First thank you sir for these vids you are seriously a life saver with these vids. Love watching them and they help a whole lot with my own 94 400L. I was replacing the starter on mine and just noticed a little coolant beside the starter bindex. So I'm now contemplating on doing what you did, or just going ahead and rebuilding the bottom end. It has a brand new top end that hasn't even been ran yet so idk.
Thanks for the video. Very helpful!!! I just bought a 1996 polaris sport 400l and I was reading up on them and they say this is a common problem for them. Mine is not leaking yet I don't think? I have to put a new starter into it. So I guess we will see lol this is my first polaris so its all new to me. I have owned mostly Yamaha banshee/ blaster/ warrior/ you get the point. I'm hoping this is a good wheeler it runs good it has been bored 40 over clutch kit and pipe im sure it has bigger jets in it as well. Thanks again 👍
It should be a good machine for you. Just make sure you keep all your fitting greased up. Keep an eye on the oil injector and put a temperature gauge on it. It will run a long time.
Thanks for the video! Very helpful. I got everything off except the water pump bearing is stuck on the shaft. I can move it maybe a quarter inch back and forth freely, but seems to get stuck. Do you have recommendations for removing this bearing? It appears to be smooth and work properly, but since I have it apart and have a replacement, I'd like to get it off. Thanks!
Nice! It's not to bad once you get into it. Just make sure you loosen bottom engine mount bolts and top engine mount bolt. It makes it easier if you can tilt engine to get cover off.
Very good, bad buy on a 1995 Explorer, overheating issues, radiator sensor looks bad, blown headgasket, had to use putty, still over^pressure in radiator and boiling antifreesze went into reserve :( So wonder if this low miliage has defective waterpump, but that impeller doesnt seem to be melting plastic ??
Still at it, is it true there are no thermostat on those models? So aluminikum and doesnt melt :) Mine has only 6,000km so the seal & bearings should be okay.
I have a 350L and just swapped in a working engine. How to I bleed the system correctly? I was test running it and the hot light came on so I shut it off. The top hose that goes back to the radiator was not hot. Thinking I did not bleed the system correctly.
I broke 9 grade 8 bolt in my balance puller one in the fly wheel drilled it tapped tried again got it good n tight then my threads gave any ideas to help
Is there a way to test if your water pump is working without taking everything apart? I’m getting some smoke coming from the water pump inlet area on a new top end rebuild. Head is getting hot quick.
Yes, it seeps into the case and goes through the exhaust. It's a common problem with 2 strokes. Replace the water pump and crank seal behind the counterbalancer cover.
Very helpful video. With out the info you provided would still be working on taking the crankshaft nut off. Only problem iv got is I can’t get the case to split. Any tips?
So with all the bolts removed. Even the little ones by the waterpump (I did that once) tap around the edge of the case. Once it starts to split take a rubber mallet and pound on the clutch side of the crankshaft. Make sure the key is out of the crankshaft that holds the gear in place. If you have anymore questions drop me a line.
Titaniumman 2012 I got everything back together. But I’m having a problem. I’m getting little to no spark now. I did cut the wires to remove the coil under fly wheel. But it’s all connected right. When putting fly wheel on I hit it with a rubber mallet to make sure it’s on. But have no spark. Any thoughts
@@cj99dj could be 2 things. One. There is the voltage regulator next to the stator. Highly unlikely but you could have knocked it out of wacky when you hit the flywheel . 2 could be the cdi box. Did you have no spark before rebuild?
Scratching my head here with a 99 xplorer 400 2 stroke I have spark but will not run the spark kept getting wet watching your videos and the water pump peep hole leak a little bit I disconnected the oil line and I took off the carb and it stopped getting wet...will it at least try to run if I put a little starting fluid without the carb?? And another question is the starter relay works but the key won't turn it over what can I look at mind you my stator ohms is 229 and the pick up is 100ohms I get good spark but it just won't even try turning on..thanks in advance
Also I took off the screw on the bottom to see if there's any water or fuel and found nothing...I been working on alot of motorcycles and 4 wheelers but never a 2 stroke with oil mixture...
Can you provide the size of the split nut/ slit nut you removed with that special socket? Or information on where to get the socket? I have been able to find absolutely no helpful information online.
@Casey Bronson I just did this project today. Had the same problem. Could not find the special socket. Decided to get creative and got a 36mm deep socket and made my own. Just used a grinder and matched the pattern. Saves money. Only problem iv got now is I can’t split the case.
@@caseybronson222494 - 03 Polaris Crankshaft nut tool socket 400 xplorer scrambler 2870967 Seller: custommachinecomponents On E bay. Comes with the nut.
My counter balancer decided to come apart and take the case and piston with it. I saw on a forum that someone just removed the balancer all together and just ran an external water pump. What do you think about this idea? The counter balancer is way to expensive for me to be throwing at this thing right now. I already spent money on a new flywheel and stator then this happened!
Hey titaniumman I have a 2000 scrambler 400 2 stroke I am going to attempt the prius water pump change , do you know what the coolant flow is???? Does it come from the radiator to the bottom port of the water pump then out the top or vice versa. I see videos of 4 strokes being changed but none of 2 strokes, any help thanks
Hey I was wondering what size bolts you’re using for you’re fly wheel puller?? Length would be very helpful. As I’m machining out my own puller. Please respond as quick as possible.
I'm not sure what size bolt. They come in a kit with the puller. I use the one that fits. The bolts are about 2 and a half inches long. I will look at the kit. Maybe it will say a number on it.
@@TitaniummanGarage yea its the pump housing. It was rusted on so use a little force. Thanks for the vid was a lot of help since it's my first time replacing
I have a 99 Xplorer 400 2 stroke. Do I need to be concerned with the pump drive gear behind the pump? Is there are bearing or bushing behind there that I need to replace?
do you have to take engine all apart just to do waterpump? I just put engine in and drove around maybe 45 minutes on motor whenbrown oily coolant started blowing out of somewhere. the only oil in the thing is counter balancer, so its most likely waterpump. Cant you do water pump on the vehicle though?
Unfortunately..The waterpump is in the counter balancer area so yes. I heard of guys installing an electric pump to bypass it. The issue with that is it could run down your battery.
@@TitaniummanGarage what were the torque specs on the water pump and pan. Also flywheel. Thank you for posting this. I start this job tomorrow except I need the castle tool
Hey Bud how are you I watch your videos all the time and enjoy them very much I have it thank you very much I have a 2001 Polaris 400 sportsman I just put a whole new top end on it I had to board out new gaskets piston blah blah blah I had started it and it ran good the 1st day no problem I was checking for leaks the fan worked came on I shut it off the next day I came down to there started water is coming out of my overflow tank it's boiling inside my overflow tank The motor is not that hot the fan did not come on Now when I pull to start it I can feel here the pressure in the overflow tank like you can hear it moving the water around what the hell is going on hell is going on do you have any ideas t thank you Steve
Haha. My friends tease me about that. I never said it in the video. You can find them on ebay. It's a socket for the nut. If you scroll down I have told others what part it is
Also I keep reading and now have heard the counter balance. Is it in a separate area from the crank or does it get lubrication the same way as the crank. Not 100% familiar with the 350/400 2 strokes. Used to have a 250 trailblazer and I definitely dont remember a counter balance shaft.
250's don't have them. They are air cooled. The counterbalancer drives the water pump and keeps engine balanced. It is separate from everything else. The only oil required is by the gears. There is a fill hole on top top the case near transmission. Other than that it runs on bearings and has just the waterpump seal to keep it sealed from water or oil.
Why not just use the impact with the puller instead of risking damaging the epoxy on the magnets and or stator itself by either with the hammer and or with the torch Plus you would have saved more time just using the impact with the puller.
Excellent video. Doing this same job today.
Both the special socket and water pump rebuild kits are available for cheap prices.
First thank you sir for these vids you are seriously a life saver with these vids. Love watching them and they help a whole lot with my own 94 400L. I was replacing the starter on mine and just noticed a little coolant beside the starter bindex. So I'm now contemplating on doing what you did, or just going ahead and rebuilding the bottom end. It has a brand new top end that hasn't even been ran yet so idk.
Thank you. I enjoy helping other people. I do this as a hobby and make the videos hopefully helping people like you.
Thanks for the video. Very helpful!!! I just bought a 1996 polaris sport 400l and I was reading up on them and they say this is a common problem for them. Mine is not leaking yet I don't think? I have to put a new starter into it. So I guess we will see lol this is my first polaris so its all new to me. I have owned mostly Yamaha banshee/ blaster/ warrior/ you get the point. I'm hoping this is a good wheeler it runs good it has been bored 40 over clutch kit and pipe im sure it has bigger jets in it as well. Thanks again 👍
It should be a good machine for you. Just make sure you keep all your fitting greased up. Keep an eye on the oil injector and put a temperature gauge on it. It will run a long time.
I have a 93 350l super useful video thanks!!
😂 The realist sh!t I ever heard! 10:11 "...DEEZ NUTZ🔩Actually hold your WATER PUMP on from the inside!"✔FACTS!😭
Thanks for sharing your experience at this is very helpful
Thanks for the video! Very helpful. I got everything off except the water pump bearing is stuck on the shaft. I can move it maybe a quarter inch back and forth freely, but seems to get stuck. Do you have recommendations for removing this bearing? It appears to be smooth and work properly, but since I have it apart and have a replacement, I'd like to get it off. Thanks!
What is the seal number behind the stator?? Can’t seem to find it making me mad man
Nice Job! I am going to tear into a 97 Polaris Sport 400 l today! #ILOVETH-cam
Nice! It's not to bad once you get into it. Just make sure you loosen bottom engine mount bolts and top engine mount bolt. It makes it easier if you can tilt engine to get cover off.
Very good, bad buy on a 1995 Explorer, overheating issues, radiator sensor looks bad, blown headgasket, had to use putty, still over^pressure in radiator and boiling antifreesze went into reserve :( So wonder if this low miliage has defective waterpump, but that impeller doesnt seem to be melting plastic ??
Still at it, is it true there are no thermostat on those models? So aluminikum and doesnt melt :) Mine has only 6,000km so the seal & bearings should be okay.
What is the part # for the socket? Trying to find one for my 91 350L 4X4 and having no luck. My book gives me 2870967, which is not a 6 prong.
I have a 350L and just swapped in a working engine. How to I bleed the system correctly? I was test running it and the hot light came on so I shut it off. The top hose that goes back to the radiator was not hot. Thinking I did not bleed the system correctly.
Did you crack open the bleeder screw on top of the head to let the air out?
I broke 9 grade 8 bolt in my balance puller one in the fly wheel drilled it tapped tried again got it good n tight then my threads gave any ideas to help
Aside from pulling the case apart to push ballancer out..I don't. except heat it up before you pull it.
Is there a way to test if your water pump is working without taking everything apart? I’m getting some smoke coming from the water pump inlet area on a new top end rebuild. Head is getting hot quick.
You can look in the radiator cap to see if its flowing.
Seems mine is just bubbling. When I hit throttle it will spin in circles doesn’t appear to flow one way or other.
Can a bad water pump seal cause my engine to burn coolant? I've already replaced my head with a machine one and new gasket.
Yes, it seeps into the case and goes through the exhaust. It's a common problem with 2 strokes. Replace the water pump and crank seal behind the counterbalancer cover.
Very helpful video. With out the info you provided would still be working on taking the crankshaft nut off. Only problem iv got is I can’t get the case to split. Any tips?
So with all the bolts removed. Even the little ones by the waterpump (I did that once) tap around the edge of the case. Once it starts to split take a rubber mallet and pound on the clutch side of the crankshaft. Make sure the key is out of the crankshaft that holds the gear in place. If you have anymore questions drop me a line.
Titaniumman 2012 I got everything back together. But I’m having a problem. I’m getting little to no spark now. I did cut the wires to remove the coil under fly wheel. But it’s all connected right. When putting fly wheel on I hit it with a rubber mallet to make sure it’s on. But have no spark. Any thoughts
@@cj99dj could be 2 things. One. There is the voltage regulator next to the stator. Highly unlikely but you could have knocked it out of wacky when you hit the flywheel . 2 could be the cdi box. Did you have no spark before rebuild?
Also try another spark plug. I've had a good one foul out already.
Well done video. Great lighting. Good visibility for the viewer and you explained what you were doing well, leaving nothing out. Thanks!
We're do you get that socket for that nut behind the stator
Ebay.
Scratching my head here with a 99 xplorer 400 2 stroke I have spark but will not run the spark kept getting wet watching your videos and the water pump peep hole leak a little bit I disconnected the oil line and I took off the carb and it stopped getting wet...will it at least try to run if I put a little starting fluid without the carb?? And another question is the starter relay works but the key won't turn it over what can I look at mind you my stator ohms is 229 and the pick up is 100ohms I get good spark but it just won't even try turning on..thanks in advance
Also I took off the screw on the bottom to see if there's any water or fuel and found nothing...I been working on alot of motorcycles and 4 wheelers but never a 2 stroke with oil mixture...
Can you provide the size of the split nut/ slit nut you removed with that special socket? Or information on where to get the socket? I have been able to find absolutely no helpful information online.
I found the socket on ebay. No part number.
@@TitaniummanGarage do you happen to know the size of the nut or the socket? So I can search correctly?
@Casey Bronson I just did this project today. Had the same problem. Could not find the special socket. Decided to get creative and got a 36mm deep socket and made my own. Just used a grinder and matched the pattern. Saves money. Only problem iv got now is I can’t split the case.
@@caseybronson222494 - 03 Polaris Crankshaft nut tool socket 400 xplorer scrambler 2870967 Seller: custommachinecomponents
On E bay. Comes with the nut.
@@TitaniummanGarage Thank you so much!
My counter balancer decided to come apart and take the case and piston with it. I saw on a forum that someone just removed the balancer all together and just ran an external water pump. What do you think about this idea? The counter balancer is way to expensive for me to be throwing at this thing right now. I already spent money on a new flywheel and stator then this happened!
It can be done with a Prius pump do I've seen. Never tried it..but it works. You do need counterbalance. There's a reason they call it that.
The counterbalancer also drives the oil pump.
@@TitaniummanGarage I had already by-passed that and just premixed instead. I decided to tear it down and scrap it. LMK if you need any parts! LOL....
I'm thinking of bypâssing the fan sensor, these 2 strokes heat up so fast.
Hey titaniumman I have a 2000 scrambler 400 2 stroke I am going to attempt the prius water pump change , do you know what the coolant flow is???? Does it come from the radiator to the bottom port of the water pump then out the top or vice versa. I see videos of 4 strokes being changed but none of 2 strokes, any help thanks
From top to bottom. And out the bottom hose.
@@TitaniummanGarage thank you for responding so quick
Hey I was wondering what size bolts you’re using for you’re fly wheel puller?? Length would be very helpful. As I’m machining out my own puller. Please respond as quick as possible.
I'm not sure what size bolt. They come in a kit with the puller. I use the one that fits. The bolts are about 2 and a half inches long. I will look at the kit. Maybe it will say a number on it.
How did u pull the water pump off. Does it just come out or is there a trick to it?
Do you mean impeller or pump housing? The housing should pull out after you unbolt impeller. Unless the bearings are rusty.
@@TitaniummanGarage yea its the pump housing. It was rusted on so use a little force. Thanks for the vid was a lot of help since it's my first time replacing
Did you have to hold the clutch when taking off the special nut
How did your crank shaft not spin
@@ogkoolad1364 The gun I used is for taking lug nuts off. I was able to use it without putting a bar in the clutch. It has a lot of torque.
Titaniumman Garage ok thanks
I have a 99 Xplorer 400 2 stroke. Do I need to be concerned with the pump drive gear behind the pump? Is there are bearing or bushing behind there that I need to replace?
There is a bearing in the pump and behind it on the plate. if It looks good lube it up. if its rusty I would replace it.
Yes replace the water pump bearing and the two seals. They go bad in every 350/400 Polaris two stroke motor. Design flaw, so trust me replace them.
do you have to take engine all apart just to do waterpump? I just put engine in and drove around maybe 45 minutes on motor whenbrown oily coolant started blowing out of somewhere. the only oil in the thing is counter balancer, so its most likely waterpump. Cant you do water pump on the vehicle though?
Unfortunately..The waterpump is in the counter balancer area so yes. I heard of guys installing an electric pump to bypass it. The issue with that is it could run down your battery.
@@TitaniummanGarage there's no possibility of doing it without pulling engine or it's easier to just rebuild engine. I'm looking for least path.
@@TitaniummanGarage what were the torque specs on the water pump and pan. Also flywheel. Thank you for posting this. I start this job tomorrow except I need the castle tool
Not positive on the waterpump, but the other bolts are 18 to 20 ft-lb the nut 45
The castle nut is 45 for the crank right. Rest are 20?
Hey Bud how are you I watch your videos all the time and enjoy them very much I have it thank you very much I have a 2001 Polaris 400 sportsman I just put a whole new top end on it I had to board out new gaskets piston blah blah blah I had started it and it ran good the 1st day no problem I was checking for leaks the fan worked came on I shut it off the next day I came down to there started water is coming out of my overflow tank it's boiling inside my overflow tank The motor is not that hot the fan did not come on Now when I pull to start it I can feel here the pressure in the overflow tank like you can hear it moving the water around what the hell is going on hell is going on do you have any ideas t thank you Steve
It's possible you have back pressure from the head gasket. Did you check to see if the head was warped?
Would this be the same for a 98 xplorer 300?
The 300 is air cooled.
hey what's the name if that special tool?
Haha. My friends tease me about that. I never said it in the video. You can find them on ebay. It's a socket for the nut. If you scroll down I have told others what part it is
Whats the part number for the tool to pull the left hand threaded nut off that crank?
Sorry I don't have the part number. I just googled It.
all good buddy.. made my own
@@TitaniummanGarage what did you Google to find it?
Ebay. 2870967 94 to 03 crank nut socket 400. $78.00.
@@TitaniummanGarage Find myself yet again watching your video to handle a scrambler 400. thanks again 3 years later hoimie!
Do these quads have thermostats?
No. They have a temperature sensor on the head that's it.
How did you get the stater out? It all appears to be wired in with no connections to take apart.
Thanks.
There should be bolts on the stator plate outer perimeter. Take those off and pull it out.
Also I keep reading and now have heard the counter balance. Is it in a separate area from the crank or does it get lubrication the same way as the crank. Not 100% familiar with the 350/400 2 strokes. Used to have a 250 trailblazer and I definitely dont remember a counter balance shaft.
250's don't have them. They are air cooled. The counterbalancer drives the water pump and keeps engine balanced. It is separate from everything else. The only oil required is by the gears. There is a fill hole on top top the case near transmission. Other than that it runs on bearings and has just the waterpump seal to keep it sealed from water or oil.
Why not just use the impact with the puller instead of risking damaging the epoxy on the magnets and or stator itself by either with the hammer and or with the torch Plus you would have saved more time just using the impact with the puller.