The 1997 Scrambler 400 4x4 is a robust sport-utility all-terrain vehicle engineered for demanding off-road adventures and utility tasks. As part of the first generation Scrambler line, this model distinguished itself with a liquid-cooled, 398cc two-stroke engine delivering approximately 34-37 horsepower, coupled with a Variable Transmission featuring high and low ranges. Its on-demand 4WD system, independent front suspension, and disc brakes on all wheels provided exceptional traction and control across varied terrains. The Scrambler 400 4x4 was designed to offer a blend of performance, durability, and essential capability, making it a competitive choice in the mid-size ATV market of its era.
This Factory Service Repair Manual provides comprehensive guidance for the maintenance, repair, and adjustment of the 1997 Scrambler 400 4x4. It covers all essential systems, including the engine, fuel, ignition, drivetrain, transmission, suspension, steering, brakes, and electrical components, offering detailed procedures for installation, removal, disassembly, assembly, inspection, and troubleshooting. The manual is intended to assist owners and technicians in ensuring the optimal performance and longevity of the vehicle, detailing everything from basic fluid changes and component checks to more complex diagnostic procedures and repairs, all presented in English.
Chassis Code:
Not specified in product data
Engine Code:
Not specified in product data, presumed to be a 398cc two-stroke
Generation Identifier:
First Generation Scrambler (1995-2002)
Market Position:
The 1997 Polaris Scrambler 400 4x4 was positioned as a capable and versatile sport-utility ATV, targeting riders who demanded robust performance and 4x4 capability for trail riding, utility tasks, and recreational off-roading. It competed with models from Yamaha, Suzuki, and Honda in the mid-size sport ATV segment.
Competitive Analysis:
Against its peers, the Scrambler 400 4x4 offered a strong two-stroke engine with good power delivery, a proven 4x4 system, and a comfortable rider position. Its reputation for durability and accessible parts made it a popular choice.
Key Features:
Liquid-cooled 2-stroke engine, Polaris Variable Transmission (PVT) with High/Low range, Shaft drive with 4WD engagement, Independent Front Suspension (IFS) with MacPherson struts, Swingarm Rear Suspension, Disc Brakes on all wheels, Electric Start.
Coverage Areas:
Comprehensive repair, maintenance, and adjustment procedures for the 1997 Polaris Scrambler 400 4x4.
Page Count:
Not specified in product data, but typical for a factory service manual of this era.
Manual Type:
Factory Service Repair Manual
Systems Covered:
Engine, Fuel System, Ignition System, Exhaust System, Cooling System, Drivetrain (including 4x4 engagement), Transmission, Clutch, Suspension (Front & Rear), Steering, Brakes (Front & Rear), Electrical System (including wiring diagrams), Bodywork, Chassis, Bearings, Seals, General Maintenance, Troubleshooting.
Procedures Included:
Installation, Removal, Disassembly, Assembly, Repair, Adjustment, Inspection, Lubrication, Troubleshooting, Diagnostic procedures, Torque specifications, Component testing.
Technical Depth:
Extensive. Covers everything from basic maintenance checks and fluid changes to complex engine rebuilds, transmission overhauls, and electrical system diagnostics. Designed for both professional mechanics and experienced DIY enthusiasts.
File Format:
PDF (Portable Document Format). Typically searchable text and high-resolution diagrams.
Print Quality:
Designed for high-quality printing, with clear diagrams and legible text. Reproduction quality will depend on the source PDF.
Binding Type:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
2-stroke, Liquid-cooled
Displacement:
398cc (24.3 cu. in.)
Bore X Stroke:
Not specified in product data, but typical for a 398cc Polaris engine of this era.
Carburetion:
Single Mikuni VM34 or similar.
Horsepower:
Approx. 34-37 HP (estimated for the era).
Torque:
Not specified in product data, but designed for strong low-end grunt.
Fuel Type:
Unleaded gasoline (typically 87 octane or higher).
Fuel Tank Capacity:
Approximately 3.2 US gallons (12.1 L).
Oil Mixture:
Pre-mix or Autolube system (refer to manual for specific requirements).
Transmission Type:
Polaris Variable Transmission (PVT) with High (H), Low (L), Neutral (N), and Reverse (R) gears.
Optional Transmission:
None.
Drive System:
Shaft Drive, On-Demand 4WD System.
Clutch Type:
Automatic CVT with primary and secondary drive/driven clutches.
Gear Ratios:
Not specified in product data, but designed for a balance of acceleration and top speed.
Length:
Approximately 74.0 inches (188 cm).
Width:
Approximately 46.0 inches (116.8 cm).
Height:
Approximately 45.0 inches (114.3 cm).
Wheelbase:
Approximately 48.5 inches (123.2 cm).
Ground Clearance:
Approximately 9.0 inches (22.9 cm).
Dry Weight:
Approximately 503 lbs (228 kg).
Towing Capacity:
Not rated for towing.
Rack Capacity Front:
Not specified.
Rack Capacity Rear:
Not specified.
Safety Ratings:
ATVs are not subject to the same automotive safety ratings (e.g., NHTSA, IIHS). Operator safety is paramount.
Active Safety Features:
On-Demand 4WD for enhanced traction, Disc brakes for stopping power.
Passive Safety Features:
Ergonomically designed handlebars and controls, footwells for rider stability.
Operator Guidance:
The manual will contain crucial safety warnings and recommendations for safe operation, including the use of protective gear (helmet, goggles, gloves, boots, long pants, long-sleeved shirt) and adherence to trail regulations.
Infotainment System:
N/A - This is a utilitarian ATV from the 1990s, focused on function over creature comforts.
Driver Assistance Features:
N/A - No electronic driver assistance systems were common on ATVs of this era.
Connectivity Features:
N/A
Lighting System:
Dual halogen headlights, taillight/stoplight.
Initial Service:
Check oil levels, chain tension (if applicable), tire pressure, and fasteners after initial break-in period (refer to manual for specific mileage/hours).
Engine Oil Change:
Refer to manual for specific intervals, typically based on hours of operation or mileage. Common interval around 50-100 hours or annually.
Air Filter Cleaning:
Frequent checks and cleaning/replacement recommended, especially in dusty conditions. Typically every 20-40 hours of operation.
Spark Plug Replacement:
Refer to manual for recommended intervals. Typically every 50-100 hours or annually.
Transmission Fluid Change:
Refer to manual for specific intervals. Typically checked for level and condition periodically, with changes recommended annually or based on hours.
Engine Oil Type:
2-stroke synthetic blend oil meeting specific API TC or JASO FD standards (refer to manual for exact specification).
Transmission Fluid Type:
Polaris recommended synthetic gearcase lubricant or equivalent (e.g., 75W-90 GL-5).
Coolant Type:
Ethylene glycol based antifreeze/coolant (typically a 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for specific requirement).
Known Issues:
Potential for exhaust port carbon buildup in 2-stroke engines requiring decarbonization, wear on CVT belt and clutches, front suspension components (bushings, ball joints) due to off-road use, electrical connectors can corrode, rear shock absorber leaks.
Common Repairs:
Carburetor cleaning and adjustment, exhaust system maintenance, suspension bushing replacement, brake caliper service, starter motor troubleshooting.
Diagnostic Tools Needed:
Basic hand tools, torque wrench, feeler gauges, multimeter for electrical checks, compression tester. Advanced diagnostics may require specialized Polaris tools mentioned in the manual.
Brand Heritage:
Polaris, founded in 1954, has a long history of innovation in the powersports industry, initially known for snowmobiles before expanding into ATVs and other recreational vehicles. Their focus on performance and off-road capability has been a hallmark of the brand.
Model Evolution:
The Scrambler line was Polaris's entry into the sport-utility ATV market. The 400 4x4 model was a significant iteration, building on previous designs and incorporating features like liquid cooling and the robust 4-wheel-drive system that defined many Polaris models. It evolved through various engine sizes and chassis updates until the early 2000s.
Production Period:
1995-2002 for the first generation Scrambler, with the 400 4x4 being a prominent variant within this period.
Manufacturing Location:
Typically manufactured in the United States by Polaris Industries.
Recognitions:
While specific awards for the 1997 model are not readily available, the Polaris Scrambler series was generally well-regarded for its performance and capability in its class during the late 1990s.
