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Old 03-12-2009, 07:50 PM   #1 (permalink)
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I Need help taking apart a polaris 700 Engine?

So i have never messed with anthing on the engine of a sled before so i have a few questions. I pulled off the head and one of the cylinders had small metal chunks in it, and it was able to twist back and forth more than the good side. So i'm thinking it's a rod bearing?
Would something like this mess up the crankshaft too? And can i inspect the crankshaft well enough by just looking at it if i just take off the cylinder and look down in there?
In the manual it looked like i need to pull the engine and i would need a few specilized tools which i don't have. If it is just a bearing could i replace it with out pulling the engine?
I kind of am just acessing the damage to see if i'm going to fix it or try to sell it to someone that has more money than i do to make the repairs.
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Old 03-12-2009, 09:30 PM   #2 (permalink)
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Remove the jugs and you should be able to get a good look at the rod bearings. No need to pull the motor.
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Old 03-13-2009, 12:32 AM   #3 (permalink)
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Is this a 700 twin (Polaris) engine? If so, it will take you less than an hour to have the engine on the bench...(personal best on my old 700 RMK was 42 minutes from rolling it in the shop to engine on the bench, but I had WAY TOO MUCH practice pulling that dang thing out).

Like SEG said, you may be able to assess the damage by removing the head and cylinder. Replacing bearings on the crank (especially inside bearings) is best left to the pros, it takes some pretty specialized tools to pull the crank apart and then get the bearing and crank back together again in phase. If the crank is damaged, you may also need case work. It's pretty easy to put more money into an engine than a sled is worth.. (new OEM crank is about 950, case is about 550, seals and gaskets, another 150 or so, cylinders, 400 ea, pistons, 150 ea)

If it has small metal chunks on the piston, probably one of the bearing cages let go or the connecting rod bearing let go. If it's the top rod bearing, that can be replaced without removing the engine, but if it's the lower, you will want to take things apart to assess all the damage. You may want to split the case regardless to make SURE there are no small pieces lurking about the bottom end, waiting to destroy your crank.

About the only specialized tools you will need is a flywheel puller and a good torque wrench If you do the work, get a manual. It's the best money you can spend. If you buy a flywheel puller, get a stout one, Polaris flywheels are notorious for being stubborn to take off. A cheap one will break and can damage the stator under the flywheel. A special wrench to torque the cylinder base nuts is nice, it's impossible to get a socket with a torque wrench on all 8 of those. A crows foot wrench will work in a pinch.

You may also find a manual online, there are several posted in the stickys in the engine/drivetrain section of the forum.

Good luck!!
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Old 03-13-2009, 05:57 PM   #4 (permalink)
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So i just took off the jug and it appears it is the bearing where the piston rod connects to the crankhsaft. There is a lot of play where it connects, i'm assuming that it should be tight. Also on either side of of the piston rod where it connects to the shaft there are what looks like a washer like ring, one of those was ripped off and that appear to be where the metal chunks came from. I was looking at some expanded parts diagrams but i couldn't see either a bearing down there where i mentioned or the rings.
So i guess my questions for you guys are what are they called? so i can look up price.
Would something like this ruin the crankshaft?
Or if you have anything else to add it would be much appreciated.
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Old 03-14-2009, 04:12 AM   #5 (permalink)
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You are going to have to split the case and have the crank pressed apart to change that rod bearing.
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Old 03-14-2009, 08:07 AM   #6 (permalink)
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Getting the crank rebuilt will cost anywhere from $400 to $600. Maybe finding a used or NOS crank may be cheaper.
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Old 03-14-2009, 03:15 PM   #7 (permalink)
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Quote:
Originally Posted by nathans8 View Post
So i just took off the jug and it appears it is the bearing where the piston rod connects to the crankhsaft. There is a lot of play where it connects, i'm assuming that it should be tight. Also on either side of of the piston rod where it connects to the shaft there are what looks like a washer like ring, one of those was ripped off and that appear to be where the metal chunks came from. I was looking at some expanded parts diagrams but i couldn't see either a bearing down there where i mentioned or the rings.
So i guess my questions for you guys are what are they called? so i can look up price.
Would something like this ruin the crankshaft?
Or if you have anything else to add it would be much appreciated.
there is a degree of movement side to side but there shouldn't be any movement if you pull up and down on the connecting rod. the washer like ring sounds like a C Clip and you should never ever use a c clip in an engine. They are hardened. What you want is the wire style wrist pin retaining clip. they come with the piston kit along with rings and the wrist pin. you will need a new wrist pin bearing as they do not come with the piston kit.

As far as crank damage, any debree left in the motor will due more damage.

If there is any doubt of debree you are best to take it apart. If you can account for all the pieces that broke stick a magnetic pick up down between the crank throw and see if any metal comes out. Note that pieces of piston are none magnetic

good luck
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Old 03-15-2009, 03:21 PM   #8 (permalink)
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I took down to a mechanic and he confirmed what i thought. He also said that the cylinder and head on the left side are shot from the metal pieces. So it seems that this is more money then I want to put into this sled. I think i'm going to sell it for parts. Next season hopefully i'll have some more money to get another sled.
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Old 01-09-2010, 08:02 PM   #9 (permalink)
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Its toast

Quote:
Originally Posted by nathans8 View Post
So i have never messed with anthing on the engine of a sled before so i have a few questions. I pulled off the head and one of the cylinders had small metal chunks in it, and it was able to twist back and forth more than the good side. So i'm thinking it's a rod bearing?
Would something like this mess up the crankshaft too? And can i inspect the crankshaft well enough by just looking at it if i just take off the cylinder and look down in there?
In the manual it looked like i need to pull the engine and i would need a few specilized tools which i don't have. If it is just a bearing could i replace it with out pulling the engine?
I kind of am just acessing the damage to see if i'm going to fix it or try to sell it to someone that has more money than i do to make the repairs.
Your looking at 2500.00 in repairs and double that if you screw up on your own. The bearing can be replaced and yes it probably took out the crank. If your lucky it didnt wipe out the case halves. Jugs are questionable
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