This factory service repair manual covers ATVs from the 1999 and 2000 model years. It provides comprehensive information for a wide range of models, including the 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, and 500 6x6 for 1999, and similar models with updated designations for 2000. ATVs are known for their robust engineering and are designed for both recreational and utility purposes, reflecting a legacy of innovation in the powersports industry.
This manual serves as the definitive guide for maintaining and repairing your ATV. It encompasses detailed information on general procedures, technical specifications, engine systems, fuel and carburetion, body, steering, suspension, clutches, final drive, transmission service, brakes, and the electrical system, including wiring diagrams. With step-by-step repair instructions, hundreds of illustrations, and clear warnings, this manual is an invaluable resource for do-it-yourself owners and experienced mechanics alike, empowering efficient troubleshooting and ensuring optimal vehicle performance and longevity.
Model Years Covered:
1999, 2000
Product Type:
Workshop Service Repair Manual
Digital Format:
PDF Download
Vehicle Identification Type:
Model Codes (Varies by specific model)
Target Market:
Owners of 1999-2000 Polaris ATVs seeking comprehensive service and repair information.
Advantage Over Alternatives:
Complete factory data, instant download, printable flexibility, cost-effective alternative to physical manuals or dealer service.
Manual Benefit:
Inexpensive way to keep your vehicle working properly, empowers DIY repairs and maintenance.
Information Source:
Number one source for repair and service information for the specified Polaris ATV models.
Specific Models 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
Specific Models 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:
Hundreds of pages (Exact count not specified, but comprehensive)
Manual Classification:
Official Factory Service Repair Manual
Accessibility:
Downloadable, Printable
General Information:
Included
Fuel System Carburetion:
Included
Body Steering Suspension:
Included
Transmission Service:
Included
Electrical System:
Included
Wiring Diagrams:
Included
Repair Procedures:
Step-by-step instructions based on complete disassembly
Troubleshooting:
Included, combined with electrical service
Diagnostics:
Facilitated for electrical systems
Assembly Disassembly:
Detailed steps for complete disassembly
Depth Of Coverage:
Complete Official Factory Service
User Audience:
Do-it-yourselfer and experienced mechanic
Visual Aid Quality:
Hundreds of photos and illustrations
Illustration Detail:
Detailed illustrations, drawings, photos, enlarged insets for detailed parts examination
Table Of Contents:
Numbered, easy to use for quick information retrieval
Instruction Format:
Numbered instructions, detailed substeps
Critical Information Highlighting:
Notes, cautions, and warnings throughout each chapter
Platform Compatibility:
All PC-based Windows operating systems and Mac
Printability:
Printable without any restriction
Printing Options:
Print entire manual or select pages
Binding Method:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download)
Delivery Method:
Instant download link after payment
Shipping Cost:
None (Digital Download)
Required Software:
Adobe PDF Reader
Engine Types Covered:
Various engine displacements and configurations based on specific models covered (e.g., 250cc, 300cc, 325cc, 335cc, 400cc, 425cc, 500cc).
Performance Details:
The manual provides specifications for engine horsepower, torque, and other performance-related data as applicable to each model.
Fuel System Coverage:
Detailed coverage of fuel system components and carburetion adjustments.
Transmission Types:
Automatic (PVT - Polaris Variable Transmission) and potentially some manual/semi-automatic configurations depending on the specific model. The manual covers 'Transmission Service'.
Transmission Features Covered:
Includes details on clutch operation, belt maintenance, and internal transmission components as required for repair and maintenance.
Exterior Dimensions:
Specifications for dimensions (length, width, height) are typically included in the 'Specifications' section for each model covered.
Weight Specifications:
Dry weight, wet weight, and towing capacities (if applicable) will be detailed in the 'Specifications' section.
Safety Ratings:
While specific crash test ratings are not applicable to ATVs in the same way as cars, the manual will detail safety features and operating procedures to ensure safe use.
Active Safety Features:
Coverage likely includes brake system operation, steering geometry, and suspension tuning for optimal control and safety.
Passive Safety Features:
Information on chassis integrity and component design contributing to rider safety.
Infotainment Features:
ATVs of this generation typically feature minimal to no infotainment systems. Focus is on functional displays like speedometer, odometer, and indicator lights.
Driver Assistance Systems:
No advanced driver-assistance systems are expected on these models. Focus is on mechanical and electrical systems.
Connectivity Features:
No on-board connectivity features such as Bluetooth or Wi-Fi are present.
Scheduled Maintenance:
The manual will detail recommended service intervals for tasks such as oil changes, filter replacements, spark plug checks, brake inspections, and belt inspection/replacement.
Engine Oil Type:
Likely SAE 0W-40 or 10W-30 synthetic engine oil, specifically formulated for 4-stroke engines and potentially wet clutches. (Consult manual for exact OEM specification).
Gear Lube Type:
Polaris front and rear gearcase lubricant or equivalent is specified for differentials and final drives. (Consult manual for exact OEM specification).
Coolant Type:
If liquid-cooled models are covered, specific antifreeze/coolant mixtures will be detailed. (Consult manual for exact OEM specification).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid is typically specified. (Consult manual for exact OEM specification).
Transmission Belt Type:
The manual will specify the correct Polaris drive belt part numbers for each model, critical for performance and durability.
Common Wear Items:
Typical wear items on ATVs of this era include drive belts, brake pads, suspension bushings, and wheel bearings. The manual addresses inspection and replacement of these.
Carburetor Maintenance:
Carburetor cleaning and adjustment is a common maintenance item, thoroughly covered in the manual.
Polaris Atv Legacy:
Polaris has a long-standing history in the powersports industry, particularly with its innovative ATV designs. The 1999-2000 era represents a significant period of expansion and refinement for their ATV lineup.
Atv Development 1999 2000:
This period saw Polaris introducing and refining various engine sizes and chassis configurations, including their signature PVT automatic transmission and 6x6 models, catering to diverse recreational and utility needs.
Manufacturing Focus:
Polaris ATVs are primarily manufactured in the United States.
Model Specific Awards:
Specific awards for individual 1999-2000 Polaris ATV models are not detailed in the product description, but Polaris as a brand is recognized for its innovation and market leadership in the ATV segment.
