I am looking to waterproof my 96 sportsman 400. I was wondering if anyone had any suggestions on what I would need to do.

 

Well being a 96 I would check the carb rubber intake, seal the recoil, and check the airbox.
Also with a 96 you have the many u.v joints that should be kept full of grease.
How deep do you want to go?
.....Caper......

 

well I am not looking to get too carried away. I was out yesterday and I was up to the headlights and it wanted to bog out, but it went right through. I was just tring to make sure that I was not going to hurt anything cause I am sure it won't be the last time. I am not looking to go scuba diving with it LOL. I noticed that my belt got really wet cause it didn't want to move after I came out of the hole. So I am looking at sealing that up right now. what all could I do to the air box ect.

 

Well just check it all over to see if the air filter lid seals and check to see if the air seal at the carb is good.

When going in water up to the headlights .....I just keep a good steady pace just enough to keep the wake of water in front of you......That way not too much water really gets around each side of the Quad.......Caper........

 

alright I will look it over, cause I know that last time I went water got into it someplace. Is there any tips on the belt, cause I see on the case that there are two holes, that were made that way. do you think that plugging the hole will hurt anything.

 

I know my buddy from work has a 96 or 97 Sportsman 500, ....he is having a problem right now with the clutch rubbing on the inside of the plastic cover. he told me he needs a new one ,made a hole right through. as for your two holes, I don't think they should be there,I not 100% sure ,someone else might jump in here and tell you.
I would say plugged them .It's a place where water will get in.

Is there a threaded hole made for a plug to drain water out on that year?
The newer ones have them.............Caper..........

 

get a new gasket for the cover, some of the older covers tend to warp, may look at replacing the cover as well, you can find one on e-bay.

 

Mine would leak. and I checked everything and was stumped. Turned out the seals # 21 and # 4 were shot. You have to take the primary and secondary clutches off to fix them.

 

that could very well be what the hole is a drain hole, or someones attempt at creating one. I think I may be better to get a new cover and seals like suggested. This is my first quad and I want to make it as good as I possibly can, without spending the enough money, that I could have got a new one. I too have a problem with clutches rubbing on the cover. I am wondering if this is because the clutches need replaced. is there any adjustment that can be done to this? Also how do you know when the clutch is bad, cause it looks so new when you take the cover off, including the belt. like is there a certain amount of play or something to look for. I did plan on replacing at least the clutches but is there more to it then I think? or can i just simply change the primary and secondary and the belt?

 

A 96 would would have the older type belt covers that warped, the new repacement covers don't any longer.