Target Audience:
Professional technicians and experienced DIY mechanics.
Competitor Manuals:
Comparable to OEM service manuals in scope and detail, offering a more accessible digital format.
Instant Access:
Immediate download available after purchase, allowing for quick service initiation.
Comprehensive Coverage:
Covers a wide array of models and all essential repair and maintenance aspects.
Diagnostic Support:
Includes an advanced troubleshooting guide to aid in problem diagnosis.
Illustrated Guidance:
Contains necessary illustrations, diagrams, and specifications for clear procedural understanding.
General Coverage:
All 1999-2000 Polaris ATV models
Specific Models 1999:
Big Boss 500 6X6, Scrambler 400 4X4, Magnum 500 4X4, Trail Blazer 250 4X2, Trail Boss 240 4X2, Xplorer 300 4X2, Xplorer 300 4X4, Xplorer 400 4X4, Scrambler 500 4X4, Sport 400 4X2, Sportsman 335 4X4, Sportsman 500 4X4
Specific Models 2000:
Magnum 325 4X2, Magnum 325 4X4, Magnum 500 4X4, Scrambler 400 4X2, Trail Blazer 250 4X2, Trail Boss 325 4X2, Xpedition 325 4X4, Xpedition 425 4X4, Xplorer 250 4X4, Xplorer 400 4X4, Scrambler 400 4X4, Scrambler 500 4X4, Sportsman 335 4X4, Sportsman 500 4X4, Sportsman 500 6X6, Sportsman 500 RSE 4X4
Estimated Pages:
Likely 800+ pages (typical for comprehensive ATV repair manuals)
Type:
Factory Service Manual / Repair Manual
Format:
PDF (Portable Document Format)
Powertrain:
Engine, cooling system, exhaust system, fuel system, transmission, drivetrain (AWD/2WD operation, CVTs, driveshafts, differentials, axles)
Chassis And Suspension:
Frame, suspension components (shocks, A-arms, bushings), steering system, braking system (hydraulic, calipers, rotors), wheel bearings
Electrical System:
Ignition system, charging system (stator, regulator/rectifier, battery), lighting system, starter system, wiring diagrams, switchgear, diagnostics
Body And Trim:
Body panels, fenders, racks, seat, storage compartments
Maintenance:
Routine checks, lubrication, fluid changes, filter replacements, spark plug service, chain/belt adjustment
Repair:
Complete disassembly, inspection, cleaning, assembly, and installation of all components and systems.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic codes, electrical testing procedures
Overhaul:
Engine rebuilds, transmission overhaul, suspension rebuilds
Depth:
Comprehensive; covers basic maintenance to complete mechanical and electrical overhauls, including detailed diagnostic procedures.
Quality:
High-resolution scans, searchable text (if OCR processed), clear illustrations and diagrams.
Compatibility:
Viewable on any device with a PDF reader (PC, Mac, tablet, smartphone).
Printability:
Printable pages for on-site use.
Binding Style:
Not applicable for digital download, but implies a professionally bound document if it were physical.
Paper Quality:
Not applicable for digital download, but factory manuals typically use durable, semi-gloss paper.
Engine Type Examples:
Single-cylinder, 4-stroke, liquid-cooled (common for Polaris models of this era, specific engine details vary by model)
Displacement Range:
Approximately 240cc to 500cc (based on listed models)
Horsepower Range:
Estimated 15-30 HP (varies significantly by model and displacement)
Torque Range:
Estimated 15-35 lb-ft (varies significantly by model and displacement)
Fuel Delivery:
Carbureted (e.g., Mikuni) on most models; fuel injection may be present on some later 2000 models or specific performance variants.
Fuel Type:
Unleaded Gasoline
Atv Safety Standards:
Adheres to relevant ATV safety standards for the period. Manual likely includes safety warnings and operating guidelines.
Active Safety Features:
On-Demand All-Wheel Drive (AWD), powerful hydraulic disc brakes
Passive Safety Features:
Integrated lighting, robust frame construction, ergonomic design
Infotainment Features:
Basic; typically limited to instrument cluster (speedometer, odometer, fuel gauge, indicator lights). No advanced infotainment systems.
Driver Assistance Features:
On-Demand All-Wheel Drive (AWD) system is the primary driver assistance technology.
Connectivity Features:
None (no Bluetooth, USB, or cellular connectivity).
Oil Change Interval:
Typically every 100 hours or annually, whichever comes first. Specific interval detailed in the manual.
Transmission Fluid Change:
Typically every 200 hours or annually. Specific interval detailed in the manual.
Engine Oil Type:
SAE 10W-40 or 20W-50 motorcycle-specific oil with JASO MA rating (check manual for precise specification).
Transmission Fluid Type:
Polaris recommended transmission fluid, or equivalent high-quality ATV transmission fluid (refer to manual for specific P/N and type).
Coolant Type:
Ethylene glycol-based antifreeze coolant (typically 50/50 mix with distilled water).
Common Wear Items:
Brake pads, suspension bushings, wheel bearings, drive belts (CVT), starter solenoids, fuel pump (on FI models if applicable).
Electrical Issues:
Stator failure, regulator/rectifier issues, and battery drain can be points of concern; manual provides diagnostic steps.
Cv Joint Wear:
Susceptible to damage from debris and improper boot maintenance; manual covers inspection and replacement.
Polaris Heritage:
Polaris Industries has a long history in powersports, originating with snowmobiles and expanding significantly into ATVs and off-road vehicles.
Atv Development:
The late 1990s was a period of rapid growth and innovation for Polaris ATVs, introducing new engine technologies, suspension designs, and AWD systems across their diverse lineup.
Production Era:
Models covered represent a key generation of Polaris ATV development, establishing many of the features and platforms still relevant today.
