Polaris Magnum 2x4 Bedienungsanleitung

LRRIS

InDUSTRIES

Inc:.

ATV AND LIGHT UTILITY VEHICLE

SERVICE MANUAL

Foreword

This manual

designed primarily for use by ATV service technicians

a properly equipped shop. Since a

certain knowledge of mechanical theory, tool use, and shop procedures

necessary to perform the service

work safely, all operations should be performed by qualified service personnel only.

order to perform the

work efficiently

and

prevent costly errors, the technician should read the text and

familiar with procedures

before starting the work. Cleanliness of parts and tools as well as the work area

of primary importance.

All references to left and right side of the vehicle are from the operator's perspective when seated

a normal

riding position.

This manual includes procedures for maintenance operations, component identification and unit repair, along

with service specifications for 1996-1998 model Polaris ATVs and Light Utility Vehicles. The section index

tabs enable the user to quickly locate the section desired.

addition, a table of contents

placed at the

beginning of each section for location of specific page numbers and service information. Keep this manual

available for reference

the shop area.

keep this manual current it

important that it is updated yearly with new model information and

specifications.

At the time of publication all information contained

this manual was current. However, all materials and

specifications are subject to change without notice.

Comments or suggestions about this manual may

directed to: Polaris Industries Inc., Service Publications

Supervisor, 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078.

1996-1998 Service Manual Volume

Part No. 9913680

1998 Service Manual Update Part No. 9914752

Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout

these

instructions, important information

brought

your

attention

the

following

symbols:

.&,.The

Safety Alert Symbol means ATIENTIONI BECOME ALERTI YOUR SAFETY

INVOLVED!

DANGER

Failure

DANGER

instructions

will

result

severe

injury

death

the

operator,

passenger,

bystand-

person

inspecting

servicing

the

ATV.

A WARNING

Failure

WARNING

instructions

could

result

severe

injury

death

the

operator,

passenger,

by-

stander

person

inspecting

servicing

the

ATV.

CAUTION

indicates

special

precautions that

must

taken

avoid

minor

personal

injury,

ATV

proper-

damage.

NOTE:

NOTE

provides

key

information

clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned

this

manual:

FLEXLOC,

Registered

Trademark

SPS

Technologies

Loctite,

Registered

Trademark

the

Loctite

Corporation

STA-BIL,

Registered

Trademark

Gold

Eagle

FOX,

Registered

Trademark

Fox

Shox

Nyogel,

Trademark

Wm.

Nye

Co.

Fluke,

Registered

Trademark

John

Fluke

Mfg.

Co.

Mity

Vac,

Registered

Trademark

Neward

Enterprises,

Inc.

Ammco,

Registered

Trademark

Ammco

Tools,

Inc.

Torx,

Registered

Trademark

Textron

Hilliard, Trademark

the

Hilliard Corporation

Table ofContents

9913680

Chapter

..............................

General Information

Chapter

.......................................

Maintenance

Chapter

...............................................

Engine

Chapter

........................

Fuel System/Carburetion

Chapter

.......................

Body/Steering/Suspension

Chapter

........................................

PVT System

Chapter

..........................................

Final Drive

Chapter

......................................

Transmission

Chapter

..............................................

Brakes

Chapter

............................................

Electrical

CHAPTER 1

GENERAL INFORMATION

Model Identification

...........................

1.1

Publications Numbers . . . . . . . . . . . . . . . . . . . . . . .

1.2 -1.2a

Service Videos

...............................

1.2a

Service/Information Bulletin

Index.

. . . . . . .. . . . .

1.3 -1.3b

Paint Codes

.................................

1.4 -1.4b

Model Specifications, 1996 1.5 -1.8

Model Specifications, 1997

....................

1.8a -1.8d

Model Specifications, 1998

....................

1.8e -1.8h

Standard Torque Specifications. . . . . . . . . . . . . . .

1.9

Decimal Equivalent Chart . . . . . .. . . . . . . . . . . . . .

1.10

Conversion Table . . . . . . . . . . . . . . . .. . . . . . . . . . .

1.11

Tap

Drill

Charts.

. . . . .. . . . . . . . . . . . . . . . . . . . . . .

1.12

Warranty

....................................

1.13

Service Tips

.................................

1.14

Glossary of Terms

............................

1.15 -1.17

Tool

Ordering Information

.....................

, 1.18

Routing Diagrams

............................

1.19 -1.24

GENERAL INFORMATION

Model Identification

Engine Serial Number Location

Whenever corresponding about

engine,

sure to refer to the engine model number and serial number. This

information can be found on the sticker applied to the manual starter recoil housing. An additional number is

stamped

one of the following locations:

• 4 stroke models -center top of crankcase beneath the cylinder coolant elbow

• 2 stroke liquid cooled models -center top of crankcase beneath the carburetor mounting flange

• 2 stroke air cooled models -top of crankcase near right side of cylinder

Machine Model Number and Serial Number Location

The machine model number and serial number are im-

portant for vehicle identification. The machine model

number

located on the frame on the left side of the

vehicle near the

oil

tank. Depending

model, the Se-

rial number will

stamped into the frame

one

the

following locations:

• On the right side

the vehicle

front

of the shift selector box (A). (1996)

• Under the seat on the upper shock

mount cross member (8) (1996)

• On the right hand frame rail (C) near

the air box. (1997)

• On the left hand lower frame rail (D)

near the rear A-arm mount.

(199B-Current)

Transmission 1.0. Number Location

Transmission model and serial numbers are located

on top of the transmission case below the shifting bell-

cranks.

Carburetor

1.0.

Number Location

The carburetor

1.0.

number

in one of the following

locations:

4 stroke models -right side center of

the carburetor body

• 2 stroke models -right side of carbu-

retor body near choke plunger boss

Polaris Industries Inc.

1.1

VIN Location -1996

VIN Location -

1996/1997

VIN Location -199B-Current

Example

Mod

:ffl

13411571

Ser

96-1Q273

Transmission

1.0.

Numbers

5/98

GENERAL

INFORMATION

Model Identification

1996 Model Identification

The machine model and serial number must be used with any correspondence regarding service or repair.

1996 Machine Model Number Identification

MOD

ATV

Light

Utility

vehicle/-

-i~

NUMBERS Year Designation Basic Chassis Engine Designation

Designation

1996

Engine Designation Numbers

1996

Chassis Designation Numbers

...........

250 75

..........

Magnum 2x4

...........

300 78

..........

Trail Blazer / Scrambler

...........

400 80

..........

Sportsman 4x4

...........

425

..........

Magnum 4x4

...........

500 85

..........

Trail Boss / Sport

..........

400 6x6 / Magnum 6x6

..........

Xplorer 300 / Xplorer 400

..........

Sportsman 500

..........

Xpress 300 / Xpress 400

5/98

1.1

a Polaris Industries Inc.

GENERAL INFORMATION

Model Identification

Vehicle Identification Number (1997 and Later Model Years)

1997 to Current ATVs and Light Utility Vehicles have a 17 digit Vehicle Identification Number (VIN). The VIN is

organized as follows: Digits 1·3: World Manufacturer Identifier. For Polaris ATVs, this is

4XA

Digits 4-9: Vehicle

Descriptor Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, drive

type, engine type, and emissions equipment. The VIN number and the model number must be used with any

correspondence regarding service or repair.

World Mfg.

Vehicle Descriptor Vehicle Identifier

1997-Current 2 3 4 5 6 7 8 9 10

12 13 14 15 16 17

4 X A B A 3 8 C 0 V 2 0 0 0 0 0 0

VIN

Number

...

I Emissions

Body Style I

~II

Engine MJdel I

Year

Individual Serial No.

Powertrain Check Digit Plant No.

Vehicle Identification Number I Model Number Key

Body Style Powertrain Engine Emissions Ogtions

A=Gen

A=2x4 chain 25:::EC25PF(250cc) A=Approved by CARB* A=Std

B=Gen III C=4x4 chain 28=EC28PF(300 cc) C=Non CARB* Approved B=1st

Color Option

C=Gen IV D=4x4 shaft 38=EC38PL(400 cc) D=Norway

E=6x6 chain 42=EH42PL (425 cc) E=Sweden

50=EH50PL (500 cc)

*CARB = California Air Resources Board

Year I Letter Identification

The tenth digit of a 17 digit VIN is the model year of the vehicle. Example: W = 1998; X = 1999 etc. Refer

the

listing below.

V 1997

W 1998

X 1999

2000

1997

Current Model Numbers

The model year

also listed

the model number. The last 4 digits

the model number correspond to digits

4 through 8 of the Vehicle Identification Number (VIN).

Machine Model Number Identification

W;:;;ATV

or Light

___

W 9 8 CH50A B Option Indicator

Utility Vehicle

---

Year Designation

Last 5

M~el

# Digits=Digits 4-8 of VIN

5/98

1.1

b Polaris Industries Inc.

GENERAL INFORMATION

5/98

1.1

c Polaris Industries Inc.

1996 Publication Numbers

Model Model No.

Trail Blazer W967827

Trail Boss W968527

Xplorer 300 W969130

Xpress 300 W969530

Sport W968540

Scrambler 4x4 W967840

Xpress 400 W969540

Xplorer 400 W969140

Sportsman 4x4 W968040

4006x6

W968740

Magnum 2x4 W967544

Magnum 4x4 W968144

Magnum 6x6 W968744

Sportsman 500 W969244

1997 Publication Numbers

Model Model No.

Trail Blazer W97BA25C

Trail Boss W97AA25C

Xplorer 300 W97CC28C

Xpress 300 W97CA28C

Sport 400 W97BA38C

Scrambler 4x4 W97BC38C

Xpress 400 W97CA38C

Xplorer 400 W97CC38C

Sportsman 4x4 W97AC38C

4006x6

W97AE38A

Magnum 2x4 W97AA42A

Magnum 4x4 W97AC42A

Magnum 6x6 W97AE42A

Sportsman 500 W97CH50A

Xplorer 500 W97CD50A

Scrambler 500 W97BC50A

Polaris Industries Inc.

Owner's Manual PN

9913584

9913506

9913332

9913327

9913584

9913519

9913327

9913511

9913414

9913516

9913512

9913522

9913269

Owner's Manual

9914011

9914056

9913980

9913959

9914011

9913988

9913959

9913974

9913966

9913917

9914069

9914074

9913998

9914134

9913988

1.2

GENERAL INFORMATION

Publications

Parts Manual

1996 Parts Micro

Fiche Set

9913586 9913433

9913588

9913590

9913592

9913586

9913582

9913592

9913598

9913594

9913596

9913603

9913605

9913607

9913609

Parts Manual , 997Parts Micro

Fiche Set

9914012 9914645

9914057

9913981

9913960

9914012

9913989

9913960

9913975

9913967

9914081

9914070

9914083

9914075

9913999

9914135

9914307

5/98

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