Polaris 400L Complete Engine Rebuild Part 1 (Removal)

[@leviscott8519]

Great Videos on these polaris 2 strokes! Thanks again brother! Very good detail and explanations! Om here for the PVT secondary spacer placement before or after the inner shroud. Nailed it Govenor!🫡🤠

[@josephf7720]

Very good step by step explanations.

[@-jimmyjames]

Great Video man! I have a all red 2x4 of same model and year. came with 90s early 2000ks goodies. wheels and tires and such. its a beast. wodner if its been oversized already. scary fast. I appreciate your instructional man. Thanks. I have mine half torn down now. Going to go ham with it. parts arent bad at all for engine rebuild. YAA HOO

[@mjbrox]

This is great content. I’m looking buy my son a project for the summer. I found a 2000 Polaris Explorer 400 that has a reported seized motor. How hard is it to find parts for the motor. Do you know what other motor options exist?

[@MrFixit1]

Engine parts are out there if you look around on the internet. If it has the 4oo engine I would stick with that because the frame will need some modifications to fit different engines.

[@Repairs2Riches]

Should I have an o ring between crank and crank bearing on stator side? Can’t remember if I replaced it or not finished rebuild and now my 400 will rev to the cloud by its self I got the other o rings on properly closer to the flywheel

[@MrFixit1]

Ok, Part stack up, crank, shim/s bearing, O-ring, sleeve, gear, O-ring, sleeve, nut.

[@Repairs2Riches]

@@MrFixit1 thank you so much you have no idea, very surprised I got a response on an old video keep up the content

[@sesslerclayton5200]

I just purchased one of these non-running. I can take the clutch or crank and it will only turn about 90 degrees the lock solid. I am thinking maybe a bent rod what do you think?

[@MrFixit1]

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.

[@sesslerclayton5200]

@@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.

[@unibrow9]

That sensor gets brittle after time , thankfull amazon sells cheap replacements that work well.