The Polaris Xplorer 400, a 2000 model year All-Terrain Vehicle (ATV), represents the third generation of this capable utility ATV. Designed for both recreational riders and light-duty work, it features a reliable 2-stroke, liquid-cooled, single-cylinder 340cc engine, independent front suspension, and an on-demand 2WD/4WD system. Its robust build, coupled with utility racks and a comfortable riding position, made it a strong contender in its segment, offering a blend of performance and practicality for various off-road applications. This comprehensive workshop service repair manual provides detailed guidance for the Polaris Xplorer 400 (2000 Model Year). It covers essential maintenance procedures, including fluid changes and component checks, along with in-depth troubleshooting for common issues. The manual also offers step-by-step instructions for the disassembly and assembly of major systems such as the engine, fuel system, transmission, drivetrain, brakes, suspension, and electrical components. With over 300 pages of English content, this manual is an invaluable resource for owners and technicians seeking to maintain, diagnose, and repair their Xplorer 400, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Xplorer 400 Year: 2000 Type: All-Terrain Vehicle (ATV) Generation Generation Identifier: Third Generation Xplorer (1999-2002) 👋 Introduction Market Position Segment: Mid-size utility ATV, targeting recreational riders and light-duty work. Competitive Analysis Competitors: Honda FourTrax 300/350, Yamaha Kodiak 400, Kawasaki Bayou 300/400 Key Features Vehicle Features: Reliable 2-stroke engine, independent front suspension, shaft drive, automatic transmission, utility racks. Manual Value Proposition Value To Owner: Empowers owners to perform all necessary maintenance, diagnostics, and repairs, saving time and money on dealership visits. 📋 Manual Details Coverage Areas Covered Models: Polaris Xplorer 400 (2000 Model Year) Page Count Estimated Pages: 300+ Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Top-end (cylinder head, piston, rings), Bottom-end (crankshaft, connecting rod, bearings), Cooling System (radiator, fan, thermostat, coolant), Lubrication System (oil pump, filter, oil passages) Fuel System: Carburetor (cleaning, adjustment, jetting, float level), Fuel Pump, Fuel Lines, Fuel Filter, Fuel Tank Transmission: Automatic Transmission (CVT - Continuously Variable Transmission) disassembly, inspection, repair, belt replacement, clutch engagement, gearcase lubrication Drivetrain: Shaft Drive, Differential, Axles, CV Joints, Bearings, Seals Brakes: Hydraulic Brake System, Master Cylinder, Calipers, Brake Pads, Rotors, Brake Lines, Bleeding Procedure Suspension: Front and Rear Suspension (A-arms, shocks, springs, bushings), Wheel Bearings, Steering Knuckles Electrical System: Ignition System (CDI, stator, spark plug), Lighting System (headlights, taillights, brake lights), Charging System (alternator, voltage regulator), Battery, Starter Motor, Wiring Diagrams, Switches, Fuses Chassis And Body: Frame Inspection and Repair, Body Panels (removal, installation), Seat, Handlebars, Fenders, Racks Procedures Included Maintenance: Oil Change, Filter Replacement, Spark Plug Check/Replacement, Air Filter Cleaning/Replacement, Gearcase Oil Change, Coolant Flush/Replacement, Brake Pad Inspection/Replacement, Chain/Belt Adjustment (if applicable) Troubleshooting: Diagnostic Flowcharts, Symptom-based Troubleshooting for Engine, Electrical, and Drivetrain Issues Repair: Complete Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair, Brake System Overhaul Disassembly Assembly: Step-by-step instructions for major component removal and installation. Technical Depth Depth: Comprehensive; covers everything from routine maintenance to full engine and transmission rebuilds, including diagnostic procedures and specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable Text (OCR optimized) Print Quality Image Resolution: High-resolution, suitable for printing. Binding Type Binding: N/A (Downloadable PDF) Paper Type Paper Type: N/A (Downloadable PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder Displacement: 340cc (20.7 ci) Bore X Stroke: 66 mm x 64 mm Compression Ratio: 7.6:1 Ignition: CDI (Capacitor Discharge Ignition) Performance Horsepower: Approximately 28 HP (estimated, varies by tuning and exhaust) Torque: Approximately 24 ft-lbs (estimated) Fuel System Carburetor: Mikuni VM34SS (or equivalent) Fuel Type: Unleaded gasoline (91 octane or higher recommended) Fuel Capacity: 3.1 gallons (11.7 liters) Oil Mixture: Pre-mix (50:1 ratio of 2-stroke oil to gasoline) or Autolube Injection System 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) Automatic (CVT) Drive Modes: 2WD / 4WD (on-demand) Features Gear Reduction: High and Low range, Neutral, Reverse Clutch: Centrifugal clutch, CVT belt drive 📐 Dimensions Exterior Length: 77.8 inches (197.6 cm) Width: 45 inches (114.3 cm) Height: 45.5 inches (115.6 cm) Wheelbase: 50 inches (127 cm) Ground Clearance: 9.2 inches (23.4 cm) Weights Dry Weight: 552 lbs (250 kg) Gross Vehicle Weight Rating: 860 lbs (390 kg) Cargo Front Rack Capacity: 100 lbs (45 kg) Rear Rack Capacity: 200 lbs (90 kg) Tires Front Tire Size: AT23x8-12 Rear Tire Size: AT24x11-10 Wheels Bolt Pattern: 4/110 🛡️ Safety Features Ratings Atv Safety Classification: Utility ATV, designed for off-road use. Active Features Braking System: Hydraulic disc brakes front and rear. Parking Brake: Hand-operated lever. Passive Features Lighting: Dual headlights, taillight/brake light. Handlebars: Grip heaters (optional/standard depending on trim), padded crossbar. Safety Recommendations Protective Gear: Always wear a helmet, eye protection, and protective clothing. 💡 Technology Features Infotainment Features: Basic instrumentation (speedometer, odometer, fuel gauge, indicator lights)....