Polaris Sportsman-6x6 Parts Manual 2004

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PARTS MANUAL PN 9918628 and MICROFICHE PN 9918629 7/03

E 2003 Polaris Sales Inc.

SPORTSMAN 6X6 Model #A04CL50AA

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TABLE OF CONTENTS SPORTSMAN 6X6 A04CL50AA Parts Manual

C

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .

CONTROLS - MASTER CYLINDER/BRAKE LINE . . . . . . . . . . . .

CONTROLS - RH MASTER CYLINDER/BRAKE LINE . . . . . . . . . . . .

CONTROLS - THROTTLE ASM./CABLE . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . .

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT and PISTON . . . . . . . . . . . . .

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .

D7-8 C6

B9 B7 A7 D3 D4 D5-6

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . .

DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . .

DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . .

DUMP BOX . . . . . . . . . . . . . . . . . . . . . . . . .

A5 C3 A14 C4 C10

H

HANDLEBAR and HEADLIGHT POD . . . . . . . D1-2

I

INTAKE and EXHAUST . . . . . . . . . . . . . . . . . D9

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B8

G

GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C13-14 GEARCASE MOUNTING . . . . . . . . . . . . . . . C8 GEARCASE SELECTOR MOUNTING . . . . . . C12

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A

A-- ARM/STRUT MOUNTING . . . . . . . . . . . . . B5 AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . C5

D

E

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . C9 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A9-10 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A8

F

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FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . .

FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .

FRONT HOUSING . . . . . . . . . . . . . . . . . . . .

FRONT RACK and BUMPER MOUNTING . . .

FRONT STRUT . . . . . . . . . . . . . . . . . . . . . .

FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .

G

B4 A3 B1 A6 B2 B3 E2 A11

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C11

M

MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . D14 MIDDLE DRIVE . . . . . . . . . . . . . . . . . . . . . . B11

O

OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D13 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D12 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . A12

P

PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . A13

R

REAR and MIDDLE WHEEL . . . . . . . . . . . . .

REAR BRAKE CALIPER . . . . . . . . . . . . . . . .

REAR CAB and SEAT . . . . . . . . . . . . . . . . .

REAR CALIPER MOUNTING . . . . . . . . . . . .

REAR DRIVE . . . . . . . . . . . . . . . . . . . . . . . .

REAR STRUT STABILIZER . . . . . . . . . . . . . .

RECOIL STARTER . . . . . . . . . . . . . . . . . . . .

B14 B10 A4 C7 B12 C1 D10

STARTING MOTOR . . . . . . . . . . . . . . . . . . .

STEERING POST . . . . . . . . . . . . . . . . . . . . .

SWING ARM WELDMENT (REAR) . . . . . . . .

SWING ARM/SHOCK MOUNTING . . . . . . . .

E1 B6 C2 B13

S

T

TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E3

W

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D11

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

FRONT CAB SPORTSMAN 6X6 A04CL50AA

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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.

1 5811491 2 5810996 3 2632663-400 2632782-400 5812138 4 7512232 5 5435110-400 6 2632146-400 7 7670057 8 7670135 9 7517312 10 5431798-070 5431799-070

Qty.

1 1 1 1 1 14 1 1 12 4 2 1 1

Description

Foil, Side Panel, GEN IV, RH Foil/Foam, Side Panel Panel/Foam, Camo Green, LH Panel/Foil, Camo Green, RH Foam, Panel, LH Screw Cover, Front, Camo Green Cab w/Warning Decals, Front, Green Nut, U-Type Speed Nut, Speed Screw Guard, Mud, Front, LH Guard, Mud, Front, RH

Ref. Part No.

11 12 13 14 15 16 17 18 19 20

7541925 7555792 7556034 7512085 7555931 7542122 5412191 7670109 7621509 5246315-067 5246316-067

Qty.

2 2 2 2 2 2 1 1 3 1 1

Description

Nut, Nylok Washer Washer Screw Washer, Flat Nut, Nylok Line, Breather Clip, Routing Rivet Guard, Splash, LH Guard, Splash, RH 7/03

A3

REAR CAB and SEAT SPORTSMAN 6X6 A04CL50AA 3

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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.

1 2 3 4 5

4 1 4 4 1 1 8 1 3 2 2 1 2 1 2 2 1 8

Description

Rivet Cab, Rear, Green Screw Washer, Flat Asm., Seat, Black (Incl. 6) Covering, Seat, Black Bumper, Rubber Frame, Main Bumper, Rubber Bolt Plug Lever, Box Nut Spring Washer, Flat Nut, Nylok Spacer, Footwell Nut, Nylok

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7661645 5433428-400 7512242 7555859 2682959-070 2682960-070 5412067 1013967-067 5410414 7512240 5432798 1013307-067 7542153 7041879 7555734 7542324 5432280 7542122

Qty.

Ref. Part No.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

7512392 1040293-067 7512279 7517377 5432221-070 5434417-070 7512232 5433429-070 5433430-070 7670057 5811111 5811106 5811087 7079902 7541925 7555792 7556034 7512085

Qty.

2 1 6 2 1 1 12 1 1 12 1 2 1 1 2 2 2 2

Description

Screw Mount, Strut, Rear Screw Screw Footwell, Black, LH Footwell, Black, RH Screw Guard, Mud, Rear, LH Guard, Mud, Rear, RH Nut, U-Type Speed Foil, Foam, Rear Fender Foil, Rear Cab, Front Foil, Foam Decal, Carb/Filter Information Nut, Nylok Washer Washer Screw 7/03

A4

DECALS SPORTSMAN 6X6 A04CL50AA 1

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RH

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LH

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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.

1 7171493 2 7170997 7170998 3 7170995 7170996 4 7078254 5 7171488 7171489 6 7078003 7 7079780 8 7078465

Qty.

2 1 1 1 1 1 1 1 1 1 1

Description

Decal, “SPORTSMAN 6X6”, Box Side Decal, Side Panel, Middle, LH Decal, Side Panel, Middle, RH Decal, Side Panel, Top, LH Decal, Side Panel, Top, RH Decal, Age Warning Decal, “SPORTSMAN”, Tank Side, LH Decal, “SPORTSMAN”, Tank Side, RH Decal, Headlight Adjustment Decal, Warning, AWD Switch Emblem, Star

Ref. Part No.

9 10 11 12 13 14 15 16

7079773 7079295 7078577 7171490 7171491 7079604 7079316 7079293 7079292

Qty.

1 1 1 1 1 1 1 1 1

Description

Decal, “POLARIS”, Front Cover Decal, Warning, Front Rack, 75 LBS. Decal, Drain Recoil Decal, “6X6”, Side Panel, LH Decal, “6X6”, Side Panel, RH Decal, Warning, Override, AWD Decal, Warning, Container/Passenger Decal, Tire Pressure Decal, Discretionary Warning 7/03

A5

FRONT RACK and BUMPER MOUNTING SPORTSMAN 6X6 A04CL50AA

1 2 5 3

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14

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18

21

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4

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.

3 4 5 6 7 8 9 10 11 12

7079926 7515399 1014023-067 7542324 7555954 5432155-070 7515391 7515390 7512232 1013744-067 1013746-067

Description

4 Screw 1 Asm., Front Rack (Incl. Ref. 3 and Warning Decal) 2 Decal, Reflector, Amber 8 Screw 1 Support, Front Rack 4 Nut, Nylok 4 Washer 1 Bumper 2 Screw 2 Screw 6 Screw 1 Support, Front Rack, LH 1 Support, Front Rack, RH

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1 7517685 2 2632340-070

Qty.

Ref. Part No.

13 2431014 2431015 4030059 14 7512329 15 7558402 16 5810467 17 5244729-067 5244730-067 18 1013772-067 19 7670094 20 7512097 21 5433923 5433924

Qty.

1 1 2 2 2 1 1 1 1 6 6 1 1

Description

Headlight, LH Headlight, RH Bulb, Replacement, 27W Bolt Washer, Flat Plug, Frame Extension, Frame, LH Extension, Frame, RH Guard, Brush Nut, U-Type Screw Shield, Side, Radiator, LH Shield, Side, Radiator, RH 7/03

A6

COOLING SYSTEM SPORTSMAN 6X6 A04CL50AA 6

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28

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32

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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.

7080614 1240044 5433364 5243505 7661637 5433948 5411811 7080827 7512084 5411632 7080826 7517659 2410430 7670111 7547069 3110032 5020572 5433059

2 1 1 1 3 1 1 2 4 1 2 4 1 4 2 2 2 1

Description

Clamp, Hose Cap, Pressure Filler, Coolant Bracket, Filler, Coolant Rivet Flexguard Hose, Engine, Upper Clamp, 1 Inch Screw Hose, Neck, Filler Clamp Screw Asm., Fan and Motor U-Clip Nutsert Mount, Rubber Spacer Shroud, Fan

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Qty.

Ref. Part No.

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

4010161 1240178 7552801 7512240 7052296 5411633 5410584 5243503-067 7512232 5411694 5521511 5430743 5810279 5433774 5433410 8450003-1525 7052065

Qty.

1 1 2 2 1 1 2 1 2 1 1 1 1 1 1 1 1

Description

Sensor, Thermal Radiator Washer, Split Lock Screw Valve, Drain O-Ring Bushing, Mount Bracket, Radiator, Lower Screw Hose, Engine, Lower Guard, Hose Cap, Overflow, Drilled Gasket, Overflow Cap Plug, Cap Tank, Surge Line, Fuel Fitting, Barbed, 90 Degree 7/03

A7

EXHAUST SYSTEM SPORTSMAN 6X6 A04CL50AA 1

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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.

1 2 3 4 5 6 7 8 9 10 11

7515316 5410241 7555863 5010192 1260989-029 7041804 5412067 7517386 5246408 1261245-029 5243518

Qty.

2 2 2 2 1 4 1 1 1 1 2

Description

Bolt, Carriage Dampener, Vibration Washer Bushing Silencer Spring, Exhaust Bumper, Rubber Screw Bracket, Support, Side Panel Pipe, Exhaust Seal, Exhaust

Ref. Part No.

12 13 14 15 16 17 18 19 20 21 22

7512232 5242344 7542301 3110064 7042029 5244014 7517615 7512666 5410436 7555716 7542324

Qty.

2 1 1 1 1 1 2 2 2 2 2

Description

Screw Bracket, Exhaust Nut Mount, Torque Stop Spring, Exhaust Shield, Heat Screw Bolt Washer, Rubber Washer, Flat Nut, Nylok 7/03

A8

ENGINE MOUNTING SPORTSMAN 6X6 A04CL50AA

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18 46 18

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39

2

27

38

24

13

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A9

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1

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26

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37

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21 22

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15

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1

40

14

29

30

31

ENGINE MOUNTING SPORTSMAN 6X6 A04CL50AA Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

7547108 7555801 4010132 7512232 3110044 5242674 7552901 7512315 7080003 8450040-600 8450003-1525 7052075 3084205 5246553 7541923 7512247 -------

6 4 1 1 1 1 2 2 4 AR AR 1 5 1 2 2 1

18 19 20 21 22 23 24 25 26 27

8360009-600 8450103 8450105-18 1012883-067 7547089 3110046 7517289 7555815 5410421 7080511

AR AR 1 1 2 2 1 2 1 1

Description

Nut, Flange Washer, Wrought Cable, Ground/Engine Screw Mount, Rubber, Top Bracket, Mount, Engine, Top Washer, Spring Lock Bolt Clamp, Hose, Red Line, Fuel Line, Fuel Fitting, Tee Screw and Washer Bracket, Carburetor Mount Nut, Well Screw Asm., Carburetor (See Carburetor Pg. D8, Ref. 32) Line, Fuel Hose, Fuel Sheath, Reflect Sleeve Mount, Rear Motor Nut, Flange, Lock Mount, Rubber Screw Washer Boot, Clutch Intake Clamp, Narrow Band

Ref. Part No.

28 29 30 31 32

Qty.

Description

5430261 5210748 7575202 7512566 -------

1 1 1 1 1

33 - - - - - - -

1

34 35 36 37 38 39 40 41 42

1040688-067 7515398 7542324 3110067 7080474 7552603 7515417 -------------

1 2 2 1 2 1 1 2 2

43 1261171-029 44 - - - - - - -

1 1

45 3085556

1

46 7051011

1

Bushing Washer, Flat Washer, Interlock Bolt Asm., Drive Clutch (See Drive Clutch Pg. C3 for Details) Bracket, Retainer, Seal (See Clutch Cover Pg. C6, Ref. 19) Mount, Engine Screw Nut, Nylok Mount, Motor Clamp, Hose Washer, Spring Lock Screw Nut (See Cylinder Pg. D6, Ref. 23) Washer, Lock (See Cylinder Pg. D6, Ref. 22) Manifold, Black Gasket, Exhaust (See Cylinder Pg. D6, Ref. 20) Engine, Short Block (EH50PLE10) NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization required for warranty consideration.

Valve, Check

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Qty.

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Ref. Part No.

A10

7/03

FUEL TANK SPORTSMAN 6X6 A04CL50AA 1 2 3

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21

20

8 9 10

12

19

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13

13

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17

12

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12

13

14

16

13

12

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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.

1 2 3 4 5 6 7

5435324 5812123 5811310 8360009-600 5431053 7517685 5222154 5222155 8 7052161 9 5432733 10 5432559

Qty.

1 1 1 AR 1 2 1 1 1 1 1

Description

Cap, Gas Tank Gasket, Fuel Cap Seal, Foam Line, Fuel Vent, Tank Bolt Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH Valve, 3-Way Nut, Fuel Valve Knob, Fuel Valve

Ref. Part No.

Qty.

11 12 13 14 15 16 17 18 19 20 21

1 6 AR 1 1 1 1 1 2 1 1

7517505 7080003 8450103 5812005 7052349 2530009 8450105-15 7052289 7052028 5812004 2520361

Description

Screw Clamp, Hose, Red Hose, Fuel Foil Fitting, Outlet, Main, 90 Degree Filter, Fuel Sheath, Reflect Sleeve Fitting, 90 Degree Grommet Foil Asm., Fuel Tank (Incl. 15,18) 7/03

A11

OIL TANK SPORTSMAN 6X6 A04CL50AA

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18

12

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16

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7515189 7558301 5412191 5410828 5333204 7555932 7542122 5434308 7080699

Qty. Description

2 2 1 2 2 2 2 1 1

14

15

1

Ref. Part No.

13

Screw Washer, Flat Line, Breather Grommet Bushing, Mounting Washer, Nylon Nut, Nylok Dipstick Clamp

5

4

2

Ref. Part No.

10 11 12 13 14 15 16 17 18

8450073-25 7080474 8450096-17 7081026 7052326 5411042 5850135 7051524 1261176

6

7

Qty. Description

1 2 1 1 1 1 1 1 1

Line, Breather Clamp, Hose Line Clamp Screen, Oil Filter, 90 Degree Grommet Washer, Nylon Plug Tank, Oil 7/03

A12

PROP SHAFT SPORTSMAN 6X6 A04CL50AA

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2

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7

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4

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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.

1 2 3 4 5 6

7512232 7558301 5433154 5411092 7080424 3260131

Qty.

2 2 1 1 1 1

Description

Screw Washer, Flat Guard, Prop Shaft, Front O-Ring Fitting, Lubrication Yoke, Prop Shaft, Transmission

Ref. Part No.

7 8 9 10 11

1350072 2202015 3260133 1380217 7661913

Qty.

1 2 1 1 1

Description

Shaft, Prop Kit, Cross and Bearing Yoke, Front Gear Case Asm., Prop Shaft, Front(Incl. 6-9) Pin, Spring 7/03

A13

DRIVE SHAFT

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SPORTSMAN 6X6 A04CL50AA

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1

7

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9

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10

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.

1 2 3 4 5

1380215 1380190 3260121 7670092 2201015

Qty. Description

1 1 1 1 1

Asm., Drive Shaft, Front Joint, CV Clamp, Band Circlip Kit, Replacement Boot

Ref. Part No.

6 7 8 9 10

1380223 2202015 3260133 7661913 3260123

Qty. Description

1 1 1 2 1

Shaft, Drive (Incl. 4) Kit, Cross and Bearing Yoke, Front Pin, Spring Clamp, Band 7/03

A14

FRONT HOUSING SPORTSMAN 6X6 A04CL50AA

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9

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15

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6

3 1

2

4

17

7

18

24

5

25

19

20

26

27

21 2

1

23

22

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.

1 12 2 1 1 1 1 1 1 1 1 1 1 AR

Description

Asm., Front Gearcase (Incl. 1-12,15-25) Screw Seal Cover, Input, Front Housing O-Ring Ring, Retaining Bearing Pinion, Input, 14T Bushing Seal, Oil Bushing Washer Plug Line, Fuel

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1341323 3233252 3233248 3233701 3233700 3233699 3233589 3233726 3233541 3233319 3233697 3233324 3233711 8450003-1525

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13

Ref. Part No.

Qty.

14 15 16 17 18 19 20 21 22 23 24 25 26 27

1 1 1 1 1 AR 1 1 AR 1 1 1 4 4

7080307 3233524 3233696 3233725 3233020 3233554 3233693 3233724 3233583 3233582 3233254 3233253 7552603 7512492

Description

Clamp, Hose Tube, Vent Gearcase, Front Housing Shaft, Output, 29T Bearing, Ball Shim O-Ring Cover, Output Shim Button, Thrust Washer Plug, Drain Washer, Spring Lock Screw 7/03

B1

FRONT STRUT SPORTSMAN 6X6 A04CL50AA

27 26 25

1

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24

6

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7

8

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5

22

4

23

11

21

4

20

12

9

19

14

10

18

13

12

15

17

11

16

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.

5411608 7041761 5211115 7558402 7080367 7542324 7512365 7552901 5810439 -------

2 2 2 10 2 4 4 4 2 1

11 12 13 14 15

3554509 3554507 5222193 7080306 2410133

4 4 2 2 2

Ref. Part No.

Bumper Strut, Front Washer Washer, Flat Clamp, Cable Nut, Nylok Screw Washer, Spring Lock Retainer, Casting Wire, Strut Asm., Front Brake Caliper, RH (See Front Brake Pg. B4 for Details) Bearing, Tapered Roller Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal Fitting, Lubrication Coil, Magnetic

16 1820954

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1 2 3 4 5 6 7 8 9 10

Description

1820955

17 18 19 20 21 22

7041450-067 5243364 5432871 7515339 5132062 -------

23 24 25 26 27

3610028 5432872 5810291 7555749 7547104

Qty.

Description

1 Asm., Hubstrut, Heavy, LH (42mm) (Incl. 9,12-15,23) 1 Asm., Hubstrut, Heavy, RH (42mm) (Incl. 9,12-15,23) 2 Spring, Compression 2 Retainer, Spring 2 Ball, Pivot, Bottom 4 Bolt 2 Spacer 1 Asm., Drive Shaft (See Drive Shaft Pg. A14 for Details) 2 Seal, Hubstrut 2 Ball, Pivot, Top 2 Spacer, Rubber 2 Washer 2 Nut, Nylok 7/03

B2

FRONT WHEEL SPORTSMAN 6X6 A04CL50AA

1

2

4

12 13

11

10

14

5 6

7

om

3

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

9

8

E 2003 Polaris Sales Inc.

15

16

25

7

24

6

17

19

18

20

21

23

22

W or

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.

1 2 3 4 5 6 7 8 9 10 11 12 13

7512325 5243676 3610019 5211148 1520281 3554506 3554507 7515513 1520243 3250028 3250010 3250032 1321814

Qty.

8 2 2 2 2 4 4 8 2 2 12 2 2

Description

Bolt Disc, Brake Seal, Front Hub Plate, Armature Clutch, Front Hub, Elec./Mech.

Bearing, Tapered Roller Cone Bearing, Tapered Roller Cup Stud Asm., Hub w/Bearing Race (Incl. 3,7,8) Cage, Roll Roll Spring, Garter Spacer

Ref. Part No.

14 15 16 17 18 19 20 21 22 23 24 25

3250030 7052045 5410947 7556004 7542810 7661401 5410470 5432611 7512027 7547237 1520269-117 1525017

Qty.

2 2 2 2 2 2 2 2 6 8 2 2

Description

Cam Plug, Magnetic Drain Tire (25x8-12) Washer Nut, Slotted Pin, Cotter O-Ring Cap, Hub Screw Nut, Flange Rim, Front, Aluminum Valve, Rim 7/03

B3

FRONT BRAKE SPORTSMAN 6X6 A04CL50AA

2

3

1

5

6

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

4

om

E 2003 Polaris Sales Inc.

13

12

11

10

9

8

7

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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.

1910692 1910693 7080352 7515489 5133412 5133413 1930642 5411596 5411597 5132405

1 1 1 1 1 1 1 1 1 1

1 2 3 4 5 6

Description

Ref. Part No.

Asm., Caliper, Brake, LH (Incl. 1-6,8,9) Asm., Caliper, Brake, RH (Incl. 1-6,8,9) Screw, Bleeder Screw, Socket Set Caliper, LH Caliper, RH Kit, Front Brake Boot Seal, Caliper, Inner Seal, Caliper, Outer Piston, Caliper

7 8 9 10 11

2202412 1910411 5410495 5410494 -------

12 - - - - - - 13 - - - - - - -

Qty.

Description

2 1 1 1 4

Kit, Front Brake Pad Mount, Caliper Boot, Bushing Boot, Pin Seal Washer (See Front Strut Pg.B2, Ref. 4) 4 Washer (See Front Strut Pg. B2, Ref. 8) 4 Screw (See Front Strut Pg. B2, Ref. 7) 7/03

B4

A-ARM/STRUT MOUNTING SPORTSMAN 6X6 A04CL50AA 3

1

4 5 6

2

7

8

om

9

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

28

E 2003 Polaris Sales Inc.

27

25

26 25

10

11 12 13

27

26

21

24

14

15

22

23

17

21

18

20

16

13

19

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.

7542439 1820805 5411291 7061034 7542711 5020926 7547028 7517909 7061054 5411920 7556099 7547177 7661203 7080927 5211121

2 2 2 2 2 2 2 2 2 1 4 2 4 2 2

Description

Ref. Part No.

Nut, Nylok Asm., Tie Rod (Incl. 3-9) Boot, Seal, Rod End Rod End Nut Tie Rod Nut, LH Bolt Rod End, LH Boot, Seal, Rod End Washer, Flat Nut Pin, Cotter Joint, Ball Bracket, Ball Joint

16 17 18 19

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Qty.

Qty.

24

7512284 5410548 7542438 5431150-070 5431149-070 7512084 5434551 5133806 2202282 2202283 --------

4 2 2 1 1 4 4 2 1 1 1

25 26 27 28

7512492 7552603 7555832 7515415

4 4 4 2

20 21 22 23

Description

Screw Boot, Rubber Nut, Castle Shield, CV Joint, LH Shield, CV Joint, RH Screw Bushing, A-Arm, Long Shaft, A-Arm Kit, A-Frame, LH (Incl. 13,21,22,25,26) Kit, A-Frame, RH (Incl. 13,21,22,25,26) Asm., Heavy Hubstrut (See Front Strut Pg. B2, Ref. 16) Screw Washer, Spring Lock Washer Screw 7/03

B5

STEERING POST SPORTSMAN 6X6 A04CL50AA

3

1

2

4

om

5

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

2

E 2003 Polaris Sales Inc.

5

11

6

1

7

8

10

6

W or

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.

1 2 3 4 5 6

7542324 5433866 1013920-067 5246732 7517428 7556162

Qty.

4 2 1 1 4 2

Description

Ref. Part No.

Nut, Nylok Bushing, Steering, Upper Post, Steering Bracket, Steering, Upper Bolt, Carriage Bushing

7 8 9 10 11

5222393 3514352 7547158 7661633 7558402

Qty.

1 1 1 1 2

Description

Flangette Bearing Nut Pin, Cotter Washer, Flat 7/03

B6

CONTROLS - THROTTLE ASM./CABLE SPORTSMAN 6X6 A04CL50AA

E 2003 Polaris Sales Inc.

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

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1

2

3

4

5

W or

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.

1 5410193 2 5434113 3 5411439

Qty. Description

Ref. Part No.

1 O-Ring 1 Cover 1 O-Ring

4 7080967 5 2010230 6 2010191

Qty. Description

1 Cable, Throttle 1 Asm., Throttle Control, AWD (Incl. 6) 1 Asm., Throttle Clamp 7/03

B7

CONTROLS - MASTER CYLINDER/BRAKE LINE SPORTSMAN 6X6 A04CL50AA

1 4

2 5

4

om

6

19

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

18

7

3

17

12

9

14

12

16

8

10

11

E 2003 Polaris Sales Inc.

13

15

14

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.

2010196 5411297 5410988 4110164 7517899 2201834

1 1 2 1 2 1

Asm., Master Cylinder Boot, Brake Line, Rubber Seal Switch Screw Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 1 Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring) 1 Kit, Master Cylinder Clamp (Incl. Clamp, Screws) 1 Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip)

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1 2 3 4 5

Qty. Description

6 2201836 7 2201833 8 2201835

Ref. Part No.

9 10 11 12 13 14 15 16 17 18 19

1910480 7621462 7080539 8360031-34 1910474 7080138 7512024 1910475 7052292 1910470 1910499

Qty. Description

1 3 3 2 1 8 2 1 1 1 1

Line, Brake, Rear, Stainless Steel Rivet Clamp, Nylon Conduit Line w/Fittings, Brake, Front, LH Cable Tie Screw Line, Brake, Stainless Steel, Front, RH Fitting, Cross Line, Brake, Stainless Steel, Pod Bolt 7/01

B8

CONTROLS - RH MASTER CYLINDER/BRAKE LINE

om

SPORTSMAN 6X6 A04CL50AA

4

E 2003 Polaris Sales Inc.

1

5

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

2 3

2

8

7

W or

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.

2010201 1910499 5410988 2202195 7517899

1 1 2 1 2

1 2 3 4

Description

Ref. Part No.

Asm., Master Cylinder Bolt Seal Kit, Lever Screw

5 2202196 6 2202194 7 2202193 8 1910481

Qty.

Description

1 Kit, Cover (Incl. Cap w/Glass, Baffle and Diaphragm) 1 Kit, Piston 1 Kit, Clamp 1 Line, Brake, Pod, RH 5/02

B9

REAR BRAKE CALIPER SPORTSMAN 6X6 A04CL50AA

1

3

om

2 5

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

4

E 2003 Polaris Sales Inc.

6

7

8

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.

Qty.

W or

Ref. Part No.

1 2 3 4

2201683 2201684 -------------------------

1 1 1 1 1 1

Description

Kit, Piston, Seals (Incl. 1-4,9) Kit, Seals (Incl. 2-4,9) Piston Seal, Dust Ring, Square Ring, Square

Ref. Part No.

5 6 7 8 9

1910408 2201428 7517758 2201749 -------

Qty.

1 2 2 1 2

Description

Asm., Caliper, Rear Kit, Bleeder Bolt, Shoulder Kit, Brake Pads O-Ring 6/02

B10

MIDDLE DRIVE SPORTSMAN 6X6 A04CL50AA

2

3

11 4

5

6

7

23

8 9

E 2003 Polaris Sales Inc.

12 10

13

14 15

16 17 18

om

1

18

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

23

19 20

22

21

24

10

25

28

17 16

9

8

7

6

5

4

21 26

27

3 2

1

23

23

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.

7710472 5510372 5411555 7547031 5630987 3610074 5132219 3515501 3610013 5132218 7542439 5244425 1520259 7710405

2 2 2 2 2 2 2 2 2 2 3 1 1 1

Description

Ref. Part No.

Ring, Retaining Retainer, Nut Seal, Foam Nut, Jam Hub, Locking Middle Axle Seal Housing, Swing Arm Bearing Seal, Axle, Rear Spacer, Bearing Nut, Nylok Disc, Brake Asm., Hub, Brake Disc, Locking Ring, Retaining

15 16 17 18 19 20 21 22 23 24 25 26 27 28

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Qty.

5010462 3610070 3554518 3554517 5132098 7080306 5410889 7515513 5411739 5132049 3221139 3221141 3221137-080 3221138

Qty.

1 2 2 2 1 1 2 3 4 1 1 1 1 1

Description

Spacer, Axle Seal, Lip Bearing, Cone Bearing, Cup Housing, Axle, Rear Fitting, Lubrication O-Ring Stud O-Ring Axle, Middle Sprocket, 38T Link, Connector Chain, 80P Sprocket, 30T 6/02

B11

REAR DRIVE SPORTSMAN 6X6 A04CL50AA

2

3

4

5

E 2003 Polaris Sales Inc.

6

om

1

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

7

8

9

6

5

4 3

10

11

W or

13

12

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.

1 2 3 4 5 6 7

7710405 5132464 5410889 3610070 3554518 3554517 5132497

Qty.

1 1 2 2 2 2 1

Description

Ref. Part No.

Ring, Retaining Spacer, Bearing O-Ring Seal Bearing, Cone, Tapered Bearing, Cup, Tapered Axle, Rear

8 9 10 11 12 13

5132875 7080306 3221140 5020468 3221137-116 3221141

Qty.

1 1 1 2 1 1

Description

Housing, Axle, Rear Fitting, Lubrication Sprocket, 30T Nut, Jam Chain, 116P Link, Connector 6/02

B12

SWING ARM/SHOCK MOUNTING SPORTSMAN 6X6 A04CL50AA 12

1

7

13 14 15

6 11

8

9

11

10

om

5

16

16

2 4

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

1

17

3

8

20

28

21

29 30

31

30

32

18

22

27

29 30

19

25

26

24

23

E 2003 Polaris Sales Inc.

33

30 32

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.

7542439 7041962 7515438 7556142 7041987-067 5241147 7515415 5134321 5133166 5434545 7080510 7661046 5432727 7547082 7556035 5434546 5133167

2 1 1 1 1 1 1 2 1 1 2 2 1 1 1 2 1

Description

Ref. Part No.

Nut, Nylok Shock Screw Washer Spring, Compression Retainer, Spring Screw Bolt, Swing Arm Pivot Bushing, Pivot, LH Bushing, Swing Arm, LH Fitting, Zerk Rivet Guide, Chain Pad Nut Washer, Flat Bushing, Swing Arm, RH Bushing, Pivot, RH

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Qty.

7512329 5247488 1541583 7078572 5432854 7515304 5332828 7558402 7542324 7542522 7512576 7542324 7558402 5222221-067 7512325 1013328-067

Qty.

2 2 1 1 1 1 1 1 1 2 2 4 8 1 4 1

Description

Screw Bracket, Bolt Lock Asm., Swing Arm (Incl. 10,11,16) Decal, “Chain Free Play” Guard, Chain Screw Bushing Washer, Flat Nut, Nylok Nut, Flange Bolt Nut, Nylok Washer Mount, Bracket, Rock Guard Screw Guard, Swing Arm 7/03

B13

REAR and MIDDLE WHEEL SPORTSMAN 6X6 A04CL50AA

2 1

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

E 2003 Polaris Sales Inc.

om

3

4

11

6

5

5

12

8

9

9

10

10

W or

7

8

7 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.

1 2 3 4 5 6

7512673 5131777 5410948 7542714 7661404 5411164

Qty.

16 4 4 16 2 4

Description

Ref. Part No.

Screw Hub, Wheel Tire, 25x11-10 Nut Pin, Cotter Hub, Dust Cover

7 8 9 10 11 12

7543005 7555745 7555796 1525017 7670081 1520183-117

Qty.

4 4 4 4 16 4

Description

Nut, Castle Washer, Flat Washer, Cone Valve, Rim Nut, Push Rim, Rear 7/00

B14

REAR STRUT STABILIZER SPORTSMAN 6X6 A04CL50AA

1

2

om

E 2003 Polaris Sales Inc.

3

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

4

4

5

6

1

2

3

7

11

8

10

9

W or

2

3

1

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.

1 2 3 4 5 6

7555832 7552603 7512492 5434551 5020764 1541853-067

Qty.

6 6 6 2 1 1

Description

Ref. Part No.

Washer Washer, Spring Lock Screw Bushing, A-Arm, Long Shaft, A-Arm, Upper Stabilizer, Upper

7 8 9 10 11

5020765 5020766 1541852-067 5434548 5434553

Qty.

1 1 1 2 2

Description

Shaft, A-Arm, Middle Shaft, A-Arm, Lower Stabilizer, Lower Bushing, A-Arm, Short Bushing, Stabilizer, Long 6/02

C1

SWING ARM WELDMENT (REAR) SPORTSMAN 6X6 A04CL50AA

8

7

7 3 6

9

11

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

2

10

9

5

13 14

12

4

1

om

1

26

3

14

13

25

12

18 19 17

13 12

24

E 2003 Polaris Sales Inc.

13

15

17

19 18

23

16

20

22

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.

Qty.

Description

Ref. Part No.

Nut Shock, Rear Screw Washer Spring, Compression Retainer Screw Cover, Chain Rivet Mount, Chain Cover, Front Mount, Chain Cover, Rear Nut, Flange Washer

14 15 16 17 18 19 20 21 22 23 24 25 26

W or

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13

7542439 7041963 7515415 7556142 7041880-067 5241147 7517386 5433539 7661637 5244077-067 5244078-067 7542522 7555883

2 1 2 1 1 1 4 1 4 1 1 6 8

7512576 7512520 1580067-067 7515321 7558402 7542324 1013327-067 7515117 5521279 7541925 2200472 7170509 1541344-067

Qty.

4 2 2 3 6 3 1 1 1 1 1 1 1

Description

Bolt Screw Bracket, Swing Arm Bolt Washer Nut, Nylok Guard, Chain, Lower Screw Guide, Chain, Rear Nut, Nylok Kit, Hitch (Incl. 12,13,14) Decal, Hitch Extension, Swing Arm 7/03

C2

DRIVE CLUTCH

E 2003 Polaris Sales Inc. 8

6

9

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

4

1

5

om

SPORTSMAN 6X6 A04CL50AA

2

3

7

6

12

11

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Qty.

Description

Ref. Part No.

Qty.

Asm., Drive Clutch (Incl. 1-2,6-10) Screw Bearing, Cover Spring, Clutch Washer, Multilube Roller and Bushing Button, Clutch, Stemless

7 5210752 5242981 5210753 5210754 8 5630513 9 7512266 10 7541906 11 3576504 12 5020422

AR AR AR AR 3 3 3 1 3

W or

Ref. Part No.

1 2 3 4 5 6

1321976 7518062 3576510 7041157 5430945 1321457 5431936

1 6 1 1 6 3 6

Description

Spacer, .020 Spacer, .025 Spacer, .032 Spacer, .050 Weight, Shift, 10-MH Bolt, Shoulder Nut, FLEXLOC Bearing, Moveable, 1/2 Inch Pin, Roller 7/03

C3

DRIVEN CLUTCH SPORTSMAN 6X6 A04CL50AA

1 3

om

E 2003 Polaris Sales Inc. 2

16

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

15 14

4

13

12

5 6

11

10

9

8

7

W or

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.

1 2 3 4 5 6 7

7556120 3211077 1322180 5220646 7552901 7515382 7555898 7556076 8 7556804

Qty.

AR 1 1 1 1 1 AR AR AR

Description

Ref. Part No.

Bushing (3 Max) Belt, Drive Asm., Driven Clutch (Incl. 7-16) Washer Washer Bolt Washer, .020 Washer, .025 Washer, .030

9 10 11 12 13 14 15 16

3576504 3576511 7041198 5131446 5210752 7710448 7511854 5430766

Qty.

1 1 1 1 1 1 3 3

Description

Bearing, Moveable, 1/2 Inch Bearing, Moveable, 1 Inch Spring, Clutch Ramp, Stationary Spacer Ring, Retaining Bolt Button, Ramp 7/01

C4

AIR BOX SPORTSMAN 6X6 A04CL50AA 1

2 3

28

4

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

5

om

E 2003 Polaris Sales Inc.

6

7

8

27

9

16

26

10

25

10

11

18

10

17

24

23

19

22

16 15

13

12

14

21

10

20

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Qty.

Description

Ref. Part No.

Screw Pad, Rack Mount Duct, Inlet Gasket, Intake Cover, Air Box Seal, Cover Screw Washer, Flat Line, Breather Clamp, Hose Filter, Breather Clamp, Hose Hose, Breather Clamp, Band Boot, Carb

16 17 18 19 20

7080413 5432473 5830128 5433387 -------

21 22 23 24 25 26 27 28

5811650 5432377 8450059-150 7080650 5242044 5432601 7080595 5811633

W or

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

7517317 5810455 5433395 5411422 5432868 5811482 7515179 7558301 8450073-600 7080699 2530029 7080694 5411921 7080511 5411540

4 1 1 1 1 1 2 2 AR 4 1 1 1 1 1

C5

Qty.

2 1 1 1 1 1 1 AR 1 6 1 1 1

Description

Clamp Duct, Carb, Inlet Gasket, Duct Box, Air Line, Breather, Oil Tank (See Oil Tank Pg. A12, Ref. 3) Foil, Air Box Plug, Trap Line, Fuel Clamp, Hose Clip Collar, Inlet, Carb Filter, Air Filter, Sleeve, Precleaner 7/03

CLUTCH COVER SPORTSMAN 6X6 A04CL50AA

1

2

5

6

4

7

9

8

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

3

om

E 2003 Polaris Sales Inc.

26

25

20

19

10

11 12 13

18

17

16

10

15

24

14

23

22

10

21

2

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.

5247524-067 7512232 5433427 5411553 2201957 7555748 7517599 5521578 5434255-070 7512094 7078689 5410542 5434264 7074782

1 3 1 1 1 3 3 1 1 10 1 1 1 1

Description

Ref. Part No.

Bracket, Clutch Cover Screw Duct, Clutch Air, Inlet Seal, Cover Kit - Inner Clutch Cover (Incl. 10) Washer Bolt/Washer Seal, Clutch Cover, Outer Cover, Clutch, Outer Screw Decal, Warning, Clutch Cover O-Ring Plug, Drain Decal, Automatic Transmission

15 16 17 18

7080707 5411489 5433657 -------

2 1 1 3

19 20 21 22 23 24 25 26

5242046 5410575 7558301 7555935 5242693-067 7661637 7556091 7080511

1 1 1 2 1 2 1 1

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Qty.

Qty.

Description

Clamp, Narrow Band Boot, Duct Duct, Air Outlet, Clutch Screw and Washer (See Crankcase Pg. D3, Ref. 6) Bracket, Retainer, Seal Seal, Cover, Case Washer, Flat Washer Bracket, Clutch Cover Rivet Spacer Clamp, Narrow Band 7/03

C6

REAR CALIPER MOUNTING SPORTSMAN 6X6 A04CL50AA 4 5

3

E 2003 Polaris Sales Inc.

om

6 1

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

2

7

8

9

10 11

W or

12

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.

1 2 3 4 5 6

5132220 1910408 1910480 7512084 7080573 1910481

Qty.

1 1 1 1 1 1

Description

Ref. Part No.

Mount, Caliper, Upper Caliper, Rear Line, Brake, LH Screw Clamp, Rubber Coated Line, Brake, RH

7 8 9 10 11 12

7517758 5131759 5131786 7558402 7552901 7512312

Qty.

2 1 1 2 2 2

Description

Bolt, Shoulder Bushing, Caliper Mount Mount, Caliper, Lower Washer Washer, Spring Lock Bolt 6/02

C7

GEARCASE MOUNTING SPORTSMAN 6X6 A04CL50AA

2 3 4

5

om

1

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

1

6 7

5

4

12

7

11

10

9

E 2003 Polaris Sales Inc.

7

8

W or

6

7

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.

1 2 3 4 5 6 7

7517632 7080138 8360009-700 5132046 7542423 7512492 7555806

Qty.

4 1 1 2 2 2 4

Description

Ref. Part No.

Screw Cable Tie Line, Vent Mount, Transmission, Rear Nut, Flange Lock Screw Washer, Flat

8 9 10 11

7517646 3221044 7710434 5211065 5210764 5211517 12 7518139

Qty.

1 1 1 AR AR AR 1

Description

Screw Sprocket, 12T Ring, Retaining Shim, .010 Shim, .020 Shim, .030 Screw 7/03

C8

ELECTRICAL SPORTSMAN 6X6 A04CL50AA

1

25

3

2

om

E 2003 Polaris Sales Inc.

23

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

24

20

7

4

6

5

26

15

7

9

19 18

27 28

6

8

22 21

16

14

17

10

11

12

13

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Qty.

W or

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13

2461190 7080138 7080492 7670109 4020139 7541925 5247782 4010937 7512018 7512024 5246747 5810455 -------

14 7512007

1 4 1 3 4 3 1 1 2 1 1 2 1

Description

Harness, Main Cable Tie Cable Tie Clip, Routing Clip, Rosebud Nut, Nylok Heat Sink Module, Controller, Fan Screw Screw Bracket, CDI Pad CDI System (See Magneto Pg. D14, Ref. 15) 1 Bolt

Ref. Part No.

15 16 17 18 19 20 21 22 23 24 25 26 27 28

4010093 4010094 2202147 4010774 7010032 5410424 4010095 2200361 5431769 5810290 7512027 4010930 7552801 7542105

Qty.

1 1 1 1 2 1 1 2 1 3 2 1 2 2

Description

Cable, Solenoid/Starter Cable, Battery/Solenoid Kit, Fusible Link Battery Hook, Battery Strap Strap, Holddown, Battery Cable, Battery/Engine Kit, Battery Bolt, Short Cover, Battery Pad, Battery Screw Switch, Magnetic Washer, Spring Lock Nut 7/03

C9

DUMP BOX SPORTSMAN 6X6 A04CL50AA 5

7

8 10

6

5

1

9

5

6

E 2003 Polaris Sales Inc.

2 4

3 17

2 13

11

5

12

19

13

20

12

5

15

14

20

21

22

25

23

17

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

1

16

5

16

om

18

11

32

31 5

29

30

28 27

21

24

22

26

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.

7515177 7558221 5132358 5433388 7517561 5433656 5433655 7661644 7556143 5132373 7517790 5243304 7517938 7517747 7556157 7517742 7080881

2 2 1 1 22 2 1 2 2 2 4 2 2 9 9 2 2

Description

Ref. Part No.

Screw Washer, Flat Rod, Hinge Tailgate Screw Latch Latch, Paddle Pin, Hitch Washer Shaft, Latch Screw Bracket, Box Latch Screw Screw Washer Screw Cable, Tailgate

18 5244068-067 19 2410179 4010340 20 7079925 21 7512329 22 7542324 23 7512492 24 7542449 25 7041301 26 7547089 27 1012893-067 28 7515350 29 1013125-067 30 7512084 31 2682522-070 2681664-070 32 5435064-070

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Qty.

C10

Qty.

1 2 2 2 2 2 4 4 1 9 1 4 1 4 1 1 1

Description

Cover, Tailgate Asm., Taillight w/Brake Light Bulb Decal, Reflector, Red Screw Nut, Nylok Screw Nut Shock, Dump Box Nut, Flange Support, Box Screw Latch, Box Screw Asm., Backrest Covering, Backrest Box, Molded (Incl. Decal) 7/03

GEAR SELECTOR SPORTSMAN 6X6 A04CL50AA

E 2003 Polaris Sales Inc.

1 2

om

3

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

4

5

6

10

16

7

11

8

15

10 11

9

14

12

13

W or

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.

1 2 3 4 5 6 7 8

1341271 3233195 7512024 3233649 3233131 3233648 3233658 3233646 3233754

Qty.

1 1 1 4 1 1 1 1 1

Description

Ref. Part No.

Asm., Gear Selector (Incl. 1-16) Asm., Knob Screw Screw Strap, Wire Cover, Gear Selector Boot Handle, Gear Selector Sphere, Plastic Pin, Groove

9 10 11 12 13 14 15 16

3233644 3233642 3233060 3233076 3233639 3233640 3233641 3233643

Qty.

1 2 2 2 1 1 1 1

Description

Pin, Dowel Spring, Detent Bullet, Detent O-Ring Slide, Low Slide, High/Reverse Body, Gear Selector Spring, Centering 9/00

C11

GEARCASE SELECTOR MOUNTING

om

SPORTSMAN 6X6 A04CL50AA

E 2003 Polaris Sales Inc.

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

2

1

2

2

4

2

3

W or

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.

1 1821428 2 7546707

Qty.

Description

1 Asm., Linkage, Short 4 Nut, FLEXLOC

Ref. Part No.

3 7517386 4 1821430

Qty.

Description

5 Screw 1 Asm., Linkage 7/03

C12

GEARCASE SPORTSMAN 6X6 A04CL50AA

1 2 E 2003 Polaris Sales Inc.

om

3 4

5

19

6

60

51

52

53

34 33

32

25

25

38

37 36 35

50 49 48

54

41

39

45

47

47 46

16

14

14 18 13 19 10 11 9

20

30

29 28

27

26

25

24

W or

31

8

21

44

59

55

40

43

62

61 9

57 56

25

42

63

58

7

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

64

C13

23

22

21

20

13 17

15

13 14

10 11 12

9

GEARCASE SPORTSMAN 6X6 A04CL50AA

1341428 3233527 3233252 3233632 3233529 3233448 3233035 3233706 3233633 3233018 3233177 3233176 3233731 3233718 3233720 3233732 3233733 3233719 3233721 3233722 3233788 3233539 3233556 3233555 3233554 3233020 3233898 3233899 3233552 3233895 3233037 3233026 3233897

1 1 11 1 2 1 1 1 1 3 2 2 1 3 3 1 1 1 1 1 3 11 1 1 1 4 1 1 1 1 1 1 1

Ref. Part No.

Asm., Gearcase (Incl. All) Bushing, Pivot Screw Gearcase, HLR, Hybrid Mach LH Pipe, Knock Plug, Drain Washer Fork, Shift, Low Fork, Shift, H/R Bearing, Ball Ring, Retaining Washer, Thrust Gear, 33T Bearing, Needle Ring, Retaining, E-Clip Dog, Engagement, Low Shaft, Reverse, 29T Sprocket, 24T Dog, Engagement Gear, 30T Seal, Triple Lip Screw Cover, Snorkel Drive O-Ring Shim Bearing, Ball Gear, 25T Shaft, Snorkel Bushing Gearcase, HLR, RH Vent, Tube Screw Guide, Chain

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Description

3233872 3233711 3233542 3233541 3233540 3233306 3233263 3233730 3233537 3233360 3233544 3233729 3233546 3233043 3233747 3233308 3233032 3233309 3233153 3233040 3233737 3233549 3233548 3233045 3233547 3233961 3234001 3233749 3234002 3233036 3233704 3233019

Qty.

1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 1 1 1 2 1 1 2 2 1 2 1 8 1 1 1 1

Description

Washer, Nylon Plug, Oil Fill Washer, Thrust Bushing Shaft, Pinion Ring, Retaining Cover, Bearing Sprocket, 15/22T Ring, Retaining Gear, 100T Shaft, Output Sprocket, 15/26T Chain, Roller Deflector, Oil Screw, Tapping Pin, Interlock Spring Bracket, Interlock Bellcrank, HLR Washer Shaft, Shift, H/R Shaft, Shift, H/R O-Ring Ring, Retaining Bellcrank, .125 Nut, Flange Lock Switch, 2 Position Screw, Tapping Switch, 3 Position, Reversed Chain, Silent Shaft, Input Bearing, Ball

om

Qty.

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

Ref. Part No.

C14

6/02

HANDLEBAR and HEADLIGHT POD SPORTSMAN 6X6 A04CL50AA 1 E 2003 Polaris Sales Inc.

2

13

4

12

4

11

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

5

om

3

15

14

10

9

4

6

7

8

36

35

16

34

17

18

30

W or

28

33

31

32

20

29

26

22

21

27

25

26

23 24

D1

19

HANDLEBAR and HEADLIGHT POD SPORTSMAN 6X6 A04CL50AA Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Qty. Description

5434380 3280425 5412138 7511881 5434284-400 ------

1 1 1 3 1 1

7 8 9 10

5244581-067 5631517 7517238 -------

1 1 4 1

11 12 13 14 15 16 17 18 19

5433903 4010592 5433834-070 5432952 7517625 5244969-067 7517317 5843350 2410268 4010253

1 1 2 1 1 1 2 1 1 1

Bezel Cluster, Instrument Mount, Rubber Screw Pod, Headlight, Upper, Green Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B7, Ref. 5) Tube, Handlebar Block, Handlebar, Pegged Screw Asm., Master Cylinder (See Controls - RH, Master Cylinder/ Brake Line Pg. B9 for details) Spacer, Switch, LH Switch, Handlebar, Off/Lo/Hi Grip, Handlebar Plug Screw, Set Bracket, Pod Mounting Screw Knob, Adjusting Asm., Head Lamp Bulb, Headlight, 50W

20 21 22 23 24 25 26

Qty. Description

4122880 7081008 7542122 4010638 7080631 5433762-070 4011002 4010278 4010321

1 1 4 1 1 1 1 1 1

7517658 4010298 5132382 5433534 5433733 7080922 5812563 7670127 5631516 7080138

1 1 1 1 1 1 1 1 1 4

Rod, Adjusting Cable, Choke Nut, Nylok Receptacle, Pod Mount, 12V Clip, Cable Retaining Pod, Headlight, Lower Switch, Key, 3 Position (Incl. Key) Key, Blank, Series 2000, 6700, 6800 Key, Blank, Series 2200, 2300, 2700, 2800 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.

Screw Sensor Cap, Sensor Cover, Key Nut, Ignition Nut, Choke Slide Pad, Adhesive Clip Block, Handlebar Cable Tie

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

1 2 3 4 5 6

Ref. Part No.

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Ref. Part No.

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27 28 29 30 31 32 33 34 35 36

D2

7/03

CRANKCASE SPORTSMAN 6X6 A04CL50AA

6

2 E 2003 Polaris Sales Inc.

7 5

23

2

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

1

om

3

8

4

9 10

11

12

5

22

21

20

14

19

18

13

15

17

16

W or

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.

1 3083669 2 3089240

3 4 5 6 7 8 9 10 11

3087266 3080676 3084840 3084205 3084839 3085525 3087154 3084842 3084834

Qty.

Description

1 Bushing, Starter 1 Asm., Crankcase (Incl. 1,4,5,7,8,11,12,17,20,21,23) 2 Pipe, Knock 1 Bearing, Ball 2 Pin, Dowel 3 Screw and Washer 1 Seal, Oil 1 Pipe, Air Breather 1 Fitting, Oil Inlet 1 Union 2 Bearing, Ball

Ref. Part No.

12 13 14 15 16 17 18 19 20 21 22 23

3084835 3084845 3084846 3084844 3086810 3084841 3082956 3083453 3084837 3084836 3084847 3080103

Qty.

1 1 1 1 1 10 1 1 1 1 1 2

Description

Bearing, Ball Plug Gasket, Aluminum Spring, Valve, One Way Valve, One Way Bolt, Flange Gasket Plug Seal, Mechanical Seal, Oil O-Ring Pin, Dowel 7/03

D3

CRANKSHAFT and PISTON SPORTSMAN 6X6 A04CL50AA 3 E 2003 Polaris Sales Inc. 1

om

2

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

1

5

6

21

8

20

4

7

9

10

19

11

14

16

18

12

15

17

13

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.

2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1

Description

Ref. Part No.

Qty.

Clip Piston Set (Std) (Incl. 1) Piston Set (0.25 O/S) (Incl. 1) Piston Set (0.50 O/S) (Incl. 1) Piston Ring Set (Std) Piston Ring Set (0.25 O/S) Piston Ring Set (0.50 O/S) Bearing, Ball Crankshaft 2 Pin, Crank Rod, Connecting Bearing, End, Large Ball, Steel Asm., Crankshaft (Incl. 4-11,19) Crankshaft 1 Gear 1, Balancer

12 3085404 13 3084895 3084896 3084897 14 3240088 3084892 3084893 3084894 15 3084882 16 3085528 17 3083904 18 3083905 19 3086838 20 3081447 21 3080130

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

W or

1 3085534 2 3087221 3087222 3087223 3 3087224 3087225 3087226 4 3085815 5 3085812 6 3085341 7 3085376 8 3085400 9 3085024 10 3089281 3089282 11 3089245

Qty.

Description

Shaft, Balancer Spacer (0.8) Spacer (1.0) Spacer (1.2) Spacer (0.6) Spacer (0.8) Spacer (1.0) Spacer (1.2) Sprocket 1 Nut, Slit Washer Nut, Lock Pin, Dowel Key Key, Woodruff 7/03

D4

CYLINDER SPORTSMAN 6X6 A04CL50AA 8

2

9

1 3 4

7

6

10

5

12

om

11

35

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

37

35

36

5

17

13

14

16

15

35

18

19

20

34

21 22 23

27

9

24

26

28

W or

29

33

30 31 E 2003 Polaris Sales Inc. 32 13

D5

25

CYLINDER SPORTSMAN 6X6 A04CL50AA Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

1 1 2 2 4 2 1 1 10 1 1 1 10 2 4 1 1 1 2

Ref. Part No.

Asm., Band, Adapter (Incl. 2) Screw Bolt Pin, Straight Guide, Valve Seal, Intake Valve O-Ring Adapter, Water Out Bolt, Flange Adapter, Camshaft Gasket, Rocker Cover Cover, Rocker Bolt, Flange Seal, Exhaust Valve Bolt, Cylinder Head Plug Gasket Plug, Blind Bolt, Flange

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

3085075 3085326 3080530 3087199 3085854 3084876 3084864 3084863 3087266 3084849 3084873 3089256 3084130 3085370 3089242 3085527 3085371 3084879

Qty.

1 2 2 2 1 4 1 1 2 1 4 1 1 1 1 1 1 1

Description

Gasket, Exhaust Stud Washer, Lock Nut Bolt, Rocker Shaft Bolt Support, Valve Rocker Shaft (PTO) Support, Valve Rocker Shaft (MAG) Pipe, Knock Union, Oil Pump Bolt, Flange Asm., Cylinder (Incl. 32) Pipe 2, Elbow Gasket, Cylinder Cover, Camshaft Head, Cylinder (Incl. 4-6,14,16-18,21) Gasket, Head Adapter

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

3083166 3081497 3081330 3084857 3084994 3084858 3084867 3085072 3084877 3084866 3085074 3085073 3084874 3084859 3084875 3084860 3084861 3084862 19 3084215

Description

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Qty.

om

Ref. Part No.

D6

7/03

CARBURETOR SPORTSMAN 6X6 A04CL50AA

29

33

32

om

30

31

27

28

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

26

25

24

4

3

2

1

1

18

15

E 2003 Polaris Sales Inc.

8

14

9

10

W or

23

19

16

6 7

22

20

17

5

21

13

12 11

D7

CARBURETOR SPORTSMAN 6X6 A04CL50AA Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

2 1 1 1 1 1 1 1 2 1 4 1 1 1 1 1 1

Seal Packing E-Ring Cap Pin, Float Washer Jet, Main, #142.5 Plate Screw O-Ring Screw Asm., Float Body Screw Asm., Float Valve, Needle (1.5) O-Ring Jet, Pilot, #40

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3131423 3130836 3130502 3130589 3130514 3130501 3130513 3130543 3130535 3130511 3130512 3130199 3130538 3130593 3131572 3084205

Qty. Description

1 1 1 1 1 2 1 1 4 1 1 1 1 1 1 2

Screw, Adjust Spring Valve, Throttle, 100 Spring Ring Screw Asm., Throttle Shaft Guide, Cable Screw Cover O-Ring Holder, Guide Spring Asm., Plunger Asm., Carburetor (Incl. All Less 25-28) Screw and Washer

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

3130515 3130517 3130518 3130519 3130361 3130014 3131391 3130594 3130591 3130532 3130520 3130590 3130521 3130529 3131360 3130533 3131390

Ref. Part No.

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Qty. Description

om

Ref. Part No.

D8

7/03

INTAKE and EXHAUST SPORTSMAN 6X6 A04CL50AA 10 9

E 2003 Polaris Sales Inc.

11 7

10 9

1 2

12

3

om

13

4

14

5

28

8

9 10

16

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

7

15

6

17

18

19

27

14

13

12

26

25

24

21 22

20

23

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.

3087129 3087130 3087131 3087132 3086493 3086448 3084910 3084913 3084912 3084911 3084909 3084908 3087203 3084906

1 1 1 1 1 1 2 1 4 4 1 8 4 4

Description

Ref. Part No.

Plug Gasket Spring Pin Asm., Tensioner (Incl. 1-4) Gasket, Tensioner Asm., Rocker Arm, Intake (Incl. 9,10) Asm., Rocker Arm, Exhaust (Incl. 9,10) Nut Screw, Adjusting Shaft, Rocker Collet, Valve Retainer, Valve Spring Spring, Valve

15 16 17 18 19 20 21 22 23 24 25 26 27 28

W or

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Qty.

D9

3086212 3086838 3085348 3085076 3084899 3084914 3081657 3084916 3084915 3084924 3084917 3085349 3085412 3083361

Qty.

1 1 1 1 1 1 3 1 1 1 1 2 2 2

Description

Camshaft (Incl. 15-19) Pin, Dowel Lever, Release Spring, Return Pin, Dowel Sprocket 2 Bolt and Washer Guide, Chain Chain, Timing Bolt, Pivot Lever Valve, Intake Valve, Exhaust Bolt and Washer

7/03

RECOIL STARTER SPORTSMAN 6X6 A04CL50AA 5 3

4

2

6

1

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

om

E 2003 Polaris Sales Inc.

7

8

9

14

11

10

W or

13

8

7

12

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.

1 2 3 4 5 6 7 8

3084822 3083463 3083378 3083379 3084744 3085266 3083453 3082956

Qty.

1 1 1 1 1 1 2 2

Description

Ref. Part No.

Reel Spring, Return Ratchet Spring, Friction Plate, Friction Bolt and Washer Plug Gasket

9 10 11 12 13

3083669 3083185 3084750 3084877 3087163 3087164 14 3085083

Qty.

1 1 1 9 1 1 1

Description

Bushing, Starter Spring, Spiral Bushing Bolt, Flange Asm., Recoil (Incl.1-6,9-11,14) Starter Case (Incl. 11) Asm., Rope 7/03

D10

WATER PUMP SPORTSMAN 6X6 A04CL50AA 1

E 2003 Polaris Sales Inc.

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

om

2

3

4

3

11

8

9

12

10

7

6

W or

5

13

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.

1 2 3 4 5 6 7

3084940 3089246 3084191 3085857 3085359 3082758 3085351

Qty.

1 1 2 1 1 1 1

Description

Ref. Part No.

Thermostat Sensor, Thermostat Clamp, Hose Hose, Main Bolt, Flange Gasket, Aluminum Cover, Water Pump

8 9 10 11 12 13

3086840 3085077 3083138 3084935 3084942 3084877

Qty.

1 1 1 1 1 4

Description

Gasket, Water Pump Nut, Self Lock Gasket, Aluminum Impeller Washer, Seal Bolt, Flange 7/03

D11

OIL PUMP SPORTSMAN 6X6 A04CL50AA

E 2003 Polaris Sales Inc.

om

4

3 2

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

1

5

10

9

11

6

7

8

12

13

15

14

W or

17

16

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.

1 2 3 4 5 6 7 8 9

3084946 3084949 3084948 3084944 3084945 3085535 3088156 3088155 3084953 3084962

Qty.

1 1 1 1 1 1 2 2 1 3

Description

Ref. Part No.

Pump, Oil, Case 2 Rotor, Outer (Feed) Rotor, Inner (Feed) Asm., Oil Pump (Incl. 1-8,10-15) Pump, Oil, Case 1 Screw Pin, Dowel Pin, Dowel Washer Bolt and Washer

10 11 12 13 14 15 16 17

3084947 3084950 3084951 3084956 3084205 3084952 3084958 3084959 3084960 3084961

Qty.

1 1 1 1 3 1 1 AR AR AR

Description

Pump, Oil, Case 3 Rotor, Inner Rotor, Outer Unit, Oil Strainer Screw and Washer Shaft, Pump Gear 2, Pump Spacer (0.8) Spacer (1.0) Spacer (1.2) 7/03

D12

OIL FILTER SPORTSMAN 6X6 A04CL50AA

E 2003 Polaris Sales Inc.

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

om

1

2

4

2

3

3

2

2

3

5

W or

2

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.

1 3084963 2 3084846 3 3086815

Qty.

Description

1 Filter, Oil 8 Gasket, Aluminum 4 Bolt, Banjo

Ref. Part No.

4 3084964 5 3085638

Qty.

Description

1 Pipe, Oil Delivery 1 1 Pipe, Oil Delivery 2 7/00

D13

MAGNETO SPORTSMAN 6X6 A04CL50AA

E 2003 Polaris Sales Inc.

om

2

1

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

3

15

14

4

13

12

5

16

10

11

6

8

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.

Qty.

Description

Ref. Part No.

Asm., Ignition Coil (Incl. 1,2) Coil, Ignition Cap, Spark Plug Plug, Spark O-Ring Metal, Bearing Asm., Plate (Incl. 5,6,8-12,14) Plate Bolt and Washer Seal, Oil

9 10 11 12 13 14 15 16

W or

Ref. Part No.

1 3089239 3089252 2 3084980 3 3070175 4 3084978 5 3084972 6 3089253 3089248 7 3081657 8 3084973

1 1 1 1 1 1 1 1 5 1

3089249 3089251 3089250 3084976 3085360 3081256 3089238 3089247

Qty.

1 3 1 2 1 1 1 1

Description

Stator (Incl. 13) Screw and Washer Band, Pulse Screw and Washer Coil, Pulser Screw and Washer CDI System Flywheel/Ring Gear 7/03

D14

STARTING MOTOR SPORTSMAN 6X6 A04CL50AA 3 E 2003 Polaris Sales Inc.

4

2

om

1

5

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

6 7

8

12

10

11

13

9

14

W or

15

16

17

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.

1 2 3 4 5 6 7 8

3084981 3088163 3088169 3088166 3088165 3082038 3085034 3088168 3088160

Qty.

1 1 1 2 3 2 1 1 1

Description

Asm., Starting Motor (Incl. 1-4,6-10,12) Set, Washer Set, Brush, Carbon Nut, Flange O-Ring Bolt and Washer Asm., Bracket, Rear Asm., Armature Asm., Bracket, Front

Ref. Part No.

9 10 11 12 13 14 15 16 17

3088161 3088164 3089255 3088162 3083737 3084412 3084411 3084410 3084409

Qty.

1 2 1 2 1 1 1 1 1

Description

O-Ring Asm., Bolt Set (Incl. 4) Asm., Gear Shaft (Incl. 13-17) Ring, Rubber Washer, Gear Shaft Clip Spring, Weight Spring, Return Clip 7/03

E1

FUEL PUMP SPORTSMAN 6X6 A04CL50AA E 2003 Polaris Sales Inc. 3

2

ld of 80 P 0- ow 40 er 7- sp 72 or 18 ts. c

om

2

4

1

W or

4

Ref. Part No.

3085275 1 3088171 2 3088173

Qty.

Description

Ref. Part No.

1 Asm., Fuel Pump (Incl. 1-4) 1 Screw and Washer 2 Screw and Washer

3 3084591 4 3088170

Qty.

Description

4 Screw and Washer 1 Set, Gasket, Diaphragm 5/03

E2

TOOL KIT SPORTSMAN 6X6 A04CL50AA

E 2003 Polaris Sales Inc.

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1

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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.

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3085544 9918775 2870725 2873647 2874743 3085001

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Description

Ref. Part No.

Asm., Tool Kit (Incl. 5-10) Manual, Owner’s, ’04 Sportsman 6X6 Gauge, Tire Pressure Wrench, Torx Wrench, 1/2 x 9/16 Wrench, Open, 8-10mm

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3085002 3085568 3085569 3082657 2682572

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Description

Wrench, Open, 12-14mm Wrench, Box, 125mm Handle, Wrench (Spark Plug Puller) Screwdriver Pouch, Tool Kit 7/03

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PRINTED IN THE USA

PARTS MANUAL PN 9918628 and MICROFICHE PN 9918629 7/03