Hello all. A western New York grumpy old diesel technician (fancy for mechanic) here. I have recently made my first ATV purchase. It’s a 1996 sportsman 400 4x4 two stroke. It really was owned by an grandpa that only drove it on weekends. After 25 years of moderate use it needs some attention and a few new pieces. Hopefully you all don’t get tired of my questions. I have no owners manual so I don’t have any other place to look for answers. It’s not a Cat or Deere diesel so I’m a little lost. Anyway thank you in advance
From one grumpy diesel guy to another, welcome. Just so happens I sold my 94 -400 about 10 months ago. Had it for 20 years. You came to the right place.
The first thing I would do is change the oil in the counter balance. If you take the seat off, stand on the right side, with a flash light, look down as fare as you can. You will see a knob that has a s crew driver slot. That is the counter balance dip stick. VERY Important!
Oldhunter1 fluid changes are on my list. I’m sure it’s been many years since it was done. I was planning to start a post in the correct thread to ask about fluid types I need. I also have one hub that makes not so nice noises when engaging the awd. Drive chains need to be replaced also. A few little things and it should serve my intended purpose just fine. I’m getting too old to be dragging deer out of the woods by hand. Although I feel it’s part of the hunt it just hurts too much anymore
Polaris Demand drive fluid in the front hubs, Polaris agl in the front gear case (more commonly known as a diff although that’s incorrect) Polaris agl in the transmission which Is pretty much another gear case. Atf can be used in the front hubs and a regular 80-90 gear oil can be used the the gear case and transmission although I recommend running the Polaris stuff.
There is drive chain , o ring style, on ebay. For the front hubs, pry off the rubber cap to drain them, and flush them a little with parts cleaner. Uptake out the 1/8 inch pipe plug to refill with ATF. Fluid should be at the 4 o clock position.
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