Target Audience:
Polaris ATV owners with basic mechanical skills and independent service professionals.
Value Proposition:
Provides dealership-level repair and maintenance information, enabling cost savings on service.
Uniqueness:
Vehicle-specific information, not generic, replicating official dealer resources.
Instructional Quality:
Accurate, clear, and concise text combined with helpful illustrations.
Diagnostic Aid:
Facilitates informed discussions with automotive technicians for owners not performing repairs themselves.
Models Covered 1999:
Trail Blazer 250, Trail Boss 250, Xpress 300, Xplorer 300, Sportsman 335, Sport 400, Scrambler 400, Xplorer 400, Scrambler 500, Magnum 500, Sportsman 500, Sportsman 500 RSE, 500 6x6
Models Covered 2000:
Trail Blazer 250, Xplorer 4x4, Trail Boss 325, Magnum 325, Xpedition 325, Sportsman 335, Xplorer 400, Scrambler 400 2x4, Scrambler 400 4x4, Xpedition 425, Magnum 500, Scrambler 500, Sportsman 500, Sportsman 500 RS, 500 6x6
Estimated Page Count:
Extensive (not specified, but implied by comprehensive coverage)
Manual Type:
Service Repair Workshop Manual
Engine:
Complete service, repair, and troubleshooting for engine components.
Fuel System Carburetion:
Detailed instructions for fuel system maintenance and carburetor adjustments.
Body Steering Suspension:
Covers maintenance and repair of chassis, steering, and suspension systems.
Clutches:
Service and repair procedures for clutch system components.
Final Drive:
Information on maintenance and repair of the final drive system.
Transmission Service:
Comprehensive procedures for transmission maintenance and repair.
Brakes:
Detailed brake system service and repair instructions.
Electrical System:
Covers all aspects of the electrical system, including troubleshooting.
Wiring Diagrams:
Includes detailed wiring schematics for electrical system diagnostics.
Maintenance:
Routine maintenance procedures, service intervals, and fluid checks.
Troubleshooting:
Diagnostic guides and step-by-step troubleshooting for common issues.
Repair:
Complete step-by-step repair instructions for all covered systems.
Diagnostics:
Advanced diagnostic procedures for identifying and resolving problems.
Engine Rebuild:
Detailed procedures for engine disassembly, inspection, repair, and reassembly, including piston, cylinder, crankshaft, and valve train work.
Suspension Overhaul:
Includes steps for shock absorber service, A-arm bushing replacement, and ball joint inspection/replacement.
Electrical Troubleshooting Charts:
Diagnostic flowcharts and tables to help pinpoint electrical system faults.
Depth Level:
Professional dealership-level technical information and procedures.
Instruction Style:
Step-by-step instructions with diagrams and illustrations.
Torque Specifications:
Provides essential torque values for critical fasteners across all systems.
Special Tools:
Identifies any specialized tools required for specific repair procedures.
Compatibility:
All versions of Windows and Mac
Printability:
Yes, all pages are printable.
Readability:
Clear and concise text with illustrations for easy understanding.
Binding Type:
Digital (PDF download)
Paper Type Implication:
Designed for printing individual pages for workshop use.
Engine Types Covered:
Covers various engine displacements including 250cc, 300cc, 325cc, 335cc, 400cc, and 500cc, for both 2-stroke and 4-stroke configurations as applicable to the models listed.
Performance Data Availability:
Includes specifications for horsepower, torque, and engine RPM ranges as relevant to repair and tuning.
Fuel Delivery System:
Detailed carburetor specifications, jetting, and adjustment procedures, potentially including fuel injection systems if equipped on specific models within the covered years.
Cooling System Type:
Covers air-cooled and liquid-cooled systems as equipped on the specific models.
Lubrication System Type:
Details on oil types, capacities, and filter replacement intervals.
Transmission Type Overview:
Covers automatic transmission systems including CVT (Continuously Variable Transmission) and potentially limited manual transmission applications.
Optional Transmission Features:
Details on gear selection, drive modes (e.g., 2WD/4WD), and any specific transmission variants.
Clutch System Details:
Includes service and adjustment procedures for primary and secondary clutches in CVT systems.
Final Drive Type:
Information on drive shafts, differentials, and hub assemblies for both rear-wheel and all-wheel drive systems.
Atv Platform Dimensions:
While exact dimensions are not listed, the manual covers various models, implying differences in wheelbase, length, width, and height across the range.
Dry Weight Variations:
Covers dry weight specifications for each model, which influences performance and handling.
Fuel Tank Capacity:
Specifications for fuel tank capacity for each model, crucial for range and refueling planning.
Safety Standards Compliance:
Implied compliance with relevant ATV safety standards for the model years covered, with procedures to maintain these standards.
Braking System Details:
Detailed procedures for hydraulic brake system maintenance, bleeding, and component replacement.
Suspension System Safety:
Information on suspension component wear and tear, impacting stability and control.
Infotainment Systems:
Not applicable to ATVs of this era, focus is on mechanical and electrical systems.
Driver Assistance Features:
Not applicable to ATVs of this era, focus is on mechanical and electrical systems.
Connectivity Features:
Not applicable to ATVs of this era, focus is on mechanical and electrical systems.
Ignition System Service:
Detailed procedures for ignition system troubleshooting, including spark plugs, coils, and CDI units.
Lighting And Accessories:
Covers maintenance and troubleshooting of headlights, taillights, and accessory electrical circuits.
Scheduled Maintenance:
Provides detailed recommended service intervals for oil changes, filter replacements, spark plugs, and other critical components.
Engine Oil Specification:
Specifies recommended engine oil viscosity grades (e.g., SAE 5W-30, 10W-40) and API service classifications.
Gearcase Oil Specification:
Details the type and quantity of gear oil required for transmissions and differentials.
Coolant Specification:
For liquid-cooled models, specifies the type and mixture ratio of antifreeze/coolant.
Common Wear Items:
Highlights common wear items such as brake pads, drive belts, suspension bushings, and wheel bearings.
Carburetor Cleaning Tips:
Offers guidance on cleaning and adjusting carburetors, a frequent maintenance task.
Pre Ride Inspection:
Implied pre-ride inspection checks are covered within general maintenance sections.
Polaris Atv Legacy:
Polaris has a long history of ATV innovation, and these manuals cover a significant period of their development in the late 90s.
Model Variations 1999 2000:
The included models represent a snapshot of Polaris's diverse ATV lineup, showcasing advancements in engine size, suspension, and drivetrain for recreational and utility use.
