Clymer Manuals Polaris 400, 450 and 500 Sportsman 1996-2013 M365-5
Polaris W969140 (1996) Xplorer 400L Parts. Oil Tank Xplorer 400L W969140. Cover, Clutch Inner 400. Out of Stock Part Number. May 23, 2020 Polaris 400 2 Stroke Engine Motor Rebuilt Power Sports Nation How to change the transmission fluid on a polaris sportsman atv polaris scrambler 500 oil change you polaris sportsman oil change 400 h o you polaris scrambler repair manual 50 90 400 500 850. Whats people lookup in. Nov 22, 2015 1993 polaris 350 4x4 owners manual, 1995 polaris xplorer 400 4x4 manual, 2004 polaris trail boss 330 owners manual, free polaris service manuals. Introduction Chapter 1: Tune-up and routine maintenance Chapter 2: Part A: 2-stroke engine Chapter 2: Part B: 4-stroke engine Chapter 2: Part C: Polaris.
- Written from hands-on experience gained from the complete strip-down and rebuild of a Polaris Xplorer 400 4X4, Clymer can help you understand, care for and repair your Polaris Xplorer 400 4X4. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos.
- The recommended engine oil and filter changes for your Polaris Off-Road Vehicle can be found listed below and in the Periodic Maintenance Chart of your Owner's Manual. Perform a break-in oil and filter change at 25 engine hours or one month of use — whichever comes first. Following break-in, change your oil and filter every 100 hours, six months or 1,000 miles — whichever comes first.
See the 'Models Covered' tab for full model listing.
Includes Color Wiring Diagrams.
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.
Includes Color Wiring Diagrams.
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.
Printed Manual 1996-2013
Free domestic shipping on orders over $35
Free domestic shipping on orders over $35
Online Manual 1996-2013
1 Year Subscription
1 Year Subscription
More About - Clymer Manuals Polaris 400, 450 and 500 Sportsman 1996-2013 M365-5
Models Covered|Contents|Online Detail|Videos|Large Image
Sportsman 400 (2001-2005)
Sportsman 400 HO (2011-2013)
Sportsman 450 (2006-2007)
Sportsman 450 Browning Edition (2006)
Sportsman 500 (1996-2010)
Sportsman 500 RSE (2000-2002)
Sportsman 500 DUSE (2001-2002)
Sportsman 500 HO (2001-2006, 2008-2013)
Sportsman 500 X2 (2006-2010)
Sportsman Touring 500 (2008-2013)
Worker 500 (1997-2001)
Xplorer 500 (1997)
This manual covers all models with EFI.
This manual does not cover 500 ATP HO models.
Sportsman 400 HO (2011-2013)
Sportsman 450 (2006-2007)
Sportsman 450 Browning Edition (2006)
Sportsman 500 (1996-2010)
Sportsman 500 RSE (2000-2002)
Sportsman 500 DUSE (2001-2002)
Sportsman 500 HO (2001-2006, 2008-2013)
Sportsman 500 X2 (2006-2010)
Sportsman Touring 500 (2008-2013)
Worker 500 (1997-2001)
Xplorer 500 (1997)
This manual covers all models with EFI.
This manual does not cover 500 ATP HO models.
This Polaris Sportsman ATV manual is 705 pages.
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers /Model identification (2004 models) / Fasteners / Shop supplies / Tools /Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control (ETC) / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch system / Gearshift linkage /Transmission / Electrical testing / Electrical troubleshooting / Meter assembly / Front gearcase / Final drive / Front suspension and steering / Brake system / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Engine oil level check / Engine oil and filter change / Oil pump priming / Oil pressure test / Transmission oil level check / Transmission oil change / Front gearcase oil level change / Front gearcase oil change / Front hub (1996-early 2004 models) oil level check / Front hub (1996-early 2004 models) oil change / Clutch draining and drying / Clutch belt inspection / Air filter service / Fuel tank vent hose / Fuel hose inspection / Fuel filter service / Brake system / Control cable lubrication Throttle cable/electronic throttle control (ETC) adjustment / Throttle cable adjustment / Choke cable inspection / Cooling system inspection / Coolant level check / Exhaust system / Suspension / Tires and wheels / Toe-in adjustment alignment / Lubrication service: front suspension arms , front struts, lower end of the steering shaft, front drive axle inner U-joints, front propeller shaft, front U-joints, rear U-joint, upper and lower rear suspension arms, and rear bar stabilizer assembly / Fastener inspection / Valve clearance / Compression test / Spark plug / Ignition timing / Idle speed / Specifications
CHAPTER FOUR / ENGINE TOP END
Engine service / Engine cooling / Engine lubrication / Servicing the engine in the frame / Exhaust system / Cylinder head cover / Rocker arm assembly / Camshaft / Cylinder head / Valves and valve components / Cylinder block / Piston and piston rings / Camshaft chain and sprockets / Break-in procedure / Specifications
CHAPTER FIVE / ENGINE LOWER END
Flywheel and stator plate / Recoil starter / Crankcase / Oil pump / Oil system one-way check valve / Break-in procedure / Specifications
CHAPTER SIX / CARBURETOR AND FUEL SYSTEM
Carburetor operation / Carburetor / Carburetor tests and adjustments / Throttle cable replacement / Starting enrichment (choke) cable / Fuel tank / Fuel shutoff valve / Fuel level sending unit (2004-on models) / Air filter air box / Fuel pump / Specifications
CHAPTER SEVEN / FUEL INJECTION SYSTEM
Fuel system initialization and starting procedure / Depressurizing the fuel system / Fuel line fittings / Throttle body / Fuel rail and fuel injector / Fuel pump / Fuel sender / Pressure regulator / Fuel tank / Crankshaft position sensor (CPS) / Manifold air pressure (MAP) sensor / Intake air temperature (IAT) sensor / Idle air control (IAC) / Throttle position sensor (TPS) / Engine coolant temperature (ECT) sensor / Electronic control module (ECM) / Self diagnosis / Throttle cable replacement / Air filter air box / Specifications
CHAPTER EIGHT / COOLING SYSTEM
Air cooling system / Liquid cooling system / Hoses and hose clamps / Radiator / Cooling fan / Coolant pump / Thermostat / Specifications
CHAPTER NINE / CLUTCH AND DRIVE BELT
Clutch system operation / Clutch tools / Clutch drying / Drive belt / Belt alignment / Drive clutch / Driven clutch / Specifications
CHAPTER TEN / TRANSMISSION (1996-early 2004 models)
Transmission / Transmission inspection / Shift shafts / Front output shaft / Transmission gearcase oil seal inspection and replacement / Shift selector linkage / Specifications
CHAPTER ELEVEN / TRANSMISSION (LATE 2004-on MODELS)
Transmission / Transmission shafts / Differential gear assembly / (X2 and Touring models) / Snorkel shaft / Shift selector linkage / Specifications
CHAPTER TWELVE / FRONT DRIVE SYSTEM
Front hub and Hilliard clutch / (1996-early 2004 models) / Front hub (late 2004-on, X2 and Touring models) / Front drive axle, boots and constant velocity (CV) / joints / Front drive shaft / Front gearcase / Front gearcase-Deluxe models with active decent / control (2007-on Sportsman 500, X2 and Touring models) / Specifications
CHAPTER THIRTEEN / ELECTRICAL SYSTEM
Electrical basics / Electrical component replacement / Electrical connectors / Battery / Battery negative terminal / Charging system / Alternator stator / Voltage regulator/rectifier / (1996-early 2004 carbureted models) / Logic box (late 2004-2006 carbureted models) / Capacitor discharge ignition (carbureted models) / DC/Ignition system (fuel injected models) / Ignition coil / Electric starting system / Starter drive gears / Starter solenoid / Headlight system / Taillight and work light / Indicator lamp (1996-2002 models) / Speed sensor / Transmission switch / Resistor module (2004-on models) / Shift indicator circuit (late 2004-on models) / Differential solenoid (X2 and Touring models) / Switches / Electronic throttle control (ETC) switch / All wheel drive (AWD) coil / Active descent control (ADC) coil / (2007-on X2 and Touring models) / Cooling system switch and sensor / Fuses and circuit breaker (2008 models) / Speedometer / On-board diagnostics / Winch (models so equipped) / Winch contactor (models so equipped) / Specifications
CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING
Front wheel / Front strut / Front strut cartridge and spring / Control arm / Handlebar / Tie rods / Steering post / Tires and wheels / Specifications
CHAPTER FIFTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Rear hub and bearing carrier / Rear drive axle / Rear drive axle boot replacement / (1996-1998 models) / Rear drive axle CV joint and boots / (1999-on models) / Upper control arm (all models except X2 and Touring) / Lower control arm (all models except X2 and / Touring) / Upper control arm (X2 and Touring models) / Lower control arm (X2 and Touring models) / Upper and lower control arm inspection / Stabilizer linkage (all models except X2 and / Touring) / Stabilizer support (all models except X2 and / Touring) / Stabilizer support and bar (X2 and Touring models) / Specifications
CHAPTER SIXTEEN / BRAKES
Brake service / Front brake pad replacement / Front caliper / Output shaft brake pad replacement / (1996-1997 models) / Output shaft brake caliper (1996-1997 models) / Output shaft brake pad replacement / (1998-2002 models) / Output shaft brake caliper (1998-2002 models) / Rear brake pad replacement (2003-on models / except X2 and Touring) / Rear caliper (2003-on models except X2 and / Touring) / Rear brake pad replacement (X2 and / Touring models) / Rear caliper (X2 and Touring models) / Front master cylinder / Rear master cylinder / Brake hose replacement / Brake bleeding tips / Brake bleeding / Brake fluid draining / Rear brake pedal / Brake disc / Specifications
CHAPTER SEVENTEEN / BODY AND FRAME
Plastic inserts / Seat / Side panel / Fender cover / Front fender / Front rack, rail and grille (1996-2004 models) / Front rack and storage box (2005-on models) / Front bumper / Radiator guard (1996-2003 models) / Radiator brush guard (2004-on models) / Brush guard grill and radiator side shield / (2004-on models) / Rear rack, rail and bumper (1996-2002 models) / Rear rack and rail (2003-on except X2 and / Touring) / Rear rack and handle (Touring models) / Rear fender / Rear quarter panel (X2 models) / Footwell / Footwell support bracket (X2 and Touring models) / Rear storage box (all models except X2 and Touring) / Cargo box (X2 models) / Specifications
INDEX
COLOR WIRING DIAGRAMS
Models covered
Clymer Manuals Polaris Sportsman 400 Manual
Clymer Manuals Polaris Sportsman 450 HO Manual
Clymer Manuals Polaris Sportsman 450 Manual
Clymer Manuals Polaris Sportsman 450 Browning Edition Manual
Clymer Manuals Polaris Sportsman 500 Manual
Clymer Manuals Polaris Sportsman 500 RSE Manual
Clymer Manuals Polaris Sportsman 500 DUSE Manual
Clymer Manuals Polaris Sportsman 500 HO Manual
Clymer Manuals Polaris Sportsman 500 X2 Manual
Clymer Manuals Polaris Sportsman Touring 500 Manual
Clymer Manuals Polaris Worker 500 Manual
Clymer Manuals Polaris Xplorer 500 Manual
Clymer Manuals Polaris Sportsman 400 Online Manual
Clymer Manuals Polaris Sportsman 450 Online Manual
Clymer Manuals Polaris Sportsman 450 Browning Edition Online Manual
Clymer Manuals Polaris Sportsman 500 Online Manual
Clymer Manuals Polaris Sportsman 500 RSE Online Manual
Clymer Manuals Polaris Sportsman 500 DUSE Online Manual
Clymer Manuals Polaris Sportsman 500 HO Online Manual
Clymer Manuals Polaris Sportsman 500 X2 Online Manual
Clymer Manuals Polaris Sportsman Touring 500 Online Manual
Clymer Manuals Polaris Worker 500 Online Manual
Clymer Manuals Polaris Xplorer 500 Online Manual
Sportsman 400 (2001-2005)
Sportsman 400 HO (2011-2013)
Sportsman 450 (2006-2007)
Sportsman 450 Browning Edition (2006)
Sportsman 500 (1996-2010)
Sportsman 500 RSE (2000-2002)
Sportsman 500 DUSE (2001-2002)
Sportsman 500 HO (2001-2006, 2008-2013)
Sportsman 500 X2 2006 (2007-2010)
Sportsman Touring 500 (2008-2013)
Worker 500 (1997-2001)
Xplorer 500 (1997)
This manual covers all models with EFI.
This manual does not cover 500 ATP HO models.
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers /Model identification (2004 models) / Fasteners / Shop supplies / Tools /Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control (ETC) / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch system / Gearshift linkage /Transmission / Electrical testing / Electrical troubleshooting / Meter assembly / Front gearcase / Final drive / Front suspension and steering / Brake system / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Engine oil level check / Engine oil and filter change / Oil pump priming / Oil pressure test / Transmission oil level check / Transmission oil change / Front gearcase oil level change / Front gearcase oil change / Front hub (1996-early 2004 models) oil level check / Front hub (1996-early 2004 models) oil change / Clutch draining and drying / Clutch belt inspection / Air filter service / Fuel tank vent hose / Fuel hose inspection / Fuel filter service / Brake system / Control cable lubrication Throttle cable/electronic throttle control (ETC) adjustment / Throttle cable adjustment / Choke cable inspection / Cooling system inspection / Coolant level check / Exhaust system / Suspension / Tires and wheels / Toe-in adjustment alignment / Lubrication service: front suspension arms , front struts, lower end of the steering shaft, front drive axle inner U-joints, front propeller shaft, front U-joints, rear U-joint, upper and lower rear suspension arms, and rear bar stabilizer assembly / Fastener inspection / Valve clearance / Compression test / Spark plug / Ignition timing / Idle speed / Specifications
CHAPTER FOUR / ENGINE TOP END
Engine service / Engine cooling / Engine lubrication / Servicing the engine in the frame / Exhaust system / Cylinder head cover / Rocker arm assembly / Camshaft / Cylinder head / Valves and valve components / Cylinder block / Piston and piston rings / Camshaft chain and sprockets / Break-in procedure / Specifications
CHAPTER FIVE / ENGINE LOWER END
Flywheel and stator plate / Recoil starter / Crankcase / Oil pump / Oil system one-way check valve / Break-in procedure / Specifications
CHAPTER SIX / CARBURETOR AND FUEL SYSTEM
Carburetor operation / Carburetor / Carburetor tests and adjustments / Throttle cable replacement / Starting enrichment (choke) cable / Fuel tank / Fuel shutoff valve / Fuel level sending unit (2004-on models) / Air filter air box / Fuel pump / Specifications
CHAPTER SEVEN / FUEL INJECTION SYSTEM
Fuel system initialization and starting procedure / Depressurizing the fuel system / Fuel line fittings / Throttle body / Fuel rail and fuel injector / Fuel pump / Fuel sender / Pressure regulator / Fuel tank / Crankshaft position sensor (CPS) / Manifold air pressure (MAP) sensor / Intake air temperature (IAT) sensor / Idle air control (IAC) / Throttle position sensor (TPS) / Engine coolant temperature (ECT) sensor / Electronic control module (ECM) / Self diagnosis / Throttle cable replacement / Air filter air box / Specifications
CHAPTER EIGHT / COOLING SYSTEM
Air cooling system / Liquid cooling system / Hoses and hose clamps / Radiator / Cooling fan / Coolant pump / Thermostat / Specifications
CHAPTER NINE / CLUTCH AND DRIVE BELT
Clutch system operation / Clutch tools / Clutch drying / Drive belt / Belt alignment / Drive clutch / Driven clutch / Specifications
CHAPTER TEN / TRANSMISSION (1996-early 2004 models)
Transmission / Transmission inspection / Shift shafts / Front output shaft / Transmission gearcase oil seal inspection and replacement / Shift selector linkage / Specifications
CHAPTER ELEVEN / TRANSMISSION (LATE 2004-on MODELS)
Transmission / Transmission shafts / Differential gear assembly / (X2 and Touring models) / Snorkel shaft / Shift selector linkage / Specifications
CHAPTER TWELVE / FRONT DRIVE SYSTEM
Front hub and Hilliard clutch / (1996-early 2004 models) / Front hub (late 2004-on, X2 and Touring models) / Front drive axle, boots and constant velocity (CV) / joints / Front drive shaft / Front gearcase / Front gearcase-Deluxe models with active decent / control (2007-on Sportsman 500, X2 and Touring models) / Specifications
CHAPTER THIRTEEN / ELECTRICAL SYSTEM
Electrical basics / Electrical component replacement / Electrical connectors / Battery / Battery negative terminal / Charging system / Alternator stator / Voltage regulator/rectifier / (1996-early 2004 carbureted models) / Logic box (late 2004-2006 carbureted models) / Capacitor discharge ignition (carbureted models) / DC/Ignition system (fuel injected models) / Ignition coil / Electric starting system / Starter drive gears / Starter solenoid / Headlight system / Taillight and work light / Indicator lamp (1996-2002 models) / Speed sensor / Transmission switch / Resistor module (2004-on models) / Shift indicator circuit (late 2004-on models) / Differential solenoid (X2 and Touring models) / Switches / Electronic throttle control (ETC) switch / All wheel drive (AWD) coil / Active descent control (ADC) coil / (2007-on X2 and Touring models) / Cooling system switch and sensor / Fuses and circuit breaker (2008 models) / Speedometer / On-board diagnostics / Winch (models so equipped) / Winch contactor (models so equipped) / Specifications
CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING
Front wheel / Front strut / Front strut cartridge and spring / Control arm / Handlebar / Tie rods / Steering post / Tires and wheels / Specifications
CHAPTER FIFTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Rear hub and bearing carrier / Rear drive axle / Rear drive axle boot replacement / (1996-1998 models) / Rear drive axle CV joint and boots / (1999-on models) / Upper control arm (all models except X2 and Touring) / Lower control arm (all models except X2 and / Touring) / Upper control arm (X2 and Touring models) / Lower control arm (X2 and Touring models) / Upper and lower control arm inspection / Stabilizer linkage (all models except X2 and / Touring) / Stabilizer support (all models except X2 and / Touring) / Stabilizer support and bar (X2 and Touring models) / Specifications
CHAPTER SIXTEEN / BRAKES
Brake service / Front brake pad replacement / Front caliper / Output shaft brake pad replacement / (1996-1997 models) / Output shaft brake caliper (1996-1997 models) / Output shaft brake pad replacement / (1998-2002 models) / Output shaft brake caliper (1998-2002 models) / Rear brake pad replacement (2003-on models / except X2 and Touring) / Rear caliper (2003-on models except X2 and / Touring) / Rear brake pad replacement (X2 and / Touring models) / Rear caliper (X2 and Touring models) / Front master cylinder / Rear master cylinder / Brake hose replacement / Brake bleeding tips / Brake bleeding / Brake fluid draining / Rear brake pedal / Brake disc / Specifications
CHAPTER SEVENTEEN / BODY AND FRAME
Plastic inserts / Seat / Side panel / Fender cover / Front fender / Front rack, rail and grille (1996-2004 models) / Front rack and storage box (2005-on models) / Front bumper / Radiator guard (1996-2003 models) / Radiator brush guard (2004-on models) / Brush guard grill and radiator side shield / (2004-on models) / Rear rack, rail and bumper (1996-2002 models) / Rear rack and rail (2003-on except X2 and / Touring) / Rear rack and handle (Touring models) / Rear fender / Rear quarter panel (X2 models) / Footwell / Footwell support bracket (X2 and Touring models) / Rear storage box (all models except X2 and Touring) / Cargo box (X2 models) / Specifications
INDEX
COLOR WIRING DIAGRAMS
Models covered
Clymer Manuals Polaris Sportsman 400 Manual
Clymer Manuals Polaris Sportsman 450 HO Manual
Clymer Manuals Polaris Sportsman 450 Manual
Clymer Manuals Polaris Sportsman 450 Browning Edition Manual
Clymer Manuals Polaris Sportsman 500 Manual
Clymer Manuals Polaris Sportsman 500 RSE Manual
Clymer Manuals Polaris Sportsman 500 DUSE Manual
Clymer Manuals Polaris Sportsman 500 HO Manual
Clymer Manuals Polaris Sportsman 500 X2 Manual
Clymer Manuals Polaris Sportsman Touring 500 Manual
Clymer Manuals Polaris Worker 500 Manual
Clymer Manuals Polaris Xplorer 500 Manual
Clymer Manuals Polaris Sportsman 400 Online Manual
Clymer Manuals Polaris Sportsman 450 Online Manual
Clymer Manuals Polaris Sportsman 450 Browning Edition Online Manual
Clymer Manuals Polaris Sportsman 500 Online Manual
Clymer Manuals Polaris Sportsman 500 RSE Online Manual
Clymer Manuals Polaris Sportsman 500 DUSE Online Manual
Clymer Manuals Polaris Sportsman 500 HO Online Manual
Clymer Manuals Polaris Sportsman 500 X2 Online Manual
Clymer Manuals Polaris Sportsman Touring 500 Online Manual
Clymer Manuals Polaris Worker 500 Online Manual
Clymer Manuals Polaris Xplorer 500 Online Manual
Sportsman 400 (2001-2005)
Sportsman 400 HO (2011-2013)
Sportsman 450 (2006-2007)
Sportsman 450 Browning Edition (2006)
Sportsman 500 (1996-2010)
Sportsman 500 RSE (2000-2002)
Sportsman 500 DUSE (2001-2002)
Sportsman 500 HO (2001-2006, 2008-2013)
Sportsman 500 X2 2006 (2007-2010)
Sportsman Touring 500 (2008-2013)
Worker 500 (1997-2001)
Xplorer 500 (1997)
This manual covers all models with EFI.
This manual does not cover 500 ATP HO models.
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Related Items
Clymer Manuals Polaris ATVS 1985-1995 M496
See the 'Models Covered' tab for full model listing. 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.
Printed Manual, 1985-1995
Free domestic shipping on orders over $35
Free domestic shipping on orders over $35
Online Manual, 1985-1995
1 Year Subscription
1 Year Subscription
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More About - Clymer Manuals Polaris ATVS 1985-1995 M496
Models Covered|Contents|Online Detail|Videos|Large Image
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)
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)
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)
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)
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Clymer manuals are copyright protected.
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