Market Segment:
Utility ATV designed for recreational riding, light work, and trail exploration.
Competitors 2002:
Yamaha Wolverine 350/450, Honda FourTrax 350/400, Suzuki QuadRunner 400, Kawasaki Bayou 300/400.
Key Features:
Robust 4x4 system, capable engine for its class, comfortable suspension, reliable utility platform.
Value Proposition:
Provides comprehensive DIY repair and maintenance capabilities, enabling owners to save on dealership service costs and maintain their ATV's performance and longevity.
Engine:
Complete engine overhaul, including disassembly, inspection, assembly, tuning, and troubleshooting of internal and external components.
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank maintenance and repair.
Ignition System:
Ignition coil, CDI unit, spark plugs, wiring diagnostics.
Cooling System:
Radiator, fan, hoses, coolant specifications and replacement.
Transmission And Drivetrain:
Drive clutch, driven clutch, belt inspection and replacement, gearcase service, chain drive, differential service, 4WD engagement system.
Brakes:
Hydraulic brake system service, caliper rebuild, master cylinder, brake lines, brake pads, rotor inspection and replacement.
Suspension:
Front and rear suspension components, shock absorbers, bushings, steering knuckles, ball joints, tie rods.
Steering:
Steering column, steering rack/gearbox, tie rod ends, alignment procedures.
Electrical System:
Battery, starter motor, alternator/stator, lighting system, wiring diagrams, troubleshooting electrical faults.
Body And Frame:
Body panel removal and installation, frame inspection and repair, fenders, racks.
Wheels And Tires:
Tire specifications, wheel torque, hub maintenance.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments, belt checks.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Rebuilds:
Detailed rebuild procedures for major components like engines and transmissions.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems.
Torque Specifications:
Detailed torque values for all critical fasteners.
Depth:
Comprehensive, covering everything from basic owner maintenance to complete engine and transmission overhauls.
Engine Type:
4-stroke, liquid-cooled, single-cylinder
Bore X Stroke:
84 mm x 68 mm
Horsepower Estimated:
~25 hp (manufacturer data often not released for ATVs of this era)
Torque Estimated:
~27 lb-ft (manufacturer data often not released for ATVs of this era)
Carburetor Type:
Mikuni VM34SS (typically)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-cooled
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Gear Selection:
High, Low, Neutral, Reverse
Drive System:
Shaft drive to rear differential, shaft drive to front differential (4WD)
Clutch Type:
Centrifugal clutch (Drive clutch) and weighted driven clutch
Safety Standards:
Designed to meet ANSI standards for recreational ATVs.
Braking System:
Hydraulic disc brakes, front and rear.
Lighting:
Dual 30W headlights, 35W taillight/brake light.
Operator Interface:
Handlebar steering with hand controls, thumb throttle, integrated hand guards.
Engine Oil Change:
Every 100 hours or annually, whichever comes first.
Gearcase Oil Change:
Every 200 hours or annually.
Drive Belt Inspection:
Inspect every 50 hours, replace as needed (recommend replacement every 2-3 years or based on wear).
Air Filter Cleaning:
Clean every 25 hours or as needed in dusty conditions.
Spark Plug Replacement:
Replace every 100 hours or annually.
Engine Oil:
Polaris Premium 2-stroke Oil (for 2-stroke models) or SAE 10W-40 API SG (for 4-stroke models). This is a 4-stroke engine. Refer to manual for specific Polaris recommendations.
Gearcase Oil:
Polaris Demand Drive Fluid or SAE 80W-90 GL-5 gear oil.
Coolant:
Ethylene glycol-based antifreeze/coolant, mixed 50/50 with distilled water. Recommended type: Polaris Coolant or equivalent.
Drive Belt Wear:
Drive belts can wear prematurely if the ATV is ridden aggressively or if there's improper alignment or tension.
Carburetor Fouling:
Carburetors can become fouled from stale fuel or dirt ingress, leading to hard starting or poor running.
Suspension Bushings:
Rubber bushings in the suspension and steering can degrade over time, leading to play and noise.
Electrical Connector Corrosion:
Connectors in exposed areas can corrode, causing intermittent electrical faults.
Polarishistory:
Polaris Industries is a long-standing American manufacturer known for its snowmobiles, ATVs, and off-road vehicles, established in 1954.
Xplorer Lineage:
The Xplorer line was Polaris's offering for the more recreational and trail-oriented rider, often featuring more suspension travel and comfort features compared to the Sportsman line. The 400cc engine was a popular choice for a balance of power and efficiency.
Production Years Approximate:
The Xplorer 400 model was in production for several years in the late 1990s and early 2000s, with the 2002 model being a refinement of earlier iterations.
