Original Market Segment:
Entry-level to mid-range utility ATV
Target Audience:
Recreational riders, light utility users, farmers, hunters
Key Competitors:
Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou
Performance Focus:
Reliable performance, capable off-road handling
Drivetrain Feature:
Selectable 2WD/4WD
Value Proposition:
Enables DIY maintenance and repairs, saving on labor costs and downtime
Content Advantage:
Official factory data ensures accuracy and completeness
Engine:
Complete engine overhaul, disassembly, assembly, tuning, troubleshooting
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank maintenance
Ignition System:
Ignition coil, spark plug, CDI unit, timing procedures
Transmission Drive:
PVT (Polaris Variable Transmission) system, belt inspection/replacement, clutch service
Drivetrain:
4x4 system, front and rear differentials, driveshafts, U-joints
Suspension:
Front and rear suspension components, shocks, bushings, alignment
Brakes:
Hydraulic brake system, caliper service, master cylinder, brake fluid, bleeding procedures
Steering:
Handlebar assembly, tie rods, steering column, lubrication
Electrical System:
Wiring diagrams, battery, charging system, lighting, starter, accessories
Cooling System:
Radiator, fan, thermostat, coolant specifications and procedures
Exhaust System:
Muffler, exhaust pipe, gaskets, torque specifications
Frame Chassis:
Frame inspection, component mounting, torque values
Bodywork Plastics:
Fender removal/installation, seat, plastic panel care
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points
Troubleshooting:
Diagnostic flowcharts, common problem identification and solutions
Repair:
Step-by-step repair instructions for all major systems
Overhaul Rebuild:
Complete engine and transmission rebuild procedures with detailed specifications
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical values
Depth Level:
Comprehensive Factory Service Level
Diagnostic Capability:
Advanced diagnostic procedures, electrical system troubleshooting
Rebuild Capability:
Full engine and transmission rebuild instructions
Digital Format:
PDF (Portable Document Format)
Printability:
Printable (designed for user printing)
Resolution:
High resolution for clear diagrams and text
Binding Type:
N/A (Digital download, user responsible for printing and binding)
Paper Type Recommendation:
Standard copier paper suitable for workshop use
Displacement:
375cc (approximate)
Bore X Stroke:
70 mm x 97.7 mm (typical for this engine family)
Cooling System:
Liquid-cooled
Cylinder Configuration:
Single Cylinder
Horsepower:
Estimated 25-30 HP (figures vary based on tuning and specific model year)
Torque:
Not readily available for this model, but sufficient for utility tasks
Fuel Delivery:
Carburetor
Carburetor Model:
Mikuni VM34 (typical for this era)
Fuel Type:
Unleaded Gasoline
Fuel Mixture:
Requires 2-stroke oil mixed with gasoline (ratio specified in manual)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK BR9ES (typical, confirm in manual)
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Drive System:
Shaft Drive
Gear Selection:
High, Low, Neutral, Reverse
Clutch System:
Centrifugal Clutch (Primary and Secondary)
Belt Drive System:
Yes, V-belt
Transmission Fluid Type:
Polaris 2-stroke oil or equivalent SAE 10W-30 API SG (confirm in manual)
Transmission Oil Capacity:
Typically around 1.5 liters (confirm in manual)
Length:
Approx. 74 inches (188 cm)
Width:
Approx. 43 inches (109 cm)
Height:
Approx. 43 inches (109 cm)
Dry Weight:
Approx. 480 lbs (218 kg)
Ground Clearance:
Approx. 7-8 inches (18-20 cm)
Towing Capacity:
Not typically specified for this model, but suitable for light trailer hauling
Rack Capacity Front:
Approx. 50 lbs (23 kg)
Rack Capacity Rear:
Approx. 100 lbs (45 kg)
Atv Safety Standards:
ANSI/SVIA 1-2010 standards (applicable to the era)
Braking System:
Hydraulic Disc Brakes (front and rear)
Tire Type:
All-terrain bias-ply tires
4X4 Engagement:
Electronic Push-Button 4WD
Rollover Protection:
None (standard for ATVs of this era)
Operator Training Recommendation:
Emphasis on helmet use, safe riding practices, and understanding vehicle limitations
Oil Change Interval:
Every 50 hours or annually (verify in manual)
Air Filter Cleaning:
Every 20 hours or as needed based on conditions (verify in manual)
Spark Plug Replacement:
Every 100 hours or annually (verify in manual)
Pvt Belt Inspection:
Every 25 hours (verify in manual)
Engine Oil Type:
Polaris 2-stroke oil or equivalent high-quality 2-stroke oil (pre-mix)
Cooling System Coolant:
Ethylene glycol-based antifreeze (e.g., Prestone or equivalent) mixed 50/50 with distilled water
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid (verify in manual)
Common Wear Item:
PVT Belt (prone to wear and breakage if overloaded or damaged)
Common Issue 1:
Carburetor adjustments and cleaning due to fuel quality or debris
Common Issue 2:
Rear shock absorber leaks or failure over time due to off-road use
Common Issue 3:
Ignition coil or stator failure, leading to no-spark conditions
Importance Of Cleaning:
Crucial to keep air intake clean to prevent engine damage; thorough washing and drying after wet/muddy use.
Brand Origin:
Polaris Inc., founded in 1954, Minnesota, USA
Brand Specialization:
Powersports vehicles, including ATVs, snowmobiles, and motorcycles
Xplorer Line Introduction:
The Xplorer line was introduced as Polaris's more trail-oriented and performance-focused ATVs, often featuring independent rear suspension on later models.
Xplorer 400 Positioning:
The Xplorer 400 filled a niche for a capable, mid-sized 4x4 ATV that offered a balance of power and maneuverability.
Production Period:
1996-1998
Manufacturing Location:
United States (typically Spirit Lake, Iowa or Roseau, Minnesota for Polaris)
Industry Awards:
Not specifically documented for individual model years of this ATV, but Polaris received industry recognition for its ATV innovations during this period.
Consumer Ratings:
Generally positive for its class, known for robust performance and good value in its time.
Manufacturing Certifications:
ISO 9001 (Polaris corporate quality standard)
