Market Segment:
Entry-level to mid-range utility ATV
Competitors:
Yamaha Timberwolf, Honda FourTrax, Suzuki QuadRunner, Kawasaki Bayou
Engine Type:
2-stroke, liquid-cooled
Transmission Type:
Automatic (PVT)
Target Audience:
Recreational riders, light utility tasks, trail riding
Engine Systems:
Engine overhaul, top-end repair, bottom-end assembly, cooling system, lubrication system, fuel delivery, ignition system, exhaust system
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, belt replacement, final drive, drive shafts, gear cases
Suspension Steering:
Front and rear suspension systems (e.g., MacPherson strut, independent suspension), shock absorbers, springs, steering linkage, tie rods, wheel bearings
Braking System:
Hydraulic brake system, master cylinders, brake calipers, brake pads, brake lines, parking brake
Electrical System:
Starter motor, charging system (stator, regulator/rectifier), battery, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, switches, ignition switch, kill switch
Body Chassis:
Frame inspection and repair, body panels, fenders, racks, seat assembly, handlebars, footrests
Fuel System:
Carburetor service and tuning, fuel tank, fuel lines, fuel filter
Maintenance Procedures:
Routine checks, lubrication, filter replacements (air, fuel), spark plug service, valve adjustments (if applicable)
Troubleshooting Procedures:
Diagnostic charts, symptom-based troubleshooting, common problem identification and solutions
Repair Procedures:
Step-by-step disassembly, reassembly, and repair instructions for all major components
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, timing data
Technical Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, detailed electrical diagnostics
Engine Type:
2-Stroke, Liquid-Cooled, Single Cylinder
Displacement:
398 cc (approx.)
Bore X Stroke:
Refer to manual for specific dimensions
Compression Ratio:
Refer to manual for specific ratio
Cooling System:
Liquid-Cooled
Lubrication:
Premix or Auto-Lube system (check manual for exact configuration)
Horsepower:
Estimated 25-30 HP (typical for this displacement and era)
Torque:
Refer to manual for specific figures
Fuel Delivery:
Carburetor (likely Mikuni or Keihin)
Carburetor Model:
Refer to manual for specific model and jetting
Fuel Type:
Unleaded Gasoline
Fuel Octane Rating:
87 Octane (minimum, refer to manual)
Fuel Tank Capacity:
Approximately 3.0-3.5 gallons (check manual)
Transmission Type:
Polaris Variable Transmission (PVT) - Automatic CVT
Drive Modes:
2WD / 4WD selection
Clutch System:
Primary (Drive) Clutch and Secondary (Driven) Clutch with Belt Drive
Gear Ratios:
Refer to manual for specific low and high range ratios
Transmission Fluid Type:
Refer to manual for specific fluid type (e.g., SAE 10W-30 or specific CVT fluid)
Transmission Fluid Capacity:
Refer to manual for specific capacity
Length:
Approximately 76-78 inches (check manual)
Width:
Approximately 42-44 inches (check manual)
Height:
Approximately 45-47 inches (check manual)
Dry Weight:
Approximately 500-550 lbs (check manual)
Ground Clearance:
Approximately 6-8 inches (check manual)
Front Rack Capacity:
Refer to manual for specific rating
Rear Rack Capacity:
Refer to manual for specific rating
Towing Capacity:
Refer to manual for specific rating (often limited on ATVs of this era)
Front Tire Size:
Commonly 23x8-12 or 24x8-12 (check manual)
Rear Tire Size:
Commonly 23x10-12 or 24x10-12 (check manual)
Wheel Bolt Pattern:
4x110 mm (typical for Polaris)
Rollover Protection:
N/A (ATVs are open-platform vehicles)
Braking System Type:
Hydraulic Disc Brakes (front and rear)
Parking Brake:
Mechanical or caliper-based (integrated with rear brake system)
Hand Guards:
Standard on many models (check manual)
Throttle Governor:
May be present and adjustable (refer to manual)
Operator Training:
Emphasizes proper ATV operation, riding gear, and terrain awareness (covered in manual)
Oil Change Interval:
Refer to manual for specific hours or miles (typically every 25-50 operating hours).
Air Filter Cleaning:
Frequent inspection and cleaning, especially in dusty conditions (refer to manual for frequency).
Spark Plug Replacement:
Refer to manual for recommended interval (e.g., annually or every 100 operating hours).
Transmission Fluid Change:
Refer to manual for recommended interval (e.g., every 100-200 operating hours).
Engine Oil Type:
Refer to manual for specific grade (e.g., SAE 10W-30, SAE 10W-40, or synthetic equivalent).
Coolant Type:
Ethylene Glycol based antifreeze/coolant (specific mixture ratio in manual).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (check manual).
Carburetor Cleaning:
Common issue on older 2-stroke engines; requires regular cleaning and jet maintenance.
Pvt Belt Wear:
CVT belts are wear items and require periodic inspection and replacement.
Cooling System Leaks:
Hose integrity and radiator performance should be monitored.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical issues.
Suspension Wear:
Bushings, ball joints, and tie rods can wear over time, affecting steering and ride quality.
Brand Origins:
Polaris Industries, founded in 1954, initially known for snowmobiles, expanded into ATVs in the late 1980s.
Xplorer Lineage:
The Xplorer line was introduced by Polaris as a more utility-focused ATV, distinct from their sportier models. The 400cc engine size was common for this segment.
Production Period:
1996-1998 for this specific generation.
Manufacturing Location:
Typically manufactured in the United States by Polaris Industries.
