I just bought a 96 polaris 400 sport a couple of months ago, and I believe the transmission may be going out. Me and a friend were seeing who could out-push the other on their quad, and mine started smoking from the middle of the quad....I immediately stopped. I drove it around a little and it felt fine, then I went to put it up and noticed it revved a bit higher before going into gear and make a couple of clunk sounds when it did.

I have a decent amount of mechanical skills, built the 350 in my truck a couple years back...and want to know how hard it would be to fix this if their indeed is something wrong with it. I think I may have just blown a transmission seal or stripped a gear or something. How hard are the transmissions to fix, and are they a permanent part of the motor, ie...does the whole motor/transmission have to be replaced in one piece?

Thanks for the help.

 

You've burnt your belt. Take the cover off the left side of the Sport and replace the belt. It is not a good idea to try to pull with a Polaris. The belt will slip under these conditions. HPD and Aaen Performance have good aftermarket belts that can have extended belt life over the Polaris belt.

 

Sounds like you may have worn a flat spot in your belt. Replace it and see if that helps.

 

YES!!! I am so glad that this thing doesnt require any rebuilding....thanks a lot!!!

 

HMM started smoking? Yep sounds like a belt. SMOKED!!!!

 

Ok, anyone want to explain to me how to change the belt....I'll be picking up the belt tomorrow and want to have it done by saturday.

 

Take the cover off your belt drive (left side). Pull the belt up and over the rear pulley, it may be tight. Then rotate the belt in the clockwise direction and it will come off.

 

Also Farmr I think It is easier to do this with the quad in neutral. [img]i/expressions/face-icon-small-smile.gif[/img]

 

You change the belt just like a snowmobile. Oh, wait, you're from Georgia! Sorry, couldn't resist a little good natured ribbing! The other guys are right, don't pull (or push, or power brake) a belt drive quad. You can tow or plow snow (like you care about that) well with a Polaris model with low range, but don't try with your sport.

 

Hah....yeah....we dont get too much snow down here....I think we got MAYBE 2 inches one time....the most snow I've seen here was about 7 years ago, we had a nice little blizzard in may....other than that....no need for a snowmobile...plow...or anything else but salt. Hopefully I'll get it done tomorrow....thanks for all the help!