Engine Management:
Detailed diagnostics, repair, and overhaul procedures for the engine and its components.
Fuel System:
Carburetor systems, fuel pump, fuel lines, fuel tank maintenance and repair.
Ignition System:
Ignition coil, spark plugs, stator, CDI unit testing and replacement.
Cooling System:
Radiator, fan, thermostat, coolant fluid specifications and service.
Exhaust System:
Muffler, exhaust pipe inspection and replacement.
Drivetrain Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, and repair.
Drive Shafts Axles:
CV joints, boots, drive shafts inspection and replacement.
Suspension Steering:
Front and rear suspension components, shocks, A-arms, ball joints, tie rods, steering column, and wheel alignment.
Brakes:
Hydraulic brake system, calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures.
Electrical System:
Battery, charging system (alternator/stator), starter motor, lighting, wiring diagrams, fuses, and relays.
Chassis Frame:
Frame inspection, alignment checks, and related component mounting.
Bodywork Plastics:
Fender, hood, seat, and other plastic body panel removal, installation, and repair.
Routine Maintenance:
Oil changes, filter replacements, lubrication, air filter cleaning/replacement, spark plug checks.
Troubleshooting Diagnostics:
Step-by-step diagnostic trees and common issue identification for electrical, mechanical, and fuel problems.
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly.
Transmission Rebuild:
Disassembly, inspection, and repair of the Polaris Variable Transmission (PVT) system.
Brake Service:
Brake pad replacement, caliper servicing, master cylinder replacement, and brake bleeding.
Electrical Component Testing:
Testing of stator, ignition coil, starter, battery, and other electrical components using multimeters.
Suspension Component Replacement:
Replacement of shocks, A-arms, bushings, ball joints, and tie rod ends.
Wheel Alignment:
Procedures and specifications for front-end wheel alignment.
Tire Maintenance:
Tire pressure recommendations and inspection.
Depth Level:
Comprehensive (covers routine maintenance to complete overhaul and diagnostics).
Diagnostic Capabilities:
Detailed troubleshooting flowcharts and fault code interpretation (if applicable).
Specification Detail:
Includes torque specifications, clearances, fluid capacities, electrical resistances, and test values.
Engine Type 300:
287cc, Liquid-cooled, 4-stroke, SOHC, Single-cylinder (Engine code may vary, often based on Polaris engines of the era).
Engine Type 400 Ho:
375cc, Liquid-cooled, 4-stroke, SOHC, Single-cylinder (Often denoted as 'High Output').
Horsepower 300 Est:
~18-20 HP (Estimated, actual figures vary).
Horsepower 400 Ho Est:
~22-25 HP (Estimated, actual figures vary).
Torque Specs:
Detailed torque specifications for all engine fasteners will be in the manual.
Fuel Delivery 300:
Carburetor (e.g., Mikuni BSR series or similar).
Fuel Delivery 400 Ho:
Carburetor (e.g., Mikuni BSR series or similar).
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Oil Type Recommendation:
Polaris recommends specific synthetic or semi-synthetic engine oils, likely SAE 0W-40 or 10W-40, meeting API service classifications (specifics in manual).
Oil Capacity Est:
~1.5 - 2.0 Liters (including filter, verify in manual).
Spark Plug Recommendation:
Specific spark plug model and gap (e.g., NGK or Champion).
Transmission Type:
Polaris Variable Transmission (PVT) with Engine Braking (CVT - Continuously Variable Transmission).
Drive System:
Shaft Drive, AWD (All-Wheel Drive) with 2WD/AWD selection.
Gear Selection:
High, Low, Neutral, Reverse.
Belt Inspection:
Critical for PVT performance; procedures for checking belt wear, tension, and alignment.
Clutch Service:
Primary and secondary clutch inspection, cleaning, and potential adjustment/replacement.
Overall Length Est:
~73 inches (185 cm) (Verify exact measurement).
Overall Width Est:
~46 inches (117 cm) (Verify exact measurement).
Overall Height Est:
~45 inches (114 cm) (Verify exact measurement).
Dry Weight Est:
~600-650 lbs (272-295 kg) (Verify exact measurement).
Ground Clearance Est:
~9-10 inches (229-254 mm) (Verify exact measurement).
Rack Capacity Front:
Approx. 90 lbs (41 kg).
Rack Capacity Rear:
Approx. 180 lbs (82 kg).
Towing Capacity:
Typically 1,500 lbs (680 kg) for this class of ATV (Verify in manual).
Front Tire Size:
Commonly 25x8-12 (Verify in manual).
Rear Tire Size:
Commonly 25x10-12 (Verify in manual).
Wheel Type:
Steel or Aluminum wheels, bolt pattern specific to Polaris.
Engine Oil Change:
Typically every 50-100 hours of operation or annually, whichever comes first. (Specific recommendation in manual).
Air Filter Service:
Regular inspection, cleaning, and replacement as needed, especially in dusty conditions. Interval usually every 20-50 hours.
Spark Plug Check:
Check/replace at ~100-200 hour intervals or annually.
Transmission Fluid:
Final drive and transmission fluid checks and changes. Specific intervals detailed in the manual, often around 100-200 hours or annually.
Brake Fluid Flush:
Recommended every 1-2 years for optimal performance.
Engine Oil Spec:
Refer to manual for exact viscosity (e.g., SAE 0W-40 or 10W-40) and API classification.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specific Polaris coolant may be recommended.
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Final Drive Gear Lube:
Specific gear oil specification for differentials and final drives (verify in manual).
Cvt Belt Wear:
Common wear item on CVTs, requiring periodic inspection and replacement.
Electrical Connector Corrosion:
Can occur in wet environments; regular inspection of connectors is advised.
Suspension Bushings:
Wear on A-arm and shock bushings can lead to play and affect handling.
