Polaris 400L Oil Injection Pump

[@marksilicato6126]

You are truly a professional. I admire your training skills and delivery. I tinker and understand the oil injector system way better now. Thanks I have a 1998 Polaris explorer 300 two-stroke. Thought about selling her, but I’m going to work through it

[@MrFixit1]

Thank you! Have fun stay dirty!

[@WagsAutomotive]

I'm getting my Polaris Sportsman 400 together. I noticed that there are vent tubes on both the engine and the transmission. I assume the transmission one vents to atmosphere and the engine one connects to the carburetor? Is that correct? And how do I adjust the idle on the engine? Is that the adjustment on the top of the carburetor? Thanks! 😊

[@MrFixit1]

@tomotive !!ALL vent tubes vent to atmosphere!! Two on the carb (one overflow one bowl vent). one on engine (balance shaft compartment) one on transmission, one on gas tank, one on oil tank. ALL Vent to atmosphere! Small thumb screw on right side of carburetor adjusts Idle speed.

[@WagsAutomotive]

@@MrFixit1 ok thanks! 👍

[@larryward1082]

Excellent information X-Men videos excellent instructor very good instructor how's avionics instructor of the royal side of the Air Force long time ago making it very easy to understand

[@HellzJester1]

Just picked up a 94 off a friend who was afraid to run straight gas in it, fouls out the plugs every half tank, now I know how to check everything, thanks bud!

[@eagle777dh]

I prefer oil injection. Back in the 70's I spent a lot of time in a Kawasaki shop. In hundreds of bikes that went thru it only one had a true oil pump failure. The other dozen or so that came in with problems with oil pump problems were owners messing with them and not knowing what they were doing. Simple and easy to adjust and pretty much bulletproof. The oil injection on other things like outboards are vacuum operated and not even close to the gear driven ones like this one. Had to call a guy out at the shop one time cause he said the oil pump failed when he let the tank go empty.

[@jonkincaid174]

Good video! Very informative great teaching through all steps thank you for the time you took to show all the steps and information needed 👍🏼

[@highlifegoodlife5400]

Great video im happy I got this machine and u have like every single thing I need to do to maintain it and fix problems as they come.

[@ciscolm]

Just found your channel and subscribed like how you explain things i bought two to hopefully make one will be checking out all your vids.

[@MrFixit1]

Welcome to the channel!

[@MiniTruckin615]

Muy buen tutorial apesar de que esta en igles me pondre a arreglar mi cuatrimoto y verificar si hace bien la mezcla de gas y aceite

[@la_plata3588]

Imma share this on the Polaris page

[@DPIOTROWSKI96]

Awesome video and well discussed . Thanks!

[@MrFixit1]

Thank you!

[@a.martinez9825]

Really love your video. You are about my only source of information for this machine. The nearest Polaris dealer is 1 hr and 30 minutes away and they don't want to help me because the ATV is to old. My question is what transmission fluid should I use? Also is it bad to use automatic type f transmission fluid to fill the front AWD on demand hubs?

[@MrFixit1]

I use Lucas Primary chain case lube in the transmission and Don't use ATF in the hubs. I use Polaris Demand Drive Fluid in the hubs. Polaris AGL gear case & transmission fluid is what is recommended for the trans.

[@ScottFrank-h5j]

I just purchased a 1996 Polaris 400l sport I am wanting to know how do I change the oil as well as a transmission oil does it even take crankcase oil being a two-stroke I am lost please help

[@MrFixit1]

No crank case oil but, there is a balance shaft oil. Dip stick under carb and a drain on bottom of engine. Will need to remove skid plate. Refer to engine drain bolt video in my play list for this drain. holds 3.4oz's of 10w30 motor oil. The transmission has a drain on bottom right side of trans. fill through the dipstick hole. Holds about 20oz's Of Polaris AGL Trans fluid.

[@ScottFrank-h5j]

Thanks bro I enjoy the hell out of your videos I'm getting ready to actually inspect my two-stroke pump make sure it is injecting oil

[@ashbyfarm]

Great video, how about changing out the oil supply line? They can break/disintegrate with age.

[@MrFixit1]

Sure anything can degrade with time.

[@miketrujillo3321]

I have the exact same machine I’m having an excessive smoke problem. When it’s running there’s a lot of white smoke coming from the exhaust. Would this possibly be a too rich on the oil side problem. I don’t believe it’s coolant because it still smells like 2 stroke exhaust just amplified about 50x. Thanks for the awesome video !

[@MrFixit1]

Excessive smoke could be any of 3 things. (1) over rich oil from oil injection. (2) Internal coolant leak. (3) Internal balancer shaft oil leak. Best way to rule out some possibility's are to, check fluid level in cooling system and balancer shaft oil. If levels are normal the look at the oil injection pump for problems.

[@miketrujillo3321]

@@MrFixit1 yup your absolutely right ! I went ahead an removed the oil inlet and ran it with a pre mix. I was still getting a good amount of white smoke so that would mean internal coolant leak or balancer shaft oil leak. You know what that means, I see a rebuild in my future lol. I saw your Polaris 400L rebuild videos and wanted to also ask you about the damage to the crank shaft housing where you were losing quite a bit of balancer shaft oil. You said you were losing oil into the exhaust, did you notice a bit of smoke from your exhaust as well ? Also, did you buy a rebuild kit ? If so do you have any info on where a dude could buy one ? Thanks for making all the awesome videos amigo ! They’re super helpful !!

[@MrFixit1]

@@miketrujillo3321 Rick Ritter cycle is the best place to get the best parts. although ebay and amazon has some cheap parts. Don't go cheap on the piston or connecting rod.

[@Mikkel584]

Great video, whats the best way to check if the oil lamp is working?

[@MrFixit1]

drain the oil tank

[@davidferency3339]

great video my machine is useing way to much oil. cant believe the smoke.would that be the check valve you talked about?

[@MrFixit1]

Check the valve for proper function but may be something else like the cable not adjusted correctly. The more you advance the cable the more oil you get.

[@davidferency3339]

@@MrFixit1 Copy that I had to replace the throttle sensor. I will check that gap that you recommend

[@wes7322]

i just serviced the oil pump after premixing the gas for years. Now i have oil dipping from the under side of the pump housing. It looks like something might have put a small hole in the housing. It doesnt appear to be coming from the bleeder screw, could a seal gone bad causing oil to leak into the housing. I did get a steading flow of oil to the check valve when running the with the line unhooked from the valve. thanks

[@MrFixit1]

OK there is supposed to be a hole in the housing from the factory for this reason. Possibly a seal failed but I would check the plastic line at the pump end for a leak. The bleed screw plastic seal would be the next culprit. It is also possible that the feed line is leaking into the housing. I haven't disassembled a pump yet to see what's inside so if you feel adventuress and you take it apart, maybe you could let us know what you found. Thanks.

[@thatmodshop7160]

Why would you bother if premix has been working for years lol

[@smallmiraclesgarage622]

sounds like the common piston slap and cracked skirt.

[@MrFixit1]

Yeah, at the time this video was made it needed a top end. No broken piston skirts but definitely had slap. over 7500 miles on this machine.

[@smallmiraclesgarage622]

@MrFixit1 I rebuild a lot of them 400s I was just surfing around and saw your video and then I heard the famous sound lol. Good video though thanks

[@omegared7p]

Great video. Nice job

[@timlynch6154]

Question, just for a quick confirmation that the pump actually works, could you just pull the output hose while engine running, give throttle and check for oil coming out? That is just to check it’s working

[@MrFixit1]

Yes, you can do that. Just don't let it run long because there will be no oil going into the engine. Unless you are running mix in the tank.

[@shelbywilson114]

Hi thanks for the videos. I bought the exact same quad a year or so ago. Only 450 miles on it. I've never heard the cooling fan kick on. I started to take the front plastics off and gave up. I saw that it does have a temperature light. My question is how often does your fan kick on? Thanks in advance

[@shelbywilson114]

I did trace wires and they are connected

[@shelbywilson114]

I have a 4 stroke sportsman 800 and the fan comes on a lot on it

[@MrFixit1]

My fan only comes on when I work it hard like haul firewood up the hill, doesn't really come on much, takes quite a bit of riding on a hot day for my fan to come on.

[@BrianUller-c5j]

Question for you. Oil pump does not spring back like yours. I replaced the spring behind it cleaned what I could see. With the cable on it or off it doesn’t have that fast snap back yours has. It get caught open slightly I believe and quad won’t start. If I push the rotating piece back to idle position it starts and runs fine. I have a spare pump it’s just nearly impossible for me to get in and work on it. I did the cable with my phone just to be able to see in there

[@MrFixit1]

I'm sorry I don't understand your question.

[@BrianUller-c5j]

@@MrFixit1 in your video the part that the cable attaches to snaps back to closed when you let go of it. I put a new spring on mine as it wasn’t turning. It now turns but does not always go back to the idle space. I’ve found that it won’t start with the oil pump in anything other than the idle (basically fouling the plug). The not springing back is the question. Does that indicate that the pump needs to be replaced after replacing the spring

[@MrFixit1]

@@BrianUller-c5j If you have a replacement pump then I would replace it. You may want to take the bolts out of the fender where it mounts the floorboard and remove the Air tube that has the coolant overflow tank to get more access to replace the pump. Not much room there to work.

[@Intentionallyalone]

Just bought a project 97 sportsman. Come to find out there is 3 holes in the case exposing the gear on the oil pump. Any idea how that would happen? Should o just delete the oil injection?

[@MrFixit1]

Hole in the case Exposing the gear? Thats doesn't sound good. Wear exactly is the holes. The Oil pump gets lubricated from the balance shaft and if this oil is leaking it will cause major engine damage.

[@redddave]

So, I have a trail boss 350L doing my first ever top end job on it, it lost compression kind of wondering if the oil pump stopped working. I was thinking of removing the oil pump, but how do you get these Phillips screws off the pump enclosure with the lower half of the engine still in the machine?

[@MrFixit1]

Try a Phillips bit and an extension on a ratchet. NOTE: Re-moving the oil pump will allow the balance shaft oil to flood into oil pump cavity and out of the oil pump housing.

[@redddave]

I was going to just remove the drive and reinstall the pump to block up the opening. I try the ratch... those things are on tight!@@MrFixit1

[@MrFixit1]

@@redddave There is a special tool called and impact screwdriver. You use a hammer and strike the end of the tool. Search on the net or local part stores.

[@thatmodshop7160]

Ive deleted oil injection on both my xplorer 400L quads reason being is that the pump box no matter what I do to seal it, it fills up with water causing the cable to sieze, lots of guys drill holes in the plate to allow water to flow out but it honestly makes no difference. I simply dont put oil im the reservoir mix gas and go never had my mix cuase an issues years later, also take a jerry of mixed gas and regardless always have 2 stroke oil with you like you do riding a 2 stroke anyway .. Ive done the same thing with my 98-2004 RMK700 motors 🤷

[@MrFixit1]

There is a rain hole in the bottom of the housing. I have not had this problem although that would be super annoying. I don't blame you for your decision. Happy riding!

[@thatmodshop7160]

@@MrFixit1 man your channel is super awesome, great knowledgeable content and a wealth of information! That weed wacker gas tank/coolant reservoir idea is genius and I will be doing the same to both mine I actually found 2 new ones I hope work, do you mind of mind personally contacting me so I don't spend the $80 on tanks for nothing lol

[@MrFixit1]

@@thatmodshop7160 This is my email: [e-mail]

[@pizzamangametime9773]

I know this video is old but I got s question for you. I have a 1995 big boss 400l and took the plastics off to paint them since i had most of them off to replace the coil and cdi. I started it a couple times over the couple days i was putting it together and it ran fine and smoked like normal. Once i had everything together i started it up and took it down the street and went to park it. It died on me suddenly and i started it back up then it revved all the way up and died then sounded funny cranking and was cranking hard(couldnt use the pull start either. I pulled the plug and cranked and it sounded fine. I put it back together and now it wont start. Any ideas?

[@MrFixit1]

Hard to say. I'm just speculating here but revving wildly is a sign of a vacuum leak. check the crank seal behind the drive clutch for a leak I have seen this seal back itself out of the engine before also the intake and cylinder base gasket could have blown out. Also check the crank case drain bolt. It could be something else but, that's where I would start. Hard cranking sounds like something bad. Hopefully no engine damage occurred. Might want to pull the carb or exhaust to inspect the piston. 2 stroke engines are always on the brink of destruction.

[@pizzamangametime9773]

@@MrFixit1 I was looking at it this morning and discovered that there was no oil supply to the oil pump I believe it ran out of oil and committed self delete of function

[@MrFixit1]

@@pizzamangametime9773 This is sadness

[@WagsAutomotive]

Question: is there a way to bypass the electric hubs on the front wheels and make it full time 4wd?

[@MrFixit1]

This is a bad idea but yes. Hook the gray wires from the hubs to the red/white port on the circuit board. A better way to do it is to connect the gray/white wire from the AWD switch to the red/ white, that way you can turn it on and off.

[@WagsAutomotive]

@@MrFixit1 What I meant is can I eliminate the wires altogether? Is there a way to make the hubs be engaged without any power going to them?

[@MrFixit1]

@@WagsAutomotive Not possible. You could get struts, hubs and axels from a 2005 Sportsman 500 shaft drive and maybe make it work. The Hillard clutch is electromagnetic, will not work without electricity. Although it would be very hard to drive this way with a solid rear and locked front. You will need arms of steel.

[@WagsAutomotive]

@@MrFixit1 ok then I guess it's 2wd. Good thing I have a winch! 😁

[@MrFixit1]

@@WagsAutomotive You can replace the magnet coils if that is the problem.

[@danielmuldowney7483]

Would letting that run dry and just filling the gas tank with pre mix cause any issues?

[@MrFixit1]

I don't think so. A lot of people have done that without any issues.

[@cbossplayz3555]

i personaly oppend up the pump housing and pulled the drive gear off the pump by tapping the pin out and just installed it just to be safe

[@michaelbarlow4468]

I checked the antifreeze and it appears to be thick like it's jelled. Is this normal ? And why it would jell like that if it isn't.

[@MrFixit1]

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

[@michaelbarlow4468]

@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.

[@storyoc]

looksw like on your bench setup u have some maybe marvel mystery oil cans laying horizontal w the side cut out staked on top of one another to use as storage bins/trays-am i right???

[@MrFixit1]

I'm not sure what came in the cans, very well could have been Marvel Mystery Oil.

[@StarshipFab]

How much oil needs to be in the front reservoir?

[@MrFixit1]

Holds two quarts keep it topped off.

[@StarshipFab]

@@MrFixit1 thank you!!

[@WagsAutomotive]

Can you tell me what the override button is for on that machine?

[@MrFixit1]

The "Override Button" is to bypass the reverse rev-limiter and allow AWD in reverse.

[@WagsAutomotive]

@@MrFixit1 Ok my 4wd doesn't work so it's not gonna do anything for me.

[@MrFixit1]

@@WagsAutomotive It will allow full power in reverse

[@tylermudge9118]

I am looking for a coil pack and cdi box for this machine. Does anybody have a good link? I have no problem fining one for 96-01, thanks in advance

[@alansgarage03]

So the oil of the engine need to full it in the front where sais oil?

[@MrFixit1]

The 2 cycle oil goes in the front by the head light.

[@alansgarage03]

@@MrFixit1 thats the oil of the engine ?

[@MrFixit1]

@@alansgarage03 OK, I think there is a language barrier here. Just to clarify. The engine is a 2 cycle engine. The engine runs on a mix of oil and gasoline. The oil injection system uses Polaris Blue 2 cycle injection oil and gets injected into the air intake. The engine also has 100cc of 10w-30 motor oil in the balance shaft compartment to lubricate the balancer shaft. I hope this helps. Bien, creo que aquí hay una barrera del idioma. Solo para aclarar. El motor es un motor de 2 tiempos. El motor funciona con una mezcla de aceite y gasolina. El sistema de inyección de aceite utiliza aceite de inyección Polaris Blue de 2 ciclos y se inyecta en la entrada de aire. El motor también tiene 100 cc de aceite de motor 10w-30 en el compartimiento del eje de equilibrio para lubricar el eje de equilibrio. Espero que esto ayude.

[@prestongriffin416]

i have a Polaris 400Lhaving a ground issue any ideas what to look for and where,

[@MrFixit1]

I'm going to need a bit more info before I can help.

[@highlifegoodlife5400]

Is it a bad idea maybe put couple table spoons of oil in the gas just in case oil pumps not working so it dont wreck nothing curious on ur thoughts I don't think Mines bad I just don't want to blow it up if its not getting the oil it needs?

[@MrFixit1]

Really, a couple tablespoons of oil will not be near enough oil to add any safety.

[@highlifegoodlife5400]

Well like half a cup or would it be bad because the carb would be get to much oil

[@highlifegoodlife5400]

How often do u fill the oil tank in the front?

[@MrFixit1]

@@highlifegoodlife5400 Might start fowling the spark plug at that point. Note: if it isn't smoking something is wrong. So that will be an indicator, also it will overheat and will struggle to idle.

[@MrFixit1]

@@highlifegoodlife5400 I fill my oil tank once maybe twice a year but I don't ride a lot. something like every 4 or 5 gas tank full for 1 oil tank full.

[@gregnapert9231]

The problem I have is it's injecting too much oil! Is there a chance the cable is hanging up or the return spring has failed?

[@MrFixit1]

Yes, there is a good chance of the happening.

[@gregnapert9231]

@@MrFixit1 Thanks - will check it out.

[@Coltster14]

I have the same exact quad !!!

[@luisacolon-sanchez1276]

Hi! I recently bought a Polaris Sportman 400 2-cycle four-track vehicle. The oil injection pump is disconnected. What mix ratio would be the best for the engine to work? Also, is it harmful for the oil injection pump to be disconnected? Thank you very much for your help!

[@MrFixit1]

32-1 would be a safe ratio. As for the pump I would think it would be ok but I can't say for sure if it will cause damage running it dry. I'm sure many people do.

[@luisacolon-sanchez1276]

@@MrFixit1 Thanks! Also, why does the vehicle lose power after a short time of using it?

[@MrFixit1]

@@luisacolon-sanchez1276 I can't really help with that unless I had more information. Could be a lot of things.

[@luisacolon-sanchez1276]

@@MrFixit1 the engine is not accelerating well. Do you happen to know what spark plug number does that engine require?

[@MrFixit1]

@@luisacolon-sanchez1276 I believe it's a NGK BR8ES

[@josephspexarth4166]

Great video

[@killerrush77]

what year is this bike?

[@MrFixit1]

1994

[@bondvagabond42]

Diesel mechanic here: I put new ones on customers cars, but an old timer showed me you can sand them down with a little 600grit wet sand paper, and reuse them many many times. I have done it on many of my own diesel motors with I'm sure much higher psi behind them, with not a drop dripped, hah.

[@soren4869]

What can I do in the even that it is pumping too much oil

[@MrFixit1]

If you have the pump set up correctly and it is pumping too much oil, then the pump may be damaged.

[@soren4869]

@@MrFixit1 If that’s the case would you just recommend a block off

[@MrFixit1]

@@soren4869 Of course I recommend fixing the issue not deleting the pump

[@soren4869]

So how can I turn the pump down?

[@MrFixit1]

@@soren4869 if you set up the pump correctly and you are having problems replace the pump.

[@la_plata3588]

I've been robbing so many parts from my parts machines.for my buggy lately saves lots of time and money

[@TheWildBoySteveO]

I think i blew my motor i thought I was adjusting idle by twisting the throttle cable lmao

[@MrFixit1]

Oh no! I hope not. Check compression, less than 120psi is the service limit and pull the exhaust pipe and look at the piston to know for sure.

[@skiptaggart8116]

THANKS!

[@kennethfrancis6209]

Wya i need my polaris serviced and a bayou 220 revived from the half working LOL

[@ozarksfamily2015]

Personally I don't even use the oiler in my polaris I just mix the oil piston and cylinders are too expensive

[@MrFixit1]

Yeah, I get it. You don't have to use it. I know it freaks a lot of people out. I just like the convenience of it. I been running it for years without any issues. Machine has over 7500 miles on it now.