*Polaris**
- Xplorer 300
Production/model years: 1996, 1997, 1998, 1999, 2000.
1996-2000 Polaris Xplorer 300 ATV service manual
Models covered in this manual:
File specifications
File type: PDF
Language: English
Printable: Yes
Estimated download time: 1.03 Minutes
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Product Information
Table of Contents
General Information
-
Model Identification
- Vehicle Identification Number (VIN) Locations
- Engine Serial Number Locations
-
Publications and Resources
- Publications Numbers
- Service Videos
- Service Information Bulletin Index
-
Specifications
- Model Specifications (1996-2000)
- Paint Codes
- Torque Specifications
-
Technical Information
- Decibel Equivalent Chart
- Conversion Table
- Tap Drill Charts
-
Warranty and Service
- Warranty Information
- Service Tips
-
Glossary and Tools
- Glossary of Terms
- Tool Ordering Information
-
Routing Diagrams
- Electrical Routing
- Cable and Hose Routing
Maintenance
-
Periodic Maintenance
- Maintenance Schedule
- Lubrication Chart
-
Inspection and Adjustment
- Pre-Ride Inspection
- Post-Ride Checklist
-
Fluids and Lubricants
- Recommended Lubricants
- Fluid Capacities and Types
Engine
-
Engine Overview
- Engine Specifications
- Component Locations
-
Disassembly and Reassembly
- Engine Removal Procedures
- Reassembly Instructions
-
Engine Components
- Cylinder and Piston
- Crankshaft and Bearings
-
Engine Cooling
- Cooling System Overview
- Radiator and Cooling Fan Maintenance
Fuel System/Carburetion
-
Fuel System Overview
- Fuel Tank and Fuel Lines
- Carburetor Components
-
Carburetor Maintenance
- Cleaning and Adjustment
- Idle Speed and Mixture Adjustment
-
Fuel System Troubleshooting
- Common Fuel Issues
- Diagnostic Procedures
Body/Steering/Suspension
-
Body Panels and Frame
- Removal and Installation
- Inspection and Repair
-
Steering System
- Steering Component Overview
- Adjustment and Maintenance
-
Suspension
- Front and Rear Suspension Types
- Suspension Adjustment and Tuning
PVT System
-
PVT (Polaris Variable Transmission) System
- Overview and Function
- Maintenance and Troubleshooting
-
Drive Belt Maintenance
- Belt Inspection and Replacement
- Clutch System Maintenance
Final Drive
-
Final Drive Overview
- Component Locations
- Function and Operation
-
Maintenance Procedures
- Differential Oil Change
- Chain/Sprocket Inspection and Adjustment
-
Final Drive Troubleshooting
- Noise and Vibration Issues
- Performance Problems
Transmission
-
Transmission Overview
- Transmission Types and Function
- Component Locations
-
Disassembly and Inspection
- Gearbox Disassembly
- Inspection and Replacement
-
Reassembly and Adjustment
- Reassembly Instructions
- Shifter Adjustment
Brakes
-
Brake System Overview
- Hydraulic Brake System
- Brake Component Locations
-
Brake Maintenance
- Brake Pad Replacement
- Brake Fluid Bleeding
-
Troubleshooting
- Brake System Issues
- Diagnostic Procedures
Electrical
-
Electrical System Overview
- Wiring Diagrams
- Electrical Component Locations
-
Battery and Charging System
- Battery Maintenance
- Charging System Testing
-
Ignition System
- Ignition Coil Testing
- Spark Plug Maintenance
-
Lighting and Indicators
- Headlight and Taillight Maintenance
- Instrument Panel Overview
-
Electrical Troubleshooting
- Diagnostic Procedures
- Common Electrical Problems
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