Positioning:
Essential diagnostic and repair resource for owners and technicians of the 1999 Polaris Xplorer 400 ATV.
Competitors:
Competes with other OEM service manuals for similar-era ATVs from brands like Yamaha, Honda, and Kawasaki, offering a factory-backed approach to maintenance.
Features:
Official factory documentation, comprehensive coverage, detailed diagrams, troubleshooting guidance, and printable format.
Engine:
Comprehensive engine overhaul, diagnostics, and tuning
Transmission:
Service and repair of the automatic transmission system
Drivetrain:
Front and rear drive axles, differentials, and CV joints
Suspension:
Front and rear suspension components, shocks, springs, and alignment
Brakes:
Hydraulic brake system diagnosis, repair, and fluid service
Electrical:
Complete electrical system schematics, component testing, and troubleshooting
Fuel System:
Carburetor service, fuel lines, and fuel tank maintenance
Cooling System:
Radiator, fan, thermostat, and coolant service
Exhaust System:
Muffler, pipes, and catalytic converter service
Steering:
Steering column, tie rods, and steering linkage maintenance
Body And Frame:
Body panel removal/installation, frame inspection, and accessory mounting
Towing And Storage:
Guidelines for towing and long-term storage
Maintenance:
Scheduled maintenance, lubrication, and fluid changes
Troubleshooting:
Diagnostic charts and step-by-step troubleshooting guides
Repair:
Detailed instructions for component repair and replacement
Disassembly Assembly:
Complete procedures for taking apart and reassembling all major components
Specifications Torque:
Torque specifications for all fasteners and critical components
Wiring Diagrams:
Detailed electrical wiring schematics
Depth:
Comprehensive: From basic maintenance to full engine rebuilds and advanced diagnostics
Digital Format:
Likely PDF, allowing for printing of specific pages or the entire manual
Quality:
High-resolution, clear diagrams and text suitable for printing
Binding:
N/A (Downloadable - user dependent)
Paper:
N/A (Downloadable - user dependent)
Engine Type:
2-stroke, liquid-cooled, single-cylinder
Displacement:
375cc (approx.)
Bore X Stroke:
Refer to manual for precise specifications
Compression Ratio:
Refer to manual for precise specifications
Horsepower:
Approximately 26-28 HP (typical for this class/era)
Torque:
Refer to manual for precise specifications
Carburetor:
Mikuni VM34SS (typical, refer to manual for exact part number)
Fuel Type:
Unleaded gasoline with 2-stroke oil mixture (refer to manual for ratio)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Oil System:
Premix or Autolube system (refer to manual for specifics)
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Gears:
High, Low, Neutral, Reverse
Clutch System:
Centrifugal clutch and drive/driven clutch system
Fluid Specification:
Polaris AGL Premium Synthetic Gearcase Lubricant (or equivalent SAE 10W-30 or SAE 5W-50 depending on application - refer to manual)
Capacity:
Refer to manual for exact capacity
Length:
Refer to manual for precise dimensions
Width:
Refer to manual for precise dimensions
Height:
Refer to manual for precise dimensions
Dry Weight:
Approximately 540 lbs (245 kg)
Ground Clearance:
Refer to manual for precise specifications
Towing Capacity:
Refer to manual for precise specifications
Rollover Protection:
N/A (ATV design)
Braking System:
Hydraulic disc brakes front and rear
Lighting:
Headlights, taillight/brake light
Operator Controls:
Handlebar steering, throttle lever, brake lever, gear selector
Operator Safety:
Emphasis on riding gear and safe operating practices detailed in manual
Oil Change Engine:
Refer to manual for specific 2-stroke oil/gas mix schedule and gearbox oil change intervals.
Air Filter Cleaning:
Recommended every 50 hours or as needed based on operating conditions (refer to manual).
Spark Plug Replacement:
Refer to manual for recommended intervals and gap specifications.
Belt Inspection:
Regular inspection of the drive belt for wear and damage (refer to manual for service life).
Engine Oil:
2-stroke oil with proper TCW-3 rating or Polaris brand specified oil. Mixture ratio in manual.
Gearcase Oil:
Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent SAE 10W-30/5W-50.
Coolant:
Ethylene glycol based coolant with corrosion inhibitors. Refer to manual for specific type and mixture.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (verify with manual).
Common Wear Items:
Drive belt, carburetor jets, suspension bushings, starter solenoid, electrical connectors.
Engine Performance:
Carburetor tuning can be critical for optimal 2-stroke performance; exhaust port carbon buildup can also occur.
Polar Is History:
Polaris Industries is a long-standing manufacturer of powersports vehicles, known for innovation in ATVs and snowmobiles.
Xplorer Lineage:
The Xplorer line was designed for utility and trail riding, often featuring independent rear suspension for improved comfort and handling compared to earlier solid-axle designs.
Production Years:
1996-2002 (approx. for Xplorer 400 models)
Manufacturing Location:
USA (Polaris Manufacturing Facilities)
