New to the forum. A buddy of mine just gave me a 2002 Sportsman 400 that hasn't been running in 4-5 years and so I'm working on getting in back in shape. He had taken to a local ATV mechanic who told him it was going to be ~$2000 to get it running (it had been used by his ranch hands and then parked once they got a UTV). The mechanic also offered him a $100 for it, he declined and gave it to me instead.
I've never played with Polaris, but currently have a couple Warriors and had a Mule 1000 in the long ago past, so I'm not completely new to working on stuff and have a pretty decent shop with mill, lathe, welder, etc.
The mechanic had taken off the pull starter, plastics and both clutches along with disconnecting the shift linkages. This was a little fishy to me since as far as my buddy knew it had not been running - so why would you take off the clutches before getting it running. So far it looks like it needs a belt, and the drive clutch has some radial cracks at the base. I went by the local Polaris dealer to pick up a belt and took the clutches in to get an opinion. The mechanic indicated that these cracks are fairly common when you get it hot and then plunge into a mud hole. The cracks are on the spider side, so basically looks like that is trash.
The driven clutch appeared visually ok, but the dealer mechanic indicated it might be a good idea to replace while I was at it. I don't want to put a bunch of money into it, as it is just going to be a play toy for around the property. So I've going to do some research and figure out what my options are.
I've never played with Polaris, but currently have a couple Warriors and had a Mule 1000 in the long ago past, so I'm not completely new to working on stuff and have a pretty decent shop with mill, lathe, welder, etc.
The mechanic had taken off the pull starter, plastics and both clutches along with disconnecting the shift linkages. This was a little fishy to me since as far as my buddy knew it had not been running - so why would you take off the clutches before getting it running. So far it looks like it needs a belt, and the drive clutch has some radial cracks at the base. I went by the local Polaris dealer to pick up a belt and took the clutches in to get an opinion. The mechanic indicated that these cracks are fairly common when you get it hot and then plunge into a mud hole. The cracks are on the spider side, so basically looks like that is trash.
The driven clutch appeared visually ok, but the dealer mechanic indicated it might be a good idea to replace while I was at it. I don't want to put a bunch of money into it, as it is just going to be a play toy for around the property. So I've going to do some research and figure out what my options are.














The concepts are pretty wild.