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1997 Sport 400
Polaris 1997 Sport 400 Manuals
Manuals and User Guides for Polaris 1997 Sport 400. We have
2
Polaris 1997 Sport 400 manuals available for free PDF download: Service Manual
Polaris 1997 Sport 400 Service Manual (666 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 15.13 MB
Table of Contents
Table of Contents
2
General Information / Specifications
2
Chapter 1 General Information / Specifications
4
Engine Serial Number Location
4
Machine Model Number and VIN Number Location
4
Model / VIN Identification
4
Transmission I.D. Number Location
4
Current Model Numbers
5
Vehicle Identification Number
5
Vehicle Identification Number / Model Number Key
5
Year / Letter Identification
5
1999 Publication Part Numbers
6
General Information
6
Service Bulletin Index
6
Service Training Videos
6
1999 Paint Codes
7
Standard Torque Specifications
8
Conversion Table
10
Metric Tap Drill Sizes
11
SAE Tap Drill Sizes
11
Tap Drill Charts
11
Service Tips
12
Glossary of Terms
13
Glossary of Terms
14
Special Tools
16
1999 Model Specifications
17
Trail Blazer
17
Trail Boss 250
19
Xpress 300
21
Xplorer 300
23
Sportsman 335
25
Sport 400
28
Scrambler 400
29
Scrambler 500
30
Magnum 500
36
1999 Model Specifications
36
Trail Blazer
41
Xplorer 4X4
43
Trail Boss 325
45
Xpedition 325
51
Sportsman 335
53
Xplorer 400
55
Scrambler 400 2X4
57
Scrambler 400 4X4
59
Xpedition 425
61
Magnum 500
63
Scrambler 500
65
Sportsman 6X6
69
Maintenance
72
Chapter 2 Maintenance
74
Periodic Maintenance Chart
74
Pre-Ride / Daily Inspection
75
Recommended Lubricants - Quick Reference
76
Polaris Premium Lubricant and Maintenance Product Part Numbers
77
Lubrication
79
Lubrication - Shaft Drive Models
81
Lubrication Chart - Shaft Drive Models
82
Gearcase Lubrication - Quick Reference
83
Front Gearcase Lubrication
84
Rear Gearcase Lubrication
86
Dipstick Models
87
Transmission Lubrication
87
Shaft / Chain Models Without Dipstick
88
Counter Balance Oil Changing Procedure
89
Counter Balancer Lubrication (400Cc Engines)
89
Procedure for Adding Oil (400)
89
Torque Stop Adjustment
90
Transmission Gearshift Linkage Adjustment, Preliminary Inspection
90
Shift Linkage Adjustment -High/Low/Reverse Transmissions
91
Shift Linkage Adjustment (High/Reverse Transmissions)
93
Carburetor Adjustments
94
Choke (Enricher) Adjustment
94
Throttle Operation - All Models
94
Air Screw Adjustment
95
Pilot Screw Anti-Tamper Plug Removal
96
Pilot Screw (Idle Mixture) Adjustment Notes
97
Pilot Screw Adjustment - 335 4- -Stroke Models
97
Pilot Screw Adjustment - 425 / 500 4- -Stroke Models
97
Idle Speed Adjustment
98
Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
99
Oil Pump Adjustment Procedure
100
Oil Pump Bleeding Procedure
102
Oil Pump Troubleshooting Procedure
102
Oil Filter (2 Strokes)
103
Fuel Filter
104
Fuel Lines
104
Fuel System
104
Vent Lines
104
Carburetor Draining
105
Compression Test - 2 Stroke
106
Compression Test - 4 Stroke
106
Engine Mounts
106
Fastener Torque - Engine
106
Battery Maintenance
107
Electrical
107
Electrical
108
Engine-To-Frame Ground
108
Ignition Timing
108
Spark Plug
108
Coolant Strength / Type
109
Cooling System Hoses
109
Liquid Cooling System Overview
109
Radiator
109
Coolant Level Inspection
110
Engine Cooling System
111
Radiator Coolant Level Inspection
111
Air Filter Service (Trail Blazer Style)
112
Dual Stage Air Cleaner - 300 Style
113
Primary Pre-Cleaner Foam Boot
113
Cleaning the Main Filter
114
Secondary (Main) Filter
114
Secondary Filter Removal and Installation
114
Air Filter Service, 2 Stroke
116
Air Filter Service, 4 Stroke
116
Breather Filter
116
Air Box Sediment Tube
117
Breather Filter Inspection
118
Breather Hose
118
Recoil Housing
119
Engine Oil Level (4 Stroke)
120
Oil and Filter Change (4 Stroke)
120
Valve Clearance - 335, 425, 500Cc Engines
122
Exhaust Valve Clearance Adjustment
123
Intake Valve Clearance Adjustment
123
Steering & Toe Alignment Inspection
125
Tie Rod End / Steering Inspection
125
Straightedge or String
126
Chalk
127
Toe Alignment Adjustment
127
Front Hub Fluid Change (AWD Models)
128
Front Hub Fluid Level Inspection (AWD Models)
128
Exhaust Pipe
129
Brake Pad Inspection
130
Brake System Inspection
130
Brake System Service
130
Hose/Fitting Inspection
130
Auxiliary Brake Adjustment (Hydraulic)
131
Auxiliary Brake Adjustment - Mechanical
132
Auxiliary Brake Testing
132
Auxiliary Mechanical Brake System
132
Drive Chain and Sprocket Inspection
133
Drive Chain Inspection
133
Sprocket Inspection
133
Rear Drive Chain Tension Adjustment - Standard Swingarm
134
Rear Drive Chain Tension Inspection - Standard Swingarm
134
Adjustment Procedure - Concentric Swingarm Rear Axles (Tapered Roller Bearings)
135
Drive Chain Adjustment, Concentric Swingarm
135
Center/Front Drive Chain Inspection/Adjustment
138
Center/Front Drive Chain Slack Adjustment
138
6X6 Chain Inspection
139
6X6 Middle Axle Chain Adjustment
139
6X6 Rear Axle Drive Chain Adjustment
139
Drive Chain Inspection/Adjustment - 6X6
139
Controls
140
Front Suspension
140
Rear Suspension
140
Suspension Spring Preload Adjustment
140
Chassis Maintenance
141
Wheel Removal Front or Rear
141
Wheel, Hub, and Spindle Torque Table
141
Wheels
141
Frame, Nuts, Bolts, Fasteners
142
Tire Inspection
142
Tire Pressure
142
Tire Tread Depth
142
Engine
144
Torque Specifications
146
Engine Fastener Torque Patterns
148
Piston Clearance Specifications (2 Stroke Engines)
149
Piston Identification
149
ES33PFE01 / 02 Engine Service Data
150
EH42PLE02 / EH50PLE04, 06, 08, 09 Engine Service Data
152
Bleed Hole Inspection
154
Radiator Cap Pressure Test
154
System Pressure Test
154
CHAPTER 3 ENGINE Torque Specifications - 2 Stroke
155
Cooling System Specifications
155
Recommended Coolant
155
Accessible Components - All Models
156
Engine Removal
156
Engine Removal
157
Bleed Cooling System
158
Engine Installation Notes
158
General Items
158
PVT System
158
EC25PF / EC28PF Engine Disassembly
159
Connecting Rod Side Clearance
160
Crankshaft Main Bearing Inspection
160
EC25PF/EC28PF Engine Assembly
161
Measure Crankshaft Width - - Bearings Installed
161
Oil Pump End Play Adjustment
166
Oil Check Valve Testing (EC25PF)
167
Oil Check Valve Testing (EC28PF)
167
Recoil Disassembly
168
EC25PF Recoil Assembly
169
EC38PL Engine Disassembly
171
EC38PL Engine Inspection
172
Connecting Radial Clearance
177
Reed Valve Inspection
178
Water Pump Impeller Clearance
178
Impeller Spacer Shim Part Numbers
179
Oil Check Valve Testing (EC38PL)
180
Cylinder Inspection/Measurement
181
Piston Inspection/Measurement (2 Stroke)
181
Piston Ring Installed Gap
182
Cleaning the Cylinder after Honing
183
Cylinder Hone Selection/Honing Procedure
183
Honing to Oversize
183
Connecting Rod Small End Bearing Inspection
184
Crankshaft Runout Inspection - 2 Stroke
185
Crankshaft Straightening
185
4 Stroke Engine Service
186
Engine Lubrication - ES33PF / EH50PL
188
Oil Pressure Test - ES33PF / EH50PL
188
Oil Flow -- ES33PF
189
335 (ES33PFE) Oil Flow Chart
190
ES50PL Lubrication/Oil Flow
191
EH50PL Oil Flow Chart
192
Es33Pfengine Exploded View
193
EH50PL Engine Exploded View
194
Cam Chain Tensioner/Rocker Arm/Camshaft Removal
195
Engine Disassembly / Inspection
195
To Position Crankshaft at Top Dead Center (TDC) on Compression Stroke
195
Cam Chain Tensioner Inspection
196
ES33PF / EH50PL Engine Removal
196
Rocker Arm/Shaft Removal
197
Rocker Arm/Shaft Inspection
198
Camshaft Removal
200
Automatic Compression Release Installation
202
Automatic Compression Release Removal/Inspection
202
If Camshaft Is Installed in the Engine
202
If Camshaft Is Removed from Engine
202
Camshaft Inspection
203
Cylinder Head Exploded View, ES33PF
204
Cylinder Head Exploded View, EH50PL
205
Cylinder Head Inspection
206
Cylinder Head Disassembly
207
Cylinder Head Warpage
207
Valve Inspection
209
Combustion Chamber
210
Cylinder Head Reconditioning
211
Valve Guide Removal/Installation
211
Valve Seat Inspection
211
Reaming the Valve Guide
212
Valve Seat Reconditioning
212
Cylinder Head Assembly
215
Valve Sealing Test
216
Cylinder/Piston Removal and Inspection
217
ES33PF / EH50PL Engine Bottom End Disassembly
217
Piston Removal
219
Cylinder Inspection
220
Piston-To-Cylinder Clearance
221
Crankcase Disassembly
224
Starter Drive Removal/Inspection
224
Flywheel/Stator Removal/Inspection
225
Cam Chain/Tensioner Blade
226
One Way Valve
227
Crankcase Separation
228
Oil Pump Removal/Inspection
229
Oil Pump Assembly
231
Counter Balancer Shaft Removal/Inspection
232
Crankshaft Removal/Inspection
233
Crankcase Bearing Inspection
234
Pump Shaft Oil Seal/ Water Pump Mechanical Seal Removal (Engine Disassembled)
234
Bearing Installation
235
Crankcase Assembly
235
Crankshaft End Play Adjustment
236
End Play Inspection/Adjustment
236
Counter Balancer Shaft End Play Adjustment
238
Pump Shaft
239
Pump Shaft Oil Seal Installation
239
Crankshaft, Counter Balancer, and Oil Pump Installation
240
Water Pump Mechanical Seal Installation (EH50PL)
241
Water Pump Mechanical Seal Removal - Engine Installed (EH50PL)
241
Cam Chain Drive Sprocket Installation
243
One Way Valve Installation
243
Tensioner Blade Installation
243
Piston Ring Installation
244
Piston Installation
245
Cylinder Installation
246
Cylinder Head Installation
248
Cam Chain/Camshaft Installation
249
Camshaft Timing
249
ES33PF / EH50PL Engine Assembly/Inspection
251
Cam Chain Tensioner Installation
252
Stator, Flywheel and Starter Drive Installation
252
Flywheel
253
Starter Drive
253
Oil Pipes
254
Rocker Shaft/Rocker Arm Assembly Installation
254
Thermostat Installation
254
Recoil Disassembly/Inspection
255
To Complete Recoil Assembly
257
To Install a New Spring
257
To Reinstall an Old Spring
257
Spark Plug Fouling - 2 Stroke Engines
258
Spark Plug Fouling - 4 Stroke Engines
258
Spark Plug Fouling Checklist
258
2 Stroke Engine Troubleshooting
259
Engine Does Not Turn over
261
Engine Idles but will Not Rev up
261
Engine Runs but will Not Idle
261
Engine Turns over but Fails to Start
261
Backfiring
262
Excessive Smoke and Carbon Buildup
262
Low Compression
262
EH42PL/EH50PL Cooling System Troubleshooting
263
Leak at Water Pump Weep Hole
263
Overheating
263
Temperature too Low
263
Fuel System/Carburetion
264
Air Screw (2 Cycle) / Pilot Screw (4 Cycle) Adjustment
266
Main Jet Selection
266
Chapter 4 Fuel System/Carburetion
266
Jetting Guidelines
266
Fuel Tank Assembly / Oil Tank Assembly
267
Fuel Flow Diagrams
269
Fuel System Diagram - 2 Stroke Models
269
Fuel System Diagram - 4 Stroke Models
269
Air/Fuel Mixture Ratio
272
E-Clip Position Vs. Fuel Flow
272
Pilot Air Screw
272
Pilot Jet
272
Jet Needle
273
Needle Jet
273
Throttle Opening Vs. Fuel Flow
273
Main Jet / Pilot Jet Part Numbers
274
Throttle Valve
274
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
Carburetor Component Function (2 Cycle)
280
Component Effect Vs. Throttle Opening (2 Cycle)
280
Mikuni Fuel Delivery (2 Cycle)
280
Assembly, CV Carburetor
281
Float Height Adjustment (2 Cycle)
281
Needle and Seat Leakage Test - 2 Cycle
281
Vent Systems (2 Cycle)
281
Mikuni VM30SS / VM34SS Carburetor Exploded View
282
4 Cycle CV Carburetor System Function
283
Vent Systems - 4 Cycle CV Carburetor
283
Mikuni CV Carb Operation
284
Pilot (Idle and Slow) System
285
Starter System (Choke or Enrichment)
285
Float System
286
Main System
286
Mikuni BST 34 Carburetor Exploded View
287
Mikuni BST 40 Carburetor Exploded View
288
Carburetor Disassembly Notes- Mikuni CV
289
Carburetor Cleaning - Mikuni CV
291
Carburetor Inspection - Mikuni CV
292
Carburetor Assembly - Mikuni CV
293
Carburetor Adjustment - Mikuni CV
294
Float Height Adjustment
294
Fuel Level
295
Fuel Pump
296
Needle and Seat Leakage Test
295
Fuel Pump Disassembly
296
Fuel Pump Inspection/Assembly
296
Fuel Pump Exploded View
297
Fuel Starvation/Lean Mixture
298
Poor Idle
298
Troubleshooting
298
Rich Mixture
298
Erratic Idle
299
Idle too Low
299
Body / Steering / Suspension
300
Torque Specifications, Special Tools
302
Body Assembly Exploded View (Gen Ll - Typical)
303
Front Cab Assembly
303
Rear Cab Assembly
303
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 250
311
Steering Assembly, Exploded View, - 2X4 Models (Except ’99 Trail Boss 250)
312
Steering Assembly, Exploded View All 4X4 and 6X6 Models
313
A-Arm Replacement
314
Concentric Swing Arm Removal
315
Standard Swing Arm and Rear Suspension Exploded View
317
Shaft Ride Swingarm Exploded View
318
Shaft Ride Swingarm
319
Swingarm Installation
319
Rear Suspension Assembly, - Shaft Drive Models
320
Rear Strut Stabilizer, 6X6 Models
321
Rear Swing Arm Weldment, 6X6 Models
322
Front Swing Arm Weldment, 6X6 Models
323
Strut Assembly Exploded View - 2X4 Models
324
Strut Assembly - AWD Models
325
Front Strut Cartridge Replacement
326
Front Strut Weldment Replacement
326
Ball Joint Replacement
327
Front Strut Ball Joint Replacement
327
Decal Replacement
330
Clutches
332
Clutch Specifications
334
PVT System Fastener Torques
334
Special Service Tools and Supplies
334
Drive Clutch Operation
335
Driven Clutch Operation
335
PVT Operation
335
Standard PVT System Introduction
335
CHAPTER 6 CLUTCHES Service Tools and Supplies
336
PVT Maintenance/Inspection
336
PVT Drying
336
PVT Overheating
336
PVT Sealing and Ducting Components
336
PVT Disassembly
337
PVT Assembly
339
PVT Sealing and Ducting Components
340
Relationship of Drive Clutch Weights and Spring in Maintaining Operating RPM
343
Drive Clutch Spring Specifications
344
Shift Weights
345
Button to Tower Clearance Inspection
346
Drive Clutch Inspection
346
Shift Weight Inspection
346
Drive Clutch & EBS Exploded View
347
Drive Clutch Disassembly/Inspection
348
Moveable Sheave Bushing Inspection
349
Spider Removal
349
Roller, Pin and Thrust Washer Inspection
350
Drive Clutch Assembly
351
Standard P-90 (Non-EBS) Clutch
353
Drive Belt Tension
355
Drive Belt Removal/Inspection
356
Clutch Alignment/Offset
357
Drive Clutch Bushing Service
359
Drive Clutch Moveable Sheave - Bushing Removal
359
Polaris Kit PN 2871226
359
Drive Clutch Moveable Sheave - Bushing Installation
360
Drive Clutch Cover - Bushing Removal
361
Drive Clutch Cover - Bushing Installation
362
Driven Clutch Disassembly/Inspection
363
Driven Clutch Assembly
366
Driven Clutch Bushing Service
367
Driven Clutch Moveable Sheave - Bushing Installation
369
Engine Braking System (EBS) Clutch
372
EBS Theory of Operation
373
Operation Guidelines for Ebs Clutches
374
EBS Exploded View
375
One-Way Clutch Inspection (Drive Clutch)
376
Driven Clutch Disassembly/Inspection - EBS
379
One-Way Clutch Preliminary Inspection (Driven)
379
Ebs Clutch Bushing Removal and Installation
383
Ebs Drive Clutch Moveable Sheave - Bushing Removal
383
Removal and Installation Instructions
383
EBS Clutch Cover - Bushing Installation
384
EBS Clutch Cover - Bushing Removal
384
EBS Drive Moveable - Bushing Installation
384
EBS Driven - Bushing Installation
385
EBS Driven - Bushing Removal
385
EBS Driven - Backside (Outer) Bushing Installation
386
EBS Driven - Backside (Outer) Bushing Removal
386
Clutch Troubleshooting
387
Final Drive
390
Final Drive
392
2X4 Hub Bearing / Seal Replacement
393
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Polaris 1997 Sport 400 Service Manual (634 pages)
Polaris ATV And Light Utility Vehicle Service Manual
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 48.29 MB
Table of Contents
Safety Labels and Instructions
2
Table of Contents
3
General Information
5
Table of Contents
5
Model Identification
6
Engine Serial Number Locationi
6
Transmission ID Number Location
6
Carburetor ID Number Location
6
1996 Model Identification
7
Vehicle Identification Number (1997 and Later Model Years)
8
1996 Publication Numbers
10
1997 Publication Numbers
10
1998 Publication Numbers
11
Service Traning Videos
11
Service/Information Bulletins
12
Bulleting Index - 1996 by Model
13
Bulleting Index - 1997 by Model
14
Bulleting Index - 1998 by Model
14
1997 Paint Codes
16
Specifications 1997
18
Specifications 1998
23
Standard Torque Specifications
26
Decimal Equivalents
27
Conversion Table
28
Tap Drill Charts
29
SAE Tap Drill Sizes
29
Metric Tap Drill Sizes
29
Warranty
30
Service Tips
31
Glossary of Terms
32
Special Tools
35
Routing Diagrams
36
Magnum Routing Diagram
36
Hoses Diagram
39
300 Fan Motor Wiring Diagram
40
Wire Harness Diagram
41
Chassis/Suspension Service Tools
42
Transmission Tool Kit - Shaft Drive
42
Yoke Gauge Tool - Shaft Drive
42
Mity Vac Pump Kit
43
Small Battery Hydrometer
43
Transmission Seal/Bearing Driver - 50 MM
43
CV Boot Clamp Pliers
43
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) Diagram
54
Maintenance
56
Periodic Maintenance Chart
58
Pre-Ride/Daily Inspection
59
Recommended Lubricants and Capacities
60
Lubrication Chart
62
Lubrication Chart - Type IV Transmission (Shaft Drive)
65
Front Gearcase Lubrication
67
Gearcase Lubricant Change
67
Carburetor Adjustments
68
Idle Speed Adjustment
68
Throttle Cable/Electronic Throttle Control ETC Switch Adjustment
68
Throttle Operation
68
Throttle Cable Adjustment
69
Choke Adjustments
69
Throttle Control Lever Stop Adjustment
69
Air Screw Adjustment - 2-Stroke Models
70
Pilot Screw (Idle Mixture) Adjustment - 4-Stroke Models
70
Fuel Lines
72
Vent Lines
72
Fuel Filter
72
Carburetor Float Bowl Draining
72
Carburetor Draining
73
Breather System (4 Strokes)
74
Breather Filter Inspection
74
Breather Hose
74
General Maintenance
76
Compression Test
76
Battery Maintenance
77
Spark Plug Maintenance
78
Ignition Timing
78
Engine Mounts
78
Coolant Level Inspection
79
Coolant Strength
79
Cooling System Pressure Test
79
Radiator
79
Oil Pump Adjustment Procedure
80
Oil Pump Bleeding Procedure
83
If Oil Starvation Is Suspected
83
Recoil Housing
84
Counter Balancer Lubrication (400)
84
Procedure for Adding Oil (400)
84
Counter Balance Oil Changing Procedure
84
Air Cleaner - Trail Boss, Xpress 300, Xplorer 300, Xplorer 400
85
Dual Stage Air Cleaner
85
Primary Pre-Cleaner Foam Boot
85
Secondary (Main) Filter
86
Secondary Filter Removal and Installation Procedure
86
Cleaning the Main Filter
86
Air Filter Service -Sport, Scrambler 400
87
Air Filter Service - Trail Blazer
88
2 Stroke Engine Maintenance
89
Oil Filter (2 Strokes)
89
4 Stroke Engine Maintenance
90
Air Filter - 4 Stroke Engine
92
Pre-Filter Service
92
Air Filter Main Element
92
Air Box Sediment Tube
93
Air Filter Service - Scrambler 500
94
Air Filter Service - Sportsman 500, Xplorer 500
94
Check Engine Oil (4 Stroke)
96
Oil and Filter Change (4 Stroke)
96
Engine Sump Drain Plug View
97
Valve Clearance
100
Intake Valve Clearance Adjustment
101
Exhaust Valve Clearance Adjustment
101
Throttle Cable Lubrication
102
Toe Alignment Inspection
103
Chassis Maintenance
104
Steering Maintenance
104
Camber and Caster Adjustment
104
Toe Alignment Inspection (Chassis Maintenance)
104
The Rod End Inspection
105
Front Hubs (4X4 AWD Model)
105
Changing Front Hub Fluid
105
Exhaust Pipe
106
Brake System Inspection
107
Brake Fluid Level Inspection
107
Wear Line
107
Auxiliary Mechanical Brake System
108
Auxiliary Brake Testing
108
Auxiliary Brake Adjustment
108
Hose/Fitting Inspection
108
Drive Chain and Sprocket Inspection
109
Rear Drive Chain Note
109
Drive Chain Inspection
109
Rear Drive Chain Tension Adjustment
110
Drive Chain Adjustment, Concentric Swingarm
111
Center/Front Drive Chain Slack Adjustment
113
Center/Front Drive Chain Inspection/Adjustment
113
Sprocket Inspection
113
Drive Chain Inspection/Adjustment
114
Rear Axle (6X6 Middle Axle) Adjustment Procedure
114
Final Drive Chain
114
6X6 Rear Axle Drive Chain Adjustment
114
Front Suspension
115
Rear Suspension
115
Controls Check
115
Transmission Lubrication
116
Transmission Oil Changing Procedure
116
Transmission Oil Change - Dipstick Models
116
Transmission Lubrication - Type V Shaft/Chain
117
Transmission Oil Change Procedure
117
Transmission Vent Line Routing
118
Transmission Linkage Adjustment
118
Wheels Inspection
119
Wheel, Hub, and Spindle Torque Table
119
Wheel Removal Front or Rear
119
Wheel Installation
119
Tire Pressure
120
Tire Tread Depth
120
Frame, Nuts, Bolts, Fasteners
120
Engine
122
2 Stroke Engine Torque Specifications
124
4 Stroke Engine Torque Specifications
124
Engine Fastener Torque Patterns
125
1996 To Current Engine Specifications
126
Piston Identification
126
EC38PL Engines
127
Jetting Guidelines for Round-Port Pistons
127
EH42PL/EH50PL Engine Service Data
129
Cooling System
131
System Pressure Test
131
Radiator Cap Pressure Test
131
Recommended Coolant
132
Cooling System Specifications
132
2 Stroke Engine Removal
133
Engine Removal Preparation, Typical (2 Stroke)
133
Engine Installation Notes (2 Stroke)
136
Bleed Cooling System
136
Transmission Readjustment
136
Engine Break in Period (2 Strokes)
136
EC25PF/EC28PF Engines Disassembly
137
Crankshaft Alignment
138
EC25PF/EC28PF Engines Assembly
139
Measure Crankshaft Width - Bearings Installed
139
Connecting Rod Side Clearance
140
EC25PF/EC28PF Engines Installation
144
Oil Pump End Play Adjustment
145
Oil Check Valve Testing (250/400)
146
Oil Check Valve Testing (300)
146
EC25PF Engine - Recoil Disassembly
147
EC25PF Engine - Recoil Assembly
148
EC38PL Engine Disassembly
150
Water Pump Impeller Clearance
156
Cylinder Hone Selection/Honing Procedure
158
Piston/Cylinder Clearance (2 Strokes)
159
Cylinder Inspection/Measurement
159
Piston Inspection/Measurement (Generic)
159
Piston Ring Installed Gap
160
Piston Pin/Needle Bearing Inspection
160
Connecting Rod Small End Inspection
161
EH42PL/EH50PL Engine Exploded View
162
EH42PL/EH50PL Lubrication/Oil Flow
163
Oil Pressure Test
163
EH42PL/EH50PL Engine Diagram
164
EH42PL/EH50PL Oil Flow Chart
164
EH42PL/EH50PL Engine Removal
165
Cylinder Head Bolts
165
Crankcase
165
AWD Models
166
PVT Disassembly, All Models
166
Recoil/Starter Removal
167
Final Coolant Draining/Engine Removal
169
EH42PL/EH50PL Engine Installation
170
Oil Supply
170
EH42PL/EH50PL Engine: Bleed Cooling System
170
Cam Chain Tensioner/Rocker Arm/Camshaft Removal
170
To Position Crankshaft at Top Dead Center (TDC) on Compression Stroke
171
Cam Chain Tensioner
171
Rocker Arm/Shaft Removal
172
Rocker Arm/Shaft Inspection
172
Camshaft Removal
174
Automatic Compression Release Removal/Inspection
175
Automatic Compression Release Installation
175
Camshaft Inspection
176
Cylinder Head Removal
177
Cylinder Head Disassembly/Inspection
178
Cylinder Head Warpage
179
Cylinder Head Disassembly
179
Valve Inspection
181
Combustion Chamber
182
Valve Seat Inspection
182
Cylinder Head Reconditioning
182
Valve Guide Removal/Installation
182
Valve Seat Reconditioning
183
Cylinder Head Assembly
186
Valve Sealing Test
187
Cylinder/Piston Removal and Inspection
187
Piston Removal
188
Cylinder Inspection
189
Piston to Cylinder Clearance
190
Piston Ring Installed Gap (EH42PL/EH50PL)
192
Crankcase Disassembly
192
Starter Drive Removal/Inspection
193
Flywheel/Stator Removal/Inspection
194
Cam Chain/Tensioner Blade
194
Stator Plate
194
One Way Valve
195
Crankcase Separation
195
Oil Pump Removal/Inspection
196
Oil Pump Assembly
198
Counter Balancer Shaft Removal/Inspection
198
Crankshaft Removal/Inspection
199
Crankcase Bearing Inspection
200
Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal
200
EH42PL/EH50PL Engine Assembly
201
Crankcase Assembly
201
End Play Inspection/Adjustment
201
Crankshaft
201
Counter Balancer
203
Pump Shaft
203
Pump Shaft Oil Seal Installation
203
Crankshaft, Counter Balancer and Oil Pump Installation
204
To Assemble the Crankcase
204
Water Pump Mechanical Seal Installation
205
Water Pump Mechanical Seal Removal - Engine Installed
205
Piston Installation
208
Cylinder Installation
209
Cylinder Head Installation
210
Cam Chain/Camshaft Installation
211
Camshaft Installation - Timing Method
212
Method 1 - Camshaft Timing with Stator Removed
213
Camshaft Installation - Timing Method 2
214
Method 2 Camshaft Timing Using Flywheel TDC Mark
215
Cam Chain Tensioner Installation
216
Stator, Flywheel and Starter Drive Installation
216
Rocker Shaft/Rocker Arm Assembly Installation
218
Thermostat Installation
218
Oil Pipes
218
Engine - Sealed Recoil
219
Recoil Disassembly/Inspection
219
Recoil Assembly
220
To Install a New Spring
220
To Reinstall an Old Spring
220
Spark Plug Fouling - 2 Stroke Engine
222
Spark Plug Fouling - 4 Stroke Engine
222
2 Stroke Engine Troubleshooting
223
Starter Motor
224
4 Stroke Engine Troubleshooting
225
Piston Damage Checklist - 2 Stroke Engines
227
Fuel System/Carburetion
228
Fuel System/Carburetion - 1996 Specifications
230
Jetting Guidelines
230
Jetting Compensation for Altitude and Temperature - 1996 Models
230
Fuel System/Carburetion - 1997 Specifications
234
Jetting Compensation for Altitude and Temperature (1997)
234
Fuel System/Carburetion - 1998 Specifications
235
1998 Trail Boss W98AA25C (Engine -EC-25PFE-10) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
235
1998 Trail Blazer W98AA25C (Engine -EC-25PFE-11) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
236
XPRESS 300 W98CA28C (Engine -EC-28PFE-12) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
237
XLPORER 300 W98CC28C (Engine -EC-28PFE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
238
1998 XLPORER 400 W98CC38C (Engine -EC-38PFE-06) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
239
1998 Sport 400 W98BA38C (Engine - EC-38PLE-07) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
240
1998 Scrambler 400 W98BC38C (Engine - EC38PLE-09) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
241
Magnum 2 X 2 W98AA42A (Engine - EH-42PLE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
242
Magnum 4 X 4 W98AC42A (Engine - EH-42PLE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
243
1998 Scrambler 500 W98BC50A (Engine - EH50PLE-04) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
244
Sportsman 500 W98CH50A (W90CH50AB) (Engine - EH-50PLE-07) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
245
1998 Big Boss 500 6X6 W98AE50A (Engine - EH50PLE-06) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
246
Fuel System/Carburetion - Jet Part Numbers
247
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 Diagrams
253
Mikuni VM Carburetor Exploded Diagram
254
Carburetor Function
255
Float System
255
Component Functions
256
Pilot Jet
256
Pilot Air Screw
256
Air/Fuel Mixture Ratio
256
Jet Needle
257
Needle Jet
257
Throttle Opening Vs. Fuel Flow
257
Throttle Valve
258
Main Jet
258
Starter System - Closed Throttle
259
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 Opening
264
Mikuni VM Fuel Delivery Chart
264
Mikuni VM Carburetor System Components
265
Venting Systems
265
Mikuni BST 34 Carburetor Exploded View
266
Venting Systems (Mikuni CV)
267
Mikuni CV Carb Operation
268
Pilot (Idle and Slow) Systems
269
Starter System (Choke or Enrichment)
269
Float System (Mikuni CV)
270
Main System (Mikuni CV)
270
Magnum Fuel Tank Removal
271
Carburetor Removal ( Mikuni CV)
272
Carburetor Disassembly - Mikuni CV
273
Carburetor Cleaning - Mikuni CV
276
Carburetor Assembly - Mikuni CV
279
Carburetor Assembly/Adjustment - Mikuni CV
280
Float Height Adjustment (Mikuni CV)
280
CV Carburetor Installation
282
Needle and Seat Pressure Test Mikuni CV
283
Inlet Needle and Seat
283
Fuel Level (Mikuni CV)
283
Float Bowl Draining
284
Fuel Pump Exploded View
286
Fuel Pump Testing
287
Fuel Pump Disassembly
287
Fuel Pump Inspection/Assembly
287
Fuel System/Carburetion Troubleshooting
288
Fuel Starvation/Lean Mixture
288
Rick Mixture
288
Poor Idle
288
Idle too Low
289
Erratic Idle
289
Body and Steering
290
Body and Steering - Torque Specifications and Special Tools
292
Body Styles
293
1996 Body Styles
293
1997 Body Styles
293
1998 Body Styles
293
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) - Disassembly
302
Headlight Pod Service (Gen IV Typical) - Installation
303
Side Panel Removal (Gen IV - Typical)
304
Toe Alignment
305
Toe Alignment - Method 2
306
Typical Steering Assembly, Exploded View, Trail Boss 250
307
Steering Assembly, Exploded View, 2X4 Models (Except Trail Boss 250)
308
Steering Assembly, Exploded View, 4X4 and 6X6 Models
309
Steering Stop Adjustment
310
Rear Axle Bend
310
A-Arm Replacement
310
Rear Drive Axle, Hub and Wheel Assembly, - 2X4 and 4X4 (Except Sportsman 500)
311
Concentric Swingarm Rear Axle Assembly, Exploded View - 1998 Scrambler 400/500
312
Concentric Swingarm Exploded View 1998 Scrambler 400/500
313
Rear Drive Axle, Hub and Wheel Assembly - Shaft Drive Models
314
Rear Strut Stabilizer, 6X6 Models
315
Rear Swing Arm Weldment, 6X6 Models
316
Swing Arm and Rear Suspension Exploded View
318
Swing Arm Removal
319
Swing Arm Removal/Inspection
320
Swing Arm Assembly/Installation
321
Concentric Swingarm Removal/Disassembly
322
Concentric Swingarm Assembly/Installation
323
Strut Assembly - 400L AWD, Magnum AWD
324
Front Strut Weldment Replacement
325
Front Strut Cartridge Replacement
325
Strut Assembly - 2X4 Models
325
Front Strut Service
326
Front Strut Removal
326
Front Strut Installation
327
Front Strut Ball Joint Replacement
328
2X4 Hub Bearing Service
329
2X4 Front Hub Disassembly/Inspection
329
2X4 Front Hub Assembly
330
2X6 Hub Bearing Service
331
2X4 Front Hub Installation
331
Fox Shock Service
332
Foxtm Shock Service
333
Fox Shock Standard Valving Chart
339
1996 Optional Suspension Springs
340
1997 Optional Suspension Springs
341
1996 Paint Codes
342
1997 Paint Codes
343
Clutches
344
Clutch - Specifications
346
Clutch - Special Service Tools and Supplies
346
1996 Productoin Specifications
346
1996 Clutch Recommendations for Altitude
346
1997 Production Specifications
347
1997 Clutch Recommendations for Altitude
347
1998 Production Specifications
348
1998 Clutch Recommendations for Altitude
348
Shift Weights
349
Drive Clutch Spring Specifications
351
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