I finally got my trailboss motor apart. I was letting some family friends use it and they ran it out of oil. The cylinder and piston look good. The problem is I have some play in the rod bearings. I can move the rod up and down a little bit. Is it possible to have rod turned and run an over sized bearing? Any idea what kind of shop and parts cost I am looking at. Thanks TonyT

 

Crankshaft journal has to be turned(if not heavily damaged) and a new rod (I personally wouldn't reuse the old rod because of stress on the lower and upper rod ends,but has been done) and oversize bearings must be installed. A good machine shop can see if the crank can be turned.
0.5 and 0.25 oversize bearings available. tell this to the machinist. If in that far I would go ahead and replace crank bearings also. OPT

 

Is there a trick to removing the PVT clutch assembly from the crankshaft. The book shows some tools that I don't own. I guess it spins off the crank counterclockwise? Thanks Tony

 

I know it is pretty close to the bottom of the Polaris barrel, But can someone tell me if ther is a trick to removing the clutch assembly on the trail boss. Thanks Tony

 

You need the clutch removal tool....or make one. The clutch is a taper fit. You'll need a 3/4-16 fine thread bolt that's long enough to get to the crank. That bolt can be hard to find though. I've also heard of guys using a trailer ball with the 3/4 fine threads and a deep well socket. Remove the center bolt, slide the socket in, screw the trailer ball in. USe a ratched strap to secure the clutch from turning...With a pipe wrench crank the ball down, the clutch should pop loose.

The above aren't the "recommended" tools but have worked in a pinch for many.

 

Wow, thanks for this posting - I just used the exact procedure to remove the drive clutch from my sportsman. Used a 2" hitch ball that had 3/4 fine thread shaft; found that a short 3/8 extension with a 7/16 deep well socket on it was exactly the right length and diameter to get down the hole to the crankshaft; used a strap wrench to hold the clutch and a big pipe wrench to tighten the hitch ball; got it good and tight and whacked it once with a ball peen hammer and off she came.