Market Segment:
Recreational ATV, aimed at utility and trail riding
Competitors:
Yamaha Wolverine, Arctic Cat Bearcat, Honda FourTrax
Vehicle Features:
4x4 drivetrain, MacPherson strut front suspension, independent rear suspension, liquid-cooled engine
Value:
Enables DIY maintenance and repair, saving on dealership costs and increasing vehicle longevity.
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
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
Depth:
Comprehensive, covering basic maintenance to complete engine and component rebuilds
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)
Ignition:
CDI (Capacitor Discharge Ignition)
Horsepower:
Approx. 28 HP (at 6000 rpm)
Torque:
Approx. 27 ft-lbs (at 5000 rpm)
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)
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water recommended)
Atv Safety Standards:
ANSI/SVIA standards compliance
Braking System:
Hydraulic disc brakes (front and rear)
Lighting:
Halogen headlights, taillight, brake light
Hand Guards:
Integrated hand guards for rider protection
Footwells:
Full floorboards with raised toe kick for foot protection
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
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
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
Brand History:
Polaris Industries, founded in 1954, has a long history of producing powersports vehicles, including ATVs.
Model Lineage:
The Xplorer line was known for its comfort and utility, with the 400 being a popular mid-size option.
Production Era:
Late 1990s to early 2000s