Segment:
Performance-oriented sport ATV.
Target Audience:
Enthusiasts seeking off-road recreation, trail riding, and performance.
Competitors 1996:
Yamaha Warrior, Suzuki QuadSport, Kawasaki Bayou.
Vehicle Features:
2-stroke liquid-cooled engine, 4WD capability, performance-oriented suspension and chassis.
Benefit To Owner:
Empowers owners to perform maintenance, diagnostics, and repairs, saving on labor costs and extending vehicle lifespan.
Usefulness:
Indispensable for DIY mechanics and a valuable reference for professional technicians.
Primary Coverage:
Comprehensive repair and service for the 1996 Polaris Scrambler 400 4X4.
Secondary Coverage:
Maintenance, troubleshooting, adjustments, and component specifications.
Estimated Pages:
Likely 300-500 pages (typical for comprehensive factory service manuals of this era).
Type:
Factory Service Repair Manual
Powertrain:
Engine (top-end, bottom-end, lubrication, cooling), Transmission, Drive System (4x4 engagement, differentials).
Chassis And Suspension:
Front and Rear Suspension (shocks, control arms, bushings), Steering System, Frame and Bodywork.
Brakes:
Hydraulic Brake System (master cylinder, calipers, lines, bleeding procedures).
Electrical System:
Ignition System, Lighting, Charging System (stator, regulator/rectifier), Starter Motor, Battery, Wiring Diagrams, Switches.
Fuel System:
Carburetor (assembly, disassembly, adjustment, jetting), Fuel Pump, Fuel Lines, Fuel Tank.
Cooling System:
Liquid Cooling System (radiator, fan, water pump, thermostat, coolant types and capacities).
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug checks, chain/belt adjustments.
Disassembly And Assembly:
Step-by-step instructions for removing and reinstalling all major components and sub-assemblies.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common performance and operational issues.
Repair And Rebuild:
Detailed instructions for repairing or rebuilding engines, transmissions, carburetors, suspension components, and more.
Adjustments:
Carburetor tuning, brake adjustments, suspension setup, clutch adjustments.
Depth:
Comprehensive, from basic rider maintenance to full engine and drivetrain rebuilds.
Diagnostics:
Includes diagnostic procedures, fault codes (if applicable), and troubleshooting flowcharts.
Specifications:
Provides critical torque values, tolerances, clearances, fluid capacities, and electrical specifications.
File Type:
PDF (Portable Document Format)
Searchability:
Typically includes text-searchable functionality for quick information retrieval.
Quality:
High-resolution scans ensuring clarity of text, diagrams, and illustrations.
Printable:
Designed to be printable for convenient workshop use.
Binding For Print:
Not applicable for PDF; digital access.
Paper Type For Print:
Not applicable for PDF; digital access.
Engine Type:
2-Stroke, Liquid-Cooled, Single Cylinder
Displacement:
340 cc (approximately)
Bore X Stroke:
Refer to manual for exact specifications (e.g., 74mm x 79mm typical for this class).
Cooling System:
Liquid-cooled with radiator and fan.
Horsepower Est:
Likely in the range of 30-35 HP (refer to manual for exact figures).
Torque Est:
Refer to manual for exact specifications.
Carburetor Model:
Likely Mikuni VM series (e.g., VM34 or similar).
Fuel Delivery:
Mechanical Fuel Pump
Fuel Type:
Unleaded Gasoline (refer to manual for octane rating recommendations).
Oil Mixing:
Premix fuel/oil or Autolube system (refer to manual for specifics).
Ignition Type:
CDI (Capacitor Discharge Ignition)
Length:
Refer to manual for exact specifications.
Width:
Refer to manual for exact specifications.
Height:
Refer to manual for exact specifications.
Dry Weight:
Likely around 500-550 lbs (refer to manual for exact figures).
Towing Capacity:
Refer to manual for specifications (often limited on sport ATVs).
Front Tire Size Std:
Refer to manual (typically 22x7-10 or similar).
Rear Tire Size Std:
Refer to manual (typically 22x10-10 or similar).
Wheel Bolt Pattern:
Refer to manual for specifications.
Safety Certifications:
ANSI/SVIA standards compliance (typical for ATVs of this era).
Braking System:
Hydraulic disc brakes front and rear.
Roll Over Protection:
No specific roll cage or ROPS; rider safety relies on proper riding techniques and personal protective equipment (PPE).
Ppe Recommendation:
Helmet, eye protection, gloves, sturdy footwear, and protective clothing are essential (as detailed in the manual).
Engine Oil Change:
Refer to manual for specific hours or mileage; typically every 20-40 operating hours or annually.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (refer to manual).
Spark Plug Replacement:
Refer to manual for recommended interval (e.g., every 100-200 operating hours).
Cv Belt Inspection:
Regular inspection for wear and damage is critical; replacement based on condition.
Engine Oil:
Refer to manual for specific SAE viscosity grade and API service classification (e.g., SAE 10W-40, API SG or higher).
Coolant Type:
Ethylene Glycol based antifreeze/coolant (refer to manual for specific type and mixture ratio).
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid (confirm in manual).
Common Wear Items:
CV joint boots, tie rod ends, wheel bearings, brake pads, control arm bushings, drive belt.
Carburetor Tuning:
Carburetors can be sensitive to altitude and fuel quality; proper jetting and adjustment are key.
Cooling System Performance:
Overheating can occur if the cooling system is not maintained (clean radiator, proper coolant level).
Polaris Heritage:
Polaris is a long-standing American manufacturer of powersports vehicles, known for innovation in snowmobiles and ATVs.
Scrambler Lineage:
The Scrambler line was Polaris's entry into the sport ATV market, emphasizing performance and off-road capability.
Production Era:
The Scrambler 400 was a popular model in the mid-to-late 1990s and early 2000s.
