This manual pertains to the ATV, specifically for the 2004 model year. Designed for a variety of off-road applications, the 500 H.O. is recognized for its robust engineering and reliable performance. This parts manual is an essential resource for identifying and understanding the components that comprise this capable all-terrain vehicle, with chassis codes including A04CH50AA, A04CH50AC, A04CH50AE, and A04CH50AG.
The purpose of this English-language parts manual is to provide comprehensive documentation for parts reference and identification of the ATV. It details numerous sections, including but not limited to the cooling system, engine mounting, electrical components, fuel system, and various suspension and drivetrain parts. This manual is an indispensable tool for owners, mechanics, and technicians seeking to accurately identify and source the correct parts for maintenance and repair, ensuring the continued optimal functioning of the vehicle.
2004 Polaris Sportsman 500 H.O. PARTS MANUAL - INSTANT DOWNLOAD (2.1 MB) !!
File Format: PDF
Compatible: All Versions of Windows & Mac
Downloadable: YES
Language: English
Requirements: Adobe PDF Reader
TABLE OF CONTENTS
===============
SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG
Parts Manual
A
A--ARM / STRUT MOUNTING . . . . . . . . . . . . B12
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
B
BUMPER MOUNTING . . . . . . . . . . . . . . . . . A-8
C
CALIPER, REAR . . . . . . . . . . . . . . . . . . . . . B7
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . D5-6
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . C7
CONTROLS -- MASTER
CYLINDER/BRAKE LINE . . . . . . . . . . . . B3
CONTROLS -- THROTTLE ASM./CABLE . . . . B4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . A10
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . D1
CRANKSHAFT and PISTON . . . . . . . . . . . . . D2
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4
D
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . C5
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . B8
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . C6
E
ELECTRICAL / TAILLIGHT . . . . . . . . . . . . . . C8
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A13-14
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A11
F
FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . B6
FRAME MOUNTING . . . . . . . . . . . . . . . . . . . C3
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . A5
FRONT HOUSING . . . . . . . . . . . . . . . . . . . . C12
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . B11
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . B13
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . D14
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . A12
G
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C4
G
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C13-14
H
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . C1-2
HEADLIGHT POD . . . . . . . . . . . . . . . . . . . . . C1-2
I
INTAKE and EXHAUST . . . . . . . . . . . . . . . . . D7
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . D12
MASTER CYLINDER, REAR . . . . . . . . . . . . B6
O
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D11
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D10
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
P
PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B10
R
RACK MOUNTING, FRONT . . . . . . . . . . . . . A7-8
REAR CAB and SEAT . . . . . . . . . . . . . . . . . A3-4
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . B9
REAR RACK MOUNTING . . . . . . . . . . . . . . . A6
REAR SUSPENSION . . . . . . . . . . . . . . . . . . C9-10
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . C11
RECOIL STARTER . . . . . . . . . . . . . . . . . . . . D8
S
STARTING MOTOR . . . . . . . . . . . . . . . . . . . D13
STEERING POST . . . . . . . . . . . . . . . . . . . . . B14
T
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E1
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D9
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
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2004 Polaris Sportsman 500 H.O. PARTS MANUAL - INSTANT DOWNLOAD (2.1 MB) !!
File Format: PDF
Compatible: All Versions of Windows & Mac
Downloadable: YES
Language: English
Requirements: Adobe PDF Reader
TABLE OF CONTENTS
===============
SPORTSMAN 500 A04CH50AA and SPORTSMAN 500 A04CH50AC and SPORTSMAN 500 A04CH50AE and SPORTSMAN 500 A04CH50AG
Parts Manual
A
A--ARM / STRUT MOUNTING . . . . . . . . . . . . B12
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
B
BUMPER MOUNTING . . . . . . . . . . . . . . . . . A-8
C
CALIPER, REAR . . . . . . . . . . . . . . . . . . . . . B7
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . D5-6
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . C7
CONTROLS -- MASTER
CYLINDER/BRAKE LINE . . . . . . . . . . . . B3
CONTROLS -- THROTTLE ASM./CABLE . . . . B4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . A10
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . D1
CRANKSHAFT and PISTON . . . . . . . . . . . . . D2
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4
D
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . C5
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . B8
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . C6
E
ELECTRICAL / TAILLIGHT . . . . . . . . . . . . . . C8
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A13-14
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A11
F
FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . B6
FRAME MOUNTING . . . . . . . . . . . . . . . . . . . C3
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . A5
FRONT HOUSING . . . . . . . . . . . . . . . . . . . . C12
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . B11
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . B13
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . D14
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . A12
G
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C4
G
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C13-14
H
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . C1-2
HEADLIGHT POD . . . . . . . . . . . . . . . . . . . . . C1-2
I
INTAKE and EXHAUST . . . . . . . . . . . . . . . . . D7
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . D12
MASTER CYLINDER, REAR . . . . . . . . . . . . B6
O
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D11
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D10
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
P
PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B10
R
RACK MOUNTING, FRONT . . . . . . . . . . . . . A7-8
REAR CAB and SEAT . . . . . . . . . . . . . . . . . A3-4
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . B9
REAR RACK MOUNTING . . . . . . . . . . . . . . . A6
REAR SUSPENSION . . . . . . . . . . . . . . . . . . C9-10
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . C11
RECOIL STARTER . . . . . . . . . . . . . . . . . . . . D8
S
STARTING MOTOR . . . . . . . . . . . . . . . . . . . D13
STEERING POST . . . . . . . . . . . . . . . . . . . . . B14
T
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E1
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D9
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
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