Dad's 400L broke the piston skirt and took out the cases. I'm removing the engine from the frame for him. Almost done but got a couple questions. How do I get the clutch hub off? And are there any tricks that I need to know about? That is about it I think and she's ready to come out.

thanks for your help, Kyle

 

Are you talking about the clutch? If so, the front one(drive clutch) has to come off with a puller......your dealer might let you borrow one, or you can buy them on hpd's website(www.hpd-inc.com). The rear clutch(driven clutch) comes of by just taking out the bolt that holds it on.


What the clutch puller does, you take out the bolt, and insert the puller(basically another fancy bolt type thing) and you twist the bolt in, and it pushes the clutch off of the shaft. While doing this, you have to have a bar to hold the clutch, and might have to tap on the clutch puller with a brass hammer(careful not to mushroom the end).

 

Oh.....and replace that piston with a wiseco too. You might also have to have the cylinder bored or honed.

 

Take it to the Polaris dealership to have them pull it for you. The dealerships will usually pull it for free if you ask.

 

the primary clutch wont come off without the puller and the bolts arent backwards thread..

 

thewayout.......I didn't want to say anything, but I agree.......his post is about totally backwards. Mine never came off without a puller(and it came off hard every time too)......and the threads on mine were normal.



Remember when you put the clutch back on to take some emery paper and take the rust off of the shaft. Makes it a little easier next time.

 

Thanks guys, that's what I had figured that I needed a puller.

I will replace it with a Wiseco piston and I'll probably go ahead and have the cylinder bored even though it looks in excellent shape. Might as well as start new.

Anyone else have idling issues with these engines? This one has never idled since dad bought it with less than 200 miles on it. We did replace the main after noticing the one in there was for higher elevation but that didn't help. Don't know if it's in the carb, think so, or not.

Thanks again.

Kyle

 

why do you want to take the primary clutch off? it's not necessary

 

Not sure if you have tried or not, but adjust your idle screw. Does it have a rough idle? You may want to take the carb apart and give it a good cleaning. The main jet doesn't affect idle. The Pilot Jet affects your idle. If it had the Higher elevation Main jet they would have adjusted the Idle air screw as well. You will need to tune your carb for the lower elevation, it may be running to lean at idle.


--Dave

 

where'd that come from dave? they were talking clutches and blown pistons! lol