SPORTSMAN 500 Model #A00CH50(AA)(AB)(AE) (AF)(AH)(AK)(AL)
SPORTSMAN 500 RSE Model #A00CH50(AC)(AJ) WORKER 500 Model
#A00CH50(EB) Rev. 05
E 2000 Polaris Sales Inc.
PARTS MANUAL PN 9915480 and MICROFICHE PN 9916574 6/00
TABLE OF
CONTENTSSPORTSMAN500A00CH50(AA)(AB)(AE)(AF)(AH)(AK)andSPORTSMAN500RSEA00CH50(AC)(AJ)
and WORKER 500 A00CH50(EB) Parts ManualA- ARM/STRUT MOUNTING . . .
. . . . . . . . . . C4 AIR BOX . . . . . . . . . . . . . . . . . .
. . . . . . . . . B4 CARBURETOR . . . . . . . . . . . . . . . . . .
. . . . CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .
CONTROLS - MASTER CYLINDER/BRAKE LINE . . . . . . . . . . . . . . .
. . . . . . . . . . . CONTROLS - THROTTLE ASM./CABLE . . . COOLING
SYSTEM . . . . . . . . . . . . . . . . . . . CRANKCASE . . . . . .
. . . . . . . . . . . . . . . . . CRANKSHAFT and PISTON . . . . . .
. . . . . . . CV JOINT - BTB . . . . . . . . . . . . . . . . . . .
. . CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . .
.
A C
GGEARCASE (Cases and Snorkel) . . . . . . . . D7 GEARCASE
(INTERNAL COMPONENTS) . . . D3-4
D13-14 C7 B12 B11 A13 D8 D11 B5 D9-10
HHANDLEBAR and HEADLIGHT POD . . . . . . C1-2
IINTAKE and EXHAUST . . . . . . . . . . . . . . . . D12
MMAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . .
E5
OOIL COOLING . . . . . . . . . . . . . . . . . . . . . . . OIL
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP .
. . . . . . . . . . . . . . . . . . . . . . . . . OIL TANK . . . .
. . . . . . . . . . . . . . . . . . . . . . D5-6 E4 E3 B14
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .
A11-12 DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . C5
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . C6
ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . C8 ENGINE
MOUNTING . . . . . . . . . . . . . . . . . . B1-2 EXHAUST SYSTEM .
. . . . . . . . . . . . . . . . . . A14 FOOT BRAKE . . . . . . . .
. . . . . . . . . . . . . . . FRAME MOUNTING . . . . . . . . . . .
. . . . . . . . FRONT BRAKE . . . . . . . . . . . . . . . . . . . .
. . FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . FRONT
HOUSING . . . . . . . . . . . . . . . . . . . . FRONT RACK and
BUMPER MOUNTING . . . FRONT STRUT . . . . . . . . . . . . . . . . .
. . . . . FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK
. . . . . . . . . . . . . . . . . . . . . . . . .
D
PPROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B7
E
RREAR BRAKE/FOOT PEDAL . . . . . . . . . . . . REAR CAB and SEAT
. . . . . . . . . . . . . . . . . REAR DRIVE SHAFT . . . . . . . .
. . . . . . . . . REAR RACK MOUNTING . . . . . . . . . . . . . . .
REAR SUSPENSION . . . . . . . . . . . . . . . . . . REAR WHEEL
DRIVE . . . . . . . . . . . . . . . . . RECOIL STARTER . . . . . .
. . . . . . . . . . . . . . C11-12 A5-6 B6 A8 C9-10 C13 E1
F
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C14
G
E9 C3 B10 A7 D1-2 A9-10 B8 B9 E7 B3
SSTARTING MOTOR . . . . . . . . . . . . . . . . . . . E6
STEERING POST . . . . . . . . . . . . . . . . . . . . . B13
TTOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . .
E8
WWATER PUMP . . . . . . . . . . . . . . . . . . . . . . . E2
The illustrations used in this Parts Manual are for reference to
replacement parts only. This manual is not to be used for
assembly.
(AA) refers to Model #A00CH50AA and (AF) refers to Model
#A00CH50AF, Olive Green. (AB) refers to Model #A00CH50AB and (AH)
refers to Model #A00CH50AH, Porsche Red. (AC) refers to Model
#A00CH50AC and (AJ) refers to Model #A00CH50AJ, Camo. (AE) refers
to Model #A00CH50AE and (AK) refers to Model #A00CH50AK, Medium
Yellow. (EB) Refers To Model #A00CH50EB, Red.
2000 SPORTSMAN 500 SPECIFICATIONSBRAKESType/Brakes Type/Brakes -
Auxiliary Park Brake Hydraulic Disc Mechanical Hydraulic Lock, All
Wheel 2.25 5.25 32 N/A N/A 2 90 180 35 Standard 1225 Engine
Braking
GEARCASETransmission Shift Type Gear Reduction - Low Gear
Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final
Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type PRD Side
Lever 6.69/1 5.17/1 3.34/1 2:1 3-16:1 N/A N/A Shaft
CAPACITIESCoolant Capacity (quarts) Fuel Tank (gallons) Gearcase
Oil (ounces) Engine Counter Balance 10W30 Oil (quarts) Injector Oil
(quarts) Engine OW40 Rack, Front (pounds) Rack, Rear (pounds)
Tongue Weight Tow Hitch Tow Weight
GRAPHICSBody Style Bumper Caps/Polyprop. Cargo Box or Bed
Fender, Front Gen IV (AE)(AK) Medium Yellow (AE)(AK) Medium Yellow
(AA)(AF) Olive Green (AB)(AH)(EB) Porsche Red (AE)(AK) Medium
Yellow (AL) Gun Metal (AC)(AJ) Camo (AA)(AF) Olive Green
(AB)(AH)(EB) Porsche Red (AE)(AK) Medium Yellow (AL) Gun Metal
50(AC)(AJ) Camo Black Semi Flat Black (AA)(AF) Black (AB)(AH)(EB)
Porsche Red (AE)(AK) Medium Yellow (AL) Gun Metal (AC)(AJ) Camo
Black (AA)(AF) Olive Green/Black (AB)(AH)(EB) PorscheRed/Black
(AE)(AK) Medium Yellow/Blk (AL) Gun Metal (AC)(AJ) Camo Black Black
(AA)(AE)(AF)(AK)(AC)(AJ) Black (AB)(AH)(EB)(AL) Aluminum Black
(AA)(AF) Olive Green (AB)(AH)(EB) Porsche Red (AE)(AK) Medium
Yellow (AL) Gun Metal (AC)(AJ) Camo Black Black
DRIVE TRAINType
DRIVE CLUTCHCenter Distance (inches) Clutch Offset (inches)
Clutch Weight Spring Color 10 1/2 10MH(50g) Blue/Green Compound
(EBS) N/A 65 6x7x14 N/A 11 47 81 34 697 50.50 46 EH50PLE09 4 Cycle,
Single Cyl. Dry Sump 92x75 499 10:2 Full Stroke Liquid 250W
Standard 1/BST34(CV type) 152.5 40 Q-0 N/A 2 5/8 Turn 4HB41-3 CDI
30 @ 3500 .028 NGK BKR5E USFS Appr.
Fender, Rear
DRIVEN CLUTCHHelix Angle Spring Position
Footwell Frame/Steel Front Cover
DIMENSIONAL FEATURESApprox. Turning Radius Box, Tool Box (cubic
feet) Ground Clearance (inches) Height (inches) Length (inches)
Seat Height (inches) Weight (lbs. dry) Wheel Base (inches) Width
(inches) Handlebar Cover w/Decal Headlight/Dash Pod
Rack, Front Rack, Rear Rims Seat Vinyl Side Panel
ENGINEEngine Model Number Engine Type Lubrication Type Bore
& Stroke (mm) Displacement (ccs) Compression Ratio Cooling
Alternator Output Elec. Start w/Recoil Back Up Carburetors (no.
of/size) Main Jet Pilot Jet Needle Jet Cut Away Air Screw/Pilot
Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark
Plug Gap (inches) Spark Plug (Type) Exhaust
Spring, Front Spring, Rear
ELECTRICALHeadlight - Handlebar (watts) Headlight - Front Hood
(watts) Headlight - Grill (watts) Taillights (watts) Brake Light
(watts) Indicator Bulb 1 Single Beam, 60W N/A 2 Single Beam, 27W
8.26W 26.9W 1.0W
SUSPENSIONFront Type Front Travel (inches) Rear Type Rear Travel
(inches) Shock Adjustment MacPherson Strut 6.7 Independent 9.5 2 -
1 3/8 Bore Gas Bag CAM
TIRES & WHEELSTire Manufacturer Tire Size - Front Tire Size
- Rear Tire Size - Center Tire Pressure - Front Tire Pressure -
Rear Tire Pressure - Center Goodyear 25x8x12 25x11x10 N/A 5 5
N/A
Polaris Industries Inc. reserves the right to make changes in
design and specifications and/or to make additions or improvements
to its products without notice.
2000 ATV PUBLICATION NUMBERSMODEL MODEL NO. OWNERS MANUAL
9915299 9915299 9915299 OWNERS MANUAL SUPPLEMENT 9915476 9915753
9915476 PARTS MANUAL 9915480 9915480 9915480 PARTS MICROFICHE
9916574 9916574 9916574 ASSEMBLY INSTRUCTIONS 9915512 9915512
9915512
Sportsman 500 Sportsman 500 RSE Worker 500
A00CH50(AA)(AB)(AE) (AF)(AH)(AK)(AL) A00CH50(AC)(AJ)
A00CH50(EB)
REAR CAB and SEATSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
E 2000 Polaris Sales Inc.
15 6 5 7 8 9 1 3 2 43 4 39 40 36 29 41 42 35 34 33 25 10 11 38
21 37 6 3 23 22 14 13 19 12 20 16 17 18
24
27 29 28 32 31 30 26
29 27 28
A5
REAR CAB and SEATSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5
6 7 8 9 10 11 12 13 14 15 16 17
18 19 20
7661645 7511930 7555792 5811107 5432117-191 5432117-136
5432117-053 5433282-283 5432117-317 7541925 5224592 5811308 7512242
7555859 7512085 5433640 7621403 5211033 1040387 7041370 2682441-070
2681747-070 5811104 5811105 5410414 7512130 7555748
10 2 4 1 1 1 1 1 1 4 1 1 4 4 2 1 2 2 1 1 1 1 1 1 8 2 2
Rivet, T-Lock Bolt Washer Foil, Rear Cab, Rear Cab, Rear, Olive
Green (AA)(AF) Cab, Rear, Porsche Red (AB)(AH)(EB) Cab, Rear, Med
Yellow (AE)(AK) Cab, Rear, Camo (AC)(AJ) Cab, Rear, Gun Metal Gray
(AL) Nut, Nylok Retainer, Seat Latch Foil, Tape, Rear Cab Screw
Washer, Flat Screw Box, Tool Rivet Bracket, Lever Retainer Latch,
Seat Spring, Latch Seat Covering, Seat Foil, Seat Base, Large Foil,
Seat Base, Small Bumper, Rubber Screw Washer
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
42 43
5431787 7052095 5410896 7661638 5242953-067 ------7552603
7512492 7542122 5432280 7517377 1012979-067 1013359-067 7078261
7517376 5432221-070 5433219-070 5811111 5811106 7073761 7077446
5811087 7512232 7670057 5431796-070 5431797-070
1 2 1 6 1 1 7 7 28 2 4 1 1 1 8 1 1 1 2 1 1 1 12 12 1 1
Cover, Tool Box Fitting, 90 Degree Cap, Drain Rivet Guard,
Clutch Front Housing (See Front Housing Pg. D1 for Details) Washer,
Spring Lock Screw Nut, Nylok Spacer, Footwell Screw Frame, Main (If
built before 3/13/00) Frame, Main (If built after 3/13/00) Decal -
Hitch Screw Footwell, Black, LH Footwell, Black, RH Foil, Foam,
Rear Fender Foil, Rear Cab, Front Decal - Carburetor Information
Decal - Filter Element Foil, Foam Screw Nut, U-Type Speed Guard,
Mud, Rear, LH Guard, Mud, Rear, RH6/00
A6
FRONT CABSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
2 3 1 4 23 22 21 20 19 18 6 7 8 5
1
5
1
17 14 13Ref. Part No.
16 12 11
15 10
9Ref. Part No. Qty. Description
Qty. Description
1 7512232 2 2631987-191 2631987-136 2631987-053 2632064-283
2632306-283 2632299-317 3 5432088-191 5432088-136 5432088-053
5432088-317 5433290-283 4 7670085 5 7670057 6 7517312 7 7661645 8
7670068 9 5811917 10 7670090 11 7670109
10 Screw 1 Cab, Front, Olive Green w/Warning Decals (AA)(AF) 1
Cab, Front, Red w/Warning Decals (AB)(AH)(EB) 1 Cab, Front, Med
Yellow (AE)(AK) 1 Cab, Front, Camo (AC)(AJ)(If built before
5/15/00) 1 Cab, Front, Camo (AC)(AJ)(If built after 5/15/00) 1 Cab,
Front, Gun Metel Gray (AL) 1 Cover, Frt., Olive Green (AA)(AF) 1
Cover, Front, Red (AB)(AH)(EB) 1 Cover, Frt., Med Yellow (AE)(AK) 1
Cover, Frt. Gun Metal Gray (AL) 1 Cover, Front, Camo (AC)(AJ) 2
Clip, Spring 10 Nut, U-Type Speed 2 Screw 4 Rivet, T-Lock 2 Nut,
Push-on 2 Shield, Deflector 3 Clip, Plastic Dart 1 Clip,
Routing
12 5411778 13 5244913-067 5244914-067 14 7517685 15 7555931 16
7542122 17 5431798-070 5431799-070 18 7541925 19 7555792 20
5431809-053 2620085-053 5431809-191 2620085-191 5431809-136
2620085-136 2632289-317 2620085-317 2632286-283 2632317-283
2632065-283 21 5810996 22 5811491 23 7512085
AR 1 1 1 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2
Line, Breather Guard, Splash, LH Guard, Splash, RH Screw Washer,
Flat Nut, Nylok Guard, Mud, Front, LH Guard, Mud, Front, RH Nut,
Nylok Washer Panel, Side, Yellow LH (AE)(AK) Panel/Foil, Yellow, RH
(AE)(AK) Panel, Side, Green, LH (AA)(AF) Panel/Foil, Green, RH
(AA)(AF) Panel, Side, Red, LH (AB)(AH)(EB) Panel/Foil, Red, RH
(AB)(AH)(EB) Panel/Foam, Gun Metal Gray, LH (AL) Panel/Foil, Gun
Metal Gray, RH (AL) PanelFoam, Camo, LH (AC) PanelFoam, Camo, LH
(AJ) Panel/Foil, Camo, RH (AC)(AJ) Foil, Foam, Side Panel Foil,
Side Panel, Gen. IV, RH Screw10/00
A7
REAR RACK MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
1
2 3 4 6
2 5
7
11 8 9 18
9 10 10 11 12 11 10
13
14 10 15
17 16
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4
2871501 7517685 7517686 2670174-070
1 4 2 1 2 6 1 1 1
5 2670070 6 7517208 7 1040490-067 1012894-067 8 5241663-067
Kit - Rack Extender, Rear (Incl. 6) Screw Screw Asm., Rack, Rear
(Incl. Ref. 5 and Warning Decal) Reflector, Red Screw Support, Rear
Rack (AA)(AB)(AE)(AF)(AH)(AK)(EB)(AL) Support, Rear Rack (AC)(AJ)
Bracket, Silencer, Frame
9 10 11 12 13 14 15 16 17 18
7512329 7558402 7542324 7670096 1040524-067 1040525-067
5333332-067 7515385 7515321 5243378-067 5433305
4 10 8 2 1 1 4 4 4 1 4
Bolt Washer, Flat Nut, Nylok Nut, Chimney Mount, Front, Rear
Rack, LH Mount, Front, Rear Rack, RH Spacer Screw Screw Bumper,
Rear (AC)(AJ) Cap, Bumper, End (AD)(AJ)(AL)10/00
A8
FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE
A00CH50AC and SPORTSMAN 500 RSE A00CH50AJ and WORKER 500
A00CH50EB
1
2 3
7 4 5 16 15 17 18 8 21 22 23 28 24 26 27 25 14 13 12 19 20 6 11
8 9 6 10
6
A9
FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE
A00CH50AC and SPORTSMAN 500 RSE A00CH50AJ and WORKER 500
A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 1040526-067 2 7517685 3 2670180 4 5 6 7 8 9 10 11 12 13 14
2670071 7517208 7515399 2200775 7542324 7558403 5432155-070 7515391
7515390 7555954 1013210-067 1013211-067 15 7512232
1 Extender, Rack, Front, Low (AC)(AJ) 4 Screw 1 Asm., Front Rack
(Incl. Ref. 4 and Warning Decal) 2 Reflector, Amber 4 Screw
(AC)(AJ) 8 Screw 1 Kit - Mount, Front Rack 4 Nut, Nylok 2 Washer 1
Bumper 2 Screw 2 Screw 4 Washer 1 Support, Front Rack, LH 1
Support, Front Rack, RH 4 Screw
16 2431014 2431015 4030059 17 7515382 18 7558402 19 5810467 20
5244623-067 5244624-067 21 5241583-067 22 7621330 23 5240591-067 24
5433305 25 5243377-067 26 7512097 27 7670094 28 5433315 5433316
1 1 2 2 4 1 1 1 1 7 1 4 1 6 6 1 1
Headlight, LH Headlight, RH Bulb, Replacement, 27W Bolt Washer
Plug, Frame Extension, Frame, LH Extension, Frame, RH Guard, Brush
Rivet Grill, Guard, Brush Cap, End, Bumper (AC)(AJ) Bumper, Front
(AC)(AJ) Screw Nut, U-Type Shield, Side, Radiator, LH Shield, Side,
Radiator, RH1/00
A10
DECALSSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and WORKER 500 A00CH50EB
1
2 3
7 4 5 6
8 9 10
RH
13
12 14
11
15 5
16 4 17 18 19
20
LHRef. Part No. Qty. Description Ref. Part No. Qty.
Description
1 2 3 4
7079110 7074110 7077749 7078455 7078456 7078774 7078775 5
7078452 7078433 6 7078459 7078777 7078513 7 7074935 7079213 8
7078003 9 7078315 7078465 10 7078449 7078859
1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1
Decal - Warning, Rear Rack Decal - Load Distribution Decal -
Park Brake Warning (EB) Decal - 4X4 ISD, LH (AA)(AB)(AF)(AH) Decal
- 4X4 ISD, RH (AA)(AB)(AF)(AH) Decal - 4X4 ISD, LH (AE)(AK)(AL)
Decal - 4X4 ISD, RH (AE)(AK)(AL) Decal - POLARIS, Side Panel
(AA)(AB))(AE)(AF)(AH(AK)(EB) Decal - POLARIS, Side Panel (AL) Decal
- Tank Side, RH (AA)(AB)(AF)(AH) Decal - Tank Side, RH (AE)(AK)
Decal - WORKER, Tank Side, RH (EB) Decal - Warning, AWD Switch
(AA)(AB))(AE)(AF)(AH(AK)(EB) Decal - Warning, AWD Switch (AL) Decal
- Headlight Adjustment Logo, 45th Anniversary (If built before
12/31/99) Logo, Polaris Star (AF)(AH)(AL) Decal - 500 L/C 4 Stroke
(AA)(AB)(AF)(AH) Decal - 500 L/C 4 Stroke (AE)(AK)(AL)
11 7074220 12 7078354 7079085 7078577 7079102 7079604 7078253
7078458 7078776 7078512 18 7077920 19 7075834 13 14 15 16 17
7079084 20 7077919 7079083
1 Decal - Macpherson Strut 1 Decal - Discretionary Warning
(AA)(AB))(AE)(AF)(AH(AK)(EB) 1 Decal - Discretionary Warning (AL) 1
Decal - Drain Recoil 2 Decal - Rack/Warning 1 Decal - Warning,
Override, AWD 1 Decal - Age Warning, ATV 1 Decal - Tank Side, LH
(AA)(AB)(AF)(AH) 1 Decal - Tank Side, LH (AE)(AK)(AL) 1 Decal -
WORKER, Tank Side, LH (EB) 1 Decal - Passenger Warning 1 Decal -
Tire Pressure (AA)(AB))(AE)(AF)(AH(AK)(EB) 1 Decal - Tire Pressure
(AL) 1 Decal - Warning, General, CPSC (AA)(AB))(AE)(AF)(AH(AK)(EB)
1 Decal - Warning, General, CPSC (AL)
10/00
A11
DECALSSPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ 1 8 2 3 4 6 7 9 10
5
RH
13
12 15 17 16 18 19
11
14
LH
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10 11
7074954 7074110 7078049 7078050 7078051 7078253 7078047 7078003
7074935 7078046 7078045
2 1 1 2 2 1 2 1 1 1 1
Decal - Rack/Warning Decal - Load Distribution Decal - EBS Dual
Sensing, RH Decal - 4X4 Indy Shaft Drive Decal - SPORTSMAN Decal -
Age Warning Decal - POLARIS Decal - Headlight Adjust Decal -Warning
AWD Switch Decal - Remington Special Edition Decal - Liquid Cooled,
Radiator
12 7078354 13 7078577 14 7078315 7078465 15 16 17 18 19 7076273
7077919 7078048 7077920 7079084
1 Decal - Discretionary Warning 1 Decal - Drain Recoil 1 Logo,
45th Anniversary (If built before 12/31/99) 1 Logo, Polaris Star
(If built after 12/31/99) 1 Decal - Override Switch, AWD 1 Decal -
Warning, General, CPSC 1 Decal - EBS Dual Sensing, LH 1 Decal -
Passenger Warning 1 Decal - Tire Pressure/Load10/00
A12
COOLING SYSTEMSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
1 2 4 3
6
7 16 9 10 11 13 19 20 15 17
8 8
18
5 12 35 34 36 37 38 39 40 9Ref. Part No.
14
21
22 23
24
14 26 27 25
29
32 33
11 31 30
28 29
41Qty. Description Ref. Part No. Qty. Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
7080807 1240044 5433364 5243505-067 7661638 5433707 5411783
7080827 7512084 5411632 7080826 7517659 2410123 7670111 7080492
7547069 3110032 5020572 5433059 4010161 1240045
1 1 1 1 3 1 1 2 4 1 2 4 1 4 1 2 2 2 1 1 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 Cable Tie
Nutsert Mount, Rubber Spacer Shroud, Fan Sensor, Thermal
Radiator
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
7552605 7512113 5433317 5410607 7052244 5410584 5243503-067
7517386 7080890 5411782 5521550 7080851 7080696 4010369 5430743
5810279 5433774 5431673 8450003-1525 7052065
2 2 1 4 1 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1
Washer, Split Lock Screw Cover, Radiator O-Ring Valve, Drain
Bushing, Mount Bracket, Radiator, Lower Screw Tie, Panel Hose,
Engine, Lower Plastic, Guard, Hose Clamp, Hose Clamp, Hose Breaker,
Circuit, Fan Cap, Overflow, Drilled Gasket, Overflow Cap Plug, Cap
Tank, Surge Line, Fuel Fitting, Barbed, 90 Degree9/00
A13
EXHAUST SYSTEMSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
1 2 3 4 5
6 7 8 5 7 8 8
9
12 13 10 11 3 13
14
5
7 15 11
1
2 12
12 16Qty. Description
14Ref. Part No. Qty. Description Ref. Part No.
1 2 3 4 5 6
7542324 7555716 5410436 7555863 5010192 ------
3 3 3 2 3 1
7 5410241 8 7515316
Nut, Nylok Washer, Flat Washer, Rubber Washer Bushing Bracket,
Silencer, Frame (See Rear Rack Mounting Pg. A8, Ref. 8) 3 Dampener,
Vibration 3 Bolt, Carriage
9 10 11 12 13 14 15 16
1260715-029 7512666 7042031 7515197 7555935 5241678 1260716-029
5240898
1 1 4 4 4 2 1 1
Silencer, Exhaust Bolt Spring, Exhaust Screw Washer Shield,
Heat, Exhaust Pipe, Exhaust Seal, Exhaust10/98
A14
ENGINE MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
2 3 1 2 48 19 4 2
7 5 6
8
9 10
9 11
12 13 14 15
4 16 47 38 18
13 17
11
39 44 46 45 24 25 22 23 20 21 30 8 31 29 26 19
42 40 41
43
19
19 38
39 19
28 27
37
36
35 34 33 32
B1
ENGINE MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
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
7546601 7080003 5811490 8450040-600 ------7080413 5410995
7080511 8450003-1525 7052075 3110032 7552605 7547069
-----5211626-067 8360009-600 7512315 7552901 7547108 7080694
------7555815 3110046 7080539 7621462 5224658-067 7512566
2 8 1 AR 1 1 1 2 AR 1 2 2 2 1 1 AR 2 2 8 1 AR 2 2 1 1 1 1
Nut, Nylok Clamp, Hose, Red Hose, 1.75 Long Line, Fuel Asm.,
Carburetor (See Carburetor Pg. D14, Ref. 47) Clamp, Narrow Band
Boot, Carburetor Clamp, Narrow Band Line, Fuel Fitting, Tee Mount,
Rubber Washer, Split Lock Nutsert Screw and Washer (See Carburetor
Pg. D14, Ref. 48) Strap, Carburetor Mount Line, Fuel Bolt Washer,
Spring Lock Nut, Flange Lock Clamp, Spring Hose Hose, Breather (See
Air Box Pg. B4, Ref. 16) Washer Mount, Rubber, Front Clamp, Nylon
Rivet Strap, Frame Support Bolt
28 29 30 31 32
7575202 5210748 5430261 5410421 -------
1 1 1 1 1 2 1 2 2 1 2 2 2 2 1 1 1
33 - - - - - - 34 - - - - - - 35 36 37 38 39 40 41 7080474
7515417 5241150-067 3110044 7555801 -------------
42 1260771-029 43 - - - - - - 44 3085556
45 46 47 48
5241453-067 7512232 4010132 2530009
1 1 1 1
Washer, Interlock Washer, Flat Bushing Boot, Clutch Intake Asm.,
Drive Clutch, Braking (See Drive Clutch Pg. C5, Ref. 17) Screw and
Washer (See Crankcase Pg. D8, Ref. 6) Bracket, Retainer, Seal (See
Clutch Cover Pg. C7, Ref. 24) Clamp, Hose Screw Mount, Engine,
Front Mount, Rubber, Top Washer, Wrought Nut (See Cylinder Pg. D10,
Ref. 22) Washer (See Cylinder Pg. D10, Ref. 23) Manifold, Black
Gasket, Exhaust (See Cylinder Pg. D10, Ref. 20) Engine, Short Block
(EH50PLE09) 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. Mount, Engine, Top Screw Cable, Ground, Engine
Filter1/00
B2
FUEL TANKSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1 2 3 4
6 5 7 8
9
21 10 19 18 15 17 11
20
16 15 14
13
12
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10
5430725 5810144 5811310 8360009-600 5431053 7517451 7512247
7552801 7558301 5222154-067 5222155-067 5332457
1 1 1 AR 1 2 2 2 2 1 1 2
Cap, Gas Tank Gasket, Fuel Cap Seal, Foam Line, Fuel Vent, Tank
Bolt (AA)(AB) Screw (AF)(AH)(AK)(AJ) Washer, Spring Lock Washer,
Flat Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH Spacer
(AA)(AB)
11 12 13 14 15 16 17 18 19 20 21
7547069 5810317 7052150 8450040-600 7080003 7052149 7517505
5432559 5432733 7052161 2520144
2 2 1 AR 4 1 1 1 1 1 1
Nutsert Pad, Fuel Tank Bracket 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.
13,16)1/00
B3
AIR BOXSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
6 1 2 3 5 9 4 10 11 7
8
12 26 25 24 23 22 21 20Ref. Part No. Qty. Description Ref. Part
No.
13
14
13
15 13 16
18 17 13 19
Qty. Description
1 2 3 4 5 6 7 8 9 10 11 12 13
5811633 7080595 7080413 5432601 5432868 7517541 5433293 5811626
5432086 5411422 5811482 5432774 7080699
1 1 1 1 1 4 1 1 1 1 1 1 4
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 Gasket, Intake Seal, Air Box Cover Box,
Air Clamp, Hose
14 15 16 17 18 19 20 21 22 23 24 25 26
8450073-600 2530029 5411847 5432858 5830128 5411668 5432377
8450059-150 7080650 5811650 7558301 7515179 5242044
AR 1 AR 1 1 1 1 AR 1 1 2 2 6
Line, Breather Filter, Breather Hose, Breather Duct, Carburetor
Inlet Gasket, Carburetor Inlet Duct Line, Breather Plug, Trap Line,
Fuel Clamp, Hose Foil, Air Box Washer, Flat Screw Clip, Air
Box3/00
B4
CV JOINT - BTBSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
BTB 7 2 3 4 5 6 8 9
1
10
11 12
13
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7
1380119 5222299 3260115 7670091 5411106 1380094 1380092
2 1 1 1 1 1 1
Asm., CV Housing w/Sleeve Sleeve, Drive Shaft Seal Clamp, CV
Joint, Large Circlip Boot, CV Joint Shaft Replacement (Incl. 4)
Cardan Replacement (Incl. 4,6,8,9)
8 9 10 11 12 13
2200771 3260130 7661913 7080627 2200773 2200961
1 1 3 1 1 1
Kit - Cross and Bearing Yoke, Splined Pin, Spring Clamp, Small
Band Kit - Boot Replacement (Incl. 3,5,11) Kit - Drive Shaft
w/Sleeve BTB10/98
B5
REAR DRIVE SHAFTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
1
2
3
4
5
6
5
7
2
8
9
11
10
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5
1380142 1590280 1350044 1350046 7710505 1350045
2 1 2 1 1 2
Asm., Drive Shaft, Rear (Incl. 1-9) CV Joint Clamp, Large
Grease, 30g Ring, Retaining Boot
6 7 8 9 10 11
1350043 1350047 1590281 1350042 2201374 2201373
2 1 1 1 1 1
Clamp, Small Grease, 50g Joint, Plunging Ring, Spring Kit - Boot
(Gear Side) Kit - Boot (Wheel Side)3/00
B6
PROP SHAFTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1 2 3 5 4 6
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1380146 1 7661913 2 3260133 3 -------
1 1 1 2
Shaft, Prop Pin Yoke, Gear Case, Front Kit - Cross and Bearing
(See CV Joint - BTB Pg. B5, Ref. 8)
4 3260136 5 3260131 6 5411092
1 Shaft, Prop 1 Yoke, Prop Shaft, Transmission 1 O-Ring
2/00
B7
FRONT STRUTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
27 26 25 24
1
2 3 4 11 6 5 7
8
4
22 21
23 12
9
4 20
19 18
14 13
10
17
15 16
12 11
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
5411608 7041761 5211115 7558402 7080573 7542324 7512365 7552901
5810439 ------3554509 3554507 5222193 7080306 2410133
2 2 2 10 2 4 4 4 2 1 4 4 2 2 2
Bumper Strut, Front Washer Washer, Flat Clamp, Rubber Coated
Nut, Nylok Screw Washer, Spring Lock Retainer, Casting Wire, Strut
Asm., Front Brake Caliper, RH (See Front Brake Pg. B10 for Details)
Bearing, Tapered Roller Bearing, Tapered Roller Cup Sleeve,
Hubstrut Seal Fitting, Lubrication Coil, Magnetic
16 2201311 2201312 17 18 19 20 21 22 23 24 25 26 27 7041375-067
5243364 5432871 7515339 5132062 ------3610028 5432872 5810291
7555749 7547104
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 BTB (See CV Joint - BTB Pg. B5, Ref. 13) 2
Seal, Hubstrut 2 Ball, Pivot, Top 2 Spacer, Rubber 2 Washer 2 Nut,
Nylok6/00
B8
FRONT WHEELSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1 2 9 4 5 26 7 6 8 10 11 12 13
3
25 14
24 23
15
6 5 16 18 17 19 20
22 21Ref. Part No. Qty. Description Ref. Part No. Qty.
Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14
7512325 3610019 5211148 1520281 3554506 3554507 7515523 1520243
3250028 3250010 3250032 1321814 3250030 7052045
8 2 2 2 4 4 8 2 2 12 2 2 2 2
Bolt 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. 2,6,7) Cage, Roll Roll
Spring, Garter Spacer Cam Plug, Magnetic Drain
15 16 17 18 19 20 21 22 23
5410947 7556004 7542810 7661401 5410470 5432611 7512027 7542459
1520269-067
2 2 2 2 2 2 6 8 2 2 2 2 2
1520269-117 24 1525017 25 5243676 26 5242935
Tire (25x8-12) Washer Nut, Slotted Pin, Cotter O-Ring Cap, Hub
Screw Nut Rim, Front, Black (AA)(AC)(AE)(AF)(AK)(AJ) Rim, Front,
Aluminum (AB)(AH)(AL)(EB) Valve, Rim Disc, Brake
(AF)(AH)(AK)(AL)(AJ)(EB) Disc, Brake (AA)(AB)(AC)(AE)6/00
B9
FRONT BRAKESPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
2
3 4 5 6 7
1
14
13
12 11
10
8 9
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1910309 1910310 1910427 1910428 1 7080352 2 7515489 3 5131115
5131116 1930642 4 1930665 5 5410779 6 5410780 7 5132294
1 Asm., Front Brake Caliper, LH (Incl. 1-7,9,10)(AA)(AB)(AC)(AE)
1 Asm., Front Brake Caliper, RH (Incl. 1-7,9,10)(AA)(AB)(AC)(AE) 1
Asm., Front Brake Caliper, LH (Incl.
1-7,9,10)(AF)(AH)(AK)(AJ)(AL)(EB) 1 Asm., Front Brake Caliper, RH
(Incl. 1-7,9,10)(AF)(AH)(AK)(AJ)(AL)(EB) 1 Screw, Bleeder 1 Screw,
Socket Set 1 Caliper, Brake, LH 1 Caliper, Brake, RH 1 Kit - Front
Brake Boot 1 Kit - Piston and Seal(Incl. 5-7) 1 Ring, Molded Square
(.094) 1 Ring, Molded Square (.103 x .134) 1 Piston, Brake,
Long
8 2200465 2200901 2201149 2201398 9 10 11 12 1910411 5410495
5410494 -------
13 - - - - - - 14 - - - - - - -
1 Kit - Front Brake Pad, General Duty (AA)(AB)(AC)(AE) 1 Kit -
Front Brake Pad, Severe Duty (AA)(AB)(AC)(AE) 1 Kit - Front Brake
Pad (AA)(AB)(AC)(AE) 1 Kit - Front Brake Pad
(AF)(AH)(AK)(AJ)(AL)(EB) 1 Mount, Caliper 1 Boot, Bushing 1 Boot,
Pin Seal 4 Washer (See Front Strut Pg.B8, Ref. 4) 4 Washer (See
Front Strut Pg. B8, Ref. 8) 4 Screw (See Front Strut Pg. B8, Ref.
7)6/00
B10
CONTROLS - THROTTLE ASM./CABLESPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE
A00CH50AC and SPORTSMAN 500 RSE A00CH50AJ and WORKER 500
A00CH50EB
1
2 3
4 5
6
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 5410193 2 5433806 3 5411439
1 O-Ring 1 Cover 1 O-Ring
4 7080709 5 2010188 6 2010191
1 Cable, Throttle 1 Asm., Throttle Control (Incl. 2,3,6) 1 Asm.,
Throttle Clamp1/00
B11
CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE
A00CH50AC and SPORTSMAN 500 RSE A00CH50AJ and WORKER 500
A00CH50EB
1 2
3 4 14
13
15 28 12 6 5
27 16 25 22 24 20 26 17 18 19
11
7 8 9
22 23Ref. Part No.
21
10Ref. Part No. Qty. Description
Qty. Description
2050078 2200809 1 2 3 4 5 6 7 8 9 10 11 12 13 1930797 1930796
1930795 2200808 1930799 1930804 2201034 ------2201090 1930806
1930792 1930805 -------
1 Asm., Master Cylinder (Incl. 13) 1 Kit - Master Cylinder
Reservoir (Incl. 1-3,13) 2 Bolt, Cap 1 Cap, Reservoir 1 Diaphragm 1
Kit - Master Cylinder Clamp 1 Asm., Piston Master Cylinder 1 Rivet
1 Kit - Brake Lever w/Parking Latch (Incl. 6-9) 1 Spring, Flat 1
Kit - Park Brake Lever (Incl. 6,8) 1 Nut 2 Bolt, Reservoir 1 Bolt 1
Ring, Square, Reservoir
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
5411297 5410988 4110164 ------7621462 7080539 8360031-30 1930752
7080138 7512024 1930753 8360011-38 7052129 1930817 1930674
1 2 1 1 2 2 1 1 8 2 1 1 1 1 1
Boot, Rubber Brake Line Seal Switch Line, Rear Brake (See Rear
Brake/ Foot Pedal Pg. C12, Ref. 5) Rivet Clamp, Nylon Conduit Line,
Brake, Left Front w/Fittings Cable Tie Screw Line, Brake, Right
Front w/Fittings Tubing, Convoluted Fitting, Inverted Flare Cross
Line, Brake, Pod Bolt, Banjo4/99
B12
STEERING POSTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1
2 14 3
16 15
4
5 6 7 11
13 12
7 6 8 6 9 10Ref. Part No. Qty. Description Ref. Part No. Qty.
Description
1 2 3 4 5 6 7 8
1843051 5433415 7080424 7515321 5431574 7555878 5410772
5431571
1 1 1 2 1 3 2 1
Asm., Steering Post (Incl. 5,13) Bushing, Steering, Console
Fitting, Lubrication Bolt Plug, Grease, Steering Washer O-Ring
Spacer, Steering Post
9 10 11 12 13 14 15 16
7543203 7661633 5431570 7661632 7080433 5433416 5222999-067
7542324
1 1 1 2 1 1 1 2
Nut Pin, Cotter Bushing, Steering, Lower Rivet Fitting,
Lubrication Bushing, Steering, Upper Bracket, Steering Bushing,
Upper Nut, Nylok1/00
B13
OIL TANKSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
To Airbox
5 4 3 9 8 2 1To Lower Oil Pump Fitting on Engine
6 7
10
23 8 11 22 12 13 9To Top Oil Pump Fitting on Engine
9
21 20 17 18 19Ref. Part No.
15
14
14
16
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10 11 12
7511848 5211523 5830053 7052163 5411668 5432289 5410889 7517102
7555896 7052109 7052133 2530020
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
13 14 15 16 17 18 19 20 21 22 23
7542122 7558301 5131785 5411042 5410828 5333204 7512130 7051524
5850135 7515158 5131255
2 2 1 1 2 2 2 1 1 9 1
Nut, Nylok Washer, Flat Tank, Oil, LH Grommet Grommet, Mounting,
Reservoir Bushing Screw Plug, Magnetic Washer Screw Tank, Oil,
RH11/02
B14
HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A00CH50AA and SPORTSMAN
500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
1 2
18 3 14 17 16 4 11 10 7 8 13 12 9 15 20 19
5
6 4 21
22 23 24 25
26
43 42
39
40
41 27 28
44
30
29 31
38
37 36 35
34
33
32
C1
HANDLEBAR and HEADLIGHT PODSPORTSMAN 500 A00CH50AA and SPORTSMAN
500 A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3280290 3280312 2 5430967 4040053 4040054 3 7511881 4 7670086
5 2460668 6 -----7 5242987-067 8 2200774 5630616-067 7541933
7555868 7558212 7515189 3280291 5433042-053 5433042-191 5433042-136
5433042-317 5433289-283 15 - - - - - - 9 10 11 12 13 14 16 17 18 19
20 21 22 23 24 5432926 4010262 5431030 5432952 7517625 5240586-067
7517317 4032079 5411120
1 1 1 1 1 3 3 1 1 1 1 2 2 2 2 4 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1
1
Speedometer Speedometer, Kilometers (EB) Plug, Indicator
Indicator, Hot Temperature Indicator, Neutral/Reverse Screw Nut,
U-Type Harness, Headlight Pod Asm., Throttle Control (See Controls
Throttle Asm./Cable Pg. B11, Ref. 5) Tube, Handlebar Kit -
Handlebar Block (Incl. Blocks and 8,12,30) Block, Handlebar
Retainer Nut, Brass Washer, Lock Washer, Flat Screw Clamp,
Speedometer Pod, Headlight, Upper (AE)(AK) Pod, Headlight, Upper
(AA)(AF) Pod, Headlight, Upper (AB)(AH)(EB) Pod, Headlingt, Upper
(AL) Pod, Headlight, Upper (AC)(AJ) Asm., Master Cylinder (See
Controls - Master Cylinder/Brake Line Pg. B12 for details) Spacer,
Switch Switch, Handlebar Grip, Handlebar Plug Screw, Set Bracket,
Pod Mounting Screw Knob, Adjusting Boot, Headlight
27 4032078 28 5410163 29 7080726 2200188 30 7542122 31 7670089
32 2410025 33 7621334 34 4010283 35 7080631 36 7522021 37
5432314-070 5433366-070 5433706-283 5431811-070 38 4110264
4010278
1 2 1 1 4 2 1 2 1 1 2 1 1 1 1 1 1
4010321
1
39 40 41 42
25 4032077 26 4032075 2870448
1 Collar, Locking 1 Lens and Reflector 1 Bulb, Headlight,
Halogen
5433534 5433733 7080229 4040081 4010298 43 5132382 44
7517658
1 1 1 1 1 1 1
Rod, Adjusting O-Ring Cable, Choke w/Adjuster Kit - Choke
Control Nut, Nylok Nut, U-Type Plug, Power, 12V (If built before
9/27/99) Rivet, Bulbex Receptacle, Pod Mount, 12V (If built after
9/27/99) Clip, Cable Retaining Screw Pod, Headlight, Lower (If
built before 9/27/99)(AA)(AB) Pod, Headlight, Lower (If built
between 9/27/99 and 4/24/00) (AA)(AB)(AE)(AF)(AH)(AK)(AL)(EB) Pod,
Headlight, Lower (If built between 9/27/99 and 4/24/00)(AC)(AJ)
Pod, Headlight, Lower (If built after 4/24/00)(AC)(AJ)(AF)(AH)
Switch, Ignition (Incl. Key) Key, Blank, 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. Key,
Blank, 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, Ignition
Nut, Choke Slide Sensor (If built before 8/09/99) Sensor (If built
after 8/09/99)(Incl. 43) Cap (If built after 8/09/99) Screw
10/00
C2
FRAME MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1 4 3 2 10 11 9
5
6 7 8
3
7
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6
7661013 1040494-067 5431107 5020850 7542122 -------
2 1 2 1 1 2
Pin, Clevis Pivot, Shift Bushing Tube, Pivot Nut, Nylok Rod End,
LH (See Gear Selector Pg. C14, Ref. 17)
7 7517386 8 7512144 9 ------10 5131277 11 7661103
4 Screw 1 Screw 4 Nut, FLEXLOC (See Gear Selector Pg. C14, Ref.
14) 1 Arm, Shift 2 Pin, Cotter4/99
C3
A-ARM/STRUT MOUNTINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1 4
5 2
6 7 8 9
3
10
31
30
11 9 29 28 12 13 14
28
29 26 22 23 24 25 20 21
23
22
27 15 16 19 14 18 17
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7542403 2 5333367 3 1820567 1820805 4 5 6 7 8 9 10 11 12 13 14
15 5411291 7061034 7542711 5020926 7547028 7061033 7061054 5411920
7517674 7555806 7556099 7546904 7661203 7080927
2 Nut, FLEXLOC 1 Bushing 2 Asm., Tie Rod (Incl. 4-9)(If Built
before 8/16/99) 2 Asm., Tie Rod (Incl. 4-9)(If Built after 8/16/99)
2 Boot, Seal, Rod End 2 Rod End 2 Nut 2 Tie Rod 2 Nut, LH 2 Rod
End, LH (If Built before 8/16/99) 2 Rod End, LH (If Built after
8/16/99) 1 Boot, Seal, Rod End 2 Bolt (If Built after 8/16/99) 4
Washer, Flat (If Built before 8/16/99) 4 Washer, Flat (If Built
after 8/16/99) 2 Nut 4 Pin, Cotter 2 Joint, Ball
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
5211121 7512284 5410548 7542438 5431837 5431838 7512084 5433066
5020677 5020681 2201607 2201608 7080433 -------7512492 7552603
7517527 7515415
2 4 2 2 1 1 6 4 4 2 1 1 2 1 4 4 1 1
Bracket, Ball Joint Screw Boot, Rubber Nut, Castle Shield, CV
Joint, LH Shield, CV Joint, RH Screw Bushing, A-Arm, Long Bushing
Shaft, A-Arm Kit - A-Frame, LH Kit - A-Frame, RH Fitting,
Lubrication Asm., Heavy Hubstrut (See Front Strut Pg. B8, Ref. 16)
Screw Washer, Spring Lock Bolt Screw10/00
C4
DRIVE CLUTCHSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
5 4 1 2 3 6 7 8 10 18 12 15 14 5 13 11 9
16
17 A00CH50(AA)AB)(AE)(AF)(AH)(AK)(AL)(AC)(AJ)
11 10
14
13
5 19
16
15
20
9
12 5
6
4 21 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10 11 12 13
1520231 7556009 5631119 7541906 5431936 5020422 3585712 7547130
3576510 7552801 7512176 7041157 1321457
1 1 1 3 6 3 1 1 1 6 6 1 3
Clutch, One Way Drive Washer Spacer Nut, FLEXLOC Button, Clutch,
Stemless Pin, Roller Bearing Nut, Jam Cover, Bearing Washer, Spring
Lock Bolt Spring, Clutch Roller and Bushing
14 15 16 17
5430945 7512266 5630513 1321706
6 3 3 1 1 AR AR AR AR 1 1
18 7556008 19 5210752 5242981 5210753 5210754 20 3576504 21
1321632
Washer, Multilube Bolt, Shoulder Weight, Shift, 10 MH Asm.,
Drive Clutch, Braking (Incl. 1-11,13-15,18)(AA)AB)(AE)(AF)(AH)(A
K)(AL)(AC)(AJ) Washer Spacer (.020) Spacer (.025) Spacer (.032)
Spacer (.050) Bearing, Moveable, 12 Asm., Drive Clutch (Incl.
4-6,10-16,19,20)(EB)6/00
C5
DRIVEN CLUTCHSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
A00CH50EB 9 8 7 6 10
1
2
3
4
11 12 13
5
A00CH50AA A00CH50AB A00CH50AE A00CH50AF A00CH50AH A00CH50AK
A00CH50AL A00CH50AC A00CH50AJ 9 10 27 26 13 25 20 22
5 1 17 18
14 15 16
21 20 23 24 19
2
3
4
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10 11
7556120 5220646 7552901 7515382 1322182
AR 1 1 1 1 1 3 3 1 1 1 1 1 1 1
3211077 5430766 7511854 7710448 5210752 5132344 5131447 12
7041198 13 3576511 14 3576504
Bushing Washer, Domed Washer, Spring Lock Bolt Asm., Driven
Clutch, 3 Angle, Heavy (Incl. 7-16)(EB) Belt, Drive Button, Ramp
Bolt Ring, Retaining Spacer Ramp, Stationary (If built before
4/01/00) Ramp, Stationary (If built after 4/01/00) Spring, Clutch
Bearing, Moveable (1) Bearing, Moveable (1/2)
15 7556804 16 7555898 7556076 17 7556013 18 7556010 19 7710461
20 1322190 21 22 23 24 25 26 27 3211069 7517323 1321977 3585710
5211115 7041636 5131674
AR AR AR 1 1 1 1 1 3 1 1 1 1 1
Washer (.030) Washer, Spacer (.020) Washer, Spacer (.025) Washer
Bushing Ring, Retaining Asm., Driven Clutch, Braking (Incl.
2,9,10,13,18,19,24-27)(AA)(AB)(AE)(A F)(AH)(AK)(AC)(AJ) Belt, Drive
Screw Roller, Taper Bearing Washer Spring Ramp, Stationary10/00
C6
CLUTCH COVERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
4 3
5
6
7 11 8 9 10 14 15 12 13
1
2
29 28 17 27
21
23 26 25 24 22 19 21 20 18 17 13 16
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 1040519-067 2 7512240 3 5410489 5411901 4 2201160 5 7555748 6
7552605 7 7512247 8 7512277 9 7512278 10 5521301 11 5433540
5433451-070 12 7670051 13 7512093 14 7074946 7078689
1 2 1 1 1 3 3 1 1 1 1 1 1 1 5 1 1
Bracket, Clutch Cover, Rear Bolt Seal, Cover Case (If built
before 3/13/00) Seal, Cover Case (If fuilt after 3/13/00) Kit -
Inner Clutch Cover (Incl. 13,18,26) Washer Washer, Split Lock Bolt
Bolt Screw Seal, Cover, Clutch Cover, Clutch, Outer (If built
before 3/13/00) Cover, Clutch, Outer (If built after 3/13/00) Clip,
Clutch Cover Screw (If built before 3/13/00)(Use 7512094 if built
after 3/13/00) Decal - Warning, Clutch Cover (If built before
10/04/99) Decal - Warning, Clutch Cover (If built after
10/04/99)
15 7077377 16 7077666 17 7555935 18 7512094 19 20 21 22 5411489
7080761 7512232 5432947 5433980 23 - - - - - 24 25 26 27 28 29
5240409-067 5410575 7512095 5241156-067 7080511 -------
1 Decal - Engine/Clutch Modification (If built before 10/04/99)
1 Decal - Automatic/EBS, Clutch 2 Washer 2 Screw (If built before
3/13/00)(Use 7512278 if built after 3/13/00) 1 Boot, Duct 2 Cable
Tie 2 Screw 1 Duct, Clutch Outlet (If built before 3/01/00) 1 Duct,
Clutch Outlet (If built after 3/01/00) 3 Screw and Washer (See
Crankcase Pg. D8, Ref. 6) 1 Bracket, Retainer, Seal 1 Seal, Cover
Case 1 Screw 1 Bracket, Cover, Clutch 1 Clamp, Narrow Band 1 Duct,
Air Inlet (See Air Box Pg. B4, Ref. 9)6/00
C7
ELECTRICAL/TAILLIGHTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1 3 2
4
5 6 7 8 13 12 11 14 15 16 17 18 19
10
9
32 31 30
11
12 24 23
15 22 21
20
29 28 27 26 25
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
2460784 2200593 2201795 2432034 4032046 4032029 4030043 4032045
4032064 7670054 7541925 7571602 7512027 5810290 4010094 2200361
1 1 1 1 1 2 1 1 1 2 4 4 2 3 1 1
Harness, Main Kit - Circuit Breaker, 20 AMP Kit - Circuit
Breaker, 10 AMP Asm., Taillight w/Brake Light (Incl. 5-10) Lens,
Taillight Screw, Taillight Bulb, Taillight Gasket, Taillight
Backing, Taillight/Brake Light Nut, Speed Nut, Nylok Washer Screw
Pad, Battery Cable, Battery/Solenoid Kit - Battery Bolt, Short
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
4010095 7010032 5410424 5432077 4140006 5431769 4010093 7512007
5810455 5241416 7512024 5131036 4060173 7512018 4020149 7670109
1 2 1 AR 1 1 1 2 2 1 1 1 1 3 5 2
Cable, Battery/Engine Hook, Battery Strap Strap, Battery
Holddown Tube, Battery Vent Battery Cover, Battery Cable,
Solenoid/Starter Bolt Pad, Rack Mount Bracket, CDI Screw Sink, Heat
Regulator Screw Clip, Rosebud Clip, Routing1/00
C8
REAR SUSPENSIONSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1 16 4 1 2 3 5 6 16 3 11 15 14 9 13 12 10 11 10 17 11 15 14 18
19 20 17 9 32 10 8 11 10 9 20 10 18 23
6 5 7
12
21 20 17 18
20 22
24 25 24 26 17 27
5 6 12
8 9
34 11 33 10 32
18
36 20 44 9 6 8 9 5 4
35
28
31 11 35 37 18
29 30
43
42 41 40
38
39
C9
REAR SUSPENSIONSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24
7512329 1580107-067 7542324 7517231 7555761 5432598 5020827
5020826 5433063 5020677 7080433 7515472 5333393-067 7555939 5433413
7558402 7512492 7552603 1541322-067 7542439 5242077-067 7515433
7542321 7515321
6 2 6 4 8 8 2 6 12 12 12 6 1 4 2 8 16 16 1 8 2 2 2 4
Bolt Arm, Stabilizer Bar Nut, Nylok Screw Washer, Flat Bushing,
Stabilizer Rod, Linkage, Stabilizer Shaft, A-Arm, Short Bushing,
A-Arm, Short Bushing Fitting, Lubrication Screw Bar, Stabilizer
Tube Washer Bushing, Stabilizer Tube Washer, Flat Screw Washer,
Spring Lock Support, Stabilizer Nut, Nylok Bracket, A-Arm Pivot
Screw Nut, Flange Bolt
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
5224667-067 7552901 5630885 7041453-067 7041519-067 5630551
7041770 7515415 5433066 5020681 1012717-067 1012718-067 5433065
1040730-067 1040731-067 5131883 7555936 7517297 5433098-070
5433099-070 7512084 5131738 3585502 7080586
1 2 2 2 2 2 2 2 4 2 1 1 8 1 1 4 4 4 1 1 4 2 2 2
Support, Transmission Washer, Spring Lock Retainer, Spring
Spring, Compression, Rear Spring, Compression, Rear (EB) Cam,
Adjusting, Spring Shock, Rear Screw Bushing, A-Arm, Long Shaft,
A-Arm Arm, Control, Lower, LH Arm, Control, Lower, RH Bushing,
Control, Lower Arm, Control, Upper, LH Arm, Control, Upper, RH
Bushing, Bearing Carrier Washer Screw Shield, LH Shield, RH Screw
Carrier, Wheel Bearing Bearing, Wheel Carrier Fitting,
Lubrication6/00
C10
REAR BRAKE/FOOT PEDALSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
7
8 9 5 4 2 3 6 11 10
1
24
23
22 21 11 12
20
19 18 15 14 15 16 14 13
17
C11
REAR BRAKE/FOOT PEDALSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4
7515497 7552603 7555806 1910366 1910441 2201093 1910339 1930860
2201399 2201180 2201428 2201181 1930853 1910305 7512111 1930854
2 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1
5 6 7 8
Screw Washer, Spring Lock Washer, Flat Asm., Caliper, Rear
(AA)(AB)(AC)(AE) Asm., Caliper, Rear (AF)(AH)(AK)(AJ)(AL)(EB) Kit -
Brake Pad (Incl. Spacer and Pin) (AA)(AB)(AC)(AE) Spacer Pin Kit -
Brake Pad (Incl. Spacer and Pin) (AF)(AH)(AK)(AJ)(EB) Kit - Brake
Seal Kit - Bleeder Replacement Piston, Stepped Bore Line, Rear
Brake Line, Brake, Caliper w/Fittings Bolt Reservoir, Brake,
Rear
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
7542153 1910315 7080003 7542122 7041750 7555919 5431107
1910280-067 7661401 1910301 7512247 1910439 1910440 1910188 7571620
7547046
1 1 2 2 1 2 2 1 1 1 2 1 1 1 1 1
Nut Hose, Reservoir Clamp, Hose Nut, Nylok Spring Washer
Bushing, Pivot, Pedal Rod, Brake Pin, Cotter Master Cylinder,
Brake, Rear Bolt Disc, Brake (EB) Disc, Brake (AF)(AH)(AK)(AJ)(AL)
Disc, Brake (AA)(AB)(AC)(AE) Washer, Spring Nut, Nylok6/00
C12
REAR WHEEL DRIVESPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
3
4 2 5
6 1
11 12
10
9 8 7
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4
7661404 7542459 5131649 -------
2 8 2 2
5 7710440 6 7515513 7 5410948
Pin, Cotter Nut Hub, Rear Wheel Carrier, Bearing, Wheel (See
Rear Suspension Pg. C10, Ref. 42) 2 Ring, Retaining 8 Stud 2 Tire,
25x11-10, Tracker P
8 1525017 9 1520217-067 1520217-117 10 7555796 11 7543005 12
5411164
2 Valve, Rim 2 Rim, Rear, Black (AA)(AC)(AE)(AF)(AK) 2 Rim,
Rear, Aluminum (AB)(AH)(AL)(EB) 4 Washer, Cone 2 Nut, Castle 2
Cover, Dust, Hub6/00
C13
GEAR SELECTORSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1 2 3 4
5
6 7 8 9 10 11 22 15 21 12 13 14 15 16 14Qty. Description
23
10 11
20
19 17 14 18
14
17
Ref. Part No.
Qty. Description
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
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
12 13 14 15 16 17 18 19 20 21 22 23
3233076 3233639 7546707 7061014 7546701 7061013 5020824 5020823
7546702 3233640 3233641 3233643
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, Centering9/00
C14
FRONT HOUSINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ and WORKER 500 A00CH50EB
14 15 13 11 12 9 8 18 19 26 25 10 17 16
7 4 5 6
1
2
3
20
21 22 2 1
24
23
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1341276 1 2 3 4 5 6 7 8 9 10 11 12 13 3233252 3233248 3233701
3233700 3233699 3233589 3233698 3233541 3233319 3233697 3233324
3233711 7080307
1 Asm., Front Gearcase (Incl. 1-12,16-26)(If Built before
8/16/99) 12 Screw 2 Seal 1 Cover, Input, Front Housing 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 Clamp, Hose
14 15 16 17 18 19 20 21 22 23 24 25 26
7080756 8450003-1525 3233524 3233696 3233710 3233694 3233695
3233020 3233554 3233693 3233692 3233583 3233702 3233253 3233254
1 AR 1 1 1 1 1 1 AR 1 1 AR 1 1 1
Clip, Snap-In Line, Fuel Tube, Vent Gearcase SubAsm., Output
Shaft, Front Housing Shaft, Output Gear, 29T Bearing Shim O-Ring
Cover, Output, Front Housing Shim Button, Thrust Plug, Drain
Washer9/99
D1
FRONT HOUSINGSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ and WORKER 500 A00CH50EB
13 14 15 11 12 9 10 16 17 18 19
8 6 3 1 2 4 5 28 27 7 25 26
20
21 22 2 1
24
23
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
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
1 Asm., Front Gearcase (Incl. 1-12,16-26)(If Built after
8/16/99) 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
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
AR 1 1 1 1 1 AR 1 1 AR 1 1 1 4 4
Line, Fuel Clamp Tube, Vent Gearcase Shaft, Output Bearing, Ball
Shim O-Ring Cover, Output, Front Housing Shim Button, Thrust
Washer, Plug Plug, Drain Screw Washer7/99
D2
GEARCASE (Internal Components)SPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ
1 2
6 4 33 32 31 23 30 29 26 34 35 51 50 36 48 47 49 46 37 38 39 28
27 26 25 4 5
11 10 9 8 7
11 10 9 8 7 6 12
3
13 14
15 16 24 23 16 21 20 19 18 17
22
4
43 40 41 42
15 44
45
D3
GEARCASE (Internal Components)SPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1341310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
23 24 3233019 3233361 3233036 3233018 3233661 3233548 3233040
3233045 3233153 3233054 3233055 3233662 3233663 3233664 3233033
3233308 3233309 3233189 3233177 3233176 3233017 3233668 3233010
3233667
1 Asm., Gearcase (Incl. 1-36 and all on Gearcase (Cases and
Snorkel) Pg. D7) (If built before 9/10/99) 1 Bearing 1 Shaft,
Input, 31T, HCR 1 Chain, Silent, 34P 3 Bearing 1 Shaft, Shift 2
O-Ring 2 Washer 2 Ring, Retaining 2 Bellcrank, HLR 6 Washer 2 Nut 1
Shaft, Shift 1 Fork, Shift, Low 1 Fork, Shift, H/R 2 Screw 2 Pin,
Interlock 1 Bracket, Interlock 1 Spring, Interlock 1 Ring,
Retaining 1 Washer, Thrust 1 Bearing, Needle 1 Gear, 30T 2 Washer 1
Engagement Dog
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51
3233029 3233012 3233014 3233532 3233362 3233666 3233009 3233665
3233007 3233020 3233715 3233360 3233262 7552901 3233263 3233364
3233265 3233365 3233282 3233669 3233434 3233433 3233432 3233431
3233268 3233670 3233430
1 2 1 1 1 1 1 1 2 2 1 1 4 4 1 1 1 1 2 1 1 1 2 1 2 1 1
Ring, Retaining Washer Bearing, Needle Sprocket, 24T Shaft,
Reverse, HCR Engagement Dog, Low Bearing, Needle Gear, 33T Washer
Bearing, Ball Shaft, Center Drive Gear, Output, 100T, HCR Screw
Washer Cover, Bearing, Center Drive Ring, Retaining Bearing Pinion,
16T, Spiral Bevel Screw Deflector, Oil Chain Tensioner, Cam Chain
Tensioner, Shoe Pin, Dowel Spring, Torsion Bearing Sprocket, 60T
Chain, Silent4/99
D4
GEARCASE (INTERNAL COMPONENTS)SPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE
A00CH50AC and SPORTSMAN 500 A00CH50AJ and WORKER 500 A00CH50EB
1 2 3 4 5
2 3 4
5 6 7 8 9 10
6 19 17 18 16 15 14 13 12
24 25
23
10
11
22
21
15
20
11
10
27 23 26
28
29
30
21
15
21
27
42
41 37 40 39 38
36
35
34 33
32
31
45 26
46
43
44
D5
GEARCASE (INTERNAL COMPONENTS)SPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE
A00CH50AC and SPORTSMAN 500 A00CH50AJ and WORKER 500 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1341332 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 3233662 3233019
3233361 3233018 3233176 3233744 3233743 3233664 3233720 3233719
3233036 3233742 3233663 3233661 3233718 3233731
1 Asm., Gearcase (Incl. 1-37 and all on Gearcase (Cases and
Snorkel) Pg. D7) (If built after 9/10/99) 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 1 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, 33T
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
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, Oil1/00
D6
GEARCASE (Cases and Snorkel)SPORTSMAN 500 A00CH50AA and
SPORTSMAN 500 A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN
500 A00CH50AF and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500
A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE
A00CH50AC and SPORTSMAN 500 A00CH50AJ and WORKER 500 A00CH50EB
7 3 4 5 6 8 9 2 1 28 29 36 35 34 33 25 26 24 27 10 11 12 13 14
15 16 18 17 19
20
21
5 22 23
30 31 32
1
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
------1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 3233256 3233026
3233636 3233252 3233248 3233716 7052095 8360009-600 3233037 3233475
3233691 3233617 3233635 3233442 3233352 3233476 -------
18 3233446 19 3233302 20 3233303
1 Asm., Gearcase (See Gearcase -Internal Components Pg. D4 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
1 Washer 1 Gear, 31T, Snorkel Bearing, Ball (See Gearcase -Internal
Components Pg. D4, Ref. 34) 1 Shaft, Drive, Snorkel 1 O-Ring 1
Snorkel
21 3233305 22 3233353 3233354 3233355 3233356 3233357 23 24 25
26 27 28 29 30 31 32 33 34 35 36 3233306 3233444 3233351 3233292
3233293 ------3233291 3233294 3233295 3233296 3233253 3233254
3233672 3233247
1 1 1 1 1 1 1 1 1 1 1 4 2 1 4 4 1 1 1 3
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. 22 indicates choices, may also be used
in combinations. Ring, Retaining Lock, Bolt Bolt Bushing Seal
Washer (See Gearcase - Internal Components Pg. D4, Ref. 10) Nut,
FLEXLOC Stamping, Cover Plate Washer Screw Plug, Drain Washer
Gearcase, RH Pin, Dowel4/99
D7
CRANKCASESPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ and WORKER 500 A00CH50EB
2
6 7
3
5
1
2
4 8 9
22 10 11 21 20 19 13 12
5
18
17
16
14 15
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3083669 2 3085633 3 4 5 6 7 8 9 10 11 3084838 3080676 3084840
3084205 3084839 3085525 3084842 3084834 3084835
1 Bushing, Starter 1 Asm., Crankcase (Incl.
1,4,5,7,10,11,16,19,20,22) 2 Pin, Straight 3 Bearing, Ball 2 Pin,
Dowel 5 Screw and Washer 1 Seal, Oil 1 Pipe, Air Breather 2 Union 2
Bearing, Ball 1 Bearing, Ball
12 13 14 15 16 17 18 19 20 21 22
3084845 3084846 3084844 3086810 3084841 3082956 3083453 3084837
3084836 3084847 3080103
1 1 1 1 10 1 1 1 1 1 2
Plug Gasket, Aluminum Spring, Valve, One Way Valve, One Way
Bolt, Flange Gasket Plug Seal, Mechanical Seal, Oil O-Ring Pin,
Dowel4/99
D8
CYLINDERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ and WORKER 500 A00CH50EB
2 1 3 4 5 38 6
8
9
7
10 12 11
36 37
36
13 5 17 36 18 24 16 14 15
35 20
19
34 21
23 22 26 25
9 28 29 18 33
27
30 31 32 13
D9
CYLINDERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ and WORKER 500 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
3083166 3081497 3081330 3084857 3084994 3084858 3084867 3085072
3084877 3084866 3085074 3085073 3084874 3084859 3084875 3084860
3084861 3084862 19 3084215
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
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 O-Ring Adapter, Water Out Bolt, Flange
Adapter, Camshaft Gasket, Rocker Cover Cover, Rocker Bolt, Flange
Seal, Exhaust Valve Bolt, Cylinder Head Plug Gasket Plug, Blind
Bolt, Flange
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 3084879
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 Adapter4/99
D10
CRANKSHAFT and PISTONSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 A00CH50AJ and WORKER 500 A00CH50EB
1 4 2 3 4
21 7 20 10 19 11 14 16 15 13 8 9
6
5
12
18Ref. Part No. Qty. Description
17
Ref. Part No.
Qty. Description
1 3085379 3085380 3085381 2 3085866 3085867 3085868 3 ------4
3085534 5 3085374 6 3085341 7 3085376 8 3085400 9 3085024 10
3085399 3085373 11 3085852
1 1 1 1 1 1 1 2 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
Crankshaft 2 Pin, Crank Rod, Connecting Bearing, Large End Ball,
Steel Asm., Crankshaft (Incl. 5-11,19) Crankshaft 1 Gear 1,
Balancer
12 3085404 13 3084895 3084896 3084897 14 3240088 3084892 3084893
3084894 15 3084882 16 3085528 17 3083904 18 3083905 19 3085346 20
3081447 21 3080130
1 1 1 1 1 1 1 1 1 1 1 1 1 1 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 Pin, Dowel Key Key, Woodruff4/99
D11
INTAKE and EXHAUSTSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 A00CH50AJ and WORKER 500 A00CH50EB
8 8 1 2 3 4 27 5 26 6 7 9
9 6
10
11 12 13 8 9
14
15
16 17
18 13 12 11
25
24 23 20 19 21
22
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3084845 3084920 3086814 3086813 3084922 3084910 3084913 3084912
3084911 3084909 3084908 3084907 3084906 3086212
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)
15 16 17 18 19 20 21 22 23 24 25 26 27
3086838 3085348 3085076 3084899 3084914 3081657 3084916 3084915
3084924 3084917 3085349 3084905 3084874
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, Flange6/99
D12
CARBURETORSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ and WORKER 500 A00CH50EB
1 3 4
2 51 50
5 49 6 7 8 45 44 41 40 39 38 36 37
43 46 47
9
48
42
10 11
15
14 13
12 34 33 32 31
12 26 27 28 29 30
35
16
25 24
17
23
22
18
21 20 19
D13
CARBURETORSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500
A00CH50AJ and WORKER 500 A00CH50EB
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
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
3130507 3130508 3130962 3130752 3130732 3130960 3130541 3130540
3130504 3130014 3130571 3130515 3130517 3130518 3130519 3130361
3130594 3130532 3130520 3130590 3130521 3130529 3130591 3130668
3130533 3130624
1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 1 4 1 1 1 1 1 1 1
Ring E-Ring Needle, Jet Ring Diaphragm Jet, Needle (Q-0) Screw
Washer, Spring Asm., Jet Block Washer Jet, Main (#155) Seal Packing
E-Ring Cap Pin, Float Plate O-Ring Screw Asm., Float Body Screw
Asm., Float Screw Valve, Needle (1.5) O-Ring Jet, Pilot (#40)
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
48 49 50 51
3130522 3130523 3130525 3130524 3130546 3130545 3130544 3130502
3130589 3130514 3130501 3130513 3130543 3130535 3130511 3130512
3130199 3130538 3130593 3130625 3131200 3084205 3130505 3130503
3130592
1 1 1 1 1 1 1 1 1 1 2 1 1 4 1 1 1 1 1 1 1 2 1 1 4
O-Ring Washer Spring Adjuster Screw, Adjust Ring Spring Valve,
Throttle (100) Spring Ring Screw Asm., Throttle Shaft Guide, Cable
Screw Cover O-Ring Holder, Guide Spring Asm., Plunger Jet, Air
(#160) Asm., Carburetor (Incl. 1-38,43-51) Screw and Washer Spring
Asm., Cover Screw4/99
D14
RECOIL STARTERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
1
2
3
4
5 6
7 8 9 15
11
10
14 13
12
8 7Ref. Part No. Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8
3084822 3083463 3083378 3083379 3084744 3085266 3083453
3082956
1 1 1 1 1 1 2 2
Reel Spring, Return Ratchet Spring, Friction Plate, Friction
Bolt and Washer Plug Gasket
9 10 11 12 13 14
3083669 3083185 3084750 3084933 3084877 3085652 3085653 15
3085083
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., Rope4/99
E1
WATER PUMPSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1
2
3
4 3 11 8 9 7 5 6 10 12
13Ref. Part No. Qty. Description Ref. Part No. Qty.
Description
1 2 3 4 5 6 7
3084940 3085352 3084191 3085857 3085359 3082758 3085351
1 1 2 1 1 1 1
Thermostat Switch, Thermostat Clamp, Hose Hose, Main Bolt,
Flange Gasket, Aluminum Cover, Water Pump
8 9 10 11 12 13
3084937 3085077 3083138 3084935 3084942 3084877
1 1 1 1 1 4
Gasket, Water Pump Nut, Self Lock Gasket Impeller Washer, Seal
Bolt, Flange7/98
E2
OIL PUMPSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
4
2 1
3
5 10 9 6 7 8 12 11
15 14
13
17Ref. Part No. Qty. Description
16Ref. Part No. Qty. Description
1 2 3 4 5 6 7 8 9
3084946 3084949 3084948 3084944 3084945 3085535 3084955 3084954
3084953 3084962
1 1 1 1 1 1 2 2 1 3
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
10 11 12 13 14 15 16 17
3084947 3084950 3084951 3084956 3084205 3084952 3084958 3084959
3084960 3084961
1 1 1 1 3 1 1 AR AR AR
Case 3, Oil Pump Rotor, Inner Rotor, Outer Strainer, Oil Screw
and Washer Shaft, Pump Gear, Pump 2 Spacer (0.8) Spacer (1.0)
Spacer (1.2)7/98
E3
OIL FILTERSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB
and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and
SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN
500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
1
2 4 3
2
3 2 2 3 5
2
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3084963 2 3084846 3 3086815
1 Filter, Oil 8 Gasket, Aluminum 4 Bolt, Banjo
4 3084964 5 3085638
1 Pipe 1, Oil Delivery 1 Pipe 2, Oil Delivery4/99
E4
MAGNETOSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
2
1
3
16 17 18 19 13 12
15 14
4
20
10
11 6 7 9 8
5
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3085227 3085228 2 3084980 3 3070175 4 3084978 5 3084972 6
3086820 3085560 3086980 3086981 7 3081657 8 3084973 9 3086821
3086984
1 1 1 1 1 1 1 1 1 1 5 1 1 1
Asm., Ignition Coil (Incl. 1,2) Coil, Ignition Cap, Plug, Spark
Plug, Spark O-Ring Metal, Bearing Asm., Plate (Incl.
5,6,8-12,14,15) (Up to S#00-29083) Plate (Up to S#00-29083) Asm.,
Plate (Incl. 5,6,8-12,14,15) (S#00-29083 & after) Plate
(S#00-29083 & after) Bolt and Washer Seal, Oil Stator (Incl.
13)(Up to S#00-29083) Stator (Incl. 13)(S#00-29083 & after)
10 3085563 3086985 11 3085554 12 3084976 13 3085360 14 3084977
15 3081256 16 3085639 3086982 17 3083073 18 3080077 19 3085521 20
3086819 3086983
3 3 1 2 1 1 3 1 1 2 2 1 1 1
Screw and Washer (Up to S#00-29083) Screw and Washer (S#00-29083
& after) Band, Pulse Screw and Washer Coil, Pulser Clamp Screw
and Washer CDI System (Up to S#00-29083) CDI System (S#00-29083
& after) Nut Washer, Spring Switch, Magnetic Flywheel w/Ring
Gear (Up to S#00-29083) Flywheel w/Ring Gear (S#00-29083 &
after)12/99
E5
STARTING MOTORSPORTSMAN 500 A00CH50AA and SPORTSMAN 500
A00CH50AB and SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF
and SPORTSMAN 500 A00CH50AH and SPORTSMAN 500 A00CH50AK and
SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and
SPORTSMAN 500 RSE A00CH50AJ and WORKER 500 A00CH50EB
5
4
6
3
2 7
8 2
1 12
9
13
11 10 15
14
16 17 18
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8 9
3084981 3084982 3085353 3084406 3083649 3084408 3082038 3085034
3085033
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)
10 11 12 13 14 15 16 17 18
3240114 3084983 3084405 3083737 3084412 3084411 3084410 3084409
3085394
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)10/98
E6
FUEL PUMPSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
4 3
3
5
2 1
5
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3085275 2 3084999 3 3085356
1 Asm., Fuel Pump (Incl. 2-5) 1 Screw and Washer 2 Screw and
Washer
4 3084591 5 3084998
4 Screw and Washer 1 Diaphragm Gasket Set10/98
E7
TOOL KITSPORTSMAN 500 A00CH50AA and SPORTSMAN 500 A00CH50AB and
SPORTSMAN 500 A00CH50AE and SPORTSMAN 500 A00CH50AF and SPORTSMAN
500 A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500
A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE
A00CH50AJ and WORKER 500 A00CH50EB
2 9 3
4
5 10 1 6
7
8
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7
3085383 2870725 3082657 3085001 3085002 3085568 3085569
1 1 1 1 1 1 1
Asm., Tool Kit (Incl.2 -8) Gauge, Tire Pressure Screwdriver
Wrench, 10-12 Open Wrench, 12-14 Open Wrench, Box, 125mm Puller,
Spark Plug (Wrench Handle)
8 2682572 9 9915299 9915476 9915753 10 2871095-067
1 Pouch, Tool Kit 1 Owners Manual, 00 ATV 1 Supplement, Owners
Manual 00 Sportsman 500 (AA)(AB)(AE)(AF)(AH)(AK)(AL)(EB) 1
Supplement, Owners Manual 00 Sportsman 500 RSE (AC)(AJ) 1 Wrench,
Spanner, Cam6/00
E8
FOOT BRAKEWORKER 500 A00CH50EB
1
2 5 3 16 14 12 4
13 6 7 8 8
15
11 9 10
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2 3 4 5 6 7 8
7512126 1040732-067 7661205 7555827 5211914 7555931 7542103
7556063
1 1 1 2 1 1 1 2
Bolt Bracket Pin, Cotter Washer Handle, Parking Brake Washer,
Flat Nut, FLEXLOC Washer, Wave
9 10 11 12 13 14 15 16
5224875 7558707 5242749 5224871 7080644 7661843 7661011
7661203
1 1 1 1 1 1 1 1
Spring, Return Bushing Pawl, Parking Brake Linkage, Parking Lock
Clevis, Threaded Pin, Clevis Pin, Cotter Pin, Cotter10/98
E9
PRINTED IN THE USA
PARTS MANUAL PN 9915480 and MICROFICHE PN 9916574 6/00
Changed pages in 99154804 5 6 7 8 9 10 11 12 13 14
1
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3
A
cover
toc
B
x
C
D
E
F
G 4 5 6 7 8 9 10 11 12 13 14
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