Polaris ATV & Light Utility Hauler Workshop Repair Manual 1985-1995 All Models PDF - MPLRATVLUV.zip
A full factory-level service and repair guide, complete with Electrical Wiring Diagrams, covering Polaris ATVs and Light Utility Haulers—packed with every technical detail you need to service, troubleshoot, fix, and rebuild your machine just like a trained professional technician.
Inside the Polaris ATV and Light Utility Hauler workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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PRODUCT DETAILS:
Total Pages: 3,702 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Polaris ATV AND LIGHT UTILITY VEHICLE SERVICE MANUAL (9913680)....2
Foreword....2
Table of Contents....4
CHAPTER 1:GENERAL INFORMATION....6
CHAPTER 2:MAINTENANCE....57
CHAPTER 3:ENGINE....123
CHAPTER 4:FUEL SYSTEM/CARBURETION....229
CHAPTER 5:BODY AND STEERING....291
CHAPTER 6:CLUTCHES....345
CHAPTER 7:FINAL DRIVE....391
CHAPTER 8:TRANSMISSION SERVICE....465
CHAPTER 9:BRAKES....515
CHAPTER 10ELECTRICAL....551
Polaris ATV and Light Utility Hauler SERVICE REPAIR MANUAL (PN 9912004 1985-1995 All-Models)....635
Table of Contents....638
1 - General Product Information....639
Publications....640
Model Identification....643
Service Tools Description....644
Service Tools & Supplies List....652
Specifications....653
1985 Models....653
1986 Models....654
1987 Models....655
1988 Models....656
1989 Models....657
1990 Models....658
1991 Models....660
1992 Models....662
1993 Models....664
1994 Models....666
1995 Models....669
Accessory Fit Chart....672
Routing Diagrams....676
How to Handle a Service Complaint....688
Service Tips....689
Warranty Policy....690
2 - Body, Steering and Suspension....691
Torque Specifications and Special Tools....692
Body Assembly Exploded View (Except Magnum, Xplorer, and Scrambler)....694
Body Assembly Exploded View, Magnum....695
Cover/Panel Removal (All Except Xplorer and Scrambler)....696
Body Assembly Exploded View, Xplorer....697
Xplorer Side Panel Removal....699
Body Assembly Exploded View, Scrambler....700
Oil Tank and Fuel Tank Assembly (Except Magnum and Scrambler)....701
Oil Tank and Fuel Tank Assembly, Scrambler....702
Fuel Tank Assembly, Magnum....703
Fuel Tank Assembly, Xplorer....704
Camber and Caster Adjustment....705
Toe Alignment....706
Typical Steering Assembly, Exploded View, 4x4 (1988-1992)....708
Typical Steering Assembly, Exploded View, 2x4 (1988-1992)....709
Typical Steering Assembly, Exploded View, 2x4 (1993-Present Except Magnum)....710
Steering Assembly, Exploded View, Magnum 2x4....711
Typical Steering Assembly, Exploded View, 4x4 (1993-Present Except Xplorer and Scrambler)....712
Steering Assembly, Exploded View, Xplorer....713
Steering Stop Adjustments....714
Frame Straightening and Reinforcement....715
Front Wheel Removal -1985-86 Scrambler Models....716
Front Fork Service -1985-86 Scrambler Models....717
Rear Drive Axle, hub and Wheel Assembly, Magnum....720
Swing Arm and Rear Suspension Exploded View - 2x4, 4x4....721
Rear Swing Arm Weldment -Big Boss 4x6 and 6x6....722
Swing Arm and Rear Suspension Exploded View, 1995 Scrambler....723
Axle Housing and Swing Arm Removal and Inspection....724
Strut Assembly - 350/400L 4x4, Magnum 4x4....727
Front Strut Weldment Replacement....728
Front Strut Ball Joint Replacement....729
2x4 Hub Bearing Service....730
Fox Shock Maintenance....731
Lubrication Guide....738
Optional Suspension Springs (1994)....739
Optional Suspension Springs (1995)....740
1995 Paint Codes....742
3 - Brake Service....743
Type I Mechanical - Front....744
Type I Mechanical - Rear....745
Hydraulic Brake System Operation....747
Type I Hydraulic Master Cylinder....748
Type II Hydraulic Master Cylinder....749
Type I Hydraulic Caliper - Front....750
Type II Hydraulic Caliper - Front....752
Type I Hydraulic Caliper - Rear....754
Type II Hydraulic Caliper - Rear....756
Output Shaft Caliper Service....759
Type III Master Cylinder....772
Brake Bleeding Procedure....774
4 - Transmission Service....781
Specifications....782
Type 1 - Chain....785
Type 2 - Gear....791
Type 3 - Gear/Chain USA (EZ Shift)....798
Torque Stop/Shift Linkage Adjustment....801
Troubleshooting....803
Selector and Wiring Harness Removal....804
Selector Installation....805
Speedometer Service....806
5 - Final Drive System Service....807
Specifications....808
Chain and Sprocket Service....809
Rear Drive Chain Adjustment....810
1987/1988 4x4 Center and Forward Chain Adjustment....811
1989 to Present All-Wheel Drive Center and Forward Chain Adjustment....812
1989 to Present Wheel Drive Chain Slack Adjustment....813
Rear Axle Chain Adjustment, 4x6 and 6x6 Models....814
Axle/Eccentric Service....815
Demand 4 Operation....816
Front Drive System Overhaul - All-Wheel Drive Models....817
Front Hub Disassembly....818
Demand 4 Roller Clutch Inspection 1989 to Current....819
Hilliard Clutch Assembly Testing....820
Wheel Hub Seal Replacement....820
Strut Casting Seal Replacement....822
Drive Shaft CV Joint Boot Replacement....823
Front Axle Seal Sleeve Replacement....823
Pole Gap Adjustment....825
Front Clutch Reassembly....825
Bearing Torque Adjustment....826
Front Hub Installation....827
6 - PVT System....828
Specifications....829
Shift Weights....832
Drive Clutch Spring Specs....834
Overview....835
PVT System Introduction....836
Maintenance....837
PVT Disassembly....839
PVT Assembly....840
Drive Belt....842
Clutch Alignment/Offset....843
Driven Clutch Disassembly....844
Driven Clutch Assembly....846
Drive Clutch Disassembly....847
Drive Clutch Inspection....849
Drive Clutch Assembly....852
Clutch Bushing Removal and Installation....853
Troubleshooting....856
7 - Engines....857
Engine Specifications....859
Piston Identification....862
Magnum Service Data....863
Torque Specifications....865
Fluid Capacity....866
Cooling System....867
2 Stroke Maintenance....870
4 Stroke Maintenance....874
Engine Removal....886
Engine Disassembly (Air Cooled 2 Stroke)....888
Crankshaft Alignment....889
Crankshaft and Crankcase Reassembly....890
Engine Installation....896
Cylinder Honing....897
Piston/Cylinder Clearance....898
Engine Service, 350L/400L....899
Oil Check Valve Testing....905
350L/400L Water Pump....906
Oil Pump End Play Adjustment....907
300 Oil Pump Check Valve Testing....908
Recoil Disassembly (Early Style EC25PF-01/02 Engines)....909
Recoil Disassembly (Late Style EC25PF-03 and Later Engines)....910
Recoil Reassembly (EC28 and EC38 Engines)....912
Magnum EH42PL Engine Exploded View....913
Magnum Lubrication/Oil Flow....914
Magnum Engine Removal....916
Magnum Engine Installation....921
Magnum Engine Disassembly/Inspection....922
Magnum Engine Assembly....952
Recoil Disassembly/lnspection/Assembly....968
2 Stroke Engine Troubleshooting....971
4 Stroke Engine Troubleshooting....972
Mikuni VM Carburetor, Exploded View....975
Function of VM Carburetor....976
Starter System....977
Pilot System....978
Main System....979
Throttle Opening....980
Component Description....981
Mikuni BST 34 Carburetor, Exploded View....983
Magnum CV Carb Operation....984
Magnum Fuel Tank Removal....988
CV Carburetor Systems....989
Float Height....991
Carburetor Disassembly....992
Carburetor Cleaning....995
Carburetor Assembly....998
Carburetor Installation....1000
Fuel Pump, Exploded View....1002
Fuel Pump Disassembly/lnspection/Assembly....1003
Troubleshooting....1004
Jetting Compensation for Altitude and Temperature....1006
8 - Electrical....1010
General Specifications....1012
Ignition Timing....1014
Ignition System Components (Exploded View)....1016
Ignition System Components (Exploded View) EC38-PL....1017
Ignition System Components (Exploded View) EC42PL(E)....1018
Ignition System Test Sequence....1020
Battery Maintenance and Testing....1022
Electric Starter System Testing....1024
Magnum Starter System Testing....1027
Starting System Troubleshooting....1030
Charging System Testing....1031
Speed Limiter System Testing....1034
Electric Demand 4 Drive System Testing....1037
Wiring Schematics and Diagrams....1042
1985-87 Scrambler, Trail Boss, Trail Boss 4x4 Schematic....1042
1987 Cyclone Schematic....1043
1988 Trail Boss 2x4 and 4x4 Schematic....1044
1988 Trail Boss 250 R/ES Schematic....1045
1989 Circuit Board And Wire Color Coding....1046
1989 Trail Boss, Trail Boss 2x4, Big Boss 4x6 Diagram....1048
1989 Trail Boss, Trail Boss 2x4, Big Boss 4x6 Schematic....1049
1989 Trail Boss 4x4 Diagram....1050
1989 Trail Boss 4x4 Schematic....1051
1990 Trail Blazer Diagram....1052
1990, 1991 Trail Boss, 2x4, 4x6 Diagram....1053
1990, 1991 Trail Boss, 2x4, 4x6 Schematic....1054
1990, 1991 Trail Boss 4x4 (Except J Model), 1991 Big Boss 6x6 Diagram....1055
1990, 1991 Trail Boss 4x4 (Except 1991 J Model) 1991 Big Boss 6x6 Schematic....1056
1991, 1991 Trail Boss 2x4-350L Diagram....1057
1990, 1991 350L 2x4 Schematic....1058
1990, 1991 Trail Boss 4x4 (Except 1991 J Model) Diagram....1059
1990, 1991 350L 4x4 (Except 1991 J Model) ....1060
1991 Trail Boss 250 (J Model) Diagram....1061
1991 Trail Boss 250 4x4 (J Model) Schematic....1062
1991 4x4-350L (J Model) Diagram....1063
1991 350L 4x4 (J Model) Schematic....1064
1991 Trail Blazer Diagram....1065
1992 Trail Blazer Diagram....1066
1992 Trail Boss, 2x4, 4x6 Diagram....1067
1992 Trail Boss, 2x4, 4x6 Schematic....1068
1992 Trail Boss 250 4x4 and Big Boss 6x6 Diagram....1069
1992 Trail Boss 250 4x4 and Big Boss 6x5 Schematic....1070
1992 350L 2x4 Diagram....1071
1992 350L 2x4 Schematic....1072
1992 350L 4x4 Trail Boss Diagram....1073
1992 350L 4x4 Trail Boss Schematic....1074
1993 Trail Blazer Diagram....1075
1993 250 2x4 and Trail Boss Diagram....1076
1993 250 2x4 and Trail Boss Schematic....1077
1993 250 4x4 and 250 6x6 Diagram....1078
1993 250 4x4 and 250 6x6 Schematic....1079
1993 350 2x4 Diagram....1080
1993 350L 2x4 Schematic....1081
1993 350L 4x4 Diagram....1082
1993 350L 4x4 Schematic....1083
1993 Sportsman Schematic....1084
1993 350 6x6 Schematic....1085
1994 Trail Blazer Schematic....1086
1994 Trail Boss Schematic....1087
1994 300 2x4 Schematic....1088
1994 400L 2x4 Schematic....1089
1994 400L Sport Schematic....1090
1994 300 4x4, 6x6 Schematic....1091
1994 400L 4x4, Sportsman, 6x6 Schematic....1092
1995 Trail Blazer Schematic....1093
1995 Trail Boss Schematic....1094
1995 300 2x4 Schematic....1095
1995 400 2x4 Schematic....1096
1995 400 Sport Schematic....1097
1995 300 4x4 Schematic....1098
1995 Xplorer 4x4, Sportsman, 400 6x6 Schematic....1099
1995 Scrambler Schematic....1100
1995 Magnum 2x4 Schematic....1101
1995 Magnum 4x4 Schematic....1102
Polaris Outlaw 450MXR_525S_525IRS '09 Service Repair Manual....1103
9921810_Chapter_1....1103
GENERAL INFORMATION....1103
VEHICLE IDENTIFICATION....1104
Model Identification....1104
Engine Designation Numbers....1104