Polaris ATVS (1985-1995) Service Repair Manual

The online edition of this manual will be available immediately without download. The physical manual will be dispatched directly by Haynes and will arrive separately from any other parts ordered.

Clymer ATV repair manuals are written specifically for the do-it-yourself enthusiast. From basic maintenance to troubleshooting to complete overhaul, Clymer manuals provide the information you need. The most important tool in your tool box may be your Clymer manual, get one today. Every Clymer manual contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of a motorcycle. This, in addition to extensive research, allows Clymer to achieve an unmatched level of detail, accuracy and clarity. The step-by-step instructions and two-column text with large print are user-friendly. Bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb-tabbed chapters, numbered table of contents and an extensive index make it possible to locate the desired section quickly.

The Haynes Online Manual gives you the trusted content of the famous printed Workshop Manual with extra features to get the job done. Online Manuals provide the following benefits: Troubleshooting tool for fast diagnosis of common problems. Colour-coded wiring diagrams for key systems. Videos tutorials for common DIY tasks. Colour photographs with approximately 750 in each manual. Photos can be zoomed in to observe key details. Fully searchable Dictionary of automotive terms. Hyperlinks to additional relevant information in other manual chapters. Print any page at home.

What's Covered

THIS POLARIS ATV MANUALS IS 424 PAGES.

QUICK REFERENCE DATA

• CHAPTER ONE / GENERAL INFORMATION
• MANUAL ORGANIZATION / NOTES, CAUTIONS AND WARNINGS / SERVICE HINTS / TORQUE SPECIFICATIONS / SAFETY FIRST / EXPENDABLE SUPPLIES / ENGINE AND CHASSIS SERIAL NUMBERS / BASIC HAND TOOLS / PRECISION MEASURING INSTRUMENTS / SPECIAL TIPS / MECHANIC'S TIPS / OPERATING TIPS / RTV SEALANT / THREADLOCK / GASKET REMOVER / PARTS REPLACEMENT / SPECIFICATIONS

• CHAPTER TWO / TROUBLESHOOTING
• OPERATING REQUIREMENTS / EMERGENCY TROUBLESHOOTING / ENGINE STARTING / ENGINE PERFORMANCE / ENGINE NOISES / EXCESSIVE VIBRATION / ELECTRICAL TESTING / POWER TRAIN / STEERING / ENGINE ELECTRICAL SYSTEM TROUBLESHOOTING / VOLTAGE REGULATOR / SPEED LIMITER

• CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
• PRE-RIDE CHECKS / SERVICE MAINTENANCE INTERVALS SCHEDULE / FLUID CHECKS / BREAK-IN / PERIODIC LUBRICATION / ENGINE OIL AND FILTER CHANGE / CONTROL CABLE LUBRICATION / ENGINE COUNTER BALANCER / TRANSMISSION OIL CHANGE / REAR AXLE HOUSING LUBRICATION / PERIODIC MAINTENANCE / DRIVE BELT CHAIN ADJUSTMENT CHECK / OIL INJECTION PUMP ADJUSTMENT / GENERAL INSPECTION AND MAINTENANCE / TOE-IN ADJUSTMENT / TUNE-UP / CYLINDER HEAD BLOT TORQUE / CYLINDER COMPRESSION CHECK / SPARK PLUG / IGNITION TIMING / CAM CHAIN ADJUSTMENT / VALVE CLEARANCE / CARBURETOR ADJUSTMENT / IDLE SPEED / STORAGE / SPECIFICATIONS

• CHAPTER FOUR / ENGINE (2-STROKE MODELS)
• REMOVAL INSTALLATION / LIQUID COOLING / CYLINDER HEAD / CYLINDER / REED VALVE ASSEMBLY / PISTON, PISTON PIN AND RINGS / RECOIL STARTER / COOLANT PUMP / ENGINE BALANCER / CRANKCASE / CRANKSHAFT, BEARINGS AND SHIM / OIL INJECTION SYSTEM / BREAK-IN / SPECIFICATIONS

• CHAPTER FIVE / ENGINE (4-STROKE MODELS)
• ENGINE COOLING / ENGINE LUBRICATION / REMOVAL INSTALLATION / CYLINDER HEAD COVER AND ROCKER ARM ASSEMBLY / CAMSHAFT / CYLINDER HEAD / CYLINDER / PISTON, PIN AND RINGS / CAM CHAIN, SPROCKETS AND TENSIONER / RECOIL STARTER / FLYWHEEL AND STATOR PLATE / COOLANT PUMP / CRANKCASE / CRANKSHAFT, BALANCE SHAFT, BEARINGS AND SEALS / OIL PUMP / ONE WAY CHECK VALVE / BREAK-IN PROCEDURE / SPECIFICATIONS

• CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
• CARBURETOR OPERATION / CARBURETOR / THROTTLE CABLE / CHOKE CABLE / FUEL TANK / FUEL SHUTOFF VALVE / AIR BOX / FUEL PUMP / EXHAUST SYSTEM / SPECIFICATIONS

• CHAPTER SEVEN / COOLING SYSTEM
• POLARIS VARIABLE TRANSMISSION PVT COOLING SYSTEM / ENGINE COOLING AIR COOLED MODELS / ENGINE COOLING LIQUID COOLED MODELS / SPECIFICATIONS

• CHAPTER EIGHT / CLUTCH/DRIVE BELT SYSTEM
• DRIVE UNIT / DRIVE PULLEY ASSEMBLY / DRIVEN PULLEY / DRIVE BELT / CLUTCH INNER COVER / SPECIFICATIONS

• CHAPTER NINE / TRANSMISSION SYSTEM
• TYPE I TRANSMISSION / TYPE II TRANSMISSION / TYPE III TRANSMISSION / SPECIFICATIONS

• CHAPTER TEN / FRONT DRIVE SYSTEM
• FRONT HUBS / FRONT DRIVE SHAFT BOOTS AND CV JOINTS / CENTER CHAIN AND SPROCKETS / FRONT CHAIN AND SPROCKETS / SPECIFICATIONS

• CHAPTER ELEVEN / ELECTRICAL SYSTEM
• CHARGING SYSTEM / ALTERNATOR STATOR / VOLTAGE REGULATOR/RECTIFIER / CAPACITOR DISCHARGE IGNITION / IGNITION HIGH TENSION COIL /IGNITION STATOR COILS EXCITER AND PULSER / ELECTRIC STARTING SYSTEM / STARTER DRIVE GEARS / STARTER SOLENOID / LIGHTING SYSTEM / SWITCHES / SPECIFICATIONS

• CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
• FRONT WHEEL / FRONT HUB / FRONT FORK TUBES / FRONT SUSPENSION / STEERING SHAFT / TIRES AND WHEELS / SPECIFICATIONS

• CHAPTER THIRTEEN / REAR SUSPENSION
• REAR WHEELS / REAR TIRES / REAR AXLE / DRIVE CHAIN / DRIVE AND DRIVEN SPROCKETS / TIRE CHANGING AND TIRE REPAIRS / SHOCK ABSORBER / REAR SWING ARM / SPECIFICATIONS

• CHAPTER FOURTEEN / BRAKES
• FRONT BRAKES / HYDRAULIC BRAKES / FRONT BRAKE CALIPER / MECHANICAL REAR BRAKE CALIPER / HYDRAULIC REAR CALIPER / MASTER CYLINDER / BRAKE HOSE / BRAKE DISC / BRAKE BLEEDING / SPECIFICATIONS

• CHAPTER FIFTEEN / BODY
• SEAT / FUEL TANK COVER / FRONT PANEL / FRONT FENDER / REAR FENDER / SIDE PANELS / SPECIFICATIONS

  INDEX

  WIRING DIAGRAMS

  MODELS COVERED:

• 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 POLARIS 250 - 425 CC 3-WHEEL MODELS
• 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 POLARIS 250 - 425 CC 4-WHEEL MODELS
• 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 POLARIS 250 - 425 CC 6-WHEEL MODELS
• SCRAMBLER, TRAIL BLAZER, TRAIL BOSS, CYCLONE, BIG BOSS, XPLORER, SPORT, SPORTSMAN, MAGNUM

  CLYMER POLARIS SCRAMBLER 250 MANUAL

• CLYMER POLARIS TRAIL BOSS 250 MANUAL
• CLYMER POLARIS CYCLONE 250 MANUAL
• CLYMER POLARIS TRAIL BOSS 250 2X4 MANUAL
• CLYMER POLARIS TRAIL BOSS 250 4X4 MANUAL
• CLYMER POLARIS TRAIL BOSS 250R MANUAL
• CLYMER POLARIS TRAIL BOSS 250ES MANUAL
• CLYMER POLARIS BIG BOSS 250 4X6 MANUAL
• CLYMER POLARIS TRAIL BLAZER 250 MANUAL
• CLYMER POLARIS TRAIL BOSS 350L 2X4 MANUAL
• CLYMER POLARIS TRAIL BOSS 350L 4X4 MANUAL
• CLYMER POLARIS BIG BOSS 250 6X6 MANUAL
• CLYMER POLARIS BIG BOSS 350 6X6 MANUAL
• CLYMER POLARIS TRAIL BOSS 300 2X4 MANUAL
• CLYMER POLARIS TRAIL BOSS 300 4X4 MANUAL
• CLYMER POLARIS TRAIL BOSS 400L 2X4 MANUAL
• CLYMER POLARIS TRAIL BOSS 400L 4X4 MANUAL
• CLYMER POLARIS SPORT 400L MANUAL
• CLYMER POLARIS SPORTSMAN 400 4X4 MANUAL
• CLYMER POLARIS BIG BOSS 300 6X6 MANUAL
• CLYMER POLARIS TRAIL BOSS 400L 6X6 MANUAL
• CLYMER POLARIS SCRAMBLER 400 MANUAL
• CLYMER POLARIS XPLORER 400 4X4 MANUAL
• CLYMER POLARIS XPLORER 300 6X6 MANUAL
• CLYMER POLARIS XPLORER 400L 6X6 MANUAL

  THIS MANUAL COVERS 3-, 4- AND 6-WHEEL MODELS WITH 250-425CC MODELS INCLUDING:

• SCRAMBLER 250 (1985-1986)
• SCRAMBLER 400 (1995)
• TRAIL BLAZER 250 (1990-1995)
• TRAIL BOSS 250 (1985-1987, 1994)
• TRAIL BOSS 250 2X4 (1988-1993)
• TRAIL BOSS 250 4X4 (1987-1993)
• TRAIL BOSS 250ES (1988)
• TRAIL BOSS 250R (1988)
• TRAIL BOSS 300 2X4 (1994-1995)
• TRAIL BOSS 300 4X4 (1994-1995)
• TRAIL BOSS 350L 2X4 (1990-1993)
• TRAIL BOSS 350L 4X4 (1990-1993)
• TRAIL BOSS 400L 2X4 (1994-1995)
• TRAIL BOSS 400L 4X4 (1994)
• CYCLONE 250 (1987)
• BIG BOSS 250 4X6 (1988-1992)
• BIG BOSS 250 6X6 (1991-1993)
• BIG BOSS 300 6X6 (1994)
• BIG BOSS 350 6X6 (1993)
• BIG BOSS 400L 6X6 (1994)
• XPLORER 300 6X6 (1995)
• XPLORER 400 4X4 (1995)
• XPLORER 400L 6X6 (1995)
• SPORT 400L (1994-1995)
• SPORTSMAN 400 4X4 (1994-1995)
• MAGNUM 2X4 (1995)
• MAGNUM 4X4 (1995)