Polaris A00BG50AA, Parts Manual

Page 1: ...PARTS MANUAL PN 9915485 and MICROFICHE PN 9916574 3 00 SCRAMBLER 500 Model A00BG50AA Rev 02 E 2000 Polaris Sales Inc ...

Page 2: ...BUMPER and SHIELDS A7 FRONT CAB A5 FRONT HOUSING B3 4 FRONT STRUT B6 FRONT WHEEL B7 FUEL PUMP E3 FUEL TANK A14 G GEAR SELECTOR D1 GEARCASE C11 14 GEARCASE BRAKE and CHAIN COVER MOUNTING C2 H HANDLEBAR HEADLIGHT B10 I INTAKE and EXHAUST D8 M MAGNETO E1 O OIL FILTER D14 OIL PUMP D13 OIL TANK A13 P PROP SHAFT B2 R REAR BRAKE MASTER CYLINDER C4 REAR CAB A6 REAR CALIPER MOUNTING C3 REAR WHEEL DRIVE C5 ...

Page 3: ...NGINE Engine Model Number Engine Type Lubrication Type Bore Stroke mm Displacement cc s Compression Ratio Cooling Alternator Output Elec Start w Recoil Back Up Carburetors no of size Main Jet Pilot Jet Needle Jet Cut Away Air Screw Jet Needle Ignition Ignition Type Deg BTDC Spark Plug Gap inches Spark Plug Type Exhaust EH50PLE04 4 Cycle Single Cylinder Dry Sump 92 0x75 499 10 2 Full Stroke Liquid ...

Page 4: ...CRAMBLER 500 ATV PUBLICATION NUMBERS MODEL MODEL NO OWNER S MANUAL OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Scrambler 500 A00BG50AA 9915299 9915470 9915485 9916574 9915506 ...

Page 5: ...288 1 Cover Front Blazing Red 9 2631988 288 1 Cab Front Blazing Red w Warning Decals 10 7522026 2 Screw 11 7558301 2 Washer Flat 12 7558201 2 Washer Flat 13 7621472 8 Rivet 14 7542122 24 Nut Nylok 15 7555859 16 Washer Flat 16 5211131 067 2 Bracket Mudflap 17 5811831 5850150 1 1 Mudflap Front LH Mudflap Front RH 18 1013083 067 1040691 067 1013249 067 1 1 2 Footpad RH If built before 11 22 99 Footpa...

Page 6: ...et 11 5410414 6 Bumper Rubber 12 5211033 2 Bracket Lever Retainer 13 7621403 1 Rivet 14 5810991 1 Foil Rear Cab Small 15 7073761 1 Decal Carb Information 16 7077446 1 Decal Filter Element 17 5432820 288 1 Cab Rear Blazing Red 18 7670057 2 Nut Speed U Type 19 2632275 1 Shield Muffler 20 7542122 17 Nut Nylok 21 7517264 4 Screw 22 5432831 2 Plug End Cap Ribbed 23 5241403 067 1 Guard Clutch 24 7661638...

Page 7: ...Front 7 7542122 4 Nut Nylok 8 7555859 4 Washer Flat 9 5432378 070 1 Plate Skid Bumper 10 7517264 4 Screw 11 7517561 7 Screw 12 5242694 067 2 Bracket Radiator Shield 13 7547085 7 Nut U Type 14 7558201 2 Washer Flat 15 5242997 067 1 Shield Radiator Side RH 16 7515399 2 Screw 17 5242996 067 1 Shield Radiator Side LH 18 7512252 2 Screw 19 7670088 4 Clip Dart 20 5242683 067 1 Shield Upper Radiator 21 2...

Page 8: ...5 4110264 4010278 4010321 1 1 1 Switch Ignition Incl Key Key Blank Series 2000 6700 6800 NOTE Spare key must be cut from existing key Key Blank Series 2200 2300 2700 2800 NOTE Spare key must be cut from existing key 6 5433733 1 Nut Ignition 7 5431976 1 Panel Control Outer 8 5432090 1 Nut Ignition Switch 9 7512026 2 Screw 10 2460723 1 Harness Indicator 11 7080229 1 Nut Choke Slide 12 5431975 1 Pane...

Page 9: ... 1 Line Fuel 10 7052065 1 Fitting Barbed 90 Degree 11 7080869 1 Clamp 12 8450050 63 1 Hose Lower 13 5411108 1 Hose Upper 14 7080614 2 Clamp Hose 15 4010202 1 Switch Thermal 16 2511189 1 Cap Pressure 17 1240015 1 Radiator U Flow 18 7515133 2 Bolt 19 7052181 1 Valve Drain Cock 20 5020937 2 Spacer Mount Radiator 21 3110032 2 Mount Rubber Radiator 22 7080492 1 Cable Tie 23 7670090 1 Clip Dart 24 41700...

Page 10: ...1 2 Dampener Vibration 3 5010192 2 Bushing 4 1261006 029 1 Silencer 5 7041804 4 Spring Exhaust 6 1261005 029 1 Pipe Exhaust 7 5243518 2 Seal Exhaust 8 7512232 2 Screw 9 5242344 067 1 Bracket Exhaust 10 7542301 1 Nut 11 3110064 1 Mount Torque Stop 12 7042029 1 Spring Exhaust 13 7512666 2 Bolt 14 7542324 2 Nut Nylok 15 7555716 2 Washer Flat 16 5410436 2 Washer Rubber 5 99 ...

Page 11: ...A11 ENGINE MOUNTING Scrambler 500 A00BG50AA 19 33 46 2 3 5 6 7 8 10 11 4 17 18 9 9 22 20 25 26 27 28 29 30 31 32 36 40 41 43 42 44 45 40 9 13 14 15 16 12 47 35 34 12 39 1 10 38 37 21 23 2 24 1 1 1 1 9 ...

Page 12: ...55815 2 Washer 25 5410421 1 Boot Clutch Intake 26 7080511 1 Clamp Narrow Band 27 5430261 1 Bushing 28 5210748 1 Washer Flat 29 7575202 1 Washer Interlock 30 7512566 1 Bolt 31 1 Asm Drive Clutch ATV 06 See Drive Clutch Pg B14 Ref 14 32 1 Bracket Retainer Seal See Clutch Cover Pg C8 Ref 21 33 1040688 067 1 Mount Engine 34 7515398 2 Screw 35 7542324 2 Nut Nylok 36 3110067 1 Mount Rubber 37 7080474 2 ...

Page 13: ... 7051524 1 Plug 7 7517102 1 Bolt Banjo 8 7555896 2 Washer Copper 9 7052213 1 Tube Banjo Return 10 5432289 1 Dipstick 11 5410889 1 O Ring 12 5411036 AR Hose Formed 13 7080474 1 Clamp Hose 14 7052106 1 Fitting 1 4 to 3 8 15 2530014 1 Screen Oil Filter 16 5131785 1 Tank Oil LH 17 7542122 1 Nut Nylok 18 5411042 1 Grommet 19 5410828 2 Grommet Mounting Reservoir 20 5333204 2 Bushing 21 7558301 2 Washer ...

Page 14: ... 600 AR Line Fuel 7 5431053 1 Vent Tank 8 7512249 2 Screw 9 7552801 2 Washer Spring Lock 10 7555859 2 Washer Flat 11 5811526 1 Seal Foam 12 5332457 2 Spacer 13 7542143 2 Insert 14 7555726 1 Washer Flat 15 5431021 1 Lever Fuel 16 7511840 1 Screw 17 5432291 1 Grommet 18 7041209 1 Spring Lever Compression 19 5431391 1 Extension Fuel Lever 20 7515136 2 Screw 21 7080003 6 Clamp Hose Red 22 2530009 1 Fi...

Page 15: ...Decal POLARIS 5 7074935 1 Decal Warning AWD Switch 6 7078315 1 Logo 45th Anniversary 7 7078430 2 Decal Scrambler 8 7078435 1 Decal Front Cover 500 L C 4 Stroke 9 7078354 1 Decal Warning Discretionary 10 7078577 1 Decal Drain Recoil 11 7079604 1 Decal Warning Override AWD 12 7078253 1 Decal Age Warning 13 7077801 1 Decal Tank Side LH 14 7077920 1 Decal Passenger Warning 15 7074690 1 Decal Caution T...

Page 16: ...on 1 5433457 1 Guard Prop Shaft Side 2 7512232 6 Screw 3 5433154 1 Guard Prop Shaft Front 4 5411092 1 O Ring 5 3260131 1 Yoke Prop Shaft Transmission 6 3260139 1 Shaft Prop 7 1590256 2 Joint Cardan 8 3260133 1 Yoke Front Gear Case 9 1380124 1 Asm Prop Shaft Incl 5 8 10 7661913 1 Pin Spring 11 7558301 2 Washer Flat 9 99 ...

Page 17: ...33698 1 Pinion Input 8 3233541 1 Bushing 9 3233319 1 Seal 10 3233697 1 Bushing 11 3233324 1 Washer 12 3233711 1 Plug Oil Fill 13 7080409 1 Clamp Wire Routing 14 8450003 1525 AR Line Fuel 15 7080307 1 Clamp Hose 16 3233524 1 Tube Vent 17 3233696 1 Gearcase 18 3233710 3233694 3233695 1 1 1 SubAsm Output Shaft Front Housing Shaft Output Gear 29T 19 3233020 1 Bearing 20 3233554 AR Shim 21 3233693 1 O ...

Page 18: ...aining 6 3233589 1 Bearing 7 3233726 1 Pinion Input 14T 8 3233541 1 Bushing 9 3233319 1 Seal Oil 10 3233697 1 Bushing 11 3233324 1 Washer 12 3233711 1 Plug 13 7080409 1 Clamp 14 8450003 1525 AR Fuel Line 15 7080307 1 Clamp Hose 16 3233524 1 Tube Vent 17 3233696 1 Gearcase Front Housing 18 3233725 1 Shaft Output 29T 19 3233020 1 Bearing Ball 20 3233554 AR Shim 21 3233693 1 O Ring 22 3233724 1 Cover...

Page 19: ...1 1 Asm Drive Shaft Splined 2 5222299 1 Sleeve Drive Shaft Seal 3 3260121 1 Clamp Band 4 7670092 1 Circlip 5 2201015 1 Kit Boot Replacement 6 1380060 1 Shaft Replacement Incl 4 7 1380061 1 Cardan Replacement Incl 4 6 8 9 8 3260104 1 Kit Cross and Bearing 9 3260101 1 Yoke Splined 10 7661913 2 Pin Spring 11 3260123 1 Clamp Band 12 2200960 2 Kit Drive Shaft Assembly w Sleeve Neapco 6 01 ...

Page 20: ...iper RH See Front Brake Pg B8 for Details 11 3554509 4 Bearing Tapered Roller 12 3554507 4 Bearing Tapered Roller Cup 13 5222193 2 Sleeve Hubstrut Seal 14 7080306 2 Fitting Lubrication 15 2410133 2 Coil Magnetic 16 2201311 2201312 1 1 Asm Hubstrut LH Incl 9 13 16 Asm Hubstrut RH Incl 9 13 16 17 7041603 067 2 Spring Coil Strut 18 5243364 2 Retainer Spring 19 5432871 2 Ball Pivot Bottom 20 7515339 4...

Page 21: ...Splined Drive Shaft 6 3554506 4 Bearing Tapered Roller Cone 7 3554507 4 Bearing Tapered Roller Cup 8 7515523 8 Stud 9 1520243 2 Asm Hub Incl 3 7 8 10 3250028 2 Cage Roll 11 3250010 12 Roll 12 3250032 2 Spring Garter 13 1321814 2 Spacer 14 3250030 2 Cam 15 7052045 2 Plug Magnetic Drain 16 5411264 2 Tire Titan 23x7 10 17 7556004 2 Washer 18 7661401 2 Pin Cotter 19 5410470 2 O Ring 20 5432611 2 Cap H...

Page 22: ...1 Caliper Brake LH Caliper Brake RH 4 1930665 1 Kit Piston and Seals Incl 5 7 5 5410779 1 Ring Square Molded 094 6 5410780 1 Ring Square Molded 103 x 134 7 5132294 1 Piston Brake Long 8 5410494 1 Boot Pin Seal 9 4 Washer Flat See Front Strut Pg B6 Ref 8 10 4 Washer Lock See Front Strut Pg B6 Ref 7 11 4 Screw See Front Strut Pg B6 Ref 6 12 5410495 1 Boot Bushing 13 1910412 2 Mount Caliper 14 220090...

Page 23: ...11920 1 Boot Seal Rod End 11 7517674 2 Bolt 12 7556099 4 Washer Flat 13 7546904 2 Nut 14 7661203 4 Pin Cotter 15 1 Asm Hubstrut See Front Strut Pg B6 Ref 16 16 7080927 2 Joint Ball 17 5211121 2 Bracket Ball Joint 18 7512284 4 Screw 19 5410548 2 Boot Rubber 20 7542438 2 Nut Castle 21 7512084 4 Screw 22 5431150 5431149 1 1 Shield CV Joint LH Shield CV Joint RH 23 5431596 4 Bushing A Arm Long 24 5020...

Page 24: ...lebar Cover 6 1 Asm Master Cylinder See Controls Master Cylinder Brake Line Pg B13 Ref 1 7 5432926 1 Spacer Switch LH 8 4010262 1 Switch Handlebar Hi Lo Rev Override 9 7517625 1 Screw Set 10 5432952 1 Plug Hole 11 5431030 2 Grip Handlebar 12 7080138 4 Cable Tie 13 7542324 2 Nut Nylok 14 7558402 2 Washer Flat 15 7558301 2 Washer Flat 16 7542122 6 Nut Nylok 17 5241973 067 1 Bracket Headlight 18 7080...

Page 25: ...g Console 3 7080510 1 Fitting Lubrication 90 Degree 4 7515321 2 Bolt 5 7555878 3 Washer 6 5410772 2 O Ring 7 5431571 1 Spacer Steering Post 8 7543203 1 Nut 9 7661633 1 Pin Cotter 10 5431570 1 Bushing Steering Lower 11 7661632 2 Rivet 12 5431574 1 Plug Grease Steering 13 7080433 1 Fitting Lubrication 14 5433416 1 Bushing Steering Upper 15 5222999 067 1 Bracket Steering Bushing Upper 16 7542324 2 Nu...

Page 26: ... 3 1 5 4 6 2 Ref Part No Qty Description Ref Part No Qty Description 1 5433806 1 Cover Throttle Control 2 5410193 1 O Ring 3 5411439 1 O Ring 4 7080709 1 Cable Throttle Control 5 2010188 1 Asm Throttle Control Incl 1 3 6 6 2010191 1 Asm Throttle Clamp 3 00 ...

Page 27: ... Master Cylinder Piston 7 1930804 1 Rivet 8 2201034 1 Kit Brake Lever w Parking Brake Latch Incl 7 9 11 9 1 Spring Flat 10 1930806 1 Nut 11 2201090 1 Kit Park Brake Lever Incl 7 9 12 1930792 2 Screw 13 1930805 1 Screw 14 1 Ring Square 15 1930762 1 Line Brake Upper w Fittings 16 4110164 1 Switch 17 1930873 1 Line Brake Hand Rear 18 7080138 8 Cable Tie 19 7080539 1 Clamp 20 7621462 1 Rivet Pop 21 19...

Page 28: ...7041157 1 Clutch Spring 5 5430945 6 Washer Multilube 6 1321457 3 Roller and Bushing 7 5431936 6 Button Clutch Stemless 8 5210752 5242981 5210753 5210754 AR AR AR AR Spacer 020 Spacer 025 Spacer 032 Spacer 050 9 5630710 3 Weight Shift 10 WH 10 7512266 3 Bolt Shoulder 11 7541906 3 Nut FLEXLOC 12 3576504 1 Bearing Moveable 1 2 13 5020422 3 Pin Roller 14 1321632 1 Asm Drive Clutch ATV 06 Incl All Less...

Page 29: ... Incl 7 17 3 5220646 1 Washer Domed 4 7552901 1 Washer Spring Lock 5 7515384 1 Bolt 6 3211077 1 Belt Drive 7 7555898 AR Washer 020 8 7556076 AR Washer 025 9 7556804 AR Washer 10 3576504 1 Bearing Moveable 1 2 11 3576511 1 Bearing Moveable 1 12 7041499 1 Spring Clutch 13 5131446 1 Ramp Stationary 14 5210752 1 Spacer 15 7710448 1 Ring Retaining 16 7511854 3 Bolt 17 5430766 3 Button Ramp 5 99 ...

Page 30: ...632 2 Screw 2 5242456 067 2 Bracket Transmission 3 7542423 4 Nut Flange 4 7512492 2 Screw 5 5433109 1 Guide Chain Transmission 6 7558301 2 Washer Flat 7 7512276 2 Screw 8 7555806 4 Washer Flat 9 7517646 1 Screw 10 3221041 1 Sprocket 13T 11 7710434 1 Ring Retaining 12 5211065 5210764 5211517 AR AR AR Shim 010 Shim 020 Shim 030 13 7517640 1 Screw 5 99 ...

Page 31: ...ement Piston Caliper Rear 4 5410988 4 Seal 5 1930873 1 Line Brake Hand Rear 6 1910381 1 Line Brake Foot Rear 7 4020139 2 Clip Rosebud 8 7670102 2 Clip Silencer Box 9 1930674 3 Bolt Banjo 10 5131759 1 Bushing Caliper Mount 11 7558402 2 Washer Flat 12 7552901 2 Washer Spring Lock 13 7512312 2 Bolt 14 5131786 1 Mount Caliper Lower 15 5131787 1 Mount Caliper Upper 16 7512325 3 Bolt 17 5242291 067 1 Gu...

Page 32: ...lok 5 7512208 1 Screw 6 7080003 2 Clamp Red 7 1910404 1 Hose Reservoir 8 1930854 1 Reservoir 9 7558301 4 Washer Flat 10 7661401 1 Pin Cotter 11 7555919 2 Washer 12 5431107 2 Bushing 13 1910375 067 1 Mount Brake 14 1930674 1 Bolt Banjo 15 5410988 2 Seal 16 1 Line Foot Brake Rear See Rear Cal iper Mounting Pg C3 Ref 6 17 7512278 2 Screw 18 1910311 1 Asm Foot Brake Master Cylinder 19 7542324 2 Nut Ny...

Page 33: ...Description 1 7512673 8 Bolt 2 2200341 2 Kit Hub Rear Incl 1 4 6 10 3 7547037 8 Nut Flange 4 7555796 2 Washer Cone 5 7543005 2 Nut Castle 6 7661404 2 Pin Cotter 7 5411164 2 Cover Dust Hub 8 7555745 2 Washer Flat 9 1525017 2 Valve Rim 10 7670081 8 Retainer Bolt Pushnut 11 1520204 117 2 Rim Rear 12 5411266 2 Tire 22x11 10 5 99 ...

Page 34: ...7515513 6 Stud 7 1520259 1 Hub Brake Disc Incl 6 8 7710496 1 Ring Retaining 9 5010462 1 Spacer Axle 10 5410889 2 O Ring 11 3610070 2 Seal 12 3554518 2 Bearing Cone Tapered 13 3554517 2 Bearing Cup Tapered 14 5132098 1 Housing Axle Rear 15 7080306 1 Fitting Lubrication 16 3225027 1 Link Connector 520 Regina 17 5020944 1 Axle Rear 18 5211585 067 1 Guard Sprocket 19 7547108 6 Nut 20 3221111 076 1 Cha...

Page 35: ... 600 AR Line Breather 9 7080544 2 Clamp Hose 10 2530029 1 Filter Breather 11 7080694 1 Clamp Hose 12 5411847 1 Hose Breather 13 7080511 1 Clamp Band 14 5411414 1 Boot Carb 15 7080413 2 Clamp 16 5432473 1 Duct Carb Inlet 17 5830128 1 Gasket Duct 18 7080699 2 Clamp Hose 19 5432774 1 Box Air 20 5411873 1 Hose Breather Oil Tank 21 5811650 1 Foil Air Box 22 5432377 1 Plug Trap 23 8450059 150 AR Line Fu...

Page 36: ... 5521301 1 Seal Clutch Cover 10 5433451 1 Cover Clutch Outer 11 7670051 1 Clip Clutch Cover 12 7512093 5 Screw 13 7074946 1 Decal Clutch Cover 14 7077377 1 Decal Eng Clutch Modification 15 7074782 1 Decal Automatic Transmission 16 7512094 2 Screw 17 7080761 2 Cable Tie 18 5411489 1 Boot Duct 19 5433409 1 Duct Clutch Hi Flow 20 3 Screw and Washer See Crankcase Pg D4 Ref 6 21 5240409 067 1 Bracket R...

Page 37: ...ip 12 7571602 4 Washer 13 7512027 2 Screw 14 5810290 3 Pad Battery 15 5431769 1 Cover Battery 16 2200361 2 Kit Battery Bolt 17 4010095 1 Cable Battery Engine Black 18 7010032 2 Hook Battery Strap 19 5410424 1 Strap Battery Holddown 20 5432077 1 Tube Vent 21 4140006 1 Battery 22 4010094 1 Cable Battery Solenoid Red 23 4010093 1 Cable Solenoid Starter 24 7541925 4 Nut Nylok 25 7512007 2 Bolt 26 7670...

Page 38: ... 1 Shock Gas 8 5631045 1 Retainer Spring 9 7515415 1 Screw 10 7661046 2 Rivet 11 5432727 1 Guide Pad Chain 12 7080510 2 Fitting Lubrication 13 7547082 1 Nut 14 7556035 1 Washer Flat 15 5433412 2 Bushing Swing Arm RH 16 5131697 2 Bolt Pivot Swing Arm 17 5131696 1 Bushing Pivot RH 18 1541395 1 Asm Swing Arm Incl 12 15 29 19 7078572 1 Decal Chain Free Play 20 5432854 1 Guard Chain 21 7515304 1 Screw ...

Page 39: ...rambler 500 A00BG50AA 27 16 12 11 51 57 60 58 56 41 2 34 10 3 4 5 6 9 50 49 8 46 55 15 14 13 44 43 42 23 22 25 21 26 48 32 47 20 16 59 1 54 7 52 45 17 19 18 53 38 29 30 39 37 36 35 33 31 4 15 2 34 41 41 24 32 34 28 40 ...

Page 40: ...4 3233054 1 Washer 25 3233045 1 Ring Retaining 26 3233548 1 O Ring 27 3233616 4 Screw and Washer 28 3233635 1 H R Switch 29 3233325 1 Plug 30 3233324 1 Washer 31 3233556 1 Cover Snorkel 32 3233539 11 Screw 33 3233555 1 O Ring 34 3233248 3 Seal 35 3233554 1 Shim 36 3233553 1 Subassembly Snorkel Gear 37 3233552 1 Bushing Garlock 38 3233634 1 Gearcase RH Mach 39 3233037 8360009 600 1 AR Tube Vent Lin...

Page 41: ...Scrambler 500 A00BG50AA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 31 33 34 35 38 36 37 32 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 4 6 21 32 29 32 13 2 12 30 30 30 32 ...

Page 42: ...g 23 3233548 1 O Ring 24 3233691 4 Screw and Washer 25 3233635 1 Switch H R 26 3233711 1 Plug 27 3233324 1 Washer 28 3233556 1 Cover Snorkel 29 3233539 11 Screw 30 3233248 3 Seal Triple Lip 31 3233555 1 O Ring 32 3233020 4 Bearing Ball 33 3233554 AR Shim 34 3233723 1 Subassembly Snorkel Gear 35 3233552 1 Bushing Garlock 36 3233037 8360009 600 1 AR Tube Vent Line Fuel 37 3233636 1 Decal Switch 38 3...

Page 43: ...over 2 7512024 1 Screw 3 5411007 1 Knob Gear Selector 4 5411008 1 Grommet Shifter Gear 5 5131976 2 Spacer Shifter 6 5433103 2 Mount Gear Selector 7 7546707 2 Nut FLEXLOC 8 7061014 1 Rod End 6mm RH 9 7546701 1 Nut RH 10 5020955 1 Rod Shift Linkage 11 7546702 1 Nut LH 12 7061013 1 Rod End 6mm LH 13 7515133 2 Bolt 14 1012797 067 1 Selector Gear 5 99 ...

Page 44: ...d Cap 9 1500011 1 Piston IFP 10 1500099 1 Asm Cap Reservoir ATV Fox Shock Incl 11 12 13 11 1500097 1 Retaining Ring ATV Fox Shock 12 1500072 1500019 1500022 1 1 1 Asm Air Valve Screw O Ring 13 1500098 1 O Ring ATV Fox Shock 14 1500286 1 Asm Reservoir 15 1500283 1 Body 16 1500013 1 Eyelet 17 1500102 1 Bushing 18 1500103 2 Bushing Eyelet 19 5410987 1 Bumper Compression 20 1500284 1 Shaft 21 1500282 ...

Page 45: ... Valve Shock 1 1 x 377 x 008 4 1500026 1 Valve Shock 1 25 x 377 x 010 5 1500047 1 Valve Shock 80 x 377 x 010 6 1500046 1 Valve Shock 90 x 377 x 010 7 1500049 1 Valve Shock 1 1 x 377 x 006 8 1500052 1 Valve Shock 1 3 x 377 x 006 9 1500095 2 Valve Shock 1 25 x 377 x 012 10 1500060 1 Valve Shock 1 1 x 377 x 012 11 1500096 1 Valve Shock 1 0 x 377 x 015 12 1500094 1 Valve Shock 90 x 377 x 015 13 150005...

Page 46: ...4 3080676 1 Bearing Ball 5 3084840 2 Pin Dowel 6 3084205 3 Screw and Washer 7 3084839 1 Seal Oil 8 3085525 1 Pipe Air Breather 9 3084842 2 Union 10 3084834 2 Bearing Ball 11 3084835 1 Bearing Ball 12 3084845 1 Plug 13 3084846 1 Gasket Aluminum 14 3084844 1 Spring Valve One Way 15 3086810 1 Valve One Way 16 3084841 10 Bolt Flange 17 3082956 1 Gasket 18 3083453 1 Plug 19 3084837 1 Seal Mechanical 20...

Page 47: ...D5 CYLINDER Scrambler 500 A00BG50AA 2 20 38 23 22 21 12 5 4 37 10 7 34 9 25 29 16 17 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 18 ...

Page 48: ...15 3084875 4 Bolt Cylinder Head 16 3084860 1 Plug 17 3084861 1 Gasket 18 3084862 1 Plug Blind 19 3084215 2 Bolt Flange 20 3085075 1 Gasket Exhaust 21 3085326 2 Stud 22 3080530 2 Washer Lock 23 3080285 2 Nut 24 3085854 1 Bolt Rocker Shaft 25 3084876 4 Bolt 26 3084864 1 Support Valve Rocker Shaft PTO 27 3084863 1 Support Valve Rocker Shaft MAG 28 3084838 2 Pin Straight 29 3084849 1 Union Oil Pump 30...

Page 49: ... 3080676 1 Bearing 5 3085815 1 Bearing Ball 6 3085812 1 Crankshaft 2 7 3085341 1 Pin Crank 8 3085813 1 Rod Connecting 9 3085400 1 Bearing End Large 10 3085024 1 Ball Steel 11 3085861 3085945 1 1 Asm Crankshaft Incl 4 5 12 20 Crankshaft 1 12 3085852 1 Gear 1 Balancer 13 3086837 1 Shaft Balancer 14 3084895 3084896 3084897 1 1 1 Spacer 0 8 Spacer 1 0 Spacer 1 2 15 3240088 3084892 3084893 3084894 1 1 ...

Page 50: ...cl 8 9 7 3084913 1 Asm Rocker Arm Exhaust Incl 8 9 8 3084912 4 Nut 9 3084911 4 Screw Adjusting 10 3084909 1 Shaft Rocker 11 3084908 8 Collet Valve 12 3084907 4 Retainer Spring 13 3084906 4 Spring Valve 14 3085855 1 Camshaft Incl 15 18 15 3086838 1 Pin Dowel 16 3085348 1 Lever Release 17 3085076 1 Spring Return 18 3084899 1 Pin Dowel 19 3084914 1 Sprocket 2 20 3081657 3 Bolt and Washer 21 3084916 1...

Page 51: ...D9 CARBURETOR Scrambler 500 A00BG50AA 14 31 20 2 8 3 9 5 6 19 40 38 11 4 29 13 28 29 27 26 41 35 32 33 36 47 42 7 52 50 16 37 51 21 49 43 1 24 23 30 17 10 12 48 44 34 39 22 25 18 15 14 45 46 ...

Page 52: ... 3131290 1 Block Jet 21 3130916 1 O Ring 22 3131208 1 Cap 23 3130593 1 Asm Plunger 24 3130538 1 Spring 25 3130199 1 Cap Plunger 26 3130519 1 Cap 27 3130518 1 E Ring 28 3130517 1 Packing 29 3130515 2 Seal 30 3130906 2 Screw 31 3130907 1 Valve Throttle 120 32 3130934 1 Adjuster 33 3130525 1 Spring 34 3130523 1 Washer 35 3130522 1 O Ring 36 3130624 1 Jet Pilot 40 37 3130922 1 Valve Needle 1 5 38 3130...

Page 53: ... Return 3 3083378 1 Ratchet 4 3083379 1 Spring Friction 5 3084744 1 Plate Friction 6 3085266 1 Bolt and Washer 7 3083453 2 Plug 8 3082956 2 Gasket 9 3083669 1 Bushing Starter 10 3083185 1 Spring Spiral 11 3084750 1 Bushing 12 3084933 1 Gasket Recoil 13 3084877 9 Bolt Flange 14 3085856 3085943 1 1 Asm Recoil Incl 1 6 9 11 14 15 Starter Case Incl 11 15 3085083 1 Asm Rope 5 99 ...

Page 54: ...940 1 Thermostat 2 3085352 1 Switch Thermostat 3 3084191 2 Clamp Hose 4 3085857 1 Hose Main 5 3085359 1 Bolt Flange 6 3082758 1 Gasket Aluminum 7 3085351 1 Cover Water Pump 8 3086840 1 Gasket Water Pump 9 3085077 1 Nut Self Lock 10 3083138 1 Gasket Aluminum 11 3084935 1 Impeller 12 3084942 1 Washer Seal 13 3084877 4 Bolt Flange 6 98 ...

Page 55: ...1 1 Asm Oil Pump Incl 1 8 10 15 Pump Oil Case 1 5 3085535 1 Screw 6 3084955 2 Pin Dowel 7 3084954 2 Pin Dowel 8 3084953 1 Washer 9 3084962 3 Bolt and Washer 10 3084947 1 Pump Oil Case 3 11 3084950 1 Rotor Inner 12 3084951 1 Rotor Outer 13 3084956 1 Unit Oil Strainer 14 3084205 3 Screw and Washer 15 3085818 1 Shaft Pump 16 3085859 1 Gear 2 Pump 17 3085820 2 Bolt Flange 18 3084959 3084960 3084961 AR...

Page 56: ...A00BG50AA 1 4 5 3 3 3 2 2 2 2 2 Ref Part No Qty Description Ref Part No Qty Description 1 3084963 1 Filter Oil 2 3084846 8 Gasket Aluminum 3 3086815 4 Bolt Banjo 4 3084964 1 Pipe Oil Delivery 1 5 3085638 1 Pipe Oil Delivery 2 6 98 ...

Page 57: ...0 04730 after Plate S 00 04730 after 7 3081657 5 Bolt and Washer 8 3084973 1 Seal Oil 9 3086821 3086984 1 1 Stator Incl 13 Up to S 00 04730 Stator Incl 13 S 00 04730 after 10 3085563 3086985 3 3 Screw and Washer Up to S 00 04730 Screw and Washer S 00 04730 after 11 3085554 1 Band Pulse 12 3084976 2 Screw and Washer 13 3085360 1 Coil Pulser 14 3084977 1 Clamp 15 3081256 3 Screw and Washer 16 308563...

Page 58: ...06 1 Brush Set Carbon 3 3083649 2 Nut Flange 4 3084408 3 O Ring 5 3082038 2 Bolt and Washer 6 3085034 1 Asm Bracket Rear 7 3085353 1 Asm Armature 8 3085033 1 Asm Bracket Front 9 3240114 1 O Ring 10 3084983 2 Asm Set Bolt Incl 4 11 3085394 1 Asm Gear Shaft Incl 13 17 12 3084405 2 Ring Rubber 13 3083737 1 Washer Gear Shaft 14 3084412 1 Clip 15 3084411 1 Spring Weight 16 3084410 1 Spring Return 17 30...

Page 59: ...BG50AA 4 1 3 2 2 4 Ref Part No Qty Description Ref Part No Qty Description 3085275 1 Asm Fuel Pump Incl 1 4 1 3084999 1 Screw and Washer 2 3085356 2 Screw and Washer 3 3084591 4 Screw and Washer 4 3084998 1 Gasket Set Diaphragm 5 99 ...

Page 60: ... Manual 00 ATV Supplement Owner s Manual 00 Scrambler 500 2 3085544 1 Asm Tool Kit Incl 4 9 3 2870725 1 Gauge Tire Pressure 4 3085001 1 Wrench Open 8 10mm 5 3085002 1 Wrench Open 12 14mm 6 3085568 1 Wrench Box 125mm 7 3085569 1 Puller Spark Plug Wrench Handle 8 3082657 1 Screwdriver 9 2682572 1 Pouch Tool Kit 10 5211627 1 Wrench Spanner 3 00 ...

Page 61: ...PRINTED IN THE USA PARTS MANUAL PN 99155485 and MICROFICHE PN 9916574 3 00 ...

Page 62: ...Changed pages in 9915485 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A cover toc x B C D E F G 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...