what you don't want to see from you motor

[clutch man]

Here are some photos of an 05 900 that the rod broke.

 

[guidoxpress]

HOLY CHIT....

so your saying it cant be buffed out then? lol...

are you rebuilding this sled for yourself? or doing it for a customer?

 

[clutch man]

yes I am for a customer and we found a motor on ebay to replace it.
about all that is good is one cylinder the head and the stator/flywheel.

 

[f15ejedi]

That has a "getting it out to the trailer" story behind it that I'd like to hear! Sometimes those are worse than the damage repair itself. Thats why you see abandon sleds in the back country.

 

[clutch man]

after a little more inspection on this motor I found that someone put too long of bolts in the reed cage and it pushed out a piece of aluminum in to the crankcase. not sure if this what made it go down but is sure could have

 

[94fordguy]

Yikes!

 

[05900]

Nice boat anchor!

 

[clutch man]

That is one of the worst i have ever had come though my shop

 

[diamonddave]

yes I am for a customer and we found a motor on ebay to replace it.
about all that is good is one cylinder the head and the stator/flywheel.

Might not be a bad idea to replace the stator as preventative maintenance, but more important...

Inspect the flywheel close, I've seen 3 now (05's) that have had the magnets come loose and wreck the stators. All 3 were very interesting back country retrieval missions.

I was told 3 years ago by my dealer that Polaris made a change to the bonding agent (glue) although no one else had heard of this. The inspection hole on the top of the case just above the flywheel is directly below the coolant reservoir overflow hose. Anitfreeze is hell on glue and bonding agents, so a simple piece of tape on this hole will help this from happening. I've also seen a bolt fall in this hole and tear up all kinds of crap.

 

[rmk2112]

The inspection hole on the top of the case just above the flywheel is directly below the coolant reservoir overflow hose................. I've also seen a bolt fall in this hole and tear up all kinds of crap.

Awesome point DD, Glad you brought that up.

Been there done that!!
Thank God for a large head on the bolt I dropped, I had a washer hit that same hole and it was about 1/16" too big to drop thru. 2 times was enough for me, I duct taped that sucker up good!!

 

[f15ejedi]

I have to pull off my recoil to put new cord on this season so should I change or inspect the stator? What do I look for on the stator? My to do list just keeps getting bigger!! We ride about 20 mile from the road though so I don't mind spending the extra time doing the little stuff to prevent a big recovery. I've riden out twice with a busted lower a-arm and shock so I haven't had to be towed out yet. Thank god, I would never hear the end of it. (1800 miles on the original stator).

 

[05900]

Might not be a bad idea to replace the stator as preventative maintenance, but more important...

Inspect the flywheel close, I've seen 3 now (05's) that have had the magnets come loose and wreck the stators. All 3 were very interesting back country retrieval missions.

Not sure about coolant issue but Have had rivet {from skidplate?} in stator.Would die everytime you laid it over until it died !!!! The holes definetley can let objects liquids in.

 

[clutch man]

Great info here thank you I will check them close.
Talked to Indy Dan and i am putting the new pistons and checking out the Crank and the case plus new seals on he replacement motor too.

 

[clutch man]

With a few PMs back and forth to Indydan and some phone calls.
I have talked the customer in to doing the TM 1 on his motor so it will get the 3 bearing kit from Indydan. Here is a photo of the bearings, this shows the a new end but we will use the old one here.

 

[volcano buster]

I just pulled my 700 apart. I had sucked in the small screw that holds the rubber intake boot to the airbox. The screw was on the mag side, but got ingested into the PTO side and took out a piston and the cylinder needs rebuilt. These motors don't fair well to foreign objects.

 

[clutch man]

The Bottom end is on its way to Indy Dan to do his TM1 on. I will post photos of what it should look like when it goes together.

 

[MARV1]

I've grenaded a couple pistons and cylinders but never sawed up a crankcase(knock on wood) yet. . .

 

[knee deep in it]

i had an 07 800 Summit with a minor coolant leak. I took it into the shop for repair. They asked me where the coolant leak was. I handed them a 3" x 4" piece of the crankcase and said " I think it is leaking through this. I think it is a bad sign when you can see the crankshaft while the motor is sitting in the sled"

Should have seen the look on thier face. They were like " Oh Oh, this is very bad".

 

[clutch man]

It is not a good thing to see the crank shaft and rod sticking out the block

 

[volcano buster]

1) What are you speculating to have caused the rod to break?
2) What happened to the mag side cylinder, I see it is showing some damage as well?