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
22
24
28
27
26
25
FRONT STRUT
Scrambler 500 A00BG50AA
1
2
4
3
8
23
6
5
5
7
8
19
18
17
11
12
14
13
16
15
16 2201311
2201312
17 7041603-067 2 Spring, Coil, Strut
18 5243364 2 Retainer, Spring
19 5432871 2 Ball, Pivot, Bottom
20 7515339 4 Bolt
21 5132062 2 Spacer
22 -- -- -- -- -- -- -- 1 Kit - Drive Shaft w/Sleeve (See CV
23 3610028 2 Seal, Hubstrut
24 5432872 2 Ball, Pivot , Top
25 5810291 2 Spacer, Rubber
26 7555749 2 Washer
27 7547104 2 Nut, Nylok
28 7052028 2 Grommet
12
11
11Asm., Hubstrut, LH (Incl. 9,13-16)
Asm., Hubstrut, RH (Incl. 9,13-16)
Joint - Neapco Pg. B5, Ref.12)
21
8
20
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5411608 2 Bumper
2 7041762 2 Strut, Front
3 5 2 1111 5 2 Washer
4 7080573 2 Clamp, Rubber Coated
5 7542303 4 Nut, FLEXLOC
6 7512365 4 Screw
7 7552901 4 Washer, Spring Lock
8 7558402 10 Washer, Flat
9 5810439 2 Retainer, Strut Casting Wire
10 -- -- -- -- -- -- -- 1 Asm., Front Brake Caliper, 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
9
10
3/00
B6
FRONT WHEEL
Scrambler 500 A00BG50AA
1
2
3
4
5
6
7
A
8
25
24
9
15
16
7
6
10
18
17
19
11
20
12
13
14
DETAIL A
23
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512325 8 Bolt
2 5211869 2 Disc, Brake
3 3610019 2 Seal, Front Hub
4 5211148 2 Plate, Armature
5 1520281 2 Asm. Clutch, Front Hub, Elec./Mech.
(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, Hub
21 7512027 6 Screw
22 7542810 2 Nut
23 7542459 8 Nut, Lock
24 1520207-117 2 Rim, Front
25 1525017 2 Valve, Rim
22
B7
21
5/99
FRONT BRAKE
Scrambler 500 A00BG50AA
23
1
5
11
10
9
8
12
4
6
7
13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1910271
1910264
1930642 1 Kit - Front Brake Boot (Incl. 8,12)
1 7080352 2 Screw, Bleeder
2 7515489 2 Screw, Socket Set
3 5131261
5131262
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
11Asm., Front Brake Caliper, LH
(Incl. 1-7)
Asm., Front Brake Caliper, RH
(Incl. 1-7)
11Caliper,Brake,LH
Caliper,Brake,RH
8 5410494 1 Boot, Pin Seal
9 -- -- -- -- -- -- -- 4 Washer, Flat
10 -- -- -- -- -- -- -- 4 Washer, Lock
11 -- -- -- -- -- -- -- 4 Screw
12 5410495 1 Boot, Bushing
13 1910412 2 Mount, Caliper
14 2200901
2201149
2200465
(See Front Strut Pg. B6 Ref. 8)
(See Front Strut Pg. B6 Ref. 7)
(See Front Strut Pg. B6, Ref. 6)
1
Kit - Severe Duty Brake Pad, Front
(Complete set of 2 pads)
1
Kit - Brake Pad, Soft, Front
1
Kit - Brake Pad, General, Front
14
10/00
B8
A- ARM/STRUT MOUNTING
Scrambler 500 A00BG50AA
29
28
23
22
21
24
31
25
30
26
28
23
11
20
4
5
6
7
8
9
10
12
13
14
15
16
17
19
18
14
1
2
3
29
24
27
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542403 2 Nut, FLEXLOC
2 5333367 1 Bushing
3 1820805 2 Asm., Tie Rod (Incl. 4-9)
4 5411291 2 Boot, Seal, Rod End
5 7061034 2 Rod End, RH
6 7542711 2 Nut
7 5020926 2 Tie Rod
8 7547028 2 Nut, LH
9 7061054 2 Rod End, LH
10 5411920 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
23 5431596 4 Bushing, A-Arm, Long
24 5020677 4 Bushing
25 5020681 2 Shaft, A-Arm
26 2201157
2201158
27 7080433 2 Fitting, Lubrication
28 7552603 4 Washer, Spring Lock
29 7512492 4 Screw
30 7517527 1 Bolt
31 7515415 1 Screw
11Shield, CV Joint, LH
Shield, CV Joint, RH
11Kit - A-Frame, LH
Kit - A-Frame, RH
B9
10/00
HANDLEBAR/HEADLIGHT
Scrambler 500 A00BG50AA
1
19
12
22
20
21
2
17
16
15
3
4
5
12
14
6
7
13
9
8
10
11
18
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
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 Handlebar
3 7515189 4 Screw
4 5521181 1 Pad, Handlebar
5 2682454 1 Pad, Handlebar 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 7080631 1 Clip, Cable Retaining
19 2431016
4030061
20 1040579-067 1 Guard, Headlight
21 7512111 2 Bolt
22 5630616-067 2 Block, Handlebar Retainer
21Headlight
Bulb, Headlamp
5/99
B10
STEERING POST
Scrambler 500 A00BG50AA
1
16
2
14
3
4
13
12
5
6
11
15
10
6
5
7
5
8
9
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1843051 1 Asm., Steering Post (Incl. 12,13)
2 5433415 1 Bushing, Steering 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 Nut, Nylok
9/99
B11
CONTROLS - THROTTLE ASM./CABLE
Scrambler 500 A00BG50AA
1
2
3
4
5
6
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
B12
CONTROLS - MASTER CYLINDER/BRAKE LINE
Scrambler 500 A00BG50AA
2
3
4
18
24
25
26
22
15
18
16
19
14
20
17
21
13
1
12
5
6
7
8
9
11
23
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2200809
2050073
2 1930797 2 Screw, Cap
3 1930796 1 Cap, Reservoir
4 1930795 1 Diaphragm
5 2200808 1 Kit - Clamp
6 1930799 1 Asm., Master Cylinder Piston
7 1930804 1 Rivet
8 2201034 1 Kit - Brake Lever w/Parking Brake
9 -- -- -- -- -- -- -- 1 Spring, Flat
10 1930806 1 Nut
11 2201090 1 Kit - Park Brake Lever (Incl. 7,9)
12 1930792 2 Screw
11Kit - Master Cylinder Reservoir
(Incl. 2,3,4,14)
Asm., Master Cylinder (Incl. 1-14)
Latch (Incl. 7, 9,11)
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 1930809 1 Line, Brake, Left Front w/Fittings
22 8360031-30 1 Conduit
23 7512024 2 Screw
24 8360011-38 1 Tubing, Convoluted
25 1930812 1 Line, Brake, Right Front w/Fittings
26 7052237 1 Fitting, Cross
10
B13
5/99
DRIVE CLUTCH
Scrambler 500 A00BG50AA
6
5
1
2
3
4
13
7
7
8
12
14
9
11
10
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512176 6 Bolt
2 7552801 6 Washer, Spring Lock
3 3576510 1 Cover, Bearing
4 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
Spacer (.020)
AR
Spacer (.025)
AR
Spacer (.032)
AR
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 4,9)
5/99
B14
15
14
13
12
16
17
DRIVEN CLUTCH
Scrambler 500 A00BG50AA
6
2
1
3
4
5
11
10
9
2
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7556120 AR Bushing
2 1321798 1 Asm., Driven Clutch (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
8
7
5/99
C1
GEARCASE MOUNTING
Scrambler 500 A00BG50AA
3
1
2
8
13
12
8
4
3
11
10
8
9
6
7
5
4
8
3
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517632 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
13 7517640 1 Screw
AR
AR
AR
Shim (.010”)
Shim (.020”)
Shim (.030”)
C2
5/99
REAR CALIPER MOUNTING
Scrambler 500 A00BG50AA
7
Frame
1
7
5
6
18
2
17
4
3
5
6
8
4
9
16
15
14
11
12
13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517231 2 Screw
2 7555806 2 Washer, Flat
3 1910367
2201385
2201428
2201467
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
1
Caliper, Rear
1
Kit - Caliper Seal
2
Kit - Bleeder Replacement
1
Piston, Caliper, Rear
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 Guard, Brake Disc
18 2201189
1910339
1930860
10
1
Kit - Brake Pad (Incl. Spacer and Pin)
1
Spacer
1
Pin
9/02
C3
REAR BRAKE MASTER CYLINDER
Scrambler 500 A00BG50AA
2
2
22
8
6
7
6
10
11
12
13
19
1
4
20
3
5
4
12
11
21
18
15
9
17
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080880 1 Clamp, Hose
2 7512113 3 Bolt
3 5244091-067 1 Bracket, Reservoir Mount
4 7542122 3 Nut, Nylok
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, Nylok
20 1910377-067 1 Rod, Brake
21 7041750 1 Spring, Torsion
22 7512383 2 Screw
16
15
14
5/99
C4
REAR WHEEL
Scrambler 500 A00BG50AA
2
1
3
4
9
8
6
7
5
4
8
12
11
9
10
2
1
6
5
7
Ref. Part No. Qty. Description Ref. Part No. Qty. 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
C5
REAR HOUSING
Scrambler 500 A00BG50AA
1
2
4
3
3
5
6
7
8
9
10
11
12
13
14
15
16
21
22
13
12
11
10
6
23
19
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7710472 2 Ring, Retaining
2 5510313 2 Extrusion, Retainer, Nut
3 7542439 6 Nut, Nylok
4 5411555 2 Seal, Foam
5 5211849 1 Disc, Brake
6 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
24
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 3 2 2 1111 - 0 7 6 1 Chain, 520 O-Ring
21 7512404 3 Bolt
22 1520258 1 Asm.,Hub,Sprocket(Incl.6)
23 3222109 1 Sprocket, 36T
24 5630586 1 Spacer
20
17
19
18
4
3
2
1
3/00
C6
27
AIR BOX
Scrambler 500 A00BG50AA
1
28
2
3
4
5
6
7
15
26
18
25
17
24
23
22
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517541 4 Screw
2 5432859 1 Duct, Inlet
3 5411422 1 Gasket, Intake
4 5432868 1 Cover, Air Box
5 5811482 1 Seal, Cover
6 7515179 2 Screw
7 7558301 2 Washer, Flat
8 8450073-600 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
21
19
18
20
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, Fuel
24 7080650 1 Clamp, Hose
25 5242044 6 Clip
26 5432601 1 Collar, Inlet, Carb
27 7080595 1 Filter, Air
28 5811633 1 Filter, Sleeve, Precleaner
8
16
9
15
10
9
11
12
14
13
3/00
C7
CLUTCH COVER
Scrambler 500 A00BG50AA
1
2
28
27
26
25
3
4
24
5
23
22
6
21
19
20
7
8
3
18
17
9
16
10
11
12
13
14
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7547067 3 Nutsert
2 5242208-067 1 Bracket, Clutch Cover
3 7512232 3 Screw
4 5432698 1 Duct, Down Tube, Inlet
5 5411553 1 Seal, Cover
6 2201160 1 Kit - Inner Clutch Cover
(Incl. 12,16,24)
7 7555748 3 Washer
8 7512278 3 Screw
9 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, Retainer, Seal
22 5410575 1 Seal, Cover, Case
23 7555932 1 Washer
24 7512098 1 Screw
25 7555935 1 Washer
26 5242693-067 1 Bracket, Clutch Cover
27 7661638 2 Rivet
28 7080511 1 Clamp, Narrow Band
9/99
C8
ELECTRICAL/TAILLIGHT
Scrambler 500 A00BG50AA
27
4
1
3
2
26
24
12
28
29
32
5
8
9
10
11
24
25
12
23
6
7
14
15
13
22
16
17
18
19
20
21
33
34
30
28
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2460787 1 Harness, Main
2 7080138 3 Cable Tie
3 2434012 1 Breaker, Circuit, 20 AMP
4 2201795 1 Kit - Circuit Breaker, 10 AMP
5 2432038 1 Light, Tail/Brake (Incl. 6-10)
6 7512088 2 Screw
7 4032085 1 Lens
8 4030043 1 Bulb
9 4032086 1 Gasket
10 4032087 1 Backing
11 7670093 2 Clip
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
31
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 7670109 2 Clip, Routing
27 4020149 4 Clip, Rosebud
28 7512024 3 Screw
29 4010195 1 Limiter, RPM, LR-83-3
30 5810317 1 Pad, Fuel Tank Bracket
31 5241416 1 Bracket, CDI
32 8360012 1 Trim, Edge
33 2620087
5431973
5811079
34 7512232 2 Screw
1
Asm., Tool Box
1
Cover, Tool Box Lid
1
Gasket
1/00
C9
SWING ARM/SHOCK MOUNTING
Scrambler 500 A00BG50AA
1
9
2
8
26
27
3
4
5
16
25
28
7
10
6
11
13
14
15
12
18
17
16
20
30
24
12
29
1
19
23
22
21
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542439 2 Nut, Nylok
2 7041865-067 1 Spring, Compression, Small
3 7041864-067 1 Spring, Compression
4 7075343 1 Decal - Warning, Fox Shock
5 1500278 1 Ring, Spring Preload
6 5433550 1 Spacer, Spring
7 7041867 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
22 5332828 1 Bushing
23 7558402 1 Washer
24 7542321 1 Nut
25 7542503 2 Nut
26 7555883 4 Washer
27 7512576 2 Bolt
28 7517761 1 Screw
29 5433411 1 Bushing, Swing Arm, LH
30 5131695 1 Bushing, Pivot, LH
8/01
C10
58
57
59
41
60
45
56
44
GEARCASE
Scrambler 500 A00BG50AA
24
37
25
27
26
28
36
29
30
35
31
34
32
33
1
43
42
34
41
2
15
46
47
34
3
4
5
6
7
4
8
55
32
54
48
49
9
2
41
50
16
51
11
14
52
10
171918
16
12
13
15
53
38
23
22
21
20
40
39
C11
GEARCASE
Scrambler 500 A00BG50AA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1341284 1 Asm., Gearcase (Incl. 1-59)(Units built
before April 23, 1999)
1 3233632 1 Gearcase, LH Mach
2 3233018 3 Bearing, Ball
3 3233557 1 Shaft, Reverse 31T
4 3233012 2 Washer, Thrust
5 3233014 1 Bearing, Needle
6 3233532 1 Sprocket, 24T
7 3233029 1 Ring, Retaining
8 3233533 1 Engagement Dog
9 3233010 1 Washer, Thrust
10 3233633 1 Fork, Shift High/Rev. Mach
11 3233534 1 Bushing, Garlock
12 3233535 1 Gear, 30T
13 3233176 1 Washer, Thrust
14 3233177 1 Ring, Retaining
15 3233019 1 Bearing, Ball
16 3233033 4 Screw
17 3233309 1 Bracket, Interlock
18 3233550 1 Spring, Shifting Interlock
19 3233308 2 Pin, Interlock
20 3233559 1 Shaft, Shift
21 3233040 1 Washer
22 3233547 1 Bellcrank
23 3233055 1 Nut, FLEXLOC
24 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
8360009-6001AR
40 3233636 1 Decal - Switch
41 3233020 3 Bearing, Ball
42 3233546 1 Chain, Roller 26P
43 3233545 1 Sprocket, 16/26T
44 3233544 1 Shaft, Output
45 3233558 1 Gear, 98T
46 3233537 1 Ring, Retaining
47 3233538 1 Sprocket, 14/22T
48 3233263 1 Bearing, Cover, Center Drive
49 3233306 1 Ring, Retaining
50 3233540 1 Shaft, Pinion 13T
51 3233541 1 Bushing, Garlock
52 3233542 1 Washer, Thrust Button Pinion
53 3233043 1 Deflector, Oil
54 3233036 1 Chain, Silent
55 3233536 1 Shaft, Input
56 3233529 2 Pipe, Knock
57 3233252 11 Screw
58 3233527 1 Bushing, Pivot
59 3233448 1 Plug
60 3233035 1 Washer
Tube, Vent
Line, Fuel
5/99
C12
55
54
56
32
57
42
53
41
GEARCASE
Scrambler 500 A00BG50AA
21
35
22
23
24
25
34
26
27
33
32
28
29
30
31
1
40
39
30
2
12
32
43
44
30
3
5
4
6
7
52
29
51
45
46
6
2
32
47
13
48
8
15
14
13
4
9
10
11
50
49
38
16
12
20
19
18
17
37
36
C13
GEARCASE
Scrambler 500 A00BG50AA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1341328 1 Asm., Gearcase (Incl. 1-57)
(Units built after April 23, 1999)
1 3233632 1 Gearcase, LH Mach
2 3233018 3 Bearing, Ball
3 3233728 1 Shaft, Reverse 31T
4 3233718 2 Bearing, Needle
5 3233719 1 Sprocket, 24T
6 3233720 2 Ring, Retaining, E-Ring
7 3233721 1 Dog, Engagement
8 3233633 1 Fork, Shift High/Rev., Mach
9 3233722 1 Gear, 30T
10 3233176 1 Washer, Thrust
11 3233177 1 Ring, Retaining
12 3233019 1 Bearing, Ball
13 3233033 4 Screw
14 3233309 1 Bracket, Interlock
15 3233550 1 Spring, Shifting Interlock
16 3233308 2 Pin, Interlock
17 3233559 1 Shaft, Shift
18 3233040 1 Washer
19 3233547 1 Bellcrank
20 3233055 1 Nut, FLEXLOC
21 3233054 1 Washer
22 3233045 1 Ring, Retaining
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
8360009-6001AR
37 3233636 1 Decal - Switch
38 3233798 1 Gearcase, RH Mach
39 3233546 1 Chain, Roller 26P
40 3233545 1 Sprocket, 16/26T
41 3233544 1 Shaft, Output
42 3233558 1 Gear, 98T
43 3233537 1 Ring, Retaining
44 3233538 1 Sprocket, 14/22T
45 3233263 1 Bearing, Cover, Center Drive
46 3233306 1 Ring, Retaining
47 3233540 1 Shaft, Pinion 13T
48 3233541 1 Bushing, Garlock
49 3233542 1 Washer, Thrust Button Pinion
50 3233043 1 Deflector, Oil
51 3233036 1 Chain, Silent
52 3233536 1 Shaft, Input
53 3233529 2 Pipe, Knock
54 3233252 11 Screw
55 3233527 1 Bushing, Pivot
56 3233448 1 Plug
57 3233035 1 Washer
Tube, Vent
Line, Fuel
12/00
C14
GEAR SELECTOR
Scrambler 500 A00BG50AA
1
2
3
4
5
14
6
7
12
11
8
9
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5411006 1 Cover
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
10
13
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
6
5/99
D1
FOX SHOCK, GAS, RESERVOIR
Scrambler 500 A00BG50AA
18
17
24
9
8
13
10
14
26
27
11
12
15
25
27
29
28
1
2
5
3
16
4
20
19
6
7
22
23
21
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
7041867 1 Shock, Gas, Reservoir
1 1500021 1 O-Ring
2 1500020 1 O-Ring
3 1500025 1 Wiper, Inner
4 1500024 1 Wiper, Clear, Outer
5 1500287 1 Asm., Screw
6 1500018
1500023
7 1500006 1 Ring, Piston, Floating, Fox
8 1500003 1 O-Ring, Fox End Cap
9 1500011 1 Piston, IFP
10 1500099 1 Asm., Cap, Reservoir, ATV Fox Shock
11 1500097 1 Retaining Ring, ATV Fox Shock
12 1500072
1500019
1500022
11Screw
O-Ring
(Incl. 11,12,13)
1
Asm., Air Valve
1
Screw
1
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 1 Asm., Cap-Body, Fox ATV
22 1500285 1 Asm., Bearing
23 1500017 1 Plate, Top-Out
24 1500002 1 Ring, Piston, Fox
25 1500015 1 Bushing, Back-up
26 1500016 1 Nut, Lock
27 1500004 1 O-Ring, Fox
28 5020657 1 Sleeve
29 1500104 2 Bushing, Eyelet
5/99
D2
SHOCK VALVING
Scrambler 500 A00BG50AA
Shaft
1
2
3
4
5
6
7
8
Piston
9
10
11
12
13
Nut
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
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
D3
CRANKCASE
Scrambler 500 A00BG50AA
3
6
2
7
5
22
21
8
9
18
17
20
2
4
10
16
11
15
5
12
13
14
1
19
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083669 1 Bushing, Starter
2 3085808 1 Asm., Crankcase
(Incl. 1,4,5,7,8,10,11,16,19,20,22)
3 3084838 2 Pin, Straight
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 3084836 1 Seal, Oil
21 3084847 1 O-Ring
22 3080103 2 Pin, Dowel
5/99
D4
CYLINDER
Scrambler 500 A00BG50AA
36
2
1
3
4
38
36
37
8
7
6
5
17
16
9
10
12
11
13
5
14
15
33
34
36
21
22
23
18
28
29
27
30
26
24
25
35
9
18
19
20
31
32
13
D5
CYLINDER
Scrambler 500 A00BG50AA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084045 1 Asm., Band, Adapter (Incl. 2)
2 3081497 1 Screw
3 3081330 2 Bolt
4 3084857 2 Pin, Straight
5 3084994 4 Guide, Valve
6 3084858 2 Seal, Intake Valve
7 3084867 1 O-Ring
8 3085072 1 Adapter, Water Out
9 3084877 10 Bolt, Flange
10 3084866 1 Adapter, Camshaft
11 3085074 1 Gasket, Rocker Cover
12 3085073 1 Cover, Rocker
13 3084874 10 Bolt, Flange
14 3084859 2 Seal, Exhaust Valve
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 3084873 4 Bolt, Flange
31 3086811 1 Cylinder (Incl. 32)
32 3084130 1 Pipe 2, Elbow
33 3085370 1 Gasket, Cylinder
34 3084868 1 Cover, Camshaft
35 3086200 1 Gasket, Cover, Cam
36 3085527 1 Head, Cylinder (Incl. 4-6,14,16-18,21)
37 3085371 1 Gasket, Head
38 3085809 1 Adapter
5/99
D6
CRANKSHAFT and PISTON
Scrambler 500 A00BG50AA
2
1
3
1
4
5
6
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
Spacer (0.6)
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
12
3084896
3084897
3084892
3084893
3084894
7
13
1
1
1
1
1
1
1
22
8
21
20
16
17
18
19
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3085534 2 Clip
2 3085866
3085867
3085868
3 3085379
3085380
3085381
4 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
Asm., Piston Set (Std) (Incl. 1)
1
Asm., Piston Set (0.25 O/S) (Incl. 1)
1
Asm., Piston Set (0.50 O/S) (Incl. 1)
1
Piston Ring Set (Std)
1
Piston Ring Set (0.25 O/S)
1
Piston Ring Set (0.50 O/S)
11Asm., Crankshaft (Incl. 4,5-12,20)
Crankshaft 1
9
10
11
15
14
12 3085852 1 Gear 1, Balancer
13 3086837 1 Shaft, Balancer
14 3084895
15 3240088
16 3084882 1 Sprocket 1
17 3085528 1 Nut, Slit
18 3083904 1 Washer
19 3083905 1 Nut, Lock
20 3085346 1 Pin, Dowel
21 3081447 1 Key
22 3240168 1 Key, Woodruff
5/99
D7
INTAKE and EXHAUST
Scrambler 500 A00BG50AA
26
27
9
8
9
8
1
2
3
4
5
25
6
7
8
9
10
6
11
12
13
18
12
13
11
14
15
16
17
24
23
20
19
21
22
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084845 1 Plug
2 3084920 1 Gasket, Plug
3 3086839 1 Spring, Tensioner
4 3086813 1 Asm., Tensioner (Incl. 1-3)
5 3084922 1 Gasket, Tensioner
6 3084910 2 Asm.,RockerArm,Intake(Incl.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 Guide, Chain
22 3084915 1 Chain, Timing
23 3084924 1 Bolt, Pivot
24 3084917 1 Lever
25 3085349 2 Valve, Intake
26 3084905 2 Valve, Exhaust
27 3084874 2 Bolt, Flange
5/99
D8
CARBURETOR
Scrambler 500 A00BG50AA
2
3
4
5
6
7
8
1
19
20
21
18
17
22
29
23
28
25
24
26
27
30
10
16
9
13
12
11
42
43
14
15
41
40
14
39
44
29
38
37
36
35
52
51
50
34
33
31
32
49
48
47
46
45
D9
CARBURETOR
Scrambler 500 A00BG50AA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3130821 2 Screw
2 3130914 1 Cover, Diaphragm
3 3130911 1 Spring
4 3130913 1 Ring
5 3130908 1 E-Ring
6 3130915 1 Ring
7 3130918 1 Needle, Jet
8 3130910 1 Diaphragm
9 3130912 1 Valve, Piston
10 3130543 1 Guide, Cable
11 3130931 1 Asm., Throttle Shaft
12 3130932 1 Ring
13 3130927 1 Spring
14 3130933 4 Screw
15 3130926 2 Washer
16 3130925 1 Case
17 3130619 1 Jet, Air
18 3130903 1 Asm., Carburetor (Incl. 1-52)
19 3130920 1 Jet, Needle
20 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 3130928 1 O-Ring
39 3131294 1 O-Ring
40 3130930 1 Cover
41 3130924 3 Screw
42 3130010 1 Spring
43 3130938 1 Asm., Adjuster, Cable
44 3130937 1 Clip
45 3131291 1 Screw, Guide
46 3130239 1 O-Ring
47 3130571 1 Jet, Main (#155)
48 3130919 1 Ring
49 3130935 1 Screw
50 3130923 1 Asm., Float Body
51 3130917 1 Seal
52 3131293 1 Asm., Float
7/00
D10
RECOIL STARTER
Scrambler 500 A00BG50AA
1
7
8
9
5
4
3
2
6
15
11
12
14
8
13
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084822 1 Reel
2 3083463 1 Spring, 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
15 3085083 1 Asm., Rope
10
11Asm., Recoil (Incl.1-6,9-11,14,15)
Starter Case (Incl. 11)
5/99
D11
WATER PUMP
Scrambler 500 A00BG50AA
1
2
3
4
3
8
7
6
5
13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084940 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
11
9
12
10
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
D12
OIL PUMP
Scrambler 500 A00BG50AA
4
3
2
1
5
10
9
6
7
18
17
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084946 1 Pump, Oil, Case 2
2 3084949 1 Rotor, Outer (Feed)
3 3084948 1 Rotor, Inner (Feed)
4 3085817
3084945
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
11Asm., Oil Pump (Incl. 1-8,10-15)
Pump, Oil, Case 1
8
15
14
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
AR
AR
13
Spacer (0.8)
Spacer (1.0)
Spacer (1.2)
D13
11
12
5/99
OIL FILTER
Scrambler 500 A00BG50AA
1
2
4
3
3
2
5
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
2
2
3
2
6/98
D14
MAGNETO
Scrambler 500 A00BG50AA
2
1
3
16
17
18
19
20
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084690
3084979
2 3084980 1 Cap, Spark Plug
3 3084997 1 Plug, Spark
4 3084978 1 O-Ring
5 3084972 1 Metal, Bearing
6 3086820
3085560
3086980
3086981
7 3081657 5 Bolt and Washer
8 3084973 1 Seal, Oil
9 3086821
3086984
11Asm., Ignition Coil (Incl. 1,2)
Coil, Ignition
1
Asm., Plate (Incl. 5,6,8-12,14,15)
(Up to S#00-04730)
1
Plate (Up to S#00-04730)
1
Asm., Plate (Incl. 5,6,8-12,14,15)
(S#00-04730 & after)
1
Plate (S#00-04730 & after)
11Stator (Incl. 13)(Up to S#00-04730)
Stator (Incl. 13)(S#00-04730 & after)
13
12
10
15
14
5
11
8
7
9
10 3085563
3086985
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 3085639
3086982
17 3083073 2 Nut
18 3080077 2 Washer, Spring
19 3085521 1 Switch, Magnetic
20 3086819
3086983
33Screw and Washer (Up to S#00-04730)
Screw and Washer (S#00-04730 & after)
11CDI System (Up to S#00-04730)
CDI System (S#00-04730 & after)
11Flywheel w/Ring Gear (Up to S#00-04730)
Flywheel w/Ring Gear (S#00-04730 & after)
6
4
12/99
E1
STARTING MOTOR
Scrambler 500 A00BG50AA
3
2
1
7
8
4
5
6
12
10
9
17
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3084981 1 Asm., Starting Motor (Incl. 1-4,6-10,12)
1 3084982 1 Washer Set
2 3084406 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
11
14
15
16
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 3084409 1 Clip
13
5/99
E2
FUEL PUMP
Scrambler 500 A00BG50AA
3
2
1
2
4
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
E3
TOOL KIT
Scrambler 500 A00BG50AA
3
1
4
5
6
2
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 9915299
9915470
2 3085544 1 Asm.,ToolKit(Incl.4-9)
3 2870725 1 Gauge, Tire Pressure
4 3085001 1 Wrench, Open, 8-10mm
5 3085002 1 Wrench, Open, 12-14mm
11Owner’s Manual, ’00 ATV
Supplement, Owner’s Manual, ’00
Scrambler 500
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
8
9
10
3/00
E4
PRINTED IN THE USA PARTS MANUAL PN 99155485 and MICROFICHE PN 9916574 3/00
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Changed pages in 9915485
A cover toc x
B
C
D
E
F
G
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