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About This File

Service manual for 1996-1998 Polaris ATVs and light utility vehicles covers: Magnum 2x4, Trail Blazer / Scrambler, Sportsman 4x4, Magnum 4x4, Trail Boss / Sport, 6x6 / Magnum 6x6,  Xplorer 300 / Xplorer 400, Sportsman 500 & Xpress 300 / Xpress 400




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    • By JacobSlabach
      Hey just picked up another scrambler 850 was told the tps was bad.  This atv has been beet to hell.  Wiring has been tinkered with the crankcase has been replaced recently and the motor rebuilt (can see horizontal scores thru spark plug hole where it’s just been honed out and rebuilt)
      my guess is it was ragged out till the motor blew a rod and rebuilt but the clown that did it couldn’t get it to run again and sold it.  When I bought it it would pulse and smoke black at idle and die with throttle.
      New tps installed and it won’t run period.  I went to celebrate it and I’m getting 5 volts on 2 of the 3 wires running to the tps.  Is this normal and if so how should I celebrate it?



    • By JacobSlabach
      Hey so i sold my 04 rubicon and wanted something new so i went to NC and bought a '13 scrambler 850XP LE EPS.  love it the only issues with it when i bought it were a leak in the front tire and the mice had chewed through one of the spark plug wires.  currently have a substitute hooking the chewed end to the ignition coil so itll run on both cylinders however im having an issue finding a replacement coil wire for it and was wondering if yall had any advice.  i need the longer of the two coil wires and i can only find the shorter one online.  will throw up some pics of it when i can
    • By Jeff Cotter
      I recently purchased a 2000 polaris xplorer 400 4x4.  When I bought it the starter was bad, speedometer didn't work,  and it had been sitting for 5 years. I replaced the battery, and starter. Changed all fluids, and got it running correctly.  Then replaced the speedometer in an attempt to make sure the awd would be available when needed.  And took it out for a couple hour ride with a buddy.  
      It ran great that ride with no serious problems just a little carb issues which I was able to take care of on the trails.  Then a couple days later I decided to take it out for a ride by myself,  again ran great no issues other than a couple times it seemed to cough and then take off again.  That day when I was loading it I noticed coolant dripping onto the trailer and the overflow bottle was empty.  
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    • By bodon
      Anyone know what the fuse terminal marked UNSWITCH  does  .  Even with the key off it is causing a drain on my battery and I'm trying to figure out  what that terminal goes to.  It's a 10 amp fuse. If I pull it the "short" goes away.  Thanks in advance.
    • By Outkast7222
      Had a spark-plug break off, had to pull the head to get it extracted. Where the heck is the timing mark on the crank? Do I need to pull the stator or flywheel to find it? When I pulled the head I had the mark on the cam lined up pretty good but I cant remember if it was perfect and don't want to reassemble a tooth off and have to go back through the bear of pulling this thing back apart.
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