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Found 16 results

  1. hello, i have a 1997 500 xplorer . it will ideal fine you go wide open and its lazy and spiting fuel out of carb. if i install the air box it runs worse . things that have been checked or replaced cam is in new condition valves adjusted carb replaced new gas fuel lines cleaned out new coil and plug seems like the ignition timing is retarded sometimes its hard to start any help would be great . thanks
  2. I am 17 and I don't have lots of money but I know my way around older 2 stroke dirtbikes but my grandpa gave me this four-wheeler and I have had nothing but issues with it. I went through gas tank/lines and the oil injection has been bypassed, I have mixed gas in the tank and it is for sure getting to the carb. I have cleaned the carb to the best of my ability. I can get it to try and start for a few seconds but won't run any longer than 5 seconds with or without ether. Please help
  3. I have a Polaris Xplorer 250 4x4. It's a great quad, ran without issue until I noticed the fuel valve was slowly dripping gas. Ordered a new one, easy enough to replace, but now it won't start! I put the old one back on to see if it was an issue with the new petcock, and it still wouldn't start (it was running fine 15 minutes earlier). Engine just cranks and cranks. Any insight would be helpful.
  4. I have a 97 Polaris xplorer I just did the head gasket in it and now it won’t start it just keeps turning over I’m not sure if my timing is off or what’s going on I had the chain tied up when I was doing it tight but I don’t know and I’m fairly new to working on wheelers thanks
  5. I recently purchased a 2000 polaris xplorer 400 4x4. When I bought it the starter was bad, speedometer didn't work, and it had been sitting for 5 years. I replaced the battery, and starter. Changed all fluids, and got it running correctly. Then replaced the speedometer in an attempt to make sure the awd would be available when needed. And took it out for a couple hour ride with a buddy. It ran great that ride with no serious problems just a little carb issues which I was able to take care of on the trails. Then a couple days later I decided to take it out for a ride by myself, again ran great no issues other than a couple times it seemed to cough and then take off again. That day when I was loading it I noticed coolant dripping onto the trailer and the overflow bottle was empty. Got home and decided to drain the counter balancer, when I did that I got about 3 cups of coolant. Im guessing that it needs new seals and all for the water pump. My question is how difficult is it to do the water pump and should I attempt it or should I send it down the road to the polaris dealership to get it done?
  6. I've had a seriously annoying time trying to deal with the brakes on my rebuild. What size is the fitting that screws into the inverted flair cross and into the caliper? I plan on trying to make parts I need with braided steel hose.
  7. I'm Micah I live in southern Indiana in the Hoosier national forest. Just picked up my first ATV for extra cheap and I've gotta get it up and running from sitting in a friend's shed for a few years. It's a '95 Polaris Xplorer 400. I've had a little bit of experience with simple ATV stuff from the cheap chinese atv my in-laws bought for our kids. I don't expect nearly as many headaches but would love suggestions on what things to go through before putting in a battery, gas, and oil and trying to fire it up. Thanks!
  8. Version 1.0.0

    4 downloads

    1996-2003 Polaris Xplorer 500 Service Manual
  9. View File 1996-2003 Polaris Xplorer 500 Service Manual 1996-2003 Polaris Xplorer 500 Service Manual Submitter Ajmboy Submitted 06/26/2019 Category Polaris ATV  
  10. Yes I just got a 1998 polaris xplorer 400 4x4. Ran fine after hauling then died. Cleaned carb and put new fuel filter, hose, and new battery in. Starts 3 out of 10 times but will only run for a short time. Any suggestions?
  11. Does anyone know where to get replacement pickup screens go inside gas tank? Mine are rusted pretty bad where they plug into the threaded connector,, thanks
  12. Version 1.0.0

    26 downloads

    Service manual for 1996-1998 Polaris ATVs and light utility vehicles covers: Magnum 2x4, Trail Blazer / Scrambler, Sportsman 4x4, Magnum 4x4, Trail Boss / Sport, 6x6 / Magnum 6x6, Xplorer 300 / Xplorer 400, Sportsman 500 & Xpress 300 / Xpress 400
  13. Hey does anyone here know where I can find another brand oil filter for the stock argo filter? Being so new its hard to find anything. Thanks
  14. View File Polaris 1996-1998 ATV Light Utility Service Manual Service manual for 1996-1998 Polaris ATVs and light utility vehicles covers: Magnum 2x4, Trail Blazer / Scrambler, Sportsman 4x4, Magnum 4x4, Trail Boss / Sport, 6x6 / Magnum 6x6, Xplorer 300 / Xplorer 400, Sportsman 500 & Xpress 300 / Xpress 400 Submitter mike rhoades Submitted 03/02/2019 Category Polaris ATV  
  15. View File Polaris 1999-2000 Multiple Models ATV Service Manual This is the service manual for multiple models of polaris atvs from 1999 to 2000 Model Specifications (1999) Trail Blazer Trail Boss Xpress 300 Xplorer 300 Sportsman 335 Sport 400 Scrambler 400 Xplorer 400 Scrambler 500 Magnum 500 Sportsman 500 Big Boss 500 6x6 Model Specifications (2000) Trail Blazer Xplorer 4x4 Trail Boss 325 Magnum 325 (01 Engine) Magnum 325 (04/05 Engine) Xpedition 325 Sportsman 335 Xplorer 400 Scrambler 400 2x4 Scrambler 400 4x4 Xpedition 425 Magnum 500 Scrambler 500 Sportsman 500 Sportsman 6x6 Submitter colin james Submitted 10/19/2018 Category Polaris ATV
  16. Version 1.0.0

    96 downloads

    This is the service manual for multiple models of polaris atvs from 1999 to 2000 Model Specifications (1999) Trail Blazer Trail Boss Xpress 300 Xplorer 300 Sportsman 335 Sport 400 Scrambler 400 Xplorer 400 Scrambler 500 Magnum 500 Sportsman 500 Big Boss 500 6x6 Model Specifications (2000) Trail Blazer Xplorer 4x4 Trail Boss 325 Magnum 325 (01 Engine) Magnum 325 (04/05 Engine) Xpedition 325 Sportsman 335 Xplorer 400 Scrambler 400 2x4 Scrambler 400 4x4 Xpedition 425 Magnum 500 Scrambler 500 Sportsman 500 Sportsman 6x6
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