This manual covers the Xplorer 400, a rugged utility ATV produced from 1996 to 1998. Engineered for demanding off-road use, the Xplorer 400 is recognized for its reliable performance and capable design, making it a favored choice for hobbyists, farmers, and outdoorsmen. Its 2-stroke, liquid-cooled engine, automatic CVT transmission, and robust chassis provide a solid foundation for tackling various terrains and tasks. This model represents a commitment to delivering durable and functional all-terrain vehicles. This comprehensive factory service manual provides detailed information for all service and repair procedures for the Xplorer 400 ATVs, model years 1996, 1997, and 1998. It includes extensive coverage of maintenance schedules, troubleshooting guides for common issues, diagnostic procedures, and essential technical specifications. With step-by-step instructions for component removal, installation, and repair, this manual is an indispensable resource for owners and technicians seeking to maintain the optimal performance and longevity of their Xplorer 400. 🏷️ Basic Information Identification Make: Polaris Model: Xplorer 400 Years Covered: 1996, 1997, 1998 Codes Chassis Codes: A96AX42AA (1996), A97AX42AA (1997), A98AX42AA (1998) Engine Codes: AX400 👋 Introduction Market Position Category: Utility ATV Target User: Hobbyists, farmers, outdoorsmen, and DIY mechanics Competitive Analysis Competitors: Yamaha Kodiak, Honda FourTrax, Suzuki King Quad Key Features Vehicle Attributes: Rugged design, reliable performance, capable off-road Manual Value: Empowers owners to perform maintenance and repairs, saving money and ensuring longevity 📋 Manual Details Coverage Areas Primary Coverage: All service and repair procedures for Polaris Xplorer 400 ATVs Secondary Coverage: Maintenance, troubleshooting, diagnostics, and specifications Page Count Estimated Pages: 300+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, top-end rebuild, lubrication system, cooling system, fuel system, ignition system, exhaust system Drivetrain: Transmission, clutch, driveshaft, rear axle, differential, four-wheel drive system (if applicable) Suspension: Front and rear suspension components, shock absorbers, control arms, bushings, bearings Brakes: Brake system diagnosis, master cylinder, calipers, brake pads, brake lines, bleeding procedures Electrical: Wiring diagrams, battery, charging system, starter, lighting, ignition switch, control modules Steering: Steering mechanism, tie rods, ball joints, steering column Body Frame: Body panels, frame inspection, seat mounting, fenders, racks Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points, chain adjustment Troubleshooting: Diagnostic charts for common starting, running, and operational issues Repair: Step-by-step repair instructions for all major components and systems Assembly Disassembly: Detailed procedures for component removal and installation Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds Diagnostic Level: Advanced diagnostics with troubleshooting guides and specifications Special Tools: Identification of specialized tools required for specific procedures 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable Print Quality Quality: High-resolution scans, clear text and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, liquid-cooled, single-cylinder Displacement: 340cc (approximately) Bore X Stroke: Refer to manual for specific dimensions Carburetion: Single carburetor (specific model varies, e.g., Mikuni VM34) Compression Ratio: Refer to manual for specific ratio Performance Horsepower: Estimated 25-30 HP (typical for this class) Torque: Refer to manual for specific torque figures Fuel System Fuel Type: Unleaded gasoline Fuel Mixture: Pre-mix gasoline and 2-stroke oil (specific ratio in manual) Fuel Tank Capacity: Approximately 3.7 gallons (14 Liters) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Gear Selection: High, Low, Neutral, Reverse Features Drive System: Shaft Drive, 2WD or 4WD (depending on sub-model) Clutch Type: Drive clutch and driven clutch assembly (CVT components) Transmission Fluid: Refer to manual for specific fluid type and capacity (likely SAE 10W-30 or similar) 📐 Dimensions Exterior Length: Approximately 76-80 inches (1930-2030 mm) Width: Approximately 44-46 inches (1118-1168 mm) Height: Approximately 45-47 inches (1143-1194 mm) Wheelbase: Approximately 48.5 inches (1232 mm) Weights Dry Weight: Approximately 500-530 lbs (227-240 kg) Ground Clearance: Approximately 5-7 inches (127-178 mm) Cargo Front Rack Capacity: Refer to manual for specific capacity Rear Rack Capacity: Refer to manual for specific capacity 🛡️ Safety Features Ratings Atv Safety Standards: Adheres to industry safety standards for ATVs of its era Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Lighting: Headlights, taillight, brake light Operator Controls: Ergonomically placed controls for ease of use 💡 Technology Features Infotainment Dashboard Indicators: Speedometer, odometer, fuel gauge (if equipped), warning lights Driver Assistance N/A: Basic ATV design, no advanced driver assistance systems Connectivity N/A: No electronic connectivity features 🔧 Maintenance Service Intervals Oil Change Engine: Refer to manual (typically every 25-50 operating hours or annually) Air Filter Cleaning: Refer to manual (frequent cleaning recommended based on operating conditions) Spark Plug Replacement: Refer to manual (e.g., every 100-200 operating hours) Cvt Belt Inspection: Refer to manual (periodic inspection for wear and tension) Fluid Specifications Engine Oil: Specific 2-stroke oil and gasoline mixture (ratio detailed in manual) Coolant: Antifreeze/coolant mixture (refer...