LRRIS InDUSTRIESInc:. ATVAND LIGHT UTILITY VEHICLE SERVICEMANUAL Foreword Thismanualisdesigned primarily for use by ATVservice techniciansina properly equipped shop.Since a certainknowledge of mechanical theory,tooluse,andshop proceduresisnecessary to perform theservice work safely,alloperations should beperformedby qualified service personnel only.Inorder toperform the work efficiently andprevent costly errors,the technicianshouldreadthe text andbefamiliar withprocedures before starting thework.Cleanliness ofpartsand tools as wellasthework area isof primary importance. Allreferences toleft andright sideof thevehicleare fromtheoperator's perspective whenseatedina normal ridingposition. This manualincludes procedures for maintenance operations,component identification andunit repair,along withservicespecifications for 1996-1998 modelPolaris ATVsandLightUtility Vehicles.The sectionindex tabsenable theuser toquickly locate thesectiondesired.Inaddition,a tableofcontentsisplacedat the beginning of eachsection for location of specific pagenumbers andserviceinformation.Keep this manual available for referencein the shop area. Tokeepthismanualcurrentitisimportantthatitisupdatedyearlywithnewmodelinformationand specifications. At the timeofpublicationallinformation containedinthismanual wascurrent.However,allmaterials and specifications aresubject tochange without notice. Comments or suggestionsabout thismanualmay bedirected to:PolarisIndustriesInc.,ServicePublications Supervisor,1225 Highway 169 North,Minneapolis,Minnesota 55441-5078. 1996-1998 Service Manual VolumeIIPart No.9913680 1998 Service ManualUpdatePartNo.9914752 Printed inU.S.A. UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout theseinstructions,important informationis brought toyour attentionby the followingsymbols: .&,.The Safety Alert Symbol means ATIENTIONI BECOME ALERTIYOURSAFETYISINVOLVED! ADANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystand-er or personinspectingor servicing the ATV. AWARNING Failure to follow WARNINGinstructions could result insevere injury or death to the operator,passenger,by-stander or personinspecting or servicing theATV. A CAUTION indicates special precautions that must be taken to avoid minor personal injury, or ATV or proper-tydamage. NOTE: A NOTE provides keyinformation toclarify instructions. Trademarks Polaris acknowledges the followingproducts mentionedinthismanual: FLEXLOC,Registered Trademark of SPS Technologies Loctite,Registered Trademark of theLoctiteCorporation STA-BIL,Registered Trademark of GoldEagle FOX,Registered Trademark of FoxShox Nyogel, Trademark of Wm.F.NyeCo. Fluke,Registered Trademark of JohnFlukeMfg.Co. Mity Vac,Registered Trademark of NewardEnterprises,Inc. Ammco,Registered Trademark of Ammco Tools,Inc. Torx,Registered Trademark of Textron Hilliard, Trademark of theHilliard Corporation Table of Contents 9913680 Chapter 01..............................General Information Chapter 02.......................................Maintenance Chapter 03............................................... Engine Chapter 04........................ Fuel System/Carburetion Chapter 05.......................Body/Steering/Suspension Chapter 06........................................ PVT System Chapter 07.......................................... Final Drive Chapter 08......................................Transmission Chapter 09..............................................Brakes Chapter 10............................................ Electrical CHAPTER 1 GENERAL INFORMATION ModelIdentification........................... 1.1- 1.1 c Publications Numbers. . . . . . . . . . . . . . . . . . . . . . . ..1.2 - 1.2a Service Videos............................... 1.2a Service/Information BulletinIndex. . . . . . . . . . . . . ..1.3 - 1.3b Paint Codes................................. 1.4 - 1.4b ModelSpecifications,19961.5 - 1.8 ModelSpecifications,1997.................... 1.8a - 1.8d ModelSpecifications,1998.................... 1.8e - 1.8h Standard TorqueSpecifications. . . . . . . . . . . . . . . ..1.9 DecimalEquivalent Chart. . . . . . . . . . . . . . . . . . . . ..1.10 Conversion Table. . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.11 TapDrillCharts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.12 Warranty.................................... 1 .13 Service Tips................................. 1.14 Glossary of Terms............................ 1.15 - 1.17 ToolOrderingInformation..................... ,1.18 RoutingDiagrams............................ 1.19 - 1.24 GENERAL INFORMATION ModelIdentification Engine SerialNumber Location Whenever correspondingabout anengine,besure to refer to the engine model number and serialnumber.This informationcanbefoundonthesticker appliedtothemanualstarter recoilhousing.Anadditionalnumber is stampedinoneof the followinglocations: 4 strokemodels - center top of crankcasebeneath the cylinder coolant elbow 2 stroke liquid cooledmodels - center top of crankcasebeneath thecarburetor mounting flange 2 stroke air cooledmodels - top of crankcasenear right side of cylinder Machine Model Number andSerialNumber Location The machine modelnumber andserialnumber are im-portant for vehicle identification.The machine model number islocated onthe frameontheleft sideof the vehicle near theoiltank.Depending onmodel,theSe-rialnumber willbestampedinto the frameinoneof the followinglocations: On therightsideof the vehicle infront of theshift selector box (A).(1996) Undertheseatontheuppershock mount crossmember (8)(1996) On therighthand framerail(C)near the air box.(1997) Onthelefthandlower framerail(D) near therear A-armmount. (199B-Current) Transmission1.0. Number Location Transmissionmodelandserialnumbersarelocated on topof the transmissioncase below the shiftingbell-cranks. Carburetor 1.0.Number Location The carburetor1.0.number isinoneof thefollowing locations: 4 strokemodels - right side center of the carburetor body 2 stroke models - right sideof carbu-retor body near chokeplunger boss Polaris Industries Inc. 1.1 VINLocation- 1996 VINLocation - 1996/1997 VINLocation- 199B-Current Example Mod:ffl13411571 Ser#t96-1Q273 Transmission1.0.Numbers 5/98 GENERAL INFORMATION ModelIdentification 1996 ModelIdentification The machine model andserialnumber must beused withany correspondenceregardingservice or repair. 1996Machine ModelNumber Identification W9681 MOD ELATVor Light Utility vehicle/- T- i ~ NUMB ERSYear DesignationBasicChassisEngine Designation Designation 1996 Engine Designation Numbers1996 Chassis Designation Numbers 27........... 25075..........Magnum 2x4 30........... 30078..........TrailBlazer / Scrambler 40........... 40080..........Sportsman 4x4 44........... 42581..........Magnum 4x4 50........... 50085..........TrailBoss / Sport 87..........400 6x6 / Magnum 6x6 91..........Xplorer 300 / Xplorer 400 92..........Sportsman 500 95..........Xpress 300 / Xpress400 5/98 1.1 a Polaris Industries Inc. GENERAL INFORMATION ModelIdentification Vehicle Identification Number (1997 andLater Model Years) 1997 to Current ATVsandLight Utility Vehicleshave a 17 digit VehicleIdentification Number (VIN).The VINis organized as follows:Digits13:WorldManufacturer Identifier.For Polaris ATVs,this is 4XADigits 4-9:Vehicle Descriptor Section.Digits10-17:VehicleIndicator Section.Digits 4-8 of the VINidentify thebody style,drive type,engine type,andemissionsequipment.The VINnumber and themodelnumber must beusedwithany correspondenceregardingservice or repair. WorldMfg.IDVehicle DescriptorVehicle Identifier 1997-Current 234567891011121314151617 4XABA38C0V2000000 VINNumberI ... T ,; I Emissions Body Style I ~ I I Engine MJdelI Year IndividualSerialNo. Powertrain CheckDigit Plant No. VehicleIdentification Number I Model Number Key Body StylePowertrainEngineEmissionsOgtions A=GenIIA=2x4 chain25:::EC25PF(250cc)A=Approvedby CARB*A=Std B=Gen IIIC=4x4 chain28=EC28PF(300 cc)C=NonCARB*ApprovedB=1st Color Option C=GenIVD=4x4 shaft38=EC38PL(400 cc)D=Norway E=6x6 chain42=EH42PL (425 cc)E=Sweden 50=EH50PL (500 cc) *CARB = California Air ResourcesBoard Year ILetter Identification The tenthdigit of a 17 digit VINis themodel year of the vehicle.Example:W=1998;X = 1999 etc.Refer tothe listing below. V1997 W1998 X1999 Y2000 1997 to Current ModelNumbers The model year isalso listedinthemodelnumber.Thelast 4 digitsinthemodelnumber correspond todigits 4 through 8 of the VehicleIdentification Number (VIN). Machine ModelNumber Identification W;:;;ATVor Light___ W98CH50ABOptionIndicator Utility Vehicle --- ~ '... Year Designation ./Last 5M ~ e l#Digits=Digits 4-8 of VIN 5/98 1.1 b Polaris Industries Inc. GENERAL INFORMATION 5/981.1 c Polaris Industries Inc. 1996 PublicationNumbers ModelModelNo. Trail BlazerW967827 TrailBossW968527 Xplorer 300W969130 Xpress300W969530 SportW968540 Scrambler 4x4W967840 Xpress 400W969540 Xplorer 400W969140 Sportsman 4x4W968040 4006x6W968740 Magnum 2x4W967544 Magnum 4x4W968144 Magnum 6x6W968744 Sportsman 500W969244 1997 PublicationNumbers ModelModel No. TrailBlazerW97BA25C TrailBossW97AA25C Xplorer 300W97CC28C Xpress300W97CA28C Sport 400W97BA38C Scrambler 4x4W97BC38C Xpress 400W97CA38C Xplorer 400W97CC38C Sportsman 4x4W97AC38C 4006x6W97AE38A Magnum 2x4W97AA42A Magnum 4x4W97AC42A Magnum 6x6W97AE42A Sportsman 500W97CH50A Xplorer 500W97CD50A Scrambler 500W97BC50A Polaris Industries Inc. Owner's ManualPN 9913584 9913506 9913332 9913327 9913584 9913519 9913327 9913511 9913414 9913516 9913512 9913512 9913522 9913269 Owner's Manual 9914011 9914056 9913980 9913959 9914011 9913988 9913959 9913974 9913966 9913917 9914069 9914069 9914074 9913998 9914134 9913988 1.2 GENERAL INFORMATION Publications Parts ManualPN1996 Parts Micro Fiche Set PN 99135869913433 9913588 9913590 9913592 9913586 9913582 9913592 9913598 9913594 9913596 9913603 9913605 9913607 9913609 PartsManual, 997Parts Micro Fiche SetPN 99140129914645 9914057 9913981 9913960 9914012 9913989 9913960 9913975 9913967 9914081 9914070 9914083 9914075 9913999 9914135 9914307 5/98 GENERAL INFORMATION Publications 1998 PublicationNumbers ModelModelNo. TrailBossW98AA25C Trail BlazerW98BA25C Xpress 300W98CA28C Xplorer 300W98CC28C Sport 400W98BA38C Scrambler 400W98BC38C Xplorer 400W98CC38C Magnum 2x4W98AA42A Magnum 4x4W98AC42A Scrambler 500W98BC50A Sportsman 500W98CH50A(&AB) BigBoss 500 6x6W98AE50A DESCRIPTION Owner's Manual 9914659 9914659 9914659 9914659 9914659 9914659 9914659 9914659 9914659 9914659 9914659 9914720 1995-1996 Magnum and Sportsman 500 Service Manual 1996 ATVService Manual VolumeII 1998 ATVService Manual Vol.IIUpdate Owner'sPartsParts ManualManualMicrofiche Supplement 991453099145319914532 991453099145469914547 991452599145369914537 991452599145269914527 991454599147239914724 991472299147259914726 991454099145419914542 991452099145529914553 991472199145219914522 991449899144999914501 991457099145719914572 N/A99146399914640 PART NUMBER 9913681 9913680 9914752 SERVICE TRAINING VIDEOS VIDEO TITLEPARTNUMBERDESCRIPTION Magnum 4-Stroke Introduction9912996Includes 4 Stroke theory of operation,engine removal, disassembly, andassembly techniques,along withand general tech-tips. Ignition SystemDiagnostics9913533Describes allcurrentPolaris ignition systems.Provides workingknowledgeofignition system theory anddiagnostics. Charging System Diagnostics9913278Describes allcurrentPolaris chargingsystems.Provides work-ingknowledgeof charging systemtheory anddiagnostics. PolarisVariable Transmissions9913987Theory,disassembly,assembly and troubleshooting of the (PVT)PolarisPVT system. Fuels andFuelDelivery9914393Describes fuel properties including octane and vapor pres-sure;fuelmixture and burncharacteristics;VMandCVcar-buretor theory andadjustments. 5/98 1.2a Polaris Industries Inc. GENERAL INFORMATION Service BulletinIndex Service/InformationBulletins - ByBulletinNumber ATV-94-0B1995 Scrambler - Oillinemay contact exhaust head pipe ATV-94-091994400 ATVs and1995 Xplorer,Sportsman,and 400 6X6 - Poor fueleconomy andhesitation 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-95-0B 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-95-1B 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 ATV-96-06 ATV-96-07 ATV-96-0B 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 - Some brake calipers may ruboninside of tirerim 1995 Scrambler - Loose clamp oncarburetor boot 1995 Xplorer 4x4,Sportsman - Front hub oilleak 1995 Xplorer 4x4 - Incorrect speedometer angle drive 1995 Scrambler - Headlight wiringreversed 1995 Magnum 2x4,Magnum 4x4 - Engine oilinair box 1995 Scrambler 4x4 - Revisedcarburetor jetting 1995 Models Equipped withAuxiliary Brake - Brake inspection andadjustment procedure 1995 Scrambler 4x4 - Missinglower front bumper bolts 1995 Scrambler 4x4 - Incorrect sprocket guard spacer 1995 Scrambler 4x4 - Front brakelines may rubagainst CV joint boot 1995 Magnum 2x4,Magnum 4x4 - Oil tank vent fittingrestricted All1995 Models - Transmissionlubricant expelled through vent line All1995 Models (exc.Scrambler,Xplorer,6x6 - Aux.brake armmay contactright footrest All1995 All WheelDriveModels - Faulty Gear Selector Switches 1995 Scrambler - Headlight Bulb May FallOut Of Socket 1995 Magnum 2x4 and4x4 - RichCondition/PlugFoulingChecklist AI!1996 - Synthetic Chaincase Lubricant Recommended for all1996 Models 1996 Sport - LooseHeadlight MountingScrews 1995 Xplorer, 400 2x4,Sport,Scrambler,6x6 - Idle Speed Adjustment on1995400 cc ATVs 1996 Scrambler,Sport 400L - Incorrect Carburetor Jetting Chart inOwner's Manual 1996 Scrambler - Water May Freeze inOilPump Housing 1996 Xplorer 400L,Xpress 300, Sportsman 500 - Plow Blade MountingKit Applications 1996 TrailBoss;Magnum 4x4 - Water Leaks at Inner PVT Cover 1996 Sportsman500 - Oil Tank Vent Hose Routing 1996 Sportsman500- LooseRear Drive Shaft RetainingBolts 1996 Sportsman 500;Magnum 2x4;4x4;6x6 - Improved Seat Fit For 1996 ATVs 1996 Gen IVmodels withrear rack extender kit.Flagmount not functionalw/ rack extender. 1996 Sport,Scrambler - BrakeLineRetention Strap May Be Missing 1996 Sport,Scrambler - Exhaust Muffler Restricted 1996 AllExcept Tr.Blazer, Tr.Boss - CoolingFanMotors May BeDamagedBy Water. 1996 Sportsman 500Hose Clamp On Coolant LineMay Contact FuelFilter 1996 Sportsman500 - Engine Overheating due to fanplacement anddebris inthe shroud 1995/ 19964 Stroke ModelsMoistureMay FreezeInOil Tank Vent Line 1996/1997 Xlorer andXpress 300s - RevisedOilPump BleedingProcedure 1996 Sportsman500;1997 Sportsman and Xplorer 500 - Rear Brake Noise /FloatingDisc Kit 1997 Magnum 6x6 - Fuel Tank VentLineRoutedIncorrectly 1997 Sportsman 500 - Pressure Relief Slit MissingForm Oil Tank Vent Line 1997 Scrambler 400 /1997 Scrambler 500 - Brake LinesMay Contact CV Boot or Clamp 1995 and19964 StrokeModels - Oil Tank Breather ModificationFor Cold Temperatures 1997 SportsmanandXplorer 500 - Rear Brake Disc Hub Bolt TorqueProcedure 1997 SportsmanandXplorer 500RevisedSerialNumber RangeFor ATV-97-02 Polaris Industries Inc. 1.35/98 GENERAL INFORMATION BulletinIndex - 1996 ByModel 1996 ModelBulletin # ALL1996 MODELSATV-96-11 1996 Sportsman SOOATV-96-13 ATV-96-10 ATV-96-09 ATV-96-0B ATV-96-05 ATV-96-04 ATV-96-03 ATV-96-02 ATV-9S-22 1996 Magnum 6x6ATV-96-0B ATV-96-04 1996 Magnum 4x4ATV-96-0B ATV-96-04 ATV-96-01 ATV-9S-17 1996 Magnum 2x4ATV-96-0B ATV-96-04 19964006x6ATV-96-0B ATV-95-17 1996Sportsman 4x4ATV-96-0B ATV-9S-17 1996 ScramblerATV-96-0B ATV-96-07 ATV-96-06 ATV-9S-21 ATV-95-20 1996400 XplorerATV-96-0B ATV-9S-22 ATV-95-17 1996 400 XpressATV-96-0B 1996 SportATV-96-0B ATV-96-07 ATV-96-06 ATV-9S-20 ATV-9S-1B 1996300 XplorerATV-96-12 ATV-96-0B ATV-9S-17 1996 300 XpressATV-96-12 ATV-96-0B ATV-9S-22 1996 TrailBossATV-96-01 1996 TrailBlazerATV-9S-1B 5/98 TypeNotes InformationMoisture May Freeze InOil Tank VentLine InformationRear Brake Noise /Floating Disc Kit ServiceEngine Overheating InformationHoseClamp May Contact FuelFilter ServiceCoolingFanMotor May BeDamaged By Water ServiceFlagMount Not Functional InformationPoor SeatFit InformationLooseRear Drive Shaft RetainingBolts ServiceOil Tank VentHose Routing InformationPlow Blade MountingKitApplications ServiceCoolingFanMotor May BeDamaged By Water InformationPoor Seat Fit ServiceCoolingFanMotor May BeDamaged By Water InformationPoor Seat Fit ServiceWater Leaks atInner PVT Cover InformationSynthetic ChaincaseLubricant Recommended ServiceCoolingFanMotor May BeDamaged By Water InformationPoor SeatFit ServiceCoolingFanMotor May BeDamagedBy Water InformationSynthetic Chaincase Lubricant Recommended ServiceCooling FanMotor May BeDamaged By Water InformationSynthetic ChaincaseLubricant Recommended ServiceCoolingFanMotor May BeDamagedBy Water InformationExhaust Muffler Restriction ServiceBrake Une Retention Strap May Be Missing InformationWater May Freeze InOilPump Housing InformationIncorrect Jetting Chart InOwners Manual ServiceCoolingFanMotor May BeDamaged By Water InformationPlow Blade MountingKit Applications InformationSynthetic Chaincase Lubricant Recommended ServiceCoolingFanMotor May BeDamaged By Water ServiceCoolingFanMotor May BeDamaged By Water InformationExhaust Muffler Restriction ServiceBrakeLineRetentionStrap May BeMissing InformationIncorrect Jetting Chart InOwners Manual ServiceLooseHeadlight Mounting Screws ServiceRevised OilPump AdjustmentProcedure ServiceCoolingFanMotor May BeDamagedBy Water InformationSynthetic Chaincase Lubricant Recommended ServiceRevised OilPump Adjustment Procedure ServiceCoolingFanMotor May BeDamaged By Water InformationPlow Blade Mounting Kit Applications ServiceWater Leaks atInner PVT Cover ServiceLooseHeadlight Mounting Screws 1.3a Polaris Industries Inc. 1997 Model All1997 Models Sportsman 500 Xplorer 500 Scrambler 500 Magnum 6x6 Magnum 4x4 Magnum 2x4 BigBoss 6x6 400L Sportsman 400L Xplorer 400L Xpress 400L Scrambler 400L Sport 400L Xplorer 300 Xpress 300 TrailBlazer ES TrailBoss 250 1998 Model All1998 Models BigBoss 500 6x6 Sportsman 500 Scrambler 500 Magnum 4x4 Magnum 2x4 Xplorer 400 Scrambler 400 Sport 400 Xplorer 300 Xpress 300 TrailBlazer TrailBoss 5/98 Bulletin # ATV-97-03 ATV-97-02 ATV-96-15 ATV-96-13 ATV-97-03 ATV-97-02 ATV-96-13 ATV-96-16 ATV-96-14 ATV-96-16 ATV-96-12 ATV-96-12 Bulletin # GENERAL INFORMATION Service BulletinIndex - 1997/1998 By Model TypeNotes ServiceLoosePinsAndLockingHubForRear DiscBrake RevisedSerialNumber RangeFor ATV-97-02 ServiceRearBrakeDiscHubBolt TorqueProcedure/HubKit ServicePressureReliefSlit MissingFromOilTankVentLine ServiceRear Brake Noise ServiceLoosePinsAndLockingHubFor Rear DiscBrake RevisedSerialNumber RangeFor ATV-97-02 ServiceRear BrakeDiscHubBolt TorqueProcedure/HubKit ServiceRear Brake Noise ServiceBrake LineMay Contact CVBoot Or Clamp ServiceFuel Tank Vent LineRouting ServiceBrake LineMay Contact CVBoot Or Clamp ServiceRevisedOilPump AdjustmentProcedure ServiceRevised OilPump Adjustment Procedure TypeNotes No bulletins issued as of 4/24/1998 1.3b Polaris Industries Inc. ModelItemColor 400LSpringsPurple Velvet RimsBrushed Aluminum TrailBlazerSpringsFireRed RimsBright White TrailBossSpringsAqua Marine RimsBright White RackAqua Marine ScramblerSpringsLavender RimsBright White Xpress 300SpringsBonnie Blue RimsBrushed Aluminum Xpress 400SpringsBlue Green RimsBrushed Aluminum Xplorer 300SpringsEddieB.Green RimsBrushedAluminum XplorerSpringsFireRed RimsBrushed Aluminum Magnum 2x4SpringsEddieB.Green RimsBrushed Aluminum RacksSteel Gray Magnum 4x4SpringsBonnie Blue RimsBrushed Aluminum RacksBonnie Blue Sportsman500SpringsBlack RimsBlack RacksBlack Magnum 6x6SpringsEddieB.Green RimsBrushed Aluminum RackEddieB.Green BoxEddie B.Green 4006x6SpringsEddieB.Green RimsBrushed Aluminum RackEddieB.Green BoxEddieB.Green GENERALINFORMATION 1996 Pai nt Codes RawMaterialNo.PPGDitzler No. 852016051467 N/AN/A 852014972060 85201532185 852015946975 85201532185 852015946975 8520157N/A 85201532185 852014812908 N/AN/A 8520202N/A N/AN/A 852015044931 N/AN/A 852014972060 N/AN/A 852015044931 N/AN/A 8520151N/A 852014812908 N/AN/A 852014812908 85201479440 85201479440 85201479440 852015044931 N/AN/A 852015044931 852015044931 852015044931 N/AN/A 852015044931 852015044931 Order direct fromMidwest Industrial Coatings (612-934-8252).Mix as directed. Polaris Industries Inc. 1.4 10/96 GENERAL INFORMATION 1997 Paint Codes MODELPAINTEDPART TrailBlazerSprings Rims TrailBossSprings Rims Rack SportSprings Rims Xpress 300Springs Rims Xpress 400Springs Rims Xplorer 300Springs Rims Xplorer 400Springs Rims Xplorer 500Springs Rims Scrambler 4x4Springs Rims Scrambler 500Springs Rims Sportsman 4x4Springs Rims Rack Sportsman500Springs Rims 4006x6Springs Rims Rack Box Magnum 2x4Springs Rims Rack Magnum 4x4Springs Rims Rack Magnum 6x6Springs Rims Rack Box BigBoss 6x6Springs Rims Rack Box 10/96 COLOR DESCRIPTION FireRed Bright White Aqua Marine Bright White Aqua Marine Purple Velvet Brushed Aluminum Bonnie Blue Brushed Aluminum Blue-green Brushed Aluminum Eddie Bauer Green Brushed Aluminum EddieBauer Green Brushed Aluminum Screamin' Yellow Brushed Aluminum Lavender Bright White Screamin' Yellow Brushed Aluminum Black Black Black Black Black Eddie Bauer Green Brushed Aluminum EddieBauer Green Eddie Bauer Green FireRed Brushed Aluminum Black Eddie Bauer Green Brushed Aluminum Eddie Bauer Green Eddie Bauer Green Brushed Aluminum EddieBauer Green EddieBauer Green Eddie Bauer Green Brushed Aluminum Eddie Bauer Green Eddie Bauer Green 1.4a DITZLERPOLARIS NUMBERNUMBER 720608520149 21858520153 469758520159 21858520153 469758520159 514678520160 N/AN/A 129088520148 N/AN/A N/A8520202 N/AN/A 449318520150 N/AN/A 449318520150 N/AN/A N/A8520241 N/AN/A N/A8520157 21858520153 N/A8520241 N/AN/A 94408520147 94408520147 94408520147 94408520147 94408520147 449318520150 N/AN/A 449318520150 449318520150 720608520149 N/AN/A 94408520147 449318520150 N/AN/A 449318520150 449318520150 N/AN/A 449318520150 449318520150 449318520150 N/AN/A 449318520150 449318520150 Polaris Industries Inc. 1998 Pai nt Codes ModelItemColor BigBoss 500 6X6SpringsEddieB Green RimsAluminum Sportsman 500 (Opt.1)SpringsBlack RimsBlack Sportsman 500 (Opt.2)SpringsBonnie Blue RimsAluminum Scrambler 500SpringsBlack RimsAluminum Magnum 4X4SpringsFireRed RimsAluminum RacksEddie B.Green Magnum 2X4SpringsBlack RimsAluminum RacksBlack Xplorer 400LSpringsBurnishedBrown RimsAluminum Scrambler 400SpringsFireRed RimsBright White Sport 400LSpringsPurple Velvet RimsBright White Xplorer 300SpringsFireRed RimsAluminum Xpress 300SpringsBonnie Blue RimsAluminum TrailBlazerSpringsFireRed RimsBright White TrailBossSpringsFireRed RimsBright White Rack(s)FireRed GENERAL INFORMATION 1998 Paint Codes Raw Material No.PPGDitzler No. 8520150 (P195)44931 (P117) 8520147 (P067)9440 8520147 (P067)9440 8520148 (P157)12908 (P117) 8520147 (P067)9440 (P117) 8520149 (P093)72060 (P117) 8520150 (P195)44931 8520147 (P067)9440 (P117) 8520147 (P067)9440 P218 (P117) 8520149 (P093)72060 8520153 (P133)2185 8520160 (P194)51467 8520153 (P133)2185 8520149 (P093)72060 (P117) 8520148 (P157)12908 (P117) 852014972060 8520153 (P133)2185 8520149 (P093)72060 8520153 (P133)2185 8520149 (P093)72060 Order direct fromMidwest Industrial Coatings(612-934-8252).Mix as directed. Frames(MediumBlack)P067 / 8520147 / Ditzler 9440 Polaris Industries Inc. 1.4b 5/98 1997 Model (GenII,III,or IV)TrailBoss (II)TrailBlazer ES (III) Model NumberW97AA25CW97BA25C Height 44/146/1 Width 44/146.5/1 Length73.2"74.5" - . ~.. , . ~.- ,' " ~ WheelBase49.75/149.75/1 Seat Height 33/134/1 Ground Clearance5.5/1 6/1 Weight4251bs.4201bs. TurningRadius(Unloaded) 60/160/1 Front Suspension Travel6.25/16.25/1 (McPhersonStrut) .....- ~ - - . ~ ~ - ~ - - - - " " .~[---.-Rear Suspension8.5/18.5/1 Front Tires23x7x1023x7x10 Rear Tires22x11x1022x11x10 Center TiresN/AN/A FronVRear/Center TirePSI4/34/3 -_. ~.. -. Front Brake ~ ~ ~Disc Hydr.Disc Rear BrakeHydr.DiscHydr.Disc AuxiliaryBrakeMechanicalMechanical FuelCapacity (U.S.Gallons)44 OilCapacity (U.S.Quarts)22 Gearcase OilCapacity (oz)1616 MainHead Light12V 60/60W12V 55W Grill Mounted LightsN/AN/A TailLight12V/8.26W12V/8.26W - n_.__. Gear BoxF/R/NF/R/N Gear ReductionLowN/AN/A Drive Type520 O-ring520 a-ring -"..~ . FinalDrive12/4288P12/4288P Center DriveN/AN/A Front DriveN/AN/A Axle toAxleN/AN/A Displacement244cc244cc EngineModelNumberEC25PFE08EC25PFE09 CompressionRatio(Effective)6.1/16.1/1 BoreandStroke72x6072x60 Spark PlugBR8ES (NGK)BR8ES(NGK) Alternator Output150W150W Timing Degrees25@300025@3000 Carburetion(1)VM30SS(1)VM30SS Main Jet145130 Pilot Jet4040 Jet Needle5DP7-35DP7-3 Needle Jet0-4 (169)0-4 (169) r. t::l\AI::I\I 2.02.0 -J Air Screw/Pilot Screw1 Turn1 Turn *See Owner's Manual for rack loadrecommendations and restrictions. Polaris Industries Inc. 1.8a GENERAL INFORMATION Specifications 1997 Xpress 300 (IV)Xplorer 300 (IV) W97CA28CW97CC28C 45.5"45.5/1 46/146/1 78.5" 81/1 -----49.75/149.75/1 33" 34/1 6.75/1 6/1 5121bs.5671bs. 60/1 57" 6.25/16.25/1 8.5"8.5/1 23x7x1023x7x10 24x11 x1 024x11x10 N/AN/A 4/34/3 Hydr.DiscHydr.Disc Hydr.DiscHydr.Disc MechanicalMechanical 44 22 2020 N/AN/A 2,12V 30/30W2,12V 30/30W 12V/8.26W12V/8.26W HI/LO/R/NHI/LO/R/N 6.64/16.64/1 520 O-ring520 a-ring 13/3886P13/4088P N/A11/2270P N/A12/2264P N/AN/A 283cc283cc EC28PFE01EC28PFE01 6.1/16.1/1 74.5x6574.5x65 BR8ES(NGK)BR8ES(NGK) 150W150W 25@300025@3000 - - ~ ~.-(1)VM30SS(1)VM30SS 155155 4040 .. 5DP7-35DP7-3 0-4 (169)0-4(169) 2.02.0 1.5 Turn1.5 Turn 5/98 GENERAL INFORMATION Specifications 1997 1997 Model(GenII,III,orIV) ModelNumber Height Width --._-Length WheelBase Seat Height Ground Clearance Weight TurningRadius (Unloaded) Front Suspension Travel (McPherson Strut) Rear Suspension Front Tires Rear Tires Center Tires Front/Rear/Center Tire PSI Front Brake Rear Brake Auxiliary Brake Fuel Capacity (U.S.Gallons) OilCapacity (U.S.Quarts) Coolant Capacity (Quarts / Liters) Gearcase Oil Capacity (oz) Engine Counter Balancer Oil Capacity(10W/30) Main HeadLight GrillMounted Lights TailLight Gear Box ,. Gear ReductionLow Drive Type FinalDrive Center Drive Front Drive Axle to Axle Displacement Engine ModelNumber CompressionRatio(Effective) Bore and Stroke Spark Plug Alternator Output Timing Degrees Carburetion Main Jet Pilot Jet Jet Needle Needle Jet Cutaway Air Screw/Pilot Screw r-' Xpress 400 (IV) W97CA38C 47.5/1 46" 78.5" 49.75" 33" 6.75/1 5431bs. 60" 6.25" 8.5" 23x7x10 24x11x10 N/A 4/3 Hydr.Disc Hydr.Disc Mechanical 4 2 2.25/2.16 20 100cc 12V 60/55W Accessory 12V/8.26W HI/LO/R/N 6.64/1 520 O-ring 13/3484P N/A N/A N/A 378.7cc EC38PLE06 6.9/1 83x70 BR8ES(NGK) 200W 23.5@3000 (1)VM34SS 200 30 6CEY6-3 0-6 (480) 1.5 1.5 Turn Xplorer 400 (IV) W972238C 47.5" 46" 81" 49.751134" 7.375" 5701bs. 65/1 6.25/1 8.5" 25x8x12 25x12x10 N/A 4/3 Hydr.Disc Hydr.Disc Mechanical 4 2 2.25/2.16 20 100cc 12V 60W 2,12V 35W 12V/8.26W HI/LO/R/N 6.64/1 520 O-ring 13/3484P 11/2270P 13/2264P N/A 378.7cc EC38PLE06 6.9/1 83X70 BR8ES(NGK) 200W 23.5@3000 (1)VM34SS 200 30 6CEY6-3 0-6(480) 1.5 1.5 Turn * See Owner's Manual for rackloadrecommendations andrestrictions. 5/98 1.8b Sport 400 (III)Sportsman 4x4 (II) W97BA38CW97AC38C 47/146/1 46.5"46/1 74.5"77/1 49.75"49.75/1 33/1 34" 5.5"6" 4791bs.5851bs. 60"65" 6.25/16.25/t 8.5"8.5" 23x7x1025x8x12 22x11x1025x12x10 N/AN/A 4/34/3 Hydr.DiscHydr.Disc Hydr.DiscHydr.Disc MechanicalMechanical 44 22 2.25/2.162.25/2.16 1620 100cc100cc 12V 55W12V 60W , , ~ N/A2,12V 35W 12V/8.26W12V/8.26W F/R/NHI/LO/R/N N/A6.64/1 520 O-ring520 O-ring 13/3484P13/3484P N/A11/2270P N/A13/2264P N/AN/A 378.7cc378.7cc EC38PLE07EC38PLE06 6.9/16.9/1 83x7083x70 BR8ES(NGK)BR8ES (NGK) 150W200W 23.5@300023.5@3000 (1)VM34SS(1)VM34SS 230200 3530 6CEY6-36CEY6-3 0-6 (480)0-6(480) 1.51.5 1.5 Turn1.5 Turn Polaris Industries Inc. 1997 Model (Gen II,III, or IV)Scrambler 4x4 (III)Magnum 2x4 (II) Model NumberW97BC38CW97AA42A Height47" 47/1 Width45.5"46.5" ~ n g t l74.5"77" WheelBase48.5/149.75" Seat Height33"33" Ground Clearance 6/1 5.5" Weight4901bs.5341bs. TumingRadius(Unloaded)60"60" Front Suspension Travel 8.5/16.25" (McPherson Strut) Rear Suspension8.5"8.5" --Front Tires23x7x1023x7x10 Rear Tires22x11x1024x11x10 Front/Rear/Center TirePSI4/34/3 Front BrakeHydr.DiscHydr.Disc Rear BrakeHydr.DiscHydr.Disc Auxiliary BrakeMechanicalMechanical FuelCapacity (U.S.Gallons)43.5 OilCapacity (U.S.Quarts)22- OW40Engine Oil Coolant Capacity (Quarts /Liters)2.25/2.162.25/2.16 Gearcase Oil Capacity (oz)1620 Engine Counter Balancer Oil100ccN/A Capacity(10W/30) Main Head Light12V 35/35W12V 60/60W Grill Mounted LightsN/AAce. TailLight12V/8.26W12V/8.26W Gear BoxF/R/NHI/LO/R/N Gear ReductionLowN/A6.64/1 ,-Drive Type520 O-ring520ing FinalDrive13/3884P12/3886P Center Drive11/2270PN/A Front Drive12/2264PN/A Axle to AxleN/AN/A Displacement378.7cc425cc Engine ModelNumberEC38PLE07EH42PLE01 CompressionRatio(Effective)6.9/19.2/1 Bore and Stroke83x7087.9x70 Spark PlugBR8ES(NGK)BKR5ES(NGK) Alternator Output150W200W Timing Degrees23.5@300030@3500 .._-".,--Carburetion(1) VM34SS(1)BST34-CV type Main Jet230140 Pilot Jet3540 --Pilot Air JetN/A#160 Jet Needle6CEY6-35F81-3 Needle Jet0-6(480)P-8 Cutaway1.5N/A Air Screw orFuelScrew (TumsOut)1.52.5 *See Owner's Manual for rack load recommendationsand restrictions. Polaris Industries Inc. 1.8c GENERAL INFORMATION Specifications1997 Magnum 4x4 (II)Sportsman 500(IV) W97AC42AW97CH50A 46/1 47" 46/1 46" 77"7" 49.75"50.5" 34"34" 6"10" 5951bs.6491bs. 65"65" 6.25"6.25" 8.5"9.5" 25x8x1225x8x12 25x12x1025x12x10 4/35/5 Hydr.DiscHydr.Disc Hydr.DiscHydr.Disc MechanicalMech. 3.55.25 2- OW40Engine Oil3 2.25/2.162.25/2.16 2032 N/AN/A 12V 60W12V 60W 2,12V 35W2,12V 35W 12V/8.26W12V 8.26W HIILO/R/NHIILO/R/N 6.64/16.64/1 520 O-ringShaft 1213886P3.16:1 11/2270PN/A 11/2268P2:1 N/AN/A 425cc498 EH42PLE01EH50PLE01 9.211N/A 87.9x7092x75 BKR5ES (NGK)BKR5ES (NGK) 200W200W 30@350030@3500 (1)BST34-CV type(1)BST34 Cv..,type 140142.5 4042.5 #160#160 5F81-35078-3 P-8P-1 N/AN/A 2.52 -- --5/98 GENERAL INFORMATION Specifications1997 1997 Model(GenII,III, or IV) ModelNumber Height Width Length WheelBase Seat Height Ground Clearance Weight TurningRadius (Unloaded) Front Suspension Travel (McPhersonStrut) Rear Suspension Front Tires Rear Tires Center Tires Front/Rear/Center TirePSI Front Brake Rear Brake AuxiliaryBrake Fuel Capacity (U.S.Gallons) OilCapacity (U.S.Quarts) Coolant Capacity (Quarts / Liters) Gearcase OilCapacity (oz) Counter Balancer OilCapacity MainHeadLight GrillMounted Lights TailLight Gear Box Gear ReductionLow Drive Type FinalDrive Center Drive FrontDrive Axle toAxle Displacement Engine ModelNumber CompressionRatio(Effective) Bore and Stroke Spark Plug Alternator Output TimingDegrees - - - - ~ ~ , . , Carburetion Main Jet Pilot Jet Pilot Air Jet Jet Needle Needle Jet Cutaway 1--------_.. ...Air Screw Scrambler 500 (III) W97BC50A 47" 45.5" 74.5" 48.5" 33" 6" 5471bs. 60" 8.5" 9.5" 23x7X10 24x11x10 N/A --_.4/3 Hydr.Disc Hydr.Disc Mech. 3.5 2 2.25/2.16 16 N/A 12V 35/35W N/A 12V 8.26W HIIR/N N/A 520 O-ring 12/38/86P 11/22/70P 11/22/68P N/A 498 EH50PLE02 N/A 92x75 BKR5ES (NGK) 200W 30@3S00 (1)BST34 CV type 125 42.S 160 SD78-3 P-3 N/A ---.. ~ - - ...~ 2.0 Xplorer 500(lV) W97CD50A 47" 46" 7" 50.5" 34" 10" 6491bs. 65" 6.25" 9.5" 25x8x12 25x12x10 .. ~..N/A 5/5 Hydr.Disc Hydr.Disc Mech. 5.25 3 2.25/2.16 32 N/A N/A 2,12V 35W 12V 8.26W HI/LO/R/N 6.64/1 Shaft 3.16:1 N/A 2:1 N/A 498 EH50PLE01 N/A 92x75 BKRSES(NGK) 200W 30@3S00 (1)BST34 CV type 142.5 42.S #160 5078-3 P-1 N/A 2 Turns ..See Owner's Manual forrack loadrecommendationsandrestrictions. 5/98 1.8d Magnum 6x6 (II)400 6x6 (II) W97AE42AW97AE38A 47/147/1 46/146/1 103/1 103" 75"75" 34"34" 5.5"5.5" 8521bs.8301bs. 98/198/1 6.25"6.25" 8.5"8.5" 25x8x1225x8x12 25x12x1025x12x10 25x12x1025x12x10 5/5/55/5/5 Hydr.DiscHydr.Disc Hydr.DiscHydr.Disc Hydr.DiscHydr.Disc 3.54 2- OW40Engine Oil2 2.25/2.162.25/2.16 2020 N/A100cc (1 OW30) 12V 60W12V 60W 2,12V 35W2,12V 35W 12V/8.26W12V/8.26W HI/LO/R/NHIILO/R/N 6.64/16.64/1 520 O-ring520 O-ring 1214288P13/4288P 11/2472P11/2270P 11/2268P1212264P 30/30116P30/30116P 425cc378.7cc EH42PLE01EC38PLE06 9.2/16.9/1 87.9x7083x70 BKRSES(NGK)BR8ES(NGK) 200W200W .._-_.-30@350023.5@3000 (1)BST34-CV type(1)VM34SS 140210 4030 #160 5F81-36DH29-3 P-80-6 (480) N/A1.5 2.5 Turn1 Turn Polaris Industries Inc. 1998 Model (GenII,III,or IV)TrailBoss (II)TrailBlazer (III) ModelNumberW98AA25CW98BA25C Height,inches (cm) 44/1 (111.8) 46/1 (116.8) Width,inches (cm)44/1(111.8)46.5/1(118.1) Length,inches(cm)73.2/1(185.9)74.5"(189.2) WheelBase,inches (cm)49.75/1(126.4)49.75/1(26.4) Seat Height,inches (cm)33'1 (83.8) 34/1 (86.4) Ground Clearance,inches (cm)5.5/1(14.0) 6/1 (15.2) Weight,Dry - Lbs.(Kg)425(203.4)420 Ibs.(199.8) TurningRadius-Unloaded,in.(cm)6011(1S2.4)60'1 (152.4) Front Suspension Travel,in.(cm)6.25/1(15.9)6.25'1 (15.9) (McPhersonStrut) Rear Suspension, inches (cm)8.5'1(21.6)8.5"(21.6) Front Tires23x7x1023x7x10 Rear Tires22x11x1022x11x10 Center Ti resN/AN/A Front/Rear/Center TirePSI4/34/3 Front BrakeHydr.DiscHydr.Disc Rear BrakeHydr.DiscHydr.Disc AuxiliaryBrakeMechanicalMechanical Fuel Capacity (U.S.Gallons)44 OilCapacity (U.S.Quarts)22 CoolingSystemCapacity (Qt'/Liter)N/AN/A Gearcase OilCapacity (oz)1616 I-----..- ~ - - -Engine Counter Balancer OilN/AN/A Capacity(10W/30) Main Head Light12V 60/60W12V 55W GrillMounted LightsN/AN/A TailLight 1 BrakeLight (Watts)12V - 8.26/26.912V - 8.26/26.9 Gear BoxF/R/NF/R/N Gear ReductionLowN/AN/A .-r----' Drive Type520 O-ring520 O-ring FinalDrive12/4288P1214288P Center DriveN/AN/A FrontDriveN/AN/A Displacement244cc244cc Engine ModelNumberEC25PFE10EC25PFE11 CompressionRatio(Effective)6.1/16.1/1 Bore and Stroke(mm)72x6072x60 Spark Plug 1 Gap,in.BR8ES(NGK).028BR8ES (NGK).028 Alternator Output150W150W TimingDegrees2S@300025@3000 Carburetion(1)VM30SS(1)VM30SS Main Jet145130 Pilot Jet4040 Jet NeedleSDP7-3SDP7-3 Needle Jet0-4 (169)0-4 (169) Cutaway2.02.0 Air Screw/Pilot Screw1 Turn1 Turn * See Owner's Manual for rack loadrecommendationsand restrictions. Polaris Industries Inc. 1.8e GENERAL INFORMATION Specifications1998 Xpress 300 (IV)Xplorer 300 (IV) W98CA28CW98CC28C 45.5/1(115.6)45.5/1 (115.6) 46" (116.8)46/1(116.8) 79.5/1(201.9) 81/1 (205.7) 49.75/1(126.4)49.75/1\126.4) 34/1(86.4)34"(86.4) 6.75/1(16.5)6"(15.2) 512 Ibs.(224.7)567 Ibs.(252.4) 60"(152.4)57/1(144.8) 6.25"(15.9)6.25"(15.9) 8.S"(21.6)8.5'1 (21.6) 23x7x1023x7x10 --24x11x1024x11x10 N/AN/A 4/34/3 Hydr.DiscHydr.Disc .----.---Hydr.DiscHydr.Disc MechanicalMechanical 44 22 N/A2.25/2.16 2020 N/AN/A N/AN/A 2,12V 30/30W2,12V 30/30W 12V - 8.26 1 26.912V - 8.261 26.9 _.__ .. _---HIILO/R/NHIILO/R/N 6.64/16.64/1 520 O-ring520 O-ring 13/3886P13/4088P N/A11/2270P N/A12/2264P 283cc283cc EC28PFE02EC28PFE02 6.1/16.1/1 74.5x6574.5x65 BR8ES (NGK).028BR8ES(NGK).028 150W150W 25@300025@3000 (1)VM30SS(1)VM30SS 155155 4040 5DP7-35DP7-3 0-4 (169)0-4 (169) 2.02.0 1.5 Turn1.5 Turn 5/98 GENERAL INFORMATION Specifications1998 1998 Model (Gen II,III, or IV) Model Number Height,inches (cm) Width,inches (cm) Length,inches (cm) Wheel Base,inches (I1) Seat Height,inches (cm) Ground Clearance,inches(cm) Weight - Lbs.(Kg) TurningRadius(Unloaded),in.(crn) Front Suspension Travel (McPherson Strut) Rear Suspension Front Tires Rear Tires Front/Rear/Center TirePSI Front Brake Rear Brake Auxiliary Brake FuelCapacity (U.S.Gallons) OilCapacity (U.S.Quarts) CoolingSystemCapacity-qt(liter) Gearcase OilCapacity (oz) Engine Counter Balancer Oil Capacity(10W/30) MainHead Light ~ . Grill Mounted Lights TailLight /BrakeLight (Watts) Gear Box Gear ReductionLow Drive Type FinalDrive Center Drive Front Drive Axle to Axle Displacement Engine ModelNumber CompressionRatio(Effective) Boreand Stroke Spark Plug Alternator Output TimingDegrees Carburetion Main Jet Pilot Jet Jet Needle Needle Jet Cutaway Air Screw/Pilot Screw Sport 400 (III) W98BA38C 47"(119.4) 46.511(118.1) 74.511(189.2) 49.75/1(f) 3311(83.8) 5.5"(15.2) 4791bs.(215) 60" (152.4) 6.2511(15.9) 8.5"(21.6) 23x7x10 22x11x10 4/3 Hydr.Disc Hydr.Disc Mechanical 4 2 2.25 (2.13) 16 100cc 12V 55W N/A 12V - 8.26/26.9 F/R/N N/A 520 O-ring 13/3484P N/A N/A N/A 378cc EC38PLE07 6.9/1 -- . 83x70 BR8ES (NGK) 150W 23.5@3000 (1)VM34SS 230 35 6CEY6-3 0-6 (480) ---1.5 1.5 Turn Scrambler 400 (III) W98BC38C 47/1 (119.4) 45.511(115.6) 74.5/1(189.2) 48.5"(123.2) 33"(83.8) 6.5/1 (15.2) 519 Ibs.(236) 6011(152.4) 8.211(21.6) 8.5"(21.6) 23x7x10 22x11x10 4/3 Hydr.Disc Hydr.Disc Mechanical 4 2 2.25 (2.13) 32 100cc (2)12V 30/30W N/A 12V - 8.26/26.9 F/R/N N/A 520 O-ring 13/3676P 11/2270P 12/2264P N/A 378cc EC38PLE09 6.9/1 83x70 BR8ES(NGK) 150W 23.5@3000 (1)VM34SS ~ ," 230 35 6CEY6-3 0-6(480) 1.5 1.5 * See Owner's Manual for rack load recommendations andrestrictions. 5/98 1.8f Xplorer 400 (IV)Magnum 2x4 (II) W98CC38CW98AA42A 47.5"(120.7)47"(119.4) 4611(116.8)46.511(118.1) 81/1 (205.7)77/1 (195.6) 49.75"(126.4)49.7511(126.4) 34/1 (86.4)33/1 (83.8) 7.375"(19.0)5.5/1 (14.0) 570 Ibs.(267)534 Ibs.(244) 65/1(165)60/1(152.4) 6.25"(15.9)6.25"(15.9) 8.5"(21.6)8.511(21.6) 25x8x1223x7x10 25x11x1024x11x10 4/34/3 -Hydr.DiscHydr.Disc Hydr.DiscHydr.Disc MechanicalMechanical 43.5 22- OW40Engine oil 2.25 (2.13)2.25(2.13) 2020 100ccN/A 12V 60W12V 60/60W 2,12V 27WAcc. 12V - 8.26 / 26.912V - 8.26/26.9 HIILO/R/NHI/LO/R/N .. ---6.64/16.64/1 .. 520 O-ring520 O-ring 13/3484P12/3886P 11/2270PN/A 13/2264PN/A N/AN/A 378cc425cc EC38PLE06EH42PLE02 6.9/19.2/1 83X7087.9x70 .. - ~ ~ . ~ - -BR8ES (NGK)BKR5ES(NGK) 200W200W 23.5@300030@3500 (1)VM34SS(1)BST34-CV type 200140 3040 6CEY6-35F14-3 0-6 (480)P-9 1.5Pilot Air Jet #160 1.5 Turn2.5 Polaris Industries Inc. 1998 Model (Gen II,III, or IV)Magnum 4x4 (II)Scrambler 500 (III) Model NumberW98AC42AW98BC50A Height,inches (cm) 46/1 (119.4) 47/1 (119.4) Width,inches (cm) 46/1 (116.8)45.5"(115.6) Length,inches (cm) 77/1 (195.6)74.5/1(189.2) WheelBase,inches (cm)49.75/1(126.4)48.5"(123.2) Seat Height,inches (I1) 34/1 (86.4)33"(83.8) Ground Clearance,inches (cm)6"(15.2) 6.5/1 (15.2) Weight - Lbs.(Kg)595 Ibs.(274)542 Ibs.(246) TurningRadius(Unloaded),in.(cm)65"(165)60" (152.4) Front Suspension Travel,in.(cm)6.25/1(15.9)8.2" (21.6) (McPherson Strut) Rear Suspension,inches (cm)8.5"(21.6)8.5/1(24.1) Front Tires25x8x1223x7X10 Rear Tires25x11x1024x11x10 Center TiresN/AN/A Front/Rear/Center TirePSI4/34/3 Front BrakeHydr.DiscHydr.Disc Rear BrakeHydr.DiscHydr.Disc AuxiliaryBrakeMechanicalMech. FuelCapacity (U.S. Gallons)3.53.5 OilCapacity (U.S.Quarts)(2)OW40Engine Oil(2)OW40EngineOil CoolingSystemCapacity(Qt./Liter)2.25/2.162.25 I 2.16 Gearcase Oil Capacity (oz)2032 Main Head Light12V 60W(2) 12V 30/30W GrillMounted2,12V 27WN/A TailLight 1 Brake Light (Watts)12V - 8.26/26.912V 8.26 I 26.9 -, Gear BoxHIILO/R/NHI/R/N Gear ReductionLow6.64/1N/A Drive Type520

520 a-ring Final Drive12/3886P13/36-76P ,-Center Drive11/2270PN/A Front Drive11/2268PN/A Axle to AxleN/AN/A Displacement425cc499 Engine Model NumberEH42PLE02EH50PLE04 CompressionRatio (FullStroke)9.2/110.2/1 Bore and Stroke87.9x7092x75 Spark PlugBKR5ES(NGK)BKR5E (NGK) Alternator Output200W250W .. -TimingDegrees30@350030@3500 Carburetion(1)BST34-CV type(1)BST 40 CV type Main Jet140155 Pilot Jet4040 Pilot Air Jet Jet Needle5F14-36H25-94-3 Needle JetP-9y-O --CutawayN/AN/A Air Screw or FuelScrew (TurnsOut)2.52.0 *See Owner's Manual for rack loadrecommendations and restrictions. Polaris Industries Inc. 1.89 GENERAL INFORMATION Specifications1998 Sportsman 500 (IV)Big Boss 5006x6 (II) W98CH50AW98AE42A 47/1 (119.4) 47/1 (119.4) 46"(116.8)46"(116.8) 81"(205.7)103"(261.6) 50.5/1(128.3)75"(190.5) 34"(86.4) 34/1 (91.4) 11 "(27.9)5.5/1 (14.0) 660 Ibs.(316)870 Ibs.(395) 65" (165)98"(249) 6.25" (15.9)6.25"(15.9) 9.5" (24.1)7.5"(21.6) 25x8x1225x8x12 -25x11x1025x11x10 N/A25x11x10 5/55/5/5 Hydr.DiscHydr.Disc Hydr.DiscHydr.Disc Hydr.DiscHydr.Disc 5.253.5 (2)OW40EngineOil(2)OW40Engine Oil 2.25 I 2.162.25 I 2.16 3220 12V 60W12V 60W 2,12V 27W2,12V 27W 12V - 8.26 I 26.912V 8.26 1 26.9 HI/LO/R/NHIILO/R/N 6.69/16.64/1 Shaft520 a-ring 3.16:11214288P N/A11/2472P 2:111/2268P N/A30/30116P 498498cc EH50PLE07EH50PLE06 10.21110.2/1 92x7592x75 BKR5E (NGK)BKR5E (NGK) 250W250W 30@350030@3500 (1)BST34 CV type(1)BST34-CV type 142.5140 42.540 5078-35078-3 P-1Q-6 N/AN/A 2.02.0 5/98 --, -,-GENERAL INFORMATION Standard Torque Specifications The following torque specifications are tobeused asa general guideline.Some fastenersrequirea specialtorque procedure duringinstallation.Inaddition,some fastener torque valuesmay be different than the standard torque value listed below.Critical fastener torques arelisted(where applicable)at thebeginning ofeachsection.Always refer to the appropriate chapter for specific torque specifications and procedures before using standard torque. o Bolt SizeThreads/InGrade 2Grade 5 #108 #10-1/4 1/4 5/16-5/16-3/8 3/8 Torgue in. Ibs. ( k g ~ m ) 24............. 27 (.31)............... 43(.50).............. 60 (.69) 32............. 31(.36)............... 49(.56).............. 68 (.78) Torgue ft.Ibs. ( k g ~ m ) * 20............. 5(.7)................. 8(1.1)............... 12{1.6) 28............. 6(.8)................. 10 {1.4}.............. 14 (1.9) 18............. 11(1.5)...............17 (2.3).............. 25 (3.5) 24............. 12 (1.6).............. 19 (2.6}.............. 29 (4.0) 16............. 20 (2.7)............... 30 (4.0).............. 45 (6.2) 24............. 23 (3.2)............... 35 (4.8).............. 50 (6.9) 14............. 30(4.0)............... 50(6.9).............. 70 (9.7) Grade 8 7/16-7/16-1/2 20............. 35 (4.8)............... 55(7.6).............. 80 (11.0) 1/2 Metric 6x 1.0 8 x1.25 10 x1.25 13............. 50(6.9)............... 75(10.4)............ 110{15.2) 20............. 55 (7.6)............... 90(12.4)............ 120 (16.6) 72878In.Ibs. 14-18 ft.Ibs. 26-30 ft.Ibs. *Toconvert ft.Ibs.tokg-mmultiply foot pounds by .1383. *Toconvertkg-m toN-m move the decimal to theright one position. Polaris Industries Inc. 1.95/98 GENERALINFORMATION DecimalEquivalents 1/64 ..........................0156 1/32....................0312................ 1 mm=.0394// 3/64 ..........................0469 1/16...............0625 5/64..........................0781................ 2mm=.0787" 3/32....................0938 7/64.. . . . . . . . . . . . . . . . . . . . ...1 094................ 3 mm=.11 81" 1/8.........1250 9/64 .......................... 1406 5/32....................1563................ 4 mm=.1575" 11/64 ......................... 1719 3/16...............1875................ 5 mm=.1969" 13/64........................2031 7/32....................2188 15/64........................2344................ 6 mm=.2362" 1/4...........25 17/64........................2656................ 7 mm=.2756" 9/32....................2813 19/64........................2969 5/16...............3125................ 8 mm=.3150" 21/64........................3281 11/32...................3438................ 9 mm=.3543" 23/64........................3594 3/8...........375 25/64........................3906................ 10 mm=.3937" 13/32...................4063 27/64........................4219................ 11mm= .4331" 7/16...............4375 29/64........................4531 15/32...................4688................ 12mm=.472411 31/64........................4844 1/2. . . . . . . . ...5.................... 13 mm=.5118 33/64........................5156 17/32...................5313 35/64........................5469................ 14 mm= .551211 9/16...............5625 37/64........................5781................ 15 mm=.5906// 19/32...................5938 39/64........................6094 5/8...........625................. 16 mm= .6299" 41/64........................6406 21/32...................6563................ 17 mm= .6693" 43/64........................6719 11/16..............6875 45/64........................7031................ 18 mm= .7087" 23/32...................7188 47/64........................7344................ 19 mm=.7480" 3/4...........75 49/64........................7656 25/32...................7813................ 20mm= .7874" 51/64........................7969 13/16..............8125................ 21mm=.8268" 53/64........................8281 27/32...................8438 55/64........................8594................ 22mm=.8661" 7/8...........875 57/64........................8906................ 23mm= .9055" 29/32...................9063 59/64........................9219 15/16. . . . . . . . . . . ...9375................ 24 mm=.9449/1 61/64........................9531 31/32...................9688................ 25mm=.9843 63/64........................9844 1...........1.0 7/96 1.10 Polaris Industries Inc. Unit of Measure ft.Ibs. in.lbs. ft.Ibs. in.lbs. kg-m kg-m kg-m in. mm in. mile(mi.) km Ounces (oz) Grams(g) lb. kg Cubic inches(cuin) Cubic centimeters(cc) Cubic centimeters(cc) Fluid Ounces (fl.oz.) Imperial pints(Imp pt) Liters(I) Imperial quarts (Impqt) Liters(I) Imperialquarts(Imp qt) US quarts(USqt) US quarts(USqt) Liters (I) US gallons (US gal) Liters(I) Pounds - force per square inch(psi) Kilopascals(kPa) Kilopascals(kPa) Kilograms- force per square cm C toOF:9 (OC+ 40)5 - 40 ::::OF OFtoC:5 (OF+40)+9 - 40 =C Polaris Industries Inc. Multiplied by x12 x.0833 x.1383 x.0115 x 7.233 x 86.796 x10 x 25.4 x.03937 x 2.54 x1.6 x.6214 x 28.35 x 0.035 x.454 x 2.2046 x 16.387 x 0.061 x.03381 x 29.57 x 0.568 x 1.76 x 1.137 x 0.88 x1.201 x 0.833 x 0.946 x1.057 x 3.785 x 0.264 x 6.895 x 0.145 x 0.01 x 98.1 1.11 GENERAL INFORMATION Conversion Table. Converts to ::::in.Ibs. = ft.Ibs. ::::kg-m kg-m = ft.Ibs. :::;in.lbs. ;;:Nm ::::mm :;::in. ::::cm ;;:km mile(mi.) Grams (g) = Ounces (oz) ;;:kg ::::lb. Cubic centimeters(cc) ::::Cubic inches(cuin) ::::Fluid Ounces (fl.oz.) ::::Cubic centimeters(cc) ::::Liters(I) ::::Imperial pints (Imp pt) ==Liters(1) ==Imperial quarts (Imp qt) US quarts(US qt) ==Imperial quarts (Imp qt) ==Liters(I) ==USquarts (US qt) =Liters (I) ::::US gallons (USgal) ==Kilopascals(kPa) = Pounds - force per square inch(psi) ==Kilograms - forceper square cm ==Kilopascals(kPa) 5/98 GENERAL INFORMATION TapDrillCharts SAE TapDrillSizes ThreadSizeDrillSize #0-803/64 #1-6453 #1-7253 #2-5651 #2-6450 #3-485/64 #3-5645 #4-4043 #4-4842 #5-4038 #5-4437 #6-3236 #6-4033 #8-3229 #8-3629 #10-2424 #10-3221 #12-2417 #12-284.6mm 1/4-207 1/4-283 5/16-18F 5/16-24I 3/8-160 3/8-24Q 7/16-14U 7/16-2025/64 Metric TapDrillSizes TapSize 3 x.50#39 3 x.603/32 4 x.70#30 4 x.751/8 5 x .80#19 5 x.90#20 6 x1.00#9 7 x1.0016/64 8 x1.00J 8 x1.2517/64 9 x1.005/16 9 x1.255/16 10 x1.2511/32 10 x1.50R 11x1.503/8 12 x1.5013/32 12 x1.7513/32 5/98 Thread SizeDrill Size 1/2-1327/64 1/2-2029/64 9/16-1231/64 9/16-1833/64 5/8-1117/32 5/8-1837/64 3/4-1021/32 3/4-1611/16 7/8-949/64 7/8-1413/16 1-87/8 1-1259/64 1 1/8-763/64 1 1/8-121 3/64 1 1/4-71 7/64 1 1/4-121 11/64 1 1/2-61 11/32 1 1/2-121 27/64 1 3/4-51 9/16 1 3/4-121 43/64 2-4 1/21 25/32 2-121 59/64 21/4-4 1/221/32 2 1/2-421/4 2 3/4-421/2 3-42 3/4 Drill SizeDecimalEquivalentNearest Fraction 0.09953/32 0.09373/32 0.12851/8 0.1251/8 0.16611/64 0.1615/32 0.19613/64 0.23415/64 0.2779/32 0.26517/64 0.31255/16 0.31255/16 0.343711/32 0.33911/32 0.3753/8 0.40613/32 0.40613/32 1.12 Polaris Industries Inc. LIMITED WARRANTY GENERAL INFORMATION Warranty PolarisIndustries Inc.,1225 Highway 169 North,Minneapolis,Minnesota 55441-5078,gives a SIX MONTHLIM-ITED WARRANTY onallcomponents of thePolaris AllTerrainVehicle(ATV)against defects inmaterialor work-manship.This warranty covers theparts andlabor charges forrepair or replacement of defective partswhichare covered by this warranty.This warranty begins onthedateof purchase.This warranty is transferrable toanother consumer during the warranty period througha Polaris dealer.Thereisa chargeof $35.00 payable toPolaris IndustriesInc. REGISTRATION At the timeofsale, the Warranty RegistrationFormmust be completed by your dealer andsubmitted toPolaris within tendays.Uponreceipt of thisregistration,Polaris willrecordtheregistration for warranty.THEPURCHAS-ERMUST COMPLETE ANATVSAFETY TRAININGCOURSEPROVIDEDBY THEDEALERINORDER TO HAVE VALIDWARRANTY ONTHEATV.Noverificationof registrationwillbesent tothe purchaser as thecopy of the Warranty RegistrationFormwillbethewarranty entitlement.If youhavenot signed theoriginalregistration andreceived the"customer copy",please contact your dealer immediately.NOWARRANTY COVERAGE WILL BEALLOWEDUNLESS YOURATVISREGISTERED WITHPOLARIS. Initialdealer preparationandset-upof your ATVisvery important inensuring trouble-free operation.Purchasing a machine inthe crate or without proper dealer set-up willvoid your warranty coverage. WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ThePolarislimited warrantyexcludes anyfailures that are not caused by a defect inmaterial or workmanship. This warranty does not cover accidentaldamage,normal wear and tear,abuseorimproper handling.This warran-ty alsodoes not cover any ATVthathasbeenalteredstructurally,modified,neglected,improperly maintained, used for racing,or used for purposes other than for whichit was manufactured,or for any damages whichoccur during trailer transit or asa result ofunauthorized service or theuseofunauthorized parts.Inaddition,this warran-ty does not cover physical damage topaint or finish,stress cracks, tearingor puncturing of upholstery material, corrosion,or defects inparts,components or the ATV due to fire,explosions or any other causebeyondPolaris' control. This warranty does not cover theuse ofunauthorizedlubricants,chemicals,or fuels that are not compatible with the ATV.The exclusive remedy for breachof this warranty shallbe,atPolaris'exclusive option,repair or replace-ment of any defective materials,or components or products.THEREMEDIESSET FORTHINTHIS WARRAN-TYARETHEONLYREMEDIESAVAILABLETOANYPERSONFORBREACHOF THISWARRANTY.PO-LARISSHALL HAVENOLIABILITY TOANYPERSONFORINCIDENTAL,CONSEQUENTIAL ORSPECIAL DAMAGES OF ANYDESCRIPTION, WHETHER ARISING OUT OFEXPRESS ORIMPLIED WARRANTY ORANY OTHERCONTRACT,NEGLIGENCE, OR OTHER TORT OROTHERWISE.Some states donotpermit theexclusionor limitationofincidentalor consequentialdamagesorimpliedwarranties,sothe abovelimitations or exclusions may not apply to youifinconsistent with controlling statelaw. ALLIMPLIEDWARRANTIES(INCLUDINGBUTNOTLIMITEDTOTHEIMPLIEDWARRANTIESOFMER-CHANTABILITYANDFITNESSFORAPARTICULARPURPOSE)ARELIMITEDINDURATIONTOTHE ABOVE SIX MONTH WARRANTYPERIOD.POLARISFURTHER DISCLAIMS ALLEXPRESS WARRANTIES NOT STATEDINTHISWARRANTY.Some states donot allow limitations onhow longanimplied warranty lasts, so the above limitationmay not apply to youifinconsistent with controllingstate law. HOW TO OBTAIN WARRANTY SERVICE If your ATVrequires warranty service,youmust takeit toa Polaris ServicingDealer.Whenrequestingwarranty service youmust present your copy of the WarrantyRegistrationform to thedealer.(THECOST OF TRANS-PORTATION TO ANDFROMTHEDEALERIS YOUR RESPONSIBILITY).Polaris suggests that youuse your original sellingdealer;however,youmay use any Polaris Servicing Dealer toperform warranty service. Please work withyour dealer toresolveany warranty issues.Should your dealer requireany additionalassistance they willcontact the appropriate personatPolaris. This warrantygives youspecific legalrights,and youmay also have other rights which vary fromstate tostate. Ifany of the above termsare voidbecause of state or federallaw,allother warranty terms willremainineffect. Engine Oil 1.AlwaysusePolarisengine oil. 2.Never substitute or mix oilbrands asserious engine damage andvoidingof warranty canresult. Polaris Industries Inc. 1.135/98 GENERAL INFORMATION Service Tips Inorder to performservice work efficiently and toprevent costly errors,the technicianshould read the text inthis manual, thoroughly familiarizinghim/herself withproceduresbefore beginning.Pictures andillustrations have beenincluded with the text asanaid.Notes,cautions andwarnings have also beenincluded for clarification of text and safety concerns.However,a knowledge of mechanical theory,tooluseandshop procedures isnecessary to perform theservice work safely and satisfactorily.Use only genuine Polaris service parts. &.Cleanliness ofpartsandtools as wellas the work area is of primary importance.Dirt andforeignmatter willact as anabrasive andcause damage toprecisionparts.Clean the vehiclebefore beginning service.Cleannew parts before installing. &.Watch for sharp edges whichcancause personalinjury.Protect hands withgloves when working withsharp components. &.If difficulty is encountered inremovingorinstalling a component,look toseeif a cause for thedifficulty canbe found.Ifitisnecessary to tap the part into place,use a soft facehammer and taplightly. &.Some of the fasteners wereinstalled withlocking agents.Use of impact drivers or wrenches willhelp avoid damage to fasteners. AAlways follow torquespecifications asoutlined throughout this manual.Incorrect torquingmaylead toserious machine damage or,as in the case of steering components, canresult ininjury or death for therider(s). AIf a torquingsequence is indicated for nuts,bolts or screws,start allfasteners intheir holes and hand tighten. Then,following themethod and sequenceindicatedinthismanual,tightenevenly tothespecified torque value. Whenremovingnuts,bolts or screws from apart withseveralfasteners,loosen them allabout 1/4 turnbefore removing them. AIf the conditionof any gasket or O-Ring isinquestion,replaceit witha new one.Besure themating surfaces around thegasket are cleanandsmooth inorder to avoidleaks. ASomeprocedures willrequireremovalofretainingringsor clips.Becauseremovalweakensanddeforms these parts,they should alwaysbereplacedwithnew parts.Wheninstalling new retainingrings andclipsuse care not to expand or compress thembeyond what isrequiredfor installation. ABecauseremovaldamages seals,replaceany oilor grease sealsremovedwith new parts. APolaris recommends theuse ofPolaris lubricants and greases, whichhavebeenspecially formulatedfor the topperformanceandbestprotectionofourmachines.Insomeapplications,suchastheengine,warranty coveragemay become voidif other brands are substituted. AGreaseshouldbecleanedfrompartsandfreshgreaseappliedbeforereassemblyofcomponents. Deteriorating greaseloses lubricity andmay containabrasive foreignmatter. AWheneverremovingorreinstallingbatteries,careshouldbetakentoavoidthepossibilityofexplosion resultinginseriousburns.Alwaysdisconnectthenegative(black)cablefirstandreconnectitlast.Battery electrolyte containssulfuric acidandispoisonous!Serious burns canresult fromcontact with theskin,eyes or clothing.ANTIDOTE:External - Flushwithwater.Internal - Drink large quantities or water or milk.Follow with milk ofmagnesia, beatenegg,or vegetable oil.Callphysicianimmediately.Eyes Flushwith water for 15 minutes andget prompt medicalattention. 5/98 1.14 Polaris Industries Inc. GENERAL INFORMATION Glossary Of Terms ABDC:After bottomdead center. ACV:Alternating current voltage. Alternator:Electrical generator producing voltage alternating current. AlDC:After top dead center. BBDC:Before bottomdead center. BDC:Bottomdead center. BlOC:Before top dead center. CC:Cubic centimeters. COl:Capacitor discharge ignition.Ignition system whichstores voltage generated by thestator plateexciter coilina capacitor or condenser (inCOlbox).At theproper moment a voltagegenerated by thestator plate pulser coil closesan electronic switch(thyristor)inthe COlbox and allows thevoltage inthe capacitor to discharge into the primary windings of the ignition coil. Center Distance:Distance betweencenter of crankshaft andcenter of drivenclutchshaft. Chain Pitch:Distance between chainlink pins(520 = 5/8" or1.6 cm).Chainlength is measured innumber of pitches (pins).A 520 x 86 has 86 totalpins,including themaster link pins. CI:Cubic inches. Clutch Buttons:Plastic bushings whichtransmit rotationof theclutchtothemovable sheave inthedrive anddriven clutch. Clutch Offset:Drive anddriven clutchesareoffset so that drive belt willstay nearly straight asitmoves along the clutch face. Clutch Weights:Three levers inthedrive clutchwhichrelative to their weight,profile and engineRPMcause the drive clutch to close. Condenser/Capacitor:A storage reservoir for electricity,usedinbothE.T.and COlsystems. Crankshaft Run-Out:Run-out or "bend" of crankshaft measured witha dialindicator while crankshaft issupported betweencentersonVblocksorrestinginlowerhalfofcrankcase.MeasureatvariouspointsespeciallyatPTO. Maximumallowable run-out is.006" (.02 cm). DCV:Direct current voltage. Detonation:Thespontaneousignitionoftheunburnedfuellairmixtureafternormalsparkignition.Pistonlooks "hammered" through,roughappearancearoundhole.Possible causes:1)toohigha compressionratio for the fuel octane;2)low octane fuel;3)over-advancedignition timing. DialBoreGauge:Acylindermeasuringinstrumentwhichusesadialindicator.Goodforshowingtaperand out-of-round inthe cylinder bore. DrivenClutch:(Also-SecondaryClutch).ThetorquesensitiveclutchinaCVTsystemwhichislocatedonthe transmissioninput shaft. Electrical Open:Open circuit.Anelectrical circuit whichisn't complete.(i.e.poor connections or brokenwireathi-Io beamswitchresultinginlossof headlights. ElectricalShort:Shortcircuit.Anelectricalcircuitwhichiscompletedbeforethecurrentreachestheintended component.(i.e.a bare wire touching the grounded chassis). End Seals:Rubber seals at eachendof the crankshaft. Engagement RPM:EngineRPMat whichthedrive clutchengages tomake contact with the drive belt. EBS:Engine BrakingSystem ft.:Foot/feet. Foot Pound:Ft.lb.A forceof onepound at the endof a lever one footinlength,appliedina rotationaldirection. g:Gram.Unit of weight inthe metric system. gal.:Gallon. Head Volume:Cylinder head capacity incc,headremoved fromengine withspark plug installed. High TensionLead:The heavy insulated wirewhich carries thehigh secondary voltage fromthe coil to the spark plug. Holed Piston:Pistonin whicha hole has formed onthe dome.Possible causes:1)detonation;2)pre-ignition. HP:Horsepower. 10:Inside diameter. Ignition Coil:A typeof transformer whichincreases voltageintheprimary windings(approx.200V) toa higher voltage inthesecondary windings(approx.14KV - 32KV) throughinduction.Secondary voltage ishighenough toionize (jump) theair gap at the spark plug. Ignition Generating Coil:Exciter coil,primary charge coil.Stator plate coilwhich generates primary ignition voltage. Polaris Industries Inc. 1.155/98 GENERAL INFORMATION Glossary Of Terms in.:Inch/inches. Inch Pound:In.lb.12 in.Ibs.1 ft.lb. 2 kg/cm:Kilogramsper squarecentimeter. k g ~ m :Kilogrammeters. Kilogram/meter:A forceof onekilogramat the end of a lever one meter inlength,appliedina rotationaldirection. I or Itr:Liter. 2 Ibs/in:Poundsper squareinch. Left Side:Alwaysreferred tobased onnormaloperating position of the driver. m:Meter/meters. Mag:Magneto. MagneticInduction:Asaconductor(coil)ismovedthroughamagneticfield,avoltagewillbegeneratedinthe windings.Thecommonmethodusedtoconvertmechanicalenerytoelectricalenergyinthelightingcoil,ignition generating coils and trigger coil. mi.:Mile/miles. mm:Millimeter.Unit of lengthinthemetric system.1mm= .040". N ~ m :Newtonmeters. 00:Outsidediameter. Ohm:The unit of electricalresistance opposing current flow. oz.:Ounce/ounces. Piston Clearance:Totaldifference between piston outside diameter and cylinder inside diameter. PistonErosion:Pistondome melts.Usually occurs at the exhaust port area.Possible causes:1)Detonationdue to lean fuel/air mixture,improper spark plugheat range,excess heat buildup,poor fuelquality / octane rating. Pre-Ignition:A problem incombustionwhere the fuel/air mixture is ignited before normalspark ignition.Piston looks melted at area of damage.Possible causes:1)toohot a spark plug;2)spark plugnot properly torqued;3)"glowing" piece of head gasket,metalburr or carbonin the combustionchamber;4)lean fuel/air mixture. Primary Circuit:This circuit isresponsible for the voltage build up in theCOlcapacitor.In theCOlsystem theparts include theexciter coil,the trigger coil, the wires fromstator plate toCOlbox andto thelow resistanceprimary windings in the ignition coil. Primary Clutch:Drive clutchonengine.Mainly RPMsensitive. psi.:Poundsper squareinch. PTO:Power take off. PVT:Polaris Variable Transmission(Drive ClutchSystem) qt.:Quart/quarts. RPM:Revolutions per minute. Resistance:Inthemechanical sense,frictionor load.Intheelectrical sense,ohms.Bothresultinenergy conversion to heat. Right Side:Alwaysreferred tobasedonnormaloperatingposition of thedriver. RPM:Revolutionsper minute. Running Time:Ignition timing when fully advanced or at specified RPM. Secondary Circuit:Thiscircuit consists of thelarge secondary coilwindings,high tension wireandground through the spark plugair gap. SecondaryClutch:{Also-DrivenClutch}ThetorquesensitiveclutchinaCVTsystemwhichislocatedonthe transmissioninput shaft. Seized Piston:Galling of thesides of a piston.Usually thereisa transfer of aluminum from the pistononto thecylinder wall.Possible causes:1)improper lubrication;2)excessive temperatures;3)insufficient piston clearance;4)stuck pistonrings. Spark Plug Reach:Lengthof threaded portionof spark plug.Polaris uses 3/4" (2cm)reachplugs. Static Timing:Ignition timing whenengine isat zeroRPM. Stator Plate:The plate mounted under the flywheelsupporting the primary ignitioncomponents andlighting coil. 5/98 1.16 Polaris Industries Inc. TOC:Topdead center.Piston'smost outward travelfromcrankshaft. GENERAL INFORMATION Glossary Of Terms TriggerCoil:Pulsercoil.Generatesthevoltagefortriggering(closing)thethyristorandtimingthesparkinCOl systems.Small coilmounted at the top of thestator platenext totheignition generating coil. Voltage Regulator:Maintains Prevents over-charging of battery or damage toelectrical components asengineRPM increases. Venturi:Anarea ofair constriction.A venturi isused incarburetors tospeed upair flow whichlowers pressureinventuri tobelow atmospheric pressure, causingfueltobepushed through jets,etc.,andinto theventuri to bemixed withair and forma combustible air/fuelmixture. Volt:The unit of measure for electrical pressure of electromotive force.Measured by a voltmeter inparallelwiththe circuit. Watt:Unit of electricalpower.Watts = amperes x volts. WaT:Wideopen throttle. Polaris Industries Inc. 1.175/98 GENERAL INFORMATION Special Tools Special toolpart numbers and usage are listedineach section of thismanualasrequired for a specific service procedure.For complete toolinformationrefer to theService ToolCatalog(PN9914681).U.S.dealers canobtain a current pricelist or get toolinformation by contactingVictor Specialty ToolCompany at theaddress,phone or FAX number listedbelow.Canadian dealers can obtain this informationby contacting the Winnipeg parts depart-ment at (204)-925-7125.Dealers serviced by a distributor should follow toolorderingprocedures established by their respective distributor partsdepartment. 5/98 POLARIS SPECIAL TOOLS VICTOR SPECIALTY TOOL CO. 66 SchoolStreet Victor,New York14564 TOPLACE ANORDER TollFree ToolOrder FAX Numbers (U.S.)1-800-716-3938 (CanadianDealers)1-800-413-4441 Phone Orders orInformation (U.S.)1-716-742-1790 (CanadianDealers)1-204-925-7125 1.18 Polaris Industries Inc. Magnum Cable tiessecure wireharness and fuelline to frame 1.19 GENERAL INFORMATION RoutingDiagram Fuelpump impulse line (frompump) ~ Cable tiesecures coolant hose to frame 5/98 GENERAL INFORMATION Magnum RoutingDiagram 5/98 Cable tie secures: -Engine wiring -Mainwireharness -Fuelline -Brakeline -Choke Cable Inlet Duct Engine wiring routedaround andunder inlet duct Clip secures brake line to frame Circuit Breaker Cable tie securing wiring fromsolenoid to starter 1.20 Shifter ~Cable tie securing fuelline Whenmounting fuel tank,carburetor vent lines shouldbein thisapproximate location Polaris Industries Inc. Edge Trim Tocarburetor (topRHside) Cable tie through bulkheadsecures threehoses Polaris Industries Inc. Cable tie oil tank vent line and fuelpump im-pulsehose Tocarburetor (lower LHside) Fuelline from fuelvalve 1.21 GENERAL INFORMATION MagnumRoutingDiagram FuelPump 5/98 GENERAL INFORMATION Hoses 5/98 Loosely cable tie wire Coolant bottle 400s / Front ~ Coolant hose ~ Convoluted tubing 1.22 Loosely cable tie Brakeline Oilline Coolant line ~ Front Polaris Industries Inc. Raisedside of reinforcement ribs face engine Front~ GENERAL INFORMATION 300 FanMotor Wiring Orient fanmotor so wiringand vent line are onbottom. Fanmotor vent line should comestraight up frommotor between the two large coolant lines,throughcab assembly andback downinto frameasshown. Polaris Industries Inc. oiltank \ , ~ ~ -- J ( ( ~3\--\ C ~ ~ / I ~ ~ 1.23 o 5/98 GENERAL INFORMATION Wire Harness Engine wiringshould beroutedbehind fuel tank cover mount ~ ~ Front ALL MODELS Fuel tank Engine wiring must not hangbe-low sidepanel Allwiring tobeonthissideof carburetor for proper air boxinstallation Allloosely ________ cable tied --....Front -----7--.1'-/, ...-Z under carburetor 5/98 1.24 Polaris Industries Inc. GENERALINFORMATION Service Tools CHASSIS/SUSPENSION TRANSMISSION TransmissionToolKit - Shaft Drive Usedtodisassemblyandassemblytransmission and front gearcase on500models. PN2871702 YokeGauge Tool ..Shaft Drive Used tocheck yokealignment PN2871813 - Large Yoke PN2871814 - SmallYoke Polaris Industries Inc. 1.2510/96 GENERAL Mity Vac PumpKit This toolisusedformanyservicefunctionsonPolaris ATVsincludingtestingofcoolingsystems,carburetor needle andseat,oilsystemcheck valves,etc. PN2870975 SmallBattery Hydrometer Measures thestrengthof battery electrolyteinterms ofspecificgravity.Speciallydesignedforsmall batteries. PN2870836 TransmissionSeal/BearingDriver - 50mm Forinstallingbearingsandcasesealsduring transmissiongearcase overhaul. PN2871282 CVBoot Clamp Pliers TheearandearlessdriveshaftCVbootsrequirea specialplierstosecuretheclampsproperly without distortion. PN8700225ForEarless(Flush)StyleClamps PN8700226ForEar Style Clamps 10/96 1.26 GENERAL INFORMATION Service Tools Polaris Industries Inc. LIMITED WARRANTY GENERAL INFORMATION Warranty Polaris Industries Inc.,1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, gives a SIX MONTH LIM-ITED WARRANTY onall components of the Polaris All Terrain Vehicle (ATV)against defects inmaterial 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 throughaPolaris dealer.Thereisa chargeof $25.00 payable toPolaris Industries Inc. REGISTRATION At the time of sale, the WarrantyRegistrationFormmust be completed by your dealer and submitted toPolaris within ten days.Upon receipt of this registration, Polaris will record the registration for warranty.THE PURCHAS-ERMUST COMPLETE ANATVSAFETY TRAININGCOURSEPROVIDEDBY THEDEALERINORDER TO HAVE VALID WARRANTY ON THE ATV.No verification of registration will be sent to the purchaser as the copy of the Warranty RegistrationForm willbe the warranty entitlement.If youhave not signed the originalregistration and received the "customer copy", please contact your dealer immediately.NO WARRANTY COVERAGE WILL BEALLOWED UNLESS YOURATVISREGISTERED WITHPOLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation.Purchasing a machine inthecrateor without proper dealer set-up willvoid your warranty coverage. WARRANTY COVERAGE ANDEXCLUSIONS: LIMITATIONS OFWARRANTIES ANDREMEDIES The Polaris limited warrantyexcludes anyfailures that are not caused by a defect inmaterial 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 ATVthat hasbeenalteredstructurally,modified,neglected,improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit 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 ATVdue 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 FORTHIN THIS WARRAN-TYARETHEONLYREMEDIESAVAILABLETOANYPERSONFORBREACHOF THISWARRANTY.PO-LARIS SHALL HAVENOLIABILITY TOANYPERSONFORINCIDENTAL,CONSEQUENTIAL ORSPECIAL DAMAGES OF ANYDESCRIPTION,WHETHER ARISING OUT OF EXPRESS ORIMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.Some states donotpermit theexclusionorlimitationofincidentalorconsequentialdamagesorimpliedwarranties,sothe above limitations or exclusions may not apply to youif inconsistent withcontrollingstatelaw. ALLIMPLIEDWARRANTIES(INCLUDINGBUTNOTLIMITEDTOTHEIMPLIEDWARRANTIESOFMER-CHANTABILITYANDFITNESSFORAPARTICULARPURPOSE)ARELIMITEDINDURATIONTOTHE ABOVE SIX MONTH WARRANTY PERIOD.POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.Some states do not allow limitations onhow long an implied warranty lasts, so the above limitationmay not apply toyouif inconsistent withcontrollingstate law. HOW TO OBTAIN WARRANTY SERVICE If your ATVrequires warranty service, you must take it to a Polaris Servicing Dealer.When requesting warranty service youmust present your copy of theWarrantyRegistrationformtothe dealer.(THECOST OF TRANS-PORTATION TO ANDFROM THEDEALERIS YOURRESPONSIBILITY).Polaris suggests that youuse your original selling dealer;however,youmay use any Polaris Servicing Dealer toperform warranty service. Please work with your dealer to resolve any warranty issues.Should your dealer require any additional assistance they will contact theappropriate person atPolaris. This warrantygives you specific legal rights,and you may also have other rights which vary from state tostate. If anyof theabove terms are voidbecause of stateor federallaw,allother warranty terms willremainineffect. Engine Oil 1.Always usePolaris engine oil. 2.Never substitute ormix oilbrands asserious engine damage and voiding of warranty canresult. Polaris Industries Inc. 1.277/96 GENERAL INFORMATION Glossary Of Terms ABOC:After bottom dead center. ACV:Alternatingcurrent voltage. Alternator:Electrical generator producing voltage alternating current. ATDC:After top dead center. BBDC:Before bottom dead center. BDC:Bottom dead center. BTOC:Before top dead center. CC:Cubic centimeters. COl:Capacitor discharge ignition.Ignition system which stores voltage generated by the stator plate exciter coilina capacitor or condenser (in COl box).At the proper moment a voltage generated by the stator plate pulser coil closes an electronic switch (thyristor) in the COl box and allows the voltage in the capacitor to discharge into the primary windings of theignition coil. Center Distance:Distance betweencenter of crankshaft and center of drivenclutchshaft. ChainPitch:Distance between chainlink pins(No.35= 3/8" or 1 cm).Polaris measures chain length innumber of pitches. CI:Cubic inches. ClutchButtons: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,usedinbothE.T.and COlsystems. CrankshaftRun-Out:Run-out or "bend" at crankshaft measured witha dialindicator while crankshaft issupported betweencentersonVblocksorrestinginlowerhalfofcrankcase.MeasureatvariouspOintsespeciallyatPTO. Maximum allowable run-out is.006" (.02cm). Dev:Direct current voltage. Detonation:Thespontaneousignitionoftheunburnedfuel/airmixtureafternormalsparkignition.Pistonlooks "hammered" through,roughappearance aroundhole.Possible causes:1)toohigh a compressionratio for the fuel octane;2)low octane fuel;3)over-advanced ignition timing. DialBoreGauge:Acylindermeasuringinstrumentwhichusesadialindicator.Goodforshowingtaperand out-at-round inthe cylinder bore. Electrical Open:Open circuit.Anelectrical circuit which isn't complete.(i.e.poor connections or broken wire at hi-Io beam switchresultinginloss of headlights. ElectricalShort:Shortcircuit.Anelectricalcircuitwhichiscompletedbeforethecurrentreachestheintended component.(i.e.a bare wire touching the snowmobile chassisunder the seat resultinginloss of taillights and brake lights). EndSeals:Rubber seals at eachend of the crankshaft. Engagement RPM:EngineRPMat which the drive clutchengages to make contact with the drive belt. ft.:Foot/feet. FootPound:Ft.lb.A force of one pound at the end of a lever one foot inlength,appliedina rotationaldirection. g:Gram.Unit of weight in the metric system. gal.:Gallon. Head Volume:Cylinder head capacity in cc,head removed fromengine withspark pluginstalled. High Tension Lead:The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug. HoledPiston:Pistoninwhicha holehas formedonthe dome.Possible causes:1)detonation;2)pre-ignition. HP:Horsepower. 10: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 ishigh 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. InchPound:In.lb.12 in.Ibs.=1 ft.lb. 7/96 1.28 Polaris Industries Inc. kg/cm 2:Kilograms per square centimeter. kg-m:Kilogrammeters. GENERALINFORMATION Glossary Of Terms Kilogram/meter:A force of one kilogramat the end of a lever one meter inlength,appliedina rotationaldirection. I or Itr:Liter. 2 Ibs/in:Pounds per square inch. Left Side:Always referred tobased onnormaloperating position of the driver. m:Meter/meters. Mag:Magneto. MagneticInduction:Asaconductor(coil)ismovedthroughamagneticfield,avoltagewillbegeneratedinthe windings.This ishow mechanicalenergyinour engines isconverted toelectricalenergyinthelightingcoil,ignition generating coils and trigger coil. mi.:Mile/miles. mm:Millimeter.Unit of lengthinthe metric system.1 mm = .040". N-m:Newtonmeters. 00:Outside diameter. Ohm:The unit of electricalresistance opposing current flow. oz.:Ounce/ounces. Piston Clearance:Totaldistance betweenpiston and cylinder wall. Piston Erosion:Piston dome melts.Usually occurs at the exhaust port area.Possible causes:1) lean fuel/air mixture; 2)improper spark plugheat range. Pre-Ignition:A problem in combustion where the fuel/air mixture isignited 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,metalburr or carbonin the combustion chamber;4)lean fuel/air mixture. Primary Circuit:This circuit is responsible for the voltage build up inthe COlcapacitor.In the COlsystem the parts include the exciter coil, the trigger coil, the wires from stator plate to COl box and to the low resistance primary windings in the ignition coil. Primary Clutch:Drive clutchonengine. psi.:Pounds per square inch. PTO:Power take off. PVT:PolarisVariable Transmission(Drive ClutchSystem) 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:Alwaysreferred tobased onnormal operatingposition of the driver. RPM:Revolutionsper minute. Running Time:Ignition timing when fullyadvanced or at specifiedRPM. Secondary Circuit:This circuit consists ofthe large secondary coil windings, high tension wire and ground through the spark plugair gap. Secondary Clutch:Driven clutchonchaincase or jackshaft. 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 pistonrings. Select Monitor:Diagnostic tool which provides static and dynamic displays of the function of critical components in an EFIsystem.It alsohas the capability to display the contents of theECUmemory. Spark PlugReach:Lengthof threaded portionof spark plug.Polaris uses 3/4/1(2cm)reachplugs. Static Timing:Ignition timing when engine isat zeroRPM. Stator Fiate:The plate mounted under the flywheelsupporting the primary ignition components andlighting coil. Surge Tank:The filltank in the liquid coolingsystem. Polaris Industries Inc. 1.297/96 GENERALINFORMATION Glossary Of Terms TOC:Top dead center.Piston's most outward travel from crankshaft. TriggerCoil:Pulser coil.Generatesthevoltagefor triggering(closing)thethyristorandtimingthesparkinCOl systems.Small coilmounted at the top of the stator plate next to the ignition generating coil. VRegulator:Voltageregulator.Maintainsmaximumlightingcoiloutputatapprox.14.5ACVasengineRPM 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/fuelmixture. Volt:The unit of measure for electrical pressure of electromotive force.Measured bya voltmeter inparallel with the circuit. Watt:Unit of electricalpower.Watts= amperes x volts. waT:Wide open throttle. 7/961.30 Polaris Industries Inc. Cable tiesecures: -Engine wiring -Mainwireharness -Fuelline -Brakeline -ChokeCable Inlet Duct Engine wiring routedaround andunder inlet duct Clip secures brakeline to frame Solenoid Polaris Industries Inc. ChokeCable FuelImpulse Line ~Cable tie securing wiring fromsolenoid tostarter 1.31 GENERAL INFORMATION MagnumRoutingDiagram Shifter ~Cable tie securing fuelline Whenmounting fuel tank,carburetor vent lines shouldbein this approximate location 7/96 GENERAL INFORMATION MagnumRoutingDiagram 7/96 Cable ties secure wireharness and fuelline toframe Fuelpump impulse line (frompump) ~ Gear Selector 1.32 Cable tie secures coolanthose to frame Polaris Industries Inc. Tocarburetor (topRHside) Cable tie through bulkhead secures threehoses Polaris Industries Inc. Cable tie oil tank vent line andfuelpumpim-pulsehose Tocarburetor (lowerLHside) GENERALINFORMATION MagnumRoutingDiagram Routedover fuelshut-off Fuelline from fuelvalve 1.337/96 GENERAL INFORMATION Hoses 7/96 Loosely cable tie Coolant bottle 4008 Inlet Duct\ / Front ~ Coolant hose ~Convoluted tubing Loosely cable tie Brakeline Oilline Coolant line '" Front Brakeline~""-y ~ ' / ) ~ ~ ~ ~ 1.34 Polaris Industries Inc. Raisedside of rei nforcem ent ribsfaceengine F r o n t ~ GENERAL INFORMATION 300 FanMotor Wiring Orient fanmotor so wiringand vent line are onbottom. Fanmotor vent line should comestraight up frommotor between the twolarge coolant lines,through cab assembly andback downinto frameasshown. Polaris Industries Inc. 1.357/96 GENERALINFORMATION WireHarness Engine wiringshould beroutedbehind fuel tank cover mou nt Front ALLMODELS -- "'", .' ".

Fueltank\,19 .rc. Polaris Industries Inc. 2.15 MAINTENANCE GeneralMaintenance 5/98 MAINTENANCE GeneralMaintenance Battery Maintenance AWARNING Battery electrolyte is poisonous.It contains sulfuric acid.Serious burns canresult fromcontact withskin,eyes or clothing.Antidote: External:Flush with water. Internal:Drink large quantities of water or milk.Follow withmilk of magnesia, beatenegg,or vegetable oil.Callphysicianimmedi-ately. Eyes:Flushwithwater for15minutesandgetpromptmedical attention. Batteriesproduceexplosivegases.Keepsparks,flame,ciga-rettes,etc.away.Ventilate when charging or usinginanenclosed space.Alwaysshieldeyes whenworkingnear batteries.KEEP OUT OF REACH OF CHILDREN. The battery islocatedunder theleft rear fender. Inspect thebattery fluidlevel.When thebattery fluidnears the lower level, the battery shouldberemoved anddistilled water shouldbe added to the upper levelline.Toremove the battery: 1.Disconnect holder strap andremove cover. 2.Disconnectbatterynegative(-)(black)cablefirst, followedby the positive(+)(red)cable. .&. CAUTION Whenever removingor reinstalling thebattery,disconnect thenegative(black)cablefirstandreinstallthenegative cablelast! 3.Disconnect the vent hose. 4.Remove the battery. Maintain betweenupper and lower level marks -- ~ ~ ~ 5.Remove the filler caps andadddistjlfed water only asneeded to bringeach cellto the proper level.Do not overfill the battery. .&. Torefilluse only distilled water.Tapwater containsminerals which areharmful toabattery. .&. Donot allow cleaning solution or tap water to enter thebattery.It willshorten the life of the battery. 6.Reinstall the battery caps. 7.Clean battery cables and terminals witha stiff wirebrush.Corrosion canbe removedusing a solutionof one cup water andone tablespoonbaking soda.Rinse willwithclean water and dry thoroughly. 8.Reinstallbattery,attachingpositive (+)(red)cable first and then the negative(-)(black) cable. 9.Reattachvent hose making sureit isnot kinked or pinched. 10.Coat terminals and bolt threads withPolaris dielectric grease PN2871027. 11.Reinstallbattery cover andholder strap . .&. Do not start the engine withthe battery disconnected.Vehiclelamps willburnout if battery is disconnected or has a specific gravity lower than1.14 during vehicle operation.Also,thereversespeed limiter canbedamaged. 5/98 2.16 Polaris Industries Inc. Spark Plug 1.Removeright body panel.SeeBody PanelRemoval, Chapter 2 (4 strokes).Ontwo strokemodels,access spark plug through theright front footwell. 2.Remove spark plug high tensionlead.Cleanplugarea sono dirt and debris canfallinto engine whenplugis removed. 3.Insert spark plug wrench providedintoolkit.Remove spark plug. 4.Inspect electrodes for wear and carbon buildup.Look for a sharp outer edge withnorounding or erosion of the electrodes. 5.Cleanwithelectricalcontact cleaner or aglassbead spark plugcleaner only.CAUTION:A wirebrush or coatedabrasive shouldnot beused. 6.Measure gap witha wiregauge.Recommended spark plug gap isshowninchart at right.Adjust if necessary by bending theside electrode carefully. 7.Ifnecessary,replacesparkplugwithpropertype. CAUTION:Severe enginedamagemay occur if the incorrect spark plugisused. 8.Coatsparkplugthreadswithasmallamountof anti-seize compound. 9.Install spark plugand torque to 14 ft.Ibs. Ignition Timing Refer to the electrical section for ignition timingprocedure. Engine Mounts Inspectrubberenginemountsforcracksordamage. Check fasteners and ensure they are tight. Polaris Industries Inc. 2.17 MAINTENANCE GeneralMaintenance Spark PlugGap .024 - .028" (.6 - .7mm) 5/98 MAINTENANCE GeneralMaintenance CoolantLevelInspection With the engine atoperating temperature,thecoolant level shouldbebetween theupper andlower marksonthere-covery bottle.Ifnot: 1.Removerecoverybottlecap.Inner splashcapvent hole must be clear andopen. 2.FillrecoverybottletouppermarkwithPolaris Premium60/40AntiFreeze/Coolantor50/50or 60/40mixture of antifreeze anddistilled water. 3.Reinstallcap. NOTE:If coolant isexcessively low intheradiator,coolant willnot circulate or bedrawninfrom the recovery bottle. Coolant Strength Testthestrengthofthecoolantusinganantifreeze hydrometer.A50/50or 60/40mixtureofantifreeze and distilled water willprovide the optimum cooling,corrosion protection,andantifreezeprotection.Donot use tap wa-ter,straight antifreeze,or straight water inthesystem.Tap water containsmineralsandimpurities whichbuildupin the system.Straight water or antifreeze willcause thesys-tem tofreeze. Cooling System Hoses 1.Inspect allhoses for cracks,deterioration,abrasion or leaks.Replaceifnecessary. 2.Check tightness of allhose clamps. Radiator 1.Checkradiatorairpassagesforrestrictionsor damage. 2.Carefully straightenany bentradiator fins. 3.Remove any obstructions withcompressed air or low pressure water. Cooling System Pressure Test Refer topage 3.6 for pressure test procedure. 5/98 2.18 AntifreezeHydrometer Polaris Industries Inc. OilPump Adjustment Procedure (1996 250cc Engines) 1.Beforeadjustingtheoilpump,checkengineidle RPM.RecommendedRPMis700.Adjustif necessary.Checkandadjustthrottleleverfree play (ETC switch).See page2.12. 2.Starttheengineandletitidle.Placeveryslight pressureonthethrottleleveruntilallfreeplayis removedfrom throttle cable to carburetor. 3.Loosenlocknut (D)andalignmarks(A)and(C)by turningadjuster (E)upor down asneeded. 4.When themarks arealigned, tightenlocknut (D). 5.Checkthrottleleverfreeplay/ETCswitch adjustmentandreadjustatthrottleblockif necessary. OilPump Adjustment Procedure (300cc Engines and1997 to current 250 ccEngines) 1.Adjustengineidlespeedto600-800 RPM. 2.Removeseat,air box cover,andair filter togain access to carburetor slide. 3.Pullboot back fromthrottle cable adjuster located onthrottlehousing.Loosenlock nut.See.III.1. 4.Turnadjuster into throttle housinguntil the oilpumplever armrests firmly against its stop onthe oilpump body.Verify thisby pushingdownwardonleverarmand checking for movement.SeeIII.2. NOTE:Ifleverarmcannotrestagainststop evenwiththrottlecableadjusterscrewedall the way in,loosenoilpump cableadjuster nuts andadjust cable downuntillever arm is firmly against stop. Polaris Industries Inc. 2.19 MAINTENANCE 2 Stroke Engine Maintenance 250cc Engine D A A.Idle Index B.OilPumpLever C.Static Line D.Locknut B E.Cable Adjuster F.Bleed Screw Throttle Housing III.1 Cable Adjuster -Turninuntiloilpump lever armrestsagainst stop(Step 4) Lock N Step 4-Verify lever isagainst stop by pushing down onlever OilPump ----'mi.t=