RANGER 500 4X4 SERIES 10 Rev. 01 - pi54.compi54.com/corp/manuals/Parts/9917097r01.pdf · E 2002...

PARTS MANUAL PN 9917097 and MICROFICHE PN 9917098 1/02E 2002 Polaris Sales Inc.

RANGER 500 4X4 SERIES 10Model #A10RD50AARev. 01

TABLE OF CONTENTSRANGER 500 4x4 Series 10 A10RD50AA

Parts Manual

AA--ARM B10. . . . . . . . . . . . . . . . . . . . . . . . . . . .AIR BOX C8. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBATTERY B3. . . . . . . . . . . . . . . . . . . . . . . . . . .BODY A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .BRAKE CALIPER, FRONT B14. . . . . . . . . . . . . .BRAKE CALIPERS, REAR C2. . . . . . . . . . . . . .BRAKE LINES B13. . . . . . . . . . . . . . . . . . . . . . .BRAKE, FOOT B12. . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D5-6. . . . . . . . . . . . . . . . . . . . . . .CHASSIS A4. . . . . . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C10. . . . . . . . . . . . . . . . . . . . .CONTROLS A6. . . . . . . . . . . . . . . . . . . . . . . . .COOLING SYSTEM A10. . . . . . . . . . . . . . . . . . .CRANKCASE D2. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT D7. . . . . . . . . . . . . . . . . . . . . . .CYLINDER D3-4. . . . . . . . . . . . . . . . . . . . . . . . . .

DDASH INSTRUMENTS A6. . . . . . . . . . . . . . . . .DECALS A9. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C6. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT, FRONT B4. . . . . . . . . . . . . . . . .DRIVEN CLUTCH C7. . . . . . . . . . . . . . . . . . . . .DUMP BOX A8. . . . . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL B3. . . . . . . . . . . . . . . . . . . . . . . .ENGINE AND CLUTCH AIR INTAKE C9. . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . . .EXHAUST D8. . . . . . . . . . . . . . . . . . . . . . . . . .EXHAUST SYSTEM B1. . . . . . . . . . . . . . . . . . .

FFLYWHEEL COVER D9. . . . . . . . . . . . . . . . . . .FUEL SYSTEM A11. . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR/DIFFERENTIAL LOCK D1. . .GEARCASE C13-14. . . . . . . . . . . . . . . . . . . . . . . . .

HHOOD A7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .HOUSING MOUNTING, FRONT C12. . . . . . . . . .

IINTAKE D8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MMAGNETO D13. . . . . . . . . . . . . . . . . . . . . . . . . .MASTER CYLINDER B13. . . . . . . . . . . . . . . . . .MOLDINGS A5. . . . . . . . . . . . . . . . . . . . . . . . .

OOIL FILTER D12. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D11. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK (If Built Before 1/01/02) A12. . . . . . . . .OIL TANK (If Built After 1/01/02) E2. . . . . . . . . . .

PPISTON D7. . . . . . . . . . . . . . . . . . . . . . . . . . . .PROP SHAFT, FRONT B6. . . . . . . . . . . . . . . . .PROP SHAFT, REAR B5. . . . . . . . . . . . . . . . . .

RREAR WHEEL DRIVE C3. . . . . . . . . . . . . . . . . .

SSEAT A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SHOCK, REAR C5. . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR D14. . . . . . . . . . . . . . . . . . .STEERING B9. . . . . . . . . . . . . . . . . . . . . . . . . .STRUT MOUNTING B10. . . . . . . . . . . . . . . . . . .STRUT, FRONT B7. . . . . . . . . . . . . . . . . . . . . .

TTHROTTLE B11. . . . . . . . . . . . . . . . . . . . . . . . .TOOL KIT E1. . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION MOUNTING B2. . . . . . . . . . . .

WWATER PUMP D10. . . . . . . . . . . . . . . . . . . . . . .WHEEL, FRONT B8. . . . . . . . . . . . . . . . . . . . .

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

A3

CAB FRAMERANGER 500 4X4 SERIES 10 A10RD50AA

1

2

47

8 93

10

1112

13

14

16

15

1817

19

29

28

30

212223

2524 20

26

E 2001 Polaris Sales Inc.

2

87

16 1718

11

11

31

11

6

6

5

5

527

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. Description Ref. Part No. Qty. Description

1 1013333-067 1 Frame, Cab, Right, Front2 5243093-067 2 Tube,Coupler, Top, Rear3 5434177 2 Headrest4 1013717 1 Frame, Cab, Right, Rear

(Incl. Warning Decals)5 7558301 12 Washer, Flat (If built before 2/18/02)6 7552801 12 Washer, Spring Lock (If built before

2/18/02)7 7512247

75172301212

Screw (If built before 2/18/02)Screw (If built after 2/18/02)

8 5243092-067 2 Tube, Coupler, Center, Rear9 7661637 40 Rivet10 1013716 1 Frame, Cab, Left, Rear

(Incl. Warning Decals)11 7542324 10 Nut, Nylok12 7515339 2 Screw13 7541923

767009688

Nut, Well (If built before 2/18/02)Nut, Chimney (If built after 2/18/02)

14 26826822683124

11

Seat, Back (If built before 2/18/02)Seat, Back (If built after 2/18/02

15 2632422 1 Asm., Seat Belt, Center16 2632421 2 Asm., Seat Belt17 7542525 4 Nut, Nylok18 7512539 4 Screw19 1013336-067 1 Base, Cab/Seat20 5411042 2 Grommet21 2682638 1 Seat, Bottom (Incl. 11,22,23,24,25,26)22 5245676 2 Tab, Seat Mount23 7661052 4 Rivet24 5910096 2 Pin, Seat Latch25 7555734 2 Washer, Flat26 5812242 4 Foil27 5812313 2 Pad, Cab Frame28 7515321 4 Screw29 1013332-067 1 Frame, Cab, Left, Front30 5244844-067 1 Tube, Frame, Top, Front31 7515319 2 Screw

1/02

A4

CHASSIS/BODYRANGER 500 4X4 SERIES 10 A10RD50AA

31

24

5

8

9

67

10

11

1216

17

22

23

20

21 25

14

26

27

28

15

4

4

4

2

1

4

16

26

14

25

21 19 18

29

13

24

24

30



1 7515522 4 Screw2 7542449 4 Nut3 1013374-067 1 Support, Floor, RH4 7515399 18 Screw5 ------ -- -- -- -- 1 Base, Cab/Seat

(See Cab Frame Pg. A3, Ref. 19)6 7670090 20 Clip, Dart7 5434028 2 Panel, Seat Frame8 7542451 8 Nut, Nylok9 5245209 4 U-Bolt10 1013138-067 1 Frame, Main11 5244968-067

5246110-06711

Bracket, Oil Tank (If built before 8/06/01)Bracket, Oil Tank (If built after 8/06/01)

12 1013373-067 1 Support, Floor, LH13 7547182 3 Nut, Insert14 7542439 2 Nut, Nylok15 7079924 2 Decal, Reflector, Amber

16 5434191 2 Cap, Bumper17 1013485-067 1 Bumper18 7621334 4 Rivet19 5430733 2 Cup, Hood Latch20 7515547 3 Screw21 7517685 6 Screw22 5245329-067 1 Plate, Grill, Bumper, Upper23 5245626-067 1 Plate, Grill, Bumper, Top24 7555801 4 Washer, Wrought25 7517583 2 Screw26 7515415 4 Screw27 7542439 4 Nut, Nylok28 1013375-067 1 Support, Cab, Front29 7547069 9 Nutsert30 7512399 2 Screw

1/02

A5

MOLDINGS AND SEATRANGER 500 4X4 SERIES 10 A10RD50AA

22

9

86

4

10

1

12

2

13

21

1514

18161719

20

1

1

1

10

1

11415

11

10

11

1

57

3



1 7517685 61 Screw2 5433827-070 1 Fender, Rear, RH3 7670145 11 Nut, U-Type4 5434004 1 Floor, Drive Shaft, Cover5 5812222 1 Foil6 5812243 1 Foil, Floor7 5812296 1 Foil8 5812242 1 Foil, Heat Shield9 2632478 1 Cover, Dog House (Incl. 7,8)10 7670057 8 Nut, U-Type Speed11 7670090 6 Clip, Dart12 5433826-070 1 Fender, Rear, LH

13 5433828-070 1 Fender, Front, LH14 7555935 8 Washer15 7542122 8 Nut, Nylok16 7517386 12 Screw17 7556065 12 Washer18 5812176 1 Plate, Skid19 7512084 9 Screw20 5434026

543402711

Panel, Wheel Well, LHPanel, Wheel Well, RH

21 5433829-070 1 Fender, Front, RH22 2632477 1 Floor, Main (Incl. Foil)

1/02

A6

DASH INSTRUMENTS AND CONTROLSRANGER 500 4X4 SERIES 10 A10RD50AA

2

11

1

12

5

3

4

810

13 14

6

79



1 4010460 1 Hourmeter2 4010283 1 Receptacle, 12V3 4010525 1 Switch, Headlight4 4010601 1 Switch, AWD5 5434192 1 Plug, Hole6 7080937 1 Cable, Choke7 7080922 1 Nut, Choke8 2460978 1 Harness, Headight

9 2201795 1 Kit, Circuit Breaker, Fan10 2460979

246107811

Harness, Dash (If built before 1/01/02)Harness, Dash w/Park(If built after 1/01/02)

11 4010390 1 Switch, Ignition12 4010527 1 Panel, Indicator13 5245469-067 1 Plate, Indicator14 7512026 4 Screw

1/02

A7

HOODRANGER 500 4X4 SERIES 10 A10RD50AA

14

6 17

18

12

1

2

910

19

3

4

13

20

910

2

1615

5

21

8

7

11

6

6



1 5434057 2 Hinge2 7517230 14 Screw3 5434278-195 1 Dash4 5434288-195 1 Cover, Steering Column5 7512026 4 Screw6 7517685 13 Screw7 7670057 1 Nut, U-Type, Speed8 8360012-04

8360060-1011

Trim, Edge (If built before 6/18/01)Trim, Edge (If built after 6/18/01)

9 7555935 10 Washer10 7542122 10 Nut, Nylok11 5810455 1 Pad (If built before 6/18/01)

12 5434279-195 1 Hood13 5410370 2 Strap, Hood Latch14 5434535 1 Liner, Hood15 4032094 4 Spring, Adjust16 4032042 4 Screw, Adjust17 7670090 4 Clip, Dart18 2410275

401068122

Asm., HeadlightBulb, Headlight

19 7670134 2 Clip, Wire20 4032003 2 Screw21 5412148 2 Grommet

1/02

A8

DUMP BOXRANGER 500 4X4 SERIES 10 A10RD50AA

17

11

6

13

4

37

9

10

5

14

13

12

39

2

26

7

8

16

25 23

15

33

18

38

19

2030

27

29

29

3132

19

16

3

53

3

2113

33

1214

17

28

6

24

21 22

22

15

8

8

36

34

35

21



1 7515177 2 Screw2 7555960 2 Washer, Flat3 7517561 20 Screw4 5244068-067 1 Cover, Tailgate5 5433656 2 Latch6 5132810 2 Shaft, Latch7 7556143 2 Washer, Rubber w/Metal Back8 7661644 6 Pin, Hitch9 5433951 1 Tailgate10 5433655 1 Latch, Paddle11 5132811 1 Rod, Hinge12 7517742 2 Screw13 5243304 2 Bracket, Box Latch14 7081001 2 Cable, Tailgate15 7517938 2 Screw16 7517790 4 Screw17 2410179

2410322

4010340

2

2

2

Asm., Taillight w/Brake Light(If built before 1/07/02)Asm., Taillight w/Brake Light(If built after 1/07/02)Bulb

18 5411009 2 Plug

19 7079925 2 Decal, Reflector, Red20 1013511-067 2 Pin, Hinge21 7517386 2 Screw (Qty. 10 if built after 2/25/02)22 7661037 4 Pin, Clevis23 7041996 2 Shock, Dump Box24 7670116 6 Clip, Routing25 1013419-067 1 Base, Box26 7547089 12 Nut, Flange Lock27 7041687 2 Spring, Exhaust28 7515319 4 Screw29 5434226 8 Bushing30 1013571-067 1 Latch, Box31 7555770 4 Washer32 7542324 4 Nut, Nylok33 5410414 4 Bumper, Rubber34 7555788 4 Washer, Thrust35 5246389 1 Shield, Exhaust (If built after 2/25/02)36 5812242 2 Foil (If built before 2/25/02)37 5434578-070 1 Box38 7556157 12 Washer39 7517959 12 Screw

1/02

A9

DECALSRANGER 500 4X4 SERIES 10 A10RD50AA

2

7

6

34

9

5

1

8

12

10 11



1 7079425 2 Decal, Warning, Cab Frame/Seat Belt2 7079902 1 Decal, 4 Stroke, Carb/Filter Info3 7079399 2 Decal, Box Side, “4X4”4 7079424 1 Decal, Tire Pressure/Load5 7079428 1 Decal, Tailgate, “POLARIS”6 7170014 1 Decal, Hitch7 7077469 1 Decal, Dash Panel, “POLARIS”

8 7079735 1 Decal, Lock/Unlock Diff9 7079426 1 Decal, Warning, Discretionary10 7170532 1 Decal, “APPLY BRAKE”

(If built after 1/01/02)11 7170544 1 Decal, Caution, “SHIFT AT IDLE”

(If built after 1/01/02)12 7079402 1 Decal, Hood, “POLARIS”

1/02

A10

COOLING SYSTEMRANGER 500 4X4 SERIES 10 A10RD50AA

272829

30

313233

34

1

2

6

78

45

13

26

16

1419

18

15

20 21

22

17

25 23

24

1

87

7

7

14

7 7

15

3

3

27

129 10 11



1 7080614 2 Clamp, Hose2 5411980 1 Hose, Engine Inlet3 5521242 2 Tubing, Convoluted4 7080898 1 Clamp5 7517386 1 Screw6 5411978 1 Hose, Engine Outlet7 7080826 6 Clamp8 7052092 2 Connector, Barbed9 7080138 1 Cable Tie10 7080965 3 Mount, Cable Tie11 7670102 1 Clip12 4020149 1 Clip, Rosebud13 5411977 1 Hose, Radiator, Inlet14 7547174 4 Nut15 7556196 4 Washer, Flat16 7517904 4 Screw17 2410227 1 Asm., Fan

18 7512163 2 Screw19 5411975 2 Asm., Grommet20 7542153 2 Nut, Flanged21 1240093 1 Cap, Pressure22 1240096 1 Radiator23 5410584 2 Bushing24 7052296 1 Valve, Plastic Radiator/Cooler Drain25 4010161 1 Sensor, Thermal26 5411979 1 Hose, Radiator, Outlet27 7080761 7 Cable Tie28 8450003-55 AR Line, Fuel29 7052065 1 Fitting30 7512084 2 Screw31 5431673 1 Tank, Surge32 5433774 1 Plug33 5810279 1 Gasket34 5430743 1 Cap

1/02

A11

FUEL SYSTEMRANGER 500 4X4 SERIES 10 A10RD50AA

123

6

7

8

910

11

20

19

12

13

15

14

16

1718

81

2

2

12

22

21

23

4

5

2



1 8450040-150 AR Line, Fuel2 7080003 6 Clamp, Hose3 7052259 1 Fitting4 7052028 1 Grommet5 8350019-41 AR Tubing6 1013471-067 2 Strap, Tank7 5812231 2 Pad, Top8 7542324 3 Nut, Nylok9 7052095 1 Fitting, 90 Degree10 8360009-50 AR Line11 5812252 1 Foil, Tank12 7512399 3 Screw

13 7515398 1 Screw14 4010658 1 Pump, Fuel15 7080138 1 Cable Tie16 7517685 2 Screw17 7542122 2 Nut, Nylok18 1013487-067 1 Support, Tank19 5812230 1 Pad, Bottom20 5433861 1 Tank, Fuel21 1240119 1 Cap, Gas Tank w/Gauge22 7052301 1 Pick-Up, Fuel23 7080402 2 Ring, Compression

1/02

A12

OIL TANK (If Built Before 1/01/02)RANGER 500 4X4 SERIES 10 A10RD50AA

17

12

8

13

14

15

19

16

76

2122

23

9

3

12

20

11

18

10

54

1112

13

10

7

65

4



1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7512163 2 Screw5 7558301 2 Washer, Flat6 5333204 2 Bushing7 5410828 2 Grommet, Mounting, Reservoir8 7052164 1 Fitting9 8450073-95 1 Line10 7542122 2 Nut, Nylok11 7555896 4 Washer, Copper12 7517102 2 Bolt, Banjo

13 7052298 2 Tube, Banjo Return14 5432289 1 Dipstick15 5410889 1 O-Ring16 5131255 1 Tank, Oil, RH17 5131785 1 Tank, Oil, LH18 7080474 2 Clamp, Hose19 2530020 1 Screen, Oil Filter20 5411042 1 Grommet21 7051524 1 Plug, Magnetic22 5850135 1 Washer, Nylon23 7515158 9 Screw

11/02

A13

ENGINE MOUNTINGRANGER 500 4X4 SERIES 10 A10RD50AA

11

28

21

4

14

26

27

17

16

18

5

24

22

1

13 9

763

15

2

25

23

10

20

8

12

4

10

17

14

14

14

14

15

19

11

29

A14

ENGINE MOUNTINGRANGER 500 4X4 SERIES 10 A10RD50AA



1 4010605 1 Cable, Battery/Frame/Engine2 7515399 4 Screw3 5244244-067 1 Bracket, Motor Mount, Top4 8450003-1525 AR Line5 7052075 1 Fitting, Tee6 5245206-067 1 Bracket, Carburetor7 3084205 2 Screw and Washer8 7517386 2 Screw9 5245024-067 1 Bracket, Dampner10 7542105 4 Nut11 7552605 4 Washer, Split Lock12 3110032 2 Mount, Rubber13 8360009-100 AR Line14 7547108 8 Nut, Flange Lock15 3110044 2 Mount, Rubber16 7512315 2 Screw17 7552901 2 Washer, Spring Lock18 5241453 1 Mount, Engine, Top

19 4010539 1 Cable, Sol/Starter20 7555815 2 Washer21 3021119 2 Mount, Rubber, Rear22 1013134-067 1 Mount, Engine, Rear23 5430261 1 Bushing24 5210748 1 Washer, Flat25 7575202 1 Washer, Interlock26 7512566 1 Screw27 7515417 2 Screw28 5244245-067 1 Bracket, Motor Mount, Front29 3085556 1 Engine, Short Block (If built before

1/01/02 use EH50PLE14)(If built after1/01/02 use EH50PLE16) NOTE: TheShort Block assembly contains acrankcase assembly, cylinder and cyl-inder head assembly, and a piston &crankshaft assembly. Prior authoriza-tion required for warranty consider-ation.

3/02

B1

EXHAUST SYSTEMRANGER 500 4x4 SERIES 10 A10RD50AA

14

32

16

5

17

67

8 9

10

12

15

1314

1118

1920

21

5

16

22

22

23

24

25

26

27

26



1 1261082-029 1 Silencer2 5410436 2 Washer, Rubber3 7555716 2 Washer, Flat4 7542324 2 Nut, Nylok5 7041804 5 Spring, Exhaust6 7547101 1 Nutsert7 7542301 1 Nut8 3110064 1 Mount, Torque Stop9 5245645 1 Shield, Heat, Frame

(If built before 2/25/02)10 7517386 2 Screw11 7515399 2 Screw (If built before 2/25/02)12 3085075 1 Gasket13 3080530 2 Washer, Lock14 3080285 2 Nut15 1261043-029 1 Manifold

16 5243518 2 Seal, Exhaust17 1261083-029

1261230-02911

Pipe, Exhaust (If built before 1/14/02)Pipe, Exhaust (If built after 1/14/02)

18 5010192 2 Bushing19 7555863 2 Washer20 5410241 2 Dampener21 7515316 2 Bolt, Carriage22 2632609

52456445246388

1

11

Asm. Shield Exhaust(If built after 2/25/02)Shield, LH (If built after 2/25/02)Shield, RH (If built after 2/25/02)

23 7661637 6 Rivet (If built after 2/25/02)24 5246454 1 Shield, Side (If built after 2/25/02)25 5246455 1 Shield, Top (If built after 2/25/02)26 7515106 4 Screw (If built after 2/25/02)27 7555935 2 Washer (If built after 2/25/02)

2/02

B2

TRANSMISSION MOUNTINGRANGER 500 4x4 SERIES 10 A10RD50AA

17

12

3

4

5

1213

14

1615

6

4

4

4

3

53

21

15

7

811

109



1 7515522 4 Screw2 7552603 4 Washer, Spring Lock3 7555976 5 Washer, Flat4 7547108 6 Nut, Flange Lock5 7515417 2 Screw6 ------ -- -- -- -- 1 Asm., Main Gearcase7 7080307 1 Clamp8 8450003-1525 AR Line9 7670102 1 Clip

10 7511840 1 Screw11 7080525 1 T-Clip12 7515398 2 Screw13 7542321 2 Nut, Flanged14 5244599-067 1 Bracket, Mount, Rear15 7517289 4 Screw16 5242820-067 1 Mount, Transmission17 1013134-067 1 Mount, Engine, Rear

1/02

B3

ELECTRICAL/BATTERYRANGER 500 4x4 SERIES 10 A10RD50AA

16

15

8

7

12

9

2 3

2322

27

31

28

13

641

18

30

20

33

21

1932

14

29 6

28

20

24

26

(If built before 7/09/01)

(If built after 7/09/01)10 11

5

25

17



1 5133190 1 Sink, Heat2 7670109 2 Clip, Routing3 4020149 4 Clip, Rosebud4 7080761 3 Cable Tie5 7670116 1 Clip, Routing6 7517386 7 Screw7 4010605 1 Cable, Battery/Engine/Frame8 2201155 1 Kit - Battery Bolt (If built before 7/09/01)9 4140012 1 Battery (If built before 7/09/01)10 2202099

2202172

1

1

Kit - Battery Bolt (If built between7/09/01 and 1/01/02)Kit - Battery Bolt (If built after 1/01/02)

11 4010630 1 Battery (If built after 7/09/01)12 5432077 1 Tube, Battery Vent13 4010541 1 Cable, Battery/Solenoid14 7555859 4 Washer, Flat15 5434037 1 Box, Battery16 2460973

246108222005934010781

1121

Harness (If built before 1/07/02)Harness (If built after 1/07/02)Kit - Circuit Breaker, 20 AMPDiode

17 7512084 1 Screw

18 5245617 1 Bracket, Electrical Cover19 3087196

308719811

Switch, Magnetic (If built before 1/07/02)Switch, Magnetic (If built after 1/07/02)

20 7512024 3 Screw21 3085639

308716911

CDI System (If built before 1/07/02)CDI System (If built after 1/07/02)

22 5810455 2 Pad, Rack Mount23 5241416

524637811

Bracket, CDI (If built before 1/07/02)Bracket, CDI (If built after 1/07/02)

24 7080138 2 Cable Tie25 4020139 1 Clip, Rosebud26 7512025 2 Screw (If built before 1/07/02)27 4060173 1 Rectifier, Regulator, LR-3928 7512018 6 Screw29 4010606 1 Switch, Hub Safety30 4060188

401074011

Cutoff, 12VDC (If built before 1/07/02)Cutoff, 12VDC (If built after 1/07/02)

31 5020864 2 Spacer (If built before 1/07/02)32 ------ -- -- -- -- 1 Bracket, Oil Tank

(See Chassis/Body Pg. A4, Ref. 11)33 3085227 1 Coil, Ignition

1/02

B4

FRONT DRIVE SHAFTRANGER 500 4X4 SERIES 10 A10RD50AA

4

5

3

21



1380178 2 Asm., Drive Shaft1 7670092 2 C-Clip2 1590327 2 Joint, CV

3 2201015 2 Kit, Boot (Incl. Clamps and Grease)4 1380187 2 Shaft (Incl. 5)5 3260104 2 Kit, Cross and Bearing

4/01

B5

REAR PROP SHAFTRANGER 500 4x4 SERIES 10 A10RD50AA

2 34

5 7

1

6



1380180 1 Asm., Prop Shaft, Rear1 7661913 1 Pin, Spring2 1350039 1 Yoke, Prop Shaft, Rear3 3260104 2 Kit, Cross and Bearing

4 1380184 1 Shaft, Prop5 3260131 1 Yoke, Prop Shaft, Transmission6 70/0424 1 Fitting, Lubrication7 5411092 1 O-Ring

4/99

B6

FRONT PROP SHAFTRANGER 500 4x4 SERIES 10 A10RD50AA

1

2 34

56 7



1380177 1 Asm., Shaft, Prop1 7661913 1 Pin, Spring2 3260133 1 Yoke, Gear Case, Front3 3260104 2 Unit Pack

4 1380182 1 Shaft, Prop5 3260131 1 Yoke, Prop Shaft, Transmission6 7080424 1 Fitting, Lubrication7 5411092 1 O-Ring

5/02

B7

FRONT STRUTRANGER 500 4x4 SERIES 10 A10RD50AA

9

10

11 1213

14

18

2021

15

178

7

6

5

22

4

3

2

1

16

1316

16

19



1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Ball, Pivot, Top5 5132062 2 Spacer6 5432871 2 Ball, Pivot, Bottom7 5243364 2 Retainer, Spring8 7041985-067 2 Spring, Compression9 5411608 2 Bumper10 7041784 2 Strut, Front11 5211115 2 Washer12 7080367 2 Clamp13 7542324 4 Nut, Nylok

14 7512365 4 Screw15 7552901 4 Washer, Spring Lock16 7558402 10 Washer, Flat17 7080306 2 Fitting, Lubrication18 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B14 for Details)19 7710507 2 Ring, Retaining20 3514342 2 Bearing21 1820899

1820901

1

1

Asm., Hubstrut, LH(42mm)(Incl. 12,13,16,19,20,22)Asm., Hubstrut, RH(42mm)(Incl. 12,13,16,19,20,22)

22 7515339 4 Bolt

5/01

B8

FRONT WHEELRANGER 500 4x4 SERIES 10 A10RD50AA

1

2

4

3

6

12

5

8

9

7

11

10



1 7512325 8 Bolt2 5244314 2 Disc, Brake3 7515523 8 Stud4 5131935 2 Hub, Wheel5 1520349-067 2 Rim, Front, Black6 5411397 2 Tire (25x10-12)

7 7542459 8 Nut, Flange Lock8 7556004 2 Washer9 7542810 2 Nut, Slotted10 5411164 2 Cover, Dust11 7661401 2 Pin, Cotter12 1525017 2 Valve, Rim

4/01

B9

STEERINGRANGER 500 4x4 SERIES 10 A10RD50AA

28 27

20

11 12

13

18

10

22

16

17

8

23

3029

24

6

4

2

5

7

3

1

25

26

13

7

5

4

3

2

1

19

15

14

9

21



1 5411920 2 Boot2 7061054 2 Rod End3 7547028 2 Nut, Jam4 1821006 2 Tie Rod5 7080978 2 Clamp, Small6 5412013 1 Boot, Passenger Side7 7080979 2 Clamp, Large8 7515382 3 Screw9 7080884 1 J-Clip10 7515434 1 Screw11 7517924 1 Screw12 7552902 1 Washer, Spring Lock13 5434106 2 Bushing, Shaft, Steering14 7556063 2 Washer, Wave15 7078465 1 Logo, Polaris Star

16 5434169 1 Cap17 7547188 1 Nut18 1821065 1 Wheel, Steering19 7556301 1 Bushing20 1821018 1 Shaft, Steering, Upper21 1821019 1 Shaft, Steering w/Joints, Lower22 7542439 1 Nut, Nylok23 7542324 5 Nut, Nylok24 5412012 1 Boot, Driver Side25 7517909 2 Screw26 7556099 4 Washer, Flat27 7547177 2 Nut28 7661203 2 Pin, Cotter29 1820921 1 Box, Steering30 7512371 2 Screw

1/02

B10

A-ARM/STRUT MOUNTINGRANGER 500 4x4 SERIES 10 A10RD50AA

13

7

8

9

1011

1215

43

16

12

56

14

2 1

56



1 7512589 4 Screw2 7553101 4 Washer, Spring Lock3 7080433 2 Fitting, Lubrication4 1541456-067

1541457-06711

A-Frame, LHA-Frame, RH

5 5132532 4 Bushing6 5434547 4 Bushing, A-Arm7 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B7, Ref. 21)8 7080927 2 Joint, Ball

9 5211121 2 Bracket, Ball Joint10 5410548 2 Boot, Rubber11 7512284 4 Screw12 7542438 2 Nut, Castle13 7661203 2 Pin, Cotter14 5433927-070

5433928-07011

Shield, CV Joint, LHShield, CV Joint, RH

15 7512084 6 Screw16 5132533 2 Shaft, A-Arm

1/02

B11

THROTTLERANGER 500 4x4 SERIES 10 A10RD50AA

1

2

7

34

5

6

8

9



1 7080938 1 Cable, Throttle2 ------ -- -- -- 1 Frame, Main3 5434327 1 Block, Pivot4 7555954 1 Washer5 7661011 1 Pin, Cotter

6 7515102 4 Screw7 1013557-067 1 Throttle8 7042004 1 Spring9 7547069 4 Nutsert

1/02

B12

FOOT BRAKERANGER 500 4x4 SERIES 10 A10RD50AA

6

3

2

4

15

7

2

8



1 7542439 1 Nut, Nylok2 5431107 2 Bushing3 5334030 1 Tube4 7515417 1 Screw

5 76611065910110

11

Pin, Clevis (If built before 1/07/02)Pin, Clevis (If built after 1/07/02)

6 1013521-067 1 Pedal, Brake7 7661209 1 Pin, Cotter (If built before 1/07/02)8 7661140 1 Pin, Clip (If built after 1/07/02)

1/02

B13

BRAKE LINES/MASTER CYLINDERRANGER 500 4x4 SERIES 10 A10RD50AA

3

5

8

4

1

13

10

6

2

9 119

12

7

10

14

15



1 1910493 1 Line, Rear, LH2 7052293 1 Fitting, Tee3 1910447 1 Asm., Master Cylinder4 1910486 1 Line, Brake, M/C, Front5 1910484 1 Line, Brake, Front, Left6 4110164 1 Switch7 7052316 1 Fitting, Cross, Brake8 1910485 1 Line, Brake, Front, Right

9 7512025 4 Screw10 1910594 2 Bolt, Banjo11 5410988 4 Seal12 1910487 1 Line, Brake, M/C, Rear13 1910494 1 Line, Rear, RH14 7080138 2 Cable Tie15 7670102 7 Clip

5/01

B14

FRONT BRAKE CALIPERRANGER 500 4x4 SERIES 10 A10RD50AA

10

12

87

3

9

45

6



1910510 1 Asm., Front Brake Caliper, LH1910511 1 Asm., Front Brake Caliper, RH

1 7515489 1 Screw, Socket Set2 5132830

51328311930642

111

Caliper, Brake, LHCaliper, Brake, RHKit - Front Brake Boot

3 5410494 1 Boot, Pin Seal

4 5412010 1 Seal, Caliper, Inner5 5412011 1 Seal, Caliper, Outer6 5132829 1 Piston, Brake7 1910513 1 Caliper, Front8 1910514 2 Pad, Front Brake9 5410495 1 Boot, Bushing10 7080352 1 Screw, Bleeder

4/01

C1

PARK BRAKE LOCKRANGER 500 4x4 SERIES 10 A10RD50AA

20

4

10

5

13

14

22

21

9

8

17

23

1112

18

28

3

6

2927

25

26

24

15

16

17

14

2425

1

72

19



1910560

1910604

1

1

Asm., Parking Brake(Incl. 4,5-10,13,14,17-20,22,23)(If built before 1/07/02)Asm., Parking Brake(Incl. 4,5-10,13,14,17-20,22,23)(If built after 1/07/02)

1 7081010 1 Cable, Park Brake, Main2 5245209 1 U-Bolt3 7542451 2 Nut, Nylok4 ------ -- -- -- -- 1 Mount, Parking Brake5 5133067 1 Rod, Parking Brake6 5410437 1 Grommet7 7546701 1 Nut8 7081013 1 Handle, Parking Brake9 7042057 1 Spring, Catch, Parking Brake10 ------ -- -- -- -- 1 Catch, Parking Brake11 7558201 1 Washer, Flat12 7661103 1 Pin, Cotter

13 ------ -- -- -- -- 1 Plate, Catch, Parking Brake14 ------ -- -- -- -- 2 Bushing15 7558402 1 Washer, Flat16 7661140 1 Pin, Clip17 ------ -- -- -- -- 2 Washer18 ------ -- -- -- -- 1 Pin, Cotter19 7080138 1 Cable Tie20 ------ -- -- -- -- 1 Lever, Parking Brake21 7042056 1 Spring, Parking Brake22 ------ -- -- -- -- 1 Pin, Clevis23 ------ -- -- -- -- 1 Washer24 7542122 2 Nut, Nylok25 7512287 2 Bolt, Brake Lever26 7517386 7 Screw27 7081012 1 Cable, Park Brake, LH28 2632418 1 Asm., Equilizer and Pin29 7081011 1 Cable, Park Brake, RH

1/02

C2

REAR BRAKE CALIPERSRANGER 500 4x4 SERIES 10 A10RD50AA

54

3

1

28

18

15

19

21

13

129

22

10

24

25

23

6

7

11

14

20

16

17

13



1 5133195 1 Plunger2 7556205 1 Washer, Flat, Plunger3 1910581 1 Spring, Compression4 5412127 2 O-Ring5 1910508

191050911

Asm., Caliper, Rear, LH (Incl. 5-25)Asm., Caliper, Rear, RH (Incl. 5-25)

6 7080352 1 Screw, Bleeder7 7515489 1 Screw8 7517963 3 Screw9 7556206 1 Washer, Flat10 7517964 1 Screw11 7542105 1 Nut12 5133196 1 Lever, Brake Actuator13 5410494 2 Boot, Pin Seal

14 52457935245794

11

Bracket, Housing, LHBracket, Housing, RH

15 5830214 1 Gasket16 5133199

513320111

Insert, Ball Track, LHInsert, Ball Track, RH

17 51332025133203

11

Actuator, LHActuator, RH

18 3514375 3 Ball19 5412010 1 Seal, Caliper, Inner20 5132829 1 Piston, Brake21 5412011 1 Seal, Caliper, Outer22 5410495 1 Boot, Bushing23 1910514 2 Pad, Brake24 5133197 1 Plate, Bracket Mount25 5910023 2 Pin, Bracket Plate

8/01

C3

REAR WHEEL DRIVERANGER 500 4x4 SERIES 10 A10RD50AA

8

10

3

12

2

1

9

4

11

5

6

7



1 5411164 2 Cover, Dust, Hub2 7661404 2 Pin, Cotter3 7555796 2 Washer, Cone4 1520483-067 2 Rim, Rear5 5132520 2 Hub, Rear Wheel6 5244635 2 Disc, Brake, Rear

7 7512325 8 Screw8 5412008 2 Tire, 25x11-129 7515513 8 Stud10 1525017 2 Valve, Rim11 7542459 8 Nut, Flange Lock12 7543005 2 Nut, Castle

1/02

C4

SWING ARMRANGER 500 4x4 SERIES 10 A10RD50AA

12

9

37

8

2 1

27

4 5

18

24

1319

23

20

10

21

11

22

17

25

1 25

4

17

5 54

4

6

6

2616

15

14



1 7710440 2 Ring, Retaining2 3585502 2 Bearing, Wheel3 1013293-067 1 Tube, Axle, RH4 7517585 8 Screw5 7553201 8 Washer, Split Lock6 5411553

5410772

2

2

Seal, Clutch Cover, Inner(If built before 4/01/02)O-Ring (If built after 4/01/02)

7 13801631380203

11

Axle, LH (If built before 2/11/02)Axle, LH (If built after 2/11/02)

8 13801641380204

11

Axle, RH (If built before 2/11/02)Axle, RH (If built after 2/11/02

9 1013292-067 1 Tube, Axle, LH10 7542525 8 Nut, Nylok11 7555984 8 Washer, Flat12 1013295-067 1 Arm, Swing13 5245127 4 U-Bolt

14 5246229 2 Bracket, Bolt Lock15 7512490 2 Screw16 7547180 2 Nut, Nylon, Flanged17 5131697 2 Bolt, Swing Arm, Pivot18 5133166 1 Bushing, Pivot, LH19 5434545 1 Bushing, Swing Arm, LH20 7080424 2 Fitting, Lubrication21 7547082 1 Nut, Jam22 7556035 1 Washer, Flat23 5434546 2 Bushing, Swing Arm, RH24 5133167 1 Bushing, Pivot, RH25 ------ -- -- -- -- 1 Asm., Gearcase, Rear (See Rear

Gearcase Pg. C11 for Details)26 5811716 2 Pad, Rubber27 5245665-067 1 Plate, Skid

1/02

C5

REAR SHOCKRANGER 500 4x4 SERIES 10 A10RD50AA

1

2

3

4

5

6

7

2



1 7517583 2 Screw2 7542439 4 Nut, Nylok3 5241147 2 Retainer, Spring4 7041955-067 2 Spring

5 5630551 2 Cam, Adjusting6 7041956 2 Shock, Rear7 7515415 2 Screw

3/02

C6

DRIVE CLUTCHRANGER 500 4x4 SERIES 10 A10RD50AA

1 23 4

7

13

5 6 7

8

12

11

910

14

Part numbersmay have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updatedmonthly.


1 75121767518062

66

Bolt (Use w/1321632)Screw (Use w/1322302)

2 7552801 6 Washer, Spring Lock (for use with7512176 only)

3 3576510 1 Bearing, Cover4 7041157 1 Spring, Clutch5 5430945 6 Washer, Multilube6 1321457 3 Asm., Roller and Bushing7 5431936 6 Button, Guide, Stemless8 5210752

524298152107535210754

ARARARAR

Spacer (.020)Spacer (.025)Spacer (.032)Spacer (.050)

9 5630513 3 Weight, Shift (10 MH)10 7512266 3 Bolt, Shoulder11 7541906 3 Nut, FLEXLOC12 3576504 1 Bearing, Moveable, 1/2 Inch13 5020422 3 Pin, Roller14 1321632

1322302

1

1

Asm., Drive Clutch, Basic ATV-06(Incl. All Less 4,9)(If built before2/01/02)Asm., Drive Clutch, Basic ATV(Incl. All Less 4,9)(If built after 2/01/02)

1/02

C7

DRIVEN CLUTCHRANGER 500 4x4 SERIES 10 A10RD50AA

2

3

45

6

7

10

11

12

13

15

1617

3

1

9

14

8

Part numbersmay have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updatedmonthly.


1 7556120 AR Bushing (3 Max)2 3211077 1 Belt, Drive3 1321848 1 Asm., Driven Clutch (Incl. 7-17)4 5220646 1 Washer, Domed5 7552901 1 Washer, Spring Lock6 7515382 1 Bolt7 7555898 AR Washer (.020)8 7556076 AR Washer (.025)9 7556804 AR Washer (.030)

10 3576504 1 Bearing, Moveable, 1/2 Inch11 3576511 1 Bearing, Moveable, 1 Inch12 7041782 1 Spring, Clutch13 5131446 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

4/01

C8

AIR BOXRANGER 500 4x4 SERIES 10 A10RD50AA

E 2001 Polaris Sales Inc.

9

13

10

8

14

11

12

7

34

62

2

5

1



1 8450073-100 AR Line2 7080699 2 Clamp, Hose3 7080913 1 P-Clamp4 2530029 1 Filter, Breather5 5411921 1 Hose, Breather6 7080694 1 Clamp, Hose7 7670132 2 Clip

8 5434060 1 Box, Air9 5412015 1 O-Ring10 5434058 1 Tube, Outlet11 7052164 2 Fitting, 90 Degree12 7080981 1 Filter13 5434059 1 Cover, Air Box14 5812196 1 Seal, Cover

4/01

C9

ENGINE AND CLUTCH AIR INTAKERANGER 500 4x4 SERIES 10 A10RD50AA

1 14

1716

18

1312

11

3 7

4

9

2021

19

53

15

33

3

1

22

2

86

3

3

10



1 5812253 2 Filter2 5434323 1 Box, Air Baffeling, Engine3 7080451 7 Clamp, Hose4 1910482 1 Hose, Air Box, Front5 5434291 1 Duct, Intake, Engine6 7080965 2 Mount, Cable Tie7 7080761 3 Cable Tie8 7080560 1 Clamp, Hose9 1910483 1 Hose, Air Box, Rear10 5810290 1 Pad, Battery (If built after 1/01/02)11 7542324 1 Nut, Nylok

12 7515398 1 Screw13 7512399 2 Screw14 1240101-067 1 Hanger, Air Cleaner15 ------ -- -- -- -- 1 Box, Air (See Air Box Pg. C8, Ref. 8)16 7080413 1 Clamp, Narrow Band17 5411976 1 Boot, Air Box18 7080656 1 Clamp, Narrow Band19 1910491 1 Hose, Clutch, Rear20 5434054 1 Duct, Air Intake21 1910490 1 Hose, Clutch, Front22 5434141 1 Box, Air Baffleing

1/02

C10

CLUTCH COVERRANGER 500 4x4 SERIES 10 A10RD50AA

21

11

9

10

13

14

8

12

43

6

5

7 6

8



1 5410489 1 Seal, Cover Case2 5434234 1 Cover, Clutch, Inner3 7555748 5 Washer4 7517312 5 Screw5 5434247 1 Duct, Clutch Outlet6 7080707 2 Clamp, Narrow Band7 5411489 1 Boot, Duct

8 7512094 9 Screw9 5433451-070 1 Cover, Clutch, Outer10 7078689 1 Decal - Warning, Clutch Cover11 5521578 1 Seal, Cover, Clutch, Outer12 3084205 3 Screw and Washer13 5242046-067 1 Bracket, Seal14 5410575 1 Seal, Cover Case

7/01

C11

REAR GEARCASERANGER 500 4x4 SERIES 10 A10RD50AA

35

1

2 34

5

6

7 89

34

11 12

41

40

13

14

15 16

39

1718

38

19

37 36

2930

252627

21 28

20

24

10

35

7

34

12

32

31

2322

33



1341339

1341442

1

1

Asm., Rear Gearcase(If built before 4/01/02)Asm., Rear Gearcase(If built after 4/01/02)

1 3233785 1 Seal2 3233800 1 Cover, Input3 3233801 1 O-Ring4 3233589 1 Bearing, Ball5 3233802 1 Pinion, 10T6 3233577 1 Bushing7 3233803 2 Seal8 3233804 1 Case, Front9 3233529 1 Pipe, Knock10 3233824

323401711

O-Ring (Use w/1341339)O-Ring (Use w/1341442)

11 3233806 1 Bearing, Ball12 3233807 2 Ring, Retaining13 3233810 1 Housing, Differential Lock14 3233811

323402211

Gear, 14T, RH (Use w/1341339)Gear, 14T, RH (Use w/1341442)

15 32338123234023

11

Gear, 14T, LH (Use w/1341339)Gear, 14T, LH (Use w/1341442)

16 3233813 1 Gear, Ring 37T17 3233815 1 Collar, Splined18 3233378 1 Washer, Thrust

19 3233268 1 Bearing, Ball20 3233822 1 Actuator, Cam21 3233820 1 Spring, Torsion22 7555923 1 Washer (Use w/1341339 Only)23 7661140 1 Pin, Clip (Use w/1341339 Only)24 3233823 1 Seal25 3233818 1 Actuator26 5410440 1 O-Ring27 3233819 1 Ring, Retaining28 3233821 1 Ring, Retaining29 3233817 1 Cover, Output30 3233524 1 Tube, Vent31 7670102 3 Clip32 8450003-600 AR Line, Vent33 7080307 1 Clamp, Hose34 3233805 2 Plug, Drain35 3233252 12 Screw36 3233816 1 Dog, Engagement37 3233581 AR Shim38 3233377 1 Ring, Retaining39 3233814 8 Screw, Cap40 3233809 2 Pinion, Differential, 10T41 3233808 1 Pin, Differential Pinion

3/02

C12

FRONT HOUSINGRANGER 500 4x4 SERIES 10 A10RD50AA

12

34 5

67

89 10

1112

1314 15 16

17

20

2122

23

2425

26272829

30

3132

3334

3536

37

2329

13

6

18

19


1341344 1 Asm., Front Gearcase(Incl. 1-16,21-30,33-37)

3233950 1 Gearcase (Incl. 16,27,28)3233951 1 Asm., Drain Plug (Incl. 33,34)3233998 1 Asm., Cover Plate (Incl. 1,3,4)3233953 1 Asm., Race/Output Hub

(Incl. 7,14,15,35)3233954 1 Asm., Clutch (Incl. 9-13,36)3233956 1 Kit, Minor Repair (Incl. 2,21,22,29)3233949 1 Asm., Roll Cage (Incl. 11,36)

1 ------ -- -- -- -- 1 Cover, Output2 ------ -- -- -- -- 1 O-Ring3 ------ -- -- -- -- 1 Insert4 ---- -- -- -- -- -- 1 Coil5 3233925 1 Kit, Shim Set (Incl. Shims)6 3233926 2 Bearing, Roller Ball7 ---- -- -- -- -- -- 1 Hub, Race/Output, Male8 3233928 1 Pin, Dowel9 3233932 1 Bearing, Roller Ball10 3233933 1 Clutch Housing/Ring Gear11 3233935 1 Spring12 3233957 14 Kit, Roll13 3233934 2 Ring, Retaining14 ------ -- -- -- -- 1 Bushing

15 ------ -- -- -- -- 1 Hub, Race/Output, Female16 ------ -- -- -- -- 1 Bushing17 8450003-1525 AR Line, Fuel18 7080693 1 Clamp, Hose19 7512024 1 Screw20 7080307 1 Clamp, Hose21 ------ -- -- -- -- 1 O-Ring22 ------ -- -- -- -- 1 Seal23 3233955 11 Kit, Bolt24 3233947 1 Cover, Input25 3233945 1 Bearing, Roller Ball26 3233944 1 Shaft, Pinion, 11T27 ------ -- -- -- -- 1 Bushing28 ------ -- -- -- -- 1 Gearcase, LH29 ------ -- -- -- -- 2 Seal, Oil30 3233942 1 Plug, Oil Fill31 7552603 4 Washer, Spring Lock32 7512492 4 Screw33 ------ -- -- -- -- 1 Plug, Oil Drain34 ------ -- -- -- -- 1 Washer35 3233929 1 Bearing, Needle, Roller Thrust36 ------ -- -- -- -- 1 Roll Cage, Aluminum37 3233924 1 Plate Armature

5/02

C13

GEARCASERANGER 500 4x4 SERIES 10 A10RD50AA

1

67

23

4

64

5 68

57

6665

636261

6059

9

5815

10

18

7

1442

43

54

44

15

454856

55

53

4647

49 50

52

14

7

51

4140

38 3736

35

11

2223

11

24252627

2829 30

313233 34

19

20

21

12

13

16

17

22

242223 22

27

11

15

2019

11

14

39

68

C14

GEARCASERANGER 500 4x4 SERIES 10 A10RD50AA



1 3233961 1 Nut2 3233826 5 Screw3 3233827 1 Cover4 3233829 1 Pawl, Detent5 3233828 1 O-Ring6 3233831 1 Shaft, Shift7 3233842 2 Seal8 3233832 1 Gear, 31T9 3233711 1 Plug, Oil Fill10 3233524 1 Tube, Vent11 3233018 4 Bearing12 3233036 1 Chain, Silent13 3233889 1 Shaft, Input14 3233019 4 Bearing15 3233529 4 Pipe, Knock16 3233865 1 Cover, LH17 3233866 1 Seal18 3233841 1 Drum, Shift19 3233858 2 Fork, Shift20 3233859 2 Pin, Dowel21 3233860 1 Rail, Shift Shaft22 3233875 4 Engagement Dog23 3233849 2 Spring, Wave24 3233850 2 Ring, Retaining25 3233851 1 Washer26 3233852 1 Gear, 33T27 3233718 2 Bearing, Needle28 3233892 1 Shaft, Reverse29 3233103 1 Bearing, Needle30 3233893 1 Sprocket, 24T31 3233894 1 Washer32 3233855 1 Washer33 3233856 1 Gear, 30T34 3233857 1 Gear, 37T

35 3233847 1 Gear, 47T36 3233608 4 Screw37 3233609 1 Cover, Bearing38 3233106 1 Ring, Retaining39 3233357 1 Spacer40 3233607 1 Bearing, Ball41 3233606 1 Shaft, Pinion, 10T42 3233619 1 Washer, Thrust43 3233843 1 Sprocket, 19T44 3233621 1 Gear, 31T45 3233622 1 Shaft, Output, Main, Rear46 3233582 1 Button, Thrust47 3233583 AR Shim48 3233611 AR Shim49 3233845 1 Cover, Output, Front50 3233846 17 Screw, Tapping51 3233777 1 Plug52 3233254 1 Washer53 3233625 1 Shaft, Output, Main, Front54 3233408 1 Chain, Silent55 3233844 1 Sprocket, 22/22T56 3233552 1 Bushing57 3233833 1 Gearcase, Main58 3233324 1 Washer59 3233840 1 O-Ring60 3233839 1 Gear, 16T61 3233838 1 Disc, Lockout62 3233837 1 Star, Detent63 3233836 1 O-Ring64 3233830 1 Spring, Compression65 3233835 1 Switch66 3233834 1 Ring, Retaining67 3233825 1 Bellcrank68 1341355 1 Asm., Main Gearcase

11/02

D1

GEAR SELECTOR/DIFFERENTIAL LOCKRANGER 500 4x4 SERIES 10 A10RD50AA

20

11

22

24

21

1323

19

10

12

1718

4

3 5

7

25

21

6

21

1

2

6

16

9

8

14

15



1 7661407 2 Pin, Cotter2 7555919 2 Washer3 5431107 2 Bushing, Pedal Pivot4 1013584-067 1 Lock, Differential5 7042029 1 Spring6 7558302 3 Washer7 7080939 1 Cable, Differential8 7080761 1 Cable Tie9 7080965 1 Mount, Cable Tie10 7542344 1 Nut, Nylok11 5132928 1 Bearing, Shifter12 7547144 1 Nut, Nylok13 7081005 1 Cable, Shifter

14 7555923 2 Washer15 7661140 2 Clip16 7670102 1 Clip17 7555795 1 Washer, Wave18 7555796 1 Washer, Cone19 7517745 1 Bolt, Shoulder20 1541628-067 1 Shifter21 5412154 2 Grommet22 5411007 1 Knob, Shifter23 7512024 1 Screw24 5412079 1 Cover25 7081016 1 Knob, Differential Lock

7/01

D2

CRANKCASERANGER 500 4x4 SERIES 10 A10RD50AA

2

4

11

12

2

20

21

1

23

7

5

17

3

1918

9

1615

1314

22

6

5

8

10



1 3083669 1 Bushing, Starter2 3085633 1 Asm., Crankcase

(Incl. 1,4,5,7,8,11,12,17,20,21,22)3 3084838 2 Pin, Straight4 3080676 3 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 3 Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3087154 1 Fitting, Oil Inlet10 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 3083453 1 Plug20 3084837 1 Seal, Mechanical21 3084836 1 Seal, Oil22 3084847 1 O-Ring23 3080103 2 Pin, Dowel

3/02

D3

CYLINDERRANGER 500 4x4 SERIES 10 A10RD50AA

2

20

38

232221

12

5

4

37

107

34

9

25

29

1617

3

6

18

27

1

26

13

35

28

33

31

32

8

11

30

36

14

24

15

19

5

36

36

13

9

D4

CYLINDERRANGER 500 4x4 SERIES 10 A10RD50AA



1 3083166 1 Asm., Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt4 3084857 2 Pin, Straight5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve7 3084867 1 O-Ring8 3085072 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 3084215 2 Bolt, Flange20 3085075 1 Gasket, Exhaust

21 3085326 2 Stud22 3080530 2 Washer, Lock23 3080285

308719922

Nut (If built before 1/01/02)Nut (If built after 1/01/02)

24 3085854 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3084838 2 Pin, Straight29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3086811 1 Cylinder (Incl. 32)32 3084130 1 Pipe 2, Elbow33 3085370 1 Gasket, Cylinder34 3084868 1 Cover, Camshaft35 3086200 1 Gasket, Cover, Cam36 3085527 1 Head, Cylinder (Incl. 4-6,14,16-18,21)37 3085371 1 Gasket, Head38 3084879 1 Adapter

3/02

D5

CARBURETORRANGER 500 4x4 SERIES 10 A10RD50AA

47

37

34

9

50

5

49

12

4

6

4142

38

36

1235

1312

1415

21

19

27

30

29

26

1110

3

22

20

16

24

18

25

40

23

51

4445

87

46

39

33

3128

17

48

43

33

31

After 1/01/02

32

D6

CARBURETORRANGER 500 4x4 SERIES 10 A10RD50AA



1 3130507 1 Ring2 3130508 1 E-Ring3 3131367 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3131366

313142011

Jet, Needle (P-8)(If built before 1/01/02)Jet, Needle (P-8)(If built after 1/01/02)

7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3130563

313142611

Jet, Main (#135)(If built before 1/01/02)Jet, Main (#135)(If built after 1/01/02)

12 3130515 2 Seal13 3130517 1 Packing14 3130518 1 E-Ring15 3130519 1 Cap16 3130361 1 Pin, Float17 3130594 1 Plate18 3130532 1 O-Ring19 3130520 4 Screw20 3131212 1 Asm., Float Body21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 1 Screw24 3131361 1 Valve, Needle25 3130533 1 O-Ring26 3130526

313142111

Jet, Pilot (#42.5)(If built before 1/01/02)Jet, Pilot (#42.5)(If built after 1/01/02)

27 3130522 1 O-Ring

28 3130523 1 Washer29 3130525 1 Spring30 3130524

313138911

Adjuster (If built before 1/01/02)Adjuster (If built after 1/01/02)

31 31305463131423

11

Screw, Adjust (If built before 1/01/02)Screw, Adjust (If built after 1/01/02)

32 3130545 1 Ring (If built before 1/01/02 Only)33 3130544

313083611

Spring (If built before 1/01/02)Spring (If built after 1/01/02)

34 3130502 1 Valve, Throttle (100)35 3130589 1 Spring36 3130514 1 Ring37 3130501 2 Screw38 3130513 1 Asm., Throttle Shaft39 3130543 1 Guide, Cable40 3130535 4 Screw41 3130511 1 Cover42 3130512 1 O-Ring43 3130199 1 Holder, Guide44 3130538 1 Spring45 3130593 1 Asm., Plunger46 3130625 1 Jet, Air (#160)47 3131365

3131441

1

1

Asm., Carburetor(Incl. 1-38,43-51)(If built before 1/01/02)Asm., Carburetor(Incl. 1-38,43-51)(If built after 1/01/02)

48 3084205 2 Screw and Washer49 3130505 1 Spring50 3130503 1 Asm., Cover51 3130592 4 Screw

3/02

D7

CRANKSHAFT and PISTONRANGER 500 4x4 SERIES 10 A10RD50AA

18

19

5

9

1311

4

7

17 12

8

16

6

10

1

14

20

15

2

3

1



1 3085534 2 Clip2 3087170

30871713087172

111

Asm., Piston Set (Std) (Incl. 1)Asm., Piston Set (0.25 O/S) (Incl. 1)Asm., Piston Set (0.50 O/S) (Incl. 1)

3 308537930853803085381

111

Piston Ring Set (Std)Piston Ring Set (0.25 O/S)Piston Ring Set (0.50 O/S)

4 3085374 1 Crankshaft 25 3085341 1 Pin, Crank6 3085376 1 Rod, Connecting7 3085400 1 Bearing, End, Large8 3085024 1 Ball, Steel9 3085399

308537311

Asm., Crankshaft (Incl. 4-10,18)Crankshaft 1

10 3085852 1 Gear 1, Balancer

11 3085404 1 Shaft, Balancer12 3084895

30848963084897

111

Spacer (0.8)Spacer (1.0)Spacer (1.2)

13 3240088308489230848933084894

1111

Spacer (0.6)Spacer (0.8)Spacer (1.0)Spacer (1.2)

14 3084882 1 Sprocket 115 3085528 1 Nut, Slit16 3083904 1 Washer17 3083905 1 Nut, Lock18 3085346 1 Pin, Dowel19 3081447 1 Key20 3080130 1 Key, Woodruff

9/01

D8

INTAKE and EXHAUSTRANGER 500 4x4 SERIES 10 A10RD50AA

14

18

15

1617

25

26

1312 11

10

6

98

22

7

19

8

21

24

4

3

2

1

5

20

27

23

89

6

9

12

11

13



1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3086839 1 Spring, Tensioner4 3086813 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Rocker Arm, Intake (Incl. 8,9)7 3084913 1 Asm., Rocker Arm, Exhaust (Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3087203 4 Retainer, Spring13 3084906 4 Spring, Valve14 3086212 1 Camshaft (Incl. 15-18)

15 3086838 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3084914 1 Sprocket 220 3081657 3 Bolt and Washer21 3084916 1 Guide, Chain22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot24 3084917 1 Lever25 3085349 2 Valve, Intake26 3085412 2 Valve, Exhaust27 3084874 2 Bolt, Flange

3/02

D9

FLYWHEEL COVERRANGER 500 4x4 SERIES 10 A10RD50AA

6

1

2

4

5

1

2 3



1 3083453 2 Plug2 3082956 2 Gasket3 3083669 1 Bushing, Starter4 3084933 1 Gasket, Recoil (If built before 1/01/02)

5 3084877 9 Bolt, Flange6 3087146

3087200

1

1

Cover, Flywheel(Incl. 3)(If built before 1/01/02)Cover, Flywheel(Incl. 3)(If built after 1/01/02)

3/02

D10

WATER PUMPRANGER 500 4x4 SERIES 10 A10RD50AA

11

7

8

3

3

2

1

9

12

13

4

10

65



1 3084940 1 Thermostat2 3085352 1 Switch, Thermostat3 3084191 2 Clamp, Hose4 3085857 1 Hose, Main5 3085359 1 Bolt, Flange6 3082758 1 Gasket, Aluminum7 3085351 1 Cover, Water Pump

8 3086840 1 Gasket, Water Pump9 3085077 1 Nut, Self Lock10 3083138 1 Gasket, Aluminum11 3084935 1 Impeller12 3084942 1 Washer, Seal13 3084877 4 Bolt, Flange

7/00

D11

OIL PUMPRANGER 500 4x4 SERIES 10 A10RD50AA

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 (Feed)3 3084948 1 Rotor, Inner (Feed)4 3084944

308494511

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 Bolt and Washer

10 3084947 1 Pump, Oil, Case 311 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Unit, Oil Strainer14 3084205 3 Screw and Washer15 3084952 1 Shaft, Pump16 3084958 1 Gear 2, Pump17 3084959

30849603084961

ARARAR

Spacer (0.8)Spacer (1.0)Spacer (1.2)

7/00

D12

OIL FILTERRANGER 500 4x4 SERIES 10 A10RD50AA

1

4

5

3

3

3

2

2

2

2

2



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

4 3084964 1 Pipe, Oil Delivery 15 3085638 1 Pipe, Oil Delivery 2

7/00

D13

MAGNETORANGER 500 4x4 SERIES 10 A10RD50AA

19 6

5

8

9

1011

1213

4

7

1

2

15

18

3

141617

After 1/01/02

15

18

20



1 30852273085228

11

Asm., Ignition Coil (Incl. 1,2)Coil, Ignition

2 3084980 1 Cap, Spark Plug3 3070175 1 Plug, Spark, BKR5E4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3087167

308698111

Asm., Plate (Incl. 5,6,8-14)Plate

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3087168 1 Stator (Incl. 13)10 3086985 3 Screw and Washer

11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3081256 1 Screw and Washer15 3087169 1 CDI System16 3083073 2 Nut (If built before 1/01/02 Only)17 3080077 2 Washer, Spring (If built before 1/01/02 Only)18 3085521

308719811

Switch, Magnetic (If built before 1/01/02)Switch, Magnetic (If built after 1/01/02)

19 3087166 1 Flywheel w/Ring Gear20 3085359 2 Bolt, Flange

3/02

D14

STARTING MOTORRANGER 500 4x4 SERIES 10 A10RD50AA

9

12

1

4

10

3

2

11 13

17

16

15

14

56

8

7



3084981 1 Asm., Starting Motor (Incl. 1-4,6-10,12)1 3084982 1 Washer Set2 3084406 1 Brush Set, Carbon3 3083649 2 Nut, Flange4 3084408 3 O-Ring5 3082038 2 Bolt and Washer6 3085034 1 Asm., Bracket, Rear7 3085353 1 Asm., Armature8 3085033 1 Asm., Bracket, Front

9 3240114 1 O-Ring10 3084983 2 Asm., Set Bolt (Incl. 4)11 3087030 1 Asm., Gear Shaft (Incl. 13-17)12 3084405 2 Ring, Rubber13 3083737 1 Washer, Gear Shaft14 3084412 1 Clip15 3084411 1 Spring, Weight16 3084410 1 Spring, Return17 3084409 1 Clip

7/00

E1

TOOL KITRANGER 500 4x4 SERIES 10 A10RD50AA

1

3

8

2

9

4

510

6

7

11



1 3085544 1 Kit - Tool (Incl. 2 -8)2 2870725 1 Gauge, Tire Pressure3 3082657 1 Screwdriver4 3085001 1 Wrench, 8-10 Open5 3085002 1 Wrench, 12-14 Open6 3085568 1 Wrench, Box7 3085569 1 Puller, Spark Plug (Wrench Handle)

8 2682572 1 Pouch, Tool Kit9 9915765

991735211

Owner’s Manual, RANGERSupplement, Owner’s Manual, RANGER500 4X4

10 2871095-067 1 Wrench, Spanner, Cam11 2871348 1 Wrench, Open 1/2-9/16

4/01

E2

OIL TANK (If Built After 1/01/02)RANGER 500 4x4 SERIES 10 A10RD50AA

4

89

3

1617

14

2

2

1

1

15

13

11

89

10

5

7

7

18

6

6

12

12



1 7512163 2 Bolt2 7558301 2 Washer, Flat3 5434307 1 Dipstick4 1261175 1 Tank, Oil5 8450073-63 AR Line6 7080761 2 Cable Tie7 7542122 2 Nut, Nylok8 5333204 2 Bushing, Mounting9 5410828 2 Grommet, Reservoir Mounting

10 7080699 1 Clamp, Hose, Spring11 8450096-51 AR Line12 7080474 2 Clamp13 7081026 1 Clamp, Hose14 7052326 1 Screen, Oil Filter, 90 Degree15 5411042 1 Grommet16 5850135 1 Washer, Nylon17 7051524 1 Plug18 8450073-95 AR Line

1/02

PARTS MANUAL PN 9917097 and MICROFICHE PN 9917098 1/02PRINTED IN THE USA

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RANGER 500 4X4 SERIES 10 Rev. 01 - pi54.compi54.com/corp/manuals/Parts/9917097r01.pdf · E 2002...

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