Went out for a ride today,that didn't last long. My wife complained that her'99 Trail Boss was making a strange noise,a rattle and some squealing.It sounded like possibly the belt was coming apart.The rattle became louder in and in a few minutes it would no longer run,it just died.It started a couple of times but the rattle was getting bad. I towed it back to the truck loaded up and returned home.After I got home it wouldn't even start it would turn over and sometimes act like it hit a hard spot.It did finally start only to come to an abrupt stop and it was locked up tight.I already took it to the dealer and left it.Does anyone have any ideas what it could be?The bike is less than a year old and has been maintained very well.The dealership said if it was some kind of oddball flaw that Polaris might fix it.I'm keeping my fingers crossed but not holding my breath.

 

Was that year the 2 stroke 250cc motor or the 325cc four stroke?

Keith

 

You should have followed your instincts and took the PVT cover off. I've seen the belt come apart and lock an engine up tight. Remember the front part of the clutch is running off the crank and if the belt becomes tangled it won't allow the egine to turn over. It would have cost you $35 for a new belt. Hope your dealer treats you right.

The latest case I saw of this was with an older 425, after hearing the noise and having the engine quit it wouldn't roll over. When we hit the start button the engine acted like it was siezed, it wouldn't turn over, made a clunk sound as the starter engaged and you could see the engine torque sideways as the starter attempted to turn it over to no avail.
Let us know what they find.
Scott.

 

It is a 250 2-stroke.I had the cover off the clutch a week ago and the belt was perfect.It was sqealing then and after I took it off the noise stopped.I did find a piece of the rubber seal behind the clutch had torn loose and was rubbing the clutch I cut the small piece off and put it back together.

 

Was there an oily residue comming out of the seal? Im not completely familiar with that motor but it sounds like a crank seal was blowing out. If it is the crank seal and you cut more of it away, thats a bad thing. 2 strokes got to have that crankcase sealed or it will suck air and run lean, and will eventually sieze. If it is siezed I hope the crank isnt hurt from trying to run it, then the repair should be just the crank seal and a new top end. Hope its not to bad. Good luck.

 

I don't believe it was the crank seal this is the large seal between the pvt cover and the crankcase.
Regardless,the dealer would not specify on the phone what it was but it was internal.It needs a new crank rod and piston and the cylinder will be bored ten over.Now for the good news,whatever it was a factory problem because Polaris is payin'!

 

35 dollars for a belt wrong answer try about 20dollars sounds like the dealer is ripping you guys off