This manual covers the Scrambler 400 and Scrambler 500 models, produced in 1999 and 2000. These versatile All-Terrain Vehicles (ATVs) are engineered for recreational and trail riding, offering a blend of performance and agility. Available in 2X4 and 4X4 configurations, the Scrambler line is recognized for its robust build and the off-road capability that is known for. The Scrambler models represent a significant part of history in the sport ATV segment, built with quality and reliability in mind for enthusiasts seeking an adventurous riding experience. This comprehensive workshop service repair manual provides detailed procedures for all aspects of the Scrambler 400 and 500. It includes in-depth coverage of engine assembly and disassembly, transmission overhauls, clutch systems, and drivetrain components. Furthermore, the manual details the electrical system, including wiring diagrams, ignition, and charging systems, as well as chassis and suspension maintenance, steering, and brake systems. Owners and technicians will find valuable troubleshooting guides, diagnostic procedures for common issues, and specific maintenance schedules, ensuring optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Scrambler 400 / Scrambler 500 Model Variants: 2X4, 4X4 Product Type: Complete Workshop Service Repair Manual Model Years: 1999, 2000 👋 Introduction Market Position 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. Competitive Analysis Manual Type Advantage: Comprehensive workshop manual, offering more detail than a basic owner's manual. Key Features 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. 📋 Manual Details Coverage Areas 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. Page Count Estimated Page Count: N/A (Downloadable, page count not specified, but indicated as comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Downloadable (PDF) Delivery: Instant Email Delivery Compatibility Computer Requirements: All PC & MAC Computers, Tablets, Mobile Phones Required Software: Adobe Reader (Free Downloadable) 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth 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. 📊 Manual Specifications File Format Format: PDF Searchable: Yes (Assumed for PDF, enhances usability) Print Quality Quality: High Quality (as per product description) Printable: Yes (Individual pages or entire manual) Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 400 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) Primary Engine 500 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) Performance Ignition System: CDI (Capacitor Discharge Ignition) Cooling System: Liquid Cooled 🔧 Transmission Drive Type Drive System: Selectable 2WD/4WD (On 4X4 models) Transmission Type Transmission Gearbox: PVT (Polaris Variable Transmission) with belt drive, High/Low range, Neutral, Reverse. Final Drive: Shaft drive, enclosed chain (2x4), geared hubs (4x4). Features Clutch: Automatic centrifugal clutch system. Fluid Specifications Transmission Fluid Type: Polaris AGL (Advanced Gear Lube) or equivalent SAE 80W-90 gear oil (Manual will specify exact viscosity and type). 📐 Dimensions Exterior Wheelbase: Undetermined (manual will provide exact measurements) Ground Clearance: Approx. 8-10 inches (Model dependent, manual will specify) Weights Dry Weight: Scrambler 400: Approx. 525 lbs; Scrambler 500: Approx. 550 lbs...