2002 Sportsman 6x6 a02cl50aa intl big boss 6x6 a02cl50da pm 1 Service Repair Manual

CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER10 ELECTRICAL

CHAPTER 1 GENERAL INFORMATION Model Identification . . . . . . . . . . . . . . . . . . . . . . . 1.1 Serial Number Location . . . . . . . . . . . . . . . . . . . 1.1 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . 1 .2-1 .3 Specifications- 2002 Sportsman 6x6 . . . . . . . 1.4-1.5 Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1 .6 Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.6 Standard Torque Specifications . . . . . . . . . . . . 1.7 Torque Conversion Table . . . . . . . . . . . . . . . . . . 1.8-1.9 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . 1.1 0 Unit of Measure Conversion Table . . . . . . . . . . 1.11 Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1 .13-1.14

GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 50AA ._, ..... , '-.-' '-.-' / / Year Designation/ Basic Chassis Model Option Designation Engine Designation ENGINE DESIGNATION NUMBERS 50 EH50PLE1 0 ............ Single, L/C. SOHC 4 Stroke, Electric Start VIN IDENTIFICATION World Mfg. ID Vehicle Descriptor Vehicle Identifier 1 2 7 8 9 1 11 12 13 14 1 1 17 4XA L50A*YPOOOOOO Body Style I I MJdel I Engine Year Individual Serial No. Powertrain Check Digit Plant No. ENGINE SERIAL NUMBER LOCATION *This could be either a number or a letter 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 LOCATION 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 LOCATION The transmission I. D. number is located on top of the transmission, right side of machine. A #.Front 8 @POLARIS' 1.1

GENERAL INFORMATION MACHINE DIMENSIONS 29.25 in 74.3 em 1<1-----"22 in 55.8 em 1<11------ 46 in 116.8 em 41 in 104.1 em 1-=<!11---------104.5 in . .;..., ______ _.,--1 265.4 em 13.5 in 34.3 em 49 in 27 in 124.5 e-m---1 43.5 in 110.5 em 1.2 ----------------------@ PCJLRRIS

MACHINE DIMENSIONS .. - ( 32in 81.3 em II REAR I \ y - .. - GENERAL INFORMATION 43.75 in ... 111.13 em =u,')> rO\ Ill u ----........_ 8 I ll I 1\ I l(Q) Q :;::;; !""'\ J. r- JIIJb.: ::1 ' 8.5 in 21.6 em + 34.875 in 88.5 em 45.5 in 115.5 em I - 1\ 48 i n 9em 121. 4D.5 in 1C 2.9 em J f p @) PDLRRIS"--------------------- 1.3

GENERAL INFORMATION 2002 MODEL SPECIFICATIONS MODEL: .......... SPORTSMAN 6X6 AND BIG BOSS 6X6 (INTERNATIONAL) MODEL NUMBER: . A02CL50AA, A02CL50DA ENGINE MODEL: .. EH50PLE10 CARBURETION Type ................ BST 34 Mikuni Main Jet ............ 142.5 Pilot Jet ............. 40 Jet Needle ........... 4HB41-3 Needle Jet ........... Q-4 (829) Throttle Valve ........ #1 00 Pilot Screw .......... 3 Pilot Air Jet . . . . . . . . . . 160 Valve Seat ........... 1.5 Float Height ......... 14.7mm (.58")± 1mm Fuel Octane (R+M/2) . 87 Non-Oxygenated or 89 Oxygenated CLUTCH Type .................... PVT Belt ..................... 3211077 Belt Width (Projected) ..... 1.188" (30.18mm) Side Angle (Overall) . . . . . . 26' Outside Circumference .... 40.86 ±.12" Center Distance . . . . . . . . . . 10±.12" (254.5mm) Clutch Offset ............ 0.5" (12.7mm) Secondary Spring . . . . . . . . Red Driven Helix ............. 40' Spring Position (Helix) . . . . 2 Spring Position (Sheave) .. 2 ENGINE Type ....................... 4 Cycle, Single Cyl. Displacement . . . . . . . . . . . . . . . 498 cc Bore ....................... 3.625" (92mm) Stroke ..................... 2.955" (75mm) JETTING CHART Altitude Meters 0-1800 (Feet) (0-6000) Above 1800 Above (6000) CLUTCH CHART Altitude Meters I 0-1800 (Feet) (0-6000) I 1800-3700 (6000·12000) 40 helix, red dnven Valve Clearance In/Ex ....... 0.006/0.006" @ TDC on compression Compression Ratio .......... 10/2 Full Stroke Cooling .................... Liquid Lubrication Type ............ Dry Sump Operating RPM±200 . . . . . . . . . 6000 RPM Idle RPM±200 (lights off) ..... 1200 RPM Compression Pressure ....... (Std) ±15% AMBIENT TEMPERATURE Below 40"F +40'\o +80°F Below +S"C +5" to +26'C 147.5 142.5 140 135 I Shift i Drive Clutch Driven Clutch Driven Weight I Spring Sprirlg Helix I 10MH I Blue/Green Rod 2-2 I 10WH I Blue/Green I Rod I 2·2 1 4 ---------------------- '-*' PIDl.FIRIS' .

GENERAL INFORMATION 2002 MODEL SPECIFICATIONS MODEL: ............ SPORTSMAN 6X6 AND BIG BOSS 6X6 (INTERNATIONAL) MODEL NUMBER: ... A02CL50AA, A02CL50DA ENGINE MODEL: .... EH50PLE10 ELECTRICAL Flywheel I. D. . ..... FF97 COl Marking ....... CU2570 Alternator Output . . . 250 Watts Ignition Timing ..... 30° BTDC@5000RPM±2° Spark Plug I Gap ... NGK BKR5E I 0.036" (0.9mm) Lights: Head ...... Halogen 60/60 watts Tail ........ 8.26 watts Brake . . . . . . 26.9 watts Voltage Regulator . . LR39 Electric Start . . . . . . . Standard SUSPENSION I CHASSIS Body Style . . . . . . . . Gen IV Front Suspension .. MacPherson Strut Tow Capacity ...... 1225 lbs. (556.2kg) Turning Radius ..... 98" (248.9cm) Toe Out ........... 1/8"-1/4" (3-6.35mm) Ground Clearance .. 5.5" (13.97cm) Front Vertical Travel 6.7" (17.02cm) Rear Suspension . . . Swing Arm w/Scissor Stabilizer Rear Travel ........ 7.5" (19.06cm) Rear Shock ........ 2" Twin Tube Shock Adjustment . . N I A Center Suspension . Progressive Rate Swing Arm Center Travel ...... 6.5" (16.5cm) Center Shock ...... 2" Twin Tube Shock Adjustment . . Cam TIRES Tire Size- Front .... 25 x 8- 12 Tire Size- Rear .... 25 x 11 - 10 TireSize-Center .. 25x11-10 Tire Pressure - F/R . 5/5/5 lbs. Total Width ........ 46" (116.84cm) Total Length ....... 105" (266.7cm) Total Height ........ 48" (121.92cm) Wheel Base ....... 77" (195.6cm) Weight- Dry ....... 895 lbs. (406.4kg) OPTIONAL SUSPENSION SPRINGS SPRING TYPE SOFT Rear Compression Spring N/A Mid Compression Spring N/A Front Strut Spring 7041375-067 Option 64/113 lb/in. PDLFIRIS' FLUID Capacity Type Fuel Tank .......... 4.25 gals. (16L) Injector Oil .......... N I A Coolant ............ 2.25 qts. (2.1 L) PP6* Transmission ....... 32 oz (946ml) PPS* Gearcase Oil (Front) . 4 oz. (118ml) . 80-90 GL5 Gearcase Oil (Center) N I A Gearcase Oil (Rear) . N I A Engine Oil .......... 2 qts. (1.9L) . . PP4* Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3 Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3 Front Hubs (AWD) ... 2.5 oz. (75ml) POD* Shift Selector Box ... 1 oz. (30m I\ .. PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris OW /40 Synthetic Engine Lubricant *POD Premium Demand Drive Hub Fluid DRIVETRAIN Chain Type ......... 520 0-Ring Gear Reduction-Low . 6.691 Gear Reduction-Rev . 5.17/1 Gear Reduction-High 3.34/1 Front Drive Ratio .... 2/1 Center Drive Ratio . . . N I A Final Drive Ratio .... 12/38 SOP Axle to Axle ......... 30/30 116P Brake (Hand) ....... Single Lever, Hyd. Disc Brake (Auxiliary Foot) Hydraulic LOAD CAPACITY Front Rack ........ 90 lbs. Rear Rack . . . . . . . . . 800 lbs. Tongue Weight ..... 35 lbs. Tow Hitch ......... Std STANDARD FIRM 7041880-067 N/A Standard 21 0/250 lb/in. 7041878-067 N/A Standard 100/160 lb/in. 7041450-067 7041696-067 Standard 1 01 lb/in. Option 140/190 lb/in. 1 5 .

GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. Owner's Manual Parts PN Manual PN 2002 Sportsman 500 6x6 A02CL50AA 9916797 9916798 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DITZLER DESCRIPTION NUMBER 2002 Sportsman 500 6x6 Black 9440 Springs 2002 Sportsman 500 6x6 Aluminum N/A Rims FRAME COLOR- (All) P067 Medium Gloss Black 9440 I 8520147. Order direct from Midwest Industrial Coatings (952-942-1840). Mix as directed. 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. P-067 N/A Parts Micro Fiche PN 9916799 POLARIS NUMBER Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 l ' <Key Series Number 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 1.6 --------------------@POLARIS'

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2002 Sportsman 6x6 a02cl50aa intl big boss 6x6 a02cl50da pm 1 Service Repair Manual

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