cylinder ok? / stator output and general questions - Snowmobile Forum: Your #1 Snowmobile Forum

chevette_boy · 09-05-2006, 01:04 AM

hey so i finally pulled the motor out of my cougar and tore it down and after a few hours with some acid and a lil light honing i managed to get the cylinder decent looking only problem is thes a small chunk missing in one spot and a longer chunk with a hairlind crack in the nikasil ? thing i could still use it of should i buy another cyl if i can get one? also the crank case is full of piston crap should i wash it out with gas or do i need to split the case and give it a thouroul cleaning and if i do that how do i pull the clutch. second question i need a new headlamp bulb and it is and h4 50/60w can it put in a brighter automotive bulb say 100w or will i fry the stator. also going to do some mild porting to clean up the transfer ports etc not gonna change the port timing tho any tips on what works well would cutting downward swirls in the intake port to help mixing do any thing?

**smallengineguy** · 09-05-2006, 06:51 AM

Replace that cylinder!! You can't run it with cracks and chunks taken out of it! You'll tear it up again. A few companies out there replate them, or check eBay for a used one.

red firecat 600 · 09-05-2006, 06:32 PM

you have to get the cy,inder redone send it to us chrome they are located in WI i beleive and they do a great job and probly have a spare one sitting on the shelf for a exchange. it will be a lot cheaper to do it this way. The web site is us chrome,metal finishing,duratech product, anodizing aluminum, www.USChrome.com

**RJ Gleason** · 09-05-2006, 11:57 PM

SEG, that would be a good one to add to the parts listing.

**smallengineguy** · 09-06-2006, 07:13 AM

Done!

BC_Dan · 09-06-2006, 10:59 AM

I would also split the crankcases and make sure none of the piston debris got into the bearings, they are not very forgiving when it comes to junk. If you just flush it, you may not get everything, and crank bearing replacement is VERY expensive.

You need a clutch puller to take the clutch off, they are available at any AC dealer, or at any of the snowmobile parts dealers such as DennisKirk.com. The puller is basically a long bolt that engages threads on the clutch. As you tighten the puller, the end of the puller pushes on the end of the crankshaft, pushing the clutch off. If the clutch has not been off in a while, it may be a PITA. I find filling the hole vacated by the clutch bolt with 5-10 shots of grease seems to help; when you tighten the bolt, it creates hydraulic pressure in the grease that helps shove the clutch off. It will come off with a BANG sometimes, so be aware.

chevette_boy · 09-06-2006, 07:41 PM

sounds like fun i tried a regular pulley on the fly wheel and no luck is there a tool for that 2 ?

BC_Dan · 09-06-2006, 08:04 PM

I use a 3-bolt flywheel puller for small engines, if you get one, spend a few bucks; some of those flywheels are really on there, you will bend a cheap unit pretty easily... SLP sells one that is pretty durable, you may want to look at one of those...

furious D · 09-12-2006, 09:05 PM

You also need to buy the correct clutch puller for that sled in order to get the clutch off. Royal; distributing should have one for your application >>>>>>>>>>>>>>>Royal Distributing - Snowmobile Parts and Accessories. ATV, Motorcycle Parts and Accessories.