When I had my 2000 Xplorer 250 4x4 I too was always adjusting the chain, but funny that non concentric drive people rarely do it. My freinds with older chain drives were tightening theres maybe once for every five times I did mine. that is the reason I bought a chain drive or one of them was because they seemed to have no trouble and I figured with concentric drive it would be better but i am not so sure? After having my chain replaced under warranty, I decided that shaft drive was for me. If the 250 was shaft in the rear wow it would be the best buy on the market for sure.

 

I torque mine down to 70ft.lbs. It will loosen slightly in about 200 hard miles but once it gets a little looser than it is supposed to be it hardly loosens up any more. When I first got it I was adjusting it alot trying to keep it at spec.It would always loosen up a little bit pretty quick. Now it gets just a tiny bit out over spec. and pretty much just stays there. I only tighten the brake bolts to a about 15-20 ft.lbs.

 

What would be the problem be with over-tightening the bolts? I seem to hardly ever touch mine and have never even seen my dealer use a torque wrench...

 

Bill,

My 2001 doesn't have an odometer, but I've adjusted mine 3 times in 2 months. One time was after riding in sand. I would bury the quad and sand would start getting between the sprockets and chain, and really stretched the chain quickly. If I were you, I would get some brake cleaner, and while loose, spray the hub where it gets clamped to try and remove any debris and/or chain lube. Then, torque the bolts to 75 ft-lbs if you leave the hitch on. I believe I read that in the owner's manual. 45 ft-lbs without, and 70 or 75 ft-lbs with trailer hitch. BTW, I went mud riding for a whole day in gumbo(clay) mud, and my chain was just as tight as when I started. Up to 1 inch of slack in the concentric drive system should be fine. It sounds to me like your rear bearing carrier is rotating, so what I've suggested may fix your problem. If it is real sandy mud that you're frequenting, that may be some of the problem as well. Hope this helps, and let us know if you figure anything else out. I'm really happy with my Xplorer. Sure, shaft drive would be nice, but I would buy another Xplorer with chain drive over anything else out there. The Kawi sounds nice, but I'm wondering if they're going to have a problem keeping the beast cool, especially in muddy conditions. That, I feel, is one of the many strong points of the Xplorer 400--runs cool even with the radiator mostly clogged. The 4-strokes produce much more heat due to a higher compression ratio, along with reduced coolant flow due to lower rpm's. Anyway, hope you get it figured out.

Later,

Waylan

 

Bill,

I had the same problem on my 99 Xplorer. No matter how many times I adjusted the chain to 3/8 deflection it always came lose. I used a torque wrench at 50# every time I adjusted chain. The problem is the concentric dirve is not a true concentric system. Have your brother follow you next time you think your chain is lose. When you are sitting on your quad and on the gas I bet your chain is a tight as a banjo string. Your brother should be able to tell you if there is any slack.

I finaly got tired of adjusting all the time and just drove mine till I could hear the chain clacking in the chain guard usually about 450 miles.

FYI my mechanic told me the concentric system was not concentric. This explains why so many Scrambler chains have been snapping. Owners adjusting for 3/8 deflection and then landing a jump with no slack = chain break( even a couple out put shafts have snapped here in MN.). Polaris kinda fixed the problem for 2000-01 with an upgraded chain. 99 chains just plain sucked.

Bill just be glad you don't own a 99.

 

I just returned from the dealership.I [once again] expressed my utter disappointment in my chain.They called Polaris and they say it is my concentric drive.A new concentric drive unit is on its way.Steve [mechanic] said he will call me when the parts arrive so he can install them.I sure hope this cures my problem.Polaris is paying for EVERYTHING.

Just this morning,I adjusted the chain,tightened the bolts to 70 ft lbs,drove it in my driveway for 2 minutes,and the freaking thing was loose again.Man,am I starting to get PISSED.Lets hope this fixes my problem.

Xplor,the book says to NOT over tighten the bolts because it could cause the bearings to crush.====Bill

 

Bill,
I have about 700 miles on my Xplorer and have only had to adjust the chain one time at about 300 miles. My hitch is still on and I use german torque (gu en tight) when tightening the bolts. I ride through all terrain and I spray my chain down before I go out and after I come back. If its all covered in mud when I get back after I clean it up I try and run it around the yard to get the chain warmed back up and then spray it down before I put it away. I did read some where that it is more helpful to spray the chain while it is still warm.

Dave

00 Xplorer 400

 

Bill,

Your pissed?

I just my H.O back from the shop yesterday because of a bad primary clutch. The sheaves where grooved and caused a driveline clunk everytime the the belt engaged. This is also after my left front hub seal blew.

Lets see now 617 miles; one bad clutch, two belts, hub seal blown, rear rubber sway bar spacers shot.

I am not impressed with the quality of my new machine at all. This is my 5 th Polaris and probably my last.

 

Bill, thats great to hear that Polaris is standing behind their product. Hopefully with the new C drive your chain problems will be history.

Andy

 

Walexa,
The dealer allready did the cleaning you mentioned,it cost me 1/2 hr labor or 33 dollars.It did'nt do a damn thing for me either.

I hate it when they charge me for something that does NOTHING.Dealers around here are not to intelligent.When I took my quad in for its 20 hr inspection,I complained about the shifter being tuff to shift.Actually,I complained about this problem 3 differant times,each time,they could find nothing wrong.

While working at my brothers house yesterday,the damn shifter hung up on me 2 differant times.I had to take and tap the outside linkage inward and it finally did work loose.

Last night ,I studied my Polaris service manual on the shifter.This morning,I repaired it MYSELF.After checking the linkage for proper adjustment,I took off the top of the shifter and noticed it hardly had any oil in it.I put in the recommended amout of 0-40 oil that Plaris recommends,and guess what?It works fine now.It just pisses me off to have something under warrenty and the dealer cant find out whats wrong,
Bill