Engine:
Detailed disassembly, assembly, inspection, and repair of all engine components.
Fuel System:
Carburetor (jetting, cleaning, adjustment), fuel pump, fuel lines, fuel tank.
Ignition System:
Ignition coil, spark plug, CDI unit, stator, wiring diagrams.
Cooling System:
Liquid cooling system components (radiator, hoses, water pump, thermostat), coolant specifications.
Exhaust System:
Muffler, exhaust pipes, gaskets, heat shields.
Transmission Drivetrain:
Clutch (primary and secondary), CVT system (drive belt inspection, sheave maintenance), gear reduction box, drive shafts, CV joints.
Suspension:
Front and rear suspension components (shocks, springs, A-arms, bushings), adjustment procedures.
Steering:
Handlebars, steering shaft, tie rods, steering linkage, adjustment and troubleshooting.
Braking System:
Hydraulic brake system (master cylinder, calipers, brake lines, brake fluid), disc brake components, parking brake.
Electrical System:
Lighting (headlights, taillights, brake lights), battery, charging system (alternator/stator), starter motor, wiring harnesses, fuses, switches, diagnostic codes.
Frame Chassis:
Frame inspection, welding repairs, mounting points.
Bodywork Plastics:
Fenders, body panels, racks, seat removal and installation.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain lubrication (if applicable), tire pressure checks.
Troubleshooting:
Systematic diagnosis of common problems and malfunctions.
Repair Rebuild:
Detailed step-by-step instructions for component disassembly, repair, and reassembly.
Inspections:
Pre-ride checks, periodic inspections of critical components.
Adjustments:
Carburetor adjustments, throttle cable, brake lever, suspension settings.
Wiring Diagrams:
Comprehensive electrical schematics for accurate troubleshooting and repair.
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds.
Type:
Liquid-cooled, 4-stroke, Single-cylinder.
Displacement 300:
Approximately 293cc (specific bore/stroke may vary slightly).
Displacement 400:
Approximately 375cc (specific bore/stroke may vary slightly).
Horsepower 300:
Estimated 15-18 HP (actual dyno figures may vary).
Horsepower 400:
Estimated 20-24 HP (actual dyno figures may vary).
Carburetor:
Mikuni VM series (specific model number for each engine variant found in manual).
Fuel Type:
Unleaded gasoline.
Ignition Type:
Electronic CDI with spark advance.
Atv Safety Guidelines:
Manual emphasizes safe operating practices, protective gear (helmet, eye protection, boots, gloves), and adherence to speed limits.
Braking System Type:
Hydraulic disc brakes front and rear, often with foot pedal operation for rear and handlebar lever for front.
Rollover Protection:
No inherent rollover protection beyond rider skill; manual stresses safe riding techniques.
Lighting:
Standard headlights, taillight, and brake light for visibility.
Engine Oil Change:
Typically every 100 hours or annually. Manual will specify exact interval and oil type.
Air Filter Cleaning:
Recommended every 25-50 hours or as needed based on operating conditions. Manual details cleaning and oiling procedures.
Spark Plug Replacement:
Refer to manual for specific mileage/hour interval, often around 100-200 hours.
Drive Belt Inspection:
Inspect at 50-hour intervals or annually. Replace as needed if wear is excessive.
Engine Oil:
Typically SAE 20W-50 API SG or higher. Manual will specify exact grade and quantity. Example: Polaris Premium 4 20W-50.
Coolant:
Permanent type antifreeze/coolant, typically a 50/50 mix with distilled water. Manual specifies type and capacity.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify correct type.
Gearcase Oil:
Specific gear oil for gearbox and differential. Manual will specify type and quantity.
Cv Boot Wear:
Common on many ATVs of this era due to terrain and exposure. Manual details replacement procedure.
Carburetor Fouling:
Can occur from stale fuel or debris. Manual provides cleaning and rebuilding instructions.
Drive Belt Slippage:
Indicates worn belt or clutch sheave issues. Manual guides inspection and repair.
Cooling System Leaks:
Hose degradation or radiator damage can lead to leaks. Manual provides leak detection and repair methods.
