This thread is where I got started: http://www.polarisatvforums.com/foru…c-bearing.html
1995 Xplorer 3 Chain & 6 Sprocket Replacement
Also the Scrambler I think. This is the 400L engine on the Xplorer made from 95-98 I think.
There are 3 chain drive systems on this unit. One from the drive shaft to the rear axle, drive shaft to the center eccentric sprocket and from the center eccentric sprocket to the front wheel axles. I bought this chain set off Amazon for $160 on Dec 2016.
http://a.co/fi1Rre0 Amazon 1995 1996 1997 1998 Polaris XPLORER 400L 4X4 Gold O Ring Chain And Sprocket
1. Loosen lugs, jack up ATV, remove wheels so the ATV is in the air. You really only need to remove the right wheels, but it was better balanced with all 4 off. I had mine on jack stands.
2. Remove rear cotter pin, axle nut and then hub on the right rear side.
3. Remove the bolts that hold the circular steel chain protector and remove.
4. Remove chain. This can be done by finding the master link and removing that or using a cut off wheel on an angle grinder and cutting a link (how I did it).
5. Remove 3 bolts that hold the rear sprocket on and remove sprocket.
6. Install new rear sprocket in the reverse order.
Drive Shaft Sprockets (2 of them)
7. I removed the black plastic right foot well. This will give access to sprockets, brake and chain.
8. Put parking brake on and loosen bolts on the end of both sprockets. Take off parking brake
8. Remove mechanical rear brake foot linkage
9. Remove rear brake cylinder by loosening 2 bolts. Somewhere in here is a "C" clip on the driveshaft you need to remove and save.
10. Remove the drive shaft sprocket (small) and mid sprockets (larger on right). You may need to remove the chain first. Either master link or cut off wheel.
11. Remove drive shaft sprocket and brake disc. Mark brake disc outside/inside (don’t get grease on this)
12.Now you will see the inside sprocket that the rear wheel chain goes to. Remove two bolts that hold the silver bushing part on and slide off. This will give you a large hole in the frame for removing the inner sprocket but it will not come out. It will get caught on this orange bushing in the picture.
13. You need to use a thin wrench and hold the nut beside the orange bushing and take this bolt out. I used a 24mm wrench pushed up from the bottom and a socket on the opposite side of the bolt. There is a black plastic chain track you need to wedge the wrench along side.
14. Once this bushing is out of the way, the sprocket can come out. Mine hit the frame was a 1/16" too high. I wacked the drive shaft with a rubber hammer while pulling the sprocket and it popped out the hole in the frame.
15. Reinstall 2 sprockets is the reverse. The picture above shows it after with new parts. Make sure to grease the orange bushing and the silver drive shaft bushing. Both have grease fittings.
