If it's disconnected does that mean the override is always engaged or always off?

 

The reverse override also allows 4x4 in reverse.

 

I never knew that. Glad I learned that now. So if the limiter wire is off. Then always 4wd in reverse or the opposite. I am going to want 4wd in reverse.

 

If I understand correct:
Override is reverse only.
The override switch, when engaged, allows more engine power to be used in reverse.
Does this by bypassing the limiter.
The only way to use awd in reverse is by pushing the override.

If o/r is disconnected:
The extra power can not be utilized.
There would be no awd while in reverse.

Is this correct??

Tech I am cleaning the carb.

 

You have full power and awd in reverse by simply pressing the over ride button "IF" the black wire from the limiter is still hooked. By pulling the black wire,you eliminate the reverse limiter module,have full power and awd in reverse without having to push a button.The way it really should have been. This was just a safety device that basically only Polaris had that I'm aware of. Good idea in theory,but the modules always ended up shorting out.When they did some machines would die when placed in reverse or the only way you could get one into reverse without dying was to hold the over ride button then shift into reverse and holding the button while giving it throttle. Also many would start limiting in forward range also. Just unplug em and be done with it.

 

If it's not unplugged it will be. I thought I could have that backwards.

 

Unhooked

 

Took the machine out without the air filter to see if it made a difference ( plugged solid). Ran rough with a bit of backfire. Did I just screw up the timing?

 

Also cleaned the carb and reinstalled. Now it won't idle. ( not sure if makes a difference but it's without the air box on). Idler screw is bottomed out. Even marked inside the carb.
Would you think timing or valves need adjusting ?

 

Read over the manual link I gave you! This is a two stroke,doesn't have valves. Don't just clean a carb on an old machine,especially the 400. They're bad about wear on needle and seats.Back firing can be because of lean condition,float level off, may still have some blockage,etc. Carb kits are cheap. http://www.ebay.com/itm/CARB-REBUILD-REPAIR-KIT-POLARIS-XPLORER-400-4WD-94-95-4X4-/271003419771?pt=Motors_ATV_Parts_Accessories&hash=item3f1910047b&vxp=mtr Plus install a new air filter and the box. The manual can help on the carb,plus several videos on the Mikuni carb on youtube.