Engine:
Internal engine repair, troubleshooting, specifications, top-end rebuild, bottom-end rebuild, cooling system.
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank, fuel filters.
Ignition System:
Ignition coil, CDI unit, spark plugs, wiring diagrams, timing.
Drivetrain:
Shaft drive system, differential, gearcase, U-joints, driveshafts.
Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) service, belt replacement, clutch inspection, planetary gearsets (if applicable).
Suspension:
Front and rear suspension components, shocks, springs, A-arms, bushings, ball joints, steering linkage.
Brakes:
Hydraulic brake system, brake calipers, brake lines, master cylinder, brake fluid flush, brake pad replacement.
Electrical System:
Wiring diagrams, battery, charging system (stator, voltage regulator), starter motor, lighting, accessories, fuses, relays.
Body And Frame:
Frame inspection, body panels, fenders, seats, racks, trim pieces.
Cooling System:
Radiator, fan, coolant hoses, thermostat, coolant specifications.
Exhaust System:
Muffler, exhaust pipes, gaskets.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, greasing points, belt inspection, spark plug service.
Troubleshooting:
Diagnostic flowcharts, common problem identification, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major components and systems.
Disassembly And Assembly:
Detailed instructions for removing, inspecting, and reinstalling parts.
Torque Specifications:
Required torque values for critical fasteners.
Wiring Diagrams:
Comprehensive electrical system schematics.
Special Tools:
Identification of necessary special tools for specific procedures.
Depth:
Comprehensive. Covers basic maintenance to complete engine and transmission rebuilds, including diagnostics and specifications.
Model 300 Engine Type:
Likely 2-stroke, liquid-cooled, single-cylinder (e.g., Polaris 250cc or 300cc class)
Model 400 Engine Type:
Likely 2-stroke, liquid-cooled, single-cylinder (e.g., Polaris 375cc or 400cc class)
Horsepower Range:
Estimated 20-30 HP for the 300cc, 25-35 HP for the 400cc (dependent on specific engine variant)
Torque Figures:
Torque figures will vary but are optimized for low-end pulling power characteristic of ATVs.
Carburetion:
Mikuni or Keihin carburetor (specific model documented in manual).
Fuel Type:
Unleaded gasoline (octane rating specified in manual).
Oil Type 300:
2-stroke oil injection system or pre-mix (specified by Polaris).
Oil Type 400:
2-stroke oil injection system or pre-mix (specified by Polaris).
Type:
Polaris Variable Transmission (PVT) - Automatic CVT
Optional Transmissions:
N/A (PVT was standard for this generation)
Gear Selection:
High, Low, Neutral, Reverse
Drive System:
Shaft drive to rear axle, likely with on-demand 4WD system (4WD engaged manually or automatically).
Transmission Fluid Type:
Specific CVT fluid or gearcase oil as per Polaris specifications (detailed in manual).
Wheelbase:
Typically around 50-52 inches, specific to model year and variant.
Ground Clearance:
Generally 8-10 inches, providing good off-road capability.
Dry Weight:
Approximately 550-650 lbs, depending on 2WD/4WD and specific model.
Towing Capacity:
Typically rated around 1000-1500 lbs, consult manual for exact figure.
Front Tire Size:
Commonly 25x8-12 or similar.
Rear Tire Size:
Commonly 25x10-12 or similar.
Oil Change Interval:
Typically every 100 hours or 12 months for engine oil (check manual for specific details).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (e.g., every 20-40 operating hours).
Belt Inspection Interval:
Regular inspection of the CVT belt for wear and tear is crucial, typically every 20-40 operating hours.
Engine Oil Type 4 Stroke:
N/A (These are likely 2-stroke engines with oil injection or pre-mix)
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (specific ratio and type in manual).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (confirm in manual).
Common Wear Items:
CVT belt, brake pads, suspension bushings, wheel bearings, spark plugs, exhaust gaskets.
Electrical Gremlins:
Wiring harness degradation or corrosion can be an issue on older units; thorough inspection is key.
Engine Carburetion Issues:
Carburetor clogging due to fuel varnish or dirt if not maintained properly.
Polaris Atv Legacy:
Polaris has a long history in powersports, with the Xplorer line being a significant contributor to their utility ATV segment.
Xplorer Series:
The Xplorer series focused on a blend of comfort, capability, and utility, often featuring independent rear suspension (IRS) on higher-end models, though this manual likely covers models with swingarm rear suspension and IRS variants depending on specific sub-models.
Manufacturing Location:
Roseau, Minnesota, USA (Polaris primary manufacturing facility).
