Table Of Contents - Polaris Magnum 2x4 Service Manual

Table of Contents

Safety Labels And Instructions2
Table Of Contents3
General Information5
Model Identification6
Engine Serial Number Locationi6
Transmission Id Number Location6
Carburetor Id Number Location6
1996 Model Identification7
Vehicle Identification Number (1997 And Later Model Years)8
1996 Publication Numbers10
1997 Publication Numbers10
1998 Publication Numbers11
Service Traning Videos11
Service/Information Bulletins12
Bulleting Index - 1996 By Model13
Bulleting Index - 1997 By Model14
Bulleting Index - 1998 By Model14
1997 Paint Codes16
Specifications 199718
Specifications 199823
Standard Torque Specifications26
Decimal Equivalents27
Conversion Table28
Tap Drill Charts29
Sae Tap Drill Sizes29
Metric Tap Drill Sizes29
Warranty30
Service Tips31
Glossary Of Terms32
Special Tools35
Routing Diagrams36
Magnum Routing Diagram36
Hoses Diagram39
300 Fan Motor Wiring Diagram40
Wire Harness Diagram41
Chassis/Suspension Service Tools42
Transmission Tool Kit - Shaft Drive42
Yoke Gauge Tool - Shaft Drive42
Mity Vac Pump Kit43
Small Battery Hydrometer43
Transmission Seal/Bearing Driver - 50 Mm43
Cv Boot Clamp Pliers43
Glossary (2)45
Magnum Routing Diagram (Cont.)48
Hosed Diagram (2)51
300 Fan Motor Wiring Diagram (2)52
Wire Harness Diagram (2)53
Oil Tank Vent Line Routing (1996 Sportsman 500) Diagram54
Maintenance56
Periodic Maintenance Chart58
Pre-Ride/Daily Inspection59
Recommended Lubricants And Capacities60
Lubrication Chart62
Lubrication Chart - Type Iv Transmission (Shaft Drive)65
Front Gearcase Lubrication67
Gearcase Lubricant Change67
Carburetor Adjustments68
Idle Speed Adjustment68
Throttle Cable/Electronic Throttle Control Etc Switch Adjustment68
Throttle Operation68
Throttle Cable Adjustment69
Choke Adjustments69
Throttle Control Lever Stop Adjustment69
Air Screw Adjustment - 2-Stroke Models70
Pilot Screw (Idle Mixture) Adjustment - 4-Stroke Models70
Fuel Lines72
Vent Lines72
Fuel Filter72
Carburetor Float Bowl Draining72
Carburetor Draining73
Breather System (4 Strokes)74
Breather Filter Inspection74
Breather Hose74
General Maintenance76
Compression Test76
Battery Maintenance77
Spark Plug Maintenance78
Ignition Timing78
Engine Mounts78
Coolant Level Inspection79
Coolant Strength79
Cooling System Pressure Test79
Radiator79
Oil Pump Adjustment Procedure80
Oil Pump Bleeding Procedure83
If Oil Starvation Is Suspected83
Recoil Housing84
Counter Balancer Lubrication (400)84
Procedure For Adding Oil (400)84
Counter Balance Oil Changing Procedure84
Air Cleaner - Trail Boss, Xpress 300, Xplorer 300, Xplorer 40085
Dual Stage Air Cleaner85
Primary Pre-Cleaner Foam Boot85
Secondary (Main) Filter86
Secondary Filter Removal And Installation Procedure86
Cleaning The Main Filter86
Air Filter Service -Sport, Scrambler 40087
Air Filter Service - Trail Blazer88
2 Stroke Engine Maintenance89
Oil Filter (2 Strokes)89
4 Stroke Engine Maintenance90
Air Filter - 4 Stroke Engine92
Pre-Filter Service92
Air Filter Main Element92
Air Box Sediment Tube93
Air Filter Service - Scrambler 50094
Air Filter Service - Sportsman 500, Xplorer 50094
Check Engine Oil (4 Stroke)96
Oil And Filter Change (4 Stroke)96
Engine Sump Drain Plug View97
Valve Clearance100
Intake Valve Clearance Adjustment101
Exhaust Valve Clearance Adjustment101
Throttle Cable Lubrication102
Toe Alignment Inspection103
Chassis Maintenance104
Steering Maintenance104
Camber And Caster Adjustment104
Toe Alignment Inspection (Chassis Maintenance)104
The Rod End Inspection105
Front Hubs (4X4 Awd Model)105
Changing Front Hub Fluid105
Exhaust Pipe106
Brake System Inspection107
Brake Fluid Level Inspection107
Wear Line107
Auxiliary Mechanical Brake System108
Auxiliary Brake Testing108
Auxiliary Brake Adjustment108
Hose/Fitting Inspection108
Drive Chain And Sprocket Inspection109
Rear Drive Chain Note109
Drive Chain Inspection109
Rear Drive Chain Tension Adjustment110
Drive Chain Adjustment, Concentric Swingarm111
Center/Front Drive Chain Slack Adjustment113
Center/Front Drive Chain Inspection/Adjustment113
Sprocket Inspection113
Drive Chain Inspection/Adjustment114
Rear Axle (6X6 Middle Axle) Adjustment Procedure114
Final Drive Chain114
6X6 Rear Axle Drive Chain Adjustment114
Front Suspension115
Rear Suspension115
Controls Check115
Transmission Lubrication116
Transmission Oil Changing Procedure116
Transmission Oil Change - Dipstick Models116
Transmission Lubrication - Type V Shaft/Chain117
Transmission Oil Change Procedure117
Transmission Vent Line Routing118
Transmission Linkage Adjustment118
Wheels Inspection119
Wheel, Hub, And Spindle Torque Table119
Wheel Removal Front Or Rear119
Wheel Installation119
Tire Pressure120
Tire Tread Depth120
Frame, Nuts, Bolts, Fasteners120
Engine122
2 Stroke Engine Torque Specifications124
4 Stroke Engine Torque Specifications124
Engine Fastener Torque Patterns125
1996 To Current Engine Specifications126
Piston Identification126
Ec38Pl Engines127
Jetting Guidelines For Round-Port Pistons127
Eh42Pl/Eh50Pl Engine Service Data129
Cooling System131
System Pressure Test131
Radiator Cap Pressure Test131
Recommended Coolant132
Cooling System Specifications132
2 Stroke Engine Removal133
Engine Removal Preparation, Typical (2 Stroke)133
Engine Installation Notes (2 Stroke)136
Bleed Cooling System136
Transmission Readjustment136
Engine Break In Period (2 Strokes)136
Ec25Pf/Ec28Pf Engines Disassembly137
Crankshaft Alignment138
Ec25Pf/Ec28Pf Engines Assembly139
Measure Crankshaft Width - Bearings Installed139
Connecting Rod Side Clearance140
Ec25Pf/Ec28Pf Engines Installation144
Oil Pump End Play Adjustment145
Oil Check Valve Testing (250/400)146
Oil Check Valve Testing (300)146
Ec25Pf Engine - Recoil Disassembly147
Ec25Pf Engine - Recoil Assembly148
Ec38Pl Engine Disassembly150
Water Pump Impeller Clearance156
Cylinder Hone Selection/Honing Procedure158
Piston/Cylinder Clearance (2 Strokes)159
Cylinder Inspection/Measurement159
Piston Inspection/Measurement (Generic)159
Piston Ring Installed Gap160
Piston Pin/Needle Bearing Inspection160
Connecting Rod Small End Inspection161
Eh42Pl/Eh50Pl Engine Exploded View162
Eh42Pl/Eh50Pl Lubrication/Oil Flow163
Oil Pressure Test163
Eh42Pl/Eh50Pl Engine Diagram164
Eh42Pl/Eh50Pl Oil Flow Chart164
Eh42Pl/Eh50Pl Engine Removal165
Cylinder Head Bolts165
Crankcase165
Awd Models166
Pvt Disassembly, All Models166
Recoil/Starter Removal167
Final Coolant Draining/Engine Removal169
Eh42Pl/Eh50Pl Engine Installation170
Oil Supply170
Eh42Pl/Eh50Pl Engine: Bleed Cooling System170
Cam Chain Tensioner/Rocker Arm/Camshaft Removal170
To Position Crankshaft At Top Dead Center (Tdc) On Compression Stroke171
Cam Chain Tensioner171
Rocker Arm/Shaft Removal172
Rocker Arm/Shaft Inspection172
Camshaft Removal174
Automatic Compression Release Removal/Inspection175
Automatic Compression Release Installation175
Camshaft Inspection176
Cylinder Head Removal177
Cylinder Head Disassembly/Inspection178
Cylinder Head Warpage179
Cylinder Head Disassembly179
Valve Inspection181
Combustion Chamber182
Valve Seat Inspection182
Cylinder Head Reconditioning182
Valve Guide Removal/Installation182
Valve Seat Reconditioning183
Cylinder Head Assembly186
Valve Sealing Test187
Cylinder/Piston Removal And Inspection187
Piston Removal188
Cylinder Inspection189
Piston To Cylinder Clearance190
Piston Ring Installed Gap (Eh42Pl/Eh50Pl)192
Crankcase Disassembly192
Starter Drive Removal/Inspection193
Flywheel/Stator Removal/Inspection194
Cam Chain/Tensioner Blade194
Stator Plate194
One Way Valve195
Crankcase Separation195
Oil Pump Removal/Inspection196
Oil Pump Assembly198
Counter Balancer Shaft Removal/Inspection198
Crankshaft Removal/Inspection199
Crankcase Bearing Inspection200
Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal200
Eh42Pl/Eh50Pl Engine Assembly201
Crankcase Assembly201
End Play Inspection/Adjustment201
Crankshaft201
Counter Balancer203
Pump Shaft203
Pump Shaft Oil Seal Installation203
Crankshaft, Counter Balancer And Oil Pump Installation204
To Assemble The Crankcase204
Water Pump Mechanical Seal Installation205
Water Pump Mechanical Seal Removal - Engine Installed205
Piston Installation208
Cylinder Installation209
Cylinder Head Installation210
Cam Chain/Camshaft Installation211
Camshaft Installation - Timing Method212
Method 1 - Camshaft Timing With Stator Removed213
Camshaft Installation - Timing Method 2214
Method 2 Camshaft Timing Using Flywheel Tdc Mark215
Cam Chain Tensioner Installation216
Stator, Flywheel And Starter Drive Installation216
Rocker Shaft/Rocker Arm Assembly Installation218
Thermostat Installation218
Oil Pipes218
Engine - Sealed Recoil219
Recoil Disassembly/Inspection219
Recoil Assembly220
To Install A New Spring220
To Reinstall An Old Spring220
Spark Plug Fouling - 2 Stroke Engine222
Spark Plug Fouling - 4 Stroke Engine222
2 Stroke Engine Troubleshooting223
Starter Motor224
4 Stroke Engine Troubleshooting225
Piston Damage Checklist - 2 Stroke Engines227
Fuel System/Carburetion228
Fuel System/Carburetion - 1996 Specifications230
Jetting Guidelines230
Jetting Compensation For Altitude And Temperature - 1996 Models230
Fuel System/Carburetion - 1997 Specifications234
Jetting Compensation For Altitude And Temperature (1997)234
Fuel System/Carburetion - 1998 Specifications235
1998 Trail Boss W98Aa25C (Engine -Ec-25Pfe-10) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature235
1998 Trail Blazer W98Aa25C (Engine -Ec-25Pfe-11) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature236
Xpress 300 W98Ca28C (Engine -Ec-28Pfe-12) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature237
Xlporer 300 W98Cc28C (Engine -Ec-28Pfe-02) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature238
1998 Xlporer 400 W98Cc38C (Engine -Ec-38Pfe-06) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature239
1998 Sport 400 W98Ba38C (Engine - Ec-38Ple-07) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature240
1998 Scrambler 400 W98Bc38C (Engine - Ec38Ple-09) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature241
Magnum 2 X 2 W98Aa42A (Engine - Eh-42Ple-02) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature242
Magnum 4 X 4 W98Ac42A (Engine - Eh-42Ple-02) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature243
1998 Scrambler 500 W98Bc50A (Engine - Eh50Ple-04) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature244
Sportsman 500 W98Ch50A (W90Ch50Ab) (Engine - Eh-50Ple-07) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature245
1998 Big Boss 500 6X6 W98Ae50A (Engine - Eh50Ple-06) - Specifications And Clutching And Jetting Guidelines For Altitude And Temperature246
Fuel System/Carburetion - Jet Part Numbers247
Oil Tank And Fuel Tank Assembly - Gen Ii (Except Magnum)248
Fuel Tank Assembly (Magnum)249
Oil Tank And Fuel Tank Assembly (Gen Iii Typical)250
Fuel Tank Assembly (Gen Iv)251
Fuel Tank Assembly - 500 Models (1997 Xplorer 500, Sportsman 500)252
Fuel Flow Diagrams253
Mikuni Vm Carburetor Exploded Diagram254
Carburetor Function255
Float System255
Component Functions256
Pilot Jet256
Pilot Air Screw256
Air/Fuel Mixture Ratio256
Jet Needle257
Needle Jet257
Throttle Opening Vs. Fuel Flow257
Throttle Valve258
Main Jet258
Starter System - Closed Throttle259
Pilot System (0-3/8 Throttle)260
Slide Cutaway (1/8-3/8 Throttle)261
Jet Needle/Needle Jet (3/8-3/4 Throttle)262
Main System (3/4 To Full Throttle)263
Component Effect Vs. Throttle Opening264
Mikuni Vm Fuel Delivery Chart264
Mikuni Vm Carburetor System Components265
Venting Systems265
Mikuni Bst 34 Carburetor Exploded View266
Venting Systems (Mikuni Cv)267
Mikuni Cv Carb Operation268
Pilot (Idle And Slow) Systems269
Starter System (Choke Or Enrichment)269
Float System (Mikuni Cv)270
Main System (Mikuni Cv)270
Magnum Fuel Tank Removal271
Carburetor Removal ( Mikuni Cv)272
Carburetor Disassembly - Mikuni Cv273
Carburetor Cleaning - Mikuni Cv276
Carburetor Assembly - Mikuni Cv279
Carburetor Assembly/Adjustment - Mikuni Cv280
Float Height Adjustment (Mikuni Cv)280
Cv Carburetor Installation282
Needle And Seat Pressure Test Mikuni Cv283
Inlet Needle And Seat283
Fuel Level (Mikuni Cv)283
Float Bowl Draining284
Fuel Pump Exploded View286
Fuel Pump Testing287
Fuel Pump Disassembly287
Fuel Pump Inspection/Assembly287
Fuel System/Carburetion Troubleshooting288
Fuel Starvation/Lean Mixture288
Rick Mixture288
Poor Idle288
Idle Too Low289
Erratic Idle289
Body And Steering290
Body And Steering - Torque Specifications And Special Tools292
Body Styles293
1996 Body Styles293
1997 Body Styles293
1998 Body Styles293
Body Assembly Exploded View (Gen Ii - Typical)295
Cover/Panel Removal (Gen Ii - Typical)296
Cover/Panel Removal (Gen Iii - Typical)297
Cover/Panel Removal (Gen Iv - Typical)298
Body Assembly Exploded View (Gen Iii - Typical)299
Body Assembly Exploded View (Gen Iv - Typical)300
Body Assembly Exploded View (Gen Iv - Headlight Pod)301
Headlight Pod Service (Gen Iv Typical) - Disassembly302
Headlight Pod Service (Gen Iv Typical) - Installation303
Side Panel Removal (Gen Iv - Typical)304
Toe Alignment305
Toe Alignment - Method 2306
Typical Steering Assembly, Exploded View, Trail Boss 250307
Steering Assembly, Exploded View, 2X4 Models (Except Trail Boss 250)308
Steering Assembly, Exploded View, 4X4 And 6X6 Models309
Steering Stop Adjustment310
Rear Axle Bend310
A-Arm Replacement310
Rear Drive Axle, Hub And Wheel Assembly, - 2X4 And 4X4 (Except Sportsman 500)311
Concentric Swingarm Rear Axle Assembly, Exploded View - 1998 Scrambler 400/500312
Concentric Swingarm Exploded View 1998 Scrambler 400/500313
Rear Drive Axle, Hub And Wheel Assembly - Shaft Drive Models314
Rear Strut Stabilizer, 6X6 Models315
Rear Swing Arm Weldment, 6X6 Models316
Swing Arm And Rear Suspension Exploded View318
Swing Arm Removal319
Swing Arm Removal/Inspection320
Swing Arm Assembly/Installation321
Concentric Swingarm Removal/Disassembly322
Concentric Swingarm Assembly/Installation323
Strut Assembly - 400L Awd, Magnum Awd324
Front Strut Weldment Replacement325
Front Strut Cartridge Replacement325
Strut Assembly - 2X4 Models325
Front Strut Service326
Front Strut Removal326
Front Strut Installation327
Front Strut Ball Joint Replacement328
2X4 Hub Bearing Service329
2X4 Front Hub Disassembly/Inspection329
2X4 Front Hub Assembly330
2X6 Hub Bearing Service331
2X4 Front Hub Installation331
Fox Shock Service332
Foxtm Shock Service333
Fox Shock Standard Valving Chart339
1996 Optional Suspension Springs340
1997 Optional Suspension Springs341
1996 Paint Codes342
Clutches344
Clutch - Specifications346
Clutch - Special Service Tools And Supplies346
1996 Productoin Specifications346
1996 Clutch Recommendations For Altitude346
1997 Production Specifications347
1997 Clutch Recommendations For Altitude347
1998 Production Specifications348
1998 Clutch Recommendations For Altitude348
Shift Weights349
Drive Clutch Spring Specifications351
Clutches Overview352
Relationship Of Drive Clutch Weights And Spring In Maintaining Operating Rpm352
Pvt System Indroduction353
Drive Clutch Operation353
Driven Clutch Operation353
Clutch Maintenance354
Pvt Maintenance/Inspection354
Pvt Overheating354
Pvt Sealing And Ducting Components - Type I354
Pvt Sealing And Ducting Components - Type Ii355
Pvt Sealing And Ducting Components - Type Iii356
Pvt Sealing And Ducting Components - Type Iv356
Typical Pvt Disassembly358
Pvt Assembly359
Drive Belt Tension361
Drive Belt Removal/Inspection361
Clutch Alignment /Offset362
Driven Clutch Disassembly363
Driven Clutch Assembly365
Drive Clutch - Springs Specifications Table367
Drive Clutch Inspection368
Spider Removal368
Moveable Sheave Bushing Inspection368
Drive Clutch Disassembly369
Roller, Pin And Thrust Washer Inspection369
Drive Clutch Assembly371
Clutch Bushing Removal And Installation372
Polaris Kit Pn 2871226372
Drive Clutch Moveable Sheave - Bushing Removal372
Drive Clutch Moveable Sheave - Bushing Installation373
Drive Clutch Cover - Bushing Removal374
Drive Clutch Cover - Bushing Installation375
Driven Clutch Moveable Sheave - Bushing Removal376
Driven Clutch Moveable Sheave - Bushing Installation378
Engine Braking System (Ebs)380
One-Way Clutch380
Driven Clutch Spring380
High Elevation Setup380
Ebs Exploded View381
Drive Clutch Disassembly - Ebs382
Drive Belt Removal - Ebs382
One-Way Clutch Inspection (Drive Clutch)382
Inspection Of Moveable Sheave Bushing383
Driven Clutch Disassembly - Ebs384
One-Way Clutch Preliminary Inspection (Driven)384
Roller Pin Disassembly385
Operation Guidelines For Ebs Clutches387
Clutches Troubleshooting388
Final Drive390
Final Drive Torque Specifications392
Wheel, Hub, And Spindle Torque392
Rolling Torque392
Final Drive Exploded View393
Awd Front Hub393
Demand 4 Operation - Awd Models394
Electricl Hub Engagement (4X4)394
Front Hub Disassembly (4X4)395
Hilliard Clutch Disassembly/Inspection396
Hilliard Clutch Assembly Testing397
Seal Sleeve Replacement397
Strut Seal Sleeve Replacement398
Magnetic Coil Replacement399
Wheel Hub Seal Replacement400
Strut Casting Seal Replacement401
Drive Shaft Boot Replacement402
Front Drive Shaft Cv Joint Boot Replacement (4X4 Models)402
Hub/Wheel Bearing Installation (4X4 Models)403
Hublwheel Bearing Installation403
Front Hub Bearing Adjustment (Awd Models)404
Front Hub Bearing Adjustment (Awd Models Equipped With Cotter Pins)405
Front Axle Identification407
Front Drive Axle Removal409
Front Drive Axle Installation410
U-Joint Service411
U-Joint Disassembly (Typical)411
U-Joint Inspection412
U-Joint Assembly (Typical)412
2X4 Front Hub Disassembly And Inspection414
2X4 Front Hub Assembl.415
2X4 Front Hub Install.416
Rear Axle Removal417
Rear Axle Installation419
6X6 Middle Axle Sprocket Service422
6X6 Middle Axle Sprocket Removal422
Brake Disc Hub Removal425
Middle Axle Assembly426
Rear Hub/Bearing Carrier Removal (Type Iv Shaft Drive)428
Rear Hub Disassembly (Shaft Drive)430
Rear Hub Assembly (Shaft Drive)431
Rear Hub Installation432
Rear Drive Shaft Removal433
Rear Drive Shaft Disassembly434
Rear Drive Shaft Assembly434
Rear Drive Shaft Installation435
Rear Eccentric Removal436
Rear Eccentric Disassembly436
Rear Eccentric Assembly437
Rear Eccentric Installation439
Center Eccentric Removal440
Center Eccentric Disassembly441
Center Eccentric Assembly441
Center Eccentric Installation443
Front Eccentric Removal445
Front Eccentric Assembly447
Front Eccentric Installation449
Front Gearcase Removal451
Prop Shaft Removal451
Front Gearcase Disassembly452
Front Gearcase Assembly455
Front Gearcase Installation458
Concentric Swingarm Rear Axle Removal460
Concentric Swingarm Rear Axle Assembly461
Concentric Swingarm Rear Axle Installation461
Concentric Swingarm Rear Axle Assembly, Exploded View463
Transmission Service464
Transmission Service - Torque Specifications466
Transmission Service - Lubrication466
Gear Ratios467
Torque Stop/Shift Linkage Adjustment468
Shift Linkage Rod End Positioning470
Transmission Service - Troubleshooting471
Gear Shift Selector Removal472
Gear Shift Selector Disassembly472
Gear Shift Selector Assembly474
Gear Shift Selector Installation475
Boot Replacement475
Transmission Service - Type Iii, Ez-Shift Transmission476
Transmission Removal (Typical)476
Type Iii Transmission Exploded View478
Type Iii Transmission Disassembly479
Type Iii Transmission Assembly480
Type Iii Transmission Installation481
Type Iii, Ez Shift Transmission Installation483
Type V Ez-Shift Transmission (1998 Scrambler 400/500) Removal484
Type Iv, Shaft Drive Transmission Removal485
Type Iv, Shaft Drive Transmission Disassembly488
1996 - Early 1997 Type Iv Shaft Drive Transmission Exploded View496
Late 1997 Type Iv Shaft Drive Transmission Exploded View497
1997 (Late) - Current Tensioner Installation498
Shaft Drive Transmission Assembly499
Transmission Output Gear Backlash Adjustment503
Shaft Drive Transmission Installation509
Front Drive Housing Seal Removal (In Frame)513
Front Drive Housing Seal Installation (In Frame)513
Brakes514
Brakes Specifications516
Brakes - Torque Specifications517
Hydraulic Brake System Operation518
Fluid Replacement/Bleeding Procedure519
Brake Bleeding - Fluid Change519
Front Pad Replacement521
Front Pad Removal521
Front Pad Inspection522
Front Pad Assembly523
Output Shaft Brake Pad Replacement/Adjustment525
Output Shaft Brake Pad Inspection526
Output Shaft Brake Pad Assembly527
6X6 Rear Brake Pad Replacement528
6X6 Rear Brake Pad Removal528
6X6 Rear Brake Pad Inspection529
6X6 Middle Axle Brake Pad Assembly530
Master Cylinder Disassembly531
Master Cylinder Inspection533
Master Cylinder Assembly533
Master Cylinder Installation535
Front Caliper Disassembly536
Front Caliper Inspection537
Front Caliper Assembly538
Front Caliper Installation538
Output Shaft Caliper Service (Auxiliary Brake) - Disassembly540
Output Shaft Caliper Inspection540
Output Shaft Caliper Reassembly541
Output Shaft Caliper Installation542
6X6 Rear Caliper Removal543
6X6 Rear Caliper Inspection543
6X6 Rear Caliper Assembly545
Dual Hydraulic Brake Caliper Bleeding546
Auxiliary Brake Adjustment (Hydraulic)547
Free Play Of The Brake Pedal547
Brakes Troubleshooting548
Electrical550
Electrical - Special Tools552
1996 Electrical Specifications553
1997 Electrical Specifications554
1998 Electrical Specifications555
1996 Stator Resistance Specifications556
Battery Type556
1997 Stator Resistance Specifications557
Flywheel Identification558
Headlamp Service, Gen Ii559
Headlight Adjustment (Gen Ii)559
Headlight Lamp Replacement (Gen Ii)559
Headlamp Service - Gen Iii561
Headlight Adjustment (Gen Iii - Scrambler, Trail Blazer E.s. And Sport)561
Adjustment - Trail Blazer E.s. And Sport561
Headlight Lamp Replacement (Gen Iii)561
Headlamp Service - Gen Iv563
High Beam Headlight Adjustment (Gen Iv)563
Headlight Lamp Replacement (Gen Iv)563
Headlight Housing Replacement (Gen Iv)563
Indicator Lamp Service564
Taillight/Brakelight Lamp Replacement564
Indicator Lamp Replacement (Gen Ii, Gen Iii And Gen Iv)564
Timing Check Procedures565
Typical Ingnition Timing Curves566
Crankshaft Degree To Piston Position Conversion Chart (2 Stroke Engines)567
Components Of Ec25/28Pl 150 Watt Alternator (Exploded View)568
Components Of Ec38Pl 150 Watt Alternator (Exploded View)569
Components Of Ec38Pl 200 Watt Alternator (Exploded View)570
Components Of Ec42Pl/Eh50Pl 200/250 Watt Alternator (Exploded View)571
Ignition System572
Cranking Output Test With Peak Reading Voltmeter573
Cdi Output Test Using Peak Reading Adaptor573
Ignition System Troubleshooting574
No Spark, Weak Or Intermittent Spark574
Battery Service575
Battery Terminals/Terminal Bolts575
Battery Inspection/Removal576
Battery Installation576
Battery Testing576
Ocv - Open Circuit Voltage Test576
Specific Gravity Test577
Load Test577
Off Season Storage578
Charging Procedure578
Charging System Testing579
Current Draw - Key Off580
Charging System "Break Even" Test580
Alternator Ouptut Test (Ac Amp)580
Starter System Troubleshooting581
Voltage Drop Test581
Starter Motor Removal583
Starter Motor Disassembly584
Brush Inspection/Replacement586
Armature Testing587
Starter Assembly587
Starter Motor Installation (Ec38Pl)588
Starter Drive590
Pinion Gear - Anti Kick-Out Shoe, Garter Spring Replacement590
Starter Solenoid Bench Test590
Speed Limiter System591
Limiter Specifications591
Speed Limiter System - Theory Of Operation592
Reverse Speed Limiter System592
Electronic Throttle Control (Etc) - Theory Of Operation592
Speed Limiter System Testing593
Module Wire Color Function593
All Wheel Drive System594
All Wheel Drive (Awd) Testing594
No Awd In Reverse594
No All Wheel Drive (Awd) On Shaft Drive Models Equipped With Hub Safety Module594
Front Hub Enlargement Limiter (Front Shaft Drive Models)595
Hub Engagement Limiter Rpm Test595
Switch Testing597
Key Switch/Auxiliary Shut Off (Kill) Switch597
Starter Switch597
Override Button597
All Wheel Drive (Awd) Switch (4X4 Model)598
Electronic Throttle Control (Etc) Switch598
Oil Level Sensor Testing (2 Stroke Models)599
Oil Level Warning Light Testing (2 Stroke Models)599
Coolant Temperature Sensor Test (Hot Light)599
Hot Light Circuit Test599
Fan Control Circuit Operation/Testing600
Fan Control Switch Bypass Test600
Fan Control Switch Operation Test600
Fan Motor Current Draw601
Brake Light Switch601
Headlamp Switch601
Neutral Light Circuit Operation601
Wiring Diagram 1996 Trail Boss, Trail Blazer602
Wiring Diagram 1996 Txpress 300, Xplorer 300603
Wiring Diagram 1996 Xpress 400, Xplorer 400, Sportsman 4X4, 400 6X6604
Wiring Diagram 1996 Scrambler, Sport605
Wiring Diagram 1996 Magnum 2X4, 4X4, 6X6606
Wiring Diagram Sportsman 500607
Alphabetical Index608
Wiring Diagram 1997 Xplorer 400, Xpress 400614
Wiring Diagram 1997 Sportsman 500, Xplorer 500615
Wiring Diagram 1997 Magnum 2X4, Magnum 4X4, Magnum 6X6616
Wiring Diagram 1997 Trail Blazer617
Wiring Diagram 1997 Scrambler 4X4, Sport618
Wiring Diagram 1997 Scrambler 500619
Wiring Diagram 1997 Trail Boss620
Wiring Diagram 1997 Sportsman 400, 400 6X6621
Wiring Diagram 1997 Xplorer 300, Xpress 300623
Wiring Diagram 1998 Trail Blazer/Trail Boss624
Wiring Diagram 1998 Xplorer 300/Xpress 300625
Wiring Diagram 1998 Sport 400626
Wiring Diagram 1998 Scrambler 400627
Wiring Diagram 1998 Xplorer 400628
Wiring Diagram 1998 Magnum 2X4629
Wiring Diagram 1998 Magnum 4X4630
Wiring Diagram 1998 Scrambler 500631
Wiring Diagram 1998 Sportsman 500632
Wiring Diagram 1998 Big Boss 500 6X6633