2004 Polaris Scrambler 500 4×4 Parts Manual – PDF Download

PARTS MANUAL PN 9918622 and MICROFICHE PN 9918623 6/03

SCRAMBLER 500 4X4 Model #A04BG50AA

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TABLE OF CONTENTS Scrambler 500 4X4 A04BG50AA Parts Manual

A

G

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

H

C CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL . . . . . . . . . . . . . . . . . . . .

CONTROLS - MASTER CYLINDER/BRAKE LINE . . . . . . . . . . . .

CONTROLS - THROTTLE ASM./CABLE . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . .

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT and PISTON . . . . . . . . . . . . .

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .

HANDLEBAR/HEADLIGHT . . . . . . . . . . . . . . B6 D1-2 C5 A6 C1 B8 A7 C11 C12 C13-14

D DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . .

DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . .

DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . .

A13 B9 B2 B10

I

INTAKE and EXHAUST . . . . . . . . . . . . . . . . . D3

M

MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . D8

O

OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D7 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D6 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . A11

P

PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . A14

R

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

F FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . .

FRONT BUMPER and SHIELDS . . . . . . . . . .

FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .

FRONT HOUSING . . . . . . . . . . . . . . . . . . . .

FRONT STRUT . . . . . . . . . . . . . . . . . . . . . .

FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .

GEARCASE MOUNTING . . . . . . . . . . . . . . . B11

B14 A5 A3 B1 B3 B5 D10 A12

REAR BRAKE MASTER CYLINDER . . . . . . .

REAR CAB . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR CALIPER MOUNTING . . . . . . . . . . . .

REAR HOUSING . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . .

RECOIL STARTER . . . . . . . . . . . . . . . . . . . .

S

SHOCK MOUNTING . . . . . . . . . . . . . . . . . . .

STARTING MOTOR . . . . . . . . . . . . . . . . . . .

STEERING POST . . . . . . . . . . . . . . . . . . . . .

SWING ARM . . . . . . . . . . . . . . . . . . . . . . . .

B12 A4 B13 C3 C2 D4

C7 D9 B7 C7

T

TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . D11

G GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C8 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C9-10

W

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D5

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

FRONT CAB SCRAMBLER 500 4X4 A04BG50AA

1 4

2

1

3

7

6 8 5 9

10

5

11

19

13 12

13

11

20

13 12

18 14

5 15

17 16

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.

1 7670057 2 5244482-067 5244483-067 3 7517386 4 1014443-067 5 7512282 6 5811527 7 5432553-177 8 2632424-177 9 7517916 10 7558201

Qty.

4 1 1 2 1 24 1 1 1

Description

Nut, Speed, U-Type Bracket, Cab Mount, LH Bracket, Cab Mount, RH Screw Frame, Main Bolt Foam, Seal Cover, Front Cab, Front, Black Met (w/Warning Decals) 2 Screw 2 Washer, Flat

Ref. Part No.

11 12 13 14 15 16 17 18 19 20

7621472 7542122 7555859 5811831 5850150 1013249-067 7661825 5431484 5242525-067 5432763 7515179

Qty.

8 24 22 1 1 2 8 2 2 1 6

Description

Rivet Nut, Nylok Washer, Flat Mudflap, Front, LH Mudflap, Front, RH Footpad Rivet Trim, Footrest Bracket, Heel Cleat Guard, Rock Screw 6/03

A3

REAR CAB SCRAMBLER 500 4X4 A04BG50AA

3 1

2

2

4

5 6

12

7 8

11

10

28

9

13

16

27

17

15

14

18

24 20 20 19

2

2 19

22

23

21

26 25 24

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.

1 2 3 4 5 6 7 8 9 10 11 12

7621472 7555859 7512232 7512242 5810991 7079902 5434014-177 7670057 7041607 1040412 5411392 2683329-070 2683328-070 13 5431986 14 7621479 15 5412067

Qty.

4 16 2 2 1 1 1 2 1 1 1 1 1 1 2 6

Description

Ref. Part No.

Rivet Washer, Flat Screw Screw Foil, Rear Cab, Small Decal, Carb/Filter Information Cab, Rear, Black Met Nut, Speed, U-Type Spring, Latch, Light Latch, Seat Cap, Seat Latch Seat, Black w/White POLARIS Covering, Seat, Black Tongue, Seat Rivet Bumper, Rubber

16 5211033 17 7621403 18 2632274 5811113 19 7542122 20 7517264 21 5432831 22 5247321-067 23 7661637 24 7512282 25 - - - - - - 26 5812134 5850148 27 5810957 28 5220880

Qty.

2 1 1 1 17 4 2 1 4 16 2 1 1 1 2

Description

Bracket, Lever Retainer Rivet Shield, Muffler Foam, Foil Nut, Nylok Screw Plug, End Cap, Ribbed Guard, Clutch Rivet Bolt Footpad (See Front Cab Pg. A3, Ref. 15) Mudflap, Rear, LH Mudflap, Rear, RH Foil, Rear Cab Bracket, Rear Seat Holddown 6/03

A4

FRONT BUMPER and SHIELDS SCRAMBLER 500 4X4 A04BG50AA 2

1

3 4 6

5

7 8 18

9 10

17 12 18

11

12 12

16

14

12

15

12 13

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.

1 2 3 4 5 6 7 8 9

5435455 7522026 5245415-067 7517386 7558402 7512329 5811675 7547071 1014309-067

Qty. Description

1 2 2 4 2 2 1 1 1

Shield, Splash, Front Screw Shield, Splash, LH Screw Washer, Flat Bolt Plug, Frame U-Nut Bumper, Front

Ref. Part No.

10 11 12 13 14 15 16 17 18

7555827 5432378-070 7661121 5242694-067 5245343-067 7515399 5245342-067 5434085 7670088

Qty. Description

2 1 13 2 1 2 1 1 4

Washer Plate, Skid, Bumper Rivet Bracket, Radiator Shield Shield, Radiator, Side, RH Screw Shield, Radiator, Side, LH Guard, Splash, RH Clip, Dart 6/03

A5

CONTROL PANEL SCRAMBLER 500 4X4 A04BG50AA

7

1

6

2

4

5

3 2

2

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.

1 5433534 2 4011002 5433733 4010278

1 1 1 1

Description

Ref. Part No.

Cover, Key Switch, Key, 3 Position Nut, Ignition Key, Ignition, Blank NOTE: Ignition key blank may be ordered by using the four digit number on the key.

3 4 5 6 7

5434127 7081007 5434128 7080922 4010315

Qty.

1 1 1 1 1

Description

Panel, Control, Outer Cable, Choke Panel, Control, Inner Nut, Choke Panel, Indicator Light, 3 Position 6/03

A6

COOLING SYSTEM SCRAMBLER 500 4X4 A04BG50AA 6 7 8

5

9 11

10 15 14

13

1 2

3

12

4 16

17

18

19

20 21

14

22

1 3

16

29

23 28

24

27

19 25

26

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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

7517659 2410430 7670111 5434043 5810279 5430743 5433774 5433410 7512084 7052065 8450003-600 5020937 3110032 7558301 7542122

Qty. Description

4 1 4 1 1 1 1 1 2 1 AR 2 2 4 2

Screw Asm., Fan and Motor U-Clip Shroud Gasket Cap Plug Tank, Surge Screw Fitting Line, Fuel Spacer Mount, Rubber Washer, Flat Nut, Nylok

Ref. Part No.

16 17 18 19 20 21 22 23 24 25 26 27 28 29

7080614 5411985 5521511 7080826 1240093 1240177 7512240 7552801 7052296 5410584 7080965 7080138 5521550 5411989

Qty. Description

2 1 1 2 1 1 2 2 1 2 1 1 1 1

Clamp, Hose Hose, Engine, Upper Guard, Hose Clamp Cap, Pressure Radiator Screw Washer, Spring, Lock Valve Bushing, Radiator Mount, Lower Mount, Cable Tie Cable Tie Guard, Plastic Hose Hose, Engine, Lower 5/03

A7

EXHAUST SYSTEM SCRAMBLER 500 4X4 A04BG50AA 1

3

15

16

2

4

18

17

5

14

6 7

5

5

13

7

12 5

11 10 8

9

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.

1 2 3 4 5 6 7 8 9

7515316 5410241 5010192 1261006-029 7041804 1261005-029 5243518 7517386 5242344

Qty.

2 2 2 1 4 1 2 2 1

Description

Ref. Part No.

Bolt, Carriage Dampener, Vibration Bushing Silencer Spring, Exhaust Pipe, Exhaust Seal, Exhaust Screw Bracket, Exhaust Support

10 11 12 13 14 15 16 17 18

7542330 7542301 3110064 7042029 7512666 7542324 7555716 5410436 7555863

Qty.

1 1 1 1 2 2 2 2 2

Description

Nut, Insert Nut Mount, Torque Stop Spring, Exhaust Bolt Nut, Nylok Washer, Flat Washer, Rubber Washer 6/02

A8

ENGINE MOUNTING SCRAMBLER 500 4X4 A04BG50AA

3 1

2

4

9 11

10

5

9

8

6

12

7 46

45 43

47

14

1

48

17

44

15

16

41 9

42 41 24

40 39

2

27

38

26

25

21 20 22

9

10 19

1

18

23 28

29

30 31

33 37

12 36

34

32 1

35

A9

13

ENGINE MOUNTING SCRAMBLER 500 4X4 A04BG50AA 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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

7547108 7555823 4010132 7517386 3110044 5242674 7552901 7512315 7080003 8450040-600 8450003-1525 3084205 3110032 5242258-067 7552605 7542105 -------

6 3 1 1 1 1 2 2 4 AR AR 3 2 1 2 2 1

18 19 20 21 22 23 24 25 26 27 28

8360009-600 8450080-58 1013222-067 5132775 5412005 7547089 3110046 7555815 5412487 7080511 5430261

AR 1 1 1 1 2 2 2 1 1 1

Description

Ref. Part No.

Nut, Flange Lock Washer, Flat Cable, Ground/Engine Screw Mount, Rubber, Top Bracket, Mount, Engine, Top Washer, Spring Lock Bolt Clamp, Hose, Red Line, Fuel Line, Fuel Screw and Washer Mount, Rubber Radiator Bracket, Carburetor Mount Washer, Split Lock Nut Asm., Carburetor (See Carburetor Pg. D2, Ref. 19) Line, Fuel Sheath, Foil, Laminated Mount, Engine, Rear Spacer O-Ring Nut, Flange, Lock Mount, Rubber, Front Washer Boot, Clutch Intake Clamp, Narrow Band Bushing

29 30 31 32

Qty.

5210748 7575202 7512566 -------

1 1 1 1

33 - - - - - - -

1

34 35 36 37 38 39 40 41 42

1040688-067 7515398 7542324 3110067 7080474 7552603 7515438 7080696 -------

1 2 2 1 2 1 1 2 AR

43 - - - - - - 44 - - - - - - -

2 2

45 1261171-029 46 - - - - - - -

1 1

47 3085822

1

48 - - - - - - -

AR

Description

Washer, Flat Washer, Interlock Bolt Asm., Drive Clutch, Wide (See Drive Clutch Pg. B9 for Details) Bracket, Retainer, Seal (See Clutch Cover Pg. C5, Ref. 18) Mount, Engine, Front Screw Nut, Nylok Mount, Motor Clamp, Hose Washer, Spring Lock Screw Clamp, Hose Hose, Engine, Lower (See Cooling System Pg. A7, Ref. 29) Nut (See Cylinder Pg. C14, Ref. 23) Washer, Lock (See Cylinder Pg. C14, Ref. 22) Manifold, Black Gasket, Exhaust (See Cylinder Pg. C14, Ref. 20) Engine, Short Block (EH50PLE12) 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.

Hose, Engine, Upper (See Cooling System Pg. A7, Ref. 17) 6/03

A10

OIL TANK SCRAMBLER 500 4X4 A04BG50AA

3 2

5 4

1

7

8

6 9

5

11

4

10

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.

1 2 3 4 5 6

5434307 1261175 5411873 5410828 5333204 7080699

Qty.

1 1 1 2 2 1

Description

Ref. Part No.

Dipstick, Oil Tank Tank, Oil Hose, Breather Grommet Bushing Clamp, Hose

7 8 9 10 11

7052326 5412227 7081026 5850135 7051524

Qty.

1 1 1 1 1

Description

Screen, Oil Filter, 90 Degree Hose, Formed Clamp, Hose Washer, Nylon Plug 6/02

A11

FUEL TANK SCRAMBLER 500 4X4 A04BG50AA 4

5

3

6 7 8 9

2

10

1

11 12

23

20 22

23

22 25

20 20

24 20

21 19

13 18

14 15

17 16

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.

1 2520241 5432879 2 5811527 3 5812123 4 2874859 5 8360009-600 6 5431053 7 7512249 8 7552801 9 7555859 10 5811526 11 5332457 12 7547069

Qty.

1 1 1 1 1 AR 1 2 2 2 1 2 2

Description

Ref. Part No.

Asm., Fuel Tank (Incl. 6,19,24,25) Tank, Fuel Seal, Foam Gasket Gauge, Fuel Line, Fuel Vent, Tank Screw Washer, Spring Lock Washer, Flat Seal, Foam Spacer Nutsert

13 14 15 16 17 18 19 20 21 22 23 24 25

7555726 5431021 7511840 5432291 7041209 5431391 7515136 7080003 2530009 8450080-27 8450040-600 7051006 5810859

Qty.

1 1 1 1 1 1 2 6 1 1 1 1 1

Description

Washer, Flat Lever, Fuel Screw Grommet Spring, Lever, Compression Extension, Fuel Lever Screw Clamp, Hose, Red Filter Sheath, Foil, Laminated Line, Fuel Valve, Fuel Gasket, Fuel Valve 6/03

A12

DECALS SCRAMBLER 500 4X4 A04BG50AA 2

3

1

4 5

9

6

7

8

RH

11

12

13

10

14 15 16 18

19 20

17

LH

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.

1 7171730 7171731 2 7171728 7171729 3 7078253 4 7079780 5 7078465 6 7171727 7 7171726 8 7077791 9 7078577 10 7171732 7171733

1 1 1 1 1 1 1 2 1 1 1 1 1

Description

Decal, “4X4”, Cab, Rear, LH Decal, “4X4”, Cab, Rear RH Decal, Tank Side, LH Decal, Tank Side, RH Decal, Age Warning Decal, Warning AWD Switch Logo, Polaris Star Decal, “Scrambler”, Side Decal, “Scrambler”, Front Cover Decal, Concentric Drive System Decal, Drain, Recoil Decal, Fender, Front, LH Decal, Fender, Front, RH

Ref. Part No.

Qty.

11 12 13 14 15

1 1 1 1 1 1 2 1 1 1 2

16 17 18 19 20

7079604 7079083 7079085 7079930 7171734 7171735 7079925 7079088 7077920 7074637 7079924

Description

Decal, Warning, Override, AWD Decal, Warning, General Decal, Warning, Discretionary Decal, “POLARIS”, Rear Decal, Fender, Rear, LH Decal, Fender, Rear, RH Decal, Reflector, Red Decal, Tire Pressure/Load Decal, Passenger Warning Decal, Fuel Lever Decal, Reflector, Amber 6/03

A13

PROP SHAFT SCRAMBLER 500 4X4 A04BG50AA

2

4 3

5

1

1

11 10

12

8 9

7

6

13

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.

1 2 3 4 5 6 7

7517916 5433457 7558301 7517386 5433154 5411092 7080424

Qty.

4 1 2 2 1 1 1

Description

Ref. Part No.

Screw Guard, Prop Shaft, Side Washer, Flat Screw Guard, Prop Shaft, Front O-Ring Fitting, Lubrication

8 9 10 11 12 13

3260131 1350072 3260104 3260133 1380217 7661913

Qty.

1 1 2 1 1 1

Description

Yoke, Prop Shaft, Transmission Shaft, Prop Kit, Cross and Bearing Yoke, Front Gear Case Asm., Prop Shaft, Front (Incl. 8-11) Pin, Spring 11/01

A14

FRONT HOUSING SCRAMBLER 500 4X4 A04BG50AA

13 14 15 16 12 9 10 11

7

2

3

4

5

17

8 18

6

19 25

1

20

21 22

26 27

2

28 24

1

23

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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1341323 3233252 3233248 3233701 3233700 3233699 3233589 3233726 3233541 3233319 3233697 3233324 3233711 7080756 8450003-1525

Qty.

1 12 2 1 1 1 1 1 1 1 1 1 1 1 AR

Description

Asm., Front Gearcase (Incl. 1-12,16-26) Screw Seal Cover, Input, Front Housing O-Ring Ring, Retaining Bearing Pinion, Input, 14T Bushing Seal, Oil Bushing Washer Plug Clamp Line, Fuel

Ref. Part No.

Qty.

15 16 17 18 19 20 21 22 23 24 25 26 27 28

1 1 1 1 1 AR 1 1 AR 1 1 1 4 4

7080307 3233524 3233696 3233725 3233020 3233554 3233693 3233724 3233583 3233582 3233254 3233253 7552603 7512492

Description

Clamp, Hose Tube, Vent Gearcase, Front Housing Shaft, Output, 29T Bearing, Ball Shim O-Ring Cover, Output, Front Housing Shim Button, Thrust Washer Plug, Drain Washer, Lock Screw 4/01

B1

DRIVE SHAFT SCRAMBLER 500 4X4 A04BG50AA

7

2

1

3

4

6

5

8

9

10

11

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.

1 2 3 4 5

2200960 1380215 5222299 3260121 7670092 2201015

Qty. Description

2 1 1 1 1 1

Kit, Drive Shaft w/Sleeve Asm., Drive Shaft, Front Sleeve, Drive Shaft Seal Clamp, Band Circlip Kit, Replacement Boot

Ref. Part No.

6 7 8 9 10 11

1380060 1380061 3260104 3260101 7661913 3260123

Qty. Description

1 1 1 1 2 1

Shaft, Replacement (Incl. 4) Cardan, Replacement (Incl. 4,6,8,9) Kit, Cross and Bearing Yoke, Splined Pin, Spring Clamp, Band 5/03

B2

FRONT STRUT SCRAMBLER 500 4X4 A04BG50AA

28 27 26

1

25

2

24

4 6

3

5

7

8

8 5 22

23 11

21

9

12

8 10

19

20

14

18

13 16

12

15

17

11

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.

1 2 3 4 5 6 7 8 9 10

5411608 7041762 5211115 7080367 7542423 7512365 7552901 7558402 5810439 -------

2 2 2 2 4 4 4 10 2 1

11 12 13 14 15

3554509 3554507 5222193 7080306 2410133

4 4 2 2 2

Description

Ref. Part No.

Bumper Strut, Front Washer Clamp, Cable Nut, Flange Screw Washer, Spring Lock Washer, Flat Retainer, Strut Casting Wire Asm., Front Brake Caliper, RH (See Front Brake Pg. B14 for Details) Bearing, Tapered Roller Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal Fitting, Lubrication Coil, Magnetic

16 1820950 1820951 17 7041603-216 18 5243364 19 5432871 20 7515339 21 5132062 22 - - - - - - -

1 1 2 2 2 4 2 1

23 24 25 26 27 28

2 2 2 2 2 2

3610028 5432872 5810291 7555749 7547104 7052028

Qty.

Description

Asm., Hubstrut, LH (Incl. 9,13-16) Asm., Hubstrut, RH (Incl. 9,13-16) Spring, Compression, Yellow Retainer, Spring Ball, Pivot, Bottom Bolt Spacer Kit, Drive Shaft w/Sleeve (See Drive Shaft Pg. B2 for Details) Seal, Hubstrut Ball, Pivot, Top Spacer, Rubber Washer Nut, Nylok, Thin Grommet 6/03

B3

A-ARM/STRUT MOUNTING SCRAMBLER 500 4X4 A04BG50AA 1

5 3

6 4 7

8

2 27

25

10

9

11

26

12 13 22

14 15

26 25

23 22

16

24

18

19

21

17

20

13

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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

7542439 1820805 5411291 7061034 7542711 5020926 7547028 7061054 5411920 7517909 7556099 7547177 7661203 -------

Qty.

2 2 2 2 2 2 2 2 1 2 4 2 4 1

Description

Ref. Part No.

Nut, Nylok Asm., Tie Rod (Incl. 3-8) Boot, Seal, Rod End Rod End, RH Nut Tie Rod Nut, Jam, LH Rod End, LH Boot, Seal, Rod End Bolt Washer, Flat Nut Pin, Cotter Asm., Hubstrut (See Front Strut Pg. B3, Ref. 16)

15 16 17 18 19 20 21 22 23 24 25 26 27

7080927 5211121 7512284 5410548 7542438 7512084 5431150-070 5431149-070 5434551 5133806 2202284-216 2202285-216 7552603 7512492 7515415

Qty.

2 2 4 2 2 4 1 1 4 2 1 1 4 4 2

Description

Joint, Ball Bracket, Ball Joint Screw Boot, Rubber Nut, Castle Screw Shield, CV Joint, LH Shield, CV Joint, RH Bushing, A-Arm, Long Shaft, A-Arm Kit, A-Frame, LH Kit, A-Frame, RH Washer, Spring Lock Screw Screw 5/03

B4

FRONT WHEEL SCRAMBLER 500 4X4 A04BG50AA

1 2 3

4

5

11 6

12

10

7

13

14 DETAIL A

9

A 8

15

16 25 24

7

18

6 17

19 20

23

21

22

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.

1 2 3 4 5

7512325 5246832 3610019 5211148 1520281

8 2 2 2 2

6 7 8 9 10 11 12

3554506 3554507 7515523 1520347 3250028 3250010 3250032

4 4 8 2 2 12 2

Description

Ref. Part No.

Bolt Disc, Brake Seal, Front Hub Plate, Armature Asm. Clutch, Front Hub, Elec./Mech.

(Splined Drive Shaft) Bearing, Tapered Roller Cone Bearing, Tapered Roller Cup Stud Asm., Hub (Incl. 3,7,8) Cage, Roll Roll Spring, Garter

13 14 15 16 17 18 19 20 21 22 23 24 25

1321814 3250030 7052045 5412324 7556004 7661401 5410470 5432611 7512027 7542810 7547237 1520175-117 1525017

Qty.

2 2 2 2 2 2 2 2 6 2 8 2 2

Description

Spacer Cam Plug, Magnetic Drain Tire, Titan, 23x7-10 Washer Pin, Cotter O-Ring Cap, Hub Screw Nut Nut, Flange Rim, Front Valve, Rim 5/03

B5

HANDLEBAR / HEADLIGHT SCRAMBLER 500 4X4 A04BG50AA 3

1 2

4 5

25

6 7 14

8 9

10

11 12

24 13 14

23 22 17 21

18

16 15

19

20

18

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.

1 ------2 3 4 5 6 7 8

7515189 7512232 5433993 7555932 7670154 5245051 -------

9 10 11 12

5433903 4010592 7517625 5432952

Qty.

Description

1 Asm., Throttle Control (See ControlsThrottle Asm./Cable Pg. B8, Ref. 5) 4 Screw 2 Screw 1 Pad, Handlebar 2 Washer 2 Retainer, Bolt 1 Mount, Handlebar Pad 1 Asm., Master Cylinder (See Controls-Master Cylinder/Brake Line Pg. C1 for Details) 1 Spacer, Switch, LH 1 Switch, Handlebar, Hi/Lo/Off 1 Screw, Set 1 Plug, Hole

Ref. Part No.

13 14 15 16 17 18 19 20 21 22 23 24 25

5433834-070 7080138 7542324 7558402 7558301 7542122 5242867-067 7080631 2431016 4030061 1040579-067 7512240 5631516 5631517 5244765-067

Qty.

2 4 2 2 2 4 1 1 2 1 1 2 1 1 1

Description

Grip, Handlebar Cable Tie Nut, Nylok Washer, Flat Washer, Flat Nut, Nylok Bracket, Headlight Clip, Cable Retaining Headlight Bulb, Headlamp Guard, Headlight Bolt Block, Handlebar Block, Handlebar, Pegged Tube, Handlebar 6/03

B6

STEERING POST SCRAMBLER 500 4X4 A04BG50AA

3

1

2 4

5

2

5

11 1

6 8

7

10 6 9

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.

1 2 3 4 5 6

7542324 5433866 1821112-067 5246732 7517428 7556162

Qty.

4 2 1 1 4 2

Description

Ref. Part No.

Nut, Nylok Bushing, Steering, Upper Asm., Steering Post Bracket, Steering, Bushing, Upper Bolt, Carriage Bushing

7 8 9 10 11

5222393 3514352 7547158 7661633 7558402

Qty.

1 1 1 1 2

Description

Flangette Bearing Nut Pin, Cotter Washer, Flat 5/03

B7

CONTROLS - THROTTLE ASM. / CABLE SCRAMBLER 500 4X4 A04BG50AA

1 2

3

4

5

6

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.

1 5434113 2 5410193 3 5411439

Qty.

Description

Ref. Part No.

1 Cover, Throttle Control 1 O-Ring 1 O-Ring

4 7080967 5 2010205 6 2010191

Qty.

Description

1 Cable, Throttle 1 Asm., Throttle Control (Incl. 6) 1 Asm., Throttle Clamp 4/01

B8

DRIVE CLUTCH SCRAMBLER 500 4X4 A04BG50AA

4 1

2

5

3

9

8

6 7

12

11 10

6

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.

1321976 1 2 3 4 5 6

7518062 3576510 7041157 5430945 1321457 5431936

Qty.

Description

1 Asm., Drive Clutch, Wide (Incl. All Less 3,8) 6 Screw 1 Cover, Bearing 1 Clutch, Spring 6 Washer, Multilube 3 Roller and Bushing 6 Button, Clutch, Stemless

Ref. Part No.

Qty.

7 5210752 5242981 5210753 5210754 8 5630710 9 7512266 10 7541906 11 3576504 12 5020422

AR AR AR AR 3 3 3 1 3

Description

Spacer, .020 Spacer, .025 Spacer, .032 Spacer, .050 Weight, Shift, 10-WH Bolt, Shoulder Nut, FLEXLOC Bearing, Moveable, 1/2 Inch Pin, Roller 6/02

B9

DRIVEN CLUTCH SCRAMBLER 500 4X4 A04BG50AA

2 1 16

17 3 6

4 5

15 14 13 12 11

10 9 2

8

7

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.

1 2 3 4 5 6 7 8 9

7556120 1321798 5220646 7552901 7515384 3211077 7555898 7556076 7556804

Qty.

AR 1 1 1 1 1 AR AR AR

Description

Ref. Part No.

Bushing Asm., Driven Clutch (Incl. 7-17) Washer, Domed Washer, Spring Lock Bolt Belt, Drive Washer, .020 Washer, .025 Washer

10 11 12 13 14 15 16 17

3576504 3576511 7041499 5131446 5210752 7710448 7511854 5430766

Qty.

1 1 1 1 1 1 3 3

Description

Bearing, Moveable, 1/2 Inch Bearing, Moveable, 1 Inch Spring, Clutch Ramp, Stationary Spacer Ring, Retaining Bolt Button, Ramp 4/01

B10

GEARCASE MOUNTING SCRAMBLER 500 4X4 A04BG50AA

2

1

3

1 4 5

3 2 10

5 9 8

7

5

6

4

5

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.

1 2 3 4 5 6

7517632 5132046 7547089 7512492 7555806 7517646

Qty.

4 2 2 2 4 1

Description

Ref. Part No.

Qty.

Screw Mount, Transmission, Rear Nut, Flange Lock Screw Washer, Flat Screw

7 3221041 8 7710434 9 5211065 5210764 5211517 10 7517642

1 1 AR AR AR 1

Description

Sprocket, 13T Ring, Retaining Shim, .010 Shim, .020 Shim, .030 Screw 6/02

B11

REAR BRAKE MASTER CYLINDER SCRAMBLER 500 4X4 A04BG50AA

1 7

2 5 4 3

6 5 8 9

21 10 10

11

9 20 19 18 17

16

14

13

15

13

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.

1 2 3 4 5 6 7 8 9 10 11

7512113 5244091-067 7542122 7517386 7080003 1910404 1930854 7661401 7555919 5433189 1910375-067

Qty. Description

2 1 2 1 2 1 1 1 2 2 1

Bolt Bracket, Reservoir Mount Nut, Nylok Screw Clamp, Hose, Red Hose, Reservoir Reservoir Pin, Cotter Washer Bushing Mount, Brake

Ref. Part No.

Qty. Description

12 13 14 15

1910499 5410988 7558301 -------

1 2 4 1

16 17 18 19 20 21

7515179 1910311 7542324 1910377-067 7041750 7515321

2 1 2 1 1 2

Bolt, Banjo Seal Washer, Flat Line, Foot Brake, Rear (See Rear Caliper Mounting Pg. B13, Ref. 6) Screw Asm., Foot Brake Master Cylinder Nut, Nylok Rod, Brake Spring, Torsion Screw 5/03

B12

REAR CALIPER MOUNTING SCRAMBLER 500 4X4 A04BG50AA

7 Frame

5

1

7

2

6

4 3

5 6

7 4

17 8 16 9

15 14 13

10 11 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.

1 7517231 2 7555806 3 1910691 7080352 1930665 4 5410988 5 -------

2 2 1 2 1 4 1

6 1910506 7 7670102 8 1910499

Description

Screw Washer, Flat Asm.,Caliper, Brake Screw, Bleeder Kit, Piston and Seal Seal Line, Brake, Rear (See Controls - Master Cylinder/Brake Line Pg. C1, Ref. 3) 1 Line, Brake, Rear 6 Clip, Silencer Box 3 Bolt, Banjo

Ref. Part No.

9 10 11 12 13 14 15 16 17

5131759 7558402 7552901 7512312 5131786 5131787 7512325 5242291-067 1910333 1910339 1930860

Qty.

1 2 2 2 1 1 3 1 1 1 1

Description

Bushing, Caliper Mount Washer, Flat Washer, Spring Lock Bolt Mount, Caliper, Lower Mount, Caliper, Upper Bolt Guard, Brake Disc Brake Pad (Incl. Spacer and Pin) Spacer Pin 12/02

B13

FRONT BRAKE SCRAMBLER 500 4X4 A04BG50AA

2 3

1

4 6 7 5

8

10

9

12

11

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.

1910695 1910696 1 7080352 2 7515489 3 5133407 5133408 1930642 4 5410494 5 5410495

Qty. Description

1 Asm., Brake Caliper, LH (Incl. 1-3,5-10) 1 Asm., Brake Caliper, RH (Incl. 1-3,5-10) 1 Screw, Bleeder 1 Screw, Socket Set 1 Caliper, Brake, LH 1 Caliper, Brake, RH 1 Kit, Front Brake Boot 1 Boot, Pin Seal 1 Boot, Bushing

Ref. Part No.

6 7 8 9 10 11

1930665 5410779 5410780 5132294 1910412 2201398 1910333 12 7512365 7558402 7552901

Qty. Description

1 1 1 1 1 1 1 4 4 4

Kit, Piston and Seals (Incl. 7-9) Square Ring, Molded, .094 Square Ring, Molded, .103 x .134 Piston, Long Mount, Caliper Kit, Front Brake Pad Pad, Brake, Front Screw Washer Washer, Lock 5/03

B14

CONTROLS - MASTER CYLINDER / BRAKE LINE SCRAMBLER 500 4X4 A04BG50AA

4 4

1

15 9

6

2

16

3

10

13

5

7

11

9

13

12 8

14

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.

2010196 1910768 4110164 1910504 7517899 2201834

1 1 1 1 2 1

1 2 3 4 5

6 2201836 7 2201833

Description

Asm., Master Cylinder (Incl. 1-16) Line, Brake, Hand Switch Line, Brake, Rear Screw Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 1 Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring) 1 Kit, Master Cylinder Clamp (Incl. Clamp, Screws)

Ref. Part No.

8 2201835 9 10 11 12 13 14 15 16

7080138 7080539 7621462 1910502 8360052-34 7512024 1910503 7052292

Qty.

Description

1 Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip) 8 Cable Tie 1 Clamp, Nylon 1 Rivet, Pop 1 Line, Brake, Left Front 1 Tubing, Convoluted 2 Screw 1 Line, Brake, Right Front 1 Fitting, Cross 6/03

C1

REAR WHEEL SCRAMBLER 500 4X4 A04BG50AA

1

2

3 4

5

6 7

9

6

8

12 11

7

5

4

8

9 10

2 1

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.

1 2 3 4 5 6

7512673 2200341 7542714 7555796 7543005 7661404

Qty.

8 2 8 2 2 2

Description

Ref. Part No.

Bolt Kit, Hub, Rear (Incl. 1,4,6,10) Nut Washer, Cone Nut, Castle Pin, Cotter

7 8 9 10 11 12

5411164 7555745 1525017 7670081 1520183-117 5412323

Qty.

2 2 2 8 2 2

Description

Cover, Dust, Hub Washer, Flat Valve, Rim Retainer, Bolt, Pushnut Rim, Rear Tire, 22x11-10 11/02

C2

REAR HOUSING SCRAMBLER 500 4X4 A04BG50AA 1

2

3

4 5

6 7 8

9 10 11

12

13

14

15 16 17

18

22 23 14

13

12

11

21 7

20 19

24

4 5

25

3

2 1

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.

1 2 3 4 5 6 7 8 9 10 11 12 13

7710472 5510313 7547196 5411555 7542439 5243678 7515513 1520259 7710405 5010462 5410889 3610070 3554518

Qty.

2 2 2 2 6 1 6 1 1 1 2 2 2

Description

Ref. Part No.

Ring, Retaining Extrusion, Retainer, Nut Nut Seal, Foam Nut, Nylok Disc, Brake Stud Hub, Brake Disc (Incl. 7) Ring, Retaining Spacer, Axle O-Ring Seal Bearing, Cone, Tapered

14 15 16 17 18 19 20 21 22 23 24 25

3554517 5132098 7080306 3225028 5133181 5211585-067 7547108 3221151-076 7512404 1520258 3222109 5630586

Qty.

2 1 1 1 1 1 3 1 3 1 1 1

Description

Bearing, Cup, Tapered Housing, Axle, Rear Fitting, Lubrication Link, Connector Axle, Rear Guard, Sprocket, 38T Nut, Flange Lock Chain, 520 O-Ring Bolt Asm., Hub, Sprocket (Incl. 7) Sprocket, 36T Spacer 5/03

C3

AIR BOX SCRAMBLER 500 4X4 A04BG50AA 29

1

2

3

4 5 6 7 28 8

15

27

9

9

26

10

17

9

16

25

15

24

14

11

13

18

23

12

22

9

19 20

21

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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

7517541 5432859 5411422 5432868 5811482 7515179 7558301 8450073-600 7080699 2530029 7080694 5411847 7080511 5411414 7080413

Qty.

4 1 1 1 1 2 2 AR 4 1 1 1 1 1 2

Description

Ref. Part No.

Screw Duct, Inlet Gasket, Intake Cover, Air Box Seal, Cover Screw Washer, Flat Line, Breather Clamp, Hose Filter, Breather Clamp, Hose Hose, Breather Clamp, Narrow Band Boot, Carburetor Clamp, Narrow Band

16 17 18 19 20 21 22 23 24 25 26 27 28 29

5432473 5830128 5432774 5411873 7621432 7080880 5811650 5432377 8450059-150 7080650 5242044 5432601 7080595 5811633

Qty.

1 1 1 1 1 1 1 1 AR 1 6 1 1 1

Description

Duct, Carburetor, Inlet Gasket, Carburetor, Inlet Duct Box, Air Hose, Breather Rivet Clamp, Hose Foil, Air Box Plug, Trap Line, Fuel Clamp, Hose Clip Collar, Inlet, Carburetor Filter, Air Intake Filter, Sleeve, Precleaner 4/01

C4

CLUTCH COVER SCRAMBLER 500 4X4 A04BG50AA

1

4

5

2

6 3 7 9

10

8

20

25

19 18

24

11 12

17

16

23 22

15 14

21

10

13

2

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.

1 2 3 4 5

5247524-067 7517386 5432698 5411553 2201957

1 3 1 1 1

6 7 8 9 10 11 12 13

7517599 5521578 7078689 5434255-070 7512094 5410542 5434264 7074782

3 1 1 1 9 1 1 1

Description

Ref. Part No.

Qty.

Bracket, Clutch Cover Screw Duct, Down Tube, Inlet Seal, Cover Kit - Inner Clutch Cover (Incl. 7,10,19,21) Bolt and Washer Seal, Clutch Cover, Inner Decal, Warning, Clutch Cover Cover, Clutch, Outer Screw O-Ring Plug Decal, Automatic Transmission

14 15 16 17

7080761 5411489 5434160 -------

2 1 1 3

18 19 20 21 22 23 24 25

5242046 5410575 7555932 7512098 7555935 5242693-067 7661637 7080511

1 1 1 1 1 1 2 1

Description

Cable Tie Boot, Duct Duct, Clutch, Hi-Flow Screw and Washer (See Crankcase Pg. C11, Ref. 6) Bracket, Clutch Seal Seal, Cover, Case Washer, Nylon Screw Washer Bracket, Clutch Cover, Front Rivet Clamp, Narrow Band 6/03

C5

ELECTRICAL/TAILLIGHT SCRAMBLER 500 4X4 A04BG50AA 1 2

3 4 5 6

31

10 11

13 14

7

8 32

12

16

9

30

15

20

18 20 21

19

17

29 28

22

27

26 24

25

24

23

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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

2461183 2410319 7512088 4032085 4030043 4032086 4032087 7670093 7571602 7512027 5810290 5431769 2200361 4010095 7010032 5410424

Qty.

1 1 2 1 1 1 1 2 2 2 3 1 2 1 2 1

Description

Ref. Part No.

Harness, Main Asm., Taillight, 12V (Incl. 3-7) Screw Lens Bulb Gasket Backing Clip Washer Screw Pad, Battery Cover, Battery Kit, Battery Bolt Cable, Battery/Engine, Black Hook, Battery Strap Strap, Battery Holddown

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

4010774 4010094 4010093 7541925 7512007 2202147 4010937 7512024 5246747 5810317 5210650 4010994 7512018 7080138 7670109 4020149

Qty.

1 1 1 3 1 1 1 3 1 1 1 1 2 3 3 3

Description

Battery Cable, Battery/Solenoid, Red Cable, Solenoid/Starter Nut, Nylok Bolt Kit, Fusible Link Controller, Module Fan Screw Bracket, CDI Pad, Fuel Tank Bracket Sink, Heat Limiter Screw Cable Tie Clip, Routing Clip, Rosebud 6/03

C6

SWING ARM/SHOCK MOUNTING SCRAMBLER 500 4X4 A04BG50AA 1

8

7

6

9 5

10

4

11 12

13 14

16 3

1

11

30

29

15

2

16 20

17

19

28

25

27

21

24 23

18

22

26

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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

7542439 7517761 7042142 5630551 5433551 7042281-216 5241147 7515415 7661046 5432727 7080510 7547082 7556035 5434546 5133167

Qty. Description

2 1 1 1 1 1 1 1 2 1 2 1 1 2 1

Nut, Nylok Screw Shock, Rear Cam, Adjusting Sleeve, Shock Protector Spring, Compression, Yellow Retainer, Shock Screw Rivet Guide, Chain, Center Fitting Nut Washer, Flat Bushing, Swing Arm, RH Bushing, Swing Arm Pivot, RH

Ref. Part No.

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

5134321 5247488 7515399 1541819-216 7078572 5432854 7515304 5332828 7558402 7542321 7547066 7555883 7512576 5434545 5133166

Qty. Description

2 2 2 1 1 1 1 1 1 1 2 2 2 1 1

Bolt, Swing Arm Pivot Bracket, Bolt Lock Screw Asm., Swing Arm (Incl. 11,14,29) Decal, Chain Free Play Guard, Chain Screw Bushing Washer, Flat Nut, Flange Nut, Nylok Washer Bolt Bushing, Swing Arm, LH Bushing, Swing Arm Pivot, LH 6/03

C7

GEAR SELECTOR SCRAMBLER 500 4X4 A04BG50AA 1 2

3

4

7

5

8 6

9 10 11 10

16 12

9

15 13

8

13

14

17

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.

1 2 3 4 5 6 7 8 9

5411006 7512024 5411007 5411008 1012797-067 7556250 7542324 7558402 5435042

Qty. Description

1 1 1 1 1 1 2 4 2

Cover Screw Knob, Gear Selector Grommet Selector, Gear Washer Nut, Nylok Washer, Flat Mount, Gear Selector

Ref. Part No.

10 11 12 13 14 15 16 17

7518001 1821206 7547083 7546703 7061102 7547198 7061101 7515306

Qty. Description

2 1 1 2 1 1 1 2

Screw Linkage, Shift Nut, RH Nut, Nylok Rod End, RH Nut, LH Rod End, LH Screw 6/03

C8

GEARCASE SCRAMBLER 500 4X4 A04BG50AA

1

2 3

5 6

4 14 59 22

58 57

49

56

53 52

46

8

36 9

22 35

42 22 32

45

34 33

12 13 10 12

44 43

51

15 8 16

50

14

31 30 29 28

17 27

26

25

38

18

41

48 47 44

37

40

8

54 55

7

39

24

23

C9

22 21

20

19

18

17

10 11

GEARCASE SCRAMBLER 500 4X4 A04BG50AA 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.

1341382 3233527 3233252 3233632 3233529 3233448 3233035 3233633 3233018 3233728 3233718 3233719 3233720 3233721 3233722 3233176 3233177 3233788 3233539 3233556 3233555 3233554 3233020 3233898 3233899 3233552 3233896 3233037 3233026 3233897

1 1 10 1 2 1 1 1 3 1 2 1 2 1 1 1 1 3 11 1 1 AR 4 1 1 1 1 1 1 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Description

Ref. Part No.

Asm., Gearcase, Main (Incl. All) Bushing, Pivot Screw Gearcase, HLR, Hybrid Mach LH Pipe, Knock Plug, Drain Washer Fork, Shift, H/R Bearing, Ball Shaft, Reverse, 31T Bearing, Needle Sprocket, 24T Ring, Retaining, E-Clip Dog, Engagement Gear, 30T Washer, Thrust Ring, Retaining Seal, Triple Lip Screw Cover, Snorkel Drive O-Ring Shim Bearing, Ball Gear, 25T Shaft, Snorkel Busing, Garlock Gearcase, RH Vent, Tube Screw Guide, Chain

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

3233324 3233711 3233542 3233541 3233540 3233306 3233263 3233538 3233537 3233558 3233544 3233545 3233546 3233043 3233747 3233308 3233550 3233635 3233749 3233309 3233549 3233548 3233045 3233547 3233055 3233054 3233040 3233036 3233536 3233019

Qty.

1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 1 1 4 1 1 1 1 1 1 1 1 1 1 1

Description

Washer Plug, Oil Fill Washer, Thrust Bushing, Garlock Shaft, Pinion Ring, Retaining Cover, Bearing Sprocket, 14T Ring, Retaining Gear, 98T Shaft, Output Sprocket, 16T Chain, Roller Deflector, Oil Screw, Tapping Pin, Interlock Spring, Shifting, Interlock Switch, 3 Position Screw, Tapping Bracket, Interlock Shaft, Shift, H/R O-Ring Ring, Retaining Bellcrank, .125 Nut, FLEXLOC Washer Washer Chain, Silent Shaft, Input, HLR Bearing, Ball 6/01

C10

CRANKCASE SCRAMBLER 500 4X4 A04BG50AA 6

2

7 5 3

8

2

1

4

9 10

23

11 12

5

22 21 20

14 19

18

13

15

17

16

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.

1 3083669 2 3089240 3 4 5 6 7 8 9 10 11

3087266 3080676 3084840 3084205 3084839 3085525 3087154 3084842 3084834

Qty.

Description

1 Bushing, Starter 1 Asm., Crankcase (Incl. 1,4,5,7,8,11,12,17,21,22,23) 2 Pipe, Knock 1 Bearing, Ball 2 Pin, Dowel 3 Screw and Washer 1 Seal, Oil 1 Pipe, Air Breather 1 Fitting, Oil Inlet 1 Union 2 Bearing, Ball

Ref. Part No.

12 13 14 15 16 17 18 19 20 21 22 23

3084835 3084845 3084846 3084844 3086810 3084841 3082956 3083453 3084837 3084836 3084847 3080103

Qty.

1 1 1 1 1 10 1 1 1 1 1 2

Description

Bearing, Ball Plug Gasket, Aluminum Spring, Valve, One Way Valve, One Way Bolt, Flange Gasket Plug Seal, Mechanical Seal, Oil O-Ring Pin, Dowel 5/03

C11

CRANKSHAFT and PISTON SCRAMBLER 500 4X4 A04BG50AA 3 1 2

1 4

5

6

21 7

8

20

9 10 19 11 14 16 18

12

15

17

13

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.

1 3085534 2 3087221 3087222 3087223 3 3087224 3087225 3087226 4 3085815 5 3085812 6 3085341 7 3085813 8 3085400 9 3085024 10 3089257 3089258 11 3089245

2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1

Description

Ref. Part No.

Qty.

Clip Piston Set (Std) (Incl. 1) Piston Set (0.25 O/S) (Incl. 1) Piston Set (0.50 O/S) (Incl. 1) Piston Ring Set (Std) Piston Ring Set (0.25 O/S) Piston Ring Set (0.50 O/S) Bearing, Ball Crankshaft 2 Pin, Crank Rod, Connecting Bearing, End, Large Ball, Steel Asm., Crankshaft (Incl. 4-11,19) Crankshaft 1 Gear 1, Balancer

12 3086837 13 3084895 3084896 3084897 14 3240088 3084892 3084893 3084894 15 3084882 16 3085528 17 3083904 18 3083905 19 3086838 20 3081447 21 3240168

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description

Shaft, Balancer Spacer (0.8) Spacer (1.0) Spacer (1.2) Spacer (0.6) Spacer (0.8) Spacer (1.0) Spacer (1.2) Sprocket 1 Nut, Slit Washer Nut, Lock Pin, Dowel Key Key, Woodruff 5/03

C12

CYLINDER SCRAMBLER 500 4X4 A04BG50AA 8

2

9

1 3 4

7

6

10

5

12 11

37

35

35

36

13 5 17

14

16

15

35 18

19 20

34

24 21 22 23

27

9

26

28 29 18

33

30 31 32 13

C13

25

CYLINDER SCRAMBLER 500 4X4 A04BG50AA 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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

3084045 3081497 3081330 3084857 3084994 3084858 3084867 3085072 3084877 3084866 3085074 3085073 3084874 3084859 3084875 3084860 3084861 3084862 19 3084215

Qty.

1 1 2 2 4 2 1 1 10 1 1 1 10 2 4 1 1 1 2

Description

Ref. Part No.

Asm., Band, Adapter (Incl. 2) Screw Bolt Pin, Straight Guide, Valve Seal, Intake Valve O-Ring Adapter, Water Out Bolt, Flange Adapter, Camshaft Gasket, Rocker Cover Cover, Rocker Bolt, Flange Seal, Exhaust Valve Bolt, Cylinder Head Plug Gasket Plug, Blind Bolt, Flange

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

3085075 3085326 3080530 3087199 3085854 3084876 3084864 3084863 3087266 3084849 3084873 3089256 3084130 3085370 3089242 3085527 3085371 3085809

Qty.

1 2 2 2 1 4 1 1 2 1 4 1 1 1 1 1 1 1

Description

Gasket, Exhaust Stud Washer, Lock Nut Bolt, Rocker Shaft Bolt Support, Valve Rocker Shaft (PTO) Support, Valve Rocker Shaft (MAG) Pipe, Knock Union, Oil Pump Bolt, Flange Asm., Cylinder (Incl. 32) Pipe 2, Elbow Gasket, Cylinder Cover, Camshaft Head, Cylinder (Incl. 4-6,14,16-18,21) Gasket, Head Adapter 5/03

C14

CARBURETOR SCRAMBLER 500 4X4 A04BG50AA 1

2

20

3

21

22

4 5

19

18

26 25

6

24

7

29

28

27

17 8

30

31

16 32 9 14

15 30

13

35

34

33

12 50

11

10

36 37

48

38

47

39 14

40 41

49

42

46 45 44 43

D1

CARBURETOR SCRAMBLER 500 4X4 A04BG50AA 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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

3130821 3130914 3130911 3130913 3130908 3130915 3131358 3130910 3130912 3130543 3130931 3130932 3130927 3130933 3130926 3130925 3130619 3084205 3131568 3131569 3131290 3130916 3131208 3130593 3130538

Qty.

2 1 1 1 1 1 1 1 1 1 1 1 1 4 2 1 1 2 1 1 1 1 1 1 1

Description

Ref. Part No.

Screw Cover, Diaphragm Spring Ring E-Ring Ring Needle, Jet Diaphragm Valve, Piston Guide, Cable Asm., Throttle Shaft Ring Spring Screw Washer Case Jet, Air Screw and Washer Asm., Carburetor (Incl. All less 18,40) Jet, Needle Block, Jet O-Ring Cap Asm., Plunger Spring

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

3130199 3130519 3130518 3130517 3130515 3131475 3130907 3131306 3131359 3130928 3131294 3130930 3130924 3130010 3131296 3131295 3131242 3131291 3130239 3131308 3130919 3130935 3130923 3130917 3131293

Qty.

1 1 1 1 2 2 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1

Description

Cap, Plunger Cap E-Ring Packing Seal Screw Valve, Throttle (120) Jet, Pilot (#40) Valve, Needle (1.5) O-Ring O-Ring Cover Screw Spring Washer Asm., Adjuster, Cable Clip Screw, Guide O-Ring Jet, Main (#155) Ring Screw Asm., Float Body Seal Asm., Float 5/03

D2

INTAKE and EXHAUST SCRAMBLER 500 4X4 A04BG50AA 9

10

11

7

10 9

1 2

12 3

13

4

28

14 5

7

8

9

15

16

10

17 18

6 19

27

14

13 12

26

25 24 21

23

20

22

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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

3087129 3087130 3087131 3087132 3086493 3086448 3084910 3084913 3084912 3084911 3084909 3084908 3087203 3084906

Qty.

1 1 1 1 1 1 2 1 4 4 1 8 4 4

Description

Ref. Part No.

Plug Gasket Spring Pin Asm., Tensioner (Incl. 1-4) Gasket, Tensioner Asm., Rocker Arm, Intake (Incl. 9,10) Asm., Rocker Arm, Exhaust (Incl. 9,10) Nut Screw, Adjusting Shaft, Rocker Collet, Valve Retainer, Valve Spring Spring, Valve

15 16 17 18 19 20 21 22 23 24 25 26 27 28

D3

3085855 3086838 3085348 3085076 3084899 3084914 3081657 3084916 3084915 3084924 3084917 3085349 3085412 3083361

Qty.

1 1 1 1 1 1 3 1 1 1 1 2 2 2

Description

Camshaft (Incl. 15-19) Pin, Dowel Lever, Release Spring, Return Pin, Dowel Sprocket 2 Bolt and Washer Guide, Chain Chain, Timing Bolt, Pivot Lever Valve, Intake Valve, Exhaust Bolt and Washer

5/03

RECOIL STARTER SCRAMBLER 500 4X4 A04BG50AA 3

2

1

5

4

6

7 8 9 14

11

10

13

8

12

7 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.

1 2 3 4 5 6 7 8

3084822 3083463 3083378 3083379 3084744 3085266 3083453 3082956

Qty. Description

1 1 1 1 1 1 2 2

Reel Spring, Return Ratchet Spring, Friction Plate, Friction Bolt and Washer Plug Gasket

Ref. Part No.

9 10 11 12 13

3083669 3083185 3084750 3084877 3087163 3087164 14 3085083

Qty. Description

1 1 1 9 1 1 1

Bushing, Starter Spring, Spiral Bushing Bolt, Flange Asm., Recoil (Incl. 1-6,9-11,13,14) Starter Case (Incl. 11) Asm., Rope 6/02

D4

WATER PUMP SCRAMBLER 500 4X4 A04BG50AA 1

2

3

4 3

11 8 9

12

10

7 5

6

13 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.

1 2 3 4 5 6 7

3084940 3089246 3084191 3085857 3085359 3082758 3085351

Qty.

1 1 2 1 1 1 1

Description

Ref. Part No.

Thermostat Sensor, Thermo Clamp, Hose Hose, Main Bolt, Flange Gasket, Aluminum Cover, Water Pump

8 9 10 11 12 13

3086840 3085077 3083138 3084935 3084942 3084877

Qty.

1 1 1 1 1 4

Description

Gasket, Water Pump Nut, Self Lock Gasket, Aluminum Impeller Washer, Seal Bolt, Flange 5/03

D5

OIL PUMP SCRAMBLER 500 4X4 A04BG50AA

4

3 2

1

5 10 9

11

6 7

12

8

13

15 14

18

17 16 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.

1 2 3 4 5 6 7 8 9 10

3084946 3084949 3084948 3085817 3084945 3085535 3088156 3088155 3084953 3084962 3084947

Qty.

1 1 1 1 1 1 2 2 1 3 1

Description

Ref. Part No.

Pump, Oil, Case 2 Rotor, Outer (Feed) Rotor, Inner (Feed) Asm., Oil Pump (Incl. 1-8,10-15) Pump, Oil, Case 1 Screw Pin, Dowel Pin, Dowel Washer Bolt and Washer Pump, Oil, Case 3

11 12 13 14 15 16 17 18

3084950 3084951 3084956 3084205 3085858 3087173 3085820 3084959 3084960 3084961

Qty.

1 1 1 3 1 1 2 AR AR AR

Description

Rotor, Inner Rotor, Outer Unit, Oil Strainer Screw and Washer Shaft, Pump Gear 2, Pump Bolt, Flange Spacer (0.8) Spacer (1.0) Spacer (1.2) 5/03

D6

OIL FILTER SCRAMBLER 500 4X4 A04BG50AA

1

2

2 4

3

3 2

2

3

5

2

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.

1 3084963 2 3084846 3 3086815

Qty.

Description

Ref. Part No.

1 Filter, Oil 8 Gasket, Aluminum 4 Bolt, Banjo

4 3084964 5 3085638

Qty.

Description

1 Pipe, Oil Delivery 1 1 Pipe, Oil Delivery 2 4/01

D7

MAGNETO SCRAMBLER 500 4X4 A04BG50AA

2

1

3

15 14

4 13

16

12

17 18 19

5 10

11

6

8 7 9

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.

1 3089260 3089261 2 3084980 3 3084997 4 3084978 5 3084972 6 3089253 3089248 7 3081657 8 3084973 9 3089249

Qty.

1 1 1 1 1 1 1 1 5 1 1

Description

Asm., Ignition Coil (Incl. 1,2) Coil, Ignition Cap, Spark Plug Plug, Spark O-Ring Metal, Bearing Asm., Plate (Incl. 5,6,8-12,14) Plate Bolt and Washer Seal, Oil Stator (Incl. 13)

Ref. Part No.

10 11 12 13 14 15 16 17 18 19

3089251 3089250 3084976 3089254 3081256 3089238 7552801 7542105 4010930 3089247

Qty.

3 1 2 1 1 1 2 2 1 1

Description

Screw and Washer Band, Pulse Screw and Washer Coil, Pulser Screw and Washer CDI System Washer, Spring Lock Nut Switch, Magnetic Flywheel/Ring Gear 6/03

D8

STARTING MOTOR SCRAMBLER 500 4X4 A04BG50AA 3

4

2

1 6

5

7

8

12

10

13

11

9 14 15 16 17 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.

1 2 3 4 5 6 7 8

3084981 3088163 3088169 3088166 3088165 3082038 3085034 3088168 3088160

Qty.

1 1 1 2 3 2 1 1 1

Description

Asm., Starting Motor (Incl. 1-4,6-10,12) Set, Washer Set, Brush, Carbon Nut, Flange O-Ring Bolt and Washer Asm., Bracket, Rear Asm., Armature Asm., Bracket, Front

Ref. Part No.

9 10 11 12 13 14 15 16 17

3088161 3088164 3089255 3088162 3083737 3084412 3084411 3084410 3084409

Qty.

1 2 1 2 1 1 1 1 1

Description

O-Ring Asm., Bolt Set (Incl. 4) Asm., Gear Shaft (Incl. 13-17) Ring, Rubber Washer, Gear Shaft Clip Spring, Weight Spring, Return Clip 5/03

D9

FUEL PUMP SCRAMBLER 500 4X4 A04BG50AA

3

2

2

4

1

4

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.

3085275 1 3088171 2 3088173

Qty.

Description

1 Asm., Fuel Pump (Incl. 1-4) 1 Screw and Washer 2 Screw and Washer

Ref. Part No.

3 3084591 4 3088170

Qty.

Description

4 Screw and Washer 1 Set, Gasket, Diaphragm 5/03

D10

TOOL KIT SCRAMBLER 500 4X4 A04BG50AA

2

3

1

4

5

6

7

8

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.

3085544 1 9918754 2 2870725 3 3085001

Qty.

Description

1 Asm., Tool Kit (Incl. 3-8) 1 Owner’s Manual, ’04 Scrambler 500 4x4 1 Gauge, Tire Pressure 1 Wrench, Open, 8-10mm

Ref. Part No.

4 5 6 7 8

3085002 3085568 3085569 3082657 2682572

Qty.

1 1 1 1 1

Description

Wrench, Open, 12-14mm Wrench, Box, 125mm Puller, Spark Plug (Wrench Handle) Screwdriver Pouch, Tool Kit 6/03

D11

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PRINTED IN THE USA

PARTS MANUAL PN 9918622 and MICROFICHE PN 9918623 6/03