Polaris Trail Boss User manual

CHAPTER 1

GENERAL INFORMATION /

SPECIFICATIONS

Model / VIN Identification 1.1-1.2......................

Publication Part Numbers 1.3......................

Service/Information Bulletin Index 1.3..............

Paint Codes 1.4.................................

Standard Torque Specifications 1.5................

Decimal Equivalent Chart 1.6......................

Conversion Table 1.7.............................

Tap Drill Charts 1.8...............................

Service Tips 1.9.................................

Glossary of Terms 1.10-1.12............................

Special Tool Ordering Information 1.13...............

Model Specifications (1999)

Trail Blazer 1.14-1.15............................

Trail Boss 1.16-1.17.............................

Xpress 300 1.18-1.19.............................

Xplorer 300 1.20-1.21.............................

Sportsman 335 1.22-1.23..........................

Sport 400 1.24-1.25..............................

Scrambler 400 1.26-1.27..........................

Xplorer 400 1.28-1.29.............................

Scrambler 500 1.30-1.31..........................

Magnum 500 1.32-1.33...........................

Sportsman 500 1.34-1.35..........................

Big Boss 500 6x6 1.36-1.37..........................

Model Specifications (2000)

Trail Blazer 1.38-1.39............................

Xplorer 4x4 1.40-1.41............................

Trail Boss 325 1.42-1.43.........................

Magnum 325 (01 Engine) 1.44-1.45.................

Magnum 325 (04/05 Engine) 1.46-1.47...............

Xpedition 325 1.48-1.49...........................

Sportsman 335 1.50-1.51..........................

Xplorer 400 1.52-1.53.............................

Scrambler 400 2x4 1.54-1.55.......................

Scrambler 400 4x4 1.56-1.57.......................

Xpedition 425 1.58-1.59...........................

Magnum 500 1.60-1.61..............................

Scrambler 500 1.62-1.63.........................

Sportsman 500 1.64-1.65........................

Sportsman 6x6 1.66-1.67........................

Enfocus Software - Customer Support

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GENERAL INFORMATION

Model Identification

Engine Serial Number Location

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This

information can be found on the sticker applied to the manual starter recoil housing. An additional number is

stamped in one of the following locations:

S 4 stroke models - center top of crankcase beneath the cylinder coolant elbow

S 2 stroke liquid cooled models - center top of crankcase beneath the carburetor mounting flange

S 2 stroke air cooled models - top of crankcase near right side of cylinder

Machine Model Number and VIN Number Location

The machine Model Number and Vehicle Identification

Number (VIN) are important for vehicle identification.

The VIN number will be stamped into the frame in one

of the following locations:

S 1998-Current

On the left hand lower frame rail (A)

near the rear A-arm mount.

Transmission I.D. Number Location

Transmission model and serial numbers are located

on top of the transmission case below the shifting bell-

cranks.

Carburetor I.D. Number Location

The carburetor I.D. number (A) is in one of the follow-

ing locations:

S 4 stroke models - right side center of

the carburetor body

S 2 stroke models - right side of carbu-

retor body near choke plunger boss

VIN Location - 1998-Current

A

Example

Mod #

Ser #

96-10275

1341157

Transmission I.D. Numbers

Carburetor I.D. Number

A

Forward

2-Stroke

A

4-Stroke

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GENERAL INFORMATION

Model Identification

Vehicle Identification Number

Current ATVs and 6X6 Vehicles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as

follows: Digits 1-3: World Manufacturer Identifier. For Polaris ATVs, this is 4XA. Digits 4-9: Vehicle Descriptor

Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, drive type, engine

type, and emissions equipment. The VIN number and the model number must be used with any correspondence

regarding service or repair.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

4XABA

38C0W2000000

Vehicle Descriptor

Vehicle Identifier

Powertrain

Engine

Emissions

Model

Year

Plant No.

Individual Serial No.

Body Style

Check Digit

World Mfg. ID

Example of

Current

VIN Number

Vehicle Identification Number / Model Number Key

Body Style Powertrain Engine Emissions Options

A=Gen II A=2x4 chain 25=EC25PF(250cc) A=Approved by CARB¡© A=Option 1

B=Gen III C=4x4 chain 28=EC28PF(300 cc) B=England B=Option 2

C=Gen IV D=4x4 shaft 33=ES33PF(335 cc) C=Non CARB Approved¡

R=RANGER E=6x6 chain 38=EC38PL(400 cc) D=Norway

F=6x6 shaft 42=EH42PL (425 cc) E=Sweden

G=4x4 chain rear/

shaft front

50=EH50PL (500 cc)

¡CARB = California Air Resources Board

©CARB Approved or not a regulated type

Year / Letter Identification

The tenth digit of a 17 digit VIN is the model year of the vehicle. Example: W = 1998; X = 1999 etc. Refer to the

listing below.

V 1997

W 1998

X 1999

Y 2000

Current Model Numbers

The model year is also listed in the model number. The last 4 digits in the model number correspond to digits

4 through 8 of the Vehicle Identification Number (VIN). The example below is a 1999 Magnum 500.

Machine Model Number Identification

Year Designation

A 9 9 CD50A A

Last 5 Model # Digits=Digits 4-8 of VIN

Option Indicator

A=ATV

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GENERAL INFORMATION

Publications

1999 Publication Part Numbers

DESCRIPTION PART NUMBER

1995-1999 4 Stroke ATV / 6x6 Service Manual 9915686

1996 ATV Service Manual Volume II 9913680

1998 ATV Service Manual Vol. II Update 9914752

1999 ATV / 6x6 Service Manual Volume lll 9915083

Diesel ATV Service Manual 9915234

RANGER Service Manual 9914985

SERVICE TRAINING VIDEOS

VIDEO TITLE PART NUMBER DESCRIPTION

Magnum 4-Stroke Introduction 9912996 Includes 4 Stroke theory of operation, engine removal, disas-

sembly, and assembly techniques, and general tech-tips.

Ignition System Diagnostics 9913533 Describes all current Polaris ignition systems. Provides

working knowledge of ignition system theory and diagnostics.

Charging System Diagnostics 9913278 Describes all current Polaris charging systems. Provides work-

ing knowledge of charging system theory and diagnostics.

Polaris Variable Transmissions

(PVT)

9913987 Theory, disassembly, assembly and troubleshooting of the

Polaris PVT system.

Fuels and Fuel Delivery 9914393 Describes fuel properties including octane and vapor pres-

sure; fuel mixture and burn characteristics; VM and CV car-

buretor theory and adjustments.

Service Bulletin Index

Always consult latest service information. Bulletins published after 3-15-99 are not listed in the following index.

1999 Model

Bulletin # Type Notes

Big Boss 500 6x6 None

Sportsman 500 None

Scrambler 500 None

Magnum 4x4 None

Magnum 2x4 None

Xplorer 400 None

Scrambler 400 None

Sport 400 None

Xplorer 300 None

Xpress 300 None

Trail Blazer ATV-99-01 Service Bulletin Rear Eccentric Bearing Lubrication

Trail Boss ATV-98-01 Service Bulletin Foil Missing From Rear Brake Disc Guard

Applies to All 1999 Models None

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GENERAL INFORMATION

Paint Codes

1999 Paint Codes

Model Item Color Material No. (Polaris #) PPG Ditzler No.

Big Boss 500 6X6 Springs /

Front Rack

Eddie B Green 8520150 (P195) 44931

Rims Aluminum (P117)

Sportsman 500 RSE Springs / Rims Black 8520147 (P067) 9440

Sportsman 500 EBS (Opt. A) Springs / Rims Black 8520147 (P067) 9440

Sportsman 500 EBS (Opt. B)

Rims Aluminum (P117)

p

(

p

)

Spring, Front Fire Red 8520149 (P093) 72060

Spring, Rear Bonnie Blue 8520148 (P157) 12908

Magnum 500 Springs Black 8520147 (P067) 9440

Rims Aluminum (P117)

Scrambler 500

Springs Fire Red 8520149 (P093) 72060

Rims Aluminum (P117)

Xplorer 400 Springs Burnished Brown P218

Rims Aluminum (P117)

Scrambler 400 Springs Fire Red 8520149 (P093) 72060

Rims Bright White 8520153 (P133) 2185

Sport 400L Springs Fire Red 8520149 (P093) 72060

Rims Bright White 8520153 (P133) 2185

Sportsman 335 (Opt. A) Springs / Rims Black 8520147 (P067) 9440

Sportsman 335 (Opt. B) Springs Black 8520147 (P067) 9440

Rims Aluminum (P117)

Xplorer 300 Springs Fire Red 8520149 (P093) 72060

Rims Aluminum (P117)

Xpress 300 Springs Bonnie Blue 8520148 (P157) 12908

Rims Aluminum (P117)

Trail Blazer Springs Fire Red 8520149 72060

Rims Bright White 8520153 (P133) 2185

Trail Boss Springs Fire Red 8520149 (P093) 72060

Rims Bright White 8520153 (P133) 2185

Rack(s) Fire Red 8520149 (P093) 72060

Order direct from Midwest Industrial Coatings (612-942-1836). Mix as directed.

Frames (Medium Black) P067 / 8520147 / Ditzler 9440

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GENERAL INFORMATION

Standard Torque Specifications

The following torque specifications are to be used as a general guideline when a specific torque is not listed for a

fastener. Some fasteners require a special torque procedure and/or the application of a locking agent or locking

device during installation. Always refer to the appropriate chapter for specific torque specifications and

procedures before using standard torque.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs.

(N-m)

#10 - 24 27 (3.1) 43 (5.0) 60 (6.9)............. .............. .............

#10 - 32 31 (3.6) 49 (5.6) 68 (7.8)............. .............. .............

Torque ft. l bs. (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)

6 x 1.0 72-78 In. lbs. (8-9)

8 x 1.25 14-18 ft. lbs. (19-25)

10 x 1.25 26-30 ft. lbs. (36-41)

*To convert Ft. lbs. to N-m multiply foot pounds by 1.383.

*To convert N-m to Kg-m move the decimal point to the left one position.

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GENERAL INFORMATION

Decimal Equivalents

1/64 .0156.........................

1/32 .0312 1 mm = .0394″................... ................

3/64 .0469.........................

1/16 .0625..............

5/64 .0781 2 mm = .0787″......................... ................

3/32 .0938...................

7/64 .1094 3 mm = .1181″....................... ................

1/8 . 1250. .......

9/64 .1406.........................

5/32 .1563 4 mm = .1575″................... ................

11/64 .1719........................

3/16 .1875 5 mm = .1969″.............. ................

13/64 .2031........................

7/32 .2188...................

15/64 .2344 6 mm = .2362″........................ ................

1/4 .25..........

17/64 .2656 7 mm = .2756″........................ ................

9/32 .2813...................

19/64 .2969........................

5/16 .3125 8 mm = .3150″.............. ................

21/64 .3281........................

11/32 .3438 9 mm = .3543″.................. ................

23/64 .3594........................

3/8 .375..........

25/64 .3906 10 mm = .3937″........................ ................

13/32 .4063..................

27/64 .4219 11 mm = .4331″........................ ................

7/16 .4375..............

29/64 .4531........................

15/32 .4688 12 mm = .4724″.................. ................

31/64 .4844........................

1/2 .5 13 mm = .5118.......... ...................

33/64 .5156........................

17/32 .5313..................

35/64 .5469 14 mm = .5512″........................ ................

9/16 .5625..............

37/64 .5781 15 mm = .5906″........................ ................

19/32 .5938..................

39/64 .6094........................

5/8 .625 16 mm = .6299″.......... .................

41/64 .6406........................

21/32 .6563 17 mm = .6693″.................. ................

43/64 .6719.......................

11/16 .6875.............

45/64 .7031 18 mm = .7087″........................ ................

23/32 .7188..................

47/64 .7344 19 mm = .7480″........................ ................

3/4 .75..........

49/64 .7656........................

25/32 .7813 20 mm = .7874″.................. ................

51/64 .7969........................

13/16 .8125 21 mm = .8268″............. ................

53/64 .8281........................

27/32 .8438..................

55/64 .8594 22 mm = .8661″........................ ................

7/8 .875..........

57/64 .8906 23 mm = .9055″........................ ................

29/32 .9063..................

59/64 .9219.......................

15/16 .9375 24 mm = .9449″............. ................

61/64 .9531........................

31/32 .9688 25 mm = .9843.................. ................

63/64 .9844........................

11.0............

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GENERAL INFORMATION

Conversion Table

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =in.lbs.

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

ft. lbs. x .1383 =kg-m

ft. lbs. x 1.383 =N-m

in. lbs. x .0115 =kg-m

kg-m x 7.233 = ft. lbs.

kg-m x 86.796 =in.lbs.

kg-m x10 =Nm

in. x 25.4 =mm

mm x .03937 =in.

in. x2.54 =cm

mile (mi.) x1.6 =km

km x .6214 = mile (mi.)

Ounces (oz) x 28.35 = Grams (g)

Grams (g) x 0.035 = Ounces (oz)

lb. x .454 =kg

kg x 2.2046 =lb.

Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)

Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)

Cubic centimeters (cc) x .03381 = Fluid Ounces (fl.oz.)

Fluid Ounces (fl.oz.) x 29.57 = Cubic centimeters (cc) or milliliters

(ml)

Imperial pints (Imp pt) x 0.568 = Liters (l)

Liters (l) x1.76 = Imperial pints (Imp pt)

Imperial quarts (Imp qt) x 1.137 = Liters (l)

Liters (l) x0.88 = Imperial quarts (Imp qt)

Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)

US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)

US quarts (US qt) x 0.946 = Liters (l)

Liters (l) x 1.057 = US quarts (US qt)

US gallons (US gal) x 3.785 =Liters (l)

Liters (l) x 0.264 = US gallons (US gal)

Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)

Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)

Kilopascals (kPa) x0.01 = Kilograms - force per square cm

Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

°Cto°F: 9 (°C + 40) ÷ 5-40=°F

°Fto°C: 5 (°F + 40) ÷ 9-40=°C

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GENERAL INFORMATION

Tap Drill Ch arts

SAE Tap Drill Sizes

Thread Size Drill Size Thread Size Drill Size

#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

1 1/8-7 63/64

1 1/8-12 1 3/64

11/4-7 17/64

1 1/4-12 1 11/64

11/2-6 111/32

1 1/2-12 1 27/64

13/4-5 19/16

1 3/4-12 1 43/64

2-4 1/2 1 25/32

2-12 1 59/64

2 1/4-4 1/2 2 1/32

21/2-4 21/4

23/4-4 21/2

3-4 2 3/4

Metric Tap Drill Sizes

Tap Size Drill Size Decimal Equivalent Nearest Fraction

3x.50

3x.60

4x.70

4x.75

5x.80

5x.90

6 x 1.00

7 x 1.00

8 x 1.00

8 x 1.25

9 x 1.00

9 x 1.25

10 x 1.25

10 x 1.50

11 x 1.50

12 x 1.50

12 x 1.75

#39

3/32

#30

1/8

#19

#20

#9

16/64

J

17/64

5/16

11/32

R

3/8

13/32

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.406

3/32

1/8

11/64

5/32

13/64

15/64

9/32

17/64

5/16

11/32

3/8

13/32

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GENERAL INFORMATION

Service Tips

In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this

manual, thoroughly familiarizing him/herself with procedures before beginning. Pictures and illustrations have

been included with the text as an aid. Notes, cautions and warnings have also been included for clarification of text

and safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to

perform the service work safely and satisfactorily. Use only genuine Polaris service parts.

Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act

as an abrasive and cause damage to precision parts. Clean the vehicle before beginning service. Clean new parts

before installing.

Watch for sharp edges which can cause personal injury. Protect hands with gloves when working with sharp

components.

If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be

found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.

Some of the fasteners were installed with locking agents. Use of impact drivers or wrenches will help avoid

damage to fasteners.

Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious

machine damage or, as in the case of steering components, can result in injury or death for the rider(s).

If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten.

Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value.

When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before

removing them.

If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces

around the gasket are clean and smooth in order to avoid leaks.

Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms

these parts, they should always be replaced with new parts. When installing new retaining rings and clips use care

not to expand or compress them beyond what is required for installation.

Because removal damages seals, replace any oil or grease seals removed with new parts.

Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the

top performance and best protection of our machines. In some applications, such as the engine, warranty

coverage may become void if other brands are substituted.

Grease should be cleaned from parts and fresh grease applied before reassembly of components.

Deteriorating grease loses lubricity and may contain abrasive foreign matter.

Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion

resulting in serious burns. Always disconnect the negative (black) cable first and reconnect it last. Battery

electrolyte contains sulfuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or

clothing. ANTIDOTE: External - Flush with water. Internal - Drink large quantities or water or milk. Follow with

milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes

and get prompt medical attention.

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GENERAL INFORMATION

Glossary Of Terms

ABDC: After bottom dead center.

ACV: Alternating current voltage.

Alternator: Electrical generator producing voltage alternating current.

ATDC: After top dead center.

BBDC: Before bottom dead center.

BDC: Bottom dead center.

BTDC: Before top dead center.

CC: Cubic centimeters.

CDI: Capacitor discharge ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a

capacitor or condenser (in CDI box). At the proper moment a voltage generated by the stator plate pulser coil closes an

electronic switch (thyristor) in the CDI box and allows the voltage in the capacitor to discharge into the primary windings

of the ignition coil.

Center Distance: Distance between center of crankshaft and center of driven clutch shaft.

Chain Pitch: Distance between chain link pins (520 = 5/8″ or 1.6 cm). Chain length is measured in number of pitches

(pins). A 520 x 86 has 86 total pins, including the master link pins.

CI: Cubic inches.

Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven

clutch.

ClutchOffset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch

face.

Clutch W eights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive

clutch to close.

Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI systems.

Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported

between centers on V blocks or resting in lower half of crankcase. Measure at various points especially at PTO.

Maximum allowable run-out is .006″ (.02 cm).

DCV: Direct current voltage.

Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition. Piston looks

“hammered” through, rough appearance around hole. Possible causes: 1) too high a compression ratio for the fuel

octane; 2) low octane fuel; 3) over-advanced ignition timing.

Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and

out-of-round in the cylinder bore.

Driven Clutch: (Also-Secondary Clutch). The torque sensitive clutch in a CVT system which is located on the

transmission input shaft.

Electrical Open: Open circuit. An electrical circuit which isn’t complete. (i.e. poor connections or broken wire at hi-lo

beam switch resulting in loss of headlights.

Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended

component. (i.e. a bare wire touching the grounded chassis).

End Seals: Rubber seals at each end of the crankshaft.

Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.

EBS: Engine Braking System

ft.: Foot/feet.

Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.

g: Gram. Unit of weight in the metric system.

gal.: Gallon.

Head Volume: Cylinder head capacity in cc, head removed from engine with spark plug installed.

High Tension Lead: The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug.

HoledPiston: Piston in which a hole has formed on the dome. Possible causes: Lean mixture; Incorrect ignition timing

HP: Horsepower.

ID: Inside diameter.

IgnitionCoil: A type of transformer which increases voltage in the primary windings (approx. 200V) to a higher voltage

in the secondary windings (approx. 14KV - 32KV) through induction. Secondary voltage is high enough to ionize (jump)

the air gap at the spark plug.

Ignition GeneratingCoil: Exciter coil, primary charge coil. Stator plate coil which generates primary ignition voltage.

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GENERAL INFORMATION

Glossary Of Terms

in.: Inch/inches.

Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

kg/cm

2

: Kilograms per square centimeter.

kg-m: Kilogram meters.

Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.

lorltr: Liter.

lbs/in

2

: Pounds per square inch.

Left Side: Always referred to based on normal operating position of the driver.

m: Meter/meters.

Mag: Magneto.

Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. The common method used to convert mechanical energy to electrical energy in the battery charging coil,

ignition generating coils, and ignition trigger (pulse) coil.

mi.: Mile/miles.

mm: Millimeter. Unit of length in the metric system. 1mm = .040″.

N-m: Newton meters.

OD: Outside diameter.

Ohm: The unit of electrical resistance opposing current flow.

oz.: Ounce/ounces.

Piston Clearance: Total difference between piston outside diameter and cylinder inside diameter.

Piston Erosion: Piston dome melts. Usually occurs at the exhaust port area. Possible causes: 1) Detonation due to

lean fuel/air mixture, improper spark plug heat range, excess heat buildup, poor fuel quality / octane rating.

Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston looks

melted at area of damage. Possible causes: 1) incorrect spark plug heat range; 2) spark plug not properly torqued; 3)

“glowing” piece of head gasket, metal burr or carbon in the combustion chamber; 4) lean fuel/air mixture.

Primary Circuit: This circuit is responsible for the voltage build up in the CDI capacitor. In the CDI system the parts

include the exciter coil, the trigger coil (pulse coil), the wires from stator plate to CDI box and to the low resistance

primary windings in the ignition coil.

Primary Clutch: Drive clutch on engine. Mainly RPM sensitive.

psi.: Pounds per square inch.

PTO: Power take off.

PVT: Polaris Variable Transmission (Drive Clutch System)

qt.: Quart/quarts.

RPM: Revolutions per minute.

Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to

heat.

Right Side: Always referred to based on normal operating position of the driver.

RPM: Revolutions per minute.

Running Time: Ignition timing when fully advanced or at specified RPM.

SecondaryCircuit: This circuit consists of the large secondary coil windings, high tension wire and ground through the

spark plug air gap.

Secondary Clutch: (Also-Driven Clutch) The torque sensitive clutch in a CVT system which is located on the

transmission input shaft.

SeizedPiston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder

wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck

piston rings;

Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4″ (2 cm) reach plugs.

Static Timing: Ignition timing when engine is at zero RPM.

Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coil.

1.12

Polaris Sales Inc.4/99

GENERAL INFORMATION

Glossary Of Terms

TDC: Top dead center. Piston’s most outward travel from crankshaft.

Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI

systems. Small coil mounted at the top of the stator plate next to the ignition generating coil.

Voltage Regulator: Maintains Prevents over-charging of battery or damage to electrical components as engine RPM

increases.

V enturi: An area of air constriction. A venturi is used in carburetors to speed up air flow which lowers pressure in venturi

to below atmospheric pressure, causing fuel to be pushed through jets, etc., and into the venturi to be mixed with air and

form a combustible air/fuel mixture.

Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the

circuit.

Watt: Unit of electrical power. Watts = amperes x volts.

WOT: Wide open throttle.

1.13

Polaris Sales Inc.

4/99

GENERAL INFORMATION

Special Tools

SPECIAL TOOLS

Special tool part numbers and usage are listed in each section of this manual as required for a specific service

procedure. For complete tool information , refer to the S P X Special Tool w e b s i t e . U.S. dealers can obtain

a current price list or get tool information by contacting the SPX Company at the address, phone or

FAX number listed below.

Dealers serviced by a distributor should follow tool ordering procedures established by

their respective distributor parts department.

SPX Service Solutions

28635 Mound Road

Warren, MI 48092-5509

TO PLACE AN ORDER

Tool Order FAX Number

1--800--328--6657

www.polaris.spx.com

1.14

Polaris Sales Inc.4/99

GENERAL INFORMATION

1999 Model Specification s

MODEL: TRAIL BLAZER..........

MODEL NUMBER: A99BA25CA.

ENGINE MODEL: EC25PFE13..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below 0°F

0_ to +40_F +40_to +80_ F

A

bove +80_F

A

l

t

i

t

u

d

e

B

e

l

o

w

0

F

Below -18°C

0

t

o

+

4

0

F

-18_to +5_C

+

4

0

t

o

+

8

0

F

+5_ to +26_C

A

b

o

v

e

+

8

0

F

Above +26_C

Meters

0-900

1

5

0

1

4

0

1

3

0

1

2

0

M

e

t

e

r

s

(Feet)

0

-

9

0

(0-3000)

150 140 130 120

(

F

e

t

)

900-1800

1

4

0

1

3

0

1

2

0

1

0

9

0

-

1

8

0

(3000-6000)

140 130 120 110

1800-2700

1

2

5

1

2

0

1

0

1

0

1

8

0

-

2

7

0

(6000-9000)

125 120 110 100

2700-3700

1

5

1

0

1

0

9

5

2

7

0

-

3

7

0

(9000-12000)

115 110 100 95

- Turn AS out 1/2 -- 3/4 turn CCW from seat

Raise needle clip 1 position to lower jet needle

CLUTCH CHART

S

h

i

f

t

C

l

u

t

c

h

D

r

i

v

e

n

A

l

t

i

t

u

d

e

Shift

W

e

i

g

h

t

Clutch

S

p

r

i

n

g

Driven

H

e

l

i

x

A

l

t

i

t

u

d

e

Weight Spring Helix

Meters

0-900

G

B

l

u

e

/

G

r

e

n

2

M

e

t

e

r

s

(Feet)

0

-

9

0

(0-3000)

G Blue/Green 2--2

(

F

e

t

)

900-1800

G

B

l

u

e

/

G

r

e

n

2

1

9

0

-

1

8

0

(3000-6000)

G Blue/Green 2--1

1800-2700

1

6

B

l

u

e

/

G

r

e

n

2

1

8

0

-

2

7

0

(6000-9000)

16 Blue/Green 2--2

2700-3700

1

6

B

l

u

e

/

G

r

e

n

2

1

2

7

0

-

3

7

0

(9000-12000)

16 Blue/Green 2--1

ENGINE

Type 2 Cycle, Single Cyl........................

Displacement 244 cc...............

Bore 2.8346” (72mm).......................

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

Compression Ratio 6.1/1 Effective..........

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

Lubrication Type Oil Injected............

Piston / Cylinder Clearance 0.0011 - 0.0021” (0.03 - 0.05mm)...

Service Limit 0.006” (0.15mm)................

Piston Marking 3W,4W..............

Piston Ring End Gap .009”-.018” (.23mm-.46mm)........

Operating RPM±200 5800 RPM.........

Idle RPM±200 700 RPM..............

Compression Pressure (Std) ±15%.......

CARBURETION

Type VM30SS Mikuni................

Main Jet 130............

Pilot Jet 40.............

Jet Needle 5DP7-3...........

Needle Jet 0-4(169)...........

Cutaway 2.0............

Air Screw 1.0 Turn...........

Valve Seat 2.5...........

Fuel Octane (R+M/2) 87 Non-Oxygenated or.

89 Oxygenated

CLUTCH

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

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

Belt Width (Projected) 1.188” (30.18mm).....

Side Angle (Overall) 26°......

Outside Circumference 40.86 ±.12”....

Center Distance 10±.12” (254.5mm)..........

Clutch Offset 0.5” (12.7mm)............

Shift Weights G............

Primary Spring Blue/Green...........

Secondary Spring Red........

Driven Helix 40°.............

Spring Position (Helix) 2....

Spring Position (Sheave) 2..

*Lubricant

1.15

Polaris Sales Inc.

4/99

GENERAL INFORMATION

1999 Model Specification s

MODEL: TRAIL BLAZER............

MODEL NUMBER: A99BA25CA...

ENGINE MODEL: EC25PFE13....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. Refer to Electrical Section Fuel Tank 4 gals. (15.1L)...... ..........

CDI Marking CU2167 Injector Oil 2 qts. (1.9L) PP2*....... .......... ..

Alternator Output 150 Watts Coolant N / A... ............

Ignition Timing 25° BTDC@3000RPM±1.5° Transmission 11 oz. (325ml) PPS*..... .......

Spark Plug / Gap NGK BR8ES / 0.028” (0.7mm) Gearcase Oil (Front) N / A... .

Lights: Head Halogen 55 watts Gearcase Oil (Center) N / A......

Tail 8.26 watts Gearcase Oil (Rear) N / A........ .

Brake 26.9 watts Engine Counter Bal. N / A...... .

Voltage Regulator LR39--1 Engine Oil N / A.. ..........

Electric Start Standard Brake (Hand) -- Dot 3....... ....... ...........

Brake (Foot) -- Dot 3........ ...........

Front Hubs (AWD) N / A...

Shift Selector Box 1 oz. (30ml) PP4*... ..

*PP2 Polaris Premium TC-W3 2 Stroke Oil

*PPS Polaris Premium Synthetic Gear Case Oil

*PP4 Polaris 0W/40 Synthetic Engine Lubricant

SUSPENSION / CHASSIS DRIVE TRAIN (Concentric Drive)

Body Style Gen III Chain Type 520 O-Ring........ .........

Front Suspension MacPherson Strut Gear Reduction-Low N / A.. .

Tow Capacity 850 lbs. (385.9kg) Gear Reduction-Rev 3.05/1...... .

Turning Radius 60” (152.4cm) Gear Reduction-High 2.68/1.....

Toe Out 1/8”-1/4” (3-6.35mm) Front Drive Ratio N / A........... ....

Ground Clearance 6” (15.24cm) Center Drive Ratio N / A.. ...

Front Vertical Travel 6.7” (17.02cm) Final Drive Ratio 11/38 78P....

Rear Suspension Progressive Rate Swing Arm Brake (Hand) Single Lever, Hyd. Disc... .......

Rear Travel 8.2 in. (20.8cm) Brake (Auxiliary Foot) Hydraulic........

Rear Shock 2” Gas Charged Mono........

Shock Adjustment Cam..

Tire Size - Front 23 x 7 - 10....

Tire Size - Rear 22 x 11 - 10....

Tire Size - Center N / A..

Tire Pressure - F/R 4/3 lbs..

Total Width 46.5” (118.11cm)........

Total Length 74.5” (189.23cm).......

Total Height 46” (116.84cm)........

Wheel Base 49.75” (126.37cm).......

Weight - Dry 440 lbs. (199.76kg).......

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring

7041777-067

Option 125 lb/in.

7041778-067

Standard 150 lb/in.

7041815-067

Option 175 lb/in.

Front Strut Spring 7041471-067

Option 41 lb/in.

7041238-067

Standard 61 lb/in.

7041375-067

Option 64/113 lb/in.

LOAD CAPACITY

Front Rack (Accy) 30 lbs.....

Rear Rack (Accy) 60 lbs.....

Tongue Weight 30 lbs.....

Tow Hitch Accy...........

1.16

Polaris Sales Inc.4/99

GENERAL INFORMATION

1999 Model Specification s

MODEL: TRAIL BOSS 250..........

MODEL NUMBER: A99AA25CA.

ENGINE MODEL: EC25PFE10..

JETTING CHART

AMBIENT TEMPERATURE

Altitude

Below 0°F

0_ to +40_F +40_to +80_ F

A

bove +80_F

A

l

t

i

t

u

d

e

B

e

l

o

w

0

F

Below -18°C

0

t

o

+

4

0

F

-18_to +5_C

+

4

0

t

o

+

8

0

F

+5_ to +26_C

A

b

o

v

e

+

8

0

F

Above +26_C

Meters

0-900

1

7

0

1

5

1

4

5

1

3

5

M

e

t

e

r

s

(Feet)

0

-

9

0

(0-3000)

170 155 145 135

(

F

e

t

)

900-1800

1

5

1

4

5

1

3

5

1

2

5

9

0

-

1

8

0

(3000-6000)

155 145 135 125

1800-2700

1

4

0

1

3

0

1

2

0

1

5

1

8

0

-

2

7

0

(6000-9000)

140 130 120 115

2700-3700

1

3

0

1

2

0

1

0

1

0

2

7

0

-

3

7

0

(9000-12000)

130 120 110 100

- Turn AS out 1/2 -- 3/4 turn CCW from seat

CLUTCH CHART

S

h

i

f

t

C

l

u

t

c

h

D

r

i

v

e

n

A

l

t

i

t

u

d

e

Shift

W

e

i

g

h

t

Clutch

S

p

r

i

n

g

Driven

H

e

l

i

x

A

l

t

i

t

u

d

e

Weight Spring Helix

Meters

0-900

1

6

B

l

u

e

/

G

r

e

n

2

M

e

t

e

r

s

(Feet)

0

-

9

0

(0-3000)

16 Blue/Green 2--2

(

F

e

t

)

900-1800

1

6

B

l

u

e

/

G

r

e

n

2

1

9

0

-

1

8

0

(3000-6000)

16 Blue/Green 2--1

1800-2700

1

6

M

o

d

B

l

u

e

/

G

r

e

n

2

1

8

0

-

2

7

0

(6000-9000)

16 Mod Blue/Green 2--2

2700-3700

1

6

M

o

d

B

l

u

e

/

G

r

e

n

2

7

0

-

3

7

0

(9000-12000)

16 Mod Blue/Green 2--2

ENGINE

Type 2 Cycle, Single Cyl........................

Displacement 244 cc...............

Bore 2.8346” (72mm).......................

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

Compression Ratio 6.1/1 Effective..........

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

Lubrication Type Oil Injected............

Piston / Cylinder Clearance 0.0011 - 0.0021” (0.03 - 0.05mm)...

Service Limit 0.006” (0.15mm)................

Piston Marking 3W,4W..............

Piston Ring End Gap .009”-.018” (.23mm-.46mm)........

Operating RPM±200 6000 RPM.........

Idle RPM±200 700 RPM..............

Compression Pressure (Std) ±15%.......

CARBURETION

Type VM30SS Mikuni................

Main Jet 145............

Pilot Jet 40.............

Jet Needle 5DP7-3...........

Needle Jet 0-4(169)...........

Cutaway 2.0............

Air Screw 1.0 Turn...........

Valve Seat 2.5...........

Fuel Octane (R+M/2) 87 Non-Oxygenated or.

89 Oxygenated

CLUTCH

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

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

Belt Width (Projected) 1.188” (30.18mm).....

Side Angle (Overall) 26°......

Outside Circumference 40.86 ±.12”....

Center Distance 10±.12” (254.5mm)..........

Clutch Offset 0.5” (12.7mm)............

Shift Weights 16............

Primary Spring Blue/Green...........

Secondary Spring Red........

Driven Helix 40°.............

Spring Position (Helix) 2....

Spring Position (Sheave) 2..

*Lubricant

1.17

Polaris Sales Inc.

4/99

GENERAL INFORMATION

1999 Model Specification s

MODEL: TRAIL BOSS 250............

MODEL NUMBER: A99AA25CA...

ENGINE MODEL: EC25PFE10....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. Refer to Electrical Section Fuel Tank 4 gals. (15.1L)...... ..........

CDI Marking CU2167 Injector Oil 2 qts. (1.9L) PP2*....... .......... ..

Alternator Output 150 Watts Coolant N / A... ............

Ignition Timing 25° BTDC@3000RPM±1.5° Transmission 16 oz. (473ml) PPS*..... .......

Spark Plug / Gap NGK BR8ES / 0.028” (0.7mm) Gearcase Oil (Front) N / A... .

Lights: Head Halogen 60/60 watts Gearcase Oil (Center) N / A......

Tail 8.26 watts Gearcase Oil (Rear) N / A........ .

Brake 26.9 watts Engine Counter Bal. N / A...... .

Voltage Regulator LR39--1 Engine Oil N / A.. ..........

Electric Start Standard Brake (Hand) Dot 3....... .......

Brake (Foot) Dot 3........

Front Hubs (AWD) N / A...

Shift Selector Box 1 oz. (30ml) PP4*... ..

*PP2 Polaris Premium TC-W3 2 Stroke Oil

*PPS Polaris Premium Synthetic Gear Case Oil

*PP4 Polaris 0W/40 Synthetic Engine Lubricant

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen II Chain Type 520 O-Ring........ .........

Front Suspension MacPherson Strut Gear Reduction-Low N / A.. .

Tow Capacity 850 lbs. (385.9kg) Gear Reduction-Rev 3.42/1...... .

Turning Radius 60” (152.4cm) Gear Reduction-High 2.68/1.....

Toe Out 1/8”-1/4” (3-6.35mm) Front Drive Ratio N / A........... ....

Ground Clearance 5.5” (13.97cm) Center Drive Ratio N / A.. ...

Front Vertical Travel 6.25” (15.88cm) Final Drive Ratio 12/42 88P....

Rear Suspension Progressive Rate Swing Arm Brake (Hand) Single Lever, Hyd. Disc... .......

Rear Travel 8.5 in. (21.6cm) Brake ( Auxiliary Foot) Mechanical........

Rear Shock 1” Bore Gas Bag........

Shock Adjustment Cam..

TIRES

Tire Size - Front 23 x 7 - 10....

Tire Size - Rear 22 x 11 - 10....

Tire Size - Center N / A..

Tire Pressure - F/R 4/3 lbs..

Total Width 44” (111.76cm)........

Total Length 73.2” (185.93cm).......

Total Height 44” (111.76cm)........

Wheel Base 49.75” (126.37cm).......

Weight - Dry 448 lbs. (203.4kg).......

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring

7041518-067

Option 175 lb/in.

7041204-067

Standard 190 lb/in.

7041303-067

Option 250 lb/in.

Front Strut Spring 7041471-067

Option 41 lb/in.

7041238-067

Standard 61 lb/in.

7041375-067

Option 64/113 lb/in.

LOAD CAPACITY

Front Rack (Accy) 75 lbs.....

Rear Rack 125 lbs...........

Tongue Weight 30 lbs.....

Tow Hitch Std...........

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Polaris Trail Boss User manual

Polaris Trail Boss User manual

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