This workshop service repair manual covers the Polaris Xpress 300 and Sport 400 ATVs manufactured for the 1998 and 1999 model years. These ATVs, known for their robust two-stroke, fan-cooled, single-cylinder engines, offered reliable performance for recreational and utility use. The Xpress 300, with its 299 cc engine, and the Sport 400, powered by a 398 cc engine, both feature automatic CVT transmissions and are equipped with hydraulic disc brakes for effective stopping power. A brand with roots dating back to 1954, was recognized during this era for its growing presence and innovation in the ATV market. This comprehensive manual provides complete service and repair procedures from A to Z, intended for ATV owners and independent repair technicians. It details maintenance schedules, troubleshooting guides, and step-by-step repair instructions for all major systems, including the engine, transmission, drivetrain, suspension, braking, steering, and electrical components. Covered maintenance includes oil changes, filter replacements, and lubrication, while repair sections address everything from basic component adjustments to complete engine and transmission overhauls. The manual aims to empower users to perform maintenance and repairs efficiently, potentially saving costs and ensuring the longevity of their vehicles. 🏷️ Basic Information Identification Make: Polaris Model: Xpress 300 & Sport 400 Model Variant: ATV Year: 1998, 1999 Codes Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Target Audience: ATV owners and independent repair technicians seeking detailed service information. Competitive Analysis Value Proposition: Enables DIY repairs, saving significant costs compared to dealership service. Key Features Ease Of Use: Easy-to-follow step-by-step instructions with pictures. Accessibility: Downloadable to PC, Mac, tablets, and smartphones. 📋 Manual Details Coverage Areas Coverage Scope: Complete Service and Repair Procedures A-Z Page Count Estimated Page Count: N/A (Digital Download) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly, disassembly, inspection, lubrication, cooling, fuel delivery, ignition, exhaust, starting, charging. Transmission Systems: Transmission operation, inspection, repair, drive belts, clutches. Drivetrain Systems: Driveshafts, differentials, CV joints, axle components. Suspension Systems: Front and rear suspension components, shock absorbers, control arms, bushings, alignment. Braking Systems: Brake hydraulics, calipers, pads, rotors, drums, parking brake. Steering Systems: Steering column, tie rods, steering linkage, steering gear (if applicable). Electrical Systems: Battery, charging system, ignition system, lighting, starter, wiring diagrams, component testing. Chassis Body: Frame, body panels, fenders, seats, handlebars, controls, racks. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication, tire pressure checks, battery maintenance. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting, common issue identification. Repair: Step-by-step repair instructions for all covered systems and components. Overhaul: Complete engine and transmission overhaul procedures. Diagnosis: Detailed diagnostic charts and flowcharts. Technical Depth Depth: Comprehensive: Covers basic maintenance to advanced diagnostics and complete component rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content (assuming standard PDF creation). Print Quality Printability: Printable by chapter or entire document. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type Xpress 300: 2-Stroke, Fan-Cooled, Single Cylinder Engine Type Sport 400: 2-Stroke, Fan-Cooled, Single Cylinder Displacement Displacement Xpress 300: 299 cc (18.2 cu. in.) Displacement Sport 400: 398 cc (24.3 cu. in.) Performance Horsepower Xpress 300: Approx. 25 HP (Varies by tune) Horsepower Sport 400: Approx. 33 HP (Varies by tune) Fuel System Fuel Delivery Type: Carburetor Carburetor Model Xpress 300: Keihin PWK (Specific model may vary, consult manual) Carburetor Model Sport 400: Keihin PWK (Specific model may vary, consult manual) Ignition Ignition System: CDI (Capacitor Discharge Ignition) Cooling Cooling System: Forced Air Cooling (Fan-assisted) Lubrication Oil Type: 2-Cycle Oil Injection System (Consult manual for specific blend/viscosity requirements) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Features Drive System: Shaft Drive (likely rear-wheel drive, RWD) Clutch Type: Centrifugal Clutch 📐 Dimensions Exterior Wheelbase Approx: Consult manual (Typical for this era ~48-50 inches) Weights Dry Weight Approx Xpress 300: Approx. 385 lbs (175 kg) Dry Weight Approx Sport 400: Approx. 410 lbs (186 kg) 🛡️ Safety Features Active Features Braking System Type: Hydraulic Disc Brakes (Front and Rear) Passive Features Throttle Limiter: Likely has a throttle limiter mechanism (common on entry-level ATVs). Kill Switch Location: Handlebar-mounted engine kill switch. 💡 Technology Features Infotainment Infotainment System: Basic, no electronic infotainment systems in this era. Driver Assistance Driver Assistance Features: None (Standard ATV operation). Connectivity Connectivity Options: None. 🔧 Maintenance Service Intervals Oil Change Interval: Consult manual (Typically every 20-40 hours of operation for CVT/gearbox oil). Spark Plug Replacement: Consult manual (Typically every 100-150 hours or annually). Fluid Specifications Engine Oil Type: 2-Cycle Pre-Mix or Oil Injection (Specific grade and ratio per manual). Transmission Gear Oil: Consult manual (Likely SAE 75W-90 or similar hypoid gear oil). Brake Fluid Type: DOT 3 or DOT 4 (Consult manual for exact specification). Known Issues Common Wear Items: Drive...