Polaris Scrambler, Cyclone, Trail Boss, Sportman Explorer 1985 - 1995

Clymer Owners Service & Repair Manual

1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995

by Clymer Staff

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Polaris Scrambler, Cyclone, Trail Boss, Sportman Explorer 1985 - 1995 - Front Cover

Front Cover

Front Cover

description

Polaris 1985 - 1995 Clymer Owners Service & Repair Manual covers 3 wheel, 4 wheel 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)

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 Instruments / Special Tips / Mechanic's Tips / Operating Tips / Rtv Sealant / Threadlock / Gasket Remover / Parts Replacement / Specifications

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

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

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

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

Fuel And Exhaust Systems
Carburetor Operation / Carburetor / Throttle Cable / Choke Cable / Fuel Tank / Fuel Shutoff Valve / Air Box / Fuel Pump / Exhaust System / Specifications

Cooling System
Polaris Variable Transmission Pvt Cooling System / Engine Cooling Air Cooled Models / Engine Cooling Liquid Cooled Models / Specifications

Clutch/Drive Belt System
Drive Unit / Drive Pulley Assembly / Driven Pulley / Drive Belt / Clutch Inner Cover / Specifications

Transmission System
Type I Transmission / Type Ii Transmission / Type Iii Transmission / Specifications

Front Drive System
Front Hubs / Front Drive Shaft Boots And Cv Joints / Center Chain And Sprockets / Front Chain And Sprockets / Specifications

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

Front Suspension And Steering
Front Wheel / Front Hub / Front Fork Tubes / Front Suspension / Steering Shaft / Tyres And Wheels / Specifications

Rear Suspension
Rear Wheels / Rear Tyres / Rear Axle / Drive Chain / Drive And Driven Sprockets / Tyre Changing And Tyre Repairs / Shock Absorber / Rear Swing Arm / Specifications

Brakes
Front Brakes / Hydraulic Brakes / Front Brake Caliper / Mechanical Rear Brake Caliper / Hydraulic Rear Caliper / Master Cylinder / Brake Hose / Brake Disc / Brake Bleeding / Specifications

Body
Seat / Fuel Tank Cover / Front Panel / Front Fender / Rear Fender / Side Panels / Specifications

Wiring Diagrams

Clymer motorcycle & ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 0892876689 (0-892-87668-9)
  • ISBN-13: 9780892876686 (978-0-892-87668-6)
  • Format: Softcover, 424 pages
  • Date Published: 06-1996

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