This manual covers the ATV Xplorer 400, a utility and recreational all-terrain vehicle produced between 1996 and 1998. Known for its robust chassis and liquid-cooled engine, this first-generation model offered reliable performance for owners and hobbyists venturing off-road. Its capabilities, including 4x4 options on certain variants, positioned it as a competitive offering against other major manufacturers of the era, providing a blend of power and durability for demanding terrain. This comprehensive workshop repair service manual provides detailed guidance for the maintenance and repair of the ATV Xplorer 400. It covers all essential systems, including the engine, transmission, electrical system, fuel system, brakes, suspension, and steering. Within its pages, you will find step-by-step repair procedures, preventative maintenance schedules, troubleshooting guides, and critical technical specifications, empowering owners and technicians to ensure the optimal performance, longevity, and safe operation of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: ATV Xplorer 400 Generation: First Generation Product Type: Repair Service Manual Codes Production Years Covered: 1996, 1997, 1998 👋 Introduction Market Position Atv Segment: Utility/Recreational ATV Target User: Owners, hobbyists, and professional mechanics Competitive Analysis Competitors Era: Yamaha Wolverine, Suzuki King Quad, Kawasaki Bayou, Honda FourTrax Key Features Vehicle Features: 4x4 capability (on some variants), robust chassis, liquid-cooled engine Manual Value: Essential for maintaining optimal performance, longevity, and safe operation of the Xplorer 400 📋 Manual Details Coverage Areas General Coverage: All models within the specified year range Page Count Estimated Page Count: Approximately 300-400 pages (estimated based on typical workshop manual size for this era) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, tuning, carburetor, cooling system, lubrication Transmission: Service, repair, clutch, gearbox, drivetrain components Electrical System: Wiring diagrams, ignition system, lighting, starter, battery, charging system, troubleshooting Fuel System: Fuel tank, lines, pump, carburetor overhaul and adjustment Suspension: Front and rear suspension, shocks, bushings, linkages, adjustment Brakes: Hydraulic system, calipers, pads, lines, master cylinder, bleeding, adjustment Steering: Handlebars, tie rods, steering knuckles, linkage service Body And Frame: Chassis components, body panels, seat, storage, troubleshooting Wheels And Tires: Wheel bearing service, tire pressures, specifications Procedures Included Preventative Maintenance: Scheduled maintenance, lubrication, fluid changes, filter replacements Troubleshooting: Systematic diagnostics for common and uncommon issues, symptom-based guides Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation Assembly Disassembly: Detailed instructions for complete vehicle and component teardown and reassembly Technical Specifications: Torque values, clearances, fluid capacities, electrical specifications Technical Depth Depth Of Coverage: Comprehensive from basic maintenance to complete engine rebuilds and electrical system diagnostics Diagnostic Capabilities: Detailed fault finding charts and procedures for all major systems Rebuild Information: Detailed procedures and specifications for rebuilding engine, transmission, and suspension components 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Text-searchable PDF for quick information retrieval Print Quality: High-resolution, printable pages for workshop use Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, 2-cylinder Displacement: 398cc (24.3 cu. in.) Bore X Stroke: 64.0 mm x 62.0 mm (2.52 in. x 2.44 in.) Compression Ratio: 7.2:1 Carburetion: Dual Mikuni VM30SS carburetors Performance Horsepower: Approximately 32-34 HP (estimated, not officially stated) Torque: Not readily published, but estimated to be in the 25-30 lb-ft range Fuel System Fuel Type: Unleaded gasoline, minimum 87 octane Oil Mixing: Pre-mix (90 octane or higher gasoline with 2-stroke oil in a 40:1 ratio) 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Drive System: Shaft Drive, 2WD or 4WD (depending on model variant) Optional Gear Selection: High, Low, Neutral, Reverse Features Clutch Type: Centrifugal clutch Final Drive: Sealed O-ring chain and gear reduction 📐 Dimensions Exterior Length: Approximately 77 inches (195.5 cm) Width: Approximately 45 inches (114.3 cm) Height: Approximately 44 inches (111.8 cm) Wheelbase: Approximately 50 inches (127 cm) Ground Clearance: Approximately 7.1 inches (18 cm) Weights Dry Weight: Approximately 535 lbs (243 kg) Towing Capacity: Not specified, but typically limited for ATVs of this era Cargo Rack Capacity Front: Not specified, but typically around 50-75 lbs Rack Capacity Rear: Not specified, but typically around 100-150 lbs 🛡️ Safety Features Ratings Crash Safety: N/A (ATVs are not subject to automotive crash safety ratings) Active Features Braking System: Hydraulic disc brakes front and rear Throttle Limiter: Not standard, but often an aftermarket or dealer-installed option for younger riders Passive Features Roll Over Protection: N/A (Standard ATV design) Lighting: Headlights, taillight/brakelight 💡 Technology Features Infotainment Infotainment Features: N/A (Basic ATV design, no integrated infotainment) Driver Assistance Driver Assistance Features: N/A Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Engine: Pre-mix fuel system, no separate engine oil change interval (2-stroke). Spark Plug Replacement: Recommended every 2,000 miles or annually, or as needed based on performance. Specific plug: NGK BR8ES...