I've decided to rebuild this 03 600 sportsman I traded for awhile back, I was originally going to repower it with a used 700 motor, but it looks like I can repair it for about 1/2 the cost of replacing the engine. It was a fresh overhaul with about 20 hours on it when it popped, had a new crankshaft put in at the time it was rebuilt. My buddy was riding it down a hill when it locked up and dropped the oil and water on the trail. I got it apart and found one of the screws that held the cam retainer plate had backed out and got wedged between the gears locking the engine up hard. It ruined the gearset, cracked the flange on the camshaft, rainbowed the counterbalance and trashed both cases. It does not appear to have damaged the crankshaft or rods other than the woodruff key is sheared off. It looks like the only parts that will not be replaced will be the oil pump, crankshaft, cylinder, head and pushrods.

I am just wondering if there are any updates or upgrades I need to do to this as I put it together or if there are any known conditions I need to be looking for while it's apart. I'm new to the twins, but have been working on the 2 strokes and 500's for quite awhile.

 

You need a good manual before you even start as it can show you step by step on tear down/rebuild,torque settings,etc.http://gh-ftp.com/ORV%20Manuals/Pola...0%20-%20SM.pdf The critical things are aligning the dots on all the gears and making sure you prime the oil pump before it's started.

 

I have a Clymer manual that my buddy gave me when we traded and I helped him put the motor in after he rebuilt it last time which is when we learned the oil pump has to be primed to get the lifters to pump up enough to start. I'll be using loctite on the cam retainer screws for sure lol If they had been loctited in the last time it would still be running.

 

OPT posted the link to a free Polaris service manual. Will have more info that the clymer.

Good luck on the rebuild.

 

I'll keep the polaris manual handy too Thanks again. It's going to be 2 weeks before I get the boot money from the trade, so I'm going to hold off ordering parts until they get here, the crank and top end are wrapped up on the bench ready and waiting for new used cases.