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