Polaris Offroad Vehicle Owner's Manual
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Polaris Offroad Vehicle Owner's Manual

Polaris Offroad Vehicle Owner's Manual

1998 atv
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  • Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • Page 4 ATV are thoroughly inspected at various intervals. All information in this manual is based upon the latest product data and specifica- tions available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or ex- planations.
  • Page 5 Do not turn at excessive speed. • Always have the ATV checked by an authorized Polaris dealer if it has been in- volved in an accident. • Never operate the ATV on hills too steep for the ATV or for your abilities. Practice...
  • Page 6 Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.
  • Page 7 Additional Important Information... Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle;...
  • Page 8 Registered Owners Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem- bership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s an owners program for Polaris owners like you, people who have chosen the finest recreational vehicle available, people who share an interest in Polaris and its prod- ucts.

  • Page 10: Table Of Contents

    CONTENTS UNDERSTANDING WARNINGS ......SAFETY WARNING AND OPERATION DECALS DAILY PRE-RIDE INSPECTION ......OPERATION WARNINGS .

  • Page 11: Understanding Warnings

    You should review this information on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, you can obtain this safety training at no charge from any authorized Polaris dealer.
  • Page 12 UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to con- vey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

  • Page 13: Safety Warning And Operation Decals

    In the event any decal becomes il- legible or comes off, contact your Polaris dealer for a replacement. Any safety de- cal needing replacement will be provided by Polaris at no charge. The part number...
  • Page 14 SAFETY WARNING AND OPERATION DECALS...
  • Page 15 SAFETY WARNING AND OPERATION DECALS...
  • Page 16 SAFETY WARNING AND OPERATION DECALS WARNING READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER USE. TO REDUCE TIPOVER RISK, BE ESPECIALLY CAREFUL WHEN ENCOUNTERING OBSTACLES AND SLOPES, WHEN BRAKING ON HILLS OR DURING TURNS.
  • Page 17 SAFETY WARNING AND OPERATION DECALS...
  • Page 18 SAFETY WARNING AND OPERATION DECALS This vehicle is equipped with a OVER-LOADING CAN CAUSE STEERING, Polaris Electronic Throttle Control TIPPING AND BRAKING PROBLEMS RE- SULTING IN LOSS OF CONTROL. (ETC) to reduce the risk of a stuck or “frozen” throttle. Please refer to LOSS OF CONTROL CAN CAUSE SEVERE INJURY OR DEATH.
  • Page 19 SAFETY WARNING AND OPERATION DECALS This decal is found only on models with dual racks. WARNING LOAD DISTRIBUTION WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating char- acteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability.
  • Page 20 SAFETY WARNING AND OPERATION DECALS This decal is found on models with only rear racks. WARNING RACK LOAD WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability.
  • Page 21 SAFETY WARNING AND OPERATION DECALS ATTENTION DOPERATION OF THIS VEHICLE WITHOUT DLiutilisation de ce véhicule sous liélément THE FILTER ELEMENT WILL SEVERELY filtre endommage sévèrement le moteur. DAMAGE THE ENGINE. DNettoyer souvent le filtre à air, surtout dans DCLEAN AIR FILTER OFTEN, MORE FRE- des situations poussiereuses.
  • Page 22 SAFETY WARNING AND OPERATION DECALS ATTEMPT ENGINE CLUTCH MODIFICATION. DOING SO CAN CAUSE IMBALANCE AND/OR EXCESSIVE ENGINE RPM. EXCESSIVE ENGINE RPM CAN CAUSE PART FAILURE RESULTING POSSIBLE SEVERE INJURY DEATH. DO NOT MODIFY ENGINE OR CLUTCH. 7077377 WARNING BELT - - CLUTCH GUARD COVERS MOVING PARTS. CONTACT WITH MOVING PARTS MAY RESULT IN SEVERE INJURY OR DEATH.

  • Page 23: Safety Warning And Operation Decals

    SAFETY WARNING AND OPERATION DECALS ATTENTION Specific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owner’s Manual. Factory setting: 40° to 80° F. at 0-3000 feet. (+5° to 26° C. at 0-900 meters). Chain Freeplay Is Le jeu libre de la chaine est Important.

  • Page 24: Daily Pre-Ride Inspection

    DAILY PRE-RIDE INSPECTION Inspect your ATV each time before riding to ensure it is in proper working or- der. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result. Always inspect your ATV before riding following the checklist carefully.

  • Page 25: Operation Warnings

    HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc. They should then reg- ularly practice the skills learned in the course and the operating tech- niques described in the Owner’s Manual.
  • Page 26 OPERATION WARNINGS WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 27 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN The ATV’s tires are designed for off-road use only; not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Never operate the ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.
  • Page 28 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
  • Page 29 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a se- vere head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 30 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
  • Page 31 OPERATION WARNINGS WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
  • Page 32 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 33 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 34 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slip- pery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the...
  • Page 35 OPERATION WARNINGS WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Own- er’s Manual. See page 63 . Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 36 OPERATION WARNINGS WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 65 through 68. Always check the terrain carefully before you start up any hill.
  • Page 37 OPERATION WARNINGS WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 67. NOTE: A special technique is required when braking as you go downhill.
  • Page 38 OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mas- tered the turning technique as described in the Owner’s Manual on level ground.
  • Page 39 OPERATION WARNINGS WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 40 OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 41 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 42 All parts and accessories added to this vehicle should be gen- uine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.

  • Page 43: Operation Warnings

    OPERATION WARNINGS WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an ac- cident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.

  • Page 44: Vehicle Identification Numbers

    VEHICLE IDENTIFICATION NUMBERS 1 VIN on the lower left side of the frame tube Important: Record these numbers from your ATV in the spaces provided. 1. Frame VIN 2. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Record your ignition key num- ber here.

  • Page 45: Control And Parts Functions

    CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a re- verse speed limiter system. To obtain additional power while backing up, depress the override button. WARNING: Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death.
  • Page 46 Light Switches and Indicator Lights Switches Each Polaris ATV has a main switch. It is located on the right hand side of the ma- chine and operated with a key. The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams.
  • Page 47 CONTROL AND PARTS FUNCTIONS With engine running, verify function of indicator lights each time ATV is used. WARNING This ATV is not equipped with highway approved lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
  • Page 48 The throttle lever is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle.
  • Page 49 CONTROL AND PARTS FUNCTIONS Throttle Control/Brakes Throttle Control Lever Stop The throttle control lever incorporates an adjustable stop. This can be ad- justed to limit the amount of throttle opening by loosening the screw (A) and sliding the stop to a desired setting. Then tighten screw.
  • Page 50 CONTROL AND PARTS FUNCTIONS Parking Brake Setting the Parking Brake 1. Squeeze the left hand brake lever two or three times and hold it. 2. Rotate the park brake lock into the notches on the master cylinder body. Release the brake lever. 3.
  • Page 51 CONTROL AND PARTS FUNCTIONS Auxiliary Mechanical Brake Your Polaris ATV has an auxiliary mechanical brake provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the hydraulic brake system, especially if the hydraulic system becomes inoperative.
  • Page 52 CONTROL AND PARTS FUNCTIONS Transmission Gear Selector Operation Shift patterns depend on the type of vehicle you own. Please check your Owner’s Manual Supplement to define your ma- chine’s shift pattern. The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter.

  • Page 53: Demand 4 Drive

    “On” Exclusive Demand 4 Drive System (All Wheel Drive) This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch on the right handlebar. When the switch is “off” the 4x4 is in 2 wheel drive at all times. When the switch is “on” the 4x4 is in Demand 4 Drive and the front wheels will automatically engage anytime the rear wheels lose traction.

  • Page 54: Pvt System

    DRoutine maintenance is the responsibility of the owner. Always follow recommended maintenance procedures. See your dealer! DThis PVT system is intended for use on Polaris products only. DThe PVT housing must be securely in place during operation. Failure to comply with this warning can result in severe injury or death.

  • Page 55: Coolant Level

    Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. Polaris recom- mends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.
  • Page 56 CONTROL AND PARTS FUNCTIONS Engine Cooling System Radiator Coolant Level Inspection NOTE: This procedure is only re- quired if the cooling system has been drained for maintenance and/or re- pair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

  • Page 57: Engine Cooling System

    Polaris recommends the use of Polaris Pre- mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com- patible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. IMPORTANT: Al- ways follow the manufacturer’s mixing recommendations for the freeze protection...
  • Page 58 CAUTION: To avoid serious engine damage always top off the oil level when refueling. CAUTION: On models with a two cycle engine, use only Polaris injection oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.
  • Page 59 CONTROL AND PARTS FUNCTIONS Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with a unique in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

  • Page 60: Oil System

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed more fre- quently if Polaris Premium 4 is not used. You will also need to follow the manufac- turers recommendations for ambient temperature operation.
  • Page 61 18. Dispose of used filter and oil properly. Fuel Filter and Oil Filter Polaris 2 cycle ATVs are equipped with a unique in-line oil filter. All Polaris ATVs are equipped with a unique in-line fuel filter. These filters should be replaced by your dealer after every 100 hours of operation or annually.
  • Page 62 CONTROL AND PARTS FUNCTIONS Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.

  • Page 63: Recoil Starter

    Polaris engines are equipped with automatic decompressors. This makes recoil starting possible by allowing compression to “leak” at cranking speeds. The de- compressor senses when the engine is spinning fast enough to start and restores compression for starting.

  • Page 64: Control And Parts Functions

    CONTROL AND PARTS FUNCTIONS Drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10mm wrench. Reinstall screw once housing has been drained.

  • Page 65: Starting The Engine

    STARTING THE ENGINE Procedure for Starting a Cold Engine 1. Place the transmission in neutral and push the vehicle to a level surface. 2. Lock the parking brake. 3. Turn the fuel tank valve to ON. 4. Sit on the vehicle. “FULL”...

  • Page 66: Vehicle Break In Period

    VEHICLE BREAK-IN PERIOD 2 Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as important as a proper break in period.
  • Page 67 VEHICLE BREAK-IN PERIOD 4 Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of op- eration, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break in period.

  • Page 68: Riding Gear

    Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding.

  • Page 69: Carrying Loads

    CARRYING LOADS Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and car- go to maintain stable driving conditions.

  • Page 70: Cargo Weight Distribution

    CARGO WEIGHT DISTRIBUTION 2/3 of Load on Rear Rack WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load af- fects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death.

  • Page 71: Daily Pre-Ride Inspection

    DAILY PRE-RIDE INSPECTION Inspect your ATV each time before riding to ensure it is in proper working or- der. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result. Always inspect your ATV before riding following the checklist carefully.

  • Page 72: Riding

    1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 73: Making Turns

    Making Turns Practice making turns at slow speeds. Polaris ATVs are equipped with a solid rear axle which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

  • Page 74: Riding On Slippery Surfaces

    Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids.

  • Page 75: Traveling Uphill

    RIDING Traveling Uphill 25_ Maximum Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills. 2. Keep both feet on the footrests. 3. Transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5.
  • Page 76 Sidehilling Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward the hill while keep- ing your feet on the footrests.

  • Page 77: Traveling Downhill

    RIDING Traveling Downhill Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs.

  • Page 78: Turning Around On A Hill

    Turning Around On A Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1.

  • Page 79: Crossing Streams

    RIDING Crossing Streams Your Polaris ATV can operate through water up to depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible.

  • Page 80: Trail Obstacles

    Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Hidden or unseen hazards on the trail can be dangerous.

  • Page 81: Backing Up

    RIDING Backing Up Backing Up 1. Whenever backing up, always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. 6.

  • Page 82: Riding

    Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off. 2. Place the transmission in gear. 3. Set the parking brake. 4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above.

  • Page 83: Battery

    BATTERY Battery CAUTION Whenever removing the battery, discon- nect the negative (black) cable first. When reinstalling the battery, connect the nega- tive (black) cable last. Maintain Replenishing the Battery Fluid between upper and A poorly maintained battery will deteriorate lower level rapidly.

  • Page 84: Battery

    Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5.

  • Page 85: Noise Emission Control System Regulation

    USFS Approved Spark Arrestor Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. For specific information on your model, see the Owner’s Manual Specification Supplement that came with your machine.

  • Page 86: Maintenance

    Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows: 1. Remove the clean out plugs located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the en- gine.
  • Page 87 MAINTENANCE Spark Arrestor (Cont.) WARNING DDo not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. DBecause of the increased fire hazard, make sure that there are no com- bustible materials in the area when purging the spark arrestor. DWear eye protection.

  • Page 88: Power Pig Tail

    CAUTION: Be sure to wrap bare wires with electrical tape and follow correct wire splicing procedures to avoid shorts in the wiring system. Additional pig tails may be pur- chased under Polaris 2460442. MAINTENANCE...

  • Page 89: Periodic Maintenance Schedule

    CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair.
  • Page 90 Periodic Maintenance Schedule (Cont.) Item Hours or Frequency Odometer Fuel System 100 hours 12 months Fuel Filter 100 hrs 12 months Carburetor Float Bowl 50 hrs 6 months Idle Speed As Required As Required Throttle Cable/ETC Switch 50 hrs 6 months Choke (Enricher) Cable 50 hrs 6 months...
  • Page 91 Pre-ride CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair. " More often under severe use, such as dirty or wet conditions...

  • Page 92: Lubrication Recommendations

    Lube Rec. Method 1. Engine Oil Polaris Fill oil tank. See page 48. (2-Cycle) Injection Oil 2.Engine OIl Polaris Pre- Add to proper level on dipstick. (4-Cycle) mium 4 Syn- See page 50. thetic 0W40 3. Brake Fluid DOT 3 Only Maintain level between fill lines.
  • Page 93 * More often under severe use, such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special. + Grease every 500 miles, or after submerging in water or before long periods of storage or after pressure washing.
  • Page 94 Lubrication Recommendations 5. Front Gear Case 4. Transmission Full Operating Range 7. Front Prop Shaft (U-Joint) 12. Axle Cardan Front Drive (AWD Models) MAINTENANCE Fill plug 8. Propshaft Yoke 6. Rear Halfshaft (U Joint) 9. Speedo meter Cable 15. Counterbalance Dipstick...
  • Page 95 MAINTENANCE Lubrication Recommendations 17. Steering Post Bushings 25. Tie Rod End Lower Upper 14. Front A-Arm Pivot Shaft 13. Ball Joint Trail Boss 17. Steering Post Bushings Lower Upper 14. Front A-Arm Pivot Shaft 13. Ball Joint 25. Tie Rod End 11.
  • Page 96 Lubrication Recommendations 14. Front A-Arm Pivot Shaft 13. Ball Joint 17. Steering Post Bushings Lower Upper 14. Front A-Arm Pivot Shaft 13. Ball Joint MAINTENANCE 25. Tie Rod End 11. Demand 4 Hubs 11. 4 O’clock position...
  • Page 97 MAINTENANCE Lubrication Recommendations 16. Output shaft sup- port bearing grease fit- ting 20. Center and Front Eccentrics 19. Swing Arm Bushings 18. Rear Axle Bearing INDEPENDENT REAR SUSPENSION 24. Rear Anti- 22. Lower Control Roll Bar Forward 21. Upper Control 23.
  • Page 98 Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Servicing Servicing Interval Date Dealer Performed or Person First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs. MAINTENANCE Remarks...

  • Page 99: Handlebar Adjustment

    MAINTENANCE Steering Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1. Locate handlebar bolts. On mod- els with a headlight pod, it will be necessary to remove the upper headlight pod. On other models remove the handlebar cover.
  • Page 100 Rear Hub Retaining Nut(s) Rear Wheel Nuts Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component op- erations. Service work must be performed by your authorized Polaris dealer. MAINTENANCE Specification 40 Ft. Lbs. 15 Ft. Lbs.
  • Page 101 MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Rear Spring Adjustment Rear Spring Adjustment...
  • Page 102 Optional Suspension Springs Although your Polaris ATV suspension has the capability of providing you with the best ride possible, the following accessory springs are available to better suit your individual riding preference. NOTE: Optional springs may be a different color than standard springs. Owner may paint springs to desired color using Polaris touch up paint, available through your dealer.
  • Page 103 MAINTENANCE SOFT Xpress 300- 7041518-067 7041204-157 Rear OPTION 175 lb/in STANDARD 190 lb/in Compression Spring Xpress 300 - 7041238-067 7041375-157 Front Strut Spring OPTION 61 lb/in STANDARD 64/113 lb/in Magnum 4x4 -- 7041238-067 7041375-195 Front Strut Spring OPTION 61 lb/in STANDARD 64/113 lb/in Magnum 4x4 -...
  • Page 104 Side Panel Removal (Gen IV Models) Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. Remove seat. Grasp rear Step 1. of side panel near rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear...
  • Page 105 Air Cleaner Trail Boss, Xpress 300, Xplorer 300, Xplorer 400 Dual Stage Air Cleaner The Polaris ATV is equipped with a dual stage engine air filtration system. The primary pre-cleaner foam boot is designed to remove the majority of dust particles before they reach the secondary dry filter element.

  • Page 106: Air Cleaner

    Air Cleaner Trail Blazer, Trail Boss, Xpress 300, Xplorer 300, Xplorer 400 Secondary (Main) Filter Inspect the secondary filter weekly or after every 50 hours of operation. CAUTION: Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage to the engine.

  • Page 107: Air Filter Service

    MAINTENANCE Air Filter Service Magnum 2 x 4, Magnum 4 x 4 It is recommended that the air filter be inspected weekly and replaced if dirty. When riding in extremely dusty conditions replacement will be required more often. 1. Lift up on the rear of the seat. Access Cover 2.

  • Page 108: Air Box Drain

    Primary Pre-Filter Service Magnum 2x4 and 4x4 The pre filter should be cleaned before each ride, using the following procedure. 1. Remove pre-filter element. Note position of duct support Element wire. It must be properly posi- tioned before reinstalling pre- filter.
  • Page 109 MAINTENANCE Air Filter Service Sport, Scrambler 400 1. Release seat latch and lift up on the rear of the seat. 2. Pull the seat back and free the tab from front cab. 3. Remove the two wing nuts and Access washers securing the air filter Cover access cover.
  • Page 110 Air Filter Service Trail Blazer Gray Collar 1. Release seat latch and lift up on the rear of the seat. Yellow Boot 2. Pull the seat back and free of Intake Silencer the tabs. 3. Remove the primary air filter box.
  • Page 111 MAINTENANCE Air Filter Service Scrambler 500 1. Remove seat. 2. Release clips and remove cov- 3. Loosen clamp and remove filter 4. Remove fabric type pre-filter Pre-Filter from main filter. Wash pre-filter in soapy water and dry it. 5. Reinstall pre-filter in main filter. Replace main filter as required.
  • Page 112 CAUTION: Operation of your ATV without a breather filter can cause engine dam- age. Breather Filter and Hoses Scrambler 500 WARNING: Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns. Remove heat shield screws and front fender to floorboard screws.
  • Page 113 MAINTENANCE Breather Filter and Hose Sportsman 500, Xplorer 500 Remove seat and airbox lid. Breather Filter Locate foam breather filter which is in the front left corner of airbox covering the engine breather hose fitting hole on the front inside of the airbox. Pull filter out and blow off with compressed air.

  • Page 114: Steering Inspection

    5. If this measurement needs to be adjusted, contact your dealer for service. WARNING: Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can result from improper adjustment. Contact your Polaris dealer. He/she has the training and tools to make these adjustments.

  • Page 115: Front Brake

    Always fill the reservoir as indicated whenever the cover is loosened or removed to insure proper diaphragm operation. Use Polaris DOT 3 brake fluid (PN 2870990). WARNING: Once a bottle of brake fluid is opened, use what is necessary and dis- card the rest.
  • Page 116 Rear and Auxiliary Mechanical Brake Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system. The rear brake sys- tem is self adjusting and requires no maintenance other than periodic checks of the pads for wear.
  • Page 117 MAINTENANCE Auxiliary Brake Adjustment (Cont.) Polaris ATVs have two different types of auxiliary brake adjustment. Consult your owner’s manual supplement to determine what type your machine has and adjust accordingly. 1. Type I: If adjustment is neces- sary turn adjuster bolt (A) clock- wise until disc rotation becomes difficult.
  • Page 118 Oil Pump Adjustment Procedure 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor ad- justments which are found in the own- Jam Nut er’s manual supplement. 2. Remove electronic throttle control (ETC) cover. 3. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16″...
  • Page 119 MAINTENANCE Oil Pump Adjustment Procedure 250 and 300 Engines 1. Before adjusting the oil pump, check engine idle RPM and car- buretor adjustments which are found in the owner’s manual sup- plement. 2. Remove electronic throttle con- trol (ETC) cover. 3.

  • Page 120: Throttle Cable

    Oil Pump Bleeding Procedure 1. Fill the oil reservoir with Polaris injector oil. 2. Loosening the bleeder screw is only necessary when the oil supply line has been disconnected from the pump or the oil reservoir and supply line have been completely run out of oil.

  • Page 121: Engine Choke Adjustment

    MAINTENANCE Engine Choke Adjustment 2 Cycle Engines With the dash mounted choke control toggle flipped to full off position, the choke plunger must be seated on the fuel passageway in the carburetor. If the plunger is not seated on the passageway, the engine will flood or run too rich, causing spark plug fouling and very poor engine performance.
  • Page 122 Carburetor/Engine Idle RPM Adjustment 2 Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running the vehicle approximately five minutes. 2.
  • Page 123 MAINTENANCE Carburetor/Engine Idle RPM Adjustment 4-cycle Engines If the engine idle speed is not satis- factory, and all other conditions are favorable, the carburetor can be ad- justed as follows: 1. Warm up the engine by running the vehicle approximately five minutes.

  • Page 124: Spark Plugs

    MAINTENANCE Spark Plugs Check your owner’s manual supplement for recommended spark plug and gap. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.

  • Page 125: Transmission Lubrication

    ATV on a level surface, remove fill plug dipstick and check the lubricant level. Lubricant should be kept at the full mark on the dipstick. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478). Transmission Oil Changing Procedure 1.

  • Page 126: Gearcase Oil Changing Procedure

    MAINTENANCE Front Gearcase Lubrication Sport 500, Xplorer 500, Scrambler 400 Fill plug Front Gearcase Lubrication The front gearcase fill plug is located on the right side of the machine. The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first.
  • Page 127 MAINTENANCE Counter Balance Lubrication 400 Engines The counter balance oil should be checked semi-annually and oil Counter should be added or changed as Balance necessary. The oil should be Drain changed annually, especially be- fore off season storage. If the ma- chine is used in wet conditions the oil should be checked more fre- quently.

  • Page 128: Wheel Installation

    Wheel Removal Front or Rear Wheel Removal Procedure 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame as shown.

  • Page 129: Tire Inspection

    MAINTENANCE Tire Inspection CAUTION: Maintain proper tire pressure according to charts below. Improper tire inflation may affect ATV maneuverability. When replacing a tire always use original equipment size and type. CAUTION: The use of non-standard size or type tires may affect ATV handling. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″...
  • Page 130 Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. CAUTION: Never wash the chain with a high pressure washer or gasoline. Dam- age to the O-rings will result, causing premature wear and drive chain failure.
  • Page 131 MAINTENANCE Adjustment Procedure (cont.) 5. Tighten eccentric clamp bolts to 45 ft. lbs. (6.21 kg/m). Check chain tension. Gen II and III Models 1. Remove cotter pin and washer connecting brake pedal linkage to caliper actu- ating arm. Remove linkage from arm. 2.
  • Page 132 Rear Drive Chain Slack Adjustment CAUTION: Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. Chain tension must be inspected with the swing arm in the position shown in illustration.

  • Page 133: Headlight Lamp Replacement

    MAINTENANCE Headlight Lamp Replacement WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain light- ing quality. Poor lighting while riding can result in severe injury or death. CAUTION: Do not service while headlight is hot.
  • Page 134 Headlight Lamp Replacement Trail Blazer, Sport WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain light- ing quality. Poor lighting while riding can result in severe injury or death. CAUTION: Do not service while headlight is hot.
  • Page 135 MAINTENANCE Headlight Lamp Replacement Magnum 2x4, Magnum 4x4, Trail Boss 1. Remove the seat. 2. Remove the plastic panel surround- ing the upper portion of the gas tank by first removing the gas tank cap. 3. Remove the Phillips head screws on either side of the panel at the junc- tion of this panel, the lower panels, and the rear of the front fenders.

  • Page 136: Headlight Adjustment

    Headlight Adjustment 10. Carefully unplug the socket from the lamp. Remove the panel and set it aside. 11. Replace the oil reservoir cap. 12. Stand the panel containing the headlight assembly on end to allow access to the back of the headlight assembly. 13.
  • Page 137 MAINTENANCE Headlight Lamp Replacement Xplorer 400, Xplorer 500, Sportsman 500 Speedometer Cable Position knob in slot and Route plug secure in over Adjustment locking handlebar Knob Stop tabs 1. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver.
  • Page 138 Headlight Housing Replacement 1. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver. Removal of the front rack and cover may also allow easier access.
  • Page 139 MAINTENANCE Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2. Remove lamp and replace it with recom- mended lamp.

  • Page 140: Cleaning Your Atv

    Cleaning Your ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

  • Page 141: Maintenance

    Storage (Cont.) 7. Drain the recoil housing. 8. Block the ATV so all tires are sus- pended off the ground. 9. Add Polaris Premium Storage Stabilizer to the fuel tank. 10. Cover the ATV with a canvas cover. Do not use plastic or...

  • Page 142: Troubleshooting

    Procedures The following information is provided to help you identify probable causes for ques- tions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START...

  • Page 143: Paint Codes

    PAINT CODES Model Item Color Springs Fire Red 1998 Rims Bright White Trail Boss Trail Boss Rack Fire Red Springs Black 1998 Rims Brushed Alu- Magnum 2x4 minum Rack Black Springs Fire Red 1998 1998 Rims Bright White Trail Blazer Springs Fire Red 1998...

  • Page 144: Paint Codes

    Model Item Color Raw Material Springs Fire Red 8520149 1998 Rims Brushed Xplorer 300 Aluminum Springs Burnished 8520264 Brown 1998 1998 Xplorer 400 Rims Brushed Aluminum Springs Black 8520147 1998 1998 Sportsman Rims Black 8520147 Springs Bonnie Blue 8520148 1998 Rims Brushed Xpress 300...

  • Page 145: Accessories

    ACCESSORIES Trail Trail Boss Blazer 14 Gallon Sprayer 2871087 Boom Mounting Kit 2871340 42″ Spray Boom 2871088 123″ Spray Boom 2871089 Seeder/Spreader, Elec. 2871219 Speedometer 2871275 2871275 20mph Speedometer Speedometer Protector Elect. Accessory Brd. Gas Gauge Cap 2871442 2871442 Chains, pair (Rear) 2870684 2870684 Ramps, for Pick-up...
  • Page 146 Magnum Scrambler Scrambler Xplorer 2871087 2871087 2871340 2871340 2871088 2871088 2871089 2871089 2871219 2871219 2871539 2871085 2871316 2871802 2871802 2871802 2871441 2871442 2871441 2871442 2870684 2870684 2870684 2870790 2871495 2871495 2871495 2871495 2871498 2871498 2871338 2871338 2870864 2871324 2871324 2870864 2871817 2871817 2871513...
  • Page 147 ACCESSORIES Trail Trail Boss Blazer Gun Scabbard 2870854 CV Protector Rack Bag, Large, Black Rack Bag, Gray/Black Rack Bag, Camo Dual Headlights 2871490 K&N Air Filter 2871509 2871509 Cover, Red/Blue 2870796 2870796 Cover for ATV w/wind- 2871313 shield Red/Blue Cover, Camo 2871084 2871084 Safety Whip Flag...
  • Page 148 Magnum Scrambler Scrambler Xplorer 2870854 2870854 2871234 2871234 2871234 2871787 2871787 2871216 2871216 2871506 2871506 2870936 2871508 2871508 2871786 2871509 2870796 2870796 2870796 2870796 2871313 2871313 2871084 2871084 2871084 2871084 2980799 2980799 2980799 2980799 2870991 2870991 2870991 2870991 2871011 2871011 2871011 2871011 2871457...
  • Page 149 ACCESSORIES Trail Trail Boss Blazer Rear Rack Kit 2871357 Front Rack Extender 3.5″ N/A 2871502 Front Rack Extender 8″ Rear Rack Extender 3.5″ 2871504 Rear Rack Extender 8″ 2870918 Gun Shovel Holder 2871315 2871315 Sport Xpress 2871357 2871499 2871318 2871501 2871319 2871315 2761427...
  • Page 150 Magnum Scrambler Scrambler Xplorer 2871357 2871357 2871502 2871499 2870931 2871318 2871503 2871501 2870942 2871319 2871315 2871315 2871315 2871427 ACCESSORIES Xplorer Xplorer 2871499 2871499 2871318 2871318 2871501 2871501 2871319 2871319 2871427 2871427...
  • Page 151 ACCESSORIES Magnum Sportsman 14 Gallon Sprayer 2871087 2871087 Boom Mounting Kit 2871340 2871340 42″ Spray Boom 2871088 2871088 123″ Spray Boom 2871089 2871089 Seeder/Spreader, Elec. 2871219 2871219 Speedometer 20mph Speedometer 2871085 2871353 Speedometer Protector 2871316 Elect. Accessory Brd. 2871802 Gas Gauge Cap 2871441 Chains, pair (Rear) 2870948...
  • Page 152 Magnum Sportsman Rear Rack Kit Front Rack Extender 2871502 2871499 (3.5″) Gun Scabbard 2870854 2870854 CV Protector 2871234 Rack Bag, Large, Black 2871787 2871787 Rack Bag, Gray/Black 2871216 2871216 Rack Bag, Camo 2871506 2871506 Dual Headlights K&N Air Filter 2871508 2871786 Cover, Red/Blue 2870796...

  • Page 153: Accessories

    ACCESSORIES Magnum Sportsman Accessory Winch Kit 2871461 2871461 Front Rack Kit Front Rack Extender 8″ 2870931 2871318 Rear Rack Extender 3.5″ 2871503 Rear Rack Extender 8″ 2870942 2871319 Gun Shovel Holder 2871315 2871427...

  • Page 154: Warranty

    This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.
  • Page 155 HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 156: Index

    Engine Cooling System ..45-47 Engine Idle Rpm Adjustment Accessories ....135-143 Engine Idle Rpm Adjustment (500) Air Box Drain .
  • Page 157 INDEX Throttle Lever ....Transporting Tire Inspection ....Traveling Downhill Toe Alignment .

This manual is also suitable for:

1998 offroad vehicle

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