Market Segment:
Recreational and utility All-Terrain Vehicle (ATV) segment, targeting users seeking robust performance and ease of maintenance.
Comparative Advantage:
The 2001 Polaris Xplorer 400 is positioned as a reliable and mechanically straightforward ATV, appealing to owners who prefer DIY maintenance and repairs, differentiating itself through its robust design and accessible componentry.
Diy Maintenance Focus:
This manual is specifically designed to empower ATV owners with the information necessary for home maintenance and repair, emphasizing the machine's ease of serviceability and the cost-saving benefits of DIY upkeep.
Comprehensive Part Listing:
Features a complete catalog of all replaceable parts, vital for accurate ordering and ensuring the correct components are used during maintenance and repair.
Systems Covered:
Engine, drivetrain, suspension, steering, braking, fuel system, cooling system, electrical system, chassis components, bodywork, accessories.
Manual Type:
Parts Manual
Engine And Internals:
Piston, crankshaft, crankcase, cylinder, oil pump, carburetor, recoil starter, magneto, starting motor.
Drivetrain And Transmission:
Front drive, front tightener, CV joints, drive clutch, driven clutch, clutch cover, gearcase, rear wheel drive, gear selector.
Chassis And Suspension:
Front strut, front wheel, front brake, A-arm/strut mounting, center tightener, swing arm/shock mounting, rear wheel, rear brake.
Controls And Steering:
Throttle assembly/cable, master cylinder/brake line, steering post, handlebar, headlight pod.
Body And Accessories:
Front cab, rear cab and seat, rear rack mounting, decals, front rack and bumper mounting, tool kit.
Cooling And Fuel Systems:
Cooling system components, fuel tank, oil tank, air box.
Part Identification:
Comprehensive exploded diagrams and part number lists for accurate component identification.
Technical Depth:
Detailed component breakdown for parts replacement, assembly verification, and component sourcing.
File Format:
Portable Document Format (PDF)
Print Quality:
High-resolution, suitable for clear printing of individual pages or sections.
Binding Type:
N/A (Digital Download - Printable)
Paper Type:
N/A (Digital Download - User Selectable)
Engine Type:
Liquid-cooled, 2-stroke, 1-cylinder (specific displacement varies by exact sub-model, but commonly around 375-400cc for the '400' designation).
Estimated Horsepower:
Approximately 29-32 HP (manufacturer specification may vary).
Estimated Torque:
Refer to specific service manual for exact torque figures, but generally designed for strong low-end and mid-range torque for utility applications.
Fuel Delivery:
Carbureted (typically a Mikuni VM series or similar).
Fuel Type:
Unleaded gasoline (Octane rating as per owner's manual, typically 87 or higher).
Oil System:
Autolube (oil injection system for 2-stroke oil).
Ignition System:
CDI (Capacitor Discharge Ignition) with magneto.
Transmission Type:
Automatic (Polaris Variable Transmission - PVT).
Drive System:
Shaft drive to rear differential, and likely a chain or shaft drive to front differential depending on 2WD/AWD configuration.
Gear Selection:
Forward, Neutral, Reverse (F-N-R).
Wheelbase:
Typically around 48-50 inches (refer to specific model variant for exact dimensions).
Dry Weight:
Approximately 550-600 lbs (refer to specific model variant for exact dimensions).
Towing Capacity:
Varies, often rated for light to moderate towing (refer to owner's manual).
Front Tire Size:
Commonly 22x8-10 or similar.
Rear Tire Size:
Commonly 22x11-10 or similar.
Atv Safety Standards:
Designed to meet applicable ANSI (American National Standards Institute) standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear, offering strong stopping power.
Operator Safety:
Emphasis on responsible riding practices, proper gear, and adherence to trail regulations as highlighted in the owner's manual (though this parts manual focuses on components).
Oil Change Interval:
Refer to owner's manual; typically every 50-100 hours of operation or annually for the transmission/gearcase oil. Engine oil (for 2-stroke premix or injection) is consumed with fuel. Spark plug inspection/replacement interval is critical.
Gearcase Oil:
Polaris Demand Drive Fluid or equivalent SAE 80W-90 gear oil (verify specific manual for exact spec).
Cooling System Coolant:
Permanent type antifreeze/coolant, typically a 50/50 mix with distilled water. Specific Polaris coolant recommended.
2 Stroke Oil:
High-quality 2-stroke synthetic or semi-synthetic oil specifically formulated for liquid-cooled, oil-injected engines (e.g., Polaris Premium 2-Stroke Oil).
Carburetor Maintenance:
Carburetors on older 2-stroke ATVs can be prone to clogging if fuel is left sitting. Regular fuel stabilizer use and periodic cleaning are recommended.
Cooling System Performance:
Overheating can be an issue if the radiator fins are clogged with debris or if the coolant level is low. Regular cleaning and coolant checks are vital.
Drive Belt Wear:
The CVT drive belt is a wear item. Inspect for cracks, fraying, or glazing. Replacement is necessary to maintain performance and prevent catastrophic failure.
Suspension Bushings:
Rubber bushings in the A-arms and other suspension components can wear over time, leading to play and reduced handling. This manual will help identify replacement parts for these wear items.
Carburetor Part Numbers:
Manual lists specific part numbers for carburetor components (jets, needles, gaskets) for precise replacement.
Brake Pad Part Numbers:
Provides part numbers for front and rear brake pads for easy sourcing.
Clutch Component Numbers:
Includes part numbers for primary and secondary clutch components, allowing for targeted repairs or upgrades.
Polarishistory:
Polaris Industries has a long history in the powersports industry, known for its innovation in ATVs, snowmobiles, and other recreational vehicles. The Xplorer line was part of their offering for versatile all-terrain use.
Xplorer Lineage:
The Xplorer series generally represented Polaris's more utility-focused or long-travel suspension ATVs, offering a blend of recreational capability and work-oriented features. The 400cc engine size was a popular displacement for this class.
Production Era:
The 2001 model year falls within a period where Polaris was refining its ATV offerings, with this model contributing to their market presence in the mid-size utility ATV segment.
