ATV Polaris 2000 Parts

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 CONTENTS
SPORTSMAN500A00CH50(AA)(AB)(AE)(AF)(AH)(AK)andSPORTSMAN500RSEA00CH50(AC)(AJ)
and WORKER 500 A00CH50(EB)
Parts Manual
A- 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 . . . . . . . . . . . . . . . . . . . . . . . . . .
B12
B11
A13
D8
D11
B5
D9-10
INTAKE and EXHAUST . . . . . . . . . . . . . . . . D12
ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . C8
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . B1-2
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A14
H
HANDLEBAR and HEADLIGHT POD . . . . . . C1-2
GEARCASE (Cases and Snorkel) . . . . . . . . D7

GEARCASE (INTERNAL COMPONENTS) . . . D3-4
D13-14
C7
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-12
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . C5
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . C6
FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . .
FRAME MOUNTING . . . . . . . . . . . . . . . . . . .
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . .
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .
FRONT HOUSING . . . . . . . . . . . . . . . . . . . .
FRONT RACK and BUMPER MOUNTING . . .
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .
E9
C3
B10
A7
D1-2
A9-10
B8
B9
E7
B3
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C14
I
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . E5
O
OIL COOLING . . . . . . . . . . . . . . . . . . . . . . .
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . .
D5-6
E4
E3
B14
P
PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B7
R
REAR 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
S
STARTING MOTOR . . . . . . . . . . . . . . . . . . . E6
STEERING POST . . . . . . . . . . . . . . . . . . . . . B13
T
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . E8
W
WATER 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 SPECIFICATIONS

BRAKES
Type/Brakes
Type/Brakes - Auxiliary
Park Brake
GEARCASE
Hydraulic Disc
Mechanical
Hydraulic Lock, All Wheel
CAPACITIES
Coolant 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
2.25
5.25
32
N/A
N/A
2
90
180
35
Standard
1225
DRIVE TRAIN
Type
Transmission
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
GRAPHICS
Body Style
Bumper Caps/Polyprop.
Cargo Box or Bed
Fender, Front
Engine Braking
DRIVE CLUTCH
Center Distance (inches)
Clutch Offset (inches)
Clutch Weight
Spring Color
10
1/2
10MH(50g)
Blue/Green
DRIVEN CLUTCH
Helix Angle
Spring Position
Compound (EBS)
N/A
Fender, Rear
Footwell
Frame/Steel
Front Cover
DIMENSIONAL FEATURES
Approx. 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)
65
6x7x14
N/A
11
47
81
34
697
50.50
46
ENGINE
Engine 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
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.
PRD
Side Lever
6.69/1
5.17/1
3.34/1
2:1
3-16:1
N/A
N/A
Shaft
Handlebar Cover w/Decal

Headlight/Dash Pod
Rack, Front
Rack, Rear
Rims
Seat Vinyl
Side Panel
Spring, Front
Spring, Rear
Gen IV
(AE)(AK) Medium Yellow
(AA)(AF) Olive Green
(AB)(AH)(EB) Porsche Red
(AL) Gun Metal
(AC)(AJ) Camo
(AL) Gun Metal
50(AC)(AJ) Camo
Black
Semi Flat Black
(AA)(AF) Black
(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
(AL) Gun Metal
(AC)(AJ) Camo
Black
Black
ELECTRICAL
Headlight - 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
SUSPENSION
TIRES & WHEELS
Front 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
Tire 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 NUMBERS

MODEL
MODEL NO.
OWNERS
MANUAL
OWNERS
MANUAL
SUPPLEMENT
PARTS
MANUAL
PARTS
MICROFICHE
ASSEMBLY
INSTRUCTIONS
Sportsman 500
A00CH50(AA)(AB)(AE)
(AF)(AH)(AK)(AL)
9915299
9915476
9915480
9916574
9915512
Sportsman 500 RSE
A00CH50(AC)(AJ)
9915299
9915753
9915480
9916574
9915512
Worker 500
A00CH50(EB)
9915299
9915476
9915480
9916574
9915512
REAR CAB and SEAT

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 RSE A00CH50AJ and WORKER 500 A00CH50EB
E 2000 Polaris Sales Inc.
15
6
14
7
8
17
19
10
12
3
2
39
38
21
40
43
18
20
11
16
13
37
23
36
22
24
29
41
42
35
25
33
34
27
29 28
32
31
26
30
29
27
28
A5
REAR CAB and SEAT

Ref. Part No.
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
Qty. Description
Ref. Part No.
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
21
22
23
24
25
26
5431787
7052095
5410896
7661638
5242953-067
-------
1
2
1
6
1
1
27
28
29
30
31
32
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
7
7
28
2
4
1
1
1
8
1
1
1
2
1
1
1
12
12
1
1
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
33
34
35
36
37
38
39
40
41
42
43
Qty. Description
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, RH
6/00
A6
FRONT CAB
2
3
1
4
23
22
21
20
7
8
19
18
17
14
16
13
Ref. Part No.
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
12
11
15
10
Qty. Description
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
Ref. Part No.
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
Qty. Description
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
Screw
10/00
A7
REAR RACK MOUNTING

2
3
4
9
10
11
10 11
8
9
10
12
18
11
13
14
17
10 15
16
Ref. Part No.
1
2
3
4
Qty. Description
2871501
7517685
7517686
2670174-070
1
4
2
1
5 2670070
6 7517208
7 1040490-067
2
6
1
1012894-067
8 5241663-067
1
1
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
Ref. Part No.
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
Qty. Description
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 MOUNTING

2
3
7
4
10
9
16
15
14
17
13 12
18
19
20
6
21
22
23
28
24
26
27
25
A9
11
FRONT RACK and BUMPER MOUNTING

Ref. Part No.
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
Qty. Description
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
Ref. Part No.
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
Qty. Description
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, RH
1/00
A10
DECALS
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 WORKER 500 A00CH50EB
2 3
7
4
RH
13
10
11
12
15
16
5
14
17
18
19
20
LH
Ref. Part No.
Qty. Description
1
2
3
4
7079110
7074110
7077749
7078455
7078456
7078774
7078775
5 7078452
1
1
1
1
1
1
1
2
7078433
6 7078459
7078777
7078513
7 7074935
2
1
1
1
1
7079213
8 7078003
9 7078315
1
1
1
7078465
10 7078449
1
1
7078859
Ref. Part No.
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
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
Qty. Description
1 Decal - Macpherson Strut

1 Decal - Discretionary Warning
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
1 Decal - Tire Pressure (AL)
1 Decal - Warning, General, CPSC
1 Decal - Warning, General, CPSC (AL)
10/00
A11
DECALS
SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 RSE A00CH50AJ
1
8
2
10
RH
13
11
12
15
17
16
18
19
14
LH
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
7074954
7074110
7078049
7078050
7078051
7078253
7078047
7078003
7074935
7078046
7078045
Qty. Description
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
Ref. Part No.
12 7078354
13 7078577
14 7078315
7078465
15
16
17
18
19
7076273
7077919
7078048
7077920
7079084
Qty. Description
1 Decal - Discretionary Warning

1 Decal - Drain Recoil
1 Logo, 45th Anniversary
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/Load
10/00
A12
COOLING SYSTEM
2
4
16
9
10
15
17
18
11
13
14
19
21
22 23
20
12
24
35
34
36
14
37
38
29
39
32
11
26
27
25
31
28
33
30
40
41
9
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
7080807
1240044
5433364
5243505-067
7661638
5433707
5411783
7080827
7512084
5411632
7080826
7517659
2410123
7670111
7080492
7547069
3110032
5020572
5433059
4010161
1240045
29
Qty. Description
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
Ref. Part No.
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
Qty. Description
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 Degree
9/00
A13
EXHAUST SYSTEM
1
2
3
4
5
6
7
8
5
7
12
13
14
10
11
7
11
15
1
12
13
12
16
14
Ref. Part No.
1
2
3
4
5
6
7542324
7555716
5410436
7555863
5010192
------
7 5410241
8 7515316
Qty. Description
3
3
3
2
3
1
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
Ref. Part No.
9
10
11
12
13
14
15
16
1260715-029
7512666
7042031
7515197
7555935
5241678
1260716-029
5240898
Qty. Description
1
1
4
4
4
2
1
1
Silencer, Exhaust
Bolt
Spring, Exhaust
Screw
Washer
Shield, Heat, Exhaust
Pipe, Exhaust
Seal, Exhaust
10/98
A14
ENGINE MOUNTING
11
15
2
47
19
42
40
11
13
16
48
17
18
38
39
44
43
46
45
24
25
19
41
22 23
21
20
26
30
39 19
8
38
37
14
19
12 13
9 10
36
35
34
33
B1
32
31
29
28
27
19
ENGINE MOUNTING
Ref. Part No.
Qty. Description
1
2
3
4
5
7546601
7080003
5811490
8450040-600
-------
2
8
1
AR
1
6
7
8
9
10
11
12
13
14
7080413
5410995
7080511
8450003-1525
7052075
3110032
7552605
7547069
------
1
1
2
AR
1
2
2
2
1
15
16
17
18
19
20
21
5211626-067
8360009-600
7512315
7552901
7547108
7080694
-------
1
AR
2
2
8
1
AR
22
23
24
25
26
27
7555815
3110046
7080539
7621462
5224658-067
7512566
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
Ref. Part No.
28
29
30
31
32
Qty. Description
7575202
5210748
5430261
5410421
-------
1
1
1
1
1
33 - - - - - - -
34 - - - - - - -
35
36
37
38
39
40
41
7080474
7515417
5241150-067
3110044
7555801
-------------
2
2
1
2
2
2
2
42 1260771-029
43 - - - - - - -
1
1
44 3085556
45
46
47
48
1
1
1
1
5241453-067
7512232
4010132
2530009
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
Filter
1/00
B2
FUEL TANK
1
2
6
5
7
8
21
10
20
19
11
18
17
15
16
13
12
15
14
Ref. Part No.
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
Qty. Description
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)
Ref. Part No.
11
12
13
14
15
16
17
18
19
20
21
7547069
5810317
7052150
8450040-600
7080003
7052149
7517505
5432559
5432733
7052161
2520144
Qty. Description
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 BOX
7
5
9
3
10
11
12
13
26
14
13
25
15
13
24
23
16
18
17
22
13
21
19
20
Ref. Part No.
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
Qty. Description
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
Ref. Part No.
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
Qty. Description
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 Box
3/00
B4
CV JOINT - BTB
BTB
7
2
10
11
12
13
Ref. Part No.
1
2
3
4
5
6
7
1380119
5222299
3260115
7670091
5411106
1380094
1380092
Qty. Description
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)
Ref. Part No.
8
9
10
11
12
13
2200771
3260130
7661913
7080627
2200773
2200961
Qty. Description
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 BTB
10/98
B5
REAR DRIVE SHAFT

11
Ref. Part No.
1
2
3
4
5
1380142
1590280
1350044
1350046
7710505
1350045
Qty. Description
2
1
2
1
1
2
Asm., Drive Shaft, Rear (Incl. 1-9)

CV Joint
Clamp, Large
Grease, 30g
Ring, Retaining
Boot
10
Ref. Part No.
6
7
8
9
10
11
1350043
1350047
1590281
1350042
2201374
2201373
Qty. Description
2
1
1
1
1
1
Clamp, Small
Grease, 50g
Joint, Plunging
Ring, Spring
Kit - Boot (Gear Side)
Kit - Boot (Wheel Side)
3/00
B6
PROP SHAFT
1
2
Ref. Part No.
1380146
1 7661913
2 3260133
3 -------
Qty. Description
1
1
1
2
Ref. Part No.
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
Qty. Description
1 Shaft, Prop
1 Yoke, Prop Shaft, Transmission
1 O-Ring
2/00
B7
FRONT STRUT
27
26
25
24
22
20
23
11
21
12
19
10
14
18
13
12
15
17
11
16
Ref. Part No.
Qty. Description
1
2
3
4
5
6
7
8
9
10
5411608
7041761
5211115
7558402
7080573
7542324
7512365
7552901
5810439
-------
2
2
2
10
2
4
4
4
2
1
11
12
13
14
15
3554509
3554507
5222193
7080306
2410133
4
4
2
2
2
Bumper
Strut, Front
Washer
Washer, Flat
Clamp, 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
Ref. Part No.
16 2201311
2201312
17
18
19
20
21
22
7041375-067
5243364
5432871
7515339
5132062
-------
23
24
25
26
27
3610028
5432872
5810291
7555749
7547104
Qty. Description
1 Asm., Hubstrut, Heavy, LH

(42mm)(Incl. 9,12-15,23)
1 Asm., Hubstrut, Heavy, RH
(42mm)(Incl. 9,12-15,23)
2 Spring, Compression
2 Retainer, Spring
2 Ball, Pivot, Bottom
4 Bolt
2 Spacer
1 Kit - Drive Shaft w/Sleeve BTB
(See CV Joint - BTB Pg. B5, Ref. 13)
2 Seal, Hubstrut
2 Ball, Pivot, Top
2 Spacer, Rubber
2 Washer
2 Nut, Nylok
6/00
B8
FRONT WHEEL
1
2
11 12
10
13
4
5
26
7
25
14
15
24
23
16
18
17
19
20
22
21
Ref. Part No.
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
Qty. Description
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
Ref. Part No.
15
16
17
18
19
20
21
22
23
Qty. Description
5410947
7556004
7542810
7661401
5410470
5432611
7512027
7542459
1520269-067
2
2
2
2
2
2
6
8
2
1520269-117
24 1525017
25 5243676
26 5242935
2
2
2
2
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 BRAKE
3
4
14
13
12
11
10
8
9
Ref. Part No.
1910309
1910310
1910427
1910428
1 7080352
2 7515489
3 5131115
5131116
1930642
4 1930665
5 5410779
6 5410780
7 5132294
Qty. Description
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
Ref. Part No.
8 2200465
2200901
2201149
2201398
9
10
11
12
1910411
5410495
5410494
-------
13 - - - - - - 14 - - - - - - -
Qty. Description
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
6/00
B10
CONTROLS - THROTTLE ASM./CABLE

2
3
4
5
Ref. Part No.
1 5410193
2 5433806
3 5411439
Qty. Description
1 O-Ring
1 Cover
1 O-Ring
Ref. Part No.
4 7080709
5 2010188
6 2010191
Qty. Description
1 Cable, Throttle
1 Asm., Throttle Control (Incl. 2,3,6)
1 Asm., Throttle Clamp
1/00
B11
CONTROLS - MASTER CYLINDER/BRAKE LINE

1
2
3
4
14
13
15
5
12
28
27
11
16
25
26
17
22
18
19
24
20
8
9
22
21
10
23
Ref. Part No.
2050078
2200809
1
2
3
4
5
6
7
1930797
1930796
1930795
2200808
1930799
1930804
2201034
8
9
10
11
12
13
------2201090
1930806
1930792
1930805
-------
Qty. Description
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
Ref. Part No.
Qty. Description
14
15
16
17
5411297
5410988
4110164
-------
1
2
1
1
18
19
20
21
22
23
24
25
26
27
28
7621462
7080539
8360031-30
1930752
7080138
7512024
1930753
8360011-38
7052129
1930817
1930674
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, Banjo
4/99
B12
STEERING POST
16
15
14
5
6
7
13
12
11
7
6
8
6
9
10
Ref. Part No.
1
2
3
4
5
6
7
8
1843051
5433415
7080424
7515321
5431574
7555878
5410772
5431571
Qty. Description
1
1
1
2
1
3
2
1
Asm., Steering Post (Incl. 5,13)

Bushing, Steering, Console
Bolt
Plug, Grease, Steering
Washer
O-Ring
Spacer, Steering Post
Ref. Part No.
9
10
11
12
13
14
15
16
7543203
7661633
5431570
7661632
7080433
5433416
5222999-067
7542324
Qty. Description
1
1
1
2
1
1
1
2
Nut
Pin, Cotter
Bushing, Steering, Lower
Rivet
Bushing, Steering, Upper
Bracket, Steering Bushing, Upper
Nut, Nylok
1/00
B13
OIL TANK
To Airbox
5
4
8
2
10
1
To Lower Oil Pump Fitting on Engine
23
8
11
9
22
12
15
21
14
9
To Top Oil Pump Fitting on Engine
13
20
17
18
19
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7511848
5211523
5830053
7052163
5411668
5432289
5410889
7517102
7555896
7052109
7052133
2530020
14
Qty. Description
2
1
1
1
1
1
1
2
4
1
1
1
Screw
Plate, Vent, Oil Tank
Gasket, Oil Reservoir
Fitting
Line, Breather
Dipstick
O-Ring
Bolt, Banjo
Washer, Copper
Tube, Banjo Return
Tube, Banjo Intake
Screen, Oil Filter
16
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
7542122
7558301
5131785
5411042
5410828
5333204
7512130
7051524
5850135
7515158
5131255
Qty. Description
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, RH
11/02
B14
HANDLEBAR and HEADLIGHT POD

SPORTSMAN 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
13
11
10
20
19
15
12
9
7
8
6
4
21
22
23
43
42
40
39
24
25
41
27
28
30
44
38
29
31
37
36
35
34
C1
33
32
26
HANDLEBAR and HEADLIGHT POD

Ref. Part No.
Qty. Description
1 3280290
3280312
2 5430967
4040053
4040054
3 7511881
4 7670086
5 2460668
6 ------
1
1
1
1
1
3
3
1
1
7 5242987-067
8 2200774
1
1
5630616-067
7541933
7555868
7558212
7515189
3280291
5433042-053
5433042-191
5433042-136
5433042-317
5433289-283
15 - - - - - - -
2
2
2
2
4
1
1
1
1
1
1
1
16
17
18
19
20
21
22
23
24
1
1
2
1
1
1
2
1
1
9
10
11
12
13
14
5432926
4010262
5431030
5432952
7517625
5240586-067
7517317
4032079
5411120
25 4032077
26 4032075
2870448
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
1 Collar, Locking
1 Lens and Reflector
1 Bulb, Headlight, Halogen
Ref. Part No.
Qty. Description
27 4032078
28 5410163
29 7080726
2200188
30 7542122
31 7670089
32 2410025
33 7621334
34 4010283
1
2
1
1
4
2
1
2
1
35 7080631
36 7522021
37 5432314-070
1
2
1
5433366-070
5433706-283
5431811-070
38 4110264
4010278
1
1
4010321
5433534
5433733
7080229
4040081
4010298
43 5132382
44 7517658
1
1
1
1
1
1
1
39
40
41
42
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
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 MOUNTING
1
4
3
2
10
11
3
8
Ref. Part No.
1
2
3
4
5
6
7661013
1040494-067
5431107
5020850
7542122
-------
Qty. Description
2
1
2
1
1
2
Pin, Clevis
Pivot, Shift
Bushing
Tube, Pivot
Nut, Nylok
Rod End, LH
(See Gear Selector Pg. C14, Ref. 17)
Ref. Part No.
7 7517386
8 7512144
9 ------10 5131277
11 7661103
Qty. Description
4 Screw
1 Screw
4 Nut, FLEXLOC
(See Gear Selector Pg. C14, Ref. 14)
1 Arm, Shift
2 Pin, Cotter
4/99
C3
A-ARM/STRUT MOUNTING
5
2
6
7
8
30
31
10
11
9
12
29 28
13
14
28
29
23
22
27
15
26
22
23
16
24 25
19
20
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
Qty. Description
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
17
14
21
Ref. Part No.
18
Ref. Part No.
16
17
18
19
20
Qty. Description
26
27
5211121
7512284
5410548
7542438
5431837
5431838
7512084
5433066
5020677
5020681
2201607
2201608
7080433
--------
2
4
2
2
1
1
6
4
4
2
1
1
2
1
28
29
30
31
7512492
7552603
7517527
7515415
4
4
1
1
21
22
23
24
25
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
Asm., Heavy Hubstrut
Screw
Washer, Spring Lock
Bolt
Screw
10/00
C4
DRIVE CLUTCH
5
6
4
1
9
8
10
18
12
15 14
16
11
5
13
17
A00CH50(AA)AB)(AE)(AF)(AH)(AK)(AL)(AC)(AJ)
14
11 10
13
16
5
19
12
5
15
20
4
21
A00CH50EB
Ref. Part No.
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
Qty. Description
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
Ref. Part No.
14
15
16
17
Qty. Description
5430945
7512266
5630513
1321706
6
3
3
1
18 7556008
19 5210752
5242981
5210753
5210754
20 3576504
21 1321632
1
AR
AR
AR
AR
1
1
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 CLUTCH
A00CH50EB
8
2
6
10
11
5
12
13
A00CH50AA
A00CH50AB
A00CH50AE
A00CH50AF
A00CH50AH
A00CH50AK
A00CH50AL
A00CH50AC
A00CH50AJ
9 10
14
15
1
17
18
21
22
27
20
16
19
23
26
13
25
24
20
Ref. Part No.
1
2
3
4
5
Qty. Description
7556120
5220646
7552901
7515382
1322182
AR
1
1
1
1
3211077
5430766
7511854
7710448
5210752
5132344
5131447
12 7041198
13 3576511
14 3576504
1
3
3
1
1
1
1
1
1
1
6
7
8
9
10
11
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)
Ref. Part No.
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
Qty. Description
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, Stationary
10/00
C6
CLUTCH COVER
7
11
3
8 9
12
13
10
14
21
29
28
15
17
27
23
26
25
24
22
19
18
17 13
16
21
20
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
1
2
1
1
1
3
3
1
1
1
1
1
5433451-070
12 7670051
13 7512093
1
5
14 7074946
7078689
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
Cover, Clutch, Outer
Clip, Clutch Cover
Screw (If built before 3/13/00)(Use
7512094 if built after 3/13/00)
Decal - Warning, Clutch Cover
Decal - Warning, Clutch Cover
Ref. Part No.
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
-------
Qty. Description
1 Decal - Engine/Clutch Modification

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
1 Duct, Clutch Outlet
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/TAILLIGHT
1
3
6
7
8
2
9
10
15
14
16
17
18
13
19
12
11
32
11
12
31
30
24
1
1
1
1
5
6
7
8
9
10
11
12
13
14
15
16
4032046
4032029
4030043
4032045
4032064
7670054
7541925
7571602
7512027
5810290
4010094
2200361
1
2
1
1
1
2
4
4
2
3
1
1
21
26
Qty. Description
2460784
2200593
2201795
2432034
22
25
27
1
2
3
4
23
29
28
Ref. Part No.
20
15
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
Ref. Part No.
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
Qty. Description
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, Routing
1/00
C8
REAR SUSPENSION
1
16
11
4
5
2
3
16
3
11
15
14
6
5
7
5
6
15
14
18
19
20
13 12
10
12
17
11
10
12
17
9
11
10
10
35
22
18
25
24
10
18
34
11
33
20
31
5
4
18
11
35
37
43
24
10
26
17
27
28
32
6
9
20
20
32
36
20
44
21
18
8
9
23
17
38
42
41
40
C9
39
29
30
REAR SUSPENSION
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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
Qty. Description
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
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
Ref. Part No.
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
Qty. Description
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
6/00
C10
REAR BRAKE/FOOT PEDAL

8
9
11
10
24
23
22
11
21
20
12
19
18
13
15
17
C11
14
15
16
14
REAR BRAKE/FOOT PEDAL

Ref. Part No.
1
2
3
4
5
6
7
8
Qty. Description
7515497
7552603
7555806
1910366
1910441
2
2
2
1
1
2201093
1910339
1930860
2201399
1
1
1
2201180
2201428
2201181
1930853
1910305
7512111
1930854
1
2
1
1
1
1
1
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
Ref. Part No.
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
Qty. Description
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, Nylok
6/00
C12
REAR WHEEL DRIVE

4
5
6
1
11
10
12
Ref. Part No.
1
2
3
4
7661404
7542459
5131649
-------
5 7710440
6 7515513
7 5410948
Qty. Description
2
8
2
2
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
Ref. Part No.
8 1525017
9 1520217-067
1520217-117
10 7555796
11 7543005
12 5411164
Qty. Description
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, Hub
6/00
C13
GEAR SELECTOR
1
2
3
4
6
23
10
11
8
22
9
10
11
15
21
20
19
17
14
14
12
13
18
14
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
1341271
3233195
7512024
3233649
3233131
3233648
3233658
3233646
3233754
3233644
3233642
3233060
Qty. Description
1
1
1
4
1
1
1
1
1
1
2
2
Asm., Gear Selector (Incl. 1-13,21-23)

Asm., Knob
Screw
Screw
Strap, Wire
Cover, Gear Selector Boot
Handle, Gear Selector
Sphere, Plastic
Pin, Groove
Pin, Dowel
Spring, Detent
Bullet, Detent
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
22
23
3233076
3233639
7546707
7061014
7546701
7061013
5020824
5020823
7546702
3233640
3233641
3233643
15 16
17
14
Qty. Description
2
1
4
2
2
2
1
1
2
1
1
1
O-Ring
Slide, Low
Nut, FLEXLOC
Rod End, RH
Nut, RH
Rod End, LH
Rod, Shift Linkage, Low-Range
Rod, Shift Linkage, Hi-Range
Nut, LH
Slide, High/Reverse
Body, Gear Selector
Spring, Centering
9/00
C14
FRONT HOUSING
500 A00CH50AK and SPORTSMAN 500 A00CH50AL and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 A00CH50AJ and WORKER 500 A00CH50EB
14
15
13
16
11 12
9
10
17
8
18
19
26
20
21
22
25
24
Ref. Part No.
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
Qty. Description
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
Ref. Part No.
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
23
Qty. Description
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
Washer
9/99
D1
FRONT HOUSING
13
14
15
16
11 12
9 10
17
8
6
3
1
18
19
25
28
27
26
1341323
1
2
3
4
5
6
7
8
9
10
11
12
13
3233252
3233248
3233701
3233700
3233699
3233589
3233726
3233541
3233319
3233697
3233324
3233711
7080756
Qty. Description
1 Asm., Front Gearcase

(Incl. 1-12,16-26)(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
21
22
2
1
24
Ref. Part No.
20
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
8450003-1525
7080307
3233524
3233696
3233725
3233020
3233554
3233693
3233724
3233583
3233582
3233254
3233253
7512492
7552603
23
Qty. Description
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
Washer
7/99
D2
GEARCASE (Internal Components)

A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 A00CH50AJ
1
2
6
4
11
10
9
8
7
12
33
32
31
23
30
13
14
29
26
28
27
34
15
26
35
25
16
24
51
23
22
50
37
36
47
46
16
21
20
19
38
39
48
49
11
10
9
8
7
6
43
40
41
42
15
44
45
D3
18
17
GEARCASE (Internal Components)

A00CH50AH and SPORTSMAN 500 A00CH50AK and SPORTSMAN 500 RSE A00CH50AC and SPORTSMAN 500 A00CH50AJ
Ref. Part No.
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
Qty. Description
1 Asm., Gearcase (Incl. 1-36 and all on

Gearcase (Cases and Snorkel) Pg. D7)
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
Ref. Part No.
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
Qty. Description
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, Silent
4/99
D4
GEARCASE (INTERNAL COMPONENTS)

3
4
2
3
4
5
24
10
23
11
22
5
6
7
6
17
19
21
10
20
15
16
18
15
12
13
14
25
27
23
28
26
42
21
30
29
41
36
35
34 33
15
21
32
31
11
10
27
37
40 39
38
45
26
43
44
D5
46
GEARCASE (INTERNAL COMPONENTS)

Ref. Part No.
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
Qty. Description
1 Asm., Gearcase (Incl. 1-37 and all on

Gearcase (Cases and Snorkel) Pg. D7)
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
Ref. Part No.
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
3233308
3233189
3233309
3233747
3233177
3233732
3233020
3233715
3233365
3233265
3233364
3233263
7552901
3233262
3233360
3233434
3233433
3233432
3233431
3233430
3233268
3233670
3233282
3233669
Qty. Description
2
1
1
2
1
1
2
1
1
1
1
1
4
4
1
1
1
2
1
1
2
1
2
1
Pin, Interlock
Spring, Interlock
Bracket, Interlock
Screw
Ring, Retaining
Engagement Dog, Low
Bearing, Ball
Shaft, Center Drive
Pinion, 16T, Spiral Bevel
Bearing
Ring, Retaining
Cover, Bearing, Center Drive
Washer
Screw
Gear, Output, 100T, HCR
Chain Tensioner, Cam
Chain Tensioner, Shoe
Pin, Dowel
Spring, Torsion
Chain, Silent
Bearing
Sprocket, 60T
Screw
Deflector, Oil
1/00
D6
GEARCASE (Cases and Snorkel)

7
3
11
10
6
8
20
19
12
13
14
21
5
22 23
18
15
17
16
1
25
26
28
29
36
35
Ref. Part No.
------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
34
33
30
31
32
Qty. Description
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
24
27
Ref. Part No.
Qty. Description
21 3233305
22 3233353
3233354
3233355
3233356
3233357
1
1
1
1
1
1
23
24
25
26
27
28
3233306
3233444
3233351
3233292
3233293
-------
1
1
1
1
1
4
29
30
31
32
33
34
35
36
3233291
3233294
3233295
3233296
3233253
3233254
3233672
3233247
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, Dowel
4/99
D7
CRANKCASE
7
5
8
9
22
10
11
21
20
19
18
Ref. Part No.
1 3083669
2 3085633
3
4
5
6
7
8
9
10
11
3084838
3080676
3084840
3084205
3084839
3085525
3084842
3084834
3084835
17
14
16
Qty. Description
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
13
12
15
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
22
3084845
3084846
3084844
3086810
3084841
3082956
3083453
3084837
3084836
3084847
3080103
Qty. Description
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, Dowel
4/99
D8
CYLINDER
1
3
4
10
12
38
11
36
36
37
13
5
17
36
35
16
14
15
18
19
24
20
23
22
34
21
27
26
28
29
18
33
30
31
32
13
D9
25
CYLINDER
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
3083166
3081497
3081330
3084857
3084994
3084858
3084867
3085072
3084877
3084866
3085074
3085073
3084874
3084859
3084875
3084860
3084861
3084862
19 3084215
Qty. Description
1
1
2
2
4
2
1
1
10
1
1
1
10
2
4
1
1
1
2
Band, Adapter (Incl. 2)

Screw
Bolt, Allen
Pin, Straight
Guide, Valve
Seal, Intake Valve
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
Ref. Part No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
3085075
3085326
3080285
3080530
3085854
3084876
3084864
3084863
3084838
3084849
3084873
3086811
3084130
3085370
3084868
3086200
3085527
3085371
3084879
Qty. Description
1
2
2
2
1
4
1
1
2
1
4
1
1
1
1
1
1
1
1
Gasket, Exhaust
Stud
Nut
Washer, Lock
Bolt, Rocker Shaft
Bolt
Support, Valve Rocker Shaft (PTO)
Support, Valve Rocker Shaft (MAG)
Pin, Straight
Union, Oil Pump
Bolt, Flange
Cylinder (Incl. 32)
Pipe 2, Elbow
Gasket, Cylinder
Cover, Camshaft
Gasket, Cover, Cam
Cylinder Head (Incl. 4-6,14,16-18,21)
Gasket, Head
Adapter
4/99
D10
CRANKSHAFT and PISTON

1
4
2
3
4
21
7
8
20
9
10
19
11
14
18
Ref. Part No.
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
17
16
15
Qty. Description
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
12
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
13
Ref. Part No.
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
Qty. Description
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, Woodruff
4/99
D11
INTAKE and EXHAUST

8
8
10
6
1
11
12
2
3
4
27
14
13
7
15
16
17
26
18
13 12
11
25
24
23
20
21
22
Ref. Part No.
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
Qty. Description
1
1
1
1
1
2
1
4
4
1
8
4
4
1
Plug
Gasket, Plug
Spring, Tensioner
Asm., Tensioner (Incl. 1-3)
Gasket, Tensioner
Asm., Intake Rocker Arm (Incl. 8,9)
Asm., Exhaust Rocker Arm (Incl. 8,9)
Nut
Screw, Adjusting
Shaft, Rocker
Collet, Valve
Retainer, Spring
Spring, Valve
Camshaft (Incl. 15-18)
19
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
3086838
3085348
3085076
3084899
3084914
3081657
3084916
3084915
3084924
3084917
3085349
3084905
3084874
Qty. Description
1
1
1
1
1
3
1
1
1
1
2
2
2
Pin, Dowel
Lever, Release
Spring, Return
Pin, Dowel
Sprocket 2
Bolt and Washer
Guide, Chain
Chain, Timing
Bolt, Pivot, Lever
Lever
Valve, Intake
Valve, Exhaust
Bolt, Flange
6/99
D12
CARBURETOR
51
4
50
5
49
7
8
43
46
48
45
47
44
41
42
40
39
10
11
38
15
14 13
12
12
25
16
24
34
26
27
28
29
33
32
31
30
17
23
22
18
21
20
19
D13
35
36
37
CARBURETOR
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
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
Qty. Description
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)
Ref. Part No.
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
Qty. Description
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
Screw
4/99
D14
RECOIL STARTER
7
8
9
15
11
10
12
14
13
7
Ref. Part No.
1
2
3
4
5
6
7
8
3084822
3083463
3083378
3083379
3084744
3085266
3083453
3082956
Qty. Description
1
1
1
1
1
1
2
2
Reel
Spring, Return
Ratchet
Spring, Friction
Plate, Friction
Bolt and Washer
Plug
Gasket
Ref. Part No.
9
10
11
12
13
14
3083669
3083185
3084750
3084933
3084877
3085652
3085653
15 3085083
Qty. Description
1
1
1
1
9
1
1
1
Bushing, Starter
Spring, Spiral
Bushing
Gasket, Recoil
Bolt, Flange
Asm., Recoil (Incl. 1-6,9-11,14,15)
Starter Case (Incl. 11)
Asm., Rope
4/99
E1
WATER PUMP
4
3
11
8
9
12
10
7
5
13
Ref. Part No.
1
2
3
4
5
6
7
3084940
3085352
3084191
3085857
3085359
3082758
3085351
Qty. Description
1
1
2
1
1
1
1
Thermostat
Switch, Thermostat
Clamp, Hose
Hose, Main
Bolt, Flange
Gasket, Aluminum
Cover, Water Pump
Ref. Part No.
8
9
10
11
12
13
3084937
3085077
3083138
3084935
3084942
3084877
Qty. Description
1
1
1
1
1
4
Gasket, Water Pump

Nut, Self Lock
Gasket
Impeller
Washer, Seal
Bolt, Flange
7/98
E2
OIL PUMP
1
5
10
9
11
6
7
12
13
15
14
17
Ref. Part No.
1
2
3
4
5
6
7
8
9
3084946
3084949
3084948
3084944
3084945
3085535
3084955
3084954
3084953
3084962
16
Qty. Description
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
Ref. Part No.
10
11
12
13
14
15
16
17
3084947
3084950
3084951
3084956
3084205
3084952
3084958
3084959
3084960
3084961
Qty. Description
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 FILTER
2
4
3
2
3
5
Ref. Part No.
1 3084963
2 3084846
3 3086815
Qty. Description
Ref. Part No.
1 Filter, Oil
8 Gasket, Aluminum
4 Bolt, Banjo
4 3084964
5 3085638
Qty. Description
1 Pipe 1, Oil Delivery

1 Pipe 2, Oil Delivery
4/99
E4
MAGNETO
16
17
18
19
15
4
14
13
12
20
10
11
6
7
9
Ref. Part No.
Qty. Description
1 3085227
3085228
2 3084980
3 3070175
4 3084978
5 3084972
6 3086820
1
1
1
1
1
1
1
3085560
3086980
1
1
3086981
7 3081657
8 3084973
9 3086821
3086984
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)
Ref. Part No.
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
Qty. Description
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 MOTOR
8
2
1
12
13
14
11
15
10
16
18
17
Ref. Part No.
1
2
3
4
5
6
7
8
9
3084981
3084982
3085353
3084406
3083649
3084408
3082038
3085034
3085033
Qty. Description
1
1
1
1
2
3
2
1
1
Motor, Starting (Incl. 2-6,8-12)

Washer Set
Armature
Brush
Nut, Flange
O-Ring
Bolt and Washer
Bracket, Rear
Bracket, Front (Incl. 10)
Ref. Part No.
10
11
12
13
14
15
16
17
18
3240114
3084983
3084405
3083737
3084412
3084411
3084410
3084409
3085394
Qty. Description
1
2
2
1
1
1
1
1
1
O-Ring
Asm., Set Bolt (Incl. 6)
Ring, Rubber
Washer, Gear Shaft
Clip
Spring, Weight
Spring, Return
Clip
Asm., Gear Shaft (Incl. 13-17)
10/98
E6
FUEL PUMP
4
3
2
1
Ref. Part No.
1 3085275
2 3084999
3 3085356
Qty. Description
Ref. Part No.
1 Asm., Fuel Pump (Incl. 2-5)

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

1 Diaphragm Gasket Set
10/98
E7
TOOL KIT
2
9
3
5
10
1
6
Ref. Part No.
1
2
3
4
5
6
7
3085383
2870725
3082657
3085001
3085002
3085568
3085569
Qty. Description
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)
Ref. Part No.
8 2682572
9 9915299
9915476
9915753
10 2871095-067
Qty. Description
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, Cam
6/00
E8
FOOT BRAKE
WORKER 500 A00CH50EB
2
5
3
16
13
14
12
6
7
15
11
9
10
Ref. Part No.
1
2
3
4
5
6
7
8
7512126
1040732-067
7661205
7555827
5211914
7555931
7542103
7556063
Qty. Description
1
1
1
2
1
1
1
2
Bolt
Bracket
Pin, Cotter
Washer
Handle, Parking Brake
Washer, Flat
Nut, FLEXLOC
Washer, Wave
Ref. Part No.
9
10
11
12
13
14
15
16
5224875
7558707
5242749
5224871
7080644
7661843
7661011
7661203
Qty. Description
1
1
1
1
1
1
1
1
Spring, Return
Bushing
Pawl, Parking Brake
Linkage, Parking Lock
Clevis, Threaded
Pin, Clevis
Pin, Cotter
Pin, Cotter
10/98
E9
PRINTED IN THE USA
PARTS MANUAL PN 9915480 and MICROFICHE PN 9916574 6/00
cover
toc
Changed pages in 9915480
10
10
11
11
12
12
13
13
14
14

ATV Polaris 2000 Parts

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SPORTSMAN 500

E 2000 Polaris Sales Inc.

PARTS MANUAL PN 9915480 and MICROFICHE PN 9916574 6/00

INTAKE and EXHAUST . . . . . . . . . . . . . . . . D12

GEARCASE (Cases and Snorkel) . . . . . . . . D7

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C14

2000 SPORTSMAN 500 SPECIFICATIONS

Handlebar Cover w/Decal

1 Single Beam, 60W

TIRES & WHEELS

Front Type Front Travel (inches)

2000 ATV PUBLICATION NUMBERS

Sportsman 500 RSE

REAR CAB and SEAT

E 2000 Polaris Sales Inc.

REAR CAB and SEAT

Ref. Part No.

Ref. Part No.

Cover, Tool Box

Ref. Part No.

Ref. Part No.

REAR RACK MOUNTING

Ref. Part No.

Kit - Rack Extender, Rear (Incl. 6)

Ref. Part No.

FRONT RACK and BUMPER MOUNTING

FRONT RACK and BUMPER MOUNTING

Ref. Part No.

1 Extender, Rack, Front, Low (AC)(AJ)

Ref. Part No.

Ref. Part No.

Decal - Warning, Rear Rack

1 Decal - Macpherson Strut

Ref. Part No.

Ref. Part No.

1 Decal - Discretionary Warning

Ref. Part No.

Washer, Split Lock

Ref. Part No.

Ref. Part No.

Ref. Part No.

Ref. Part No.

Cap, Gas Tank

Ref. Part No.

Filter, Precleaner Sleeve

Ref. Part No.

Ref. Part No.

Asm., CV Housing w/Sleeve

Ref. Part No.

Kit - Cross and Bearing

REAR DRIVE SHAFT

Ref. Part No.

Asm., Drive Shaft, Rear (Incl. 1-9)

Ref. Part No.

Ref. Part No.

Ref. Part No.

Ref. Part No.

Ref. Part No.

1 Asm., Hubstrut, Heavy, LH

Ref. Part No.