1994 Polaris 400 Sportsman Engine Problems

[outlander560]

Hey guys i recently picked up this 94 polaris for real cheap it ran but barely..their are many problems i need your guys help figuring out.

1.)when the atv is put into reverse the engines rpms start slowing down and the engine starts clunking and begins to shake, then it dies i dont understand why it does this?

2.) the engine rocks back and forth a lot? is their anything beside the motor mounts that i should check?

3.)even though it is shifted into reverse it does not engage..is this something that just needs adjusting?

4.) I took the exhaust off and realized that the previous owner broke one of the bolts holding the exhaust to the engine how could i get this bolt out? should i take the engine apart?

5.) The engine is covered in oil and grease could that all be because of the exhaust barely staying on? or is their something worse that i should worry about

[Stoopidbot1]

It is very possible that the exhaust leak is responsible for the motor being covered. Is there a portion of the bolt sticking out or is it flush with the motor. Other than the mounts, I don't know what you would check for the motor moving.

I can't really help you on the other questions.

[BuckBilly]

Is there a reverse over ride button mounted on the left side of the handle bars??

[outlander560]

yea theirs a very small portion of the bolt sticking out...im thinking a pair of vice grips would help with that problem...and BB yea their is a reverse over ride on the left side of handle bars

[Stoopidbot1]

You could either try vise grips or try to make a notch on the end of the stud. Then try a flat head screw driver.

[BuckBilly]

Is there a reverse over ride button mounted on the left side of the handle bars??

Do you use the button when backing up.

[outlander560]

i havent been able to get it to go in reverse...once i try putting it in reverse the engine rattles then dies on me

[outlander560]

You could either try vise grips or try to make a notch on the end of the stud. Then try a flat head screw driver.

the notch with the dremel is a good idea thanks BOT

[Ajmboy]

You should GUNK that motor and see where the oil is coming from.

I like BOTS idea, if that does not work, get someone to weld a 1/2 inch nut to the broken bolt, or drill the thing out enough to get an easy out bolt remover in there.

Have you checked the oil level?

[outlander560]

thanks..um i did check the oil level and it was a little high..so that could be the problem

[DirtDemon]

1. inspect your clutch assembly, ignition timing, and carb.

2. check the mounts, ignition timing and carb.

3. again, the clutch.

4. if none of the other suggestions work, drill a hole in the stud and use an easy-out, make sure to use plenty of penetrating lubricant, i recommend PB Blaster, also, a sharp rap on the stud with a hammer before you attempt to remove it may help shock the threads loose.

5. fix the ehaust and go from there, keep in mind, if it is actually oil on the motor and not just carbon buildup, and it is coming from the exhaust leak, that indicates that you are getting oil in the combustion area, which is an indication that you may have worn piston, rings, cylinder bore or valves.

[ATVmechanic]

Do you use the button when backing up.

You need to hold the reverse override button, are you doing that when engaging reverse?

[outlander560]

i have not gotten it to engage in reverse

[DirtDemon]

Find the actuator, and test it manually by applying voltage directly to the leads. If it does not respond replace it, if it does, inspect the circuit that operates it, look for loose or broken connections/wires and check any grounds. Fuses?

[pachm]

check you belt, i have the same quad and it did the same thing, the belt was wore down and grabbing all the time.

[outlander560]

really? the belt i have on it is a little stretched...did u go with an oem belt or an aftermarket belt?

[pachm]

i tend to go with oem parts some aftermarket belts are made of a harder material and wear into the clutch sheaves

[outlander560]

alright good to hear..thanks for the info

[outlander560]

You need to hold the reverse override button, are you doing that when engaging reverse?

when i hold the button down and then engage it in reverse the engine stops sputtering but it still does not engage.. i really have to slam it in reverse for it to go

[fireman2828]

Any updades on your quad?

[outlander560]

yea i have done some engine work but still having problems with the reverse. have u checked out the project room i have been updating photos of the project and its coming together pretty good...today i just mounted the front dirt devil tires on the rims,replacing the really old stockers. and i just placed an order for a whole bunch of parts...