I have an 03.5 Summit 800. Issues thus far:
- Engine has toasted 3 times, once ring, once piston clip, lost crank @ 5,000 miles
- Toasted 2 Primary clutches, due to sliding sheeve bushing coming out
- Nun bent easily
- Clutches (both) heat up like crazy. Aligned and balanced even.
- A-Arm mounts crack
- A-Arm bolts bend and get stuck in spacer
- Secondary clutch washer on backside broke (the one that retains the clips)
- Suspension rails tweak/bend
- Rear suspension arm snapped in two
- HPG shocks suck
- Fox shocks in rear had to be modified to fit
- DPM went bad
- Motor mounts break every season
- Recoil starter inner plastics needed replaced @ 5000 miles
- Carb boots crack and leak air
- Left hand warmer stopped working
- Rotor key replaced @ 6000 miles, should have sooner
- Throttle cable snapped @ 4,500 miles
- Mine floods really bad if I get stuck upside down in pow. 30+ pulls to start
I ran out of mean things to say about it. And even after riding all the other chassis new and old, the rev is still my favorite.
Oh yeah, my lightbulb burnt out.