Polaris Scrambler 500 4×4 manual.
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Models:
Scrambler 500 4X4 (1997-2000)
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Cleaning parts / Handling gasoline safely / Service hints / Torque specifications / Fasteners / Lubricants / Threadlocking compound / RTV gasket sealant / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Fabricating tools / Mechanic¿s tips / Bearing replacement / Seals / Riding safety / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Starting difficulties / Engine is difficult to start / Engine starting system / Charging system / Ignition system / Speed limiter and electronic throttle control (1997-98 models) / Electronic throttle control (1999-on models) / Fuel system / Engine overheating / Engine / Engine noises / Cylinder leakdown test / Power train / Steering / Frame noise / Brakes
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-checks / Service intervals / Periodic lubrication / Drive chain cleaning lubrication adjustment / Engine oil and filter change / Fork oil change / Control cables / Periodic maintenance / Tune-up / Air filter / Toe in adjustment / Valve clearance / Compression test / Spark plugs / Specifications
CHAPTER FOUR / ENGINE TOP END
Engine principles / Engine cooling / Engine lubrication / Servicing the engine in the frame / Exhaust system / Cylinder head cover / Rocker arm assembly / Camshaft / Cylinder head / Valves and valve components / Cylinder block / Piston and piston rings / Camshaft chain and sprockets / Break-in procedure / Specifications
CHAPTER FIVE / ENGINE LOWER END
Engine / Flywheel and stator plate / Recoil starter / Crankcase / Crankshaft inspection / Balancer shaft inspection / Shaft end play measurement and shim selection / Oil pump / Oil system one-way check valve / Break-in procedure / Specifications
CHAPTER SIX / FUEL SYSTEM
Carburetor operation / Carburetor cleaning inspection tests adjustments / Throttle cable replacement / Starting enrichment choke cable / Fuel tank / Fuel valve / Air filter air box / Fuel pump / Specifications
CHAPTER SEVEN / COOLING SYSTEMS
Polaris variable transmission PVT cooling system / Engine cooling system / Cooling system inspection / Radiator / Cooling fan / Coolant pump / Thermostat / Temperature sensors / Specifications
CHAPTER EIGHT / CLUTCH/DRIVE BELT SYSTEM
Drive unit / Drive pulley / Driven pulley / Drive belt / Drive pulley / Driven pulley / Clutch outer and inner cover / Specifications
CHAPTER NINE / TRANSMISSION
Transmission / Shift shaft / Transmission inspection / Transmission gear case seal inspection and replacement / Shift linkage / Specifications
CHAPTER TEN / FRONT DRIVE SYSTEM
Front hub and hillard clutch / Front drive axle, boots and CV (constant velocity) joints / Center chain and sprockets / Front chain and sprockets / Front and rear eccentric shaft / Front drive shaft / Front drive unit / Specifications
CHAPTER ELEVEN / ELECTRICAL SYSTEM
Battery / Charging system / Alternator stator / Voltage regulator rectifier / Capacitor discharge ignition / Ignition coil / Ignition stator coils / Electric starting system / Starter drive gears / Starter solenoid / Lighting system / Specifications
CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Front strut cartridge and spring / Front strut / Control arm / Handlebar / Tie rods / Steering shaft / Tires and wheels / Specifications
CHAPTER THIRTEEN / REAR SUSPENSION
Rear wheels / Rear hub / Tire changing and tire repairs / Drive chain / Rear axle / Rear axle inspection / Rear eccentric / Driven sprocket / Shock absorber / Swing arm CHAPTER FOURTEEN / BRAKES
Disc brakes / Front brake pads / Front caliper / Output shaft brake pad / Output shaft brake caliper / Rear axle caliper brake pad / Rear axle caliper and mounting bracket / Front master cylinder / Rear master cylinder / Brake hose / Brake disc / Bleeding the system / Specifications
CHAPTER FIFTEEN / BODY
Seat / Front fender / Front skid plate, front bumper and radiator shield / Center chain and sprocket cover / Front drive shaft guard / Rear fender and muffler guard / Specifications
INDEX
WIRING DIAGRAMS
