Muddy, I am not trying to just blame the mods for your problem, but I just can't seem to see what else it could be, unless you are using contaminated grease or something.

Dumb question, but are the replacement Polaris parts holding up any better than the originals did, or are they wearing out just as fast, too?

Also, double-check your sprocket alignment, a Sidewinder should NOT wear out that fast.
Check for both sprocket-to sprocket alignment, as well as the 'squareness' of the chain on the sprockets. Something has to be amiss.

To be honest, I am becoming amiss...I can't think of ANY Polaris machine that has so many parts replaced in so short a time as you, not even the guy that bought the 'bargain' wrecked one, and his frame is so sprung, you can SEE that things don't line up right!!

 

farmr123,
I just finished taking the front SideWinder sprocket off and replaced it with my Stock Polaris one.I have NEVER seen a sprocket worn like this before.There are only 4 teeth that are of the correct length/size out of 13.There are 2 teeth next to each other on one side of this sprocket that are good,and DIRECTLY across from them,there are 2 more teeth that are good.All the other teeth look like someone took a grinder to them and wore them down.I checked alignment,it looks very good.Swingarm is tight to.Im going to call SideWinder tommorrow and talk this over with them.Im looking at my receipt and I bought their chain/sprockets in June of this yr,spent 297 bucks with these guys and I want to know whats going on.The rear sprocket looks real good.

Now about my replacement parts?
I no longer have any problems with my steering stem since I went aftermarket.I just ordered the complete updated brake kit for the Xplorer.Im looking forward to installing it when it arrives.It consists of 3 harder disks,and all the brake pads that are suppose to last alot longer than stock,all for 89 bucks.I have not had any problems from my RcR airbox mod,my PSI pipe,or V-Force reeds.

Here's a list of some troubled items,
NEVER a problem with the 400 engine[2300 miles]
2 Spark plugs[wear item]
5 sets of outter tie rod ends
1 set of inners[tie rods]
3 steering stem bushings
3 sets a-arm bushings
3 sets chains/sprockets[unusual to wear out these many]
1 new Primary and Secondary clutch[EBS]
1 new throttle cable
1 new speedo head
1 new speedo sensor
About 7 or 8 sets of brake pads[wear item]
A complete set of brake disks[wear item]
1 new master cyclinder
Maybe 2 or 3 new belts[wear item]
Hub seals/sleeves been replaced about 3 or 4 times
Axle bearings in the rear[once]
EVERY drivshaft/halfshafts been replaced
2 sets of swing arm bushings
1 set of swing arm pivot pins
1 electronic hub sensor


Im sure I left something out,but this is all I could think of.Can you at least feel a little bit of my bitterness?

Looking at that list,makes one beleive that im an abusive ATV operator/owner?Lets remember one thing here?If that were true,would'nt it also seem that I'd be having engine problems as well?This engine has been bulletproof.I spend ALOT of time with my quads.My wife has told me MANY times that she wished she were a quad.In which I responded,''me to'',we'd surly spend alot more time together![lol]

Bill

 

Muddy, I feel for you. Just wish I could help figure out what is going wrong there.
For the record, I don't know of an ATV engine that takes abuse better than the Polaris 400. They don't stand neglect well (dirty air cleaners, improper oil, plugged radiator, etc), but you can't blow them up unless you try. Run them full throttle all the time, and they just keep coming back for more! As a matter of fact, the mechanic at the dealership says he sees more problems with the 400s because of people thinking they have to 'baby' them all the time, and carboning them up, followed by the cracked piston skirt thing.

 

Muddy, this may seem like a really strange question, but have you ever replaced your chain? You mentioned going through 3 sets of sprockets in an unusually short period of time, but you did not say that you replaced the chain in your list. I wonder if maybe there's something screwy about your chain that's at least causing so much wear on the sprockets, though I can't for the life of me think of what about a chain would do that...

[Edit] Nevermind, I just re-read your post and realized that you replaced the chain each time. Sorry, I'm tired... lol
[/Edit]

 

Muddy I thought i had trouble but i knew what i was in for when i got my 400.A teenage boy had it and did NOTHING but ride it.I got it cheap but i have put on a battry,starter relay,all light bulbs,all 4 tie rod ends,arm bushings,swing arm bushings,front brakes and a left caliper(it had been run till it ate the whole caliper away)now it looks like i m going to have to rebuild the starter.This all that had to be done.Now i have done things it didnt need like a new winch,GBC Gators,Aaen Torquer pipeand a Uni filter.I ride this harder than do my Magnum but the things i fix dont seem to go bad again.It is a full time job to keep maintaned but i love the 2 stroke power for the mud. Just what i have had to do on this one.I think if it had been cared for it wouldnt have been like this.

 

Muddy-
It sounds to me like the sproket is warped. Have you checked it with a straight edge, to see if it is flat? Either you got a bent one from them or inadvertantly over tourqed it when it was installed. Just a thought.....

 

You cant over torque a Polaris front sprocket,they install on the crank and stay in place with just a c-clip.

Bill

 

MUDDY,
YOU ARE FIGHTING A LOOSING BATTLE,TOO MANY OTHERS THINK PROBLEMS LIKE YOURS ARE NORMAL. POLARIS OWNERS MUST THINK THIS IS O.K., ME I JUST ENJOY MY ROUGH RIDING,ANTIQUE DRUM BRAKED,UNDER POWERED,3 DRIVE WHEELED,NON-LIQUID COOLED,P.O.S. HONDA, WHICH I POUND RELENTLESSLY,AS I EXTREME RIDE WITH MY SON AND HIS RANCHER ALSO. HE TREATS HIS THE SAME WAY. I SELL HONDA WHEELERS AND AM BRAND LOYAL ,BUT WITH GOOD REASON ,THEY ARE LIKE A TIMEX WATCH..... GOOD LUCK, THIS WILL KEEP EM' GOIN.



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2001 RANCHER S MODEL 4X4 W/ 2000# WARN AND 60"PLOW

PREVIOUSLY 1983 185 S 3WHEELER,84' 200 M 3WHEELER,99' 300 FOURTRAX 4X4

 

HONRON01,
I understand exactly where your coming from.Now to add to my sprocket problem,my engine quit today while riding.I think the head gasket or piston failed me,I have no compression left?Wont know until later this wk what the deal is?

I had a conversation with a leading ATV parts supplier/engine rebuilder thats well know to most of us,and he said its real funny how alot of Polaris owners will defend a Polaris product no matter how it treats them.While Polaris does offer a lot of nice features,they certainly need to address reliability issues on alot of the 4x4s.

No more ''POLmebackARIS''for me.Its going to be a 3wd Honda Rincon or a new 660 Grizz in the near future.

Bill

 

MUDDY,
NICE TO TALK TO SOMEONE WHO CAN BE HONEST FOR A CHANGE, MOST ARE JUST IN DENIAL. I SEE HOW BUSY OUR MECHANICS ARE ,GOOD THING SLED SEASON IS HERE,SO THEY HAVE WORK. TRULY WE ONLY HAVE ONE PROBLEM FOREMAN 4X4 ,THIS GUY SPENDS MAJOR BUCKS BUT HE MAKES HIS OWN PROBLEMS, AND HE KNOWS IT. I ONLY SPEND TIME ON THIS FORUM BECAUSE NOTHING EXCITING WITH A HONDA . P.S. I USE ALL CAPS BECAUSE I PREFER TO . NOT SHOUTING....


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"HONDA BEST ON EARTH"

BACK WINDOW OF MY CARAVAN IN 4in LETTERS ("HONDA BUILDS 4 WHEELERS AND OTHERS TRY&quotI GET THE ONE FINGER SALUTE ALOT- OH WELL!

2001 RANCHER S W/ 2000# WARN AND 60" PLOW