Atv Segment:
The Polaris Scrambler 400 4x4 was positioned as a capable and versatile recreational and utility ATV, known for its 4x4 capability and a balance of performance and user-friendliness in its era.
Key Competitors:
Competed with models from Yamaha (e.g., Wolverine), Arctic Cat (e.g., Bearcat), and Suzuki (e.g., QuadSport) in the mid-size to large displacement 4x4 ATV market.
Performance Attributes:
Known for its agile handling, reliable 4x4 system, and a powerful two-stroke engine suitable for various terrains and riding styles.
Utility And Recreation:
Adaptable for both recreational trail riding and light utility tasks, such as hauling or property maintenance.
Primary Coverage:
Parts identification and cataloging for the 2002 Polaris Scrambler 400 4x4.
Specific Components Covered:
Engine mounting, cooling system, exhaust system, fuel tank, oil tank, air box, front drive assembly, front suspension components (struts, A-arms), steering system, handlebars, front and rear brakes, drive clutch, driven clutch, gearcase, electrical systems, and various bodywork and chassis components.
Powertrain:
Engine, cooling, exhaust, fuel, oil, drive clutches, gearcase, and drive axle components.
Chassis And Suspension:
Front A-arms, struts, swing arm, shocks, steering column, handlebars, front and rear wheels, brakes, and mounting hardware.
Electrical:
Wiring harnesses, lights (headlight, taillight), starting motor, magneto, and related electrical components.
Bodywork And Accessories:
Cab components, seat, racks, bumper mounting, decals, and fuel/oil tanks.
Identification:
Identification of all replaceable parts with corresponding part numbers through detailed exploded diagrams.
Assembly Disassembly Reference:
Facilitates understanding of component relationships for assembly and disassembly, aiding in repair and maintenance planning.
Ordering Parts:
Provides essential part numbers required for ordering replacements from dealerships or aftermarket suppliers.
Depth:
Detailed exploded views with part number callouts for every major and minor component. Focuses on part identification rather than repair procedures, but is crucial for accurate part selection in repairs.
Searchability:
Likely text-searchable if generated from OCR or native PDF, enhancing ease of locating specific parts or sections.
Print Capability:
Print-on-demand, allowing users to print only necessary pages for specific maintenance or repair tasks, promoting efficiency and resource conservation.
Binding Recommendation:
Users can print and bind sections relevant to their immediate needs, such as a workshop manual binder or individual printouts.
Recommended Paper Type:
Standard printer paper is suitable. For workshop use, consider heavier cardstock for frequently referenced pages or lamination for durability.
Engine Type:
Two-stroke, liquid-cooled, single-cylinder
Displacement:
375cc (approximate)
Bore X Stroke:
Specifics usually found in a service manual, but characteristic of its class.
Ignition System:
CDI (Capacitor Discharge Ignition)
Horsepower:
Typically in the range of 30-35 HP, though exact figures may vary by year and tuning.
Torque:
Provides strong low-end torque for pulling and climbing.
Carburetor Type:
Likely a Mikuni or Keihin carburetor, specific model number found in manual.
Fuel Type:
Unleaded gasoline (e.g., 87 octane or higher)
Oil Mixing:
Requires pre-mix of oil and gasoline or an injection system, depending on the specific variant. This manual covers the oil tank, suggesting an injection system.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Optional Features:
Forward, Neutral, Reverse (F-N-R) gear selection.
Drive System:
Shaft-driven 4x4 with automatic engagement (on-demand).
Clutch System:
Primary and secondary CVT clutches with belt drive.
Length:
Approx. 76 inches (193 cm) - Varies slightly by model year.
Width:
Approx. 46 inches (117 cm) - Varies slightly by model year.
Height:
Approx. 44 inches (112 cm) - Varies slightly by model year.
Dry Weight:
Approx. 550-570 lbs (250-258 kg) - Varies slightly by model year and equipment.
Ground Clearance:
Approx. 8-10 inches (20-25 cm) - Varies slightly by model year and suspension setup.
Atv Safety Standards:
Designed to meet industry safety standards for ATVs. Always wear appropriate safety gear including helmet, goggles, gloves, and protective clothing.
Braking System:
Hydraulic disc brakes (front and rear) for reliable stopping power.
4X4 System:
On-demand 4WD provides enhanced traction in challenging conditions.
Frame Construction:
Robust steel frame designed for durability and stability.
Lighting:
Headlights and taillight for visibility.
Oil Change:
Refer to the specific Polaris service manual for exact intervals, but typically every 50-100 hours of operation or annually.
Air Filter Cleaning:
Regular inspection and cleaning, especially in dusty conditions. Replacement as needed.
Spark Plug Replacement:
Periodically, based on engine performance and hour meter readings.
Drive Belt Inspection:
Inspect for wear and damage at regular intervals, replace as per service manual recommendations.
Engine Oil:
Specific SAE viscosity and API service classification recommended in the service manual. Likely a 2-stroke oil for injection or pre-mix.
Gearcase Oil:
Specific gear oil with SAE viscosity rating (e.g., SAE 80W-90 GL-5) as per the service manual. The parts manual lists the gearcase assembly.
Coolant:
Ethylene glycol-based antifreeze/coolant mixture suitable for liquid-cooled engines. Specific type and mix ratio in service manual.
Cvt Belt Wear:
CVT belts can wear over time and may require replacement, especially with aggressive riding or heavy use. The parts manual will list the correct belt part number.
Carburetor Cleaning:
Carburetors on older two-stroke engines can require periodic cleaning and adjustment for optimal performance, especially if the ATV sits for extended periods.
Two Stroke Engine Maintenance:
Two-stroke engines require proper oil-fuel mixture and can be more prone to carbon buildup if not operated at optimal conditions.
Polaris Heritage:
Polaris Industries is a long-standing American manufacturer known for its pioneering work in snowmobiles and its expansion into ATVs, off-road vehicles, and powersports equipment.
Scrambler Lineage:
The Scrambler line has a history of performance-oriented ATVs, often featuring sporty designs and powerful engines, evolving to meet changing consumer demands and technological advancements.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States.
