2004 POLARIS SPORTSMAN 500 HO ATV Parts CATALOG

SPORTSMAN 500 Model #A04CH50AA Model #A04CH50AC Model #A04CH50AE Model #A04CH50AG E 2003 Polaris Sales Inc. PARTS MANUAL PN 9918608 and MICROFICHE PN 9918609 12/02

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TABLE OF CONTENTS SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG Parts Manual A A -ARM / STRUT MOUNTING B12 ............ AIR BOX B1 ........................... B BUMPER MOUNTING A-8 ................. C CALIPER, REAR B7 ..................... CARBURETOR D5-6 ....................... CLUTCH COVER C7 ..................... CONTROLS - MASTER CYLINDER/BRAKE LINE B3 ............ CONTROLS - THROTTLE ASM./CABLE B4 .... COOLING SYSTEM A10 ................... CRANKCASE D1 ........................ CRANKSHAFT and PISTON D2 ............. CYLINDER D3-4 .......................... D DECALS A9 ........................... DRIVE CLUTCH C5 ...................... DRIVE SHAFT B8 ....................... DRIVEN CLUTCH C6 ..................... E ELECTRICAL / TAILLIGHT C8 .............. ENGINE MOUNTING A13-14 .................. EXHAUST SYSTEM A11 ................... F FOOT PEDAL B6 ........................ FRAME MOUNTING C3 ................... FRONT CAB A5 ........................ FRONT HOUSING C12 .................... FRONT STRUT B11 ...................... FRONT WHEEL B13 ...................... FUEL PUMP D14 ......................... FUEL TANK A12 ......................... G GEAR SELECTOR C4 .................... G GEARCASE C13-14 ......................... H HANDLEBAR C1-2 ........................ HEADLIGHT POD C1-2 ..................... I INTAKE and EXHAUST D7 ................. M MAGNETO D12 .......................... MASTER CYLINDER, REAR B6 ............ O OIL FILTER D11 ......................... OIL PUMP D10 .......................... OIL TANK B2 ........................... P PROP SHAFT B10 ....................... R RACK MOUNTING, FRONT A7-8 ............. REAR CAB and SEAT A3-4 ................. REAR DRIVE SHAFT B9 .................. REAR RACK MOUNTING A6 ............... REAR SUSPENSION C9-10 .................. REAR WHEEL DRIVE C11 .................. RECOIL STARTER D8 .................... S STARTING MOTOR D13 ................... STEERING POST B14 ..................... T TOOL KIT E1 ........................... W WATER PUMP D9 ....................... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3 REAR CAB and SEAT SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG 1 6 2 5 8 9 14 13 15 16 17 33 12 19 20 29 35 36 37 34 31 11 3 32 18 2 21 27 25 26 21 7 24 23 22 28 30 5 21 23 24 E 2003 Polaris Sales Inc. 4 10

A4 REAR CAB and SEAT SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7511930 2 Bolt 2 7555792 4 Washer 3 5811107 1 Foil, Rear Cab, Rear 4 5432117-400 5434852 -419A 5432117-053 5432117-341 1 1 1 1 Cab, Rear, Camo Green Metallic (AA) Cab, Rear, New Break-Up (AC) Cab, Rear, Med Yellow (AE) Cab, Rear, Sonic Blue (AG) 5 7541925 4 Nut, Nylok 6 5224592 1 Retainer, Seat Latch 7 5811308 1 Foil, Tape, Rear Cab 8 7512242 4 Screw 9 7555859 4 Washer, Flat 10 7556034 4 Washer 11 7512085 2 Screw 12 5431786 1 Box, Tool 13 7621403 2 Rivet 14 5211033 2 Bracket, Lever Retainer 15 1040387 1 Latch, Seat 16 7041370 1 Spring, Latch 17 2683222-070 2682958-070 5811104 5811105 1 1 1 1 Asm., Seat, Black Covering, Seat, Black Foil, Seat Base, Large Foil, Seat Base, Small 18 5412067 8 Bumper, Rubber 19 7517375 2 Screw 20 5431787 1 Cover, Tool Box 21 7542122 28 Nut, Nylok 22 ------- 1 Front Housing (See Front Housing Pg. C12 for Details) 23 7552603 7 Washer, Spring Lock 24 7512492 7 Screw 25 5432280 2 Spacer, Footwell 26 7517377 4 Screw 27 1014322-067 1 Frame, Main, Black 28 7170911 1 Decal, Hitch 29 7517376 8 Screw 30 5432221-070 5433219-070 1 1 Footwell, Black, LH Footwell, Black, RH 31 5811111 1 Foil, Foam, Rear Fender 32 5811106 2 Foil, Rear Cab, Front 33 7079902 1 Decal, Carb/Filter Information 34 5811087 1 Foil, Foam 35 7512232 22 Screw 36 7670057 22 Nut, U-Type Speed 37 5434704-070 5434705-070 1 1 Guard, Mud, Rear, LH Guard, Mud, Rear, RH 2/03

A5 FRONT CAB SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG 6 7 5 8 9 15 3 2 13 12 20 19 21 8 1 4 4 10 4 16 17 11 12 18 14 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5811491 1 Foil, Side Panel, Gen. IV, RH 2 5812329 1 Foil, Foam, Side Panel 3 2632289-400 2632678-419 2632289-053 2632289-341 2620085-400 2632679-419 2620085-053 2620085-341 1 1 1 1 1 1 1 1 Panel/Foil, Camo Green Met, LH (AA) Panel/Foil, New Break-Up, LH (AC) Panel/Foil, Yellow, LH (AE) Panel/Foil, Sonic Blue, LH (AG) Panel/Foil, Camo Green Met, RH (AA) Panel/Foil, New Break-UP, RH (AC) Panel/Foil, Med Yellow, RH (AE) Panel/Foil, Sonic Blue, RH (AG) 4 7517312 2 Screw 5 2632299-400 2632677-419 2632299-053 2632299-341 1 1 1 1 Cab, Front, Camo Green Met (AA) Cab, Front, New Bread-Up (AC) Cab, Front, Med Yellow (AE) Cab, Front, Sonic Blue (AG) 6 5432088-400 5434857-419A 5432088-053 5432088-341 1 1 1 1 Cover, Front, Camo Green Met (AA) Cover, Front, New Break-Up (AC) Cover, Front, Med Yellow (AE) Cover, Front, Sonic Blue (AG) 7 7670085 2 Clip, Spring 8 7670057 10 Nut, U-Type Speed 9 7670135 4 Nut, Speed 10 7512232 10 Screw 11 7670156 2 Clip, Retainer 12 7542122 2 Nut, Nylok 13 7556034 2 Washer 14 7555859 2 Washer, Flat 15 5434702-070 5434703-070 1 1 Guard, Mud, Front, LH Guard, Mud, Front, RH 16 5246641-067 5244914-067 1 1 Guard, Splash, LH Guard, Splash, RH 17 7621509 3 Rivet, Plasti Loc 18 7515158 2 Screw 19 7541925 2 Nut, Nylok 20 7555792 2 Washer 21 7512085 2 Screw 12/02

A6 REAR RACK MOUNTING SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG 1 2 3 4 8 9 7 10 11 12 5 2 7 6 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 1040510-067 1 Extender, Rack, Rear (Incl. 12)(AC) 2 7517983 2 Screw 3 7517685 2 Screw 4 2632669-070 2632837-070 1 1 Asm., Rack, Rear (Incl. Warning Decal) (If built before 2/03/03) Asm., Rack, Rear (Incl. Warning Decal) (If built after 2/03/03) 5 5334092 2 Spacer 6 7555916 2 Washer, Nylon 7 7558402 8 Washer, Flat 8 7512329 4 Bolt 9 ------- 1 Bracket, Silencer, Frame (See Ex- haust System Pg. A11, Ref. 6) 10 7542324 4 Nut, Nylok 11 1013724-067 1 Support, Rear Rack 12 7517208 6 Screw (AC) 2/03

A7 FRONT RACK and BUMPER MOUNTING SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG 28 7 23 5 27 10 11 15 4 1 21 2 6 25 14 18 17 22 16 3 12 15 22 22 9 5 19 23 5 5 9 28 13 5 8 26 24 20 9

A8 FRONT RACK and BUMPER MOUNTING SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 1040526-385 1040526-067 1 1 Extender, Front Rack Extender, Front Rack (AC) 2 7517685 4 Screw 3 7081085 2 Plug 4 5434697-070 5435240-070 1 1 Rack, Front, Black (If built before 2/03/03) Rack, Front, Black (If built after 2/03/03) 5 7558402 12 Washer, Flat 6 7512307 4 Screw 7 2431017 4030059 2 2 Headlight Bulb, Replacement, 27W 8 7555843 2 Washer, Flat 9 7542324 8 Nut, Nylok 10 2632758-070 1 Asm., Bumper, Front, Black (Incl. Warning Decal) 11 7515306 4 Screw 12 5434699-070 1 Panel 13 7512094 2 Screw 14 1013366-067 1 Guard, Brush 15 5434314 5434315 1 1 Shield, Side, Radiator, LH Shield, Side, Radiator, RH 16 5410774 4 Grommet 17 5435046 1 Cover, Radiator 18 5247137-067 1 Grill 19 7528046 4 Screw 20 7670094 6 Nut, U-Type 21 7512097 6 Screw 22 7515399 4 Screw 23 7512329 2 Screw 24 7171474 7171475 1 1 Decal, Reflector, Amber, LH Decal, Reflector, Amber, RH 25 1014020-067 1 Support, Front Rack 26 5810467 1 Plug, Frame 27 1014261-067 1014262-067 1 1 Support, Front Rack, LH Support, Front Rack, RH 28 7512232 6 Screw 2/03

A9 DECALS SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG RH LH 15 2 12 4 3 6 5 21 9 19 7 11 1 17 20 18 1 10 16 14 8 13 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7170021 1 Decal, Warning, Front and Rear Rack 2 7170999 7171484 7171001 7171485 1 1 1 1 Decal, “4x4”, Side Panel, Lower, LH (AA)(AE)(AG) Decal, “4x4”, Side Panel, LH (AC) Decal, “4x4”, Side Panel, Lower, RH (AA)(AE)(AG) Decal, “4x4”, Side Panel, RH (AC) 3 7170997 7171480 7170998 7171481 1 1 1 1 Decal, Side Panel, Middle, LH (AA)AE)(AG) Decal, Side Panel, 500, LH (AC) Decal, Side Panel, Middle, RH (AA)AE)(AG) Decal, Side Panel, 500, RH (AC) 4 7078253 2 Decal, Age Warning 5 7079780 1 Decal, Warning, Switch, AWD 6 7078003 1 Decal, Headlight Adjustment 7 7078465 1 Logo, Polaris Star 8 7171067 1 Decal, Front Cover (AC) 9 7078577 1 Decal, Drain Recoil 10 7079773 7079916 1 1 Decal, “POLARIS” (AA)(AC)(AG) Decal, “POLARIS” (AE) 11 7079604 1 Decal, Warning, Override, AWD 12 7171002 7171478 7171003 7171479 1 1 1 1 Decal, Tank Side, LH (AA)(AE)(AG) Decal, Tank Side, LH (AC) Decal, Tank Side, RH (AA)(AE)(AG) Decal, Tank Side, RH (AC) 13 7170995 7170996 1 1 Decal, Side Panel, Top, LH Decal, Side Panel, Top, RH 14 7079977 1 Decal, IRS, Rear 15 7170991 2 Decal, Red Reflector 16 7079959 7079960 1 1 Decal, “POLARIS”, Rear (AA)(AC)(AG) Decal, “POLARIS”, Rear (AE) 17 7077920 1 Decal, Passenger Warning 18 7079084 1 Decal, Tire Pressure 19 7079085 1 Decal, Discretionary Warning 20 7079083 1 Decal, Warning, General, CPSC 21 7171474 7171475 1 1 Decal, Reflector, Amber, LH Decal, Reflector, Amber, RH 12/02

2004 POLARIS SPORTSMAN 500 HO ATV Parts CATALOG

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