Have you ever wrecked or rolled the bike? Could your frame be bent? Sounds like it is not alligned. Do you check the tension when you are sitting on the bike? You must have some slack when you are sitting on it. When you get off of it, it will seem like you have to much slack but that is ok. What other problems did you have to make you never want to buy another Polaris? Just curiouse! seems like a small problem to give up on Polaris for.

 

There was plenty of slck in the chain, now that one of the gus mentioned it I recall the chain having a slight curve to the right looking from the rear of the bike. You had to look real hard to notice it. If I'm guessing correctly is its probably in the loop that was cracked and welded back together, maybe the carrier bearing and axel are twisted (actually back further in the loop than the right hand side loop which would make the carrier and axel sit with R wheel closer to fender than left wheel. This in turn would also cause rear sprocket to be turned to the left slightly which would cause the chain to curve to the right. I will have to check it out in more detail. Maybe even pull out some carpenter tools to pinpoint my guestimate.
If not How do i tell if its the swingarm thats crooked????

 

Have the dealer rivet the chain together on the bike. No master link to pop off.

Polaris doesn't manufacture chains, so don't let some cheap taiwanese chain give you an opinion of the whole bike. Get a regina or a D.I.D. chain with the highest possible tensile strength. If you're still worried about the alignment being off, get a non-o-ring chain, they are thinner and tend to have more side flex.

 

Well guys I found it the whole gear case and axel is out of line which means I need a new Swing Arm.
The swin arm angle(looks aqward from factory)is weird and the two loops on the carrier bearing are a joke. That section should be solid. The paint peeled a little and rusted, broke in two, in less than a year and a half. Plastic bushings all through the bike that wear easily( i would rather see polyurethane). They are certainly nice quads cheaper price than others, but go and work on one and its a pain in the neck. I like my Trail Boss but I wish I would have just broke down at the time(July 2001) and bought a 400EX, a machine that would certainly meet my type and style of ridding. Overall its been a good quad but I wouldn't buy anther one. One word to anyone.... the stock tires(Titan 489s) last a good while but they don't climb for crap on these Automatic quad. I just can't compare this machine with a ol TRX300 Honda. They quit making them because they just wouldn't quit and they are still going strong today. You have to try real hard to blow one up and a buddy of mine had one that had the frame, swing arm and anything else you can think of welded together and to this day its still going strong. All I am saying, is buy a quad that meets your ridding style and is dependable. I can't stand to work on something for days then ride 5 or 10mins just long enough to get in the woods and it breaks down and you have to push or pull it home(like some of the older 2 strokes in first year production). It is sad when a utility bike breaks down before a sport quad(you'd think they would be higher maintence and prone to breaking down) and it has to pull you home.

The only reason I would ever buy another Polaris quad is to use on a farm just to work or maybe mud bogg. The best big bore 4X4 quad is the Kawi Prarie. It absolutely sreams. Although the Idependent Rear Suspension of the 700Twin Sportsman is quite a nice ride.

As for the Predator, Looks awesome. Plenty of Power but A guy from our area had the head go bad after two small rides still within the break in period. He said I haven't even had the chance to open the throttle up and see what it really has yet. Its will take a long time for Polaris to work the bugs out of this one. I don't look for many people in this area to invest their $$$ in a Polaris yet. They are Make Stubborn(ex: I only ride Red or I only ride Yellow) To each his own........

 

It dosen't sound like replacing the swingarm is going to fix it, sounds like your repair job on the frame may be the problem. Take the rear wheels off and measure from the tip of the axle to a common point on the front of the frame on both sides and I would bet that it's off by some. It should be even from side to side. Did any of the swingarm bushings get damaged when the welding was done? Could be that the frame is ok and you just need to replace bushings that melted during the weld.

 

Sounds like you need to keep all the wheels on the ground while riding. I ride my race mod HARD and dont break anything. My 99 model has all the original bushings and bearings. And as far as the titans, I havent found a better trail tire than that. Maybe your having bad luck, but sounds like ya'll are pretty rough on the machines.Bubba