Market Segment:
Mid-size utility ATV, positioned for recreational and light-duty work.
Competitors:
Competed with models from Yamaha (Kodiak), Honda (FourTrax), and Suzuki (King Quad) in the utility ATV market of the late 1990s.
Performance Focus:
Known for its torquey 2-stroke engine and capable independent front suspension.
Utility Design:
Designed for trail riding, hunting, and general farm use with features like a decent towing capacity and racks.
Digital Format Benefit:
PDF format allows for easy searching, digital storage, and printing of specific sections as needed, offering an advantage over older paper manuals.
Engine:
Complete engine overhaul, including disassembly, inspection, assembly, tuning, and troubleshooting for the 2-stroke liquid-cooled engine.
Transmission:
Detailed procedures for the PVT (Polaris Variable Transmission), including belt inspection and replacement, clutch assembly, and gearbox maintenance.
Drivetrain:
Front and rear differential maintenance, driveshaft inspection, universal joint servicing, and hub bearing replacement.
Suspension:
Front and rear suspension system repair, shock absorber servicing, swingarm bushings, and steering linkage components.
Brakes:
Hydraulic brake system service, including caliper disassembly, brake pad replacement, fluid bleeding, master cylinder repair, and component inspection.
Electrical System:
Complete wiring diagrams, troubleshooting guides for lighting, ignition system, starter, charging system (stator and regulator/rectifier), and accessory circuits.
Fuel System:
Carburetor (Mikuni VM34) overhaul, cleaning, jetting, fuel line maintenance, fuel pump (if applicable), and fuel tank servicing.
Cooling System:
Radiator maintenance, fan operation, coolant types and specifications, and water pump seal inspection.
Exhaust System:
Exhaust pipe and muffler inspection, leak detection, and basic repair procedures.
Body And Frame:
Body panel removal and installation, frame inspection for damage, plastic component repair, and seat assembly.
Preventive Maintenance:
Detailed maintenance schedules, lubrication points, and regular inspection checklists.
Troubleshooting:
Systematic troubleshooting guides for common starting, running, electrical, and drivetrain issues.
Repair Procedures:
Step-by-step repair instructions with torque specifications and critical clearances for all major components.
Diagnostic Procedures:
Methods for diagnosing ignition system problems, fuel delivery issues, and mechanical wear.
Adjustment Procedures:
Carburetor adjustments, throttle cable adjustments, brake lever free play settings.
Depth:
Comprehensive, covering from basic fluid changes and inspections to complete engine and transmission rebuilds, electrical system diagnostics, and frame repairs.
Engine Type:
2-stroke, 2-cylinder, liquid-cooled
Bore X Stroke:
61 mm x 65 mm
Fuel Delivery:
Mikuni VM34 carburetor
Horsepower:
Approximately 28-30 hp (estimated)
Torque:
Not explicitly stated, but known for good low-end torque
Fuel Type:
Unleaded gasoline (87 octane minimum)
Oil Mixture:
50:1 ratio with 2-stroke oil for the injection system.
Atv Safety Standards:
Adheres to ANSI (American National Standards Institute) standards for ATVs.
Braking System:
Hydraulic disc brakes, front and rear.
Throttle Limiter:
Thumb throttle with safety mechanism.
Kill Switch:
Handlebar-mounted emergency stop switch.
Lighting:
Headlights and taillight for visibility.
Infotainment System:
N/A (Basic utility ATV, no integrated infotainment).
Driver Assistance Features:
N/A (Basic utility ATV, no electronic driver aids).
Connectivity Features:
N/A (Basic utility ATV, no electronic connectivity).
Oil Change:
Every 20-30 hours or annually. Check owner's manual for specific recommendations.
Air Filter:
Clean/inspect every 10-20 hours, replace as needed.
Spark Plug:
Inspect and gap every 15-25 hours, replace as needed (NGK BR8ES or equivalent).
Drive Belt:
Inspect every 20 hours for wear and damage, replace at first sign of fraying or glazing.
Engine Oil:
Polaris 2-Stroke Synthetic or equivalent 50:1 pre-mix oil.
Transmission Fluid:
Polaris Demand Drive Fluid or SAE 30W API GL-4 gear oil for the front differential. Rear differential (if applicable) and gearbox typically use SAE 30W or 80W-90 gear oil. (Refer to manual for specific quantities and types).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Carburetor Clogging:
Common with stored fuel; requires regular cleaning and use of fuel stabilizer.
Voltage Regulator Failure:
Can lead to charging system issues or battery drain.
Pvt Belt Wear:
Regular inspection and timely replacement are crucial to prevent drivetrain damage.
Cooling System Leaks:
Check hoses, radiator, and water pump seal for integrity.
Polaris Atv History:
Polaris has been a significant player in the ATV market since the introduction of the Scrambler and Trail Boss models, continuously innovating in the off-road vehicle sector.
Xplorer Lineage:
The Xplorer line was introduced to offer a more specialized and performance-oriented ATV compared to some of Polaris's utility-focused models, often featuring independent front suspension and more powerful engines for its time.
Manufacturing Era:
The 1999 model year falls within the peak era of 2-stroke engine dominance in the ATV market before the shift towards 4-stroke power.
