Polaris ATV Repair Manual 1985-1997

This DIY repair and service manual by Haynes, covers 1985-1997 Polaris ATVs, including the following models:

• Polaris Big Boss
• Polaris Cyclone
• Polaris Magnum
• Polaris Scrambler
• Polaris Sport
• Polaris Sportsman
• Polaris Trail Blazer
• Polaris Trail Boss
• Polaris Xplorer
• Polaris Xpress

Note: Info on 3-wheel models is also included. The manual covers the most popular models, from 1985 to 1997. 2x4, 4x4 and 6x6 2-wheelers and 4-wheelers are here, making this Haynes shop manual a must-have for the ATVing enthusiast. Like all DIY how-to guides, this workshop guide allows weekend mechanics to take care of their all-terrain vehicles at home without the need of special tools. From oil changes to tune-up, brake service and suspension, all the way to a complete teardown of the ATV - including the engine and transmission - make this manual required reading for anyone working on one of the models covered by the book. Model Coverage by Year:

• 1985 Polaris Scrambler 3-wheeler, Trail Boss
• 1986 Polaris Scrambler 3-wheeler, Trail Boss
• 1987 Polaris Trail Boss 250, Trail Boss 2x4, Trail Boss 4x4
• 1988 Polaris Trail Boss 2x4, Trail Boss 250R/ES, Trail Boss 4x4
• 1989 Polaris Trail Boss 250, Trail Boss 2x4, Trail Boss 4x4, Big Boss 4x6
• 1990 Polaris Trail Blazer, Trail Boss 250, Trail Boss 2x4, Trail Boss 4x4, Big Boss 4x6, Trail Boss 2x4 350L, Trail Boss 4x4 350L
• 1991 Polaris Trail Blazer, Trail Boss 250, Trail Boss 2x4, Trail Boss 4x4, Big Boss 4x6, Big Boss 6x6, Trail Boss 2x4 350L, Trail Boss 4x4 350L
• 1992 Polaris Trail Blazer, Trail Boss 250, Trail Boss 2x4, Trail Boss 4x4, Big Boss 4x6, Big Boss 6x6, Trail Boss 2x4 350L, Trail Boss 4x4 350L
• 1993 Polaris Trail Blazer, Trail Boss 250, 2x4 250, 2x4 350L, Trail Boss 4x4 250, Trail Boss 4x4 350L/Sportsman, Big Boss 6x6 250, Big Boss 6x6 350L
• 1994 Polaris Trail Blazer, Trail Boss 250, 2x4 300, Sport 400L, 2x4 400L, 4x4 300, 4x4 400L, Sportsman 4x4, Big Boss 6x6 300, Big Boss 6x6 400L
• 1995 Polaris Trail Blazer, Trail Boss 250, 2x4 300, Sport 400L, 2x4 400L, 4x4 300, Xplorer 4x4, Sportsman 4x4, Scrambler, 6x6 400L, Magnum 2x4, Magnum 4x4
• 1996 Polaris Trail Boss, Trail Blazer, Xpress 300, Xplorer 300, Xpress 400, Xplorer 400, Sport 4x4, Sportsman 4x4, Scrambler, Magnum 2x4, Magnum 4x4, Sportsman 500, Magnum 6x6, 6x6 400
• 1997 Polaris Trail Boss, Trail Blazer, Xpress 300, Xplorer 300, Xpress 400, Xplorer 400, Sport 400, Sportsman 4x4, Scrambler 4x4, Magnum 2x4, Magnum 4x4, Sportsman 500, Scrambler 500, Xplorer 500, Magnum 6x6, 400 6x6

Book Excerpt

TROUBLESHOOTING

POOR RUNNING OR NO POWER AT HIGH SPEED FIRING INCORRECT

1. Air cleaner restricted. Clean or replace element (Chapter 1).
2. Spark plug fouled, defective or worn out. See Chapter 1 for spark plug maintenance.
3. Spark plug cap or wire defective. See Chapter 1 and 5 for details of the ignition system.
4. Spark plug cap not in good contact. See Chapter 5.
5. Incorrect spark plug. Wrong type, heat range or cap configuration. Check and install correct plugs listed in Chapter 1. A cold plug or one with a recessed firing electrode will not operate at low speeds without fouling.
6. CDI box defective. See Chapter 5.
7. Ignition coil defective. See Chapter 5.

POLARIS VARIABLE TRANSMISSION (PVT) PROBLEMS

DRIVE BELT SLIPPING

1. Too much belt deflection. Adjust the belt (Chapter 1).
2. Worn belt. Replace the belt (Chapter 2).
3. Oil or grease on belt. Clean belt and check for leaking seals (Chapter 2).
4. Water (not engine coolant) on belt. Check PVT cover for proper sealing.

TWO-STROKE ENGINES

GENERAL INFORMATION The engine/transmission unit on all models is a single-cylinder two-stroke design. The engine/transmission assembly is constructed from aluminum alloy. The crankcase is divided vertically. The cylinder, piston, crankshaft bearings and connecting rod lower end bearing are lubricated by the fuel, which is a mixture of gasoline and two-stroke oil. The transmission (and counterbalancer, if equipped) is lubricated by four-stroke engine oil, which is contained in a sump within the crankcase.
OPERATIONS POSSIBLE WITH THE ENGINE IN THE FRAME The components and assemblies listed below can be removed without having to remove the engine from the frame. If, however, a number of areas require attention at the same time, removal of the engine is recommended.

• Cylinder and piston
• Oil pump (250 and 400)
• Counterbalancer (if equipped)
• Water pump
• Recoil starter (if equipped)

OPERATIONS REQUIRING ENGINE REMOVAL It is necessary to remove the engine/transmission assembly from the frame and separate the crankcase halves to gain access to the following components:

• Crankshaft and connecting rod
• Oil pump (350)
• Connecting rod
• Crankshaft
• Crankcase bearings

Subject: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Polaris 400, Boss, Cyclone, Magnum, Scrambler, Sport, Sportman, Trail Blazer, Trail Boss, Xplorer, Xpress service, maintenance, repair ISBN-10: 1563923025 | ISBN-13: 9781563923029 | Haynes 2302