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Discussion Starter #1
I have a what I believe to be a 2004 Sportsman 500 H.O. The information I pulled off a VIN decoder is below:

Image of VIN stamped on frame here


2004 POLARIS SPORTSMAN 500/RSE/DUSE

VIN: 4XACH50A84A316037

World region: North America

Manufactured in: USA

Year: 2004

Make: Polaris

Model: SPORTSMAN 500/RSE/DUSE

Body style: All Terrain

Drive type: RWD

Cylinders: 1 Cylinders



There appears to be so many variations of these Sportsman 500's that trying to find parts for the correct one is becoming a pain. If I could be positive about what I actually have it might make things simpler.

looking at partspitstop.com I see a listing of 2004 sportsman 500's with engine numbers? next to them such as "A04CH50AA SPORTSMAN 500 (2004)". None of these numbers match my VIN exactly as you can see. There is also the sportsman 500 4x4 and then the sportsman 500 HO. My 500 is a 4x4 (AWD) it has the selector switch to change back to 2WD as well.
 

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I use to be able to do this, but I cant anymore. You are going to have to call a dealer. You do have an 2004. All the Sportsman 500's in that year where 4x4.

If you give then VIN to a dealer, they will be able to tell you your A04CH50AA number...a hint, the last two letters "AA" "AC" etc, are color codes for plastics and decals and do not play a factor in what parts you need in non-color related. There really are not as many models as you think, and 95% of the parts are the exact same from model to model in that year.

But the only way to get the model # is to call the dealer and ask for it. Again, I wish I could help. 3 weeks ago I could have.
 

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The VIN number says it's a 2004 Sportsman 500 but the VIN doesn't have the info to determine if it's a 500 or 500HO. The 500 will have a 34mm carb and the 500HO will have a 40mm carb. Maybe the dealer can help if the difference is in the last 6 digits. He probably will need to consult Polaris database. You could check the Polaris parts diagrams for the 500 and 500HO and determine which one you have from them.
 

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Discussion Starter #4
The VIN number says it's a 2004 Sportsman 500 but the VIN doesn't have the info to determine if it's a 500 or 500HO. The 500 will have a 34mm carb and the 500HO will have a 40mm carb. Maybe the dealer can help if the difference is in the last 6 digits. He probably will need to consult Polaris database. You could check the Polaris parts diagrams for the 500 and 500HO and determine which one you have from them.
The body of the atv says its a sportsman 500 HO. So I am pretty sure it is, unless the body was changed out for some reason. I suppose my only solution is to contact the dealer.
 

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Looks like it's the dealer because the Polaris parts listings don't have a 500HO in 2004. There are two series of Sportsman 500's and that's it. Usually the 500HO is listed separately from the 500. Take the serial number that's on top of the recoil housing also.
 

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Discussion Starter #6 (Edited)
Looks like it's the dealer because the Polaris parts listings don't have a 500HO in 2004. There are two series of Sportsman 500's and that's it. Usually the 500HO is listed separately from the 500. Take the serial number that's on top of the recoil housing also.
I took a pic of the sticker on top of the recoil housing..i don't find anything when i search the numbers however. view image here
 

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Looks like the 2004 500's were all HO's. Model number will be AO4CH50??
You'll have to ask the dealer about the last two letters(Color Code) and also the date of manufacture since some parts changed during the year. For example the driven clutch parts can be different depending on date of manufacture. A manual might tell you the last two letters but not the date.
 

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All 500's after 2001 were HO, the "purple is actually realtree camo hat has seen some sun, it changed alot of them to purple
 

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Discussion Starter #11 (Edited)
called the dealership it's a 2004.5 SPORTSMAN 500 (A04CH50AO) (N.B.U. SUB. CAMO)

can't seem to find the wheel bearings on babbittsonline.com though...all I see is axle bearings, unless those are the same things? The part number from the front axel bearing is "3514342 BEARING-AXLE TUBE/HUBSTRUT $59.08"

Being that I need to change out my front wheel bearings, should I replace anything else while I'm in there? tie rod ends for example?

btw, can you guys recommend a place where I can get cheaper aftermarket parts? I see some stuff on ebay/amazon that isn't OEM and has a much nicer price tag.
 

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ATV Registered to: Bryan L. Stewart

Vehicle Identification Number 4XACH50A84A316037
Model Year 2004
Model Number A04CH50AO
Model Description 2004.5 ATV,SPORTSMAN 500,NEW BREAKUP
Engine Serial Number D006370426153
Purchased Date 04/09/2004
Warranty End Date 10/09/2004
Extended Warranty N
Dealer Name MALONE POLARIS

Here is the link for the VIN decoder:

Search-VIN
 

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o.k. the A04CH50AA is the machine model number identification,the two letters you are asking about are,the first A is the options indicator,the next A is color indicator.for 2004 polaris had two build dates for the 500,the first build models were model # A04CH50AA/AC/AE/AG. the late build models(2004.5) were models A04CH50AO/AQ/AR/AS/AT/AV. to get the right part#'s for your machine and to see your model#AO4CH50AA go to polarisindustries.com.you can only get the part#'s from their you cant buy parts their.
 

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i just bought the same ride, i pick it up tommorw at 2. mine needs a u joint and charge the battery and i am ready to ride. when i get mine tommorrow maybe i can help you with your questions and u can help me with some of mine. thx. ps i love the color of the camo. mine is camo also. its the only camo i actually like. i gave 1400 for it. with some accesories. heated grips, rear box, winch, new itp tires etc.
 

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A04CH50AO - 2004.5 ATV,SPORTSMAN 500,NEW BREAKUP - Engine Number : D006370426153 - Production Date 03/04/2004
 

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A04CH50AO - 2004.5 ATV,SPORTSMAN 500,NEW BREAKUP - Engine Number : D006370426153 - Production Date 03/04/2004
OK - is there a question or what is the purpose of the post?
 

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ATV Registered to: Bryan L. Stewart

Vehicle Identification Number 4XACH50A84A316037
Model Year 2004
Model Number A04CH50AO
Model Description 2004.5 ATV,SPORTSMAN 500,NEW BREAKUP
Engine Serial Number D006370426153
Purchased Date 04/09/2004
Warranty End Date 10/09/2004
Extended Warranty N
Dealer Name MALONE POLARIS

Here is the link for the VIN decoder:

Search-VIN
AWESOME.. Thank you.. time to change my profile info once AGAIN..
SO I am not looking for a 2002 service manual.. is it the same as a 2001??
Model Name
SPORTSMAN 500 HO RED
Model Year
2002
Model Number
A02CH50AB
Purchase Date
4/7/2003
VIN
4XACH50A82A552374
Engine Serial Number
D004600226612
 

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AWESOME.. Thank you.. time to change my profile info once AGAIN..
SO I am not looking for a 2002 service manual.. is it the same as a 2001??
Model Name
SPORTSMAN 500 HO RED
Model Year
2002
Model Number
A02CH50AB
Purchase Date
4/7/2003
VIN
4XACH50A82A552374
Engine Serial Number
D004600226612
If this post was never replied to, the service manual you need is publication # 9917202 and it is no longer available from Polaris. The manual is not the same for other years, but it is the same for the 02 400, the DUSE and the Sportsman X. I have a copy in PDF, but it is missing the wiring diagrams.
 
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