1996-1998 Polaris ATV/Light Utility Vehicle OEM Service & Repair Manual

LRRIS InDUSTRIES Inc:. ATV AND LIGHT UTILITY VEHICLE SERVICE MANUAL Foreword This manual is designed primarily for use by ATV service technicians in a properly equipped shop. Since a certain knowledge of mechanical theory, tool use, and shop procedures is necessary to perform the service work safely, all operations should be performed by qualified service personnel only. In order to perform the work efficiently and prevent costly errors, the technician should read the text and be familiar with procedures before starting the work. Cleanliness of parts and tools as well as the work area is of primary importance. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for 1996-1998 model Polaris ATVs and Light Utility Vehicles. The section index tabs enable the user to quickly locate the section desired. In addition, a table of contents is placed at the beginning of each section for location of specific page numbers and service information. Keep this manual available for reference in the shop area. To keep this manual current it is important that it is updated yearly with new model information and specifications. At the time of publication all information contained in this manual was current. However, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Polaris Industries Inc., Service Publications Supervisor, 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078. 1996-1998 Service Manual Volume II 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 is brought to your attention by the following symbols: .&,.The Safety Alert Symbol means ATIENTIONI BECOME ALERTI YOUR SAFETY IS INVOLVED! A DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystand- er or person inspecting or servicing the ATV. A WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, by- stander or person inspecting or servicing the ATV. A CAUTION indicates special precautions that must be taken to avoid minor personal injury, or ATV or proper- ty damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation

Table of Contents 9913680 Chapter 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 Model Identification ........................... 1.1 - 1.1 c 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 an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the manual starter recoil housing. An additional number is stamped in one of the following locations: • 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 important for vehicle identification. The machine model number is located on the frame on the left side of the vehicle near the oil tank. Depending on model, the Se- rial number will be stamped into the frame in one of the following locations: • On the right side of the vehicle in front of the shift selector box (A). (1996) • Under the seat on the upper shock mount cross member (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 is in one of the following locations: 4 stroke models - right side center of the carburetor body • 2 stroke models - right side of carburetor 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 #t 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 W 96 81 MOD EL ATV or Light Utility vehicle/- T -i~ NUMBERS Year Designation Basic Chassis Engine Designation Designation 1996 Engine Designation Numbers 1996 Chassis Designation Numbers 27 ........... 250 75 .......... Magnum 2x4 30 ........... 300 78 .......... Trail Blazer / Scrambler 40 ........... 400 80 .......... Sportsman 4x4 44 ........... 425 81 .......... Magnum 4x4 50 ........... 500 85 .......... Trail Boss / Sport 87 .......... 400 6x6 / Magnum 6x6 91 .......... Xplorer 300 / Xplorer 400 92 .......... Sportsman 500 95 .......... 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. ID Vehicle Descriptor Vehicle Identifier 1997-Current 2 3 4 5 6 7 8 9 10 11 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 ... T ,; 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 II 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 to the listing below. V 1997 W 1998 X 1999 Y 2000 1997 to Current Model Numbers The model year is also listed in the model number. The last 4 digits in the model number correspond to digits 4 through 8 of the Vehicle Identification Number (VIN). Machine Model Number Identification W;:;;ATV or Light ___ 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 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 Manual PN 1996 Parts Micro Fiche Set PN 9913586 9913433 9913588 9913590 9913592 9913586 9913582 9913592 9913598 9913594 9913596 9913603 9913605 9913607 9913609 Parts Manual , 997Parts Micro Fiche Set PN 9914012 9914645 9914057 9913981 9913960 9914012 9913989 9913960 9913975 9913967 9914081 9914070 9914083 9914075 9913999 9914135 9914307 5/98

1996-1998 Polaris ATV/Light Utility Vehicle OEM Service & Repair Manual

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