Yesterday I flipped my 2000 Explore 2stroke backwards. Fixed a few things, then went back out. 20 minutes later my transmission let's loose. I just had a new engine put in, so I want to fix this. Anyone have one laying around for a 4x4? What years will interchange? I was hoping Old Polaris Tech would see this and chime in. Also, I think I am going to tear it apart and see about replacing whatever broke.

Thanks.

 

1341326 (built after 7/99)

Year Product Model Assembly
2001 ATV XPLORER 400 GEARCASE (If built before 4/01/01)- A01CG38CA (4963916391C007)
2000 ATV XPLORER 400 GEARCASE - A00CG38CA (4954875487C013)1341326


1341273 (if built before 7/99)

Year Product Model Assembly
2000 ATV XPLORER 400 GEARCASE - A00CG38CA (4954875487C011)
1999 ATV XPLORER 400 GEARCASE - A99CG38CA (4949634963C011)

This is what the Polaris parts catalog lists.Hopefully you still have the sticker on the transmission. Other wise the latest model still should work.Doesn't show the entire gear case on the later model. Individual parts maybe.Polaris Xplorer 400 Gearcase PN 1341273 | eBay Plus here's a cheaper place than most dealers if you need hard parts.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Same machine that was upside down in the creek on the other forum?

 

Old Polaris Tech, you are a lifesaver. Thanks a bunch. I should have the transmission out tomorrow, and I will know what the damage is.

 

I didn't see that you listed that one on eBay until now. 799.00 for a transmission, that is crazy. I'm thinking I will just let the quad sit before I spend that one one. Does anyone know where I can maybe get a case half for mine, or a transmission that isn't going to almost cost what the quad is worth?

 

You might try here on case parts.Used Polaris Parts Plus here's one cheaper at 400 bucks. Still buying a used one doesn't mean it's perfect and wont need repairs.http://www.ebay.com/itm/Polaris-Xplorer-400-4x4-99-02-Transmission-Gear-Case-9116-/301542499324?pt=Motors_ATV_Parts_Accessories&hash=item46355563fc&vxp=mtr

 

I saw that one too, it is more reasonable. I am tearing out the transmission today if I can figure out how to get the pto yoke off of the 4x4 output shaft. I have a Chilton for the transmission, but it does not show this step, oddly enough. I'm hoping my case isn't trashed where the bearing seats, but it is not likely. I have the transmission ready to come out, except for getting the front drive shaft off. Any ideas?

 

Easy if you have an air impact with a small round bit to impact the spring pin out. Once that's out just change to a dull flat bit and impact on the rear yoke to slide it back.Move the front shaft to the left of the diff then impact the prop shaft off the transmission shaft. Better than using a punch and chisel and busting your hands up. Plus replace the spring pin,don't reuse it. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

Mine must be full of mud and not viseable. I was looking for a pin of some sort, no luck. I will go out and clean it and see what I find.

 

Old Polaris Tech, I figured out what you meant. I found the spring pin in the front yolk assembIy and I had to use a air chisel, with the punch grinded down, but it worked great. My front u joints were trashed, so that is good to know. Tomorrow I will disassembled the clutch side, and then be able to yank the transmission out. Do you know it it is necessary to buy that alignment tool, to re-align the tranny to the engine when you re-install? I am also looking for that long bolt tool, that pops off the front clutch. Any good places to pick these tools up from?

Thanks in advance

 

Not necessary on the alignment tool.All mine hung on the wall for the most part. Eyeballing the belt and clutches is just as good.The transmission just bolts back up flush to the frame.Any shimming needed is usually adding spacer washers behind the rear clutch. Most times not needed on the non ebs systems. You can get a bolt from a hardware store this size if you don't want to get the 20 buck tool.