SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB WORKER 500 Model #A99CH50EA Model #A99CH50EB Rev. 01

Transcription

1 SPORTSMAN 00 Model #ACH0AA Model #ACH0AB WORKER 00 Model #ACH0EA Model #ACH0EB Rev. 0 PARTS MANUAL PN and MICROFICHE PN /

2

3 A A ARM/STRUT MOUNTING C AIR BOX B CARBURETOR D- CLUTCH COVER C CONTROLS MASTER CYLINDER/ BRAKE LINE B CONTROLS THROTTLE ASM./ CABLE B0 COOLING SYSTEM A CRANKCASE D CRANKSHAFT and PISTON D CV JOINT BTB B CYLINDER D- DECALS A0- DRIVE CLUTCH C DRIVEN CLUTCH C C D E TABLE OF CONTENTS SPORTSMAN 00 ACH0(AA)(AB) and WORKER 00 ACH0(EA)(EB) Parts Manual ELECTRICAL/TAILLIGHT C ENGINE MOUNTING A- REAR BRAKE/FOOT PEDAL C- EXHAUST SYSTEM B REAR CAB and SEAT A- REAR DRIVE SHAFT B F REAR RACK MOUNTING A FOOT BRAKE C REAR SUSPENSION C-0 FRAME MOUNTING C REAR WHEEL DRIVE C FRONT BRAKE B RECOIL STARTER D FRONT CAB A S FRONT HOUSING C-D STARTING MOTOR E FRONT RACK and STEERING POST B BUMPER MOUNTING A FRONT STRUT B T FRONT WHEEL B TOOL KIT E FUEL PUMP E W FUEL TANK B WATER PUMP D The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. G GEAR SELECTOR D GEARCASE (CASES and SNORKEL) D GEARCASE (INTERNAL COMPONENTS)..... D- H HANDLEBAR and HEADLIGHT POD B- I INTAKE and EXHAUST D0 M MAGNETO E O OIL FILTER E OIL PUMP E OIL TANK C PART NUMBER INDEX E- PROP SHAFT B P R

4 SPORTSMAN 00 and WORKER 00 SPECIFICATIONS BRAKES GEARCASE Type/Brakes Type/Brakes - Auxiliary Park Brake CAPACITIES Coolant Capacity (quarts) Fuel Tank (gallons) Gearcase Oil (ounces) Engine Counter Balance 0W0 Oil (quarts) Injector Oil (quarts) Engine OW0 Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight Type DRIVE TRAIN DRIVE CLUTCH Center Distance (inches) Clutch Offset (inches) Clutch Weight Spring Color DRIVEN CLUTCH Helix Angle Spring Position DIMENSIONAL FEATURES Approx. Turning Radius Box, Tool Box (cubic feet) Ground Clearance (inches) Height (inches) Length (inches) Seat Height (inches) Weight (lbs. dry) Wheel Base (inches) Width (inches) ENGINE Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (cc s) Compression Ratio Cooling Alternator Output Elec. Start w/recoil Back Up Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Air Screw/Pilot Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust Hydraulic Disc Mechanical Hydraulic Lock, All Wheel.. N/A N/A 0 0 Standard Engine Braking 0 / 0MH(0g) Blue/Green Compound (EBS) N/A xx N/A EH0PLE0 Cycle, Single Cyl. Dry Sump x 0: Full Stroke Liquid 0W Standard /BST(CV type). 0 Q-0 N/A / Turn HB- CDI 00.0 NGK BKRE USFS Appr. Transmission Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type GRAPHICS Body Style Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover w/decal Headlight/Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear ELECTRICAL Headlight - Handlebar (watts) Headlight - Front Hood (watts) Headlight - Grill (watts) Taillights (watts) Brake Light (watts) Indicator Bulb SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Adjustment TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center PRD Side Lever./././ : -: N/A N/A Shaft Gen IV N/A N/A (ACH0(AA)(EA)) Olive Green (ACH0(AB)(EB)) Porsche Red (ACH0(AA)(EA)) Olive Green (ACH0(AB)(EB)) Porsche Red Black Semi Flat Black (ACH0(AA)(EA)) Black (ACH0(AB)(EB)) Porsche Red Black (ACH0(AA)(EA)) Olive Green/ Black (ACH0(AB)(EB)) Porsche Red/Black Black Black (ACH0(AA)(EA)) Black (ACH0(AB)(EB)) Aluminum Black (ACH0(AA)(EA)) Olive Green (ACH0(AB)(EB)) Porsche Red (ACH0(AA)(EA)) Black (ACH0(AB)(EB)) Blue (ACH0(AA)(EA)) Black (ACH0(AB)(EB)) Blue Single Beam, 0W N/A Single Beam, W.W.W.0W MacPherson Strut. Independent. - Bore Gas Bag CAM Goodyear xx xx0 N/A N/A Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

5 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER S MANUAL OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Sportsman 00 ACH0(AA)(AB) 0 0 Worker 00 ACH0(EA)(EB) 0 0

6 REAR CAB and SEAT SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB A

7 REAR CAB and SEAT SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 0 Rivet, T-Lock 0 Bolt Washer 0 Foil, Rear Cab, Rear 0 Grommet - - Cab, Rear, Olive Green (ACH0(AA)(EA)) Cab, Rear, Porsche Red (ACH0(AB)(EB)) Nut, Nylok Retainer, Seat Latch 0 Foil, Tape, Rear Cab 0 Screw Washer 0 Screw Box, Tool 0 Rivet 0 Bracket, Lever Retainer 00 Latch, Seat 00 Spring, Latch Seat Covering, Seat Foil, Seat Base, Large Foil, Seat Base, Small 0 Bumper, Rubber 0 0 Screw Washer Cover, Tool Box 0 Cap, Drain Rivet -0 Guard, Clutch Front Housing (See Front Housing Pg. C and Pg. D for Details) 0 Washer Bolt 00 Clamp, Hose 0 0 Screw Nut, Nylok 0 Spacer, Footwell Screw 0-0 Frame, Main 00 Grommet 0 Decal - Hitch Screw Footwell, Black, LH Footwell, Black, RH Foil, Foam, Rear Fender 0 0 Foil, Rear Cab, Front 0 Decal - Carburetor Information 0 Decal - Filter Element 0 Foil, Foam 0 Screw Screw 00 Nut, U-Type Speed Guard, Mud, Rear, LH Guard, Mud, Rear, RH / A

8 FRONT CAB SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Foil, Side Panel, Gen. IV, RH 0 Foil, Foam, Side Panel Panel, Side, Green, LH (ACH0(AA)(EA)) Panel, Side, w/foil, Green, RH (ACH0(AA)(EA)) Panel, Side, Red, LH, (ACH0(AB)(EB)) Panel, Side, Red, w/foil, RH (ACH0(AB)(EB)) 0 Screw 0-0- Cover, Front, Olive Green (ACH0(AA)(EA)) Cover, Front, Red (ACH0(AB)(EB)) 00 Clip, Spring - - Cab, Front, Olive Green w/warning- Decals (ACH0(AA)(EA)) Cab, Front, Red w/warning Decals (ACH0(AB)(EB)) A 00 0 Nut, U-Type Speed 000 Nut, Push-on 0 Rivet, T-Lock Guard, Mud, Front, LH Guard, Mud, Front, RH Nut, Nylok Washer 0 Screw 00 Clamp, Hose AR Line, Breather 0 Screw Washer Nut 0 Shield, Deflector 00 Clip, Dart Screw /

9 REAR RACK MOUNTING SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Rack Extender, Rear (Incl. ) Screw Screw 0 Asm., Rack, Rear (Incl. Ref. and Warning Decal) 000 Reflector, Red 0 Screw Support, Rear Rack -0 Bracket, Silencer, Frame Bolt 0 00 Nut, Chimney Nut, Nylok Mount, Front, Rear Rack, LH Mount, Front, Rear Rack, RH 0 Washer -0 Spacer Screw 0/ A

10 FRONT RACK and BUMPER MOUNTING SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw 00 Asm., Front Rack (Incl. Ref. and Warning Decal) 00 Reflector, Amber Screw 00 Kit - Front Rack Mount Nut, Nylok 0 Washer -00 Bumper Screw 0 0 Screw Washer Support, Front Rack, LH Support, Front Rack, RH Screw Headlight, LH Headlight, RH Bulb, Replacement, W Bolt 0 Washer 0 Plug, Frame -0-0 Extension, Frame, LH Extension, Frame, RH -0 Guard, Brush Grill, Guard, Brush 0 Rivet -0 Hitch, U-Bolt 00 Nut, U-Type 0 Screw Shield, Side, Radiator, LH Shield, Side, Radiator, RH Screw -0 Plate, Back Mount 0/ A

11 DECALS SPORTSMAN 00 ACH0AA and WORKER 00 ACH0EA 0 RH 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 0 Decal - Rack/Warning 00 Decal - Load Distribution 00 Decal - EBS DUAL SENSING 00 Decal - Side Panel, RH (ACH0AA) 0 Decal - x Ind. Shaft Drive Decal - SPORTSMAN (ACH0AA) Decal - WORKER (ACH0EA) 00 Decal - Tank Side, RH 00 Decal - POLARIS 000 Decal - Headlight Adjustment 0 0 Decal - Warning, AWD Switch 0 Decal - POLARIS Domed 0 Decal Decal - LIQUID COOLED 0 Decal - Discretionary Warning 0 Decal - Drain Recoil 0 Decal - Park Brake Lock (ACH0EA) 00 Decal - CE Regulation 0 Decal - Override Switch, AWD 00 Decal - Tank Side, LH 0 0 Decal - Age Warning, ATV 00 Decal - Passenger Warning 0 Decal - Tire Pressure 00 Decal - Side Panel, LH (ACH0AA) 0 Decal - Warning, General, CPSC / A0

12 DECALS SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EB 0 RH 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 0 Decal - Rack/Warning 00 Decal - Load Distribution 00 Decal - EBS DUAL SENSING 00 Decal - Side Panel, RH 0 Decal - x Ind. Shaft Drive Decal - SPORTSMAN (ACH0AB) Decal - WORKER (ACH0EB) 0 Decal - Age Warning 00 Decal - POLARIS 000 Decal - Headlight Adjust 0 0 Decal - Warning, AWD Switch 00 Decal - Tank Side, RH 00 Decal - LIQUID COOLED 0 Decal - Discretionary Warning 0 Decal - Drain Recoil 0 Decal - Demand Drive 0 Decal - Park Brake Lock (ACH0EB) 0 Decal Decal - POLARIS Domed 00 Decal - CE Regulation 0 0 Decal - Override Switch, AWD 00 Decal - Tank Side, LH 00 Decal - Passenger Warning 0 Decal - Tire Pressure 00 Decal - Side Panel, LH 0 Decal - Warning, General, CPSC / A

13 COOLING SYSTEM SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 00 Clamp, Hose, Worm Gear 00 Clamp, Hose, Worm Gear 0 Hose, Water 0 Hose, Lower Engine 00 Cable Tie 000 Switch, Thermal, Fan Cap, Pressure 00 Radiator, U-Flow 0 Washer 0 Bolt 00 O-Ring 0 Cover, Radiator w/mesh 0 Bushing, Mount, Lower Radiator 0 Valve, Drain Cock Shroud, Fan, ATV 00 Spacer, Mount, Radiator 00 Mount, Rubber, Radiator 0 Washer Nut, Nylok 0 00 Nut 0 Washer 00 Motor, Fan -0 Bracket, Cooling Fan Screw Screw 0 Blade, Fan 0 Cap, Overflow, Drilled 0 Gasket, Cap, Overflow Plug, Cap 0 Tank, Surge 000- Line, Fuel 00 Fitting, Barbed, 0 Degree 0 Screw 0/ A

14 ENGINE MOUNTING SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB A

15 ENGINE MOUNTING SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, Nylok 0000 Clamp, Hose, Red 0 Hose,. Long AR Line, Fuel 00- Line, Fuel, Impulse Asm., Carburetor (See Carburetor Pg. D, Ref. ) 00 Clamp, Narrow Band 0 Boot, Carburetor 00 Clamp, Narrow Band AR Line, Fuel 00 Fitting, Tee 00 Mount, Rubber 0 Washer 0 Nut Screw and Washer (See Crankcase Pg. D, Ref. ) -0 Strap, Carburetor Mount Bolt 0 Washer 0 Nut, FLEXLOC 0 00 Clamp, Spring Hose AR Hose, Breather (See Air Box Pg. B, Ref. ) Washer 00 Mount, Rubber, Front 00 Clamp, Nylon Rivet -0 Strap, Frame Support Bolt 0 Washer, Interlock 0 Washer, Clutch Retainer 0 0 Bushing 0 Boot, Clutch Intake Asm., Drive Clutch, Braking (See Drive Clutch Pg. C, Ref. ) Screw and Washer (See Crankcase Pg. D, Ref. ) Bracket, Retainer, Seal (See Clutch Cover Pg. C, Ref. ) 00 Clamp, Hose Bolt 0-0 Mount, Engine, Front 00 Mount, Rubber, Top 0 Washer, Wrought 0 Nut (See Cylinder Pg. D, Ref. ) Washer (See Cylinder Pg. D, Ref. ) 0-0 Manifold, Black Gasket, Exhaust (See Cylinder Pg. D, Ref. 0) 0 Engine, EH0PLE0 - Short Block NOTE: The Short Block assembly contains a crankcase assembly, cylinder & cylinder head assembly and a piston & crankshaft assembly. Prior authorization is required for warranty consideration. -0 Mount, Engine, Top 00 Cable, Ground, Engine 000 Filter / A

16 EXHAUST SYSTEM SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok Washer 0 Washer Bushing 00 Bushing Bracket, Silencer, Frame (See Rear Rack Mounting Pg. A, Ref. ) 0 Dampener, Vibration Bolt, Carriage B 0-0 Silencer, Exhaust 0 Bolt 00 Spring, Exhaust Screw Washer Shield, Heat, Exhaust 0-0 Pipe, Exhaust 0 Seal, Exhaust 0/

17 FUEL TANK SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Cap, Gas Tank 0 Gasket, Fuel Cap 0 Seal, Foam AR Line, Fuel 0 Vent, Tank Bolt 0 Washer 0 Washer -0-0 Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH 0 Spacer Insert 0 Pad, Bracket, Fuel Tank 00 Fitting, Fuel Outlet, Main AR Line, Fuel 0000 Clamp, Hose, Red 0 Fitting, Fuel Outlet, Reserve 0 Screw Knob, Fuel Valve Nut, Fuel Valve 0 0 Valve, Fuel, -Way 0 Asm., Fuel Tank (Incl.,) 0/ B

18 AIR BOX SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Foam, Filter 00 Filter, Air Intake 00 Clamp 0 Collar, Carburetor Inlet Cover, Air Box Screw Duct, Air Inlet Seal, Foam 0 Duct, Clutch Air Inlet 0 Gasket, Intake Seal, Air Box Cover Box, Air 00 Clamp AR Line, Fuel 00 Clamp 00 Filter, Breather AR Hose, Breather Duct, Carburetor Inlet 0 Gasket, Carburetor Inlet Duct 0 Line, Breather Plug, Trap 00-0 AR Line, Fuel 000 Clamp, Hose 0 Foil 0 Washer Screw 0 Clip, Air Box / B

19 CV JOINT - BTB SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB BTB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., CV Housing w/sleeve Sleeve, Seal, Drive Shaft 0 Clamp, CV Joint, Large 00 Circlip 0 Boot, CV 00 Shaft Replacement (Incl. ) 00 Cardan Replacement (Incl.,,,) 00 Kit - Cross and Bearing 00 Yoke, Splined 0 Pin, Spring 00 Clamp, Band, Small 00 Kit - Boot Replacement, CV Joint (Incl.,,) 00 Kit - Drive Shaft w/sleeve BTB 0/ B

20 REAR DRIVE SHAFT SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Drive Shaft, Rear (Incl. -) 00 CV Joint 00 Clamp, Large 00 Grease, Outer, 0g 00 Boot 00 Clamp, Small 00 Grease, Inner, 0g 0 Joint, Plunging 00 Ring, Spring 0 Kit - Boot (Gear Side) 0 0 Kit - Boot (Wheel Side) 0/ B

21 PROP SHAFT SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 0 Shaft, Prop 0 Yoke, Gear Case, Front Kit - Cross and Bearing (See CV Joint Pg. B, Ref. ) 0 Shaft, Prop 0 Yoke, Prop Shaft, Transmission 0 O-Ring 0/ B

22 FRONT STRUT SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bumper, Strut (For Strut 0) Bumper, Strut (For Strut 0) 0 0 Strut, Front, Arvin Strut, Front, Sachs Washer, Spring Retainer 0 0 Washer 00 Clamp, Rubber Coated 0 Nut, FLEXLOC Bolt 0 Washer 0 Retainer, Casting Wire, Strut 0 Asm., Front Brake Caliper, RH (See Front Brake Pg. B for Details) 0 Bearing, Tapered Roller 0 Bearing, Cup, Tapered Roller Sleeve, Hubstrut Seal 000 Fitting, Lubrication 0 Coil, Magnetic B 0 0 Asm., Hubstrut, Heavy, LH (mm) (Incl.,-,) Asm., Hubstrut, Heavy, RH (mm) (Incl.,-,) 0-0 Spring, Coil 00 Retainer, Spring (For Strut 0) Retainer, Spring (For Strut 0) 00 Ball, Pivot, Bottom 0 Bolt 0 0 Spacer (For Strut 0) Spacer (For Strut 0) Kit - Drive Shaft w/sleeve BTB (See CV Joint - BTB Pg. B, Ref. ) 00 Seal, Hubstrut 00 Ball, Pivot, Top 0 Spacer, Rubber Washer 0 0 Nut, FLEXLOC (For Strut 0) Nut, Nylok (For Strut 0) /

23 FRONT WHEEL SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt Disc, Brake 00 Seal, Front Hub Plate, Armature 0 Clutch, Front Hub, Elec./Mech. 0 Bearing, Roller Cone, Tapered 0 Bearing, Roller Cup, Tapered Stud 0 Asm., Hub w/bearing Race (Incl.,,) 0 00 Cage, Roll 000 Roll 00 Spring, Garter Spacer B 000 Cam 00 Plug, Magnetic Drain 0 Tire (x-) 00 Washer 0 Nut, Slotted 0 Pin, Cotter 0 00 O-Ring Cap, Hub 0 Screw Nut, Lock Rim, Front, Black (ACH0(AA)(EA)) Rim, Front, Aluminum (ACH0(AB)(EB)) 0 Valve, Rim /

24 FRONT BRAKE SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Front Brake Caliper, LH (Incl. -,0,) 00 Asm., Front Brake Caliper, RH (Incl. -,0,) 00 Screw, Bleeder Screw, Socket Set 0 Caliper, Brake, LH Caliper, Brake, RH Kit - Front Brake Boot 0 Kit - Piston and Insulator Seal (Incl. -) 0 Square Ring, Molded (.0) 00 Square Ring, Molded (.0 x.) 000 Piston, Caliper 00 Insulator, Caliper Kit - Front Brake Pad, General Duty Kit - Front Brake Pad, Severe Duty Kit - Front Brake Pad, Soft Duty 0 0 Mount, Caliper 0 Boot, Bushing 0 Boot, Pin Seal Washer (See Front Strut Pg.B, Ref. ) Washer (See Front Strut Pg. B, Ref. ) Bolt (See Front Strut Pg. B, Ref. ) / B

25 CONTROLS THROTTLE ASM./CABLE SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 0 O-Ring Cover O-Ring 000 Cable, Throttle Control 00 Asm., Throttle Control (Incl.,,) 00 Asm., Throttle Clamp / B0

26 CONTROLS MASTER CYLINDER/BRAKE LINE SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Master Cylinder (Incl. ) Kit - Master Cylinder Reservoir (Incl. -,) 0 Bolt, Cap 0 Cap, Reservoir 0 Diaphragm 000 Kit - Master Cylinder Clamp 0 Asm., Piston Master Cylinder 00 Rivet 00 Kit - Brake Lever w/parking Latch (Incl. -) Spring, Flat 000 Kit - Park Brake Lever (Incl.,) 0 00 Nut 0 Bolt, Reservoir 00 Bolt, Lever Ring, Square, Reservoir B Boot, Brake Line, Rubber 0 Seal 0 Switch, Brake Line Line, Rear Brake (See Rear Brake/ Foot Pedal Pg. C, Ref. ) Rivet 00 Clamp, Nylon Conduit 0 Line, Brake, Left Front w/fittings 00 Strap, Black, Weather Resistant 0 Screw 00- Conduit 0 Line, Brake, Right Front w/fittings 0 Fitting, Inverted Flare Cross 0 Line, Brake, Hyd., Pod 0 Bolt, Banjo 0/

27 STEERING POST SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Steering Post (Incl.,) Bushing, Steering, Console 00 Fitting, Lubrication Bolt Plug, Grease, Steering Washer 0 O-Ring Spacer, Steering Post 0 Nut 0 Pin, Cotter 0 Bushing, Steering, Lower Rivet 00 Fitting, Lubrication Bushing, Steering, Console -0 Bracket, Steering Bushing, Upper Nut, Nylok 0/ B

28 HANDLEBAR and HEADLIGHT POD SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB B

29 HANDLEBAR and HEADLIGHT POD SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 00 0 Speedometer, (Sportsman) Speedo, Kilometer (Worker) Plug, Indicator Indicator, Hot Temperature Indicator, Neutral/Reverse Screw 00 Nut, U-Type 0 Harness, Headlight Pod Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B0, Ref. ) -0 Tube, Handlebar Kit - Handlebar Block (Incl. Blocks and,,0) Block, Handlebar Retainer Nut 0 Washer Washer Screw 0 Clamp, Speedometer Asm., Master Cylinder (See Controls - Master Cylinder/ Brake Line Pg. B for details) 0-0- Pod, Headlight, Upper (ACH0(AA)(EA)) Pod, Headlight, Upper (ACH0(AB)(EB)) Plug Screw 0 Switch, Handlebar, LH Spacer, Switch 0 00 Grip, Handlebar 0-0 Bracket, Pod Mounting Screw 00 Knob, Adjusting 0 Boot, Headlight 00 Collar, Locking 00 0 Lens and Reflector Bulb, Headlight, Halogen 00 Rod, Adjusting 0 O-Ring Cable, Choke Control w/adjuster Kit - Choke Lever 0 Nut, Nylok 00 Nut, U-Type 00 Plug, Power, V Rivet, Bulbex 00 Clip, Cable Retaining 0 Screw -00 Pod, Headlight, Lower 00 Switch, Ignition (Incl. Key) NOTE: Ignition Key may be ordered by using the four digit number on the key. Cover, Key 00 Nut, Choke Slide Sensor, Speedometer Bolt 0 Washer / B

30 OIL TANK SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB To Airbox To Lower Oil Pump Fitting on Engine 0 To Top Oil Pump Fitting on Engine 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Plate, Vent, Oil Tank 00 Gasket, Oil Reservoir 0 Fitting AR Line, Breather Dipstick 0 O-Ring Washer 00 Tube, Banjo Return 0 0 Bolt, Banjo 0 Tube, Banjo Intake 000 Screen, Oil Filter Nut, Nylok 0 Washer Tank, Oil, LH 0 Grommet 0 Grommet, Mounting, Reservoir 0 Bushing 0 Bolt 0 0 Plug, Mag. 0 Washer Screw Tank, Oil, RH 0/ C

31 FRAME MOUNTING SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Pin, Clevis 0 Bushing 000 Tube, Pivot Nut, Nylok Rod End, LH (See Gear Selector Pg. D, Ref. ) 0 Washer C Bolt Bolt Screw Pivot, Shift Arm, Shift 0 Pin, Cotter 0/

32 A-ARM/STRUT MOUNTING SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, FLEXLOC Bushing 0 Asm., Tie Rod (Incl. -) Boot, Seal, Rod End 00 Rod End, RH Nut 00 Tie Rod 0 Nut, LH 00 Rod End w/fitting, LH 0 0 Washer 0 Nut 0 Pin, Cotter Asm., Heavy Hubstrut (See Front Strut Pg. B, Ref. ) 00 Joint, Ball Bracket, Ball Joint C Bolt 0 Boot, Rubber Nut, Castle Shield, CV Joint, LH Shield, CV Joint, RH 0 0 Screw Bushing, A-Arm, Long 00 Bushing 00 Shaft, A-Arm Kit - A-Frame, LH Kit - A-Frame, RH 00 Fitting, Lubrication Bolt 0 Washer Bolt Bolt 0/

33 DRIVE CLUTCH SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Clutch, One Way Drive 00 Washer Sleeve, Spacer 0 Nut, FLEXLOC Button, Clutch, Stemless 00 Pin, Roller Bearing 0 Cover, Bearing 0 Washer 0 Bolt 0 Spring, Clutch Roller and Bushing 0 Washer, Multilube Bolt, Shoulder 0 Weight, Shift, 0 MH 0 Asm., Drive Clutch, Braking (Incl. All Less,) 00 Washer / C

34 DRIVEN CLUTCH SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WOR- KER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 AR Bushing 0 Asm., Driven Clutch, Braking (Incl. -,-) 0 Washer 00 Bushing 0 Ring, Retaining 0 Washer, Domed 0 Washer Bolt 0 Belt, Drive 0 Screw 00 Roller, Taper, Engine Brake 0 Bearing, Moveable, / Washer Bearing, Moveable, 0 Spring, Clutch Ramp, Stationary 0 Spacer 0 Ring, Retaining / C

35 CLUTCH COVER SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 00-0 Bracket, Clutch Cover, Rear 0 Bolt 0 Seal, Cover Case 00 Kit - Inner Clutch Cover (Incl.,,) Washer 0 Washer Bolt Bolt Bolt 0 0 Seal, Cover, Clutch Cover, Clutch 00 Clip, Cover, Clutch 0 Screw 0 Decal - Clutch Cover 0 Decal - Engine/Clutch Modification 0 Decal - Automatic/EBS Clutch 0 Screw Boot, Clutch Intake 00 Cable Tie 0 Screw Duct, Air Outlet Screw and Washer (See Crankcase Pg. D, Ref. ) 00-0 Bracket, Retainer, Seal 0 Seal, Cover Case 0 Screw -0 Bracket, Cover, Clutch Washer 00 Clamp, Narrow Band Duct, Air Inlet (See Air Box Pg. B, Ref. ) 0/ C

36 ELECTRICAL/TAILLIGHT SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 0 Harness, Main Wire 00 Kit - Circuit Breaker, 0 AMP 0 Asm., Taillight w/brake Light (Incl. -) 00 Lens, Taillight 00 Screw, Taillight 000 Bulb, Taillight 00 Gasket, Taillight 00 Backing, Taillight/Brake Light 00 Nut, Speed 0 Nut, Nylok 0 Washer 0 Screw 00 Pad, Battery 00 Decal - Battery 000 Cable, Battery/Solenoid 00 Kit - Battery Bolt, Short 000 Cable, Battery/Engine 000 Hook, Battery Strap C 0 Strap, Battery Holddown 0 0 AR Tube, Vent, Battery 000 Battery Cover, Battery 000 Cable, Solenoid/Starter 00 Bolt 0 Pad, Rack Mount 00 Harness, Jumper, AWD w/diode 00 Cable Tie 00 Cable Tie, 0 Pigtail, Power 0 00 Plug, Power, V Bracket, CDI 0 Screw 0 Sink, Heat 00 Regulator 00 Clip, Rosebud 00 Clip, Routing 0/

37 REAR WHEEL DRIVE SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Pin, Cotter Nut Hub, Rear Wheel Carrier, Bearing, Wheel (See Rear Suspension Pg. C0, Ref. ) 00 Ring, Retaining Stud 0 Tire, x-0, Tracker P 0 Valve, Rim Rim, Rear, Black (ACH0(AA)(EA)) Rim, Rear, Aluminum (ACH0(AB)(EB)) 0 Washer, Cone 00 Nut, Castle Cover, Dust, Hub 0/ C

38 REAR SUSPENSION SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB C

39 REAR SUSPENSION SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description Bolt 00-0 Arm, Stabilizer Bar 0 Nut, FLEXLOC Screw Washer Bushing, Stabilizer 00 Rod, Linkage, Stabilizer 00 Shaft, A-Arm, Short 0 Bushing, A-Arm, Short 0 00 Bushing 00 Fitting, Lubrication Bolt -0 Bar, Stabilizer Tube Washer Bushing, Stabilizer Tube 0 Washer Bolt 0 Washer -0 Support, Stabilizer 0 0 Nut, FLEXLOC 0-0 Bracket, A-Arm Pivot Bolt Nut, Flange Bolt -0 Support, Transmission 0 Washer 0 Retainer, Spring Spring, Compression, Rear (Sportsman) Spring, Compression, Rear (Worker) 0 Cam, Adjusting, Spring 0 00 Shock, Rear Bolt Bushing, A-Arm, Long 00 Shaft, A-Arm Arm, Control, Lower, LH Arm, Control, Lower, RH Nut, Nylok 0 Bushing, Control, Lower Arm, Control, Upper, LH Arm, Control, Upper, RH Bushing, Bearing Carrier Washer 0 Screw 0 0 Shield, LH Shield, RH 0 Screw Carrier, Bearing, Wheel 0 Bearing, Carrier, Wheel 00 Fitting, Lubrication 0/ C0

40 REAR BRAKE/FOOT PEDAL SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 C

41 REAR BRAKE/FOOT PEDAL SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer 0 Washer Caliper, Brake Spacer, Brake Pad Kit - Brake Pad Kit - Brake Seal Pin Kit - Bleeder Replacement Piston, Caliper, Rear 0 Line, Rear Brake 00 Line, Brake, Caliper w/fittings Bolt 0 Reservoir, Brake, Rear Nut 0 0 Hose, Reservoir 0000 Clamp, Hose Nut, Nylok 00 Spring Washer 0 Bushing, Pivot, Pedal 00-0 Rod, Brake 0 Pin, Cotter 00 Master Cylinder, Brake, Rear Bolt 0 0 Disc, Brake 0 Washer 0 Nut / C

42 FOOT BRAKE WORKER 00 AC H0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt 00-0 Bracket 0 Pin, Cotter Washer Handle, Parking Brake Washer, Flat 0 Nut, FLEXLOC 0 Washer Spring, Return 0 0 Bushing Pawl, Parking Brake Linkage, Parking 00 Clevis, Threaded Pin, Clevis 0 Pin, Cotter 0 Pin, Cotter 0/ C

43 FRONT HOUSING SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Front Gearcase (Incl. All Less,)NOTE: Used on Machines built before --. Seal O-Ring Cover, Input, Front Housing 0 Bearing, Ball 0 Ring, Retaining 00 Bearing, Ball Shaft, Input, Front Housing Bushing 0 Washer 0 Seal 0 Ring, Retaining Screw 000 Clamp C AR Line, Vent 0 Tube, Vent Housing, Front, Gearcase Rivet Washer Plug, Drain 0 Washer Plug Bearing, Needle Shaft, Output, Front Housing Gear, T, Spiral Bevel Washer, Thrust Washer, Thrust Bearing, Ball 0 Cover, Output, Front Housing O-Ring /

44 FRONT HOUSING SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Front Gearcase (Incl. -,-)NOTE: Used on Machines Built After -- Screw Seal 0 Cover, Input, Front Housing 00 O-Ring Ring, Retaining Bearing Pinion, Input Bushing Seal, Oil 0 Bushing Washer Plug 000 Clamp 000- AR Line Tube, Vent Gearcase, Front Housing 0 SubAsm., Output Shaft, Front Housing 00 Bearing, Ball AR Shim 0 O-Ring Cover, Output, Front Housing AR Shim 0 Button, Thrust Plug, Drain Washer / D

45 GEARCASE (Cases and Snorkel) SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gearcase (See Gearcase -Internal Components Pg. D for- Details) Seal Screw Decal - Switch 0 Screw Seal Gearcase, LH 0 Vent Dipstick Screw 0 Switch, Position Switch, Position Screw Washer Gear, T, Extended Bearing, Ball (See Gearcase -Internal Components Pg. D, Ref. ) Shaft, Drive, Snorkel 0 O-Ring 0 Snorkel 0 Bearing, Ball 0 Spacer (.0x.x.00) Spacer (.0x.x.0) Spacer (.0x.x.00) Spacer (.0x.x.00) Spacer (.0x.x.00) NOTE: Ref. 0 indicates choices, may also be used in combinations. 0 Ring, Retaining Lock, Bolt Bolt Bushing Seal Washer (See Gearcase - Internal- Components Pg. D, Ref. 0) Nut, FLEXLOC Stamping, Cover Plate Washer 0 Screw Plug, Drain Washer Gearcase, RH Pin, Dowel 0/ D

46 GEARCASE (Internal Components) SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB D

47 GEARCASE (Internal Components) SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gearcase (Incl. - and all on Gearcase - Cases and Snorkel Pg. D) 0 Bearing Shaft, Input, T, HCR 0 Chain, Silent, P 0 Bearing Shaft, Shift O-Ring 00 Washer 0 Ring, Retaining Bellcrank, HLR 0 0 Washer 0 Nut Shaft, Shift Fork, Shift, Low Fork, Shift, H/R 0 Screw 0 Pin, Interlock 0 Bracket, Interlock Spring, Interlock Ring, Retaining 0 Washer, Thrust 0 Bearing, Needle Gear, 0T 00 Washer Engagement Dog 0 Ring, Retaining 0 Washer 0 Bearing, Needle Sprocket, T Shaft, Reverse, HCR 0 Engagement Dog, Low 00 Bearing, Needle Gear, T 00 Washer 00 Bearing, Ball Shaft, Center Drive 0 Gear, Output, 00T, HCR Screw 0 Washer Cover, Bearing, Center Drive 0 Ring, Retaining Bearing Pinion, T, Spiral Bevel Screw Deflector, Oil Chain Tensioner, Cam Chain Tensioner, Shoe Pin, Dowel Spring, Torsion Bearing 0 0 Sprocket, 0T 0 Chain, Silent 0/ D

48 GEAR SELECTOR SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gear Selector (Incl. -,-) Knob, HLR 0 Screw Strap, Wire Clamp Boot, Gear Selector Screw Cover, Gear Selector Handle 0 Cup, Bearing 0 0 Spring, Centering 0 Pin, Stop 0 Spring, Detent 00 Bullet, Detent Grommet 00 Rod End, RH 0 Nut, LH 00 Rod, Shift Linkage, Hi-Range 00 Rod End, LH 0 Nut, FLEXLOC 0 00 Rod, Shift Linkage, Low-Range 0 Nut, RH 0 O-Ring Slide, Low Slide, High/Reverse Body, Gear Selector 0/ D

49 CRANKCASE SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bush, Starter 0 Asm., Crankcase (Incl.,,,,,0,,,,0,) 0 Pin, Straight 00 Bearing, Ball 00 Pin, Dowel 00 Screw and Washer 0 Seal, Oil 0 Pipe, Air Breather 0 Union 0 0 Bearing, Ball 0 Bearing, Ball D 0 Plug 0 Gasket, Aluminum 0 Spring, Valve, One Way 0 Valve, One Way 0 0 Bolt, Flange 0 Gasket 0 Plug 0 Seal, Mechanical 0 0 Seal, Oil 0 O-Ring 000 Pin, Dowel 0/

50 CYLINDER SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB D

51 CYLINDER SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 0 Band, Adapter (Incl. ) 0 Screw 00 Bolt 0 Pin, Straight 0 Guide, Valve 0 Seal, Intake Valve 0 O-Ring 00 Adapter, Water Out 0 0 Bolt, Flange 0 0 Adapter, Camshaft 00 Gasket, Rocker Cover 00 Cover, Rocker 0 0 Bolt, Flange 0 Seal, Exhaust Valve 0 Bolt, Cylinder Head 00 Plug 0 Gasket 0 Plug, Blind 0 Bolt, Flange 0 00 Gasket, Exhaust 0 Stud 00 Nut 000 Washer 00 Bolt, Rocker Shaft 0 Bolt 0 Support, Valve Rocker Shaft (PTO) 0 Support, Valve Rocker Shaft (MAG) 0 Pin, Straight 0 Union, Oil Pump 0 0 Bolt, Flange 0 Cylinder (Incl. ) 00 Pipe, Elbow 00 Gasket, Cylinder 0 Cover, Camshaft 0 Gasket, Cover, Cam 0 Cylinder Head (Incl. -,,-,) 0 Gasket, Head 0 Adapter 0/ D

52 CRANKSHAFT and PISTON SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Clip 0 Pin, Piston Piston Set (Std)(Incl. -) Piston Set (0. O/S)(Incl. -) Piston Set (0.0 O/S)(Incl. -) Piston Ring Set (Std) Piston Ring Set (0. O/S) Piston Ring Set (0.0 O/S) 0 Crankshaft 0 Pin, Crank 0 Rod, Connecting 000 Bearing, Large End 00 Ball, Steel Asm., Crankshaft (Incl. -,) Crankshaft 0 Gear, Balancer 00 Shaft, Balancer Spacer (0.) Spacer (.0) Spacer (.) Spacer (0.) Spacer (0.) Spacer (.0) Spacer (.) 0 Sprocket 0 Nut, Slit 00 Washer 00 Nut, Lock 0 Pin, Dowel 0 0 Key 000 Key, Woodruff 0/ D

53 INTAKE and EXHAUST SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Plug 00 Gasket, Plug 0 Spring, Tensioner 0 Asm., Tensioner (Incl. -) 0 Gasket, Tensioner 00 Asm., Rocker Arm, Intake (Incl.,) 0 Asm., Rocker Arm, Exhaust (Incl.,) 0 Nut 0 Screw, Adjusting 0 00 Shaft, Rocker 00 Collet, Valve 00 Retainer, Spring 00 Spring, Valve D0 0 Camshaft (Incl. -) 000 Pin, Dowel 0 Lever, Release 00 Spring, Return 0 Pin, Dowel 0 Sprocket 0 0 Guide, Chain 0 Bolt and Washer 0 Chain, Timing 0 Bolt, Pivot, Lever 0 Lever 0 Valve, Intake 00 Valve, Exhaust 0 Bolt, Flange 0/

54 CARBURETOR SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB D

55 CARBURETOR SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 00 Ring 00 E-Ring 0 Needle, Jet (J-HB) 0 Ring 0 Diaphragm 00 Jet, Needle (Q-0) 0 Screw 00 Washer 00 Asm., Jet Block 0 00 Washer 00 Jet, Main (#.) 0 Seal 0 Packing 0 E-Ring 0 Cap 0 Pin, Float 0 Plate 0 O-Ring 00 Screw 0 00 Body, Float 0 Screw 0 Float 0 Screw 0 Valve, Needle (.) 0 O-Ring 0 Jet, Pilot (#0) 0 O-Ring 0 Washer 0 Spring 0 0 Adjuster 0 Screw, Adjust 0 Ring 0 Spring 00 Valve, Throttle (00) 0 Spring 0 Ring 00 Screw 0 Asm., Throttle Shaft 0 Guide, Cable 0 0 Screw 0 Cover 0 O-Ring 0 Holder, Guide 0 Spring 0 Asm., Plunger 0 Jet, Air (#0) 0 Asm., Carburetor (Incl. -,-) 00 Screw and Washer 00 Spring 0 00 Cover 0 Screw 0/ D

56 RECOIL STARTER SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Reel 0 Spring, Return 0 Ratchet 0 Spring, Friction 0 Plate, Friction 0 Bolt and Washer 0 Plug 0 Gasket D 0 Bush, Starter 0 0 Spring, Power 00 Bush 0 Gasket, Recoil 0 Bolt, Flange 0 0 Asm., Recoil (Incl. -,-,,) Starter Case (Incl. ) 00 Rope 0/

57 WATER PUMP SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Thermostat 0 Switch, Thermostat 0 Clamp, Hose 0 Hose, Main 0 Bolt, Flange 0 Gasket, Aluminum 0 Cover, Water Pump D 0 Gasket, Water Pump 00 Nut, Self Lock 0 0 Gasket 0 Impeller 0 Washer, Seal 0 Bolt, Flange 0/

58 OIL PUMP SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Case, Oil Pump 0 Rotor, Outer (Feed) 0 Rotor, Inner (Feed) 0 0 Asm., Oil Pump (Incl. -,0-) Case, Oil Pump 0 Screw 0 Pin, Dowel 0 Pin, Dowel 0 Washer 0 Bolt and Washer E 0 0 Case, Oil Pump 00 Rotor, Inner (Scav) 0 Rotor, Outer 0 Oil Strainer Unit 00 Screw and Washer 0 Shaft, Pump 0 Gear, Pump AR AR AR Spacer (0.) Spacer (.0) Spacer (.) 0/

59 OIL FILTER SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 0 Filter, Oil 0 Gasket, Aluminum 0 Bolt, Banjo 0 Pipe, Oil Delivery 0 Pipe, Oil Delivery 0/ E

60 MAGNETO SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 0 Asm., Coil, Ignition (Incl.,) Coil, Ignition 00 Cap, Plug, Spark 00 Plug, Spark 0 O-Ring 0 Metal, Bearing 0 00 Asm., Plate (Incl.,,-,,) Plate 0 Bolt and Washer 0 Seal, Oil 0 Stator (Incl. ) E 0 0 Screw and Washer 0 Band, Pulse 0 Screw and Washer 00 Coil, Pulser 0 Clamp 0 Screw and Washer 0 CDI System 00 Nut 000 Washer 0 Switch, Magnetic 0 0 Flywheel w/ring Gear 0/

61 STARTING MOTOR SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Motor, Starting (Incl. -,-) 0 Washer Set 0 Armature 00 Brush 0 Nut, Flange 00 O-Ring 00 Bolt and Washer 00 Bracket, Rear 00 Bracket, Front (Incl. 0) E 0 0 O-Ring 0 Asm., Set Bolt (Incl. ) 00 Ring, Rubber 0 Washer, Gear Shaft 0 Clip 0 Spring, Weight 00 Spring, Return 00 Clip 0 Asm., Gear Shaft (Incl. -) 0/

62 FUEL PUMP SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Fuel Pump (Incl. -) 0 Screw and Washer 0 Screw and Washer 0 Screw and Washer 0 Diaphragm Gasket Set 0/ E

63 TOOL KIT SPORTSMAN 00 ACH0AA and SPORTSMAN 00 ACH0AB and WORKER 00 ACH0EA and WORKER 00 ACH0EB 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Tool Kit (Incl. -) 0 Gauge, Tire Pressure 0 Screwdriver 0 Wrench, Box, Special 0 Wrench, 0- Spanner 00 Pouch, Tool Kit Lube, U-Joint, oz., Case 0 0 Owner s Manual, ATV Supplement, Owner s Manual Sportsman Wrench, Spanner, Cam 0 0 Pigtail, Power 0/ E

64 Part Ref. Grid PART NUMBER INDEX SPORTSMAN 00 ACH0(AA)(AB) and WORKER 00 ACH0(EA)(EB) Part Ref. Grid Part Ref. Grid C C A A A C C A A A A C C C A B B A C C B C C D D D B B B B B B B B B B B C C C B B B B B... C C C B B C B C B C B C C B C C B B B B B B B B B B B B B B C C C C B B B B C B C C C B B B A B B B B B B C B C C B B B B C C C B B A A C E... C C B C A B A C B E A A A A A A A A A A E B E E E A E E E D.. D D D D D E D D D D0... E E D D.. D E D D D D D D.. D D E E E D.. D E E D D D D D.. D... E D E E E E

65 Part Ref. Grid PART NUMBER INDEX SPORTSMAN 00 ACH0(AA)(AB) and WORKER 00 ACH0(EA)(EB) Part Ref. Grid Part Ref. Grid E E E E D D D D D D D D... D D D D D D D D.. D D... E D D D D D D D D D D D D D D D D.. D D D D.. D.. D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E D E E D E E D D D D D D D E E E D E D D D D D D D E E D E D D D D D D D D E D D D E D D D D D E E A E E E E E D D E E D D D D D D D A.. A A A D D D D D D D D D

66 Part Ref. Grid PART NUMBER INDEX SPORTSMAN 00 ACH0(AA)(AB) and WORKER 00 ACH0(EA)(EB) Part Ref. Grid Part Ref. Grid D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D C D D D D D D D C... D C... D... D D D D D C... D D D D D D D D D D D D D D D D D D D D D C... D... D D... D C... D... D C... D... D D D D D D D D D D D D D D D D C... D D D C C C... D C C C... D C... D C C C C E C C D C C D D D D D D D D D D D D D D D D D D D D D C D D C C C D C D D D D D D D D D D D D D D D D D D D D D D D D D D D D D

67 Part Ref. Grid PART NUMBER INDEX SPORTSMAN 00 ACH0(AA)(AB) and WORKER 00 ACH0(EA)(EB) Part Ref. Grid Part Ref. Grid D D D D D D D D D E B B B B C B B B B B B B B B B... B B C C C C C B B C C C A A C C A C C C C B B B B B B B C B B B C A B C B A C 0.. C D D C C C C C.. C B C B B C C C C C C C C B A C A B... C C B C A A C B C B B B B B A A C C C C B A B A C A A A A C A A A B E B C A C B A B B B C A C C B B B A A C B B C B B C C A A A B B B C C A B C B A A... C A B B B C C B C A B B B B C B B A B A B B C

68 Part Ref. Grid PART NUMBER INDEX SPORTSMAN 00 ACH0(AA)(AB) and WORKER 00 ACH0(EA)(EB) Part Ref. Grid Part Ref. Grid B B B C.. C B B B B B C.. C A A C A A A A A A A A A A C C A C B C B A A C C A A A C A A C B B B A C B B B B B C B B B C B B B C C A B C C C B C B A C B B B C A A A A A A A A B A B B A A A B B C B C B C C A B C C C C B B C B C B A A C B C B B B C A D D E C C C A A0.. A A0 0.. A C A0.. A A0.. A A0.. A A0.. A A0 0.. A A A0.. A A0.. A C A A0.. A A0.. A A0.. A C A0.. A A0.. A A0.. A A0.. A A0.. A A A A0.. A A0.. A A A A0.. A A0.. A A0.. A A A0.. A A... B.. C