I am going to help my brother fix a few things on his 2001 Polaris 400 Xplorer. He needs a new drive belt, a new seat, new sprocket, and a new starter gear. Have any of you done any of these things? I think that I will have Rexburg Motor Sports fix the starter and I will attempt to do the rest of it. How hard is it to replace the belt will I need any specialized tools? Also is there anywhere online that I can buy the parts? Thanks for any help you can give me.[img]i/expressions/face-icon-small-happy.gif[/img]

 

Belts are a piece of cake!!! Just pull off the cover and force the belt over the driven clutch. You can leave it in gear and roll it backwards once you get it going, just watch your fingers!!! There are som aftermarket seat cover companies out there, check ebay. They have had some pretty nice ones fairly cheap. As far as the starter goes I will leave that one up to someone who knows

Chris

 

I think that HPD has new belts, they say they are better then stock...and they are the same price, $50.00 to $55.00 bucks. I just bought a new belt from Polaris. I did not know at the time about the HPD belt.

 

the starter gear would not be a tough job you could do that yourself to.

 

Got a Kevlar belt from Rick at RCR for 50 bucks. The belts are really easy to put on. Starter gear an the Boss was easy to get to. Take off the Recoil housing, there it is. Haven't done the sprocket, but need to. I'm sure I'll need to do the seat sooner or later.
Rick Ritter

 

the kevlar belt is well worth the money..all the work you mentioned should be a do-it-yourself job,pretty simple to do..

 

do you notice any performance gain with a kevlar belt or will it just last longer?

 

In theory it is supposed to last longer. Only had it on for about a month, so it really hasn't gotten broken in. I replaced a belt that was 4 years old, so it should run better.

 

Gates make the Kevlar belt for HPD. YOu can go to your local NAPA delaer and pick up the same Gates belt for 1/2 the price. The part # is AT4090 for a non-ebs Polaris machine. Or you can get a Dayco Max2 #MAX1121M2 belt for around $30