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Polaris Scrambler 500 4X4 ATV 1997 - 2000 Clymer Owners Service & Repair Manual Covers 1997-2000 Polaris Scrambler 500 4X4 ATVs, equipped with single-cylinder, single overhead camshaft (SOHC) engines
● QUICK REFERENCE DATA
● 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 / Mechanics tips / Bearing replacement / Seals / Riding safety / Storage / Specifications
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
● 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
● 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
● 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
● 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
● COOLING SYSTEMS
Polaris variable transmission PVT cooling system / Engine cooling system / Cooling system inspection / Radiator / Cooling fan / Coolant pump / Thermostat / Temperature sensors / Specifications
● CLUTCH/DRIVE BELT SYSTEM
Drive unit / Drive pulley / Driven pulley / Drive belt / Drive pulley / Driven pulley / Clutch outer and inner cover / Specifications
Transmission / Shift shaft / Transmission inspection / Transmission gear case seal inspection and replacement / Shift linkage / Specifications
● 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
● 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
● FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Front strut cartridge and spring / Front strut / Control arm / Handlebar / Tie rods / Steering shaft / Tyres and wheels / Specifications
● REAR SUSPENSION
Rear wheels / Rear hub / Tyre changing and Tyre repairs / Drive chain / Rear axle / Rear axle inspection / Rear eccentric / Driven sprocket / Shock absorber / Swing arm
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
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
● WIRING DIAGRAMS
Clymer motorcycle & ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.
Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.
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