xplorer 400 model #a02cg38ca rev. 01pi54.com/corp/manuals/parts/9917024r01.pdfxplorer 400 model...

PARTS MANUAL PN 9917024 and MICROFICHE PN 9918266 9/02

XPLORER 400Model #A02CG38CA

Rev. 01

E 2001 Polaris Sales Inc.

TABLE OF CONTENTSXplorer 400 A02CG38CA

Parts Manual

AA-ARM/STRUT MOUNTING B9. . . . . . . . . . . . .AIR BOX A14. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D2. . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C5. . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER

CYLINDER/BRAKE LINE B7. . . . . . . . . . .CONTROLS - THROTTLE ASM./CABLE B6. . .COOLING SYSTEM A8. . . . . . . . . . . . . . . . . . .CRANKCASE and CYLINDER C11-12. . . . . . . . . . .CV JOINT B3. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A6. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C3. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C4. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C6. . . . . . . . . . . . . . .ENGINE MOUNTING A9-10. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A11. . . . . . . . . . . . . . . . . . .

FFRONT CAB A3. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING B2. . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A7. . .FRONT STRUT B1. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B4. . . . . . . . . . . . . . . . . . . . . .FUEL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C10. . . . . . . . . . . . . . . . . . . .

GGEARCASE C7-8. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING C9. . . . . . . . . . . . . . .

HHANDLEBAR B10. . . . . . . . . . . . . . . . . . . . . . . .

MMAGNETO D4. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL PUMP D3. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK A13. . . . . . . . . . . . . . . . . . . . . . . . . .

PPISTON and CRANKSHAFT C13. . . . . . . . . . . . .PROP SHAFT B12. . . . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE MASTER CYLINDER C1. . . . . . .REAR CAB and SEAT A4. . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING B13. . . . . . . . . . . .REAR HOUSING B14. . . . . . . . . . . . . . . . . . . . .REAR RACK MOUNTING A5. . . . . . . . . . . . . . .REAR WHEEL DRIVE C2. . . . . . . . . . . . . . . . .RECOIL STARTER C14. . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR D5. . . . . . . . . . . . . . . . . . .STEERING POST B8. . . . . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING B11. . . . . . . .

TTOOL KIT D6. . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D1. . . . . . . . . . . . . . . . . . . . . . .

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

A3

FRONT CABXPLORER 400 A02CG38CA

45

6

7

8

13

2

7

16 17

3

3

1415

10

11 12

3

1

9


Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

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

1 58114915810996

11

Foil, Side Panel, RHFoil, Foam, Side Panel (RH)

2 2632284-1942620085-195

11

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

3 7512232 10 Screw4 5431806-195 1 Cover, Front, EB Green5 7670085 2 Clip, Spring6 2632303-195 1 Cab, Front, EB Green

(Incl. Warning Decals)7 7670057 12 Nut, U-Type Speed8 7670135 4 Nut, Speed

9 7517312 2 Screw10 7512085 2 Screw11 7555792 2 Washer12 7541925 2 Nut, Nylok13 5431798-070

5431799-07011

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

14 7555931 2 Washer, Flat15 7542122 2 Nut, Nylok16 7670088 4 Clip, Dart17 5811512

581191711

Shield, Deflector, LHShield, Deflector, RH

12/01

A4

REAR CAB and SEATXPLORER 400 A02CG38CA

21

33

2

23

1

34

9

8

10

1112

24

6

7

14

15

28

22

32

31

29

30

34

25

27

5

1716

35

26

1323

20 18

19

1

4



1 7541925 4 Nut, Nylok2 5246091 1 Retainer, Seat Latch3 7512242 4 Screw4 7555859 10 Washer, Flat5 7512085 2 Screw6 5434040 1 Box, Tool7 7517375 2 Screw8 7621403 2 Rivet9 5211033 2 Bracket, Lever Retainer10 1040387 1 Latch, Seat11 7041370 1 Spring, Latch12 2682957-276

2682958-2765811104

111

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

13 5412067 8 Bumper, Rubber14 5431787 1 Cover, Tool Box15 5410896 1 Cap, Drain16 5241403-067 1 Guard, Clutch17 7661637 4 Rivet18 5432763 1 Guard, Rock

19 7515179 6 Screw20 1013643-067 1 Frame, Main21 7542122 8 Nut, Nylok22 7517376 8 Screw23 7555792 4 Washer24 7079901 1 Decal, Carb/Filter Information25 5811087 1 Foil, Foam26 5811106 2 Foil, Rear Cab, Front27 5811111 1 Foil Foam, Rear Fender28 5432056-070

5434417-07011

Footwell, Black, LHFootwell, Black, RH

29 7670057 12 Nut, U-Type Speed30 5431796-070

5431797-07011

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

31 7512232 12 Screw32 5432117-195 1 Cab, Rear, E.B. Green33 7511930 2 Bolt34 7661645 10 Rivet35 5811107 1 Foil, Rear Cab, Rear

3/02

A5

REAR RACK MOUNTINGXPLORER 400 A02CG38CA

4

3

1

2

6

95

7

8

2

10

7

(If built after 4/09/02)

5



1 7517983 2 Screw2 7517685 4 Screw3 2670174-070 1 Rack, Rear

(Incl. Ref. 4 and Warning Decal)4 7079927 2 Decal, Reflector, Red5 1040490-067

1013724-067

1

1

Support, Rear Rack(If built before 4/09/02)Support, Rear Rack(If built after 4/09/02)

6 7512329 4 Bolt7 7558402 8 Washer, Flat8 7670096 2 Nut, Chimney9 7542324 8 Nut, Nylok10 5334092 2 Spacer

7/02

A6

DECALSXPLORER 400 A02CG38CA

1413

10

8

3

6

1511

17

12

43

9

7

21

2

4

1

16

5



1 7170021 2 Decal, Warning, Front and Rear Rack2 7078444

707844511

Decal, “4x4 CDS”, LHDecal, “4x4 CDS”, RH

3 7078443 2 Decal, “POLARIS” Side Panel4 7078441

707844211

Decal, Tank Side, LHDecal, Tank Side, RH

5 7170025 1 Decal, Ignition6 7079780 1 Decal, Warning, AWD Switch7 7078045 1 Decal, “Liquid Cooled”, Radiator8 7078577 1 Decal, Drain Recoil

9 7079773 1 Decal, “POLARIS” Front Cover10 7078465 1 Logo - Polaris Star11 7079083 1 Decal, Warning, General, CPSC12 7079604 1 Decal, Warning, Override, AWD13 7078253 1 Decal, Age Warning14 7079085 1 Decal, Discretionary Warning15 7077920 1 Decal, Passenger Warning16 7079959 1 Decal, “POLARIS”, Rear17 7079087 1 Decal, Tire Pressure/Load Distribution

11/01

A7

FRONT RACK and BUMPER MOUNTINGXPLORER 400 A02CG38CA

15

12

1314

10

16

17

11

5

6

78

1819

20

2223

2

3

4

9

4

1

10

214

9

(If builtafter 12/12/01)

19



1 7517685 4 Screw2 2670180-070 1 Rack, Front (Incl. Ref. 3 and Decal)3 7079924 2 Decal, Reflector, Amber4 7515399 8 Screw5 2200775 1 Kit, Front Rack Mount6 5432155-070 1 Bumper7 7515391 2 Screw8 7515390 2 Screw9 7555954 4 Washer10 7542324 4 Nut, Nylok11 1013744-067

1013746-06711

Support, Front Rack, LHSupport, Front Rack, RH

12 7512232 4 Screw13 2431011

24310124030061

112

Headlight, LHHeadlight, RHBulb, Headlamp

14 7512329 2 Bolt15 7558402 4 Washer, Flat16 5810467 1 Plug, Frame17 5244729-067

5244730-06711

Extension, Frame, LHExtension, Frame, RH

18 5244731-067 1 Guard, Brush19 5240591-067

1013772-067

1

1

Grill, Brush Guard(If built before 12/12/01)Grill, Brush Guard(If built after 12/12/01)

20 7621330 7 Rivet21 7670094 6 Nut, U-Type22 7512097 6 Screw23 5433923

543392411

Shield, Radiator Side, LHShield, Radiator Side, RH

7/02

A8

COOLING SYSTEMXPLORER 400 A02CG38CA

13

42

9

24

12

23

10

17

3

111

22

20

8

21

15

16

65

7

1

3 8

10

14

18

19



1 7517656 4 Screw2 2410123 1 Asm., Fan and Motor3 7670111 4 U-Clip4 5434043 1 Shroud5 5020572 2 Spacer, Radiator Mount6 3110032 2 Mount, Rubber7 7547069 2 Nutsert8 7080614 2 Clamp, Hose9 5411986 1 Hose, Engine, Upper10 7080826 2 Clamp11 4010161 1 Sensor, Thermal w/Harness12 1240093 1 Cap, Pressure

13 1240090 1 Radiator14 7558301 2 Washer, Flat15 7512240 2 Screw16 7552801 2 Washer, Spring Lock17 7052296 1 Valve, Drain18 5433317 1 Cover, Radiator w/Mesh19 5410607 1 O-Ring20 5410584 2 Bushing, Radiator Mount, Lower21 7080965 1 Mount, Cable Tie22 7080138 1 Cable Tie23 5521550 1 Guard, Plastic Hose24 5411989 1 Hose, Engine, Lower

12/01

A9

ENGINE MOUNTINGXPLORER 400 A02CG38CA

6

1

3

7

16151413

1211

24

2322

20

25

10

9

27

28

29

31

23

4

34

35

34

18

19

33

32

37

35

5

36

36

8

2

26 21

1730

6

6

8

6

22

21

6

6

A10

ENGINE MOUNTINGXPLORER 400 A02CG38CA



1 3110038 1 Mount, Rubber Engine2 7552901 2 Washer, Spring Lock3 7512315 2 Screw4 4010132 1 Cable, Ground, Engine5 7517386 1 Screw6 7547108 7 Nut, Flange Lock7 5242692-067 1 Bracket, Engine Mount, Top8 7555823 2 Washer, Flat9 3070156 1 Spark Plug, NGK BR8ES10 4010218 1 Cable, Solenoid/Starter11 ------ -- -- -- -- 1 Seal, Cover Case

(See Clutch Cover Pg. C5, Ref. 1)12 ------ -- -- -- -- 1 Asm., Drive Clutch, Basic ATV-06

(See Drive Clutch Pg. C3, Ref. 14)13 5430261 1 Bushing14 5210748 1 Washer, Flat15 7575202 1 Washer, Interlock16 7512566 1 Screw17 8360012-04 1 Trim, Edge18 1040687-067 1 Mount, Engine, Front19 7517289 2 Screw20 7080511 1 Clamp, Narrow Band

21 3110042 2 Mount, Rubber Engine22 7552603 6 Washer, Spring Lock23 7512490 6 Screw24 1040231-067 1 Mount, Engine, Front25 5411681 1 Boot, Clutch Inlet26 7080656 1 Clamp, Narrow Band27 3085821 1 Engine, Short Block (EC38PLE10)

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

28 8360009-600 AR Line, Fuel29 7051011 1 Valve, Check30 7542411 1 Nut, FLEXLOC, Thin31 5242463-067 1 Bracket, Engine Mount, Rear32 3110048 1 Mount, Torque Stop, Rubber33 7542432 2 Nut, Jam34 7080003 2 Clamp, Hose, Red35 8450040-600 AR Line, Fuel36 7080534 2 Clamp, Hose37 2530008 1 Filter, Fuel

12/01

A11

EXHAUST SYSTEMXPLORER 400 A02CG38CA

123

4

5

6

7

9

11

1317

1615

2019

21

12

13

10

8

18

8

14

14



1 7542324 1 Nut, Nylok2 7555716 1 Washer, Flat3 5010192 1 Bushing4 5410241 1 Dampener, Vibration5 3110064 1 Mount, Torque Stop6 7542301 1 Nut7 5410436 1 Washer, Rubber8 7517386 4 Screw9 7515316 1 Bolt, Carriage10 5243199-067

754710111

Bracket, Exhaust MountNutsert

11 7512666 1 Bolt

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

C12, Ref. 9)20 ------ -- -- -- -- 2 Washer, Lock (See Crankcase and

Cylinder Pg. C12, Ref. 10)21 1260902-029 1 Manifold

3/99

A12

FUEL TANKXPLORER 400 A02CG38CA

56

7

8

13

14

10

9

1817

15

16

1

4

3

2

11

1920

11

11

11

11

10

12



1 2520183 1 Tank, Fuel (Incl. 6,15,16)2 5811052 1 Foam, Seal3 5433687 1 Cap, Gas Tank4 5812123 1 Gasket5 8360009-600 AR Hose, Vent6 5431053 1 Vent, Tank7 7512310 2 Bolt8 7512208 2 Screw9 2530008 1 Filter, Fuel10 8450040-600 AR Line, Fuel

11 7080003 6 Clamp, Hose12 7080534 2 Clamp, Hose13 5220916-067 1 Bracket, Tank Mount, Rear14 7542324 2 Nut, Nylok15 7052146 1 Fitting, Fuel Outlet, Main16 7052149 1 Fitting, Fuel Outlet, Reserve17 7052154 1 Valve, 3-Way18 5432733 1 Nut, Fuel Valve19 5432559 1 Knob, Fuel Valve20 7517505 1 Screw

7/02

A13

OIL TANKXPLORER 400 A02CG38CA

12

1

2

4

5

67

8

11

13

1413

12

109

3

15

12



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

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

3/99

A14

AIR BOXXPLORER 400 A02CG38CA

1

21

8

2

5

4

3

9 10

11

13

14

1817

19

20

15

7

16

6

12



1 5811660 1 Sleeve, Precleaner2 7670117 4 Clip, Airbox3 7527815 4 Screw4 5433052 1 Duct, Airbox Cover5 5411422 1 Gasket, Intake6 5812249 1 Foam, Seal7 5433740 1 Baffle, Air Inlet8 5433051 1 Cover, Airbox9 5811659 1 Seal, Cover10 7515179 2 Screw11 7558301 2 Washer, Flat

12 7555716 2 Washer, Flat13 5433050 1 Airbox, Intake14 1253388 1 Asm., Carburetor Boot15 7080643 1 Clamp16 5810317 1 Pad, Fuel Tank Bracket17 7080865 1 Clamp, Wire18 5411765 1 Cap, Drain19 5411766 1 Bumper, Rubber20 7080707 1 Clamp, Narrow Band21 1253355 1 Asm., Filter (Incl. 1)

8/02

B1

FRONT STRUTXPLORER 400 A02CG38CA

1

2

3

4

8

5

6

9

10

11

12

13

15

16

14

17

18

19

21

8

20

22 23

24

252627

1112

78



1 5411608 2 Bumper2 7041761 2 Strut, Front3 5211115 2 Washer4 7080367 2 Clamp, Cable5 7542324 4 Nut, Nylok6 7512365 4 Screw7 7552901 4 Washer, Spring Lock8 7558402 10 Washer, Flat9 5810439 2 Retainer, Strut Casting Wire10 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B5 for Details)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 1820950

1820951

1

1

Asm., Hubstrut, LH ,42mm, Heavy(Incl. 9,12-15,23)Asm., Hubstrut,RH, 42mm, Heavy(Incl. 9,12-15,23)

17 7041375-067 2 Spring, Compression18 5243364 2 Retainer, Spring, Strut19 5432871 2 Pivot, Ball, Bottom20 7515339 4 Bolt21 5132062 2 Spacer, Strut22 ------ -- -- -- -- 1 Kit, Drive Shaft w/Sleeve (See CV

Joint-Neapco Pg. B3, Ref. 12)23 3610028 2 Seal, Hubstrut24 5432872 2 Pivot, Ball, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, Nylok, Thin

7/00

B2

FRONT HOUSINGXPLORER 400 A02CG38CA

1 2

34 5

67

8

9 10

11 12

13

14

1516

17

18

1920 21

22

2324

25

26

27

28

21



1341323 1 Asm. Front Gearcase(Incl. 1-12,16-26)

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

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

9/99

B3

CV JOINT - NEAPCOXPLORER 400 A02CG38CA

12

6

7

8 9

11

3 51

2 4

Brand Designated

10



1 1380118 1 Asm., CV Housing w/Sleeve, NEA2 ------ -- -- -- -- 1 Sleeve, Drive Shaft Seal3 3260121 1 Clamp, Band4 7670092 1 Circlip5 2201015 1 Kit, Replacement Boot6 1380060 1 Shaft, Replacement (Incl. 4)

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

5/03

B4

FRONT WHEELXPLORER 400 A02CG38CA

10

11

1214

1

2 34

5

89

7

15

1625

24 8

2021

23

DETAIL A

A 13

6

6

22

191817



1 7512325 8 Bolt2 5243676 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub, Elec./Mech.6 3554506 4 Bearing, Tapered Roller Cone7 7515523 8 Stud8 3554507 4 Bearing, Tapered Roller Cup9 1520243 2 Asm., Hub w/Bearing Race (Incl. 3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter13 1321814 2 Spacer

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

1/99

B5

FRONT BRAKEXPLORER 400 A02CG38CA

12 3

4

56

7 8

9

10

11


1910549 1 Asm., Brake Caliper, LH(Incl. 1-7,9,10)

1910550 1 Asm., Brake Caliper, RH(Incl. 1-7,9,10)

1 7515489 1 Screw, Socket Set2 5132960

5132961

5133407

5133408

1930642

1

1

1

1

1

Caliper, Brake, LH(If built before 5/02/02)Caliper, Brake, RH(If built before 5/02/02Caliper, Brake, LH(If built after 5/02/02)Caliper, Brake, RH(If built after 5/02/02Kit, Front Brake Boot

3 5410494 1 Boot, Pin Seal4 1930665 1 Kit, Piston and Seal (Incl. 5-7)5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)7 5132294 1 Piston, Brake, Long8 2201398 1 Kit, Front Brake Pad9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 7080352 1 Screw, Bleeder

12/01

B6

CONTROLS - THROTTLE ASM./CABLEXPLORER 400 A02CG38CA

2

1

3

6

5

4

7



1 5434113 1 Cover, Throttle Control2 5411439 1 O-Ring3 2010205 1 Asm., Throttle Control (Incl. 4)4 2010191 1 Asm., Throttle Clamp

5 7556047 1 Washer, Cable End Sealing6 7080968 1 Cable, Throttle7 5410193 1 O-Ring

7/03

B7

CONTROLS - MASTER CYLINDER/BRAKE LINEXPLORER 400 A02CG38CA

15

18

9

12

13

14

14

1617

3

1011

19

2

1

8

7

6

5

12

4

4



2010196 1 Asm., Master Cylinder1 5411297 1 Boot, Brake Line, Rubber2 5410988 2 Seal3 4110164 1 Switch4 7517899 2 Screw5 2201834 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)6 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)7 2201833 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)8 2201835 1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)

9 1910504 1 Line, Brake, Stainless Steel, Rear10 7621462 2 Rivet11 7080539 2 Clamp, Nylon12 8360031-34 2 Conduit13 1910474 1 Line, Brake, Left Front14 7080138 8 Cable Tie15 7512024 2 Screw16 1910475 1 Line, Brake, Right Front Stainless

Steel17 7052292 1 Fitting, Cross18 1910472 1 Line, Brake, Stainless Steel19 1910499 1 Bolt, Banjo

12/01

B8

STEERING POSTXPLORER 400 A02CG38CA

41

53

2

6

10

12

8

11

9

3

8

1

713



1 7542324 4 Nut, Nylok2 7080424 1 Fitting, Lubrication3 5433866 2 Bushing, Steering, Upper4 1821111-067 1 Post, Steering5 5222999-067 1 Bracket, Steering, Upper6 7515321 2 Bolt, Carriage7 7512377 2 Screw

8 7556162 2 Bushing9 5222393 1 Flangette10 3514352 1 Bearing11 7547158 1 Nut12 7661633 1 Pin, Cotter13 7558402 2 Washer, Flat

12/01

B9

A-ARM/STRUT MOUNTINGXPLORER 400 A02CG38CA

1 3

45

6

7

82

11

1213

26

14

15

171618

20

24

25

2322

21

2728

28 27

2221

19

29

13

10

9




1 7542439 2 Nut, Nylok2 1820805 2 Asm., Tie Rod (Incl. 3-8)3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End5 7542711 2 Nut6 5020926 2 Tie Rod7 7547028 2 Nut, Jam, LH8 7061054 2 Rod End, LH9 5411920 1 Boot, Seal, Rod End10 7517909 2 Bolt11 7556099 4 Washer, Flat12 7547177 2 Nut13 7661203 4 Pin, Cotter14 7080927 2 Joint, Ball15 5211121 2 Bracket, Ball Joint16 7512284 4 Screw

17 5410548 2 Boot, Rubber18 7542438 2 Nut, Castle19 5431150-070

5431149-07011

Shield, CV Joint, LHShield, CV Joint, RH

20 7512084 4 Screw21 5434551 4 Bushing, A-Arm, Long22 5020677 4 Bushing23 5020681 2 Shaft, A-Arm24 2201611

220161211

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

25 7080433 2 Fitting, Lubrication26 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B1, Ref. 16)27 7512492 4 Screw28 7552603 4 Washer, Spring Lock29 7515415 2 Screw

12/01

B10

HANDLEBARXPLORER 400 A02CG38CA

3

1

5

6

9

10

12

13

15

18

17

19

23

22

21

74

20

14

14

22

16

811

2



1 5432247-070 1 Cover, Logo2 7512024 2 Screw3 5433842-070 1 Panel, Instrument4 7517216 4 Screw5 5244292-067 1 Bracket, Instrument Panel6 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Control - Master Cylinder/BrakeLine Pg. B7 for Details)

7 7081008 1 Cable, Choke8 5433903 1 Spacer, Switch, LH9 4010422 1 Switch, Handlebar, Hi/Lo/Rev. Override10 5433834-070 2 Grip, Handlebar11 5432952 1 Plug, Hole12 7517625 1 Screw13 5224715-067 1 Tube, Handlebar14 5630629 4 Block, Handlebar

15 7542122 4 Nut, Nylok16 7080631 1 Clip, Cable Retaining17 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B6, Ref. 3)18 2460872 1 Harness, Control Panel19 4040054 1 Indicator, Neutral/Reverse20 4040053 1 Indicator, “Hot Temperature”21 4010140 1 Indicator, Low Oil22 4010390

40102784010321

54337335433534

111

11

Switch, IgnitionBlank, Key, Series 2000, 6700, 6800Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.Nut, IgnitionCover, Key

23 7080922 1 Nut, Choke12/01

B11

SWING ARM/SHOCK MOUNTINGXPLORER 400 A02CG38CA

6

52

4

24

3

25

1

27

7

8

12

9

15

28

13

29

14

1011

2120

1918

17

26

2322

9

13116



1 7542439 2 Nut, Nylok2 7041204-067 1 Spring, Compression3 5630551 1 Cam, Adjusting4 7041961 1 Shock5 5241147 1 Retainer, Shock6 7515415 1 Screw7 7661046 2 Rivet8 5432727 1 Guide, Chain Pad9 7080510 2 Fitting10 7547082 1 Nut11 7556035 1 Washer, Flat12 5434546 2 Bushing, Swing Arm, RH13 5131697 2 Bolt, Swing Arm Pivot14 5133167 1 Bushing, Swing Arm Pivot, RH15 1580111 1 Asm., Swing Arm (Incl. 9,12,28)

16 7078572 1 Decal, “Chain Free Play”17 5432854 1 Guard, Chain18 7515304 1 Screw19 5332828 1 Bushing20 7558402 1 Washer, Flat21 7542321 1 Nut, Flange22 7547066 2 Nut, Nylok23 7555883 2 Washer24 7072533 1 Decal, Hitch25 2873036 1 Kit, Hitch (Incl. 22-26)26 7512576 2 Bolt27 7515438 1 Screw28 5434545 1 Bushing, Swing Arm, LH29 5133166 1 Bushing, Swing Arm Pivot, LH

12/01

B12

PROP SHAFTXPLORER 400 A02CG38CA

6 5 4 3

7

125



1380169 1 Asm., Prop Shaft1 5411092 1 O-Ring2 7080424 1 Fitting, Lubrication3 3260131 1 Yoke, Prop Shaft, Transmission

4 1350072 1 Shaft, Prop5 3260104 2 Kit, Cross and Bearing6 3260133 1 Yoke, Front Gear Case7 7661913 1 Pin, Spring

12/01

B13

REAR CALIPER MOUNTINGXPLORER 400 A02CG38CA

9

13

14

16

15

12

1110

1

8

4

3 54

17

Frame

7

5

6

627

7



1 7517231 2 Screw2 7555806 2 Washer, Flat3 1910449

220138522014282201467

1121

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

4 5410988 4 Seal5 1910504 1 Line, Brake, Rear6 1910506 1 Line, Brake, Rear7 7670102 6 Clip, Silencer Box8 1910499 2 Bolt, Banjo

9 5131759 1 Bushing, Caliper Mount10 7558402 2 Washer, Flat11 7552901 2 Washer, Spring Lock12 7512312 2 Bolt13 5131786 1 Mount, Caliper, Lower14 5131979 1 Mount, Caliper, Upper15 7512325 3 Bolt16 5243134-067 1 Guard, Brake Disc17 2201189

19103391930860

111

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

9/02

B14

REAR HOUSINGXPLORER 400 A02CG38CA

1

7

12

1722

19

18

8

5

1415

10

21

9

20

23

11

13

2

6

21

6

1011

1213

16

4

4

24

3

3

25

25



1 7710472 2 Ring, Retaining2 5510313 2 Retainer, Nut3 7542439 6 Nut, Nylok4 5411555 2 Seal, Foam5 5243679 1 Disc, Brake6 7515513 6 Stud7 1520259 1 Hub, Brake (Incl. 6)8 7710405 1 Ring, Retaining9 5010462 1 Spacer, Axle10 5410889 2 O-Ring11 3610070 2 Seal12 3554518 2 Bearing, Cone, Tapered13 3554517 2 Bearing, Cup, Tapered

14 5132098 1 Housing, Axle, Rear15 7080306 1 Fitting, Lubrication16 3225027 1 Link, Connector, 520 Regina17 5133181 1 Axle, Rear18 5211585-067 1 Guard, Sprocket, 38T19 5630586 1 Spacer20 3221111-076 1 Chain, 520 ORD, O-Ring21 3222109 1 Sprocket, 36T22 7512404 3 Bolt23 1520258 1 Asm., Hub, Sprocket (Incl. 6)24 7547108 3 Nut, Flange Lock25 7547196 2 Nut

12/01

C1

REAR BRAKE MASTER CYLINDERXPLORER 400 A02CG38CA

5

17

19

13

1

11

8

10

9

6

7

4

2

21

18

16

3

12

20

5

910

1315 14



1 7512113 2 Bolt2 5244091-067 1 Bracket, Reservoir Mount3 7542122 2 Nut, Nylok4 7517386 1 Screw5 7080003 2 Clamp, Hose, Red6 1910404 1 Hose, Reservoir7 1930854 1 Reservoir8 7661401 1 Pin, Cotter9 7555919 2 Washer10 5431107 2 Bushing11 1910375-067 1 Mount, Brake

12 1910499 1 Bolt, Banjo13 5410988 2 Seal14 ------ -- -- -- -- 1 Line, Foot Brake, Rear (See Rear Cal-

iper Mounting Pg. B13, Ref. 6)15 7552801 2 Washer, Spring16 7515179 2 Screw17 1910311 1 Asm., Foot Brake Master Cylinder18 7542324 2 Nut, Nylok19 1910376-067 1 Brake, Rod20 7041750 1 Spring, Torsion21 7515321 2 Screw

12/01

C2

REAR WHEELXPLORER 400 A02CG38CA

12

9

3

8

4

56

7

2

1

11

612

98

5

4

7

10



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

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

1/99

C3

DRIVE CLUTCHXPLORER 400 A02CG38CA

14

1 23 4

7

13

5 6 7

1211

10

89



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

10 7541906 3 Nut, FLEXLOC11 3576504 1 Bearing, Moveable, 1/2 Inch12 5210752

524298152107535210754

ARARARAR

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

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

(Incl. All Less 4,8)

7/98

C4

DRIVEN CLUTCHXPLORER 400 A02CG38CA

3

4

56

7

8

10

11

12

13

1516

17

4

12

9

14



1 5010266 1 Spacer, Driven Clutch2 7556120 AR Bushing3 3211077 1 Belt, Drive4 1322182 1 Asm., Driven Clutch, 3 Angle, Heavy

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

7556076ARAR

Washer (.020)Washer (.025)

9 7556804 AR Washer (.030)10 3576504 1 Bearing, Moveable, 1/2 Inch11 3576511 1 Bearing, Moveable, 1 Inch12 7041198 1 Spring, Clutch13 5132344 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

10/00

C5

CLUTCH COVERXPLORER 400 A02CG38CA

17

23

4

5

6

8

10

11

24

25

26

27

32 31

28

33

20

13

12

15

2

1

16

7

9

18

3

29

30

23

2122

23 14

19

3435



1 5411553 1 Seal, Clutch Cover2 7555748 3 Washer, Rubber3 7512278 3 Screw4 5521301 1 Seal, Clutch Cover5 5433451-070 1 Cover, Clutch, Outer6 7512093 5 Screw7 7078689 1 Decal, Warning, Clutch Cover8 7074782 1 Decal, Automatic Transmission9 7512094 9 Screw10 7080707 2 Clamp, Narrow Band11 5411489 1 Boot, Duct, Hi-Flow12 ------ -- -- -- -- 4 Screw and Washer (See Crankcase

and Cylinder Pg. C12, Ref. 58)13 5222446-067 1 Bracket, Retainer Seal14 7512098 1 Screw15 7555935 1 Washer16 5410575 1 Seal, Cover, Case17 7661638 2 Rivet18 5242693-067 1 Bracket, Clutch Cover, Front

19 7555932 1 Washer, Nylon20 2201159 1 Kit, Inner Clutch Cover

(Incl. 4,6,9,14,16)21 5242208-067 1 Bracket, Clutch Cover, Rear22 7547067 2 Nutsert23 7517386 2 Screw24 5434213 1 Duct, Air Outlet, Clutch25 5430743 1 Cap, Overflow, Drilled26 5810279 1 Gasket, Overflow Cap27 5433774 1 Plug, Cap28 7555783 1 Washer, Flat29 7080511 1 Clamp, Narrow Band30 7512018 1 Screw31 8450003-1525 1 Line, Fuel32 7052065 1 Fitting, Barbed, 90 Degree33 5433342 1 Duct, Clutch Inlet34 7512232 1 Screw35 7558301 1 Washer, Flat

12/01

C6

ELECTRICAL/TAILLIGHTXPLORER 400 A02CG38CA

1

2

4 5

6

78

910 13

12

11

2423

14

22

1516

17

18

20

2125

1211

3332

35

3634

31

28

3

27

30

31

29

2619



1 2460938 1 Harness, Main2 2200593 1 Kit, Circuit Breaker, 20 AMP3 2201795 1 Kit, Circuit Breaker, Fan4 2410320 1 Asm., Taillight (Incl. 5-10)5 4032046 1 Lens, Taillight6 4032029 2 Screw7 4030043 1 Bulb, Taillight8 4032045 1 Gasket, Taillight9 4032064 1 Backing10 7670054 2 Nut, Speed11 7541925 4 Nut, Nylok12 7571602 4 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 2200361 1 Kit, Battery Bolt, Short16 4010095 1 Cable, Battery/Engine17 7010032 2 Hook, Battery Strap18 5410424 1 Strap, Battery Holddown19 7670102 2 Clip

20 5432077 AR Tube, Battery Vent21 4140006 1 Battery22 5431769 1 Cover, Battery23 4010094 1 Cable, Battery/Solenoid24 ------ -- -- -- -- 1 Cable, Solenoid/Starter (See Engine

Mounting Pg. A10, Ref. 10)25 7512007 2 Bolt26 7080138 5 Cable Tie27 7670109 3 Clip, Routing28 4020149 2 Clip, Rosebud29 4020139 3 Clip, Rosebud30 4010195 1 Limiter, RPM31 7512017 4 Screw32 7511864 1 Screw33 5241416 1 Bracket, CDI34 7512018 2 Screw35 4060191 1 Rectifier36 5131818 1 Heat Sink

12/01

C7

GEARCASEXPLORER 400 A02CG38CA

1

7

37

124647

5549

2

5054

35

85657

586061

22

62

63

65

42

64

6667

454443

41

3938

31

33

32

30

26

27

252423

28

48

59

29

51

40

53

52

8

13

9

21

20

15

1918

34

1716

11

10

14

6

36

3

4

5

49

50

5049

124647

29

29

4029

2

12

8

C8

GEARCASEXPLORER 400 A02CG38CA


1341379 1 Asm., Gearcase (Incl. All)1 3233525 1 Screw2 3233054 3 Washer3 3233526 1 Dampener, Carb Vibration4 3233527 1 Bushing, Pivot5 3233252 10 Screw6 3233632 1 Gearcase, HLR, Hybrid Mach, LH7 3233529 2 Pipe, Knock8 3233788 3 Seal, Triple Lip9 3233019 1 Bearing, Ball10 3233704 1 Shaft, Input, HLR11 3233036 1 Chain, Silent12 3233018 3 Bearing, Ball13 3233749 8 Screw, Tapping14 3233617 1 Switch, 2 Position15 3233040 2 Washer16 3233153 1 Bellcrank, HLR17 3233055 2 Nut, FLEXLOC18 3233547 1 Bellcrank19 3233045 2 Ring, Retaining20 3233548 2 O-Ring21 3233549 2 Shaft, Shift, H/R22 3233895 1 Gearcase, RH23 3233308 2 Pin, Interlock24 3233032 1 Spring, Shifting, Interlock25 3233309 1 Bracket, Interlock26 3233043 1 Deflector, Oil27 3233747 4 Screw, Tapping28 3233635 1 Switch, 3 Position29 3233020 4 Bearing, Ball30 3233546 1 Chain, Roller31 3233545 1 Sprocket, 16T32 3233544 1 Shaft, Output33 3233558 1 Gear, 98T

34 3233448 1 Plug, Drain35 3233035 1 Washer36 3233633 1 Fork, Shift, H/R37 3233706 1 Fork, Shift, Low38 3233537 1 Ring, Retaining39 3233538 1 Sprocket, 14T40 3233539 11 Screw41 3233263 1 Cover, Bearing42 3233306 1 Ring, Retaining43 3233540 1 Shaft, Pinion44 3233541 1 Bushing, Garlock45 3233542 1 Washer, Thrust46 3233177 2 Ring, Retaining47 3233176 2 Washer, Thrust48 3233722 1 Gear, 30T49 3233718 3 Bearing, Needle50 3233720 3 Ring, Retaining, E-Clip51 3233721 1 Dog, Engagement52 3233719 1 Sprocket, 24T53 3233736 1 Shaft, Reverse, 31T54 3233732 1 Dog, Engagement, Low55 3233731 1 Gear, 33T56 3233556 1 Cover, Snorkel Drive57 3233555 1 O-Ring58 3233554 1 Shim59 3233898 1 Gear, 25T60 3233899 1 Shaft, Snorkel61 3233552 1 Bushing, Garlock62 3233037 1 Vent, Tube63 3233286 1 Plug, Vent Cap64 3233026 1 Screw65 3233897 1 Guide, Chain66 3233324 1 Washer67 3233711 1 Plug, Oil Fill

6/01

C9

GEARCASE MOUNTINGXPLORER 400 A02CG38CA

1

2

6

8 7

4

4

3

10

3

5

5

9

5

5



1 7517632 4 Screw2 5132046 2 Mount, Transmission, Rear3 7547089 4 Nut, Flange Lock4 7512492 2 Screw5 7555806 4 Washer, Flat6 7517646 1 Screw

7 3221041 1 Sprocket, 13T8 7710434 1 Ring, Retaining9 5211065

52107645211517

ARARAR

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

10 7517642 1 Screw

12/01

C10

GEAR SELECTORXPLORER 400 A02CG38CA

2

34

5

6

7

8

11910

22

1

15

14

12

1716

13

18

23

19

21

24

1820

1011



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

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

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

5/99

C11

CRANKCASE and CYLINDERXPLORER 400 A02CG38CA

1

2

34

7

8

910

1112

1314

15

28

16

27 25

17

181920

212223

24

2637

38

39

40

41

42

43

44

4748

4950

51

52

50

53

56

57

54

50

58

33

34

3231 30

2529

35

36

3334 35

44

13

55

4645

6

5

65

255 6

C12

CRANKCASE and CYLINDERXPLORER 400 A02CG38CA



1 3086753 1 Cylinder (Incl. 2,12,13)2 3084138 6 Stud3 3084731 1 Gasket, Head4 3086755 1 Cylinder Head (Incl. 8)5 3082758 3 Gasket6 3086744 3 Plug7 3082910 6 Nut, Flange8 3086756 1 Pipe, Water9 3086787 2 Nut10 3080530 2 Washer, Lock11 3086757 1 Gasket, Exhaust12 3085326 2 Stud13 3086746 2 Pipe 1, Elbow14 3082911 4 Nut, Flange15 3086758 1 Bolt, Banjo16 3083138 2 Gasket17 3085277 1 Adapter18 3240064 2 Valve19 3240065 2 Stopper20 3240066 6 Screw and Washer21 3086760 1 Gasket, Reed Valve22 3084147 1 Asm., Reed Valve (Incl. 18-20)23 3240164 1 Stuffer24 3081497 1 Screw, Pan Head25 3083590 3 Clamp26 3084144 1 Asm., Band, Adapter (Incl. 24)27 3087150 6 Bolt, Flange28 3083894 1 Check Valve29 3084729 1 Gasket, Cylinder30 3083384 1 Clamp

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

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

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

12/01

C13

PISTON and CRANKSHAFTXPLORER 400 A02CG38CA

1

23

4

5

2

6

7

8910

1112

1314

11

10

15

1718

19

2021

17

22

23

16



1 308473730847383084739

222

Piston Ring (Std)Piston Ring (0.25)Piston Ring (0.50)

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

30858873085888

111

Piston (Std)Piston (0.25)Piston (0.50) NOTE: This Part Is In-terchangeable In A Combination OfCarburetor Parts.

5 3087042 1 Balancer6 3086768 1 Plate7 3086769 2 Bolt, Flange8 3084156 1 Gear, Drive9 3086764 1 Washer, Guide10 3084160 2 O-Ring11 3086763 2 Collar

12 3086762 1 Nut, Slit13 3086767 1 Washer14 3083905 1 Nut, Lock15 3084776

3084149

1

1

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

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

3086766ARAR

Spacer 1Spacer 2

23 3084152 1 Crank Pin 1

7/00

C14

RECOIL STARTERXPLORER 400 A02CG38CA

1

2 3

4

7

9

10

11

12

14

13

8

6

5

5



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

308565611

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

6 3084782 1 Bolt and Washer7 3086751 8 Bolt, Flange

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

3/99

D1

WATER PUMPXPLORER 400 A02CG38CA

1

2

3

15

2

1413

12

10

11

9

8

7

5

4

6

4



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

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

308677111

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

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

5/99

D2

CARBURETORXPLORER 400 A02CG38CA

1

2

34

5

6

10

1112

31

30

2729

28262524

23

222120

19

1817

16

1514

13

9

8

7



1 3130184 1 Asm., Top2 3130496 1 Spring, Throttle3 3130027 1 Plate, Throttle4 3130003 1 E-Ring5 3131298 1 Needle, Jet (J8-DEY12)6 3130355 1 Packing7 3130199 1 Cap, Plunger8 3130006 1 Spring9 3130328 1 Plunger10 3130494 1 Valve, Throttle (1.5)11 3130429 1 Asm., Jet, Needle (480)12 3130596 1 Ring, Main Jet13 3130436 1 Spring, Throttle Adjuster14 3130447 1 Washer15 3130009 1 Screw, Throttle Stop16 3130011 1 Adjuster

17 3130012 1 Spring, Air Adjuster18 3130066 1 Jet, Pilot (#35)19 3130025 4 Screw20 3130432 1 Screw, Guide21 3130239 1 O-Ring22 3130123 1 Jet, Main (#200)23 3130443 1 Float Chamber24 3130430 2 Float25 3130237 2 Cap26 3130020 1 Gasket27 3131385 1 Valve, Needle (2.5)28 3130018 1 Arm, Float29 3130361 1 Pin, Float30 3130047 1 Packing31 3131384 1 Asm., Carburetor (Incl. 1-31)

12/01

D3

OIL PUMPXPLORER 400 A02CG38CA

12

3

4

5

6

8

9

10

8

11

13

14

1516

1718

1219

7

7



3085284 1 Asm., Oil Pump (Incl. 10-19)1 3084757 3 Bolt and Washer2 3085281 1 Cover, Case, Oil Pump3 3085280 1 Gasket, Case, Oil Pump4 3085520 1 Case, Oil Pump5 3086777 1 Grommet6 3086779 1 Grommet7 3086778 5 Screw and Washer8 3083141 2 Clamp, Hose9 3086776 1 Pipe, Vinyl

10 3083120 1 Nut11 3083121 1 Washer, Spring12 3083445 1 Collar, Camshaft13 3083127 1 O-Ring14 3084195 1 Spacer15 3084196 1 Wheel16 3084197 1 Pin, Spring17 3084194 1 Washer18 3083125 1 Screw, Air Vent19 3085570 1 Lever and Spring Set

7/00

D4

MAGNETOXPLORER 400 A02CG38CA

1 23

4

5

1

6

7

1

8

910

11

12

15

16

1314

7



1 3081260 3 Screw and Washer2 3081146 1 Clamp3 3084761

308476211

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

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

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

7/98

D5

STARTING MOTORXPLORER 400 A02CG38CA

3

12

4

7

9

10

11

12

1314

154

1718

19

20

21

22

23

24

8

6

5

16

8



1 3083649 2 Nut, Flange2 3084406 1 Brush3 3087043

3085393

1

1

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

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

12 3084404 1 Asm., Armature (Incl. 13,14)13 3083934 1 O-Ring14 3083777 1 Bearing, Ball15 3083741 1 O-Ring16 3085305 1 Cover, Front (Incl. 15)17 3083737 1 Washer, Gear Shaft18 3085283 1 Gasket, Starter19 3086781 2 Bolt, Flange20 3084409 1 Clip21 3084410 1 Spring, Return22 3087030 1 Asm., Gear Shaft (Incl. 17,20-24)23 3084411 1 Spring, Weight24 3084412 1 Clip

7/00

D6

TOOL KITXPLORER 400 A02CG38CA

1

3

4

5

6

8

2

7

9



1 2682572 1 Pouch, Tool Kit2 9916632

991702311

Owner’s Manual, ’02 ATVSupplement, Owner’s Manual, ’02Xplorer 400

3 3083612 1 Wrench, Box, Special4 3083613 1 Wrench, 10-12 Spanner

5 3083843 1 Screwdriver6 2870725 1 Gauge, Tire Pressure7 5211627 1 Wrench, Spanner8 3083920 1 Tool Kit (Incl. 1-7)9 2873647 1 Wrench, Torx, T-27

12/01

PRINTED IN THE USA PARTS MANUAL PN 9917024 and MICROFICHE PN 9918266 9/02

Changed

pages

in9917024

12

34

56

78

910

1112

1314

Acover

toc

Bx

C D E F G

12

34

56

78

910

1112

1314

xplorer 400 model #a02cg38ca rev. 01pi54.com/corp/manuals/parts/9917024r01.pdfxplorer 400 model...

Documents