Polaris Magnum 2x4 Service manual

Table of Contents

• 2. Safety labels and instructions
• 3. Table of contents
• 5. General information
• 6. Model Identification
• 7. 1996 Model Identification
• 8. Vehicle Identification Number (1997 and ...
• 10. 1996 Publication Numbers
• 11. 1998 Publication Numbers
• 12. Service/Information Bulletins
• 13. Bulleting Index - 1996 By Model
• 14. Bulleting Index - 1997 By Model
• 16. 1997 Paint Codes
• 18. Specifications 1997
• 23. Specifications 1998
• 26. Standard Torque Specifications
• 27. Decimal Equivalents
• 28. Conversion Table
• 29. Tap Drill Charts
• 30. Warranty
• 31. Service Tips
• 32. Glossary of Terms
• 35. Special Tools
• 36. Routing Diagrams
• 39. Hoses diagram
• 40. 300 Fan Motor Wiring Diagram
• 41. Wire Harness Diagram
• 42. Chassis/Suspension Service Tools
• 43. Mity Vac Pump Kit
• 45. Glossary (2)
• 48. Magnum Routing Diagram (cont.)
• 51. Hosed diagram (2)
• 52. 300 Fan Motor Wiring Diagram (2)
• 53. Wire Harness Diagram (2)
• 54. Oil Tank Vent Line Routing (1996 Sportsm...
• 56. Maintenance
• 58. Periodic Maintenance Chart
• 59. Pre-Ride/Daily Inspection
• 60. Recommended Lubricants and Capacities
• 62. Lubrication Chart
• 65. Lubrication Chart - Type IV Transmission...
• 67. Front Gearcase Lubrication
• 68. Carburetor Adjustments
• 69. Throttle Cable Adjustment
• 70. Air Screw Adjustment - 2-Stroke Models
• 72. Fuel Lines
• 73. Carburetor Draining
• 74. Breather System (4 Strokes)
• 76. General Maintenance
• 77. Battery Maintenance
• 78. Spark Plug Maintenance
• 79. Coolant Level Inspection
• 80. Oil Pump Adjustment Procedure
• 83. Oil Pump Bleeding Procedure
• 84. Recoil Housing
• 85. Air Cleaner - Trail Boss, Xpress 300, Xp...
• 86. Secondary (Main) Filter
• 87. Air Filter Service -Sport, Scrambler 400
• 88. Air Filter Service - Trail Blazer
• 89. 2 Stroke Engine Maintenance
• 90. 4 Stroke Engine Maintenance
• 92. Air Filter - 4 Stroke Engine
• 93. Air Box Sediment Tube
• 94. Air Filter Service - Scrambler 500
• 96. Check Engine Oil (4 Stroke)
• 97. Engine Sump Drain Plug View
• 100. Valve Clearance
• 101. Intake Valve Clearance Adjustment
• 102. Throttle Cable Lubrication
• 103. Toe Alignment Inspection
• 104. Chassis Maintenance
• 105. The Rod End Inspection
• 106. Exhaust Pipe
• 107. Brake System Inspection
• 108. Auxiliary Mechanical Brake System
• 109. Drive Chain and Sprocket Inspection
• 110. Rear Drive Chain Tension Adjustment
• 111. Drive Chain Adjustment, Concentric Swing...
• 113. Center/Front Drive Chain Slack Adjustmen...
• 114. Drive Chain Inspection/Adjustment
• 115. Front Suspension
• 116. Transmission Lubrication
• 117. Transmission Lubrication - Type V Shaft/...
• 118. Transmission Vent Line Routing
• 119. Wheels inspection
• 120. Tire Pressure
• 122. Engine
• 124. 2 Stroke Engine Torque Specifications
• 125. Engine Fastener Torque Patterns
• 126. 1996 to Current Engine Specifications
• 127. EC38PL Engines
• 129. EH42PL/EH50PL Engine Service Data
• 131. Cooling System
• 132. Recommended Coolant
• 133. 2 Stroke Engine Removal
• 136. Engine Installation Notes (2 Stroke)
• 137. EC25PF/EC28PF Engines Disassembly
• 138. Crankshaft Alignment
• 139. EC25PF/EC28PF Engines Assembly
• 140. Connecting Rod Side Clearance
• 144. EC25PF/EC28PF Engines Installation
• 145. Oil Pump End Play Adjustment
• 146. Oil Check Valve Testing (250/400)
• 147. EC25PF Engine - Recoil Disassembly
• 148. EC25PF Engine - Recoil Assembly
• 150. EC38PL Engine Disassembly
• 156. Water Pump Impeller Clearance
• 158. Cylinder Hone Selection/Honing Procedure
• 159. Piston/Cylinder Clearance (2 Strokes)
• 160. Piston Ring Installed Gap
• 161. Connecting Rod Small End Inspection
• 162. EH42PL/EH50PL Engine Exploded View
• 163. EH42PL/EH50PL Lubrication/Oil Flow
• 164. EH42PL/EH50PL Engine Diagram
• 165. EH42PL/EH50PL Engine Removal
• 166. AWD Models
• 167. Recoil/Starter Removal
• 169. Final Coolant Draining/Engine Removal
• 170. EH42PL/EH50PL Engine Installation
• 171. To position crankshaft at Top Dead Cente...
• 172. Rocker Arm/Shaft Removal
• 174. Camshaft Removal
• 175. Automatic Compression Release Removal/In...
• 176. Camshaft Inspection
• 177. Cylinder Head Removal
• 178. Cylinder Head Disassembly/Inspection
• 179. Cylinder Head Warpage
• 181. Valve Inspection
• 182. Combustion Chamber
• 183. Valve Seat Reconditioning
• 186. Cylinder Head Assembly
• 187. Valve Sealing Test
• 188. Piston Removal
• 189. Cylinder Inspection
• 190. Piston to Cylinder Clearance
• 192. Piston Ring Installed Gap (EH42PL/EH50PL...
• 193. Starter Drive Removal/Inspection
• 194. Flywheel/Stator Removal/Inspection
• 195. One Way Valve
• 196. Oil Pump Removal/Inspection
• 198. Oil Pump Assembly
• 199. Crankshaft Removal/Inspection
• 200. Crankcase Bearing Inspection
• 201. EH42PL/EH50PL Engine Assembly
• 203. Counter Balancer
• 204. Crankshaft, Counter Balancer and Oil Pum...
• 205. Water Pump Mechanical Seal Installation
• 208. Piston Installation
• 209. Cylinder Installation
• 210. Cylinder Head Installation
• 211. Cam Chain/Camshaft Installation
• 212. Camshaft Installation - Timing Method
• 213. Method 1 - Camshaft Timing with Stator R...
• 214. Camshaft Installation - Timing Method 2
• 215. Method 2 Camshaft Timing Using Flywheel ...
• 216. Cam Chain Tensioner Installation
• 218. Rocker Shaft/Rocker Arm Assembly Install...
• 219. Engine - Sealed Recoil
• 220. Recoil Assembly
• 222. Spark Plug Fouling - 2 Stroke Engine
• 223. 2 Stroke Engine Troubleshooting
• 224. Starter Motor
• 225. 4 Stroke Engine Troubleshooting
• 227. Piston Damage Checklist - 2 Stroke Engin...
• 228. Fuel System/Carburetion
• 230. Fuel System/Carburetion - 1996 Specifica...
• 234. Fuel System/Carburetion - 1997 Specifica...
• 235. Fuel System/Carburetion - 1998 Specifica...
• 236. 1998 Trail Blazer W98AA25C (Engine -EC-2...
• 237. XPRESS 300 W98CA28C (Engine -EC-28PFE-12...
• 238. XLPORER 300 W98CC28C (Engine -EC-28PFE-0...
• 239. 1998 XLPORER 400 W98CC38C (Engine -EC-38...
• 240. 1998 Sport 400 W98BA38C (Engine - EC-38P...
• 241. 1998 Scrambler 400 W98BC38C (Engine - EC...
• 242. Magnum 2 x 2 W98AA42A (Engine - EH-42PLE...
• 243. Magnum 4 x 4 W98AC42A (Engine - EH-42PLE...
• 244. 1998 Scrambler 500 W98BC50A (Engine - EH...
• 245. Sportsman 500 W98CH50A (W90CH50AB) (Engi...
• 246. 1998 Big Boss 500 6x6 W98AE50A (Engine -...
• 247. Fuel System/Carburetion - Jet Part Numbe...
• 248. Oil Tank and Fuel Tank Assembly - Gen II...
• 249. Fuel Tank Assembly (Magnum)
• 250. Oil Tank and Fuel Tank Assembly (Gen III...
• 251. Fuel Tank Assembly (Gen IV)
• 252. Fuel Tank Assembly - 500 Models (1997 Xp...
• 253. Fuel Flow Diagrams
• 254. Mikuni VM Carburetor Exploded Diagram
• 255. Carburetor function
• 256. Component Functions
• 257. Jet Needle
• 258. Throttle Valve
• 259. Starter System - Closed Throttle
• 260. Pilot System (0-3/8 Throttle)
• 261. Slide Cutaway (1/8-3/8 Throttle)
• 262. Jet Needle/Needle Jet (3/8-3/4 Throttle)
• 263. Main System (3/4 to Full Throttle)
• 264. Component Effect vs. Throttle Opening
• 265. Mikuni VM Carburetor System Components
• 266. Mikuni BST 34 Carburetor Exploded View
• 267. Venting Systems (Mikuni CV)
• 268. Mikuni CV Carb Operation
• 269. Pilot (Idle and Slow) Systems
• 270. Float System (Mikuni CV)
• 271. Magnum Fuel Tank Removal
• 272. Carburetor Removal ( Mikuni CV)
• 273. Carburetor Disassembly - Mikuni CV
• 276. Carburetor Cleaning - Mikuni CV
• 279. Carburetor Assembly - Mikuni CV
• 280. Carburetor Assembly/Adjustment - Mikuni ...
• 282. CV Carburetor Installation
• 283. Needle and Seat Pressure Test Mikuni CV
• 284. Float Bowl Draining
• 286. Fuel Pump Exploded View
• 287. Fuel Pump Testing
• 288. Fuel System/Carburetion Troubleshooting
• 289. Idle Too Low
• 290. Body and Steering
• 292. Body and Steering - Torque Specification...
• 293. Body Styles
• 295. Body Assembly Exploded View (Gen II - Ty...
• 296. Cover/Panel Removal (Gen II - Typical)
• 297. Cover/Panel Removal (Gen III - Typical)
• 298. Cover/Panel Removal (Gen IV - Typical)
• 299. Body Assembly Exploded View (Gen III - T...
• 300. Body Assembly Exploded View (Gen IV - Ty...
• 301. Body Assembly Exploded View (Gen IV - He...
• 302. Headlight Pod Service (Gen IV Typical) -...
• 303. Headlight Pod Service (Gen IV Typical) -...
• 304. Side Panel Removal (Gen IV - Typical)
• 305. Toe Alignment
• 306. Toe Alignment - Method 2
• 307. Typical Steering Assembly, Exploded View...
• 308. Steering Assembly, Exploded View, 2x4 Mo...
• 309. Steering Assembly, Exploded View, 4x4 an...
• 310. Steering Stop Adjustment
• 311. Rear Drive Axle, Hub and Wheel Assembly,...
• 312. Concentric Swingarm Rear Axle Assembly, ...
• 313. Concentric Swingarm Exploded View 1998 S...
• 314. Rear Drive Axle, Hub and Wheel Assembly ...
• 315. Rear Strut Stabilizer, 6x6 Models
• 316. Rear Swing Arm Weldment, 6x6 Models
• 318. Swing Arm and Rear Suspension Exploded V...
• 319. Swing Arm Removal
• 320. Swing Arm Removal/Inspection
• 321. Swing Arm Assembly/Installation
• 322. Concentric Swingarm Removal/Disassembly
• 323. Concentric Swingarm Assembly/Installatio...
• 324. Strut Assembly - 400L AWD, Magnum AWD
• 325. Front Strut Weldment Replacement
• 326. Front Strut Service
• 327. Front Strut Installation
• 328. Front Strut Ball Joint Replacement
• 330. 2x4 Front Hub Assembly
• 331. 2x6 Hub Bearing Service
• 332. Fox Shock Service
• 333. FoxTM Shock Service
• 339. Fox Shock Standard Valving Chart
• 340. 1996 Optional Suspension Springs
• 341. 1997 Optional Suspension Springs
• 342. 1996 Paint Codes
• 343. 1997 Paint Codes
• 344. Clutches
• 346. Clutch - Specifications
• 347. 1997 Production Specifications
• 348. 1998 Production Specifications
• 349. Shift Weights
• 351. Drive Clutch Spring Specifications
• 352. Clutches Overview
• 353. PVT System Indroduction
• 354. Clutch Maintenance
• 355. PVT Sealing and Ducting Components - Typ...
• 356. PVT Sealing and Ducting Components - Typ...
• 358. Typical PVT Disassembly
• 359. PVT Assembly
• 361. Drive Belt Tension
• 362. Clutch Alignment /Offset
• 363. Driven Clutch Disassembly
• 365. Driven Clutch Assembly
• 367. Drive Clutch - Springs Specifications Ta...
• 368. Drive Clutch Inspection
• 369. Drive Clutch Disassembly
• 371. Drive Clutch Assembly
• 372. Clutch Bushing Removal and Installation
• 373. Drive Clutch Moveable Sheave - Bushing I...
• 374. Drive Clutch Cover - Bushing Removal
• 375. Drive Clutch Cover - Bushing Installatio...
• 376. Driven Clutch Moveable Sheave - Bushing ...
• 378. Driven Clutch Moveable Sheave - Bushing ...
• 380. Engine Braking System (EBS)
• 381. EBS Exploded View
• 382. Drive Clutch Disassembly - EBS
• 383. Inspection of Moveable Sheave Bushing
• 384. Driven Clutch Disassembly - EBS
• 385. Roller Pin Disassembly
• 387. Operation Guidelines For EBS Clutches
• 388. Clutches Troubleshooting
• 390. Final Drive
• 392. Final Drive Torque Specifications
• 393. Final Drive Exploded View
• 394. Demand 4 Operation - AWD Models
• 395. Front Hub Disassembly (4x4)
• 396. Hilliard Clutch Disassembly/Inspection
• 397. Hilliard Clutch Assembly Testing
• 398. Strut Seal Sleeve Replacement
• 399. Magnetic Coil Replacement
• 400. Wheel Hub Seal Replacement
• 401. Strut Casting Seal Replacement
• 402. Drive Shaft Boot Replacement
• 403. Hub/Wheel Bearing Installation (4x4 Mode...
• 404. Front Hub Bearing Adjustment (AWD Models...
• 405. Front Hub Bearing Adjustment (AWD Models...
• 407. Front Axle Identification
• 409. Front Drive Axle Removal
• 410. Front Drive Axle Installation
• 411. U-Joint Service
• 412. U-Joint Inspection
• 414. 2x4 Front Hub Disassembly and Inspection
• 415. 2x4 Front Hub Assembl.
• 416. 2x4 Front Hub Install.
• 417. Rear Axle Removal
• 419. Rear Axle Installation
• 422. 6x6 Middle Axle Sprocket Service
• 425. Brake Disc Hub Removal
• 426. Middle Axle Assembly
• 428. Rear Hub/Bearing Carrier Removal (Type I...
• 430. Rear Hub Disassembly (Shaft Drive)
• 431. Rear Hub Assembly (Shaft Drive)
• 432. Rear Hub Installation
• 433. Rear Drive Shaft Removal
• 434. Rear Drive Shaft Disassembly
• 435. Rear Drive Shaft Installation
• 436. Rear Eccentric Removal
• 437. Rear Eccentric Assembly
• 439. Rear Eccentric Installation
• 440. Center Eccentric Removal
• 441. Center Eccentric Disassembly
• 443. Center Eccentric Installation
• 445. Front Eccentric Removal
• 447. Front Eccentric Assembly
• 449. Front Eccentric Installation
• 451. Front Gearcase Removal
• 452. Front Gearcase Disassembly
• 455. Front Gearcase Assembly
• 458. Front Gearcase Installation
• 460. Concentric Swingarm Rear Axle Removal
• 461. Concentric Swingarm Rear Axle Assembly
• 463. Concentric Swingarm Rear Axle Assembly, ...
• 464. Transmission Service
• 466. Transmission Service - Torque Specificat...
• 467. Gear Ratios
• 468. Torque Stop/Shift Linkage Adjustment
• 470. Shift Linkage Rod End Positioning
• 471. Transmission Service - Troubleshooting
• 472. Gear Shift Selector Removal
• 474. Gear Shift Selector Assembly
• 475. Gear Shift Selector Installation
• 476. Transmission Service - Type III, EZ-Shif...
• 478. Type III Transmission Exploded View
• 479. Type III Transmission Disassembly
• 481. Type III Transmission Installation
• 483. Type III, EZ Shift Transmission Installa...
• 484. Type V EZ-Shift Transmission (1998 Scram...
• 485. Type IV, Shaft Drive Transmission Remova...
• 488. Type IV, Shaft Drive Transmission Disass...
• 497. Late 1997 Type IV Shaft Drive Transmissi...
• 498. 1997 (Late) - Current Tensioner Installa...
• 499. Shaft Drive Transmission Assembly
• 503. Transmission Output Gear Backlash Adjust...
• 509. Shaft Drive Transmission Installation
• 513. Front Drive Housing Seal Removal (In Fra...
• 514. Brakes
• 516. Brakes Specifications
• 517. Brakes - Torque Specifications
• 518. Hydraulic Brake System Operation
• 519. Fluid Replacement/Bleeding Procedure
• 521. Front Pad Replacement
• 522. Front Pad Inspection
• 523. Front Pad Assembly
• 525. Output Shaft Brake Pad Replacement/Adjus...
• 526. Output Shaft Brake Pad Inspection
• 527. Output Shaft Brake Pad Assembly
• 528. 6x6 Rear Brake Pad Replacement
• 529. 6x6 Rear Brake Pad Inspection
• 530. 6x6 Middle Axle Brake Pad Assembly
• 531. Master Cylinder Disassembly
• 533. Master Cylinder Inspection
• 535. Master Cylinder Installation
• 536. Front Caliper Disassembly
• 537. Front Caliper Inspection
• 538. Front Caliper Assembly
• 540. Output Shaft Caliper Service (Auxiliary ...
• 541. Output Shaft Caliper Reassembly
• 542. Output Shaft Caliper Installation
• 543. 6x6 Rear Caliper Removal
• 545. 6x6 Rear Caliper Assembly
• 546. Dual Hydraulic Brake Caliper Bleeding
• 547. Auxiliary Brake Adjustment (Hydraulic)
• 548. Brakes Troubleshooting
• 550. Electrical
• 552. Electrical - Special Tools
• 553. 1996 Electrical Specifications
• 554. 1997 Electrical Specifications
• 555. 1998 Electrical Specifications
• 556. 1996 Stator Resistance Specifications
• 557. 1997 Stator Resistance Specifications
• 558. Flywheel Identification
• 559. Headlamp Service, Gen II
• 561. Headlamp Service - Gen III
• 563. Headlamp Service - Gen IV
• 564. Indicator Lamp Service
• 565. Timing Check Procedures
• 566. Typical Ingnition Timing Curves
• 567. Crankshaft Degree to Piston Position Con...
• 568. Components of EC25/28PL 150 Watt Alterna...
• 569. Components of EC38PL 150 Watt Alternator...
• 570. Components of EC38PL 200 Watt Alternator...
• 571. Components of EC42PL/EH50PL 200/250 Watt...
• 572. Ignition System
• 573. Cranking Output Test With Peak Reading V...
• 574. Ignition System Troubleshooting
• 575. Battery Service
• 576. Battery Inspection/Removal
• 577. Specific Gravity Test
• 578. Off Season Storage
• 579. Charging System Testing
• 580. Current Draw - Key Off
• 581. Starter System Troubleshooting
• 583. Starter Motor Removal
• 584. Starter Motor Disassembly
• 586. Brush Inspection/Replacement
• 587. Armature Testing
• 588. Starter Motor Installation (EC38PL)
• 590. Starter Drive
• 592. Speed Limiter System - Theory of Operati...
• 593. Speed Limiter System Testing
• 594. All Wheel Drive System
• 595. Front Hub Enlargement Limiter (Front Sha...
• 597. Switch Testing
• 598. All Wheel Drive (AWD) Switch (4x4 Model)
• 599. Oil Level Sensor Testing (2 Stroke Model...
• 600. Fan Control Circuit Operation/Testing
• 601. Fan Motor Current Draw
• 602. Wiring Diagram 1996 Trail Boss, Trail Bl...
• 603. Wiring Diagram 1996 TXpress 300, Xplorer...
• 604. Wiring Diagram 1996 Xpress 400, Xplorer ...
• 605. Wiring Diagram 1996 Scrambler, Sport
• 606. Wiring Diagram 1996 Magnum 2x4, 4x4, 6x6
• 607. Wiring Diagram Sportsman 500
• 608. Alphabetical Index
• 614. Wiring Diagram 1997 Xplorer 400, Xpress ...
• 615. Wiring Diagram 1997 Sportsman 500, Xplor...
• 616. Wiring Diagram 1997 Magnum 2x4, Magnum 4...
• 617. Wiring Diagram 1997 Trail Blazer
• 618. Wiring Diagram 1997 Scrambler 4x4, Sport
• 619. Wiring Diagram 1997 Scrambler 500
• 620. Wiring Diagram 1997 Trail Boss
• 621. Wiring Diagram 1997 Sportsman 400, 400 6...
• 623. Wiring Diagram 1997 Xplorer 300, Xpress ...
• 624. Wiring Diagram 1998 Trail Blazer/Trail B...
• 625. Wiring Diagram 1998 Xplorer 300/Xpress 3...
• 626. Wiring Diagram 1998 Sport 400
• 627. Wiring Diagram 1998 Scrambler 400
• 628. Wiring Diagram 1998 Xplorer 400
• 629. Wiring Diagram 1998 Magnum 2x4
• 630. Wiring Diagram 1998 Magnum 4x4
• 631. Wiring Diagram 1998 Scrambler 500
• 632. Wiring Diagram 1998 Sportsman 500
• 633. Wiring Diagram 1998 Big Boss 500 6x6