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Polaris Xplorer 400 2000 Workshop Service Repair Manual

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This document provides comprehensive technical information for the 2000 Xplorer 400, an all-terrain vehicle (ATV) renowned for its capable off-road performance and utility-focused design. Built by a leader in the...
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Tipo: Atv
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SKU: 103894
Polaris Xplorer 400 2000 Workshop Service Repair Manual
This document provides comprehensive technical information for the 2000 Xplorer 400, an all-terrain vehicle (ATV) renowned for its capable off-road performance and utility-focused design. Built by a leader in the powersports industry, the Xplorer 400 features a robust 398cc liquid-cooled, 2-stroke engine, a selectable 2WD/4WD Variable Transmission (PVT) with high and low range, and a sturdy chassis designed for challenging terrain. Its engineering prioritizes reliability and a strong utility-focused design, positioning it as a competitive option in the early 2000s ATV market alongside models from major manufacturers. This workshop service repair manual is designed to be an exhaustive resource for owners, mechanics, and technicians. It covers all essential aspects of the 2000 Xplorer 400, including detailed procedures for scheduled maintenance, engine overhauls, transmission repairs, chassis servicing, and electrical system diagnostics. The manual offers guidance on troubleshooting common issues, provides critical technical specifications, and outlines safety precautions. With its comprehensive coverage from basic adjustments to complete rebuilds, this English-language manual aims to facilitate the proper maintenance and repair of all 2000 Xplorer 400 models.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Xplorer 400
Year:
2000
Product Name:
Polaris Xplorer 400 2000 Workshop Service Repair Manual
Codes
Vin Prefix:
4US
👋 Introduction
Market Position
Category:
All-Terrain Vehicle (ATV)
Competitive Analysis
Competitors Circa 2000:
Yamaha Kodiak 400, Suzuki QuadRunner 500, Honda FourTrax Foreman 450
Key Features
Vehicle Attributes:
Capable off-road performer, utility-focused design, Polaris's established off-road reputation
📋 Manual Details
Coverage Areas
Vehicle Variants:
All 2000 Polaris Xplorer 400 models
Page Count
Estimated Pages:
Hundreds (printable)
Manual Type
Type:
Workshop Service Repair Manual (Factory Official)
Language
Language:
English
Format
Format:
Downloadable Digital Format (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, drivetrain, exhaust
Chassis:
Suspension (front and rear), steering, brakes, wheels, tires
Electrical:
Ignition system, starting and charging, lighting, instrumentation, wiring diagrams
Bodywork:
Body panels, trim, seat, controls, storage
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication
Repair:
Engine overhaul, transmission repair, brake service, suspension component replacement, electrical diagnostics
Troubleshooting:
Diagnostic procedures, fault finding, common problems and solutions
Technical Depth
Depth:
Comprehensive (from basic adjustments to complete rebuilds)
📊 Manual Specifications
File Format
File Type:
PDF (expected)
Print Quality
Printability:
Full printability (pages can be selected for printing)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Features
Searchability:
Likely searchable text for quick information retrieval
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, liquid-cooled, single cylinder
Displacement:
398cc (24.3 cubic inches)
Bore X Stroke:
71 mm x 51 mm (estimated)
Performance
Horsepower:
Approximately 30-35 HP (estimated)
Torque:
Not readily available, but significant low-end torque for its class
Fuel System
Carburetion:
Mikuni VM30SS carburetor
Fuel Type:
Unleaded gasoline
Ignition
Ignition System:
CDI (Capacitor Discharge Ignition)
🔧 Transmission
Standard
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Drive Modes:
2WD/4WD selectable
Features
Gear Reduction:
High and Low range, Reverse
Clutch Type:
Centrifugal clutch
📐 Dimensions
Exterior
Length:
81.5 inches (2070 mm)
Width:
46 inches (1168 mm)
Height:
47 inches (1194 mm)
Weights
Dry Weight:
540 lbs (245 kg)
Ground Clearance:
10 inches (254 mm)
Cargo
Front Rack Capacity:
25 lbs (11.3 kg)
Rear Rack Capacity:
50 lbs (22.7 kg)
Wheels
Wheelbase:
50 inches (1270 mm)
Wheel Bolt Pattern:
4/110 mm
Front Tire Size:
AT25x8-12
Rear Tire Size:
AT25x11-10
🛡️ Safety Features
Ratings
Atv Safety:
ATVs are inherently dangerous; always wear appropriate safety gear and operate responsibly. Consult manual for specific warnings.
Active Features
Braking System:
Hydraulic disc brakes (front and rear)
Passive Features
Lighting:
Halogen headlights, taillight, brake light
Throttle Limiter:
Thumb throttle with safety mechanism
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation: speedometer, odometer, fuel gauge, engine hour meter, warning lights.
Driver Assistance
Driver Aid Features:
None specific beyond the inherent design of the vehicle for its intended purpose.
Connectivity
Connectivity Features:
None
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual; typically every 100-200 hours or annually for severe use.
Spark Plug Replacement:
Refer to manual; usually around 100-300 hours depending on plug type and usage.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity grade (e.g., 0W-40, 10W-40 for 2-stroke oil injection).
Gear Case Oil:
Refer to manual for specific type and capacity (e.g., SAE 80W-90 GL-5).
Coolant Type:
Ethylene glycol based antifreeze/coolant suitable for powersports applications.
Known Issues
Common Problems:
Carburetor tuning issues, PVT belt wear, potential exhaust leaks, stator failures (common in some older Polaris models), power valve issues in 2-stroke engines.
Parts Numbers
Air Filter Part Number:
Refer to manual for specific OEM or aftermarket part numbers.
Oil Filter Part Number:
N/A (dry sump 2-stroke, typically no oil filter in engine crankcase)
📚 Vehicle History
Brand Heritage
Polarishistory:
Polaris Industries Inc. is a long-standing American manufacturer known for its leadership in the powersports industry, particularly with ATVs and snowmobiles.
Model Evolution
Xplorer Lineage:
The Xplorer line was Polaris's utility-focused ATV series, offering robust performance for work and recreation. The 400 was a popular mid-range model.
Production
Production Period:
The Xplorer 400 was produced throughout the late 1990s and early 2000s.
🏆 Awards & Recognition
Recognitions
Atv Industry Awards:
While specific awards for the 2000 Xplorer 400 are not prominently documented, Polaris models generally received positive reviews for their performance and utility in industry publications of the era.
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