Polaris Xpress (1998 – 2007) Manual

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Written from hands-on experience gained from the complete strip-down and rebuild of a Polaris Xpress, this can help you understand, care for and repair your Polaris Xpress. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Polaris Xpress can help maintain its resale value, save you money, and make it safer to drive.

What’s covered

Polaris Big Boss 6×6, 1998-2007
Polaris Magnum, 1998-2007
Polaris Scrambler, 1998-2007
Polaris Sportsman, 1998-2007
Polaris Sportsman 6×6, 1998-2007
Polaris Trail Boss, 1998-2007
Polaris Trailblazer, 1998-2007
Polaris Xplorer, 1998-2007
Polaris Xpress, 1998-2007

Exclusions: Does not include Xpedition, Predator, X-2, diesel or 335cc gasoline models. 250 to 800cc 98 – 07

Table of contents


CHAPTER 1: Tune-up and routine maintenance

CHAPTER 2: Part A: 2-stroke engine

CHAPTER 2: Part B: 425 trough 500 4-stroke engines

CHAPTER 2: Part C: 325 and 330 4-stroke engines

CHAPTER 2: Part D: 600 through 800 4-stroke engines

CHAPTER 2: Part E: Polaris Variable Transmission

CHAPTER 2: Part F: Transmission

CHAPTER 3: Cooling system

CHAPTER 4: Part A: Fuel and exhaust systems – carbureted models

CHAPTER 4: Part B: Fuel and exhaust systems – fuel injected models

CHAPTER 5: Electrical and ignition systems

CHAPTER 6: Steering, suspension and final drive

CHAPTER 7: Brakes, wheels and tires

CHAPTER 8: Body and frame


Print manual

Part number: M2508
ISBN-13: 9781563929533
Language: English
# of pages: 288
Publication date:
UPC: 038345025082
Dimensions: 270 x 210mm