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Discussion Starter #1
Hello, new here and could use some advice. I am working on my brothers 2012 Ranger 400 that had the oil filter come loose while running. Engine was shut down while still running, but wouldn’t restart. Checked compression and was only 30psi so I pulled the head and cylinder and it’s badly worn. No play in connecting rod to lower end and the head looks good so I want to put in one of the top end piston/cylinder rebuild kits. The issue is there don’t seem to be that many aftermarket kits for the 400 compared to the 500. Do the 500 kits fit the 400 engines so you end up with a 498cc carbureted engine? With only 43cc difference it seems like they might. Can anyone recommend where to get a good top end kit for the 400? I see some 500 kits on eBay that say they fit the 400, but others do not. Any advise on this is appreciated. I mostly work on old tractors so I’m not up to speed on the good/bad websites for Polaris parts.

What is a legit site to download the service/shop manual PDF? I need to get one but don’t want to be scammed.

Thanks!
Dan
 

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Here's whats known:

The crankcase (part number 3089240 ) is the same for the 400, 450 and 500 98-14
The cylinder head (part number 3090038) is unique to the 400 08-14

Just based on that, it is possible to make the 400 into a 450 or 500, but you will need the correct head, exhaust, intake and possibly need to change the cam chain and cam chain tensioners.

If you got the time, go for it.

You can use service manual 9923134 (2011 400/500 Ranger) or 9923511 (11-12 400/500 Ranger) - there is nine 9923134 printed copies on Ebay from $39.88 to $99.99 and two 9923511 in print for $89.99 and $108.88 plus shipping.

You can download a PDF version from emanualonline.com for $21.99
 

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Discussion Starter #5
Here's whats known:

The crankcase (part number 3089240 ) is the same for the 400, 450 and 500 98-14
The cylinder head (part number 3090038) is unique to the 400 08-14

Just based on that, it is possible to make the 400 into a 450 or 500, but you will need the correct head, exhaust, intake and possibly need to change the cam chain and cam chain tensioners.

If you got the time, go for it.

You can use service manual 9923134 (2011 400/500 Ranger) or 9923511 (11-12 400/500 Ranger) - there is nine 9923134 printed copies on Ebay from $39.88 to $99.99 and two 9923511 in print for $89.99 and $108.88 plus shipping.

You can download a PDF version from emanualonline.com for $21.99
Thanks for the info. I'm not looking to increase the bore, just fix it as a stock 400 so I am looking for a direct fit 400 kit. There are a few kits on Ebay that claim 'will fit' a ranger 400. I hope that they mean they work with the stock head.

Thanks for the link to emanualonline.com
 

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So many choices.....
 

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Discussion Starter #9
400 cc Sportsman, Ranger and Hawkeye all use the same engine
The easiest to look up on ebay or elsewhere is likely to be listed for a Sportsman but I don't know that for sure.
Here's a quick search results for a 400 Ranger
400 ranger top end cylinder | eBay
Thanks, it's helpfull to know what other machines used the same engine.
Looking at that Ebay listing, most don't fit the ranger 400. I have been searching ebay and searching for the 400 seems to bring up a lot of kits for the 500 instead.
 

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Well, you sorta seemed to asking about a complete kit and there aren't many available at a reasonable price.
If it were me and depending on how bad the cylinder is, I'd probably just get a Namura top end kit about 1mm oversized and send the cylinder and piston to U.S. Chrome to have it bored and the new piston fitted. The top end kit + boring and shipping should cost you around $250 + time.
 

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Discussion Starter #11
Well, you sorta seemed to asking about a complete kit and there aren't many available at a reasonable price.
If it were me and depending on how bad the cylinder is, I'd probably just get a Namura top end kit about 1mm oversized and send the cylinder and piston to U.S. Chrome to have it bored and the new piston fitted. The top end kit + boring and shipping should cost you around $250 + time.
Yes, I was hoping I could just buy a matched cylinder/piston kit. It doesn't look like the aftermarket supports the 455cc 400 engine as well as it does the 498cc 500 engines when it comes to top end kits.
 
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