Basic Routine Maintenance for the Polaris 400L 4X4

[@MrSprintcat]

I could have sworn the manual said to load the rear of the Quad before you tighten the chain? Thank you for the video

[@MrFixit1]

Yes, you should. Thanks for pointing that out! I have done it so many times that I know how much slack should be there.

[@martinrodman8272]

I just bought one today 1-30-24 this video is pure gold!! Thank you!!!!

[@MrFixit1]

I have many more videos of this quad on my channel

[@SJF_LooneyBin]

I have a ‘96 Xplorer 400 L 4x4. I am in the process of doing the much needed maintenance. Your video will be a big help to me. I thought that I got all the grease fits yesterday; your video showed that I only found about half of them. I appreciate your guidance.

[@SZYSZUNIA80]

Thank you very much for your help. Now I have 2, probably the last wires from the oil tank, but I don't know where to connect them

[@MrFixit1]

Look for the Purple/Black wire coming from the dash lights going to the board (this is the oil light wire) connect the purple wire from the oil tank into the same connector group. And the RED/White wire into the red/ white section of the board like for the ETC switch.

[@cm517chris]

thanks for making this video! recently picked up a 1997 400l 2-stroker that needs alot of love, and these checks have helped us!

[@MrFixit1]

Thank you for watching!

[@bandracchio]

Nice video, just bought a polaris 93' 350L 4x4 2 stroke, so good information 👍

[@michellealms3238]

Finally I got answer where coolant reservoir is! Thank you!,

[@MrFixit1]

Yes, I moved it from under the gas tank to under the seat.

[@michellealms3238]

Would my oil light go on if the counterbalance oil was low? It appears that I have enough of the two cycle. It’s filled pretty much to the top and my oil light goes off and on sporadically.?

[@MrFixit1]

@@michellealms3238 The counterbalance oil will not activate the 2-cycle oil light. The oil level light will come on when the oil is at or just above the halfway point. If the oil level is close to this point, then the light will randomly come on and off as you ride. If the tank is completely topped off and the light is coming on, then you have a short to ground in the wiring circuit.

[@michellealms3238]

Ok. You are really helping me. I appreciate it so much. So this is a dumb question what if that counterbalance oil runs dry? Are you in danger of wrecking an engine like actual motor oil? I guess I am just confused with it. I never even knew it existed on my machine until after I had it for over a year. I’m guessing it’s purpose is for lubrication but I was just wondering it’s such a pain in the you know what to check to access that dipstick.

[@MrFixit1]

@@michellealms3238 Yes, major engine damage can happen if the Counterbalance oil runs dry, but not in the way a 4 stroke engine will. The counterbalance oil lubricates the balance shaft bearings, oil injection pump drive gear and the water pump hearings. It is important to maintain this oil level. It is not the easiest thing to check but is necessary.

[@la_plata3588]

When you pointed at the exhaust drain I thought to myself that ain't coming off haha

[@Yz4Life]

Excellent video thank you

[@SZYSZUNIA80]

thank you for the previous advice. it helped me a lot. I rebuilt all the electrical. now I have another problem. can you help me with the lights hi bim because I don't have them

[@MrFixit1]

Check power & ground at the head light connector. If no power problem might be in the switch. If no ground check if the wire is plugged into the circuit board.

[@MoparNewport]

Hello from the Yukon! I just picked up a 96 400. Im an automotive mechanic, but i dont know shit about these old Polaris units. Mine is missing drive chains, someone previous left the brake master open to the elements for years so its junk, every panel is loose, the speedo is missing and the center headlight is melted, BUT the crazy thing runs much to my shock so ima fix it. Thanx for the in deep eh? gonna be scopin yer channel out.

[@MrFixit1]

Welcome friend! I have more videos coming.

[@dldinak]

Just inherited a 1997/98 Polaris Big Boss 400L. I’ve crawled all over this. Where do you check oil level, add oil, change oil? Sorry if I sound like a dumb az, but I’m new to these guys.

[@MrFixit1]

ok The 400L is a 2 cycle so no engine oil. There is a oil injection pump located on the lower left side of the engine and an oil tank on the front of the machine. There is however a compartment in the engine case for the balance shaft. The balance shaft requires about 100cc of 10w 30 oil. the dipstick is located under the carburetor. The drain is in the bottom of the engine. There are 3 drains (10mm bolts) the left and right drains should be empty and dry, the middle drain is for the balance shaft oil. Hope this helps.

[@a.martinez9825]

First of all love your videos. I have the exact 4 wheeler and was trying to check the counter balance dip stick for oil when it snapped on me. I had to drill it out and may have gotten some plastic that may have fell in. What would you recommend to flush that out and how bad will plastic shavings affect it if I don't get them all out? Also would you know a part # to replace counter balance dip stick or at least another alternative?

[@MrFixit1]

I would suggest trying to remove all dipstick particles as it would be harmful to the gear set and seals. I would suggest flushing the counterbalance compartment with kerosene or diesel fuel and compressed air. On the front of the engine by the water pump housing there is a large bolt that leads into the balancer compartment remove this bolt to aid in flushing and also a small drain bolt on the bottom of the engine. Complete disassembly of the balance shaft compartment would be recommended for confirming all foreign matter is removed but, do as you will. As far as the dipstick goes, it is unavailable and will need to source this from the internet or a salvage yard. I don't know of any alternative replacement. Here is the part number (GAUGE, OIL 3084732). One I know of offhand is Gargon's ATV in butler KY. You can look him up on Facebook Market Place. Here is a link: facebook.com/guy.grogan

[@danielhamaoui4402]

I have a 1995 polaris 300 2x4 w957530 I'm trying to find out what is the engine oil spec and if it is 2 or 4 stroke ?

[@adamap1]

Another good one. I have to ask, how do you know that the speedo cable is a pain to replace?! If you say you’ve had the tranny out on this I might have some questions for you if you would be so kind as to help.

[@MrFixit1]

You can replace the speedometer key without removing the transmission.

[@austinschafer3346]

Just inherited the 1994 sportsman. Don’t know much about these, not sure if it’s a 2 or 4 stroke, don’t know what kind of oil it takes or how to change it. Also may need a new electric starter- where and what would I need to order for that?

[@MrFixit1]

Many places like #1 Ebay, Partzilla.com, just do a google search and you will find replacement parts. Also check FB Market place. I'm not affiliated with any of them, that's just where I go to get parts.

[@donaldreece7037]

Thanks for your videos. It's been helpful for me! I do have a question for you. I have a 1996 polaris Sportsman 400 4x4 that I acquired, and the break handle master cylinder didn't come with it. I ordered one on eBay, and i have the wrong one. I'm trying to find the right one to order. My model # is the W968040. Hopefully, you can help.

[@MrFixit1]

Here is the part number for the brake master cylinder 4110157

[@donaldreece7037]

I bring up that part # and it gives me the on and off switch

[@donaldreece7037]

I looked on Google as well as eBay.

[@MrFixit1]

@@donaldreece7037 This is what I found www.amazon.com/MATI-Cylinder-Replacement-Polaris-Sportsman/dp/B08DNRD5Z6/ref=asc_df_B08DNRD5Z6/?tag=hyprod-20&linkCode=df0&hvadid=692875362841&hvpos=&hvnetw=g&hvrand=13172301499116825762&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9058936&hvtargid=pla-2281435180058&psc=1&mcid=b10169532e92369bb1a0678c93ee1217&hvocijid=13172301499116825762-B08DNRD5Z6-&hvexpln=73&gad_source=1

[@donaldreece7037]

This is the one I bought, but the break line end is too large to insert into it. The new handle has a smaller dia female fitting. This is why I thought I bought the wrong one. Also, the two prongs for a plug, I guess! I didn't see any plug hanging anywhere. This was another reason I thought I had the wrong one. But I do appreciate you helping, I will look at it closer!! Thanks again!!

[@bradcohen3801]

Thanks for the video Just bought the same atv except mine is 2x4. The only issue I have so far is the carb. It runs waaay too rich, so much so that gas actually backed up into the airbox. I ordered a new carb on Amazon-any suggestions for installation and tuning?

[@MrFixit1]

All I can say is, I hope the Amazon carburetor will work for you. I have had better luck making the factory carb work on most quads. I would check the reeds. Carb is a bit tricky to get out.

[@bradcohen3801]

@@MrFixit1 the factory carb is looong gone. Lol

[@a.martinez9825]

I have a hose thats connected on a fitting ingront of the air filter and if you follow it down its just dangling at the bottom. I was wondering if you can tell me where it goes but i don't know how to send you a picture.

[@MrFixit1]

If the hose is attached to the carburetor the other end is open. Vented to atmosphere. If the hose is attached to the fuel tank the other end is open, vented to atmosphere..

[@a.martinez9825]

Thanks so much I appreciate you!

[@SZYSZUNIA80]

I have the same one but there is an electrical problem, maybe you can help me how to start it?

[@MrFixit1]

Ok, can you explain your problem?

[@RobRoueche-xq1mi]

I have the exact same machine. I am the original owner. I've had a hard time finding anyone to work on it. The local Polaris dealers won't work on anything older than a 2000. My instrument lights are out as well as the brake light. Not sure what to do to fix it. I do have headlights.

[@MrFixit1]

probably just need the bulbs replaced. Look on eBay for the indicator bulbs. Long glass bulbs looks like a fuse.

[@Josh-jj5hk]

I have the exact atv but had to replace the front axle cv shaft. And did so but the hub keeps falling off is there any thing that holds it the front hub on?

[@MrFixit1]

Check out this video kzbin.info/www/bejne/pYKqpJZ5j7uLZ9E

[@berad187]

I have this same model and Year and what was the size chain for the center middle chain and the front chain I baught this and noticed I was gonna need new drive chains and was curious where would be recommended to purchase a set of them

[@MrFixit1]

520 o-ring chain. I don't know how many links. A good mid quality chain would be D.I.D. brand or bike master.

[@bradleytrafton-s1o]

I got the same bike as you. It's my plow bike. I bought it used, I plowed a month with it before it started to over heat and blew the bung out the head of the motor. I machined the head put it back together topped up the fluid at a dealership they pressure tested it for me. But within a hour the bike overheated again and blew the bung out the head of the motor where the coolant goes in. Any idea on what I'm going threw ?

[@MrFixit1]

Colling system may need to be inspected. Clogged radiator, fan motor bad. Thermal fan switch bad, water pump bad. Should get the temp light on before it gets too hot. Hard to say without knowing the condition of the cooling system.

[@bradleytrafton-s1o]

@@MrFixit1 I appreciate those tips I'm going to be inspecting my cooling system and see from there 💪🏽

[@shizzel122]

Who knew snake made KZbin videos about his Polaris scrambler 400!!

[@MrFixit1]

Haha! Escape from Reality.

[@webstella]

I hear if you disassemble the starter and reassemble using rtv to aid in sealing it up that they will last a while longer. We will see. I bought a cheapy and sealed it that way.

[@MrFixit1]

The biggest problem I had is, the water comes in through the pull rope and trickles down into the starter. Because the starter is at the bottom of the engine and the lowest point. Later models moved the starter on top.

[@webstella]

@@MrFixit1 Ah i see. Doesn't your pull rope handle seal up against the recoil case? Mine pushes on to seal it. Hmm, guess i better rtv my recoil gasket surface too.

[@MrFixit1]

@@webstella Well it's supposed to seal but it doesn't really seal well. Once I figured out what was wrong, I made sure to not let water come above that point or drain the pull cover if it did. Note: Use Anaerobic sealant to seal the pull cover. Mutch les work to clean up if you need to go back in there again.

[@SZYSZUNIA80]

the previous owner wanted to save on a new ignition switch and started cutting wires and adding his own electrical installation. but it didn't save him. he left it and I bought it back. I repaired almost the entire electrical installation, but I have 5 wires left that I don't know where to connect.

[@MrFixit1]

OK, on the connection board there are groups of spade connecters, all marked with a color code. WTE, for white GRN, for green and so on. Just connect the wires the corresponding connector. Black is for the kill switch and rev limiter, brown is ground, red/white is BATT+ after the ignition switch $ RED is the main power coming from the Battery. Gray and gray/white are for the AWD system Green & Yellow are head lights and so on.

[@SZYSZUNIA80]

I understand fine. tell me where to connect these two wires, they probably come from the AWD switch, right handlebar

[@MrFixit1]

What color are they?@@SZYSZUNIA80

[@SZYSZUNIA80]

white and red white.

[@MrFixit1]

@@SZYSZUNIA80 Sounds like the (ETC) electronic throttle control. Red/White and White. one end is connected to the board and other end is connected into the throttle housing to the ETC switch.

[@SZYSZUNIA80]

It doesn't come out of the switch. The blue wire is connected to the red and white wire and then goes on. There is only yellow in the bulb plug and the brown wire is missing to hi bim

[@MrFixit1]

Ok do you have 12 volts at the yellow wire at the head light connector with the High beam switched in the high beam position? If yes, then all you need to do is make a new brown wire to connect between the head light connector and the brown section on the circuit board.

[@highlifegoodlife5400]

Can u tell me what colors ur wires are coming off the machine going to the fan thank you

[@MrFixit1]

Brown - Red white +

[@highlifegoodlife5400]

Really I disconnected old one and I got a brown wire that's + I think with nothing on it and I got a black that has a male plug. The black also has a red wire that's connected somewhere else but there in same protective sleeve. I was gonna run a tago switch to new fan but guy that was helping me told me to hook it up to old wires that old fan came off. Thanks for ur help.

[@highlifegoodlife5400]

Also when I took old one out look like they had jumper wire going to positive and negative? Wire nuted

[@MrFixit1]

@@highlifegoodlife5400 Wow Good Luck

[@highlifegoodlife5400]

Do u happen to no about how long it would take for the fan to turn on once I run it really good?

[@Mikkel584]

Do you run the oil pump or mix?

[@MrFixit1]

I use the oil injection

[@Mikkel584]

@@MrFixit1 Thanks

[@joelkiel4156]

My buddy has this exact 4 wheeler. Brakes keep going out on him/very little brakes. Any good troubleshooting?

[@MrFixit1]

Try adjusting the rear brake foot peddle adjuster. (Bolt and jam nut on rear brake caliper inside rear right fender) so that the foot lever has little play before engagement. NOTE: don't tighten too far or rear brake will engage. Thanks for watching, I hope this helps.

[@SZYSZUNIA80]

hi. I have another problem. I don't want to start, there is a spark, there is fuel in the carburetor. compression pressure is 6 bar

[@MrFixit1]

Compression is low. 8.5 bar or more is required. 10 bar is where you want to be

[@rubenortega9756]

Need help Installing my carb I have the same quad !

[@MrFixit1]

How Can I help?

[@cbossplayz3555]

Hey man I have the 1997 sportsman 400L and I am wondering how often do you lubricate your chain because if I do not lubricate mine it starts to pop and it’s a brand new chain just wondering and what do you use for it

[@MrFixit1]

I use O-ring chain and I hardly ever lubricate it, when I do I dismount the chain and clean it with kerosene, and I use gear oil or chain saw bar chain oil. Nothing fancy. if you are using standard roller chain and you ride in the wet a lot you should lube it every time you ride. Chain wax works well and many other expensive chain lubes out there.

[@cbossplayz3555]

@@MrFixit1 I also I have o ring but I am always lubeing the crap out of it it’s brand new and it’s a D.I.D

[@MrFixit1]

@@cbossplayz3555 Something else is going on. Check the chain tension according to the manual, there should be a lot of slack in the chain, also check the sprockets front and rear for damage. It's not uncommon for the small drive sprocket to have broken teeth. Something could be out of alignment.

[@cbossplayz3555]

@@MrFixit1 yep just checked that about how much slack should be in the rear non compressed cause i am doing this myself

[@cbossplayz3555]

but once i get the lube on there it woks fine just want to know the corect amout of slack cause mabe thats my issue

[@SZYSZUNIA80]

This means that there is no difference in hi beem and Lbeem. The switch doesn't separate it, it's just a hi beep

[@MrFixit1]

The two lights on the bumper are the low beam (green wire and a brown wire). The light in the cowl is the high beam (yellow wire and a brown wire) You can add a green wire to the cowl light and have both high and low beam but, this may cause damage to the switch because of all the power needed to run all three lights at the same time.

[@jandeband]

Whats the L , mine is a 400

[@MrFixit1]

(L) Liquid cooled

[@jandeband]

@@MrFixit1 makes sense, thanks

[@SZYSZUNIA80]

that means I have to overhaul the engine

[@la_plata3588]

Wayyy too much... Perfect lol

[@a.martinez9825]

I just bought one of these what kind of 2 stroke oil do you recommend? What does it mean when you see VES on 2 stroke oil?

[@MrFixit1]

I have been using TCW-3 2 cycle oil probably not the best selection. VES is (variable Exhaust System) This engine does not have this system. Polaris blue would be the oil I would recommend for this machine but quite expensive at $45us for 1 gallon of oil. Although even if you ride 6-7 hundred miles a year one gallon would last the entire year.