800 "fix"

[GKR]

Here is what I found on tear down. Interesting to note that both pistons looked marginal on the exhaust side but both had damage on the intake side. Beware, the Y pipe inspection method would not have revealed this.

PTO exhaust side

Mag exhaust side

PTO intake side

Mag intake side

After measuring I found both sides had 0.008" piston to cylinder clearance.

Cylinders were still nice and just under the recommended spec for the Fix kit of 3.347". With a light hone they came out perfect at this dimension.

New clearance is now right around 0.0040" to 0.0045"

One other thing I noticed is that my wrist pin bearings looked fairly "blued" from heat or possible limited lube so I will change them out as another precautionary step.

 

[GKR]

One question I have for PMSPOLARIS or others is when installing the kit, what is the target spec for wall clearance and ring end gap. As it stands now I have 0.0040" on wall clearance and spot on 0.019" ring end gap. This is right at the minimum spec on both. Ring end gap is recommended at 0.019-0.028" Am I better to be in the middle of the range or on the tight end? Some opinions please. I will leave it right at 0.019" if that is the best option.

 

[gerrman]

GKR...scoring on my pistons were on same side of pistons...both sides of skirt though, but worse. Similar mileage, 1250 miles. Just placing your new pistons in the cylinder for a test fit, you will notice a huge difference. Color on top of piston looks good, your PCV map is working for you. People that like these sleds should be doing this. Keep the update posts coming.

 

[Joe57]

09 800 D

I agree with you 100%. I am sitting here with a 2010 800 Dragon 155 with 1000 miles on it. Warranty about to runout. As much as i want a Pro, I really don't want to spend the money because this dragon is an awesome sled.I JUST DON'T TRUST IT!! i would rather spend the money though and get a new sled with warranty rather than have this one cost me $2000 down the road and still have a 3 or 4 year old sled. Do i want a Pro? Yes. just didn't want to feel like i HAVE to buy one. I do HAVE to buy one right??? at least that's what i'm gonna tell the wife!!!

I was in the same boat as you I put in the Mtn tek kit ,Gary @ Buckies got mine warrentied jugs and pistons I bought the kit they installed it and kept the oem pistons for the price of the rebuild , I sold it for 5 grand and am holding the paper on it till it gets payed off.I'm riding a 2012 pro with 4 years of peace of mind......The Dragon runs waaaay better than it ever did new... But I didn't trust it....I was working with a guy that had his burn down sat.800 miles.

 

[brokedragon]

What's the verdict?

Just smoked my 2008 RMK 800 Dragon 163" for the second time. Can't afford another sled but I am sure not going to put OEM parts back in it. Which fix kit is better? MTNTK or Dragon Saver?

 

[Snow Duck]

MTNTK KIT BY FAR!

I have both...i am not afraid to ride my 09 with the MTNTK but everytime i get on my 10 with the no name kit i am running scared thats why i carry a tow rope with that sled!!

call and chat with them ....at least you can get the answers you are looking for...

 

[SummitFox]

Newbie question warning......I have an 08 800 as well and I'm wondering if my sled already has the MTNTK kit installed. When I bought the sled I didn't do much research, but I swear I remember the guy mentioning he had done something to the motor like this. How would I be able to tell? If it's not already done I'll definitely be doing it as well.

 

[St0rm77]

if there is the MTNTK kit, there will be a 1/4" spacer between the case and cylinders of a different metal than the engine's aluminum.
other kits, i wouldn't know

 

[Snow Duck]

mtntk's spacer is a goldish steel plate and knock offs are usually alum..