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By 97kingquad
I have been rebuilding some ATVs in my spare time and teaching myself along with the help from the internet how an engine works and getting bikes running again is quite enjoyable. I even built an arctic cat 300 4x4 from two parts bikes the had seized motors and missing parts. It was pretty enjoyable.
So I am now working on a sazuki quadrunner 300 1992 which had a whole list of issues when I got it. I have fixed almost everything I need to in order to get this bike running. But something is going on inside the head or crankcase.
I had to replace the timing chain because it was very stretched due to the previous owner.
What the issue was, the timing chain was off the sprocket inside the engine due to it being stretched it slipped off. So the previous owner rebuilt the top end thinking it would fix it which it may have temporarily, but when doing so they welded an extra inch onto the tensioner to hold the chain tight. Which as you can imagine caused a dozen other issues.
So that stretched the chain to the point where I could remove the cam with the tensioner in.
It beat the sliders all to hell. Destroyed the cylinder housing and obviously ruined the tensioner.
I didn't realise all of this until after I rebuilt the engine. I noticed wear where the timing chain runs through the cylinder. I found the cam had no retaining chair, or clip whatever you want to call it so the cam was beat to sh** also. It had almost an inch of play side to side.
So I pulled the head off of my parts bike and fixed all of it. Then put it together and went to pull it over and found it was not on the sprocket (this is when I realised that all that damage and the welded tensioner was because the timing chain had been off the sprocket)
So I pulled the stator cover off and pulled the flywheel (which I should add to get at the stator cover I have to remove the rear tire and a arm as well as remove the bolt through the front of the engine. And the exhaust system has to be removed to pull the cylinder as the exhaust guard is bolted to the side of the timing chain tensioner. Stupid setup. Glad the king quad doesn't have that.
So I got everything apart and the flywheel off. New timing chain (nice and tight now) put the head back together and flywheel but it is quite hard to turn the engine over. I can but with difficulty. When the valve cover was off it seemed to spin much more freely. Before I tear everything back apart and start again any ideas on what it is?
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By Gwbarm
Im finishing up on the Big Bear, just tying up some loose ends and its done.
My next project I actually bought first, but the Big Bear seemed like it was more challenging so tackled it first. Now looking the Eiger over im not so Sure.
I bought this Suzuki Eiger, almost a year ago, rear wheels locked up, but it ran fairly well. It was so bad that it took 3 Big Guys to get it on my trailer. All the parts were there it ran. He wanted 600.00 and I offered him 400.00. a plus it had the original Kei Hin carb on it.
You might ask, why would you want something so ugly, it is often referred to as the ugly sister to the King Quad. I actually like the Eiger I have this one and also a 2007. I have riden them before, they are strong a true beast, I am a fairly Big Guy 6' 3" 195 pds, and it fits me good, but what I really like is the wide foot print and low center of gravity , not so easy to turn over.
So I get it home and I don't have 3 big guys to help me get it off my trailer, but I do have a John Deere, hooked it up and drug it off the trailer,an afterthought I should have used a couple of furniture moving dolly's under the rear wheels, oh well. Maybe I didn't ruin the already stuck rear end or transmission I was sure which, I was fairly sure it wasn't locked brake drums, after all that they should have popped free.
This is what I have done so far. It's off the trailer I took the drive shaft bolts loose, they were tight, had to get a 3 foot cheater, I thought they were going to break. Got them out and now I can roll it around. I checked the shifter, this is a manual shift Eiger LTF400F. Foot shifter moved didn't seem to be going to any gear, but it was hard to tell, the shifter on the tank which has Low, High, and Reverse did not move. I took it apart and oiled it up good still wouldn't move. Thought the cable was stuck so I unhooked it from the linkage and cable moved freely. Looked at the linkage closely and it was stuck. I tapped it lightly, very lightly , with small hammer and it freed up kind of, but still stiff. I could tell this side cover had been off before and put back very sloppily. This is kind of where i left off except the plastics are all off, you might have seen me working on them in another post. Nothing I have done so far has helped, my next step was to take the side cover off the engine to see what's going on in there, but installing my Granite counter top, numerous honeydews, and the big bear kind of slowed down my progress. I did determine that it wasn't the rear end, that's actually what I thought it was going to be. If anyone has any ideas, they would be appreciated.
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By GatorHunter
Clymer ATV Manual - Polaris ATVs
You can also find ATV Manuals on Amazon.
Here is my list, some I have had, some I got online
I have put all Manuals on my dedicated server, so the links won't go dead. Most the manuals listed below are on the server and there may be some on the server that's not on the list. Scroll to the bottom of this post to get the link.
If you need a Manual that's not on the list, leave a reply, I will try to locate it, if I can't, I'm sure another member would share if they have it.
If you have manuals that are not in the list and you would like to share them, leave a reply, with a link to your manuals and I will add them to my post so they are all in one spot.
Thank you, and enjoy
GH
1985 thru 1995 Polaris service manual
Below is the list of machines this Manual covers
1985 Scrambler
1985 Trail Boss
1986 Scrambler
1986 Trail Boss
1987 Trail Boss
1987 Trail Boss 4X4
1987 Cyclone
1988 Trail Boss 2X4
1988 Trail Boss 4X4
1988 Trail Boss 250 R/ES
1989 Trail Boss
1989 Trail Boss 2X4
1989 Trail Boss 4X4
1989 Big Boss 4X6
1990 Trail Blazer
1990 Trail Boss 250
1990 Trail Boss 2X4
1990 Trail Boss 2X4 350L
1990 Trail Boss 4X4
1990 Trail Boss 4X4 350L
1990 Big Boss 4X6
1991 Trail Blazer
1991 Trail Boss 250
1991 Trail Boss 2X4
1991 Trail Boss 2X4 350L
1991 Trail Boss 4X4
1991 Trail Boss 4X4 350L
1991 Big Boss 4X6
1991 Big Boss 6X6
1992 Trail Blazer
1992 Trail Boss 250
1992 Trail Boss 2X4
1992 Trail Boss 2X4 350L
1992 Trail Boss 4X4
1992 Trail Boss 4X4 350L
1992 Big Boss 4X6
1992 Big Boss 6X6
1993 250 2X4
1993 350 2X4
1993 250 4X4
1993 350 4X4
1993 250 6X6
1993 350 6X6
1993 Trail Boss
1993 Trail Blazer
1993 Sportsman
1994 300 2X4
1994 400 2X4
1994 300 4X4
1994 400 4X4
1994 300 6X6
1994 400 6X6
1994 Trail Boss 2W
1994 Trail Blazer 2W
1994 Sportsman 4X4
1994 Sport
1995 300 2X4
1995 400 2X4
1995 300 4X4
1995 400 6X6
1995 Trail Boss
1995 Trail Blazer
1995 Sportsman 4X4
1995 Sport
1995 Xplorer 4X4
1995 Scrambler
1995 Magnum 2x4
1995 Madnum 4X4
1996 thru 1998 Polaris service manual
Below is the list of machines this Manual covers
1996 Trail Blazer
1996 Trail Boss
1996 Xplorer 300
1996 Xpress 300
1996 Xplorer 400
1996 Xpress 400
1996 Sport
1996 Scrambler 4X4
1996 Sportsman 4X4
1996 Sportsman 500
1996 400 6X6
1996 Magnum 2X4
1996 Magnum 4X4
1996 Magnum 6X6
1997 Trail Blazer
1997 Trail Boss
1997 Xplorer 300
1997 Xpress 300
1997 Xplorer 400
1997 Xpress 400
1997 Xplorer 500
1997 Sport 400
1997 Scrambler 4X4
1997 Scrambler 500
1997 Sportsman 4X4
1997 Sportsman 500
1997 400 6X6
1997 Magnum 2X4
1997 Magnum 4X4
1997 Magnum 6X6
1998 Trail Blazer
1998 Trail Boss
1998 Xplorer 300
1998 Xpress 300
1998 Sport 400
1998 Scrambler 400
1998 Scrambler 500
1998 Xplorer 400
1998 Magnum 2X4
1998 Magnum 4X4
1998 Sportsman 500
1998 Big Boss 500 6X6
1996 thru 2003 Sportsman 400 and 500, Xplorer 500 4X4 service manual
Below is the list of machines this Manual covers
1996 Sportsman 400
1996 Sportsman 500
1996 Xplorer 500 4X4
1997 Sportsman 400
1997 Sportsman 500
1997 Xplorer 500 4X4
1998 Sportsman 400
1998 Sportsman 500
1998 Xplorer 500 4X4
1999 Sportsman 400
1999 Sportsman 500
1999 Xplorer 500 4X4
2000 Sportsman 400
2000 Sportsman 500
2000 Xplorer 500 4X4
2001 Sportsman 400
2001 Sportsman 500
2001 Xplorer 500 4X4
2002 Sportsman 400
2002 Sportsman 500
2002 Xplorer 500 4X4
2003 Sportsman 400
2003 Sportsman 500
2003 Xplorer 500 4X4
2001 Sportsman 90 service manual
2001 Scrambler 50 and 90 service manual
2001 Sportsman 500 DUSE Parts Manual rev.2
A01CH50AD
2001 Sportsman 500 HO Parts Manual rev.3
A01CH50AA
A01CH50AB
A01CH50AE
A01CH50AK
2001 Sportsman 500 DUSE HO Parts Manual rev.3
A01CH50AF
2001 Sportsman 500 RSE HO Parts Manual rev.3
A01CH50AJ
2001 Worker 500 Parts Manual rev.3
A01CH50EB
2002 Sportsman 6X6 Parts Manual rev. 1
A02CL50AA
2002 Big Boss 6X6 INTL Parts Manual rev.1
A02CL50DA
2002 Sportsman 500 HO Parts Manual rev.4
A02CH50AA
A02CH50AB
A02CH50AE
A02CH50AK
2002 Sportsman 500 RSE Parts Manual rev.4
A02CH50AC
2002 Sportsman 500 DUSE Parts Manual rev.4
A02CH50AD
2002 Sportsman X Parts Manual rev.4
A02CH50AJ
2002 Sportsman 500 HO Freedom Parts Manual rev.4
A02CH50AL
2002 Sportsman 500 PSE HO Parts Manual rev.4
A02CH50AM
2002 Sportsman 500 Parts Manual rev.4
A02CH50AN
2002 Desert Sportsman 500 Parts Manual rev.4
A02CH50FA
2002 Worker 500 Parts Manual rev.4
A02CH50AAEB
2002 Sportsman 700 Parts Manual rev.2
A02CH68AA
A02CH68AB
A02CH68AC
A02CH68CA
A02CH68CB
2002 Sportsman 700 service manual
2003 Sportsman 6X6 Owners Manual
2003 Sportsman 6X6 Parts Manual rev.1
A03CL50AA
2003 Sportsman 6X6 service manual
2003 Sportsman 400 and 500 HO service manual
2003 Sportsman 400 Parts Manual
A03CH42AA
A03CH42AB
A03CH42AC
2003 Sportsman 500 HO Parts Manual
A03CH50AA
A03CH50AA
A03CH50AA
A03CH50AA
A03CH50AA
A03CH50AA
2003 Sportsman 600 and 700 Owners Manual
2003 Sportsman 600 and 700 service manual
2003 Sportsman 700 Parts Manual rev.4
2003 Predator Parts Manual rev. 1
A03GJ50AA
A03GJ50AB
2003 Trail Boss 330 service manual
2004 Sportsman 6X6 Parts Manual
A04CL50AA
2004 Sportsman 6X6 Owners Manual
2004 Sportsman 6X6 service manual
2004 Sportsman 400,500,600 and 700 Owners manual
2004 Sportsman 400 Parts Manual rev.1
A04CH42AA
A04CH42AE
A04CH42AG
2004 Sportsman 400 Parts Manual rev.1
A04CH42AQ
A04CH42AT
A04CH42AV
A04CH42AS
A04CH42AR
2004 Sportsman 500 Parts Manual rev.1
A04CH50AA
A04CH50AC
A04CH50AE
A04CH50AG
2004 Sportsman 500 Parts Manual rev.1
A04CH50AO
A04CH50AQ
A04CH50AR
A04CH50AS
A04CH50AT
A04CH50AV
A04CH50AW
2004 Sportsman 600 Parts Manual rev.2
A04CH59AF
A04CH59AH
A04CH59AJ
A04CH59AT
A04CH59AV
2004 Sportsman 600 Parts Manual rev.1
A04CH59AK
A04CH59AL
A04CH59AN
A04CH59AW
2004 Sportsman 600 and 700 service manual
2004 Sportsman 700 Parts Manual rev.2
A04CH68AC
A04CH68AF
A04CH68AH
A04CH68AJ
A04CH68AT
A04CH68AV
2004 Sportsman 700 Parts Manual
A04CH68AK
A04CH68AL
A04CH68AN
A04CH68AO
2004 Sportsman 700 MV Parts Manual
A04CH68MB
2004 Sportsman 700 MV service manual
2004 Ranger 2X4 Parts Manual
A04RB42AA
2004 Ranger 4X4 Parts Manual
A04RD50AA
2004 Ranger 6X6 Parts Manual
A04RF50AA
2005 Sportsman 6X6 Parts Manual
A05CL50AA
2005 Sportsman 6X6 Owners Manual
2005 Sportsman 6X6 service manual
2005 Sportsman 400,500.600 and 700 Owners Manual
2005 Sportsman 400 Parts Manual
A05MH42AB
A05MH42AG
A05MH42AH
2005 Sportsman 400 and 500 service manual
2005 Sportsman 500 HO/INT'L Parts Manual
A05MH50AB
A05MH50AC
A05MH50AG
A05MH50AH
A05MH50FB
2005 Sportsman 600 Parts Manual
A05MH59AK
A05MH59AN
2005 Sportsman 700 Parts Manual
A05MH68AK
A05MH68AN
2005 Sportsman 700 EFI Parts Manual
A05MH68AC
A05MH68AS
A05MH68AU
A05MH68AW
2005 Sportsman 700 EFI and 800 EFI Service Manaul
2005 Sportsman 800 EFI Parts Manual
A05MH76AC
A05MH76AU
A05MH76AW
2005 Sportsman MV7 Parts Manaul
A05MH68AP
2005 Sportsman MV7 service manual
2006 Outlaw 500 service manual
2007 Sportsman 6X6 service manual
2007 Sportsman 450 service manual
2007 Sportsman 500 EFI service manual
2007 Sportsman 500 X2 EFI service manual
2007 Sportsman 700 service manual
2007 Sportsman 800 service manual
2007 Sportsman 800 EFI service manual
2007 Sportsman 700 MV Parts Manual
A07MH68MA
2007 Sportsman 700 MV service manual
2007 Outlaw 500 service manual
2007 Ranger 700 EFI 6X6 Parts Manual
R07RF68AD
R07RF68AF
2007 Ranger XP 4X4 service manual
2007 Ranger XP 6X6 service manual
2008 Sportsman 500 service manual
2008 Sportsman 500 EFI service manual
2008 Sportsman X2 500 EFI service manual
2008 Sportsman Touring 500 EFI service manual
2008 Sportsman X2 700 service manual
2008 Sportsman 800 EFI service manual
2008 Sportsman 800 Touring service manual
2008 Ranger 6X6 700 EFI Parts Manual
R08RF68AD
R08RF68AF
2009 Sportsman 6X6 800 EFI service manual
2009 Sportsman 90 service manual
2009 Sportsman 300 service manual
2009 Sportsman 400 HO service manual
2009 Sportsman 500 HO service manual
2009 Sportsman 500 EFI service manual
2009 Sportsman X2 500 EFI service manual
2009 Sportsman Touring 500 EFI service manual
2009 Sportsman 800 EFI service manual
2009 Sportsman X2 800 EFI service manual
2009 Sportsman Touring 800 EFI service manual
2009 Sportsman XP 550 service manual
2009 Sportsman XP 550 EPS service manual
2009 Sportsman XP 850 service manual
2009 Sportsman XP 850 EPS service manual
2009 Outlaw 90 service manual
2009 Outlaw 450 MXR service manual
2009 Outlaw 525 S service manual
2009 Outlaw 525 IRS service manual
2009 Predator 50 service manual
2009 Ranger RZR service manual
2009 Ranger RZR S service manual
2009 Ranger INT'L service manual
2009 Ranger 2x4 service manual
2009 Ranger 4x4 Crew service manual
2009 Ranger 6x6 service manual
2009 Ranger 500 4x4 EFI service manual
2009 Ranger RZR 170 service manual
2009 Ranger XP 700 4x4 service manual
2009 Ranger HD 700 4x4 service manual
2009 Scrambler 500 service manual
2009 Trail Blazer 330 service manual
2009 Trail Boss 330 service manual
2010 Ranger RZR service manual
2010 Ranger RZR S service manual
2010 Ranger INT'L service manual
2011 Ranger RZR SW service manual
2011 Ranger RZR service manual
2011 Ranger RZR S service manual
2011 Ranger RZR 4 service manual
Other Stuff
2500lb Polaris Winch Install Instructions and Parts List
2500lb Warn Winch Install Instructions
2500lb Warn Winch Parts Manual
Warn Winch Motor Rotation Instructions
Warn - The Basic Guide to Winching Techniques
Sportsman 600 and 700 Ignition Replacement Kit Install Instructions
Polaris Special Tools - ATV,Snowmobile,Watercraft
Download Manuals HERE
Some ATV manuals available in the downloads section at https://www.quadcrazy.com/files/
Find them on on:
Get 15% at emanualsonline.com with coupon code EMOAFF
Get 20% at emanualsonline.com with coupon code BLAZE and $50 purchase
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By preppypyro
Hey guys and gals,
I recently bought a 1994 yamaha big bear 350 with... surprise surprise.. rear diff problems.
I have taken the rear diff all apart and the problem is the pinion bearings are both screwed. (Hope Im using the correct terms) Anyways there is a collar that has 4 "divets" in it that ya can beat on with a punch and it should turn. Well Ive beat on that collar and it is not turning. I have lubed, soaked, heated, cooled, you name it, and that collar will NOT budge.
So as a last ditch effort before I take a die grinder and grind that collar outta there, I thought I would throw a post in here, and maybe someone has some trick or advice they can add that maybe I havent thought of.
Now the axle, taking it out needed a beating, and I ended up screwing up the threads that hold the hub on, and eventually broke them right off. My plan is to drill about an inch hole in the end of the axle, thread it, thread a grade 8 bolt in there, loctite it in, then throw a bead of weld around the bolt. Im thinking for the little light duty puttering around I do with this quad, that this idea should be enough to repair the axle so the hub stays on, rather then fork out big bucks for a used or new one.
Thoughts on both repairs would be great!
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