Home

9913680 1996-1998 Vol. II ATV Service Manual Chapter

1. 2 Drain tube 3 Reinstall drain plug Magnum Style Sportsman Style 598 229h Polaris Industries Inc MAINTENANCE 4 Stroke Engine Maintenance Air Filter Service Scrambler 500 1 Remove seat 2 Release clips and remove cover 3 Loosen clamp and remove filter a 4 Main Filter 4 x Remove fabric type pre filter from main filter Wash pre filter in soapy water and dry it 5 Reinstall pre filter in main filter Replace main filter as required Air Filter Service Sportsman 500 Xplorer 500 1 Remove seat 2 Remove wingnuts securing the airbox lid and re move lid EOS Pull foam breather filter out Pre cleaner Loosen clamp and remove filter Breather Filter Remove foam pre cleaner from main filter Wash the pre filter in soapy water and dry it Install dry pre filter over new main filter and reinstall SNPA Push foam breather filter straight down into airbox until flush with upper edge of box Make certain foam is flush with front edge of airbox so air cannot enter engine breather fitting hole without first pass ing through the foam Polaris Industries Inc 2 22 5 98 MAINTENANCE 4 Stroke Engine Maintenance NOTES 5 98 2 22 Polaris Industries Inc MAINTENANCE 4 Stroke Engine Maintenance Check Engine Oil 4 Stroke The oil tank is located on the left side of the vehicle To check the oil 1 Set machine on a level surface 2 Start and run engine for 20 30 seco
2. 2 14 4 Strokes Drain tube attached here Drain Screw 400cc 2 Strokes Remove Plug SS Carburetor Bowl ON Fuel Valve Polaris Industries Inc Breather Filter Inspection 1 Inspect the breather filter s for obstruction Replace if necessary Breather filter service life is extended when the air box pre filter is in place and maintained properly Never operate the engine without the pre filter Breather Hose 1 Be sure breather line is routed properly and secured in place CAUTION Make sure lines are not kinked or pinched Polaris Industries Inc 2 14a MAINTENANCE Breather System 4 Strokes 1997 Magnums 500 6x6 and 1998 Sportsman 500 Breather Filter In Line Scrambler 500 AT Ne Ex i ET ay Ka 1 XI 5 EN LN Y 7 A YN Breather Filter In Line Breather Filter 5 98 MAINTENANCE 5 98 2 14b Polaris Industries Inc Compression Test 2 Stroke 1 Remove spark plug and install compression tester 2 Connect high tension lead to a good ground on engine 3 Open throttle and crank engine until maximum reading is obtained approximately 3 5 revolutions Compression Test 4 Stroke NOTE 4 Stroke engines are equipped with an automatic decompressor Compression readings will vary in propor tion to cranking speed during the test Average compres sion measured is about 50 90 psi during a compression test Smooth idle generally indicates good compression L
3. 2 of the total pedal travel See Illustration 1 Type Il If adjustment is necessary loosen jam nut A and turn adjuster bolt B clockwise until disc rotation becomes difficult Turn adjuster bolt counterclockwise until brake engagement starts at approximately 1 2 of the total pedal travel See Illustration Tighten the lock nut securely See Illustration 2 3 Check brakes to be sure they are not dragging Read just pedal deflection if necessary 4 Type Ill Hydraulic Refer to Inspection Procedure Linkake adjustment on page 9 30b Hose Fitting Inspection Check brake system hoses and fittings for cracks deterio ration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts Polaris Industries Inc 2 35 MAINTENANCE Chassis Maintenance Auxiliary Foot Brake Pedal Full Height Engagement Full 1 2 Height Engagement Flush IF Board Surface Side View Auxiliary Brake Adjustment Type Ill 1 Side View Auxiliary Brake Adjustment Type II lil 2 5 98 MAINTENANCE Drive Chain Drive Chain and Sprocket Inspection Inspect the drive chain for missing or damaged O Rings link plates or rollers Do not wash the chain with a high pressure washer gasoline or solvents do not use a wire brush to clean the chain as damage to the O Rings may occur Clean chain with hot soapy water and a soft bristled nylon brush Never allow battery acid to contact the drive chain Pe
4. Measure from string to rim at front and rear of rim along the horizontal centerline of the hub Rear rim measure ment should be 1 16 to 1 8 2 to 3 cm more than front rim measure ment NOTE The steering post arm can be used as an indicator of whether the handlebars are straight The arm should always point straight back from the steering post 5 98 2 30 Polaris Industries Inc MAINTENANCE Chassis Maintenance Steering The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure all cotter pins are in place If cotter pins are removed they must not be re used Always use new cotter pins Replace any worn or damaged steering components Steering should move freely through entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replaced check front end alignment See page 5 9 for an optional alignment procedure Polaris recommends steering component repair and adjustment be performed by an authorized Polaris dealer Camber and Caster The camber and caster are non adjustable Toe Alignment Inspection 1 Place machine on a smooth level surface 2 Set handlebars in a straight ahead position and secure handlebars in this position NOTE The steering frog can be used as an indicator of whether the handlebars are straig
5. Suspension Compress and release front suspension Damping should be smooth throughout the range of travel Check all front suspension components for wear or dam age Inspect front strut cartridges for leakage Rear Suspension Compress and release rear suspension Damping should be smooth throughout the range of travel Check all rear suspension components for wear or dam age Inspect shock for leakage Shock spring preload can be adjusted using the shock spanner wrench Operator weight and loading affect spring preload require ments Adjust as necessary Controls Check controls for proper operation positioning and ad justment Brake lever and switches must be positioned to allow adequate clearance for the movement of the lever The brake control and switch must be positioned to allow the brake lever to travel throughout the entire range without contacting the switch body 5 98 2 40 Rear Spring Adjustment Cam Rear Spring Adjustment Cam Position Master Cylinder and Switch to Provide Clearance Polaris Industries Inc MAINTENANCE Chassis Maintenance Transmission Lubrication The transmission dipstick is located on the right side of the machine The transmission lubricant level should be checked monthly or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a level surface remove fill plug dipstick and check the lubricant level Lubricant
6. 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 gt Enim ele 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 Radiator Inspect Clean external surface Cooling System Hoses Inspect Engine Mounts Inspect Drain Recoil Housing More often if operating in wet environment Exhaust Muffler Pipe j100hrs 12months fo ELECTRICAL Spark Plug Inspect Replace if necessary Ignition Timing Inspect Battery Check terminals Clean Check fluid level Headlight Aim Adjust if Necessary Headlamp Inspection Daily Daily 10 4 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 Front Hub Spindle Nut Torque Annually Annually 7 21 AWD Models Lee pene eese EE erate Rud aos EE EE gt erate Fidiee GE mese 794 LAT perde Reste EE Brake Pad Wear 10 hrs 100 Monthly 2 34 miles mensenn E E 793 A LEE m
7. and close NOTE At this point watch the camshaft sprocket marks and slowly rotate engine until marks are parallel to rocker cover gasket surface The cam sprocket locating pin will be facing upward directly in line with the crankshaft to cam shaft center line as shown See photo at right 9 Verify accurate TDC positioning by observing the mark aligned with the line in the timing inspection hole In this position there should be clearance on all valves Polaris Industries Inc 2 21 MAINTENANGE 4 Stroke Engine Maintenance 10 96 MAINTENANCE 4 Stroke Engine Maintenance Intake Valve Clearance Adjustment 1 Insert a 006 15 mm feeler gauge between the end of the intake valve stem and the clearance adjuster screw as shown 2 Using a 10 mm wrench and a screwdriver loosen the adjuster lock nut and turn the adjusting screw until there is a slight drag on the feeler gauge 3 Hold the adjuster screw and tighten the adjuster lock nut to a torque of 5 8 to 7 2 ft Ibs using the 10mm flank drive torque adapter at a 90 angle to the torque wrench as shown NOTE The flank drive must be positioned at a 90 angle to the torque wrench to prevent over torquing 4 Re check the valve clearance 5 Repeat adjustment procedure if necessary until clearance is correct 6 Repeat this step for the other intake valve Exhaust Valve Clearance Adjustment NOTE The exhaust valves share a common rocker arm and must be adjus
8. and distilled water should be added to the upper level line To remove the battery 1 Disconnect holder strap and remove cover 2 Disconnect battery negative black cable first E Maintain followed by the positive red cable between upper and lower level AN CAUTION marks Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Disconnect the vent hose 4 Remove the battery 5 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery AN To refill use only distilled water Tap water contains minerals which are harmful to a battery AN Do notallow cleaning solution or tap water to enter the battery It will shorten the life of the battery 6 Reinstall the battery caps 7 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse will with clean water and dry thoroughly 8 Reinstall battery attaching positive red cable first and then the negative black cable 9 Reattach vent hose making sure it is not kinked or pinched 10 Coat terminals and bolt threads with Polaris dielectric grease PN 2871027 11 Reinstall battery cover and holder strap Noo not start the engine with the battery disconnected Vehicle lamps will burn out if battery is disconnected
9. chain Total slack should be 1 1 4 to 1 1 2 3 to 3 8 cm If slack is not within specification it must be adjusted Rear Axle 6x6 Middle Axle Adjustment Procedure 1 Loosen chain guard Proper 2 Loosen two eccentric locking bolts Splicelink Clip Opening nm Position 3 Insert a pin punch through the sprocket hub and into the eccen tric axle housing Hear Drive Chain Adjustment 4 Roll the vehicle ahead or back to adjust chain slack to the proper dimension Correct chain slack adjustment is 1 1 4 to 1 1 2 3 to 3 8 cm total at the midpoint 5 Tighten the eccentric locking bolts to 60 ft Ibs 6 Reinstall chain guard NOTE Reposition chain guide to allow 1 8 3 cm clearance be tween sprocket and guide Final Drive Chain CAUTION Never adjust or operate the vehicle with the drive chain slack out of the 1 1 4 to 1 1 2 3 to 3 8 cm specification Severe damage to the transmission and drive components can result 6x6 Rear Axle Drive Chain Adjustment To adjust the rear axle drive chain on 6x6 models loosen the rear most eccentric and rotate using the same meth od as outlined for the middle axle chain Total slack however should be adjusted to 1 4 1 2 6 1 3 cm Check to be sure all cotter pins cable ties hose clamps etc are in place and in good condition 1 1 4 to 1 1 2 3 to 3 8 cm 1 4 1 2 6 1 3 cm Polaris Industries Inc 2 39 5 98 MAINTENANCE Chassis Maintenance Front
10. or has a specific gravity lower than 1 14 during vehicle operation Also the reverse speed limiter can be damaged 5 98 2 16 Polaris Industries Inc MAINTENANCE General Maintenance Spark Plug 1 Remove right body panel See Body Panel Removal Chapter 2 4 strokes On two stroke models access spark plug through the right front footwell 2 Remove spark plug high tension lead Clean plug area so no dirt and debris can fall into engine when plug is removed 3 Insert spark plug wrench provided in tool kit Remove spark plug 4 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 5 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 6 Measure gap with a wire gauge Recommended spark plug gap is shown in chart at right Adjust if necessary by bending the side electrode carefully 7 f necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 8 Coat spark plug threads with a small amount of anti seize compound AL 9 Install spark plug and torque to 14 ft Ibs Spark Plug Gap 024 028 6 7 mm Ignition Timing Refer to the electrical section for ignition timing procedure Engine Mounts Inspect rubber engine mounts for cracks or damage Check fasteners and ensure they are t
11. should be kept at the full mark on the dipstick The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant PN 2871478 Transmission Oil Changing Procedure 1 Remove skid plate Transmission Dipstick 2 Remove fill plug dipstick 3 Remove transmission drain plug located on the bot tom right hand side and drain the oil Catch and dis card used oil properly 4 Clean and reinstall the drain plug 5 Add Polaris Premium Synthetic Gearcase Lubricant PN 2871478 12 oz bottle to full mark on the fill plug dipstick 6 Check for leaks 7 Reinstall skid plate removed in step 1 Operating Range Operating Hange Transmission Oil Change Dipstick Models 1 Place a drain pan beneath the transmission oil drain plug area 2 Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings 3 After the oil has drained completely install a new sealing washer and install the drain plug Torque to 14 ft Ibs 1 93 kg m 4 Remove dipstick and clean accumulated metallic filings from the magnetic end NOTE On some models the magnet is located on the drain plug Polaris Industries Inc 2 41 5 98 MAINTENANCE Chassis Maintenance 5 Add Polaris Chaincase Oil through the dipstick hole Insert the dipstick all the way remove and check the level on the stick Add oil if necessary until the oil level is between the upper and lower limits of the kn
12. 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 100 hrs Check Level Daily Break in service at 1 month Oil Filter 4 strokes 100 hrs Replace with oil change Replace Engine Oil Level Change Oil Filter 2 strokes 100 hrs 12 months 2 22 Oil Pump Cable 2 strokes Inspect Adjust Lubricate Replace if Reguired Air Filter Foam Pre Cleaner 2 22 2 25 Inspect Clean 8 oil more often in dirty cond Air Filter Main Element Inspect Replace if necessary Air Box Sediment Tube Daily 226 Drain deposits whenever visible Engine Breather Filter 20hrs X Monty Inspect and replace if necessary Oil Tank Vent Hose j1O0hrs 12months Inspect hose routing hose condition Valve Clearance 4 strokes 100 hrs 12 months Inspect Adjust Counter Balancer Fluid 400s 100 hrs 12 months Check Monthly Change Annually Throttle Cable ETC Switch Inspect Adjust Lubricate Replace if necessary 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 00 Inspect
13. 0 Premium 2 Cycle Engine Oil 55 Gallon n Premium Gold 2 Cycle Synthetic Lubricant Premium Synthetic Gearcase Lubricant 1 Gal 2871478 Oil Pump for Gearcase Oil Premium Demand Drive Hub Fluid 12 oz mE Premium Front Gearcase Fluid 12 oz Cable Lube Loctite RC 680 10cc Retaining Compound UU 2870587 518 Gasket Eliminator i 2870601 Loctite Chisel Gasket Remover CT 2870661 RTV Silicone Sealer 7 8560054 Marine Grade Silicone Sealer 14 02 cartridge Fogging Oil JA DOT3 Brake Fluid 2871027 Anti Corrosive Dielectric Grease 2871326 Premium Carbon Clean 12 oz 2870652 Fuel Stabilizer 16 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge Premium Carbon Clean i20z Fuel Stabilizer 16 oz ooo 5 98 24 Polaris Industries Inc MAINTENANCE Lubrication Chart Frequency Bodies 1 Engine Oil Polaris OW 40 4 Strokes Synthetic ic Gear Case 2 Transmission Lubricant 3 Brake Fluid PolarisDOT3 Fill master cylinder reservoir to Brake Fluid 1 4 6 4mm from top or between indicated lines See page 2 34 4 Throttle Cable Polaris Cable See page 2 11 Lube 5 Speedometer Polaris Cable Disconnect cable on back of Lube speedometer and lubricate inner 1 Add oil to proper level See page 2 23 Change after 1st month 6 months or 100 hours thereafter Change
14. CHAPTER 2 MAINTENANCE Periodic Maintenance Chart Pre Ride Inspection Recommended Lubricants and Capacities Lubricant and Maintenance Product Numbers EUDNCAtOn Ghat sass peace eae pues Front Gearcase Lubrication Carburetor Adjustments erre RR RR Carburetor Draining s ep Ea SERE EE Breather System Maintenance Compression TeSt ues ete eee oed 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 conditions 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 sCAUTION 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
15. Cable Lubrication Lubricate throttle cable from the throttle block end Turn engine off Remove three throttle block cover screws Slide boot off throttle cable adjuster and jam nut Loosen cable adjuster jam nut Turn adjuster in to obtain maximum cable freeplay Open throttle and hold cable Carefully disconnect throttle cable from throttle lever Do not kink or bend throttle cable Unscrew adjuster and remove cable Hold throttle cable up and lubricate with Polaris Cable Lube KO 00 41 00 eS 10 Turn adjuster in to obtain maximum cable freeplay 11 Reinstall cable onto throttle lever 12 Perform throttle cable adjustment Polaris Industries Inc 2 29 10 96 MAINTENANCE Toe Alignment Inspection CAUTION Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer One of two methods can be used to measure toe alignment The string method is shown below and the chalk method on page 2 31 If adjust ment is required refer to page 2 31 for procedure Method 1 Be sure to keep handlebars centered See note below Q a A IS co c2 OS es a NE gt O C Q S c Do cov Oo 2 17 v VU Gc lt C p Sy o NOTE String Sg S Wo should just touch ASD 2 NG C side surface of rear N csc O a Wes tire on each side of NS C27 NO He machine e us O Ww D d SSO SS EO nI c
16. asoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poison ous and can cause loss of consciousness and death in a short time Never drain the float bowl when the engine is hot Severe burns may result 5 98 2 13 Polaris Industries Inc MAINTENANCE Carburetor Draining Carburetor Draining The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl or before ex tended periods of storage NOTE The bowl drain screw is located on the bottom left side of the float bowl on 4 stroke models A drain plug which also acts as a water sediment trap is located on the bottom of the float bowl on 400cc 2 stroke models T 2 ONAN Turn fuel valve to the off position Remove left side body panel See Body Panel Removal Chapter 5 Place a clean container beneath the bowl drain spigot or bowl drain hose Turn drain screw out two turns remove drain plug for 2 Strokes and allow fuel in the float bowl and fuel line to drain completely Inspect the drained fuel for water or sediment Tighten drain screw Turn fuel valve to on Start machine and check for leaks 5 98
17. ble Failure to properly maintain this important area can result in premature wear or possible failure of the counter balanc er components Always use SAE 10W30 oil Procedure for Adding Oil 400 1 Remove seat and locate dipstick Remove by loosening with a long handled screwdriver 2 Remove dipstick Oil level is shown on dipstick 3 Add SAE 10W30 oil with a transmission fluid funnel The recommended oil level is indicated by the knurled area on the dipstick Dipstick NOTE Screw dipstick in fully and remove to check Check with engine at room temperature Do not overfill If overfilled excess oil will be expelled through the vent hose 4 Reinstall dipstick Do not over tighten 5 Inspect vent line for kinks or obstructions Counter Balance Oil Changing Procedure 1 Remove seat Locate and remove dipstick 2 Remove drain plug and drain oil Catch and discard used oil properly Clean and reinstall drain plug 4 Add SAE 10W30 oil using a transmission fluid funnel The recommended oil level is indicated by the knurled area on the abd palad Recommended dipstick The dipstick should be screwed in fully to check Do Oil Level not overfill If overfilled excess oil will be expelled through the vent hose Reinstall dipstick Check for leaks Polaris Industries Inc 2 21 5 98 MAINTENANCE 2 Stroke Engine Maintenance Air Cleaner Trail Boss Xpress 300 Xplorer 300 Xplorer 400 Dual Stage Air Cleaner T
18. case Oil GL5 80 90 Weight Add to bottom of fill plug Change annually Gear Lube threads See page 2 10 Slip Yoke No grease fitting on Premium U Joint Locate fittings and grease 3 Semi annually 1 late models Grease pumps maximum 3 Rear Halfshafts Premium U Joint Locate Fittings and Grease Semi annually 4 Grease 4 Axle Cardan U Joint Front Drive Premium U Joint Locate Fittings and Grease Semi annually 7 Shaft Prop Shaft Grease 5 Propshaft Yoke Premium U Joint Locate fittings and grease 3 Annually Q Grease pumps maximum Transmission Synthetic Add to proper level on dipstick Inspect Monthly Transmission Approx 20 02 at change Lubricant Approx 32 oz initial fill after disassembly 2 Change annually More often under severe use such as wet or dusty conditions Semi annually or 50 hours of operation Annually or 100 hours of operation NOTE Hours are based on 10 mph average 5 98 2 8 Polaris Industries Inc MAINTENANCE Lubrication Chart Type IV Transmission Shaft Drive 7 Upper Control a 8 Lower Control Arm 8 Lower Control Arm 10 Rear Anti 9 Rear Wheel Hub Bearing Roll Bar E a No m Upper Control Arms Grease Locate fittings and grease Semi annually Lower Control Arms Grease Locate fittings and grease Semi annually Rear Wheel Hub Bearing Carrier Grease Locate fittings and grease Semi annually 10 Rear Anti Ro
19. e ver Fluid may squirt out the compensating port if lever is pulled Wear Line e Pads should be changed when worn to the indicator lines A as shown See page 9 1 for pad wear specifications Inspect the brake disc spline and pad wear surface for excessive wear Brake Pad Wear 5 98 2 34 Polaris Industries Inc Auxiliary Mechanical Brake System The auxiliary brake system is intended to be used as a backup for the hydraulic system Should the hydraulic system fail the rear brake can be activated by depressing the foot pedal on the inside of the right floorboard NOTE Since this is a rear brake only it will not be as ef fective as the all wheel system Auxiliary Brake Testing The auxiliary brake should be checked for proper adjust ment 1 Support the rear wheels off the ground 2 While turning the rear wheels by hand apply the auxil iary foot brake This brake should not stop the wheels from turning until the lever is half way between its rest position and bottoming on the footrest Auxiliary Brake Adjustment The auxiliary brake should be adjusted if the brake pedal deflection is under 1 2 1 3 cm or exceeds 3 4 1 9 cm prior to brake activation 1 Put the machine in neutral Stop engine 2 Type i If adjustment is necessary turn adjuster bolt A clockwise until disc rotation becomes difficult Turn adjuster bolt counterclockwise until brake en gagement starts at approximately 1
20. eme E 7x Lowe 70 E meme E Fame Nus Bs Fasones Pere Rene EEE Pre Ride Daily Inspection Lubricate All Fittings Pivots Cables Etc Check monthly Check monthly POT no Gi C2 NJ N Inspect and replace if necessary Inspect Torque and Locking Fastenerand re place if necessary Inspect Adjust Replace if Necessary o NI Inspect Clean Inspect Monthly Change Annually Inspect Lubricate Adjust Change Lubricant Every Two Years Inspect Daily Lubricate Periodic Inspection Adjust When Parts are Re placed Inspect Bearings Grease Fitting Inspect Lubricate Inspect Lubricate Inspect Daily Adjust and Lubricate if Needed Inspect Daily Pre Ride Inspection Item Change Every Two Years Inspect Daily Pre Ride Inspection Item Inspect Daily Pre Ride Inspection Item Inspect Periodically Inspect Deflection Daily Adjust Grease Monthly Pre Ride Inspection item Pre Ride Inspection Item Pre Ride Inspection Item Perform the following pre ride inspection daily and when servicing the vehicle at each scheduled maintenance 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 functi
21. engine with the bleed screw loose Loss of oil will cause serious engine damage 3 Start the engine and lift the oil pump lever or reel to its full up Open position Allow engine to idle with the lever or wheel in this position for ten to twenty seconds to make sure all air is out of the system If oil starvation is suspected proceed as follows 1 Premix fuel in tank at a 40 1 fuel oil ratio 2 With the oil reservoir full and the pump bled remove the oil delivery line from the intake manifold 3 Test the oil delivery check valve with a low pressure pump and gauge See Page 3 21 4 Start engine and lift oil pump lever to full open position C Lift Lever 5 Oil should pulse from the delivery line every few second If it does not suspect one of the following A Oil line or filter plugged Oil tank vent line restricted B Oil lines leaking or blocked 250 300 Oil Pump Bleeding C Faulty oil pump or drive mechanism 5 98 2 20 Polaris Industries Inc MAINTENANCE 2 Stroke Engine Maintenance Recoil Housing Counter Balance Drain Crankcase Drain the housing periodically to remove moisture Drain Starter Recoil Drain Counter Balancer Lubrication 400 The counter balance oil should be checked semi annually espe cially before off season storage If the machine is used in wet conditions the oil should be checked more frequently If the oil has a milky white or gray appearance it should be changed as soon as possi
22. ent over main filter Be sure the element covers entire surface of main filter without folds or creases p Air Filter Main Element 1 Remove the two wing nuts and washers securing the air filter access cover 6 on Gen IV 500s 2 Remove the cover Inspect the gasket It should adhere tightly to the cover and seal all the way around MAINTENANCE 4 Stroke Engine Maintenance Duct Support Wire Must Be Positioned Properly on Magnum Magnum Pre filter Pr ne Polaris Industries Inc 2 229 5 98 MAINTENANCE 4 Stroke Engine Maintenance Air Filter Main Element Cont 3 Remove the wing nut and washer securing the filter cover The cover should be straight and not distorted Loosen clamp on Gen IV 500s A RU SY Access Cover s ad Cover Gasket 4 Hemove the air filter Inspect and replace if necessary Ned If the filter has been soaked with water fuel or oil it must 8 be replaced c zor Main Filter NOTE Apply a small amount of general purpose grease GA Element to the sealing edges of the filter before reinstalling Filter Cover Air Box Sediment Tube Periodically check the air box drain tube located toward the rear of the machine Drain whenever deposits are visible in the clear tube NOTE The sediment tube will require more frequent ser vice if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 Remove drain plug from end of sediment tube
23. essary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 5 98 2 24 Engine Sump Drain Plug Polaris Industries Inc MAINTENANCE 4 Stroke Engine Maintenance NOTES Polaris Industries Inc 2 25 5 98 MAINTENANCE 4 Stroke Engine Maintenance NOTES 5 98 2 26 Polaris Industries Inc Valve Clearance Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center TDC on compression stroke 1 Lift up on the rear of the seat 2 Pullthe seat back and free of the tabs NOTE When reinstalling seat make sure the slots in the seat engage the tabs in the fuel tank 3 Remove the left and right side body panels and fuel tank cover See Body Panel Removal Chapter 2 4 Remove the fuel tank 5 Remove the spark plug high tension lead and remove the spark plug CAUTION Place a clean shop towel into the spark plug cavity to prevent dirt from entering 6 Removethe eight 6 x 20 mm bolts securing the rocker cover Remove the cover and gasket NOTE It may be necessary to tap the cover lightly with a plastic hammer to loosen it from the cylinder head 7 Remove the timing inspection plug from the recoil housing CAUTION Failure to position the crankshaft exactly as shown TDC on compression stroke will result in improper valve adjustment 8 Rotate the engine slowly with the recoil rope watching the intake valves open
24. ew Idle Mixture Adjustment 4 Stroke Models NOTE The pilot screw is pre set at the factory The fol lowing adjustment procedure should be used after disas sembly and cleaning or if the pilot screw is replaced Be sure all engine maintenance items have been performed and are within specifications before adjusting pilot screw 1 Turn pilot screw in clockwise until lightly seated Turn screw out the specified number of turns 2 Start engine and warm it up to operating temperature about 10 minutes 3 Connect an accurate tachometer that will read in increments of or 50 RPM 4 Setidle speed to 1200 RPM Always check throttle cable freeplay after adjusting idle speed and adjust if necessary 5 Slowly turn mixture screw clockwise until RPM begins to decrease by 50 RPM or greater 5 98 2 12a MAINTENANCE Carburetor Adjustments 250 300 400cc Engines mag Air Screw 425 500 Engines n Pilot Screw y TAN Idle Speed Screw Polaris Industries Inc MAINTENANCE Carburetor Adjustments Pilot Screw Idle Mixture Adjustment Cont 4 Stroke Models NOTE If tamper proof plug is installed refer to removal procedure below 6 Slowly turn mixture screw counterclockwise until idle 425 500 Enai speed increases to maximum RPM Continue turning tes Engines counterclockwise until idle RPM begins to drop 7 Center the pilot screw between the points in step 5 and 6 8 Re adjust idle speed i
25. f not within specification abo dl Pilot Screw 5 98 2 12b Polaris Industries Inc MAINTENANCE Fuel Lines Vent Lines Fuel Lines i 3 Check fuel lines for signs of wear deterioration damage or leakage Replace if necessary Be sure fuel lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched Replace all fuel lines every two years Vent Lines ju Fuel Filter The fuel filter should be replaced periodically or whenever sediment is visible in the filter ja coi IM 5 6 7 Check fuel tank oil tank carburetor battery and transmission vent lines for signs of wear deterioration damage or leakage Replace every two years Be sure vent lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched Shut off fuel supply at fuel valve Remove line clamps at both ends of the filter Remove fuel lines from filter Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow Install clamps on fuel line Start engine and inspect for leaks Reinstall fuel tank Carburetor Float Bowl Draining A WARNING Gasoline is extremely flammable and explosive under certain conditions gt BBBB BB Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where g
26. h throttle opening and closing in all han dlebar positions Throttle lever operation should be smooth and lever must return freely without binding Re place the throttle cable if worn kinked or damaged 5 98 2 11 MAINTENANCE Carburetor Adjustments 425 500 Engines Idle Screw 250 300 400 Engines 1 16 Throttle Lever Freeplay Switch Plunger Must Be Held In By Cable Tension Polaris Industries Inc MAINTENANCE Carburetor Adjustments Throttle Cable Adjustment NOTE If the proper freeplay cannot be obtained with the throttle block adjuster adjust the cable at the carburetor using the following procedure See Ill 1 and 3 1 Remove fuel tank 2 Slide boot off throttle cable adjuster and jam nut 3 Loosen lock nut and turn adjuster until proper throttle lever freeplay is obtained 4 Tighten locknut and slide boot back over adjuster 5 Reinstall fuel tank 6 Check for proper throttle operation and correct freeplay in all handlebar positions Choke Adjustments With the choke control toggle flipped to the full off position the choke plunger must be seated on the fuel passage way in the carburetor If the plunger is not seated on the pas sage way the engine will flood or run too rich causing plug fouling and very poor engine performance If cable slack is too great there will be excessive toggle free play resulting in hard cold starting Also the half on position used for intermittent app
27. he Polaris ATV is equipped with a dual stage engine Primary Air Filter Box air filtration system The primary pre cleaner foam boot is designed to remove the majority of dust particles be fore they reach the secondary dry filter element Primary Pre cleaner Foam Boot Inspect the primary air cleaner boot daily or on a regular basis depending on running conditions and dust 1 Remove the ATV seat 2 Remove the primary air filter box 3 Remove the yellow pre cleaner foam boot held in place by a gray collar from the air box Do not re Pre cleaner Boot move the collar 4 Carefully wash the yellow foam boot in soapy water and dry it 5 Oil the foam boot with engine injection oil 1 to 2 tea spoons Squeeze out the excess into an absorbant cloth 6 Reinstall the yellow foam boot onto the air filter box 7 Reinstall the primary air filler box removed in step 2 NOTE There will be some resistance Be sure the black rubber sealing ring is securely positioned over the main filter neck CAUTION When installing the primary air filter box be sure the gray foam collar B is below the intake opening of the air box intake A Improper installation will re strict airflow to the engine possibly resulting in engine damage 5 98 2 22 Polaris Industries Inc MAINTENANCE 2 Stroke Engine Maintenance Air Cleaner Trail Blazer Trail Boss Xpress 300 Xplorer 300 Xplorer 400 Secondary Main Filter Inspect the seconda
28. heel nuts to the proper torque listed in the table above Tapered side of nut goes in If wheels are improperly installed it could affect vehicle handling and tire wear On vehicles with tapered rear wheel nuts make sure the tapered end of the nut goes into the taper on the wheel 5 98 2 44 Polaris Industries Inc MAINTENANCE Chassis Maintenance Tire Pressure Tire Pressure Inspection PSI Cold Mode 1996 Current 4 All Except Models Listed Below 1996 Current 5 5 6x6 Sportsman Xplorer 500 5 1996 Current Tire Inspection Maintain proper tire pressure Improper tire inflation may affect ATV maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires may affect ATV sets 1 8 handling n Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less A WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less Frame Nuts Bolts Fasteners Periodically inspect the tightness of all fasteners in accor dance with the maintenance schedule Check that all cot ter pins are in place Refer to specific fastener torques listed in each chapter Polaris Industries Inc 2 45 5 98
29. ht The frog should always point straight back from the steering post 3 Place a chalk mark on the face of the front tires approximately 10 25 4 cm from the floor as close to the horizontal center line of the hub as possible NOTE It is important that both marks be equally Chalk Line positioned from the ground in order to get an accurate Measurement measurement A Measurement B 4 Measure the distance between the marks and record Call this measurement A 5 Rotate the tires 180 by moving vehicle forward or backward Position chalk marks approximately 10 25 4 cm from the floor Measure the distance between the marks and record Call this measurement B 6 Subtract measurement B from measurement A The difference between measurements A and B is called vehicle toe alignment The recommended vehicle toe tolerance is 1 8 to 1 4 3 to 6 cm total toe out This means the measurement at the front of the tire A is 1 8 to 1 4 3 to 6 cm wider than the measurement at the rear B 7 fthis measurement needs to be adjusted measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure handlebars are straight ahead before determining which tie rod s need adjustment The steering post arm can be used as an indicator of whether the handlebars are straight CAUTION During tie rod adjustment it is very important that the following precautions be ta
30. ight Polaris Industries Inc 2 17 5 98 MAINTENANCE General Maintenance Coolant Level Inspection With the engine at operating temperature the coolant level should be between the upper and lower marks on the re covery bottle If not 1 Remove recovery bottle cap Inner splash cap vent hole must be clear and open 2 Fill recovery bottle to upper mark with Polaris Premium 60 40 Anti Freeze Coolant or 50 50 or 60 40 mixture of antifreeze and distilled water 3 Reinstall cap NOTE If coolant is excessively low in the radiator coolant will not circulate or be drawn in from the recovery bottle Coolant Strength Test the strength of the coolant using an antifreeze hydrometer A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap wa ter straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system Straight water or antifreeze will cause the sys tem to freeze Cooling System Hoses 1 Inspect all hoses for cracks deterioration abrasion or leaks Replace if necessary 2 Check tightness of all hose clamps Radiator 1 Check radiator air passages for restrictions or damage Carefully straighten any bent radiator fins Remove any obstructions with compressed air or low pressure water Cooling System Pressure Test Refer to page 3 6 for pres
31. ill or the selector may hydro lock 2 18 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 Front Gear Case Premium Front Gear 3 25 oz Add to bottom of fill plug threads 2 10 Shaft Drive case Fluid or GL5 100 cc thetic Engine Lubri Front Hubs Premium Demand 2 5 OZ Fill hub at 4 00 or 8 00 position until fluid AWD Models Drive Hub Fluid 75CC trickles out Do not force fluid into hub 80 90 Gear Lube 1 oz 30cc cant or 10W Motor Oil Brake Fluid Polaris DOT 3 Brake BN Fill reservoir to 1 4 6 4 mm below cover Fluid Polaris OW 40 Syn Coolant Level Polaris Premium Approx 60 40 pre mixed Anti 2 Quarts freeze Coolant or 50 50 mixture antifreeze coolant and distilled water gasket surface for aluminum reservoir Fill between Min amp Max indicators on plastic reservoir 5 98 2 3 Polaris Industries Inc MAINTENANCE Recommended Lubricants Polaris Premium Lubricant and Maintenance Product Part Numbers PartNo Description 2871281 Premium 4 Synthetic 0 W40 4 Cycle Engine Oil Quart SO Premium 4 Synthetic 0 W40 4 Cycle Engine Oil 16 Gallon Premium 2 Cycle Engine Oil Quart ME 2871097 Premium 2 Cycle Engine Oil Gallon NG 2871240 Premium 2 Cycle Engine Oil 2 5 Gallon i Premium 2 Cycle Engine Oil 16 Gallon 2871385 Premium 2 Cycle Engine Oil 30 Gallon Ka 287124
32. in until free play is obtained tighten the lock nut and then proceed with Step 7 7 Place gear selector in neutral and set parking brake 8 Startengine 9 Turn the adjuster on the throttle lever housing out until the engine RPM just begins to rise Repeat this step to make sure you have the throttle cable set to the exact point where the slide engine RPM just begins to rise 10 Stop engine Polaris Industries Inc 2 19a Forward Adjuster Turn adjuster in If lever free play can not be obtained with adjuster on throttle lever housing Throttle Housing Cable Adjuster Turn out until engine RPM just begins to in crease Step 9 Il 5 Lock Nut 5 98 12 13 14 15 16 5 98 Adjust the dividers to a distance 3mm less than the measurement recorded in Step 6 Set the distance from the bracket to the lever arm tip or mark made in Step 5 by placing the divider points in exactly the same location as in step 5 Loosen lock nuts and adjust oil pump cable to new divider dimension Tighten lock nuts Note Adjustment may change when oil pump cable adjuster lock nuts are tightened Verify the distance is 3mm less than the recorded measurement Reinstall air filter air box cover and seat Turn throttle cable adjuster in at throttle housing approximately 1 turn Place transmission in neutral set parking brake start engine and let it idle Turn throttle cable ad
33. juster out until engine RPM starts to increase Turn adjuster in until there is 1 16 of throttle lever movement before engine RPM begins to increase Tighten lock nut and slide boot over adjuster Turn handlebars from left to right through the entire turning range If engine RPM increases readjust throttle cable free play and check for proper cable routing 2 19b MAINTENANCE 2 Stroke Engine Maintenance Distance must be 3mm less than recorded measurement Throttle Housing Lock Nut Cable Adjuster 1 16 Throttle NK Lever Free Play Polaris Industries Inc MAINTENANCE 2 Stroke Engine Maintenance Oil Pump Adjustment Procedure 400L Engines 1 Before adjusting the oil pump check engine idle RPM Recommended RPM is 700 Adjust if necessary Check and adjust throttle lever free play ETC switch See page 2 11 Screw o e Spee 2 Adjust oil pump cable until marks F align when throttle slide just begins to raise and engine speed just begins to increase 3 Tighten jam nuts 4 Reinstall the ETC cover removed in step 1 making sure cover gasket is properly seated If not moisture can enter the ETC and damage the switch Oil Pump Bleeding Procedure Oil Outlet Oil Inlet 1 Fill the oil reservoir with Polaris injector oil Bleed Screw 2 Loosen the pump bleed screw one full turn Allow oil to flow from the bleed screw for five to ten seconds Tighten bleed screw CAUTION Never run the
34. ken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment the jam nuts must be loos ened and the tie rod either shortened or lengthened for proper toe setting When the tie rod end jam nuts are tightened be sure to hold tie rod ends so they are parallel with the steering arm or the steering frog respectively 8 After alignment is complete torque jam nuts to 12 14 ft Ibs 1 66 1 93 kg m Correctly Incorrectly Tightened Tightened Jam Nut Jam Nut Polaris Industries Inc 2 31 5 98 MAINTENANCE Chassis Maintenance Tie Rod End Inspection A WARNING Only a qualified technician should replace worn or damaged steering parts To check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement Replace any worn steering components Steering should move freely through entire range of travel without binding Front Hubs 4x4 AWD Model To check front hub fluid 1 Place vehicle on a level surface 2 Turn wheel until front hub fill check plug is in either the 4 00 or 8 00 position 3 Remove fill check plug 4 Add Polaris Premium Demand Drive Hub Fluid or Type F Automatic Transmission Fluid if necessary until fluid trickles out NOTE Do not force the fluid into the hub under pressure or seal damage may occur 5 Reinstall plug 6 Repeat procedure for other hub Changing Front Hub Fl
35. les aligns with hole provided in eccentric 7 Insert a large punch or screwdriver through sprocket and into eccentric hole Rotate vehicle rearward to tight en chain Chain deflection should be 1 4 1 2 6 1 2 cm with 18 lbs 8 18 kg of force at center of chain 8 Tighten eccentric clamp bolts to 45 ft Ibs 6 21 kg m NOTE This does not include nut rolling torque Check chain tension 9 Loosen forward chain eccentric clamp bolt B Install punch as was done previously and adjust chain to 1 4 1 2 6 1 2 cm with 18 lbs 8 18 kg force at center of chain 10 Tighten forward eccentric clamp bolt to 45 ft Ibs 6 21 kg m NOTE This does not include nut rolling torque When this bolt is tightened the chain deflection may change Check deflection and adjust again if needed Sprocket Inspection Inspect the sprocket for worn broken or bent teeth To check for wear pull outward on the chain as shown Re place sprocket if chain movement exceeds 1 4 6 cm 5198 sss BB Polaris Industries Inc MAINTENANCE Drive Chain Drive Chain Inspection Adjustment Never adjust or operate the vehicle with the rear drive chain slack out of the 1 1 4 to 1 1 2 3 to 3 8 cm specifica tion as severe damage to the transmission and drive components can result Check the amount of chain slack by moving the vehicle slightly for ward to gain slack at the top side of the rear chain Then pull up and 1 1 4 1 1 2 down on the
36. lications will not function 1 Flip choke toggle to full off position 2 Loosen adjustment locknut A on carburetor 3 Turn cable sleeve adjusting nut B clockwise on carburetor until 1 4 6 mm or more choke toggle free play is evident 4 Turn cable sleeve adjusting nut counterclockwise on carburetor until toggle has zero free play then rotate it clockwise until 1 8 1 4 3 6 mm toggle free play is evident 5 Tighten adjustment locknut A Throttle Control Lever Stop Adjustment The throttle control lever incorporates an adjustable stop This can be adjusted to limit the amount of throttle opening by loosening the screw A and sliding the stop to a desired setting Then tighten screw See Ill 4 5 98 2 12 Throttle Cable Lock Nut 1 8 1 4 3 6 cm Choke Toggle Position Freeplay A Full On Throttle Cable Adjuster Bottom View Polaris Industries Inc Air Screw Adjustment 2 Stroke Models 1 Turn carburetor air screw in until lightly seated Back screw out the specified number of turns 2 Warm up the engine to operating temperature 3 Set idle speed to 600 800 RPM NOTE Adjusting the air screw may affect idle speed Always check throttle cable freeplay after adjusting idle speed and adjust if necessary 4 Turn the screw in to richen or out to lean the mixture Adjust air screw for best throttle response and smooth idle 5 Re adjust idle if necessary Pilot Scr
37. linkage should be periodically in Hiah Reverse spected for wear and proper adjustment Refer to Trans Ae bs mission Chapter 8 for more information Sportsman 500 Polaris Industries Inc 2 43 5 98 MAINTENANCE Chassis Maintenance Wheels Inspect all wheels for runout or damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts Wheel Hub and Spindle Torque Table EI Front Wheel Nuts 15 Ft Lbs Rear Wheel Nuts 50 Ft Lbs 4x4 Chain i Front Spindle Nut Refer to procedures listed on following pages an Chair Shaft Models Rear Hub Retaining Nut 80 Ft Lbs Front Wheel Nuts 15 Ft Lbs xd Rear Wheel Nuts 15 Ft Lbs Shaft Drive Front Spindle Nut Refer to procedures listed on following pages Rear Hub Retaining Nut 100 Ft Lbs Wheel Removal Front or Rear 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the w
38. ll Bar Locate fittings and grease More often under severe use such as wet or dusty conditions Grease conforming to NLGI No 2 such as Polaris Premium All Season Grease Conoco Superlube M or Mobilegrease Special Semi annually or 50 hours of operation Annually or 100 hours of operation NOTE Hours are based on 10 mph average Semi annually 5 98 2 9 Polaris Industries Inc MAINTENANCE Front Gearcase Lubrication Type IV Transmission Shaft Drive Front Gearcase Lubrication The front gearcase fill plug is located on the right side i Make sure vent is unobstructed of the machine The gearcase lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Change front gearcase lubricant annually or at 100 hour intervals whichever comes first With the ATV on a level surface remove fill plug and check the lubricant level Lubricant should be kept at the bottom of the fill hole threads The correct gearcase lubricant to use is GL5 80 90 Gear Lube Fill plug Gearcase Lubricant Change 1 Remove fill plug 2 Remove gearcase drain plug located on the bottom right hand side and drain the oil Catch and discard used oil properly 3 Clean and reinstall the drain plug using a new seal ing washer 4 Add GL5 80 90W Gear Lube to bottom of fill hole threads 5 Install fill plug 6 Check for leaks 7 Make sure vent hose is clear and free of kinks 5 98 2 10 Polaris Indu
39. ll the yellow foam boot onto the air filter box Reinstall the primary air filter box removed in step 2 NOTE There will be some resistance Be sure the black rubber sealing ring is securely positioned over the main filter neck CAUTION When installing the primary air filter box be sure the gray foam collar B is below the intake Opening of the air box intake A Improper installation will restrict airflow to the engine possibly resulting in engine damage Polaris Industries Inc 2 22C MAINTENANCE 2 Stroke Engine Maintenance EQS ts Gray NAA kd Yellow Boot Intake Silencer S C CNN Airbox Retainer Airbox Cover Airbox 5 98 MAINTENANCE 2 Stroke Engine Maintenance Oil Filter 2 Strokes The oil filter is located in line between the oil tank and the oil pump on all 2 stroke models The in line oil filter is a special type and must not be substituted Replace the oil filter annually or whenever water or debris has entered the oil tank Do not attempt to clean this filter 1 Remove clamps securing lines to filter 2 Remove lines and replace filter with arrow pointing in direction of oil flow towards pump 3 Reinstall clamps on each line and check for leaks Oil Filter Oil Filter Change 2 Strokes Replace oil filter every 100 hours of operation 5 98 2 22d Polaris Industries Inc MAINTENANCE 4 Stroke Engine Maintenance 4 Stroke Engine Maintenance Polaris Industries I
40. more often 25 50 hours in extremely dirty conditions or short trip cold weather operation Polaris Synthet Add lube to FULL level on dip stick See pages 2 41 Change annually As required Change fluid every 2 years Semi annually Semi annually Transmission Dipstick cable Polaris Chain Lube or O Ring chain lube Apply to chain link plates and rollers Dipstick Filter Operating Range 1 Engine Oil and Filter 4 Cycle 2 Transmission Dipstick Maximum Master Cylinder Reservoir Minimum Lubricate 4 Throttle Cable 5 Speedometer Cable 6 Drive Chain s 5 98 2 5 Polaris Industries Inc Operating Range MAINTENANCE Lubrication Chart 12 Tie Rod Wheel 2x4 Models Bearings 11 Front A Arm Pivot Shaft 10 Ball Joint 14 Steering Post 9 Front Drive Axle Bushings 12 Tie Rod End 13 Counter balance dipstick 4x4 Models 7 Demand 4 Hubs 4 or 8 O clock position end view 11 Front A Arm Pivot Shaft 10 Ball Joint Frequency a Demand 4 Hubs Polaris Demand All Wheel Drive Drive Hub Fluid or ATVs ATF Type F Front Wheel Bear Sealed Replace Inspect and replace bearings if necessary ings Non driving front wheels Front Drive Axle U Polaris U Joint Locate grease fitting and grease with grease gun Semi annually Joints Grease Remove filler hole scre
41. nc 2 220 5 98 MAINTENANCE 4 Stroke Engine Maintenance NOTES 5 98 2 22f Polaris Industries Inc Air Filter 4 Stroke Engines It is recommended the air filter be replaced yearly When riding in extremely dusty conditions replacement will be re quired more often The pre filter should be cleaned before each ride using the following procedure Pre Filter Service 1 Lift up on the rear of the seat 2 Pull the seat back and free of the tabs NOTE When reinstalling seat make sure the slots in the seat engage the tabs in the fuel tank Magnum 3 Remove splash guard foam securing pre filter Remove pre filter element Note position of duct support wire It must be properly positioned before reinstalling pre filter Gen IV 500s Remove wing nuts 6 from air box cover and remove cover Slip the pre filter element off of main element Cleaning 4 Clean the element with high flash point solvent followed by hot soapy water 5 Rinse and dry thoroughly Inspect element for tears or damage 7 Apply a 1 2 oz of 2 stroke oil or foam filter oil to the pre filter Thoroughly work oil completely into foam Squeeze out excess oil Installation Magnum 8 Reinstall pre filter element making sure duct support wire is in proper position Secure splash guard foam removed in step 3 Do not allow splash guard foam to restrict air intake Do not tuck the element under the noise baffle foam Gen IV 500s Reinstall elem
42. nd poss ibly more often in very dirty conditions Polaris Industries Inc 2 22a 5 98 MAINTENANCE 2 Stroke Engine Maintenance Air Filter Service Sport Scrambler 400 1 Release seat latch and lift up on the rear of the seat 2 Pull the seat back and free the tab from front cab 3 Remove the two wing nuts and washers securing Access the air filter access cover Cover 4 Remove the cover Inspect the gasket It should adhere tightly to the cover and seal all the way around 5 Remove the wing nut and washer securing the se cond cover The cover should be straight and not distorted 6 Remove pre filter from main filter and discard the Gasket main air filter Second 7 Carefully wash the pre filter in soapy water and dry Cover it 8 Install dry pre filter over new main filter and install NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 98 2 22b Polaris Industries Inc Air Filter Service Trail Blazer 1 Release seat latch and lift up on the rear of the seat Pull the seat back and free of the tabs Remove the primary air filter box Remove the yellow pre cleaner foam boot held in place by a gray collar from the air box Do not re move the collar Carefully wash the yellow foam boot in soapy wa ter and dry it Oil the foam boot with engine injection oil 1 to 2 teaspoons Squeeze out the excess into an ab sorbant cloth Reinsta
43. nds This will return oil to its true level in the oil tank About a cup of oil will remain in the crankcase 3 Stop engine remove dipstick and wipe dry with a clean cloth 4 Reinstall dipstick screwing into place NOTE The dipstick must be screwed completely in to keep the angle and depth of stick consistent 5 Remove dipstick and check to see that the oil level is between the safe and add marks Add oil as indicated by the level on the dipstick Do not overfill Cro 807 e norma f ra NOTE Rising oil level between checks in cold weather driving can indicate moisture collecting in the oil reservoir Maintain Oil Level In Normal Range Screw in completely to check Oil and Filter Change 4 Stroke The recommended oil change interval is 100 hours 1000 miles or every six months whichever comes first Sug gested break in oil change is at 20 hours 500 miles or one month whichever comes first Severe use such as contin uous duty in dirt dust water short trip winter driving or any driving below 10 F 23 C requires more frequent ser vice Be sure to change the oil filter wnenever changing oil 1 Place vehicle on a level surface 2 Run engine for two to three minutes until warm Shut engine off 3 Clean area around drain plug at the bottom of the oil tank 4 Place a drain pan beneath the oil tank and remove the drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin a
44. nt bolts 10 12 ft Ibs 1 4 1 7 ing Position kg m 8 Tighten the eccentric locking bolts to 60 ft Ibs 8 3 kg m 9 Reinstall chain guard NOTE Reposition chain guide to allow 1 8 3 cm clearance between sprocket and guide Polaris Industries Inc 2 3 a 5 98 MAINTENANCE Drive Chain NOTES 5 98 2 37b Polaris Industries Inc MAINTENANCE Drive Chain Center Front Drive Chain Slack Adjustment Periodically remove the chain guards to check chain quality and adjustment The center chain should be adjusted before the front chain This adjustment affects the front chain slack After the recommended center chain adjustment is made proceed to the front chain NOTE This procedure should be performed while the vehicle is empty i e no one sitting on the machine Center Front Drive Chain In spection Adjustment 1 Remove cotter pin and washer connecting brake pedal linkage to caliper actuating arm Re move linkage from arm 2 Remove right front fender mud flap foot rest attaching hardware 3 Remove center chain guard at taching hardware Press brake pedal downward and remove guard 4 Remove forward chain guard at Pin Punch taching bolts and guard 1 Em A 5 N Eu Lan Po j LANG kuts A BE u nf ta Ehk ix Y NA N x kyi LI Ki x 1 n Eon 50 ft Ibs 5 Loosen center chain eccentric clamp bolts A 6 Rotate vehicle forward or rearward until one of sprocket ho
45. often they need checking depends upon the type of driving that has been done Keep fluid level in the master cylinder reservoir 1 4 6 4 mm from the top between Min 8 Max lines on plastic reservoirs at all times Normal functioning of the diaphragm is to extend into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is indicated and the dia phragm should be replaced Always fill the reservoir to within 1 4 6 4 mm of the top between Min amp Max lines on plastic reservoirs whenever the cover is loosened or removed to insure proper diaphragm operation Use Polaris DOT 3 brake fluid PN 2870990 e Check brake system for fluid leaks Check brake for excessive travel or spongy feel e Check friction pads for wear damage and looseness e Check surface condition of the disc Pads should be changed when worn to 3 64 1 cm or about the thickness of a dime Brake Fluid Level Inspection The master cylinder is located on the left handlebar Re move the cover and check the brake fluid level often The Thickness correct fluid level is 1 4 6 4 mm from the top A be tween Min 8 Max lines on plastic reservoirs Ifthe fluid level is low add DOT 3 brake fluid PN 2870990 only Fill to 1 4 6 4 mm from the top between Min amp Max lines on plastic reservoirs When reservoir cover is removed do not squeeze brake l
46. on 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 50 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 Guarts 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 SG SH Rated 2 41 Transmission Polaris Synthetic Gear Add to proper level on dipstick See trans Gearcase Case Oil mission oil change Type III HLR 20 oz Type III HR 16 02 Type IV 32 OZ Capacity after draining is approx 20 ounces Shift Selector Box Oil in selector box should be at the center line of the shift selector plungers Do not overf
47. or an approved O ring chain spray lube 5 98 2 36 Polaris Industries Inc MAINTENANCE Drive Chain Rear Drive Chain Tension Adjustment NOTE On models with concentric swingarm such as 1998 Scramblers chain tension can be measured at any point in the swingarm arc It is not necessary to compress the suspension on concentric models as shown below Refer to page 2 37a for drive chain adjustment procedure on concentric swingarm models Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain Collapse the suspension by using an adjustable buckle type trailer tie down Fasten the strap around the axle and rear bumper tube Tighten until a straight line A 1 4 6 cm can be drawn from the axle to the Deflection transmission output shaft intersect ing the swing arm pivot If the chain IMPORTANT Suspension must be compressed as shown to needs adjustment use the following check drive chain tension except concentric swingarm models procedure 1 Loosen chain guard 2 Loosen two eccentric locking bolts 3 Insert a pin punch through the sprocket hub and into the eccentric axle housing 4 Rollthe vehicle ahead or back to adjust chain slack to 1 4 inch 6mm in the center of the chain as shown ab
48. ove 5 Tighten the eccentric locking bolts to 60 ft Ibs 8 3 kg m Re check chain deflection measurement 6 Reinstall chain guard 7 Adjust stone guard to allow 1 8 clearance between sprocket and guide Rear Drive Chain Adjustment Polaris Industries Inc 2 37 5 98 MAINTENANCE Drive Chain Drive Chain Adjustment Concentric Swingarm caution Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain At this point the chain should have 3 16 3 8 48 cm 95 cm deflection If the chain needs adjustment use the following procedure NR Pin Punch 6 ame Li o 3 16 3 8 48 cm 95 cm Deflection Loosen caliper mounting 1 bracket bolts Step 3 Adjustment Procedur j nt Procedure Alternate Adjustment Method Pin Punch 1 Loosen chain guard 2 Loosen two eccentric locking bolts 3 Loosen caliper mount bolts 4 Using a 2 1 2 wrench rotate the housing to adjust chain slack to the proper dimension and then pro ceed to Step 7 or follow Steps 5 and 6 5 Insert a pin punch through the sprocket hub and into the eccentric axle housing 6 Roll the vehicle ahead or back to adjust chain slack to the proper dimension link Clip Open E3 7 Tighten caliper mou
49. ow engine compression is rarely a factor in running condition problems above idle speed Abnormally high compres sion can be caused by a decompressor malfunction or worn or damaged exhaust cam lobes Inspect camshaft and automatic decompression mechanism if compression is abnormally high A cylinder leakage test is the best indication of engine condition on models with automatic decompression Fol low manufacturer s instructions to perform a cylinder leak age test Never use high pressure leakage tester as crank seals may dislodge and leak Polaris Industries Inc 915 MAINTENANCE General Maintenance 5 98 MAINTENANCE General Maintenance Battery Maintenance A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immedi ately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame ciga rettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN The battery is located under the left rear fender Inspect the battery fluid level When the battery fluid nears the lower level the battery should be removed
50. rake Clean Out Plugs and block the wheels Make sure the machine is in neu tral and repeat steps 2 and 3 WARNING SEE BELOW 5 f particles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the parking brake and block the wheels Make sure the machine is in neu tral and repeat steps 2 and 3 WARNING SEE BELOW 6 Repeat steps 2 through 5 until no more particles are ex pelled when the engine is revved 7 Stop the engine and allow the arrestor to cool 8 Reinstall the clean out plugs Clean Out Plug Clean Out Plugs Clean Out Plug A WARNING Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot Because of the increased fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor Wear eye protection Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor Never run the engine in an enclosed area The exhaust con tains poisonous carbon monoxide gas Do not go under the machine while it is inclined Failure to heed these warnings could result in serious personal injury or death Polaris Industries Inc 2 33 5 98 MAINTENANCE Chassis Maintenance Brake System Inspection The following checks are recommended to keep the brake system in good operating condition How
51. riodically lubricate the chain with Polaris O Ring Chain Lubricant PN 2871079 Drive Chain Inspection The chain must be replaced when it reaches 3 elonga tion 1 Stretch the chain tightly in a straight line 2 Measure a length of twenty pitches pins from pin center to pin center and compare to the specification Proper Replace the chain if the length exceeds the wear limit Splicelink Clip 3 When replacing or reinstalling drive chain install the Opening CE closed end of the splice link clip as shown with the Position Rear Chain closed end leading in forward operation Shown Rear Drive Chain Note All Except Models With Concentric Swingarm The rear chain will change tension as the swingarm moves through the range of travel Adjusting the chain at the tightest point swingarm pivot output shaft sprocket and rear axle are aligned in a straight line will ensure proper adjustment and prevent damage to the chain sprockets axle bearings and transmission bearings Drive Chain Inspection Polaris ATV drive chains are equipped with O ring sealed permanently greased pins and rollers The sprockets and outer rollers require periodic lubrication Always inspect the drive chain prior to operating the vehicle checking for damaged or missing O rings rollers and correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 cm Regularly lubricate the drive chain with Polaris O Ring Chain Lube
52. ris All Season a Grease 16 Rear and Middle Polaris All Season Locate grease fitting on eccentric and grease with semi annually Axle Bearings Grease grease gun 6x6 owing Arm Polaris All Season Locate grease fitting on swing arm and grease with Semi annually Bushings and Grease grease gun Center Swing Arm Housing 6x6 Chain Adjusters Polaris All Season Locate grease fitting on center eccentric and semi annually Center and Front Grease grease Locate grease fitting on front eccentric side Eccentrics opposite chain and grease Rear Strut 6x6 Polaris All Season Locate fitting on rear strut and grease with grease semi annually Grease gun More often under severe use such as wet or dusty conditions Grease conforming to NLGI No 2 such as Polaris Premium All Season Grease Conoco Superlube M or Mobilegrease Special i Semi annually or 50 hours of operation Annually or 100 hours of operation NOTE Hours are based on 10 mph average 5 98 27 Polaris Industries Inc MAINTENANCE Lubrication Chart Type IV Transmission Shaft Drive 3 Rear Halfshaft 2 Slip Yoke 6 Transmission 4 Axle Cardan U Joint Full 5S Operating Range N Magnet 4 Front Prop Shaft Pre 1998 Axle Cardan U Joint 5 Propshaft Yoke 3 pumps max O NOTE On Shaft Drive models lubricate these areas in addition to applicable general lubrication items E OM m 1 Front Gear
53. ry filter weekly or after every 50 hours of operation CAUTION Never operate the ATV with the filter ele ment removed Dirt will enter the engine causing seri ous rapid wear and damage to the engine Secondary filter removal and installation pro cedure 1 Remove ATV seat 2 Remove primary air filter box 3 Remove four wing nuts holding cover assembly to secondary air filter housing 4 Remove filter element 5 Inspect gaskets on both sides of filter Replace if required 6 Coat top and bottom gaskets of filter with a gener ous amount of grease 7 Check condition of air box and replace if necessary Install filter into airbox Be sure filter element seats securely 8 Check cover gasket and replace if required Be sure cover is seated properly and wing nuts are fin ger tightened securely 9 Reinstall primary air filter box as per instructions found on page 2 22 10 Reinstall ATV seat Cleaning the Main Filter Important It is advisable to replace the filter when it is dirty How ever in an emergency it is permissible to clean the main filter if you observe the following practices 1 Never immerse the filter in water since dirt can be transferred to the clean air side of the filter 2 f compressed air is used never exceed a pressure of 40 PSI Always use a dispersion type nozzle to prevent filter damage and clean from the outside to the inside NOTE Replace the air filter every 50 hours a
54. s serious burns may result 5 Allow oil to drain completely 6 Replace sealing washer on oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 ft lbs 1 9 kgm Polaris Industries Inc 2 23 5 98 MAINTENANCE 4 Stroke Engine Maintenance Oil and Filter Change Cont 4 Stroke 8 10 11 12 Place shop towels beneath oil filter Using an oil filter wrench turn filter counterclockwise to remove Using a clean dry cloth clean filter sealing surface on crankcase Lubricate O ring on new filter with a film of engine oil Check to make sure the O ring is in good condition Install new filter and turn by hand until filter gasket contacts the sealing surface then turn and additional 1 2 turn Approximately 1 cup of engine oil will remain in the crankcase To drain remove drain plug found on lower right side of crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 13 14 15 16 17 18 Reinstall drain plug Remove dipstick and fill tank with 2 quarts 1 9 1 of Polaris Premium 4 synthetic oil Place gear selector in neutral and set parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Re check the oil level on the dipstick and add oil as nec
55. shing downward on lever arm and checking for movement See Ill 2 Verify lever is against 1 stop by pushing down on lever a NOTE If lever arm cannot rest against stop even with throttle cable adjuster screwed all the way in loosen oil pump cable adjuster nuts and adjust cable down until lever arm is firmly against stop Lever Stop IIl 2 Polaris Industries Inc 2 19 5 98 MAINTENANCE 2 Stroke Engine Maintenance Oil Pump Adjustment Procedure 300cc Engines and 1997 to current 250 cc Engines cont 5 Using machinist s dividers or a drafting compass gauge the distance from the bottom of the cable bracket to the bottom of the lever arm tip as shown in Ill 3 Note the exact position of the divider on the bracket and lever arm The divider must be in the same position on these parts when you perform the oil pump cable measurements in Step 8 It may be helpful to scribe or mark a line on the end of the lever arm to use as a reference See Ill 2 and 3 6 Measure the width of the divider on a metric ruler to the nearest 1 2 millimeter Record this measurement Note The carburetor slide must be resting against the idle stop screw and the throttle lever must have free play before proceeding with Step 7 If you cannot ob tain free play at the carburetor even with the throttle housing adjuster screwed completely into the throttle housing loosen the lock nut on top of carburetor turn the throttle cable adjuster
56. stries Inc Carburetor Adjustments Idle Speed Adjustment 1 Start engine and warm it up thoroughly 2 Adjust idle speed by turning the idle adjustment screw See illustrations at right NOTE Adjusting the idle speed affects throttle cable freeplay and electronic throttle control ETC adjustment Always check throttle cable freeplay after adjusting idle speed and adjust if necessary Throttle Cable Electronic Throttle Control ETC Switch Adjustment 1 Slide boot off throttle cable adjuster and jam nut at throttle block 2 Place shift selector in neutral and set parking brake 3 Start engine and set idle to NOTE Be sure the engine is at operating temperature See Idle Speed Adjustment 4 Loosen lock nut 5 Turn cable adjuster out until engine RPM starts to increase 6 Turn cable adjuster back in until throttle lever has 1 16 16 cm of travel before engine RPM increases Be sure ETC switch plunger is held inward by throttle cable tension 7 Tighten lock nut securely and slide boot completely in place to ensure a water tight seal NOTE On 2 stroke models whenever throttle cable ad justments are made always check oil pump adjustment Refer to pages 2 19 2 20 for adjustment procedure 8 Turn handlebars from left to right through the entire turning range If idle speed increases the throttle cable freeplay must be increased or check for proper cable routing Throttle Operation Check for smoot
57. sure test procedure 5 98 2 18 Antifreeze Hydrometer Polaris Industries Inc MAINTENANCE 2 Stroke Engine Maintenance Oil Pump Adjustment Procedure 1996 250cc Engines 1 Before adjusting the oil pump check engine idle RPM Recommended RPM is 700 Adjust if 250cc Engine necessary Check and adjust throttle lever free play ETC switch See page 2 12 2 Start the engine and let it idle Place very slight pressure on the throttle lever until all freeplay ts removed from throttle cable to carburetor 3 Loosen locknut D and align marks A and C by turning adjuster E up or down as needed A Idle Index B Oil Pump Lever 4 When the marks are aligned tighten locknut D C Static Line 5 Check throttle lever freeplay ETC switch D Locknut adjustment and readjust at throttle block if E e ACIUSISr jus J F Bleed Screw necessary Oil Pump Adjustment Procedure 300cc Engines and 1997 to current 250 cc Engines Throttle Housing 1 Adjust engine idle speed to 600 800 RPM Lock Nut 2 Remove seat air box cover and air filter to gain access to carburetor slide 3 Pull boot back from throttle cable adjuster located on throttle housing Loosen lock nut See Ill 1 Cable Adjuster Turn in until oil pump lever arm rests against stop Step 4 4 Turn adjuster into throttle housing until the oil pump lever arm rests firmly against its fra Adjuster stop on the oil pump body Verify this by ig pu
58. ted using two feeler gauges 1 Insert a 006 15 mm feeler gauge between each of the exhaust valves and adjuster screws 2 f adjustment is needed loosen the locknuts and turn the adjuster screws until there is a slight drag on both feeler gauges NOTE Both feeler gauges should remain inserted during adjustment 3 Whenthe clearance is correct hold the adjuster screw and tighten the locknut to 5 8 to 7 2 ft Ibs using the 10mm flank drive torque adapter at a 90 angle to the torque wrench as shown NOTE The flank drive must be positioned at a 90 angle to the torque wrench to prevent over torquing 4 Re check the valve clearance 5 Repeat adjustment procedure if necessary until clearance is correct 6 Scrape gasket surfaces to remove all traces of the old i m M nu gasket CAUTION Use care not to damage the Use torque adaptor for all valve adjuster sealing surface of the cover or cylinder head locknuts 10 96 2 28 Polaris Industries Inc MAINTENANCE 4 Stroke Engine Maintenance Exhaust Valve Clearance Adjustment Cont 7 Reinstall the cover using a new gasket 8 Torque cover bolts to 72 in lbs 9 Remove the shop towel from the spark plug cavity 10 Reinstall the spark plug Torque to 11 ft Ibs new 18 ft los used 11 Reinstall the spark plug high tension lead 12 Reinstall the fuel tank 13 Reinstall the fuel tank shroud 14 Reinstall the left and right body panels Throttle
59. uid 1 Place a drain pan beneath the hub 2 Remove the hub cap by carefully prying with a screwdriver in the notches provided Pry equally until cap is removed NOTE Mid 1996 to current AWD model ATVs are equipped with three Torx head screws to secure the hub cap 3 Allow fluid to drain completely 4 Inspect hub cap O rings for nicks cuts or abrasions Replace if necessary 5 Remove check fill plug 6 Reinstall the hub cap NOTE The check fill plug must be removed before reinstalling the hub cap 7 Turn wheel until front hub fill check plug is in either the 4 00 or 8 00 position 8 Add fluid until it trickles out NOTE Do not force the fluid into the hub under pressure or seal damage may occur 5 98 2 32 Polaris Industries Inc MAINTENANCE Chassis Maintenance Exhaust Pipe The exhaust pipe must be periodically purged of accumu lated carbon as follows 1 Remove the clean out plugs located on the bottom of the muffler as shown above 2 Place the transmission in neutral and start the engine Purge accumulated carbon from the system by momen tarily revving the engine several times 3 If some carbon is expelled cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times 4 f particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the parking b
60. urled portion Do not overfill Transmission Lubrication Type V Shaft Chain The transmission fill plug is located on the right side of the machine behind the propshaft shield The transmission lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a level surface remove fill plug and check the lubricant level Lubricant level is correct when it reaches the bottom thread of filler hole Use Polaris Premium Syn thetic Gearcase Lubricant PN 2871478 Transmission Oil Change Procedure 1 Remove propshaft shield from the right side of the vehicle 2 Remove fill plug 3 Remove transmission drain plug located on the bot tom left hand side and drain the oil Catch and discard used oil properly 4 Clean and reinstall the drain plug 5 Add Polaris Premium Synthetic Gearcase Lubricant PN 2871478 12 oz bottle until oil reaches the bot tom thread of the filler hole 6 Check for leaks 7 Reinstall propshaft shield removed in step 1 5 98 2 42 Full Operating Operating Hanga Range Polaris Industries Inc MAINTENANCE Chassis Maintenance Transmission Vent Line Routing 1 Check the transmission vent line for proper routing cracks or damage Be sure the vent line is not kinked or pinched NOTE Vent line location varies by model Transmission Linkage Adjustment The transmission shift
61. w in hubs Rotate wheels to 4 or 8 O clock position If lubricant is not visible add until it flows from filler hole screw Reinstall screw Semi annually Annually 10 Ball Joint Polaris All Season Locate grease fitting on back side of struts and ay annually Grease 7 grease with grease gun 11 Front A Arm Pivot Polaris All Season Locate grease fitting on pivot shaft and grease with 22 annually Shaft Grease grease gun Polaris All Season Locate grease fitting and grease with grease gun Semi annually Grease where applicable On others Lift boot Clean o away dirt and grease Apply fresh grease by hand and reassemble Tie Rod Ends 13 Er Balance 10W30 Motor Oil Er 400L 14 Steering Post Bush All Season ings Grease 5 98 26 Polaris Industries Inc Check level on dipstick and add oil as necessary Change annually To change oil see page 2 21 Change Annually Locate fittings on upper and lower steering post and Semi annually grease with grease gun MAINTENANCE Lubrication Chart 15 Output shaft support bearing grease fitting 17 Swing Arm Bushings 17 Center Swing Arm Housing 6x6 19 Rear Strut Stabilizer 6x6 16 Rear Axle Bearing 15 Transmission Polaris All Season Locate grease fitting on transmission output shaft semi annually Output Shaft Grease and grease with grease gun 15 Rear Strut Assy Pola

9913680 1996-1998 Vol. II ATV Service Manual Chapter

Contents

Download Pdf Manuals

Related Search

Related Contents