2003 Polaris Ranger 500 4x4 Parts Manual

PARTS MANUAL PN 9917097 and MICROFICHE PN 9917098 1/02 RANGER 500 4X4 SERIES 10 Model #A10RD50AA Rev. 01

TABLE OF CONTENTS RANGER 500 4x4 Series 10 A10RD50AA Parts Manual A A -ARM B10 ............................ AIR BOX C8 ........................... B BATTERY B3 ........................... BODY A4 ............................. BRAKE CALIPER, FRONT B14 .............. BRAKE CALIPERS, REAR C2 .............. BRAKE LINES B13 ....................... BRAKE, FOOT B12 ...................... C CARBURETOR D5-6 ....................... CHASSIS A4 ........................... CLUTCH COVER C10 ..................... CONTROLS A6 ......................... COOLING SYSTEM A10 ................... CRANKCASE D2 ........................ CRANKSHAFT D7 ....................... CYLINDER D3-4 .......................... D DASH INSTRUMENTS A6 ................. DECALS A9 ........................... DRIVE CLUTCH C6 ...................... DRIVE SHAFT, FRONT B4 ................. DRIVEN CLUTCH C7 ..................... DUMP BOX A8 ......................... E ELECTRICAL B3 ........................ ENGINE AND CLUTCH AIR INTAKE C9 ....... ENGINE MOUNTING A13-14 .................. EXHAUST D8 .......................... EXHAUST SYSTEM B1 ................... F FLYWHEEL COVER D9 ................... FUEL SYSTEM A11 ....................... G GEAR SELECTOR/DIFFERENTIAL LOCK D1 ... GEARCASE C13-14 ......................... H HOOD A7 ............................. HOUSING MOUNTING, FRONT C12 .......... I INTAKE D8 ............................ M MAGNETO D13 .......................... MASTER CYLINDER B13 .................. MOLDINGS A5 ......................... O OIL FILTER D12 ......................... OIL PUMP D11 .......................... OIL TANK (If Built Before 1/01/02) A12 ......... OIL TANK (If Built After 1/01/02) E2 ........... P PISTON D7 ............................ PROP SHAFT, FRONT B6 ................. PROP SHAFT, REAR B5 .................. R REAR WHEEL DRIVE C3 .................. S SEAT A5 .............................. SHOCK, REAR C5 ...................... STARTING MOTOR D14 ................... STEERING B9 .......................... STRUT MOUNTING B10 ................... STRUT, FRONT B7 ...................... T THROTTLE B11 ......................... TOOL KIT E1 ........................... TRANSMISSION MOUNTING B2 ............ W WATER PUMP D10 ....................... WHEEL, FRONT B8 ..................... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3 CAB FRAME RANGER 500 4X4 SERIES 10 A10RD50AA 1 2 4 7 8 9 3 10 11 12 13 14 16 15 18 17 19 29 28 30 21 22 23 25 24 20 26 2 8 7 16 17 18 11 11 31 11 6 6 5 5 5 27 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 1013333-067 1 Frame, Cab, Right, Front 2 5243093-067 2 Tube,Coupler, Top, Rear 3 5434177 2 Headrest 4 1013717 1 Frame, Cab, Right, Rear (Incl. Warning Decals) 5 7558301 12 Washer, Flat (If built before 2/18/02) 6 7552801 12 Washer, Spring Lock (If built before 2/18/02) 7 7512247 7517230 12 12 Screw (If built before 2/18/02) Screw (If built after 2/18/02) 8 5243092-067 2 Tube, Coupler, Center, Rear 9 7661637 40 Rivet 10 1013716 1 Frame, Cab, Left, Rear (Incl. Warning Decals) 11 7542324 10 Nut, Nylok 12 7515339 2 Screw 13 7541923 7670096 8 8 Nut, Well (If built before 2/18/02) Nut, Chimney (If built after 2/18/02) 14 2682682 2683124 1 1 Seat, Back (If built before 2/18/02) Seat, Back (If built after 2/18/02 15 2632422 1 Asm., Seat Belt, Center 16 2632421 2 Asm., Seat Belt 17 7542525 4 Nut, Nylok 18 7512539 4 Screw 19 1013336-067 1 Base, Cab/Seat 20 5411042 2 Grommet 21 2682638 1 Seat, Bottom (Incl. 11,22,23,24,25,26) 22 5245676 2 Tab, Seat Mount 23 7661052 4 Rivet 24 5910096 2 Pin, Seat Latch 25 7555734 2 Washer, Flat 26 5812242 4 Foil 27 5812313 2 Pad, Cab Frame 28 7515321 4 Screw 29 1013332-067 1 Frame, Cab, Left, Front 30 5244844-067 1 Tube, Frame, Top, Front 31 7515319 2 Screw 1/02

A4 CHASSIS/BODY RANGER 500 4X4 SERIES 10 A10RD50AA 3 1 2 4 5 8 9 6 7 10 11 12 16 17 22 23 20 21 25 14 26 27 28 15 4 4 4 2 1 4 16 26 14 25 21 19 18 29 13 24 24 30 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 7515522 4 Screw 2 7542449 4 Nut 3 1013374-067 1 Support, Floor, RH 4 7515399 18 Screw 5 ------- 1 Base, Cab/Seat (See Cab Frame Pg. A3, Ref. 19) 6 7670090 20 Clip, Dart 7 5434028 2 Panel, Seat Frame 8 7542451 8 Nut, Nylok 9 5245209 4 U-Bolt 10 1013138-067 1 Frame, Main 11 5244968-067 5246110-067 1 1 Bracket, Oil Tank (If built before 8/06/01) Bracket, Oil Tank (If built after 8/06/01) 12 1013373-067 1 Support, Floor, LH 13 7547182 3 Nut, Insert 14 7542439 2 Nut, Nylok 15 7079924 2 Decal, Reflector, Amber 16 5434191 2 Cap, Bumper 17 1013485-067 1 Bumper 18 7621334 4 Rivet 19 5430733 2 Cup, Hood Latch 20 7515547 3 Screw 21 7517685 6 Screw 22 5245329-067 1 Plate, Grill, Bumper, Upper 23 5245626-067 1 Plate, Grill, Bumper, Top 24 7555801 4 Washer, Wrought 25 7517583 2 Screw 26 7515415 4 Screw 27 7542439 4 Nut, Nylok 28 1013375-067 1 Support, Cab, Front 29 7547069 9 Nutsert 30 7512399 2 Screw 1/02

A5 MOLDINGS AND SEAT RANGER 500 4X4 SERIES 10 A10RD50AA 22 9 8 6 4 10 1 12 2 13 21 15 14 18 16 17 19 20 1 1 1 10 1 1 14 15 11 10 1 1 1 5 7 3 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 7517685 61 Screw 2 5433827-070 1 Fender, Rear, RH 3 7670145 11 Nut, U-Type 4 5434004 1 Floor, Drive Shaft, Cover 5 5812222 1 Foil 6 5812243 1 Foil, Floor 7 5812296 1 Foil 8 5812242 1 Foil, Heat Shield 9 2632478 1 Cover, Dog House (Incl. 7,8) 10 7670057 8 Nut, U-Type Speed 11 7670090 6 Clip, Dart 12 5433826-070 1 Fender, Rear, LH 13 5433828-070 1 Fender, Front, LH 14 7555935 8 Washer 15 7542122 8 Nut, Nylok 16 7517386 12 Screw 17 7556065 12 Washer 18 5812176 1 Plate, Skid 19 7512084 9 Screw 20 5434026 5434027 1 1 Panel, Wheel Well, LH Panel, Wheel Well, RH 21 5433829-070 1 Fender, Front, RH 22 2632477 1 Floor, Main (Incl. Foil) 1/02

A6 DASH INSTRUMENTS AND CONTROLS RANGER 500 4X4 SERIES 10 A10RD50AA 2 11 1 12 5 3 4 8 10 13 14 6 7 9 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 4010460 1 Hourmeter 2 4010283 1 Receptacle, 12V 3 4010525 1 Switch, Headlight 4 4010601 1 Switch, AWD 5 5434192 1 Plug, Hole 6 7080937 1 Cable, Choke 7 7080922 1 Nut, Choke 8 2460978 1 Harness, Headight 9 2201795 1 Kit, Circuit Breaker, Fan 10 2460979 2461078 1 1 Harness, Dash (If built before 1/01/02) Harness, Dash w/Park (If built after 1/01/02) 11 4010390 1 Switch, Ignition 12 4010527 1 Panel, Indicator 13 5245469-067 1 Plate, Indicator 14 7512026 4 Screw 1/02

A7 HOOD RANGER 500 4X4 SERIES 10 A10RD50AA 14 6 17 18 12 1 2 9 10 19 3 4 13 20 9 10 2 16 15 5 21 8 7 11 6 6 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 5434057 2 Hinge 2 7517230 14 Screw 3 5434278-195 1 Dash 4 5434288-195 1 Cover, Steering Column 5 7512026 4 Screw 6 7517685 13 Screw 7 7670057 1 Nut, U-Type, Speed 8 8360012-04 8360060-10 1 1 Trim, Edge (If built before 6/18/01) Trim, Edge (If built after 6/18/01) 9 7555935 10 Washer 10 7542122 10 Nut, Nylok 11 5810455 1 Pad (If built before 6/18/01) 12 5434279-195 1 Hood 13 5410370 2 Strap, Hood Latch 14 5434535 1 Liner, Hood 15 4032094 4 Spring, Adjust 16 4032042 4 Screw, Adjust 17 7670090 4 Clip, Dart 18 2410275 4010681 2 2 Asm., Headlight Bulb, Headlight 19 7670134 2 Clip, Wire 20 4032003 2 Screw 21 5412148 2 Grommet 1/02

A8 DUMP BOX RANGER 500 4X4 SERIES 10 A10RD50AA 17 11 6 13 4 37 9 10 5 14 1 3 12 39 2 26 7 8 16 25 23 15 33 18 38 19 20 30 27 29 29 31 32 19 16 3 5 3 3 2 1 13 3 3 12 14 17 28 6 24 21 22 22 15 8 8 36 34 35 21 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 7515177 2 Screw 2 7555960 2 Washer, Flat 3 7517561 20 Screw 4 5244068-067 1 Cover, Tailgate 5 5433656 2 Latch 6 5132810 2 Shaft, Latch 7 7556143 2 Washer, Rubber w/Metal Back 8 7661644 6 Pin, Hitch 9 5433951 1 Tailgate 10 5433655 1 Latch, Paddle 11 5132811 1 Rod, Hinge 12 7517742 2 Screw 13 5243304 2 Bracket, Box Latch 14 7081001 2 Cable, Tailgate 15 7517938 2 Screw 16 7517790 4 Screw 17 2410179 2410322 4010340 2 2 2 Asm., Taillight w/Brake Light (If built before 1/07/02) Asm., Taillight w/Brake Light (If built after 1/07/02) Bulb 18 5411009 2 Plug 19 7079925 2 Decal, Reflector, Red 20 1013511-067 2 Pin, Hinge 21 7517386 2 Screw (Qty. 10 if built after 2/25/02) 22 7661037 4 Pin, Clevis 23 7041996 2 Shock, Dump Box 24 7670116 6 Clip, Routing 25 1013419-067 1 Base, Box 26 7547089 12 Nut, Flange Lock 27 7041687 2 Spring, Exhaust 28 7515319 4 Screw 29 5434226 8 Bushing 30 1013571-067 1 Latch, Box 31 7555770 4 Washer 32 7542324 4 Nut, Nylok 33 5410414 4 Bumper, Rubber 34 7555788 4 Washer, Thrust 35 5246389 1 Shield, Exhaust (If built after 2/25/02) 36 5812242 2 Foil (If built before 2/25/02) 37 5434578-070 1 Box 38 7556157 12 Washer 39 7517959 12 Screw 1/02

A9 DECALS RANGER 500 4X4 SERIES 10 A10RD50AA 2 7 6 3 4 9 5 1 8 12 10 11 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 7079425 2 Decal, Warning, Cab Frame/Seat Belt 2 7079902 1 Decal, 4 Stroke, Carb/Filter Info 3 7079399 2 Decal, Box Side, “4X4” 4 7079424 1 Decal, Tire Pressure/Load 5 7079428 1 Decal, Tailgate, “POLARIS” 6 7170014 1 Decal, Hitch 7 7077469 1 Decal, Dash Panel, “POLARIS” 8 7079735 1 Decal, Lock/Unlock Diff 9 7079426 1 Decal, Warning, Discretionary 10 7170532 1 Decal, “APPLY BRAKE” (If built after 1/01/02) 11 7170544 1 Decal, Caution, “SHIFT AT IDLE” (If built after 1/01/02) 12 7079402 1 Decal, Hood, “POLARIS” 1/02

A10 COOLING SYSTEM RANGER 500 4X4 SERIES 10 A10RD50AA 27 28 29 30 31 32 33 34 1 2 6 7 8 4 5 13 26 16 14 19 18 15 20 21 22 17 25 23 24 1 8 7 7 7 14 7 7 15 3 3 27 12 9 10 11 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 7080614 2 Clamp, Hose 2 5411980 1 Hose, Engine Inlet 3 5521242 2 Tubing, Convoluted 4 7080898 1 Clamp 5 7517386 1 Screw 6 5411978 1 Hose, Engine Outlet 7 7080826 6 Clamp 8 7052092 2 Connector, Barbed 9 7080138 1 Cable Tie 10 7080965 3 Mount, Cable Tie 11 7670102 1 Clip 12 4020149 1 Clip, Rosebud 13 5411977 1 Hose, Radiator, Inlet 14 7547174 4 Nut 15 7556196 4 Washer, Flat 16 7517904 4 Screw 17 2410227 1 Asm., Fan 18 7512163 2 Screw 19 5411975 2 Asm., Grommet 20 7542153 2 Nut, Flanged 21 1240093 1 Cap, Pressure 22 1240096 1 Radiator 23 5410584 2 Bushing 24 7052296 1 Valve, Plastic Radiator/Cooler Drain 25 4010161 1 Sensor, Thermal 26 5411979 1 Hose, Radiator, Outlet 27 7080761 7 Cable Tie 28 8450003-55 AR Line, Fuel 29 7052065 1 Fitting 30 7512084 2 Screw 31 5431673 1 Tank, Surge 32 5433774 1 Plug 33 5810279 1 Gasket 34 5430743 1 Cap 1/02

2003 Polaris Ranger 500 4x4 Parts Manual

You're Reading a Preview

Recently Viewed