Polaris Xplorer 400 ATV Complete Workshop Service Repair Manual 2000

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Stichworte: 2000 ATV Misc Polaris Powersports Xplorer 400

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Beschreibung

The Polaris Xplorer 400, a 2000 model year All-Terrain Vehicle (ATV), represents the third generation of this capable utility ATV. Designed for both recreational riders and light-duty work, it features a reliable 2-stroke, liquid-cooled, single-cylinder 340cc engine, independent front suspension, and an on-demand 2WD/4WD system. Its robust build, coupled with utility racks and a comfortable riding position, made it a strong contender in its segment, offering a blend of performance and practicality for various off-road applications. This comprehensive workshop service repair manual provides detailed guidance for the Polaris Xplorer 400 (2000 Model Year). It covers essential maintenance procedures, including fluid changes and component checks, along with in-depth troubleshooting for common issues. The manual also offers step-by-step instructions for the disassembly and assembly of major systems such as the engine, fuel system, transmission, drivetrain, brakes, suspension, and electrical components. With over 300 pages of English content, this manual is an invaluable resource for owners and technicians seeking to maintain, diagnose, and repair their Xplorer 400, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Xplorer 400

Year:

Type:

All-Terrain Vehicle (ATV)

Generation

Generation Identifier:

Third Generation Xplorer (1999-2002)

👋 Introduction

Market Position

Segment:

Mid-size utility ATV, targeting recreational riders and light-duty work.

Competitive Analysis

Competitors:

Honda FourTrax 300/350, Yamaha Kodiak 400, Kawasaki Bayou 300/400

Key Features

Vehicle Features:

Reliable 2-stroke engine, independent front suspension, shaft drive, automatic transmission, utility racks.

Manual Value Proposition

Value To Owner:

Empowers owners to perform all necessary maintenance, diagnostics, and repairs, saving time and money on dealership visits.

📋 Manual Details

Coverage Areas

Covered Models:

Polaris Xplorer 400 (2000 Model Year)

Page Count

Estimated Pages:

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Top-end (cylinder head, piston, rings), Bottom-end (crankshaft, connecting rod, bearings), Cooling System (radiator, fan, thermostat, coolant), Lubrication System (oil pump, filter, oil passages)

Fuel System:

Carburetor (cleaning, adjustment, jetting, float level), Fuel Pump, Fuel Lines, Fuel Filter, Fuel Tank

Transmission:

Automatic Transmission (CVT - Continuously Variable Transmission) disassembly, inspection, repair, belt replacement, clutch engagement, gearcase lubrication

Drivetrain:

Shaft Drive, Differential, Axles, CV Joints, Bearings, Seals

Brakes:

Hydraulic Brake System, Master Cylinder, Calipers, Brake Pads, Rotors, Brake Lines, Bleeding Procedure

Suspension:

Front and Rear Suspension (A-arms, shocks, springs, bushings), Wheel Bearings, Steering Knuckles

Electrical System:

Ignition System (CDI, stator, spark plug), Lighting System (headlights, taillights, brake lights), Charging System (alternator, voltage regulator), Battery, Starter Motor, Wiring Diagrams, Switches, Fuses

Chassis And Body:

Frame Inspection and Repair, Body Panels (removal, installation), Seat, Handlebars, Fenders, Racks

Procedures Included

Maintenance:

Oil Change, Filter Replacement, Spark Plug Check/Replacement, Air Filter Cleaning/Replacement, Gearcase Oil Change, Coolant Flush/Replacement, Brake Pad Inspection/Replacement, Chain/Belt Adjustment (if applicable)

Troubleshooting:

Diagnostic Flowcharts, Symptom-based Troubleshooting for Engine, Electrical, and Drivetrain Issues

Repair:

Complete Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair, Brake System Overhaul

Disassembly Assembly:

Step-by-step instructions for major component removal and installation.

Technical Depth

Depth:

Comprehensive; covers everything from routine maintenance to full engine and transmission rebuilds, including diagnostic procedures and specifications.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable Text (OCR optimized)

Print Quality

Image Resolution:

High-resolution, suitable for printing.

Binding Type

Binding:

N/A (Downloadable PDF)

Paper Type

Paper Type:

N/A (Downloadable PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled, single-cylinder

Displacement:

340cc (20.7 ci)

Bore X Stroke:

66 mm x 64 mm

Compression Ratio:

7.6:1

Ignition:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower:

Approximately 28 HP (estimated, varies by tuning and exhaust)

Torque:

Approximately 24 ft-lbs (estimated)

Fuel System

Carburetor:

Mikuni VM34SS (or equivalent)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Capacity:

3.1 gallons (11.7 liters)

Oil Mixture:

Pre-mix (50:1 ratio of 2-stroke oil to gasoline) or Autolube Injection System

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) Automatic (CVT)

Drive Modes:

2WD / 4WD (on-demand)

Features

Gear Reduction:

High and Low range, Neutral, Reverse

Clutch:

Centrifugal clutch, CVT belt drive

📐 Dimensions

Exterior

Length:

77.8 inches (197.6 cm)

Width:

45 inches (114.3 cm)

Height:

45.5 inches (115.6 cm)

Wheelbase:

50 inches (127 cm)

Ground Clearance:

9.2 inches (23.4 cm)

Weights

Dry Weight:

552 lbs (250 kg)

Gross Vehicle Weight Rating:

860 lbs (390 kg)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Tires

Front Tire Size:

AT23x8-12

Rear Tire Size:

AT24x11-10

Wheels

Bolt Pattern:

4/110

🛡️ Safety Features

Ratings

Atv Safety Classification:

Utility ATV, designed for off-road use.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Parking Brake:

Hand-operated lever.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

Handlebars:

Grip heaters (optional/standard depending on trim), padded crossbar.

Safety Recommendations

Protective Gear:

Always wear a helmet, eye protection, and protective clothing.

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, odometer, fuel gauge, indicator lights). No advanced infotainment systems.

Driver Assistance

Features:

On-demand 4WD system.

Connectivity

Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 40 hours of operation or annually.

Gearcase Oil Change:

Every 80 hours of operation or annually.

Air Filter Cleaning:

Every 20 hours of operation or as needed based on dust conditions.

Spark Plug Inspection:

Every 40 hours of operation or annually.

Brake Fluid Flush:

Every 2 years or as recommended.

Fluid Specifications

Engine Oil Type:

API-TC rated 2-stroke oil (for autolube system) or premix oil.

Gearcase Oil Type:

Polaris Demand Drive Fluid (or SAE 75W-90 Synthetic Gear Oil)

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water).

Known Issues

Carburetor Cleaning:

Common issue due to fuel varnish, especially if stored with fuel in the carburetor.

Cvt Belt Wear:

Belts can wear and stretch over time, affecting performance. Regular inspection and replacement are crucial.

Water Pump Seals:

Seals can degrade, leading to coolant leaks.

Starter Bendix:

Can sometimes stick or fail, preventing engine cranking.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries

Founding Year:

Model Evolution

Xplorer Lineage:

The Xplorer line was Polaris's mid-range utility ATV offering, known for its comfort and capable suspension.

Predecessors:

Xplorer 400 2-stroke (introduced around 1995)

Successors:

Polaris Sportsman 400 models (which adopted the 4-stroke engine)

Production

Production Period:

The Xplorer 400 2-stroke was produced for several years, with the 2000 model being part of the third generation.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2000 Xplorer 400 are not prominently documented, Polaris ATVs of this era were generally well-regarded for their utility and value in the recreational and entry-level work segments.

Ratings

Consumer Reviews:

Owners often praise its robust build for its price point and the effectiveness of its 2-stroke engine's torque, while noting the typical maintenance requirements of a 2-stroke engine.