Polaris Scrambler 400 & Scrambler 500 ATV Complete Workshop Service Repair Manual 1999

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Art.-Nr: 94515

Stichworte: 1999 ATV Misc Polaris Powersports Scrambler 400 Scrambler 500

Produktvarianten

Beschreibung

This manual covers the 1999 Scrambler 400 and 500 All-Terrain Vehicles (ATVs). A respected American manufacturer, has a strong heritage in off-road vehicles, and the Scrambler line represents their commitment to performance and capability in the sport ATV segment. These ATVs are known for their robust engineering, offering a balance of power and handling suitable for various off-road terrains. The Scrambler 400, typically powered by a liquid-cooled, 2-stroke engine, and the Scrambler 500, featuring a liquid-cooled, 4-stroke engine, were designed to provide an exhilarating riding experience. This comprehensive workshop service repair manual in English provides detailed instructions and specifications essential for the maintenance, repair, and troubleshooting of your 1999 Scrambler. It covers all major systems, including the engine, transmission, drivetrain, suspension, steering, braking, and electrical systems. Within its pages, you will find step-by-step procedures for routine maintenance, disassembly and reassembly of components, diagnostic guidance for common issues, and critical technical data such as torque specifications and fluid requirements. This manual is an invaluable resource for owners, DIY mechanics, and professional technicians aiming to ensure the optimal performance and longevity of their ATV.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Scrambler 400 & 500

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Market Position

Target Audience:

Owners, DIY mechanics, and professional service technicians working on 1999 Polaris Scrambler 400 and 500 ATVs.

Competitive Analysis

Value Proposition:

Provides essential information for maintaining, repairing, and troubleshooting the specific ATV models, saving time and money on professional service.

Key Features

Content Focus:

Detailed procedures, diagrams, troubleshooting guides, and specifications tailored to the 1999 models.

📋 Manual Details

Coverage Areas

Manual Scope:

Complete Workshop Service Repair

Page Count

Estimated Page Count:

High (typically 300+ pages for this type of comprehensive manual)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine overhaul, top-end, bottom-end, cooling system, lubrication system, fuel system components (carburetor).

Transmission Drivetrain:

Gearbox, clutch, drive shafts, differential (if applicable), chain/belt drive maintenance and adjustment.

Suspension Steering:

Front and rear suspension systems, shock absorbers, steering mechanism, tie rods, wheel alignment.

Braking System:

Hydraulic brake system, brake fluid, calipers, master cylinder, brake lines, pad and shoe replacement.

Electrical System:

Ignition system, starting system, charging system (stator, regulator/rectifier), lighting, battery, wiring diagrams, troubleshooting.

Chassis Bodywork:

Frame inspection, body panel removal/installation, seat, fenders, handlebars, controls.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, chain lubrication and adjustment, battery care, air filter cleaning/replacement.

Troubleshooting:

Diagnostic procedures for common performance issues, starting problems, electrical faults, and mechanical failures.

Disassembly Reassembly:

Detailed step-by-step instructions for major component removal and installation.

Specifications Data:

Torque values, clearances, fluid capacities, electrical specifications, engine timing.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to in-depth engine rebuilds and electrical diagnostics.

📊 Manual Specifications

File Format

Digital File Format:

PDF (Portable Document Format)

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type 400:

Liquid-cooled, 2-stroke, single-cylinder (likely Polaris's own design or a derivative).

Engine Type 500:

Liquid-cooled, 4-stroke, single-cylinder (likely a Polaris Liberty engine variant).

Performance

Horsepower 400 Approx:

Estimated 30-35 HP

Horsepower 500 Approx:

Estimated 40-45 HP

Fuel System

Carburetion 400:

Mikuni VM Series carburetor (specific model number required from manual).

Fuel Delivery 500:

Carburetor (likely Keihin or Mikuni, specific model number required from manual).

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission) with high/low range and reverse.

Optional

Optional Transmission:

N/A (CVT was standard for this model)

Features

Drive System:

2WD or 4WD (On-Demand) depending on specific sub-model, with shaft drive to front and rear differentials.

📐 Dimensions

Exterior

Length:

Typically around 75-80 inches

Width:

Typically around 46-48 inches

Height:

Typically around 45-48 inches

Weights

Dry Weight Approx:

Around 500-550 lbs

Ground Clearance Approx:

Around 8-10 inches

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adheres to industry safety standards applicable to ATVs for the era.

Active Features

Braking System Type:

Hydraulic disc brakes, front and rear.

Passive Features

Handlebar Design:

Ergonomic handlebar with handguards for protection.

💡 Technology Features

Infotainment

Infotainment System:

Basic controls, no advanced infotainment systems.

Driver Assistance

Driver Assistance:

N/A (ATVs of this era typically lacked advanced driver-assistance features).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 50-100 operating hours or annually (refer to manual for exact intervals and specific oil type).

Gearbox Oil Change:

Typically every 100-200 operating hours or annually (refer to manual for exact intervals).

Air Filter Cleaning:

Recommended every 20-40 operating hours or as needed based on dusty conditions.

Fluid Specifications

Engine Oil Type 400:

2-stroke oil, specific API TC-W3 rated oil recommended (refer to manual for exact viscosity and brand).

Engine Oil Type 500:

SAE 20W-50 or SAE 10W-40 (depending on temperature range), API SG or higher (refer to manual for exact specification).

Gearbox Oil Type:

Polaris Demand Drive Fluid (front differential) or SAE 80W-90 gear oil for rear gearbox (refer to manual).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for exact specification).

Known Issues

Common Wear Items:

Brake pads, suspension bushings, drive belts (CVT), wheel bearings, carburetor jets.

Electrical Gremlins:

Wiring harness issues, stator failures, and regulator/rectifier problems can occur with age and vibration. Detailed troubleshooting is crucial.

Carburetor Maintenance:

Carburetor cleaning and adjustment is often necessary for optimal performance, especially after periods of storage or fuel contamination.

📚 Vehicle History

Brand Heritage

Polaris Atv History:

Polaris is a long-standing American manufacturer known for its off-road vehicles, including ATVs and snowmobiles, with a focus on performance and utility.

Model Evolution

Scrambler Line History:

The Scrambler line was Polaris's performance-oriented ATV, often featuring more powerful engines, sportier suspension, and aggressive styling compared to utility models.

Production

Production Era:

The Scrambler 400 and 500 were popular models in the late 1990s and early 2000s, representing a significant segment of Polaris's sport ATV offerings.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 1999 models may not be readily available, Polaris ATVs generally received positive reviews for performance and capability in their respective classes.