Target Audience:
Polaris Scrambler 400/500 owners, DIY mechanics, service technicians.
Value Proposition:
Empowers users to perform their own repairs and maintenance, saving significant costs.
Manual Type Advantage:
Comprehensive workshop manual, offering more detail than a basic owner's manual.
Accessibility:
Instant download and multi-device compatibility (PC, Mac, Tablet, Phone).
Usability:
Easy-to-follow step-by-step instructions and pictures.
Permanence:
Download once, keep forever.
Completeness:
Covers all models/engines/trim/transmission types within the specified years.
Overall Coverage:
Complete service and repair procedures for all aspects of the vehicle.
Engine Coverage:
Engine assembly, disassembly, diagnostics, repair, tuning.
Transmission Coverage:
Transmission overhaul, clutch, drivetrain components.
Electrical System Coverage:
Wiring diagrams, ignition system, charging system, lighting, accessories.
Chassis Suspension Coverage:
Front and rear suspension, steering system, brakes, wheels, tires.
Bodywork Coverage:
Body panels, plastics, seat, controls.
Troubleshooting Coverage:
Diagnostic procedures, common problems and solutions.
Estimated Page Count:
N/A (Downloadable, page count not specified, but indicated as comprehensive)
Type:
Workshop Service Repair Manual
Format:
Digital Downloadable (PDF)
Delivery:
Instant Email Delivery
Computer Requirements:
All PC & MAC Computers, Tablets, Mobile Phones
Required Software:
Adobe Reader (Free Downloadable)
Powertrain:
Engine, fuel system, exhaust system, transmission, drive shafts, differentials.
Chassis:
Frame, suspension (front and rear), steering, wheels, tires.
Braking:
Hydraulic brake system, calipers, master cylinder, brake lines, parking brake.
Electrical:
Ignition system, charging system (stator, regulator/rectifier), battery, starter, lighting, instrumentation, switches, wiring diagrams.
Body:
Body panels, fenders, handlebars, seat, controls, racks.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, lubrication, chain adjustment (if applicable).
Component Overhaul:
Engine teardown and reassembly, transmission rebuild, carburetor overhaul.
Diagnostics:
Troubleshooting guides for common issues, electrical system diagnostics, engine performance issues.
Adjustments:
Carburetor tuning, brake adjustments, throttle cable adjustments.
Special Tools:
Identification of specialized tools required for specific procedures.
Level Of Detail:
Comprehensive, step-by-step instructions with pictorial guidance.
Diagnostics Coverage:
Detailed fault finding and diagnostic flowcharts.
Repair Procedures:
Covers complete disassembly, repair, and reassembly of all major components.
Torque Specifications:
Includes critical torque values for fasteners throughout the vehicle.
Wiring Diagrams:
Detailed electrical schematics for all systems.
Engine Type:
2-stroke, liquid-cooled
Displacement:
398cc (24.3 cu in)
Bore X Stroke:
Undetermined (manual will specify)
Carburetor:
Mikuni VM34 (Typical for this era/model, manual will confirm exact spec)
Horsepower:
Approx. 32-34 HP (Estimated, manual will provide precise figures)
Fuel System:
Carbureted, Oil Injection (AVS - Automatic Volume System)
Engine Type:
4-stroke, liquid-cooled, SOHC
Displacement:
498cc (30.4 cu in)
Bore X Stroke:
Undetermined (manual will specify)
Fuel System:
Carbureted (Likely Mikuni, manual will specify)
Horsepower:
Approx. 40-44 HP (Estimated, manual will provide precise figures)
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid Cooled
Drive System:
Selectable 2WD/4WD (On 4X4 models)
Transmission Gearbox:
PVT (Polaris Variable Transmission) with belt drive, High/Low range, Neutral, Reverse.
Final Drive:
Shaft drive, enclosed chain (2x4), geared hubs (4x4).
Clutch:
Automatic centrifugal clutch system.
Transmission Fluid Type:
Polaris AGL (Advanced Gear Lube) or equivalent SAE 80W-90 gear oil (Manual will specify exact viscosity and type).
Wheelbase:
Undetermined (manual will provide exact measurements)
Ground Clearance:
Approx. 8-10 inches (Model dependent, manual will specify)
Dry Weight:
Scrambler 400: Approx. 525 lbs; Scrambler 500: Approx. 550 lbs (Manual will provide exact specifications)
Fuel Capacity:
Approx. 3.7 gallons (Manual will confirm exact capacity)
Oil Capacity:
Engine Oil: Approx. 1.5 Quarts (2-stroke requires oil injection reservoir, 4-stroke wet sump. Manual will specify exact capacities and oil types).
Atv Classification:
Recreational ATV
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Headlights, taillight/brakelight.
Operator Safety:
Manual emphasizes the importance of wearing protective gear (helmet, eye protection, gloves, boots) and following safe operating practices.
Engine Oil Change:
Refer to manual, typically every 50-100 operating hours or annually. (4-stroke engine requires specific interval, 2-stroke requires oil injection system checks).
Air Filter Cleaning:
Refer to manual, typically every 20-50 operating hours or as needed based on riding conditions.
Spark Plug Service:
Refer to manual, typically inspect every 50 operating hours, replace as needed. Manual will specify correct spark plug type (e.g., NGK).
Transmission Fluid Change:
Refer to manual, typically annually or every 100-200 operating hours.
Engine Oil 400:
2-stroke oil for injection system. Manual will specify brand and API TC specification or equivalent. For premix, manual will specify ratio.
Engine Oil 500:
4-stroke engine oil, likely SAE 10W-40 or 20W-50, API SG or higher. Manual will specify exact viscosity and API rating.
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixed with distilled water. Manual will specify the correct ratio and type.
Common Wear Items:
Drive belt in PVT system, wheel bearings, tie rod ends, brake pads, starter motor brushes (common on many ATVs of this age).
Carburetor Issues:
Clogging from fuel varnish after storage, jetting adjustments for altitude. Manual will provide cleaning and adjustment procedures.
Electrical Gremlins:
Corroded connections, failing regulator/rectifier, battery issues. Manual's wiring diagrams are crucial for diagnosis.
Polarisfactor:
Polaris Industries is a prominent American manufacturer known for its off-road vehicles, including ATVs and snowmobiles.
Scrambler Lineage:
The Scrambler line is Polaris's sporty performance ATV offering, designed for aggressive trail riding and recreational use, building on a legacy of off-road innovation.
Manufacturing Origin:
United States
Market Introduction:
The Scrambler 400 and 500 were popular models during their production run, known for their performance and agility in the sport ATV segment of the late 1990s and early 2000s.
Industry Reputation:
Polaris ATVs, including the Scrambler line, have historically received positive reviews for performance and capability within their class.
Magazine Reviews:
Contemporary ATV publications likely offered favorable reviews for these models at their release, highlighting their sport-oriented features.
Atv Standards:
Manufactured to meet or exceed applicable industry safety and performance standards for ATVs.
