Category:
Sport/Utility ATV
Target Audience:
Recreational riders, hunters, and general utility users.
Competitors:
Yamaha Wolverine, Honda FourTrax, Kawasaki Bayou.
Features:
Robust chassis, reliable engine, versatile for trail riding and utility tasks.
Purpose:
To provide comprehensive technical guidance for the maintenance, repair, and troubleshooting of the Polaris Xplorer 400 ATV, enabling owners to perform a wide range of service tasks.
Engine Mechanical:
Comprehensive coverage including disassembly, inspection, repair, and reassembly of engine components (cylinder, piston, crankshaft, connecting rods, valve train).
Engine Fuel System:
Carburetor service, fuel pump operation, fuel lines, and fuel tank maintenance.
Engine Ignition System:
Ignition coil, spark plug, CDI unit, and stator testing and replacement procedures.
Cooling System:
Radiator, fan, coolant, and thermostat service and troubleshooting.
Transmission Drive System:
CVT (Continuously Variable Transmission) operation, belt inspection/replacement, clutch service, and gearbox maintenance.
Drivetrain:
Front and rear driveshafts, differential, and wheel hub service.
Suspension:
Front and rear suspension components, shock absorbers, control arms, bushings, and steering linkage service.
Brakes:
Hydraulic brake system, master cylinder, brake calipers, brake pads, brake discs, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, starter motor, alternator, lighting system, and switchgear troubleshooting.
Frame And Bodywork:
Chassis inspection, seat removal, fender service, and plastics repair.
Routine Maintenance:
Oil changes, filter replacements, lubrication, chain adjustment (if applicable), and general inspections.
Troubleshooting:
Diagnostic flowcharts and guides for identifying and resolving common mechanical and electrical issues.
Major Repairs:
Complete engine rebuilds, transmission overhauls, and suspension component replacement.
Component Overhaul:
Detailed instructions for rebuilding carburetors, brake calipers, and other key assemblies.
Electrical Diagnostics:
Testing of electrical components, continuity checks, and troubleshooting of wiring faults.
Depth:
Comprehensive, covering everything from basic maintenance tasks to full engine and transmission rebuilds. Suitable for both DIY enthusiasts and professional mechanics.
Diagnostic Tools:
Likely includes specifications for basic tools and potentially some diagnostic procedures that may require specialized tools.
Torque Specifications:
Includes precise torque values for critical fasteners to ensure proper assembly and prevent damage.
Clearances And Tolerances:
Detailed specifications for critical component clearances and wear tolerances, essential for accurate repairs.
Format:
PDF (Portable Document Format)
Searchability:
Typically PDF manuals are text-searchable, allowing quick access to specific topics.
Quality:
N/A (Digital format, quality depends on original source and PDF creation).
Binding:
N/A (Digital format, no physical binding).
Paper:
N/A (Digital format, no physical paper).
Engine Type:
2-stroke, liquid-cooled
Bore X Stroke:
N/A (Specific bore/stroke not provided in product info)
Power Output:
Approximately 30-35 HP (estimated based on similar models of the era)
Torque:
N/A (Specific torque figures not provided in product info)
Carburetion:
Single Mikuni VM34 (typical for this model, specific confirmation required from manual)
Fuel Type:
Unleaded gasoline
Fuel Octane Rating:
87 octane (minimum recommended)
Ignition Type:
Electronic Ignition (CDI)
Oil Type:
2-stroke synthetic or semi-synthetic oil, meeting JASO FD or ISO-L-EGD specifications.
Oil Ratio:
50:1 (gasoline to oil mixture)
Length:
N/A (Specific dimensions not provided in product info)
Width:
N/A (Specific dimensions not provided in product info)
Height:
N/A (Specific dimensions not provided in product info)
Dry Weight:
N/A (Specific weight not provided in product info)
Ground Clearance:
N/A (Specific clearance not provided in product info)
Towing Capacity:
N/A (Towing capacity typically limited on ATVs of this era)
Front Tire Size:
N/A (Likely 22x7-10 or similar, manual will confirm)
Rear Tire Size:
N/A (Likely 22x10-10 or similar, manual will confirm)
Safety Certifications:
Likely meets relevant ATV safety standards of the time, but no specific ratings provided.
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Headlights, taillight, and brake light.
Rollover Protection:
N/A (ATVs of this era do not typically feature factory-installed ROPS systems).
Recommendations:
Manual will emphasize proper riding techniques, protective gear (helmet, gloves, boots), and awareness of surroundings.
Engine Oil Change:
Manual will specify intervals, typically every 20-40 hours of operation or annually.
Air Filter Cleaning:
Recommended every 10-20 hours of operation or more frequently in dusty conditions.
Spark Plug Inspection:
Recommended at every oil change or as per manual's schedule.
Cv Belt Inspection:
Crucial to inspect regularly, typically every 20-40 hours, for wear and damage. Replacement intervals vary based on usage.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Gearbox Oil:
Specific gear oil type and viscosity will be detailed in the manual, likely a SAE 80W-90 or similar.
Common Wear Items:
CVT belt wear, carburetor jetting issues, suspension bushing wear, and electrical connector corrosion.
2 Stroke Considerations:
Importance of correct oil-to-fuel ratio, spark plug fouling, and potential for carbon buildup in the exhaust and piston rings.
Brand Focus:
Polaris Industries is a long-standing manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles.
Xplorer Series:
The Xplorer line was positioned as a versatile sport/utility ATV, offering a balance of performance and comfort for various riding conditions.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States.
Model Context:
The Xplorer 400 was a significant model in Polaris's ATV lineup during the mid-to-late 1990s, contributing to the brand's growth in the ATV market.
