SCRAMBLER 500 Model #A00BG50AA Rev. 02. E 2000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00

Transcription

1 SCRAMBLER 00 Model #A00BG0AA Rev. 0 E 000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00

2 TABLE OF CONTENTS Parts Manual A-ARM/STRUT MOUNTING... AIR BOX... A C B C CARBURETOR... D-0 CLUTCH COVER... C CONTROL PANEL... A CONTROLS - MASTER CYLINDER/BRAKE LINE... B CONTROLS - THROTTLE ASM./CABLE... B COOLING SYSTEM... A CRANKCASE... D CRANKSHAFT and PISTON... D CV JOINT... B CYLINDER... D- DECALS... DRIVE CLUTCH... DRIVEN CLUTCH... D E B B C ELECTRICAL/TAILLIGHT... C ENGINE MOUNTING... A- EXHAUST SYSTEM... A0 FOX SHOCK, GAS, RESERVOIR... D FRONT BRAKE... B FRONT BUMPER and SHIELDS... A FRONT CAB... A FRONT HOUSING... B- FRONT STRUT... B FRONT WHEEL... B FUEL PUMP... E FUEL TANK... A F GEAR SELECTOR... D GEARCASE... C- GEARCASE/BRAKE and CHAIN COVER MOUNTING... C HANDLEBAR/HEADLIGHT INTAKE and EXHAUST G H I M MAGNETO... OIL FILTER... OIL PUMP... OIL TANK... PROP SHAFT O P... REAR BRAKE MASTER CYLINDER... REAR CAB... REAR CALIPER MOUNTING... REAR WHEEL DRIVE... RECOIL STARTER... SHOCK VALVING... STARTING MOTOR... STEERING POST... SWING ARM/SHOCK MOUNTING... TOOL KIT WATER PUMP R S T... W... B0 D E D D A B C A C C D D E B C0 E D The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

3 Type - Front Type - Rear Type - Auxiliary Type - Parking BRAKES CAPACITIES Coolant Capacity (quarts) Fuel Tank (gallon) Gearcase Oil (ounces) Engine Counter Balance 0W0 Oil (quarts) Injector Oil (quarts) Engine (OW0) Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight Type DRIVE TRAIN DRIVE CLUTCH Center Distance (inches) Clutch Offset (inches) Clutch Weight Spring Color 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) 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 TIRES&WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center 000 SCRAMBLER 00 SPECIFICATIONS ENGINE Hydraulic Disc Hydraulic Disc Hydraulic Disc Hydraulic Lock, All Wheel.. NA NA Accessory 0 Accessory 0 0 Accessory 0 PVT 0 / 0 WH Blue/Green 0-0 N/A...0. PRD Side Lever N/A./.0/ : / P N/A N/A 0 O-Ring Titan xx0 xx0 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 Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Air Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust GRAPHICS 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 LIGHTS/BATTERY Headlight (watts) Taillight (watts) Brake Light (watts) Indicator Bulb SUSPENSION Front Type - Front Travel (inches) Adjustment Rear Type - Rear Travel (inches) Shock Adjustment EH0PLE0 Cycle, Single Cylinder Dry Sump.0x 0: Full Stroke Liquid 0W Standard /BST0 (CV Type) 0 Y-0 NA.0 Turn H-- CDI 00.0 NGKBKRE USFS Pending 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 Dual Beam, 0/0 W V/. W V/. W V/ W MacPherson Strut Progressive Rate Swing Arm 0. Gas Charged w/remote Reservoir Threaded Adjuster Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

4 MODEL MODEL NO. OWNER S MANUAL 000 SCRAMBLER 00 ATV PUBLICATION NUMBERS OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS 0 0

5 FRONT CAB E 000 Polaris Sales Inc Nut, Speed, U-Clip -0 Bracket, Cab Mount Screw 00-0 Frame Rivet, Pop -0 Strap, Fuel Pump Mounting Bolt - Cover, Front, Blazing Red - Cab, Front, Blazing Red (w/warning Decals) 0 0 Screw 0 Washer, Flat 0 Washer, Flat Rivet Nut, Nylok Washer, Flat -0 Bracket, Mudflap Mudflap, Front, LH Mudflap, Front, RH Footpad, RH (If built before //) Footpad, LH (If built before //) Footpad (If built after //) Rivet 0 Trim, Footrest -0 Bracket, Heel Cleat Guard, Rock Screw /00 A

6 REAR CAB Rivet 0 Washer, Flat Screw Screw 00 Spring, Latch, Light 00 Latch, Seat Cap, Seat Latch Seat, Black Covering, Seat, Black Tongue, Seat 0 Rivet 0 Bumper, Rubber 0 Bracket, Lever Retainer 0 Rivet 0 Foil, Rear Cab, Small 0 Decal - Carb Information 0 Decal - Filter Element 0- Cab, Rear, Blazing Red 00 Nut, Speed, U-Type Shield, Muffler 0 Nut, Nylok Screw Plug, End Cap, Ribbed 0-0 Guard, Clutch Rivet 0 Reflector, Red Bolt Footpad (See Front Cab Pg. A, Ref. ) Mudflap, Rear, LH Mudflap, Rear, RH Bracket, Mudflap 0 0 Foil, Rear Cab 00 Bracket, Rear Seat Holddown /00 A

7 FRONT BUMPER and SHIELDS Washer, Flat Bolt Plug, Frame 0 U-Nut 0 Shield, Deflector 0-0 Bumper, Front Nut, Nylok Washer, Flat -00 Plate, Skid, Bumper 0 Screw Screw -0 Bracket, Radiator Shield 0 Nut, U-Type A 0 Washer, Flat -0 Shield, Radiator Side, RH Screw -0 Shield, Radiator Side, LH Screw 00 Clip, Dart 0-0 Shield, Upper Radiator 0 Reflector, Amber Rivet 0 Heat Sink 00 Regulator, Rectifier 0 Screw /

8 CONTROL PANEL 0 0 Plug 000 Indicator, Neutral/Reverse 000 Indicator, Hot Temperature Cover, Key Switch, Ignition (Incl. Key) Key, Blank, Series 000, 00, 00. NOTE: Spare key must be cut from existing key. Key, Blank, Series 00, 00, 00, 00. NOTE: Spare key must be cut from existing key. A Nut, Ignition Panel, Control, Outer 00 Nut, Ignition Switch 0 Screw 0 0 Harness, Indicator 00 Nut, Choke Slide Panel, Control, Inner 00 Cable, Choke 0/00

9 COOLING SYSTEM Nut, Nylok 0 Washer, Flat Shroud, Fan, ATV 0 Screw 0 Cap, Overflow, Drilled 0 Gasket, Overflow Cap Plug, Cap 0 0 Asm., Surge Tank w/fitting Tank, Surge 000- Line, Fuel 0 00 Fitting, Barbed, 0 Degree 00 Clamp 000- Hose, Lower 0 Hose, Upper 00 Clamp, Hose 000 Switch, Thermal Cap, Pressure A 00 Radiator, U-Flow Bolt 0 Valve, Drain Cock 0 00 Spacer, Mount, Radiator 00 Mount, Rubber, Radiator 00 Cable Tie 000 Clip, Dart 00 Motor, Fan -0 Bracket, Cooling Fan 0 Blade, Fan Screw Screw 0 Bushing, Mount, Lower Radiator 0 0 Washer, Flat 00 Nut, Nylok 00 Breaker, Circuit /00

10 EXHAUST SYSTEM 0 Bolt 0 Dampener, Vibration 00 Bushing 00-0 Silencer 00 Spring, Exhaust 00-0 Pipe, Exhaust Seal, Exhaust Screw A0-0 Bracket, Exhaust 0 0 Nut 00 Mount, Torque Stop 00 Spring, Exhaust Bolt Nut, Nylok Washer, Flat 0 Washer, Rubber /

11 A ENGINE MOUNTING

12 ENGINE MOUNTING 0 Nut, Flange Washer, Flat 00 Cable, Ground/Engine Screw 00 Mount, Rubber, Top -0 Bracket, Mount, Engine, Top 0 Washer, Spring Lock Bolt 0000 Clamp, Hose, Red AR Line, Fuel 000- AR Line, Fuel 00 Screw and Washer 00 Mount, Radiator -0 Bracket, Carburetor Mount 0 Washer, Split Lock 0 Nut Asm., Carburetor (See Carburetor Pg. D0, Ref. ) AR Line, Fuel 000- Sheath, Foil, Laminated Mount, Rear Motor 0 Nut, Flange, Lock 00 Mount, Rubber Screw Washer 0 Boot, Clutch Intake 00 Clamp, Narrow Band 0 Bushing 0 Washer, Flat 0 Washer, Interlock 0 Bolt Asm., Drive Clutch, ATV-0 (See Drive Clutch Pg. B, Ref. ) Bracket, Retainer, Seal (See Clutch Cover Pg. C, Ref. ) 00-0 Mount, Engine Screw Nut, Nylok 00 Mount, Rubber 00 Clamp 0 Washer, Spring Lock Screw 0 00 Clamp AR Hose, Engine, Lower (See Cooling System Pg. A, Ref. ) Nut (See Cylinder Pg. D, Ref. ) Washer, Lock (See Cylinder Pg. D, Ref. ) 0-0 Manifold, Black Gasket, Exhaust (See Cylinder Pg. D, Ref. 0) 0 Engine, Short Block (EH0PLE0) NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization required for warranty consideration AR Hose, Engine, Upper (See Cooling System Pg. A, Ref. ) / A

13 OIL TANK 0 0 Screw Plate, Vent, Oil Tank 00 Gasket, Oil Reservoir 0 Fitting Hose, Breather 0 Plug 0 Bolt, Banjo Washer, Copper 0 Tube, Banjo Return 0 Dipstick 0 O-Ring 0 AR Hose, Formed 00 Clamp, Hose A 00 Fitting, / to / 00 Screen, Oil Filter Tank, Oil, LH Nut, Nylok 0 Grommet 0 Grommet, Mounting, Reservoir 0 0 Bushing 0 Washer, Flat 0 Screw 0 Washer Screw Tank, Oil, RH /0

14 FUEL TANK 0 0 Asm., Fuel Tank (Incl.,0,,) Tank, Fuel Seal, Foam 0 Grommet, Fuel Tank 0 Gasket, Fuel Cap 0 Cap, Gas Tank AR Line, Fuel 0 Vent, Tank Screw 0 Washer, Spring Lock 0 Washer, Flat Seal, Foam Spacer Insert A Washer, Flat 0 Lever, Fuel 0 Screw Grommet 00 Spring, Lever, Compression Extension, Fuel Lever 0 Screw 0000 Clamp, Hose, Red 000 Filter 000- Sheath, Foil, Laminated Line, Fuel 00 Valve, Fuel 0 Gasket, Fuel Valve 00 Foam, Tape, Black /

15 DECALS RH 0 LH 0 Decal - Warning, Heavy Loads 0 0 Decal - x CDS, LH Decal - x CDS, RH 00 Decal - Tank Side, RH 000 Decal - POLARIS 0 Decal - Warning, AWD Switch 0 Logo, th Anniversary 00 Decal - Scrambler 0 Decal - Front Cover, 00 L/C, Stroke 0 Decal - Warning, Discretionary 0 0 Decal - Drain, Recoil 00 Decal - Warning, Override, AWD 0 Decal - Age Warning 00 Decal - Tank Side, LH 00 Decal - Passenger Warning 00 Decal - Caution, Tire Pressure 0 Decal - Warning, General 0 Decal - Fuel Lever 0/00 B

16 PROP SHAFT 0 Guard, Prop Shaft, Side Screw Guard, Prop Shaft, Front 0 O-Ring 0 Yoke, Prop Shaft, Transmission 0 Shaft, Prop 0 Joint, Cardan 0 Yoke, Front Gear Case 0 Asm.,PropShaft(Incl.-) 0 Pin, Spring 0 Washer, Flat / B

17 FRONT HOUSING 0 0 Asm., Front Gearcase (Incl. -,-)(If built before /0/) Screw Seal 0 Cover, Input, Front Housing 00 O-Ring Ring, Retaining Bearing, Ball Pinion, Input Bushing Seal 0 Bushing Washer Plug, Oil Fill 000 Clamp, Wire Routing 000- AR Line, Fuel 000 Clamp, Hose Tube, Vent Gearcase 0 SubAsm., Output Shaft, Front Housing Shaft, Output Gear, T 00 Bearing 0 AR Shim O-Ring Cover, Output, Front Housing AR Shim 0 Button, Thrust Washer, Plug Plug, Drain Screw 0 Washer, Spring Lock / B

18 FRONT HOUSING 0 0 Asm., Front Gearcase (Incl. -,-) (Units built after /0) Screw Seal 0 Cover, Input, Front Housing 00 O-Ring Ring, Retaining Bearing Pinion, Input, T Bushing Seal, Oil 0 Bushing Washer Plug 000 Clamp 000- AR Fuel Line 000 Clamp, Hose Tube, Vent Gearcase, Front Housing Shaft, Output, T 00 Bearing, Ball 0 AR Shim O-Ring Cover, Output, Front Housing AR Shim Button, Thrust Washer Plug, Drain 0 Washer, Lock Screw / B

19 CV JOINT - NEAPCO Brand Designated 0 0 Asm., CV Housing w/sleeve (Incl. ) Asm., Drive Shaft, Splined Sleeve, Drive Shaft Seal 0 Clamp, Band 00 Circlip 00 Kit - Boot, Replacement 000 Shaft, Replacement (Incl. ) 00 Cardan Replacement (Incl.,,,) 00 Kit - Cross and Bearing 00 Yoke, Splined 0 Pin, Spring 0 Clamp, Band 000 Kit - Drive Shaft Assembly w/sleeve Neapco /0 B

20 FRONT STRUT Bumper 0 Strut, Front Washer 00 Clamp, Rubber Coated 0 Nut, FLEXLOC Screw 0 Washer, Spring Lock 0 0 Washer, Flat 0 Retainer, Strut Casting Wire Asm., Front Brake Caliper, RH (See Front Brake Pg. B for Details) 0 Bearing, Tapered Roller 0 Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal 000 Fitting, Lubrication 0 Coil, Magnetic B 0 0 Asm., Hubstrut, LH (Incl.,-) Asm., Hubstrut, RH (Incl.,-) 00-0 Spring, Coil, Strut Retainer, Spring Ball, Pivot, Bottom 0 Bolt 0 Spacer Kit - Drive Shaft w/sleeve (See CV Joint - Neapco Pg. B, Ref.) 00 Seal, Hubstrut Ball, Pivot, Top 0 Spacer, Rubber Washer 0 Nut, Nylok 00 Grommet /00

21 FRONT WHEEL 0 DETAIL A A 0 Bolt Disc, Brake 00 Seal, Front Hub Plate, Armature 0 Asm. Clutch, Front Hub, Elec./Mech. (Splined Drive Shaft) 0 Bearing, Tapered Roller Cone 0 Bearing, Tapered Roller Cup Stud 0 Asm., Hub (Incl.,,) 0 00 Cage, Roll 000 Roll 00 Spring, Garter Spacer 000 Cam 00 Plug, Magnetic Drain Tire, Titan (x-0) 00 Washer 0 Pin, Cotter 00 O-Ring 0 Cap, Hub 0 Screw 0 Nut Nut, Lock 00- Rim, Front 0 Valve, Rim / B

22 FRONT BRAKE Asm., Front Brake Caliper, LH (Incl. -) Asm., Front Brake Caliper, RH (Incl. -) 0 Kit - Front Brake Boot (Incl.,) 00 Screw, Bleeder Screw, Socket Set Caliper,Brake,LH Caliper,Brake,RH 0 Kit - Piston and Seals (Incl. -) 0 Ring, Square, Molded (.0) 00 Ring, Square, Molded (.0 x.) Piston, Brake, Long 0 Boot, Pin Seal Washer, Flat (See Front Strut Pg. B Ref. ) Washer, Lock (See Front Strut Pg. B Ref. ) Screw (See Front Strut Pg. B, Ref. ) 0 Boot, Bushing 0 Mount, Caliper Kit - Severe Duty Brake Pad, Front (Complete set of pads) Kit - Brake Pad, Soft, Front Kit - Brake Pad, General, Front 0/00 B

23 A- ARM/STRUT MOUNTING Nut, FLEXLOC Bushing 00 Asm., Tie Rod (Incl. -) Boot, Seal, Rod End 00 Rod End, RH Nut 00 Tie Rod 0 Nut, LH 00 Rod End, LH 0 0 Boot, Seal, Rod End Bolt 0 Washer, Flat 0 Nut 0 Pin, Cotter Asm., Hubstrut (See Front Strut Pg. B, Ref. ) 00 Joint, Ball Bracket, Ball Joint Screw 0 Boot, Rubber 0 Nut, Castle 0 Screw 0 Shield, CV Joint, LH Shield, CV Joint, RH Bushing, A-Arm, Long 00 Bushing 00 Shaft, A-Arm 0 0 Kit - A-Frame, LH Kit - A-Frame, RH 00 Fitting, Lubrication 0 Washer, Spring Lock Screw 0 Bolt Screw B 0/00

24 HANDLEBAR/HEADLIGHT Kit - Handlebar Block (Incl.,,) Asm., Throttle Control (See Controls- Throttle Asm./Cable Pg. B, Ref. ) 0-0 Handlebar Screw Pad, Handlebar Pad, Handlebar Cover Asm., Master Cylinder (See Controls-Master Cylinder/Brake Line Pg. B, Ref. ) Spacer, Switch, LH 00 Switch, Handlebar, Hi/Lo/Rev/Override Screw, Set 0 Plug, Hole 00 Grip, Handlebar 00 Cable Tie Nut, Nylok 0 Washer, Flat 0 Washer, Flat Nut, Nylok -0 Bracket, Headlight 00 Clip, Cable Retaining Headlight Bulb, Headlamp Guard, Headlight Bolt 0-0 Block, Handlebar Retainer / B0

25 STEERING POST 0 0 Asm., Steering Post (Incl.,) Bushing, Steering Console 000 Fitting, Lubrication, 0 Degree Bolt Washer 0 O-Ring Spacer, Steering Post 0 Nut B Pin, Cotter 0 0 Bushing, Steering, Lower Rivet Plug, Grease, Steering 00 Fitting, Lubrication Bushing, Steering, Upper -0 Bracket, Steering Bushing, Upper Nut, Nylok /

26 CONTROLS - THROTTLE ASM./CABLE 0 Cover, Throttle Control 0 O-Ring O-Ring 000 Cable, Throttle Control 00 Asm., Throttle Control (Incl.,,) 00 Asm., Throttle Clamp /00 B

27 CONTROLS - MASTER CYLINDER/BRAKE LINE Kit - Master Cylinder Reservoir (Incl.,,,) Asm., Master Cylinder (Incl. -) 0 Screw, Cap 0 Cap, Reservoir 0 Diaphragm 000 Kit - Clamp 0 Asm., Master Cylinder Piston 00 Rivet 00 Kit - Brake Lever w/parking Brake Latch (Incl.,,) Spring, Flat 0 00 Nut 000 Kit - Park Brake Lever (Incl.,) 0 Screw B 00 Screw Ring, Square 0 Line, Brake, Upper w/fittings 0 Switch 0 Line, Brake, Hand, Rear 00 Cable Tie 00 Clamp 0 Rivet, Pop 00 Line, Brake, Left Front w/fittings 00-0 Conduit 0 Screw 00- Tubing, Convoluted 0 Line, Brake, Right Front w/fittings 0 Fitting, Cross /

28 DRIVE CLUTCH 0 Bolt 0 Washer, Spring Lock 0 Cover, Bearing 0 Clutch, Spring 0 Washer, Multilube Roller and Bushing Button, Clutch, Stemless AR AR AR AR Spacer (.00) Spacer (.0) Spacer (.0) Spacer (.00) 00 Weight, Shift (0-WH) 0 Bolt, Shoulder 0 Nut, FLEXLOC 0 Bearing, Moveable, / 00 Pin, Roller Asm., Drive Clutch, ATV-0 (Incl. All Less,) / B

29 DRIVEN CLUTCH 0 0 AR Bushing Asm., Driven Clutch (Incl. -) 0 Washer, Domed 0 Washer, Spring Lock Bolt 0 Belt, Drive AR Washer (.00) 0 AR Washer (.0) 0 AR Washer 0 0 Bearing, Moveable, / Bearing, Moveable, 0 Spring, Clutch Ramp, Stationary 0 Spacer 0 Ring, Retaining Bolt 0 Button, Ramp / C

30 GEARCASE MOUNTING 0 Screw -0 Bracket, Transmission Nut, Flange Screw 0 Guide, Chain, Transmission 0 Washer, Flat Screw 0 Washer, Flat C Screw 0 0 Sprocket, T 0 Ring, Retaining 0 0 AR AR AR Shim (.00 ) Shim (.00 ) Shim (.00 ) 0 Screw /

31 REAR CALIPER MOUNTING Frame 0 Screw 0 Washer, Flat Caliper, Rear Kit - Caliper Seal Kit - Bleeder Replacement Piston, Caliper, Rear 0 Seal 0 Line, Brake, Hand, Rear 0 Line, Brake, Foot, Rear 00 Clip, Rosebud 00 Clip, Silencer Box 0 Bolt, Banjo 0 Bushing, Caliper Mount 0 Washer, Flat 0 Washer, Spring Lock Bolt Mount, Caliper, Lower Mount, Caliper, Upper Bolt -0 Guard, Brake Disc Kit - Brake Pad (Incl. Spacer and Pin) Spacer Pin /0 C

32 REAR BRAKE MASTER CYLINDER Clamp, Hose Bolt 0-0 Bracket, Reservoir Mount Nut, Nylok 0 Screw 0000 Clamp, Red 00 Hose, Reservoir 0 Reservoir 0 Washer, Flat 0 0 Pin, Cotter Washer 0 Bushing 0-0 Mount, Brake 0 Bolt, Banjo 0 Seal Line, Foot Brake, Rear (See Rear Caliper Mounting Pg. C, Ref. ) Screw 0 Asm., Foot Brake Master Cylinder Nut, Nylok Rod, Brake 00 Spring, Torsion Screw / C

33 REAR WHEEL 0 Bolt 00 Kit - Hub, Rear (Incl.,,,0) 0 Nut, Flange Washer, Cone 00 Nut, Castle 0 Pin, Cotter Cover, Dust, Hub Washer, Flat 0 Valve, Rim 0 00 Retainer, Bolt, Pushnut 00- Rim, Rear Tire (x-0) / C

34 REAR HOUSING Ring, Retaining 0 Extrusion, Retainer, Nut Nut, Nylok Seal, Foam Disc, Brake Stud 0 Hub, Brake Disc (Incl. ) 0 Ring, Retaining 00 Spacer, Axle 0 0 O-Ring 000 Seal Bearing, Cone, Tapered Bearing, Cup, Tapered 0 Housing, Axle, Rear 000 Fitting, Lubrication 0 Link, Connector, 0 Regina 00 Axle, Rear -0 Guard, Sprocket 0 Nut 0-0 Chain, 0 O-Ring 0 Bolt 0 Asm.,Hub,Sprocket(Incl.) 0 Sprocket, T 0 Spacer /00 C

35 AIR BOX 0 0 Screw Duct, Inlet Gasket, Intake Cover, Air Box Seal, Cover Screw 0 Washer, Flat AR Line, Breather 00 Clamp, Hose 0 00 Filter, Breather 00 Clamp, Hose Hose, Breather 00 Clamp, Band Boot, Carb 00 Clamp Duct, Carb, Inlet 0 Gasket, Duct 00 Clamp, Hose Box, Air 0 Hose, Breather, Oil Tank 0 Foil, Air Box Plug, Trap 00-0 AR Line, Fuel 000 Clamp, Hose 0 Clip 0 Collar, Inlet, Carb 00 Filter, Air Filter, Sleeve, Precleaner /00 C

36 CLUTCH COVER Nutsert 0-0 Bracket, Clutch Cover Screw Duct, Down Tube, Inlet Seal, Cover 00 Kit - Inner Clutch Cover (Incl.,,) Washer Screw 0 Seal, Clutch Cover 0 Cover, Clutch, Outer 00 Clip, Clutch Cover 0 Screw 0 Decal - Clutch Cover 0 Decal - Eng./Clutch Modification 0 Decal - Automatic Transmission 0 Screw 00 Cable Tie Boot, Duct 0 Duct, Clutch, Hi-Flow Screw and Washer (See Crankcase Pg. D, Ref. ) 00-0 Bracket, Retainer, Seal 0 Seal, Cover, Case Washer 0 Screw Washer -0 Bracket, Clutch Cover Rivet 00 Clamp, Narrow Band / C

37 ELECTRICAL/TAILLIGHT Harness, Main 00 Cable Tie 0 Breaker, Circuit, 0 AMP 0 Kit - Circuit Breaker, 0 AMP 0 Light, Tail/Brake (Incl. -0) 0 Screw 00 Lens 000 Bulb 00 Gasket 0 00 Backing 00 Clip 0 Washer 0 Screw 00 Pad, Battery Cover, Battery 00 Kit - Battery Bolt 000 Cable, Battery/Engine, Black 000 Hook, Battery Strap 0 Strap, Battery Holddown 0 0 Tube, Vent 000 Battery 000 Cable, Battery/Solenoid, Red 000 Cable, Solenoid/Starter Nut, Nylok 00 Bolt 00 Clip, Routing 00 Clip, Rosebud 0 Screw 00 Limiter, RPM, LR Pad, Fuel Tank Bracket Bracket, CDI 00 Trim, Edge 00 0 Screw Asm., Tool Box Cover, Tool Box Lid Gasket /00 C

38 SWING ARM/SHOCK MOUNTING Nut, Nylok 0-0 Spring, Compression, Small 0-0 Spring, Compression 0 Decal - Warning, Fox Shock 00 Ring, Spring Preload 0 Spacer, Spring 0 Shock, Gas 0 Retainer, Spring Screw 0 0 Rivet Guide, Pad, Chain 000 Fitting, Lubrication 0 Nut 0 Washer, Flat Bushing, Swing Arm, RH Bolt, Pivot, Swing Arm Bushing, Pivot, RH Asm., Swing Arm (Incl.,,) 0 Decal - Chain Free Play 0 Guard, Chain 0 Screw Bushing 0 Washer Nut 0 Nut Washer Bolt Screw Bushing, Swing Arm, LH 0 Bushing, Pivot, LH /0 C0

39 C GEARCASE

40 GEARCASE Asm., Gearcase (Incl. -)(Units built before April, ) Gearcase, LH Mach 0 Bearing, Ball Shaft, Reverse T 0 Washer, Thrust 0 Bearing, Needle Sprocket, T 0 Ring, Retaining Engagement Dog 00 Washer, Thrust 0 Fork, Shift High/Rev. Mach Bushing, Garlock Gear, 0T Washer, Thrust Ring, Retaining 0 Bearing, Ball 0 Screw 0 Bracket, Interlock 0 Spring, Shifting Interlock 0 Pin, Interlock 0 Shaft, Shift 00 Washer Bellcrank 0 Nut, FLEXLOC 0 Washer 0 Ring, Retaining O-Ring Screw and Washer H/R Switch Plug 0 Washer Cover, Snorkel Screw O-Ring Seal Shim Subassembly, Snorkel Gear Bushing, Garlock Gearcase, RH Mach AR Tube, Vent Line, Fuel 0 Decal - Switch 00 Bearing, Ball Chain, Roller P Sprocket, /T Shaft, Output Gear, T Ring, Retaining Sprocket, /T Bearing, Cover, Center Drive 0 Ring, Retaining 0 0 Shaft, Pinion T Bushing, Garlock Washer, Thrust Button Pinion 0 Deflector, Oil 0 Chain, Silent Shaft, Input Pipe, Knock Screw Bushing, Pivot Plug 0 0 Washer / C

41 GEARCASE C

42 GEARCASE Asm., Gearcase (Incl. -) (Units built after April, ) Gearcase, LH Mach 0 Bearing, Ball Shaft, Reverse T Bearing, Needle Sprocket, T 0 Ring, Retaining, E-Ring Dog, Engagement Fork, Shift High/Rev., Mach Gear, 0T 0 Washer, Thrust Ring, Retaining 0 Bearing, Ball 0 Screw 0 Bracket, Interlock 0 Spring, Shifting Interlock 0 Pin, Interlock Shaft, Shift 00 Washer Bellcrank 0 0 Nut, FLEXLOC 0 Washer 0 Ring, Retaining O-Ring Screw and Washer Switch, H/R Plug Washer Cover, Snorkel Screw 0 Seal, Triple Lip O-Ring 00 Bearing, Ball AR Shim Subassembly, Snorkel Gear Bushing, Garlock AR Tube, Vent Line, Fuel Decal - Switch Gearcase, RH Mach Chain, Roller P 0 Sprocket, /T Shaft, Output Gear, T Ring, Retaining Sprocket, /T Bearing, Cover, Center Drive 0 Ring, Retaining 0 Shaft, Pinion T Bushing, Garlock Washer, Thrust Button Pinion 0 0 Deflector, Oil 0 Chain, Silent Shaft, Input Pipe, Knock Screw Bushing, Pivot Plug 0 Washer /00 C

43 GEAR SELECTOR 0 00 Cover 0 Screw 00 Knob, Gear Selector 00 Grommet, Shifter, Gear Spacer, Shifter 0 Mount, Gear Selector 0 Nut, FLEXLOC 00 Rod End, mm, RH 0 Nut, RH 0 00 Rod, Shift Linkage 0 Nut, LH 00 Rod End, mm, LH Bolt 0-0 Selector, Gear / D

44 FOX SHOCK, GAS, RESERVOIR Shock, Gas, Reservoir 000 O-Ring 0000 O-Ring 000 Wiper, Inner 000 Wiper, Clear, Outer 00 Asm., Screw Screw O-Ring 0000 Ring, Piston, Floating, Fox 0000 O-Ring, Fox End Cap 000 Piston, IFP Asm., Cap, Reservoir, ATV Fox Shock (Incl.,,) 000 Retaining Ring, ATV Fox Shock Asm., Air Valve Screw O-Ring D 000 O-Ring, ATV Fox Shock 00 Asm., Reservoir 00 Body 000 Eyelet 000 Bushing 000 Bushing, Eyelet 0 Bumper, Compression 0 00 Shaft 00 Asm., Cap-Body, Fox ATV 00 Asm., Bearing 000 Plate, Top-Out 0000 Ring, Piston, Fox 000 Bushing, Back-up 000 Nut, Lock 0000 O-Ring, Fox 00 Sleeve 000 Bushing, Eyelet /

45 SHOCK VALVING Shaft Piston 0 Nut 000 Valve, Shock (.0 x. x.00) 000 Valve, Shock (.0 x. x.00) 000 Valve, Shock (. x. x.00) 000 Valve, Shock (. x. x.00) 000 Valve, Shock (.0 x. x.00) 000 Valve, Shock (.0 x. x.00) 000 Valve, Shock (. x. x.00) D 000 Valve, Shock (. x. x.00) 000 Valve, Shock (. x. x.0) Valve, Shock (. x. x.0) 000 Valve, Shock (.0 x. x.0) 000 Valve, Shock (.0 x. x.0) 000 Valve, Shock (.0 x. x.0) /

46 CRANKCASE Bushing, Starter 00 Asm., Crankcase (Incl.,,,,,0,,,,0,) 0 Pin, Straight 00 Bearing, Ball 00 Pin, Dowel 00 Screw and Washer 0 Seal, Oil 0 Pipe, Air Breather 0 Union 0 0 Bearing, Ball 0 Bearing, Ball D 0 Plug 0 Gasket, Aluminum 0 Spring, Valve, One Way 00 Valve, One Way 0 0 Bolt, Flange 0 Gasket 0 Plug 0 Seal, Mechanical 0 0 Seal, Oil 0 O-Ring 000 Pin, Dowel /

47 CYLINDER D

48 CYLINDER 00 Asm., Band, Adapter (Incl. ) 0 Screw 00 Bolt 0 Pin, Straight 0 Guide, Valve 0 Seal, Intake Valve 0 O-Ring 00 Adapter, Water Out 0 0 Bolt, Flange 0 0 Adapter, Camshaft 00 Gasket, Rocker Cover 00 Cover, Rocker 0 0 Bolt, Flange 0 Seal, Exhaust Valve 0 Bolt, Cylinder Head 00 Plug 0 Gasket 0 Plug, Blind 0 Bolt, Flange 0 00 Gasket, Exhaust 0 Stud 000 Washer, Lock 00 Nut 0 Bolt, Rocker Shaft 0 Bolt 0 Support, Valve Rocker Shaft (PTO) 0 Support, Valve Rocker Shaft (MAG) 0 Pin, Straight 0 Union, Oil Pump 0 0 Bolt, Flange 0 Cylinder (Incl. ) 00 Pipe, Elbow 00 Gasket, Cylinder 0 Cover, Camshaft 000 Gasket, Cover, Cam 0 Head, Cylinder (Incl. -,,-,) 0 Gasket, Head 00 Adapter / D

49 CRANKSHAFT and PISTON Clip 0 0 Asm., Piston Set (Std) (Incl. ) Asm., Piston Set (0. O/S) (Incl. ) 0 Asm., Piston Set (0.0 O/S) (Incl. ) Piston Ring Set (Std) Piston Ring Set (0. O/S) Piston Ring Set (0.0 O/S) 00 Bearing 0 Bearing, Ball 0 Crankshaft 0 Pin, Crank 0 Rod, Connecting 000 Bearing, End, Large 0 00 Ball, Steel 0 0 Asm., Crankshaft (Incl.,-,0) Crankshaft 0 Gear, Balancer 0 Shaft, Balancer Spacer (0.) Spacer (.0) Spacer (.) Spacer (0.) Spacer (0.) Spacer (.0) Spacer (.) 0 Sprocket 0 Nut, Slit 00 Washer 00 Nut, Lock 0 0 Pin, Dowel 0 Key 0 Key, Woodruff / D

50 INTAKE and EXHAUST Plug 00 Gasket, Plug 0 Spring, Tensioner 0 Asm., Tensioner (Incl. -) 0 Gasket, Tensioner 00 Asm.,RockerArm,Intake(Incl.,) 0 Asm., Rocker Arm, Exhaust (Incl.,) 0 Nut 0 Screw, Adjusting 0 00 Shaft, Rocker 00 Collet, Valve 00 Retainer, Spring 00 Spring, Valve 0 Camshaft (Incl. -) D 0 Pin, Dowel 0 Lever, Release 00 Spring, Return 0 Pin, Dowel 0 Sprocket 0 0 Bolt and Washer 0 Guide, Chain 0 Chain, Timing 0 Bolt, Pivot 0 Lever 0 Valve, Intake 00 Valve, Exhaust 0 Bolt, Flange /

51 D CARBURETOR

52 CARBURETOR 0 Screw 0 Cover, Diaphragm 0 Spring 0 Ring 00 E-Ring 0 Ring 0 Needle, Jet 00 Diaphragm 0 Valve, Piston 0 0 Guide, Cable 0 Asm., Throttle Shaft 0 Ring 0 Spring 0 Screw 0 Washer 0 Case 0 Jet, Air 00 Asm., Carburetor (Incl. -) 00 Jet, Needle 0 0 Block, Jet 0 O-Ring 0 Cap 0 Asm., Plunger 0 Spring 0 Cap, Plunger 0 Cap 0 E-Ring 0 Packing 0 Seal 0 00 Screw 00 Valve, Throttle (0) 0 Adjuster 0 Spring 0 Washer 0 O-Ring 0 Jet, Pilot (#0) 0 Valve, Needle (.) 0 O-Ring O-Ring 0 00 Cover 0 Screw 000 Spring 0 Asm., Adjuster, Cable 0 Clip Screw, Guide 0 O-Ring 0 Jet, Main (#) 0 Ring 0 Screw 0 0 Asm., Float Body 0 Seal Asm., Float /00 D0

53 RECOIL STARTER 0 0 Reel 0 Spring, Return 0 Ratchet 0 Spring, Friction 0 Plate, Friction 0 Bolt and Washer 0 Plug 0 Gasket D 0 Bushing, Starter 0 0 Spring, Spiral 00 Bushing 0 Gasket, Recoil 0 Bolt, Flange 0 0 Asm., Recoil (Incl.-,-,,) Starter Case (Incl. ) 00 Asm., Rope /

54 WATER PUMP 0 00 Thermostat 0 Switch, Thermostat 0 Clamp, Hose 0 Hose, Main 0 Bolt, Flange 0 Gasket, Aluminum 0 Cover, Water Pump D 00 Gasket, Water Pump 00 Nut, Self Lock 0 0 Gasket, Aluminum 0 Impeller 0 Washer, Seal 0 Bolt, Flange /

55 OIL PUMP 0 0 Pump, Oil, Case 0 Rotor, Outer (Feed) 0 Rotor, Inner (Feed) Screw 0 Pin, Dowel 0 Pin, Dowel 0 Washer 0 Bolt and Washer 0 0 Pump, Oil, Case Asm., Oil Pump (Incl. -,0-) Pump, Oil, Case D 00 Rotor, Inner 0 Rotor, Outer 0 Unit, Oil Strainer 00 Screw and Washer 0 Shaft, Pump 0 Gear, Pump 00 Bolt, Flange AR AR AR Spacer (0.) Spacer (.0) Spacer (.) /

56 OIL FILTER 0 Filter, Oil 0 Gasket, Aluminum 0 Bolt, Banjo 0 Pipe, Oil Delivery 0 Pipe, Oil Delivery / D

57 MAGNETO Asm., Ignition Coil (Incl.,) Coil, Ignition 00 Cap, Spark Plug 0 Plug, Spark 0 O-Ring 0 Metal, Bearing Asm., Plate (Incl.,,-,,) (Up to S#00-00) Plate (Up to S#00-00) Asm., Plate (Incl.,,-,,) (S#00-00 & after) Plate (S#00-00 & after) 0 0 Bolt and Washer 0 Seal, Oil 0 0 Stator (Incl. )(Up to S#00-00) Stator (Incl. )(S#00-00 & after) E Screw and Washer (Up to S#00-00) Screw and Washer (S#00-00 & after) 0 Band, Pulse 0 Screw and Washer 00 Coil, Pulser 0 Clamp 0 Screw and Washer Nut 000 Washer, Spring 0 Switch, Magnetic CDI System (Up to S#00-00) CDI System (S#00-00 & after) Flywheel w/ring Gear (Up to S#00-00) Flywheel w/ring Gear (S#00-00 & after) /

58 STARTING MOTOR 0 0 Asm., Starting Motor (Incl. -,-0,) 0 Washer Set 00 Brush Set, Carbon 0 Nut, Flange 00 O-Ring 00 Bolt and Washer 00 Asm., Bracket, Rear 0 Asm., Armature 00 Asm., Bracket, Front E 0 O-Ring 0 0 Asm., Set Bolt (Incl. ) 0 Asm., Gear Shaft (Incl. -) 00 Ring, Rubber 0 Washer, Gear Shaft 0 Clip 0 Spring, Weight 00 Spring, Return 00 Clip /

59 FUEL PUMP 0 Asm., Fuel Pump (Incl. -) 0 Screw and Washer 0 Screw and Washer 0 Screw and Washer 0 Gasket Set, Diaphragm / E

60 TOOL KIT 0 0 Owner s Manual, 00 ATV Supplement, Owner s Manual, 00 Scrambler 00 0 Asm.,ToolKit(Incl.-) 0 Gauge, Tire Pressure 000 Wrench, Open, -0mm 000 Wrench, Open, -mm 0 Wrench, Box, mm 0 Puller, Spark Plug (Wrench Handle) 0 Screwdriver Pouch, Tool Kit 0 Wrench, Spanner /00 E

61 PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN /00

62 Changed pages in 0 A cover toc x B C D E F G 0