Hi all. New to the Forum and looking for some advice. I have been a long time Foreign ATV/Dirtbike owner. I'm very pro american of course, but am a strong believer that you can't beat the engines in Honda's and Yamahas and that has been my experience. I have had both and never once had to replace major engine parts or anything. But when buying a utility ATV, I had a lot of recommendations to buy a Polaris - particularly the older Explorers that had the 2 cycle snowmobile engines (or at least that's what I'm told). So I did. We now have a 1998 Polaris Explorer 400. It has brand new blackwater tires that grip like glue and I have pulled rocks the size of small houses with it. Totally awed by the pulling power and sheer tank-like capability. However, the thing leaks gas like a siv and cannot seem to figure out from where. You would think it wouldn't be that hard, but as I always doing major projects around our house, I have little patience to sit around on a Saturday and pull the thing apart (I know - then why did I buy used... good question).

My question: Is this a problem any of you have heard of and might know the solution. I have already replaced what I'll refer to in my non-mechanic language) the bolt on the bottom of the bowl that sits just below the gas tank. It had a small pin hole in it, but I couldn't tell for sure if that was the problem. it was not. Now I am about to replace the entire gas tank, but I can't see any obvious cracks or anything so before spending the time/money wanted to see if any of you had heard of the problem.

Thanks in advance for any help!!

 

You didn't say where the gas seemed to be leaking from. I previously owned a 1997 Explorer 400. The only time it leaked gas was when the needle valve and seat in the carburetor wore out. This is a common problem. Other things that can be problematic are swing arm bushings, output shaft bearing, starter problems,front axle seals,rear chain and sprockets,front cv joint wear, sender switch for fan. I found mine to be reliable until the miles started to roll up, then it started to be a pain - very high maintainence. The motor is very reliable and powerful but I hate to have to disassemble a whole lot of things just to remove the starter. Anyway, good luck with her.

 

depending on what you will be doing with it whatch out for the piston as well, a compression tester is a good investment.

 

I just finished fixing my sisters 500 Scrammy that needed new needle for the bowl, $35 will fix you right up. Check to see if it leaking from the carb.

 

Thanks to all of you for your feedback. Based on what you have said and from what I can see where the gas is leaking from, I have to believe it is the needle valve.

Funny thing is I just changed one out on one of my lawnmowers earlier in the summer and never even thought about it the explorer.

Thanks!!