Category:
All-Terrain Vehicle (ATV)
Intended Use:
Recreational riding, utility tasks, property maintenance, and exploration.
Key Differentiators Atv:
Polaris ATVs are generally known for their robust build, capable suspension systems, and user-friendly design, making them popular for both work and play.
Manual Value Proposition:
Empowers owners to perform accurate part identification for maintenance and repairs, saving time and money compared to dealership services. Supports DIY approach to ATV care.
Powertrain:
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, piston and crankshaft, crankcase and cylinder, recoil starter, carburetor, oil pump, magneto, starting motor.
Chassis And Suspension:
Front cab, rear cab and seat, rear rack mounting, front rack and bumper mounting, front drive, front tightener, front strut, CV joint – BTB, front wheel, front brake, A-arm/strut mounting, center tightener, swing arm/shock mounting, rear brake, rear wheel.
Controls And Electrical:
Controls -- throttle asm./cable, controls - master cylinder/brake line, steering post, handlebar and headlight pod, electrical/taillight, gear selector.
Decals:
Covers various decals and their placement on the vehicle.
Tool Kit:
Details the contents of the standard tool kit provided with the ATV.
Part Identification:
Detailed exploded diagrams and corresponding part number lists for all components.
Maintenance Support:
Facilitates identification of parts for routine maintenance and repair tasks.
Depth:
Component-level parts identification, crucial for accurate part ordering and replacement during repairs and maintenance.
Index Availability:
Includes a part number index for efficient lookup.
Searchability:
PDF format typically allows for text searching, aiding in quickly finding specific part numbers or system names.
Printable:
Yes, allows printing of specific sections or the entire manual.
Binding:
Digital (PDF) - User printable.
Paper Recommendation:
Standard paper for home printing; heavier stock recommended for frequently accessed pages.
Engine Type:
Likely a single-cylinder, liquid-cooled 4-stroke engine based on common Polaris configurations of this era.
Displacement:
Approximately 425cc (specific details would be in a service manual).
Horsepower:
Estimated 20-30 HP (typical for this class and displacement).
Torque:
Torque figures would vary, focused on low-end grunt for utility.
Engine Configuration:
Single-cylinder
Fuel Delivery:
Likely carburetor-fed, given the year and model simplicity. Specific carburetor model would be detailed in the manual.
Oil Type:
Typically SAE 10W-40 or 20W-50 motorcycle or ATV specific oil. Manual will specify exact grade and API classification.
Cooling Medium:
Liquid-cooled.
Coolant Type:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water). Manual will specify type and capacity.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission).
Drive System:
Likely On-Demand All-Wheel Drive (AWD) or Selectable 2WD/4WD, depending on specific sub-model.
Gear Reduction:
Includes high and low range for versatile power delivery.
Drive Type:
Shaft drive for rear wheel, likely CV shafts for front wheel drive.
Gearcase Oil Type:
Likely a dedicated ATV gearcase lubricant or a suitable heavy-duty gear oil. Manual will specify viscosity and API rating.
Wheelbase:
Specific wheelbase dimensions would be found in a full service manual, but typically around 50-55 inches for this class.
Dry Weight:
Estimated 600-700 lbs (specifics in full manual).
Towing Capacity:
Typically rated for around 1,500 lbs for utility models.
Display:
Basic digital display for odometer, trip meter, and potentially gear indicator. Manual covers indicator light functions.
Throttle Control:
Thumb throttle with cable actuation. Manual details throttle cable routing and adjustment.
Accessories Mounting:
Features front and rear racks for mounting accessories like cargo boxes or gun scabbards. Manual lists mounting hardware part numbers.
Oil Change Interval:
Typically every 100 hours or 1,000 miles, or annually. Manual will provide specific intervals.
Air Filter Replacement:
Recommended every 6 months or as needed based on operating conditions. Manual lists part numbers.
Spark Plug Replacement:
Typically every 12-24 months or based on hours. Manual specifies plug type and gap.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify exact type and capacity.
Coolant Capacity:
Capacity would be listed in the manual, typically around 1.5-2 liters.
Gearcase Capacity:
Manual will specify the precise volume of gearcase lubricant required. Typically around 0.5 - 1 liter.
Common Wear Items:
Drive belts, brake pads, suspension bushings, and CV joint boots are common wear items on ATVs of this era.
Cv Joint Maintenance:
The manual provides part numbers for CV boots and related components, crucial for preventing joint damage due to contamination.
Parts Catalog Benefit:
Essential for correctly identifying and ordering replacement parts for repairs, ensuring proper fitment and function.
Manufacturer History:
Polaris Industries has a long history of manufacturing powersports vehicles, including ATVs, snowmobiles, and motorcycles, dating back to the 1950s.
Xpedition Lineage:
The Xpedition line was part of Polaris's broader ATV offering, known for its utility and recreational capabilities.
Production Era:
Early 2000s, a period of significant growth and innovation in the ATV market.
