1985-1995 Polaris ATVS Clymer Maintenance Troubleshooting Repair Manual
M496
Contents:
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)
Softcover: 424 pages
ISBN 9780892876686
Publisher: Clymer
Shipping weight 700g