scrambler 500 4x4 model #a03bg50aa rev. 01pi54.com/corp/manuals/parts/9917511r01.pdf · 12...

PARTS MANUAL PN 9917511 and MICROFICHE PN 9918976 3/03

SCRAMBLER 500 4X4Model #A03BG50AA

Rev. 01

E 2002 Polaris Sales Inc.

TABLE OF CONTENTSScrambler 500 4X4 A03BG50AA

Parts Manual

AA--ARM/STRUT MOUNTING B4. . . . . . . . . . . . .AIR BOX C4. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D3-4. . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C5. . . . . . . . . . . . . . . . . . . . .CONTROL PANEL A6. . . . . . . . . . . . . . . . . . . .CONTROLS -- MASTER

CYLINDER/BRAKE LINE C1. . . . . . . . . . . .CONTROLS -- THROTTLE ASM./CABLE B8. . . .COOLING SYSTEM A7. . . . . . . . . . . . . . . . . . .CRANKCASE C13. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON C14. . . . . . . . . . . . .CYLINDER D1-2. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A13. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B9. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT B2. . . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH B10. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C6. . . . . . . . . . . . . . .ENGINE MOUNTING A9-10. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A8. . . . . . . . . . . . . . . . . . .

FFOX SHOCK, GAS, RESERVOIR C11. . . . . . . . .FRONT BRAKE B14. . . . . . . . . . . . . . . . . . . . . .FRONT BUMPER and SHIELDS A5. . . . . . . . . .FRONT CAB A3. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING B1. . . . . . . . . . . . . . . . . . . .FRONT STRUT B3. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B5. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP D12. . . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C8. . . . . . . . . . . . . . . . . . . .GEARCASE C9. . . . . . . . . . . . . . . . . . . . . . . . .

GGEARCASE C10. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING B11. . . . . . . . . . . . . . .

HHANDLEBAR/HEADLIGHT B6. . . . . . . . . . . . . .

IINTAKE and EXHAUST D5. . . . . . . . . . . . . . . . .

MMAGNETO D10. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL FILTER D9. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D8. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK A11. . . . . . . . . . . . . . . . . . . . . . . . . . .

PPROP SHAFT A14. . . . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE MASTER CYLINDER B12. . . . . . .REAR CAB A4. . . . . . . . . . . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING B13. . . . . . . . . . . .REAR HOUSING C3. . . . . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE C2. . . . . . . . . . . . . . . . . .RECOIL STARTER D6. . . . . . . . . . . . . . . . . . . .

SSHOCK VALVING C12. . . . . . . . . . . . . . . . . . . . .STARTING MOTOR D11. . . . . . . . . . . . . . . . . . .STEERING POST B7. . . . . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING C7. . . . . . . .

TTOOL KIT D13. . . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D7. . . . . . . . . . . . . . . . . . . . . . .

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

A3

FRONT CABSCRAMBLER 500 4X4 A03BG50AA

6

7

1112

5

5

11

13

18

19

4

14

1516

9

10

1

1

17

8

11

5

2

3

1210

12


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

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

1 7670057 4 Nut, Speed, U-Type2 5244482-067

5244483-06711

Bracket, Cab Mount, LHBracket, Cab Mount, RH

3 7517386 2 Screw4 1013384-067 1 Frame5 7512282 24 Bolt6 5432553-177 1 Cover, Front7 2632424-341 1 Cab, Front, Sonic Blue

(w/Warning Decals)8 7517916 2 Screw9 7558201 2 Washer, Flat

10 7621472 8 Rivet11 7542122 24 Nut, Nylok12 7555859 22 Washer, Flat13 5811831

585015011

Mudflap, Front, LHMudflap, Front, RH

14 1013249-067 2 Footpad15 7661825 8 Rivet16 5431484 2 Trim, Footrest17 5242525-067 2 Bracket, Heel Cleat18 5432763 1 Guard, Rock19 7515179 6 Screw

6/02

A4

REAR CABSCRAMBLER 500 4X4 A03BG50AA

20

127

27

53

1

28

19

18

8

26

2422

23

17

1610

9

21

13

1415

6

25

2

24

19220

11

24

2




1 7621472 4 Rivet2 7555859 16 Washer, Flat3 7512232 2 Screw4 7512242 2 Screw5 5810991 1 Foil, Rear Cab, Small6 7079902 1 Decal, Carb/Filter Information7 5434014-341 1 Cab, Rear, Sonic Blue8 7670057 2 Nut, Speed, U-Type9 7041607 1 Spring, Latch, Light10 1040412 1 Latch, Seat11 5411392 1 Cap, Seat Latch12 2682453-070

2681769-07011

Seat, BlackCovering, Seat, Black

13 5431986 1 Tongue, Seat14 7621479 2 Rivet15 5412067 6 Bumper, Rubber

16 5211033 2 Bracket, Lever Retainer17 7621403 1 Rivet18 2632274

581111311

Shield, MufflerFoam, Foil

19 7542122 17 Nut, Nylok20 7517264 4 Screw21 5432831 2 Plug, End Cap, Ribbed22 5247321-067 1 Guard, Clutch23 7661637 4 Rivet24 7512282 16 Bolt25 ------ -- -- -- -- 2 Footpad

(See Front Cab Pg. A3, Ref. 14)26 5812134

585014811

Mudflap, Rear, LHMudflap, Rear, RH

27 5810957 1 Foil, Rear Cab28 5220880 2 Bracket, Rear Seat Holddown

5/03

A5

FRONT BUMPER and SHIELDSSCRAMBLER 500 4X4 A03BG50AA

78

9

10

11

13

15

16

18

2

19

14

14

14

14

1420

21

22

14

23

31

5

2

2 4

6

12

17




1 5434162 1 Shield, Splash, Rear2 7670088 4 Clip, Dart3 5434161 1 Shield, Splash, Front4 7522026 2 Screw5 5245415-067 2 Shield, Splash, LH6 7517386 4 Screw7 7558402 2 Washer, Flat8 7512329 2 Bolt9 5811675 1 Plug, Frame10 7547071 1 U-Nut11 1012773-067 1 Bumper, Front12 7555827 2 Washer

13 5432378-070 1 Plate, Skid, Bumper14 7661121 15 Rivet15 5242694-067 2 Bracket, Radiator Shield16 5245343-067 1 Shield, Radiator, Side, RH17 7515399 2 Screw18 5245342-067 1 Shield, Radiator, Side, LH19 5245344-067 1 Shield, Radiator, Upper20 5131036 1 Heat Sink21 4010670 1 Regulator, Rectifier22 7512018 3 Screw23 5434085 1 Guard, Splash, RH

6/02

A6

CONTROL PANELSCRAMBLER 500 4X4 A03BG50AA

2

3

45

2

1 6

7

2




1 5433534 1 Cover, Key2 4010390

54337334010278

111

Switch, Ignition, Key StartNut, IgnitionKey, Ignition, Blank NOTE: Ignitionkey blank may be ordered by using thefour digit number on the key.

3 5434127 1 Panel, Control, Outer4 7081007 1 Cable, Choke5 5434128 1 Panel, Control, Inner6 7080922 1 Nut, Choke7 4010315 1 Panel, Indicator Light, 3 Position

4/01

A7

COOLING SYSTEMSCRAMBLER 500 4X4 A03BG50AA

22

42

17

30

21

29

19

25

3

120

18

28

26

16

27

23

24

8

10 11

67

5

9

1312

15

1

3 16

19

14

14




1 7517659 4 Screw2 2410123 1 Asm., Fan and Motor3 7670111 4 U-Clip4 5434043 1 Shroud5 5810279 1 Gasket6 5430743 1 Cap7 5433774 1 Plug8 5433410 1 Tank, Surge9 7512084 2 Screw10 7052065 1 Fitting11 8450003-600 AR Line, Fuel12 5020937 2 Spacer13 3110032 2 Mount, Rubber14 7558301 4 Washer, Flat15 7542122 2 Nut, Nylok

16 7080614 2 Clamp, Hose17 5411985 1 Hose, Engine, Upper18 5521511 1 Guard, Hose19 7080826 2 Clamp20 4010161 1 Sensor, Thermal w/Harness21 1240093 1 Cap, Pressure22 1240090 1 Radiator23 7512240 2 Screw24 7552801 2 Washer, Spring, Lock25 7052296 1 Valve26 5410584 2 Bushing, Radiator Mount, Lower27 7080965 1 Mount, Cable Tie28 7080138 1 Cable Tie29 5521550 1 Guard, Plastic Hose30 5411989 1 Hose, Engine, Lower

4/01

A8

EXHAUST SYSTEMSCRAMBLER 500 4X4 A03BG50AA

1516

32

12

11

17

1

14

13 7

6

4

5

5

5

5

89

7

18

10




1 7515316 2 Bolt, Carriage2 5410241 2 Dampener, Vibration3 5010192 2 Bushing4 1261006-029 1 Silencer5 7041804 4 Spring, Exhaust6 1261005-029 1 Pipe, Exhaust7 5243518 2 Seal, Exhaust8 7517386 2 Screw9 5242344 1 Bracket, Exhaust Support

10 7542330 1 Nut, Insert11 7542301 1 Nut12 3110064 1 Mount, Torque Stop13 7042029 1 Spring, Exhaust14 7512666 2 Bolt15 7542324 2 Nut, Nylok16 7555716 2 Washer, Flat17 5410436 2 Washer, Rubber18 7555863 2 Washer

6/02

A9

ENGINE MOUNTINGSCRAMBLER 500 4X4 A03BG50AA

19

34

47

2

3

5

6

7

8

1011

4

17

189

9

24

20

2627

282930

31

32

33

37

41

42

4443

45 46

41

9

1314

1516

12

48

36

35

12

40

1

10

39

38

23

225

1

1

1

9

2122


A10

ENGINE MOUNTINGSCRAMBLER 500 4X4 A03BG50AA



1 7547108 6 Nut, Flange Lock2 7555823 3 Washer, Flat3 4010132 1 Cable, Ground/Engine4 7517386 1 Screw5 3110044 1 Mount, Rubber, Top6 5242674-067 1 Bracket, Mount, Engine, Top7 7552901 2 Washer, Spring Lock8 7512315 2 Bolt9 7080003 4 Clamp, Hose, Red10 8450040-600 AR Line, Fuel11 8450003-1525 AR Line, Fuel12 3084205 3 Screw and Washer13 3110032 2 Mount, Rubber Radiator14 5242258-067 1 Bracket, Carburetor Mount15 7552605 2 Washer, Split Lock16 7542105 2 Nut17 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D4, Ref. 18)18 8360009-600 AR Line, Fuel19 8450080-58 1 Sheath, Foil, Laminated20 1013222-067 1 Mount, Engine, Rear21 5132775 1 Spacer22 5412005 1 O-Ring23 7547089 2 Nut, Flange, Lock24 3110046 2 Mount, Rubber, Front25 7555815 2 Washer26 5410421 1 Boot, Clutch Intake27 7080511 1 Clamp, Narrow Band28 5430261 1 Bushing

29 5210748 1 Washer, Flat30 7575202 1 Washer, Interlock31 7512566 1 Bolt32 ------ -- -- -- -- 1 Asm., Drive Clutch, ATV-06

(See Drive Clutch Pg. B9, Ref. 13)33 ------ -- -- -- -- 1 Bracket, Retainer, Seal

(See Clutch Cover Pg. C5, Ref. 19)34 1040688-067 1 Mount, Engine, Front35 7515398 2 Screw36 7542324 2 Nut, Nylok37 3110067 1 Mount, Motor38 7080474 2 Clamp, Hose39 7552603 1 Washer, Spring Lock40 7515438 1 Screw41 7080696 2 Clamp, Hose42 ------ -- -- -- -- AR Hose, Engine, Lower (See Cooling

System Pg. A7, Ref. 30)43 ------ -- -- -- -- 2 Nut (See Cylinder Pg. D2, Ref. 23)44 ------ -- -- -- -- 2 Washer, Lock

(See Cylinder Pg. D2, Ref. 22)45 1261171-029 1 Manifold, Black46 ------ -- -- -- -- 1 Gasket, Exhaust

(See Cylinder Pg. D2, Ref. 20)47 3085822 1 Engine, Short Block (EH50PLE12)

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

48 ------ -- -- -- -- AR Hose, Engine, Upper (See CoolingSystem Pg. A7, Ref. 17)

11/01

A11

OIL TANKSCRAMBLER 500 4X4 A03BG50AA

25

1

3

8

6

9

11

4

10

7

5

4




1 5434307 1 Dipstick, Oil Tank2 1261175 1 Tank, Oil3 5411873 1 Hose, Breather4 5410828 2 Grommet5 5333204 2 Bushing6 7080699 1 Clamp, Hose

7 7052326 1 Screen, Oil Filter, 90 Degree8 5412227 1 Hose, Formed9 7081026 1 Clamp, Hose10 5850135 1 Washer, Nylon11 7051524 1 Plug

6/02

A12

FUEL TANKSCRAMBLER 500 4X4 A03BG50AA

12

6

78

11

1516

2018

14

19

25

26

1

4

5

910

2124

22

17

21

23

23

3

13

24

2

2121




1 25202415432879

11

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

2 5811527 1 Seal, Foam3 5410842 1 Grommet, Fuel Tank4 5812123 1 Gasket5 5433687 1 Cap, Gas Tank6 8360009-600 AR Line, Fuel7 5431053 1 Vent, Tank8 7512249 2 Screw9 7552801 2 Washer, Spring Lock10 7555859 2 Washer, Flat11 5811526 1 Seal, Foam12 5332457 2 Spacer13 7552801 2 Washer, Spring Lock

14 7555726 1 Washer, Flat15 5431021 1 Lever, Fuel16 7511840 1 Screw17 5432291 1 Grommet18 7041209 1 Spring, Lever, Compression19 5431391 1 Extension, Fuel Lever20 7515136 2 Screw21 7080003 6 Clamp, Hose, Red22 2530009 1 Filter23 8450080-27 1 Sheath, Foil, Laminated24 8450040-600 1 Line, Fuel25 7051006 1 Valve, Fuel26 5810859 1 Gasket, Fuel Valve

6/02

A13

DECALSSCRAMBLER 500 4X4 A03BG50AA

6

13

4

18

8

2

7

RH

LH15

14

1

1

11

10

5

9

3

17

12

16

19




1 71706367170637

11

Decal, Cab Side, Rear, LHDecal, Cab Side, Rear, RH

2 7078253 1 Decal, Age Warning3 7079780 1 Decal, Warning AWD Switch4 7078465 1 Logo, Polaris Star5 7170633

717063411

Decal, “Scrambler”, Tank Side, LHDecal, “Scrambler”, Tank Side, RH

6 7170635 1 Decal, “500”, Front Cover7 7079604 1 Decal, Warning, Override, AWD8 7079083 1 Decal, Warning, General9 7079085 1 Decal, Warning, Discretionary10 7079930 1 Decal, “POLARIS”, Rear

11 71706407170641

11

Decal,”4X4” Fender, Rear, LHDecal,”4X4” Fender, Rear, RH

12 7079925 2 Decal, Reflector, Red13 7079088 1 Decal, Tire Pressure/Load14 7077920 1 Decal, Passenger Warning15 7074637 1 Decal, Fuel Lever16 7079924 2 Decal, Reflector, Amber17 7077791 1 Decal, Concentric Drive System18 7078577 1 Decal, Drain, Recoil19 7170638

717063911

Decal, Fender, Front, LHDecal, Fender, Front, RH

6/02

A14

PROP SHAFTSCRAMBLER 500 4X4 A03BG50AA

10 9 87

5

2 4

12

6

3

11

1

1




1 7517916 4 Screw2 5433457 1 Guard, Prop Shaft, Side3 7558301 2 Washer, Flat4 7517386 2 Screw5 5433154 1 Guard, Prop Shaft, Front6 5411092 1 O-Ring

7 3260131 1 Yoke, Prop Shaft, Transmission8 1350072 1 Shaft, Prop9 3260104 2 Kit, Cross and Bearing10 3260133 1 Yoke, Front Gear Case11 1380169 1 Asm., Prop Shaft (Incl. 7-10)12 7661913 1 Pin, Spring

11/01

B1

FRONT HOUSINGSCRAMBLER 500 4X4 A03BG50AA

12

34

56

78

9 1011

12

13

14

15

16

17

18

1920 21

22

2324

25

2627

282

1




1341323 1 Asm., Front Gearcase (Incl. 1-12,16-26)1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing7 3233726 1 Pinion, Input, 14T8 3233541 1 Bushing9 3233319 1 Seal, Oil10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug13 7080756 1 Clamp14 8450003-1525 AR Line, Fuel

15 7080307 1 Clamp, Hose16 3233524 1 Tube, Vent17 3233696 1 Gearcase, Front Housing18 3233725 1 Shaft, Output, 29T19 3233020 1 Bearing, Ball20 3233554 AR Shim21 3233693 1 O-Ring22 3233724 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233582 1 Button, Thrust25 3233254 1 Washer26 3233253 1 Plug, Drain27 7552603 4 Washer, Lock28 7512492 4 Screw

4/01

B2

DRIVE SHAFTSCRAMBLER 500 4X4 A03BG50AA

12

6

7

8 9

11

3 51

2 4 10




1 1380118 1 Asm., Drive Shaft w/Sleeve, NEA2 5222299 1 Sleeve, Drive Shaft Seal3 3260121 1 Clamp, Band4 7670092 1 Circlip5 2201015 1 Kit, Replacement Boot6 1380060 1 Shaft, Replacement (Incl. 4)

7 1380061 1 Cardan, Replacement (Incl. 4,6,8,9)8 3260104 1 Kit, Cross and Bearing9 3260101 1 Yoke, Splined10 7661913 2 Pin, Spring11 3260123 1 Clamp, Band12 2200960 2 Kit, Drive Shaft w/Sleeve

5/03

B3

FRONT STRUTSCRAMBLER 500 4X4 A03BG50AA

1

2

3

4

8 5

6

9

11

12

13

1516

14

17

18

19

21

8

20

23

24

25

2627

1112

22

10

857

28




1 5411608 2 Bumper2 7041762 2 Strut, Front3 5211115 2 Washer4 7080367 2 Clamp, Cable5 7542423 4 Nut, Flange6 7512365 4 Screw7 7552901 4 Washer, Spring Lock8 7558402 10 Washer, Flat9 5810439 2 Retainer, Strut Casting Wire10 ------ -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B14 for Details)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 18209501820951

11

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

17 7041603-0677041603-216

22

Spring, Compression, BlackSpring, Compression, Yellow

18 5243364 2 Retainer, Spring19 5432871 2 Ball, Pivot, Bottom20 7515339 4 Bolt21 5132062 2 Spacer22 ------ -- -- -- -- 1 Kit, Drive Shaft w/Sleeve (See CV

Joint - Neapco Pg. B2, Ref.12)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, Nylok, Thin28 7052028 2 Grommet

3/03

B4

A-ARM/STRUT MOUNTINGSCRAMBLER 500 4X4 A03BG50AA

1

34

5

6

78

2

12

13

1415

16

18

17

19

20

2423

22

2625

2526

22

21

27

13

11

109




1 7542439 2 Nut, Nylok2 1820805 2 Asm., Tie Rod (Incl. 3-8)3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End, RH5 7542711 2 Nut6 5020926 2 Tie Rod7 7547028 2 Nut, Jam, LH8 7061054 2 Rod End, LH9 5411920 1 Boot, Seal, Rod End10 7517909 2 Bolt11 7556099 4 Washer, Flat12 7547177 2 Nut13 7661203 4 Pin, Cotter14 ------ -- -- -- -- 1 Asm., Hubstrut

(See Front Strut Pg. B3, Ref. 16)

15 7080927 2 Joint, Ball16 5211121 2 Bracket, Ball Joint17 7512284 4 Screw18 5410548 2 Boot, Rubber19 7542438 2 Nut, Castle20 7512084 4 Screw21 5431150-070

5431149-07011

Shield, CV Joint, LHShield, CV Joint, RH

22 5434551 4 Bushing, A-Arm, Long23 5133806 2 Shaft, A-Arm24 2202284-216

2202285-21611

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

25 7552603 4 Washer, Spring Lock26 7512492 4 Screw27 7515415 2 Screw

5/03

B5

FRONT WHEELSCRAMBLER 500 4X4 A03BG50AA

10

11

12 14

12

34

5

79

8

15

1625

24 7

1920

23

DETAIL A

A

136

6

21

17

22

18




1 7512325 8 Bolt2 5243675

524683222

Disc, Brake (If built before 7/31/02)Disc, Brake (If built after 7/31/02)

3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Asm. Clutch, Front Hub, Elec./Mech.

(Splined Drive Shaft)6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515523 8 Stud9 1520347 2 Asm., Hub (Incl. 3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter

13 1321814 2 Spacer14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5411264 2 Tire, Titan (23x7-10)17 7556004 2 Washer18 7661401 2 Pin, Cotter19 5410470 2 O-Ring20 5432611 2 Cap, Hub21 7512027 6 Screw22 7542810 2 Nut23 7542459 8 Nut, Flange Lock24 1520175-117 2 Rim, Front25 1525017 2 Valve, Rim

5/03

B6

HANDLEBAR / HEADLIGHTSCRAMBLER 500 4X4 A03BG50AA

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. B8, Ref. 5)2 1820934-067 1 Handlebar3 7517238 4 Screw4 5521181 1 Pad, Handlebar5 2682454 1 Cover, Handlebar Pad6 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls-Master Cylinder/BrakeLine Pg. C1 for Details)

7 5433903 1 Spacer, Switch, LH8 4010422 1 Switch, Handlebar, Hi/Lo/Rev/Override9 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 5631146-067

5631147-06711

Block, Handlebar PeggedBlock, Handlebar

6/02

B7

STEERING POSTSCRAMBLER 500 4X4 A03BG50AA

31

4

2

9

11

7

10

8

2

6

7

112

5




1 7542324 4 Nut, Nylok2 5433866 2 Bushing, Steering, Upper3 1821112-067 1 Asm., Steering Post4 5222999-067

5246732

1

1

Bracket, Steering, Bushing, Upper(If built before 5/15/02)Bracket, Steering, Bushing, Upper(If built after 5/15/02)

5 75123777515321

22

Bolt, Carriage (If built before 5/15/02)Bolt (If built after 5/15/02)

6 7512377 2 Bolt, Carriage7 7556162 2 Bushing8 5222393 1 Flangette9 3514352 1 Bearing10 7547158 1 Nut11 7661633 1 Pin, Cotter12 7558402 2 Washer, Flat

6/02

B8

CONTROLS - THROTTLE ASM. / CABLESCRAMBLER 500 4X4 A03BG50AA

3

1

5

4

6

2




1 5434113 1 Cover, Throttle Control2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7080967 1 Cable, Throttle5 2010205 1 Asm., Throttle Control (Incl. 6)6 2010191 1 Asm., Throttle Clamp

4/01

B9

DRIVE CLUTCHSCRAMBLER 500 4X4 A03BG50AA

13

12 3

612

4 56

7

11

10

8 9




1 7518062 6 Screw2 3576510 1 Cover, Bearing3 7041157 1 Clutch, Spring4 5430945 6 Washer, Multilube5 1321457 3 Roller and Bushing6 5431936 6 Button, Clutch, Stemless7 5210752

524298152107535210754

ARARARAR

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

8 5630710 3 Weight, Shift (10-WH)9 7512266 3 Bolt, Shoulder10 7541906 3 Nut, FLEXLOC11 3576504 1 Bearing, Moveable, 1/2 Inch12 5020422 3 Pin, Roller13 1321976 1 Asm., Drive Clutch, Wide

(Incl. All Less 3,8)

6/02

B10

DRIVEN CLUTCHSCRAMBLER 500 4X4 A03BG50AA

6

2

34

5

7

10

11

12

13

15

1617

2

1

9

14

8




1 7556120 AR Bushing2 1321798 1 Asm., Driven Clutch (Incl. 7-17)3 5220646 1 Washer, Domed4 7552901 1 Washer, Spring Lock5 7515384 1 Bolt6 3211077 1 Belt, Drive7 7555898 AR Washer (.020)8 7556076 AR Washer (.025)9 7556804 AR Washer

10 3576504 1 Bearing, Moveable, 1/2 Inch11 3576511 1 Bearing, Moveable, 1 Inch12 7041499 1 Spring, Clutch13 5131446 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

4/01

B11

GEARCASE MOUNTINGSCRAMBLER 500 4X4 A03BG50AA

1

2

6

8 7

4

4

3

10

3

5

5

9

5

5

2

1




1 7517632 4 Screw2 5132046 2 Mount, Transmission, Rear3 7547089 2 Nut, Flange Lock4 7512492 2 Screw5 7555806 4 Washer, Flat6 7517646 1 Screw

7 3221041 1 Sprocket, 13T8 7710434 1 Ring, Retaining9 5211065

52107645211517

ARARAR

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

10 7517642 1 Screw

6/02

B12

REAR BRAKE MASTER CYLINDERSCRAMBLER 500 4X4 A03BG50AA

5

17

19

13

1

11

8

10

9

6

7

4

2

21

18

16

3

12

20

5

910

1314 15




1 7512113 2 Bolt2 5244091-067 1 Bracket, Reservoir Mount3 7542122 2 Nut, Nylok4 7517386 1 Screw5 7080003 2 Clamp, Hose, Red6 1910404 1 Hose, Reservoir7 1930854 1 Reservoir8 7661401 1 Pin, Cotter9 7555919 2 Washer10 5431107 2 Bushing11 1910375-067 1 Mount, Brake

12 1910499 1 Bolt, Banjo13 5410988 2 Seal14 7558301 4 Washer, Flat15 ------ -- -- -- -- 1 Line, Foot Brake, Rear (See Rear Cal-

iper Mounting Pg. B13, Ref. 6)16 7515179 2 Screw17 1910311 1 Asm., Foot Brake Master Cylinder18 7542324 2 Nut, Nylok19 1910377-067 1 Rod, Brake20 7041750 1 Spring, Torsion21 7515321 2 Screw

11/01

B13

REAR CALIPER MOUNTINGSCRAMBLER 500 4X4 A03BG50AA

9

13

14

16

15

12

1110

1

8

4

3 54

17

Frame

7

5

6

62

7

7




1 7517231 2 Screw2 7555806 2 Washer, Flat3 1910691

70803521930665

121

Asm.,Caliper, BrakeScrew, BleederKit, Piston and Seal

4 5410988 4 Seal5 ------ -- -- -- -- 1 Line, Brake, Rear (See Controls - Mas-

ter Cylinder/Brake Line Pg. C1, Ref. 3)6 1910506 1 Line, Brake, Rear7 7670102 6 Clip, Silencer Box8 1910499 3 Bolt, Banjo

9 5131759 1 Bushing, Caliper Mount10 7558402 2 Washer, Flat11 7552901 2 Washer, Spring Lock12 7512312 2 Bolt13 5131786 1 Mount, Caliper, Lower14 5131787 1 Mount, Caliper, Upper15 7512325 3 Bolt16 5242291-067 1 Guard, Brake Disc17 1910333

19103391930860

111

Brake Pad (Incl. Spacer and Pin)SpacerPin

12/02

B14

FRONT BRAKESCRAMBLER 500 4X4 A03BG50AA

2

3

4

12

11

5

6

13

7

89

10

1




1 1910695

1910696

1

1

Asm., Brake Caliper, LH(Incl. 2-4,6-11)Asm., Brake Caliper, RH(Incl. 2-4,6-11)

2 7080352 1 Screw, Bleeder3 7515489 1 Screw, Socket Set4 5133407

51334081930642

111

Caliper, Brake, LHCaliper, Brake, RHKit, Front Brake Boot

5 5410494 1 Boot, Pin Seal6 5410495 1 Boot, Bushing

7 1930665 1 Kit, Piston and Seals (Incl. 8-10)8 5410779 1 Square Ring, Molded (.094)9 5410780 1 Square Ring, Molded (.103 x .134)10 5132294 1 Piston, Long11 1910412 1 Mount, Caliper12 2201398 1 Kit, Front Brake Pad13 7512365

75584027552901

444

ScrewWasherWasher, Lock

12/02

C1

CONTROLS - MASTER CYLINDER / BRAKE LINESCRAMBLER 500 4X4 A03BG50AA

1

3

12

1516

2

14

11109

13

9

5

6

7

8

44

13




2010196 1 Asm., Master Cylinder (Incl. 1-16)1 1910699 1 Asm., Brake System, Scrambler2 4110164 1 Switch3 1910504 1 Line, Brake, Rear4 7517899 2 Screw5 2201834 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)6 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)7 2201833 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)

8 2201835 1 Kit, Master Cylinder Lever(Incl. Pin, Lever, Clip)

9 7080138 8 Cable Tie10 7080539 1 Clamp, Nylon11 7621462 1 Rivet, Pop12 1910502 1 Line, Brake, Left Front13 8360052-34 1 Tubing, Convoluted14 7512024 2 Screw15 1910503 1 Line, Brake, Right Front16 7052292 1 Fitting, Cross

6/03

C2

REAR WHEELSCRAMBLER 500 4X4 A03BG50AA

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 7542714 8 Nut4 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 1520183-117 2 Rim, Rear12 5412323 2 Tire (22x11-10)

11/02

C3

REAR HOUSINGSCRAMBLER 500 4X4 A03BG50AA

1

8

13

1822

25

19

9

6

1516

11

24

10

21

23

12

14

2

7

21

7

1112

1314

17

4

4

20

53

35




1 7710472 2 Ring, Retaining2 5510313 2 Extrusion, Retainer, Nut3 7547196 2 Nut4 5411555 2 Seal, Foam5 7542439 6 Nut, Nylok6 5243678 1 Disc, Brake7 7515513 6 Stud8 1520259 1 Hub, Brake Disc (Incl. 7)9 7710405 1 Ring, Retaining10 5010462 1 Spacer, Axle11 5410889 2 O-Ring12 3610070 2 Seal13 3554518 2 Bearing, Cone, Tapered

14 3554517 2 Bearing, Cup, Tapered15 5132098 1 Housing, Axle, Rear16 7080306 1 Fitting, Lubrication17 3225028 1 Link, Connector18 5133181 1 Axle, Rear19 5211585-067 1 Guard, Sprocket, 38T20 7547108 3 Nut, Flange Lock21 3221151-076 1 Chain, 520 O-Ring22 7512404 3 Bolt23 1520258 1 Asm., Hub, Sprocket (Incl. 7)24 3222109 1 Sprocket, 36T25 5630586 1 Spacer

5/03

C4

AIR BOXSCRAMBLER 500 4X4 A03BG50AA

23

16

27

17

14

6

2

18

5

28

10

25

1224

4

15

9

13

11

7

15

9

8

29

22

3

1

19

26

9

9

2021




1 7517541 4 Screw2 5432859 1 Duct, Inlet3 5411422 1 Gasket, Intake4 5432868 1 Cover, Air Box5 5811482 1 Seal, Cover6 7515179 2 Screw7 7558301 2 Washer, Flat8 8450073-600 AR Line, Breather9 7080699 4 Clamp, Hose10 2530029 1 Filter, Breather11 7080694 1 Clamp, Hose12 5411847 1 Hose, Breather13 7080511 1 Clamp, Narrow Band14 5411414 1 Boot, Carburetor15 7080413 2 Clamp, Narrow Band

16 5432473 1 Duct, Carburetor, Inlet17 5830128 1 Gasket, Carburetor, Inlet Duct18 5432774 1 Box, Air19 5411873 1 Hose, Breather20 7621432 1 Rivet21 7080880 1 Clamp, Hose22 5811650 1 Foil, Air Box23 5432377 1 Plug, Trap24 8450059-150 AR Line, Fuel25 7080650 1 Clamp, Hose26 5242044 6 Clip27 5432601 1 Collar, Inlet, Carburetor28 7080595 1 Filter, Air Intake29 5811633 1 Filter, Sleeve, Precleaner

4/01

C5

CLUTCH COVERSCRAMBLER 500 4X4 A03BG50AA

6

7

5

8

109

1415

16

3

17

1819

20

4

26

11

25

2423

22

3

1

2

21

11

1213

27




1 7547067 3 Nutsert2 5242208-067 1 Bracket, Clutch Cover3 7517386 3 Screw4 5432698 1 Duct, Down Tube, Inlet5 5411553 1 Seal, Cover6 2201957 1 Kit - Inner Clutch Cover

(Incl. 8,11,20,22)7 7517860 3 Bolt and Washer8 5521578 1 Seal, Clutch Cover, Inner9 7078689 1 Decal, Warning, Clutch Cover10 5434255-070 1 Cover, Clutch, Outer11 7512094 9 Screw12 5410542 1 O-Ring13 5434264 1 Plug14 7074782 1 Decal, Automatic Transmission

15 7080761 2 Cable Tie16 5411489 1 Boot, Duct17 5434160 1 Duct, Clutch, Hi-Flow18 ------ -- -- -- -- 3 Screw and Washer

(See Crankcase Pg. C13, Ref. 6)19 5242046-067 1 Bracket, Clutch Seal20 5410575 1 Seal, Cover, Case21 7555932 1 Washer, Nylon22 7512098 1 Screw23 7555935 1 Washer24 5242693-067 1 Bracket, Clutch Cover, Front25 7661637 2 Rivet26 7080511 1 Clamp, Narrow Band27 7517916 1 Screw

6/02

C6

ELECTRICAL/TAILLIGHTSCRAMBLER 500 4X4 A03BG50AA

1

2 3

5

7

10

9

6

11

8

1225

26

32

29 31

2425

23

12

14

15

1617

18

19

20

21

13

29 28

30

33

4

22

27




1 2461059 1 Harness, Main2 7080138 3 Cable Tie3 2434012 1 Breaker, Circuit, 20 AMP4 2201795 1 Kit, Circuit Breaker, Fan5 2410319 1 Asm., Taillight, 12V (Incl. 6-10)6 7512088 2 Screw7 4032085 1 Lens8 4030043 1 Bulb9 4032086 1 Gasket10 4032087 1 Backing11 7670093 2 Clip12 7571602 4 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 5431769 1 Cover, Battery16 2200361 2 Kit, Battery Bolt17 4010095 1 Cable, Battery/Engine, Black

18 7010032 2 Hook, Battery Strap19 5410424 1 Strap, Battery Holddown20 5432077 1 Tube, Battery Vent21 4140006 1 Battery22 7670102 1 Clip23 4010094 1 Cable, Battery/Solenoid, Red24 4010093 1 Cable, Solenoid/Starter25 7541925 4 Nut, Nylok26 7512007 2 Bolt27 2202147 1 Kit, Fusible Link28 5246378

524674711

Bracket, CDI (If built before 6/10/02)Bracket, CDI (If built after 6/10/02)

29 7512024 3 Screw30 5810317 1 Pad, Fuel Tank Bracket31 4010195 1 Limiter, RPM, LR-83-332 7670109 3 Clip, Routing33 4020149 3 Clip, Rosebud

6/02

C7

SWING ARM/SHOCK MOUNTINGSCRAMBLER 500 4X4 A03BG50AA

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

7041865-21611


3 7041864-0677041864-216

11


4 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 Fitting13 7547082 1 Nut14 7556035 1 Washer, Flat15 5434546 2 Bushing, Swing Arm, RH

16 5131697 2 Bolt, Pivot, Swing Arm17 5133167 1 Bushing, Swing Arm Pivot, RH18 1541819-216 1 Arm, Swing (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 5434545 1 Bushing, Swing Arm, LH30 5133166 1 Bushing, Swing Arm Pivot, LH

3/03

C8

GEAR SELECTORSCRAMBLER 500 4X4 A03BG50AA

12

3

4

6

14

5

5

11

9

7

10

9

7

12

8

13




1 54110075411006

11

KnobCover

2 7512024 1 Screw3 5411008 1 Grommet, Gear Shifter4 1012810-067 1 Selector, Gear5 5433103 2 Mount, Gear Selector6 7515133 2 Screw7 7546707 2 Nut

8 7061101 1 Rod End, LH9 7518001 2 Screw10 7547198 1 Nut, LH11 1821206 1 Asm., Shift Linkage12 7547083 1 Nut, RH13 7061102 1 Rod End, RH14 5131976 2 Spacer, Shifter

6/02

C9

GEARCASESCRAMBLER 500 4X4 A03BG50AA

4

8

6

171920

2124252627

29

35

28

3031

323334

36

3738

41

39

40

42

4344

47 46

45

48

14

23

22

13

18

9

11

17

49

59

50

51

56

5253

5

54

57

58

3

7

12

10

12

1210

81615

22

22

1822

55

8

14

44


C10

GEARCASESCRAMBLER 500 4X4 A03BG50AA



1341382 1 Asm., Gearcase, Main (Incl. All)1 3233527 1 Bushing, Pivot2 3233252 10 Screw3 3233632 1 Gearcase, HLR, Hybrid Mach LH4 3233529 2 Pipe, Knock5 3233448 1 Plug, Drain6 3233035 1 Washer7 3233633 1 Fork, Shift, H/R8 3233018 3 Bearing, Ball9 3233728 1 Shaft, Reverse, 31T10 3233718 2 Bearing, Needle11 3233719 1 Sprocket, 24T12 3233720 2 Ring, Retaining, E-Clip13 3233721 1 Dog, Engagement14 3233722 1 Gear, 30T15 3233176 1 Washer, Thrust16 3233177 1 Ring, Retaining17 3233788 3 Seal, Triple Lip18 3233539 11 Screw19 3233556 1 Cover, Snorkel Drive20 3233555 1 O-Ring21 3233554 AR Shim22 3233020 4 Bearing, Ball23 3233898 1 Gear, 25T24 3233899 1 Shaft, Snorkel25 3233552 1 Busing, Garlock26 3233896 1 Gearcase, RH27 3233037 1 Vent, Tube28 3233026 1 Screw29 3233897 1 Guide, Chain

30 3233324 1 Washer31 3233711 1 Plug, Oil Fill32 3233542 1 Washer, Thrust33 3233541 1 Bushing, Garlock34 3233540 1 Shaft, Pinion35 3233306 1 Ring, Retaining36 3233263 1 Cover, Bearing37 3233538 1 Sprocket, 14T38 3233537 1 Ring, Retaining39 3233558 1 Gear, 98T40 3233544 1 Shaft, Output41 3233545 1 Sprocket, 16T42 3233546 1 Chain, Roller43 3233043 1 Deflector, Oil44 3233747 4 Screw, Tapping45 3233308 2 Pin, Interlock46 3233550 1 Spring, Shifting, Interlock47 3233309 1 Bracket, Interlock48 3233635 1 Switch, 3 Position49 3233749 4 Screw, Tapping50 3233549 1 Shaft, Shift, H/R51 3233548 1 O-Ring52 3233045 1 Ring, Retaining53 3233547 1 Bellcrank, .12554 3233055 1 Nut, FLEXLOC55 3233054 1 Washer56 3233040 1 Washer57 3233036 1 Chain, Silent58 3233536 1 Shaft, Input, HLR59 3233019 1 Bearing, Ball

6/01

C11

FOX SHOCK, GAS, RESERVOIRSCRAMBLER 500 4X4 A03BG50AA

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 Shaft, U-Cup4 1500024 1 Wiper, Shaft5 1500287 1 Screw6 1500018

150002311

ScrewO-Ring

7 1500006 1 Bearing, External8 1500003 1 O-Ring9 1500011 1 Piston, Floating10 1500099 1 Asm., Cap, Reservoir, (Incl. 11,12,13)11 1500097 1 Ring, Retaining12 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 Sleeve18 1500103 2 Bushing19 5410987 1 Bumper, Compression20 1500284 1 Shaft21 1500282 1 Cap, Body22 1500285 1 Bearing23 1500017 1 Plate, Top-Out24 1500002 1 Bearing, External Piston25 1500015 1 Plate, Back-up26 1500016 1 Nut, Lock27 1500004 1 O-Ring28 5020657 1 Bushing29 1500104 2 Bushing

4/01

C12

SHOCK VALVINGSCRAMBLER 500 4X4 A03BG50AA

8

1011

9

12

1

2

4

7

6

5

3

Shaft

Piston

Nut

13




1 1500033 1 Valve (.90 x .377 x .008)2 1500032 1 Valve (1.0 x .377 x .008)3 1500031 1 Valve (1.1 x .377 x .008)4 1500026 1 Valve (1.25 x .377 x .010)5 1500047 1 Valve (.80 x .377 x .010)6 1500046 1 Valve (.90 x .377 x .010)7 1500049 1 Valve (1.1 x .377 x .006)

8 1500052 1 Valve (1.3 x .377 x .006)9 1500095 2 Valve (1.25 x .377 x .012)10 1500060 1 Valve (1.1 x .377 x .012)11 1500096 1 Valve (1.0 x .377 x .015)12 1500094 1 Valve (.90 x .377 x .015)13 1500057 1 Valve (.80 x .377 x .012)

4/01

C13

CRANKCASESCRAMBLER 500 4X4 A03BG50AA

2

4

11

12

2

20

21

1

23

7

5

17

3

1918

10

1615

1314

22

6

5

8

9




1 3083669 1 Bushing, Starter2 3085808 1 Asm., Crankcase

(Incl. 1,4,5,7,8,11,12,17,20,21,22)3 3084838 2 Pin, Straight4 3080676 1 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 3 Screw and Washer7 3084839 1 Seal, Oil8 3085525 1 Pipe, Air Breather9 3087154 1 Fitting, Oil Inlet10 3084842 1 Union11 3084834 2 Bearing, Ball

12 3084835 1 Bearing, Ball13 3084845 1 Plug14 3084846 1 Gasket, Aluminum15 3084844 1 Spring, Valve, One Way16 3086810 1 Valve, One Way17 3084841 10 Bolt, Flange18 3082956 1 Gasket19 3083453 1 Plug20 3084837 1 Seal, Mechanical21 3084836 1 Seal, Oil22 3084847 1 O-Ring23 3080103 2 Pin, Dowel

6/02

C14

CRANKSHAFT and PISTONSCRAMBLER 500 4X4 A03BG50AA

20

21

7

11

1513

6

9

19 14

10

18

8

4

12

1

16

22

17

2

3

1

5




1 3085534 2 Clip2 3087221

30872223087223

111

Piston Set (Std) (Incl. 1)Piston Set (0.25 O/S) (Incl. 1)Piston Set (0.50 O/S) (Incl. 1)

3 308722430872253087226

111

Piston Ring Set (Std)Piston Ring Set (0.25 O/S)Piston Ring Set (0.50 O/S)

4 3080676 1 Bearing5 3085815 1 Bearing, Ball6 3085812 1 Crankshaft 27 3085341 1 Pin, Crank8 3085813 1 Rod, Connecting9 3085400 1 Bearing, End, Large10 3085024 1 Ball, Steel11 3085861

308594511

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

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

30848963084897

111

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

15 3240088308489230848933084894

1111

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

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

6/02

D1

CYLINDERSCRAMBLER 500 4X4 A03BG50AA

2

20

38

232221

12

5

4

37

107

34

9

25

29

1617

3

6

18

27

1

26

13

35

28

33

31

32

8

11

30

36

14

24

15

19

5

36

36

13

9

18


D2

CYLINDERSCRAMBLER 500 4X4 A03BG50AA



1 3084045 1 Asm., Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt4 3084857 2 Pin, Straight5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve7 3084867 1 O-Ring8 3085072 1 Adapter, Water Out9 3084877 10 Bolt, Flange10 3084866 1 Adapter, Camshaft11 3085074 1 Gasket, Rocker Cover12 3085073 1 Cover, Rocker13 3084874 10 Bolt, Flange14 3084859 2 Seal, Exhaust Valve15 3084875 4 Bolt, Cylinder Head16 3084860 1 Plug17 3084861 1 Gasket18 3084862 1 Plug, Blind19 3084215 2 Bolt, Flange

20 3085075 1 Gasket, Exhaust21 3085326 2 Stud22 3080530 2 Washer, Lock23 3087199 2 Nut24 3085854 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3084838 2 Pin, Straight29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3086811 1 Cylinder (Incl. 32)32 3084130 1 Pipe 2, Elbow33 3085370 1 Gasket, Cylinder34 3084868 1 Cover, Camshaft35 3086200 1 Gasket, Cover, Cam36 3085527 1 Head, Cylinder (Incl. 4-6,14,16-18,21)37 3085371 1 Gasket, Head38 3085809 1 Adapter

6/02

D3

CARBURETORSCRAMBLER 500 4X4 A03BG50AA

14

31

20

2

8

3

9

5

6

19

36

34

11

4

29

13

28

29

2726

37

32

4438

7

49

47

16

33

48

21

46

40

1

2423

3017

10

12

45

41

35

222518

15

14

42

43

39


D4

CARBURETORSCRAMBLER 500 4X4 A03BG50AA



1 3130821 2 Screw2 3130914 1 Cover, Diaphragm3 3130911 1 Spring4 3130913 1 Ring5 3130908 1 E-Ring6 3130915 1 Ring7 3131358 1 Needle, Jet8 3130910 1 Diaphragm9 3130912 1 Valve, Piston10 3130543 1 Guide, Cable11 3130931 1 Asm., Throttle Shaft12 3130932 1 Ring13 3130927 1 Spring14 3130933 4 Screw15 3130926 2 Washer16 3130925 1 Case17 3130619 1 Jet, Air18 3131452 1 Asm., Carburetor (Incl. 1-49)19 3131309 1 Jet, Needle20 3131290 1 Block, Jet21 3130916 1 O-Ring22 3131208 1 Cap23 3130593 1 Asm., Plunger24 3130538 1 Spring25 3130199 1 Cap, Plunger

26 3130519 1 Cap27 3130518 1 E-Ring28 3130517 1 Packing29 3130515 2 Seal30 3130906 2 Screw31 3130907 1 Valve, Throttle (120)32 3131306 1 Jet, Pilot (#40)33 3131359 1 Valve, Needle (1.5)34 3130928 1 O-Ring35 3131294 1 O-Ring36 3130930 1 Cover37 3130924 3 Screw38 3130010 1 Spring39 3131296 1 Washer40 3131295 1 Asm., Adjuster, Cable41 3131242 1 Clip42 3131291 1 Screw, Guide43 3130239 1 O-Ring44 3131308 1 Jet, Main (#155)45 3130919 1 Ring46 3130935 1 Screw47 3130923 1 Asm., Float Body48 3130917 1 Seal49 3131293 1 Asm., Float

4/03

D5

INTAKE and EXHAUSTSCRAMBLER 500 4X4 A03BG50AA

14

18

15

1617

25

26

1312 11

10

6

98

22

7

19

8

21

24

4

3

2

1

5

20

27

23

89

6

9

12

11

13




1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3086839 1 Spring, Tensioner4 3086813 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Rocker Arm, Intake (Incl. 8,9)7 3084913 1 Asm., Rocker Arm, Exhaust (Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3087203 4 Retainer, Valve Spring13 3084906 4 Spring, Valve14 3085855 1 Camshaft (Incl. 15-18)

15 3086838 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3084914 1 Sprocket 220 3081657 3 Bolt and Washer21 3084916 1 Guide, Chain22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot24 3084917 1 Lever25 3085349 2 Valve, Intake26 3085412 2 Valve, Exhaust27 3084874 2 Bolt, Flange

6/02

D6

RECOIL STARTERSCRAMBLER 500 4X4 A03BG50AA

13

6

4

7

10

5

31 2

11

8

12

14

9

8

7




1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Bolt and Washer7 3083453 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084877 9 Bolt, Flange13 3087163

308716411

Asm., Recoil (Incl. 1-6,9-11,13,14)Starter Case (Incl. 11)

14 3085083 1 Asm., Rope

6/02

D7

WATER PUMPSCRAMBLER 500 4X4 A03BG50AA

11

7

83

3

2

1

9

12

13

4

10

65




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

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

4/01

D8

OIL PUMPSCRAMBLER 500 4X4 A03BG50AA

4

1

10

3

2

11

17

15

87

6

13

14

5

16

18

9

12




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

308494511

Asm., Oil Pump (Incl. 1-8,10-15)Pump, Oil, Case 1

5 3085535 1 Screw6 3084955 2 Pin, Dowel7 3084954 2 Pin, Dowel8 3084953 1 Washer9 3084962 3 Bolt and Washer10 3084947 1 Pump, Oil, Case 3

11 3084950 1 Rotor, Inner12 3084951 1 Rotor, Outer13 3084956 1 Unit, Oil Strainer14 3084205 3 Screw and Washer15 3085818 1 Shaft, Pump16 3087173 1 Gear 2, Pump17 3085820 2 Bolt, Flange18 3084959

30849603084961

ARARAR

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

9/01

D9

OIL FILTERSCRAMBLER 500 4X4 A03BG50AA

1

4

5

3

3

3

2

2

2

2

2




1 3084963 1 Filter, Oil2 3084846 8 Gasket, Aluminum3 3086815 4 Bolt, Banjo

4 3084964 1 Pipe, Oil Delivery 15 3085638 1 Pipe, Oil Delivery 2

4/01

D10

MAGNETOSCRAMBLER 500 4X4 A03BG50AA

18 6

5

8

9

1011

12

13

4

7

1

2

15

17

3

14

16




1 30846903084979

11

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

2 3084980 1 Cap, Spark Plug3 3084997 1 Plug, Spark4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3087167

308698111

Asm., Plate (Incl. 5,6,8-12,14)Plate

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3087168 1 Stator (Incl. 13)

10 3086985 3 Screw and Washer11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3085360 1 Coil, Pulser14 3081256 1 Screw and Washer15 3087169 1 CDI System16 3085359 2 Bolt, Flange17 3087196 1 Switch, Magnetic18 3087166 1 Flywheel/Ring Gear

6/02

D11

STARTING MOTORSCRAMBLER 500 4X4 A03BG50AA

9

12

1

4

10

3

2

11 13

17

16

15

14

56

8

7




3084981 1 Asm., Starting Motor (Incl. 1-4,6-10,12)1 3084982 1 Washer Set2 3084406 1 Brush Set, Carbon3 3083649 2 Nut, Flange4 3084408 3 O-Ring5 3082038 2 Bolt and Washer6 3085034 1 Asm., Bracket, Rear7 3085353 1 Asm., Armature8 3085033 1 Asm., Bracket, Front

9 3240114 1 O-Ring10 3084983 2 Asm., Set Bolt (Incl. 4)11 3087030 1 Asm., Gear Shaft (Incl. 13-17)12 3084405 2 Ring, Rubber13 3083737 1 Washer, Gear Shaft14 3084412 1 Clip15 3084411 1 Spring, Weight16 3084410 1 Spring, Return17 3084409 1 Clip

4/01

D12

FUEL PUMPSCRAMBLER 500 4X4 A03BG50AA

4

1

3 2

2

4




3085275 1 Asm., Fuel Pump (Incl. 1-4)1 3084999 1 Screw and Washer2 3085000 2 Screw and Washer

3 3084591 4 Screw and Washer4 3084998 1 Gasket Set, Diaphragm

4/01

D13

TOOL KITSCRAMBLER 500 4X4 A03BG50AA

2

10

3

4

5

6

7

8

9

1




1 99174929917510

11

Owner’s Manual, ’03 ATVSupplement, Owner’s Manual, ’03Scrambler 500

2 3085544 1 Asm., Tool Kit (Incl. 4-9)3 2870725 1 Gauge, Tire Pressure4 3085001 1 Wrench, Open, 8-10mm

5 3085002 1 Wrench, Open, 12-14mm6 3085568 1 Wrench, Box, 125mm7 3085569 1 Puller, Spark Plug (Wrench Handle)8 3082657 1 Screwdriver9 2682572 1 Pouch, Tool Kit10 5211627 1 Wrench, Spanner

6/02

PRINTED IN THE USA PARTS MANUAL PN 9917511 and MICROFICHE PN 9918976 3/03

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scrambler 500 4x4 model #a03bg50aa rev. 01pi54.com/corp/manuals/parts/9917511r01.pdf · 12...

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