POLARIS ATV 300 & 400 REPAIR SHOP MANUAL 1985-1995 Cyclone Trail Boss Scrambler

THE COMPLETE, LARGEST & EASY-TO-USE REPAIR & RESTORER MANUAL FOR

POLARIS 300 & 400L ATVs

SCRAMBLER - CYCLONE - TRAIL BOSS - SPORTSMAN - EXPLORER - TRAIL BLAZER - MAGNUM

1985 ~ 1995

This repair manual covers Polaris ATVs, 1985-1995; all 3-, 4-, and 6-wheel drive models including:

Scrambler 1985-1986, 1995

Cyclone 1987

Trail Boss 1989-1994

300, 400L 4x4 1993-on

Sportsman 6x6 1995

Explorer 1995

Trail Blazer 1990-1995

Magnum 2x4

Magnum 4x4

Table of Contents

THIS ESSENTIAL 408 PAGE REPAIR & SERVICE MANUAL IS A MUST FOR OWNERS, RESTORERS, PROFESSIONAL & DO-IT-YOURSELF MECHANICS

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION

Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Basic tools /Special tools | Precision measuring tools | Electrical system fundamentals | Basic service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING

Engine operating requirements | Starting the engine | Starting difficulty | Poor idle speed performance | Poor medium and high speed performance | Electric starting system | Charging system | Ignition system | Lighting system | Cooling system | Combination meter | Fuel system | Engine overheating | Engine | Engine noises | Cylinder leakdown test | Engine oil pressure test | Clutch | Sub-transmission | Main (automatic) transmission | Global positioning system (GPS) | Drivetrain troubleshooting | Handling | Frame noise | Brakes

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP

Pre-ride check list | Maintenance schedule | Tires and wheels | Battery | Periodic lubrication | Unscheduled lubrication | Periodic maintenance | Cooling system | Engine tune-up | Storage

CHAPTER FOUR: ENGINE TOP END

Cleanliness | Exhaust system | Cylinder head cover, rocker arms | and push rods | Cylinder head | Valves and valve components | Camshaft | Camshaft chain tensioner | Cylinder | Piston and piston ring

CHAPTER FIVE: ENGINE LOWER END

Servicing engine in frame | Engine | Recoil starter | Driven pulley | Alternator cover | Starter reduction gears | Rear crankcase cover | Flywheel and starter clutch | Crankcase and crankshaft | Lubrication system | Oil strainer screens | Oil tank | Oil pump | Engine break-in

CHAPTER SIX: CLUTCH AND PRIMARY DRIVE GEAR

Clutch cover | Centrifugal clutch and primary drive gear

CHAPTER SEVEN: TRANSMISSIONS AND SHIFT MECHANISM

Shift mechanism | Sub-transmission | Automatic transmission

CHAPTER EIGHT: FUEL SYSTEM

Carburetor | Carburetor float level adjustment | Carburetor adjustments | Carburetor heater | Throttle housing and cable | Fuel tank | Fuel valve | Air box | Air intake duct | Air intake guide plate | Choke cable replacement

CHAPTER NINE: ELECTRICAL SYSTEM

Resistance and peak voltage testing | Electrical component replacement | Electrical connectors | Charging system | Alternator | Ignition system | Electric starting system | Starter relay switch | Start circuit diode | Automatic transmission (Hondamatic) | Lighting system | Combination meter | Switches | Throttle position sensor | Oil thermosensor | Coolant thermosensor | Coolant fan motor | Speed sensor unit | Fuses | GPS | Wiring diagrams

CHAPTER TEN: COOLING SYSTEM

Coolant | Cooling system inspection | Hoses and hose clamps | Coolant reserve tank | Radiator | Cooling fan | Thermostat | Water pump | Oil cooler | Thermosensors

CHAPTER ELEVEN: FRONT SUSPENSION and STEERING

Front wheel | Tires and wheels | Front hub | Shock absorbers | Tie rods | Steering knuckle | Control arms | Handlebar | Steering shaft

CHAPTER TWELVE: FRONT DRIVE MECHANISM

Front drive axles | Driveshaft | Front differential

CHAPTER THIRTEEN: REAR AXLE, SUSPENSION AND FINAL DRIVE

Rear wheels | Shock absorbers | Rear axle | Final drive unit | Swing arm

CHAPTER FOURTEEN: BRAKES

Brake service | Front brake drum | Front brake shoe replacement | Front brake panel | Wheel cylinders | Front master cylinder | Brake fluid draining | Brake bleeding | Rear drum brake | Rear brake shoe replacement | Brake panel | Front brake hose replacement | Rear brake pedal and cable | Rear brake lever/parking brake cable

CHAPTER FIFTEEN: BODY

Retaining clips | Retaining tabs | Seat | Recoil starter cover | Right side cover | Left side cover | Fuel tank cover | Front carrier | Front bumper | Center mud guards | Front mud guards | Inner front fender | Front fender | Headlight grill | Rear carrier | Rear fender | Tool box | Handlebar cover

Clymer motorcycle 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.

From the Publisher: This detailed, comprehensive manual covers Polaris Scrambler, Cyclone, Trail Boss, 300, 400L, Sportman, Explorer, Trail Blazer, Magnum ATVs, 1985 to 1995.

The expert text gives complete information on maintenance, tune-up, repair and overhaul. Hundreds of photos and drawings guide you through every step. The book includes all you will need to know to keep your Polaris ATV running right. Throughout this book where differences occur among the models, they are clearly identified.

A shop manual is a reference. You want to be able to find information fast. As in all Clymer books, this one is designed with you in mind. All chapters are thumb tabbed. Important items are extensively indexed. All procedures, tables, photos, etc., in this manual are for the reader who may be working on the ATV for the first time. All the most frequently used specifications and capacities are summarized in the Quick Reference Data pages at the front of the book.

Keep the book handy in your tool box. It will help you better understand how your all-terrain-vehicle runs, lower repair costs and generally improve your satisfaction with your Polaris ATV.

CONDITION: NEW

SIZE: 7 1/2 x 10

FORMAT: GLOSSY HEAVY PAPER STOCK COVER

NUMBER OF PAGES: 408

PROFUSELY ILLUSTRATED WITH HUNDREDS OF ORIGINAL PHOTOS & DRAWINGS