Tear Down
- Thread starter Newfy
- Start date
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Newfy
New member
Well since no one posted anything to watch out for I dove in today head first.
The cause of the problem is the Mag piston deceide to drop the aft side of its skirt.
There is a big chunk missing and is no where to be found..... I guess I know what all the little pieces of aluminum are from now. The cylinder walls look good and but one spot, there is a ding right at the edge of a port.
Now for the big one.....
The connecting rod for that piston has a spot that it gets real tight on when it rolls through. Seems like there is something down in the bearing on the crank.
My questions to your great minds are:
Is the cylinder ok with the ding, should it be sent out or just replace it?
What can be done about the crank, if anything ?
Thanks again guys
The cause of the problem is the Mag piston deceide to drop the aft side of its skirt.
There is a big chunk missing and is no where to be found..... I guess I know what all the little pieces of aluminum are from now. The cylinder walls look good and but one spot, there is a ding right at the edge of a port. Now for the big one.....
The connecting rod for that piston has a spot that it gets real tight on when it rolls through. Seems like there is something down in the bearing on the crank.
My questions to your great minds are:
Is the cylinder ok with the ding, should it be sent out or just replace it?
What can be done about the crank, if anything ?
Thanks again guys
If you have the 05 stock crank, I wouldn't bother trying to fix it. Get the updated one from http://www.babbittsonline.com/ with the new clutch and new 06 pistons. Can you take a photo of the cylinder?
2203617 KIT-CRANKSHAFT 866 LARGE TAPER $882.20
2203098 KIT-PISTON 86-86 $99.48 (2 required)
2203617 KIT-CRANKSHAFT 866 LARGE TAPER $882.20
2203098 KIT-PISTON 86-86 $99.48 (2 required)
P
polaris all the way
New member
would this be Paul Sharpe of twillingate..
Doesn't look bad to me, but I would get a few opinions on this from the guys who have torn these down before. I'm about to open mine up for the first time. Not excited about your mileage. Mine is about the same I think. Guess I need to fine some money for two pistons.
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Newfy
New member
I done the intake boots on mine half way in the season last year, had some studs broke off and dug down a bit to get them replaced. At that point I really looked hard into replacing the pistons. But for some reason I didnt, I may have put 200kms since then, BOY am I kicking myself now
I done the intake boots on mine half way in the season last year, had some studs broke off and dug down a bit to get them replaced. At that point I really looked hard into replacing the pistons. But for some reason I didnt, I may have put 200kms since then, BOY am I kicking myself now
That's not what I want to hear man. I will have to wait two more weeks to get them.
If you end up needing a cylinder, this is where I got mine. They will ship you a new one and give you a refund when you ship yours back to them.
http://www.cvtech-aab.com/contenu/index_ang.cfm
If you decide to go this way, you will need the number on the side of yours when you order. I got mine the day after I ordered it! (I'm not as far from them as you are though)
http://www.cvtech-aab.com/contenu/index_ang.cfm
If you decide to go this way, you will need the number on the side of yours when you order. I got mine the day after I ordered it! (I'm not as far from them as you are though)
B
bustamove
Active member
i wouldn't chance it.
2 new pistons and rings 200 bucks.
when a skirt breaks off,
cylinder 200
pistons 200
crank rod 400
sometimes cases 500
B
bustamove
Active member
it sounds like your rod bearing is toast. if there is ANY rough spots at all gotta be replaced, there were probably chucks lodged in the open slit?
as for the crank its hard to say.
it will probably be 400 for the new rod and around here its 150 roughly to get it pressed apart and back on. plus any immediate bearings that might have gotten stuff in there.
new crank comes with new clutch (have to transfer weights and spring), all gaskets you would need to get to the crank. and its a total drop in crank its quite nice.
with those little chunks you gotta probably have to replace the cylinder, use your finger nail and drag it around the cylinder if it gets caught on any ridges needs to be replaced. i got my cylinders from MCB performance $209 i think., he shipped some out for me then i shipped mine back once i got the old ones off.
with a pistons skirt breaking you gotta make sure you have no cracks or holes in the case.
good luck
as for the crank its hard to say.
it will probably be 400 for the new rod and around here its 150 roughly to get it pressed apart and back on. plus any immediate bearings that might have gotten stuff in there.
new crank comes with new clutch (have to transfer weights and spring), all gaskets you would need to get to the crank. and its a total drop in crank its quite nice.
with those little chunks you gotta probably have to replace the cylinder, use your finger nail and drag it around the cylinder if it gets caught on any ridges needs to be replaced. i got my cylinders from MCB performance $209 i think., he shipped some out for me then i shipped mine back once i got the old ones off.
with a pistons skirt breaking you gotta make sure you have no cracks or holes in the case.
good luck
Last edited:
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millwall
Member
The 2005 pistons are an accident waiting to happen, Polaris didn't do a recall, for the added expense, but will gladly supply you with the updated 2006 pistons. Don't even think you can get 2005 pistons even if you asked for them specifically.
Before you venture too far into the cylinders you have, you will need to know if the cylinders are still round or shaped like an egg. As this will create a condition known as piston slap. This is as it sounds, is when the bore wears out front and backside of the cylinder, so as the piston goes up and over and down, it will wear out more on those sides of the bore, compared to the sides next to the ends of the wrist pin. So as the bore wears out, the piston skirt bangs against the wall of the cylinder on the way up, and the opposite piston skirt bangs on the way down, till eventually the cnc machined 2005 piston breaks as in your case.
So you could have either a worn out bore, or the piston had just enough movement even though the bore is still within spec, but broke off due to a piston defect or this piston slap.
Send your crank out for a new rod bearing, do not damage either of the two seals in the center, or they will have to break the crank down even further to replace those. They will check the rest of the bearings for you, and then check runout of the crank as a whole unit.
My advise, send to Indy Dan, there are a few crank shops out there (3 shops i know of, that will do a 900), but none that know the 900 crank better than him.
Or ask him if he will check out the cylinders for you, to see if they are still good for 2006 pistons after a diamond hone.
Sorry for the lecture.
Good Luck!
Before you venture too far into the cylinders you have, you will need to know if the cylinders are still round or shaped like an egg. As this will create a condition known as piston slap. This is as it sounds, is when the bore wears out front and backside of the cylinder, so as the piston goes up and over and down, it will wear out more on those sides of the bore, compared to the sides next to the ends of the wrist pin. So as the bore wears out, the piston skirt bangs against the wall of the cylinder on the way up, and the opposite piston skirt bangs on the way down, till eventually the cnc machined 2005 piston breaks as in your case.
So you could have either a worn out bore, or the piston had just enough movement even though the bore is still within spec, but broke off due to a piston defect or this piston slap.
Send your crank out for a new rod bearing, do not damage either of the two seals in the center, or they will have to break the crank down even further to replace those. They will check the rest of the bearings for you, and then check runout of the crank as a whole unit.
My advise, send to Indy Dan, there are a few crank shops out there (3 shops i know of, that will do a 900), but none that know the 900 crank better than him.
Or ask him if he will check out the cylinders for you, to see if they are still good for 2006 pistons after a diamond hone.
Sorry for the lecture.
Good Luck!
Have you seen my post on my 2010 upgrades...lol. What $200 more, sure why not. I will be riding by next year at this rate.
By gladly you mean if we give them our credit card they will gladly give them to us right? Or are you suggesting they would be free?
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Newfy
New member
Free from Polaris, outside warrenty, now thats a joke.
Thanks guys for all the info, the support on here is unreal.
Im going to call IndyDan today, the crank will go to him maybe even case. I guess now is the time to get everything done. Where is a good place to send out the clutchs for balance and rebuild. Now to go through the long list of mods that need to be done and figure out what to do.
Wallet is realy starting to hurt now, and the finacial manager
isnt to happy.
Thanks guys for all the info, the support on here is unreal.
Im going to call IndyDan today, the crank will go to him maybe even case. I guess now is the time to get everything done. Where is a good place to send out the clutchs for balance and rebuild. Now to go through the long list of mods that need to be done and figure out what to do.
Wallet is realy starting to hurt now, and the finacial manager
isnt to happy.
B
BIGGDAWG
Well-known member
Free from Polaris, outside warrenty, now thats a joke.
Thanks guys for all the info, the support on here is unreal.
Im going to call IndyDan today, the crank will go to him maybe even case. I guess now is the time to get everything done. Where is a good place to send out the clutchs for balance and rebuild. Now to go through the long list of mods that need to be done and figure out what to do.
Wallet is realy starting to hurt now, and the finacial manager
isnt to happy.
indy dan balances clutches too and does a great job, i have him do mine.
M
millwall
Member
Will that be American, Visa or Mastercard, Sir!
