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PARTS MANUAL PN 9915484 and MICROFICHE PN 9916574 3/00

SCRAMBLER 400Model #A00BG38CA

Rev. 02

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSScrambler 400 A00BG38CA

Parts Manual

AA-ARM/STRUT MOUNTING B9. . . . . . . . .AIR BOX C10. . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D8. . . . . . . . . . . . . . . . . . . .CLUTCH COVER C7. . . . . . . . . . . . . . . . . .CONTROL PANEL A8. . . . . . . . . . . . . . . . .CONTROLS - MASTER

CYLINDER/BRAKE LINE B13. . . . . . .CONTROLS -

THROTTLE ASM./CABLE B12. . . . . . .COOLING SYSTEM A11. . . . . . . . . . . . . . .CRANKCASE and CYLINDER D5-6. . . . . .CV JOINT B5. . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS B1. . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B14. . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C1. . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C9. . . . . . . . . .ENGINE MOUNTING A9-10. . . . . . . . . . . . . .EXHAUST SYSTEM A12. . . . . . . . . . . . . . . .

FFOX 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 TANK A13. . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR D1. . . . . . . . . . . . . . . . .GEARCASE C11-14. . . . . . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING C2. . . . . . . . . . .

HHANDLEBAR/HEADLIGHT B10. . . . . . . . .

MMAGNETO D11. . . . . . . . . . . . . . . . . . . . . . . .

OOIL PUMP D7. . . . . . . . . . . . . . . . . . . . . . . .OIL TANK A14. . . . . . . . . . . . . . . . . . . . . . . . .

PPISTON and CRANKSHAFT D4. . . . . . .PROP SHAFT B2. . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE MASTER CYLINDER C4.REAR CAB A6. . . . . . . . . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING C3. . . . . . . .REAR HOUSING C6. . . . . . . . . . . . . . . . . .REAR WHEEL C5. . . . . . . . . . . . . . . . . . . .RECOIL STARTER D9. . . . . . . . . . . . . . . . .

SSHOCK VALVING D3. . . . . . . . . . . . . . . . . .STARTING MOTOR D10. . . . . . . . . . . . . . . .STEERING POST B11. . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING C8. . .

TTOOL KIT D13. . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D12. . . . . . . . . . . . . . . . . . . . .

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

2000 SCRAMBLER 400 SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic DiscHydraulic DiscHydraulic Disc

Hydraulic Lock, All Wheel

CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallon)Gearcase Oil (ounces)Engine Counter Balance 10W30Oil (quarts) InjectorOil (quarts) Engine (0W40)Rack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

2.25432

100 cc2

N/A306030

Accessory850

DRIVE TRAINType PVT

DRIVE CLUTCHCenter Distance (inches)Clutch Offset (inches)Clutch WeightDiameterSpiderSpring Color

101/255g7.38CastWhite

DRIVEN CLUTCHHelix AngleOutside Diameter (inches)Spring Position

40�9.52-2

DIMENSIONAL FEATURESApprox. Turning Radius (inches)Box, Cargo BedBox, ToolBox (cubic feet)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

9.25 x 3.25776.547

74.533519

48.5045.5

GEARCASETransmission TypeShift TypeGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Chain TypeChain Adjustment

PRDSide Lever

4.36/12.82/12:1

13/36 76P520 O-RingEccentric

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

Titan23x7-1022x11-10

ENGINEEngine Model NumberEngine TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCoolingAlternator OutputElec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayAir ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

EC38PLE092 Cycle,Oil Injection

83.0x70378

6.9:1 EffectiveLiquid150W

Standard1/VM34SS

0-6 (480)1.5 Nickel/Aluminum

1.5 Turn6CEY6-3

CDI23.5 @ 3000

.028NGKBR8ESUSFS Appr.

GRAPHICSBrake LeverBumpers, Front & Rear/SteelBumper Caps/Polyprop.Cargo Box or BedFender, FrontFender, RearFootwellFrame/SteelFront CoverGrips/TPRHandlebar/SteelHandlebar Cover w/DecalHeadlight Pod/HDPEMud Flaps/EVARack, Front/SteelRack, Rear/SteelRims/SteelSeat VinylSide Panel/HDPESpring, FrontSpring, RearTank Cover/HDPE

BlackBlackN/AN/A

Blazing RedBlazing Red

BlackBlack

Porsche RedBlackBlack

Black/Fire RedN/A

BlackN/AN/A

SilverBlazing Red

N/AFire RedFire Red

LIGHTS/BATTERYHeadlight (watts)Taillight (watts)Brake Light (watts)Indicator BulbBattery

12 V 30/30 W12 V/8.26 W12 V/26.9 W12 V/1 W

12 V 14 AH

SUSPENSIONFront Type -

Front Travel (inches)StrutAdjustment

Rear Type -Rear Travel (inches)ShockAdjustment

MacPherson Strut8.2

SACHS-- -- -- -- --

Progressive Rate Swing Arm10.5Fox

Threaded Adjuster

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

2000 SCRAMBLER 400 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUALSUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Scrambler 400 A00BG38CA 9915299 9915469 9915484 9916574 9915505

FRONT CABScrambler 400 A00BG38CA

E 2000 Polaris Sales Inc.

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

1 7670060 4 Nut, U-Clip Speed2 5224718-067 2 Bracket, Mount, Cab3 7512232 2 Screw4 1013039-067 1 Frame5 7080409 1 Clamp, Wire Routing6 7512282 24 Screw7 5431875-288 1 Cover, Front, Blazing Red8 2631988-288 1 Cab, Front, Blazing Red

(w/Warning Decals)9 7522026 2 Screw10 7558301 2 Washer11 7558201 2 Washer12 7621457 8 Rivet

13 7555859 16 Washer14 7542122 24 Nut, Nylok15 5211131-067 2 Bracket, Mudflap16 5811831

585015011

Mudflap, Front, LHMudflap, Front, RH

17 1040691-0671013083-0671013249-067

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

18 7661825 8 Rivet19 5431484 2 Trim, Footrest20 5242525-067 2 Bracket, Cleat, Heel21 5432763 1 Guard, Rock22 7515179 6 Screw

REAR CABScrambler 400 A00BG38CA

2032121

1 7621472 4 Rivet2 7512232 2 Screw3 7555859 16 Washer4 7512242 4 Screw5 7041607 1 Spring, Latch, Light6 1040412 1 Latch, Seat7 5411392 1 Cap, Seat Latch8 2682453-288

2681769-28811

Seat, Blazing RedCovering, Seat, Blazing Red

9 5431986 1 Tongue, Seat10 7621479 2 Rivet11 5410414 6 Bumper, Rubber12 5211033 1 Bracket, Lever Retainer13 7621403 1 Rivet14 5810991 1 Foil, Rear Cab, Small15 7073761 1 Decal - Carb Information16 7072791 1 Decal - Filter Element

17 5432820-288 1 Cab, Rear, Blazing Red18 7670057 2 Nut, U-Type Speed19 5431869-070

581111311

Shield, MufflerFoil, Foam

20 7542122 18 Nut, Nylok21 7517264 4 Screw22 5432831 2 Plug, End Cap, Ribbed23 5241403-067 1 Guard, Clutch24 7661638 4 Rivet25 2670133 2 Reflector, Red26 7512282 16 Screw27 ------ -- -- -- -- 1 Footpad

(See Front Cab Pg. A5, Ref. 17)28 5850147

585014811

Mudflap, Rear, LHMudflap, Rear, RH

29 5211131-067 2 Bracket, Mudflap30 5810957 1 Foil, Rear Cab31 5220880 2 Bracket, Rear Seat Holddown

FRONT BUMPER and SHIELDSScrambler 400 A00BG38CA

21 1222

1 7558402 2 Washer2 7512329 2 Screw3 5810467 1 Plug, Frame4 7547071 2 Nut, U-Type5 5850140

585014111

Shield, Deflector, LHShield, Deflector, RH

6 1012773-067 1 Bumper, Front7 7542122 4 Nut, Nylok8 7555859 4 Washer9 5432378-070 1 Plate, Skid, Bumper10 7517264 4 Screw11 7517561 7 Screw

12 7547085 7 Nut, U-Type13 5242694-067 2 Bracket, Radiator Shield14 7621467 2 Rivet15 7558201 2 Washer16 5242997-067 1 Shield, Side, Radiator, RH17 7515399 2 Screw18 5242996-067 1 Shield, Side, Radiator, LH19 7512252 2 Screw20 2670134 2 Reflector, Amber21 5242683-067 1 Shield, Radiator, Upper22 7670088 3 Clip, Dart

CONTROL PANELScrambler 400 A00BG38CA

1 4010140 1 Indicator, Low Oil (Symbol)2 4040054 1 Indicator, Neutral/Reverse3 4040053 1 Indicator, Hot Temperature4 5433534 1 Cover, Key5 4110264

4010278

4010321

Switch, Ignition (Incl. Key)Key, Blank, Series 2000, 6700, 6800.NOTE: Spare key must be cut fromexisting key.Key, Blank, Series 2200, 2300, 2700,2800. NOTE: Spare key must be cutfrom existing key.

6 543733 1 Nut, Ignition7 5431976 1 Panel, Control, Outer8 7512026 2 Screw9 2460664 1 Harness, Control Panel10 5431975 1 Panel, Control, Inner11 7080371 1 Cable, Choke Control

ENGINE MOUNTINGScrambler 400 A00BG38CA

171615

ENGINE MOUNTINGScrambler 400 A00BG38CA

1 3110038 1 Mount, Engine, Rubber2 7552901 2 Washer, Spring Lock3 7512315 2 Screw4 4010132 1 Cable, Ground, Engine5 7512232 1 Screw6 7547108 7 Nut, Flange Lock7 7555806 1 Washer8 5242692-067 1 Bracket, Engine Mount, Top9 7555823 AR Washer10 3070156 1 Spark Plug, NGK BR8ES11 7080614 2 Clamp, Hose12 5410570 1 Hose, Engine, Upper13 4010218 1 Cable, Solenoid/Starter14 ------ -- -- -- -- 1 Seal, Cover Case

(See Clutch Cover Pg. C7, Ref. 3)15 ------ -- -- -- -- 1 Asm., Drive Clutch, Basic ATV-06

(See Drive Clutch Pg. B14, Ref. 14)16 5430261 1 Bushing17 5210748 1 Washer18 7575202 1 Washer19 7512566 1 Screw20 8360012-04 1 Trim, Edge

21 1040687-067 1 Mount, Engine, Front22 7517289 2 Screw23 5411637 1 Hose, Formed24 7080656 1 Clamp25 7080511 1 Clamp, Band, Narrow26 3110042 2 Mount, Rubber27 7552603 6 Washer, Spring Lock28 7512490 6 Screw29 1040231-067 1 Mount, Engine, Front30 5411681 1 Boot31 3085821 1 Engine, Short Block (EC38PLE09)

NOTE: The Short Block assemblycontains a crankcase assembly, cylin-der and cylinder head assembly, and apiston & crankshaft assembly. Priorauthorization required for warrantyconsideration.

32 8360009-600 AR Line, Fuel33 7051011 1 Valve, Check34 5242463-067 1 Bracket, Mount, Engine, Rear35 7542411 1 Nut, FLEXLOC36 7542432 2 Nut, Jam37 3110048 1 Mount, Torque Stop, Rubber

COOLING SYSTEMScrambler 400 A00BG38CA

1 7542122 2 Nut, Nylok2 7558301 2 Washer3 4170013

241014111

Motor, Fan (If built before 1/01/00)Motor, Fan (If built after 1/01/00)

4 5241355-067 1 Bracket, Cooling Fan5 7052181 1 Valve, Drain Cock6 5020937 2 Spacer, Mount, Radiator7 3110032 2 Mount, Rubber, Radiator8 ------ -- -- -- -- 1 Hose, Upper Engine (See Engine

Mounting Pg. A10, Ref. 12)9 7080492 2 Cable Tie10 ------ -- -- -- -- 1 Hose, Lower Engine (See Engine

Mounting Pg. A10, Ref. 23)11 7080614 2 Clamp, Hose12 4110226 1 Switch, Thermal

13 2511189 1 Cap, Pressure14 1240015 1 Radiator, U-Flow15 5431610 1 Cover, Radiator w/Mesh

(If built before 9/01/99)16 5410607 4 O-Ring (If built before 9/01/99)17 7515133 2 Screw18 5242550 1 Blade, Fan19 7517475 3 Screw20 7512232 4 Screw21 5432870 3 Spacer22 5410584 2 Bushing, Mount, Lower Radiator23 7558201 3 Washer24 7547004 3 Nut, Nylok25 4010369 1 Breaker, Circuit

EXHAUST SYSTEMScrambler 400 A00BG38CA

141312

1 5410957 4 Dampener2 5010339 2 Spacer3 7555852 2 Washer4 7515316 2 Bolt, Carriage5 1260679-029 1 Manifold6 ------ -- -- -- -- 1 Washer, Spring (See Crankcase and

Cylinder Pg. D6, Ref. 8)7 ------ -- -- -- -- 1 Nut (See Crankcase and Cylinder Pg.

D6, Ref. 7)8 7042029 4 Spring, Exhaust9 7542324 3 Nut, Nylok10 7555716 6 Washer

11 5410436 1 Washer, Rubber12 7556401 1 Bushing13 5010350 1 Bushing14 5410241 1 Dampener, Vibration15 7515306 1 Screw16 5211592 2 Gasket, Exhaust17 1260680-029 1 Head Pipe18 1260881-029 1 Muffler19 7042031 2 Spring, Exhaust20 1260884-029 1 Silencer21 7512666 2 Screw

FUEL TANKScrambler 400 A00BG38CA

1 5811527 1 Seal, Foam2 1240048

1240082

Asm., Fuel Tank(Incl. 7,18,24)(If built before 8/16/99)Asm., Fuel Tank(Incl. 7,18,24)(If built after 8/16/99)

3 5410842 1 Grommet, Fuel Tank4 5810144 1 Gasket, Fuel Cap5 5430725 1 Cap, Fuel Tank6 8360009-600 AR Hose, Vent7 5431053 1 Vent8 7512310 2 Bolt9 7555734 2 Washer10 7512208 2 Screw11 7080534 2 Clamp, Hose

12 7080003 6 Clamp, Hose13 8450040-600 AR Line, Fuel14 2530008 1 Filter, Fuel15 5220916-067 1 Bracket, Tank Mount, Rear16 7542324 2 Nut, Nylok17 8360026 AR Pad, Fuel, Bulk18 7052147 1 Fitting, Fuel Outlet, Main, 90 Degree19 5242977 1 Spacer, Fuel Valve20 5432559 1 Knob, Fuel Valve21 7517505 1 Screw22 5432733 1 Nut, Fuel Valve23 7052154 1 Valve, Fuel, 3-Way24 7052148 1 Fitting, Fuel Outlet, 90 Degree

OIL TANKScrambler 400 A00BG38CA

1 7052077 1 Fitting2 8360009-600 AR Line, Fuel3 4110265 1 Sensor, Oil Level4 7621460 2 Rivet5 7080525 1 T-Clip6 7517389 1 Screw7 5431793 1 Tank, Oil, Drilled8 7052153 1 Fitting

9 7080568 2 Clamp10 8450003-1525 AR Line, Fuel11 7080307 2 Clamp, Hose, Green12 2530009 1 Filter13 7555932 2 Washer14 5810141 1 Gasket, Oil Cap15 5430779 1 Cap, Oil Tank

DECALSScrambler 400 A00BG38CA

1 70784337078434

Decal - “4x4 CDS”, Side Panel, LHDecal - “4x4 CDS”, Side Panel, RH

2 7072786 1 Decal - Warning, Heavy Loads3 7078315 1 Logo - 45th Anniversary4 7077802 1 Decal - Tank Side, RH5 7077848

220089111

Decal - “Polaris”Kit - Decal Application Solution

6 7074935 1 Decal - Warning, AWD Switch7 7078430 2 Decal - “Scrambler”8 7078469 1 Decal - Front Cover, “400 LC”

9 7078354 1 Decal - Warning, Discretionary10 7078577 1 Decal - Drain Recoil11 7079604 1 Decal - Warning, Override, AWD12 7078253 1 Decal - Age Warning13 7077801 1 Decal - Tank Side, LH14 7077920 1 Decal - Passenger Warning15 7074690 1 Decal - Caution, Tire Pressure16 7077919 1 Decal - Warning, General17 7074637 1 Decal - Fuel Lever

PROP SHAFTScrambler 400 A00BG38CA

8 7 6 5

1380124 1 Asm., Shaft, Prop (Incl. 5-8)1 5433457 1 Guard, Prop Shaft, Side2 7512232 6 Screw3 5433154 1 Guard, Prop Shaft, Front4 5411092 1 O-Ring5 3260131 1 Yoke, Prop Shaft, Transmission

6 3260139 1 Shaft, Prop7 1590256 2 Kit - Cross and Bearing8 3260133 1 Yoke, Front Gear Case9 7661913 1 Pin, Spring10 7558301 2 Washer

FRONT HOUSINGScrambler 400 A00BG38CA

1 222120

Units built before July 1, 1999

1341276 1 Asm., Front Gearcase (Incl. 1-12,16-26)(Units built before July 1, 1999)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing7 3233698 1 Pinion, Input8 3233541 1 Bushing9 3233319 1 Seal, Oil10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug, Oil Fill13 7080409 1 Clamp14 8450003-1525 AR Fuel Line

15 7080307 1 Clamp, Hose16 3233524 1 Tube, Vent17 3233696 1 Gearcase, Front Housing18 3233710

32336943233695

SubAsm., Output ShaftShaft, OutputGear, 29T

19 3233020 1 Bearing, Ball20 3233554 AR Shim21 3233693 1 O-Ring22 3233692 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233702 1 Button, Thrust25 3233254 1 Washer26 3233253 1 Plug, Drain27 7552603 4 Washer, Lock28 7512492 4 Screw

FRONT HOUSINGScrambler 400 A00BG38CA

Units built after July 1, 1999

9 1011

1920 21

1341323 1 Asm., Front Gearcase (Incl. 1-12,16-26)(Units built after July 1, 1999)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing7 3233726 1 Pinion, Input, 14T8 3233541 1 Bushing9 3233319 1 Seal, Oil10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug13 7080409 1 Clamp

14 8450003-1525 AR Line, Fuel15 7080307 1 Clamp, Hose16 3233524 1 Tube, Vent17 3233696 1 Gearcase, Front Housing18 3233725 1 Shaft, Output, 29T19 3233020 1 Bearing, Ball20 3233554 AR Shim21 3233693 1 O-Ring22 3233724 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233582 1 Button, Thrust25 3233254 1 Washer26 3233253 1 Plug, Drain27 7552603 4 Washer, Lock28 7512492 4 Screw

CV JOINT - NEAPCOScrambler 400 A00BG38CA

Brand Designated

1 ------ -- -- -- -- 1 Asm., Drive Shaft, Splined2 5222299 1 Sleeve, Drive Shaft Seal3 3260121 1 Clamp, Band4 7670092 1 Circlip5 2201015 1 Kit - Boot Replacement6 1380060 1 Shaft Replacement (Incl. 4)7 1380061 1 Cardan Replacement (Incl. 4,6,8,9)

8 3260104 1 Kit - Cross and Bearing9 3260101 1 Yoke, Splined10 7661913 3 Pin, Spring11 3260123 1 Clamp, Band12 2200960 2 Kit - Drive Shaft Asm. w/Sleeve,

Neapco

FRONT STRUTScrambler 400 A00BG38CA

1 5411608 2 Bumper, Strut2 7041762 2 Strut, Front, Sachs3 5211115 2 Washer4 7080573 2 Clamp, Rubber Coated5 7558402 10 Washer6 7542303 4 Nut, FLEXLOC7 7512365 4 Screw8 7552901 4 Washer, Spring Lock9 5810439 2 Retainer, Strut Casting Wire10 ------ -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B8 for Details)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 22013112201312

Asm., Hubstrut, LH (Incl. 9,13-16)Asm., Hubstrut, RH (Incl. 9,13-16)

17 7041603-067 2 Spring18 5243364 2 Retainer, Spring19 5432871 2 Ball, Pivot, Bottom20 7515339 4 Screw21 5132062 2 Spacer22 ------ -- -- -- -- 1 Asm., Drive Shaft w/Sleeve (See CV

Joint - Neapco Pg. B5, Ref. 12)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, Nylok28 7052028 2 Grommet

FRONT WHEELScrambler 400 A00BG38CA

DETAIL A

1 7512325 8 Screw2 5211869 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Asm., Clutch, Front Hub, E/M6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515523 8 Stud9 1520243 2 Asm., Hub, 4WD (Incl. 3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter13 1321814 2 Spacer

14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5411264 2 Tire (23x7-10)17 7556004 2 Washer18 7661401 2 Pin, Cotter19 5410470 2 O-Ring20 5432611 2 Cap, Hub21 7512027 6 Screw22 7542810 2 Nut23 7542459 8 Nut, Flange Lock24 1520207-117 2 Rim, Front25 1525017 2 Valve, Rim

FRONT BRAKEScrambler 400 A00BG38CA

1910271

1910264

Asm., Front Brake Caliper, LH(Incl. 1-7)Asm., Front Brake Caliper, RH(Incl. 1-7)

1930642 1 Kit - Front Brake Boot (Incl. 8,12)1 7080352 2 Screw, Bleeder2 7515489 2 Screw, Socket Set3 5131115

513111611

Caliper, Brake, LHCaliper, Brake, RH

4 1930665 1 Kit - Piston and Seals (Incl. 5-7)5 5410779 1 Ring, Square, Molded (.094)6 5410780 1 Ring, Square, Molded (.103 x .134)7 5132294 1 Piston, Brake, Long

8 5410494 1 Boot, Pin Seal9 ------ -- -- -- -- 4 Washer, Flat

(See Front Strut Pg. B6 Ref. 5)10 ------ -- -- -- -- 4 Washer, Lock

(See Front Strut Pg. B6 Ref. 8)11 ------ -- -- -- -- 4 Screw

(See Front Strut Pg. B6, Ref. 7)12 5410495 1 Boot, Bushing13 1910412 2 Mount, Caliper14 2200901

22011492200465

Kit - Severe Duty Brake Pad, Front(Complete set of 2 pads)Kit - Brake Pad, Soft, FrontKit - Brake Pad, Front

A - ARM/STRUT MOUNTINGScrambler 400 A00BG38CA

1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820805 2 Asm., Tie Rod (Incl. 5-10)4 7517674 2 Bolt5 5411291 2 Boot, Seal, Rod End6 7061034 2 Rod End, RH7 7542711 2 Nut8 5020926 2 Tie Rod9 7547028 2 Nut, LH10 7061054 2 Rod End, LH11 5411920 2 Boot, Seal, Rod End12 7556099 4 Washer13 7546904 2 Nut14 7661203 4 Pin, Cotter15 ------ -- -- -- -- 1 Asm., Hubstrut

(See Front Strut Pg. B6, Ref. 16)16 7080927 2 Joint, Ball

17 5211121 2 Bracket, Ball Joint18 7512284 4 Screw19 5410548 2 Boot, Rubber20 7542438 2 Nut21 7512084 4 Screw22 5431150

543114911

Shield, CV Joint, LHShield, CV Joint, RH

23 5431596 4 Bushing, A-Arm, Long24 5020677 4 Bushing25 5020681 2 Shaft, A-Arm26 2201611

220161211

Kit - A-Frame, LHKit - A-Frame, RH

27 7080433 2 Fitting, Lubrication28 7552603 4 Washer, Spring Lock29 7512492 4 Screw30 7517527 1 Screw31 7515415 1 Screw

HANDLEBAR/HEADLIGHTScrambler 400 A00BG38CA

141316

2200774 1 Kit - Handlebar Block (Incl. 3,16,22)1 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B12, Ref. 3)2 1820594-067 1 Handlebar3 7515189 4 Screw4 5521181 1 Pad, Handlebar5 2690149 1 Cover, Pad, Handlebar6 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls - Master Cylinder/BrakeLine Pg. B13, Ref. 1)

7 5432926 1 Spacer, Switch, LH8 4010191 1 Switch, Handlebar, Hi/Lo/Off9 7517625 1 Screw, Set10 5432952 1 Plug, Hole

11 5431030 2 Grip, Handlebar12 7080138 3 Cable Tie13 7542324 2 Nut, Nylok14 7558402 2 Washer15 7558301 2 Washer16 7542122 6 Nut, Nylok17 5241973-067 1 Bracket, Headlight18 7080631 2 Clip, Cable Retaining19 2431016

403006122

HeadlightBulb, Headlamp

20 1040579-067 1 Guard, Headlight21 7512111 2 Screw22 5630616-067 2 Block, Handlebar Retainer

STEERING POSTScrambler 400 A00BG38CA

1 1843051 1 Asm., Steering Post (Incl. 12,13)2 5433415 1 Bushing, Steering Console3 7080510 1 Fitting, Zerk, 90 Degree4 7515321 2 Screw5 7555878 3 Washer6 5410772 2 O-Ring7 5431571 1 Spacer, Steering Post8 7543203 1 Nut

9 7661633 1 Pin, Cotter10 5431570 1 Bushing, Steering, Lower11 7661632 2 Rivet12 5431574 1 Plug, Grease, Steering13 7080433 1 Fitting, Lubrication14 5433416 1 Bushing, Steering, Upper15 5222999-067 1 Bracket, Upper Steering Bushing16 7542324 2 Nut, Nylok

CONTROLS - THROTTLE ASM./CABLEScrambler 400 A00BG38CA

1 5433806 1 Cover, Throttle Control2 5411439 1 O-Ring3 2010188 1 Asm., Throttle Control (Incl. 1-4)4 2010191 1 Asm., Throttle Clamp

5 7556047 1 Washer, Sealing, Cable End6 7080708 1 Cable, Throttle7 5410193 1 O-Ring

CONTROLS - MASTER CYLINDER/BRAKE LINEScrambler 400 A00BG38CA

2425 16

1 2200809

2050073

Kit - Master Cylinder Reservoir(Incl. 2,3,4,14)Asm., Master Cylinder (Incl. 1-14)

2 1930797 2 Bolt, Cap3 1930796 1 Cap, Reservoir4 1930795 1 Diaphragm5 2200808 1 Kit - Clamp6 1930799 1 Asm., Piston, Master Cylinder7 1930804 1 Rivet8 2201034 1 Kit - Brake Lever w/Park Brake Latch

(Incl. 7, 9,11)9 ------ -- -- -- -- 1 Spring, Flat10 1930806 1 Nut11 2201090 1 Kit - Park Brake Lever (Incl. 7,9)12 1930792 2 Screw, Reservoir

13 1930805 1 Screw14 ------ -- -- -- -- 1 Ring, Square, Reservoir15 1930762 1 Line w/Fittings, Brake, Upper16 4110164 1 Switch17 1930873 1 Line, Brake, Hand, Rear18 7080539 1 Clamp19 7621462 1 Rivet20 8360031-30 1 Conduit21 1930809 1 Line w/Fittings, Brake, Left Front22 7512024 2 Screw23 8360011-38 1 Conduit24 1930812 1 Line w/Fittings, Brake Right Front25 7052194 1 Fitting, Cross

DRIVE CLUTCHScrambler 400 A00BG38CA

1 23 4

1 7512176 6 Screw2 7552801 6 Washer, Spring Lock3 3576510 1 Cover, Bearing4 7041132 1 Spring, Clutch5 5430945 6 Washer, Multilube6 1321457 3 Roller and Bushing7 5431936 6 Button, Clutch, Stemless8 5210752

524298152107535210754

ARARARAR

Spacer (.020)Spacer (.025)Spacer (.032)Spacer (.050)

9 5630509 3 Weight, Shift (S-55)10 7512266 3 Bolt, Shoulder11 7541906 3 Nut, FLEXLOC12 3576504 1 Bearing, Moveable, 1/2”13 5020422 3 Pin, Roller14 1321632 1 Clutch, Drive (Incl. All Less 4,9)

DRIVEN CLUTCHScrambler 400 A00BG38CA

1 5010266 1 Spacer, Driven Clutch2 7556401 AR Bushing3 3211077 1 Belt, Drive4 1322180 1 Asm., Driven Clutch (Incl. 8-17)5 5220646 1 Washer, Domed6 7552901 1 Washer, Spring Lock7 7515382 1 Screw8 7555898 AR Washer9 7556804 AR Washer

10 7556076 AR Washer11 3514314 1 Bearing12 7041198 1 Spring, Clutch13 5131446 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Screw17 5430766 3 Button, Ramp

GEARCASE MOUNTINGScrambler 400 A00BG38CA

1 7517632 2 Screw2 5242456-067 2 Bracket, Transmission3 7542423 4 Nut, Flange4 7512492 2 Screw5 7555806 4 Washer6 5433109 1 Guide, Chain7 7558301 2 Washer8 7512276 2 Screw

9 7517646 1 Screw10 3221041 1 Sprocket, 13T11 7710434 1 Ring, Retaining12 5210764

52110655211517

ARARAR

Shim (.020)Shim (.010)Shim (.030)

13 7517640 1 Screw

REAR CALIPER MOUNTINGScrambler 400 A00BG38CA

2201385 1 Kit - Rear Caliper Seal1 7517231 2 Screw2 7555806 2 Washer3 1910367

220138522014282201467

Caliper, RearKit - Caliper SealKit - Bleeder ReplacementPiston, Caliper, Rear

4 5410988 4 Seal5 1930873 1 Line, Brake, Hand, Rear6 1910381 1 Line, Brake, Foot, Rear7 4020139 2 Clip, Rosebud8 7670102 2 Clip, Silencer Box

9 1930674 3 Bolt, Banjo10 5131759 1 Bushing, Caliper Mount11 7558402 2 Washer12 7552901 2 Washer, Spring Lock13 7512312 2 Screw14 5131786 1 Mount, Caliper, Lower15 5131787 1 Mount, Caliper, Upper16 7512325 3 Screw17 5242291-067 1 Guard, Brake Disc18 2201189

19103391930860

Kit - Brake Pad (Incl. Spacer and Pin)SpacerPin

REAR BRAKE MASTER CYLINDERScrambler 400 A00BG38CA

1 7080880 1 Clamp2 7542122 3 Nut, Nylok3 5244091-067 1 Bracket, Reservoir4 7512113 3 Bolt5 7512208 1 Screw6 7080003 2 Clamp, Red7 1910404 1 Hose, Reservoir8 1930854 1 Reservoir9 7661401 1 Pin, Cotter10 7555919 2 Washer11 5431107 2 Bushing

12 1910375-067 1 Mount, Brake13 1930674 1 Bolt, Banjo14 5410988 2 Seal15 ------ -- -- -- -- 1 Line, Foot Brake, Rear (See Rear Cal-

iper Mounting Pg. C3, Ref. 6)16 7515179 2 Screw17 1910311 1 Asm., Foot Brake Master Cylinder18 7542324 2 Nut, Nylok19 1910377-067 1 Brake, Foot20 7041750 1 Spring, Torsion21 7512383 2 Screw

REAR WHEELScrambler 400 A00BG38CA

1 7512673 8 Screw2 2200341 2 Kit - Hub, Rear (Incl. 1,4,6,10)3 7547037 8 Nut4 7555796 2 Washer, Cone5 7543005 2 Nut, Castle6 7661404 2 Pin, Cotter

7 5411164 2 Hub, Dust Cover8 7555745 2 Washer, Flat9 1525017 2 Valve, Rim10 7670081 8 Pushnut11 1520204-117 2 Rim, Rear, Aluminum12 5411266 2 Tire (22x11-10)

REAR HOUSINGScrambler 400 A00BG38CA

1 7710472 2 Ring, Retaining2 5510313 2 Retainer, Nut3 7542439 11 Nut, Nylok4 5411555 2 Seal, Foam5 5211849 1 Disc, Brake6 7515513 6 Stud7 1520259 1 Hub, Brake (Incl. 6)8 7710496 1 Ring, Retaining9 5010462 1 Spacer, Axle10 5410889 2 O-Ring11 3610070 2 Seal12 3554518 2 Bearing, Cone, Tapered

13 3554517 2 Bearing, Cup, Tapered14 5132098 1 Housing, Axle, Rear15 7080306 1 Fitting, Lubrication16 3225027 1 Link, Connector17 5020944 1 Axle, Rear18 5211585-067 1 Guard, Sprocket19 7547108 3 Nut, Flange Lock20 5630586 1 Spacer21 3221111-076 1 Chain, 520 ORD, O-Ring22 3222109 1 Sprocket, 36T23 7512404 3 Screw24 1520258 1 Asm., Hub, Sprocket (Incl. 6)

CLUTCH COVERScrambler 400 A00BG38CA

1 7547067 2 Nutsert2 5242208-067 1 Bracket, Clutch Cover3 5411554 1 Seal, Clutch Cover, Inner4 7555748 3 Washer5 7517542 3 Screw6 5521301 1 Seal, Clutch Cover7 5433542 1 Cover, Clutch8 7670051 1 Clip, Clutch Cover9 7512093 5 Screw10 7074946 1 Decal - Clutch Cover11 7077377 1 Decal - Eng./Clutch Modification12 7074782 1 Decal - Automatic Transmission13 7512094 2 Screw14 7080492 2 Cable Tie15 5410421 1 Boot, Clutch Intake16 7512232 3 Screw17 5432615 1 Duct, Air Outlet, Clutch18 5430743 1 Cap, Overflow, Drilled

19 5810279 1 Gasket, Overflow Cap20 5431895 1 Plug, Cap21 7555783 1 Washer22 7512018 1 Screw23 7080511 1 Clamp, Narrow Band24 8450003-1525 AR Line, Fuel25 7052065 1 Fitting, Barbed, 90 Degree26 5433342 1 Duct, Inlet, Clutch27 2201159 1 Kit - Clutch Cover, Inner (Incl. 9,13,31,33)28 7555932 1 Washer29 5242693-067 1 Bracket, Clutch Cover30 7555935 1 Washer31 7512098 1 Screw32 7661638 2 Rivet33 5410575 1 Seal, Cover Case34 5222446-067 1 Bracket, Retainer Seal35 ------ -- -- -- -- 4 Screw and Washer (See Crankcase and

Cylinder Pg. D6, Ref. 48)

SWING ARM/SHOCK MOUNTINGScrambler 400 A00BG38CA

1 7542439 2 Nut, Nylok2 7041865-067 1 Spring, Compression, Small3 7041864-067 1 Spring, Compression4 7075343 1 Decal - Warning, Fox Shock5 1500278 2 Ring, Spring Preload6 5433550 1 Spacer, Spring7 7041867 1 Shock, Gas, Reservoir8 5631045 1 Retainer, Spring9 7515415 1 Screw10 7661046 2 Rivet11 5432727 1 Guide, Pad, Chain12 7080510 2 Fitting, Lubrication13 7547082 1 Nut14 7556035 1 Washer15 5433412 2 Bushing, Swing Arm, RH

16 5131697 2 Bolt, Swing Arm17 5131696 1 Bushing, Pivot, RH18 1541395 1 Asm., Swing Arm (Incl. 12,15,29)19 7078572 1 Decal - “Chain Free Play”20 5432854 1 Guard, Chain21 7515304 1 Screw22 5332828 1 Bushing23 7558402 1 Washer24 7542321 1 Nut25 7542503 2 Nut26 7555883 4 Washer27 7512576 2 Screw28 7517761 1 Screw29 5433411 1 Bushing, Swing Arm, LH30 5131695 1 Bushing, Pivot, LH

ELECTRICAL/TAILLIGHTScrambler 400 A00BG38CA

26 2728

252624

1 2460788 1 Harness, Main2 4020149 4 Clip, Rosebud3 7670109 3 Clip, Routing4 7080138 3 Cable Tie5 2434012 1 Breaker, Circuit, 20 AMP6 2201795 1 Kit - Circuit Breaker, 10 AMP7 2432038 1 Light, Tail/Brake (Incl. 8-13)8 7512088 2 Screw9 4032085 1 Lens10 4030043 1 Bulb11 4032086 1 Gasket12 4032087 1 Backing13 7670093 2 Clip, Retainer14 7571602 4 Washer15 7512027 2 Screw16 5810290 3 Pad, Battery17 5431769 1 Cover, Battery18 2200361 2 Kit - Battery Bolt, Short

19 4010095 1 Cable, Battery/Engine20 7010032 2 Hook, Battery Strap21 5410424 1 Strap, Battery Holddown22 5432077 1 Tube, Battery Vent23 4140006 1 Battery24 4010094 1 Cable, Battery/Solenoid25 4010218 1 Cable, Solenoid/Starter26 7541925 4 Nut, Nylok27 7512007 2 Screw28 7512076 1 Screw29 7512024 4 Screw30 4010188 1 Limiter, LR 83-131 4060208 1 Rectifier, Regulator, LR39-132 2620087

54319735811079

Asm.,Tool Box(Incl. Lid Cover and Gasket)Cover, Tool Box LidGasket

33 7512232 2 Screw

AIR BOXScrambler 400 A00BG38CA

1 7542127 3 Nut, Wing2 7558301 4 Washer3 5240424 1 Cover, Air Box4 5810948 1 Gasket, Cover5 5240336 1 Cover, Filter6 5811099 1 Foam, Precleaner, Sleeve7 1253118 1 Filter, Air8 5810966 1 Foil, Air Box9 5432883 1 Box, Air Silencer10 7080483 1 Cable Tie11 7080487 1 Plug, Cap12 7080476 1 Clamp13 8450051-600 AR Line, Fuel14 7555932 2 Washer

15 5411413 1 Boot, Carburetor16 7511881 8 Screw17 7080643 1 Clamp, Notched18 5431698 2 Ventura, Intake19 5410934 1 Boot, Air Silencer20 5811102 1 Foam, Collar21 7080598 1 Strap, Cable22 7515180 2 Screw23 5432607 1 Stand, Filter24 7515150 2 Stud25 7515151 1 Stud26 5811012 1 Seal, Foam, Air Box27 5211804 1 Plate, Air Box

GEARCASEScrambler 400 A00BG38CA

1367 8 9

503449

20 2221

Units built before April 23, 1999

1341285 1 Asm., Gearcase (Incl. 1-62)(Units built before April 23, 1999)

1 3233525 1 Screw2 3233054 2 Washer3 5432856 1 Dampener, Carb Vibration4 3233632 1 Gearcase, LH Mach5 3233018 3 Bearing, Ball6 3233531 1 Shaft, Reverse 33T7 3233012 2 Washer, Thrust8 3233014 1 Bearing, Needle9 3233532 1 Sprocket, 24T10 3233029 1 Ring, Retaining11 3233533 1 Dog, Engagement12 3233010 1 Washer, Thrust13 3233633 1 Fork, Shift High/Rev., Mach14 3233534 1 Bushing, Garlock15 3233535 1 Gear, 30T16 3233176 1 Washer, Thrust17 3233177 1 Ring, Retaining18 3233019 1 Bearing, Ball19 3233033 4 Screw20 3233309 1 Bracket, Interlock21 3233550 1 Spring, Shifting Interlock22 3233308 2 Pin, Interlock23 3233549 1 Shaft, Shift24 3233040 1 Washer25 3233547 1 Bellcrank26 3233055 1 Nut, FLEXLOC27 3233045 1 Ring, Retaining28 3233548 1 O-Ring29 3233616 4 Screw and Washer30 3233635 1 Switch, H/R31 3233325 1 Plug

32 3233324 1 Washer33 3233556 1 Cover, Snorkel34 3233539 11 Screw35 3233555 1 O-Ring36 3233248 3 Seal37 3233554 AR Shim38 3233553 1 Subassembly, Snorkel Gear39 3233552 1 Bushing, Garlock40 3233634 1 Gearcase, RH Mach41 3233037

8360009-6001

ARTube, VentLine, Fuel

42 3233636 1 Decal - Switch43 3233020 3 Bearing, Ball44 3233546 1 Chain, Roller 26P45 3233545 1 Sprocket, 16/26T46 3233544 1 Shaft, Output47 3233543 1 Gear, 96T48 3233537 1 Ring, Retaining49 3233538 1 Sprocket, 14/22T50 3233263 1 Bearing, Cover, Center Drive51 3233306 1 Ring, Retaining52 3233540 1 Shaft, Pinion 13T53 3233541 1 Bushing, Garlock54 3233542 1 Washer, Thrust Button Pinion55 3233043 1 Deflector, Oil56 3233036 1 Chain, Silent57 3233536 1 Shaft, Input58 3233529 2 Pipe, Knock59 3233252 10 Screw60 3233527 1 Bushing, Pivot61 3233448 1 Plug62 3233035 1 Washer

GEARCASEScrambler 400 A00BG38CAUnits built after April 23, 1999

7 89 10

1617 18 19 20

212223

2627 28

424344

45 464748

495051 52

3134 16

1341327 1 Asm., Gearcase (Incl. 1-59)(Units built after April 23, 1999)

1 3233525 1 Screw2 3233054 2 Washer3 3233526 1 Dampener, Carb Vibration4 3233632 1 Gearcase, LH Mach5 3233018 3 Bearing, Ball6 3233717 1 Shaft, Reverse 33T7 3233718 2 Bearing, Needle8 3233719 1 Sprocket, 24T9 3233720 2 Ring, Retaining, E-Ring10 3233721 1 Dog, Engagement11 3233633 1 Fork, Shift High/Rev., Mach12 3233722 1 Gear, 30T13 3233176 1 Washer, Thrust14 3233177 1 Ring, Retaining15 3233019 1 Bearing, Ball16 3233033 4 Screw17 3233309 1 Bracket, Interlock18 3233550 1 Spring, Shifting Interlock19 3233308 2 Pin, Interlock20 3233549 1 Shaft, Shift21 3233040 1 Washer22 3233547 1 Bellcrank23 3233055 1 Nut, FLEXLOC24 3233045 1 Ring, Retaining25 3233548 1 O-Ring26 3233691 4 Screw and Washer27 3233635 1 Switch, H/R28 3233711 1 Plug29 3233324 1 Washer

30 3233556 1 Cover, Snorkel31 3233539 11 Screw32 3233248 3 Seal, Triple Lip33 3233555 1 O-Ring34 3233020 4 Bearing, Ball35 3233554 AR Shim36 3233723 1 Subassembly, Snorkel Gear37 3233552 1 Bushing, Garlock38 3233798 1 Gearcase, RH Mach39 3233037

8360009-6001

ARTube, VentLine, Fuel

40 3233636 1 Decal - Switch41 3233546 1 Chain, Roller 26P42 3233545 1 Sprocket, 16/26T43 3233544 1 Shaft, Output44 3233543 1 Gear, 96T45 3233537 1 Ring, Retaining46 3233538 1 Sprocket, 14/22T47 3233263 1 Bearing, Cover, Center Drive48 3233306 1 Ring, Retaining49 3233540 1 Shaft, Pinion 13T50 3233541 1 Bushing, Garlock51 3233542 1 Washer, Thrust Button Pinion52 3233043 1 Deflector, Oil53 3233036 1 Chain, Silent54 3233536 1 Shaft, Input55 3233529 2 Pipe, Knock56 3233252 10 Screw57 3233527 1 Bushing, Pivot58 3233448 1 Plug59 3233035 1 Washer

GEAR SELECTORScrambler 400 A00BG38CA

1 54110075411006

KnobCover

2 7512024 1 Screw3 5411008 1 Grommet, Gear Shifter4 5243085-067 1 Rod, Gear Selector5 5433103 2 Mount, Gear Selector6 7515133 2 Screw

7 7546707 2 Nut, FLEXLOC8 7061013 1 Rod End, 6mm, LH9 7546702 1 Nut, LH10 5020955 1 Rod, Shift Linkage11 7546701 1 Nut, RH12 7061014 1 Rod End, 6mm, RH13 5131976 2 Spacer, Shifter

FOX SHOCK, GAS, RESERVOIRScrambler 400 A00BG38CA

7041867 1 Shock, Gas, Reservoir1 1500024 1 Wiper, Clear, Outer2 1500025 1 Wiper, Inner3 1500020 1 O-Ring4 1500009 1 Bearing w/DU5 1500021 1 O-Ring6 1500018

150002311

ScrewO-Ring

7 1500006 1 Ring8 1500003 1 O-Ring, Fox End Cap9 1500011 1 Piston, IFP10 1500099 1 Asm., Cap, Reservoir, ATV Fox Shock

(Incl. 11,12,13)11 1500097 1 Ring, Retaining12 1500072

15000191500022

Asm., Air ValveScrewO-Ring

13 1500098 1 O-Ring, ATV Fox Shock14 1500013 1 Eyelet15 1500102 1 Sleeve16 1500103 2 Bushing, Eyelet17 5410987 1 Bumper, Compression18 1500272 1 Shaft19 1500101 1 Cap, Body20 1500017 1 Plate, Top-Out21 1500002 1 Ring, Piston, Fox22 1500015 1 Plate, Back-up23 1500016 1 Nut24 1500004 1 O-Ring, Fox25 5020657 1 Bushing26 1500104 2 Bushing

SHOCK VALVINGScrambler 400 A00BG38CA

Piston

1 1500033 1 Valve, Shock (.90 x .377 x .008)2 1500032 1 Valve, Shock (1.0 x .377 x .008)3 1500031 1 Valve, Shock (1.1 x .377 x .008)4 1500026 1 Valve, Shock (1.25 x .377 x .010)5 1500047 1 Valve, Shock (.80 x .377 x .010)6 1500046 1 Valve, Shock (.90 x .377 x .010)7 1500049 1 Valve, Shock (1.1 x .377 x .006)

8 1500052 1 Valve, Shock (1.3 x .377 x .006)9 1500095 2 Valve, Shock (1.25 x .377 x .012)10 1500060 1 Valve, Shock (1.1 x .377 x .012)11 1500096 1 Valve, Shock (1.0 x .377 x .015)12 1500094 1 Valve, Shock (.90 x .377 x .015)13 1500057 1 Valve, Shock (.80 x .377 x .012)

PISTON and CRANKSHAFTScrambler 400 A00BG38CA

9 10 1112

202117

1 308473730847383084739

Piston Ring (Std.)Piston Ring (0.25mm/.010 O/S)Piston Ring (0.50mm/.020 O/S)

2 3084167 2 Clip, Pin, Piston3 3083838 1 Pin, Piston4 3085886

30858873085888

Piston (Std.)Piston (0.25mm/.010 O/S)Piston (0.50mm/.020 O/S)

5 3084172 1 Balancer6 3086768 1 Plate7 3086769 2 Bolt, Flange8 3080130 2 Key, Woodruff9 3084156 1 Gear, Drive10 3086764 1 Washer, Guide11 3084160 2 O-Ring

12 3086763 2 Collar13 3086762 1 Nut, Slit14 3086767 1 Washer15 3083905 1 Nut, Lock16 3084776

3084149

Asm., Crankshaft(Incl. 16,17,18,20,21,23)Crankshaft 1

17 3084155 2 Spacer, Pin, Crank18 3084154 1 Bearing, End, Large19 3084168 1 Bearing, End, Small20 3084153 1 Rod, Connecting21 3084777 1 Crankshaft 222 3086765

3086766ARAR

Spacer 1 (0.2mm)Spacer 2 (0.3mm)

23 3084152 1 Pin 1, Crank

CRANKCASE and CYLINDERScrambler 400 A00BG38CA

22242526

37383940

CRANKCASE and CYLINDERScrambler 400 A00BG38CA

1 3084731 1 Gasket, Head2 3086755 1 Head, Cylinder (Incl. 6)3 3082758 3 Gasket, Aluminum4 3086744 3 Plug, Drain5 3082910 6 Nut, Flange6 3086756 1 Pipe, Water7 3080285 2 Nut8 3080530 2 Washer9 3086757 1 Gasket, Exhaust10 3085326 2 Stud11 3086746 2 Pipe 1, Elbow12 3082911 4 Nut, Flange13 3086758 1 Bolt, Banjo14 3083894 1 Valve, Check15 3083138 2 Gasket16 3085277 1 Adapter17 3240064 2 Valve18 3240065 2 Stopper19 3240066 6 Screw and Washer20 3086760 1 Gasket, Valve, Reed21 3084147 1 Valve, Reed (Incl. 17-19)22 3240164 1 Stuffer23 3081497 1 Screw24 3083590 3 Clamp25 3086759 6 Bolt, Flange26 3084144 1 Asm., Band (Incl. 23)27 3086749 1 Plug28 3082956 1 Gasket29 3086748 1 Gasket, Case 330 3084128 1 Pipe, Breather

31 3086751 2 Bolt, Flange32 3086747 1 Pipe 2, Elbow33 3086752 1 Bolt, Flange34 3084120 2 Seal, Oil35 3086750 1 Plug36 3083482 1 Gasket, Aluminum37 3086743 2 Bolt, Flange38 3086745 1 Asm., Crankcase 3

(Incl. 11,30,32,34,35,36,40,41)39 3084134 4 Screw, Flange40 3086741 6 Pin, Dowel41 3084131 1 Bearing42 3084733 1 O-Ring43 3086761 1 Oil Gauge44 3086742 3 Bolt, Flange45 3084775 1 Bearing46 3084121 2 Bearing47 3084725 1 Seal, Oil48 3084205 4 Screw and Washer49 3084118 2 Stud50 3084119 2 Stud51 3086740 1 Asm., Crankcase

(Incl. 3,4,34,37,40,44-47,49-52,56)52 3084123 1 Bearing53 3084729 1 Gasket, Cylinder54 3083384 1 Clamp55 3080142 1 Washer56 3084124 2 Bolt, Flange57 3086753 1 Cylinder (Incl. 10,11,58)58 3084138 6 Stud

OIL PUMPScrambler 400 A00BG38CA

1 3084757 3 Bolt and Washer2 3085281 1 Cover, Case, Oil Pump3 3085280 1 Gasket, Case, Oil Pump4 3085520 1 Case, Oil Pump5 3086777 1 Grommet6 3086779 1 Grommet7 3086778 3 Screw and Washer8 3083783 2 Screw and Washer9 3083141 2 Clamp, Hose10 3086776 1 Pipe, Vinyl11 3083120 1 Nut

12 3083121 1 Washer, Spring13 3083445 1 Collar14 3085571 1 Spring and Lever15 3083127 1 O-Ring16 3084195 1 Spacer17 3084196 1 Wheel18 3084197 1 Pin, Spring19 3085285 1 Asm., Oil Pump (Incl. 11-21)20 3084194 1 Washer21 3083125 1 Screw, Air Vent

CARBURETORScrambler 400 A00BG38CA

191817

151413

1 3130184 1 Asm., Top2 3130496 1 Spring, Throttle3 3130027 1 Plate, Throttle4 3130476 1 Needle, Jet (6CEY6-3)5 3130355 1 Packing6 3130494 1 Valve, Throttle (1.5)7 3130199 1 Cap, Plunger8 3130006 1 Spring9 3130328 1 Asm., Plunger10 3130436 1 Spring, Throttle Adjuster11 3130447 1 Washer12 3130009 1 Screw, Throttle Stop13 3130011 1 Adjuster14 3130012 1 Spring, Air Adjuster15 3130066 1 Jet, Pilot (#35)16 3130025 4 Screw

17 3130432 1 Screw, Guide18 3130239 1 O-Ring19 3130126 1 Jet, Main (#230)20 3130443 1 Asm., Float Chamber21 3130430 2 Asm., Float22 3130237 2 Cap23 3130020 1 Gasket24 3130495 1 Valve, Needle (2.5)25 3130018 1 Arm, Float26 3130361 1 Pin, Float27 3130047 1 Packing28 3130709 1 Asm., Carburetor (Incl. 1-31)29 3130596 1 Ring, Main Jet30 3130429 1 Jet, Needle31 3130003 1 E-Ring

RECOIL STARTERScrambler 400 A00BG38CA

1 3083185 1 Spring, Spiral2 3084750 1 Bush3 3086749 1 Plug4 3082956 1 Gasket5 3085651

3085656

Asm., Recoil Starter(Incl. 1,2,5,8-14)Case, Starter

6 3084782 1 Bolt and Washer

7 3086751 8 Bolt, Flange8 3085266 1 Bolt and Washer9 3084744 1 Plate, Friction10 3083379 1 Spring, Friction11 3084822 1 Reel12 3085083 1 Rope13 3083463 1 Spring, Return14 3083378 1 Ratchet

STARTING MOTORScrambler 400 A00BG38CA

1 3085032 1 Cover, Rear2 3083649 2 Nut, Flange3 3084406 1 Brush4 3085392

3085393

Asm., Starting Motor(Incl. 1-5,8-10,12-17,20-24)Asm., Starter(Incl. 1-5,8-10,12-16)

5 3084405 2 Ring, Rubber6 3082758 1 Gasket7 3086782 5 Bolt, Flange8 3085305 1 Cover, Front (Incl. 16)9 3084408 3 O-Ring10 3084407 2 Bolt, Through11 3086780 1 Bracket

12 3083754 1 Washer Set13 3084404 1 Asm., Armature (Incl. 14,15)14 3083934 1 O-Ring15 3083777 1 Bearing16 3083741 1 O-Ring17 3083737 1 Washer, Shaft, Gear18 3085283 1 Gasket, Starter19 3086781 2 Bolt, Flange20 3084409 1 Clip21 3084410 1 Spring, Return22 3085394 1 Asm., Gear Shaft (Incl. 17,20-24)23 3084411 1 Spring, Weight24 3084412 1 Clip

MAGNETOScrambler 400 A00BG38CA

1 3081256 1 Screw and Washer2 3081146 1 Clamp3 3084785

308478611

Asm., Plate (Incl. 1-3,5-7,9-13)Plate, Coil

4 3084766 3 Screw, Flange5 3083422 1 Coil, Exciter6 3083423 2 Screw and Washer7 3084788 1 Stator 18 3084784 1 Flywheel w/Ring Gear9 3081342 2 Screw and Washer

10 3081260 1 Screw and Washer11 3084789 1 Grommet12 3084787 1 Harness, Wire13 3083909 1 Coupler, 3P14 3080077 2 Washer, Spring15 3083073 2 Nut16 4020129 1 Cap, Spark Plug17 3083923 1 Coil, Ignition18 3085521 1 Switch, Magnetic19 3084790 1 CDI System

WATER PUMPScrambler 400 A00BG38CA

1 3084284 1 Switch, Thermostat, 105 Degree2 3084183 1 Bearing3 3084184 1 Seal, Oil4 3084185 1 Seal, Oil5 3086770

308677111

Casing, Water Pump (Incl. 2-7,6)Casing, Water Pump (Incl. 5,7,6)

6 3086772 3 Stud7 3086775 1 Stud

8 3083856 3 Nut, Flange9 3084187 1 Gasket, Casing10 3084186 1 Impeller11 3082206 1 Washer12 3080077 2 Washer, Spring13 3083073 1 Nut14 3086774 2 Clamp, Hose15 3086773 1 Hose, Main

TOOL KITScrambler 400 A00BG38CA

3083675 1 Asm., Tool Kit (Incl. 1-5)1 2682572 1 Pouch, Tool Kit2 3083612 1 Wrench, Box, Special3 3083613 1 Wrench, 10-12 Spanner4 3083843 1 Screwdriver

5 2870725 1 Gauge, Tire Pressure6 5211627 1 Wrench, Spanner7 9915299

991546911

Manual, Owner’s, ’00 ATVSupplement, Owner’s Manual ’00Scrambler 400

PRINTED IN THE USA PARTS MANUAL PN 9915484 and MICROFICHE PN 9916574 3/00

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SCRAMBLER400 Model#A00BG38CA Rev. 02pi54.com/corp/manuals/Parts/9915484r02.pdfDiameter Spider...

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