1999-2000 Polaris ATV Service Manual

I .. ,. I l' I SALES InC:. ATVAND6x6 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, thoroughly familiarizing him/herself witl'l 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 1999/2000 model Polaris ATVs and 6 x 6. The section index tabs enable the user to quickly locate the component unit 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. Complete service manuals ordered after the release of new model year manual updates will contain the latest update. At the tim~ of publication all information contained in this manual was technically correct. However, all materials p.nd specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Technical Writer, 1225 Hwy 169North, Minneapolis, MN. 55441-5078. 1999 ATV /6x6 Service Manual Volume Ill (PN 9915083) Other Service Manuals Available: Polaris ATV and 6x6 Service Manual (Vol.l 1985-1995) Polaris ATV and 6x6 Service Manual (Vol.ll 1996-1998) Polaris ATV and 6x6 Service Manual (2000 Update) Polaris. Diesel ATV Polaris RANGER Copyright 1999 Polaris Sales Inc. 9912004 9913680 9915881 9915234 9914985 Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: A The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED I 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 ' '- J

CHAPTER 1 GENERAL INFORMATION I SPECIFICATIONS Model I VIN Identification ...................... 1.1-1.2 Publication Part Numbers ...................... 1.3 Service/Information Bulletin Index .............. 1.3 Paint Codes ................................. 1 .4 Standard Torque Specifications ................ 1 .5 Decimal Equivalent Chart ...................... 1.6 Conversion Table ............................. 1 .7 Tap Drill Charts ............................... 1.8 Service Tips ................................. 1.9 Glossary of Terms ............................ 1.10-1.12 Special Tool Ordering Information ............... 1.13 Model Specifications (1999) Trail Blazer ............................ 1.14-1.15 Trail Boss ............................. 1.16-1.17 Xpress 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18-1 .19 Xplorer 300 ............................. 1.20-1.21 Sportsman 335 .......................... 1.22-1.23 Sport 400 .............................. 1 .24-1.25 Scrambler 400 .......................... 1 .26-1.27 Xplorer 400 ............................. 1 .28-1.29 Scrambler 500 .......................... 1.30-1.31 Magnum 500 ........................... 1.32-1 .33 Sportsman 500 .......................... 1.34-1.35 Big Boss 500 6x6 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36-1 .37 Model Specifications (2000) Trail Blazer ............................ 1.38-1.39 Xplorer 4x4 ............................ 1.40-1.41 Trail Boss 325 ......................... 1.42-1.43 Magnum 325 (01 Engine) ................. 1.44-1.45 Magnum 325 (04/05 Engine) ............... 1.46-1.47 Xpedition 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .48-1 .49 Sportsman 335 .......................... 1.50-1.51 Xplorer 400 ............................. 1.52-1 .53 Scrambler 400 2x4 ....................... 1.54-1 .55 Scrambler 400 4x4 ....................... 1.56-1 .57 Xpedition 425 ........................... 1.58-1 .59 Magnum 500 .............................. 1.60-1.61 Scrambler 500 ......................... 1.62-1.63 Sportsman 500 ........................ 1.64-1.65 Sportsman 6x6 ........................ 1.66-1.67

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) 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 VIN Number Location The machine Model Number and Vehicle Identification Number (VIN) are important for vehicle identification. The VIN number will be stamped into the frame in one of the following locations: • 1998-Current On the left hand lower frame rail (A) near the rear A-arm mount. 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 I. D. number (A) 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 Sales Inc. 1.1 VIN Location- 1998-Current Example Mod #I 13411szl Ser #I as-1o2zs Transmission I.D. Numbers 2-Stroke A Forward 4-Stroke Carburetor I.D. Number 4/99 ..

GENERAL INFORMATION Model Identification Vehicle Identification Number Current ATVs and 6X6 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 1 2 3 4 5 7 8 9 10 4XABA 38COW2 Vehicle Identifier 13 14 1 0 0 0 17 0 Example of Current VIN Number Body S~le I --r:,iss\ons I MJdel I Engine Year Individual Serial No. Powertrain Check Digit Plant No. Vehicle Identification Number I Model Number Key Bod¥ St¥1e Powertrain Engine A=Gen II A=2x4 chain 25=EC25PF(250cc) B=Gen Ill C=4x4 chain 28=EC28PF(300 cc) C=Gen IV D=4x4 shaft 33=ES33PF(335 cc) R=RANGER E=6x6 chain 38=EC38PL(400 cc) F=6x6 shaft 42=EH42PL (425 cc) G=4x4 chain rear/ 50=EH50PL (500 cc) shaft front [I]CARB = California Air Resources Board [l]CARB Approved or not a regulated type Year I Letter Identification Emis~ions A=Approved by CARB[I] !ll B=England C=Non GARB Approved [I] D=Norway E=Sweden Ogtions A=Option 1 B=Option 2 The tenth digit of a 17 digit VI N 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 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). The example below is a 1999 Magnum 500. Machine Model Number Identification ---- A ~ CDSOA A Option Indicator A=ATV ""' Year Designation /Last 5 Model # Digits=Digits 4-8 of VIN 4/99 1.2 Polaris Sales Inc. ( (

1999 Publication Part Numbers DESCRIPTION 1995-1999 4 Stroke ATV I 6x6 Service Manual 1996 ATV Service Manual Volume II 1998 ATV Service Manual Vol. II Update 1999 ATV I 6x6 Service Manual Volume Ill Diesel ATV Service Manual RANGER Service Manual PART NUMBER 9915686 9913680 9914752 9915083 9915234 9914985 GENERAL JNFORMATION Publications SERVICE TRAINING VIDEOS VIDEO TITLE PART NUMBER DESCRIPTION Magnum 4-Stroke Introduction 9912996 Includes 4 Stroke theory of operation, engine removal, disassembly, and assembly techniques, and general tech-tips. Ignition System Diagnostics 9913533 Describes all current Polaris ignition systems. Provides working knowledge of ignition system theory and diagnostics. Charging System Diagnostics 9913278 Describes all current Polaris charging systems. Provides working knowledge of charging system theory and diagnostics. Polaris Variable Transmissions 9913987 Theory, disassembly, assembly and troubleshooting of the (PVT) Polaris PVT system. Fuels and Fuel Delivery 9914393 Describes fuel properties including octane and vapor pres- sure; fuel mixture and burn characteristics; VM and CV carburetor theory and adjustments. Service Bulletin Index Always consult latest service information. Bulletins published after 3-15-99 are not listed in the following index. 1999 Model Bulletin# Type Notes Big Boss 500 6x6 None Sportsman 500 None Scrambler 500 None Magnum 4x4 None Magnum 2x4 None Xplorer 400 None Scrambler 400 None Sport 400 None Xplorer 300 None Xpress 300 None Trail Blazer ATV-99-01 Service Bulletin Rear Eccentric Bearing Lubrication Trail Boss ATV-98-01 Service Bulletin Foil Missing From Rear Brake Disc Guard Applies to All 1999 Models None Polaris Sales Inc. 1.3 4/99

GENERAL INFORMATION Paint Codes 1999 Paint Codes Model Item Color Material No. (Polaris #) PPG Ditzler No. Big Boss 500 6X6 Springs I Eddie B Green 8520150 (P195) Front Rack Rims Aluminum (P117) Sportsman 500 RSE Springs I Rims Black 8520147 (P067) Sportsman 500 EBS (Opt. A) Springs I Rims Black 8520147 (P067) Sportsman 500 EBS (Opt. B) Rims Aluminum (P117) Spring, Front Fire Red 8520149 (P093) Spring, Rear Bonnie Blue 8520148 (P157) Magnum 500 Springs Black 8520147 (P067) Rims Aluminum (P117) Scrambler 500 Springs Fire Red 8520149 (P093) Rims Aluminum (P117) Xplorer 400 Springs Burnished Brown P218 Rims Aluminum (P117) Scrambler 400 Springs Fire Red 8520149 (P093) Rims Bright White 8520153 (P133) Sport 400L Springs Fire Red 8520149 (P093} Rims Bright White 8520153 (P133) Sportsman 335 (Opt. A) Springs I Rims Black 8520147 (P067) Sportsman 335 (Opt. B) Springs Black 8520147 (P067) Rims Aluminum (P117) Xplorer 300 Springs Fire Red 8520149 (P093) Rims Aluminum (P117) Xpress 300 Springs Bonnie Blue 8520148 (P157) Rims Aluminum (P117} Trail Blazer Springs Fire Red 8520149 Rims Bright White 8520153 (P133) Trail Boss Springs Fire Red 8520149 (P093} Rims Bright White 8520153 (P133) Rack(s) Fire Red 8520149 (P093) Order direct from Midwest Industrial Coatings (612-942-1836). Mix as directed. Frames (Medium Black) P067 I 8520147 I Ditzler 9440 4/99 1.4 44931 9440 9440 72060 12908 9440 72060 72060 2185 72060 2185 9440 9440 72060 12908 72060 2185 72060 2185 72060 Polaris Sales Inc. ) ) )

) GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used as a general guideline when a specific torque is not listed for a fastener. Some fasteners require a special torque procedure and/or the application of a locking agent or locking device during installation. Always refer to the appropriate chapter for specific torque specifications and procedures before using standard torque. 0 Bolt Size Threads/In Grade 2 Grade 5 #10 - #10 - 1/4 1/4 5/16 - 5/16 - 3/8 Torque in. lbs. (N-m) 24 . . . .. ........ 27 (3.1) . . . . . . . . . . . . . . . 43 (5 .0) . .... ....... . . 60 (6.9) 32 ..... .. ...... 31 (3.6) ...... ... ...... 49 (5.6) ....... .... ... 68 (7.8) Torque ft. lbs. (N-m)* 20 .... . ........ 5(7) .......... .. ..... 8(11) ........... .. .. 12(16) 28 ..... .. . .. ... 6 (8) . .......... . ..... 10 (14) .............. 14 (19) 18 ··· · ······· ·· 11 (15) ··············· 17(23) .............. 25(35) 24 ............. 12 (16) . .... . ... ...... 19 (26) ........ ... ... 29 (40) 16 .. . .... . ..... 20 (27) ...... ... ...... 30 (40) .............. 45 (62) 24 .... .. ....... 23 (32) ............... 35 (48) .............. 50 (69) 14 ............. 30 (40) ............... 50 (69) .............. 70 (97) 20 ............ . 35 (48) ............... 55 (76) .............. 80 (110) Grade 8 3/8 7/16 - 7/16 - 1/2 13 .... ....... .. 50 (69) ..... .. ........ 75 (104) ............. 110 (152) 1/2 20 ............. 55 (76) ............... 90 (124) ............. 120 (166) Metric Torque in ln. lb. I Ft. lb. (N-m) 6 x 1.0 72-78 ln. lbs. (8-9) 8 x 1.25 14-18 ft. lbs. (19-25) 10 x 1.25 26-30 ft. lbs. (36-41) *To convert Ft. lbs. to N-m multiply foot pounds by 1.383. *To convert N-m to Kg-m move the decimal point to the left one position. Polaris Sales Inc. 1.5 4/99

GENERAL INFORMATION Decimal Equivalents 1/64 ... .. .. . ........... . .. . ... 0156 1/32 .. .. .. ........ .. .... 0312 .. ............ .. 1 mm = .0394" 3/64 ................... . ..... .0469 1/16 ...... .. .. .. .. .0625 5/64 . . . . . . . . . . . . . . . . . . . . . . . . . .0781 . .. .......... . .. 2 mm = .0787" 3/32 .............. . ..... 0938 7/64 .... .. .. ......... .... ... 1094 .. .. .. ..... .. .. . 3 mm = .1181" 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 .. .............. 11 mm = .4331 " 7/16 ...... ........ .4375 29/64 ..... .. ........... . .... .4531 15/32 .. ...... .... .... .. .4688 .. .... ...... .. .. 12 mm = .4724" 31/64 ...... .. ......... ... ... .4844 1/2 .... .... ... 5 .. .. . .. .... .... ..... 13 mm = .5118 33/64 .. .. .. .... .... .... .... .. 5156 17/32 ............ .... ... 5313 35/64 .. .... ...... .. .... .. .... 5469 .. .............. 14 mm = .5512" 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 .. ...... . ....... 20 mm = .7874" 51/64 .. ... .. . ... . .. ... ... .. . .7969 13/16 ............ .. 8125 .. ...... ........ 21 mm = . 8268" 53/64 .... ... ......... . ....... 8281 27/32 . .. . ..... . .. .... ... 8438 55/64 ........ ................ 8594 .. .............. 22 mm = .8661" 7/8 . ....... . . .875 57/64 . . . . . . . . . . . . . . . . . . . . . . . .8906 . . .. ... .. .. ..... 23 mm = .9055" 29/32 .... ...... ... .. . .. .9063 59/64 . ... .. ....... . .. ..... ... 9219 15/16 . . . . . . . . . . . . . .9375 .. ........... .. . 24 mm = .9449" 61/64 ... .... .. ..... . .. ... .... 9531 31/32 . . ............ .. . . .9688 .... ............ 25 mm = .9843 63/64 ........... . ...... .... .. 9844 1 . . .. .. ..... 1.0 4/99 1.6 ( ( ) ( ( ( } Polaris Sales Inc.

1999-2000 Polaris ATV Service Manual

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