Hey, I am new the forum and wanted to see if
anyone can give me a few hints on a issue that
came up today on my 1999 Polaris Xplorer 400.
At idle the clutch cover is making a wild vibration
/ noise. Immediately stops on acceleration. I assume
this is based on the clutch engaging and compressing.

Thanks in advance for you help!

 

Probably a warped cover from the heat.This was a common problem. Just pull the cover off and see if it has wear marks inside where the front clutch has been rubbing at idle.The noise/vibration goes away past idle as the clutch moves inward. Plenty of later model covers on Ebay that can solve the problem,or you can try to adjust the small "L" bracket at the bottom of the backing plate to see if it helps on the vibration and noise. Some have reheated the covers with heat guns and pried em out to restore clearance,but don't think that would last too long.

 

Thanks for the feedback, I did pull the cover and
your thought was correct, seams odd that just all
of a sudden that would occur.

Is there any way to adjust the outer clutch to create
space so I can continue riding until I am able to get
a late model cover?

Thanks again

 

Will a cover from a 2005 - 2008 Sportsman work on 1999
Xplorer?

 

See if you can adjust the small "L" bracket one the backing plate first to see if it helps "tweak" the cover out a little and helps on the problem. #21.http://www.cyclepartswarehouse.com/f...1999&fveh=5478 Some covers may have an empty screw slot on later model covers,but I've seen plenty of people use the newer type clutch covers with no problems.I've even see latest covers that allow even more clearance on clutches used ,BUT you have to make alterations to fit the larger exhaust outlet to your exhaust tube.Might not be a bad idea also to use a pry bar on the front and rear motor mounts to see if it any has separated.This can cause problems too on movement and vibration.

 

Thanks, another question is; I just sold my 2004
Sportsman 400. I am looking for a 2004 Sportsman
500 or 600.

It seams that after 2005 the market price for these
ATV's falls off a cliff. In some instances you can
purchase a 2010 Sportsman 500HO for the same
price as 2004's are selling for? Makes no sense any
thoughts?

Thanks again, this forum is invaluable for us "Newbies"

 

It all depends on condition and how it was maintained not just age!I've seen some early models that were in great shape compared to some late models that were rode hard and put up wet. Some short cuts were taken on the later models such as eliminating the recoil start and eliminating grease fittings,both stupid ideas on Polaris' part. If you go after a 2004 600 I'd make sure it was a later model production that had the Kokusan ignition.

 

Thanks is the Kokusan ignition on both the 500
and 600 and how do I determine if they quads are
equipped with this specific ignition?

Thanks!

 

Just the 2003 and early 2004 600 had the Ducati ignition which was junk. Later 2004 models (made after Feb/2003) had the better Kokusan ignition. The Ducati has a combination cdi/coil which is very easy to spot once you pop the front panel. The Kokusan system has a separate cdi and coil.