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Old 10-05-2010, 02:36 PM   #1 (permalink)
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2002 Polaris RMK 800

Hey everyone,

I am new to the forum and new to the Colorado Area. After some extensive research I bought my first sled:

2002 Polaris 2002 RMK 800
-159 track extensions (stock 151) 2 inch paddles
-SLP straight line intake
-SLP single pipes and can
-Large Bearing Kit

(500 miles since)
- Top and bottom end rebuild
-Clutch servicing

the sled has been babied its whole life and was stored inside.

I have noticed that it takes quite a few pulls to start up right now, but it is also still fairly warm out, not at elevation that it is tuned for (9,000 -10,000 ft), and also has not been run since last winter.

I just ordered the service manual and considered doing a full carb cleaning myslef. I am not completely unfamiliar with engines but i would by no means consider myself an avid mechanic. Do you think cleaning the carbs will be too much for me to handle? Are there any other preseason tunings i should be aware of minus standard greasing, filters, plugs?

Thanks Guys!
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Old 10-05-2010, 10:54 PM   #2 (permalink)
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Welcome, I am new as well. I have the same sled, but am unable to find the manual, where did you order it from?

Sounds like the same sleds I got, I picked up 2 of them and a trailer for 6k. They are great so far, cant wait to get them in the snow.

Jack
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Old 10-06-2010, 12:30 AM   #3 (permalink)
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Welcome to the forum!

The carbs are not difficult, do it on a bench so you don't lose any of the jets or screws. It's very likely the temps are making it difficult to start, but cleaning is always a good idea to start the season!
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Old 10-06-2010, 03:02 AM   #4 (permalink)
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welcome,I have same sled.Unfortunatly the motor went out last year.
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Old 10-06-2010, 10:54 AM   #5 (permalink)
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Quote:
Originally Posted by Jack 02 RMK View Post
Welcome, I am new as well. I have the same sled, but am unable to find the manual, where did you order it from?

Sounds like the same sleds I got, I picked up 2 of them and a trailer for 6k. They are great so far, cant wait to get them in the snow.

Jack
I bought a service manual through a local dealership for around $54. But check the manual-links section of this forum
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Old 10-06-2010, 10:55 AM   #6 (permalink)
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Quote:
Originally Posted by 97cummins View Post
welcome,I have same sled.Unfortunatly the motor went out last year.
What exactly blew out on the motor? The top and bottom end of the engine was rebuilt after 3,000 miles last year so i am hoping that will extend the life of the engine.
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Old 10-06-2010, 11:52 AM   #7 (permalink)
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The most common failure in the Liberty 800 is failure of the crankcase which leads to failure of the crankshaft. The cases from Polaris are very porous and the amount of torque available in that engine, especially with a lot of off and on throttle, usually causes the crank to enlarge the PTO end of the crankcase. With no support, the crank fails. Fixes include getting a wider bearing on the PTO end of the crank (to disperse the force over a greater area) and to have a marginal case machined and line-bored. Keeping the primary clutch balanced is also key to keeping the crank from failing. Some other things that seem to help is the addition of an engine plate, torque stop, and engine stop to keep the engine solid. There are also more durable motor mounts to help that as well.

If your engine was gone through, it's likely that a wider bearing was installed. Depending on who did the work, that may keep you going for several thousand miles. If the shop didn't true the crankcase, the mileage you get from the rebuilt engine may not be very satisfactory.
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