Market Position:
The Polaris Scrambler 400 was positioned as a capable, mid-size sport-utility ATV, suitable for trail riding and recreational use, competing with models from Yamaha, Suzuki, and Kawasaki in the late 1990s.
Competitive Analysis:
Key competitors for the 1999 Scrambler 400 included the Yamaha Warrior 350, Suzuki Quadsport Z400 (though later, the 300/330 models were contemporaries), and Kawasaki Bayou 400. The Scrambler 400 often differentiated itself with its Polaris long-travel suspension and torquey 2-stroke engine.
Key Features:
High-performance 2-stroke engine, Polaris's proprietary long-travel suspension for superior handling and comfort, reliable drivetrain, and rugged construction for off-road use.
Coverage Overview:
Comprehensive service, maintenance, and troubleshooting for all models, engines, trims, and transmission types of the 1999 Polaris Scrambler 400.
Page Count:
Hundreds of pages (as per product description)
Manual Type:
Workshop Service Repair Manual
Engine:
Engine overhaul, internal components, cooling system, lubrication, ignition system.
Fuel System:
Carburetion, fuel pump, fuel lines, fuel tank servicing.
Drivetrain:
Clutches (primary and secondary), final drive, transmission service, driveshafts, gears.
Chassis:
Frame, bodywork, steering system, suspension (front and rear), shocks, bearings.
Brakes:
Brake system overhaul, hydraulic components, pads, rotors, lines.
Electrical System:
Wiring diagrams, starter, battery, lighting, ignition system, charging system, troubleshooting electrical faults.
General Information:
Includes an overview of the ATV, safety precautions, general maintenance guidelines, and tools required.
Specifications:
Detailed technical specifications, torque values, clearances, and measurements for all components.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, lubrication, spark plug replacement, drive chain adjustment (if applicable).
Repair Procedures:
Step-by-step disassembly, cleaning, inspection, assembly, and reinstallation of all major components.
Troubleshooting:
Diagnostic charts, common problem identification, and solutions for mechanical and electrical issues.
Installation Procedures:
Instructions for installing aftermarket accessories or replacement parts are not explicitly mentioned but may be covered within relevant sections.
Technical Depth:
Comprehensive, covering basic maintenance to advanced diagnostics and complete rebuilds, as used by professional technicians.
Print Quality:
Full Printable, allowing users to print specific sections for workshop use.
Binding Type:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Searchability:
Likely searchable PDF, facilitating quick information retrieval.
Zoom Functionality:
Yes (Zoom IN/OUT capability)
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader, WinZip
Operating Systems:
All Versions of Windows & Mac
Displacement:
398 cc (estimated based on model name)
Bore X Stroke:
Specific details not in product info, but typical for Polaris 400cc 2-stroke
Cooling System:
Liquid-cooled
Power Output:
Estimated 30-35 HP (typical for this class and engine type), specific figures not in product info
Torque Output:
Specific figures not in product info
Fuel Delivery:
Carbureted
Carburetor Type:
Likely Mikuni VM34 or similar, specific details in manual
Fuel Type:
Unleaded gasoline (higher octane recommended for 2-stroke)
Oil Mixture:
Pre-mix or oil injection system, specific details in manual
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Gear Selection:
Forward, Neutral, Reverse
Drive System:
Shaft Drive (to rear differential), likely CV jointed shafts.
Clutch Type:
Centrifugal Clutch (Primary), Drive Clutch (Secondary)
Length:
Specific dimensions not in product info, but typical for a 400cc ATV of the era.
Width:
Specific dimensions not in product info, but typical for a 400cc ATV of the era.
Height:
Specific dimensions not in product info, but typical for a 400cc ATV of the era.
Dry Weight:
Approximately 500-550 lbs (estimated, specific figures not in product info)
Payload Capacity:
Specific figures not in product info
Safety Ratings:
ATVs are not typically crash-tested or rated by organizations like NHTSA. Safety is inherent in design and operator responsibility.
Active Safety:
Powerful braking system, responsive steering, and balanced suspension for stability.
Passive Safety:
Handlebar grips, footwells, and integrated lighting.
Oil Change Interval:
Refer to manual for specific interval (typically every 20-40 hours or annually for gearbox oil).
Spark Plug Replacement:
Refer to manual for specific interval (typically every 100-200 hours or annually).
Air Filter Cleaning Inspection:
Refer to manual for specific interval (frequently, depending on operating conditions).
Engine Oil:
Refer to manual for specific 2-stroke oil recommendation (e.g., Polaris Synthetic 2-Stroke Oil) and pre-mix ratio if applicable. Gearbox oil type is also specified in the manual.
Coolant Type:
Ethylene glycol based antifreeze/coolant (e.g., Polaris Premium All-Season Antifreeze)
Known Issues:
Common issues for vintage 2-stroke ATVs can include carburetor gumming, stator failures, worn primary/secondary clutch rollers, leaks from crank seals, and suspension wear. The manual will detail specific diagnostic and repair procedures for these.
Maintenance Tips:
Regular cleaning of the air filter, proper fuel storage, and ensuring the cooling system is free of debris are crucial for longevity.
Brand Heritage:
Polaris Industries, founded in 1954, is a well-established American manufacturer known for its snowmobiles, ATVs, and later, UTVs and motorcycles. They have a strong reputation for innovation and off-road vehicle development.
Model Evolution:
The Scrambler line was a performance-oriented ATV for Polaris, offering a balance of sport and utility. The 400cc model was a popular choice in its displacement class, evolving from earlier 2-stroke Polaris models.
Production Era:
The 1999 model year is part of the mid-to-late 1990s production run for the Scrambler 400.
