Target Audience:
        
        
            ATV owners and independent repair technicians seeking detailed service information.
        
     
    
    
        
            Value Proposition:
        
        
            Enables DIY repairs, saving significant costs compared to dealership service.
        
     
    
    
        
            Ease Of Use:
        
        
            Easy-to-follow step-by-step instructions with pictures.
        
     
    
        
            Accessibility:
        
        
            Downloadable to PC, Mac, tablets, and smartphones.
        
     
 
    
    
    
        
            Engine Systems:
        
        
            Engine assembly, disassembly, inspection, lubrication, cooling, fuel delivery, ignition, exhaust, starting, charging.
        
     
    
        
            Transmission Systems:
        
        
            Transmission operation, inspection, repair, drive belts, clutches.
        
     
    
        
            Drivetrain Systems:
        
        
            Driveshafts, differentials, CV joints, axle components.
        
     
    
        
            Suspension Systems:
        
        
            Front and rear suspension components, shock absorbers, control arms, bushings, alignment.
        
     
    
        
            Braking Systems:
        
        
            Brake hydraulics, calipers, pads, rotors, drums, parking brake.
        
     
    
        
            Steering Systems:
        
        
            Steering column, tie rods, steering linkage, steering gear (if applicable).
        
     
    
        
            Electrical Systems:
        
        
            Battery, charging system, ignition system, lighting, starter, wiring diagrams, component testing.
        
     
    
        
            Chassis Body:
        
        
            Frame, body panels, fenders, seats, handlebars, controls, racks.
        
     
    
    
        
            Maintenance:
        
        
            Scheduled maintenance, oil changes, filter replacements, lubrication, tire pressure checks, battery maintenance.
        
     
    
        
            Troubleshooting:
        
        
            Diagnostic procedures, symptom-based troubleshooting, common issue identification.
        
     
    
        
            Repair:
        
        
            Step-by-step repair instructions for all covered systems and components.
        
     
    
        
            Overhaul:
        
        
            Complete engine and transmission overhaul procedures.
        
     
    
        
            Diagnosis:
        
        
            Detailed diagnostic charts and flowcharts.
        
     
    
    
        
            Depth:
        
        
            Comprehensive: Covers basic maintenance to advanced diagnostics and complete component rebuilds.
        
     
 
    
    
    
        
            Engine Type Xpress 300:
        
        
            2-Stroke, Fan-Cooled, Single Cylinder
        
     
    
        
            Engine Type Sport 400:
        
        
            2-Stroke, Fan-Cooled, Single Cylinder
        
     
    
    
        
            Displacement Xpress 300:
        
        
            299 cc (18.2 cu. in.)
        
     
    
        
            Displacement Sport 400:
        
        
            398 cc (24.3 cu. in.)
        
     
    
    
        
            Horsepower Xpress 300:
        
        
            Approx. 25 HP (Varies by tune)
        
     
    
        
            Horsepower Sport 400:
        
        
            Approx. 33 HP (Varies by tune)
        
     
    
    
        
            Fuel Delivery Type:
        
        
            Carburetor
        
     
    
        
            Carburetor Model Xpress 300:
        
        
            Keihin PWK (Specific model may vary, consult manual)
        
     
    
        
            Carburetor Model Sport 400:
        
        
            Keihin PWK (Specific model may vary, consult manual)
        
     
    
    
        
            Ignition System:
        
        
            CDI (Capacitor Discharge Ignition)
        
     
    
    
        
            Cooling System:
        
        
            Forced Air Cooling (Fan-assisted)
        
     
    
    
        
            Oil Type:
        
        
            2-Cycle Oil Injection System (Consult manual for specific blend/viscosity requirements)
        
     
 
    
    
    
        
            Oil Change Interval:
        
        
            Consult manual (Typically every 20-40 hours of operation for CVT/gearbox oil).
        
     
    
        
            Spark Plug Replacement:
        
        
            Consult manual (Typically every 100-150 hours or annually).
        
     
    
    
        
            Engine Oil Type:
        
        
            2-Cycle Pre-Mix or Oil Injection (Specific grade and ratio per manual).
        
     
    
        
            Transmission Gear Oil:
        
        
            Consult manual (Likely SAE 75W-90 or similar hypoid gear oil).
        
     
    
        
            Brake Fluid Type:
        
        
            DOT 3 or DOT 4 (Consult manual for exact specification).
        
     
    
    
        
            Common Wear Items:
        
        
            Drive belts (CVT), suspension bushings, brake pads, starter motor brushes.
        
     
    
        
            Carburetor Issues:
        
        
            Can be prone to clogging with fuel varnish if not stored properly, requiring cleaning and adjustment.
        
     
    
        
            Cooling System Efficiency:
        
        
            Fan and cooling fins require regular cleaning to maintain optimal operating temperatures.
        
     
 
    
    
    
        
            Brand Origin:
        
        
            Polaris Industries, founded in 1954 in Roseau, Minnesota, USA.
        
     
    
    
        
            Model Introduction Era:
        
        
            The Xpress series represented Polaris's entry-level and mid-range utility and recreational ATVs during the late 1990s.
        
     
    
    
        
            Production Period:
        
        
            1998-1999 (for the models covered by this manual).