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Polaris Trailblazer 400 4x4 Transmission Repair

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Hey guys sorry it's been awhile since I have posted on the forum. I have been without an atv for two years and finally bought another one today. It is a Polaris Trailblazer 400 4x4. It needs a transmission chain. I bought it and was told the atv was taken apart with the intention of repairing and never finished. Has anyone owned one of these or had any experience working on a Polaris transmission? Any help would be great! I am mechanically inclined but have never worked on a Polaris.


Thanks again,


Tyler

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bryan

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Sorry, can't help you with that one as I have never been into a Polaris!

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I had a polaris scrambler 500 4x4, but my tranny cracked, so I just bought another one off of e-bay, most of thoses years interchange. Can go to Bikebandit.com and check part numbers to see

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seadog37

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nope

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The guy I bought it from said the case was cracked but he welded and put a sealer on top of the weld. It looks like he did a good job. I just hope it dosen't leak tranny fluid. I ordered a transmission chain today and should be in Wednesday. Everything else inside is good so hopefully I can get it driving next week! I took off the carb and cleaned it inside and out with carb cleaner so I'll try to start it tomorrow. It ran when I gave it a shot of 32:1 in the intake boot, so I am hoping it has good compression. The rope on these is sure hard to pull and i haven't got a battery for it yet.

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Grizzly Rick

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Sorry cant help on this one, but it seems you have it handled, hope to see you on the trails soon.

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keep us informed on how this goes, glad to have you back


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Rick Willis
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Good and bad news. New chain came in today and and it is definitely a tighter fit than the old. That is the good. The bad is that when I was taking the old chain out i noticed that the shaft inside the transmission had a broken bolt on both ends. I asked the tech that was working at the dealer what those bolts do. He said that one is the speed sensor bolt? Im not sure if this is correct or not. Do any of you guys know? My atv DOES NOT have a speedometer. He said that the broken bolt could cause the 4x4 not to engage. Does that sound correct? The tech told me that i could put it all back together and then see if the 4x4 works and if it does great. If it does not he said that i could possibly drill out the old bolt and put in a new using ez out or a left handed drill bit. Im kind of in the middle of this on what to do. Any suggestions on getting the bolt out. It has some sort of lock tite on it so it might be hard to do. Thats where im at right now... Any suggestions? Thanks guys!

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bryan

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I would defainately replace any broken or stressed parts while you are already into it. It has been my previous experinece that it seems to always come back to bite me later.

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I finally got the broken bolt out. Lots of torching and hit the edge in a clockwise direction. Wish I knew that the speed sensor bolt was reverse threaded before I tried to remove it! Came out a lot easier. I have all my parts now so hoping to get this finished by the weekend! I let it run for about 20 mins and the fan doesn't seem to be working. So I'm going to take it out and see if it is good or I have a wiring problem. The headlight wires are cut but all others look to be intact.

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bryan

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Sounds like you are getting really close now. Wishing you the best of luck getting it back together and hope to see you along the trail real soon!

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Administrator

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Sounds like you are getting it all resolved, its always best to get it fixed while your in there because it sucks bad to get everything put together just to have the part cause problems and have to tear it back apart


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Finally got her all put back together. It runs perfect and has tons of power. Only running 2wd untill i order some bearings for the front jackshaft because the shaft has alot of play! But it works fine in 2wd. Hope to come to the next group ride Exclamation

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Grizzly Rick

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Going to Perry tomorrow, come on out.

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bryan

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Yes SuzukiRider, come on out to Perry Lake today. I will be leaving Independence around 10:00 AM on Sunday morning. Call me on my cell phone should you have any questions or need directions. My number is listed here:

http://www.mokanriders.com/t1600-phone-list?highlight=phone

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