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1999-2000 Polaris Scrambler 400 500 4x2 4x4 ATV Repair Manual

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The Polaris Scrambler, offered in 400 and 500cc engine variants, represents a significant entry in the sport All-Terrain Vehicle (ATV) market from the late 1990s and early 2000s. These performance-oriented...
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1999-2000 Polaris Scrambler 400 500 4x2 4x4 ATV Repair Manual1999-2000 Polaris Scrambler 400 500 4x2 4x4 ATV Repair Manual1999-2000 Polaris Scrambler 400 500 4x2 4x4 ATV Repair Manual1999-2000 Polaris Scrambler 400 500 4x2 4x4 ATV Repair Manual
The Polaris Scrambler, offered in 400 and 500cc engine variants, represents a significant entry in the sport All-Terrain Vehicle (ATV) market from the late 1990s and early 2000s. These performance-oriented ATVs were engineered to provide versatility and power, featuring both 2-wheel drive and 4-wheel drive configurations to tackle a variety of terrains. With their sport-tuned suspension and robust engine performance for their era, the Scrambler models were designed to deliver an engaging riding experience, competing with other prominent brands in the performance ATV segment. This comprehensive manual serves as an essential guide for owners and technicians alike, covering all aspects of the 1999 and 2000 Scrambler 400 and 500 models. It details routine maintenance procedures, in-depth engine repair, fuel and cooling systems, transmission, steering, brakes, and the electrical system. The manual provides clear instructions for repairs, parts lookup, and advanced troubleshooting, ensuring that users can effectively maintain, diagnose, and repair their vehicles to keep them in optimal working condition.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Scrambler
Model Variant:
400, 500
Model Years:
1999, 2000
Vehicle Type:
All-Terrain Vehicle (ATV)
Drivetrain:
2WD (4x2) and 4WD (4x4) variants
👋 Introduction
Market Position
Market Segment:
Performance-oriented sport ATVs
Key Features
Primary Selling Points:
Versatility (400/500cc engines, 2WD/4WD), sport-tuned suspension, powerful engine performance for its era
Competitive Analysis
Competitors:
Yamaha Wolverine, Suzuki QuadRunner, Honda FourTrax, Kawasaki Bayou/Prairie (depending on specific configurations)
📋 Manual Details
Coverage
Coverage Areas:
All versions of 1999 Polaris Scrambler 400/500 ATVs; 2000 Polaris Scrambler 400 4x2, 400 4x4, and 500 ATVs
Type
Manual Type:
Repair Manual, Owner's Manual, Parts Catalog (implied)
Format
Format:
Electronic Downloadable PDF
Language
Language:
English (assumed based on typical product offerings)
Accessibility
Delivery:
Instant download after payment
📖 Manual Coverage
Systems
Systems Covered:
General Information, Routine Maintenance, Engine Removal & Installation, Fuel System, Lubrication & Cooling System, Engine Specifications, Transmission, Drive Chain & Sprockets, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting
Procedures
Procedures Included:
Repair procedures, parts lookup, routine maintenance, diagnostic troubleshooting
Depth
Technical Depth:
Comprehensive, suitable for performing repairs, maintenance, and diagnostics
📊 Manual Specifications
File Format
File Format:
PDF
Features
Searchable Text:
Implied, standard for quality PDF manuals
Printability:
Printable pages for workshop use
Support
Lifetime Policy:
Lifetime protection policy against loss or damage
⚙️ Engine Specifications
Scrambler 400
Primary Engine:
375cc liquid-cooled, 2-stroke, single-cylinder engine
Fuel System:
Carburetor (e.g., Mikuni VM36/38 series, specific to model year)
Ignition:
CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid-cooled
Scrambler 500
Primary Engine:
499cc liquid-cooled, 4-stroke, single-cylinder engine
Fuel System:
Carburetor (e.g., Mikuni BSR series, specific to model year)
Ignition:
CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid-cooled
Common
Compression Ratio:
Varies by engine (e.g., 6.2:1 for Scrambler 400, 9.0:1 for Scrambler 500 - typical values, manual to confirm)
🔧 Transmission
Drive System
Transmission Type:
Automatic, Polaris Variable Transmission (PVT) with Polaris Demand Drive (for 4x4 models)
Gear Reduction:
High and Low range, Reverse
Drive Chain:
O-ring sealed chain, specific size (e.g., 520) and pitch to be detailed in manual
Final Drive:
Shaft drive with differentials (front on 4x4), sealed chain drive (rear)
📐 Dimensions
Exterior
Length:
Approx. 74.5 inches (189.2 cm) - typical for the era, manual to confirm exact
Width:
Approx. 44.5 inches (113 cm) - typical for the era, manual to confirm exact
Height:
Approx. 45.5 inches (115.6 cm) - typical for the era, manual to confirm exact
Weights
Dry Weight:
Approx. 515-560 lbs (233-254 kg) depending on model/drivetrain - manual to confirm exact
Payload Capacity:
Typically around 200 lbs (90 kg) for racks - manual to confirm exact
Towing Capacity:
Typically around 1,500 lbs (680 kg) with accessory hitch - manual to confirm exact
🛡️ Safety Features
Active Features
Braking System:
Hydraulic disc brakes (front and rear) - specifics on caliper and rotor size in manual
Passive Features
Handlebars:
ATV-style handlebars with thumb throttle and brake levers
Lighting:
Headlights, taillight/brake light
💡 Technology Features
Infotainment
Dashboard Display:
Basic digital/analog display for speedometer, odometer, fuel level, possibly engine hour meter. Specifics in manual.
Driver Assistance
Drive System Engagement:
Polaris Demand Drive system for automatic 4WD engagement on 4x4 models, activated by throttle position and wheel speed sensors. Operation details in manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 20-40 operating hours or annually; specific type and capacity in manual
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions; replacement intervals in manual
Spark Plug Maintenance:
Inspection and replacement intervals specified in manual
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 0W-40 or 10W-40 (for 4-stroke Scrambler 500); 2-stroke oil injection for Scrambler 400 (specific type in manual)
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixture; specific ratio and type in manual
Transmission Fluid:
Refer to manual for specific Polaris PVT fluid or compatible fluid for final drives/gearboxes
Known Issues
Common Wear Items:
CV boots (especially on 4x4 models), drive belts in PVT, brake pads, wheel bearings, throttle cables
Engine Considerations:
2-stroke engine requires proper fuel/oil mixture or oil injection system maintenance for Scrambler 400; 4-stroke 500cc engine generally robust but requires standard maintenance
Electrical Considerations:
Wiring harness integrity, stator/rectifier function, battery health are critical maintenance points
📚 Vehicle History
Brand Heritage
Manufacturer:
Polaris Industries, Inc.
Model Evolution
Predecessors:
Polaris Xplorer series, earlier Polaris ATVs
Market Positioning:
Polaris's push into the sport ATV segment, building on their utility ATV reputation
Production
Manufacturing Location:
USA (Roseau, Minnesota for Polaris)
🏆 Awards & Recognition
Recognitions
Industry Impact:
Polaris Scrambler series contributed to Polaris's growth in the sport ATV market, known for a good balance of power and handling for its time.
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