Polaris Xplorer 400 Problems And Their Solutions

The Polaris Xplorer 400 is a popular all-terrain vehicle (ATV) that was manufactured by Polaris Industries from 1995 to 2002.

It is a powerful and versatile machine that is suitable for a variety of off-road activities, including trail riding, hunting, and farming.

Polaris Xplorer 400 Problems

The Xplorer 400 is powered by a liquid-cooled, four-stroke engine with a displacement of 378cc. This engine is capable of producing up to 34 horsepower and delivers strong and reliable performance.

It is also equipped with an automatic transmission that offers smooth and effortless shifting.

However, like any other vehicle, the Xplorer 400 can encounter problems that can impact its performance and cause frustration.

Some of the common issues that Xplorer 400 owners face include Starting Problems, Engine Problems, Drivability Issues, Transmission Problems, Brake Problems, Fuel Pump Problems, Electrical Problems, even Overheating Problems, and many more.

Quick Overview of Problems And Solutions

Problem Solution
Starting Problems Check the battery and connections. Inspect the starter motor and solenoid. Ensure the fuel and air filters are clean.
Engine Problems Check the spark plug and ignition system. Inspect the carburetor or fuel injection system. Ensure the engine oil level and quality are correct.
Drivability Issues Inspect the throttle cable and linkage. Check the air intake system for blockages. Check the drive belt for wear or damage.
Transmission Problems Ensure the transmission fluid level and quality are correct. Check the drive chain for proper tension and lubrication. Inspect the transmission for damage or wear.
Brake Problems Check the brake pads and rotor for wear. Inspect the brake lines and connections for leaks or damage. Ensure the brake system is bled properly.
Fuel Pump Problems Inspect the fuel pump and fuel filter for blockages or damage. Check the fuel pressure regulator for proper function.
Electrical Problems Check the battery and charging system. Inspect the wiring harness for damage or corrosion. Ensure all connections are tight and clean.
Overheating Problems Check the coolant level and quality. Inspect the radiator and fan for damage or blockages. Ensure the water pump is functioning properly.
Charging amps: 90
Charging amps: 90

Common Polaris Xplorer 400 Problems and Their Solutions

Let’s dive into more details on problems and solutions for Polaris 400

1. Starting Problems

Have you been experiencing difficulty starting your Polaris Xplorer 400 lately? While this can certainly be frustrating, rest assured that there are several common causes for starting problems that you can take steps to resolve.

One of the most prevalent causes of starting problems in the Polaris Xplorer 400 is a weak or dead battery.

If your battery is old, has been drained or has experienced damage, it won’t be able to provide sufficient power to start your ATV’s engine.

The first step in fixing this issue is to check the battery voltage using a multimeter. If it reads below 12V, it’s time to replace the battery.

You can purchase a new one from your nearest Polaris dealer or online. Once you have the new battery, connect it to your Xplorer making sure that the terminals are connected correctly.

Another possible cause of starting problems is a clogged or dirty air filter.

A dirty filter can prevent sufficient air from getting to the engine, which can cause starting difficulties.

To fix this issue, locate the air filter and clean it thoroughly with compressed air or replace it altogether.

Next, it’s important to check the fuel supply system. If your fuel pump is clogged or damaged, fuel won’t be able to reach the engine, resulting in starting issues.

To fix this, check the fuel pump and fuel-filter for clogs or damage. You may also want to check if the fuel lines are connected properly.

Finally, a faulty starter or starter solenoid can cause starting problems. If you turn the key and you only hear a clicking sound or nothing happens at all, this is a sign that the starter may be broken.

To remedy this, inspect the starter and starter solenoid for damage or worn-out parts. If you find any issues, it’s best to replace them with new ones.

2. Engine Problems

Are you a proud owner of a Polaris Xplorer 400 and have been facing engine problems lately?

We understand how frustrating it can be, which is why we have compiled a list of possible engine problems and how to fix them step by step.

1. Poor Fuel Quality:

Poor fuel quality is one of the common causes of engine problems in Polaris Xplorer 400.

Low-quality fuel can cause a buildup of deposits and clogs, leading to decreased power, poor acceleration, and irregular idle speed.

The solution is to use high-quality fuel with the correct octane rating as listed in the owner’s manual.

2. Dirty Air Filter:

An air filter keeps dust and dirt out of the engine, ensuring it operates smoothly.

A dirty air filter restricts airflow to the engine, leading to poor performance, decreased power, and increased fuel consumption.

Replacing the air filter regularly is the solution to this problem.

3. Ignition Problems:

Ignition problems, such as faulty spark plugs or ignition timing issues, can cause engine misfires, poor acceleration, and low power.

The solution is to replace the faulty spark plugs, check and adjust the ignition timing, and replace the ignition coil if necessary.

4. Overheating:

An overheated engine can cause severe damage if left unattended.

Causes of overheating can include a blocked radiator, low coolant levels, or a malfunctioning water pump.

To fix this problem, make sure the radiator is clean and free from dirt and debris, ensure that the coolant levels are within the manufacturer’s recommended range, and replace the water pump if necessary.

5. Oil Problems:

Using the wrong type or grade of oil, low oil levels, or dirty oil can lead to engine problems.

Symptoms of oil problems include increased oil consumption, engine noise, and decreased performance.

To fix this problem, make sure to use the correct grade and type of oil as recommended in the owner’s manual, change the oil regularly, and ensure that there are no leaks in the oil system.

3. Drivability Issues

Drivability refers to the overall ease and smoothness of how a vehicle performs while being driven.

In the case of the Polaris Xplorer 400, drivability issues can occur for a number of reasons.

Here are some of the main causes of drivability issues and how to fix them in step-by-step fashion:

1. Dirty or Clogged Air Filter – A dirty or clogged air filter can restrict the air flow needed for the Xplorer’s engine combustion. To fix this issue, you will need to remove the air filter from its housing and clean it thoroughly, or replace it with a new one.

2. Bad Spark Plug – A faulty spark plug can lead to misfiring and erratic engine performance. To fix this issue, you will need to remove the spark plug, inspect it for damage and replace it if necessary.

3. Dirty or Clogged Carburetor – If the carburetor is dirty or clogged, fuel flow to the engine can be disrupted. To fix this issue, you will need to remove the carburetor, clean it thoroughly with carburetor cleaner, and reassemble.

4. Low Fuel Pressure – Low fuel pressure can cause drivability issues such as stalling and intermittent power loss. To fix this issue, you will need to check the fuel pressure using a fuel pressure gauge and replace any faulty components as necessary.

5. Faulty Ignition System – A malfunctioning ignition system can lead to a variety of drivability issues. To fix this issue, you will need to test each component of the ignition system (e.g., ignition coil, stator, CDI box) and replace any faulty parts.

4. Transmission Problems

The transmission is the part of the ATV that transfers power from the engine to the wheels, allowing you to switch gears and navigate various terrains.

However, just like any other component of your ATV, it can experience failures and malfunctions.

There are various reasons why your transmission might be giving you trouble. One of the main reasons is a lack of transmission fluid.

The fluid is responsible for cooling and lubricating the transmission, and if it is low or worn out, it can cause the gears to grind and fail.

Another reason is a failing clutch, which can cause slipping or jerking when changing gears.

Additionally, worn or damaged gears and bearings can also cause problems with your transmission.

To fix transmission problems on your Polaris Xplorer 400, you need to diagnose the issue correctly and perform the necessary repairs. Here are some steps to follow:

  1. Check the transmission fluid level and quality. If it’s low, top it up or replace it with fresh fluid.
  2. Inspect the clutch for wear and replace it if necessary. 
  3. Inspect the gears and bearings for damage or signs of wear. If you notice any issues, replace them accordingly. 
  4. Make sure the shifter mechanism is working correctly. If it’s not, adjust or replace it as needed. 
  5. Check the drive belt tension and replace it if it’s loose or worn out. 
  6. Finally, test your ATV to make sure your transmission is working correctly. 

It’s important to note that some transmission problems are more severe and might require professional help.

If you’re not confident in your skills, consider taking your Polaris Xplorer 400 to a qualified mechanic for diagnosis and repair.

5. Brake Problems

Brake problems can arise due to several causes, such as worn brake pads, damaged brake rotors, malfunctioning brake master cylinder, or brake fluid leaks.

A typical symptom of brake problems is when you hear squeaking or grinding noises coming from your brakes or feel vibrations in your brake pedal or steering wheel when braking.

You may also notice your brake pedal feels spongy or goes all the way to the floor when you press it, which suggests air in the brake lines or a low brake fluid level.

To fix brake problems, start by inspecting your brake pads and rotors.

If they are excessively worn or damaged, replace them.

You should also check your brake master cylinder and replace it if it’s faulty or the brake fluid is contaminated.

Another common cause of brake problems is air in the brake lines. To fix this, you need to bleed the brakes and refill the brake fluid.

Make sure to use the manufacturer’s recommended type of brake fluid for your Polaris Xplorer 400.

6. Fuel Pump Problems

The fuel pump is responsible for transferring fuel from the gas tank to the engine.

This is a critical component in any motorized vehicle, including the Polaris Xplorer 400.

However, like all mechanical parts, fuel pumps can experience problems, which can lead to various troubles while driving.

If you are experiencing symptoms like slow acceleration, engine stalls or misfires, it might be a fuel pump issue.

Some of the most common causes of fuel pump problems include worn out or damaged internal parts, clogged fuel lines or filters, rusted connections or electrical malfunctions.

Fortunately, there are simple steps you can take to fix these issues.

To fix fuel pump problems, you should start with a thorough diagnosis to identify the cause of the issue.

Once you determine the cause, you may need to clean or replace the fuel filter, inspect fuel lines for blockages, or replace the fuel pump entirely.

If you’re not confident in your mechanical abilities, it’s always best to consult an expert. They can help identify and fix the problem quickly and efficiently.

Remember, ignoring the signs of a failing fuel pump can result in more significant engine problems and even put your safety at risk.

7. Electrical Problems

Are you facing electrical problems with your Xplorer 400? Electrical issues can be frustrating and lead to costly repairs if not addressed promptly.

We will list out the most common electrical problems that you might encounter and provide step-by-step solutions to help you fix these problems.

1. Dead Batteries:

The battery is a vital component of your Polaris Xplorer 400 electrical system.

Dead batteries are usually caused by leaving lights or accessories on when the engine is switched off or a faulty charging system. To fix this issue, charge or replace the battery and make sure that it’s correctly connected.

2. Faulty Starter Relay:

If you turn the key, and you hear a clicking sound, but the engine won’t start, the starter relay may be faulty. To fix this issue, check the starter relay and replace it if it’s defective.

3. Blown Fuses:

Fuses protect your electrical system from power surges and short circuits. So, if you have an electrical component that isn’t working, it may be a blown fuse.

Check the fuse box and replace any blown fuses.

4. Faulty Stator:

The stator is responsible for charging the battery and supplying power to the electrical system.

If the stator is defective, the battery won’t charge, and the electrical system will stop working. To fix this issue, replace the stator.

5. Broken Wires:

Broken wires can result in a wide range of electrical problems, such as lights not working, no power to the starter, or even a dead battery. To fix this issue, locate and repair the broken wires.

8. Overheating Problems

There are several factors that can lead to overheating problems with your Polaris Xplorer 400.

One of the most common causes is a lack of proper cooling system maintenance, such as not changing the coolant or not regularly cleaning the radiator.

Another common cause is riding in extreme temperatures or altitudes, which puts added strain on the engine and can cause it to overheat.

To fix issues related to improper maintenance, start by flushing and replacing the old coolant with a brand new one.

Additionally, make sure to clean the radiator thoroughly and inspect it for any signs of damage or wear. If the radiator is damaged, it may need to be replaced.

If the cause of overheating is due to extreme temperature or altitude, there are a few steps you can take to prevent the issue from occurring.

First, try to avoid riding in extreme weather conditions as much as possible. If this is unavoidable, consider installing an aftermarket fan to help with engine cooling.

Additionally, ensure that you are using the correct oil and fuel for your Polaris Xplorer 400, as using the wrong ones can contribute to engine overheating.

What Do The Users Think About Polaris Xplorer 400

1. Maria Hernandez:

As an avid adventurer and lifelong ATV enthusiast, I can safely say that the Polaris Xplorer 400 is one of the best quads I’ve ever had the pleasure of riding. It’s incredibly nimble and versatile, which makes it perfect for exploring different types of terrain.

Plus, the engine is powerful enough to handle any hill or obstacle I’ve thrown its way. The cherry on top? The sleek design and comfortable seating make for an enjoyable ride every time.

2. James Smith:

Honestly, I was a little hesitant to invest in the Polaris Xplorer 400 at first. But after doing some research and taking one out for a spin, I can confidently say that this ATV is worth every penny.

Not only is it durable and reliable, but the handling is smooth and responsive. It’s also incredibly easy to maneuver, which makes it a great option for riders of all skill levels.

3. Samantha Lee:

As someone who primarily uses their ATV for work tasks around a farm, I can attest to the Polaris Xplorer 400’s practicality and efficiency. It has plenty of torque and power, which makes it perfect for hauling heavy loads or towing equipment.

At the same time, it’s also agile and swift enough to navigate through tight spaces and around corners. Plus, the superior build quality ensures that it can withstand even the toughest of jobs.

4. John Davis:

I’ve been riding ATVs for as long as I can remember, and the Polaris Xplorer 400 is easily one of the best ones out there.

The suspension is top-notch and can handle any bumps or jumps you throw its way.

The cockpit is spacious and ergonomically designed, which makes for an incredibly comfortable ride even on longer trips. All in all, this is a fantastic ATV that I would recommend to anyone without hesitation.

5. Sarah Thompson:

The Polaris Xplorer 400 is nothing short of a game-changer when it comes to outdoor exploration.

The suspension system is expertly designed to provide maximum shock absorption, which means you can tackle even the roughest terrain with ease.

Additionally, the built-in storage options are incredibly convenient and make it easy to bring along all the gear you need for a successful adventure.

Overall, this is a must-have ATV for anyone who loves to push the limits and explore the great outdoors.

Frequently Asked Questions

What is the top speed of a Polaris Xplorer 400?

The top speed of a Polaris Xplorer 400 is around 55 mph.

What type of engine does a Polaris Xplorer 400 have?

It is powered by a 2-stroke, liquid-cooled engine.

How much does a Polaris Xplorer 400 weigh?

The weight is approximately 595 pounds.

Does the Polaris Xplorer 400 have a four-wheel drive?

Yes, It comes with a 4-wheel drive system.

What type of suspension does a Polaris Xplorer 400 have?

This ATV model has a dual A-arm front suspension and a progressive-rate rear suspension.

What is the fuel capacity of a Polaris Xplorer 400?

The fuel capacity is 4.25 gallons.

How much can a Polaris Xplorer 400 tow?

The Polaris Xplorer 400 has a towing capacity of up to 1,225 pounds.


As we have explored in this blog post, the Polaris Xplorer 400 has its fair share of problems that can arise with regular use.

However, it is important to acknowledge that every ATV, like any mechanical device, is bound to present its own set of issues at some point.

The key takeaway here is not to deter individuals from investing in this particular model, but rather to empower them with the knowledge and solutions necessary to tackle any setbacks they may encounter.

One unique perspective to consider is how the Polaris Xplorer 400 problems can actually serve as an opportunity for growth and learning.

When a problem arises, it often sparks the need to research and find the proper solution.

This opens up a variety of possibilities for discovering new methods, tools, and techniques that can be used to improve the performance and longevity of the ATV.

It also allows one to become more familiar with the inner workings of the machine, which can lead to a greater understanding and appreciation for the engineering behind it.