Positioning:
The Polaris Magnum was positioned as a robust utility and recreational ATV, known for its strong performance and versatility in its era.
Competitors:
Competed with models from Yamaha (Grizzly), Honda (FourTrax), Kawasaki (Bayou), and Suzuki (King Quad) in the mid-to-late 1990s utility ATV market.
Features:
Available in 2x4 and 4x4 configurations, robust chassis, capable suspension for varied terrain, and a powerful engine for its class.
Systems Covered:
All systems including engine, transmission, drivetrain, electrical, chassis, body, suspension, brakes, and fuel system.
Page Count:
Detailed, comprehensive (exact count not provided, but implied to be extensive for full service/repair).
Manual Type:
Factory Service & Repair Workshop Manual
Engine Systems:
Engine disassembly, assembly, tuning, diagnostics, cooling system, lubrication system, and component testing.
Transmission Drivetrain:
Gearbox, drive shafts, differentials (front and rear for 4x4), chain drive, clutch, and hub assemblies.
Electrical Systems:
Wiring diagrams, ignition system, charging system, lighting, starter motor, battery, and electronic control units (if applicable).
Chassis Suspension:
Frame inspection and repair, front and rear suspension components, steering system, shocks, and A-arms.
Braking Systems:
Brake fluid replacement, caliper service, disc inspection, brake line routing, and parking brake adjustments.
Fuel System:
Carburetor adjustment and cleaning, fuel pump, fuel lines, fuel tank, and petcock operation.
Bodywork Plastics:
Fender removal and installation, seat, handlebars, and plastic panel maintenance.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain lubrication and adjustment, air filter cleaning/replacement, and fluid level checks.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts.
Major Repairs:
Engine rebuilds, transmission overhauls, differential repairs, suspension component replacement, and electrical system diagnosis.
Adjustments:
Carburetor tuning, valve clearance adjustment, brake lever free play, clutch cable adjustment, and throttle cable adjustment.
Depth:
Comprehensive factory-level detail, covering routine maintenance to complete engine and transmission rebuilds.
Engine Type:
Four-stroke, liquid-cooled, SOHC (Single Overhead Cam)
Displacement:
Typically 325cc to 375cc range for the Magnum series in this period. Specific variant might be 325cc or 400cc.
Bore X Stroke:
Specific to engine variant, e.g., for a 325cc, could be around 76 x 73 mm; for a 400cc, closer to 83 x 70 mm. Manual will have exact figures.
Compression Ratio:
Typically around 8.5:1 to 9.5:1. Manual will confirm.
Horsepower:
Estimated 20-25 HP. Manual will provide precise figures.
Torque:
Specific figures not readily available, but designed for strong low-end torque for utility. Manual will provide.
Carburetor:
Mikuni BSR carburetor (likely 32mm or 34mm).
Fuel Type:
Unleaded Gasoline (Octane rating as specified in manual)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with Hi/Lo range.
Optional Transmission:
N/A (CVT was standard for this model).
Drive Selection:
Selectable 2WD/4WD (on 4x4 models), likely with a viscous or automatic locking front differential.
Gearbox Ratios:
Manual will detail specific low and high range ratios and reverse gear ratios.
Length:
Approx. 77-80 inches (1956-2032 mm). Manual will have exact specs.
Width:
Approx. 45-48 inches (1143-1219 mm). Manual will have exact specs.
Height:
Approx. 45-48 inches (1143-1219 mm). Manual will have exact specs.
Dry Weight:
Approx. 550-650 lbs (249-295 kg). Manual will have precise figures.
Ground Clearance:
Typically around 8-10 inches (203-254 mm). Manual will confirm specific value.
Front Rack Capacity:
Approx. 50 lbs (22.7 kg). Manual will confirm.
Rear Rack Capacity:
Approx. 100 lbs (45.4 kg). Manual will confirm.
Towing Capacity:
Typically around 1500 lbs (680 kg). Manual will specify exact rating.
Atv Safety Standards:
Complies with ANSI/SVIA 1-2001 (relevant safety standards for ATVs of the era).
Braking System:
Hydraulic disc brakes front and rear, often single disc front and rear, with a foot-operated rear brake and a thumb-operated front brake lever. Parking brake integrated into rear caliper or separate mechanism.
Throttle Limiter:
Often includes a throttle limiter screw for younger or less experienced riders, detailed in the owner's manual, and likely covered in the service manual for adjustment/removal.
Operator Training:
Emphasis on proper training and safe riding practices, as highlighted in the owner's manual and recommended in service procedures.
Infotainment System:
N/A - Basic ATV design, no advanced infotainment systems.
Driver Assistance Features:
N/A - Basic ATV design, no driver assistance systems.
Connectivity Options:
N/A - Basic ATV design, no connectivity options.
Oil Change Interval:
Typically every 100 hours or annually. Manual will specify precise hours and calendar intervals.
Air Filter Cleaning:
Check every 20-30 hours, clean or replace as needed. Manual will detail specific intervals and procedures.
Spark Plug Replacement:
Inspect annually, replace as recommended. Manual will provide recommended plug type and gap.
Chain Lubrication:
Lubricate chain every 10-15 hours or after riding in wet conditions. Manual will specify lubricant type.
Engine Oil Type:
Polaris PS-4 5W-50 Synthetic or equivalent API SG/SH rated oil. Manual will list exact specifications.
Engine Oil Capacity:
Approximately 2.1 US quarts (2.0 L) with filter change. Manual will confirm exact capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify exact type and bleeding procedure.
Coolant Type:
Ethylene glycol-based antifreeze coolant. Manual will specify mixture ratio and capacity.
Common Wear Items:
CVT belt wear, suspension bushings, wheel bearings, and throttle cables are common wear items on ATVs of this age.
Carburetor Tuning:
Carburetor can require periodic cleaning and adjustment due to fuel quality or debris. Manual provides detailed tuning procedures.
Polaris History:
Polaris Industries has a long history of producing snowmobiles and expanded into ATVs in the 1980s, becoming a major player in the off-road vehicle market.
Magnum Lineage:
The Magnum line was a core offering for Polaris, known for its powerful engines and utility-focused design. It evolved through various displacements and feature sets throughout the 1990s.
Manufacturing Location:
Primarily manufactured in the USA by Polaris Industries.
