Found my oil leak - cylinder gasket
#51
12-08-2017, 09:12 PM
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Just realized that I was looking at one cut away slots on the slotted nut holding the crank sprocket..You can pull the nut off (remember left hand threads) and check the condition of the key. If the sprocket has any side to side play,replace the key. Use blue loc tite on the shaft threads and then the slotted nut. You don't need the slotted nut tool. Just tighten by hand and then use a punch and hammer to final tighten the slotted nut. Fairly snug but don't break the nut.. 
#52
12-09-2017, 08:09 AM
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Retired and loving it!
Retired and loving it!
#53
12-09-2017, 02:41 PM
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Originally Posted by old polaris tech
Sorry,I said punch but meant a flat dull chisel a little smaller or same size of the cut out slot on the nut. That should work a lot better. Even a shot of heat from a propane torch can help break the stubborn ones loose.
Both keys look good. No play on the sprocket. No play on the crankshaft. Ready for new seals and chain.
Question on the guide - is it supposed to have grooves like this?
I also found damage where the other guide sits. Do I have to be worried about this?
Finally - previous owner must of loved his impact wrench - any thoughts on how to repair?
#54
12-09-2017, 04:13 PM
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Retired and loving it!
Guide is supposed to have the ridges as over time the chain will cut grooves. If in doubt order a new one. You can retap the bottom hole,but peel all the blue silicon off the top and see what all damage the po did. If the top of the case is broken, a good machine shop could build the broken part up and tap it out.Plus they may be able to do something with the guide slot.
#55
12-09-2017, 05:57 PM
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Originally Posted by old polaris tech
Guide is supposed to have the ridges as over time the chain will cut grooves. If in doubt order a new one. You can retap the bottom hole,but peel all the blue silicon off the top and see what all damage the po did. If the top of the case is broken, a good machine shop could build the broken part up and tap it out.Plus they may be able to do something with the guide slot.
https://m.ebay.ca/itm/1999-2000-Pola...cAAOSwCkZZWUpH
#56
12-09-2017, 06:18 PM
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Retired and loving it!
If at all possible I'd see if a machinist can solve this one. Cases are sold as a matched pair. One different run case half may or may not match up exactly with the other case which would be frustrating.Plus you'd be creating a whole lot more work for yourself if you swapped out both cases.
#57
12-09-2017, 06:46 PM
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Originally Posted by old polaris tech
If at all possible I'd see if a machinist can solve this one. Cases are sold as a matched pair. One different run case half may or may not match up exactly with the other case which would be frustrating.Plus you'd be creating a whole lot more work for yourself if you swapped out both cases.
#58
12-09-2017, 06:57 PM
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Retired and loving it!
#59
12-21-2017, 02:56 PM
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Update - took the ATV to a machine shop - they fixed up all the issues. I can now attach the recoil housing with 3 more bolts, the metal plate behind the stator was straightened out and crack fixed. And the ledge for the timing guide was repaired. Another shop is pulling out the valves for cleaning/inspection - I know my limitations - and then I can start to put Humpty Dumpty back together again.
#60
12-21-2017, 03:15 PM
Polaris ATV Expert
Retired and loving it!
Retired and loving it!
Good deal that they were able to repair the case.Saved you some headaches. Make sure the guys that are doing the valves replace the valve guide seals also.Better now than later. Unless you ordered a complete gasket kit that comes with them.Some folks said let your reach exceed your grasp. I'm like you,I knew my limitations on things I could do myself.. Even more so now..
