Segment:
Entry-level to mid-range utility ATV segment for its era.
Competitors:
Competed with models from Yamaha (Grizzly), Honda (FourTrax), Kawasaki (Bayou), and Suzuki (King Quad) during the late 1990s.
Vehicle Features:
Independent front suspension, shaft drive (on some models, check specific configuration), automatic transmission, durable utility design for work and recreational use.
General Coverage:
Comprehensive repair, maintenance, rebuilding, and refurbishment of the Polaris ATV Xplorer 400 1997 model.
Estimated Page Count:
Detailed page count not explicitly provided, but described as 'very detailed' and containing 'everything you will ever need'.
Type:
Service Manual / Repair Manual
Engine And Powertrain:
Engine overhaul, cylinder head, piston, crankshaft, lubrication system, cooling system, fuel system (carburetor, fuel lines), exhaust system, ignition system, starting system, clutch, final drive, differential.
Chassis And Suspension:
Frame, front suspension (shocks, control arms), rear suspension (swingarm, shocks), steering system (handlebar, tie rods, steering column), wheels, tires.
Brakes And Controls:
Brake system (hydraulic lines, calipers, master cylinder, brake fluid), control levers, throttle cable, brake cables.
Electrical System:
Wiring diagrams, battery, starter motor, alternator, lights (headlight, taillight, brake light), ignition switch, kill switch, CDI unit, fuses, relays.
Bodywork And Plastics:
Body panels, fenders, seat, racks, storage compartments, graphics and decals.
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment, cable lubrication, brake bleeding, battery maintenance.
Repair Procedures:
Engine rebuild, carburetor tuning and overhaul, transmission repair, suspension component replacement, brake caliper rebuild, electrical component diagnosis and replacement, steering system repair.
Troubleshooting Guide:
Systematic diagnosis of common problems, fault finding for engine, electrical, and mechanical issues with step-by-step solutions.
Depth Of Information:
Detailed technical specifications, torque values, clearances, timing settings, diagnostic procedures, and component-specific repair instructions suitable for professional technicians and advanced DIY enthusiasts.
Digital Format:
PDF (Portable Document Format)
Readability:
Assumed high quality for digital reproduction, enabling clear viewing of text, diagrams, and illustrations.
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
2-Stroke, 2-cylinder, Liquid-Cooled
Displacement:
398 cc (Cubic Centimeters)
Bore X Stroke:
64 mm x 64 mm (Typical for this engine family)
Fuel System:
Carburetor (likely dual Mikuni VM or similar)
Horsepower Estimate:
Approximately 25-30 HP (estimated, actual may vary by specific tuning and market).
Torque Estimate:
Estimated torque figures are not readily available, but designed for low-end grunt.
Carburetor Details:
Dual carburetors, likely requiring synchronized adjustment and jetting for optimal performance.
Ignition Type:
CDI (Capacitor Discharge Ignition)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with Hi/Lo range and Reverse.
Optional Transmission:
N/A (CVT was standard for this model).
Cvtfabric Type:
Polaris Variable Transmission (PVT)
Gear Selection:
Forward (High/Low), Neutral, Reverse.
Transmission Fluid:
Polaris specific CVT fluid or compatible heavy-duty synthetic oil (refer to manual for exact specification and capacity).
Length:
Approximately 80-83 inches (Varies slightly by configuration).
Width:
Approximately 45-48 inches.
Height:
Approximately 45-48 inches.
Dry Weight:
Approximately 550-600 lbs.
Towing Capacity:
Not typically specified for this class of ATV, but designed for moderate utility tasks.
Ground Clearance:
Approximately 6-8 inches.
Front Tire Size:
24x8-12 (Common, refer to manual for exact fitment).
Rear Tire Size:
24x11-10 (Common, refer to manual for exact fitment).
Wheel Bolt Pattern:
4x110 mm (Typical for Polaris of this era).
Atv Safety Standards:
Complied with ANSI standards for All-Terrain Vehicles at the time of manufacture. User must always wear a helmet and appropriate safety gear.
Braking System:
Hydraulic disc brakes front and rear.
Rollover Protection:
Standard handlebar and footwells provide some protection, but not designed for occupant protection in severe rollovers.
Seatbelt Anchorage:
N/A (ATVs are not equipped with seatbelts).
Engine Oil Change:
Every 100 hours or annually, whichever comes first (typical for this era, refer to manual for exact mileage/hour).
Air Filter Cleaning:
Every 20 hours or as needed in dusty conditions.
Spark Plug Replacement:
Every 100 hours or annually.
Engine Oil Type:
2-stroke specific oil, premixed with gasoline at a ratio specified in the manual (e.g., 50:1, 40:1).
Engine Oil Capacity:
N/A (premix, not sump oil).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for precise specification).
2 Stroke Engine Wear:
Carbon buildup in exhaust ports, piston ring wear, and cylinder scoring can occur with improper maintenance or excessive hard use.
Carburetor Clogging:
Fuel system contamination can lead to clogged carburetor jets, affecting idle and performance.
Cvtfan Belt Wear:
CVT belt wear is a common maintenance item; premature failure can occur if the belt is damaged or the clutch system is not properly maintained.
Electrical Connector Corrosion:
Exposure to elements can lead to corrosion in electrical connectors, causing intermittent issues.
Polarisfamiliy History:
Polaris Industries Inc. has a long history dating back to 1954, initially producing snowmobiles and later diversifying into ATVs, motorcycles, and powersports vehicles.
Xplorer Series Context:
The Xplorer line was Polaris's range of utility and recreational ATVs, known for their ruggedness and versatility. The 400 model represented a significant step in performance and capability within the Polaris ATV lineup.
Production Years:
The Polaris Xplorer 400 was produced in the mid-to-late 1990s, with 1997 being a specific model year in that generation.
