Market Segment:
Mid-size utility ATV, popular for recreational trail riding and light farm work.
Competitors 1994 1995:
Competed with models from Honda (e.g., FourTrax 300/400), Yamaha (e.g., Kodiak 400), Suzuki (e.g., King Quad 300), and Kawasaki (e.g., Bayou 300/400).
Key Features Vehicle:
4x4 capability, reliable Polaris engine, comfortable ride for its era, utility focused design.
Manual Value:
Essential resource for owners and technicians to maintain, diagnose, and repair the ATV, ensuring longevity and optimal performance.
Engine Mechanical:
Detailed disassembly, inspection, and reassembly of engine components including cylinder, piston, crankshaft, connecting rod, and valve train.
Fuel System:
Carburetor service (cleaning, adjustment, jetting), fuel pump operation, fuel tank, and fuel lines.
Ignition System:
CDI unit, ignition coil, spark plug specifications, timing checks, and troubleshooting.
Cooling System:
Radiator, coolant, fan operation, and associated plumbing (if applicable).
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, final drive, and driveshaft maintenance.
4X4 System:
Operation of the 4-wheel drive system, front differential, and engagement mechanisms.
Suspension System:
Front and rear suspension components, shock absorbers, control arms, and lubrication points.
Steering System:
Handlebar assembly, tie rods, steering linkage, and wheel alignment.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, starter, lighting, charging system (stator, rectifier/regulator), and accessory connections.
Body Chassis:
Frame inspection, body panels, racks, and seat removal/installation.
Routine Maintenance:
Oil changes, filter replacements, lubrication, spark plug checks, and air filter cleaning/replacement.
Troubleshooting Diagnostics:
Systematic diagnostic flowcharts and symptom-based troubleshooting guides for common issues.
Rebuild Procedures:
Detailed instructions for complete engine, transmission, and differential rebuilds.
Adjustment Procedures:
Carburetor jetting, throttle cable slack, brake lever free play, and chain tension (if applicable).
Testing Procedures:
Electrical component testing, compression testing, and ignition system performance checks.
Wiring Diagrams:
Color-coded, system-specific wiring schematics for accurate electrical diagnosis.
Depth Of Coverage:
Factory-level repair and overhaul, suitable for experienced DIY mechanics and professional technicians.
Print Quality:
High-resolution, suitable for printing all pages.
Binding Type:
Not applicable (PDF Download)
Paper Type:
Not applicable (PDF Download)
Searchable Text:
Likely searchable text within the PDF for efficient information retrieval.
Organizational Structure:
Typically organized by system with clear chapter breaks and an index.
Engine Type:
4-stroke, liquid-cooled, single-cylinder (typical for this model, confirm with manual)
Displacement:
Approximately 375-400cc (exact figure to be confirmed with manual)
Bore X Stroke:
Specific dimensions required from manual.
Compression Ratio:
Specific ratio required from manual.
Horsepower:
Estimated 20-25 HP (exact figure to be confirmed with manual)
Torque:
Specific torque figures required from manual.
Carburetor Type:
Likely Mikuni or Keihin (specific model number required from manual).
Fuel Type:
Unleaded gasoline (Octane rating to be confirmed).
Ignition Timing:
Specific ignition timing specifications required from manual.
Transmission Type:
Automatic with Variable Transmission (CVT) or Polaris Variable Transmission (PVT).
Gear Selection:
Forward, Neutral, Reverse.
Drive System:
Shaft drive with automatic engagement of front differential for 4x4 operation.
Transmission Fluid Type:
Specific Polaris transmission fluid or equivalent SAE 10W-30/SAE 30 motorcycle oil (verify with manual).
Transmission Fluid Capacity:
Specific capacity to be confirmed with manual.
Wheelbase:
Approximate 48-50 inches (exact measurement required from manual).
Ground Clearance:
Approximate 8-10 inches (exact measurement required from manual).
Dry Weight:
Approximate 500-550 lbs (exact weight required from manual).
Cargo Capacity Rack Front:
Specific capacity to be confirmed with manual.
Cargo Capacity Rack Rear:
Specific capacity to be confirmed with manual.
Front Tire Size:
Typically 23x7-10 or similar (verify with manual).
Rear Tire Size:
Typically 24x11-10 or similar (verify with manual).
Safety Standards:
ATVs are not subject to automotive crash safety ratings. Adherence to industry safety recommendations is paramount.
Braking System Type:
Hydraulic disc brakes front and rear.
Lighting:
Headlights, taillight, brake light.
Operator Safety:
Importance of proper PPE (helmet, goggles, gloves, sturdy footwear, long sleeves/pants) and safe riding practices emphasized in manual.
Engine Oil Change Interval:
Recommended every 50-100 operating hours or annually (specific interval to be found in manual).
Air Filter Cleaning Interval:
Check frequently, clean/replace as needed based on operating conditions (specific interval in manual).
Spark Plug Replacement Interval:
Recommended every 100-200 operating hours or annually (specific interval in manual).
Transmission Fluid Change Interval:
Recommended every 100-200 operating hours or annually (specific interval in manual).
Engine Oil Specification:
SAE 10W-30 or SAE 30 API SG or higher (verify with manual).
Engine Oil Capacity:
Specific capacity to be confirmed with manual.
Coolant Type:
Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio recommended).
Common Wear Items:
Brake pads, tires, drive belts (CVT), suspension bushings.
Typical Failures:
Carburetor issues (gumming up if not run regularly), starter solenoid problems, occasional electrical connection corrosion.
Carburetor Cleaning Importance:
Regular cleaning and proper fuel stabilization are crucial for carb-equipped ATVs to prevent starting issues and rough running.
