xplorer400 model#a00cg38ca rev. 02pi54.com/corp/manuals/parts/9915487r02.pdf · parts manual pn...

PARTS MANUAL PN 9915487 and MICROFICHE PN 9916574 3/00

XPLORER 400Model #A00CG38CA

Rev. 02

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSXplorer 400 A00CG38CA

Parts Manual

AA - ARM/STRUT MOUNTING B12. . . . . . . . . . . .AIR BOX B2. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D8. . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C9. . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER CYLINDER

/BRAKE LINE B10. . . . . . . . . . . . . . . . . . . .CONTROLS - THROTTLE ASM./CABLE B9. . .COOLING SYSTEM A10. . . . . . . . . . . . . . . . . . .CRANKCASE and CYLINDER D3-4. . . . . . . . . . .CV JOINT - NEAPCO B6. . . . . . . . . . . . . . . . . .

DDECALS A8. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C7. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C8. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C10. . . . . . . . . . . . . . .ENGINE MOUNTING A11-12. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A13. . . . . . . . . . . . . . . . . . .

FFRONT BRAKE B8. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING B4-5. . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A9. . .FRONT STRUT B3. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B7. . . . . . . . . . . . . . . . . . . . . .FUEL TANK A14. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR D2. . . . . . . . . . . . . . . . . . . .

GGEARCASE C11-14. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING D1. . . . . . . . . . . . . . .

HHANDLEBAR and HEADLIGHT POD B13-14. . . . . .

MMAGNETO D10. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL PUMP D9. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK B1. . . . . . . . . . . . . . . . . . . . . . . . . .

PPISTON and CRANKSHAFT D5. . . . . . . . . . . . .PROP SHAFT C2. . . . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE MASTER CYLINDER C5. . . . . . .REAR CAB and SEAT A6. . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING C3. . . . . . . . . . . .REAR HOUSING C4. . . . . . . . . . . . . . . . . . . . .REAR RACK MOUNTING A7. . . . . . . . . . . . . . .REAR WHEEL C6. . . . . . . . . . . . . . . . . . . . . .RECOIL STARTER D6. . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR D11. . . . . . . . . . . . . . . . . . .STEERING POST B11. . . . . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING C1. . . . . . . .

TTOOL KIT D12. . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D7. . . . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for as-sembly.

2000 XPLORER 400 SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic/Fixed DiscHydraulic/Rear Axle DiscHydraulic/Rear Axel DiscHydraulic Lock/All Wheel

CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallon)Gearcase Oil (ounces)Engine Counter Balance 10W30Oil (quarts) InjectorOil (quarts) Engine OW40Rack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

2.25432

100 cc2

N/A9018030

Standard850

DRIVE TRAINType Concentric

DRIVE CLUTCHDrive System TypeCenter Distance (inches)Clutch Offset (inches)Clutch WeightSpring Color

PVT101/2

S55 (55)Blue/Green

DRIVEN CLUTCHHelix AngleSpring Position

Compound2-2

DIMENSIONAL FEATURES

Approx. Turning Radius (inches)Tool Box Volume (cubic inches)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

655887.5478134588

49.7546

GEARCASETransmissionShift TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain Type

PRDSide Lever

6.14/14.74/13.06/12:1

13/36 76PN/AN/A

520 O-Ring

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

Dunlop25x8-1225x11-10

N/A43

N/A

ENGINEEngine Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCoolingAlternator OutputElec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayAir ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

EC38PLE084 Cycle, Single Cylinder

Oil Injected83.0x70

3786.9/1 Effective

Liquid200W

Standard1/VM34SS

21035

0-6 (480)1.5 Nickel/Aluminum

1.5 Turn6CEY6-3

CDI23.5 @ 3000

.028NGK BR8ES

USFS Appr. Pending

GRAPHICSBody StyleBumper Caps/Polyprop.Cargo Box or BedFender, FrontFender, RearFootwellFrame/SteelFront CoverHandlebar Cover w/DecalHeadlight Dash PodRack, FrontRack, RearRimsSeat VinylSide PanelSpring, FrontSpring, RearTank CoverTool Box Cover

w/lettering Color

Gen IVN/AN/A

E. B. GreenE. B. Green

BlackBlack

E. B. GreenBlack

E. B. Green/BlackBlackBlack

AluminumBurnished Brown

E. B. GreenBurnished BrownBurnished Brown

N/AN/AN/A

ELECTRICALHeadlight - HandlebarHeadlight - Front HoodTaillight (watts)Brake Light (watts)Indicator BulbBattery

1 Single Beam, 60W2 Single Beams, 27W

8.26W12V/26.9W12V/1.0W12V/14 AH

SUSPENSIONFront Type -

Front Travel (inches)Rear Type -

Rear Travel (inches)ShockShock Adjustment

MacPherson Strut6.7

Progressive Rate Swing Arm9

1 3/8� Bore Gas ChargedCAM

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

2000 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUAL

SUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Xplorer 400 A00CG38CA 9915299 9915472 9915487 9916574 9915508

A5

FRONT CABXPLORER 400 A00CG38CA

45

6

7

8

9

14

2

7

1718

3

3

1516

11

12 13

3

1

10

E 2000 Polaris Sales Inc.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 58114915810996

11

Foil, Side PanelFoil, Foam, Side Panel

2 5431809-1952620085-195

11

Panel, Side, LH, EB GreenPanel/Foil, RH, EB Green(Incl. Foil and Foam)

3 7512232 10 Screw4 5431806-195 1 Cover, Front, EB Green5 7670085 2 Clip, Spring6 2631990-195 1 Cab, Front, EB Green

(Incl. Warning Decals)7 7670057 10 Nut, U-Type Speed8 7670009 2 Nut, Push-on

9 7661645 4 Rivet10 7517312 2 Screw11 7512085 2 Screw12 7555792 2 Washer13 7541925 2 Nut, Nylok14 5431798

543179911

Guard, Mud, Front, LHGuard, Mud, Front, RH

15 7555931 2 Washer16 7542122 2 Nut, Nylok17 7670088 4 Clip, Dart18 5811512

581148911

Shield, Deflector, LHShield, Deflector, RH

10/00

A6

REAR CAB and SEATXPLORER 400 A00CG38CA

21

33

2

23

1

34

9

8

10

1112

24

366

7

14

15

28

22

32

31

29

30

34

25

27

5

1716

35

26

1323

2018

19

1

4


1 7541925 4 Nut, Nylok2 5224592 1 Retainer, Seat Latch3 7512242 4 Screw4 7555859 10 Washer, Flat5 7512085 2 Screw6 5431786 1 Box, Tool7 7517375 2 Screw8 7621403 2 Rivet9 5211033 2 Bracket, Lever Retainer10 1040387 1 Latch, Seat11 7041370 1 Spring, Latch12 2682441-276

2681747-27658111045811105

1111

Asm., Seat, Brown (Incl. 8-13)Covering, Seat, BrownFoil, Seat Base, LargeFoil, Seat Base, Small

13 5410414 8 Bumper, Rubber14 5431787 1 Cover, Tool Box15 5410896 1 Cap, Drain16 5241403-067 1 Guard, Clutch17 7661638 4 Rivet18 5432763 1 Guard, Rock

19 7515179 6 Screw20 1012770-067 1 Frame21 7542122 8 Nut, Nylok22 7517376 8 Bolt23 7555792 4 Washer24 7072791 1 Decal - Filter Element25 5811087 1 Foil, Foam26 5811106 2 Foil, Rear Cab, Front27 5811111 1 Foil Foam, Rear Fender28 5432056-070

5433196-07011

Footwell, Black, LHFootwell, Black, RH

29 7670057 12 Nut, U-Type Speed30 5431796

543179711

Guard, Mud, Rear, LHGuard, Mud, Rear, RH

31 7512232 12 Screw32 5433204-195 1 Cab, Rear, Green33 7511930 2 Bolt34 7661645 10 Rivet35 5811107 1 Foil, Rear Cab, Rear36 7073761 1 Decal - Carb Information

3/99

A7

REAR RACK MOUNTINGXPLORER 400 A00CG38CA

4

3

1

2

7

8

5

10

1213

118

6

11

9


1 7517686 2 Screw2 7517685 2 Screw3 2670174 1 Rack, Rear

(Incl. Ref. 4 and Warning Decal)4 2670070 2 Reflector, Red5 7517264 2 Screw6 1040490-067 1 Support, Rear Rack7 7512329 4 Bolt

8 7542343 8 Nut, Nylok, Flanged9 7670096 2 Nut, Chimney10 1040524-067

1040525-06711

Mount, Rear Rack, Front, LHMount, Rear Rack, Front, RH

11 7558402 4 Washer12 5333332-067 4 Spacer13 7515385 4 Screw

3/99

A8

DECALSXPLORER 400 A00CG38CA

7

10

16

12

5

9

153

6

18

13

8

19

14

43

11

1

17

8

2

1


1 7074954 2 Decal - Rack/Warning2 7078445 1 Decal - “4x4 CDS”, RH3 7078443 2 Decal - “POLARIS” Side Panel4 7078442 1 Decal - Tank Side, RH5 7078003 1 Decal - Headlight Adjustment6 7074935 1 Decal - Warning, AWD Switch7 7078354 1 Decal - Discretionary Warning8 7074220 2 Decal - “Macpherson Strut”9 7078577 1 Decal - Drain Recoil10 7074110 1 Decal - Load Distribution

11 7078446 1 Decal - “400 L/C” Front Cover12 7078315 1 Logo - “45th Anniversary”13 7077919 1 Decal - Warning, General, CPSC14 7076273 1 Decal - Override Switch, AWD15 7078441 1 Decal - Tank Side, LH16 7078253 1 Decal - Age Warning17 7078444 1 Decal - “4x4 CDS”, LH18 7077920 1 Decal - Passenger Warning19 7074750 1 Decal - Tire Pressure

9/99

A9

FRONT RACK and BUMPER MOUNTINGXPLORER 400 A00CG38CA

16

1213

1514

17

18

11

5

6

89

2122

23

2425

2

3

4

10

4

7

1

19

14

20


1 7515194 4 Screw2 2670180 1 Rack, Front (Incl. Ref. 3 and Decal)3 2670071 2 Reflector, Amber4 7515399 6 Screw5 2200775 1 Kit - Front Rack Mount6 5432155-070 1 Bumper7 7558403 2 Washer8 7515391 2 Screw9 7515390 2 Screw10 7555954 2 Washer11 1013210-067

1013211-06711

Support, Front Rack, LHSupport, Front Rack, RH

12 7512232 4 Screw13 2431014

24310154030059

112

Headlight, LHHeadlight, RHBulb, Replacement

14 7542324 4 Nut, Nylok15 7515384 2 Bolt16 7558402 4 Washer17 5810467 1 Plug, Frame18 5241398-067

5241399-06711

Extension, Frame, LHExtension, Frame, RH

19 7515547 2 Screw20 5211633-067 1 Plate Back Mount21 5241583-067 1 Guard, Brush22 5240591-067 1 Grill, Brush Guard23 7621330 7 Rivet24 7512097 6 Screw25 5431814

543181511

Shield, Radiator Side, LHShield, Radiator Side, RH

3/00

A10

COOLING SYSTEMXPLORER 400 A00CG38CA

109

8

11

5

12

1918

7

15

12

13

22

14

6

4

1723

3

2524

20

16

21


1 7542122 2 Nut, Nylok2 7558301 2 Washer, Flat3 4170013 1 Asm., Fan Motor (Incl. Hardware)4 5241355-067 1 Bracket, Cooling Fan5 ------ -- -- -- -- 1 Hose, Engine, Lower (See Engine

Mounting Pg. A12, Ref. 22)6 7080492 2 Cable Tie7 7080138 3 Cable Tie8 4110225 1 Switch, Fan Thermal9 ------ -- -- -- -- 1 Hose, Engine, Upper (See Engine

Mounting Pg. A12, Ref. 11)10 7080614 2 Clamp, Hose11 2511189 1 Cap, Pressure12 1240015 1 Radiator, U-Flow

13 5431760 1 Cover, Radiator w/Mesh14 5410607 4 O-Ring15 7515133 2 Bolt16 7052181 1 Valve, Drain17 5242550 1 Blade, Fan18 5020572 2 Spacer, Radiator Mount19 3110032 2 Mount, Rubber Radiator20 7517475 3 Screw21 4010369 1 Breaker, Circuit22 7512232 4 Screw23 5410584 2 Bushing, Radiator Mount, Lower24 7558201 3 Washer25 7547004 3 Nut, Nylok

3/00

A11

ENGINE MOUNTINGXPLORER 400 A00CG38CA

6

1

3

7

18171615

1413

27

2625

23

28

22

10

12

11

9 10

30

31

32

34

26

4

37

38

37

20

21

36

35

40

38

5

39

39

8

2

29 24

1933

6

6

8

6

25

24

6

6

A12

ENGINE MOUNTINGXPLORER 400 A00CG38CA


1 3110038 1 Mount, Rubber Engine2 7552901 2 Washer, Spring Lock3 7512315 2 Screw4 4010132 1 Cable, Ground, Engine5 7512232 1 Screw6 7547108 7 Nut, Locking Flange7 5242692-067 1 Bracket, Engine Mount, Top8 7555823 2 Washer9 3070156 1 Spark Plug, NGK BR8ES10 7080614 2 Clamp, Hose11 5410570 1 Hose, Upper Engine12 4010218 1 Cable, Solenoid/Starter13 ------ -- -- -- -- 1 Seal, Cover Case

(See Clutch Cover Pg. C9, Ref. 1)14 ------ -- -- -- -- 1 Asm., Drive Clutch, Basic ATV-06

(See Drive Clutch Pg. C7, Ref. 14)15 5430261 1 Bushing16 5210748 1 Washer17 7575202 1 Washer18 7512566 1 Screw19 8360012-04 1 Trim, Edge20 1040687-067 1 Mount, Engine, Front21 7517289 2 Screw22 5411637 1 Hose, Formed

23 7080511 1 Clamp, Narrow Band24 3110042 2 Mount, Rubber Engine25 7552603 6 Washer, Spring Lock26 7512490 6 Screw27 1040231-067 1 Mount, Engine, Front28 5411681 1 Boot, Clutch Inlet29 7080656 1 Clamp, Narrow Band30 3085821 1 Engine, Short Block (EC38PLE08)

NOTE: The Short Block assemblycontains a crankcase assembly, cylin-der and cylinder head assembly, and apiston & crankshaft assembly. Priorauthorization required for warrantyconsideration.

31 8360009-600 AR Line, Fuel32 7051011 1 Valve, Check33 7542411 1 Nut34 5242463-067 1 Bracket, Engine Mount, Rear35 3110048 1 Mount, Torque Stop, Rubber36 7542432 2 Nut37 7080003 2 Clamp, Hose, Red38 8450040-600 AR Line, Fuel39 7080534 2 Clamp, Hose40 2530008 1 Filter, Fuel

10/00

A13

EXHAUST SYSTEMXPLORER 400 A00CG38CA

123

4

5

6

7

9

11

1317

1615

2019

21

12

13

10

8

18

8

14

14


1 7542324 1 Nut, Nylok2 7555716 1 Washer3 5010192 1 Bushing4 5410241 1 Dampener, Vibration5 3110064 1 Mount, Torque Stop6 7542301 1 Nut7 5410436 1 Washer, Rubber8 7512232 3 Screw9 7515316 1 Bolt, Carriage10 5243199-067

754710111

Bracket, Exhaust MountNutsert

11 7512666 1 Bolt

12 7052083 1 Plug, Clean Out13 7042031 2 Spring, Exhaust14 5211688 2 Gasket, Exhaust15 1260906-029 1 Exhaust16 7042029 4 Spring, Exhaust17 1260901-029 1 Headpipe18 5222665 1 Tab, Spring19 ------ -- -- -- -- 2 Nut (See Crankcase and Cylinder Pg.

D4, Ref. 9)20 ------ -- -- -- -- 2 Washer, Lock (See Crankcase and

Cylinder Pg. D4, Ref. 10)21 1260902-029 1 Manifold w/o Gaskets

3/99

A14

FUEL TANKXPLORER 400 A00CG38CA

56

7

8

9

13

14

11

10

19

18

1617

11

15

1

4

3

2

12

2011

21

12

12

12

12

11

11


1 1240048

1240082

1

1

Tank, Fuel(Incl. 6,16,17)(If built before 8/16/99)Tank, Fuel(Incl. 6,16,17)(If built after 8/16/99)

2 5811052 1 Foam, Seal3 5430725 1 Cap, Gas Tank4 5810144 1 Gasket, Fuel Cap5 8360009-600 AR Hose, Vent6 5431053 1 Vent, Tank7 7512310 2 Bolt8 5222154-067

5222155-06711

Bracket, Cover Mount, Rear, LHBracket, Cover Mount, Rear, RH

9 7512208 2 Screw

10 2530008 1 Filter, Fuel

11 8450040-600 AR Line, Fuel12 7080003 8 Clamp, Hose13 5220916-067 1 Bracket, Tank Mount, Rear14 7542324 2 Nut, Nylok15 8360026 AR Tape, Foam16 7052147 1 Fitting, Fuel Outlet, Main, 90 Degree17 7052148 1 Fitting, Fuel Outlet, Reserve, 90 De-

gree18 7052154 1 Valve, 3-Way19 5432733 1 Nut, Fuel Valve20 5432559 1 Knob, Fuel Valve21 7517505 1 Screw

3/00

B1

OIL TANKXPLORER 400 A00CG38CA

12

1

2

4

5

67

8

11

13

1413

12

109

3

15

12


1 5430779 1 Cap, Oil Tank2 5810141 1 Gasket, Oil Cap3 5410991 1 Grommet4 5431793 1 Tank, Drilled Oil5 7052077 1 Fitting6 8360009-600 AR Line, Fuel7 4110265 1 Sensor, Oil Level8 7621460 2 Rivet

9 7080525 1 T-Clip10 7517389 1 Screw11 7052153 1 Fitting12 7080307 2 Clamp, Hose, Large Green13 8450003-1525 AR Line, Fuel14 2530009 1 Filter15 7080568 1 Clamp, Double Wire

3/99

B2

AIR BOXXPLORER 400 A00CG38CA

21

3

4

239

15

18

1920

7

5

16

22

242526

8

21

11

16

10

13

1

17

14

6

27

122


1 7542127 3 Nut, Wing2 7558301 4 Washer3 5240424 1 Cover, Air Box4 5810948 1 Gasket, Cover5 5240336 1 Cover, Filter6 5811099 1 Foam, Precleaner, Sleeve7 1253118 1 Filter, Air8 5810966 1 Foil, Air Box9 5432883 1 Box, Air Silencer10 7080483 1 Cable Tie11 7080487 1 Plug, Cap12 7080476 1 Clamp, Hose13 8450051-600 AR Line, Fuel14 7555932 2 Washer

15 5411413 1 Boot, Carburetor16 7511881 8 Screw17 7080643 1 Clamp, Notched18 5431698 2 Ventura, Intake19 5410934 1 Boot, Air Silencer20 5810988 1 Seal, Foam21 7080598 1 Cable Tie22 7515180 2 Screw23 5432607 1 Stand, Filter24 7515150 2 Stud25 7515151 1 Stud26 5811012 1 Seal, Air Box Foam27 5211804 1 Plate, Air Box

7/98

B3

FRONT STRUTXPLORER 400 A00CG38CA

1

2

3

4

7

5

6

8

9

10

11

12

14

15

13

16

17

18

20

7

19

21 22

23

242526

1011


1 5411608 2 Bumper2 7041761 2 Strut, Front3 5211115 2 Washer4 7080573 2 Clamp, Rubber Coated5 7542303 4 Nut, FLEXLOC6 7517445 4 Screw7 7558402 6 Washer8 5810439 2 Retainer, Strut Casting Wire9 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B8 for Details)10 3554509 4 Bearing, Tapered Roller11 3554507 4 Bearing, Tapered Roller Cup12 5222193 2 Sleeve, Hubstrut Seal13 7080306 2 Fitting, Lubrication14 2410133 2 Coil, Magnetic

15 2201311

2201312

1

1

Asm., Hubstrut, LH ,42mm, Heavy(Incl. 8,11-14,22)Asm., Hubstrut,RH, 42mm, Heavy(Incl. 8,11-14,22)

16 7041375-067 2 Spring, Compression17 5243364 2 Retainer, Spring, Strut18 5432871 2 Pivot, Ball, Bottom19 7515339 4 Bolt20 5132062 2 Spacer, Strut21 ------ -- -- -- -- 1 Kit - Drive Shaft w/Sleeve

(See CV Joint Pg. B6, Ref. 12)22 3610028 2 Seal, Hubstrut23 5432872 2 Pivot, Ball, Top24 5810291 2 Spacer, Rubber25 7555749 2 Washer26 7547104 2 Nut, Nylok

3/00

B4

FRONT HOUSINGXPLORER 400 A00CG38CA

1 222120

19

18

17

1211

9 10

87

65

43

26

25

2423

12

2

16

13

14

15

28

27


1341276 1 Asm., Front Gearcase (Incl.1-12,16-25)(If built before 7/01/99)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Front Housing Input4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing, Ball7 3233698 1 Pinion, Input8 3233697 1 Bushing9 3233319 1 Seal10 3233541 1 Bushing11 3233324 1 Washer12 3233711 1 Plug, Oil Fill13 7080756 1 Clip, Snap In14 8450003-1525 AR Line, Fuel

15 7080307 1 Clamp16 3233524 1 Tube, Vent17 3233696 1 Gearcase18 3233710

32336943233695

111

SubAsm., Output Shaft, Front HousingShaft, OutputGear, 29T

19 3233020 1 Bearing20 3233554 AR Shim21 3233693 1 O-Ring22 3233692 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233702 1 Button, Thrust25 3233254 1 Washer26 3233253 1 Plug, Drain27 7512492 1 Screw28 7552603 1 Washer

3/99

B5

FRONT HOUSINGXPLORER 400 A00CG38CA

1 2

34 5

67

8

9 10

11 12

13

14

1516

17

18

1920 21

22

2324

25

26

27

28

21


1341323 1 Asm. Front Gearcase (Incl.1-12,16-26)(If built after 7/01/99)

1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Front Housing Input4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing, Ball7 3233726 1 Pinion, Input8 3233541 1 Bushing9 3233319 1 Seal10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug, Oil Fill13 7080756 1 Clip, Snap In

14 8450003-1525 AR Line, Fuel15 7080307 1 Clamp16 3233524 1 Tube, Vent17 3233696 1 Gearcase18 3233725 1 Shaft, Output19 3233020 1 Bearing, Ball20 3233554 AR Shim21 3233693 1 O-Ring22 3233724 1 Cover, Output, Front Housing23 3233583 AR Shim24 3233582 1 Button, Thrust25 3233254 1 Washer, Plug26 3233253 1 Plug, Drain27 7512492 4 Screw28 7552603 4 Washer

9/99

B6

CV JOINT - NEAPCOXPLORER 400 A00CG38CA

12

6

7

8 9

11

3 51

2 4

Brand Designated

10


1 ------ -- -- -- -- 1 Asm., CV Housing w/Sleeve2 5222299 1 Sleeve, Drive Shaft Seal3 3260121 1 Clamp, Band4 7670092 1 Circlip5 2201015 1 Kit - Replacement Boot6 1380060 1 Shaft, Replacement (Incl. 4)

7 1380061 1 Cardan, Replacement (Incl. 4,6,8,9)8 3260104 1 Kit - Cross and Bearing9 3260101 1 Yoke, Splined10 7661913 2 Pin, Spring11 3260123 1 Clamp, Band12 2200960 2 Kit - Drive Shaft Asm. w/Sleeve

10/98

B7

FRONT WHEELXPLORER 400 A00CG38CA

10

11

1214

1

2 34

5

89

7

15

1625

24 8

2021

23

DETAIL A

A 13

6

6

22

191817


1 7512325 8 Bolt2 5242935 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub, Elec./Mech.6 3554506 4 Bearing, Tapered Roller Cone7 7515523 8 Stud8 3554507 4 Bearing, Tapered Roller Cup9 1520243 2 Asm., Hub w/Bearing Race (Incl.

3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter13 1321814 2 Spacer

14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5410568 2 Tire (25x8-12)17 7556004 2 Washer18 7542810 2 Nut19 7661401 2 Pin, Cotter20 5410470 2 O-Ring21 5432611 2 Cap, Hub22 7512027 6 Screw23 7542459 8 Nut, Lock24 1520269-117 2 Rim, Front25 1525017 2 Valve, Rim

1/99

B8

FRONT BRAKEXPLORER 400 A00CG38CA

1

2 3

89

11

10

12

4

5 6 7


1910309 1 Asm., Brake Caliper, Front, LH(Incl. 1-10)

1910310 1 Asm., Brake Caliper, Front, RH(Incl. 1-10)

1930642 1 Kit - Front Brake Boot1 7080352 2 Screw, Bleeder2 7515489 2 Screw, Socket Set3 5131115

513111611

Caliper, Brake, LHCaliper, Brake, RH

4 1930665 1 Kit - Seal, Piston and Seal (Incl. 5-7)5 5410779 2 Ring, Molded Square (.094)

6 5410780 2 Ring, Molded Square (.103 x .134)

7 5132294 2 Piston, Caliper8 2200901

2200465

2201149

1

1

1

Kit - Severe Duty Brake Pad, Front(Complete set of 2 pads)Kit - Brake Pad, Front(Complete set of 2 pads)Kit - Brake Pads, Soft, Front

9 1910299 2 Mount, Caliper10 5410495 2 Boot, Bushing11 5410494 2 Boot, Pin Seal12 ------ -- -- -- -- 4 Screw (See Front Strut Pg. B3, Ref.

6)

7/98

B9

CONTROLS - THROTTLE ASM./CABLEXPLORER 400 A00CG38CA

2

1

3

6

5

4

7


1 5433806 1 Cover, Throttle Control2 5411439 1 O-Ring3 2010188 1 Asm., Throttle Control (Incl. 1-4,7)4 2010191 1 Asm., Throttle Clamp

5 7556047 1 Washer, Cable End Sealing6 7080708 1 Cable, Throttle7 5410193 1 O-Ring

3/00

B10

CONTROLS - MASTER CYLINDER/BRAKE LINEXPLORER 400 A00CG38CA

9

4

14

11

10

7

7

8

65

15

2 3

1312

19

20

22

26

23

21

29

18

28

17

1

16

27 25

24


2050078 1 Asm., Master Cylinder (Incl. 17-29)1 5411297 1 Boot, Brake Line2 1930674 1 Bolt, Banjo3 5410988 2 Seal4 1930817 1 Line, Brake5 7052194 1 Fitting, Cross6 1930753 1 Line, Brake, Right, Front w/Fittings7 7080138 8 Cable Tie8 8360011-38 1 Conduit9 7512024 2 Screw10 1930752 1 Line, Brake, Left, Front w/Fittings11 8360031-30 1 Conduit12 7080539 1 Clamp, Nylon13 7621462 1 Rivet14 1930873 1 Line, Brake, Rear Hand15 4110164 1 Switch

16 2200809 1 Kit - Master Cylinder Reservoir(Incl. 17-20)

17 ------ -- -- -- -- 1 Ring, Square, Master Cylinder18 1930797 2 Bolt, Cap19 1930796 1 Cap, Reservoir20 1930795 1 Diaphragm21 2200808 1 Kit - Master Cylinder Clamp22 1930799 1 Asm., Master Cylinder Piston23 1930804 1 Rivet24 2201034 1 Kit - Brake Lever w/Park Brake Latch

(Incl. 23,24,25,27)25 ------ -- -- -- -- 1 Spring26 1930806 1 Nut27 2201090 1 Kit - Park Brake Lever28 1930792 2 Bolt, Master Cylinder Reservoir29 1930805 1 Bolt, Master Cylinder Handle Pivot

3/99

B11

STEERING POSTXPLORER 400 A00CG38CA

1

1615

14

2

3

4

13

8

125

6

10

5

5

9

11

6

7


1 1843051 1 Asm., Steering Post (Incl. 12,13)2 5433416 1 Bushing, Steering, Upper3 7080424 1 Fitting, Lubrication4 7515321 2 Bolt5 7555878 3 Washer6 5410772 2 O-Ring7 5431571 1 Spacer, Steering Post8 7661633 1 Pin, Cotter

9 7543203 1 Nut10 5431570 1 Bushing, Steering, Lower11 7661632 2 Rivet12 5431574 1 Plug, Grease, Steering13 7080433 1 Fitting, Lubrication14 5433415 1 Bushing, Steering, Console15 5222999-067 1 Bracket, Upper Steering Bushing16 7542324 2 Nut, Nylok

9/99

B12

A-ARM/STRUT MOUNTINGXPLORER 400 A00CG38CA

1 45

6

7

89

3

12

1314

27

15

16

181719

21

25

26

2423

22

2829

29 28

2322

20

31 30

2

14

9

11

10


1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820567

1820805

2

2

Asm., Tie Rod(Incl. 4-9)(If Built before 8/16/99)Asm., Tie Rod(Incl. 4-9)(If Built after 8/16/99)

4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061033

706105422

Rod End, LH (If Built before 8/16/99)Rod End, LH (If Built after 8/16/99)

10 5411920 1 Boot, Seal, Rod End11 7517674 2 Bolt (If Built after 8/16/99)12 7555806

755609944

Washer, Flat (If Built before 8/16/99)Washer, Flat (If Built after 8/16/99)

13 7546904 2 Nut14 7661203 4 Pin, Cotter15 7080927 2 Joint, Ball

16 5211121 2 Bracket, Ball Joint17 7512284 4 Screw18 5410548 2 Boot, Rubber19 7542438 2 Nut, Castle20 5431150

543114911

Shield, CV Joint, LHShield, CV Joint, RH

21 7512084 6 Screw22 5433066 4 Bushing, A-Arm, Long23 5020677 4 Bushing24 5020681 2 Shaft, A-Arm25 2201157

220115811

Kit - A-Frame, LHKit - A-Frame, RH

26 7080433 2 Fitting, Lubrication27 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B3, Ref. 15)28 7512492 4 Screw29 7552603 4 Washer, Spring Lock30 7517527 1 Bolt31 7515415 1 Screw

10/00

B13

HANDLEBAR and HEADLIGHT PODXPLORER 400 A00CG38CA

19

42

1312

11

16

40

1

2

3

5

7

8

9

10

15

17

18

20

21

25

26

28

30

39

343235

31

23

29

6

4

4

24

38

22

27

33

14

41

36

37

B14

HANDLEBAR and HEADLIGHT PODXPLORER 400 A00CG38CA


1 3280290 1 Asm., Speedometer (Incl. 14)2 4010140

40400534040054

111

Indicator, Low Oil (Symbol)Indicator, Hot TemperatureIndicator, Neutral/Reverse

3 7511881 3 Screw4 7670086 3 Nut, U-Type5 5433042-195 1 Pod, Headlight, Upper, EB Green6 2460720 1 Harness, Headlight Pod7 ------ -- -- -- -- 1 Asm., Throttle Control

(See Controls - Throttle Asm./CablePg. B9, Ref. 3)

8 5242987-067 1 Tube, Handlebar9 2200774

5630616-067

1

2

Kit - Handlebar Block(Incl. Blocks, 9,10,28)Block, Handlebar

10 7515189 4 Screw11 7541933 2 Nut12 7555868 2 Washer, Lock13 7558212 2 Washer14 3280291 1 Clamp, Speedometer15 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls - Master Cylinder/BrakeLine Pg. B10 for Details)

16 5432926 1 Spacer, Switch, LH17 4010262 1 Switch, Handlebar, Hi/Lo/Rev./Over-

ride, LH18 7517625 1 Screw19 5432952 1 Plug20 5431030 2 Grip, Handlebar

21 5240586-067 1 Bracket, Pod Mounting22 7517317 2 Screw23 4032079 1 Knob, Adjusting

24 5411120 1 Boot25 4032077 1 Collar, Locking26 4032075

287044811

Lens and ReflectorBulb, Replacement, Halogen

27 4032078 1 Rod, Adjusting28 7542122 4 Nut, Nylok29 5410163 2 O-Ring30 7080371

220018811

Cable, Choke ControlKit - Choke Control

31 7670089 2 Nut, U-Type32 7522021 2 Screw33 7080631 1 Clip, Cable Retaining34 5431811-070 1 Pod, Headlight, Lower35 4110264

411014141101484010278

4010321

1111

1

Switch, Ignition (Incl. Key)Key, Blank (#3100-3199)Key, Blank (#3200-3299)Key, Blank, Series 2000, 6700, 6800NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Key, Blank, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

36 7080936 1 Caplug37 5433733 1 Nut, Ignition38 5433534 1 Cover, Key39 7080229 1 Nut, Choke Slide40 4010298 1 Sensor, Hall Effect41 5132382 1 Cap, Hall Sensor42 7517658 1 Screw

10/00

C1

SWING ARM/SHOCK MOUNTINGXPLORER 400 A00CG38CA

6

52

4

24

3

25

1

27

7

8

12

9

15

28

13

29

14

1011

21 20

1918

17

26

2322

9

13

1

16


1 7542439 2 Nut, Nylok2 7041204-067 1 Spring, Compression3 5630551 1 Cam, Adjusting4 7041775 1 Shock5 5241147 1 Retainer, Spring6 7515415 1 Screw7 7661046 2 Rivet8 5432727 1 Guide, Chain Pad9 7080510 2 Fitting, Lubrication10 7547082 1 Nut11 7556035 1 Washer12 5433412 2 Bushing, Swing Arm, RH13 5131697 2 Bolt, Swing Arm14 5131696 1 Bushing, Pivot, RH15 1541383 1 Asm., Swing Arm (Incl. 9,12,28)

16 7078572 1 Decal - Chain Free Play17 5432854 1 Guard, Chain18 7515304 1 Screw19 5332828 1 Bushing20 7558402 1 Washer21 7542321 1 Nut22 7547066 2 Nut, Nylok23 7555883 2 Washer24 7072533 1 Decal - Hitch25 2200472 1 Kit - Hitch (Incl. 22-26)26 7512576 2 Bolt27 7515438 1 Screw28 5433411 1 Bushing, Swing Arm, LH29 5131695 1 Bushing, Pivot, LH

8/00

C2

PROP SHAFTXPLORER 400 A00CG38CA

6 5 4 3

7

12


1380124 1 Asm., Prop Shaft1 5411092 1 O-Ring2 7080424 1 Fitting, Lubrication3 3260131 1 Yoke, Prop Shaft, Transmission

4 3260139 1 Shaft, Prop5 1590256 2 Joint, Cardan6 3260133 1 Yoke, Front Gear Case7 7661913 1 Pin, Spring

3/99

C3

REAR CALIPER MOUNTINGXPLORER 400 A00CG38CA

9

13

14

16

15

12

1110

1

8

3

2 43

17

Frame

7

6

64

5

5


1 7517231 2 Screw2 1910367

220138522014282201467

1121

Caliper, RearKit - Caliper SealKit - Bleeder ReplacementPiston, Caliper, Rear

3 5410988 4 Seal4 1930873 1 Line, Hand Brake, Rear5 1930872 1 Line, Foot Brake, Rear6 4020139 2 Clip, Rosebud7 7670102 2 Clip, Silencer Box8 1930674 2 Bolt, Banjo

9 5131759 1 Bushing, Caliper Mount10 7558402 2 Washer11 7552901 2 Washer, Spring Lock12 7512312 2 Bolt13 5131786 1 Mount, Caliper, Lower14 5131979 1 Mount, Caliper, Upper15 7512325 3 Bolt16 5243134-067 1 Guard, Brake Disk17 2201189

19103391930860

111

Kit - Brake Pad (Incl. Spacer and Pad)SpacerPin

9/02

C4

REAR HOUSINGXPLORER 400 A00CG38CA

1

73

12

1722

19

18

8

5

1415

10

21

9

20

23

11

13

2

6

32

1

6

1011

1213

16

4

4

24

3

3


1 7710472 2 Ring, Retaining2 5510313 2 Retainer, Nut3 7542439 2 Nut, Nylok4 5411555 2 Seal, Foam5 5243133 1 Disk, Brake6 7515513 6 Stud7 1520259 1 Hub, Brake (Incl. 6)8 7710496 1 Ring, Retaining9 5010462 1 Spacer, Axle10 5410889 2 O-Ring11 3610070 2 Seal12 3554518 2 Bearing, Cone, Tapered

13 3554517 2 Bearing, Cup, Tapered14 5132098 1 Housing, Axle, Rear15 7080306 1 Fitting, Lubrication16 3225027 1 Link, Connector, 520 Regina17 5131968 1 Axle, Rear18 5211585-067 1 Guard, Sprocket19 5630586 1 Spacer20 3221111-078 1 Chain, 520 ORD, O-Ring21 3222109 1 Sprocket, 36T22 7512404 3 Bolt23 1520258 1 Asm., Hub, Sprocket (Incl. 6)24 7547108 6 Nut

3/00

C5

REAR BRAKE MASTER CYLINDERXPLORER 400 A00CG38CA

3

19

10

6

1

11

8

9

7

15

4

2

20

21

313

14

1218

5

1617


1 7512247 2 Bolt2 1930854 1 Reservoir3 7080003 2 Clamp, Hose, Red4 1910331 1 Hose5 7661011 1 Pin, Cotter6 7041769 1 Spring7 7555919 2 Washer8 7661401 1 Pin, Cotter9 5431107 2 Bushing10 1012771-067 1 Brake, Foot11 7661843 1 Pin, Clevis

12 7080644 1 Clevis13 7542129 1 Nut14 1910314 1 Asm., Plunger (Incl. 12,13)15 8360012-04 1 Trim, Edge16 7080654 1 Retainer17 7661638 1 Rivet18 7542122 2 Nut, Nylok19 1930899 1 Asm., Master Cylinder, Brake, Foot20 7512208 1 Screw21 5243220-067 1 Bracket, Reservoir

9/99

C6

REAR WHEELXPLORER 400 A00CG38CA

12

9

3

8

4

56

7

2

1

11

612

98

5

4

7

10


1 7512673 8 Screw2 2200341 2 Kit - Hub, Rear (Incl 1,4,6,10)3 7542714 8 Nut4 7555796 2 Washer, Cone5 7543005 2 Nut, Castle6 7661404 2 Pin, Cotter

7 5411164 2 Hub, Cover, Dust8 7555745 2 Washer, Flat9 1525017 2 Valve, Rim10 7670081 8 Pushnut11 1520183-117 2 Rim, Rear12 5411408 2 Tire (25x11-10)

1/99

C7

DRIVE CLUTCHXPLORER 400 A00CG38CA

14

1 23 4

7

13

5 6 7

1211

10

89


1 7512176 6 Bolt2 7552801 6 Washer, Spring Lock3 3576510 1 Cover, Bearing4 7041157 1 Spring, Clutch5 5430945 6 Washer, Multilube6 1321457 3 Roller and Bushing7 5431936 6 Button, Clutch, Stemless8 5630509 3 Weight, Shift (S-55)9 7512266 3 Bolt, Shoulder

10 7541906 3 Nut, FLEXLOC11 3576504 1 Bearing, Moveable (1/2”)12 5210752

524298152107535210754

ARARARAR

Spacer (.020 mm)Spacer (.025 mm)Spacer (.032 mm)Spacer (.050 mm)

13 5020422 3 Pin, Roller14 1321632 1 Asm., Drive Clutch, ATV-06

(Incl. All Less 4,8)

7/98

C8

DRIVEN CLUTCHXPLORER 400 A00CG38CA

3

4

56

7

8

10

11

12

13

1516

17

4

12

9

14


1 5010266 1 Spacer, Driven Clutch2 7556401 AR Bushing3 3211077 1 Belt, Drive4 1322182 1 Asm., Driven Clutch, 3 Angle, Heavy

(Incl. 8-17)5 5220646 1 Washer, Domed6 7552901 1 Washer, Spring Lock7 7515382 1 Bolt8 7555898

7556076ARAR

Washer, Spacer (.020 ”)Washer, Spacer (.025 ”)

9 7556804 AR Washer (.030”)

10 3576504 1 Bearing, Moveable (1/2”)11 3576511 1 Bearing, Moveable (1”)12 7041198 1 Spring, Clutch13 5131447

5132344

1

1

Ramp, Stationary(If built before 9/23/99)Ramp, Stationary(If built after 9/23/99)

14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

3/00

C9

CLUTCH COVERXPLORER 400 A00CG38CA

19

23

4

5

7

9

10

6

12

13

20

27

28

29

34 33

26

30

35

23

15

14

17

2

1

18

8

11

21

3

31

32

26

2425

26 16

22


1 5411554 1 Seal, Clutch Cover2 7555748 3 Washer3 7517542 3 Screw4 5521301 1 Seal, Clutch Cover5 5433542 1 Cover, Clutch, Front6 7670051 1 Clip, Clutch Cover7 7512093 5 Screw8 7078689 1 Decal - Clutch Cover9 7077377 1 Decal - Engine/Clutch Modification10 7074782 1 Decal - Automatic Transmission11 7512094 2 Screw12 7080492 2 Cable Tie13 5410421 1 Boot, Clutch Intake14 ------ -- -- -- -- 4 Screw and Washer (See Crankcase

and Cylinder Pg. D4, Ref. 58)15 5222446-067 1 Bracket, Retainer Seal16 7512098 1 Screw17 7555935 1 Washer18 5410575 1 Seal, Cover, Case

19 7661638 2 Rivet20 5432615 1 Duct, Air Outlet, Clutch21 5242693-067 1 Bracket, Clutch Cover, Front22 7555932 1 Washer23 2201159 1 Kit - Inner Clutch Cover

(Incl. 4,7,11,16,18)24 5242208-067 1 Bracket, Clutch Cover, Rear25 7547067 2 Nutsert26 7512232 3 Screw27 5430743 1 Cap, Overflow, Drilled28 5810279 1 Gasket, Overflow Cap29 5431895 1 Plug, Cap30 7555783 1 Washer31 7080511 1 Clamp, Narrow Band32 7512018 1 Screw33 8450003-1525 1 Line, Fuel34 7052065 1 Fitting, Barbed, 90 Degree35 5433342 1 Duct, Clutch Inlet

3/00

C10

ELECTRICAL/TAILLIGHTXPLORER 400 A00CG38CA

1

2

4 5

6

78

910 11

12

13

1415

16

24

1819

20

21

22

2325

26

1213

17

2928

32

3330

34

31

27

3


1 2460786 1 Harness, Main2 2200593 1 Kit - Circuit Breaker, 20 AMP3 2201795 1 Kit - Circuit Breaker, 10 AMP4 2432034 1 Asm., Taillight w/Brake Light (Incl.

5-10)5 4032046 1 Lens, Taillight6 4032029 2 Screw7 4030043 1 Bulb, Taillight8 4032045 1 Gasket, Taillight9 4032064 1 Backing, Taillight10 7670054 2 Nut, Speed11 7512027 2 Screw12 7571602 4 Washer13 7541925 4 Nut, Nylok14 ------ -- -- -- -- 1 Cable, Solenoid/Starter (See Engine

Mounting Pg. A12, Ref. 12)15 4010094 1 Cable, Battery/Solenoid16 5810290 3 Pad, Battery17 7670109 3 Clip, Routing

18 2200361 1 Kit - Battery Bolt, Short19 4010095 1 Cable, Battery/Engine20 7010032 2 Hook, Battery Strap21 5410424 1 Strap, Battery Holddown22 5432077 AR Tube, Vent23 4140006 1 Battery24 5431769 1 Cover, Battery25 7512007 2 Bolt26 7080138 6 Cable Tie27 4020149 6 Clip, Rosebud28 7511864 1 Screw29 5241416 1 Bracket, CDI30 7512018 2 Screw31 7512017 2 Screw32 4060191 1 Rectifier33 5131818 1 Heat Sink34 2460442 1 Pigtail, Power

3/00

C11

GEARCASEXPLORER 400 A00CG38CA

49

23

4

5

6

46

1

10

25

35

26

41

27

38

28

40

3037

39

31

34

36

15

2415 33

23

22 2120 19

18 17 16

1112

1314

4544

48

50

47

6261

68

6667

98

7

38

3230

26

35

25

25

10

10 15

21

2

65

51

5354

55

63

60

59

5857

56

42 43

29

64

52

C12



1341273 1 Asm., Gearcase (Incl. 1-68)(Confirmpart number before ordering parts)(Ifbuilt before 7/01/99)

1 3233525 1 Screw2 3233054 3 Washer3 3233526 1 Dampener4 3233448 1 Plug5 3233035 1 Washer6 3233527 1 Bushing, Pivot7 3233252 10 Screw8 3233632 1 Gearcase. LH9 3233529 2 Pipe, Knock10 3233020 3 Bearing11 3233558 1 Gear, 98T12 3233544 1 Shaft, Output13 3233545 1 Sprocket, 16/26T14 3233546 1 Chain, Roller15 3233248 3 Seal16 3233542 1 Washer17 3233541 1 Bushing, Garlock18 3233540 1 Shaft, Pinion 13T19 3233306 1 Ring, Retaining20 3233263 1 Cover, Bearing21 3233539 11 Screw22 3233538 1 Sprocket, 14/22T23 3233537 1 Ring, Retaining24 3233704 1 Shaft, Input High/Low/Reverse25 3233018 3 Bearing26 3233176 2 Washer27 3233009 1 Bearing, Needle28 3233666 1 Engagement Dog, Low29 3233019 1 Bearing30 3233010 2 Washer31 3233532 1 Sprocket, 24T32 3233029 1 Ring, Retaining33 3233036 1 Chain, Silent

34 3233535 1 Gear, 30T35 3233177 2 Ring, Retaining36 3233534 1 Bearing, Garlock37 3233533 1 Engagement Dog, High/Reverse38 3233012 2 Washer39 3233014 1 Bearing, Needle40 3233703 1 Shaft, Reverse, 31T41 3233665 1 Gear, 33T42 3233706 1 Fork, Shift, Low43 3233633 1 Fork, Shift, High/Reverse44 3233547 1 Bellcrank45 3233055 2 Nut46 3233153 1 Bellcrank, High/Low/Reverse47 3233045 2 Ring, Retaining48 3233040 2 Washer49 3233548 2 O-Ring50 3233549 2 Shaft, Shift51 3233691 8 Screw52 3233636 1 Decal - Switch53 3233635 1 Switch, High/Reverse54 3233617 1 Switch55 3233037 1 Vent56 3233556 1 Cover, Snorkel57 3233555 1 O-Ring58 3233554 1 Shim59 3233553 1 Gear, Snorkel60 3233552 1 Bushing, Garlock61 3233324 1 Washer62 3233325 1 Dipstick63 3233705 1 Gearcase64 3233043 1 Deflector, Oil65 3233033 4 Screw66 3233309 1 Bracket, Interlock67 3233032 1 Spring68 3233308 2 Pin, Interlock

12/00

C13


45

64 63

6 7

43

62 6160

59

39

52 53 40 5455

56 5758

5150

49

2019

8 9

101112 14

1617

18

13 15

2122 23

24

27

2

28

26

29

25

30

31

3536

32 33

34

3738

48

47

46

4544

4241

1 3

1011

11

108

19 20

27

2

2

262925

30

3940

43

21

20

43

43 39

C14



1341326 1 Asm., Gearcase (Incl 1-64)(Confirmpart number prior to ordering parts)(Ifbuilt after 7/01/99)

1 3233525 1 Screw2 3233054 3 Washer3 3233526 1 Dampener, Carb Vibration4 3233448 1 Plug5 3233035 1 Washer6 3233632 1 Gearcase, LH7 3233529 2 Pipe, Knock8 3233176 2 Washer, Thrust9 3233731 1 Gear, 33T10 3233718 3 Bearing, Needle11 3233720 3 Ring, Retaining12 3233732 1 Engagement Dog, Low13 3233706 1 Fork, Shift Low14 3233736 1 Shaft, Reverse, 31T15 3233633 1 Fork, Shift, High/Rev.16 3233719 1 Sprocket, 24T17 3233721 1 Engagement Dog, High/Rev.18 3233722 1 Gear, 30T19 3233177 2 Ring, Retaining20 3233018 3 Bearing21 3233033 4 Screw22 3233309 1 Bracket, Interlock23 3233032 1 Spring24 3233308 2 Pin, Interlock25 3233548 2 O-Ring26 3233045 2 Ring, Retaining27 3233055 2 Nut, FLEXLOC28 3233547 1 Bellcrank29 3233040 2 Washer30 3233549 2 Shaft, Shift31 3233153 1 Bellcrank, High/Low/Rev.

32 3233691 8 Screw33 3233636 1 Decal - Switch34 3233635 1 Switch35 3233711 1 Plug, Oil Fill36 3233324 1 Washer37 3233617 1 Switch38 3233037 1 Vent39 3233248 3 Seal40 3233539 11 Screw41 3233556 1 Cover, Snorkel42 3233555 1 O-Ring43 3233020 4 Bearing44 3233554 AR Shim45 3233723 1 Shaft, Snorkel46 3233552 1 Bushing47 3233799 1 Gearcase, RH48 3233043 1 Deflector, Oil49 3233036 1 Chain, Silent50 3233704 1 Shaft, Input51 3233019 1 Bearing52 3233537 1 Ring, Retaining53 3233538 1 Sprocket, 14/22T54 3233263 1 Cover, Bearing55 3233306 1 Ring, Retaining56 3233540 1 Shaft, Pinion, 13T57 3233541 1 Bushing58 3233542 1 Washer59 3233546 1 Chain, Roller60 3233545 1 Sprocket, 16/26T61 3233544 1 Shaft, Output62 3233558 1 Gear, 98T63 3233252 10 Screw64 3233527 1 Bushing, Pivot

12/00

D1

GEARCASE MOUNTINGXPLORER 400 A00CG38CA

1

2

9

11 10

4

4

3

13

3

8

8

12

67

5

8

8


1 7517632 2 Screw2 5242456-067 2 Bracket, Transmission3 7542423 4 Nut, Flange4 7512492 2 Screw5 5433109 1 Guide, Chain6 7558301 2 Washer7 7512276 2 Bolt

8 7555806 4 Washer9 7517646 1 Screw10 3221041 1 Sprocket, 13T11 7710434 1 Ring, Retaining12 5211065

52107645211517

ARARAR

Shim (.010)Shim (.020)Shim (.030)

13 7517640 1 Screw

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D2

GEAR SELECTORXPLORER 400 A00CG38CA

2

34

5

6

7

8

11910

22

1

15

14

12

1716

13

18

23

19

21

24

1820

1011


1341289 1 Asm., Gear Selector(Incl. 1-11,19-22,24)

1 3233195 1 Asm., Knob2 7512024 1 Screw3 3233131 1 Strap, Wire4 3233649 4 Screw5 3233648 1 Cover, Gear Selector Boot6 3233646 1 Sphere, Plastic7 3233645 1 Pin, Groove8 3233647 1 Rod, Gear Selector9 3233643 1 Spring, Centering10 3233642 2 Spring, Detent11 3233060 2 Bullet, Detent

12 7061013 2 Rod End, 6mm, LH13 7546702 2 Nut, LH14 5020743 1 Rod, Shift Linkage, Low15 5132042 1 Rod, Shift Linkage, Hi Range16 7546701 2 Nut, RH17 7061014 2 Rod End, 6mm, RH18 7546707 4 Nut, FLEXLOC19 3233639 1 Slide, Low20 3233076 2 O-Ring21 3233640 1 Slide, High/Reverse22 3233641 1 Body, Gear Selector23 7512232 5 Screw24 3233644 1 Pin, Dowel

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D3

CRANKCASE and CYLINDERXPLORER 400 A00CG38CA

1

2

34

7

8

910

1112

1314

15

28

16

27 25

17

181920

212223

24

2637

38

39

40

41

42

43

44

4748

4950

51

52

50

53

56

57

54

50

58

33

34

3231 30

2529

35

36

3334 35

44

13

55

4645

6

5

65

255 6

D4

CRANKCASE and CYLINDERXPLORER 400 A00CG38CA


1 3086753 1 Cylinder (Incl. 2,12,13)2 3084138 6 Stud3 3084731 1 Gasket, Head4 3086755 1 Cylinder Head (Incl. 8)5 3082758 3 Gasket6 3086744 3 Plug7 3082910 6 Nut, Flange8 3086756 1 Pipe, Water9 3080285 2 Nut10 3080530 2 Washer, Lock11 3086757 1 Gasket, Exhaust12 3085326 2 Stud13 3086746 2 Pipe 1, Elbow14 3082911 4 Nut, Flange15 3086758 1 Bolt, Banjo16 3083138 2 Gasket17 3085277 1 Adapter18 3240064 2 Valve19 3240065 2 Stopper20 3240066 6 Screw and Washer21 3086760 1 Gasket, Reed Valve22 3084147 1 Asm., Reed Valve (Incl. 18-20)23 3240164 1 Stuffer24 3081497 1 Screw, Pan Head25 3083590 3 Clamp26 3084144 1 Asm., Band, Adapter (Incl. 24)27 3086759 6 Bolt, Flange, Adapter28 3083894 1 Check Valve29 3084729 1 Gasket, Cylinder30 3083384 1 Clamp

31 3080142 1 Washer32 3084124 2 Bolt, Flange33 3084118 2 Stud34 3084119 2 Stud35 3086740 1 Asm., Crankcase

(Incl. 5,6,32-36,44,47,50,54-57)36 3084123 1 Bearing, Ball37 3086749 1 Plug38 3082956 1 Gasket39 3086748 1 Gasket, Case 340 3084128 1 Pipe, Breather41 3086751 2 Bolt, Flange42 3086747 1 Pipe 2, Elbow43 3086752 1 Bolt, Flange44 3084120 2 Seal, Oil45 3086750 1 Plug46 3083482 1 Gasket47 3086743 2 Bolt, Flange48 3086745 1 Asm., Crankcase 3

(Incl. 13,40,42,44,45,46,50,51)49 3084134 4 Bolt, Flange50 3086741 6 Pin, Dowel51 3084131 1 Bearing, Ball52 3084733 1 O-Ring53 3086761 1 Gauge, Oil54 3086742 3 Bolt, Flange55 3084775 1 Bearing, Ball56 3084121 2 Bearing, Ball57 3084725 1 Seal, Oil58 3084205 4 Screw and Washer

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D5

PISTON and CRANKSHAFTXPLORER 400 A00CG38CA

1

23

4

5

2

6

7

8910

1112

1314

1110

15

1718

19

2021

17

22

23

16


1 308473730847383084739

222

Piston Ring (Std)Piston Ring (0.25”/.010mm O/S)Piston Ring (0.50”/.020mm O/S)

2 3084167 2 Clip, Piston Pin3 3083838 1 Piston Pin4 3085886

30858873085888

111

Piston (Std)Piston (0.25”/.010mm O/S)Piston (0.50”/.020mm O/S) NOTE:This Part Is Interchangeable In ACombination Of Carburetor Parts.

5 3084172 1 Balancer6 3086768 1 Plate7 3086769 2 Bolt, Flange8 3084156 1 Gear, Drive9 3086764 1 Washer, Guide10 3084160 2 O-Ring

11 3086763 2 Collar12 3086762 1 Nut, Slit13 3086767 1 Washer14 3083905 1 Nut, Lock15 3084776

3084149

1

1

Asm., Crankshaft(Incl. 15,17,18,20,21,23)Crankshaft 1

16 3080130 2 Key, Woodruff17 3084155 2 Spacer, Crank Pin18 3084154 1 Bearing, Large End19 3084168 1 Bearing, Small End20 3084153 1 Rod, Connecting21 3084777 1 Crankshaft 222 3086765

3086766ARAR

Spacer 1 (0.2mm)Spacer 2 (0.3mm)

23 3084152 1 Crank Pin 1

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D6

RECOIL STARTERXPLORER 400 A00CG38CA

1

2 3

4

7

9

10

11

12

14

13

8

6

5

5


1 3083185 1 Spring, Spiral2 3084750 1 Bushing3 3086749 1 Plug4 3082956 1 Gasket5 3085651

308565611

Asm., Recoil Starter (Incl. 1,2,5,8-14)Starter Case

6 3084782 1 Bolt and Washer7 3086751 8 Bolt, Flange

8 3085266 1 Bolt and Washer9 3084744 1 Plate, Friction10 3083379 1 Spring, Friction11 3084822 1 Reel12 3085083 1 Rope13 3083463 1 Spring, Return14 3083378 1 Ratchet

3/99

D7

WATER PUMPXPLORER 400 A00CG38CA

1

2

3

15

2

1413

12

10

11

9

8

7

5

4

6

4


1 3084284 1 Thermo Switch (105 Degree C)2 3086774 2 Clamp, Hose3 3086773 1 Hose, Main4 3083856 4 Nut, Flange5 3083073 1 Nut6 3080077 1 Washer, Spring7 3082206 1 Washer8 3084186 1 Impeller

9 3084187 1 Gasket, Casing10 3086775 1 Stud11 3086772 3 Stud12 3086770

308677111

Casing, Water Pump (Incl.10-15)Casing, Water Pump (Incl. 10,11)

13 3084185 1 Seal, Oil14 3084184 1 Seal, Oil15 3084183 1 Bearing, Ball

5/99

D8

CARBURETORXPLORER 400 A00CG38CA

1

2

34

5

6

10

1112

31

30

2729

28262524

23

222120

19

1817

16

1514

13

9

8

7


1 3130184 1 Asm., Top2 3130496 1 Spring, Throttle3 3130027 1 Plate, Throttle4 3130003 1 E-Ring5 3130476 1 Needle, Jet (6CEY6-3)6 3130355 1 Packing7 3130199 1 Cap, Plunger8 3130006 1 Spring9 3130328 1 Plunger10 3130494 1 Valve, Throttle (1.5)11 3130429 1 Asm., Jet, Needle (480)12 3130596 1 Ring, Main Jet13 3130436 1 Spring, Throttle Adjuster14 3130447 1 Washer15 3130009 1 Screw, Throttle Stop16 3130011 1 Adjuster

17 3130012 1 Spring, Air Adjuster18 3130066 1 Jet, Pilot (#35)19 3130025 4 Screw20 3130432 1 Screw, Guide21 3130239 1 O-Ring22 3130124 1 Jet, Main (#210)23 3130443 1 Float Chamber24 3130430 2 Float25 3130237 2 Cap26 3130020 1 Gasket27 3130495 1 Valve, Needle (2.5)28 3130018 1 Arm, Float29 3130361 1 Pin, Float30 3130047 1 Packing31 3130957 1 Asm., Carburetor (Incl. 1-31)

7/98

D9

OIL PUMPXPLORER 400 A00CG38CA

1

2

3

4

5

6

8

9

10

11

9

12

14

15

1617

1819

1320

7


3085284 1 Asm., Oil Pump (Incl. 11-20)1 3084757 3 Bolt and Washer2 3085281 1 Cover, Case, Oil Pump3 3085280 1 Gasket, Case, Oil Pump4 3085520 1 Case, Oil Pump5 3086777 1 Grommet6 3086779 1 Grommet7 3086778 3 Screw and Washer8 3083783 2 Screw and Washer9 3083141 2 Clamp, Hose10 3086776 1 Pipe, Vinyl

11 3083120 1 Nut12 3083121 1 Washer, Spring13 3083445 1 Collar, Camshaft14 3083127 1 O-Ring15 3084195 1 Spacer16 3084196 1 Wheel17 3084197 1 Pin, Spring18 3084194 1 Washer19 3083125 1 Screw, Air Vent20 3085570 1 Lever and Spring Set

7/98

D10

MAGNETOXPLORER 400 A00CG38CA

1 23

4

5

1

6

7

1

8

910

11

12

15

16

1314

7


1 3081260 3 Screw and Washer2 3081146 1 Clamp3 3084761

308476211

Asm., Plate (Incl. 1-3,5-9)Plate, Coil

4 3084766 3 Screw, Flange5 3081342 3 Screw and Washer6 3084765 1 Clamp7 3084763 1 Stator8 3084764 2 Screw and Washer

9 3084099 1 Band10 3084760 1 Flywheel w/Ring Gear11 4020129 1 Cap, Spark Plug12 3083923 1 Ignition Coil13 3083073 2 Nut14 3080077 2 Washer15 3085521 1 Switch, Magnetic16 3085623 1 C.D.I. System

7/98

D11

STARTING MOTORXPLORER 400 A00CG38CA

31

2

4

7

9

10

11

12

1314

154

1718

19

20

21

22

23

24

8

6

5

16

8


1 3083649 2 Nut, Flange2 3084406 1 Brush3 3085392

3085393

1

1

Asm., Starting Motor(Incl. 1-5,7,9,11-17,20-24)Asm., Starter (Incl. 1-5,7,9,11-16)

4 3084405 2 Ring, Rubber5 3085032 1 Cover, Rear6 3082758 1 Gasket, Aluminum7 3084408 3 O-Ring8 3086782 5 Bolt, Flange9 3084407 2 Asm., Bolt, Through10 3086780 1 Bracket11 3083754 1 Washer Set

12 3084404 1 Asm., Armature (Incl. 13,14)13 3083934 1 O-Ring14 3083777 1 Bearing, Ball15 3083741 1 O-Ring16 3085305 1 Cover, Front (Incl. 15)17 3083737 1 Washer, Gear Shaft18 3085283 1 Gasket, Starter19 3086781 2 Bolt, Flange20 3084409 1 Clip21 3084410 1 Spring, Return22 3085394 1 Asm., Gear Shaft (Incl. 17,20-24)23 3084411 1 Spring, Weight24 3084412 1 Clip

3/99

D12

TOOL KITXPLORER 400 A00CG38CA

1

3

4

5

6

8

2

7


1 2682572 1 Pouch, Tool Kit2 9915299

991547211

Owner’s Manual, ’00 ATVSupplement, Owner’s Manual, ’00Xplorer 400

3 3083612 1 Wrench, Box, Special

4 3083613 1 Wrench, 10-12 Spanner5 3083843 1 Screwdriver6 2870725 1 Gauge, Tire Pressure7 5211627 1 Wrench, Spanner8 2870694 1 Tool Kit (Incl. 1-7)

3/00

PRINTED IN THE USA PARTS MANUAL PN 9915487 and MICROFICHE PN 9916574 3/00

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xplorer400 model#a00cg38ca rev. 02pi54.com/corp/manuals/parts/9915487r02.pdf · parts manual pn...

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