Description
This Haynes Polaris Big Boss Cyclone Magnum Sportsman Repair Manual 1985-1997 provides service, maintenance and repair information for 2 & 4 Stroke 1985-1997 Polaris ATVs. Fix most 2 and 4 wheel drive Polaris ATVs with this Haynes Polaris ATV manual.
1985 1986 1987 1988 1989
1990 1991 1992 1993 1994 1995 1996 1997
This Haynes Polaris Big Boss Cyclone Magnum Sportsman Repair Manual 1985-1997 will help you get the best value from your Polaris ATV. With this Haynes ATV manual you decide what work must be done, even if you choose to have it done by your local Polaris ATV dealer or independent repair shop; This Haynes Polaris ATV manual provides information and procedures for routine maintenance and servicing of your Polaris ATV; and it offers diagnostic and repair procedures to follow when trouble occurs. This Haynes Polaris ATV manual should allow you to tackle any Polaris ATV repair job yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get your Polaris ATV into the shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the Polaris ATV dealer must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.
Haynes Polaris ATV Repair Manual Table of Contents
Introduction to your Polaris ATV
About this manual, Introduction to the Polaris ATV, Identification numbers, Buying parts, General specifications, Maintenance techniques, tools and working facilities, Safety, ATV chemicals and lubricants.
Polaris ATV Troubleshooting
Symptoms and solutions cover: Engine doesn’t start or is difficult to start (Starter motor doesn’t rotate, Starter motor rotates but engine does not turn over, Starter works but engine won’t turn over (seized), No fuel flow, Engine flooded, No spark or weak spark, Compression low, Stalls after starting, Rough idle), Poor running at low speed (Spark weak, Fuel/air mixture incorrect, Compression low, Poor acceleration), Poor running or no power at high speed (Firing incorrect, Fuel/air mixture incorrect, Compression low, Knocking or pinging, Miscellaneous causes), Overheating (Engine overheats, Firing incorrect, Fuel/air mixture incorrect, Compression too high, Engine load excessive, Lubrication inadequate, Miscellaneous causes), Polaris Variable Transmission (PVT) problems (Drive belt slipping, Drive belt upside down in pulleys, Burn marks or thin spots on drive belt, Harsh engagement, Grabby or erratic engagement, Noisy operation, Melted PVT cover, Engine rpm too low when vehicle is driven, Engine rpm erratic when vehicle is driven), Gear shifting problems (Doesn’t go into gear), Abnormal engine noise (Knocking or pinging, Piston slap or rattling, Valve noise (4-stroke), Other noise), Abnormal driveline noise (Chain noise, Polaris Variable Transmission (PVT) noise, Transmission noise, Front gearcase noise (shaft drive models)), Abnormal chassis noise (Suspension noise, Driveaxle noise, Brake noise), Oil level light comes on (2-stroke) (Engine lubrication system, Electrical system, Excessive exhaust smoke, White smoke, Black smoke, Brown smoke), Poor handling or stability (Handlebar hard to turn, Handlebar shakes or vibrates excessively, Handlebar pulls to one side, Poor shock absorbing qualities), Braking problems (Brakes are spongy, don’t hold (hydraulic brakes), Brake lever pulsates, Brakes drag, Electrical problems, Battery dead or weak, Battery overcharged).
Polaris ATV Tune-up and routine maintenance
Air cleaner drain tube – cleaning, Air cleaner – prefilter check and main element replacement, Battery – electrolyte level/specific gravity – check, Brake fluid -change, Brake lever and pedal freeplay – check and adjustment, Brake system – general check, Choke – check and freeplay adjustment, Cooling system – draining, flushing and refilling, Cooling system – inspection, Counterbalancer fluid – change, Cylinder compression – check, Drive chain and sprockets – check, adjustment and lubrication, Driveaxle boots – inspection, Engine oil/filter – change, Exhaust system – inspection, Fasteners – check, Fluid levels – check, Front gearcase oil (shaft drive models) – change, Front hub fluid – change, Fuel system -check and filter cleaning, Idle speed ancrthrottle operation – check and adjustment, Ignition timing – check, Introduction to tune-up and routine maintenance, Lubrication – general, PVT – check and clean, Recoil housing – draining, Routine maintenance intervals, Sparkplug -replacement, Steering system – inspection and1oe-in adjustment, Suspension – check, Tires/wheels – general check, Transmission oil – change, Valve clearances – check and adjustment.
Polaris ATV Two-stroke engines repair
Counterbalancer (350 and 400 models) – removal, inspection and installation, Crankcase – disassembly and reassembly, Crankcase – inspection and servicing, Crankcase pressure and vacuum – check, Crankshaft and connecting rod – removal, inspection and installation, Cylinder – removal, inspection and installation, Cylinder head – removal, inspection and installation, Engine – removal and installation, Engine disassembly and reassembly – general information, General information, Major engine repair – general note, Oil pump – check valve test, cable adjustment and pump test, Oil pump – removal, inspection, installation and bleeding, Operations possible with the engine in the frame, Operations requiring engine removal, Piston and rings – removal, inspection and installation, Recoil starter – removal, inspection and installation, Recommended start-up and break-in procedure, Reed valve – removal, inspection and installation.
Polaris ATV Four-stroke engines repair
Cam chain tensioner – removal and installation, Counterbalancer – removal and installation, Crankcase – disassembly and reassembly, Crankcase components – inspection and servicing, Crankshaft and connecting rod – removal, inspection and installation, Cylinder head and valves – disassembly, inspection and reassembly, Cylinder head covers – removal, inspection and installation, Cylinder head – removal and installation, Cylinder – removal, inspection and installation, Engine- removal and installation, Engine disassembly and reassembly – general information, External oil lines, check valve and tank – removal and installation, General information, Initial start-up after overhaul, Major engine repair – general note, Oil pump – removal, inspection and installation, Operations possible with the engine in the frame, Operations requiring engine removal, Piston – removal, inspection and installation, Piston rings – installation, Recoil starter – removal, inspection and installation, Recommended break-in procedure, Rocker arms and camshaft – removal, inspection and installation, Valves/valve seats/valve guides – servicing.
Polaris ATV Polaris Variable Transmission (PVT) service
Air ducts – removal and installation, Clutches, inner cover and seal – removal and installation, Drive and driven clutches – disassembly, inspection and reassembly, Drive belt – removal, inspection and installation, Drive belt – width and play check, General information, Outer cover and seal – removal, inspection and installation, Pulleys – alignment and offset check.
Polaris ATV Transmission Repair
EZ Shift shifter – disassembly, inspection and reassembly, EZ Shift shifter – removal and installation, General information, Shift linkage – adjustment, Transmission – disassembly, inspection and reassembly, Transmission – removal and installation
Polaris ATV Cooling system service
Coolant hoses – replacement, Coolant level check, Coolant reservoir – removal and installation, Cooling fan and thermostat switch – check and replacement, Cooling system check, Cooling system draining, flushing and refilling, General information, Radiator – removal and installation, Radiator cap – check, Thermostat (4-stroke models) – removal, check and installation, Water pump – removal, inspection and installation.
Polaris ATV Fuel and exhaust systems
Air cleaner housing – removal and installation, Air filter element – servicing, Carburetor overhaul – general information, Carburetor – removal and installation, Carburetors – disassembly, cleaning and inspection, Carburetors – reassembly and float height check, Choke cable – removal and installation, Exhaust system – check, Exhaust system – removal and installation, Fuel pump – disassembly, inspection and reassembly, Fuel pump – removal and installation, Fuel tank – cleaning and repair, Fuel tank – removal and installation, General information, Idle fuel/air mixture adjustment, Spark arrester cleaning, Throttle cable – removal, installation and adjustment.
Polaris ATV Electrical and ignition system
Alternator – check and replacement, Battery – charging, Battery- check, Battery – inspection and maintenance, Brake switch – check and replacement, GDI magneto – check, removal and installation, GDI unit – check, removal and installation, Charging system – output test, Charging system testing – general information and precautions, Circuit breaker – check, Electrical troubleshooting, General information, Handlebar switches – check, Handlebar switches – removal and installation, Headlight aim – check and adjustment, Headlight bulb – replacement, Ignition coil – check, removal and installation, Ignition main (key) switch – check and replacement, Ignition system – check, Ignition timing – general information and check, Indicator bulbs – replacement, Lighting system – check, Neutral switch – check and replacement, Regulator/rectifier – check and replacement, Speedometer cable and drive – removal and installation, Starter circuit – check and component replacement, Starter motor – disassembly, inspection and reassembly, Starter motor – removal and installation, Starter pinion – removal, inspection and installation, Taillight/brake light bulb – replacement, Wiring diagrams.
Polaris ATV Steering, suspension and final drive service
Drive chain and sprockets – removal, cleaning, inspection and installation, Driveaxles – boot replacement and U-joint overhaul, Driveaxles – removal and installation, Eccentrics – removal, inspection and installation, Front forks (3-wheel models) – disassembly, inspection and reassembly, Front forks (3-wheel models) – removal and installation, Front gearcase and driveshaft (shaft drive models) – removal and installation, Front struts – ball-joint replacement, Front struts – removal and installation, Front struts – spring and cartridge replacement, General information, Handlebar – removal, inspection and installation, Rear axle – removal, inspection and installation, Rear shock absorbers – removal and installation, Rear stabilizer struts (shaft drive models) – removal, inspection and installation, Steering shaft and tie-rods – removal, inspection and installation, Suspension – check, Suspension arms – removal, inspection and installation, Swingarm – removal and installation, Swingarm bearings – check.
Polaris ATV Brakes, wheels and tires service
Brake check, Brake discs – inspection, removal and installation, Brake drum and shoes – removal, inspection and installation, Brake hoses and lines – inspection and replacement, Brake pads – replacement, Brake system bleeding, Front brake master cylinder – removal, overhaul and installation, Front hubs (except 3-wheel models) – removal, inspection and installation, General information, Hydraulic brake calipers – overhaul, Hydraulic brake calipers – removal and installation, Mechanical rear caliper – removal, inspection and installation, Rear hubs – removal and installation, Tires – general information, Wheels and tires – general check, Wheels – inspection, removal and installation.
Polaris ATV Body and frame service
Dump bed (6X6 and 4X6) – removal and installation, Frame – general information, inspection and repair, Front cargo rack – removal and installation, Front fenders – removal and installation, Front skid plate – removal and installation, Fuel tank cover – removal and installation, General information, Headlight cover – removal and installation, Rear cargo rack – removal and installation, Rear fenders – removal and installation, Seat – removal and installation.
Polaris ATV Wiring Diagrams
Complete Polaris ATV wiring diagrams.
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