DOWNLOAD PDF Polaris 1999-2000 ATVS Service Manual

CHAPTER1

GENERALINFORMATION/ SPECIFICATIONS

Scrambler400 1.26-1.27

Xplorer400 1.28-1.29

Scrambler500 1.30-1.31

Magnum500 1.32-1.33

Sportsman500 1.34-1.35

BigBoss5006x6 1.36-1.37 ..........................

ModelSpecifications(2000)

TrailBlazer1.38-1.39

Xplorer4x41.40-1.41

TrailBoss3251.42-1.43 .........................

Magnum325(01Engine) 1.44-1.45 .................

Magnum325(04/05Engine) 1.46-1.47 ...............

Xpedition325 1.48-1.49 ...........................

Sportsman335 1.50-1.51 ..........................

Xplorer400 1.52-1.53 .............................

Scrambler4002x4 1.54-1.55

Scrambler4004x4 1.56-1.57

Xpedition425 1.58-1.59

Magnum500 1.60-1.61

Scrambler500 1.62-1.63

Sportsman500 1.64-1.65

Sportsman6x6 1.66-1.67

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EngineSerialNumberLocation

Whenevercorrespondingaboutanengine,besuretorefertotheenginemodelnumberandserialnumber.This informationcanbefoundonthestickerappliedtothemanualstarterrecoilhousing.Anadditionalnumberis stampedinoneofthefollowinglocations:

S 4strokemodels-centertopofcrankcasebeneaththecylindercoolantelbow

S 2strokeliquidcooledmodels-centertopofcrankcasebeneaththecarburetormountingflange

S 2strokeaircooledmodels-topofcrankcasenearrightsideofcylinder

MachineModelNumberandVINNumberLocation

ThemachineModelNumberandVehicleIdentification Number(VIN)areimportantforvehicleidentification. TheVINnumberwillbestampedintotheframeinone ofthefollowinglocations:

S 1998-Current Onthelefthandlowerframerail(A) neartherearA-armmount.

TransmissionI.D.NumberLocation

Transmissionmodelandserialnumbersarelocated ontopofthetransmissioncasebelowtheshiftingbellcranks.

CarburetorI.D.NumberLocation

ThecarburetorI.D.number(A)isinoneofthefollowinglocations:

S 4strokemodels-rightsidecenterof thecarburetorbody

S 2strokemodels-rightsideofcarburetorbodynearchokeplungerboss VINLocation-1998-Current

GENERALINFORMATION

ModelIdentification

VehicleIdentificationNumber

CurrentATVsand6X6Vehicleshavea17digitVehicleIdentificationNumber(VIN).TheVINisorganizedas follows:Digits1-3:WorldManufacturerIdentifier.ForPolarisATVs,thisis4XA.Digits4-9:VehicleDescriptor Section.Digits10-17:VehicleIndicatorSection.Digits4-8oftheVINidentifythebodystyle,drivetype,engine type,andemissionsequipment.TheVINnumberandthemodelnumbermustbeusedwithanycorrespondence regardingserviceorrepair.

VehicleIdentificationNumber/ModelNumberKey

A=GenII A=2x4chain 25=EC25PF(250cc) A=ApprovedbyCARB¡© A=Option1

B=GenIII C=4x4chain 28=EC28PF(300cc) B=England B=Option2

C=GenIV D=4x4shaft 33=ES33PF(335cc) C=NonCARBApproved¡

R=RANGER E=6x6chain 38=EC38PL(400cc) D=Norway F=6x6shaft 42=EH42PL(425cc) E=Sweden G=4x4chainrear/ shaftfront 50=EH50PL(500cc)

¡ CARB=CaliforniaAirResourcesBoard ©CARBApprovedornotaregulatedtype

Year/LetterIdentification

Thetenthdigitofa17digitVINisthemodelyearofthevehicle.Example:W=1998;X=1999etc.Refertothe listingbelow. V1997 W1998 X1999 Y2000

CurrentModelNumbers

Themodelyearisalsolistedinthemodelnumber.Thelast4digitsinthemodelnumbercorrespondtodigits 4through8oftheVehicleIdentificationNumber(VIN).Theexamplebelowisa1999Magnum500.

MachineModelNumberIdentification

OptionIndicator

1999PublicationPartNumbers

DESCRIPTION

1995-19994StrokeATV/6x6ServiceManual 9915686

1996ATVServiceManualVolumeII 9913680

1998ATVServiceManualVol.IIUpdate 9914752

1999ATV/6x6ServiceManualVolumelll 9915083

DieselATVServiceManual 9915234

RANGER ServiceManual 9914985

SERVICETRAININGVIDEOS

Magnum4-StrokeIntroduction 9912996

IgnitionSystemDiagnostics 9913533

ChargingSystemDiagnostics 9913278

PolarisVariableTransmissions (PVT) 9913987

FuelsandFuelDelivery 9914393

ServiceBulletinIndex

Includes4Stroketheoryofoperation,engineremoval,disassembly,andassemblytechniques,andgeneraltech-tips.

DescribesallcurrentPolarisignitionsystems.Provides workingknowledgeofignitionsystemtheoryanddiagnostics.

DescribesallcurrentPolarischargingsystems.Providesworkingknowledgeofchargingsystemtheoryanddiagnostics.

Theory,disassembly,assemblyandtroubleshootingofthe PolarisPVTsystem.

Describesfuelpropertiesincludingoctaneandvaporpressure;fuelmixtureandburncharacteristics;VMandCVcarburetortheoryandadjustments.

Alwaysconsultlatestserviceinformation.Bulletinspublishedafter3-15-99arenotlistedinthefollowingindex.

1999Model

BigBoss5006x6 None

Sportsman500 None

Scrambler500 None

Magnum4x4 None

Magnum2x4 None

Xplorer400 None

Scrambler400 None

Sport400 None

Xplorer300 None

Xpress300 None

Notes

TrailBlazer ATV-99-01 ServiceBulletin RearEccentricBearingLubrication

TrailBoss ATV-98-01 ServiceBulletin FoilMissingFromRearBrakeDiscGuard

AppliestoAll1999Models None

GENERALINFORMATION

BigBoss5006X6 Springs/ FrontRack EddieBGreen 8520150(P195) 44931

Rims Aluminum (P117)

Sportsman500RSE Springs/Rims Black 8520147(P067) 9440

Sportsman500EBS(Opt.A) Springs/Rims Black 8520147(P067) 9440

Sportsman500EBS(Opt.B) Rims Aluminum (P117) p ( p )

Spring,Front FireRed 8520149(P093) 72060

Spring,Rear BonnieBlue 8520148(P157) 12908

Magnum500 Springs Black 8520147(P067) 9440

Rims Aluminum (P117)

Scrambler500 Springs FireRed 8520149(P093) 72060

Rims Aluminum (P117)

Xplorer400 Springs BurnishedBrown P218

Rims Aluminum (P117)

Scrambler400 Springs FireRed 8520149(P093) 72060

Rims BrightWhite 8520153(P133) 2185

Sport400L Springs FireRed 8520149(P093) 72060 Rims BrightWhite 8520153(P133) 2185

Sportsman335(Opt.A) Springs/Rims Black 8520147(P067) 9440

Sportsman335(Opt.B) Springs Black 8520147(P067) 9440

Rims Aluminum (P117)

Xplorer300 Springs FireRed 8520149(P093) 72060

Rims Aluminum (P117)

Xpress300 Springs BonnieBlue 8520148(P157) 12908

Rims Aluminum (P117)

TrailBlazer Springs FireRed 8520149 72060

Rims BrightWhite 8520153(P133) 2185

TrailBoss Springs FireRed 8520149(P093) 72060

Rims BrightWhite 8520153(P133) 2185

Rack(s) FireRed 8520149(P093) 72060

OrderdirectfromMidwestIndustrialCoatings(612-942-1836).Mixasdirected. Frames(MediumBlack)P067/8520147/Ditzler9440

Thefollowingtorquespecificationsaretobeusedasageneralguidelinewhenaspecifictorqueisnotlistedfora fastener.Somefastenersrequireaspecialtorqueprocedureand/ortheapplicationofalockingagentorlocking deviceduringinstallation.Alwaysrefertotheappropriatechapterforspecifictorquespecificationsand proceduresbeforeusingstandardtorque.

BoltSizeThreads/InGrade2

Torquein.lbs. (N-m)

#10-2427(3.1)43(5.0)60(6.9) ........................................ #10-3231(3.6)49(5.6)68(7.8) ........................................

Torqueft.lbs.(N-m)*

1/4-20 5(7) 8(11) 12(16) .............................................

1/4-28 6(8) 10(14) 14(19)

5/16-18 11(15) 17(23) 25(35)

5/16-24 12(16) 19(26) 29(40)

3/8-16 20(27) 30(40) 45(62)

3/8-24 23(32) 35(48) 50(69)

7/16-14 30(40) 50(69) 70(97) 7/16-20 35(48) 55(76) 80(110) 1/2-13 50(69) 75(104) 110(152) ......................................... 1/2-20 55(76) 90(124) 120(166)

Metric

TorqueinIn.lb./Ft.lb.(N-m)

6x1.072-78In.lbs.(8-9)

8x1.2514-18ft.lbs.(19-25)

10x1.2526-30ft.lbs.(36-41)

*ToconvertFt.lbs.toN-mmultiplyfootpoundsby1.383.

*ToconvertN-mtoKg-mmovethedecimalpointtotheleftoneposition.

GENERALINFORMATION

DecimalEquivalents

1/64 .0156 1/32 .0312 1mm=.0394″ ................................... 3/64 .0469 ......................... 1/16 .0625 5/64 .0781 2mm=.0787″ 3/32 .0938 7/64 .1094 3mm=.1181″ ....................................... 1/8.1250 ........ 9/64 .1406 5/32 .1563 4mm=.1575″ 11/64 .1719 3/16 .1875 5mm=.1969″ 13/64 .2031 7/32 .2188 15/64 .2344 6mm=.2362″ 1/4 .25 .......... 17/64 .2656 7mm=.2756″ 9/32 .2813 19/64 .2969 5/16 .3125 8mm=.3150″ 21/64 .3281 ........................ 11/32 .3438 9mm=.3543″ 23/64 .3594 3/8 .375 25/64 .3906 10mm=.3937″ 13/32 .4063 .................. 27/64 .4219 11mm=.4331″ 7/16 .4375 29/64 .4531 15/32 .4688 12mm=.4724″ 31/64 .4844 ........................ 1/2 .5 13mm=.5118 33/64 .5156 17/32 .5313 35/64 .5469 14mm=.5512″ 9/16 .5625

37/64 .5781 15mm=.5906″ 19/32 .5938

39/64 .6094 5/8 .625 16mm=.6299″ ........................... 41/64 .6406 21/32 .6563 17mm=.6693″ 43/64 .6719 11/16 .6875

45/64 .7031 18mm=.7087″ ........................................ 23/32 .7188 47/64 .7344 19mm=.7480″ 3/4 .75

49/64 .7656 25/32 .7813 20mm=.7874″ .................................. 51/64 .7969 13/16 .8125 21mm=.8268″ 53/64 .8281 27/32 .8438 55/64 .8594 22mm=.8661″ ........................................ 7/8 .875

57/64 .8906 23mm=.9055″ 29/32 .9063 ..................

59/64 .9219 ....................... 15/16 .9375 24mm=.9449″

61/64 .9531

31/32 .9688 25mm=.9843

63/64 .9844 ........................ 11 0

UnitofMeasure Multipliedby

GENERALINFORMATION

ft.lbs. x12 =in.lbs. in.lbs. x.0833 =ft.lbs.

ft.lbs. x.1383 =kg-m

ft.lbs. x1.383 =N-m in.lbs. x.0115 =kg-m

kg-m x7.233 =ft.lbs. kg-m x86.796 =in.lbs.

x.6214 =mile(mi.)

Ounces(oz) x28.35 =Grams(g)

Grams(g) x0.035 =Ounces(oz) lb. x.454 =kg kg x2.2046 =lb.

Cubicinches(cuin) x16.387 =Cubiccentimeters(cc)

Cubiccentimeters(cc) x0.061 =Cubicinches(cuin)

Cubiccentimeters(cc) x.03381 =FluidOunces(fl.oz.)

FluidOunces(fl.oz.) x29.57 =Cubiccentimeters(cc)ormilliliters (ml)

Imperialpints(Imppt) x0.568 =Liters(l)

Liters(l) x1.76 =Imperialpints(Imppt)

Imperialquarts(Impqt) x1.137 =Liters(l)

Liters(l) x0.88 =Imperialquarts(Impqt)

Imperialquarts(Impqt) x1.201 =USquarts(USqt)

USquarts(USqt) x0.833 =Imperialquarts(Impqt)

USquarts(USqt) x0.946 =Liters(l)

Liters(l) x1.057 =USquarts(USqt)

USgallons(USgal) x3.785 =Liters(l)

Liters(l) x0.264 =USgallons(USgal)

Pounds-forcepersquareinch(psi) x6.895 =Kilopascals(kPa)

Kilopascals(kPa) x0.145 =Pounds-forcepersquareinch(psi)

Kilopascals(kPa) x0.01 =Kilograms-forcepersquarecm

Kilograms-forcepersquarecm x98.1 =Kilopascals(kPa)

°Cto °F:9(°C+40) ÷ 5-40= °F

°Fto °C:5(°F+40) ÷ 9-40= °C

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GENERALINFORMATION

SAETapDrillSizes

#0-80 3/64

#1-64 53 #1-72 53 #2-56 51

#2-64 50

#3-48 5/64

#3-56 45

#4-40 43 #4-48 42

#5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 11/8-7 63/64 11/8-12 13/64 11/4-7 17/64 11/4-12 111/64 11/2-6 111/32 11/2-12 127/64 13/4-5 19/16 13/4-12 143/64 2-41/2 125/32 2-12 159/64 21/4-41/2 21/32 21/2-4 21/4 23/4-4 21/2 3-4 23/4

MetricTapDrillSizes

3x.50

3x.60

4x.70

4x.75

5x.80

5x.90

6x1.00

7x1.00

8x1.00

8x1.25

9x1.00

9x1.25

10x1.25

10x1.50

11x1.50

12x1.50

12x1.75

3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32

ServiceTips

Inordertoperformserviceworkefficientlyandtopreventcostlyerrors,thetechnicianshouldreadthetextinthis manual,thoroughlyfamiliarizinghim/herselfwithproceduresbeforebeginning.Picturesandillustrationshave beenincludedwiththetextasanaid.Notes,cautionsandwarningshavealsobeenincludedforclarificationoftext andsafetyconcerns.However,aknowledgeofmechanicaltheory,tooluseandshopproceduresisnecessaryto performtheserviceworksafelyandsatisfactorily.UseonlygenuinePolarisserviceparts.

Cleanlinessofpartsandtoolsaswellastheworkareaisofprimaryimportance.Dirtandforeignmatterwillact asanabrasiveandcausedamagetoprecisionparts.Cleanthevehiclebeforebeginningservice.Cleannewparts beforeinstalling.

Watchforsharpedgeswhichcancausepersonalinjury.Protecthandswithgloveswhenworkingwithsharp components.

Ifdifficultyisencounteredinremovingorinstallingacomponent,looktoseeifacauseforthedifficultycanbe found.Ifitisnecessarytotapthepartintoplace,useasoftfacehammerandtaplightly.

Someofthefastenerswereinstalledwithlockingagents.Useofimpactdriversorwrencheswillhelpavoid damagetofasteners.

Alwaysfollowtorquespecificationsasoutlinedthroughoutthismanual.Incorrecttorquingmayleadtoserious machinedamageor,asinthecaseofsteeringcomponents,canresultininjuryordeathfortherider(s).

Ifatorquingsequenceisindicatedfornuts,boltsorscrews,startallfastenersintheirholesandhandtighten. Then,followingthemethodandsequenceindicatedinthismanual,tightenevenlytothespecifiedtorquevalue. Whenremovingnuts,boltsorscrewsfromapartwithseveralfasteners,loosenthemallabout1/4turnbefore removingthem.

IftheconditionofanygasketorO-Ringisinquestion,replaceitwithanewone.Besurethematingsurfaces aroundthegasketarecleanandsmoothinordertoavoidleaks.

Someprocedureswillrequireremovalofretainingringsorclips.Becauseremovalweakensanddeforms theseparts,theyshouldalwaysbereplacedwithnewparts.Wheninstallingnewretainingringsandclipsusecare nottoexpandorcompressthembeyondwhatisrequiredforinstallation.

Becauseremovaldamagesseals,replaceanyoilorgreasesealsremovedwithnewparts.

PolarisrecommendstheuseofPolarislubricantsandgreases,whichhavebeenspeciallyformulatedforthe topperformanceandbestprotectionofourmachines.Insomeapplications,suchastheengine,warranty coveragemaybecomevoidifotherbrandsaresubstituted.

Greaseshouldbecleanedfrompartsandfreshgreaseappliedbeforereassemblyofcomponents. Deterioratinggreaseloseslubricityandmaycontainabrasiveforeignmatter.

Wheneverremovingorreinstallingbatteries,careshouldbetakentoavoidthepossibilityofexplosion resultinginseriousburns.Alwaysdisconnectthenegative(black)cablefirstandreconnectitlast.Battery electrolytecontainssulfuricacidandispoisonous!Seriousburnscanresultfromcontactwiththeskin,eyesor clothing. ANTIDOTE: External-Flushwithwater.Internal-Drinklargequantitiesorwaterormilk.Followwith milkofmagnesia,beatenegg,orvegetableoil.Callphysicianimmediately.Eyes-Flushwithwaterfor15minutes andgetpromptmedicalattention.

GENERALINFORMATION

GlossaryOfTerms

ABDC: Afterbottomdeadcenter.

ACV: Alternatingcurrentvoltage.

Alternator: Electricalgeneratorproducingvoltagealternatingcurrent.

ATDC: Aftertopdeadcenter.

BBDC: Beforebottomdeadcenter.

BDC: Bottomdeadcenter.

BTDC: Beforetopdeadcenter.

CC: Cubiccentimeters.

CDI: Capacitordischargeignition.Ignitionsystemwhichstoresvoltagegeneratedbythestatorplateexcitercoilina capacitororcondenser(inCDIbox).Atthepropermomentavoltagegeneratedbythestatorplatepulsercoilclosesan electronicswitch(thyristor)intheCDIboxandallowsthevoltageinthecapacitortodischargeintotheprimarywindings oftheignitioncoil.

CenterDistance: Distancebetweencenterofcrankshaftandcenterofdrivenclutchshaft.

ChainPitch: Distancebetweenchainlinkpins(520=5/8″ or1.6cm).Chainlengthismeasuredinnumberofpitches (pins).A520x86has86totalpins,includingthemasterlinkpins.

CI: Cubicinches.

ClutchButtons: Plasticbushingswhichtransmitrotationoftheclutchtothemovablesheaveinthedriveanddriven clutch.

ClutchOffset: Driveanddrivenclutchesareoffsetsothatdrivebeltwillstaynearlystraightasitmovesalongtheclutch face.

ClutchWeights: Threeleversinthedriveclutchwhichrelativetotheirweight,profileandengineRPMcausethedrive clutchtoclose.

Condenser/Capacitor: Astoragereservoirforelectricity,usedinbothE.T.andCDIsystems.

CrankshaftRun-Out: Run-outor“bend”ofcrankshaftmeasuredwithadialindicatorwhilecrankshaftissupported betweencentersonVblocksorrestinginlowerhalfofcrankcase.MeasureatvariouspointsespeciallyatPTO. Maximumallowablerun-outis.006″ (.02cm).

DCV: Directcurrentvoltage.

Detonation: Thespontaneousignitionoftheunburnedfuel/airmixtureafternormalsparkignition.Pistonlooks “hammered”through,roughappearancearoundhole.Possiblecauses:1)toohighacompressionratioforthefuel octane;2)lowoctanefuel;3)over-advancedignitiontiming.

DialBoreGauge: Acylindermeasuringinstrumentwhichusesadialindicator.Goodforshowingtaperand out-of-roundinthecylinderbore.

DrivenClutch:(Also-SecondaryClutch). ThetorquesensitiveclutchinaCVTsystemwhichislocatedonthe transmissioninputshaft.

ElectricalOpen: Opencircuit.Anelectricalcircuitwhichisn’tcomplete.(i.e.poorconnectionsorbrokenwireathi-lo beamswitchresultinginlossofheadlights.

ElectricalShort: Shortcircuit.Anelectricalcircuitwhichiscompletedbeforethecurrentreachestheintended component.(i.e.abarewiretouchingthegroundedchassis).

EndSeals: Rubbersealsateachendofthecrankshaft.

EngagementRPM: EngineRPMatwhichthedriveclutchengagestomakecontactwiththedrivebelt.

EBS: EngineBrakingSystem ft.: Foot/feet.

FootPound: Ft.lb.Aforceofonepoundattheendofaleveronefootinlength,appliedinarotationaldirection. g: Gram.Unitofweightinthemetricsystem. gal.: Gallon.

HeadVolume: Cylinderheadcapacityincc,headremovedfromenginewithsparkpluginstalled.

HighTensionLead: Theheavyinsulatedwirewhichcarriesthehighsecondaryvoltagefromthecoiltothesparkplug.

HoledPiston: Pistoninwhichaholehasformedonthedome.Possiblecauses:Leanmixture;Incorrectignitiontiming HP: Horsepower.

ID: Insidediameter.

IgnitionCoil: Atypeoftransformerwhichincreasesvoltageintheprimarywindings(approx.200V)toahighervoltage inthesecondarywindings(approx.14KV-32KV)throughinduction.Secondaryvoltageishighenoughtoionize(jump) theairgapatthesparkplug.

IgnitionGeneratingCoil: Excitercoil,primarychargecoil.Statorplatecoilwhichgeneratesprimaryignitionvoltage.

in.: Inch/inches.

InchPound: In.lb.12in.lbs.=1ft.lb.

kg/cm 2 : Kilogramspersquarecentimeter.

kg-m: Kilogrammeters.

Kilogram/meter: Aforceofonekilogramattheendofaleveronemeterinlength,appliedinarotationaldirection.

lorltr: Liter.

lbs/in 2 : Poundspersquareinch.

LeftSide: Alwaysreferredtobasedonnormaloperatingpositionofthedriver.

m: Meter/meters.

Mag: Magneto.

MagneticInduction: Asaconductor(coil)ismovedthroughamagneticfield,avoltagewill begeneratedinthe windings.Thecommonmethodusedtoconvertmechanicalenergytoelectricalenergyinthebatterychargingcoil, ignitiongeneratingcoils,andignitiontrigger(pulse)coil.

mi.: Mile/miles.

mm: Millimeter.Unitoflengthinthemetricsystem.1mm=.040″

N-m: Newtonmeters.

OD: Outsidediameter.

Ohm: Theunitofelectricalresistanceopposingcurrentflow.

oz.: Ounce/ounces.

PistonClearance: Totaldifferencebetweenpistonoutsidediameterandcylinderinsidediameter.

PistonErosion: Pistondomemelts.Usuallyoccursattheexhaustportarea.Possiblecauses:1)Detonationdueto leanfuel/airmixture,impropersparkplugheatrange,excessheatbuildup,poorfuelquality/octanerating.

Pre-Ignition: Aproblemincombustionwherethefuel/airmixtureisignitedbeforenormalsparkignition.Pistonlooks meltedatareaofdamage.Possiblecauses:1)incorrectsparkplugheatrange;2)sparkplugnotproperlytorqued;3) “glowing”pieceofheadgasket,metalburrorcarboninthecombustionchamber;4)leanfuel/airmixture.

PrimaryCircuit: Thiscircuitisresponsibleforthevoltagebuildup intheCDIcapacitor.IntheCDIsystemtheparts includetheexcitercoil,thetriggercoil(pulsecoil),thewiresfromstatorplatetoCDIboxandtothelowresistance primarywindingsintheignitioncoil.

PrimaryClutch: Driveclutchonengine.MainlyRPMsensitive.

psi.: Poundspersquareinch.

PTO: Powertakeoff.

PVT: PolarisVariableTransmission(DriveClutchSystem) qt.: Quart/quarts.

RPM: Revolutionsperminute.

Resistance: Inthemechanicalsense,frictionorload.Intheelectricalsense,ohms.Bothresultinenergyconversionto heat.

RightSide: Alwaysreferredtobasedonnormaloperatingpositionofthedriver.

RPM: Revolutionsperminute.

RunningTime: IgnitiontimingwhenfullyadvancedoratspecifiedRPM.

SecondaryCircuit: Thiscircuitconsistsofthelargesecondarycoilwindings,hightensionwireandgroundthroughthe sparkplugairgap.

SecondaryClutch:(Also-DrivenClutch) ThetorquesensitiveclutchinaCVTsystemwhichislocatedonthe transmissioninputshaft.

SeizedPiston: Gallingofthesidesofapiston.Usuallythereisatransferofaluminumfromthepistonontothecylinder wall.Possiblecauses:1)improperlubrication;2)excessivetemperatures;3)insufficientpistonclearance;4)stuck pistonrings;

SparkPlugReach: Lengthofthreadedportionofsparkplug.Polarisuses3/4″ (2cm)reachplugs.

StaticTiming: IgnitiontimingwhenengineisatzeroRPM.

StatorPlate: Theplatemountedundertheflywheelsupportingtheprimaryignitioncomponentsandlightingcoil.

GENERALINFORMATION

GlossaryOfTerms

TDC: Topdeadcenter.Piston’smostoutwardtravelfromcrankshaft.

TriggerCoil: Pulsercoil.Generatesthevoltagefortriggering(closing)thethyristorandtimingthesparkinCDI systems.Smallcoilmountedatthetopofthestatorplatenexttotheignitiongeneratingcoil.

VoltageRegulator: MaintainsPreventsover-chargingofbatteryordamagetoelectricalcomponentsasengineRPM increases.

Venturi: Anareaofairconstriction.Aventuriisusedincarburetorstospeedupairflowwhichlowerspressureinventuri tobelowatmosphericpressure,causingfueltobepushedthroughjets,etc.,andintotheventuritobemixedwithairand formacombustibleair/fuelmixture.

Volt: Theunitofmeasureforelectricalpressureofelectromotiveforce.Measuredbyavoltmeterinparallelwiththe circuit.

Watt: Unitofelectricalpower.Watts=amperesxvolts.

WOT: Wideopenthrottle.

SPECIALTOOLS

Specialtoolpartnumbersandusagearelistedineachsectionofthismanualasrequiredforaspecificservice procedure.Forcompletetoolinformation,refertotheSPXSpecial Tool website.U.S.dealerscanobtain acurrentpricelistorgettoolinformationbycontacting the SPX Companyattheaddress,phoneor FAXnumberlistedbelow. Dealersservicedbyadistributorshouldfollowtoolorderingproceduresestablishedby theirrespectivedistributorpartsdepartment.

MODELNUMBER:A99BA25CA

ENGINEMODEL:EC25PFE13 ..

CARBURETION

Type VM30SSMikuni ................

MainJet 130 ............

PilotJet 40 .............

JetNeedle 5DP7-3 ...........

NeedleJet 0-4(169) ...........

Cutaway 2.0

AirScrew 1.0Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights G

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix 40°

SpringPosition(Helix)2

SpringPosition(Sheave)2

ENGINE

Type

JETTINGCHART

(3000-6000)

(6000-9000)

-TurnASout1/2--3/4turnCCWfromseat Raiseneedleclip1positiontolowerjetneedle

CLUTCHCHART

2Cycle,SingleCyl.

Displacement 244cc

Bore

2.8346”(72mm)

Stroke 2.3622”(60mm)

CompressionRatio 6.1/1Effective

Cooling Air

LubricationType OilInjected

Piston/CylinderClearance0.0011-0.0021”(0.03-0.05mm)

ServiceLimit 0.006”(0.15mm)

PistonMarking 3W,4W

PistonRingEndGap.009”-.018”(.23mm-.46mm)

OperatingRPM±200 5800RPM

IdleRPM±200 700RPM ..............

CompressionPressure(Std) ±15%

MODEL: TRAILBLAZER

MODELNUMBER:A99BA25CA ...

ENGINEMODEL:EC25PFE13

ELECTRICAL FLUID

CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank 4gals.(15.1L) ...... .......... CDIMarkingCU2167

InjectorOil 2qts.(1.9L)PP2* ....... .......... ..

AlternatorOutput150Watts

Coolant N/A

IgnitionTiming25° BTDC@3000RPM±1.5° Transmission11oz.(325ml)PPS* SparkPlug/GapNGKBR8ES/0.028”(0.7mm)GearcaseOil(Front)N/A

Lights:HeadHalogen55watts

GearcaseOil(Center)N/A

Tail8.26watts GearcaseOil(Rear)N/A ........ . Brake26.9watts

EngineCounterBal.N/A

VoltageRegulatorLR39--1 EngineOil N/A

ElectricStartStandard Brake(Hand)-- Dot3 Brake(Foot)-- Dot3 FrontHubs(AWD)N/A ShiftSelectorBox1oz.(30ml)PP4*

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant

SUSPENSION/CHASSIS

DRIVETRAIN(ConcentricDrive)

BodyStyle GenIII ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A TowCapacity850lbs.(385.9kg) GearReduction-Rev3.05/1 ...... . TurningRadius60”(152.4cm) GearReduction-High2.68/1

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance6”(15.24cm)

FrontDriveRatioN/A

CenterDriveRatioN/A .. ...

FrontVerticalTravel6.7”(17.02cm) FinalDriveRatio11/3878P RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc ... ....... RearTravel8.2in.(20.8cm) Brake(AuxiliaryFoot)Hydraulic RearShock2”GasChargedMono ShockAdjustmentCam ..

TireSize-Front23x7-10

TireSize-Rear22x11-10

TireSize-CenterN/A TirePressure-F/R4/3lbs.

TotalWidth46.5”(118.11cm)

TotalLength74.5”(189.23cm)

TotalHeight46”(116.84cm)

WheelBase49.75”(126.37cm)

Weight-Dry440lbs.(199.76kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Accy)30lbs. .... RearRack(Accy)60lbs. .... TongueWeight30lbs. TowHitchAccy ...........

RearCompressionSpring 7041777-067 Option125lb/in. 7041778-067 Standard150lb/in. 7041815-067 Option175lb/in.

FrontStrutSpring 7041471-067 Option41lb/in. 7041238-067 Standard61lb/in. 7041375-067 Option64/113lb/in.

MODELNUMBER:A99AA25CA

ENGINEMODEL:EC25PFE10 ..

CARBURETION

Type VM30SSMikuni ................

MainJet 145 ............

PilotJet 40 .............

JetNeedle 5DP7-3 ...........

NeedleJet 0-4(169) ...........

Cutaway 2.0

AirScrew 1.0Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT ....................

Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights 16

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix 40°

SpringPosition(Helix)2 SpringPosition(Sheave)2

ENGINE

Type

2Cycle,SingleCyl. .......................

Displacement 244cc Bore 2.8346”(72mm) .......................

Stroke 2.3622”(60mm) .....................

CompressionRatio 6.1/1Effective

Cooling Air ....................

LubricationType OilInjected

JETTINGCHART

(3000-6000)

(6000-9000)

(9000-12000) -TurnASout1/2--3/4turnCCWfromseat

CLUTCHCHART

Piston/CylinderClearance0.0011-0.0021”(0.03-0.05mm) ...

ServiceLimit 0.006”(0.15mm) ................

PistonMarking 3W,4W

PistonRingEndGap.009”-.018”(.23mm-.46mm) ........

OperatingRPM±200 6000RPM

IdleRPM±200 700RPM ..............

CompressionPressure(Std) ±15%

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MODEL: TRAILBOSS250

MODELNUMBER:A99AA25CA ...

ENGINEMODEL:EC25PFE10

ELECTRICAL FLUID

CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank 4gals.(15.1L) ...... ..........

CDIMarkingCU2167

InjectorOil 2qts.(1.9L)PP2* ....... .......... ..

AlternatorOutput150Watts

Coolant N/A

IgnitionTiming25° BTDC@3000RPM±1.5° Transmission16oz.(473ml)PPS*

SparkPlug/GapNGKBR8ES/0.028”(0.7mm)GearcaseOil(Front)N/A

Lights:HeadHalogen60/60watts

Tail8.26watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)N/A ........ .

Brake26.9watts

VoltageRegulatorLR39--1

ElectricStartStandard

SUSPENSION/CHASSIS

BodyStyle GenII

EngineCounterBal.N/A

EngineOil N/A

Brake(Hand) Dot3

Brake(Foot) Dot3

FrontHubs(AWD)N/A

ShiftSelectorBox1oz.(30ml)PP4*

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant

DRIVETRAIN

ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A .. . TowCapacity850lbs.(385.9kg)

GearReduction-Rev3.42/1

TurningRadius60”(152.4cm) GearReduction-High2.68/1

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance5.5”(13.97cm)

FrontDriveRatioN/A

CenterDriveRatioN/A

FrontVerticalTravel6.25”(15.88cm) FinalDriveRatio12/4288P .... RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel8.5in.(21.6cm) Brake(AuxiliaryFoot)Mechanical ........

RearShock1”BoreGasBag ShockAdjustmentCam TIRES

TireSize-Front23x7-10 ....

TireSize-Rear22x11-10

TireSize-CenterN/A .. TirePressure-F/R4/3lbs. .

TotalWidth44”(111.76cm)

TotalLength73.2”(185.93cm) .......

TotalHeight44”(111.76cm)

WheelBase49.75”(126.37cm) .......

Weight-Dry448lbs.(203.4kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Accy)75lbs. .... RearRack125lbs. ..........

TongueWeight30lbs. TowHitchStd ...........

RearCompressionSpring 7041518-067 Option175lb/in. 7041204-067 Standard190lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041471-067 Option41lb/in. 7041238-067 Standard61lb/in. 7041375-067 Option64/113lb/in.

MODEL: XPRESS300 ..........

MODELNUMBER:A99CA28CA

ENGINEMODEL:EC28PFE02 ..

CARBURETION

Type VM30SSMikuni ................

MainJet 155 ............

PilotJet 40 .............

JetNeedle 5DP7--3 ...........

NeedleJet 0-4(169) ...........

Cutaway 2.0

AirScrew 1.25Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights G

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix Compound

SpringPosition(Helix)2

SpringPosition(Sheave)2

ENGINE

Type

JETTINGCHART

(3000-6000)

(6000-9000)

(9000-12000)

-Dropjetneedleoneposition(raiseE--Clip) -Turnairscrewin1/2to3/4turn

CLUTCHCHART

2Cycle,SingleCyl.

Displacement 283cc

Bore

2.9331”(74.5mm)

Stroke 2.5591”(65mm)

CompressionRatio 6.1/1Effective

Cooling Air

LubricationType OilInjected

Piston/CylinderClearance0.0012-0.0026”(0.03-0.07mm) ...

ServiceLimit 0.006”(0.15mm)

PistonMarking 28

PistonRingEndGap.012”-.022”(.31mm-.56mm) ........

OperatingRPM±200 5600RPM

IdleRPM±200 600RPM ..............

CompressionPressure(Std) ±15%

MODEL: XPRESS300 ............

MODELNUMBER:A99CA28CA ...

ENGINEMODEL:EC28PFE02

ELECTRICAL FLUID

CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank 4gals.(15.1L) ...... ..........

CDIMarkingCU2513

InjectorOil 2qts.(1.9L)PP2* ....... .......... ..

AlternatorOutput150Watts

Coolant N/A

IgnitionTiming25° BTDC@3000RPM±2 ° Transmission20oz.(592ml)PPS*

SparkPlug/GapNGKBR8ES/0.028”(0.7mm)GearcaseOil(Front)N/A

Lights:Head(Twin)Halogen30/30watts

Tail8.26watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)N/A ........ .

Brake26.9watts

VoltageRegulatorLR39--1

ElectricStartStandard

SUSPENSION/CHASSIS

EngineCounterBal.N/A

EngineOil N/A

Brake(Hand) Dot3

Brake(Foot) Dot3

FrontHubs(AWD)N/A

ShiftSelectorBox1oz.(30ml)PP4*

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W40SyntheticEngineLubricant

DRIVETRAIN

BodyStyle GenIV ChainType 520O-Ring ........ .........

FrontSuspensionMacPhersonStrut

GearReduction-Low6.64/1 TowCapacity850lbs.(385.9kg)

GearReduction-Rev5.13/1

TurningRadius60”(152.4cm) GearReduction-High3.29/1

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance6.5”(16.51cm)

FrontDriveRatioN/A

CenterDriveRatioN/A

FrontVerticalTravel6.25”(15.88cm) FinalDriveRatio13/3886P RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel8.5″ (21.59cm) Brake(AuxiliaryFoot)Mechanical RearShock1″ GasBag ........ ShockAdjustmentCam

TIRES

TireSize-Front23x7-10

TireSize-Rear24x11-10

TireSize-CenterN/A

TirePressure-F/R4/3lbs. .

TotalWidth46”(116.84cm)

TotalLength79.5”(201.93cm)

TotalHeight45.5”(115.57cm)

WheelBase49.75”(126.37cm)

Weight-Dry512lbs.(224.73kg) .......

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Std)90lbs. RearRack(Std)180lbs. TongueWeight30lbs. TowHitchStd

RearCompressionSpring 7041518-067 Option175lb/in. 7041204-067 Standard190lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041238-067 Option61lb/in. 7041375--157 Standard64/113lb/in. 7041450-067 Option101lb/in.

MODELNUMBER:A99CC28CA

ENGINEMODEL:EC28PFE02 ..

CARBURETION

Type VM30SSMikuni ................

MainJet 155 ............

PilotJet 40 .............

JetNeedle 5DP7--3 ...........

NeedleJet 0-4(169) ...........

Cutaway 2.0

AirScrew 1.25Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights G

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix Compound

SpringPosition(Helix)2

SpringPosition(Sheave)2

ENGINE

Type 2Cycle,SingleCyl.

Displacement 283cc

Bore

JETTINGCHART

(3000-6000)

(6000-9000)

(9000-12000)

-Dropjetneedleoneposition(raiseE--Clip) -Turnairscrewin1/2to3/4turn

CLUTCHCHART

2.9331”(74.5mm)

Stroke 2.5591”(65mm)

CompressionRatio 6.1/1Effective

Cooling Air

LubricationType OilInjected

Piston/CylinderClearance0.0012-0.0026”(0.03-0.07mm) ...

ServiceLimit 0.006”(0.15mm)

PistonMarking 28

PistonRingEndGap.012”-.022”(.31mm-.56mm) ........

OperatingRPM±200 5600RPM

IdleRPM±200 600RPM ..............

CompressionPressure(Std) ±15%

MODEL:

MODELNUMBER:A99CC28CA ...

ENGINEMODEL:EC28PFE02

ELECTRICAL FLUID

CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank 4gals.(15.1L)

CDIMarkingCU2513

AlternatorOutput150Watts

InjectorOil 2qts.(1.9L)PP2*

Coolant N/A ... ............

IgnitionTiming25° BTDC@3000RPM±2 ° Transmission20oz.(592ml)PPS* SparkPlug/GapNGKBR8ES/0.028”(0.7mm)GearcaseOil(Front)N/A ... . Lights:HeadHalogen30/30watts

Tail8.26watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)N/A Brake26.9watts EngineCounterBal.N/A ...... .

VoltageRegulatorLR39--1

ElectricStartStandard

EngineOil N/A

Brake(Hand) Dot3 ....... .....................

Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... ..

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS DRIVETRAIN

BodyStyle GenIV ChainType 520O-Ring ........ .........

FrontSuspensionMacPhersonStrut

GearReduction-Low6.64/1 .. . TowCapacity850lbs.(385.9kg) GearReduction-Rev5.13/1 ...... . TurningRadius57”(144.78cm) GearReduction-High3.39/1

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance6”(15.24cm)

FrontVerticalTravel6.25”(15.88cm)

FrontDriveRatio12/2264P

CenterDriveRatio11/2270P

FinalDriveRatio13/4088P ....

RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel8.5“(21.59cm) Brake(AuxiliaryFoot)Mechanical RearShock1”BoreGasBag ........ ShockAdjustmentCam

TIRES

TireSize-Front23x7-10 ....

TireSize-Rear24x11-10

TireSize-CenterN/A TirePressure-F/R4/3lbs. .

TotalWidth46”(116.84cm)

TotalLength81”(205.74cm)

TotalHeight45.5”(115.57cm)

WheelBase49.75”(126.37cm)

Weight-Dry567lbs.(252.4kg) .......

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring 7041518-067 Option175lb/in. 7041204-067 Standard190lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041238-067 Option61lb/in. 7041375--157 Standard64/113lb/in. 7041450-067 Option101lb/in.

MODELNUMBER:A99CH33CA/B,A99CH33AA/AB(CALIF.APPROVED)

ENGINEMODEL:ES33PFE01,ES33PFE02(CALIF.APPROVED) ..

CARBURETION

Type BST34Mikuni ................

MainJet 150 ............

PilotJet 40 .............

JetNeedle 5F14--3 ...........

NeedleJet P-9 ...........

ThrottleValve#100

PilotScrew 2.5TurnsOut ..........

PilotAirJet 160 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights 16

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix Compound

SpringPosition(Helix)2

SpringPosition(Sheave)2

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 334cc

Bore

3.0732”(78mm) .......................

Stroke 2.758”(70mm) .....................

CompressionRatio 9.2/1FullStroke

Cooling AirW/OilCoolerAssist ....................

LubricationType DrySump

JETTINGCHART

-Pilotscrewin1/2turn

CLUTCHCHART

Piston/CylinderClearance0.0012-0.0035”(0.03-0.09mm) ...

ServiceLimit 0.0043”(0.11mm)

PistonMarking...............

PistonRingEndGap(top) .0079”-.0138”(.20mm-.36mm) ....

PistonRingEndGap(second).0138”-.0197”(.36mm-.50mm)

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1200RPM

CompressionPressure(Std) ±15%

MODEL:

MODELNUMBER:A99CH33CA/B,A99CH33AA/AB(CALIF.APPROVED) ...

ENGINEMODEL:ES33PFE01,ES33PFE02(CALIF.APPROVED)

ELECTRICAL FLUID CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank 3.75gals.(14.2L)

CDIMarkingCU2557

AlternatorOutput200Watts

InjectorOil N/A

Coolant N/A ... ............

IgnitionTiming30° BTDC@3500RPM±1.5° Transmission32oz.PPS* SparkPlug/GapNGKBKR7E/0.028”(0.7mm)GearcaseOil(Front)3.25oz.80-90GL5 ... ......

Lights:HeadHalogen60/60watts

GearcaseOil(Center)N/A Tail8.26watts

GearcaseOil(Rear)N/A Brake26.9watts

EngineCounterBal.N/A ...... ..........

VoltageRegulatorLR39 EngineOil 2.25qts.(2.1L)PP4*

ElectricStartStandard Brake(Hand) Dot3 ....... .....................

Brake(Foot) Dot3

FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... ..

*Lubricant

*PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenIV ChainType ShaftDrive FrontSuspensionMacPhersonStrut

TowCapacity850lbs.(385.9kg)

TurningRadius65”(165.1cm)

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance10.25”(26.04cm)

FrontVerticalTravel6.25”(15.88cm)

GearReduction-Low6.89/1

GearReduction-Rev5.17/1

GearReduction-High3.56/1

FrontDriveRatio2:1

CenterDriveRatioN/A

FinalDriveRatio3.16:1 ....

RearSuspensionProgressiveRateIndependentBrake(Hand)SingleLever,Hyd.Disc RearTravel9.5“(24.13cm)

Brake(AuxiliaryFoot)Hydraulic ........ RearShock1”BoreGasBag ShockAdjustmentCam TIRES

TireSize-Front23x7-10

TireSize-Rear24x11-10

TireSize-CenterN/A ..

TirePressure-F/R5/5lbs.

TotalWidth46”(116.84cm)

TotalLength81”(205.74cm) .......

TotalHeight46”(118.22cm)

WheelBase50.50”(128.27cm) .......

Weight-Dry670lbs.(304.2kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Std)90lbs. .....

RearRack(Std)180lbs. ......

TongueWeight30lbs.

TowHitchStd ...........

RearCompressionSpring 7041517-067 Option80lb/in. 7041546-067 Standard100lb/in. 7041519-067 Option140lb/in.

FrontStrutSpring 7041238-067 Option61lb/in. 7041375-067 Standard64/113lb/in. 7041450-067 Option101lb/in.

MODEL: SPORT400 ..........

MODELNUMBER:A99BA38CA

ENGINEMODEL:EC38PLE09 ..

CARBURETION

Type VM34SSMikuni ................

MainJet 230 ............

PilotJet 35 .............

JetNeedle 6CEY6-3 ...........

NeedleJet 0-6(480) ...........

Cutaway 1.5

AirScrew 1.5Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights S55

PrimarySpring White ...........

SecondarySpringRed ........

DrivenHelix 40°

SpringPosition(Helix)2

SpringPosition(Sheave)2

ENGINE

Type

2Cycle,SingleCyl. .......................

Displacement 378cc

Bore

3.2677”(83mm) .......................

Stroke 2.7559”(70mm)

CompressionRatio 6.9/1Effective ..........

Cooling Liquid ....................

LubricationType OilInjected

JETTINGCHART

MJ=MainJet

AS=AirScrew(TurnsOut)

CLUTCHCHART

Piston/CylinderClearance0.0023-0.0037”(0.06-0.09mm) ...

ServiceLimit 0.006”(0.15mm)

PistonMarking...............

PistonRingEndGap.007”-.015”(.18mm-.38mm)

OperatingRPM±200 5700RPM

IdleRPM±200 600RPM ..............

CompressionPressure(Std) ±15%

MODEL: SPORT400

MODELNUMBER:A99BA38CA ...

ENGINEMODEL:EC38PLE09

ELECTRICAL FLUID CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank 4gals.(15.1L)

CDIMarkingCU2515 InjectorOil 2qts.(1.9L)PP2* ....... .......... ..

AlternatorOutput150Watts Coolant 2.25qts.(2.1L)PP6*

IgnitionTiming23.5° BTDC@3000RPM±1.5° Transmission11oz.(325ml)PPS* ..... ....... SparkPlug/GapNGKBR8ES/0.028”(0.7mm)GearcaseOil(Front)N/A Lights:HeadHalogen60/60watts GearcaseOil(Center)N/A Tail8.26watts GearcaseOil(Rear)N/A ........ . Brake26.9watts EngineCounterBal.100ml10W30 VoltageRegulatorLR39--1 EngineOil N/A .. .......... ElectricStartStandard Brake(Hand) Dot3 Brake(Foot) Dot3 FrontHubs(AWD)N/A ShiftSelectorBox1oz.(30ml)PP4*

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP6PolarisPremium60/40Antifreeze/Coolant *PP4Polaris0W/40SyntheticEngineLubricant

SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenIII ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A TowCapacity850lbs.(385.9kg) GearReduction-Rev3.05/1 TurningRadius60”(152.4cm) GearReduction-High2.68/1 .....

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance6”(15.24cm)

FrontDriveRatioN/A

CenterDriveRatioN/A .. ...

FrontVerticalTravel8.2”(20.83cm)

FinalDriveRatio13/3676P

RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel8.2“(20.83cm) Brake(AuxiliaryFoot)Hydraulic RearShock2”GasChargedMono ShockAdjustmentThreadAdjuster

TIRES

TireSize-Front23x7-10

TireSize-Rear22x11-10

TireSize-CenterN/A ..

TirePressure-F/R4/3lbs.

TotalWidth46.5”(118.11cm)

TotalLength74.5”(189.23cm)

TotalHeight47”(119.38cm)

WheelBase49.75”(126.37cm)

Weight-Dry475lbs.(215.6kg) OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Accy)30lbs. RearRack(Accy)60lbs. TongueWeight30lbs. ....... TowHitchAccy

RearCompressionSpring 7041389-067 Option175lb/in. 7041691-067 Standard170/210lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041471-067 Option41lb/in. 7041238-067 Standard61lb/in. 7041375-067 Option64/113lb/in.

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

MODELNUMBER:A99BG38C(AorB)

ENGINEMODEL:EC38PLE09 ..

CARBURETION

Type VM34SSMikuni ................

MainJet 230 ............

PilotJet 35 .............

JetNeedle 6CEY6-3 ...........

NeedleJet 0-6(480) ...........

Cutaway 1.5

AirScrew 1.5Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights S55

PrimarySpring White ...........

SecondarySpringRed ........

DrivenHelix 40°

SpringPosition(Helix)2

SpringPosition(Sheave)2

ENGINE

Type

2Cycle,SingleCyl. .......................

Displacement 378cc

Bore

3.2677”(83mm) .......................

Stroke 2.7559”(70mm)

CompressionRatio 6.9/1Effective ..........

Cooling Liquid ....................

LubricationType OilInjected

JETTINGCHART

MJ=MainJet

AS=AirScrew(TurnsOut)

CLUTCHCHART

Piston/CylinderClearance0.0023-0.0037”(0.06-0.09mm) ...

ServiceLimit 0.006”(0.15mm)

PistonMarking...............

PistonRingEndGap.007”-.015”(.18mm-.38mm)

OperatingRPM±200 5700RPM

IdleRPM±200 600RPM ..............

CompressionPressure(Std) ±15%

MODEL: SCRAMBLER400

MODELNUMBER:A99BG38CB ...

ENGINEMODEL:EC38PLE09 ....

ELECTRICAL FLUID

FlywheelI.D.RefertoElectricalSectionFuelTank 4gals.(15.1L)

CDIMarkingCU2515

InjectorOil 2qts.(1.9L)PP2*

AlternatorOutput150Watts Coolant 2.25qts.(2.1L)PP6* ... ............

IgnitionTiming23.5° BTDC@3000RPM±3° Transmission16oz.(473ml)PPS*

SparkPlug/GapNGKBR8ES/0.028”(0.7mm)GearcaseOil(Front)3.25oz.80-90GL5 ... ......

Lights:HeadHalogen30/30watts

Tail8.26watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)N/A Brake26.9watts EngineCounterBal.100ml10W30 ...... ........

VoltageRegulatorLR39--1

ElectricStartStandard

EngineOil N/A

Brake(Hand) Dot3 ....... .......

Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD* ... ShiftSelectorBox1oz.(30ml)PP4* ... ..

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PP6PolarisPremium60/40Antifreeze/Coolant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenIII ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A .. . TowCapacity850lbs.(385.9kg) GearReduction-Rev4.36/1

TurningRadius60”(152.4cm) GearReduction-High2.82/1

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance6.5”(16.51cm)

FrontDriveRatio2:1

CenterDriveRatioN/A .. ...

FrontVerticalTravel8.2”(20.83cm) FinalDriveRatio13/3676P RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel8.8“(22.35cm) Brake(AuxiliaryFoot)Hydraulic ........

RearShockFoxt GasChargedw/remoteres. ShockAdjustmentThreadAdjuster TIRES

TireSize-Front23x7-10

TireSize-Rear22x11-10

TireSize-CenterN/A ..

TirePressure-F/R4/3lbs.

TotalWidth45.5”(115.57cm)

TotalLength74.5”(189.23cm)

TotalHeight47”(119.38cm)

WheelBase48.5”(123.19cm) .......

Weight-Dry519lbs.(235.6kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Accy)30lbs. RearRack(Accy)60lbs. TongueWeight30lbs. ....... TowHitchAccy

RearCompressionSpring 7041389-067 Option175lb/in. 7041691-067 Standard170/210lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041471-067 Option41lb/in. 7041238-067 Standard61lb/in. 7041375-067 Option64/113lb/in.

MODELNUMBER:A99CG38CA

ENGINEMODEL:EC38PLE08 ..

CARBURETION

Type VM34SSMikuni ................

MainJet 210 ............

PilotJet 35 .............

JetNeedle 6CEY6-3 ...........

NeedleJet 0-6(480) ...........

Cutaway 1.5

AirScrew 1.5Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights S55

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix Compound

SpringPosition(Helix)2

SpringPosition(Sheave)2

ENGINE

Type

JETTINGCHART

(6000-9000)

(9000-12000)

-Dropjetneedleoneposition(raiseE--Clip) -Turnairscrewin1/2to3/4turn

CLUTCHCHART

2Cycle,SingleCyl.

Displacement 378cc

Bore

3.2677”(83mm)

Stroke 2.7559”(70mm)

CompressionRatio 6.9/1Effective

Cooling Liquid

LubricationType OilInjected

Piston/CylinderClearance0.0023-0.0037”(0.06-0.09mm) ...

ServiceLimit 0.006”(0.15mm)

PistonMarking...............

PistonRingEndGap.007”-.015”(.18mm-.38mm) ........

OperatingRPM±200 5700RPM

IdleRPM±200 600RPM ..............

CompressionPressure(Std) ±15%

(6000-9000)

MODEL:

............

MODELNUMBER:A99CG38CA ...

ENGINEMODEL:EC38PLE08 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank 4gals.(15.1L)

CDIMarkingCU2510

InjectorOil 2qts.(1.9L)PP2*

AlternatorOutput200Watts Coolant 2.25qts.(2.1L)PP6* ... ............

IgnitionTiming23.5° BTDC@3000RPM±1.5° Transmission16oz.(473ml)PPS*

SparkPlug/GapNGKBR8ES/0.028”(0.7mm)GearcaseOil(Front)3.25oz.80-90GL5 Lights:HeadHalogen60/60watts GearcaseOil(Center)N/A Tail8.26watts GearcaseOil(Rear)N/A Brake26.9watts EngineCounterBal.3.3oz.(100ml)10W30 ...... .

VoltageRegulatorLR39--1 EngineOil N/A

ElectricStartStandard

Brake(Hand) Dot3 ....... .....................

ElectronicSpeedoStandard Brake(Foot) Dot3 .. ...................... FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... ..

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenIV ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-Low6.14/1 .. . TowCapacity850lbs.(385.9kg) GearReduction-Rev4.74/1

TurningRadius65”(165.1cm)

GearReduction-High3.06/1 .....

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance7.5”(19.05cm)

FrontDriveRatio2:1

CenterDriveRatioN/A .. ...

FrontVerticalTravel6.7”(17.02cm)

FinalDriveRatio13/3676PitchChain .... RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel9“(22.86cm) Brake(AuxiliaryFoot)Hydraulic ........ RearShock3/8”BoreGasCharged ShockAdjustmentCam

TIRES

TireSize-Front25x8-12 ....

TireSize-Rear25x11-10

TireSize-CenterN/A ..

TirePressure-F/R4/3lbs.

TotalWidth46”(116.84cm)

TotalLength81”(205.74cm) .......

TotalHeight47”(119.38cm)

WheelBase49.75”(126.37cm) .......

Weight-Dry588lbs.(266.95kg)

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring 7041518-067 Option175lb/in. 7041204-067 Standard190lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041238-067 Option61lb/in. 7041375--195 Standard64/113lb/in.

7041450-067 Option101lb/in.

MODELNUMBER:A99BG50AA

ENGINEMODEL:EH50PLE04 ..

CARBURETION

Type BST40Mikuni ................

MainJet 155

PilotJet 40 .............

JetNeedle 6H25--94--3 ...........

NeedleJet Y--O ...........

ThrottleValve#120

PilotScrew 2.0 ..........

PilotAirJet 1.3 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights 10WH

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix 40°

SpringPosition(Helix)1

SpringPosition(Sheave)1

ENGINE

Type

Displacement

Bore

Stroke

JETTINGCHART

-Pilotscrewin1/2turn

-Pilotscrewout1/2turn

CLUTCHCHART

4Cycle,SingleCyl.

499cc

3.6248”(92mm)

2.955”(75mm)

CompressionRatio 10/2FullStroke

Cooling Liquid

LubricationType DrySump

Piston/CylinderClearance0.0006-0.0018”(0.015-0.046mm) ...

ServiceLimit 0.0024”(0.061mm)

PistonMarking...............

PistonRingEndGap.008”-.015”(.20mm-.38mm) ........

OperatingRPM±200 6500RPM

IdleRPM±200(lightsoff)1200RPM .....

CompressionPressure(Std) ±15%

MODEL: SCRAMBLER500

MODELNUMBER:A99BG50AA ...

ENGINEMODEL:EH50PLE04

ELECTRICAL FLUID

FlywheelI.D.RefertoElectricalSectionFuelTank

CDIMarkingCU2544

3.5gals.(13.2L)

InjectorOil N/A ....... ...................

AlternatorOutput250Watts

Coolant 2.25qts.(2.1L)PP6*

IgnitionTiming30° BTDC@3500RPM±1.5° Transmission16oz.(473ml)PPS* ..... .......

SparkPlug/GapNGKBKR6E/0.028”(0.7mm)GearcaseOil(Front)4.0oz.80-90GL5

Lights:Head(Twin)Halogen30/30watts

Tail8.26watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)N/A ........ .

Brake26.9watts

VoltageRegulatorLR39

EngineCounterBal.N/A

EngineOil 2qts.(1.9L)PP4* .. .......... ..

ElectricStartStandard

SUSPENSION/CHASSIS

Brake(Hand) Dot3

Brake(Foot) Dot3

FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4*

*Lubricant

*PPSPolarisPremiumSyntheticGearCaseOil *PP6PolarisPremium60/40Antifreeze/Coolant *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

DRIVETRAIN

BodyStyle GenIII ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A TowCapacity850lbs.(385.9kg) GearReduction-Rev4.74/1

TurningRadius60”(152.4cm)

GearReduction-High3.06/1 .....

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance6.5”(16.51cm)

FrontDriveRatio2:1

CenterDriveRatioN/A .. ...

FrontVerticalTravel8.2”(20.83cm)

FinalDriveRatio13/3676P

RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel8.8“(22.35cm) Brake(AuxiliaryFoot)Hydraulic

RearShockFoxt GasChargedw/remoteres ShockAdjustmentThreadAdjuster

TIRES

TireSize-Front23x7-10

TireSize-Rear22x11-10

TireSize-CenterN/A ..

TirePressure-F/R4/3lbs.

TotalWidth45.5”(115.57cm)

TotalLength74.5”(189.23cm)

TotalHeight47”(119.38cm)

WheelBase48.5”(123.19cm)

Weight-Dry542lbs.(246.1kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Accy)30lbs. RearRack(Accy)60lbs. TongueWeight30lbs. ....... TowHitchAccy

RearCompressionSpring 7041389-067 Option175lb/in. 7041691-067 Standard170/210lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041548-067 Option75/100lb/in. 7041503-215 Standard75/110lb/in. 7041647-067 Option80/120lb/in.

MODEL: MAGNUM500 ..........

MODELNUMBER:A99CD50AA

ENGINEMODEL:EH50PLE08 ..

CARBURETION

Type BST34Mikuni ................

MainJet 157.5 ............

PilotJet 40 .............

JetNeedle 4HB40-2 ...........

NeedleJet Q-O ...........

ThrottleValve#100

PilotScrew 25/8TurnsOut ..........

PilotAirJet 160 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211069 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights 10MH

PrimarySpring Blue/Green ...........

SecondarySpringWhitew/GreenStripe ........

DrivenHelix Compound(EBS)

SpringPosition(Helix)N/A

SpringPosition(Sheave)N/A

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 498cc

Bore

3.6248”(92mm) .......................

Stroke 2.955”(75mm) .....................

CompressionRatio 10/2FullStroke

Cooling Liquid ....................

LubricationType DrySump

JETTINGCHART

-Pilotscrewin1/2turn

CLUTCHCHART

Meters 0-900 10MH Blue/Green EBS (Feet) (0-3000) 900-1800 10BH Blue/Green EBS (3000-6000) 1800-2700 10WH Blue/Green EBS (6000-9000) 2700-3700 10RH Blue/Green EBS (9000-12000)

*EBSrequiresnohelixadjustment

Piston/CylinderClearance0.0006-0.0018”(0.015-0.046mm) ...

ServiceLimit 0.0024”(0.061mm)

PistonMarking...............

PistonRingEndGap.008”-.015”(.20mm-.38mm) ........

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1200RPM

CompressionPressure(Std) ±15%

MODEL:

MODELNUMBER:A99CD50AA ...

ENGINEMODEL:EH50PLE08 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank

CDIMarkingCU2557

3.75gals.(14.2L)

InjectorOil N/A

AlternatorOutput250Watts Coolant 2.25qts.(2.1L)PP6* ... ............

IgnitionTiming30° BTDC@3500RPM±1.5° Transmission13.5oz.(400ml)PPS*

SparkPlug/GapNGKBKR5E/0.028”(0.7mm)GearcaseOil(Front)5.oz(150ml)80-90GL5 ... . .

Lights:HeadHalogen60/60watts

Tail8.26watts

Brake26.9watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)10.0oz.(300ml)80-90GL5

EngineCounterBal.N/A ...... ..........

VoltageRegulatorLR39 EngineOil 2qts.(1.9L)PP4*

ElectricStartStandard Brake(Hand) Dot3 ....... .....................

ElectronicSpeedoStandard Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... ..

*Lubricant

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenIV ChainType N/A

FrontSuspensionMacPhersonStrut

GearReduction-Low7.46/1 TowCapacity850lbs.(385.9kg)

TurningRadius65”(165.1cm)

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance7.25”(18.42cm)

GearReduction-Rev5.12/1

GearReduction-High3.3/1

FrontDriveRatio3.7/1(Shaft)

CenterDriveRatioN/A .. ...

FrontVerticalTravel6.7”(17.02cm)

FinalDriveRatio3.1/1(Shaft) RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc ... ....... RearTravel6.5“(16.51cm)

Brake(AuxiliaryFoot)Hydraulic RearShock2”GasChargedMono ShockAdjustmentCam ..

TIRES

TireSize-Front25x8-12

TireSize-Rear25x11-10 ....

TireSize-CenterN/A

TirePressure-F/R4/3lbs.

TotalWidth46”(116.84cm) ........

TotalLength81”(205.74cm)

TotalHeight47”(119.38cm) ........

WheelBase49.75”(126.37cm)

Weight-Dry647lbs.(293.7kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Std)90lbs. RearRack(Std)180lbs. TongueWeight30lbs. TowHitchStd

RearCompressionSpring 7041777-067 Standard125lb/in. 7041778-067 Option150lb/in. FrontStrutSpring 7041375-067

MODELNUMBER:A99CH50AA/AB/AC ENGINEMODEL:EH50PLE09 ..

CARBURETION

Type BST34Mikuni ................

MainJet 155 ............

PilotJet 40 .............

JetNeedle 4HB41-3 ...........

NeedleJet Q-0 ...........

ThrottleValve#100

PilotScrew 25/8TurnsOut ..........

PilotAirJet 160 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211069 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26° OutsideCircumference40.86 ±.12” .... CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights 10MH

PrimarySpring Blue/Green ...........

SecondarySpringWhitew/GreenStripe ........

DrivenHelix Compound(EBS)

SpringPosition(Helix)N/A

SpringPosition(Sheave)N/A

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 498cc

Bore

3.625”(92mm) .......................

Stroke 2.955”(75mm) .....................

CompressionRatio 10/2FullStroke

Cooling Liquid ....................

LubricationType DrySump

JETTINGCHART

-Pilotscrewin1/2turn

CLUTCHCHART

Meters 0-900 10MH

(Feet) (0-3000) 900-1800 10BH Blue/Green EBS (3000-6000) 1800-2700 10WH Blue/Green EBS (6000-9000) 2700-3700 10RH Blue/Green EBS (9000-12000)

*EBSrequiresnohelixadjustment

Piston/CylinderClearance0.0006-0.0018”(0.015-0.046mm) ...

ServiceLimit 0.0024”(0.061mm)

PistonMarking...............

PistonRingEndGap.008”-.015”(.20mm-.38mm) ........

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1200RPM

CompressionPressure(Std) ±15%

*Remingtont SpecialEdition

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

MODEL: SPORTSMAN500/SPORTSMAN500RSE*

MODELNUMBER:A99CH50AA/AB/AC ...

ENGINEMODEL:EH50PLE09 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank 5.25gals.(19.9L)

CDIMarkingCU2557

InjectorOil N/A

AlternatorOutput250Watts Coolant 2.25qts.PP6* ... .................

IgnitionTiming30° BTDC@3500RPM±1.5° Transmission32oz.PPS*

SparkPlug/GapNGKBKR5E/0.028”(0.7mm)GearcaseOil(Front)3.25oz.80-90GL5 ... ......

Lights:HeadHalogen60/60watts

GearcaseOil(Center)N/A ......

Tail8.26watts

Brake26.9watts

GearcaseOil(Rear)N/A

EngineCounterBal.N/A ...... ..........

VoltageRegulatorLR39 EngineOil 2qts.(1.9L)PP4*

ElectricStartStandard

SUSPENSION/CHASSIS

BodyStyle GenIV

Brake(Hand) Dot3

Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD*

ShiftSelectorBox1oz.(30ml)PP4* ... ..

LubricantKey

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

DRIVETRAIN

ChainType ShaftDrive ........ ......... FrontSuspensionMacPhersonStrut

GearReduction-Low6.69/1 .. .

TowCapacity1225lbs.(556.2kg)

TurningRadius65”(165.1cm)

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance11”(27.94cm)

FrontVerticalTravel6.25”(15.88cm)

GearReduction-Rev5.17/1

GearReduction-High3.34/1

FrontDriveRatio2/1

CenterDriveRatioN/A

FinalDriveRatio3.16/1 ....

RearSuspensionProgressiveRateIndependentBrake(Hand)SingleLever,Hyd.Disc RearTravel9.5“(24.13cm) Brake(AuxiliaryFoot)Hydraulic RearShock13/8”BoreGasBag ........ ShockAdjustmentCam

TIRES

TireSize-Front25x8-12 ....

TireSize-Rear25x11-10

TireSize-CenterN/A

TirePressure-F/R5/5lbs. .

TotalWidth46”(116.84cm)

TotalLength85”(215.9cm) .......

TotalHeight47”(119.38cm)

WheelBase50.50”(128.27cm)

Weight-Dry697lbs.(316.4kg) .......

Weight-Dry(RSE)730lbs.(331.4kg)

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring N/A

FrontStrutSpring

*Remingtont SpecialEdition

7041238-067 Option61lb/in.

7041453-067 Standard100lb/in. 7041519-067 Option140lb/in.

7041375-067 Standard64/113lb/in. 7041450-067 Option101lb/in.

MODEL: 5006X6 ..........

MODELNUMBER:A99AE50AA

ENGINEMODEL:EH50PLE06 ..

CARBURETION

Type BST34Mikuni ................

MainJet 140 ............

PilotJet 40 .............

JetNeedle 4D33-3 ...........

NeedleJet Q-6 ...........

ThrottleValve#100

PilotScrew 2 ..........

PilotAirJet 160 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188”(30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12” ....

CenterDistance 10±.12”(254.5mm) ..........

ClutchOffset 0.5”(12.7mm)

ShiftWeights 10MH

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix Compound

SpringPosition(Helix)2

SpringPosition(Sheave)2

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 498cc

Bore

3.625”(92mm) .......................

Stroke 2.955”(75mm) .....................

CompressionRatio 10/2FullStroke

Cooling Liquid ....................

LubricationType DrySump

JETTINGCHART

CLUTCHCHART

Piston/CylinderClearance0.0006-0.0018”(0.015-0.046mm) ...

ServiceLimit 0.0024”(0.061mm)

PistonMarking...............

PistonRingEndGap.008”-.015”(.20mm-.38mm) ........

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1200RPM

CompressionPressure(Std) ±15%

MODEL: 5006X6

MODELNUMBER:A99AE50AA ...

ENGINEMODEL:EH50PLE06 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.RefertoElectricalSectionFuelTank

CDIMarkingCU2557

3.5gals.(13.2L)

InjectorOil N/A

AlternatorOutput250Watts Coolant 2.25qts.PP6*

IgnitionTiming30° BTDC@3500RPM±1.5° Transmission20oz.PPS* ..... ..............

SparkPlug/GapNGKBKR5E/0.028”(0.7mm)GearcaseOil(Front)N/A

Lights:HeadHalogen60/60watts

GearcaseOil(Center)N/A ......

Tail8.26watts

GearcaseOil(Rear)N/A

Brake26.9watts EngineCounterBal.N/A

VoltageRegulatorLR39 EngineOil 2qts.(1.9L)PP4* .. .......... ..

ElectricStartStandard

Brake(Hand) Dot3

Brake(Foot) Dot3 ...................... FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4*

LubricantKey

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenII ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-Low6.64/1 TowCapacity1225lbs.(556.2kg)

GearReduction-Rev5.13/1 ...... .

TurningRadius98”(248.9cm)

ToeOut 1/8”-1/4”(3-6.35mm)

GroundClearance5.5”(13.97cm)

FrontVerticalTravel6.25”(15.88cm)

GearReduction-High3.29/1

FrontDriveRatio11/2268P

CenterDriveRatio11/2472P

FinalDriveRatio12/4288P

RearSuspensionSwingArmw/ScissorStabilizerAxletoAxle30/30116P ... .........

RearTravel7.25“(18.42cm)

Brake(Hand)SingleLever,Hyd.Disc

RearShock5mmBoreGasBag Brake(AuxiliaryFoot)Hydraulic ShockAdjustmentCam CenterSuspensionProgressiveRateSwingArm CenterTravel5”(12.7cm)

CenterShock1”Bore ShockAdjustmentCam TIRES

TireSize-Front25x8-12

TireSize-Rear25x11-10

TireSize-Center25x11-10 ..

TirePressure-F/R5/5/5lbs.

TotalWidth46”(116.84cm)

TotalLength103”(261.62cm)

TotalHeight47”(119.38cm)

WheelBase75”(190.5cm)

Weight-Dry870lbs.(395kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Accy)75lbs.

RearRack(Accy)125lbs. ....

TongueWeight (Accy)30lbs.

TowHitchStd ...........

RearCompressionSpring N/A 7041303-067 Standard250lb/in. N/A

MidCompressionSpring N/A 7041305-067

Standard60lb/in. N/A

FrontStrutSpring

SPECIFICATIONS

2000ModelSpecifications

MODEL: TRAILBLAZER ..........

MODELNUMBER:A00BA25CA ENGINEMODEL:EC25PFE13 ..

CARBURETION

Type

JetNeedle 5DP7-3 ...........

NeedleJet 0-4(169) ........... Cutaway 2.0

AirScrew 1.0Turn ........... ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

SecondarySpringRed DrivenHelix 40° .............

ENGINE

Type 2Cycle,SingleCyl. .......................

Displacement 244cc

Bore 2.8346I (72mm)

Stroke 2.3622I (60mm) .....................

CompressionRatio 6.1/1Effective

Cooling Air ....................

LubricationType OilInjected

PistonMarking 3W,4W

OperatingRPM±200 5800RPM

IdleRPM±200 700RPM

CompressionPressure(Std) ±15%

JETTINGCHART

-TurnASout1/2--3/4turnCCWfromseat Raiseneedleclip1positiontolowerjetneedle

CLUTCHCHART

2000ModelSpecifications

MODEL: TRAILBLAZER

MODELNUMBER:A00BA25CA ...

ENGINEMODEL:EC25PFE13

ELECTRICAL FLUID

FlywheelI.D.FF45

CapacityType

FuelTank 4gals.(15.1L) ...... ..........

CDIMarkingCU2167

InjectorOil 2qts.(1.9L)PP2* ....... .......... ..

AlternatorOutput150Watts

Coolant N/A

IgnitionTiming25° BTDC@3000RPM±3° Transmission11oz.(325ml)PPS* SparkPlug/GapNGKBR8ES/0.028I (0.7mm)GearcaseOil(Front)N/A

Lights:HeadHalogen55watts

Tail8.26watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)N/A ........ . Brake26.9watts

EngineCounterBal.N/A

VoltageRegulatorLR39--1 EngineOil N/A

ElectricStartStandard

SUSPENSION/CHASSIS

Brake(Hand)-- Dot3 Brake(Foot)-- Dot3 FrontHubs(AWD)N/A ShiftSelectorBox1oz.(30ml)PP4*

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant

DRIVETRAIN(ConcentricDrive)

BodyStyle GenIII ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A TowCapacity850lbs.(385.9kg) GearReduction-Rev3.05/1 ...... . TurningRadius60I (152.4cm) GearReduction-High2.68/1

ToeOut 1/8I-1/4I (3-6.35mm)

GroundClearance6I (15.24cm)

FrontDriveRatioN/A

CenterDriveRatioN/A .. ...

FrontVerticalTravel6.7I (17.02cm) FinalDriveRatio11/3878P RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel8.2I (20.8cm) Brake(AuxiliaryFoot)Hydraulic RearShock2I GasChargedMono ShockAdjustmentCam ..

TireSize-Front23x7-10

TireSize-Rear22x11-10

TireSize-CenterN/A

TirePressure-F/R4/3lbs.

TotalWidth46.5I (118.11cm)

TotalLength74.5I (189.23cm)

TotalHeight46I (116.84cm)

WheelBase49.75I (126.37cm)

Weight-Dry440lbs.(199.76kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Accy)30lbs. .... RearRack(Accy)60lbs. .... TongueWeight30lbs.

TowHitchAccy ...........

RearCompressionSpring 7041777-067 Option125lb/in. 7041778-067 Standard150lb/in. 7041815-067 Option175lb/in.

FrontStrutSpring N/A 7041850-067 Standard41lb/in. 7041375-067 Option64/113lb/in.

SPECIFICATIONS

2000ModelSpecifications

MODEL: XPLORER4X4 ..........

MODELNUMBER:A00AG25CA

ENGINEMODEL:EC25PFE12 ..

CARBURETION

Type VM30SSMikuni

JetNeedle 5DP7--3 ...........

NeedleJet 0-4(169) ...........

Cutaway 2.0

AirScrew 1Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

SecondarySpringRed DrivenHelix 40° .............

ENGINE

Type 2Cycle,SingleCyl. .......................

Displacement 244cc Bore 2.8346I (72mm) Stroke 2.3622I (60mm) .....................

CompressionRatio 6.1/1Effective

Cooling Air ....................

LubricationType OilInjected

OperatingRPM±200 5800RPM

IdleRPM±200 700RPM

CompressionPressure(Std) ±15%

JETTINGCHART

-Turnairscrewout1/2turn(counterclockwise) Raiseneedleclip1positiontolowerjetneedle

CLUTCHCHART

2000ModelSpecifications

MODEL: XPLORER4X4 ............

MODELNUMBER:A00AG25CA ...

ENGINEMODEL:EC25PFE12 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.FF45

CDIMarkingCU2167

FuelTank 4gals.(15.1L)

InjectorOil 2qts.(1.9L)PP2* ....... .......... ..

AlternatorOutput150Watts

Coolant N/A

IgnitionTiming25° BTDC@3000RPM±3° Transmission32oz.(947ml)PPS* ..... .......

SparkPlug/GapNGKBR8ES/0.028I (0.7mm)GearcaseOil(Front)4oz.(118ml)80-90GL5 Lights:Head1DualBeam60/60wattsGearcaseOil(Center)N/A ....

Tail8.26watts

GearcaseOil(Rear)N/A ........ . Brake26.9watts EngineCounterBal.N/A

VoltageRegulatorLR39--1

EngineOil N/A .. .......... ElectricStartStandard

Brake(Hand) Dot3

Brake(Foot) Dot3 ........ FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4*

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenII ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A TowCapacity850lbs.(385.9kg) GearReduction-Rev3.05/1 ...... .

TurningRadius60I (152.4cm)

ToeOut 1/8I-1/4I (3-6.35mm)

GroundClearance6I (15.24cm)

GearReduction-High3.34/1

FrontDriveRatio2:01

CenterDriveRatioN/A .. ...

FrontVerticalTravel6.7I (17.02cm)

FinalDriveRatio12/4282P RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel9I (22.86cm) Brake(AuxiliaryFoot)Hydraulic RearShock2I GasChargedTwinTube

ShockAdjustmentCam

TIRES

TireSize-Front23x7-10

TireSize-Rear24x11-10

TireSize-CenterN/A TirePressure-F/R4/3lbs.

TotalWidth45.5I (115.57cm) ........

TotalLength73I (185.42cm)

TotalHeight44.5I (113.03cm)

WheelBase49.75I (126.37cm)

Weight-Dry534lbs.(234.39kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Std)90lbs. RearRack(Std)180lbs.

TongueWeight30lbs. ....... TowHitchStd

RearCompressionSpring 7041518-067 Option175lb/in. 7041877-067 Standard160/200lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041238-067 Option61lb/in. 7041873--067 Standard55/105lb/in. 7041450-067 Option101lb/in.

SPECIFICATIONS

MODELNUMBER:A00AA32CA/AA

ENGINEMODEL:ES32PFE02/04 ..

CARBURETION

Type BST31Mikuni

MainJetPFE02142.5 ......

MainJetPFE04145 ......

PilotJet 50

JetNeedlePFE025F14-2

JetNeedlePFE045F14--3 ....

NeedleJetPFE02P-0(829) ....

NeedleJetPFE04P-2(829) ....

ThrottleValve#120

PilotScrew 2TurnsOut ..........

PilotAirJet 175 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT

Belt 3211077

BeltWidth(Projected)1.188I (30.18mm) .....

SideAngle(Overall)26° ......

OutsideCircumference40.86 ±.12I

CenterDistance 10±.12I (254.5mm)

ClutchOffset 0.5I (12.7mm) ............

SecondarySpringWhitew/GreenStripe ........ SpringPosition(Helix)N/A .... SpringPosition(Sheave)N/A

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 324cc

Bore 3.073I (78mm) .......................

Stroke 2.679I (68mm)

JETTINGCHART-ES32PFE02

AMBIENTTEMPERATURE

JETTINGCHART-ES32PFE04

AMBIENTTEMPERATURE

CLUTCHCHART

*40 helix,blackdrivenspring

ValveClearanceIn/Ex0.006/0.006I @BTDConcompression

Cooling Airw/fanassistedoilcooler

LubricationType DrySump

PistonMarking None

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1300RPM

CompressionRatio 9.2:1

CompressionPressure(Std) ±15%

MODEL:

MODELNUMBER:A00AA32CA/AA ...

ENGINEMODEL:ES32PFE02/04 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.F1475ER

CDIMarkingF8T19271

AlternatorOutput200Watts

FuelTank

3.7gals.(14.0L)

InjectorOil N/A

Coolant N/A ... .....................

IgnitionTiming30°±2° BTDC@5000RPMTransmission11.3oz.(335ml)PPS* SparkPlug/GapNGKBKR6E/0.036I (0.9mm)GearcaseOil(Front)N/A ... .

Lights:HeadDualBeam60/60watts

GearcaseOil(Center)N/A

Tail8.26watts GearcaseOil(Rear)N/A Brake26.9watts EngineCounterBal.N/A ...... ..........

VoltageRegulatorLR35

ElectricStartStandard

EngineOil

1.9qts.(1.8L)PP4*

Brake(Hand) Dot3 ....... .....................

ElectronicSpeedoN/A Brake(Foot) Dot3 FrontHubs(AWD)N/A ShiftSelectorBoxN/A ...

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS DRIVETRAIN

BodyStyle GenII ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A TowCapacity850lbs.(385.9kg) GearReduction-Rev3.05/1

TurningRadius60I (152.4cm) GearReduction-High2.68/1

ToeOut 1/8I-1/4I (3-6.35mm)

FrontDriveRatioN/A

GroundClearance5.5I (13.97cm) CenterDriveRatioN/A

FrontVerticalTravel6.7I (17.02cm) FinalDriveRatio11/4280P ....

RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel9.0I (22.86cm) Brake(AuxiliaryFoot)Hydraulic ........ RearShock2I GasChargedTwinTube ShockAdjustmentCam

TIRES

TireSize-Front23x7-10 ....

TireSize-Rear22x11-10

TireSize-CenterN/A

TirePressure-F/R4/3lbs.

TotalWidth46.5I (118.11cm)

TotalLength71.5I (181.61cm) .......

TotalHeight46I (116.84cm)

WheelBase49.5I (125.73cm) .......

Weight-Dry504lbs.(228.8kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Accy)75lbs. .... RearRack(Std)125lbs. ......

TongueWeight30lbs.

TowHitchStd ...........

RearCompressionSpring N/A 7041518-067 175lb/in. 7041303-067 250lb/in.

FrontStrutSpring N/A 7041850-067 41lb/in. 7041375-067 64-113lb/in.

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SPECIFICATIONS

2000ModelSpecifications

MODEL: MAGNUM325 ..........

MODELNUMBER:(2x4’s)A00CB32CA-(4x4’s)A00CD32CA

ENGINEMODEL:ES32PFE01 ..

CARBURETION

Type BST31Mikuni ................

MainJet 142.5 ............

PilotJet 50 .............

JetNeedle 5F14-2 ...........

NeedleJet P-0(829) ...........

ThrottleValve#120

PilotScrew 2TurnsOut ..........

PilotAirJet 175 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26° OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

ShiftWeights 10RH

PrimarySpring Blue/Green ...........

SecondarySpringWhitew/GreenStripe ........

DrivenHelix 2--2

SpringPosition(Helix)N/A

SpringPosition(Sheave)N/A

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 324cc

Bore

JETTINGCHART

CLUTCHCHART

*40 helix,blackdrivenspring

3.073I (78mm)

Stroke 2.679I (68mm)

ValveClearanceIn/Ex0.006/0.006I @TDConcompression

Cooling Airw/fanassistedoilcooler ....................

LubricationType DrySump

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1300RPM

CompressionRatio 9.2:1

CompressionPressure(Std) ±15%

MODEL:

MODELNUMBER:(2x4’s)A00CB32CA-(4x4’s)A00CD32CA ... ENGINEMODEL:ES32PFE01 ....

ELECTRICAL

FlywheelI.D.F1475ER

CDIMarkingF8T19271

AlternatorOutput200Watts

FuelTank 3.75gals.(14.2L)

InjectorOil N/A

Coolant N/A ... .....................

IgnitionTiming30°±2° BTDC@5000RPMTransmission13.5oz.(400ml)PPS* SparkPlug/GapNGKBKR6E/0.036I (0.9mm)GearcaseOil(Front)5oz.(150ml)80-90Lube ... .

Lights:Head2SingleBeam/30watts

GearcaseOil(Center)N/A

Tail8.26watts GearcaseOil(Rear)10oz.(300ml)80-90Lube Brake26.9watts

EngineCounterBal.N/A ...... ..........

VoltageRegulatorLR35

EngineOil 2qts.(1.9L)PP4*

ElectricStartStandard Brake(Hand) Dot3 ....... .....................

ElectronicSpeedoN/A

SUSPENSION/CHASSIS

BodyStyle GenIV

FrontSuspensionMacPhersonStrut

TowCapacity850lbs.(385.9kg)

TurningRadius65I (165.1cm)

ToeOut 1/8I-1/4I (3-6.35mm)

GroundClearance7.25I (18.42cm)

Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... .

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

DRIVETRAIN

ChainType N/A

GearReduction-Low7.46/1

GearReduction-Rev5.12/1

GearReduction-High3.3/1

FrontDriveRatio3.7/1(Shaft)

CenterDriveRatioN/A

FrontVerticalTravel6.7I (17.02cm) FinalDriveRatio3.1/1(Shaft) ....

RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel6.5I (16.51cm) Brake(AuxiliaryFoot)Hydraulic ........

RearShock2I GasChargedMono

ShockAdjustmentCam TIRES

TireSize-Front24x8-12 ....

TireSize-Rear24x11.5-10

TireSize-CenterN/A

TirePressure-F/R4/3lbs.

TotalWidth46I (116.84cm)

TotalLength81I (205.74cm) .......

TotalHeight46I (116.84cm)

WheelBase49.75I (126.37cm) .......

Weight-Dry(2x4)574lbs.(260.5kg)

Weight-Dry(4x4)620lbs.(281.4kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Std)90lbs. .....

RearRack(Std)180lbs. ......

TongueWeight30lbs.

TowHitchStd ...........

SPECIFICATIONS

2000ModelSpecifications

MODEL: MAGNUM325 ..........

MODELNUMBER:(2x4’s)A00CB32CA&A00CB32AA-(4x4’s)A00CD32CA&A00CD32AA ENGINEMODEL:ES32PFE04&ES32PFE05 ..

CARBURETION

Type BST31Mikuni ................

MainJet 145 ............

PilotJet 50 .............

JetNeedle 5F14-3 ...........

NeedleJet P-2(829) ...........

ThrottleValve#120

PilotScrew 2TurnsOut ..........

PilotAirJet 175 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

ShiftWeights 10RH

PrimarySpring Blue/Green ...........

SecondarySpringWhitew/GreenStripe ........

DrivenHelix 2--2

SpringPosition(Helix)N/A

SpringPosition(Sheave)N/A

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 324cc

Bore 3.073I (78mm)

Stroke 2.679I (68mm)

JETTINGCHART

CLUTCHCHART

ValveClearanceIn/Ex0.006/0.006I @TDConcompression

Cooling

Airw/fanassistedoilcooler ....................

LubricationType DrySump

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1300RPM

CompressionRatio 9.2:1

CompressionPressure(Std) ±15%

MODEL:

MODELNUMBER:(2x4’s)A00CB32CA&A00CB32AA-(4x4’s)A00CD32CA&A00CD32AA ...

ENGINEMODEL:ES32PFE04&ES32PFE05 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.F1475ER

CDIMarkingF8T19271

AlternatorOutput200Watts

FuelTank 3.75gals.(14.2L)

InjectorOil N/A

Coolant N/A ... ..................... IgnitionTiming30°±2° BTDC@5000RPMTransmission13.5oz.(400ml)PPS* SparkPlug/GapNGKBKR6E/0.036I (0.9mm)GearcaseOil(Front)5oz.(150ml)80-90Lube ... .

Lights:Head2SingleBeam/30watts

GearcaseOil(Center)N/A Tail8.26watts GearcaseOil(Rear)10oz.(300ml)80-90Lube Brake26.9watts EngineCounterBal.N/A ...... ..........

VoltageRegulatorLR35 EngineOil 2qts.(1.9L)PP4*

ElectricStartStandard Brake(Hand) Dot3 ....... .....................

ElectronicSpeedoN/A

Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... .

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS DRIVETRAIN

BodyStyle GenIV

FrontSuspensionMacPhersonStrut

ChainType N/A

GearReduction-Low7.46/1 TowCapacity850lbs.(385.9kg) GearReduction-Rev5.12/1

TurningRadius65I (165.1cm)

ToeOut 1/8I-1/4I (3-6.35mm)

GearReduction-High3.3/1

FrontDriveRatio3.7/1(Shaft)

GroundClearance7.25I (18.42cm) CenterDriveRatioN/A

FrontVerticalTravel6.7I (17.02cm) FinalDriveRatio3.1/1(Shaft) ....

RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel6.5I (16.51cm) Brake(AuxiliaryFoot)Hydraulic ........ RearShock2I GasChargedMono ShockAdjustmentCam TIRES

TireSize-Front24x8-12 ....

TireSize-Rear24x11.5-10

TireSize-CenterN/A

TirePressure-F/R4/3lbs.

TotalWidth46I (116.84cm)

TotalLength81I (205.74cm) .......

TotalHeight46I (116.84cm)

WheelBase49.75I (126.37cm) .......

Weight-Dry(2x4)574lbs.(260.5kg)

Weight-Dry(4x4)620lbs.(281.4kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Std)90lbs. .....

RearRack(Std)180lbs. ......

TongueWeight30lbs.

TowHitchStd ...........

2000ModelSpecifications

MODEL:

MODELNUMBER:A00CK32AA

ENGINEMODEL:ES32PLE03 ..

CARBURETION

Type BST31Mikuni

MainJet 152.5

PilotJet 47.5

JetNeedle 4HB40-3

NeedleJet P-0(829)

ThrottleValve#120

PilotScrew TBD

PilotAirJet 100

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

ENGINE

Type

JETTINGCHART

4Cycle,SingleCyl.

Displacement 325cc Bore 3.071I (78mm) ....................... Stroke 2.677I (68mm)

ValveClearanceIn/Ex0.006/0.006I @TDConcompression

Cooling Air

LubricationType WetSump

PistonMarking None ..............

OperatingRPM±200 6500RPM

IdleRPM±200(lightsoff)1350RPM

CompressionPressure(Std) ±15%

SUSPENSION/CHASSIS

I-1/4I (3-6.35mm)

I (17.78cm)

RearShock1-5/8I GasChargedTwintubeFrontDriveRatio 3.7/1(Shaft)

ShockAdjustmentCam

Brake(Hand) S/LHyd.Disc

Brake(AuxiliaryFoot)Hydraulic

MODEL:

MODELNUMBER:A00CK32AA ...

ENGINEMODEL:ES32PLE03 ....

ELECTRICAL FLUID

FlywheelI.D.F4T757

CDIMarkingF8T19271

AlternatorOutput200Watts

FuelTank

3.75gals.(14.9L)

InjectorOil N/A

Coolant N/A

IgnitionTiming30° BTDC@3500RPM±2° TransmissionN/A ..... .......

SparkPlug/GapNGKBKR6E/0.036I (0.9mm)GearcaseOil(Front)5oz.(150ml)80-90GL5

Lights:Head(2)Dualbeam30/30wattsGearcaseOil(Center)N/A ......

Tail8.26watts

Brake26.9watts

VoltageRegulatorLR39

ElectricStartStandard

ElectronicSpeedoAccessory

GearcaseOil(Rear)10oz.(300ml)80-90GL5

EngineCounterBal.N/A

EngineOil

Brake(Hand) Dot3

Brake(Foot) Dot3 .. ......................

FrontHubs(AWD)2.5oz.(75ml)PDD*

ShiftSelectorBoxN/A

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

TIRES

TireSize-Front24x8-12 ....

TireSize-Rear24x11.5-10

TireSize-CenterN/A

TirePressure-F/R4/3lbs.

TotalWidth46I (116.84cm)

TotalLength81I (205.74cm)

TotalHeight47I (119.38cm)

WheelBase49.75I (126.37cm)

Weight-Dry635lbs.(288kg)

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring 7041777-067 125lb/in.

LOADCAPACITY

FrontRack(Std)90lbs. RearRack(Std)180lbs.

TongueWeight30lbs.

TowHitchStd

7041849-067 125-180lb/in. 7041815-067 175lb/in.

FrontStrutSpring 7041238-067 61lb/in. 7041375-067 64-113lb/in. 7041450-067 101lb/in.

SPECIFICATIONS

2000ModelSpecifications

MODEL: SPORTSMAN335 ..........

MODELNUMBER:A00CH33AA/AB(CALIF.APPROVED)

ENGINEMODEL:ES33PFE02(CALIF.APPROVED) ..

CARBURETION

Type BST34Mikuni ................

MainJet 150 ............

PilotJet 40 .............

JetNeedle 5F14--3 ...........

NeedleJet P-9 ...........

ThrottleValve#100

PilotScrew 2.5TurnsOut ..........

PilotAirJet 160 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

ShiftWeights 16

PrimarySpring Blue/Green ...........

SecondarySpringRed ........

DrivenHelix Compound SpringPosition(Helix)2 SpringPosition(Sheave)2

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 334cc

Bore

3.0732I (78mm) .......................

Stroke 2.758I (70mm) .....................

JETTINGCHART

-Pilotscrewin1/2turn

CLUTCHCHART

ValveClearanceIn/Ex0.006/0.006I @TDConcompression

CompressionRatio 9.2/1FullStroke ..........

Cooling AirW/OilCoolerAssist

LubricationType DrySump ............

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1200RPM

CompressionPressure(Std) ±15% .......

MODEL: SPORTSMAN335 ............

MODELNUMBER:A00CH33AA/AB(CALIF.APPROVED) ...

ENGINEMODEL:ES33PFE02(CALIF.APPROVED)

ELECTRICAL FLUID CapacityType

FlywheelI.D.FF97

CDIMarkingCU2557

AlternatorOutput200Watts

FuelTank 3.75gals.(14.2L)

InjectorOil N/A

Coolant N/A ... ............

IgnitionTiming30° BTDC@3500RPM±1.5° Transmission32oz.PPS*

SparkPlug/GapNGKBKR7E/0.028I (0.7mm)GearcaseOil(Front)4oz.(120ml)80-90GL5 ... . .

Lights:HeadHalogen60/60watts

Tail8.26watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)N/A Brake26.9watts EngineCounterBal.N/A ...... ..........

VoltageRegulatorLR39

EngineOil 2.25qts.(2.1L)PP4*

ElectricStartStandard Brake(Hand) Dot3 ....... ..................... Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... ..

*Lubricant

*PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

BodyStyle GenIV

DRIVETRAIN

DriveType ShaftDrive FrontSuspensionMacPhersonStrut

TowCapacity850lbs.(385.9kg)

TurningRadius65I (165.1cm)

ToeOut 1/8I-1/4I (3-6.35mm)

GroundClearance10.25I (26.04cm)

FrontVerticalTravel6.25I (15.88cm)

GearReduction-Low6.89/1

GearReduction-Rev5.17/1

GearReduction-High3.56/1

FrontDriveRatio2:1

CenterDriveRatioN/A

FinalDriveRatio3.16:1 ....

RearSuspensionProgressiveRateIndependentBrake(Hand)SingleLever,Hyd.Disc

RearTravel9.5I (24.13cm) Brake(AuxiliaryFoot)Hydraulic ........ RearShock1I BoreGasBag

ShockAdjustmentCam TIRES

TireSize-Front23x7-10

TireSize-Rear24x11-10

TireSize-CenterN/A ..

TirePressure-F/R5/5lbs.

TotalWidth46I (116.84cm)

TotalLength81I (205.74cm) .......

TotalHeight46I (118.22cm)

WheelBase50.50I (128.27cm) .......

Weight-Dry670lbs.(304.2kg)

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Std)90lbs. ..... RearRack(Std)180lbs. ...... TongueWeight30lbs. TowHitchStd ...........

RearCompressionSpring N/A 7041453-067 Standard100lb/in. 7041519-067 Option140lb/in.

FrontStrutSpring 7041238-067 Option61lb/in. 7041375-067 Standard64/113lb/in. 7041450-067 Option101lb/in.

SPECIFICATIONS

2000ModelSpecifications

MODEL: XPLORER400 ..........

MODELNUMBER:A00CG38CA

ENGINEMODEL:EC38PLE08 ..

CARBURETION

Type VM34SSMikuni ................ MainJet 210 ............ PilotJet 35 .............

JetNeedle 6CEY6-3 ...........

NeedleJet 0-6(480) ...........

Cutaway 1.5

AirScrew 1.5Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

SecondarySpringRed DrivenHelix Compound .............

ENGINE

Type 2Cycle,SingleCyl. .......................

Displacement 378cc

Bore 3.2677I (83mm)

Stroke 2.7559I (70mm) .....................

CompressionRatio 6.9/1Effective

Cooling Liquid ....................

LubricationType OilInjected

OperatingRPM±200 5700RPM .........

IdleRPM±200 600RPM ..............

CompressionPressure(Std) ±15%

JETTINGCHART

-Dropjetneedleoneposition(raiseE--Clip) -Turnairscrewin1/2to3/4turn

CLUTCHCHART

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MODEL: XPLORER400 ............

MODELNUMBER:A00CG38CA ...

ENGINEMODEL:EC38PLE08 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.FF95

CDIMarkingCU2510

AlternatorOutput200Watts

FuelTank 4gals.(15.1L)

InjectorOil 2qts.(1.9L)PP2*

Coolant 2.25qts.(2.1L)PP6* ... ............

IgnitionTiming23.5° BTDC@3000RPM±1.5°

Transmission16oz.(473ml)PPS*

SparkPlug/GapNGKBR8ES/0.028I (0.7mm)GearcaseOil(Front)4oz(118ml)80-90GL5

Lights:HeadHalogen60/60watts

Tail8.26watts

GearcaseOil(Center)N/A

GearcaseOil(Rear)N/A Brake26.9watts EngineCounterBal.3.3oz.(100ml)10W30 ...... .

VoltageRegulatorLR39--1

ElectricStartStandard

EngineOil N/A

Brake(Hand) Dot3 ....... .....................

ElectronicSpeedoStandard

Brake(Foot) Dot3 .. ...................... FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... ..

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenIV ChainType 520O-Ring FrontSuspensionMacPhersonStrut

GearReduction-Low6.14/1 .. .

TowCapacity850lbs.(385.9kg)

TurningRadius65I (165.1cm)

GearReduction-Rev4.74/1

GearReduction-High3.06/1 .....

ToeOut 1/8I-1/4I (3-6.35mm)

FrontDriveRatio2:1

GroundClearance7.5I (19.05cm) CenterDriveRatioN/A

FrontVerticalTravel6.7I (17.02cm) FinalDriveRatio13/3676PitchChain .... RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel9I (22.86cm) Brake(AuxiliaryFoot)Hydraulic ........

RearShock2I GasChargedTwintube

ShockAdjustmentCam TIRES

TireSize-Front25x8-12 ....

TireSize-Rear25x11-10

TireSize-CenterN/A ..

TirePressure-F/R4/3lbs.

TotalWidth46I (116.84cm)

TotalLength81I (205.74cm) .......

TotalHeight47I (119.38cm)

WheelBase49.75I (126.37cm) .......

Weight-Dry588lbs.(266.95kg)

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring 7041518-067 Option175lb/in. 7041204-067 Standard190lb/in. 7041303-067 Option250lb/in.

FrontStrutSpring 7041238-067 Option61lb/in.

7041375--067 Standard64/113lb/in. 7041450-067 Option101lb/in.

CARBURETION

Type VM34SSMikuni ................ MainJet 230 ............ PilotJet 35 .............

JetNeedle 6CEY6-3 ...........

NeedleJet 0-6(480) ...........

Cutaway 1.5

AirScrew 1.5Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

SecondarySpringRed DrivenHelix 40° .............

SpringPosition(Helix)2 ....

SpringPosition(Sheave)2

ENGINE

Type

2Cycle,SingleCyl.

Displacement 378cc

Bore

3.2677I (83mm)

Stroke 2.7559I (70mm)

CompressionRatio 6.9/1Effective

Cooling Liquid ....................

LubricationType OilInjected

PistonMarking...............

OperatingRPM±200 5700RPM

IdleRPM±200 600RPM

CompressionPressure(Std) ±15% .......

JETTINGCHART

MJ=MainJet

AS=AirScrew(TurnsOut)

**For87OctaneOxygenatedFuelRefertojettingrecommendation inFuelSystem/Carburetionsection.

CLUTCHCHART

40 ° Helix,RedDriven

MODEL: SCRAMBLER4002x4 ............

MODELNUMBER:A00BA38CA ...

ENGINEMODEL:EC38PLE09 ....

ELECTRICAL FLUID

FlywheelI.D.FF95

CDIMarkingCU2515

FuelTank 4gals.(15.1L)

InjectorOil 2qts.(1.9L)PP2*

AlternatorOutput150Watts Coolant 2.25qts.(2.1L)PP6* ... ............

IgnitionTiming23.5° BTDC@3000RPM±3° Transmission11oz.(325ml)PPS*

SparkPlug/GapNGKBR8ES/0.028I (0.7mm)GearcaseOil(Front)4oz(118ml)80-90GL5 ... . ..

Lights:HeadHalogen30/30watts

GearcaseOil(Center)N/A Tail8.26watts

GearcaseOil(Rear)N/A Brake26.9watts EngineCounterBal.100ml10W30 ...... ........

VoltageRegulatorLR39--1

ElectricStartStandard

EngineOil N/A

Brake(Hand) Dot3 ....... .......

Brake(Foot) Dot3

FrontHubs(AWD)N/A ... ShiftSelectorBox1oz.(30ml)PP4* ...

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PP6PolarisPremium60/40Antifreeze/Coolant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

BodyStyle GenIII

DRIVETRAIN

ChainType 520O-Ring FrontSuspensionMacPhersonStrut GearReduction-LowN/A .. . TowCapacity850lbs.(385.9kg)

GearReduction-Rev3.05/1

TurningRadius60I (152.4cm) GearReduction-High2.68/1

ToeOut 1/8I-1/4I (3-6.35mm)

GroundClearance5.5I (13.97cm)

FrontDriveRatioN/A

CenterDriveRatioN/A .. ...

FrontVerticalTravel8.2I (20.83cm)

FinalDriveRatio13/3676P

RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel10.5I (26.67cm) Brake(AuxiliaryFoot)Hydraulic ........

RearShock2I GasChargedMonoTube ShockAdjustmentThreadAdjuster

TIRES

TireSize-Front23x7-10

TireSize-Rear22x11-10

TireSize-CenterN/A ..

TirePressure-F/R4/3lbs.

TotalWidth46.5I (118.11cm)

TotalLength74.5I (189.23cm)

TotalHeight47I (119.38cm)

WheelBase49.75I (126.37cm) .......

Weight-Dry501lbs.(227.4kg)

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring N/A

FrontStrutSpring N/A

LOADCAPACITY

FrontRack(Accy)30lbs. RearRack(Accy)60lbs. TongueWeight30lbs. ....... TowHitchAccy

7041865/864-067 Standard180/280lb/in. N/A

7041868-067 Standard55/80lb/in. 7041776-067 Option60/85lb/in.

CARBURETION

Type VM34SSMikuni ................ MainJet 230 ............ PilotJet 35 .............

JetNeedle 6CEY6-3 ...........

NeedleJet 0-6(480) ...........

Cutaway 1.5

AirScrew 1.5Turn ...........

ValveSeat 2.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

SecondarySpringRed DrivenHelix 40° .............

SpringPosition(Helix)2 ....

SpringPosition(Sheave)2

ENGINE

Type

2Cycle,SingleCyl.

Displacement 378cc

Bore

3.2677I (83mm)

Stroke 2.7559I (70mm)

CompressionRatio 6.9/1Effective

Cooling Liquid ....................

LubricationType OilInjected

PistonMarking...............

OperatingRPM±200 5700RPM

IdleRPM±200 600RPM

CompressionPressure(Std) ±15% .......

JETTINGCHART

MJ=MainJet

AS=AirScrew(TurnsOut)

**For87OctaneOxygenatedFuelRefertojettingrecommendation inFuelSystem/Carburetionsection.

CLUTCHCHART

40 ° Helix,RedDriven

MODEL: SCRAMBLER4004x4 ............

MODELNUMBER:A00BG38CA ...

ENGINEMODEL:EC38PLE09 ....

ELECTRICAL FLUID

FlywheelI.D.FF95

CDIMarkingCU2515

FuelTank 4gals.(15.1L)

InjectorOil 2qts.(1.9L)PP2*

AlternatorOutput150Watts Coolant 2.25qts.(2.1L)PP6* ... ............

IgnitionTiming23.5° BTDC@3000RPM±3° Transmission32oz.(946ml)PPS*

SparkPlug/GapNGKBR8ES/0.028I (0.7mm)GearcaseOil(Front)4oz(118ml)80-90GL5 ... . ..

Lights:HeadHalogen30/30watts

GearcaseOil(Center)N/A Tail8.26watts

GearcaseOil(Rear)N/A Brake26.9watts

EngineCounterBal.100ml10W30 ...... ........

VoltageRegulatorLR39--1

ElectricStartStandard

EngineOil N/A

Brake(Hand) Dot3 ....... .......

Brake(Foot) Dot3

FrontHubs(AWD)2.5oz.(75ml)PDD* ... ShiftSelectorBox1oz.(30ml)PP4* ... ..

*Lubricant

*PP2PolarisPremiumTC-W32StrokeOil *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PP6PolarisPremium60/40Antifreeze/Coolant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenIII ChainType 520O-Ring FrontSuspensionMacPhersonStrut

GearReduction-LowN/A .. . TowCapacity850lbs.(385.9kg)

TurningRadius60I (152.4cm)

GearReduction-Rev4.36/1

GearReduction-High2.82/1 .....

ToeOut 1/8I-1/4I (3-6.35mm)

GroundClearance5.5I (13.97cm)

FrontDriveRatio2:1

CenterDriveRatioN/A .. ...

FrontVerticalTravel8.2I (20.83cm)

FinalDriveRatio13/3676P RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel10.5I (26.67cm) Brake(AuxiliaryFoot)Hydraulic ........ RearShockFoxt GasChargedw/remoteres. ShockAdjustmentThreadAdjuster

TIRES

TireSize-Front23x7-10

TireSize-Rear22x11-10

TireSize-CenterN/A ..

TirePressure-F/R4/3lbs.

TotalWidth45.5I (115.57cm)

TotalLength74.5I (189.23cm)

TotalHeight47I (119.38cm)

WheelBase48.5I (123.19cm) .......

Weight-Dry541lbs.(245.6kg)

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring N/A

FrontStrutSpring

LOADCAPACITY

FrontRack(Accy)30lbs. RearRack(Accy)60lbs. TongueWeight30lbs. ....... TowHitchAccy

7041865/864-067 Standard180/280lb/in. N/A

7041648-067 Option75/100lb/in. 7041603-067 Standard75/110lb/in.

7041647-067 Option80/120lb/in.

2000ModelSpecifications

MODELNUMBER:A00CK42AA/AB

ENGINEMODEL:EH42PLE03 ..

CARBURETION

Type BST34Mikuni

MainJet 150

PilotJet 42.5

JetNeedle 4HB41-3

NeedleJet P-8

ThrottleValve#100

PilotScrew 25/8TurnsOut

PilotAirJet 160

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

ENGINE

Type

JETTINGCHART

4Cycle,SingleCyl.

Displacement 425cc

Bore 3.461I (87.9mm) .......................

Stroke 2.756I (70mm)

ValveClearanceIn/Ex0.006/0.006I @TDConcompression

Cooling Liquid

LubricationType WetSump

PistonMarking “257” ..............

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1200RPM .....

CompressionRatio 9.2/1FullStroke ..........

CompressionPressure60-90lbs.

SUSPENSION/CHASSIS

BodyStyle GenIV

I (165.1cm)

ToeOut(Total)1/8I-1/4I (3-6.35mm)

DRIVETRAIN

I (16.51cm) Secondary(atbeveldrive)1.313

RearShock2I GasChargedMono

ShockAdjustmentCam FinalDriveRatio 3.1/1(Shaft) .. ...........

Brake(Hand) S/LHyd.Disc

Brake(AuxiliaryFoot)Hydraulic

MODEL:

MODELNUMBER:A00CK42AA/AB ...

ENGINEMODEL:EH42PLE03 ....

ELECTRICAL

FlywheelI.D.FF95

CDIMarkingCU2557

FuelTank

3.75gals.(14.2L)

InjectorOil N/A

AlternatorOutput200Watts Coolant

2.25qts.(2.1L)PP6*

IgnitionTiming30° BTDC@3500RPM±1.5° TransmissionN/A ..... .......

SparkPlug/GapNGKBKR5E/0.028I (0.7mm)GearcaseOil(Front)5oz.(150ml)80-90GL5

Lights:HeadHalogen60/60watts

GearcaseOil(Center)N/A ......

Tail8.26watts

Brake26.9watts

VoltageRegulatorLR39

ElectricStartStandard

ElectronicSpeedoStandard

GearcaseOil(Rear)10oz.(300ml)80-90GL5

EngineCounterBal.N/A

Brake(Hand) Dot3

Brake(Foot) Dot3 .. ......................

FrontHubs(AWD)2.5oz.(75ml)PDD*

ShiftSelectorBoxN/A

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

TIRES

TireSize-Front25x8-12 ....

TireSize-Rear25x11-10

TireSize-CenterN/A

TirePressure-F/R4/3lbs.

TotalWidth46I (116.84cm)

TotalLength81I (205.74cm)

TotalHeight47I (119.38cm)

WheelBase49.75I (126.37cm)

Weight-Dry647lbs.(293.7kg)

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring 7041777-067 125lb/in.

LOADCAPACITY

FrontRack(Std)90lbs. RearRack(Std)180lbs.

TongueWeight30lbs. TowHitchStd

7041849-067 125-180lb/in. 7041815-067 175lb/in.

FrontStrutSpring 7041238-067 61lb/in. 7041375-067 64-113lb/in. 7041450-067 101lb/in.

SPECIFICATIONS

2000ModelSpecifications

MODELNUMBER:A00CD50AA

ENGINEMODEL:EH50PLE08 ..

CARBURETION

Type BST34Mikuni ................

MainJet 157.5 ............

PilotJet 40 .............

JetNeedle 4HB40-2 ...........

NeedleJet Q-O ...........

ThrottleValve#100

PilotScrew 25/8TurnsOut ..........

PilotAirJet 160 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211082 .....................

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)28°

OutsideCircumference41.44 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

ShiftWeights 10MH

PrimarySpring Blue/Green ...........

SecondarySpringWhitew/GreenStripe ........

DrivenHelix Compound(EBS)

SpringPosition(Helix)N/A

SpringPosition(Sheave)N/A

ENGINE

Type

4Cycle,SingleCyl. .......................

Displacement 498cc

Bore

Stroke

JETTINGCHART

CLUTCHCHART

*EBSrequiresnohelixadjustment

3.6248I (92mm)

2.955I (75mm)

ValveClearanceIn/Ex0.006/0.006I @TDConcompression

Cooling Liquid ....................

LubricationType DrySump

PistonMarking ArrowtoMAGside

OperatingRPM±200 6000RPM

IdleRPM±200(lightsoff)1200RPM

CompressionRatio 10/2FullStroke

CompressionPressure(Std) ±15%

MODEL:

MODELNUMBER:A00CD50AA ...

ENGINEMODEL:EH50PLE08 ....

ELECTRICAL FLUID CapacityType

FlywheelI.D.FF97

CDIMarkingCU2557

FuelTank 3.75gals.(14.2L)

InjectorOil N/A

AlternatorOutput250Watts Coolant 2.25qts.(2.1L)PP6* ... ............

IgnitionTiming30° BTDC@3500RPM±1.5° Transmission13.5oz.(400ml)PPS*

SparkPlug/GapNGKBKR5E/0.028I (0.7mm)GearcaseOil(Front)5oz.(150ml)80--90Lube ... .

Lights:HeadHalogen60/60watts

GearcaseOil(Center)N/A

Tail8.26watts GearcaseOil(Rear)N/A

Brake26.9watts EngineCounterBal.N/A ...... ..........

VoltageRegulatorLR39 EngineOil 2qts.(1.9L)PP4*

ElectricStartStandard Brake(Hand) Dot3 ....... .....................

ElectronicSpeedoStandard Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4* ... .

*PP6PolarisPremium60/40Antifreeze/Coolant *PPSPolarisPremiumSyntheticGearCaseOil *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

SUSPENSION/CHASSIS

DRIVETRAIN

BodyStyle GenIV ChainType N/A

FrontSuspensionMacPhersonStrut GearReduction-Low7.46/1 .. . TowCapacity850lbs.(385.9kg)

TurningRadius65I (165.1cm)

ToeOut 1/8I-1/4I (3-6.35mm)

GroundClearance7.25I (18.42cm)

FrontVerticalTravel6.7I (17.02cm)

GearReduction-Rev5.12/1

GearReduction-High3.3/1

FrontDriveRatio3.7/1(Shaft)

CenterDriveRatioN/A

FinalDriveRatio3.1/1(Shaft) .... RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel6.5I (16.51cm) Brake(AuxiliaryFoot)Hydraulic ........ RearShock2I GasChargedMono ........ ShockAdjustmentCam TIRES

TireSize-Front25x8-12 ....

TireSize-Rear25x11-10

TireSize-CenterN/A

TirePressure-F/R4/3lbs. .

TotalWidth46I (116.84cm)

TotalLength81I (205.74cm) .......

TotalHeight47I (119.38cm)

WheelBase49.75I (126.37cm) .......

Weight-Dry647lbs.(293.7kg) .......

OPTIONALSUSPENSIONSPRINGS

LOADCAPACITY

FrontRack(Std)90lbs. ..... RearRack(Std)180lbs. ......

TongueWeight30lbs.

TowHitchStd ...........

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SPECIFICATIONS

2000ModelSpecifications

MODEL: SCRAMBLER500 ..........

MODELNUMBER:A00BG50AA

ENGINEMODEL:EH50PLE04 ..

CARBURETION

Type BST40Mikuni ................

MainJet 155 ............

PilotJet 40 .............

JetNeedle 6H25--94--3 ...........

NeedleJet Y--O ...........

ThrottleValve#120

PilotScrew 2.0 ..........

PilotAirJet 1.3 ..........

ValveSeat 1.5

FuelOctane(R+M/2)87Non-Oxygenatedor 89Oxygenated

CLUTCH

Type PVT .................... Belt 3211077 .....................

BeltWidth(Projected)1.188I (30.18mm)

SideAngle(Overall)26°

OutsideCircumference40.86 ±.12I ....

CenterDistance 10±.12I (254.5mm) ..........

ClutchOffset 0.5I (12.7mm)

ShiftWeights 10WH

PrimarySpring Blue/Green ...........

SecondarySpringSilver ........

DrivenHelix 40°

SpringPosition(Helix)1

SpringPosition(Sheave)1

ENGINE

Type 4Cycle,SingleCyl.

Displacement 499cc ............... Bore 3.6248I (92mm)

Stroke 2.955I (75mm)

JETTINGCHART

CLUTCHCHART

ValveClearanceIn/Ex0.006/0.006I @TDConcompression .......

CompressionRatio 10/2FullStroke

Cooling Liquid

LubricationType DrySump

OperatingRPM±200 6500RPM

IdleRPM±200(lightsoff)1200RPM .....

CompressionPressure(Std) ±15%

MODEL: SCRAMBLER500 ............

MODELNUMBER:A00BG50AA ...

ENGINEMODEL:EH50PLE04

ELECTRICAL FLUID

FlywheelI.D.FF97

CDIMarkingCU2544

CapacityType

FuelTank 3.5gals.(13.2L)

InjectorOil N/A ....... ...................

AlternatorOutput250Watts

Coolant 2.25qts.(2.1L)PP6*

IgnitionTiming30° BTDC@3500RPM±1.5° Transmission32oz.(946ml)PPS* ..... ....... SparkPlug/GapNGKBKR6E/0.028I (0.7mm)GearcaseOil(Front)4.0oz.(118ml)80-90GL5

Lights:Head(Twin)Halogen30/30watts

GearcaseOil(Center)N/A Tail8.26watts GearcaseOil(Rear)N/A ........ . Brake26.9watts

VoltageRegulatorLR39

EngineCounterBal.N/A

EngineOil 2qts.(1.9L)PP4* .. .......... ..

ElectricStartStandard

SUSPENSION/CHASSIS

BodyStyle GenIII

Brake(Hand) Dot3 Brake(Foot) Dot3 FrontHubs(AWD)2.5oz.(75ml)PDD* ShiftSelectorBox1oz.(30ml)PP4*

*Lubricant

*PPSPolarisPremiumSyntheticGearCaseOil *PP6PolarisPremium60/40Antifreeze/Coolant *PP4Polaris0W/40SyntheticEngineLubricant *PDDPremiumDemandDriveHubFluid

DRIVETRAIN

ChainType 520O-Ring FrontSuspensionMacPhersonStrut

GearReduction-LowN/A TowCapacity850lbs.(385.9kg)

TurningRadius60I (152.4cm)

GearReduction-Rev4.74/1

GearReduction-High3.06/1 .....

ToeOut 1/8I-1/4I (3-6.35mm)

GroundClearance5.5I (13.97cm)

FrontVerticalTravel8.2I (20.83cm)

FrontDriveRatio2:1

CenterDriveRatioN/A

FinalDriveRatio13/3676P RearSuspensionProgressiveRateSwingArmBrake(Hand)SingleLever,Hyd.Disc RearTravel10.5I (26.67cm) Brake(AuxiliaryFoot)Hydraulic RearShockFoxt GasChargedw/remoteres ShockAdjustmentThreadAdjuster

TIRES

TireSize-Front23x7-10

TireSize-Rear22x11-10

TireSize-CenterN/A ..

TirePressure-F/R4/3lbs.

TotalWidth45.5I (115.57cm)

TotalLength74.5I (189.23cm)

TotalHeight47I (119.38cm)

WheelBase48.5I (123.19cm)

Weight-Dry542lbs.(246.1kg)

OPTIONALSUSPENSIONSPRINGS

RearCompressionSpring N/A

LOADCAPACITY

FrontRack(Accy)30lbs. RearRack(Accy)60lbs. TongueWeight30lbs. ....... TowHitchAccy

7041865/864-067 Standard180/280lb/in. N/A

FrontStrutSpring 7041648-067 Option75/100lb/in. 7041603-067 Standard75/110lb/in. 7041647-067 Option80/120lb/in.

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.