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2000 Polaris Xplorer 400 Parts Manual
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đˇď¸ Basic Information Identification Make: Polaris Model: Xplorer 400 Year: 2000 Product Type: Parts Manual Codes Vin Decoder Notes: While this manual is specific to the 2000 Xplorer 400, VIN...
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Typ: Atv
Anbieter:
Art.-Nr: 25660
Stichworte:
2000
ATV
Polaris
Powersports
Xplorer 400
Xplorer Models
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đˇď¸ Basic Information
Identification
Make:
Polaris
Model:
Xplorer 400
Year:
2000
Product Type:
Parts Manual
Codes
Vin Decoder Notes:
While this manual is specific to the 2000 Xplorer 400, VIN decoding for Polaris ATVs typically identifies model series, engine size, and manufacturing location. Always cross-reference with specific component part numbers.
đ Introduction
Market Position
Atv Market Segment:
The Polaris Xplorer series was positioned as a capable utility and recreational ATV, known for its blend of performance and versatility in the late 1990s and early 2000s. The 400cc class was a popular segment for general trail riding and light work.
Target User Base:
Ideal for ATV owners looking to perform their own maintenance and repairs, saving on dealership labor costs and gaining a deeper understanding of their vehicle's mechanics. Recreational riders and utility users alike benefit from accurate parts identification.
Competitive Analysis
Key Competitors Circa 2000:
Competitors in the 400cc class for the year 2000 included models from Yamaha (e.g., Wolverine 350/450), Honda (e.g., FourTrax 300/400), Suzuki (e.g., QuadSport 300/KingQuad 300), and Kawasaki (e.g., Bayou 300/400). Polaris often differentiated with its Polaris Variable Transmission (PVT) and Polaris Independent Front Suspension (IFS) on higher-spec models.
Key Features
Vehicle Key Features Relevant To Parts:
This manual would detail components for a robust, often 4x4, ATV designed for varied terrain. Key areas for parts identification include the durable chassis, the Polaris PVT automatic transmission, the reliable 2-stroke or 4-stroke engine (depending on specific Xplorer 400 sub-model), and the suspension systems.
đ Manual Details
Coverage Areas
Manual Coverage Summary:
Comprehensive coverage of all major mechanical and electrical components for the 2000 Polaris Xplorer 400 ATV, including detailed diagrams and part numbers for user maintenance and repair.
Page Count
Page Count:
62
Manual Type
Manual Type:
Parts Catalog / Illustrated Parts Manual
Language
Language:
English
Format
Format:
PDF Download
Print Selectivity:
The PDF format enables users to print only the specific pages or sections relevant to their current maintenance task, making it a highly practical and resource-efficient manual.
đ Manual Coverage
Systems Covered
Systems Covered List:
⢠Front Cab Components
⢠Rear Cab and Seat Assembly
⢠Rear Rack Mounting
⢠Decals and Graphics
⢠Front Rack and Bumper Mounting
⢠Engine Mounting and Isolation
⢠Cooling System Components
⢠Exhaust System Components
⢠Fuel Tank Assembly
⢠Oil Tank and Lines
⢠Air Box and Filtration System
⢠Front Drive System (2WD/AWD components)
⢠Front Tighter/Tensioner Assembly
⢠Front Suspension Struts and Mounting
⢠CV Joint and Driveshaft Assembly (BTB - Back to Back)
⢠Front Wheel Hubs and Bearings
⢠Front Brake System (caliper, rotor, lines, master cylinder)
⢠Throttle Control Assembly and Cables
⢠Brake Master Cylinder, Lines, and Lever Assembly
⢠Steering Column and Components
⢠Handlebar Assembly and Headlight Pod
⢠A-Arm and Strut Mounting Hardware
⢠Center Tighter/Tensioner Assembly
⢠Swing Arm and Shock Absorber Mounting
⢠Drive Clutch Assembly
⢠Driven Clutch Assembly
⢠Clutch Cover and Housing
⢠Gearcase, Brake, and Chain Cover Assembly
⢠Rear Brake System (caliper, rotor, lines, master cylinder)
⢠Rear Wheel Drive Components
⢠Electrical System Components (tail light, wiring harnesses, etc.)
⢠Gearcase Lubrication and Seals
⢠Gear Selector Mechanism
⢠Engine Internals (Piston, Crankshaft)
⢠Crankcase and Cylinder Components
⢠Recoil Starter Assembly
⢠Carburetor Components
⢠Oil Pump and Drive
⢠Magneto/Stator Assembly
⢠Starting Motor Assembly
⢠Tool Kit Components (if applicable)
Part Number Availability:
Crucially provides OEM (Original Equipment Manufacturer) part numbers for all listed components, essential for accurate ordering and ensuring compatibility.
Steering And Suspension Parts:
Comprehensive coverage of steering components (tie rods, ball joints, steering post) and suspension elements (A-arms, shocks, bushings, ball joints) for precise identification during wear-related repairs.
Procedures Included
Procedures Included List:
⢠Identification of all replaceable parts via exploded diagrams
⢠Verification of correct part numbers for ordering
⢠Disassembly and reassembly guidance based on component breakdown
⢠Visual confirmation of part fitment and interchangeability
Diagram Type:
Detailed exploded view diagrams illustrating how components assemble and relate to each other within each system.
Technical Depth
Technical Depth Level:
Detailed Component Identification and Part Number Referencing
Document Purpose:
Facilitates accurate parts ordering and aids in the correct identification of components during maintenance and repair procedures.
Scope Of Coverage:
Covers all genuine Polaris manufactured parts and some common aftermarket accessory mounting hardware if integrated into the OEM design. Excludes purely aftermarket accessories unless they directly interface with OEM mounting points.
đ Manual Specifications
File Format
File Format Details:
High-quality PDF, optimized for digital viewing and selective printing. Allows users to print only necessary pages, saving on ink and paper.
Searchable Text:
Typically PDF documents of this nature are text-searchable, allowing users to quickly find specific part names or numbers within the document.
Print Quality
Print Quality Notes:
Designed for clear reproduction of exploded diagrams and legible part numbers. Users can adjust print settings for optimal clarity on their own printers.
Binding Type
Binding Type For Download:
N/A (Digital Download - User Printable)
Paper Type
Recommended Paper Type For Printing:
Standard printer paper (8.5" x 11" or A4) is suitable. For durable field use, consider printing on heavier stock.
âď¸ Engine Specifications
Primary Engine
Engine Type Notes:
The 2000 Polaris Xplorer 400 typically featured a 2-stroke, liquid-cooled, single-cylinder engine. Specific displacement may vary slightly, but it was generally around 398cc. Some later models or variants might have had 4-stroke options, but the dominant engine for this era's Xplorer 400 was the 2-stroke.
Bore Stroke Notes:
Specific bore and stroke dimensions are critical for engine rebuilds and are detailed in the manual's engine section, aiding in piston and ring selection.
Cooling Method:
Liquid-cooled, requiring specific radiator, hoses, water pump, and thermostat parts that are detailed in the manual.
Ignition System Components:
Covers components of the ignition system, including the magneto/stator, ignition coil, and spark plug cap, crucial for diagnosing and repairing starting and running issues.
Performance
Estimated Horsepower Range:
Estimated 25-35 horsepower range, typical for a 400cc 2-stroke utility ATV of this era, providing adequate torque for trail riding and moderate hauling.
Torque Output Estimate:
Estimated torque output typically in the range of 25-30 lb-ft, providing good low-end grunt for climbing and towing.
Fuel System
Fuel System Type:
Carbureted. Likely a Mikuni or Keihin carburetor, with specific model numbers detailed in the manual for rebuild kits and individual components.
Carburetor Rebuild Kit Part Numbers:
Facilitates ordering of specific carburetor rebuild kits or individual components (jets, needles, floats) for tune-up and repair.
Lubrication
Lubrication System:
Premix or Autolube oil injection system, common for 2-stroke engines. The manual would specify oil tank parts and the oil pump assembly. For 4-stroke variants, it would be a wet-sump system with oil filter.
đ§ Transmission
Standard
Transmission Type:
Polaris Variable Transmission (PVT) - Automatic CVT (Continuously Variable Transmission) with a belt-driven system.
Drive Belt Part Number Identification:
The manual would list the specific part number for the drive belt, a critical wear item for the PVT system, enabling users to purchase the correct replacement.
Optional
Drive System Options:
Likely available in 2WD (rear-wheel drive) and 4WD (selectable or full-time 4WD) configurations. The parts manual would differentiate components for each drivetrain.
Features
Gear Selection:
Typically featured High, Low, Neutral, Reverse, and Park gears, operated by a single lever or shifter mechanism. The manual would detail the gear selector linkage and housing.
Gearcase Components:
Detailed breakdown of the gearcase assembly, including gears, shafts, bearings, seals, and lubrication components, vital for addressing drivetrain issues.
đ Dimensions
Exterior
General Dimensions Notes:
While exact dimensions aren't provided, the Xplorer 400 was a mid-size utility ATV. The manual covers exterior body panels, racks, bumpers, and wheels, which define its physical footprint.
Cargo
Rack Configuration:
Equipped with front and rear racks designed for carrying gear. The manual provides specific mounting hardware and rack components for these parts.
Weights
Dry Weight Estimate:
Estimated dry weight typically in the range of 500-600 lbs, depending on 2WD/4WD configuration and specific model options.
đĄď¸ Safety Features
Ratings
Safety Features Overview:
ATVs are designed for off-road use and require responsible operation. Safety features covered in parts would include brake components, lighting, and potentially throttle limiter mechanisms.
Active Features
Braking System Details:
Hydraulic disc brakes on front and rear wheels, operated by hand levers and a foot pedal for the rear brake. The manual details all brake calipers, rotors, lines, master cylinders, and associated hardware.
Passive Features
Lighting System Coverage:
Includes front headlights, taillight/brake light, and potentially indicators or work lights depending on the specific trim. The manual covers bulbs, lenses, housings, and basic wiring harness connectors.
đĄ Technology Features
Infotainment
Infotainment Features Atv Context:
ATVs of this era generally lacked complex infotainment systems. Components covered would include basic lighting controls and potentially accessory electrical outlets.
Driver Assistance
Driver Assistance Features Atv Context:
No advanced driver-assistance systems. Safety and operational control relies on mechanical and electrical systems like brakes, throttle, and steering, all of which are meticulously detailed in this parts manual.
Connectivity
Connectivity Features Atv Context:
No modern connectivity features like Bluetooth or GPS. The electrical section of the manual covers essential wiring harnesses and connectors for basic vehicle operation and lighting.
đ§ Maintenance
Service Intervals
General Maintenance Recommendations:
While this is a parts manual, it implicitly supports routine maintenance by identifying components. Typical maintenance includes oil changes (if 4-stroke), spark plug replacement, air filter cleaning/replacement, coolant checks, brake system inspection, and belt inspection. Referencing a service manual alongside this parts manual is ideal for detailed intervals.
Filter Replacement Guidance:
Parts numbers for air filters and oil filters (if applicable) are provided, facilitating timely replacement as part of scheduled maintenance to ensure optimal engine performance and longevity.
Fluid Specifications
Fluid Types Covered In Parts:
The manual would list parts related to fluid systems, such as oil filter part numbers (for 4-stroke), coolant hoses, and seals. Specific fluid types and capacities (e.g., engine oil viscosity, coolant type, gearcase oil type and quantity) would typically be found in a separate owner's or service manual, but parts for these systems are covered.
Seal And Gasket Part Numbers:
Comprehensive listing of seals and gaskets for all major assemblies (engine, transmission, gearcase, suspension), essential for preventing leaks during maintenance and repairs.
Known Issues
Common Wear Items Indicated By Parts:
Common wear items for ATVs of this era include drive belts, CV boots, brake pads and rotors, suspension bushings, and wheel bearings. The parts manual allows for easy identification of these replacement items. 2-stroke engines of this period could also experience wear on pistons and rings, which are detailed in this manual.
Common Atv Repair Parts Availability:
This manual is indispensable for sourcing common replacement parts for typical ATV wear and tear, such as brake pads, spark plugs, filters, and drive components, ensuring the ATV remains operational and reliable.
đ Vehicle History
Brand Heritage
Polaris Atv History:
Polaris has a long history in the powersports industry, becoming a dominant player in the ATV market through innovation and a wide range of models catering to utility, recreational, and performance segments. The Xplorer line represented their commitment to versatile all-terrain vehicles.
Polaris Innovation In Atvs:
Polaris pioneered many ATV innovations, including independent front suspension (IFS) and the Polaris Variable Transmission (PVT), making their manuals valuable resources for understanding these advanced systems.
Model Evolution
Xplorer Series Notes:
The Xplorer series evolved from earlier Polaris ATV designs, often emphasizing comfort and capability for longer rides. The 400cc engine was a popular displacement offering a good balance of power and efficiency for its intended use.
Production
Production Era:
The Xplorer 400 model was part of Polaris's lineup from the mid-1990s through the early 2000s, with the 2000 model year being a significant iteration of this platform.
đ Awards & Recognition
Recognitions
Atv Industry Awards General:
Polaris ATVs, including models from the Xplorer line, have historically received accolades for performance, innovation, and utility from various powersports publications and industry bodies. Specific awards for the 2000 Xplorer 400 would likely be found in period reviews.