Polaris Xplorer 400 1999 Service Repair Workshop Manual

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The 1999 Xplorer 400 is a capable and versatile all-terrain vehicle (ATV) designed for a range of activities including trail riding, hunting, and light utility work. It is powered by...

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Taper: Atv

Distributeur:

UGS: 99954

Mots clés: 1999 ATV Misc Polaris Powersports Xplorer 400

Variantes de produits

Description

The 1999 Xplorer 400 is a capable and versatile all-terrain vehicle (ATV) designed for a range of activities including trail riding, hunting, and light utility work. It is powered by a robust 375cc liquid-cooled, 2-stroke engine, delivering strong low-end torque for challenging terrain. Key features include an automatic PVT transmission with shaft drive for ease of operation, independent front suspension and a long-travel rear swingarm for superior ride quality and ground clearance, and hydraulic disc brakes front and rear for reliable stopping power. The Xplorer 400 was a significant model in the utility ATV lineup during its production era, known for its blend of performance and durability. This Service Repair Workshop Manual provides comprehensive information for the 1999 Xplorer 400 ATV. It covers all aspects of maintenance, repair, and troubleshooting, including detailed procedures for the engine, fuel system, ignition, transmission, suspension, brakes, and electrical systems. The manual also includes technical specifications, parts diagrams, and diagnostic guides to assist owners, mechanics, and technicians. With over 300 pages of detailed instructions and high-resolution scans, this English-language digital manual is an essential resource for maintaining and repairing the vehicle to ensure optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Xplorer 400

Year:

Codes

Model Code:

A99AS42AA

👋 Introduction

Market Position

Positioning:

The Polaris Xplorer 400 1999 was positioned as a capable and versatile utility ATV, designed for trail riding, hunting, and light farm work. It offered a blend of performance, durability, and comfort for its era.

Competitive Analysis

Competitors:

Competed with other mid-size utility ATVs from brands like Yamaha (Grizzly 350/400), Honda (FourTrax 300/400), and Kawasaki (Bayou 300/400).

Key Features

Engine Type:

375cc liquid-cooled, 2-stroke engine providing strong low-end torque.

Transmission:

Automatic PVT (Polaris Variable Transmission) with shaft drive, offering ease of use.

Suspension:

Independent front suspension (IFS) and a long-travel rear swingarm for superior ride quality and ground clearance.

Braking:

Hydraulic disc brakes front and rear for reliable stopping power.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full service, repair, and maintenance for the 1999 Polaris Xplorer 400 ATV.

Secondary Coverage:

Troubleshooting, diagnostics, electrical systems, component specifications, and parts diagrams.

Page Count

Estimated Pages:

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Detailed breakdown of the 375cc 2-stroke engine, including top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), cooling system (liquid-cooled), and lubrication system.

Fuel System:

Carburetor (Mikuni VM34) removal, cleaning, adjustment, specifications, fuel pump, and fuel lines.

Ignition System:

CDI ignition, stator, flywheel, spark plug specifications, troubleshooting ignition faults.

Transmission Drive:

CVT (Continuously Variable Transmission) system, belt inspection and replacement, clutch assembly (drive and driven), gearcase lubrication, and internal gearbox components.

Suspension:

Front and rear suspension systems, shock absorber specifications and adjustments, control arms, bushings, and alignment procedures.

Brakes:

Hydraulic disc brake system (front and rear), brake caliper overhaul, brake pad replacement, master cylinder, brake fluid specifications, bleeding procedures, and rotor specifications.

Electrical System:

Wiring diagrams, battery specifications, charging system (stator, voltage regulator), lighting system (headlights, taillight, brake light), starter motor, and accessory circuits.

Chassis Body:

Frame inspection and repair, body panel removal and installation, seat, handlebars, and rack components.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug service, drive belt inspection, lubrication points, and fluid level checks.

Engine Repair:

Top-end rebuilds (piston, rings, cylinder), decarbonizing, valve adjustments (if applicable to 2-stroke), gasket replacement, and crankshaft seal replacement.

Transmission Repair:

CVT belt replacement, clutch assembly servicing, gearcase seal replacement, and lubricant changes.

Brake Service:

Brake pad replacement, caliper rebuilding, master cylinder servicing, brake line replacement, and bleeding the hydraulic system.

Electrical Troubleshooting:

Diagnosing and repairing common electrical faults using wiring diagrams, voltage testing, and continuity checks.

Suspension Adjustment:

Setting spring preload, rebound, and compression adjustments on shock absorbers; inspecting and replacing suspension bushings.

Carburetor Tuning:

Detailed steps for cleaning, reassembling, and adjusting the Mikuni VM34 carburetor for optimal performance.

Troubleshooting Guides:

Comprehensive diagnostic trees and symptom-based troubleshooting for common mechanical and electrical issues.

Technical Depth

Depth:

Comprehensive, covering everything from basic routine maintenance and fluid changes to complete engine and transmission overhauls, and detailed electrical system diagnostics.

📊 Manual Specifications

File Format

Format:

Searchable:

Yes, text-searchable for quick information retrieval.

Print Quality

Quality:

High-resolution scans of original factory documentation.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke

Displacement:

375 cc (22.8 cu in)

Cooling System:

Liquid-cooled

Bore X Stroke:

70.0 mm x 64.0 mm (2.76 in x 2.52 in)

Compression Ratio:

6.8:1

Carburetor:

Mikuni VM34SS

Air Cleaner:

Dual-stage, foam element

Performance

Horsepower Approximate:

25 HP @ 5500 RPM

Torque Approximate:

28 lb-ft @ 4500 RPM

Fuel System

Fuel Type:

Unleaded gasoline (minimum 87 octane)

Fuel Tank Capacity:

3.2 gallons (12.1 liters)

Fuel Mixture:

Pre-mix or oil injection system (manual will detail if applicable)

🔧 Transmission

Standard

Type:

Automatic PVT (Polaris Variable Transmission)

Drive:

Shaft drive

Gear Reduction:

High and Low range, Reverse

Features

Clutch Type:

Centrifugal clutch with CVT belt drive

Gearcase Oil Type:

Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent (e.g., SAE 80W-90 GL-5 gear oil)

Gearcase Oil Capacity:

0.5 U.S. qt (0.47 L)

📐 Dimensions

Exterior

Length:

77.3 in (196.3 cm)

Width:

44.6 in (113.3 cm)

Height:

44.5 in (113.0 cm)

Wheelbase:

49.2 in (124.9 cm)

Ground Clearance:

9.5 in (24.1 cm)

Weights

Dry Weight:

520 lbs (236 kg)

Gross Vehicle Weight Rating:

860 lbs (390 kg)

Cargo

Rack Capacity Front:

90 lbs (41 kg)

Rack Capacity Rear:

180 lbs (82 kg)

Dimensions

Towing Capacity:

1500 lbs (680 kg)

🛡️ Safety Features

Ratings

Atv Safety Guidelines:

Manual will emphasize safe operating practices, use of helmets and protective gear, and proper rider training, consistent with ATV industry safety standards.

Active Features

Braking System:

Dual hydraulic disc brakes front, single hydraulic disc brake rear, providing robust stopping power.

Throttle Limiter:

Often equipped with an adjustable throttle stop for new or less experienced riders.

Passive Features

Lighting:

Halogen headlights, taillight, and brake light for visibility.

Handlebars:

Comfortable, padded handlebars with handgrips for control and vibration dampening.

💡 Technology Features

Infotainment

Features:

Basic functionality: Analog speedometer, odometer, trip meter, and indicator lights. No advanced infotainment systems.

Driver Assistance

Features:

None specific to modern driver assistance. Focus is on mechanical and electrical systems.

Connectivity

Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or annually, whichever comes first. (Manual will provide precise guidance based on usage.)

Gearcase Oil Change:

Every 50 hours or annually.

Air Filter Cleaning:

Every 25 hours or as needed in dusty conditions.

Spark Plug Service:

Check and clean every 50 hours, replace as needed.

Brake Fluid Flush:

Every 2 years or as recommended by manual.

Fluid Specifications

Engine Oil Type:

Polaris 2-stroke oil injection oil or equivalent TC-W3 certified 2-stroke oil for pre-mix (if applicable).

Coolant Type:

Ethylene glycol-based antifreeze suitable for aluminum engines (e.g., 50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

CVT belt wear, suspension bushings, brake pads, and carburetor jets can be common wear items needing regular inspection and replacement.

Cooling System Maintenance:

Ensuring proper coolant levels and system integrity is crucial for the liquid-cooled 2-stroke engine to prevent overheating.

📚 Vehicle History

Brand Heritage

Polarish Heritage:

Polaris Industries, founded in 1954, has a long history of innovation in recreational vehicles, including snowmobiles and ATVs. The Xplorer line was part of their expansion and refinement of their ATV offerings.

Model Evolution

Xplorer Line Context:

The Xplorer 400 was a key model in Polaris's utility ATV lineup during the late 1990s, representing a step up in engine size and features from earlier models, and it laid groundwork for subsequent Polaris utility ATV designs.

Production

Production Period:

The Polaris Xplorer 400 model series spanned several years, with the 1999 model being a specific iteration of this well-regarded utility ATV.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

The Polaris Xplorer 400 was generally well-regarded for its performance and utility in its class. Specific awards may not be readily documented for this particular model year, but it contributed to Polaris's strong market presence.