I got my flywheel back and put it on today. I had noticed before that the front of my motor was covered in oil. I talked to rick and he said prolly the oil injection eliminator plate was leaking oil around it. I pulled it off and sure enough the sealer i put on it had broken down and was letting it leak. I got some yamabond per ricks request, and put it back together.

Well today, i refilled the counterbalance oil, andstarted it up. Once i got it going i did a few laps around the yard and everthing seemed good. But when i pulled it in the shop it had a puddle under it after sitting for a minute. I think i may have overfilled the counterbalance, because the oil all looked really new. But i couldn't see where it was coming from. I started it up to see if i could tel anything and there seems to be a knocking in the front of the motor..... Any thoughts....?

 

I just talked to Rick.... He said if its coming from the bottom its prolly the counterbalancer. Damn..

 

Any tips on getting to the counterbalancer and getting it off?

 

I got the flywheel off, 2 of the three stator screws out, one wants to strip. I got the 11 bolts and nuts off the case. It says something about a slotted nut, what is that?

It seems like i should be able to pull that third of the case off.

I am kinda nervous about breaking something, as i have never been in the motors bottom end...

Anyone?

 

Troyer,

You're in for a lot of fun. The crankshaft has a slotted nut(REVERSE THREADS) , a spacer, a seal, and a bearing. You can take off the inner crankshaft cover by pulling the cover and seal over the slotted nut. However, more than likely you will damage the seal. The tool you need to take the nut off is about 60 bucks (from polaris only). I tried making my own, but failed miserably. I wound up grinding and hammering the nut off. Perhaps you will have better luck. After reading your post, I'm not sure why you would need to get into this space. Before you start pulling all this stuff apart, I would make sure that all of your drain bolts are tight. I replaced a head gasket thinking it was leaking when all it was, was the coolant bleed bolt vibrated lose. I felt like a real dumb @ss.

Just guessing here:
1)Make certain all of you drain bolts are tight. I believe there are 3. One for the flywheel, one for the counterbalance, and one for the crank.

2)When you took off the flywheel cover, did you see oil in there? (I mean standing oil, like the case was partly full) If that was the case, then your seal behind the slotted nut is probably bad and you are getting counterbalancer fluid into the flywheel cavity

3)It's possible that you may have cracked your case by the counterbalancer. (I really hope not)

4)You are still leaking from the Oil injection plate. Yamabond is good stuff so I would be surprised.

Good luck my friend,

Greg

 

Hey man. I am glad you replied. You posted a while back and i forgot your name, you are from near me.

Sounds like you have some experience in this. The oil leak is just from the counterbalance being over filled. I have everything off down to that slotted nut. I cant get it off. I will try to heat it a little tomorrow to get it loose. I am also trying to make my own tool, I have a pipe that is the perfect size, I am gonna cut it down and leave two things to cath in the slots. Then weld a socket on the end to turn it.

I am fairly sure its the balancer that is knocking, damn, after doing this I hope so.

 

John

That's exactly the tool that I made. Didn't work, DAMN. I used black thick walled pipe and the tangs just broke right off. Some sort of tool steel ground to the right shape might work a little better. Just don't forget, left handed threads or you'll be banging the wrong way all day long. I also tried heat and the nut wouldn't budge. Every one I talked to said if you use a cold chisel and hammer, the nut should come off. But just think, every time you whack that nut, the bearing races are taking the brunt of the blow. So, I opted to use a dremel tool to cut the nut and just replace it. The nut is around 15.00 if you need to replace it. We should get together and ride some time.

I like what you said about loud bikes. I'm the same way. I want it as quiet as possible. I am using a stock scrambler silencer with a custom mount courtesy of RcR. That is one good man. Let me know if you have anymore questions.

Greg

 

Well damn, that is the same type of pipe I have, guess its not gonna work then. I will try to find an old socket to cut up and use for it instead. I use a punch and a screwdriver last night, and some penetrating oil, and beat the hell outta it, but it didn't budge. I may end up cutting it too.

Where do you ride at? We will have to get together when I get this finished. You arenear the Enoree OHV trails arent you? Some buddys of mine used to ride dirtbikes there, but I have never been.

Anyway, hopefully I can get this damn nut off today, thanks for the tips.

 

I have a very large long blunted chisel and a dead blow hammer that will pop those slotted nuts right loose. You have to use a heavy enough hammer and also a large enough chisel (remember blunted) to transfer the power to the nut. Just FYI my chisel is about 18' long and is about 1' in diameter. Hope this helps,Bubba

 

Well, i got it off. I beat on it until the nut was so trashed it was hardly recognizable then it finally broke loose. What a pain. I got that off, then got to the counterbalance and pulled it out without any problems. I had the puller from my dealer, so it came out easily.

I plan to send it to Rick for re-building, the bearing on the balance doesnt seem bad, but i dont know. I guess i need to get the one out of the other end where the balance goes eh? How do I get to that?