1985-1995 Polaris 3, 4 & 6 wheel ATV Clymer Repair Manual

Description

How do I repair my Polaris ATV? This 408 page, 1985-1995 Polaris ATV Clymer Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1985-1995 Polaris 3, 4 & 6 wheel ATVs including 1987 Cyclone, 1989-1994 Trail Boss, 300, 400L 4×4, 1995 Sportsman 6×6, 1995 Explorer, 1990-1995 Trail Blazer, Magnum 2-Wheel Drive and Magnum 4×4 ATVs.

1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995

This Polaris ATV manual includes everything you need to know to perform tune-up and routine maintenance on the Polaris ATV engines. You’ll have everything you need to service your Polaris clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, frame and body, and electrical system. Detailed wiring diagrams are included.

This manual is organized into the following chapters and topics:

1985-1995 Polaris 3, 4 & 6 wheel ATV QUICK REFERENCE DATA

1985-1995 Polaris ATV 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 tools / Special tools / Mechanic’s tips / Operating tips / RTV gasket sealant / Threadlock / Gasket remover / Parts replacement

CHAPTER TWO / TROUBLESHOOTING

Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Testing electrical components / Power train / Steering / Engine electrical system troubleshooting / Voltage regulator / Speed limiter

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP

Pre-ride checks / Service intervals / Tires and wheels / Battery / Fluid checks / Break-in procedure / Periodic lubrication / Periodic maintenance / General inspection and maintenance / Engine tune-up / Storage

CHAPTER FOUR / ENGINE (2-STROKE MODELS)

Engine principles / Engine lubrication / Service precautions / Servicing the engine in the frame / Liquid cooling / Engine removal and installation / Cylinder head / Cylinder / Reed valve assembly / Piston, piston pin and rings / Recoil starter (early 250 models) / Recoil starter (all 300, 350L, and 400 L and let 250 models) / Coolant pump / Engine balancer / Crankcase / Crankshaft, bearings and shim / Oil injection system / Break-in procedure

CHAPTER FIVE / ENGINE (4-STROKE MODELS)

Engine principles / Engine cooling / Engine lubrication / Servicing the engine in the frame / Engine removal and installation / Cylinder head cover and rocker arm assembly / Camshaft / Cylinder head / Cylinder / Piston, piston pin and piston 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

CHAPTER SIX / FUEL AND EXHAUST SYSTEMS

Carburetor operation / Carburetor (with 2-stroke engine) / Carburetor (with 4-stroke engines) / Throttle cable replacement / Choke cable / Fuel tank / Fuel shutoff valve / Air box / Fuel pump / Exhaust system

CHAPTER SEVEN / COOLING SYSTEM

Polaris variable transmission (PVT) cooling system / Engine cooling (air cooled models) / Engine cooling (liquid cooled models)

CHAPTER EIGHT / CLUTCH/DRIVE BELT SYSTEM

Drive unit / Drive pulley assembly / Driven pulley / Drive belt / Drive pulley service / Driven pulley service / Clutch inner cover

CHAPTER NINE / TRANSMISSION SYSTEM

Transmission oil / Type I transmission / Type II transmission / Type III transmission

CHAPTER TEN / FRONT DRIVE SYSTEM

Front hubs / Front drive shaft boots and CV joints / Center chain and sprockets / Front chain and sprockets

CHAPTER ELEVEN / ELECTRICAL SYSTEM

Charging system / Alternator stator (charging or lighting coil) / 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

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING

Front wheel (4-wheel models) / Front wheel (3-wheel Scrambler model) / Front hub (4-wheel without all-wheel drive) / Front hub (3-wheel tricycle models) / Front fork tubes (3-wheel Scrambler model) / Front suspension (4-wheel models) / Steering shaft / Tires and wheels

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

CHAPTER FOURTEEN / BRAKES

Front brakes (drum type) / Hydraulic brakes / Front brake caliper (1987 with all wheel drive) / Front brake caliper (1988-on) / Mechanical rear brake caliper (1985-1987 with rear wheel drive only) / Hydraulic rear caliper (1987 with all-wheel drive and all 1988 models) / Hydraulic rear brake caliper (all 1989-on models) / Master cylinder / Brake hose replacement / Brake disc / Brake bleeding

CHAPTER FIFTEEN / BODY

Seat / Fuel tank cover / Front panel / Front fender (except Xplorer and Scrambler) / Front fender (Xplorer) / Front fender (Scrambler) / Rear fender / Side panels (Xplorer models)

INDEX

1985-1995 Polaris 3, 4 & 6 wheel ATV WIRING DIAGRAMS