xplorer 300 model #w98cc28c rev. 02 - pi54. pump d5..... oil tank b1..... p partnumberindex..... no...

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  • PARTS MANUAL PN 9914526 and MICROFICHE PN 9915239 8/98

    XPLORER 300Model #W98CC28C

    Rev. 02

  • 2

    This page left blank intentionally.

  • 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.

  • 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)

    576x7x14

    N/A6

    45.58134567

    49.7546

    ENGINEEngine Model NumberEngine TypeBore & Stroke (mm)Displacement (ccs)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.

  • 1998 XPLORER 300 ATV PUBLICATION NUMBERS

    MODEL MODEL NO. OWNERSMANUAL

    OWNERSMANUALSUPPLEMENT

    PARTSMANUAL

    PARTSMICROFICHE

    ASSEMBLYINSTRUCTIONS

    Xplorer 300 W98CC28C 9914659 9914525 9914526 9915239 9914528

    1998 XPLORER 300 PAINT CODES

    MODEL MODEL NO.COMPONENTTYPE COLOR DESCRIPTION

    POLARISP NO.

    Xplorer 300 W98CC28C Springs Fire Red P093

    Rims Aluminum P117

  • 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

  • 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

  • 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

  • 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

    1040525-067

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