🏷️ Basic Information

Make:

Polaris

Product Type:

Service Repair Manual

Product Format:

PDF Download

👋 Introduction

Target Audience:

Polaris ATV owners, technicians, and enthusiasts performing maintenance and repairs

Content Highlight:

Original Factory Service Repair Manual, providing authorized procedures and specifications.

Delivery Method:

Instant download post-payment, eliminating shipping costs and delays.

Usability:

Designed for ease of use with clear text and high-quality visuals, making it accessible for both novice and experienced mechanics.

📋 Manual Details

Vehicle Years:

1985-1995

Vehicle Types:

ATV, Light Utility Hauler

Specific Models Listed:

1985 Scrambler, 1985 Trail Boss, 1986 Scrambler, 1986 Trail Boss, 1987 Trail Boss, 1987 Cyclone, 1987 Trail Boss 4x4, 1988 Trail Boss 2x4, 1988 Trail Boss 4x4, 1988 Trail Boss 250 R/ES, 1989 Trail Boss, 1989 Trail Boss 2x4, 1989 Trail Boss 4x4, 1989 Big Boss 4x6, 1990 Trail Blazer, 1990 Trail Boss 250, 1990 Trail Boss 2x4, 1990 Trail Boss 4x4, 1990 Big Boss 4x6, 1991 Trail Blazer, 1991 Trail Boss 250, 1991 Trail Boss 2x4, 1991 Trail Boss 4x4, 1991 Big Boss 4x6, 1991 Big Boss 6x6, 1992 Trail Blazer, 1992 Trail Boss 250, 1992 Trail Boss 2x4, 1992 Trail Boss 4x4, 1992 Big Boss 4x6, 1992 Big Boss 6x6, 1993 250 2x4, 350 2x4, 250 4x4, 350 4x4, Sportsman, 250 6x6, 350 6x6, Trail Boss, Trail Blazer, 1994 300 2x4, 400 2x4, 3004x4, 400 4x4, 300 6x6, 400 6x6, Trail Boss 2W, Trail Blazer 2W, Sportsman 4x4, Sport, 1995 300 2x4, 400 2x4, 300 x4, Xplorer 4x4, 400 6x6,Trail Boss, Trail Blazer, Sportsman 4x4, Scrambler, Magnum2x4, Magnum 4x4, Sport.

Type:

Factory Service Repair Manual

Language:

English

File Format:

PDF

Print Capability:

Printable

Software Requirements:

Adobe PDF Reader

Compatibility:

All Versions of Windows & Mac

Estimated Pages:

Page count not specified, but factory service manuals for this period are typically extensive, likely several hundred pages.

📖 Manual Coverage

General Info:

Chapter 01 General Product Information

Chassis:

Chapter 02 Body, Steering and Suspension

Brakes:

Chapter 03 Brake Service

Transmission:

Chapter 04 Transmission Service

Drivetrain:

Chapter 05 Final Drive System Service

Drive System:

Chapter 06 PVT System

Engine:

Chapter 07 Engines

Electrical System:

Chapter 08 Electrical

Cooling System:

Likely includes details on liquid-cooled systems if present on specific models, or air-cooling system maintenance.

Fuel System:

Detailed coverage of fuel tanks, lines, fuel pumps (if applicable), and carburetors.

Exhaust System:

Information on exhaust system components, maintenance, and potential repairs.

Diagnostic Procedures:

Detailed troubleshooting for all covered systems

Repair Procedures:

Step-by-step repair instructions for components and systems

Maintenance Procedures:

Routine maintenance tasks and schedules

Component Overhaul:

Instructions for engine, transmission, and other major component overhauls

Torque Specifications:

Essential torque specifications for critical fasteners across all systems.

Suspension Rebuild:

Procedures for servicing suspension components, including shocks, bushings, and control arms.

Steering System Repair:

Detailed steps for steering column, tie rod, and steering rack maintenance and repair.

Depth:

Comprehensive, from basic adjustments to complete engine rebuilds

Wiring Diagrams:

Detailed electrical system diagrams included for troubleshooting and repair.

Troubleshooting Guides:

Comprehensive troubleshooting trees and diagnostic flowcharts for various symptoms.

📊 Manual Specifications

Text Readability:

Easy-to-read text sections

Graphic Quality:

High quality diagrams

Diagram Clarity:

Diagrams are presented with clarity and detail, aiding in understanding complex assemblies and procedures.

Type:

Digital Download (No physical binding)

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Types Covered:

Multiple engine configurations across various models (e.g., 2-stroke, 4-stroke, displacements vary by model).

Performance Details:

Engine specifications (horsepower, torque) vary by specific model and year; manual provides detailed data.

Fuel System Details:

Coverage includes carburetor systems and fuel delivery components specific to each model.

Carburetor Information:

Detailed specifications for carburetor types, jetting, idle speed settings, and adjustment procedures.

Engine Configurations:

Includes coverage for 2-stroke and 4-stroke engines, with varying displacements like 250cc, 300cc, 350cc, and 400cc depending on the specific model.

🔧 Transmission

Transmission Types:

Automatic (PVT - Polaris Variable Transmission), Manual (on select models, e.g., transmissions with specific gear sets).

Optional Transmissions:

Not explicitly detailed as optional, but different configurations and gear ratios exist across models.

Pvtsystem:

Detailed coverage of the Polaris Variable Transmission (PVT) system, including belt inspection, replacement, and clutch tuning.

Gear Ratios:

Manual will provide specific gear ratios for transmissions where applicable, and PVT clutching specifications.

📐 Dimensions

Dimensional Data:

Specific dimensions (length, width, height, wheelbase) vary significantly by model; manual will contain these details per model.

Weight Data:

Dry weight and curb weight specifications are provided for each model within the manual.

Towing Capacity:

Towing and rack capacity specifications are typically included for utility models.

🛡️ Safety Features

Safety Features Coverage:

Manual covers brake system maintenance, steering system integrity, and suspension safety, crucial for ATV operation.

💡 Technology Features

Infotainment Systems:

Not applicable for this era of ATVs; focus is on mechanical and electrical systems.

Driver Assistance Features:

No electronic driver assistance systems common in modern vehicles; focus is on mechanical linkages and rider control.

Connectivity Options:

N/A

🔧 Maintenance

Maintenance Schedule:

Detailed service intervals for engine oil changes, filter replacements, PVT belt inspection, brake service, and chassis lubrication.

Engine Oil:

Specific viscosity grades (e.g., SAE 10W-30, SAE 5W-30) and API service classifications for engine oil are detailed per model.

Transmission Fluid:

Specifications for transmission and final drive lubricants, including types and capacities.

Brake Fluid:

Specifications for brake fluid type (e.g., DOT 3) and replacement intervals.

Common Problems:

While not explicitly listed as 'known issues' in the product description, the manual's troubleshooting sections will address common wear-and-tear components and potential failure points for this era of ATVs.

Pvtbeltwear:

Emphasis on PVT belt inspection and replacement is crucial due to potential for wear and failure.

Carburetor Tuning:

Manual will provide procedures for carburetor cleaning, adjustment, and synchronization, addressing common performance issues.

📚 Vehicle History

Polarishistory:

Polaris has a long history of innovation in powersports, particularly with ATVs, starting with the original ATV in the early 1980s.

Atv Evolution 1985-1995:

This period saw significant advancements in Polaris ATVs, from early utility models to sportier options and the introduction of 6x6 configurations and more powerful engines.

Key Models Evolution:

Covers early models like the Trail Boss and Scrambler, progressing through the development of the Big Boss 4x6/6x6, Trail Blazer, and the introduction of models like the Sportsman and Xplorer, showcasing the broadening of Polaris' ATV line-up.

Production Overview:

The manual consolidates information for a decade of Polaris ATV production, highlighting a diverse range of models and evolving technologies.