The Polaris Xplorer 300 and Xplorer 400 are All-Terrain Vehicles (ATVs) manufactured by a company with a strong heritage in powersports. These models, produced for the 1999 and 2000 model years, were designed for both recreational trail riding and utility tasks, catering to outdoor enthusiasts and those needing a capable off-road workhorse. Key features include selectable 2WD/4WD capability, an automatic transmission utilizing a PVT system, and independent front suspension, all contributing to their robust build and performance in varied terrain. The Xplorer line represented a commitment to delivering reliable and versatile ATVs. This Workshop Service Repair Manual provides comprehensive guidance for the service and repair of the Polaris Xplorer 300 and Xplorer 400 ATVs. It covers a wide array of systems, including detailed procedures for engine overhaul, transmission maintenance, drivetrain, suspension, brakes, and electrical systems. The manual also details scheduled maintenance, troubleshooting common issues, diagnostic procedures, and provides essential technical specifications. Its scope is designed to assist professional technicians and experienced DIY mechanics in effectively maintaining and repairing these vehicles, ensuring their optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Xplorer 300 / Xplorer 400 Model Variants: 300, 400 Years Covered: 1999, 2000 Codes Manual Identifier: Workshop Service Repair Manual 👋 Introduction Market Position Vehicle Type: All-Terrain Vehicle (ATV) Target Demographic: Recreational riders, utility users, outdoor enthusiasts. Competitive Analysis Competitors: Other ATVs from manufacturers like Yamaha, Honda, Kawasaki, Suzuki in the utility and recreational segments. Key Features Atv Features: Selectable 2WD/4WD, automatic transmission, independent front suspension, robust build for trail riding and utility tasks. Manual Value Value Proposition: Provides in-depth technical guidance to maintain and repair the Polaris Xplorer 300 and 400 models, saving time and cost on professional services. 📋 Manual Details Coverage Areas Manual Type: Complete Workshop Service Repair Manual Primary Coverage: Service and Repair Procedures Additional Coverage: Troubleshooting, Diagnostics, Maintenance Page Count Estimated Page Count: Varies based on specific sub-models and engine options, typically 300-500+ pages for comprehensive coverage. Manual Type Manual Format: PDF Download Language Language: English 📖 Manual Coverage Systems Covered Engine: Engine overhaul, carburetor tuning, cooling system, lubrication system, ignition system, exhaust system. Transmission: Automatic transmission service, gearcase maintenance, drive clutch, driven clutch, belt inspection and replacement. Drivetrain: Front and rear differential service, driveshaft inspection and repair, CV joint maintenance, hub assemblies. Suspension: Front and rear suspension components, shock absorbers, bushings, ball joints, steering linkage. Brakes: Hydraulic brake system, brake calipers, master cylinder, brake pads, brake lines, bleeding procedures. Electrical: Wiring diagrams, lighting system, battery, starter, charging system (stator, regulator/rectifier), ignition switch, kill switch. Fuel System: Fuel tank, fuel lines, fuel pump, carburetor specifications and adjustment. Bodywork: Body panel removal and installation, fenders, racks, seat, handlebars. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points, spark plug replacement. Troubleshooting: Diagnostic charts, symptom analysis, common problems and solutions. Repair: Component disassembly, inspection, repair, and reassembly for all covered systems. Diagnostics: Fault finding for electrical and mechanical issues, component testing. Specifications: Torque values, clearances, fluid capacities, electrical resistance values. Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine and transmission overhauls). User Level: Suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable, allowing for quick access to specific information. Print Quality Printability: Designed to be printable for workshop use. Binding Type Digital Binding: N/A (Digital download) Paper Type Digital Paper Simulation: Simulates typical workshop manual pages. ⚙️ Engine Specifications Primary Engine Xplorer 300 Engine Type: 2-stroke, liquid-cooled, reed valve inducted, single-cylinder (specific model designation may vary, e.g., Fuji/Polaris). Xplorer 300 Displacement: Approximately 293cc Xplorer 400 Engine Type: 2-stroke, liquid-cooled, reed valve inducted, single-cylinder (specific model designation may vary, e.g., Fuji/Polaris). Xplorer 400 Displacement: Approximately 375cc Performance Horsepower Estimate: Xplorer 300: ~25-30 HP; Xplorer 400: ~35-40 HP (estimates vary by specific year and tuning). Torque Estimate: Xplorer 300: ~20-24 lb-ft; Xplorer 400: ~28-32 lb-ft (estimates vary by specific year and tuning). Fuel System Carburetor Type: Mikuni VM series or similar (specific model number in manual). Fuel Type: Unleaded gasoline, minimum 87 octane. Oil Mixture: Pre-mix or Auto-lube injection system (check specific model in manual for correct ratio/type). 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) with Polaris Variable Transmission (PVT) system. Drive Modes: 2WD / 4WD selectable. Features Clutch System: Drive clutch (primary) and driven clutch (secondary) with belt drive. Gear Reduction: Likely includes a sealed gearbox with reduction gears for front and rear differentials. Maintenance Fluid Type: Polaris specific AGL Gearcase Lubricant or equivalent high-quality gear oil (refer to manual for exact specification). 📐 Dimensions Exterior Length: Approx. 73-76 inches (varies slightly between models). Width: Approx. 42-45 inches (varies slightly between models). Height: Approx. 45-47 inches (varies slightly between models). Cargo Front Rack Capacity: Typically around 50-75 lbs. Rear Rack Capacity: Typically around...