DOWNLOAD Polaris Scrambler Repair Manual 50 90 400 500 850

Polaris Scrambler Repair Manual, Service Manual, Workshop PDF Repair Guide

A downloadable Polaris Scrambler repair manual is a transferable electronic version of a printed book containing instructions on how to fix or mend the all-terrine vehicle back to working order. The Polaris Scrambler repair manual, also termed online factory service manual, includes complete maintenance, tune-up, servicing and repair information. The digitally delivered book of repair instructions also incorporates advanced troubleshooting guides to aid the mechanic in the process of tracing and correcting faults in the Polaris Scrambler’s mechanical or electrical system.

DOWNLOAD Polaris Scrambler Repair Manual 50 90 400 500

An electronically transmitted Scrambler repair manual is virtually identical to a printed book you’d find in a Polaris dealership repair shop. It contains a preface, table of contents, main chapters containing step-by-step repair information, as well as an appendix. Pictures and illustrations are scattered throughout the book to help the mechanic complete the repair work successfully. Here’s a list of main-chapters and sub-chapters typically found in a Polaris Scrambler repair manual (actual topics may vary depending on year and model):

General Information

  • Scrambler model identification

  • Scrambler serial number location
  • Scrambler replacement keys
  • Publication numbers
  • Paint codes
  • Scrambler specifications
  • Special tools
  • Standard tightening torque specifications
  • Tap drill charts
  • Decimal equivalent chart
  • Unit of measure conversions table
  • Glossary of terms


  • Torque specifications
  • Special tools required
  • Torque patterns
  • Piston identification chart
  • Cooling system pressure testing
  • Cooling system specs
  • Engine removal and installation
  • Cylinder honing
  • Crankshaft runout checking
  • Oil pressure test and engine lubricant
  • Oil pump priming procedure
  • Lubrication and oil flow diagrams
  • Exploded view of engine
  • Top end engine disassembly and assembly
  • Valve seat service
  • Cylinder head disassembly and assembly
  • Engine bottom end disassembly and assembly
  • Crankcase and bearing assembly
  • Crankshaft end play measurement and checking
  • Counter balancer end play inspection
  • Oil pump shaft end play inspection
  • Engine cleaning, inspection and assembly
  • Recoil disassembly and inspection
  • Recoil assembly
  • Spark plug fouling checklist
  • Cooling system bleeding
  • Troubleshooting

Final Drive

  • Drive torque specifications
  • Front hub exploded view
  • Front hub removal, disassembly and assembly
  • Front hub installation
  • Front hub/bearing
  • Hub seal replacement
  • Magnetic coil service
  • Hillard clutch disassembly and inspection
  • Armature plate inspection
  • Front drive axel removal and install
  • Front CV join boot replacement
  • Front drive axle exploded view
  • Struct casting sleeve replacement
  • Front prop shaft removal
  • U-joint disassembly
  • U-joint assembly
  • Front housing disassembly and assembly
  • Front housing installation
  • Front housing exploded view
  • Rear axel servicing

Electrical System

  • Alternator exploded view
  • Special tools required
  • Electrical system information
  • Timing check procedure
  • ECM operation
  • Hot light operation
  • Fan operation and testing
  • Fan ECM bypass test
  • Fan motor current draw test
  • Temperature sensor tests
  • ETC system operation and test
  • DC CDI ignition system testing
  • Cranking output test
  • Reverse limiter wiring diagram
  • Reverse limiter troubleshooting
  • Charging system testing
  • Headlight and brake light service
  • Starter system testing and troubleshooting
  • Starter motor service
  • Starter drive
  • Wiring diagrams


  • Brake specifications
  • Torque specifications
  • Front brake servicing
  • Rear brake servicing


  • Scheduled maintenance charts
  • Lubricant and maintenance part numbers
  • Pre-ride check
  • Lubrication points and charts
  • Front gearcase lubrication
  • Transmission lubrication
  • Transmission linkage adjustment procedure
  • Throttle operation and choke adjustment
  • Carburetor tune-up and adjustments
  • ETC switch operation (if equipped)
  • Fuel system maintenance
  • Compression pressure testing procedure
  • Battery charging and maintenance
  • Electrical system maintenance
  • Coolant system maintenance
  • Air filter and air box sediment tube servicing
  • Breather filter maintenance
  • Recoil housing maintenance
  • PVT drying
  • Engine oil and oil filter change
  • Valve clearance measuring and adjustment
  • Steering and toe alignment
  • Front hum maintenance (all wheel drive AWD models)
  • Exhaust system maintenance
  • Brake system service
  • Drive chain and sprocket service
  • Suspension service
  • Tire and wheel removal and install
  • Tire and wheel inspection

Fuel System

  • Exploded new carburetor
  • Fuel tank assembly exploded view
  • Fuel flow diagram
  • Jetting guidelines
  • Special tools required
  • Carburetor jetting
  • Part numbers: main jet and pilot jet
  • CV carburetor system (4 cycle models)
  • Pilot screw information
  • Carburetor disassembly and cleaning
  • Carburetor assembly and installation
  • Carburetor inspection procedures
  • Carburetor tuning
  • Float adjustment
  • Needle and seat leakage test
  • Pilot screw and fuel level
  • Fuel pump service
  • Fuel system troubleshooting

Body And Steering

  • Torque specs and special tools required
  • Body assembly and exploded view
  • Steering assembly and exploded view
  • A-arm replacement
  • Concentric swing arm removal, disassembly
  • Concentric swing arm cleaning, assembly, install
  • Rear swing arm weldment
  • Strut assembly exploded view
  • Front strut weldment replacement
  • Front strut ball join replacement
  • Steering post assembly
  • Decal replacement


  • Service tools and supplies required
  • PVT system operating and maintenance
  • PVT system inspection and disassembly
  • PVT system assembly, sealing and ducting
  • Drive clutch exploded view
  • Drive clutch spring specs
  • Shift weights
  • Drive clutch inspection
  • Drive clutch disassembly and checking
  • Drive clutch assembly and install
  • Drive belt tension, removal and inspection
  • Drive belt install
  • Clutch offset and alignment
  • Drive clutch disassembly and inspection
  • Driven clutch assembly
  • Driven clutch bushing service
  • Troubleshooting


  • Torque specifications
  • Transmission removal and installation
  • Transmission exploded view
  • Transmission disassembly and reassembly
  • Transmission troubleshooting

A Polaris Scrambler four-wheeler repair manual can be downloaded to a computer, tablet or smart phone. However, for best viewing experience, it should be downloaded to a computer or tablet. The manual is in Portable Document Format (PDF). Therefore no special software is needed to download and view the manual. Once the manual is downloaded you can save it to your downloads folder or desktop forever. You can even burn it to a CD or transfer it to a thumb drive. Polaris Scrambler manual.


Admin. “DOWNLOAD Polaris Scrambler 850 Repair Manual.” 911 Manual, 23 Apr. 2019,


    • There are downloadable repair manuals available for the following year and models:

      1995-1996 Polaris Scrambler 400 4X4
      1997-1998 Polaris Scrambler 400 4X4
      1997-1998 Polaris Scrambler 400L 4X4
      1999-2000 Polaris Scrambler 400 2X4
      1999-2000 Polaris Scrambler 400 4X4
      1999-2000 Polaris Scrambler 500 4X4
      2001-2002 Polaris Scrambler 400 4X4
      2001-2003 Polaris Scrambler 500 4X4
      2001-2003 Polaris Scrambler 50cc
      2001-2003 Polaris Scrambler 90cc
      2004-2005 Polaris Scrambler 500 4X4
      2004-2005 Polaris Scrambler 400 4X4
      2006-2007 Polaris Scrambler 400/500 4X4
      2008-2009 Polaris Scrambler 500 4X4
      2010-2011 Polaris Scrambler 400 4X4
      2013-2014 Polaris Scrambler XP 850 H.O.
      2013-2014 Polaris Scrambler XP 850 H.O. EPS
      2013-2014 Polaris Scrambler XP850 H.O. EPS International
      2015-2016 Polaris Scrambler XP 850
      2017 Polaris Scrambler 1000 XP HO

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