Target Audience:
DIY enthusiasts, service technicians, and Polaris ATV owners
Historical Significance:
Covers a crucial period in Polaris's history, solidifying its position as a major ATV manufacturer.
Key Benefit:
Comprehensive DIY repair and maintenance resource for a wide range of Polaris ATVs
Market Comparison:
Offers a more comprehensive solution than basic owner's manuals, covering deep mechanical repairs often found in dealership-level service manuals.
Unique Selling Points:
Extensive model year and model coverage, detailed illustrations, searchable PDF format, and a lifetime replacement guarantee.
Applicable Years:
1985-1995
Format Type:
PDF Download
Usage Rights:
No restrictions on printing or saving/burning to disc
Specific Models Covered:
1985-1995 Polaris Scrambler (3-wheeler), Trail Boss (2x4, 4x4, 250 R/ES, 250, 350L), Cyclone, Big Boss (4x6, 6x6), Trail Blazer, 250 (2x4, 4x4, 6x6), 300 (2x4, 4x4, 6x6), 350 (2x4, 4x4, 6x6), Sportsman (4x4), Sport, Scrambler, Xplorer 4x4, Magnum (2x4, 4x4).
Model Subgroups:
Includes 2-wheel drive, 4-wheel drive, and 6x6 variants across various model lines.
Depth Of Coverage:
Complete tear down and rebuild
Included Illustrations:
Pictures and part diagrams
Torque Specifications:
Included
Maintenance Procedures:
Included
Diagnostic Guides:
Included
Navigation:
Clickable chapters and searchable text
Core Atv Systems:
Engine (internal components, rebuild), fuel system, ignition system, electrical system (charging, lighting, starting), transmission, drive train, suspension (front forks, rear shocks/struts, swingarm), braking system (rotors, pads), chassis, body panels, plastics, skis.
Body And Frame:
Body panels, plastics, frame inspection, fenders, seat, handlebars, and associated hardware.
Wheels And Tires:
Wheel specifications, tire sizing, and likely procedures for mounting and balancing.
Repair And Rebuild:
Complete tear down and rebuild procedures for all major components, engine overhaul, transmission repair, suspension service, brake system overhaul.
Maintenance And Adjustment:
Routine maintenance schedules, fluid changes (coolant, oil), carburetor adjustment (idle speed, mixture), valve clearance adjustment, throttle cable adjustment, lubrication.
Troubleshooting And Diagnostics:
Troubleshooting common problems such as 'no spark', starting issues, performance problems, electrical faults, and diagnostic guides.
Diagnostic Level:
Advanced diagnostics, including electrical system troubleshooting and error code interpretation.
Rebuild Scope:
Detailed step-by-step instructions for complete engine rebuilds, transmission overhauls, and component-level repairs.
Specifications And Data:
Comprehensive technical specifications including torque values, fluid capacities, measurements, and performance data.
Engine Types Covered:
2-stroke and 4-stroke engines (specifics vary by model)
Performance Tuning:
Information likely includes carburetor adjustments, timing, and possibly performance enhancement tips for specific models.
Fuel And Air System Coverage:
Carburetor (including jets, idle speed, mixture screw, pilot jet, slow jet, main jet), intake, fuel pump, fuel lines, fuel tank.
Ignition Components:
Ignition, magneto, stator, spark plugs, coil, flywheel.
Cooling System Maintenance:
Procedure for changing coolant, radiator, cooler.
Displacement Range:
Covers models ranging from 250cc to 400cc, with various engine configurations including 2-stroke and 4-stroke.
Internal Engine Parts Coverage:
Piston, cylinder (jug), connecting rod (conrod), crankshaft, crank, flywheel, cams, camshafts, valves, valve clearance, head, intake, exhaust.
Starter System:
Starter motor, starter solenoid, starter switch, and related wiring.
Cooling System Components:
Radiator, cooling fan (if applicable), coolant reservoir, hoses.
Carburetor Tuning Details:
Detailed information on adjusting pilot jet, slow jet, main jet, mixture screw, and idle for optimal performance.
Transmission Coverage:
Drive train, primary reduction gear, transmission, gears, linkages, shafts.
Clutch Coverage:
Clutch, clutch adjustment, clutch service.
Clutch Type:
Likely includes details on centrifugal clutches or CVT systems depending on the specific model and year.
Drive System Coverage:
Front drive, rear drive, 4x4 systems, 6x6 systems, drive shafts, CV joints (likely covered under chassis/drivetrain).
Weight Information:
Likely includes dry weight, wet weight, and potentially GVWR for various models.
Component Weights:
Likely includes weights for key components during removal/installation procedures.
Gross Vehicle Weight Rating:
GVWR information is typically provided for each model to indicate maximum load capacity.
Dimensional Data:
Likely includes width, length, height, and wheelbase for specific models. Also mentions tire size.
Safety Information:
Likely includes safety precautions during maintenance and repair procedures.
Brake Coverage:
Brakes, brake pads, brake rotors, hydraulic brakes, brake system maintenance and repair.
Electrical Safety:
Includes information on battery, charging system, rectifier, fuses, and electrical troubleshooting to prevent hazards.
Frame And Suspension Safety:
Information on frame inspection, strut and suspension maintenance to ensure safe operation.
Efi Coverage:
Mentions EFI (Electronic Fuel Injection) and PGM-FI, suggesting coverage for models equipped with these systems.
Fuel Injection Diagnostics:
Troubleshooting for EFI systems, including potential sensor issues and fuel delivery problems.
Error Code Troubleshooting:
Includes troubleshooting for error codes and electronic systems.
Battery And Charging Diagnostics:
Procedures for testing battery condition, charging system output, and diagnosing electrical shorts or open circuits.
Starter And Kickstart:
Covers starter motor, kickstart mechanism, and troubleshooting for starting issues.
Lighting System Maintenance:
Includes information on lights and associated electrical components.
Scheduled Maintenance:
Maintenance schedule and intervals for routine servicing are included.
Engine Oil Change Interval:
Specific mileage or hour-based intervals for engine oil changes, depending on model and usage.
Fluid Recommendations:
Specifications for essential fluids such as engine oil (which engine oil), coolant, and brake fluid.
Engine Oil Viscosity:
Specific viscosity recommendations for engine oil (e.g., SAE 10W-40, SAE 20W-50).
Coolant Type:
Recommended coolant type and mixture ratio.
Known Problems And Fixes:
Troubleshooting section addresses common issues, including 'no spark' problems, and provides guidance for fixing them.
Lubrication Requirements:
Covers lubrication for various components and systems.
Transmission Lubrication:
Lubrication requirements and procedures for the transmission and drive systems.
Suspension And Steering Maintenance:
Maintenance and adjustment procedures for suspension and steering components like forks, struts, swinger, and triple trees.
Tire And Wheel Care:
Information on tire pressure (psi), wheel maintenance, and potentially tire replacement.
Charging System Issues:
Troubleshooting for charging system problems, including rectifier and stator checks.
Carburetor Problems:
Guidance on common carburetor issues like gumming, leaks, and incorrect fuel-air mixture.
Starting Problems:
Troubleshooting for failure to start, intermittent starting, and starting system component failures.
Idle Control Issues:
Guidance on adjusting or repairing issues related to engine idle speed and stability.
Polarís Atv Development:
Covers a significant period of Polaris's ATV development, including the transition from 3-wheelers to 4-wheelers and the introduction of various popular models.
Model Lineup Changes:
Documents the evolution of Polaris ATV lines such as Scrambler, Trail Boss, Big Boss, Trail Blazer, Sportsman, Sport, Xplorer, and Magnum.
3-Wheeler To 4-Wheeler Transition:
Covers the earlier 3-wheeler models (Scrambler) and their progression into the more stable 4-wheel designs of later years.
Production Years Covered:
1985 to 1995, a decade of significant innovation and growth for Polaris in the ATV market.
