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Polaris SCRAMBLER 500 2000 Parts Manual

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SCRAMBLER 500
Model #A00BG50AA
Rev. 02
E 2000 Polaris Sales Inc.
PARTS MANUAL PN 9915485 and MICROFICHE PN 9916574 3/00

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Summary of Contents for Polaris SCRAMBLER 500 2000

  • Page 1 SCRAMBLER 500 Model #A00BG50AA Rev. 02 E 2000 Polaris Sales Inc. PARTS MANUAL PN 9915485 and MICROFICHE PN 9916574 3/00...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Scrambler 500 A00BG50AA Parts Manual GEAR SELECTOR ....A-ARM/STRUT MOUNTING ... . . GEARCASE .

  • Page 3: Drive Train

    Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center 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.
  • Page 4 2000 SCRAMBLER 500 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER’S OWNER’S PARTS PARTS ASSEMBLY MANUAL MANUAL MANUAL MICROFICHE INSTRUCTIONS SUPPLEMENT Scrambler 500 A00BG50AA 9915299 9915470 9915485 9916574 9915506...
  • Page 5 FRONT CAB Scrambler 500 A00BG50AA E 2000 Polaris Sales Inc. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7670060 4 Nut, Speed, U-Clip 13 7621472 8 Rivet 2 5224718-067 2 Bracket, Cab Mount 14 7542122 24 Nut, Nylok...
  • Page 6 REAR CAB Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7621472 4 Rivet 17 5432820-288 1 Cab, Rear, Blazing Red 2 7555859 10 Washer, Flat 18 7670057 2 Nut, Speed, U-Type 3 7512232 2 Screw 19 2632275 1 Shield, Muffler 4 7512242...
  • Page 7 FRONT BUMPER and SHIELDS Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7558402 2 Washer, Flat 14 7558201 2 Washer, Flat 2 7512329 2 Bolt 15 5242997-067 1 Shield, Radiator Side, RH 3 5811675 1 Plug, Frame 16 7515399 2 Screw...

  • Page 8: Control Panel

    CONTROL PANEL Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5430967 1 Plug 6 5433733 1 Nut, Ignition 2 4040054 1 Indicator, Neutral/Reverse 7 5431976 1 Panel, Control, Outer 3 4040053 1 Indicator, Hot Temperature 8 5432090 1 Nut, Ignition Switch 4 5433534...

  • Page 9: Cooling System

    COOLING SYSTEM Scrambler 500 A00BG50AA 31 30 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7542122 2 Nut, Nylok 17 1240015 1 Radiator, U-Flow 2 7558301 2 Washer, Flat 18 7515133 2 Bolt 3 5432593 1 Shroud, Fan, ATV 19 7052181 1 Valve, Drain Cock 4 7512084...

  • Page 10: Exhaust System

    EXHAUST SYSTEM Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7515316 2 Bolt 9 5242344-067 1 Bracket, Exhaust 2 5410241 2 Dampener, Vibration 10 7542301 1 Nut 3 5010192 2 Bushing 11 3110064 1 Mount, Torque Stop 4 1261006-029 1 Silencer 12 7042029...
  • Page 11 ENGINE MOUNTING Scrambler 500 A00BG50AA...
  • Page 12 ENGINE MOUNTING Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7547108 6 Nut, Flange 29 7575202 1 Washer, Interlock 2 7555823 3 Washer, Flat 30 7512566 1 Bolt 3 4010132 1 Cable, Ground/Engine 31 - - - - - - - - - - - - - - 1 Asm., Drive Clutch, ATV-06 (See Drive Clutch Pg.
  • Page 13 OIL TANK Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7511848 2 Screw 14 7052106 1 Fitting, 1/4” to 3/8” 2 5211523 1 Plate, Vent, Oil Tank 15 2530014 1 Screen, Oil Filter 3 5830053 1 Gasket, Oil Reservoir 16 5131785 1 Tank, Oil, LH...
  • Page 14 FUEL TANK Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2511342 Asm., Fuel Tank (Incl. 7,20,25,26) 14 7555726 1 Washer, Flat 5432879 Tank, Fuel 15 5431021 1 Lever, Fuel 2 5811527 1 Seal, Foam 16 7511840 1 Screw 3 5410842...
  • Page 15 1 Decal - Warning, Override, AWD 3 7077802 1 Decal - Tank Side, RH 12 7078253 1 Decal - Age Warning 4 7078020 1 Decal - “POLARIS” 13 7077801 1 Decal - Tank Side, LH 5 7074935 1 Decal - Warning, AWD Switch 14 7077920...
  • Page 16 PROP SHAFT Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5433457 1 Guard, Prop Shaft, Side 7 1590256 2 Joint, Cardan 2 7512232 6 Screw 8 3260133 1 Yoke, Front Gear Case 3 5433154 1 Guard, Prop Shaft, Front 9 1380124 1 Asm., Prop Shaft (Incl.
  • Page 17 FRONT HOUSING Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1341276 1 Asm., Front Gearcase (Incl. 15 7080307 1 Clamp, Hose 1-12,16-25)(If built before 7/01/99) 16 3233524 1 Tube, Vent 1 3233252 12 Screw 17 3233696 1 Gearcase 2 3233248 2 Seal...
  • Page 18 FRONT HOUSING Scrambler 500 A00BG50AA 9 10 11 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1341323 1 Asm., Front Gearcase (Incl. 1-12,16-26) 14 8450003-1525 AR Fuel Line (Units built after 7/0199) 15 7080307 1 Clamp, Hose 1 3233252 12 Screw 16 3233524 1 Tube, Vent...
  • Page 19 CV JOINT - NEAPCO Scrambler 500 A00BG50AA Brand Designated Ref. Part No. Qty. Description Ref. Part No. Qty. Description 8 3260104 1 Kit - Cross and Bearing 1380118 2 Asm., CV Housing w/Sleeve (Incl. 1) 9 3260101 1 Yoke, Splined 1 - - - - - - - - - - - - - - 1 Asm., Drive Shaft, Splined 10 7661913...
  • Page 20 FRONT STRUT Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5411608 2 Bumper 16 2201311 Asm., Hubstrut, LH (Incl. 9,13-16) 2201312 Asm., Hubstrut, RH (Incl. 9,13-16) 2 7041762 2 Strut, Front 17 7041603-067 2 Spring, Coil, Strut 3 5211115 2 Washer 18 5243364...
  • Page 21 FRONT WHEEL Scrambler 500 A00BG50AA DETAIL A Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512325 8 Bolt 13 1321814 2 Spacer 2 5211869 2 Disc, Brake 14 3250030 2 Cam 3 3610019 2 Seal, Front Hub 15 7052045 2 Plug, Magnetic Drain 4 5211148...
  • Page 22 FRONT BRAKE Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1910271 Asm., Front Brake Caliper, LH 8 5410494 1 Boot, Pin Seal (Incl. 1-7) 9 - - - - - - - - - - - - - - 4 Washer, Flat 1910264 Asm., Front Brake Caliper, RH...
  • Page 23 A- ARM/STRUT MOUNTING Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7542403 2 Nut, FLEXLOC 17 5211121 2 Bracket, Ball Joint 2 5333367 1 Bushing 18 7512284 4 Screw 3 1820805 2 Asm., Tie Rod (Incl. 4-9) 19 5410548 2 Boot, Rubber 4 5411291...
  • Page 24 HANDLEBAR/HEADLIGHT Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 2200774 1 Kit - Handlebar Block (Incl. 3,16,22) 11 5431030 2 Grip, Handlebar 1 - - - - - - - - - - - - - - 1 Asm., Throttle Control (See Controls- 12 7080138 4 Cable Tie...
  • Page 25 STEERING POST Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 1843051 1 Asm., Steering Post (Incl. 12,13) 9 7661633 1 Pin, Cotter 2 5433415 1 Bushing, Steering Console 10 5431570 1 Bushing, Steering, Lower 3 7080510 1 Fitting, Lubrication, 90 Degree 11 7661632...
  • Page 26 CONTROLS - THROTTLE ASM./CABLE Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5433806 1 Cover, Throttle Control 4 7080709 1 Cable, Throttle Control 2 5410193 1 O-Ring 5 2010188 1 Asm., Throttle Control (Incl.1,3,6) 3 5411439 1 O-Ring 6 2010191...
  • Page 27 CONTROLS - MASTER CYLINDER/BRAKE LINE Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2200809 Kit - Master Cylinder Reservoir 13 1930805 1 Screw (Incl. 2,3,4,14) 14 - - - - - - - - - - - - - - 1 Ring, Square 2050073 Asm., Master Cylinder (Incl.
  • Page 28 DRIVE CLUTCH Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512176 6 Bolt 9 5630710 3 Weight, Shift (10-WH) 2 7552801 6 Washer, Spring Lock 10 7512266 3 Bolt, Shoulder 3 3576510 1 Cover, Bearing 11 7541906 3 Nut, FLEXLOC 4 7041157...
  • Page 29 DRIVEN CLUTCH Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7556120 AR Bushing 10 3576504 1 Bearing, Moveable, 1/2” 2 1321798 1 Asm., Driven Clutch (Incl. 7-17) 11 3576511 1 Bearing, Moveable, 1” 3 5220646 1 Washer, Domed 12 7041499 1 Spring, Clutch...
  • Page 30 GEARCASE MOUNTING Scrambler 500 A00BG50AA 11 10 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517632 2 Screw 9 7517646 1 Screw 2 5242456-067 2 Bracket, Transmission 10 3221041 1 Sprocket, 13T 3 7542423 4 Nut, Flange 11 7710434 1 Ring, Retaining 4 7512492...
  • Page 31 REAR CALIPER MOUNTING Scrambler 500 A00BG50AA Frame Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517231 2 Screw 10 5131759 1 Bushing, Caliper Mount 2 7555806 2 Washer, Flat 11 7558402 2 Washer, Flat 3 1910367 Caliper, Rear 12 7552901 2 Washer, Spring Lock 2201385...
  • Page 32 REAR BRAKE MASTER CYLINDER Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7080880 1 Clamp, Hose 13 1910375-067 1 Mount, Brake 2 7512113 3 Bolt 14 1930674 1 Bolt, Banjo 3 5244091-067 1 Bracket, Reservoir Mount 15 5410988 2 Seal 4 7542122...
  • Page 33 REAR WHEEL Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512673 8 Bolt 7 5411164 2 Cover, Dust, Hub 2 2200341 2 Kit - Hub, Rear (Incl. 1,4,6,10) 8 7555745 2 Washer, Flat 3 7547037 8 Nut, Flange 9 1525017 2 Valve, Rim...
  • Page 34 REAR HOUSING Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7710472 2 Ring, Retaining 13 3554517 2 Bearing, Cup, Tapered 2 5510313 2 Extrusion, Retainer, Nut 14 5132098 1 Housing, Axle, Rear 3 7542439 6 Nut, Nylok 15 7080306 1 Fitting, Lubrication...
  • Page 35 AIR BOX Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517541 4 Screw 15 7080413 2 Clamp 2 5432859 1 Duct, Inlet 16 5432473 1 Duct, Carb, Inlet 3 5411422 1 Gasket, Intake 17 5830128 1 Gasket, Duct 4 5432868 1 Cover, Air Box...

  • Page 36: Clutch Cover

    CLUTCH COVER Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7547067 3 Nutsert 15 7074782 1 Decal - Automatic Transmission 2 5242208-067 1 Bracket, Clutch Cover 16 7512094 2 Screw 3 7512232 3 Screw 17 7080761 2 Cable Tie 4 5432698...
  • Page 37 ELECTRICAL/TAILLIGHT Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2460787 1 Harness, Main 19 5410424 1 Strap, Battery Holddown 2 7080138 3 Cable Tie 20 5432077 1 Tube, Vent 3 2434012 1 Breaker, Circuit, 20 AMP 21 4140006 1 Battery 4 2201795...
  • Page 38 SWING ARM/SHOCK MOUNTING Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7542439 2 Nut, Nylok 16 5131697 2 Bolt, Pivot, Swing Arm 2 7041865-067 1 Spring, Compression, Small 17 5131696 1 Bushing, Pivot, RH 3 7041864-067 1 Spring, Compression 18 1541395...
  • Page 39 GEARCASE Scrambler 500 A00BG50AA...
  • Page 40 GEARCASE Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1341284 1 Asm., Gearcase (Incl. 1-59)(Units built 31 3233556 1 Cover, Snorkel before April 23, 1999) 32 3233539 11 Screw 1 3233632 1 Gearcase, LH Mach 33 3233555 1 O-Ring 2 3233018...
  • Page 41 GEARCASE Scrambler 500 A00BG50AA 56 57 14 15 16 43 44 49 50...
  • Page 42 GEARCASE Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1341328 1 Asm., Gearcase (Incl. 1-57) 29 3233539 11 Screw (Units built after April 23, 1999) 30 3233248 3 Seal, Triple Lip 1 3233632 1 Gearcase, LH Mach 31 3233555 1 O-Ring 2 3233018...
  • Page 43 GEAR SELECTOR Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5411006 1 Cover 8 7061014 1 Rod End, 6mm, RH 2 7512024 1 Screw 9 7546701 1 Nut, RH 3 5411007 1 Knob, Gear Selector 10 5020955 1 Rod, Shift Linkage 4 5411008...
  • Page 44 FOX SHOCK, GAS, RESERVOIR Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 7041867 1 Shock, Gas, Reservoir 13 1500098 1 O-Ring, ATV Fox Shock 1 1500021 1 O-Ring 14 1500286 1 Asm., Reservoir 2 1500020 1 O-Ring 15 1500283 1 Body...
  • Page 45 SHOCK VALVING Scrambler 500 A00BG50AA Shaft Piston Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 1500033 1 Valve, Shock (.90 x .377 x .008) 8 1500052 1 Valve, Shock (1.3 x .377 x .006) 2 1500032 1 Valve, Shock (1.0 x .377 x .008) 9 1500095 2 Valve, Shock (1.25 x .377 x .012) 3 1500031...
  • Page 46 CRANKCASE Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3083669 1 Bushing, Starter 12 3084845 1 Plug 2 3085808 1 Asm., Crankcase 13 3084846 1 Gasket, Aluminum (Incl. 1,4,5,7,8,10,11,16,19,20,22) 14 3084844 1 Spring, Valve, One Way 3 3084838 2 Pin, Straight 15 3086810...

  • Page 47: Cylinder

    CYLINDER Scrambler 500 A00BG50AA...
  • Page 48 CYLINDER Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084045 1 Asm., Band, Adapter (Incl. 2) 20 3085075 1 Gasket, Exhaust 2 3081497 1 Screw 21 3085326 2 Stud 3 3081330 2 Bolt 22 3080530 2 Washer, Lock 4 3084857 2 Pin, Straight...
  • Page 49 CRANKSHAFT and PISTON Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3085534 2 Clip 12 3085852 1 Gear 1, Balancer 2 3085866 Asm., Piston Set (Std) (Incl. 1) 13 3086837 1 Shaft, Balancer 3085867 Asm., Piston Set (0.25 O/S) (Incl.
  • Page 50 INTAKE and EXHAUST Scrambler 500 A00BG50AA 12 11 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084845 1 Plug 15 3086838 1 Pin, Dowel 2 3084920 1 Gasket, Plug 16 3085348 1 Lever, Release 3 3086839 1 Spring, Tensioner 17 3085076 1 Spring, Return 4 3086813...
  • Page 51 CARBURETOR Scrambler 500 A00BG50AA...
  • Page 52 CARBURETOR Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3130821 2 Screw 27 3130518 1 E-Ring 2 3130914 1 Cover, Diaphragm 28 3130517 1 Packing 3 3130911 1 Spring 29 3130515 2 Seal 4 3130913 1 Ring 30 3130906 2 Screw...
  • Page 53 RECOIL STARTER Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084822 1 Reel 9 3083669 1 Bushing, Starter 2 3083463 1 Spring, Return 10 3083185 1 Spring, Spiral 3 3083378 1 Ratchet 11 3084750 1 Bushing 4 3083379 1 Spring, Friction...
  • Page 54 WATER PUMP Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084940 1 Thermostat 8 3086840 1 Gasket, Water Pump 2 3085352 1 Switch, Thermostat 9 3085077 1 Nut, Self Lock 3 3084191 2 Clamp, Hose 10 3083138 1 Gasket, Aluminum 4 3085857...
  • Page 55 OIL PUMP Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084946 1 Pump, Oil, Case 2 11 3084950 1 Rotor, Inner 2 3084949 1 Rotor, Outer (Feed) 12 3084951 1 Rotor, Outer 3 3084948 1 Rotor, Inner (Feed) 13 3084956 1 Unit, Oil Strainer...
  • Page 56 OIL FILTER Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084963 1 Filter, Oil 4 3084964 1 Pipe, Oil Delivery 1 2 3084846 8 Gasket, Aluminum 5 3085638 1 Pipe, Oil Delivery 2 3 3086815 4 Bolt, Banjo 6/98...
  • Page 57 MAGNETO Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084690 Asm., Ignition Coil (Incl. 1,2) 10 3085563 Screw and Washer (Up to S#00-04730) 3084979 Coil, Ignition 3086985 Screw and Washer (S#00-04730 & after) 2 3084980 1 Cap, Spark Plug 11 3085554 1 Band, Pulse...
  • Page 58 STARTING MOTOR Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 3084981 1 Asm., Starting Motor (Incl. 1-4,6-10,12) 9 3240114 1 O-Ring 1 3084982 1 Washer Set 10 3084983 2 Asm., Set Bolt (Incl. 4) 2 3084406 1 Brush Set, Carbon 11 3085394 1 Asm., Gear Shaft (Incl.

  • Page 59: Fuel Pump

    FUEL PUMP Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 3085275 1 Asm., Fuel Pump (Incl. 1-4) 3 3084591 4 Screw and Washer 1 3084999 1 Screw and Washer 4 3084998 1 Gasket Set, Diaphragm 2 3085356 2 Screw and Washer 5/99...

  • Page 60: Tool Kit

    TOOL KIT Scrambler 500 A00BG50AA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 9915299 Owner’s Manual, ’00 ATV 6 3085568 1 Wrench, Box, 125mm 9915470 Supplement, Owner’s Manual, ’00 7 3085569 1 Puller, Spark Plug (Wrench Handle) Scrambler 500 8 3082657 1 Screwdriver...
  • Page 61 PRINTED IN THE USA PARTS MANUAL PN 99155485 and MICROFICHE PN 9916574 3/00...

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