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).