PARTS MANUAL PN and MICROFICHE PN 0 /0 SPORTSMAN 00 Model #A0MHAK Model #A0MHAN E 00 Polaris Sales Inc.
TABLE OF CONTENTS Parts Manual A H A -ARM... AIR BOX... C A B BRAKE LINES, FRONT... B BUMPER MOUNTING... A- C CALIPER, REAR... B CARBURETOR... D- CLUTCH COVER... C0 CONTROLS... B CONTROLS - THROTTLE ASM./CABLE. B COOLING SYSTEM... A- CRANKCASE... D CRANKSHAFT... D CYLINDER... D-0 CYLINDER HEAD... D-0 D DECALS... DRIVE CLUTCH... DRIVE SHAFT, FRONT... DRIVE SHAFT, REAR... DRIVEN CLUTCH... A0 C B0 B C E ELECTRICAL... C ENGINE MOUNTING... B- EXHAUST... D EXHAUST SYSTEM... A F FOOT PEDAL... FRONT BRAKE... FRONT CAB... FUEL TANK... B B A B G GEAR SELECTOR... C GEARCASE... D- GEARCASE MOUNTING, REAR... D GEARCASE, REAR... D HANDLEBAR... C- HEADLIGHT POD... C- HEADLIGHTS... C HOUSING, FRONT... D INTAKE I... M MAGNETO... MASTER CYLINDER, REAR... OIL PUMP O... P PISTON... PROP SHAFT, FRONT... PROP SHAFT, REAR... D E B E D B B R REAR CAB and SEAT... A- REAR RACK MOUNTING... A REAR SUSPENSION... C- REAR WHEEL DRIVE... C S STARTING MOTOR... STEERING POST... STORAGE BOX, REAR... STORAGE, FRONT... STORAGE, FRONT... STRUT MOUNTING... STRUT, FRONT... T TAILLAMPS... TOOL KIT... TRANSMISSION MOUNTING... W WATER PUMP... WHEEL, FRONT... WORKLAMPS... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. E C A A A C B C E D E C C
REAR CAB and SEAT E 00 Polaris Sales Inc. 0 0 0 A
REAR CAB and SEAT 0 Screw Washer 0 Screw 0 Washer 0 Retainer, Seat Latch 0 Screw Washer Nut, Nylok -00 - Cab, Rear, Camo Green Metallic (AK) Cab, Rear, Sonic Blue (AN) 0 00 Decal, Hitch Rivet -00-00 Footwell, Black, LH Footwell, Black, RH 0 Screw Nut, Nylok 0 Foil, Rear Cab, Front, Top 0 Foil, Rear, Cab, Front, Bottom 0 Foil, Cab, Rear 0-0 Frame, Main, Black Screw 0-0 Bracket, Bumper, Lower, Black Nut, Nylok, Flange Screw -0 Brace, Support, Frame, Front, Black, LH 0 Rivet 0 Bracket, Lever Retainer 00 Spring, Latch -00-00 Asm.,Seat,Black Covering, Seat, Black 00 Latch, Seat Grommet, Rubber Mount 0 Decal, Filter Cleaning /0 A
FRONT CAB E 00 Polaris Sales Inc. 0-00 - Cover, Front, Camo Green Metallic (AK) Cover, Front, Sonic Blue (AN) -00 - Cab, Front, Camo Green Metallic (AK) Cab, Front, Sonic Blue (AN) 00 Nut, Speed Screw - - Panel, Side, Black Metallic, LH Asm., Panel/Foil, Black Metallic, RH Foil, RH 00 Clip, Snap In Screw 00 Guard, Splash, RH 0 0 Nut, Nylok Guard, Splash, LH/Pump Mount Rivet 0 Screw 0 Washer /0 A
REAR RACK MOUNTING E 00 Polaris Sales Inc. 0 0 0 Screw Screw - Channel, Rear Rack, Black Screw -00 Asm., Rack, Rear, Black (Incl. Warning Decal and Reflectors) Screw Spacer Washer, Flat Nut, Nylok A 0 - Channel, Rear Rack, Front, Black 0 Spacer 0-0 Support, Rear Rack, Black Bolt, Flange - - - - - - - Bracket, Silencer, Frame (See Exhaust System Pg. A, Ref. ) Nut, Flange Nut, Nylok, Flange Screw /0
FRONT STORAGE and BUMPER MOUNTING E 00 Polaris Sales Inc. 0 0 0 A
FRONT STORAGE and BUMPER MOUNTING Screw 0-0 0-0 Support, Rack, Black LH Support, Rack, Black, RH Bolt, Flange Nut, Flange 0-0 Guard, Brush, Black Cover, Radiator 0 0 Latch, LH Latch, RH 0 Screw Latch, Wire 0 Rivet Shield, Side, Radiator, LH Shield, Side, Radiator, RH 0 Grommet, Rubber Mount 0 Cover, Radiator 0-0 Grill, Brush Guard, Black 0 Screw Decal, Amber Reflector, LH Decal, Amber Reflector, RH 0 0 Cover, Bumper, ACC, LH Cover, Bumper, ACC, RH -00 Panel, Bumper, Front, Black Screw 0 Bolt Washer, Flat -00 Asm., Bumper, Front, Black (Incl. Warning Decal) 0 Asm., Box, Lower, Front Plug, Compartment Seal, Radiator Cover Cover, Strut 0 Washer, Flat 0 Screw Seal 0 0 Seal, Lid/Bumper -00 Cover, Box, Front, Black Nut, Nylok Screw - Channel, Lid, Front, Black Pin, Hinge, Front /0 A
REAR STORAGE BOX E 00 Polaris Sales Inc. 0 Box, Storage, Rear, Upper 00 Latch Cover Seal A 0 Pad 0 Box, Storage, Rear, Lower Plug, Compartment Rivet /0
DECALS E 00 Polaris Sales Inc. RH 0 LH Decal, Reflector, Red 0 Urocal, 0th Anniversary Decal, Warning Front and Rear Rack 0 0 Decal, Rear Cab, AWD, LH Decal, Rear Cab, AWD, RH Decal, Age Warning, 0 0 Decal, SPORTSMAN, LH Decal, SPORTSMAN, RH 00 Decal, Warning, AWD Switch, White Decal, Reflector, Amber, LH Decal, Reflector, Amber, RH 0 Logo, Polaris Star 0 0 Decal, Foot Brake Decal, Warning, Override, AWD Decal, Tank Side, 00 TWIN, LH Decal, Tank Side, 00 TWIN, RH 0 Decal, Warning, General, CPSC Decal, Discretional Warning Decal, Passenger Warning Decal, Tire Pressure/Load /0 A0
EXHAUST SYSTEM E 00 Polaris Sales Inc. 0 0 Nut, Nylok Washer 00 Bushing 0 Washer, Rubber Bushing Bracket, Silencer, Frame 0 Dampener, Vibration Bolt -0 - Silencer, Exhaust, Black (If built before //0) Silencer, Exhaust, Black (If built after //0) 0 0 Washer, Clean Out Bolt 00 Seal, Exhaust Socket A 00 Spring -0 - Pipe, Exhaust, Blk(If built before //0) Pipe, Exhaust, Blk (If built after //0) 0 Shield, Heat, Exhaust Washer Screw 0 Nut, Hex 0 Nutsert 0 0 Mount, Torque Stop 0 Spring Screw 0-0 Manifold, Black Gasket 0 Shield, Heat, Exhaust /0
AIR BOX E 00 Polaris Sales Inc. 0 0 0 Filter, Precleaner Sleeve 00 Filter, Air 00 Clamp, Narrow Band Sleeve, Carburetor, Inner Cover, Air Box Screw Seal, Foam 0 Duct, Air Inlet Gasket, Intake 0 Seal, Cover 0 Duct, Clutch Air Inlet 00 Clip 00 Clamp, Hose - - - - - - - Boot, Intake (See Engine Mounting Pg. B, Ref. ) 00 Clamp, Hose, Spring A Hose, Breather 00- AR Sheath, Reflective Sleeve 00 Clamp, Narrow Band 00 Clamp, Hose 0 Box, Air 00 Clamp, Hose Cap, End 0 Clip Plug, Trap 00-0 AR Line, Fuel 000 Clamp, Hose 0 Foil Washer, Flat Screw 0 0 Boot, Carburetor /0
COOLING SYSTEM E 00 Polaris Sales Inc. 0 0 0 A
COOLING SYSTEM Bolt U-Clip 0 Asm., Fan 0 Screw w/washer 0000 Clamp, Hose 000 Line 00 Clamp Filler, Neck 0 Screw 0 00 Cap, Pressure 0 Clamp, Hose Guard, Hose, Inch 00 Hose, Engine, Upper 00 Clamp 0 Cap, Overflow 0 Gasket Plug, Cap Tank, Surge 00 Fitting, 0 Degree 0 000- Line, Fuel 000 Clamp, Hose Bracket, Radiator Mount, Upper Hose, Filler Neck Guard, Hose,. Inch 0 T-Connector Hose, Lower Radiator Asm., Grommet and Insert Screw 00 Radiator 0-0 Bracket, Radiator, Lower, Black Screw 0 Bushing, Mount, Lower Radiator 0 Valve, Drain 00 Cable Tie 00 Cable Tie Hose, Engine, Lower 00 Retainer, Hose Shroud, Fan /0 A
ENGINE MOUNTING E 00 Polaris Sales Inc. 0 0 0 0 B
ENGINE MOUNTING 0000 Clamp, Hose 00 AR Line, Fuel 000 Filter 00- Sheath, Reflective Sleeve 000-00 AR Line, Fuel 0 Kit, Short Block, 00 ATV 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. Screw 000-00 AR Line, Fuel Hose, Formed, Vent 0 Screw Bracket, Carburetor Mount 0 Nut, Hex 0 Washer 000 Mount, Carburetor Insert 00 Valve, Check Screw Nut, Nylok Bracket, Engine Mount, Top 0 Washer, Flat Bolt 0 Cable, Black Boot, Intake 00 Clamp, Hose 0 Mount, Rubber Bolt 0 Washer, Lock 0 Washer 0 Bushing 0 Bolt 00 Mount, Rubber, Top -0 Mount, Engine, Lower, Front, Black AR Washer 0 Bracket, Torque Stop /0 B
FUEL TANK E 00 Polaris Sales Inc. 0 0 Screw Bracket, Fuel Cover Mount, LH Bracket, Fuel Cover Mount, RH 00 Foil 00 Asm., Fuel Tank w/sender (Incl.,,,,) 00 Foil Seal, Foam Foam 0 Vent, Tank 000-00 AR Line, Fuel 0 Cap, Gas Tank Gasket 0 Valve, On/Off Knob, Fuel Valve 0 Screw Nut, Fuel Valve 0000 Clamp, Hose 00 AR Line, Fuel 00 Cable Tie 00- Sheath, Reflective Sleeve 0 Screw 0 Sender, Fuel 0 Gasket 0 Fitting, Fuel Screw /0 B
CONTROLS E 00 Polaris Sales Inc. 00 Asm., Master Cylinder Screw, Torx 0 Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 0 Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring) B 0 Kit, Master Cylinder Clamp (Incl. Clamp, Screws) 00 Kit, Piston (Incl. Piston, Seals, Boot, Spring) 0 Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip) /0
FRONT BRAKE E 00 Polaris Sales Inc. 0 0 0 Asm.,BrakeCaliper,LH(Incl.-,,0) Asm.,BrakeCaliper,RH(Incl.-,,0) Screw, Socket Set 0 0 Caliper,Brake,LH Caliper,Brake,RH Kit, Front Brake Boot 0 Boot, Pin Seal 0 Kit, Piston and Seal (Incl.,) 00 Ring, Molded Square,.0 x. 0 Ring, Molded Square,.0 Piston, Brake, Long 0 Kit, Asm., Front Brake Pad 0 Asm., Mount, Caliper 0 0 Boot, Bushing 00 Screw, Bleeder /0 B
FRONT BRAKE LINES E 00 Polaris Sales Inc. 0 0 Seal 0 Bolt, Banjo 0 Line, Brake 0 Fitting, Cross 0 Line, Brake, Right Front 00- Conduit 00 Cable Tie 0 Line, Brake, Left Front 0 Screw 0 0 Switch, Stoplight /0 B
REAR CALIPER E 00 Polaris Sales Inc.,,,,, 00 Asm., Caliper 0 Kit, Anvil Body 0 Fitting, Bleed, Compact 00 Kit, Slide Bolt 0 Kit, Seal 0 Kit, Piston and Seal 0 Bracket, Caliper 0 Kit, Asm., Brake Pad /0 B
REAR MASTER CYLINDER/FOOT PEDAL 0 E 00 Polaris Sales Inc. 0 00 Kit, Brake Line, Rear (Incl. ) TBA Kit, Brake Line, Rear (Incl. -) - - - - - - - Asm., Caliper (See Rear Caliper Pg. B for Details) 0 Seal 0 Line, Brake, Hand, Rear 0 Bolt, Banjo 0 Washer, Flat 0 Washer, Spring Lock Screw, Cap 0 Clip, Retaining Screw 0 00 Cable Tie Rivet 000 Clamp, Cable B 0000 Clamp, Hose Screw 0 Asm., Reservoir, Brake, Rear 0 Hose, Reservoir 00 Master Cylinder, Brake, Rear 0 Line, Rear Brake, Foot 00 Spring 0 Screw 0 Pin, Cotter Washer Bushing, Pivot, Pedal 0-0 Rod, Brake, Black 00 Spring, Torsion 0-0 Mount, Brake, Black /0
CONTROLS - THROTTLE ASM./CABLE E 00 Polaris Sales Inc. 0 O-Ring 000 Asm., Throttle Control, AWD Cover, Throttle Control (Incl. )(If built before 0/0/0) 000 Asm., Throttle Control, AWD O-Ring (Incl. )(If built after 0/0/0) 0 Cable, Throttle 00 Asm., Throttle Clamp B /0
FRONT DRIVE SHAFT E 00 Polaris Sales Inc. 0 Asm., Drive Shaft, Front 00 Circlip 0 Joint (CV, Inner) 0 Kit, Circlip 0 Kit, Boot (Inner)(Incl. Clamps and Grease) 00 Kit, Boot (Outer)(Incl. Clamps and Grease) 0 Joint, CV (Outer) /0 B0
REAR DRIVE SHAFT E 00 Polaris Sales Inc. 0 00 Asm., Drive Shaft, Rear (Incl. -) 0 CV Joint 00 Clamp, Large 00 Grease, 0g 00 Boot 00 Clamp, Small 00 Grease, 0g 0 Joint, Plunging 00 Ring, Spring 0 Kit, Boot, Gear Side 0 0 Kit, Boot, Wheel Side /0 B
FRONT PROP SHAFT E 00 Polaris Sales Inc. 0 Asm., Front Prop Shaft Pin, Spring 0 Yoke 00 Kit, Cross and Bearing 00 Asm., Shaft, Bar 0 Yoke 00 Fitting, Lubrication 0 O-Ring /0 B
REAR PROP SHAFT E 00 Polaris Sales Inc. 00 Asm, Prop Shaft, Rear 00 Yoke, Prop Shaft, Rear 0 Shaft, Rear 00 Kit, Cross and Bearing Pin, Spring /0 B
FRONT STRUT E 00 Polaris Sales Inc. 0 0 0 Nut, Nylok Washer 0 Spacer, Rubber Ball, Pivot, Top 0 Spacer Ball, Pivot, Bottom Retainer, Spring 00- Spring, Compression, Red Bumper 0 Bolt 0 0 Washer, Flat Hubstrut, LH Hubstrut, RH 00 Ring, Retaining Bearing, Hubstrut 000 Fitting, Lubrication Nut, Nylok - - - - - - - Asm., Front Brake Caliper, LH (See Front Brake Pg. B for Details) 0 Washer, Spring Lock Screw 0 00 Clamp, Rubber Coated Washer 0 Strut, Front /0 B
HANDLEBAR and HEADLIGHT POD E 00 Polaris Sales Inc. 0 0 0 C
HANDLEBAR and HEADLIGHT POD 00 Switch, Worklight, On/Off -00 - Pod, Headlight, Upper, Camo Grn (AK) Pod, Headlight, Upper, Sonic Blue (AN) 0 Bezel 0 Asm., Cluster Mount, Rubber Screw - - - - - - - Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B, Ref. ) 0 Knob, Adjusting 0 Rod, Adjusting 0 00 Cable Tie 0 Clip, Screw 0 O-Ring 00 Nut, Choke Cover, Key 000 00 00 Switch, Key, Position (Incl. Key) Blank, Key, Series 000, 00, 00, 00 Blank, Key, Series 00, 00, 00, 00 NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. - Pod, Headlight, Lower, Black Metallic Screw Cap, Hall Sensor 00 Sensor, Hall Effect 0 Nut, Nylok 0 Cable, Choke 00 Receptacle, Pod Mount, V Screw -0 Bracket, Pod Mounting, Black Block, Handlebar Block, Handlebar, Pegged - - - - - - - Asm., Master Cylinder (See Controls Pg. B for Details) Plug, Hole Screw, Set 0-00 Grip, Handlebar, Black 00 Switch, Handlebar, Hi/Lo/Off 0 Spacer, Switch, LH -0 Tube, Handlebar, Black Screw 0 00 Asm., Headlamp Bulb, Headlight /0 C
FRONT WHEEL E 00 Polaris Sales Inc. 0 0 Tire, Front, x- 0-0 0- Rim, Front, Black (AK) Rim, Front, Silver (AN) Cover, Dust, Hub 0 Pin, Cotter 00 Washer 0 Hub, Wheel Stud Disc, Brake, Front Bolt 0 0 Nut, Slotted 0 Valve, Rim Nut, Flange /0 C
TAILLAMPS/WORKLAMPS/HEADLIGHTS E 00 Polaris Sales Inc. 0 0 0 Asm., Taillight, LH Asm., Taillight, RH 00 Nut, Push-On Screw 0 U-Nut 0 0 Asm., Headlight, LH Asm., Headlight, RH C 00 Bulb, Bumperlight 00 Socket, Worklight 00 Bulb, Worklight 00 Socket, Taillight 0 00 Bulb, Tail/Stop /0
A-ARM/STRUT MOUNTING E 00 Polaris Sales Inc. 0 0 - - - - - - - Support Hubstrut (See Front Strut Pg. B, Ref. ) 00 Joint, Ball Bracket, Ball Joint 0 Boot, Rubber Bolt, Socket 0 0 Kit, A-Frame, LH (Incl.,,,,) Kit, A-Frame, RH (Incl.,,,,) Nut, Castle 0 Pin, Cotter 0-00 0-00 Shield, CV Joint, Black, LH Shield, CV Joint, Black, RH 0 0 Screw 0 Bolt 0 Washer Nut C 0 Boot, Seal, Rod End 00 Rod End, LH 0 Nut, Jam, LH Tie Rod Nut, Jam 00 Rod End, RH 0 Boot, Seal, Rod End Asm., Tie Rod (Incl. -0) Screw Nut, Nylok Screw 0 Washer, Spring Lock Washer 0 Shaft, A-Arm Bushing, A-Arm, Long /0
STEERING POST E 00 Polaris Sales Inc. 0 0 Bolt Bracket, Upper Bushing, Upper 0-0 Post, Steering, Black Bushing Flangette Bearing Nut, Slotted, Hex Pin, Cotter 0 Nut, Flange /0 C
GEAR SELECTOR E 00 Polaris Sales Inc. 0 Nut, Nylok Bolt 0 Asm., Linkage Rod 0-0 Selector, Gear, Black Nut, Nylok 00-0 Trim, Edge C 0 Mount, Gear Selector Bolt, Flange 00 Knob, Gear Selector 0 0 Screw 00 Cover, Shift Knob /0
DRIVE CLUTCH E 00 Polaris Sales Inc. 0 Asm., Drive Clutch, EBS, Wide (Incl. All Less,) 0 Clutch, One Way Drive 0 Washer, Brass Spacer 0 Nut, FLEXLOC Button, Clutch, Stemless 00 Pin, Roller Bearing 0 Nut, Jam 0 Cover, Bearing 0 0 Screw 0 Spring, Clutch Roller and Bushing 0 Washer, Multilube Bolt, Shoulder 0 Weight, Shift, 0-MH 0 Washer, Thrust /0 C
DRIVEN CLUTCH E 00 Polaris Sales Inc. 0 0 AR Bushing 0 Asm., Driven Clutch, EBS (Incl. -,-) 0 Washer, Domed 0 Washer, Spring Lock Bolt 0 Ring, Retaining Plate 0 Washer Bearing, Moveable 0 Roller, Taper Screw 0 Belt, Drive 0 Bearing Washer 0 Spring, Driven Ramp, Stationary 0 Spacer /0 C
CLUTCH COVER E 00 Polaris Sales Inc. 0 0 Kit, Inner Clutch Cover (Incl. ) Asm., Bolt/Washer Seal, Cover, Clutch, Outer -00 Cover, Clutch, Outer, Black 0 O-Ring Plug, Drain Boot, Duct 000 Clamp, Narrow Band 0 Duct, Clutch Outlet (If built before //0) Duct, Clutch Outlet (If built after //0) 0 Decal, Automatic Transmission, EBS Decal, Warning, Clutch Cover 0 Screw Screw -0 Bracket, Retainer, Seal, Black Seal, Cover, Clutch, Inner Stopper, Inner Clutch Cover /0 C0
REAR SUSPENSION E 00 Polaris Sales Inc. 0 0 0 0 C
REAR SUSPENSION Bolt, Flange Nut, Flange Washer Bushing, Stabilizer Tube -0 Bar, Stabilizer Tube, Black 00-0 Arm, Stabilizer Bar, Black Screw Washer Bushing, Stabilizer, Link 0 00 Rod, Linkage, Stabilizer 0 Carrier, Wheel Bearing Bushing, Bearing Carrier 0 Bushing, Control, Lower Washer, Lock 0 Washer Bolt Screw 0 Nut, Nylok 000 Shock, Rear 0 0 Cam, Adjusting, Spring 00-0 Spring, Compression, Rear, Black 0 Retainer, Spring Screw 00 Shaft, A-Arm, Short 00-0- Arm, Control, Upper, Red, LH Arm, Control, Upper, Red, RH 0-0 Strap, Black 0 Washer, Spring Lock Screw Washer 0 Bushing, A-Arm, Long 0-0- Arm, Control, Lower, Red, LH Arm, Control, Lower, Red, RH 0 Screw 0-0 -0 Shield, CV, Rear, LH Shield, CV, Rear, RH 0 Shaft, A-Arm Bolt Bushing, A-Arm, Short 0-0 Support, Stabilizer, Black /0 C
REAR WHEEL DRIVE 0 E 00 Polaris Sales Inc. Tire, x- 0-0 0- Rim, Rear, Black (AK) Rim, Rear, Silver (AN) Cover, Dust, Hub 00 Nut, Castle 0 Pin, Cotter Washer, Cone Hub, Rear Wheel Stud C 00 Ring, Retaining 0 0 Bearing - - - - - - - Carrier, Wheel Bearing (See Rear Suspension Pg. C, Ref. ) Bolt Disc, Brake, Rear 0 Valve, Rim Nut, Flange /0
ELECTRICAL 0 0 E 00 Polaris Sales Inc. Box, Battery Washer, Flat Bolt 000 Battery Strap, Battery Holddown 00 Kit, Battery Bolt 0 Cable, Battery/Frame Nut, Hex, Jam 0 Washer, Spring Lock 0 00 Switch, Magnetic 0 AR Tube, Vent 00 Cable, Battery/Solenoid 0 Screw 00 Cable, Solenoid/Starter 00 Mount, Cable Tie 00 Clip, Rosebud 00 Cable Tie 00 Cable Tie 00 Bolt 0 Nut, Nylok 00 Coil, Ignition 0 Screw 00 Controller, Ignition 00 Module, Controller 0 Harness, Winch 0 Harness, Main 00 Module, Resistor /0 C
TRANSMISSION MOUNTING E 00 Polaris Sales Inc. 0 000- AR Line, Fuel 00 T-Fitting 000 Clamp, Hose 00 Clip, Snap In Nut, Nylok Screw D 0-0 Mount, Rear Engine, Black Screw Bolt, Flange 0 Bracket, Mount, Rear Transmission Nut, Flange Bolt, Carriage /0
GEARCASE E 00 Polaris Sales Inc. 0 0 0 0 0 0 0 0 0 D
GEARCASE Asm., Main Gearcase Nut Screw Cover Gasket Pawl, Detent O-Ring Shaft, Shift Seal Gear, T 0 Gearcase, Main Tube, Vent Label, Oil Fill/Level Check 0 Bearing 0 Chain, Silent 0 Shaft, Input 0 Bearing Plug Cover, LH Seal 0 0 Screw Bracket, Mount 0 Drum, Shift O-Ring Fork, Shift Pin, Dowel 0 Rail, Shift Shaft Plate, Park 00 Engagement Dog Spring, Wave 0 Engagement Dog 0 Ring, Retaining Washer Gear, T Bearing, Needle Shaft, Reverse Sprocket, T Washer 0 Gear, T Gear, T 0 Gear, T 0 Screw Cover, Bearing 0 Ring Spacer 0 Bearing, Ball 0 Shaft, Pinion, 0T Washer, Thrust Sprocket, T/T Gear, T 0 Shaft, Output, Main, Rear Button, Thrust Shim Shim 0 Cover, Output, Front Screw Shaft, Output, Front Chain, Silent Sprocket, T Bushing 0 0 Clamp, Tie Lockout, Park Pin, Dowel 0 Nut Gear, T Disc, Lockout 0 Star, Detent 0 O-Ring 0 Spring, Compression Switch 0 Ring, Retaining 0 Bellcrank /0 D
FRONT HOUSING E 00 Polaris Sales Inc. 0 0 Asm., Front Gearcase Kit, Bolt Screw, Set Asm., Cover Plate (Incl. Output Cover, Insert and Coil) Shim, Armature Plate Bearing, Roller Ball Asm., Race/Output Hub (Incl. ) Pin, Dowel Clutch Housing/Ring Gear - - - - - - - Asm., Roll Cage (Incl. Spring and Roll Cage) Spring Kit, Roller 0 Bushing 000 Clamp, Hose 000 AR Line, Fuel 0 Screw D 00 Clamp, Hose Kit, Minor Repair (Incl. O-Rings and Seals) Screw Cover, Input Bearing, Roller Ball Shaft, Pinion, T 0 - - - - - - - Bushing - - - - - - - Gearcase, LH Plug, Oil Fill Bolt, Flange Asm., Drain Plug (Incl. Plug and Washer) Bearing, Needle, Roller Thrust Asm., Clutch (Incl. -) Ring, Retaining, Internal 0 Plate Armature /0
REAR GEARCASE E 00 Polaris Sales Inc. 0 Asm., Gearcase, Rear Screw Tube, Vent Cover, Rear, LH Pin, Dowel Bearing, Ball Gearcase, Rear, RH 0 Plug Seal 00 Seal, Triple Lip 0 Ring, Retaining Bearing, Ball Shaft, Pinion, 0T Bushing Gear, T AR Shim Button, Thrust AR Shim /0 D
REAR GEARCASE MOUNTING E 00 Polaris Sales Inc. Bolt, Flange Screw Screw D 0 Washer, Flat 00 Nut, FLEXLOC 0 Nut, Flange /0
CRANKCASE 0 0 E 00 Polaris Sales Inc. Seal, Flanged Bearing, Ball Bushing Bearing, Ball 00 Plug Dowel 0000 Plug 0 Ring 0 Asm., Crankcase (Incl. -) 0 Bearing Gasket Seal, Oil 0000 Cover, Magneto 0 Screw D Seal 0 Bearing, Main Journal 00 Plug, Magnetic Washer, Copper 00 Plug 0 Screw Screw 00 Pin, Dowel Baffle 0 Screw 0 Screw 0 Pickup, Oil 0 O-Ring /0
CRANKSHAFT and PISTON E 00 Polaris Sales Inc. 0 0 Kit, Piston (Incl.,,) 0 Circlip, Piston - - - - - - - Pin, Piston 0 Kit, Piston Ring (Incl. Control, Iron, and Chrome Rings) 0 Kit, Crankshaft 00 ATV (Incl., from Crankcase Pg. D, Ref.,,,) Key, Woodruff 0 Gear, Set Screw Washer 0 Key, Woodruff Shaft, Balance /0 D
CYLINDER and CYLINDER HEAD E 00 Polaris Sales Inc. 0 0 D
CYLINDER and CYLINDER HEAD Screw Cover, Breather 0 Reed w/gasket Screw 0 Cover, Rocker Seal Bolt Gasket, Exhaust 0-0 Manifold, Exhaust 0 Screw 0 Head, Cylinder Guide, Valve Gasket, Head 0 Kit, Cylinder (Incl. ) 0 Gasket, Base 0 Plug Dowel - - - - - - - Asm., Carburetor (See Carburetor Pg. D, Ref. ) 00 Clamp, Hose Screw 0 Adapter, Carburetor 00 Spark Plug, RCYC Screw 0 Cover, Thermostat 0 Thermostat O-Ring 00 00 Sensor, Thermister (If built before 0/0/0) Sensor, Thermister (If built after 0/0/0) 0 Fitting /0 D0
CARBURETOR 0 E 00 Polaris Sales Inc. 0 0 0 0 D
CARBURETOR 00 Ring 00 E-Ring 0 Needle, Jet 0 Ring 0 Diaphragm Jet, Needle, P- 0 Screw 00 Washer, Spring - - - - - - - Asm., Jet Block 0 00 Washer 0 Jet, Main, #. 0 Cap 0 Seal 0 Packing - - - - - - - E-Ring 0 Cap 0 Pin, Float 0 Plate 0 O-Ring 0 00 Screw 00 Asm., Float Body 0 Screw 0 Asm., Float 0 Screw 0 Valve, Needle (.) 0 O-Ring Jet, Pilot, # 0 O-Ring 0 Washer 0 0 Spring 0 Adjuster 0 Screw, Adjust 0 Ring 0 Spring - - - - - - - Valve, Throttle (00) Spring 0 Ring - - - - - - - Screw - - - - - - - Asm., Throttle Shaft 0 0 Guide, Cable 0 Screw 0 Cover 0 O-Ring Holder, Guide 0 Spring Asm., Plunger 0 Jet, Air, #0 Asm., Carburetor, 00 (Incl. -) Spring, Compression 0 00 Asm., Cover 0 Screw /0 D
INTAKE and EXHAUST E 00 Polaris Sales Inc. 0 0 Asm., Rocker Arm 0 Pushrod 0 Kit, Camshaft (Incl. ) Plate, Thrust Screw 0 Kit, Gear Set, Twin, -Stroke 0 Spring, Compression Washer, Spring Screw 0 Lifter, Valve Valve, Exhaust Valve, Intake Seal, Valve Guide 0 Spring, Valve Retainer, Spring 00 Lock, Valve Stem /0 D
OIL DIPSTICK E 00 Polaris Sales Inc. 0 Asm., Dipstick 0 Tube, Oil Fill Screw 0 Clamp O-Ring /0 D
WATER PUMP E 00 Polaris Sales Inc. 0 Shaft, Oil/Water Pump 0 Bearing, Ball 0 Ring, Retaining - - - - - - - Kit, Gear Set, Twin, -Stroke (See Intake and Exhaust Pg. D, Ref. ) Impeller Washer, Flat E 0 Nut, Hex, Nylok Screw 0 Screw 0 Cover Seal, Water Pump 00 Seal, Water Pump /0
OIL PUMP 0 E 00 Polaris Sales Inc. 0 00 Filter, Oil (If built before 0/0/0) Filter, Oil (If built after 0/0/0) 0 Nipple, Oil Filter 0 Screw Housing, Oil Pump 0 Gerotor Pin, Dowel 00 Spring 00 Washer Screw 0 0 Kit, Oil Pump (Incl.,, from Water Pump Pg. E, Ref.,,) /0 E
MAGNETO E 00 Polaris Sales Inc. 0 Holddown, Wire 00 Asm., Stator Screw Screw 00 Asm., Flywheel 0 Washer Nut O-Ring 0 Cover, Stator 0 Cover, Sound 0 Cover, Outer 0 0 Screw /0 E
STARTING MOTOR E 00 Polaris Sales Inc. Screw 00 Starter 0 Washer, Thrust 00 Bendix Washer, Lock 0 Nut Bolt /0 E
TOOL KIT E 00 Polaris Sales Inc. Kit, Tool (Incl. -) 0 Gauge, Tire Pressure - - - - - - - Screwdriver - - - - - - - Wrench, -0 Open - - - - - - - Wrench, / x / Open - - - - - - - Wrench, Plug - - - - - - - Puller, Spark Plug (Wrench Handle) Pouch, Tool Kit Owner s Manual, 0 Sportsman ///00 Wrench, Torx /0 E
PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN 0 /0