scrambler 4002x4 model #a01ba38ca - pi54.· scrambler 4002x4 model #a01ba38ca e ... speed, u-clip

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  • 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

    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 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

    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 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

    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 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

    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 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

    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. Pa

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