The Xplorer 400 4x4, produced from 1996 to 1998, is a capable all-terrain vehicle designed for recreational riders and light utility tasks. This single-cylinder, 2-stroke ATV offers reliable performance and manageable off-road handling, featuring a selectable 2WD/4WD system for versatile traction. Engineered for durability and ease of operation, the Xplorer 400 was positioned as a solid choice in the entry-level to mid-range utility ATV market, competing with other established brands. Its robust construction and straightforward design contribute to its reputation for dependable service in various conditions. This comprehensive workshop service repair manual provides detailed guidance for the maintenance, diagnosis, repair, and overhaul of the Xplorer 400 4x4. Covering all major systems including the engine, fuel, ignition, transmission, drivetrain, suspension, brakes, steering, and electrical systems, this manual offers step-by-step instructions and critical technical specifications. It is an essential resource for owners and technicians alike, enabling efficient troubleshooting, routine maintenance, and in-depth repair procedures to ensure the optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Xplorer 400 Model Variant: 4x4 Generation Generation Name: First Generation Codes Vin Decode Standard: Not applicable to ATVs in the same manner as cars 👋 Introduction Market Position Original Market Segment: Entry-level to mid-range utility ATV Target Audience: Recreational riders, light utility users, farmers, hunters Competitive Analysis Key Competitors: Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou Key Features Vehicle Performance Focus: Reliable performance, capable off-road handling Drivetrain Feature: Selectable 2WD/4WD Key Features Manual Value Proposition: Enables DIY maintenance and repairs, saving on labor costs and downtime Content Advantage: Official factory data ensures accuracy and completeness 📋 Manual Details Coverage Areas Years Covered: 1996, 1997, 1998 Regions Covered: North America (standard) Page Count Estimated Page Count: Hundreds (specific count not provided, but typical for a full workshop manual) Manual Type Manual Type: Workshop Service Repair Manual Manual Purpose: Diagnostic, repair, maintenance, and overhaul procedures Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, troubleshooting Fuel System: Carburetor service, fuel pump, fuel lines, fuel tank maintenance Ignition System: Ignition coil, spark plug, CDI unit, timing procedures Transmission Drive: PVT (Polaris Variable Transmission) system, belt inspection/replacement, clutch service Drivetrain: 4x4 system, front and rear differentials, driveshafts, U-joints Suspension: Front and rear suspension components, shocks, bushings, alignment Brakes: Hydraulic brake system, caliper service, master cylinder, brake fluid, bleeding procedures Steering: Handlebar assembly, tie rods, steering column, lubrication Electrical System: Wiring diagrams, battery, charging system, lighting, starter, accessories Cooling System: Radiator, fan, thermostat, coolant specifications and procedures Exhaust System: Muffler, exhaust pipe, gaskets, torque specifications Frame Chassis: Frame inspection, component mounting, torque values Bodywork Plastics: Fender removal/installation, seat, plastic panel care Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points Troubleshooting: Diagnostic flowcharts, common problem identification and solutions Repair: Step-by-step repair instructions for all major systems Overhaul Rebuild: Complete engine and transmission rebuild procedures with detailed specifications Specifications Data: Torque specifications, clearances, fluid capacities, electrical values Technical Depth Depth Level: Comprehensive Factory Service Level Diagnostic Capability: Advanced diagnostic procedures, electrical system troubleshooting Rebuild Capability: Full engine and transmission rebuild instructions 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Printability: Printable (designed for user printing) Resolution: High resolution for clear diagrams and text Binding Type Binding Type: N/A (Digital download, user responsible for printing and binding) Paper Type Paper Type Recommendation: Standard copier paper suitable for workshop use ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke Displacement: 375cc (approximate) Bore X Stroke: 70 mm x 97.7 mm (typical for this engine family) Cooling System: Liquid-cooled Cylinder Configuration: Single Cylinder Performance Horsepower: Estimated 25-30 HP (figures vary based on tuning and specific model year) Torque: Not readily available for this model, but sufficient for utility tasks Fuel System Fuel Delivery: Carburetor Carburetor Model: Mikuni VM34 (typical for this era) Fuel Type: Unleaded Gasoline Fuel Mixture: Requires 2-stroke oil mixed with gasoline (ratio specified in manual) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Spark Plug Type: NGK BR9ES (typical, confirm in manual) 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Drive System: Shaft Drive Gear Selection: High, Low, Neutral, Reverse Features Clutch System: Centrifugal Clutch (Primary and Secondary) Belt Drive System: Yes, V-belt Fluid Specifications Transmission Fluid Type: Polaris 2-stroke oil or equivalent SAE 10W-30 API SG (confirm in manual) Fluid Capacity Transmission Oil Capacity: Typically around 1.5 liters (confirm in manual) 📐 Dimensions Exterior Length: Approx. 74 inches (188 cm) Width: Approx. 43 inches (109 cm) Height: Approx. 43 inches (109 cm) Weights Dry Weight: Approx. 480 lbs (218 kg) Ground Clearance: Approx. 7-8 inches (18-20 cm) Towing Capacity: Not typically specified for this model, but suitable for light trailer hauling Rack Capacity Front: Approx. 50 lbs (23 kg) Rack Capacity Rear: Approx. 100 lbs (45 kg) 🛡️...