lbdrummer3

Boy know the feeling, right there with ya.

44 minutes ago, Gwbarm said:

Oh, OK, so this wasn't the Polaris it was the Moto 4 you were riding.

I'm the OP, Big_McLargeHuge was the one riding his.

5 hours ago, Gwbarm said:

So you got it going how much did you end up replacing.

I'm just into it for a battery and a diaphragm for the carb.  I picked up an old Yamaha Moto 4 and it uses the same battery so just 20 for the diaphragm at the moment plus about 3 hours of tinkering.

Just an update on this.  I've decided to back burner this project.  A new output shaft from Polaris if $450 and there is a used trans on ebay for $500.  I still don't know if the 4X4 hubs function and have to replace all of the chains.  There is just too much uncertainty with all of the other things that could be wrong to dump that much money into it at this point. 

I think the best option would be to find a decent Magnum that has everything working but with a blown or tired engine and do an engine swap.   Unfortunately, as far as I can tell, the engine and transmission for this was only used on the 95 425 Magnum 4x4 with no other interchangeability that I can determine.  If someone reading this has better resources to check where these components interchange, please help me out on this.  It would be easier to find a blown up quad if I didn't have to only look for one unique year and model.  This is like trying to find a unicorn right now.  

In the short term, I found an 85 Yamaha 200 Moto4 to get me though the spring planting and maintenance.  She's a bit rough and tired but it was a good deal and I'll be posting some content on it later.

I solved a no spark issue already and got the engine running.  The transmission is not going to be easy.  Was hoping to get this thing running for work this weekend, that ain't gonna happen...  Now I think it's getting parked in the corner of the shop until I can find a transmission, an output shaft that doesn't cost and arm and a leg, or another quad with blown engine, or anther quad project that isn't going to be a money pit.

Thanks for the heads up Gwbarm, checked bother and neither have an output shaft.

I found a complete gear box used on ebay for 500, which is pretty much what Polaris wants for just the shaft.  Will check partzilla.  Thx.

Spent some time looking for an output shaft and they are $450 bucks and nobody has any in stock.  Hell I don't think this quad is worth that much.  I also think that 1995 is an odd ball year.  I found a cross-reference chart for the cases and they only fit 1995 Magunums.

I've been thing about a 6x6 too.  The back of my property along the fence line is all drainage so you sink to you ankles just walking though it and the fence needs some love this year.  One came up on FB marketplace a few months back for free, ad was up for 3 minutes before I replied I'll take it and it was already claimed...  You've given me a good idea though, finding something with a blown up motor might work out.  

Does anyone know if the 95 motor will interchange with any other years?  That would give me more options.

This beast is quickly becoming a money pit...  Need folks input on deciding to make it run or sell it off for parts.

Background.  It's been sitting in my neighbors yard in Wyoming for an unknow number of years, at minimum, 5+ probably more.  The oil filter was last changed in 2007 if that's any indication.  It's been beat to hell, probably died and left to rot.  They were just happy to get rid of it.  

The first thing I did was checked for spark.  Figured out that the left handlebar grip switch was grounding the ignition out, fixed it and we have spark again.  Rebuilt the carb and flushed the fuel system.  In cranking it over by hand, I could tell it had great compression.  The 3 magic item to make her run.  I got a new battery, sprayed a little starting fluid down the airbox and she fired right up!  Ran it for a while and it doesn't want to rev out on the top end, more on that later.   It didn't even smoke either and I'm getting excited at this point! 

Next was the transmission, will it move under its own power?  This is where my excitement ended. The output shaft turns on the transmission side and just outside of where the sprocket goes, it is cleanly severed.  Also, when I put it in reverse, the engine dies.

Here are the things that I know are wrong with it.

1. Critical, Output shaft is broken.  Does anyone know where I can get an aftermarket output shaft?  Guessing Polaris would be pretty proud of that part if they even make it anymore.  I looked on the net for one and couldn't find anything.  Also, does this have a type I, II or III trans?  I think it is a Type III
2. Critical, Shifting into reverse kills the engine.  Could be indicative of the shifter being worn out.  I think I saw a work around for that on Youtube.
3. Critical, Cooling fan is toast.   It appears to be a sealed unit, tried looking to see if I could get it apart and I can't figure it out.
4. Front frame under the luggage rack is bent and also a down tube broken at the weld.  My family has 2 welders in it so no problem there.
5. Handlebar on off switch doesn't shut the engine off but it does turn off by using the key.
6. Critical, Gas tank is cracked, I repaired it with 2 part epoxy but that is probably a temporary fix so I may need a new tank if I keep it.
7. Critical, All of the chains are shot and need to replaced.
8. None of the dash lights work.  The light in the right 4WD handlebar switch doesn't work.
9. Missing the speedo and cable doesn't turn (not a big deal)
10. No title on it.  Not planning to go on public land though, just need a ranch quad.
11. Seat needs to be recovered.
12. Missing left side cover.
13. Rear rack is bent and broken in several spots.
14. Rear shock is pretty springy for the first several inches of travel before the oil dampens things out.
15. Critical, Engine doesn't rev out on the top end.  Starts popping and just wants to stall, could be running lean.  The clip on the needle was in the top most position though.

Things untested.

1. Critical, Don't know if the lockers on the front wheels even work.  When I hit the 4WD button, nothing happens but that could be because of the output shaft being broken.
2. The electrical system has been monkeyed with.  There is a sensor on the driver side of the cylinder with a wire coming out of it and nothing to plug into.  
3. The thermostat wires are disconnected from the main board and one side is just cut.
4. The wires to the fan were cut and a manual switch was installed to turn it on and off.  
5. Not sure what wheel bearing surprise I may find.
6. What else could be wrong inside of the tranny once I get it apart.

So far, I've just bought a battery, a new diaphragm for the carb, and an oil filter so not into it for very much.  I just need a working quad to haul stuff around my 21 acres.  It doesn't have to be pretty, just needs to work.  I am mechanically inclined and could probably rebuild the transmission myself.  I've seen some older Yamaha Warriors, Honda Formans, and Yamaha Big Bears for $1500 from time to time, sometimes a little less but the all need some love.  Is fixing all of the 7 critical problems on this going to end up costing more than I could buy something else in better shape for.  I'm not opposed to cutting bait on this thing and moving on.  The only good things is the engine runs and doesn't smoke and the tires are good and holding air.

Thanks for your input.

How many acres to you have?

7 hours ago, Gwbarm said:

Nice job, they look good.

Thank you!  Both took several years to finish but that was working on and off.  I'd get to a stuck screw or pin and try soaking it for several weeks.  Most times I had to just drill them out and retap the threads. 

Nice place, like all of the trees.  All of our land is flat prairie.

I haven't had good luck with Chineseium garbage from lawn mowers to Toyota 22r's.  Everyone one of them was junk.  Sure the engines ran, barely.  I'd rather buy a used rebuildable carb on ebay instead of a Chineseium copy.

I worked at a bike shop in my early 20's and got to ride my share of Banshees, Warriors, and Blasters.  Super fun quads but way out of my affordability range at the time.  Years later when I could afford one I didn't have space so I got a YZ250 instead.  We just moved to the country now and have plenty of space and some land so a work quad makes sense.  Neighbor gave me a Polaris Magnum 425 so yeah that's do.  I'd still like to get a Warrior or a 400EX eventually.  Got too many projects though and my 85 4runner rock crawler project is getting priority for KOH next year. 

I've been restoring a few old guns.  Here are a few before and afters.  First is a Rossi Overland 12 gauge.

2nd is a Model 94 Winchester post 64 in 32 Specl.

I just moved to Wyoming, hunting will be in my future.  Using a quad opens up a lot of opportunities.

I put up a post in the Polaris sub forum about how I got spark back.  Turned out it was a spring inside of the on/off switch that broke.

The short answer is that spring inside of the red on/off slide switch on the handle bar switch was rusted out and broken.  Below is the more detailed version.

My neighbor gave me this quad that has been sitting outside abandoned on her property for 5+ years.  We're in Casper so it's been getting rained and snowed on all of this time.  I pulled it apart and the plug was not sparking.  There is a great Youtube video that goes over how to test the exciter, stator, and pick up coil and I checked the continuity on all 3 and they were not grounded out.  The last thing he checked was the kill switch and I ended up having the same problem the guy had in the video but he didn't go into how to fix it.  This is how I fix mine.

I took the left handle bar switch off and removed the little plastic and metal covers inside that hold the red on/off button in place. There are 2 wires for that, a black one and a brown one.  I use a volt meter to verify that the wires were not severed between the contact points inside the handle bar switch and the end of wire and all were good.  Then I noticed that the little copper U shaped clip on the red button was sitting at an odd angle and not springy so I took that apart to clean it and see why.  I guess all of the years of sitting outside rusted out that spring and it broke in two.  That was preventing the copper U shaped piece from touching the contact points.  I reassembled and reinstalled the switch and we're sparking good now.  

Hope that may be of help to someone.

Just picked up an 85 4runner that will eventually be a crawler.  My son's 85 pick up project that he's been working on for a few years now is flexing on my tire.  First thing is to deal with the surface rust and make it one color.  Not bad for a rattle can job, from 10 feet away lol....

"CDI is capacitive discharge ignition."  Huh, I had no idea, learn something new everyday.  

Neighbor gave me this quad that's been sitting outside in the east Wyoming snow and rain for at least 5 years, maybe longer.  Looking to share my revival discoveries with others and hopefully learn from what others have already done on here.  

I'm from Casper Wy and my neighbor gave me an abandoned 1995 Polaris magnum 425 4X4 that's been sitting outside for at least 5 years.  It's been Bubba'd quite a bit and I'm just trying to get it going again.  Would be a great utility quad for my property.