1999-2000 Polaris ATV and 6x6 Repair Manual

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🏷️ Basic Information Identification Make: Polaris Model: All 1999-2000 Polaris ATVs and 6x6 models Codes Manual Product Name: 1999-2000 Polaris ATV and 6x6 Repair Manual PDF Download 👋 Introduction Market Position Target User: DIY mechanics, ATV enthusiasts, small repair shops, and owners seeking to maintain or repair their 1999-2000 Polaris ATVs. Competitive Analysis Comparison To Print: Offers instant access and portability compared to traditional paper manuals, preventing damage from grease and dirt. Enables on-trail repairs via smart devices. Key Features Benefits: Instant download after payment, no shipping costs, lifetime protection policy against loss or damage, covers a wide range of Polaris models from 1999-2000. 📋 Manual Details Coverage Areas Vehicle Coverage: 1999 Polaris Big Boss 500 6x6, 1999 Polaris Magnum 500 4x4, 1999 Polaris Scrambler 400 4x4, 1999 Polaris Scrambler 500 4x4, 1999 Polaris Sport 400 4x2, 1999 Polaris Sportsman 335 4x4, 1999 Polaris Sportsman 500 4x4, 1999 Polaris Trail Blazer 250 4x2, 1999 Polaris Trail Boss 250 4x2, 1999 Polaris Xplorer 300 4x2, 1999 Polaris Xplorer 300 4x4, 1999 Polaris Xplorer 400 4x4, 2000 Polaris Magnum 325 4x2, 2000 Polaris Magnum 325 4x4, 2000 Polaris Magnum 500 4x4, 2000 Polaris Scrambler 400 4x2, 2000 Polaris Scrambler 400 4x4, 2000 Polaris Scrambler 500 4x4, 2000 Polaris Sportsman 335 4x4, 2000 Polaris Sportsman 500 4x4, 2000 Polaris Sportsman 500 6x6, 2000 Polaris Sportsman 500 RSE 4x4, 2000 Polaris Trail Blazer 250 4x2, 2000 Polaris Trail Boss 325 4x2, 2000 Polaris Xpedition 325 4x4, 2000 Polaris Xpedition 425 4x4, 2000 Polaris Xplorer 250 4x4, 2000 Polaris Xplorer 400 4x4 Parts Catalog Information: Includes references for locating and identifying OEM parts, often with diagrams and part numbers for repair and replacement. Page Count Estimated Page Count: Varies by specific model, typically 300-600 pages per model or comprehensive collection Manual Type Type: Comprehensive Repair Manual, Owner's Manual, Parts Catalog Download Content Scope: Covers both basic owner information and in-depth workshop repair procedures. Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Mechanical Systems: Engine, Fuel System, Lubrication & Cooling, Transmission, Drive Chain & Sprockets, Steering, Shocks, Body Work, Intake & Exhaust Electrical Systems: Full Electrical System, Wiring Diagrams, Troubleshooting Chassis And Suspension: Front and rear suspension components (shocks, springs, control arms, bushings), steering mechanism, wheel hubs, and bearings. Frame And Body: Frame inspection for damage, body panel removal/installation, fender repairs, and accessory mounting. Accessories: May include installation guidance or troubleshooting for common factory or dealer-installed accessories. Procedures Included Maintenance And Repair: Routine Maintenance, Engine Removal & Installation, Advanced Troubleshooting, Component Repair and Overhaul Troubleshooting Guides: Detailed symptom-based troubleshooting charts for common issues, guiding users through diagnostic steps for engine, electrical, and drivetrain problems. Reassembly Instructions: Detailed step-by-step instructions for reassembling components after repair or overhaul, including torque specifications and lubrication points. Engine Rebuilding: Detailed steps for engine disassembly, inspection of internal components (pistons, rings, valves, bearings), and reassembly with required clearances and torque specs. Technical Depth Depth: Comprehensive: From basic adjustments and fluid changes to complete engine and transmission rebuilds, electrical diagnostics, and chassis component repair. Diagnostic Techniques: Detailed electrical system diagnostics, including voltage testing, continuity checks, and interpretation of wiring diagrams. Carburetor tuning and adjustment procedures. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Digital Quality: High-resolution, printable pages with searchable text for easy navigation and reference. Binding Type Binding Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital Download), printable on standard paper ⚙️ Engine Specifications Primary Engine Engine Types Covered: Various Polaris single-cylinder, liquid-cooled, 4-stroke engines including 2-stroke models for some Sport/Trail variants. Common displacements: 250cc, 300cc, 325cc, 335cc, 400cc, 500cc. Performance Typical Hp Range: Approx. 15 HP (250cc/300cc) up to 35-40 HP (500cc models). Torque Figures: Specific torque values for critical engine fasteners, bolt tightening sequences, and cylinder head torquing procedures. Fuel System Fuel Delivery: Carbureted (e.g., Mikuni, Keihin) for most models. Specific carburetor models and jetting details covered. Fuel Pump Type: Mechanical or electric fuel pumps depending on the model. Procedures for testing and replacement are covered. Engine Types Covered Engine Construction: Aluminum alloy cylinder blocks and heads, overhead valve (OHV) or single overhead camshaft (SOHC) configurations. Cooling System: Liquid-cooled systems with radiators, fans, thermostats, and hoses. Procedures for coolant flush, leak testing, and component replacement. Ignition System: CDI (Capacitor Discharge Ignition) systems. Manual covers testing of ignition coils, pick-up coils, and spark plugs. 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) with Polaris Variable Transmission (PVT) system. Features high/low range and reverse. Gear Ratios: Information on transmission gear ratios for high, low, and reverse gears. Also, final drive gear ratios. Optional Clutch Systems: Explains operation, maintenance, and troubleshooting of primary and secondary clutch assemblies. Features Drive Systems: Covers operation and maintenance of Polaris' AWD (All-Wheel Drive) system, shaft drive, and differentials for 4x4 and 6x6 models....

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Type: Atv

Vendor:

Sku: 68380

Collections: ALL ATV Powersports

Availability: In stock

Tags: 1999 2000 ATV Polaris Powersports

Product variants

Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

All 1999-2000 Polaris ATVs and 6x6 models

Codes

Manual Product Name:

1999-2000 Polaris ATV and 6x6 Repair Manual PDF Download

👋 Introduction

Market Position

Target User:

DIY mechanics, ATV enthusiasts, small repair shops, and owners seeking to maintain or repair their 1999-2000 Polaris ATVs.

Competitive Analysis

Comparison To Print:

Offers instant access and portability compared to traditional paper manuals, preventing damage from grease and dirt. Enables on-trail repairs via smart devices.

Key Features

Benefits:

Instant download after payment, no shipping costs, lifetime protection policy against loss or damage, covers a wide range of Polaris models from 1999-2000.

📋 Manual Details

Coverage Areas

Vehicle Coverage:

1999 Polaris Big Boss 500 6x6, 1999 Polaris Magnum 500 4x4, 1999 Polaris Scrambler 400 4x4, 1999 Polaris Scrambler 500 4x4, 1999 Polaris Sport 400 4x2, 1999 Polaris Sportsman 335 4x4, 1999 Polaris Sportsman 500 4x4, 1999 Polaris Trail Blazer 250 4x2, 1999 Polaris Trail Boss 250 4x2, 1999 Polaris Xplorer 300 4x2, 1999 Polaris Xplorer 300 4x4, 1999 Polaris Xplorer 400 4x4, 2000 Polaris Magnum 325 4x2, 2000 Polaris Magnum 325 4x4, 2000 Polaris Magnum 500 4x4, 2000 Polaris Scrambler 400 4x2, 2000 Polaris Scrambler 400 4x4, 2000 Polaris Scrambler 500 4x4, 2000 Polaris Sportsman 335 4x4, 2000 Polaris Sportsman 500 4x4, 2000 Polaris Sportsman 500 6x6, 2000 Polaris Sportsman 500 RSE 4x4, 2000 Polaris Trail Blazer 250 4x2, 2000 Polaris Trail Boss 325 4x2, 2000 Polaris Xpedition 325 4x4, 2000 Polaris Xpedition 425 4x4, 2000 Polaris Xplorer 250 4x4, 2000 Polaris Xplorer 400 4x4

Parts Catalog Information:

Includes references for locating and identifying OEM parts, often with diagrams and part numbers for repair and replacement.

Page Count

Estimated Page Count:

Varies by specific model, typically 300-600 pages per model or comprehensive collection

Manual Type

Type:

Comprehensive Repair Manual, Owner's Manual, Parts Catalog Download

Content Scope:

Covers both basic owner information and in-depth workshop repair procedures.

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Mechanical Systems:

Engine, Fuel System, Lubrication & Cooling, Transmission, Drive Chain & Sprockets, Steering, Shocks, Body Work, Intake & Exhaust

Electrical Systems:

Full Electrical System, Wiring Diagrams, Troubleshooting

Chassis And Suspension:

Front and rear suspension components (shocks, springs, control arms, bushings), steering mechanism, wheel hubs, and bearings.

Frame And Body:

Frame inspection for damage, body panel removal/installation, fender repairs, and accessory mounting.

Accessories:

May include installation guidance or troubleshooting for common factory or dealer-installed accessories.

Procedures Included

Maintenance And Repair:

Routine Maintenance, Engine Removal & Installation, Advanced Troubleshooting, Component Repair and Overhaul

Troubleshooting Guides:

Detailed symptom-based troubleshooting charts for common issues, guiding users through diagnostic steps for engine, electrical, and drivetrain problems.

Reassembly Instructions:

Detailed step-by-step instructions for reassembling components after repair or overhaul, including torque specifications and lubrication points.

Engine Rebuilding:

Detailed steps for engine disassembly, inspection of internal components (pistons, rings, valves, bearings), and reassembly with required clearances and torque specs.

Technical Depth

Depth:

Comprehensive: From basic adjustments and fluid changes to complete engine and transmission rebuilds, electrical diagnostics, and chassis component repair.

Diagnostic Techniques:

Detailed electrical system diagnostics, including voltage testing, continuity checks, and interpretation of wiring diagrams. Carburetor tuning and adjustment procedures.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Digital Quality:

High-resolution, printable pages with searchable text for easy navigation and reference.

Binding Type

Binding Digital:

N/A (Digital Download)

Paper Type

Paper Type Digital:

N/A (Digital Download), printable on standard paper

⚙️ Engine Specifications

Primary Engine

Engine Types Covered:

Various Polaris single-cylinder, liquid-cooled, 4-stroke engines including 2-stroke models for some Sport/Trail variants. Common displacements: 250cc, 300cc, 325cc, 335cc, 400cc, 500cc.

Performance

Typical Hp Range:

Approx. 15 HP (250cc/300cc) up to 35-40 HP (500cc models).

Torque Figures:

Specific torque values for critical engine fasteners, bolt tightening sequences, and cylinder head torquing procedures.

Fuel System

Fuel Delivery:

Carbureted (e.g., Mikuni, Keihin) for most models. Specific carburetor models and jetting details covered.

Fuel Pump Type:

Mechanical or electric fuel pumps depending on the model. Procedures for testing and replacement are covered.

Engine Types Covered

Engine Construction:

Aluminum alloy cylinder blocks and heads, overhead valve (OHV) or single overhead camshaft (SOHC) configurations.

Cooling System:

Liquid-cooled systems with radiators, fans, thermostats, and hoses. Procedures for coolant flush, leak testing, and component replacement.

Ignition System:

CDI (Capacitor Discharge Ignition) systems. Manual covers testing of ignition coils, pick-up coils, and spark plugs.

🔧 Transmission

Standard

Transmission Type:

Automatic Continuously Variable Transmission (CVT) with Polaris Variable Transmission (PVT) system. Features high/low range and reverse.

Gear Ratios:

Information on transmission gear ratios for high, low, and reverse gears. Also, final drive gear ratios.

Optional

Clutch Systems:

Explains operation, maintenance, and troubleshooting of primary and secondary clutch assemblies.

Features

Drive Systems:

Covers operation and maintenance of Polaris' AWD (All-Wheel Drive) system, shaft drive, and differentials for 4x4 and 6x6 models.

Final Drive:

Shaft drive to rear wheels and front differential (4x4 models), and front/rear differentials for 6x6 models. Maintenance procedures for these components are included.

Cv Shafts:

Maintenance and replacement of Constant Velocity (CV) shafts and boots, critical for 4x4 and 6x6 drivelines.

📐 Dimensions

Exterior

Bodywork Materials:

Durable thermoplastic body panels, steel frame construction. Manual provides instructions for panel removal, repair, and replacement.

Tire Sizes:

Covers standard tire sizes for front and rear axles, recommended inflation pressures, and wheel specifications (bolt pattern, offset).

Weights

Dry Weight Range:

Typically ranges from 500 lbs to over 700 lbs depending on model and configuration.

Towing Capacity:

Information on recommended towing capacities and proper towing procedures for models equipped with hitch receivers.

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adheres to ATV industry safety guidelines. Manual emphasizes safe operating procedures, pre-ride inspections, and protective gear.

Active Features

Braking Systems:

Hydraulic disc brakes (front and rear), often sealed braking systems. Manual covers brake pad replacement, bleeding procedures, and caliper service.

Passive Features

Operator Safety:

Emphasis on proper riding techniques, safe handling characteristics, and maintenance of safety-related components like kill switches and handguards.

💡 Technology Features

Infotainment

Instrumentation:

Basic digital or analog dashboards displaying speed, odometer, trip meter, fuel level, and indicator lights. Manual covers diagnostics for these components.

Driver Assistance

AWD System Technology:

Polaris' automatic all-wheel-drive (AWD) system, which engages front wheels when rear wheels lose traction. Manual details its operation and maintenance.

Connectivity

Diagnostic Tools:

While OBD-II was not standard on ATVs of this era, the manual provides diagnostic flowcharts and procedures for electrical systems, often requiring multimeters and basic hand tools.

🔧 Maintenance

Service Intervals

Typical Maintenance Schedule:

Includes intervals for oil changes (e.g., every 50-100 operating hours or annually), spark plug inspection, air filter cleaning/replacement, chain lubrication, and brake inspection.

Filter Replacement Schedule:

Recommended intervals for replacing oil filters, air filters, and fuel filters.

Fluid Specifications

Engine Oil:

Typically SAE 10W-40 or 20W-50, API SG or higher, often with JASO MA certification. Specific capacities provided for each model.

Gear Lube:

Viscosity grades and types for transmission and differential gearboxes (e.g., SAE 75W-90 GL-4).

Coolant:

Ethylene glycol-based antifreeze (e.g., 50/50 mix with distilled water). Manual specifies type and capacity for the cooling system.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid. Manual details fluid type, capacity, and bleeding procedures.

Known Issues

Common Wear Items:

CVT belt wear, drive clutch alignment, rear suspension bushings, starter motor reliability on certain models, carburetor jetting adjustments for altitude/conditions.

Electrical Component Failures:

Potential issues with voltage regulators, stators, and starter solenoids. Manual provides diagnostic steps for these components.

Drive Line Wear:

Wear on CV joints and boots, driveshaft U-joints (if applicable), and differential seals. Manual covers inspection and replacement procedures.

📚 Vehicle History

Brand Heritage

Polarismfg History:

Polaris Industries Inc. has a long history in powersports, starting with snowmobiles and expanding into ATVs in the late 1980s. Known for innovation in drivetrain and suspension.

Model Evolution

Platform Development:

This era represents a significant expansion and refinement of Polaris' ATV lineup, introducing larger displacement engines (500cc) and popular models like the Sportsman and Magnum.

Engine Technology Advancements:

This period saw Polaris solidify its use of the 500cc engine platform across multiple utility and sport models, with refinements in power delivery and reliability.

Production

Manufacturing Locations:

Polaris vehicles of this era were primarily manufactured in the United States, particularly at their facilities in Minnesota and Iowa.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

Polaris ATVs of this period were generally well-regarded for their performance, versatility (especially the 6x6 models), and rider comfort, establishing a strong market presence.