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
 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.
A

VIN Location - 1998-Current

Transmission I.D. Number Location
Transmission model and serial numbers are located
on top of the transmission case below the shifting bell-
cranks.
Example
Mod # 1341157
Ser # 96-10275

Transmission I.D. Numbers

Carburetor I.D. Number Location

The carburetor I.D. number (A) is in one of the follow-
ing locations: 2-Stroke Forward
S 4 stroke models - right side center of
the carburetor body A
S 2 stroke models - right side of carbu- A
retor body near choke plunger boss

Forward
4-Stroke
Carburetor I.D. Number

Polaris Sales Inc. 1.1 4/99

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.

World Mfg. ID Vehicle Descriptor Vehicle Identifier

Example of 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Current 4 X A B A 3 8 C 0 W 2 0 0 0 0 0 0

VIN Number Body Style Emissions

Engine
Model
Year Individual Serial No.
Check Digit Plant No.
Powertrain

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/ 50=EH50PL (500 cc)
shaft front

¡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
A 9 9 CD50A A Option Indicator
A=ATV

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

4/99 1.2 Polaris Sales Inc.

 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 9913987 Theory, disassembly, assembly and troubleshooting of the
(PVT) 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

Polaris Sales Inc. 1.3 4/99

GENERAL INFORMATION
Paint Codes

1999 Paint Codes

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

Big Boss 500 6X6 Springs / Eddie B Green 8520150 (P195) 44931
Front Rack
Rims Aluminum (P117)

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

Sportsman 500 EBS (Opt. A) Springs / Rims Black 8520147 (P067) 9440
Sportsman
p 500 EBS ((Opt.
p B)) Rims Aluminum (P117)
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

4/99 1.4 Polaris Sales Inc.

 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. lbs. (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
Torque in In. 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.

Polaris Sales Inc. 1.5 4/99

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
1 ............ 1.0

4/99 1.6 Polaris Sales Inc.

 GENERAL INFORMATION
Conversion Table
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = 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 x 10 = Nm
in. x 25.4 = mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = 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) x 1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Liters (l)
Liters (l) x 0.88 = 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) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F

°F to °C: 5 (°F + 40) ÷ 9 - 40 = °C

Polaris Sales Inc. 1.7 4/99

GENERAL INFORMATION
Tap Drill Charts

SAE Tap Drill Sizes

Thread Size Drill Size Thread Size Drill Size
#0-80 3/64 1/2-13 27/64
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50 5/8-11 17/32
#3-48 5/64
5/8-18 37/64
#3-56 45
#4-40 43 3/4-10 21/32
#4-48 42 3/4-16 11/16
#5-40 38 7/8-9 49/64
#5-44 37 7/8-14 13/16
#6-32 36 1-8 7/8
#6-40 33 1-12 59/64
#8-32 29 1 1/8-7 63/64
#8-36 29 1 1/8-12 1 3/64
#10-24 24
1 1/4-7 1 7/64
#10-32 21
1 1/4-12 1 11/64
#12-24 17
#12-28 4.6mm 1 1/2-6 1 11/32
1/4-20 7 1 1/2-12 1 27/64
1/4-28 3 1 3/4-5 1 9/16
5/16-18 F 1 3/4-12 1 43/64
5/16-24 I 2-4 1/2 1 25/32
3/8-16 O 2-12 1 59/64
3/8-24 Q 2 1/4-4 1/2 2 1/32
7/16-14 U 2 1/2-4 2 1/4
7/16-20 25/64
2 3/4-4 2 1/2
3-4 2 3/4

Metric Tap Drill Sizes

Tap Size Drill Size Decimal Equivalent Nearest Fraction
3 x .50 #39 0.0995 3/32
3 x .60 3/32 0.0937 3/32
4 x .70 #30 0.1285 1/8
4 x .75 1/8 0.125 1/8
5 x .80 #19 0.166 11/64
5 x .90 #20 0.161 5/32
6 x 1.00 #9 0.196 13/64
7 x 1.00 16/64 0.234 15/64
8 x 1.00 J 0.277 9/32
8 x 1.25 17/64 0.265 17/64
9 x 1.00 5/16 0.3125 5/16
9 x 1.25 5/16 0.3125 5/16
10 x 1.25 11/32 0.3437 11/32
10 x 1.50 R 0.339 11/32
11 x 1.50 3/8 0.375 3/8
12 x 1.50 13/32 0.406 13/32
12 x 1.75 13/32 0.406 13/32

4/99 1.8 Polaris Sales Inc.

 GENERAL INFORMATION
Service Tips
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.

Polaris Sales Inc. 1.9 4/99

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.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch
face.
Clutch Weights: 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.
Holed Piston: Piston in which a hole has formed on the dome. Possible causes: Lean mixture; Incorrect ignition timing
HP: Horsepower.
ID: Inside diameter.
Ignition Coil: 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 Generating Coil: Exciter coil, primary charge coil. Stator plate coil which generates primary ignition voltage.

4/99 1.10 Polaris Sales Inc.

 GENERAL INFORMATION
Glossary Of Terms

in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
2
kg/cm : 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.
l or ltr: Liter.
2
lbs/in : 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.
Secondary Circuit: 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.
Seized Piston: 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.

Polaris Sales Inc. 1.11 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.
Venturi: 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.

4/99 1.12 Polaris Sales Inc.

 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
1--800--328--6657
www.polaris.spx.com

Tool Order FAX Number

1--800--328--6657

Polaris Sales Inc. 1.13 4/99

GENERAL INFORMATION
1999 Model Specifications

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

MODEL NUMBER: . A99BA25CA
ENGINE MODEL: . . EC25PFE13

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM30SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 130 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

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

(Feet)
0-900
(0-3000) 150 140 130 120
Needle Jet . . . . . . . . . . . 0-4(169) 900-1800
140 130 120 110
Cutaway . . . . . . . . . . . . 2.0 (3000-6000)

Air Screw . . . . . . . . . . . 1.0 Turn 1800-2700

(6000-9000) 125 120 110 100
Valve Seat . . . . . . . . . . . 2.5 2700-3700
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000) 115 110 100 95

89 Oxygenated
- Turn AS out 1/2 -- 3/4 turn CCW from seat
Raise needle clip 1 position to lower jet needle

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188” (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-900
G Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12” (Feet) (0-3000)

Center Distance . . . . . . . . . . 10±.12” (254.5mm) 900-1800

(3000-6000)
G Blue/Green 2 -1
2- 1
Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700
Shift Weights . . . . . . . . . . . . G (6000-9000)
16 Blue/Green 2 -2
2- 2

Primary Spring . . . . . . . . . . . Blue/Green 2700-3700

16 Blue/Green 2 -1
2- 1
(9000-12000)
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . 40°
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 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 . . . . . . . . . 5800 RPM
Idle RPM±200 . . . . . . . . . . . . . . 700 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.14 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

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*
*Lubricant
*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 LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10
Tire Size - Rear . . . . 22 x 11 - 10 Front Rack (Accy) . . . . 30 lbs.
Tire Size - Center . . N/A Rear Rack (Accy) . . . . 60 lbs.
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . 30 lbs.
Total Width . . . . . . . . 46.5” (118.11cm)
Tow Hitch . . . . . . . . . . . Accy
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 7041778-067 7041815-067

Option 125 lb/in. Standard 150 lb/in. Option 175 lb/in.
Front Strut Spring 7041471-067 7041238-067 7041375-067
Option 41 lb/in. Standard 61 lb/in. Option 64/113 lb/in.

Polaris Sales Inc. 1.15 4/99

 GENERAL INFORMATION
1999 Model Specifications

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

MODEL NUMBER: . A99AA25CA
ENGINE MODEL: . . EC25PFE10

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM30SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 145 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

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

(Feet)
0-900
(0-3000) 170 155 145 135
Needle Jet . . . . . . . . . . . 0-4(169) 900-1800
155 145 135 125
Cutaway . . . . . . . . . . . . 2.0 (3000-6000)

Air Screw . . . . . . . . . . . 1.0 Turn 1800-2700

(6000-9000) 140 130 120 115
Valve Seat . . . . . . . . . . . 2.5 2700-3700
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000) 130 120 110 100

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

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 Shift Clutch Driven
Altitude
Belt Width (Projected) . . . . . 1.188” (30.18mm) Weight Spring Helix

Side Angle (Overall) . . . . . . 26° Meters

(Feet)
0-900
(0-3000)
16 Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12” 900-1800
16 Blue/Green 2 -1
2- 1
Center Distance . . . . . . . . . . 10±.12” (254.5mm) (3000-6000)

Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700

(6000-9000)
16 Mod Blue/Green 2 -2
2- 2
Shift Weights . . . . . . . . . . . . 16 2700-3700
Primary Spring . . . . . . . . . . . Blue/Green (9000-12000)
16 Mod Blue/Green 2 -2
2- 2

Secondary Spring . . . . . . . . Red

Driven Helix . . . . . . . . . . . . . 40°
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 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%

4/99 1.16 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

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*
*Lubricant
*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 LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Accy) . . . . 75 lbs.
Tire Size - Rear . . . . 22 x 11 - 10
Tire Size - Center . . N/A Rear Rack . . . . . . . . . . 125 lbs.
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . 30 lbs.
Total Width . . . . . . . . 44” (111.76cm) Tow Hitch . . . . . . . . . . . Std
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 7041204-067 7041303-067

Option 175 lb/in. Standard 190 lb/in. Option 250 lb/in.
Front Strut Spring 7041471-067 7041238-067 7041375-067
Option 41 lb/in. Standard 61 lb/in. Option 64/113 lb/in.

Polaris Sales Inc. 1.17 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . XPRESS 300

MODEL NUMBER: . A99CA28CA
ENGINE MODEL: . . EC28PFE02

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM30SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 155 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

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

(Feet)
0-900
(0-3000) 180 170 155 145
Needle Jet . . . . . . . . . . . 0-4(169) 900-1800
165 150 140 130
Cutaway . . . . . . . . . . . . 2.0 (3000-6000)

Air Screw . . . . . . . . . . . 1.25 Turn 1800-2700

(6000-9000) 150 140 130 120
Valve Seat . . . . . . . . . . . 2.5 2700-3700
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000) 135 125 115 110

89 Oxygenated - Drop jet needle one position (raise E--Clip)

- Turn air screw in 1/2 to 3/4 turn

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188” (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-900 G Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12” (Feet) (0-3000) 48GR
Center Distance . . . . . . . . . . 10±.12” (254.5mm) 900-1800
(3000-6000)
G Blue/Green 2 -2
2- 2 or 2-
2 -1
1
48GR
Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700 F
Shift Weights . . . . . . . . . . . . G (6000-9000) 45GR
Blue/Green 2 -2
2- 2

Primary Spring . . . . . . . . . . . Blue/Green 2700-3700 F Blue/Green 2 -1

2- 1
(9000-12000) 45GR
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . Compound
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 283 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.9331” (74.5mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.5591” (65mm)
Compression Ratio . . . . . . . . . . 6.1/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Air
Lubrication Type . . . . . . . . . . . . Oil Injected
Piston / Cylinder Clearance . . . 0.0012 - 0.0026” (0.03 - 0.07mm)
Service Limit . . . . . . . . . . . . . . . . 0.006” (0.15mm)
Piston Marking . . . . . . . . . . . . . . 28
Piston Ring End Gap . . . . . . . . .012”-.022” (.31mm-.56mm)
Operating RPM±200 . . . . . . . . . 5600 RPM
Idle RPM±200 . . . . . . . . . . . . . . 600 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.18 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . . . XPRESS 300

MODEL NUMBER: . . . A99CA28CA
ENGINE MODEL: . . . . EC28PFE02

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 4 gals. (15.1L)
CDI Marking . . . . . . . CU2513 Injector Oil . . . . . . . . . . 2 qts. (1.9L) . . PP2*
Alternator Output . . . 150 Watts Coolant . . . . . . . . . . . . N / A
Ignition Timing . . . . . 25° BTDC@3000RPM±2 ° Transmission . . . . . . . 20 oz. (592ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028” (0.7mm) Gearcase Oil (Front) . N / A
Lights: Head (Twin) Halogen 30/30 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*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W40 Synthetic Engine Lubricant
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . 520 O-Ring
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.64/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 5.13/1
Turning Radius . . . . . 60” (152.4cm) Gear Reduction-High 3.29/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . N/A
Ground Clearance . . 6.5” (16.51cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.25” (15.88cm) Final Drive Ratio . . . . 13/38 86P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 8.5″ (21.59cm) Brake (Auxiliary Foot) Mechanical
Rear Shock . . . . . . . . 1″ Gas Bag
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 24 x 11 - 10
Tire Size - Center . . N/A Rear Rack (Std) . . . . . . 180 lbs.
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46” (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 79.5” (201.93cm)
Total Height . . . . . . . . 45.5” (115.57cm)
Wheel Base . . . . . . . 49.75” (126.37cm)
Weight - Dry . . . . . . . 512 lbs. (224.73kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041518-067 7041204-067 7041303-067

Option 175 lb/in. Standard 190 lb/in. Option 250 lb/in.
Front Strut Spring 7041238-067 7041375--157 7041450-067
Option 61 lb/in. Standard 64/113 lb/in. Option 101 lb/in.

Polaris Sales Inc. 1.19 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . XPLORER 300

MODEL NUMBER: . A99CC28CA
ENGINE MODEL: . . EC28PFE02

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM30SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 155 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

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

(Feet)
0-900
(0-3000) 180 170 155 145
Needle Jet . . . . . . . . . . . 0-4(169) 900-1800
165 150 140 130
Cutaway . . . . . . . . . . . . 2.0 (3000-6000)

Air Screw . . . . . . . . . . . 1.25 Turn 1800-2700

(6000-9000) 150 140 130 120
Valve Seat . . . . . . . . . . . 2.5 2700-3700
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000) 135 125 115 110

89 Oxygenated - Drop jet needle one position (raise E--Clip)

- Turn air screw in 1/2 to 3/4 turn

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188” (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-900 G Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12” (Feet) (0-3000) 48GR
Center Distance . . . . . . . . . . 10±.12” (254.5mm) 900-1800
(3000-6000)
G Blue/Green 2 -2
2- 2 or 2-
2 -1
1
48GR
Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700 F
Shift Weights . . . . . . . . . . . . G (6000-9000) 45GR
Blue/Green 2 -2
2- 2

Primary Spring . . . . . . . . . . . Blue/Green 2700-3700 F Blue/Green 2 -1

2- 1
(9000-12000) 45GR
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . Compound
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 283 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.9331” (74.5mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.5591” (65mm)
Compression Ratio . . . . . . . . . . 6.1/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Air
Lubrication Type . . . . . . . . . . . . Oil Injected
Piston / Cylinder Clearance . . . 0.0012 - 0.0026” (0.03 - 0.07mm)
Service Limit . . . . . . . . . . . . . . . . 0.006” (0.15mm)
Piston Marking . . . . . . . . . . . . . . 28
Piston Ring End Gap . . . . . . . . .012”-.022” (.31mm-.56mm)
Operating RPM±200 . . . . . . . . . 5600 RPM
Idle RPM±200 . . . . . . . . . . . . . . 600 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.20 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . . . XPLORER 300

MODEL NUMBER: . . . A99CC28CA
ENGINE MODEL: . . . . EC28PFE02
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 4 gals. (15.1L)
CDI Marking . . . . . . . CU2513 Injector Oil . . . . . . . . . . 2 qts. (1.9L) . . PP2*
Alternator Output . . . 150 Watts Coolant . . . . . . . . . . . . N / A
Ignition Timing . . . . . 25° BTDC@3000RPM±2 ° Transmission . . . . . . . 20 oz. (592ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028” (0.7mm) Gearcase Oil (Front) . N / A
Lights: Head . . . . . . Halogen 30/30 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) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . 520 O-Ring
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.64/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 5.13/1
Turning Radius . . . . . 57” (144.78cm) Gear Reduction-High 3.39/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . 12/22 64P
Ground Clearance . . 6” (15.24cm) Center Drive Ratio . . . 11/22 70P
Front Vertical Travel 6.25” (15.88cm) Final Drive Ratio . . . . 13/40 88P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 8.5“ (21.59cm) Brake (Auxiliary Foot) Mechanical
Rear Shock . . . . . . . . 1” Bore Gas Bag
Shock Adjustment . . Cam
TIRES
Tire Size - Front . . . . 23 x 7 - 10
Tire Size - Rear . . . . 24 x 11 - 10
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs.
Total Width . . . . . . . . 46” (116.84cm)
Total Length . . . . . . . 81” (205.74cm)
Total Height . . . . . . . . 45.5” (115.57cm)
Wheel Base . . . . . . . 49.75” (126.37cm)
Weight - Dry . . . . . . . 567 lbs. (252.4kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041518-067 7041204-067 7041303-067

Option 175 lb/in. Standard 190 lb/in. Option 250 lb/in.
Front Strut Spring 7041238-067 7041375--157 7041450-067
Option 61 lb/in. Standard 64/113 lb/in. Option 101 lb/in.

Polaris Sales Inc. 1.21 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . SPORTSMAN 335

MODEL NUMBER: . A99CH33CA/B, A99CH33AA/AB(CALIF. APPROVED)
ENGINE MODEL: . . ES33PFE01, ES33PFE02(CALIF. APPROVED)

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 150 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 5F14--3 Meters

(Feet)
0-900
(0-3000) 162 5
162.5 155 150 145
Needle Jet . . . . . . . . . . . P-9 900-1800
155 150 145 137 5
137.5
Throttle Valve . . . . . . . . #100 (3000-6000)

Pilot Screw . . . . . . . . . . 2.5 Turns Out 1800-2700

(6000-9000) 150 145 137 5
137.5 132 5
132.5
Pilot Air Jet . . . . . . . . . . 160 2700-3700
Valve Seat . . . . . . . . . . . 1.5 (9000-12000) 142 5
142.5 137 5
137.5 130 125

Fuel Octane (R+M/2) . 87 Non-Oxygenated or - Pilot screw in 1/2 turn

89 Oxygenated

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 Shift Clutch Driven
Altitude
Belt Width (Projected) . . . . . 1.188” (30.18mm) Weight Spring Helix

Side Angle (Overall) . . . . . . 26° Meters

(Feet)
0-900
(0-3000)
16 Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12” 900-1800
16 Blue/Green 2 -1
2- 1
Center Distance . . . . . . . . . . 10±.12” (254.5mm) (3000-6000)

Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700

(6000-9000)
16 Mod Blue/Green 2 -2
2- 2
Shift Weights . . . . . . . . . . . . 16 2700-3700
Primary Spring . . . . . . . . . . . Blue/Green (9000-12000)
16 Mod Blue/Green 2 -2
2- 2

Secondary Spring . . . . . . . . Red

Driven Helix . . . . . . . . . . . . . Compound
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 334 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.0732” (78mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.758” (70mm)
Compression Ratio . . . . . . . . . . 9.2/1 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Air W/ Oil Cooler Assist
Lubrication Type . . . . . . . . . . . . Dry Sump
Piston / Cylinder Clearance . . . 0.0012 - 0.0035” (0.03 - 0.09mm)
Service Limit . . . . . . . . . . . . . . . . 0.0043” (0.11mm)
Piston Marking . . . . . . . . . . . . . . .
Piston Ring End Gap (top) . . . . .0079”-.0138” (.20mm-.36mm)
Piston Ring End Gap (second) .0138”-.0197” (.36mm-.50mm)
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.22 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . . . SPORTSMAN 335

MODEL NUMBER: . . . A99CH33CA/B, A99CH33AA/AB(CALIF. APPROVED)
ENGINE MODEL: . . . . ES33PFE01, ES33PFE02(CALIF. APPROVED)
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 3.75 gals. (14.2L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . N / A
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 32 oz. . . . . . . . PPS*
Spark Plug / Gap . . . NGK BKR7E / 0.028” (0.7mm) Gearcase Oil (Front) . 3.25 oz. . . . . . 80-90 GL5
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 Engine Oil . . . . . . . . . . 2.25 qts. (2.1L) PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . Shaft Drive
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.89/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 5.17/1
Turning Radius . . . . . 65” (165.1cm) Gear Reduction-High 3.56/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . 2:1
Ground Clearance . . 10.25” (26.04cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.25” (15.88cm) Final Drive Ratio . . . . 3.16:1
Rear Suspension . . . Progressive Rate Independent Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 9.5“ (24.13cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 1” Bore Gas Bag
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 24 x 11 - 10
Tire Size - Center . . N/A Rear Rack (Std) . . . . . . 180 lbs.
Tire Pressure - F/R . 5/5 lbs. Tongue Weight . . . . 30 lbs.
Total Width . . . . . . . . 46” (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81” (205.74cm)
Total Height . . . . . . . . 46” (118.22cm)
Wheel Base . . . . . . . 50.50” (128.27cm)
Weight - Dry . . . . . . . 670 lbs. (304.2kg)

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring 7041517-067 7041546-067 7041519-067

Option 80 lb/in. Standard 100 lb/in. Option 140 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
Option 61 lb/in. Standard 64/113 lb/in. Option 101 lb/in.

Polaris Sales Inc. 1.23 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . SPORT 400

MODEL NUMBER: . A99BA38CA
ENGINE MODEL: . . EC38PLE09

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 230 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 35 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 6CEY6-3 Meters

(Feet)
0-900
0 900
(0-3000)
(0 3000)
270 MJ 250 MJ 230 MJ 210 MJ
0.5 AS 1.0 AS 1.5 AS 1.5 AS
Needle Jet . . . . . . . . . . . 0-6(480) 900-1800
900 1800 250 MJ 230 MJ 210 MJ 195 MJ
Cutaway . . . . . . . . . . . . 1.5 (3000-6000)
(3000 6000)
0.5 AS 1.0 AS 1.5 AS 1.75 AS
Air Screw . . . . . . . . . . . 1.5 Turn 1800-2700
1800 2700 220 MJ 210 MJ 195 MJ 175 MJ
Valve Seat . . . . . . . . . . . 2.5 (6000-9000)
(6000 9000)
1.5 AS 1.5 AS 1.75 AS 1.75 AS
Fuel Octane (R+M/2) . 87 Non-Oxygenated or 2700-3700
2700 3700
(9000-12000)
(9000 12000)
200 MJ 190 MJ 175 MJ 160 MJ
1.5 AS 1.75 AS 1.75 AS 1.75 AS
89 Oxygenated
MJ = Main Jet
AS = Air Screw (Turns Out)

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188” (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-900
S -55
S- 55 White 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12” (Feet) (0-3000)

Center Distance . . . . . . . . . . 10±.12” (254.5mm) 900-1800

(3000-6000)
S -55
S- 55 White 2 -2
2- 2 or 2-
2 -1
1
Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700
S White 2 -1
2- 1
Shift Weights . . . . . . . . . . . . S55 (6000-9000)

Primary Spring . . . . . . . . . . . White 2700-3700

(9000-12000)
S or White 2 -1
2- 1
10MH
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . 40°
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 378 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.2677” (83mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.7559” (70mm)
Compression Ratio . . . . . . . . . . 6.9/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Oil Injected
Piston / Cylinder Clearance . . . 0.0023 - 0.0037” (0.06 - 0.09mm)
Service Limit . . . . . . . . . . . . . . . . 0.006” (0.15mm)
Piston Marking . . . . . . . . . . . . . . .
Piston Ring End Gap . . . . . . . . .007”-.015” (.18mm-.38mm)
Operating RPM±200 . . . . . . . . . 5700 RPM
Idle RPM±200 . . . . . . . . . . . . . . 600 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.24 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . . . SPORT 400

MODEL NUMBER: . . . A99BA38CA
ENGINE MODEL: . . . . EC38PLE09

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 4 gals. (15.1L)
CDI Marking . . . . . . . CU2515 Injector Oil . . . . . . . . . . 2 qts. (1.9L) . . PP2*
Alternator Output . . . 150 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 23.5° 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 60/60 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . N / A
Brake . . . . . . 26.9 watts Engine Counter Bal. . 100ml . . . . . . . 10W30
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*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PPS Polaris Premium Synthetic Gear Case Oil
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
SUSPENSION / CHASSIS DRIVE TRAIN
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 8.2” (20.83cm) Final Drive Ratio . . . . 13/36 76P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 8.2“ (20.83cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2” Gas Charged Mono
Shock Adjustment . . Thread Adjuster
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Accy) . . . . 30 lbs.
Tire Size - Rear . . . . 22 x 11 - 10
Rear Rack (Accy) . . . . 60 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46.5” (118.11cm) Tow Hitch . . . . . . . . . . . Accy
Total Length . . . . . . . 74.5” (189.23cm)
Total Height . . . . . . . . 47” (119.38cm)
Wheel Base . . . . . . . 49.75” (126.37cm)
Weight - Dry . . . . . . . 475 lbs. (215.6kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041389-067 7041691-067 7041303-067

Option 175 lb/in. Standard 170/210 lb/in. Option 250 lb/in.
Front Strut Spring 7041471-067 7041238-067 7041375-067
Option 41 lb/in. Standard 61 lb/in. Option 64/113 lb/in.

Polaris Sales Inc. 1.25 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . SCRAMBLER 400

MODEL NUMBER: . A99BG38C(A or B)
ENGINE MODEL: . . EC38PLE09

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 230 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 35 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 6CEY6-3 Meters

(Feet)
0-900
0 900
(0-3000)
(0 3000)
270 MJ 250 MJ 230 MJ 210 MJ
0.5 AS 1.0 AS 1.5 AS 1.5 AS
Needle Jet . . . . . . . . . . . 0-6(480) 900-1800
900 1800 250 MJ 230 MJ 210 MJ 195 MJ
Cutaway . . . . . . . . . . . . 1.5 (3000-6000)
(3000 6000)
0.5 AS 1.0 AS 1.5 AS 1.75 AS
Air Screw . . . . . . . . . . . 1.5 Turn 1800-2700
1800 2700 220 MJ 210 MJ 195 MJ 175 MJ
Valve Seat . . . . . . . . . . . 2.5 (6000-9000)
(6000 9000)
1.5 AS 1.5 AS 1.75 AS 1.75 AS
Fuel Octane (R+M/2) . 87 Non-Oxygenated or 2700-3700
2700 3700
(9000-12000)
(9000 12000)
200 MJ 190 MJ 175 MJ 160 MJ
1.5 AS 1.75 AS 1.75 AS 1.75 AS
89 Oxygenated
MJ = Main Jet
AS = Air Screw (Turns Out)

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188” (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-900
S -55
S- 55 White 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12” (Feet) (0-3000)

Center Distance . . . . . . . . . . 10±.12” (254.5mm) 900-1800

(3000-6000)
S -55
S- 55 White 2 -2
2- 2 or 2-
2 -1
1
Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700
S White 2 -1
2- 1
Shift Weights . . . . . . . . . . . . S55 (6000-9000)

Primary Spring . . . . . . . . . . . White 2700-3700

(9000-12000)
S or White 2 -1
2- 1
10MH
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . 40°
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 378 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.2677” (83mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.7559” (70mm)
Compression Ratio . . . . . . . . . . 6.9/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Oil Injected
Piston / Cylinder Clearance . . . 0.0023 - 0.0037” (0.06 - 0.09mm)
Service Limit . . . . . . . . . . . . . . . . 0.006” (0.15mm)
Piston Marking . . . . . . . . . . . . . . .
Piston Ring End Gap . . . . . . . . .007”-.015” (.18mm-.38mm)
Operating RPM±200 . . . . . . . . . 5700 RPM
Idle RPM±200 . . . . . . . . . . . . . . 600 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.26 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications
MODEL: . . . . . . . . . . . . SCRAMBLER 400
MODEL NUMBER: . . . A99BG38CB
ENGINE MODEL: . . . . EC38PLE09
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 4 gals. (15.1L)
CDI Marking . . . . . . . CU2515 Injector Oil . . . . . . . . . . 2 qts. (1.9L) . . PP2*
Alternator Output . . . 150 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 23.5° BTDC@3000RPM±3° Transmission . . . . . . . 16 oz. (473ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028” (0.7mm) Gearcase Oil (Front) . 3.25 oz. . . . . . 80-90 GL5
Lights: Head . . . . . . Halogen 30/30 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . N / A
Brake . . . . . . 26.9 watts Engine Counter Bal. . 100ml . . . . . . . 10W30
Voltage Regulator . . LR39--1 Engine Oil . . . . . . . . . . N / A
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . Dot 3
Brake (Foot) . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
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 . 4.36/1
Turning Radius . . . . . 60” (152.4cm) Gear Reduction-High 2.82/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . 2:1
Ground Clearance . . 6.5” (16.51cm) Center Drive Ratio . . . N/A
Front Vertical Travel 8.2” (20.83cm) Final Drive Ratio . . . . 13/36 76P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 8.8“ (22.35cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . Foxt Gas Charged w/remote res.
Shock Adjustment . . Thread Adjuster
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Accy) . . . . 30 lbs.
Tire Size - Rear . . . . 22 x 11 - 10
Rear Rack (Accy) . . . . 60 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 45.5” (115.57cm) Tow Hitch . . . . . . . . . . . Accy
Total Length . . . . . . . 74.5” (189.23cm)
Total Height . . . . . . . . 47” (119.38cm)
Wheel Base . . . . . . . 48.5” (123.19cm)
Weight - Dry . . . . . . . 519 lbs. (235.6kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041389-067 7041691-067 7041303-067

Option 175 lb/in. Standard 170/210 lb/in. Option 250 lb/in.
Front Strut Spring 7041471-067 7041238-067 7041375-067
Option 41 lb/in. Standard 61 lb/in. Option 64/113 lb/in.

Polaris Sales Inc. 1.27 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . XPLORER 400

MODEL NUMBER: . A99CG38CA
ENGINE MODEL: . . EC38PLE08

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 210 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 35 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 6CEY6-3 Meters

(Feet)
0-900
(0-3000) 240 230 210 195
Needle Jet . . . . . . . . . . . 0-6(480) 900-1800
220 210 195 180
Cutaway . . . . . . . . . . . . 1.5 (3000-6000)

Air Screw . . . . . . . . . . . 1.5 Turn 1800-2700

(6000-9000) 200 190 175 165
Valve Seat . . . . . . . . . . . 2.5 2700-3700
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000) 185 175 160 150

89 Oxygenated - Drop jet needle one position (raise E--Clip)

- Turn air screw in 1/2 to 3/4 turn

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188” (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-900
S -55
S- 55 Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12” (Feet) (0-3000)

Center Distance . . . . . . . . . . 10±.12” (254.5mm) 900-1800

(3000-6000)
S -55
S- 55 Blue/Green 2 -2
2- 2 or 2-
2 -1
1
Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700
Shift Weights . . . . . . . . . . . . S55 (6000-9000)
S Blue/Green 2 -1
2- 1

Primary Spring . . . . . . . . . . . Blue/Green 2700-3700

S Blue/Green 2 -1
2- 1
(9000-12000)
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . Compound
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 378 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.2677” (83mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.7559” (70mm)
Compression Ratio . . . . . . . . . . 6.9/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Oil Injected
Piston / Cylinder Clearance . . . 0.0023 - 0.0037” (0.06 - 0.09mm)
Service Limit . . . . . . . . . . . . . . . . 0.006” (0.15mm)
Piston Marking . . . . . . . . . . . . . . .
Piston Ring End Gap . . . . . . . . .007”-.015” (.18mm-.38mm)
Operating RPM±200 . . . . . . . . . 5700 RPM
Idle RPM±200 . . . . . . . . . . . . . . 600 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.28 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications
MODEL: . . . . . . . . . . . . XPLORER 400
MODEL NUMBER: . . . A99CG38CA
ENGINE MODEL: . . . . EC38PLE08
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 4 gals. (15.1L)
CDI Marking . . . . . . . CU2510 Injector Oil . . . . . . . . . . 2 qts. (1.9L) . . PP2*
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 23.5° BTDC@3000RPM±1.5° Transmission . . . . . . . 16 oz. (473ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028” (0.7mm) Gearcase Oil (Front) . 3.25 oz. . . . . . 80-90 GL5
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. . 3.3 oz. (100ml) 10W30
Voltage Regulator . . LR39--1 Engine Oil . . . . . . . . . . N / A
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . Standard Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . 520 O-Ring
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.14/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 4.74/1
Turning Radius . . . . . 65” (165.1cm) Gear Reduction-High 3.06/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . 2:1
Ground Clearance . . 7.5” (19.05cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7” (17.02cm) Final Drive Ratio . . . . 13/36 76Pitch Chain
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 9“ (22.86cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 3/8” Bore Gas Charged
Shock Adjustment . . Cam
TIRES
Tire Size - Front . . . . 25 x 8 - 12
Tire Size - Rear . . . . 25 x 11 - 10
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs.
Total Width . . . . . . . . 46” (116.84cm)
Total Length . . . . . . . 81” (205.74cm)
Total Height . . . . . . . . 47” (119.38cm)
Wheel Base . . . . . . . 49.75” (126.37cm)
Weight - Dry . . . . . . . 588 lbs. (266.95kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041518-067 7041204-067 7041303-067

Option 175 lb/in. Standard 190 lb/in. Option 250 lb/in.
Front Strut Spring 7041238-067 7041375--195 7041450-067
Option 61 lb/in. Standard 64/113 lb/in. Option 101 lb/in.

Polaris Sales Inc. 1.29 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . SCRAMBLER 500

MODEL NUMBER: . A99BG50AA
ENGINE MODEL: . . EH50PLE04

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 40 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 155 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 6H25--94--3 Meters

(Feet)
0-900
(0-3000) 167 5
167.5 160 155 147 5
147.5
Needle Jet . . . . . . . . . . . Y--O 900-1800
160 155 147 5
147.5 142 5
142.5
Throttle Valve . . . . . . . . #120 (3000-6000)

Pilot Screw . . . . . . . . . . 2.0 1800-2700

(6000-9000) 152 5
152.5 147 5
147.5 142 5
142.5 135
Pilot Air Jet . . . . . . . . . . 1.3 2700-3700
Valve Seat . . . . . . . . . . . 1.5 (9000-12000) 145 140 135 130

Fuel Octane (R+M/2) . 87 Non-Oxygenated or - Pilot screw in 1/2 turn

89 Oxygenated
- Pilot screw out 1/2 turn

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188” (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-900
10WH Blue/Green 1 -1
1- 1
Outside Circumference . . . . 40.86 ±.12” (Feet) (0-3000)

Center Distance . . . . . . . . . . 10±.12” (254.5mm) 900-1800

(3000-6000)
10WH Blue/Green 2 -1
2- 1
Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700
Shift Weights . . . . . . . . . . . . 10WH (6000-9000)
10RH Blue/Green 1 -1
1- 1

Primary Spring . . . . . . . . . . . Blue/Green 2700-3700

10RH Blue/Green 2 -1
2- 1
(9000-12000)
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . 40°
Spring Position (Helix) . . . . 1
Spring Position (Sheave) . . 1

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 499 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.6248” (92mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.955” (75mm)
Compression Ratio . . . . . . . . . . 10/2 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Dry Sump
Piston / Cylinder Clearance . . . 0.0006 - 0.0018” (0.015 - 0.046mm)
Service Limit . . . . . . . . . . . . . . . . 0.0024” (0.061mm)
Piston Marking . . . . . . . . . . . . . . .
Piston Ring End Gap . . . . . . . . .008”-.015” (.20mm-.38mm)
Operating RPM±200 . . . . . . . . . 6500 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.30 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . . . SCRAMBLER 500

MODEL NUMBER: . . . A99BG50AA
ENGINE MODEL: . . . . EH50PLE04

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 3.5 gals. (13.2L)
CDI Marking . . . . . . . CU2544 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 250 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 16 oz. (473ml) PPS*
Spark Plug / Gap . . . NGK BKR6E / 0.028” (0.7mm) Gearcase Oil (Front) . 4.0 oz. . . . . . . . 80-90 GL5
Lights: Head (Twin) Halogen 30/30 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 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . Dot 3
Brake (Foot) . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
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 . 4.74/1
Turning Radius . . . . . 60” (152.4cm) Gear Reduction-High 3.06/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . 2:1
Ground Clearance . . 6.5” (16.51cm) Center Drive Ratio . . . N/A
Front Vertical Travel 8.2” (20.83cm) Final Drive Ratio . . . . 13/36 76P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 8.8“ (22.35cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . Foxt Gas Charged w/remote res
Shock Adjustment . . Thread Adjuster
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Accy) . . . . 30 lbs.
Tire Size - Rear . . . . 22 x 11 - 10
Rear Rack (Accy) . . . . 60 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 45.5” (115.57cm) Tow Hitch . . . . . . . . . . . Accy
Total Length . . . . . . . 74.5” (189.23cm)
Total Height . . . . . . . . 47” (119.38cm)
Wheel Base . . . . . . . 48.5” (123.19cm)
Weight - Dry . . . . . . . 542 lbs. (246.1kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041389-067 7041691-067 7041303-067

Option 175 lb/in. Standard 170/210 lb/in. Option 250 lb/in.
Front Strut Spring 7041548-067 7041503-215 7041647-067
Option 75/100 lb/in. Standard 75/110 lb/in. Option 80/120 lb/in.

Polaris Sales Inc. 1.31 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . MAGNUM 500

MODEL NUMBER: . A99CD50AA
ENGINE MODEL: . . EH50PLE08

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 157.5 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 4HB40-2 Meters

(Feet)
0-900
(0-3000) 170 165 157 5
157.5 152 5
152.5
Needle Jet . . . . . . . . . . . Q-O 900-1800
165 160 155 147 5
147.5
Throttle Valve . . . . . . . . #100 (3000-6000)

Pilot Screw . . . . . . . . . . 2 5/8 Turns Out 1800-2700

(6000-9000) 162 5
162.5 155 150 145
Pilot Air Jet . . . . . . . . . . 160 2700-3700
Valve Seat . . . . . . . . . . . 1.5 (9000-12000) 157 5
157.5 150 145 140

Fuel Octane (R+M/2) . 87 Non-Oxygenated or - Pilot screw in 1/2 turn

89 Oxygenated

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211069 Shift Clutch Driven
Altitude
Belt Width (Projected) . . . . . 1.188” (30.18mm) Weight Spring Helix

Side Angle (Overall) . . . . . . 26° Meters

(Feet)
0-900
(0-3000)
10MH Blue/Green EBS
Outside Circumference . . . . 40.86 ±.12” 900-1800
10BH Blue/Green EBS
Center Distance . . . . . . . . . . 10±.12” (254.5mm) (3000-6000)

Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700

(6000-9000)
10WH Blue/Green EBS
Shift Weights . . . . . . . . . . . . 10MH 2700-3700
Primary Spring . . . . . . . . . . . Blue/Green (9000-12000)
10RH Blue/Green EBS

Secondary Spring . . . . . . . . White w/Green Stripe * EBS requires no helix adjustment

Driven Helix . . . . . . . . . . . . . Compound (EBS)

Spring Position (Helix) . . . . N/A
Spring Position (Sheave) . . N/A

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 498 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.6248” (92mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.955” (75mm)
Compression Ratio . . . . . . . . . . 10/2 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Dry Sump
Piston / Cylinder Clearance . . . 0.0006 - 0.0018” (0.015 - 0.046mm)
Service Limit . . . . . . . . . . . . . . . . 0.0024” (0.061mm)
Piston Marking . . . . . . . . . . . . . . .
Piston Ring End Gap . . . . . . . . .008”-.015” (.20mm-.38mm)
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.32 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . . . MAGNUM 500

MODEL NUMBER: . . . A99CD50AA
ENGINE MODEL: . . . . EH50PLE08

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 3.75 gals. (14.2L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 250 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 13.5 oz.(400 ml)PPS*
Spark Plug / Gap . . . NGK BKR5E / 0.028” (0.7mm) Gearcase Oil (Front) . 5. oz (150ml) . 80-90 GL5
Lights: Head . . . . . . Halogen 60/60 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . 10.0 oz. (300ml)80-90 GL5
Brake . . . . . . 26.9 watts Engine Counter Bal. . N / A . . . . . . . . .
Voltage Regulator . . LR39 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . Standard Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . N/A
Front Suspension . . MacPherson Strut Gear Reduction-Low . 7.46/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 5.12/1
Turning Radius . . . . . 65” (165.1cm) Gear Reduction-High 3.3/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . 3.7/1 (Shaft)
Ground Clearance . . 7.25” (18.42cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7” (17.02cm) Final Drive Ratio . . . . 3.1/1 (Shaft)
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 6.5“ (16.51cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2” Gas Charged Mono
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 25 x 8 - 12 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 25 x 11 - 10
Rear Rack (Std) . . . . . . 180 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46” (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81” (205.74cm)
Total Height . . . . . . . . 47” (119.38cm)
Wheel Base . . . . . . . 49.75” (126.37cm)
Weight - Dry . . . . . . . 647 lbs. (293.7kg)

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring 7041777-067 7041778-067

Standard 125 lb/in. Option 150 lb/in.
Front Strut Spring 7041375-067

Polaris Sales Inc. 1.33 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . SPORTSMAN 500 / SPORTSMAN 500 RSE*

MODEL NUMBER: . A99CH50AA/AB/AC
ENGINE MODEL: . . EH50PLE09

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 155 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 4HB41-3 Meters

(Feet)
0-900
(0-3000) 167 5
167.5 162 5
162.5 155 150
Needle Jet . . . . . . . . . . . Q-0 900-1800
162 5
162.5 157 5
157.5 152 5
152.5 145
Throttle Valve . . . . . . . . #100 (3000-6000)

Pilot Screw . . . . . . . . . . 2 5/8 Turns Out 1800-2700

(6000-9000) 160 152 5
152.5 147 5
147.5 142 5
142.5
Pilot Air Jet . . . . . . . . . . 160 2700-3700
Valve Seat . . . . . . . . . . . 1.5 (9000-12000) 155 147 5
147.5 142 5
142.5 137 5
137.5

Fuel Octane (R+M/2) . 87 Non-Oxygenated or - Pilot screw in 1/2 turn

89 Oxygenated

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211069 Shift Clutch Driven
Altitude
Belt Width (Projected) . . . . . 1.188” (30.18mm) Weight Spring Helix

Side Angle (Overall) . . . . . . 26° Meters

(Feet)
0-900
(0-3000)
10MH Blue/Green EBS
Outside Circumference . . . . 40.86 ±.12” 900-1800
10BH Blue/Green EBS
Center Distance . . . . . . . . . . 10±.12” (254.5mm) (3000-6000)

Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700

(6000-9000)
10WH Blue/Green EBS
Shift Weights . . . . . . . . . . . . 10MH 2700-3700
Primary Spring . . . . . . . . . . . Blue/Green (9000-12000)
10RH Blue/Green EBS

Secondary Spring . . . . . . . . White w/Green Stripe * EBS requires no helix adjustment

Driven Helix . . . . . . . . . . . . . Compound (EBS)

Spring Position (Helix) . . . . N/A
Spring Position (Sheave) . . N/A

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 498 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.625” (92mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.955” (75mm)
Compression Ratio . . . . . . . . . . 10/2 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Dry Sump
Piston / Cylinder Clearance . . . 0.0006 - 0.0018” (0.015 - 0.046mm)
Service Limit . . . . . . . . . . . . . . . . 0.0024” (0.061mm)
Piston Marking . . . . . . . . . . . . . . .
Piston Ring End Gap . . . . . . . . .008”-.015” (.20mm-.38mm)
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

*Remingtont Special Edition

4/99 1.34 Polaris Sales Inc.

 GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . . . SPORTSMAN 500 / SPORTSMAN 500 RSE*

MODEL NUMBER: . . . A99CH50AA/AB/AC
ENGINE MODEL: . . . . EH50PLE09

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 5.25 gals. (19.9L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 250 Watts Coolant . . . . . . . . . . . . 2.25 qts. . . . . . PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 32 oz. . . . . . . . PPS*
Spark Plug / Gap . . . NGK BKR5E / 0.028” (0.7mm) Gearcase Oil (Front) . 3.25 oz. . . . . . 80-90 GL5
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 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . Dot 3
Brake (Foot) . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
Lubricant Key
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . Shaft Drive
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.69/1
Tow Capacity . . . . . . 1225 lbs. (556.2kg) Gear Reduction-Rev . 5.17/1
Turning Radius . . . . . 65” (165.1cm) Gear Reduction-High 3.34/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . 2/1
Ground Clearance . . 11” (27.94cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.25” (15.88cm) Final Drive Ratio . . . . 3.16/1
Rear Suspension . . . Progressive Rate Independent Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 9.5“ (24.13cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 1 3/8” Bore Gas Bag
Shock Adjustment . . Cam
TIRES
Tire Size - Front . . . . 25 x 8 - 12
Tire Size - Rear . . . . 25 x 11 - 10
Tire Size - Center . . N/A
Tire Pressure - F/R . 5/5 lbs.
Total Width . . . . . . . . 46” (116.84cm)
Total Length . . . . . . . 85” (215.9cm)
Total Height . . . . . . . . 47” (119.38cm)
Wheel Base . . . . . . . 50.50” (128.27cm)
Weight - Dry . . . . . . . 697 lbs. (316.4kg)
Weight - Dry (RSE) . 730 lbs. (331.4kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring N/A 7041453-067 7041519-067

Standard 100 lb/in. Option 140 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
Option 61 lb/in. Standard 64/113 lb/in. Option 101 lb/in.

*Remingtont Special Edition

Polaris Sales Inc. 1.35 4/99

GENERAL INFORMATION
1999 Model Specifications

MODEL: . . . . . . . . . . 500 6X6

MODEL NUMBER: . A99AE50AA
ENGINE MODEL: . . EH50PLE06

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 140 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 4D33-3 Meters

(Feet)
0-900
(0-3000) 150 145 140 135
Needle Jet . . . . . . . . . . . Q-6 900-1800
145 140 135 130
Throttle Valve . . . . . . . . #100 (3000-6000)

Pilot Screw . . . . . . . . . . 2 1800-2700

(6000-9000) 137 5
137.5 135 130 122 5
122.5
Pilot Air Jet . . . . . . . . . . 160 2700-3700
Valve Seat . . . . . . . . . . . 1.5 (9000-12000) 132 5
132.5 127 5
127.5 122 5
122.5 117 5
117.5

Fuel Octane (R+M/2) . 87 Non-Oxygenated or - Pilot screw in 1/2 turn

89 Oxygenated

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 Shift Clutch Driven
Altitude
Belt Width (Projected) . . . . . 1.188” (30.18mm) Weight Spring Helix

Side Angle (Overall) . . . . . . 26° Meters

(Feet)
0-900
(0-3000)
10MH Blue/Green 22
2-2
Outside Circumference . . . . 40.86 ±.12” 900-1800
10BH Blue/Green 22
2-2
Center Distance . . . . . . . . . . 10±.12” (254.5mm) (3000-6000)

Clutch Offset . . . . . . . . . . . . 0.5” (12.7mm) 1800-2700

(6000-9000)
10WH Blue/Green 21
2-1
Shift Weights . . . . . . . . . . . . 10MH 2700-3700
Primary Spring . . . . . . . . . . . Blue/Green (9000-12000)
10RH Blue/Green 21
2-1

Secondary Spring . . . . . . . . Red

Driven Helix . . . . . . . . . . . . . Compound
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 498 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.625” (92mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.955” (75mm)
Compression Ratio . . . . . . . . . . 10/2 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Dry Sump
Piston / Cylinder Clearance . . . 0.0006 - 0.0018” (0.015 - 0.046mm)
Service Limit . . . . . . . . . . . . . . . . 0.0024” (0.061mm)
Piston Marking . . . . . . . . . . . . . . .
Piston Ring End Gap . . . . . . . . .008”-.015” (.20mm-.38mm)
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

4/99 1.36 Polaris Sales Inc.

 SPECIFICATIONS
1999 Model Specifications
MODEL: . . . . . . . . . . . . 500 6X6
MODEL NUMBER: . . . A99AE50AA
ENGINE MODEL: . . . . EH50PLE06
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . Refer to Electrical Section Fuel Tank . . . . . . . . . . 3.5 gals. (13.2L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 250 Watts Coolant . . . . . . . . . . . . 2.25 qts. . . . . . PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 20 oz. . . . . . . . PPS*
Spark Plug / Gap . . . NGK BKR5E / 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 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
Lubricant Key
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen II Chain Type . . . . . . . . . 520 O-Ring
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.64/1
Tow Capacity . . . . . . 1225 lbs. (556.2kg) Gear Reduction-Rev . 5.13/1
Turning Radius . . . . . 98” (248.9cm) Gear Reduction-High 3.29/1
Toe Out . . . . . . . . . . . 1/8”-1/4” (3-6.35mm) Front Drive Ratio . . . . 11/22 68P
Ground Clearance . . 5.5” (13.97cm) Center Drive Ratio . . . 11/24 72P
Front Vertical Travel 6.25” (15.88cm) Final Drive Ratio . . . . 12/42 88P
Rear Suspension . . . Swing Arm w/Scissor Stabilizer Axle to Axle . . . . . . . . . 30/30 116P
Rear Travel . . . . . . . . 7.25“ (18.42cm) Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Shock . . . . . . . . 5mm Bore Gas Bag Brake (Auxiliary Foot) Hydraulic
Shock Adjustment . . Cam
Center Suspension . Progressive Rate Swing Arm
Center Travel . . . . . . 5” (12.7cm) LOAD CAPACITY
Center Shock . . . . . . 1” Bore
Shock Adjustment . . Cam Front Rack (Accy) . . . . 75 lbs.
TIRES Rear Rack (Accy) . . . . 125 lbs.
Tire Size - Front . . . . 25 x 8 - 12 Tongue Weight (Accy) . 30 lbs.
Tire Size - Rear . . . . 25 x 11 - 10 Tow Hitch . . . . . . . . . . . Std
Tire Size - Center . . 25 x 11 - 10
Tire Pressure - F/R . 5/5/5 lbs.
Total Width . . . . . . . . 46” (116.84cm)
Total Length . . . . . . . 103” (261.62cm)
Total Height . . . . . . . . 47” (119.38cm)
Wheel Base . . . . . . . 75” (190.5cm)
Weight - Dry . . . . . . . 870 lbs. (395kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM
Rear Compression Spring N/A 7041303-067 N/A
Standard 250 lb/in.
Mid Compression Spring N/A 7041305-067 N/A
Standard 60 lb/in.
Front Strut Spring

Polaris Sales Inc. 1.37 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

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

MODEL NUMBER: . A00BA25CA
ENGINE MODEL: . . EC25PFE13

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM30SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 130 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

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

(Feet)
0-900
(0-3000) 150 140 130 120
Needle Jet . . . . . . . . . . . 0-4(169) 900-1800
140 130 120 110
Cutaway . . . . . . . . . . . . 2.0 (3000-6000)

Air Screw . . . . . . . . . . . 1.0 Turn 1800-2700

(6000-9000) 125 120 110 100
Valve Seat . . . . . . . . . . . 2.5 2700-3700
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000) 115 110 100 95

89 Oxygenated
- Turn AS out 1/2 -- 3/4 turn CCW from seat
Raise needle clip 1 position to lower jet needle

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188I (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-1800
G Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12I (Feet) (0-6000)

Center Distance . . . . . . . . . . 10±.12I (254.5mm) 1800-3700

(6000-12000)
16 Blue/Green 2 -2
2- 2
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . 40°

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 244 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346I (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622I (60mm)
Compression Ratio . . . . . . . . . . 6.1/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Air
Lubrication Type . . . . . . . . . . . . Oil Injected
Piston Marking . . . . . . . . . . . . . . 3W,4W
Operating RPM±200 . . . . . . . . . 5800 RPM
Idle RPM±200 . . . . . . . . . . . . . . 700 RPM
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.38 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

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

MODEL NUMBER: . . . A00BA25CA
ENGINE MODEL: . . . . EC25PFE13

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . FF45 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±3° Transmission . . . . . . . 11 oz. (325ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028I (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*
*Lubricant
*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 . . . . . 60I (152.4cm) Gear Reduction-High 2.68/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . N/A
Ground Clearance . . 6I (15.24cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 11/38 78P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 8.2I (20.8cm) Brake (Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Gas Charged Mono
Shock Adjustment . . Cam LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10
Tire Size - Rear . . . . 22 x 11 - 10 Front Rack (Accy) . . . . 30 lbs.
Tire Size - Center . . N/A Rear Rack (Accy) . . . . 60 lbs.
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . 30 lbs.
Total Width . . . . . . . . 46.5I (118.11cm)
Tow Hitch . . . . . . . . . . . Accy
Total Length . . . . . . . 74.5I (189.23cm)
Total Height . . . . . . . . 46I (116.84cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry . . . . . . . 440 lbs. (199.76kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041777-067 7041778-067 7041815-067

Option 125 lb/in. Standard 150 lb/in. Option 175 lb/in.
Front Strut Spring N/A 7041850-067 7041375-067
Standard 41 lb/in. Option 64/113 lb/in.

Polaris Sales Inc. 1.39 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . XPLORER 4X4

MODEL NUMBER: . A00AG25CA
ENGINE MODEL: . . EC25PFE12

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM30SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 130 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

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

(Feet)
0-900
(0-3000) 150 140 130 120
Needle Jet . . . . . . . . . . . 0-4(169) 900-1800
140 130 120 110
Cutaway . . . . . . . . . . . . 2.0 (3000-6000)

Air Screw . . . . . . . . . . . 1 Turn 1800-2700

(6000-9000) 125 120 110 100
Valve Seat . . . . . . . . . . . 2.5 2700-3700
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000) 115 110 100 95

89 Oxygenated - Turn air screw out 1/2 turn (counterclockwise)

Raise needle clip 1 position to lower jet needle

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188I (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-1800
G Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12I (Feet) (0-6000)

Center Distance . . . . . . . . . . 10±.12I (254.5mm) 1800-3700

(6000-12000)
16 Blue/Green 2 -2
2- 2
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . 40°

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 244 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346I (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622I (60mm)
Compression Ratio . . . . . . . . . . 6.1/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Air
Lubrication Type . . . . . . . . . . . . Oil Injected
Operating RPM±200 . . . . . . . . . 5800 RPM
Idle RPM±200 . . . . . . . . . . . . . . 700 RPM
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.40 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications
MODEL: . . . . . . . . . . . . XPLORER 4X4
MODEL NUMBER: . . . A00AG25CA
ENGINE MODEL: . . . . EC25PFE12

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . FF45 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±3° Transmission . . . . . . . 32 oz. (947ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028I (0.7mm) Gearcase Oil (Front) . 4 oz. (118ml) . 80-90 GL5
Lights: Head .... 1 Dual Beam 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) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
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 . 3.05/1
Turning Radius . . . . . 60I (152.4cm) Gear Reduction-High 3.34/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 2:01
Ground Clearance . . 6I (15.24cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 12/42 82P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 9I (22.86cm) Brake (Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Gas Charged Twin Tube
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 24 x 11 - 10
Tire Size - Center . . N/A Rear Rack (Std) . . . . . . 180 lbs.
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 45.5I (115.57cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 73I (185.42cm)
Total Height . . . . . . . . 44.5I (113.03cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry . . . . . . . 534 lbs. (234.39kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041518-067 7041877-067 7041303-067

Option 175 lb/in. Standard 160/200 lb/in. Option 250 lb/in.
Front Strut Spring 7041238-067 7041873--067 7041450-067
Option 61 lb/in. Standard 55/105 lb/in. Option 101 lb/in.

Polaris Sales Inc. 1.41 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . TRAIL BOSS 325

MODEL NUMBER: . A00AA32CA/AA
ENGINE MODEL: . . ES32PFE02/04

CARBURETION JETTING CHART-ES32PFE02

Type . . . . . . . . . . . . . . . . BST 31 Mikuni AMBIENT TEMPERATURE
Altitude
Main Jet PFE02 . . . . . . 142.5 Below 40
40°F
Below 5°C
F +40 F to +80
+40_F +80_F
+5_C to +26_C
F

Main Jet PFE04 . . . . . . 145 Meters 0-1800

Pilot Jet . . . . . . . . . . . . . 50 (Feet) (0-6000) 147 5
147.5 142 5
142.5

Jet Needle PFE02 . . . . 5F14-2 above 1800

(above 6000) 140 135
Jet Needle PFE04 . . . . 5F14--3
Needle Jet PFE02 . . . . P-0(829)
Needle Jet PFE04 . . . . P-2(829) JETTING CHART-ES32PFE04
Throttle Valve . . . . . . . . #120 AMBIENT TEMPERATURE
Pilot Screw . . . . . . . . . . 2 Turns Out Altitude Below 40
40°F
F +40 F to +80
+40_F +80_F
F
Pilot Air Jet . . . . . . . . . . 175 Below 5°C +5_C to +26_C

Valve Seat . . . . . . . . . . . 1.5 Meters 0-1800

(0-6000) 150 145
(Feet)
Fuel Octane (R+M/2) . 87 Non-Oxygenated or above 1800
89 Oxygenated (above 6000) 142 5
142.5 137 5
137.5

CLUTCH CLUTCH CHART

Type . . . . . . . . . . . . . . . . . . . . PVT Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 Meters 0-1800
10RH Blue/Green 22
2-2
Belt Width (Projected) . . . . . 1.188I (30.18mm) (Feet) (0-6000)

Side Angle (Overall) . . . . . . 26° 1800-3700

(6000-12000)
16 Mod Blue/Green 22
2-2
Outside Circumference . . . . 40.86 ±.12I * 40_ helix, black driven spring
Center Distance . . . . . . . . . . 10±.12I (254.5mm)
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Secondary Spring . . . . . . . . White w/Green Stripe
Spring Position (Helix) . . . . N/A
Spring Position (Sheave) . . N/A

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 324 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.073I (78mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.679I (68mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ BTDC on compression
Cooling . . . . . . . . . . . . . . . . . . . . Air w/fan assisted oil cooler
Lubrication Type . . . . . . . . . . . . Dry Sump
Piston Marking . . . . . . . . . . . . . . None
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1300 RPM
Compression Ratio . . . . . . . . . . 9.2:1
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.42 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . . . TRAIL BOSS 325

MODEL NUMBER: . . . A00AA32CA/AA
ENGINE MODEL: . . . . ES32PFE02/04

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . F1475ER . . . . . . Fuel Tank . . . . . . . . . . 3.7 gals. (14.0L)
CDI Marking . . . . . . . F8T19271 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . N / A . . . . . . . . .
Ignition Timing . . . . . 30°±2° BTDC@5000RPM Transmission . . . . . . . 11.3 oz. (335 ml)PPS*
Spark Plug / Gap . . . NGK BKR6E / 0.036I (0.9mm) Gearcase Oil (Front) . N / A
Lights: Head . . . . . . Dual Beam 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 . . LR35 Engine Oil . . . . . . . . . . 1.9 qts. (1.8L) PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . N/A Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . N / A
Shift Selector Box . . . N / A

*PP6 Polaris Premium 60/40 Antifreeze/Coolant

*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
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 . 3.05/1
Turning Radius . . . . . 60I (152.4cm) Gear Reduction-High 2.68/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . N/A
Ground Clearance . . 5.5I (13.97cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 11/42 80P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 9.0I (22.86cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Gas Charged Twin Tube
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Accy) . . . . 75 lbs.
Tire Size - Rear . . . . 22 x 11 - 10
Rear Rack (Std) . . . . . . 125 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46.5I (118.11cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 71.5I (181.61cm)
Total Height . . . . . . . . 46I (116.84cm)
Wheel Base . . . . . . . 49.5I (125.73cm)
Weight - Dry . . . . . . . 504 lbs. (228.8kg)

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM
Rear Compression Spring N/A 7041518-067 7041303-067
175 lb/in. 250 lb/in.
Front Strut Spring N/A 7041850-067 7041375-067
41 lb/in. 64 - 113 lb/in.

Polaris Sales Inc. 1.43 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . MAGNUM 325

MODEL NUMBER: . (2x4’s) A00CB32CA - (4x4’s) A00CD32CA
ENGINE MODEL: . . ES32PFE01

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 31 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 142.5 Altitude Below 40
40°F
F +40 F to +80
+40_F +80_F
F
Pilot Jet . . . . . . . . . . . . . 50 Below 5°C +5_C to +26_C

Jet Needle . . . . . . . . . . . 5F14-2 Meters

(Feet)
0-1800
(0-6000) 147 5
147.5 142 5
142.5
Needle Jet . . . . . . . . . . . P-0(829) above 1800
140 135
Throttle Valve . . . . . . . . #120 (above 6000)

Pilot Screw . . . . . . . . . . 2 Turns Out

Pilot Air Jet . . . . . . . . . . 175
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated

CLUTCH CLUTCH CHART

Type . . . . . . . . . . . . . . . . . . . . PVT Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 Meters 0-1800
16 Blue/Green 22
2-2
Belt Width (Projected) . . . . . 1.188I (30.18mm) (Feet) (0-6000)

Side Angle (Overall) . . . . . . 26° 1800-3700

(6000-12000)
16 Mod Blue/Green 22
2-2
Outside Circumference . . . . 40.86 ±.12I * 40_ helix, black driven spring
Center Distance . . . . . . . . . . 10±.12I (254.5mm)
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Shift Weights . . . . . . . . . . . . 10RH
Primary Spring . . . . . . . . . . . Blue/Green
Secondary Spring . . . . . . . . White w/Green Stripe
Driven Helix . . . . . . . . . . . . . 2--2
Spring Position (Helix) . . . . N/A
Spring Position (Sheave) . . N/A

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 324 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.073I (78mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.679I (68mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Cooling . . . . . . . . . . . . . . . . . . . . Air w/fan assisted oil cooler
Lubrication Type . . . . . . . . . . . . Dry Sump
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1300 RPM
Compression Ratio . . . . . . . . . . 9.2:1
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.44 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . . . MAGNUM 325

MODEL NUMBER: . . . (2x4’s) A00CB32CA - (4x4’s) A00CD32CA
ENGINE MODEL: . . . . ES32PFE01

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . F1475ER Fuel Tank . . . . . . . . . . 3.75 gals. (14.2L)
CDI Marking . . . . . . . F8T19271 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . N / A . . . . . . . . .
Ignition Timing . . . . . 30°±2° BTDC@5000RPM Transmission . . . . . . . 13.5 oz. (400 ml)PPS*
Spark Plug / Gap . . . NGK BKR6E / 0.036I (0.9mm) Gearcase Oil (Front) . 5 oz. (150 ml) 80-90 Lube
Lights: Head . . . . . . 2 Single Beam/30 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . 10 oz. (300ml) 80-90 Lube
Brake . . . . . . 26.9 watts Engine Counter Bal. . N / A . . . . . . . . .
Voltage Regulator . . LR35 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . N/A Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75 ml) PDD*
Shift Selector Box . . . 1 oz. (30 ml) . PP4*

*PP6 Polaris Premium 60/40 Antifreeze/Coolant

*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . N/A
Front Suspension . . MacPherson Strut Gear Reduction-Low . 7.46/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 5.12/1
Turning Radius . . . . . 65I (165.1cm) Gear Reduction-High 3.3/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 3.7/1 (Shaft)
Ground Clearance . . 7.25I (18.42cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 3.1/1 (Shaft)
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 6.5I (16.51cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Gas Charged Mono
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 24 x 8 - 12 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 24 x 11.5 - 10
Rear Rack (Std) . . . . . . 180 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46I (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81I (205.74cm)
Total Height . . . . . . . . 46I (116.84cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry (2x4) . . 574 lbs. (260.5kg)
Weight - Dry (4x4) . . 620 lbs. (281.4kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM
Rear Compression Spring 7041777-067 7041849-067 7041815-067
125 lb/in. 125 - 180 lb/in. 175 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
61 lb/in. 64 - 113 lb/in. 101 lb/in.

Polaris Sales Inc. 1.45 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . MAGNUM 325

MODEL NUMBER: . (2x4’s) A00CB32CA & A00CB32AA - (4x4’s) A00CD32CA & A00CD32AA
ENGINE MODEL: . . ES32PFE04 & ES32PFE05

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 31 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 145 Altitude Below 40
40°F
F +40 F to +80
+40_F +80_F
F
Pilot Jet . . . . . . . . . . . . . 50 Below 5°C +5_C to +26_C

Jet Needle . . . . . . . . . . . 5F14-3 Meters

(Feet)
0-1800
(0-6000) 150 145
Needle Jet . . . . . . . . . . . P-2(829) above 1800
142 5
142.5 137 5
137.5
Throttle Valve . . . . . . . . #120 (above 6000)

Pilot Screw . . . . . . . . . . 2 Turns Out

Pilot Air Jet . . . . . . . . . . 175
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated

CLUTCH CLUTCH CHART

Type . . . . . . . . . . . . . . . . . . . . PVT Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 Meters 0-1800
16 Blue/Green 22
2-2
Belt Width (Projected) . . . . . 1.188I (30.18mm) (Feet) (0-6000)

Side Angle (Overall) . . . . . . 26° 1800-3700

(6000-12000)
16 Mod Blue/Green 22
2-2
Outside Circumference . . . . 40.86 ±.12I * compound helix, black driven spring
Center Distance . . . . . . . . . . 10±.12I (254.5mm)
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Shift Weights . . . . . . . . . . . . 10RH
Primary Spring . . . . . . . . . . . Blue/Green
Secondary Spring . . . . . . . . White w/Green Stripe
Driven Helix . . . . . . . . . . . . . 2--2
Spring Position (Helix) . . . . N/A
Spring Position (Sheave) . . N/A

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 324 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.073I (78mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.679I (68mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Cooling . . . . . . . . . . . . . . . . . . . . Air w/fan assisted oil cooler
Lubrication Type . . . . . . . . . . . . Dry Sump
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1300 RPM
Compression Ratio . . . . . . . . . . 9.2:1
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.46 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . . . MAGNUM 325

MODEL NUMBER: . . . (2x4’s) A00CB32CA & A00CB32AA - (4x4’s) A00CD32CA & A00CD32AA
ENGINE MODEL: . . . . ES32PFE04 & ES32PFE05

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . F1475ER Fuel Tank . . . . . . . . . . 3.75 gals. (14.2L)
CDI Marking . . . . . . . F8T19271 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . N / A . . . . . . . . .
Ignition Timing . . . . . 30°±2° BTDC@5000RPM Transmission . . . . . . . 13.5 oz. (400 ml)PPS*
Spark Plug / Gap . . . NGK BKR6E / 0.036I (0.9mm) Gearcase Oil (Front) . 5 oz. (150 ml) 80-90 Lube
Lights: Head . . . . . . 2 Single Beam/30 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . 10 oz. (300ml) 80-90 Lube
Brake . . . . . . 26.9 watts Engine Counter Bal. . N / A . . . . . . . . .
Voltage Regulator . . LR35 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . N/A Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75 ml) PDD*
Shift Selector Box . . . 1 oz. (30 ml) . PP4*

*PP6 Polaris Premium 60/40 Antifreeze/Coolant

*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . N/A
Front Suspension . . MacPherson Strut Gear Reduction-Low . 7.46/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 5.12/1
Turning Radius . . . . . 65I (165.1cm) Gear Reduction-High 3.3/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 3.7/1 (Shaft)
Ground Clearance . . 7.25I (18.42cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 3.1/1 (Shaft)
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 6.5I (16.51cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Gas Charged Mono
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 24 x 8 - 12 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 24 x 11.5 - 10
Rear Rack (Std) . . . . . . 180 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46I (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81I (205.74cm)
Total Height . . . . . . . . 46I (116.84cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry (2x4) . . 574 lbs. (260.5kg)
Weight - Dry (4x4) . . 620 lbs. (281.4kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM
Rear Compression Spring 7041777-067 7041849-067 7041815-067
125 lb/in. 125 - 180 lb/in. 175 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
61 lb/in. 64 - 113 lb/in. 101 lb/in.

Polaris Sales Inc. 1.47 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . XPEDITION 325

MODEL NUMBER: . A00CK32AA
ENGINE MODEL: . . ES32PLE03

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 31 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 152.5 Altitude Below 40
40°F
F +40 F to +80
+40_F +80_F
F
Below 5°C +5_C to +26_C
Pilot Jet . . . . . . . . . . . . . 47.5 Meters 0-1800
Jet Needle . . . . . . . . . . . 4HB40-3 (Feet) (0-6000) 157 5
157.5 152 5
152.5
Needle Jet . . . . . . . . . . . P-0(829) above 1800
150 145
(above 6000)
Throttle Valve . . . . . . . . #120
Pilot Screw . . . . . . . . . . TBD
Pilot Air Jet . . . . . . . . . . 100
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 325 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.071I (78mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.677I (68mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Cooling . . . . . . . . . . . . . . . . . . . . Air
Lubrication Type . . . . . . . . . . . . Wet Sump
Piston Marking . . . . . . . . . . . . . . None
Operating RPM±200 . . . . . . . . . 6500 RPM
Idle RPM±200 (lights off) . . . . . 1350 RPM
Compression Ratio . . . . . . . . . . 9.2:1
Compression Pressure . . . . . . . (Std) ±15%

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style . . . . . . . . Gen IV Gear 1 Ratio . . . . . . . . . . . . . . . 4.182
Front Suspension . . MacPherson Strut Gear 2 Ratio . . . . . . . . . . . . . . . 2.562
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear 3 Ratio . . . . . . . . . . . . . . . 1.522
Turning Radius . . . . . 65I (165.1cm) Gear 4 Ratio . . . . . . . . . . . . . . . 1.111
Toe Out (Total) . . . . . 1/8I-1/4I (3-6.35mm) Gear 5 Ratio . . . . . . . . . . . . . . . 0.813
Ground Clearance . . 7.25I (18.42cm) Reverse . . . . . . . . . . . . . . . . . . . 4.128
Front Vertical Travel 6.7I (17.02cm) Primary . . . . . . . . . . . . . . . . . . . 2.655
Rear Suspension . . . Progressive Rate Swing Arm Secondary (at chain) . . . . . . . . 1.333
Rear Travel . . . . . . . . 7.0I (17.78cm) Secondary (at bevel drive) . . . 1.313
Rear Shock . . . . . . . . 1-5/8I Gas Charged Twintube Front Drive Ratio . . . . . . . . . . . 3.7/1 (Shaft)
Shock Adjustment . . Cam Final Drive Ratio . . . . . . . . . . . 3.1/1 (Shaft)
Brake (Hand) . . . . . . . . . . . . . . S/L Hyd. Disc
Brake (Auxiliary Foot) . . . . . . . Hydraulic

Polaris Sales Inc. 1.48 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . . . XPEDITION 325

MODEL NUMBER: . . . A00CK32AA
ENGINE MODEL: . . . . ES32PLE03

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . F4T757 Fuel Tank . . . . . . . . . . 3.75 gals. (14.9L)
CDI Marking . . . . . . . F8T19271 Injector Oil . . . . . . . . . . N / A
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . N / A
Ignition Timing . . . . . 30° BTDC@3500RPM±2° Transmission . . . . . . . N / A
Spark Plug / Gap . . . NGK BKR6E / 0.036I (0.9mm) Gearcase Oil (Front) . 5 oz. (150 ml) 80-90 GL5
Lights: Head . . . . . . (2) Dual beam 30/30 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . 10 oz. (300 ml) 80-90 GL5
Brake . . . . . . 26.9 watts Engine Counter Bal. . N / A . . . . . . . . .
Voltage Regulator . . LR39 Engine Oil . . . . . . . . . . 4.5 qts. (4.25L) PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . Accessory Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75 ml) PDD*
Shift Selector Box . . . N / A

*PP6 Polaris Premium 60/40 Antifreeze/Coolant

*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid

TIRES LOAD CAPACITY

Tire Size - Front . . . . 24 x 8 - 12 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 24 x 11.5 - 10
Tire Size - Center . . N/A Rear Rack (Std) . . . . . . 180 lbs.
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46I (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81I (205.74cm)
Total Height . . . . . . . . 47I (119.38cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry . . . . . . . 635 lbs. (288kg)

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring 7041777-067 7041849-067 7041815-067

125 lb/in. 125 - 180 lb/in. 175 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
61 lb/in. 64 - 113 lb/in. 101 lb/in.

Polaris Sales Inc. 1.49 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . SPORTSMAN 335

MODEL NUMBER: . A00CH33AA/AB(CALIF. APPROVED)
ENGINE MODEL: . . ES33PFE02(CALIF. APPROVED)

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 150 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 5F14--3 Meters

(Feet)
0-900
(0-3000) 162 5
162.5 155 150 145
Needle Jet . . . . . . . . . . . P-9 900-1800
155 150 145 137 5
137.5
Throttle Valve . . . . . . . . #100 (3000-6000)

Pilot Screw . . . . . . . . . . 2.5 Turns Out 1800-2700

(6000-9000) 150 145 137 5
137.5 132 5
132.5
Pilot Air Jet . . . . . . . . . . 160 2700-3700
Valve Seat . . . . . . . . . . . 1.5 (9000-12000) 142 5
142.5 137 5
137.5 130 125

Fuel Octane (R+M/2) . 87 Non-Oxygenated or - Pilot screw in 1/2 turn

89 Oxygenated

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 Shift Clutch Driven
Altitude
Belt Width (Projected) . . . . . 1.188I (30.18mm) Weight Spring Helix

Side Angle (Overall) . . . . . . 26° Meters

(Feet)
0-900
(0-3000)
16 Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12I 900-1800
16 Blue/Green 2 -1
2- 1
Center Distance . . . . . . . . . . 10±.12I (254.5mm) (3000-6000)

Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm) 1800-2700

(6000-9000)
16 Mod Blue/Green 2 -2
2- 2
Shift Weights . . . . . . . . . . . . 16 2700-3700
Primary Spring . . . . . . . . . . . Blue/Green (9000-12000)
16 Mod Blue/Green 2 -2
2- 2

Secondary Spring . . . . . . . . Red

Driven Helix . . . . . . . . . . . . . Compound
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 334 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.0732I (78mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.758I (70mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Compression Ratio . . . . . . . . . . 9.2/1 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Air W/ Oil Cooler Assist
Lubrication Type . . . . . . . . . . . . Dry Sump
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.50 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . . . SPORTSMAN 335

MODEL NUMBER: . . . A00CH33AA/AB(CALIF. APPROVED)
ENGINE MODEL: . . . . ES33PFE02(CALIF. APPROVED)
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . FF97 Fuel Tank . . . . . . . . . . 3.75 gals. (14.2L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . N / A
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 32 oz. . . . . . . . PPS*
Spark Plug / Gap . . . NGK BKR7E / 0.028I (0.7mm) Gearcase Oil (Front) . 4 oz. (120ml) . 80-90 GL5
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 Engine Oil . . . . . . . . . . 2.25 qts. (2.1L) PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style . . . . . . . . Gen IV Drive Type . . . . . . . . . . Shaft Drive
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.89/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 5.17/1
Turning Radius . . . . . 65I (165.1cm) Gear Reduction-High 3.56/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 2:1
Ground Clearance . . 10.25I (26.04cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.25I (15.88cm) Final Drive Ratio . . . . 3.16:1
Rear Suspension . . . Progressive Rate Independent Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 9.5I (24.13cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 1I Bore Gas Bag
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 24 x 11 - 10
Tire Size - Center . . N/A Rear Rack (Std) . . . . . . 180 lbs.
Tire Pressure - F/R . 5/5 lbs. Tongue Weight . . . . 30 lbs.
Total Width . . . . . . . . 46I (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81I (205.74cm)
Total Height . . . . . . . . 46I (118.22cm)
Wheel Base . . . . . . . 50.50I (128.27cm)
Weight - Dry . . . . . . . 670 lbs. (304.2kg)

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring N/A 7041453-067 7041519-067

Standard 100 lb/in. Option 140 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
Option 61 lb/in. Standard 64/113 lb/in. Option 101 lb/in.

Polaris Sales Inc. 1.51 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . XPLORER 400

MODEL NUMBER: . A00CG38CA
ENGINE MODEL: . . EC38PLE08

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 210 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 35 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 6CEY6-3 Meters

(Feet)
0-900
(0-3000) 240 230 210 195
Needle Jet . . . . . . . . . . . 0-6(480) 900-1800
220 210 195 180
Cutaway . . . . . . . . . . . . 1.5 (3000-6000)

Air Screw . . . . . . . . . . . 1.5 Turn 1800-2700

(6000-9000) 200 190 175 165
Valve Seat . . . . . . . . . . . 2.5 2700-3700
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (9000-12000) 185 175 160 150

89 Oxygenated - Drop jet needle one position (raise E--Clip)

- Turn air screw in 1/2 to 3/4 turn

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188I (30.18mm) Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Side Angle (Overall) . . . . . . 26° Meters 0-1800
S55 Blue/Green 2 -2
2- 2
Outside Circumference . . . . 40.86 ±.12I (Feet) (0-6000)

Center Distance . . . . . . . . . . 10±.12I (254.5mm) 1800-3700

(6000-12000)
S Blue/Green 2--1
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . Compound

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 378 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.2677I (83mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.7559I (70mm)
Compression Ratio . . . . . . . . . . 6.9/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Oil Injected
Operating RPM±200 . . . . . . . . . 5700 RPM
Idle RPM±200 . . . . . . . . . . . . . . 600 RPM
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.52 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications
MODEL: . . . . . . . . . . . . XPLORER 400
MODEL NUMBER: . . . A00CG38CA
ENGINE MODEL: . . . . EC38PLE08
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . FF95 Fuel Tank . . . . . . . . . . 4 gals. (15.1L)
CDI Marking . . . . . . . CU2510 Injector Oil . . . . . . . . . . 2 qts. (1.9L) . . PP2*
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 23.5° BTDC@3000RPM±1.5° Transmission . . . . . . . 16 oz. (473ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028I (0.7mm) Gearcase Oil (Front) . 4 oz (118ml) . . 80-90 GL5
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. . 3.3 oz. (100ml) 10W30
Voltage Regulator . . LR39--1 Engine Oil . . . . . . . . . . N / A
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . Standard Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . 520 O-Ring
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.14/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 4.74/1
Turning Radius . . . . . 65I (165.1cm) Gear Reduction-High 3.06/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 2:1
Ground Clearance . . 7.5I (19.05cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 13/36 76Pitch Chain
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 9I (22.86cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Gas Charged Twintube
Shock Adjustment . . Cam
TIRES
Tire Size - Front . . . . 25 x 8 - 12
Tire Size - Rear . . . . 25 x 11 - 10
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs.
Total Width . . . . . . . . 46I (116.84cm)
Total Length . . . . . . . 81I (205.74cm)
Total Height . . . . . . . . 47I (119.38cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry . . . . . . . 588 lbs. (266.95kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041518-067 7041204-067 7041303-067

Option 175 lb/in. Standard 190 lb/in. Option 250 lb/in.
Front Strut Spring 7041238-067 7041375--067 7041450-067
Option 61 lb/in. Standard 64/113 lb/in. Option 101 lb/in.

Polaris Sales Inc. 1.53 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . SCRAMBLER 400 2x4

MODEL NUMBER: . A00BA38CA
ENGINE MODEL: . . EC38PLE09

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 230 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 35 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 6CEY6-3 Meters

(Feet)
0-900
0 900
(0-3000)
(0 3000)
270 MJ 250 MJ 230 MJ** 210 MJ
0.5 AS 1.0 AS 1.5 AS 1.5 AS
Needle Jet . . . . . . . . . . . 0-6(480) 900-1800
900 1800 250 MJ 230 MJ 210 MJ 195 MJ
Cutaway . . . . . . . . . . . . 1.5 (3000-6000)
(3000 6000)
0.5 AS 1.0 AS 1.5 AS 1.75 AS
Air Screw . . . . . . . . . . . 1.5 Turn 1800-2700
1800 2700 220 MJ 210 MJ 195 MJ 175 MJ
Valve Seat . . . . . . . . . . . 2.5 (6000-9000)
(6000 9000)
1.5 AS 1.5 AS 1.75 AS 1.75 AS
Fuel Octane (R+M/2) . 87 Non-Oxygenated or 2700-3700
2700 3700
(9000-12000)
(9000 12000)
200 MJ 190 MJ 175 MJ 160 MJ
1.5 AS 1.75 AS 1.75 AS 1.75 AS
89 Oxygenated
MJ = Main Jet
AS = Air Screw (Turns Out)
** For 87 Octane Oxygenated Fuel Refer to jetting recommendation
CLUTCH in Fuel System / Carburetion section.

Type . . . . . . . . . . . . . . . . . . . . PVT
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188I (30.18mm) CLUTCH CHART
Side Angle (Overall) . . . . . . 26°
Outside Circumference . . . . 40.86 ±.12I Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Center Distance . . . . . . . . . . 10±.12I (254.5mm) Meters 0-1800
S55 White 22
2-2
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm) (Feet) (0-6000)

Secondary Spring . . . . . . . . Red 1800-3700

(6000-12000)
S White 21
2-1
Driven Helix . . . . . . . . . . . . . 40°
Spring Position (Helix) . . . . 2 40 ° Helix, Red Driven
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 378 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.2677I (83mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.7559I (70mm)
Compression Ratio . . . . . . . . . . 6.9/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Oil Injected
Piston Marking . . . . . . . . . . . . . . .
Operating RPM±200 . . . . . . . . . 5700 RPM
Idle RPM±200 . . . . . . . . . . . . . . 600 RPM
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.54 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications
MODEL: . . . . . . . . . . . . SCRAMBLER 400 2x4
MODEL NUMBER: . . . A00BA38CA
ENGINE MODEL: . . . . EC38PLE09
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . FF95 Fuel Tank . . . . . . . . . . 4 gals. (15.1L)
CDI Marking . . . . . . . CU2515 Injector Oil . . . . . . . . . . 2 qts. (1.9L) . . PP2*
Alternator Output . . . 150 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 23.5° BTDC@3000RPM±3° Transmission . . . . . . . 11 oz. (325ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028I (0.7mm) Gearcase Oil (Front) . 4 oz (118ml) . . 80-90 GL5
Lights: Head . . . . . . Halogen 30/30 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . N / A
Brake . . . . . . 26.9 watts Engine Counter Bal. . 100ml . . . . . . . 10W30
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*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
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 . . . . . 60I (152.4cm) Gear Reduction-High 2.68/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . N/A
Ground Clearance . . 5.5I (13.97cm) Center Drive Ratio . . . N/A
Front Vertical Travel 8.2I (20.83cm) Final Drive Ratio . . . . 13/36 76P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 10.5I (26.67cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Gas Charged Mono Tube
Shock Adjustment . . Thread Adjuster
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Accy) . . . . 30 lbs.
Tire Size - Rear . . . . 22 x 11 - 10
Rear Rack (Accy) . . . . 60 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46.5I (118.11cm) Tow Hitch . . . . . . . . . . . Accy
Total Length . . . . . . . 74.5I (189.23cm)
Total Height . . . . . . . . 47I (119.38cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry . . . . . . . 501 lbs. (227.4kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring N/A 7041865/864-067 N/A

Standard 180/280 lb/in.
Front Strut Spring N/A 7041868-067 7041776-067
Standard 55/80 lb/in. Option 60/85 lb/in.

Polaris Sales Inc. 1.55 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . SCRAMBLER 400 4x4

MODEL NUMBER: . A00BG38CA
ENGINE MODEL: . . EC38PLE09

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 230 Altitude Below 0
0°F
F 0_ to +40_F
0 +40 F +40 to +80_F
+40_to +80 F Above +80
+80_F
F
Pilot Jet . . . . . . . . . . . . . 35 Below -18°C -18_to +5_C +5_ to +26_C Above +26_C

Jet Needle . . . . . . . . . . . 6CEY6-3 Meters

(Feet)
0-900
0 900
(0-3000)
(0 3000)
270 MJ 250 MJ 230 MJ** 210 MJ
0.5 AS 1.0 AS 1.5 AS 1.5 AS
Needle Jet . . . . . . . . . . . 0-6(480) 900-1800
900 1800 250 MJ 230 MJ 210 MJ 195 MJ
Cutaway . . . . . . . . . . . . 1.5 (3000-6000)
(3000 6000)
0.5 AS 1.0 AS 1.5 AS 1.75 AS
Air Screw . . . . . . . . . . . 1.5 Turn 1800-2700
1800 2700 220 MJ 210 MJ 195 MJ 175 MJ
Valve Seat . . . . . . . . . . . 2.5 (6000-9000)
(6000 9000)
1.5 AS 1.5 AS 1.75 AS 1.75 AS
Fuel Octane (R+M/2) . 87 Non-Oxygenated or 2700-3700
2700 3700
(9000-12000)
(9000 12000)
200 MJ 190 MJ 175 MJ 160 MJ
1.5 AS 1.75 AS 1.75 AS 1.75 AS
89 Oxygenated
MJ = Main Jet
AS = Air Screw (Turns Out)
** For 87 Octane Oxygenated Fuel Refer to jetting recommendation
CLUTCH in Fuel System / Carburetion section.

Type . . . . . . . . . . . . . . . . . . . . PVT
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.188I (30.18mm) CLUTCH CHART
Side Angle (Overall) . . . . . . 26°
Outside Circumference . . . . 40.86 ±.12I Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Center Distance . . . . . . . . . . 10±.12I (254.5mm) Meters 0-1800
S55 White 22
2-2
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm) (Feet) (0-6000)

Secondary Spring . . . . . . . . Red 1800-3700

(6000-12000)
S White 21
2-1
Driven Helix . . . . . . . . . . . . . 40°
Spring Position (Helix) . . . . 2 40 ° Helix, Red Driven
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 2 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 378 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.2677I (83mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.7559I (70mm)
Compression Ratio . . . . . . . . . . 6.9/1 Effective
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Oil Injected
Piston Marking . . . . . . . . . . . . . . .
Operating RPM±200 . . . . . . . . . 5700 RPM
Idle RPM±200 . . . . . . . . . . . . . . 600 RPM
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.56 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications
MODEL: . . . . . . . . . . . . SCRAMBLER 400 4x4
MODEL NUMBER: . . . A00BG38CA
ENGINE MODEL: . . . . EC38PLE09
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . FF95 Fuel Tank . . . . . . . . . . 4 gals. (15.1L)
CDI Marking . . . . . . . CU2515 Injector Oil . . . . . . . . . . 2 qts. (1.9L) . . PP2*
Alternator Output . . . 150 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 23.5° BTDC@3000RPM±3° Transmission . . . . . . . 32 oz. (946ml) PPS*
Spark Plug / Gap . . . NGK BR8ES / 0.028I (0.7mm) Gearcase Oil (Front) . 4 oz (118ml) . . 80-90 GL5
Lights: Head . . . . . . Halogen 30/30 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . N / A
Brake . . . . . . 26.9 watts Engine Counter Bal. . 100ml . . . . . . . 10W30
Voltage Regulator . . LR39--1 Engine Oil . . . . . . . . . . N / A
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . Dot 3
Brake (Foot) . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PP2 Polaris Premium TC-W3 2 Stroke Oil
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
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 . 4.36/1
Turning Radius . . . . . 60I (152.4cm) Gear Reduction-High 2.82/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 2:1
Ground Clearance . . 5.5I (13.97cm) Center Drive Ratio . . . N/A
Front Vertical Travel 8.2I (20.83cm) Final Drive Ratio . . . . 13/36 76P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 10.5I (26.67cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . Foxt Gas Charged w/remote res.
Shock Adjustment . . Thread Adjuster
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Accy) . . . . 30 lbs.
Tire Size - Rear . . . . 22 x 11 - 10
Rear Rack (Accy) . . . . 60 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 45.5I (115.57cm) Tow Hitch . . . . . . . . . . . Accy
Total Length . . . . . . . 74.5I (189.23cm)
Total Height . . . . . . . . 47I (119.38cm)
Wheel Base . . . . . . . 48.5I (123.19cm)
Weight - Dry . . . . . . . 541 lbs. (245.6kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring N/A 7041865/864-067 N/A

Standard 180/280 lb/in.
Front Strut Spring 7041648-067 7041603-067 7041647-067
Option 75/100 lb/in. Standard 75/110 lb/in. Option 80/120 lb/in.

Polaris Sales Inc. 1.57 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . XPEDITION 425

MODEL NUMBER: . A00CK42AA/AB
ENGINE MODEL: . . EH42PLE03

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 150 Altitude Below 40
40°F
F +40 F to +80
+40_F +80_F
F
Below 5°C +5_C to +26_C
Pilot Jet . . . . . . . . . . . . . 42.5 Meters 0-1800
Jet Needle . . . . . . . . . . . 4HB41-3 (Feet) (0-6000) 155 150
Needle Jet . . . . . . . . . . . P-8 above 1800
147 5
147.5 142 5
142.5
(above 6000)
Throttle Valve . . . . . . . . #100
Pilot Screw . . . . . . . . . . 2 5/8 Turns Out
Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 425 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.461I (87.9mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.756I (70mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Wet Sump
Piston Marking . . . . . . . . . . . . . . “257”
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Ratio . . . . . . . . . . 9.2/1 Full Stroke
Compression Pressure . . . . . . . 60-90 lbs.

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style . . . . . . . . Gen IV Gear 1 Ratio . . . . . . . . . . . . . . . 4.182
Front Suspension . . MacPherson Strut Gear 2 Ratio . . . . . . . . . . . . . . . 2.562
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear 3 Ratio . . . . . . . . . . . . . . . 1.522
Turning Radius . . . . . 65I (165.1cm) Gear 4 Ratio . . . . . . . . . . . . . . . 1.036
Toe Out (Total) . . . . . 1/8I-1/4I (3-6.35mm) Gear 5 Ratio . . . . . . . . . . . . . . . 0.758
Ground Clearance . . 7.25I (18.42cm) Reverse . . . . . . . . . . . . . . . . . . . 4.484
Front Vertical Travel 6.7I (17.02cm) Primary . . . . . . . . . . . . . . . . . . . 2.406
Rear Suspension . . . Progressive Rate Swing Arm Secondary (at chain) . . . . . . . . 1.333
Rear Travel . . . . . . . . 6.5I (16.51cm) Secondary (at bevel drive) . . . 1.313
Rear Shock . . . . . . . . 2I Gas Charged Mono Front Drive Ratio . . . . . . . . . . . 3.7/1 (Shaft)
Shock Adjustment . . Cam Final Drive Ratio . . . . . . . . . . . 3.1/1 (Shaft)
Brake (Hand) . . . . . . . . . . . . . . S/L Hyd. Disc
Brake (Auxiliary Foot) . . . . . . . Hydraulic

Polaris Sales Inc. 1.58 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . . . XPEDITION 425

MODEL NUMBER: . . . A00CK42AA/AB
ENGINE MODEL: . . . . EH42PLE03

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . FF95 Fuel Tank . . . . . . . . . . 3.75 gals. (14.2L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 200 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . N / A
Spark Plug / Gap . . . NGK BKR5E / 0.028I (0.7mm) Gearcase Oil (Front) . 5 oz. (150 ml) 80-90 GL5
Lights: Head . . . . . . Halogen 60/60 watts Gearcase Oil (Center) N / A
Tail . . . . . . . . 8.26 watts Gearcase Oil (Rear) . 10 oz. (300 ml) 80-90 GL5
Brake . . . . . . 26.9 watts Engine Counter Bal. . N / A . . . . . . . . .
Voltage Regulator . . LR39 Engine Oil . . . . . . . . . . 5.5 qts. (5.2L) PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . Standard Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75 ml) PDD*
Shift Selector Box . . . N / A

*PP6 Polaris Premium 60/40 Antifreeze/Coolant

*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid

TIRES LOAD CAPACITY

Tire Size - Front . . . . 25 x 8 - 12 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 25 x 11 - 10
Tire Size - Center . . N/A Rear Rack (Std) . . . . . . 180 lbs.
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46I (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81I (205.74cm)
Total Height . . . . . . . . 47I (119.38cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry . . . . . . . 647 lbs. (293.7kg)

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring 7041777-067 7041849-067 7041815-067

125 lb/in. 125 - 180 lb/in. 175 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
61 lb/in. 64 - 113 lb/in. 101 lb/in.

Polaris Sales Inc. 1.59 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . MAGNUM 500

MODEL NUMBER: . A00CD50AA
ENGINE MODEL: . . EH50PLE08

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 157.5 Altitude Below 40
40°F
F +40 F to +80
+40_F +80_F
F
Pilot Jet . . . . . . . . . . . . . 40 Below 5°C +5_C to +26_C

Jet Needle . . . . . . . . . . . 4HB40-2 Meters

(Feet)
0-1800
(0-6000) 162 5
162.5 157 5
157.5
Needle Jet . . . . . . . . . . . Q-O above 1800
155 150
Throttle Valve . . . . . . . . #100 (above 6000)

Pilot Screw . . . . . . . . . . 2 5/8 Turns Out

Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated

CLUTCH CLUTCH CHART

Type . . . . . . . . . . . . . . . . . . . . PVT Altitude Shift
Weight
Clutch
Spring
Driven
Helix
Belt . . . . . . . . . . . . . . . . . . . . . 3211082 Meters 0-1800
10MH Blue/Green EBS
Belt Width (Projected) . . . . . 1.188I (30.18mm) (Feet) (0-6000)

Side Angle (Overall) . . . . . . 28° 1800-3700

(6000-12000)
10WH Blue/Green EBS
Outside Circumference . . . . 41.44 ±.12I * EBS requires no helix adjustment
Center Distance . . . . . . . . . . 10±.12I (254.5mm)
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Shift Weights . . . . . . . . . . . . 10MH
Primary Spring . . . . . . . . . . . Blue/Green
Secondary Spring . . . . . . . . White w/Green Stripe
Driven Helix . . . . . . . . . . . . . Compound (EBS)
Spring Position (Helix) . . . . N/A
Spring Position (Sheave) . . N/A

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 498 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.6248I (92mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.955I (75mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Dry Sump
Piston Marking . . . . . . . . . . . . . . Arrow to MAG side
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Ratio . . . . . . . . . . 10/2 Full Stroke
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.60 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . . . MAGNUM 500

MODEL NUMBER: . . . A00CD50AA
ENGINE MODEL: . . . . EH50PLE08

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . FF97 Fuel Tank . . . . . . . . . . 3.75 gals. (14.2L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 250 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 13.5 oz. (400 ml)PPS*
Spark Plug / Gap . . . NGK BKR5E / 0.028I (0.7mm) Gearcase Oil (Front) . 5 oz. (150 ml) 80--90 Lube
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 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Electronic Speedo . . Standard Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75 ml) PDD*
Shift Selector Box . . . 1 oz. (30 ml) . PP4*

*PP6 Polaris Premium 60/40 Antifreeze/Coolant

*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . N/A
Front Suspension . . MacPherson Strut Gear Reduction-Low . 7.46/1
Tow Capacity . . . . . . 850 lbs. (385.9kg) Gear Reduction-Rev . 5.12/1
Turning Radius . . . . . 65I (165.1cm) Gear Reduction-High 3.3/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 3.7/1 (Shaft)
Ground Clearance . . 7.25I (18.42cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 3.1/1 (Shaft)
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 6.5I (16.51cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Gas Charged Mono
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 25 x 8 - 12 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 25 x 11 - 10
Rear Rack (Std) . . . . . . 180 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 46I (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81I (205.74cm)
Total Height . . . . . . . . 47I (119.38cm)
Wheel Base . . . . . . . 49.75I (126.37cm)
Weight - Dry . . . . . . . 647 lbs. (293.7kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring 7041777-067 7041849-067 7041815-067

125 lb/in. 125 - 180 lb/in. 175 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
61 lb/in. 64 - 113 lb/in. 101 lb/in.

Polaris Sales Inc. 1.61 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . SCRAMBLER 500

MODEL NUMBER: . A00BG50AA
ENGINE MODEL: . . EH50PLE04

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 40 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 155 Altitude Below 40
40°F
F +40 to +80_F
+40_to +80 F
Pilot Jet . . . . . . . . . . . . . 40 Below +5°C +5_ to +26_C

Jet Needle . . . . . . . . . . . 6H25--94--3 Meters

(Feet)
0-1800
(0-6000) 160 155
Needle Jet . . . . . . . . . . . Y--O Above 1800
152 5
152.5 147 5
147.5
Throttle Valve . . . . . . . . #120 Above (6000)

Pilot Screw . . . . . . . . . . 2.0

Pilot Air Jet . . . . . . . . . . 1.3
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated
CLUTCH CHART
Shift Clutch Driven
Altitude Weight Spring Helix
CLUTCH Meters 0-1800
10WH Blue/Green 11
1-1
(Feet) (0-6000)
Type . . . . . . . . . . . . . . . . . . . . PVT
1800-3700
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 (6000-12000)
10RH Blue/Green 11
1-1

Belt Width (Projected) . . . . . 1.188I (30.18mm) 40_ helix, silver driven

Side Angle (Overall) . . . . . . 26°
Outside Circumference . . . . 40.86 ±.12I
Center Distance . . . . . . . . . . 10±.12I (254.5mm)
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Shift Weights . . . . . . . . . . . . 10WH
Primary Spring . . . . . . . . . . . Blue/Green
Secondary Spring . . . . . . . . Silver
Driven Helix . . . . . . . . . . . . . 40°
Spring Position (Helix) . . . . 1
Spring Position (Sheave) . . 1

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 499 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.6248I (92mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.955I (75mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Compression Ratio . . . . . . . . . . 10/2 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Dry Sump
Operating RPM±200 . . . . . . . . . 6500 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.62 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . . . SCRAMBLER 500

MODEL NUMBER: . . . A00BG50AA
ENGINE MODEL: . . . . EH50PLE04

ELECTRICAL FLUID Capacity Type

Flywheel I.D. . . . . . . FF97 Fuel Tank . . . . . . . . . . 3.5 gals. (13.2L)
CDI Marking . . . . . . . CU2544 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 250 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 32 oz. (946ml) PPS*
Spark Plug / Gap . . . NGK BKR6E / 0.028I (0.7mm) Gearcase Oil (Front) . 4.0 oz. (118ml) 80-90 GL5
Lights: Head (Twin) Halogen 30/30 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 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . Dot 3
Brake (Foot) . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
*Lubricant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
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 . 4.74/1
Turning Radius . . . . . 60I (152.4cm) Gear Reduction-High 3.06/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 2:1
Ground Clearance . . 5.5I (13.97cm) Center Drive Ratio . . . N/A
Front Vertical Travel 8.2I (20.83cm) Final Drive Ratio . . . . 13/36 76P
Rear Suspension . . . Progressive Rate Swing Arm Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 10.5I (26.67cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . Foxt Gas Charged w/remote res
Shock Adjustment . . Thread Adjuster
TIRES LOAD CAPACITY
Tire Size - Front . . . . 23 x 7 - 10 Front Rack (Accy) . . . . 30 lbs.
Tire Size - Rear . . . . 22 x 11 - 10
Rear Rack (Accy) . . . . 60 lbs.
Tire Size - Center . . N/A
Tire Pressure - F/R . 4/3 lbs. Tongue Weight . . . . . . . 30 lbs.
Total Width . . . . . . . . 45.5I (115.57cm) Tow Hitch . . . . . . . . . . . Accy
Total Length . . . . . . . 74.5I (189.23cm)
Total Height . . . . . . . . 47I (119.38cm)
Wheel Base . . . . . . . 48.5I (123.19cm)
Weight - Dry . . . . . . . 542 lbs. (246.1kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring N/A 7041865/864-067 N/A

Standard 180/280 lb/in.
Front Strut Spring 7041648-067 7041603-067 7041647-067
Option 75/100 lb/in. Standard 75/110 lb/in. Option 80/120 lb/in.

Polaris Sales Inc. 1.63 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . SPORTSMAN 500 / SPORTSMAN 500 RSE*

MODEL NUMBER: . A00CH50AA/AB/AC
ENGINE MODEL: . . EH50PLE09

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 155 Altitude Below 40
40°F
F +40 to +80_F
+40_to +80 F
Pilot Jet . . . . . . . . . . . . . 40 Below +5°C +5_ to +26_C

Jet Needle . . . . . . . . . . . 4HB41-3 Meters

(Feet)
0-1800
(0-6000) 162 5
162.5 155
Needle Jet . . . . . . . . . . . Q-0 Above 1800
157 5
157.5 147 5
147.5
Throttle Valve . . . . . . . . #100 Above (6000)

Pilot Screw . . . . . . . . . . 2 5/8 Turns Out

Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated
CLUTCH CHART
Shift Clutch Driven
Altitude Weight Spring Helix
CLUTCH Meters 0-1800
10MH Blue/Green EBS
(Feet) (0-6000)
Type . . . . . . . . . . . . . . . . . . . . PVT
1800-3700
Belt . . . . . . . . . . . . . . . . . . . . . 3211069 (6000-12000)
10WH Blue/Green EBS

Belt Width (Projected) . . . . . 1.188I (30.18mm) * EBS requires no helix adjustment

Side Angle (Overall) . . . . . . 26°
Outside Circumference . . . . 40.86 ±.12I
Center Distance . . . . . . . . . . 10±.12I (254.5mm)
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Shift Weights . . . . . . . . . . . . 10MH
Primary Spring . . . . . . . . . . . Blue/Green
Secondary Spring . . . . . . . . White w/Green Stripe
Driven Helix . . . . . . . . . . . . . Compound (EBS)
Spring Position (Helix) . . . . N/A
Spring Position (Sheave) . . N/A

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 498 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.625I (92mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.955I (75mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Compression Ratio . . . . . . . . . . 10/2 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Dry Sump
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

*Remingtont Special Edition

Polaris Sales Inc. 1.64 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications
MODEL: . . . . . . . . . . . . SPORTSMAN 500 / SPORTSMAN 500 RSE*
MODEL NUMBER: . . . A00CH50AA/AB/AC
ENGINE MODEL: . . . . EH50PLE09
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . FF97 Fuel Tank . . . . . . . . . . 5.25 gals. (19.9L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A . . . . . . . . .
Alternator Output . . . 250 Watts Coolant . . . . . . . . . . . . 2.25 qts. . . . . . PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 32 oz. . . . . . . . PPS*
Spark Plug / Gap . . . NGK BKR5E / 0.028I (0.7mm) Gearcase Oil (Front) . 4 oz. (120ml) . 80-90 GL5
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 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . Dot 3
Brake (Foot) . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
Lubricant Key
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . Shaft Drive
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.69/1
Tow Capacity . . . . . . 1225 lbs. (556.2kg) Gear Reduction-Rev . 5.17/1
Turning Radius . . . . . 65I (165.1cm) Gear Reduction-High 3.34/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 2/1
Ground Clearance . . 11I (27.94cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 3.16/1
Rear Suspension . . . Progressive Rate Independent Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Travel . . . . . . . . 9.5I (24.13cm) Brake ( Auxiliary Foot) Hydraulic
Rear Shock . . . . . . . . 2I Twin Tube
Shock Adjustment . . Cam
TIRES LOAD CAPACITY
Tire Size - Front . . . . 25 x 8 - 12 Front Rack (Std) . . . . . 90 lbs.
Tire Size - Rear . . . . 25 x 11 - 10
Tire Size - Center . . N/A Rear Rack (Std) . . . . . . 180 lbs.
Tire Pressure - F/R . 5/5 lbs. Tongue Weight . . . . . . 35 lbs.
Total Width . . . . . . . . 46I (116.84cm) Tow Hitch . . . . . . . . . . . Std
Total Length . . . . . . . 81I (205.74cm)
Total Length (RSE) . 85I (215.9cm)
Total Height . . . . . . . . 47I (119.38cm)
Wheel Base . . . . . . . 50.50I (128.27cm)
Weight - Dry . . . . . . . 697 lbs. (316.4kg)
Weight - Dry (RSE) . 730 lbs. (331.4kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM

Rear Compression Spring N/A 7041453-067 7041519-067

Standard 100 lb/in. Option 140 lb/in.
Front Strut Spring 7041238-067 7041375-067 7041450-067
Option 61 lb/in. Standard 64/113 lb/in. Option 101 lb/in.
*Remingtont Special Edition

Polaris Sales Inc. 1.65 99/00 ATV Update 12/99

SPECIFICATIONS
2000 Model Specifications

MODEL: . . . . . . . . . . SPORTSMAN 6X6

MODEL NUMBER: . A00CL50AA
ENGINE MODEL: . . EH50PLE10

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . BST 34 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 142.5 Altitude Below 40
40°F
F +40 to +80_F
+40_to +80 F
Pilot Jet . . . . . . . . . . . . . 40 Below +5°C +5_ to +26_C

Jet Needle . . . . . . . . . . . 4HB41-3 Meters

(Feet)
0-1800
(0-6000) 147 5
147.5 142 5
142.5
Needle Jet . . . . . . . . . . . Q-4 (829) Above 1800
140 135
Throttle Valve . . . . . . . . #100 Above (6000)

Pilot Screw . . . . . . . . . . 3
Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated
CLUTCH CHART
Shift Clutch Driven
Altitude Weight Spring Helix
CLUTCH Meters 0-1800
10MH Blue/Green 22
2-2
(Feet) (0-6000)
Type . . . . . . . . . . . . . . . . . . . . PVT
1800-3700
Belt . . . . . . . . . . . . . . . . . . . . . 3211077 (6000-12000)
10WH Blue/Green 22
2-2

Belt Width (Projected) . . . . . 1.188I (30.18mm) 40_ helix, red driven

Side Angle (Overall) . . . . . . 26°
Outside Circumference . . . . 40.86 ±.12I
Center Distance . . . . . . . . . . 10±.12I (254.5mm)
Clutch Offset . . . . . . . . . . . . 0.5I (12.7mm)
Shift Weights . . . . . . . . . . . . 10MH
Primary Spring . . . . . . . . . . . Blue/Green
Secondary Spring . . . . . . . . Red
Driven Helix . . . . . . . . . . . . . Compound
Spring Position (Helix) . . . . 2
Spring Position (Sheave) . . 2

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 498 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.625I (92mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.955I (75mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I @ TDC on compression
Compression Ratio . . . . . . . . . . 10/2 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Dry Sump
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1200 RPM
Compression Pressure . . . . . . . (Std) ±15%

Polaris Sales Inc. 1.66 99/00 ATV Update 12/99

 SPECIFICATIONS
2000 Model Specifications
MODEL: . . . . . . . . . . . . SPORTSMAN 6X6
MODEL NUMBER: . . . A00CL50AA
ENGINE MODEL: . . . . EH50PLE10
ELECTRICAL FLUID Capacity Type
Flywheel I.D. . . . . . . FF97 Fuel Tank . . . . . . . . . . 4.25 gals. (16L)
CDI Marking . . . . . . . CU2557 Injector Oil . . . . . . . . . . N / A
Alternator Output . . . 250 Watts Coolant . . . . . . . . . . . . 2.25 qts. (2.1L) PP6*
Ignition Timing . . . . . 30° BTDC@3500RPM±1.5° Transmission . . . . . . . 32 oz (946ml) PPS*
Spark Plug / Gap . . . NGK BKR5E / 0.028I (0.7mm) Gearcase Oil (Front) . 4 oz. (118ml) . 80-90 GL5
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 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . PP4*
Electric Start . . . . . . . Standard Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
Front Hubs (AWD) . . . 2.5 oz. (75ml) PDD*
Shift Selector Box . . . 1 oz. (30ml) . . PP4*
Lubricant Key
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style . . . . . . . . Gen IV Chain Type . . . . . . . . . 520 O-Ring
Front Suspension . . MacPherson Strut Gear Reduction-Low . 6.691
Tow Capacity . . . . . . 1225 lbs. (556.2kg) Gear Reduction-Rev . 5.17/1
Turning Radius . . . . . 98I (248.9cm) Gear Reduction-High 3.34/1
Toe Out . . . . . . . . . . . 1/8I-1/4I (3-6.35mm) Front Drive Ratio . . . . 2/1
Ground Clearance . . 5.5I (13.97cm) Center Drive Ratio . . . N/A
Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio . . . . 12/38 80P
Rear Suspension . . . Swing Arm w/Scissor Stabilizer Axle to Axle . . . . . . . . . 30/30 116P
Rear Travel . . . . . . . . 7.5I (19.06cm) Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Rear Shock . . . . . . . . 2I Gas Charged Twin Tube Brake (Auxiliary Foot) Hydraulic
Shock Adjustment . . N/A
Center Suspension . Progressive Rate Swing Arm
Center Travel . . . . . . 6.5I (16.5cm) LOAD CAPACITY
Center Shock . . . . . . 1-5/8I Twin Tube Front Rack . . . . . . . . 75 lbs.
Shock Adjustment . . Cam
TIRES Rear Rack . . . . . . . . . 800 lbs.
Tire Size - Front . . . . 25 x 8 - 12 Tongue Weight . . . . . 35 lbs.
Tire Size - Rear . . . . 25 x 11 - 10 Tow Hitch . . . . . . . . . Std
Tire Size - Center . . 25 x 11 - 10
Tire Pressure - F/R . 5/5/5 lbs.
Total Width . . . . . . . . 46I (116.84cm)
Total Length . . . . . . . 105I (266.7cm)
Total Height . . . . . . . . 48I (121.92cm)
Wheel Base . . . . . . . 76.5I (194.3cm)
Weight - Dry . . . . . . . 895 lbs. (406.4kg)
OPTIONAL SUSPENSION SPRINGS
SOFT STANDARD FIRM
7041880-067
Rear Compression Spring N/A N/A
Standard 210/250 lb/in.
7041878-067
Mid Compression Spring N/A N/A
Standard 100/160 lb/in.
7041375-067 7041450-067 7041696-067
Front Strut Spring
Option 64/113 lb/in. Standard 101 lb/in. Option 140/190 lb/in.

Polaris Sales Inc. 1.67 99/00 ATV Update 12/99

NOTES