Complete Polaris 800 CFI Engine Rebuild Switchback and RMK

[@lowercherty]

I remember when there were two engine wires and one tube, a belt and 4 bolts to get the engine out. Of course I remember when a 16 HP Scorpion was a hot machine. I can't believe how complex these machines are now. You know what? Back in the day those machines were just as much fun.

[@arnoldromppai5395]

yes but also back in the day, you could go slow and brake ffresh trail though 6 feet of snow, now you need a groomed trail or they just sink like a 1200 pond rock, but will go 100mph, oh ya so much fun,, not...

[@rdyjur]

@@arnoldromppai5395 they're still fun in flatland and bush situations but yea I agree nothing touches mountain riding.

[@thomasbailey8306]

I love snowmobiling I always owned a sled. Up until the middle to late ninetys. My last sled was the 97 Polaris 700 Triple. Fastest sled I ever had. So This one late fall I figured I would take my sled to the polaris dealer that sold this sled to the original owner so knew the sled. I would take and get carbs cleaned and adjusted. They put bigger Jets in the sled when it was new., Badass clutch, and 144 spikes in track, and Pipes. Well needless to say they put the jets in wrong Carbs and Gave it back and my first ride it let loose. No sorry Or repair. Hell at the end of fighting with them I would of been happy with a Fuck You to me. But NOTHING... So I quit riding plus we didnt get snow like we used to anyhow. You brought back alot of good memories and one bad...LOL...Those 800 are Rockets ..Great Video.. I bet that long track is a hell of a trail breaker .. Sweet Sleds Bud ..

[@oldtimerf7602]

Just watching how intricate and complicated that whole engine tear down is gave me a mild stroke. You are a better man than I Dave! - The artist formerly known as effinghamhick.

[@jeffreybegeman9544]

Brings back memories from last fall when I had to go through my 600 Rush at 8400 miles. A piece of something got in the PTO cylinder transfer port and ripped the whole side apart. New pistons, cylinder refurbish by US Chrome, seals and a used set of cases from ebay. I also sent the injectors out to be tested. They were all a little low but the were cleaned and brought up to spec. I changed my first set of pistons at 5500 miles due to the ring grooves getting wider. At 7000 miles I changed the jackshaft bearings and kinked my oil line from the tank to the pump. It locked up within 2 miles which caused me to put in my 3 set of pistons. I am on set 4 now and bought a 4-stroke for my main ride. The Rush is now the back up sled. My 2003 600 XCSP has 9400 miles on it and has never been apart!!!

[@doobyboy21]

Best thing for these snowmobiles is to have a durability kit and getting a fuel controller from Dynotech Research... Jim has found all the imperfections and found the way to make these engines finally rock solid !

[@jimshoe6828]

Welcome to Dave and Matt's snowmobile repair shop 😉. It's good that there is something to fix so you have something to do 😏 Good job, now if we get some snow, you can ride them🤔 👍👍

[@adriannettlefold9084]

Merry Christmas Dave. God Bless You and Your family. Best Wishes from Oz

[@jimrichards8703]

Wasn't gonna watch but glad I did. Man I miss all the fun I had.

[@billyshumate853]

Well you can go back to having fun now. Take care and have a MERRY CHRISTMAS

[@eugeneodell1543]

David you really should check in to using amsoil for those sleds. It will make a hudge difference In the performance and longevity. I have used it for years with great success. Just an idea!! Great vid with good camera shots. Thanks!!!

[@mikeysgarage3697]

Ahh the joys of ding-ding-a-ding ownership, been a long time since I was that deep into one, thank frick! lol!

[@racingruss7263]

I am doing the same full rebuild on my 800.This video helped me out.Thanks

[@davidhaley7053]

Glad it helped!

[@racingruss7263]

Did you have to prime the oil pump?

[@davidhaley7053]

@@racingruss7263 you definitely should prime it.

[@wtfbuddy1]

Nice video - just imagine if you were using both hands lol, you have more skills and patients than I have working on modern technology. Cheers and stay safe and Happy holidays.

[@larrywarner9314]

This was brought to my attention a couple years ago rather stock or aftermarket reeds should be serviced every 2500 to 3000 miles

[@zukowski2023]

David, thanks for helping pull us through "2020" it's ups and downs. Your videos helps lots of us get through tough times. Thank You Sir. From my house to your house, Merry Christmas and Happy New Year to you and your family. Here's to a brighter and hopefully happier new year in 2021! Thank You again for your time and effort and sharing your world with us all. Cheers! Stay Safe!

[@scruffy6151]

Have fun in the snow a have a great day. Merry Christmas.

[@timshelton4041]

Happy Christmas David and also to your Family and thank you for keeping us entertained this past year.🎄👍

[@ericrice4156]

Nice job there guys, I had one of those power valves brake on my XC 600, glad it was under warranty as I got a fresh rebuild out of that one... Merry Christmas Haley family and crew if I don't see you before then!!!

[@lewiemcneely9143]

I'm just thankful it doesn't snow much here so I don't need/get any of those toys. The only snow toys I have are a wood heater and a shovel which ain't a lot of fun A-tall. And tyhe Self-Made Millionaire said if it ain't smoking, you're not getting enough oil. GBWYall!

[@chrisrobl9341]

Merry Christmas to you and your family Mr Dave

[@betheleskimo9680]

I think the screw with the springs you adjusted on the throttle body was the synchronization screw, the one with the lock nut in front is the oil adjuster screw I believe

[@larrywarner9314]

Little tip I use zip lock bags and Mark the bags for the bolts so it's not a puzzle when reassembly

[@Rickydbaby]

Nice video, I tore into my sled season before last had to replace a crank bearing and replaced the pistons at that time as well. gotta tear into it again and just ran across this video. runs strong but getting water blowing out into the engine bay intermittently and can't quite determine where it's coming from. Suspecting either a bad head gasket o ring, or a mechanical seal issue. Hoping I get it back together before the snow starts falling!

[@richardlincoln8438]

Thanks for sharing David. Your content has been a shining light for us this year. Best Wishes to You and Your Family, hope that You enjoy the Holidays... 👍💪

[@gdmclnh]

Trying to restore a 1980 Artic Cat Panther for my granddaughter to ride. Parts is hard to find. Enjoyed the video. New sleds are just tooooooo complicated for this old man.

[@firecaptaintom1977]

Hah! My buddies grandpa rode a Panther. I miss Gramps.

[@tinachambers4887]

Great job David it's a running Merry Christmas and a happy new year have a day love from TEXAS

[@jacksak]

That was great and have a very Merry Christmas from us over here in NH...

[@edwardabrahamiii3742]

Yea i dont miss my 2014 polaris indy 800sp rebuilt it twice an sold it using wiseco forged pistons both times

[@kendallmastre3356]

Tearing my 09 assault down rn, bought the fix kit aswell, the crank actually siezed on mine but ya, my engine mounts were broken, fun stuff

[@davidhaley7053]

Good luck

[@kendallmastre3356]

@@davidhaley7053 thanks

[@kendallmastre3356]

@@davidhaley7053 update, the crankcase is cracked around one of the drain plugs at the bottom of the crankcase 🤦

[@davidhaley7053]

@@kendallmastre3356 that stinks. So I'm guessing it was running lean and that's what caused it to seize up? The motor is junk now?

[@kendallmastre3356]

@@davidhaley7053 I think I'm gonna get it welded, it's not super bad so hopefully

[@birdhunter2754]

1998 ZRT 600. 😊 fast enough for me.

[@axecuttimber8307]

Super great job !!! Merry Christmas and Happy frozen swamp Year !!!

[@pat5225]

Super helpful! Thanks for doing this!

[@dstevenpaisley]

Well that's a rare thing getting a bolt out with a easy out .let alone two and on top of that dissimilar metals

[@mcd5082]

Great video Dave! Lots of info thank you!!

[@madmodifier]

Guess we know what assisted in the piston wear with the reeds having pieces broken off. I thought it was strange that the wear was on the intake side. I thought 2 strokes usually wear on the side exhaust first.

[@markbalkenbusch4922]

Good Job David !! Merry Xmas and Happy Holidays and a Prosperous and Healthy 2021

[@txsviking]

Great work. Have a Merry Christmas.

[@larrykluckoutdoors8227]

Nice engine build

[@darreng2639]

I have never seen anyone put grease on the pistons. I use 2 stroke oil 😊

[@aldredske6197]

Hi Dave and Mathew!!😀😀 Nice job guys!! I couldn't have ever considered doing the job you guys just did. Looks like just in time for the blizzard that's heading your way. Take care guys and Merry Christmas!!😀😀👍👍❤

[@morgansword]

Should a person try this, I suggest that the "Barley Sandwiches" be left at the home base a good ten miles away as it encourages a man to abuse this food substance to the limits. I put heads on a 429 ford truck engine out in the snow bank and it wasn't this complicated. I haven't drank for nearly twenty five years and this could cause me to severely test my sobriety for absolute positively serious overdosing. That would have my nails gone and the knuckles on both of my nose pickers in serious troubles. Wow, I did play with a few that had a half a dozen bolts holding it together. I took a snowmachine engine in to the machine shop and seen the amount of my engines in for catastrophically messed up machines and instead asked him if I had any parts he needed to put some of his down and dirty ones back on the trails... he offered me a hundred dollars and I took it. Best deal ever as I was too poor to own one

[@mikeembrey9176]

Great job 🇺🇲 have a great day

[@CJE2007.5]

On my no fuel injected sleds i always put a oz of oil in with a full tank of fuel just for that reason. Polaris had a pretty long run of not getting enough oil. Tip for anyone who is looking to buy a used sled pop the exhaust off and look at the piston skirts especially if in the description it say's "Fresh rebuild" unfortunately there are a lot of dishonest people out there these day's and you can have just as much $ wrapped up rebuilding engines in sleds like these as it cost to rebuilding a small block chevy. The 4 strokes are even worse especially if they have any power adders such as a turbo or nitrous or both. In my opinion snowmobiles these days have taken the crown from boats on cost to repair. "Break out another thousand" is definitely a true statement for both. I rebuild a lot of toys and nothing tugs on the heart strings more than when you get a guy who busted his butt to buy a nice used sled only to ride it a couple times and then it blows up. Just like my rigs i won't go any newer than a 07 with anything because of the electronics and the cost of repairs and even 07 has to much junk on them. Thanks for the video Dave it was nice to watch someone else turn wrenches on them. Feel bad for your pocket book though.

[@mariusgage5471]

Thank you

[@markreetz1001]

Good stuff David! You guys can do a lot of stuff!!

[@JoshRex7ven]

How do you take the flywheels off?

[@waltermattson5566]

I think you could do heart surgery on a person if you had a little time to read a book first. I am very impressed again.

[@td3293]

Hey Dave thanks for the Video great help, any tips on removing the flywheel

[@1armedguy4]

Hope you didn't forget the windshield washer hose ?

[@jsnowstorm1311]

Some of the problem was piston to cylinder clearance. The dealer I deal with was saying he got

[@jsnowstorm1311]

3 sets of cylinders and 16 pistons then measure and match piston to cylinder clearance. Since not all pistons were the same size. Some were off by 7to8 thousands. Your clearance was way to much. My 880 went 7200 miles. Ring locating pin moved ring moved hooked a port..4 year warranty took care of it. To much sealant on the newer sleds was blocking the oil to crank

[@bhermon265]

Thanks for another great informative video have a merry Christmas and happy new year 🥳 and safe holidays

[@The_Mimewar]

Did you check the compression? “Yep”. What was it? “Nope”

[@nuts319]

You should rebuild chainsaws... hint hint...

[@firecaptaintom1977]

First in line would be a 1962 Partner Chip Flinger.

[@nuts319]

@@firecaptaintom1977 🤣🤣

[@larrywarner9314]

I'd use some never seize on those motor mount bolts .

[@nfra1663]

Any updates on the sleds??

[@sucapizda]

Im just about to do this myself on a 800 Rush. What did it cost you to rebuild the entire engine? Thanx.

[@1187titanium]

What kind of grease?

[@MarkDulisse]

What about setting timing ?

[@nathanburgess4928]

👍

[@ericgryba4234]

Hi, which pistons did you use? Heard OEM pistons don’t stay within spec. For very long. Is there a better option? And what would you recommend? Thanks

[@davidhaley7053]

There's a lot of opinions out there. The original pistons went over 4,000 miles with very little oil so I went with them again and turned up the oiler. I've put 1,500 miles on since then and I'm very happy with the performance. Good luck.

[@Mburin_B]

I don't know why those clutch bushings are so effing expensive they were that expensive 25 years ago obviously they've been overpriced enough to stay clear of inflation

[@gregmulfort9577]

Jeez glad I am a cat man

[@maxcheerio6837]

Mine blew at 1,700 miles 47 hours

[@MarkDulisse]

What grease you use for pistons and wrist pin?

[@greaseemoutdoors8049]

How much did this all cost

[@HappyGilmore321]

Its been a year hows is the sleds working?

[@davidhaley7053]

Been great. Both running strong.

[@ericclancy9748]

where did you send off your crank and monoblock to get repaired? (what company)

[@davidhaley7053]

Indy Specialty I think in Canon Falls Mn.

[@dstevenpaisley]

I always add a little oil to the gas 100:1 ish

[@Gordonseries385]

Where and when to use a new seal does anybody where and when use a new walrus?

[@maxcheerio6837]

Looks like it was running lean

[@willmarnach3153]

How much total cost were you into this rebuild?

[@davidhaley7053]

The switchback was about $2,300. RMK was $400?

[@willmarnach3153]

@@davidhaley7053 just new pistons? On the rmk? How many miles did the rmk fail at again?

[@davidhaley7053]

@@willmarnach3153 put a durability kit in it. Pistons, rings, wrist pins and bearings, gaskets, spacer, longer bolts. I think it was around 3,000 miles and 150?? hours.

[@Badgermatt-nc5nr]

I think it might have been easier to trade em on new ones with all that loggin money you have. lol ;)

[@jeffreyhagelin5927]

Time to trade up to a Ski doo

[@seecampacp5107]

Note to self. Don't ever buy a used snow machine. 2nd note to self. If I ever need a snow machine in South Carolina move 😏

[@whylee1377]

Thanks for the vid but far from detailed. Basically an overview of the process.

[@michaelweatherhead9470]

Send it to the scrap yard.

[@firecaptaintom1977]

An average of 17.4 mph. 😴

[@edwardabrahamiii3742]

Polaris junk i rebuilt my 14 indy 800 sp cfi engine what a trash engine needed 2 rebuilds then i sold it

[@arnoldromppai5395]

by the time you spend all that money and time, you would have been a head if you just put them in the scrap pile. were they belong

[@nighttracker1472]

Id only toss them on the scrap pile if you cushioned there fall

[@gobigparts]

I don't think a saw it in footage. Do you have to do anything special to remove fuel rail and reinstall? Do injectors come with it?