Polaris SCRAMBLER 500 2000 Bedienungsanleitung

PARTS MANUAL PN 9915485 and MICROFICHE PN 9916574 3/00

SCRAMBLER 500

Model #A00BG50AA

Rev. 02

E2000 Polaris Sales Inc.

TABLE OF CONTENTS

Scrambler 500 A00BG50AA

Parts Manual

A-ARM/STRUT MOUNTING B9.............

AIR BOX C7...........................

CARBURETOR D9-10......................

CLUTCH COVER C8.....................

CONTROL PANEL A8....................

CONTROLS -

MASTER CYLINDER/BRAKE LINE B13....

CONTROLS - THROTTLE ASM./CABLE B12....

COOLING SYSTEM A9...................

CRANKCASE D4.......................

CRANKSHAFT and PISTON D7.............

CV JOINT B5..........................

CYLINDER D5-6..........................

DECALS B1...........................

DRIVE CLUTCH B14......................

DRIVEN CLUTCH C1.....................

ELECTRICAL/TAILLIGHT C9...............

ENGINE MOUNTING A11-12..................

EXHAUST SYSTEM A10...................

FOX SHOCK, GAS, RESERVOIR D2.........

FRONT BRAKE B8......................

FRONT BUMPER and SHIELDS A7..........

FRONT CAB A5........................

FRONT HOUSING B3-4....................

FRONT STRUT B6......................

FRONT WHEEL B7......................

FUEL PUMP E3........................

FUEL TANK A14.........................

GEAR SELECTOR D1....................

GEARCASE C11-14.........................

GEARCASE/BRAKE

and CHAIN COVER MOUNTING C2......

HANDLEBAR/HEADLIGHT B10.............

INTAKE and EXHAUST D8................

MAGNETO E1..........................

OIL FILTER D14.........................

OIL PUMP D13..........................

OIL TANK A13..........................

PROP SHAFT B2.......................

REAR BRAKE MASTER CYLINDER C4.......

REAR CAB A6.........................

REAR CALIPER MOUNTING C3............

REAR WHEEL DRIVE C5.................

RECOIL STARTER D11....................

SHOCK VALVING D3.....................

STARTING MOTOR E2...................

STEERING POST B11.....................

SWING ARM/SHOCK MOUNTING C10........

TOOL KIT E4..........................

WATER PUMP D12.......................

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

2000 SCRAMBLER 500 SPECIFICATIONS

BRAKES

Type - Front

Type - Rear

Type - Auxiliary

Type - Parking

Hydraulic Disc

Hydraulic Lock, All Wheel

CAPACITIES

Coolant Capacity (quarts)

Fuel Tank (gallon)

Gearcase Oil (ounces)

Engine Counter Balance 10W30

Oil (quarts) Injector

Oil (quarts) Engine (OW40)

Rack, Front (pounds)

Rack, Rear (pounds)

Tongue Weight

Tow Hitch

Tow Weight

2.25

3.5

Accessory 30

Accessory 60

Accessory

850

DRIVE TRAIN

Type PVT

DRIVE CLUTCH

Center Distance (inches)

Clutch Offset (inches)

Clutch Weight

Spring Color

1/2

10 WH

Blue/Green

DRIVEN CLUTCH

Helix Angle

Spring Position

40°

1-1

DIMENSIONAL FEATURES

Approx. Turning Radius (inches)

Box, Cargo Bed

Box, Tool (cubic feet)

Ground Clearance (inches)

Height (inches)

Length (inches)

Seat Height (inches)

Weight (dry)

Wheel Base (inches)

Width (inches)

N/A

6.5

74.5

542

48.50

45.5

GEARCASE

Trans. Number and Type

Shift Type

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Front Drive (ratio)

Final Drive (ratio)

Center Drive (ratio)

Axle to Axle

Chain Type

PRD

Side Lever

N/A

4.74/1

3.06/1

2:1

13/36 76P

N/A

520 O-Ring

TIRES&WHEELS

Tire Manufacturer

Tire Size - Front

Tire Size - Rear

Tire Size - Center

Tire Pressure - Front

Tire Pressure - Rear

Tire Pressure - Center

Titan

23x7x10

22x11x10

N/A

ENGINE

Engine Model Number

Engine Type

Lubrication Type

Bore & Stroke (mm)

Displacement (cc’s)

Compression Ratio

Cooling

Alternator Output

Elec. Start w/Recoil Back Up

Carburetors (no. of/size)

Main Jet

Pilot Jet

Needle Jet

Cut Away

Air Screw

Jet Needle

Ignition

Ignition (Type & Deg. BTDC)

Spark Plug Gap (inches)

Spark Plug (Type)

Exhaust

EH50PLE04

4 Cycle, Single Cylinder

Dry Sump

92.0x75

499

10:2 Full Stroke

Liquid

250W

Standard

1/BST40 (CV Type)

155

Y-0

2.0 Turn

6H25-94-3

CDI

30 @ 3500

.028

NGKBKR5E

USFS Pending

GRAPHICS

Bumper Caps/Polyprop.

Cargo Box or Bed

Fender, Front/HDPE

Fender, Rear/HDPE

Footwell

Frame/Steel

Front Cover

Grips/TPR

Handlebar/Steel

Handlebar Cover w/Decal

Headlight Pod/HDPE

Rack, Front/Steel

Rack, Rear/Steel

Rims/Steel

Seat, Vinyl

Side Panel/HDPE

Spring, Front/Steel

Spring, Rear/Steel

Tank Cover/HDPE

Tool Box Cover/HDPE

w/lettering Color

N/A

Blazing Red

Black

Blazing Red

Black

Black/White

N/A

Silver

Black

N/A

Fire Red

N/A

LIGHTS/BATTERY

Headlight (watts)

Taillight (watts)

Brake Light (watts)

Indicator Bulb

2 Dual Beam, 30/30 W

12 V/8.26 W

12 V/26.9 W

12 V/1 W

SUSPENSION

Front Type -

Front Travel (inches)

Adjustment

Rear Type -

Rear Travel (inches)

Shock

Adjustment

MacPherson Strut

8.2

-- -- -- -- --

Progressive Rate Swing Arm

10.5

Gas Charged w/Remote

Reservoir

Threaded Adjuster

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements toits products without

notice.

2000 SCRAMBLER 500 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’S

MANUAL

OWNER’S

MANUAL

SUPPLEMENT

PARTS

MANUAL

PARTS

MICROFICHE

ASSEMBLY

INSTRUCTIONS

Scrambler 500 A00BG50AA 9915299 9915470 9915485 9916574 9915506

FRONT CAB

Scrambler 500 A00BG50AA

E2000 Polaris Sales Inc.

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

17670060 4Nut, Speed, U-Clip

25224718-067 2Bracket, Cab Mount

37517386 2Screw

41013037-067 1Frame

57621432 2Rivet, Pop

65211547-067 1Strap, Fuel Pump Mounting

77512282 24 Bolt

85432553-288 1Cover, Front, Blazing Red

92631988-288 1Cab, Front, Blazing Red

(w/Warning Decals)

10 7522026 2Screw

11 7558301 2Washer, Flat

12 7558201 2Washer, Flat

13 7621472 8Rivet

14 7542122 24 Nut, Nylok

15 7555859 16 Washer, Flat

16 5211131-067 2Bracket, Mudflap

17 5811831

5850150

Mudflap, Front, LH

Mudflap, Front, RH

18 1013083-067

1040691-067

1013249-067

Footpad, RH (If built before 11/22/99)

Footpad, LH (If built before 11/22/99)

Footpad (If built after 11/22/99)

19 7661825 8Rivet

20 5431484 2Trim, Footrest

21 5242525-067 2Bracket, Heel Cleat

22 5432763 1Guard, Rock

23 7515179 6Screw

3/00

REAR CAB

Scrambler 500 A00BG50AA

23 24

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

17621472 4Rivet

27555859 10 Washer, Flat

37512232 2Screw

47512242 2Screw

57041607 1Spring, Latch, Light

61040412 1Latch, Seat

75411392 1Cap, Seat Latch

82682453-070

2681769-070

Seat, Black

Covering, Seat, Black

95431986 1Tongue, Seat

10 7621479 2Rivet

11 5410414 6Bumper, Rubber

12 5211033 2Bracket, Lever Retainer

13 7621403 1Rivet

14 5810991 1Foil, Rear Cab, Small

15 7073761 1Decal - Carb Information

16 7077446 1Decal - Filter Element

17 5432820-288 1Cab, Rear, Blazing Red

18 7670057 2Nut, Speed, U-Type

19 2632275 1Shield, Muffler

20 7542122 17 Nut, Nylok

21 7517264 4Screw

22 5432831 2Plug, End Cap, Ribbed

23 5241403-067 1Guard, Clutch

24 7661638 4Rivet

25 2670133 2Reflector, Red

26 7512282 16 Bolt

27 -- -- -- -- -- -- -- 2Footpad

(See Front Cab Pg. A5, Ref. 18)

28 5850147

5850148

Mudflap, Rear, LH

Mudflap, Rear, RH

29 5211131-067 2Bracket, Mudflap

30 5810957 1Foil, Rear Cab

31 5220880 2Bracket, Rear Seat Holddown

3/00

FRONT BUMPER and SHIELDS

Scrambler 500 A00BG50AA

20 13

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

17558402 2Washer, Flat

27512329 2Bolt

35811675 1Plug, Frame

47547071 2U-Nut

55850141 2Shield, Deflector

61012773-067 1Bumper, Front

77542122 4Nut, Nylok

87555859 4Washer, Flat

95432378-070 1Plate, Skid, Bumper

10 7517264 4Screw

11 7517561 7Screw

12 5242694-067 2Bracket, Radiator Shield

13 7547085 7Nut, U-Type

14 7558201 2Washer, Flat

15 5242997-067 1Shield, Radiator Side, RH

16 7515399 2Screw

17 5242996-067 1Shield, Radiator Side, LH

18 7512252 2Screw

19 7670088 4Clip, Dart

20 5242683-067 1Shield, Upper Radiator

21 2670134 2Reflector, Amber

22 7621467 2Rivet

23 5131036 1Heat Sink

24 4060173 1Regulator, Rectifier

25 7512018 3Screw

9/99

CONTROL PANEL

Scrambler 500 A00BG50AA

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

15430967 1Plug

24040054 1Indicator, Neutral/Reverse

34040053 1Indicator, Hot Temperature

45433534 1Cover, Key

54110264

4010278

4010321

Switch, Ignition (Incl. Key)

Key, Blank, Series 2000, 6700, 6800.

NOTE: Spare key must be cut from

existing key.

Key, Blank, Series 2200, 2300, 2700,

2800. NOTE: Spare key must be cut

from existing key.

65433733 1Nut, Ignition

75431976 1Panel, Control, Outer

85432090 1Nut, Ignition Switch

97512026 2Screw

10 2460723 1Harness, Indicator

11 7080229 1Nut, Choke Slide

12 5431975 1Panel, Control, Inner

13 7080746 1Cable, Choke

10/00

COOLING SYSTEM

Scrambler 500 A00BG50AA

21 20 18

31 30

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

17542122 2Nut, Nylok

27558301 2Washer, Flat

35432593 1Shroud, Fan, ATV

47512084 2Screw

55430743 1Cap, Overflow, Drilled

65810279 1Gasket, Overflow Cap

75431895 1Plug, Cap

82520165

5433410

Asm., Surge Tank w/Fitting

Tank, Surge

98450003-1525 1Line, Fuel

10 7052065 1Fitting, Barbed, 90 Degree

11 7080869 1Clamp

12 8450050-63 1Hose, Lower

13 5411108 1Hose, Upper

14 7080614 2Clamp, Hose

15 4010202 1Switch, Thermal

16 2511189 1Cap, Pressure

17 1240015 1Radiator, U-Flow

18 7515133 2Bolt

19 7052181 1Valve, Drain Cock

20 5020937 2Spacer, Mount, Radiator

21 3110032 2Mount, Rubber, Radiator

22 7080492 1Cable Tie

23 7670090 1Clip, Dart

24 4170013 1Motor, Fan

25 5241355-067 1Bracket, Cooling Fan

26 5242550 1Blade, Fan

27 7517475 3Screw

28 7512232 4Screw

29 5410584 2Bushing, Mount, Lower Radiator

30 7558201 3Washer, Flat

31 7547004 3Nut, Nylok

32 4010369 1Breaker, Circuit

3/00

A10

EXHAUST SYSTEM

Scrambler 500 A00BG50AA

14 15

12 7

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

17515316 2Bolt

25410241 2Dampener, Vibration

35010192 2Bushing

41261006-029 1Silencer

57041804 4Spring, Exhaust

61261005-029 1Pipe, Exhaust

75243518 2Seal, Exhaust

87512232 2Screw

95242344-067 1Bracket, Exhaust

10 7542301 1Nut

11 3110064 1Mount, Torque Stop

12 7042029 1Spring, Exhaust

13 7512666 2Bolt

14 7542324 2Nut, Nylok

15 7555716 2Washer, Flat

16 5410436 2Washer, Rubber

5/99

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