Polaris Repair Manual: Big Boss 6x6, Magnum, Scrambler, Sportsman, Trail Blazer, Trail Boss, Xplorer, Xpress 1998-2006

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Item # 2508  ISBN: 9781563926310




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This repair and service manual covers Polaris ATVs single-seat, gasoline engine, and Polaris Variable Transmission (PVT), 250cc through 800cc, including Big Boss 6x6, Magnum, Scrambler, Sportsman, Sportsman 6x6, Trail Blazer, Trail Boss, Xplorer, and Xpress. 2-stroke and 4-stroke singles and twin cylinder, carbureted and fuel injected, 2-wheel, 4-wheel, and 6-wheel drive models, 1998-2006.

Note: this manual DOES NOT include Xpedition, Predator, X-2, diesel or 335 gasoline models.

Table of 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 tires
• Body and frame
• Wiring diagrams

Haynes motorcycle 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.

Polaris Repair Manual: Big Boss 6x6, Magnum, Scrambler, Sportsman, Trail Blazer, Trail Boss, Xplorer, Xpress 1998-2006