SPORTSMAN 6X6 MV Model #A05CL50MA - Military ATV Parts

PARTS MANUAL PN 9919953 and MICROFICHE PN 9919954 8/04

E 2004 Polaris Sales Inc.

SPORTSMAN 6X6 MVModel #A05CL50MA

Military

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* * * MILITARY USE ONLY * * *

Order Online at www.worldofpowersports.com

TABLE OF CONTENTSSPORTSMAN 6X6 MV A05CL50MA

Parts Manual

AA--ARM/STRUT MOUNTING B7. . . . . . . . . . . . .AIR BOX C7. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBRUSH GUARD A7. . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D9-10. . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C8. . . . . . . . . . . . . . . . . . . . .CONTROLS -- MASTER

CYLINDER/BRAKE LINE B10. . . . . . . . . . . .CONTROLS -- RH MASTER

CYLINDER/BRAKE LINE B11. . . . . . . . . . . .CONTROLS -- THROTTLE ASM./CABLE B9. . . .COOLING SYSTEM A9. . . . . . . . . . . . . . . . . . .CRANKCASE D5. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D6. . . . . . . . . . . . .CYLINDER D7-8. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A5. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C5. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT B2. . . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C6. . . . . . . . . . . . . . . . . . . . .DUMP BOX C12. . . . . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL C11. . . . . . . . . . . . . . . . . . . . . . . .ENGINE MOUNTING A11-12. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A10. . . . . . . . . . . . . . . . . . .

FFRONT BRAKE B6. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A3. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING B3. . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A6. . .FRONT STRUT B4. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B5. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP E4. . . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK A13. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C13. . . . . . . . . . . . . . . . . . . .

GGEARCASE D1-2. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING C10. . . . . . . . . . . . . . .GEARCASE SELECTOR MOUNTING C14. . . . . .

HHANDLEBAR and HEADLIGHT POD D3-4. . . . . . .

IINTAKE and EXHAUST D11. . . . . . . . . . . . . . . . .

MMAGNETO E2. . . . . . . . . . . . . . . . . . . . . . . . . .MIDDLE DRIVE B13. . . . . . . . . . . . . . . . . . . . . .

OOIL COOLING A8. . . . . . . . . . . . . . . . . . . . . . .OIL FILTER E1. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D14. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK A14. . . . . . . . . . . . . . . . . . . . . . . . . . .

PPROP SHAFT B1. . . . . . . . . . . . . . . . . . . . . . .

RREAR and MIDDLE WHEEL C2. . . . . . . . . . . . .REAR BRAKE CALIPER B12. . . . . . . . . . . . . . . .REAR CAB and SEAT A4. . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING C9. . . . . . . . . . . .REAR DRIVE B14. . . . . . . . . . . . . . . . . . . . . . . .REAR STRUT STABILIZER C3. . . . . . . . . . . . . .RECOIL STARTER D12. . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR E3. . . . . . . . . . . . . . . . . . .STEERING POST B8. . . . . . . . . . . . . . . . . . . . .SWING ARM WELDMENT (REAR) C4. . . . . . . .SWING ARM/SHOCK MOUNTING C1. . . . . . . .

TTOOL KIT E5. . . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D13. . . . . . . . . . . . . . . . . . . . . . .WINCH A7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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A3

FRONT CABSPORTSMAN 6X6 MV A05CL50MA

5

6

7

810

32

1617

1211

14

1918

7

1

15

9

20


21

13

21

22

4

4

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5811491 1 Foil, Side Panel, RH2 5810996 1 Foil/Foam, Side Panel3 2632663-177

2632782-1775812138

111

Asm., Panel/Foam, Black Metallic, LHAsm., Panel/Foil, Black Metallic, RHFoam, Panel, LH

4 7517386 4 Screw5 5435110-400 1 Cover, Front, Camo Green6 2632986-400 1 Asm., Cab, Front, Camo Green

(w/Warning Decals)7 7670057 12 Nut, Speed8 7670135 4 Nut, Speed9 7517312 2 Screw10 5431798-070

5431799-07011

Guard, Mud, Front, Black, LHGuard, Mud, Front, Black, RH

11 7541925 2 Nut, Nylok12 7555792 2 Washer13 7556034 2 Washer14 7512085 2 Screw15 7512232 10 Bolt16 7555931 2 Washer17 7542122 2 Nut, Nylok18 5412191 1 Line, Breather19 7670109 1 Clip, Routing20 7621509 2 Rivet21 5246315-067

5246316-06711

Guard, Splash, Black, LHGuard, Splash, Black, RH

22 7517685 1 Screw

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A4

REAR CAB and SEATSPORTSMAN 6X6 MV A05CL50MA

31

34

34

5

6

18

21

323029

28

27

23

26

25

24

21

10

20

8

11

9

12

15

19

16

7


33

22

17

13

14

4



1 7661645 4 Rivet2 5433428-400 1 Cab, Rear, Camo Green Metallic3 7512242 4 Screw4 7555859 10 Washer, Flat5 2682959-070

2682960-07011

Asm., Seat, BlackCovering, Seat, Black

6 1013967-067 1 Frame, Main, Black7 5410414 3 Bumper, Rubber8 7512240 2 Bolt9 5432798 2 Plug, Nylon10 1013307-067 1 Lever, Box, Black11 7542153 2 Nut, Nylok, Flange12 7041879 1 Spring, Latch Return13 7515179 6 Screw14 5432763 1 Guard, Rock15 7555734 2 Washer, Flat16 7542324 2 Nut, Nylok17 5432280 1 Spacer, Footwell18 7542122 8 Nut, Nylok

19 7512392 2 Bolt20 1040293-067 1 Mount, Strut, Rear21 7512279 6 Screw22 7517377 2 Screw23 5432221-070

5434417-07011

Footwell, Black, LHFootwell, Black, RH

24 7512232 12 Bolt25 5431796-070

5431797-07011

Guard, Mud, Rear, Black, LHGuard, Mud, Rear, Black, RH

26 7670057 12 Nut, Speed27 5811111 1 Foil28 5811106 2 Foil, Rear Cab, Front29 5811087 1 Foil30 7079902 1 Decal, Carb/Filter Information31 7541925 2 Nut, Nylok32 7555792 2 Washer33 7556034 2 Washer34 7512085 2 Screw

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A5

DECALSSPORTSMAN 6X6 MV A05CL50MA

LH

1

2

3



1 7172588 1 Decal, Warning, Age 162 7172592 1 Decal, Warning, Front Rack, 75 LBS.3 7172589 1 Decal, Discretionary Warning

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A6

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 6X6 MV A05CL50MA

9

1112

1314

15

10

6

5

7

8

16

1718

19

2

3

4

4

1

6

9

4




1 7517685 4 Screw2 2632987-070 1 Asm., Front Rack, Black

(Incl. Ref. 3 and Warning Decal)3 7079926 2 Decal, Reflector, Amber4 7515399 8 Screw5 1014023-067 1 Support, Front Rack, Black6 7542324 4 Nut, Nylok7 5432155-070 1 Bumper, Black8 7517977 4 Bolt9 7512232 6 Bolt10 1013744-067

1013746-06711

Support, Front Rack, Black, LHSupport, Front Rack, Black, RH

11 243101424310154030059

112

Asm., Headlight, LHAsm., Headlight, RHBulb, Replacement, 27W

12 7512329 2 Bolt13 7558402 2 Washer, Flat14 5810467 1 Plug, Frame15 5244729-067

5244730-06711

Extension, Frame, Black, LHExtension, Frame, Black, RH

16 1013772-067 1 Guard, Brush, Black17 7670094 6 Nut18 7512097 6 Screw19 5433923

543392411

Shield, Side, Radiator, LHShield, Side, Radiator, RH

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A7

WINCH and BRUSH GUARDSPORTSMAN 6X6 MV A05CL50MA


8

12

11

4

2

3

14

15

6

1

19

7

9

10

1816

5

13

17

4



1 1014996-067 1 Guard, Headlight, Black, RH2 7515203 6 Screw3 7517208 4 Screw4 7542122 8 Nut, Nylok5 1014994-067 1 Guard, Brush, Black6 1014995-067 1 Guard, Headlight, Black, LH7 2202876 1 Winch, Warn8 5247293-067 1 Plate, Winch Mount, Black9 1015038 1 Roller, Fairlead, Warn Winch10 7552901 4 Washer, Spring Lock

11 7515317 4 Screw12 7542343 4 Nut, Flange13 7512310 4 Screw14 7517686 6 Screw15 7670057 6 Nut, U16 7517386 2 Screw17 7512247 2 Screw18 4011179 1 Asm., Contactor w/Wires19 5246340 1 Bracket, Contactor/Solenoid, Winch

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A8

WINCH SWITCH and HOOKSPORTSMAN 6X6 MV A05CL50MA


1

2

3

4



1 40111802202255

11

Asm., Handlebar SwitchSwitch, Winch

2 7512247 2 Bolt

3 5133010 2 Spacer, Master Cylinder Clamp4 2202253 1 Asm., Hook, Warn Winch

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A9

COOLING SYSTEMSPORTSMAN 6X6 MV A05CL50MA

29

2

13

12

28 27

18

32

1130

33

34

9

31

3 15

2019

24

10

23

17

21

26

25

14

168

14

11

7

8

4

5

1

1 6

9

E 2004 Polaris Sales Inc.22



1 7080614 2 Clamp, Hose2 1240044 1 Cap, Pressure3 5433364 1 Filler, Coolant4 5243505 1 Bracket, Filler, Coolant5 7661637 3 Rivet6 5433948 1 Flexguard7 5411811 1 Hose, Engine, Upper8 7080827 2 Clamp, 1 Inch9 7512084 4 Screw10 5411632 1 Hose, Neck, Filler11 7080826 2 Clamp12 7517659 4 Screw13 2410430 1 Asm., Fan and Motor14 7670111 4 U-Clip15 7547069 2 Nutsert16 3110032 2 Mount, Rubber17 5020572 2 Spacer, Mount18 5433059 1 Shroud, Fan

19 1240178 1 Radiator20 7552801 2 Washer, Split Lock21 7512240 2 Bolt22 7558301 2 Washer, Flat23 7052296

541163311

Valve, DrainO-Ring

24 5410584 2 Bushing, Mount, Lower, Red25 5243503-067 1 Bracket, Radiator, Lower, Black26 7512232 2 Bolt27 5411694 1 Hose, Engine, Lower28 5521511 1 Guard, Hose29 5430743 1 Cap, Overflow30 5810279 1 Gasket31 5433774 1 Plug, Cap32 5433410 1 Tank, Surge33 8450003-1525 AR Line, Fuel34 7052065 1 Fitting, 90 Degree

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A10

EXHAUST SYSTEMSPORTSMAN 6X6 MV A05CL50MA

2221

3

2

14

13

20

1

18

15 10

9

4

5

5

5

5

1112

10

16

17


6

8

7

19



1 7515316 2 Bolt2 5412233 2 Dampener, Vibration3 5010192 2 Bushing4 1260989-029 1 Silencer, Black5 7041804 4 Spring, Exhaust6 5412067 1 Bumper, Rubber7 7517386 1 Screw8 5246408 1 Bracket, Support, Side Panel, RH9 1261245-029 1 Pipe, Exhaust, Black10 5243518 2 Seal, Exhaust11 7512232 2 Bolt

12 5242344 1 Bracket, Exhaust, Support13 7542301 1 Nut, Hex14 3110064 1 Mount, Torque Stop15 7042029 1 Spring, Exhaust16 5244014 1 Shield, Heat, Exhaust17 7517615 2 Screw18 7512666 2 Bolt19 7556230 1 Washer20 5410436 2 Washer, Rubber21 7555716 2 Washer22 7542324 2 Nut, Nylok

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A11

ENGINE MOUNTINGSPORTSMAN 6X6 MV A05CL50MA

21

35

46

2

3

5

6

7

8

10

114

17

18

9

9

2422

2728

293031

32

33

34

38

4342

44 45

9

15

14

16

13

37

36

13

25

1

40

39

2341

2

26

1

1

1

1

9

12

2

11 11

1918

18


20

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A12

ENGINE MOUNTINGSPORTSMAN 6X6 MV A05CL50MA



1 7547108 6 Nut2 7555801 4 Washer3 4010132 1 Cable, Ground/Engine4 7512232 1 Bolt5 3110044 1 Mount, Rubber, Top6 5242674 1 Bracket, Mount, Engine, Top7 7552901 2 Washer, Spring Lock8 7512315 2 Bolt9 7080003 4 Clamp, Hose10 8450040-600 AR Line, Fuel11 8450003-1525 AR Line, Fuel12 7052075 1 Fitting, Tee13 3084205 5 Screw and Washer14 5246553 1 Bracket, Carburetor Mount15 7541923 2 Nut, Well16 7512247 2 Bolt17 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D10, Ref. 31)18 8360009-600 AR Line, Fuel19 7051011 1 Valve, Check20 8450103 AR Hose, Fuel21 8450105-65 AR Sheath, Reflect Sleeve22 1014993-067 1 Mount, Rear Engine, Black23 7547089 2 Nut, Flange, Lock24 3110046 2 Mount, Rubber, Front25 7517289 1 Screw26 7555815 2 Washer, Flat27 5412487 1 Boot, Clutch Intake

28 7080511 1 Clamp, Narrow Band29 5430261 1 Bushing, Returning Bolt30 5210748 1 Washer31 7575202 1 Washer, Lock32 7512566 1 Bolt33 ------ -- -- -- -- 1 Asm., Drive Clutch

(See Drive Clutch Pg. C5 for Details)34 ------ -- -- -- -- 1 Bracket, Clutch, Seal

(See Clutch Cover Pg. C8, Ref. 16)35 1040688-067 1 Mount, Engine, Front, Black36 7515398 2 Screw37 7542324 2 Nut, Nylok38 3110067 1 Mount, Motor39 7080474 2 Clamp, Hose40 7552603 1 Washer, Spring Lock41 7515417 1 Screw42 ------ -- -- -- -- 2 Nut (See Cylinder Pg. D8, Ref. 23)43 ------ -- -- -- -- 2 Washer, Spring

(See Cylinder Pg. D8, Ref. 22)44 1261171-029 1 Manifold, Black45 ------ -- -- -- -- 1 Gasket, Exhaust

(See Cylinder Pg. D8, Ref. 20)46 3089538

3089539

1

1

Engine, Short Block(If built before 8/09/04)Engine, Short Block (If built after8/09/04) NOTE: The Short Block as-sembly contains a crankcase assembly,cylinder and cylinder head assembly,and a piston & crankshaft assembly.Prior authorization required forwarrantyconsideration.

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A13

FUEL TANKSPORTSMAN 6X6 MV A05CL50MA

20

5

15

7

910

1

2

3

8

12

11

4

13

6

12

19

14

13

12

1213

18

13


17 16



1 5433687 1 Cap, Gas Tank2 5812123 1 Gasket, Gas Cap3 5811310 1 Seal, Foam4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7517685 2 Screw7 5222154

522215511

Bracket, Fuel Mounting, Rear, LHBracket, Fuel Mounting, Rear, RH

8 7052161 1 Valve, 3-Way9 5432733 1 Nut, Fuel Valve10 5432559 1 Knob, Fuel Valve

11 7517505 1 Screw12 7080003 6 Clamp, Hose13 8450103 AR Hose, Fuel14 5812005 1 Foil15 7052364 1 Fitting, Dual, Outlet16 7515136 1 Screw17 8450105-65 AR Sheath, Reflect Sleeve18 2530009 1 Filter19 5812004 1 Foil20 2520407 1 Asm., Fuel Tank (Incl. 14-16,19)

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A14

OIL TANKSPORTSMAN 6X6 MV A05CL50MA

18

54

8

1617

14

1 72

13

3

10

75421

9

15

12

11

11

6

6




1 7515189 2 Screw2 7558301 2 Washer, Flat3 5412191 1 Line, Breather4 5410828 2 Grommet5 5333204 2 Bushing, Mounting6 7555932 2 Washer, Nylon7 7542122 2 Nut, Nylok8 5434308 1 Dipstick, Oil Tank9 7080699 1 Clamp, Hose

10 8450073-25 1 Line, Breather11 7080474 2 Clamp, Hose12 8450096-100 AR Line13 7081026 1 Clamp, Hose, Spring14 7052326 1 Screen, Oil Filter, 90 Degree15 5412507 1 Grommet16 5850135 1 Washer17 7051524 1 Plug18 1261176 1 Tank, Oil

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B1

PROP SHAFTSPORTSMAN 6X6 MV A05CL50MA

9 8 7 6

3

1

11

4105

2




1 7512232 2 Bolt2 7558301 2 Washer, Flat3 5433154 1 Guard, Prop Shaft, Front4 5411092 1 O-Ring5 7080424 1 Fitting, Lubrication6 3260131 1 Yoke

7 1350072 1 Shaft, Prop8 2202015 2 Kit, Cross and Bearing9 3260133 1 Yoke10 1380217 1 Asm., Prop Shaft, Front (Incl. 6-9)11 7661913 1 Pin, Spring

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B2

DRIVE SHAFTSPORTSMAN 6X6 MV A05CL50MA

6 7 8

10

3 51

2 4 9




1 1380215 1 Asm., Drive Shaft, Front2 1380190 1 Joint, CV3 3260121 1 Clamp, Band4 7670092 1 Circlip5 2201015 1 Kit, Replacement Boot

6 1380223 1 Shaft, Drive (Incl. 4)7 2202015 1 Kit, Cross and Bearing8 3260133 1 Yoke9 7661913 2 Pin, Spring10 3260123 1 Clamp, Band

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B3

FRONT HOUSINGSPORTSMAN 6X6 MV A05CL50MA

123

4 56

7

8

910

1112

13

1415

16

17

1819 20

21

22

23

24

25

2627 2

1




1341323 1 Asm., Front Gearcase (Incl. 1-12,15-25)1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing, Ball7 3233726 1 Pinion, Input, 14T8 3233541 1 Bushing9 3233319 1 Seal10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug, Oil Fill13 8450003-1525 AR Line, Fuel

14 7080307 1 Clamp, Hose15 3233524 1 Tube, Vent16 3233696 1 Gearcase17 3233725 1 Shaft, Output, 29T18 3233020 1 Bearing19 3233554 AR Shim20 3233693 1 O-Ring21 3233724 1 Cover, Output22 3233583 AR Shim23 3233582 1 Button, Thrust24 3233254 1 Washer, Plug25 3233253 1 Plug, Drain26 7552603 4 Washer, Spring Lock27 7512492 4 Screw

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B4

FRONT STRUTSPORTSMAN 6X6 MV A05CL50MA

1

2

3

45

6

9

10

8

11

12

13

15

16

7

14

17

18

19

2120

2223

24

2526

27

1112


8

8



1 5412665 2 Bumper2 7041761 2 Strut, Front3 5211115 2 Washer, Spring Retainer4 7080367 2 Clamp, Cable5 7542324 4 Nut, Nylok6 7512365 4 Screw, Cap7 7552901 4 Washer, Spring Lock8 7558402 10 Washer, Flat9 5810439 2 Retainer, Casting Wire, Strut10 ------ -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B6 for Details)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 1820950

1820951

1

1

Asm., Hubstrut, LH(42mm)(Incl. 9,12-15,23)Asm., Hubstrut, RH(42mm)(Incl. 9,12-15,23)

17 7041450-067 2 Spring, Coil, Black18 5243364 2 Retainer, Spring19 5432871 2 Ball, Pivot, Bottom20 7515339 4 Bolt21 5132062 2 Spacer22 ------ -- -- -- -- 1 Asm., Drive Shaft

(See Drive Shaft Pg. B2 for Details)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut

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B5

FRONT WHEELSPORTSMAN 6X6 MV A05CL50MA

10 11 12 14

1 2

34

5

79

8

15

1625

24 7

17 1820

21

23

13

6

6

22

19




1 7512325 8 Bolt2 5243676 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub, Elec./Mech.6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515513 8 Stud9 1520243 2 Asm., Hub w/Bearing Race (Incl. 3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter13 1321814 2 Spacer

14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 2872464 2 Tire, 25x8-1217 7556004 2 Washer18 7542810 2 Nut, Slotted19 7661401 2 Pin, Cotter20 5410470 2 O-Ring21 5432611 2 Cap, Hub22 7512027 6 Screw23 7547237 8 Nut, Flange24 1520269-463 2 Rim, Front, Flat Black25 1525017 2 Valve, Rim

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B6

FRONT BRAKESPORTSMAN 6X6 MV A05CL50MA

1

2 3

78

10

9

111213

4 5 6




1910692

1910877

1

1

Asm., Caliper, Brake, LH(If built before 4/1/04)(Incl. 1-6,8,9)Asm., Caliper, Brake, LH(If built after 4/1/04)(Incl. 1-6,8,9)

1910693

1910878

1

1

Asm., Caliper, Brake, RH(If built before 4/1/04)(Incl. 1-6,8,9)Asm., Caliper, Brake, RH(If built after 4/1/04)(Incl. 1-6,8,9)

1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 5133412

5134754513341351347551930642

11111

Caliper, LH (If built before 4/1/04)Asm., Caliper, LH (If built after 4/1/04)Caliper, RH (If built before 4/1/04)Asm., Caliper, RH (If built after 4/1/04)Kit, Front Brake Boot

4 5411596 1 Seal, Caliper, Inner5 5411597 1 Seal, Caliper, Outer6 5132405 1 Piston, Caliper7 2202412 2 Kit, Asm., Brake Pad8 1910411 1 Asm., Mount, Caliper9 5410495 1 Boot, Bushing10 5410494 1 Boot, Pin Seal11 ------ -- -- -- -- 4 Washer, Flat

(See Front Strut Pg.B4, Ref. 8)12 ------ -- -- -- -- 4 Washer, Spring Lock

(See Front Strut Pg. B4, Ref. 7)13 ------ -- -- -- -- 4 Screw, Cap

(See Front Strut Pg. B4, Ref. 6)

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B7

A-ARM/STRUT MOUNTINGSPORTSMAN 6X6 MV A05CL50MA

1 3

45

6

7

9

2

11

12

13

24

14

15

17

1618

20

2322

21

25

25

21

19 13

8

10

26




1 7542439 2 Nut, Nylok2 1820805 2 Asm., Tie Rod (Incl. 3-9)3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End, RH5 7542711 2 Nut, Jam6 5020926 2 Tie Rod7 7547028 2 Nut, Jam, LH8 7517909 2 Bolt9 7061054 2 Rod End, LH10 5411920 1 Boot, Seal, Rod End11 7556099 4 Washer12 7547177 2 Nut13 7661203 4 Pin, Cotter14 7080673 2 Joint, Ball

15 5211121 2 Bracket, Ball Joint16 7512284 4 Bolt, Socket17 5410548 2 Boot, Rubber18 7542438 2 Nut, Castle19 5431150-070

5431149-07011

Shield, CV Joint, Black, LHShield, CV Joint, Black, RH

20 7512084 4 Screw21 5434551 4 Bushing, A-Arm, Long, Black22 5133806 2 Shaft, A-Arm23 2202282

220228311

Kit, A-Frame, LH (Incl. 13,21,22,25)Kit, A-Frame, RH (Incl. 13,21,22,25)

24 ------ -- -- -- -- 1 Asm., Hubstrut(See Front Strut Pg. B4, Ref. 16)

25 7518364 4 Bolt26 7515415 2 Screw

5/04

Military

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B8

STEERING POSTSPORTSMAN 6X6 MV A05CL50MA

31

42

8

10

6

9

7

2

5

6

1


5



1 7542343 4 Nut, Flange2 5433866 2 Bushing, Steering, Upper3 1822630-067 1 Post, Steering, Black4 5246732 1 Bracket, Steering, Upper5 7517428 4 Bolt

6 7556162 2 Bushing7 5222393 1 Flangette8 3514352 1 Bearing9 7547158 1 Nut, Slotted, Hex10 7661633 1 Pin, Cotter

5/04

Military

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B9

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 6X6 MV A05CL50MA

5

2

4

3

6

1 E 2004 Polaris Sales Inc.



1 5410193 1 O-Ring2 5434113 1 Cover3 5411439 1 O-Ring

4 7081170 1 Cable, Throttle5 2010230 1 Asm., Throttle Control, AWD (Incl. 6)6 2010191 1 Asm., Throttle Clamp

5/04

Military

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B10

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 6X6 MV A05CL50MA

16

19

10

13

14

15

15

4

17

183

1112

20

2

1

9

7

6

5

4

13


8

2 22020



2010238 1 Asm., Master Cylinder1 5411297 1 Boot, Brake Line, Rubber2 5410988 6 Seal3 4110164 1 Switch4 7517899 2 Screw5 2202725 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)6 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)7 2201833 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)8 2202410 1 Kit, Piston

(Incl. Piston, Seals, Boot, Spring)9 2201835 1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)10 1910480 1 Line, Brake, JB to Rear

11 7621462 3 Rivet12 7080539 3 Clamp, Nylon13 8360031-34 2 Conduit14 1910474

1910838

1

1

Line, Brake, Front, LH(w/Fittings)(If built before 4/1/04)Line, Brake, Front, LH(w/Fittings)(If built after 4/1/04)

15 7080138 8 Cable Tie16 7512024 2 Screw17 1910475

1910839

1

1

Line, Brake, Front, RH(If built before 4/1/04Line, Brake, Front, RH(If built after 4/1/04)

18 7052292 1 Fitting, Cross19 1910470 1 Line, Brake, Pod20 1910499 3 Bolt, Banjo

5/04

Military

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B11

CONTROLS - RH MASTER CYLINDER/BRAKE LINESPORTSMAN 6X6 MV A05CL50MA

41

2

8

7

6

3

5




2010201 1 Asm., Master Cylinder1 1910499 1 Bolt, Banjo2 5410988 2 Seal3 2202195 1 Kit, Lever, RH4 7517899 2 Screw

5 2202196 1 Kit, Cover (Incl. Cap w/Glass, Baffleand Diaphragm)

6 2202194 1 Kit, Piston, RH7 2202193 1 Kit, Clamp, RH8 1910481 1 Line, Brake, Pod, RH

5/04

Military

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B12

REAR BRAKE CALIPERSPORTSMAN 6X6 MV A05CL50MA

5

1

2

34

6

7

9 8E 2004 Polaris Sales Inc.



2201683 1 Kit, Piston, Seals (Incl. 1-4,9)2201684 1 Kit, Seals (Incl. 2-4,9)

1 ------ -- -- -- -- 1 Piston2 ------ -- -- -- -- 1 Seal, Dust3 ------ -- -- -- -- 1 Ring, Square4 ------ -- -- -- -- 1 Ring, Square

5 1910408 1 Asm., Caliper, Brake6 2201428 2 Kit, Bleeder7 7517758 2 Bolt, Shoulder8 2201749 1 Kit, Brake Pads9 ------ -- -- -- -- 2 O-Ring

5/04

Military

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B13

MIDDLE DRIVESPORTSMAN 6X6 MV A05CL50MA

1432

5

23

78 9

6

10

12

13

11

14 15 16 17 18

24

19

22

27

28

21

20 181617

21

41

25

3

96

78

23

10

23

23

2625




1 7710472 2 Ring, Retaining2 5510372 2 Retainer, Nut3 5411555 2 Seal, Foam4 7547031 2 Nut, Jam5 5630987 2 Hub, Locking Middle Axle6 3610074 2 Seal7 5132219 2 Housing, Swing Arm8 3515501 2 Bearing, Ball9 3610013 2 Seal, Axle, Rear10 5132218 2 Spacer, Bearing11 7542439 3 Nut, Nylok12 5244425 1 Disc, Brake13 1520259 1 Asm., Hub, Brake Disc, Locking14 7710405 1 Ring, Snap

15 5010462 1 Spacer, Axle16 3610070 2 Seal, Lip17 3554518 2 Bearing, Cone, Tapered18 3554517 2 Bearing, Cup, Tapered19 5132098 1 Housing, Axle, Rear20 7080306 1 Fitting, Lubrication21 5410889 2 O-Ring22 7515513 3 Stud23 5411739 4 O-Ring24 5132049 1 Axle, Middle25 3221139 1 Sprocket, 38T26 3221138 1 Sprocket, 30T27 3221193-080 1 Chain, 80P28 3221192 1 Link, Connector

5/04

Military

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B14

REAR DRIVESPORTSMAN 6X6 MV A05CL50MA

11

5

7

1

89

3

13

4 6

12

2

645 3

10




1 7710405 1 Ring, Snap2 5132464 1 Spacer, Bearing3 5410889 2 O-Ring4 3610070 2 Seal, Lip5 3554518 2 Bearing, Cone, Tapered6 3554517 2 Bearing, Cup, Tapered7 5132497 1 Axle, Rear

8 5132875 1 Housing, Axle, Rear9 7080306 1 Fitting, Lubrication10 3221140 1 Sprocket, 30T11 5020468 2 Nut, Jam12 3221192 1 Link, Connector13 3221193-116 1 Chain, 116P

5/04

Military

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C1

SWING ARM/SHOCK MOUNTINGSPORTSMAN 6X6 MV A05CL50MA

7

6

5

2

4

1

3

12

13

16

11

20

109

17

14 15

2524

23 22

21

8

27

26

1

16

11

8

28

28

29

2929

29

30

31

32

31


1918



1 7542439 2 Nut, Nylok2 7041962 1 Shock, Mid Axle3 7515438 1 Bolt4 7556142 1 Washer5 7041987-067 1 Spring, Compression, Black6 5241147 1 Retainer, Shock7 7515415 1 Screw8 5134321 2 Bolt, Swing Arm Pivot9 5133166 1 Bushing, Swing Arm Pivot, LH10 5434545 1 Bushing, Swing Arm, Black, LH11 7080510 2 Fitting, Zerk12 7661046 2 Rivet13 5432727 1 Guide, Chain Pad14 7547082 1 Nut, Hex, Jam15 7556035 1 Washer, Flat16 5434546 2 Bushing, Swing Arm, Black, RH

17 5133167 1 Bushing, Swing Arm Pivot, RH18 7515399 2 Screw19 5247488 2 Bracket, Bolt Lock20 1541583 1 Asm., Swing Arm (Incl. 10,11,16)21 5432854 1 Guard, Chain22 7515304 1 Screw, Flange23 5332828 1 Bushing24 7558402 1 Washer, Flat25 7542343 1 Nut, Flange26 7542522 2 Nut, Flange27 7512576 2 Bolt28 7542324 4 Nut, Nylok29 7558402 8 Washer, Flat30 5222221-067 1 Mount, Rock Guard31 7512325 4 Bolt32 1013328-067 1 Guard, Swing Arm, Black

8/04

Military

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C2

REAR and MIDDLE WHEELSPORTSMAN 6X6 MV A05CL50MA

2

3

10

4

87

5

6

12

1087

6

5

1

9

11

9




1 7512673 16 Bolt2 5131777 4 Hub, Wheel3 2872463 4 Tire, 25x11-104 7542714 16 Nut5 7661404 2 Pin, Cotter6 5411164 4 Dust Cover, Hub

7 7543005 4 Nut, Castle8 7555745 4 Washer9 7555796 4 Washer, Cone10 1525017 4 Valve, Rim11 7670081 16 Nut, Push12 1520183-463 4 Rim, Rear, Flat Black

8/04

Military

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C3

REAR STRUT STABILIZERSPORTSMAN 6X6 MV A05CL50MA

6

9

7

4

11

10

32

1

5

8

32

1

32

1

4




1 7555832 6 Washer2 7552603 6 Washer, Spring Lock3 7512492 6 Screw4 5434551 2 Bushing, A-Arm, Long, Black5 5020764 1 Shaft, Upper6 1541853-067 1 Stabilizer, Upper, Black

7 5020765 1 Shaft, Stabilizer8 5020766 1 Shaft, Stabilizer, Lower9 1541852-067 1 Stabilizer, Lower, Black10 5434548 2 Bushing, A-Arm, Short, Black11 5434553 2 Bushing, Stabilizer, Long, Black

5/04

Military

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C4

SWING ARM WELDMENT (REAR)SPORTSMAN 6X6 MV A05CL50MA

7

16

3

15

9

105

25

11

2223

21

20

8

24

14

12

6

1

4

213

17

1918

13

7

9

1819

17

12

1313

12

13

14




1 7542439 2 Nut, Nylok2 7041963 1 Shock, Rear3 7515415 2 Screw4 7556142 1 Washer5 7041880-067 1 Spring, Compression, Black6 5241147 1 Retainer, Short7 7517386 4 Screw8 5433539 1 Cover, Chain9 7661637 4 Rivet10 5244077-067 1 Mount, Chain Cover, Front, Black11 5244078-067 1 Mount, Chain Cover, Rear, Black12 7542522 6 Nut, Flange13 7555883 8 Washer

14 7512576 4 Bolt15 7512520 2 Bolt16 1580067-067 2 Bracket, Swing Arm17 7515321 3 Bolt18 7558402 6 Washer, Flat19 7542324 3 Nut, Nylok20 1013327-067 1 Guard, Chain, Lower, Black21 7515117 1 Screw22 5521279 1 Guide, Chain, Rear23 7541925 1 Nut, Nylok24 2200472 1 Kit, Hitch (Incl. 12-14)25 1541344-067 1 Extension, Swing Arm, Black

8/04

Military

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C5

DRIVE CLUTCHSPORTSMAN 6X6 MV A05CL50MA

12 3

612

4 5 6

7

11

10

89E 2004 Polaris Sales Inc.



1321976 1 Asm., Drive Clutch (Incl. 1-2,6-10)1 7518062 6 Screw2 3576510 1 Bearing, Cover3 7041157 1 Spring, Clutch4 5430945 6 Washer5 1321457 3 Asm., Roller and Bushing6 5431936 6 Button, Clutch

7 5210752524298152107535210754

ARARARAR

Spacer, .020Spacer, .025Spacer, .032Spacer, .050

8 5630513 3 Weight, Shift, 10-MH9 7512266 3 Bolt, Shoulder10 7541906 3 Nut, FLEXLOC11 3576504 1 Bushing, Moveable12 5020422 3 Pin, Roller

5/04

Military

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C6

DRIVEN CLUTCHSPORTSMAN 6X6 MV A05CL50MA

2

3

45

6

7

9

10

11

12

14

1516

1

8

13




1 7556120 AR Bushing (3 Max)2 3211077 1 Belt, Drive3 1322180 1 Asm., Driven Clutch (Incl. 7-16)4 5220646 1 Washer, Dome5 7552901 1 Washer, Spring Lock6 7515382 1 Bolt7 7555898

7556076ARAR

Washer, .020Washer, .025

8 7556804 AR Washer, .030

9 3576504 1 Bushing, Moveable10 3576511 1 Bushing, Moveable, 1 Inch11 7041198 1 Spring, Clutch, Red12 5131446 1 Ramp, Stationary13 5210752 1 Spacer, 02014 7710448 1 Ring, Retaining15 7511854 3 Bolt16 5430766 3 Button, Ramp

5/04

Military

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C7

AIR BOXSPORTSMAN 6X6 MV A05CL50MA

22

17

26

18

15

7

3

19

6

27

11

24

1323

5

16

10

14

12

8

16

10

9

28

21

4

1

20

25

2

10

10




1 7517317 4 Screw2 5810455 1 Pad, Rack Mount3 5433395 1 Duct, Inlet4 5411422 1 Gasket, Intake5 5432868 1 Cover, Air Box6 5811482 1 Seal, Cover7 7515179 2 Screw8 7558301 2 Washer, Flat9 8450073-600 AR Line, Breather10 7080699 4 Clamp, Hose11 2530029 1 Filter, Breather12 7080694 1 Clamp, Hose, Spring13 5411921 1 Hose, Breather14 7080511 1 Clamp, Band15 5411540 1 Boot, Carburetor

16 7080413 2 Clamp, Band17 5432473 1 Duct, Carburetor, Inlet18 5830128 1 Gasket, Carburetor Inlet Duct19 5433387 1 Box, Air20 ------ -- -- -- -- 1 Line, Breather, Oil Tank

(See Oil Tank Pg. A14, Ref. 3)21 5811650 1 Foil22 5432377 1 Plug, Trap23 8450059-150 AR Line, Fuel24 7080650 1 Clamp, Hose25 5242044 6 Clip26 5432601 1 Collar, Inlet, Carburetor27 7080595 1 Filter, Air28 5811633 1 Filter, Sleeve, Precleaner

5/04

Military

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C8

CLUTCH COVERSPORTSMAN 6X6 MV A05CL50MA

5 64 7

8

12

13

2

14

151617

3

23

921

2019

2

1

22

9

9

18

10 11




1 5247524-067 1 Bracket, Clutch Cover2 7512232 3 Bolt3 5433427 1 Duct, Clutch Air, Inlet4 5411553 1 Seal, Cover5 2201957 1 Kit - Inner Clutch Cover (Incl. 9)6 7510000 3 Asm., Bolt and Washer7 5521578 1 Seal, Clutch Cover, Outer8 5434255-070 1 Cover, Clutch, Outer, Black9 7512094 10 Screw10 5410542 1 O-Ring11 5434264 1 Plug, Drain12 7080707 2 Clamp, Narrow Band

13 5411489 1 Boot, Duct14 5433657 1 Duct, Air Outlet, Clutch15 ------ -- -- -- -- 3 Asm., Screw and Washer

(See Crankcase Pg. D5, Ref. 6)16 5242046 1 Bracket, Clutch, Seal17 5410575 1 Seal, Cover, Case18 7558301 1 Washer, Flat19 7555935 1 Washer20 5247949 1 Bracket, Clutch Cover, Front21 7661637 2 Rivet22 7556091 1 Spacer23 7080511 1 Clamp, Narrow Band

8/04

Military

AtvPart

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C9

REAR CALIPER MOUNTINGSPORTSMAN 6X6 MV A05CL50MA

8

9

1

12

1110

7

2

6

35

4




1 5132220 1 Mount, Caliper, Upper2 1910408 1 Asm., Caliper, Rear3 1910480 1 Line, Brake, JB to Rear4 7512084 1 Screw5 7080573 1 Clamp, Rubber Coated6 1910481 1 Line, Brake, RH

7 7517758 2 Bolt, Shoulder8 5131759 1 Bushing, Caliper Mount9 5131786 1 Mount, Caliper, Lower10 7558402 2 Washer, Flat11 7552901 2 Washer, Spring Lock12 7512312 2 Bolt

5/04

Military

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C10

GEARCASE MOUNTINGSPORTSMAN 6X6 MV A05CL50MA

1 4

8

10 9

6

6

5

12

5

7

7

11

7

7

4


32

5



1 7517632 2 Screw2 7080138 1 Cable Tie3 8360009-600 AR Line, Vent4 1014772 2 Mount, Transmission, Rear5 7547089 4 Nut, Flange Lock6 7512492 2 Screw7 7555806 4 Washer, Flat

8 7517646 1 Screw9 3221044 1 Sprocket, 12T10 7710434 1 Ring, Snap11 5211065

52107645211517

ARARAR

Shim, .010Shim, .020Shim, .030

12 7517640 1 Screw

5/04

Military

AtvPart

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C11

ELECTRICALSPORTSMAN 6X6 MV A05CL50MA

19

7

21

1

25

3029

20

18

23

17

148

22

11

24

5

4

2

9

3

16


26

2827

10

12

13

6

15



1 2410576 1 Harness, Main2 7080138 4 Cable Tie3 7080492 1 Cable Tie4 7670109 4 Clip, Routing5 4020139 4 Clip, Rosebud6 7541925 1 Nut, Nylok7 5247782 1 Heat Sink8 4011110 1 Module, Controller9 7512018 2 Screw10 7512024 1 Screw11 5246747 1 Bracket, CDI12 5810317 1 Pad13 ------ -- -- -- -- 1 CDI System

(See Magneto Pg. E2, Ref. 16)14 7512007 1 Bolt15 2410573 1 Harness, IR/Blk Out

16 2202147 1 Kit, Fusible Link17 4011138 1 Battery18 7010032 2 Hook, Battery Strap19 5412499 1 Strap, Holddown, Battery20 4010095 1 Cable, Battery/Engine21 2202848 1 Kit, Battery Bolt22 5431769 1 Cover, Battery23 5810290 3 Pad, Battery24 7512027 2 Screw25 7518287 2 Nut, Nylok26 4011072 1 Switch, Magnetic27 7552801 2 Washer, Spring Lock28 7547283 2 Nut, Jam29 4010093 1 Cable, Solenoid/Starter30 4010094 1 Cable, Battery/Solenoid

8/04

Military

AtvPart

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C12

DUMP BOXSPORTSMAN 6X6 MV A05CL50MA

20

3

10

13

19

32

4

7

6

181

28

5

17

14

15

2

26

9

8

31

12

27

29

25

2122

23

24

5 5

5

2

1

12

5

1718

14

21

22

135

6

16

30

5


11



1 7515177 2 Screw2 7558221 2 Washer3 5132358 1 Rod, Hinge4 5433388 1 Tailgate5 7517561 22 Screw6 5433656 2 Latch7 5433655 1 Latch, Paddle8 7661644 2 Pin, Hitch9 7556143 2 Washer, Rubber10 5132373 2 Shaft, Latch11 1014998 1 Asm., Litter Mount12 7517790 4 Screw13 5243304 2 Bracket, Box Latch14 7517938 2 Screw15 7517747 9 Screw16 7556157 9 Washer17 7517742 2 Screw

18 7080881 2 Cable, Tailgate19 5244068-067 1 Cover, Tailgate, Black20 2410179

401034022

Asm., Taillight w/Brake LightBulb

21 7512329 2 Bolt22 7542324 2 Nut, Nylok23 7512492 4 Screw24 7542449 4 Nut, Flange Lock25 7041301 1 Shock, Dump Box26 7547089 9 Nut, Flange27 1012893-067 1 Support, Box, Black28 7515350 4 Screw29 1013125-067 1 Latch, Box, Black30 7512084 4 Screw31 2682522-070

2681664-07011

Asm., Backrest, BlackCovering, Backrest, Black

32 5435705-070 1 Box, Molded, Black

8/04

Military

AtvPart

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C13

GEAR SELECTORSPORTSMAN 6X6 MV A05CL50MA

2

43

5

7

8

6

111610

15

1

13

14

9

12

1011




1341271 1 Asm., Gear Selector (Incl. All)1 3233195 1 Asm., Knob2 7512024 1 Screw3 3233649 4 Screw4 3233131 1 Strap, Wire5 3233648 1 Cover, Gear Selector Boot6 3233658 1 Handle, Gear Selector7 3233646 1 Sphere, Plastic8 3233754 1 Pin, Dowel

9 3233644 1 Pin, Dowel10 3233642 2 Spring, Detent11 3233060 2 Bullet, Detent12 3233076 2 O-Ring13 3233639 1 Slide, Low14 3233640 1 Slide, High/Reverse15 3233641 1 Body, Gear Selector16 3233643 1 Spring, Centering

5/04

Military

AtvPart

s.com



C14

GEARCASE SELECTOR MOUNTINGSPORTSMAN 6X6 MV A05CL50MA

1

8

6

4


3

2

5

2

7



1 7061128 2 Rod End, LH2 7546707 4 Nut3 7547198 2 Nut, Jam, LH4 1821430 1 Asm., Linkage

5 7547083 2 Nut, Jam, RH6 7517386 5 Screw7 7061129 2 Rod End, RH8 1821428 1 Asm., Linkage, Short

5/04Milit

aryAtvP

arts.c

om



D1

GEARCASESPORTSMAN 6X6 MV A05CL50MA

4

9

6

202223

2427282930

32

38

31

3334

353637

39

4041

44

42

43

45

4647

50 49 48

61

19

26

25

18

21

16

17

20

60

64

5455

52

5657

5

58

62

63

3

7

1

2

13

14

1413

910 11

25

25

2125

9

19

47

8

121110

131415

59

53

51


Military

AtvPart

s.com



D2

GEARCASESPORTSMAN 6X6 MV A05CL50MA



1341428 1 Asm., Gearcase (Incl. All)1 3233527 1 Bushing, Pivot2 3233252 11 Screw3 3233632 1 Gearcase, LH4 3233529 2 Pipe, Knock5 3233448 1 Plug6 3233035 1 Washer7 3233706 1 Fork, Shift, Low8 3233633 1 Fork, Shift, H/R9 3233018 3 Bearing10 3233177 2 Ring, Retaining11 3233176 2 Washer12 3233731 1 Gear, 33T13 3233718 3 Bearing, Needle14 3233720 3 Ring, Retaining15 3233732 1 Dog, Engagement, Low16 3233733 1 Shaft, Reverse, 29T17 3233719 1 Sprocket, 24T18 3233721 1 Dog, Engagement, H/R19 3233722 1 Gear, 30T20 3233788 3 Seal, Triple Lip21 3233539 11 Screw22 3233556 1 Cover, Snorkel23 3233555 1 O-Ring24 3233554 1 Shim25 3233020 4 Bearing26 3233898 1 Gear, 25T27 3233899 1 Shaft, Snorkel28 3233552 1 Bushing29 3233895 1 Gearcase, HLR, RH30 3233037 1 Vent31 3233026 1 Screw32 3233897 1 Guide, Chain

33 3233872 1 Washer, Nylon34 3233711 1 Plug, Oil Fill35 3233542 1 Washer, Thrust36 3233541 1 Bushing37 3233540 1 Shaft, Pinion38 3233306 1 Ring, Retaining39 3233263 1 Cover, Bearing40 3233730 1 Sprocket, 15/22T41 3233537 1 Ring, Retaining42 3233360 1 Gear, 100T43 3233544 1 Shaft, Output44 3233729 1 Sprocket, 15/26T45 3233546 1 Chain, Roller46 3233043 1 Deflector, Oil47 3233747 4 Screw, Tapping w/Lock Washer48 3233308 2 Pin, Interlock49 3233032 1 Spring50 3233309 1 Bracket, Interlock51 3233153 1 Bellcrank52 3233040 2 Washer53 3233737 1 Shaft, Shift, H/R54 3233549 1 Shaft, Shift55 3233548 2 O-Ring56 3233045 2 Ring, Retaining57 3233547 1 Bellcrank58 3233961 2 Nut, Flange Lock59 3234001 1 Switch, 2 Position60 3233749 8 Screw61 3234002 1 Switch, 3 Position62 3233036 1 Chain, Silent63 3233704 1 Shaft, Input64 3233019 1 Bearing

5/04

Military

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D3

HANDLEBAR and HEADLIGHT PODSPORTSMAN 6X6 MV A05CL50MA

28

12

2

5

6

7

8

10

11

13

14

17

21

2322

31

2526

1918

1516

29

24

30

5

5

33

9

34

1

3


35

32

20

4

26

27

Military

AtvPart

s.com



D4

HANDLEBAR and HEADLIGHT PODSPORTSMAN 6X6 MV A05CL50MA



1 5434380 1 Bezel2 3280431 1 Asm., Cluster, Instrument3 5412138 1 Mount, Rubber4 4011074 1 Switch, Worklight5 7511881 3 Screw6 5436055-400 1 Pod, Headlight, Upper, Camo Green7 ------ -- -- -- -- 1 Asm., Throttle Control, AWD

(See Controls - Throttle Asm./CablePg. B9, Ref. 5)

8 5244581-067 1 Tube, Handlebar, Black9 5631517 1 Block, Handlebar, Pegged10 7515189 4 Screw11 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls - RH, Master Cylinder/Brake Line Pg. B11 for details)

12 5433903 1 Spacer, Switch, LH13 4010592 1 Switch, Handlebar, Off/Lo/Hi14 5433834-070 2 Grip, Handlebar, Black15 5432952 1 Plug, Hole16 7517625 1 Screw, Set17 5244969-067 1 Bracket, Pod Mounting, Black

18 7517317 2 Screw19 4032079 1 Knob, Adjusting (w/Rod)20 5410163 2 O-Ring21 2410268

401025311

Asm., Head LampBulb, Headlight, 50W

22 7081176 1 Cable, Choke23 7542122 4 Nut, Nylok24 4010638 1 Receptacle, Pod Mount, 12V25 5433762-070 1 Pod, Headlight, Lower, Black26 4010821

40108227517560

111

Switch, Ignition, KeylessLever, Ignition SwitchScrew

27 7517658 1 Screw28 4010298 1 Sensor29 5132382 1 Cap, Sensor30 5433733 1 Nut, Ignition31 7080922 1 Nut, Choke32 5812563 1 Pad, Adhesive33 7670127 1 Clip34 5631516 1 Block, Handlebar35 7080138 5 Cable Tie

5/04

Military

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D5

CRANKCASESPORTSMAN 6X6 MV A05CL50MA

2

4

11

12

2

20

21

1

23

7

5

17

3

1918

10

1615

1314

22

6

5

8

9




1 3083669 1 Bushing, Starter2 3089240 1 Asm., Crankcase

(Incl. 1,2,4,5,7,8,11,12,17,20,21,23)3 3087266 2 Pipe, Knock4 3080676 1 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 3 Asm., Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3087154 1 Union10 3084842 1 Union11 3084834 2 Bearing, Ball

12 3084835 1 Bearing, Ball13 3084845 1 Plug14 3084846 1 Gasket, Aluminum15 3084844 1 Spring, Valve, One Way16 3086810 1 Valve, One Way17 3084841 10 Bolt, Flange18 3082956 1 Gasket19 3086749 1 Plug20 3084837 1 Seal, Mechanical21 3084836 1 Seal, Oil22 3084847 1 O-Ring23 3086838 2 Pin, Dowel

6/04

Military

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D6

CRANKSHAFT and PISTONSPORTSMAN 6X6 MV A05CL50MA

19

6

10

1412

5

8

18 13

9

17

7

11

1

15

20

16

2

3

1

4




1 3085534 2 Clip2 3087221

30872223087223

111

Set, Piston, Standard (Incl. 1)Set, Piston, .010 Inch/.25MM O/S (Incl. 1)Set, Piston, .020 Inch/.50MM O/S (Incl. 1)

3 308722430872253087226

111

Set, Piston, Ring, StandardSet, Piston, Ring, .010 Inch/.25MM O/SSet, Piston, Ring, .020 Inch/.50MM O/S

4 3085815 2 Bearing, Ball5 3085812 1 Crankshaft 26 3087090 1 Pin, Crank7 3085376 1 Rod, Connecting8 3085343 1 Bearing, End, Large9 3085024 1 Ball, Steel10 3089540

308954111

Asm., Crankshaft (Incl. 4-11)Crankshaft 1

11 3089245 1 Gear 1, Balancer12 3085404 1 Shaft, Balancer13 3084895

30848963084897

111

Spacer, 0.8Spacer, 1.0Spacer, 1.2

14 3240088308489230848933084894

1111

Spacer, 0.6Spacer, 0.8Spacer, 1.0Spacer, 1.2

15 3084882 1 Sprocket 116 3085528 1 Nut, Slit17 3086767 1 Washer18 3083905 1 Nut, Lock19 3081447 1 Key20 3081543 1 Key, Woodruff

1/04

Military

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D7

CYLINDERSPORTSMAN 6X6 MV A05CL50MA

2

20

37

232221

12

5

4

36

107

34

9

25

29

1617

3

6

18

27

1

26

13

28

33

31

32

8

11

30

35

14

24

15

19

5

35

35

13

9

E 2004 Polaris Sales Inc.Military

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D8

CYLINDERSPORTSMAN 6X6 MV A05CL50MA



1 3083166 1 Asm., Band, Adapter (Incl. 2)2 3081497 1 Asm., Screw and Washer3 3081330 2 Bolt, Socket Head4 3084857 2 Pipe, Knock5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve7 3084867 1 O-Ring8 3084870 1 Adapter, Water Out9 3084877 10 Bolt, Flange10 3084866 1 Adapter, Camshaft11 3085074 1 Gasket, Rocker Cover12 3085073 1 Cover, Rocker13 3084874 10 Bolt, Flange14 3084859 2 Seal, Exhaust Valve15 3084875 4 Bolt, Cylinder Head16 3084860 1 Plug17 3084861 1 Gasket18 3084862 1 Plug, Blind19 3086781 2 Bolt, Flange

20 3085075 1 Gasket, Exhaust21 3085326 2 Stud22 3080530 2 Washer, Spring23 3087199 2 Nut24 3085854 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3087266 2 Pipe, Knock29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3089256 1 Asm., Cylinder (Incl. 32)32 3086747 1 Pipe 2, Elbow33 3085370 1 Gasket, Cylinder34 3089242 1 Cover, Camshaft35 3085527 1 Head, Cylinder (Incl. 4-6,14,16-18,21)36 3085371 1 Gasket, Head37 3084879 1 Adapter

6/04

Military

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D9

CARBURETORSPORTSMAN 6X6 MV A05CL50MA

31

23

20

27

24

22

121

21

34

13

11

17

76

14

12

5

15

10

16

26

9

2930

25

19

18

8

32

28


Military

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D10

CARBURETORSPORTSMAN 6X6 MV A05CL50MA



1 3130515 2 Seal2 ---- -- -- -- -- -- 1 Packing3 3130518 1 E-Ring4 3130519 1 Cap5 3130361 1 Pin, Float6 3130014 1 Washer7 3130566 1 Jet, Main, #142.58 3130594 1 Plate9 3130591 2 Screw10 3130532 1 O-Ring11 3130520 4 Screw12 3130590 1 Asm., Float Body13 3130521 1 Screw14 3130529 1 Asm., Float15 3131360 1 Valve, Needle, 1.516 3130533 1 O-Ring

17 3130624 1 Jet, Pilot, #4018 3131423 1 Screw, Adjust19 3130836 1 Spring20 3130502 1 Valve, Throttle, 10021 3130589 1 Spring22 3130514 1 Ring23 3130501 2 Screw24 3130513 1 Asm., Throttle Shaft25 3130543 1 Guide, Cable26 3130535 4 Screw27 3130511 1 Cover28 3130199 1 Holder, Guide29 3130538 1 Spring30 3130539 1 Asm., Plunger31 3131572 1 Asm., Carburetor (Incl. 1-24,26,28-32)32 3084205 2 Asm., Screw and Washer

6/04

Military

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D11

INTAKE and EXHAUSTSPORTSMAN 6X6 MV A05CL50MA

15

19

16

1718

26

2714 13

12

11

7

109

23

8

20

9

22

25

5

3

21

6

21

28

24

910

7

10

1312

14


4



1 3087129 1 Plug2 3087130 1 Gasket, Plug3 3087131 1 Spring, Tensioner4 3087132 1 Pin5 3086493 1 Asm., Tensioner (Incl. 1-4)6 3086448 1 Gasket, Tensioner7 3084910 2 Asm., Rocker Arm, Intake (Incl. 9,10)8 3084913 1 Asm., Rocker Arm, Exhaust (Incl. 9,10)9 3084912 4 Nut10 3084911 4 Screw, Adjusting11 3084909 1 Shaft, Rocker12 3084908 8 Collet, Valve13 3087203 4 Retainer, Valve Spring14 3086892 4 Spring, Valve

15 3086212 1 Camshaft (Incl. 15-19)16 3086838 1 Pin, Dowel17 3085348 1 Lever, Release18 3085076 1 Spring, Return19 3084899 1 Pin, Dowel20 3084914 1 Sprocket 221 3081657 3 Asm., Bolt and Washer22 3084916 1 Guide, Chain23 3084915 1 Chain, Timing24 3084924 1 Bolt, Pivot Lever25 3084917 1 Lever26 3085349 2 Valve, Intake27 3085412 2 Valve, Exhaust28 3083361 2 Bolt, Flange

6/04

Military

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D12

RECOIL STARTERSPORTSMAN 6X6 MV A05CL50MA

13

13

10

42

6

5

14

9

11

7

8

12

7

8




1 3084822 1 Asm., Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3085266 1 Asm., Bolt and Washer6 3084744 1 Plate, Friction7 3086749 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084877 9 Bolt, Flange13 3087163

308716411

Asm., Recoil (Incl.1-5,9-11,13,14)Starter Case (Incl. 11)

14 3085083 1 Asm., Rope

6/04

Military

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D13

WATER PUMPSPORTSMAN 6X6 MV A05CL50MA

10

7

8

3

3

2

1

9

11

12

4

65


6



1 3084940 1 Thermostat2 3089246 1 Sensor, Thermostat3 3086774 2 Clamp, Hose4 3085857 1 Hose, Main5 3085359 1 Bolt, Flange6 7555998 2 Gasket, Aluminum

7 3085351 1 Cover, Water Pump8 3086840 1 Gasket, Water Pump9 3085077 1 Nut, Self Lock10 3084935 1 Impeller11 3084942 1 Washer, Seal12 3084877 4 Bolt, Flange

6/04

Military

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D14

OIL PUMPSPORTSMAN 6X6 MV A05CL50MA

4

1

10

3

2

11

15

87

6

13

14

5

16

17

9

12




1 3084946 1 Pump, Oil, Case 22 3084949 1 Rotor, Outer, Feed3 3084948 1 Rotor, Inner, Feed4 3087276

308726411

Asm., Oil Pump (Incl. 1-8,10-15)Pump, Oil, Case 1

5 3085535 1 Screw6 3084955 2 Pin, Dowel7 3084954 2 Pin, Dowel8 3084953 1 Washer9 3084962 3 Asm., Bolt and Washer

10 3087265 1 Pump, Oil, Case 311 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Unit, Oil Strainer14 3084205 3 Asm., Screw and Washer15 3084952 1 Shaft, Pump16 3084958 1 Gear 2, Pump17 3084959

30849603084961

ARARAR

Spacer, 0.8Spacer, 1.0Spacer, 1.2

6/04

Military

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E1

OIL FILTERSPORTSMAN 6X6 MV A05CL50MA

1

4

5

3

3

3

2

2

2

2

2




1 3084963 1 Asm., Filter, Oil2 3084846 8 Gasket, Aluminum3 3086815 4 Bolt, Banjo

4 3084964 1 Pipe, Oil Delivery 15 3084965 1 Pipe, Oil Delivery 2

6/04

Military

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E2

MAGNETOSPORTSMAN 6X6 MV A05CL50MA

106

5

8

9

11

12

13

14

4

7

1

2

16

3

15




1 3089239 1 Asm., Ignition Coil (Incl. 1,2)2 3084980 1 Cap, Spark Plug3 3070175 1 Plug, Spark4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3089545

308924811

Asm., Plate (Incl. 5,6,8,9,11-15)Plate

7 3081657 5 Asm., Bolt and Washer8 3084973 1 Seal, Oil

9 3089546 1 Stator (Incl. 14)10 3089544 1 Flywheel w/Ring Gear11 3089547 3 Asm., Screw and Washer12 3089250 1 Clamp13 3084976 2 Asm., Screw and Washer14 3089254 1 Coil, Pulser15 3081256 1 Asm., Screw and Washer16 3089238 1 CDI System

6/04

Military

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E3

STARTING MOTORSPORTSMAN 6X6 MV A05CL50MA

9

11

1

4

10

3

2

12

16

15

14

13

56

8

7




3084981 1 Asm., Starting Motor (Incl. 1-4,6-11)3087030 1 Asm., Gear Shaft (Incl. 13-16)

1 3084982 1 Set, Washer2 3088169 1 Set, Brush, Carbon3 3083649 2 Nut, Flange4 3084408 3 O-Ring5 3082038 2 Asm., Bolt and Washer6 3085034 1 Asm., Bracket, Rear7 3085353 1 Asm., Armature

8 3085033 1 Asm., Bracket, Front (Incl. 9)9 3240114 1 O-Ring10 3084983 2 Asm., Bolt Set (Incl. 4)11 3084405 2 Ring, Rubber12 7555908 1 Washer, Gear Shaft13 3084412 1 Clip14 3084411 1 Spring, Weight15 3084410 1 Spring, Return16 3084409 1 Clip

7/03

Military

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E4

FUEL PUMPSPORTSMAN 6X6 MV A05CL50MA

4

3

1 2

2

4




3085275 1 Asm., Fuel Pump (Incl. All)1 3084591 4 Asm., Screw and Washer2 3085356 2 Asm., Screw and Washer

3 3084999 1 Asm., Screw and Washer4 3088170 1 Set, Gasket, Diaphragm

5/03

Military

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E5

TOOL KITSPORTSMAN 6X6 MV A05CL50MA

5

8

9

10

11

12

13

4

7

6


14

21

3



2874925 1 Asm., Tool Kit (Incl. 8-13)1 2202868 1 Cover, Seat2 2202860 1 Bag, Gas Tank3 2202875

268367021

Bag, FenderCover, Storage

4 9919500 1 Manual, Owner’s, ’05 Sportsman 6X65 2870725 1 Gauge, Tire Pressure6 2874858 1 Wrench, Torx

7 2874743 1 Wrench, 1/2 x 9/168 2874742 1 Wrench, Open, 8-10mm9 2875090 1 Wrench, Open, 12-14mm10 2875088 1 Socket, Spark Plug11 2875091 1 Handle, Spark Plug Socket12 2874746 1 Screwdriver13 2682572 1 Pouch, Tool Kit14 1015007 1 Asm., Steering Lock Cable

8/04

Military

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PRINTED IN THE USA PARTS MANUAL PN 9919953 and MICROFICHE PN 9919954 8/04Military

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SPORTSMAN 6X6 MV Model #A05CL50MA - Military ATV Parts

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Transcript of SPORTSMAN 6X6 MV Model #A05CL50MA - Military ATV Parts