Target Audience:
Owners, mechanics, and service centers for the 2000 Polaris Xplorer 400 ATV.
Utility Segment:
Positioned as a utility ATV, capable of various off-road tasks and recreational use.
Competitors At Launch:
Honda FourTrax, Yamaha Big Bear, Suzuki QuadRunner, Kawasaki Bayou.
Engine Type:
Two-stroke, liquid-cooled engine.
Drive System:
Shaft-driven, selectable 2WD/4WD.
Suspension Type:
Independent front suspension (IFS), swingarm rear suspension.
Overall Coverage:
Comprehensive service, repair, and maintenance information for the 2000 Polaris Xplorer 400 ATV.
Engine Coverage:
Engine disassembly, assembly, tuning, diagnostics, and repair.
Transmission Coverage:
Transmission system inspection, maintenance, and repair.
Drivetrain Coverage:
Front and rear drive systems, differentials, and CV joints.
Suspension Coverage:
Front and rear suspension components, shock absorbers, and linkages.
Braking System Coverage:
Brake system maintenance, bleeding procedures, caliper, and master cylinder repair.
Electrical System Coverage:
Wiring diagrams, ignition system, charging system, lighting, and starter motor.
Fuel System Coverage:
Carburetor adjustment and cleaning, fuel pump, and fuel lines.
Cooling System Coverage:
Radiator, hoses, coolant, and fan system.
Body And Frame Coverage:
Body panel removal and installation, frame inspection, and seat components.
Troubleshooting Coverage:
Diagnostic procedures for common problems and fault finding.
Type:
Workshop Service Manual
Format:
Digital (likely PDF, searchable)
All Major Systems:
Yes, covers all essential mechanical and electrical systems of the vehicle.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, lubrication.
Repair Procedures:
Step-by-step instructions for component repair and replacement.
Diagnostic Procedures:
Troubleshooting guides and flowcharts for identifying and resolving issues.
Assembly Disassembly:
Detailed instructions for taking apart and reassembling various components.
Depth:
Mechanic-level detail, suitable for professional technicians and experienced DIYers.
Engine Configuration:
Single-cylinder, 2-stroke
Bore X Stroke:
66.0 mm x 72.0 mm
Cooling System:
Liquid-cooled
Ignition System:
CDI (Capacitor Discharge Ignition)
Starting System:
Electric Start with Recoil Backup
Horsepower:
Approximately 26 hp (estimated based on similar models)
Torque:
Not explicitly published, but significant low-end torque for utility.
Carburetor:
Mikuni VM34SS (likely)
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Fuel Mixture:
Automatic oil injection system for pre-mixing oil and fuel.
Atv Safety Standards:
Meets ANSI/SVIA standards for recreational trail riding.
Braking System:
Hydraulic disc brakes front and rear.
Parking Brake:
Yes, hand-operated.
Lighting:
Dual headlights, taillight/brake light.
Throttle Limiter:
Thumb throttle with safety return spring.
Engine Oil Change Interval:
Every 25 hours or annually (check manual for exact interval).
Air Filter Cleaning:
Every 10-15 hours or as needed depending on conditions.
Spark Plug Replacement:
Every 100 hours or annually.
Transmission Fluid Change:
Every 100 hours or annually.
Engine Oil Type:
Polaris 2-stroke Premium Synthetic Oil (or equivalent meeting API TC and ISO-L-EGD specifications)
Engine Oil Capacity:
N/A (2-stroke, mixed with fuel)
Cooling System Coolant:
Ethylene Glycol based antifreeze (50/50 mix with distilled water).
Transmission Fluid Type:
Polaris CVT Fluid (specific part number required, check manual).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Carburetor Clogging:
Common with 2-stroke engines if not run regularly or with stale fuel; requires cleaning.
Starter Solenoid Failure:
Can be a point of failure on older models; manual provides testing procedures.
Cvt Belt Wear:
Normal wear and tear; manual covers inspection and replacement procedures.
Suspension Bushings:
Wear can lead to clunking or poor handling; manual details replacement.
Polaris Atv History:
Polaris has been a pioneer in the ATV market since the 1980s, known for innovation and performance.
Xplorer Lineage:
The Xplorer line focused on comfort, independent suspension, and utility for a broader range of riders.
Manufacturing Location:
USA (Roseau, Minnesota)
Production Years:
Polaris produced the Xplorer 400 from the mid-1990s through the early 2000s, with the 2000 model being a significant iteration.
