A very good family friend recently bought a 1992 350 4x4 2stroke. This struck me, as I hadn't seen a 2 stroke 4x4 (let alone really any 4x4s out here in southern Cal.). Are there any major issues I should be aware of since I am working on geting it dune and desert ready? What kind of fuel do you recomend (I have a few 2 strokes and they always get premium and race gas with a high end oil). It's oil injected so that is a no brainer. Any help would be gladly appreciated.

Thank you

I don't want to cause any huffing, but I have to say I a have observed quite a few polaris's that have been brought in to a friend's shop and they normally have issues with part quality or electrical. So I am a little leary on this purchase, to say the least.

Also I would like to strip a lot of the extra stamped steel junk and shrouding off to get some weight off the brute. That and are there any performance upgrades for them?

 

More maintenance required than on the 4-stroke,but good machines IF taken care of! Problem areas are broken air boxes(check at box neck area) waterpump bearings and seals,absolute regular air filter maintenance required, oil pump corrosion since on front of machine. NO longer in the Polaris lineup,BUT have customers that keep em alive along with the old 250 2-stroke! Best if your handy with tools as many dealers now refuse to service over 10 years old! Good luck Plenty of members can give you their tips and mods for keeping it going! They do have problems with reverse limiters shorting out,IF worried just pull black wire from terminal bord that goes to limiter (small module above cdi) this eliminates the override button,will have full power in reverse and stopping any future problems!

 

So a clamp on pod style filter would be a good idea out here in desert country. Good, I'll ditch the air box all together, Many of use use them out here.

I notice you emphasized if, I can tell you that maintenance won't be too regular for this tired beast. The owners are not very savy as far as technical know how goes.
Oh yeah they mentioned the radiator fan does not come on, is there a fuse box or is it just direct lined?

 

JUST dont use a K&N unless maintain frequently UNI or equivalent foam filter especially in dusty areas and also must keep clean and oiled or engine will go south!! As far as the fan,can check if fan works by jumping across sensor two wires with needle nose pliers at top of radiator. If fan works,then possible sensor bad. they usually go out because their at the top of radiator and sometimes low coolant level causes them to short out.

 

No K&N filters allowed in my camp. I am a freak about air filter maintenence.

 

I had this exact machine years ago. It had about 3000 miles on it. The engine maintenece is not much at all being all you have to do is change the counterbalace oil vs oil and filter and valve adjustments with 4 strokes. Mine had issues with motor mounts failing, suspension shock tower bushing, starter bendix, A-arm bushings. You have to keep an eye on the 3 drive chains and keep them properly adjusted which is always a pain. Was a great machine would pull great in LOW range, pulled a dead truck through the plowing in low range. Change the 4x4 hub oil, counterbalance, transmission, air filter, grease the heck out of it.

 

Is the any way that I can lighten up the handling on this great pig? I am going to strip it as much as I can but I don't know how far it will get me.