Polaris Magnum 2x4 User manual

LRRIS
InDUSTRIES Inc:.
ATV AND LIGHT UTILITY VEHICLE
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 and be familiar with procedures
before starting the work. Cleanliness of parts and tools as well as the work area
is of primary importance.
All references to left and right side of the vehicle are from the operator's perspective when seated
in a normal
riding position.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 1996-1998 model Polaris ATVs and Light Utility Vehicles. The section index
tabs enable the user to quickly locate the 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.
At the time of publication all information contained
in this manual was current. However, all materials and
specifications are subject to change without notice.
Comments or suggestions about this manual may
be directed to: Polaris Industries Inc., Service Publications
Supervisor, 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078.
1996-1998 Service Manual Volume II Part No. 9913680
1998 Service Manual Update Part No. 9914752
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 ATIENTIONI BECOME ALERTI YOUR SAFETY IS INVOLVED!
A DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystand-
er or person inspecting or servicing the ATV.
A WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, by-
stander or person inspecting or servicing the ATV.
A CAUTION indicates special precautions that must be taken to avoid minor personal injury, or ATV or proper-
ty damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation

Table ofContents
9913680
Chapter 01 .............................. General Information
Chapter 02 ....................................... Maintenance
Chapter 03 ............................................... Engine
Chapter 04 ........................ Fuel System/Carburetion
Chapter 05 ....................... Body/Steering/Suspension
Chapter 06 ........................................ PVT System
Chapter 07 .......................................... Final Drive
Chapter 08 ...................................... Transmission
Chapter 09 .............................................. Brakes
Chapter 10 ............................................ Electrical

CHAPTER 1
GENERAL INFORMATION
Model Identification ........................... 1.1 - 1.1 c
Publications Numbers . . . . . . . . . . . . . . . . . . . . . . .
.. 1.2 -1.2a
Service Videos
............................... 1.2a
Service/Information Bulletin
Index. . . . . . . .. . . . . .. 1.3 -1.3b
Paint Codes
................................. 1.4 -1.4b
Model Specifications, 1996 1.5 -1.8
Model Specifications, 1997
.................... 1.8a -1.8d
Model Specifications, 1998
.................... 1.8e -1.8h
Standard Torque Specifications. . . . . . . . . . . . . . .
.. 1.9
Decimal Equivalent Chart . . . . . .. . . . . . . . . . . . . .
.. 1.10
Conversion Table . . . . . . . . . . . . . . . .. . . . . . . . . . . .. 1.11
Tap Drill Charts. . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. 1.12
Warranty
.................................... 1.13
Service Tips
................................. 1.14
Glossary of Terms
............................ 1.15 -1.17
Tool Ordering Information ..................... , 1.18
Routing Diagrams
............................ 1.19 -1.24

GENERAL INFORMATION
Model Identification
Engine Serial Number Location
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This
information can be found on the sticker applied to the manual starter recoil housing. An additional number is
stamped
in one of the following locations:
• 4 stroke models -center top of crankcase beneath the cylinder coolant elbow
• 2 stroke liquid cooled models -center top of crankcase beneath the carburetor mounting flange
• 2 stroke air cooled models -top of crankcase near right side of cylinder
Machine Model Number and Serial Number Location
The machine model number and serial number are im-
portant for vehicle identification. The machine model
number
is located on the frame on the left side of the
vehicle near the
oil tank. Depending on model, the Se-
rial number will be stamped into the frame in one of the
following locations:
• On the right side of the vehicle in front
of the shift selector box (A). (1996)
• Under the seat on the upper shock
mount cross member (8) (1996)
• On the right hand frame rail (C) near
the air box. (1997)
• On the left hand lower frame rail (D)
near the rear A-arm mount.
(199B-Current)
Transmission 1.0. Number Location
Transmission model and serial numbers are located
on top of the transmission case below the shifting bell-
cranks.
Carburetor 1.0. Number Location
The carburetor 1.0. number is in one of the following
locations:
4 stroke models -right side center of
the carburetor body
• 2 stroke models -right side of carbu-
retor body near choke plunger boss
Polaris Industries Inc.
1.1
VIN Location -1996
VIN Location - 1996/1997
VIN Location -199B-Current
Example
Mod :ffl 13411571
Ser #t 96-1Q273
Transmission 1.0. Numbers
5/98

GENERAL INFORMATION
Model Identification
1996 Model Identification
The machine model and serial number must be used with any correspondence regarding service or repair.
1996 Machine Model Number Identification
W 96 81
MOD EL ATV or Light Utility vehicle/- T -i~
NUMBERS Year Designation Basic Chassis Engine Designation
Designation
1996 Engine Designation Numbers 1996 Chassis Designation Numbers
27 ........... 250 75
.......... Magnum 2x4
30 ........... 300 78
.......... Trail Blazer / Scrambler
40
........... 400 80
.......... Sportsman 4x4
44
........... 425 81 .......... Magnum 4x4
50 ........... 500 85
.......... Trail Boss / Sport
87 .......... 400 6x6 / Magnum 6x6
91 .......... Xplorer 300 / Xplorer 400
92 .......... Sportsman 500
95 .......... Xpress 300 / Xpress 400
5/98
1.1 a Polaris Industries Inc.

GENERAL INFORMATION
Model Identification
Vehicle Identification Number (1997 and Later Model Years)
1997 to Current ATVs and Light Utility Vehicles have a 17 digit Vehicle Identification Number (VIN). The VIN is
organized as follows: Digits 1·3: World Manufacturer Identifier. For Polaris ATVs, this is
4XA Digits 4-9: Vehicle
Descriptor Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, drive
type, engine type, and emissions equipment. The VIN number and the model number must be used with any
correspondence regarding service or repair.
World Mfg. ID
Vehicle Descriptor Vehicle Identifier
1997-Current 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17
4 X A B A 3 8 C 0 V 2 0 0 0 0 0 0
VIN Number
I
...
T
,;
I Emissions
Body Style I
~II
Engine MJdel I
Year
Individual Serial No.
Powertrain Check Digit Plant No.
Vehicle Identification Number I Model Number Key
Body Style Powertrain Engine Emissions Ogtions
A=Gen II
A=2x4 chain 25:::EC25PF(250cc) A=Approved by CARB* A=Std
B=Gen III C=4x4 chain 28=EC28PF(300 cc) C=Non CARB* Approved B=1st
Color Option
C=Gen IV D=4x4 shaft 38=EC38PL(400 cc) D=Norway
E=6x6 chain 42=EH42PL (425 cc) E=Sweden
50=EH50PL (500 cc)
*CARB = California Air Resources Board
Year I Letter Identification
The tenth digit of a 17 digit VIN is the model year of the vehicle. Example: W = 1998; X = 1999 etc. Refer to the
listing below.
V 1997
W 1998
X 1999
Y 2000
1997 to Current Model Numbers
The model year is also listed in the model number. The last 4 digits in the model number correspond to digits
4 through 8 of the Vehicle Identification Number (VIN).
Machine Model Number Identification
W;:;;ATV or Light ___ W 9 8 CH50A B Option Indicator
Utility Vehicle --- ~' .. .
Year Designation
./ Last 5 M~el # Digits=Digits 4-8 of VIN
5/98
1.1 b Polaris Industries Inc.

GENERAL INFORMATION
5/98
1.1 c Polaris Industries Inc.

1996 Publication Numbers
Model Model No.
Trail Blazer W967827
Trail Boss W968527
Xplorer 300 W969130
Xpress 300 W969530
Sport W968540
Scrambler 4x4 W967840
Xpress 400 W969540
Xplorer 400 W969140
Sportsman 4x4 W968040
4006x6 W968740
Magnum 2x4 W967544
Magnum 4x4 W968144
Magnum 6x6 W968744
Sportsman 500 W969244
1997 Publication Numbers
Model Model No.
Trail Blazer W97BA25C
Trail Boss W97AA25C
Xplorer 300 W97CC28C
Xpress 300 W97CA28C
Sport 400 W97BA38C
Scrambler 4x4 W97BC38C
Xpress 400 W97CA38C
Xplorer 400 W97CC38C
Sportsman 4x4 W97AC38C
4006x6 W97AE38A
Magnum 2x4 W97AA42A
Magnum 4x4 W97AC42A
Magnum 6x6 W97AE42A
Sportsman 500 W97CH50A
Xplorer 500 W97CD50A
Scrambler 500 W97BC50A
Polaris Industries Inc.
Owner's Manual PN
9913584
9913506
9913332
9913327
9913584
9913519
9913327
9913511
9913414
9913516
9913512
9913512
9913522
9913269
Owner's Manual
9914011
9914056
9913980
9913959
9914011
9913988
9913959
9913974
9913966
9913917
9914069
9914069
9914074
9913998
9914134
9913988
1.2
GENERAL INFORMATION
Publications
Parts Manual PN 1996 Parts Micro
Fiche Set
PN
9913586 9913433
9913588
9913590
9913592
9913586
9913582
9913592
9913598
9913594
9913596
9913603
9913605
9913607
9913609
Parts Manual , 997Parts Micro
Fiche Set
PN
9914012 9914645
9914057
9913981
9913960
9914012
9913989
9913960
9913975
9913967
9914081
9914070
9914083
9914075
9913999
9914135
9914307
5/98

GENERAL INFORMATION
Publications
1998 Publication Numbers
Model Model No.
Trail Boss W98AA25C
Trail Blazer W98BA25C
Xpress 300 W98CA28C
Xplorer 300 W98CC28C
Sport 400 W98BA38C
Scrambler 400 W98BC38C
Xplorer 400 W98CC38C
Magnum 2x4 W98AA42A
Magnum 4x4 W98AC42A
Scrambler 500 W98BC50A
Sportsman 500 W98CH50A(&AB)
Big Boss 500 6x6 W98AE50A
DESCRIPTION
Owner's
Manual
9914659
9914659
9914659
9914659
9914659
9914659
9914659
9914659
9914659
9914659
9914659
9914720
1995-1996 Magnum and Sportsman 500 Service Manual
1996 ATV Service Manual Volume
II
1998 ATV Service Manual Vol. II Update
Owner's Parts Parts
Manual Manual Microfiche
Supplement
9914530 9914531 9914532
9914530 9914546 9914547
9914525 9914536 9914537
9914525 9914526 9914527
9914545 9914723 9914724
9914722 9914725 9914726
9914540 9914541 9914542
9914520 9914552 9914553
9914721 9914521 9914522
9914498 9914499 9914501
9914570 9914571 9914572
N/A 9914639 9914640
PART NUMBER
9913681
9913680
9914752
SERVICE TRAINING VIDEOS
VIDEO TITLE PART NUMBER DESCRIPTION
Magnum 4-Stroke Introduction 9912996 Includes 4 Stroke theory of operation, engine removal,
disassembly, and assembly techniques, along with and
general tech-tips.
Ignition System Diagnostics 9913533 Describes all current Polaris ignition systems. Provides
working knowledge of ignition system theory and diagnostics.
Charging System Diagnostics 9913278 Describes
all current Polaris charging systems. Provides work-
ing knowledge
of charging system theory and diagnostics.
Polaris Variable Transmissions 9913987 Theory, disassembly, assembly and troubleshooting of the
(PVT) Polaris PVT system.
Fuels and Fuel Delivery 9914393 Describes fuel properties including octane and vapor pres-
sure; fuel mixture and burn characteristics; VM and
CV car-
buretor theory and adjustments.
5/98 1.2a Polaris Industries Inc.

GENERAL INFORMATION
Service Bulletin Index
Service/Information Bulletins - By Bulletin Number
ATV-94-0B 1995 Scrambler -Oil line may contact exhaust head pipe
ATV-94-09 1994400 ATVs and 1995 Xplorer, Sportsman, and 400 6X6 -Poor fuel economy and hesitation
ATV-94-10
ATV-95-01
ATV-95-02
ATV-95-03
ATV-95-04
ATV-95-05
ATV-95-06
ATV-95-07
ATV-95-0B
ATV-95-09
ATV-95-10
ATV-95-11
ATV-95-12
ATV-95-13
ATV-95-14
ATV-95-15
ATV-95-16
ATV-95-17
ATV-95-1B
ATV-95-19
ATV-95-20
ATV-95-21
ATV-95-22
ATV-96-01
ATV-96-02
ATV-96-03
ATV-96-04
ATV-96-05
ATV-96-06
ATV-96-07
ATV-96-0B
ATV-96-09
ATV-96-10
ATV-96-11
ATV-96-12
ATV-96-13
ATV-96-14
ATV-96-15
ATV-96-16
ATV-97-01
ATV-97-02
ATV-97-03
1995 Scrambler -Some brake calipers may rub on inside of tire rim
1995 Scrambler -Loose clamp on carburetor boot
1995 Xplorer 4x4, Sportsman -Front hub oil leak
1995 Xplorer 4x4 -Incorrect speedometer angle drive
1995 Scrambler -Headlight wiring reversed
1995 Magnum 2x4, Magnum 4x4 -Engine oil
in air box
1995 Scrambler 4x4 -Revised carburetor jetting
1995 Models Equipped with Auxiliary Brake -Brake inspection and adjustment procedure
1995 Scrambler 4x4 -Missing lower front
bumper bolts
1995 Scrambler 4x4 -Incorrect sprocket guard spacer
1995 Scrambler 4x4 -Front brake lines
may rub against CV joint boot
1995 Magnum 2x4, Magnum 4x4 -Oil tank vent fitting restricted
All 1995 Models -Transmission lubricant expelled through vent line
All 1995 Models (exc. Scrambler, Xplorer, 6x6 -Aux. brake arm may contact right footrest
All 1995 All Wheel Drive Models -Faulty Gear Selector Switches
1995 Scrambler -Headlight Bulb May Fall Out Of Socket
1995 Magnum 2x4 and 4x4 -Rich Condition/Plug Fouling Checklist
AI! 1996 -Synthetic Chaincase Lubricant Recommended for all 1996 Models
1996 Sport -Loose Headlight Mounting Screws
1995 Xplorer, 400 2x4, Sport, Scrambler, 6x6 -Idle Speed Adjustment on 1995400 cc ATVs
1996 Scrambler, Sport 400L -Incorrect Carburetor Jetting Chart in Owner's Manual
1996 Scrambler -Water May Freeze in Oil Pump Housing
1996 Xplorer 400L, Xpress 300, Sportsman 500 -Plow Blade Mounting Kit Applications
1996 Trail Boss; Magnum 4x4 -Water Leaks at Inner PVT Cover
1996 Sportsman 500 -Oil Tank Vent Hose Routing
1996 Sportsman 500 -Loose Rear Drive Shaft Retaining Bolts
1996 Sportsman 500; Magnum 2x4; 4x4; 6x6 -Improved Seat Fit For 1996 ATVs
1996 Gen IV models with rear rack extender kit. Flag mount not functional w/ rack extender.
1996 Sport, Scrambler -Brake Line Retention Strap May Be Missing
1996 Sport, Scrambler -Exhaust Muffler Restricted
1996 All Except
Tr. Blazer, Tr. Boss -Cooling Fan Motors May Be Damaged By Water.
1996 Sportsman 500 Hose Clamp On Coolant Line May Contact Fuel Filter
1996 Sportsman 500 -Engine Overheating due to fan placement and debris
in the shroud
1995/ 19964 Stroke Models Moisture May Freeze In Oil Tank Vent Line
1996/1997 Xlorer and Xpress 300s -Revised Oil Pump Bleeding Procedure
1996 Sportsman 500; 1997 Sportsman and Xplorer 500 -Rear Brake Noise / Floating Disc Kit
1997 Magnum 6x6 -Fuel Tank Vent Line Routed Incorrectly
1997 Sportsman 500 -Pressure Relief Slit Missing Form Oil Tank Vent Line
1997 Scrambler 400 / 1997 Scrambler 500 -Brake Lines May Contact CV Boot or Clamp
1995 and 19964 Stroke Models -Oil Tank Breather Modification For Cold Temperatures
1997 Sportsman and Xplorer 500 -Rear Brake Disc Hub Bolt Torque Procedure
1997 Sportsman and Xplorer 500 Revised Serial Number Range For ATV-97-02
Polaris Industries Inc. 1.3 5/98

GENERAL INFORMATION
Bulletin Index -1996 By Model
1996 Model Bulletin #
ALL 1996 MODELS ATV-96-11
1996 Sportsman
SOO
ATV-96-13
ATV-96-10
ATV-96-09
ATV-96-0B
ATV-96-05
ATV-96-04
ATV-96-03
ATV-96-02
ATV-9S-22
1996 Magnum 6x6 ATV-96-0B
ATV-96-04
1996 Magnum 4x4 ATV-96-0B
ATV-96-04
ATV-96-01
ATV-9S-17
1996 Magnum 2x4 ATV-96-0B
ATV-96-04
19964006x6
ATV-96-0B
ATV-95-17
1996 Sportsman 4x4 ATV-96-0B
ATV-9S-17
1996 Scrambler ATV-96-0B
ATV-96-07
ATV-96-06
ATV-9S-21
ATV-95-20
1996400 Xplorer ATV-96-0B
ATV-9S-22
ATV-95-17
1996 400 Xpress ATV-96-0B
1996 Sport ATV-96-0B
ATV-96-07
ATV-96-06
ATV-9S-20
ATV-9S-1B
1996300 Xplorer ATV-96-12
ATV-96-0B
ATV-9S-17
1996 300 Xpress ATV-96-12
ATV-96-0B
ATV-9S-22
1996 Trail Boss ATV-96-01
1996 Trail Blazer ATV-9S-1B
5/98
Type Notes
Information Moisture May Freeze
In Oil Tank Vent Line
Information Rear Brake Noise / Floating Disc Kit
Service Engine Overheating
Information Hose Clamp May Contact Fuel Filter
Service Cooling Fan Motor May Be Damaged By Water
Service Flag Mount Not Functional
Information Poor Seat Fit
Information Loose Rear Drive Shaft Retaining Bolts
Service Oil Tank Vent Hose Routing
Information Plow Blade Mounting Kit Applications
Service Cooling Fan Motor May Be Damaged By Water
Information Poor Seat Fit
Service Cooling Fan Motor May Be Damaged By Water
Information Poor Seat Fit
Service Water Leaks at Inner PVT Cover
Information Synthetic Chaincase Lubricant Recommended
Service Cooling Fan Motor May Be Damaged By Water
Information Poor Seat Fit
Service Cooling Fan Motor May Be Damaged By Water
Information Synthetic Chaincase Lubricant Recommended
Service Cooling Fan Motor May
Be Damaged By Water
Information Synthetic Chaincase Lubricant Recommended
Service Cooling Fan Motor May Be Damaged By Water
Information Exhaust Muffler Restriction
Service Brake Une Retention Strap May Be Missing
Information Water May Freeze In Oil Pump Housing
Information Incorrect Jetting Chart In Owners Manual
Service Cooling Fan Motor May Be Damaged By Water
Information Plow Blade Mounting Kit Applications
Information Synthetic Chaincase Lubricant Recommended
Service Cooling Fan Motor May Be Damaged By Water
Service Cooling Fan Motor May Be Damaged By Water
Information Exhaust Muffler Restriction
Service Brake Line Retention Strap May Be Missing
Information Incorrect Jetting Chart
In Owners Manual
Service Loose Headlight Mounting Screws
Service Revised Oil Pump Adjustment Procedure
Service Cooling Fan Motor May Be Damaged By Water
Information Synthetic Chaincase Lubricant Recommended
Service Revised Oil Pump Adjustment Procedure
Service Cooling Fan Motor May Be Damaged By Water
Information Plow Blade Mounting Kit Applications
Service Water Leaks at Inner PVT Cover
Service Loose Headlight Mounting Screws
1.3a Polaris Industries Inc.

1997 Model
All 1997 Models
Sportsman 500
Xplorer 500
Scrambler 500
Magnum 6x6
Magnum
4x4
Magnum 2x4
Big Boss 6x6 400L
Sportsman 400L
Xplorer 400L
Xpress 400L
Scrambler 400L
Sport 400L
Xplorer 300
Xpress 300
Trail Blazer ES
Trail Boss 250
1998 Model
All 1998 Models
Big Boss 500 6x6
Sportsman 500
Scrambler 500
Magnum 4x4
Magnum 2x4
Xplorer 400
Scrambler 400
Sport 400
Xplorer 300
Xpress 300
Trail Blazer
Trail Boss
5/98
Bulletin #
ATV-97-03
ATV-97-02
ATV-96-15
ATV-96-13
ATV-97-03
ATV-97-02
ATV-96-13
ATV-96-16
ATV-96-14
ATV-96-16
ATV-96-12
ATV-96-12
Bulletin #
GENERAL INFORMATION
Service Bulletin Index - 1997/1998 By Model
Type Notes
Service Loose Pins And Locking Hub For Rear Disc Brake
Revised Serial Number Range For ATV-97-02
Service Rear Brake Disc Hub Bolt
Torque Procedure/Hub Kit
Service Pressure Relief Slit Missing From
Oil Tank Vent Line
Service Rear Brake Noise
Service Loose
Pins And Locking Hub For Rear Disc Brake
Revised Serial Number Range For ATV-97-02
Service Rear Brake Disc Hub Bolt Torque Procedure/Hub
Kit
Service Rear Brake Noise
Service Brake Line May Contact CV Boot Or Clamp
Service Fuel Tank Vent Line Routing
Service Brake Line May Contact CV Boot
Or Clamp
Service Revised Oil Pump Adjustment Procedure
Service Revised Oil Pump Adjustment Procedure
Type Notes
No bulletins issued as of 4/24/1998
1.3b Polaris Industries Inc.

Model Item Color
400L Springs Purple Velvet
Rims Brushed Aluminum
Trail Blazer Springs Fire Red
Rims Bright White
Trail Boss Springs Aqua Marine
Rims Bright White
Rack Aqua Marine
Scrambler Springs Lavender
Rims Bright White
Xpress 300 Springs Bonnie Blue
Rims Brushed Aluminum
Xpress 400 Springs Blue Green
Rims Brushed Aluminum
Xplorer 300 Springs Eddie
B. Green
Rims Brushed Aluminum
Xplorer Springs Fire Red
Rims Brushed Aluminum
Magnum 2x4 Springs Eddie
B. Green
Rims Brushed Aluminum
Racks Steel Gray
Magnum 4x4 Springs Bonnie Blue
Rims Brushed Aluminum
Racks Bonnie Blue
Sportsman 500 Springs Black
Rims Black
Racks Black
Magnum 6x6 Springs Eddie
B. Green
Rims Brushed Aluminum
Rack Eddie
B. Green
Box Eddie
B. Green
4006x6 Springs Eddie
B. Green
Rims Brushed Aluminum
Rack Eddie
B. Green
Box Eddie
B. Green
GENERAL INFORMATION
1996 Pai nt Codes
Raw Material No.
PPG Ditzler No.
8520160 51467
N/A N/A
8520149 72060
8520153 2185
8520159 46975
8520153 2185
8520159 46975
8520157
N/A
8520153 2185
8520148 12908
N/A N/A
8520202
N/A
N/A N/A
8520150 44931
N/A N/A
8520149 72060
N/A N/A
8520150 44931
N/A N/A
8520151
N/A
8520148 12908
N/A N/A
8520148 12908
8520147 9440
8520147 9440
8520147 9440
8520150 44931
N/A N/A
8520150 44931
8520150 44931
8520150 44931
N/A N/A
8520150 44931
8520150 44931
Order direct from Midwest Industrial Coatings (612-934-8252). Mix as directed.
Polaris Industries Inc. 1.4 10/96

GENERAL INFORMATION
1997 Paint Codes
MODEL PAINTED PART
Trail Blazer Springs
Rims
Trail Boss Springs
Rims
Rack
Sport Springs
Rims
Xpress 300 Springs
Rims
Xpress 400 Springs
Rims
Xplorer 300 Springs
Rims
Xplorer 400 Springs
Rims
Xplorer 500 Springs
Rims
Scrambler 4x4 Springs
Rims
Scrambler 500 Springs
Rims
Sportsman 4x4 Springs
Rims
Rack
Sportsman 500 Springs
Rims
4006x6
Springs
Rims
Rack
Box
Magnum 2x4 Springs
Rims
Rack
Magnum 4x4 Springs
Rims
Rack
Magnum 6x6 Springs
Rims
Rack
Box
Big Boss 6x6 Springs
Rims
Rack
Box
10/96
COLOR
DESCRIPTION
Fire Red
Bright White
Aqua Marine
Bright White
Aqua Marine
Purple Velvet
Brushed Aluminum
Bonnie Blue
Brushed Aluminum
Blue-green
Brushed Aluminum
Eddie Bauer Green
Brushed Aluminum
Eddie Bauer Green
Brushed Aluminum
Screamin' Yellow
Brushed Aluminum
Lavender
Bright White
Screamin' Yellow
Brushed Aluminum
Black
Black
Black
Black
Black
Eddie Bauer Green
Brushed Aluminum
Eddie Bauer Green
Eddie Bauer Green
Fire Red
Brushed Aluminum
Black
Eddie Bauer Green
Brushed Aluminum
Eddie Bauer Green
Eddie Bauer Green
Brushed Aluminum
Eddie Bauer Green
Eddie Bauer Green
Eddie Bauer Green
Brushed Aluminum
Eddie Bauer Green
Eddie Bauer Green
1.4a
DITZLER POLARIS
NUMBER NUMBER
72060 8520149
2185 8520153
46975 8520159
2185 8520153
46975 8520159
51467 8520160
N/A N/A
12908 8520148
N/A N/A
N/A
8520202
N/A N/A
44931 8520150
N/A N/A
44931 8520150
N/A N/A
N/A
8520241
N/A N/A
N/A
8520157
2185 8520153
N/A
8520241
N/A
N/A
9440 8520147
9440 8520147
9440 8520147
9440 8520147
9440 8520147
44931 8520150
N/A N/A
44931 8520150
44931 8520150
72060 8520149
N/A N/A
9440 8520147
44931 8520150
N/A N/A
44931 8520150
44931 8520150
N/A N/A
44931 8520150
44931 8520150
44931 8520150
N/A
N/A
44931 8520150
44931 8520150
Polaris Industries Inc.

1998 Paint Codes
Model Item Color
Big Boss 500 6X6 Springs Eddie B Green
Rims Aluminum
Sportsman 500 (Opt.
1)
Springs Black
Rims Black
Sportsman 500 (Opt. 2) Springs Bonnie Blue
Rims Aluminum
Scrambler 500 Springs Black
Rims Aluminum
Magnum 4X4 Springs Fire Red
Rims Aluminum
Racks Eddie
B. Green
Magnum 2X4 Springs Black
Rims Aluminum
Racks Black
Xplorer 400L Springs Burnished Brown
Rims Aluminum
Scrambler 400 Springs Fire Red
Rims Bright White
Sport 400L Springs Purple Velvet
Rims Bright White
Xplorer 300 Springs Fire Red
Rims Aluminum
Xpress 300 Springs Bonnie Blue
Rims Aluminum
Trail Blazer Springs Fire Red
Rims Bright White
Trail Boss Springs Fire Red
Rims Bright White
Rack(s) Fire Red
GENERAL INFORMATION
1998 Paint Codes
Raw Material No. PPG Ditzler No.
8520150 (P195) 44931
(P117)
8520147 (P067) 9440
8520147 (P067) 9440
8520148 (P157) 12908
(P117)
8520147 (P067) 9440
(P117)
8520149 (P093) 72060
(P117)
8520150 (P195) 44931
8520147 (P067) 9440
(P117)
8520147 (P067) 9440
P218
(P117)
8520149 (P093) 72060
8520153 (P133) 2185
8520160 (P194) 51467
8520153 (P133) 2185
8520149 (P093) 72060
(P117)
8520148 (P157) 12908
(P117)
8520149 72060
8520153 (P133) 2185
8520149 (P093) 72060
8520153 (P133) 2185
8520149 (P093) 72060
Order direct from Midwest Industrial Coatings (612-934-8252). Mix as directed.
Frames (Medium Black) P067 / 8520147 / Ditzler 9440
Polaris Industries Inc. 1.4b 5/98

1997 Model (Gen II, III, or IV) Trail
Boss (II) Trail Blazer ES (III)
Model Number W97AA25C W97BA25C
Height
44/1
46/1
Width
44/1
46.5/1
Length 73.2" 74.5"
-.~ .. ,.~
.- ,
'"~
WheelBase
49.75/1 49.75/1
Seat Height
33/1 34/1
Ground Clearance
5.5/1
6/1
Weight 4251bs. 4201bs.
Turning Radius (Unloaded)
60/1 60/1
Front Suspension Travel
6.25/1
6.25/1
(McPherson Strut)
.....
-~- - .~~-~----"". ~
[---.-
Rear Suspension
8.5/1 8.5/1
Front Tires 23x7x10 23x7x10
Rear Tires 22x11x10 22x11x10
Center Tires N/A N/A
FronVRear/Center Tire
PSI
4/3 4/3
-_.
~ .. -.
Front Brake
~~~ Disc Hydr. Disc
Rear Brake Hydr. Disc Hydr. Disc
Auxiliary Brake Mechanical Mechanical
Fuel Capacity (U.S. Gallons) 4 4
Oil Capacity (U.S. Quarts) 2 2
Gearcase Oil Capacity (oz) 16 16
Main Head Light 12V 60/60W 12V 55W
Grill Mounted Lights N/A N/A
Tail Light 12V/8.26W 12V/8.26W
- n_. __ .
Gear Box F/R/N F/R/N
Gear Reduction Low
N/A
N/A
Drive Type 520 O-ring 520
a-ring
-" .. ~.
Final Drive 12/4288P 12/4288P
Center Drive N/A N/A
Front Drive N/A
N/A
Axle to Axle
N/A
N/A
Displacement 244cc 244cc
Engine Model Number EC25PFE08 EC25PFE09
Compression Ratio (Effective) 6.1/1
6.1/1
Bore and Stroke 72x60 72x60
Spark Plug BR8ES (NGK) BR8ES (NGK)
Alternator Output 150W 150W
Timing Degrees 25@3000 25@3000
Carburetion (1) VM30SS (1) VM30SS
Main Jet 145 130
Pilot Jet 40 40
Jet Needle 5DP7-3 5DP7-3
Needle Jet 0-4 (169) 0-4 (169)
r. •• t::l\AI::I\I
2.0 2.0
-J
Air Screw/Pilot Screw 1 Turn 1 Turn
* See Owner's Manual for rack load recommendations and restrictions.
Polaris Industries Inc. 1.8a
GENERAL INFORMATION
Specifications 1997
Xpress 300 (IV)
Xplorer 300 (IV)
W97CA28C W97CC28C
45.5"
45.5/1
46/1
46/1
78.5"
81/1
-----
49.75/1
49.75/1
33"
34/1
6.75/1
6/1
5121bs. 5671bs.
60/1
57"
6.25/1 6.25/1
8.5"
8.5/1
23x7x10 23x7x10
24x11 x1 0 24x11x10
N/A N/A
4/3 4/3
Hydr. Disc Hydr. Disc
Hydr. Disc Hydr. Disc
Mechanical Mechanical
4 4
2 2
20 20
N/A N/A
2, 12V 30/30W
2, 12V 30/30W
12V/8.26W 12V/8.26W
HI/LO/R/N HI/LO/R/N
6.64/1
6.64/1
520 O-ring 520 a-ring
13/3886P 13/4088P
N/A
11/2270P
N/A
12/2264P
N/A N/A
283cc 283cc
EC28PFE01 EC28PFE01
6.1/1 6.1/1
74.5x65 74.5x65
BR8ES (NGK) BR8ES (NGK)
150W 150W
25@3000 25@3000
--~~ .-
(1) VM30SS (1) VM30SS
155 155
40 40
..
5DP7-3 5DP7-3
0-4 (169) 0-4 (169)
2.0 2.0
1.5 Turn 1.5 Turn
5/98

GENERAL INFORMATION
Specifications 1997
1997 Model (Gen II, III, or IV)
Model Number
Height
Width
--._-
Length
Wheel Base
Seat Height
Ground Clearance
Weight
Turning Radius (Unloaded)
Front Suspension Travel
(McPherson Strut)
Rear Suspension
Front Tires
Rear Tires
Center Tires
Front/Rear/Center Tire
PSI
Front Brake
Rear Brake
Auxiliary Brake
Fuel Capacity (U.S. Gallons)
Oil Capacity (U.S. Quarts)
Coolant Capacity (Quarts / Liters)
Gearcase Oil Capacity (oz)
Engine Counter Balancer Oil
Capacity (10W/30)
Main Head Light
Grill Mounted Lights
Tail Light
Gear Box
,.
Gear Reduction Low
Drive Type
Final Drive
Center Drive
Front Drive
Axle to Axle
Displacement
Engine Model Number
Compression Ratio (Effective)
Bore and Stroke
Spark Plug
Alternator Output
Timing Degrees
Carburetion
Main Jet
Pilot Jet
Jet Needle
Needle Jet
Cutaway
Air Screw/Pilot Screw
r-'
Xpress 400 (IV)
W97CA38C
47.5/1
46"
78.5"
49.75"
33"
6.75/1
5431bs.
60"
6.25"
8.5"
23x7x10
24x11x10
N/A
4/3
Hydr. Disc
Hydr. Disc
Mechanical
4
2
2.25/2.16
20
100cc
12V 60/55W
Accessory
12V/8.26W
HI/LO/R/N
6.64/1
520 O-ring
13/3484P
N/A
N/A
N/A
378.7cc
EC38PLE06
6.9/1
83x70
BR8ES (NGK)
200W
23.5@3000
(1) VM34SS
200
30
6CEY6-3
0-6 (480)
1.5
1.5 Turn
Xplorer 400 (IV)
W972238C
47.5"
46"
81"
49.75
11
34"
7.375"
5701bs.
65/1
6.25/1
8.5"
25x8x12
25x12x10
N/A
4/3
Hydr. Disc
Hydr. Disc
Mechanical
4
2
2.25/2.16
20
100cc
12V 60W
2, 12V 35W
12V/8.26W
HI/LO/R/N
6.64/1
520 O-ring
13/3484P
11/2270P
13/2264P
N/A
378.7cc
EC38PLE06
6.9/1
83X70
BR8ES (NGK)
200W
23.5@3000
(1) VM34SS
200
30
6CEY6-3
0-6 (480)
1.5
1.5 Turn
* See Owner's Manual for rack load recommendations and restrictions.
5/98 1.8b
Sport 400 (III) Sportsman 4x4 (II)
W97BA38C W97AC38C
47/1
46/1
46.5"
46/1
74.5"
77/1
49.75"
49.75/1
33/1
34"
5.5"
6"
4791bs. 5851bs.
60"
65"
6.25/1
6.25/t
8.5"
8.5"
23x7x10 25x8x12
22x11x10 25x12x10
N/A N/A
4/3 4/3
Hydr. Disc Hydr. Disc
Hydr. Disc Hydr. Disc
Mechanical Mechanical
4 4
2 2
2.25/2.16
2.25/2.16
16 20
100cc 100cc
12V 55W 12V 60W
,,~
N/A
2, 12V 35W
12V/8.26W 12V/8.26W
F/R/N HI/LO/R/N
N/A
6.64/1
520 O-ring 520 O-ring
13/3484P 13/3484P
N/A 11/2270P
N/A
13/2264P
N/A N/A
378.7cc 378.7cc
EC38PLE07 EC38PLE06
6.9/1 6.9/1
83x70 83x70
BR8ES (NGK) BR8ES (NGK)
150W 200W
23.5@3000 23.5@3000
(1) VM34SS (1) VM34SS
230 200
35 30
6CEY6-3 6CEY6-3
0-6 (480) 0-6 (480)
1.5 1.5
1.5 Turn 1.5 Turn
Polaris Industries Inc.

1997 Model (Gen II, III, or IV)
Scrambler 4x4 (III)
Magnum 2x4 (II)
Model Number W97BC38C W97AA42A
Height 47"
47/1
Width 45.5" 46.5"
~ngtl 74.5"
77"
Wheel Base
48.5/1
49.75"
Seat Height 33"
33"
Ground Clearance
6/1
5.5"
Weight 4901bs. 5341bs.
Tuming Radius (Unloaded)
60"
60"
Front Suspension Travel
8.5/1
6.25"
(McPherson Strut)
Rear Suspension 8.5" 8.5"
--
Front Tires 23x7x10 23x7x10
Rear Tires 22x11x10 24x11x10
Front/Rear/Center Tire
PSI 4/3 4/3
Front Brake Hydr. Disc Hydr. Disc
Rear Brake Hydr. Disc Hydr. Disc
Auxiliary Brake Mechanical Mechanical
Fuel Capacity (U.S. Gallons) 4 3.5
Oil Capacity (U.S. Quarts) 2 2-
OW40 Engine Oil
Coolant Capacity (Quarts / Liters)
2.25/2.16 2.25/2.16
Gearcase Oil Capacity (oz) 16 20
Engine Counter Balancer Oil 100cc N/A
Capacity (10W/30)
Main Head Light 12V
35/35W 12V 60/60W
Grill Mounted Lights N/A Ace.
Tail Light 12V/8.26W 12V/8.26W
Gear Box F/R/N HI/LO/R/N
Gear Reduction Low N/A 6.64/1
,-
Drive Type 520 O-ring 520 ing
Final Drive 13/3884P
12/3886P
Center Drive 11/2270P N/A
Front Drive 12/2264P N/A
Axle to Axle N/A N/A
Displacement 378.7cc 425cc
Engine Model Number EC38PLE07 EH42PLE01
Compression Ratio (Effective)
6.9/1 9.2/1
Bore and Stroke 83x70 87.9x70
Spark Plug BR8ES (NGK) BKR5ES (NGK)
Alternator Output 150W 200W
Timing Degrees 23.5@3000 30@3500
.. _-".,--
Carburetion (1) VM34SS (1) BST34-CV type
Main Jet 230 140
Pilot Jet 35 40
--
Pilot Air Jet N/A #160
Jet Needle 6CEY6-3 5F81-3
Needle Jet 0-6 (480) P-8
Cutaway 1.5 N/A
Air Screw or Fuel Screw (Tums Out)
1.5 2.5
* See Owner's Manual for rack load recommendations and restrictions.
Polaris Industries Inc. 1.8c
GENERAL INFORMATION
Specifications 1997
Magnum 4x4 (II) Sportsman 500(IV)
W97AC42A W97CH50A
46/1
47"
46/1
46"
77"
7"
49.75" 50.5"
34"
34"
6" 10"
5951bs. 6491bs.
65"
65"
6.25" 6.25"
8.5" 9.5"
25x8x12 25x8x12
25x12x10 25x12x10
4/3 5/5
Hydr. Disc Hydr. Disc
Hydr. Disc Hydr. Disc
Mechanical Mech.
3.5 5.25
2-
OW40 Engine Oil 3
2.25/2.16 2.25/2.16
20 32
N/A N/A
12V 60W 12V 60W
2,12V 35W 2,12V 35W
12V/8.26W 12V 8.26W
HIILO/R/N HIILO/R/N
6.64/1 6.64/1
520 O-ring Shaft
1213886P 3.16:1
11/2270P N/A
11/2268P 2:1
N/A N/A
425cc 498
EH42PLE01 EH50PLE01
9.211 N/A
87.9x70 92x75
BKR5ES (NGK) BKR5ES (NGK)
200W 200W
30@3500 30@3500
(1) BST34-CV type (1) BST34
Cv.., type
140 142.5
40 42.5
#160 #160
5F81-3 5078-3
P-8
P-1
N/A N/A
2.5 2
-- --
5/98