Positioning:
Mid-size utility ATV, offering a balance of power and maneuverability for recreational and light work tasks.
Competitors 2009:
Honda Rancher, Yamaha Grizzly 350/400, Can-Am Outlander 400.
Powertrain:
4-stroke engine, automatic transmission (CVT).
Drivetrain:
Switchable 2WD/4WD (likely on 400 HO, potential for 2WD only on 300 HO, needs verification from manual).
Suspension:
Independent Front Suspension (IFS), Swingarm Rear Suspension.
Engine:
Comprehensive coverage including disassembly, assembly, inspection, and repair.
Fuel System:
Carburetor (likely Keihin or similar), fuel pump, fuel filter, fuel lines, and tank.
Lubrication Cooling:
Oil pump, oil filter, oil passages, coolant system (if liquid-cooled), radiator, fan.
Transmission Drive:
CVT (Continuously Variable Transmission) operation, belt replacement, roller maintenance, drive clutch, driven clutch, final drive, chain/shaft drive specifics.
Steering:
Handlebar, steering stem, tie rods, ball joints, wheel alignment.
Suspension:
Front and rear shocks, springs, bushings, control arms, A-arms.
Brakes:
Hydraulic brake system, caliper service, master cylinder, brake lines, pads, rotors, bleeding procedures.
Electrical:
Starter, alternator/stator, battery, ignition system, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, relays, switches.
Bodywork Chassis:
Fenders, racks, seat, plastics, frame inspection and repair.
Intake Exhaust:
Airbox, air filter, intake manifold, exhaust pipe, muffler, emissions components (if applicable).
Routine Maintenance:
Oil changes, filter replacements, lubrication points, tire pressure checks, chain adjustment.
Troubleshooting:
Diagnostic flowcharts for common problems, fault code interpretation (if applicable).
Engine Overhaul:
Complete engine rebuild procedures from top to bottom.
Transmission Service:
CVT belt inspection/replacement, clutch service, gearcase oil changes.
Electrical Diagnostics:
Wiring harness testing, component testing, charging system diagnosis.
Suspension Adjustment:
Preload and damping adjustments, component replacement.
Brake System Repair:
Pad replacement, rotor service, caliper rebuild, line flushing.
Component Installation Removal:
Detailed steps for removing and reinstalling major components.
Depth:
Comprehensive: Covers basic to advanced repairs, diagnostics, and overhauls.
Diagrams:
Includes exploded views, wiring diagrams, and service illustrations.
Specifications:
Provides torque values, clearances, tolerances, and fluid capacities.
Engine Type:
4-stroke, liquid-cooled (likely for 400 HO, air-cooled possible for 300 HO).
Displacement 300:
Approximately 299cc (refer to manual for exact specific)
Displacement 400:
Approximately 375-400cc (refer to manual for exact specific)
Bore X Stroke:
Specific to model, detailed in manual.
Compression Ratio:
Specific to model, detailed in manual.
Horsepower Approx 300:
Likely in the 20-25 HP range.
Horsepower Approx 400:
Likely in the 25-30 HP range.
Torque:
Specific to model, detailed in manual.
Carburetor Type:
Likely Mikuni or Keihin, single barrel.
Fuel Type:
Unleaded gasoline (87 octane recommended).
Oil Type:
SAE 10W-40, API SG or higher (check manual for precise specification).
Coolant Type:
Ethylene glycol based antifreeze mixture (check manual for specific mix ratio and type).
Length:
Approx. 81 inches (varies slightly between models).
Width:
Approx. 46 inches.
Height:
Approx. 47 inches.
Dry Weight:
Approx. 600-650 lbs (varies).
Towing Capacity:
Refer to manual for specific rating, typically around 1500 lbs.
Cargo Capacity Front Rack:
Approx. 50 lbs.
Cargo Capacity Rear Rack:
Approx. 100 lbs.
Front Tire Size:
Typically 25x8-12 (check manual for exact).
Rear Tire Size:
Typically 25x10-12 (check manual for exact).
Wheel Bolt Pattern:
4/156 (common for Polaris ATVs).
Initial Service:
Refer to manual for break-in service (typically around 10-20 hours).
Engine Oil Change:
Typically every 100 hours or annually, whichever comes first (verify in manual).
Air Filter Cleaning:
Frequent inspection and cleaning, especially in dusty conditions (refer to manual).
Spark Plug Replacement:
Typically every 1-2 years or 100-200 hours (verify in manual).
Cv Belt Inspection:
Regular inspection for wear and damage (refer to manual for specific interval).
Engine Oil Capacity:
Refer to manual, typically around 1.5-2 quarts.
Gearcase Oil Capacity:
Refer to manual, typically around 0.5-0.7 quarts.
Common Wear Items:
CVT belt, brake pads, wheel bearings, tie rod ends, ball joints.
Potential Electrical:
Stator or voltage regulator failures can occur over time.
Chassis Stress:
Frame or suspension components can experience stress with heavy use or impacts.
