1996-1998 Polaris Scrambler 400 400L & 500 Service Repair Workshop Manual

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This workshop service and repair manual covers the Scrambler 400, 400L, and 500 All-Terrain Vehicles (ATVs) manufactured between 1996 and 1998. These 4X4 models are known for their capable engine...

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Tipo: Atv

Proveedor:

SKU: 74404

Etiquetas: 1996 1997 1998 ATV Polaris Powersports Scrambler 400 Scrambler 400L Scrambler 500 Xplorer Models

Variantes de producto

Descripción

This workshop service and repair manual covers the Scrambler 400, 400L, and 500 All-Terrain Vehicles (ATVs) manufactured between 1996 and 1998. These 4X4 models are known for their capable engine options, including 2-stroke 398 cc and 4-stroke 499 cc variants, and feature independent front suspension, a durable chassis, and signature automatic transmission. Positioned as versatile off-road vehicles, the Scrambler series offered a compelling blend of performance and utility for trail riding and recreational activities, competing effectively within the powersports market of its era. This manual provides comprehensive guidance for maintaining and repairing your Scrambler. It details procedures for all major systems, including the engine, fuel, suspension, PVT, final drive, transmission, brakes, and electrical components. You will find step-by-step instructions for repairs, rebuilds, diagnostics, and routine maintenance, along with essential technical specifications and wiring schematics. This resource is designed to empower owners, mechanics, and technicians with the knowledge required to keep these ATVs in optimal working condition.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Scrambler

Model Variant:

400, 400L, 500

Model Years Covered:

1996, 1997, 1998

Vehicle Type:

All-Terrain Vehicle (ATV)

Drive Type:

4X4 (All-Wheel Drive)

👋 Introduction

Market Position

Market Position:

Polaris Scrambler ATVs were positioned as capable, sporty, and versatile off-road vehicles, suitable for trail riding, utility tasks, and recreational use. This manual caters to owners and technicians seeking to maintain and repair these models.

Competitive Analysis

Competitive Analysis:

During the mid-to-late 1990s, Polaris competed with brands like Yamaha (Grizzly, Kodiak), Suzuki (King Quad), Kawasaki (Bayou, Prairie), and Honda (FourTrax) in the ATV market. The Scrambler 400/500 offered a blend of performance and 4x4 capability.

Key Features

Key Features:

4WD capability, capable engine options (2-stroke 400/400L, 4-stroke 500), independent front suspension (on many models), durable chassis, and Polaris's PVT (Polaris Variable Transmission) system.

Product Value

Product Value:

This comprehensive workshop manual is an indispensable tool for owners and mechanics, offering detailed instructions and diagrams to ensure the proper maintenance, repair, and longevity of the Polaris Scrambler 400/500 ATVs.

📋 Manual Details

Coverage Areas

Models Covered:

1996 Polaris Scrambler 400 4X4, 1997 Polaris Scrambler 400 4x4, 1997 Polaris Scrambler 400L 4x4, 1997 Polaris Scrambler 500, 1998 Polaris Scrambler 400 4x4, 1998 Polaris Scrambler 400L 4x4, 1998 Polaris Scrambler 500

Years Covered:

1996-1998

Page Count

Page Count:

Not Specified (typically extensive for a full workshop manual)

Manual Type

Manual Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Systems Covered:

General Information, Maintenance, Engine, Fuel System, Body / Suspension, PVT / System, Final Drive, Transmission, Brakes, Electrical, Wiring Schematics

Suspension Details:

Front and rear suspension system inspection, adjustment, and repair (e.g., shock absorbers, control arms, bushings).

Electrical Details:

Wiring diagrams, component testing, lighting system, ignition system, charging system, starter system.

Procedures Included

Procedures Included:

Repair, Maintenance, Rebuild, Refurbish, Restoration, Diagnostic procedures, Step-by-step instructions

Engine Rebuild:

Complete engine disassembly, cleaning, inspection, component replacement (pistons, rings, valves, seals), and reassembly procedures.

Brake System Service:

Brake pad replacement, caliper service, master cylinder overhaul, brake fluid flush and bleeding procedures.

Pvt System Service:

PVT belt inspection, replacement, clutch disassembly, cleaning, and adjustment procedures.

Technical Depth

Technical Depth:

Comprehensive (from basic maintenance to complete overhaul and diagnostics)

Diagnostic Troubleshooting:

Systematic troubleshooting guides and flowcharts for identifying and resolving common and uncommon issues across all vehicle systems.

📊 Manual Specifications

File Format

File Format:

Compatibility:

All Versions of Windows & Mac

Searchable Text:

Typically PDF format allows for text searching of keywords, enhancing usability.

Print Quality

Print Quality:

Printable (all pages)

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine 400

Engine Type 400:

2-stroke, liquid-cooled, single-cylinder

Displacement 400:

398 cc

Primary Engine 500

Engine Type 500:

4-stroke, liquid-cooled, single-cylinder (OHC)

Displacement 500:

499 cc

Fuel System

Fuel System 400:

Carbureted (e.g., Mikuni VM34SS for 400)

Fuel System 500:

Carbureted (e.g., Keihin CVK40 for 500)

Performance

Ignition Type:

CDI (Capacitor Discharge Ignition)

Cooling System:

Liquid-Cooled

🔧 Transmission

Transmission Type

Transmission Type:

Polaris Variable Transmission (PVT) Automatic

Gear Selection:

High, Low, Neutral, Reverse

Features

Drive System:

Shaft Drive (to front and rear differentials)

📐 Dimensions

Exterior

Length:

Approx. 78-80 inches (model dependent)

Width:

Approx. 46 inches (model dependent)

Height:

Approx. 45-47 inches (model dependent)

Weights

Dry Weight:

Approx. 550-600 lbs (model dependent)

Towing Capacity:

Typically around 1500 lbs (refer to manual for exact specification)

Ground Clearance:

Approx. 9-10 inches (model dependent)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (ATVs are not subject to the same formal crash safety ratings as passenger vehicles)

Active Features

Active Features:

4WD system, engine braking (via PVT), hydraulic disc brakes

Passive Features

Passive Features:

Handlebar controls for throttle and braking, footwells for rider stability

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic ATV instrumentation)

Driver Assistance

Driver Assistance:

Connectivity

Connectivity:

Instrumentation

Instrumentation:

Speedometer, odometer, neutral indicator, high beam indicator, oil/temp warning lights (model dependent)

🔧 Maintenance

Service Intervals

Service Intervals:

Refer to manual for specific intervals (e.g., oil changes, filter replacements, spark plug checks, belt inspections). Typical intervals would include: 100-hour or annual checks for general maintenance, specific mileage/hour intervals for major component inspections.

Fluid Specifications

Engine Oil 400:

2-stroke oil (pre-mix or injection, refer to manual for specific type and ratio)

Engine Oil 500:

SAE 10W-40 or 20W-50 API SG or higher (refer to manual for specific viscosity and API rating)

Coolant:

Ethylene Glycol based antifreeze/coolant (typically 50/50 mix with distilled water)

Gearcase Oil:

Hypoid gear oil (e.g., SAE 80W-90 GL-4 or GL-5, refer to manual for exact specification)

Known Issues

Known Issues:

Common issues on ATVs of this era can include carburetor tuning, PVT belt wear, starter motor issues, suspension component wear, and fuel system cleaning. This manual will address all these potential problems.

Filter Part Numbers

Air Filter Part Number:

Varies by model year and specific application (refer to manual for exact Polaris part number)

Oil Filter Part Number:

N/A for 2-stroke 400; Varies for 4-stroke 500 (refer to manual for exact Polaris part number)

Tune Up

Tune Up Procedures:

Includes spark plug replacement/gap adjustment, carburetor cleaning/adjustment, air filter service, and general inspection of all systems.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Polaris has a long history in motorsports and powersports, originating in the snowmobile industry. They expanded into ATVs in the late 1980s and early 1990s, quickly becoming a major player with innovative designs and powerful engines.

Model Evolution

Model Evolution:

The Scrambler line was introduced as a sportier, higher-performance ATV compared to utility-focused models like the Sportsman. The 400 and 500 engines provided a good balance of power for trail riding and recreational use. The 400L designation likely indicates a variant or slight update to the 400 engine.

Production

Production Period:

The Scrambler 400 and 500 models were produced through the late 1990s and into the early 2000s, with variations and updates throughout their lifecycle.

🏆 Awards & Recognition

Recognitions

Recognitions:

Specific awards for the 1996-1998 Scrambler models are not widely publicized in the same way as automotive awards. However, Polaris ATVs of this era were generally well-regarded for their performance and 4x4 capabilities in their class.