95 Xplorer 400 floats?

[saxmo]

last ones....

[Woody_YZF]

The heat sending unit does look a little corroded and the antifreeze on the top would have just been from you taking the head off. I wish I knew more about the Polaris to help you out. Hopefully someone can chime in here as I know there are some Polaris gurus around.

[saxmo]

thanks, I was hoping hardly dangerous would log back in, but I guess with the holidays he may be out of pocket. Since the teardown was relatively easy, I am thinking about just replacing the head gasket, and seeing what happens. My kids are here for the holiday, and they have been drooling over the 4 wheeler. If that works, then I know what was the prob...

[hardlydangerous]

Sorry bout that. I've been pretty busy

That line is your oil feed line. If it has a hole in it you can bet the engine was #1 running lean
#2 starving for oil
If it was just melted it may have only starved for oil and overheated

Pop the cylinder off if you have not done so and check the piston and rings for any marks or signs if scoring, check the rings end gap in the cylinder as well to make sure the rings are not worn.
Make sure the head is not warped and re-lap it before you install it.
if all is in check... then put it back togather with new gaskets and properly re-torque all nuts and bolts.
replace the oil line and the coolant sensor

[saxmo]

thanks Hardly, and welcome back. I was pre-mixing my gas, so I averted the problem with the oil line before it became critical. The cylinder and all looked REALLY good, so I put it back together and torqued the bolts to 20#. It runs with quite a bit more gusto now! I believe that the guy who rebuilt it never re-torqued the bolts, because one was hand tight... The only prob I'm still having is getting the fans to consistantly come on. The coolant no longer blows out the radiator anymore...yippeee! might this problem with the fans is because of the temp sending unit? Are there two sending units? I see one on the head, and one on the radiator itself.? saxmo

[hardlydangerous]

The sensor on the radiator is the thermostatic switch that kicks in the fans when the temps get hot enough, the sensor on the head is the thermosensor witch controls the idiot light that tells you when it's over heating.

BUT Like I said way back at the beginning of this thread make sure the neutral lights and what not are working and on before you start the bike. If not, clean the contacts in the switch. If the switch is dirty or corroded it will still allow the engine to run but the instrument lights and cooling system fans/warning lights will not work. If the switch is real touchy just replace it. Because as you ride over bumps and stuff it may jiggle and not properly connect the circuit and the bike may overheat again.

As for the fans they should not be coming on constantly, for the most part the radiator does a pretty good job of cooling and the fans should only kick in occasionally after hard riding or after say 15 minutes of idling. The cleaner you keep the radiator and the better it will cool the system. Also taking the time to straiten and align any bent fins will also greatly help.

Make sure you plug up the old oil inlet line other wise it will cause the bike to run lean and blow up. The best way to plug it up is remove the hose from the fitting on the intake and plug up the hole on the brass fitting where the hose fit over with JB weld. (Do not use silicone)

[saxmo]

thanks for the information. Where is the switch located that needs cleaning and/or replacement? I have noticed, as you said, that the fan is running intermittantly. BUT, my lights are still not coming on, so I will proceed with the switch.

[hardlydangerous]

Kill switch on the left side of the handlebars.

Remove it from the bars. Disassemble the switch and clean it with contact cleaner, then relube the switch with dielectric grease and re-install the switch. it's pretty easy and should be done every couple months.