Muggzy

Help! This hub has been soaking in liquid wrench for two days now. The hub puller in the picture has been on under tension with an impact wrench for 24 hours, removed and re-tightened at least twice in that time. I've tried smacking it from two sides simultaneously with ball peen hammers while under tension and also heating it until the liquid wrench began to smoke also while under tension and it's not budging. Anyone have any advice?

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What made you clean the carb in the first place? You're not giving us much history to go on.

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The behavior you're describing sounds like the jetting is rich. When you cleaned the carb, did you use any hard objects to clean out passages?

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When did this start happening? Was anything done to it recently or since you last rode it?

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Nice quad!

Thanks. Plastics are much worse than they look in the pic and the frame is pretty rust around the pegs but I think I got a fair deal.

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Ive never had an issue with those base gaskets! If anything do a compression check that will tell u if the rings are going bad !Keep it stock for girls ! those things have plenty of power for novice riders change the oil (check for metal shavings ) spark plug and air filter

Compression test is definitely on my to-do list. It'll just be a few weeks before I can get back in the garage. [emoji106]

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I rode it some and it seems like it'll have plenty of power for them even with the 15:38 Gearing. Since it needs a chain, it's a good time to consider that too. I figure going back to stock or in that direction would make it more forgiving of shifting errors on the trails.

Would love to get some opinions

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those 400ex`s are tough as nails Ive owned 4 of them over the years Good buy !!

Thanks quadnut. I bought this one primarily for my daughters in law to ride when they visit with my sons. If there's any mods to do when (if) I do the cylinder gasket what might you recommend? They have little to no experience on 4-wheelers but I've seen one of the mods people do to the 400ex is to put an aftermarket cam in it. Should I bother? The "she rides" section of this site is the main reason I went with the 400ex. The girls over there said they loved theirs.

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Just picked this up over the weekend;

2001 400ex starts and runs great with fairly new rubber, nerf bars, aftermarket subframe (needs a grab bar), aftermarket bearing carrier & LEX MXe exhaust. Needs bushings and bearings front and rear. Oh yeah and it's got alum wheels too.

It may be leaking at the bottom of the cylinder on the carb side (cleaned it all off and ran it/road it for an hour or so but didnt see any sign of oil or leaking and needs the chain replaced. picked it up for $1200

If I take the cylinder off to replace the gaskets, should i do anything else while Im in there?

I made something had makes circlips super to install.

All it is a piece of steel stock that I ground down to fit in the wrist pin(because I didn't have the right size steel stock on hand so I just took some metal off w/the grinder). Then I drilled a hole about half way through it and hammered a short pin into the hole. Then I ground the pin so it would just fit in the circlip's hole. then put the one end of the circlip in, put the pin on the end you just in. Press press the tool in pretty hard and twist. It makes putting them in a breeze.

The main handle part ended up being 15/32" and the pin was 1/8".

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Not sure I understand your description of how to use it. Can you post a pic of it in action? Circlips can be a real pia. And a good tool for them is expensive.

Thanks!

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To tinkerman or any one that may be able to help me.

I saw on quadcrazy you was helping out jamison1969 with his 97sportsman I have a 96 sportsman 400 and beleive the wiring is the same. My AWD switch stoped working and no front wheel drive. I shot a hot wire from the speedometer to the solid gray wire and my switch works. I havent took it out yet to try the AWD. If it works, would it be ok to leave it that way? Or could it damage other parts?

Where is the hot wire coming from to feed the AWD switch? What color is that wire?

I asked some questions on quadcrazy but no one got back to me.

Thanks, Jimc from Pa.

It worked intermittenly the last couple times I had it out. Now the switch will not work at all nor the 4 wheel drive. I got the hood off exposing the wires. I checked all connections. The wiring diagram shows the power is coming from the hub safty switch and going to the front AWD hubs and then to the AWD switch. I have no power to the switch. (After 96 & 97 Polaris did away with the hub safty switch.) Any help will be appreciated.

There's a very thorough thread on polaris atv that ought to help. If it wasn't so extensive, it copy it here. Good luck:

http://www.polarisatvforums.com/forums/polaris-atv-how-tos/32989-awd-hubstrut-hilliard-clutch-troubleshooting-diagnoses.html

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Hey All,

Looking for some recommendations on an ATV for my Daughters-in-law to ride when they visit with my sons. We ride mostly woods trails. It needs to be fairly easy to ride, automatic is't necessary but shifting should be forgiving and it needs to be under $2000. I have a Banshee and a Polaris Sportsman 500HO now.

One DIL is tiny, 5' and about 100lbs, the other is about 5'8" and 130lbs. I'm concerned that steering on the Sportsman may require too much upper body strength and the Banshee is definitely not a beginner's ride.

I'm thinking about a Warrior (may be under powered) or a Honda 400EX but I'd love to hear what others might suggest?

Thanks!