Polaris Xpress 300 Specs and Review 2022

Polaris Xpress 300: One year after Polaris hit record sales, the company introduced its Polaris Xpress 300 for the general public. 

The four-wheeler had an extended production run of four years and, in the process was able to gain a significant fan base. 

Polaris Xpress 300

It may not have gained in popularity the same way as its larger displacement counterparts however, it did leave an impression on those who utilized the quad for the daily jobs and exciting weekend excursions.

Its model Polaris Xpress 300 is a two-stroke vehicle for all-terrain vehicles manufactured by Polaris from 1996 until 1999. 

It is famous for its sturdy components, powerful engines, and minimalist design. It was a popular project for skilled mechanics and enthusiasts, and it was a fantastic vehicle for those who are just beginning.

The Xpress 300 was a small but powerful ATV that was small but powerful. It was able to haul wood and cargo just like its bigger-bore counterparts.

It also carried off-roaders on wooded trails, gravel roads, and even farms. Learn more about this car from the ’90s and the features it has to offer.

About the Polaris Xpress 300

The timing couldn’t be more different than the launch of the Polaris Xpress 300 in 1996. 

It was a period of conflict in the ATV industry after the 1998 Consent Decree. In contrast, Polaris emerged with 25 percent of ATV sales in North America during the ’90s which is why its Xpress 300 was instrumental in making this happen.

 If it weren’t due to the shortcomings that the tiny quad had (along with its more dated siblings) the current Polaris all-terrain vehicles might not be the renowned beasts they are currently.

In production from 1996 until 1999, the design of this four-wheeler was very straightforward. 

It featured a two-cycle motor and a Polaris Variable Transmission that required no shifting. It also featured the fuel-injection system, minimal exterior with knobby-style tires. 

The 300 was not equipped with an EPS system or a differential lock or differential lock, nor did it come with fancy instruments or extravagant bodywork. 

It was merely equipped with an impressive engine as well as blue-colored plastics. storage racks for cargo.

Polaris Xpress 300 Specs

Polaris Xpress 300 Specs & Features

  • Engine The power source is a two-stroke, air-cooled single-cylinder SOHC engine that has an octave-to-stroke ratio of 74.5 65 millimeters (2.93 2.56 inches). 2.56 inches). 
  • The engine is able to handle a displacement of 283 cubic centimeters. It is a VM30SS Mikuni carburetor that handles fuel and air, and the compressive ratio of 6.1:1. The capacity of the fuel tank is 4 US 15 liters/gallons. An 87 non-oxygenated or an oxygenated rating of 89 for fuel is suggested.
  • Lubrication – The recommended motor oil can be found in Polaris Premium Synthetic 2 Stroke TC-W3 SAE 5W-30, or equivalent and with the API classification SH or greater. Around 2 quarts/1.9 Liters of oil are required when paired with a PN 3084963 filters and Snap-On PN YA997, or a similar filter wrench. The normal oil pressure requirement for 20 PSI at 5500 RPM.
  • Drivetrain The power source is an automatic dual-range Polaris Variable Transmission with reverse and Chain drive with O-rings. The reduction in high gear is 3.29 and the last drive gear ratio 13/38.86p.
  • ignition The Ignition CDI ignition that has the electronic start system, as well as an auxiliary recoil mechanical backup, brings the engine to life. A 150-watt alternator powers electronic components. 
  • Its spark plug model is NGK the BR8ES. It needs a 12V 12AH Polaris Xpress 300 battery with assembled dimensions of 5.20 x 3.50 x 6.40 inches (L x W x H). A NOCO Genius G26000 Pro-Series 12V/24V 26 Amp Battery Maintainer and Charger (view at Amazon) can help maintain your battery’s 12V capacity in top shape.
  • Tires the Xpress 300 tires consist of 23 x 7-10 front tires, and 24 x 11 10 rear tires fitted with steel rims. The recommended tension for the front tire is psi/27.58 KPa (0.28 kg/cm2) and 3 psi/20.68 kPa (0.21 kg/cm2). Replace the stock rubber by Carlisle All Trail II ATV Tires(view on Amazon) in the event that it gets worn down.
  • Brakes It comes with hand-operated front disc brakes that are hydraulic with one lever, and an electronic auxiliary rear brake.
  •  This model Polaris Xpress 300 was among the models that didn’t have an engine Braking System. The helix is pushed against the secondary clutch buttons instead.
  • Suspension The quad comes with MacPherson struts for the front and a single-shock, variable speed swing arm to provide the rear suspension. It is able to provide 6.25 as well as 8.5 inches of travel for the wheel respectively.
  • Dimensions The overall dimension is 79.5 x 46 inches. 45.5 inches (2,019 1168 1155 millimeters, L x Wx H). The minimum clearance for the ground of 6.5 inches (no-load). The wheelbase of the vehicle has a length of 49.75 inches. Dry weights are 224.73 Kg/512 pounds. Its towing capability is 850lbs and the rack’s capacity is 270lbs (90 pounds for the front, and 180 lbs to the rear). Tongue weight is 30 pounds. The rear and front racks are stocked with tie-down points to store cargo.
  • Exterior The Xpress features an aluminum tubular frame and a body made of plastic. The left handlebar houses the majority of the controls. the 4WD button is located on the right-hand bar, with the shifter. 
  • Floorboards that are fully enclosed allow the rider to be more aggressive in their more upright position. In contrast to some of its competitors, it is this Xpress 300 does not have under-seat storage (the underside of the seat houses an air purifier). Twin 30-watt Halogen headlights an 8.26-watt taillight and a 26.9-watt brake light give the vehicle a superior distribution of light.

Polaris Xpress 300 Pros & Cons


Despite being among the earlier Polaris quad models The 1996 Polaris Xpress 300 only had two TSBs issued to help. 

They were related to an issue with the cooling fan motor and bleeding of the oil pump in the year 1997 Polaris Xpress 300. In terms of performance, it is able to go for a spin over dry branches and fallen leaves or through shallow water and stream crossings. 

The wheeler’s Lock & Ride cargo system accessories are easy to acquire and install. It permits Polaris owners to buy genuine accessories that can be bolted onto their four-wheelers, without the need to drill. 

In general, the vehicle is ideal for trails in woods as well as straightaways, grasslands that are open, or dirt routes.


The downside is that it isn’t perfect. Xpress 300 makes clunky noises when it’s carrying excessive weight. 

A few users are inclined to overload the vehicle or make it two-seater with the addition of the passenger seat to take place on the back utility rack. 

The stock tires are able to withstand minor mud crossings, but cannot endure the rigors of mud. So, you’ll have to upgrade your tires to better ones like ITP Mud tires or similar.

Since it comes with MacPherson struts, but not the two A-arms, the Xpress isn’t equipped with spring-motion control which can lead to wheel rubbing. The handlebars are uncomfortable for those who like more aggressive riding.

This is because they are designed with long trails and cruise speeds. The quad isn’t as powerful when driving over rough or bumpy terrain or extremely rough surfaces. 

Furthermore, the vehicle isn’t equipped with instruments, and there are only two analog gauges on the dashboard.

How Much Does It Cost

How Much Does It Cost?

The basic version included in the Polaris Xpress 300 was valued at $3,999 and was just incremented by $100 for this year’s Polaris Xpress 300 until its final production run in the year 1999. 

For an additional $2,200, you can get ultra-performance exhaust power blades, power blades, snow-blower, winch, and a CB radio in the package. 

You could save up to $500 by purchasing the Polaris Xpress 300 parts from aftermarket dealers.

Secondhand Xpress 300s can be purchased for $800 to $1,200 on auction listings. They are typically in good condition, but without a title. 

The retail price of Xpress 300 models is from $400 to $705. Be sure to examine the vehicle prior to buying it in this price range.

Known Issues & Fixes

A lot of Polaris Xpress 300 owners say that their quad is reliable, but is prone to some issues that are quite ironic for a car with just two TSBs that were released throughout its production. 

However, we’ll learn from experts and familiarize ourselves with possible issues before they happen. Here are some of them:

Smoky Start-ups

The engine begins at the first pull, cold or hot. The fuel injector spits gas into the carburetor and the compression appears to work well, without spitting or sparks. You may however observe the quad smoking in a frenzied manner. 

You could try taking the air filter off, or verify whether the throttle cable is moving the arm that measures. However, these don’t often cause problems. 

The owners who have experienced the problem attribute the issue to the buildup of oil (quite normal for pre-loved models like Xpress300s) or a malfunctioning oiler caused by a premix.

Apart from the fact that the engine has been dual dosing (premix as well as the oil pump) wear-out of the carb needles and seats are also possible causes since excessive gas entering the cylinder can lead to excessive smoke.

 If your results point to this, you should empty the fuel tank full of old gasoline and then replace it with a new one. 

Also, make sure you verify the pump’s operation. Find a high-quality filter and airbox since 2-stroke machines can be particularly sensitive in the face of dirt.

Restricted Speed

Sometimes it is the case that the Xpress keeps revving but not speeding up in the manner it should. It becomes uncomfortable and strives to reach 25-30 mph when it should be cruising at 53 miles per hour. 

Additionally, the engine is screaming. Expert mechanics might have discovered the cause and that’s because the clutch could need some work or is worn out. To determine that this is indeed the case with your quads, try these steps:

  • Before you begin, you must have a manual for your vehicle before performing any of these actions.
  • Verify that you can verify that the pump for oil is functioning by letting the machine idle by raising the pump arm and pulling the carburetor’s injection line. If the machine’s RPMs increase but the power remains minimal, examine the belt and clutches.
  • Examine both rear and front buttons for wear (although the most likely culprit is typically the ramp buttons on the rear).
  • Worn-down buttons are usually associated with the worn-out belt.
  • Set a straight edge across the upper part of the clutches, and pull the belt down. If you’re left with more than 1 1/2 inches of space between the upper part of your belt up to the straight edge it means that the belt has been worn down. Belts are worn down over the length and width, as well as stretching.
  • Replace your clutch cover with a newer or 2000 version. Covers made of older models could get swollen and damage your drive gear. This can be caused by a poor design that does not match the form of the clutches, which causes an insufficient space for air circulation.
  • You might have to alter the design of your air exit pipe or purchase one with the new clutch cover to fit the size of the exhaust tube.

If you’ve completed all of these steps but not achieved a minimum 40-mph maximum speed, then you might require an overhaul of your clutch.

Grinding Noise

The expectation of grinding noise when you purchase an unworkable Xpress. Contrary to popular opinion the top of the line model will not be able to fix the issue.

The method you take to tackle this issue will depend on whether you are using an automatic or standard quad.

 Standard quads should determine if your clutch is pulling or dragging and then decide to change or adjust it. 

If the clutch is automatic, it means that the idle setting is too high or your shift linkage is not long enough. If this is the case, both will require adjustment.

A worn belt is likely to be the cause – If the pully at the rear of the belt system is rotating at idle, the engine is likely to grind when you attempt to get it into the gear.

Other causes could include 4WD not working front brakes not functioning broken tie rod ends and carburetor issues. In the case of 4WD, one reason could be the chain tensioner is not working properly and the 4WD design (three chains, however, five gears). 

A second thing to consider is that 4WD cannot function without batteries. If none of the above are the cause, then you must ensure that the shifter is set to high either low or high and that you’ve pressed the four-wheel button. When you use 4WD when in reverse mode, it is necessary to press the override button.

About Polaris

Polaris Inc. is the manufacturer of Polaris Xpress 300 – an American manufacturer of snowmobiles, ATVs, motorcycles as well as many other electronic vehicles. 

The range of products offered by the company has grown to include Moto-Roadsters as well as commercial vehicles, tactical vehicles parts, apparel, and equipment, making the company an established name in the motorsports, automotive, and defense sectors.

 Most of the powertrains and off-road cars are manufactured by and assembled at Osceola, Wisconsin, and Roseau, Minnesota.

Conclusion – The Polaris Xpress 300

The Polaris Xpress 300 may be tiny and outdated in comparison to the current standard, but it’s top-of-the-line in the way it performs and functions. 

There will be some niggles in the midst. In the end, it’s common for riders to be extra careful with vehicles that work continuously towards the ground. 

Even though it may test your mechanics up to the test what’s amazing about this vehicle is that it’s easy to use and operates like a pro. In the end, the Polaris Xplorer 300 is a superb four-wheeler to test out.

What years did Polaris make the Sportsman 300?

The Polaris Hawkeye 300 is a 4-stroke ATV produced between 2006 and 2011. The Hawkeye 300 ranked 2 2nd among 116 ATVs for utility; it became popular due to its durable components and practical design.

Is a Polaris Xplorer a 2 stroke?

Polaris Xplorer 400 Specifications and Features. Engine – Two-stroke liquid-cooled oil-injected motor is the engine that powers the quad. It is equipped with an 83-millimetre bore and a stroke of 70 millimetres. The engine’s displacement of 378.7 cubic centimetres was produced by an X-34-mm VM34SS Mikuni carburettor. Its compression ratio is 6-9:1.

What years did they make the Polaris Sportsman 90?

The Polaris Sportsman 90 is one of the most popular mini-ATVs in history and one of those that we’re the first young quads to the general public. It comes with ETC and a kill switch, and two brake levers along with PVT. The ATV was a hit for 14 years production period – it was released on the market between 2001 and 2014...

Who makes the engines for Polaris?

The entire lineup of 2015 Polaris ORV (Ranger, RZR, Sportsman, and ACE) is driven with ProStar engines. Before this, Polaris worked with different makers (Robin/Fuji industries is one) to supply motors for their ATVs and UTVs.

How fast is a Polaris 400 2 stroke?

Polaris Scrambler 400 Top Speed 

The speed limit of the Polaris Scrambler 400 can reach 70 miles per hour and, quite astonishingly, outperforms its 500-class peers. 

Where are Polaris ATVs built?

Polaris is headquartered in Roseau, Minnesota, USA. Components are mainly produced at Osceola, Wisconsin, and the vehicle assembly is in Roseau, Minnesota. That’s the definition of an American manufactured ATV. A lot more people than before are interested in the place where their machines are manufactured.

Does a Polaris Sportsman 90 have reverse?

Its Sportsman 90 is powered by an air-cooled overhead cam motor. It comes with forwarding, neutral as well as reverse. Minis are always a hit when they feature to reverse.

What’s better Honda or Polaris?

The Honda is renowned for its reliability, ease of operation and smooth ride. Ease of riding and its capability to be agile. The Polaris is more smooth than the glass on rough terrain. It has excellent power, the EBS performs well and is exceptionally comfortable, while the electric steering system is top quality.

Polaris Xpress 300 FAQ

1. How fast is a Polaris Xpress 300?

Sometimes the Xpress will continue to rev without accelerating in the manner it ought to. It becomes uncomfortable, pushing it until it reaches 25-30 miles per hour instead of peaking at 53 mph.

2. Where is the serial number on a Polaris Xplorer 300?

It is the VIN (Vehicle Identification Number (VIN) for the Polaris ATV is a unique number that is used in order to identify the vehicle you own. It is written on the frame of your ATV.

3. Will Polaris Ranger tires fit on a sportsman?

Yes, you can! Sportsman’s and Rangers both share the same size for the 4 on 156mm mounting.

4. How do you tell what year Polaris I have?

Examine the 10th character in the number that identifies the vehicle. The 10th character is used to identify the year of manufacture of the four-wheeler.

5. Where is the VIN on a Polaris ATV?

Your vehicle identification number (VIN) for the Polaris is a unique number that is used in order to recognize your automobile. It is printed on the frame of your ATV.

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