I just bought a '96 400 Explorer 4x4 last night and do not have a maintenance manual yet. I would really like to do all the maintenance before I ride...can anyone tell me the recommended oil and capacity, plugs, and how to adjust chain?

 

The plug is an NGK BR8ES The oil capacity is 2 quarts and the best oil to use is Polaris synthetic gold. If you don't have easy access to a Polaris dealear then Amsoil or a number of other injector type synthetic oils will suffice. A 96 Explorer is a non-concentric drive type machine. You need to take a ratchet type tiedown and hook it to the grab bar ( located directly underneath the rear rack) at one end and to the hitch point at the other and compress the suspension untill the two sprockets are alligned. Loosen the to rear concentric bolts ( the ones just to the rear of the axle) then take a punch or a screwdriver and put it trough the hole located in the sprocket (down low close to the axle) roll the machine forward and backward untill you can push it into a corresponding hole in the axle carrier housing. Once you push it through roll the machine slightly untill there is about 1/8-1/12 inch of freeplay in the chain then retighten the concentric bolts to about 65ft.lbs. I hope this helps, enjoy your new machine.
Joe

 

Steve
I am in the market for a similar year and model. I was wondering what you paid for the 400 and howmany miles did it have.

Trying to learn their values.

AJ

 

AJ, I think I got the deal of the century so my purchase is not a good data point. I found this one for $1500 with 1500 miles on it. I thought it was a misprint in the cycle trader, but I raced the 150 miles and beat everybody else to it. This guy took it as partial payment for a car and has never been around four wheelers, and didn't want one, so he had no idea what it was worth. People were calling from 500 miles away begging him not to sell it before they got there. I think the going rate for this machine would be around $3000.

 

Steve

I think your machine has the three chain system. Follow JoeMag's instructions for the rear chain. The middle and front chains are similar to the back chain, expect I think you roll it backward. Adjust the middle chain first. It should have about 1/4 to 1/2 inch freeplay. This adjustment affects the front chain. Once the middle is adjusted, You have to tighten the front chain. This one is more of a pain. You have to loosen the bolt from underneath and insert the pin and roll it backward. There is several holes in the bearing housing. Try to put a pin in the one that gives the best leverage. What ever you do, do not try to use the engine to back the chain up. In a moment of stupidity, I tried this and broke the sprocket. Another $50 screw up. Post another response if you have any questions or get stuck.

 

Steve

I looked up this machine in Kelley's blue book:

Trade In Value - $2,445
Retail Value - $3,585

Sounds like you got a great deal.