Market Position:
Essential technical resource for owners and mechanics of 1999-2000 Polaris ATVs, offering factory-level repair and maintenance guidance.
Competitive Analysis:
Directly sourced from factory service documentation, providing a significant advantage over generic repair guides for specific model years and configurations.
Key Features:
Comprehensive coverage, detailed diagrams, torque specifications, troubleshooting guides, no printing/saving restrictions, free replacement offer.
Engine Systems:
Engine overhaul, disassembly, reassembly, lubrication, ignition system, fuel system (carburetor/EFI), cooling system, exhaust system, starting system, charging system, drive train.
Transmission Drivetrain:
Transmission operation and repair, differential, drive shafts, axles, clutches, gearboxes, AWD systems where applicable.
Chassis Suspension:
Front and rear suspension, steering system, shocks, springs, bushings, linkages, swingarms.
Braking System:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake pads, rotors, parking brake.
Electrical System:
Wiring diagrams, lighting, battery, starter motor, alternator/stator, ignition coil, CDI unit, fuses, switches, electronic control modules (ECMs).
Bodywork Plastics:
Body panels, fenders, seats, racks, handlebars, trim components, plastics.
Fuel Delivery Efi:
For EFI models, coverage likely includes basic troubleshooting of fuel pump, injectors, and ECU signals.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, gear oil), spark plug service, tire pressure checks.
Troubleshooting:
Diagnostic charts, common problems and solutions, error code interpretation (EFI models), no-spark troubleshooting, starting issues, performance problems.
Repair Rebuild:
Complete tear down and rebuild procedures for major components, including engine, transmission, suspension, and brake systems.
Specifications:
Detailed torque specifications for all fasteners, fluid capacities, component dimensions, engine specifications (bore, stroke, compression ratio), electrical specifications.
Performance Enhancement:
While not a performance tuning guide, it provides baseline specifications for tuning carburetor settings and checking engine health.
Depth:
Comprehensive, covering everything from basic maintenance and routine checks to complete engine and transmission rebuilds, including advanced diagnostics.
Diagnostic Capabilities:
Includes troubleshooting guides for common electrical faults (e.g., no spark, charging issues) and mechanical problems.
Engine Types Covered:
Various single-cylinder and twin-cylinder 2-stroke and 4-stroke engines, including 250cc, 300cc, 325cc, 335cc, 400cc, and 500cc displacements.
Performance Tuning:
While primarily focused on repair, the manual contains specifications that aid in understanding engine performance parameters such as compression ratios and valve clearances.
Fuel System Details:
Covers carburetor adjustment, cleaning, and rebuilding (including main jet, pilot jet, mixture screw settings) and basic fuel injection (EFI) troubleshooting for applicable models.
Lubrication System:
Details engine oil specifications, capacities, lubrication points, and oil change procedures. Specific oil viscosity recommendations are provided (e.g., SAE 20W-50 for many Polaris models of this era).
Cooling System:
Information on radiator, coolant types, coolant capacity, flushing, and bleeding procedures. Specific coolant ratios are likely mentioned.
Engine Displacements:
250cc, 300cc, 325cc, 335cc, 400cc, 425cc, 500cc
Service Intervals:
Detailed schedule for oil changes (e.g., every 100 hours or 6 months), filter replacements, spark plug service, valve adjustments (if applicable), and component inspections. Specific intervals for PVT belt inspection/replacement.
Engine Oil Specification:
Likely SAE 20W-50 or SAE 10W-40 depending on specific engine and temperature range. Manual will specify exact Polaris or compatible oil grades.
Coolant Specification:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Manual will specify capacity and type.
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify type and capacity.
Gear Oil Specification:
Polaris Demand Drive (front differential) fluid and rear final drive gear oil specification will be detailed. Likely GL-4 or GL-5 rated gear oils.
Spark Plug Specification:
Manual will list correct spark plug type and gap for each engine variant (e.g., NGK).
Common Issues:
Manual addresses common issues such as PVT belt wear, carburetor jetting problems, ignition system failures (stator, coil), suspension wear, and steering linkage play.
Brand Heritage:
Polaris has a long history in recreational vehicles, known for innovation and ruggedness in the ATV market since the early days of ATVs.
Model Evolution Summary:
The 1999-2000 models represent a significant period of growth and refinement for Polaris ATVs, introducing or refining popular lines like the Sportsman, Scrambler, and Magnum.
Production Focus:
This manual covers a transition period where Polaris was solidifying its market share with diverse models catering to utility, sport, and recreational riders.
Model List 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
Model List 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
