Well here's a follow up to a thread months ago
http://forums.atvconnection.com/pola...-no-power.html

I took the plastics off, took it to a shop and after some inspection he noticed a 1/2" vertical opening half way down the dipstick tube where it was rubbing on the belt housing. So mud was getting in there and settling in the crank. thus destroying the bearings. The oil never changed colors, I changed the oil in January and the failure occured in may. We ride often mostly sand some mud and of course the mud holes but I stay away from deep water. So anyway this looks like a new project for me, the shop stated it would be 12-15 hrs for them to do it plus parts so it will be my first rebuild EVER.

I will be purchasing a Clymers manual and then slowly getting the parts for the crank and bearings and while I have it torn down what else should I do to it? I want to put a new clutch spring and some other stuff but none of that matters without an engine.

Im not wanting to get rid of it and willing to put about $1000 if I have too to make it a nice bike again.
Any thoughts appreciated, thanks.

 

Get the manual like you mentioned and read about this engine several times before you tear it apart!! There is a special alignment tool when you get to the cam double sprocket,but if you're careful it may not be needed(if you don't let the sprockets slip!)You can possibly rig up a small rod that inserts in this sprocket assembly.You'll read about it in the manual. Check for any up and down play on the rods as this is what happened a lot with me and hardly anyone that can rebuild them that I've been able to find! Hopefully it's just the crank bearings as you mentioned. Keep us up dated. OPT