What to do??? Polaris Crank problems

Dutchman · Jan 19, 2012

looks like I need some engine work on my '03 700. I'm guessing the PTO crank bearing gave out. I haven't opened the case yet, but removed the top end. The crank looks like it seperated at the connecting rod journal. Is that one spot where the crank is pressed together?
Can turn clutch 1/4" back/forth without the pistons moving, and see movement in that journal area. The pto side piston has a couple marks from debris, something come apart down below.

Who does crank work in Alberta?
First I need to find out what this will cost?
That will determine what my options are??
Rebuild my motor, find another engine, sell sled without motor, etc.????

Any great ideas out there??

markoo · Jan 19, 2012

Cvtech in Quebec. They can ship you a rebuilt crank or a shortblock.

flying frenchman · Jan 19, 2012

Yes, CV Tech. I recommend them too. Never had any problems with their work. Cranks usually $600, cyl $350. Pistons get them from Polaris $190x2 + gaskets.

capt. crunch · Jan 19, 2012

At some point you have to ask yourself is the repairs worth more than the sled. I sold mine for parts and got a new one.

trench · Jan 19, 2012

capt. crunch said:
At some point you have to ask yourself is the repairs worth more than the sled. I sold mine for parts and got a new one.

Some good advice right there, the 03 Polaris was a good sled in it's day, but the new stuff is just so much better.

Dutchman · Jan 19, 2012

capt. crunch said:
At some point you have to ask yourself is the repairs worth more than the sled. I sold mine for parts and got a new one.

I know what you mean............I rode an 08 Summit the entire second day, and it would be easy to get used to that.

IRC · Jan 19, 2012

I had an 03 800 and had it rebuilt three times in three years. Low end price was $1600, high end was $2000 (big bearing crank and case mod). I sold it after the last repair and have not looked back. Loved the sled, hated the lack of reliability. I don't think those motors are worth putting any money into.

summitbound · Jan 19, 2012

Cycle Works
Edmonton

bdietz · Jan 19, 2012

recreation supply in Saskatoon has cranks

Ohmz · Jan 19, 2012

had the crank go on my 02 800 last year and took it to sherwood park motercycle... i think i paid 1400 for a used crank and new pistons installed... great guys to deal with and sled still running strong

jbb · Jan 19, 2012

part it...........you have a 2g sled and needs over a g in parts, plus labour. let alone what else it may need.

flying frenchman · Jan 19, 2012

You know what, fix the old one cause you pay$13000 for a new sled and when warranty is up your back in the same boat. All new sleds have their problems too.

barleyfarmer · Jan 20, 2012

Ohmz said:
had the crank go on my 02 800 last year and took it to sherwood park motercycle... i think i paid 1400 for a used crank and new pistons installed... great guys to deal with and sled still running strong

Is that it upside down in your avatar?

trench · Jan 20, 2012

flying frenchman said:
You know what, fix the old one cause you pay$13000 for a new sled and when warranty is up your back in the same boat. All new sleds have their problems too.

Don't have to buy brand new to get a serious upgrade from the 03. Any Rev, M, or IQ chassis sled is better than the edge chassis!!!

KatMan · Jan 20, 2012

problem when things let go and travel through the engine is the damage you do not see, and do not repair. No shop will warranty the whole engine if they only do some work(even if they will warranty their work???). Ticking bomb.

Brand new shortblock with warranty or part out. You can pick up good used sleds for 5-9 K with partial warranty, or spend 200$ to have a garage check it out.

WopOnTour · Jan 22, 2012

summitbound said:
Cycle Works
Edmonton

AGREE!
Don G. and his boys are awesome.
(been dealing with then since the 80s)
We're fortunate to have expertise like them so "local"
Get them to true and weld the crank so you never see this failure again!
JMO
WOT

PS> also agree though that you'll have to carefully weight the costs of such a repair against the value of the sled.
But it sounds like you are confident enough to rip it apart and reasemble yourself so...

Ohmz · Jan 22, 2012

ch!t yeah.... was following too close on a climb and came up to a road half way up the hill that neiter of us saw and oh crap !! that was the result

barleyfarmer said:
Is that it upside down in your avatar?

duner · Jan 22, 2012

WopOnTour said:
Get them to true and weld the crank so you never see this failure again!

A reman exchange crank will come fully rebuilt and all two stroke cranks are trued when they are repaired. The pol cranks don't need to be welded. Plus this is probably a broken rod pin so welding wouldn't have helped. That sled is well worth rebuilding, cranks pistons and the other parts aren't that much. Most remans are between $500 and $600.

WopOnTour · Jan 22, 2012

duner said:
A reman exchange crank will come fully rebuilt and all two stroke cranks are trued when they are repaired. The pol cranks don't need to be welded. Plus this is probably a broken rod pin so welding wouldn't have helped. That sled is well worth rebuilding, cranks pistons and the other parts aren't that much. Most remans are between $500 and $600.

The fact that some people say "Polaris cranks don't need welding" doesnt make it true.All sorts of high performance 2-stroke shops that specialize in Polaris (like Hooper) certainly continue to do so with good results. (especially so if billet parts are used at the PTO end) But if you don't believe me call John and ask yourself! 603-863-0049 (he should be enroute from Eagle River and back in the shop for Tuesday) Had somone welded that rod pin during the last rebuild it just might have prevented this type of failure. (breakage was very likely after-the-fact)

Also"truing" at the brown-box reman level is usually to very basic manufactuers specs/tolerance (if that depending on source) that actually can be quite wide. A quality rebuilt/race crank is often trued to specs much tighter than that. I have my own pressing jig & stand and have assembled and trued many dozens of cranks for race sleds. It can be pain-staking, time-consuming work, but comes with big pay-offs both on the dyno and durability and CERTAIN welding operations can insure it stays that way.
WOT

What to do??? Polaris Crank problems

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