Transcript
Page 1: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

PARTS MANUAL PN 9914526 and MICROFICHE PN 9915239 8/98

XPLORER 300Model #W98CC28C

Rev. 02

Page 2: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

2

This page left blank intentionally.

Page 3: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

TABLE OF CONTENTSXplorer 300 W98CC28C

Parts Manual

AA-ARM/STRUT MOUNTING B13. . . . . . . . .AIR BOX B2. . . . . . . . . . . . . . . . . . . . . . . . . .

BBUMPER and

FRONT RACK MOUNTING A10. . . . .

CCARBURETOR D6. . . . . . . . . . . . . . . . . . .CENTER TIGHTENER C2. . . . . . . . . . . . . .CHAIN COVER and GEARCASE/BRAKE

MOUNTING C6. . . . . . . . . . . . . . . . . . .CLUTCH COVER C5. . . . . . . . . . . . . . . . . .CONTROLS - MASTER

CYLINDER/BRAKE LINE B10. . . . . . .CONTROLS - THROTTLE

ASSEMBLY/CABLE B9. . . . . . . . . . . .COOLING SYSTEM A12. . . . . . . . . . . . . . .CRANKCASE and CYLINDER C13-C14. . . . . .CRANKSHAFT and PISTON D1. . . . . . .CV JOINT - BTB B5. . . . . . . . . . . . . . . . . . .CYLINDER and CRANKCASE C13-C14. . . . . .

DDECALS A9. . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C3. . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C4. . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C9. . . . . . . . . .ENGINE MOUNTING A11. . . . . . . . . . . . . .EXHAUST SYSTEM A13. . . . . . . . . . . . . . . .

FFRONT BRAKE B8. . . . . . . . . . . . . . . . . . .FRONT CAB A7. . . . . . . . . . . . . . . . . . . . . .FRONT DRIVE B3. . . . . . . . . . . . . . . . . . . .FRONT RACK and

BUMPER MOUNTING A10. . . . . . . . . .

FFRONT STRUT B6. . . . . . . . . . . . . . . . . . . .FRONT TIGHTENER B4. . . . . . . . . . . . . . .FRONT WHEEL B7. . . . . . . . . . . . . . . . . . .FUEL TANK A14. . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C10. . . . . . . . . . . . . . . . .GEARCASE C11-C12. . . . . . . . . . . . . . . . . . . . . . .GEARCASE/BRAKE and

CHAIN COVER MOUNTING C6. . . . .

HHANDLEBAR B11. . . . . . . . . . . . . . . . . . . . .

MMAGNETO D2. . . . . . . . . . . . . . . . . . . . . . .

OOIL PUMP D5. . . . . . . . . . . . . . . . . . . . . . . .OIL TANK B1. . . . . . . . . . . . . . . . . . . . . . . . .

PPART NUMBER INDEX . . . . . . . . . . . . . .

NO TAG-NO TAGPISTON and CRANKSHAFT D1. . . . . . .

RREAR BRAKE C7. . . . . . . . . . . . . . . . . . . . .REAR CAB and SEAT A5-A6. . . . . . . . . . . . . .REAR RACK MOUNTING A8. . . . . . . . . . .REAR WHEEL DRIVE C8. . . . . . . . . . . . . .RECOIL STARTER D4. . . . . . . . . . . . . . . .

SSEAT and REAR CAB A5-A6. . . . . . . . . . . . . .STARTING MOTOR D3. . . . . . . . . . . . . . .STEERING POST B12. . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING B14. . .

TTAILLIGHT/ELECTRICAL C9. . . . . . . . . .TOOL KIT C1. . . . . . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not tobe used for assembly.

Page 4: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

1998 XPLORER 300 SPECIFICATIONS

BRAKESType/BrakesType/Brakes - AuxiliaryPark Brake

Hydraulic DiscMechanicalStandard

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

N/A420N/A2

N/A9018030

Standard850

DRIVE TRAINType PVT

DRIVE CLUTCHCenter Distance (inches)Clutch Offset (inches)Clutch WeightSpring Color

101/248g

Blue/Green

DRIVEN CLUTCHHelix AngleSpring Position

Compound2-2

DIMENSIONAL FEATURES

Approx. Turning RadiusBox, ToolBox (cubic feet)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

57⟩6x7x14

N/A6

45.58134567

49.7546

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

Main JetPilot JetNeedle JetCut AwayAir Screw/Pilot ScrewJet Needle

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

EC28PFE-022 Cycle, Oil Inj.

74.5x65283

6.1:1 EffectiveAir w/Fan Assist

150WStandard

1/VM30SS15540

O-4(169)2.0

1.5 Turn5DP7-3

CDI25 @ 3000

.028NGK BR8ESUSFS Appr.

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

PRDSide Lever

6.64/15.13/13.29/1

12/22 64P13/40 88P11/22 70P

N/A520 O-Ring

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

EB GreenEB Green

BlackSemi Flat Black

EB GreenBlackBlackBlackBlack

AluminumBurnished Brown

EB GreenFire RedFire Red

N/AN/AN/A

LIGHTSHeadlight (watts)Taillight (watts)Brake Light (watts)Other (Grill Mntd. Lights)Indicator Bulb

N/A12V/8.26W12V/26.9W

2, 12V 30/30W12V/1.0W

SUSPENSIONFront Type -

Front Travel (inches)Rear Type -

Rear Travel (inches)Adjustment

MacPherson Strut6.25

MONO8.5

CAM

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center (6x6)

Titan23x7-1024x7-10

N/A43

N/A

Polaris Industries Inc. reserves the right tomake changes in designand specifications and/or tomake additions or improvements to its productswithout notice.

Page 5: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

1998 XPLORER 300 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUALSUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Xplorer 300 W98CC28C 9914659 9914525 9914526 9915239 9914528

1998 XPLORER 300 PAINT CODES

MODEL MODEL NO.COMPONENTTYPE COLOR DESCRIPTION

POLARIS“P” NO.

Xplorer 300 W98CC28C Springs Fire Red P093

Rims Aluminum P117

Page 6: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A5

REAR CAB and SEATXPLORER 300 W98CC28C

41

2

27

1

31

34

9

8

10

1112

29

326

7

1415

36

24

40

38

39

42

30

34

5

1817

33

26

13

27

22

21

19

20

28

23

25

35

37

16

20

Page 7: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A6

REAR CAB and SEATXPLORER 300 W98CC28C

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

1 7541925 4 Nut, Nylok2 5224592 1 Retainer, Seat Latch3 7512242 4 Screw4 7555859 4 Washer, Flat5 7512085 2 Screw6 5431786 1 Box, Tool7 7517375 2 Screw8 7621403 2 Rivet, Pop9 5211033 2 Bracket, Lever Retainer10 1040387 1 Latch, Seat11 7041370 1 Spring, Latch12 2682360-218

2681747-21858111045811105

1111

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

13 5410414 8 Bumper, Rubber14 5431787 1 Cover, Tool Box15 5410896 1 Cap, Drain16 5241418 1 Tab, Air Box Mount17 5241403-067 1 Guard, Clutch18 7661638 4 Rivet19 5242016-067 1 Guard, Rock20 7512232 19 Screw

21 1040544-067 1 Frame22 7542122 8 Nut, Nylok23 5411009 2 Plug, Hole, Rubber24 7517376 8 Bolt25 5811401 1 Foil, Footwell, Ribbed26 5811106 2 Foil, Rear Cab, Front27 7555792 4 Washer28 7541929 2 Nut, Nylok29 7072791 1 Decal - Filter Element30 5811087 1 Foil, Foam31 5411042 1 Grommet32 7073761 1 Decal - Carb Information33 5811107 1 Foil, Rear Cab, Rear34 5811111 1 Foil, Foam, Rear Fender35 5811399 1 Foil, Footwell, Slotted36 5431772-070

5431771-07011

Footwell, RH, BlackFootwell, LH, Black

37 5811402 1 Foil, Footwell38 7670057 12 Nut, “U” Type, Speed39 5431797

543179611

Guard, Mud, Rear, RHGuard, Mud, Rear, LH

40 5432663-195 1 Cab, Rear, EB Green41 7511930 2 Bolt42 7661645 10 Rivet, T-Lock

6/97

Page 8: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A7

FRONT CABXPLORER 300 W98CC28C

6

7

8

9

1110

18

32

9

1514

4

4

1716

5

12

13

1920

21

4

1

4

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

1 5811491 1 Foil, Side Panel, RH2 5811210 1 Foil, Foam, Side Panel3 2620096-195

5431809-195

1

1

Asm., Panel/Foil, RH, EB Green(Incl. Foil & Foam)Panel, Side, LH, EB Green

4 7512232 6 Screw5 7512085 2 Screw6 5431806-195 1 Cover, Front, EB Green7 7670085 2 Clip, Spring, Trim8 2631928-195 1 Asm., Cab, Front, Service, EB

Green (Incl. Warning Decals)9 7670057 6 Nut, “U” Type Speed10 7661645 4 Rivet, T-Lock

11 7670009 2 Nut, Push On12 7080409 1 Clamp, Wire Routing13 7074819 1 Decal - Caution, Rotating Fan14 5811489 2 Shield, Deflector15 7670088 4 Clip, Dart16 7542122 2 Nut, Nylok17 7555931 2 Washer, Flat18 5431799

543179811

Guard, Mud, Front, RHGuard, Mud, Front, LH

19 7541929 2 Nut, Nylok20 7555792 2 Washer21 -------------- 1 Decal - Drain Recoil

(See Decal Page A9, Ref. 11)

8/98

Page 9: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A8

REAR RACK MOUNTINGXPLORER 300 W98CC28C

4

3

1

2

69

7

13

11

129

9

5

8

10

8

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

1 7515193 2 Screw2 7515194 2 Screw3 2670174 1 Asm., Rack, Rear

(Incl. 4 & Warning Decal)4 2670070 2 Reflector, Red5 1040380-067 1 Support, Rear Rack6 7515398 4 Screw7 7517264 2 Screw

8 7542343 8 Nut, Flange, Nylok9 7555770 8 Washer, Wrought10 7670096 2 Nut11 5333332-067 4 Spacer12 7515385 4 Screw13 1040524-067

1040525-06711

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

11/97

Page 10: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A9

DECALSXPLORER 300 W98CC28C

9

2

18

13

11

8

5

6

1617

20

4

19

3

14

5

21

1

12

6

15

3

7

1

10RH

LH

4

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

1 7074954 2 Decal - Rear Rack2 7074110 1 Decal - Load Distribution3 7075656 2 Decal - “4x4”4 7077864 2 Decal - “300” Side Panel5 7076523 2 Decal - “Xplorer”6 7076524 2 Decal - “POLARIS”7 7074935 1 Decal - Warning, AWD Switch8 7077863 1 Decal - Tank Side, RH9 7075413 1 Decal - Warning, Discretionary10 7077867 1 Decal - Side Panel, RH11 7075741 1 Decal - Recoil Drain

12 7073453 1 Decal - Demand-4-Drive13 7073024 1 Decal - USA14 7076273 1 Decal - Override Switch, AWD15 7077862 1 Decal - Tank Side, LH16 7074827 1 Decal - Age Warning17 7077920 1 Decal - Passenger Warning18 7074750 1 Decal - Tire Pressure19 7077866 1 Decal - Side Panel, LH20 7077919 1 Decal - Warning, General, CPSC21 7074220 1 Decal - MacPherson Strut

6/97

Page 11: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A10

FRONT RACK and BUMPER MOUNTINGXPLORER 300 W98CC28C

4

3

1

2

1617

2218

15

9

8

10

12

13

21

2019

5

4

14

4

11

7

17

6

9

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

1 2460611 1 Harness, Headlight, Hi/Lo2 2431012

24310114030059

112

Headlight, Side, RHHeadlight, Side, LHBulb, Replacement

3 7512232 4 Screw4 7515399 6 Screw5 2670071 2 Reflector, Amber6 2670180 1 Asm., Rack, Front (Incl. 5 & Decal)7 7515194 4 Screw8 2200775 1 Kit - Front Rack Mount9 7542324 4 Nut, Nylok10 5432155-070 1 Bumper11 7558403 2 Washer

12 7515391 2 Screw13 7515390 2 Screw14 7555954 2 Washer15 1040554-067

1040555-06711

Support, Rack, Front, LHSupport, Rack, Front, RH

16 7515384 2 Bolt17 7558402 4 Washer18 5241398-067

5241399-06711

Extension, Frame, LHExtension, Frame, RH

19 7621330 9 Rivet, Pop20 5240591-067 1 Grill, Brush Guard21 5241583-067 1 Guard, Brush22 5810467 1 Plug, Frame

11/97

Page 12: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A11

ENGINE MOUNTINGXPLORER 300 W98CC28C

12

4 5 6

11

121314

15

20

22

231

2627

28

31

32

33

18

26

35

37

37

8

9

21

19

19

19

19

29

1716

19

36

30

29

30

25

34

30

19

18

18

10

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

1 3110026 2 Mount, Motor2 5430802 1 Insulator, Mount, Motor3 4010132 1 Cable, Ground/Engine4 7515321 2 Bolt5 7552901 2 Washer, Spring Lock6 5241799-067 1 Mount, Engine, Top7 7542411 1 Nut, FLEXLOC8 4010211 1 Thermostat, Cooling Fan9 7541906 1 Nut, FLEXLOC10 7052192 2 Fitting, Vent11 7512566 1 Bolt12 7575202 1 Washer, Lock13 5210748 1 Washer, Clutch Retainer14 5430261 1 Bushing15 -------------- 1 Asm., Drive Clutch, ATV-06

(See Drive Clutch Pg. C3, Ref. 14)16 7512457 2 Bolt17 1040532-067 1 Mount, Lower Engine18 7555806 4 Washer, Flat19 7542403 5 Nut, FLEXLOC20 3070156 1 Spark Plug, NGK BR8ES21 -------------- 1 Cable, Solenoid Starter (See

Electrical/Taillight Pg. C9, Ref. 23)

22 7080511 2 Clamp, Narrow Band23 5410421 1 Boot, Clutch Intake24 7555823 AR Washer25 7552603 4 Washer, Spring26 7512490 4 Bolt27 5242229-067 1 Mount, Engine, Front28 3084720 1 Engine, EC28PF01-Short Block

NOTE: The Short Block assemblycontains a crankcase assembly,cylinder & cylinder head assemblyand a piston & crankshaft assem-bly. Prior authorization required forwarranty consideration.

29 7080003 4 Clamp, Hose, Red30 8450040-600 AR Line, Fuel31 7052047 1 Check Valve, Vent32 7052005 1 Fitting, Tee33 8360009-600 AR Line, Fuel34 5241176-067 1 Mount, Rear35 3110028 1 Mount, Engine, Rubber36 2530009 1 Filter37 8450003-1525 AR Line, Fuel

8/98

Page 13: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A12

COOLING SYSTEMXPLORER 300 W98CC28C

5

3

6

8

9

2

1

4

7

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

1 7080680 1 Clamp, Fan Blade2 5432619 1 Blade, Fan3 7547004 3 Nut, Nylok4 7558201 3 Washer5 1040568-067 1 Mount, Fan

6 7511875 3 Screw7 4170014 1 Motor, Fan, Air Cooled8 7512113 4 Bolt9 7542122 4 Nut, Nylok

11/97

Page 14: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A13

EXHAUST SYSTEMXPLORER 300 W98CC28C

1

2

34

5

6

910

11

1516

1314

1819

17

12

11

8

7

13

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

1 7542327 1 Nut, Nylok2 7555716 1 Washer3 5010192 1 Bushing4 5410241 1 Dampener, Vibration5 3110064 1 Mount, Torque Stop6 7542301 2 Nut7 7512232 2 Screw8 5242081-067 1 Bracket, Muffler Support9 5410436 1 Washer, Rubber10 7515316 1 Bolt

11 7512666 2 Bolt12 7052083 1 Plug, Clean Out13 7042029 4 Spring, Exhaust14 1260702-029 1 Exhaust15 7042031 2 Spring, Exhaust16 1260658-029 1 Headpipe17 1260543-029 1 Manifold18 -------------- 2 Washer, Spring (See Crankcase

and Cylinder Page C14, Ref. 36)19 -------------- 2 Nut (See Crankcase and Cylinder

Page C14, Ref. 37)

8/98

Page 15: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

A14

FUEL TANKXPLORER 300 W98CC28C

5

6 7

8

9

13

14

11

12

10

15

20

19

1718

11

16

1

3

4

2

21

11

22

12

12

12

12

11

11

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

1 2511272 1 Asm., Tank, Fuel (Incl. 6,17,18)2 5811052 1 Seal, Foam3 5810144 1 Gasket, Fuel Cap4 5430725 1 Cap, Fuel Tank5 8360009-600 AR Hose, Gas Tank Vent6 5431053 1 Vent, Tank7 7512310 2 Bolt8 5222154-067

5222155-06711

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

9 7512232 2 Screw10 2530009 1 Filter11 8450040-600 AR Line, Fuel

12 7080003 8 Clamp, Hose, Red13 5220916-067 1 Bracket, Tank Mount, Rear14 7542324 2 Nut, Nylok15 5411272 1 Hose, Fuel, Formed16 8360026 AR Pad, Fuel, Bulk17 7052147 1 Fitting, 90, Fuel Outlet, Main18 7052148 1 Fitting, 90, Fuel Outlet, Reserve19 7052154 1 Valve, 3 Way20 5432733 1 Nut, Fuel Valve21 5432559 1 Knob, Fuel Valve22 7517505 1 Screw

11/97

Page 16: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B1

OIL TANKXPLORER 300 W98CC28C

1

2

8

54

6

7

1112

14

12

17

16

109

3

13

15

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

1 5430779 1 Cap, Oil Tank2 5810141 1 Gasket, Oil Cap3 5410991 1 Grommet, Oil Tank4 8360009-600 AR Fuel Line5 7052095 1 Fitting6 4110177 1 Sensor, Oil Level7 7621460 2 Rivet, Pop8 5431793 1 Tank, Oil, Drilled9 7080526 1 Mount, Tie Anchor

10 7511866 1 Screw11 7052153 1 Fitting12 7080134 2 Clamp, Hose13 8450003-1525 AR Line, Fuel14 2530009 1 Filter15 8450042-600 AR Line, Fuel16 7080307 2 Clamp, Hose (Large Green)17 8360026 1 Pad

12/97

Page 17: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B2

AIR BOXXPLORER 300 W98CC28C

1

2

4

6 7

8

9

101112

15 14 13

16

175

18

19

20

21

3

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

1 5810444 1 Filter, Foam2 5810441 1 Seal, Foam3 5432245 1 Box, Air Silencer4 5410506 1 Boot, Air Silencer5 7080369 1 Filter, Air Intake6 7512246 2 Screw7 7558302 2 Washer8 7670060 2 Nut, Speed, “U”-Clip9 5431124 1 Box, Air Intake (Incl. 16)10 5410549 1 Valve, Umbrella11 5410529 1 Bushing, Molded

12 7512275 4 Bolt, Carriage13 7080413 1 Clamp, Band, Narrow14 5411159 1 Boot, Carburetor15 7080140 1 Clamp16 5810310 1 Tape, Foil, Air Box17 7670080 4 Palnut18 5410510 1 Seal, Air Intake Cover19 5430884 1 Cover, Air Intake20 5220980 1 Retainer, Cover, Air Intake21 7542127 4 Nut, Wing

6/97

Page 18: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B3

FRONT DRIVEXPLORER 300 W98CC28C

4

7

1

12

8

18

17

16

1915

2

9

6

13

14

20

11

15

10

3

5

8

5

1

2

2

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

1 7542503 3 Nut, FLEXLOC2 7555883 3 Washer3 7670101 1 Clip, Christmas Tree4 7512583 2 Bolt5 7542449 2 Nut6 5811519 1 Spacer, Front Eccentric7 -------------- 1 Asm., Front Tightener (See Front

Tightener Page B4 For Details)8 7517303 2 Screw9 5131379 1 Clamp, Front Eccentric10 7552603 2 Washer

11 7515522 2 Bolt12 7517304 1 Screw13 3225026 1 Link, Connector14 3224056-064 1 Asm., Drive Chain, 64P (Incl. 13)15 7512252 3 Screw16 7074956 1 Decal - Front Chain Tension17 5432572 1 Guard, Front Chain18 5811502 1 Foil, Chain Guard19 -------------- 1 Asm., Center Tightener (See Center

Tightener Page C2 For Details)20 3224056-070 1 Asm., Drive Chain, 70P (Incl. 13)

8/98

Page 19: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B4

FRONT TIGHTENERXPLORER 300 W98CC28C

1 2

3

45 6 7 8

9

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

1 3222044 1 Sprocket, 22T2 5130701 1 Eccentric, Front3 7080306 1 Fitting, Lubrication4 5020527 1 Shaft, Output5 3514402 2 Bearing, Open

6 3610017 2 Seal, Tightener7 5410463 2 O-Ring8 5020474 2 Spacer, Front Tightener9 1380024 1 Asm., Front Tightener (Incl. 2-8)

6/97

Page 20: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B5

CV JOINT - BTBXPLORER 300 W98CC28C

BTB

1012 3 4 5

6

7

8 9

12

13

11

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

1 1380119 2 Asm., CV Housing w/Sleeve2 5222299 1 Sleeve, Drive Shaft Seal3 3260115 1 Clamp, Large, CV Joint4 7670091 1 Circlip5 5411106 1 Boot, CV6 1380094 1 Shaft (Incl. 4)7 1380092 1 Cardan (Incl. 4,6,8,9)

8 2200771 1 Kit - Cross and Bearing9 3260130 1 Yoke, Splined10 7661913 3 Pin, Spring11 7080627 1 Clamp, Band, Small12 2200773 1 Kit - Repl. Boot, CV Joint

(Incl. 3,5,11)13 2200961 2 Kit - Drive Shaft w/sleeve BTB

6/97

Page 21: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B6

FRONT STRUTXPLORER 300 W98CC28C

8

9

10 11

15

12

13

16

17

20

21

14

22

27

7

5

6

26

25

24

4

321

18

15

1919

18

15

23

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

1 7542507 2 Nut, FLEXLOC2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5430806 2 Pivot, Ball Top5 5430807 2 Pivot, Ball Bottom6 5130668 2 Spacer, Threaded7 5220602 2 Retainer, Spring, Top8 5411468 2 Bumper, Strut9 7041755 2 Strut, Front10 5211115 2 Washer, Spring Retainer11 7080573 2 Clamp, Rubber Coated12 7542303 4 Nut, FLEXLOC13 7512365 4 Bolt14 7552901 4 Washer, Spring Lock15 7558402 8 Washer16 5810439 2 Retainer, Strut Casting Wire

17 -------------- 1 Asm., Front Brake Caliper (SeeFront Brake Pg. B8 for Details)

18 3554509 4 Bearing, Tapered Roller19 3554507 4 Bearing, Tapered Roller Cup20 5222193 2 Sleeve, Hubstrut Seal21 4170016 2 Coil, Magnetic22 7080306 2 Fitting, Lubrication23 2200609

2200610

1

1

Asm., Hubstrut, Service, LH, 32mm,Heavy (Incl. 16,19-22,24)Asm., Hubstrut, Service, RH, 32mm,Heavy (Incl. 16,19-22,24)

24 3610028 2 Seal, Hubstrut25 -------------- 1 Asm., Drive Shaft, Long (See CV

Joint - BTB Page B5, Ref. 13)26 7515339 4 Bolt27 7041375-067 2 Spring, Coil

8/98

Page 22: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B7

FRONT WHEELXPLORER 300 W98CC28C

10

11

1214

12

34

5

7

9

8

15

1625

24 7

2021

23

DETAIL A

A

136

6

22

17 18

19

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

1 7512325 8 Bolt2 5211325 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520214 2 Asm. Clutch, Front Hub, Elec./Mech.,

Heavy (Splined Drive Shaft)6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515523 8 Stud9 1520243 2 Asm. Hub w/Bearing Race

(Incl. 3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter

13 3250031 2 Spacer (Splined Drive Shaft)14 3250030 2 Cam (Splined Drive Shaft)15 7052045 2 Plug, Magnetic Drain16 5411264 2 Tire (23x7x10)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 1520175-117 2 Rim, Front25 1525017 2 Valve, Rim

6/97

Page 23: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B8

FRONT BRAKEXPLORER 300 W98CC28C

1

2 3

910

12

11

1314

4

5 6 78

15

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

1910232 1 Asm., Front Brake Caliper, LH(Incl. 1-11)

1910233 1 Asm., Front Brake Caliper, RH(Incl. 1-11)

1 7080352 2 Screw, Bleeder2 7515489 2 Screw, Socket Set3 5131115

513111611

Caliper, Brake, LHCaliper, Brake, RH

1930642 1 Kit - Boot, Front Brake4 1930665 1 Kit - Piston and Insulator Seal

(Incl. 6-8)5 5410779 1 Ring, Square (.094)6 5410780 1 Ring, Square (.103 x .134)7 5020506 1 Piston, Caliper

8 5910026 1 Insulator, Caliper9 2200901

22004652201149

1

11

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

10 1910057 2 Mount, Caliper11 5410495 1 Boot, Bushing12 5410494 1 Boot, Pin Seal13 -------------- 8 Washer

(See Front Strut Page B6, Ref. 15)14 -------------- 4 Washer, Spring Lock

(See Front Strut Page B6, Ref. 14)15 -------------- 4 Bolt

(See Front Strut Page B6, Ref. 13)

8/98

Page 24: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B9

CONTROLS -- THROTTLE ASM./CABLEXPLORER 300 W98CC28C

1

2

3

4

5

6

5

8

9

11

13

7

12

10

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

1 2010079 3 Screw, Button Head2 7072724 1 Decal - Throttle3 2010080 1 Cap4 2010081 1 Packing5 2010158 1 Asm., Throttle Control (Incl. 1-12)6 4110166 1 Switch, Demand Drive7 4030047 1 Bulb, Demand Drive Indicator

8 2010078 1 Holder9 2010077 2 Screw10 2010076 1 Bolt11 2010075 1 Plate12 4110203 1 Switch, ETC13 7080615 1 Cable, Throttle Control

6/97

Page 25: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B10

CONTROLS - MASTER CYLINDER/BRAKE LINEXPLORER 300 W98CC28C

8

23

27

17

20

21

22

22

24

2526

16

28

15

1819

2

3

5

6

4

12

1

11

1314

710

9

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

20500782200809

11

Asm., Master Cylinder (Incl. 1-13)Kit - Master Cylinder Reservoir(Incl. 1-3,13)

1 1930797 2 Bolt, Cap2 1930796 1 Cap, Reservoir3 1930795 1 Diaphragm4 2200808 1 Kit - Clamp, Master Cylinder5 1930799 1 Asm., Piston, Master Cylinder6 1930804 1 Rivet, Park Brake7 2201034 1 Kit - Brake Lever, w/Pkg. Brake

Latch (Incl. 6,8,10)8 -------------- 1 Spring, Flat9 1930806 1 Nut10 2201090 1 Kit - Park Brake Lever (Incl. 6,8)11 1930792 2 Bolt, Master Cylinder Reservoir12 1930805 1 Bolt, Lever Pivot

13 -------------- 1 Ring, Square, Master Cylinder14 5411297 1 Boot, Brake Line15 5410988 2 Seal16 4110164 1 Switch17 1930751 1 Line, Brake18 7621462 2 Rivet, Pop19 7080539 2 Clamp, Nylon20 8360031-30 1 Conduit, 30cm21 1930752 1 Line, Brake, Left Front w/Fittings22 7080138 8 Panduit23 7512024 2 Screw24 8360031-38 1 Conduit, 38cm25 1930753 1 Line, Brake Right Front w/Fittings26 7052103 1 Fitting, Inverted Flare Cross27 1930777 1 Line, Brake, Hydraulic28 1930674 1 Bolt, Banjo, Brake

11/97

Page 26: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B11

HANDLEBARXPLORER 300 W98CC28C

3

1

2

5

6

9

10

11

12

14

17

16

18

22

21

20

7

4

19

13

13

21

15

8

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

1 5432247-070 1 Cover, Logo2 7512024 2 Screw3 5432246-070 1 Panel, Instrument4 7517216 4 Screw5 5241397-067 1 Bracket, Instrument Panel6 -------------- 1 Asm., Master Cylinder (See Controls

- M.C./Brake Line Pg. B10 for Details)7 7080579

220018811

Cable, Choke ControlKit - Choke Lever

8 5433198 1 Spacer, Plastic9 4110193 1 Switch, Handlebar, Hi/Low/Off, LH10 5431030 2 Grip, Handlebar11 2010055 2 Screw12 5224715-067 1 Tube, Handlebar

13 5630629 4 Block, Handlebar14 7542122 4 Nut, Nylok15 7080278 1 Clip, Tinnerman16 -------------- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B9, Ref. 5)17 2460553 1 Harness, Control Panel18 4040054 1 Indicator, Neutral/Reverse19 4040052 1 Indicator, Low Oil/High Beam20 5430967 1 Plug, Indicator Hole21 4110194

...

5431964

1

.

1

Switch, Ignition (Incl. Key)Note: Ignition Key may be or-dered by using the four digit num-ber on the key.Cover, Key

22 7080229 1 Nut, Choke Slide

8/98

Page 27: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B12

STEERING POSTXPLORER 300 W98CC28C

1

2

34

16

15

14

5

10

69

13

8

911

7

13

12

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

1 1843067 1 Asm., Steering Post (Incl. 5,6)2 7542324 2 Nut, Nylok3 5222999-067 1 Bracket, Upper Steering Bushing4 5431572 1 Bushing, Steering Console5 7080433 1 Fitting, Lubrication6 5431574 1 Plug, Grease, Steering7 7661632 2 Rivet8 5431570 1 Bushing, Steering, Lower

9 7555878 3 Bushing10 7661633 1 Pin, Cotter11 7543203 1 Nut, Hex, Slotted12 5431571 1 Spacer, Steering Post13 5410772 2 O-Ring14 7515321 2 Bolt15 7080424 1 Fitting, Lubrication16 5431573 1 Bushing, Steering Console

6/97

Page 28: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B13

A--ARM/STRUT MOUNTINGXPLORER 300 W98CC28C

1 67

8

9

1011

5

12

13

14

15

16

17

19

1820

21

27

2524

23

2829

29 28

2423

22

3

4

2

14

26

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

1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 7515415 1 Bolt4 7515554 1 Bolt & Washer5 1822478 2 Asm., Tie Rod (Incl. 6-11)6 5411291 2 Boot, Seal, Rod End7 7061019 2 Rod End, RH8 7542711 2 Nut, RH9 5020926 2 Rod, Tie10 7547028 2 Nut, LH11 7061018 2 Rod End, LH, w/Fitting12 7555806 4 Washer13 7546904 2 Nut14 7661203 2 Cotter Pin15 -------------- 1 Asm., Hubstrut, Service

(See Front Strut Page B6, Ref. 23)16 7080673 2 Ball Joint, High Angle

17 5211121 2 Bracket, Ball Joint18 7512284 4 Bolt19 5410548 2 Boot, Rubber20 7542438 2 Nut, Castle21 7512084 4 Screw22 5431149

543115011

Shield, CV Joint, RHShield, CV Joint, LH

23 5431596 4 Bushing, A-Arm Long24 5020677 4 Bushing25 5020681 2 Shaft, A-Arm26 2200531

2200532

1

1

Kit - A-Frame, LH(Incl. 14,23,24,27-29)Kit - A-Frame, RH(Incl. 14,23,24,27-29)

27 7080433 2 Fitting, Lubrication28 7515458 4 Bolt29 7552603 4 Washer, Spring Lock

8/98

Page 29: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

B14

SWING ARM/SHOCK MOUNTINGXPLORER 300 W98CC28C

7

8

96

10

311121314

15

1

14 1312 11

2

17

19

18

16

19

17

2

22

21

2524

26

23

35

3029

3433

31

3227

28

5

4

20

7

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

1 7512701 1 Bolt, Shoulder2 5220958 2 Plate, Bolt Lock3 5630334 1 Cam, Adjustment, Spring4 5630351 1 Adaptor, Spring Seat5 5431032 1 Sleeve, Spring Protector6 7041204-067 1 Spring, Compression7 7542439 2 Nut, Nylok8 7515415 1 Bolt9 5222118 1 Retainer, Shock10 7041448 1 Shock, Rear11 5240952 2 Washer, Stamped12 5431977 2 Bushing, Thrust13 7555911 2 Washer14 7542602 2 Nut, Nylok15 -------------- 2 Bushing, Pivot

(See Gearcase Page C12, Ref. 4)16 7512702 1 Bolt, Shoulder17 5020793 2 Bushing, Swing Arm Extended

18 7080438 2 Fitting, Lubricated (45)19 5431972 4 Bushing, Swing Arm20 7074214 1 Decal - Lubrication21 7621433 2 Rivet, Pop22 5431310 1 Guide, Chain23 7515304 1 Bolt24 5332828 1 Bushing25 5430776 1 Guard, Chain26 7558402 1 Washer27 7542321 1 Nut28 1580090 1 Asm., Swing Arm (Incl. 18,19)29 7555883 2 Washer30 7542503 2 Nut, FLEXLOC31 7074752 1 Decal - Chain Free Play32 7072533 1 Decal - Hitch33 2200472 1 Kit - Hitch (Incl. 29-34)34 7512576 2 Bolt35 7515438 1 Bolt

8/98

Page 30: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C1

TOOL KITXPLORER 300 W98CC28C

2

3

4

5

6

1

7

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

1 2870694 1 Asm., Tool Kit (Incl. 2-6)2 2690016 1 Pouch, Tool Kit3 3083612 1 Wrench, Box, Special4 3083613 1 Wrench, 10-12 Spanner

5 3083843 1 Screwdriver6 2870725 1 Tire Pressure Gauge7 9914659

991452511

Manual, Owners, ‘98 ATVSupplement, Manual, Owners,‘98 Xplorer 300

6/97

Page 31: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C2

CENTER TIGHTENERXPLORER 300 W98CC28C

9

1

13

3

12

10

7

8

2

45

6

1415

16

11

87

2

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

1380129 1 Asm., Center Tightener(Incl. 1,2,4-12,14-16)

1 5020935 1 Shaft, Center Tightener, Short2 3610017 2 Seal, Tightener, 4WD3 3221044 1 Sprocket, 12T, Splined4 7555815 1 Washer5 7571611 1 Washer, Dish Lock6 7512492 1 Bolt7 3554506 2 Bearing, Tapered Roller Cone

8 3554507 2 Bearing, Tapered Roller Cup9 1380136 1 Asm., Eccentric, Center w/Cup10 7080306 1 Fitting, Lube w/Ball11 5410463 1 O-Ring12 5010444 1 Spacer, Tapered13 3222044 1 Sprocket, 22T14 7555788 1 Washer15 7542810 1 Nut16 7661402 1 Pin, Cotter

8/98

Page 32: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C3

DRIVE CLUTCHXPLORER 300 W98CC28C

14

1 2

13 12

5

11

34 5

10 9

8

67

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

1 7512176 6 Bolt2 7552801 6 Washer, Spring Lock3 5430945 6 Washer, Multilube4 1321457 3 Asm., Roller and Bushing5 5431936 6 Button, Clutch, Stemless6 5630514 3 Weight, Shift (G)7 7512266 3 Bolt, Shoulder8 7541906 3 Nut, FLEXLOC9 3576504 1 Bearing, Moveable, 1/2I

10 5210752524298152107535210754

ARARARAR

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

11 5020422 3 Pin, Roller12 7041157 1 Spring, Clutch13 3576510 1 Bearing, Cover14 1321632 1 Asm., Drive Clutch, ATV-06

(Less 6,12)

11/97

Page 33: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C4

DRIVEN CLUTCHXPLORER 300 W98CC28C

3

4

56

7

8

11

12

1718

4

12

10

13

14

16

15

9

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

1 7555990 1 Bushing2 7556401 AR Bushing3 3211077 1 Belt, Drive4 1322182 1 Asm., Driven Clutch, 3 Angle,

Heavy (Incl. 8-18)5 5220646 1 Washer, Domed6 7552901 1 Washer, Spring Lock7 7515382 1 Bolt8 7555898 AR Washer (.020)9 7556076 AR Washer (.025)

10 7556804 AR Washer11 3576504 1 Bearing, Moveable, 1/2⟩12 3576511 1 Bearing, Moveable, 1I13 7041198 1 Spring, Clutch14 5131447 1 Ramp, Stationary15 5210752 1 Spacer16 7710448 1 Ring, Retaining17 7511854 3 Bolt18 5430766 3 Button, Ramp

8/98

Page 34: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C5

CLUTCH COVERXPLORER 300 W98CC28C

30

17

13

4

5

7

8

9

10

12

6

13

22

14

2329

28

12

31

1511

19

20

21

25 2726

24

16

2

14

24

18

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

1 5410489 1 Seal, Cover Case2 7555748 3 Washer3 7517312 3 Screw4 5521301 1 Seal, Clutch Cover5 5431961 1 Cover, Clutch, Front6 7670051 1 Clip, Clutch Cover7 7512093 5 Screw8 7074946 1 Decal - Clutch Cover9 7077377 1 Decal - Engine/Clutch Modification10 7074782 1 Decal - Automatic Transmission11 7512094 2 Screw12 7080492 4 Strap, Panduit13 5410421 1 Boot, Clutch Intake14 7512232 2 Screw15 5432302 2 Clip, Retainer, Oil Line16 7080511 1 Clamp, Band, Narrow

17 5432441 1 Duct, Inlet Down Tube18 5811373 1 Tape, Foil19 5410509 1 Boot, Intake20 5431794 1 Duct, Inlet Top21 7512084 1 Screw22 5432649 1 Duct, Air Outlet Clutch23 2200792 1 Kit - Clutch Cover, Inner

(Incl. 7,12,27)24 7555932 2 Washer, Nylon25 5241213-067 1 Bracket, Clutch Cover26 7555935 1 Washer27 7512098 1 Screw28 5222877-067 1 Bracket, Retainer Seal29 5410749 1 Seal, Cover Case30 7661638 2 Rivet31 -------------- 4 Screw and Washer (See Crankcase

and Cylinder Page C14, Ref. 27)

8/98

Page 35: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C6

GEARCASE/BRAKE and CHAIN COVER MOUNTINGXPLORER 300 W98CC28C

12 3

56

98

10

7

21201911

1716

22

23

2425

8 926

4

11

18

28 30 2927

28 27

1514

1213

2

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

1 7515345 2 Bolt2 7552901 2 Washer, Spring Lock3 7558402 2 Washer4 7075339 1 Decal - Brake Shield5 5241018-067 1 Shield, Caliper, Rear6 1910226 1 Asm., Brake Caliper, Rear7 -------------- 1 Plate, Bolt Lock (See Swing Arm/

Shock Mounting Pg. B14, Ref. 2)8 7552603 2 Washer, Spring Lock9 7515522 2 Bolt10 -------------- 1 Bolt, Shoulder (See Swing Arm/

Shock Mounting Pg. B14, Ref. 16)11 1590265 1 Asm., Output Shaft Bearing12 7555701 1 Washer13 7515321 1 Bolt14 3221058 1 Sprocket, 11T

15 7710433 1 Ring, Retaining16 1910177 1 Disc, Brake17 7542449 2 Nut18 7080433 1 Fitting, Lubrication19 7515484 2 Bolt, Carriage20 7710434 1 Ring, Retaining21 3221041 1 Sprocket, 13T, Splined22 7542403 1 Nut, FLEXLOC23 7515472 1 Bolt24 7542404 1 Nut25 7515485 1 Bolt26 7555784 1 Washer27 3610062 2 Seal, Brake28 5242072 2 Flangette, Output Shaft Bearing29 3554202 1 Bearing, Needle30 5131643 1 Housing, Bearing, Output Shaft

8/98

Page 36: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C7

REAR BRAKEXPLORER 300 W98CC28C

2

3

4678

1

910

1112

13

14

15

1617

18192021

26 29

27

28

22

23

2524

22

23

5

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

1 7080352 1 Screw, Bleeder2 7661820 2 Pin, Brake3 1910226

5131272

1

1

Asm., Brake Caliper, Rear(Incl. 1-3,6-21)Caliper, Brake, Rear

4 22008992200464

11

Kit - Severe Duty Brake Pad, RearKit - General Duty Brake Pad, Rear

5 2200463 1 Kit - Piston and Seal (Incl. 6-8)6 5410766 1 Ring, Square (.134⟩)7 5410767 1 Ring, Square (.099⟩)8 5020667 1 Piston, Brake9 5240993 1 Spring, Anti-Rattle10 5410542 2 O-Ring11 7041219 1 Spring, Compression, Brake12 5020666 1 Pin, Brake Caliper13 5830009 1 Gasket, Brake14 5630651 1 Ramp, Moveable, Brake

15 5630652 1 Ramp, Stationary Brake16 7512173 2 Screw17 3610026 1 Seal, Brake18 5211692 1 Arm, Brake Caliper19 7555828 1 Washer20 7542129 1 Nut21 7515145 1 Bolt22 7661205 2 Pin, Cotter23 7555827 2 Washer24 5241621 1 Rod, Brake25 1040514-067 1 Foot Brake26 7042029 1 Spring, Exhaust27 5431107 2 Bushing, Pedal Pivot28 7555919 2 Washer29 7661401 1 Pin, Cotter

6/97

Page 37: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C8

REAR WHEEL DRIVEXPLORER 300 W98CC28C

12

3

4 5

67

10

9

111213

14

8

15

19

222123

2425

26

2827

252423

2930

5 4

3

31

32

7911

12

13

14

17

16

18

20

16

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

1 7555764 1 Washer2 5020468 2 Nut, Jam, Rear Axle3 7512673 8 Bolt4 2200341 2 Kit - Mach., Hub (Incl. 11)5 7670081 8 Retainer, Bolt, Pushnut6 5411265 2 Tire (24X11X10)7 1525017 2 Valve, Rim8 3225026 1 Link, Connector, Drive Chain9 7555745 2 Washer, Flat10 7542714 8 Nut, Wheel11 7555796 2 Washer, Cone12 7543005 2 Nut, Castle13 7661404 2 Pin, Cotter14 5411164 2 Hub, Dust Cover15 3224056-088 1 Drive Chain, 88P16 7542439 6 Nut, Nylok

17 5211618-067 1 Guard, Sprocket, 42T18 5630586 1 Spacer, Sprocket Guard19 3222061 1 Sprocket, Rear, 40T20 7515540 3 Bolt21 7515513 3 Stud22 1520170 1 Asm., Hub Sprocket (Incl. 21)23 5410415 2 O-Ring24 3610013 2 Seal, Rear Axle25 3515501 2 Bearing, Rear Axle26 5010204 1 Tube, Bearing Spacer27 7080306 1 Fitting, Lubrication28 5130663 1 Housing, Axle29 5010206 1 Spacer, Bearing30 7710405 1 Ring, Retaining31 5020789 1 Axle, Rear32 1520183-117 2 Rim, Rear

6/97

Page 38: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C9

ELECTRICAL/TAILLIGHTXPLORER 300 W98CC28C

1 2

3

5

4

67

8

9 12

1110

2322

13

14

21

1516

17

18

19

20

30

24

11

10

25

27

27

29

28

26

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

1 2460554 1 Harness, Main Wire2 2200593 1 Kit - Circuit Breaker, 20 AMP3 2432034 1 Asm., Taillight w/Brake Light

(Incl. 5-9)4 4032029 2 Screw, Taillight5 4032046 1 Lens, Taillight6 4030043 1 Bulb, Taillight7 4032045 1 Gasket, Taillight8 4032064 1 Backing, Taillight/Brake Light9 7670054 2 Nut, Speed10 7541925 4 Nut, Nylok11 7571602 2 Washer12 7512027 2 Screw13 5810290 3 Pad, Battery14 7072606 1 Decal - Battery15 2200361 1 Kit - Battery Bolt (Short)

16 4010095 1 Cable, Battery/Engine17 7010032 2 Hook, Battery Strap18 5410424 1 Strap, Battery Holddown19 5432077 AR Tube, Battery Vent20 4140006 1 Battery21 5431769 1 Cover, Battery22 4010094 1 Cable, Battery/Solenoid23 4010064 1 Cable, Solenoid/Starter24 4040063 1 Board, Terminal25 7621336 5 Rivet26 -------------- 1 Ignition Coil Complete

(See Magneto Page D2, Ref. 19)27 7512024 2 Screw28 4060085 1 Limiter, Reverse Speed29 4060193 1 Rectifier, Regulator, LR 39-130 7512007 2 Bolt

8/98

Page 39: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C10

GEAR SELECTORXPLORER 300 W98CC28C

2

3

4

5

6

7

8

9

28

13

14

10

11 12

25

29

1

19

20

1716

21

18

22

26

24

23

1527

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

1341264 1 Asm., Gear Selector(Incl. 1-15,23-25,28-29)

1 3233195 1 Asm., Knob2 7512024 1 Screw3 3233131 1 Clamp4 3233132 1 Clamp5 3233368 1 Boot, Gear Selector6 3233213 1 Cover, Gear Selector7 3233158 1 Spring, Holding8 3233456 1 Sub Asm., Handle9 3233063 1 Cup, Bearing10 3233083 1 Spring, Centering11 3233062 1 Pin, Stop12 3233069 2 Spring, Detent13 3233060 2 Bullet, Detent14 3233215 1 Switch, Gear Selector

15 3233090 1 Strap, Wire16 7061014 2 Rod End, 6mm, RH17 7061013 2 Rod End, 6mm, LH18 7546702 2 Nut, LH19 5020936 1 Rod, Shift Linkage20 5020690 1 Rod, Shift Linkage21 7546701 2 Nut, RH22 7546707 4 Nut, FLEXLOC23 3233217 1 Asm., Slide, High/Reverse24 3233218 1 Asm., Slide, Low25 3233457 1 Body, Gear Selector26 7515181 3 Screw27 3233070 1 Pin, Interlock28 3233084 1 Butterfly, Interlock29 3233085 5 Screw

6/97

Page 40: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C11

GEARCASEXPLORER 300 W98CC28C

47

12

3

45

6

6

78

9

1011 12

13 14 15

16

21 18

19

23

22

20

2420

25

262728

29

30 3132333430

35362737 38

39

46

20

48

45

46

21

4443

42 3

4

40 41

49

1011 12

13 1415

17

17

Page 41: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C12

GEARCASEXPLORER 300 W98CC28C

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

1341146 1 Asm., Gearcase (Incl. 1-49)1 3233002 1 Gearcase, LH2 3233026 10 Screw3 3233248 3 Seal4 3233024 2 Bushing, Pivot5 3233025 1 Stud6 3233021 2 Pipe, Knock7 3233022 1 Shift Rail, Low8 3233023 1 Shift Rail, High/Reverse9 3233038 1 Shaft, Low Shift10 3233044 2 O-Ring11 3233040 2 Washer12 3233045 2 Ring, Retaining13 3233153 2 Bell Crank14 3233054 2 Washer15 3233055 2 Nut16 3233039 1 Shaft, High/Reverse Shift17 3233031 2 Pin18 3233030 1 Bracket19 3233032 1 Spring20 3233018 3 Bearing21 3233033 4 Screw22 3233122 1 Shaft, Input23 3233019 1 Bearing24 3233007 2 Washer

25 3233125 1 Gear, 33T26 3233009 1 Bearing, Needle27 3233010 2 Washer28 3233126 1 Engagement Dog, Low29 3233175 1 Shaft, Reverse30 3233012 2 Washer31 3233127 1 Sprocket, 24T32 3233036 1 Chain, Silent 34P (11W)33 3233014 1 Bearing, Needle34 3233029 1 Ring, Retaining35 3233128 1 Engagement Dog, High/Reverse36 3233129 1 Gear, 25T37 3233017 1 Bearing, Needle38 3233176 1 Washer, Thrust39 3233177 1 Ring, Retaining40 3233037 1 Vent41 3233478 1 Dipstick42 3233448 1 Plug43 3233035 1 Washer44 3233003 1 Gearcase, RH45 3233043 1 Oil Deflector46 3233020 2 Bearing47 3233123 1 Shaft, Output48 3233130 1 Gear, 65T49 5020741 1 Bushing, Speedo

9/97

Page 42: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C13

CRANKCASE and CYLINDERXPLORER 300 W98CC28C

1

2

34 5

4

6

7 4

9 10

11

1213

14

1516

17

18

19

2120

2223

24

14

2526

27

28

20

29

30

31

32

33

3435

3637

38

29

21

8

18

Page 43: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

C14

CRANKCASE and CYLINDERXPLORER 300 W98CC28C

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

1 3085097 1 Head, Cylinder2 3083930 2 Fin Damper 23 3082910 6 Nut, Flange4 3084799 5 Fin Damper B5 3084798 1 Fin Damper A6 3085098 1 Gasket Complete (Head)7 3080283 4 Stud8 3084292 1 O-Ring9 3085013 1 Adapter, Carburetor (Incl. 8)10 3081330 2 Bolt (Socket Head)11 3081497 1 Screw (Pan Head)12 3082257 1 Asm., Band (Incl. 11)13 3082162 1 Seal, Oil14 3080103 4 Pin, Dowel15 3084801 1 Grommet16 3084800 1 Bracket, Wire17 3084802 2 Bolt and Washer18 3084791 1 Asm., Crankcase

(Incl. 13,14,21-26,28,29)19 3084018 1 Gasket, Starter

20 3082758 2 Gasket21 3083767 2 Plug, Drain22 3084775 1 Bearing, Ball23 3084792 1 Spacer24 3084121 1 Bearing, Ball25 3080739 3 Bolt and Washer26 3083615 2 Bolt and Washer27 3081635 4 Screw and Washer28 3084581 1 Seal, Oil (PTO)29 3084119 4 Stud30 3084795 1 Gasket, Cylinder31 3082911 4 Nut, Flange32 3083929 1 Fin Damper 133 3084793 1 Cylinder (Incl. 7,34,38)34 3085326 2 Stud35 3084439 1 Gasket, Exhaust36 3080530 2 Washer, Spring37 3080285 2 Nut38 3084794 2 Stud

6/97

Page 44: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

D1

CRANKSHAFT and PISTONXPLORER 300 W98CC28C

1

4

2

3

4

17

5

89

10

1112

13

76

14

15

16

7

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

1 308480930848103084811

222

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

2 308509930851003085101

111

Asm., Piston (Std)Asm., Piston (.010⟩/0.25mm O/S)Asm., Piston (.020⟩/0.50mm O/S)

3 3083858 1 Pin, Piston4 3084167 2 Clip, Piston Pin5 3083626 1 Bearing, Small End6 3083803 1 Bearing, Large End7 3083804 2 Spacer, Crank Pin8 3084580 1 Bearing, Ball

9 3083745 1 Crankshaft Gear10 3080130 1 Key, Woodruff11 3083904 1 Washer12 3083905 1 Nut, Lock13 3084803

3084804

1

1

Asm., Crankshaft(Incl. 6-9,13,14,16,17)Crankshaft 1

14 3084805 1 Crankshaft 215 3084778

3084779ARAR

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

16 3082796 1 Crank Pin 2, PTO Side17 3082790 1 Rod, Connecting

6/97

Page 45: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

D2

MAGNETOXPLORER 300 W98CC28C

5

8

7

6

43

1

14

13

12

11

910

1817

2

1615

19

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

1 3081467 1 Screw and Washer2 3081296 1 Clamp3 3084814

308481511

Asm., Plate (Incl. 1-3,6,7,9-14)Plate, Coil

4 3082226 3 Screw and Washer5 4020129 1 Cap, Spark Plug6 3084817 1 Stator 17 3081253 2 Screw and Washer8 3084813 1 Flywheel, w/Ring Gear9 3083422 1 Exciting Coil Complete

10 3084818 2 Screw and Washer11 3084819 1 Grommet12 3084816 1 Harness, Wire (Incl. 11,14)13 3081260 1 Screw and Washer14 3083909 1 Coupler, 3P15 3083073 2 Nut16 3080077 2 Spring Washer17 3085521 1 Magnetic Switch18 3084820 1 C.D.I. System Complete19 3083923 1 Ignition Coil Complete

6/97

Page 46: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

D3

STARTING MOTORXPLORER 300 W98CC28C

321

4

89

10

12

13

14 15

16

4

18

19

20

21

24

22

23

7 65

17

11

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

1 3083649 1 Nut, Flange2 3084406 1 Brush3 3085392

3085393

1

1

Asm., Starting Motor(Incl. 1-5,8,9,12-18,20-23)Asm., Starter(Incl. 1,2,4-5,8,9,12-17)

4 3084405 2 Rubber Ring5 3085032 1 Rear Cover6 3082758 1 Gasket, Aluminum7 3083568 1 Bolt8 3084408 2 O-Ring9 3084407 2 Through Bolt10 3083650 1 Bracket11 3081665 4 Bolt and Washer12 3083754 1 Washer Set

13 3084404 1 Asm., Armature (Incl. 14,15)14 3083934 1 O-Ring15 3083777 1 Bearing, Ball16 3083741 1 O-Ring17 3085305 1 Front Cover (Incl. 16)18 3083737 1 Washer, Gear Shaft19 3082038 2 Bolt and Washer20 3084409 1 Clip21 3084410 1 Spring, Return22 3084411 1 Spring, Weight23 3084412 1 Clip24 3085394 1 Asm., Gear Shaft

(Incl. 18,20-23)

6/97

Page 47: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

D4

RECOIL STARTERXPLORER 300 W98CC28C

1

2

3

4

5

67

89

10

1314

12

11

5

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

1 3083185 1 Spring, Spiral2 3084750 1 Bush3 3083453 1 Plug4 3082956 1 Gasket5 3085082

3085054

1

1

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

6 3084782 1 Bolt and Washer

7 3084177 8 Bolt, Flange8 3085266 1 Bolt9 3084744 1 Plate, Friction10 3083379 1 Spring, Friction11 3084822 1 Reel Complete12 3085083 1 Asm., Rope13 3083463 1 Spring, Return14 3083378 1 Ratchet

6/97

Page 48: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

D5

OIL PUMPXPLORER 300 W98CC28C

12

3

4

5

4

6

7

8

9

10

11

1213

14

16

17

18

19

20

15

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

1 3084829 1 Bolt2 3083138 2 Washer3 3084828 1 Check Valve4 3240173 2 Clamp, Hose5 3084826 1 Vinyl Pipe 1 (170mm)6 3083125 1 Screw, Air Vent7 3083126 1 Packing8 3085620 1 Asm., Oil Pump

(Incl. 1-3,6-13,20)9 3083758 1 Cap10 3083757 1 Collar, Camshaft11 3085622

308562111

Spring & LeverLever, Control

12 3083121 1 Washer, Spring13 3083120 1 Nut14 3083783 2 Screw and Washer15 3083428 1 Spacer16 3083429 1 Small Gear17 3083129 1 O-Ring18 3083353 1 Bush, Oil Pump19 3083671

30836723083673

ARARAR

Spacer 1 (0.15mm)Spacer 2 (0.3mm)Spacer 3 (0.6mm)

20 3083127 1 O-Ring

6/97

Page 49: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

D6

CARBURETORXPLORER 300 W98CC28C

1

4

56

7

8

9

10

1311

12 141516

17

1819

20

21

22

23

2425

2627

2829

30

2

3

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

1 3130184 1 Asm., Top (Incl. Gasket)2 3130354 1 Spring, Throttle3 3130002 1 Plate, Throttle4 3130003 1 E-Ring5 3130356 1 Jet Needle (5DP7-2)6 3130355 1 Washer7 3130420 1 Throttle Valve (2.0)8 3130409 1 Needle Jet (0-4)9 3130498 1 Asm., Carburetor (Incl. 1-30)10 3130017 1 Packing, Needle Valve11 3130361 1 Pin, Float12 3130018 1 Arm, Float13 3130360 1 Needle Valve (2.5)14 3130020 1 Packing, Float Chamber15 3130237 2 Cap

16 3130021 2 Float17 3130441 1 Float Chamber18 3130114 1 Main Jet (#155)19 3130239 1 O-Ring20 3130321 1 Bolt, Banjo21 3130025 4 Screw and Washer22 3130014 1 Washer, Main Jet23 3130067 1 Pilot Jet (#40)24 3130012 1 Spring, Air Adjuster25 3130011 1 Screw, Air26 3130324 1 Throttle Stop Screw27 3130010 1 Spring, Throttle Adjuster28 3130328 1 Starter Plunger29 3130006 1 Spring, Plunger30 3130359 1 Cap, Plunger

6/97

Page 50: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

XPLORER 300 W98CC28C

D7

1040380-067 5 A8. . . . . .1040387 10 A6. . . . . . . . .1040514-067 25 C7. . . . .1040524-067 13 A8. . . . .1040525-067 13 A8. . . . .1040532-067 17 A11. . . .1040544-067 21 A6. . . . .1040554-067 15 A10. . . .1040555-067 15 A10. . . .1040568-067 5 A12. . . . .1260543-029 17 A13. . . .1260658-029 16 A13. . . .1260702-029 14 A13. . . .1321457 4 C3. . . . . . . . . .1321632 14 C3. . . . . . . . .1322182 4 C4. . . . . . . . . .1341146 C12. . . . . . . . . . . .1341264 C10. . . . . . . . . . . .1380024 9 B4. . . . . . . . . .1380092 7 B5. . . . . . . . . .1380094 6 B5. . . . . . . . . .1380119 1 B5. . . . . . . . . .1380129 C2. . . . . . . . . . . . .1380136 9 C2. . . . . . . . . .1520170 22 C8. . . . . . . . .1520175-117 24 B7. . . . . .1520183-117 32 C8. . . . . .1520214 5 B7. . . . . . . . . .1520243 9 B7. . . . . . . . . .1525017 25 B7. . . . . . . . .

7 C8. . .1580090 28 B14. . . . . . . .1590265 11 C6. . . . . . . . .1822478 5 B13. . . . . . . . .1843067 1 B12. . . . . . . . .1910057 10 B8. . . . . . . . .1910177 16 C6. . . . . . . . .1910226 6 C6. . . . . . . . . . .

3 C7. . .1910232 B8. . . . . . . . . . . . .1910233 B8. . . . . . . . . . . . .1930665 4 B8. . . . . . . . . .1930674 28 B10. . . . . . . .1930751 17 B10. . . . . . . .1930752 21 B10. . . . . . . .1930753 25 B10. . . . . . . .1930777 27 B10. . . . . . . .1930792 11 B10. . . . . . . .1930795 3 B10. . . . . . . . .1930796 2 B10. . . . . . . . .1930797 1 B10. . . . . . . . .1930799 5 B10. . . . . . . . .1930804 6 B10. . . . . . . . .1930805 12 B10. . . . . . . .1930806 9 B10. . . . . . . . .2010055 11 B11. . . . . . . .2010075 11 B9. . . . . . . . .2010076 10 B9. . . . . . . . .

2010077 9 B9. . . . . . . . . .2010078 8 B9. . . . . . . . . .2010079 1 B9. . . . . . . . . .2010080 3 B9. . . . . . . . . .2010081 4 B9. . . . . . . . . .2010158 5 B9. . . . . . . . . .2050078 B10. . . . . . . . . . . .2200188 7 B11. . . . . . . . .2200341 4 C8. . . . . . . . . .2200361 15 C9. . . . . . . . .2200463 5 C7. . . . . . . . . .2200464 4 C7. . . . . . . . . .2200465 9 B8. . . . . . . . . .2200472 33 B14. . . . . . . .2200531 26 B13. . . . . . . .2200532 26 B13. . . . . . . .2200593 2 C9. . . . . . . . . .2200609 23 B6. . . . . . . . .2200610 23 B6. . . . . . . . .2200771 8 B5. . . . . . . . . .2200773 12 B5. . . . . . . . .2200775 8 A10. . . . . . . . .2200792 23 C5. . . . . . . . .2200808 4 B10. . . . . . . . .2200809 B10. . . . . . . . . . . .2200899 4 C7. . . . . . . . . .2200901 9 B8. . . . . . . . . .2200961 13 B5. . . . . . . . .2201034 7 B10. . . . . . . . .2201090 10 B10. . . . . . . .2201149 9 B8. . . . . . . . . .2431011 2 A10. . . . . . . . .2431012 2 A10. . . . . . . . .2432034 3 C9. . . . . . . . . .2460553 17 B11. . . . . . . .2460554 1 C9. . . . . . . . . .2460611 1 A10. . . . . . . . .2511272 1 A14. . . . . . . . .2530009 36 A11. . . . . . . .

10 A14. .14 B1. . .

2620096-195 3 A7. . . . . .2631928-195 8 A7. . . . . .2670070 4 A8. . . . . . . . . .2670071 5 A10. . . . . . . . .2670174 3 A8. . . . . . . . . .2670180 6 A10. . . . . . . . .2681747-218 12 A6. . . . .2682360-218 12 A6. . . . .2690016 2 C1. . . . . . . . . .2870694 1 C1. . . . . . . . . .2870725 6 C1. . . . . . . . . .3070156 20 A11. . . . . . . .3080077 16 D2. . . . . . . . .3080103 14 C14. . . . . . . .3080130 10 D1. . . . . . . . .3080283 7 C14. . . . . . . . .3080285 37 C14. . . . . . . .

3080530 36 C14. . . . . . . .3080739 25 C14. . . . . . . .3081253 7 D2. . . . . . . . . .3081260 13 D2. . . . . . . . .3081296 2 D2. . . . . . . . . .3081330 10 C14. . . . . . . .3081467 1 D2. . . . . . . . . .3081497 11 C14. . . . . . . .3081635 27 C14. . . . . . . .3081665 11 D3. . . . . . . . .3082038 19 D3. . . . . . . . .3082162 13 C14. . . . . . . .3082226 4 D2. . . . . . . . . .3082257 12 C14. . . . . . . .3082758 20 C14. . . . . . . .

6 D3. . .3082790 17 D1. . . . . . . . .3082796 16 D1. . . . . . . . .3082910 3 C14. . . . . . . . .3082911 31 C14. . . . . . . .3082956 4 D4. . . . . . . . . .3083073 15 D2. . . . . . . . .3083120 13 D5. . . . . . . . .3083121 12 D5. . . . . . . . .3083125 6 D5. . . . . . . . . .3083126 7 D5. . . . . . . . . .3083127 20 D5. . . . . . . . .3083129 17 D5. . . . . . . . .3083138 2 D5. . . . . . . . . .3083185 1 D4. . . . . . . . . .3083353 18 D5. . . . . . . . .3083378 14 D4. . . . . . . . .3083379 10 D4. . . . . . . . .3083422 9 D2. . . . . . . . . .3083428 15 D5. . . . . . . . .3083429 16 D5. . . . . . . . .3083453 3 D4. . . . . . . . . .3083463 13 D4. . . . . . . . .3083568 7 D3. . . . . . . . . .3083612 3 C1. . . . . . . . . .3083613 4 C1. . . . . . . . . .3083615 26 C14. . . . . . . .3083626 5 D1. . . . . . . . . .3083649 1 D3. . . . . . . . . .3083650 10 D3. . . . . . . . .3083671 19 D5. . . . . . . . .3083672 19 D5. . . . . . . . .3083673 19 D5. . . . . . . . .3083737 18 D3. . . . . . . . .3083741 16 D3. . . . . . . . .3083745 9 D1. . . . . . . . . .3083754 12 D3. . . . . . . . .3083757 10 D5. . . . . . . . .3083758 9 D5. . . . . . . . . .3083767 21 C14. . . . . . . .3083777 15 D3. . . . . . . . .3083783 14 D5. . . . . . . . .3083803 6 D1. . . . . . . . . .3083804 7 D1. . . . . . . . . .

Page 51: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

XPLORER 300 W98CC28C

D8

3083843 5 C1. . . . . . . . . .3083858 3 D1. . . . . . . . . .3083904 11 D1. . . . . . . . .3083905 12 D1. . . . . . . . .3083909 14 D2. . . . . . . . .3083923 19 D2. . . . . . . . .3083929 32 C14. . . . . . . .3083930 2 C14. . . . . . . . .3083934 14 D3. . . . . . . . .3084018 19 C14. . . . . . . .3084119 29 C14. . . . . . . .3084121 24 C14. . . . . . . .3084167 4 D1. . . . . . . . . .3084177 7 D4. . . . . . . . . .3084292 8 C14. . . . . . . . .3084404 13 D3. . . . . . . . .3084405 4 D3. . . . . . . . . .3084406 2 D3. . . . . . . . . .3084407 9 D3. . . . . . . . . .3084408 8 D3. . . . . . . . . .3084409 20 D3. . . . . . . . .3084410 21 D3. . . . . . . . .3084411 22 D3. . . . . . . . .3084412 23 D3. . . . . . . . .3084439 35 C14. . . . . . . .3084580 8 D1. . . . . . . . . .3084581 28 C14. . . . . . . .3084720 28 A11. . . . . . . .3084744 9 D4. . . . . . . . . .3084750 2 D4. . . . . . . . . .3084775 22 C14. . . . . . . .3084778 15 D1. . . . . . . . .3084779 15 D1. . . . . . . . .3084782 6 D4. . . . . . . . . .3084791 18 C14. . . . . . . .3084792 23 C14. . . . . . . .3084793 33 C14. . . . . . . .3084794 38 C14. . . . . . . .3084795 30 C14. . . . . . . .3084798 5 C14. . . . . . . . .3084799 4 C14. . . . . . . . .3084800 16 C14. . . . . . . .3084801 15 C14. . . . . . . .3084802 17 C14. . . . . . . .3084803 13 D1. . . . . . . . .3084804 13 D1. . . . . . . . .3084805 14 D1. . . . . . . . .3084809 1 D1. . . . . . . . . .3084810 1 D1. . . . . . . . . .3084811 1 D1. . . . . . . . . .3084813 8 D2. . . . . . . . . .3084814 3 D2. . . . . . . . . .3084815 3 D2. . . . . . . . . .3084816 12 D2. . . . . . . . .3084817 6 D2. . . . . . . . . .3084818 10 D2. . . . . . . . .3084819 11 D2. . . . . . . . .3084820 18 D2. . . . . . . . .

3084822 11 D4. . . . . . . . .3084826 5 D5. . . . . . . . . .3084828 3 D5. . . . . . . . . .3084829 1 D5. . . . . . . . . .3085013 9 C14. . . . . . . . .3085032 5 D3. . . . . . . . . .3085054 5 D4. . . . . . . . . .3085082 5 D4. . . . . . . . . .3085083 12 D4. . . . . . . . .3085097 1 C14. . . . . . . . .3085098 6 C14. . . . . . . . .3085099 2 D1. . . . . . . . . .3085100 2 D1. . . . . . . . . .3085101 2 D1. . . . . . . . . .3085266 8 D4. . . . . . . . . .3085305 17 D3. . . . . . . . .3085326 34 C14. . . . . . . .3085392 3 D3. . . . . . . . . .3085393 3 D3. . . . . . . . . .3085394 24 D3. . . . . . . . .3085521 17 D2. . . . . . . . .3085620 8 D5. . . . . . . . . .3085621 11 D5. . . . . . . . .3085622 11 D5. . . . . . . . .3110026 1 A11. . . . . . . . .3110028 35 A11. . . . . . . .3110064 5 A13. . . . . . . . .3130002 3 D6. . . . . . . . . .3130003 4 D6. . . . . . . . . .3130006 29 D6. . . . . . . . .3130010 27 D6. . . . . . . . .3130011 25 D6. . . . . . . . .3130012 24 D6. . . . . . . . .3130014 22 D6. . . . . . . . .3130017 10 D6. . . . . . . . .3130018 12 D6. . . . . . . . .3130020 14 D6. . . . . . . . .3130021 16 D6. . . . . . . . .3130025 21 D6. . . . . . . . .3130067 23 D6. . . . . . . . .3130114 18 D6. . . . . . . . .3130184 1 D6. . . . . . . . . .3130237 15 D6. . . . . . . . .3130239 19 D6. . . . . . . . .3130321 20 D6. . . . . . . . .3130324 26 D6. . . . . . . . .3130328 28 D6. . . . . . . . .3130354 2 D6. . . . . . . . . .3130355 6 D6. . . . . . . . . .3130356 5 D6. . . . . . . . . .3130359 30 D6. . . . . . . . .3130360 13 D6. . . . . . . . .3130361 11 D6. . . . . . . . .3130409 8 D6. . . . . . . . . .3130420 7 D6. . . . . . . . . .3130441 17 D6. . . . . . . . .3130498 9 D6. . . . . . . . . .3211077 3 C4. . . . . . . . . .

3221041 21 C6. . . . . . . . .3221044 3 C2. . . . . . . . . .3221058 14 C6. . . . . . . . .3222044 1 B4. . . . . . . . . . .

13 C2. . .3222061 19 C8. . . . . . . . .3224056-064 14 B3. . . . .3224056-070 20 B3. . . . .3224056-088 15 C8. . . . .3225026 13 B3. . . . . . . . .

8 C8. . .3233002 1 C12. . . . . . . . .3233003 44 C12. . . . . . . .3233007 24 C12. . . . . . . .3233009 26 C12. . . . . . . .3233010 27 C12. . . . . . . .3233012 30 C12. . . . . . . .3233014 33 C12. . . . . . . .3233017 37 C12. . . . . . . .3233018 20 C12. . . . . . . .3233019 23 C12. . . . . . . .3233020 46 C12. . . . . . . .3233021 6 C12. . . . . . . . .3233022 7 C12. . . . . . . . .3233023 8 C12. . . . . . . . .3233024 4 C12. . . . . . . . .3233025 5 C12. . . . . . . . .3233026 2 C12. . . . . . . . .3233029 34 C12. . . . . . . .3233030 18 C12. . . . . . . .3233031 17 C12. . . . . . . .3233032 19 C12. . . . . . . .3233033 21 C12. . . . . . . .3233035 43 C12. . . . . . . .3233036 32 C12. . . . . . . .3233037 40 C12. . . . . . . .3233038 9 C12. . . . . . . . .3233039 16 C12. . . . . . . .3233040 11 C12. . . . . . . .3233043 45 C12. . . . . . . .3233044 10 C12. . . . . . . .3233045 12 C12. . . . . . . .3233054 14 C12. . . . . . . .3233055 15 C12. . . . . . . .3233060 13 C10. . . . . . . .3233062 11 C10. . . . . . . .3233063 9 C10. . . . . . . . .3233069 12 C10. . . . . . . .3233070 27 C10. . . . . . . .3233083 10 C10. . . . . . . .3233084 28 C10. . . . . . . .3233085 29 C10. . . . . . . .3233090 15 C10. . . . . . . .3233122 22 C12. . . . . . . .3233123 47 C12. . . . . . . .3233125 25 C12. . . . . . . .3233126 28 C12. . . . . . . .3233127 31 C12. . . . . . . .3233128 35 C12. . . . . . . .

Page 52: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

XPLORER 300 W98CC28C

D9

3233129 36 C12. . . . . . . .3233130 48 C12. . . . . . . .3233131 3 C10. . . . . . . . .3233132 4 C10. . . . . . . . .3233153 13 C12. . . . . . . .3233158 7 C10. . . . . . . . .3233175 29 C12. . . . . . . .3233176 38 C12. . . . . . . .3233177 39 C12. . . . . . . .3233195 1 C10. . . . . . . . .3233213 6 C10. . . . . . . . .3233215 14 C10. . . . . . . .3233217 23 C10. . . . . . . .3233218 24 C10. . . . . . . .3233248 3 C12. . . . . . . . .3233368 5 C10. . . . . . . . .3233448 42 C12. . . . . . . .3233456 8 C10. . . . . . . . .3233457 25 C10. . . . . . . .3233478 41 C12. . . . . . . .3240173 4 D5. . . . . . . . . .3250010 11 B7. . . . . . . . .3250028 10 B7. . . . . . . . .3250030 14 B7. . . . . . . . .3250031 13 B7. . . . . . . . .3250032 12 B7. . . . . . . . .3260115 3 B5. . . . . . . . . .3260130 9 B5. . . . . . . . . .3514402 5 B4. . . . . . . . . .3515501 25 C8. . . . . . . . .3554202 29 C6. . . . . . . . .3554506 6 B7. . . . . . . . . . .

7 C2. . .3554507 19 B6. . . . . . . . .

7 B7. . .8 C2. . .

3554509 18 B6. . . . . . . . .3576504 9 C3. . . . . . . . . . .

11 C4. . .3576510 13 C3. . . . . . . . .3576511 12 C4. . . . . . . . .3610013 24 C8. . . . . . . . .3610017 6 B4. . . . . . . . . . .

2 C2. . .3610019 3 B7. . . . . . . . . .3610026 17 C7. . . . . . . . .3610028 24 B6. . . . . . . . .3610062 27 C6. . . . . . . . .4010064 23 C9. . . . . . . . .4010094 22 C9. . . . . . . . .4010095 16 C9. . . . . . . . .4010132 3 A11. . . . . . . . .4010211 8 A11. . . . . . . . .4020129 5 D2. . . . . . . . . .4030043 6 C9. . . . . . . . . .4030047 7 B9. . . . . . . . . .4030059 2 A10. . . . . . . . .4032029 4 C9. . . . . . . . . .

4032045 7 C9. . . . . . . . . .4032046 5 C9. . . . . . . . . .4032064 8 C9. . . . . . . . . .4040052 19 B11. . . . . . . .4040054 18 B11. . . . . . . .4040063 24 C9. . . . . . . . .4060085 28 C9. . . . . . . . .4060193 29 C9. . . . . . . . .4110164 16 B10. . . . . . . .4110166 6 B9. . . . . . . . . .4110177 6 B1. . . . . . . . . .4110193 9 B11. . . . . . . . .4110194 21 B11. . . . . . . .4110203 12 B9. . . . . . . . .4140006 20 C9. . . . . . . . .4170014 7 A12. . . . . . . . .4170016 21 B6. . . . . . . . .5010192 3 A13. . . . . . . . .5010204 26 C8. . . . . . . . .5010206 29 C8. . . . . . . . .5010444 12 C2. . . . . . . . .5020422 11 C3. . . . . . . . .5020468 2 C8. . . . . . . . . .5020474 8 B4. . . . . . . . . .5020506 7 B8. . . . . . . . . .5020527 4 B4. . . . . . . . . .5020666 12 C7. . . . . . . . .5020667 8 C7. . . . . . . . . .5020677 24 B13. . . . . . . .5020681 25 B13. . . . . . . .5020690 20 C10. . . . . . . .5020741 49 C12. . . . . . . .5020789 31 C8. . . . . . . . .5020793 17 B14. . . . . . . .5020926 9 B13. . . . . . . . .5020935 1 C2. . . . . . . . . .5020936 19 C10. . . . . . . .5130663 28 C8. . . . . . . . .5130668 6 B6. . . . . . . . . .5130701 2 B4. . . . . . . . . .5131115 3 B8. . . . . . . . . . .5131116 3 B8. . . . . . . . . . .5131272 3 C7. . . . . . . . . .5131379 9 B3. . . . . . . . . .5131447 14 C4. . . . . . . . .5131643 30 C6. . . . . . . . .5210748 13 A11. . . . . . . .5210752 10 C3. . . . . . . . .

15 C4. . .5210753 10 C3. . . . . . . . .5210754 10 C3. . . . . . . . .5211033 9 A6. . . . . . . . . .5211115 10 B6. . . . . . . . . .5211121 17 B13. . . . . . . . .5211148 4 B7. . . . . . . . . . .5211325 2 B7. . . . . . . . . .5211618-067 17 C8. . . . . .5211692 18 C7. . . . . . . . .

5220602 7 B6. . . . . . . . . .5220646 5 C4. . . . . . . . . .5220916-067 13 A14. . . .5220958 2 B14. . . . . . . . .5220980 20 B2. . . . . . . . .5222118 9 B14. . . . . . . . .5222154-067 8 A14. . . . .5222155-067 8 A14. . . . .5222193 20 B6. . . . . . . . .5222299 2 B5. . . . . . . . . .5222877-067 28 C5. . . . .5222999-067 3 B12. . . . .5224592 2 A6. . . . . . . . . .5224715-067 12 B11. . . .5240591-067 20 A10. . . .5240952 11 B14. . . . . . . .5240993 9 C7. . . . . . . . . .5241018-067 5 C6. . . . . .5241176-067 34 A11. . . . .5241213-067 25 C5. . . . .5241397-067 5 B11. . . . .5241398-067 18 A10. . . .5241399-067 18 A10. . . .5241403-067 17 A6. . . . .5241418 16 A6. . . . . . . . .5241583-067 21 A10. . . .5241621 24 C7. . . . . . . . .5241799-067 6 A11. . . . .5242016-067 19 A6. . . . .5242072 28 C6. . . . . . . . .5242081-067 8 A13. . . . .5242229-067 27 A11. . . .5242981 10 C3. . . . . . . . .5332828 24 B14. . . . . . . .5333332-067 11 A8. . . . .5333367 2 B13. . . . . . . . .5410241 4 A13. . . . . . . . .5410414 13 A6. . . . . . . . .5410415 23 C8. . . . . . . . .5410421 23 A11. . . . . . . .

13 C5. . .5410424 18 C9. . . . . . . . .5410436 9 A13. . . . . . . . .5410463 7 B4. . . . . . . . . . .

11 C2. . .5410470 20 B7. . . . . . . . .5410489 1 C5. . . . . . . . . .5410494 12 B8. . . . . . . . .5410495 11 B8. . . . . . . . .5410506 4 B2. . . . . . . . . .5410509 19 C5. . . . . . . . .5410510 18 B2. . . . . . . . .5410529 11 B2. . . . . . . . .5410542 10 C7. . . . . . . . .5410548 19 B13. . . . . . . .5410549 10 B2. . . . . . . . .5410749 29 C5. . . . . . . . .5410766 6 C7. . . . . . . . . .5410767 7 C7. . . . . . . . . .

Page 53: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

XPLORER 300 W98CC28C

D10

5410772 13 B12. . . . . . . .5410779 5 B8. . . . . . . . . .5410780 6 B8. . . . . . . . . .5410896 15 A6. . . . . . . . .5410988 15 B10. . . . . . . .5410991 3 B1. . . . . . . . . .5411009 23 A6. . . . . . . . .5411042 31 A6. . . . . . . . .5411106 5 B5. . . . . . . . . . .5411159 14 B2. . . . . . . . . .5411164 14 C8. . . . . . . . . .5411264 16 B7. . . . . . . . .5411265 6 C8. . . . . . . . . .5411272 15 A14. . . . . . . .5411291 6 B13. . . . . . . . .5411297 14 B10. . . . . . . .5411468 8 B6. . . . . . . . . .5430261 14 A11. . . . . . . .5430725 4 A14. . . . . . . . .5430766 18 C4. . . . . . . . .5430776 25 B14. . . . . . . .5430779 1 B1. . . . . . . . . .5430802 2 A11. . . . . . . . .5430806 4 B6. . . . . . . . . .5430807 5 B6. . . . . . . . . .5430884 19 B2. . . . . . . . .5430945 3 C3. . . . . . . . . .5430967 20 B11. . . . . . . .5431030 10 B11. . . . . . . .5431032 5 B14. . . . . . . . .5431053 6 A14. . . . . . . . .5431107 27 C7. . . . . . . . .5431124 9 B2. . . . . . . . . .5431149 22 B13. . . . . . . .5431150 22 B13. . . . . . . .5431310 22 B14. . . . . . . .5431570 8 B12. . . . . . . . .5431571 12 B12. . . . . . . .5431572 4 B12. . . . . . . . .5431573 16 B12. . . . . . . .5431574 6 B12. . . . . . . . .5431596 23 B13. . . . . . . .5431769 21 C9. . . . . . . . .5431771-070 36 A6. . . . .5431772-070 36 A6. . . . .5431786 6 A6. . . . . . . . . .5431787 14 A6. . . . . . . . .5431793 8 B1. . . . . . . . . .5431794 20 C5. . . . . . . . .5431796 39 A6. . . . . . . . .5431797 39 A6. . . . . . . . .5431798 18 A7. . . . . . . . .5431799 18 A7. . . . . . . . .5431806-195 6 A7. . . . . .5431809-195 3 A7. . . . . .5431936 5 C3. . . . . . . . . .5431961 5 C5. . . . . . . . . .5431964 21 B11. . . . . . . .

5431972 19 B14. . . . . . . .5431977 12 B14. . . . . . . .5432077 19 C9. . . . . . . . .5432155-070 10 A10. . . .5432245 3 B2. . . . . . . . . .5432246-070 3 B11. . . . .5432247-070 1 B11. . . . .5432302 15 C5. . . . . . . . .5432441 17 C5. . . . . . . . .5432559 21 A14. . . . . . . .5432572 17 B3. . . . . . . . .5432611 21 B7. . . . . . . . .5432619 2 A12. . . . . . . . .5432649 22 C5. . . . . . . . .5432663-195 40 A6. . . . .5432733 20 A14. . . . . . . .5433198 8 B11. . . . . . . . .5521301 4 C5. . . . . . . . . .5630334 3 B14. . . . . . . . .5630351 4 B14. . . . . . . . .5630514 6 C3. . . . . . . . . .5630586 18 C8. . . . . . . . .5630629 13 B11. . . . . . . .5630651 14 C7. . . . . . . . .5630652 15 C7. . . . . . . . .5810141 2 B1. . . . . . . . . .5810144 3 A14. . . . . . . . .5810290 13 C9. . . . . . . . .5810291 3 B6. . . . . . . . . .5810310 16 B2. . . . . . . . .5810439 16 B6. . . . . . . . .5810441 2 B2. . . . . . . . . .5810444 1 B2. . . . . . . . . .5810467 22 A10. . . . . . . .5811052 2 A14. . . . . . . . .5811087 30 A6. . . . . . . . .5811104 12 A6. . . . . . . . . .5811105 12 A6. . . . . . . . . .5811106 26 A6. . . . . . . . . .5811107 33 A6. . . . . . . . . .5811111 34 A6. . . . . . . . . .5811210 2 A7. . . . . . . . . .5811373 18 C5. . . . . . . . .5811399 35 A6. . . . . . . . .5811401 25 A6. . . . . . . . .5811402 37 A6. . . . . . . . .5811489 14 A7. . . . . . . . .5811491 1 A7. . . . . . . . . .5811502 18 B3. . . . . . . . .5811519 6 B3. . . . . . . . . .5830009 13 C7. . . . . . . . .5910026 8 B8. . . . . . . . . .7010032 17 C9. . . . . . . . .7041157 12 C3. . . . . . . . .7041198 13 C4. . . . . . . . .7041204-067 6 B14. . . . .7041219 11 C7. . . . . . . . .7041370 11 A6. . . . . . . . .

7041375-067 27 B6. . . . .7041448 10 B14. . . . . . . .7041755 9 B6. . . . . . . . . .7042029 13 A13. . . . . . . .

26 C7. . .7042031 15 A13. . . . . . . .7052005 32 A11. . . . . . . .7052045 15 B7. . . . . . . . .7052047 31 A11. . . . . . . .7052083 12 A13. . . . . . . .7052095 5 B1. . . . . . . . . .7052103 26 B10. . . . . . . .7052147 17 A14. . . . . . . .7052148 18 A14. . . . . . . .7052153 11 B1. . . . . . . . .7052154 19 A14. . . . . . . .7052192 10 A11. . . . . . . .7061013 17 C10. . . . . . . .7061014 16 C10. . . . . . . .7061018 11 B13. . . . . . . .7061019 7 B13. . . . . . . . .7072533 32 B14. . . . . . . .7072606 14 C9. . . . . . . . .7072724 2 B9. . . . . . . . . .7072791 29 A6. . . . . . . . .7073024 13 A9. . . . . . . . .7073453 12 A9. . . . . . . . .7073761 32 A6. . . . . . . . .7074110 2 A9. . . . . . . . . .7074214 20 B14. . . . . . . .7074220 21 A9. . . . . . . . .7074750 18 A9. . . . . . . . .7074752 31 B14. . . . . . . .7074782 10 C5. . . . . . . . .7074819 13 A7. . . . . . . . .7074827 16 A9. . . . . . . . .7074935 7 A9. . . . . . . . . .7074946 8 C5. . . . . . . . . .7074954 1 A9. . . . . . . . . .7074956 16 B3. . . . . . . . .7075339 4 C6. . . . . . . . . .7075413 9 A9. . . . . . . . . .7075656 3 A9. . . . . . . . . .7075741 11 A9. . . . . . . . .7076273 14 A9. . . . . . . . .7076523 5 A9. . . . . . . . . .7076524 6 A9. . . . . . . . . .7077377 9 C5. . . . . . . . . .7077862 15 A9. . . . . . . . .7077863 8 A9. . . . . . . . . .7077864 4 A9. . . . . . . . . .7077866 19 A9. . . . . . . . .7077867 10 A9. . . . . . . . .7077919 20 A9. . . . . . . . .7077920 17 A9. . . . . . . . .7080003 29 A11. . . . . . . .

12 A14. .7080134 12 B1. . . . . . . . .7080138 22 B10. . . . . . . .

Page 54: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

XPLORER 300 W98CC28C

D11

7080140 15 B2. . . . . . . . .7080229 22 B11. . . . . . . .7080278 15 B11. . . . . . . .7080306 3 B4. . . . . . . . . . .

22 B6. . .10 C2. . .27 C8. . .

7080307 16 B1. . . . . . . . .7080352 1 B8. . . . . . . . . .

1 C7. . .7080369 5 B2. . . . . . . . . .7080409 12 A7. . . . . . . . .7080413 13 B2. . . . . . . . .7080424 15 B12. . . . . . . .7080433 5 B12. . . . . . . . . .

27 B13. .18 C6. . .

7080438 18 B14. . . . . . . .7080492 12 C5. . . . . . . . .7080511 22 A11. . . . . . . .

16 C5. . .7080526 9 B1. . . . . . . . . .7080539 19 B10. . . . . . . .7080573 11 B6. . . . . . . . .7080579 7 B11. . . . . . . . .7080615 13 B9. . . . . . . . .7080627 11 B5. . . . . . . . .7080673 16 B13. . . . . . . .7080680 1 A12. . . . . . . . .7511854 17 C4. . . . . . . . .7511866 10 B1. . . . . . . . .7511875 6 A12. . . . . . . . .7511930 41 A6. . . . . . . . .7512007 30 C9. . . . . . . . .7512024 23 B10. . . . . . . .

2 B11. .27 C9. . .2 C10. .

7512027 22 B7. . . . . . . . .12 C9. . .

7512084 21 B13. . . . . . . .21 C5. . .

7512085 5 A6. . . . . . . . . .5 A7. . .

7512093 7 C5. . . . . . . . . .7512094 11 C5. . . . . . . . .7512098 27 C5. . . . . . . . .7512113 8 A12. . . . . . . . .7512173 16 C7. . . . . . . . .7512176 1 C3. . . . . . . . . .7512232 20 A6. . . . . . . . .

4 A7. . .3 A10. .7 A13. .9 A14. .14 C5. . .

7512242 3 A6. . . . . . . . . .7512246 6 B2. . . . . . . . . .

7512252 15 B3. . . . . . . . .7512266 7 C3. . . . . . . . . .7512275 12 B2. . . . . . . . .7512284 18 B13. . . . . . . .7512310 7 A14. . . . . . . . .7512325 1 B7. . . . . . . . . .7512365 13 B6. . . . . . . . .7512457 16 A11. . . . . . . .7512490 26 A11. . . . . . . .7512492 6 C2. . . . . . . . . .7512566 11 A11. . . . . . . .7512576 34 B14. . . . . . . .7512583 4 B3. . . . . . . . . .7512666 11 A13. . . . . . . .7512673 3 C8. . . . . . . . . .7512701 1 B14. . . . . . . . .7512702 16 B14. . . . . . . .7515145 21 C7. . . . . . . . .7515181 26 C10. . . . . . . .7515193 1 A8. . . . . . . . . .7515194 2 A8. . . . . . . . . . .

7 A10. .7515304 23 B14. . . . . . . .7515316 10 A13. . . . . . . .7515321 4 A11. . . . . . . . . .

14 B12. .13 C6. . .

7515339 26 B6. . . . . . . . .7515345 1 C6. . . . . . . . . .7515382 7 C4. . . . . . . . . .7515384 16 A10. . . . . . . .7515385 12 A8. . . . . . . . .7515390 13 A10. . . . . . . .7515391 12 A10. . . . . . . .7515398 6 A8. . . . . . . . . .7515399 4 A10. . . . . . . . .7515415 3 B13. . . . . . . . . .

8 B14. .7515438 35 B14. . . . . . . .7515458 28 B13. . . . . . . .7515472 23 C6. . . . . . . . .7515484 19 C6. . . . . . . . .7515485 25 C6. . . . . . . . .7515489 2 B8. . . . . . . . . .7515513 21 C8. . . . . . . . .7515522 11 B3. . . . . . . . . .

9 C6. . .7515523 8 B7. . . . . . . . . .7515540 20 C8. . . . . . . . .7515554 4 B13. . . . . . . . .7517216 4 B11. . . . . . . . .7517264 7 A8. . . . . . . . . .7517303 8 B3. . . . . . . . . .7517304 12 B3. . . . . . . . .7517312 3 C5. . . . . . . . . .7517375 7 A6. . . . . . . . . .7517376 24 A6. . . . . . . . .7517505 22 A14. . . . . . . .

7541906 9 A11. . . . . . . . . .8 C3. . .

7541925 1 A6. . . . . . . . . . .10 C9. . .

7541929 28 A6. . . . . . . . .19 A7. . .

7542122 22 A6. . . . . . . . .16 A7. . .9 A12. .14 B11. .

7542127 21 B2. . . . . . . . .7542129 20 C7. . . . . . . . .7542301 6 A13. . . . . . . . .7542303 12 B6. . . . . . . . .7542321 27 B14. . . . . . . .7542324 9 A10. . . . . . . . . .

14 A14. .2 B12. .

7542327 1 A13. . . . . . . . .7542343 8 A8. . . . . . . . . .7542403 19 A11. . . . . . . .

1 B13. .22 C6. . .

7542404 24 C6. . . . . . . . .7542411 7 A11. . . . . . . . .7542438 20 B13. . . . . . . .7542439 7 B14. . . . . . . . . .

16 C8. . .7542449 5 B3. . . . . . . . . . .

17 C6. . .7542459 23 B7. . . . . . . . .7542503 1 B3. . . . . . . . . . .

30 B14. .7542507 1 B6. . . . . . . . . .7542602 14 B14. . . . . . . .7542711 8 B13. . . . . . . . .7542714 10 C8. . . . . . . . .7542810 18 B7. . . . . . . . .

15 C2. . .7543005 12 C8. . . . . . . . .7543203 11 B12. . . . . . . .7546701 21 C10. . . . . . . .7546702 18 C10. . . . . . . .7546707 22 C10. . . . . . . .7546904 13 B13. . . . . . . .7547004 3 A12. . . . . . . . .7547028 10 B13. . . . . . . .7552603 25 A11. . . . . . . .

10 B3. . .29 B13. .8 C6. . .

7552801 2 C3. . . . . . . . . .7552901 5 A11. . . . . . . . . .

14 B6. . .6 C4. . .2 C6. . .

7555701 12 C6. . . . . . . . .7555716 2 A13. . . . . . . . .7555745 9 C8. . . . . . . . . .

Page 55: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

XPLORER 300 W98CC28C

D12

7555748 2 C5. . . . . . . . . .7555749 2 B6. . . . . . . . . .7555764 1 C8. . . . . . . . . .7555770 9 A8. . . . . . . . . .7555784 26 C6. . . . . . . . .7555788 14 C2. . . . . . . . .7555792 27 A6. . . . . . . . .

20 A7. . .7555796 11 C8. . . . . . . . .7555806 18 A11. . . . . . . .

12 B13. .7555815 4 C2. . . . . . . . . .7555823 24 A11. . . . . . . .7555827 23 C7. . . . . . . . .7555828 19 C7. . . . . . . . .7555859 4 A6. . . . . . . . . .7555878 9 B12. . . . . . . . .7555883 2 B3. . . . . . . . . . .

29 B14. .7555898 8 C4. . . . . . . . . .7555911 13 B14. . . . . . . .7555919 28 C7. . . . . . . . .7555931 17 A7. . . . . . . . .7555932 24 C5. . . . . . . . .7555935 26 C5. . . . . . . . .7555954 14 A10. . . . . . . .7555990 1 C4. . . . . . . . . .7556004 17 B7. . . . . . . . .7556076 9 C4. . . . . . . . . .7556401 2 C4. . . . . . . . . .7556804 10 C4. . . . . . . . .

7558201 4 A12. . . . . . . . .7558302 7 B2. . . . . . . . . .7558402 17 A10. . . . . . . .

15 B6. . .26 B14. .3 C6. . .

7558403 11 A10. . . . . . . .7571602 11 C9. . . . . . . . .7571611 5 C2. . . . . . . . . .7575202 12 A11. . . . . . . .7621330 19 A10. . . . . . . .7621336 25 C9. . . . . . . . .7621403 8 A6. . . . . . . . . .7621433 21 B14. . . . . . . .7621460 7 B1. . . . . . . . . .7621462 18 B10. . . . . . . .7661203 14 B13. . . . . . . .7661205 22 C7. . . . . . . . .7661401 19 B7. . . . . . . . .

29 C7. . .7661402 16 C2. . . . . . . . .7661404 13 C8. . . . . . . . .7661632 7 B12. . . . . . . . .7661633 10 B12. . . . . . . .7661638 18 A6. . . . . . . . .

30 C5. . .7661645 42 A6. . . . . . . . .

10 A7. . .7661820 2 C7. . . . . . . . . .7661913 10 B5. . . . . . . . .7670009 11 A7. . . . . . . . .

7670051 6 C5. . . . . . . . . .7670054 9 C9. . . . . . . . . .7670057 38 A6. . . . . . . . .

9 A7. . .7670060 8 B2. . . . . . . . . .7670080 17 B2. . . . . . . . .7670081 5 C8. . . . . . . . . .7670085 7 A7. . . . . . . . . .7670088 15 A7. . . . . . . . .7670091 4 B5. . . . . . . . . .7670096 10 A8. . . . . . . . .7670101 3 B3. . . . . . . . . .7710405 30 C8. . . . . . . . .7710433 15 C6. . . . . . . . .7710434 20 C6. . . . . . . . .7710448 16 C4. . . . . . . . .8360009-600 33 A11. . . .

5 A14. .4 B1. . .

8360026 16 A14. . . . . . . .17 B1. . .

8360031-30 20 B10. . . .8360031-38 24 B10. . . . .8450003-1525 37 A11. . .

13 B1. . .8450040-600 30 A11. . . .

11 A14. .8450042-600 15 B1. . . . .9914525 7 C1. . . . . . . . . .9914659 7 C1. . . . . . . . . .

Page 56: XPLORER 300 Model #W98CC28C Rev. 02 - pi54.compi54.com/corp/manuals/Parts/9914526r02.pdf · OIL PUMP D5..... OIL TANK B1..... P PARTNUMBERINDEX..... NO TAG ... 1998 XPLORER 300 ATV

PRINTED IN THE USA PARTS MANUAL PN 9914526 and MICROFICHE PN 9915239 8/98


Top Related