Polaris Sportsman 500 2002 Factory Service & Work Shop Manual

PARTS MANUAL PN 9916743 and MICROFICHE PN 9918266 5/02 E 2001 Polaris Sales Inc. SPORTSMAN 500 HO Model #A02CH50AA Model #A02CH50AB Model #A02CH50AE Model #A02CH50AK SPORTSMAN 500 RSE Model #A02CH50AC SPORTSMAN 500 DUSE Model #A02CH50AD WORKER 500 Model #A02CH50EB SPORTSMAN X Model #A02CH50AJ Rev. 04 DESERT SPORTSMAN 500 Model #A02CH50FA SPORTSMAN 500 HO FREEDOM Model #A02CH50AL SPORTSMAN 500 PSE HO Model #A02CH50AM SPORTSMAN 500 Model #A02CH50AN

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TABLE OF CONTENTS SPORTSMAN 500 A02CH50(AA)(AB)(AE)(AK) and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 RSE A02CH50AC and SPORTSMAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB Parts Manual A A-ARM / STRUT MOUNTING C4 ............ AIR BOX B1 ........................... C CARBURETOR D9-10 ....................... CLUTCH COVER C7 ..................... CONTROLS - MASTER CYLINDER/BRAKE LINE B8 ..... CONTROLS - THROTTLE ASM./CABLE B12 .... COOLING SYSTEM A10 ................... CRANKCASE D3 ........................ CRANKSHAFT and PISTON D4 ............. CYLINDER D5-6 .......................... D DECALS A9 ........................... DECALS (AJ) E5 ........................ DECALS (AL) E6 ........................ DECALS (AM) E7 ....................... DRIVE CLUTCH C5 ...................... DRIVEN CLUTCH C6 ..................... E ELECTRICAL / TAILLIGHT C8 .............. ENGINE MOUNTING A13-14 .................. EXHAUST SYSTEM A11 ................... F FOOT BRAKE B11 ....................... FRAME MOUNTING C3 ................... FRONT CAB A5 ........................ FRONT HOUSING C13 .................... FRONT RACK and BUMPER MOUNTING A7-8 ... FRONT STRUT B5 ...................... FRONT WHEEL B6 ...................... FUEL PUMP E2 ......................... FUEL TANK A12 ......................... G GEAR SELECTOR C12 .................... G GEARCASE (Cases and Snorkel) C14 .......... GEARCASE (Internal Components ) D1-2 ........ H HANDLEBAR and HEADLIGHT POD B13-14 ....... I INTAKE and EXHAUST D7 ................. M MAGNETO D14 .......................... MULTI MOUNT WINCH (AJ) E4 ............. O OIL FILTER D13 ......................... OIL PUMP D12 .......................... OIL TANK (If Built Before 1/02/02) C2 ......... OIL TANK (If Built After 1/02/02) E8 ........... P PROP SHAFT B3 ....................... R REAR BRAKE/FOOT PEDAL B9-10 ............ REAR CAB and SEAT A3-4 ................. REAR DRIVE SHAFT B4 .................. REAR RACK MOUNTING A6 ............... REAR SUSPENSION C9-10 .................. REAR WHEEL DRIVE C11 .................. RECOIL STARTER D8 .................... S STARTING MOTOR E1 ................... STEERING POST C1 ..................... T TOOL KIT E3 ........................... W WATER PUMP D11 ....................... 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 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS- MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB 2 7 3 6 9 10 14 13 15 16 17 36 12 19 20 21 32 38 40 41 1 37 34 11 22 23 4 35 18 3 27 30 28 29 27 8 26 25 24 31 33 6 27 39 25 26 E 2001 Polaris Sales Inc. 5

A4 REAR CAB and SEAT SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS- MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB 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 7661645 10 Rivet, T-Lock 2 7511930 2 Bolt 3 7555792 4 Washer 4 5811107 1 Foil, Rear Cab, Rear 5 5432117-359 5432117-136 5433282-283A 5433941-315A 5432117-053 5432117-341 5432117-317 5432117-177 5432117-333 5434393-375A 1 1 1 1 1 1 1 1 1 1 Cab, Rear, Olive Green Metallic (AA) Cab, Rear, Porsche Red (AB)(EB) Cab, Rear, Mossy Oak (AC) Cab, Rear, Wetlands Camo (AD) Cab, Rear, Yellow (AE) Cab, Rear, Sonic Blue (AJ)(AL) Cab, Rear, Gun Metal (AK) Cab, Rear, Black Metallic (AM) Cab, Rear, Sterling Spruce (AN) Cab, Rear, Camo (FA) 6 7541925 4 Nut, Nylok 7 5224592 1 Retainer, Seat Latch 8 5811308 1 Foil, Tape, Rear Cab 9 7512242 4 Screw 10 7555859 4 Washer, Flat 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 2682441-316 2682441-070 2683017 2683104 2681747-316 2682958-070 2683018 2683105 5811104 5811105 1 1 1 1 1 1 1 1 1 1 Asm., Seat, Delta Marsh (AD) Asm., Seat, Black (AA)(AB)(AC)(EB)(AK)(FA)(AN) Asm., Seat (AJ) Asm., Seat (AL)(AM) Covering, Seat, Delta Marsh (AD) Covering, Seat, Black (AA)(AB)(AC)(EB)(AN) Covering, Seat (AJ) Cover, Seat (AL)(AM) Foil, Seat Base, Large Foil, Seat Base, Small 18 5412067 8 Bumper, Rubber 19 7517375 2 Screw 20 5431787 1 Cover, Tool Box 21 5410896 1 Cap, Drain 22 7661638 6 Rivet 23 5246103-067 1 Guard, Clutch 24 ------- 1 Front Housing (See Front Housing Pg. C13 for Details) 25 7552603 7 Washer, Spring Lock 26 7512492 7 Screw 27 7542122 28 Nut, Nylok 28 5432280 2 Spacer, Footwell 29 7517377 4 Screw 30 1013325-067 1013729-067 1 1 Frame, Main (If built before 9/03/01) Frame, Main (If built after 9/03/01) 31 7078261 1 Decal, Hitch 32 7517376 8 Screw 33 5432221-070 5433219-070 1 1 Footwell, Black, LH Footwell, Black, RH 34 5811111 1 Foil, Foam, Rear Fender 35 5811106 2 Foil, Rear Cab, Front 36 7079902 1 Decal, Carb/Filter Information 37 5811087 1 Foil, Foam 38 7512232 12 Screw 39 7517685 2 Screw 40 7670057 12 Nut, U-Type Speed 41 5431796-070 5431797-070 1 1 Guard, Mud, Rear, LH Guard, Mud, Rear, RH 5/02

A5 FRONT CAB SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS- MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB 6 7 5 8 10 15 3 2 11 12 17 16 18 8 1 4 4 9 4 14 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 5811491 1 Foil, Side Panel, Gen. IV, RH 2 5810996 5812329 1 1 Foil, Foam, Side Panel (If built before 6/18/01) Foil, Foam, Side Panel (If built after 6/18/01) 3 2632289-359 2632289-136 2632317-283 2632288-315 2632289-053 2632289-341 2632289-317 2632289-177 2632289-333 2632481-375 2620085-359 2620085-136 2632065-283 2632272-315 2620085-053 2620085-341 2620085-317 2620085-177 2620085-333 2632480-375 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Panel/Foil, Olive Green, LH (AA) Panel/Foil, Porsche Red, LH (AB)(EB) Panel/Foil, Mossy Oak, LH (AC) Panel/Foil, Wetlands Camo, LH (AD) Panel/Foil, Yellow, LH (AE) Panel/Foil, Sonic Blue, LH (AJ)(AL) Panel/Foil, Gun Metal, LH (AK) Panel/Foil, Black Metallic, LH (AM) Panel/Foil, Sterling Spruce, LH (AN) Panel/Foil, C.E.W. Camo, LH (FA) Panel/Foil, Olive Green, RH (AA) Panel/Foil, Porsche Red, RH (AB)(EB) Panel/Foil, Mossy Oak, RH (AC) Panel/Foil, Wetlands Camo, RH (AD) Panel/Foil, Yellow, RH (AE) Panel/Foil, Sonic Blue, RH (AJ)(AL) Panel/Foil, Gun Metal, RH (AK) Panel/Foil, Black Metallic, RH (AM) Panel/Foil, Sterling Spruce, RH (AN) Panel/Foil, C.E.W. Camo, RH (FA) 4 7512232 10 Screw 5 2632299-359 2632299-136 2632306-283 2632271-315 2632299-053 2632299-341 2632299-317 2632479-375 2632299-288 2632299-177 2632299-333 1 1 1 1 1 1 1 1 1 1 1 Cab, Front, Olive Green Metallic (AA) Cab, Front, Porsche Red (AB)(EB) Cab, Front, Mossy Oak (AC) Cab, Front, Wetlands Camo (AD) Cab, Front, Yellow (AE) Cab, Front, Sonic Blue (AJ) Cab, Front, Gun Metal (AK) Cab, Front, Camo (FA) Cab, Front, Blazing Red (AL) Cab, Front, Black Metallic (AM) Cab, Front, Sterling Spruce (AN) 6 5432088-359 5432088-136 5433290-283A 5433944-315A 5432088-053 5432088-341 5432088-317 5434395-375A 5432088-288 5432088-177 5432088-333 1 1 1 1 1 1 1 1 1 1 1 Cover, Front, Olive Green Metallic (AA) Cover, Front, Porsche Red (AB)(EB) Cover, Front, Mossy Oak (AC) Cover, Front, Wetlands Camo (AD) Cover, Front, Yellow (AE) Cover, Front, Sonic Blue (AJ) Cover, Front, Gun Metal (AK) Cover, Front, C.E.W. Camo (FA) Cover, Front, Blazing Red (AL) Cover, Front, Black Metallic (AM) Cover, Front, Sterling Spruce (AN) 7 7670085 2 Clip, Spring 8 7670057 10 Nut, U-Type Speed 9 7517312 2 Screw 10 7670135 4 Nut, Speed 11 7555931 2 Washer, Flat 12 7542122 2 Nut, Nylok 13 7621509 3 Rivet, Plasti Loc 14 5244913-067 5244914-067 1 1 Guard, Splash, LH Guard, Splash, RH 15 5431798-070 5431799-070 1 1 Guard, Mud, Front, LH Guard, Mud, Front, RH 16 7541925 2 Nut, Nylok 17 7555792 2 Washer 18 7512085 2 Screw 5/02

A6 REAR RACK MOUNTING SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS- MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB 4 3 2 9 10 11 13 12 12 5 14 1 15 3 8 7 5 6 16 17 14 (After 4/19/02) 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 2871501 2871501-156 1 1 Kit, Rack Extender, Rear (Incl. 15)(AC)(AD)(FA)(AL) Kit, Rack Extender, Rear (Incl. 15)(AM) 2 7517686 2 Screw 3 7517685 4 Screw 4 2670174-070 1 Asm., Rack, Rear, w/Warning Decal 5 7542324 8 Nut, Nylok (If built before 9/03/01) 6 5243378-067 1013913-156 1 1 Bumper, Rear (AC)(AD)(FA)(AL) Bumper, Rear (AM) 7 5433305 4 Cap (AC)(AD)(FA)(AL)(AM) 8 7515321 4 Bolt (AC)(AD)(FA)(AL)(AM) 9 7670096 2 Nut, Chimney 10 1040524-067 1040525-067 1 1 Mount, Front, Rear Rack, LH (If built before 9/03/01) Mount, Front, Rear Rack, RH (If built between 9/03/01 and 2/19/02)) 11 5333332-067 4 Spacer (If built before 9/03/01) 12 7558402 8 Washer, Flat (If built before 9/03/01) 13 7515385 4 Screw (If built before 9/03/01) 14 1012894-067 1040490-067 1013724-067 1 1 1 Support, Rear Rack (AC)(AD)(FA)(AL)(AM) Support, Rear Rack (AA)(AB)(AE)(EB)(AJ)(AK)(AN) (If built before 2/19/02) Support, Rear Rack (AA)(AB)(AE)(EB)(AJ)(AK)(AN) (If built after 2/19/02) 15 7517208 6 Screw 16 5334092 2 Spacer (If built after 9/03/01) 17 7517983 2 Screw (If built after 9/03/01) 2/02

A7 FRONT RACK and BUMPER MOUNTING SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS- MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB 21 22 23 10 24 25 20 7 6 9 18 19 26 28 27 36 37 3 5 8 5 1 7 5 34 2 4 30 29 34 35 8 A02CH50AJ and A02CH50AL 32 33 31 1 3 4 5 5 5 7 7 10 10 A02CH50FA Only 2 12 13 11 14 15 16 17 23 26 After 12/12/01

A8 FRONT RACK and BUMPER MOUNTING SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS- MAN 500 DUSE A02CH50AD and SPORTSMAN X A02CH50AJ and SPORTSMAN 500 HO FREEDOM A02CH50AL and SPORTSMAN 500 PSE HO A02CH50AM and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB 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 1040526-067 2871499-156 1 1 Extender, Front Rack, Low (AC)(AD)(FA) Kit, Extender, Front Rack, Low (AM) 2 7517685 4 Screw 3 2670180-070 1 Asm., Front Rack (Incl. Warning Decal) 4 7517208 4 Screw 5 7515399 8 Screw 6 2200775 1 Kit, Front Rack Mount 7 7542324 4 Nut, Nylok 8 7555954 4 Washer 9 5432155-070 1 Bumper 10 7558402 4 Washer, Flat 11 5432387 4 Insert (FA) 12 7556175 2 Washer (FA) 13 1013461-067 1 Support, Front Rack (FA) 14 5434001-070 1 Bumper (FA) 15 7515306 4 Screw (FA) 16 5434002-067 1 Panel (FA) 17 7512093 2 Screw (FA) 18 7515391 2 Screw 19 7515390 2 Screw 20 1013744-067 1013746-067 1 1 Support, Front Rack, LH Support, Front Rack, RH 21 7512232 4 Screw 22 2431014 2431015 4030059 1 1 2 Headlight, LH Headlight, RH Bulb, Replacement, 27W 23 7512329 4 Bolt 24 5810467 1 Plug, Frame 25 5244729-067 5244730-067 1 1 Extension, Frame, LH Extension, Frame, RH 26 5244731-067 1013772-067 1 1 Guard, Brush (If built before 12/12/01) Guard, Brush (If built after 12/12/01) 27 7621330 7 Rivet (If built before 12/12/01) 28 5240591-067 1 Grill, Brush Guard (If built before 12/12/01) 29 5433305 4 Cap, End, Bumper (AC)(AD)(AL)(AM) 30 5243377-067 5243377-156 1 1 Bumper, Front (AC)(AD)(AL) Bumper, Front (AM) 31 7515547 2 Screw (AJ)(AL) 32 5211633-067 1 Plate, Back Mount (AJ)(AL) 33 5241224-067 1 Hitch, U-Bolt (AJ)(AL) 34 7512097 6 Screw 35 7556034 6 Washer 36 7670094 6 Nut, U-Type 37 5433923 5433924 1 1 Shield, Side, Radiator, LH Shield, Side, Radiator, RH 5/02

A9 DECALS SPORTSMAN 500 A02CH50AA and SPORTSMAN 500 A02CH50AB and SPORTSMAN 500 A02CH50AE and SPORTSMAN 500 A0250CHAK and SPORTSMAN 500 RSE A02CH50AC and SPORTS- MAN 500 DUSE A02CH50AD and SPORTSMAN 500 A02CH50AN and DESERT SPORTSMAN 500 A02CH50FA and WORKER 500 A02CH50EB RH LH 15 18 6 3 2 5 4 21 9 22 19 7 12 1 16 20 17 1 18 8 14 13 10 23 11 (Decal Pg. for AJ see Pg. E5) (Decal Pg. for AL see Pg. E6) (Decal Pg. for AM see Pg. E7) 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 7078443 7078452 7170593 7170594 2 2 1 1 Decal, “POLARIS” (AA)(AB)(AC)(AD)(EB)(AK)(FA) Decal, “POLARIS” (AE) Decal, “POLARIS”, Side Panel, LH (AN) Decal, “POLARIS”, Side Panel, RH (AN) 3 7078253 2 Decal, Age Warning 4 7079780 1 Decal, Warning, Switch, AWD 5 7078003 1 Decal, Headlight Adjustment 6 7079920 7079979 7079921 7079917 7079931 7079513 7079514 7170062 2 2 2 2 2 1 1 2 Decal, Tank Side (AA)(AN) Decal, Tank Side (AB) Decal, Tank Side (AC)(AD) Decal, Tank Side (AE) Decal, Tank Side (EB) Decal, Tank Side, LH (AK) Decal, Tank Side, RH (AK) Decal, Tank Side, (FA) 7 7078465 1 Logo, Polaris Star 8 7079773 7079916 1 1 Decal, “POLARIS” (AA)(AB)(AC)(AD)(EB)(AK)(FA)(AN) Decal, “POLARIS” (AE) 9 7078045 1 Decal, “Liquid Cooled”, Radiator 10 7170018 7170019 1 1 Decal, “RSE Legend”, Pod (AC) Decal, “DUSE Legend”, Pod (AD) 11 7079520 1 Decal, Ignition 12 7079604 1 Decal, Warning, Override, AWD 13 7079977 1 Decal, IRS, Rear 14 7079959 7079960 1 1 Decal, “POLARIS”, Rear (AA)(AB)(AC) (AD)(EB)(AK)(FA) Decal, “POLARIS”, Rear (AE) 15 7079927 2 Decal, Red Reflector 16 7077920 1 Decal, Passenger Warning 17 7079084 1 Decal, Tire Pressure 18 7079928 7079929 7079918 7079919 7079961 7079962 7079515 7079516 1 1 1 1 1 1 1 1 Decal, “4x4”, LH (AA)(AE)(AN) Decal, “4x4”, RH (AA)(AE)(AN) Decal, “4x4”, LH (AB)(EB) Decal, “4x4”, RH (AB)(EB) Decal, “4x4”, LH (AC)(AD)(FA) Decal, “4x4”, RH (AC)(AD)(FA) Decal, “4X4 ISD”, LH (AK) Decal, “4X4 ISD”, RH (AK) 19 7079085 1 Decal, Discretionary Warning 20 7079083 1 Decal, Warning, General, CPSC 21 7079926 2 Decal, Amber Reflector 22 7078577 1 Decal, Drain Recoil 23 7077749 1 Decal, Warning, Park Lock (EB Only) 5/02

Polaris Sportsman 500 2002 Factory Service & Work Shop Manual

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