Your shopping cart
😊 Product added to cart successfully   Product removed to cart successfully
Your shopping cart is empty!
Continue shopping
1 of 2

Polaris Xplorer 400 1999 Service Repair Manual

Regular price
$16.99
Sale price
$16.99
Regular price
The 1999 Polaris Xplorer 400 is a mid-size utility all-terrain vehicle (ATV) designed for recreational trail riding and light-duty work. Known for its torquey 2-stroke, 2-cylinder liquid-cooled engine and capable...
16 people are viewing this right now
Type: Atv
Vendor:
Sku: 101234
Polaris Xplorer 400 1999 Service Repair Manual
The 1999 Polaris Xplorer 400 is a mid-size utility all-terrain vehicle (ATV) designed for recreational trail riding and light-duty work. Known for its torquey 2-stroke, 2-cylinder liquid-cooled engine and capable independent front suspension, this model offered a robust package for its era. It competed in the utility ATV market, providing features like a decent towing capacity and sturdy racks, making it suitable for activities such as hunting and general farm use. The Xplorer line was developed by Polaris to offer a more performance-oriented option within their ATV lineup, distinguishing itself with its engine power and suspension design during a period when 2-stroke engines were prevalent in ATVs. This comprehensive Factory Service Manual (FSM) provides detailed repair and maintenance information for the 1999 Polaris Xplorer 400 ATV. It covers a wide array of systems, including the engine, transmission (PVT), drivetrain, suspension, brakes, electrical system, fuel system, cooling system, exhaust system, and body/frame. The manual includes step-by-step repair procedures, diagnostic guides, adjustment procedures, and preventive maintenance schedules. Its purpose is to assist owners, mechanics, and technicians in effectively maintaining and repairing the vehicle, ensuring optimal performance and longevity. The digital format allows for easy searching and access to crucial technical data, torque specifications, and clear diagrams.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Xplorer 400
Year:
1999
Product Type:
Service Repair Manual
👋 Introduction
Market Position
Market Segment:
Mid-size utility ATV, positioned for recreational and light-duty work.
Competitive Analysis
Competitors:
Competed with models from Yamaha (Kodiak), Honda (FourTrax), and Suzuki (King Quad) in the utility ATV market of the late 1990s.
Key Features
Performance Focus:
Known for its torquey 2-stroke engine and capable independent front suspension.
Utility Design:
Designed for trail riding, hunting, and general farm use with features like a decent towing capacity and racks.
Manual Advantage
Digital Format Benefit:
PDF format allows for easy searching, digital storage, and printing of specific sections as needed, offering an advantage over older paper manuals.
📋 Manual Details
Coverage Areas
Overall Coverage:
Comprehensive repair and maintenance for the 1999 Polaris Xplorer 400 ATV.
Page Count
Estimated Page Count:
300-400
Manual Type
Manual Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, including disassembly, inspection, assembly, tuning, and troubleshooting for the 2-stroke liquid-cooled engine.
Transmission:
Detailed procedures for the PVT (Polaris Variable Transmission), including belt inspection and replacement, clutch assembly, and gearbox maintenance.
Drivetrain:
Front and rear differential maintenance, driveshaft inspection, universal joint servicing, and hub bearing replacement.
Suspension:
Front and rear suspension system repair, shock absorber servicing, swingarm bushings, and steering linkage components.
Brakes:
Hydraulic brake system service, including caliper disassembly, brake pad replacement, fluid bleeding, master cylinder repair, and component inspection.
Electrical System:
Complete wiring diagrams, troubleshooting guides for lighting, ignition system, starter, charging system (stator and regulator/rectifier), and accessory circuits.
Fuel System:
Carburetor (Mikuni VM34) overhaul, cleaning, jetting, fuel line maintenance, fuel pump (if applicable), and fuel tank servicing.
Cooling System:
Radiator maintenance, fan operation, coolant types and specifications, and water pump seal inspection.
Exhaust System:
Exhaust pipe and muffler inspection, leak detection, and basic repair procedures.
Body And Frame:
Body panel removal and installation, frame inspection for damage, plastic component repair, and seat assembly.
Procedures Included
Preventive Maintenance:
Detailed maintenance schedules, lubrication points, and regular inspection checklists.
Troubleshooting:
Systematic troubleshooting guides for common starting, running, electrical, and drivetrain issues.
Repair Procedures:
Step-by-step repair instructions with torque specifications and critical clearances for all major components.
Diagnostic Procedures:
Methods for diagnosing ignition system problems, fuel delivery issues, and mechanical wear.
Adjustment Procedures:
Carburetor adjustments, throttle cable adjustments, brake lever free play settings.
Technical Depth
Depth:
Comprehensive, covering from basic fluid changes and inspections to complete engine and transmission rebuilds, electrical system diagnostics, and frame repairs.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, searchable text and clear, legible diagrams.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, 2-cylinder, liquid-cooled
Displacement:
375 cc
Bore X Stroke:
61 mm x 65 mm
Compression Ratio:
6.8:1
Fuel Delivery:
Mikuni VM34 carburetor
Performance
Horsepower:
Approximately 28-30 hp (estimated)
Torque:
Not explicitly stated, but known for good low-end torque
Fuel System
Fuel Type:
Unleaded gasoline (87 octane minimum)
Oil Mixture:
50:1 ratio with 2-stroke oil for the injection system.
🔧 Transmission
Standard
Transmission Type:
Polaris Variable Transmission (PVT)
Drive Modes:
2WD/4WD automatic with locking front differential
Features
Gear Reduction:
High and Low range, Neutral, Reverse
Clutch Type:
Centrifugal clutch with belt drive
📐 Dimensions
Exterior
Length:
Approx. 77 inches
Width:
Approx. 46 inches
Height:
Approx. 46 inches
Weights
Dry Weight:
Approx. 510 lbs
Towing Capacity:
650 lbs
Rack Capacity Front:
30 lbs
Rack Capacity Rear:
60 lbs
🛡️ Safety Features
Ratings
Atv Safety Standards:
Adheres to ANSI (American National Standards Institute) standards for ATVs.
Active Features
Braking System:
Hydraulic disc brakes, front and rear.
Passive Features
Throttle Limiter:
Thumb throttle with safety mechanism.
Kill Switch:
Handlebar-mounted emergency stop switch.
Lighting:
Headlights and taillight for visibility.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic utility ATV, no integrated infotainment).
Driver Assistance
Driver Assistance Features:
N/A (Basic utility ATV, no electronic driver aids).
Connectivity
Connectivity Features:
N/A (Basic utility ATV, no electronic connectivity).
🔧 Maintenance
Service Intervals
Oil Change:
Every 20-30 hours or annually. Check owner's manual for specific recommendations.
Air Filter:
Clean/inspect every 10-20 hours, replace as needed.
Spark Plug:
Inspect and gap every 15-25 hours, replace as needed (NGK BR8ES or equivalent).
Drive Belt:
Inspect every 20 hours for wear and damage, replace at first sign of fraying or glazing.
Fluid Specifications
Engine Oil:
Polaris 2-Stroke Synthetic or equivalent 50:1 pre-mix oil.
Transmission Fluid:
Polaris Demand Drive Fluid or SAE 30W API GL-4 gear oil for the front differential. Rear differential (if applicable) and gearbox typically use SAE 30W or 80W-90 gear oil. (Refer to manual for specific quantities and types).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Carburetor Clogging:
Common with stored fuel; requires regular cleaning and use of fuel stabilizer.
Voltage Regulator Failure:
Can lead to charging system issues or battery drain.
Pvt Belt Wear:
Regular inspection and timely replacement are crucial to prevent drivetrain damage.
Cooling System Leaks:
Check hoses, radiator, and water pump seal for integrity.
📚 Vehicle History
Brand Heritage
Polaris Atv History:
Polaris has been a significant player in the ATV market since the introduction of the Scrambler and Trail Boss models, continuously innovating in the off-road vehicle sector.
Model Evolution
Xplorer Lineage:
The Xplorer line was introduced to offer a more specialized and performance-oriented ATV compared to some of Polaris's utility-focused models, often featuring independent front suspension and more powerful engines for its time.
Production
Manufacturing Era:
The 1999 model year falls within the peak era of 2-stroke engine dominance in the ATV market before the shift towards 4-stroke power.
🏆 Awards & Recognition
Recognitions
Atv Industry Awards:
Specific awards for the 1999 Polaris Xplorer 400 are not widely documented, but Polaris consistently received recognition for its innovative ATV designs during this period.
Ratings
Consumer Reviews:
Generally well-regarded for its power and suspension by users of the era, though 2-stroke maintenance requirements were a factor.
Sale

Unavailable

Sold Out