ok fellas, took the top end off the engine this weekend and it was not a pretty sight.
i removed all the top end bolts and this point the engine was still locked up. decided to put some penetrating oil down the cylinder and wiggle the jug and it came right off.
piston was partially melted on top, looked like it had been arching with the spark plug. looks like some of the aluminum from the piston melted down the cylinder along with some the chips from the arching. surprisingly the cylinder is not in as bad of a shape as i had expected. most of the aluminum smeared dry along the side of the piston and cylinder. i was able to get all of it out by scraping lightly with a screw driver and WD40.
went back to check on the inside of the crank and realized the rod was still locked up. i looked down the crank and some of the aluminum shavings were visible.
i completely removed the motor of the atv and placed on the bench. i put a ratchet on the stattor side and cranked it, thus moving the piston rod.
i was able to break it loose but, on the down stroke as the piston reaches the very bottom of the crank, there seems to be metal shavings that are still wedged between the crank and crankcase wall, it doesnt spin freely on that spot, it kinda grinds on that part of the cycle.
i havent started yet to take apart the crank. but, i know i will have to. once i get the crank apart i can take a better look and see whats going on. i dont think theres any damage but there are also pieces of smeared dry aluminum on the crank that have to scraped and cleaned off. ill have some pics for you guys later on.
i will have my hands on a puller today or tomorrow. is there anything i need to know about pulling that crankcase apart. please let me know your thoughts
thanks
oz