Bill,
Yes.. there is that nylion bushing... sorry, there is another one that im referring to, its the bronze bushing in the primary clutch cover plate... Its there, and when it gets loose, your engagement won't be consistent...
Look for it when you get the new spring...

 

Yes my 98 400 Xplorer well wheelie big time. Even with a winch on the front and 1200 miles on the orignal belt. It has to be in low range and on pavement. In grass or dirt it just spins.

Andy G

 

I will get that part number on as soon as possible. It's buried somewhere in my filing cabinet. I will be on it first chance I get. Your dealers should have the part number though. It's the EPI sport/utility kit.

I am still surprised that some of you can wheelie that machine... Maybe I am just to chicken or not doing something right?!?!

 

Bill, Did your dealer set up the proper amount of belt deflection? It should be 1 1/4" Factory belts can vary as much as 3/8" of an inch in length. You must set up the belt tension by adding or removing shims in the secondary. Your best bet is to get the deflection set up with a new belt then remove it and measure it carefully, then write that measurement down. When you need a new belt just take your measurement to the dealer and check belts until you get a good one.

I dont have these problems anymore, I sold my 2000 Scrambler 500, And my new Raptor doesn't have a belt!
See YA Drew

 

Bill,
You may want to reset the air screw on the right side of the carb. It should be set to 1.5 turns out. If your spark plug is black, try changing main jets by going down one size at a time. I understand that a brown color is what you should be looking for on the plug. My Xplorer has a rad valve installed, a 195 main jet, and the air screw is set to the above mentioned factory setting of 1.5 turns out. It will wheelie in low range and in high range. It would not wheelie in high until I changed the main jet from a 200 to a 195. My plug is a dark chocolate/black color. If you buy any jets, be sure to buy genuine Mikuni jets. I paid $5 each for mine. It is easy to change the main jet, and they're cheap. You just remove the air box, loosen the front clamp on the carb, pick the carb up, remove the 17mm nut on the bottom of the carb, and then you'll be looking at the main jet. Don't overtighten the new main jet or the 17mm nut I mentioned.
Other than that, you could call Steve and ask him if he did anything to the carb. Hope this helps.

Waylan

 

Waylan,
I received a phone call this afternoon from Steve.He told me that he got ahold of Polaris and they agreed to buy the belt for me.The dealership refunded me 33 dollars.He stepped up to the plate for me and convinced Polaris to do what they did.

I installed a KN air filter about a month ago.If anything,it should make the engine run leaner.I beleive I got a BAD tank of fuel.Im getting some mild spark knock and a real rich smell coming from the exaust.I have the air screw turned out about as far as you can go with it,[lean]and the exaust still burns eyes.I filled my PU truck at the same time I fueled up the quad,I have spark knock in the truck to.I run 89 octane allways with no problems.The plug was very black,I replaced it.Im going to refuel with some fresh gas tommorrow and see how things are.I dont understand this sudden surge of richness from my exaust.The quad is running fine,except for the smelly exaust.===Bill

 

Mine won't pull the wheels either . But, it seems to shoot outa the hole very well. I have 500mi. on it now and haven't noticed any difference in the clutch application from when it was new. I did notice a nice improvement in the power at around the 300mi mark though. Everything must have seated in. Let us know what you find. I'll bet it's the gas. I've noticed differences in performance with varying tanks of gas and the weather effects it too.