XPLORER 400 Model #A00CG38CA Rev. 02

Transcription

1 XPLORER 00 Model #A00CGCA Rev. 0 E 000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00

2 TABLE OF CONTENTS Xplorer 00 A00CGCA Parts Manual A - ARM/STRUT MOUNTING... AIR BOX... A C B B CARBURETOR... D CLUTCH COVER... C CONTROLS - MASTER CYLINDER /BRAKE LINE... B0 CONTROLS - THROTTLE ASM./CABLE... B COOLING SYSTEM... A0 CRANKCASE and CYLINDER... D- CV JOINT - NEAPCO... B DECALS... DRIVE CLUTCH... DRIVEN CLUTCH... D E A C C ELECTRICAL/TAILLIGHT... C0 ENGINE MOUNTING... A- EXHAUST SYSTEM... A FRONT BRAKE... B FRONT CAB... A FRONT HOUSING... B- FRONT RACK and BUMPER MOUNTING... A FRONT STRUT... B FRONT WHEEL... B FUEL TANK... A GEAR SELECTOR... D F G GEARCASE... C- GEARCASE MOUNTING... H D HANDLEBAR and HEADLIGHT POD... B- G M MAGNETO... OIL PUMP... OIL TANK... PISTON and CRANKSHAFT... PROP SHAFT... REAR BRAKE MASTER CYLINDER... REAR CAB and SEAT... REAR CALIPER MOUNTING... REAR HOUSING... REAR RACK MOUNTING... REAR WHEEL... RECOIL STARTER... STARTING MOTOR... STEERING POST... SWING ARM/SHOCK MOUNTING... TOOL KIT WATER PUMP O P R S T... W... D0 D B D C C A C C A C D D B C D D The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

3 Type - Front Type - Rear Type - Auxiliary Type - Parking BRAKES CAPACITIES Coolant Capacity (quarts) Fuel Tank (gallon) Gearcase Oil (ounces) Engine Counter Balance 0W0 Oil (quarts) Injector Oil (quarts) Engine OW0 Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight Type DRIVE TRAIN DRIVE CLUTCH Drive System Type Center Distance (inches) Clutch Offset (inches) Clutch Weight Spring Color DRIVEN CLUTCH Helix Angle Spring Position 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) GEARCASE Transmission Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type TIRES&WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center 000 XPLORER 00 SPECIFICATIONS ENGINE Hydraulic/Fixed Disc Hydraulic/Rear Axle Disc Hydraulic/Rear Axel Disc Hydraulic Lock/All Wheel. 00 cc N/A Standard 0 Concentric PVT 0 / S () Blue/Green Compound -.. PRD Side Lever././.0/ : / P N/A N/A 0 O-Ring Dunlop x- x-0 N/A N/A Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (cc s) Compression Ratio Cooling Alternator Output Elec. Start w/recoil Back Up Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Air Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust GRAPHICS Body Style Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover w/decal Headlight Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Tank Cover Tool Box Cover w/lettering Color ELECTRICAL Headlight - Handlebar Headlight - Front Hood Taillight (watts) Brake Light (watts) Indicator Bulb Battery SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Shock Adjustment ECPLE0 Cycle, Single Cylinder Oil Injected.0x0./ Effective Liquid 00W Standard /VMSS 0 0- (0). Nickel/Aluminum. Turn CEY NGK BRES USFS Appr. Pending Gen IV N/A N/A E. B. Green E. B. Green Black Black E. B. Green Black E. B. Green/Black Black Black Aluminum Burnished Brown E. B. Green Burnished Brown Burnished Brown N/A N/A N/A Single Beam, 0W Single Beams, W.W V/.W V/.0W V/ AH MacPherson Strut. Progressive Rate Swing Arm / Bore Gas Charged CAM 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.

4 000 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER S MANUAL OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Xplorer 00 A00CGCA 0

5 FRONT CAB XPLORER 00 A00CGCA E 000 Polaris Sales Inc. 0 0 Foil, Side Panel Foil, Foam, Side Panel Panel, Side, LH, EB Green Panel/Foil, RH, EB Green (Incl. Foil and Foam) 0 Screw 0- Cover, Front, EB Green 00 Clip, Spring 0- Cab, Front, EB Green (Incl. Warning Decals) 00 0 Nut, U-Type Speed 000 Nut, Push-on A Rivet 0 Screw 0 Screw Washer Nut, Nylok Washer Nut, Nylok 00 Clip, Dart Guard, Mud, Front, LH Guard, Mud, Front, RH Shield, Deflector, LH Shield, Deflector, RH 0/00

6 REAR CAB and SEAT XPLORER 00 A00CGCA Nut, Nylok Retainer, Seat Latch Screw 0 Washer, Flat 0 Screw Box, Tool Screw 0 Rivet 0 Bracket, Lever Retainer 0 00 Latch, Seat 00 Spring, Latch Asm., Seat, Brown (Incl. -) Covering, Seat, Brown Foil, Seat Base, Large Foil, Seat Base, Small 0 Bumper, Rubber Cover, Tool Box 0 Cap, Drain 0-0 Guard, Clutch Rivet Guard, Rock Screw Frame Nut, Nylok Bolt Washer 0 Decal - Filter Element 0 Foil, Foam 0 Foil, Rear Cab, Front Foil Foam, Rear Fender Footwell, Black, LH Footwell, Black, RH 00 Nut, U-Type Speed 0 Guard, Mud, Rear, LH Guard, Mud, Rear, RH Screw 0- Cab, Rear, Green 0 Bolt 0 Rivet 0 Foil, Rear Cab, Rear 0 Decal - Carb Information / A

7 REAR RACK MOUNTING XPLORER 00 A00CGCA 0 Screw Screw 0 Rack, Rear (Incl. Ref. and Warning Decal) 000 Reflector, Red Screw Support, Rear Rack Bolt A Nut, Nylok, Flanged 00 Nut, Chimney Mount, Rear Rack, Front, LH Mount, Rear Rack, Front, RH 0 Washer -0 Spacer Screw /

8 DECALS XPLORER 00 A00CGCA 0 0 Decal - Rack/Warning 0 Decal - x CDS, RH 0 Decal - POLARIS Side Panel 0 Decal - Tank Side, RH 000 Decal - Headlight Adjustment 0 Decal - Warning, AWD Switch 0 Decal - Discretionary Warning 00 Decal - Macpherson Strut 0 Decal - Drain Recoil 0 00 Decal - Load Distribution 0 Decal - 00 L/C Front Cover 0 Logo - th Anniversary 0 Decal - Warning, General, CPSC 0 Decal - Override Switch, AWD 0 Decal - Tank Side, LH 0 Decal - Age Warning 0 Decal - x CDS, LH 00 Decal - Passenger Warning 00 Decal - Tire Pressure / A

9 FRONT RACK and BUMPER MOUNTING XPLORER 00 A00CGCA 0 0 Screw 00 Rack, Front (Incl. Ref. and Decal) 00 Reflector, Amber Screw 00 Kit - Front Rack Mount -00 Bumper 0 Washer Screw 0 Screw 0 Washer Support, Front Rack, LH Support, Front Rack, RH Screw Headlight, LH Headlight, RH Bulb, Replacement Nut, Nylok Bolt 0 Washer 0 Plug, Frame -0-0 Extension, Frame, LH Extension, Frame, RH Screw 0-0 Plate Back Mount -0 Guard, Brush 0-0 Grill, Brush Guard 0 Rivet 0 Screw Shield, Radiator Side, LH Shield, Radiator Side, RH /00 A

10 COOLING SYSTEM XPLORER 00 A00CGCA 0 0 Nut, Nylok 0 Washer, Flat 00 Asm., Fan Motor (Incl. Hardware) -0 Bracket, Cooling Fan Hose, Engine, Lower (See Engine Mounting Pg. A, Ref. ) 00 Cable Tie 00 Cable Tie 0 Switch, Fan Thermal Hose, Engine, Upper (See Engine Mounting Pg. A, Ref. ) 0 00 Clamp, Hose Cap, Pressure 00 Radiator, U-Flow 0 Cover, Radiator w/mesh 00 O-Ring Bolt 0 Valve, Drain 0 Blade, Fan 00 Spacer, Radiator Mount 00 Mount, Rubber Radiator 0 Screw 00 Breaker, Circuit Screw 0 Bushing, Radiator Mount, Lower 0 Washer 00 Nut, Nylok /00 A0

11 A ENGINE MOUNTING XPLORER 00 A00CGCA

12 ENGINE MOUNTING XPLORER 00 A00CGCA 00 Mount, Rubber Engine 0 Washer, Spring Lock Screw 00 Cable, Ground, Engine Screw 0 Nut, Locking Flange -0 Bracket, Engine Mount, Top Washer 00 Spark Plug, NGK BRES 0 00 Clamp, Hose 00 Hose, Upper Engine 00 Cable, Solenoid/Starter Seal, Cover Case (See Clutch Cover Pg. C, Ref. ) Asm., Drive Clutch, Basic ATV-0 (See Drive Clutch Pg. C, Ref. ) 0 Bushing 0 Washer 0 Washer Screw 00-0 Trim, Edge Mount, Engine, Front Screw Hose, Formed 00 Clamp, Narrow Band 00 Mount, Rubber Engine 0 Washer, Spring Lock 0 Screw 00-0 Mount, Engine, Front Boot, Clutch Inlet 00 Clamp, Narrow Band 0 0 Engine, Short Block (ECPLE0) NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization required for warranty consideration AR Line, Fuel 00 Valve, Check Nut -0 Bracket, Engine Mount, Rear 00 Mount, Torque Stop, Rubber Nut 0000 Clamp, Hose, Red AR Line, Fuel 00 Clamp, Hose Filter, Fuel 0/00 A

13 EXHAUST SYSTEM XPLORER 00 A00CGCA 0 0 Nut, Nylok Washer 00 Bushing 0 Dampener, Vibration 00 Mount, Torque Stop 0 Nut 0 Washer, Rubber Screw Bolt, Carriage Bracket, Exhaust Mount Nutsert Bolt A 00 Plug, Clean Out 00 Spring, Exhaust Gasket, Exhaust 00-0 Exhaust 00 Spring, Exhaust 00-0 Headpipe Tab, Spring Nut (See Crankcase and Cylinder Pg. D,Ref.) Washer, Lock (See Crankcase and Cylinder Pg. D, Ref. 0) 00-0 Manifold w/o Gaskets /

14 FUEL TANK XPLORER 00 A00CGCA Tank, Fuel (Incl.,,)(If built before //) Tank, Fuel (Incl.,,)(If built after //) 0 Foam, Seal 0 Cap, Gas Tank 0 Gasket, Fuel Cap AR Hose, Vent 0 Vent, Tank 0 Bolt Screw Filter, Fuel Bracket, Cover Mount, Rear, LH Bracket, Cover Mount, Rear, RH A AR Line, Fuel 0000 Clamp, Hose 0-0 Bracket, Tank Mount, Rear Nut, Nylok 00 AR Tape, Foam 0 Fitting, Fuel Outlet, Main, 0 Degree 0 Fitting, Fuel Outlet, Reserve, 0 Degree 0 Valve, -Way Nut, Fuel Valve 0 Knob, Fuel Valve 0 Screw /00

15 OIL TANK XPLORER 00 A00CGCA 0 0 Cap, Oil Tank 0 Gasket, Oil Cap 0 Grommet Tank, Drilled Oil 00 Fitting AR Line, Fuel 0 Sensor, Oil Level 0 Rivet 00 T-Clip 0 Screw 0 Fitting 000 Clamp, Hose, Large Green 000- AR Line, Fuel 000 Filter 00 Clamp, Double Wire / B

16 AIR BOX XPLORER 00 A00CGCA 0 0 Nut, Wing 0 Washer 0 Cover, Air Box 0 Gasket, Cover 0 Cover, Filter 0 Foam, Precleaner, Sleeve Filter, Air 0 Foil, Air Box Box, Air Silencer 0 00 Cable Tie 00 Plug, Cap 00 Clamp, Hose AR Line, Fuel Washer B Boot, Carburetor Screw 00 Clamp, Notched Ventura, Intake 0 Boot, Air Silencer 0 0 Seal, Foam 00 Cable Tie 0 Screw 0 Stand, Filter 0 Stud Stud 0 Seal, Air Box Foam 0 Plate, Air Box /

17 FRONT STRUT XPLORER 00 A00CGCA Bumper 0 Strut, Front Washer 00 Clamp, Rubber Coated 0 Nut, FLEXLOC Screw 0 Washer 0 Retainer, Strut Casting Wire Asm., Front Brake Caliper, RH (See Front Brake Pg. B for Details) 0 0 Bearing, Tapered Roller 0 Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal 000 Fitting, Lubrication 0 Coil, Magnetic B 0 0 Asm., Hubstrut, LH,mm, Heavy (Incl.,-,) Asm., Hubstrut,RH, mm, Heavy (Incl.,-,) 0-0 Spring, Compression Retainer, Spring, Strut Pivot, Ball, Bottom Bolt 0 0 Spacer, Strut Kit - Drive Shaft w/sleeve (See CV Joint Pg. B, Ref. ) 00 Seal, Hubstrut Pivot, Ball, Top 0 Spacer, Rubber Washer 0 Nut, Nylok /00

18 FRONT HOUSING XPLORER 00 A00CGCA 0 0 Asm., Front Gearcase (Incl. -,-)(If built before /0/) Screw Seal 0 Cover, Front Housing Input 00 O-Ring Ring, Retaining Bearing, Ball Pinion, Input Bushing Seal 0 Bushing Washer Plug, Oil Fill 00 Clip, Snap In 000- AR Line, Fuel B 000 Clamp Tube, Vent Gearcase 0 SubAsm., Output Shaft, Front Housing Shaft, Output Gear, T 00 Bearing 0 AR Shim O-Ring Cover, Output, Front Housing AR Shim 0 Button, Thrust Washer Plug, Drain Screw 0 Washer /

19 FRONT HOUSING XPLORER 00 A00CGCA 0 0 Asm. Front Gearcase (Incl. -,-)(If built after /0/) Screw Seal 0 Cover, Front Housing Input 00 O-Ring Ring, Retaining Bearing, Ball Pinion, Input Bushing Seal 0 Bushing Washer Plug, Oil Fill 00 Clip, Snap In B 000- AR Line, Fuel 000 Clamp Tube, Vent Gearcase Shaft, Output 00 Bearing, Ball 0 AR Shim O-Ring Cover, Output, Front Housing AR Shim Button, Thrust Washer, Plug Plug, Drain Screw 0 Washer /

20 CV JOINT - NEAPCO XPLORER 00 A00CGCA Brand Designated Asm., CV Housing w/sleeve Sleeve, Drive Shaft Seal 0 Clamp, Band 00 Circlip 00 Kit - Replacement Boot 000 Shaft, Replacement (Incl. ) 00 Cardan, Replacement (Incl.,,,) 00 Kit - Cross and Bearing 00 Yoke, Splined 0 Pin, Spring 0 Clamp, Band 000 Kit-DriveShaftAsm.w/Sleeve 0/ B

21 FRONT WHEEL XPLORER 00 A00CGCA A 0 DETAIL A 0 Bolt Disc, Brake 00 Seal, Front Hub Plate, Armature 0 Clutch, Front Hub, Elec./Mech. 0 Bearing, Tapered Roller Cone Stud 0 Bearing, Tapered Roller Cup 0 Asm., Hub w/bearing Race (Incl.,,) 0 00 Cage, Roll 000 Roll 00 Spring, Garter Spacer B 000 Cam 00 Plug, Magnetic Drain 0 Tire (x-) 00 Washer 0 Nut 0 Pin, Cotter 0 00 O-Ring Cap, Hub 0 Screw Nut, Lock 0- Rim, Front 0 Valve, Rim /

22 FRONT BRAKE XPLORER 00 A00CGCA 0 00 Asm., Brake Caliper, Front, LH (Incl. -0) 00 Asm., Brake Caliper, Front, RH (Incl. -0) 0 Kit - Front Brake Boot 00 Screw, Bleeder Screw, Socket Set Caliper,Brake,LH Caliper,Brake,RH 0 Kit - Seal, Piston and Seal (Incl. -) 0 Ring, Molded Square (.0) 00 Ring, Molded Square (.0 x.) Piston, Caliper Kit - Severe Duty Brake Pad, Front (Complete set of pads) Kit - Brake Pad, Front (Complete set of pads) Kit - Brake Pads, Soft, Front 0 0 Mount, Caliper 0 0 Boot, Bushing 0 Boot, Pin Seal Screw (See Front Strut Pg. B, Ref. ) / B

23 CONTROLS - THROTTLE ASM./CABLE XPLORER 00 A00CGCA 0 Cover, Throttle Control O-Ring 00 Asm., Throttle Control (Incl. -,) 00 Asm., Throttle Clamp 0 Washer, Cable End Sealing 000 Cable, Throttle 0 O-Ring /00 B

24 CONTROLS - MASTER CYLINDER/BRAKE LINE XPLORER 00 A00CGCA Asm., Master Cylinder (Incl. -) Boot, Brake Line 0 Bolt, Banjo 0 Seal 0 Line, Brake 0 Fitting, Cross 0 Line, Brake, Right, Front w/fittings 00 Cable Tie 00- Conduit 0 Screw 0 0 Line, Brake, Left, Front w/fittings 00-0 Conduit 00 Clamp, Nylon Rivet 0 Line, Brake, Rear Hand 0 Switch 000 Kit - Master Cylinder Reservoir (Incl. -0) Ring, Square, Master Cylinder 0 Bolt, Cap 0 Cap, Reservoir 0 0 Diaphragm 000 Kit - Master Cylinder Clamp 0 Asm., Master Cylinder Piston 00 Rivet 00 Kit - Brake Lever w/park Brake Latch (Incl.,,,) Spring 00 Nut 000 Kit - Park Brake Lever 0 Bolt, Master Cylinder Reservoir 00 Bolt, Master Cylinder Handle Pivot / B0

25 STEERING POST XPLORER 00 A00CGCA 0 0 Asm., Steering Post (Incl.,) Bushing, Steering, Upper 00 Fitting, Lubrication Bolt Washer 0 O-Ring Spacer, Steering Post Pin, Cotter B 0 Nut 0 0 Bushing, Steering, Lower Rivet Plug, Grease, Steering 00 Fitting, Lubrication Bushing, Steering, Console -0 Bracket, Upper Steering Bushing Nut, Nylok /

26 A-ARM/STRUT MOUNTING XPLORER 00 A00CGCA Nut, FLEXLOC Bushing 0 00 Asm., Tie Rod (Incl. -)(If Built before //) Asm., Tie Rod (Incl. -)(If Built after //) Boot, Seal, Rod End 00 Rod End Nut 00 Tie Rod 0 Nut, LH Boot, Seal, Rod End Bolt (If Built after //) Nut 0 Pin, Cotter 00 Joint, Ball Rod End, LH (If Built before //) Rod End, LH (If Built after //) Washer, Flat (If Built before //) Washer, Flat (If Built after //) Bracket, Ball Joint Screw 0 Boot, Rubber Nut, Castle 0 0 Shield, CV Joint, LH Shield, CV Joint, RH 0 Screw 0 Bushing, A-Arm, Long 00 Bushing 00 Shaft, A-Arm 0 0 Kit - A-Frame, LH Kit - A-Frame, RH 00 Fitting, Lubrication Asm., Heavy Hubstrut (See Front Strut Pg. B, Ref. ) Screw 0 Washer, Spring Lock 0 Bolt Screw B 0/00

27 HANDLEBAR and HEADLIGHT POD XPLORER 00 A00CGCA B

28 HANDLEBAR and HEADLIGHT POD XPLORER 00 A00CGCA 00 Asm., Speedometer (Incl. ) Indicator, Low Oil (Symbol) Indicator, Hot Temperature Indicator, Neutral/Reverse Screw 00 Nut, U-Type 0- Pod, Headlight, Upper, EB Green 00 Harness, Headlight Pod Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B, Ref. ) -0 Tube, Handlebar 00 Kit - Handlebar Block (Incl. Blocks,,0,) 0-0 Block, Handlebar 0 Screw Nut Washer, Lock Washer 0 Clamp, Speedometer Asm., Master Cylinder (See Controls - Master Cylinder/Brake Line Pg. B0 for Details) Spacer, Switch, LH 00 Switch, Handlebar, Hi/Lo/Rev./Override, LH Screw Plug 0 00 Grip, Handlebar 0-0 Bracket, Pod Mounting Screw 00 Knob, Adjusting 0 Boot 00 Collar, Locking 00 0 Lens and Reflector Bulb, Replacement, Halogen 00 Rod, Adjusting Nut, Nylok 0 O-Ring Cable, Choke Control Kit - Choke Control 00 Nut, U-Type 0 Screw 00 Clip, Cable Retaining -00 Pod, Headlight, Lower Caplug Nut, Ignition Cover, Key 00 Nut, Choke Slide 0 00 Sensor, Hall Effect Cap, Hall Sensor Screw Switch, Ignition (Incl. Key) Key, Blank (#00-) Key, Blank (#00-) Key, Blank, Series 000, 00, 00 NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. Key, Blank, Series 00, 00, 00, 00. NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. 0/00 B

29 SWING ARM/SHOCK MOUNTING XPLORER 00 A00CGCA 0 0 Nut, Nylok 00-0 Spring, Compression 0 Cam, Adjusting 0 Shock Retainer, Spring Screw 0 Rivet Guide, Chain Pad 000 Fitting, Lubrication 0 0 Nut 0 Washer Bushing, Swing Arm, RH Bolt, Swing Arm Bushing, Pivot, RH Asm., Swing Arm (Incl.,,) C 0 Decal-ChainFreePlay Guard, Chain 0 Screw Bushing 0 0 Washer Nut 0 Nut, Nylok Washer 0 Decal - Hitch 00 Kit - Hitch (Incl. -) Bolt Screw Bushing, Swing Arm, LH Bushing, Pivot, LH /00

30 PROP SHAFT XPLORER 00 A00CGCA 0 Asm., Prop Shaft 0 O-Ring 00 Fitting, Lubrication 0 Yoke, Prop Shaft, Transmission 0 Shaft, Prop 0 Joint, Cardan 0 Yoke, Front Gear Case Pin, Spring / C

31 REAR CALIPER MOUNTING XPLORER 00 A00CGCA Frame 0 Screw Caliper, Rear Kit - Caliper Seal Kit - Bleeder Replacement Piston, Caliper, Rear 0 Seal 0 Line, Hand Brake, Rear 0 Line, Foot Brake, Rear 00 Clip, Rosebud 00 Clip, Silencer Box 0 Bolt, Banjo Bushing, Caliper Mount 0 0 Washer 0 Washer, Spring Lock Bolt Mount, Caliper, Lower Mount, Caliper, Upper Bolt -0 Guard, Brake Disk Kit - Brake Pad (Incl. Spacer and Pad) Spacer Pin /0 C

32 REAR HOUSING XPLORER 00 A00CGCA Ring, Retaining 0 Retainer, Nut Nut, Nylok Seal, Foam Disk, Brake Stud 0 Hub, Brake (Incl. ) 0 Ring, Retaining 00 Spacer, Axle 0 0 O-Ring 000 Seal Bearing, Cone, Tapered Bearing, Cup, Tapered 0 Housing, Axle, Rear 000 Fitting, Lubrication 0 Link, Connector, 0 Regina Axle, Rear -0 Guard, Sprocket 0 Spacer 0-0 Chain, 0 ORD, O-Ring 0 Sprocket, T 0 Bolt 0 Asm.,Hub,Sprocket(Incl.) 0 Nut /00 C

33 REAR BRAKE MASTER CYLINDER XPLORER 00 A00CGCA 0 0 Bolt 0 Reservoir 0000 Clamp, Hose, Red 0 Hose 0 Pin, Cotter 0 Spring Washer 0 Pin, Cotter 0 Bushing Brake, Foot Pin, Clevis 00 Clevis Nut 0 Asm., Plunger (Incl.,) 00-0 Trim, Edge 00 Retainer Rivet Nut, Nylok 0 Asm., Master Cylinder, Brake, Foot 0 0 Screw 0-0 Bracket, Reservoir / C

34 REAR WHEEL XPLORER 00 A00CGCA 0 Screw 00 Kit - Hub, Rear (Incl,,,0) Nut Washer, Cone 00 Nut, Castle 0 Pin, Cotter Hub, Cover, Dust Washer, Flat 0 Valve, Rim 0 00 Pushnut 0- Rim, Rear 0 Tire (x-0) / C

35 DRIVE CLUTCH XPLORER 00 A00CGCA 0 Bolt 0 Washer, Spring Lock 0 Cover, Bearing 0 Spring, Clutch 0 Washer, Multilube Roller and Bushing Button, Clutch, Stemless 00 Weight, Shift (S-) Bolt, Shoulder 0 0 Nut, FLEXLOC 0 Bearing, Moveable (/ ) AR AR AR AR Spacer (.00 mm) Spacer (.0 mm) Spacer (.0 mm) Spacer (.00 mm) 00 Pin, Roller Asm., Drive Clutch, ATV-0 (Incl. All Less,) / C

36 DRIVEN CLUTCH XPLORER 00 A00CGCA 0 00 Spacer, Driven Clutch 0 AR Bushing 0 Belt, Drive Asm., Driven Clutch, Angle, Heavy (Incl. -) 0 Washer, Domed 0 Washer, Spring Lock Bolt 0 AR AR Washer, Spacer (.00 ) Washer, Spacer (.0 ) 0 AR Washer (.00 ) C 0 0 Bearing, Moveable (/ ) Bearing, Moveable ( ) 0 Spring, Clutch Ramp, Stationary (If built before //) Ramp, Stationary (If built after //) 0 Spacer 0 Ring, Retaining Bolt 0 Button, Ramp /00

37 CLUTCH COVER XPLORER 00 A00CGCA Seal, Clutch Cover Washer Screw 0 Seal, Clutch Cover Cover, Clutch, Front 00 Clip, Clutch Cover 0 Screw 0 Decal - Clutch Cover 0 Decal - Engine/Clutch Modification 0 0 Decal - Automatic Transmission 0 Screw 00 Cable Tie 0 Boot, Clutch Intake Screw and Washer (See Crankcase and Cylinder Pg. D, Ref. ) -0 Bracket, Retainer Seal 0 Screw Washer 0 Seal, Cover, Case C Rivet 0 Duct,AirOutlet,Clutch -0 Bracket, Clutch Cover, Front Washer 0 Kit - Inner Clutch Cover (Incl.,,,,) 0-0 Bracket, Clutch Cover, Rear 0 Nutsert Screw 0 Cap, Overflow, Drilled 0 Gasket, Overflow Cap Plug, Cap 0 Washer 00 Clamp, Narrow Band 0 Screw 000- Line, Fuel 00 Fitting, Barbed, 0 Degree Duct, Clutch Inlet /00

38 ELECTRICAL/TAILLIGHT XPLORER 00 A00CGCA Harness, Main 00 Kit - Circuit Breaker, 0 AMP 0 Kit - Circuit Breaker, 0 AMP 0 Asm., Taillight w/brake Light (Incl. -0) 00 Lens, Taillight 00 Screw 000 Bulb, Taillight 00 Gasket, Taillight 00 Backing, Taillight 0 00 Nut, Speed 0 Screw 0 Washer Nut, Nylok Cable, Solenoid/Starter (See Engine Mounting Pg. A, Ref. ) 000 Cable, Battery/Solenoid 00 Pad, Battery 00 Clip, Routing C0 00 Kit - Battery Bolt, Short 000 Cable, Battery/Engine Hook, Battery Strap 0 Strap, Battery Holddown 0 AR Tube, Vent 000 Battery Cover, Battery 00 Bolt 00 Cable Tie 00 Clip, Rosebud Screw Bracket, CDI 0 0 Screw 0 Screw 00 Rectifier Heat Sink 0 Pigtail, Power /00

39 GEARCASE XPLORER 00 A00CGCA C

40 GEARCASE XPLORER 00 A00CGCA Asm., Gearcase (Incl. -)(Confirm part number before ordering parts)(if built before /0/) Screw 0 Washer Dampener Plug 0 Washer Bushing, Pivot 0 Screw Gearcase. LH Pipe, Knock 0 00 Bearing Gear, T Shaft, Output Sprocket, /T Chain, Roller Seal Washer Bushing, Garlock 0 Shaft, Pinion T 0 Ring, Retaining 0 Cover, Bearing Screw Sprocket, /T Ring, Retaining 0 Shaft, Input High/Low/Reverse 0 Bearing Washer 00 Bearing, Needle Engagement Dog, Low 0 Bearing 0 00 Washer Sprocket, T 0 Ring, Retaining 0 Chain, Silent Gear, 0T Ring, Retaining Bearing, Garlock Engagement Dog, High/Reverse 0 Washer 0 Bearing, Needle 0 0 Shaft, Reverse, T Gear, T 0 Fork, Shift, Low Fork, Shift, High/Reverse Bellcrank 0 Nut Bellcrank, High/Low/Reverse 0 Ring, Retaining 00 Washer O-Ring 0 Shaft, Shift Screw Decal - Switch Switch, High/Reverse Switch 0 Vent Cover, Snorkel O-Ring Shim Gear, Snorkel 0 Bushing, Garlock Washer Dipstick 0 Gearcase 0 Deflector, Oil 0 Screw 0 Bracket, Interlock 0 Spring 0 Pin, Interlock /00 C

41 GEARCASE XPLORER 00 A00CGCA C

42 GEARCASE XPLORER 00 A00CGCA Asm., Gearcase (Incl -)(Confirm part number prior to ordering parts)(if built after /0/) Screw 0 Washer Dampener, Carb Vibration Plug 0 Washer Gearcase, LH Pipe, Knock Washer, Thrust Gear, T 0 Bearing, Needle 0 Ring, Retaining Engagement Dog, Low 0 Fork, Shift Low Shaft, Reverse, T Fork, Shift, High/Rev. Sprocket, T Engagement Dog, High/Rev. Gear, 0T Ring, Retaining 0 0 Bearing 0 Screw 0 Bracket, Interlock 0 Spring 0 Pin, Interlock O-Ring 0 Ring, Retaining 0 Nut, FLEXLOC Bellcrank 00 Washer 0 Shaft, Shift Bellcrank, High/Low/Rev. Screw Decal - Switch Switch Plug, Oil Fill Washer Switch 0 Vent Seal 0 Screw Cover, Snorkel O-Ring 00 Bearing AR Shim Shaft, Snorkel Bushing Gearcase, RH 0 Deflector, Oil 0 Chain, Silent 0 0 Shaft, Input 0 Bearing Ring, Retaining Sprocket, /T Cover, Bearing 0 Ring, Retaining 0 Shaft, Pinion, T Bushing Washer Chain, Roller 0 Sprocket, /T Shaft, Output Gear, T 0 Screw Bushing, Pivot /00 C

43 GEARCASE MOUNTING XPLORER 00 A00CGCA 0 Screw -0 Bracket, Transmission Nut, Flange Screw 0 Guide, Chain 0 Washer Bolt 0 Washer Screw 0 0 Sprocket, T 0 Ring, Retaining 0 0 AR AR AR Shim (.00) Shim (.00) Shim (.00) 0 Screw / D

44 GEAR SELECTOR XPLORER 00 A00CGCA Asm., Gear Selector (Incl. -,-,) Asm., Knob 0 Screw Strap, Wire Screw Cover, Gear Selector Boot Sphere, Plastic Pin, Groove Rod, Gear Selector Spring, Centering 0 Spring, Detent 00 Bullet, Detent 00 Rod End, mm, LH 0 Nut, LH 00 Rod, Shift Linkage, Low 0 Rod, Shift Linkage, Hi Range 0 Nut, RH 00 Rod End, mm, RH 0 Nut, FLEXLOC Slide, Low 0 0 O-Ring 0 Slide, High/Reverse Body, Gear Selector Screw Pin, Dowel / D

45 CRANKCASE and CYLINDER XPLORER 00 A00CGCA D

46 CRANKCASE and CYLINDER XPLORER 00 A00CGCA 0 Cylinder (Incl.,,) 0 Stud 0 Gasket, Head 0 Cylinder Head (Incl. ) 0 Gasket 0 Plug 00 Nut, Flange 0 Pipe, Water 00 Nut Washer, Lock 0 Gasket, Exhaust 0 Stud 0 Pipe, Elbow 0 Nut, Flange 0 Bolt, Banjo 0 Gasket 0 Adapter 00 Valve 00 Stopper 0 00 Screw and Washer 00 Gasket, Reed Valve 0 Asm., Reed Valve (Incl. -0) 0 Stuffer 0 Screw, Pan Head 00 Clamp 0 Asm., Band, Adapter (Incl. ) 0 Bolt, Flange, Adapter 0 Check Valve 0 Gasket, Cylinder 0 0 Clamp 00 Washer 0 Bolt, Flange 0 Stud 0 Stud 00 Asm., Crankcase (Incl.,,-,,,0,-) 0 Bearing, Ball 0 Plug 0 Gasket 0 Gasket, Case 0 0 Pipe, Breather 0 Bolt, Flange 0 Pipe, Elbow 0 Bolt, Flange 00 Seal, Oil 00 Plug 0 Gasket 0 Bolt, Flange 0 Asm., Crankcase (Incl.,0,,,,,0,) 0 Bolt, Flange 0 0 Pin, Dowel 0 Bearing, Ball 0 O-Ring 0 Gauge, Oil 0 Bolt, Flange 0 Bearing, Ball 0 Bearing, Ball 0 Seal, Oil 00 Screw and Washer / D

47 PISTON and CRANKSHAFT XPLORER 00 A00CGCA Piston Ring (Std) Piston Ring (0. /.00mm O/S) Piston Ring (0.0 /.00mm O/S) 0 Clip, Piston Pin 0 Piston Pin Balancer 0 Plate 0 Bolt, Flange 0 Gear, Drive 0 Washer, Guide 0 00 O-Ring Piston (Std) Piston (0. /.00mm O/S) Piston (0.0 /.00mm O/S) NOTE: This Part Is Interchangeable In A Combination Of Carburetor Parts. D 0 Collar 0 Nut, Slit 0 Washer 00 Nut, Lock 0 0 Asm., Crankshaft (Incl.,,,0,,) Crankshaft 000 Key, Woodruff 0 Spacer, Crank Pin 0 Bearing, Large End 0 Bearing, Small End 0 0 Rod, Connecting 0 Crankshaft 0 0 AR AR Spacer (0.mm) Spacer (0.mm) 0 Crank Pin /

48 RECOIL STARTER XPLORER 00 A00CGCA 0 0 Spring, Spiral 00 Bushing 0 Plug 0 Gasket Bolt and Washer 0 Bolt, Flange Asm., Recoil Starter (Incl.,,,-) Starter Case 0 Bolt and Washer 0 Plate, Friction 0 0 Spring, Friction 0 Reel 00 Rope 0 Spring, Return 0 Ratchet / D

49 WATER PUMP XPLORER 00 A00CGCA 0 0 Thermo Switch (0 Degree C) 0 Clamp, Hose 0 Hose, Main 0 Nut, Flange 00 Nut 000 Washer, Spring 00 Washer 0 Impeller 0 Gasket, Casing 0 0 Stud 0 Stud Seal, Oil 0 Seal, Oil 0 Bearing, Ball Casing, Water Pump (Incl.0-) Casing, Water Pump (Incl. 0,) / D

50 CARBURETOR XPLORER 00 A00CGCA Asm., Top 0 Spring, Throttle 00 Plate, Throttle 000 E-Ring 0 Needle, Jet (CEY-) 0 Packing 0 Cap, Plunger 000 Spring 0 Plunger 0 0 Valve, Throttle (.) 0 Asm., Jet, Needle (0) 0 Ring, Main Jet 0 Spring, Throttle Adjuster 0 Washer 000 Screw, Throttle Stop 00 Adjuster 00 Spring, Air Adjuster 00 Jet, Pilot (#) 00 Screw 0 0 Screw, Guide 0 O-Ring 0 Jet, Main (#0) 0 Float Chamber 00 Float 0 Cap 000 Gasket 0 Valve, Needle (.) 00 Arm, Float 0 Pin, Float 0 00 Packing 0 Asm., Carburetor (Incl. -) / D

51 OIL PUMP XPLORER 00 A00CGCA Asm., Oil Pump (Incl. -0) 0 Bolt and Washer 0 Cover, Case, Oil Pump 00 Gasket, Case, Oil Pump 00 Case, Oil Pump 0 Grommet 0 Grommet 0 Screw and Washer 0 Screw and Washer 0 Clamp, Hose 0 0 Pipe, Vinyl D 00 Nut 0 Washer, Spring 0 Collar, Camshaft 0 O-Ring 0 Spacer 0 Wheel 0 Pin, Spring 0 Washer 0 Screw, Air Vent 0 00 Lever and Spring Set /

52 MAGNETO XPLORER 00 A00CGCA 0 00 Screw and Washer 0 Clamp 0 0 Asm., Plate (Incl. -,-) Plate, Coil 0 Screw, Flange 0 Screw and Washer 0 Clamp 0 Stator 0 Screw and Washer D0 00 Band 0 00 Flywheel w/ring Gear 00 Cap, Spark Plug 0 Ignition Coil 00 Nut 000 Washer 0 Switch, Magnetic 0 C.D.I. System /

53 STARTING MOTOR XPLORER 00 A00CGCA Nut, Flange 00 Brush 0 0 Asm., Starting Motor (Incl. -,,,-,0-) Asm., Starter (Incl. -,,,-) 00 Ring, Rubber 00 Cover, Rear 0 Gasket, Aluminum 00 O-Ring 0 Bolt, Flange 00 Asm., Bolt, Through 0 00 Bracket 0 Washer Set D 00 Asm., Armature (Incl.,) 0 O-Ring 0 Bearing, Ball 0 O-Ring 00 Cover, Front (Incl. ) 0 Washer, Gear Shaft 0 Gasket, Starter 0 Bolt, Flange 0 00 Clip 00 Spring, Return 0 Asm., Gear Shaft (Incl.,0-) 0 Spring, Weight 0 Clip /

54 TOOL KIT XPLORER 00 A00CGCA Pouch, Tool Kit Owner s Manual, 00 ATV Supplement, Owner s Manual, 00 Xplorer 00 0 Wrench, Box, Special 0 Wrench, 0- Spanner 0 Screwdriver 0 Gauge, Tire Pressure Wrench, Spanner 0 ToolKit(Incl.-) /00 D

55 PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN /00

56 Changed pages in 0 A cover toc B C x D E F G 0