Polaris SCRAMBLER 500 2000, A00BG50AA Parts Manual

SCRAMBLER 500

Model #A00BG50AA

Rev. 02

E 2000 Polaris Sales Inc.

P ARTS MANUAL PN 9915485 and MICROFICHE PN 9916574 3/00

T ABLE OF CONTENTS

Scrambler 500 A00BG50AA

Parts Manual

A

A-ARM/STRUT MOUNTING B9.............

AIR BOX C7...........................

C

CARBURETOR 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..........................

D

DECALS B1...........................

DRIVE CLUTCH B14......................

DRIVEN CLUTCH C1.....................

E

ELECTRICAL/TAILLIGHT C9...............

ENGINE MOUNTING A11-12..................

EXHAUST SYSTEM A10...................

F

FOX 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.........................

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.................

RECOIL STARTER D11....................

S

SHOCK VALVING D3.....................

STARTING MOTOR E2...................

STEERING POST B11.....................

SWING ARM/SHOCK MOUNTING C10........

T

TOOL KIT E4..........................

W

WATER 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 SPECIFICATIONS

BRAKES

Type - Front
Type - Rear
Type - Auxiliary
Type - Parking

Hydraulic Lock, All Wheel

Hydraulic Disc
Hydraulic Disc
Hydraulic Disc

CAPACITIES

Coolant Capacity (quarts)
Fuel Tank (gallon)
Gearcase Oil (ounces)
Engine Counter Balance 10W30
Oil (quarts) Injector
Oil (quarts) Engine (OW40)
Rack, Front (pounds)
Rack, Rear (pounds)
Tongue Weight
Tow Hi t c h
Tow Weight

2.25

3.5

NA
NA

Accessory 30
Accessory 60

Accessory

850

DRIVE TRAIN

Type PVT

DRIVE CLUTCH

Center Distance (inches)
Clutch Offset (inches)
Clutch Weight
Spring Color

1/2

10 WH

Blue/Green

DRIVEN CLUTCH

Helix Angle
Spring Position

DIMENSIONAL FEATURES

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

40°

1-1

N/A

6.5

74.5

542

48.50

45.5

GEARCASE

Trans. Number and Type
Shift Type
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Front Drive (ratio)
Final Drive (ratio)
Center Drive (ratio)
Axle to Axle
Chain Type

PRD

Side Lever

N/A

4.74/1

3.06/1
2:1

13/36 76P

N/A
N/A

520 O-Ring

TIRES&WHEELS

Tire Manufacturer
Tire Size - Front
Tire Size - Rear
Tire Size - Center
Tire Pressure - Front
Tire Pressure - Rear
Tire Pressure - Center

Titan

23x7x10

22x11x10

N/A

N/A

Engine Model Number
Engine Type
Lubrication Type
Bore & Stroke (mm)
Displacement (cc’s)
Compression Ratio
Cooling
Alternator Output
Elec. Start w/Recoil Back Up

32

Carburetors (no. of/size)

Main Jet

2

30

10

60

77

47

33

4
3

Pilot Jet
Needle Jet
Cut Away
Air Screw

Jet Needle
Ignition
Ignition (Type & Deg. BTDC)
Spark Plug Gap (inches)
Spark Plug (Type)
Exhaust

Bumper Caps/Polyprop.
Cargo Box or Bed
Fender, Front/HDPE
Fender, Rear/HDPE
Footwell
Frame/Steel
Front Cover
Grips/TPR
Handlebar/Steel
Handlebar Cover w/Decal
Headlight Pod/HDPE
Rack, Front/Steel
Rack, Rear/Steel
Rims/Steel
Seat, Vinyl
Side Panel/HDPE
Spring, Front/Steel
Spring, Rear/Steel
Tank Cover/HDPE
Tool Box Cover/HDPE

w/lettering Color

Headlight (watts)
Taillight (watts)
Brake Light (watts)
Indicator Bulb

Front Type -

Front Travel (inches)

Adjustment
Rear Type -

Rear Travel (inches)

Shock

Adjustment

ENGINE

EH50PLE04

4 Cycle, Single Cylinder

Dry Sump

92.0x75
499

10:2 Full Stroke

Liquid
250W

Standard

1/BST40 (CV Type)

155

40
Y-0
NA

2.0 Turn

6H25-94-3

CDI

30 @ 3500

.028

NGKBKR5E

USFS Pending

GRAPHICS

N/A

N/A
Blazing Red
Blazing Red

Black
Black

Blazing Red

Black
Black

Black/White

N/A

N/A

N/A

Silver
Black

N/A

Fire Red
Fire Red

N/A

N/A

N/A

LIGHTS/BATTERY

2 Dual Beam, 30/30 W

12 V/8.26 W
12 V/26.9 W

12 V/1 W

SUSPENSION

MacPherson Strut

8.2

-- -- -- -- --

Progressive Rate Swing Arm

10.5

Gas Charged w/Remote

Reservoir

Threaded Adjuster

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to makeadditions or improvements to its productswithout
notice.

2000 SCRAMBLER 500 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’S

MANUAL

Scrambler 500 A00BG50AA 9915299 9915470 9915485 9916574 9915506

OWNER’S
MANUAL
SUPPLEMENT

PARTS
MANUAL

PARTS
MICROFICHE

ASSEMBLY
INSTRUCTIONS

FRONT CAB

Scrambler 500 A00BG50AA

5

1

6

4

2

1

3

7

7

22

E 2000 Polaris Sales Inc.

14

15

10

8

9

11

12

13

15

20

21

13

19

16

14

17

7

18

14

13 7621472 8 Rivet
14 7542122 24 Nut, Nylok
15 7555859 16 Washer, Flat
16 5211131-067 2 Bracket, Mudflap
17 5811831

5850150

18 1013083-067

1040691-067

1013249-067
19 7661825 8 Rivet
20 5431484 2 Trim, Footrest
21 5242525-067 2 Bracket, Heel Cleat
22 5432763 1 Guard, Rock
23 7515179 6 Screw

11Mudflap, Front, LH

Mudflap, Front, RH

1

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

1

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

2

Footpad (If built after 11/22/99)

23

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

1 7670060 4 Nut, Speed, U-Clip
2 5224718-067 2 Bracket, Cab Mount
3 7517386 2 Screw
4 1013037-067 1 Frame
5 7621432 2 Rivet, Pop
6 5211547-067 1 Strap, Fuel Pump Mounting
7 7512282 24 Bolt
8 5432553-288 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

3/00

A5

REAR CAB

Scrambler 500 A00BG50AA

8

20

29

30

2

28

15

16

7

23

9

10

24

14

21

13

12

22

17

11

18

19

2

20

6

5

3

2

1

31

27

4

2

26

21

26

25

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

1 7621472 4 Rivet
2 7555859 10 Washer, Flat
3 7512232 2 Screw
4 7512242 2 Screw
5 7041607 1 Spring, Latch, Light
6 1040412 1 Latch, Seat
7 5411392 1 Cap, Seat Latch
8 2682453-070

2681769-070

9 5431986 1 Tongue, Seat

10 7621479 2 Rivet

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

11Seat, Black

Covering, Seat, Black

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 4 Rivet
25 2670133 2 Reflector, Red
26 7512282 16 Bolt
27 -- -- -- -- -- -- -- 2 Footpad

28 5850147

5850148
29 5211131-067 2 Bracket, Mudflap
30 5810957 1 Foil, Rear Cab
31 5220880 2 Bracket, Rear Seat Holddown

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

11Mudflap, Rear, LH

Mudflap, Rear, RH

3/00

A6

FRONT BUMPER and SHIELDS

Scrambler 500 A00BG50AA

2

1

3

4

5

6

19

25

24

23

11

21

22

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

1 7558402 2 Washer, Flat
2 7512329 2 Bolt
3 5811675 1 Plug, Frame
4 7547071 2 U-Nut
5 5850141 2 Shield, Deflector
6 1012773-067 1 Bumper, 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

20 13

18

15

14

13

12

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 2670134 2 Reflector, Amber
22 7621467 2 Rivet
23 5131036 1 Heat Sink
24 4060173 1 Regulator, Rectifier
25 7512018 3 Screw

17

11

7

8

16

11

7

8

9

10

9/99

A7

CONTROL PANEL

Scrambler 500 A00BG50AA

1

2

3

9

4

5

6

7

8

10

11

12

5

13

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

1 5430967 1 Plug
2 4040054 1 Indicator, Neutral/Reverse
3 4040053 1 Indicator, Hot Temperature
4 5433534 1 Cover, Key
5 4110264

4010278

4010321

1

Switch, Ignition (Incl. Key)

1

Key, Blank, Series 2000, 6700, 6800.
NOTE: Spare key must be cut from
existing key.

1

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 Panel, Control, Inner
13 7080746 1 Cable, Choke

10/00

A8

COOLING SYSTEM

Scrambler 500 A00BG50AA

5

6

7

15

8

1

2

4

11

3

23

12

22

9

10

13

14

16

17

19

26

21

20

24

25

31

30

32

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

1 7542122 2 Nut, Nylok
2 7558301 2 Washer, Flat
3 5432593 1 Shroud, Fan, ATV
4 7512084 2 Screw
5 5430743 1 Cap, Overflow, Drilled
6 5810279 1 Gasket, Overflow Cap
7 5431895 1 Plug, Cap
8 2520165

5433410

9 8450003-1525 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

11Asm., Surge Tank w/Fitting

Tank, Surge

29

28

27

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 4170013 1 Motor, Fan
25 5241355-067 1 Bracket, Cooling Fan
26 5242550 1 Blade, Fan
27 7517475 3 Screw
28 7512232 4 Screw
29 5410584 2 Bushing, Mount, Lower Radiator
30 7558201 3 Washer, Flat
31 7547004 3 Nut, Nylok
32 4010369 1 Breaker, Circuit

18

3/00

A9

14

EXHAUST SYSTEM

Scrambler 500 A00BG50AA

1

2

3

4

16

15

5

13

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

1 7515316 2 Bolt
2 5410241 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

7

5

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

6

12

11

10

9

5

7

5

8

5/99

A10

ENGINE MOUNTING

Scrambler 500 A00BG50AA

3

1

2

4

9

39

42

40

41

38

43

27

17

9

28

19

11

10

12

13

14

15

16

1

9

18

29

23

22

10

9

1

20

21

5

6

44

2

37

45

46

47

1

8

7

40

24

25

26

36

35

34

32

12

33

30

31

1

A11

ENGINE MOUNTING

Scrambler 500 A00BG50AA

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

1 7547108 6 Nut, Flange
2 7555823 3 Washer, Flat
3 4010132 1 Cable, Ground/Engine
4 7512232 1 Screw
5 3110044 1 Mount, Rubber, Top
6 5242674-067 1 Bracket, Mount, Engine, Top
7 7552901 2 Washer, Spring Lock
8 7512315 2 Bolt
9 7080003 4 Clamp, Hose, Red

10 8450040-600 AR Line, Fuel

11 8450003-1525 AR Line, Fuel
12 3084205 3 Screw and Washer
13 3110032 2 Mount, Radiator
14 5242258-067 1 Bracket, Carburetor Mount
15 7552605 2 Washer, Split Lock
16 7542105 2 Nut
17 -- -- -- -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D10, Ref. 18)
18 8360009-600 AR Line, Fuel
19 8450080-58 1 Sheath, Foil, Laminated
20 1012883-067 1 Mount, Rear Motor
21 7547089 2 Nut, Flange, Lock
22 3110046 2 Mount, Rubber
23 7517289 1 Screw
24 7555815 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 Clamp
38 7552603 1 Washer, Spring Lock
39 7515438 1 Screw
40 7080696 2 Clamp
41 -- -- -- -- -- -- -- 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, Black
45 -- -- -- -- -- -- -- 1 Gasket, Exhaust

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

NOTE: The Short Block assembly

contains a crankcase assembly, cylin-

der and cylinder head assembly, and a

piston & crankshaft assembly. Prior

authorization required for warranty

consideration.
47 -- -- -- -- -- -- -- AR Hose, Engine, Upper (See Cooling

System Pg. A9, Ref. 13)

9/99

A12

OIL T ANK

Scrambler 500 A00BG50AA

5

6

4

7

3

2

1

25

24

8

11

9

12

13

14

15

16

10

23

6

19

20

21

22

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

1 7511848 2 Screw
2 5211523 1 Plate, Vent, Oil Tank
3 5830053 1 Gasket, Oil Reservoir
4 7052163 1 Fitting
5 5411873 1 Hose, Breather
6 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

17

18

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, Flat
22 7512130 2 Screw
23 5850135 1 Washer
24 7515158 9 Screw
25 5131255 1 Tank, Oil, RH

11/02

A13

FUEL TANK

Scrambler 500 A00BG50AA

5

6

4

3

2

7

8

9
10

21

23

24

1

12

13

15

16

21

24

23

21

21

27

25

26

20

14

19

18

17

11

22

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

1 2511342

5432879
2 5811527 1 Seal, Foam
3 5410842 1 Grommet, Fuel Tank
4 5810144 1 Gasket, Fuel Cap
5 5430725 1 Cap, Gas Tank
6 8360009-600 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

11Asm., Fuel Tank (Incl. 7,20,25,26)

Tank, Fuel

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 Filter
23 8450080-27 1 Sheath, Foil, Laminated
24 8450040-600 1 Line, Fuel
25 7052190 1 Valve, Fuel
26 5810859 1 Gasket, Fuel Valve
27 8360026 2 Foam, Tape, Black

5/99

A14

DECALS

Scrambler 500 A00BG50AA

4

1

2

10

RH

7

8

3

5

6

7

8

9

14

11

12

13

2

15

16

17

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

1 7072786 1 Decal - Warning, Heavy Loads
2 7078433

7078434
3 7077802 1 Decal - Tank Side, RH
4 7078020 1 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

11Decal - “4x4 CDS”, LH

Decal - “4x4 CDS”, RH

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, Tire Pressure
16 7077919 1 Decal - Warning, General
17 7077365 1 Decal - Fuel Lever

LH

10/00

B1

PROP SHAFT

Scrambler 500 A00BG50AA

2

1

11

2

2

8

10

9

7

6

3

5

4

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

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.,PropShaft(Incl.5-8)
10 7661913 1 Pin, Spring
11 7558301 2 Washer, Flat

B2

9/99

FRONT HOUSING

Scrambler 500 A00BG50AA

13

14

15

26

16

25

17

18

19

20

21

22

12

11

10

9

8

7

6

5

4

3

2

1

28

27

24

23

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

1341276 1 Asm., Front Gearcase (Incl.

1-12,16-25)(If built before 7/01/99)
1 3233252 12 Screw
2 3233248 2 Seal
3 3233701 1 Cover, Input, Front Housing
4 3233700 1 O-Ring
5 3233699 1 Ring, Retaining
6 3233589 1 Bearing, Ball
7 3233698 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
19 3233020 1 Bearing
20 3233554 AR Shim
21 3233693 1 O-Ring
22 3233692 1 Cover, Output, Front Housing
23 3233583 AR Shim
24 3233702 1 Button, Thrust
25 3233254 1 Washer, Plug
26 3233253 1 Plug, Drain
27 7512492 4 Screw
28 7552603 4 Washer, Spring Lock

1

SubAsm., Output Shaft, Front Housing

1

Shaft, Output

1

Gear, 29T

2

1

9/99

B3

FRONT HOUSING

Scrambler 500 A00BG50AA

13

14

15

16

12

10

9

11

8

7

6

5

4

3

2

1

27

28

26

25

17

18

19

20

21

22

2

1

24

23

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

1341323 1 Asm., Front Gearcase (Incl. 1-12,16-26)

(Units built after 7/0199)
1 3233252 12 Screw
2 3233248 2 Seal
3 3233701 1 Cover, Input, Front Housing
4 3233700 1 O-Ring
5 3233699 1 Ring, Retaining
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, Output, Front Housing
23 3233583 AR Shim
24 3233582 1 Button, Thrust
25 3233254 1 Washer
26 3233253 1 Plug, Drain
27 7552603 4 Washer, Lock
28 7512492 4 Screw

5/99

B4

CV JOINT - NEAPCO

Scrambler 500 A00BG50AA

Brand Designated

7

2

1

3

5

4

11

12

6

8

9

10

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

1380118 2 Asm., CV Housing w/Sleeve (Incl. 1)
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

B5