I would like to purchase a used (cannot afford new) Scrambler 500 4x4 in the next few weeks. I have found useful information with reference to the ’97 and ’98 models, and now I am seeking information about the subtle changes that have taken place in ’99, ’00, ’01, and ’02. Can anyone give a brief upgrade history for this time period? Additionally if you were going to purchased a used Scram-500, what year model range would you choose?

 

The Biggest change that I can think of right off hand is the brakes. They changed the rotors and brake pads in 2001 and also added steel braided brake lines. I wish my 2000 had these updates.

 

Some changes that I can think of are

99 first year of HO motor
00 first year of SACHS struts
01 new steering, brakes, rear shock with more travel
02 new belt cover with better airflow

I am sure there are some other differnces like stickers, plastic and other minor changes.

 

They added 75 lbs, dropped it 10 HP, put on drum brakes and made it break more. [img]i/expressions/face-icon-small-wink.gif[/img]

 

1998 was the first year with the H.O. motor. Just clearing that up.

Anyways, besides the changes listed above, there are other changes they made through the years. I am not exactly sure of what year though. I will just list what is different from my quad ('98 Scrambler).

Some where along the line, Polaris put in a better radiator. Mine is a plastic one, the newer ones are aluminum. The new aluminum ones are better designed because they have the fan temp sensor at the bottom of the radiator instead of the top. This is better because the newer set up allows the sensor to be submerged(for lack of a better word) in the anti-freeze at all times. So, for instance, lets say my fan wasn't coming on and I was over heating. Well, it could simply be because my coolant level is low and it is not making contact with my temp sensor, thus not activating the fan. And while I'm talking about the fan, I might as well include that the newer Scramblers have a better (bigger) fan with a better (sealed) motor.

Another change that Polaris made after my 1998 model is a better swing arm. I guess the swing arm on my '98 isn't as strong as the newer ones. The area of the swing arm I am talking about is the part that wraps around the axle housing. I guess the welds were not holding up too good, so they redesigned the whole thing. Again, I am not sure exactly when they made this change either.

In '99 they added more travel to the Scrambler line. They also started making them in red. I'm pretty sure '99 is when they got rid of the aluminum bumper, aluminum floorboards, and aluminum wheels. That explains the weight increase.

2001, we saw a lot of improvements. I think they all were already mentioned.

Hope I helped. I gotta get sum ZZZZ's. If I think of anything else, I'll let you know.

 

Quick Break down

97 and older 4x4s are Chain Drive in the Front (From what I hear, Terible design)
98 got Front Shaft drive.(++++)
98 got Concentric Rear Chain Drive. (Helps elimate chain binding and breakage +++++)
99 got a Rear FOX w/reservoir on 4x4 models
00 got different Rear Brake foot Lever from 99.
00 got 2 more inches of rear suspension travel with a swing arm change. Also got 2 stage rear spring.
(A LOT better CUSHIOR ride ++++++++)
01 got Lifetime belt warranties
01 got better brakes ( Drilled and slotted rotors, Upaded pads, Updated Brake lever and Fluid Reservoir,Steel Braded Line
01 Late 01 models got sealed bearing to support the Steering Shaft (Steering effort was decreased and Durability up)
02 got a Gear case saver behind Drive sprocket. (Helps elimate case cracking when and if chain Breaks
03 gets a SPLICELESS drive belt.

If It where me I would not go older than a 98/99.
I would Prefer a 2000 (Rear suspension feels SOOOOOO much better.)
2001 would get you the Brakes and Lower Steering support.
Just my 2 cents.