POLARIS Xplorer 300 Xplorer 400 Xpress 300 Xpress 400 1996 1997 1998 Service Repair Manual

POLARIS 1996 1997 1998 Service Repair Manual

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your POLARIS. Read and print pages, or copy the entire manual to your hard drive.

633 Pages

Models Covered :  

Magnum 2×4

Trail Blazer / Scrambler

Sportsman 4×4

Magnum 4×4

Trail Boss / Sport

400 6×6 / Magnum 6×6

Xplorer 300 / Xplorer 400

Sportsman 500

Xpress 300 / Xpress 400

Model Year:

 1996, 1997, 1998

Manual Covers :

• General Information
• Maintenance
• Engine
• Fuel Carburetion
• Body
• Steering
• Suspension
• Clutch
• Final Drive
• Transmission
• Brakes
• Starter
• Electrical
• Wiring Diagram 1996, 1997, 1998

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• Xplorer 300

  : Powered by a 283cc air-cooled, two-stroke engine with oil injection and an electric fan assist.

• Xplorer 400

  : Features a 378cc liquid-cooled, two-stroke engine with oil injection and a liquid-cooling system.

• Transmission: Both models used the Polaris Variable Transmission (PVT), a continuously variable transmission (CVT) system. The 400cc model also featured a push-button operated On-Demand true 4-wheel drive system.
• Weight: Dry weight for the Xplorer 300 is listed as 257 kg (about 566 lbs), while the Xplorer 400 is slightly heavier at 258 kg (about 568 lbs).
• Known issues: Some later model Xplorer 400s were recalled for sticky throttles and manual transmission problems.

• Xpress 300

  : Utilized the same 283cc air-cooled, two-stroke engine as the Xplorer 300.

• Xpress 400

  : Equipped with the same 378cc liquid-cooled, two-stroke engine as the Xplorer 400. The 1996 model was rear-wheel-drive, with 4WD introduced in later years.

• Weight: Dry weight for the Xpress 300 is approximately 484 lbs (based on the heavier 400’s listed weight and drivetrain differences). The Xpress 400 weighs 570 lbs (258.6 kg).
• Recalls: Some model year 1999 Scrambler, Sport, and Xplorer 400 ATVs were part of a recall for a sticky throttle. There is no information that indicates the Xpress was included in this recall.