Hello!

Hey -

I bought a 2012 Sportsman HO last December and have had trouble with it starting correctly since I bought it. Took it to the dealer to have it looked at in May 2012 (I was told it was "normal" due to the high compression engine) and then again in August 2012. Dealer tried to stuff me with a new starter because there was a lag when I turned the key. About two weeks ago, the compression release lever blew a hole in the camshaft cover on the engine. I pulled off the cover and the compression lever sheared off the shaft, dowel pin "ovaled" the cam, and end of the cam was chewed up. Pulled the cam this afternoon and found that the ball bearing was missing from the camshaft.

Without proof that this was the issue the whole time - I'm out of warranty and out of luck for replacing this through Polaris - seriously disappointed it wasn't caught earlier.

I'm replacing the cam for another $250+. Problem is - I'm nervous about not finding the ball bearing that was in the old cam. Any ideas where it might be? I'll be changing the oil and hoping that it'll fall out the bottom. Otherwise - I'm thinking it's in the engine someplace.

Thanks for the help. ~john

 

Welcome! Freaky failure!If the dealer really tried he could get the cam warrantied for you!! You might check all the rocker arm pads also to see if they might be scored. Best to replace if any are. As far as this small bearing it's possible it could have been worn down by the rocker arm. About the only thing you can do short of splitting the engine is to drain the oil tank,clean the filter screen in the tank for any shavings, pull the sump drain plug and if you have a small flexible magnet(it's a tight spot to bend close to the prop shaft),you may be able to fish it around to see what might stick to it. Kinda of hard for this bearing to get down into the cases unless it was able to get over to the cam sprocket area. OPT

 

Thanks for the feedback - I planned on fishing around with a magnet to see what I can find.

As for the dealer - that's a whole other story. When I complained that the bike never started right - he tried to tell me that it was normal. I took the bike in around April for it misfiring (sheared a flywheel pin and timing) and then again in August when it wouldn't start. So I proceeded to ask him to show me that on another new bike sitting on the showroom. He told me that they didn't have time to start bikes on the showroom floor and it went downhill fast from there. He ended up charging me $350 for a throw arm on the starter and labor to put it in. Wanted another $200 to deliver after I told him that it was a pain to keep taking time off work. (Which I didn't do)

Needless to say, I've burned my bridge with that dealer - and vow to never return. They wouldn't stand by it. I think the thing only has about 53 hrs on it total since last December 29th when I brought it home.

Thanks again -

John

 

Ok - so for those following along - I finally found time to put the cam into my bike. I couldn't get it to time right so I thought I sheared the flywheel pin (that was just replaced by the dealer in April 2012).

Pulled the flywheel and stator and found out that the lower sprocket for the timing chain was in pieces. Popped it off and now ordering it...another $20 down the drain...Argh!!

 

What's the old saying about luck: If it weren't for bad luck,I'd have no luck at all! I've seen all sorts of damage in almost 23 years of wrenching,but never saw a lower cam sprocket shatter.I think somewhere a little heat treatment was missing on some of your parts Good luck, you deserve a little. OPT

 

It took off part of the housing with it when it came off...oddly enough - it ran for a short time until I heard the "tink" and it broke. I wanted to see it the timing was right before I buttoned it up.

I'm assuming I'm at fault - so who knows at this point. I'm ready to put it back together and ride.