Hi everyone,
I have a Spring project and found these forums in hope of getting some advice to head in the right direction.

Background: I picked up a ???? year model Xplorer 400 2-stroke. The guy said it was running a few years ago when they parked it but it did need a new top end at least and was stuck in hi-range.

To start I have a couple of questions:

1. I removed the range selector assembly yesterday but was unable to move either of the lnkage arms in an effort to determine if the issue was the selector assembly or in the tranny itself. With the machine not moving, and the engine not running "should" I be able to change the tranny range using the linkage arms?

2. If its internally, where is the best, and cheapest, place online to order Polaris parts?

3. Can you reccomend a very thorough repair manual with all the wiring diagrams, torque specs, and maybe most important will be exploded views of the inside of the tranny with instruction for dis-assembly and re-assembly.

Thanks in advance to anyone who can get me headed in the right direction as I attempt to bring this old machine back to life.

RA

 

personally i just order through my local dealer. he stays pretty competitive with the lowest prices i can ever find online plus he doesnt charge for shipping or tax. and i only takes 3 days to get the parts.

you should be able to change gears without the motor running. and i could be as simple as something stuck and not letting the tranny shift.

ebay is going to be your best bet on a manual. generally pretty cheap. any haynes or clymer manual will do

 

for parts, try cheapcycleparts.com there are also tons of other ones, I can't think of right know
IMO the Polaris service manuals are the best, although I here clymer's are good
Hayne's manuals are kind of hit and miss, they are great for some bikes and not others
Good luck gettin her fixed

 

check to see if the shifting fork is bent inside. maybe the reason it wont shift. if your going to keep the bike, i would change all the fluids if you know it hasnt been done in awhile.

 

<div class="FTQUOTE"><begin quote>Originally posted by: riata_ag

Hi everyone,

I have a Spring project and found these forums in hope of getting some advice to head in the right direction.



Background: I picked up a ???? year model Xplorer 400 2-stroke. The guy said it was running a few years ago when they parked it but it did need a new top end at least and was stuck in hi-range. SORRY,just saw wasn't running,but can still try by pushing back and forth to see if shifting ok!



To start I have a couple of questions:



1. I removed the range selector assembly yesterday but was unable to move either of the lnkage arms in an effort to determine if the issue was the selector assembly or in the tranny itself. With the machine not moving, and the engine not running "should" I be able to change the tranny range using the linkage arms?



2. If its internally, where is the best, and cheapest, place online to order Polaris parts?



3. Can you reccomend a very thorough repair manual with all the wiring diagrams, torque specs, and maybe most important will be exploded views of the inside of the tranny with instruction for dis-assembly and re-assembly.



Thanks in advance to anyone who can get me headed in the right direction as I attempt to bring this old machine back to life.



RA</end quote></div>

Clamp on trans belcrank with vice grips and try to shift into neutral! A lot of times linkage out of adjustment cause these problems on "locking" up. If able to get in neutal,check shift box for proper movement WITHOUT linkage arms hooked up! If ok,then loosen linkage arm locknuts,turn shaft or linkage ball to where both H-N-R linkage just drops STRAIGHT in hole on shift box arm,same for LOW linkage arm,crank up and try shifting. I have to do this quite a lot on the older machines!