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Polaris Xplorer 400 2000 Factory Service Repair Manual

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$16.99
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The Polaris Xplorer 400, produced around the year 2000, is a versatile All-Terrain Vehicle (ATV) designed for recreational use, utility tasks, and trail riding. This model features a robust 2-stroke,...
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类型: Atv
厂商:
斯库: 100790
Polaris Xplorer 400 2000 Factory Service Repair Manual
The Polaris Xplorer 400, produced around the year 2000, is a versatile All-Terrain Vehicle (ATV) designed for recreational use, utility tasks, and trail riding. This model features a robust 2-stroke, liquid-cooled, 2-cylinder engine displacing 398cc, delivering approximately 28 horsepower and 27 ft-lbs of torque. Its engineering highlights include a 4x4 drivetrain, MacPherson strut front suspension, independent rear suspension, and a Variable Transmission with high, low, neutral, and reverse modes. With a 7.5-inch ground clearance and a towing capacity of 1500 lbs, the Xplorer 400 is built for demanding conditions, offering a blend of capability and rider protection through features like integrated hand guards and full floorboards. This comprehensive factory service repair manual in English provides complete service and repair information for the Xplorer 400 (chassis code A00CN42AA). It covers all essential systems, including detailed procedures for engine overhaul, transmission service, drivetrain maintenance, suspension and brake system repairs, steering, electrical diagnostics, fuel system adjustments, and cooling system servicing. The manual also includes scheduled maintenance guidelines, troubleshooting charts for common issues, and precise technical specifications such as torque values and fluid capacities. Its purpose is to empower owners and technicians with the knowledge required for effective maintenance and repair, ensuring the longevity and optimal performance of the vehicle.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Xplorer 400
Year:
2000
Vehicle Type:
All-Terrain Vehicle (ATV)
Codes
Chassis Code:
A00CN42AA
👋 Introduction
Market Position
Market Segment:
Recreational ATV, aimed at utility and trail riding
Competitive Analysis
Competitors:
Yamaha Wolverine, Arctic Cat Bearcat, Honda FourTrax
Key Features
Vehicle Features:
4x4 drivetrain, MacPherson strut front suspension, independent rear suspension, liquid-cooled engine
Manual Value Proposition
Value:
Enables DIY maintenance and repair, saving on dealership costs and increasing vehicle longevity.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Page Count
Estimated Pages:
Hundreds (Specific count not provided, but implies comprehensive coverage)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnosis, and component testing
Transmission:
Automatic transmission operation, disassembly, assembly, and adjustment
Drivetrain:
Front and rear drive systems, differentials, drive shafts, and CV joints
Suspension:
Front and rear suspension components, shocks, springs, bushings, and alignment
Brakes:
Hydraulic brake system, calipers, master cylinder, lines, bleeding procedures, and pad replacement
Steering:
Steering column, tie rods, steering rack, and universal joints
Electrical:
Ignition system, charging system, lighting, starter, battery, wiring diagrams, and component testing
Fuel System:
Carburetor tuning and overhaul, fuel lines, fuel pump, and fuel tank
Cooling System:
Radiator, fan, hoses, thermostat, and coolant specifications
Exhaust System:
Muffler, exhaust pipe, and mounting components
Bodywork:
Panel removal and installation, body trim, and plastics
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points
Troubleshooting:
Diagnostic flowcharts, common problems and solutions, symptom-based diagnosis
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly
Adjustment:
Carburetor, idle speed, brake adjustments, clutch adjustments
Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and component rebuilds
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, suitable for printing individual pages or the entire manual
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, liquid-cooled, 2-cylinder
Displacement:
398cc (24.3 cubic inches)
Bore X Stroke:
62.0 mm x 64.0 mm (2.44 in x 2.52 in)
Compression Ratio:
6.5:1
Ignition:
CDI (Capacitor Discharge Ignition)
Performance
Horsepower:
Approx. 28 HP (at 6000 rpm)
Torque:
Approx. 27 ft-lbs (at 5000 rpm)
Fuel System
Carburetor Model:
Mikuni VM34SS (dual carburetors)
Fuel Type:
Unleaded gasoline (87 octane minimum)
Fuel Mixture:
Pre-mixed fuel (50:1 gasoline to 2-stroke oil ratio)
Cooling System
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water recommended)
🔧 Transmission
Standard
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Drive Modes:
High, Low, Neutral, Reverse
Features
Drive System:
Shaft Drive (4x4)
Clutch Type:
Centrifugal clutch with CVT belt drive
📐 Dimensions
Exterior
Length:
78.5 inches (1994 mm)
Width:
46.0 inches (1168 mm)
Height:
45.0 inches (1143 mm)
Wheelbase:
50.5 inches (1283 mm)
Ground Clearance:
7.5 inches (190.5 mm)
Weights
Dry Weight:
555 lbs (252 kg)
Fuel Capacity:
3.2 US gallons (12.1 L)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg)
🛡️ Safety Features
Ratings
Atv Safety Standards:
ANSI/SVIA standards compliance
Active Features
Braking System:
Hydraulic disc brakes (front and rear)
Passive Features
Lighting:
Halogen headlights, taillight, brake light
Hand Guards:
Integrated hand guards for rider protection
Footwells:
Full floorboards with raised toe kick for foot protection
💡 Technology Features
Infotainment
Infotainment Features:
Basic analog instrumentation (speedometer, odometer, fuel gauge, warning lights)
Driver Assistance
Assistance Features:
None (basic mechanical design)
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Engine:
Every 50 hours or annually (using pre-mix)
Air Filter Cleaning:
Every 20 hours or as needed based on conditions
Spark Plug Inspection:
Every 50 hours
Cvt Belt Inspection:
Every 100 hours or annually
Fluid Specifications
Transmission Fluid Type:
Polaris AGL Premium Synthetic Gearcase Lubricant (or equivalent SAE 80W-90 GL-5)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
2-Stroke Oil Type:
API-TC rated synthetic 2-stroke oil for air-cooled engines
Known Issues
Common Problems:
Carburetor tuning sensitivity, CVT belt wear, ignition coil failures, starter motor issues
Preventative Measures:
Regular cleaning of carburetors, proper clutch maintenance, consistent use of quality 2-stroke oil
📚 Vehicle History
Brand Heritage
Brand History:
Polaris Industries, founded in 1954, has a long history of producing powersports vehicles, including ATVs.
Model Evolution
Model Lineage:
The Xplorer line was known for its comfort and utility, with the 400 being a popular mid-size option.
Production
Production Era:
Late 1990s to early 2000s
🏆 Awards & Recognition
Recognitions
Industry Awards:
Not specifically documented for the 2000 model year, but Polaris ATVs generally received positive reviews for performance and reliability in their segment.
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