Polaris ATV workshop repair manual book Workshop Manuals

Polaris ATV workshop repair manual book

Polaris Industries was an United states maker of snowmobiles, ATV, and local electric automobiles. Robin develops and provides all-terrain vehicle and snowmobile motors for U. However, in 2010 Polaris relocated some of its utility and sport vehicle system to Mexico. An all-terrain automobile,

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(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) Contents: * Quick Reference Data * 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 Voltage Regulator / Speed Limiter * 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 come here

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Manual covers the following models: * Polaris Sportsman 400 2001-2005 * Polaris Sportsman 450 2006-2007 * Polaris Sportsman 450 Browning Edition 2006 * Polaris Sportsman 500 1996-2010 * Polaris Sportsman 500 RSE 2000-2002 * Polaris Sportsman 500 DUSE 2001-2002 * Polaris Sportsman 500 HO 2001-2006 2008-2010 * Polaris Sportsman 500 X2 2006-2010 * Polaris Sportsman 500 Touring 2008-2010 * Polaris Worker 500 1997-2001 * Polaris Xplorer 500 1997 Contents: * QUICK REFERENCE DATA * 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 * TROUBLESHOOTING Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control Specifications * 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 details

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Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications * TROUBLESHOOTING Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Front suspension and steering / Brake system / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Pre-ride inspection / Air box drain plugs / Air filter / Engine oil and filter change / Oil pressure test / Spark plug / Spark arrester cleaning / Fuel tank vent hose / Fuel hose inspection / Carburetor / Choke adjustment / Tune-up / Ignition timing / Valve clearance / Compression test / Control cables / Cooling system / Skid plate inspection / Specifications * ENGINE TOP END Engine service / Cylinder head cover / Specifications * TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM (2005-ON MODELS) Transmission and internal shift mechanism / Transmission inspection / Internal shift mechanism inspection / Reverse gear arm shifter / Specifications * FUEL AND EXHAUST SYSTEMS Carburetor / Pilot screw / Carburetor details

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Safety / Cleaning parts / Handling gasoline safely / Service hints / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable shop supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Fabricating tools / Mechanics tips / Ball bearing replacement / Oil seals / Riding safely / Storage / Specifications * TROUBLESHOOTING Operating requirements / Starting the engine / Starting difficulties / Engine starting system / Charging system / Ignition system / Speed limiter and electronic throttle control / Fuel system / Engine overheating Engine / Engine noises / Cylinder leak down test / Power train / Steering / Frame noise / Brakes * LUBRICATION MAINTENANCE AND TUNE-UP Pre-ride checklist / Service intervals / Maintenance schedule / Battery / Tyres and wheels / unit / Drive pulley / Driven pulley / Drive belt / Clutch inner cover * TRANSMISSION Mainshaft / Countershaft / Shift selector / Shift selector and linkage * FRONT DRIVE SYSTEM Front hub and Hillard clutch / Front drive axle boots and constant velocity CV joints / Center chain and sprockets related info

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this manual DOES NOT include Xpedition Predator X-2 diesel or 335 gasoline models. Contents: * Introduction: About This Manual; Introduction To The Polaris ATV; Identification Numbers; Buying Parts; General Specs; Maintenance Techniques Tools And Working Facilities; Safety First!; ATV Chemicals And Lubricants; Fraction/Decimal/Millimiter Equivalents; Conversion Factors; Troubleshooting * Tune-Up And Routing Maintenance * 2-Stroke Engines * 425 Through 500 4-Stroke Engines * 325 And 330 4-Stroke Engines * 600 Through 800 4-Stroke Engines * Polaris Variable Transmission (PVT) * Transmission * Cooling System * Fuel And Exhaust System - Carbureted Models * Fuel And Exhaust System - Fuel-Injected Models * Electrical And Ignition Systems * Steering Suspension And Final Drive * Brakes Wheels And Tyres * Body And Frame * Wiring Diagrams Haynes motorcycle and ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and illustrations guide you through every job from basic maintenance and troubleshooting to complete teardown & rebuild. considerably more details

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repair manual
hints / Torque specifications / Fasteners / Lubricants / Threadlocking compound / RTV gasket sealant / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Fabricating tools / Mechanics tips / Bearing replacement / Seals / Riding safety / Storage / Specifications * TROUBLESHOOTING Operating requirements / Starting the engine / Starting difficulties / Engine is difficult to start / Engine starting system / Charging system / Ignition system / Speed limiter and electronic throttle control (1997-98 models) / Electronic throttle control (1999-on models) / Fuel system / Engine overheating / Engine / Engine noises / Cylinder leakdown test / Power train / Steering / Frame noise / Brakes * LUBRICATION MAINTENANCE AND TUNE-UP Pre-checks / Service intervals / Periodic lubrication / Drive chain cleaning Camshaft / Cylinder head / Valves and valve components / Cylinder block / Piston and piston rings / Camshaft chain and sprockets / Break-in procedure / Specifications * ENGINE LOWER END Engine / Flywheel and stator plate / Recoil starter / Crankcase / Crankshaft inspection / Balancer shaft here

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Manual covers the following models: * Sportsman 600 (2003-2005) * Sportsman 700 (2002-2006) * Sportsman 700 EFI (2004-2007) * Sportsman 700 EFI X2 (2008) * Sportsman MV7 (2005-2006) * Sportsman 800 EFI (2005-2010) * Sportsman 800 EFI X2 (2007-2009) * Sportsman 800 EFI Touring (2008-2009) Contents: * QUICK REFERENCE DATA * 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 * TROUBLESHOOTING Warning light system / Starting the engine / Engine will not start / Starting difficulties / Poor engine performance / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch system / Electrical testing / Electrical troubleshooting / Meter models) / Relays / Ignition system identification / CDI unit / Trigger coil / Ignition coil / Electronic control unit (ECU) / Starting system / Starter / Starter solenoid / Electronic throttle control (ETC) switch / Headlight pod / Headlight / Taillight assembly / Work light (models so lots more

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following manual: * Polaris Big Boss * Polaris Cyclone * Polaris Magnum * Polaris Scrambler * Polaris Sport * Polaris Sportsman * Polaris Trail Blazer * Polaris Trail Boss * Polaris Xplorer * Polaris Xpress Contents: * About this manual Intro to the Polaris ATV Identification numbers Buying parts; General specifications; Maintenance techniques tools and working facilities; Safety first!; ATV chemicals and lubricants; Troubleshooting * Tune-up and routine maintenance * 2-stroke engines * 4-stroke engines * Polaris Variable Transmission * Transmissions * Cooling system * Fuel and exhaust systems * Electrical and ignition systems * Steering suspension and final drive * Brakes wheels and tyres * Frame and bodywork * Wiring diagrams * Conversion factors information

Polaris Industries was an United states maker of snowmobiles, ATV, and local electric automobiles. Polaris relies in Minneapolis exurb of Medina, Minnesota, American. The organization in addition manufactures motorbikes through its success motorbikes subsidiary and through the Indian Motorcycle subsidiary which they bought in April 2011. Polaris no longer produces watercraft.

Robin develops and provides all-terrain vehicle and snowmobile motors for U.S.-based leisure equipment manufacturer Polaris Industries Inc. Starting in 1995 because of the Polaris Magnum 425 4-stroke atv and in 1997, with the introduction associated with "twin 700" snowmobile engine Polaris begun the growth and production of in-house produced energy plants, known as the "freedom" distinct motors, now present many models across their present production lines. This production makes some Polaris items 100% United states made.

However, in 2010 Polaris relocated some of its utility and sport vehicle system to Mexico. Polaris snowmobiles continue to be 100% American created using the powertrain equipment manufactured in Osceola, WI and the automobile set up in Roseau, MN. Almost all powertrain and automobiles for the off road line tend to be manufactured in the Osceola and Roseau facilities, correspondingly. The Victory and Indian bike companies are United states created using complete powertrains and automobile installation situated in Osceola, WI and nature Lake, IA, correspondingly.

An all-terrain automobile, also referred to as a quad, quad bike, three-wheeler, four-wheeler, or quadricycle are defined by the United states nationwide requirements Institute as a car that moves on low-pressure tires, with a chair that's straddled by the operator, along with handlebars for steering controls. While the title implies, it is made to handle a wider selection of terrain than other vehicles. Even though it is a street-legal automobile in some countries, it's not street-legal within most shows and provinces of Australian Continent, america or Canada.

Because of the latest ANSI meaning, ATVs tend to be meant for use by one operator, even though some companies are suffering from ATVs designed for usage by the operator and one traveler. These ATVs tend to be referred to as combination ATVs.

The driver sits on and runs these cars like a bike, nevertheless extra rims provide most stability at slowly rates. Although designed with 3 or 4 wheels, six-wheel designs exist for specialized applications. System dimensions of ATVs presently accessible in the usa,, are normally taken for 49 to 1,000 cc.


Suzuki had been a chief when you look at the improvement four-wheeled ATVs. It offered initial design, the 1982 QuadRunner LT125, that was a recreational machine for novices. Suzuki offered the very first four-wheeled mini ATV, the LT50, from 1984 to 1987. After the LT50, Suzuki sold 1st ATV with a CVT transmission, the LT80, from 1987 to 2006.

In 1985 Suzuki launched to your industry the very first high-performance four-wheel ATV, the Suzuki LT250R QuadRacer. This machine was in production for the 1985–1992 model years. During its production run it underwent three major manufacturing makeovers. However, the core qualities were retained. These were: an advanced long-travel suspension system, a liquid-cooled two-stroke motor and a completely manual five-speed transmission for 1985–1986 brands and a six-speed transmission for the 87–92 models. It absolutely was a machine solely designed for rushing by highly trained bikers.

Honda responded a-year later using FourTrax TRX250R—a machine which have maybe not already been replicated until recently. It presently continues to be a trophy winner and competitor to big-bore ATVs. Kawasaki Heavy companies reacted having its Tecate-4 250. The TRX250R was very similar to the ATC250R they eventually changed, and is frequently considered one of the greatest athletics ATVs ever built.

In 1987, Yamaha Motor business introduced an alternate sort of superior machine, the Banshee 350, which showcased a twin-cylinder liquid-cooled two-stroke engine from RD350LC street bike. Heavier and more difficult to ride in the soil versus 250s, the Banshee became a favorite device with sand dune riders because of its unique energy distribution. The Banshee stays well-known, but 2006 is the just last year it had been for sale in the U.S.; they stayed available in Canada until 2008 plus in Australian Continent until 2012.

Shortly after the development of the Banshee in 1987, Suzuki released the LT500R QuadRacer. This excellent quad was run on a 500 cc liquid-cooled two-stroke engine with a five-speed transmission. This ATV made the nickname "Quadzilla" with its remarkable number of speeds and dimensions. While you will find reports of 100+ mph inventory Quadzillas, it was officially taped by 3&4 Wheel Action mag as achieving a top rate of over 79 mph in a higher speeds shootout with its 1988 June problem, which makes it the fastest production four-wheeled ATV ever before produced. Suzuki discontinued producing the LT500R in 1990 after simply four ages.

On top of that, improvement energy ATVs had been quickly escalating. The 1986 Honda FourTrax TRX350 4x4 ushered when you look at the age of four-wheel drive ATVs. More manufacturers quickly then followed match, and 4x4s need remained the preferred type of ATV ever since. These machines is popular with hunters, farmers, ranchers and staff at construction web sites.
ATV with a tow spreader mounted

Models carry on, today, to-be split into the game and energy markets. Sport designs are little, light, two-wheel drive cars that accelerate quickly, posses a manual transmission and run at increases to roughly 80 miles per hour. Utility systems are generally larger four-wheel drive cars with a maximum speed as much as roughly 70 miles per hour. They usually have the ability to haul little plenty on affixed racks or tiny dump beds. They might also tow little trailers. As a result of the different and varying weights, each possess advantages on different sorts of landscapes. A well known model is Yamaha's Raptor 700, which features a nearly 700 cc four-stroke system.

Six-wheel models usually have a small dump sleep, with a supplementary set of rims behind to improve the payload ability. They may be either four-wheel drive, or six-wheel drive.

In 2011 LandFighter ended up being founded, "initial Dutch/European ATV brand name". The greatest part of manufacturing takes web site in Taiwan, to European guidelines; the ATVs were finally put together inside Netherlands.
Edgar Hetteen, who was described because of the Snowmobile Hall of popularity in St. Germain, Wisconsin, whilst the daddy associated with the snowmobile, and Allan Hetteen, are partners in Hetteen Hoist and Derrick store in Roseau, Minnesota. Edgar had fallen out of school following the eighth level in 1934. Their workers, David Johnson, partnered with Paul Knochenmus, and Orlen Johnson, who was simply 1st person ever before to drive a Polaris, decided to develop a car that may travel through snow. These motors' biggest usage was to create searching places considerably accessible. The staff worked overtime in order to complete their particular idea design in 1954. After generating they making use of a grain silo conveyor buckle as a track and a vintage Chevy bumper for skis, they had initial snow machine. After returning from a vacation, Edgar was shown the device, but was skeptical of the price. and was disappointed that the team have invested team some time items regarding device. The No 1 sled is quickly marketed to Roseau lumberyard holder "gold Pete" H.F. Peterson for $465 to be able to fulfill company payroll.

However, the staff always been centered on building snowmobiles and soon an additional design was made, known as the Polaris Sno Traveler. 1st manufacturing design rolled off the assembly line in Minnesota in 1956. The initial versions weighed close to 1,000 pound and moved at a speed of about 20 miles per hour. They arrived in a two-tone paint task. In order to publicize the newest snowmobile and show their dependability and usefulness, in 1960 Edgar led three snowmobiles on a 1200-mile trek throughout the Alaskan backwoods, starting from Bethel, Alaska. The journey took three months, and much of that time period, Edgar struggled to steadfastly keep up 10 mph over the snowfall. The Fairbanks Daily News-Miner wear them their front-page. However, their lack caused difficulties for him aided by the organization's board of administrators. Soon after completing the trip, Edgar remaining the company in June and begun a competing business called Polar production in Thief lake Falls, Minnesota. The organization title later on altered to Arctic businesses; when you look at the mid-1980s they recorded for personal bankruptcy amid intense competition as snowmobiles shot to popularity also producers hopped in to the marketplace. The company emerged from bankruptcy and continues on these days as Arctic Cat.

Polaris began developing a smaller consumer-sized, front motor snowmobile to contend with the SkiDoo in the early sixties. In 1964, Polaris released the Comet. However, the Comet soon ran into troubles because could not travel in every kinds of snowfall problems. Polaris then recalled the sleds and quickly created a brand new prototype to prevent bankruptcy. The brand new design, the 1965 Mustang, became a winner as a family group snowmobile and boosted Polaris product sales. Polaris proceeded to develop snowmobiles similar to this model throughout the 1960s-1970s, and continued to become one of several management in snowmobile industry.

During the early 1980s, Polaris going producing an Indy style snowmobile with IFS and a wider stance. They carried on because of the Indy style sled when you look at the 90's utilizing the violent storm, Ultra, and path outlines, within the last few years Polaris has re released the Indy. In 1985, Polaris launched the Trailboss, which is considered to be the initial American-made all-terrain vehicles. Nowadays, Polaris is among the best selling brands of ATV's. When you look at the late 1990s, Polaris introduced the Polaris Rocky hill King- a snowmobile certain for mountain surface. In May 2009, Polaris revealed the development of an On-Road Vehicle unit. The brand new division are going to be dedicated to the growth of Victory motorcycles and other on-road merchandise and brands. This year, Polaris launched the Polaris Rush snowmobile which had an innovative new suspension system system and better trail managing features. This snowmobile normally available with retro layouts on the dash and Iq models. In late 2005, Polaris sectors announced it would buy a portion of KTM Motorcycles. Through this venture KTM is rolling out their ATV and Polaris has developed Sport ATVs which utilize KTM 525 and 450 powerplants that have seen great profits on the ATV rushing circuit.
A Polaris Ranger altered as an Ambulance.

May 21, 2010, Polaris launched it was opening a brand new manufacturing plant in Mexico. The sis premises in Osceola, WI however stays in full process. The opening associated with Monterrey, Mexico facility was likely to cut the organization $30 million yearly, with almost all of that savings via lower wages. The Monterrey center has actually 3 set up outlines dedicated to production of Ranger side-by-sides for global markets. The initial intention associated with Monterrey facility was to offer markets when you look at the Southern United States plus Mexico and South America. The announcement regarding the Huntsville, AL factory suggests the Monterrey premises will primarily provide non-US markets.

In October 2011, Polaris announced a good investment in Brammo, Inc., an electric powered car business situated in Ashland, Oregon, United States. Their first production electric motorcycle, the Brammo Enertia, was put together in Ashland and sold at dealerships. Polaris proceeded their investment in Brammo when it took part in the $13 million orifice tranche of Brammo's show C funding round in July 2012. Polaris was indeed showing interest in electric propulsion, making a power type of their Ranger Side-by-Side and more recently purchasing worldwide Electrical Motorcars from Chrysler. As you publication put it, "This current move likely signals the extension of clean and quiet drivetrains to ATVs and motorcycles under the global large's brand name umbrella – snowmobiles may have to wait on power advancements before they come to be commercially feasible." On January 15, 2015, Polaris announced that it have purchased the complete electric motorcycle business from Brammo. Creation of electric motorbikes was slated to start at Polaris' factory in Spirit pond, IA during the last half of 2015. Polaris furthermore manufactures Victory and Indian motorbikes within nature Lake factory.

In 2012, production restarted on the Indy-named sleds using the launch of the 2013 Indy 600 and Indy 600 SP. For 2014, Polaris will expand the Indy name and supply model variants for nearly all groups.

On April 11, 2013, Polaris established that it obtained Aixam-Mega, a French quadricycle maker.

On January 9, 2015, Polaris launched it should be opening a new 600,000-square-foot facility in Huntsville, Alabama that use at least 1,700 workers. Building in the brand-new manufacturer is set to start during the early 2015 and should be exposed because of the springtime of 2016. The plant will supporting a few core processes like, vehicle assembly, chassis and body painting, welding, fabrication and injection molding.

After assessment with stakeholders like farmers and quad bicycle producers, Australian Continent's Heads of office security Authorities in 2011 released a technique meant to reduce steadily the range deaths and serious accidents connected with quad-bike utilize. The introduction of the report is closely followed by The Weekly circumstances magazine and ABC television which reviewed the problem through their 7.30 regimen. Aside from motivating of standard security precautions like helmet-wearing, the technique additionally suggest improvement a national instruction curriculum, point of purchase information for purchasers and, controversially, a recommendation that owners think about appropriate of an after-market anti-crush unit which may provide added cover in case of a roll-over.

If the report was launched the only real model of anti-crush coverage in the marketplace ended up being the Australian-made "Quad bar" which was vigorously opposed because of the business through news activity and a poster venture at local activities for farmers which are generally always showcase new items.

The argued that the unit was not precisely tested hence past researches of tractor-style ROPS eg a full-frame 'cage' round the operator are not best ineffective, but could add to the danger to injury or death.

In February 2012, the Melbourne-based Institute for security, payment and healing study posted a paper which criticised the study reports of this makers concerning crush safeguards devices. The report assessed research in a number of nations since 1993 concerning rollover safeguards and discovered your industry's opposition to rollover security couldn't be supported as a result of limits in previous study. They suggested more research on the subject in addition to growth of studies apparatus on the basis of the usage of ATV/quadbikes in Australian problems.

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