Polaris 1985-1995 ATV & Light Hauler Repair Service Manual

SERVICE MANUAL PN ATV and Light Utility Hauler 9912004

InDUSTRIES ATV AND LIGHT UTILITY HAULER 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 with procedures before starting the work. Cleanliness of parts and tools as well as the work area is of primary importance. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the 1985 through 1995 model Polaris ATVs. 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. Annual update packet part numbers are found in Chapter 1. At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Engineering Services, Supervisor, Technical Publications, Polaris Industries, Route 1 Box 35A, Roseau, MN 56751, or call (218) 463-2312. Technical Training Center Roseau, Mn 56751 1985-1995 Service Manual (PN 9912004) 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 ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystander or person inspecting or servicing the ATV. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, bystander or person inspecting or servicing the ATV. CAUTION A CAUTION indicates special precautions that must be taken to avoid minor personal injury or ATV or property damage. NOTE A NOTE provides key information to clarify instructions. Polaris acknowledges the following products mentioned in this manual: Loctite, Registered Trademark of the Loctite Corporation FLEXLOC, Registered Trademark of SPS Technologies Hilliard, Trademark of the Hilliard Corporation MityVac, Registered Trademark of Neward Enterprises

Table of Contents 9912004 Chapter 01 General Product Information Chapter 02 Body, Steering and Suspension Chapter 03 Brake Service Chapter 04 Transmission Service Chapter 05 Final Drive System Service Chapter 06 PVTSystem Chapter 07 Engines Chapter 08 Electrical

CHAPTER 1 GENERAL PRODUCT INFORMATION Publications ......................................................... 1.1 Model Identification ................................................... 1.3 Service Tools Description ............................................. 1.4 Service Tools & Supplies List ......................................... 1 .12 Specifications 1985 Models .................................................... 1 .13 1986 Models .................................................... 1 .14 1987 Models .................................................... 1 .15 1988 Models .................................................... 1 .16 1989 Models .................................................... 1 .17 1990 Models .................................................... 1 .18 1991 Models .................................................... 1 .20 1992 Models .................................................... 1 .22 1993 Models .................................................... 1 .24 1994 Models .................................................... 1 .26 1995 Models ................................................... 1 .28a Accessory Fit Chart .................................................. 1 .29 Routing Diagrams .................................................. 1.30c How to Handle a Service Complaint .................................... 1 .39 Service Tips ........................................................ 1.40 Warranty Policy ..................................................... 1.41

ATV SERVICE PUBLICATIONS DESCRIPTION PART NO. MICROFICHE 1985-1993 Service Manual (Includes Binder) 9912004 9912386 1991 Service Manual Update -Includes info. to update PN 9912004 to 9911974 N/A 1991 Specification 1992 Service Manual Update - Includes info. to update manual to 1992 9912195 N/A specs. (PN 9911974 must be inserted prior to this update) 1993 Service Manual Update - Includes info to update manual to 1993 9912477 N/A specs. (PN's 9911974 and 9912195 must be inserted prior to this update) 1994 Dealer ATV Tech. Update Packet (Inc!. Service/Warranty Manual 9912717 N/A Update & Wallcharts) 1994 ATV Service Bulletin Packet 9911421 9911769 YEAR MODEL MODEL NO. PARTS BOOK PN OWNER'S MANUAL PN 1985 Scrambler W857027 9911098 9911056 1985 Trail Boss W857527 1986 Scrambler W867027 9911170 9911167 1986 Trail Boss W867527 1986 Scrambler W862027 9911199 9911197 1986 Trail Boss W867627 1987 Trail Boss W877527 9911349 9911267 1987 Cyclone W877828 9911350 9911324 1987 Trail Boss 4x4 W878027 9911351 9911277 1987 Trail Boss 4x4 W878127 9911352 9911353 1987 Trail Boss 4x4 W878327 9911475 9911451 1988 Trail Boss 2x4 W887527 9911477 9911441 1988 Trail Boss 4x4 W888127 9911476 9911427 1988 Trail Boss 250 R/ES X888528 9911478 9911433 1988 Trail Boss 250 R/ES W888528 9911489 9911488 1989 Trail Boss W898527 9911633 9911641 1989 Trail Boss 2x4 W897527 9911634 9911642 1989 Trail Boss 4x4 W898127 9911635 9911643 1989 Big Boss 4x6 X898627 9911595 9911573 1989 Big Boss 4x6 W899627 9911636 9911644 1990 Trail Blazer W907221 9911841 9911857 1990 Trail Boss 250 W908527 9911771 9911762 1990 Trail Boss 2x4 W907527 9911772 9911764 1990 Trail Boss 2x4 350L W907539 9911853 9911855 1990 Trail Boss 4x4 W908127 9911773 9911765 1990 Trail Boss 4x4 350L W908139 9911854 9911856 1990 Big Boss 4x6 W908627 9911774 9911766 1991 Trail Blazer W917221 9911976 9911901 1991 Trail Boss 250 W918527 9911977 9911905 1991 Trail Boss 2x4 W917527 9911978 9911877 1991 Trail Boss 2x4 350L W917539 9911982 9911908 1991 Trail Boss 4x4 W918127 9911979 9911880 1991 Trail Boss 4x4 350L W918139 9911983 9911894 1991 Big Boss 4x6 W918627 9911980 9911898 1991 Big Boss 6x6 W918727 9911981 9911883 1992 Trail Blazer W927221 9912285 9912042 1992 Trail Boss 250 W928527 9912289 9912042 1992 Trail Boss 2x4 W927527 9912286 9912060 1992 Trail Boss 2x4 350L W927539 9912288 9912060 1992 Trail Boss 4x4 W928127 9912287 9912049 1992 Trail Boss 4x4 350L W928139 9912283 9912049 1992 Big Boss 4x6 W928627 9912290 9912036 1992 Big Boss 6x6 W928727 9912284 9912056 1.1 1/94

SERVICE PUBLICATIONS YEAR MODEL MODEL NO. OWNER'S MANUAL PARTS MANUAL PARTS ASSEMBLY INST. PN PN MICRO-FICHE PN PN 1993 2502x4 W937527 9912426 9912402 9912410 9912427 3502x4 W937539 9912426 9912403 9912411 9912430 2504x4 W938127 9912397 9912404 9912412 9912431 3504x4 W938139 9912397 9912405 9912413 9912428 Sportsman W938039 9912635 9912638 9912639 9912636 2506x6 W938727 9912398 9912409 9912417 9912432 3506x6 W938739 9912553 9912406 9912414 9912429 Trail Boss W938527 9912399 9912407 9912415 9912427 Trail Blazer W937221 9912399 9912408 9912416 9912427 1994 3002x4 W947530 9912660 9912674 9912687 9912655 4002x4 W947540 9912660 9912675 9912688 9912661 3004x4 W948130 9912653 9912676 9912689 9912665 4004x4 W948140 9912653 9912677 9912690 9912656 3006x6 W948730 9912664 9912679 9912692 9912666 4006x6 W948740 9912664 9912680 9912693 9912667 Trail Boss2W W9485?7 9912650 9912682 9912697 9912655 Trail Blazer 2W W947221 9912650 9912683 9912698 9912655 Sportsman 4x4 W948040 9912827 9912684 9912704 9912828 Sport W948540 9912660 9912723 9912724 9912721 1995 3002x4 W957530 9912998 9913005 9913006 9913007 4002x4 W957540 9912998 9913009 9913010 9912999 3004x4 W958130 9913017 9913018 9913019 9913020 Xplorer4x4 W959140 9913017 9913022 9913023 9913024 4006x6 W958740 9913026 9913027 9913028 9913029 Trail Boss W958527 9913031 9913032 9913033 9913034 Trail Blazer W957221 9913031 9913036 9913037 9913034 Sportsman 4x4 W958040 9912966 9913040 9913041 9912965 Scrambler W957840 9912727 9912725 9913044 9912728 Magnum2x4 W957544 9912730 9912685 9913045 9912997 Magnum4x4 W958144 9912730 9912686 9913046 9912731 Sport W958540 9912998 9913013 9913014 9913015 1/95 1.2

GENERAL SPECIFICATIONS AND INFORMATION The following is an index of ATV service bulletins. If you need a bulletin packet or individual bulletins, please con- tact your area service representative or the Roseau Service Department at #218-463-4400. ATV-89-03 1989 Trail Boss Rear Brake Caliper Pad Retention Plate ATV-89-04 1989 2x4, 4x4, and 4x6 Transmission Linkage Adjustment Procedures ATV-90-01 1990 350L 2x4 and 4x4 Pre-delivery Setup Checks ATV-90-02 Battery Bolt Lengths ATV-90-03 Brake Lever Kit PN 2200347 ATV-91-01 1991 4x4 Front Wheel Hub Retaining Nut ATV-91-02 1991 350L ATV Fan Motor Bullet Terminal Connector ATV-91-03 1. Reverse Override Switch Wiring Precaution During Setup 2. Fuel Grade/Octane Recommendation ATV-91-04 1. General ATV Service Info 2. Speedometer Cable Routing 3. Replacement Starter Drive Garter Spring 4. Front Strut Upper Pivot Retaining Nut ATV-92-01 350L 4x4 Engine Oil Injection Line ATV-92-02 General Setup and Service Information 1. Front Wheel Nut Torque Revision 2. ETC Freeplay Adjustment 3. Carburetor Temperature Jetting Compensation ATV-92-03 General Service Information 1. New Engine Airbox Kit 2. New 350L Cylinder Head Gasket 3. Headpipe-Muffler Ball/Socket ATV-92-04 Demand 4 Front Wheel Drive Engagement Troubleshooting Guides 1. Front Wheel Drive Does Not Engage 2. Front Wheel Drive Engages With the Switch in the "Off' Position ATV-93-01 1993 250 4x4/250 6x6 Front Wheel Drive System Electrical Wiring ATV-93-02 1993 Models ATVs with Low Oil Warning Lights that Remain On After Oil Tank Has Been Filled ATV-93-03 Electronic Throttle Control (ETC) and 4x4 Throttle Switch Operation Maintenance Tips ATV-93-04 1. Revised Carburetor Recommendation for All EC35PL Engines 2. Inner Strut Casting Seal Placement 3. Transmission Case Damaged in Torque Stop Area Caused by I mproper Assembly Procedures Used During Rear Shock Installation ATV-93-05 1. Drive Chain Adjustment and Maintenance 2. Chain Adjuster Eccentric Pinch Nuts Stripping 3. Indicator Bulbs Inoperative or Failure at Pre-delivery Inspection 4. Accessory Power Outlet Information and Parts Information 5. Hot Light on Without Fan 6. ATV Fuel Tank Vent Lines 7.350 Engine Noise/Lean Condition 8. 350 6x6 Brake Line Wear ATV-93-06 1993 Improvement Kits or Parts to Upgrade Earlier Machines and New Accessories ATV-93-07 1. Carburetor Needle and Seat Wear - All ATVs 2. 1993 350 6x6 Chain Guide Roller Wear ATV-93-08 1993 Model 13 Tooth Drive Sprockets ATV-93-09 350L ATVs With a Loose Carburetor Jet Needle Locating Pin ATV-94-01 1994 Trail Blazer, Trail Boss, and 400 4x4 Front A-arm Attachment Hardware May Work Loose ATV-94-02 Procedure to Follow When a Complete ATV Transmission Must Be Replaced Under Warranty ATV-94-03 Some 1994300 4x4s May Have Cooling Fan Blade Installed Improperly ATV-94-04 1. Transmission Bell Crank Available to Units Difficult to Adjust 2. Proper Procedure for Shift Linkage Adjustment ATV-94-05 1. 1994 Models with Air Box Positioned Too Far Forward 2. Trail Boss/Trail Blazer Drive Chain May Be Too Tight ATV-94-06 Improved Performance and Fuel Economy on Magnum 2x4 and 4x4 ATV-94-07 Magnum 4x4 Throttle Cable Routing May Cause Engine Idle Speed to Increase When Turning 1.2a 1195

MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warrant or service. When ordering service parts be sure to use the correct Parts Manual. Machine Model Number Identification W-U~g~ . . / Basic Chassis ~ . .. Year Designation Designation Engine Designation Some model numbers begin with the letter X which designates production pilot build machines. Basic Chassis Designation Numbers and Description 70 Scrambler Three Wheels 72* Trail Blazer 75* Trail Boss (1985-87) or Trail Boss 2x4, First Production of Given Year; Magnum 2x4 76 Trail Boss, Second Production of Given Year 78* 1987 Cyclone; 1995 Scrambler 80 Trail Boss 4x4, First Production of a Given Year 81 * Trail Boss 4x4, Second Production of a Given Year; Magnum 4x4 83 Trail Boss 4x4, Third Production of a Given Year 85* Trail Boss RlES (1988) and newer Trail Boss, First Production of a Given Year 86* Big Boss 4x6, 250 87* Big Boss 6x6, 250, 350L 91 * .. .. Xplorer 4x4 * Currently used Chassis Nos. Engine Designation Numbers and Description 21 EC25PF-07*,09* ......... Single, Free Air, Oil Injected, 22 h.p. @6000 RPM 27 EC25PF-01,03,05,08 ..... Single, Free Air, Oil Injected, 22 h.p. @6000 RPM, Electric Start 28 EC25PF-02 .............. Single, Free Air, Oil Injected, 30 h.p. @7000 RPM EC25PF-04 .............. Single, Free Air, Oil Injected, 27 h.p. @6600 RPM 39 EC35PL-02* ............. Single, UC, Oil Injected, 32 h.p. @5800 RPM, Electric Start EC28PF-01 * ............. Single, FIA, Oil Injected, 24 h.p. @5600 RPM, Electric Start 40 EC38PL-01 * ............. Single, UC, Oil Injected, 35 h.p. @5700 RPM, Electric Start 44 EH42PL-01 * ............. Single, UC, SOHC 4 Stroke, 26 h.p. @ 6000 RPM, Electric Start * Currently used Engine Nos. Engine Model Number and Serial Number Location Whenever corresponding about an engine, be sure to call out the engine model number and serial number. You can find this information on the crankcase. See A. Machine Model Number and Serial Number Location t 985 & 1986 Models: Model Number, see A Serial Number, see B 1989 & Newer Models (with square tube frame): Serial Number, see B 1987 & 1988 Models: Model Number, see C Serial Number, see D 1988 RIES Model: Model and Serial Number, see D 1.3 1/95

SERVICE TOOLS Fluke 73 Analog/Digital Multltester Tests all electrical circuits and components. PN 2870659 Crankshaft Alignment Fixture Holds shaft while checking runout. Indicators not included. PN 2870710 Slotted Nut Socket This special socket must be used to remove the slotted nut on the crankshaft mag end of the 350L engine. PN 2870967 Counter Balancer Puller This special puller is used to remove the counterbalancer shaft from the 350/400L engine for service, replacement, or during engine disassembly. PN 2870968 1/94 1.4

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Polaris 1985-1995 ATV & Light Hauler Repair Service Manual

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