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1996 Xplorer 400 Info Needed

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Old 05-07-2018, 04:38 PM
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Default 1996 Xplorer 400 Info Needed

Good afternoon I just purchased a 1996 Xplorer 400 with about 500 miles on it. I am looking to do a complete change of all the fluids before I start riding it. I have downloaded the Polaris service manual but it is very vague in terms of the finding the drain and fill plugs. I will attach some pics of my machine in the hopes you all could steer me in the right direction. I appreciate the help.

I believe I have found the transmission and the counter balance fills but cannot find the oil, transmission, gear or counter balance drain bolts.

1996 Xplorer 400 Info Needed-3odvk7c.jpg

1996 Xplorer 400 Info Needed-vxr5u1r.jpg

1996 Xplorer 400 Info Needed-8ymulvu.jpg
 
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Old 05-08-2018, 03:11 PM
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I can't remember for sure so I ask the dumb question, is this a 2 stroke as some 400's were. it's been apart for sure as there is red silicone gasket material visible for sure.
 
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Old 05-08-2018, 09:49 PM
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Correct I should have added that to the original post. This is the 2 stroke model. The transmission and motor have the red gasket seal so it’s definitely been worked on before. The incredible thing is I am the third owner of the ATV. I have the original invoice from the original owner and the owner I purchased it from. Both older gentlemen.
 
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Old 05-09-2018, 12:31 PM
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There are a few 10mm head plugs on the bottom of the crankcase. If you go on partzilla.com and look up your machine, they will give a break down of your motor. There are two plugs marked #6. One is for the crankcase cavity and the other is for the counterbalance. The one marked #45 is for the flywheel cavity. Hope this helps.

Mike
 
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Old 05-09-2018, 12:32 PM
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well at least there is no engine oil to change out. with out seeing it (been a long time since worked on one of those)it's hard to tell you what is a drain. look near the bottom or side for a different bolt then the assembly bolts and that might help to see it. hopefully the oil in the counterbalance won't be white. that happens when water gets in there.
 
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Old 05-09-2018, 05:31 PM
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I’ll check that tomorrow for sure!

Here’s a video I took today. Fixed the pull start and new battery fires it right up.

https://youtu.be/zviTEhg4RjE
 
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Old 05-10-2018, 12:29 AM
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That thing has too many chains. The Sportsman 500 came out the same year.

Here's a working link to the video. https://www.youtube.com/watch?v=zviT...ature=youtu.be
 
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Old 05-10-2018, 06:42 AM
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First bike with a chain, but the price was too good to pass up on this one. Thanks for the link!
 
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Old 05-10-2018, 08:34 AM
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Found this 2 cycle oil at my dealer. Not sure if it’ll work though. Says for variable exhaust systems.

 
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Old 05-10-2018, 11:15 AM
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Here is what I got out of the crankcase (transmission). Going to flush it a few times.

Nothing came out of the counterbalance drain unfortunately.

 


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