2001 Polaris Scrambler 500 2x4 & 4x4 ATV Service Manual PDF (P/N 9916578)

Polaris service manual P/N 9916578 covers the 2001 Scrambler 500 2x4 (A01BA50AA) and Scrambler 500 4x4 (A01BG50AA) with Gen III bodywork.

Supplied as one 382-page PDF in English.

• Engine repair: EH50PL top-end and bottom-end disassembly, valve-seat reconditioning, crankcase assembly, camshaft timing, and component inspection.

• Fuel system: Mikuni BST 40 carburetor overhaul, float adjustment, needle-and-seat leakage testing, fuel-pump inspection, and jetting charts.

• PVT and transmission: Drive and driven clutch service, belt inspection, clutch alignment, and separate 2x4 and 4x4 transmission disassembly and assembly.

• AWD and final drive: Hilliard clutch inspection, magnetic hub-coil service, front gearcase overhaul, CV boot replacement, and concentric-swingarm rear axle service.

• Chassis and brakes: Steering and strut repair, Fox shock service, master-cylinder and caliper overhaul, disc inspection, and dual hydraulic brake bleeding.

• Electrical diagnosis: CDI and stator tests, charging and starter troubleshooting, reverse-limiter and AWD testing, plus separate model wiring diagrams.

This manual is suited to experienced ATV technicians equipped for precision engine measurements and component overhaul.

EH50PL Engine Repair, Lubrication and Cooling

EH50PL coverage includes EH50PLE04 and EH50PLE12 engine identification, piston and cylinder measurements, crankshaft runout, and end-play checks for the crankshaft, counterbalancer and oil-pump shaft. Service tables provide wear limits and component-specific torque data.

Maintenance coverage includes periodic schedules, valve-clearance procedures, fluid capacities and tire-pressure specifications. The EH50PL Oil Flow Diagram supports lubrication-system diagnosis alongside oil-pressure testing and oil-pump priming. Cooling-system pressure tests and coolant bleeding are also covered.

The accessible-component list distinguishes work possible in the frame from repairs requiring engine removal. Water-pump mechanical-seal replacement is documented with puller PN 2872105 and installation tool PN 5131135, helping plan seal repair without unnecessary crankcase separation.

The seal procedure warns that side-loading the puller can bend the pump shaft, which then requires engine removal and crankcase separation.

Mikuni BST 40 Carburetor and Fuel Pump

The carburetor chapter explains the pilot, starter-enrichment, float and main systems. Its BST 40 Carburetor Exploded View, needle-and-seat tests and fuel-pump diaphragm checks support fault tracing for fuel starvation, flooding and erratic idle.

Jetting charts account for temperature and altitude, while the service text explains the relationship between carburetor calibration and clutch setup.

PVT Clutches and 2x4/4x4 Transmissions

Drive-clutch engagement, spring and shift-weight selection, offset alignment and belt-deflection checks are covered alongside bushing replacement. Troubleshooting charts address belt slip, harsh engagement, erratic operating RPM and PVT overheating.

Separate transmission procedures identify the shafts, chains and gear assemblies used in each drivetrain configuration, with exploded views and shift-linkage checks.

Polaris specifies that PVT maintenance and repair be performed by authorized technicians with Polaris service training and factory-authorized tools.

AWD Hubs, Suspension and Hydraulic Brakes

The 4x4 sections cover magnetic hub coils, armature plates and the Hilliard roller clutch; the 2x4 has separate front-hub bearing and seal procedures. An AWD assembly caution explains how a displaced armature plate can damage the roller clutch.

Chassis coverage includes body-panel removal, model-specific steering layouts, MacPherson struts and the concentric swingarm. Rear drive-chain adjustment and sprocket inspection are also covered.

Fox shock service extends to internal floating-piston work, valving and nitrogen recharging.

The Dual Hydraulic Caliper cutaway distinguishes the separate hand- and foot-brake circuits within the rear caliper. Master-cylinder and caliper repair procedures accompany brake-noise and drag troubleshooting.

Follow the manual's shop safety precautions and consult a qualified technician before undertaking brake, steering or pressurized-shock work.

CDI, Charging and Control-Circuit Diagnosis

Ignition testing covers CDI output and stator exciter and trigger coils, including peak-reading voltmeter requirements. Charging and starter test charts sit alongside Electronic Throttle Control (ETC), fan-control and gear-position-switch tests.

The LR44 Reverse Limit System schematic for the 2x4 and LR83 Reverse Limit System schematic for the 4x4 complement the two model wiring diagrams and AWD electrical tests.

File Format and Readability

Embedded OCR supports text searches across the main chapters, but recognition of small wiring labels is incomplete. PDF bookmarks link to all ten chapters and the alphabetical index; the wiring bookmark opens the 4x4 diagram. Small wiring labels are best read when enlarged.

The page total includes one chapter-index page, ten chapter-opening contents pages, a six-page alphabetical index, 18 blank pages and one electrical notes page.