Market Segment:
All-terrain vehicle (ATV) / Utility ATV.
Target User:
Recreational riders, utility users, farm work, trail riding, hunting.
Competitors:
Other ATVs of similar displacement and capability from brands like Yamaha, Suzuki, Honda, Kawasaki, and Can-Am from the mid-to-late 1990s.
Vehicle Type:
4x4 All-Terrain Vehicle
Powertrain Configuration:
2-stroke engine, automatic transmission, selectable 4x4.
Manual Utility:
Provides essential knowledge for owners to perform maintenance, repairs, and diagnostics, reducing reliance on expensive dealer services.
Engine Systems:
Engine overhaul, top-end and bottom-end repair, cooling system, lubrication system, fuel system (carburetor, fuel pump), ignition system, exhaust system.
Transmission Drivetrain Systems:
Automatic transmission (PVT - Polaris Variable Transmission) service and repair, drive belts, clutch system, differential, driveshafts, axles, chain drive (if applicable).
Chassis Suspension Steering:
Front and rear suspension (shock absorbers, A-arms, bushings), steering system (tie rods, steering column), wheel bearings, hubs.
Braking Systems:
Front and rear brake systems (hydraulic, calipers, master cylinder, brake lines, brake pads, rotors/drums).
Electrical Systems:
Wiring diagrams, lighting system, battery, starter, alternator/stator, ignition switch, diagnostic codes (if applicable).
Body Frame Bodywork:
Body panel removal and installation, fenders, racks, seat, fuel tank, trim pieces.
Maintenance Procedures:
Oil change, filter replacement, spark plug replacement, air filter cleaning/replacement, coolant checks and changes, lubrication points, brake system bleeding, drive belt inspection and replacement, battery maintenance.
Repair Procedures:
Engine rebuilding, transmission repair, suspension component replacement, brake caliper overhaul, carburetor adjustment and rebuilding, electrical component troubleshooting and replacement.
Troubleshooting Guidance:
Step-by-step diagnostic procedures for common issues related to starting, running, braking, and electrical systems.
Special Tools:
Details on any specific tools required for certain procedures (e.g., clutch compressor, flywheel puller, torque wrenches).
Technical Depth:
Comprehensive (from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications).
Specifications Data:
Includes torque specifications, clearances, timing settings, electrical resistance values, and other critical data for accurate repairs.
Engine Type:
2-Stroke, Liquid-Cooled, Reed Valve, Single Cylinder
Bore X Stroke:
82mm x 75mm (Typical for this engine family)
Carburetion:
Mikuni VM34SS (or similar 34mm carburetor)
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid Cooling
Ignition Timing:
Specific timing advance values would be detailed in the manual.
Horsepower:
Approx. 30-35 HP (Varies slightly by year and tuning)
Torque:
Estimated 30-35 lb-ft (Varies)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Fuel Oil Mixture:
50:1 Ratio (Gasoline to 2-stroke oil)
Transmission Type:
Polaris Variable Transmission (PVT) - Automatic
Drive System:
Shaft Drive
Drive Modes:
2WD / 4WD (On-Demand)
Gear Ratios:
Specific gear ratios for High, Low, and Reverse are provided in the manual.
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Clutch Type:
Centrifugal Clutch (Primary and Secondary)
Length:
Approx. 74 inches (188 cm)
Width:
Approx. 46 inches (117 cm)
Height:
Approx. 45 inches (114 cm)
Dry Weight:
Approx. 530-550 lbs (240-250 kg)
Ground Clearance:
Approx. 8-10 inches (20-25 cm)
Towing Capacity:
Typically 0 lbs (ATVs are not designed for towing)
Rack Capacity Front:
Approx. 90 lbs (40.8 kg)
Rack Capacity Rear:
Approx. 180 lbs (81.6 kg)
Safety Standards:
Adherence to ANSI/SVIA standards for ATVs.
Braking System:
Hydraulic Disc Brakes (Front and Rear)
4Wd System:
On-demand 4WD system for enhanced traction.
Handlebars:
Grip warmers (often optional or standard depending on trim), padded center bar.
Tires:
Aggressive tread pattern AT tires for stability and grip.
Engine Oil Change:
Every 20-30 engine operating hours or annually, whichever comes first (check manual for specific type of oil).
Air Filter Cleaning:
Every 10-20 engine operating hours, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 30-40 engine operating hours or annually.
Drive Belt Inspection:
Every 20-30 engine operating hours; replacement as needed based on wear.
Engine Oil Type:
2-stroke Synthetic Oil (Recommended: Polaris Premium 2-Stroke Oil, or equivalent API-TC rated oil).
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water recommended).
Gearcase Oil Type:
SAE 80W-90 Hypoid Gear Lubricant (API GL-5).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Problems:
Carburetor tuning issues (jetting, pilot circuit), drive belt wear and slippage, starter solenoid failure, water pump seal leaks, suspension bushing wear.
Preventative Maintenance:
Regular cleaning of the air filter, proper fuel/oil mixture, timely drive belt replacement, and consistent lubrication are crucial for longevity.
Brand Focus:
Polaris is a long-standing manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles, known for innovation and ruggedness.
Xplorer Lineup:
The Xplorer line was positioned as a more trail-oriented and versatile ATV compared to pure sport ATVs, offering utility features.
Engine Progression:
The 400cc 2-stroke engine was a popular and robust powerplant used across various Polaris models during this era.
Manufacturing Origin:
Polaris vehicles are primarily manufactured in the United States (e.g., Roseau, Minnesota).
Production Period:
The Polaris Xplorer 400 was produced for several years in the late 1990s, with this manual covering the core 1996-1998 models.
