Introducing the Xplorer 400 4x4, a capable all-terrain vehicle produced between 1996 and 1998. This model, featuring a 398 cc liquid-cooled, 2-stroke engine and an automatic Variable Transmission (PVT), was designed for recreational riders and light utility tasks, offering reliable performance for trail riding and general use. Engineered with a robust 4x4 drive system, it provides excellent traction in varied terrain, making it a versatile choice for outdoor enthusiasts. This comprehensive workshop service manual serves as an essential guide for the maintenance and repair of your Xplorer 400 4x4. Covering a wide array of systems, including engine overhaul, transmission, suspension, braking, and electrical components, this manual provides detailed procedures for routine maintenance, troubleshooting, and component repair. It includes vital technical specifications, diagnostic charts, and step-by-step instructions, empowering owners and technicians to effectively service and preserve the longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Xplorer 400 Model Variant: 4x4 Codes Chassis Code: N/A (ATV) Engine Code: Likely derived from engine displacement (e.g., 400cc) 👋 Introduction Market Position Market Segment: Entry-level to mid-range utility ATV Competitive Analysis Competitors: Yamaha Timberwolf, Honda FourTrax, Suzuki QuadRunner, Kawasaki Bayou Key Features Engine Type: 2-stroke, liquid-cooled Drive System: 4x4 Transmission Type: Automatic (PVT) Target Audience Target Audience: Recreational riders, light utility tasks, trail riding 📋 Manual Details Coverage Areas Model Years Covered: 1996, 1997, 1998 Geographic Coverage: Global (typical for Polaris service manuals) Page Count Page Count: 633 Manual Type Manual Type: Workshop Service Manual Manual Purpose: Repair and Maintenance Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end repair, bottom-end assembly, cooling system, lubrication system, fuel delivery, ignition system, exhaust system Transmission Drivetrain: Automatic transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, belt replacement, final drive, drive shafts, gear cases Suspension Steering: Front and rear suspension systems (e.g., MacPherson strut, independent suspension), shock absorbers, springs, steering linkage, tie rods, wheel bearings Braking System: Hydraulic brake system, master cylinders, brake calipers, brake pads, brake lines, parking brake Electrical System: Starter motor, charging system (stator, regulator/rectifier), battery, lighting (headlights, taillights, brake lights), wiring diagrams, fuses, switches, ignition switch, kill switch Body Chassis: Frame inspection and repair, body panels, fenders, racks, seat assembly, handlebars, footrests Fuel System: Carburetor service and tuning, fuel tank, fuel lines, fuel filter Procedures Included Maintenance Procedures: Routine checks, lubrication, filter replacements (air, fuel), spark plug service, valve adjustments (if applicable) Troubleshooting Procedures: Diagnostic charts, symptom-based troubleshooting, common problem identification and solutions Repair Procedures: Step-by-step disassembly, reassembly, and repair instructions for all major components Technical Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, timing data Technical Depth Technical Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, detailed electrical diagnostics 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF Print Quality Print Quality: High-resolution scans suitable for printing 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, Single Cylinder Displacement: 398 cc (approx.) Bore X Stroke: Refer to manual for specific dimensions Compression Ratio: Refer to manual for specific ratio Cooling System: Liquid-Cooled Lubrication: Premix or Auto-Lube system (check manual for exact configuration) Performance Horsepower: Estimated 25-30 HP (typical for this displacement and era) Torque: Refer to manual for specific figures Fuel System Fuel Delivery: Carburetor (likely Mikuni or Keihin) Carburetor Model: Refer to manual for specific model and jetting Fuel Type: Unleaded Gasoline Fuel Octane Rating: 87 Octane (minimum, refer to manual) Fuel Tank Capacity: Approximately 3.0-3.5 gallons (check manual) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) - Automatic CVT Drive Modes: 2WD / 4WD selection Features Clutch System: Primary (Drive) Clutch and Secondary (Driven) Clutch with Belt Drive Gear Ratios: Refer to manual for specific low and high range ratios Transmission Fluid Type: Refer to manual for specific fluid type (e.g., SAE 10W-30 or specific CVT fluid) Transmission Fluid Capacity: Refer to manual for specific capacity 📐 Dimensions Exterior Length: Approximately 76-78 inches (check manual) Width: Approximately 42-44 inches (check manual) Height: Approximately 45-47 inches (check manual) Weights Dry Weight: Approximately 500-550 lbs (check manual) Ground Clearance: Approximately 6-8 inches (check manual) Cargo Front Rack Capacity: Refer to manual for specific rating Rear Rack Capacity: Refer to manual for specific rating Towing Towing Capacity: Refer to manual for specific rating (often limited on ATVs of this era) Wheels Tires Front Tire Size: Commonly 23x8-12 or 24x8-12 (check manual) Rear Tire Size: Commonly 23x10-12 or 24x10-12 (check manual) Wheel Bolt Pattern: 4x110 mm (typical for Polaris) 🛡️ Safety Features Ratings Rollover Protection: N/A (ATVs are open-platform vehicles) Active Features Braking System Type: Hydraulic Disc Brakes (front and rear) Parking Brake: Mechanical or caliper-based (integrated with rear brake system) Passive Features Hand Guards: Standard on many models (check...