Polaris 400 Xplorer 1996-1998 Workshop Manual

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Type: Atv

Vendor:

Sku: 57020

Tags: 1996 1997 1998 400 Xplorer ATV Misc Polaris Powersports

Product variants

Description

This manual covers the Xplorer 400, produced between 1996 and 1998. The Xplorer 400 is an All-Terrain Vehicle (ATV) designed for outdoor enthusiasts, recreational riders, and utility users. It features a robust 398cc two-stroke, liquid-cooled engine with a Mikuni VM34SS carburetor and CDI ignition, delivering an estimated 25-30 horsepower. Its independent front suspension and swingarm rear suspension, combined with shaft drive and a 2WD system, provide capable performance on varied terrain. The vehicle is equipped with hydraulic disc brakes for reliable stopping power and features essential lighting for visibility. This comprehensive workshop repair manual provides detailed procedures for maintaining and repairing the Xplorer 400. It covers all major systems, including the engine, transmission, suspension, brakes, electrical system, fuel system, cooling system, exhaust system, and steering. Within its approximately 500-700 pages, you will find step-by-step repair instructions, disassembly and reassembly guidance, engine tuning procedures, and complete electrical schematics. The manual also includes troubleshooting tips, diagnostic flowcharts, and essential technical specifications such as torque values and clearances, making it an indispensable resource for owners and technicians alike.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Xplorer 400

Model Variant:

Production Years Covered:

1996, 1997, 1998

👋 Introduction

Market Position

Vehicle Segment:

All-Terrain Vehicle (ATV)

Target Audience:

Outdoor enthusiasts, recreational riders, utility users

Competitive Analysis

Competitors:

Yamaha Warrior, Suzuki Quadsport, Honda FourTrax

Key Features

Powertrain Type:

Two-stroke, liquid-cooled engine

Suspension Type:

Independent front suspension, swingarm rear suspension

Drive System:

Shaft drive, 2WD

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Repair Manual

Scope:

Comprehensive repair and maintenance procedures

Page Count

Estimated Page Count:

Approximately 500-700 pages (typical for this era of detailed workshop manuals)

Manual Type

Manual Type:

Workshop Manual / Service Manual

Language

Language:

English

Format

Format:

PDF Download

Manual Specifications

File Format:

Print Quality:

High-resolution scans, suitable for printing

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Detailed engine overhaul, tuning, and diagnostics

Transmission:

Clutch, gearbox, and drivetrain servicing

Suspension:

Front and rear suspension component inspection, repair, and alignment

Brakes:

Brake system diagnosis, fluid service, caliper and master cylinder repair

Electrical System:

Wiring diagrams, component testing, starter, ignition, lighting, and charging systems

Fuel System:

Carburetor tuning and overhaul, fuel pump and lines

Cooling System:

Radiator, fan, thermostat, and coolant system maintenance

Exhaust System:

Muffler and pipe inspection and replacement

Steering System:

Handlebar, tie rods, and steering column components

Body Chassis:

Frame inspection, body panel removal/installation, and seat servicing

Procedures Included

Maintenance:

Scheduled maintenance, lubrication, filter changes, and general upkeep

Troubleshooting:

Diagnostic flowcharts and symptom-based problem solving

Repair:

Step-by-step repair instructions for all major components

Disassembly Reassembly:

Detailed instructions for component removal and installation

Engine Tuning:

Carburetor adjustment, ignition timing, and performance optimization

Wiring Diagrams:

Complete electrical schematics for all circuits

Technical Depth

Depth:

Comprehensive, covering from basic checks to complete engine rebuilds

Diagnostics:

Advanced diagnostic procedures and specifications

Specifications Data:

Provides all necessary torque specifications, clearances, and tolerances for repairs

Manual Specifications

Searchability:

Likely text-searchable PDF for quick information retrieval

Diagrams Illustrations:

Includes detailed diagrams, exploded views, and illustrations for clarity

Parts Catalog Integration:

Often cross-references to part numbers for ordering replacements

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled, reed valve

Displacement:

398cc

Bore X Stroke:

80.0 mm x 78.0 mm

Compression Ratio:

6.2:1

Carburetor:

Mikuni VM34SS

Ignition:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower Est:

~25-30 HP (estimated)

Torque Est:

~25-30 lb-ft (estimated)

Fuel System

Fuel Type:

Unleaded gasoline, 87 octane minimum (pre-mix with 2-stroke oil)

Fuel Delivery:

Carburetor

Oil Type:

API-TC or JASO FD certified 2-stroke oil

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive Select:

Features

Gear Reduction:

Forward, Neutral, Reverse

Clutch Type:

Centrifugal wet clutch

Final Drive:

Shaft Drive

📐 Dimensions

Exterior

Length:

Approximately 71.6 inches (1818 mm)

Width:

Approximately 45.0 inches (1143 mm)

Height:

Approximately 43.3 inches (1100 mm)

Wheelbase:

Approximately 48.5 inches (1232 mm)

Weights

Dry Weight:

Approximately 425 lbs (193 kg)

Ground Clearance:

Approximately 5.0 inches (127 mm)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Compliant with applicable ANSI/SVIA standards for recreational ATVs

Active Features

Braking System:

Hydraulic disc brakes front and rear

Parking Brake:

Handlebar lever operated

Passive Features

Lighting:

Headlights, taillight/brake light

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic controls typical for this era of ATV)

Driver Assistance

Assistance Features:

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Engine:

Refer to manual for specific intervals; typically every 20-40 hours or annually for 2-stroke pre-mix.

Air Filter Cleaning:

Inspect and clean every 10-20 operating hours, replace as needed.

Spark Plug Replacement:

Inspect every 20 hours, replace as needed. Use specified plug type.

Brake Fluid Flush:

Recommended every 12-24 months or as per manual.

Clutch Inspection:

Inspect clutch sheaves and belt at regular intervals as specified in the manual.

Cooling System Flush:

Recommended every 24 months to prevent corrosion and maintain cooling efficiency.

Fluid Specifications

Engine Oil Type:

API-TC or JASO FD certified 2-stroke oil

Gear Oil Type:

API GL-4, SAE 80W-90 hypoid gear oil

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Known Issues

Common Wear Items:

CVT belt, brake pads, suspension bushings, carburetor jets

Engine Considerations:

Proper pre-mix ratio is critical for 2-stroke engine longevity; carbon buildup in exhaust ports can occur if not maintained.

📚 Vehicle History

Brand Heritage

Brand Focus:

Polaris Industries is a long-standing manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles.

Model Evolution

Xplorer Lineup:

The Xplorer line was Polaris's entry into the utility and recreational ATV market, known for their ruggedness and capability.

Production

Manufacturing Location:

USA (Polaris manufacturing facilities)