Hey Everybody! I'm a newbie here so try and bear with me.

I have a 1992 Trail Boss 250 that runs good, but has a few problems.

First off, it is loud. I don't know how loud this machine should be. When I take it out, all I hear is the engine/exhaust from under me. I do not hear the exhaust out the back. Are there gaskets that I need to replace, or is everything just held together by springs? I can see a little smoke leaking from where the head pipe connects to the tail pipe. Do they sell donut gaskets or manifold gaskets for these or should I just buy new springs. All I know is that an exhaust leak on a two cycle is not a good thing. It's as loud as a mid 1980's snowmobile with the hood off, plus I don't hear the sound coming out the back. I debate whether to buy ear plugs for a long ride.

Second...
I bought it and the headlight was burnt out. I put in a new one, hit the gas, and pop. My brother told me I need a new voltage regulator. But, since my starter is junk, there is no batter. Could that be the problem too? Does a battery absorb voltage spikes? Is there a way to test a voltage regulator? It pull starts just fine so I did not feel the need to put a battery and starter into it.

Like I said, the machine starts/runs great. I just have a lot of nickel dime problems. Exhaust, electrical, bushings, breaks. But this seems to be a good starting point.

Any help is Greatly Appreciated!

 

Try new springs first, verify that the muffler isn't plugged wiyth nowhere else to go. Yes it needs a battery to help control the voltage. Doc

 

Joe:

If the lightbulb pops when you gun it, that points to the voltage regulator being a problem. It is supposed to limit the voltage as RPMs increase.

I have a 1988 Trail Boss, and it is loud. I am also a newbie, so have no frame of reference, but it certainly is loud. (You have to be close to someone to have a conversation even at idle). Mine is a 2 cycle, and I understand that loud is normal. I assume that the 1992 is 2 cycle also.

One other note, since my 1988 was refurbished same as you are doing: the brakes certainly aren't "nickel and dime" ! (at least on the 1988 model). In fact, Plan A was to replace all 3 brake assemblies, but when I saw the prices, I quickly went to Plan B (take apart and clean up as best I can). They are now good enough for normal use.

 

Take your battery out Carl and see what happens, you admitted to being a newbie, sit back and learn. Early Polaris quads needed the battery to knock the voltage down. Doc