SCRAMBLER 500 4X4 Model #A03BG50AA Rev. 01. E 2002 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /03

Transcription

1 SCRAMBLER 00 X Model #A0BG0AA Rev. 0 E 00 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /0

2 TABLE OF CONTENTS Scrambler 00 X A0BG0AA Parts Manual A -ARM/STRUT MOUNTING... AIR BOX... A B C GEARCASE... GEARCASE MOUNTING... G C0 B CARBURETOR... D- CLUTCH COVER... C CONTROL PANEL... A CONTROLS - MASTER CYLINDER/BRAKE LINE... C CONTROLS - THROTTLE ASM./CABLE... B COOLING SYSTEM... A CRANKCASE... C CRANKSHAFT and PISTON... C CYLINDER... D- DECALS... A DRIVE CLUTCH... B DRIVE SHAFT... B DRIVEN CLUTCH... B0 ELECTRICAL/TAILLIGHT... C ENGINE MOUNTING... A-0 EXHAUST SYSTEM... A FOX SHOCK, GAS, RESERVOIR... FRONT BRAKE... FRONT BUMPER and SHIELDS... FRONT CAB... FRONT HOUSING... FRONT STRUT... FRONT WHEEL... FUEL PUMP... FUEL TANK... C D E F G C B A A B B B D A GEAR SELECTOR... C GEARCASE... C HANDLEBAR/HEADLIGHT H... INTAKE and EXHAUST... I M MAGNETO... OIL FILTER... OIL PUMP... OIL TANK... PROP SHAFT O P... REAR BRAKE MASTER CYLINDER... REAR CAB... REAR CALIPER MOUNTING... REAR HOUSING... REAR WHEEL DRIVE... RECOIL STARTER... SHOCK VALVING... STARTING MOTOR... STEERING POST... SWING ARM/SHOCK MOUNTING... TOOL KIT... WATER PUMP R S T W... B D D0 D D A A B A B C C D C D B C D 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 FRONT CAB SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Nut, Speed, U-Type -0-0 Bracket, Cab Mount, LH Bracket, Cab Mount, RH Screw 0-0 Frame Bolt - Cover, Front - Cab, Front, Sonic Blue (w/warning Decals) Screw 0 Washer, Flat 0 Rivet Nut, Nylok Washer, Flat 00 Mudflap, Front, LH Mudflap, Front, RH 0-0 Footpad Rivet Trim, Footrest -0 Bracket, Heel Cleat Guard, Rock Screw /0 A

4 REAR CAB SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Rivet Washer, Flat Screw Screw 0 Foil, Rear Cab, Small 00 Decal, Carb/Filter Information 0- Cab, Rear, Sonic Blue 00 Nut, Speed, U-Type 00 Spring, Latch, Light 0 00 Latch, Seat Cap, Seat Latch Seat, Black Covering, Seat, Black Tongue, Seat Rivet 0 Bumper, Rubber 0 Bracket, Lever Retainer 0 Rivet Shield, Muffler Foam, Foil Nut, Nylok 0 Screw Plug, End Cap, Ribbed -0 Guard, Clutch Rivet Bolt Footpad (See Front Cab Pg. A, Ref. ) 0 Mudflap, Rear, LH Mudflap, Rear, RH 0 Foil, Rear Cab 00 Bracket, Rear Seat Holddown /0 A

5 FRONT BUMPER and SHIELDS SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Shield, Splash, Rear 00 Clip, Dart Shield, Splash, Front 0 Screw -0 Shield, Splash, LH Screw 0 Washer, Flat Bolt Plug, Frame 0 0 U-Nut 0-0 Bumper, Front Washer -00 Plate, Skid, Bumper Rivet -0 Bracket, Radiator Shield -0 Shield, Radiator, Side, RH Screw -0 Shield, Radiator, Side, LH -0 Shield, Radiator, Upper 0 0 Heat Sink 000 Regulator, Rectifier 0 Screw 0 Guard, Splash, RH /0 A

6 CONTROL PANEL SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. Cover, Key Switch, Ignition, Key Start Nut, Ignition Key, Ignition, Blank NOTE: Ignition key blank may be ordered by using the four digit number on the key. Panel, Control, Outer 000 Cable, Choke Panel, Control, Inner 00 Nut, Choke 00 Panel, Indicator Light, Position /0 A

7 COOLING SYSTEM SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Screw 0 Asm., Fan and Motor 0 U-Clip 0 Shroud 0 Gasket 0 Cap Plug 0 Tank, Surge 0 Screw 0 00 Fitting AR Line, Fuel 00 Spacer 00 Mount, Rubber 0 Washer, Flat Nut, Nylok 00 Clamp, Hose Hose, Engine, Upper Guard, Hose 00 Clamp 0 00 Sensor, Thermal w/harness 00 Cap, Pressure 000 Radiator 0 Screw 0 Washer, Spring, Lock 0 Valve 0 Bushing, Radiator Mount, Lower 00 Mount, Cable Tie 00 Cable Tie 0 Guard, Plastic Hose 0 Hose, Engine, Lower /0 A

8 EXHAUST SYSTEM SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 Bolt, Carriage 0 Dampener, Vibration 00 Bushing 00-0 Silencer 00 Spring, Exhaust 00-0 Pipe, Exhaust Seal, Exhaust Screw Bracket, Exhaust Support 0 0 Nut, Insert 0 Nut 00 Mount, Torque Stop 00 Spring, Exhaust Bolt Nut, Nylok Washer, Flat 0 Washer, Rubber Washer /0 A

9 ENGINE MOUNTING SCRAMBLER 00 X A0BG0AA 0 E 00 Polaris Sales Inc A

10 ENGINE MOUNTING SCRAMBLER 00 X A0BG0AA 0 Nut, Flange Lock 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, Rubber Radiator -0 Bracket, Carburetor Mount 0 Washer, Split Lock 0 Nut Asm., Carburetor (See Carburetor Pg. D, Ref. ) AR Line, Fuel 000- Sheath, Foil, Laminated Mount, Engine, Rear Spacer 00 O-Ring 0 Nut, Flange, Lock 00 Mount, Rubber, Front Washer 0 Boot, Clutch Intake 00 Clamp, Narrow Band 0 Bushing 0 Washer, Flat 0 0 Washer, Interlock 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, Front Screw Nut, Nylok 00 Mount, Motor 00 Clamp, Hose 0 Washer, Spring Lock 0 Screw 00 Clamp, Hose AR Hose, Engine, Lower (See Cooling System Pg. A, Ref. 0) Nut (See Cylinder Pg. D, Ref. ) Washer, Lock (See Cylinder Pg. D, Ref. ) -0 Manifold, Black Gasket, Exhaust (See Cylinder Pg. D, Ref. 0) 0 Engine, Short Block (EH0PLE) 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. ) /0 A0

11 OIL TANK SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Dipstick, Oil Tank Tank, Oil Hose, Breather 0 Grommet 0 Bushing 00 Clamp, Hose 0 Screen, Oil Filter, 0 Degree Hose, Formed 00 Clamp, Hose 0 0 Washer, Nylon 0 Plug /0 A

12 FUEL TANK SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Asm., Fuel Tank (Incl.,0,,) Tank, Fuel Seal, Foam 0 Grommet, Fuel Tank Gasket Cap, Gas Tank AR Line, Fuel 0 Vent, Tank Screw 0 Washer, Spring Lock 0 Washer, Flat Seal, Foam Spacer 0 Washer, Spring Lock 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 000 Valve, Fuel 0 Gasket, Fuel Valve /0 A

13 DECALS SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. RH 0 LH 0 0 Decal, Cab Side, Rear, LH Decal, Cab Side, Rear, RH 0 Decal, Age Warning 00 Decal, Warning AWD Switch 0 Logo, Polaris Star 0 0 Decal, Scrambler, Tank Side, LH Decal, Scrambler, Tank Side, RH 0 Decal, 00, Front Cover 00 Decal, Warning, Override, AWD 00 Decal, Warning, General 00 Decal, Warning, Discretionary 0 00 Decal, POLARIS, Rear 00 0 Decal, X Fender, Rear, LH Decal, X Fender, Rear, RH 0 Decal, Reflector, Red 00 Decal, Tire Pressure/Load 00 Decal, Passenger Warning 0 Decal, Fuel Lever 0 Decal, Reflector, Amber 0 Decal, Concentric Drive System 0 Decal, Drain, Recoil 0 0 Decal, Fender, Front, LH Decal, Fender, Front, RH /0 A

14 PROP SHAFT SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 Screw Guard, Prop Shaft, Side 0 Washer, Flat Screw Guard, Prop Shaft, Front 0 O-Ring 0 Yoke, Prop Shaft, Transmission 00 Shaft, Prop 00 Kit, Cross and Bearing 0 0 Yoke, Front Gear Case 0 Asm.,PropShaft(Incl.-0) Pin, Spring /0 A

15 FRONT HOUSING SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Asm., Front Gearcase (Incl. -,-) Screw Seal 0 Cover, Input, Front Housing 00 O-Ring Ring, Retaining Bearing Pinion, Input, T Bushing Seal, Oil 0 Bushing Washer Plug 00 Clamp 000- AR Line, Fuel B 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 /0

16 DRIVE SHAFT SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Asm., Drive Shaft w/sleeve, NEA Sleeve, Drive Shaft Seal 0 Clamp, Band 00 Circlip 00 Kit, Replacement Boot 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 w/sleeve /0 B

17 FRONT STRUT SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Bumper 0 Strut, Front Washer 00 Clamp, Cable Nut, Flange 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 00 0 Asm., Hubstrut, LH (Incl.,-) Asm., Hubstrut, RH (Incl.,-) Spring, Compression, Black Spring, Compression, Yellow 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, Thin 00 Grommet /0 B

18 A-ARM/STRUT MOUNTING SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Nut, Nylok 00 Asm., Tie Rod (Incl. -) Boot, Seal, Rod End 00 Rod End, RH Nut 00 Tie Rod 0 Nut, Jam, LH 00 Rod End, LH 0 Boot, Seal, Rod End 0 0 Bolt 0 Washer, Flat Nut 0 Pin, Cotter Asm., Hubstrut (See Front Strut Pg. B, Ref. ) 00 Joint, Ball Bracket, Ball Joint Screw 0 Boot, Rubber Nut, Castle 0 0 Screw Shield, CV Joint, LH Shield, CV Joint, RH Bushing, A-Arm, Long 0 Shaft, A-Arm 0-0- Kit, A-Frame, LH Kit, A-Frame, RH 0 Washer, Spring Lock Screw Screw /0 B

19 FRONT WHEEL SCRAMBLER 00 X A0BG0AA 0 DETAIL A A E 00 Polaris Sales Inc. 0 Bolt Disc, Brake (If built before //0) Disc, Brake (If built after //0) 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, Flange Lock 0- Rim, Front 0 Valve, Rim /0 B

20 HANDLEBAR / HEADLIGHT SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Kit, Handlebar Block (Incl.,,) Asm., Throttle Control (See Controls- Throttle Asm./Cable Pg. B, Ref. ) 0-0 Handlebar Screw Pad, Handlebar Cover, Handlebar Pad Asm., Master Cylinder (See Controls-Master Cylinder/Brake Line Pg. C for Details) 0 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 0 Bolt -0-0 Block, Handlebar Pegged Block, Handlebar /0 B

21 STEERING POST SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 Nut, Nylok Bushing, Steering, Upper -0 Asm., Steering Post -0 Bracket, Steering, Bushing, Upper (If built before //0) Bracket, Steering, Bushing, Upper (If built after //0) Bolt, Carriage (If built before //0) Bolt (If built after //0) Bolt, Carriage Bushing Flangette Bearing 0 Nut Pin, Cotter 0 Washer, Flat /0 B

22 CONTROLS - THROTTLE ASM. / CABLE SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. Cover, Throttle Control 0 O-Ring O-Ring 00 Cable, Throttle 000 Asm., Throttle Control (Incl. ) 00 Asm., Throttle Clamp /0 B

23 DRIVE CLUTCH SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Screw 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) Bolt, Shoulder 0 0 Nut, FLEXLOC 0 Bearing, Moveable, / Inch 00 Pin, Roller Asm., Drive Clutch, Wide (Incl. All Less,) /0 B

24 DRIVEN CLUTCH SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 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, / Inch Bearing, Moveable, Inch 0 Spring, Clutch Ramp, Stationary 0 Spacer 0 Ring, Retaining Bolt 0 Button, Ramp /0 B0

25 GEARCASE MOUNTING SCRAMBLER 00 X A0BG0AA 0 E 00 Polaris Sales Inc. Screw 0 Mount, Transmission, Rear 0 Nut, Flange Lock Screw 0 Washer, Flat Screw 0 Sprocket, T 0 Ring, Retaining 0 0 AR AR AR Shim (.00) Shim (.00) Shim (.00) 0 Screw /0 B

26 REAR BRAKE MASTER CYLINDER SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Bolt 0-0 Bracket, Reservoir Mount Nut, Nylok Screw 0000 Clamp, Hose, Red 00 Hose, Reservoir 0 Reservoir 0 Pin, Cotter Washer 0 0 Bushing 0-0 Mount, Brake 0 Bolt, Banjo 0 Seal 0 Washer, Flat Line, Foot Brake, Rear (See Rear Caliper Mounting Pg. B, Ref. ) Screw 0 Asm., Foot Brake Master Cylinder Nut, Nylok 0-0 Rod, Brake 0 00 Spring, Torsion Screw /0 B

27 REAR CALIPER MOUNTING SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. Frame 0 Screw 0 Washer, Flat Asm.,Caliper, Brake Screw, Bleeder Kit, Piston and Seal 0 Seal Line, Brake, Rear (See Controls - Master Cylinder/Brake Line Pg. C, Ref. ) 00 Line, Brake, Rear 00 Clip, Silencer Box 0 Bolt, Banjo Bushing, Caliper Mount 0 0 Washer, Flat 0 Washer, Spring Lock Bolt Mount, Caliper, Lower Mount, Caliper, Upper Bolt -0 Guard, Brake Disc Brake Pad (Incl. Spacer and Pin) Spacer Pin /0 B

28 FRONT BRAKE SCRAMBLER 00 X A0BG0AA 0 E 00 Polaris Sales Inc. 0 Asm., Brake Caliper, LH 0 Kit, Piston and Seals (Incl. -0) (Incl. -,-) 0 Square Ring, Molded (.0) 0 Asm., Brake Caliper, RH (Incl. -,-) 00 Square Ring, Molded (.0 x.) 00 Screw, Bleeder 0 Piston, Long Screw, Socket Set 0 Mount, Caliper Caliper,Brake,LH Caliper,Brake,RH Kit, Front Brake Boot 0 Boot, Pin Seal 0 Boot, Bushing 0 Kit, Front Brake Pad 0 Screw Washer 0 Washer, Lock /0 B

29 CONTROLS - MASTER CYLINDER / BRAKE LINE SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Asm., Master Cylinder (Incl. -) 0 Asm., Brake System, Scrambler 0 Switch 00 Line, Brake, Rear Screw 0 Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 0 Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring) 0 Kit, Master Cylinder Clamp (Incl. Clamp, Screws) 0 Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip) 00 Cable Tie 0 00 Clamp, Nylon Rivet, Pop 00 Line, Brake, Left Front 00- Tubing, Convoluted 0 Screw 00 Line, Brake, Right Front 0 Fitting, Cross /0 C

30 REAR WHEEL SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 Bolt 00 Kit, Hub, Rear (Incl.,,,0) Nut Washer, Cone 00 Nut, Castle 0 Pin, Cotter Cover, Dust, Hub Washer, Flat 0 Valve, Rim 0 00 Retainer, Bolt, Pushnut 0- Rim, Rear Tire (x-0) /0 C

31 REAR HOUSING SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Ring, Retaining 0 Extrusion, Retainer, Nut Nut Seal, Foam Nut, Nylok Disc, Brake Stud 0 Hub, Brake Disc (Incl. ) 00 Ring, Retaining 0 00 Spacer, Axle 0 O-Ring 000 Seal Bearing, Cone, Tapered Bearing, Cup, Tapered 0 Housing, Axle, Rear 000 Fitting, Lubrication 0 Link, Connector Axle, Rear -0 Guard, Sprocket, T 0 0 Nut, Flange Lock -0 Chain, 0 O-Ring 0 Bolt 0 Asm.,Hub,Sprocket(Incl.) 0 Sprocket, T 0 Spacer /0 C

32 AIR BOX SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 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, Narrow Band Boot, Carburetor 00 Clamp, Narrow Band 0 Duct, Carburetor, Inlet 0 Gasket, Carburetor, Inlet Duct Box, Air Hose, Breather 0 Rivet 000 Clamp, Hose 0 Foil, Air Box Plug, Trap 00-0 AR Line, Fuel 000 Clamp, Hose 0 Clip 0 Collar, Inlet, Carburetor 00 Filter, Air Intake Filter, Sleeve, Precleaner 0 /0 C

33 CLUTCH COVER SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Nutsert 0-0 Bracket, Clutch Cover Screw Duct, Down Tube, Inlet Seal, Cover 0 Kit - Inner Clutch Cover (Incl.,,0,) 0 Bolt and Washer Seal, Clutch Cover, Inner 0 Decal, Warning, Clutch Cover 0-00 Cover, Clutch, Outer 0 Screw 0 O-Ring Plug 0 Decal, Automatic Transmission 00 Cable Tie Boot, Duct 0 Duct, Clutch, Hi-Flow Screw and Washer (See Crankcase Pg. C, Ref. ) 0-0 Bracket, Clutch Seal 0 0 Seal, Cover, Case Washer, Nylon 0 Screw Washer -0 Bracket, Clutch Cover, Front Rivet 00 Clamp, Narrow Band Screw /0 C

34 ELECTRICAL/TAILLIGHT SCRAMBLER 00 X A0BG0AA 0 0 E 00 Polaris Sales Inc. 0 0 Harness, Main 00 Cable Tie 0 Breaker, Circuit, 0 AMP 0 Kit, Circuit Breaker, Fan 0 Asm., Taillight, V (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, Battery Vent 000 Battery 00 Clip 000 Cable, Battery/Solenoid, Red 000 Cable, Solenoid/Starter Nut, Nylok 00 Bolt 0 Kit, Fusible Link Bracket, CDI (If built before /0/0) Bracket, CDI (If built after /0/0) 0 Screw 0 0 Pad, Fuel Tank Bracket 00 Limiter, RPM, LR-- 00 Clip, Routing 00 Clip, Rosebud /0 C

35 SWING ARM/SHOCK MOUNTING SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Nut, Nylok Spring, Compression, Black Spring, Compression, Yellow Spring, Compression, Black Spring, Compression, Yellow 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 0 Nut 0 Washer, Flat Bushing, Swing Arm, RH Bolt, Pivot, Swing Arm Bushing, Swing Arm Pivot, RH - Arm, Swing (Incl.,,) 0 Decal, Chain Free Play 0 Guard, Chain 0 Screw Bushing 0 Washer, Flat Nut, Flange 0 Nut, Nylok Washer Bolt Screw Bushing, Swing Arm, LH 0 Bushing, Swing Arm Pivot, LH 0 /0 C

36 GEAR SELECTOR SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Knob Cover 0 Screw 00 Grommet, Gear Shifter 00-0 Selector, Gear 0 Mount, Gear Selector Screw 0 Nut 00 Rod End, LH 00 Screw 0 Nut, LH 0 Asm., Shift Linkage 0 Nut, RH 00 Rod End, RH Spacer, Shifter /0 C

37 GEARCASE SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc C

38 GEARCASE SCRAMBLER 00 X A0BG0AA Asm., Gearcase, Main (Incl. All) Bushing, Pivot 0 Screw Gearcase, HLR, Hybrid Mach LH Pipe, Knock Plug, Drain 0 Washer Fork, Shift, H/R 0 Bearing, Ball Shaft, Reverse, T 0 Bearing, Needle Sprocket, T 0 Ring, Retaining, E-Clip Dog, Engagement Gear, 0T Washer, Thrust Ring, Retaining Seal, Triple Lip Screw Cover, Snorkel Drive 0 O-Ring AR Shim 00 Bearing, Ball Gear, T Shaft, Snorkel Busing, Garlock Gearcase, RH 0 Vent, Tube 0 Screw Guide, Chain 0 Washer Plug, Oil Fill Washer, Thrust Bushing, Garlock 0 Shaft, Pinion 0 Ring, Retaining Cover, Bearing Sprocket, T Ring, Retaining Gear, T 0 Shaft, Output Sprocket, T Chain, Roller 0 Deflector, Oil Screw, Tapping 0 Pin, Interlock 0 Spring, Shifting, Interlock 0 Bracket, Interlock Switch, Position Screw, Tapping 0 Shaft, Shift, H/R O-Ring 0 Ring, Retaining Bellcrank,. 0 Nut, FLEXLOC 0 Washer 00 Washer 0 Chain, Silent Shaft, Input, HLR 0 Bearing, Ball /0 C0

39 FOX SHOCK, GAS, RESERVOIR SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Shock, Gas 000 O-Ring 0000 O-Ring 000 Shaft, U-Cup 000 Wiper, Shaft 00 Screw Screw O-Ring 0000 Bearing, External 0000 O-Ring 000 Piston, Floating Asm., Cap, Reservoir, (Incl.,,) 000 Ring, Retaining Asm., Air Valve Screw O-Ring 000 O-Ring, ATV Fox Shock 00 Asm., Reservoir 00 Body 000 Eyelet 000 Sleeve 000 Bushing 0 Bumper, Compression 0 00 Shaft 00 Cap, Body 00 Bearing 000 Plate, Top-Out 0000 Bearing, External Piston 000 Plate, Back-up 000 Nut, Lock 0000 O-Ring 00 Bushing 000 Bushing /0 C

40 SHOCK VALVING SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. Shaft Piston 0 Nut 000 Valve (.0 x. x.00) 000 Valve (.0 x. x.00) 000 Valve (. x. x.00) 000 Valve (. x. x.00) 000 Valve (.0 x. x.00) 000 Valve (.0 x. x.00) 000 Valve (. x. x.00) C 000 Valve (. x. x.00) 000 Valve (. x. x.0) Valve (. x. x.0) 000 Valve (.0 x. x.0) 000 Valve (.0 x. x.0) 000 Valve (.0 x. x.0) /0

41 CRANKCASE SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Bushing, Starter 00 Asm., Crankcase (Incl.,,,,,,,,0,,) 0 Pin, Straight 00 Bearing, Ball 00 Pin, Dowel 00 Screw and Washer 0 Seal, Oil 0 Pipe, Air Breather 0 Fitting, Oil Inlet 0 0 Union 0 Bearing, Ball C 0 Bearing, Ball 0 Plug 0 Gasket, Aluminum 0 Spring, Valve, One Way 00 Valve, One Way 0 0 Bolt, Flange 0 Gasket 0 Plug 0 0 Seal, Mechanical 0 Seal, Oil 0 O-Ring 000 Pin, Dowel /0

42 CRANKSHAFT and PISTON SCRAMBLER 00 X A0BG0AA 0 E 00 Polaris Sales Inc. 0 0 Clip 0 0 Piston Set (Std) (Incl. ) Piston Set (0. O/S) (Incl. ) 0 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 C 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 /0

43 CYLINDER SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. D

44 CYLINDER SCRAMBLER 00 X A0BG0AA 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 0 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 /0 D

45 CARBURETOR SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc D

46 CARBURETOR SCRAMBLER 00 X A0BG0AA 0 Screw 0 Cover, Diaphragm 0 Spring 0 Ring 00 E-Ring 0 Ring 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 Asm., Carburetor (Incl. -) 0 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 Jet, Pilot (#0) Valve, Needle (.) 0 O-Ring O-Ring 00 Cover 0 Screw 000 Spring Washer 0 Asm., Adjuster, Cable Clip Screw, Guide 0 O-Ring 0 Jet, Main (#) 0 Ring 0 Screw 0 Asm., Float Body 0 Seal Asm., Float /0 D

47 INTAKE and EXHAUST SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc 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, Valve 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 0 Valve, Exhaust 0 Bolt, Flange /0

48 RECOIL STARTER SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 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 Bolt, Flange 0 0 Asm., Recoil (Incl. -,-,,) Starter Case (Incl. ) 00 Asm., Rope /0

49 WATER PUMP SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Thermostat 0 Switch, Thermostat 0 Clamp, Hose 0 Hose, Main 0 Bolt, Flange 0 Gasket, Aluminum 0 Cover, Water Pump 00 Gasket, Water Pump 00 Nut, Self Lock 0 0 Gasket, Aluminum 0 Impeller 0 Washer, Seal 0 Bolt, Flange /0 D

50 OIL PUMP SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Pump, Oil, Case 0 Rotor, Outer (Feed) 0 Rotor, Inner (Feed) 0 0 Asm., Oil Pump (Incl. -,0-) Pump, Oil, Case 0 Screw 0 Pin, Dowel 0 Pin, Dowel 0 Washer 0 Bolt and Washer 0 0 Pump, Oil, Case 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 (.) /0 D

51 OIL FILTER SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 Filter, Oil 0 Gasket, Aluminum 0 Bolt, Banjo 0 Pipe, Oil Delivery 0 Pipe, Oil Delivery /0 D

52 MAGNETO SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc Asm., Ignition Coil (Incl.,) Coil, Ignition 00 Cap, Spark Plug 0 Plug, Spark 0 O-Ring 0 Metal, Bearing 0 0 Asm., Plate (Incl.,,-,) Plate 0 Bolt and Washer 0 Seal, Oil 0 Stator (Incl. ) 0 0 Screw and Washer 0 Band, Pulse 0 Screw and Washer 00 Coil, Pulser 0 Screw and Washer 0 CDI System 0 Bolt, Flange 0 Switch, Magnetic 0 Flywheel/Ring Gear /0 D0

53 STARTING MOTOR SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 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 0 O-Ring 0 0 Asm., Set Bolt (Incl. ) 000 Asm., Gear Shaft (Incl. -) 00 Ring, Rubber 0 Washer, Gear Shaft 0 Clip 0 Spring, Weight 00 Spring, Return 00 Clip /0 D

54 FUEL PUMP SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 Asm., Fuel Pump (Incl. -) 0 Screw and Washer 0000 Screw and Washer 0 Screw and Washer 0 Gasket Set, Diaphragm /0 D

55 TOOL KIT SCRAMBLER 00 X A0BG0AA E 00 Polaris Sales Inc. 0 0 Owner s Manual, 0 ATV Supplement, Owner s Manual, 0 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 /0 D

56 PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN /0

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