2003 Sportsman 500 HO - A03CH50AA,AB,AC,AD,AE,AH - PM.pdf

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SPORTSMAN 500 HO
Model #A03CH50AA
Model #A03CH50AB
Model #A03CH50AC
Model #A03CH50AD
Model #A03CH50AE
Model #A03CH50AH
E 2002 Polaris Sales Inc.
PARTS MANUAL PN 9917541 and MICROFICHE PN 9917542 6/02
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TABLE OF CONTENTS
SPORTSMAN 500 A03CH50AA and SPORTSMAN 500 A03CH50AB and SPORTSMAN 500 A03CH50AC and SPORTSMAN 500
A03CH50AD and SPORTSMAN 500 A03CH50AE
Parts Manual
A
G
A-ARM / STRUT MOUNTING
............
C2
GEARCASE
.........................
C13-14
AIR BOX
...........................
B1
H
C
HANDLEBAR
........................
HEADLIGHT POD
B11-12
.....................
B11-12
CALIPER, REAR
.....................
B7
CARBURETOR
.......................
CLUTCH COVER
D5-6
I
.....................
CONTROLS -- MASTER
CYLINDER/BRAKE LINE
C11
INTAKE and EXHAUST
.................
D8
............
CONTROLS -- THROTTLE ASM./CABLE
B6
....
B9
M
COOLING SYSTEM
...................
A10
MAGNETO
..........................
MASTER CYLINDER, REAR
D13
CRANKCASE
........................
CRANKSHAFT and PISTON
D2
............
B8
.............
D7
MULTI MOUNT WINCH
.................
E3
CYLINDER
..........................
D3-4
O
D
OIL FILTER
.........................
D12
DECALS
...........................
DRIVE CLUTCH
A9
OIL PUMP
..........................
D11
......................
C8
OIL TANK
...........................
B13
DRIVE SHAFT
.......................
DRIVEN CLUTCH (If Built After 7/08/02)
B2
.....
DRIVEN CLUTCH (If Built Before 7/08/02)
C10
P
...
C9
PROP SHAFT
.......................
B3
E
R
ELECTRICAL / TAILLIGHT
..............
C12
REAR CAB and SEAT
.................
A3-4
ENGINE MOUNTING
..................
A13-14
REAR DRIVE SHAFT
..................
REAR RACK MOUNTING
B4
EXHAUST SYSTEM
...................
A11
...............
A6
REAR SUSPENSION
..................
C5-6
F
REAR WHEEL DRIVE
..................
C7
FOOT PEDAL
........................
FRAME MOUNTING
B8
RECOIL STARTER
....................
D9
...................
B14
FRONT CAB
........................
FRONT HOUSING
A5
S
....................
FRONT RACK and BUMPER MOUNTING
D1
STARTING MOTOR
...................
D14
...
A7-8
STEERING POST
.....................
B10
FRONT STRUT
......................
C3
FRONT WHEEL
......................
C4
T
FUEL PUMP
.........................
E1
FUEL TANK
.........................
A12
TOOL KIT
...........................
E2
G
W
GEAR SELECTOR
....................
C1
WATER PUMP
.......................
D10
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
REAR CAB and SEAT
SPORTSMAN 500 A03CH50AA and SPORTSMAN 500 A03CH50AB and SPORTSMAN 500 A03CH50AC and SPORTSMAN 500 A03CH50AD and
SPORTSMAN 500 A03CH50AE and SPORTSMAN 500 A03CH50AH
E 2002 Polaris Sales Inc.
15
14
6
7
16
13
17
8
5
19
9
18
10
12
11
4
1
3
34
20
2
21
35
6
3
33
39
32
22
37
36
29
38
31
30
24
25
28
22
27
26
23
22
24
25
A3
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REAR CAB and SEAT
SPORTSMAN 500 A03CH50AA and SPORTSMAN 500 A03CH50AB and SPORTSMAN 500 A03CH50AC and SPORTSMAN 500 A03CH50AD and
SPORTSMAN 500 A03CH50AE and SPORTSMAN 500 A03CH50AH
Part numbers may have changed since this microfiche was issued. To ensure th at correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7661645
10 Rivet, T-Lock
18 5412067
8 Bumper, Rubber
2 7511930
2 Bolt
19 7517375
2 Screw
3 7555792
4 Washer
20 5431787
1 Cover, Tool Box
4 5811107
1 Foil, Rear Cab, Rear
21 5410896
1 Cap, Drain
5 5432117-400
5432117-288
5434852--419A
5434862-420A
5432117-053
5432117-333
1
1
1
1
1
1
Cab, Rear, Camo Green Metallic (AA)
Cab, Rear, Blazing Red (AB)
Cab, Rear, New Break-Up (AC)
Cab, Rear, Shadow Grass (AD)
Cab, Rear, Med Yellow (AE)
Cab, Rear, Sterling Spruce (AH)
22 7542122
28 Nut, Nylok
23 --
--
--
--
--
--
--
1 Front Housing
(See Front Housing Pg. D1 for Details)
24 7552603
7 Washer, Spring Lock
25 7512492
7 Screw
26 5432280
2 Spacer, Footwell
6 7541925
4 Nut, Nylok
27 7517377
4 Screw
7 5224592
1 Retainer, Seat Latch
28 1013966-067
1 Frame, Main, Black
8 5811308
1 Foil, Tape, Rear Cab
9 7512242
4 Screw
29 7170911
1 Decal, Hitch
10 7555859
4 Washer, Flat
30 7517376
8 Screw
31 5432221-070
5433219-070
1
1
Footwell, Black, LH
Footwell, Black, RH
11 7512085
2 Screw
12 5431786
1 Box, Tool
32 5811111
1 Foil, Foam, Rear Fender
13 7621403
2 Rivet
33 5811106
2 Foil, Rear Cab, Front
14 5211033
2 Bracket, Lever Retainer
34 7079902
1 Decal, Carb/Filter Information
15 1040387
1 Latch, Seat
35 5811087
1 Foil, Foam
16 7041370
1 Spring, Latch
36 7512232
12 Screw
17 2682441-316
2682441-070
2681747-316
2682958-070
1
1
1
Asm., Seat, Delta Marsh (AD)
Asm., Seat, Black (AA)(AB)(AC)(AE)(AH)
Covering, Seat, Delta Marsh (AD)
Covering, Seat, Black
(AA)(AB)(AC)(AE)(AH)
Foil, Seat Base, Large
Foil, Seat Base, Small
37 7517685
2 Screw
38 7670057
12 Nut, U-Type Speed
39 5431796-070
5431797-070
1
1
Guard, Mud, Rear, LH
Guard, Mud, Rear, RH
5811104
5811105
1
1
6/02
A4
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