SPORTSMAN 500 Model #A99CH50AA Model #A99CH50AB …

1 PARTS MANUAL PN 9914911 and MICROFICHE PN 9915651 1/99 SPORTSMAN 500 Model # a99ch50aa Model #A99CH50 ABWORKER 500 Model #A99CH50 EAModel #A99CH50 EBRev.

2 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.. 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.. 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.

3 REAR RACK MOUNTING A8.. REAR SUSPENSION C9-10.. REAR WHEEL DRIVE C8.. RECOIL STARTER D13.. SSTARTING MOTOR E4.. STEERING POST B12.. TTOOL KIT E6.. 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)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.)

4 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. 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)(E A)) 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)

5 ShockAdjustmentMacPherson - 2 Bore Gas BagCAMTIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - CenterGoodyear25x8x1225x11x10N/A55N/APol aris Industries Inc. 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. 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, Clutch26 1 Front Housing (See Front HousingPg.)

6 C14 and Pg. D1 for Details)2775526034 Washer2875124924 Bolt2970806531 Clamp, Hose3075120241 Screw31754212228 Nut, Nylok3254322802 Spacer, Footwell3375173774 Screw341012796-0671 Frame, Main3554107702 Grommet3670782611 Decal - Hitch3775173768 Screw385432221-0705433219-07011 Footwell, Black, LHFootwell, Black, RH3958111111 Foil, Foam, Rear Fender4058111062 Foil, Rear Cab, Front4170737611 Decal - Carburetor Information4270774461 Decal - Filter Element4358110871 Foil, Foam44751223210 Screw4575151942 Screw46767005712 Nut, U-Type Speed475431796543179711 Guard, Mud, Rear, LHGuard, Mud, Rear, RH1/99A7 FRONT CABSPORTSMAN 500 a99ch50aa and SPORTSMAN 500 a99ch50ab and WORKER 500 A99CH50EA and WORKER500 A99CH50EB5678910113221204181913121415168 1174422 Ref. Part DescriptionRef. Part Description158114911 Foil, Side Panel, Gen. IV, RH258109961 Foil, Foam, Side Panel35431809-1912620085-1915431809-1362 620085-1361111 Panel, Side, Green, LH(A99CH50(AA)(EA))Panel, Side, w/Foil, Green, RH(A99CH50(AA)(EA))Panel, Side, Red, LH,(A99CH50(AB)(EB))Panel, Side, Red, w/Foil, RH (A99CH50(AB)(EB))4751223210 Screw55432088-1915432088-13611 Cover, Front, Olive Green(A99CH50(AA)(EA))Cover, Front, Red(A99CH50(AB)(EB))676700852 Clip, Spring72631987-1912631987-13611 Cab, Front, Olive Green w/Warning-Decals (A99CH50(AA)(EA))Cab, Front, Red w/Warning Decals(A99CH50(AB)(EB))

7 8767005710 Nut, U-Type Speed976700092 Nut, Push-on1076616454 Rivet, T-Lock115431798543179911 Guard, Mud, Front, LHGuard, Mud, Front, RH1275419252 Nut, Nylok1375557922 Washer1475120852 Screw1570806931 Clamp, Hose168450073-600 ARLine, Breather1775120171 Screw1875559312 Washer1975421222 Nut2058114892 Shield, Deflector2176700884 Clip, Dart2275173122 Screw1/99A8 REAR RACK MOUNTINGSPORTSMAN 500 a99ch50aa and SPORTSMAN 500 a99ch50ab and WORKER 500 A99CH50EA and WORKER500 A99CH50EB54239111012141513131171683 Ref. Part DescriptionRef. Part Description128715011 Kit - Rack Extender, Rear (Incl. 6)275151932 Screw375151944 Screw426701741 Asm., Rack, Rear (Incl. Ref. 5 and Warning Decal)526700702 Reflector, Red675172086 Screw71040490-0671 Support, Rear Rack85241663-0671 Bracket, Silencer, Frame975123294 Bolt1076700962 Nut, Chimney1175423438 Nut, Nylok121040524-0671040525-06711 Mount, Front, Rear Rack, LHMount, Front, Rear Rack, RH1375584022 Washer145333332-0674 Spacer1575153854 Screw10/98A9 FRONT RACK and BUMPER MOUNTINGSPORTSMAN 500 a99ch50aa and SPORTSMAN 500 a99ch50ab and WORKER 500 A99CH50EA and WORKER500 A99CH50EB1314151617181265891019202123242 5234114712762622 Ref.

8 Part DescriptionRef. Part Description175151944 Screw226701801 Asm., Front Rack(Incl. Ref. 3 and Warning Decal)326700712 Reflector, Amber475153998 Screw522007751 Kit - Front Rack Mount675423244 Nut, Nylok775584032 Washer85432155-0701 Bumper975153912 Screw1075153902 Screw1175559544 Washer121040554-0671040555-06711 Support, Front Rack, LHSupport, Front Rack, RH1375122324 Screw14243101424310154030059112 Headlight, LHHeadlight, RHBulb, Replacement, 27W1575153842 Bolt1675584024 Washer1758104671 Plug, Frame185241398-0675241399-06711 Extension, Frame, LHExtension, Frame, RH195241583-0671 Guard, Brush205240591-0671 Grill, Guard, Brush2176213307 Rivet225241224-0671 Hitch, U-Bolt2376700946 Nut, U-Type2475120976 Screw255431814543181511 Shield, Side, Radiator, LHShield, Side, Radiator, RH2675155472 Screw275211633-0671 Plate, Back Mount10/98A10 DECALSSPORTSMAN 500 a99ch50aa and WORKER 500 A99CH50EA1254678101314159818192062352122 2417 LHRH312111316 Ref. Part DescriptionRef. Part Description170749542 Decal - Rack/Warning270741101 Decal - Load Distribution370776602 Decal - EBS DUAL SENSING 470780261 Decal - Side Panel, RH( a99ch50aa )570776652 Decal - 4x4 Ind.

9 Shaft Drive 67076502707805522 Decal - SPORTSMAN ( a99ch50aa )Decal - WORKER (A99CH50EA)770780241 Decal - Tank Side, RH870765012 Decal - POLARIS 970780031 Decal - Headlight Adjustment1070749351 Decal - Warning, AWD Switch1170777651 Decal - POLARIS Domed1270776631 Decal - 500 1370780451 Decal - LIQUID COOLED 1470783541 Decal - Discretionary Warning1570757411 Decal - Drain Recoil1670777491 Decal - Park Brake Lock(A99CH50EA)1770762021 Decal - CE Regulation1870762731 Decal - Override Switch, AWD1970780231 Decal - Tank Side, LH2070782531 Decal - Age Warning, ATV2170779201 Decal - Passenger Warning2270758341 Decal - Tire Pressure2370780251 Decal - Side Panel, LH( a99ch50aa )2470779191 Decal - Warning, General, CPSC1/99A11 DECALSSPORTSMAN 500 a99ch50ab and WORKER 500 A99CH50EB8222257131810232015621112416141 2193317161 LHRH9455 Ref. Part DescriptionRef. Part Description170749542 Decal - Rack/Warning270741101 Decal - Load Distribution370776602 Decal - EBS DUAL SENSING 470780261 Decal - Side Panel, RH570776652 Decal - 4x4 Ind.

10 Shaft Drive 67076502707805522 Decal - SPORTSMAN ( a99ch50ab )Decal - WORKER (A99CH50EB)770782531 Decal - Age Warning870765012 Decal - POLARIS 970780031 Decal - Headlight Adjust1070749351 Decal - Warning, AWD Switch1170780281 Decal - Tank Side, RH1270780451 Decal - LIQUID COOLED 1370783541 Decal - Discretionary Warning1470757411 Decal - Drain Recoil1570764831 Decal - Demand 4 Drive1670777491 Decal - Park Brake Lock(A99CH50EB)1770776631 Decal - 500 1870777651 Decal - POLARIS Domed1970762021 Decal - CE Regulation2070762731 Decal - Override Switch, AWD2170780271 Decal - Tank Side, LH2270779201 Decal - Passenger Warning2370758341 Decal - Tire Pressure2470780251 Decal - Side Panel, LH2570779191 Decal - Warning, General, CPSC1/99A12 COOLING SYSTEMSPORTSMAN 500 a99ch50aa and SPORTSMAN 500 a99ch50ab and WORKER 500 A99CH50EA and WORKER500 A99CH50EB4181918171691012111312830313233 2729362623227152520219245142 Ref. Part DescriptionRef. Part Description170806143 Clamp, Hose, Worm Gear270806961 Clamp, Hose, Worm Gear354114101 Hose, Water454110721 Hose, Lower Engine570804921 Cable Tie640102021 Switch, Thermal, Fan725111891 Cap, Pressure812400151 Radiator, U-Flow975526052 Washer1075121132 Bolt1154106074O-Ring1254317601 Cover, Radiator w/Mesh1354105842 Bushing, Mount, Lower Radiator1470521811 Valve, Drain Cock1554325931 Shroud, Fan, ATV1650205722 Spacer, Mount, Radiator1731100322 Mount, Rubber, Radiator1875583012 Washer1975421222 Nut, Nylok2075470043 Nut2175582013 Washer2241700131 Motor, Fan235241355-0671 Bracket, Cooling Fan2475122324 Screw2575174753 Screw2652425501 Blade, Fan2754307431 Cap, Overflow, Drilled2858102791 Gasket, Cap, Overflow2954318951 Plug, Cap3054316731 Tank, Surge318450003-15251 Line, Fuel3270520651 Fitting, Barbed.