POLARIS SPORTSMAN 500 Service Manual 2001

CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM/CARBURETION CHAPTER 5 BODY / SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL

1 CHAPTER 1 GENERAL INFORMA TION Model Identification 1.1 ........................... Serial Number Location 1.1 ....................... Replacement Keys 1.2 ............................ Model Color Identification 1.3-1.7 ...................... Machine Dimensions 1.8-1.10 .......................... Specifications - Sportsman 400 1.11-1.12 ................. Specifications - Sportsman 500 DUSE 1.13-1.14 .......... Specifications - Sportsman 500 H.O. 1.15-1.16 ............ Publication Numbers 1.17 .......................... Paint Codes 1.17 ................................. Standard Torque Specifications 1.18 ................ Torque Conversion Table 1.19-1.20 ...................... Decimal Equivalent Chart 1.21 ...................... Conversion Table 1.22 ............................. Tap Drill Charts 1.23 ............................... Glossary of Terms 1.24-1.25 ............................

GENERAL INFORMATION 1.1 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation A 01 CH 50 AA Emissions & Model Option ENGINE DESIGNATION NUMBERS 42 EH42PLE05 Single, L/C, SOHC 4 Stroke, Electric Start ............ 50 EH50PLE09/13 Single, L/C, SOHC 4 Stroke, Electric Start .......... VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A C H 5 0 A * 1 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter ENGINE SERIAL NUMBER LOCA TION Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow. MACHINE MODEL NUMBER AND SERIAL NUMBER LOCA TION The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B) TRANSMISSION I.D. NUMBER LOCA TION The transmission I.D. number is located on top of the transmission snorkel, right side of machine. A B Front

GENERAL INFORMATION 1.2 REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Series # Part Number 31 4110141 32 4110148 67 4010278 68 4010278 27 4010321 28 4010321 31XX Key Series Number

SPORTSMAN 400 - A01CH42AB SPORTSMAN 400 - A01CH42AA GENERAL INFORMATION 1.3 MODEL COLOR IDENTIFICA TION

SPORTSMAN 400 - A01CH42AC GENERAL INFORMATION 1.4 MODEL COLOR IDENTIFICA TION

SPORTSMAN 500 H.O. - A01CH50AB SPORTSMAN 500 H.O. - A01CH50AA GENERAL INFORMATION 1.5 MODEL COLOR IDENTIFICA TION

SPORTSMAN 500 DUSE - A01CH50AD SPORTSMAN 500 H.O. - A01CH50AE GENERAL INFORMATION 1.6 MODEL COLOR IDENTIFICA TION

SPORTSMAN 500 H.O. DUSE - A01CH50AF SPORTSMAN 500 H.O. RSE - A01CH50AJ GENERAL INFORMATION 1.7 MODEL COLOR IDENTIFICA TION

SPORTSMAN 500 SPORTSMAN 400 30 in 76.2 cm 45 in 114.3 cm 41 in 104.1 cm 22 in 55.8 cm 22 in 55.8 cm 42 in 106.6 cm 46 in 116.8 cm 32 in 81.2 cm GENERAL INFORMATION 1.8 MACHINE DIMENSIONS

POLARIS SPORTSMAN 500 Service Manual 2001

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