Polaris Trail Blazer Manuals

Manuals and User Guides for Polaris Trail Blazer. We have 3 Polaris Trail Blazer manuals available for free PDF download: Service Manual, Owner's Manual

Polaris Trail Blazer Service Manual (666 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 15.13 MB

Table of Contents
2
General Information / Specifications
2
Chapter 1 General Information / Specifications

4
- Engine Serial Number Location
  4
- Machine Model Number and VIN Number Location
  4
- Model / VIN Identification
  4
- 1999 Publication Part Numbers
  6
- Standard Torque Specifications
  8
- Conversion Table
  10
  - Metric Tap Drill Sizes
    11
  - SAE Tap Drill Sizes
    11
- Tap Drill Charts
  11
- Service Tips
  12
- Glossary of Terms
  13
- Glossary of Terms
  14
- Special Tools
  16
- 1999 Model Specifications
  17
  - Trail Blazer
    17
  - Trail Boss 250
    19
  - Xpress 300
    21
  - Xplorer 300
    23
  - Sportsman 335
    25
  - Sport 400
    28
  - Scrambler 400
    29
  - Scrambler 500
    30
  - Magnum 500
    36
- 1999 Model Specifications
  36
  - Trail Blazer
    41
  - Xplorer 4X4
    43
  - Trail Boss 325
    45
  - Xpedition 325
    51
  - Sportsman 335
    53
  - Xplorer 400
    55
  - Scrambler 400 2X4
    57
  - Scrambler 400 4X4
    59
  - Xpedition 425
    61
  - Magnum 500
    63
  - Scrambler 500
    65
  - Sportsman 6X6
    69
  - Maintenance
    72
Chapter 2 Maintenance

74
- Periodic Maintenance Chart
  74
  - Pre-Ride / Daily Inspection
    75
  - Recommended Lubricants - Quick Reference
    76
  - Polaris Premium Lubricant and Maintenance Product Part Numbers
    77
  - Lubrication
    79
  - Lubrication - Shaft Drive Models
    81
  - Lubrication Chart - Shaft Drive Models
    82
  - Gearcase Lubrication - Quick Reference
    83
  - Front Gearcase Lubrication
    84
  - Rear Gearcase Lubrication
    86
    
    Dipstick Models
    87
    
    Transmission Lubrication
    87
    
    Shaft / Chain Models Without Dipstick
    88
    
    Counter Balance Oil Changing Procedure
    89
    
    Counter Balancer Lubrication (400Cc Engines)
    89
    
    Procedure for Adding Oil (400)
    89
    
    Torque Stop Adjustment
    90
    
    Transmission Gearshift Linkage Adjustment, Preliminary Inspection
    90
    
    Shift Linkage Adjustment -High/Low/Reverse Transmissions
    91
    
    Shift Linkage Adjustment (High/Reverse Transmissions)
    93
  - Carburetor Adjustments
    94
    
    Choke (Enricher) Adjustment
    94
    
    Throttle Operation - All Models
    94
    
    Air Screw Adjustment
    95
    
    Pilot Screw Anti-Tamper Plug Removal
    96
    
    Pilot Screw (Idle Mixture) Adjustment Notes
    97
    
    Pilot Screw Adjustment - 335 4- -Stroke Models
    97
    
    Pilot Screw Adjustment - 425 / 500 4- -Stroke Models
    97
    
    Idle Speed Adjustment
    98
    
    Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
    99
    
    Oil Pump Adjustment Procedure
    100
    
    Oil Pump Bleeding Procedure
    102
    
    Oil Pump Troubleshooting Procedure
    102
    
    Oil Filter (2 Strokes)
    103
    
    Fuel Filter
    104
    
    Fuel Lines
    104
  - Fuel System
    104
    
    Vent Lines
    104
    
    Carburetor Draining
    105
    
    Compression Test - 2 Stroke
    106
    
    Compression Test - 4 Stroke
    106
    
    Engine Mounts
    106
    
    Fastener Torque - Engine
    106
  - Battery Maintenance
    107
  - Electrical
    107
  - Electrical
    108
    
    Engine-To-Frame Ground
    108
    
    Ignition Timing
    108
    
    Spark Plug
    108
    
    Coolant Strength / Type
    109
    
    Cooling System Hoses
    109
    
    Liquid Cooling System Overview
    109
    
    Radiator
    109
    
    Coolant Level Inspection
    110
    
    Engine Cooling System
    111
    
    Radiator Coolant Level Inspection
    111
    
    Air Filter Service (Trail Blazer Style)
    112
    
    Dual Stage Air Cleaner - 300 Style
    113
    
    Primary Pre-Cleaner Foam Boot
    113
    
    Cleaning the Main Filter
    114
    
    Secondary (Main) Filter
    114
    
    Secondary Filter Removal and Installation
    114
  - Air Filter Service, 2 Stroke
    116
  - Air Filter Service, 4 Stroke
    116
  - Breather Filter
    116
    
    Air Box Sediment Tube
    117
    
    Breather Filter Inspection
    118
    
    Breather Hose
    118
  - Recoil Housing
    119
    
    Engine Oil Level (4 Stroke)
    120
    
    Oil and Filter Change (4 Stroke)
    120
    
    Valve Clearance - 335, 425, 500Cc Engines
    122
    
    Exhaust Valve Clearance Adjustment
    123
    
    Intake Valve Clearance Adjustment
    123
    
    Steering & Toe Alignment Inspection
    125
    
    Tie Rod End / Steering Inspection
    125
    
    Straightedge or String
    126
    
    Chalk
    127
    
    Toe Alignment Adjustment
    127
    
    Front Hub Fluid Change (AWD Models)
    128
    
    Front Hub Fluid Level Inspection (AWD Models)
    128
    
    Exhaust Pipe
    129
    
    Brake Pad Inspection
    130
    
    Brake System Inspection
    130
  - Brake System Service
    130
    
    Hose/Fitting Inspection
    130
    
    Auxiliary Brake Adjustment (Hydraulic)
    131
    
    Auxiliary Brake Adjustment - Mechanical
    132
    
    Auxiliary Brake Testing
    132
    
    Auxiliary Mechanical Brake System
    132
    
    Drive Chain and Sprocket Inspection
    133
    
    Drive Chain Inspection
    133
    
    Sprocket Inspection
    133
    
    Rear Drive Chain Tension Adjustment - Standard Swingarm
    134
    
    Rear Drive Chain Tension Inspection - Standard Swingarm
    134
    
    Adjustment Procedure - Concentric Swingarm Rear Axles (Tapered Roller Bearings)
    135
    
    Drive Chain Adjustment, Concentric Swingarm
    135
    
    Center/Front Drive Chain Inspection/Adjustment
    138
    
    Center/Front Drive Chain Slack Adjustment
    138
    
    6X6 Chain Inspection
    139
    
    6X6 Middle Axle Chain Adjustment
    139
    
    6X6 Rear Axle Drive Chain Adjustment
    139
    
    Drive Chain Inspection/Adjustment - 6X6
    139
    
    Controls
    140
    
    Front Suspension
    140
    
    Rear Suspension
    140
    
    Suspension Spring Preload Adjustment
    140
    
    Chassis Maintenance
    141
    
    Wheel Removal Front or Rear
    141
    
    Wheel, Hub, and Spindle Torque Table
    141
    
    Wheels
    141
    
    Frame, Nuts, Bolts, Fasteners
    142
  - Tire Inspection
    142
  - Tire Pressure
    142
  - Tire Tread Depth
    142
  - Engine
    144
  - Torque Specifications
    146
  - Engine Fastener Torque Patterns
    148
  - Piston Clearance Specifications (2 Stroke Engines)
    149
  - Piston Identification
    149
  - ES33PFE01 / 02 Engine Service Data
    150
  - EH42PLE02 / EH50PLE04, 06, 08, 09 Engine Service Data
    152
  - Bleed Hole Inspection
    154
  - Radiator Cap Pressure Test
    154
  - System Pressure Test
    154
CHAPTER 3 ENGINE Torque Specifications - 2 Stroke

155
- Cooling System Specifications
  155
  - Recommended Coolant
    155
  - Accessible Components - All Models
    156
  - Engine Removal
    156
    
    Engine Removal
    157
    
    Bleed Cooling System
    158
  - Engine Installation Notes
    158
    
    General Items
    158
    
    PVT System
    158
    
    EC25PF / EC28PF Engine Disassembly
    159
    
    Connecting Rod Side Clearance
    160
    
    Crankshaft Main Bearing Inspection
    160
    
    EC25PF/EC28PF Engine Assembly
    161
    
    Measure Crankshaft Width - - Bearings Installed
    161
    
    Oil Pump End Play Adjustment
    166
    
    Oil Check Valve Testing (EC25PF)
    167
    
    Oil Check Valve Testing (EC28PF)
    167
    
    Recoil Disassembly
    168
  - EC25PF Recoil Assembly
    169
  - EC38PL Engine Disassembly
    171
  - EC38PL Engine Inspection
    172
    
    Connecting Radial Clearance
    177
    
    Reed Valve Inspection
    178
    
    Water Pump Impeller Clearance
    178
    
    Impeller Spacer Shim Part Numbers
    179
    
    Oil Check Valve Testing (EC38PL)
    180
    
    Cylinder Inspection/Measurement
    181
    
    Piston Inspection/Measurement (2 Stroke)
    181
    
    Piston Ring Installed Gap
    182
    
    Cleaning the Cylinder after Honing
    183
    
    Cylinder Hone Selection/Honing Procedure
    183
    
    Honing to Oversize
    183
    
    Connecting Rod Small End Bearing Inspection
    184
  - Crankshaft Runout Inspection - 2 Stroke
    185
    
    Crankshaft Straightening
    185
    
    4 Stroke Engine Service
    186
    
    Engine Lubrication - ES33PF / EH50PL
    188
    
    Oil Pressure Test - ES33PF / EH50PL
    188
    
    Oil Flow -- ES33PF
    189
    
    335 (ES33PFE) Oil Flow Chart
    190
  - ES50PL Lubrication/Oil Flow
    191
  - EH50PL Oil Flow Chart
    192
  - Es33Pfengine Exploded View
    193
  - EH50PL Engine Exploded View
    194
    
    Cam Chain Tensioner/Rocker Arm/Camshaft Removal
    195
    
    Engine Disassembly / Inspection
    195
    
    To Position Crankshaft at Top Dead Center (TDC) on Compression Stroke
    195
    
    Cam Chain Tensioner Inspection
    196
  - ES33PF / EH50PL Engine Removal
    196
    
    Rocker Arm/Shaft Removal
    197
    
    Rocker Arm/Shaft Inspection
    198
    
    Camshaft Removal
    200
    
    Automatic Compression Release Installation
    202
    
    Automatic Compression Release Removal/Inspection
    202
    
    If Camshaft Is Installed in the Engine
    202
    
    If Camshaft Is Removed from Engine
    202
    
    Camshaft Inspection
    203
    
    Cylinder Head Exploded View, ES33PF
    204
    
    Cylinder Head Exploded View, EH50PL
    205
    
    Cylinder Head Inspection
    206
    
    Cylinder Head Disassembly
    207
    
    Cylinder Head Warpage
    207
    
    Valve Inspection
    209
    
    Combustion Chamber
    210
    
    Cylinder Head Reconditioning
    211
    
    Valve Guide Removal/Installation
    211
    
    Valve Seat Inspection
    211
    
    Reaming the Valve Guide
    212
    
    Valve Seat Reconditioning
    212
    
    Cylinder Head Assembly
    215
    
    Valve Sealing Test
    216
    
    Cylinder/Piston Removal and Inspection
    217
  - ES33PF / EH50PL Engine Bottom End Disassembly
    217
    
    Piston Removal
    219
    
    Cylinder Inspection
    220
    
    Piston-To-Cylinder Clearance
    221
    
    Crankcase Disassembly
    224
    
    Starter Drive Removal/Inspection
    224
    
    Flywheel/Stator Removal/Inspection
    225
    
    Cam Chain/Tensioner Blade
    226
    
    One Way Valve
    227
    
    Crankcase Separation
    228
    
    Oil Pump Removal/Inspection
    229
    
    Oil Pump Assembly
    231
    
    Counter Balancer Shaft Removal/Inspection
    232
    
    Crankshaft Removal/Inspection
    233
    
    Crankcase Bearing Inspection
    234
    
    Pump Shaft Oil Seal/ Water Pump Mechanical Seal Removal (Engine Disassembled)
    234
    
    Bearing Installation
    235
    
    Crankcase Assembly
    235
    
    Crankshaft End Play Adjustment
    236
    
    End Play Inspection/Adjustment
    236
    
    Counter Balancer Shaft End Play Adjustment
    238
    
    Pump Shaft
    239
    
    Pump Shaft Oil Seal Installation
    239
    
    Crankshaft, Counter Balancer, and Oil Pump Installation
    240
    
    Water Pump Mechanical Seal Installation (EH50PL)
    241
    
    Water Pump Mechanical Seal Removal - Engine Installed (EH50PL)
    241
    
    Cam Chain Drive Sprocket Installation
    243
    
    One Way Valve Installation
    243
    
    Tensioner Blade Installation
    243
    
    Piston Ring Installation
    244
    
    Piston Installation
    245
    
    Cylinder Installation
    246
    
    Cylinder Head Installation
    248
    
    Cam Chain/Camshaft Installation
    249
    
    Camshaft Timing
    249
  - ES33PF / EH50PL Engine Assembly/Inspection
    251
    
    Cam Chain Tensioner Installation
    252
    
    Stator, Flywheel and Starter Drive Installation
    252
    
    Flywheel
    253
    
    Starter Drive
    253
    
    Oil Pipes
    254
    
    Rocker Shaft/Rocker Arm Assembly Installation
    254
    
    Thermostat Installation
    254
    
    Recoil Disassembly/Inspection
    255
    
    To Complete Recoil Assembly
    257
    
    To Install a New Spring
    257
    
    To Reinstall an Old Spring
    257
    
    Spark Plug Fouling - 2 Stroke Engines
    258
    
    Spark Plug Fouling - 4 Stroke Engines
    258
  - Spark Plug Fouling Checklist
    258
    
    2 Stroke Engine Troubleshooting
    259
    
    Engine Does Not Turn over
    261
    
    Engine Idles but will Not Rev up
    261
    
    Engine Runs but will Not Idle
    261
    
    Engine Turns over but Fails to Start
    261
    
    Backfiring
    262
    
    Excessive Smoke and Carbon Buildup
    262
    
    Low Compression
    262
    
    EH42PL/EH50PL Cooling System Troubleshooting
    263
    
    Leak at Water Pump Weep Hole
    263
    
    Overheating
    263
    
    Temperature too Low
    263
    
    Fuel System/Carburetion
    264
    
    Air Screw (2 Cycle) / Pilot Screw (4 Cycle) Adjustment
    266
  - Main Jet Selection
    266
Chapter 4 Fuel System/Carburetion

266
- Jetting Guidelines
  266
  - Fuel Tank Assembly / Oil Tank Assembly
    267
  - Fuel Flow Diagrams
    269
    
    Fuel System Diagram - 2 Stroke Models
    269
    
    Fuel System Diagram - 4 Stroke Models
    269
    
    Air/Fuel Mixture Ratio
    272
    
    E-Clip Position Vs. Fuel Flow
    272
    
    Pilot Air Screw
    272
    
    Pilot Jet
    272
    
    Jet Needle
    273
    
    Needle Jet
    273
    
    Throttle Opening Vs. Fuel Flow
    273
  - Main Jet / Pilot Jet Part Numbers
    274
    
    Throttle Valve
    274
    
    Starter System - Closed Throttle (2 Cycle)
    275
    
    Pilot System (0-3/8 Throttle) (2 Cycle)
    276
    
    Slide Cutaway (1/8-3/8 Throttle) (2 Cycle)
    277
    
    Jet Needle/Needle Jet (3/8-3/4 Throttle) (2 Cycle)
    278
    
    Main System (3/4 to Full Throttle) (2 Cycle)
    279
  - Carburetor Component Function (2 Cycle)
    280
    
    Component Effect Vs. Throttle Opening (2 Cycle)
    280
    
    Mikuni Fuel Delivery (2 Cycle)
    280
  - Assembly, CV Carburetor
    281
  - Float Height Adjustment (2 Cycle)
    281
  - Needle and Seat Leakage Test - 2 Cycle
    281
  - Vent Systems (2 Cycle)
    281
  - Mikuni VM30SS / VM34SS Carburetor Exploded View
    282
  - 4 Cycle CV Carburetor System Function
    283
  - Vent Systems - 4 Cycle CV Carburetor
    283
  - Mikuni CV Carb Operation
    284
  - Pilot (Idle and Slow) System
    285
  - Starter System (Choke or Enrichment)
    285
  - Float System
    286
  - Main System
    286
  - Mikuni BST 34 Carburetor Exploded View
    287
  - Mikuni BST 40 Carburetor Exploded View
    288
  - Carburetor Disassembly Notes- Mikuni CV
    289
  - Carburetor Cleaning - Mikuni CV
    291
  - Carburetor Inspection - Mikuni CV
    292
  - Carburetor Assembly - Mikuni CV
    293
  - Carburetor Adjustment - Mikuni CV
    294
  - Float Height Adjustment
    294
  - Fuel Level
    295
Fuel Pump

296
- Needle and Seat Leakage Test
  295
- Fuel Pump Disassembly
  296
- Fuel Pump Inspection/Assembly
  296
- Fuel Pump Exploded View
  297
  - Fuel Starvation/Lean Mixture
    298
  - Poor Idle
    298
  - Troubleshooting
    298
  - Rich Mixture
    298
  - Erratic Idle
    299
  - Idle too Low
    299
  - Body / Steering / Suspension
    300
  - Torque Specifications, Special Tools
    302
  - Body Assembly Exploded View (Gen Ll - Typical)
    303
  - Front Cab Assembly
    303
  - Rear Cab Assembly
    303
  - Cover/Panel Removal (Gen Ll - Typical)
    304
  - Body Assembly Exploded View (Gen Lll - Typical)
    305
  - Cover/Panel Removal (Gen Lli - Typical)
    306
  - Body Assembly Exploded View (Gen Lv - Typical)
    307
  - Cover/Panel Removal (Gen Lv - Typical)
    308
  - Headlight Pod Exploded View (Gen Lv - Typical)
    309
  - Side Panel Removal (Gen Lv - Typical)
    310
  - Typical Steering Assembly, Exploded View, ’99 Trail Boss 250
    311
  - Steering Assembly, Exploded View, - 2X4 Models (Except ’99 Trail Boss 250)
    312
  - Steering Assembly, Exploded View All 4X4 and 6X6 Models
    313
  - A-Arm Replacement
    314
  - Concentric Swing Arm Removal
    315
  - Standard Swing Arm and Rear Suspension Exploded View
    317
  - Shaft Ride Swingarm Exploded View
    318
  - Shaft Ride Swingarm
    319
  - Swingarm Installation
    319
  - Rear Suspension Assembly, - Shaft Drive Models
    320
  - Rear Strut Stabilizer, 6X6 Models
    321
  - Rear Swing Arm Weldment, 6X6 Models
    322
  - Front Swing Arm Weldment, 6X6 Models
    323
  - Strut Assembly Exploded View - 2X4 Models
    324
  - Strut Assembly - AWD Models
    325
  - Front Strut Cartridge Replacement
    326
  - Front Strut Weldment Replacement
    326
  - Ball Joint Replacement
    327
  - Front Strut Ball Joint Replacement
    327
  - Decal Replacement
    330
  - Clutches
    332
  - Clutch Specifications
    334
  - PVT System Fastener Torques
    334
  - Special Service Tools and Supplies
    334
  - Drive Clutch Operation
    335
  - Driven Clutch Operation
    335
  - PVT Operation
    335
  - Standard PVT System Introduction
    335
CHAPTER 6 CLUTCHES Service Tools and Supplies

336
- PVT Maintenance/Inspection
  336
  - PVT Drying
    336
  - PVT Overheating
    336
  - PVT Sealing and Ducting Components
    336
  - PVT Disassembly
    337
  - PVT Assembly
    339
  - PVT Sealing and Ducting Components
    340
    
    Relationship of Drive Clutch Weights and Spring in Maintaining Operating RPM
    343
    
    Drive Clutch Spring Specifications
    344
  - Shift Weights
    345
  - Button to Tower Clearance Inspection
    346
  - Drive Clutch Inspection
    346
  - Shift Weight Inspection
    346
  - Drive Clutch & EBS Exploded View
    347
  - Drive Clutch Disassembly/Inspection
    348
    
    Moveable Sheave Bushing Inspection
    349
    
    Spider Removal
    349
    
    Roller, Pin and Thrust Washer Inspection
    350
  - Drive Clutch Assembly
    351
  - Standard P-90 (Non-EBS) Clutch
    353
  - Drive Belt Tension
    355
  - Drive Belt Removal/Inspection
    356
  - Clutch Alignment/Offset
    357
  - Drive Clutch Bushing Service
    359
    
    Drive Clutch Moveable Sheave - Bushing Removal
    359
    
    Polaris Kit PN 2871226
    359
    
    Drive Clutch Moveable Sheave - Bushing Installation
    360
    
    Drive Clutch Cover - Bushing Removal
    361
    
    Drive Clutch Cover - Bushing Installation
    362
  - Driven Clutch Disassembly/Inspection
    363
  - Driven Clutch Assembly
    366
  - Driven Clutch Bushing Service
    367
    
    Driven Clutch Moveable Sheave - Bushing Installation
    369
    
    Engine Braking System (EBS) Clutch
    372
    
    EBS Theory of Operation
    373
    
    Operation Guidelines for Ebs Clutches
    374
  - EBS Exploded View
    375
  - One-Way Clutch Inspection (Drive Clutch)
    376
  - Driven Clutch Disassembly/Inspection - EBS
    379
  - One-Way Clutch Preliminary Inspection (Driven)
    379
  - Ebs Clutch Bushing Removal and Installation
    383
  - Ebs Drive Clutch Moveable Sheave - Bushing Removal
    383
  - Removal and Installation Instructions
    383
  - EBS Clutch Cover - Bushing Installation
    384
  - EBS Clutch Cover - Bushing Removal
    384
  - EBS Drive Moveable - Bushing Installation
    384
  - EBS Driven - Bushing Installation
    385
  - EBS Driven - Bushing Removal
    385
  - EBS Driven - Backside (Outer) Bushing Installation
    386
  - EBS Driven - Backside (Outer) Bushing Removal
    386
  - Clutch Troubleshooting
    387
  - Final Drive
    390
  - Final Drive
    392
  - 2X4 Hub Bearing / Seal Replacement
    393

Polaris Trail Blazer Service Manual (634 pages)

Polaris ATV And Light Utility Vehicle Service Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 48.29 MB

Safety Labels and Instructions
2
Table of Contents
3
General Information
5
Table of Contents
5
Model Identification
6
Engine Serial Number Locationi
6
Transmission ID Number Location
6
Carburetor ID Number Location
6
1996 Model Identification
7
Vehicle Identification Number (1997 and Later Model Years)
8
1996 Publication Numbers
10
1997 Publication Numbers
10
1998 Publication Numbers
11
Service Traning Videos
11
Service/Information Bulletins
12
Bulleting Index - 1996 by Model
13
Bulleting Index - 1997 by Model
14
Bulleting Index - 1998 by Model
14
1997 Paint Codes
16
Specifications 1997
18
Specifications 1998
23
Standard Torque Specifications
26
Decimal Equivalents
27
Conversion Table
28
Tap Drill Charts
29
SAE Tap Drill Sizes
29
Metric Tap Drill Sizes
29
Warranty
30
Service Tips
31
Glossary of Terms
32
Special Tools
35
Routing Diagrams
36
Magnum Routing Diagram
36
Hoses Diagram
39
300 Fan Motor Wiring Diagram
40
Wire Harness Diagram
41
Chassis/Suspension Service Tools
42
Transmission Tool Kit - Shaft Drive
42
Yoke Gauge Tool - Shaft Drive
42
Mity Vac Pump Kit
43
Small Battery Hydrometer
43
Transmission Seal/Bearing Driver - 50 MM
43
CV Boot Clamp Pliers
43
Glossary (2)
45
Magnum Routing Diagram (Cont.)
48
Hosed Diagram (2)
51
300 Fan Motor Wiring Diagram (2)
52
Wire Harness Diagram (2)
53
Oil Tank Vent Line Routing (1996 Sportsman 500) Diagram
54
Maintenance
56
Periodic Maintenance Chart
58
Pre-Ride/Daily Inspection
59
Recommended Lubricants and Capacities
60
Lubrication Chart
62
Lubrication Chart - Type IV Transmission (Shaft Drive)
65
Front Gearcase Lubrication
67
Gearcase Lubricant Change
67
Carburetor Adjustments
68
Idle Speed Adjustment
68
Throttle Cable/Electronic Throttle Control ETC Switch Adjustment
68
Throttle Operation
68
Throttle Cable Adjustment
69
Choke Adjustments
69
Throttle Control Lever Stop Adjustment
69
Air Screw Adjustment - 2-Stroke Models
70
Pilot Screw (Idle Mixture) Adjustment - 4-Stroke Models
70
Fuel Lines
72
Vent Lines
72
Fuel Filter
72
Carburetor Float Bowl Draining
72
Carburetor Draining
73
Breather System (4 Strokes)
74
Breather Filter Inspection
74
Breather Hose
74
General Maintenance
76
Compression Test
76
Battery Maintenance
77
Spark Plug Maintenance
78
Ignition Timing
78
Engine Mounts
78
Coolant Level Inspection
79
Coolant Strength
79
Cooling System Pressure Test
79
Radiator
79
Oil Pump Adjustment Procedure
80
Oil Pump Bleeding Procedure
83
If Oil Starvation Is Suspected
83
Recoil Housing
84
Counter Balancer Lubrication (400)
84
Procedure for Adding Oil (400)
84
Counter Balance Oil Changing Procedure
84
Air Cleaner - Trail Boss, Xpress 300, Xplorer 300, Xplorer 400
85
Dual Stage Air Cleaner
85
Primary Pre-Cleaner Foam Boot
85
Secondary (Main) Filter
86
Secondary Filter Removal and Installation Procedure
86
Cleaning the Main Filter
86
Air Filter Service -Sport, Scrambler 400
87
Air Filter Service - Trail Blazer
88
2 Stroke Engine Maintenance
89
Oil Filter (2 Strokes)
89
4 Stroke Engine Maintenance
90
Air Filter - 4 Stroke Engine
92
Pre-Filter Service
92
Air Filter Main Element
92
Air Box Sediment Tube
93
Air Filter Service - Scrambler 500
94
Air Filter Service - Sportsman 500, Xplorer 500
94
Check Engine Oil (4 Stroke)
96
Oil and Filter Change (4 Stroke)
96
Engine Sump Drain Plug View
97
Valve Clearance
100
Intake Valve Clearance Adjustment
101
Exhaust Valve Clearance Adjustment
101
Throttle Cable Lubrication
102
Toe Alignment Inspection
103
Chassis Maintenance
104
Steering Maintenance
104
Camber and Caster Adjustment
104
Toe Alignment Inspection (Chassis Maintenance)
104
The Rod End Inspection
105
Front Hubs (4X4 AWD Model)
105
Changing Front Hub Fluid
105
Exhaust Pipe
106
Brake System Inspection
107
Brake Fluid Level Inspection
107
Wear Line
107
Auxiliary Mechanical Brake System
108
Auxiliary Brake Testing
108
Auxiliary Brake Adjustment
108
Hose/Fitting Inspection
108
Drive Chain and Sprocket Inspection
109
Rear Drive Chain Note
109
Drive Chain Inspection
109
Rear Drive Chain Tension Adjustment
110
Drive Chain Adjustment, Concentric Swingarm
111
Center/Front Drive Chain Slack Adjustment
113
Center/Front Drive Chain Inspection/Adjustment
113
Sprocket Inspection
113
Drive Chain Inspection/Adjustment
114
Rear Axle (6X6 Middle Axle) Adjustment Procedure
114
Final Drive Chain
114
6X6 Rear Axle Drive Chain Adjustment
114
Front Suspension
115
Rear Suspension
115
Controls Check
115
Transmission Lubrication
116
Transmission Oil Changing Procedure
116
Transmission Oil Change - Dipstick Models
116
Transmission Lubrication - Type V Shaft/Chain
117
Transmission Oil Change Procedure
117
Transmission Vent Line Routing
118
Transmission Linkage Adjustment
118
Wheels Inspection
119
Wheel, Hub, and Spindle Torque Table
119
Wheel Removal Front or Rear
119
Wheel Installation
119
Tire Pressure
120
Tire Tread Depth
120
Frame, Nuts, Bolts, Fasteners
120
Engine
122
2 Stroke Engine Torque Specifications
124
4 Stroke Engine Torque Specifications
124
Engine Fastener Torque Patterns
125
1996 To Current Engine Specifications
126
Piston Identification
126
EC38PL Engines
127
Jetting Guidelines for Round-Port Pistons
127
EH42PL/EH50PL Engine Service Data
129
Cooling System
131
System Pressure Test
131
Radiator Cap Pressure Test
131
Recommended Coolant
132
Cooling System Specifications
132
2 Stroke Engine Removal
133
Engine Removal Preparation, Typical (2 Stroke)
133
Engine Installation Notes (2 Stroke)
136
Bleed Cooling System
136
Transmission Readjustment
136
Engine Break in Period (2 Strokes)
136
EC25PF/EC28PF Engines Disassembly
137
Crankshaft Alignment
138
EC25PF/EC28PF Engines Assembly
139
Measure Crankshaft Width - Bearings Installed
139
Connecting Rod Side Clearance
140
EC25PF/EC28PF Engines Installation
144
Oil Pump End Play Adjustment
145
Oil Check Valve Testing (250/400)
146
Oil Check Valve Testing (300)
146
EC25PF Engine - Recoil Disassembly
147
EC25PF Engine - Recoil Assembly
148
EC38PL Engine Disassembly
150
Water Pump Impeller Clearance
156
Cylinder Hone Selection/Honing Procedure
158
Piston/Cylinder Clearance (2 Strokes)
159
Cylinder Inspection/Measurement
159
Piston Inspection/Measurement (Generic)
159
Piston Ring Installed Gap
160
Piston Pin/Needle Bearing Inspection
160
Connecting Rod Small End Inspection
161
EH42PL/EH50PL Engine Exploded View
162
EH42PL/EH50PL Lubrication/Oil Flow
163
Oil Pressure Test
163
EH42PL/EH50PL Engine Diagram
164
EH42PL/EH50PL Oil Flow Chart
164
EH42PL/EH50PL Engine Removal
165
Cylinder Head Bolts
165
Crankcase
165
AWD Models
166
PVT Disassembly, All Models
166
Recoil/Starter Removal
167
Final Coolant Draining/Engine Removal
169
EH42PL/EH50PL Engine Installation
170
Oil Supply
170
EH42PL/EH50PL Engine: Bleed Cooling System
170
Cam Chain Tensioner/Rocker Arm/Camshaft Removal
170
To Position Crankshaft at Top Dead Center (TDC) on Compression Stroke
171
Cam Chain Tensioner
171
Rocker Arm/Shaft Removal
172
Rocker Arm/Shaft Inspection
172
Camshaft Removal
174
Automatic Compression Release Removal/Inspection
175
Automatic Compression Release Installation
175
Camshaft Inspection
176
Cylinder Head Removal
177
Cylinder Head Disassembly/Inspection
178
Cylinder Head Warpage
179
Cylinder Head Disassembly
179
Valve Inspection
181
Combustion Chamber
182
Valve Seat Inspection
182
Cylinder Head Reconditioning
182
Valve Guide Removal/Installation
182
Valve Seat Reconditioning
183
Cylinder Head Assembly
186
Valve Sealing Test
187
Cylinder/Piston Removal and Inspection
187
Piston Removal
188
Cylinder Inspection
189
Piston to Cylinder Clearance
190
Piston Ring Installed Gap (EH42PL/EH50PL)
192
Crankcase Disassembly
192
Starter Drive Removal/Inspection
193
Flywheel/Stator Removal/Inspection
194
Cam Chain/Tensioner Blade
194
Stator Plate
194
One Way Valve
195
Crankcase Separation
195
Oil Pump Removal/Inspection
196
Oil Pump Assembly
198
Counter Balancer Shaft Removal/Inspection
198
Crankshaft Removal/Inspection
199
Crankcase Bearing Inspection
200
Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal
200
EH42PL/EH50PL Engine Assembly
201
Crankcase Assembly
201
End Play Inspection/Adjustment
201
Crankshaft
201
Counter Balancer
203
Pump Shaft
203
Pump Shaft Oil Seal Installation
203
Crankshaft, Counter Balancer and Oil Pump Installation
204
To Assemble the Crankcase
204
Water Pump Mechanical Seal Installation
205
Water Pump Mechanical Seal Removal - Engine Installed
205
Piston Installation
208
Cylinder Installation
209
Cylinder Head Installation
210
Cam Chain/Camshaft Installation
211
Camshaft Installation - Timing Method
212
Method 1 - Camshaft Timing with Stator Removed
213
Camshaft Installation - Timing Method 2
214
Method 2 Camshaft Timing Using Flywheel TDC Mark
215
Cam Chain Tensioner Installation
216
Stator, Flywheel and Starter Drive Installation
216
Rocker Shaft/Rocker Arm Assembly Installation
218
Thermostat Installation
218
Oil Pipes
218
Engine - Sealed Recoil
219
Recoil Disassembly/Inspection
219
Recoil Assembly
220
To Install a New Spring
220
To Reinstall an Old Spring
220
Spark Plug Fouling - 2 Stroke Engine
222
Spark Plug Fouling - 4 Stroke Engine
222
2 Stroke Engine Troubleshooting
223
Starter Motor
224
4 Stroke Engine Troubleshooting
225
Piston Damage Checklist - 2 Stroke Engines
227
Fuel System/Carburetion
228
Fuel System/Carburetion - 1996 Specifications
230
Jetting Guidelines
230
Jetting Compensation for Altitude and Temperature - 1996 Models
230
Fuel System/Carburetion - 1997 Specifications
234
Jetting Compensation for Altitude and Temperature (1997)
234
Fuel System/Carburetion - 1998 Specifications
235
1998 Trail Boss W98AA25C (Engine -EC-25PFE-10) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
235
1998 Trail Blazer W98AA25C (Engine -EC-25PFE-11) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
236
XPRESS 300 W98CA28C (Engine -EC-28PFE-12) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
237
XLPORER 300 W98CC28C (Engine -EC-28PFE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
238
1998 XLPORER 400 W98CC38C (Engine -EC-38PFE-06) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
239
1998 Sport 400 W98BA38C (Engine - EC-38PLE-07) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
240
1998 Scrambler 400 W98BC38C (Engine - EC38PLE-09) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
241
Magnum 2 X 2 W98AA42A (Engine - EH-42PLE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
242
Magnum 4 X 4 W98AC42A (Engine - EH-42PLE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
243
1998 Scrambler 500 W98BC50A (Engine - EH50PLE-04) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
244
Sportsman 500 W98CH50A (W90CH50AB) (Engine - EH-50PLE-07) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
245
1998 Big Boss 500 6X6 W98AE50A (Engine - EH50PLE-06) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
246
Fuel System/Carburetion - Jet Part Numbers
247
Oil Tank and Fuel Tank Assembly - Gen II (Except Magnum)
248
Fuel Tank Assembly (Magnum)
249
Oil Tank and Fuel Tank Assembly (Gen III Typical)
250
Fuel Tank Assembly (Gen IV)
251
Fuel Tank Assembly - 500 Models (1997 Xplorer 500, Sportsman 500)
252
Fuel Flow Diagrams
253
Mikuni VM Carburetor Exploded Diagram
254
Carburetor Function
255
Float System
255
Component Functions
256
Pilot Jet
256
Pilot Air Screw
256
Air/Fuel Mixture Ratio
256
Jet Needle
257
Needle Jet
257
Throttle Opening Vs. Fuel Flow
257
Throttle Valve
258
Main Jet
258
Starter System - Closed Throttle
259
Pilot System (0-3/8 Throttle)
260
Slide Cutaway (1/8-3/8 Throttle)
261
Jet Needle/Needle Jet (3/8-3/4 Throttle)
262
Main System (3/4 to Full Throttle)
263
Component Effect Vs. Throttle Opening
264
Mikuni VM Fuel Delivery Chart
264
Mikuni VM Carburetor System Components
265
Venting Systems
265
Mikuni BST 34 Carburetor Exploded View
266
Venting Systems (Mikuni CV)
267
Mikuni CV Carb Operation
268
Pilot (Idle and Slow) Systems
269
Starter System (Choke or Enrichment)
269
Float System (Mikuni CV)
270
Main System (Mikuni CV)
270
Magnum Fuel Tank Removal
271
Carburetor Removal ( Mikuni CV)
272
Carburetor Disassembly - Mikuni CV
273
Carburetor Cleaning - Mikuni CV
276
Carburetor Assembly - Mikuni CV
279
Carburetor Assembly/Adjustment - Mikuni CV
280
Float Height Adjustment (Mikuni CV)
280
CV Carburetor Installation
282
Needle and Seat Pressure Test Mikuni CV
283
Inlet Needle and Seat
283
Fuel Level (Mikuni CV)
283
Float Bowl Draining
284
Fuel Pump Exploded View
286
Fuel Pump Testing
287
Fuel Pump Disassembly
287
Fuel Pump Inspection/Assembly
287
Fuel System/Carburetion Troubleshooting
288
Fuel Starvation/Lean Mixture
288
Rick Mixture
288
Poor Idle
288
Idle too Low
289
Erratic Idle
289
Body and Steering
290
Body and Steering - Torque Specifications and Special Tools
292
Body Styles
293
1996 Body Styles
293
1997 Body Styles
293
1998 Body Styles
293
Body Assembly Exploded View (Gen II - Typical)
295
Cover/Panel Removal (Gen II - Typical)
296
Cover/Panel Removal (Gen III - Typical)
297
Cover/Panel Removal (Gen IV - Typical)
298
Body Assembly Exploded View (Gen III - Typical)
299
Body Assembly Exploded View (Gen IV - Typical)
300
Body Assembly Exploded View (Gen IV - Headlight Pod)
301
Headlight Pod Service (Gen IV Typical) - Disassembly
302
Headlight Pod Service (Gen IV Typical) - Installation
303
Side Panel Removal (Gen IV - Typical)
304
Toe Alignment
305
Toe Alignment - Method 2
306
Typical Steering Assembly, Exploded View, Trail Boss 250
307
Steering Assembly, Exploded View, 2X4 Models (Except Trail Boss 250)
308
Steering Assembly, Exploded View, 4X4 and 6X6 Models
309
Steering Stop Adjustment
310
Rear Axle Bend
310
A-Arm Replacement
310
Rear Drive Axle, Hub and Wheel Assembly, - 2X4 and 4X4 (Except Sportsman 500)
311
Concentric Swingarm Rear Axle Assembly, Exploded View - 1998 Scrambler 400/500
312
Concentric Swingarm Exploded View 1998 Scrambler 400/500
313
Rear Drive Axle, Hub and Wheel Assembly - Shaft Drive Models
314
Rear Strut Stabilizer, 6X6 Models
315
Rear Swing Arm Weldment, 6X6 Models
316
Swing Arm and Rear Suspension Exploded View
318
Swing Arm Removal
319
Swing Arm Removal/Inspection
320
Swing Arm Assembly/Installation
321
Concentric Swingarm Removal/Disassembly
322
Concentric Swingarm Assembly/Installation
323
Strut Assembly - 400L AWD, Magnum AWD
324
Front Strut Weldment Replacement
325
Front Strut Cartridge Replacement
325
Strut Assembly - 2X4 Models
325
Front Strut Service
326
Front Strut Removal
326
Front Strut Installation
327

Polaris Trail Blazer Owner's Manual (118 pages)

Polaris 2005 ATV Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 7.05 MB

Welcome
6
Table of Contents
8
Vehicle Identification Numbers
10
Age Restrictions
11
Safety
11
- Operator Safety
  12
- Equipment Modifications
  15
- Safety Decals and Locations
  31
- Override Switch
  33
- Safe Riding Gear
  34
- Electrical Switches
  35
Features and Controls
35
- Throttle Lever
  36
- Indicator Lights
  37
- Light Switches
  37
- Brake Lever
  39
- Parking Brake
  40
- Auxiliary Brake
  41
- Fuel Valve
  42
- Fuel Tank
  42
- Fuel Filter
  42
- Fuel Safety
  43
- Oil Injection Tank
  44
- Recoil Starter
  46
- Break-In Period
  47
Operation
47
- Pre-Ride Inspection
  49
- Starting the Engine
  50
- Starting a Cold Engine
  50
- Starting a Warm Engine
  51
- Driving Safely
  52
- Driving Procedures
  52
- Making Turns
  53
- Driving on Slippery Surfaces
  54
- Driving Uphill
  55
- Driving Downhill
  57
- Turning Around on a Hill
  58
- Driving through Water
  59
- Driving over Obstacles
  61
- Driving in Reverse
  62
- Hauling Cargo
  63
- Parking on an Incline
  65
- Noise Emission Control System
  66
Emission Control Systems
66
Maintenance and Lubrication
67
- Periodic Maintenance Chart
  68
- Lubrication Recommendations
  72
- Engine Oil Check
  74
- Transmission Oil Change
  75
- Transmission Oil Check
  75
- Oil Pump Bleeding
  76
- Oil Pump
  77
- Toe Alignment
  79
- Steering Assembly
  80
- Camber and Caster
  80
- Rear Spring
  80
- Throttle Cable Freeplay
  81
- Wheel Removal
  83
- Wheel Nut Torque Specifications
  84
- Wheel Installation
  84
- Front Wheel Hub Tightening
  85
- Tire Tread Depth
  85
- Drive Chain
  86
- Rear Drive Chain Slack
  87
- Filter Systems
  89
- Air Filter Cleaning
  89
- Headlight Lamp Replacement
  90
- Headlight Adjustment
  91
- Indicator Lamp Replacement
  92
- Spark Plugs
  93
- Vehicle Immersion
  94
- Spark Arrestor
  95
- Recoil Housing
  96
- Pvt System
  97
- Pvt Drying
  98
- Battery Removal
  99
- Battery Installation
  99
- Battery Charging
  100
- Cleaning and Storage
  102
- Cleaning the Atv
  102
- Washing the Atv
  102
- Waxing the Atv
  102
- Fuel Stabilizer
  103
- Fluid Levels
  103
- Storage Tips
  104
- Battery Storage
  104
- Transporting an Atv
  105

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