I tried to go to Canada once in my younger years and was treated like a criminal, hand cuffed and my car was ransacked, and I was turned away. I don't think I will try again. Haha

At engine start up speed there will be very little air moving through airbox inlet. I would check compression and check the crank seals and other vacuum leaks. It should suck your hand to the carburetor with airbox removed.

@ compression is at 90 psi. Bike has been sitting up for about 6 years. Thanks for your reply

Refer to this video kzbin.info/www/bejne/onW8mYCGoM6sfKM

Interesting, I didn't know people was using it to bed rifles.

The internet is a wonderful source of information.

If coolant concentrate was used without a water mix it will turn to gel.

@MrFixit1 thank you for that. Looks like I will be draining the coolant and starting over. I bought it a while back, and it was already like that. Again thanks.

The weep hole is between the to shaft seals for the water pump shaft. If the seal on the impeller side fails then coolant will come out the weep hole.

Assuming you tested and installed everything correctly, including doing the AC/output test from the stator, check voltage at the red terminal on the circuit board and ground with engine running, you should see charging voltage. Check that the key switch is functioning and ground wire from stator is connected to frame and circuit board. Were the magnets all intact in the flywheel? I have also seen the wires get pushed out of the connectors when plugging in the stator wires at the black connectors. Make sure all the red and red/white and brown wires are in their correct places on the circuit board. Rev the engine to 3000-4000 RPM when testing the battery charging voltage. That's about all I can think of.

Assuming you tested and installed everything correctly, including doing the AC/output test from the stator, check voltage at the red terminal on the circuit board and ground with engine running, you should see charging voltage. Check that the key switch is functioning and ground wire from stator is connected to frame and circuit board. Were the magnets all intact in the flywheel? I have also seen the wires get pushed out of the connectors when plugging in the stator wires at the black connectors. Make sure all the red and red/white and brown wires are in their correct places on the circuit board. Rev the engine to 3000-4000 RPM when testing the battery charging voltage. That's about all I can think of.

​@@MrFixit1 Appreciate it. On the flywheel there were no magnets like yours but when I looked at new flywheels they don't have them either it's just a solid surface all the way around. Possibly replaced before as someone had been in there at some point as one of the screws was almost stripped out where the stator connects to.

@@tc7584 There must be magnets or it wont charge

Not on all wheels.

​@@MrFixit1gotcha mine has the factory wheels still

Not the same carburetor.

Put the mineral oil in the gas tank and mix with a full tank of gas. Top off oil tank with 2 cycle oil and run both premix and oil injection at the same time. Run for 20 -30 seconds shut off then cool for 10 minuets. Check fluids and for leaks, then run until engine is at operating temp (about 15 minuets) let cool 15-20 minuets, then go for a gentle ride and do this for the first full tank and stay away from full throttle and long high-speed runs for the first full tank of gas, then go play all you want.

Premix the mineral oil in the gas tank at 50/1. Top off oil tank with 2 cycle oil and run both premix and oil injection at the same time. This might fowl the spark plug so keep an eye on that. Run for 20 -30 seconds shut off then cool for 10 minuets. Check fluids and for leaks, then run until engine is at operating temp (about 15 minuets) let cool 15-20 minuets, then go for a gentle ride and do this for the first full tank and stay away from full throttle and long high-speed runs for the first full tank of gas, then go play all you want.

(Q1) Yes. (Q2) No. (Q3) Yes, no harm will be done (Q4) Front hubs are an oil bath. Polaris demand drive fluid or ATF+4.

You can rent a harmonic balancer puller from Auto Zone or Oreily's

1996 scrambler 400, all i did was swap out the spring.

I'd say it was 3/16 or a 1/4 inch or so. You will know because you will feel the difference between the aluminum and the hardened steel pin. But this was a few years ago now so my memory is a bit faded. Good luck.

@@MrFixit1 thanks

@@MrFixit1 yeah its not coming out man.

You're welcome

Not sure what is called to be honest.

Not hard at all. you need to remove the plastic surrounding the gas tank and handlebars then the part that houses the bulbs. Just a few screws.

@@MrFixit1 Ok thanks, then i should try to change the bulbs. 👍😊

Specialized tools and knowledge are required to rebuild the crankshaft. I don't think I've ever heard of a welded crankshaft from the factory, but anything is possible, I guess. I have a video series where I disassembled the crankshaft and installed a new bearing and rod. Polaris 400 engine rebuild. there are 4 parts. I believe it was part 3. look in my playlist for Polaris 400L

Thank you for the reply. I will check out the recommended video!

Look at the crank case under the carburetor ad see if it busted out. A common issue with these 400 engines is the piston skirts brake off and destroy the engine. It is also possible the magnets delaminated from the flywheel and destroyed the stator. Also, possible the reed cage came apart and it protruding into the cylinder bore. A bent rod is a possible cause but, in my experience, if the rod was bent it wouldn't come to a hard stop when rotating the crank but rather have a tight spot. Another possible reason is a broken piston ring catching on a port. The only way to know for sure is to have a look inside. A quick access into the cylinder is by removing the exhaust from the cylinder and look through the exhaust port. Other less common issues are in the balancer shaft compartment, the dipstick detached and is bound up in the gears or water pump bearing fragmented and has gotten into the gears. There are many possible problems. Start with the easiest first.

@@MrFixit1 I appreciate the advise it turns 90 degrees then comes to a hard stop, but worse case I only paid $150 for it and your rebuild videos will help me a lot if I have to rebuild the motor as long as the case is not busted.

Yes, Low compression. 115psi is the service limit. try adding a spoon full of oil through the spark plug hole and see if the compression rises. if so then you need a rebuild for sure. (Note use the pull starter to perform compression test and not the electric starter and make sure you hold the throttle wide open)

It is your preference. A lot of people don't use it.

@@MrFixit1 yeah... ima grab a pizza tonight

Man, it was a mess, wasn't it?! Yeah, the pipe sings a different song now.

@@MrFixit1 You'll really stuck to the vision and with a ton of hard work made it happen, really looks good, fabricating parts to fit something it never came from is no joke! enjoy!

@@Kingsoupturbo Thank you!

Yes, a little is normal

Yeah, me too. Thanks

Thank you. You will get it done just be patient and don't get overwhelmed.

Yeap, and my biggest fear was crashing it after all the hard work haha.

@@MrFixit1 I know the feeling, don't let it be a Garage Queen.

@@skandix No way that will happen lol. I put 200+ miles on it over the weekend