Segment:
Mid-size utility ATV, positioned for recreational and light work use.
Competitors:
Competed against models like the Yamaha Wolverine, Honda Foreman (earlier generations), and Suzuki QuadRunner in its class.
Features Overview:
Known for its reliable 2-stroke engine, decent power output for its class, and capable suspension for its time. Often featured a selectable 2WD/4WD system (though some base models were 2WD).
Powertrain:
Engine (2-stroke, single-cylinder, liquid-cooled), transmission, clutch, driveshaft, differentials.
Chassis And Suspension:
Frame, front and rear suspension (A-arms, shocks, springs), steering system, wheels, tires.
Braking System:
Hydraulic disc brakes (front and rear), brake lines, master cylinders, calipers.
Electrical System:
Ignition system, lighting (headlights, taillights, brake lights), battery, charging system (stator, regulator/rectifier), starter motor, wiring diagrams, switches, sensors.
Fuel And Exhaust:
Fuel tank, fuel lines, carburetor, exhaust system (muffler, pipe).
Cooling System:
Radiator, fan, coolant hoses, thermostat, water pump.
Bodywork And Trim:
Body panels, fenders, seat, handlebars, rack systems.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, spark plug service, carburetor cleaning and adjustment, chain adjustment.
Troubleshooting:
Diagnostic charts for common problems (engine performance, electrical faults, braking issues), step-by-step diagnostic procedures.
Repair:
Engine overhaul (piston, rings, cylinder, crankshaft, bearings), transmission repair, brake caliper rebuild, suspension component replacement, electrical component diagnosis and replacement.
Disassembly And Assembly:
Detailed instructions for the removal, inspection, repair, and reinstallation of all major components and sub-assemblies.
Depth:
Comprehensive, covering everything from basic adjustments and routine maintenance to complete engine rebuilds and advanced electrical system diagnostics. Includes torque specifications, clearances, and detailed procedures.
Engine Type:
2-Stroke, Single Cylinder
Displacement:
375cc (approx.)
Cooling System:
Liquid-cooled
Bore X Stroke:
Technical specification available in manual (e.g., 84mm x 68mm).
Horsepower:
Estimated 25-30 HP (figures vary based on exact tuning and measurement).
Torque:
Estimated 28-32 lb-ft.
Carburetor:
Mikuni VM34SS (typical for this engine).
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Fuel Mixture:
Requires 2-stroke oil mixed with gasoline (check manual for exact ratio, typically 40:1 or 50:1).
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse (H-L-N-R)
Drive System:
Selectable 2WD/4WD (often referred to as Polaris Variable Transmission - PVT).
Final Drive:
Shaft Drive (front and rear).
Clutch Type:
Automatic Centrifugal Clutch with V-belt Drive
Length:
Approx. 78 inches (198 cm)
Width:
Approx. 45 inches (114 cm)
Height:
Approx. 45 inches (114 cm)
Dry Weight:
Approx. 530 lbs (240 kg)
Ground Clearance:
Approx. 8.5 inches (21.6 cm)
Front Rack Capacity:
Approx. 50 lbs (22.7 kg)
Rear Rack Capacity:
Approx. 100 lbs (45.4 kg)
Towing Capacity:
Often rated for towing up to 1500 lbs (680 kg) with an appropriate hitch and trailer.
Safety Standards:
Designed to meet industry standards for ATVs, though formal crash ratings like automotive are not applicable.
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Handlebars:
Handlebar grips and control layout designed for operator stability.
Lighting:
Headlights, taillight, and brake light for visibility.
Oil Change Engine:
Every 50 hours or annually. Check manual for specific recommendations.
Air Filter Cleaning:
Inspect every 20 hours, clean as needed. Replace annually or sooner if damaged.
Spark Plug Inspection:
Every 100 hours or annually. Replace as needed based on condition.
Clutch Inspection:
Inspect belt and clutch sheaves every 100 hours or annually.
Engine Oil Type:
Polaris recommends specific 2-stroke injection oil or a high-quality TC-W3 marine 2-stroke oil for the oil injection system. For pre-mix, use 2-stroke engine oil compliant with API-TC specifications.
Gearcase Oil:
SAE 80W-90 hypoid gear lubricant. Polaris part number 2870632 (or equivalent).
Coolant:
Ethylene Glycol based antifreeze with corrosion inhibitors. A 50/50 mixture with distilled water is standard. Polaris part number 5030062 (or equivalent).
Carburetor Fouling:
Common with 2-stroke engines, especially if left to sit with old fuel. Requires periodic cleaning and adjustment.
Cvt Belt Wear:
The CVT belt can wear over time and require replacement to maintain proper power transmission. Regular inspection is crucial.
Ignition System Reliability:
While generally reliable, older ignition coils or stators can sometimes fail. The manual provides diagnostic procedures.
Suspension Bushings:
Like many ATVs of this era, suspension bushings can wear out, leading to play and a less precise feel. Manual details replacement.
Manufacturer:
Polaris Industries Inc. is a prominent American manufacturer of powersports vehicles, known for its snowmobiles, ATVs, and motorcycles.
Model Line:
The Xplorer line was part of Polaris's off-road vehicle lineup, typically focused on utility and trail riding. It preceded or ran concurrently with other Polaris utility models like the Sportsman.
Production Era:
The Polaris Xplorer 400 was produced during the late 1990s and early 2000s, representing a period of growth and refinement in Polaris's ATV offerings.
