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Old 05-15-2010, 06:09 PM
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My repair weekend ( long)

So 2 years ago I buy a 95 Scrambler 400 4x4 for my son to ride. It had bad wheel bearings and wasted caliper. Bought it cheap and brought it home. Could not start it there because battery was dead and pull rope broke. Bought a new rope and used front hub with rotor and caliper. Spent a weekend fixing it. Started it up and put new battery in it. Turns out starter is bad or at least the bendix. Starts and runs OK. Drive it around the yard and up and down the street. I live in the country so it is not an issue. Seemed OK. Last fall loaded it on the trailer with the rest and headed to the Badlands off road park. After 20 minutes of running it gets hot and cooling fan does not work. I had brought my son my nephew and one of my sons friends with. Let my son ride the 500 and I stayed back at the trailer and tried to fix the overheating problem. An hour later the friend rolls his and ends our day. Unload the quads to put in the shed. The 400s transmission locks in reverse and shift rod breaks Went riding with some friends 2 weeks ago and just left that one to fix later. I find a twin on Craigslist with blown motor. I buy it and spent the last 3 nights swapping the trans, rear axle(bent) the cooling fan, and starter motor. First road test it quits, Ran out of gas. Tow it back with the 500. Second road trip it quits like ran out of gas. Cleaned the petcock and I drive it this time, ( a friend was driving it first two times. So he follows me with the 500. It is now running great! I get back and second friend is pointing back and saying the other on is sitting on the road! Ride back and ask what happened. I have owned this for 10 years and this is only the second time it let me down. He said he heard a terrible noise and now the engine wont turn! I said the engine blew? He wasn't sure. Looked down and it had blown the belt and wrapped around the clutch Towed it back and pulled it apart. Clutch is broken and belt is everywhere. 2 weeks earlier i pulled another friend out and must of got the belt hot. I guess there was as good a place as any to blow. Turns out I was on borrowed time with this clutch. The sheaves were worn badly. I had a new on in stock, it was given to be for some work I did 8 years ago. Also had one new belt left. It is back together and pulls much harder. Going to order some clutch secondary buttons and change them all next. How is your weekend going?
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Old 05-15-2010, 06:16 PM
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WOW I got a fleet of mine own to keep up with. glad I havent had a weekend like that !!!
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Old 05-15-2010, 06:20 PM
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Your story reminds me of the days when I had a 1987 Polaris 250 Trail Boss...and a 1989 250 Trail Boss. These 2 stroke wonders got a lot of use...and run flawlessly one you got them running and warmed up. But after sitting all winter....they were always hard to start...broken pull cords....broken springs in pull cords....bad gas...even with "Stable" put in. I cant count the carb issues over owning 2 of them for 20 years.. They were still alot of fun, and went a lot of places. I must admit, that I now enjoy the Polaris 800 EFI... that starts at -40C with no problem. I can see that I will not enjoy replacing some CV Boots.....but all in all...the sport is well worth the issues we face. Ross
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Old 05-16-2010, 05:13 AM
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400 wont start , Time to pull the car and clean. When does it end?
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Old 05-16-2010, 05:38 AM
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Sounds busy to me, haha. I'm sure you will get this issues resolved and have many weeks of no problems.
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Old 05-16-2010, 06:11 AM
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I decided to try to figure out why my foot brake doesn't do anything. While I was down there looking around I noticed my pull start cover is missing over half of the bolts that hold it on. I tried to find a match at the hardware store but the ones I got aren't the right thread.
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Old 05-16-2010, 09:15 AM
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i just spent the last 2 weeks chasing down problems on my magnum + engineering 3 inches of lift for it ..and rebuilding my wifes xplorer so right now both my polaris are up and running(still working bugs out of xplorer)...but i still have my daughters 220 kawasaki to finish ...so i took this weekend off from wrenching and did some much needed riding!
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Old 05-16-2010, 10:12 AM
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Carb is clean and it runs great. Bring on them trails. Next project is to make a tandem axle boat trailer into a 4 or 5 quad trailer.
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