Positioning:
Essential resource for owners and technicians of the 1999 Polaris Scrambler 400, enabling cost-effective maintenance and repairs.
Uniqueness:
Vehicle-specific, factory-level detail not found in generic repair guides.
Accuracy:
Authoritative and accurate information, directly from manufacturer's service data.
Clarity:
Clear, concise text coupled with diagrams and illustrations for easy comprehension.
Cost Savings:
Enables significant savings on maintenance and repair costs by empowering DIY efforts.
Primary Coverage:
Comprehensive service, repair, and troubleshooting for the 1999 Polaris Scrambler 400.
Secondary Coverage:
Maintenance, diagnostics, and technical specifications.
Estimated Page Count:
Likely 300-500 pages (typical for a comprehensive service manual).
Type:
Service Repair Workshop Manual
Engine:
Detailed coverage of engine disassembly, assembly, inspection, and repair.
Fuel System:
Includes carburetor tuning, fuel pump, fuel lines, and fuel tank service.
Cooling System:
Radiator, fan, coolant, and related component service.
Clutches:
Primary and secondary clutch service, including weights, springs, and belt replacement.
Transmission:
Gearbox service, shift mechanism, and internal component inspection.
Final Drive:
Rear differential, driveshafts, and wheel hub service.
Brakes:
Front and rear brake system service, including master cylinders, calipers, pads, and bleeding procedures.
Electrical System:
Ignition system, lighting, charging system, battery service, and component testing.
Wiring Diagrams:
Comprehensive, color-coded wiring schematics for accurate diagnosis.
Steering:
Steering column, tie rods, and knuckle service.
Suspension:
Front and rear suspension components, shocks, and A-arm service.
Body And Frame:
Body panel removal, installation, and frame inspection.
Preventative Maintenance:
Detailed maintenance schedules for oil changes, filter replacements, spark plugs, and chain adjustments.
Troubleshooting:
Step-by-step diagnostic guides for common and uncommon issues.
Repair Procedures:
Complete, detailed instructions for virtually all repair operations.
Rebuilds:
Engine, transmission, and carburetor rebuild procedures included.
Diagnostic Tests:
Specific tests and checks for electrical components, fuel system, and engine performance.
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls.
Target Audience:
Professional mechanics, experienced DIY enthusiasts, and informed owners.
Compatibility:
All Windows versions, Mac OS X.
Printability:
Fully printable, allowing users to print specific pages as needed.
Binding:
Digital (PDF), so no physical binding.
Paper Type For Printing:
Standard printer paper is suitable for printing.
Searchability:
Text is generally searchable within a PDF reader, aiding quick information retrieval.
Engine Type:
2-stroke, liquid-cooled
Bore X Stroke:
Not specified, but typical for a 398cc 2-stroke.
Compression Ratio:
Not specified, but typical for a performance-oriented 2-stroke.
Horsepower:
Approx. 35-40 HP (estimated based on typical 400cc 2-stroke ATVs of the era).
Torque:
Not specified, but indicative of strong low-end power.
Carburetor:
Single Mikuni VM Series (e.g., VM34 or similar) carburetor.
Fuel Type:
Unleaded gasoline, typically 87-91 octane.
Oil Type:
2-stroke engine oil (pre-mix or injection, manual will specify).
Ignition Type:
CDI (Capacitor Discharge Ignition)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
2WD or 4WD (depending on specific model configuration).
Gear Selection:
Forward, Neutral, Reverse (selector lever).
Gear Oil Type:
Not applicable for CVT; requires specific CVT fluid (manual will specify).
Length:
Not specified, but typical for a 400cc class ATV.
Width:
Not specified, but typical for a 400cc class ATV.
Height:
Not specified, but typical for a 400cc class ATV.
Dry Weight:
Approx. 500-550 lbs (estimated).
Ground Clearance:
Not specified, but typically adequate for off-road use.
Atv Safety Standards:
Designed to meet relevant ATV safety standards of the era.
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Headlights, taillight, brake light.
Handlebar Design:
Grip guards and padded handlebar for control and comfort.
Oil Change Interval:
Typically every 50-100 hours or annually, specified in the manual.
Spark Plug Replacement:
Recommended at specific mileage or hours, and as part of regular checks.
Air Filter Cleaning:
Frequent checks and cleaning/replacement recommended, especially in dusty conditions.
Engine Oil Viscosity:
Specific 2-stroke oil viscosity as per manual, e.g., SAE 30 or 50.
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, as specified by Polaris.
Carburetor Fouling:
Common issue with 2-strokes, requiring regular cleaning and jetting checks.
Clutch Wear:
Clutch belt and components can wear over time, requiring inspection and replacement.
Cooling System Leaks:
Potential for leaks in hoses or radiator connections, necessitating regular checks.
Polar Heritage:
Polaris is a well-established manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles, known for innovation and off-road capability.
Scrambler Lineage:
The Scrambler line has historically been positioned as a sport-oriented ATV, offering performance and agility.
Production Period:
The Scrambler 400 was produced for several years, with the 1999 model being part of that lineage.
