Target Audience:
Do-it-yourself owners and experienced mechanics seeking comprehensive repair information.
Advantage Over Print:
More cost-effective and convenient than traditional paper manuals, easy to access and search.
Content Completeness:
Complete official full factory service repair manual, covering all styles.
Accessibility:
Instant download, no expiry dates, accessible on multiple devices.
Cost Effectiveness:
Provides a highly cost-effective alternative to dealership service or expensive proprietary repair manuals.
Manual Title:
Polaris ATV 1999 2000 Service Repair Manual PDF
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 Pages:
Hundreds (specific number not provided, but implies comprehensive coverage)
Type:
Factory Service Repair Manual / Workshop Manual
Engine Service:
Complete engine overhaul, disassembly, assembly, tuning.
Fuel System:
Carburetion, fuel pump, fuel lines, fuel tank maintenance and repair.
Body Steering Suspension:
Body panel removal/installation, steering system overhaul, suspension component replacement and adjustment.
Clutches:
Primary and secondary clutch service, inspection, and replacement.
Final Drive:
Drive shaft, differential (if applicable), and axle service.
Transmission Service:
Gearbox maintenance, disassembly, assembly, and troubleshooting.
Brakes:
Brake system diagnostics, pad/shoe replacement, caliper/master cylinder service, bleeding procedures.
Electrical System:
Ignition system, lighting, battery, starter, charging system diagnostics and repair.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
General Information:
Provides essential operational guidelines, safety precautions, and vehicle identification details.
Specifications:
Detailed technical data including torque values, clearances, electrical specifications, and fluid capacities.
Body And Trim:
Covers the removal, installation, and repair of plastic body panels, fenders, and trim pieces.
Diagnostic Procedures:
Troubleshooting guides for common and complex issues.
Repair Procedures:
Step-by-step instructions for all major repair tasks.
Maintenance Procedures:
Scheduled maintenance tasks, fluid changes, filter replacements, inspections.
Disassembly Assembly:
Complete breakdown and reassembly guidance for major components.
Engine Rebuild:
Covers complete engine disassembly, inspection of internal components, and reassembly procedures.
Suspension Repair:
Detailed steps for shock absorber replacement, ball joint servicing, tie rod adjustments, and wheel bearing maintenance.
Electrical Troubleshooting:
Systematic approach to diagnosing electrical faults using wiring diagrams and test procedures.
Tire And Wheel:
Information on tire pressure, wheel mounting, and rim maintenance.
Depth Of Information:
Complete factory level detail, suitable for both DIY enthusiasts and professional mechanics.
Visual Aids:
Hundreds of photos and illustrations to guide procedures.
Engine Tuning:
Includes information on ignition timing (if adjustable), carburetor adjustments, and valve clearances (for 4-stroke models).
Chassis Alignment:
Guidance on checking and adjusting steering alignment for optimal handling.
Performance Tuning:
While not an aftermarket tuning guide, it provides the factory specifications for optimal engine and clutch performance.
Compatibility:
All Versions of Windows, Mac, Smartphones, Tablets (via web browser or Adobe Reader)
Requirements:
Adobe PDF Reader, Winzip (free)
Searchability:
PDF format typically allows for text searching, greatly improving efficiency in finding specific information.
Printability:
Fully printable, allowing users to print specific pages or the entire manual.
Binding:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Engine Types Common:
Primarily 2-stroke and 4-stroke single-cylinder engines, with displacements ranging from 250cc to 500cc.
Engine Configurations:
Predominantly single-cylinder, air-cooled or liquid-cooled engines.
Horsepower Range:
Typically 15-30 HP depending on model and engine size.
Carburetor Details:
Likely Mikuni or Keihin carburetors, with specific jetting and tuning procedures detailed in the manual.
Cooling Method:
Air-cooled and liquid-cooled systems are common across the covered models.
Oil Change Interval:
Typically every 50-100 operating hours or annually, depending on usage. Specific recommendations in manual.
Air Filter Service:
Regular cleaning or replacement of the air filter is critical for engine longevity, with specific intervals provided.
Engine Oil Type:
Likely SAE 5W-30 or 10W-40 for 4-stroke engines. Manual will specify exact API service classification and viscosity.
Gearcase Oil:
Specific gear oil for the transmission and final drive will be detailed.
Coolant Type:
If liquid-cooled, a specific ethylene glycol-based antifreeze mixture is required.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid is typically specified.
Common Wear Items:
Brake pads, drive belts (CVT), suspension bushings, and spark plugs are common wear items requiring periodic inspection and replacement.
Carburetor Tuning:
Carburetors may require periodic cleaning and adjustment due to fuel quality and usage.
Electrical Connectors:
Corrosion or loose connections in electrical harnesses can be a common issue on ATVs exposed to elements; the manual will aid in diagnosis.
