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I picked up a 94 sportsman 400, unknown hours, overall in good running condition, except for these issues.

1. Carb leaks like crazy, in 2 hours or so, I use a TANK of gas, yet I see no "leakage" anywhere.

2. 4 wheel drive not engaging no lights that it is engaged, but once in a while if i play with the switch it will engage.

3. repairing or replacing the rear brakes.

I cannot locate a book or maual for this unit, and I am not a atv expert by ANY stretch of the imagination.

I got a note from a "polaris" guy that said: "some of those sportsmans where early efi and there was a flaw in that that sent gas into the air box"

Can this be confirmed?

I really really like this 4 wheeler, it has enough power for my usage, and is a real beast going up the mountain......

I had preliminarily talked to a Pol dealer, but his "guesstimates" scared the crap out of me. I am of limited resources, so can use any and all help available. How to's ?

 

Haynes makes a good manual for you to research on do it yourself repairs. A LOT of dealer wont take in a 15 year old machine and to address all problems would be costly! Manual will pay for itself quickly! As for gas problem could be carb dumping( 94 models had a bulletin to support carb with a rubber mount under float bowl at transmission.Does yours have this support? Also can be internal carb problems,needle valve assy,reed valves broken/distorted allowing too much fuel. ALSO 2-stroke 400 uses a lot more fuel than the 4-strokes simply by design. If gas in air box then could be carb,as far as 4 wheel drive, switch on this model controlled by shift box wires instead of trans switches,shifter can get slack over the years and NOT trigger 4-wheel drive without pushing hard on lever. Usually lights up in low range! IF this is happening,shift box repair/replacement needed. PLUS switch itself can be shorting or small internal bulb may not be making good contact. Manual will explain how to repair brakes! OTHER MEMBERS will help,BUT a HAYNES manual is worth the 20 bucks or so! Good luck, keep us posted.

 

tyvm for the info, i found a manual on ebay a haynes, it will be a week or so, but I did go out and look at the carb situation, there is no rubber mount under the bowl area, should i try and fabricate something, and was its intent to push the back of the carb upwards somewhat? Also can you please tell me what that big red **** is, on the top of the case? (Its under the carb and to the right of it.)

"switch on this model controlled by shift box wires instead of trans switches,shifter can get slack over the years and NOT trigger 4-wheel drive without pushing hard on lever." What lever are you in reference too? I only have a push button type switch, then of course the shifter itself. (Do I need to be in low range for 4 wheel to work?)

re rear brakes, when I step on the peddle positively nothing happens, I kept watch on the caliper, and I didn't even see a attempt at working......

 

Shifter lever assy and awd (4 wheel drive) light switch button work together for completion of circuit. Has switch in shifter box also that shows gear display and triggers awd light. CARB ADAPTER kits for under carb are still available from dealers,last time I checked about 15-16 bucks? ALSO preferable to be in LOW range under pulling conditions and awd if needed YOU DONT have to be in low for light to work,its just that from my experience most people leave in hi range and over time shifter box switch will wear and awd light will not light up unless extra push forward on lever because of wear. When you shift to low which is normally NOT used as much,USUALLY makes better contact on switch and awd light works. Rear brakes may need adjusting( loosen locknut and TURN large plastic nut clockwise) or caliper piston might be frozen and need repair. DONT FREAK just get the manual and take it one step at a time! PS RED **** is counter balancer dipstick,holds 30 wt oil only about 75-150 cc oil (cant remember off top of my head) but dipstick has a full line.