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1996-1998 Polaris Magnum, Trail Blazer, Scrambler, Sportsman, Trail Boss, Xplorer, Express, 300, 400, 500 manual Preview image 1
1996-1998 Polaris Magnum, Trail Blazer, Scrambler, Sportsman, Trail Boss, Xplorer, Express, 300, 400, 500 manual Preview image 2
1996-1998 Polaris Magnum, Trail Blazer, Scrambler, Sportsman, Trail Boss, Xplorer, Express, 300, 400, 500 manual Preview image 3
1996-1998 Polaris Magnum, Trail Blazer, Scrambler, Sportsman, Trail Boss, Xplorer, Express, 300, 400, 500 manual Preview image 4
1996-1998 Polaris Magnum, Trail Blazer, Scrambler, Sportsman, Trail Boss, Xplorer, Express, 300, 400, 500 manual Preview image 5
1996-1998 Polaris Magnum, Trail Blazer, Scrambler, Sportsman, Trail Boss, Xplorer, Express, 300, 400, 500 manual Preview image 6

1996-1998 Polaris Magnum, Trail Blazer, Scrambler, Sportsman, Trail Boss, Xplorer, Express, 300, 400, 500 manual

Models covered in this manual:

Polaris Industries Inc

  • Magnum 2x4
  • Magnum 4x4
  • Trail Blazer
  • Scrambler 400 2x4
  • Scrambler 400 4x4
  • Sportsman 400 4x4
  • Trail Boss 250
  • Trail Boss 350L 2x4
  • Trail Boss 350L 4x4
  • Xplorer 300 4x4
  • Xplorer 400L 4x4
  • Xplorer 500 4x4
  • Xpress 300
  • Xpress 400

Production/model years: 1996, 1997, 1998.

File specifications

File size: 50.24 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 1.03 Minutes
$18.99 Instant Download

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Product Information

Table of Contents

Chapter 01: General Information

  • Model Identification
  • Publications Numbers
  • Service Videos
  • Service Information Bulletin Index
  • Paint Codes
  • Model Specifications, 1996
  • Model Specifications, 1997
  • Model Specifications, 1998
  • Standard Torque Specifications
  • Decimal Equivalent Chart
  • Conversion Table
  • Tap Drill Charts
  • Warranty
  • Service Tips
  • Glossary of Terms
  • Tool Ordering Information
  • Routing Diagrams

Chapter 02: Maintenance

  • Maintenance Schedule
  • Lubrication
  • Pre-Ride Inspection
  • Engine Maintenance
  • Transmission Maintenance
  • Brake Maintenance
  • Electrical Maintenance
  • Chassis Maintenance

Chapter 03: Engine

  • Engine Removal
  • Engine Disassembly
  • Engine Inspection
  • Engine Reassembly
  • Engine Installation
  • Cooling System
  • Lubrication System

Chapter 04: Fuel System/Carburetion

  • Fuel System Overview
  • Carburetor Adjustment
  • Fuel Pump
  • Fuel Tank
  • Fuel Lines

Chapter 05: Body/Steering/Suspension

  • Body Panels
  • Steering System
  • Front Suspension
  • Rear Suspension
  • Frame
  • Wheels and Tires

Chapter 06: PVT System

  • PVT Overview
  • Clutch Maintenance
  • Belt Replacement
  • PVT Adjustment

Chapter 07: Final Drive

  • Final Drive Overview
  • Differential
  • Axles
  • Drive Shaft
  • Drive Chain

Chapter 08: Transmission

  • Transmission Removal
  • Transmission Disassembly
  • Transmission Inspection
  • Transmission Reassembly
  • Transmission Installation

Chapter 09: Brakes

  • Brake System Overview
  • Front Brakes
  • Rear Brakes
  • Brake Adjustment
  • Brake Bleeding

Chapter 10: Electrical

  • Electrical System Overview
  • Wiring Diagrams
  • Battery
  • Starter Motor
  • Charging System
  • Ignition System
  • Lighting System
  • Switches and Controls
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