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  • PARTS MANUAL PN 9914963 and MICROFICHE PN 9915651 1/99

    XPLORER 400Model #A99CG38CA

    Rev. 01

  • TABLE OF CONTENTSXplorer 400 A99CG38CA

    Parts Manual

    AAARM/STRUT MOUNTING B13. . . . . . . . . AIR BOX B2. . . . . . . . . . . . . . . . . . . . . . . . . . .

    CCARBURETOR D5. . . . . . . . . . . . . . . . . . . . . CLUTCH COVER C8. . . . . . . . . . . . . . . . . . . CONTROLS MASTER CYLINDER

    /BRAKE LINE B9. . . . . . . . . . . . . . . . . . . CONTROLS THROTTLE ASM.

    /CABLE B8. . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM A10. . . . . . . . . . . . . . . . . CRANKCASE and CYLINDER D1-2. . . . . . . CV JOINT B5. . . . . . . . . . . . . . . . . . . . . . . . . .

    DDECALS A8. . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH C6. . . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH C7. . . . . . . . . . . . . . . . . . .

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

    FFRONT BRAKE B7. . . . . . . . . . . . . . . . . . . . FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . FRONT HOUSING B4. . . . . . . . . . . . . . . . . . FRONT RACK and

    BUMPER MOUNTING A9. . . . . . . . . . . FRONT STRUT B3. . . . . . . . . . . . . . . . . . . . . FRONT WHEEL B6. . . . . . . . . . . . . . . . . . . . FUEL TANK A14. . . . . . . . . . . . . . . . . . . . . . . .

    GGEAR SELECTOR C13. . . . . . . . . . . . . . . . . . GEARCASE C11-12. . . . . . . . . . . . . . . . . . . . . . . . GEARCASE MOUNTING C9. . . . . . . . . . . .

    HHANDLEBAR and

    HEADLIGHT POD B11-12. . . . . . . . . . . . . . .

    MMAGNETO D7. . . . . . . . . . . . . . . . . . . . . . . . .

    OOIL PUMP D6. . . . . . . . . . . . . . . . . . . . . . . . . OIL TANK B1. . . . . . . . . . . . . . . . . . . . . . . . . .

    PPART NUMBER INDEX D10-E1. . . . . . . . . . . . . . PISTON and CRANKSHAFT C14. . . . . . . . . PROP SHAFT C1. . . . . . . . . . . . . . . . . . . . . .

    RREAR BRAKE MASTER CYLINDER C4. . REAR CAB and SEAT A6. . . . . . . . . . . . . . REAR CALIPER MOUNTING C2. . . . . . . . . REAR HOUSING C3. . . . . . . . . . . . . . . . . . . REAR RACK MOUNTING A7. . . . . . . . . . . . REAR WHEEL DRIVE C5. . . . . . . . . . . . . . . RECOIL STARTER D3. . . . . . . . . . . . . . . . . .

    SSTARTING MOTOR D8. . . . . . . . . . . . . . . . . STEERING POST B10. . . . . . . . . . . . . . . . . . . SWING ARM/SHOCK MOUNTING B14. . . .

    TTOOL KIT D9. . . . . . . . . . . . . . . . . . . . . . . . . .

    WWATER PUMP D4. . . . . . . . . . . . . . . . . . . . . .

    The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is notto be used for assembly.

  • 1999 XPLORER 400 SPECIFICATIONSBRAKES

    Type - FrontType - RearType - AuxiliaryType - Parking

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

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

    2.254

    16100 cc

    2N/A

    9018030

    Standard850

    DRIVE TRAINType Concentric

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

    PVT101/2

    S55 (55)Blue/Green

    DRIVEN CLUTCHHelix AngleSpring Position

    Compound2-2

    DIMENSIONAL FEATURES

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

    655887.5478134

    58849.75

    46

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

    PRDSide Lever

    6.14/14.74/13.06/1

    2:113/36 76P

    N/AN/A

    520 O-Ring

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

    Dunlop25x8-12

    25x11-10N/A

    43

    N/A

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

    Main JetPilot JetNeedle JetCut AwayAir ScrewJet Needle

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

    EC38PLE082 Cycle, Single Cylinder

    Oil Injected83.0x70

    3786.9/1 Effective

    Liquid200W

    Standard1/VM34SS

    21035

    0-6 (480)1.5 Nickel/Aluminum

    1.5 Turn6CEY6-3

    CDI23.5 @ 3000

    .028NGK BR8ES

    USFS Appr. Pending

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

    w/lettering Color

    Gen IVN/AN/A

    E. B. GreenE. B. Green

    BlackBlack

    E. B. GreenBlack

    E. B. Green/BlackBlackBlack

    AluminumBurnished Brown

    E. B. GreenBurnished BrownBurnished Brown

    N/AN/AN/A

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

    1 Single Beam, 60W2 Single Beams, 27W

    8.26W12V/26.9W12V/1.0W

    12V/14 AH

    SUSPENSIONFront Type -

    Front Travel (inches)Rear Type -

    Rear Travel (inches)ShockShock Adjustment

    MacPherson Strut6.7

    Progressive Rate Swing Arm9

    1 3/8 Bore Gas ChargedCAM

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

  • 1999 ATV PUBLICATION NUMBERS

    MODEL MODEL NO. OWNERSMANUAL

    OWNERSMANUAL

    SUPPLEMENT

    PARTSMANUAL

    PARTSMICROFICHE

    ASSEMBLYINSTRUCTIONS

    Xplorer 400 A99CG38CA 9914905 9914907 9914963 9915651 9914908

  • A5

    FRONT CABXPLORER 400 A99CG38CA

    45

    6

    7

    8

    9

    13

    2

    7

    16

    17

    3

    3

    1415

    10

    11 12

    3

    1

    3

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

    1 58114915810996

    11

    Foil, Side PanelFoil, Foam, Side Panel

    2 5431809-1952620085-195

    11

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

    3 7512232 12 Bolt4 5431806-195 1 Cover, Front, EB Green5 7670085 2 Clip, Spring6 2631990-195 1 Cab, Front, EB Green

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

    9 7661645 4 Rivet10 7512085 2 Bolt11 7555792 2 Washer12 7541925 2 Nut, Nylok13 5431798

    543179911

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

    14 7555931 2 Washer15 7542122 2 Nut, Nylok16 7670088 4 Clip, Dart17 5811512

    581148911

    Shield, Deflector, LHShield, Deflector, RH

    1/99

  • A6

    REAR CAB and SEATXPLORER 400 A99CG38CA

    21

    33

    2

    23

    1

    37

    34

    9

    8

    10

    1112

    24

    36

    6

    7

    14

    15

    28

    22

    32

    31

    29

    30

    34

    25

    27

    5

    1716

    35

    26

    1323

    2018

    19

    1

    4

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

    1 7541925 4 Nut, Nylok2 5224592 1 Retainer, Seat Latch3 7512242 4 Screw4 7555859 10 Washer, Flat5 7512085 2 Screw6 5431786 1 Box, Tool7 7517375 2 Screw8 7621403 2 Rivet9 5211033 2 Bracket, Lever Retainer

    10 1040387 1 Latch, Seat11 7041370 1 Spring, Latch12 2682360-276

    2681747-27658111045811105

    1111

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

    13 5410414 8 Bumper, Rubber14 5431787 1 Cover, Box, Tool15 5410896 1 Cap, Drain16 5241403-067 1 Guard, Clutch, Outer17 7661638 4 Rivet18 5432763 1 Guard, Rock

    19 7515179 6 Screw20 1012770-067 1 Frame21 7542122 8 Nut, Nylok22 7517376 8 Bolt23 7555792 4 Washer24 7072791 1 Decal - Filter Element25 5811087 1 Foil, Foam26 5811106 2 Foil, Rear Cab, Front27 5811111 1 Foil Foam, Rear Fender28 5431771-070

    5433196-07011

    Footwell, Black, LHFootwell, Black, RH

    29 7670057 12 Nut, U-Type Speed30 5431796

    543179711

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

    31 7512232 12 Screw32 5433204-195 1 Cab, Rear, Green33 7511930 2 Bolt34 7661645 10 Rivet35 5811107 1 Foil, Rear Cab, Rear36 7073761 1 Decal - Carb Information37 5411042 1 Grommet

    1/99

  • A7

    REAR RACK MOUNTINGXPLORER 400 A99CG38CA

    4

    3

    1

    2

    7

    8

    5

    10

    1213

    118

    6

    11

    9

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

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

    (Incl. Ref. 4 and Warning Decal)4 2670070 2 Reflector, Red5 7517264 2 Bolt6 1040490-067 1 Support, Rear Rack7 7512329 4 Bolt

    8 7542343 8 Nut, Nylok, Flanged9 7670096 2 Nut, Chimney

    10 1040524-0671040525-067

    11

    Bracket, Front Mount, LHBracket, Front Mount, RH

    11 7558402 4 Washer, Wrought12 5333332-067 4 Spacer13 7515385 4 Screw

    1/99

  • A8

    DECALSXPLORER 400 A99CG38CA

    7

    11

    18

    13

    5

    109

    1715

    3

    6

    20

    14

    8

    21

    16

    43

    12

    1

    19

    8

    2

    1

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

    1 7074954 2 Decal - Rack

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