Hey old Polaris tech, so when I start the 02 boss...the temp light immediately comes on? It needs a battery and I have just been using the pull starter. Could that be my issue?? Any help would be great. Thanks !!

 

Replace the battery first and see if that solves the problem. If it doesn't you could have either a shorted out thermistor at the oil cooler.Item#10 Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Or a shorted out thermistor switch module. #21.http://www.cyclepartswarehouse.com/f...2002&fveh=5598

 

I have had the same noises and issues that the previous users have talked about and found a very loose chain. I replaced the chain believing that was the only issue and after putting everything back together the noise still happens when giving it too much gas or climbing a hill. After pulling apart again it does appear that the forward part of the fork rail is pretty rounded and shinny. Would that alone account for the slipping still happening?

 

If it's still grinding,jumping out of gear then it could be the slider gear dogs along with the forward gear mating dogs that could be worn down not allowing it to stay in gear,plus if shift forks are badly worn replace them.Check all the bearings for any roughness.Some transmissions have a mix of Russian and Chinese bearings,the Russian bearings being the worst on making noise.Plus don't over look simple things like burrs on the shafts,worn/ bent circlips,or circlips out of their grooves. Even a belt or worn rear clutch ramp buttons could cause problems if it's just slipping and not jumping out of gear.

 

So looks like my next question is what would you do if you call parts shops and the forks piece part number (3233098) is discontinued? Should I start looking on ebay for a used transmission or is this machine just trash since Polaris is discontinuing parts now.

 

Beginning to happen on older machines as far as parts being NLA. Most manufacturers supply parts for about 10-12 years on average for a lot of different street bikes,atvs,etc. Plenty of aftermarket places on basic engine parts,gasket kits,stators, plastics,common wear items,but some parts are why salvage yards are in business along with ebay and craigslist. Most good salvage yards now have a parts network that they can find hard parts for you if you have one close by. If not,then keep a check on ebay. It's about like trying to find a windshield visor for a 52 Ford.You just have to keep checking.http://www.ebay.com/itm/1952-1953-1954-Vintage-Ford-Factory-Accessory-Exterior-Sun-Visor-/151260627072?pt=Vintage_Car_Truck_Parts_Accessories&hash=item2337d60080&vxp=mtr

 

Old Polaris Tech,

I just picked up a 2000 trail boss 325 last night. It has that clicking/clacking noise under heavy loads. Can you/would you explain how to replace that "silent chain" or would you have a manual that explains how to do it? Only paid $600 for the atv from the original owner. Title and all! Pretty excited about it, but spent my load and can't afford to pay someone to fix it. I'm pretty mechanically inclined just need pointed in the right direction.

Thank you very much for any help you can provide!!

 

Here's a fairly good video on an older 4x4 tranny removal and split,but the basics are pretty well the same as yours. Look over the forks and dogs on the gears for wear and always replace the silent chain. Wouldn't hurt to have a manual as it does show how to and what to check for.DOWNLOAD 1999-2000 Polaris ATV Repair Manual ALL MODELS - Download ...

 

Old Polaris tech,

could it possibly be just the drive chain and sprockets making that noise under loads? I don't hear that noise in reverse, even with the override button pushed and at full throttle. it's only in forward gear.

Chad

 

Yes before you tear into the gear case check the teeth on the main drive sprocket for broken,worn teeth,plus the sprocket is softer than the shaft and can strip its splines causing the problem your having also.If it's not an external problem,a lot of times when I tore into gear cases the only thing that needed replacing was the silent chain. You can tell pretty quick on the chain as they will usually be loose. Should be a fairly tight fit. If the shift forks,gears and engagement dogs look ok,bearings feel good,then just replace the chain and always replace the seals.Use a good sealant such as Three bond,Yamabond,etc for the cases.Item #15. http://www.cyclepartswarehouse.com/f...2000&fveh=5491