1998pi54.com/corp/manuals/Parts/9914723r02.pdf · · 2004-09-141998 SPORT 400L Model #W98BA38C Rev. 02. TABLE OF CONTENTS Sport 400L W98BA38C Parts Manual A ... 33 3085547 1 Engine,

PARTS MANUAL PN 9914723 and MICROFICHE PN 9915239 8/98

1998

SPORT 400LModel #W98BA38C

Rev. 02

TABLE OF CONTENTSSport 400L W98BA38C

Parts Manual

AA-ARM/STRUT MOUNTING B5. . . . . . . . .AIR BOX A14. . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D1. . . . . . . . . . . . . . . . . . .CLUTCH COVER C3. . . . . . . . . . . . . . . . . .CONTROL PANEL A8. . . . . . . . . . . . . . . . .CONTROLS - MASTER

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

ASSEMBLY/CABLE B8. . . . . . . . . . . .COOLING SYSTEM C4. . . . . . . . . . . . . . .CRANKCASE and CYLINDER C11-C12. . . . . .CRANKSHAFT and PISTON C13. . . . . . .CYLINDER and CRANKCASE C11-C12. . . . . .

DDECALS A12. . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B11. . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH B12. . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C2. . . . . . . . . .ENGINE MOUNTING A9-A10. . . . . . . . . . . . . .EXHAUST SYSTEM A11. . . . . . . . . . . . . . . .

FFOX SHOCK, GAS, RESERVOIR C6. . . .FRONT BRAKE B4. . . . . . . . . . . . . . . . . . .FRONT BUMPER and SHIELDS A7. . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B3. . . . . . . . . . . . . . . . . . .FUEL TANK A13. . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C8. . . . . . . . . . . . . . . . .GEARCASE C9-C10. . . . . . . . . . . . . . . . . . . . . . .GEARCASE/BRAKE MOUNTING B13. . . .

HHANDLEBAR B6. . . . . . . . . . . . . . . . . . . . .

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

OOIL PUMP C14. . . . . . . . . . . . . . . . . . . . . . . .OIL TANK B1. . . . . . . . . . . . . . . . . . . . . . . . .

PPART NUMBER INDEX D6-11. . . . . . . . . . . . .PISTON and CRANKSHAFT C13. . . . . . .

RREAR BRAKE B14. . . . . . . . . . . . . . . . . . . . .REAR CAB A6. . . . . . . . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE C1. . . . . . . . . . . . . .RECOIL STARTER D2. . . . . . . . . . . . . . . .

SSHOCK VALVING C7. . . . . . . . . . . . . . . . . .STARTING MOTOR D3. . . . . . . . . . . . . . .STEERING POST B7. . . . . . . . . . . . . . . . . .STRUT B2. . . . . . . . . . . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING B10. . .

TTAILLIGHT/ELECTRICAL C2. . . . . . . . . .TOOL KIT C5. . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D5. . . . . . . . . . . . . . . . . . . .

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

1998 SPORT 400L SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic DiscHydraulic Disc

MechanicalStandard

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

2.25416

100 cc2

N/AN/A

Accessory 6030

Accessory850

DRIVE TRAINType PVT

DRIVE CLUTCHBearingsCenter Distance (inches)Clutch Offset (inches)Clutch WeightDiameterSpiderSpring Color

Garlock D.U.101/255g7.38CastWhite

DRIVEN CLUTCHBearingsHelix AngleOutside Diameter (inches)Spring Position

Garlock D.U.40°9.52-2

DIMENSIONAL FEATURES

Approx. Turning RadiusBox, Cargo BedBox, ToolBox (cubic feet)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

60″N/A

9.25 x 3.25N/A5.547

74.533479

49.7546.5

GEARCASETrans. Number and TypeShift TypeGear Reduction - ReverseGear Reduction - HighFinal Drive (ratio)Chain TypeChain Adjustment

PRD420055Side Lever

3.42/12.68/1

84P/13/34520 O-RingEccentric

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - CenterWheel Bolt Pattern - FrontWheel Bolt Pattern - RearWheel Bolt Pattern - Center

Goodyear23x7x1022x11x10

N/A43

N/A4 Bolt, 6.15 Dia.4 Bolt, 4.0 Dia.

N/A

ENGINEEngine Model NumberEngine TypeBore & Stroke (mm)Displacement (cc’s)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

EC38PLE072 Cycle,Oil Injection

83.0x70378.7

6.9:1 EffectiveLiquid150W

Standard1/VM34SS

23035

0-6 (480)1.5 Nickel/Aluminum

1.5 Turn6CEY6-3

CDI23.5 @ 3000

.028NGKBR8ES

USFS Pending

GRAPHICSBrake LeverBumpers, Front & Rear/SteelBumper Caps/Polyprop.Cargo Box or BedClutch Cover/NylonDecal, Demand-4-Drive ColorDecal, “Polaris” ColorDecal, MacPherson Strut LocationFender, Front/HDPEFender, Rear/HDPEFootwellFrame/SteelFront CoverGrips/TPRHandlebar/SteelHandlebar Cover/TPEHeadlight Pod/HDPEMud Flaps/EVARack, Front/SteelRack, Rear/SteelRims/SteelRadiator Structure ColorSeat VinylSide Panel/HDPESpring, Front/SteelSpring, Rear/SteelTank Cover/HDPE

Fire RedSemi Flat Black

N/AN/A

BlackN/A

White/on seatN/A

Screamin’ YellowScreamin’ Yellow

BlackSemi Flat Black Black

Purple VelvetBlack

Semi Flat BlackBlackN/A

BlackN/AN/A

Bright WhiteBlack

Purple VelvetN/A

Purple VelvetPurple Velvet

N/A

LIGHTS/BATTERYHeadlight (watts)Taillight (watts)Brake Light (watts)Other (Grill Mntd. Lights)Indicator BulbBattery

12 V 55 W12 V/8.26 W12 V/26.9 W

N/A12 V/1 W

12 V 14 AH

SUSPENSIONFront Type -

Front Travel (inches)StrutAdjustment

Rear Type -Rear Travel (inches)ShockAdjustment

MacPherson Strut6.25

Gabriel----------MONO

8.5Gas

Thread

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

1998 SPORT 400L ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUALSUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Sport 400L W98BA38C 9914659 9914545 9914723 9915239 9914548

1998 SPORT 400L PAINT CODES

MODEL MODEL NO.COMPONENTTYPE COLOR DESCRIPTION

POLARIS“P” NO.

Sport 400L W98BA38C Springs Purple Velvet P194

Rims Bright White P133

A5

FRONT CABSport 400L W98BA38C

12

14

16

2120

16

21

22

23

30

2

24

2526

27

18

17

1

1

15

5

6

4

8910

13

115

7

3

29

19

24

28

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

1 7670060 4 Nut, U-Clip Speed2 1040538-067 1 Frame3 7080409 1 Clamp, Wire Routing4 4032093 2 Spring, Adjustment5 7670095 3 Insert, Nut6 5241436-067 1 Bracket, Headlight Mounting7 4030056 1 Bulb, H3, 55W, Halogen8 7512084 2 Screw9 4030053 1 Headlight, Single Beam (Incl. 7)10 4032094 1 Spring11 7511886 1 Screw12 5432179-194 1 Cover, Front (Purple Velvet)13 7511887 2 Screw14 2631925-216 1 Asm., Cab, Front Service, (Yellow)

(w/Warning Decals)15 7555776 2 Washer16 7512282 19 Bolt

17 7621471 2 Rivet18 7558201 2 Washer19 7517264 4 Screw20 7555859 10 Washer, Flat21 7542122 15 Nut, Nylok22 5211020-067

5211131-06711

Bracket, Mudflap, RH (2 Hole)Bracket, Mudflap, LH (3 Hole)

23 58501145850113

11

Mudflap, Front, RHMudflap, Front, LH

24 7621472 18 Rivet25 1040691-067

1040692-06711

Footpad, LHFootpad, RH

26 7661825 8 Rivet, Semi Tubular27 5431484 1 Trim, Footrest28 5242525-067 2 Cleat, Heel29 7512232 7 Screw30 5242016-067 1 Guard, Rock

8/97

A6

REAR CABSport 400L W98BA38C

3

11

21

2928

27

26

15

25

13

9

15

24

2219

1718

8

7

2

1

20

4

65

10

23

15

22

15

12

14

1614

16


1 7041607 1 Spring, Latch2 1040412-067 1 Latch, Seat3 2682358-194

2681769-19411

Asm., Seat (Purple Velvet)Covering, Seat (Purple Velvet)

4 5431986 1 Tongue, Seat5 7621479 2 Rivet6 5410414 6 Bumper7 5211033 1 Bracket, Lever Retainer8 7621403 1 Rivet9 7073761 1 Decal - Carb Information10 7072791 1 Decal - Filter Element11 5432606-216 1 Cab, Rear (Yellow)12 7670057 2 Nut, U-Clip Speed13 5431869-070

581111311

Shield, MufflerFoil, Foam

14 7517264 5 Screw15 7555859 16 Washer, Flat

16 7542122 17 Nut17 5222860-067 1 Guard, Clutch, Outer18 7661638 4 Rivet19 2670133 2 Reflector, Red20 5432047 2 Plug, End Cap, Ribbed21 5810957 1 Foil, Rear Cab22 7512282 16 Bolt23 -------------- 1 Footpad

(See Front Cab Page A5, Ref. 25)24 5850123

585012211

Mudflap, Rear, RHMudflap, Rear, LH

25 5211131-067 1 Bracket, Mudflap, Blk LH Side Only26 5220880 2 Bracket, Rear Seat Holddown27 7621472 4 Rivet, Pop28 5411042 2 Grommet29 7512232 2 Screw

8/98

A7

FRONT BUMPER and SHIELDSSport 400L W98BA38C

2

3

1

4

5

7

6

76

76

8

9

710

7

11

21

13711

715

11

16

1819

17

20

14

12


1 7542324 2 Nut, Nylok2 7512329 2 Bolt3 7558402 2 Washer4 5810467 1 Plug, Frame5 5850125

585012411

Shield, Deflector, RHShield, Deflector, LH

6 7542124 6 Nut, Nylok7 7555776 16 Washer8 1040527-067 1 Front Bumper9 5432378-070 1 Plate, Skid, Bumper10 7512252 4 Bolt

11 7517417 4 Screw12 7515399 2 Screw13 5242682-067 1 Shield, Radiator Side, RH14 2670134 2 Reflector, Amber15 7512281 2 Screw16 5242683-067 1 Shield, Upper Radiator17 7670088 3 Clip, Dart18 7670060 3 Nut, Speed19 7515190 3 Screw20 7552605 3 Washer, Spring Lock21 5240869-067 1 Shield, Radiator Side, LH

8/97

A8

CONTROL PANELSport 400L W98BA38C

12

3

4

5

6

98

4

7


1 4040012 1 Indicator - Low Oil2 4040054 1 Indicator, Neutral - Reverse3 4040053 1 Indicator, Hot Temperature4 4110194

4110141-31xx4110148-32xx

1 Switch, Ignition (Incl. Key)NOTE: Ignition key may be or-dered by using the four digit num-ber on the key.

5 5431976 1 Panel, Control, Outer6 7512026 2 Screw7 2460521 1 Harness, Control Panel8 5431975 1 Panel, Control Inner9 7080371 1 Cable, Choke Control

8/97

A9

ENGINE MOUNTINGSport 400L W98BA38C

12

5

4

8

7

1918

171615

14

29

2827

24

25

3031

11

13

12

10 11

33

34

3536

38

2728 7

20

7

6

41

42

20

20

41

41

41

26

22

23

37

3940

43

42

21

3

3

20

32

9

A10

ENGINE MOUNTINGSport 400L W98BA38C


1 3110038 1 Mount, Motor2 5430802 1 Insulator, Motor Mount3 7555823 2 Washer4 7552901 2 Washer, Spring Lock5 7515321 2 Bolt6 4010132 1 Cable, Ground/Engine7 7542411 2 Nut, FLEXLOC8 5241801-067 1 Mount, Engine, Top9 7052192 3 Fitting, Vent10 3070156 1 Spark Plug, NGK BR8ES11 7080614 1 Clamp, Hose12 5410570 1 Hose, Upper Engine13 4010129 1 Cable, Solenoid/Starter14 -------------- 1 Seal, Cover Case

(See Clutch Cover Pg. C3, Ref. 29)15 -------------- 1 Asm., Drive Clutch, Basic ATV-07

(See Drive Clutch Pg. B11, Ref. 14)16 5430261 1 Bushing, Retaining Bolt17 5210748 1 Washer, Clutch Retainer18 7575202 1 Washer, Lock19 7512566 1 Bolt20 7542403 5 Nut, FLEXLOC21 7555823 3 Washer22 1040532-067 1 Mount, Lower Engine23 7512457 2 Screw

24 7080511 2 Clamp, Narrow Band25 5410883 1 Boot, Clutch Intake26 3110026 1 Mount, Motor27 7553001 6 Washer, Spring Lock28 7512490 6 Bolt29 1040231-067 1 Engine Mount, Front30 7041079 1 Spring, Hose Retainer31 5411173 1 Hose, Lower Engine32 7075741 1 Decal - Drain Recoil33 3085547 1 Engine, EC38PLE07-Short Block

NOTE: The Short Block assemblycontains a crankcase assembly,cylinder and cylinder head assem-bly, and a piston & crankshaft as-sembly. Prior authorization re-quired for warranty consideration.

34 8360009-600 AR Line, Fuel35 7052047 1 Valve, Check Vent36 5240542-067 1 Mount, Rear Engine37 7555801 1 Washer38 3110042 1 Mount, Rubber, Engine39 7542432 2 Nut40 3110048 1 Mount, Torque Stop41 7080236 4 Clamp, Hose (Yellow)42 8450003-1525 AR Line, Fuel43 2530009 1 Filter

8/98

A11

EXHAUST SYSTEMSport 400L W98BA38C

1314

2

3

1

4

5

6

2019

181716

1514

1312

8

87

9

1011


1 5410957 4 Dampener2 5010339 3 Spacer3 7515316 2 Bolt, Carriage4 1260811-029 1 Silencer, Black5 7042031 2 Spring, Exhaust6 1260681-029 1 Muffler7 1260680-029 1 Headpipe8 5211592 2 Gasket, Exhaust9 1260679-029 1 Manifold10 -------------- 2 Washer, Lock (See Crankcase and

Cylinder Page C12, Ref. 8)

11 -------------- 2 Nut (See Pg. C12, Ref. 7)12 7042029 4 Spring, Exhaust13 7542324 3 Nut, Nylok14 7555716 3 Washer15 5410436 1 Washer, Rubber16 7556401 1 Bushing17 5010350 1 Bushing18 5410241 1 Dampener, Vibration19 7555843 1 Washer, Flat20 7515352 1 Screw

8/98

A12

DECALSSport 400L W98BA38C

LH

RH9

8

15

1

4

16

3

1411

12

5

6

13

7

10

2

5

10


1 7072786 1 Decal - Warning, Heavy Loads2 7077920 1 Decal - Passenger Warning3 7074827 1 Decal - Age Warning, ATV4 7073024 1 Decal - USA5 7076491 2 Decal - “SPORT”6 7077853 1 Decal - Front Nose, “400 LC”7 7077856 1 Decal - Tank Side, RH8 7075413 1 Decal - Discretionary Warning

9 7075741 1 Decal - Recoil Drain10 7077857 2 Decal - “400 LC”11 7076206 1 Decal - CE Regulation12 7076274 1 Decal - Override Switch13 7077855 1 Decal - Tank Side, LH14 7075725 1 Decal - Tire Pressure15 7077919 1 Decal - Warning, General16 7074637 1 Decal - Fuel Lever

8/97

A13

FUEL TANKSport 400L W98BA38C

56

7

8

9

13

14 11

12

17

19

22

1623

11

15

1

3

4

2

10

2011

21

10

10

10

10

11

11

18


1 2511272 1 Tank, Fuel (Incl. 6,16,23)2 5410842 1 Grommet, Fuel Tank3 5810144 1 Gasket, Fuel Cap4 5430725 1 Cap, Fuel Tank5 8360009-600 AR Hose, Vent6 5431053 1 Vent7 7512310 2 Bolt8 7555734 2 Washer9 7512232 2 Screw10 7080003 8 Clamp, Hose11 8450040-600 AR Fuel Line12 2530008 1 Filter

13 5220916-067 1 Bracket, Tank Mount, Rear14 7542324 2 Nut, Nylok15 8360026 AR Pad, Fuel, Bulk16 7052147 1 Fitting, Fuel Outlet, Main, 90°17 5411272 1 Hose, Formed18 5242977 1 Spacer, Fuel Valve19 5432733 1 Nut, Fuel Valve20 5432559 1 Knob, Fuel Valve21 7517505 1 Screw22 7052154 1 Valve, Fuel, 3-Way23 7052148 1 Fitting, Fuel Outlet, Reserve, 90°

8/98

A14

AIR BOXSport 400L W98BA38C

21

3

4

23 9

14

17

1819

7

5

15

2221

24

26

25

8

20

11

15

10

12

1

16

13

6


1 7542127 3 Nut, Wing2 7555776 2 Washer3 5240424 1 Cover, Air Box4 5810948 1 Gasket, Cover5 5240336 1 Cover, Filter6 5811099 1 Foam, Precleaner, Sleeve7 1253118 1 Filter, Air8 5810966 1 Foil, Air Box9 5432883 1 Box, Air Silencer10 7080483 1 Strap, Cable11 7080487 1 Plug, Cap12 8450051-600 AR Line, Fuel13 5431997 2 Insulator

14 5410857 1 Boot, Carburetor15 7511881 8 Screw16 7080584 1 Clamp17 5431698 2 Ventura, Intake18 5410934 1 Boot, Air Silencer19 5811102 1 Foam, Collar20 7080598 1 Strap, Panduit21 7558301 2 Washer, Flat22 7515179 2 Screw23 5432607 1 Stand, Filter24 7515150 2 Stud25 5811012 1 Seal, Foam Air Box26 7515151 1 Stud

8/97

B1

OIL TANKSport 400L W98BA38C

12

34

5

6

7

11

17

1098

16

14

13

15

13

14

12

12


1 5430779 1 Cap, Oil Tank2 5810141 1 Gasket, Oil Cap3 5431793 1 Tank, Oil, Drilled4 7052077 1 Fitting5 8360009-600 AR Line, Fuel6 4110177 1 Sensor, Oil Level7 7621460 2 Rivet, Pop8 7080525 1 T-Clip9 7080526 1 Mount, Tie Anchor

10 7517389 1 Screw11 7052153 1 Fitting12 7080568 2 Clamp13 8450003-1525 AR Line, Fuel14 7080307 2 Clamp, Hose (Large Green)15 2530009 1 Filter, Fuel16 7555932 2 Washer17 8360026 1 Pad, Bulk

8/98

B2

STRUTSport 400L W98BA38C

1

2

3

4

5

6

7

8 9

10

11

12

13

14

16

1315

17


1 7542507 2 Nut, FLEXLOC2 7555749 2 Washer3 5810291 2 Spacer Rubber4 5430806 2 Pivot, Ball Top5 5430807 2 Pivot, Ball Bottom6 5130668 2 Spacer, Threaded7 5220602 2 Retainer, Spring (Top)8 7041238-067 2 Spring, Coil, Front Shock9 5410791 2 Bumper, Strut

10 7041755 2 Strut, Front11 7080573 2 Clamp, Rubber Coated12 7542303 4 Nut, FLEXLOC13 7558402 6 Washer14 7080306 2 Fitting, Lubrication15 7515339 4 Bolt16 5131039

513104011

Support, Strut & Spindle, LHSupport, Strut & Spindle, RH

17 5211115 2 Washer, Spring Retainer

8/97

B3

FRONT WHEELSport 400L W98BA38C

1

23

4

5 6

7

8

93

1112

1314

15

16

17

10


1 -------------- 1 Support, Strut & Spindle(See Strut Page B2, Ref. 16)

2 3610020 2 Seal, Front Hub3 3513519 4 Bearing, Ball4 5211325 2 Brake, Disc5 5130940 2 Hub, Wheel6 5410906 2 Tire, Front (23x7x10)7 1520175-133 2 Rim, Front8 1525017 2 Valve, Rim

9 5010256 2 Spacer, Hub Front10 7555721 2 Washer11 7542712 2 Nut, Castle12 7661407 2 Pin, Cotter13 5431018 2 Cap, Hub14 5410470 2 O-Ring15 7542459 8 Nut, Flanged16 7515523 8 Stud17 7512325 8 Bolt

8/98

B4

FRONT BRAKESport 400L W98BA38C

1

2 3

9

10

12

11

131415

8

4 5 67


1910232 1 Asm., Front Brake Caliper, LH1910233 1 Asm., Front Brake Caliper, RH1930642 1 Kit - Front Brake Boot (Incl. 11,12)

1 7080352 2 Screw, Bleeder2 7515489 2 Screw, Socket Set3 5131115

513111611

Caliper, Brake, LHCaliper, Brake, RH

4 5410779 1 Square Ring Molded (.094)5 5410780 1 Square Ring Molded (.103 x .134)6 5020506 1 Piston, Caliper7 5910026 1 Insulator, Caliper

8 1930665 1 Kit - Piston and Insulator Seal(Incl. 4-7)

9 2200901

22011492200465

1

11

Kit - Severe Duty Brake Pad, Front(Complete set of 2 pads)Kit - Brake Pad, Soft, FrontKit - Brake Pad, General, Front

10 1910057 2 Caliper Mount11 5410495 1 Boot, Bushing12 5410494 1 Boot, Pin Seal13 7558402 4 Washer14 7552901 4 Washer, Spring Lock15 7512365 4 Bolt

11/97

B5

A--ARM/STRUT MOUNTINGSport 400L W98BA38C

1 34

5

6

78

9

11

12

17

1613

15

1421

22

20

23

19

18

2524

26

2

10

12

2524

19

18


1 7542403 2 Nut, FLEXLOC2 5333367 2 Bushing3 5411291 2 Boot, Seal, Rod End4 7061019 2 Rod End, RH5 7542711 2 Nut6 5020927 2 Tie Rod7 7547028 2 Nut, LH8 7061018 2 Rod End, LH, w/Fitting9 1822477 2 Asm., Tie Rod, w/Fitting10 7555806 4 Washer11 7546904 2 Nut12 7661203 4 Cotter Pin13 5240717 2 Bracket, Ball Joint14 7512284 4 Bolt

15 5410548 2 Boot, Rubber16 7080673 2 Ball Joint17 -------------- 1 Support, Strut and Spindle

(See Strut Page B2, Ref. 16)18 5431596 2 Bushing, A-Arm Long19 5020677 2 Bushing20 7080433 2 Fitting, Lubrication21 7542438 2 Nut, Castle22 2200560

220056111

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

23 5020681 2 Shaft, A-Arm24 7515458 4 Bolt25 7552603 4 Washer, Spring Lock26 7515554 2 Bolt

8/98

B6

HANDLEBARSport 400L W98BA38C

1

2

3 4

8

5

7

6

11

12

10

7

13

14

9


1 -------------- 1 Asm., Throttle Control(See Controls - Throttle Asm./CablePage B8, Ref. 5)

2 5224316-067 1 Handlebar3 7515188 4 Screw4 5810379 1 Pad, Handlebar5 7517395 2 Screw6 5220946 1 Mount, Handlebar Pad7 2200774

5630616-06712

Kit - Handlebar Block (Incl. 3,13)Block, Handlebar

8 ------------- 1 Asm., Master Cylinder(See Controls - Master Cylinder/Brake Line Page. B9 For Details)

9 5433198 1 Spacer, Plastic10 4110192 1 Switch, LH, Handlebar, ON/OFF11 5431030 2 Grip, Handlebar12 2010055 2 Screw13 7542122 4 Nut, Nylok14 7080631 1 Clip, Cable Retainer

8/98

B7

STEERING POSTSport 400L W98BA38C

1

16

15

14

2

3

4

13

8

1256

10

5

5

9

11

6

7


1 1843077 1 Asm., Steering Post (Incl. 12,13)2 5431573 1 Bushing, Steering Console3 7080510 1 Fitting, Zerk (90°)4 7515321 2 Screw5 7555878 3 Bushing6 5410772 2 O-Ring7 5431571 1 Spacer, Steering Post8 7661633 1 Pin, Cotter

9 7543203 1 Nut10 5431570 1 Bushing, Steering, Lower11 7661632 2 Rivet12 5431574 1 Plug, Grease, Steering13 7080433 1 Fitting, Lubrication14 5431572 1 Bushing, Steering Console15 5222999-067 1 Bracket, Upper Steering Bushing16 7542324 2 Nut, Nylok

8/97

B8

CONTROLS - THROTTLE ASM./CABLESport 400L W98BA38C

12

3

4

5

6

7

8

9

12

10

11


1 2010079 3 Screw2 7072724 1 Decal - Throttle3 2010080 1 Cap4 2010081 1 Packing5 2010159 1 Asm., Throttle Control (Incl. 1-10)6 2010078 1 Holder

7 2010077 2 Screw8 2010076 1 Bolt9 2010075 1 Plate10 4110203 1 Switch, ETC11 7556047 1 Washer, Sealing12 7080728 1 Cable, Throttle Control

8/97

B9

CONTROLS -- MASTER CYLINDER/BRAKE LINESport 400L W98BA38C

3

4

6

10

7

5

15

17

20

2223 16

21

19

13

2

18

12

14

1

8

9

11


1 2200809

2050073

1

1

Kit - Master Cylinder Reservoir(Incl. 2,3,4,14)Asm., Master Cylinder (Incl. 1-14)

2 1930797 2 Bolt, Cap3 1930796 1 Cap, Reservoir4 1930795 1 Diaphragm5 2200808 1 Kit - Clamp6 1930799 1 Asm., Piston, Master Cylinder7 1930804 1 Rivet8 2201034 1 Kit - Brake Lever, w/Parking Brake

Latch (Incl. 7, 9,11)9 -------------- 1 Spring, Flat10 1930806 1 Nut11 2201090 1 Kit - Park Brake Lever (Incl. 7,9)

12 1930792 2 Bolt, Master Cylinder Reservoir13 1930805 1 Bolt, Lever14 -------------- 1 Ring, Square, Master Cylinder, Res.15 1930762 1 Line, Brake, Upper w/Fittings16 4110164 1 Switch17 1930751 1 Line, Brake, Rear18 7080539 2 Clamp19 7621462 2 Rivet, Pop20 1930752 1 Line, Brake, Left Front w/Fittings21 7512024 2 Screw22 1930753 1 Line, Brake Right Front w/Fittings23 7052103 1 Fitting, Inverted Flare Cross

11/97

B10

SWING ARM/SHOCK MOUNTINGSport 400L W98BA38C

5

6

11 1213 14

15

1

141312

11

2

16

1718

19

17

16

2

20

21

262527

24

33

30

31

32 23

28

29

5

3

4

8

910

7

22


1 7512701 1 Bolt, Shoulder2 5220958 2 Plate, Bolt Lock3 7075343 1 Decal - Warning, Fox Shock4 7041389-067 1 Spring, Rear5 7542439 2 Nut, Nylok6 7515415 1 Bolt7 5630885 1 Retainer, Spring8 7041383 1 Shock, Gas, Reservoir9 1500063 2 Retainer, Spring, Body, Threaded10 5431734 2 Ring, Spring Preload, Adjustable11 5241460 2 Bushing, Thrust, Steel12 5431977 2 Bushing, Thrust13 7555911 2 Washer14 7542602 2 Nut, Nylok15 -------------- 2 Bushing, Pivot

(See Gearcase Page C10, Ref. 6)16 5020793 2 Bushing, Swing Arm Extended

17 5431972 4 Bushing, Swing Arm18 7080438 2 Fitting, Lubrication (45°)19 7512702 1 Bolt, Shoulder20 5431310 1 Guide, Chain21 7621433 1 Rivet, Pop22 7074214 1 Decal - Lubrication23 7074752 1 Decal - Chain Free Play24 7515304 1 Bolt25 5332828 1 Bushing26 5430776 1 Guard, Chain27 7558402 1 Washer28 7542321 1 Nut29 2201038 1 Kit - Swing Arm30 7542503 2 Nut, FLEXLOC31 7555883 4 Washer32 7512576 2 Bolt33 7515438 1 Bolt

8/98

B11

DRIVE CLUTCHSport 400L W98BA38C

1 23 4

7

13

5 6 7

8

12

11

910

14


1 7512176 6 Bolt2 7552801 6 Washer, Spring Lock3 3576510 1 Bearing, Cover4 7041132 1 Spring, Clutch5 5430945 6 Washer, Multilube6 1321457 3 Roller and Bushing7 5431936 6 Guide Button, Stemless8 5210752

524298152107535210754

ARARARAR

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

9 5630509 3 Weight, Shift (S-55)10 7512266 3 Bolt, Shoulder11 7541906 3 Nut, FLEXLOC12 3576504 1 Bearing, Moveable, 1/2″13 5020422 3 Pin, Spider14 1321632 1 Asm., Drive Clutch Basic ATV-07

(Less 4,9)

11/97

B12

DRIVEN CLUTCHSport 400L W98BA38C

3

4

56

7

8

11

12

13

14

16

1718

4

12

10

15

9


1 5010379 1 Spacer, Driven Clutch2 7556401 AR Bushing (3 Max)3 3211077 1 Belt, Drive4 1322180 1 Asm., Driven Clutch5 5220646 1 Washer, Domed6 7552901 1 Washer, Spring Lock7 7515327 1 Bolt8 7555898 AR Washer9 7556076 AR Washer

10 7556804 AR Washer11 3576504 1 Bearing, Moveable, 1/2″12 3576511 1 Bearing, Moveable, 1I13 7041198 1 Spring, Clutch14 5131446 1 Ramp, Stationary15 5210752 1 Spacer16 7710448 1 Ring, Retaining17 7511854 3 Bolt18 5430766 3 Button, Ramp

8/98

B13

GEARCASE/BRAKE MOUNTINGSport 400L W98BA38C

12

3

4

5

9

29

28

30

19

16

8

10

9

1112

14

15

2025

27

22

2324

21

26

6

7

13

17

17 18


1 7515345 2 Bolt2 7552901 2 Washer, Spring Lock3 7558402 2 Washer4 5241018-067 1 Shield, Caliper, Rear5 1910227 1 Asm., Caliper, Brake, Rear6 7710434 1 Ring, Retaining7 3221044 1 Sprocket, 12T, Splined8 -------------- 1 Asm., Gearcase

(See Gearcase Pg. C10 For Details)9 5220958 2 Plate, Bolt Lock10 7512701 1 Bolt, Shoulder, Short (LH Side)11 7515522 1 Bolt12 7552603 1 Washer, Spring Lock13 7555784 1 Washer14 7515472 1 Bolt15 7542403 1 Nut, FLEXLOC16 7515484 2 Bolt, Carriage

17 3610026 2 Seal18 5211065

52107645211517

ARARAR

Shim - Bearing (.010)Shim - Bearing (.020)Shim - Bearing (.030)

19 7542449 2 Nut, Flange Lock20 5333255 1 Spacer21 7075339 1 Decal - Brake Shield22 7515328 1 Bolt23 7552606 1 Washer, Split24 7555770 1 Washer, Wrought25 5431766 1 Guard, Brake Disc26 7555776 1 Washer27 7512252 1 Screw28 1910177 1 Disc, Brake29 7512702 1 Bolt, Shoulder, Long30 1590237 1 Bearing, Output Shaft

8/98

B14

REAR BRAKESport 400L W98BA38C

4

5

689

10

3

11

1213

14

15

1718

1920

212223

28 31

29

302425

2726

24

25

7

2

16

1


1 7555921 1 Washer2 7542149 1 Nut3 7080352 1 Screw, Bleeder4 7661820 2 Pin, Brake5 5131272 1 Caliper, Brake, Rear6 2200899

22011502200464

111

Kit - Severe Duty Brake Pad, RearKit - Brake Pad, Soft, RearKit- Brake Pad, General, Rear

7 2200463 1 Kit - Piston and Seal (Incl. 8-10)8 5410766 1 Square Ring (.134 Sq.)9 5410767 1 Square Ring (.099 Sq.)10 ------------- 1 Piston11 5240993 1 Spring, Anti-Rattle, Rear Brake12 5410542 2 O-Ring13 7041219 1 Spring, Compression, Brake14 5020791 1 Pin, Brake Caliper15 5830009 1 Gasket, Brake

16 7555827 2 Washer17 5630538 1 Ramp, Moveable, Brake18 5630457 1 Ramp, Stationery Brake19 7512173 2 Screw20 3610026 1 Seal, Brake21 5240901 1 Arm, Brake Caliper22 7571632 1 Washer, Square Cone23 7515160 1 Bolt24 7661203 2 Pin, Cotter25 7555806 2 Washer26 5224531 1 Rod, Brake27 1910196-067 1 Brake, Foot28 7042029 1 Spring, Exhaust29 5431107 2 Bushing, Pedal Pivot30 7555919 2 Washer31 7661401 1 Pin, Cotter

11/97

C1

REAR WHEEL DRIVESport 400L W98BA38C

12

3 4

5

6

8

10

9

11 12 13

14

7

15

19

21

222324

2526

27

30

2524

2328

29

54

3

31

32

89

11

12

13

14

17

16

18

20

16


1 7555764 1 Washer2 5020468 2 Nut, Jam, Rear Axle3 7512673 8 Bolt4 2200341 1 Kit - Mach., Hub5 7670081 8 Retainer, Bolt, Pushnut6 5410539 2 Tire (22X11X10)7 3225026 1 Link, Connector8 1525017 2 Valve, Rim9 7555745 2 Washer, Flat10 7542714 8 Nut, Wheel11 7555796 2 Washer, Cone12 7543005 2 Nut, Castle13 7661404 2 Pin, Cotter14 5411164 2 Hub, Dust Cover15 3224056-084 1 Drive Chain, 84P16 7542439 6 Nut

17 5211617-067 1 Guard, Sprocket, 34T18 5630586 1 Spacer, Sprocket Guard19 3222068 1 Sprocket, 34T20 7515540 3 Bolt21 1520170 1 Asm., Hub Sprocket (Incl. 22)22 7515513 3 Stud23 5410415 2 O-Ring24 3610013 2 Seal, Rear Axle25 3515501 2 Bearing, Rear Axle26 5010204 1 Tube, Bearing Spacer27 5130663 1 Housing, Axle28 5010206 1 Spacer, Bearing29 7710405 1 Ring, Retaining30 7080306 1 Fitting, Lubrication31 5020790 1 Axle, Rear32 1520183-133 2 Rim, Rear

8/97

C2

ELECTRICAL/TAILLIGHTSport 400L W98BA38C

1

2

3

4

6

9

8

5

10

7

1125

26

3433

31

32

30

29

27

28

2425

23

11

13

15

14

1718

19

20

21

22

12

16


1 2460495 1 Harness, Main Wire2 7080138 3 Strap, Panduit3 2200593 1 Kit - Circuit Breaker, 20 AMP4 2432038 1 Light, Tail/Brake5 7512088 2 Screw6 4032085 1 Lens7 4030043 1 Bulb8 4032086 1 Gasket9 4032087 1 Backing10 7670093 2 Clip11 7571602 3 Washer12 7512027 2 Screw13 5810290 3 Pad, Battery14 5431769 1 Cover, Battery15 7072606 1 Decal - Battery16 5410346 1 Insulator, Cable17 2200361 1 Kit - Battery Bolt (Short)18 4010095 1 Cable, Black Battery/Engine

19 7010032 2 Hook, Battery Strap20 5410424 1 Strap, Battery Holddown21 5432077 1 Line, Vent22 4140006 1 Battery23 4010094 1 Cable, Battery/Solenoid24 4010064 1 Cable, Solenoid/Starter25 7541925 4 Nut, Nylok26 7512007 2 Bolt27 5431973

581107911

Lid Cover, Tool BoxGasket

28 7512252 2 Screw29 2620087 1 Asm., Tool Box (Incl. 27 & Gasket)30 4060193 1 Rectifier, LR-39-131 7512024 4 Screw32 4060114 1 Limiter, Reverse Speed33 7621336 4 Rivet34 4040063 1 Board, Terminal

8/97

C3

CLUTCH COVERSport 400L W98BA38C

23

4 5

6

8

9

10

1113

14

16

1724

18

1920

2223

25

28

32

23

7

1

21

29

15

26

31

27

12

30


1 5411180 1 Seal, Cover, Case2 7555748 3 Washer3 7552605 3 Washer, Spring Lock4 7517219 3 Screw5 5521301 1 Seal, Clutch Cover6 5431961 1 Cover, Clutch, Front7 7670051 1 Clip, Clutch Cover8 7512093 5 Screw9 7074946 1 Decal - Clutch Cover10 7077377 1 Decal - Engine/Clutch Modification11 7074782 1 Decal - Automatic Transmission12 7512094 2 Screw13 7080492 2 Strap, Panduit14 5410421 1 Boot, Clutch Intake15 7512232 1 Screw16 5432615 1 Duct, Air Outlet Clutch17 5430743 1 Cap, Overflow Drilled

18 5431895 1 Plug, Cap19 7052065 1 Fitting, Barbed 90°20 8450003-1525 AR Line, Fuel21 7080511 1 Clamp, Narrow Band22 7512084 1 Screw23 5432440 1 Duct, Inlet Down Tube24 5810279 1 Gasket, Overflow Cap25 2200790 1 Kit - Cover, Clutch, Inner

(Incl. 8,12,27)26 5241213-067 1 Bracket, Clutch Cover, Rear27 7512095 1 Screw28 5222446-067 1 Bracket, Retainer Seal29 5410575 1 Seal, Cover Case30 7555935 1 Washer31 7661638 2 Rivet, Pop32 -------------- 4 Screw and Washer (See Crankcase

and Cylinder Page C12, Ref. 48)

8/98

C4

COOLING SYSTEMSport 400L W98BA38C

10

8

12

22

13

9

1 2

76

17

18

1415

26

25 24

16

11

43

21

19

20

23

25 24

5


1 7542122 2 Nut, Nylok2 7558301 2 Washer, Flat3 4170009 1 Motor, Fan4 5241355-067 1 Bracket, Cooling Fan5 7052181 1 Valve, Drain Cock6 5020572 2 Spacer, Mount, Radiator7 3110032 2 Mount, Rubber, Radiator8 -------------- 1 Hose, Upper Engine (See Engine

Mounting Page A10, Ref. 12)9 -------------- 1 Hose, Lower Engine (See Engine

Mounting Page A10, Ref. 31)10 7080614 3 Clamp, Hose11 2460515 1 Harness, Fan/Thermal Switch12 4110226 1 Switch, Thermal Fan13 2511189 1 Cap, Pressure

14 1240015 1 Radiator, U-Flow15 5431610 1 Cover, Radiator w/Mesh16 5410607 4 O-Ring17 7552605 2 Washer, Spring Lock18 7512113 2 Bolt19 7542154 2 Nut20 5240822 1 Blade, Fan21 5333457 2 Bushing22 7511875 3 Screw23 7512232 4 Screw24 7558201 7 Washer25 7547004 7 Nut, Nylok26 5410584 2 Bushing, Mount, Lower Radiator

8/98

C5

TOOL KITSport 400L W98BA38C

1

2

3

4

5

7

8

6


1 2690016 1 Pouch, Tool Kit2 3083612 1 Wrench, Box, Special3 3083613 1 Wrench, 10-12 Spanner4 3083843 1 Screwdriver5 2870725 1 Tire Pressure Gauge

6 5211627 1 Spanner, Wrench7 2870694 1 Asm., Tool Kit (Incl. 1-5)8 9914545

9914659

1

1

Supplement, Manual, Owners, ’98SportManual, Owners, ’98 ATV

8/97

C6

FOX SHOCK, GAS, RESERVOIRSport 400L W98BA38C

15

23 16

24

22

25

1718

1920

21

14

12

6 9

7 8

4

3

5

1

2

13

11 10

14


7041383 1 Shock, Gas, Reservoir1 1500024 1 Wiper, Clear, Outer2 1500025 1 Wiper, Inner3 1500020 1 O-Ring4 1500009 1 Bearing5 1500021 1 O-Ring6 1500018

150002311

ScrewO-Ring

7 1500006 1 Ring, Piston, Floating, Fox8 1500003 1 O-Ring, Fox End Cap9 1500011 1 Piston, IFP10 1500099 1 Asm., Cap, Reservoir

(Incl. 11,12,13)11 1500097 1 Retaining Ring12 1500072

15000191500022

111

Air ValveScrewO-Ring

13 1500098 1 O-Ring, ATV Fox Shock14 1500004 1 O-Ring, Fox15 1500104 2 Bushing, Eyelet16 5020657 1 Sleeve17 1500016 1 Nut, Lock18 1500015 1 Bushing, Back-up19 1500002 1 Ring, Piston, Fox20 1500017 1 Plate, Top-Out21 1500101 1 Cap, Body22 5410987 1 Bumper, Compression23 1500103 2 Bushing, Eyelet24 1500102 1 Bushing25 1500013 1 Eyelet

12/96

C7

SHOCK VALVINGSport 400L W98BA38C

8

10

11

9

12

1

2

4

7

6

5

3

Shaft

Piston

Nut

13


1 1500033 1 Valve, Shock (.90 x .375 x .008)2 1500032 1 Valve, Shock (1.0 x .375 x .008)3 1500031 1 Valve, Shock (1.1 x .375 x .008)4 1500026 1 Valve, Shock (1.25 x .375 x .010)5 1500047 1 Valve, Shock (.80 x .375 x .010)6 1500046 1 Valve, Shock (.90 x .375 x .010)7 1500049 1 Valve, Shock (1.1 x .375 x .006)

8 1500052 1 Valve, Shock (1.3 x .375 x .006)9 1500095 2 Valve, Shock (1.25 x .375 x .012)10 1500060 1 Valve, Shock (1.1 x .375 x .012)11 1500096 1 Valve, Shock (1.0 x .375 x .015)12 1500094 1 Valve, Shock (.90 x .375 x .015)13 1500057 1 Valve, Shock (.80 x .375 x .012)

8/97

C8

GEAR SELECTORSport 400L W98BA38C

12

3

4

6

7

89

16

18

19

9

8

10

14

11

12

15

17

13

5


1341144 1 Asm., Gear Selector(Incl. 1-9,16,18,19)

1 3233198 1 Asm., Knob HR2 7512024 1 Screw3 5411008 1 Grommet, HR Shifter4 3233166 1 Rod, HR Shifter5 3233090 1 Strap, Wire6 3233167 1 Switch, HR Shifter7 3233168 1 Switch, Sensor8 3233169 2 Bearing9 1610030 2 O-Ring

10 7061013 1 Rod End, 6mm, LH11 7546702 1 Nut, LH12 5020802 1 Rod, Shift Linkage13 7515133 2 Bolt14 7546701 1 Nut, RH15 7061014 1 Rod End, 6mm, RH16 3233170 1 Base Plate, HR Shifter17 7546707 1 Nut, FLEXLOC18 3233171 1 Top Plate, HR Shifter19 3233494 4 Screw

8/97

C9

GEARCASESport 400L W98BA38C

7

6 5

4

1011

1213 14

1516 17

18

19

22

3433

2129

28

2726 25

2423

3637

3839

41

40

4243

44

32

31

30

45 46

32

1

9

20

19

36

6

8

35

4

4

C10

GEARCASESport 400L W98BA38C


1341174 1 Asm., Gearcase (Incl. 1-46)1 7512265 1 Bolt2 7555827 1 Washer3 5432082 1 Dampener, Carb Vibration4 3233248 3 Seal5 3233025 1 Stud6 3233024 2 Bushing, Pivot7 3233026 9 Screw8 3233095 1 Gearcase, LH9 3233021 2 Knock, Pipe10 3233231 1 Shift, Fork, HR11 3233178 1 Plug, Expansion12 3233232 1 Weld., Shaft, Shift13 3233179 1 O-Ring14 3233119 1 Washer15 3233045 1 Ring, Retainer16 3233155 1 Bellcrank, HR17 3233054 1 Washer18 3233055 1 Nut, FLEXLOC19 3233031 2 Pin, Interlock20 3233033 2 Screw21 3233030 1 Bracket, Interlock22 3233233 1 Spring23 3233018 1 Bearing, Ball

24 3233007 1 Washer25 3233237 1 Engagement Dog Forward26 3233106 1 Ring, Retaining27 3233105 1 Washer28 3233236 1 Sprocket, Forward, 19T29 3233103 1 Needle, Bearing30 3233235 1 Gear, Reverse, 19T31 3233181 1 Shaft, Input32 3233234 1 Engagement, Dog Reverse33 3233099 1 Washer34 3233019 1 Bearing35 5020741 1 Bushing, Speedo Drive36 3233020 2 Bearing, Ball37 1500032 1 Washer38 3233109 1 Gear, 65T39 3233121 1 Sprocket, 51T40 3233112 1 Shaft, Output41 3233111 1 Chain, Silent, 60P (11W)42 3233238 1 Gearcase, RH43 3233035 1 Washer44 3233448 1 Plug45 3233037 1 Tube, Vent46 3233478 1 Dipstick

8/97

C11

CRANKCASE and CYLINDERSport 400L W98BA38C

1

2

3

45

6

78

91011

1213

14

15

1617

1819

2021

22242526

2728

29

30

24

23

31

32

33

34

37383940

41

4243

4645

47

44

48

49

5051

52

4950

51

53

54

24

5556

57

58

4

4

3

3

4034

11

35

40

36

C12

CRANKCASE and CYLINDERSport 400L W98BA38C


1 3084731 1 Gasket (Head)2 3084730 1 Cylinder Head (Incl. 6)3 3082758 3 Gasket, Aluminum4 3083767 3 Plug, Drain5 3082910 6 Nut, Flange6 3083452 1 Pipe Complete (Water)7 3080285 2 Nut8 3080530 2 Washer, Lock9 3084439 1 Gasket (Exhaust) Non-Asbestos10 3085326 2 Stud11 3084129 2 Pipe 1 (Elbow)12 3082911 4 Nut, Flange13 3083137 1 Bolt, Banjo14 3083894 1 Check Valve15 3083138 2 Gasket16 3085277 1 Adapter17 3240064 2 Valve18 3240065 2 Stopper19 3240066 6 Screw and Washer20 3084148 1 Gasket (Reed Valve)21 3084147 1 Reed Valve (Incl. 17-19)22 3240164 1 Stuffer23 3081497 1 Screw, Pan Head24 3083590 3 Clamp25 3084145 6 Bolt, Flange (Adapter)26 3084144 1 Asm., Band (Adapter) (Incl. 23)27 3083453 1 Plug28 3082956 1 Gasket29 3084727 1 Gasket (Case 3)30 3084128 1 Pipe (Breather)

31 3084177 2 Bolt, Flange32 3084130 1 Pipe 2 (Elbow)33 3084435 1 Bolt, Flange34 3084120 2 Seal, Oil35 3085152 1 Plug36 3083482 1 Gasket, Aluminum37 3084126 2 Bolt, Flange38 3085278 1 Asm., Crankcase 3

(Incl. 11,30,32,34,35,36,40,41)39 3084134 4 Bolt, Flange40 3080103 6 Pin, Dowel41 3084131 1 Bearing, Ball42 3084733 1 O-Ring43 3084732 1 Asm., Oil Gauge (Incl. 42)44 3084125 3 Bolt, Flange45 3084775 1 Bearing, Ball46 3084121 2 Bearing, Ball47 3084725 1 Seal, Oil48 3084205 4 Screw and Washer49 3084118 2 Stud50 3084119 2 Stud51 3084774 1 Asm., Crankcase

(Incl. 3,4,34,40,44-47,49-52,56)52 3084123 1 Bearing, Ball53 3084729 1 Gasket, Cylinder Non-Asbestos54 3083384 1 Clamp55 3080142 1 Washer56 3084124 2 Bolt, Flange57 3085276 1 Cylinder (Incl. 10,11,58)58 3084138 6 Stud

8/97

C13

PISTON and CRANKSHAFTSport 400L W98BA38C

1

23

4

52

6

7

910

1112

1314

15

1211

16

1718

19

202117

22

23

8


1 308473730847383084739

222

Piston Ring (Std)Piston Ring (0.25mm/.010 O/S)Piston Ring (0.50mm/.020 O/S)

2 3084167 2 Clip, Piston Pin3 3083838 1 Piston Pin4 3085488

30855183085519

111

Piston (Std)Piston (0.25mm/.010 O/S)Piston (0.50mm/.020 O/S)

5 3084172 1 Balancer6 3084173 1 Plate7 3084174 2 Bolt, Flange8 3080130 2 Key, Woodruff9 3084156 1 Gear, Drive10 3084159 1 Washer, Guide11 3084160 2 O-Ring

12 3084158 2 Collar13 3084157 1 Nut, Slit14 3083904 1 Washer15 3083905 1 Nut, Lock16 3084776

3084149

1

1

Asm., Crankshaft(Incl. 16,17,18,20,21,23)Crankshaft 1

17 3084155 2 Spacer, Crank Pin18 3084154 1 Bearing, Large End19 3084168 1 Bearing, Small End20 3085631 1 Rod, Connecting21 3084777 1 Crankshaft 222 3084778

3084779ARAR

Spacer 1 (0.2mm)Spacer 2 (0.3mm)

23 3084152 1 Crank Pin 1

8/97

C14

OIL PUMPSport 400L W98BA38C

1

2

3

4

5

67

8

9

108

11

14

15

1617

1920

18

12 13


1 3084757 3 Bolt and Washer2 3085281 1 Cover (Oil Pump Case)3 3085280 1 Gasket (Oil Pump Case)4 3085520 1 Case (Oil Pump)5 3084201 1 Grommet6 3084758 1 Grommet7 3083783 5 Screw and Washer8 3083141 2 Clamp, Hose9 3084199 1 Pipe, Rubber10 3083120 1 Nut

11 3083121 1 Washer, Spring12 3083445 1 Collar13 3085571 1 Spring & Lever14 3083127 1 O-Ring15 3084195 1 Spacer16 3084196 1 Wheel17 3084197 1 Pin, Spring18 3085285 1 Asm., Oil Pump (Incl. 10-20)19 3084194 1 Washer20 3083125 1 Screw, Air Vent

8/97

D1

CARBURETORSport 400L W98BA38C

1

2

3

31 4

5

6

30

29

28

27

24

26

25 2322

21

20

191817

16

1514

13

1211

10

9

8

7


1 3130184 1 Top2 3130496 1 Spring, Throttle3 3130027 1 Plate (Throttle)4 3130476 1 Needle, Jet (6CE6-3)5 3130355 1 Packing6 3130751 1 Valve, Throttle (1.5)7 3130199 1 Guide, Holder8 3130006 1 Spring9 3130328 1 Asm., Plunger10 3130436 1 Spring, Throttle Adjuster11 3130447 1 Washer12 3130009 1 Screw, Throttle Stop13 3130011 1 Air Screw14 3130012 1 Spring, Air Adjuster15 3130066 1 Jet, Pilot (#35)16 3130025 4 Screw & Washer

17 3130432 1 Screw, Guide18 3130239 1 O-Ring19 3130126 1 Jet, Main (#230)20 3130443 1 Float Chamber21 3130430 2 Float22 3130237 2 Cap23 3130020 1 Gasket24 3130495 1 Needle Valve (2.5)25 3130018 1 Arm, Float26 3130361 1 Pin, Float27 3130047 1 Packing28 3130709 1 Asm., Carburetor (Incl. 1-31)29 3130596 1 Ring, Main Jet30 3130429 1 Needle Jet (0-6) (480)31 3130003 1 E-Ring

8/97

D2

RECOIL STARTERSport 400L W98BA38C

1

2 3

4

5

6

79

10

11

1514

13 12

8


1 3083185 1 Spring, Spiral2 3084750 1 Bush3 3083453 1 Plug4 3082956 1 Gasket5 3085082

3085054

1

1

Asm., Recoil Starter(Incl. 1,2,5,9-15)Starter Case

6 3084782 1 Bolt and Washer7 3084177 8 Bolt, Flange

8 3083669 1 Bushing9 3085266 1 Bolt & Washer10 3084744 1 Plate, Friction11 3083379 1 Spring, Friction12 3084822 1 Reel13 3085083 1 Rope14 3083463 1 Spring, Return15 3083378 1 Ratchet

8/97

D3

STARTING MOTORSport 400L W98BA38C

1

23

5

9

10

11

12

13

1415

16

5

1718

19

20

21

22

23

24

1

8

67

7

4


1 3085032 1 Rear Cover2 3083649 1 Nut, Flange3 3084406 1 Brush

4 3085392

3085393

1

1

Asm., Starting Motor(Incl. 1-5,8-10,12-17,20-24)Asm., Starter(Incl. 1-5,8-10,12-16)

5 3084405 2 Ring, Rubber6 3082758 1 Gasket7 3083568 5 Bolt, Flange8 3085305 1 Front Cover (Incl. 16)9 3084408 2 O-Ring10 3084407 2 Through Bolt11 3084214 1 Bracket

12 3083754 1 Set, Washer13 3084404 1 Asm., Armature (Incl. 14,15)14 3083934 1 O-Ring15 3083777 1 Bearing, Ball16 3083741 1 O-Ring17 3083737 1 Washer, Gear Shaft18 3085283 1 Gasket, Starter Non-Asbestos19 3084215 2 Bolt, Flange20 3084409 1 Clip21 3084410 1 Spring, Return22 3085394 1 Asm., Gear Shaft (Incl. 17,20-24)23 3084411 1 Spring, Weight24 3084412 1 Clip

8/97

D4

MAGNETOSport 400L W98BA38C

1 2

34

5 6

7 8

9

10

11

12

13

16

17

18

19

1514


1 3081256 1 Screw and Washer2 3081146 1 Clamp3 3084785

308478611

Asm., Plate (Incl. 1-3,5-7,9-13)Plate, Coil

4 3084766 3 Screw, Flange (Pilot)5 3083422 1 Coil, Exciter6 3083423 2 Screw and Washer7 3084788 1 Stator 18 3084784 1 Flywheel, w/Ring Gear9 3081342 2 Screw and Washer

10 3081260 1 Screw and Washer11 3084789 1 Grommet12 3084787 1 Harness, Wire13 3083909 1 Coupler, 3P14 3080077 2 Washer, Lock15 3083073 2 Nut16 4020129 1 Cap, Resistor17 3083923 1 Ignition Coil18 3085521 1 Switch, Magnetic19 3085632 1 C.D.I. System

8/97

D5

WATER PUMPSport 400L W98BA38C

1

15

16

2

15

34

5

8

9 10

11

12

14

7

13

7

6


1 3084284 1 Thermo Switch 105°2 3084183 1 Bearing, Ball3 3084184 1 Seal, Oil4 3084185 1 Seal, Oil5 3085084

308508511

Water Pump Casing (Incl. 2-6,8)Water Pump Casing (Incl. 5,6,8)

6 3085086 1 Stud7 3083856 3 Nut, Flange8 3084520 3 Stud

9 30841883084189

ARAR

Spacer 3 (0.1mm)Spacer 4 (0.2mm)

10 3084187 1 Gasket, Casing Non-Asbestos11 3084186 1 Impeller12 3082206 1 Washer13 3080077 2 Washer, Spring14 3083073 1 Nut15 3084191 2 Clamp, Hose16 3084190 1 Hose, Main

8/97

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

Sport 400L W98BA38C

D6

1040231-067 29 A10. . . .1040412-067 2 A6. . . . . .1040527-067 8 A7. . . . . .1040532-067 22 A10. . . .1040538-067 2 A5. . . . . .1040691-067 25 A5. . . . .1040692-067 25 A5. . . . .1240015 14 C4. . . . . . . . .1253118 7 A14. . . . . . . . .1260679-029 9 A11. . . . .1260680-029 7 A11. . . . .1260681-029 6 A11. . . . .1260811-029 4 A11. . . . . .1321457 6 B11. . . . . . . . .1321632 14 B11. . . . . . . .1322180 4 B12. . . . . . . . .1341144 C8. . . . . . . . . . . . .1341174 C10. . . . . . . . . . . .1500002 19 C6. . . . . . . . .1500003 8 C6. . . . . . . . . .1500004 14 C6. . . . . . . . .1500006 7 C6. . . . . . . . . .1500009 4 C6. . . . . . . . . .1500011 9 C6. . . . . . . . . .1500013 25 C6. . . . . . . . .1500015 18 C6. . . . . . . . .1500016 17 C6. . . . . . . . .1500017 20 C6. . . . . . . . .1500018 6 C6. . . . . . . . . .1500019 12 C6. . . . . . . . .1500020 3 C6. . . . . . . . . .1500021 5 C6. . . . . . . . . .1500022 12 C6. . . . . . . . .1500023 6 C6. . . . . . . . . .1500024 1 C6. . . . . . . . . .1500025 2 C6. . . . . . . . . .1500026 4 C7. . . . . . . . . .1500031 3 C7. . . . . . . . . .1500032 2 C7. . . . . . . . . . .

37 C10. .1500033 1 C7. . . . . . . . . .1500046 6 C7. . . . . . . . . .1500047 5 C7. . . . . . . . . .1500049 7 C7. . . . . . . . . .1500052 8 C7. . . . . . . . . .1500057 13 C7. . . . . . . . .1500060 10 C7. . . . . . . . .1500063 9 B10. . . . . . . . .1500072 12 C6. . . . . . . . .1500094 12 C7. . . . . . . . .1500095 9 C7. . . . . . . . . .1500096 11 C7. . . . . . . . .1500097 11 C6. . . . . . . . .1500098 13 C6. . . . . . . . .1500099 10 C6. . . . . . . . .1500101 21 C6. . . . . . . . .1500102 24 C6. . . . . . . . .1500103 23 C6. . . . . . . . .1500104 15 C6. . . . . . . . .1520170 21 C1. . . . . . . . .1520175-133 7 B3. . . . . .1520183-133 32 C1. . . . .1525017 8 B3. . . . . . . . . .

8 C1. . .

1590237 30 B13. . . . . . . .1610030 9 C8. . . . . . . . . .1822477 9 B5. . . . . . . . . .1843077 1 B7. . . . . . . . . .1910057 10 B4. . . . . . . . .1910177 28 B13. . . . . . . .1910196-067 27 B14. . . .1910227 5 B13. . . . . . . . .1910232 B4. . . . . . . . . . . . .1910233 B4. . . . . . . . . . . . .1930642 B4. . . . . . . . . . . . .1930665 8 B4. . . . . . . . . .1930751 17 B9. . . . . . . . .1930752 20 B9. . . . . . . . .1930753 22 B9. . . . . . . . .1930762 15 B9. . . . . . . . .1930792 12 B9. . . . . . . . .1930795 4 B9. . . . . . . . . .1930796 3 B9. . . . . . . . . .1930797 2 B9. . . . . . . . . .1930799 6 B9. . . . . . . . . .1930804 7 B9. . . . . . . . . .1930805 13 B9. . . . . . . . .1930806 10 B9. . . . . . . . .2010055 12 B6. . . . . . . . .2010075 9 B8. . . . . . . . . .2010076 8 B8. . . . . . . . . .2010077 7 B8. . . . . . . . . .2010078 6 B8. . . . . . . . . .2010079 1 B8. . . . . . . . . .2010080 3 B8. . . . . . . . . .2010081 4 B8. . . . . . . . . .2010159 5 B8. . . . . . . . . .2050073 1 B9. . . . . . . . . .2200341 4 C1. . . . . . . . . .2200361 17 C2. . . . . . . . .2200463 7 B14. . . . . . . . .2200464 6 B14. . . . . . . . .2200465 9 B4. . . . . . . . . .2200560 22 B5. . . . . . . . .2200561 22 B5. . . . . . . . .2200593 3 C2. . . . . . . . . .2200774 7 B6. . . . . . . . . .2200790 25 C3. . . . . . . . .2200808 5 B9. . . . . . . . . .2200809 1 B9. . . . . . . . . .2200899 6 B14. . . . . . . . .2200901 9 B4. . . . . . . . . .2201034 8 B9. . . . . . . . . .2201038 29 B10. . . . . . . .2201090 11 B9. . . . . . . . .2201149 9 B4. . . . . . . . . .2201150 6 B14. . . . . . . . .2432038 4 C2. . . . . . . . . .2460495 1 C2. . . . . . . . . .2460515 11 C4. . . . . . . . .2460521 7 A8. . . . . . . . . .2511189 13 C4. . . . . . . . . .2511272 1 A13. . . . . . . . .2530008 12 A13. . . . . . . .2530009 43 A10. . . . . . . .

15 B1. . .2620087 29 C2. . . . . . . . .2631925-216 14 A5. . . . .

2670133 19 A6. . . . . . . . .2670134 14 A7. . . . . . . . .2681769-194 3 A6. . . . . .2682358-194 3 A6. . . . . .2690016 1 C5. . . . . . . . . .2870694 7 C5. . . . . . . . . .2870725 5 C5. . . . . . . . . .3070156 10 A10. . . . . . . .3080077 14 D4. . . . . . . . .

13 D5. . .3080103 40 C12. . . . . . . .3080130 8 C13. . . . . . . . .3080142 55 C12. . . . . . . .3080285 7 C12. . . . . . . . .3080530 8 C12. . . . . . . . .3081146 2 D4. . . . . . . . . .3081256 1 D4. . . . . . . . . .3081260 10 D4. . . . . . . . .3081342 9 D4. . . . . . . . . .3081497 23 C12. . . . . . . .3082206 12 D5. . . . . . . . .3082758 3 C12. . . . . . . . . .

6 D3. . .3082910 5 C12. . . . . . . . .3082911 12 C12. . . . . . . .3082956 28 C12. . . . . . . .

4 D2. . .3083073 15 D4. . . . . . . . .

14 D5. . .3083120 10 C14. . . . . . . .3083121 11 C14. . . . . . . .3083125 20 C14. . . . . . . .3083127 14 C14. . . . . . . .3083137 13 C12. . . . . . . .3083138 15 C12. . . . . . . .3083141 8 C14. . . . . . . . .3083185 1 D2. . . . . . . . . .3083378 15 D2. . . . . . . . .3083379 11 D2. . . . . . . . .3083384 54 C12. . . . . . . .3083422 5 D4. . . . . . . . . .3083423 6 D4. . . . . . . . . .3083445 12 C14. . . . . . . .3083452 6 C12. . . . . . . . .3083453 27 C12. . . . . . . .

3 D2. . .3083463 14 D2. . . . . . . . .3083482 36 C12. . . . . . . .3083568 7 D3. . . . . . . . . .3083590 24 C12. . . . . . . .3083612 2 C5. . . . . . . . . .3083613 3 C5. . . . . . . . . .3083649 2 D3. . . . . . . . . .3083669 8 D2. . . . . . . . . .3083737 17 D3. . . . . . . . .3083741 16 D3. . . . . . . . .3083754 12 D3. . . . . . . . .3083767 4 C12. . . . . . . . .3083777 15 D3. . . . . . . . .3083783 7 C14. . . . . . . . .3083838 3 C13. . . . . . . . .3083843 4 C5. . . . . . . . . .3083856 7 D5. . . . . . . . . .3083894 14 C12. . . . . . . .

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

Sport 400L W98BA38C

D7

3083904 14 C13. . . . . . . .3083905 15 C13. . . . . . . .3083909 13 D4. . . . . . . . .3083923 17 D4. . . . . . . . .3083934 14 D3. . . . . . . . .3084118 49 C12. . . . . . . .3084119 50 C12. . . . . . . .3084120 34 C12. . . . . . . .3084121 46 C12. . . . . . . .3084123 52 C12. . . . . . . .3084124 56 C12. . . . . . . .3084125 44 C12. . . . . . . .3084126 37 C12. . . . . . . .3084128 30 C12. . . . . . . .3084129 11 C12. . . . . . . .3084130 32 C12. . . . . . . .3084131 41 C12. . . . . . . .3084134 39 C12. . . . . . . .3084138 58 C12. . . . . . . .3084144 26 C12. . . . . . . .3084145 25 C12. . . . . . . .3084147 21 C12. . . . . . . .3084148 20 C12. . . . . . . .3084149 16 C13. . . . . . . .3084152 23 C13. . . . . . . .3084154 18 C13. . . . . . . .3084155 17 C13. . . . . . . .3084156 9 C13. . . . . . . . .3084157 13 C13. . . . . . . .3084158 12 C13. . . . . . . .3084159 10 C13. . . . . . . .3084160 11 C13. . . . . . . .3084167 2 C13. . . . . . . . .3084168 19 C13. . . . . . . .3084172 5 C13. . . . . . . . .3084173 6 C13. . . . . . . . .3084174 7 C13. . . . . . . . .3084177 31 C12. . . . . . . .

7 D2. . .3084183 2 D5. . . . . . . . . .3084184 3 D5. . . . . . . . . .3084185 4 D5. . . . . . . . . .3084186 11 D5. . . . . . . . .3084187 10 D5. . . . . . . . .3084188 9 D5. . . . . . . . . .3084189 9 D5. . . . . . . . . .3084190 16 D5. . . . . . . . .3084191 15 D5. . . . . . . . .3084194 19 C14. . . . . . . .3084195 15 C14. . . . . . . .3084196 16 C14. . . . . . . .3084197 17 C14. . . . . . . .3084199 9 C14. . . . . . . . .3084201 5 C14. . . . . . . . .3084205 48 C12. . . . . . . .3084214 11 D3. . . . . . . . .3084215 19 D3. . . . . . . . .3084284 1 D5. . . . . . . . . .3084404 13 D3. . . . . . . . .3084405 5 D3. . . . . . . . . .3084406 3 D3. . . . . . . . . .3084407 10 D3. . . . . . . . .3084408 9 D3. . . . . . . . . .3084409 20 D3. . . . . . . . .

3084410 21 D3. . . . . . . . .3084411 23 D3. . . . . . . . .3084412 24 D3. . . . . . . . .3084435 33 C12. . . . . . . .3084439 9 C12. . . . . . . . .3084520 8 D5. . . . . . . . . .3084725 47 C12. . . . . . . .3084727 29 C12. . . . . . . .3084729 53 C12. . . . . . . .3084730 2 C12. . . . . . . . .3084731 1 C12. . . . . . . . .3084732 43 C12. . . . . . . .3084733 42 C12. . . . . . . .3084737 1 C13. . . . . . . . .3084738 1 C13. . . . . . . . .3084739 1 C13. . . . . . . . .3084744 10 D2. . . . . . . . .3084750 2 D2. . . . . . . . . .3084757 1 C14. . . . . . . . .3084758 6 C14. . . . . . . . .3084766 4 D4. . . . . . . . . .3084774 51 C12. . . . . . . .3084775 45 C12. . . . . . . .3084776 16 C13. . . . . . . .3084777 21 C13. . . . . . . .3084778 22 C13. . . . . . . .3084779 22 C13. . . . . . . .3084782 6 D2. . . . . . . . . .3084784 8 D4. . . . . . . . . .3084785 3 D4. . . . . . . . . .3084786 3 D4. . . . . . . . . .3084787 12 D4. . . . . . . . .3084788 7 D4. . . . . . . . . .3084789 11 D4. . . . . . . . .3084822 12 D2. . . . . . . . .3085032 1 D3. . . . . . . . . .3085054 5 D2. . . . . . . . . .3085082 5 D2. . . . . . . . . .3085083 13 D2. . . . . . . . .3085084 5 D5. . . . . . . . . .3085085 5 D5. . . . . . . . . .3085086 6 D5. . . . . . . . . .3085152 35 C12. . . . . . . .3085266 9 D2. . . . . . . . . .3085276 57 C12. . . . . . . .3085277 16 C12. . . . . . . .3085278 38 C12. . . . . . . .3085280 3 C14. . . . . . . . .3085281 2 C14. . . . . . . . .3085283 18 D3. . . . . . . . .3085285 18 C14. . . . . . . .3085305 8 D3. . . . . . . . . .3085326 10 C12. . . . . . . .3085392 4 D3. . . . . . . . . .3085393 4 D3. . . . . . . . . .3085394 22 D3. . . . . . . . .3085488 4 C13. . . . . . . . .3085518 4 C13. . . . . . . . .3085519 4 C13. . . . . . . . .3085520 4 C14. . . . . . . . .3085521 18 D4. . . . . . . . .3085547 33 A10. . . . . . . .3085571 13 C14. . . . . . . .3085631 20 C13. . . . . . . .

3085632 19 D4. . . . . . . . .3110026 26 A10. . . . . . . .3110032 7 C4. . . . . . . . . .3110038 1 A10. . . . . . . . .3110042 38 A10. . . . . . . .3110048 40 A10. . . . . . . .3130003 31 D1. . . . . . . . .3130006 8 D1. . . . . . . . . .3130009 12 D1. . . . . . . . .3130011 13 D1. . . . . . . . .3130012 14 D1. . . . . . . . .3130018 25 D1. . . . . . . . .3130020 23 D1. . . . . . . . .3130025 16 D1. . . . . . . . .3130027 3 D1. . . . . . . . . .3130047 27 D1. . . . . . . . .3130066 15 D1. . . . . . . . .3130126 19 D1. . . . . . . . .3130184 1 D1. . . . . . . . . .3130199 7 D1. . . . . . . . . .3130237 22 D1. . . . . . . . .3130239 18 D1. . . . . . . . .3130328 9 D1. . . . . . . . . .3130355 5 D1. . . . . . . . . .3130361 26 D1. . . . . . . . .3130429 30 D1. . . . . . . . .3130430 21 D1. . . . . . . . .3130432 17 D1. . . . . . . . .3130436 10 D1. . . . . . . . .3130443 20 D1. . . . . . . . .3130447 11 D1. . . . . . . . .3130476 4 D1. . . . . . . . . .3130495 24 D1. . . . . . . . .3130496 2 D1. . . . . . . . . .3130596 29 D1. . . . . . . . .3130709 28 D1. . . . . . . . .3130751 6 D1. . . . . . . . . .3211077 3 B12. . . . . . . . .3221044 7 B13. . . . . . . . .3222068 19 C1. . . . . . . . .3224056-084 15 C1. . . . .3225026 7 C1. . . . . . . . . .3233007 24 C10. . . . . . . .3233018 23 C10. . . . . . . .3233019 34 C10. . . . . . . .3233020 36 C10. . . . . . . .3233021 9 C10. . . . . . . . .3233024 6 C10. . . . . . . . .3233025 5 C10. . . . . . . . .3233026 7 C10. . . . . . . . .3233030 21 C10. . . . . . . .3233031 19 C10. . . . . . . .3233033 20 C10. . . . . . . .3233035 43 C10. . . . . . . .3233037 45 C10. . . . . . . .3233045 15 C10. . . . . . . .3233054 17 C10. . . . . . . .3233055 18 C10. . . . . . . .3233090 5 C8. . . . . . . . . .3233095 8 C10. . . . . . . . .3233099 33 C10. . . . . . . .3233103 29 C10. . . . . . . .3233105 27 C10. . . . . . . .3233106 26 C10. . . . . . . .3233109 38 C10. . . . . . . .

PartNo.

Ref.No.

PartNo.

Ref.No.

PartNo.

Ref.No.

PART NUMBER INDEX

GridNo.

GridNo.

GridNo.

Sport 400L W98BA38C

D8

3233111 41 C10. . . . . . . . .3233112 40 C10. . . . . . . .3233119 14 C10. . . . . . . .3233121 39 C10. . . . . . . .3233155 16 C10. . . . . . . .3233166 4 C8. . . . . . . . . .3233167 6 C8. . . . . . . . . .3233168 7 C8. . . . . . . . . .3233169 8 C8. . . . . . . . . .3233170 16 C8. . . . . . . . .3233171 18 C8. . . . . . . . .3233178 11 C10. . . . . . . .3233179 13 C10. . . . . . . .3233181 31 C10. . . . . . . .3233198 1 C8. . . . . . . . . .3233231 10 C10. . . . . . . .3233232 12 C10. . . . . . . .3233233 22 C10. . . . . . . .3233234 32 C10. . . . . . . .3233235 30 C10. . . . . . . .3233236 28 C10. . . . . . . .3233237 25 C10. . . . . . . .3233238 42 C10. . . . . . . .3233248 4 C10. . . . . . . . .3233448 44 C10. . . . . . . .3233478 46 C10. . . . . . . .3233494 19 C8. . . . . . . . .3240064 17 C12. . . . . . . .3240065 18 C12. . . . . . . .3240066 19 C12. . . . . . . .3240164 22 C12. . . . . . . .3513519 3 B3. . . . . . . . . .3515501 25 C1. . . . . . . . .3576504 12 B11. . . . . . . .

11 B12. .3576510 3 B11. . . . . . . . .3576511 12 B12. . . . . . . .3610013 24 C1. . . . . . . . .3610020 2 B3. . . . . . . . . .3610026 17 B13. . . . . . . .

20 B14. .4010064 24 C2. . . . . . . . .4010094 23 C2. . . . . . . . .4010095 18 C2. . . . . . . . .4010129 13 A10. . . . . . . .4010132 6 A10. . . . . . . . .4020129 16 D4. . . . . . . . .4030043 7 C2. . . . . . . . . .4030053 9 A5. . . . . . . . . .4030056 7 A5. . . . . . . . . .4032085 6 C2. . . . . . . . . .4032086 8 C2. . . . . . . . . .4032087 9 C2. . . . . . . . . .4032093 4 A5. . . . . . . . . .4032094 10 A5. . . . . . . . .4040012 1 A8. . . . . . . . . .4040053 3 A8. . . . . . . . . .4040054 2 A8. . . . . . . . . .4040063 34 C2. . . . . . . . .4060114 32 C2. . . . . . . . .4060193 30 C2. . . . . . . . .4110141-31xx 4 A8. . . . . .4110148-32xx 4 A8. . . . . .4110164 16 B9. . . . . . . . .

4110177 6 B1. . . . . . . . . .4110192 10 B6. . . . . . . . .4110194 4 A8. . . . . . . . . .4110203 10 B8. . . . . . . . .4110226 12 C4. . . . . . . . .4140006 22 C2. . . . . . . . .4170009 3 C4. . . . . . . . . .5010204 26 C1. . . . . . . . .5010206 28 C1. . . . . . . . .5010256 9 B3. . . . . . . . . .5010339 2 A11. . . . . . . . .5010350 17 A11. . . . . . . .5010379 1 B12. . . . . . . . .5020422 13 B11. . . . . . . .5020468 2 C1. . . . . . . . . .5020506 6 B4. . . . . . . . . .5020572 6 C4. . . . . . . . . .5020657 16 C6. . . . . . . . .5020677 19 B5. . . . . . . . .5020681 23 B5. . . . . . . . .5020741 35 C10. . . . . . . .5020790 31 C1. . . . . . . . .5020791 14 B14. . . . . . . .5020793 16 B10. . . . . . . .5020802 12 C8. . . . . . . . .5020927 6 B5. . . . . . . . . .5130663 27 C1. . . . . . . . .5130668 6 B2. . . . . . . . . .5130940 5 B3. . . . . . . . . .5131039 16 B2. . . . . . . . .5131040 16 B2. . . . . . . . .5131115 3 B4. . . . . . . . . . .5131116 3 B4. . . . . . . . . . .5131272 5 B14. . . . . . . . .5131446 14 B12. . . . . . . .5210748 17 A10. . . . . . . .5210752 8 B11. . . . . . . . . .

15 B12. .5210753 8 B11. . . . . . . . .5210754 8 B11. . . . . . . . .5210764 18 B13. . . . . . . .5211020-067 22 A5. . . . . .5211033 7 A6. . . . . . . . . .5211065 18 B13. . . . . . . .5211115 17 B2. . . . . . . . . .5211131-067 22 A5. . . . . .

25 A6. . .5211325 4 B3. . . . . . . . . .5211517 18 B13. . . . . . . .5211592 8 A11. . . . . . . . .5211617-067 17 C1. . . . . .5211627 6 C5. . . . . . . . . .5220602 7 B2. . . . . . . . . .5220646 5 B12. . . . . . . . .5220880 26 A6. . . . . . . . .5220916-067 13 A13. . . .5220946 6 B6. . . . . . . . . .5220958 2 B10. . . . . . . . . .

9 B13. .5222446-067 28 C3. . . . .5222860-067 17 A6. . . . .5222999-067 15 B7. . . . .5224316-067 2 B6. . . . . .5224531 26 B14. . . . . . . .

5240336 5 A14. . . . . . . . .5240424 3 A14. . . . . . . . .5240542-067 36 A10. . . .5240717 13 B5. . . . . . . . .5240822 20 C4. . . . . . . . .5240869-067 21 A7. . . . .5240901 21 B14. . . . . . . .5240993 11 B14. . . . . . . .5241018-067 4 B13. . . . .5241213-067 26 C3. . . . .5241355-067 4 C4. . . . . .5241436-067 6 A5. . . . . .5241460 11 B10. . . . . . . .5241801-067 8 A10. . . . .5242016-067 30 A5. . . . .5242525-067 28 A5. . . . .5242682-067 13 A7. . . . .5242683-067 16 A7. . . . .5242977 18 A13. . . . . . . .5242981 8 B11. . . . . . . . .5332828 25 B10. . . . . . . .5333255 20 B13. . . . . . . .5333367 2 B5. . . . . . . . . .5333457 21 C4. . . . . . . . .5410241 18 A11. . . . . . . .5410346 16 C2. . . . . . . . .5410414 6 A6. . . . . . . . . .5410415 23 C1. . . . . . . . .5410421 14 C3. . . . . . . . .5410424 20 C2. . . . . . . . .5410436 15 A11. . . . . . . .5410470 14 B3. . . . . . . . .5410494 12 B4. . . . . . . . .5410495 11 B4. . . . . . . . .5410539 6 C1. . . . . . . . . .5410542 12 B14. . . . . . . .5410548 15 B5. . . . . . . . .5410570 12 A10. . . . . . . .5410575 29 C3. . . . . . . . .5410584 26 C4. . . . . . . . .5410607 16 C4. . . . . . . . .5410766 8 B14. . . . . . . . .5410767 9 B14. . . . . . . . .5410772 6 B7. . . . . . . . . .5410779 4 B4. . . . . . . . . .5410780 5 B4. . . . . . . . . .5410791 9 B2. . . . . . . . . .5410842 2 A13. . . . . . . . .5410857 14 A14. . . . . . . .5410883 25 A10. . . . . . . .5410906 6 B3. . . . . . . . . .5410934 18 A14. . . . . . . .5410957 1 A11. . . . . . . . .5410987 22 C6. . . . . . . . .5411008 3 C8. . . . . . . . . .5411042 28 A6. . . . . . . . .5411164 14 C1. . . . . . . . . .5411173 31 A10. . . . . . . . .5411180 1 C3. . . . . . . . . . .5411272 17 A13. . . . . . . .5411291 3 B5. . . . . . . . . .5430261 16 A10. . . . . . . .5430725 4 A13. . . . . . . . .5430743 17 C3. . . . . . . . .5430766 18 B12. . . . . . . .

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Sport 400L W98BA38C

D9

5430776 26 B10. . . . . . . .5430779 1 B1. . . . . . . . . .5430802 2 A10. . . . . . . . .5430806 4 B2. . . . . . . . . .5430807 5 B2. . . . . . . . . .5430945 5 B11. . . . . . . . .5431018 13 B3. . . . . . . . .5431030 11 B6. . . . . . . . .5431053 6 A13. . . . . . . . .5431107 29 B14. . . . . . . .5431310 20 B10. . . . . . . .5431484 27 A5. . . . . . . . .5431570 10 B7. . . . . . . . .5431571 7 B7. . . . . . . . . .5431572 14 B7. . . . . . . . .5431573 2 B7. . . . . . . . . .5431574 12 B7. . . . . . . . .5431596 18 B5. . . . . . . . .5431610 15 C4. . . . . . . . .5431698 17 A14. . . . . . . .5431734 10 B10. . . . . . . .5431766 25 B13. . . . . . . .5431769 14 C2. . . . . . . . .5431793 3 B1. . . . . . . . . .5431869-070 13 A6. . . . .5431895 18 C3. . . . . . . . .5431936 7 B11. . . . . . . . .5431961 6 C3. . . . . . . . . .5431972 17 B10. . . . . . . .5431973 27 C2. . . . . . . . .5431975 8 A8. . . . . . . . . .5431976 5 A8. . . . . . . . . .5431977 12 B10. . . . . . . .5431986 4 A6. . . . . . . . . .5431997 13 A14. . . . . . . .5432047 20 A6. . . . . . . . .5432077 21 C2. . . . . . . . .5432082 3 C10. . . . . . . . .5432179-194 12 A5. . . . .5432378-070 9 A7. . . . . .5432440 23 C3. . . . . . . . .5432559 20 A13. . . . . . . .5432606-216 11 A6. . . . .5432607 23 A14. . . . . . . .5432615 16 C3. . . . . . . . .5432733 19 A13. . . . . . . .5432883 9 A14. . . . . . . . .5433198 9 B6. . . . . . . . . .5521301 5 C3. . . . . . . . . .5630457 18 B14. . . . . . . .5630509 9 B11. . . . . . . . .5630538 17 B14. . . . . . . .5630586 18 C1. . . . . . . . .5630616-067 7 B6. . . . . .5630885 7 B10. . . . . . . . .5810141 2 B1. . . . . . . . . .5810144 3 A13. . . . . . . . .5810279 24 C3. . . . . . . . .5810290 13 C2. . . . . . . . .5810291 3 B2. . . . . . . . . .5810379 4 B6. . . . . . . . . .5810467 4 A7. . . . . . . . . .5810948 4 A14. . . . . . . . .5810957 21 A6. . . . . . . . .

5810966 8 A14. . . . . . . . .5811012 25 A14. . . . . . . .5811079 27 C2. . . . . . . . .5811099 6 A14. . . . . . . . .5811102 19 A14. . . . . . . . .5811113 13 A6. . . . . . . . . .5830009 15 B14. . . . . . . .5850113 23 A5. . . . . . . . .5850114 23 A5. . . . . . . . .5850122 24 A6. . . . . . . . .5850123 24 A6. . . . . . . . .5850124 5 A7. . . . . . . . . .5850125 5 A7. . . . . . . . . .5910026 7 B4. . . . . . . . . .7010032 19 C2. . . . . . . . .7041079 30 A10. . . . . . . .7041132 4 B11. . . . . . . . .7041198 13 B12. . . . . . . .7041219 13 B14. . . . . . . .7041238-067 8 B2. . . . . .7041383 C6. . . . . . . . . . . . .

8 B10. .7041389-067 4 B10. . . . .7041607 1 A6. . . . . . . . . .7041755 10 B2. . . . . . . . .7042029 12 A11. . . . . . . .

28 B14. .7042031 5 A11. . . . . . . . .7052047 35 A10. . . . . . . .7052065 19 C3. . . . . . . . .7052077 4 B1. . . . . . . . . .7052103 23 B9. . . . . . . . .7052147 16 A13. . . . . . . .7052148 23 A13. . . . . . . .7052153 11 B1. . . . . . . . .7052154 22 A13. . . . . . . .7052181 5 C4. . . . . . . . . .7052192 9 A10. . . . . . . . .7061013 10 C8. . . . . . . . .7061014 15 C8. . . . . . . . .7061018 8 B5. . . . . . . . . .7061019 4 B5. . . . . . . . . .7072606 15 C2. . . . . . . . .7072724 2 B8. . . . . . . . . .7072786 1 A12. . . . . . . . .7072791 10 A6. . . . . . . . .7073024 4 A12. . . . . . . . .7073761 9 A6. . . . . . . . . .7074214 22 B10. . . . . . . .7074637 16 A12. . . . . . . .7074752 23 B10. . . . . . . .7074782 11 C3. . . . . . . . .7074827 3 A12. . . . . . . . .7074946 9 C3. . . . . . . . . .7075339 21 B13. . . . . . . .7075343 3 B10. . . . . . . . .7075413 8 A12. . . . . . . . .7075725 14 A12. . . . . . . .7075741 32 A10. . . . . . . .

9 A12. .7076206 11 A12. . . . . . . .7076274 12 A12. . . . . . . .7076491 5 A12. . . . . . . . .7077377 10 C3. . . . . . . . .

7077853 6 A12. . . . . . . . .7077855 13 A12. . . . . . . .7077856 7 A12. . . . . . . . .7077857 10 A12. . . . . . . .7077919 15 A12. . . . . . . .7077920 2 A12. . . . . . . . .7080003 10 A13. . . . . . . .7080138 2 C2. . . . . . . . . .7080236 41 A10. . . . . . . .7080306 14 B2. . . . . . . . .

30 C1. . .7080307 14 B1. . . . . . . . .7080352 1 B4. . . . . . . . . . .

3 B14. .7080371 9 A8. . . . . . . . . .7080409 3 A5. . . . . . . . . .7080433 20 B5. . . . . . . . .

13 B7. . .7080438 18 B10. . . . . . . .7080483 10 A14. . . . . . . .7080487 11 A14. . . . . . . .7080492 13 C3. . . . . . . . .7080510 3 B7. . . . . . . . . .7080511 24 A10. . . . . . . .

21 C3. . .7080525 8 B1. . . . . . . . . .7080526 9 B1. . . . . . . . . .7080539 18 B9. . . . . . . . .7080568 12 B1. . . . . . . . .7080573 11 B2. . . . . . . . .7080584 16 A14. . . . . . . .7080598 20 A14. . . . . . . .7080614 11 A10. . . . . . . . .

10 C4. . .7080631 14 B6. . . . . . . . .7080673 16 B5. . . . . . . . .7080728 12 B8. . . . . . . . .7511854 17 B12. . . . . . . .7511875 22 C4. . . . . . . . .7511881 15 A14. . . . . . . .7511886 11 A5. . . . . . . . .7511887 13 A5. . . . . . . . .7512007 26 C2. . . . . . . . .7512024 21 B9. . . . . . . . .

31 C2. . .2 C8. . .

7512026 6 A8. . . . . . . . . .7512027 12 C2. . . . . . . . .7512084 8 A5. . . . . . . . . . .

22 C3. . .7512088 5 C2. . . . . . . . . .7512093 8 C3. . . . . . . . . .7512094 12 C3. . . . . . . . .7512095 27 C3. . . . . . . . .7512113 18 C4. . . . . . . . .7512173 19 B14. . . . . . . .7512176 1 B11. . . . . . . . .7512232 29 A5. . . . . . . . .

29 A6. . .9 A13. .15 C3. . .23 C4. . .

7512252 10 A7. . . . . . . . .27 B13. .

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PART NUMBER INDEX

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Sport 400L W98BA38C

D10

7512252 28 C2. . . . . . . . .7512265 1 C10. . . . . . . . .7512266 10 B11. . . . . . . .7512281 15 A7. . . . . . . . .7512282 16 A5. . . . . . . . .

22 A6. . .7512284 14 B5. . . . . . . . .7512310 7 A13. . . . . . . . .7512325 17 B3. . . . . . . . .7512329 2 A7. . . . . . . . . .7512365 15 B4. . . . . . . . .7512457 23 A10. . . . . . . .7512490 28 A10. . . . . . . .7512566 19 A10. . . . . . . .7512576 32 B10. . . . . . . .7512673 3 C1. . . . . . . . . .7512701 1 B10. . . . . . . . . .

10 B13. .7512702 19 B10. . . . . . . .

29 B13. .7515133 13 C8. . . . . . . . .7515150 24 A14. . . . . . . .7515151 26 A14. . . . . . . .7515160 23 B14. . . . . . . .7515179 22 A14. . . . . . . .7515188 3 B6. . . . . . . . . .7515190 19 A7. . . . . . . . .7515304 24 B10. . . . . . . .7515316 3 A11. . . . . . . . .7515321 5 A10. . . . . . . . . .

4 B7. . .7515327 7 B12. . . . . . . . .7515328 22 B13. . . . . . . .7515339 15 B2. . . . . . . . .7515345 1 B13. . . . . . . . .7515352 20 A11. . . . . . . .7515399 12 A7. . . . . . . . .7515415 6 B10. . . . . . . . .7515438 33 B10. . . . . . . .7515458 24 B5. . . . . . . . .7515472 14 B13. . . . . . . .7515484 16 B13. . . . . . . .7515489 2 B4. . . . . . . . . .7515513 22 C1. . . . . . . . .7515522 11 B13. . . . . . . .7515523 16 B3. . . . . . . . .7515540 20 C1. . . . . . . . .7515554 26 B5. . . . . . . . .7517219 4 C3. . . . . . . . . .7517264 19 A5. . . . . . . . .

14 A6. . .7517389 10 B1. . . . . . . . .7517395 5 B6. . . . . . . . . .7517417 11 A7. . . . . . . . .7517505 21 A13. . . . . . . .7541906 11 B11. . . . . . . .7541925 25 C2. . . . . . . . .7542122 21 A5. . . . . . . . .

16 A6. . .13 B6. . .1 C4. . .

7542124 6 A7. . . . . . . . . .7542127 1 A14. . . . . . . . .

7542149 2 B14. . . . . . . . .7542154 19 C4. . . . . . . . .7542303 12 B2. . . . . . . . .7542321 28 B10. . . . . . . .7542324 1 A7. . . . . . . . . . .

13 A11. .14 A13. .16 B7. . .

7542403 20 A10. . . . . . . .1 B5. . .15 B13. .

7542411 7 A10. . . . . . . . .7542432 39 A10. . . . . . . .7542438 21 B5. . . . . . . . .7542439 5 B10. . . . . . . . . .

16 C1. . .7542449 19 B13. . . . . . . .7542459 15 B3. . . . . . . . .7542503 30 B10. . . . . . . .7542507 1 B2. . . . . . . . . .7542602 14 B10. . . . . . . .7542711 5 B5. . . . . . . . . .7542712 11 B3. . . . . . . . .7542714 10 C1. . . . . . . . .7543005 12 C1. . . . . . . . .7543203 9 B7. . . . . . . . . .7546701 14 C8. . . . . . . . .7546702 11 C8. . . . . . . . .7546707 17 C8. . . . . . . . .7546904 11 B5. . . . . . . . .7547004 25 C4. . . . . . . . .7547028 7 B5. . . . . . . . . .7552603 25 B5. . . . . . . . .

12 B13. .7552605 20 A7. . . . . . . . .

3 C3. . .17 C4. . .

7552606 23 B13. . . . . . . .7552801 2 B11. . . . . . . . .7552901 4 A10. . . . . . . . . .

14 B4. . .6 B12. .2 B13. .

7553001 27 A10. . . . . . . .7555716 14 A11. . . . . . . .7555721 10 B3. . . . . . . . .7555734 8 A13. . . . . . . . .7555745 9 C1. . . . . . . . . .7555748 2 C3. . . . . . . . . .7555749 2 B2. . . . . . . . . .7555764 1 C1. . . . . . . . . .7555770 24 B13. . . . . . . .7555776 15 A5. . . . . . . . .

7 A7. . .2 A14. .26 B13. .

7555784 13 B13. . . . . . . .7555796 11 C1. . . . . . . . .7555801 37 A10. . . . . . . .7555806 10 B5. . . . . . . . .

25 B14. .7555823 3 A10. . . . . . . . . .

21 A10. .

7555827 16 B14. . . . . . . .2 C10. .

7555843 19 A11. . . . . . . .7555859 20 A5. . . . . . . . .

15 A6. . .7555878 5 B7. . . . . . . . . .7555883 31 B10. . . . . . . .7555898 8 B12. . . . . . . . .7555911 13 B10. . . . . . . .7555919 30 B14. . . . . . . .7555921 1 B14. . . . . . . . .7555932 16 B1. . . . . . . . .7555935 30 C3. . . . . . . . .7556047 11 B8. . . . . . . . .7556076 9 B12. . . . . . . . .7556401 16 A11. . . . . . . .

2 B12. .7556804 10 B12. . . . . . . .7558201 18 A5. . . . . . . . .

24 C4. . .7558301 21 A14. . . . . . . .

2 C4. . .7558402 13 B2. . . . . . . . .

13 B4. . .27 B10. .3 A7 B13

7571602 11 C2. . . . . . . . .7571632 22 B14. . . . . . . .7575202 18 A10. . . . . . . .7621336 33 C2. . . . . . . . .7621403 8 A6. . . . . . . . . .7621433 21 B10. . . . . . . .7621460 7 B1. . . . . . . . . .7621462 19 B9. . . . . . . . .7621471 17 A5. . . . . . . . .7621472 24 A5. . . . . . . . .

27 A6. . .7621479 5 A6. . . . . . . . . .7661203 12 B5. . . . . . . . .

24 B14. .7661401 31 B14. . . . . . . .7661404 13 C1. . . . . . . . .7661407 12 B3. . . . . . . . .7661632 11 B7. . . . . . . . .7661633 8 B7. . . . . . . . . .7661638 18 A6. . . . . . . . .

31 C3. . .7661820 4 B14. . . . . . . . .7661825 26 A5. . . . . . . . .7670051 7 C3. . . . . . . . . .7670057 12 A6. . . . . . . . .7670060 1 A5. . . . . . . . . . .

18 A7. . .7670081 5 C1. . . . . . . . . .7670088 17 A7. . . . . . . . .7670093 10 C2. . . . . . . . .7670095 5 A5. . . . . . . . . .7710405 29 C1. . . . . . . . .7710434 6 B13. . . . . . . . .7710448 16 B12. . . . . . . .8360009-600 34 A10. . . .

5 A13. .5 B1. . .

8360026 15 A13. . . . . . . .17 B1. . .

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Sport 400L W98BA38C

D11

8450003-1525 42 A10. . .13 B1. . .20 C3. . .

8450040-600 11 A13. . . .8450051-600 12 A14. . . .9914545 8 C5. . . . . . . . . .9914659 8 C5. . . . . . . . . .

PRINTED IN THE USA PARTS MANUAL PN 9914723 and MICROFICHE PN 9915239 8/98

Documents

1998pi54.com/corp/manuals/Parts/9914723r02.pdf · · 2004-09-141998 SPORT 400L Model #W98BA38C Rev. 02. TABLE OF CONTENTS Sport 400L W98BA38C Parts Manual A ... 33 3085547 1 Engine,