The 2001 Xplorer 400 4x4 is a capable utility all-terrain vehicle, recognized for its robust 4x4 drivetrain and Variable Transmission (PVT) system, designed to provide reliable performance across varied terrains. This model, part of the Xplorer lineage, offered a balance of power and utility, competing with other mid-range ATVs of its era. Its engineering emphasizes durability and effective traction, making it suitable for recreational riding and light work. Key features include its liquid-cooled, 2-stroke, single-cylinder 375cc engine, independent rear suspension on some variants, and a sturdy chassis built for demanding conditions. This comprehensive repair and workshop manual provides detailed guidance for the 2001 Xplorer 400 4x4. It covers essential maintenance procedures, including routine servicing, fluid changes, and component checks, alongside in-depth repair and rebuild instructions for the engine, powertrain, chassis, and electrical systems. Troubleshooting guidance, technical specifications, and diagnostic procedures are also included to assist owners and technicians. The manual aims to facilitate the proper upkeep and repair of the vehicle, ensuring its longevity and optimal performance. 🏷️ Basic Information Identification Make: Polaris Model: Xplorer 400 4X4 Year: 2001 Generation Model Generation: Likely 2nd Generation Xplorer (1999-2002) Codes Vehicle Identification Number Vin Format: ATV VIN format (typically 17 characters, but specific Polaris structure may vary) 👋 Introduction Market Position Positioning: The Polaris Xplorer 400 4x4 was positioned as a capable mid-range utility ATV, often favored for its 4WD capability and reliable performance in varied terrain. Competitive Analysis Competitors: Competed with models from Yamaha (like the Kodiak 400), Honda (like the FourTrax 400/450), and Suzuki (like the King Quad 300/400). Key Features Highlights: 4x4 drivetrain for enhanced traction, Polaris's Polaris Variable Transmission (PVT), independent rear suspension (IRS) on some models, durable chassis design. 📋 Manual Details Coverage Areas Coverage: Comprehensive coverage for 2001 Polaris 400 Xplorer 4x4 ATVs Page Count Page Count: Undisclosed (typical for download PDFs, but expect hundreds of pages for a full repair manual) Manual Type Type: Repair Manual / Workshop Manual Language Language: English (Assumed based on product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine And Powertrain: Engine removal and installation, fuel system, lubrication and cooling system, engine specifications, transmission, drive chain & sprockets, intake & exhaust Chassis And Suspension: Steering system, shocks, body work Electrical And Diagnostics: Electrical system, advanced troubleshooting Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, spark plug service, brake adjustments, chain lubrication and adjustment Repair And Rebuild: Engine rebuild procedures, carburetor overhaul, transmission disassembly and assembly, suspension component replacement, electrical component testing and replacement Troubleshooting: Diagnostic procedures for common problems, fault finding, component testing Technical Depth Depth: Comprehensive technical details for both novice and experienced technicians, including step-by-step instructions, torque specifications, and diagnostic flowcharts. 📊 Manual Specifications File Format Format: Digital PDF Print Quality Quality: High-resolution, suitable for printing individual pages for on-the-job use. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download - Printable) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 375cc (approximate, often rounded to 400) Bore X Stroke: Typical for 375cc class (specifics found in manual) Performance Horsepower: Approximately 30-34 HP (estimated) Torque: Torque figures specific to engine model, detailed in manual Fuel System Carburetor: Mikuni VM Series (likely VM34 or similar), specific model detailed in manual. Fuel Type: Unleaded gasoline Fuel Octane Rating: 87 octane (minimum) Lubrication Oil Type: 2-stroke engine oil (pre-mix or injection depending on specific configuration, check manual for exact type like JASO FD or similar) Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with High/Low range and Reverse Optional Optional Transmissions: N/A for this specific model year and trim. Features Drive System: Shaft drive with automatic chain tensioner for rear drive. Gear Ratios: Specific high/low range and reverse gear ratios are detailed within the manual. Fluid Specifications Transmission Fluid Type: Polaris Demand Drive Fluid (for front differential) and specific PVT belt fluid if applicable (check manual for exact specifications and part numbers). 📐 Dimensions Exterior Length: Approx. 80-82 inches (specifics depend on model variant) Width: Approx. 46-48 inches Height: Approx. 45-47 inches (to handlebars) Weights Dry Weight: Approx. 550-600 lbs (specifics vary) Ground Clearance: Approx. 8-10 inches Cargo Rack Capacity Front: Typically around 50 lbs Rack Capacity Rear: Typically around 100 lbs Towing Towing Capacity: Typically around 1500 lbs Tires Front Tire Size: Typically 25x8-12 Rear Tire Size: Typically 25x10-12 Wheels Bolt Pattern: 4x110mm 🛡️ Safety Features Ratings Crash Test Ratings: N/A (ATVs are not subjected to standardized crash testing like passenger vehicles) Active Features Braking System: Hydraulic disc brakes, front and rear. Single lever handlebar control for front and rear, foot pedal for rear brake. Parking Brake: Integrated into the brake lever or a separate mechanism. Passive Features Lighting: Dual headlights, single taillight/brake light. Operator Presence: Throttle safety interlock, typically a lever that must be squeezed...