I rebuilding my 95 Xplorer 400 top-end. The piston skirt broke on one side and I guess it fell to the bottom? So, I'm going with an oversized piston, bore job, new rings, shaved head etc. I would like some advice on how to get the broken piece out if bottom if there is an easy way... But mainly, some advice on how to cheaply get some more power while it is in pieces. I'm open to any suggestions (exhaust, carb. jets etc)
I think the rebuild alone will leave the others in the dust again. I have to say it is an excellent machine. It was still running and just started to smoke too bad.

 

Find out if RCR has a pipe for it, I love mine. Rick says the stock pistons are weak and should be changed before they break. If you put on a pipe, Wiseco piston, have your carb bored, and add performance reeds you'd have a reliable screamer. Porting is the next option after that but I would go in steps to see how much more is needed, that's what I'm doing.

 

marcus

re:getting pc out i'm sure you now by now.but any way .remove entire mtr assy. remove drive clutch from pto remove flywheel and stator assy.
split base and wash up every thing .[ note polaris has a very good dealer man.on this it may be needed for there is some very important settings to make on reassy.p.s. as to cutting head and using wiesco pistons i think your headed toward more problems. great for performance racing etc. but not long term trail reliable.
what ever you do have a good day.
polarman