Polaris Top End Rebuild Part 3: Replace Piston and Rings| Partzilla.com

[@utahwanderlust700]

Well done series. Very informative. I never knew you had to completely disassemble the entire block to get to the cylinders on these Polaris. Yet one more feature of that company that makes me glad I don't own one! On all the Japanese ATV's, you can simply unbolt the cylinder section from the bottom end so you don't have to take the whole bloody engine out of the frame to simply hone the cylinder walls or change piston rings. Honestly, many things Polaris does just make me wonder what in the hell their engineers are smoking.

[@crazyflyboy30]

It's because the Japanese are using a out dated design and that's why they're so far behind in Horse Power.

[@utahwanderlust700]

@@crazyflyboy30 It's not an outdated design, it's a smart design. And it has nothing to do with power. It's simply smart engineering. So smart in fact that Polaris finally saw the light and now does the same thing on their newer engines.

[@crazyflyboy30]

@@utahwanderlust700 every engine Polaris makes is a total different design and the latest version SXS engine is just like a car has to be pulled out to get to the rings so what engine are you referring to. And power has everything to do with it Polaris and Can Am is only ones that make any real power all the others are a joke.

[@dylanaaron5839]

As always, some of the best videos of their kind on KZbin. Well done and very informative! Keep up the good work!

[@TheBreedxxx]

Best instructional video I have seen yet keep up the good work !!!

[@whitenas]

Just wanted to say thank you for these videos.

[@Powerstroke904]

Where in the world do I get the flywheel holder and puller?

[@utahwanderlust700]

After going through all that just to get to the rings, there's no way I would've put that engine back together without honing the cylinders. You could clearly see a mirror finish in 40% of one cylinder, and probably 60-70% of the other. Maybe John just realized these Polaris engines are just throw away engines anyway and didn't want to be bothered.

[@williamsantiago7303]

I would of liked your camera guy to zoom in when you were installing the rings onto the pistons other than that you put together a great video.I really enjoyed it.

[@PartzillaParts]

Thanks William! We appreciate the feedback. Glad you were able to get it all back together

[@chrisburnsed6349]

When you pull out an egg shaped ring, it’s an indicator the cylinder is not round. It should of been sent out to be trued and honed . That customer will eventually be back with the same problems. I guarantee it.

[@crazyflyboy30]

I highly doubt that the cylinder was out of round and there is only a small coating of Nikasil in the cylinders so a boring the cylinder out is costly a new engine is a better option at that point.

[@joshuag.6387]

Where can I find the flywheel holder tool. No one seems to have it my way or online. And how much is it? Getting ready to fabricate one🤦‍♂️

[@SuperMrCARBON]

Why didn't you hone the cylinders?

[@PartzillaParts]

Case by case. This one didn't need it.

[@chrisburnsed6349]

Partzilla , yes it did need it. Those misshaped rings were a clear indicator. But what do I know, I’ve only built race engines for 29 years. Just because it still had cross hatch’s, that doesn’t mean squat.

[@LifeofAedan]

Could this apply to a scrambler 1000? While I have a shop manual for all the specs, a visual guide is always nice since I tend to forget where parts go.

[@2msmykids]

What direction do the notches for the bearings go on the connecting rod? I know on cars that the notches go towards the exhaust side of the engine but when I took this engine apart the notches were on opposite sides but I'm not sure if this engine has been into before or not because I bought used

[@jessebroering3871]

I just rebuilt my 2014 Polaris sportsman scrambler 850 and forgot to install the oil tube that is attached to the top crankcase and I'm just wondering if I can leave it out without tearing apart the whole engine again?

[@PartzillaParts]

No, sir. That oil tube brings oil to the top half of the motor...you're going to have to tear it down again. Don't run it without it.

[@matthewjohnson1993]

Where to get the special tools for the job been looking not easy to find

[@Sober4277]

John when do u put in the round rubber seals? Do u put them in before you put the halves back together? The round brown big seals?

[@kolineckstrom2762]

Do you have part numbers to all the special tooling?

[@leonardojaviercruzmartinez7962]

Good afternoon, can you help me with the torque of the polaris sportaman bench 850

[@homegrowed.offroad]

Fly wheel holder tool Part# pa 49318. Does not work on 16 HL strap with teeth holder .cheep one

[@DIABOLOALDEBARAN]

Hi there Just bought a set of main rods for an 850 highlifter 2019 .. there are numbers marked on each of them Is there an specific order to place them?

[@endlesssummerfamily1374]

Excellent video. Did you have to check the end gap on the new rings?

[@bearbait2221]

I was looking for crank timing chain timing marks and you never looked at them. Polaris never put a keyway on cam gear in my 2011 x2 850 so it can rotate out of time. that engine it looked like one peace crank with gear cast on it the worst thing ever all they needed to do is key way the crank like the rear of the crank. ps it looked like dangel barries hanging on lower case when you put it together that went between mating surface

[@reltsihW]

Just curious all that work and you didn't tig weld the crankshaft timing gear for that known issue.

[@beeasy4360]

I didn’t see a gasket go on the case 🤔

[@coukislam]

Mr. tally when connecting bottom end , what type crankcase sealant do you use?

[@jasonbell1698]

hello, i have a scrambler 1000 which is essentially the same engine. the exhaust smells like oil but only smokes a little bit at hard throttle but it still seems to use a ton of oil. almost a quart per tank of fuel. i’m down to valve guides or piston rings. very unfortunate though. the engine only has 70 hours and i don’t know what caused this problem.

[@jasonbell1698]

also i did a compression test and both cylinders are 230 with the throttle wide open. haven’t done a leak down test

[@jamesthomas6587]

what is the torque specs on the crank main bearing bolts

[@MrBlakeladner]

Piston/rod orientation would have made this an actual rebuild video.

[@AlexTechLtd]

Hey, I have a 2011 Genesis 2.0t and it knocks hard and ticks a little at higher rpms, runs smooth at idle, was hoping for some insight on it. Is there anything I can check or do before I jump straight to the conclusion it's the rods? Maybe pistons? Maybe timing chain?

[@PartzillaParts]

Ticking is probably valves...anything hard knocking generally needs a tear down for inspection.

[@suckafatone]

How many miles on this unit?

[@pedrobennetts5982]

Hey John.. what colour bearings go in when doing a replacement piston and con rod kit? very helpful videos mate cheers from down under!

[@PartzillaParts]

You have to go through the bearing selection process using the chart with the number on each rod and crankshaft. If you are using aftermarket rods, you will need to break out the plastigauge. www.plastigaugeusa.com/how.html

[@nbw_1383]

Some help me I have 850cc Polaris sports man 2016 and it got flooded and the water went into the motar and I tried to turn it on while it still had water in it and it made it worst some one plz help

[@PartzillaParts]

If there is water in the motor, drain all fluids and check your cylinders.

[@beaubobbitt67]

How would you re-install the engine balancers if you took them out?

[@littlechicken963]

beau bobbitt there's a punch mark on the gear on the balance shaft and one on the gear of the crank . Just line them up and your good .

[@josephjquintero8325]

if your 4wheeler has oil coming out of the exhaust dose that mean the piston rings are worn out?

[@aidannina494]

Josephj Quintero it could mean hundreds of different things

[@LarryJones-ds9oq]

If reusing the factory Pistons does it matter which direction they go? I couldn't find anything in the service manual

[@PartzillaParts]

If reusing, you want to put them back in the way they came out. If you didn't mark them, look for a stamp head of the piston, some have one. Some have an orientation, some don't, but if they are used, it's preferable to put them back in the same way.

[@sxscustom]

i have a question. is the cylinders able to be bored or repaired if scored? since it is a crank case and cylinder all in 1 is theres way of boring?

[@PartzillaParts]

Hello Fantastically. yes the cylinders can be bored but only so much. it will depend on how bad the cylinder is scored.

[@victorchavez6077]

does this procedure apply on a 2015 sportsman 850? and what is the rebuild kit part number?

[@PartzillaParts]

Here is the diagram for the 2015 Sportsman 850 SP. www.partzilla.com/parts/search/Polaris/ATV/2015/A15SXE85AS-AM-A85AA-AC-AJ+SPORTSMAN+850+SP/ENGINE%2C+CRANKSHAFT+and+PISTON/parts.html If you have a different variation of the model, just switch to that one in the menu.

[@ramonbroomfield7742]

I'm doing a rebuild on a 2013 sportsman 850 xp. Do I need hone my cylinder walls they don't have any scratches they are smooth as a baby's bottom if so what grit hone I should use? Thanks

[@PartzillaParts]

Yes, you should hone it a little bit. Use a Flexhone 320.

[@ramonbroomfield7742]

Partzilla Thanks

[@joshuag.6387]

​@@PartzillaParts iv been struggling with this same queastion for 3 days now. I get alot of back and forth answers and the service manual says not to rehone the cylinders due to the nicasil lining. To the poster of this queastion did u hone it and what was the result if I may ask. I know this thread is stupid old but it would help me a bunch!

[@GNR325]

Is this a common problem on Sportsman 850’s?

[@PartzillaParts]

Depends on how you ride. It can happen.

[@RoMaN-vy4sx]

I heard, after 3,000 miles the crankshaft sprocket could be broken, need to be checked also, is it true ?

[@sxscustom]

Pacific Rim. if you have a 2012 or older. if u have a 2013 and newer the sprocket is bolted to the crank.

[@RoMaN-vy4sx]

Fantastically Dillon I Have 2010 and odometer shows almost 3000miles. What should I do ? Be ready for surprise or change crankshaft? Thanks

[@sxscustom]

Pacific Rim. honestly i would look at changing the crank. and while you are doing that check pistons and maybe replace rings a freshen up.

[@whitenas]

@@sxscustom are you sure about the years? I have read the 13s were affected too. I have a 13 and been expecting a problem at some point.

[@sxscustom]

another question why wouldnt you re cross hatch the cylinders?

[@PartzillaParts]

we did not cross hatch the cylinders because the motor only had 1 hour on it before it locked down.

[@whitenas]

@@PartzillaParts 1 hour!? Gees are these engines any good.? Worried about my cam gear slipping on my 2013. Brought me here.