Clymer Repair Service Manual Polaris Big Boss 250 4x6 6x6 300 350 400L 6x6

Description

Clymer Polaris Manual
Models covered:
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Online Detail
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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)
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
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International
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WARRANTY:
If any products are found defective, we will assist in resolving the issue. The product will need to be returned to us or the manufacturer to determine if a replacement item will be issued. However, it is at the discretion of the manufacturer to determine if the item is defective.
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Thank You,
Vintage Cycle Parts
A Division of
Factory Powersports