built After 1/02/02)

3
9
10
14
10
11
12 13
(Oil Tank built before 1/02/02 See Pg. C2)
Ref. Part No.
1
2
3
4
5
6
7
7512130
7558301
7080699
5411668
5410828
5333204
7542122
Qty. Description
2
2
4
1
2
2
2
Screw
Washer, Flat
Clamp
Line, Breather
Grommet
Bushing, Mounting
Nut, Nylok
Ref. Part No.
8
9
10
11
12
13
14
5434574
7081026
8450096-16
7052326
7051524
5850135
1261176
Qty. Description
1
2
1
1
1
1
1
Dipstick
Clamp
Line
Screen, Oil Filter, 90 Degree
Plug
Washer, Nylon
Tank, Oil
2/02
E8
PRINTED IN THE USA
PARTS MANUAL PN 9916743 and MICROFICHE PN 99168266 5/02

Sportsman 500 HO, RSE, DUSE, 2002 Parts Manual

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Sportsman 500 HO, RSE, DUSE, 2002 Parts Manual

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SPORTSMAN 500 HO

PARTS MANUAL PN 9916743 and MICROFICHE PN 9918266 5/02

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

A-ARM / STRUT MOUNTING . . . . . . . . . . . . C4

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C12

REAR BRAKE/FOOT PEDAL . . . . . . . . . . . .

GEARCASE (Cases and Snorkel) . . . . . . . . . . C14

REAR CAB and SEAT

E 2001 Polaris Sales Inc.

REAR CAB and SEAT

Ref. Part No.

1 Foil, Side Panel, Gen. IV, RH

Ref. Part No.

Cover, Front, Olive Green Metallic (AA)

REAR RACK MOUNTING

1 Kit, Rack Extender, Rear

Ref. Part No.

Spacer (If built before 9/03/01)

FRONT RACK and BUMPER MOUNTING

A02CH50AJ and A02CH50AL

FRONT RACK and BUMPER MOUNTING

1 Extender, Front Rack, Low

Ref. Part No.

(Decal Pg. for AJ see Pg. E5)

(Decal Pg. for AM see Pg. E7)

1 Decal, Warning, Front and Rear Rack

Ref. Part No.

Ref. Part No.

Ref. Part No.

Cap, Gas Tank

Ref. Part No.

Ref. Part No.

Strap, Frame Support

Filter, Precleaner Sleeve

Ref. Part No.

Asm., Drive Shaft w/Sleeve (NEA)

Ref. Part No.

Cardan, Replacement (Incl. 4,6,8,9)

Ref. Part No.

1 Yoke, Prop Shaft, Transmission

REAR DRIVE SHAFT

Asm., Drive Shaft, Rear (Incl. 1-8)

Ref. Part No.

Ref. Part No.

1 Asm., Hubstrut, Heavy, LH

Ref. Part No.

2 Plug, Magnetic Drain

Ref. Part No.

1 Asm., Brake Caliper, LH

Ref. Part No.

Kit, Piston and Seal (Incl. 5-7)

CONTROLS - MASTER CYLINDER/BRAKE LINE

Asm., Master Cylinder

Ref. Part No.

REAR BRAKE/FOOT PEDAL

REAR BRAKE/FOOT PEDAL

Ref. Part No.

Ref. Part No.

CONTROLS - THROTTLE ASM./CABLE

Ref. Part No.

Asm., Throttle Control

HANDLEBAR and HEADLIGHT POD

HANDLEBAR and HEADLIGHT POD