Target Audience:
Owners and technicians performing maintenance, repairs, and diagnostics on 1995 Polaris Magnum 2x4 and 4x4 ATVs.
Utility And Recreation:
Positioned as a versatile ATV suitable for both work and play, a hallmark of Polaris's early ATV offerings.
Competitive Landscape 1995:
Polaris competed with other major ATV manufacturers like Yamaha (Big Bear, Kodiak), Suzuki (QuadRunner), Honda (FourTrax), and Kawasaki (Bayou).
Magnum 1995 Highlights:
Reputation for reliability, powerful 2-stroke engine, capable 4x4 system, comfortable ride for its class.
Value For Owner:
Enables owners to perform their own maintenance and repairs, saving money and understanding their ATV better.
Value For Technician:
Provides essential technical data, procedures, and specifications for efficient and accurate servicing.
Systems Covered:
Engine (2-stroke, 300cc and 4x4 models), Drivetrain (2WD/4WD engagement, differentials), Transmission (automatic/CVT), Fuel System (carburetor, fuel pump), Ignition System, Cooling System, Exhaust System, Suspension (front and rear), Steering, Brakes (hydraulic disc), Electrical System (lighting, starting, charging), Chassis, Bodywork, Axles, Bearings
Body And Trim:
Includes procedures for removal, installation, and repair of fenders, body panels, racks, and seat.
Carburetor Overhaul:
Detailed steps for disassembling, cleaning, and reassembling the carburetor, including jetting information.
Procedures Included:
Routine maintenance, preventive maintenance schedules, troubleshooting guides, diagnostic procedures, repair and overhaul instructions, component replacement, torque specifications, wiring diagrams, exploded views, specifications and data, special tool recommendations
Wheel Bearing Replacement:
Instructions for safely removing and installing front and rear wheel bearings.
Steering Component Adjustment:
Tie rod end adjustment, steering post tightness, and related alignment checks.
Technical Depth:
Comprehensive, covering from basic adjustments and fluid changes to complete engine rebuilds, transmission overhauls, and suspension repairs.
Engine Type:
2-Stroke, Single Cylinder, Liquid-Cooled (typical for this era and model range)
Displacement:
Approximately 299cc to 375cc (depending on specific Magnum variant within the 1995 range)
Horsepower Range:
Estimated 20-30 HP (typical for a 2-stroke ATV of this displacement)
Torque Figure:
Estimated 25-35 lb-ft (manual will provide precise figures)
Carburetor Type:
Mikuni VM Series (common for Polaris of this era)
Fuel Type:
Unleaded Gasoline, mixed with 2-stroke oil (premix or injection system)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-Cooled
Exhaust Type:
Expansion Chamber (typical for 2-stroke performance)
Transmission Type:
Automatic Continuously Variable Transmission (CVT) with Hi/Lo range and Reverse
Drive Type:
Shaft Drive (2x4 and 4x4 models)
4Wd System:
On-demand, 4WD engagement (likely Polaris's Lock & Ride or similar system for the era)
Transmission Fluid Type:
Polaris AGRI-Plex Synthetic Gearcase Lube (or equivalent SAE 80W-90 gear oil)
Low Gear Ratio:
Detailed in manual, crucial for low-speed torque and pulling power.
High Gear Ratio:
Detailed in manual, for higher speed cruising.
Length:
Approximately 77-82 inches (1956-2083 mm)
Width:
Approximately 43-46 inches (1092-1168 mm)
Height:
Approximately 44-47 inches (1118-1194 mm)
Dry Weight:
Approximately 500-550 lbs (227-249 kg)
Ground Clearance:
Approximately 8-10 inches (203-254 mm)
Towing Capacity:
Often rated around 1500 lbs (680 kg), manual will confirm.
Wheelbase:
Approximately 50-52 inches (1270-1321 mm)
Front Rack Capacity:
Typically around 50 lbs (23 kg)
Rear Rack Capacity:
Typically around 100 lbs (45 kg)
Braking System:
Hydraulic Disc Brakes (Front and Rear), Foot Operated
Lighting:
Dual Halogen Headlights, Taillight, Brake Light
Tyre Size Front:
22x7-10 or 23x8-10 (common)
Tyre Size Rear:
22x10-10 or 24x11-10 (common)
Frame Construction:
Steel frame, robust construction for off-road use.
4Wd Engagement Mechanism:
Mechanical or electronic activation for 4WD engagement, described in detail within the manual.
Final Drive:
Gearcase (rear differential) and front differential (on 4x4 models).
Oil Injection System:
Many Polaris 2-strokes of this era featured an oil injection system; the manual will detail its operation and maintenance.
Oil Change Interval:
Every 50-100 hours or annually (specifics in manual)
Spark Plug Inspection:
Every 25-50 hours
Air Filter Cleaning:
Every 25-50 hours or as needed based on conditions
Gearcase Oil Change:
Every 100 hours or annually
Engine Oil Type:
Polaris 2-Stroke Oil (or API-TC rated synthetic 2-stroke oil)
Coolant Type:
Ethylene Glycol based antifreeze (typically 50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Common Wear Items:
CVT belt wear, carburetor tuning, starter motor reliability, suspension bushings and ball joints, 2-stroke top-end wear (piston and rings).
Electrical Gremlins:
Degradation of wiring insulation or connectors in older units, impacting lights or ignition.
Suspension Wear:
Kingpin bearings, ball joints, and shock absorber seals are common wear items in high-mileage ATVs.
Fuel Lines:
Cracked or degraded fuel lines requiring replacement.
Carburetor Issues:
Pilot circuit clogging leading to poor idling, main jet issues affecting top-end performance.
Starting Problems:
Can stem from ignition coil, stator, CDI unit, or battery/starter solenoid issues.
Engine Coolant Capacity:
Approx. 1.5 Liters (check manual for exact)
Brand Origin:
Polaris Industries Inc., an American manufacturer founded in 1954, known for snowmobiles and later ATVs.
Magnum Lineage:
The Magnum line was a significant part of Polaris's early ATV success, offering a balance of performance and utility. It evolved from earlier models and paved the way for future Polaris ATV designs.
Magnum Legacy:
The Magnum series represented Polaris's commitment to the utility and recreational ATV market, emphasizing power and durability.
Production Period:
The Magnum model was produced through the 1990s and early 2000s, with the 1995 model year being a key iteration.
