A little history...98 xplorer 400, 2" lift, 26" mud runners(heavy).

Over the last year I started to notice it become a bit doggy in High gear. Low gear it runs like a champ, lots of pep. Out of the hole (high) it is doggy and the motor takes time to get revs. Once it gets moving it runs out pretty well.

First thought was compression, checked out at 104...time for a rebuild no matter what. Went with Ritter, bore, Wiseco, Rings, gaskets...etc. All back together, proper break in is done. Starts up nice, idles...good to go in that regard. After break in was done I ran it through the paces and still does the above. I also noticed...when I was in a sloppy water hole, (clutches weren't wet)...I had to reverse out as the water was high and moving, didn't want to take the chance of crossing(chicken). When I gave it throttle to get the tires turning in reverse it bogged. Wasn't the limiter, just kind of acted that way.

I kind of lean towards clutching? I havn't had a chance to pull the cover and take a look yet though. It's basically happening when I put a load on the motor, out of the hole in high and in reverse....it bogs until the motor gets some revs going. Thoughts?

Wenty

 

Have you just looked at the belt first for stretch or excessive wear? Plus low range intended for pulling loads, high range is designed for no load riding,will burn up and glaze belts under loads. OPT

 

Good thought...I will change the belt regardless as it's been on the machine for a while. I run mostly low gear, plowing snow, ice fishing, woods riding. I've never run my machine in high when should be in low...but I will change the belt out anyway as it's been on the machine for about 4 years now. Good time to check out the clutch(s) as well.

Wenty

 

Well OPT...check the simple stuff first! Pulled the cover off to inspect the belt/clutches. First thing I noticed was the belt dust, hands were black in a hurry. I also noticed the belt was sitting low on the driven...just a hair below and belt had light "sheen" to it. So it's definitly in need of replacing. I checked out my clutches, everything is snug, smooth easy in/out with the primary...nothing binding.

Out of curiousity I brought the belt inside, cleaned with hot soapy water and lightly scuffed with a 3m pad. Cleaned the clutches and inner cover. Reinstalled the belt and took it for a spin. In high gear the doggy feel it had prior was much better...but still had a hair of hesitation...I attribute that to the worn belt. I put it in low to test it out...lets just say I was a bit UNPREPARED!! I canned it from a stop and nearly flipped backwards!! I almost forgot how much snap these 400's have...The new top end along with a clean belt was night and day different...with a NEW belt I should be on my way.

With the amount of plowing, low gear, heavy work i do with this machine...am I better off with a HD belt...or one other than stock?

Thanks

Wenty

 

im thinkin bout changing sprockets on my xplorer 400,..i got a lil taller tire too an just feels like low ant to low an high is lord faster than a 4wheeler need be!! lower geard sprockets have to help low end grunt a lot!

 

check the buttons in the secondary clutch, Ill bet there worn, replace them then put on new belt

 

alot of times when people feel like thie rbikes are doggy in the older bikes w/ the non roller set up the buttons are the biggest cluprit. an easy fix and cheap as well.

 

Well...

Again, it's the simple stuff!! I changed the belt out and it helped quite a bit. But still a bit doggy out of the hole and I had a slight "miss" at mid range. Beyond that thought it ran out "ok"...so I thought. Went through the list of simple things in my head, thought maybe needle/seat. As I was pulling the lid off the airbox I noticed the issue, air filter...plugged, it was black. Literally couldn't get any air going through. Installed a new filter today and it runs like a raped ape again. I realize now just how doggy my machine was throughout the range!

I must admit...I feel a little silly for posting and not having gone through the simple stuff first.

I had the clutches apart last fall when I replaced the swing arm and everything was in good shape, and still seems to be. Buttons are good, smooth in/out of both clutches. That said, I should probably replace the buttons, just because they're a wear item.

Truth be told...I have totaled this machine out twice now. I've spent so much time/effort into repairing the major stuff, first the front end, then the rear, then a new top end, that I honestly overlooked the maintenence items...and thats not like me. Well, it's a good reminder anyway...check the simple stuff first. How is it a can completely rebuild a bike front to back but I dismiss the belt and air filter??!!!! Ugh.

Wenty

 

wenty what size sprocket do you have on the back. 34 or 38 and front chain small sprocket 12 or 13 you can go 11 on the front drive sprocket leacing the 38 on and going to a 12 on the back drive sprocket.

Do you have any clutch mods? a stiffer drive clutch spring and 53g weights over 55g
at 2000-3000 feet. that's what my stocker runs. i can check what color sring that is.

 

Pretty sure my rear is a 34T, front is a 11T...stock I believe, which were replaced last fall. Clutching is stock besides secondary spring being at "2". I was considering a kit or going with some different springs/weights with the way the machine was acting recently. That said...with the way this machine runs out after rebuild and maintenence, I'm very pleased with performance.

We went riding yesterday with a group of 4, a nice mix of top end and mud/4 low(lots of mud around here this year)....been rainy this summer!
Machines were a stock Rancher and popo, foreman w/27's and myself. Rancher got stuck....ALOT! (hehe) Myself and the foreman with tires were running circles around the other 2 in the mud, showed how big of a difference tires make. Stock popo made it through but really had to work it. (said he's ordering tires this week!!)Top end I was right there with the stock popo, low gear I threw mud...lots of tire turning torque! Seemed I had the easiest time jumping out of the ruts and moving around the mud holes. Yesterday was the test/run I needed to convince myself the Ol' xplorer can still get it done...and done in good fashion! Bike ran and performed great.

Wenty