Guys, I have been asked to look at a 97 Express 400 2wd, for a friend that has a locked up engine.
He says the rope will not pull the engine over, and the electric start is dead due to a dead battery.
Any common areas of interest I should focus my attention on first??

 

2 one is the piston skirt have a tendence to shatter on the stock piston 2nd the counter balance drain the oil from it an see what you find. The water pumps had issue when get bad leaking in the counter balances an rusting the braerings.

 

First thing I would look at is take the clutch cover off and be sure there hasnt been a mouse build a nest in the clutch.This happens alot.
Then take the belt off (even if you have to cut it)if it still wont turn take the exhaust off and take a light to see if the piston has broken.Then go to the counterbalance.If this has locked up you are looking at major $$$$$ to repair.

 

Thanks for the advice, I will be getting my first look at this machine on Monday evening so at least I will now have a starting point.
When you say MAJOR $$$ like how major? In the event that this guy is not willing to fork out alot for repairs.

 

The counterbalancers cost over $200 from Polaris. If you get lucky you might find a used one, but the shaft end might not be very good. I know a guy in the Dallas,TX area who welds them up and turns them back down to save them. if interested let me know. The piston kit is around $100, labor to bore, gaskets and seals, etc. Depends on whether or not it needs a total rebuild or just partial for the price.

 

the thing with the counter balance is it is the bearing that go out then then tend to break then get in to alot of other stuff. I belive the cost of counter balance an bearing is $325. I t also just thinking about it could be the conecting rod my friends is out on his 400 motor right now piston if fine a counter balance but won't turn over. If it is not the balace or piston look at the bottom of the connecting rod an see if there is a spot that is a differnt color. Friend had one go back his scrambler 400 the one out now is in his explore.

 

Again, Thanks to everyone who has posted their input! I think now I may not be so anxious to get started on this one? Who knows, he may decide to bag the project and I can retro-fit a Harley V twin in the frame?? LOL!!