Table Of Contents - Polaris Trail Blazer Service Manual

Table of Contents

General Information / Specifications2
Table Of Contents2
Engine Serial Number Location4
Machine Model Number And Vin Number Location4
Transmission I.d. Number Location4
Model / Vin Identification4
Vehicle Identification Number5
Vehicle Identification Number / Model Number Key5
Year / Letter Identification5
Current Model Numbers5
1999 Publication Part Numbers6
Service Bulletin Index6
Service Training Videos6
General Information6
1999 Paint Codes7
Standard Torque Specifications8
Conversion Table10
Sae Tap Drill Sizes11
Metric Tap Drill Sizes11
Tap Drill Charts11
Service Tips12
Glossary Of Terms13
Special Tools16
1999 Model Specifications17
Trail Blazer17
Trail Boss 25019
Xpress 30021
Xplorer 30023
Sportsman 33525
Sport 40028
Scrambler 40029
Scrambler 50030
Magnum 50036
Xplorer 4X443
Trail Boss 32545
Xpedition 32551
Xplorer 40055
Scrambler 400 2X457
Scrambler 400 4X459
Xpedition 42561
Sportsman 6X669
Maintenance72
Periodic Maintenance Chart74
Pre-Ride / Daily Inspection75
Recommended Lubricants - Quick Reference76
Polaris Premium Lubricant And Maintenance Product Part Numbers77
Lubrication79
Lubrication - Shaft Drive Models81
Lubrication Chart - Shaft Drive Models82
Gearcase Lubrication - Quick Reference83
Front Gearcase Lubrication84
Rear Gearcase Lubrication86
Transmission Lubrication87
Dipstick Models87
Shaft / Chain Models Without Dipstick88
Counter Balancer Lubrication (400Cc Engines)89
Procedure For Adding Oil (400)89
Counter Balance Oil Changing Procedure89
Transmission Gearshift Linkage Adjustment, Preliminary Inspection90
Torque Stop Adjustment90
Shift Linkage Adjustment -High/Low/Reverse Transmissions91
Shift Linkage Adjustment (High/Reverse Transmissions)93
Carburetor Adjustments94
Throttle Operation - All Models94
Choke (Enricher) Adjustment94
Air Screw Adjustment95
Pilot Screw Anti-Tamper Plug Removal96
Pilot Screw (Idle Mixture) Adjustment Notes97
Pilot Screw Adjustment - 425 / 500 4- -Stroke Models97
Pilot Screw Adjustment - 335 4- -Stroke Models97
Idle Speed Adjustment98
Throttle Cable / Electronic Throttle Control (Etc Switch) Adjustment99
Oil Pump Adjustment Procedure100
Oil Pump Bleeding Procedure102
Oil Pump Troubleshooting Procedure102
Oil Filter (2 Strokes)103
Fuel Lines104
Vent Lines104
Fuel Filter104
Fuel System104
Carburetor Draining105
Compression Test - 2 Stroke106
Compression Test - 4 Stroke106
Engine Mounts106
Fastener Torque - Engine106
Electrical107
Battery Maintenance107
Spark Plug108
Ignition Timing108
Engine-To-Frame Ground108
Liquid Cooling System Overview109
Coolant Strength / Type109
Cooling System Hoses109
Radiator109
Coolant Level Inspection110
Engine Cooling System111
Radiator Coolant Level Inspection111
Air Filter Service (Trail Blazer Style)112
Dual Stage Air Cleaner - 300 Style113
Primary Pre-Cleaner Foam Boot113
Secondary (Main) Filter114
Secondary Filter Removal And Installation114
Cleaning The Main Filter114
Air Filter Service, 2 Stroke116
Air Filter Service, 4 Stroke116
Breather Filter116
Air Box Sediment Tube117
Breather Filter Inspection118
Breather Hose118
Recoil Housing119
Engine Oil Level (4 Stroke)120
Oil And Filter Change (4 Stroke)120
Valve Clearance - 335, 425, 500Cc Engines122
Intake Valve Clearance Adjustment123
Exhaust Valve Clearance Adjustment123
Steering & Toe Alignment Inspection125
Tie Rod End / Steering Inspection125
Straightedge Or String126
Chalk127
Toe Alignment Adjustment127
Front Hub Fluid Level Inspection (Awd Models)128
Front Hub Fluid Change (Awd Models)128
Exhaust Pipe129
Brake System Inspection130
Brake Pad Inspection130
Hose/Fitting Inspection130
Brake System Service130
Auxiliary Brake Adjustment (Hydraulic)131
Auxiliary Mechanical Brake System132
Auxiliary Brake Testing132
Auxiliary Brake Adjustment - Mechanical132
Drive Chain And Sprocket Inspection133
Sprocket Inspection133
Drive Chain Inspection133
Rear Drive Chain Tension Inspection - Standard Swingarm134
Rear Drive Chain Tension Adjustment - Standard Swingarm134
Drive Chain Adjustment, Concentric Swingarm135
Adjustment Procedure - Concentric Swingarm Rear Axles (Tapered Roller Bearings)135
Center/Front Drive Chain Slack Adjustment138
Center/Front Drive Chain Inspection/Adjustment138
Drive Chain Inspection/Adjustment - 6X6139
6X6 Chain Inspection139
6X6 Middle Axle Chain Adjustment139
6X6 Rear Axle Drive Chain Adjustment139
Suspension Spring Preload Adjustment140
Front Suspension140
Rear Suspension140
Controls140
Chassis Maintenance141
Wheels141
Wheel, Hub, And Spindle Torque Table141
Wheel Removal Front Or Rear141
Tire Pressure142
Tire Inspection142
Tire Tread Depth142
Frame, Nuts, Bolts, Fasteners142
Engine144
Torque Specifications146
Engine Fastener Torque Patterns148
Piston Identification149
Piston Clearance Specifications (2 Stroke Engines)149
Es33Pfe01 / 02 Engine Service Data150
Eh42Ple02 / Eh50Ple04, 06, 08, 09 Engine Service Data152
Bleed Hole Inspection154
System Pressure Test154
Radiator Cap Pressure Test154
Recommended Coolant155
Cooling System Specifications155
Accessible Components - All Models156
Engine Removal156
Engine Installation Notes158
General Items158
Pvt System158
Bleed Cooling System158
Ec25Pf / Ec28Pf Engine Disassembly159
Connecting Rod Side Clearance160
Crankshaft Main Bearing Inspection160
Ec25Pf/Ec28Pf Engine Assembly161
Measure Crankshaft Width - - Bearings Installed161
Oil Pump End Play Adjustment166
Oil Check Valve Testing (Ec25Pf)167
Oil Check Valve Testing (Ec28Pf)167
Recoil Disassembly168
Ec25Pf Recoil Assembly169
Ec38Pl Engine Disassembly171
Ec38Pl Engine Inspection172
Connecting Radial Clearance177
Reed Valve Inspection178
Water Pump Impeller Clearance178
Impeller Spacer Shim Part Numbers179
Oil Check Valve Testing (Ec38Pl)180
Cylinder Inspection/Measurement181
Piston Inspection/Measurement (2 Stroke)181
Piston Ring Installed Gap182
Cylinder Hone Selection/Honing Procedure183
Honing To Oversize183
Cleaning The Cylinder After Honing183
Connecting Rod Small End Bearing Inspection184
Crankshaft Straightening185
Crankshaft Runout Inspection - 2 Stroke185
4 Stroke Engine Service186
Engine Lubrication - Es33Pf / Eh50Pl188
Oil Pressure Test - Es33Pf / Eh50Pl188
Oil Flow -- Es33Pf189
335 (Es33Pfe) Oil Flow Chart190
Es50Pl Lubrication/Oil Flow191
Eh50Pl Oil Flow Chart192
Es33Pfengine Exploded View193
Eh50Pl Engine Exploded View194
Engine Disassembly / Inspection195
Cam Chain Tensioner/Rocker Arm/Camshaft Removal195
To Position Crankshaft At Top Dead Center (Tdc) On Compression Stroke195
Cam Chain Tensioner Inspection196
Es33Pf / Eh50Pl Engine Removal196
Rocker Arm/Shaft Removal197
Rocker Arm/Shaft Inspection198
Camshaft Removal200
Automatic Compression Release Removal/Inspection202
Automatic Compression Release Installation202
If Camshaft Is Removed From Engine202
If Camshaft Is Installed In The Engine202
Camshaft Inspection203
Cylinder Head Exploded View, Es33Pf204
Cylinder Head Exploded View, Eh50Pl205
Cylinder Head Inspection206
Cylinder Head Warpage207
Cylinder Head Disassembly207
Valve Inspection209
Combustion Chamber210
Valve Seat Inspection211
Cylinder Head Reconditioning211
Valve Guide Removal/Installation211
Valve Seat Reconditioning212
Reaming The Valve Guide212
Cylinder Head Assembly215
Valve Sealing Test216
Cylinder/Piston Removal And Inspection217
Es33Pf / Eh50Pl Engine Bottom End Disassembly217
Piston Removal219
Cylinder Inspection220
Piston-To-Cylinder Clearance221
Crankcase Disassembly224
Starter Drive Removal/Inspection224
Flywheel/Stator Removal/Inspection225
Cam Chain/Tensioner Blade226
One Way Valve227
Crankcase Separation228
Oil Pump Removal/Inspection229
Oil Pump Assembly231
Counter Balancer Shaft Removal/Inspection232
Crankshaft Removal/Inspection233
Crankcase Bearing Inspection234
Pump Shaft Oil Seal/ Water Pump Mechanical Seal Removal (Engine Disassembled)234
Crankcase Assembly235
Bearing Installation235
End Play Inspection/Adjustment236
Crankshaft End Play Adjustment236
Counter Balancer Shaft End Play Adjustment238
Pump Shaft239
Pump Shaft Oil Seal Installation239
Crankshaft, Counter Balancer, And Oil Pump Installation240
Water Pump Mechanical Seal Installation (Eh50Pl)241
Water Pump Mechanical Seal Removal - Engine Installed (Eh50Pl)241
One Way Valve Installation243
Cam Chain Drive Sprocket Installation243
Tensioner Blade Installation243
Piston Ring Installation244
Piston Installation245
Cylinder Installation246
Cylinder Head Installation248
Cam Chain/Camshaft Installation249
Camshaft Timing249
Es33Pf / Eh50Pl Engine Assembly/Inspection251
Cam Chain Tensioner Installation252
Stator, Flywheel And Starter Drive Installation252
Flywheel253
Starter Drive253
Rocker Shaft/Rocker Arm Assembly Installation254
Thermostat Installation254
Oil Pipes254
Recoil Disassembly/Inspection255
To Install A New Spring257
To Reinstall An Old Spring257
To Complete Recoil Assembly257
Spark Plug Fouling - 2 Stroke Engines258
Spark Plug Fouling - 4 Stroke Engines258
Spark Plug Fouling Checklist258
2 Stroke Engine Troubleshooting259
Engine Turns Over But Fails To Start261
Engine Does Not Turn Over261
Engine Runs But Will Not Idle261
Engine Idles But Will Not Rev Up261
Excessive Smoke And Carbon Buildup262
Low Compression262
Backfiring262
Eh42Pl/Eh50Pl Cooling System Troubleshooting263
Overheating263
Temperature Too Low263
Leak At Water Pump Weep Hole263
Fuel System/Carburetion264
Jetting Guidelines266
Air Screw (2 Cycle) / Pilot Screw (4 Cycle) Adjustment266
Main Jet Selection266
Fuel Tank Assembly / Oil Tank Assembly267
Fuel Flow Diagrams269
Fuel System Diagram - 2 Stroke Models269
Fuel System Diagram - 4 Stroke Models269
Pilot Jet272
Pilot Air Screw272
Air/Fuel Mixture Ratio272
E-Clip Position Vs. Fuel Flow272
Jet Needle273
Needle Jet273
Throttle Opening Vs. Fuel Flow273
Throttle Valve274
Main Jet / Pilot Jet Part Numbers274
Starter System - Closed Throttle (2 Cycle)275
Pilot System (0-3/8 Throttle) (2 Cycle)276
Slide Cutaway (1/8-3/8 Throttle) (2 Cycle)277
Jet Needle/Needle Jet (3/8-3/4 Throttle) (2 Cycle)278
Main System (3/4 To Full Throttle) (2 Cycle)279
Component Effect Vs. Throttle Opening (2 Cycle)280
Mikuni Fuel Delivery (2 Cycle)280
Carburetor Component Function (2 Cycle)280
Vent Systems (2 Cycle)281
Needle And Seat Leakage Test - 2 Cycle281
Float Height Adjustment (2 Cycle)281
Assembly, Cv Carburetor281
Mikuni Vm30Ss / Vm34Ss Carburetor Exploded View282
4 Cycle Cv Carburetor System Function283
Vent Systems - 4 Cycle Cv Carburetor283
Mikuni Cv Carb Operation284
Pilot (Idle And Slow) System285
Starter System (Choke Or Enrichment)285
Float System286
Main System286
Mikuni Bst 34 Carburetor Exploded View287
Mikuni Bst 40 Carburetor Exploded View288
Carburetor Disassembly Notes- Mikuni Cv289
Carburetor Cleaning - Mikuni Cv291
Carburetor Inspection - Mikuni Cv292
Carburetor Assembly - Mikuni Cv293
Carburetor Adjustment - Mikuni Cv294
Float Height Adjustment294
Needle And Seat Leakage Test295
Fuel Level295
Fuel Pump296
Fuel Pump Disassembly296
Fuel Pump Inspection/Assembly296
Fuel Pump Exploded View297
Fuel Starvation/Lean Mixture298
Rich Mixture298
Poor Idle298
Troubleshooting298
Idle Too Low299
Erratic Idle299
Body / Steering / Suspension300
Torque Specifications, Special Tools302
Body Assembly Exploded View (Gen Ll - Typical)303
Rear Cab Assembly303
Front Cab Assembly303
Cover/Panel Removal (Gen Ll - Typical)304
Body Assembly Exploded View (Gen Lll - Typical)305
Cover/Panel Removal (Gen Lli - Typical)306
Body Assembly Exploded View (Gen Lv - Typical)307
Cover/Panel Removal (Gen Lv - Typical)308
Headlight Pod Exploded View (Gen Lv - Typical)309
Side Panel Removal (Gen Lv - Typical)310
Typical Steering Assembly, Exploded View, '99 Trail Boss 250311
Steering Assembly, Exploded View, - 2X4 Models (Except '99 Trail Boss 250)312
Steering Assembly, Exploded View All 4X4 And 6X6 Models313
A-Arm Replacement314
Concentric Swing Arm Removal315
Standard Swing Arm And Rear Suspension Exploded View317
Shaft Ride Swingarm Exploded View318
Shaft Ride Swingarm319
Swingarm Installation319
Rear Suspension Assembly, - Shaft Drive Models320
Rear Strut Stabilizer, 6X6 Models321
Rear Swing Arm Weldment, 6X6 Models322
Front Swing Arm Weldment, 6X6 Models323
Strut Assembly Exploded View - 2X4 Models324
Strut Assembly - Awd Models325
Front Strut Weldment Replacement326
Front Strut Cartridge Replacement326
Front Strut Ball Joint Replacement327
Ball Joint Replacement327
Decal Replacement330
Clutches332
Clutch Specifications334
Special Service Tools And Supplies334
Pvt System Fastener Torques334
Standard Pvt System Introduction335
Pvt Operation335
Drive Clutch Operation335
Driven Clutch Operation335
Pvt Maintenance/Inspection336
Pvt Drying336
Pvt Overheating336
Pvt Sealing And Ducting Components336
Pvt Disassembly337
Pvt Assembly339
Relationship Of Drive Clutch Weights And Spring In Maintaining Operating Rpm343
Drive Clutch Spring Specifications344
Shift Weights345
Drive Clutch Inspection346
Shift Weight Inspection346
Button To Tower Clearance Inspection346
Drive Clutch & Ebs Exploded View347
Drive Clutch Disassembly/Inspection348
Spider Removal349
Moveable Sheave Bushing Inspection349
Roller, Pin And Thrust Washer Inspection350
Drive Clutch Assembly351
Standard P-90 (Non-Ebs) Clutch353
Drive Belt Tension355
Drive Belt Removal/Inspection356
Clutch Alignment/Offset357
Drive Clutch Bushing Service359
Polaris Kit Pn 2871226359
Drive Clutch Moveable Sheave - Bushing Removal359
Drive Clutch Moveable Sheave - Bushing Installation360
Drive Clutch Cover - Bushing Removal361
Drive Clutch Cover - Bushing Installation362
Driven Clutch Disassembly/Inspection363
Driven Clutch Assembly366
Driven Clutch Bushing Service367
Driven Clutch Moveable Sheave - Bushing Installation369
Engine Braking System (Ebs) Clutch372
Ebs Theory Of Operation373
Operation Guidelines For Ebs Clutches374
Ebs Exploded View375
One-Way Clutch Inspection (Drive Clutch)376
Driven Clutch Disassembly/Inspection - Ebs379
One-Way Clutch Preliminary Inspection (Driven)379
Ebs Clutch Bushing Removal And Installation383
Removal And Installation Instructions383
Ebs Drive Clutch Moveable Sheave - Bushing Removal383
Ebs Drive Moveable - Bushing Installation384
Ebs Clutch Cover - Bushing Removal384
Ebs Clutch Cover - Bushing Installation384
Ebs Driven - Bushing Removal385
Ebs Driven - Bushing Installation385
Ebs Driven - Backside (Outer) Bushing Removal386
Ebs Driven - Backside (Outer) Bushing Installation386
Clutch Troubleshooting387
Final Drive390
2X4 Hub Bearing / Seal Replacement393
2X4 Front Hub Disassembly/Inspection393
2X4 Front Hub Installation396
2X4 Front Hub Assembly397
2X4 Front Hub Exploded View397
Awd Operation Overview399
Electric Hub Engagement (Awd)399
Front Hub Removal (Awd)400
Awd Front Hub Disassembly400
Hub/Wheel Bearing Installation401
Awd Front Hub Bearing Adjustment402
Awd Front Hub Exploded View403
Awd Hub Seal Replacement405
Magnetic Coil Removal406
Magnetic Coil Installation406
Awd Magnetic Coil Service406
Awd Hilliard Clutch Disassembly/Inspection407
Awd Armature Plate Inspection408
Awd Front Drive Axle Removal409
Awd Front Drive Axle Installation410
Driveshaft And Cv Joint Handling Tips411
Front Drive Shaft Cv Joint Boot Replacement411
Front Drive Axle Components413
Front Prop Shaft Components413
Awd Front Drive Axle Exploded View413
Awd Strut Casting Front Drive Axle Seal Replacement414
Bearing Replacement Note For Front Drive Axle And Front Hub414
Seal Sleeve Replacement415
Seal Sleeve Tool415
Awd Front Prop Shaft Removal416
U-Joint Service417
U-Joint Disassembly (Typical)417
U-Joint Assembly418
Awd Front Housing Removal420
Front Housing Disassembly420
Awd Front Housing Identification421
Awd Front Housing Disassembly422
Awd Front Housing Assembly424
Awd Front Housing Installation424
Front Housing Installation427
Awd Front Housing Exploded View428
Rear Drive429
Rear Drive Axle Service - Xpress / Xplorer 300430
Rear Axle Bend430
Rear Axle Removal431
Rear Axle Installation431
Concentric Swingarm Rear Axle Removal432
Concentric Swingarm Rear Axle Installation434
Concentric Swingarm Rear Axle Assembly, Exploded View435
Concentric Swingarm Rear Axle Disassembly436
Concentric Swingarm Rear Axle Assembly437
Concentric Swingarm Rear Housing Removal438
Concentric Swingarm Rear Housing Service440
Rear Housing Disassembly/Bearing Service440
Rear Housing Assembly/Bearing Service440
Concentric Swingarm Rear Housing Installation440
Rear Hub Inspection441
Rear Axle Bearing Removal445
Rear Axle Bearing Installation446
Rear Hub/Bearing Carrier Removal447
Rear Hub Installation - Independent449
Rear Hub Disassembly - Independent450
Rear Hub Assembly - Independent451
Rear Drive Shaft Removal - Independent452
Rear Drive Shaft Installation454
Rear Drive Shaft Disassembly (U-Joint Style)455
U-Joint Inspection - Rear Drive Shafts455
Rear Drive Shaft Disassembly (Dual Cv Joint Style)456
Cv Joint Assembly Procedure457
Boot Replacement458
Cv Joint Cleaning / Replacement458
Boot Installation458
Independent Rear Suspension Exploded View459
Tapered Bearing Center Eccentric Assembly Procedure460
Center Eccentric Housing Service460
Front Eccentric Housing Service461
Front Eccentric Removal / Installation Procedure461
Front Eccentric Disassembly / Assembly Procedure461
Center / Front Chain Tightener Exploded View462
Transmission Service464
Transmission Type Identification466
Gear Shift Selector Removal467
Gear Shift Selector Disassembly467
Gear Shift Selector Assembly469
Gear Shift Selector Installation470
Type Iii, Ez Shift Transmission Disassembly471
Type Iii, Ez Shift Transmission Assembly471
Type Iii, Ez Shift Transmission Installation472
Type Iii, Ez-Shift Transmission Installation (Typical)477
Speedometer Service478
Type Iii, Ez Shift Transmission, Exploded View479
Type Iv, Shaft Drive Transmission Removal480
Type Iv, Shaft Drive Transmission Installation480
Type Iv, Shaft Drive Transmission Disassembly480
Type Iv, Shaft Drive Transmission Assembly480
Transmission Installation484
U Joint Style Shafts486
Premium Synthetic Gear Case Lubricant487
Rear Wheel Retaining Bolt Torque487
Transmission Disassembly488
Bushing Drive Tool496
Bushing Installation, Transmission Center Shaft497
Front Output Housing (Snorkel) Assembly497
Front Output Housing (Snorkel) Installation499
Final Installed Shaft End Play499
Front Output Housing (Snorkel) Backlash Adjustment500
Transmission Output Gear Backlash Inspection/Adjustment501
Oil Deflector Screws505
Tensioner Installation506
Tensioner Assembly - Top View506
View From Left Side Of Transmission506
Seal Installation Tool508
Transmission Exploded View509
Transmission Removal/Installation510
Type V, Shaft/Chain Transmission Disassembly510
Type V, Shaft/Chain Transmission Assembly510
Remove Gear Indicator Switch(Es)511
Transmission Assembly514
Type Vi, Shaft Ride Transmission Removal518
Type Vi, Shaft Ride Transmission Installation518
Type Vi, Shaft Ride Transmission Disassembly518
Type Vi, Shaft Ride Transmission Assembly518
Transmission Troubleshooting Checklist527
Brakes528
Brakes Specifications530
Brakes Torque Specifications531
Brake System Service Notes532
Brake Pad Basics532
Brake Pad Kits532
Brake Noise Troubleshooting533
Hydraulic Brake System Operation534
Typical Hydraulic Brake System534
Dual Hydraulic Brake Caliper (Dh Caliper)535
Dual Hydraulic Caliper Bleeding535
Fluid Replacement/Bleeding Procedure537
Brake Bleeding - Fluid Change537
Master Cylinder Fluid Level538
Reservoir Cover Torque538
Master Cylinder Disassembly539
Master Cylinder Inspection539
Master Cylinder Assembly541
Master Cylinder Installation542
Front Pad Removal544
Front Pad Brake Service545
Front Disc Inspection546
Front Brake Disc Removal / Replacement547
Caliper Disassembly548
Front Caliper Removal548
Front Caliper Disassembly549
Front Caliper Inspection550
Front Caliper Assembly550
Front Caliper Installation551
Front Brake Caliper Exploded View552
Dual Hydraulic Brake Caliper553
Brake Pad Removal553
Brake Pad Installation554
Dh Brake Caliper554
Auxiliary Brake Master Cylinder Fluid Level554
Dual Hydraulic Brake Caliper Removal/Inspection555
Dual Hydraulic Brake Caliper Assembly556
Caliper Mounting Bolt Torque557
Dual Hydraulic Brake Disc Inspection558
Dh (Trans. Mounted) Caliper/Master Cylinder559
Dh (Rear Axle Mounted) Caliper/Master Cylinder560
Dh (Shaft Ride) Caliper/Master Cylinder561
Auxiliary Brake Caliper Service (Mechanical) Disassembly562
Auxiliary Brake Caliper Service (Mechanical) Assembly563
Auxiliary Brake Caliper Service (Mechanical) Installation564
Polaris Dot 3 Brake Fluid564
Caliper Mount Bolt Torque564
Auxiliary Brake Caliper (Mechanical)565
Auxiliary Brake Caliper Mounting (Mechanical)566
Brakes Troubleshooting567
Brakes Squeal567
Poor Brake Performance567
Caliper Overheats (Brakes Drag)567
Electrical Special Tools570
Headlight Adjustment (Gen Ii)571
Headlight Lamp Replacement (Gen Ii)571
Headlamp Service, Gen Ii571
Headlamp Service, Gen Iii571
Headlamp Service, Gen Iv571
Headlight Adjustment (Gen Iii -Scrambler, Trail Blazer And Sport)573
Adjustment - Trail Blazer And Sport573
Headlight Lamp Replacement (Gen Iii)573
Trail Blazer And Sport573
Scrambler574
Headlamp Service - Gen Lv575
High Beam Headlight Adjustment (Gen Iv)575
Headlight Lamp Replacement (Gen Iv)575
Headlight Housing Replacement (Gen Iv)575
Indicator Lamp Service576
Taillight/Brakelight Lamp Replacement576
Indicator Lamp Replacement (Gen Ii)576
Indicator Lamp Replacement (Gen Lll And Gen Iv)576
Timing Check Procedures577
Typical Ignition Timing Curves578
Typical 2-Stroke578
Typical 4-Stroke578
Crankshaft Degree To Piston Position Conversion579
Flywheel Identification580
Flywheel Identification Stamp Location580
Components Of Ec25/28Pl 150 Watt Alternator (Exploded View)581
Components Of Ec38Pl 150 Watt Alternator (Exploded View)582
Components Of Ec38Pl 200 Watt Alternator (Exploded View)583
Components Of Es33Pf/Eh50Pl 200 / 250 Watt Alternator (Exploded View)584
Ignition System Testing585
Cranking Output Test With Peak Reading Voltmeter586
Cdi Output Test Using Peak Reading Adaptor586
Ignition System Troubleshooting587
No Spark, Weak Or Intermittent Spark587
Initial Battery Service588
Battery Terminals/Terminal Bolts588
Battery Inspection/Removal589
Battery Installation589
Battery Testing589
Ocv - Open Circuit Voltage Test589
Specific Gravity Test590
Load Test590
Off Season Storage591
Charging Procedure591
Electrolyte Freezing Points591
Polaris Dielectric Grease591
Charging System Testing592
Charging System593
Current Draw - Key Off593
Charging System "Break Even" Test593
Alternator Output Test (Ac Amp)594
Starter System Troubleshooting595
Starter Motor Does Not Turn595
Starter Motor Turns Over Slowly595
Voltage Drop Testing596
Starter Motor Disassembly (Typical)597
Brush Inspection/Replacement598
Armature Testing600
Starter Assembly601
Starter Motor Installation (Ec38Pl)601
Pinion Gear - Anti Kick-Out Shoe, Garter Spring Replacement602
Starter Solenoid Bench Test602
Speed Limiter System603
Limiter Specifications603
Speed Limiter System - Theory Of Operation (Sportsman 335, Xplorer/Xpress 300, Trail Boss)604
Electronic Throttle Control (Etc) - Theory Of Operation (Sportsman 335, Xplorer/Xpress 300, Trail Boss)(Lr44)604
Speed Limiter System Testing606
Module Wire Color Function606
Reverse Limit System607
Reverse Speed Limit System608
No Reverse Speed Limit608
All Wheel Drive (Awd) Testing610
No Awd In Reverse610
No All Wheel Drive (Awd) On Shaft Drive Models Equipped With Hub Safety Module610
All Wheel Drive System611
Front Hub Engagement Limiter (Front Shaft Drive Models)611
Hub Engagement Limiter Rpm Test611
Electronic Speedometer Troubleshooting Overview Of Operation613
Vehicle Speed And Odometer613
Engine Run Time Hour Meter613
Reverse Speed Limit (Pvt Models Only)613
Electronic Speedometer (Pvt Models)615
No All Wheel Drive616
No Speedometer And/Or Odometer Display616
No Reverse Speed Limit (Vehicle Will Exceed 7-9Mph In Reverse)617
No High Speed Engagement Limit617
Reverse Speed Limiter Activated In Forward Gear(S)618
Wheel Speed Sensor618
Reset Speedometer619
Switch Testing (Sportsman 335, Xplorer/Xpress 300, Trail Boss)621
Key Switch/Auxiliary Shut Off (Kill) Switch621
Starter Switch621
Override Button621
Gear Selector Switch/Neutral Light622
Oil Level Sensor Testing (2 Stroke Models)623
Oil Level Warning Light Testing (2 Stroke Models)623
Coolant Temperature Sensor Test (Hot Light)623
Hot Light Circuit Test623
Switch Testing623
Oil Cooler Fan Notes624
Thermistor / Lr60 Fan Control Test624
Oil Cooler Fan Circuit624
Brake Light Switch625
Fan Motor Current Draw Test625
Gear Position Indicator Switch Test626
Switch Continuity Table626
Switch Schematic626
Electronic Throttle Control System Operation627
Etc Operation Test627
Wiring Diagrams629
Wiring Diagram 1999 Trail Blazer630
Wiring Diagram 1999 Trail Boss631
Wiring Diagram 1999 Xplorer 300 / Xpress 300632
Wiring Diagram 1999 Sportsman 335633
Wiring Diagram 1999 Sport 400634
Wiring Diagram 1999 Scrambler 400 (Early)635
Wiring Diagram 1999 Scrambler 400 (Late)636
Wiring Diagram 1999 Xplorer 400637
Wiring Diagram 1999 Scrambler 500638
Wiring Diagram 1999 Magnum 500639
Wiring Diagram 1999 Sportsman 500 / Sportsman 500 Rse640
Wiring Diagram 1999 Worker 500 (International)641
Wiring Diagram 1999 Big Boss 500 6X6642
Wiring Diagram 2000 Trail Blazer643
Wiring Diagram 2000 Xplorer 4X4644
Wiring Diagram 2000 Trail Boss 325645
Wiring Diagram 2000 Magnum 325 2X4646
Wiring Diagram 2000 Magnum 325 4X4647
Wiring Diagram 2000 Xpedition 325648
Wiring Diagram 2000 Sportsman 335 (Early)649
Wiring Diagram 2000 Sportsman 335 (Late)650
Wiring Diagram 2000 Xplorer 400651
Wiring Diagram 2000 Scrambler 400 2X4652
Wiring Diagram 2000 Scrambler 400 4X4653
Wiring Diagram 2000 Xpedition 425654
Wiring Diagram 2000 Magnum 500 (Early)655
Wiring Diagram 2000 Magnum 500 (Late)656
Wiring Diagram 2000 Scrambler 500 (Early)657
Wiring Diagram 2000 Scrambler 500 (Late)658
Wiring Diagram 2000 Sportsman 500 (Early)659
Wiring Diagram 2000 Sportsman 500 (Late)660
Index662