1985-1995 Polaris Atv All Models Service Repair Manual (Free Preview)

Precio habitual: $17.99
Precio de venta: $17.99
Precio habitual
Precio unitario: por

Basic Information Identification Make: Polaris Vehicle Type: All-Terrain Vehicle (ATV) Product Type: Service Repair Manual Introduction Market Position Target Audience: Owners and technicians looking for detailed repair and maintenance information...

28 people are viewing this right now

Tipo: Atv

Proveedor:

SKU: 48459

Etiquetas: 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 All Models ATV Polaris Powersports

Variantes de producto

Descripción

Basic Information
Identification
Make:	Polaris
Vehicle Type:	All-Terrain Vehicle (ATV)
Product Type:	Service Repair Manual

Introduction
Market Position
Target Audience:	Owners and technicians looking for detailed repair and maintenance information for Polaris ATVs from 1985 to 1995.
Historical Significance:	Covers a critical period of ATV development where technology advanced rapidly, introducing more powerful engines, 4-wheel drive, and improved suspension systems.
Competitive Analysis
Value Proposition:	Offers dealer-level service information, comprehensive coverage of a wide range of models, and printable pages for workshop use, at a fraction of the cost of dealership service.
Key Features
Features:	Includes complete tear-down and rebuild instructions, detailed part diagrams, essential torque specifications, maintenance schedules, and troubleshooting guides.
Troubleshooting Guides:	Offers systematic troubleshooting for various performance issues, helping to diagnose and rectify problems efficiently.
Preview Option
Preview:	Users can preview select pages via a 'PREVIEW BUTTON' before purchase.

Manual Details
Coverage Areas
Years Covered:	1985-1995
Model List:	1985 Scrambler (3-wheeler), Trail Boss; 1986 Scrambler (3-wheeler), Trail Boss; 1987 Cyclone, Trail Boss, Trail Boss 4x4; 1988 Trail Boss 2x4, Trail Boss 4x4, Trail Boss 250 R/ES; 1989 Big Boss 4x6, Trail Boss, Trail Boss 2x4, Trail Boss 4x4; 1990 Big Boss 4x6, Trail Blazer, Trail Boss 250, Trail Boss 2x4, Trail Boss 2x4 350L, Trail Boss 4x4, Trail Boss 4x4 350L; 1991 Big Boss 4x6, Big Boss 6x6, Trail Blazer, Trail Boss 250, Trail Boss 2x4, Trail Boss 2x4 350L, Trail Boss 4x4, Trail Boss 4x4 350L; 1992 Big Boss 4x6, Big Boss 6x6, Trail Blazer, Trail Boss 250, Trail Boss 2x4, Trail Boss 2x4 350L, Trail Boss 4x4, Trail Boss 4x4 350L; 1993 250 2x4, 250 4x4, 250 6x6, 350 2x4, 350 4x4, 350 6x6, Sportsman, Trail Blazer, Trail Boss; 1994 300 2x4, 300 4x4, 300 6x6, 400 2x4, 400 4x4, 400 6x6, Trail Blazer 2W, Trail Boss 2W, Sportsman 4x4, Sport; 1995 300 2x4, 300 4x4, 400 2x4, 400 6x6, Trail Blazer, Trail Boss, Scrambler, Sport, Sportsman 4x4, Xplorer 4x4, Magnum 2x4, Magnum 4x4.
Page Count
Total Pages:	468
Manual Type
Type:	Service and Repair Manual
Language
Language:	English
Format
Format:	PDF

Manual Coverage
Systems Covered
Engine:	Complete overhaul, troubleshooting, diagnostics, rebuild procedures.
Fuel System:	Carburetor adjustment, cleaning, fuel pump, fuel lines, filters.
Transmission Drivetrain:	PVT (Polaris Variable Transmission) system, final drive, gearbox, drive shafts, differentials (where applicable).
Brakes:	Hydraulic brake system, caliper overhaul, pad replacement, bleeding procedures, drum brakes (if applicable).
Electrical:	Wiring diagrams, ignition system, lighting, battery, starter, charging system, troubleshooting electrical faults.
Body Suspension:	Frame inspection, body panel removal/installation, suspension components, shocks, steering.
Frame And Chassis:	Inspection and repair of the ATV's frame, welds, and structural integrity.
Steering System:	Tie rod ends, steering shafts, wheel alignment, and general steering system maintenance and repair.
Cooling System:	Radiator, hoses, water pump, and thermostat for liquid-cooled models.
Procedures Included
Maintenance:	Scheduled maintenance, lubrication, fluid changes, filter replacements, general upkeep.
Repair:	Complete tear-down and rebuild procedures for all major components.
Troubleshooting:	Diagnostic guides for common problems, symptom-based troubleshooting.
Engine Rebuild:	Detailed step-by-step instructions for complete engine disassembly, cleaning, inspection, component replacement (pistons, rings, valves, bearings), and reassembly.
Suspension Service:	Instructions for fork seal replacement, shock absorber servicing, bushing replacement, and alignment checks.
Electrical Diagnostics:	Comprehensive troubleshooting trees for common electrical issues, including starting problems, charging system failures, and lighting malfunctions, supported by wiring diagrams.
Pvt System Maintenance:	Specific procedures for inspecting and replacing the CVT belt, clutch weights, springs, and sheaves for optimal performance.
Carburetor Rebuild:	Detailed instructions for disassembling, cleaning, and reassembling carburetors, including jetting and needle adjustments.
Gearbox Overhaul:	Procedures for servicing and rebuilding the transmission and differential units.
Technical Depth
Depth:	Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds. Suitable for both novice and experienced mechanics.
Diagrams And Illustrations:	Features numerous pictures and detailed part diagrams to visually guide repairs and component identification.

Manual Specifications
File Format
File Type:	PDF
Searchability:	PDF format typically allows for keyword searching within the document for specific terms or parts.
Print Quality
Printability:	All pages are printable without restriction.
Binding Type
Binding:	N/A (Digital PDF Download)
Paper Type
Paper Quality:	N/A (Digital PDF Download)
Compatibility
Operating Systems:	Compatible with all versions of Windows & Mac.
Requirements
Software:	Adobe PDF Reader

Engine Specifications
Primary Engine
Engine Types:	Likely single-cylinder, 2-stroke and possibly early 4-stroke engines across the model range. Specific displacements will vary by model and year (e.g., 250cc, 350cc, 400cc).
Performance
Performance Details:	Manual will contain specific horsepower and torque figures for each covered engine variant.
Fuel System
Fuel System Components:	Primarily carburetor-based fuel delivery systems, often Mikuni or Keihin models. Manual will cover tuning, cleaning, and component replacement.
Engine Types
Engine Configurations:	Includes coverage for both 2-stroke and 4-stroke engines, with details on air-cooling and liquid-cooling systems where applicable.

Transmission
Standard
Transmission Type:	Polaris Variable Transmission (PVT) - Automatic CVT (Continuously Variable Transmission) is a core feature across most models.
Optional
Gearbox Options:	Some models might feature sequential gearboxes or variations on the PVT system. Manual will detail differences.
Features
Transmission Features:	Belt drive, clutch adjustments, sheave maintenance, roller replacement, and overall PVT system operation and repair.

Dimensions
Exterior
Chassis Type:	Steel tube frame, RWD (Rear-Wheel Drive) and AWD/4WD (All-Wheel Drive) configurations present across the model range. 3-wheelers noted in early years.
Weights
Dry Weight Range:	Varies significantly by model. Expect dry weights from approximately 350 lbs to over 600 lbs depending on 2WD/4WD, engine size, and features.

Safety Features
Ratings
Safety Features:	While specific safety ratings were less standardized for ATVs in this era, the manual will cover brakes, suspension, and steering system integrity crucial for safe operation.

Technology Features
Infotainment
Infotainment Features:	Minimal to non-existent in the modern sense. Focus is on functionality: headlights, taillights, speedometer, basic gauge cluster.
Driver Assistance
Assistance Features:	Not applicable for this era of ATVs. The manual focuses on mechanical and electrical systems.
Connectivity
Connectivity Features:	None. This manual deals with purely mechanical and electrical systems of the ATV.

Maintenance
Service Intervals
Typical Intervals:	Manual will detail specific intervals for oil changes (e.g., every 20-50 operating hours or annually), filter replacements, spark plug checks, drive belt inspection, and lubrication points.
Clutch Inspection Interval:	Manual will specify recommended intervals for checking the drive clutch and driven clutch for wear and proper function.
Fluid Specifications
Engine Oil:	Likely SAE 10W-30 or 10W-40 for 4-stroke engines, and specific 2-stroke oil/fuel mix ratios for 2-stroke models. Manual will specify exact grades and brands.
Transmission Gear Oil:	Manual will specify the correct type and viscosity of gear oil for the transmission and final drive units.
Brake Fluid:	DOT 3 or DOT 4 hydraulic brake fluid is typical for this era. Manual will confirm specifications and bleeding procedures.
Coolant Specifications:	For liquid-cooled models, manual will specify the type and mixture ratio of antifreeze coolant.
Known Issues
Common Wear Items:	Potential wear items include drive belts (PVT), wheel bearings, brake pads, suspension bushings, and carburetor jets due to fuel quality or usage. The manual addresses diagnosis and replacement.
Torque Specs
Torque Specifications:	Critical torque specifications for engine components, suspension fasteners, wheel nuts, and other critical areas are provided.

Vehicle History
Brand Heritage
Polarishistory:	Polaris has a long history in off-road vehicle manufacturing, starting with snowmobiles and expanding into ATVs. This manual covers a pivotal era of their ATV development.
Model Evolution
Model Progression:	The period from 1985-1995 saw Polaris transition from primarily 3-wheelers to a dominant force in 2WD and 4WD ATVs, introducing iconic models like the Trail Boss, Big Boss, and Sportsman. This manual captures these transitions.
4X4 Introduction:	The period covered saw the widespread adoption and refinement of 4-wheel drive systems on Polaris ATVs, a key technological advancement detailed in the manual.
Production
Production Period:	1985-1995 (for models covered by this specific manual).