I was wondering if I should freshen up some stuff on my 96 Xplorer 400. The guy I bought it from had the top end done but that was it. The machine was very well taken care of, with the hub oil and trans oil changed regularly. My counterbalance oil is good, and I change it every year, but it does have a tendency to get discolored, not milky, but just darker after its been in awhile. I was going to do a coolant flush and put new coolant in but I'm wondering if I should go ahead and do crank seals and water pump seal since they are probably still the originals. Like I said, my counterbalance is still clean and I don't loose coolant but I want to be a step ahead of it before it does start to leak and make the counterbalance oil milky. Is this a fairly straight forward job or does it require a bunch of specialized tools and stuff? I have the manual, but I haven't looked at the process yet, just want input from people who have done it and if it would be recommended at this time.


Thanks,
Mike

 

19 year old machine.. Yes change the seals and water pump seals and bearing before something major happens.. Need a drive clutch puller along with a good flywheel puller. Crank seals are easy,just pop out and install new ones.Water pump seals and bearing are a little more involved. Get the 5 buck manual as it shows you step by step.DOWNLOAD 1996-1998 Polaris ATV Repair Manual ALL MODELS - Download ...

 

Thanks OPT! I do have the manual already downloaded and have used it pretty regularly. I looked into the process of the cranks and WP seals and it looks easily manageable. How long do you think this would take for a guy like me who is pretty mechanically inclined(I'm an autobody repair/auto mechanic by trade). Reason I am asking is, we have pretty much missed winter completely up here in northern Wisconsin and besides still be cold, the snow has been nonexistent. My fourwheeler looks at me with lonely eyes every day as I walk by it at the shop because I was jumping on it almost every other day to plow last year. If I ordered up all the parts, would it be easily done on a Saturday when I am off of work? I know Murphys Law, as soon as I tear it down we will get a blizzard and I dont feel like swapping all the plow stuff over to my Sportsman just to plow snow. Is there anything else I should look for since I will have it tore down and will be in there?

Thanks,
Mike

 

Make sure you get the w/p gasket along with the counter balancer cover gasket also.Only problem I had with doing the water pump seals with the engine in the frame is that the inlet nipple hits the frame down tube on certain models and can be a little troublesome when getting the cover back on. Some I removed the bearing from the cover,installed on the crank shaft and tapped the cover back on. Not the way I like to do it,but better than removing the engine to line the case and bearing back up.You'll see what I mean if this is the case with yours. You could always heat the coolant nipple up if it hits and jb weld it back,but possible you'd break it taking it off.MAY or MAY not be a problem on your machine on clearance issues.Plus not a bad idea on replacing the outer oil seal.Depending on any problems encountered,you should be able to do this plus refill the radiator(bleed the head bolt also!) in an afternoon.Maybe quicker if you have good small hands and everything goes well.. Part#39 on the gasket,42 on the nipple,44 on the outer seal. Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Thanks OPT! I ordered everything tonight so if I have some slow time I will tackle this some Saturday before spring hits. Since I am going to be flushing the cooling system, what do you recommend for coolant? Will the green automotive stuff work or is it ok to use the pink/orange long life stuff?


Thanks,
Mike

 

Any 50/50,60/40 coolant will work as most are compatible with aluminum radiators now days. My own preference is either Zerex,Peak or Prestone,but just like engine oils and filters everyone has one they swear by.Some may even be happy with Super Tech coolant from Wallyworld. Like engine oils some private label brands of antifreeze are probably produced by a big name manufacturer.

 

Sounds good OPT. One last question, I noticed on my machine, someone has taken the wires off the upper sensor on the radiator and jumped them to make the fan run all the time. I am sure the sensor is shot so they did this to bypass it. Would you recommend putting a new sensor in so the fan only comes on at a certain temp? I dont know if this affects the drivability but it will cause a draw on the charging/electrical system. If it isnt a big deal, i will leave it alone.

Thanks,
Mike

 

Yes by all means replace this sensor if they jumped the two sensor wires and the fan runs constantly. Will just eventually burn out this high dollar fan motor.Common problem of sensors burning out on early models as people let coolant level fall below sensor on the radiator. Later model sensors moved to the bottom of the radiator.Just take this two prong sensor out and match it up at any auto supply.Item #8.Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse