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LRRIS
InDUSTRIES Inc:.
ATV AND LIGHT UTILITY VEHICLE
SERVICE MANUAL
Foreword
This manual is designed primarily for use by ATV service technicians in a properly equipped shop. Since a
certain knowledge of mechanical theory, tool use, and shop procedures is necessary to perform the service
work safely, all operations should be performed by qualified service personnel only. In order to perform the
work efficiently and prevent costly errors, the technician should read the text and be familiar with procedures
before starting the work. Cleanliness of parts and tools as well as the work area is of primary importance.
All references to left and right side of the vehicle are from the operator's perspective when seated in a normal
riding position.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 1996-1998 model Polaris ATVs and Light Utility Vehicles. The section index
tabs enable the user to quickly locate the section desired. In addition, a table of contents is placed at the
beginning of each section for location of specific page numbers and service information. Keep this manual
available for reference in the shop area.
To keep this manual current it is important that it is updated yearly with new model information and
specifications.
At the time of publication all information contained in this manual was current. However, all materials and
specifications are subject to change without notice.
Comments or suggestions about this manual may be directed to: Polaris Industries Inc., Service Publications
Supervisor, 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078.
1996-1998 Service Manual Volume II Part No. 9913680
1998 Service Manual Update Part No. 9914752
Printed in U.S.A.
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Table of Contents
Troubleshooting
Need help?
Do you have a question about the Magnum 2x4 and is the answer not in the manual?
Questions and answers
Do you have a factory service manual for a 1996 polaris XPLORER , 300 , 4X4
Yes, a factory service manual is available for the 1996 Polaris Xplorer 300 4x4. It includes maintenance, repair procedures, specifications, diagnostics, and covers systems such as the engine, fuel system, transmission, brakes, and electrical components.
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Does this manual cover 1996 polaris xplorer 300 4x4
No, the Polaris Magnum 2x4 manual does not cover the 1996 Polaris Xplorer 300 4x4.
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Throdle sticking when operating unite
To fix a sticking throttle on a Polaris Magnum 2x4, follow these steps:
1. Turn off the engine to ensure safety.
2. Remove the three throttle block cover screws to access the throttle cable.
3. Slide the boot off the throttle cable adjuster and jam nut.
4. Loosen the cable adjuster jam nut.
5. Turn the adjuster in to obtain maximum cable freeplay.
6. Open the throttle and hold the cable.
7. Carefully disconnect the throttle cable from the throttle lever, ensuring not to kink or bend it.
8. Unscrew the adjuster and remove the cable.
9. Hold the throttle cable upright and lubricate it using Polaris Cable Lube.
10. Reinstall the adjuster and set maximum cable freeplay.
11. Reconnect the cable to the throttle lever.
12. Perform a throttle cable adjustment to ensure proper operation.
This process should help resolve a sticking throttle by ensuring the cable is clean, lubricated, and properly adjusted.
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