Home

ATV AND LIGHT UTILITY VEHICLE SERVICE MANUAL

1. 100 hrs 12 months Check Monthly Change Annually Throttle Cable ETC Switch Inspect Adjust Lubricate Replace if necessary 2 il D D Inspect hose routing hose condition Choke Enricher Cable Inspect Adjust Lubricate Replace if necessary Carburetor Float Bowl Drain bowl periodically and prior to storage Carburetor Air Intake Ducts Flange 50hrs 6months Inspect all ducts for proper sealing air leaks Fuel System 100 hrs 12 months 2 13 Check for leaks at tank cap lines fuel valve filter pump amp carburetor Replace lines every 2 years Fuel Filter 100 hrs 12 months Replace filter annually Coolant Level Inspection Replace engine coolant every 2 years Coolant Strength Pressure Test 100 hrs 6 months 2 18 Inspect strength seasonally Pressure test sys System tem annually Drain Recoil Housing More often if operating in wet environment Battery Check terminals Clean Check fluid level Headlamp Inspection Daily Daily Check operation daily Apply Polaris Dielectric Grease to connector when lamp is replaced Tail Lamp Inspection Daily Daily 10 9 Check Operation Daily Apply Polaris Dielectric Grease to socket when lamp is replaced 5 98 2 1 Polaris Industries Inc MAINTENANCE Periodic Maintenance Chart Cont CHASSIS Hours or Frequency See Page Odometer 2 5 2 9 Lubricate All Fittings Pivots Cables Etc General Lubrication Front Hubs Fluid Check Front Hubs Fluid
2. ETE wee mue peeuso paasa VET esser Jesse Emm queen a UU enm EA Wes esse desse A Desin uses esser CIS p SEE eet asi eorum ssa uses CO ums A eorum ess ws enim a _ 1997 Publication Numbers Model No Owner s Manual Parts Manual 1997Parts Micro Fiche Set PN FB werausc sewoss esser aires warocesc esso perisset 1 EEE wsrowec CS EEN Eee LC a EIC wercmc mmm CI 1 ess 00 wercasee esso jeeesso Ca muss Sponsrar 2x4 weree esse Jess ones wemexs fesso Jesse magpuno womcen snas Jews 1 cs i ACA pe Polaris Industries Inc 1 2 5 98 GENERAL INFORMATION Publications 1998 Publication Numbers Owner s Manual Model No Parts Manual Supplement WSECHSONGEAS Owner s Manual Parts Microfiche SERVICE TRAINING VIDEOS VIDEO TITLE PART NUMBER DESCRIPTION Magnum 4 Stroke Introduction 9912996 Includes 4 Stroke theory of operation engine removal disassembly and assembly techniques along with and general tech tips Ignition System Diagnostics 9913533 Describes all current Polaris ignition systems Provides working knowledge of ignition system theory and diagnostics Charging System Diagnostics 9913278 Describes all current Polaris charging s
3. There is a charge of 35 00 payable to Polaris Industries Inc REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHAS ER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warran ty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages w
4. Transmission Tool Kit Shaft Drive Used to disassembly and assembly transmission and front gearcase on 500 models PN 2871702 Yoke Gauge Tool Shaft Drive Used to check yoke alignment PN 2871813 Large Yoke PN 2871814 Small Yoke Polaris Industries Inc 1 25 10 96 GENERAL Mity Vac Pump Kit This tool is used for many service functions on Polaris ATVs including testing of cooling systems carburetor needle and seat oil system check valves etc PN 2870975 Small Battery Hydrometer Measures the strength of battery electrolyte in terms of specific gravity Specially designed for small batteries PN 2870836 Transmission Seal Bearing Driver 50mm For installing bearings and case seals during transmission gearcase overhaul PN 2871282 CV Boot Clamp Pliers The ear and earless driveshaft CV boots require a special pliers to secure the clamps properly without distortion PN 8700225 For Earless Flush Style Clamps PN 8700226 For Ear Style Clamps 10 96 1 26 GENERAL INFORMATION Service Tools 8700226 Polaris Industries Inc GENERAL INFORMATION Warranty LIMITED WARRANTY Polaris Industries Inc 1225 Highway 169 North Minneapolis Minnesota 55441 5078 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or work manship This warranty covers the parts and labor charges for repair or replacement of defective
5. 1995 Scrambler 4x4 Revised carburetor jetting 1995 Models Equipped with Auxiliary Brake Brake inspection and adjustment procedure 1995 Scrambler 4x4 Missing lower front bumper bolts 1995 Scrambler 4x4 Incorrect sprocket guard spacer 1995 Scrambler 4x4 Front brake lines may rub against CV joint boot 1995 Magnum 2x4 Magnum 4x4 Oil tank vent fitting restricted All 1995 Models Transmission lubricant expelled through vent line All 1995 Models exc Scrambler Xplorer 6x6 Aux brake arm may contact right footrest All 1995 All Wheel Drive Models Faulty Gear Selector Switches 1995 Scrambler Headlight Bulb May Fall Out Of Socket 1995 Magnum 2x4 and 4x4 Rich Condition Plug Fouling Checklist Al 1996 Synthetic Chaincase Lubricant Recommended for all 1996 Models 1996 Sport Loose Headlight Mounting Screws 1995 Xplorer 400 2x4 Sport Scrambler 6x6 Idle Speed Adjustment on 1995 400 cc ATVs 1996 Scrambler Sport 400L Incorrect Carburetor Jetting Chart in Owner s Manual 1996 Scrambler Water May Freeze in Oil Pump Housing 1996 Xplorer 400L Xpress 300 Sportsman 500 Plow Blade Mounting Kit Applications 1996 Trail Boss Magnum 4x4 Water Leaks at Inner PVT Cover 1996 Sportsman 500 Oil Tank Vent Hose Routing 1996 Sportsman 500 Loose Rear Drive Shaft Retaining Bolts 1996 Sportsman 500 Magnum 2x4 4x4 6x6 Improved Seat Fit For 1996 ATVs 1996 Gen IV models with rear rack extender kit Flag mount not functional w
6. 44 46 45 5 45 5 44 46 46 Length 73 2 78 5 81 Wheel Base 4975 4975 49 75 Seat Height co o o 83 84 Ground Clearance 5 5 6 75 6 Weight 425 lbs 420 Ibs 512 lbs 567 lbs Turning Radius Unloaded 60 60 60 Front Suspension Travel 6 25 6 25 6 25 McPherson Strut Rear Suspension Front Tires Rear Tires 8 5 23x7x10 24x11x10 8 5 23x7x10 22x11x10 8 5 23x7x10 24x11x10 as 23x7x10 22x11x10 Center Tires N A N A N A N A Front Rear Center Tire PSI 4 3 43 4 3 Front Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Rear Brake Hydr Disc Hydr Disc Hydr Disc Auxiliary Brake Mechanical Mechanical Mechanical Mechanical Fuel Capacity U S Gallons 4 4 4 Oil Capacity U S Quarts 2 2 2 Gearcase Oil Capacity oz 16 Main Head Light 12V 60 60W N A Grill Mounted Lights N A 2 12V 30 30W 2 12V 30 30W Tail Light 12V 8 26W 12V 8 26W 12V 8 26W 12V 8 26W Gear Box F R N F RIN HI LO R N HI LO R N Gear Reduction Low N A N A 6 64 1 6 64 1 Drive Type 520 O ring 520 O ring 520 O ring 520 O ring FInal Drive 12 42 88P 12 42 88P 13 38 86P 13 40 88P Center Drive N A N A N A 11 22 70P Front Dri
7. 5 21 6 23x7x10 22x11x10 8 5 21 6 23x7x10 24x11x10 8 5 21 6 24x11x10 Center Tires N A N A N A N A Front Rear Center Tire PSI 48 4 3 4 3 4 3 Front Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Rear Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Auxiliary Brake Mechanical Mechanical Mechanical Mechanical Fuel Capacity U S Gallons Oil Capacity U S Quarts Cooling System Capacity Qt Liter Gearcase Oil Capacity oz Engine Counter Balancer Oil Capacity 10W 30 Main Head Light Grill Mounted Lights Tail Light Brake Light Watts 4 2 2 25 2 16 12V 60 60W 12V 55W 2 12V 30 30W 12V 8 26 26 9 2 12V 30 30W 12V 8 26 26 9 12V 8 26 26 9 12V 8 26 26 9 Gear Box F R N _F RIN HI LO R N Gear Reduction Low N A N A 6 64 1 Drive Type 520 O ring 520 O ring 520 O ring 520 O ring Final Drive 12 42 88P 12 42 88P 13 38 86P 13 40 88P Center Drive N A N A 11 22 70P Front Drive N A N A 12 22 64P Displacement 244cc 283cc 283cc Engine Model Number EC25PFE10 EC25PFE11 EC28PFE02 EC28PFE02 Compression Ratio Effective 6 1 1 6 1 1 6 1 1 Bore and Stroke mm 72x60 74 5x65 74 5
8. 500 Opt 1 Springs 8520147 P067 9440 Rims Black 8520147 P067 9440 Sportsman 500 Opt 2 Springs Bonnie Blue 8520148 P157 12908 Rims Aluminum P117 Scrambler 500 Springs 8520147 P087 9440 We mam enm Springs 8520149 P093 72060 ao Mmmm Len BEEN Racks 8520150 P195 44931 Springs 8520147 P067 9440 am aim PM EE Racks 8520147 P067 9440 Scrambler 400 Springs 8520149 Sport 400L Springs Purple Velvet 8520160 Springs Fire Red 8520149 P093 Xpress 300 P093 P133 P194 P133 72060 2185 x 51467 2185 72060 tan Xpress 300 Springs Bonnie Blue 8520148 P157 12908 Trail Blazer Springs Fire Red 8520149 72060 2185 Rims Bright White 8520153 P133 Springs 8520149 P093 Trail Boss BI Bright White 8520153 P133 Back s 8520149 P093 Order direct from Midwest Industrial Coatings 612 934 8252 Mix as directed 72060 2185 72060 me Frames Medium Black P067 8520147 Ditzler 9440 Polaris Industries Inc 1 4b 5 98 GENERAL INFORMATION Specifications 1997 1997 Model Gen Il Ill or IV Trail Boss Il Trail Blazer ES III Xpress 300 IV Xplorer 300 IV Model Number W97AA25C W97BA25C W97CA28C W97CC28C
9. a SUGA deco a 5938 SOB dh voc siete an ute boit AT aie NG 6094 1515 POK OPO Tana eta 16 mm 6299 POG ny eich awk oni een keane 6406 21 9 e awe ERES 6563 ununes 17 mm 6693 43 64 ao a 6719 TTO sors drei 6875 Ls ORT NR TOST Danda tt irent 18 mm 7087 EX AAP 7188 ATOA o oc ts ac oce e POOR uot O 19 mm 7480 diurno 75 ADE solite 7656 PIO pria la aaa MB leali 20 mm 7874 DIO Lili Teo RT AC RAE ws 7969 TS TB e th deosque B125 a factus 21 mm 8268 cjr METER 8281 BB cac eR Y 8438 55 04 schiena BBA rocked iocans A 22 mm 8661 NG red 875 AI oin ucefe d 8906 e oboe ris dots b 23 mm 9055 PID a ra 9063 A 5 9219 315 16 22 5 cea thes S ET uou ete aca d dca 24 mm z 9449 a AANI I 9531 A mha kalag et 19688 cea UPANG ANAN 25 mm 9843 ei il AA 9844 d nisus DAN 1 0 7 96 1 10 Polaris Industries Inc GENERAL INFORMATION Conversion Table Converts to kg m Multiplied by in lbs ft Ibs kg m ft lbs in lbs Nm x i o Il x Q 3 Il il a T x 25 4 x 6214 in mm in T km 9 kg ee CEN mm cm km mile mi Grams g X 16 387 Cubic centimeters cc x 03381 Fluid Ounces fl oz Imperial quarts Imp qt x 1 201 US quarts US at x 0 833 US quarts US qt x 0 946 US gallons US gal x 3 785 y j Ounces 02 Liters 1 x 0 264 US gallons US gal Pounds force per square inch psi x 6 895
10. at specified RPM Secondary Circuit This circuit consists ofthe large secondary coil windings high tension wire and ground through the spark plug air gap Secondary Clutch Driven clutch on chaincase or jackshaft Seized Piston Galling of the sides of a piston Usually there is atransfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Select Monitor Diagnostic tool which provides static and dynamic displays of the function of critical components in an EFI system It also has the capability to display the contents of the ECU memory Spark Plug Reach Length of threaded portion of spark plug Polaris uses 3 4 2 cm reach plugs Static Timing lgnition timing when engine is at zero RPM Stator Fiate The plate mounted under the flywheel supporting the primary ignition components and lighting coil Surge Tank The fill tank in the liquid cooling system Polaris Industries Inc 1 29 7 96 GENERAL INFORMATION Glossary Of Terms TDC Top dead center Piston s most outward travel from crankshaft Trigger Coil Pulser coil Generates the voltage for triggering closing the thyristor and timing the spark in CDI systems Small coil mounted at the top of the stator plate next to the ignition generating coil V Regulator Voltage regulator Maintains maximum lighting coil output at approx 14 5 ACV as engine RPM increase
11. one meter in length applied in a rotational direction lor Itr Liter Ibs in i Pounds per square inch Left Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnetic Induction As a conductor coil is moved through a magnetic field a voltage will be generated in the windings The common method used to convert mechanical enery to electrical energy in the lighting coil ignition generating coils and trigger coil mi Mile miles mm Millimeter Unit of length in the metric system 1mm 040 N m Newton meters OD Outside diameter Ohm The unit of electrical resistance opposing current flow oz Ounce ounces Piston Clearance Total difference between piston outside diameter and cylinder inside diameter Piston Erosion Piston dome melts Usually occurs at the exhaust port area Possible causes 1 Detonation due to lean fuel air mixture improper spark plug heat range excess heat buildup poor fuel quality octane rating Pre Ignition A problem in combustion where the fuel air mixture is ignited before normal spark ignition Piston looks melted at area of damage Possible causes 1 too hot a spark plug 2 spark plug not properly torqued 3 glowing piece of head gasket metal burr or carbon in the combustion chamber 4 lean fuel air mixture Primary Circuit This circuit is responsible for the voltage build up in the CDI capacitor In the CDI system the
12. or clothing ANTIDOTE External Flush with water Internal Drink large quantities or water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention 5 98 1 14 Polaris Industries Inc GENERAL INFORMATION Glossary Of Terms ABDC After bottom dead center ACV Alternating current voltage Alternator Electrical generator producing voltage alternating current ATDC After top dead center BBDC Before bottom dead center BDC Bottom dead center BTDC Before top dead center CC Cubic centimeters CDI Capacitor discharge ignition Ignition system which stores voltage generated by the stator plate exciter coil in a capacitor or condenser in CDI box At the proper moment a voltage generated by the stator plate pulser coil closes an electronic switch thyristor in the CDI box and allows the voltage in the capacitor to discharge into the primary windings of the ignition coil Center Distance Distance between center of crankshaft and center of driven clutch shaft Chain Pitch Distance between chain link pins 520 2 5 8 or 1 6 cm Chain length is measured in number of pitches pins A 520 x 86 has 86 total pins including the master link pins CI Cubic inches Clutch Buttons Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven clutch Clutch Offset Drive and drive
13. parts include the exciter coil the trigger coil the wires from stator plate to CDI box and to the low resistance primary windings in the ignition coil Primary Clutch Drive clutch on engine Mainly RPM sensitive psi Pounds per square inch PTO Power take off PVT Polaris Variable Transmission Drive Clutch System qt Quart quarts RPM Revolutions per minute Resistance In the mechanical sense friction or load In the electrical sense ohms Both result in energy conversion to heat Right Side Always referred to based on normal operating position of the driver RPM Revolutions per minute Running Time Ignition timing when fully advanced or at specified RPM Secondary Circuit This circuit consists of the large secondary coil windings high tension wire and ground through the spark plug air gap Secondary Clutch Also Driven Clutch The torque sensitive clutch in a CVT system which is located on the transmission input shaft Seized Piston Galling of the sides of a piston Usually there is a transfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Spark Plug Reach Length of threaded portion of spark plug Polaris uses 3 4 2 cm reach plugs Static Timing Ignition timing when engine is at zero RPM Stator Plate The plate mounted under the flywheel supporting the primary ignition compone
14. parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer There is a charge of 25 00 payable to Polaris Industries Inc REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHAS ER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sentto the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear andtear abuse or improper handling This warran ty also does not
15. rack extender 1996 Sport Scrambler Brake Line Retention Strap May Be Missing 1996 Sport Scrambler Exhaust Muffler Restricted 1996 All Except Tr Blazer Tr Boss Cooling Fan Motors May Be Damaged By Water 1996 Sportsman 500 Hose Clamp On Coolant Line May Contact Fuel Filter 1996 Sportsman 500 Engine Overheating due to fan placement and debris in the shroud 1995 1996 4 Stroke Models Moisture May Freeze In Oil Tank Vent Line 1996 1997 Xlorer and Xpress 300s Revised Oil Pump Bleeding Procedure 1996 Sportsman 500 1997 Sportsman and Xplorer 500 Rear Brake Noise Floating Disc Kit 1997 Magnum 6x6 Fuel Tank Vent Line Routed Incorrectly 1997 Sportsman 500 Pressure Relief Slit Missing Form Oil Tank Vent Line 1997 Scrambler 400 1997 Scrambler 500 Brake Lines May Contact CV Boot or Clamp 1995 and 1996 4 Stroke Models Oil Tank Breather Modification For Cold Temperatures 1997 Sportsman and Xplorer 500 Rear Brake Disc Hub Bolt Torque Procedure 1997 Sportsman and Xplorer 500 Revised Serial Number Range For ATV 97 02 Polaris Industries Inc 1 3 5 98 GENERAL INFORMATION Bulletin Index 1996 By Model 1996 Model Bulletin Notes ALL 1996 MODELS ATV 96 11 Moisture May Freeze In Oil Tank Vent Line 1996 Sportsman 500 ATV 96 13 Rear Brake Noise Floating Disc Kit Engine Overheating Hose Clamp May Contact Fuel Filter Cooling Fan Motor May Be Damaged By Water ESE ATV 95 22 Information Plow Blade M
16. this information by contacting the Winnipeg parts depart ment at 204 925 7125 Dealers serviced by a distributor should follow tool ordering procedures established by their respective distributor parts department POLARIS SPECIAL TOOLS VICTOR SPECIALTY TOOL CO 66 School Street Victor New York 14564 TO PLACE AN ORDER Toll Free Tool Order FAX Numbers U S 1 800 7 16 3938 Canadian Dealers 1 800 413 4441 Phone Orders or Information U S 1 716 742 1790 Canadian Dealers 1 204 925 7125 5 98 1 18 Polaris Industries Inc GENERAL INFORMATION Routing Diagram Magnum Cable ties secure wire harness and fuel line to frame Fuel pump impulse line from pump Yee c PSP x kak AE IN s J Cable tie secures coolant hose to frame RN e TA W II L Polaris Industries Inc 1 19 5 98 GENERAL INFORMATION Magnum Routing Diagram 5 98 Cable tie secures Engine wiring Main wire harness Fuel line Brake line Choke Cable Choke Cable Inlet Duct Engine wiring routed around and under inlet duct Clip secures brake line to frame Vent Line Circuit Breaker i Hinr ner mt ug x ad NN GS Solenoid 1 20 Shifter Fuel Impulse Line Su 4 y V b i AN Carburetor Cable tie securing fuel line When mounting fuel tank carburetor vent lines should be in this approximate location B tay Cable tie securing wiring from solenoid
17. to starter Polaris Industries Inc GENERAL INFORMATION Magnum Routing Diagram Cable tie oil tank vent line and fuel pump im pulse hose To carburetor lower LH side Routed over fuel shut off Edge Trim To carburetor top RH side Fuel Pump Cable tie through bulkhead secures three hoses Fuel line from fuel valve Polaris Industries Inc 1 21 5 98 GENERAL INFORMATION Hoses 400s Loosely cable tie Y Spark plug N Oil line wire ps Coolant hose Convoluted tubing Coolant line Loosely cable tie Brake line Cil line Coolant line N OM Front Coolant bottle 5 98 Polaris Industries Inc GENERAL INFORMATION 300 Fan Motor Wiring Raised side of reinforcement ribs face engine Orient fan motor so wiring and vent line are on bottom Fan motor vent line should come straight up from motor between the two large coolant lines through cab assembly and back down into frame as shown Polaris Industries Inc 1 23 5 98 GENERAL INFORMATION Wire Harness ALL MODELS Engine wiring should be routed behind fuel tank cover mount Front Engine wiring must not hang be low side panel All wiring to be on this side of carburetor for proper air box installation Front All loosely A cable tied Loop under carburetor 5 98 1 24 Polaris Industries Inc GENERAL INFORMATION Service Tools CHASSIS SUSPENSION TRANSMISSION
18. 0W ats N A 2 12V 27W Acc Tail Light Brake Light Watts 12V 8 26 26 9 12V 8 26 26 9 12V 8 26 26 9 Gear Box F R N HI LO R N HI LO R N Gear Reduction Low N A N A 6 64 1 6 64 1 Drive Type 520 O ring 520 O ring 520 O ring 520 O ring Final Drive I 13 34 84P 13 36 76P 13 34 84P 12 38 86P Center Drive N A 11 22 70P 11 22 70P Front Drive N A 12 22 64P 13 22 64P Axle to Axle N A N A N A Displacement 378cc 378cc 425cc Engine Model Number EC38PLE07 EC38PLE09 EC38PLE06 Compression Ratio Effective 6 9 1 6 9 1 6 9 1 9 2 1 Bore and Stroke 83x70 83x70 83X70 87 9x70 Spark Plug BR8ES NGK BR8ES NGK BR8ES NGK BKRSES NGK Alternator Output 150W 150W 200W 200W Timing Degrees 23 5 3000 23 5 3000 23 5 3000 30 3500 Carburetion 1 VM34SS 1 VM34SS 1 VM34SS 1 BST34 CV type Main Jet EN 230 230 200 140 Pilot Jet 35 35 30 40 Jet Needle 6CEY6 3 6CEY6 3 6CEY6 3 5F14 3 Needle Jet 0 6 480 0 6 480 0 6 480 P 9 Cutaway a5 1 5 1 5 Pilot Air Jet 4160 Air Screw Pilot Screw 1 5 Turn 15 1 5 Turn 25 See Owner s Manual for rack load recommendations and restrictions 5 98 1 8f Polaris Industries Inc GENERAL INFORMATION Specifications 1998 1998 Model Gen Il Ill or IV Magnum 4x4 II Scrambler 500 III Sportsman 500 IV Big Boss 500 6x6 II Model Number W98AC42A W98BC50A W98CH50A W98AE42A
19. 1 25 26 30 ft Ibs To convert ft Ibs to kg m multiply foot pounds by 1383 To convert kg m to N m move the decimal to the right one position Polaris Industries Inc 1 9 5 98 GENERAL INFORMATION Decimal Equivalents TED Lors ud eee a es 0156 02 ces domaine ler a T AR PRA La ahd 1 mm 0394 BID BRNO PERO ME MER EE 0469 M TD e diese Ga 0625 Din an A takna he DO TTE 2 mm 0787 BA a feiss doting gba 0938 DA AAP 1004 AAP ARA 3 mm 1181 UB eia EE 1250 A ect ota a Test bo BA EUER 1406 B nad aU A RD UG NR 1589 coss EID 4 mm 1575 nk CA cre eR eis 1719 Shoes osi oC er EA ABTS A v 5 mm 1969 Qj cg MX TM 2031 Ig NG atten cw awaits 2188 TODA A 2008 dalai 6 mm 2362 E a hoses 25 A on Cat E 2050 saman WAH KGG 7 mm 2756 Oe sth NA NEE NG 2813 19 04 venue vate A rro EA ERR 2969 B Ib lt valetinsatieas 101025 paaa hace NG 8 mm 3150 DUDA aa teta Aa NG NOLO 3281 11 32 rca Pan Baa xs d S406 A EN 9 mm 3543 23 64 Loi duoc doo ILES a 3594 3 8 err oec dup 375 25 04 DER 3906 zarpar ds 10 mm 3937 VO CARTE iaa ae wee dd 4063 A A EE deir es 4219 cielo 11 mm 4331 TAE AAA TREE 4375 29 04 sola luo Gara POEM 4531 1904 ELE WAGES iria vri ter a 12 mm s 4724 a AAO 4844 TB ianea Bia e vere eu s itta 13 mm 5118 33 04 MESE ERE 5156 NTG a cesa M t paa s 5313 35 604 AA ER ATE di BAGS cobi sos qai e 14 mm 5512 OF Gry ashe Pent bis 5625 SA dite ned WO Da aa 5781 sila 15 mm 5906 19 32
20. 60 Jet Needle 5D78 3 5D78 3 5F81 3 6DH29 3 Needle Jet P 3 7 P 1 P 8 0 6 480 Cutaway N A N A N A 15 Air Screw I Sg P 2 Turns 2 5 Turn 1 Tum See Owner s Manual for rack load recommendations and restrictions 5 98 1 8d Polaris Industries Inc GENERAL INFORMATION Specifications 1998 1998 Model Gen Il Ill or IV Trail Boss Il Trail Blazer 111 Xpress 300 IV Xplorer 300 IV Model Number W98AA25C W98BA25C W98CA28C W98CC28C Height inches cm 44 111 8 46 116 8 45 5 115 6 45 5 115 6 Width inches cm 46 5 118 1 46 116 8 46 116 8 Length inches cm 73 2 185 9 74 5 189 2 79 5 201 9 81 205 7 Wheel Base inches cm 49 75 126 4 49 75 126 4 49 75 126 4 49 75 126 4 Seat Height inches cm 33 83 8 34 86 4 34 86 4 34 86 4 Ground Clearance inches cm 5 5 14 0 6 15 2 6 75 16 5 6 15 2 Weight Dry Lbs Kg 425 203 4 420 Ibs 199 8 512 Ibs 224 7 567 Ibs 252 4 Turning Radius Unloaded in cm 60 152 4 60 152 4 60 152 4 57 144 8 Front Suspension Travel in cm 6 25 15 9 6 25 15 9 6 25 15 9 6 25 15 9 McPherson Strut Rear Suspension inches cm Front Tires Rear Tires 8 5 21 6 23x7x10 22x11x10 8
21. 8x12 25x8x12 Rear Tires 22x11x10 24x11x10 25x12x10 25x12x10 Front Rear Center Tire PSI 4 3 4 3 4 3 5 5 Front Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Rear Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Auxiliary Brake Mechanical Mechanical Mechanical Nec Fuel Capacity U S Gallons 4 3 5 3 5 5 25 Oil Capacity U S Quarts 2 2 OW40 Engine Oil 2 0W40 Engine Oil 3 Coolant Capacity Quarts Liters 2 25 2 16 2 25 2 16 2 25 2 16 2 25 2 16 Gearcase Oil Capacity oz 16 20 20 32 Engine Counter Balancer Oil 100cc N A N A N A Capacity 10W 30 Main Head Light 12V 35 35W 12V 60 60W 12V 60W 12V 60W Grill Mounted Lights 2 12V 35W 2 12V 35W 12V 8 26W 12V 8 26W 12V 8 26W 12V 8 26W HI LO R N HI LO R N HI LO R N Gear Reduction Low N A 6 64 1 6 64 1 6 64 1 Drive Type 520 O ring 520 O ring 520 O ring Shaft Final Drive 1 3 38 84P 12 38 86P 12 38 86P 3 16 1 Center Drive 11 22 70P N A 11 22 70P Front Drive 12 22 64P N A 11 22 68P 2 1 Axle to Axle N A N A N A N A Displacement 425cc 425cc 498 Engine Model Number EC38PLE07 EH42PLE01 EH42PLE01 EHS50PLE01 Compression Ratio Effective 6 9 1 9 2 1 9 2 1 N A Bore and Stroke 83x70 87 9x70 87 9x70 92x75 Spark Plug BR8ES NGK BKR5ES NGK BKR5ES NGK BKR5ES NGK Alternator Output 150W 200W 200W 200W Timing Degrees 23 5 3000 30 3500 30 3500 30 3500 Carburetion 1 VM34SS 1 BST34 CV type 1 BST34 CV type 1 BS
22. Change 100 hrs 12 months Check monthly Front Wheel Bearings 2x4 Annually Annually Inspect and replace if necessary Front Hub Spindle Nut Torque Annually Annually 7 21 Inspect Torque and Locking Fastenerand re AWD Models place if necessary Drive Belt 50 hrs Inspect Adjust Replace if Necessary Clutches Drive And Driven 100 hrs 12 months Inspect Clean Transmission Oil Level Shift Linkage Shift Selector Box 6 As required Periodic Inspection Adjust When Parts are Re placed 50 hrs Inspect Bearings Grease Fitting 50 hrs Inspect Lubricate 50 hrs Inspect Lubricate n o gt o Steering Toe Adjustment Rear Axle Front Suspension Rear Suspension Drive Chain 50 hrs Inspect Daily Adjust and Lubricate if Needed Pre ride Inspect Daily Pre Ride Inspection Item Tires Brake Fluid Brake Fluid Level Brake Lever Travel Brake Pad Wear 200 hrs 24 months Change Every Two Years Pre ride Inspect Daily Pre Ride Inspection Item Pre ride Inspect Daily Pre Ride Inspection Item 10 hrs 100 Monthly 2 34 Inspect Periodically miles Auxiliary Brake Adjustment As required 2 35 Inspect Deflection Daily Adjust ele e Poesie pene nur pensan use meme menus nar ree recente Fane Ru Bois Fasteners Persie merde 248 Ferie venecir tem Pre Ride Daily Inspection Perform the following pre ride inspection daily and when servicing the vehicle at each scheduled ma
23. Disc Fuel Capacity U S Gallons 5 25 3 5 Oil Capacity U S Quarts 3 2 0W40 Engine Oil Coolant Capacity Quarts Liters 2 25 2 16 Gearcase Oil Capacity 0z Counter Balancer Oil Capacity 2 25 2 16 32 2 25 2 16 20 N A 2 25 2 16 100cc 10W30 i2V 60W 12V 60W ziovesw 2tovasw 2 12V 35W Tail Light 12V 8 26W 12V 8 26W 12V 8 26W 12V 8 26W Gear Box HI R N HI LO R N HI LO R N HI LO R N Gear Reduction Low i N A 6 64 1 6 64 1 6 64 1 Drive Type 520 O ring Shaft 520 O ring 520 O ring Final Drive 12 38 86P 3 16 1 12 42 88P 13 42 88P Center Drive NAA 11 22 68P 2 1 11 22 68P 12 22 64P Axle to Axle N A 30 30 116P 30 30 116P Displacement 498 498 425cc Engine Model Number EM50PLE02 EHS50PLE01 EH42PLE01 Compression Ratio Effective 9 2 1 6 9 1 Bore and Stroke 92x75 92x75 87 9x70 83x70 Spark Plug BKR5ES NGK BKR5ES NGK BKR5ES NGK BR8ES NGK Alternator Output 200W 200W 200W 200W 378 7cc EC38PLE06 Timing Degrees 300 3500 30 3500 30 3500 23 593000 Carburetion 1 BST34 CV type 1 BST34 CV type 1 BST34 CV type 1 VM34SS Main Jet 125 142 5 140 210 Pilot Jet 425 42 5 40 30 Pilot Air Jet 160 160 1
24. G SH Rated Transmission Polaris Synthetic Gear Add to proper level on dipstick See trans Gearcase Case Oil mission oil change Type Ill HLR Type Ill HR Type IV Front Gear Case Shaft Drive 2 41 20 oz 16 oz 32 Oz Capacity after draining is approx 20 ounces 3 25 Oz Add to bottom of fill plug threads 100 cc Shift Selector Box Polaris OW 40 Syn 1 oz Oil in selector box should be at the center 30cc antifreeze coolant and thetic Engine Lubri line of the shift selector plungers Do not Coolant Level Approx 2 Quarts distilled water cant or 10W Motor Oil overfill or the selector may hydro lock Front Hubs Premium Demand 2 5 Oz AWD Models Drive Hub Fluid 75cc Polaris Premium Brake Fluid Polaris DOT 3 Brake Fluid Premium Front Gear case Fluid or GL5 80 90 Gear Lube Fill reservoir tank to full line Check after short period of operation when system is cold Add if necessary Refer to 2 18 for more information 60 40 pre mixed Anti freeze Coolant or 50 50 mixture Fill hub at 4 00 or 8 00 position until fluid trickles out Do not force fluid into hub Fill reservoir to 1 4 6 4 mm below cover gasket surface for aluminum reservoir Fill between Min amp Max indicators on plastic reservoir 5 98 2 3 Polaris Industries Inc
25. Height inches cm 46 119 4 47 119 4 47 119 4 47 119 4 Width inches cm 46 116 8 45 5 115 6 46 116 8 46 116 8 Length inches cm 77 195 6 74 5 189 2 81 205 7 103 261 6 Wheel Base inches cm 49 75 126 4 48 5 123 2 50 5 128 3 75 190 5 Seat Height inches cm 34 86 4 33 83 8 34 86 4 34 91 4 Ground Clearance inches cm 6 152 6 5 15 2 1 27 9 5 5 14 0 Weight Lbs Kg 595 Ibs 274 542 Ibs 246 660 Ibs 316 870 Ibs 395 Turning Radius Unloaded in cm 65 165 60 152 4 65 165 98 249 Front Suspension Travel in cm 6 25 15 9 8 2 21 6 6 25 15 9 6 25 15 9 McPherson Strut Rear Suspension inches cm Front Tires 8 5 21 6 25x8x12 8 5 24 1 23x7X10 9 5 24 1 25x8x12 7 5 21 6 25x8x12 Rear Tires 25x11x10 24x11x10 25x11x10 25x11x10 Center Tires N A N A N A 25x11x10 Front Rear Center Tire PSI 4 3 4 3 5 5 i 5 5 5 Front Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Rear Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Auxiliary Brake Mechanical Mech Hydr Di
26. Kilopascals kPa Kilopascals kPa x 0 145 Pounds force per square inch psi Kilopascals kPa x 0 01 Kilograms force per square cm Kilograms force per square cm x 98 1 Kilopascals kPa C to F 9 C 40 5 40 F F to C 5 F 40 9 40 C Polaris Industries Inc 1 11 5 98 GENERAL INFORMATION Tap Drill Charts SAE Tap Drill Sizes Thread Size Drill Size Thread Size Drill Size 1 2 13 27 64 1 2 20 29 64 9 16 12 31 64 9 16 18 33 64 5 8 11 17 32 5 8 18 37 64 3 4 10 21 32 3 4 16 11 16 7 8 9 49 64 7 8 14 13 16 1 8 7 8 1412 59 64 1 1 8 7 63 64 1 1 8 12 1 3 64 1 1 4 7 1 7 64 1 1 4 12 1 11 64 1 1 2 6 1 11 32 1 1 2 12 1 27 64 1 3 4 5 1 9 16 1 3 4 12 1 43 64 2 4 1 2 1 25 32 2 12 1 59 64 2 1 4 4 1 2 2 1 32 2 1 2 4 2 1 4 2 3 4 4 2 1 2 3 4 2 3 4 10 x 1 25 10 x 1 50 11x 1 50 12x 1 50 12x 1 75 5 98 1 12 Polaris Industries Inc GENERAL INFORMATION Warranty LIMITED WARRANTY Polaris Industries Inc 1225 Highway 169 North Minneapolis Minnesota 55441 5078 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or work manship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer
27. Location mie oe The carburetor I D number is in one of the following gt locations e 4stroke models right side center of the carburetor body e 2stroke models right side of carbu retor body near choke plunger boss Transmission I D Numbers Polaris Industries Inc 1 1 5 98 GENERAL INFORMATION Model Identification 1996 Model Identification The machine model and serial number must be used with any correspondence regarding service or repair 1 996 Machine Model Number Identification W 96 8144 MODEL arvorLight Utility Vehicle N U M B E RS Year Designation Basic si Engine Designation Designation 1996 Engine Designation Numbers 1996 Chassis Designation Numbers OE aera cae 250 Serer ee Magnum 2x4 c 300 VB istiga Trail Blazer Scrambler A APR 400 BO occ een 4 Sportsman 4x4 dd bolo qs 425 BT oie sues Magnum 4x4 o ANA spetta 500 da Parada Trail Boss Sport do 400 6x6 Magnum 6x6 e a Xplorer 300 Xplorer 400 dE med Sportsman 500 Bb e pitt bores Xpress 300 Xpress 400 5 98 1 1a Polaris Industries Inc GENERAL INFORMATION Model Identification Vehicle Identification Number 1997 and Later Model Years 1997 to Current ATVs and Light Utility Vehicles have a 17 digit Vehicle Identification Number VIN The VIN is organized as follows Digits 1 3 World Manufacturer Identifier For Polaris ATVs this is 4XA Digits 4 9 Vehicle Descriptor Section Digits 10 17 Vehicle Indicator Section Digits 4 8 of the VI
28. N identify the body style drive type engine type and emissions equipment The VIN number and the model number must be used with any correspondence regarding service or repair World Mfg ID Vehicle Descriptor Vehicle Identifier 1997 Current VIN Number Emissions Model Body Style p Engine Year Individual Serial No Powertrain Check Digit Plant No Vehicle Identification Number Model Number Key A Gen Il A 2x4 chain 25 EC25PF 250cc A Approved by CARB A Std B Gen Ill C 4x4 chain 28 EC28PF 300 cc CzNon CARB Approved B 1st Color Option CARB California Air Resources Board Year Letter Identification The tenth digit of a 17 digit VIN is the model year of the vehicle Example W 1998 X 1999 etc Refer to the listing below V 1997 W 1998 X 1999 Y 2000 1997 to Current Model Numbers The model year is also listed in the model number The last 4 digits in the model number correspond to digits 4 through 8 of the Vehicle Identification Number VIN Machine Model Number Identification W ATV or Light Utility Vehicle TTT W 98 CH50A B Option Indicator Year Designation p it 5 Model st DigitszDigits 4 8 of VIN 5 98 1 1b Polaris Industries Inc GENERAL INFORMATION E 4c Polaris Industries Inc GENERAL INFORMATION Publications 1996 Publication Numbers Model No Owner s Manual PN Parts Manual PN 1996 Parts Micro Fiche Set PN Wars ses esso Jesse
29. NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANT Y SERVICE If your ATV requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Always use Polaris engine oil 2 Never substitute or mix oil brands as serious engine damage and voiding of warranty can result Polaris Industries Inc 1 13 5 98 GENERAL INFORMATION Service Tips In order to perform service work efficiently and to prevent costly errors the technician should read the text in this manual thoroughly familiarizing him herself with procedures before beginning Pictures and illustrati
30. PLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your origina selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealerto resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms wili remain in effect Engine Oil 1 Always use Polaris engine oil 2 Never substitute or mix oil brands as serious engine damage and voiding of warranty can result Polaris Industries Inc 1 27 7 96 GENERAL INFORMATION Glossary Of Terms ABDC After bottom dead ce
31. POLARIS INDUSTRIES INC ATV AND LIGHT UTILITY VEHICLE SERVICE MANUAL Foreword This manual is designed primarily for use by ATV service technicians in a properly equipped shop Since a certain knowledge of mechanical theory tool use and shop procedures is necessary to perform the service work safely all operations should be performed by qualified service personnel only In order to perform the work efficiently and prevent costly errors the technician should read the text and be familiar with procedures before starting the work Cleanliness of parts and tools as well as the work area is of primary importance All references to left and right side of the vehicle are from the operator s perspective when seated in a normal riding position This manual includes procedures for maintenance operations component identification and unit repair along with service specifications for 1996 1998 model Polaris ATVs and Light Utility Vehicles The section index tabs enable the user to quickly locate the section desired In addition a table of contents is placed at the beginning of each section for location of specific page numbers and service information Keep this manual available for reference in the shop area To keep this manual current it is important that it is updated yearly with new model information and specifications At the time of publication all information contained in this manual was current However all materials and specifica
32. See Owner s Manual for rack load recommendations and restrictions Polaris Industries Inc 1 8g 5 98 GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used as a general guideline Some fasteners require a special torque procedure during installation In addition some fastener torque values may be different than the standard torque value listed below Critical fastener torques are listed where applicable at the beginning of each section Always refer to the appropriate chapter for specific torque specifications and procedures before using standard torque O OG Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque in Ibs kg m 10 BAY ANNE OT BT o O soda IN vy 60 69 10 Be loses Ina ate aes ILS cebat view cate 49456 eic ore nA 68 78 Torque ft Ibs kg m 14 A O AA BA Bi ad ited wma MP RAP Bol beside ees 12 1 6 14 2 SMARRITI BO MUNERA E CIEN 10 1 4 c bna rura 14 1 9 5 6 ji PD MALI dels ERI Seis RS AA 25 3 5 56 PA aid A a o baba wacess bosoni 29 4 0 3 8 O N PIRATA RETRO TRE TIRO 30 ACRI ue ba dua Race s 45 6 2 3 8 Lr TT 23182 cresce Rt 3544 8 IN 50 6 9 716 e O FORO 50 519 cibo dang a 70 9 7 TIG PO akan 55 4 8 5 someter Rs ETE ERA MR M 80 11 0 12 A cok GE NA 50 6 9 75 10 4 ic a hahaa 110 15 2 12 20 ooi Ba tk ES v oso motas 90 12 4 120 16 6 Metric 6x 1 0 72 78 In Ibs 8 x 1 25 14 18 ft Ibs 10x
33. Sport ATV 96 08 Service Cooling Fan Motor May Be Damaged By Water PL ATV 98 07 Information Exhaust Muffler Restriction Me oe on T eM ATV 96 06 Service Brake Line Retention Strap May Be Missing ATV 95 20 Information Incorrect Jetting Chart In Owners Manual ATV 95 18 Service Loose Headlight Mounting Screws ATV 96 12 Service Revised Oil Pump Adjustment Procedure ATV 96 08 Service Cooling Fan Motor May Be Damaged By Water ATV 95 17 Information 1996 300 Xpress ATV 96 12 Service 1996 300 Xplorer Synthetic Chaincase Lubricant Recommended Revised Oil Pump Adjustment Procedure Cooling Fan Motor May Be Damaged By Water ATV 95 22 Information Plow Blade Mounting Kit Applications 1996 Trail Boss ATV 96 01 Service Water Leaks at Inner PVT Cover 1996 Trail Blazer ATV 95 18 Service Loose Headlight Mounting Screws 5 98 1 3a Polaris Industries Inc GENERAL INFORMATION Service Bulletin Index 1997 1998 By Model 1897 Model Bulletin Type Nos All 1997 Models Z Z Sportsman 500 ATV 97 03 Service Loose Pins And Locking Hub For Rear Disc Brake Revised Serial Number Range For ATV 97 02 COO favre seme Reer Brake Disc Hub Bot Torque Procedure Co i favs Service Pressure Re Sit Missing From Oi Tank Vent Lre ATV9618 Semice RearBrakeNoise O Loose Pins And Locking Hub For Rear Disc Brake Revised Serial Number Range For ATV 97 02 E o favoro Service Roar Bak
34. Suspension Travel McPherson Strut Rear Suspension 8 5 8 5 6 585 Ibs 65 6 25 8 5 8 5 Front Tires 23x7x10 25x8x12 23x7x10 25x8x12 Rear Tires 24x11x10 25x12x10 22x11x10 25x12x10 Center Tires N A N A N A Front Rear Center Tire PSI 4 3 4 3 4 3 Front Brake Hydr Disc Hydr Disc Hydr Disc Rear Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Auxiliary Brake Mechanical Mechanical Mechanical Fuel Capacity U S Gallons 4 4 4 Oil Capacity U S Quarts 2 2 Coolant Capacity Quarts Liters 2 25 2 16 2 25 2 16 Gearcase Oil Capacity oz 20 Engine Counter Balancer Oil 100cc 100cc 100cc 100cc Capacity 10W 30 Main Head Light 12V 60 55W 12V 60W 12V 55W 12V 60W Accessory 2 12V 35W N A 2 12V 35W 12V 8 26W 12V 8 26W 12V 8 26W Gear Box HI LO R N HI LO R N F F N HI LO R N Gear Reduction Low 6 64 1 6 64 1 N A 6 64 1 Drive Type 520 O ring 520 O ring 520 O ring 520 O ring Final Drive 13 34 84P 13 34 84P 13 34 84P 13 34 84P Center Drive 11 22 70P N A 11 22 70P Front Drive 13 22 64P 13 22 64P Axle to Axle Displacement Engine Model Number Compression Ratio Effect
35. T34 CV type Main Jet 230 140 140 142 5 Pilot Jet 40 40 Pilot Air Jet N A 160 160 Jet Needle 6CEY6 3 5F81 3 5F81 3 Needle Jet 0 6 480 P 8 P 8 P 1 N A N A Air Screw or Fuel Screw Tums Out See Owner s Manual for rack load recommendations and restrictions Polaris Industries Inc 5 98 GENERAL INFORMATION Specifications 1997 1997 Model Gen Il Ill or IV Scrambler 500 III Xplorer 500 1V Magnum 6x6 II Model Number W97BC50A W97CD50A W97AE42A Height 47 47 47 400 6x6 IN W97AE38A Width 455 5 46 46 Length PE 7 Wheel Base 48 5 Seat Height Ground Clearance Weight uu Turning Radius Unloaded Front Suspension Travel McPherson Strut 5 5 852 Ibs 98 6 25 5 5 830 Ibs 98 6 25 649 Ibs 65 6 25 Rear Suspension 9 5 8 5 8 5 Front Tires 23x7X10 25x8x12 25x8x12 25x8x12 Rear Tires 24x11x10 25x12x10 25x12x10 25x12x10 Center Tires N A N A 25x12x10 25x12x10 Front Rear Center Tire PSI 4 3 5 5 5 5 5 5 5 5 Front Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Rear Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Auxiliary Brake Hydr Disc Hydr
36. cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur duringtrailertransit or as a result of unauthorized service orthe use of unauthorized parts In addition this warran ty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replace ment of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRAN TY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY PO LARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IM
37. e loop from line ZL al Le SZ Shift Lever Route smoothly downward to oil tank vent fitting Attach oil tank vent line to air box l ittin Forward _ a IR fitting on Air box Be sure hose is routed smooth ly with no kinks sharp bends or Route over top of carb low areas under carburetor vent line T Polaris Industries Inc 1 37 10 96 CHAPTER 2 MAINTENANCE Periodic Maintenance Chart Pre Ride Inspection a aes Recommended Lubricants and Capacities Lubricant and Maintenance Product Numbers Lubrication Chart a Front Gearcase Lubrication Carburetor Adjustments Carburetor Draining o Breather System Maintenance Compression Test Battery Maintenance General Maintenance Coolant System Maintenance 2 Stroke Engine Maintenance 4 Stroke Engine Maintenance Toe Alignment Inspection Chassis Maintenance Drive Chain Inspection Adjustment Drive Chain Adjustment Concentric Swingarm 2 13 2 14 2 14a 2 14b 2 37a MAINTENANCE Periodic Maintenance Chart Inspection adjustment and lubrication intervals of important components is listed in the following chart Maintenance intervals are based upon average riding conditio
38. e metric system 1mm 040 N m Newton meters OD Outside diameter Ohm The unit of electrical resistance opposing current flow oz Ounce ounces Piston Clearance Total distance between piston and cylinder wall Piston Erosion Piston dome melts Usually occurs atthe exhaust port area Possible causes 1 lean fuel air mixture 2 improper spark plug heat range Pre Ignition A problem in combustion where the fuel air mixture is ignited before normal spark ignition Piston looks melted at area of damage Possible causes 1 too hot a spark plug 2 spark plug not properly torqued 3 glowing piece of head gasket metal burr or carbon in the combustion chamber 4 lean fuel air mixture Primary Circuit This circuit is responsible for the voltage build up in the CDI capacitor In the CDI system the parts include the exciter coil the trigger coil the wires from stator plate to CDI box andto the low resistance primary windings in the ignition coil Primary Clutch Drive clutch on engine psi Pounds per square inch PTO Power take off PVT Polaris Variable Transmission Drive Clutch System qt Quart quarts RPM Revolutions per minute Resistance Inthe mechanical sense friction orload Inthe electrical sense ohms Both result in energy conversionto heat Right Side Always referred to based on normal operating position of the driver RPM Revolutions per minute Running Time Ignition timing when fully advanced or
39. ed torque value When removing nuts bolts or screws from a part with several fasteners loosen them all about 1 4 turn before removing them A If the condition of any gasket or O Ring is in question replace it with a new one Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks A Some procedures will require removal of retaining rings or clips Because removal weakens and deforms these parts they should always be replaced with new parts When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation A Because removal damages seals replace any oil or grease seals removed with new parts A Polaris recommends the use of Polaris lubricants and greases which have been specially formulated for the top performance and best protection of our machines In some applications such as the engine warranty coverage may become void if other brands are substituted A Grease should be cleaned from parts and fresh grease applied before reassembly of components Deteriorating grease loses lubricity and may contain abrasive foreign matter A Whenever removing or reinstalling batteries care should be taken to avoid the possibility of explosion resulting in serious burns Always disconnect the negative black cable first and reconnect it last Battery electrolyte contains sulfuric acid and is poisonous Serious burns can result from contact with the skin eyes
40. hich occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warran ty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replace ment of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRAN TY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY PO LARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES
41. ing Diagrams 104 ote owerd aes DOE ELS 1 19 1 24 GENERAL INFORMATION Model Identification Engine Serial Number Location Whenever corresponding about an engine be sure to refer to the engine model number and serial number This information can be found on the sticker applied to the manual starter recoil housing An additional number is stamped in one of the following locations e 4stroke models center top of crankcase beneath the cylinder coolant elbow e 2 stroke liquid cooled models center top of crankcase beneath the carburetor mounting flange e 2stroke air cooled models top of crankcase near right side of cylinder Machine Model Number and Serial Number Location The machine model number and serial number are im portant for vehicle identification The machine model mm number is located on the frame on the left side of the ET vehicle near the oil tank Depending on model the Se rial number will be stamped into the frame in one of the following locations On the right side of the vehicle in front of the shift selector box A 1996 Under the seat on the upper shock mount cross member B 1996 e On the right hand frame rail C near the air box 1997 On the left hand lower frame rail D near the rear A arm mount 1998 Current Transmission I D Number Location Transmission model and serial numbers are located on top of the transmission case below the shifting bell cranks Carburetor I D Number
42. intenance e Tires check condition and pressures Fuel and oil tanks fill both tanks to their proper level Do not overfill 4 stroke oil tank All brakes check operation and adjustment includes auxiliary brake Throttle check for free operation and closing Headlight Taillight Brakelight check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for tightness of wheel nuts and axle nuts check to be sure axle nuts are secured by cotter pins Drive chain condition and slack refer to drive chain adjustment Air cleaner element check for dirt clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle 5 98 2 2 Polaris Industries Inc MAINTENANCE Recommended Lubricants and Capacities Recommended Lubricants Quick Reference Lubricants and maintenance product part numbers are listed on page 2 4 Type Capacity See Page Engine Oil Polaris Premium 4 2 Quarts Add to proper level on dipstick See oil 2 23 4 Strokes Synthetic OW 40 change Engine Injector Polaris Premium 2 Quarts Add to top of oil reservoir as required 2 22 Oil 2 Strokes TC W3 2 Stroke oil Counter Balancer SAE 10W30 Motor Oil 3 2 oz Add to proper level on dipstick 2 21 Oil 400L Engines S
43. ive N A ECGBPLEOS 6 9 1 6 9 1 6 9 1 6 9 1 83x70 83x70 N A Bore and Stroke 83x70 Spark Plug BR8ES NGK BR8ES NGK BR8ES NGK Alternator Output 200W 150W 200W Timing Degrees 23 59 3000 23 5 3000 23 59 3000 23 5 3000 Carburetion 1 VM34SS 1 VM34SS 1 VM34SS Main Jet 200 200 230 Pilot Jet 30 30 35 30 Jet Needle 6CEY6 3 6CEY6 3 6CEY6 3 0 6 480 0 6 480 0 6 480 Needle Jet 0 6 480 Cutaway 1 5 1 5 Air Screw Pilot Screw 1 5 Tum 1 5 Turn See Owner s Manual for rack load recommendations and restrictions 5 98 1 8b Polaris Industries Inc 1 5 1 5 Turn 1 5 EL n GENERAL INFORMATION Specifications 1997 1997 Model Gen Il Ili or IV Scrambler 4x4 Ill Magnum 2x4 Il Magnum 4x4 Il Sportsman 500 IV Model Number W97BC38C W97AA42A W97AC42A W97CH50A Height 47 46 47 71 77 7 Wheel Base 49 75 49 75 50 5 Seat Height 33 gg 34 34 Ground Clearance 6 5 5 6 10 490 Ibs 534 lbs 595 lbs 649 lbs Turning Radius Unloaded 60 60 65 65 Front Suspension Travel 8 5 6 25 6 25 McPherson Strut Rear Suspension 8 5 8 5 8 5 Front Tires i 23x7x10 23x7x10 25x
44. lower LH side Routed over fuel shut off Edge Trim To carburetor top RH side Fuel Pump Cable tie through bulkhead secures three hoses Fuel line from fuel valve Polaris Industries Inc 1 33 7 96 GENERAL INFORMATION Hoses Loosely cable tie j Front Spark plug Pi Oil line wire gt HAS Coolant hose 7 GIS Mg KA Na Convoluted tubing Coolant line Loosely cable tie Brake line Oil line Coolant line Front Coolant bottle 7 96 1 34 Polaris Industries Inc GENERAL INFORMATION 300 Fan Motor Wiring Raised side of reinforcement ribs face engine Orient fan motor so wiring and vent line are on bottom Fan motor vent line should come straight up from motor between the two large coolant lines through cab assembly and back down into frame as shown Polaris Industries Inc 1 35 7 96 GENERAL INFORMATION Wire Harness ALL MODELS Engine wiring should be routed behind fuel tank cover mount Fuel tank Engine wiring must not hang be low side panel All wiring to be on this side of carburetor for proper air box installation Front All loosely 7 ta cable tied Wal Carburetor Loop under carburetor 7 96 1 36 Polaris Industries Inc GENERAL INFORMATION Oil Tank Vent Line Routing Oil Tank Vent Line Routing 1996 Sportsman 500 Forward Area of e possible ng kink gt Be sure to route line through top half of hold de ug er remov
45. n clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face Clutch Weights Three levers in the drive clutch which relative to their weight profile and engine RPM cause the drive clutch to close Condenser Capacitor A storage reservoir for electricity used in both E T and CDI systems Crankshaft Run Out Run out or bend of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in lower half of crankcase Measure at various points especially at PTO Maximum allowable run out is 006 02 cm DCV Direct current voltage Detonation The spontaneous ignition of the unburned fuel air mixture after normal spark ignition Piston looks hammered through rough appearance around hole Possible causes 1 too high a compression ratio for the fuel octane 2 low octane fuel 3 over advanced ignition timing Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Driven Clutch Also Secondary Clutch The torque sensitive clutch in a CVT system which is located on the transmission input shaft Electrical Open Open circuit An electrical circuit which isn t complete i e poor connections or broken wire at hi lo beam switch resulting in loss of headlights Electrical Short Short circuit An electrical circuit which is completed before the current reaches the in
46. ns and a vehicle speed of approximately 10 miles per hour Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for re placement parts Always use genuine Polaris parts mCAUTION Due to the nature of these adjustments it is recommended that service be performed by an authorized Polaris dealer For engine oil short trip cold weather riding also constitutes severe use Pay special attention to oil level A rise in oil level in cold weather can indicate moisture collecting in the oil tank p Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently E Emission Control System Service California For 4 cycle models built after January 1 1997 Engine Oil Level Change Haus Frequency See Page Remi 100 hrs Check Level Daily Break In service at 1 month Oil Filter 4 strokes 100 hrs Replace with oil change Oil Pump Cable 2 strokes Inspect Adjust Lubricate Replace if Required i Foam Pre Cleaner 2 22 2 25 Inspect Clean amp oil more often in dirty cond Air Filter Main Element Weekly Weekly 2 22 2 25 Inspect Replace if necessary Air Box Sediment Tube Drain deposits whenever visible Engine Breather Filter Monthly ae Inspect and replace if necessary gt Oil Tank Vent Hose 100 hrs 12 months Valve Clearance 4 strokes 100 hrs 12 months Inspect Adjust Counter Balancer Fluid 400s
47. nter ACV Alternating current voltage Alternator Electrical generator producing voltage alternating current ATDC After top dead center BBDC Before bottom dead center BDC Bottom dead center BTDC Before top dead center CC Cubic centimeters CDI Capacitor discharge ignition Ignition system which stores voltage generated by the stator plate exciter coil in a capacitor or condenser in CDI box Atthe proper moment a voltage generated by the stator plate pulser coil closes an electronic switch thyristor in the CDI box and allows the voltage in the capacitor to discharge into the primary windings of the ignition coil Center Distance Distance between center of crankshaft and center of driven clutch shaft Chain Pitch Distance between chain link pins No 35 3 8 or 1 cm Polaris measures chain length in number of pitches Cl Cubic inches Clutch Buttons Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven clutch Clutch Offset Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face Clutch Weights Three levers in the drive clutch which relative to their weight profile and engine RPM cause the drive clutch to close Condenser Capacitor A storage reservoir for electricity used in both E T and CDI systems Crankshaft Run Out Run out or bend of crankshaft measured with a dial indicator while crankshaf
48. nts and lighting coil 5 98 1 16 Polaris Industries Inc GENERAL INFORMATION Glossary Of Terms TDC Top dead center Piston s most outward travel from crankshaft Trigger Coil Pulser coil Generates the voltage for triggering closing the thyristor and timing the spark in CDI systems Small coil mounted at the top of the stator plate next to the ignition generating coil Voltage Regulator Maintains Prevents over charging of battery or damage to electrical components as engine RPM increases Venturi An area of air constriction A venturi is used in carburetors to speed up air flow which lowers pressure in venturi to below atmospheric pressure causing fuel to be pushed through jets etc and into the venturi to be mixed with air and form a combustible air fuel mixture Volt The unit of measure for electrical pressure of electromotive force Measured by a voltmeter in parallel with the circuit Watt Unit of electrical power Watts amperes x volts WOT Wide open throttle Polaris Industries Inc 1 17 5 98 GENERAL INFORMATION Special Tools Special too part numbers and usage are listed in each section of this manual as required for a specific service procedure For complete tool information refer to the Service Tool Catalog PN 9914681 U S dealers can obtain a current price list or get tool information by contacting Victor Specialty Tool Company at the address phone or FAX number listed below Canadian dealers can obtain
49. o Dis Hub Bot Torque Procedure KI vea series Rare nos AAA EITC OOO O EA IN 1998 Model Bule n Type Notes O Z O o No bulletins issued as of 4 24 1998 All 1998 Models he Big Boss 500 6x6 Sportsman 500 Scrambler 500 pore c TTE cede i Cressi Ti ee EE AS Trail Boss 5 98 1 3b Polaris Industries Inc GENERAL INFORMATION 1996 Paint Codes O moa fon coor Rasse PFBDiGerHs Order direct from Midwest Industrial Coatings 612 934 8252 Mix as directed Polaris Industries Inc 1 4 10 96 GENERAL INFORMATION 1997 Paint Codes Xplorer 300 Brushed Aluminum N A Xplorer 500 Springs Screamin Yellow N A DESCRIPTION NUMBER NUMBER Tal Bazar Ce Bre fee res nsi Tra Boss Spon UU im rie e a Xpress 300 fei fee AM Xpress 400 LL tw NRT NR CO Nx NA a A EN Na NA Xplorer 400 44931 O eee ce N A Springs WA Scrambler ax ees e dee a Scrambler 50 A ee O e 00Na fh Sposa Da Sportsman 500 e Rr fos ar E Bo Magnum zd Brushed Aluminum N A N A Rack S500 Magnum Da Brushed Aluminum N A N A Eddie Bauer Green 8520150 Magnum DE Brushed Aluminum Big Boss OS 10 96 1 4a Polaris Industries Inc GENERAL INFORMATION 1998 Paint Codes 1998 Paint Codes Big Boss 500 6X6 Springs Eddie B Green 8520150 P195 44931 Sportsman
50. ons have been included with the text as an aid Notes cautions and warnings have also been included for clarification of text and safety concerns However a knowledge of mechanical theory tool use and shop procedures is necessary to perform the service work safely and satisfactorily Use only genuine Polaris service parts AN Cleanliness of parts and tools as well as the work area is of primary importance Dirt and foreign matter will act as an abrasive and cause damage to precision parts Clean the vehicle before beginning service Clean new parts before installing A Watch for sharp edges which can cause personal injury Protect hands with gloves when working with sharp components A If difficulty is encountered in removing or installing a component look to see if a cause for the difficulty can be found If it is necessary to tap the part into place use a soft face hammer and tap lightly A Some of the fasteners were installed with locking agents Use of impact drivers or wrenches will help avoid damage to fasteners A Always follow torque specifications as outlined throughout this manual Incorrect torquing may lead to serious machine damage or as in the case of steering components can result in injury or death for the rider s A If a torquing sequence is indicated for nuts bolts or screws start all fasteners in their holes and hand tighten Then following the method and sequence indicated in this manual tighten evenly to the specifi
51. ounting Kit Applications ATV 96 08 Cooling Fan Motor May Be Damaged By Water ATv 96 04 Poor Seat Fit 1996 Magnum 4x4 Cooling Fan Motor May Be Damaged By Water Poor Seat Fit Water Leaks at Inner PVT Cover Synthetic Chaincase Lubricant Recommended Cooling Fan Motor May Be Damaged By Water Poor Seat Fit Cooling Fan Motor May Be Damaged By Water 3131313 SE SIE gt o co Service Information Service 96 04 96 01 95 17 Information Service Information 1996 Magnum 2x4 Service AGA o o e Co 96 04 96 08 Information 1996 400 6x6 Service Ea aa di ATV 95 17 Information Synthetic Chaincase Lubricant Recommended 1996 Sportsman 4x4 ATV 96 08 Service Cooling Fan Motor May Be Damaged By Water 1996 Scrambler ATV 96 08 ATV 96 07 ATV 96 06 Service ATV 95 21 Information ATV 95 20 Information 1996 400 Xplorer ATV 96 08 Service ATV 95 22 ATV 95 17 1996 400 Xpress ATV 96 08 Synthetic Chaincase Lubricant Recommended Cooling Fan Motor May Be Damaged By Water Exhaust Muffler Restriction Service Information Brake Line Retention Strap May Be Missing Water May Freeze In Oil Pump Housing Incorrect Jetting Chart In Owners Manual Cooling Fan Motor May Be Damaged By Water Information Plow Blade Mounting Kit Applications Information Synthetic Chaincase Lubricant Recommended Cooling Fan Motor May Be Damaged By Water Service 1996
52. s Venturi An area of air constriction A venturi is used in carburetors to speed up air flow which lowers pressure in venturi to below atmospheric pressure causing fuel to be pushed through jets etc and into the venturi to be mixed with air and form a combustible air fuel mixture Volt The unit of measure for electrical pressure of electromotive force Measured by a voltmeter in parallel with the circuit Watt Unit of electrical power Watts amperes x volts WOT Wide open throttle 7 96 1 30 Polaris Industries Inc GENERAL INFORMATION Magnum Routing Diagram Cable tie secures Shifter Engine wiring Main wire harness Fuel Impulse Fuel line Line Brake line Choke Cable Choke Cable Cable tie securing fuel line Inlet Duct Engine wiring routed around and under inlet duct UN al When mounting fuel Vo tank carburetor vent Clip secures 3 lines should be in brake line to a this approximate frame i Vent Line location 3 E Circuit Breaker FB Cable tie securing wiring from solenoid EA to starter Solenoid Polaris Industries Inc 1 3 7 96 GENERAL INFORMATION Magnum Routing Diagram Cable ties secure wire harness and fuel line to frame Fuel pump impulse line from pump Cable tie secures coolant hose to frame 7 96 1 32 Polaris Industries Inc GENERAL INFORMATION Magnum Routing Diagram Cable tie oil tank vent line and fuel pump im pulse hose To carburetor
53. sc Hydr Disc 35 5 25 35 2 0W40 Engine Oil 2 0W40 Engine Oil 2 0W40 Engine Oil Cooling System Capacity Qt iter 2 25 2 16 2 25 2 16 2 25 2 16 Gearcase Oil Capacity oz 32 Main Head Light 12V 60W 2 12V 30 30W 12V 60W 12V 60W Grill Mounted Lights 2 12V 27W N A 2 12V 27W 212V 27W Tail Light Brake Light Watts 12V 8 26 26 9 12V 826 269 12V 8 26 26 9 12V 8 26 26 9 Gear Box HI LO R N HI R N HI LO R N HI LO R N Gear Reduction Low 6 64 1 N A 6 69 1 6 64 1 Drive Type 520 O ring 520 O ring Shaft 520 O ring Final Drive 12 38 86P 13 36 76P 3 16 1 12 42 88P Center Drive 11 22 70P N A N A 11 24 72P Front Drive 11 22 68P N A 2 1 11 22 68P Axle to Axle N A N A N A 30 30 116P Displacement 425cc 499 498 498cc Engine Model Number EH42PLE02 EH50PLE04 EH50PLE07 EH50PLE06 10 2 1 92x75 Compression Ratio Full Stroke 9 2 1 10 2 1 Bore and Stroke 87 9x70 92x75 Spark Plug BKR5ES NGK BKR5E NGK BKR5E NGK BKR5E NGK Alternator Output 250W 250W 250W Timing Degrees 30 3500 300 3500 300 3500 30 3500 Carburetion 1 BST34 CV type 1 BST40 CV type 1 BST34 CV type 1 BST34 CV type Main Jet 140 155 142 5 140 Pilot Jet 40 40 42 5 40 Pilot Air Jet Jet Needle 6H25 94 3 5D78 3 5D78 3 Needle Jet Y 0 P 1 Q 6 Cutaway N A NA N A N A Air Screw or Fuel Screw Tums Out 2 5 2 0 2 0 2 0
54. t Suspension Travel 6 25 15 9 8 2 21 6 McPherson Strut 5 5 15 2 6 5 152 7 375 19 0 570 lbs 267 65 165 6 25 15 9 5 5 14 0 534 Ibs 244 60 152 4 6 25 15 9 Rear Suspension 8 5 21 6 8 5 21 6 8 5 21 6 8 5 21 6 Front Tires 23x7x10 23x7x10 25x8x12 23x7x10 Rear Tires 22x11x10 22x11x10 25x11x10 24x11x10 Front Rear Center Tire PSI 4 3 4 3 4 3 4 3 Front Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Rear Brake Hydr Disc Hydr Disc Hydr Disc Hydr Disc Auxiliary Brake Mechanical Mechanical Mechanical Mechanical Fuel Capacity U S Gallons 4 4 3 5 Oil Capacity U S Quarts 2 2 0W40 Engine oil Cooling System Capacity qt liter 2 25 2 13 2 25 2 13 2 25 2 13 2 25 2 13 32 100cc Gearcase Oil Capacity oz Engine Counter Balancer Oil Capacity 10W 30 20 100cc 20 N A 100cc Main Head Light 12V 55W 2 12V 30 30W 12V 60W 12V 60 6
55. t is supported between centers on V blocks or resting in lower half of crankcase Measure at various points especially at PTO Maximum allowable run out is 006 02 cm DCV Direct current voltage Detonation The spontaneous ignition of the unburned fuel air mixture after normal spark ignition Piston looks hammered through rough appearance around hole Possible causes 1 too high a compression ratio for the fuel octane 2 low octane fuel 3 over advanced ignition timing Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Electrical Open Open circuit An electrical circuit which isn t complete i e poor connections or broken wire at hi lo beam switch resulting in loss of headlights Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended oo i e a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake ights End Seals Rubber seals at each end of the crankshaft Engagement RPM Engine RPM at which the drive clutch engages to make contact with the drive belt ft Foot feet Foot Pound Ft lb A force of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon Head Volume Cylinder head capacity in cc head removed from engine with spark plug ins
56. talled High Tension Lead The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug Holed Piston Piston in which a hole has formed on the dome Possible causes 1 detonation 2 pre ignition HP Horsepower ID Inside diameter Ignition Coil A type of transformer which increases voltage in the primary windings approx 200V to a higher voltage in the secondary windings approx 14KV 32KV through inductions Secondary voltage is high enough to arc the air gap at the spark plug Ignition Generating Coil Exciter coil primary charge coil Stator plate coil which generates primary ignition voltage in Inch inches Inch Pound In ib 12 in lbs 1 ft Ib 7 96 1 28 Polaris Industries Inc GENERAL INFORMATION Glossary Of Terms kg cm ui Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction lor Itr Liter Ibs in Pounds per square inch Left Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnetic Induction As a conductor coil is moved through a magnetic field a voltage will be generated in the windings This is how mechanical energy in our engines is converted to electrical energy in the lighting coil ignition generating coils and trigger coil mi Mile miles mm Millimeter Unit of length in th
57. tended component i e a bare wire touching the grounded chassis End Seals Rubber seals at each end of the crankshaft Engagement RPM Engine RPM at which the drive clutch engages to make contact with the drive belt EBS Engine Braking System ft Foot feet Foot Pound Ft Ib A force of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon Head Volume Cylinder head capacity in cc head removed from engine with spark plug installed High Tension Lead The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug Holed Piston Piston in which a hole has formed on the dome Possible causes 1 detonation 2 pre ignition HP Horsepower ID Inside diameter Ignition Coil A type of transformer which increases voltage in the primary windings approx 200V to a higher voltage in the secondary windings approx 14KV 32KV through induction Secondary voltage is high enough to ionize jump the air gap at the spark plug Ignition Generating Coil Exciter coil primary charge coil Stator plate coil which generates primary ignition voltage Polaris Industries Inc 1 15 5 98 GENERAL INFORMATION Glossary Of Terms in Inch inches Inch Pound In Ib 12 in lbs 1 ft Ib 2 kg cm Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever
58. tions are subject to change without notice Comments or suggestions about this manual may be directed to Polaris Industries Inc Service Publications Supervisor 1225 Highway 169 North Minneapolis Minnesota 55441 5078 1996 1998 Service Manual Volume Il Part No 9913680 1998 Service Manua Update Part No 9914752 Printed in U S A UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions important information is brought to your attention by the following symbols N Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator passenger bystand er or person inspecting or servicing the ATV A WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator passenger by stander or person inspecting or servicing the ATV A CAUTION indicates special precautions that must be taken to avoid minor personal injury or ATV or proper ty damage NOTE A NOTE provides key information to clarify instructions Trademarks Polaris acknowledges the following products mentioned in this manual FLEXLOC Registered Trademark of SPS Technologies Loctite Registered Trademark of the Loctite Corporation STA BIL Registered Trademark of Gold Eagle FOX Registered Trademark of Fox Shox Nyogel Trademark of Wm F Nye Co Fluke Registered Trademark of John Fl
59. uke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Ammco Registered Trademark of Ammco Tools Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Table of Contents 9913680 Chapter OL sorna General Information Chapter 02 senatori Maintenance Chapter Ds oo sosta et aves NAGA Engine Chapter 04 Fuel System Carburetion Chapter 05 caninas Body Steering Suspension Chapter e PVT System Chapter 07 nado Final Drive Chapter 05 aaa AA ANA AA Transmission Chapter 09 asl ANAN Brakes A A ANG Electrical CHAPTER 1 GENERAL INFORMATION Model Identification audies sd ea SR EE der EE 1 1 1 1c Publications Numbers rano 1 2 1 2a Service Videos sexes e rad ae 1 2a Service Information Bulletin Index 1 3 1 3b Pant Codes iin es Os de Qoa sai 1 4 1 4b Model Specifications 1996 1 5 1 8 Model Specifications 1997 1 8a 1 8d Model Specifications 1998 1 8e 1 8h Standard Torque Specifications 1 9 Decimal Equivalent Chart 1 10 Conversion Table iis nia luca rede 1 11 Tap Drill Charts oo ox direc a doro OLOR been AE ns 1 12 Waranty 27525 ote AA Te d RR 1 13 Service TIPS v uses ose ep v Ea Yo Vs Pei a iaa 1 14 Glossary of Terms dex hha eb a es ipa 1 45 1 17 Tool Ordering Information 1 18 Rout
60. ve N A N A N A 12 22 64P Axle to Axle N A N A N A N A Displacement Engine Model Number 244cc EC25PFE08 244cc EC25PFE09 283cc 283cc EC28PFE01 EC28PFE01 Compression Ratio Effective 6 1 1 6 1 1 6 1 1 74 5x65 Bore and Stroke 72x60 74 5x65 Spark Plug BR8ES NGK BR8ES NGK BR8ES NGK BR8ES NGK Alternator Output 150W 150W 150W Timing Degrees 2583000 2583000 2593000 Carburetion 1 VM30SS 1 VM30SS 1 VM30SS 1 VM30SS MainJet 145 130 155 155 Pilot Jet 40 40 40 40 Jet Needle 5DP7 3 5DP7 3 5DP7 3 5DP7 3 Needle Jet 0 4 169 0 4 169 0 4 169 0 4 169 Cutaway 2 0 2 0 2 0 2 0 Air Screw Pilot Screw KA 1 Turn 1 Turn 1 5 Turn 1 5 Tum See Owner s Manual for rack load recommendations and restrictions 25 3000 Polaris Industries Inc 1 8a 5 98 GENERAL INFORMATION Specifications 1997 1997 Model Gen II Ill or IV Xpress 400 IV Xplorer 400 IV Sport 400 III Sportsman 4x4 Il Model Number W97CA38C W972238C W97BA38C W97AC38C 47 5 47 5 47 46 46 5 46 74 5 77 Wheel Base 49 75 Seat Height Ground Clearance 33 5 5 479 Ibs 60 6 75 7 375 Weight 543 Ibs 570 Ibs Turning Radius Unloaded 60 65 Front
61. x65 Spark Plug Gap in BR8ES NGK 028 BR8ES NGK 028 BR8ES NGK 028 BR8ES NGK 028 Timing Degrees 2503000 2503000 2503000 2503000 Carburetion 1 VM30SS 1 VM30SS 1 VM30SS 1 VM30SS Main Jet 145 130 155 155 Pilot Jet 40 40 40 40 Jet Needle 5DP7 3 5DP7 3 5DP7 3 5DP7 3 Needle Jet 0 4 169 0 4 169 0 4 169 0 4 169 Cutaway 2 0 2 0 2 0 Air Screw Pilot Screw 1 Turn 1 5 Turn 1 5 Turn See Owner s Manual for rack load recommendations and restrictions Polaris Industries Inc 1 8e 5 98 GENERAL INFORMATION Specifications 1998 1998 Model Gen Il III or IV Sport 400 111 Scrambler 400 lil Xplorer 400 IV Magnum 2x4 II Model Number W98BA38C W98BC38C W98CC38C W98AA42A Height inches cm 47 119 4 47 119 4 47 5 120 7 47 119 4 Width inches cm 46 5 118 1 45 5 115 6 46 116 8 46 5 118 1 Length inches cm 74 5 189 2 74 5 189 2 81 205 7 77 195 6 Wheel Base inches cm 49 75 126 4 48 5 123 2 49 75 126 4 49 75 126 4 Seat Height inches cm 33 83 8 33 83 8 34 86 4 33 83 8 Ground Clearance inches cm Weight Lbs Kg 479 lbs 215 519 Ibs 236 Turning Radius Unloaded in cm 60 152 4 60 152 4 Fron
62. ystems Provides work ing knowledge of charging system theory and diagnostics Polaris Variable Transmissions 9913987 Theory disassembly assembly and troubleshooting of the PVT Polaris PVT system Fuels and Fuel Delivery 9914393 Describes fuel properties including octane and vapor pres sure fuel mixture and burn characteristics VM and CV car buretor theory and adjustments 5 98 1 2a Polaris Industries Inc GENERAL INFORMATION Service Bulletin Index Service Information Bulletins By Bulletin Number ATV 94 08 ATV 94 09 ATV 94 10 ATV 95 01 ATV 95 02 ATV 95 03 ATV 95 04 ATV 95 05 ATV 95 06 ATV 95 07 ATV 95 08 ATV 95 09 ATV 95 10 ATV 95 11 ATV 95 12 ATV 95 13 ATV 95 14 ATV 95 15 ATV 95 16 ATV 95 17 ATV 95 18 ATV 95 19 ATV 95 20 ATV 95 21 ATV 95 22 ATV 96 01 ATV 96 02 ATV 96 03 ATV 96 04 ATV 96 05 AT V 96 06 ATV 96 07 ATV 96 08 ATV 96 09 ATV 96 10 ATV 96 11 ATV 96 12 ATV 96 13 ATV 96 14 ATV 96 15 ATV 96 16 ATV 97 01 ATV 97 02 ATV 97 03 1995 Scrambler Oil line may contact exhaust head pipe 1994 400 ATVs and 1995 Xplorer Sportsman and 400 6X6 Poor fuel economy and hesitation 1995 Scrambler Some brake calipers may rub on inside of tire rim 1995 Scrambler Loose clamp on carburetor boot 1995 Xplorer 4x4 Sportsman Front hub oil leak 1995 Xplorer 4x4 Incorrect speedometer angle drive 1995 Scrambler Headlight wiring reversed 1995 Magnum 2x4 Magnum 4x4 Engine oil in air box

ATV AND LIGHT UTILITY VEHICLE SERVICE MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents