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1998 Polaris Big Boss 500 6x6 Service Repair Manual.pdf
- 1. LRRIS InDUSTRIES Inc:. ATV ANDLIGHT 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.
- 2. UNDERSTANDING SAFETY LABELSAND 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. ACAUTION 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
- 3. Table of Contents 9913680 Chapter01 ..............................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
- 4. CHAPTER 1 GENERAL INFORMATION ModelIdentification ........................... 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
- 5. GENERAL INFORMATION Model Identification EngineSerial 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
- 6. GENERAL INFORMATION Model Identification 1996Model 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 MODEL 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.
- 7. GENERAL INFORMATION Model Identification VehicleIdentification 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.
- 8. GENERAL INFORMATION 5/98 1.1c Polaris Industries Inc.
- 9. 1996 Publication Numbers ModelModel 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
- 10. GENERAL INFORMATION Publications 1998 PublicationNumbers 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.
- 11. GENERAL INFORMATION Service BulletinIndex 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
- 12. 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.
- 13. 1997 Model All 1997Models 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.
- 14. Model Item Color 400LSprings 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 Paint 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
- 15. GENERAL INFORMATION 1997 PaintCodes 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.
- 16. 1998 Paint Codes ModelItem 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
- 17. 1997 Model (GenII, 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::lAI::II 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
- 18. GENERAL INFORMATION Specifications 1997 1997Model (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" 49.7511 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.
- 19. 1997 Model (GenII, 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
- 20. GENERAL INFORMATION Specifications 1997 1997Model (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) Counter Balancer Oil Capacity 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 Pilot Air Jet Jet Needle Needle Jet Cutaway 1--------_.. ... Air Screw Scrambler 500 (III) W97BC50A 47" 45.5" 74.5" 48.5" 33" 6" 5471bs. 60" 8.5" 9.5" 23x7X10 24x11x10 N/A --_. 4/3 Hydr. Disc Hydr. Disc Mech. 3.5 2 2.25/2.16 16 N/A 12V 35/35W N/A 12V 8.26W HIIR/N N/A 520 O-ring 12/38/86P 11/22/70P 11/22/68P N/A 498 EH50PLE02 N/A 92x75 BKR5ES (NGK) 200W 30@3S00 (1) BST34 CV type 125 42.S 160 SD78-3 P-3 N/A ---.. ~-- ...~ 2.0 Xplorer 500(lV) W97CD50A 47" 46" 7" 50.5" 34" 10" 6491bs. 65" 6.25" 9.5" 25x8x12 25x12x10 ..~ .. N/A 5/5 Hydr. Disc Hydr. Disc Mech. 5.25 3 2.25/2.16 32 N/A N/A 2,12V 35W 12V 8.26W HI/LO/R/N 6.64/1 Shaft 3.16:1 N/A 2:1 N/A 498 EH50PLE01 N/A 92x75 BKRSES (NGK) 200W 30@3S00 (1) BST34 CV type 142.5 42.S #160 5078-3 P-1 N/A 2 Turns .. See Owner's Manual for rack load recommendations and restrictions. 5/98 1.8d Magnum 6x6 (II) 400 6x6 (II) W97AE42A W97AE38A 47/1 47/1 46/1 46/1 103/1 103" 75" 75" 34" 34" 5.5" 5.5" 8521bs. 8301bs. 98/1 98/1 6.25" 6.25" 8.5" 8.5" 25x8x12 25x8x12 25x12x10 25x12x10 25x12x10 25x12x10 5/5/5 5/5/5 Hydr. Disc Hydr. Disc Hydr. Disc Hydr. Disc Hydr. Disc Hydr. Disc 3.5 4 2- OW40 Engine Oil 2 2.25/2.16 2.25/2.16 20 20 N/A 100cc (1 OW30) 12V 60W 12V 60W 2,12V 35W 2, 12V 35W 12V/8.26W 12V/8.26W HI/LO/R/N HIILO/R/N 6.64/1 6.64/1 520 O-ring 520 O-ring 1214288P 13/4288P 11/2472P 11/2270P 11/2268P 1212264P 30/30 116P 30/30 116P 425cc 378.7cc EH42PLE01 EC38PLE06 9.2/1 6.9/1 87.9x70 83x70 BKRSES (NGK) BR8ES (NGK) 200W 200W .._-_.- 30@3500 23.5@3000 (1) BST34-CV type (1) VM34SS 140 210 40 30 #160 5F81-3 6DH29-3 P-8 0-6 (480) N/A 1.5 2.5 Turn 1 Turn Polaris Industries Inc.
- 21. 1998 Model (GenII, III, or IV) Trail Boss (II) Trail Blazer (III) Model Number W98AA25C W98BA25C Height, inches (cm) 44/1 (111.8) 46/1 (116.8) Width, inches (cm) 44/1 (111.8) 46.5/1 (118.1) Length, inches (cm) 73.2/1 (185.9) 74.5" (189.2) Wheel Base, inches (cm) 49.75/1 (126.4) 49.75/1 ( 26.4) Seat Height, inches (cm) 33'1 (83.8) 34/1 (86.4) Ground Clearance, inches (cm) 5.5/1 (14.0) 6/1 (15.2) Weight, Dry - Lbs. (Kg) 425 (203.4) 420 Ibs. (199.8) Turning Radius-Unloaded, in. (cm) 60 11 (1S2.4) 60 '1 (152.4) Front Suspension Travel, in. (cm) 6.25/1 (15.9) 6.25'1 (15.9) (McPherson Strut) Rear Suspension, inches (cm) 8.5 '1 (21.6) 8.5" (21.6) Front Tires 23x7x10 23x7x10 Rear Tires 22x11x10 22x11x10 Center Tires N/A N/A 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 4 Oil Capacity (U.S. Quarts) 2 2 Cooling System Capacity (Qt'/Liter) N/A N/A Gearcase Oil Capacity (oz) 16 16 I - - - - -..-~--- Engine Counter Balancer Oil N/A N/A Capacity (10W/30) Main Head Light 12V 60/60W 12V 55W Grill Mounted Lights N/A N/A Tail Light 1Brake Light (Watts) 12V - 8.26/26.9 12V - 8.26/26.9 Gear Box F/R/N F/R/N Gear Reduction Low N/A N/A . -r----' Drive Type 520 O-ring 520 O-ring Final Drive 12/4288P 1214288P Center Drive N/A N/A Front Drive N/A N/A Displacement 244cc 244cc Engine Model Number EC25PFE10 EC25PFE11 Compression Ratio (Effective) 6.1/1 6.1/1 Bore and Stroke (mm) 72x60 72x60 Spark Plug 1Gap, in. BR8ES (NGK) .028 BR8ES (NGK) .028 Alternator Output 150W 150W Timing Degrees 2S@3000 25@3000 Carburetion (1) VM30SS (1) VM30SS Main Jet 145 130 Pilot Jet 40 40 Jet Needle SDP7-3 SDP7-3 Needle Jet 0-4 (169) 0-4 (169) Cutaway 2.0 2.0 Air Screw/Pilot Screw 1 Turn 1 Turn * See Owner's Manual for rack load recommendations and restrictions. Polaris Industries Inc. 1.8e GENERAL INFORMATION Specifications 1998 Xpress 300 (IV) Xplorer 300 (IV) W98CA28C W98CC28C 45.5/1 (115.6) 45.5/1 (115.6) 46" (116.8) 46/1 (116.8) 79.5/1 (201.9) 81/1 (205.7) 49.75/1 (126.4) 49.75 /1 126.4) 34 /1 (86.4) 34" (86.4) 6.75/1 (16.5) 6" (15.2) 512 Ibs. (224.7) 567 Ibs. (252.4) 60" (152.4) 57 /1 (144.8) 6.25" (15.9) 6.25" (15.9) 8.S" (21.6) 8.5'1 (21.6) 23x7x10 23x7x10 -- 24x11x10 24x11x10 N/A N/A 4/3 4/3 Hydr. Disc Hydr. Disc . - - - - . - - - Hydr. Disc Hydr. Disc Mechanical Mechanical 4 4 2 2 N/A 2.25/2.16 20 20 N/A N/A N/A N/A 2, 12V 30/30W 2, 12V 30/30W 12V - 8.26 126.9 12V - 8.261 26.9 _ .__.._ - - - HIILO/R/N HIILO/R/N 6.64/1 6.64/1 520 O-ring 520 O-ring 13/3886P 13/4088P N/A 11/2270P N/A 12/2264P 283cc 283cc EC28PFE02 EC28PFE02 6.1/1 6.1/1 74.5x65 74.5x65 BR8ES (NGK) .028 BR8ES (NGK) .028 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
- 22. GENERAL INFORMATION Specifications 1998 1998Model (Gen II, III, or IV) Model Number Height, inches (cm) Width, inches (cm) Length, inches (cm) Wheel Base, inches (I 1) Seat Height, inches (cm) Ground Clearance, inches (cm) Weight - Lbs. (Kg) Turning Radius (Unloaded), in.(crn) Front Suspension Travel (McPherson Strut) Rear Suspension Front Tires Rear Tires Front/Rear/Center Tire PSI Front Brake Rear Brake Auxiliary Brake Fuel Capacity (U.S. Gallons) Oil Capacity (U.S. Quarts) Cooling System Capacity-qt (liter) Gearcase Oil Capacity (oz) Engine Counter Balancer Oil Capacity (10W/30) Main Head Light ~. Grill Mounted Lights Tail Light / Brake Light (Watts) 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 Sport 400 (III) W98BA38C 47" (119.4) 46.511 (118.1) 74.511 (189.2) 49.75/1 ( f) 3311 (83.8) 5.5" (15.2) 4791bs. (215) 60" (152.4) 6.2511 (15.9) 8.5" (21.6) 23x7x10 22x11x10 4/3 Hydr. Disc Hydr. Disc Mechanical 4 2 2.25 (2.13) 16 100cc 12V 55W N/A 12V - 8.26/26.9 F/R/N N/A 520 O-ring 13/3484P N/A N/A N/A 378cc EC38PLE07 6.9/1 -- . 83x70 BR8ES (NGK) 150W 23.5@3000 (1) VM34SS 230 35 6CEY6-3 0-6 (480) --- 1.5 1.5 Turn Scrambler 400 (III) W98BC38C 47/1 (119.4) 45.511 (115.6) 74.5/1 (189.2) 48.5" (123.2) 33" (83.8) 6.5/1 (15.2) 519 Ibs. (236) 60 11 (152.4) 8.211 (21.6) 8.5" (21.6) 23x7x10 22x11x10 4/3 Hydr. Disc Hydr. Disc Mechanical 4 2 2.25 (2.13) 32 100cc (2) 12V 30/30W N/A 12V - 8.26/26.9 F/R/N N/A 520 O-ring 13/3676P 11/2270P 12/2264P N/A 378cc EC38PLE09 6.9/1 83x70 BR8ES (NGK) 150W 23.5@3000 (1) VM34SS ~, " 230 35 6CEY6-3 0-6 (480) 1.5 1.5 * See Owner's Manual for rack load recommendations and restrictions. 5/98 1.8f Xplorer 400 (IV) Magnum 2x4 (II) W98CC38C W98AA42A 47.5" (120.7) 47" (119.4) 4611 (116.8) 46.511 (118.1) 81/1 (205.7) 77/1 (195.6) 49.75" (126.4) 49.7511 (126.4) 34/1 (86.4) 33/1 (83.8) 7.375" (19.0) 5.5/1 (14.0) 570 Ibs. (267) 534 Ibs. (244) 65/1 (165) 60/1 (152.4) 6.25" (15.9) 6.25" (15.9) 8.5" (21.6) 8.511 (21.6) 25x8x12 23x7x10 25x11x10 24x11x10 4/3 4/3 - Hydr. Disc Hydr. Disc Hydr. Disc Hydr. Disc Mechanical Mechanical 4 3.5 2 2- OW40 Engine oil 2.25 (2.13) 2.25 (2.13) 20 20 100cc N/A 12V 60W 12V 60/60W 2, 12V 27W Acc. 12V - 8.26 / 26.9 12V - 8.26/26.9 HIILO/R/N HI/LO/R/N .. --- 6.64/1 6.64/1 •.. 520 O-ring 520 O-ring 13/3484P 12/3886P 11/2270P N/A 13/2264P N/A N/A N/A 378cc 425cc EC38PLE06 EH42PLE02 6.9/1 9.2/1 83X70 87.9x70 ..-~~.~-- BR8ES (NGK) BKR5ES (NGK) 200W 200W 23.5@3000 30@3500 (1) VM34SS (1) BST34-CV type 200 140 30 40 6CEY6-3 5F14-3 0-6 (480) P-9 1.5 Pilot Air Jet #160 1.5 Turn 2.5 Polaris Industries Inc.
- 23. 1998 Model (GenII, III, or IV) Magnum 4x4 (II) Scrambler 500 (III) Model Number W98AC42A W98BC50A Height, inches (cm) 46/1 (119.4) 47/1 (119.4) Width, inches (cm) 46/1 (116.8) 45.5" (115.6) Length, inches (cm) 77/1 (195.6) 74.5/1 (189.2) Wheel Base, inches (cm) 49.75/1 (126.4) 48.5" (123.2) Seat Height, inches (I 1) 34/1 (86.4) 33" (83.8) Ground Clearance, inches (cm) 6" (15.2) 6.5/1 (15.2) Weight - Lbs. (Kg) 595 Ibs. (274) 542 Ibs. (246) Turning Radius (Unloaded), in. (cm) 65" (165) 60" (152.4) Front Suspension Travel, in. (cm) 6.25/1 (15.9) 8.2" (21.6) (McPherson Strut) Rear Suspension, inches (cm) 8.5" (21.6) 8.5/1 (24.1) Front Tires 25x8x12 23x7X10 Rear Tires 25x11x10 24x11x10 Center Tires N/A N/A Front/Rear/Center Tire PSI 4/3 4/3 Front Brake Hydr. Disc Hydr. Disc Rear Brake Hydr. Disc Hydr. Disc Auxiliary Brake Mechanical Mech. Fuel Capacity (U.S. Gallons) 3.5 3.5 Oil Capacity (U.S. Quarts) (2) OW40 Engine Oil (2) OW40 Engine Oil Cooling System Capacity (Qt./Liter) 2.25/2.16 2.25 I 2.16 Gearcase Oil Capacity (oz) 20 32 Main Head Light 12V 60W (2)12V 30/30W Grill Mounted_Li~ 2,12V 27W N/A Tail Light 1Brake Light (Watts) 12V - 8.26/26.9 12V ~ 8.26 I 26.9 -, Gear Box HIILO/R/N HI/R/N Gear Reduction Low 6.64/1 N/A Drive Type 520 O~ring ~-- 520 a-ring Final Drive 12/3886P 13/36-76P ,- Center Drive 11/2270P N/A Front Drive 11/2268P N/A Axle to Axle N/A N/A Displacement 425cc 499 Engine Model Number EH42PLE02 EH50PLE04 Compression Ratio (Full Stroke) 9.2/1 10.2/1 Bore and Stroke 87.9x70 92x75 Spark Plug BKR5ES (NGK) BKR5E (NGK) Alternator Output 200W 250W ..- Timing Degrees 30@3500 30@3500 Carburetion (1) BST34-CV type (1) BST40 CV type Main Jet 140 155 Pilot Jet 40 40 Pilot Air Jet Jet Needle 5F14-3 6H25-94-3 Needle Jet P-9 y-O -- Cutaway N/A N/A Air Screw or Fuel Screw (Turns Out) 2.5 2.0 * See Owner's Manual for rack load recommendations and restrictions. Polaris Industries Inc. 1.89 GENERAL INFORMATION Specifications 1998 Sportsman 500 (IV) Big Boss 500 6x6 (II) W98CH50A W98AE42A 47/1 (119.4) 47/1 (119.4) 46" (116.8) 46" (116.8) 81" (205.7) 103" (261.6) 50.5/1 (128.3) 75" (190.5) 34" (86.4) 34/1 (91.4) 11 " (27.9) 5.5/1 (14.0) 660 Ibs. (316) 870 Ibs. (395) 65" (165) 98" (249) 6.25" (15.9) 6.25" (15.9) 9.5" (24.1) 7.5" (21.6) 25x8x12 25x8x12 - 25x11x10 25x11x10 N/A 25x11x10 5/5 5/5/5 Hydr. Disc Hydr. Disc Hydr. Disc Hydr. Disc Hydr. Disc Hydr. Disc 5.25 3.5 (2) OW40 Engine Oil (2) OW40 Engine Oil 2.25 I 2.16 2.25 I 2.16 32 20 12V 60W 12V 60W 2,12V 27W 2,12V 27W 12V - 8.26 I 26.9 12V ~ 8.26 126.9 HI/LO/R/N HIILO/R/N 6.69/1 6.64/1 Shaft 520 a-ring 3.16:1 1214288P N/A 11/2472P 2:1 11/2268P N/A 30/30 116P 498 498cc EH50PLE07 EH50PLE06 10.211 10.2/1 92x75 92x75 BKR5E (NGK) BKR5E (NGK) 250W 250W 30@3500 30@3500 (1) BST34 CV type (1) BST34-CV type 142.5 140 42.5 40 5078-3 5078-3 P-1 Q-6 N/A N/A 2.0 2.0 5/98 --, -,-
- 25. GENERAL INFORMATION Standard TorqueSpecifications The following torque specifications are to be used as a general guideline. Some fasteners require a special torque procedure during installation. In addition, some fastener torque values may be different than the standard torque value listed below. Critical fastener torques are listed (where applicable) at the beginning of each section. Always refer to the appropriate chapter for specific torque specifications and procedures before using standard torque. o Bolt Size Threads/In Grade 2 Grade 5 #10 8 #10 - 1/4 1/4 5/16 - 5/16 - 3/8 3/8 Torgue in. Ibs. (kg~m) 24 ............. 27 (.31) ............... 43 (.50) .............. 60 (.69) 32 ............. 31 (.36) ............... 49 (.56) .............. 68 (.78) Torgue ft. Ibs. (kg~m)* 20 ............. 5 (.7) ................. 8(1.1) ............... 12{1.6) 28 ............. 6 (.8) ................. 10 {1.4} .............. 14 (1.9) 18 ............. 11 (1.5) ............... 17 (2.3) .............. 25 (3.5) 24 ............. 12 (1.6) .............. 19 (2.6} .............. 29 (4.0) 16 ............. 20 (2.7) ............... 30 (4.0) .............. 45 (6.2) 24 ............. 23 (3.2) ............... 35 (4.8) .............. 50 (6.9) 14 ............. 30 (4.0) ............... 50 (6.9) .............. 70 (9.7) Grade 8 7/16 - 7/16 - 1/2 20 ............. 35 (4.8) ............... 55 (7.6) .............. 80 (11.0) 1/2 Metric 6 x 1.0 8 x 1.25 10 x 1.25 13 ............. 50(6.9) ............... 75(10.4) ............ 110{15.2) 20 ............. 55 (7.6) ............... 90 (12.4) ............ 120 (16.6) 728 78 In. Ibs. 14-18 ft. Ibs. 26-30 ft. Ibs. *To convert ft. Ibs. to kg-m multiply foot pounds by .1383. *To convert kg-m to N-m move the decimal to the right one position. Polaris Industries Inc. 1.9 5/98
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