The Xpress 300 / 400 ATV, manufactured between 1996 and 1998, represents a capable and reliable option for recreational trail riding and utility tasks. These ATVs are recognized for their agile chassis, designed for maneuverability in varied terrain, and are powered by efficient 2-stroke engines, with displacements of approximately 293 cc for the 300 model and 399 cc for the 400 model. Key features include an automatic CVT transmission, robust suspension systems, and effective braking for confident operation. A respected American manufacturer, engineered these models to offer a balance of performance and accessibility, making them a popular choice for those seeking dependable off-road adventure. This comprehensive workshop service repair manual provides complete A-Z coverage for the Xpress 300 / 400 ATVs. It is designed to empower owners and technicians with the knowledge needed for all service and repair procedures, from routine maintenance such as oil changes and air filter cleaning to complex tasks like engine rebuilding and transmission overhauls. The manual details engine assembly, drivetrain systems, chassis components, electrical systems, and fuel systems, offering step-by-step instructions, troubleshooting guides, and essential technical specifications including torque values and fluid capacities. Its clear, concise language and included illustrations ensure that maintenance and repair can be performed with confidence, helping to maintain the longevity and performance of your vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Xpress 300 / 400 Model Variant: ATV Years Covered: 1996, 1997, 1998 👋 Introduction Market Position Target Audience: DIY enthusiasts, ATV owners seeking to perform their own maintenance and repairs, saving significant costs. Key Features Benefit Statement: Empowers owners to confidently perform all service and repair jobs with clear, concise instructions and visual aids. Unique Selling Proposition: Comprehensive coverage for specific model years, enabling cost-effective DIY solutions. 📋 Manual Details Coverage Coverage Areas: Complete Service & Repair Procedures (A-Z) Format Format: PDF Download Language Language: English Manual Type Manual Type: Workshop Service Repair Manual Computer Requirements Software Required: Adobe Reader (free download available) Compatible Devices: All PC & MAC Computers, Tablets, Mobile Phones 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly, disassembly, tuning, carburetor, lubrication, cooling, exhaust Drivetrain Systems: Transmission, final drive, clutch, belt drive, differentials Chassis Systems: Frame, suspension (front and rear), steering, wheels, tires Braking Systems: Hydraulic brakes, brake calipers, master cylinders, brake fluid, lines Electrical Systems: Ignition system, lighting, battery, charging system, starter, wiring diagrams, switches Fuel Systems: Fuel tank, fuel lines, fuel pump, fuel filter, carburetor (specific models) Bodywork And Trim: Body panels, fenders, seat, handlebars, controls, rack systems Procedures Included Maintenance Procedures: Routine checks, lubrication, filter changes, spark plug replacement, chain adjustment, battery maintenance Repair Procedures: Engine rebuilding, transmission overhauls, suspension component replacement, brake system repairs, electrical troubleshooting Troubleshooting Guides: Diagnostic charts, common problem identification, solutions for performance issues, starting problems, electrical faults Technical Specifications: Torque values, clearances, fluid capacities, electrical specifications, engine timing Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds Visual Aids Illustrations: Step-by-step instructions with pictures 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Printable (single page, chapter, or entire manual) Accessibility Accessibility: Instant email delivery after payment ⚙️ Engine Specifications Primary Engine 300 Engine Type 300: 2-stroke, 1-cylinder Displacement 300: 293 cc (approx.) Primary Engine 400 Engine Type 400: 2-stroke, 1-cylinder Displacement 400: 399 cc (approx.) Fuel System Carburetion: Mikuni VM series carburetor (specific model varies by year/engine) Cooling System Cooling Method: Air-cooled Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) 🔧 Transmission Transmission Type Transmission: Automatic (CVT - Continuously Variable Transmission) Drive System Drive: Shaft Drive (2WD) Clutch Type Clutch: Automatic CVT clutch with primary and secondary sheaves Gear Ratios Gear Selection: Forward, Neutral, Reverse (with High/Low range often available on 400 models, check specific variant) 📐 Dimensions Exterior Dimensions General Design: Compact, agile ATV chassis optimized for trail riding and utility tasks. Weights Dry Weight: Varies by model, typically in the range of 450-550 lbs (estimated, refer to manual for exact specs) Towing Capacity: Typically around 150-250 lbs (for rack systems, not official towing ratings) 🛡️ Safety Features Active Features Braking System: Front and rear drum or disc brakes (depending on exact model/year), controlled by handlebar levers. Passive Features Handlebars: Ergonomically designed handlebars with comfortable grips and control placement. Lighting: Halogen headlights and taillight for visibility. 💡 Technology Features Infotainment Display: Basic digital odometer and indicator lights for gear selection and warning lights. Driver Assistance Features: Focus on mechanical simplicity and rider control rather than electronic driver assistance systems. 🔧 Maintenance Service Intervals Oil Change Interval: Every 100 hours or annually (refer to manual for exact recommendation based on usage). Air Filter Cleaning: Inspect and clean every 20-30 hours of operation, replace as needed. Spark Plug Replacement: Recommend checking and cleaning at 50-hour intervals, replacement typically at 100-200 hours or as specified. Fluid Specifications Engine Oil Type: SAE...