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SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB …

a8 rear rack mounting sportsman 500 a99ch50aa and sportsman 500 a99ch50ab and worker 500 a99ch50ea and worker 500 a99ch50eb 5 4 2 3 9 11 10 12 14 15 13 13 11

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Transcription of SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB …

1

2 PARTS MANUAL PN 9914911 and MICROFICHE PN 9915651 1/99 SPORTSMAN 500 Model # a99ch50aa Model #A99CH50 ABWORKER 500 Model #A99CH50 EAModel #A99CH50 EBRev. 01 hi in n i n n TABLE OF CONTENTSSPORTSMAN 500 A99CH50(AA)(AB)and WORKER 500 A99CH50(EA)(EB)Parts ManualAA ARM/STRUT MOUNTING C3.

3 AIR BOX B3.. CCARBURETOR D11-12.. CLUTCH COVER C6.. CONTROLS MASTER CYLINDER/BRAKE LINE B11.. CONTROLS THROTTLE B10.. COOLING SYSTEM A12.. CRANKCASE D6.. CRANKSHAFT and PISTON D9.. CV JOINT BTB B4.. CYLINDER D7-8.. DDECALS A10-11.. DRIVE CLUTCH C4.. DRIVEN CLUTCH C5.. EELECTRICAL/TAILLIGHT C7.. ENGINE MOUNTING A13-14.. EXHAUST SYSTEM B1.. FFOOT BRAKE C13.. FRAME MOUNTING C2.. FRONT BRAKE B9.. FRONT CAB A7.. FRONT HOUSING C14-D1.. FRONT RACK and BUMPER MOUNTING A9.. FRONT STRUT B7.. FRONT WHEEL B8.

4 FUEL PUMP E5.. FUEL TANK B2.. GGEAR SELECTOR D5.. GEARCASE (CASES and SNORKEL) D2.. GEARCASE (INTERNAL COMPONENTS) D3-4.. HHANDLEBAR and HEADLIGHT POD B13-14.. IINTAKE and EXHAUST D10.. MMAGNETO E3.. OOIL FILTER E2.. OIL PUMP E1.. OIL TANK C1.. PPART NUMBER INDEXE7-13.. PROP SHAFT B6.. RREAR BRAKE/FOOT PEDAL C11-12.. REAR CAB and SEAT A5-6.. REAR DRIVE SHAFT B5.. REAR RACK MOUNTING A8.. REAR SUSPENSION C9-10.. REAR WHEEL DRIVE C8.. RECOIL STARTER D13.. SSTARTING MOTOR E4.. STEERING POST B12.. TTOOL KIT E6.

5 WWATER PUMP D14.. The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for SPORTSMAN 500 and WORKER 500 SPECIFICATIONSBRAKESType/BrakesType/Brak es - AuxiliaryPark BrakeHydraulic DiscMechanicalHydraulic Lock, All WheelCAPACITIESC oolant Capacity (quarts)Fuel Tank (gallons)Gearcase Oil (ounces)Engine Counter Balance 10W30 Oil (quarts) InjectorOil (quarts) Engine OW40 Rack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow TRAINTypeEngine BrakingDRIVE CLUTCHC enter Distance (inches)Clutch Offset (inches)

6 Clutch WeightSpring Color101/210MH(50g)Blue/GreenDRIVEN CLUTCHH elix AngleSpring PositionCompound (EBS)N/ADIMENSIONAL FEATURESA pprox. Turning RadiusBox, ToolBox (cubic feet)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (lbs. dry)Wheel Base (inches)Width (inches)65 6x7x14 Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (cc s)Compression RatioCoolingAlternator OutputElec. Start w/Recoil Back UpCarburetors (no. of/size)Main JetPilot JetNeedle JetCut AwayAir Screw/Pilot ScrewJet NeedleIgnitionIgnition (Type & Deg.)

7 BTDC)Spark Plug Gap (inches)Spark Plug (Type)ExhaustEH50 PLE094 Cycle, Single Sump92x7549910:2 Full StrokeLiquid250 WStandard1/BST34(CV type) 5/8 Turn4HB41-3 CDI30 @ BKR5 EUSFS TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain TypePRDSide :13-16:1N/AN/AShaftGRAPHICSBody StyleBumper Box or BedFender, FrontFender, RearFootwellFrame/SteelFront CoverHandlebar Cover w/DecalHeadlight/Dash PodRack, FrontRack, RearRimsSeat VinylSide PanelSpring, FrontSpring, RearGen IVN/AN/A(A99CH50(AA)(EA)) Olive Green(A99CH50(AB)(EB)) Porsche Red(A99CH50(AA)(EA)) Olive Green(A99CH50(AB)(EB)) Porsche RedBlackSemi Flat Black(A99CH50(AA)(EA)) Black(A99CH50(AB)(EB)) Porsche RedBlack(A99CH50(AA)(EA)) Olive Green/Black(A99CH50(AB)(EB)) PorscheRed/BlackBlackBlack(A99CH50(AA)

8 (EA)) Black(A99CH50(AB)(EB)) AluminumBlack(A99CH50(AA)(EA)) Olive Green(A99CH50(AB)(EB)) Porsche Red(A99CH50(AA)(EA)) Black(A99CH50(AB)(EB)) Blue(A99CH50(AA)(EA)) Black(A99CH50(AB)(EB)) BlueELECTRICALH eadlight - Handlebar (watts)Headlight - Front Hood (watts)Headlight - Grill (watts)Taillights (watts)Brake Light (watts)Indicator Bulb1 Single Beam, 60WN/A2 Single Beam, Type -Front Travel (inches)Rear Type -Rear Travel (inches)ShockAdjustmentMacPherson - 2 Bore Gas BagCAMTIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - CenterGoodyear25x8x1225x11x10N/A55N/APol aris Industries Inc.

9 Reserves the right to make changes in design and specifications and/or to make additions or improvements to its productswithout ATV PUBLICATION NUMBERS MODELMODEL SMANUALOWNER SMANUALSUPPLEMENTPARTSMANUALPARTSMICROFI CHEASSEMBLYINSTRUCTIONSS portsman 500A99CH50(AA)(AB)9914905991491099149119 9156519914913 Worker 500A99CH50(EA)(EB)9914905991491099149119 9156519914913A5 REAR CAB and SEATSPORTSMAN 500 a99ch50aa and SPORTSMAN 500 a99ch50ab and WORKER 500 A99CH50EA and WORKER500 A99CH50EB2837510111514161718424113202223 3764446471433912242544019331343233319282 72635362930382173145A6 REAR CAB and SEATSPORTSMAN 500 a99ch50aa and SPORTSMAN 500 a99ch50ab and WORKER 500 A99CH50EA and WORKER500 A99CH50 EBRef.

10 Part DescriptionRef. Part Description1766164510 Rivet, T-Lock275119302 Bolt375557924 Washer458111071 Foil, Rear Cab, Rear554110421 Grommet65432117-1915432117-13611 Cab, Rear, Olive Green(A99CH50(AA)(EA))Cab, Rear, Porsche Red(A99CH50(AB)(EB))775419254 Nut, Nylok852245921 Retainer, Seat Latch958113081 Foil, Tape, Rear Cab1075122424 Screw1175558594 Washer1275120852 Screw1354317861 Box, Tool1476214032 Rivet1552110332 Bracket, Lever Retainer1610403871 Latch, Seat1770413701 Spring, Latch182682441-0702681747-07058111045811 1051111 SeatCovering, SeatFoil, Seat Base, LargeFoil, Seat Base, Small1954104148 Bumper, Rubber2075121302 Screw2175557482 Washer2254317871 Cover, Tool Box2354108961 Cap, Drain2476616386 Rivet255242953-0671 Guard.


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