SCRAMBLER500 Model#A00BG50AA Rev. 02pi54.com/corp/manuals/Parts/9915485r02.pdf · Titan 23x7x10...

PARTS MANUAL PN 9915485 and MICROFICHE PN 9916574 3/00

SCRAMBLER 500Model #A00BG50AA

Rev. 02

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSScrambler 500 A00BG50AA

Parts Manual

AA-ARM/STRUT MOUNTING B9. . . . . . . . . . . . .AIR BOX C7. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D9-10. . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C8. . . . . . . . . . . . . . . . . . . . .CONTROL PANEL A8. . . . . . . . . . . . . . . . . . . .CONTROLS -

MASTER CYLINDER/BRAKE LINE B13. . . .CONTROLS - THROTTLE ASM./CABLE B12. . . .COOLING SYSTEM A9. . . . . . . . . . . . . . . . . . .CRANKCASE D4. . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D7. . . . . . . . . . . . .CV JOINT B5. . . . . . . . . . . . . . . . . . . . . . . . . .CYLINDER D5-6. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS B1. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B14. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C1. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C9. . . . . . . . . . . . . . .ENGINE MOUNTING A11-12. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A10. . . . . . . . . . . . . . . . . . .

FFOX SHOCK, GAS, RESERVOIR D2. . . . . . . . .FRONT BRAKE B8. . . . . . . . . . . . . . . . . . . . . .FRONT BUMPER and SHIELDS A7. . . . . . . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING B3-4. . . . . . . . . . . . . . . . . . . .FRONT STRUT B6. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B7. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP E3. . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK A14. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR D1. . . . . . . . . . . . . . . . . . . .GEARCASE C11-14. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE/BRAKE

and CHAIN COVER MOUNTING C2. . . . . .

HHANDLEBAR/HEADLIGHT B10. . . . . . . . . . . . .

IINTAKE and EXHAUST D8. . . . . . . . . . . . . . . .

MMAGNETO E1. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL FILTER D14. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D13. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK A13. . . . . . . . . . . . . . . . . . . . . . . . . .

PPROP SHAFT B2. . . . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE MASTER CYLINDER C4. . . . . . .REAR CAB A6. . . . . . . . . . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING C3. . . . . . . . . . . .REAR WHEEL DRIVE C5. . . . . . . . . . . . . . . . .RECOIL STARTER D11. . . . . . . . . . . . . . . . . . . .

SSHOCK VALVING D3. . . . . . . . . . . . . . . . . . . . .STARTING MOTOR E2. . . . . . . . . . . . . . . . . . .STEERING POST B11. . . . . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING C10. . . . . . . .

TTOOL KIT E4. . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D12. . . . . . . . . . . . . . . . . . . . . . .

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

2000 SCRAMBLER 500 SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic DiscHydraulic DiscHydraulic Disc

Hydraulic Lock, All Wheel

CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallon)Gearcase Oil (ounces)Engine Counter Balance 10W30Oil (quarts) InjectorOil (quarts) Engine (OW40)Rack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

2.253.532NANA2

Accessory 30Accessory 60

30Accessory

850

DRIVE TRAINType PVT

DRIVE CLUTCHCenter Distance (inches)Clutch Offset (inches)Clutch WeightSpring Color

101/2

10 WHBlue/Green

DRIVEN CLUTCHHelix AngleSpring Position

40�1-1

DIMENSIONAL FEATURES

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

60N/A776.547

74.533542

48.5045.5

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

PRDSide Lever

N/A4.74/13.06/12:1

13/36 76PN/AN/A

520 O-Ring

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

Titan23x7x1022x11x10

N/A43

N/A

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

Main JetPilot JetNeedle JetCut AwayAir ScrewJet Needle

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

EH50PLE044 Cycle, Single Cylinder

Dry Sump92.0x75

49910:2 Full Stroke

Liquid250W

Standard1/BST40 (CV Type)

15540Y-0NA

2.0 Turn6H25-94-3

CDI30 @ 3500

.028NGKBKR5E

USFS Pending

GRAPHICSBumper Caps/Polyprop.Cargo Box or BedFender, Front/HDPEFender, Rear/HDPEFootwellFrame/SteelFront CoverGrips/TPRHandlebar/SteelHandlebar Cover w/DecalHeadlight Pod/HDPERack, Front/SteelRack, Rear/SteelRims/SteelSeat, VinylSide Panel/HDPESpring, Front/SteelSpring, Rear/SteelTank Cover/HDPETool Box Cover/HDPE

w/lettering Color

N/AN/A

Blazing RedBlazing Red

BlackBlack

Blazing RedBlackBlack

Black/WhiteN/AN/AN/A

SilverBlackN/A

Fire RedFire Red

N/AN/AN/A

LIGHTS/BATTERYHeadlight (watts)Taillight (watts)Brake Light (watts)Indicator Bulb

2 Dual Beam, 30/30 W12 V/8.26 W12 V/26.9 W12 V/1 W

SUSPENSIONFront Type -

Front Travel (inches)Adjustment

Rear Type -Rear Travel (inches)Shock

Adjustment

MacPherson Strut8.2

-- -- -- -- --Progressive Rate Swing Arm

10.5Gas Charged w/Remote

ReservoirThreaded Adjuster

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products withoutnotice.

2000 SCRAMBLER 500 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUALSUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Scrambler 500 A00BG50AA 9915299 9915470 9915485 9916574 9915506

A5

FRONT CABScrambler 500 A00BG50AA

8

9

1415

7

7

1416

17

22

23

4

1819

20

12

13

1

1

11

21

10

14

7

2

3

15

6

5

13

E 2000 Polaris Sales Inc.

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

1 7670060 4 Nut, Speed, U-Clip2 5224718-067 2 Bracket, Cab Mount3 7517386 2 Screw4 1013037-067 1 Frame5 7621432 2 Rivet, Pop6 5211547-067 1 Strap, Fuel Pump Mounting7 7512282 24 Bolt8 5432553-288 1 Cover, Front, Blazing Red9 2631988-288 1 Cab, Front, Blazing Red

(w/Warning Decals)10 7522026 2 Screw11 7558301 2 Washer, Flat12 7558201 2 Washer, Flat

13 7621472 8 Rivet14 7542122 24 Nut, Nylok15 7555859 16 Washer, Flat16 5211131-067 2 Bracket, Mudflap17 5811831

585015011

Mudflap, Front, LHMudflap, Front, RH

18 1013083-0671040691-0671013249-067

112

Footpad, RH (If built before 11/22/99)Footpad, LH (If built before 11/22/99)Footpad (If built after 11/22/99)

19 7661825 8 Rivet20 5431484 2 Trim, Footrest21 5242525-067 2 Bracket, Heel Cleat22 5432763 1 Guard, Rock23 7515179 6 Screw

3/00

A6

REAR CABScrambler 500 A00BG50AA

21

8

17

30

143

1

31

2

20

29

19

15

18

28

26

25

23 24

13

126

5

22

9

1011

16

27

2

26

20221

7

24


1 7621472 4 Rivet2 7555859 10 Washer, Flat3 7512232 2 Screw4 7512242 2 Screw5 7041607 1 Spring, Latch, Light6 1040412 1 Latch, Seat7 5411392 1 Cap, Seat Latch8 2682453-070

2681769-07011

Seat, BlackCovering, Seat, Black

9 5431986 1 Tongue, Seat10 7621479 2 Rivet11 5410414 6 Bumper, Rubber12 5211033 2 Bracket, Lever Retainer13 7621403 1 Rivet14 5810991 1 Foil, Rear Cab, Small15 7073761 1 Decal - Carb Information16 7077446 1 Decal - Filter Element

17 5432820-288 1 Cab, Rear, Blazing Red18 7670057 2 Nut, Speed, U-Type19 2632275 1 Shield, Muffler20 7542122 17 Nut, Nylok21 7517264 4 Screw22 5432831 2 Plug, End Cap, Ribbed23 5241403-067 1 Guard, Clutch24 7661638 4 Rivet25 2670133 2 Reflector, Red26 7512282 16 Bolt27 ------ -- -- -- -- 2 Footpad

(See Front Cab Pg. A5, Ref. 18)28 5850147

585014811

Mudflap, Rear, LHMudflap, Rear, RH

29 5211131-067 2 Bracket, Mudflap30 5810957 1 Foil, Rear Cab31 5220880 2 Bracket, Rear Seat Holddown

3/00

A7

FRONT BUMPER and SHIELDSScrambler 500 A00BG50AA

21

3

5

7

6

9

17

15

20 1319

21

8

8

11

7

13

12

4

1811

11

16

23

24

25

10

1422


1 7558402 2 Washer, Flat2 7512329 2 Bolt3 5811675 1 Plug, Frame4 7547071 2 U-Nut5 5850141 2 Shield, Deflector6 1012773-067 1 Bumper, Front7 7542122 4 Nut, Nylok8 7555859 4 Washer, Flat9 5432378-070 1 Plate, Skid, Bumper10 7517264 4 Screw11 7517561 7 Screw12 5242694-067 2 Bracket, Radiator Shield13 7547085 7 Nut, U-Type

14 7558201 2 Washer, Flat15 5242997-067 1 Shield, Radiator Side, RH16 7515399 2 Screw17 5242996-067 1 Shield, Radiator Side, LH18 7512252 2 Screw19 7670088 4 Clip, Dart20 5242683-067 1 Shield, Upper Radiator21 2670134 2 Reflector, Amber22 7621467 2 Rivet23 5131036 1 Heat Sink24 4060173 1 Regulator, Rectifier25 7512018 3 Screw

9/99

A8

CONTROL PANELScrambler 500 A00BG50AA

1

2

3

5

7

9

1312

5

10

4

8

11

6


1 5430967 1 Plug2 4040054 1 Indicator, Neutral/Reverse3 4040053 1 Indicator, Hot Temperature4 5433534 1 Cover, Key5 4110264

4010278

4010321

11

1

Switch, Ignition (Incl. Key)Key, Blank, Series 2000, 6700, 6800.NOTE: Spare key must be cut fromexisting key.Key, Blank, Series 2200, 2300, 2700,2800. NOTE: Spare key must be cutfrom existing key.

6 5433733 1 Nut, Ignition7 5431976 1 Panel, Control, Outer8 5432090 1 Nut, Ignition Switch9 7512026 2 Screw10 2460723 1 Harness, Indicator11 7080229 1 Nut, Choke Slide12 5431975 1 Panel, Control, Inner13 7080746 1 Cable, Choke

10/00

A9

COOLING SYSTEMScrambler 500 A00BG50AA

14

12

15

27

16

13

12

2120

18

17

29

31 30

25

24

26

28

19

3

6

8

9

104

5

7

22

11

23

32


1 7542122 2 Nut, Nylok2 7558301 2 Washer, Flat3 5432593 1 Shroud, Fan, ATV4 7512084 2 Screw5 5430743 1 Cap, Overflow, Drilled6 5810279 1 Gasket, Overflow Cap7 5431895 1 Plug, Cap8 2520165

543341011

Asm., Surge Tank w/FittingTank, Surge

9 8450003-1525 1 Line, Fuel10 7052065 1 Fitting, Barbed, 90 Degree11 7080869 1 Clamp12 8450050-63 1 Hose, Lower13 5411108 1 Hose, Upper14 7080614 2 Clamp, Hose15 4010202 1 Switch, Thermal16 2511189 1 Cap, Pressure

17 1240015 1 Radiator, U-Flow18 7515133 2 Bolt19 7052181 1 Valve, Drain Cock20 5020937 2 Spacer, Mount, Radiator21 3110032 2 Mount, Rubber, Radiator22 7080492 1 Cable Tie23 7670090 1 Clip, Dart24 4170013 1 Motor, Fan25 5241355-067 1 Bracket, Cooling Fan26 5242550 1 Blade, Fan27 7517475 3 Screw28 7512232 4 Screw29 5410584 2 Bushing, Mount, Lower Radiator30 7558201 3 Washer, Flat31 7547004 3 Nut, Nylok32 4010369 1 Breaker, Circuit

3/00

A10

EXHAUST SYSTEMScrambler 500 A00BG50AA

1415

32

11

10

16

1

13

12 7

6

4

5

5

5

5

89

7


1 7515316 2 Bolt2 5410241 2 Dampener, Vibration3 5010192 2 Bushing4 1261006-029 1 Silencer5 7041804 4 Spring, Exhaust6 1261005-029 1 Pipe, Exhaust7 5243518 2 Seal, Exhaust8 7512232 2 Screw

9 5242344-067 1 Bracket, Exhaust10 7542301 1 Nut11 3110064 1 Mount, Torque Stop12 7042029 1 Spring, Exhaust13 7512666 2 Bolt14 7542324 2 Nut, Nylok15 7555716 2 Washer, Flat16 5410436 2 Washer, Rubber

5/99

A11

ENGINE MOUNTINGScrambler 500 A00BG50AA

19

33

46

2

3

5

6

7

8

1011

4

17

18

9

9

2220

2526

272829

30

31

32

36

40

41

4342

44 45

40

9

1314

1516

12

47

35

34

12

39

1

10

38

37

2123

2

24

11

1

1

9

A12

ENGINE MOUNTINGScrambler 500 A00BG50AA


1 7547108 6 Nut, Flange2 7555823 3 Washer, Flat3 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 3084205 3 Screw and Washer13 3110032 2 Mount, Radiator14 5242258-067 1 Bracket, Carburetor Mount15 7552605 2 Washer, Split Lock16 7542105 2 Nut17 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D10, Ref. 18)18 8360009-600 AR Line, Fuel19 8450080-58 1 Sheath, Foil, Laminated20 1012883-067 1 Mount, Rear Motor21 7547089 2 Nut, Flange, Lock22 3110046 2 Mount, Rubber23 7517289 1 Screw24 7555815 2 Washer25 5410421 1 Boot, Clutch Intake26 7080511 1 Clamp, Narrow Band27 5430261 1 Bushing28 5210748 1 Washer, Flat

29 7575202 1 Washer, Interlock30 7512566 1 Bolt31 ------ -- -- -- -- 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, Engine34 7515398 2 Screw35 7542324 2 Nut, Nylok36 3110067 1 Mount, Rubber37 7080474 2 Clamp38 7552603 1 Washer, Spring Lock39 7515438 1 Screw40 7080696 2 Clamp41 ------ -- -- -- -- AR Hose, Engine, Lower (See Cooling

System Pg. A9, Ref. 12)42 ------ -- -- -- -- 2 Nut (See Cylinder Pg. D6, Ref. 23)43 ------ -- -- -- -- 2 Washer, Lock

(See Cylinder Pg. D6, Ref. 22)44 1260994-029 1 Manifold, Black45 ------ -- -- -- -- 1 Gasket, Exhaust

(See Cylinder Pg. D6, Ref. 20)46 3085822 1 Engine, Short Block (EH50PLE04)

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

47 ------ -- -- -- -- AR Hose, Engine, Upper (See CoolingSystem Pg. A9, Ref. 13)

9/99

A13

OIL TANKScrambler 500 A00BG50AA

25

1

2

87

9

10

11

12

13

14

15

16

20

22

23

24

21

5

3

18

4

6

19

617


1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7052163 1 Fitting5 5411873 1 Hose, Breather6 7051524 1 Plug7 7517102 1 Bolt, Banjo8 7555896 2 Washer, Copper9 7052213 1 Tube, Banjo Return10 5432289 1 Dipstick11 5410889 1 O-Ring12 5411036 AR Hose, Formed13 7080474 1 Clamp, Hose

14 7052106 1 Fitting, 1/4” to 3/8”15 2530014 1 Screen, Oil Filter16 5131785 1 Tank, Oil, LH17 7542122 1 Nut, Nylok18 5411042 1 Grommet19 5410828 2 Grommet, Mounting, Reservoir20 5333204 2 Bushing21 7558301 2 Washer, Flat22 7512130 2 Screw23 5850135 1 Washer24 7515158 9 Screw25 5131255 1 Tank, Oil, RH

11/02

A14

FUEL TANKScrambler 500 A00BG50AA

12

6

78

11

1516

2018

14

19

25

26

27

1

4

5

910

2124

22

17

21

23

23

3

13

24

2

21

21


1 25113425432879

11

Asm., Fuel Tank (Incl. 7,20,25,26)Tank, Fuel

2 5811527 1 Seal, Foam3 5410842 1 Grommet, Fuel Tank4 5810144 1 Gasket, Fuel Cap5 5430725 1 Cap, Gas Tank6 8360009-600 AR Line, Fuel7 5431053 1 Vent, Tank8 7512249 2 Screw9 7552801 2 Washer, Spring Lock10 7555859 2 Washer, Flat11 5811526 1 Seal, Foam12 5332457 2 Spacer13 7542143 2 Insert

14 7555726 1 Washer, Flat15 5431021 1 Lever, Fuel16 7511840 1 Screw17 5432291 1 Grommet18 7041209 1 Spring, Lever, Compression19 5431391 1 Extension, Fuel Lever20 7515136 2 Screw21 7080003 6 Clamp, Hose, Red22 2530009 1 Filter23 8450080-27 1 Sheath, Foil, Laminated24 8450040-600 1 Line, Fuel25 7052190 1 Valve, Fuel26 5810859 1 Gasket, Fuel Valve27 8360026 2 Foam, Tape, Black

5/99

B1

DECALSScrambler 500 A00BG50AA

7

8

15

6

109

7

51

16

1211

3

13

RH

LH17

14

2

2

4

8


1 7072786 1 Decal - Warning, Heavy Loads2 7078433

707843411

Decal - “4x4 CDS”, LHDecal - “4x4 CDS”, RH

3 7077802 1 Decal - Tank Side, RH4 7078020 1 Decal - “POLARIS”5 7074935 1 Decal - Warning, AWD Switch6 7078315 1 Logo, 45th Anniversary7 7078430 2 Decal - “Scrambler”8 7078435 1 Decal - Front Cover, “500 L/C, 4

Stroke”

9 7078354 1 Decal - Warning, Discretionary10 7078577 1 Decal - Drain, Recoil11 7079604 1 Decal - Warning, Override, AWD12 7078253 1 Decal - Age Warning13 7077801 1 Decal - Tank Side, LH14 7077920 1 Decal - Passenger Warning15 7074690 1 Decal - Caution, Tire Pressure16 7077919 1 Decal - Warning, General17 7077365 1 Decal - Fuel Lever

10/00

B2

PROP SHAFTScrambler 500 A00BG50AA

8 7 65

31

2

2

2

10

4

11

9


1 5433457 1 Guard, Prop Shaft, Side2 7512232 6 Screw3 5433154 1 Guard, Prop Shaft, Front4 5411092 1 O-Ring5 3260131 1 Yoke, Prop Shaft, Transmission6 3260139 1 Shaft, Prop

7 1590256 2 Joint, Cardan8 3260133 1 Yoke, Front Gear Case9 1380124 1 Asm., Prop Shaft (Incl. 5-8)10 7661913 1 Pin, Spring11 7558301 2 Washer, Flat

9/99

B3

FRONT HOUSINGScrambler 500 A00BG50AA

1 222120

19

18

17

1211

9

8

10

76

54

3

26

25

2423

12

2

16

13

14

15

28

27


1341276 1 Asm., Front Gearcase (Incl.1-12,16-25)(If built before 7/01/99)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing, Ball7 3233698 1 Pinion, Input8 3233541 1 Bushing9 3233319 1 Seal10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug, Oil Fill13 7080409 1 Clamp, Wire Routing14 8450003-1525 AR Line, Fuel

15 7080307 1 Clamp, Hose16 3233524 1 Tube, Vent17 3233696 1 Gearcase18 3233710

32336943233695

111

SubAsm., Output Shaft, Front HousingShaft, OutputGear, 29T

19 3233020 1 Bearing20 3233554 AR Shim21 3233693 1 O-Ring22 3233692 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233702 1 Button, Thrust25 3233254 1 Washer, Plug26 3233253 1 Plug, Drain27 7512492 4 Screw28 7552603 4 Washer, Spring Lock

9/99

B4

FRONT HOUSINGScrambler 500 A00BG50AA

12

34

56

78

9 1011

12

13

14

15

16

17

18

1920 21

22

2324

25

2627

282

1


1341323 1 Asm., Front Gearcase (Incl. 1-12,16-26)(Units built after 7/0199)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing7 3233726 1 Pinion, Input, 14T8 3233541 1 Bushing9 3233319 1 Seal, Oil10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug13 7080409 1 Clamp

14 8450003-1525 AR Fuel Line15 7080307 1 Clamp, Hose16 3233524 1 Tube, Vent17 3233696 1 Gearcase, Front Housing18 3233725 1 Shaft, Output, 29T19 3233020 1 Bearing, Ball20 3233554 AR Shim21 3233693 1 O-Ring22 3233724 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233582 1 Button, Thrust25 3233254 1 Washer26 3233253 1 Plug, Drain27 7552603 4 Washer, Lock28 7512492 4 Screw

5/99

B5

CV JOINT - NEAPCOScrambler 500 A00BG50AA

12

6

7

8 9

11

3 51

2 4

Brand Designated

10


1380118 2 Asm., CV Housing w/Sleeve (Incl. 1)1 ------ -- -- -- -- 1 Asm., Drive Shaft, Splined2 5222299 1 Sleeve, Drive Shaft Seal3 3260121 1 Clamp, Band4 7670092 1 Circlip5 2201015 1 Kit - Boot, Replacement6 1380060 1 Shaft, Replacement (Incl. 4)

7 1380061 1 Cardan Replacement (Incl. 4,6,8,9)

8 3260104 1 Kit - Cross and Bearing9 3260101 1 Yoke, Splined10 7661913 2 Pin, Spring11 3260123 1 Clamp, Band12 2200960 2 Kit - Drive Shaft Assembly w/Sleeve

Neapco

6/01

B6

FRONT STRUTScrambler 500 A00BG50AA

1

2

3

4

8 5

6

9

11

12

13

1516

14

17

18

19

21

8

20

23

24

25

2627

1112

22

10

857

28


1 5411608 2 Bumper2 7041762 2 Strut, Front3 5211115 2 Washer4 7080573 2 Clamp, Rubber Coated5 7542303 4 Nut, FLEXLOC6 7512365 4 Screw7 7552901 4 Washer, Spring Lock8 7558402 10 Washer, Flat9 5810439 2 Retainer, Strut Casting Wire10 ------ -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B8 for Details)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 22013112201312

11

Asm., Hubstrut, LH (Incl. 9,13-16)Asm., Hubstrut, RH (Incl. 9,13-16)

17 7041603-067 2 Spring, Coil, Strut18 5243364 2 Retainer, Spring19 5432871 2 Ball, Pivot, Bottom20 7515339 4 Bolt21 5132062 2 Spacer22 ------ -- -- -- -- 1 Kit - Drive Shaft w/Sleeve (See CV

Joint - Neapco Pg. B5, Ref.12)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, Nylok28 7052028 2 Grommet

3/00

B7

FRONT WHEELScrambler 500 A00BG50AA

10

11

12 14

12

34

5

79

8

15

1625

24 7

1920

23

DETAIL A

A

136

6

21

17

22

18


1 7512325 8 Bolt2 5211869 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Asm. Clutch, Front Hub, Elec./Mech.

(Splined Drive Shaft)6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515523 8 Stud9 1520243 2 Asm., Hub (Incl. 3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter

13 1321814 2 Spacer14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5411264 2 Tire, Titan (23x7-10)17 7556004 2 Washer18 7661401 2 Pin, Cotter19 5410470 2 O-Ring20 5432611 2 Cap, Hub21 7512027 6 Screw22 7542810 2 Nut23 7542459 8 Nut, Lock24 1520207-117 2 Rim, Front25 1525017 2 Valve, Rim

5/99

B8

FRONT BRAKEScrambler 500 A00BG50AA

1

2 3

14

13

8

12

11

4

5 6 7

10 9


1910271

1910264

1

1

Asm., Front Brake Caliper, LH(Incl. 1-7)Asm., Front Brake Caliper, RH(Incl. 1-7)

1930642 1 Kit - Front Brake Boot (Incl. 8,12)1 7080352 2 Screw, Bleeder2 7515489 2 Screw, Socket Set3 5131261

513126211

Caliper, Brake, LHCaliper, 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 Seal9 ------ -- -- -- -- 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, Bushing13 1910412 2 Mount, Caliper14 2200901

22011492200465

1

11

Kit - Severe Duty Brake Pad, Front(Complete set of 2 pads)Kit - Brake Pad, Soft, FrontKit - Brake Pad, General, Front

10/00

B9

A-ARM/STRUT MOUNTINGScrambler 500 A00BG50AA

30

14

56

7

89

3

13

14

1516

17

19

18

20

21

26

27

2524

23

2928

2829

2423

22

31

2

14

12

1110


1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820805 2 Asm., Tie Rod (Incl. 4-9)4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End, RH6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061054 2 Rod End, LH10 5411920 1 Boot, Seal, Rod End11 7517674 2 Bolt12 7556099 4 Washer, Flat13 7546904 2 Nut14 7661203 4 Pin, Cotter15 ------ -- -- -- -- 1 Asm., Hubstrut

(See Front Strut Pg. B6, Ref. 16)16 7080927 2 Joint, Ball

17 5211121 2 Bracket, Ball Joint18 7512284 4 Screw19 5410548 2 Boot, Rubber20 7542438 2 Nut, Castle21 7512084 4 Screw22 5431150

543114911

Shield, CV Joint, LHShield, CV Joint, RH

23 5431596 4 Bushing, A-Arm, Long24 5020677 4 Bushing25 5020681 2 Shaft, A-Arm26 2201157

220115811

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

27 7080433 2 Fitting, Lubrication28 7552603 4 Washer, Spring Lock29 7512492 4 Screw30 7517527 1 Bolt31 7515415 1 Screw

10/00

B10

HANDLEBAR/HEADLIGHTScrambler 500 A00BG50AA

1

2 3

5

22

6

8

11

21

20

15

19

18

4

17

14 13

16

16

7

910

12

12


2200774 1 Kit - Handlebar Block (Incl. 3,16,22)1 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls-

Throttle Asm./Cable Pg. B12, Ref. 5)2 1820594-067 1 Handlebar3 7515189 4 Screw4 5521181 1 Pad, Handlebar5 2682454 1 Pad, Handlebar Cover6 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls-Master Cylinder/BrakeLine Pg. B13, Ref. 1)

7 5432926 1 Spacer, Switch, LH8 4010262 1 Switch, Handlebar, Hi/Lo/Rev/Override9 7517625 1 Screw, Set10 5432952 1 Plug, Hole

11 5431030 2 Grip, Handlebar12 7080138 4 Cable Tie13 7542324 2 Nut, Nylok14 7558402 2 Washer, Flat15 7558301 2 Washer, Flat16 7542122 6 Nut, Nylok17 5241973-067 1 Bracket, Headlight18 7080631 1 Clip, Cable Retaining19 2431016

403006121

HeadlightBulb, Headlamp

20 1040579-067 1 Guard, Headlight21 7512111 2 Bolt22 5630616-067 2 Block, Handlebar Retainer

5/99

B11

STEERING POSTScrambler 500 A00BG50AA

1

16

15

14

2

3

4

13

9

1256

10

5

58

11

6

7


1 1843051 1 Asm., Steering Post (Incl. 12,13)2 5433415 1 Bushing, Steering Console3 7080510 1 Fitting, Lubrication, 90 Degree4 7515321 2 Bolt5 7555878 3 Washer6 5410772 2 O-Ring7 5431571 1 Spacer, Steering Post8 7543203 1 Nut

9 7661633 1 Pin, Cotter10 5431570 1 Bushing, Steering, Lower11 7661632 2 Rivet12 5431574 1 Plug, Grease, Steering13 7080433 1 Fitting, Lubrication14 5433416 1 Bushing, Steering, Upper15 5222999-067 1 Bracket, Steering Bushing, Upper16 7542324 2 Nut, Nylok

9/99

B12

CONTROLS - THROTTLE ASM./CABLEScrambler 500 A00BG50AA

3

1

5

4

6

2


1 5433806 1 Cover, Throttle Control2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7080709 1 Cable, Throttle Control5 2010188 1 Asm., Throttle Control (Incl.1,3,6)6 2010191 1 Asm., Throttle Clamp

3/00

B13

CONTROLS - MASTER CYLINDER/BRAKE LINEScrambler 500 A00BG50AA

3

4

6

10

7

5

15

17

21

2526

16

23

20

13

2

19

12

14

1

8

9

11

1824

22

18


1 2200809

2050073

1

1

Kit - Master Cylinder Reservoir(Incl. 2,3,4,14)Asm., Master Cylinder (Incl. 1-14)

2 1930797 2 Screw, Cap3 1930796 1 Cap, Reservoir4 1930795 1 Diaphragm5 2200808 1 Kit - Clamp6 1930799 1 Asm., Master Cylinder Piston7 1930804 1 Rivet8 2201034 1 Kit - Brake Lever w/Parking Brake

Latch (Incl. 7, 9,11)9 ------ -- -- -- -- 1 Spring, Flat10 1930806 1 Nut11 2201090 1 Kit - Park Brake Lever (Incl. 7,9)12 1930792 2 Screw

13 1930805 1 Screw14 ------ -- -- -- -- 1 Ring, Square15 1930762 1 Line, Brake, Upper w/Fittings16 4110164 1 Switch17 1930873 1 Line, Brake, Hand, Rear18 7080138 8 Cable Tie19 7080539 1 Clamp20 7621462 1 Rivet, Pop21 1930809 1 Line, Brake, Left Front w/Fittings22 8360031-30 1 Conduit23 7512024 2 Screw24 8360011-38 1 Tubing, Convoluted25 1930812 1 Line, Brake, Right Front w/Fittings26 7052237 1 Fitting, Cross

5/99

B14

DRIVE CLUTCHScrambler 500 A00BG50AA

14

1 23 4

7

13

5 6 7

8

12

11

910


1 7512176 6 Bolt2 7552801 6 Washer, Spring Lock3 3576510 1 Cover, Bearing4 7041157 1 Clutch, Spring5 5430945 6 Washer, Multilube6 1321457 3 Roller and Bushing7 5431936 6 Button, Clutch, Stemless8 5210752

524298152107535210754

ARARARAR

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

9 5630710 3 Weight, Shift (10-WH)10 7512266 3 Bolt, Shoulder11 7541906 3 Nut, FLEXLOC12 3576504 1 Bearing, Moveable, 1/2”13 5020422 3 Pin, Roller14 1321632 1 Asm., Drive Clutch, ATV-06

(Incl. All Less 4,9)

5/99

C1

DRIVEN CLUTCHScrambler 500 A00BG50AA

6

2

34

5

7

10

11

12

13

15

1617

2

1

9

14

8


1 7556120 AR Bushing2 1321798 1 Asm., Driven Clutch (Incl. 7-17)3 5220646 1 Washer, Domed4 7552901 1 Washer, Spring Lock5 7515384 1 Bolt6 3211077 1 Belt, Drive7 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, Clutch13 5131446 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

5/99

C2

GEARCASE MOUNTINGScrambler 500 A00BG50AA

1

2

9

11 10

43

4

3

13

3

8

8

12

57

8

8

6


1 7517632 2 Screw2 5242456-067 2 Bracket, Transmission3 7542423 4 Nut, Flange4 7512492 2 Screw5 5433109 1 Guide, Chain, Transmission6 7558301 2 Washer, Flat7 7512276 2 Screw8 7555806 4 Washer, Flat

9 7517646 1 Screw10 3221041 1 Sprocket, 13T11 7710434 1 Ring, Retaining12 5211065

52107645211517

ARARAR

Shim (.010”)Shim (.020”)Shim (.030”)

13 7517640 1 Screw

5/99

C3

REAR CALIPER MOUNTINGScrambler 500 A00BG50AA

10

14

15

17

16

13

1211

1

9

4

3 54

18

Frame

8

7

7

5

6

62


1 7517231 2 Screw2 7555806 2 Washer, Flat3 1910367

220138522014282201467

1121

Caliper, RearKit - Caliper SealKit - Bleeder ReplacementPiston, Caliper, Rear

4 5410988 4 Seal5 1930873 1 Line, Brake, Hand, Rear6 1910381 1 Line, Brake, Foot, Rear7 4020139 2 Clip, Rosebud8 7670102 2 Clip, Silencer Box9 1930674 3 Bolt, Banjo

10 5131759 1 Bushing, Caliper Mount11 7558402 2 Washer, Flat12 7552901 2 Washer, Spring Lock13 7512312 2 Bolt14 5131786 1 Mount, Caliper, Lower15 5131787 1 Mount, Caliper, Upper16 7512325 3 Bolt17 5242291-067 1 Guard, Brake Disc18 2201189

19103391930860

111

Kit - Brake Pad (Incl. Spacer and Pin)SpacerPin

9/02

C4

REAR BRAKE MASTER CYLINDERScrambler 500 A00BG50AA

6

18

20

15

2

13

10

12

11

1

7

8

5

3

22

19

17

4

14

21

6

1112

159 16

2

4


1 7080880 1 Clamp, Hose2 7512113 3 Bolt3 5244091-067 1 Bracket, Reservoir Mount4 7542122 3 Nut, Nylok5 7512208 1 Screw6 7080003 2 Clamp, Red7 1910404 1 Hose, Reservoir8 1930854 1 Reservoir9 7558301 4 Washer, Flat10 7661401 1 Pin, Cotter11 7555919 2 Washer12 5431107 2 Bushing

13 1910375-067 1 Mount, Brake14 1930674 1 Bolt, Banjo15 5410988 2 Seal16 ------ -- -- -- -- 1 Line, Foot Brake, Rear (See Rear Cal-

iper Mounting Pg. C3, Ref. 6)17 7512278 2 Screw18 1910311 1 Asm., Foot Brake Master Cylinder19 7542324 2 Nut, Nylok20 1910377-067 1 Rod, Brake21 7041750 1 Spring, Torsion22 7512383 2 Screw

5/99

C5

REAR WHEELScrambler 500 A00BG50AA

12

9

3

8

4

56

7

2

1

11

612

98

5

4

7

10


1 7512673 8 Bolt2 2200341 2 Kit - Hub, Rear (Incl. 1,4,6,10)3 7547037 8 Nut, Flange4 7555796 2 Washer, Cone5 7543005 2 Nut, Castle6 7661404 2 Pin, Cotter

7 5411164 2 Cover, Dust, Hub8 7555745 2 Washer, Flat9 1525017 2 Valve, Rim10 7670081 8 Retainer, Bolt, Pushnut11 1520204-117 2 Rim, Rear12 5411266 2 Tire (22x11-10)

5/99

C6

REAR HOUSINGScrambler 500 A00BG50AA

1

7

3

12

1721

24

18

8

5

1415

10

23

9

20

22

11

13

2

6

32

1

6

1011

1213

16

4

4

19

19

3


1 7710472 2 Ring, Retaining2 5510313 2 Extrusion, Retainer, Nut3 7542439 6 Nut, Nylok4 5411555 2 Seal, Foam5 5211849 1 Disc, Brake6 7515513 6 Stud7 1520259 1 Hub, Brake Disc (Incl. 6)8 7710496 1 Ring, Retaining9 5010462 1 Spacer, Axle10 5410889 2 O-Ring11 3610070 2 Seal12 3554518 2 Bearing, Cone, Tapered

13 3554517 2 Bearing, Cup, Tapered14 5132098 1 Housing, Axle, Rear15 7080306 1 Fitting, Lubrication16 3225027 1 Link, Connector, 520 Regina17 5020944 1 Axle, Rear18 5211585-067 1 Guard, Sprocket19 7547108 6 Nut20 3221111-076 1 Chain, 520 O-Ring21 7512404 3 Bolt22 1520258 1 Asm., Hub, Sprocket (Incl. 6)23 3222109 1 Sprocket, 36T24 5630586 1 Spacer

3/00

C7

AIR BOXScrambler 500 A00BG50AA

22

16

26

17

14

9

6

2

19

5

27

10

24

1223

4

15

18

13

11

7

9

15

18

8

28

21

3

1

20

25


1 7517541 4 Screw2 5432859 1 Duct, Inlet3 5411422 1 Gasket, Intake4 5432868 1 Cover, Air Box5 5811482 1 Seal, Cover6 7515179 2 Screw7 7558301 2 Washer, Flat8 8450073-600 AR Line, Breather9 7080544 2 Clamp, Hose10 2530029 1 Filter, Breather11 7080694 1 Clamp, Hose12 5411847 1 Hose, Breather13 7080511 1 Clamp, Band14 5411414 1 Boot, Carb

15 7080413 2 Clamp16 5432473 1 Duct, Carb, Inlet17 5830128 1 Gasket, Duct18 7080699 2 Clamp, Hose19 5432774 1 Box, Air20 5411873 1 Hose, Breather, Oil Tank21 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

3/00

C8

CLUTCH COVERScrambler 500 A00BG50AA

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 5432698 1 Duct, Down Tube, 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 5433451 1 Cover, Clutch, Outer11 7670051 1 Clip, Clutch Cover12 7512093 5 Screw13 7074946 1 Decal - Clutch Cover14 7077377 1 Decal - Eng./Clutch Modification

15 7074782 1 Decal - Automatic Transmission16 7512094 2 Screw17 7080761 2 Cable Tie18 5411489 1 Boot, Duct19 5433409 1 Duct, Clutch, Hi-Flow20 ------ -- -- -- -- 3 Screw and Washer

(See Crankcase Pg. D4, 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

9/99

C9

ELECTRICAL/TAILLIGHTScrambler 500 A00BG50AA

1

2 3

5

7

10

9

6

11

8

1224

25

26

28 2933

34

2324

22

12

14

15

1617

18

19

20

21

13

28 31

30

32

27

4


1 2460787 1 Harness, Main2 7080138 3 Cable Tie3 2434012 1 Breaker, Circuit, 20 AMP4 2201795 1 Kit - Circuit Breaker, 10 AMP5 2432038 1 Light, Tail/Brake (Incl. 6-10)6 7512088 2 Screw7 4032085 1 Lens8 4030043 1 Bulb9 4032086 1 Gasket10 4032087 1 Backing11 7670093 2 Clip12 7571602 4 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 5431769 1 Cover, Battery16 2200361 2 Kit - Battery Bolt17 4010095 1 Cable, Battery/Engine, Black18 7010032 2 Hook, Battery Strap

19 5410424 1 Strap, Battery Holddown20 5432077 1 Tube, Vent21 4140006 1 Battery22 4010094 1 Cable, Battery/Solenoid, Red23 4010093 1 Cable, Solenoid/Starter24 7541925 4 Nut, Nylok25 7512007 2 Bolt26 7670109 2 Clip, Routing27 4020149 4 Clip, Rosebud28 7512024 3 Screw29 4010195 1 Limiter, RPM, LR-83-330 5810317 1 Pad, Fuel Tank Bracket31 5241416 1 Bracket, CDI32 8360012 1 Trim, Edge33 2620087

54319735811079

111

Asm., Tool BoxCover, Tool Box LidGasket

34 7512232 2 Screw

1/00

C10

SWING ARM/SHOCK MOUNTINGScrambler 500 A00BG50AA

9

82

7

46

3

1

28

10

11

1512

18

29

16

30

17

1314

2423

2221

20

27

26

25

12

16

1

19

5


1 7542439 2 Nut, Nylok2 7041865-067 1 Spring, Compression, Small3 7041864-067 1 Spring, Compression4 7075343 1 Decal - Warning, Fox Shock5 1500278 1 Ring, Spring Preload6 5433550 1 Spacer, Spring7 7041867 1 Shock, Gas8 5631045 1 Retainer, Spring9 7515415 1 Screw10 7661046 2 Rivet11 5432727 1 Guide, Pad, Chain12 7080510 2 Fitting, Lubrication13 7547082 1 Nut14 7556035 1 Washer, Flat15 5433412 2 Bushing, Swing Arm, RH

16 5131697 2 Bolt, Pivot, Swing Arm17 5131696 1 Bushing, Pivot, RH18 1541395 1 Asm., Swing Arm (Incl. 12,15,29)19 7078572 1 Decal - “Chain Free Play”20 5432854 1 Guard, Chain21 7515304 1 Screw22 5332828 1 Bushing23 7558402 1 Washer24 7542321 1 Nut25 7542503 2 Nut26 7555883 4 Washer27 7512576 2 Bolt28 7517761 1 Screw29 5433411 1 Bushing, Swing Arm, LH30 5131695 1 Bushing, Pivot, LH

8/01

C11

GEARCASEScrambler 500 A00BG50AA

27

16

1211

51

57

60

58

56

41

2

34

1034 5 6

9

5049

8

46

55

15

14

13

4443

42

2322

25

21

26

483247

2016

59

1

54

7

52

45

17 1918

53

38

2930

39

3736

3533

31

415

2

34

41

41

24

32

34

28

40

C12



1341284 1 Asm., Gearcase (Incl. 1-59)(Units builtbefore April 23, 1999)

1 3233632 1 Gearcase, LH Mach2 3233018 3 Bearing, Ball3 3233557 1 Shaft, Reverse 31T4 3233012 2 Washer, Thrust5 3233014 1 Bearing, Needle6 3233532 1 Sprocket, 24T7 3233029 1 Ring, Retaining8 3233533 1 Engagement Dog9 3233010 1 Washer, Thrust10 3233633 1 Fork, Shift High/Rev. Mach11 3233534 1 Bushing, Garlock12 3233535 1 Gear, 30T13 3233176 1 Washer, Thrust14 3233177 1 Ring, Retaining15 3233019 1 Bearing, Ball16 3233033 4 Screw17 3233309 1 Bracket, Interlock18 3233550 1 Spring, Shifting Interlock19 3233308 2 Pin, Interlock20 3233559 1 Shaft, Shift21 3233040 1 Washer22 3233547 1 Bellcrank23 3233055 1 Nut, FLEXLOC24 3233054 1 Washer25 3233045 1 Ring, Retaining26 3233548 1 O-Ring27 3233616 4 Screw and Washer28 3233635 1 H/R Switch29 3233325 1 Plug30 3233324 1 Washer

31 3233556 1 Cover, Snorkel32 3233539 11 Screw33 3233555 1 O-Ring34 3233248 3 Seal35 3233554 1 Shim36 3233553 1 Subassembly, Snorkel Gear37 3233552 1 Bushing, Garlock38 3233634 1 Gearcase, RH Mach39 3233037

8360009-6001

ARTube, VentLine, Fuel

40 3233636 1 Decal - Switch41 3233020 3 Bearing, Ball42 3233546 1 Chain, Roller 26P43 3233545 1 Sprocket, 16/26T44 3233544 1 Shaft, Output45 3233558 1 Gear, 98T46 3233537 1 Ring, Retaining47 3233538 1 Sprocket, 14/22T48 3233263 1 Bearing, Cover, Center Drive49 3233306 1 Ring, Retaining50 3233540 1 Shaft, Pinion 13T51 3233541 1 Bushing, Garlock52 3233542 1 Washer, Thrust Button Pinion53 3233043 1 Deflector, Oil54 3233036 1 Chain, Silent55 3233536 1 Shaft, Input56 3233529 2 Pipe, Knock57 3233252 11 Screw58 3233527 1 Bushing, Pivot59 3233448 1 Plug60 3233035 1 Washer

5/99

C13


1

23

4 56 7

8

910

11

12

1314 15 16 17

181920

2223

2425 26

2728

29

3133

3435

38

36

37

3239

404142

43 444546

474849 50

5152

5354

55

56 57

46

21

32

2932 13

2

1230

30

30

32

C14



1341328 1 Asm., Gearcase (Incl. 1-57)(Units built after April 23, 1999)

1 3233632 1 Gearcase, LH Mach2 3233018 3 Bearing, Ball3 3233728 1 Shaft, Reverse 31T4 3233718 2 Bearing, Needle5 3233719 1 Sprocket, 24T6 3233720 2 Ring, Retaining, E-Ring7 3233721 1 Dog, Engagement8 3233633 1 Fork, Shift High/Rev., Mach9 3233722 1 Gear, 30T10 3233176 1 Washer, Thrust11 3233177 1 Ring, Retaining12 3233019 1 Bearing, Ball13 3233033 4 Screw14 3233309 1 Bracket, Interlock15 3233550 1 Spring, Shifting Interlock16 3233308 2 Pin, Interlock17 3233559 1 Shaft, Shift18 3233040 1 Washer19 3233547 1 Bellcrank20 3233055 1 Nut, FLEXLOC21 3233054 1 Washer22 3233045 1 Ring, Retaining23 3233548 1 O-Ring24 3233691 4 Screw and Washer25 3233635 1 Switch, H/R26 3233711 1 Plug27 3233324 1 Washer28 3233556 1 Cover, Snorkel

29 3233539 11 Screw30 3233248 3 Seal, Triple Lip31 3233555 1 O-Ring32 3233020 4 Bearing, Ball33 3233554 AR Shim34 3233723 1 Subassembly, Snorkel Gear35 3233552 1 Bushing, Garlock36 3233037

8360009-6001

ARTube, VentLine, Fuel

37 3233636 1 Decal - Switch38 3233798 1 Gearcase, RH Mach39 3233546 1 Chain, Roller 26P40 3233545 1 Sprocket, 16/26T41 3233544 1 Shaft, Output42 3233558 1 Gear, 98T43 3233537 1 Ring, Retaining44 3233538 1 Sprocket, 14/22T45 3233263 1 Bearing, Cover, Center Drive46 3233306 1 Ring, Retaining47 3233540 1 Shaft, Pinion 13T48 3233541 1 Bushing, Garlock49 3233542 1 Washer, Thrust Button Pinion50 3233043 1 Deflector, Oil51 3233036 1 Chain, Silent52 3233536 1 Shaft, Input53 3233529 2 Pipe, Knock54 3233252 11 Screw55 3233527 1 Bushing, Pivot56 3233448 1 Plug57 3233035 1 Washer

12/00

D1

GEAR SELECTORScrambler 500 A00BG50AA

1

2

3

5

14

12

6

9

7

8 10

11

13

7

6

4


1 5411006 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector4 5411008 1 Grommet, Shifter, Gear5 5131976 2 Spacer, Shifter6 5433103 2 Mount, Gear Selector7 7546707 2 Nut, FLEXLOC

8 7061014 1 Rod End, 6mm, RH9 7546701 1 Nut, RH10 5020955 1 Rod, Shift Linkage11 7546702 1 Nut, LH12 7061013 1 Rod End, 6mm, LH13 7515133 2 Bolt14 1012797-067 1 Selector, Gear

5/99

D2

FOX SHOCK, GAS, RESERVOIRScrambler 500 A00BG50AA

29

18

17

19

16

262524

23

21

27

12

6 9

7 85

21

43

13

11 10

27

2820

14

15

22


7041867 1 Shock, Gas, Reservoir1 1500021 1 O-Ring2 1500020 1 O-Ring3 1500025 1 Wiper, Inner4 1500024 1 Wiper, Clear, Outer5 1500287 1 Asm., Screw6 1500018

150002311

ScrewO-Ring

7 1500006 1 Ring, Piston, Floating, Fox8 1500003 1 O-Ring, Fox End Cap9 1500011 1 Piston, IFP10 1500099 1 Asm., Cap, Reservoir, ATV Fox Shock

(Incl. 11,12,13)11 1500097 1 Retaining Ring, ATV Fox Shock12 1500072

15000191500022

111

Asm., Air ValveScrewO-Ring

13 1500098 1 O-Ring, ATV Fox Shock14 1500286 1 Asm., Reservoir15 1500283 1 Body16 1500013 1 Eyelet17 1500102 1 Bushing18 1500103 2 Bushing, Eyelet19 5410987 1 Bumper, Compression20 1500284 1 Shaft21 1500282 1 Asm., Cap-Body, Fox ATV22 1500285 1 Asm., Bearing23 1500017 1 Plate, Top-Out24 1500002 1 Ring, Piston, Fox25 1500015 1 Bushing, Back-up26 1500016 1 Nut, Lock27 1500004 1 O-Ring, Fox28 5020657 1 Sleeve29 1500104 2 Bushing, Eyelet

5/99

D3

SHOCK VALVINGScrambler 500 A00BG50AA

8

10

11

9

12

1

2

4

7

6

5

3

Shaft

Piston

Nut

13


1 1500033 1 Valve, Shock (.90 x .377 x .008)2 1500032 1 Valve, Shock (1.0 x .377 x .008)3 1500031 1 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 1500057 1 Valve, Shock (.80 x .377 x .012)

5/99

D4

CRANKCASEScrambler 500 A00BG50AA

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 3085808 1 Asm., Crankcase

(Incl. 1,4,5,7,8,10,11,16,19,20,22)3 3084838 2 Pin, Straight4 3080676 1 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

5/99

D5

CYLINDERScrambler 500 A00BG50AA

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

18

D6

CYLINDERScrambler 500 A00BG50AA


1 3084045 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 3085809 1 Adapter

5/99

D7

CRANKSHAFT and PISTONScrambler 500 A00BG50AA

20

21

7

11

1513

6

9

19 14

10

18

8

4

12

1

16

22

17

2

3

1

5


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 3080676 1 Bearing5 3085815 1 Bearing, Ball6 3085812 1 Crankshaft 27 3085341 1 Pin, Crank8 3085813 1 Rod, Connecting9 3085400 1 Bearing, End, Large10 3085024 1 Ball, Steel11 3085861

308594511

Asm., Crankshaft (Incl. 4,5-12,20)Crankshaft 1

12 3085852 1 Gear 1, Balancer13 3086837 1 Shaft, Balancer14 3084895

30848963084897

111

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

15 3240088308489230848933084894

1111

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

16 3084882 1 Sprocket 117 3085528 1 Nut, Slit18 3083904 1 Washer19 3083905 1 Nut, Lock20 3085346 1 Pin, Dowel21 3081447 1 Key22 3240168 1 Key, Woodruff

5/99

D8

INTAKE and EXHAUSTScrambler 500 A00BG50AA

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 3085855 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 3084905 2 Valve, Exhaust27 3084874 2 Bolt, Flange

5/99

D9

CARBURETORScrambler 500 A00BG50AA

14

31

20

2

8

3

9

5

6

19

40

38

11

4

29

13

28

29

2726

41

35

3233

36

4742

7

52

50

16

37

51

21

49

43

1

2423

3017

10

12

48

44

34

39

222518

15

14

45

46

D10

CARBURETORScrambler 500 A00BG50AA


1 3130821 2 Screw2 3130914 1 Cover, Diaphragm3 3130911 1 Spring4 3130913 1 Ring5 3130908 1 E-Ring6 3130915 1 Ring7 3130918 1 Needle, Jet8 3130910 1 Diaphragm9 3130912 1 Valve, Piston10 3130543 1 Guide, Cable11 3130931 1 Asm., Throttle Shaft12 3130932 1 Ring13 3130927 1 Spring14 3130933 4 Screw15 3130926 2 Washer16 3130925 1 Case17 3130619 1 Jet, Air18 3130903 1 Asm., Carburetor (Incl. 1-52)19 3130920 1 Jet, Needle20 3131290 1 Block, Jet21 3130916 1 O-Ring22 3131208 1 Cap23 3130593 1 Asm., Plunger24 3130538 1 Spring25 3130199 1 Cap, Plunger26 3130519 1 Cap

27 3130518 1 E-Ring28 3130517 1 Packing29 3130515 2 Seal30 3130906 2 Screw31 3130907 1 Valve, Throttle (120)32 3130934 1 Adjuster33 3130525 1 Spring34 3130523 1 Washer35 3130522 1 O-Ring36 3130624 1 Jet, Pilot (#40)37 3130922 1 Valve, Needle (1.5)38 3130928 1 O-Ring39 3131294 1 O-Ring40 3130930 1 Cover41 3130924 3 Screw42 3130010 1 Spring43 3130938 1 Asm., Adjuster, Cable44 3130937 1 Clip45 3131291 1 Screw, Guide46 3130239 1 O-Ring47 3130571 1 Jet, Main (#155)48 3130919 1 Ring49 3130935 1 Screw50 3130923 1 Asm., Float Body51 3130917 1 Seal52 3131293 1 Asm., Float

7/00

D11

RECOIL STARTERScrambler 500 A00BG50AA

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 3085856

308594311

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

15 3085083 1 Asm., Rope

5/99

D12

WATER PUMPScrambler 500 A00BG50AA

11

7

83

3

2

1

9

12

13

4

10

65


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

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

6/98

D13

OIL PUMPScrambler 500 A00BG50AA

4

1

10

3

2

11

17

15

87

6

13

14

5

16

18

9

12


1 3084946 1 Pump, Oil, Case 22 3084949 1 Rotor, Outer (Feed)3 3084948 1 Rotor, Inner (Feed)4 3085817

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 Washer10 3084947 1 Pump, Oil, Case 3

11 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Unit, Oil Strainer14 3084205 3 Screw and Washer15 3085818 1 Shaft, Pump16 3085859 1 Gear 2, Pump17 3085820 2 Bolt, Flange18 3084959

30849603084961

ARARAR

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

5/99

D14

OIL FILTERScrambler 500 A00BG50AA

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

E1

MAGNETOScrambler 500 A00BG50AA

20 6

5

8

9

1011

12

13

14

4

7

1

2

16

19

3

151718


1 30846903084979

11

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

2 3084980 1 Cap, Spark Plug3 3084997 1 Plug, Spark4 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#00-04730)Plate (Up to S#00-04730)Asm., Plate (Incl. 5,6,8-12,14,15)(S#00-04730 & after)Plate (S#00-04730 & after)

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

308698411

Stator (Incl. 13)(Up to S#00-04730)Stator (Incl. 13)(S#00-04730 & after)

10 30855633086985

33

Screw and Washer (Up to S#00-04730)Screw and Washer (S#00-04730 & 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#00-04730)CDI System (S#00-04730 & after)

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

308698311

Flywheel w/Ring Gear (Up to S#00-04730)Flywheel w/Ring Gear (S#00-04730 & after)

12/99

E2

STARTING MOTORScrambler 500 A00BG50AA

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

E3

FUEL PUMPScrambler 500 A00BG50AA

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 Gasket Set, Diaphragm

5/99

E4

TOOL KITScrambler 500 A00BG50AA

2

10

3

4

5

6

7

8

9

1


1 99152999915470

11

Owner’s Manual, ’00 ATVSupplement, Owner’s Manual, ’00Scrambler 500

2 3085544 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 2682572 1 Pouch, Tool Kit10 5211627 1 Wrench, Spanner

3/00

PRINTED IN THE USA PARTS MANUAL PN 99155485 and MICROFICHE PN 9916574 3/00

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