Download - SCRAMBLER 4002X4 Model #A01BA38CA - pi54.compi54.com/corp/manuals/Parts/9916836.pdf · SCRAMBLER 4002X4 Model #A01BA38CA E ... Speed, U-Clip 2 5244482-067 5244483-067 1 1 ... 17 7052147

PARTS MANUAL PN 9916836 and MICROFICHE PN 9916837 10/00

SCRAMBLER 400 2X4Model #A01BA38CA

E 2000 Polaris Sales Inc.E 2000 Polaris Sales Inc.

TABLE OF CONTENTSScrambler 400 2x4 A01BA38CA

Parts Manual

AA-ARM/STRUT MOUNTING B3. . . . . . . . . . . . .AIR BOX B14. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR C14. . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C1. . . . . . . . . . . . . . . . . . . . .CONTROL PANEL A6. . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER

CYLINDER/BRAKE LINE B7. . . . . . . . . . .CONTROLS - THROTTLE ASM./CABLE B6. . .COOLING SYSTEM A7. . . . . . . . . . . . . . . . . . .CRANKCASE and CYLINDER C11-12. . . . . . . . . . .

DDECALS A13. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B8. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH B9. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C2. . . . . . . . . . . . . . .ENGINE MOUNTING A9-10. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A8. . . . . . . . . . . . . . . . . . .

FFOX SHOCK, GAS, RESERVOIR C4. . . . . . . . .FRONT BRAKE B2. . . . . . . . . . . . . . . . . . . . . .FRONT BUMPER and SHIELDS A5. . . . . . . . . .FRONT CAB A3. . . . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B1. . . . . . . . . . . . . . . . . . . . . .FUEL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C6. . . . . . . . . . . . . . . . . . . .

GGEARCASE C7-8. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING C9. . . . . . . . . . . . . . .

HHANDLEBAR/HEADLIGHT B4. . . . . . . . . . . . .

MMAGNETO D3. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL PUMP C13. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK A11. . . . . . . . . . . . . . . . . . . . . . . . . .

PPISTON and CRANKSHAFT C10. . . . . . . . . . . .

RREAR BRAKE MASTER CYLINDER B11. . . . . . .REAR CAB A4. . . . . . . . . . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING B10. . . . . . . . . . . .REAR HOUSING B13. . . . . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE B12. . . . . . . . . . . . . . . . .RECOIL STARTER D1. . . . . . . . . . . . . . . . . . . .

SSHOCK VALVING C5. . . . . . . . . . . . . . . . . . . . .STARTING MOTOR D2. . . . . . . . . . . . . . . . . . .STEERING POST B5. . . . . . . . . . . . . . . . . . . . .STRUT A14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING C3. . . . . . . .

TTOOL KIT D5. . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D4. . . . . . . . . . . . . . . . . . . . . . .

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

A3

FRONT CABScrambler 400 2X4 A01BA38CA

11

6

7

1213

5

5

12

14

19

20

4

1516

17

10

1

1

9

18

8

12

5

2

3

13

11

E 2000 Polaris Sales Inc.

Part numbersmay have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updatedmonthly.

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

1 7670060 4 Nut, Speed, U-Clip2 5244482-067

5244483-06711

Bracket, Cab Mount, LHBracket, Cab Mount, RH

3 7517386 2 Screw4 1013530-067 1 Frame5 7512282 24 Bolt6 5431875-288 1 Cover, Front, Blazing Red7 2631988-288

2632424-288

1

1

Cab, Front, Blazing Red (w/WarningDecals)(If built before 11/13/00)Cab, Front, Blazing Red (w/WarningDecals)(If built after 11/13/00)

8 75220267517916

22

Screw (If built before 12/04/00)Screw (If built after 12/04/00)

9 7558301 2 Washer, Flat (If built befor 12/04/00)

10 7558201 2 Washer, Flat11 7621472 8 Rivet12 7542122 24 Nut, Nylok13 7555859 16 Washer, Flat14 5811831

585015011

Mudflap, Front, LHMudflap, Front, RH

15 1040691-067 2 Footpad16 7661825 8 Rivet17 5431484 2 Trim, Footrest18 5242525-067 2 Bracket, Heel Cleat19 5432763 1 Guard, Rock20 7515179 6 Screw

10/00

A4

REAR CABScrambler 400 2X4 A01BA38CA

20

8

16

28

14

3

1

29

2

19

18

2

17

27

25

24

22 23

13

126

5

21

9

1011

15

26

2

25

19220

7

24



1 7621472 4 Rivet2 7555859 16 Washer, Flat3 7512232 2 Screw4 7512242 2 Screw5 7041607 1 Spring, Latch, Light6 1040412 1 Latch, Seat7 5411392 1 Cap, Seat Latch8 2682453-288

2681769-28811

Seat, Blazing RedCovering, Seat, Blazing Red

9 5431986 1 Tongue, Seat10 7621479 2 Rivet11 5412067 6 Bumper, Rubber12 5211033 2 Bracket, Lever Retainer13 7621403 1 Rivet14 5810991 1 Foil, Rear Cab, Small15 7079901 1 Decal - Carb/Filter Information16 5432820-288

5434014-288

1

1

Cab, Rear, Blazing Red(If built before 11/16/00)Cab, Rear, Blazing Red(If built after 11/16/00)

17 7670057 2 Nut, Speed, U-Type18 2632274

581111311

Shield, MufflerFoil, Foam

19 7542122 17 Nut, Nylok20 7517264 8 Screw21 5432831 2 Plug, End Cap, Ribbed22 5241403-067 1 Guard, Clutch23 7661637 4 Rivet24 2670133 2 Reflector, Red25 7512282 16 Bolt26 ------ -- -- -- -- 2 Footpad

(See Front Cab Pg. A3, Ref. 15)27 5812134

585014811

Mudflap, Rear, LHMudflap, Rear, RH

28 5810957 1 Foil, Rear Cab29 5220880 2 Bracket, Rear Seat Holddown

1/01

A5

FRONT BUMPER and SHIELDSScrambler 400 2X4 A01BA38CA

21

3

5

6

8

12

1413

15

7

7

10

4

9

9

9

9

9

9

9

11



1 7558402 4 Washer, Flat2 7512329 2 Bolt3 5810467 1 Plug, Frame4 7542324 2 Nut, Nylok5 5850140

585014111

Shield, Deflector, LHShield, Deflector, RH

6 1040725-067 1 Bumper, Front7 7555827 4 Washer8 5432378-070 1 Plate, Skid, Bumper9 7661121 15 Rivet10 5242694-067 2 Bracket, Radiator Shield

11 5242997-067

5245343-067

1

1

Shield, Radiator Side, RH(If built before 11/13/00)Shield, Radiator Side, RH(If built after 11/13/00)

12 5242996-067

5245342-067

1

1

Shield, Radiator Side, LH(If built before 11/13/00)Shield, Radiator Side, LH(If built after 11/13/00)

13 7670088 4 Clip, Dart14 5242683-067

5245344-067

1

1

Shield, Upper Radiator(If built before 11/13/00)Shield, Upper Radiator(If built after 11/13/00)

15 2670134 2 Reflector, Amber10/00

A6

CONTROL PANELScrambler 400 2X4 A01BA38CA

12

3

5

7

8

11

10

5

9

46



1 4010140 1 Indicator, Low Oil (Symbol)2 4040054 1 Indicator, Neutral - Reverse3 4040053 1 Indicator, Temperature, Hot4 5433534 1 Cover, Key5 4110264

4010278

4010321

11

1

Switch, Ignition (Incl. Key)Blank, Key, Series 2000, 6700, 6800.NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

6 5433733 1 Nut, Ignition7 5431976 1 Panel, Control, Outer8 7512026 2 Screw9 2460664 1 Harness, Panel, Control10 5431975 1 Panel, Control, Inner11 7080371 1 Cable, Choke Control

4/02

A7

COOLING SYSTEMScrambler 400 2X4 A01BA38CA

14

42

10

23

13

22

11

18

3

112

21

19

9

20

16

17

65

8

1

3 9

11

15

7



1 7517656 4 Screw2 2410123 1 Asm., Fan and Motor3 7670111 4 U-Clip4 5434043 1 Shroud5 5020937 2 Spacer, Radiator Mount6 3110032 2 Mount, Rubber7 7558301 2 Washer, Flat8 7542122 2 Nut, Nylok9 7080614 2 Clamp, Hose10 5411986 1 Hose, Engine, Upper11 7080826 2 Clamp12 4010161 1 Sensor, Thermal w/Harness

13 1240093 1 Cap, Pressure14 1240090 1 Radiator15 7558301 2 Washer, Flat16 7512240 2 Screw17 7552801 2 Washer, Spring Lock18 7052296 1 Valve, Drain19 5410584 2 Bushing, Radiator Mount, Lower20 7080965 1 Mount, Cable Tie21 7080138 1 Cable Tie22 5521550 1 Guard, Plastic Hose23 5411989 1 Hose, Engine, Lower

9/00

A8

EXHAUST SYSTEMScrambler 400 2X4 A01BA38CA

1415

2

4

1

5

6

7

20

191817

1615

1413

9

98

10

1112

21

15

1

3



1 5410957 4 Dampener2 5010339 2 Spacer3 7555852 2 Washer4 7515316 2 Bolt, Carriage5 1260884-029 1 Silencer6 7042031 2 Spring, Exhaust7 1260881-029 1 Muffler8 1260680-029 1 Headpipe9 5211592 2 Gasket, Exhaust10 1260899-029 1 Manifold11 ------ -- -- -- -- 2 Washer (See Crankcase and Cylinder

Pg. C12, Ref. 8)

12 ------ -- -- -- -- 2 Nut (See Crankcase and Cylinder Pg.C12, Ref. 7)

13 7042029 4 Spring, Exhaust14 7542324 3 Nut, Nylok15 7555716 4 Washer16 5410436 1 Washer, Rubber17 7556401 1 Bushing18 5010350 1 Bushing19 5410241 1 Dampener, Vibration20 7515306 1 Screw21 7512666 2 Bolt

9/00

A9

ENGINE MOUNTINGScrambler 400 2X4 A01BA38CA

1

43

8

1918

171615

14

30

2928

2625

10

12

119 10

31

32

34

2829 35

5

22

23

7

3637

20

2

2

2

13

6

33

24

21

27

27

7

7

7

7

7

A10

ENGINE MOUNTINGScrambler 400 2X4 A01BA38CA



1 3110038 1 Mount, Motor2 7555823 3 Washer, Flat3 7552901 2 Washer, Spring Lock4 7512315 2 Bolt5 4010132 1 Cable, Ground, Engine6 7512232 1 Screw7 7547108 7 Nut, Flange Lock8 5242692-067 1 Bracket, Mount, Engine, Top9 3070156 1 Plug, Spark, NGK BR8ES10 7080614 2 Clamp, Hose11 ------ -- -- -- -- 1 Hose, Engine, Upper (See Cooling

System Pg. A7, Ref. 10)12 4010218 1 Cable, Solenoid/Starter, Red13 ------ -- -- -- -- 1 Hose, Engine, Lower (See Cooling

System Pg. A7, Ref. 23)14 ------ -- -- -- -- 1 Seal, Case, Cover

(See Clutch Cover Pg. C1, Ref. 29)15 ------ -- -- -- -- 1 Asm., Drive Clutch, Basic ATV-06

(See Drive Clutch Pg. B8, Ref. 14)16 5430261 1 Bushing17 5210748 1 Washer, Flat18 7575202 1 Washer, Lock19 7512566 1 Bolt20 7555806 1 Washer, Flat

21 8360012-04 1 Trim, Edge22 1040687-067 1 Mount, Engine, Front23 7517289 2 Screw24 7080511 1 Clamp25 5410883 1 Boot, Clutch Intake26 7080656 1 Clamp, Band, Narrow27 3110042 2 Mount, Rubber28 7552603 6 Washer, Spring Lock29 7512490 6 Screw30 1040231-067 1 Mount, Engine, Front31 3085821 1 Engine, Short Block (EC38PLE09)

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

32 8360009-600 AR Line, Fuel33 7051011 1 Valve, Check, Vent34 5242463-067 1 Bracket, Mount, Engine, Rear35 7542411 1 Nut, FLEXLOC36 7542432 2 Nut, Jam37 3110048 1 Mount, Torque Stop

8/01

A11

OIL TANKScrambler 400 2X4 A01BA38CA

12

34

5

6

7

10

98

15

12

11

1311

12

14



1 5430779 1 Cap, Tank, Oil2 5810141 1 Gasket, Cap, Oil3 5431793 1 Tank, Oil, Drilled4 7052077 1 Fitting5 8360009-600 AR Line, Fuel6 4110265 1 Sensor, Oil Level7 7621460 2 Rivet8 7080525 1 T-Clip

9 7517389 1 Screw10 7052153 1 Fitting11 8450003-1525 AR Line, Fuel12 7080307 2 Clamp, Hose, Large Green13 2530009 1 Filter14 7080568 1 Clamp15 7555932 2 Washer, Nylon

9/00

A12

FUEL TANKScrambler 400 2X4 A01BA38CA

5

6

7

8

15

14

1311

12

19

22

1723

11

16

1

3

4

2

10

20

1121

10

10

10

10

1111

18

9



1 1240082 1 Asm., Fuel Tank (Incl. 6,17,23)2 5410842 1 Grommet, Tank, Fuel3 5812123 1 Gasket, Cap, Fuel4 5433687 1 Cap, Tank, Fuel5 8360009-600 AR Line, Fuel6 5431053 1 Vent7 7512310 2 Bolt8 7555734 2 Washer, Flat9 7080534 2 Clamp10 7080003 6 Clamp, Hose11 8450040-600 AR Line, Fuel12 2530008 1 Filter

13 7542324 2 Nut, Nylok14 5220916-067 1 Bracket, Tank Mount, Rear15 7512208 2 Screw16 5810317 2 Pad, Fuel Tank17 7052147 1 Fitting, Fuel Outlet, Main, 90 Degree18 5242977 1 Spacer, Valve, Fuel19 5432733 1 Nut, Valve, Fuel20 5432559 1 Knob, Valve, Fuel21 7517505 1 Screw22 7052154 1 Valve, Fuel, 3-Way23 7052148 1 Fitting, Fuel Outlet, 90 Degree

9/00

A13

DECALSScrambler 400 2X4 A01BA38CA

5

6

13

4

87

5

14

109

2

11

RH

LH15

12

1

1

3

6



1 70784317078432

11

Decal - “2x4 CDS”, LHDecal - “2x4 CDS”, RH

2 7077802 1 Decal - Tank Side, RH3 7078020 1 Decal - “POLARIS”4 7078465 1 Logo, Polaris Star5 7078430 2 Decal - “Scrambler”6 7078429 1 Decal - Front Cover, “400 L/C7 7078354 1 Decal - Warning, Discretionary

8 7078577 1 Decal - Drain, Recoil9 7079604 1 Decal - Warning, Override, AWD10 7078253 1 Decal - Age Warning11 7077801 1 Decal - Tank Side, LH12 7077920 1 Decal - Passenger Warning13 7079088 1 Decal - Tire Pressure/Load14 7077919 1 Decal - Warning, General15 7074637 1 Decal - Fuel Lever

10/00

A14

STRUTScrambler 400 2X4 A01BA38CA

1

23

4

5

6

7

89

10

11

12

13

14

16

1315

17



1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Pivot, Ball, Top5 5432871 2 Pivot, Ball, Bottom6 5132062 2 Spacer7 5243364 2 Retainer, Spring8 7041868-067 2 Spring, Compression9 5411608 2 Bumper

10 7041762 2 Strut, Front11 7080367 2 Clamp, Rubber Coated12 7542324 4 Nut, Nylok13 7558402 6 Washer, Flat14 7080306 2 Fitting, Lubrication15 7515339 4 Bolt16 5131039

513104011

Support, Strut/Spindle, LHSupport, Strut/Spindle, RH

17 5211115 2 Washer

9/00

B1

FRONT WHEELScrambler 400 2X4 A01BA38CA

1

23 4

5 6

7

8

93

11

12

1415

16

17

18

10

13



1 ------ -- -- -- -- 1 Support, Strut and Spindle(See Strut Pg. A14, Ref. 16)

2 3610020 2 Seal, Hub, Front3 3513519 4 Bearing, Ball4 5243675 2 Disc, Brake5 5130940

513262722

Hub, Wheel (If built before 9/18/00)Hub, Wheel (If built after 9/18/00)

6 5411264 2 Tire, Front (23x7-10)7 1520207-117 2 Rim, Front8 1525017 2 Valve, Rim9 5010256 2 Spacer, Hub, Front

10 7555721 2 Washer11 7542712 2 Nut, Castle12 7661407 2 Pin, Cotter13 7511866 2 Screw14 5431018

543386822

Cap, Hub (If built before 9/18/00)Cap, Hub (If built after 9/18/00)

15 5410470 2 O-Ring16 7542459 8 Nut, Flange Lock17 7515523 8 Stud18 7512325 8 Bolt

9/00

B2

FRONT BRAKEScrambler 400 2X4 A01BA38CA

1

2 3

4

5 6 7

8

91011

12

1314



1910547

1910548

1

1

Asm., Front Brake Caliper, LH(Incl. 1-8)Asm., Front Brake Caliper, RH(Incl. 1-8)

1930642 1 Kit - Boot, Front Brake (Incl. 8,12)1 7080352 2 Screw, Bleeder2 7515489 2 Screw, Socket Set3 5132960

513296111

Caliper, Brake, LHCaliper, Brake, RH

4 1930665 1 Kit - Piston and Seal (Incl. 5-7)5 5410779 1 Ring, Square, Molded (.094)

6 5410780 1 Ring, Square, Molded (.103 x .134)7 5132294 1 Piston, Brake, Long8 5410494 1 Boot, Pin Seal9 7558402 4 Washer, Flat10 7552901 4 Washer, Spring Lock11 7512365 4 Screw12 5410495 1 Boot, Bushing13 1910412 2 Mount, Caliper14 2201398 1 Kit - Brake Pad, AFT, Front

9/00

B3

A-ARM/STRUT MOUNTINGScrambler 400 2X4 A01BA38CA

1 34

5

6

78

10

13

14

19

18 15

17

16

23

24

22

25

21

20

2726

28

12

14

2726

21

20

9

11

2E 2000 Polaris Sales Inc.



1 7542403 2 Nut, FLEXLOC2 7558403 2 Washer3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End, RH5 7542711 2 Nut6 5020927 2 Tie Rod7 7547028 2 Nut, Jam, LH8 7061054 2 Rod End, LH9 5411920 2 Boot, Seal, Rod End10 1820806 2 Asm., Tie Rod11 7517674 2 Screw12 7556099 4 Washer, Flat13 7546904 2 Nut14 7661203 4 Pin, Cotter15 5240717 2 Bracket, Joint, Ball

16 7512284 4 Screw17 5410548 2 Boot, Rubber18 7080927 2 Joint, Ball19 ------ -- -- -- -- 1 Support, Strut and Spindle

(See Strut Pg. A14, Ref. 16)20 5433066 4 Bushing, A-Arm, Long21 5020677 4 Bushing22 7080433 2 Fitting, Lubrication23 7542438 2 Nut, Castle24 2201601

220160211

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

25 5020681 2 Shaft, A-Arm26 7512492 4 Screw27 7552603 4 Washer, Spring Lock28 7517930 2 Bolt

9/00

B4

HANDLEBAR/HEADLIGHTScrambler 400 2X4 A01BA38CA

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. B6, Ref. 5)2 1820934-067 1 Handlebar3 7515189 4 Screw4 5521181 1 Pad, Handlebar5 2682454 1 Pad, Handlebar Cover6 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls-Master Cylinder/BrakeLine Pg. B7 for Details)

7 5432926 1 Spacer, Switch, LH8 4010191 1 Switch, Handlebar, Hi/Lo/Off9 7517625 1 Screw, Set10 5432952 1 Plug, Hole

11 5433834-070 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 7512240 2 Bolt22 5630616-067 2 Block, Handlebar Retainer

9/00

B5

STEERING POSTScrambler 400 2X4 A01BA38CA

41

53

2

6

9

11

7

10

8

3

6

7

1



1 7542324 4 Nut, Nylok2 7080424 1 Fitting, Lubrication3 5433866 2 Bushing, Steering, Upper4 1820982-067 1 Post, Steering5 5132679 1 Bracket, Steering Post6 7512377 4 Bolt, Carriage

7 7556162 2 Bushing8 5222393 1 Flangette9 3514352 1 Bearing10 7547158 1 Nut11 7661633 1 Pin, Cotter

10/00

B6

CONTROLS - THROTTLE ASM./CABLEScrambler 400 2X4 A01BA38CA

3

1

5

4

6

2



1 5434113 1 Cover2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7080968 1 Cable, Throttle5 2010204 1 Asm., Throttle Control (Incl. 6)6 2010191 1 Asm., Throttle Clamp

9/00

B7

CONTROLS - MASTER CYLINDER/BRAKE LINEScrambler 400 2X4 A01BA38CA

1

3

11

1617 2

15

910

12

5

7

8

64

4

1314



2010197 1 Asm., Master Cylinder1 1910501 1 Line, Brake2 4110164 1 Switch3 1910504 1 Line, Brake4 7517899 2 Screw5 2201834 1 Kit - Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)6 2201835 1 Kit - Master Cylinder Lever

(Incl. Pin, Lever, Clip)7 2201836 1 Kit - Master Cylinder Park Brake Lever

(Incl. Lever, Spring)

8 2201833 1 Kit - Master Cylinder Clamp(Incl. Clamp, Screws)

9 7621462 2 Rivet10 7080539 2 Clamp, Nylon11 1910502 1 Line, Brake, Left, Front12 7080492 1 Cable Tie13 7512084 1 Screw14 7080653 1 Clamp, Hose15 7512024 2 Screw16 1910503 1 Line, Brake, Right, Front17 7052292 1 Fitting, Cross

9/00

B8

DRIVE CLUTCHScrambler 400 2X4 A01BA38CA

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 7041132 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 5630509 3 Weight, Shift (S-55)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)

9/00

B9

DRIVEN CLUTCHScrambler 400 2X4 A01BA38CA

3

4

56

7

8

11

12

13

14

16

1718

4

12

10

15

9



1 5010266 1 Spacer, Driven Clutch2 7556120 AR Bushing (3 Max)3 3211077 1 Belt, Drive4 1322180 1 Asm., Driven Clutch (Incl. 8-18)5 5220646 1 Washer, Domed6 7552901 1 Washer, Spring Lock7 7515382 1 Bolt8 7555898 AR Washer (.020)9 7556076 AR Washer (.025)

10 7556804 AR Washer (.030)11 3576504 1 Bearing, Moveable, 1/2”12 3576511 1 Bearing, Moveable, 1”13 7041198 1 Spring, Clutch14 5131446 1 Ramp, Stationary15 5210752 1 Spacer16 7710448 1 Ring, Retaining17 7511854 3 Bolt18 5430766 3 Button, Ramp

9/00

B10

REAR CALIPER MOUNTINGScrambler 400 2X4 A01BA38CA

9

13

14

16

15

12

1110

1

8

4

3 54

17

Frame

7

5

6

627

7



1 7517231 2 Screw2 7555806 2 Washer, Flat3 1910367

220138522014282201467

1121

Caliper, BrakeKit - Caliper SealKit - Bleeder ReplacementPiston, Caliper, Rear

4 5410988 4 Seal5 1930873 1 Line, Brake, Hand, Rear6 1910381 1 Line, Brake, Foot, Rear7 7670102 5 Clip, Silencer Box8 1930674 2 Bolt, Banjo

9 5131759 1 Bushing, Caliper Mount10 7558402 2 Washer, Flat11 7552901 2 Washer, Spring Lock12 7512365 2 Bolt13 5131786 1 Mount, Caliper, Lower14 5131787 1 Mount, Caliper, Upper15 7512325 3 Bolt16 5242291-067 1 Guard, Brake Disc17 2201189 1 Kit - Brake Pad (Incl. Spacer and Pin)

9/02

B11

REAR BRAKE MASTER CYLINDERScrambler 400 2X4 A01BA38CA

6

21

23

17

2

15

12

14

13

1

7

8

5

3

25

22

20

4

16

24

9

10

11

9

6

1314

17 1819



1 7670102 1 Clip2 7512113 2 Bolt3 5244091-067 1 Bracket, Reservoir Mount4 7542122 2 Nut, Nylok5 7512208 1 Screw6 7080003 2 Clamp, Hose, Red7 1910404 1 Hose, Reservoir8 1930854 1 Reservoir9 7512232

751791644

Screw (If built before 12/04/00)Screw (If built after 12/04/00)

10 7558301 2 Washer, Flat (If built before 12/04/00)11 5433457 1 Guard, Prop Shaft, Side12 7661401 1 Pin, Cotter13 7555919 2 Washer

14 5431107 2 Bushing15 1910375-067 1 Mount, Brake16 1930674 1 Bolt, Banjo17 5410988 2 Seal18 ------ -- -- -- -- 1 Line, Foot Brake, Rear (See Rear Cal-

iper Mounting Pg. B10, Ref. 6)19 7552801 2 Washer, Spring Lock20 7515179 2 Screw21 1910311 1 Asm., Foot Brake Master Cylinder22 7542324 2 Nut, Nylok23 1910377-067 1 Rod, Brake24 7041750 1 Spring, Torsion25 7515321 2 Screw

10/00

B12

REAR WHEELScrambler 400 2X4 A01BA38CA

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)

9/00

B13

REAR HOUSINGScrambler 400 2X4 A01BA38CA

1

83

13

1822

25

19

9

6

1516

11

24

10

21

23

12

14

2

7

32

1

5

7

1112

1314

17

4

4

20

20



1 7710472 2 Ring, Retaining2 5510313 2 Extrusion, Retainer, Nut3 7547031 2 Nut, Jam4 5411555 2 Seal, Foam5 7542439 3 Nut, Nylok6 5243678 1 Disc, Brake7 7515513 6 Stud8 1520259 1 Hub, Brake Disc (Incl. 7)9 7710496

771040511

Ring, Retaining (If built before 10/19/00)Ring, Retaining (If built after 10/19/00)

10 5010462 1 Spacer, Axle11 5410889 2 O-Ring12 3610070 2 Seal

13 3554518 2 Bearing, Cone, Tapered14 3554517 2 Bearing, Cup, Tapered15 5132098 1 Housing, Axle, Rear16 7080306 1 Fitting, Lubrication17 3225027 1 Link, Connector, 520 Regina18 5020944 1 Axle, Rear19 5211585-067 1 Guard, Sprocket20 7547108 6 Nut, Flange Lock21 3221111-076 1 Chain, 520 O-Ring22 7512404 3 Bolt23 1520258 1 Asm., Hub, Sprocket (Incl. 7)24 3222109 1 Sprocket, 36T25 5630586 1 Spacer

10/00

B14

AIR BOXScrambler 400 2X4 A01BA38CA

21

3

4

239

15

18

1920

7

5

16

22

24

26

25

8

21

11

16

10

12

1

17

14

6

132



1 7542127 3 Nut, Wing2 7558301 4 Washer, Flat3 5240424 1 Cover, Air Box4 5810948 1 Gasket, Cover5 5240336 1 Cover, Filter6 5811099 1 Foam, Precleaner, Sleeve7 1253118 1 Filter, Air8 5810966 1 Foil, Air Box9 5432883 1 Box, Silencer, Air10 7080483 1 Cable Tie11 7080487 1 Plug, Cap12 8450051-600 AR Line, Fuel13 7080476 1 Clamp, Hose

14 7555932 2 Washer, Nylon15 5411413 1 Boot, Carburetor16 7511881 8 Screw17 7080643 1 Clamp18 5431698 2 Ventura, Intake19 5410934 1 Boot, Silencer, Air20 5811102 1 Foam, Collar21 7080598 1 Cable Tie22 7515180 2 Screw23 5432607 1 Stand, Filter24 7515150 2 Stud25 5811012 1 Seal, Foam, Air Box26 7515151 1 Stud

5/99

C1

CLUTCH COVERScrambler 400 2X4 A01BA38CA

2

4

5

7

8

911

12

14

15

1617

22 21

20

23

31

28

3 6

1

19

29

13

25

3024

10

26

32

33

13

18

13

2724



1 5411180 1 Seal, Cover, Inner2 7517860 3 Screw3 ------ -- -- -- -- 4 Screw and Washer (See Crankcase

and Cylinder Pg. C12, Ref. 48)4 5521301 1 Seal, Cover, Clutch5 5433542 1 Cover, Clutch, Front6 7670051 1 Clip, Cover, Clutch7 7512093 5 Screw8 7078689 1 Decal - Warning, Clutch Cover9 7074782 1 Decal - Automatic Transmission10 7512094 2 Screw11 7080492 2 Cable Tie12 5410421 1 Boot, Intake, Clutch13 7512232 3 Screw14 5432615 1 Duct, Clutch, Air Outlet15 5430743 1 Cap, Drilled, Overflow Bottle16 5810279 1 Gasket, Cap, Overflow

17 5433774 1 Plug, Cap18 7555783 1 Washer19 7080511 1 Clamp, Band, Narrow20 7512018 1 Screw21 8450003-1525 AR Fuel Line22 7052065 1 Fitting, Barbed, 90 Degree23 5433342 1 Duct, Clutch Inlet24 7555932 2 Washer, Nylon25 5242693-067 1 Bracket, Clutch Cover26 7555935 1 Washer27 7512098 1 Screw28 5222446-067 1 Bracket, Seal, Retainer29 5410575 1 Seal, Case, Cover30 7661637 2 Rivet31 2201159 1 Kit - Inner Clutch Cover (Incl. 7,10)32 7547067 3 Nut33 5242208-067 1 Bracket, Clutch Cover

9/00

C2

ELECTRICAL/TAILLIGHTScrambler 400 2X4 A01BA38CA

1

2

3

5

7

10

9

6

11

8

1224

25

3129

28

26

27

2324

22

12

14

15

1617

18

19

20

21

13

30

34

33

30

32

4



1 2460927 1 Harness, Wire, Main2 7080138 3 Cable Tie3 2200593 1 Kit - Circuit Breaker, 20 AMP4 2201795 1 Kit - Circuit Breaker, 10 AMP5 2432038 1 Light, Tail/Brake6 7512088 2 Screw7 4032085 1 Lens8 4030043 1 Bulb9 4032086 1 Gasket10 4032087 1 Backing11 7670093 2 Clip12 7571602 4 Washer, Lock13 7512027 2 Screw14 5810290 3 Pad, Battery15 5431769 1 Cover, Battery16 2200361 1 Kit - Battery Bolt, Short17 4010095 1 Cable, Battery/Engine, Black18 7010032 2 Hook, Strap, Battery

19 5410424 1 Strap, Holddown, Battery20 5432077 1 Tube, Battery Vent21 4140006 1 Battery22 4010094 1 Cable, Battery/Solenoid, Red23 4010218 1 Cable, Solenoid/Starter, Red24 7541925 4 Nut, Nylok25 7512007 2 Bolt26 5431973

581107911

Cover, Lid, Tool BoxGasket

27 7517386 2 Screw28 2620087 1 Asm., Tool Box (Incl. 26 and Gasket)29 4060208 1 Rectifier, LR39-130 7512024 4 Screw31 4010186 1 Limiter, RPM32 7512076 1 Screw33 4020149 4 Clip, Rosebud34 7670109 3 Clip, Routing

9/00

C3

SWING ARM/SHOCK MOUNTINGScrambler 400 2X4 A01BA38CA

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, Zerk13 7547082 1 Nut14 7556035 1 Washer, Flat15 5433412 2 Bushing, Swing Arm, RH

16 5131697 2 Bolt, Pivot, Swing Arm17 5133167 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 Washer, Flat24 7542321 1 Nut, Flange25 7547066 2 Nut, Nylok26 7555883 4 Washer27 7512576 2 Bolt28 7517761 1 Screw29 5433411 1 Bushing, Swing Arm, LH30 5133166 1 Bushing, Pivot, LH

5/01

C4

FOX SHOCK, GAS, RESERVOIRScrambler 400 2X4 A01BA38CA

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, Gas1 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 Shock

14 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

C5

SHOCK VALVINGScrambler 400 2X4 A01BA38CA

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

C6

GEAR SELECTORScrambler 400 2X4 A01BA38CA

12

3

4

8

11

9

10

12

7

6

7

13

5

5



1 54110075411006

11

KnobCover

2 7512024 1 Screw3 5411008 1 Grommet, Gear Shifter4 5243085-067 1 Rod, Gear Selector5 5433103 2 Mount, Gear Selector6 7515133 2 Screw

7 7546707 2 Nut, FLEXLOC8 7061013 1 Rod End, 6mm, LH9 7546702 1 Nut, LH10 5020955 1 Rod, Shift Linkage11 7546701 1 Nut, RH12 7061014 1 Rod End, 6mm, RH13 5131976 2 Spacer, Shifter

5/99

C7

GEARCASEScrambler 400 2X4 A01BA38CA

20

2125

31

35

1817

32

14

23

33

22

1516

34

45

11

40

10

1

1213

8

3938

3028

24

67

41

27

26

29

3637

32

9

19

25

1

12

42

C8

GEARCASEScrambler 400 2X4 A01BA38CA

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.


1 3233018 2 Bearing, Ball2 3233177 1 Ring, Retaining3 3233673 1 Washer, Thrust4 3233674 1 Sprocket, 19T5 3233010 1 Washer, Thrust6 3233675 1 Dog, Engagement, High/Reverse7 3233676 1 Shaft, Input8 3233677 1 Gear, 21T9 3233678 1 Bushing10 3233105 1 Washer11 3233106 2 Ring, Retaining12 3233019 2 Bearing, Ball13 3233961 1 Nut14 3233153 1 Bellcrank, HLR15 3233045 1 Ring, Retaining16 3233040 1 Washer17 3233548 1 O-Ring18 3233679 1 Shaft, Shift19 3234002 1 Switch, 3 Position20 3233749 4 Screw21 3233680 1 Bullet, Shifting

22 3233681 1 Spring, Compression23 3233872 1 Washer, Nylon24 3233682 1 Plug, Detent, Extension25 3233788 2 Seal, Triple Lip26 3233478 1 Dipstick27 3233524 1 Tube, Vent28 3234049 1 Gearcase, RH29 3233529 2 Pipe, Knock30 3233684 1 Shaft, Shift31 3233685 1 Fork, Shift32 3234048 1 Gearcase, LH33 3233636 1 Decal, Switch34 3233252 9 Screw35 3233687 1 Plug36 3233527 1 Bushing, Pivot37 3233035 1 Washer38 3233111 1 Chain, Silent, 60P, 11W39 3233688 1 Sprocket, 51T40 3233689 1 Shaft, Output41 3233690 1 Gear, 64T42 1341274 1 Asm., Gearcase (Incl. 1-41)

11/02

C9

GEARCASE MOUNTINGScrambler 400 2X4 A01BA38CA

14

4

13

2

1

1918

11

12

8

7

7

7

3

3

9

10

8

3

8

15

1617

5

6

1

2

7

8

8



1 7517632 4 Screw2 5132046 2 Mount, Transmission, Rear3 7555806 4 Washer4 7517642 1 Screw5 5243943-067 1 Bracket, Carb Dampener6 5410414 1 Bumper7 7512492 5 Screw8 7547089 5 Nut, Flange9 1012785-067 1 Bracket, Stop, Torque10 7512325 2 Screw11 1012886-067 1 Mount, Transmission

12 5243296-067 1 Spacer13 5210764

52110655211517

ARARAR

Shim (.020)Shim (.010)Shim (.030)

14 7517646 1 Screw15 7517631 1 Screw16 7542440 1 Nut17 ------ -- -- -- -- 1 Plug, Drain

(See Gearcase Pg. C8, Ref. 35)18 7710434 1 Ring, Retaining19 3221041 1 Sprocket, 13T

9/00

C10

PISTON and CRANKSHAFTScrambler 400 2X4 A01BA38CA

1

23

4

52

6

7

9 10 1112

1314

15

1211

16

1718

19

202117

22

23

8



1 308473730847383084739

222

Piston Ring (Std.)Piston Ring (0.25mm/.010 O/S)Piston Ring (0.50mm/.020 O/S)

2 3084167 2 Clip, Pin, Piston3 3083838 1 Pin, Piston4 3085886

30858873085888

111

Piston (Std.)Piston (0.25mm/.010 O/S)Piston (0.50mm/.020 O/S)

5 3084172 1 Balancer6 3086768 1 Plate7 3086769 2 Bolt, Flange8 3080130 2 Key, Woodruff9 3084156 1 Gear, Drive10 3086764 1 Washer, Guide11 3084160 2 O-Ring

12 3086763 2 Collar13 3086762 1 Nut, Slit14 3086767 1 Washer15 3083905 1 Nut, Lock16 3084776

3084149

1

1

Asm., Crankshaft(Incl. 16,17,18,20,21,23)Crankshaft 1

17 3084155 2 Spacer, Pin, Crank18 3084154 1 Bearing, End, Large19 3084168 1 Bearing, End, Small20 3084153 1 Rod, Connecting21 3084777 1 Crankshaft 222 3086765

3086766ARAR

Spacer 1 (0.2mm)Spacer 2 (0.3mm)

23 3084152 1 Pin 1, Crank

5/99

C11

CRANKCASE and CYLINDERScrambler 400 2X4 A01BA38CA

1

2

34

5

6

78

91011

1213

14

15

1617

1819

2021

22242526

27

28

29

30

24

23

31

32

33

34

37383940

41

4243

4645

47

44

48

49

5051

52

4950

51

53

54

24

5556

57

58

4

4

3

3

4034

11

35

36

40

C12

CRANKCASE and CYLINDERScrambler 400 2X4 A01BA38CA



1 3084731 1 Gasket, Head2 3086755 1 Head, Cylinder (Incl. 6)3 3082758 3 Gasket, Aluminum4 3086744 3 Plug, Drain5 3082910 6 Nut, Flange6 3086756 1 Pipe, Water7 3080285 2 Nut8 3080530 2 Washer9 3086757 1 Gasket, Exhaust10 3085326 2 Stud11 3086746 2 Pipe 1, Elbow12 3082911 4 Nut, Flange13 3086758 1 Bolt, Banjo14 3083894 1 Valve, Check15 3083138 2 Gasket16 3085277 1 Adapter17 3240064 2 Valve18 3240065 2 Stopper19 3240066 6 Screw and Washer20 3086760 1 Gasket, Valve, Reed21 3084147 1 Valve, Reed (Incl. 17-19)22 3240164 1 Stuffer23 3081497 1 Screw24 3083590 3 Clamp25 3086759 6 Bolt, Flange26 3084144 1 Asm., Band (Incl. 23)27 3086749 1 Plug28 3082956 1 Gasket29 3086748 1 Gasket, Case 330 3084128 1 Pipe, Breather

31 3086751 2 Bolt, Flange32 3086747 1 Pipe 2, Elbow33 3086752 1 Bolt, Flange34 3084120 2 Seal, Oil35 3086750 1 Plug36 3083482 1 Gasket, Aluminum37 3086743 2 Bolt, Flange38 3086745 1 Asm., Crankcase 3

(Incl. 11,30,32,34,35,36,40,41)39 3084134 4 Screw, Flange40 3086741 6 Pin, Dowel41 3084131 1 Bearing42 3084733 1 O-Ring43 3086761 1 Oil Gauge44 3086742 3 Bolt, Flange45 3084775 1 Bearing46 3084121 2 Bearing47 3084725 1 Seal, Oil48 3084205 4 Screw and Washer49 3084118 2 Stud50 3084119 2 Stud51 3086740 1 Asm., Crankcase

(Incl. 3,4,34,37,40,44-47,49-52,56)52 3084123 1 Bearing53 3084729 1 Gasket, Cylinder54 3083384 1 Clamp55 3080142 1 Washer56 3084124 2 Bolt, Flange57 3086753 1 Cylinder (Incl. 10,11,58)58 3084138 6 Stud

5/99

C13

OIL PUMPScrambler 400 2X4 A01BA38CA

1

2

3

4

5

68

9

10

119

12

15

16

1718

20

21

19

13 14

7



1 3084757 3 Bolt and Washer2 3085281 1 Cover, Case, Oil Pump3 3085280 1 Gasket, Case, Oil Pump4 3085520 1 Case, Oil Pump5 3086777 1 Grommet6 3086779 1 Grommet7 3086778 3 Screw and Washer8 3083783 2 Screw and Washer9 3083141 2 Clamp, Hose10 3086776 1 Pipe, Vinyl11 3083120 1 Nut

12 3083121 1 Washer, Spring13 3083445 1 Collar14 3085571 1 Spring and Lever15 3083127 1 O-Ring16 3084195 1 Spacer17 3084196 1 Wheel18 3084197 1 Pin, Spring19 3085285 1 Asm., Oil Pump (Incl. 11-21)20 3084194 1 Washer21 3083125 1 Screw, Air Vent

5/99

C14

CARBURETORScrambler 400 2X4 A01BA38CA

1

2

3

31 4

5

6

30

29

28

27

24

2625

23

2221

20191817 16

151413

1211

10

9

8

7



1 3130184 1 Asm., Top2 3130496 1 Spring, Throttle3 3130027 1 Plate, Throttle4 3130476 1 Needle, Jet (6CEY6-3)5 3130355 1 Packing6 3130494 1 Valve, Throttle (1.5)7 3130199 1 Cap, Plunger8 3130006 1 Spring9 3130328 1 Asm., Plunger10 3130436 1 Spring, Throttle Adjuster11 3130447 1 Washer12 3130009 1 Screw, Throttle Stop13 3130011 1 Adjuster14 3130012 1 Spring, Air Adjuster15 3131325 1 Jet, Pilot (#25)16 3130025 4 Screw

17 3130432 1 Screw, Guide18 3130239 1 O-Ring19 3130126 1 Jet, Main (#230)20 3130443 1 Asm., Float Chamber21 3130430 2 Asm., Float22 3130237 2 Cap23 3130020 1 Gasket24 3130495 1 Valve, Needle (2.5)25 3130018 1 Arm, Float26 3130361 1 Pin, Float27 3130047 1 Packing28 3131404 1 Asm., Carburetor (Incl. 1-31)29 3130596 1 Ring, Main Jet30 3130429 1 Jet, Needle31 3130003 1 E-Ring

5/03

D1

RECOIL STARTERScrambler 400 2X4 A01BA38CA

1

2 3

4

5

6

789

10

1413

12 11



1 3083185 1 Spring, Spiral2 3084750 1 Bush3 3086749 1 Plug4 3082956 1 Gasket5 3085651

308565611

Asm., Recoil Starter (Incl. 1,2,5,8-14)Case, Starter

6 3084782 1 Bolt and Washer7 3086751 8 Bolt, Flange

8 3085266 1 Bolt and Washer9 3084744 1 Plate, Friction10 3083379 1 Spring, Friction11 3084822 1 Reel12 3085083 1 Rope13 3083463 1 Spring, Return14 3083378 1 Ratchet

5/99

D2

STARTING MOTORScrambler 400 2X4 A01BA38CA

1

23

5

9

10

11

12

13

14 15

16

5

1718

19

20

21

22

23

24

1

8

67

7

4



1 3085032 1 Cover, Rear2 3083649 2 Nut, Flange3 3084406 1 Brush4 3085392

3085393

1

1

Asm., Starting Motor(Incl. 1-5,8-10,12-17,20-24)Asm., Starter (Incl. 1-5,8-10,12-16)

5 3084405 2 Ring, Rubber6 3082758 1 Gasket7 3086782 5 Bolt, Flange8 3085305 1 Cover, Front (Incl. 16)9 3084408 3 O-Ring10 3084407 2 Bolt, Through11 3086780 1 Bracket

12 3083754 1 Washer Set13 3084404 1 Asm., Armature (Incl. 14,15)14 3083934 1 O-Ring15 3083777 1 Bearing16 3083741 1 O-Ring17 3083737 1 Washer, Shaft, Gear18 3085283 1 Gasket, Starter19 3086781 2 Bolt, Flange20 3084409 1 Clip21 3084410 1 Spring, Return22 3085394 1 Asm., Gear Shaft (Incl. 17,20-24)23 3084411 1 Spring, Weight24 3084412 1 Clip

5/99

D3

MAGNETOScrambler 400 2X4 A01BA38CA

1 2

34

5 6

7 8

9

10

11

12

13

16

17

18

19

1514



1 3081256 1 Screw and Washer2 3081146 1 Clamp3 3084785

308478611

Asm., Plate (Incl. 1-3,5-7,9-13)Plate, Coil

4 3084766 3 Screw, Flange5 3083422 1 Coil, Exciter6 3083423 2 Screw and Washer7 3084788 1 Stator 18 3084784 1 Flywheel w/Ring Gear9 3081342 2 Screw and Washer

10 3081260 1 Screw and Washer11 3084789 1 Grommet12 3084787 1 Harness, Wire13 3083909 1 Coupler, 3P14 3080077 2 Washer, Spring15 3083073 2 Nut16 4020129 1 Cap, Spark Plug17 3083923 1 Coil, Ignition18 3085521 1 Switch, Magnetic19 3084790 1 CDI System

5/99

D4

WATER PUMPScrambler 400 2X4 A01BA38CA

1

14

15

2

14

34

5

6

9

10

11

13

8

12

87



1 3084284 1 Switch, Thermostat, 105 Degree2 3084183 1 Bearing3 3084184 1 Seal, Oil4 3084185 1 Seal, Oil5 3086770

308677111

Casing, Water Pump (Incl. 2-7,6)Casing, Water Pump (Incl. 5,7,6)

6 3086772 3 Stud7 3086775 1 Stud

8 3083856 3 Nut, Flange9 3084187 1 Gasket, Casing10 3084186 1 Impeller11 3082206 1 Washer12 3080077 1 Washer, Spring13 3083073 1 Nut14 3086774 2 Clamp, Hose15 3086773 1 Hose, Main

10/00

D5

TOOL KITScrambler 400 2X4 A01BA38CA

1

2

3

4

5

7

8

6



1 2682572 1 Pouch, Tool Kit2 3083612 1 Wrench, Box, Special3 3083613 1 Wrench, 10-12 Spanner4 3083843 1 Screwdriver5 2870725 1 Tire Pressure Gauge

6 5211627 1 Spanner, Wrench7 2870694 1 Asm., Tool Kit (Incl. 1-5)8 9915754

991683511

Owner’s Manual, ’01 ATVSupplement, Owners Manual, ’01Scrambler 2x4

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PRINTED IN THE USA PARTS MANUAL PN 991636 and MICROFICHE PN 9916837 10/00

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Download - SCRAMBLER 4002X4 Model #A01BA38CA - pi54.compi54.com/corp/manuals/Parts/9916836.pdf · SCRAMBLER 4002X4 Model #A01BA38CA E ... Speed, U-Clip 2 5244482-067 5244483-067 1 1 ... 17 7052147

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