Atv Segment:
Utility/Recreational ATV
Target User:
ATV owners who perform their own maintenance and repairs.
Common Competitors Era:
Arctic Cat 400, Yamaha Kodiak 400, Honda Foreman 400
Atv Design Philosophy:
Reliable design, relatively simple construction, ease of repair for home mechanics.
Manual Value Proposition:
Essential for identifying correct parts, facilitating home maintenance and repair, saving costs, and prolonging ATV lifespan.
Atv Construction Advantage:
Designed for home maintenance and repair, making it accessible for enthusiasts.
Major Systems:
Engine Mounting, Cooling System, Exhaust System, Fuel System (Tank), Oil System (Tank), Air Intake System, Front Drive System, Front Suspension, Front Brakes, Steering System, Controls (Throttle, Master Cylinder, Brake Lines), Rear Drive System, Rear Brakes, Gearcase, Electrical System (Taillight), Clutch System, Recoil Starter, Carburetor, Oil Pump, Magneto, Starting Motor.
Body And Chassis:
Front Cab, Rear Cab and Seat, Rear Rack Mounting, Front Rack and Bumper Mounting, Decals.
Powertrain:
Engine Mounting, Cooling System, Exhaust System, Fuel Tank, Oil Tank, Air Box, Drive Clutch, Driven Clutch, Clutch Cover, Gearcase/Brake and Chain Cover Mounting, Rear Wheel Drive, Piston and Crankshaft, Crankcase and Cylinder, Oil Pump, Magneto.
Suspension And Steering:
Front Drive, Front Tightener, Front Strut, CV Joint – BTB, Front Wheel, A-Arm/Strut Mounting, Center Tightener, Swing Arm/Shock Mounting, Steering Post, Handlebar and Headlight Pod.
Braking System:
Front Brake, Rear Brake.
Controls And Electrical:
Controls -- Throttle ASM./Cable, Controls - Master Cylinder/Brake Line, Handlebar and Headlight Pod, Electrical/Taillight, Gear Selector, Recoil Starter, Starting Motor, Tool Kit.
Component Groups:
Frame, body panels, racks, steering column, handlebars, engine components, transmission, drivetrain, suspension, brakes, wheels, tires, electrical system, fuel and oil systems.
Engine Internal:
Piston, Crankshaft, Crankcase, Cylinder, Carburetor, Oil Pump, Magneto.
Drive Train Components:
Drive Clutch, Driven Clutch, Clutch Cover, Gearcase, Drive Chain.
Diagnostic Support:
Assists in identifying correct replacement parts for diagnostic and repair purposes.
Maintenance Support:
Facilitates identification of parts for routine maintenance tasks such as oil changes, filter replacements, and component inspections.
Part Identification:
Comprehensive identification of all part numbers with corresponding exploded views.
Repair Planning:
Essential for planning repairs by identifying necessary components and their part numbers.
Level Of Detail:
Detailed exploded diagrams and comprehensive part number lists for all components.
Diagram Quality:
Detailed exploded diagrams for all listed components, enabling clear visualization of assembly.
Completeness:
Comprehensive parts catalog covering all major assemblies and sub-assemblies of the 2002 Polaris Xplorer 400.
Part Number Accuracy:
Provides specific OEM part numbers for correct ordering and replacement.
Engine Type:
Liquid-cooled, 2-stroke, 1-cylinder, reed valve induction (common configuration for this model, though not explicitly stated in product info)
Engine Displacement:
Approximately 398cc (typical for the '400' designation in Polaris models of this era).
Estimated Horsepower:
Approximately 25-30 HP (typical for this displacement and configuration, specific figure requires actual manual lookup)
Carburetor Type:
Single carburetor (specific model/size not provided)
Fuel Type:
Unleaded gasoline (standard for ATVs)
General Recommendations:
Frequent and regular intervals for oil changes, filter checks/replacements, spark plug service, and component inspections (as per product description).
Specific Maintenance Tasks:
Oil change, shift linkage inspection, steering inspection, suspension inspection, coolant system inspection, fuel system inspection, drive belt inspection, engine mount inspection, spark plug replacement, fuel filter replacement, air filter replacement.
Engine Oil:
Specific viscosity and type would be detailed in a full service manual, typically SAE 10W-40 or 20W-50 for air-cooled or liquid-cooled 2-strokes/4-strokes.
Coolant Type:
Ethylene glycol-based antifreeze/coolant (if liquid-cooled, specific type TBD)
Gearcase Oil:
Specific viscosity and type would be detailed in a full service manual.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (typical, specific requirement to be confirmed in a full service manual).
Common Atv Wear Items:
Drive belts, ball joints, tie rod ends, brake pads, wheel bearings, suspension bushings are common wear items on ATVs of this era.
Parts Identification Importance:
Crucial for sourcing OEM or equivalent quality replacement parts to ensure proper fit and function, especially for critical engine or drivetrain components.
