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Discussion Starter #1 (Edited)
Hi all, I recently picked up a 99 Xplorer 400 4x4 for a few hundred bucks due to the amount of work it needs. Overall it seems to be in good shape with nothing bent, minimal rust, plastics are good, etc. The main issue is that it won't go into gear. I've read on here and other forums about the multiple reasons that can happen and have a list going of things to start looking into. There are a few things about this model that I'm not clear on and searching the forums and repair manuals haven't cleared it up for me.

#1 - I don't see a radiator or fan. I have seen some references to the 400 and the 400L. Am I right in assuming that the 400L is Liquid Cooled and the 400 is Air Cooled? If correct and mine is Air Cooled, am I missing a fan? I do see a two wire plug hanging from the top near where I would expect a fan to be located.

#2 - The air vent tube going into the clutch is very lose and I've seen where there is a coupler in the manual and I'll see if I can find that part. The other end of that air vent just curves down and is open. That seems like it has the potential to let in a lot of dirt/dust. Is there supposed to be some sort of air filter there? Edit: based on a diagram I was just looking at this is the output, so I guess no filter needed, but I'm not seeing the input, maybe that is what I mention in #4?

#3 - The engine fires up immediately and runs strong. I have noticed that I get a few large drops of oil right under where the exhaust pipe connects to the exhaust manifold. I've only had 4 stroke ATVs in the past. Is this typical of a 2 stroke?

#4 - At the front of the engine I see a hole that looks like where a radiator hose or maybe an air filter might connect. I attached a picture of it. What am I missing there? Maybe my engine is liquid cooled and a previous owner removed the whole system?





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I question the year you say you have - all the 400's I checked in 1998, 1999 & 2000 were liquid cooled. What is the VIN or serial number of your quad. The pic you posted is of an air cooled engine, thus no radiator or cooling fan.

The first reference to an Xplorer 400 I could find was 1995 and it was a liquid cooled 400 - I'm betting you have a 250 or 300 4x4

Find that VIN or model number, post it and I can help verify what it is that you have.

A little oil from the exhaust is fine.
 

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Discussion Starter #3
The guy I bought it from said it was a 2004 but he also said he wasn't positive and the previous owner wasn't sure either. I will look up the VIN as soon as I get home from work and post it here. I started thinking it was a 1999 because the transmission has a label on it with model #1341273 and serial #99-10980. When I searched that online I found references to 1999.

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The model # on the transmission is the part # - 1341273 was originally used on 1999 and 2000 Xplorer - what you have is a 1999 Xplorer 300 or 2000 Xplorer 250 air cooled or a different year model depending on the VIN or serial # you find embossed on the frame
 

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By the VIN you have a 2000 Xplorer 400 frame, but I cannot find an air cooled 400 on any search - can you find any numbers on the engine?
 

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Discussion Starter #7
What part of the engine might have the numbers on it? I see a few on a label on the pull start.

Here's a video of it. Let me know if there is another angle or close up that would help.


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Discussion Starter #8
I can't find anything online about an air cooled 400 in the xplorer either. I am starting to wonder if a previous owner pulled the original engine and replaced with a 300 or 250 air cooled.
 

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Nope, its a stock machine guys...2000 Xplorer 2 stroke air cooled. Its supposed to have a cooling fan on it but not radiator or oil cooler. :gruebel:

2000 ATV XPLORER - A00AG25CA

Here's the "cooling system" (fan) and the engine mounting diagrams. Number 7 in the engine pic is the 260* temp switch on the engine mount to turn the fan on.
 

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Discussion Starter #10
I'm a little confused. Are you saying this is an air cooled 400? Or are you thinking it's a 400 frame and all other parts but with a 250 engine?

The sticker under the headlight is long gone but the discoloration from it remains and is clear enough to show it said 400.


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Hey pman - I think you are wrong - according to my info, the 2000 250 has these dimensions:
Displacement 244 cc - Bore 2.8346" (72mm) Stroke 2.3622" (60mm)
The 400 these:
Displacement 378 cc Bore 3.2677" (83mm) Stroke 2.7559" (70mm)

The piston part numbers are 3083942 and 3085886

I can't figure out how you deduced that the 250 and the 400 used the same piston?
 

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Hey pman - I think you are wrong - according to my info, the 2000 250 has these dimensions:
Displacement 244 cc - Bore 2.8346" (72mm) Stroke 2.3622" (60mm)
The 400 these:
Displacement 378 cc Bore 3.2677" (83mm) Stroke 2.7559" (70mm)

The piston pare numbers are 3083942 and 3085886

I can't figure out how you deduced that the 250 and the 400 used the same piston?
Yeah latebird I kept thinking that something was just not right about what I was coming up with. I was just hitting the "usage" button for the standard size piston on the parts catalog and the results weren't adding up. I'm not sure if the catalog is wrong or I did something wrong but it wasn't making any logical sense. I should probably delete my posts since it must be bad information.
Did you find the machine I was talking about?
It appears to have the same engine as the 250 Trail Blazer but I don't know if I can trust this Parts catalog now lol. :pat:
 

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Sorry for the confusion guys. I cleaned up my posts and am going to see if I can figure out what's up with my info source.
 

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Here's a cross reference for the short block and it appears to have the same 250 engine as the TB.
Must just be a mistake in the catalog when I was getting the Sport popping up on the pistons.

3084717

Year
Product
Model
Assembly

2004
ATV
A04BA25CA TRAIL BLAZER
ENGINE MOUNTING - A04BA25CA/CB (4986208620A07)


2003
ATV
TRAIL BLAZER 250
ENGINE MOUNTING - A03BA25CA/CB (4975037503A07)


2002
ATV
TRAIL BLAZER
ENGINE MOUNTING - A02BA25CA/CB/CD (4969896989A07)


2002
ATV
TRAIL BLAZER FREEDOM
ENGINE MOUNTING - A02BA25CA/CB/CD (4969896989A07)


2002
ATV
XPLORER 4X4
ENGINE MOUNTING - A02CG25CA (4969856985A07)


2001
ATV
XPLORER
ENGINE MOUNTING - A01AG25CA (4963866386A007)


2001
ATV
TRAIL BLAZER
ENGINE MOUNTING - A01BA25CA (4963666366A007)


2001
ATV
TRAIL BLAZER
ENGINE MOUNTING - A01BA25CA (4963666366A007)


2000
ATV
XPLORER
ENGINE MOUNTING - A00AG25CA (4954865486A009)


2000
ATV
TRAIL BLAZER
ENGINE MOUNTING - A00BA25CA (4954825482A009)


1999
ATV
TRAIL BOSS
ENGINE MOUNTING - A99AA25CA (4949594959a009)


1999
ATV
TRAIL BLAZER 250
ENGINE MOUNTING - A99BA25CA (4949574957a009)


1998
ATV
TRAIL BLAZER
ENGINE MOUNTING Trail Blazer W98BA25C (4945464546A009)


1998
ATV
TRAIL BOSS
ENGINE MOUNTING Trail Boss W98AA25C (4945314531A009)


1997
ATV
SPORT 400L
ENGINE MOUNTING (BLAZER) Trail Blazer W97BA25C (4940124012A010)


1997
ATV
TRAIL BLAZER
ENGINE MOUNTING (BLAZER) Trail Blazer W97BA25C (4940124012A010)


1997
ATV
TRAIL BOSS
ENGINE MOUNTING Trail Boss W97AA25C (4940574057A009)


1996
ATV
SPORT 400L
ENGINE MOUNTING (BLAZER) - W967827 (4935863586A010)


1996
ATV
TRAIL BLAZER ES
ENGINE MOUNTING (BLAZER) - W967827 (4935863586A010)


1996
ATV
TRAIL BOSS
ENGINE MOUNTING Trail Boss W968527 (4935883588A009)


1995
ATV
TRAIL BLAZER
ENGINE MOUNTING Trail Blazer W957221 (4930363036A009)


1995
ATV
TRAIL BOSS 250
ENGINE MOUNTING Trail Boss W958527 (4930323032A009)
 

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Using the info on the engine my research identifies the engine as a 2005-2006 Trail Boss 250 - here's the text from the service manual:
MODEL: . . . . . . . . . . 2005--2006 TRAIL BLAZER 250
MODEL NUMBER: . A05BA25CA/CB / A06BA25CA
ENGINE MODEL: . . EC250PFE154

I now believe it's a 2000 Xplorer 400 frame with a 05-06 250 air cooled engine
 

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Discussion Starter #16
Thanks for all the research and input. I've looked all over the engine and don't see any numbers or markings on it for identification. I guess I won't worry about it for now since the engine is running without issue. I ordered the fan, mount, and heat switch on eBay. I plan to pull the transmission next weekend and see what's going on inside it. I'm thinking the shift forks and/or dog gears are bad.

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plus there should be a fan just in front of the engine. there is also a thermocouple on the frame. if you have a manual it will show you where it is under cooling.
 
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