I recently acquired a 94 400 4x4 2-stroke for $45 from a friend and have a couple questions. It wont start now but i found that the spark plug wire end is bad so im buying a new one of those. So here come the questions.

1) The lights dont work or the Gear Indicator lights by the key dont work. He said it might have been when a battery exploded? but its not the whole electrical system becuase it will still turn over with the electric start.

2) The Front Wheel Drive doesnt work. He said it jsut went out sumtime. The chains wont move by pullinh but idk if the quad has to be on for that.

3) Im currently trying to get a Compression tester to test it as i expect it to need a top end rebuild. Now should i build a topend rebuilt kit for around $100, which id rather not do, or would i jsut be better to take it to a dealer and have it done. what does that usually run?

Its basically a rebuild project for me. Thats all the questions for now. Ill post more when im sure they'll come. Any help is greatly appreciated!

 

if the battery exploded and he kept running it it could have damaged electrical components. shouldnt hurt the starter solinoid but would definatly start effecting the cdi and rev limiter and voltage regulator. 15v going straight through a 12v system will start to hurt things after a while. if a battery is there to act like a buffer then it doesnt become a problem

 

Contact Rick Ridder, his number is here on the forums, he's a master at these and has everything you need to get it runnin.

 

ok thanks. its got anew battery in it and i think he took the exploded one out shortly after it happened. the starter is fine its just the spark plug cap i believe. Anyone have any ideas how to fix the front wheel drive?

 

Ok. So today i did a compression test and it read mostly 75. I know thats low so i was thinking if i jsut replace the rings will it give me compression? what about a new piston and rings? I really would like to do it without a jug rebore becuase im low on funds. what are my options?

 

if you send it to rick he charges $50 for the bore plus parts. or $75 for the bore without parts. your going to need a bore anyway you look at it. you see once you take the jug off. the piston will probably be scored and the jug will be scored.

on the 4wd can you get the chains to move at all? seems like if you jack up the front end and put the bike in neutral you should be able to grab the front chain and spin it? shouldnt have to be running for that either

 

ok thanks. theres a local bike shop and polaris dealer nearby so ill price em out there too. i guess i was trying to avoid the unavoidable. i thought about the chain too. im going to tear it apart even more tomorow.

 

well jsut found out i need both a top end rebuild AND a new stator. the stator alone is $360

 

have you looked at ebay for a used one?

 

Definitely do not but the stator for that price from a dealer, there are tons of parts for these machines on eBay.

The 4wd switch on the right handle may be bad, or the reverse override switch on the left may also screw up your 4wd. Sometimes my machine will not go into 4wd unless I stop, put the machine in reverse, then put it back in forward.

The chances of both hubs being bad is low, so I would bet that your 4wd problems are electrical