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Polatis Sportsman 400 Parts list www.manualedereparatie.info .pdf



Nom original: Polatis_Sportsman_400_Parts_list_www.manualedereparatie.info.pdf
Titre: 9919413

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PARTS MANUAL PN 9919413 and MICROFICHE PN 9919414 7/04

SPORTSMAN 400
Model #A05MH42AB
Model #A05MH42AG
Model #A05MH42AH
E 2004 Polaris Sales Inc.

TABLE OF CONTENTS
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

A

A-- ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B1

B

BRAKE LINES, FRONT . . . . . . . . . . . . . . . . B6
BUMPER MOUNTING . . . . . . . . . . . . . . . . . A7-8

C

CALIPER, REAR . . . . . . . . . . . . . . . . . . . . .
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS - THROTTLE ASM./CABLE . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT and PISTON . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .

D

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT, FRONT . . . . . . . . . . . . . . . . .
DRIVE SHAFT, REAR . . . . . . . . . . . . . . . . .
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . .

B7
D7-8
C9
B4
B9
A11
D4
D6
D5
A10
C7
B10
B11
C8

E

ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . C13
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A13-14
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A12

F

FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . .
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .
FRONT HOUSING . . . . . . . . . . . . . . . . . . . .
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .

B8
A5
D3
D11
B2

G

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C6
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . D1-2
HANDLEBAR . . .

H

. . . . . . . . . . . . . . . . . . . C1-2

H

HEADLIGHT POD . . . . . . . . . . . . . . . . . . . . . C1-2
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . C3

I

INTAKE and EXHAUST . . . . . . . . . . . . . . . . . D9

M

MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . E2
MASTER CYLINDER, REAR . . . . . . . . . . . . B8

O

OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D13
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D12
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . B3

P

PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B12

R

RACK MOUNTING FRONT . . . . . . . . . . . . .
REAR CAB and SEAT . . . . . . . . . . . . . . . . .
REAR RACK MOUNTING . . . . . . . . . . . . . . .
REAR SUSPENSION . . . . . . . . . . . . . . . . . .
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . .
RECOIL STARTER . . . . . . . . . . . . . . . . . . . .

S

STARTING MOTOR . . . . . . . . . . . . . . . . . . .
STEERING POST . . . . . . . . . . . . . . . . . . . . .
STORAGE BOX, REAR . . . . . . . . . . . . . . . .
STORAGE, FRONT . . . . . . . . . . . . . . . . . . .
STRUT MOUNTING . . . . . . . . . . . . . . . . . . .
STRUT, FRONT . . . . . . . . . . . . . . . . . . . . . .

A8
A3 -4
A6
C11-12
C10
D14
E1
C5
A9
A7-8
C4
B13

T

TAILLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . C3
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
TRANSMISSION MOUNTING . . . . . . . . . . . . C14

W

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D10
WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . . B14
WORKLAMPS . . . . . . . . . . . . . . . . . . . . . . . C3

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

REAR CAB and SEAT
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

5

3

6

E 2004 Polaris Sales Inc.

2

4

11

24

7

23

8

22 21

9

20
19

25

12
10

11

11

12
13
14

18
15

16

17

Rear Cab Foil
View From Bottom

A3

REAR CAB and SEAT
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9

7512095
7555798
7512026
7556034
7511930
5246076
7555792
7541925
5435363-400
5435363-293
5435363-341
10 7170911
11 7661855
12 5435354-070
5435355-070

Qty. Description

Ref. Part No.

2
2
3
3
2
1
4
2
1
1
1
1
14
1
1

13
14
15
16
17
18
19
20
21
22
23

Screw
Washer
Screw
Washer
Bolt
Retainer, Seat Latch
Washer
Nut, Nylok
Cab, Rear, Camo Green Metallic (AH)
Cab, Rear, Indy Red (AB)
Cab, Rear, Sonic Blue (AG)
Decal, Hitch
Rivet
Footwell, Black, LH
Footwell, Black, RH

7517230
7542122
5812703
5812702
5812701
1014536-067
7621403
5211033
7041370
1040387
2683433-070
2683434-070
24 7079902
25 5412623

Qty. Description

8
8
2
1
1
1
2
2
1
1
1
1
1
2

Screw
Nut, Nylok
Foil, Rear Cab, Front, Top
Foil, Rear, Cab, Front, Bottom
Foil, Cab, Rear
Frame, Main, Black
Rivet
Bracket, Lever Retainer
Spring, Latch
Latch, Seat
Asm., Seat, Black
Covering, Seat, Black
Decal, Carb/Filter Information
Grommet
7/04

A4

FRONT CAB
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1
E 2004 Polaris Sales Inc.

5
13

2
4

3

12

14
13

5
6

7

10

11

8

8
9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 5435352-400
5435352-293
5435352-341
2 2632864-400
2632864-293
2632864-341
3 7670057
4 7517219
5 5435353-177
2632936-177
5435353-070
2632936-070

Qty. Description

1
1
1
1
1
1
2
2
1
1
1
1

Cover, Front, Camo Grn Met (AH)
Cover, Front, Indy Red (AB)
Cover, Front, Sonic Blue (AG)
Cab, Front, Camo Green Met (AH)
Cab, Front, Indy Red (AB)
Cab, Front, Sonic Blue (AG)
Nut, U-Type Speed
Screw
Panel, Side, LH, Black (AH)(AG)
Asm., Panel/Foil, RH, Black (AH)(AG)
Panel, Side, LH, Black (AB)
Asm., Panel/Foil, RH, Black (AB)

Ref. Part No.

6
7
8
9
10
11
12
13
14

5812615
7080756
7517386
5248100
7546601
5246872
7661855
7512026
7556034

Qty. Description

1
1
4
1
2
1
2
8
4

Foil, Side Panel, RH
Clip
Screw
Guard, Splash, RH
Nut, Nylok
Guard, Splash, LH/Pump Mount
Rivet
Screw
Washer
7/04

A5

REAR RACK MOUNTING
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
1
E 2004 Polaris Sales Inc.
17

2

16

3
4
10

5
6
13

7
10

8

15

11
12

9
14
13

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9

7517230
7517983
5248469-418
7518375
2632867-070
7518213
5435959
7555843
7542324

Qty. Description

4
2
1
2
1
2
2
2
2

Screw
Screw
Channel, Rear
Screw
Asm., Rack, Rear (Incl. Warning Decal)
Screw
Spacer
Washer, Flat
Nut, Nylok

Ref. Part No.

10
11
12
13
14

5248471-418
5334092
1014668-067
7518341
-------

15 7542343
16 7542153
17 7517685

Qty. Description

1
2
1
4
1

Channel, Front
Spacer
Support, Rear Rack
Bolt, Flange
Bracket, Silencer, Frame (See Exhaust System Pg. A12, Ref. 6)
4 Nut, Nylok, Flange
4 Nut, Nylok
2 Screw
7/04

A6

FRONT STORAGE and BUMPER MOUNTING
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
E 2004 Polaris Sales Inc.

4

2

3

33
32

1
31

5

3

30

34
35
29
1
2

6

7

9

28

8

26

27

25

11
10
11
13

24

23

13

22
21

14
15

20

12

16
18

17

A7

19

FRONT STORAGE and BUMPER MOUNTING
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 7515399
2 1014591-067
1014592-067
3 7518341
4 5810467
5 7542343
6 1014636-067
7 5435629
8 5812778
9 7081145
7081125
10 7512076
11 5334257
12 7661855
13 5434314
5434315
14 5412504
15 5435046
16 5247507-067
17 7518046

Qty. Description

6
1
1
2
1
8
1
1
1
1
1
4
2
6
1
1
4
1
1
4

Screw
Support, Rack, LH
Support, Rack, RH
Screw, Flange
Plug, Frame
Nut, Nylok, Flange
Guard, Brush
Cover, Radiator
Seal, Radiator Cover
Latch, LH
Latch, RH
Screw
Latch, Wire
Rivet
Shield, Side, Radiator, LH
Shield, Side, Radiator, RH
Grommet
Cover, Radiator
Grill, Brush Guard
Screw

Ref. Part No.

Qty. Description

18 5435701
5435702
19 5435357-070
20 7518383
21 7518382
22 7556341
23 2632865-070

1
1
1
2
4
4
1

24
25
26
27
28
29
30
31
32
33
34
35

1
3
2
4
4
1
1
2
8
8
2
1

1202838
5412352
5435628
7555960
7517208
5521693
5435362-070
5247653-418
7542122
7518427
5134576
5521706

Cover, Bumper, LH
Cover, Bumper, RH
Panel, Bumper, Front
Screw
Screw
Washer, Flat
Asm., Bumper, Front, Black
(Incl. Warning Decal)
Asm., Box, Lower, Front
Plug
Cover, Strut
Washer, Flat
Screw, Flange
Seal
Cover, Box, Front
Channel, Lid, Front
Nut, Nylok
Screw
Pin, Hinge, Front
Seal, Lid/Bumper
7/04

A8

REAR STORAGE BOX
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

E 2004 Polaris Sales Inc.

2

3

7

4

8

5
6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4

5435605
7081205
5435368
5521694

Qty. Description

1
1
1
1

Ref. Part No.

Box, Upper
Latch
Cover, Tool Box
Seal

5
6
7
8

5810455
5435630
5412352
7661855

Qty. Description

2
1
1
2

Pad, Rack Mount
Box, Lower
Plug
Rivet
7/04

A9

DECALS
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
2

3

1

4

5

6

7
3

E 2004 Polaris Sales Inc.

RH

11
8

9

14

12

15

13

16

10

17

LH

8

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8

7172689
7173013
7172572
7172707
7172708
7172559
7172704
7172710
7079780
7172687
7172688

Qty. Description

2
1
2
1
1
1
1
1
1
1
1

Decal, Reflector, Red
Urocal, 50th Anniversary
Decal, Warning Front and Rear Rack
Decal, Rear Cab, “AWD”, LH
Decal, Rear Cab, “AWD”, RH
Decal, Age Warning, 16 ATV
Decal, “SPORTSMAN”, LH
Decal, “SPORTSMAN”, RH
Decal, Warning, AWD Switch, White
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH

Ref. Part No.

9
10
11
12
13
14
15
16
17

7172562
7078465
7079672
7172564
7172705
7172706
7172560
7172561
7172566
7172748

Qty. Description

1
1
1
1
1
1
1
1
1
1

Decal, Drain Recoil
Logo, Polaris Star
Decal, Foot Brake
Decal, Warning, Override, AWD
Decal, Tankside, “400”, LH
Decal, Tankside, “400”, RH
Decal, Warning, General, CPSC
Decal, Discretional Warning
Decal, Passenger Warning
Decal, Tire Pressure/Load
7/04

A10

COOLING SYSTEM
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
8
1

25

2

24
23

10
5
3
26
5

6

4

22

27

21
20

6
7
8

19
6

18

19

E 2004 Polaris Sales Inc.

17

9
10

13

11
12

16

14

15
12

6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14

7517975
2410383
1240044
5412402
7512084
7080826
5412405
7080696
5412404
5521550
7080851
7517386
7080138
7080492

Qty. Description

4
1
1
1
4
4
1
2
1
2
1
3
1
1

Screw
Asm., Fan and Motor
Cap, Pressure
Neck, Filler
Screw
Clamp
Hose, Filler Neck
Clamp
Hose, Engine, Lower
Guard, Hose, Plastic
Clamp, Hose
Screw
Cable Tie
Cable Tie

Ref. Part No.

15
16
17
18
19
20
21
22
23
24
25
26
27

5247047-067
5410584
7515179
1240152
5411975
8450003-1525
7052065
5431673
5433774
5810279
5430743
5412403
5246754-067

Qty. Description

1
2
2
1
2
1
1
1
1
1
1
1
1

Bracket, Radiator, Lower
Bushing, Mount, Lower
Screw
Radiator
Asm., Grommet and Insert
Line, Fuel
Fitting, Barbed, 90 Degree
Tank, Surge
Plug, Cap
Gasket, Overflow Cap
Cap, Overflow, Drilled
Hose, Engine, Upper
Bracket, Radiator, Lower
7/04

A11

EXHAUST SYSTEM
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

6
5

4

3

2

1

7

E 2004 Polaris Sales Inc.

8

13
14
12

9

15

11
10
4

17

8
12

16

7

5

2

1

3

12

13 14

18
17
12

15

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9

7542324
7555716
5410436
7555863
5010192
5241663
5412508
7515316
1261042-029

Qty. Description

3
3
3
3
3
1
3
3
1

Nut, Nylok
Washer, Flat
Washer, Rubber
Washer
Bushing
Bracket, Silencer, Frame
Dampener, Vibration
Bolt, Carriage
Silencer, Exhaust

Ref. Part No.

10
11
12
13
14
15
16
17
18

7512666
7556230
7041804
7515197
7555935
5248727
1261246-029
5243518
1261043-029

Qty. Description

1
1
4
4
4
2
1
2
1

Bolt
Washer, Clean Out
Spring, Exhaust
Screw
Washer
Shield, Heat, Exhaust
Pipe, Exhaust
Seal, Exhaust
Manifold
9/04

A12

ENGINE MOUNTING
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
32

E 2004 Polaris Sales Inc.

1

33
32

1

2
1
4

35

32
32

3

32

33

5

34

6

32

9

7

33

10

8

11
12

15

10

20
31
30

13

29
14

28

27
26
25
24
23

17
15

22

18 19

15
21

16

20
15

A13

15

ENGINE MOUNTING
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

Qty. Description

1
2
3
4
5
6
7
8
9

8450003-1525
7052075
5247154
3084205
7542105
7558203
3110050
7542143
-------

AR
1
1
2
2
2
2
2
1

10
11
12
13
14
15
16
17
18
19
20

8360009-600
7051011
5412487
7080511
4010895
7547263
5224658-067
3110046
7555815
7555797
3110044

AR
1
1
2
1
8
1
2
2
2
2

Line, Fuel
Fitting, Tee
Strap, Carburetor Mount
Screw and Washer
Nut
Washer
Mount, Carb
Insert
Asm., Carburetor
(See Carburetor Pg. D8, Ref. 9)
Line, Fuel
Valve, Check Vent
Boot, Clutch Intake
Clamp, Narrow Band
Cable, Black, Frame/Engine
Nut, Flange Lock
Strap, Frame Support
Mount, Rubber, Front
Washer
Washer, Flat
Mount, Rubber, Top

Ref. Part No.

21 5241150
22 7518415
23 3087023

24
25
26
27
28
29
30
31
32
33
34
35

5430261
7575202
7512566
5210748
3082038
5241453
7552901
7512315
7080003
8450103
2530009
8450040-600

Qty. Description

1 Mount, Engine, Front
2 Screw
1 Engine, Short Block (EH42PLE053)
NOTE: The Short Block assembly
contains a crankcase assembly, cylinder & cylinder head assembly and a
piston & crankshaft assembly. Prior
authorization is required for warranty
consideration.
1 Bushing
1 Washer, Interlock
1 Bolt
1 Washer, Flat
1 Asm., Bolt and Washer
1 Mount, Engine, Top
2 Washer, Spring Lock
2 Bolt
8 Clamp, Hose, Red
AR Hose, Fuel
1 Filter
AR Line, Fuel
7/04

A14

AIR BOX
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
8
6
E 2004 Polaris Sales Inc.

9
7

5

10

1
4

2

3

11
6

12
13

27

12

14

26

12
25

15

24
23
22

17

20

16

12
19

21

18

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14

5811633
7080595
7080413
5811482
5432868
5242044
5411422
7517317
5433293
5811626
5433387
7080699
8450073-600
7080913

Qty. Description

1
1
1
1
1
6
1
4
1
1
1
4
AR
1

Filter, Precleaner Sleeve
Filter, Air Intake
Clamp, Narrow Band
Seal, Air Box Cover
Cover, Air Box
Clip, Air Box
Gasket, Intake
Screw
Duct, Air Inlet
Seal, Foam
Box, Air
Clamp, Hose
Line, Breather
P-Clamp

Ref. Part No.

15
16
17
18
19
20
21
22
23
24
25
26
27

5411858
7080694
2530029
7080511
5412283
5433847
5411668
5432377
8450059-150
7080650
5811650
7558301
7515179

Qty. Description

1
1
1
1
1
1
1
1
AR
1
1
2
2

Hose, Breather
Clamp
Filter, Breather
Clamp
Boot, Carburetor
Sleeve
Line, Breather
Plug, Trap
Line, Fuel
Clamp, Hose
Foil, Air Box
Washer, Flat
Screw
7/04

B1

FUEL TANK
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
9
E 2004 Polaris Sales Inc.

1

8

10
11

2
6

4

3

12
13

7

5

14

15
16

22
21
20

17

18
19

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 7517685
2 5247184
5247185
3 5812265
4 8360009-600
5 5431053
6 5433687
7 5812123
8 7052159
9 5432559
10 7517505
11 5432733

Qty. Description

2
1
1
1
AR
1
1
1
1
1
1
1

Screw
Bracket, Fuel Cover Mount, LH
Bracket, Fuel Cover Mount, RH
Seal, Foam
Line, Fuel
Vent, Tank
Cap, Gas Tank
Gasket, Fuel Cap
Valve, On/Off
Knob, Fuel Valve
Screw
Nut, Fuel Valve

Ref. Part No.

12
13
14
15
16
17
18
19
20
21
22

7080003
8450103
7080492
7518257
2410554
5810858
7052363
7515136
5812005
5812004
2520403

Qty. Description

4
AR
1
5
1
1
1
2
1
1
1

Clamp, Hose, Red
Hose, Fuel
Cable Tie
Screw
Sender, Fuel
Gasket
Fitting, Fuel, Single Outlet
Screw
Foil, Tank
Foil, Tank
Asm., Fuel Tank w/Sender
(Incl. 15-21)
7/04

B2

OIL TANK
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

E 2004 Polaris Sales Inc.

2
3

4

14

15
12

13

2

18

16

17
5
6
15
7
8

9

14
11

10

12

13

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9

5411668
7080699
5434574
8450073-34
7080474
8450096-25
7512017
7080693
7081026

Qty. Description

1
2
1
1
2
1
1
1
1

Line, Breather
Clamp
Dipstick
Hose, Breather
Clamp
Line
Screw
Clamp
Clamp

Ref. Part No.

10
11
12
13
14
15
16
17
18

7052326
5412507
5333204
5410828
7512242
7558301
7051524
5850135
1261176

Qty. Description

1
1
2
2
2
2
1
1
1

Screen, Oil Filter, 90 Degree
Grommet
Bushing, Mounting
Grommet
Screw
Washer, Flat
Plug
Washer, Nylon
Tank, Oil
7/04

B3

CONTROLS
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.
1
2
3

4
6

5

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

2010238
1 7517899
2 2202725
3 2201836

Qty. Description

Ref. Part No.

1 Asm., Master Cylinder
2 Screw, Torx
1 Kit, Master Cylinder Cap
(Incl. Cap, Screws, Sight, Gasket)
1 Kit, Master Cylinder Park Brake Lever
(Incl. Lever, Spring)

4 2201833
5 2202410
6 2201835

Qty. Description

1 Kit, Master Cylinder Clamp
(Incl. Clamp, Screws)
1 Kit, Piston
(Incl. Piston, Seals, Boot, Spring)
1 Kit, Master Cylinder Lever
(Incl. Pin, Lever, Clip)
7/04

B4

FRONT BRAKE
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

2

3
E 2004 Polaris Sales Inc.

11

4

5
6

7

8

10

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4

1910841
1910842
7515489
5134639
5134640
1930642
5410494
1930665

Qty. Description

1
1
1
1
1
1
1
1

Asm., Brake Caliper, LH (Incl. 1-7,9,10)
Asm., Brake Caliper, RH (Incl. 1-7,9,10)
Screw, Socket Set
Caliper, Brake, LH
Caliper, Brake, RH
Kit, Front Brake Boot
Boot, Pin Seal
Kit, Piston and Seal (Incl. 5-7)

Ref. Part No.

5
6
7
8
9
10
11

5410780
5410779
5132294
2202412
1910411
5410495
7080352

Qty. Description

1
1
1
1
1
1
1

Ring, Molded Square (.103 x .134)
Ring, Molded Square (.094)
Piston, Brake, Long
Kit, Front Brake Pad
Mount, Caliper
Boot, Bushing
Screw, Bleeder
7/04

B5

FRONT BRAKE LINES
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.

1
2

3

3
4

10
9
8

5
6
2

7
2

1

1

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5

5410988
1910499
1910883
7052292
1910839

Qty. Description

6
3
1
1
1

Seal
Bolt, Banjo
Line, Brake, Stainless Steel
Fitting, Cross
Line, Brake, Right Front, SS

Ref. Part No.

6
7
8
9
10

8360031-34
7080138
1910838
7512024
4110164

Qty. Description

1
4
1
2
1

Conduit
Cable Tie
Line, Brake, Left Front, SS
Screw
Switch
7/04

B6

REAR CALIPER
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1
2

E 2004 Polaris Sales Inc.

1
3

4, 5
3

5
5
3
4, 5
6
7

1, 3

1
1, 3, 7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1910690
1 2201873
2 1910538
3 2201870

Qty. Description

1
1
2
1

Ref. Part No.

Asm., Caliper
Kit, Anvil Body
Fitting, Bleed, Compact
Kit, Slide Bolt

4
5
6
7

2201872
2201869
1910529
2202414

Qty. Description

1
1
1
1

Kit, Seal
Kit, Piston and Seal
Bracket, Caliper
Kit, Brake Pad
3/04

B7

REAR MASTER CYLINDER/FOOT PEDAL
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

6

E 2004 Polaris Sales Inc.

5
3

11

12

7

4

13
2
14

10
8
1
2

9

4

25
27

26

15
16

18

17

20

22
23

21

21

20

19

24

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13

2202708
2202660
1910690
5410988
1910760
1910499
7670126
7517756
7080138
7512024
7080499
7080003
7542153
1930854
7512240

Qty. Description

1
1
1
4
1
2
1
1
3
1
1
2
1
1
1

Kit, Brake Line, Rear (Incl. 16)
Kit, Brake Line, Rear (Incl. 3)
Asm., Caliper
Seal
Line, Brake, Caliper, Rear
Bolt, Banjo
Clip, Retaining
Screw
Cable Tie
Screw
Clamp, Cable
Clamp, Hose
Nut
Reservoir, Brake, Rear
Screw

Ref. Part No.

14
15
16
17
18
19
20
21
22
23
24
25
26
27

1910315
7042291
1910765
1910790
7542122
7041750
7555919
5433189
7512247
1910814-067
7661401
7512365
7552901
7558402

Qty. Description

1
1
1
1
2
1
2
2
2
1
1
2
2
2

Hose, Reservoir
Spring, Park Lockout
Line, Rear Brake
Master Cylinder, Brake, Rear
Nut, Nylok
Spring
Washer
Bushing, Pivot, Pedal
Screw
Pedal, Brake
Pin, Cotter
Screw
Washer, Spring Lock
Washer, Flat
7/04

B8

CONTROLS - THROTTLE ASM./CABLE
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

E 2004 Polaris Sales Inc.

2
3

4
5

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4

5410193
5434113
5411439
7081181

Qty. Description

1
1
1
1

Ref. Part No.

O-Ring
Cover
O-Ring
Cable, Throttle

5 2010230
2010250
6 2010191

Qty. Description

1 Asm., Throttle Control, AWD
(Incl. 6)(If built before 10/04/04)
1 Asm., Throttle Control, AWD
(Incl. 6)(If built after 10/04/04)
1 Asm., Throttle Clamp
7/04

B9

FRONT DRIVE SHAFT
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.
2

3

4

5

1

3
6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1380234
1 7670092
2 1590395
3 7710557

Qty. Description

2
2
2
2

Asm., Drive Shaft, Front
Circlip
Joint (CV, Inner)
Circlip

Ref. Part No.

4 2202826
5 2201015
6 1590396

Qty. Description

2 Kit, Boot
(Inner)(Incl. Clamps and Grease)
1 Kit, Boot
(Outer)(Incl. Clamps and Grease)
1 Joint, CV (Outer)
7/04

B10

REAR DRIVE SHAFT
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.
1

2

3

4

4

5

10

6

2

7

8

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1380240
1
2
3
4

1590325
1350044
1350046
1350045

Qty. Description

2 Asm., Drive Shaft, Rear
(Incl. 1-8)(If built after 11/24/03)
1 CV Joint
2 Clamp, Large
1 Grease, 30g
2 Boot

Ref. Part No.

5
6
7
8
9
10

1350043
1350047
1590281
1350042
2201374
2201373

Qty. Description

2
1
1
1
1
1

Clamp, Small
Grease, 50g
Joint, Plunging
Ring, Spring
Kit, Boot (Gear Side)
Kit, Boot (Wheel Side)
7/04

B11

PROP SHAFT
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

3

E 2004 Polaris Sales Inc.

4

5

2

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1380233
1 3260133
2 2202015
3 3260131

Qty. Description

1
1
2
1

Asm., Shaft, Prop, Front
Yoke, Gear Case, Front
Kit, Cross and Bearing
Yoke, Prop Shaft, Transmission

Ref. Part No.

4 7080424
5 5411092
6 7661913

Qty. Description

1 Fitting, Lubrication
1 O-Ring
1 Pin, Spring
7/04

B12

FRONT STRUT
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.

16

5

1
2

6

3

7

22

4

8
21

17

11

20

19

18

9

16

11

13

14

15
11
10
12

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12

7547104
7555749
5810291
5432872
5132062
5432871
5243364
7042299-067
5412665
7515339
7558402
5134154
5134155

Qty. Description

2
2
2
2
2
2
2
2
2
4
10
1
1

Nut, Nylok
Washer
Spacer, Rubber
Ball, Pivot, Top
Spacer
Ball, Pivot, Bottom
Retainer, Spring
Spring, Compression
Bumper
Bolt
Washer, Flat
Hubstrut, LH
Hubstrut, RH

Ref. Part No.

Qty. Description

13
14
15
16
17

7710507
3514342
7080306
7542324
-------

2
2
2
4
1

18
19
20
21
22

7552901
7512365
7080367
5211115
7041762

4
4
2
2
2

Ring, Retaining
Bearing, Hubstrut
Fitting, Lubrication
Nut, Nylok
Asm., Front Brake Caliper, LH
(See Front Brake Pg. B5 for Details)
Washer, Spring Lock
Screw
Clamp, Rubber Coated
Washer
Strut, Front

9/04

B13

FRONT WHEEL
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

8

9

7
E 2004 Polaris Sales Inc.

6
4
2

5

3
10

1

12

11

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 5412396
2 1520269-067
1520269-486
3 5411164
4 7661401
5 7556004
6 5134310

Qty. Description

2
2
2
2
2
2
2

Tire, Front, 25x8-12
Rim, Front, Black (AB)(AH)
Rim, Front, Silver (AG)
Cover, Dust
Pin, Cotter
Washer
Hub

Ref. Part No.

7
8
9
10
11
12

7515513
5244314
7512325
7542810
1525017
7547237

Qty. Description

8
2
8
2
2
8

Stud
Disc, Brake
Bolt
Nut, Slotted
Valve, Rim
Nut
7/04

B14

HANDLEBAR and HEADLIGHT POD
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
1

E 2004 Polaris Sales Inc.
2

30

6
31
32

3

29

28

35

4
6

5

33
8

7

9
27

34

26
10

13

25
22

11

24
23

12
14
15
16

21
20

17

15

19
18

C1

HANDLEBAR and HEADLIGHT POD
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 4011074
2 5435364-400
5435364-293
5435364-341
3 5434380
4 3280431
5 5412138
6 7511881
7 ------8
9
10
11
12
13
14
15

5843350
4122550
7080138
7670127
5410163
7080922
5433534
4011002
4010278
4010321

Qty. Description

1
1
1
1
1
1
1
3
1
1
1
1
1
2
1
1
1
1
1

Switch, Worklight
Pod, Headlight, Upper (AH)
Pod, Headlight, Upper (AB)
Pod, Headlight, Upper (AG)
Bezel
Cluster
Mount, Rubber
Screw
Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B9, Ref. 5)
Knob, Adjusting
Rod, Adjusting
Cable Tie
Clip, Screw
O-Ring
Nut, Choke
Cover, Key
Switch, Key, 3 Position (Incl. Key)
Blank, Key, Series 2000, 6700, 6800
Blank, Key, Series 2200, 2300, 2700,
2800 NOTE: Your key can be duplicated only by obtaining a key blank
from Polaris and having it cut by mating it with your existing key.

Ref. Part No.

Qty. Description

16
17
18
19
20
21
22
23
24
25
26
27

5435365-177
7517658
5132382
4010298
7542122
7081176
4010638
7517317
5244969-067
5631516
5631517
-------

1
1
1
1
4
1
1
2
1

28
29
30
31
32
33
34
35

5432952
7517625
5433834-070
4010592
5433903
5242987-067
7515189
2410429
4831060

1
1
2
1
1
1
4
1
1

1
1

Pod, Headlight, Lower
Screw
Cap
Sensor
Nut, Nylok
Cable, Choke
Receptacle, Pod Mount, 12V
Screw
Bracket, Pod Mounting
Block, Handlebar
Block, Handlebar, Pegged
Asm., Master Cylinder
(See Controls Pg. B4 for Details)
Plug
Screw, Set
Grip, Handlebar
Switch, Handlebar, Hi/Lo/Off
Spacer, Switch, LH
Tube, Handlebar
Screw
Asm., Headlight
Bulb, Headlight
7/04

C2

TAILLAMPS/WORKLAMPS/HEADLIGHTS
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.
1
8

10

7
9

2

6

5

4
3

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 2410427
2410428
2 7670054
3 7517561
4 7670112
5 2410425
2410426

Qty. Description

1
1
4
2
2
1
1

Asm., Tail/Worklight, LH
Asm., Tail/Worklight, RH
Nut, Speed
Screw
U-Nut
Asm., Headlight, LH
Asm., Headlight, RH

Ref. Part No.

6
7
8
9
10

4011066
4011102
4011065
4011101
4011064

Qty. Description

2
2
2
2
2

Bulb, Bumperlight
Socket, Worklight
Bulb, Worklight
Socket, Taillight
Bulb, Tail/Stop
7/04

C3

A-ARM/STRUT MOUNTING
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

24

1
2

E 2004 Polaris Sales Inc.
25

26

28

3
4

26
28

5

25

24

23

27
22

6
7

21
8
9

10

18

11

19

20

17
12
8

14

13

15

16

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 ------2
3
4
5
6
7
8
9
10
11
12
13

7080927
5211121
5410548
7512284
2202906
2202907
7542438
7661203
5435028-070
5435029-070
7512084
7517909
7556099
7547177

Qty. Description

1 Asm., Hubstrut
(See Front Strut Pg. B13, Ref. 12)
2 Joint, Ball
2 Bracket, Ball Joint
2 Boot, Rubber
4 Screw
1 Kit, A-Frame, LH (Incl. 8,24,25,27,28)
1 Kit, A-Frame, RH (Incl. 8,24,25,27,28)
2 Nut, Castle
4 Pin, Cotter
1 Shield, CV Joint, LH
1 Shield, CV Joint, RH
6 Screw
2 Bolt
4 Washer, Flat
2 Nut

Ref. Part No.

14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

5411920
7061054
7547028
5134242
7542711
7061034
5411291
1821498
7515415
7542439
7512492
7552603
7555832
5133806
5434551

Qty. Description

1
2
2
2
2
2
2
2
2
2
4
4
4
2
4

Boot, Seal, Rod End
Rod End, LH
Nut, Jam, LH
Tie Rod
Nut
Rod End
Boot, Seal, Rod End
Asm., Tie Rod (Incl. 14-20)
Screw
Nut, FLEXLOC
Screw
Washer, Spring Lock
Washer
Shaft, A-Arm
Bushing, A-Arm, Long
7/04

C4

STEERING POST
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
2

E 2004 Polaris Sales Inc.

1

3
10
3
4

5
6

7

1

5
10

8

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5

7517428
5246732
5433866
1822630-067
7556162

Qty.

4
1
2
1
2

Description

Ref. Part No.

Bolt, Carriage
Bracket, Steering Post, Upper
Bushing, Steering, Upper
Post, Steering
Bushing

6
7
8
9
10

5222393
3514352
7547158
7661633
7542343

Qty.

1
1
1
1
4

Description

Flangette
Bearing
Nut
Pin, Cotter
Nut, Nylok, Flange
7/04

C5

GEAR SELECTOR
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1
2
E 2004 Polaris Sales Inc.

3
4

9

11
10

5
4

6

8

5

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6

5412003
7512024
5411007
7515175
7542122
1822730

Qty. Description

1
1
1
2
2
1

Cover
Screw
Knob, Gear Selector
Screw
Nut, Nylok
Asm., Linkage

Ref. Part No.

7
8
9
10
11

1013315-067
7542324
8360012-10
5435042
7518342

Qty. Description

1
2
1
2
2

Selector, Gear
Nut, Nylok
Trim, Edge
Mount, Gear Selector
Screw
7/04

C6

DRIVE CLUTCH
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.
4
1

2

3

5

8

6

9

7

12

11
10

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1321976
1
2
3
4
5
6

7518062
3576510
7042202
5430945
1321457
5431936

Qty. Description

1 Asm., Drive Clutch, Basic
(Incl. All Less 3,8)
6 Bolt
1 Bearing, Cover
1 Spring, Clutch
6 Washer, Multilube
3 Asm., Roller and Bushing
6 Button, Guide, Stemless

Ref. Part No.

7 5210752
5242981
5210753
5210754
8 5630710
9 7512266
10 7541906
11 3576504
12 5020422

Qty. Description

AR
AR
AR
AR
3
3
3
1
3

Spacer, .020
Spacer, .025
Spacer, .032
Spacer, .050
Weight, Shift, 10 WH
Bolt, Shoulder
Nut, FLEXLOC
Bearing, Moveable, 1/2 Inch
Pin, Roller
7/04

C7

DRIVEN CLUTCH
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1
E 2004 Polaris Sales Inc.
2
16
15

17

4
14

3

5
6

13
12
11

10
9
3

8

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9

7556120
3211077
1321848
5220646
7552901
7515327
7555898
7556076
7556804

Qty. Description

AR
1
1
1
1
1
AR
AR
AR

Bushing (3 Max)
Belt, Drive
Asm., Driven Clutch (Incl. 7-17)
Washer, Domed
Washer, Spring Lock
Bolt
Washer (.020)
Washer (.025)
Washer (.030)

Ref. Part No.

10
11
12
13
14
15
16
17

3576504
3576511
7041782
5131446
5210752
7710448
7511854
5430766

Qty. Description

1
1
1
1
1
1
3
3

Bearing, Moveable, 1/2 Inch
Bearing, Moveable, 1 Inch
Spring, Clutch
Ramp, Stationary
Spacer
Ring, Retaining
Bolt
Button, Ramp
7/04

C8

CLUTCH COVER
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

9
7

10

8

11

6
10

4
5

12
3

1

13

2

14

15

E 2004 Polaris Sales Inc.

16
17

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9

2201954
7517599
7080511
5435236
5521578
5434255-070
5410542
5434264
5411489

Qty. Description

1
5
1
1
1
1
1
1
1

Kit, Inner Clutch Cover (Incl. 14)
Asm., Bolt/Washer
Clamp, Narrow Band
Duct, Clutch Air Inlet
Seal, Cover, Clutch
Cover, Clutch, Outer
O-Ring
Plug, Drain
Boot, Duct

Ref. Part No.

10
11
12
13
14
15

7080707
5435235
7172746
7172563
7512094
-------

16 5242046
17 5410575

Qty. Description

2
1
1
1
9
3

Clamp, Narrow Band
Duct, Clutch Outlet
Decal, “Automatic Transmission”
Decal, Warning, Clutch Cover
Screw
Screw and Washer
(See Crankcase Pg. D4, Ref. 6)
1 Bracket, Clutch, Seal
1 Seal, Cover Case
7/04

C9

REAR WHEEL DRIVE
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

12
11
10
E 2004 Polaris Sales Inc.

9
8
13
6

7
5

4
3

2

1

15

14

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 5412451
2 1520457-067
1520457-486
3 5411164
4 7543005
5 5244635
6 7661404
7 7555796
8 5134311

Qty. Description

2
2
2
2
2
2
2
4
2

Tire, 25x11-12
Rim, Rear, Black (AB)(AH)
Rim, Rear, Silver (AG)
Cover, Dust, Hub
Nut, Castle
Disc, Brake, Rear
Pin, Cotter
Washer, Cone
Hub, Rear Wheel

Ref. Part No.

9
10
11
12

7515513
7710440
3585502
-------

13 7512325
14 1525017
15 7547237

Qty. Description

8
2
2
2

Stud
Ring, Retaining
Bearing
Carrier, Bearing, Wheel (See Rear
Suspension Pg. C12, Ref. 11)
8 Screw
2 Valve, Rim
8 Nut, Flange
7/04

C10

REAR SUSPENSION
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

4

3

2

7

1

4

5

18

3

35
37

6
8

18
36

2

9

30

29

8

26
28

28

8

18
22

29
21

31

30

8
7

20

E 2004 Polaris Sales Inc.
11
12

13
14

19
15

16
18
17

C11

24

25

27

32

9

18

26
34

33

10

36

35

23

REAR SUSPENSION
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

7518341
7542343
7555939
5434549
5334114-067
1580107-067
7517231
7555761
5432598
5020827
5134206
5631142
5434550
7552614
7555740
7517873
7515415
7542439
7043100
5630551

Qty. Description

6
6
2
2
1
2
4
8
8
2
2
4
8
4
4
4
2
10
2
2

Bolt, Flange
Nut, Nylok
Washer
Bushing, Stabilizer Tube
Bar, Stabilizer Tube
Arm, Stabilizer Bar
Screw
Washer, Flat
Bushing, Stabilizer
Rod, Linkage, Stabilizer
Carrier, Wheel Bearing
Bushing, Bearing Carrier
Bushing, Control, Lower
Washer, Lock
Washer, Flat
Bolt
Screw
Nut, Nylok
Shock, Rear
Cam, Adjusting, Spring

Ref. Part No.

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

7043091-067
5630885
7515433
5247345
7518364
5020826
1014320-293
1014321-293
5434551
7552603
7512492
1014174-293
1014175-293
7512084
5435008-067
5435009-067
5133806
7515472
5434548
1541802-067

Qty. Description

2
2
2
2
4
6
1
1
4
4
4
1
1
4
1
1
2
6
12
1

Spring, Compression, Rear
Retainer, Spring
Screw
Bracket, A-Arm Pivot
Screw
Shaft, A-Arm, Short
Arm, Control, Upper, LH
Arm, Control, Upper, RH
Bushing, A-Arm, Long
Washer, Spring Lock
Screw
Arm, Control, Lower, LH
Arm, Control, Lower, RH
Screw
Shield, Rear, LH
Shield, Rear, RH
Shaft, A-Arm
Screw
Bushing, A-Arm, Short
Support, Stabilizer
7/04

C12

ELECTRICAL/TAILLIGHT
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

19

1

18

17

16

20

2

19
3

21

22

14

24

4
5

15

23
27

26

25

13

6

11

7
12

E 2004 Polaris Sales Inc.

8

10

11

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13

5431769
2202848
4011138
4011139
5810290
7512232
2410535
2410466
2202147
4010924
4011110
7512024
5246747
5810317

Qty. Description

1
1
1
1
3
1
1
1
1
1
1
4
1
1

Cover, Battery
Kit, Battery Bolt
Battery
Cable, Battery/Frame
Pad, Battery
Screw
Harness, Winch
Harness, Main
Kit, Fusible Link
Module, Resistor
Module, Controller
Screw
Bracket, CDI
Pad

Ref. Part No.

14
15
16
17
18
19
20
21
22
23
24
25
26
27

7541925
7512007
7080138
4020139
7080965
7010032
5412499
7552801
7547283
7512027
4010094
4010093
7518287
4011072

Qty. Description

1
1
12
3
3
2
1
2
2
2
1
1
2
1

Nut, Nylok
Screw
Cable Tie
Clip, Rosebud
Mount, Cable Tie
Hook, Battery Strap
Strap, Battery Holddown
Washer, Spring Lock
Nut
Screw
Cable, Battery/Solenoid
Cable, Solenoid/Starter
Nut
Switch, Magnetic
7/04

C13

TRANSMISSION MOUNTING
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1

E 2004 Polaris Sales Inc.
7

9

2

8

7
6

5
4

3

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5

7518365
7547180
7518364
7080307
8450003

Qty. Description

3
3
4
1
AR

Screw
Nut, Flange
Screw, Flange
Clamp
Line, Fuel

Ref. Part No.

6
7
8
9

7515382
7542343
7515398
5221624-067

Qty. Description

1
3
2
1

Screw
Nut, Flange
Screw, Flange
Support, Transmission, Upper
7/04

C14

GEARCASE
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

24

7

25

23
E 2004 Polaris Sales Inc.

18

21

22

20

19

27

18

26

17
15
12 13

16

14
31

11
32

8

65 64

67
68

63

62

61

2

24

60

45

41 44

50

59
58

69
72
74

71

80

56

70

73

75

57

73

74

75

71

76

70

77
78

79

D1

55

54

53

51

52

38
47
48

46

16

27

40

43

14

46

37
39

41
42

35

33

6

66

34

34

9
3 5
1 2 4

35

35

10

7

36

29
28
30

49

GEARCASE
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

1341450
3233906
3233826
3233827
3233829
3233869
3233831
3233878
3233832
3233524
3234059
3234066
3234065
3234064
3233364
3234063
3234086
3234062
3233268
3234058
3234057
3233247
3234056
3233846
3234087
3233874
3233749
3233018
3234061
3234060
3233699
3234080
3234088
3233915
3233851
3233718
3233176
3234067
3234068
3233855
3234070

Qty. Description

1
1
8
1
1
1
1
2
1
1
1
1
1
1
2
1
5
1
2
1
1
2
1
22
2
1
2
2
1
1
1
1
1
1
2
3
1
1
1
1
1

Asm., Gearcase
Bellcrank
Screw
Cover, Gear
Pawl, Detent
O-Ring
Shaft, Shift
Seal, Triple Lip
Gear, 31T
Tube, Vent
Gearcase, RH
Shaft, Center Drive
Bearing, Ball
Spacer
Ring, Retaining
Cover, Bearing
Screw
Gear, Output, 91T
Bearing, Ball
Sprocket, 59T
Chain
Pin, Dowel
Gearcase, LH
Screw
Plug
Seal, Dual Lip
Screw
Bearing
Deflector, Oil
Sprocket, 19T
Ring, Retaining
Drum, Shift
Baffle, Oil
Plate, Park
Washer
Bearing, Needle
Washer, Thrust
Ring, Retaining
Gear, 28T
Washer
Dog, Engagement

Ref. Part No.

41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80

3233850
3233854
3234071
3233852
3234069
3234074
3233019
3234075
3233036
3233357
3234092
3234076
3233788
3233106
3233305
3234085
3234084
3233265
3234083
3233917
3233839
3233548
3234081
3234082
3233076
3233830
3233961
3233834
3233835
3234091
3234077
3234073
3234089
3234078
3234090
3233432
3233433
3233434
3233431
3234079

Qty. Description

2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
2
2
2
1
1
1
1

Ring, Retaining
Sprocket, 24T
Shaft, Reverse, 26T
Gear, 33T
Dog, Engagement
Bearing, Ball
Bearing
Asm., Input Shaft
Chain, Silent
Spacer
Ring, Retaining
O-Ring
Seal, Triple Lip
Ring, Snap
Bearing, Ball
Tube, Snorkel
O-Ring
Bearing, Ball
Shaft, Snorkel
Asm., Park Lockout
Gear, 16T
O-Ring
Disc, Lockout
Star, Detent
O-Ring
Spring, Compression
Nut, Lock
Ring, Retaining
Switch
Washer
Fork, Shift
Collar, Shift
Spring, Compression
Spring, Compression
Ring, Retaining
Pin, Dowel
Shoe, Chain Tensioner
Cam, Chain Tensioner
Spring, Torsion
Rail, Shift Shaft
5/03

D2

FRONT HOUSING
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

E 2004 Polaris Sales Inc.

1
2

3
4
16

14
5

7

6
15

2

28

13
8

15

12

9

27

11

5

16

10
26

25

20

19

18

17

21

4
24

22
23

15

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

Qty. Description

1341497
3233955
1 3234163
2 3234159

1
1
1
1

3
4
5
6
7
8

3234161
3233926
3233953
3233928
3234166
3234167

1
2
1
1
1
1

9
10
11
12
13

------3233957
3234169
7080307
8450003
7512024

1
14
1
1
AR
1

Asm., Front Gearcase
Kit, Bolt
Screw, Set
Asm., Cover Plate
(Incl. Output Cover, Insert and Coil)
Shim, Armature Plate
Bearing, Roller Ball
Asm., Race/Output Hub (Incl. 25)
Pin, Dowel
Clutch Housing/Ring Gear
Asm., Roll Cage
(Incl. Spring and Roll Cage)
Spring
Kit, Roll
Bushing
Clamp
Line
Screw

Ref. Part No.

14 7080693
15 3233956
16
17
18
19
20
21
22
23
24

3233918
3233947
3234112
3233944
------------3233942
7518364
3233951

25
26
27
28

3233929
3234168
3234162
3234160

Qty. Description

1 Clamp
1 Kit, Minor Repair
(Incl. O-Rings and Seals)
11 Bolt
1 Cover, Input
1 Bearing, Roller Ball
1 Shaft, Pinion, 11T
1 Bushing
1 Gearcase, LH
1 Plug, Oil Fill
4 Screw, Flange
1 Asm., Drain Plug
(Incl. Plug and Washer)
1 Bearing, Needle, Roller Thrust
1 Asm., Clutch (Incl. 7-9)
1 Ring, Retaining, Internal
1 Plate Armature
7/04

D3

CRANKCASE
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

6

2
E 2004 Polaris Sales Inc.

7
5

3

8

2

1

4
9
10

23

22
15
21

16

20

18

5
14

13

12

11

17

19
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 3083669
2 3089240
3
4
5
6
7
8
9
10
11

3087266
3080676
3084840
3084205
3084839
3085525
3087154
3084842
3084845

Qty. Description

1 Bushing, Starter
1 Asm., Crankcase
(Incl. 1,4,5,7,8,15,16,17,20,21,23)
2 Pipe, Knock
1 Bearing, Ball
2 Pin, Dowel
3 Screw and Washer
1 Seal, Oil
1 Pipe, Air Breather
1 Fitting, Oil Inlet
1 Union
1 Plug

Ref. Part No.

12
13
14
15
16
17
18
19
20
21
22
23

3084846
3084844
3086810
3084834
3084835
3084841
3082956
3086749
3084837
3084836
3084847
3086838

Qty. Description

1
1
1
2
1
10
1
1
1
1
1
2

Gasket, Aluminum
Spring, One Way Valve
Valve, One Way
Bearing, Ball
Bearing, Ball
Bolt, Flange
Gasket
Plug
Seal, Mechanical
Seal, Oil
O-Ring
Pin, Dowel
7/04

D4

CYLINDER
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
2

1

8

7

3
4

5

6

9
11

10

37
36

35

12
16

5
13

17
18

31

34

33

15
14

19

32
24

8

23

21

22

20

25

30

26
27
28
29

16

E 2004 Polaris Sales Inc.

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

3083166
3081497
3081330
3084857
3084994
3084858
3084870
3084877
3084866
3084867
3085073
3085074
3084861
3084860
3084859
3084874
3084875
3085854
3084864

Qty. Description

1
1
2
2
4
2
1
10
1
1
1
1
1
1
2
10
4
1
1

Asm., Band, Adapter (Incl. 2)
Screw
Bolt, Socket Head
Pin, Straight
Guide, Valve
Seal, Intake Valve
Adapter, Water Out
Bolt, Flange
Adapter, Camshaft
O-Ring
Cover, Rocker
Gasket, Rocker Cover
Gasket
Plug
Seal, Exhaust Valve
Bolt, Flange
Bolt, Cylinder Head
Bolt, Rocker Shaft
Support, Valve Rocker Shaft

Ref. Part No.

20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

3084876
3084863
3080530
3087199
3085326
3087266
3084849
3084873
3089241
3086747
3085370
3084862
3089242
3085075
3086781
3085337
3085527
3084879

Qty. Description

4
1
2
2
2
2
1
4
1
1
1
1
1
1
2
1
1
1

Bolt
Support, Valve Rocker Shaft
Washer, Lock
Nut
Stud
Pipe, Knock
Union, Oil Pump
Bolt, Flange
Cylinder (Incl. 29)
Pipe, Elbow, 2
Gasket, Cylinder
Plug, Blind
Cover, Camshaft
Gasket, Exhaust
Bolt, Flange
Gasket, Head
Head, Cylinder (Incl. 4-6,13-15,24,31)
Adapter
7/04

D5

CRANKSHAFT and PISTON
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH
4
1

3

2
1
5

6

7

21
8
9

20

10

E 2004 Polaris Sales Inc.

11

12

15
19

16
18

13

17

14

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.

1 3085534
2 ------3 3087230
3087231
3087232
4 3087233
3087234
3087235
5 3085815
6 3088719
7 3087090
8 3086206
9 3085343
10 3085024
11 3089573
3089574

Qty. Description

2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1

Clip
Pin, Piston
Piston Set (Std)(Incl. 1)
Piston Set (0.25 mm O/S)(Incl. 1)
Piston Set (0.50 mm O/S)(Incl. 1)
Ring Set, Piston (Std)
Ring Set, Piston (0.25 mm O/S)
Ring Set, Piston (0.50 mm O/S)
Bearing, Ball
Crankshaft 2
Pin, Crank
Rod, Connecting
Bearing, Large End
Ball, Steel
Asm., Crankshaft (Incl. 6-12)
Crankshaft 1

Ref. Part No.

12 3089245
13 3085404
14 3084895
3084896
3084897
15 3240088
3084892
3084893
3084894
16 3084882
17 3085528
18 3086767
19 3083905
20 3081447
21 3081543

Qty. Description

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Balancer, Gear 1
Shaft, Balancer
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
Spacer (0.6)
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
Sprocket 1
Nut, Slit
Washer
Nut, Lock
Key
Key, Woodruff
8/04

D6

CARBURETOR
SPORTSMAN 400 A05MH42AB and SPORTSMAN 400 A05MH42AG and SPORTSMAN 400 A05MH42AH

1
2

45

5

E 2004 Polaris Sales Inc.

44

6

43
3
4

42

7
13
10

41

8

12

11

14

9

16
15

40
39

17
18
37

38

21

19
22

25

36

23

26

35

24

27

34
33

28

32

29
30
31

D7

21

20


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