MAGNUM 500 MAGNUM 500 EB 500 MAGNUM 4X4, HDS …pi54.com/corp/manuals/Parts/9915488r03.pdf · parts manual pn 9915488 and microfiche pn 9916574 3/00 magnum 500 model #a00cd50aa magnum

PARTS MANUAL PN 9915488 and MICROFICHE PN 9916574 3/00

MAGNUM 500Model #A00CD50AAMAGNUM 500 EBModel #A00CD50AB

500 MAGNUM 4X4, HDSModel #A00CD50FA

500 MAGNUM 4X4, HDS IIModel #A00CD50FB

Rev. 03

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSMagnum500A00CD50AAandMagnum500EBA00CD50ABand500Magnum4X4HDSA00CD50FAand

500 Magnum 4X4 HDS II A00CD50FB

Parts Manual

AA-ARM/STRUT MOUNTING B14. . . . . . . . . .AIR BOX B2. . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D7-8. . . . . . . . . . . . . . . . . . .CLUTCH COVER C4. . . . . . . . . . . . . . . . . .CONTROLS - MASTER

CYLINDER/BRAKE LINE B9. . . . . . . . .CONTROLS - THROTTLE ASM./CABLE B8.COOLING SYSTEM A11. . . . . . . . . . . . . . . .CRANKCASE D10. . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D9. . . . . . . . . .CV JOINT - BTB B3. . . . . . . . . . . . . . . . . . .CYLINDER D5-6. . . . . . . . . . . . . . . . . . . . . . .

DDECALS A10. . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C1-2. . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C3. . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C5. . . . . . . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . .EXHAUST SYSTEM A12. . . . . . . . . . . . . . . .

FFRONT BRAKE B7. . . . . . . . . . . . . . . . . . .FRONT CAB A7. . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C11. . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A9FRONT STRUT B5. . . . . . . . . . . . . . . . . . . .FRONT WHEEL B6. . . . . . . . . . . . . . . . . . .FUEL PUMP E4. . . . . . . . . . . . . . . . . . . . . .FUEL TANK B1. . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C14-D1. . . . . . . . . . . . . . . . .

GGEARCASE SELECTOR MOUNTING D1. . .

HHANDLEBAR and HEADLIGHT POD B11-12. . .

IINTAKE and EXHAUST D11. . . . . . . . . . . . . .

MMAGNETO E2. . . . . . . . . . . . . . . . . . . . . . .MAIN GEARCASE C9-10. . . . . . . . . . . . . . . . .

OOIL FILTER E1. . . . . . . . . . . . . . . . . . . . . .OIL PUMP D14. . . . . . . . . . . . . . . . . . . . . . .OIL TANK B13. . . . . . . . . . . . . . . . . . . . . . .

PPROP SHAFT B4. . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE C7-8. . . . . . . . . . . . . . . . . . . .REAR CAB and SEAT A5-6. . . . . . . . . . . . . .REAR HOUSING C12-13. . . . . . . . . . . . . . . . . .REAR RACK MOUNTING A8. . . . . . . . . . . .REAR WHEEL DRIVE C6. . . . . . . . . . . . . . .RECOIL STARTER D12. . . . . . . . . . . . . . . . .

SSHOCK MOUNTING D3. . . . . . . . . . . . . . . .STARTING MOTOR E3. . . . . . . . . . . . . . . .STEERING POST B10. . . . . . . . . . . . . . . . . .SWING ARM/REAR GEARCASE

MOUNTING D2. . . . . . . . . . . . . . . . . . .T

TOOL KIT E5. . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION MOUNTING D4. . . . . . . . .

WWATER PUMP D13. . . . . . . . . . . . . . . . . . . .

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

2000 MAGNUM 500 SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic DiscHydraulic DiscHydraulic Disc

Hydraulic Lock, All Wheel

CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallon)Gearcase Oil (ounces)Engine Oil (quarts) 0W40Engine Counter BalanceOil (quarts) InjectorRack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

2.253.75

400 (ml)2

N/AN/A9018030

Standard850

DRIVE TRAINType Shaft Ride System

DRIVE CLUTCHDrive System TypeCenter Distance (inches)Clutch Offset (inches)Clutch Weight (grams)Spring Color

PVT101/2

10 MHBlue/Green

DRIVEN CLUTCHHelix AngleOutside Diameter (inches)Spring Position

Compound (EBS)9.5N/A

DIMENSIONAL FEATURES

Approx. Turning Radius (inches)Box, Tool Volume (Cu. Inches)Box Dimensions (inches)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

65588N/A7.25478134647

49.7546

GEARCASETrans. Number and TypeShift TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain Type

PRDSide Lever

7.46/15.12/13.3/13.7/13.1/1N/AN/AN/A

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

Dunlop25x8-1225x11-10

N/A43

N/A

ENGINEEngine Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCoolingAlternator Output (watts)Elec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayAir ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

EH50PLE084 Cycle, Single Cylinder

Dry Sump92x75499

10:2 Full StrokeLiquid250

Standard1/BST34 (CV Type)

16540Q-0N/A2-5/8

4HB40-3CDI

[email protected]

NGKBKR5EUSFA Appr. Pending

GRAPHICSBumper Caps/Polyprop.Cargo Box or BedFender, FrontFender, RearFootwellFrame/SteelFront CoverHandlebar CoverHeadlight/Dash PodRack, FrontRack, RearRimsSeat VinylSide PanelSpring, FrontSpring, RearTank CoverTool Box Cover

w/lettering Color

N/AN/A

Eddie B. GreenEddie B. Green

BlackBlack

Eddie B. GreenBlack

Eddie B. Green/BlackBlackBlack

AluminumBlack

Eddie B. GreenBlackBlackN/AN/A

ELECTRICALHeadlight - Handlebar(watts)Headlight - Front Hood (watts)Headlight - Grill (watts)Taillight (watts)Brake Light (watts)Indicator BulbBattery

1 Single Beam/60 WN/A

2 Single Beam/27 W12 V/8.26 W12 V/26.9 W12 V/1.0 W12 V/14 AH

SUSPENSIONFront Type -

Front Travel (inches)Rear Type -

Rear Travel (inches)ShockAdjustment

MacPherson Strut6.7

Progressive Rate Swing Arm6.5

2� Gas Charged MonotubeCam

Polaris Industries Inc. reserves the right tomakechanges indesignandspecifications and/or tomakeadditions or improvements to its productswithoutnotice.

2000 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUAL

SUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Magnum 500 A00CD50AA 9915299 9915473 9915488 9916574 9915509

Magnum 500 EB A00CD50AB 9915299 9915473 9915488 9916574 9915509

500 Magnum 4X4, HDS A00CD50FA 9915299 9915473 9915488 9916574 9915509

500 Magnum 4X4, HDS II A00CD50FB 9915299 9915473 9915488 9916574 9915509

A5

REAR CAB and SEATMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

3029

2

8

3

7

5

1011

15

14

16

17

18

4443

13

20

22

23

38

6

35

46

47

1

45

41

124

42

19

3

37

39

36

9

32

26

28

27

40

21

31

7

2524

35

33

34

E 2000 Polaris Sales Inc.

A6

REAR CAB and SEATMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

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

1 7661645 10 Rivet2 7511930 2 Bolt3 7555792 6 Washer4 5811107 1 Foil, Rear Cab, Rear5 5411042 1 Grommet6 5432117-195 1 Cab, Rear, E.B. Green7 7541925 4 Nut, Nylok8 5224592 1 Retainer, Seat Latch9 5811308 1 Foil, Tape, Rear Cab10 7512242 4 Screw11 7555859 4 Washer, Flat12 7512085 2 Screw13 5431786 1 Box, Tool14 7621403 2 Rivet15 5211033 2 Bracket, Lever Retainer16 1040387 1 Latch, Seat17 7041370 1 Spring, Latch18 2682441-070

2681747-07058111045811105

1111

SeatCovering, SeatFoil, Seat Base, LargeFoil, Seat Base, Small

19 5410414 8 Bumper, Rubber20 7517599 2 Bolt/Washer21 7555748 2 Washer22 5431787 1 Cover, Tool Box23 5410896 1 Cap, Drain24 5243188-067 1 Guard, Clutch

25 7661638 4 Rivet26 7621509 2 Rivet, Plastic27 5243829-067 1 Strap, Fuel Pump28 ------ -- -- -- -- 1 Asm., Gearcase

(See Front Housing Pg. C11 for Details)29 7552603 4 Washer30 7512492 4 Screw31 5433435 1 Guard, Rock32 7556065 7 Washer33 7517386 9 Screw34 7558301 2 Washer35 7512232 19 Screw36 7542122 8 Nut, Nylok37 5411548 8 Mount, Rubber38 7517264 8 Screw39 1012764-067 1 Frame, Main40 5432221-070

5433219-07011

Footwell, LH, BlackFootwell, RH, Black

41 5811111 1 Foil, Foam, Rear Fender42 5811106 2 Foil, Rear Cab, Front43 7073761 1 Decal - Carb Information44 7077446 1 Decal - Filter Element45 5811087 1 Foil, Foam46 7670057 12 Nut, U-Type Speed47 5431796

54317972873213

111

Guard, Mud, Rear, LHGuard, Mud, Rear, RHKit - Mud Skirt, Full Set

3/00

A7

FRONT CABMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

5

6

7

8

910

12

32

1920

1718

1413

15

16

8

1

4

4

4

11


1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5811210 1 Foil, Foam, Side Panel3 5433263-195

2632285-195

2631977-195

1

1

1

Panel, Side, LH, E.B. Green(If built before 3/13/00)Panel, w/Foam, LH, E.B. Green(If built after 3/13/00)Panel, Side, RH w/Foil, E.B. Green

4 7512232 10 Screw5 5432088-195 1 Cover, Front, E.B. Green6 7670085 2 Clip, Spring7 2632031-195 1 Cab, Front, E.B. Green8 7670057 10 Nut, U-Type Speed9 7670068 2 Nut, Push-on

10 7661645 4 Rivet11 7517312 2 Screw12 5431798

543179911

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

13 7541925 2 Nut, Nylok14 7555792 2 Washer15 7512085 2 Screw16 8450073-600 AR Line, Breather17 7555931 2 Washer, Flat18 7542122 2 Nut, Nylok19 7621509 4 Rivet, Plastic20 5811917 2 Shield, Deflector

3/00

A8

REAR RACK MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

4

3

1

2

9

6

10

11

127

7

6

5

8

2

7


1 7517685 2 Screw2 7517686 4 Screw3 2670174 1 Asm., Rack, Rear

(Incl. Ref. 4 and Warning Decal)4 2670070 2 Reflector, Red5 1040490-067 1 Support, Rear Rack6 7542324 8 Nut, Nylok

7 7558402 4 Washer, Flat8 7670096 2 Nut, Chimney9 7512329 4 Bolt10 1040524-067

1040525-06711

Mount, Front, Rear Rack, LHMount, Front, Rear Rack, RH

11 5333332-067 4 Spacer12 7515385 4 Screw

9/99

A9

FRONT RACK and BUMPER MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

13

14

15

1617

18

12

6

5

8

910

19

20

21

22

23

24

2

3

4

11

4

7

1

6


1 7517686 4 Screw2 2670180 1 Asm., Rack, Front

(Incl. Ref. 3 and Warning Decal)3 2670071 2 Reflector, Amber4 7515399 8 Screw5 2200775 1 Kit - Front Rack Mount6 7542324 4 Nut, Nylok7 7558403 2 Washer8 5432155-070 1 Bumper9 7515391 2 Screw10 7515390 2 Screw11 7555954 4 Washer12 1013210-067

1013211-06711

Support, Front Rack, LHSupport, Front Rack, RH

13 7517386 4 Screw14 2431014

24310154030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

15 7515382 2 Bolt16 7558402 4 Washer, Flat17 5810467 1 Plug, Frame18 5241398-067

5241399-067

5244623-067

5244624-067

1

1

1

1

Extension, Frame, LH(If built before 12/01/99)Extension, Frame, RH(If built before 12/01/99)Extension, Frame, LH(If built after 12/01/99)Extension, Frame, RH(If built after 12/01/99)

19 5241583-067 1 Guard, Brush20 5240591-067 1 Grill, Brush Guard21 7621330 7 Rivet22 7670094 6 Nut, U-Type23 7512097 6 Screw24 5433315

543331611

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

1/00

A10

DECALSMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1 26

3 54

7

910

11

4

13 1415

18

16

17

199 LH

RH

12

8

1


1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution, 4W3 7077807 1 Decal - “4x4”, Side Panel, RH4 7078443 2 Decal - ‘‘POLARIS”, Side Panel5 7078448 1 Decal - Tank Side, RH6 7078003 1 Decal - Headlight Adjustment7 7074935 1 Decal - Warning, AWD Switch8 7078315

7078465

1

1

Logo, “45th Anniversary”(If built before 12/31/99)Logo, Polaris Star(If built after 12/31/99)

9 7074220 1 Decal - “Macpherson Strut”

10 7078354 1 Decal - Discretionary Warning11 7078577 1 Decal - Drain Recoil12 7078449

707900911

Decal - “500 L/C, 4 Stroke” (AA)(AB)Decal - “500 4 Stroke HDS II” (FB)

13 7079604 1 Decal - Warning, Override, AWD14 7078447 1 Decal - Tank Side, LH15 7078253 1 Decal - Age Warning, ATV16 7077920 1 Decal - Passenger Warning17 7078038 1 Decal - Tire Pressure18 7077806 1 Decal - “4x4”, Side Panel, LH19 7077919 1 Decal - Warning, General, CPSC

10/00

A11

COOLING SYSTEMMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

41

2

13

12

31 30

19

38

24

1140

35

36

37

16

39

3

20

15

2221

27

10

26

18

23

29

28

25

14

178

14

11

7

8

4

5

9

1

32

33

29

34

6

1

42


1 7080696 2 Clamp, Hose2 1240044 1 Cap, Pressure3 5433364 1 Filler, Coolant4 5243505-067 1 Bracket, Filler, Coolant5 7661638 3 Rivet6 5433707 1 Flexguard7 5411794 1 Hose, Engine, Upper8 7080827 2 Clamp, 1”9 7512024 2 Screw10 5411632 1 Hose, Neck, Filler11 7080826 2 Clamp12 7517659 4 Screw13 2410123 1 Asm., Fan and Motor14 7670111 4 U-Clip15 7547069 2 Nutsert16 7558301 2 Washer17 3110032 2 Mount, Rubber18 5020572 2 Spacer19 5433059 1 Shroud, Fan20 4010161 1 Sensor, Thermal21 1240045 1 Radiator22 7552605 2 Washer, Split Lock

23 7512113 2 Screw24 5433317 1 Cover, Radiator25 5410607 4 O-Ring26 7052244

541163311

Valve, DrainO-Ring

27 5410584 2 Bushing, Mount28 5243503-067 1 Bracket, Radiator, Lower29 7517386 3 Screw30 5411694 1 Hose, Engine, Lower31 5521511 1 Guard, Hose32 5244064-067 1 Bracket, Coolant Hose Mount33 7080807 1 Clamp, Hose34 ------ -- -- -- -- 1 Screw

(See Front Housing Pg C11, Ref. 2)35 8450003-1525 1 Line, Fuel36 7052065 1 Fitting, Barbed, 90 Degree37 7512084 2 Screw38 5433410 1 Tank, Surge39 5433774 1 Plug, Cap40 5810279 1 Gasket, Overflow Cap41 5430743 1 Cap, Overflow, Drilled42 4010369 1 Breaker, Circuit

3/00

A12

EXHAUST SYSTEMMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

13

8

14

3

1

10

9

2

11

6

4

16

5

7

12

12

12

13

1110

15

1617

(If built after 7/01/99)

816

14

13


1 7542324 1 Nut, Nylok2 7555716 1 Washer3 5410436 1 Washer, Rubber4 7555863 1 Washer (If built before 7/01/99)5 5010192

513229511

Bushing (If built before 7/01/99)Bushing (If built after 7/01/99)

6 54102415411790

11

Dampener, Vib. (If built before7/01/99)Dampener, Vib. (If built after 7/01/99)

7 751531675153397515394

111

Bolt, Carriage (If built before 7/01/99)Bolt (If built after 7/01/99)Screw, Carriage (If built after 8/12/99)

8 1260977-0291260961-029

11

Silencer (If built before 7/01/99)Silencer (If built after 7/01/99)

9 7512666 1 Bolt10 3110064 2 Mount, Torque Stop11 7542301 2 Nut12 7041804 4 Spring, Exhaust13 7042029 2 Spring, Exhaust (If built before

7/01/99)(Only 1 used if built after 7/01/99)

14 1260976-0291260987-029

11

Headpipe (If built before 7/01/99)Headpipe (If built after 7/01/99)

15 ------ -- -- -- -- 1 Manifold, Black (See Engine MountingPg. A14 Ref. 29)

16 5243517 2 Seal, Exhaust17 7041789 1 Spring, Exhaust (If built after 7/01/99)

1/00

A13

ENGINE MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

17

39

22

1513

29

45

6

4

41 40

36

47

43

2

42

3031

28

38

37

19

33

35

3

34

1

27

10

46

2

5

5

11

12

8

24

7

5150

16

9

44

25

3

48

24

26

2021

16

9

49

23

18

14

3

3

25

1818

32

18

A14

ENGINE MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB


1 7546601 2 Nut, Nylok2 7080003 8 Clamp, Hose, Red3 8450040-600 AR Line, Fuel4 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D8, Ref. 47)5 8450003-1525 AR Line, Fuel6 7052075 1 Fitting, Tee7 8450073-600 AR Line, Breather8 5240609-067 1 Bracket, Carb Mount9 ------ -- -- -- 3 Screw and Washer

(See Crankcase Pg. D10, Ref. 6)10 7547069 2 Nutsert11 3021086 2 Mount, Carburetor, Rubber12 7552604 2 Washer13 7515106 2 Bolt14 8360009-600 AR Line15 4010132 1 Cable, Ground, Engine16 7512315 2 Bolt17 7552901 2 Washer, Spring Lock18 7547108 6 Nut, Flange Lock19 5242936-067 1 Mount, Engine, Top20 7555823 1 Washer21 5132007 1 Spacer, Motor Mount, Top22 3085556 1 Engine (EH50PLE08) NOTE: The

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

23 3021045 1 Mount, Rubber24 7555806 3 Washer, Flat25 7542403 2 Nut, FLEXLOC

26 7517386 1 Screw27 2530009 1 Filter28 ------ -- -- -- -- 1 Gasket, Exhaust

(See Cylinder Pg. D6, Ref. 20)29 1260978-029 1 Manifold30 3080530 2 Washer, Lock31 3080285 2 Nut32 7080474 2 Clamp, Hose33 3110044 1 Mount, Rubber34 5242818-067 1 Mount, Engine, Front35 7515417 2 Screw36 ------ -- -- -- -- 1 Bracket, Retainer, Seal

(See Clutch Cover Pg. C4, Ref. 18)37 ------ -- -- -- -- 1 Asm., Drive Clutch, ATV-06

(See Drive Clutch Pg. C1 for Details)38 7512566 1 Bolt39 7575202 1 Washer, Interlock40 5210748 1 Washer, Flat41 5430261 1 Bushing42 5410421 1 Boot, Clutch Intake43 7080511 1 Clamp, Narrow Band44 7080694 1 Clamp, Spring Hose45 ------ -- -- -- -- AR Hose, Breather

(See Air Box Pg. B2, Ref. 12)46 7555815 2 Washer47 3110046

302111922

Mount, Rubber (If built before 1/01/00)Mount, Rubber (If built after 1/01/00)

48 ------ -- -- -- -- 1 Mount, Motor, Rear (See TransmissionMounting Pg. D4, Ref.11)

49 7542459 2 Nut, Flange50 7621462 1 Rivet51 7080539 1 Clamp, Nylon

1/00

B1

FUEL TANKMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

22

4

20

21

8

14

13

1

9

2

11

23

17

16

12

6

3

15

7

5

16

10

15

19

18


1 5430725 1 Cap, Gas Tank2 5810144 1 Gasket, Fuel Cap3 8360009-600 AR Line, Fuel4 5431053 1 Vent, Tank5 7517451 2 Bolt6 7552801 2 Washer, Spring Lock7 7558301 2 Washer, Flat8 5222154-067

5222155-06711

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

9 5332457 2 Spacer10 7547069 4 Nutsert11 5810317 2 Pad, Fuel Tank Bracket

12 7517505 1 Screw13 5432559 1 Knob, Fuel Valve14 5432733 1 Nut, Fuel Valve15 8450040-600 AR Line, Fuel16 7080003 4 Clamp, Hose, Red17 7052161 1 Valve, 3-Way18 7661637 2 Rivet19 5240577-067 1 Bracket, Fuel Valve20 7052150 1 Fitting, Fuel Outlet, Main21 7052149 1 Fitting, Fuel Outlet, Reserve22 2520143 1 Asm., Fuel Tank (Incl. 4,20,21)23 5811942 1 Seal, Foam

9/99

B2

AIR BOXMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

22

25

16

26

17

14

6

2

19

5

27

10

24

1223

4

15

8

13

11

7

15

8

9

28

21

3

1

18

20

8

8


1 7517541 4 Screw2 5432859 1 Duct, Inlet3 5411422 1 Gasket, Intake4 5432868 1 Cover, Air Box5 5811482 1 Seal, Cover6 7515180 2 Screw7 7558301 2 Washer, Flat8 7080699 4 Clamp, Hose9 8450073-600 AR Tube, Breather, Engine10 2530029 1 Filter, Breather11 7080694 1 Clamp, Hose12 5411847 1 Hose, Breather13 7080511 1 Clamp, Narrow band14 5411540 1 Boot, Carb15 7080413 2 Clamp, Narrow Band

16 5432473 1 Duct, Carb, Inlet17 5830128 1 Gasket, Duct18 ------ -- -- -- -- 1 Line, Breather

(See Oil Tank Pg. B13, Ref. 5)19 5433678 1 Box, Air20 5431863 2 Insulator21 5811650 1 Foil, Air Box22 5432377 1 Plug23 8450059-150 AR Line, Fuel24 7080650 1 Clamp, Hose25 5243694 6 Clip26 5432601 1 Collar, Carb Inlet27 7080595 1 Filter, Air28 5811633 1 Filter, Precleaner Sleeve

1/00

B3

CV JOINT - BTBMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

BTB

1012 3 4 5

6

7

8 9

12

11

13


1 1380119 2 Asm., CV Housing w/Sleeve2 5222299 1 Sleeve, Drive Shaft Seal3 3260115 1 Clamp, CV Joint, Large4 7670091 1 Circlip5 5411106 1 Boot, CV Joint6 1380094 1 Shaft Replacement (Incl. 4)7 1380092 1 Cardan Replacement (Incl. 4,6,8,9)

8 2200771 1 Kit - Cross and Bearing9 3260130 1 Yoke, Splined10 7661913 1 Pin, Spring11 7080627 1 Clamp, Small Band12 2200773 1 Kit - Boot Replacement, CV Joint

(Incl. 3,5,11)13 2200961 1 Kit - Drive Shaft w/Sleeve BTB

7/98

B4

PROP SHAFTMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1 23

46

7

5


1380138 1 Asm., Prop Shaft, Front (Incl. 1-4)1 3260133 1 Yoke, Gear Case, Front2 3260104 2 Kit - Cross and Bearing3 ------ -- -- -- -- 1 Shaft, Prop

4 3260131 1 Yoke, Prop Shaft, Transmission5 7080424 1 Fitting, Lubrication6 5411092 1 O-Ring7 7661913 1 Pin, Spring

4/99

B5

FRONT STRUTMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

2

35

67

8

9

1011

12

14

15

13

16

17

18

20

4

19

2122

23

2425

26

1011

4


1 5411608 2 Bumper2 7041761 2 Strut, Front3 5211115 2 Washer4 7558402 6 Washer5 7080573 2 Clamp, Rubber Coated6 7542303 4 Nut, FLEXLOC7 7517445 4 Screw8 5810439 2 Retainer, Strut Casting Wire9 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B7 for Details)10 3554509 4 Bearing, Tapered Roller11 3554507 4 Bearing, Tapered Roller Cup12 5222193 2 Sleeve, Hubstrut Seal13 7080306 2 Fitting, Lubrication14 2410133 2 Coil, Magnetic

15 2201311

2201312

1

1

Asm., Hubstrut, Heavy, LH (42mm)(Incl. 8,11-14,22)Asm., Hubstrut, Heavy, RH (42mm)(Incl. 8,11-14,22)

16 7041375-067 2 Spring, Compression17 5243364 2 Retainer, Spring18 5432871 2 Ball, Pivot, Bottom19 7515339 4 Bolt20 5132062 2 Spacer, Strut21 ------ -- -- -- -- 1 Kit - Drive Shaft w/Sleeve

(See CV Joint - BTB Pg. B3, Ref. 13)22 3610028 2 Seal, Hubstrut23 5432872 2 Ball, Pivot, Top24 5810291 2 Spacer, Rubber25 7555749 2 Washer26 7547104 2 Nut, Nylok

9/99

B6

FRONT WHEELMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

10 11 12 14

1 2

34

5

79

8

15

1625

24 7

17 18 2021

23

13

6

6

22

19


1 7512325 8 Bolt2 5242935 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub, Elec./Mech.6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515523 8 Stud9 1520243 2 Asm., Hub w/Bearing Race (Incl.3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter13 1321814 2 Spacer

14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5410568 2 Tire (25x8-12)17 7556004 2 Washer18 7542810 2 Nut, Slotted19 7661401 2 Pin, Cotter20 5410470 2 O-Ring21 5432611 2 Cap, Hub22 7512027 6 Screw23 7542459 8 Nut, Lock24 1520269-117 2 Rim, Front25 1525017 2 Valve, Rim

1/99

B7

FRONT BRAKEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

2 3

89

11

10

12

4

5 6 7


1910309 1 Asm., Front Brake Caliper, LH(Incl. 1-7,9,10)

1910310 1 Asm., Front Brake Caliper, RH(Incl. 1-7,9,10)

1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 5131115

51311161930642

111

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

4 1930665 1 Kit - Piston and Seal (Incl. 5-7)5 5410779 1 Ring, Square, Molded (.094)

6 5410780 1 Ring, Square, Molded (.103 x .134)

7 5132294 1 Piston, Long8 2200465

22009012201149

111

Kit - Front Brake Pad, General DutyKit - Front Brake Pad, Severe DutyKit - Front Brake Pad, Soft

9 19102991910411

11

Mount, Caliper (If built before 7/09/99)Mount, Caliper, Front(If built after 7/09/99)

10 5410495 1 Boot, Bushing11 5410494 1 Boot, Pin Seal12 ------ -- -- -- -- 4 Screw (See Front Strut Pg. B5, Ref.

7)

1/00

B8

CONTROLS - THROTTLE ASM./CABLEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

3

1

6

5

4

2


1 5433806 1 Cover2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7080709 1 Cable, Throttle Control5 2010188 1 Asm., Throttle Control (Incl.1,3,6)6 2010191 1 Asm., Throttle Clamp

1/00

B9

CONTROLS - MASTER CYLINDER/BRAKE LINEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

2

3

5

10

6

4

12

1

11

13

23

27

17

20

21

22

22

24

2526

16

1819

28

15

14

9

8

7


20500782200809

11

Asm., Master Cylinder (Incl. 1-13)Kit - Master Cylinder Reservoir(Incl. 1-3,13)

1 1930797 2 Bolt2 1930796 1 Cap, Reservoir3 1930795 1 Diaphragm4 2200808 1 Kit - Master Cylinder Clamp5 1930799 1 Asm. Piston Master Cylinder6 1930804 1 Rivet7 2201034 1 Kit - Brake Lever w/Parking Latch

(Incl. 6-9)8 ------ -- -- -- -- 1 Spring, Flat9 2201090 1 Kit - Park Brake Lever (Incl. 6,8)10 1930806 1 Nut11 1930792 2 Bolt12 1930805 1 Bolt

13 ------ -- -- -- -- 1 Ring, Square, Reservoir14 5411297 1 Boot, Brake Line, Rubber15 5410988 2 Seal16 4110164 1 Switch17 1910286 1 Line, Brake, Front Hand18 7621462 2 Rivet19 7080539 2 Clamp, Nylon20 8360031-30 1 Conduit21 1930752 1 Line, Brake, Left Front w/Fittings22 7080138 8 Cable Tie23 7512024 2 Screw24 8360011-38 1 Tubing, Convoluted25 1930753 1 Line, Brake, Right Front w/Fittings26 7052194 1 Fitting, Cross27 1930817 1 Line, Brake28 1930674 1 Bolt, Banjo

4/99

B10

STEERING POSTMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

16

1514

2

3

4

13

9

125

6

10

5

5

8

11

6

7


1 1843051 1 Asm., Steering Post (Incl. 12,13)2 5433416 1 Bushing, Steering, Upper3 7080424 1 Fitting, Lubrication4 7515321 2 Bolt5 7555878 3 Washer6 5410772 2 O-Ring7 5431571 1 Spacer, Steering Post8 7543203 1 Nut

9 7661633 1 Pin, Cotter10 5431570 1 Bushing, Steering, Lower11 7661632 2 Rivet12 5431574 1 Plug, Grease, Steering13 7080433 1 Fitting, Lubrication14 5433415 1 Bushing, Steering, Console15 5222999-067 1 Bracket, Upper Steering Bushing16 7542324 2 Nut, Nylok

9/98

B11

HANDLEBAR and HEADLIGHT PODMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

27

32

10

39

98

15

41

1

2

3

14

6

7

20

12

13

1619

21

25 26

3029

38

35

34

33

3531

23

28

4

4

5

24

37

22

1817

11

40

36

B12

HANDLEBAR and HEADLIGHT PODMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB


1 32802903280312

11

SpeedometerSpeedometer, Kilometers (FA)

2 5430967404005340400544010313

1111

Plug, Indicator HoleIndicator, Hot TemperatureIndicator, Neutral/ReverseIndicator, “P”, Park (FA)

3 7511881 3 Screw4 7670086 3 Nut, U-Type5 2460714

246084011

Harness, Headlight PodHarness, Headlight Pod (FA)

6 ------ -- -- -- 1 Asm., Throttle Control(See Controls - Throttle Asm./CablePg. B8, Ref. 5)

7 5242987-067 1 Tube, Handlebar8 7558212 2 Washer, Flat9 7555868 2 Washer, Lock10 7541933 2 Nut11 3280291 1 Clamp12 7515189 4 Screw13 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls - Master Cylinder/BrakeLine Pg. B9 for details)

14 5433042-195 1 Pod, Headlight, Upper, E.B. Green15 5432926 1 Spacer, Switch, LH16 4010262 1 Switch, Handlebar17 7517625 1 Screw, Set18 5432952 1 Plug19 5431030 2 Grip, Handlebar20 2200774

5630616-067

1

2

Kit - Handlebar Block(Incl. Blocks and 12,20,30)Block, Handlebar Retainer

21 5240586-067 1 Bracket, Pod Mounting22 7517317 2 Screw

23 4032079 1 Knob, Adjusting24 5411120 1 Boot, Headlight25 4032077 1 Collar, Locking26 4032075

287044811

Lens and ReflectorBulb, Headlight, Halogen

27 4032078 1 Rod, Adjusting28 5410163 2 O-Ring29 7080726

220018811

Cable, Choke w/AdjusterKit - Choke Lever Control

30 7542122 4 Nut, Nylok31 7670089 2 Nut, U-Type32 7080631 1 Clip, Cable Retaining33 7522021 2 Screw34 5431811-070 1 Pod, Headlight, Lower35 4110264

54337334010278

4010321

111

1

Switch, Ignition (Incl. Key)Nut, IgnitionKey, Blank, Series 2000, 6700, 6800.NOTE: Your key can be diplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Key, Blank, Series 2200, 2300, 2700,2800. NOTE: Your key can be dipli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

36 7080936 1 Caplug37 5433534 1 Cover, Key38 7080229 1 Nut, Choke Slide39 4040081

401029811

Sensor (If built before 8/09/99)Sensor (If built after 8/09/99)(Incl. 40)

40 5132382 1 Cap (Used with 4010298 only)41 7517658 1 Screw

10/00

B13

OIL TANKMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

11

1

2

4

10

6

7

13

17

27

2021

23

2425

26

22

5

38

19

9

1214

15

16

18


1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7052163 1 Fitting5 8450073-85 1 Line, Breather6 5432289 1 Dipstick7 5410889 1 O-Ring8 7517102 1 Bolt, Banjo9 7555896 2 Washer10 7052240 1 Tube, Banjo Return11 5131785 1 Tank, Oil, LH12 7052106 1 Fitting13 5411036 1 Hose, Formed14 7080474 1 Clamp, Hose

15 5242817-067 1 Bracket, Oil Tank Support16 7517386 2 Screw17 2530014 1 Screen, Oil Filter18 7542122 2 Nut, Nylok19 5411042 1 Grommet20 5410828 2 Grommet, Mounting, Reservoir21 5333204 2 Bushing22 7558301 2 Washer, Flat23 7512130 2 Screw24 7051524 1 Plug, Magnetic25 5850135 1 Washer26 7515158 9 Screw27 5131255 1 Tank, Oil, RH

11/02

B14

A-ARM/STRUT MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

4

56

7

89

3

12

1314

27

15

16

181719

21

25

26

2423

22

2829

29 28

2322

20

31 30

2

14

9

11

10


1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820567

1820805

2

2

Asm., Tie Rod(Incl. 4-9)(If Built before 8/16/99)Asm., Tie Rod(Incl. 4-9)(If Built after 8/16/99)

4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061033

706105422

Rod End, LH (If Built before 8/16/99)Rod End, LH (If Built after 8/16/99)

10 5411920 1 Boot, Seal, Rod End11 7517674 2 Bolt (If Built after 8/16/99)12 7555806

755609944

Washer, Flat (If Built before 8/16/99)Washer, Flat (If Built after 8/16/99)

13 7546904 2 Nut14 7661203 4 Pin, Cotter15 7080927 2 Joint, Ball16 5211121 2 Bracket, Ball Joint

17 7512284 4 Screw18 5410548 2 Boot, Rubber19 7542438 2 Nut, Castle20 5431150

543114911

Shield, CV Joint, LHShield, CV Joint, RH

21 7512084 6 Screw22 5433066 4 Bushing, A-Arm, Long23 5020677 4 Bushing24 5020681 2 Shaft, A-Arm25 2201157

220115822016092201610

1111

Kit - A-Frame, LH (If built before 7/01/99)Kit - A-Frame, RH (If built before 7/01/99)Kit - A-Frame, LH (If built after 7/01/99)Kit - A-Frame, RH (If built after 7/01/99)

26 7080433 2 Fitting, Lubrication27 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B5, Ref. 15)28 7512492 4 Screw29 7552603 4 Washer, Spring Lock30 7517527 1 Bolt31 7515415 1 Screw

10/00

C1

DRIVE CLUTCHMAGNUM 500 A00CD50AA

1 2

3 4

56

78

5

9

10

11

1213


1321632 1 Asm., Drive Clutch (Incl. 1-3,5-11,13)1 7512176 6 Screw2 7552801 6 Washer, Spring Lock3 3576510 1 Bearing, Cover4 7041157 1 Spring, Clutch5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 5430945 6 Washer, Multilube

8 1321457 3 Roller and Bushing9 5210752

524298152107535210754

ARARARAR

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

10 3576504 1 Bearing, Moveable, 1/2”11 7541906 3 Nut, FLEXLOC12 5630513 3 Weight, Shift, 10-MH13 7512266 3 Bolt, Shoulder

5/98

C2

DRIVE CLUTCHMAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1 2 3

4

5

6

7

8

9

10

1112

13

141516

17

18

5


1 1520231 1 Clutch, One Way Drive2 7556009 1 Washer3 5631119 1 Spacer4 7541906 3 Nut, FLEXLOC5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 3585712 1 Bearing8 7547130 1 Nut, Jam9 3576510 1 Cover, Bearing10 7552801 6 Washer, Spring Lock

11 7512176 6 Bolt12 7041157 1 Spring, Clutch13 1321457 3 Roller and Bushing14 5430945 6 Washer, Multilube15 7512266 3 Bolt, Shoulder16 5630513 3 Weight, Shift, 10 MH17 1321706 1 Asm., Drive Clutch, Braking

(Incl. All Less 4,12)18 7556008 1 Washer

10/00

C3

DRIVEN CLUTCHMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

6

5

23

4

16

14

1312

11

987

5

1

15

10

1

34

13

109

21718

1920

20

A00CD50AA

A00CD50ABA00CD50FAA00CD50FB

21

22

2425

26

27 23


1 7556120 AR Bushing2 5220646 1 Washer, Domed3 7552901 1 Washer, Spring Lock4 7515382 1 Bolt5 1322182 1 Asm., Driven Clutch, 3 Angle, Heavy

(Incl. 7-16)(A00CD50AA)6 3211077 1 Belt, Drive7 5430766 3 Button, Ramp8 7511854 3 Bolt9 7710448 1 Ring, Retaining10 5210752 1 Spacer11 5132344

513144711

Ramp, Stationary (If built before 4/01/00)Ramp, Stationary (If built after 4/01/00)

12 7041198 1 Spring, Clutch13 3576511 1 Bearing, Moveable (1”)14 3576504 1 Bearing, Moveable (1/2”)

15 7556804 AR Washer (.030”)16 7555898

7556076ARAR

Washer, Spacer (.020”)Washer, Spacer (.025”)

17 7556013 1 Washer18 7556010 1 Bushing19 7710461 1 Ring, Retaining20 1322190 1 Asm., Driven Clutch, Braking (Incl.

2,9,10,13,18,19,24-27)(AB)(FA)(FB)21 3211069 1 Belt, Drive22 7517323 3 Screw23 1321977 1 Roller, Taper24 3585710 1 Bearing25 5211115 1 Washer26 7041636 1 Spring27 5131674 1 Ramp, Stationary

10/00

C4

CLUTCH COVERMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

2

1

4

57

8

9

10

6

12

17

1819

21

20

11

3

13

14

16

or 11

1415

15


1 5411901 1 Seal, Cover Case2 2201421

2201678

1

1

Kit - Inner Clutch Cover(Incl. 4,7,11,19)(If built before 1/03/00)Kit - Inner Clutch Cover(Incl. 4,7,19)(If built after 1/03/00)

3 75176017517599

35

Bolt and Washer (With 2201520)Bolt/Washer (With 2201678)

4 5521301 1 Seal, Cover, Clutch5 5433540-328

5433451

1

1

Cover, Clutch, Outer(If built before 1/03/00)Cover, Clutch, Outer(If built after 1/03/00)

6 7670051 1 Clip, Cover, Clutch (With 2201520)7 7512093 5 Screw (With 2201520)8 7078689 1 Decal - Warning, Clutch Cover9 7077377 1 Decal - Engine/Clutch Modification

10 7077666 1 Decal - “Automatic/EBS” Clutch(AB)(FA)(FB)

11 7512094 2 Screw (Qty. 2 with 2201520)(Qty. 9with 2201678)

12 5411489 1 Boot, Duct13 7080761 2 Cable Tie14 7517386 1 Screw (Use qty. 2 with 5433744)15 7558301 2 Washer, Flat16 5433172

543374411

Duct, Air Outlet (If built before 11/08.99)Duct, Air Outlet (If built after 11/08.99)

17 ------ -- -- -- 3 Screw and Washer(See Crankcase Pg. D10, Ref. 6)

18 5240409-067 1 Bracket, Retainer, Seal19 5410575 1 Seal, Cover Case20 7080511 1 Clamp, Narrow Band21 5432698 1 Duct, Inlet, Down Tube

3/00

C5

ELECTRICAL/TAILLIGHTMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

2

4 5

6

78

910 13

12

11

26

18

14

25

19 2021

22

23

2427

1211

35

34

29

28

33

32

30

30

18

31

3

1516

17


1 246079024608292460887

111

Harness, Main Wire (AA)(AB)Harness, Main Wire (FA)Harness, Main Wire (FB)

2 2200593 1 Kit - Circuit Breaker, 20 AMP3 2201795 1 Kit - Circuit Breaker, 10 AMP4 2432034 1 Asm., Taillight w/Brake Light (Incl. 5-10)5 4032046 1 Lens, Taillight6 4032029 2 Screw, Taillight7 4030043 1 Bulb, Taillight8 4032045 1 Gasket, Taillight9 4032064 1 Backing, Taillight/Brake Light10 7670054 2 Nut, Speed11 7541925 4 Nut, Nylok12 7571602 4 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 4010311 1 Switch, Horn (FA)(FB)16 4010310 1 Horn (FA)(FB)17 7512057 1 Screw (FA)(FB)

18 4010094 1 Cable, Battery/Solenoid19 2200361 1 Kit - Battery Bolt, Short20 4010095 1 Cable, Battery/Engine21 7010032 2 Hook, Battery Strap22 5410424 1 Strap, Battery Holddown23 5432077 AR Tube, Battery Vent24 4140006 1 Battery25 5431769 1 Cover, Battery26 4010093 1 Cable, Solenoid/Starter27 7512007 2 Bolt28 5810455 2 Pad, Rack Mount29 5241416 1 Bracket, CDI30 7512018 3 Screw31 8360012-10 1 Trim, Edge32 5131036 1 Sink, Heat33 4060173 1 Rectifier, Regulator, LR 3934 4020149 6 Clip, Rosebud35 7670109 3 Clip, Routing

3/00

C6

REAR WHEEL DRIVEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

67

1011

1

12

4

8

2

3

5

9


1 7661404 2 Pin, Cotter2 7542714 8 Nut3 5131777 2 Hub, Wheel, Rear4 7512673 8 Bolt5 7670081 8 Pushnut6 5411408 2 Tire, 25x11-10

7 1525017 2 Valve, Rim8 1520183-117 2 Rim, Rear, Silver9 7555745 2 Washer, Flat10 7555796 2 Washer, Cone11 7543005 2 Nut, Castle12 5411164 2 Cover, Dust, Hub

7/98

C7

REAR BRAKEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

31

4

30

12

9

20

8

7

10

13

28

19

1

65

18

14

22

25

23

16

3

2

26

17

24

5

7

14

5

1918

2728

29

15

20

20

23

9

11

21

C8

REAR BRAKEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB


1 220118919103391930860

111

Kit - Brake Pad (Incl. Spacer and Pin)SpacerPin

2 1910367220146722014282201385

1121

Asm., Brake CaliperPiston, Rear CaliperKit - Bleeder ReplacementKit - Caliper Seal

3 7515406 2 Screw4 7555806 2 Washer, Flat5 5410988 6 Seal6 1910286 1 Line, Brake, Front Hand, Master Cyl.7 1910288 1 Line, Brake, Rear Foot, Master Cyl.8 7080573 1 Clamp, Rubber Coated9 7512232 2 Screw10 7080762 3 Clip, Brake Line11 7558201 1 Washer, Flat12 7661048 1 Rivet (If built before 11/15/99)13 7080816

767011311

T-Clip, Dual (If built before 11/15/99)Clip, Dual Retaining(If built after 11/15/99)

14 1930674 3 Bolt, Banjo15 7542403 2 Nut, FLEXLOC16 7542153 1 Nut, Flanged17 1930854 1 Reservoir, Brake, Rear18 7080003 2 Clamp, Hose19 1910331 1 Hose, Reservoir20 7515158 2 Screw21 7558301 3 Washer, Flat22 1012753-067 1 Pivot, Mount, Brake, Rear23 7542122 2 Nut, Nylok24 7512240 3 Bolt25 1012752-067 1 Rod, Brake26 7041750 1 Spring27 7555919 1 Washer28 5433189 2 Bushing, Pedal Pivot29 7556090 1 Washer, Spring30 7661401 1 Pin, Cotter31 1910311 1 Master Cylinder, Foot

9/02

C9

GEARCASEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS II A00CD50FB

46

56

5

33

52

11

15

54

10

12

13

57

60

62

37

6463

32

18

20 30

22

49

2987

1634

232425

2

50

5

3614

61

51

4

914

55

4

1

5958

19

26

31

39

6

38

27

21

1

1

2

9

9

30

26

1820

9

4847

35

45

4342

41

3

53

40

44

28

265

5

17

C10

GEARCASEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS II A00CD50FB


1341252 1 Asm., Gearcase, Main (Incl. 1-64)(AA/AB/FB)(See Gearcase Pg. E7 for FAModel Information)

1 3233788 3 Seal2 3233252 17 Screw3 3233610 1 Gearcase, LH4 3233529 4 Pipe, Knock5 3233019 4 Bearing6 3233604 1 Shaft, Input, 31T7 3233036 1 Chain, Silent8 3233603 1 Gear, 16T w/22T Spline9 3233018 4 Bearing10 3233153 2 Bellcrank11 3233961 2 Nut12 3233045 2 Ring, Retaining13 3233040 2 Washer14 3233749 8 Screw15 3233615 1 Switch, 3 Position16 3233614 1 Gearcase, RH17 3233037 1 Vent, Tube18 3233306 2 Ring, Retaining19 3233631 1 Gear20 3233103 2 Bearing, Needle21 3233598 1 Shaft, Reverse22 3233014 1 Bearing, Needle23 3233599 1 Sprocket, 24T24 3233029 1 Ring, Retaining25 3233533 1 Engagement Dog, H/R, HLR26 3233619 3 Washer, Thrust27 3233601 1 Gear, Helical, 40T28 3233613 1 Spacer29 3233600 1 Gear, 30T30 3233012 2 Washer31 3233629 1 Engagement Dog, Low

32 3233628 1 Washer33 3233617 1 Switch, 2 Position34 3233627 1 Shaft, Shift, H/R35 3233548 2 O-Ring36 3233618 2 Ring, Retaining37 3233624 1 Shaft, Shift38 3233602 1 Fork, Shift, H/R39 3233605 1 Fork, Shift, Low40 3233747 2 Screw, Tapping41 3233309 1 Bracket, Interlock42 3233032 1 Spring43 3233308 2 Pin, Interlock44 3233612 1 Gear, Helical, 44T45 3233608 4 Screw46 3233609 1 Cover, Bearing47 3233106 1 Ring, Snap48 3233607 1 Bearing, Ball49 3233606 1 Shaft, 10T50 3233781 1 Cover, Output51 3233583 1 Shim52 3233582 1 Button, Thrust53 3233611 1 Shim54 3233622 1 Shaft, Rear Output55 3233621 1 Gear, Spiral, Bevel, 31T56 3233620 1 Sprocket, 12T w/18T Spline57 3233626 1 Chain, Roller58 3233711 1 Plug59 3233324 1 Washer60 3233552 1 Bushing, Garlock61 3233093 1 Sprocket, 12T62 3233625 1 Shaft, Front Output63 3233254 1 Washer64 3233777 1 Plug, Drain

6/01

C11

FRONT HOUSINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

2

1

3

4

5

6

7

8 13

2314

19 2017 21 22

25 24

2

12

16 18

11

15

1

1213

10

9


1341253 1 Asm., Front Gearcase (Incl. 1-25)1 3233319 2 Seal2 3233252 11 Screw3 3233573 1 Cover, Gearcase4 3233588 1 O-Ring5 3233574 1 Nut, Lock6 3233589 1 Bearing, Ball7 3233590 1 Shaft8 3233591 1 Bushing9 7080307 1 Clamp, Hose10 7080756 1 Clip11 8450003-1525 AR Line, Vent12 3233253 2 Plug, Drain

13 3233254 2 Washer14 3233524 1 Tube, Vent15 3233592 1 Housing, Front, Gearcase16 3233593 1 Bushing17 3233594 1 Gear, 37T, Bevel18 3233595 1 Shaft, Output, Front Housing19 3233020 1 Bearing20 3233554 1 Shim21 3233596 1 O-Ring22 3233597 1 Cover, Output, Gearcase23 3233248 1 Seal24 3233583 1 Shim25 3233582 1 Button, Thrust

1/99

C12

REAR HOUSINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB

9

16

7

4

1

15

22

6

5

23

3

2019

14

2

12

18 2421

17

8 25

10

8

217

3

26

11

16

13


1341254

1341309

1

1

Asm., Gearcase, Rear (Incl. 1-10,14-26) (If built before 2/21/99)Asm., Gearcase, Rear (Incl. 1-10,14-26) (If built between 2/21/99 and7/01/99)

1 3233585 2 Screw2 3233256 2 Seal3 3233252 10 Screw4 3233584 1 Cover, Gearcase, Output5 3233529 1 Pipe, Knock6 3233587 1 O-Ring7 3233581 1 Shim8 3233268 2 Bearing, Ball9 3233580 1 Shaft, Rear Axle10 3233579 1 Gear, Bevel, 31T, Rear11 7670102 3 Clip12 8450003-1525 AR Line, Vent

13 7080307 1 Clamp,Hose14 3233524 1 Tube, Vent15 3233586 1 Gearcase, Rear Housing16 3233711 2 Plug17 3233324 2 Washer18 3233577 1 Bushing19 3233576

3233707

1

1

Shaft, Pinion, 10T, Bevel, Rear(For Gearcase 1341254)Shaft, Pinion, 10T, Bevel, Rear(For Gearcase 1341309)

20 3233575 1 Bearing, Ball21 3233574 1 Nut, Lock22 3233588 1 O-Ring23 3233573 1 Gearcase, Cover, Input24 3233319 1 Seal, Oil25 3233582 1 Button, Thrust26 3233583 1 Shim

6/01

C13

REAR HOUSINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

25

14

1

24

5

6

7

8

9

2 3

1011

12

13

1516 17 18 19 20

21

4

2223

8

14

12

13 1


1341321 1 Asm., Rear Gearcase(Incl. 1,5-25)(If built after 7/01/99)

1 3233252 10 Screw2 7670102 3 Clip3 8450003-1525 AR Line, Vent4 7080307 1 Clamp5 3233524 1 Tube, Vent6 3233587 1 O-Ring7 3233581 AR Shim8 3233268 2 Bearing, Ball9 3233740 1 Gear, Bevel, 31T, Rear10 3233529 1 Pipe, Knock11 3233739 1 Gearcase, Rear Housing12 3233711 2 Plug

13 3233324 2 Washer14 3233256 2 Seal15 3233577 1 Bushing16 3233738 1 Shaft, Pinion, 10T, Bevel, Rear17 3233714 1 Bearing. Ball18 3233574 1 Nut, Lock19 3233588 1 O-Ring20 3233573 1 Gearcase, Input Cover21 3233319 1 Seal, Oil22 3233582 1 Button, Thrust23 3233583 AR Shim24 3233741 1 Cover, Gearcase, Output25 3233585 2 Screw

3/00

C14

GEAR SELECTORMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

2

4

3

5

7

8

6

111610

15

1

13

14

9

12

1011


1341271

1341337

1

1

Asm., Gear Selector(Incl. 1-16)(AA)(CA)(FB)Asm., Gear Selector (Incl. 1-16)(FA)

1 32331953233767

11

Asm., Knob (AA)(CA)(FB)Asm., Knob (FA)

2 7512024 1 Screw3 3233649 4 Screw4 3233131 1 Strap, Wire5 3233648 1 Cover, Gear Selector Boot6 3233658

323376611

Handle, Gear Selector (AA)(CA)(FB)Handle, Gear Selector (FA)

7 3233646 1 Sphere, Plastic8 3233754 1 Pin, Groove9 3233644 1 Pin, Dowel10 3233642 2 Spring, Detent11 3233060 2 Bullet, Detent12 3233076 2 O-Ring13 3233639 1 Slide, Low (AA)(CA)(FB)14 3233640 1 Slide, High/Reverse (FA use Qty. 2)15 3233641 1 Body, Gear Selector16 3233643 1 Spring, Centering

2/00

D1

GEARCASE SELECTOR MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

2

9

12

4

3

5

713

2

2

6

6

2

9

10

11

8

11


1 7061013 2 Rod End, LH2 7546707 4 Nut, FLEXLOC3 7546702 2 Nut, LH4 5020974 1 Rod, Shift Linkage, Low5 7546701 2 Nut6 7061014 2 Rod End, RH7 1012822-067 1 Bracket, Shifter

8 7512130 2 Screw9 7542122 4 Nut, Nylok10 7512126 2 Bolt11 7555827 3 Washer12 7517386 4 Screw13 5020973 1 Rod, Shift Linkage, High, Rev

1/00

D2

SWING ARM/REAR GEARCASE MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

12

23

33

11

20

17

24

28

38

2622

35

15

9

21

11

37

910

10

15

31

75

5

30

34

8

32

1

16

27

192

3

13

14

361213

14

29

25

64

31

18


1 5132152 1 Hub, Brake Disc, Rear Axle2 ------ -- -- -- -- 1 Asm., Rear Brake Caliper

(See Rear Brake Pg C8, Ref. 2)3 3513523 2 Bearing, Ball4 5411653 1 Shield, Brake Line5 7517604 3 Bolt6 7512084 2 Screw7 7555721 3 Washer8 7542703 3 Nut, FLEXLOC9 5411532 2 Cap, Pivot, Swing Arm10 5131863 2 Nut11 5131864 2 Pivot, Threaded12 3610072 2 Seal, Pivot, Swing Arm13 3554506 2 Bearing, Tapered Roller Cone14 3554507 2 Bearing, Tapered Roller Cup15 5411602 2 Seal, Pivot, Swing Arm16 1541323 1 Asm., Swing Arm (Incl. 14,15)17 5132201

708043311

Coupling, Prop Shaft, GreasedFitting, Lubrication

18 5411092 1 O-Ring19 1380137 1 Asm., Prop Shaft, Rear20 7517585 8 Bolt

21 5411531 1 O-Ring22 7710482 1 Ring, Retaining23 5131930 1 Collar, Rear Axle24 5131862 1 Axle, Rear25 7517612 3 Screw26 1012881

5242851-0675811716

111

Asm., Skid Plate, RearPlate, Skid, Rear HousingPad, Rubber

27 ------ -- -- -- -- 1 Asm., Gearcase, Rear (See RearHousing Pg. C12 for Details)

28 5411707 1 O-Ring29 7078261 1 Decal - Hitch30 7661913 1 Pin, Spring31 7553201 8 Washer, Split Lock32 1012740-067

1013193-06711

Tube, Axle, LH (If built before 3/01/00)Tube, Axle, LH (If built after 3/01/00)

33 7515481 3 Screw34 5132075 1 Spacer, Bearing35 7710471 1 Ring, Retaining36 3610071 1 Seal, Axle, Rear37 5211849 1 Disc, Brake38 5411092 1 O-Ring

4/00

D3

SHOCK MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

3

8

4

711

5

6

1

9

2

10

1


1 7542439 2 Nut, Nylok2 5433213 2 Bushing3 7515415 1 Screw4 5132022 1 Tube5 5241147 1 Retainer, Shock6 7041849-067

7041815-06711

Spring, Compression (AA)(AB)Spring, Compression (FA)(FB)

7 7041774 1 Shock8 5630921 1 Cam, Adjuster9 5132021 1 Tube10 5433212 2 Bushing11 7515438 1 Screw

1/00

D4

TRANSMISSION MOUNTINGMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

2

34

9 8

77

89

5

2

15

6

10

11

2

2


-- -- -- -- -- -- -- 1 Asm., Main Gearcase (See MainGearcase Pg. C10 for Details)

1 7515417 2 Screw2 7547108 6 Nut, Flange, Lock3 7515398 2 Screw4 7542321 2 Nut, Flange5 7555976 3 Washer, Flat6 5242819-067 1 Mount, Rear Transmission

7 7517289 4 Screw8 7552603 4 Washer, Spring Lock9 7515522 4 Bolt10 5242820-067 1 Mount, Transmission11 1012975-067

1013134-067

1

1

Mount, Rear Motor(If built before 1/01/00)Mount, Rear Engine(If built after 1/01/00)

1/00

D5

CYLINDERMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

2

20

38

2223

21

12

5

4

37

107

34

9

25

29

1617

3

6

18

27

1

26

13

35

28

33

31

32

8

11

30

36

14

24

15

19

5

36

36

13

9

18

D6

CYLINDERMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB


1 3083166 1 Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt, Allen4 3084857 2 Pin, Straight5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve7 3084867 1 O-Ring8 3085072 1 Adapter, Water Out9 3084877 10 Bolt, Flange10 3084866 1 Adapter, Camshaft11 3085074 1 Gasket, Rocker Cover12 3085073 1 Cover, Rocker13 3084874 10 Bolt, Flange14 3084859 2 Seal, Exhaust Valve15 3084875 4 Bolt, Cylinder Head16 3084860 1 Plug17 3084861 1 Gasket18 3084862 1 Plug, Blind19 3084215 2 Bolt, Flange

20 3085075 1 Gasket, Exhaust21 3085326 2 Stud22 3080285 2 Nut23 3080530 2 Washer, Lock24 3085854 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3084838 2 Pin, Straight29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3086811 1 Cylinder (Incl. 32)32 3084130 1 Pipe 2, Elbow33 3085370 1 Gasket, Cylinder34 3084868 1 Cover, Camshaft35 3086200 1 Gasket, Cover, Cam36 3085527 1 Cylinder Head (Incl. 4-6,14,16-18,21)37 3085371 1 Gasket, Head38 3084879 1 Adapter

4/99

D7

CARBURETORMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

47

37

34

9

50

5

49

12

4

6

4142

38

36

1235

1312

1415

21

19

27

30

29

26

1110

3

22

20

16

24

18

25

40

23

51

4445

87

46

39

3332

31

28

17

48

43

D8

CARBURETORMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB


1 3130507 1 Ring2 3130508 1 E-Ring3 3130962 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3130960 1 Jet, Needle (Q-0)7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3130572 1 Jet, Main (#157.5)12 3130515 2 Seal13 3130517 1 Packing14 3130518 1 E-Ring15 3130519 1 Cap16 3130361 1 Pin, Float17 3130594 1 Plate18 3130532 1 O-Ring19 3130520 4 Screw20 3130590 1 Asm., Float Body21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 1 Screw24 3130668 1 Valve, Needle (1.5)25 3130533 1 O-Ring26 3130624 1 Jet, Pilot (#40)

27 3130522 1 O-Ring28 3130523 1 Washer29 3130525 1 Spring30 3130524 1 Adjuster31 3130546 1 Screw, Adjust32 3130545 1 Ring33 3130544 1 Spring34 3130502 1 Valve, Throttle (100)35 3130589 1 Spring36 3130514 1 Ring37 3130501 2 Screw38 3130513 1 Asm., Throttle Shaft39 3130543 1 Guide, Cable40 3130535 4 Screw41 3130511 1 Cover42 3130512 1 O-Ring43 3130199 1 Holder, Guide44 3130538 1 Spring45 3130593 1 Asm., Plunger46 3130625 1 Jet, Air (#160)47 3131199 1 Asm., Carburetor (Incl. 1-38,43-51)48 3084205 2 Screw and Washer49 3130505 1 Spring50 3130503 1 Asm., Cover51 3130592 4 Screw

4/99

D9

CRANKSHAFT and PISTONMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

19

20

6

10

1412

5

8

18 13

9

17

7

3

11

4

15

21

16

2

1

4


1 308537930853803085381

111

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

2 308586630858673085868

111

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

3 ------ -- -- -- -- 1 Pin, Piston4 3085534 2 Clip5 3085374 1 Crankshaft 26 3085341 1 Pin, Crank7 3085376 1 Rod, Connecting8 3085400 1 Bearing, Large End9 3085024 1 Ball, Steel10 3085399

308537311

Asm., Crankshaft (Incl. 5-11,19)Crankshaft 1

11 3085852 1 Gear 1, Balancer

12 3085404 1 Shaft, Balancer13 3084895

30848963084897

111

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

14 3240088308489230848933084894

1111

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

15 3084882 1 Sprocket 116 3085528 1 Nut, Slit17 3083904 1 Washer18 3083905 1 Nut, Lock19 3085346 1 Pin, Dowel20 3081447 1 Key21 3080130 1 Key, Woodruff

4/99

D10

CRANKCASEMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

2

4

10

11

2

19

20

1

22

7

5

16

3

1817

9

1514

1213

21

6

5

8


1 3083669 1 Bushing, Starter2 3085633 1 Asm., Crankcase

(Incl. 1,4,5,7,10,11,16,19,20,22)3 3084838 2 Pin, Straight4 3080676 3 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 5 Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3084842 2 Union10 3084834 2 Bearing, Ball11 3084835 1 Bearing, Ball

12 3084845 1 Plug13 3084846 1 Gasket, Aluminum14 3084844 1 Spring, Valve, One Way15 3086810 1 Valve, One Way16 3084841 10 Bolt, Flange17 3082956 1 Gasket18 3083453 1 Plug19 3084837 1 Seal, Mechanical20 3084836 1 Seal, Oil21 3084847 1 O-Ring22 3080103 2 Pin, Dowel

5/99

D11

INTAKE and EXHAUSTMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

14

18

15

1617

25

26

13 12 11

10

6

98

22

7

19

8

21

24

4

3

21

5

20

27

23

89 6

9

1211

13


1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3086814 1 Spring, Tensioner4 3086813 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Intake Rocker Arm (Incl. 8,9)7 3084913 1 Asm., Exhaust Rocker Arm (Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3084907 4 Retainer, Spring13 3084906 4 Spring, Valve14 3086212 1 Camshaft (Incl. 15-18)

15 3086838 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3084914 1 Sprocket 220 3081657 3 Bolt and Washer21 3084916 1 Guide, Chain22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot, Lever24 3084917 1 Lever25 3085349 2 Valve, Intake26 3084905 2 Valve, Exhaust27 3084874 2 Bolt, Flange

6/99

D12

RECOIL STARTERMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

14

6

4

7

10

5

31 2

11

8

12

13

15

9

8

7


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

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084933 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3085856

308594311

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

15 3085083 1 Asm., Rope

7/98

D13

WATER PUMPMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

11

7

83

3

2

1

9

12

13

4

10

65


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

8 3084937 1 Gasket, Water Pump9 3085077 1 Nut, Self Lock10 3083138 1 Gasket11 3084935 1 Impeller12 3084942 1 Washer, Seal13 3084877 4 Bolt, Flange

7/98

D14

OIL PUMPMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

4

1

10

32

11

12

15

87

6

13

14

5

1617

9


1 3084946 1 Case 2, Oil Pump2 3084949 1 Rotor, Outer Feed3 3084948 1 Rotor, Inner Feed4 3084944

308494511

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

5 3085535 1 Screw6 3084955 2 Pin, Dowel7 3084954 2 Pin, Dowel8 3084953 1 Washer9 3084962 3 Bolt and Washer

10 3084947 1 Case 3, Oil Pump11 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Strainer, Oil14 3084205 3 Screw and Washer15 3084952 1 Shaft, Pump16 3084958 1 Gear, Pump 217 3084959

30849603084961

ARARAR

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

7/98

E1

OIL FILTERMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

4

5

3

3

3

2

2

2

2

2


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

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

4/99

E2

MAGNETOMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

206

5

89

10

11

12

13 14

4

7

1

2

16

19

3

1517

18


1 30846903084979

11

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

2 3084980 1 Cap, Plug, Spark3 3070175 1 Plug, Spark4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3086820

30855603086980

3086981

1

11

1

Asm., Plate (Incl. 5,6,8-12,14,15)(Up to S#00-01961)Plate (Up to S#00-01961)Asm., Plate (Incl. 5,6,8-12,14,15)(S#00-01961 & after)Plate (S#00-01961 & after)

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3086821

308698411

Stator (Incl. 13)(Up to S#00-01961)Stator (Incl. 13)(S#00-01961 & after)

10 30855633086985

33

Screw and Washer (Up to S#00-01961)Screw and Washer (S#00-01961 & after)

11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3084977 1 Clamp15 3081256 3 Screw and Washer16 3085639

308698211

CDI System (Up to S#00-01961)CDI System (S#00-01961 & after)

17 3083073 2 Nut18 3080077 2 Washer, Spring19 3085521 1 Switch, Magnetic20 3086819

308698311

Flywheel w/Ring Gear (Up to S#00-01961)Flywheel w/Ring Gear (S#00-01961 & after)

12/99

E3

STARTING MOTORMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

10

12

2

6

11

5

4

18

13

17

16

15

14

78

9

32


1 3084981 1 Motor, Starting (Incl. 2-6,8-12)2 3084982 1 Washer Set3 3085353 1 Asm., Armature4 3084406 1 Brush, Carbon5 3083649 2 Nut, Flange6 3084408 3 O-Ring7 3082038 2 Bolt and Washer8 3085034 1 Asm., Rear Bracket9 3085033 1 Asm., Front Bracket (Incl. 10)

10 3240114 1 O-Ring11 3084983 2 Asm., Set Bolt (Incl. 6)12 3084405 2 Ring, Rubber13 3083737 1 Washer, Gear Shaft14 3084412 1 Clip15 3084411 1 Spring, Weight16 3084410 1 Spring, Return17 3084409 1 Clip18 3085394 1 Asm., Gear Shaft (Incl. 13-17)

7/98

E4

FUEL PUMPMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

5

2

4 3

3

5

1


1 3085275 1 Asm., Fuel Pump (Incl. 2-5)2 3084999 1 Screw and Washer3 3085356 2 Screw and Washer

4 3084591 4 Screw5 3084998 1 Diaphragm Gasket Set

7/98

E5

TOOL KITMAGNUM 500 A00CD50AA and MAGNUM 500 EB A00CD50AB and 500 MAGNUM 4X4, HDS A00CD50FA and 500 MAGNUM 4X4, HDS II A00CD50FB

1

3

8

2

10

5

12

9

116

7

4


1 3085544 1 Asm., Tool Kit (Incl. 3-8)2 2870725 1 Gauge, Tire Pressure3 3082657 1 Screwdriver4 3085001 1 Wrench, 8-10 Open5 3085002 1 Wrench, 12-14 Open6 3085567 1 Wrench, Box7 3085569 1 Puller, Spark Plug (Wrench Handle)

8 2682572 1 Pouch, Tool Kit9 2871515 1 Lube, U-Joint, 3 oz., Case10 9915299

991547311

Owner’s Manual, 2000 ATVSupplement, Owner’s Manual 2000Magnum 500

11 2871095-067 1 Wrench, Spanner, Cam12 2460442 1 Pigtail, Power

9/99

E6

GEARCASE500 MAGNUM 4X4, HDS A00CD50FA

2

1

3

4

56

7

8

9

1011 12 13 14

18

19

22

23 24

2728

2930

31

32

39

33

3435

36

3738

40

4142

45

2

9

34

2930

32

9

43

44

46

47

9

26

484950

51

52

18

26

2517

21

15 16

19

54

65

55

56

5758

606162

59

63

64

53

5

2

4

1

5

30

20

5

E7

GEARCASE500 MAGNUM 4X4, HDS A00CD50FA

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


1341353 1 Asm., Gearcase, Main (FA)(Incl. 1-65)(See Gearcase Pg. C10 for AA/AB/FBinformation)

1 3233252 17 Screw2 3233248 3 Seal3 3233763 1 Cover w/Park Lock, LH4 3233529 4 Pipe, Knock5 3233019 4 Bearing6 3233756 1 Shaft, Input7 3233036 1 Chain, Silent8 3233755 1 Gear, 14/19T9 3233018 4 Bearing10 3233055 2 Nut11 3233054 2 Washer12 3233153 2 Bellcrank13 3233045 2 Ring, Retaining14 3233040 2 Washer15 3233548 2 O-Ring16 3233618 2 Ring, Retaining17 3233624 1 Shaft, Shift18 3233749 8 Screw19 3233615 2 Switch, 3 Position20 3233037 1 Vent, Tube21 3233627 1 Shaft, Shift, H/R22 3233765 1 Gearcase, RH23 3233711 1 Plug24 3233324 1 Washer25 3233757 1 Plate, Park Lock26 3233608 8 Screw27 3233628 1 Washer28 3233758 1 Engagement Dog, Low/Park29 3233306 2 Ring, Retaining30 3233619 3 Washer, Thrust31 3233760 1 Gear, 36T

32 3233103 2 Bearing, Needle33 3233761 1 Shaft, Reverse34 3233012 2 Washer35 3233014 1 Bearing, Needle36 3233599 1 Sprocket, 24T37 3233029 1 Ring, Retaining38 3233533 1 Engagement Dog, H/R, HLR39 3233602 1 Fork, Shift, H/R40 3233600 1 Gear, 30T41 3233613 1 Spacer42 3233708 1 Gear, Helical, 36T43 3233032 1 Spring44 3233308 2 Pin, Interlock45 3233309 1 Bracket, Interlock46 3233747 2 Screw, Tapping47 3233709 1 Gear, Helical, 48T48 3233609 1 Cover, Bearing49 3233106 1 Ring, Snap50 3233607 1 Bearing, Ball51 3233606 1 Shaft, 10T52 3233759 1 Fork, Shift, Low/Park53 3233626 1 Chain, Roller54 3233620 1 Sprocket, 12T w/18T Spline55 3233621 1 Gear, Spiral, Bevel, 31T56 3233622 1 Shaft, Rear Output57 3233582 1 Button, Thrust58 3233583 1 Shim59 3233611 1 Shim60 3233623 1 Cover, Output61 3233253 1 Plug, Drain62 3233254 1 Washer63 3233625 1 Shaft, Front Output64 3233903 1 Sprocket, 12T65 3233552 1 Bushing, Garlock

6/01

PRINTED IN THE USA PARTS MANUAL PN 9915488 and MICROFICHE PN 9916574 3/00

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MAGNUM 500 MAGNUM 500 EB 500 MAGNUM 4X4, HDS …pi54.com/corp/manuals/Parts/9915488r03.pdf · parts manual pn 9915488 and microfiche pn 9916574 3/00 magnum 500 model #a00cd50aa magnum