I am getting a '01 Xplorer 400 4x4 tomorrow. Anything I should know about break-in or anything else? Please let me know.

BTW, I'm taking it up north this weekend to break it in before deer hunting.

 

Take it easy first couple tanks of gas. Don't just idle around, though. Try to run from 1/3 to 2/3 throttle with alot of speed variations. Let it warm up before putting load on it. You can ride as soon as the engine runs clean, but take it easy for the first few minutes.
Also, don't be alarmed if the 4wd doesn't seem to work very well right at first. My brother in law got 2 new machines this year - a Sportsman & Magnum - both 500s. The Magnum's 4wd didn't engage right away. He was ticked! I suggested he trail ride with it in 4wd & within 5 or 6 miles of riding, it worked beautifully.
Your chain will stretch some almost right away, then wear more slowly, so don't be alarmed at that. Check the coolant level frequently as the level may drop if there are any air pockets in the motor.

Lastly, don't forget to smile and wave at everybody you pass after you get it all broken in!
Farmr

 

Use a pre-mix in the firsts 2 tanks of gas. It will help break in the new piston and is also recomended by Polaris.

 

I am curious about this pre-mix thing. I have heard this several times and wondering...would it not have too much oil to burn? Especially with the auto-injection system working.

Just curious...

 

I think that that is the idea, to get as much oil going through the moving parts of the engine to make sure it starts it's life off well lubed and doesn't end up grinding itself up.

 

Farmr123,

Do you not ride until the engine runs clean? Sometimes, it takes 5 or 6 minutes before mine cleans out. I always just run it easy for a couple minutes and then run it hard enough to clean itself out. Once it revs clean, it's good to go.

JWool,

Mine ran pretty cruddy for the first tank, but ran much better after I had burned up all the premix(I only ran 1 tank, which is the time required for break-in by Polaris). After that, it ran real good. I put in a Boyesen Rad Valve, and it seems to make throttle response and acceleration almost instant.
Make sure the tires are at the recommended pressures, otherwise, the bike will not ride as good.
Take a grease needle and fill each of the rubber boots covering the tie rod ends(inner and outer) with grease to pro-long their life.
If you expect to travel in much water, raise the height of all the vent lines. I ran all mine down into the top of the steering stem. The vent lines I know of include:
1) front gear box
2) transmission
3) counter-balancer
4) carburetor

Also, after break-in, either get the dealership to adjust the oil injection system or do it yourself, as it is set rich from the factory. This will save you oil along with producing less smoke. I'm sure that even when set correctly, the engine is getting more than enough oil.

When adjusting the chain, be sure to loosen the bolts that hold the brake caliper mount in place.

Get some good chain wax or other lube to keep the chain in good condition.

I would also check the air filter to make sure that it is seated correctly, and is making a good seal.

As far as lubricants, I would use the Polaris Gold injection oil, and use mobil 1 synthetic products everywhere else:
Mobil 1 synthetic 75W-90 Gear lube in the front gear box and transmission
Mobil 1 synthetic ATF in the front hubs
Mobil 1 synthetic 10W-30 oil in the counter balancer
Mobil 1 synthetic grease for all the zerk fittings.

I would also grease the machine right away, since one of the zerks that is hardest to get to had not been greased by my local dealership. I discovered this by noticing how much grease I had to pump in before any came out.

I'm probably just rambling now, but I could come up with a few more, I'm sure. Let me know if you have any more questions. I don't know everything about the Xplorer, but enough to get by.

 

Thanks guys. I got my Xplerer today, and already impressed! The upgrades from my '96 are defiitely noticeable. I pre-mixed 4 gallons with 12.8 oz. of Polaris 2 cycle oil. I had to have the brakes adjusted at the dealer before I brought it home. They were sticking in the rear and making a noise when pressing on the rear suspension. Also, the dealer only had about 0.5 gallons of gas in it when I got it. They did however fill the oil with the polaris gold. Also, the reservoir for the hand brake was low, so I had to add some Dot 3. The handle bars seem to be a little low, but I will get used to that. So far so good.
What do you guys recommend for chain lube?
Also looking for a rear rack extender and a gun scabbard. Dealer wants $70 for the rack extender.
Thanks for all the help!
Joe '01 Xplorer 400

 

I meant to wait till it runs clean during break in. Once mine was run in I do the same thing you do. Must have done something right as it is running as strong now @ 3600 miles as when new.
Very good post, by the way. Came up with a lot of details I forgot to mention.
Farmr