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1995 Polaris Sportsman 400 4x4 Honed Cylinder
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By Brian Sosebee
I just rebuilt my 03 sportsman 400. Put everything back together added oil per the manual. Pinched off the oil tank vent line 2" away ran for 45 seconds then cut it off. Check oil level and it was still way high so I wasn't confident that it primed so I did it again. Checked again and it's the same. Remove the oil filter and it is dry. I did the procedure again and the same results.
I'm worried to keep trying this as the only oil in the engine is what I used to lubricate the parts when reassembling the piston. The crankcase was drained as well.
I Removed the oil tank and checked all the lines for obstructions and the screen filter and the vent hose and everything is clear. I even pulled a small vacuum on the oil tank while it was pulled off to make sure there were no leaks. The dipstick cap was on tight so I'm not sure why this thing is not priming.
Anyone have any suggestions. I thought about pre-priming the oil lines from the oil tank to the crankcase to hopefully help the system prime. I'd like to be able to add some oil to the crankcase to so I wouldn't feel so bad about running the engine for another 60 seconds without oil. I dropped just a little bit of oil in the spark plug hole to help condition the sleeve right now.
What do I do? Anyone had or heard of an oil pump failure on these. Btw oil pump is working fine before I did the top-end rebuild and the oil pump was not touched.
Please help!!! Thanks all for any and all help.
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By bren7176
What would be the compression on a 1995 Polaris sportsman 400 4x4 ?? Have one in great shape plastic is almost like new and the engine only has 90 psi which I figure is Capulet ...
brendan
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By colin james
2012-2014 Sportsman 400/500 factory service manual
View File This is the factory service manual for multiple models of the years 2012-2014 sortsman 400/500 including hd edition's.
Submitter colin james Submitted 08/13/2019 Category Polaris ATV
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By colin james
This is the factory service manual for multiple models of the years 2012-2014 sortsman 400/500 including hd edition's.
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By Resurgence Small Engine Inc.
In this video, Jonathan describes how he cleaned a Nikasil plated cylinder.
Aluminum cylinders are often coated with a harder material such as Nikasil (Nickel Silicon Carbide). Over time, the softer aluminum of the pistons can rub off onto the cylinder. When rebuilding the top-end, this should be cleaned off.
This can be done using hydrochloric acid which reacts with aluminum to produce hydrogen gas and aluminum chloride, which washed off with water. Since Nikasil is resistant to corrosion, it is undamaged and protects the cylinder during this process.
Here is the chemical reaction:
2 Al (s) + 6 HCl (aq) → 2 AlCl3 (aq) + 3 H2 (g)
Resurgence Small Engine Inc.
ATV, Snowmachine, Motorcycle, & Outdoor Power Equipment
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Similar Topics
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By Fittzy
So I have a Polaris predator 500 and everything works on it but not getting spark and no power going to CDI box. Please help
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By Hodadical
I've inherited a 1995 Lakota 300... it has the knob in the center of the handbar to twist to go into reverse, but I've notice when downshifting, you don't have to have the knob turned, it will shift right past neutral and into reverse which is a little dicey if not all the way stopped. I followed the linkage back and twisting the knob seems to actuate the lever on the outside of the trans, the internals just don't seem to care about this.
What is the likely problem and how back is it to get to? I've never been inside of one of these transmissions.
TIA,
-Rob
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By chimmike
Anyone know where to locate these, or generics? The generics I seem to find have the mount on the wrong side versus the hose outlet. PITA!
Also, is the rear master cylinder rebuild kit any good?
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By Sandbox
What all is included in the normal maintenance service of the Polaris ranger 1000 Xp ? My neighbor wants to service his machine and says he has a “kit” for it , oil change. Are there any hidden grease fittings? Pitfalls?
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