97 Polaris Sport 400L 2x4
 

I was out ride with friends and while riding, I heard what sounded like a hose bursting, (more like opening a can of beer sound), right after that, I hear this secondary engine noise that is louder than the exhaust pipe.

Turned it off, looked around, and noticed what appears to gear oil leaking from the bottom left of the engine. Near the motor mount. See the RED ARROW :huh:
http://s1198.photobucket.com/albums/aa459/medwayis/http://s1198.photobucket.com/albums/aa459/medwayis/
http://s1198.photobucket.com/albums/aa459/medwayis/

Any idea's fellas....

Welcome to the forum! First off have you attempted to crank it back up? I've had piston skirts break and crack cases and would still run. If this is the cause its possible the engine case could be cracked at the bottom in the channel area where the counter balancer rides which would explain the oil leak. Only way to really tell is to remove the bash plate and maybe the front motor mount to where you can see a little closer. Keep us updated. OPT

Does that mean I have to remove the engine, or can I do this without the removal of the engine?

You don't have to remove the engine, removing bash plate just allows better access to where you may see where it's leaking from.May not need to remove the front motor mount. If you have help,just stand on it's tail end and easy to remove the bash plate and check out the bottom of the engine! OPT

update. Got the plate off.. Lord and behold this is what I found.

cracked002.jpg picture by medwayis - Photobucket

When looking at the pics, click (next) to see what has broken off..

Something tells me I'm in for a total rebuild.. (Low end).. :huh: -- :confused:

yup, looks like you are due for a set of cases and possibly some counterbalance parts.

2nd Update
 

What would cause this damage. I do not see anything at this point, but I do see a a bunch of metal shavings on the bottom of the case. However, I do see 2 mangled teeth (see pic) "cracked2 001" :huh::hmmmm:

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Update 3 -- Correction
 

cracked2004.jpg picture by medwayis - Photobucket

:confused: See above..

Pretty nasty looking! Once you tear it down you should be able to see what caused it. Could have been part of the water pump bearing could have separated and gotten into the counter balancer and crank gear?
I think I would check on a set of used cases if you can find some,as a new set is over $400,plus a counter balancer is close to $500 now! You have to be careful if you go after a used counter balancer! Or you can try to find a used engine that might be a little easier on the pocket bock that you can rebuild? OPT

What's it called
 

Crap !!

Ok. I can't seem to locate the part.. Is it the 2nd, or 3rd left crank. or does anyone know what it called..

See Pic. - What is this part(s) called ?

cracked002.jpg picture by medwayis - Photobucket :huh: