2002 Polaris Ranger 6x6 Parts Manual

PARTS MANUAL PN 9914649 and MICROFICHE PN 9914650 4/01 RANGER Model #A99RF50AA Rev. 06

TABLE OF CONTENTS RANGER A99RF50AA Parts Manual A A- ARM/STRUT MOUNTING C1 ............. AIR BOX A14 ........................... B BRAKE LINES C4 ....................... C CAB FRAME A3 ........................ CARBURETOR D13-14 ...................... CHASSIS\BODY A4 ..................... CLUTCH COVER C10 ..................... CONSOLE A6 .......................... COOLING SYSTEM A11 ................... CRANKCASE D9 ....................... CRANKSHAFT and PISTON D10 ............. CYLINDER D11-12 .......................... D DECALS A10 ........................... DRIVE CLUTCH C8 ...................... DRIVE SHAFT, FRONT B6 ................. DRIVE SHAFT, MID AXLE (LH) B10 .......... DRIVE SHAFT, MID AXLE (RH) B9 .......... DRIVE SHAFT, TAIL B7 ................... DRIVEN CLUTCH C9 ..................... E ELECTRICAL / BATTERY B5 ............... ENGINE MOUNTING B1-2 .................. EXHAUST SYSTEM B3 ................... F FOOT BRAKE C2 ....................... FRONT BRAKE B13 ...................... FRONT HOUSING D2-4 .................... FRONT STRUT B11 ...................... FRONT WHEEL B12 ...................... FUEL TANK A12 ......................... G GEAR SELECTOR D5 .................... G GEARCASE (CASES & SNORKEL) D6 ....... GEARCASE (INTERNAL COMPONENTS) D7-8 ... H HOOD A7 ............................. I INSTRUMENT PANEL A9 ................. INTAKE and EXHAUST E1 ................ M MAGNETO E6 .......................... MID ANGLE DRIVE D1 ................... MIDDLE BRAKE / PARKING BRAKE C5 ...... MIDDLE SHOCK MOUNTING C7 ............ MIDDLE WHEEL DRIVE C6 ................ MOLDING AND SEAT A5 ................. O OIL FILTER E5 ......................... OIL PUMP E4 .......................... OIL TANK A13 .......................... P PROP SHAFT B8 ....................... PART NUMBER INDEX E9-F2 ................ R REAR BOX AND SHOCK MOUNTING A8 ..... REAR BRAKE C12 ....................... REAR GEARCASE C14 .................... REAR WHEEL DRIVE C13 ................. RECOIL STARTER E2 .................... S STARTING MOTOR E7 ................... STEERING B14 .......................... SWING ARM/REAR SHOCK C11 ............. T THROTTLE C3 ......................... TOOL KIT E8 .......................... TRANSMISSION/ENGINE MOUNTING B4 ..... W WATER PUMP E3 ....................... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for as- sembly.

A3 CAB FRAME RANGER A99RF50AA 6 11 12 13 10 20 14 3 26 27 1 5 24 8 4 21 25 9 1 1 1 23 Cab for models built after 4/20/98 Cab for models built prior to 4/20/98 7 1 1 2 3 15 15 15 16 22 1 1 15 15 17 18 19 2 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7080817 20 Cable Tie 2 5811709 6 Pad, Cab Frame, Center/Side 3 7661638 38 Rivet 4 1012804-195 1 Roof, Cab Frame, RH 5 5811706 1 Pad, Cab, Frame, Front 6 1012802-195 1 Cab Frame, Rear, RH 7 5811708 2 Pad, Cab Frame, Top, Rear 8 5243093-195 1 Tube, Coupler, Top, Rear 9 7552801 4 Washer 10 5243092-195 2 Tube, Coupler, Rear, Center 11 7558301 4 Washer 12 7512240 4 Bolt 13 1012801-195 1 Cab Frame, Rear, LH 14 5432798 2 Plug, Nylon 15 7512399 26 Bolt 16 1012805-195 1 Base, Cab Frame 17 7515369 2 Bolt 18 7512102 6 Bolt 19 7542122 6 Nut 20 7042029 1 Spring, Exhaust 21 1012803-195 1 Roof, Cab, Frame, LH 22 7542324 12 Nut 23 7515339 12 Bolt 24 2682365-132 2681664-132 2 2 Asm., Backrest, Gray Covering, Backrest, Gray 25 5243095-195 1 Tube, Cab Frame, Top, Front 26 1040620-195 1 Cab Frame, Rear (For models manufactured prior to 4/20/98) 27 1040619-195 1 Cab Frame, Front (For models manufactured prior to 4/20/98) 10/00

A4 CHASSIS\BODY RANGER A99RF50AA 16 6 17 27 12 3 14 4 29 2 18 28 15 8 19 20 9 23 13 14 3 3 3 3 3 11 21 21 14 14 10 10 10 10 22 3 14 5 7 11 21 24 24 25 26 10 10 1 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5411836 2 Mat, Floor 2 1012723-067 1012724-067 1 1 Bracket, Body, Front, Top, LH Bracket, Body, Front, Top, RH 3 7661638 108 Rivet 4 5242427-067 5243222-067 1 1 Body (If Built prior to 4/20/98) Body (If Built after 4/20/98) 5 7542122 6 Nut 6 5242378-067 5242379-067 1 1 Bracket, Fender, Rear, LH Bracket, Fender, Rear, RH 7 7558301 6 Washer 8 5242490-067 1 Plate, Mount, Shifter 9 7542338 6 Nutsert 10 7515399 49 Bolt 11 5410414 6 Bumper, Rubber 12 1040715-067 1 Brace, Upper Chassis 13 1040707-067 1 Chassis, Upper 14 7515398 21 Screw 15 1040641-067 2 Shock Tower, Mid-Axle 16 1040598-067 1 Chassis 17 1040703-067 2 Brace, Engine Compartment 18 1040738-067 1040737-067 1 1 Support, Strut, LH Support, Strut, RH 19 7621462 2 Rivet 20 5432848-070 2 End Cap, Bumper, Front 21 7542324 27 Nut 22 7515321 2 Bolt 23 2670192-067 1 Bumper 24 5243908-067 5243909-067 1 1 Footwell LH (If Built after 1/18/99) Footwell RH (If Built after 1/18/99) 25 5243906-067 1 Body, Front (If Built after 1/18/99) 26 5243907-067 1 Body, Rear (If Built after 1/18/99) 27 5242662-067 1 Brace, Wheel Well 28 5242393-067 2 Brace, Floorboard 29 1040677-067 1040678-067 1 1 Support, Fender, Front, LH Support, Fender, Front, RH 7/99

A5 MOLDING AND SEAT RANGER A99RF50AA 8 9 1 30 29 3 6 2 4 7 26 5 22 10 18 11 20 23 27 28 19 12 13 2 4 5 24 21 14 14 9 9 15 16 17 25 9 9 9 9 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2682334 2 Asm., Seat 2 7512539 4 Screw 3 7010089 2 Latch, Seat Belt 4 7553101 4 Washer 5 7542525 4 Nut 6 7080940 2 Belt, Seat, Lap 7 7555883 2 Washer 8 5432756 2 Fender, Box 9 7512084 74 Screw 10 5432757 5432758 5433253 5433254 1 1 1 1 Fender, Rear, LH (Built before Serial Number 070006) Fender, Rear, RH (Built before Serial Number 070006) Fender, Rear, LH (Built after Serial Number 070006) Fender, Rear, RH (Built after Serial Number 070006) 11 5432752 5432753 1 1 Panel, Engine Access, LH Panel, Engine Access, RH 12 7075705 2 Decal - Demand 6 Drive 13 5242514 2 Handle, Access Panel 14 5020663 8 Pin, Latch, Seat 15 7542122 8 Nut 16 7621472 8 Rivet 17 5242885-067 4 Support, Access Panel 18 5432759 5432760 1 1 Fender, Front, LH Fender, Front, RH 19 7670088 3 Clip, Dart, Plastic 20 5432725 1 Panel, Wheel Well, Rear, LH 21 5410774 8 Grommet, Mount, Rubber 22 5432724 1 Panel, Wheel Well, Front, LH 23 5432755 1 Liner, Hood 24 7512208 22 Screw 25 4020139 2 Clip, Rosebud 26 5242833 1 Plate, Exhaust, Wheel Well 27 5432751 1 Panel, Wheel Well, RH 28 7621457 5 Rivet 29 7558402 8 Washer 30 7542324 8 Nut 2/00

A6 CONSOLE RANGER A99RF50AA 1 4 5 6 8 7 2 10 18 9 11 12 13 14 15 17 17 8 16 3 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5432722-132 1 Cover, Instrument Panel, Gray 2 5432723-132 1 Console, Gray 3 7078053 1 Decal - Driving Range 4 5411249 1 Boot, Tie Rod, CRC 5 7621479 4 Rivet 6 5433095 5433862 1 1 Tray, Console (If built before 1/14/00) Tray, Console (If built after 1/14/00) 7 5410774 1 Grommet, Mount, Rubber 8 7621467 10 Rivet 9 5020663 1 Pin, Latch, Seat 10 7542122 1 Nut 11 5243123-067 1 Plate, Console Lid 12 7621485 7 Rivet 13 5432754 1 Base, Console Lid 14 5243124-067 1 Bracket, Console Lid 15 7020025 1 Hinge, Console Lid 16 7512232 4 Screw 17 7512084 14 Screw 18 5211796-067 1 Plate, Boot 2/00

A7 HOOD RANGER A99RF50AA 25 26 10 16 6 8 3 19 28 23 2 18 14 5 15 11 7 22 24 20 21 12 29 30 4 9 27 1 2 4 5 5 5 6 4 8 14 2 2 28 15 15 4 13 17 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2460644 1 Harness, Headlight 2 7517298 14 Screw 3 5432694-195 1 Hood, E.B. Green 4 7542122 14 Nut 5 7621601 4 Rivet 6 5242765-067 2 Bracket, Hood Strap 7 5430733 2 Cup, Hood Latch 8 5410370 2 Strap, Hood Latch 9 7515339 6 Bolt 10 5242627-067 5242931-067 1 1 Hinge, Hood, RH Hinge, Hood, LH 11 5131915-067 2 Spacer, Hinge 12 7547095 2 Nutsert 13 7077616 2 Decal - Headlamp Information 14 7555998 12 Washer 15 7571602 6 Washer 16 5242737-067 2 Bracket, Headlight 17 7555859 4 Washer 18 7546601 6 Nut 19 7511909 6 Bolt 20 7080414 1 Cable, Hood Retainer 21 7512232 1 Screw 22 7041202 1 Spring, Extension 23 7661638 1 Rivet 24 7080372 1 Clamp, Retainer 25 4030067 4010204 4010389 2 1 1 Headlight, Single Beam, Fog Bulb/Harness, High Beam Bulb, Cargo Lamp 26 4030068 4010204 2 1 Headlight, Single Beam, 35W Bulb, Replacement 27 7542324 6 Nut 28 5242535-067 4 Mount, Hinge 29 7515189 2 Screw 30 7621334 4 Rivet 12/00

A8 REAR BOX AND SHOCK MOUNTING RANGER A99RF50AA 19 6 5 3 18 25 20 11 24 29 26 28 13 2 16 17 10 8 27 9 21 1 4 23 15 6 14 14 13 22 12 5 7 6 6 6 21 19 3 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5242421-195 1 Panel, Side, Box, LH 2 1040643-195 1 Box, Flatbed 3 7542122 8 Nut 4 1040662-195 1 Latch, Box 5 7512282 8 Bolt 6 7517560 44 Screw 7 7512232 2 Screw 8 1040648-195 1040647-195 1 1 Cap, Front Panel, RH Cap, Front Panel, LH 9 5242422-195 1 Panel, Side, Box, RH 10 1040650-195 1040649-195 1 1 Cap, Rear Panel, RH Cap, Rear Panel, LH 11 5433173 2 Pad, Tailgate 12 7512024 2 Screw 13 7661830 4 Pin, Clevis 14 7661644 4 Pin, Hitch 15 7041725 2 Shock, Dump Box 16 1040660-067 2 Pin, Hinge, Box 17 7512208 2 Screw 18 1040642-195 1 Tailgate 19 7041302 4 Spring, Latch, Tailgate 20 5431524 2 Handle, Tailgate 21 7555859 4 Washer, Flat 22 7517242 2 Screw 23 5020662 2 Pivot Rod 24 7080496 2 Cable, Tailgate 25 5020839 2 Pivot Rod, Tapered 26 7542105 8 Nut 27 7515137 4 U-Bolt 28 7558301 8 Washer 29 7542101 8 Nut 3/01

A9 INSTRUMENT PANEL RANGER A99RF50AA 3 2 1 20 15 10 21 5 7 18 28 26 14 9 23 16 24 17 12 22 11 13 29 8 6 13 26 4 19 27 25 30 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 4010158 1 Meter, Hour 2 5410611 1 Ignition Key w/Cap NOTE: When or- dering ignition key PN 5410611 be sure to specify if for an A,B,C,D, or E switch. Letter code will be labeled on underside of switch body behind console. Key dot code found on key cap (i.e. one dot = A, two dots = B, etc.). 3 7543101 1 Nut 4 ------- 1 Decal - “Passenger” Warning (See Decal Pg. A10, Ref. 7)) 5 4040054 1 Indicator, Neutral/Reverse 6 4040035 1 Indicator, Brake Warning 7 4040053 1 Indicator, “Hot Temp” 8 ------- 1 Decal - Ignition w/Start (See Decal Pg. A10, Ref. 10) 9 5433035 2 Plug, Hole, Eaton Switch 10 4110251 1 Switch, Rocker 11 4110255 1 Switch, Hi/Fog Beam 12 3280282 3280279 1 1 Asm., Fuel Gauge Fuel Gauge 13 2410097 1 Asm., Power Plug, 12V 14 2632157 1 Panel, Instrument 15 5433068 1 Clamp 16 7512240 2 Bolt 17 7552801 2 Washer 18 7558301 2 Washer 19 ------- 1 Decal - “POLARIS”, Domed (See Decal Pg. A10, Ref. 8) 20 7547004 2 Nut 21 5432959 1 Spacer 22 2410109 1 Switch, Ignition 23 1040716-067 1 Support, Instrument Panel 24 7542143 2 Insert 25 7515196 4 Screw 26 7621432 8 Rivet 27 4020139 2 Clip, Rosebud 28 7020024 1 Hinge, Panel 29 2460645 1 Harness, Instrument Panel 30 2410130 1 Diode, 14 VDC, 3 AMP 2/00

A10 DECALS RANGER A99RF50AA 6 5 4 8 15 16 7 12 LH RH 2 13 19 1 18 9 11 3 2 3 1 10 14 17 19 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7077372 2 Decal - “POLARIS RANGER” 2 7077681 2 Decal - Rider Warning 3 7077374 2 Decal - “6x6” 4 7077376 1 Decal - Hood, RH 5 7074220 1 Decal - MacPherson Strut 6 7078353 1 Decal - Warning, Discretionary 7 7075439 1 Decal - “Passenger” Warning 8 7077765 1 Decal - “POLARIS”, Domed 9 7077469 1 Decal - “POLARIS”, Dash Panel 10 7074203 1 Decal - Ignition w/Start 11 7077646 1 Decal - Warning, Safety Belt/Off Road 12 7077447 1 Decal - “POLARIS”, Hood 13 7077375 1 Decal - Hood, LH 14 2670071 2 Reflector, Amber 15 7077683 1 Decal - Operator/Load Warning 16 7077475 1 Decal - Tire Pressure 17 2670070 2 Reflector, Red 18 7077371 1 Decal - “POLARIS” 19 7077478 2 Decal - Warning, Cab Frame 7/99

2002 Polaris Ranger 6x6 Parts Manual

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