This manual provides comprehensive guidance for all 1999 and 2000 ATV models. The brand has a strong heritage in powersports, and these ATVs represent a significant era of their development, offering robust engineering for various off-road applications. The models covered span a range of capabilities, from utility-focused utility vehicles to sportier configurations, each benefiting from the brand's commitment to performance and reliability. This guide is designed to assist owners and technicians in understanding and maintaining these versatile machines. The purpose of this factory service manual is to offer detailed instructions for the maintenance, repair, and troubleshooting of your ATV. It encompasses all major systems, including the powertrain, chassis, suspension, and electrical components. Within its pages, you will find routine maintenance procedures, diagnostic guides for identifying and resolving issues, and step-by-step instructions for complex repairs and overhauls. This resource is invaluable for ensuring the longevity and optimal performance of your vehicle, covering everything from basic fluid changes to in-depth engine and transmission work. 🏷️ Basic Information Identification Make: Polaris Model: ATV (All Models) Year: 1999-2000 Codes Product Sku: POL9900ATVREP 👋 Introduction Market Position Target Audience: Professional technicians and experienced DIY mechanics. Competitive Analysis Competitor Manuals: Comparable to OEM service manuals in scope and detail, offering a more accessible digital format. Key Features Instant Access: Immediate download available after purchase, allowing for quick service initiation. Comprehensive Coverage: Covers a wide array of models and all essential repair and maintenance aspects. Diagnostic Support: Includes an advanced troubleshooting guide to aid in problem diagnosis. Illustrated Guidance: Contains necessary illustrations, diagrams, and specifications for clear procedural understanding. 📋 Manual Details Coverage Areas General Coverage: All 1999-2000 Polaris ATV models Specific Models 1999: Big Boss 500 6X6, Scrambler 400 4X4, Magnum 500 4X4, Trail Blazer 250 4X2, Trail Boss 240 4X2, Xplorer 300 4X2, Xplorer 300 4X4, Xplorer 400 4X4, Scrambler 500 4X4, Sport 400 4X2, Sportsman 335 4X4, Sportsman 500 4X4 Specific Models 2000: Magnum 325 4X2, Magnum 325 4X4, Magnum 500 4X4, Scrambler 400 4X2, Trail Blazer 250 4X2, Trail Boss 325 4X2, Xpedition 325 4X4, Xpedition 425 4X4, Xplorer 250 4X4, Xplorer 400 4X4, Scrambler 400 4X4, Scrambler 500 4X4, Sportsman 335 4X4, Sportsman 500 4X4, Sportsman 500 6X6, Sportsman 500 RSE 4X4 Page Count Estimated Pages: Likely 800+ pages (typical for comprehensive ATV repair manuals) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Powertrain: Engine, cooling system, exhaust system, fuel system, transmission, drivetrain (AWD/2WD operation, CVTs, driveshafts, differentials, axles) Chassis And Suspension: Frame, suspension components (shocks, A-arms, bushings), steering system, braking system (hydraulic, calipers, rotors), wheel bearings Electrical System: Ignition system, charging system (stator, regulator/rectifier, battery), lighting system, starter system, wiring diagrams, switchgear, diagnostics Body And Trim: Body panels, fenders, racks, seat, storage compartments Procedures Included Maintenance: Routine checks, lubrication, fluid changes, filter replacements, spark plug service, chain/belt adjustment Repair: Complete disassembly, inspection, cleaning, assembly, and installation of all components and systems. Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic codes, electrical testing procedures Overhaul: Engine rebuilds, transmission overhaul, suspension rebuilds Technical Depth Depth: Comprehensive; covers basic maintenance to complete mechanical and electrical overhauls, including detailed diagnostic procedures. 📊 Manual Specifications File Format Quality: High-resolution scans, searchable text (if OCR processed), clear illustrations and diagrams. Compatibility: Viewable on any device with a PDF reader (PC, Mac, tablet, smartphone). Print Quality Printability: Printable pages for on-site use. Binding Type Binding Style: Not applicable for digital download, but implies a professionally bound document if it were physical. Paper Type Paper Quality: Not applicable for digital download, but factory manuals typically use durable, semi-gloss paper. ⚙️ Engine Specifications Primary Engine Engine Type Examples: Single-cylinder, 4-stroke, liquid-cooled (common for Polaris models of this era, specific engine details vary by model) Displacement Range: Approximately 240cc to 500cc (based on listed models) Performance Horsepower Range: Estimated 15-30 HP (varies significantly by model and displacement) Torque Range: Estimated 15-35 lb-ft (varies significantly by model and displacement) Fuel System Fuel Delivery: Carbureted (e.g., Mikuni) on most models; fuel injection may be present on some later 2000 models or specific performance variants. Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) with High/Low range and Reverse Optional Optional Transmission: Not applicable; CVT was standard across the range. Features Drive System: Shaft Drive with selectable 2WD/4WD (On-Demand AWD on many models), some 6x6 configurations 📐 Dimensions Exterior Dimensions Variability: Dimensions vary significantly by model (e.g., Big Boss 6x6 vs. Trail Blazer 250 4x2). Manual will provide specific measurements. Weights Dry Weight Range: Approximately 500 - 700+ lbs (varies by model, drivetrain, and size) 🛡️ Safety Features Ratings Atv Safety Standards: Adheres to relevant ATV safety standards for the period. Manual likely includes safety warnings and operating guidelines. Active Features Active Safety Features: On-Demand All-Wheel...