xplorer 400l model #w98cc38c rev. xplorer 400l w98cc38c 8 4 13 19 6 14 3 12 11 18 16 2 7 20 15 9 21

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  • PARTS MANUAL PN 9914541 and MICROFICHE PN 9915239 8/98

    XPLORER 400L Model #W98CC38C

    Rev. 02

  • 2

    This page left blank intentionally.

  • TABLE OF CONTENTS Xplorer 400 W98CC38C

    Parts Manual

    A A-ARM/STRUT MOUNTING B13. . . . . . . . . AIR BOX B1. . . . . . . . . . . . . . . . . . . . . . . . . .

    B BUMPER MOUNTING and

    FRONT RACK A9. . . . . . . . . . . . . . . . .

    C CARBURETOR D3. . . . . . . . . . . . . . . . . . . . CENTER TIGHTENER B14. . . . . . . . . . . . . . CHAIN COVER MOUNTING and

    GEARCASE/BRAKE C5. . . . . . . . . . . . CLUTCH COVER C4. . . . . . . . . . . . . . . . . . CONTROLS - MASTER

    CYLINDER/BRAKE LINE B9. . . . . . . CONTROLS -

    THROTTLE ASM./CABLE B8. . . . . . . COOLING SYSTEM A11. . . . . . . . . . . . . . . . CRANKCASE and CYLINDER C13-C14. . . . . . CRANKSHAFT and PISTON C12. . . . . . . . CV JOINT - BTB B5. . . . . . . . . . . . . . . . . . . CYLINDER and CRANKCASE C13-C14. . . . . .

    D DECALS A8. . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH C2. . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH C3. . . . . . . . . . . . . . . . . .

    E ELECTRICAL/TAILLIGHT C8. . . . . . . . . . ENGINE MOUNTING A10. . . . . . . . . . . . . . . EXHAUST SYSTEM A12. . . . . . . . . . . . . . . .

    F FRONT BRAKE B7. . . . . . . . . . . . . . . . . . . FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . FRONT DRIVE B2. . . . . . . . . . . . . . . . . . . . FRONT RACK and

    BUMPER MOUNTING A9. . . . . . . . . . FRONT STRUT B4. . . . . . . . . . . . . . . . . . . .

    F FRONT TIGHTENER B3. . . . . . . . . . . . . . . FRONT WHEEL B6. . . . . . . . . . . . . . . . . . . FUEL TANK A13. . . . . . . . . . . . . . . . . . . . . . .

    G GEAR SELECTOR C11. . . . . . . . . . . . . . . . . GEARCASE C9-C10. . . . . . . . . . . . . . . . . . . . . . . GEARCASE/BRAKE and CHAIN

    COVER MOUNTING C5. . . . . . . . . . . .

    H HANDLEBAR and

    HEADLIGHT POD B11-B12. . . . . . . . . . . . . .

    M MAGNETO D5. . . . . . . . . . . . . . . . . . . . . . . .

    O OIL PUMP D4. . . . . . . . . . . . . . . . . . . . . . . . OIL TANK A14. . . . . . . . . . . . . . . . . . . . . . . . .

    P PART NUMBER INDEX D8-13. . . . . . . . . . . . . PISTON and CRANKSHAFT C12. . . . . . . .

    R REAR BRAKE C6. . . . . . . . . . . . . . . . . . . . . REAR CAB and SEAT A6. . . . . . . . . . . . . REAR RACK MOUNTING A7. . . . . . . . . . . REAR WHEEL DRIVE C7. . . . . . . . . . . . . . RECOIL STARTER D1. . . . . . . . . . . . . . . . .

    S SEAT and REAR CAB A6. . . . . . . . . . . . . . STARTING MOTOR D6. . . . . . . . . . . . . . . . STEERING POST B10. . . . . . . . . . . . . . . . . . SWING ARM/SHOCK MOUNTING C1. . .

    T TOOL KIT D7. . . . . . . . . . . . . . . . . . . . . . . . .

    W WATER PUMP D2. . . . . . . . . . . . . . . . . . . . .

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

  • 1998 XPLORER 400 SPECIFICATIONS BRAKES

    Type - Front Type - Rear Type - Auxiliary Type - Parking

    Hydraulic Disc Hydraulic Disc

    Mechanical Hydraulic

    CAPACITIES Coolant Capacity (quarts) Fuel Tank (gallon) Gearcase Oil (ounces) Engine Counter Balance 10W30 Oil (quarts) Injector Oil (quarts) Engine OW40 Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight

    2.25 4 20

    100 cc 2

    N/A 90 180 30

    Standard 850

    DRIVE TRAIN Type PVT

    DRIVE CLUTCH Center Distance (inches) Clutch Offset (inches) Clutch Weight Spring Color

    10 1/2

    S55 (55) Blue/Green

    DRIVEN CLUTCH Helix Angle Spring Position

    Compound 2-2

    DIMENSIONAL FEATURES

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

    65〉 N/A

    6x7x14 N/A

    7.375 47.5 81 34 570

    49.75 46

    GEARCASE Transmission Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type

    PRD Side Lever

    6.64/1 5.13/1 3.29/1

    13/22 64P 13/34 84P 11/22 70P

    N/A 520 O-Ring

    TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center

    Dunlop 25x8x12 25x11x10

    N/A 4 3

    N/A

    ENGINE Engine Model Number Engine Type Bore & Stroke (mm) Displacement (cc’s) Compression Ratio Cooling Alternator Output Elec. Start w/Recoil Back Up Carburetors (no. of/size)

    Main Jet Pilot Jet Needle Jet Cut Away Air Screw Jet Needle

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

    EC38PLE06 2 Cycle, Single Cylinder

    83.0x70 378.7

    6.9/1 Effective Liquid 200W

    Standard 1/VM34SS

    200 30

    0-6 (480) 1.5 Nickel/Aluminum

    1.5 Turn 6CEY6-3

    CDI 23.5 @ 3000

    .028 NGK BR8ES USFS Appr.

    GRAPHICS Body Style Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover w/Decal Headlight Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Tank Cover Tool Box Cover

    w/lettering Color

    Gen IV N/A N/A

    E. B. Green E. B. Green

    Black Black

    E. B. Green Black

    E. B. Green/Black Black Black

    Aluminum Burnished Brown

    E. B. Green Burnished Brown Burnished Brown

    N/A N/A N/A

    LIGHTS Headlight - Handlebar Headlight - Grill Taillight (watts) Brake Light (watts) Indicator Bulb

    1 Single Beam, 60W 2 Single Beams, 27W

    8.26W 12V/26.9W 12V/1.0W

    SUSPENSION Front Type -

    Front Travel (inches) Rear Type -

    Rear Travel (inches) Shock Shock Adjustment

    MacPherson Strut 6.25

    Progressive Rate Swing Arm 8.5

    1 3/8〉 Bore Gas Bag CAM

    Polaris Industries Inc. reserves the right tomake changes in designand specifications and/or tomake additions or improvements to its products without notice.

  • 1998 ATV PUBLICATION NUMBERS

    MODEL MODEL NO. OWNER’S MANUAL

    OWNER’S MANUAL

    SUPPLEMENT

    PARTS MANUAL

    PARTS MICROFICHE

    ASSEMBLY INSTRUCTIONS

    Xplorer 400L W98CC38C 9914659 9914540 9914541 9915239 9914543

    1998 ATV PAINT CODES

    MODEL MODEL NO. COMPONENT

    TYPE COLOR DESCRIPTION POLARIS “P” NO.

    Xplorer 400L W98CC38C Springs Burnished Brown P218

    Rims Aluminum P117

  • A5

    FRONT CAB XPLORER 400L W98CC38C

    4 5

    6

    7

    9

    10

    15

    2

    7

    18 19

    3

    3

    16 17

    11

    12

    13 14

    8

    3

    1

    3

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

    1 5811491 5811210

    1 1

    Foil, Side Panel Foil, Foam, Side Panel

    2 2620096-195

    5431809-195

    1

    1

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

    3 7512232 6 Bolt 4 5431806-195 1 Cover, Front, EB Green 5 7670085 2 Clip, Spring 6 2631928-195 1 Cab, Front, EB Green

    (Incl. Warning Decals) 7 7670057 6 Nut, U-Type Speed 8 7080409 1 Clamp, Wire Routing 9 7670009 2 Nut, Push-on

    10 7661645 4 Rivet 11 7512085 2 Bolt 12 7075741 1 Decal - Drain Recoil 13 7555792 2 Washer 14 7541929 2 Nut, Nylok 15 5431799

    5431798 1 1

    Guard, Mud, Front, RH Guard, Mud, Front, LH

    16 7555931 2 Washer 17 7542122 2 Nut, Nylok 18 7670088 4 Clip, Dart 19 5811489

    5811512 1 1

    Shield, Deflector, RH Shield, Deflector, LH

    8/97

  • A6

    REAR CAB and SEAT XPLORER 400L W98CC38C

    21

    23

    39

    2

    25

    1

    43

    3 4

    9

    8

    10

    11 12

    27

    42

    6

    7

    14

    15

    32

    22

    38

    37

    35

    36

    40

    28

    30

    5

    17 16

    41

    29

    13 25

    20

    18

    19

    34

    26

    24 31

    33

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

    1 7541925 4 Nut, Nylok 2 5224592 1 Retainer, Seat Latch 3 7512242 4 Screw 4 7555859 4 Washer, Flat 5 7512085 2 Screw 6 5431786 1 Tool Box 7 7517375 2 Screw 8 7621403 2 Rivet, Pop 9 5211033 2 Bracket, Lever Retainer 10 1040387 1 Seat Latch 11 7041370 1 Spring, Latch 12 2682360-218

    2681747-218 5811104 5811105

    1 1 1 1

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

    13 5410414 8 Bumper, Rubber 14 5431787 1 Cover, Tool Box 15 5410896 1 Cap, Drain 16 5241403-067 1 Guard, Clutch, Outer 17 7661638 4 Rivet 18 5242016-067 1 Guard, Rock 19 7512252 7 Screw 20 1040540-067 1 Frame 21 7542122 8 Nut, Nylok

    22 7517376 8 Bolt 23 5411009 1 Plug, Hole 24 5222646 1 Tab, Airbox Mount 25 7555792 4 Washer 26 7541929 2 Nut, Nylok 27 7072791 1 Decal - Filter Element 28 5811087 1 Foil, Foam 29 5811106 2 Foil, Rear Cab, Front 30 5811111 1 Foil Foam, Rear Fender 31 5811401 1 Foil, Footwell, Rib 32 5431772-070

    5431771-070 1 1

    Footwell, Black, RH Footwell, Black, LH

    33 5811402 1 Foil, Footwell 34 5811399 1 Foil, Footwell, Slotted 35 7670057 12 Nut, U-Type Speed 36 5431797

    5431796 1 1

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

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