Polaris Xplorer 400 2000 Service Repair Workshop Manual

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Tipo: Atv

Proveedor:

SKU: 99955

Etiquetas: 2000 ATV Misc Polaris Powersports Xplorer 400

Variantes de producto

Descripción

This manual provides comprehensive service, repair, and maintenance information for the 2000 Xplorer 400 ATV. Designed as a capable utility ATV, the Xplorer 400 features a two-stroke, liquid-cooled 375 cc engine, selectable 2WD/4WD shaft drive, and independent front suspension. The Xplorer line was known for its comfort and versatility for various off-road tasks and recreational use. The 2000 model, produced in the USA, represents a solid iteration of this well-regarded utility vehicle. This workshop service manual is intended for owners, mechanics, and service centers, offering detailed guidance across all major mechanical and electrical systems. It covers essential procedures such as engine disassembly and assembly, transmission maintenance, drivetrain servicing, suspension and braking system repairs, and electrical system diagnostics, including wiring diagrams. Additionally, the manual includes troubleshooting guides for common issues, scheduled maintenance intervals, fluid specifications, and component replacement instructions, ensuring the optimal performance and longevity of your 2000 Xplorer 400.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Xplorer 400

Year:

Product Type:

Service Repair Workshop Manual

👋 Introduction

Market Position

Target Audience:

Owners, mechanics, and service centers for the 2000 Polaris Xplorer 400 ATV.

Utility Segment:

Positioned as a utility ATV, capable of various off-road tasks and recreational use.

Competitive Analysis

Competitors At Launch:

Honda FourTrax, Yamaha Big Bear, Suzuki QuadRunner, Kawasaki Bayou.

Key Features Vehicle

Engine Type:

Two-stroke, liquid-cooled engine.

Drive System:

Shaft-driven, selectable 2WD/4WD.

Suspension Type:

Independent front suspension (IFS), swingarm rear suspension.

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive service, repair, and maintenance information for the 2000 Polaris Xplorer 400 ATV.

Engine Coverage:

Engine disassembly, assembly, tuning, diagnostics, and repair.

Transmission Coverage:

Transmission system inspection, maintenance, and repair.

Drivetrain Coverage:

Front and rear drive systems, differentials, and CV joints.

Suspension Coverage:

Front and rear suspension components, shock absorbers, and linkages.

Braking System Coverage:

Brake system maintenance, bleeding procedures, caliper, and master cylinder repair.

Electrical System Coverage:

Wiring diagrams, ignition system, charging system, lighting, and starter motor.

Fuel System Coverage:

Carburetor adjustment and cleaning, fuel pump, and fuel lines.

Cooling System Coverage:

Radiator, hoses, coolant, and fan system.

Body And Frame Coverage:

Body panel removal and installation, frame inspection, and seat components.

Troubleshooting Coverage:

Diagnostic procedures for common problems and fault finding.

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, searchable)

📖 Manual Coverage

Systems Covered

All Major Systems:

Yes, covers all essential mechanical and electrical systems of the vehicle.

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, lubrication.

Repair Procedures:

Step-by-step instructions for component repair and replacement.

Diagnostic Procedures:

Troubleshooting guides and flowcharts for identifying and resolving issues.

Assembly Disassembly:

Detailed instructions for taking apart and reassembling various components.

Technical Depth

Depth:

Mechanic-level detail, suitable for professional technicians and experienced DIYers.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format) - Optimized for clear viewing and printing.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Configuration:

Single-cylinder, 2-stroke

Displacement:

375 cc

Bore X Stroke:

66.0 mm x 72.0 mm

Cooling System:

Liquid-cooled

Ignition System:

CDI (Capacitor Discharge Ignition)

Starting System:

Electric Start with Recoil Backup

Performance

Horsepower:

Approximately 26 hp (estimated based on similar models)

Torque:

Not explicitly published, but significant low-end torque for utility.

Fuel System

Carburetor:

Mikuni VM34SS (likely)

Fuel Type:

Unleaded gasoline (minimum 87 octane recommended)

Fuel Mixture:

Automatic oil injection system for pre-mixing oil and fuel.

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive Selection:

Selectable 2WD/4WD

Gear Reduction:

Single reduction with differential

Features

Transmission Fluid Type:

Polaris specific CVT Fluid (check manual for exact spec/part number)

📐 Dimensions

Exterior

Length:

Approx. 77.7 inches

Width:

Approx. 46.0 inches

Height:

Approx. 47.0 inches

Wheelbase:

Approx. 50.2 inches

Weights

Dry Weight:

Approx. 565 lbs

Ground Clearance:

Approx. 9.2 inches

Cargo

Front Rack Capacity:

Not specified, but typical for utility ATVs.

Rear Rack Capacity:

Not specified, but typical for utility ATVs.

🛡️ Safety Features

Ratings

Atv Safety Standards:

Meets ANSI/SVIA standards for recreational trail riding.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Parking Brake:

Yes, hand-operated.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

Throttle Limiter:

Thumb throttle with safety return spring.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Basic Utility ATV)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 25 hours or annually (check manual for exact interval).

Air Filter Cleaning:

Every 10-15 hours or as needed depending on conditions.

Spark Plug Replacement:

Every 100 hours or annually.

Transmission Fluid Change:

Every 100 hours or annually.

Fluid Specifications

Engine Oil Type:

Polaris 2-stroke Premium Synthetic Oil (or equivalent meeting API TC and ISO-L-EGD specifications)

Engine Oil Capacity:

N/A (2-stroke, mixed with fuel)

Cooling System Coolant:

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

Transmission Fluid Type:

Polaris CVT Fluid (specific part number required, check manual).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Carburetor Clogging:

Common with 2-stroke engines if not run regularly or with stale fuel; requires cleaning.

Starter Solenoid Failure:

Can be a point of failure on older models; manual provides testing procedures.

Cvt Belt Wear:

Normal wear and tear; manual covers inspection and replacement procedures.

Suspension Bushings:

Wear can lead to clunking or poor handling; manual details replacement.

📚 Vehicle History

Brand Heritage

Polaris Atv History:

Polaris has been a pioneer in the ATV market since the 1980s, known for innovation and performance.

Model Evolution

Xplorer Lineage:

The Xplorer line focused on comfort, independent suspension, and utility for a broader range of riders.

Production

Manufacturing Location:

USA (Roseau, Minnesota)

Production Years:

Polaris produced the Xplorer 400 from the mid-1990s through the early 2000s, with the 2000 model being a significant iteration.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Polaris ATVs generally received positive reviews for their performance and features during their production run, though specific awards for the 2000 Xplorer 400 are not widely publicized.