Polaris ATV and Light Utility Hauler 1985-1995 Service Manual – PDF

Description

Polaris ATV and Light Utility Hauler 1985-1995 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Polaris ATV and Light Utility Hauler 1985-1995 Service Manual – PDF DOWNLOAD

PN 9912004

Language : English
Pages : 468
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Polaris ATV and Light Utility Hauler 1985-1995 Service Manual – PDF DOWNLOAD

PN 9912004

Chapter 01 – General Product Information
Chapter 02 – Body, Steering, and Suspension
Chapter 03 – Brake Service
Chapter 04 – Transmission Service
Chapter 05 – Final Drive System Service
Chapter 06 – PVT System
Chapter 07 – Engines
Chapter 08 – Electrical

DESCRIPTION:

Polaris ATV and Light Utility Hauler 1985-1995 Service Manual – PDF DOWNLOAD

PN 9912004

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 through 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.

GENERAL INFORMATION 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. A 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. A 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. A Some of the fasteners were installed with locking agents.
• Use of impact drivers or wrenches will help avoid damage to fasteners. A 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). A 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. A 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. A Because removal damages seals, replace any oil or grease seals removed with new parts. A 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.
• A Grease should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating grease loses lubricity and may contain abrasive foreign matter. A 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 sulfphuric 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.

G.B 05/04/25