1996 Sportsman 400 4X4
Boy howdy! My name is Ben and I am from eastern NC. I am active duty on Ft Carson in Colorado. I recently came across a Sportsman 400 in sorry shape. After a few minutes, I got it to crank and fire, but there is no power to the lights. The 12V outlet reads ~13.2V.
Here's the rest of the bad:
Over heats after about 5 minutes
Overflow bottle missing
Drive belt cover got rubbed through by a loose belt
None of the plastic is good
Front drive chain gone
The only brake present and firmly attached is the foot brake. The rest have been removed and lines cut.
I have no clue what fluid to change, drain, use, etc.
This was an air force quad that was given to the Air Force Academy Equestrian Center. It sat for about 10 years because no one had the knowledge base to fix it. Honestly, I don't know where to start. Flush the cooling system first? No clue! I need it to be reliable. It does a few quirky things like shutting off unless you hold the throttle, boggs down and stalls if you give it too much throttle, and slips when it's in gear.
I'll donate the finished product to the wounded warrior guys that can't ride our horses for one reason or another. I could really use some help with this. It doesn't need to be a monster or tricked out, it just needs to work. I'm doing this out of pocket, so the budget isn't huge. Any info and help would be awesome!
Sounds like you have a carburetor to clean and a few parts to replace..... I'd start by replacing all the fluids, cleaning the carburetor and cleaning the radiator fins thoroughly! Than go from there!
Check this link out.... http://gh-ftp.com/ORV%20Manuals/Pola...0%20-%20SM.pdf
2012 POLARIS SPORTSMAN 800 EFI (INDY RED) September 2015 ATV Of The Month
Mods: Polaris 2500HD Winch - Glacier3 60" Plow System - Front & Rear Rack Extensions - Front & Rear Bumpers - LowPro Windshield - Warning Debadge - 3 Way Head Light (Relay) - Rear View Mirror - Kolpin KXP Rhino Double Gun Rack - Madd Dog Chainsaw Holder - Kolpin Rear Seat/Storage Box - Kolpin Fuel Pack Jr - 26" ITP Mud Lite Tires - Front & Rear High Lifter HD Springs
2005 POLARIS SPORTSMAN 400 (SONIC BLUE)
Mods: Warn 2500 Winch - Polaris Hand Guards - WES Ind. Rear Seat/Storage Box - Shift Interlock Delete - Rear View Mirror - Front & Rear Bumpers - 25" Kenda K590 Tires - PVC Spring Spacers
Son's: 2012 TaoTao 125D (BLUE/BLACK)
2014 POLARIS RZR 570 EFI EPS LE TRAIL (WHITE LIGHTENING)
Mods: HF Badland 3500 Winch - MotoAlliance Winch Mount - Polaris Sport Roof - 1/2 Windshield - Warning Debadge - Rear View Mirror - Seat Adjuster - 26" Maxxis Tires
Sounds like you really have your hands full. Just know that before you begin this project it is likely that you will exceed the value of the machine. I'm not discouraging, I'm realistic.
That being said...
I don't know many fluids that stay reliable for a decade. Drain them all and refill.
The overflow tank is not a must have at this time but can be picked up fairly cheap.
My guess on the lights being blown is that someone ran it with either a dead battery or battery disconnected. This will cause it to put out in excess of 20 volts and blow any bulb that is on (highs, lows, indicator bulbs, brake light, 4x4 indicator).
Majority of the "quirky" things you described sound like they are being caused by the carburetor. It's a bit tedious but the carb needs to be thoroughly dissected and cleaned with brake cleaner.
For their age, those plastics seem to be in fairly amazing shape if you ask me. There are a number of products that you can buy at your local auto parts store to improve them further (search "plastics" on your homepage).
Over heating is usually caused by a stopped up radiator. Disconnect it and soak it over night. Then gently spray out whatever is compacted in there. Be careful not to bend the veins!
The other parts can be picked up on eBay as a lot or there are several guys on here that have a pile of parts for these older machines.
I hope I've been of some assistance.
Good luck on your build.
'14 scrambler XP 1000
32" Silverbacks on SS wheels
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'96 Sportsman 400L
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Marshall Racing chains
Sunstar/ custom sprockets
HPD Oil injection block off
4 alpine 6.5" in fiberglass boxes
2" High Lifter kit
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