Segment:
Entry-to-mid level All-Terrain Vehicle (ATV) designed for recreational use and light utility tasks.
Competitors Era:
Competed against other 400cc class ATVs from brands like Yamaha (Warrior, Kodiak), Suzuki (King Quad), Kawasaki (Bayou), and Honda (FourTrax).
Powertrain Type:
Two-stroke engine, known for its power-to-weight ratio and simplicity.
Transmission Type:
Polaris Variable Transmission (PVT) - automatic CVT system.
Suspension Design:
Independent front suspension (IFS) and a swingarm rear suspension, offering a balance of comfort and capability.
Target Audience:
Recreational riders, trail riders, and those needing a capable utility ATV for moderate work.
Coverage Scope:
All Models, Engines, Trims, and Transmissions for the 1999 Polaris Xplorer 400
Estimated Pages:
Likely 300-500 pages (typical for comprehensive service manuals of this era)
Type:
Workshop Service Repair Manual
Engine:
Detailed breakdown of the 400cc two-stroke engine, including disassembly, assembly, component inspection, lubrication, cooling system, and exhaust system.
Transmission Drivetrain:
Coverage of the automatic transmission (PVT - Polaris Variable Transmission), including belt inspection/replacement, clutch operation, and final drive components.
Chassis Suspension:
Front and rear suspension systems, including shock absorbers, springs, control arms, steering components, and wheel bearings.
Brakes:
Hydraulic brake system, including master cylinders, calipers, brake lines, brake fluid specifications, and maintenance procedures.
Electrical System:
Wiring diagrams, ignition system, lighting, charging system (stator, rectifier/regulator), starter motor, battery maintenance, and troubleshooting common electrical faults.
Fuel System:
Carburetor specifications, fuel pump, fuel lines, and fuel tank maintenance.
Bodywork Plastics:
Front and rear racks, fenders, body panels, seat, and handlebar assembly.
Maintenance:
Scheduled maintenance items, fluid changes (oil, coolant, brake fluid), filter replacements, and lubrication points.
Troubleshooting:
Diagnostic procedures for common performance issues, starting problems, electrical malfunctions, and drivetrain issues.
Repair Rebuild:
Detailed step-by-step instructions for engine teardown and rebuild, transmission overhaul, suspension component replacement, and brake system repair.
Specifications Data:
Torque specifications, clearances, tolerances, fluid capacities, and electrical component specifications.
Depth:
Comprehensive, covering basic maintenance to complete engine and drivetrain overhauls. Suitable for both DIY enthusiasts and professional technicians.
Digital Format:
PDF (Portable Document Format)
Resolution Clarity:
High-resolution, ensuring clear text and readable diagrams for printing or on-screen viewing.
Binding For Digital:
N/A (Digital Download - no physical binding)
Paper Type For Digital:
N/A (Digital Download - no physical paper type)
Text Searchability:
Likely searchable text within the PDF, allowing for quick location of specific information.
Engine Type:
Two-stroke, liquid-cooled, single-cylinder
Displacement:
Approximately 340cc (exact figures may vary slightly based on sub-model or specific engine variant, but commonly referred to as 400cc class)
Bore X Stroke:
Specifics detailed in manual (typical for this class might be around 72mm x 80mm, but requires manual confirmation)
Compression Ratio:
Detailed in manual (important for tuning and diagnostics)
Cooling System:
Liquid-cooled with fan assist
Horsepower:
Estimated 25-30 HP (typical for a 340-400cc 2-stroke ATV of this era)
Torque:
Specific figures detailed in manual
Carburetor:
Single Mikuni carburetor (specific model like VM34 or similar will be in manual)
Fuel Type:
Unleaded gasoline (typically 87 octane or higher, check manual for exact recommendation)
Oil Mixture:
Requires pre-mix of 2-stroke oil and gasoline (ratio specified in manual, commonly 40:1 or 50:1).
Type:
Polaris Variable Transmission (PVT) - Automatic Continuously Variable Transmission (CVT)
Drive System:
Shaft drive to rear axle, chain drive to front wheels (on 4x4 models, though Xplorer 400 was primarily 2WD for this year unless specified otherwise in manual)
Optional Drivetrains:
While the 400 typically featured 2WD, later or specific sub-models might have had 4x4 variants. Manual will clarify if 4WD options exist for this year.
Gear Selection:
Forward, Neutral, Reverse (F-N-R)
Clutch System:
Centrifugal clutch system for automatic engagement.
Belt Maintenance:
Crucial to check drive belt condition and tension as part of regular maintenance.
Length:
Approximately 77 inches (195.6 cm)
Width:
Approximately 44 inches (111.8 cm)
Height:
Approximately 46 inches (116.8 cm) to handlebars
Wheelbase:
Approximately 48 inches (121.9 cm)
Ground Clearance:
Approximately 6-7 inches (15-18 cm)
Rack Capacity Front:
Typically around 50 lbs (22.7 kg)
Rack Capacity Rear:
Typically around 100 lbs (45.4 kg)
Dry Weight:
Approximately 500-550 lbs (227-250 kg) - dry weight.
Towing Capacity:
Typically around 900-1000 lbs (408-454 kg), check manual for exact specification.
Fuel Capacity:
Approximately 3.2 gallons (12.1 L)
Atv Safety Standards:
Designed to meet relevant safety standards for ATVs of its era. Manual will cover safe operating procedures.
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power.
Throttle Control:
Thumb throttle with safety interlock.
Operator Presence Control:
Standard safety feature on most Polaris ATVs requiring operator presence for operation.
Ignition Safety Switch:
Keyed ignition and potential kill switch lanyard.
Infotainment System:
As a 1999 ATV, this model does not feature modern infotainment systems. Focus is on mechanical and electrical function.
Driver Assistance Features:
No electronic driver assistance features typical of modern vehicles. Safety is primarily through mechanical design and rider skill.
Connectivity Features:
No electronic connectivity features.
Oil Change Engine:
Requires 2-stroke oil/gas mixture for lubrication. Check manual for specific oil recommendations and interval for checking the oil injection system if equipped.
Transmission Fluid:
The PVT system uses specific CVT fluids or gear oil for the final drive. Check manual for capacity and change intervals (typically annually or every 100 hours).
Air Filter:
Inspect and clean/replace regularly, especially in dusty conditions. Interval detailed in manual.
Spark Plug:
Inspect and gap periodically. Replacement interval in manual.
Brake Fluid:
Check level regularly and flush/replace as recommended by manual (typically every 1-2 years).
Engine Oil Type:
Specific 2-stroke oil for air-cooled engines. Manual will specify API/TCW rating and brand recommendations (e.g., Polaris Premium 2-Stroke Oil).
Transmission Fluid Type:
Manual will specify the type and grade of gear oil for the final drive and potentially specific CVT fluid if applicable.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (manual will specify exact type).
Coolant Type:
Ethylene glycol-based antifreeze/coolant (e.g., a 50/50 mix with distilled water). Manual will specify type and capacity.
Drive Belt Wear:
CVT drive belts can wear and require replacement. Regular inspection for cracks, fraying, or excessive wear is recommended.
Carburetor Cleaning:
Carburetors on 2-stroke engines can sometimes become gummed up if fuel sits for extended periods, requiring cleaning.
Cooling System Maintenance:
Ensuring the radiator is clean and the cooling system is properly filled and bled is crucial for preventing overheating in liquid-cooled 2-strokes.
Electrical Connections:
Corrosion on electrical connectors can lead to intermittent issues. The manual provides guidance on checking and cleaning these.
Polarishistory:
Polaris Industries has a long history in powersports, starting with snowmobiles and expanding into ATVs in the late 1980s. They are known for innovation in the ATV market.
Xplorer Lineage:
The Xplorer line was Polaris's foray into the multi-purpose ATV segment, balancing utility with trail-riding comfort. The 400 model was a popular choice within this range, offering a good mix of power and maneuverability.
Production Period:
The Xplorer 400 was produced across several years in the late 1990s and early 2000s, with the 1999 model being a significant iteration.
Manufacturing Origin:
Polaris vehicles are primarily manufactured in the United States.
