Product Type:
Service Manual
Model List:
Trail Blazer, Trail Boss, Xplorer 300, Xpress 300, Sport, Scrambler 4x4, Xpress 400, Xplorer 400, Sportsman 4x4, 4006x6, Magnum 2x4, Magnum 4x4, Magnum 6x6, Sportsman 500, Xplorer 500, Scrambler 500, Big Boss 500 6x6
Polaris Publication Numbers:
9913680, 9914752
Segment:
Utility and Recreational ATVs
Market Competitors Era:
Competed against models from Yamaha (Grizzly, Kodiak), Honda (FourTrax), Suzuki (King Quad), and Kawasaki (Bayou)
Features Of Vehicles Covered:
These ATVs often featured liquid-cooled engines, independent front suspension (IFS) on some models, shaft drive, and the Polaris Variable Transmission (PVT) automatic clutch system.
Engine:
Detailed engine diagnostics, overhaul, and repair procedures
Fuel System Carburetion:
Carburetor adjustment, cleaning, rebuilding, fuel pump, fuel lines, and tank service
Body Steering Suspension:
Body panel removal/installation, steering system components, front and rear suspension geometry and repair
Pvt System:
Polaris Variable Transmission (PVT) system: clutch inspection, adjustment, and replacement; belt service
Final Drive:
Front and rear differential service, hub components, and driveshaft maintenance
Transmission:
Gearbox overhaul, lubrication, and shift mechanism repair
Brakes:
Hydraulic brake system service, caliper, master cylinder, brake lines, and pad replacement
Electrical:
Wiring diagrams, battery, starter, lighting, ignition system, and accessory circuits
General Information:
Introduction to the manual, safety precautions, vehicle identification numbers (VIN), general tools and shop practices.
Drive Chain Or Shaft Drive:
Maintenance, lubrication, and adjustment for chain-driven models (if applicable) or inspection of shaft drive components.
Exhaust System:
Inspection, repair, and replacement of exhaust pipes, mufflers, and heat shields.
Maintenance:
Scheduled maintenance, lubrication points, filter changes, and fluid level checks
Troubleshooting:
Diagnostic charts for common problems and their solutions
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly
Technical Specifications:
Torque specifications, clearances, fluid capacities, and electrical resistance values
Component Removal Installation:
Detailed procedures for removing and reinstalling major components like engines, transmissions, suspension arms, and body panels.
Bearing Replacement:
Instructions for replacing wheel bearings, suspension bushings, and steering components.
Ignition System Diagnostics:
Testing of ignition coils, spark plugs, stator, and CDI unit for proper function.
Depth:
Comprehensive: Covers routine maintenance to full engine and component rebuilds
Diagnostic Procedures:
Includes methods for diagnosing electrical and mechanical faults using specialized tools and troubleshooting charts.
Performance Tuning:
Guidance on carburetor jetting for altitude and modifications, and PVT clutch tuning for specific performance needs.
Special Tool Requirements:
Highlights specialized tools required for specific procedures, such as clutch holding tools, pullers, and diagnostic equipment.
Engine Types:
Predominantly liquid-cooled, 2-stroke and 4-stroke single-cylinder engines, with some 400cc and 500cc models.
Bore And Stroke Examples:
Specific bore and stroke dimensions vary by engine size (e.g., 300cc vs. 500cc models), detailed in the manual.
Typical Displacement Range:
250cc to 500cc
Horsepower And Torque Range:
Horsepower output typically ranged from approximately 20 HP for smaller engines to over 35 HP for larger 500cc models. Torque figures also vary significantly. Exact specs are in manual.
Carburetion:
Mikuni carburetors were common across many models, requiring precise adjustment and maintenance for optimal performance.
Fuel Pump Type:
Mechanical or electric fuel pumps depending on model and engine configuration.
Typical Wheelbase Range:
Approximately 48-50 inches, varying by model
Ground Clearance Range:
Typically 8-12 inches, depending on model and tire size.
Typical Dry Weight Range:
Approximately 500-650 lbs, depending on model and drivetrain (2x4 vs. 4x4)
Towing Capacity Range:
Towing capacity varied, often rated around 650-1500 lbs, depending on the model and its intended use. The manual will specify for each model.
Oil Change Interval Engine:
Typically every 50-100 operating hours or annually, depending on usage and specific model recommendations. Manual will detail exact intervals.
Pvt Belt Inspection:
Regular inspection for wear and damage, typically recommended every 50 operating hours. Replacement based on wear indicators.
Brake Fluid Flush:
Recommended every 12-24 months or as needed based on fluid condition and water absorption.
Engine Oil Type:
SAE 5W-30 or 10W-40 synthetic or conventional ATV-specific engine oil (refer to manual for exact grade and API service category).
Gearcase Lubricant:
Typically SAE 80W-90 hypoid gear lubricant for differentials and gearcases. Manual specifies exact types and capacities.
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water for liquid-cooled models.
Pvt Drive Clutch Grease:
Specific high-temperature, water-resistant grease for drive clutch rollers and bushings; manual will specify part number and application points.
Common Issues Era:
Early PVT belt wear, carburetor jetting issues in varying altitudes, minor electrical connector corrosion, and some specific engine seal leaks are commonly reported issues for this generation.
Maintenance Recommendations:
Regularly cleaning air filters, checking spark plug condition, inspecting brake pads, and ensuring PVT belt is free from debris are crucial.
Cooling System Maintenance:
Emphasis on checking radiator fins for blockage and ensuring proper coolant level and mixture for liquid-cooled engines.
Polaris Heritage:
Polaris Industries has a long history dating back to 1954, initially known for snowmobiles and later expanding into ATVs and powersports vehicles.
Evolution 1996-1998:
This era saw Polaris solidify its position in the ATV market, with models like the Sportsman and Scrambler becoming popular. Improvements focused on engine performance, suspension, and the introduction of their PVT system.
Specific Model Introductions:
Key models introduced or refined during this period include the Sportsman 500, Scrambler 500, and various iterations of the Trail Blazer, Trail Boss, and Xplorer lines.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
