Target Audience:
Home mechanics, DIY owners, and ATV service technicians
Intended Use:
Identifying correct part numbers during maintenance and repair
Primary Benefit:
Accurate exploded diagrams and part number lists for ordering replacement parts
Repair Ease:
ATVs offer reliable design, simple construction, and ease of repair at home
Cost Savings:
Routine maintenance at home is less expensive than shop service
Longevity:
Proper care and scheduled maintenance prolong the life of the ATV
Body and Chassis Sections
Specifications:
General specification tables for the 2000 Xplorer
Front Cab:
Front body and cab components
Rear Cab and Seat:
Rear cab panels and seat parts
Rear Rack Mounting:
Rear rack hardware and mounting components
Decals:
Graphic decal kit part numbers
Front Rack and Bumper Mounting:
Front rack and bumper hardware
Steering Post:
Steering post assembly parts
Handlebar and Headlight Pod:
Handlebar and headlight pod components
Engine and Drivetrain Sections
Engine Mounting:
Engine mount hardware and brackets
Piston and Crankshaft:
Piston, rings, and crankshaft assemblies
Crankcase and Cylinder:
Crankcase and cylinder components
Recoil Starter:
Pull starter assembly parts
Carburetor:
Carburetor components and jets
Oil Pump and Oil Tank:
Oil injection pump and oil tank parts
Magneto:
Ignition magneto assembly
Starting Motor:
Electric starter components
Drive Clutch:
Primary clutch parts
Driven Clutch:
Secondary clutch parts
Clutch Cover:
Clutch cover and seals
Gearcase:
Front gearcase components
Gear Selector:
Shifter linkage and selector parts
Suspension, Brakes, and Wheels
Front Drive and Tightener:
Front drive and chain tightener assemblies
Front Strut:
Front strut suspension parts
A-Arm / Strut Mounting:
A-arm and strut mounting hardware
CV Joint - BTB:
CV joint and boot components
Center and Swing Arm Tighteners:
Chain tightener and swing arm shock mounting
Front Wheel:
Front wheel and hub parts
Rear Wheel Drive:
Rear axle and wheel drive components
Front Brake Controls:
Throttle assembly, cable, master cylinder, and brake line
Rear Brake:
Rear brake assembly parts
Fuel, Cooling, Exhaust, and Electrical
Cooling System:
Radiator, fan, and cooling components
Exhaust System:
Muffler and exhaust pipe parts
Fuel Tank and Air Box:
Fuel tank, air box, and filter components
Electrical / Taillight:
Wiring, lighting, and taillight parts
Tool Kit:
Onboard tool kit contents
Part Number Index:
Complete alphabetical part number index for fast lookup
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Transmission Type:
CVT (continuously variable transmission) with drive and driven clutches
Clutch System:
Primary drive clutch and secondary driven clutch, both covered
Final Drive:
Gearcase with chain drive and chain tighteners
Gear Selection:
Gearcase gear selector with shift linkage
Service Detail:
Exploded diagrams for clutch, cover, gearcase, and chain components
Oil Changes:
Regular engine oil changes at frequent intervals
Inspections:
Inspect shift linkage, steering, suspension, and coolant system routinely
Fuel System Checks:
Inspect fuel system; replace fuel and air filters regularly
Drivetrain Checks:
Inspect drive belts and engine mounts at scheduled intervals
Spark Plugs:
Replace spark plugs as part of routine maintenance
Drive Belt:
CVT drive belt is a frequent wear item
Chain and Tighteners:
Drive chain stretch requires tightener adjustment
CV Boots:
CV joint boots are prone to tears and periodic replacement
Filters:
Air and fuel filters require scheduled replacement
