Polaris Atv 350 6×6 1992 Service Repair Workshop Manual
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LANGUAGE:ENGLISH
PAGES:468
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DESCRIPTION:
Polaris Atv 350 6×6 1992 Service Repair Workshop Manual
Foreword :
This manual is designed primarily for use by ATV service technicians in a properly equipped shop. Since a certain knowledge of mechanical theory. tool use. and shop procedures is necessary to perform the service work safely. all operations should be performed by qualified service personnel only. in order to perform the work efficiently and prevent costly errors. the technician should read the text. thoroughly familiarizing him/herself with procedures before starting the work.
- Cleanliness of parts and tools as well as the work area is of primary importance. This manual includes procedures for maintenance operations. component identification and unit repair. along with service specifications for the 1985 th rough 1995 model Polaris ATVs.
- The section index tabs enable the user to quickly locate the component unit section desired. In addition. a table of contents is placed at the beginning of each section for location of specific page numbers and service Information.
- Keep this manual available for reference in the shop area To keep this manual current it is important that it is updated yearly with new model information and specifications. Annual update packet part numbers are found in Chapter 1. At the time of publication all information contained In this manual was technically correct. However, all materials and specifications are subject to change without notice.
TABLE OF CONTENTS:
Polaris Atv 350 6×6 1992 Service Repair Workshop Manual
GENERAL PRODUCT INFORMATION
Publications
Model identification
Service ToolsDescription
Servic eTools eruppiies List
Specifications
1985 Models
1986 Modeis
1987Models
1988Models
1989Models
1990Models
1991 Models
1992Models
1993Models
1994Models
1995Models
AccessoryFitChart
RoutingDiagrarns
HowtoHandleaServiceComplaint
Sen/ice’i‘tps
WarrantyPolicy
TorqueSpecificationsandSpecialTooIs
Body Assembly Exploded View (Except Magnum, Xplorer, and Scrambler
BodyAssemnyExplodedViewMagnum
Cover/Panel Removal (All ExcethpIorer and Scrambler)
BodyAssemblyExplodedViewXpIorer
XplorerSidePanelRemoval
BodyAssemblyExplodedViewScrambler
Oil Tankand FuelTankAssemny (Except Magnum and Scrambler)
OiiTankandFuelTankAssemny,Scrambler
FueiTankAssemnyMagnum
FuelTankAssemblyXplorer
CamberandCasterAdjustment
ToeAlignment
TypicalSteeringAssemblyExploded View4x4(1988-1992)
Typical SteeringAssembiyExpioded View2x4(1988-1992)
Typical Steering Assembly Exploded View 2×4 (1993-Present Except Magnum)
SteeringAssembly,ExpiodedViewMagnum2x4
Typical Steering Assembly Exploded Wew 4×4 (1993-Present Except Xplorer and
Scrambler)
SteeringAssemblyExplodedView,Xplorer
SteeringStopAdjustments
FrameStraighteningandReinforcement
FrontWheelRemoval-1985—868cramblerModels
FrontForkService-1985-868cmmblerModels
RearDriveAxiehubandWheeiAssemblyMagnum
Swing Arm and RearSuspensIon Exploded View-2x44x4
RearSwingArmWeldment-BigBoss4x6and6x5
Swing Arm and Rear Suspension Exploded Wew,1995 Scrambler
AxleHousingandSwingArmRemovalandInspection
StrutAssemny-350/400L4x4Magnum4x4
FrontStrutWeldmentReplacement
FrontStrutBallJointRepIacement
2x4HubBearingServIce
Fox’”ShockMaintenance
LubricationGuIde
OptionalSuspensionSprings(1994)
OptionalSuspensionSprings(1995)
1995PaintCodes
Type I Mechanical – Front
TypelMechanical-Rear
Hydraulic Brake System Operation
Type i Hydraulic Master Cylinder
Type il Hydraulic Master Cylinder
Type i Hydraulic Caliper – Front
Type ll Hydraulic Caliper – Front
Type l Hydraulic Caliper – Rear
Type 1! Hydraulic Caliper – Rear
Output Shaft Caliper Service
Type iil MasterCylinder
Brake Bleeding Procedure
Specifications
Typet—Chain
Specifications
ChalnandSprocketServioe
RearDriveChalnAdjustment
1987/1988 4×4 Centerand Forward Chain Adjustment
1989 to Present AikWheel Drive Center and Forward Chain Adjustment
198910PresentWheeiDriveChainSlackAdjustment
RearAxle Chain Adjustment, 4×8 and 6×6 Models
Axle/EocentricServioe
Demand40peration
Front Drive System Overhaul-All-Wheel Drive Models
FrontHubDlsassemblyt
Demand4RollerCiutchinspection1989to Current
HilliardCiutchAssembinesting
WheelHubSealReplacement,
StrutCastingSealReplacement
DriveShattCVJointBootReplacement
FrontAxleSeaiSieeveReplacement
PoleGapAdjustment
FrontClutchReassembly
BearingTorqueAdjustment
FrontHublnstallation
CoiiReplacement
FrontAxleldentification
Specifications
ShiitWeights
DriveClutchSpringSpecs
Overview
PVTSystemlntroduction
Maintenance
PVTDisassembly
PVTAssembiy
DriveBelt
CiutchAiignmenUOffset
DrivenClutchDisassembly
DrivenCiutchAssembly
DrlveClutcthsassembiy
DriveCiutchlnspection
DriveCiutchAssembiy,i,i
Clutch Bushing Removal and Installation
Troubleshooting
EngineSpecifications
Pistonldentification
MagnumServiceData
TorqueSpecifications
FiuidCapacity
CoolingSystem
ZStrokeMalnienanoe
4StrokeMaintenanoe
EngineRemovai
EngineDisassembly(Aerooled28troke)
CrankshaftAlignment
CrankshaftandCrankcaseReassembly
Englnelnstaliatlon
CylinderHoning
Piston/CylinderClearance
EngineSewice,350U400L
OiiCheokVaiveTesting
350L/4DOLWaterPump
OilPumpEndPlayAdjustment
3000ilPumpCheokValveTesting
Recoil Disassembly (Early Style ECZSPF-Oi/OZ Engines)
Recoil Dlsassembly (Late Style EC25PF-03 and Later Engines)
ReooliReassembly(EC28 and E038 Engines)
MagnumEH42PLEngineExplodedView
MagnumLubrication/OiiFiow
MagnumEngineFlemoval
MagnumEnginelnstaiiation
Magnum Engine Disassembly/inspection,
MagnumEngineAssembly
Recoil Disassembiyiinspection/Assembiy
2$trokeEngineTroubieshooting
4SlrokeEngineTroubleshooting
GeneralSpeciiications
lgnitionTrming
ignition System Components(ExplodedView)
ignition System Components (Exploded View) aces-PL
ignition System Components (Exploded View) EC42PL(E)
IgnitionSystemTestSequence
BatteryMaintenanceandTesting
ElectriCStarterSystemTesting
MagnumStarterSystemTesting
StartingSystemTroubieshootfng
ChargingSystemTesting
SpeedLimiterSystemTesting
EIectricDemand4DriveSystemTesting
Wiring Schematics and Diagrams
1985-87 Scrambler Trail Boss Trail Boss4x4
1987 Cyclone
1988 Trail Boss2x48r4x4
1988 Trail Boss250R/ES
1989 Circuit BoardColorCoding
1989 Trail Boss,2×4&4×6
1990 Trail Blazer
1990-91 TrailBoss,2×4&4×6
1990-91 4×4&6×6 (Except‘91JModeI)
1990-91 350 L2x4
1990—91 350 L4x4(Except’91JModel)
1991 250 4×4 JModel
1991 350 L4x4 JModel
1991 Trail Blazer
1992 Trail Blazer
1992 Trail Boss,2502×4&2504×6
1992 250 4×4 & 6×6
1992 350 L2x4
1992 350 L4x4
1993 Trail Blazer
1993 Trail Boss2 602×4
1993 250 4×4 82 60 6×6
1993 350L2x4
1993 350L4x4
1993 Sportsman
1993 350L6x6
1994 Trail Blazer
1994 Trail B035250
1994 300 2×4
1994 400L 2×4
1994 400L Sport
1994 300 4x46x6
1994 400L 4×4,Sportsman,6×6
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