Polaris 250 1985-1995 Workshop Repair Service Manual

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This workshop service manual is designed for the Polaris 250 for the years 1985 to 1995. It is intended for use by mechanical technicians familiar with service procedures for BRP products and covers repair and overhaul of the Polaris 250. The manual assumes familiarity with general automobile practices and emphasizes the special aspects of the product to enable the maintenance of quality service.

It includes instructions on components manufactured for the Polaris 250 and incorporates instructions from respective component manufacturers for repairs of proprietary components. The manual provides reliable information and aims to help both professional mechanics and DIY enthusiasts get the best value from their Polaris 250.

This manual contains many of the specifications and procedures available in an authorized Polaris 250 dealer service department and emphasizes particular information denoted by the wording and symbols: WARNING, CAUTION, NOTE. It provides information and procedures for routine maintenance, servicing, diagnostic, and repair procedures.

For those intending to do maintenance and repair on their Polaris 250, it is essential to use safety equipment and observe safety precautions. The manual also refers to special tools recommended or required to accomplish adjustments or repairs, often identified by their Polaris 250 special tool number and illustrated.

The owner will find that owning and referring to this manual will make it possible to be better informed and to more knowledgeably perform repairs like a professional automotive technician. The manual contains all necessary instructions needed for any repair the Polaris 250 may require, including tune-ups, maintenance, removal & install procedures, assemblies & disassemblies, and more extensive repairs involving engine and transmission disassembly.

This is an electronic delivery via email in English language and is printable. The content of the service manual depicts parts and/or procedures applicable to the particular product at the time of writing.

  • General Information
  • Maintenance
  • Lubrication
  • Heating
  • Ventilation
  • Air Conditioning
  • Suspension
  • Front Suspension
  • Rear Suspension
  • Wheel
  • Tire System
  • Differential
  • Driveline
  • Drive Shaft
  • Transfer Case
  • Brakes
  • Engine
  • Engine Mechanical
  • Engine Cooling
  • Engine Fuel
  • Engine Electrical
  • Ignition System
  • Starting
  • Charging System
  • Emissions
  • Engine Exhaust
  • Engine Lubrication
  • Engine Speed Control System
  • Clutch
  • Cooling
  • Electronic Control Modules
  • Engine Systems
  • Heated Systems
  • Horn
  • Ignition Control
  • Instrument Cluster
  • Lamps
  • Power Systems
  • Restraints
  • Speed Control
  • Transmission
  • Exhaust System
  • Body Structure
  • Seats
  • Security and Locks
  • Air Bag System
  • Exterior Trim
  • Interior Trim
  • Frame
  • Bumpers
  • Fuel System
  • Steering
  • Transmission and Transfer Case
  • Tires
  • Wheels
  • Body
  • Heating
  • Air Conditioning
  • Emissions Control
  • Engine Removal
  • Engine Installation
  • Final Drive
  • Electrical System
  • Air cleaner element renewal
  • Air cleaner temperature control check
  • Auxiliary drivebelt check
  • Battery electrolyte level check
  • Battery terminal check
  • Brake hydraulic fluid renewal
  • Brake hydraulic system seal and hose renewal
  • Brake pipe and hose check
  • Choke adjustment check
  • Contact breaker point renewal and distributor lubrication
  • Crankcase ventilation system check
  • Emission control filter element renewal
  • Engine coolant renewal
  • Engine idle speed check
  • Engine oil and filter renewal
  • Engine valve clearance check - OHV engines
  • Exhaust system check
  • Fluid leak check
  • Fluid level checks
  • Front and rear brake pad/shoe check
  • Front wheel alignment check
  • Gearbox oil level check
  • Handbrake check
  • Hinge and lock check and lubrication
  • HT lead, distributor cap
  • ignition circuit check
  • Ignition timing
  • contact breaker gap (dwell angle) check
  • Intensive maintenance
  • Mixture adjustment check
  • Road test
  • Roadwheel security check
  • Seat belt check
  • Spark plug check
  • Spark plug renewal
  • Steering and suspension security check
  • Throttle damper operation check
  • Timing belt renewal
  • Tyre checks
  • Underbody inspection
  • Wiper blade check
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