Target Audience:
Polaris Xplorer 400 owners, mechanics, and DIY enthusiasts requiring detailed service information.
Value Proposition:
Provides official factory data, ensuring accuracy and completeness for proper maintenance and repair, superior to generic aftermarket guides.
Completeness:
Complete official factory manual, covering all aspects of the vehicle's operation and maintenance.
Accuracy:
Authoritative information directly from the manufacturer.
Engine:
Detailed diagnostics, repair, overhaul, and specifications for the 400cc engine.
Fuel System:
Carburetor adjustment, cleaning, fuel pump, fuel tank, and lines.
Ignition System:
CDI unit, ignition coil, spark plug, timing adjustments.
Cooling System:
Radiator, fan, coolant specifications, thermostat, and water pump.
Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) maintenance, belt inspection/replacement, drive clutch, driven clutch, and gearcase.
Drivetrain:
Shaft drive, universal joints, differential (if applicable), and rear axle assembly.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, and bushings.
Brakes:
Hydraulic brake system, caliper service, master cylinder, brake pads, rotors, and bleeding procedures.
Steering:
Handlebar assembly, steering post, tie rods, and steering knuckle service.
Electrical System:
Battery, starter, charging system, lighting, switches, wiring diagrams, and component testing.
Body And Frame:
Frame inspection, body panel removal/installation, fenders, racks, and plastics.
Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning, chain/belt adjustments, lubrication points.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common issues.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Overhaul:
Complete engine and transmission overhaul procedures.
Wiring Diagrams:
Detailed electrical system wiring schematics.
Depth:
Comprehensive, covering basic maintenance to full engine rebuilds and complex electrical diagnostics.
Engine Type:
2-stroke, liquid-cooled
Displacement:
340cc (Note: While the model is Xplorer 400, some 400-class Polaris ATVs of this era used 340cc engines. The manual would specify the exact displacement.)
Bore X Stroke:
Refer to manual for exact specifications (typically around 66mm x 64mm for similar engines).
Horsepower:
Refer to manual for exact specifications (estimated 25-30 HP).
Torque:
Refer to manual for exact specifications.
Carburetor:
Single Mikuni VM34SS (typical for this engine).
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended).
Oil Mixture:
Pre-mix or Autolube system (manual specifies mixture ratio if applicable).
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid Cooling
Coolant Type:
Ethylene glycol based antifreeze/coolant (refer to manual for specific Polaris recommendation).
Length:
Refer to manual (typically around 70-75 inches for this model).
Width:
Refer to manual (typically around 40-45 inches).
Height:
Refer to manual (typically around 40-45 inches).
Dry Weight:
Refer to manual (estimated 500-550 lbs).
Ground Clearance:
Refer to manual (typically 6-8 inches).
Front Tire Size:
Refer to manual (e.g., AT24x8-12).
Rear Tire Size:
Refer to manual (e.g., AT24x11-10).
Wheel Bolt Pattern:
Refer to manual (typically 4x110mm or similar for ATVs).
Infotainment System:
N/A (Basic utility ATV, no advanced infotainment features).
Driver Assistance Features:
N/A (Basic utility ATV, no electronic driver assistance systems).
Connectivity Options:
N/A (No electronic connectivity features).
Engine Oil Change:
Refer to manual (typically every 20-40 operating hours or annually).
Air Filter Cleaning:
Refer to manual (frequently, depending on operating conditions).
Spark Plug Service:
Refer to manual (typically every 100-200 operating hours or annually).
Transmission Oil Change:
Refer to manual (typically every 40-60 operating hours or annually).
Engine Oil:
Refer to manual for specific grade and type (likely 2-stroke oil for autolube, or specific blend for pre-mix if applicable).
Gearcase Oil:
Refer to manual for specific viscosity and API rating (e.g., SAE 80W-90 GL-5).
Coolant:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water recommended.
Pvttuning:
PVT clutch wear, belt slippage, and proper engagement are common areas for maintenance and adjustment.
Carburetor:
Carburetor tuning and cleaning can be crucial for optimal 2-stroke engine performance.
Electricalconnectors:
Corrosion on electrical connectors due to exposure to elements can lead to intermittent issues.
Polarishistory:
Polaris Industries is a long-standing American manufacturer known for its pioneering role in the powersports industry, particularly with snowmobiles and ATVs.
Xplorer Line:
The Xplorer line was Polaris's utility-focused ATV offering, emphasizing comfort and capability for longer rides and work tasks, distinct from sportier models.
Production Period:
The Polaris Xplorer 400 was produced in the late 1990s and early 2000s, a period of significant growth and development for Polaris ATVs.
