Welcome to the comprehensive service manual for the ATV Trail Boss 250 R ES, covering production years from 1985 through 1995. This All-Terrain Vehicle, a foundational model in the off-road lineup, is recognized for its ruggedness and versatility, making it suitable for both recreational trail riding and utility tasks. Engineered with a 2-stroke, air-cooled 244 cc engine and featuring an automatic transmission with electric start and recoil backup, the Trail Boss 250 R ES offered a robust platform for its era, competing with other notable ATVs of the period. Its design emphasizes practicality and durability, reflecting a long-standing heritage in powersports manufacturing.
This workshop repair service manual provides detailed, professional-quality information essential for the maintenance and repair of your Trail Boss 250 R ES. It covers all aspects of the vehicle, including general information, fuel and cooling systems, engine components, drivetrain, suspension, steering, frame, and the complete electrical system. Within its hundreds of pages, you will find step-by-step repair procedures, disassembly and assembly instructions, diagnostic guides, and critical specifications, all supported by numerous diagrams and illustrations. The manual is designed to empower owners, mechanics, and technicians with the knowledge needed to keep this ATV in optimal working condition.
Model:
ATV Trail Boss 250 R ES
Vehicle Type:
All-Terrain Vehicle (ATV)
Chassis Code:
Not explicitly stated, typically internal Polaris designation
Engine Code:
Not explicitly stated, typically internal Polaris designation
Market Segment:
Utility/Recreational ATV (period relevant)
Competitors:
Honda FourTrax, Yamaha Moto-4, Kawasaki Bayou, Suzuki QuadRunner
Manual Value Proposition:
Provides comprehensive, professional-quality service and repair information directly from the manufacturer, enabling DIY maintenance and repair, saving time and money.
Digital Advantage:
Easily printable sections for clean workshop use, instant access, no physical wear and tear.
Covered Years:
1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
Covered Models:
All Trail Boss 250 R ES models
Covered Trims:
All Trim Levels
Covered Transmissions:
All Transmission Types
Estimated Page Count:
Hundreds (specific number not provided, typical for workshop manuals)
Type:
Workshop Repair Service Manual
Source:
Original Manufacturer (Polaris)
Completeness Statement:
Complete and intact, no missing or corrupt parts/pages. Identical to manuals used by service/repair shops.
Systems:
General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Procedures:
Service, Maintenance, Troubleshooting, Repair, Disassembly, Assembly, Cleaning, Reinstallation, Diagnostic Procedures, Electrical Service Procedures
Depth:
Comprehensive; covers from basic maintenance to advanced diagnostics and component-level repair
Detail Level:
Step-by-step repair procedures, detailed substeps, critical specifications, critical information (notes, cautions, warnings), enlarged inset views for parts examination
Illustrations:
Hundreds of diagrams, detailed illustrations, drawings, and photos
Included:
Yes, detailed wiring diagrams for the electrical system
Troubleshooting Scope:
Comprehensive troubleshooting guides for common and complex issues across all covered systems, including electrical diagnostics.
Searchable:
Likely searchable (common PDF feature for technical manuals)
Printability:
Full Printable
Zoom Functionality:
Yes (Zoom IN/OUT)
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Software Requirements:
Adobe PDF Reader, WinZip
Operating System Compatibility:
All Versions of Windows & Mac
Delivery Method:
Instant Download
Type:
2-stroke, Reed Valve
Displacement:
244 cc (approximate)
Bore X Stroke:
Specifications available within the manual
Cooling System:
Air-Cooled
Horsepower:
Specifications available within the manual (typically in the range of 15-20 HP)
Torque:
Specifications available within the manual
Carburetor:
Mikuni VM Series (specific model details in manual)
Fuel Type:
Unleaded Gasoline
Fuel Mix Ratio:
Oil-injected or pre-mix (typically 50:1 or 40:1 for 2-stroke, depending on oil)
Type:
Automatic (CVT - Continuously Variable Transmission) with 2-speed AWD (All-Wheel Drive) or 2WD (Two-Wheel Drive) depending on sub-model
Gear Ratios:
Detailed specifications within the manual
Drive System:
Shaft Drive to Rear Wheel, Chain Drive to Front Wheel (AWD models)
Clutch Type:
Automatic Centrifugal Clutch
Length:
Specifications available within the manual (typical range 70-80 inches)
Width:
Specifications available within the manual (typical range 35-45 inches)
Height:
Specifications available within the manual (typical range 40-50 inches)
Dry Weight:
Specifications available within the manual (typically around 450-500 lbs)
Ground Clearance:
Specifications available within the manual (typically 6-10 inches)
Safety Standard Compliance:
ATV safety standards of the era (manual would detail specific manufacturer guidelines)
Braking System:
Hydraulic Disc Brakes (Front and Rear, specific configurations vary)
Lighting:
Headlights, Taillight/Brake Light
Handlebars:
Wide handlebars for stability and control
Footwells:
Wide footwells with traction pegs
Features:
Basic analog instrumentation (speedometer, odometer, warning lights), no advanced infotainment systems
Features:
None (primitive for the era)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Starting System:
Electric Start with Recoil Backup
Lighting System:
12V DC system
Oil Change Engine:
Refer to manual for specific intervals based on usage (e.g., every 20-30 hours of operation or annually)
Spark Plug Replacement:
Refer to manual for specific intervals (e.g., annually or every 100 hours)
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions; refer to manual for specific intervals
Cvt Belt Inspection:
Regular inspection for wear and tension (refer to manual for detailed schedule)
Engine Oil Type:
2-stroke engine oil (specific API/JASO rating and viscosity grade in manual)
Transmission Fluid Type:
Refer to manual for specific type and capacity (likely a gear oil or SAE 30/90)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification)
Common Wear Items:
CVT belt, brake pads, suspension bushings, throttle cables, carburetor jets (due to age and typical use)
Potential Problems:
Carburetor gumming if not run regularly, cooling fin blockage on engine, aging electrical connectors, suspension wear
Tune Up Components:
Spark plug, air filter, fuel filter, carburetor adjustment, engine oil change
Brand History:
Polaris, founded in 1954, has a long history of manufacturing off-road vehicles, snowmobiles, and powersports equipment.
Trail Boss Lineage:
The Trail Boss line was a foundational model for Polaris in the ATV market, known for its ruggedness and versatility in trail riding and utility tasks.
Production Period:
1985-1995 for the 250 R ES model
Manufacturing Location:
USA (Polaris manufacturing facilities)
Awards:
Not specifically documented for this model, but Polaris ATVs of this era were recognized for their reliability and performance in their class.