Category:
All-terrain vehicle (ATV)
Target Audience:
Owners and mechanics of 2001 Polaris Xplorer 400 4x4 ATVs
Segment:
Mid-size utility/sport ATV segment, competing with models from Yamaha, Honda, Kawasaki, and Suzuki.
Vehicle Focus:
Designed for versatile off-road use, offering a balance of power, 4x4 capability, and comfort for trail riding and utility tasks.
Engine:
Detailed coverage of engine disassembly, assembly, inspection, and repair, including top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), valve train, and cooling system.
Fuel System:
Comprehensive information on the carburetor (cleaning, adjustment, jetting), fuel pump, fuel lines, and fuel tank.
Ignition System:
Details on spark plugs, ignition coils, CDI unit, and troubleshooting ignition faults.
Transmission:
Coverage of the PVT (Polaris Variable Transmission) system, including belt inspection and replacement, primary and secondary clutch service, and gearbox operation.
Drivetrain:
In-depth repair procedures for the 4x4 system, including front and rear driveshafts, differentials, and the engagement mechanism.
Suspension:
Information on front and rear suspension components, including A-arms, shock absorbers, springs, bushings, and adjustment procedures.
Brakes:
Detailed procedures for front and rear brake systems, including hydraulic brake lines, master cylinders, calipers, brake pads, and rotor servicing.
Electrical System:
Wiring diagrams, troubleshooting guides for lighting, starting system, charging system (stator, voltage regulator), battery, and accessories.
Steering:
Components of the steering system, including tie rods, steering shaft, handlebars, and adjustment procedures.
Body And Frame:
Procedures for body panel removal and installation, frame inspection, and general chassis maintenance.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, spark plug checks, chain/belt adjustments, and lubrication points.
Troubleshooting:
Diagnostic procedures for common problems, including no-start conditions, poor running, electrical failures, and drivetrain issues.
Repair:
Step-by-step instructions for component repair and replacement, covering engine, transmission, suspension, brakes, and electrical systems.
Rebuilds:
Comprehensive instructions for engine and transmission rebuilds, including torque specifications and tolerances.
Depth:
Covers everything from basic owner maintenance to advanced engine and drivetrain diagnostics and repairs, suitable for both DIY enthusiasts and professional mechanics.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder engine.
Displacement:
375 cc (approximate)
Bore X Stroke:
Typically around 83 mm x 70 mm (verify specific model data)
Compression Ratio:
Typically around 6.2:1 (verify specific model data)
Horsepower:
Estimated 25-30 hp (verify specific model data)
Torque:
Not readily available publicly, but sufficient for its class.
Carburetor:
Mikuni VM34SS (typical for this era/model)
Fuel Type:
Unleaded gasoline (87 octane or higher recommended)
Oil Type:
2-stroke engine oil specifically formulated for air- or liquid-cooled engines (e.g., Polaris Premium 2-Stroke Oil, Yamalube 2M).
Spark Plug Gap:
Typically 0.028-0.031 in (0.7-0.8 mm) - confirm with manual.
Spark Plug Type:
NGK BR8ES or equivalent (verify specific model data).
Type:
Polaris Variable Transmission (PVT) with automatic centrifugal clutch and drive/driven clutches.
Gears:
High, Low, Neutral, Reverse.
Drive System:
Shaft drive, with on-demand 4x4 (4WD) engagement system.
Gear Oil:
Polaris Demand Drive Fluid (for front differential) or equivalent SAE 75W-90 synthetic gear oil. Rear differential typically uses SAE 80W-90 gear oil. Verify specific manual recommendations.
Length:
Approx. 77.3 inches (196.3 cm)
Width:
Approx. 45.5 inches (115.6 cm)
Height:
Approx. 45.2 inches (114.8 cm)
Wheelbase:
Approx. 50.6 inches (128.5 cm)
Dry Weight:
Approx. 540 lbs (245 kg)
Ground Clearance:
Approx. 7.5 inches (19 cm)
Rack Capacity Front:
Typically around 50 lbs (22.7 kg)
Rack Capacity Rear:
Typically around 100 lbs (45.4 kg)
Towing Capacity:
Typically rated at 1,500 lbs (680 kg)
Front Tire Size:
AT25x8-12 (or similar)
Rear Tire Size:
AT25x10-12 (or similar)
Oil Change Engine:
Every 50 hours of operation or annually, whichever comes first (for 4-stroke oil if applicable, though this is a 2-stroke). For 2-stroke, monitor oil injection reservoir and ensure proper mix if pre-mixing.
Air Filter Cleaning:
Inspect every 10-20 hours, clean or replace as needed. More frequently in dusty conditions.
Spark Plug Inspection:
Inspect every 25 hours, replace as needed. Check gap and condition.
Pvt Belt Inspection:
Inspect belt for wear, cracks, or fraying every 50 hours. Replace if wear exceeds manufacturer specifications.
Gearbox Oil Change:
Every 100 hours or annually.
Engine Oil:
Polaris Premium 2-Stroke Oil or equivalent API-TC certified 2-stroke oil.
Front Differential Fluid:
Polaris Demand Drive Fluid or SAE 75W-90 Synthetic Gear Oil.
Rear Differential Fluid:
SAE 80W-90 Gear Oil.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
PVT belt, tie rod ends, wheel bearings, front differential seals, carburetor jets due to fuel quality.
2 Stroke Considerations:
Proper 2-stroke oil mixing or function of the oil injection system is critical for engine longevity. Carbon buildup in exhaust and ports can occur if not maintained.
Manufacturer:
Polaris Industries Inc.
Specialty:
Long-standing manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles, known for innovation in 4x4 technology.
Xplorer Line:
The Xplorer line was a significant part of Polaris's ATV offerings, known for their robust utility and trail-riding capabilities, often featuring independent rear suspension in later models or variants.
Manufacturing Location:
Primarily manufactured in the USA by Polaris Industries.
Model Variant:
The 400 4x4 Xplorer was a popular model during the late 1990s and early 2000s, evolving from earlier Polaris utility ATV designs.
