2005 POLARIS SPORTSMAN 500 HO / INTL Parts Manual 05 (PN 9919416 and MICROFICHE PN 9919417) - Models Covered ( SPORTSMAN 500 HO

PARTS MANUAL PN 9919416 and MICROFICHE PN 9919417 7/04 E 2004 Polaris Sales Inc. SPORTSMAN 500 HO/INT’L Model #A05MH50AB Model #A05MH50AC Model #A05MH50AG Model #A05MH50AH Model #A05MH50FB

TABLE OF CONTENTS SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTS- MAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB A A-ARM C4 ............................. AIR BOX B1 ........................... B BRAKE LINES, FRONT B6 ................. BUMPER MOUNTING A7-8 ................. C CALIPER, REAR B7 ..................... CARBURETOR D7-8 ....................... CLUTCH COVER C9 ..................... CONTROLS B4 ......................... CONTROLS - THROTTLE ASM./CABLE B9 .... COOLING SYSTEM A11 ................... CRANKCASE D4 ........................ CRANKSHAFT and PISTON D6 ............. CYLINDER D5 .......................... D DECALS A10 ........................... DRIVE CLUTCH C7 ...................... DRIVE SHAFT, FRONT B10 ................. DRIVE SHAFT, REAR B11 ................. DRIVEN CLUTCH C8 ..................... E ELECTRICAL/TAILLIGHT C13 ............... ENGINE MOUNTING A13-14 .................. EXHAUST SYSTEM A12 ................... F FOOT PEDAL B8 ........................ FRONT BRAKE B5 ...................... FRONT CAB A5 ........................ FRONT HOUSING D3 .................... FUEL PUMP D11 ......................... FUEL TANK B2 ......................... G GEAR SELECTOR C6 .................... GEARCASE D1-2 ......................... H HANDLEBAR C1-2 ........................ H HEADLIGHT POD C1-2 ..................... HEADLIGHTS C3 ....................... I INTAKE and EXHAUST D9 ................. M MAGNETO E2 .......................... MASTER CYLINDER, REAR B8 ............ O OIL FILTER D13 ......................... OIL PUMP D12 .......................... OIL TANK B3 ........................... P PROP SHAFT B12 ....................... R RACK MOUNTING FRONT A8 ............. REAR CAB and SEAT A3-4 ................. REAR RACK MOUNTING A6 ............... REAR SUSPENSION C11-12 .................. REAR WHEEL DRIVE C10 .................. RECOIL STARTER D14 .................... S STARTING MOTOR E1 ................... STEERING POST C5 ..................... STORAGE BOX, REAR A9 ................ STORAGE, FRONT A7 ................... STRUT MOUNTING C4 ................... STRUT, FRONT B13 ...................... T TAILLAMPS C3 ......................... TOOL KIT E3 ........................... TRANSMISSION MOUNTING C14 ............ W WATER PUMP D10 ....................... WHEEL, FRONT B14 ...................... WORKLAMPS C3 ....................... 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 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB 5 6 7 8 21 20 23 22 24 25 14 18 17 3 16 15 19 11 13 E 2004 Polaris Sales Inc. 9 4 1 2 12 26 13 12 12 Rear Cab Foil View From Bottom 10

A4 REAR CAB and SEAT SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512095 2 Screw 2 7555798 2 Washer 3 7512026 3 Screw 4 7556034 3 Washer 5 7511930 2 Bolt 6 5246076 1 Retainer, Seat Latch 7 7555792 4 Washer 8 7541925 2 Nut, Nylok 9 5435363-400 5435363-293 5435664-455 5435363-341 1 1 1 1 Cab, Rear, Camo Green Metallic (AH) Cab, Rear, Indy Red (AB)(FB) Cab, Rear, New Break Up (AC) Cab, Rear, Sonic Blue (AG) 10 7558403 2 Washer (AC) 11 7170911 1 Decal, Hitch 12 7661855 14 Rivet 13 5435354-070 5435355-070 1 1 Footwell, Black, LH Footwell, Black, RH 14 7517230 8 Screw 15 7542122 8 Nut, Nylok 16 5812703 2 Foil, Rear Cab, Front, Top 17 5812702 1 Foil, Rear, Cab, Front, Bottom 18 5812701 1 Foil, Cab, Rear 19 1014536-067 1 Frame, Main, Black 20 7621403 2 Rivet 21 5211033 2 Bracket, Lever Retainer 22 7041370 1 Spring, Latch 23 1040387 1 Latch, Seat 24 2683433-070 2683434-070 2683661-070 1 1 1 Asm., Seat, Black Covering, Seat, Black Asm., Seat, Black (AC) 25 7079902 1 Decal, Carb/Filter Information 26 5412623 2 Grommet 7/04

A5 FRONT CAB SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB 1 12 2 10 5 6 14 3 4 13 7 9 11 8 E 2004 Polaris Sales Inc. 8 13 5 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5435352-400 5435352-293 5435352-341 5435668-455 1 1 1 1 Cover, Front, Camo Green Met (AH) Cover, Front, Indy Red (AB)(FB) Cover, Front, Sonic Blue (AG) Cover, Front, New Break Up (AC) 2 2632864-400 2632864-293 2632864-341 2632975-455 1 1 1 1 Cab, Front, Camo Green Met (AH) Cab, Front, Indy Red (AB)(FB) Cab, Front, Sonic Blue (AG) Cab, Front, New Break Up (AC) 3 7670057 2 Nut, U-Type Speed 4 7517219 2 Screw 5 5435353-177 2632936-177 5435353-070 2632936-070 5435915-455 2633048-455 1 1 1 1 1 1 Panel, Side, LH, Black (AG)(AH) Asm., Panel/Foil, RH, Black (AG)(AH) Panel, Side, LH, Black (AB)(FB) Asm., Panel/Foil, RH, Black (AB)(FB) Panel, Side, LH, New Break Up (AC) Asm., Panel/Foil, RH, NBU (AC) 6 5812615 1 Foil, Side Panel, RH 7 7080756 1 Clip 8 7517386 4 Screw 9 5248100 1 Guard, Splash, RH 10 7546601 2 Nut, Nylok 11 5246872 1 Guard, Splash, LH/Pump Mount 12 7661855 2 Rivet 13 7512026 8 Screw 14 7556034 4 Washer 7/04

A6 REAR RACK MOUNTING SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB 7 15 16 17 14 4 9 2 E 2004 Polaris Sales Inc. 3 12 8 13 11 18 10 19 12 15 1 5 6 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517230 4 Screw 2 7517983 2 Screw 3 5248469-418 1 Channel, Rear Rack, Black 4 7518418 2 Screw 5 1014768-418 1 Extender, Rear Rack (AC) 6 7517208 6 Screw (AC) 7 2632867-070 1 Asm., Rack, Rear, Black (Incl. Warning Decal and Reflectors) 8 7518213 2 Screw 9 5435959 2 Spacer 10 7555843 2 Washer, Flat 11 7542324 2 Nut, Nylok 12 5248471-418 2 Channel, Rear Rack, Front, Black 13 5334092 2 Spacer 14 1014668-067 1 Support, Rear Rack, Black 15 7518341 4 Bolt, Flange 16 ------- 1 Bracket, Silencer, Frame (See Ex- haust System Pg. A12, Ref. 6) 17 7542343 4 Nut, Flange 18 7542153 4 Nut, Nylok, Flange 19 7518424 2 Screw 8/04

A7 FRONT STORAGE and BUMPER MOUNTING SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB 22 2 23 28 13 12 21 6 16 15 1 14 19 13 1 5 17 3 20 33 4 E 2004 Polaris Sales Inc. 27 24 11 25 29 10 30 9 34 26 7 31 32 2 3 11 35 8 18

A8 FRONT RACK and BUMPER MOUNTING SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7515399 6 Screw 2 1014591-067 1014592-067 1 1 Support, Front Rack, LH Support, Front Rack, RH 3 7518341 2 Screw, Flange 4 5810467 1 Plug, Frame 5 7542343 8 Nut, Nylok, Flange 6 1014636-067 1 Guard, Brush 7 5435629 1 Cover, Radiator 8 5812778 1 Seal, Radiator Cover 9 7081241 7081242 1 1 Latch, LH Latch, RH 10 7512076 4 Screw 11 5334257 2 Latch, Wire 12 7661855 6 Rivet 13 5434314 5434315 1 1 Shield, Side, Radiator, LH Shield, Side, Radiator, RH 14 5412504 4 Grommet 15 5435046 1 Cover, Radiator 16 5247507-067 1 Grill, Brush Guard 17 7518046 4 Screw 18 5435701 5435702 1 1 Cover, Bumper, LH Cover, Bumper, RH 19 5435357-070 1 Panel 20 7518383 2 Screw 21 7518382 4 Screw 22 7556341 4 Washer, Flat 23 2632865-070 1 Asm., Bumper, Front, Black (Incl. Warning Decal) 24 1202838 1 Asm., Box, Lower, Front 25 5412352 3 Plug 26 5435628 2 Cover, Strut 27 7555960 4 Washer, Flat 28 7517208 4 Screw, Flange 29 5521693 1 Seal 30 5435362-070 1 Cover, Box, Front 31 5247653-418 2 Channel, Lid, Front 32 7542122 8 Nut, Nylok 33 7518427 8 Screw 34 5134576 2 Pin 35 5521706 1 Seal, Lid/Bumper 7/04

A9 REAR STORAGE BOX SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB E 2004 Polaris Sales Inc. 3 1 6 4 5 7 2 8 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5435605 1 Box, Upper 2 7081205 1 Latch 3 5435368 1 Cover 4 5521694 1 Seal 5 5810455 2 Pad 6 5435630 1 Box, Lower 7 5412352 1 Plug 8 7661855 2 Rivet 7/04

A10 DECALS SPORTSMAN 500 HO A05MH50AB and SPORTSMAN 500 HO A05MH50AC and SPORTSMAN 500 HO A05MH50AG and SPORTSMAN 500 HO A05MH50AH and SPORTSMAN 500 INT’L A05MH50FB RH LH 10 17 16 15 8 11 18 13 7 5 6 9 3 1 9 E 2004 Polaris Sales Inc. 12 14 4 2 3 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7172689 2 Decal, Reflector, Red 2 7173013 1 Urocal, 50th Anniversary 3 7172572 2 Decal, Warning, Front and Rear Rack 4 7172707 7172708 7172893 7172894 1 1 1 1 Decal, Rear Cab, “AWD”, LH Decal, Rear Cab, “AWD”, RH Decal, Rear Cab, “AWD”, LH (AC) Decal, Rear Cab, “AWD”, RH (AC) 5 7172559 1 Decal, Age Warning, 16, ATV 6 7172704 7172710 7172896 7172897 1 1 1 1 Decal, “SPORTSMAN”, LH Decal, “SPORTSMAN”, RH Decal, “SPORTSMAN 500”, LH (AC) Decal, “SPORTSMAN 500”, RH (AC) 7 7079780 1 Decal, Warning, AWD Switch, White 8 7171067 1 Decal, Front Cover, “New Break Up” (AC) 9 7172687 7172688 1 1 Decal, Reflector, Amber, LH Decal, Reflector, Amber, RH 10 7172562 1 Decal, Drain Recoil 11 7078465 1 Logo, Polaris Star 12 7079672 1 Decal, Foot Brake 13 7172564 1 Decal, Warning, Override, AWD 14 7172711 7172712 1 1 Decal, Tankside, “500”, LH (Not on AC) Decal, Tankside, “500”, RH (Not on AC) 15 7172560 1 Decal, Warning, General, CPSC 16 7172561 1 Decal, Discretional Warning 17 7172566 1 Decal, Passenger Warning 18 7172748 1 Decal, Tire Pressure/Load 7/04

2005 POLARIS SPORTSMAN 500 HO / INTL Parts Manual 05 (PN 9919416 and MICROFICHE PN 9919417) - Models Covered ( SPORTSMAN 500 HO

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