I recently helped a friend of mine, rebuild his Xplorer.
The reason is, that on a day long trip, his oil injecter quit, and the whole side of the piston blew off.
He ended up completely rebuilding the engine with a new piston, cylinder bored 20 thou. over, all new bearings and about $700.00.
While it was apart, we thought that if the engine was new, the Quad should look new.
We started with 600 grit wet sand paper, then 800, then 1000, and finished with 1500.
It took a lot of hours, and a lot of elbow grease, but it looks pretty good.
Needless to say, the injector was replaced with a steel plate, and now he does all the mixing by hand.
Go here for a look, and while your there take a look at the Scrambler 500 on a recent trip .
P.S. We got a local Sign Shop to make the decals.

 

Oil injector quit...i know how that feels, I got off lucky, i only had to replace my piston and bore out. Only cost me 50 for the piston 20 for the gaskets and got it bored for nothing(friends with a guy that does it)

I used the think they would never go out, but i will never trust one again!

The plastic looks great, and those decals look good too, i never thought of that. When i had my Trailblazer i really needed new decals. All the polaris ones sucked.

 

Aaron...
The thing is, I went to the Polaris dealer, and asked how much it would be for a complete new set of decals...$150.00 !!!.
Unfortunately, Polaris plastic contains a lot of Parafin to keep it pliable, so hopefully they will adhere properly.
Hey... nice looking Quad...

 

my trail boss also suffered from some oil injector problems once... back when my grandpa had it (he passed it down to me when he got his spt 335) he was riding full throttle down the road, and for some reason the oil injection cable had gotten stuck. so it was giving the motor the amount of oil it needed at a idle, not at top end. It froze up tite, couldnt even pull the starter rope. Pulled it home, the next day, got on it and it started right up. Hows that for durability honda lovers hehe

 

$150 for stickers? That's crazy.

Hopefully they do stick. If not maybe you could use some spray on glue. That might stick better.

Thanks for the comments on the Trailblazer. Some days, I still wish i had it.

 

I have had the following 2-stroke bikes:
250r, lt250r, blaster, rm125,cr125,cr80

All of which I have removed the oil injector. It is easy and full-proof to pre-mix your fuel, and in aging bikes you get a much more accurate mixture meaning your top end last longer.

Just my opinion.

Greg