Market Segment:
Mid-size utility ATV, popular for trail riding, hunting, and general farm work.
Competitors 1998:
Competed with models from Yamaha (e.g., Kodiak 400), Suzuki (e.g., King Quad 300), Honda (e.g., FourTrax 300/400), and Kawasaki (e.g., Bayou 300).
Engine Type:
Powerful 2-stroke liquid-cooled engine offering good performance for its class.
Transmission Type:
Polaris Variable Transmission (PVT) for automatic shifting and ease of operation.
Suspension Design:
Independent front suspension and a rear swingarm or independent rear suspension (IRS) depending on exact sub-model.
Target Audience:
Recreational riders, hunters, and agricultural users seeking a capable and reliable ATV.
Coverage Scope:
Comprehensive service, repair, maintenance, and rebuilding of the 1998 Polaris Xplorer 400 ATV.
Page Count:
Estimated 200-300 pages based on typical full service repair manuals for this era and complexity.
Manual Type:
Full Service Repair Manual
Engine System:
Detailed diagnostics, disassembly, assembly, tuning, and troubleshooting for the 2-stroke engine.
Fuel System:
Carburetor adjustment, cleaning, and overhaul; fuel pump operation; fuel lines and tank maintenance.
Ignition System:
CDI ignition, spark plug specifications, timing checks, and component testing.
Cooling System:
Liquid cooling system maintenance, coolant specifications, radiator, fan, and water pump.
Drive System:
PVT (Polaris Variable Transmission) operation, belt inspection and replacement, drive clutch and driven clutch service.
Suspension System:
Front and rear suspension component inspection, adjustment, and replacement (shocks, springs, A-arms).
Braking System:
Hydraulic brake system diagnosis, pad replacement, fluid bleeding, caliper and master cylinder service.
Electrical System:
Wiring diagrams, battery maintenance, lighting system, starter motor, charging system, and troubleshooting.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fenders, and handlebars.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, lubrication points, and general upkeep.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues.
Repair:
Step-by-step repair procedures for all major and minor components.
Rebuild:
Complete engine rebuild, transmission overhaul, and suspension component rebuilding.
Disassembly Assembly:
Detailed instructions for dismantling and reassembling all major ATV systems.
Depth Level:
Complete factory-level technical information, suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostic Tools:
Specifies when specific tools are required, though advanced electronic diagnostic tools are less common for this model's era.
Torque Specifications:
All critical torque specifications for fasteners are included.
Clearances:
Engine component clearances (piston-to-cylinder, bearing clearances, etc.) are detailed.
File Type:
PDF (Portable Document Format)
Searchability:
Typically searchable text within PDF, allowing quick access to specific topics.
Print Readability:
Designed for clear viewing on screen and printing to paper; typically includes diagrams and illustrations.
Binding Type:
N/A (Digital PDF download)
Paper Type:
N/A (Digital PDF download)
Engine Type:
2-stroke, liquid-cooled
Displacement:
Approximately 398cc (24.3 cubic inches)
Bore X Stroke:
Not specified, but typical for 400cc 2-stroke
Cooling Method:
Liquid-cooled
Power Output:
Estimated 25-30 HP (Horsepower) at the crankshaft, specific figures not provided in product description.
Torque:
Not specified, but expected to be robust for its class.
Carburetor:
Single Mikuni carburetor (specific model not provided in product description, likely VM series).
Fuel Type:
Unleaded gasoline, minimum 87 octane recommended.
Fuel Tank Capacity:
Typically around 3.5 - 4.0 gallons (13-15 liters).
Oil Mixture Ratio:
Premix required for 2-stroke engine. Manual will specify recommended oil type and ratio (e.g., 40:1 or 50:1).
Type:
Polaris Variable Transmission (PVT) - Automatic CVT with high/low range and reverse.
Drive System:
Shaft drive to rear wheels, likely with selectable 2WD/4WD depending on trim.
Optional Gearbox:
N/A for this model year and engine size.
Clutch System:
Centrifugal drive clutch and spring-loaded driven clutch.
Transmission Fluid:
The manual will specify the correct CVT fluid type and change intervals.
Length:
Approx. 77-80 inches (195-203 cm)
Width:
Approx. 45-48 inches (114-122 cm)
Height:
Approx. 44-46 inches (112-117 cm)
Wheelbase:
Approx. 50-51 inches (127-130 cm)
Front Rack Capacity:
Typically rated around 50-75 lbs (23-34 kg).
Rear Rack Capacity:
Typically rated around 100-125 lbs (45-57 kg).
Dry Weight:
Approx. 500-550 lbs (227-250 kg), actual weight varies with configuration.
Towing Capacity:
Not typically specified for this era of utility ATV, but generally limited due to chassis design.
Atv Safety Standards:
Manufactured to meet ANSI standards for ATVs at the time of production.
Braking System Type:
Hydraulic disc brakes, typically front and rear.
Parking Brake:
Integrated into the rear brake caliper or a separate mechanism.
Lighting:
Headlights, taillight, and brake light.
Operator Presence Control:
Standard throttle lever safety mechanism requiring engagement.
Initial Service:
Typically around 10-20 hours or 1 month of operation (break-in service).
Engine Oil Change:
Every 50-100 hours or annually. The manual will provide specific interval and grade.
Air Filter Cleaning:
Every 25-50 hours or as needed based on operating conditions.
Spark Plug Replacement:
Every 100-200 hours or annually.
Transmission Belt Inspection:
Every 50-100 hours or annually.
Engine Oil Type:
2-stroke engine oil meeting API TC or JASO FD standards, mixed with gasoline at specified ratio. Manual to confirm grade and ratio.
Coolant Type:
Ethylene glycol-based antifreeze coolant, usually a 50/50 mix with distilled water. Manual to specify exact type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual to specify exact type and bleeding procedure.
Common Wear Items:
Drive belts, carburetor jets, suspension bushings, and brake pads are common wear items on ATVs of this age.
Engine Performance Issues:
Hard starting, poor acceleration, or bogging can indicate carburetor issues, air leaks, or ignition problems.
Transmission Problems:
Slipping or inconsistent engagement of the PVT system can be due to belt wear, clutch issues, or incorrect tension.
Polaris History:
Polaris Industries, Inc. has a long history dating back to 1954, initially focused on snowmobiles, expanding into ATVs in the late 1980s.
Xplorer Series:
The Xplorer line was part of Polaris's effort to offer more performance-oriented utility ATVs, often featuring more powerful engines and independent suspension compared to their Big Boss or Trail Boss predecessors.
Production Period:
The Xplorer 400 model was produced from the mid-1990s through the early 2000s, with various updates and iterations.
Manufacturing Location:
Manufactured in the USA by Polaris Industries.
