SPORTSMAN 6X6 Model #A00CL50AA INT’L BIG BOSS 6X6 Model...

PARTS MANUAL PN 9915481 and MICROFICHE PN 9916574 3/00

SPORTSMAN 6X6Model #A00CL50AAINT’L BIG BOSS 6X6Model #A00CL50DA

Rev. 03

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

Parts Manual

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

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. . . . . . . . . . . . .CV JOINT - BTB B2. . . . . . . . . . . . . . . . . . . . .CYLINDER D7-8. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A7. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C5. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C6. . . . . . . . . . . . . . . . . . . . .DUMP BOX C12. . . . . . . . . . . . . . . . . . . . . . . . .

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

FFRONT BRAKE B6. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING B3. . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A8. . .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 FILTER E1. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D14. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK A14. . . . . . . . . . . . . . . . . . . . . . . . . .

PPARK LOCK E6. . . . . . . . . . . . . . . . . . . . . . . .PROP SHAFT B1. . . . . . . . . . . . . . . . . . . . . . .

RREAR and MIDDLE WHEEL C2. . . . . . . . . . . . .REAR BRAKE CALIPER B12. . . . . . . . . . . . . . .REAR CAB and SEAT A6. . . . . . . . . . . . . . . . .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. . . . . . . . . . . . . . . . . . . . . . .

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

2000 SPORTSMAN 6X6 SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Fixed Disc, Hyd. Floating CaliperFixed Disc, Hyd. Floating CaliperFixed Disc, Hyd. Floating Caliper

Hydraulic Lock, All Wheel

CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallon)Engine Oil (quarts) 10W30Engine Counter BalanceGearcase Oil (ounces)Oil (quarts) InjectorRack, Front (pounds)Box, Rear (pounds)Tongue WeightTow HitchTow Weight

2.254.252

N/AN/A327580035

Standard1225

DRIVE TRAINType Dual Sensing, Automatic PVT

DRIVE CLUTCHCenter Distance (inches)Clutch Offset (inches)Clutch Weight (grams)Spring Color

101/250

Blue/Green

DRIVEN CLUTCHHelix AngleSpring Position

40 Degrees2-2

DIMENSIONAL FEATURES

Approx. Turning Radius (inches)Box, Cargo BedBox, ToolBox Dimensions (inches)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

98Standard

N/A43.75x42

5.5481053589576.546

GEARCASETrans. Number and TypeShift TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain TypeChain Adjustment

PRDSide Lever

6.69/15.17/13.34/12:1

12/38 80PN/A

30/30 116P520 O-Ring

Rear

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

GoodYear25x8-1225x11-1025x11-10

555

ENGINEEngine Model NumberEngine TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCoolingAlternator Output (watts)Elec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayPilot ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

EH50PLE104 Valve, 4 Stroke, Single Cyl.

92x75499

10.2:1 Full StrokeLiquid250

Standard1/BST34 (CV Type)

15540Q-0N/A2 5/8

4HB41-3CDI

[email protected]

NGKBKR5EUSFA Appr.

GRAPHICSBumper CapsCargo Box or BedFender, FrontFender, RearFootwellFrame/SteelHeadlight/Dash PodRack, FrontRack, RearRimsSeat VinylSide PanelSpring, FrontSpring, RearTank CoverTool Box Cover

w/lettering Color

BlackBlack

Eddie Bauer GreenEddie Bauer Green

BlackBlack

Eddie Bauer Green/BlackBlackBlackSilverBlack

Eddie Bauer GreenBlackBlackN/AN/A

LIGHTSHeadlight (watts)Taillight (watts)Brake Light (watts)Headlight/Grill (watts)Indicator Bulb

1 Single Beam, Halogen, 602 Single Beam, 52 Single Beam, 5

2 Single Beam, Halogen, 271

SUSPENSIONFront Type -

Front Travel (inches)StrutAdjustment

Rear Type -Rear Travel (inches)ShockAdjustment

MacPherson Strut6.7

Sachs-- -- -- -- --

Swing Arm w/Scissor Stabilizer7.5

25” Gas Charged Twin TubeN/A

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

2000 SPORTSMAN 6X6 PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

SPORTSMAN 6X6 A00CL50AA 9915477 9915481 9916574 N/A

INT’L BIG BOSS 6X6 A00CL50DA 9915477 9915481 9916574 N/A

A5

FRONT CABSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

5

6

7

8

910

12

32

20

21

1617

1413

15

1918

8

1

4

4

11

422

20

E 2000 Polaris Sales Inc.

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

1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5810996 1 Foil, Foam, Side Panel3 5433263-195

2620085-19511

Panel, Side, E. B. Green, LHPanel, Side, w/Foil, E. B. Green, RH

4 7512232 10 Screw5 5432088-195 1 Cover, Front, E. B. Green6 7670085 2 Clip, Spring7 2632146-195 1 Cab, Front, E. B. Green w/Warning

Decals8 7670057 10 Nut, U-Type Speed9 7670068 2 Nut, Push-on10 7661645 4 Rivet, T-Lock11 7517312 2 Screw

12 54317985431799

11

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

13 7541925 2 Nut, Nylok14 7555792 2 Washer15 7512085 2 Screw16 7555931 4 Washer, Flat17 7542122 2 Nut, Nylok18 8450073-600 AR Line, Breather19 7670109 1 Clip, Routing20 7621509 3 Rivet21 5811917 2 Shield, Deflector22 5243829-067 1 Strap, Fuel Pump

1/00

A6

REAR CAB and SEATSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

34

56

36

7

8

16

15

18 17

9

21

24

353231

30

29

25

28

27

26

21 3

4

6

8

33 12

23

10

13

11

14

19

22

20


1 7661645 10 Rivet2 2632158-195 1 Cab, Rear, E. B. Green3 5811107 1 Foil, Rear Cab, Rear4 7073761 1 Decal - Carb Information5 7512242 4 Screw6 7555859 10 Washer, Flat7 2682520-070

268251958111045811105

1111

Asm., Seat, Black (Incl. 8)Covering, Seat, BlackFoil, Seat Base, LargeFoil, Seat Base, Small

8 5410414 11 Bumper, Rubber9 1012820-067 1 Frame10 7512111 2 Bolt11 5432798 2 Plug12 1013011-067

1013307-06711

Lever, Box (If built before 2/28/00)Lever, Box (If built after 2/28/00)

13 7542153 2 Nut14 7041879 1 Spring15 7661638 6 Rivet16 5242953-067 1 Guard, Clutch17 7515179 6 Screw

18 5432763 1 Guard, Rock19 7555734 2 Washer, Flat20 7542324 2 Nut, Nylok21 7542122 8 Nut, Nylok22 7512392 2 Screw23 1040293-067 1 Mount, Strut, Rear24 7512279 8 Screw25 5432221-070

5433196-07011

Footwell, Black, LHFootwell, Black, RH

26 7512232 12 Screw27 5433429

543343011

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

28 7670057 12 Nut, U-Type Speed29 5811111 1 Foil, Foam, Rear Fender30 5811106 2 Foil, Rear Cab, Front31 5811087 1 Foil, Foam32 7077446 1 Decal - Filter Element33 7555932 4 Washer, Nylon34 7541925 2 Nut, Nylok35 7555792 2 Washer36 7512085 2 Screw

1/00

A7

DECALSSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

16

10

4 6

1214

19

LH

RH

17

18

1

2

32

9

157

8

13

1

15

13

11

7

5


1 7078537 2 Decal - “Polaris”, Box2 7078443 2 Decal - “POLARIS”, Side Panel3 7078254 1 Decal - Age Warning4 7078534

707854511

Decal - Tank Side, RH (AA)Decal - Tank Side, RH (DA)

5 7078003 1 Decal - Headlight Adjustment6 7074935 1 Decal - Warning, AWD Switch7 7078315

7078465

1

1

Logo, 45th Anniversary(If built before 12/31/99)Logo, Polaris Star(If built after 12/31/99)

8 7078449 1 Decal - “500 L/C 4 Stroke”, Front Cover9 7074954 1 Decal - Rack/Warning

10 7074220 1 Decal - MacPherson Strut11 7079292 1 Decal - Discretionary Warning12 7078577 1 Decal - Drain Recoil13 7078535

707853611

Decal - “6X6 CDS”, LHDecal - “6X6 CDS”, RH

14 7072715 1 Decal - Operator Warning15 7078538

707854911

Decal - Stripe, Box, LHDecal - Stripe, Box, RH

16 7079604 1 Decal - Warning, Override, AWD17 7078533

707854411

Decal - Tank Side, LH (AA)Decal - Tank Side, LH (DA)

18 7074109 1 Decal - Load Distribution19 7075719 1 Decal - Tire Pressure

10/00

A8

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

13

24

14

1516

17

12

6

5

8

910

18

19

20

2122

23

2

3

4

11

4

7

1

6

14


1 7517685 4 Screw2 2670180 1 Asm., Front Rack

(Incl. Ref. 3 and Warning Decal)3 2670071 2 Reflector, Amber4 7515399 8 Screw5 2200775 1 Kit - Front Rack Mount6 7542324 4 Nut, Nylok7 7558403 2 Washer8 5432155-070 1 Bumper9 7515391 2 Screw10 7515390 2 Screw11 7555954 4 Washer12 1013210-067

1013211-06711

Support, Front Rack, LHSupport, Front Rack, RH

13 7512232 4 Screw

14 7515384 4 Bolt15 7558402 4 Washer, Flat16 5810467 1 Plug, Frame17 5244623-067

5244624-06711

Extension, Frame, LHExtension, Frame, RH

18 5241583-067 1 Guard, Brush19 5240591-067 1 Grill, Brush Guard20 7621330 7 Rivet21 7670094 6 Nut, U-Type22 7512097 6 Screw23 5433315

543331611

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

24 243101424310154030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

1/00

A9

COOLING SYSTEMSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

31

2

13

12

30 29

18

34

23

11

32

35

36

37

33

3

19

15

2120

26

10

25

17

22

28

27

24

14

168

14

11

7

8

4

5

9

1

1 6

38


1 7080614 2 Clamp, Hose2 1240044 1 Cap, Pressure3 5433364 1 Filler, Coolant4 5243505-067 1 Bracket, Filler, Coolant5 7661638 3 Rivet6 5433707 1 Flexguard7 5411811 1 Hose, Engine, Upper8 7080827 2 Clamp, 1”9 7512024 2 Screw10 5411632 1 Hose, Neck, Filler11 7080826 2 Clamp12 7517659 4 Screw13 2410123 1 Asm., Fan and Motor14 7670111 4 U-Clip15 7547069 2 Nutsert16 3110032 2 Mount, Rubber17 5020572 2 Spacer18 5433059 1 Shroud, Fan19 4010161 1 Sensor, Thermal20 1240045 1 Radiator

21 7552605 2 Washer, Split Lock22 7512113 2 Screw23 5243506 1 Screen, Radiator24 5410607 4 O-Ring25 7052244

541163311

Valve, DrainO-Ring

26 5410584 2 Bushing, Mount27 5243503-067 1 Bracket, Radiator, Lower28 7517386 2 Screw29 5411694 1 Hose, Engine, Lower30 5521511 1 Guard, Hose31 5430743 1 Cap, Overflow, Drilled32 5810279 1 Gasket, Overflow Cap33 5433774 1 Plug, Cap34 5433410 1 Tank, Surge35 8450003-1525 1 Line, Fuel36 7052065 1 Fitting, Barbed, 90 Degree37 7512084 2 Screw38 4010369 1 Breaker, Circuit

3/00

A10

EXHAUST SYSTEMSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1617

32

11

10

18

1

15

12 7

6

4

5

5

5

5

89

7

13

14


1 7515316 2 Bolt, Carriage2 5410241 2 Dampener, Vibration3 5010192 2 Bushing4 1260989-029 1 Silencer5 7041804 4 Spring, Exhaust6 1260946-029 1 Pipe, Exhaust7 5243518 2 Seal, Exhaust8 7512232 2 Screw9 5242344-067 1 Bracket, Exhaust

10 7542301 1 Nut11 3110064 1 Mount, Torque Stop12 7042029 1 Spring, Exhaust13 5244014 1 Shield, Heat14 7517615 2 Screw15 7512666 2 Bolt16 7542324 2 Nut, Nylok17 7555716 2 Washer, Flat18 5410436 2 Washer, Rubber

1/00

A11

ENGINE MOUNTINGSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

20

34

45

2

3

5

6

7

8

10

114

18

19

9

9

2321

2627

282930

31

32

33

37

4241

43 44

9

1415

1617

13

36

35

13

40

1

10

39

38

2224

2

25

11

1

1

9

12

2

11 11

A12

ENGINE MOUNTINGSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA


1 7547108 6 Nut, Flange2 7555801 4 Washer, Wrought3 4010132 1 Cable, Ground/Engine4 7512232 1 Screw5 3110044 1 Mount, Rubber, Top6 5242674-067 1 Bracket, Mount, Engine, Top7 7552901 2 Washer, Spring Lock8 7512315 2 Bolt9 7080003 4 Clamp, Hose, Red10 8450040-600 AR Line, Fuel11 8450003-1525 AR Line, Fuel12 7052075 1 Fitting, T13 3084205 5 Screw and Washer14 3110032 2 Mount, Radiator15 5243803-067 1 Bracket, Carburetor Mount16 7552605 2 Washer, Split Lock17 7542105 2 Nut18 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D10, Ref. 47)19 8360009-600 AR Line, Fuel20 8450080-58 1 Sheath, Foil, Laminated21 1012883-067 1 Mount, Rear Motor22 7547089 2 Nut, Flange, Lock23 3110046 2 Mount, Rubber24 7515417 1 Screw25 7555815 2 Washer26 5410421 1 Boot, Clutch Intake

27 7080511 1 Clamp, Narrow Band28 5430261 1 Bushing29 5210748 1 Washer, Flat30 7575202 1 Washer, Interlock31 7512566 1 Bolt32 ------ -- -- -- -- 1 Asm., Drive Clutch

(See Drive Clutch Pg. C5 for Details)33 ------ -- -- -- -- 1 Bracket, Retainer, Seal

(See Clutch Cover Pg. C8, Ref. 21)34 1040688-067 1 Mount, Engine35 7515398 2 Screw36 7542324 2 Nut, Nylok37 3110067 1 Mount, Motor38 7080474 2 Clamp, Hose39 7552603 1 Washer, Spring Lock40 7515438 1 Screw41 ------ -- -- -- -- 2 Nut (See Cylinder Pg. D8, Ref. 23)42 ------ -- -- -- -- 2 Washer, Lock

(See Cylinder Pg. D8, Ref. 22)43 1260994-029 1 Manifold, Black44 ------ -- -- -- -- 1 Gasket, Exhaust

(See Cylinder Pg. D8, Ref. 20)45 3085556 1 Engine, Short Block (EH50PLE010)

NOTE: The Short Block assemblycontains a crankcase assembly, cylin-der and cylinder head assembly, and apiston & crankshaft assembly. Priorauthorization required for warrantyconsideration.

1/00

A13

FUEL TANKSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

23

5

1714

9

20

19

1

10

2

12

3

21

16

18

7

4

15

8

6

16

11

22

13


1 5430725 1 Cap, Gas Tank2 5810144 1 Gasket, Fuel Cap3 5811310 1 Seal, Foam4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7517451 2 Bolt7 7552801 2 Washer, Spring Lock8 7558301 2 Washer, Flat9 5222154-067

5222155-06711

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

10 5332457 2 Spacer11 7547069 2 Nutsert

12 5810317 2 Pad, Fuel Tank Bracket13 5812005 1 Foil14 7052147 1 Fitting, Fuel Outlet, Main15 8450040-600 AR Line, Fuel16 7080003 4 Clamp, Hose, Red17 7052148 1 Fitting, Fuel Outlet, Reserve18 7517505 1 Screw19 5432559 1 Knob, Fuel Valve20 5432733 1 Nut, Fuel Valve21 7052161 1 Valve, 3-Way22 5812004 1 Foil23 2520166 1 Asm., Fuel Tank (Incl. 14,17)

1/00

A14

OIL TANKSPORTSMAN 6x6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

15

1

2

76

8

9

10

11

12

13

14

24

1820

2122

23

19

5

3

16

4

17


1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7052163 1 Fitting5 5411321 AR Line, Breather, Special6 7517102 1 Bolt, Banjo7 7555896 2 Washer, Copper8 7052240 1 Tube, Banjo Return9 5432289 1 Dipstick10 5410889 1 O-Ring11 5411846 AR Hose, Formed12 7080474 1 Clamp, Hose

13 7052106 1 Fitting, 1/4” to 3/8”14 2530014 1 Screen, Oil Filter15 5131785 1 Tank, Oil, LH16 5411042 1 Grommet17 5410828 2 Grommet, Mounting Reservoir18 5333204 2 Bushing19 7558301 2 Washer, Flat20 7512242 2 Screw21 7051524 1 Plug22 5850135 1 Washer, Nylon23 7515158 9 Screw24 5131255 1 Tank, Oil, RH

11/02

B1

PROP SHAFTSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

7 6 54

2

1

9

3

8


1 7512232 2 Screw2 5433154 1 Guard, Prop Shaft, Front3 5411092 1 O-Ring4 3260131 1 Yoke, Prop Shaft, Transmission5 3260139 1 Shaft, Prop

6 1590256 2 Joint, Cardan7 3260133 1 Yoke, Front Gear Case8 1380124 1 Asm., Prop Shaft (Incl. 4-7)9 7661913 1 Pin, Spring

8/99

B2

CV JOINT - BTBSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

BTB

1012 3 4 5 6

7

8 9

12

11

13


1 1380119 2 Asm., CV Housing w/Sleeve2 5222299 1 Sleeve, Drive Shaft Seal3 3260115 1 Clamp, CV Joint, Large4 7670091 1 Circlip5 5411106 1 Boot, CV Joint6 1380094 1 Shaft Replacement (Incl. 4)7 1380092 1 Cardan Replacement (Incl. 4,6,8,9)

8 2200771 1 Kit - Cross and Bearing9 3260130 1 Yoke, Splined10 7661913 3 Pin, Spring11 7080627 1 Clamp, Small Band12 2200773 1 Kit - Boot Replacement (Incl. 3,5,11)13 2200961 1 Kit - Drive Shaft w/Sleeve BTB

10/98

B3

FRONT HOUSINGSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

12

34

56

78

9 1011

12

13

14

15

16

17

18

1920 21

22

2324

25

2627

282

1


1341276

1341323

1

1

Asm., Front Gearcase(Incl. 1-12,16-26)(If built before 7/1/99)Asm., Front Gearcase(Incl. 1-12,16-26)(If built after 7/1/99)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing7 3233698

323372611

Pinion, Input (1341276)Pinion, Input, 14T (1341323)

8 3233541 1 Bushing9 3233319 1 Seal, Oil10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug13 7080756 1 Clip, Snap-In14 8450003-1525 AR Line, Fuel

15 7080307 1 Clamp, Hose

16 3233524 1 Tube, Vent17 3233696 1 Gearcase, Front Housing18 3233710

323369432336953233725

1111

SubAsm., Output Shaft (1341276)Shaft, Output (1341276)Gear, 29T (1341276)Shaft, Output, 29T (1341323)

19 3233020 1 Bearing, Ball20 3233554 AR Shim21 3233693 1 O-Ring22 3233692

323372411

Cover, Output, Front Housing(1341276)Cover, Output, Front Housing(1341323)

23 3233583 AR Shim24 3233702

323358211

Button, Thrust (1341276)Button, Thrust (1341323)

25 3233254 1 Washer26 3233253 1 Plug, Drain27 7552603 4 Washer, Spring Lock28 7512492 4 Screw

1/00

B4

FRONT STRUTSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1

2

35

67

9

10

4

1112

13

15

16

8

14

17

18

19

21

4

20

2223

24

252627

1112

4


1 5411608 2 Bumper2 7041761 2 Strut, Front3 5211115 2 Washer4 7558402 10 Washer, Flat5 7080573 2 Clamp, Rubber Coated6 7542303 4 Nut, FLEXLOC7 7512365 4 Screw8 7552901 4 Washer, Spring Lock9 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 4170010 2 Coil, Magnetic

16 2201311

2201312

1

1

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

17 7041450-067 2 Spring, Compression18 5243364 2 Retainer, Spring19 5432871 2 Ball, Pivot, Bottom20 7515339 4 Bolt21 5132062 2 Spacer22 ------ -- -- -- -- 1 Kit - Drive Shaft w/Sleeve BTB

(See CV Joint - BTB Pg. B2, Ref. 13)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, Nylok

11/99

B5

FRONT WHEELSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

10 11 12 14

1 2

34

5

79

8

15

1625

24 7

17 18 2021

23

13

6

6

22

19


1 7512325 8 Bolt2 5242935 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 7515523 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 5410947 2 Tire (25x8-12)17 7556004 2 Washer18 7542810 2 Nut, Slotted19 7661401 2 Pin, Cotter20 5410470 2 O-Ring21 5432611 2 Cap, Hub22 7512027 6 Screw23 7542459 8 Nut24 1520269-117 2 Rim, Front, Aluminum25 1525017 2 Valve, Rim

8/99

B6

FRONT BRAKESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1

2 3

78

10

9

111213

4 5 6


1910327 1 Asm., Caliper, LH (Incl. 1-6,8,9)1910328 1 Asm., Caliper, RH (Incl. 1-6,8,9)

1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 5131997

51319981930642

111

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

4 5411596 1 Seal, Caliper, Inner5 5411597 1 Seal, Caliper, Outer6 5132405 1 Piston, Caliper

7 220046522009012201149

111

Kit - Front Brake Pad, General DutyKit - Front Brake Pad, Severe DutyKit - Front Brake Pad, Soft Duty

8 1910411 1 Mount, Caliper9 5410495 1 Boot, Bushing10 5410494 1 Boot, Pin Seal11 ------ -- -- -- -- 4 Washer

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

(See Front Strut Pg. B4, Ref. 8)13 ------ -- -- -- -- 4 Screw(See Front Strut Pg. B4, Ref. 7)

8/99

B7

A-ARM/STRUT MOUNTINGSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1 45

6

7

89

3

12

1314

27

15

16

181719

21

25

26

2423

22

2829

29 28

2322

20

31 30

2

14

9

11

10


1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820567

1820805

2

2

Asm., Tie Rod(Incl. 4-9)(If Built before 8/16/99)Asm., Tie Rod(Incl. 4-9)(If Built after 8/16/99)

4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061033

706105422

Rod End, LH (If Built before 8/16/99)Rod End, LH (If Built after 8/16/99)

10 5411920 1 Boot, Seal, Rod End11 7517674 2 Bolt (If Built after 8/16/99)12 7555806

755609944

Washer, Flat (If Built before 8/16/99)Washer, Flat (If Built after 8/16/99)

13 7546904 2 Nut14 7661203 4 Pin, Cotter15 7080927 2 Joint, Ball

16 5211121 2 Bracket, Ball Joint17 7512284 4 Screw18 5410548 2 Boot, Rubber19 7542438 2 Nut, Castle20 5431150

543114911

Shield, CV Joint, LHShield, CV Joint, RH

21 7512084 6 Screw22 5433066 4 Bushing, A-Arm, Long23 5020677 4 Bushing24 5020681 2 Shaft, A-Arm25 2201609

220161011

Kit - A-Frame, LHKit - A-Frame, RH

26 7080433 2 Fitting, Lubrication27 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B4, Ref. 16)28 7512492 4 Screw29 7552603 4 Washer, Spring Lock30 7517527 1 Bolt31 7515415 1 Screw

10/00

B8

STEERING POSTSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1

16

1514

2

3

4

13

10

567

11

6

6

9

12

7

8


1 1843051 1 Asm., Steering Post (Incl. 5,13)2 5433415 1 Bushing, Steering, Console3 7080424 1 Fitting, Lubrication4 7515321 2 Bolt5 5431574 1 Plug, Grease, Steering6 7555878 3 Washer7 5410772 2 O-Ring8 5431571 1 Spacer, Steering Post

9 7543203 1 Nut10 7661633 1 Pin, Cotter11 5431570 1 Bushing, Steering, Lower12 7661632 2 Rivet13 7080433 1 Fitting, Lubrication14 5433416 1 Bushing, Steering, Upper15 5222999-067 1 Bracket, Steering Bushing, Upper16 7542324 2 Nut, Nylok

8/99

B9

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

5

2

4

3

6

1


1 5410193 1 O-Ring2 5433806 1 Cover3 5411439 1 O-Ring

4 7080709 1 Cable, Throttle5 2010188 1 Asm., Throttle Control (Incl. 2,3,6)6 2010191 1 Asm., Throttle Clamp

1//00

B10

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

4

5

11

12

25

10

1

2

3

22

24

1615

18

19

20 23

17

14 136

7

9

8

26

21

27


2050078

2200809

1

1

Asm., Master Cylinder (Incl. 1-12,25)Kit - Master Cylinder Reservoir(Incl. 1-3,25)

1 1930797 2 Screw2 1930796 1 Cap, Reservoir3 1930795 1 Diaphragm, Master Cylinder4 2200808 1 Kit - Clamp, Master Cylinder5 1930799 1 Asm., Piston, Master Cylinder6 1930804 1 Rivet7 2201034 1 Kit - Brake Lever, w/Parking, Brake

Latch (Incl. 6-9)8 ------ -- -- -- -- 1 Spring, Flat9 2201090 1 Kit - Park Brake Lever (Incl. 6,8,9)10 1930806 2 Nut11 1930792 1 Screw12 1930805 1 Screw

13 7621462 2 Rivet, Pop14 7080539 2 Clamp, Cable, Nylon15 1930752 1 Line, Brake, Left Front w/Fittings16 8360031-30 1 Conduit17 7512024 2 Screw18 8360011-38 1 Tubing, Convoluted19 1930753 1 Line, Brake, Front, RH w/Fittings20 7052237 1 Fitting, Flare Cross21 5411297 1 Boot, Brake Line, Rubber22 1930817 1 Line, Brake Pod23 4110164 1 Switch24 1910369 1 Line, Brake, Middle Axle, LH25 ------ -- -- -- -- 1 Reservoir26 5410988 2 Seal27 1930674 1 Bolt, Banjo

8/99

B11

CONTROLS - RH MASTER CYLINDER/BRAKE LINESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1

2

3

4

10

8

12

13

14

11

15

16

5

75

9

6


20500752200809

11

Asm., Master Cylinder (Incl. 1-4,8-16)Kit - Reservoir (Incl. 1-4,10)

1 1930797 2 Screw2 1930796 1 Cap, Reservoir3 1930795 1 Diaphragm, Master Cylinder4 ------ -- -- -- -- 1 Reservoir5 5410469 2 Washer6 1910371 1 Line, Brake, Pod, RH7 1930674 1 Bolt

8 1930687 1 Screw9 ------ -- -- -- -- 1 Seal, Reservoir10 1930807 2 Screw11 1930688 1 Nut12 5630362 1 Lever, Brake, RH13 2200805 1 Kit - Rebuild, Master Cylinder14 1930788 1 Nut15 1930786 1 Washer, Lock16 1930787 1 Screw

8/99

B12

REAR BRAKE CALIPERSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

5

1

2

34

6

7

9 8


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, Rear6 2201428 2 Kit - Bleeder7 7517758 2 Bolt, Shoulder8 2201685 1 Kit - Pad, Brake9 ------ -- -- -- -- 2 O-Ring

8/99

B13

MIDDLE DRIVESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1432

5

24

78 9

6

10

13

14

11

15 16 17 18 19

25

20

23

26

30

37

333436

35

32

31

22

2927

28

2119

1718

22

41

25 3

96

78

24

10

30

28

24

24

12


1 7710472 2 Ring, Retaining2 5510372 2 Retainer, Nut3 5411555 2 Seal, Foam4 7547031 2 Nut, Jam5 5630987 2 Hub, Locking Mid Axle6 3610074 2 Seal, Inner7 5132219 2 Housing, Swing Arm8 3515501 2 Bearing9 3610013 2 Seal, Axle, Rear10 5132218 2 Spacer, Bearing11 7542439 6 Nut, Nylok (DA)12 5244597 1 Hub, Brake Disc (DA)13 5243794 1 Disc, Brake14 1520373 1 Asm., Hub, Brake Disc15 7710496 1 Ring, Retaining16 5010462 1 Spacer, Axle17 3610070 2 Seal, Lip18 3554518 2 Bearing, Cone19 3554517 2 Bearing, Cup

20 5132098 1 Housing, Axle, Rear21 7080306 1 Fitting, Lubrication22 5410889 1 O-Ring23 7515513 3 Stud24 5411739 4 O-Ring25 5132049 1 Axle, Middle26 1520311 1 Asm., Hub, Sprocket27 7542411 3 Nut, FLEXLOC28 7542507 6 Nut, FLEXLOC29 7514334 3 Bolt30 7517762 6 Stud31 3225027 1 Link, Connector32 3224056-080 1 Chain, 80P33 3221121 1 Sprocket, 30T34 1520319 1 Asm., Hub, Sprocket, Mid35 5211585-067 1 Guard36 5630586 1 Spacer, Guard37 3221120 1 Sprocket, 38T

10/00

B14

REAR DRIVESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

15

5

7

13

1

89

3

10

17

11

4 6

12

18

2

645 3 14

16


1 7710496 1 Ring, Retaining2 5132464 1 Spacer, Bearing3 5410889 2 O-Ring4 3610070 2 Seal5 3554518 2 Bearing, Cone, Tapered6 3554517 2 Bearing, Cup, Tapered7 5132365 1 Axle, Rear8 5132098 1 Housing, Axle, Rear9 7080306 1 Fitting, Lubrication

10 5132311 1 Spacer, Axle11 1520312 1 Asm., Hub, Sprocket, Rear (Incl. 12)12 7517763 3 Stud13 1013196-067 1 Guard, Chain14 3221121 1 Sprocket, 30T15 5020468 2 Nut, Jam16 7542507 3 Nut, FLEXLOC17 3224055 1 Chain, 116P18 3225024 1 Link, Connector, Drive Train

10/01

C1

SWING ARM/SHOCK MOUNTINGSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

76

5

2

4

1

3

12

13

16

11

18

109

17

14 15

25

24

23

2221

8

19

27

26

1 1611

8

20


1 7542439 2 Nut, Nylok2 7041842 1 Shock3 7515438 1 Screw4 5210953 1 Retainer, Spring5 7041878-067 1 Spring, Compression6 5220225 1 Retainer, Spring, Top7 7515415 1 Screw8 5131697 2 Bolt, Swing Arm9 5131695 1 Bushing, Pivot, LH10 5433411 1 Bushing, Swing Arm, LH11 7080510 2 Fitting, Zerk12 7661046 2 Rivet13 5432727 1 Guide, Chain Pad14 7547082 1 Nut

15 7556035 1 Washer, Flat16 5433412 2 Bushing, Swing Arm, RH17 5131696 1 Bushing, Pivot, RH18 1541383 1 Asm., Swing Arm (Incl. 10,11,16)19 7078572 1 Decal - “Chain Free Play”20 7074214 1 Decal - Lubrication21 5432854 1 Guard, Chain22 7515304 1 Screw23 5332828 1 Bushing24 7558402 1 Washer, Flat25 7542321 1 Nut, Flange26 7542522 2 Nut, Flange27 7512576 2 Bolt

1/00

C2

REAR and MIDDLE WHEELSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

2

3

10

4

87

5

6

12

1087

6

5

1

9

11

9


1 7512673 16 Screw2 5131777 4 Hub, Wheel3 5410948 4 Tire (25x11-10)4 7547037 16 Nut5 7661404 2 Pin, Cotter6 5411164 4 Hub, Dust Cover

7 7543005 4 Nut, Castle8 7555745 4 Washer, Flat9 7555796 4 Washer, Cone10 1525017 4 Valve, Rim11 7670081 16 Nut, Push12 1520183-117 4 Rim, Rear

8/99

C3

REAR STRUT STABILIZERSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

8

11

5

9

4

13

127

32

1

6

10

7

7

32

1

32

1

4

5

5


1 7555832 6 Washer2 7552603 6 Washer, Spring Lock3 7512492 6 Screw4 5433066 2 Bushing, A-Arm, Long5 5020677 6 Bushing6 5020764 1 Shaft, A-Arm, Upper7 7080433 3 Fitting, Lubrication

8 1580082-067 1 Stabilizer, Upper9 5020765 1 Shaft, A-Arm, Middle10 5020766 1 Shaft, A-Arm, Lower11 1541424-067 1 Stabilizer, Lower12 5433063 2 Bushing, A-Arm, Short13 5433064 2 Bushing, Stabilizer, Long

8/99

C4

SWING ARM WELDMENT (REAR)SPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

7

15

3

14

13

9

105

28

11

2022

21

19

8

23

26

25

27

12

6

1

4

2

24

1618 17

13

7

9

1718 16

12

24


1 7542439 1 Nut2 7041819 1 Shock, Rear3 7515415 2 Screw4 7556142 1 Washer5 7041880-067 1 Spring, Compression6 5241147 1 Retainer7 7517386 4 Screw8 5433539 1 Cover, Chain9 7661637 4 Rivet10 5244077-067 1 Mount, Chain Cover, Front11 5244078-067 1 Mount, Chain Cover, Rear12 7542522 4 Nut, Flange13 7512569 2 Screw14 7512520 2 Screw

15 1580067-067 2 Bracket, Swing Arm16 7515321 3 Bolt17 7558402 3 Washer18 7542324 3 Nut, Nylok19 1013021-067 1 Extension, Chain Guard , Lower20 5521279 1 Guide, Chain, Rear21 7515117 1 Screw22 7541925 1 Nut, Nylok23 7542503 3 Nut, FLEXLOC24 7555883 4 Washer25 2200472 1 Kit - Hitch (Incl. 23,24,27)26 7078261 1 Decal - Hitch27 7512576 2 Bolt28 1541344-067 1 Extension, Swing Arm

11/99

C5

DRIVE CLUTCHSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1 2

3 4

56

78

5

9

10

11

1213


1321632 1 Asm., Drive Clutch (Incl. 1-3,5-11,13)1 7512176 6 Screw2 7552801 6 Washer, Spring Lock3 3576510 1 Bearing, Cover4 7041157 1 Spring, Clutch5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 5430945 6 Washer, Multilube

8 1321457 3 Roller and Bushing9 5210752

524298152107535210754

ARARARAR

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

10 3576504 1 Bearing, Moveable, 1/2”11 7541906 3 Nut, FLEXLOC12 5630513 3 Weight, Shift, 10-MH13 7512266 3 Bolt, Shoulder

5/98

C6

DRIVEN CLUTCHSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

3

4

56

7

8

10

11

12

13

15

1617

4

12

9

14


1 5010409 1 Spacer2 7556401 AR Bushing (3 Max)3 3211077 1 Belt, Drive4 1322180 1 Asm., Driven Clutch (Incl. 8-17)5 5220646 1 Washer6 7552901 1 Washer7 7515382 1 Bolt8 7555898

7556076ARAR

Washer (.020)Washer (.025)

9 7556804 AR Washer (.030)10 3576504 1 Bearing, Moveable, 1/2”11 3576511 1 Bearing, Moveable, 1”12 7041198 1 Spring, Clutch13 5131446 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

8/99

C7

AIR BOXSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

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 7517541 4 Screw2 5810455 2 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, Hose13 5411847 1 Hose, Breather14 7080511 1 Clamp, Band15 5411540 1 Boot, Carb

16 7080413 2 Clamp17 5432473 1 Duct, Carb, Inlet18 5830128 1 Gasket, Duct19 5433387 1 Box, Air20 ------ -- -- -- -- 1 Line, Breather, Oil Tank

(See Oil Tank Pg. A14, Ref. 5)21 5811650 1 Foil, Air Box22 5432377 1 Plug, Trap23 8450059-150 AR Line, Fuel24 7080650 1 Clamp, Hose25 5242044 6 Clip26 5432601 1 Collar, Inlet, Carb27 7080595 1 Filter, Air28 5811633 1 Filter, Sleeve, Precleaner

12/99

C8

CLUTCH COVERSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

67

85 9 1012

13

14

15

11

17

18

3

19

202122

4

28

1627

2625

24

3

1

2

23


1 7547067 3 Nutsert2 5242208-067 1 Bracket, Clutch Cover3 7512232 3 Screw4 5433427 1 Duct, Clutch Air, Inlet5 5411553 1 Seal, Cover6 2201160 1 Kit - Inner Clutch Cover

(Incl. 12,16,24)7 7555748 3 Washer8 7512278 3 Screw9 5521301 1 Seal, Clutch Cover10 5433540 1 Cover, Clutch, Outer11 7670051 1 Clip, Clutch Cover12 7512093 5 Screw13 7074946

7078689

1

1

Decal - Clutch Cover(If built before 10/04/99)Decal - Warning, Clutch Cover(If built after 10/04/99)

14 7077377 1 Decal - Eng./Clutch Modification15 7074782 1 Decal - Automatic Transmission16 7512094 2 Screw17 7080761 2 Cable Tie18 5411489 1 Boot, Duct19 5433657 1 Duct, Air Outlet, Clutch20 ------ -- -- -- -- 3 Screw and Washer

(See Crankcase Pg. D5, Ref. 6)21 5240409-067 1 Bracket, Retainer, Seal22 5410575 1 Seal, Cover, Case23 7555932 1 Washer24 7512098 1 Screw25 7555935 1 Washer26 5242693-067 1 Bracket, Clutch Cover27 7661638 2 Rivet28 7080511 1 Clamp, Narrow Band

1/00

C9

REAR CALIPER MOUNTINGSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

7

8

1

12

13

11

109

6

2

4

5

3


1 5132220 1 Mount, Caliper, Upper2 1910408 1 Caliper, Rear3 1910369 1 Line, Pod Brake, LH4 4020139 2 Clip, Rosebud5 1910371 1 Line, Pod Brake, RH6 7517758 2 Bolt, Shoulder7 5131759 1 Bushing, Caliper Mount

8 5131786 1 Mount, Caliper, Lower9 7558402 2 Washer10 7552901 2 Washer, Spring Lock11 7512312 2 Bolt12 5244480-067 1 Guard, Brake Disk13 7512325 3 Bolt

11/99

C10

GEARCASE MOUNTINGSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1

2

9

11 10

5

3

5

3

13

3

4

4

12

68

4

4

7


1 7517632 2 Screw2 5242456-067 2 Bracket, Transmission3 7542423 4 Nut, Flange4 7555806 4 Washer, Flat5 7512492 2 Screw6 5433109 1 Guide, Chain, Transmission7 7558301 2 Washer, Flat

8 7512276 2 Screw9 7517646 1 Screw10 3221044 1 Sprocket, 12T11 7710434 1 Ring, Retaining12 5211065

52107645211517

ARARAR

Shim (.010”)Shim (.020”)Shim (.030”)

13 7517640 1 Screw

8/99

C11

ELECTRICALSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

21

6

24

1

7

1716

2322

20

19

18

7

15

10 911

6

25

13

26

8

5

4

14

12

3

27

2829

2


1 2460701 1 Harness, Main Wire2 2201795 1 Kit - Circuit Breaker, 10AMP3 7080138 12 Cable Tie4 7670109 3 Clip, Routing5 4020149 7 Clip, Rosebud6 7571602 4 Washer7 7541925 4 Nut, Nylok8 8360011-15 1 Tubing, Convoluted9 5131036 1 Sink, Heat10 4060173 1 Rectifier, LR-3911 7512018 4 Screw12 7512024 1 Screw13 5241416 1 Bracket, CDI14 5810455 1 Pad15 7512007 2 Bolt

16 4010093 1 Cable, Solenoid/Starter17 4010094 1 Cable, Battery/Solenoid18 4140006 1 Battery19 5810290 3 Pad, Battery20 5432077 1 Tube, Battery Vent21 5410424 1 Strap, Battery Holddown22 7010032 2 Hook, Battery Strap23 4010095 1 Cable, Battery/Engine24 2200361 2 Kit - Battery Bolt, Short25 5431769 1 Cover, Battery26 7512027 4 Screw27 4010311 1 Switch, Horn28 4010310 1 Horn29 7512057 1 Screw

2/00

C12

DUMP BOXSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

19

3

10

12

18

30

4

7

6

171

27

5

16

13

14

2

25

9

8

29

11

26

28

24

2021

22

23

5 5

5

2

1

11

5

1617

13

20

21

125

6

11

15


1 7515177 2 Screw2 7555931 2 Washer3 5132358 1 Rod, Hinge4 5433388 1 Tailgate5 7517561 12 Screw6 5433656 2 Latch7 5433655 1 Latch, Paddle8 7661644 2 Pin, Hitch9 7556143 2 Washer10 5132373 2 Shaft, Latch11 7517790 6 Screw12 5243304 2 Bracket, Box Latch13 7517743 2 Screw14 7517747 9 Screw15 7556157 9 Washer16 7517742 2 Screw

17 7080881 2 Cable, Tailgate18 5244068-067 1 Cover, Tailgate19 2410179

401034022

Asm., Taillight w/Brake LightBulb

20 7512329 4 Screw21 7542324 2 Nut, Nylok22 7512492 4 Screw23 7542449 4 Nut24 7041301 1 Shock, Pump Box25 7547089 9 Nut, Flange26 1012893-067 1 Support, Box27 7515350 4 Screw28 1013125-067 1 Latch, Box29 2682522-070 1 Asm., Backrest30 5433248 1 Box

11/99

C13

GEAR SELECTORSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

2

43

5

7

8

6

111610

15

1

13

14

9

12

1011


1341271 1 Asm., Gear Selector (Incl. 1-16)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, Groove

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

9/00

C14

GEARCASE SELECTOR MOUNTINGSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

1

1

6

6

2

2

3

4

4

5

5

6

7

6

7

8


1 7061013 2 Rod End, LH2 7546702 2 Nut, LH3 5020824 1 Rod, Shift Linkage, Low4 7546701 2 Nut

5 7061014 2 Rod End, RH6 7546707 4 Nut, FLEXLOC7 7517386 5 Screw8 5333806 1 Rod, Shift Linkage, High, Rev

8/99

D1

GEARCASESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

43

1

2

3

40

7

22

31

23

34

25

33

32

27

30

12

2112

28

20

19 1817 16

15 14 13

89

1011

38

37

42

44

41

5756

63

6162

65

4 23

31

22

22

7

7 12

18

39

60

46

4849

50

58

55

5453

5251

35 36

26

59

47

24

29

45

7

2429

29

24

60

D2

GEARCASESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA


1341291 1 Asm., Gearcase (Incl. 1-63)1 3233448 1 Plug2 3233035 1 Washer3 3233527 1 Bushing, Pivot4 3233252 11 Screw5 3233632 1 Gearcase, LH6 3233529 2 Pipe, Knock7 3233020 4 Bearing8 3233360 1 Gear, 100T9 3233544 1 Shaft, Output10 3233729 1 Sprocket, 15/26T11 3233546 1 Chain, Roller12 3233248 3 Seal13 3233542 1 Washer14 3233541 1 Bushing, Garlock15 3233540 1 Shaft, Pinion 13T16 3233306 1 Ring, Retaining17 3233263 1 Cover, Bearing18 3233539 11 Screw19 3233730 1 Sprocket, 15/22T20 3233537 1 Ring, Retaining21 3233704 1 Shaft, Input High/Low/Reverse22 3233018 3 Bearing23 3233176 2 Washer24 3233718 3 Bearing, Needle25 3233732 1 Engagement Dog, Low26 3233019 1 Bearing27 3233719 1 Sprocket, 24T28 3233036 1 Chain, Silent29 3233720 3 Ring, Retaining30 3233722 1 Gear, 30T31 3233177 2 Ring, Retaining

32 3233721 1 Engagement Dog, High/Reverse33 3233733 1 Shaft, Reverse, 29T34 3233731 1 Gear, 33T35 3233706 1 Fork, Shift, Low36 3233633 1 Fork, Shift, High/Reverse37 3233547 1 Bellcrank38 3233055 2 Nut39 3233054 2 Washer40 3233153 1 Bellcrank, High/Low/Reverse41 3233045 2 Ring, Retaining42 3233040 2 Washer43 3233548 2 O-Ring44 3233737 1 Shaft, Shift, High/Rev.45 3233549 1 Shaft, Shift, High/Low/Rev.46 3233691 8 Screw47 3233636 1 Decal - Switch48 3233635 1 Switch, High/Reverse49 3233617 1 Switch50 3233037 1 Vent51 3233556 1 Cover, Snorkel52 3233555 1 O-Ring53 3233554 1 Shim54 3233723 1 Gear, Snorkel55 3233552 1 Bushing, Garlock56 3233324 1 Washer57 3233711 1 Plug, Oil Fill58 3233799 1 Gearcase, RH59 3233043 1 Deflector, Oil60 3233033 4 Screw61 3233309 1 Bracket, Interlock62 3233032 1 Spring63 3233308 2 Pin, Interlock

12/00

D3

HANDLEBAR and HEADLIGHT PODSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

35

9

43

1011

16

44

1

2

3 14

6

7

8

12

15

17

18

21

2526

3029

41

38

37

36

3831

23

28

4

4

5

24

39

3233

22

27

1920

13

42

34

40

D4

HANDLEBAR and HEADLIGHT PODSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA


1 32802903280312

11

Speedometer (AA)Speedometer (DA)

2 543096740400534040054

111

Plug, IndicatorIndicator, Hot TemperatureIndicator, Neutral/Reverse

3 7511881 3 Screw4 7670086 3 Nut, U-Type5 2460668 1 Harness, Headlight Pod6 ------ -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B9, Ref. 5)7 5242987-067 1 Tube, Handlebar8 2200774

5630616-067

1

2

Kit - Handlebar Block(Incl. Blocks and 8,12,30)Block, Handlebar Retainer

9 7541933 2 Nut, Brass10 7555868 2 Washer, Lock11 7558212 2 Washer, Flat12 7515189 4 Screw13 3280291 1 Clamp, Speedometer14 5433042-195 1 Pod, Headlight, Upper15 ------ -- -- -- -- 1 Asm., Master Cylinder

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

16 5432926 1 Spacer, Switch17 4010262 1 Switch, Handlebar18 5431030 2 Grip, Handlebar19 5432952 1 Plug20 7517625 1 Screw, Set21 5240586-067 1 Bracket, Pod Mounting22 7517317 2 Screw23 4032079 1 Knob, Adjusting24 5411120 1 Boot, Headlight

25 4032077 1 Collar, Locking26 4032075

287044811

Lens and ReflectorBulb, Headlight, Halogen

27 4032078 1 Rod, Adjusting28 5410163 2 O-Ring29 7080726

220018811

Cable, Choke w/AdjusterKit - Choke Control

30 7542122 4 Nut, Nylok31 7670089 2 Nut, U-Type32 2410025 1 Plug, Power, 12V

(If built before 9/27/99)33 7621334 2 Rivet, Bulbex

(If built before 9/27/99)34 4010283 1 Receptacle, Pod Mount, 12V

(If built after 9/27/99)35 7080631 1 Clip, Cable Retaining36 7522021 2 Screw37 5432314-070

5433366-070

1

1

Pod, Headlight, Lower(If built before 9/27/99)Pod, Headlight, Lower(If built after 9/27/99)

38 41102644010278

4010321

11

1

Switch, Ignition (Incl. Key)Blank, Key, Series 2000, 6700, 6800NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Blank, Key, Series 2200, 2300, 2700,2800 NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

39 5433534 1 Cover, Key40 5433733 1 Nut, Ignition41 7080229 1 Nut, Choke Slide42 5132382 1 Cap, Sensor (Used w/401298 only)43 4040081

401029811

Sensor (If built before 8/09/99)Sensor (If built after 8/09/99)

44 7517658 1 Screw

10/00

D5

CRANKCASESPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

2

4

10

11

2

19

20

1

22

7

5

16

3

1817

9

1514

1213

21

6

5

8


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

(Incl. 1,4,5,7,8,10,11,16,19,20,22)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 3084842 2 Union10 3084834 2 Bearing, Ball11 3084835 1 Bearing, Ball

12 3084845 1 Plug13 3084846 1 Gasket, Aluminum14 3084844 1 Spring, Valve, One Way15 3086810 1 Valve, One Way16 3084841 10 Bolt, Flange17 3082956 1 Gasket18 3083453 1 Plug19 3084837 1 Seal, Mechanical20 3084836 1 Seal, Oil21 3084847 1 O-Ring22 3080103 2 Pin, Dowel

7/99

D6

CRANKSHAFT and PISTONSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

18

19

5

9

1311

4

7

17 12

8

16

6

10

1

14

20

15

2

3

1


1 3085534 2 Clip2 3085866

30858673085868

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

7/99

D7

CYLINDERSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

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

D8

CYLINDERSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA


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, Flange

20 3085075 1 Gasket, Exhaust21 3085326 2 Stud22 3080530 2 Washer, Lock23 3080285 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 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

7/99

D9

CARBURETORSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

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

3332

31

28

17

48

43

D10

CARBURETORSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA


1 3130507 1 Ring2 3130508 1 E-Ring3 3131224 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3131223 1 Jet, Needle (Q-4)7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3130566 1 Jet, Main (#142.5)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 3130590 1 Asm., Float Body21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 2 Screw24 3130668 1 Valve, Needle (1.5)25 3130533 1 O-Ring26 3130624 1 Jet, Pilot (#40)

27 3130522 1 O-Ring28 3130523 1 Washer29 3130525 1 Spring30 3130524 1 Adjuster31 3130546 1 Screw, Adjust32 3130545 1 Ring33 3130544 1 Spring34 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 3131222 1 Asm., Carburetor (Incl. 1-38,43-51)48 3084205 2 Screw and Washer49 3130505 1 Spring50 3130503 1 Asm., Cover51 3130592 4 Screw

7/99

D11

INTAKE and EXHAUSTSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

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 3084907 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

7/99

D12

RECOIL STARTERSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

14

1

3

10

4

2

5

6

15

9

11

7

8

12

13

7

8


1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Bolt and Washer7 3083453 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084933 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3086213

308686811

Asm., Recoil (Incl.1-6,9-11,14,15)Starter Case (Incl. 11)

15 3085083 1 Asm., Rope

7/99

D13

WATER PUMPSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

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 3084937 1 Gasket, Water Pump9 3085077 1 Nut, Self Lock10 3083138 1 Gasket, Aluminum11 3084935 1 Impeller12 3084942 1 Washer, Seal13 3084877 4 Bolt, Flange

6/98

D14

OIL PUMPSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

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)

5/99

E1

OIL FILTERSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

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

6/98

E2

MAGNETOSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

20 6

5

8

9

1011

12

13

14

4

7

1

2

16

19

3

15

1718


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 3086820

30855603086980

3086981

1

11

1

Asm., Plate (Incl. 5,6,8-12,14,15)(Up to S#00-1899)Plate (Up to S#00-1899)Asm., Plate (Incl. 5,6,8-12,14,15)(S#00-1899 & after)Plate (S#00-1899 & after)

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3086821

308698411

Stator (Incl. 13)(Up to S#00-1899)Stator (Incl. 13)(S#00-1899 & after)

10 30855633086985

33

Screw and Washer (Up to S#00-1899)Screw and Washer (S#00-1899 & after)

11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3084977 1 Clamp15 3081256 3 Screw and Washer16 3085639

308698211

CDI System (Up to S#00-1899)CDI System (S#00-1899 & after)

17 3083073 2 Nut18 3080077 2 Washer, Spring19 3085521 1 Switch, Magnetic20 3086819

308698311

Flywheel w/Ring Gear (Up to S#00-1899)Flywheel w/Ring Gear (S#00-1899 & after)

12/99

E3

STARTING MOTORSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

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 3085394 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

5/99

E4

FUEL PUMPSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

4

1

3 2

2

4


3085275 1 Asm., Fuel Pump (Incl. 1-4)1 3084999 1 Screw and Washer2 3085356 2 Screw and Washer

3 3084591 4 Screw and Washer4 3084998 1 Diaphragm, Gasket Set

5/99

E5

TOOL KITSPORTSMAN 6X6 A00CL50AA and INT’L BIG BOSS 6X6 A00CL50DA

2

3

4

5

6

7

8

9

1


1 9915477 1 Owner’s Manual, ’00 ATV2 3086872 1 Asm., Tool Kit (Incl. 4-9)3 2870725 1 Gauge, Tire Pressure4 3085001 1 Wrench, Open, 8-10mm5 3085002 1 Wrench, Open, 12-14mm

6 3085568 1 Wrench, Box, 125mm7 3085569 1 Puller, Spark Plug (Wrench Handle)8 3082657 1 Screwdriver9 2690016 1 Pouch, Tool Kit

7/99

E6

PARK LOCKINT’L BIG BOSS 6X6 A00CL50DA

3822

40

17

7

11

10

27

30

33

15

21

32

12

39

18

32

514

36

8

37

1

9

6

2326

29

13

31

16

20

4

19

34

28

35

24

25

1

8

146

1

13

26

831


1 7542319 4 Nut, FLEXLOC2 7512383 1 Screw3 7512329 2 Bolt4 7661203 1 Pin, Cotter5 7512242 2 Screw6 7555859 3 Washer, Flat7 5244594 1 Bracket, Cable Guide8 7542103 4 Nut, FLEXLOC9 7542324 1 Nut, Nylok10 5244596 1 Lever11 5244595 1 Bracket, Handle12 7512102 2 Bolt13 7558301 2 Washer, Flat14 7515159 2 Screw15 5333796 1 Spacer16 7571619 2 Washer, Wave17 5244592 1 Bracket, Swing Arm18 7512325 1 Bolt19 7661205 1 Pin, Cotter20 7661407 1 Pin, Cotter

21 7080925 1 Cable22 5224875 1 Spring, Return23 7555931 1 Washer, Flat24 7556168 1 Bushing25 7556169 1 Bushing26 7556063 2 Washer, Wave27 5244680 1 Bracket, Handle Adjustment28 7661830 1 Pin, Clevis29 7556301 1 Bushing30 5224871 1 Linkage31 7558707 2 Bushing32 7080644 1 Clevis, Threaded33 5242749 1 Pawl34 7661843 1 Pin, Clevis35 7661106 1 Pin, Clevis36 7517737 1 Screw37 7542105 4 Nut38 1013247-067 1 Bracket39 7512126 1 Bolt40 5244591 1 Bracket, Linkage

1/00

PRINTED IN THE USA PARTS MANUAL PN 9915481 and MICROFICHE PN 9916574 3/00

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SPORTSMAN 6X6 Model #A00CL50AA INT’L BIG BOSS 6X6 Model...

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