1999 Polaris Sportsman 500 Remmington Parts Manual

PARTS MANUAL PN 9915245 and MICROFICHE PN 9915651 1/99 SPORTSMAN 500 REMINGT ON SPECIAL EDITION Model #A99CH50AC Rev. 01 1999

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TABLE OF CONTENTS SPORTSMAN 500 REMINGTON SPECIAL A99CH50AC Parts Manual A A–ARM/STRUT MOUNTING C3 . . . . . . . . . AIR BOX B3 . . . . . . . . . . . . . . . . . . . . . . . . . . . C CARBURETOR D1 1-12 . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER C6 . . . . . . . . . . . . . . . . . . . CONTROLS – MASTER CYLINDER/ BRAKE LINE B1 1 . . . . . . . . . . . . . . . . . . . CONTROLS – THROTTLE ASM./ CABLE B10 . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM A12 . . . . . . . . . . . . . . . . . CRANKCASE D6 . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT and PISTON D9 . . . . . . . . . CV JOINT – BTB B4 . . . . . . . . . . . . . . . . . . . CYLINDER D7-8 . . . . . . . . . . . . . . . . . . . . . . . . . D DECALS A1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH C4 . . . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH C5 . . . . . . . . . . . . . . . . . . . E ELECTRICAL/TAILLIGHT C7 . . . . . . . . . . . ENGINE MOUNTING A13-14 . . . . . . . . . . . . . . . . EXHAUST SYSTEM B1 . . . . . . . . . . . . . . . . . F FRAME MOUNTING C2 . . . . . . . . . . . . . . . . FRONT BRAKE B9 . . . . . . . . . . . . . . . . . . . . FRONT CAB A7 . . . . . . . . . . . . . . . . . . . . . . . FRONT HOUSING C13-14 . . . . . . . . . . . . . . . . . . FRONT RACK and BUMPER MOUNTING A9-10 . . . . . . . . . . . FRONT STRUT B7 . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL B8 . . . . . . . . . . . . . . . . . . . . FUEL PUMP E4 . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK B2 . . . . . . . . . . . . . . . . . . . . . . . . G GEAR SELECTOR D1 . . . . . . . . . . . . . . . . . . GEARCASE (CASES AND SNORKEL) D2 . . . . . . . . GEARCASE (INTERNAL COMPONENTS) D3-4 . . . . . H HANDLEBAR and HEADLIGHT POD B13-14 . . . . . . . . . . . . . . . I INTAKE and EXHAUST D5 . . . . . . . . . . . . . M MAGNETO E2 . . . . . . . . . . . . . . . . . . . . . . . . . O OIL FILTER E1 . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP D14 . . . . . . . . . . . . . . . . . . . . . . . . . OIL TANK C1 . . . . . . . . . . . . . . . . . . . . . . . . . . P PART NUMBER INDEX E6-12 . . . . . . . . . . . . . . PROP SHAFT B6 . . . . . . . . . . . . . . . . . . . . . . R REAR BRAKE/FOOT PEDAL C1 1-2 . . . . . . . . REAR CAB and SEA T A5-6 . . . . . . . . . . . . . . REAR DRIVE SHAFT B5 . . . . . . . . . . . . . . . REAR RACK MOUNTING A8 . . . . . . . . . . . . REAR SUSPENSION C9-10 . . . . . . . . . . . . . . . . REAR WHEEL DRIVE C8 . . . . . . . . . . . . . . . RECOIL ST ARTER D10 . . . . . . . . . . . . . . . . . . S STARTING MOTOR E3 . . . . . . . . . . . . . . . . . STEERING POST B12 . . . . . . . . . . . . . . . . . . . T TOOL KIT E5 . . . . . . . . . . . . . . . . . . . . . . . . . . W WATER 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 .

1999 SPORTSMAN 500 REMINGTON SPECIAL SPECIFICA TIONS BRAKES Type/Brakes Type/Brakes - Auxiliary Park Brake Hydraulic Disc Hydraulic Hydraulic Lock, All Wheel CAPACITIES Coolant Capacity (quarts) Fuel T ank (gallons) Gearcase Oil (ounces) Engine Counter Balance 10W30 Oil (quarts) Injector Oil (quarts) Engine OW40 Rack, Front (pounds) Rack, Rear (pounds) T ongue Weight T ow Hitch T ow Weight 2.25 5.25 32 N/A N/A 2 90 180 30 Standard 1225 DRIVE TRAIN Type 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 DIMENSIONAL FEATURES Approx. Turning Radius Box, T ool 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 85 34 730 50.50 46 ENGINE Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (cc’s) 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) 155 40 Q-0 N/A 2 5/8 Turn 4HB41-3 CDI 30 @ 3500 .028 NGK BKR5E USFS Appr . GEARCASE 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 PRD Side Lever 6.69/1 5.17/1 3.34/1 2:1 3-16:1 N/A N/A Shaft GRAPHICS Body Style Bumper Caps/Polyprop. Cargo Box or Bed Fender , Front Fender , Rear Footwell Frame/Steel Front Cover Handlebar Cover w/Decal Headlight/Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Gen IV N/A N/A Mossy Oak, “Break Up” Mossy Oak, “Break Up” Black Semi Flat Black Mossy Oak, “Break Up” Mossy Oak, “Break Up” Mossy Oak, “Break Up” Black Black Black Black Mossy Oak, “Break Up” Black Black ELECTRICAL Headlight - Handlebar (watts) Headlight - Front Hood (watts) Headlight - Grill (watts) T aillights (watts) Brake Light (watts) Indicator Bulb 1 Single Beam, 60W N/A 2 Single Beam, 27W 8.26W 26.9W 1.0W SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Adjustment MacPherson Strut 6.25 Independent 9.5 2 - 1 3/8″ Bore Gas Bag CAM TIRES & WHEELS 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 i n design and specifications and/or to make additions or i mprovements to i ts products without notice.

1999 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER’S MANUAL OWNER’S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Sportsman 500 Remington Special A99CH50AC 9914905 9915195 9915245 9915651 9914913

A5 REAR CAB and SEAT SPORTSMAN 500 REMINGTON SPECIAL EDITION A99CH50AC 2 8 3 7 5 10 11 15 14 16 17 18 43 42 13 20 22 23 38 6 45 46 47 1 44 40 12 24 25 4 41 19 3 31 34 32 33 31 9 28 27 26 35 37 29 30 39 21 7 36

A6 REAR CAB and SEAT SPORTSMAN 500 REMINGTON SPECIAL EDITION A99CH50AC Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7661645 10 Rivet, T-Lock 2 7511930 2 Bolt 3 7555792 4 Washer 4 5811107 1 Foil, Rear Cab, Rear 5 5411042 1 Grommet 6 5433282-283 1 Cab, Rear 7 7541925 4 Nut, Nylok 8 5224592 1 Retainer , Latch, Seat 9 5811308 1 Foil, T ape, Rear Cab 10 7512242 4 Screw 11 7555859 4 Washer , Flat 12 7512085 2 Screw 13 5431786 1 Box, Tool 14 7621403 2 Rivet 15 5211033 2 Bracket, Retainer , Lever 16 1040387 1 Latch, Seat 17 7041370 1 Spring, Latch 18 2682441-070 2681747-070 5811104 5811105 1 1 1 1 Seat Covering, Seat Foil, Seat Base, Large Foil, Seat Base, Small 19 5410414 8 Bumper , Rubber 20 7512130 2 Screw 21 7555748 2 Washer 22 5431787 1 Cover, Box, Tool 23 5410896 1 Cap, Drain 24 7661638 6 Rivet 25 5242953-067 1 Guard, Clutch 26 ––––––– 1 Front Housing (See Front Housing Pg. C13 for Details) 27 7552603 4 Washer 28 7512492 4 Bolt 29 7080653 1 Clamp, Hose 30 7512024 1 Screw 31 7542122 28 Nut, Nylok 32 5432280 2 Spacer , Footwell 33 7517377 4 Screw 34 1012796-067 1 Frame, Main 35 5410770 2 Grommet 36 7542153 2 Nut 37 7078261 1 Decal - Hitch 38 7517376 8 Screw 39 5432221-070 5433118-070 1 1 Footwell, Black, LH Footwell, Black, RH 40 5811111 1 Foil, Foam, Rear Fender 41 5811106 2 Foil, Rear Cab, Front 42 7073761 1 Decal - Carb Information 43 7077446 1 Decal - Filter Element 44 5811087 1 Foil, Foam 45 7512232 12 Screw 46 7670057 12 Nut, U-Type Speed 47 5431796 5431797 1 1 Guard, Mud, Rear , LH Guard, Mud, Rear , RH 8/98

A7 FRONT CAB SPORTSMAN 500 REMINGTON SPECIAL EDITION A99CH50AC 17 5 6 7 8 9 10 11 3 2 21 20 4 18 19 13 12 14 15 16 8 1 4 4 4 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5811491 1 Foil, Side Panel, Gen. IV , RH 2 5810996 1 Foil, Foam, Side Panel 3 5433285-283 2632065-283 1 1 Panel, Side, LH Panel, Side, RH w/Foil 4 7512232 12 Screw 5 5433290-283 1 Cover , Front 6 7670085 2 Clip, Spring 7 2632064-283 1 Cab, Front, M.O. Camo 8 7670057 10 Nut, Speed, U-Type 9 7670009 2 Nut, Push-on 10 7661645 4 Rivet, T-Lock 11 5431798 5431799 1 1 Guard, Mud, Front, LH Guard, Mud, Front, RH 12 7541925 2 Nut, Nylok 13 7555792 2 Washer 14 7512085 2 Screw 15 7080693 1 Clamp, Hose 16 8450073-600 AR Line, Breather 17 7512017 1 Screw 18 7555931 2 Washer , Flat 19 7542122 2 Nut 20 5811489 2 Shield, Deflector 21 7670088 4 Clip, Dart 8/98

A8 REAR RACK MOUNTING SPORTSMAN 500 REMINGTON SPECIAL EDITION A99CH50AC 5 4 2 3 15 12 13 16 18 19 17 17 12 10 1 8 14 3 6 7 9 11 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2871501 1 Kit - Rack Extender , Rear (Incl. 8) 2 7515193 2 Screw 3 7515194 4 Screw 4 2670174 1 Asm., Rear Rack (Incl. Ref. 5 and Warning Decal) 5 2670070 2 Reflector , Red 6 5433305 4 Cap, End, Bumper 7 7515321 4 Bolt 8 7517208 6 Screw 9 5243378-067 1 Bumper , Rear , RSE 10 1040490-067 1 Support, Rack, Rear 11 7542324 4 Nut 12 7542343 8 Nut, Nylok 13 7670096 2 Nut, Chimney 14 5241663-067 1 Bracket, Silencer , Frame 15 7512329 4 Bolt 16 1040524-067 1040525-067 1 1 Mount , Front, Rear Rack, LH Mount , Front, Rear Rack, RH 17 7558402 2 Washer 18 5333332-067 4 Spacer 19 7515385 4 Screw 8/98

A9 FRONT RACK and BUMPER MOUNTING SPORTSMAN 500 REMINGTON SPECIAL EDITION A99CH50AC 15 16 17 18 19 20 14 8 7 10 11 12 21 23 22 28 29 3 4 6 13 6 9 1 31 8 30 26 6 27 2 5 25 24

1999 Polaris Sportsman 500 Remmington Parts Manual

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