Atv Segment:
Utility ATV, designed for recreational and light work applications.
Competitors 1999:
Key competitors in this segment included Yamaha (e.g., Wolverine), Suzuki (e.g., Quad Runner), and Kawasaki (e.g., Bayou).
Design Philosophy:
Emphasizes reliable design, simple construction, and ease of repair, making it suitable for home mechanics.
Owner Benefits:
Promotes cost savings through DIY maintenance, extended ATV lifespan, and a deeper understanding of the machine's mechanics.
Chassis And Body:
Front Cab, Rear Cab and Seat, Rear Rack Mounting, Front Rack and Bumper Mounting, Decals
Engine And Drivetrain:
Engine Mounting, Cooling System, Exhaust System, Fuel Tank, Oil Tank, Air Box, Drive Clutch, Driven Clutch, Clutch Cover, Gearcase/Brake and Chain Cover Mounting, Rear Wheel Drive, Gearcase, Gear Selector, Piston and Crankshaft, Crankcase and Cylinder, Carburetor, Oil Pump, Magneto, Starting Motor, Recoil Starter
Suspension And Steering:
Front Strut, A-Arm/Strut Mounting, Swing Arm/Shock Mounting, Steering Post, Handlebar and Headlight Pod
Brakes And Wheels:
Front Brake, Rear Brake, Front Wheel
Controls And Electrical:
Controls -- Throttle Asm./Cable, Controls - Master Cylinder/Brake Line, Electrical/Taillight
Drivetrain Components:
Front Drive, Front Tightener, CV Joint – BTB, Center Tightener
Part Identification:
Detailed exploded diagrams and part number lists for all components.
Maintenance Assistance:
Assists in identifying parts for routine maintenance tasks such as oil changes, filter replacement, and spark plug replacement.
Repair Guidance:
Facilitates repair by providing precise part identification and relationships between components.
Depth:
Component-level detail with specific part numbers for replacement. Focuses on part identification rather than step-by-step repair procedures.
Printable Pages:
Yes, allows printing of specific pages.
Searchable Text:
Implied by PDF format, typically allows for text searching.
Diagram Clarity:
High quality, suitable for detailed inspection of components.
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
Liquid-cooled, 2-stroke, 1-cylinder (based on general Polaris 400 configurations of the era, specific details require cross-referencing with service manual).
Displacement:
Approximately 340-398cc (common range for Polaris 400 models of this generation).
Horsepower Estimate:
Typically in the range of 25-30 HP, though official figures may vary.
Torque Estimate:
Estimated range of 25-30 lb-ft.
Fuel Delivery:
Carbureted (likely a Mikuni or Keihin carburetor).
Fuel Type:
Unleaded gasoline (typically 87 octane or higher).
Cooling Method:
Liquid-cooled.
Coolant Type:
Ethylene glycol-based antifreeze/coolant (typically a 50/50 mix with distilled water).
Transmission Type:
Automatic (CVT - Continuously Variable Transmission).
Drive System:
Shaft drive to rear wheels, often with selectable 2WD/4WD capability (though this manual primarily focuses on parts, the underlying drive system is relevant).
Gear Reduction:
Integrated gearcase for final drive reduction and reverse.
Clutch System:
Drive clutch and driven clutch assembly for CVT operation.
Oil Change Interval:
Recommended every 20-40 operating hours or annually, whichever comes first (refer to detailed service manual for precise intervals).
Air Filter Maintenance:
Inspect and clean/replace based on operating conditions, typically every 10-20 operating hours or as needed in dusty environments.
Spark Plug Replacement:
Check and gap at regular intervals, replace every 100-200 operating hours or as needed.
Engine Oil:
Polaris recommends specific 2-stroke synthetic or semi-synthetic engine oil, or a high-quality 2-stroke engine oil meeting API TC or JASO FD standards. Refer to manual for exact viscosity grade (e.g., SAE 0W-40 or 10W-40 depending on temperature).
Gearcase Oil:
Polaris Gearcase Lubricant or equivalent SAE 80W-90 hypoid gear oil. Capacity typically around 0.5 - 0.7 liters.
Coolant:
Mixture of 50% permanent type antifreeze and 50% distilled water. Ensure it has corrosion inhibitors suitable for aluminum engines.
Cooling System Maintenance:
Regular flushing and replacement of coolant is crucial to prevent overheating and corrosion in liquid-cooled 2-stroke engines.
Cv Joint Boots:
Torn CV joint boots can lead to rapid wear of the CV joints. Regular inspection is recommended.
Carburetor Tuning:
Carburetors, especially on 2-stroke engines, can require periodic cleaning and adjustment due to fuel quality or wear.
Drive Belt Wear:
The CVT drive belt is a wear item and requires regular inspection for cracks, fraying, or excessive wear. Replacement is necessary when dimensions fall outside specifications.
Recoil Starter Issues:
Recoil starters can wear over time, leading to difficulty in starting. The parts manual will show the components for repair or replacement.
Polaris Heritage:
Polaris has a long history of manufacturing powersports vehicles, including ATVs, snowmobiles, and motorcycles, dating back to the mid-20th century.
Xplorer Series:
The Xplorer line was known for its focus on trail riding and comfort, often featuring independent rear suspension and more creature comforts than pure work-oriented models.
Production Period:
The 1999 model year falls within a period of significant growth and refinement for Polaris ATVs.
