Hello-

Thank you all for your help. I finally found the fill plug behind the plastic on the footwell. It was not what I would call easy access.

This 2000 Polaris Xplorer 400 4x4 has been fun to work on so far. There is a 1996 version of the same one next to it in the barn that will benefit from all I have learned here.

I did the front hub fluid, front diff fluid, gearcase fluid last night.

Fixed the brake light.

Now, it's time to rectify the "no low beams" problem and bend back the handlebar mount perch where the previous owner rolled it.

When he did so, it bent the bars down and a little to the side. I wonder if the headlight switch is bad from that. The high beam cannot be adjusted down far enough, so I know something between the steer tower and the high beam light is bent.

I bought some camo cover stuff for the plastics, too.

Onward to the cosmetic stuff and trying to minimize the grind going into reverse.

 

Does the Xplorer have the single Pod light at the bars? If so there is "no low beam" on the pod light. High beam is the 60w pod light on its own, low beam is the two 30w grill lights on there own.

Do a seach on this site and there is a way to wire it that all 3 lights work at once while on hight beam, they call it the "3 light mod" I think.

On mine ,I can actually slide the high/low switch just in the middle and have all 3 lights on for awhile until a bump knocks it off position.

Fool with the reverse adjuster rod from the lever to the tranny until it engages smoother, but it will always require a quick backwards jerk. They all grind abit if you try to slowly move the lever in gear.

 

Howdy-
Yeah, it's the two bumper lights that are a no go. The bulbs look good, reterminated the ground for them. Still nothing. I have not had time to test it point by point with the voltmeter. I need to test the blower fan, too. I have never heard it come on.

 

On my 2000 500 mag, you can test the fan by....
1 disconnect the harness from fan switch on radiator.
2 place a jumper wire between the wires on the connector
3 turn the ignition key to on, the fan should come on.

If you're set up similar maybe that will help.

Also let me know how the camo works out. I am thinking of trying the same thing.

 

Thank you. Good tip.

You just saved me a half hour of schematic reading!!!

Now I can't wait to try!!

I am planning to use camo tape and clear engine paint- it flexes.