'96 POLARIS XPRESS 400 2x4
#31
Could be a broken piston skirt locking it up. Don't try to rock in gear because if it is a broken skirt you could crack the engine case if the piston hits it. This is entirely up to you on another machine. May just be a piston and bore job needed or may need to rebuild the whole thing. Wouldn't second guess anything until it was torn down and inspected. As it sits now it's salvage parts for ebay.
#32
#33
Depending on what all is wrong with the Polaris, should I restore the engine? It has well over 4500 miles on it, the odometer broke. Absolutely no telling how many hours. I figured it was about time it blew out, but I don't want to waste money on it if it's not gonna last me. I love the four wheeler, I just think if I get the Yamaha I won't ride it, but i dont know.
#34
Only way for sure you will know that it will last is to rebuild it from the bottom up. That many hours on a 2 stroke no sense in doing just a top end even if you think you might can get by with it. I've seen too many people try that over the years to only have to go back in and do it right. You can save money ordering the piston kit and gaskets along with the rod kit, bearings and gaskets and having a shop rebuild the crank,bore out the cylinder and you reassemble it. The engine should then last for several more years. Most people just run 2 strokes into the ground,then see the damage that can happen. They don't last as long as most 4 strokes and weren't designed to in the first place. You can tie up several hundred bucks quick on engines parts and labor,but you'll at least know what you have.Either rebuild this and keep it or sell it,then buy a different machine. Again as it sits now it's a parts machine for ebay. If you have the patience and inclination you can get some pretty fair money parting one out also.
#36
This earlier post doesn't sound good. Could be anything from thrown flywheel magnets locking up against the stator,a broken piston skirt lodging against the crankshaft or a lower rod bearing hard seizure and locks and unlocks after a certain point on its travel. Can be any of these. Easiest thing to do first is to pull the recoil starter and check for any debris around the flywheel. Pull the flywheel to check to see if thrown magnets are the problem. If that's not it then sounds internal and top end needs to be torn down to find out what's wrong. On your first post on this you were going wide open.If you had noticed any marbles in tin can type of noise on this old 400 from piston slap,it could have picked that point in time to grenade on you. I've had belts break and wrap around drive clutches locking things up a little,but normally you'd hear this noise from the clutch cover area.
#38
Really doesn't matter if you're going slow or wide open when it really comes down to it. If the piston is worn, an engine can fail at any speed. Going fast may just speed up the process a little.
#39

#40
I meant basically pushing the throttle all the way in, revved way up because I was having some problems, probably should've got in a car....


