PICS! Snowmobile restore/Piston Carnage

yamaha28

Member
Apr 8, 2011
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Alrighty, I have decided to try my hand at working on snowmobiles. I found a guy that had a 1985 Polaris Indy SS 440, he was selling it for $50. He said it lost compression in one cylinder when he was riding it last year. New piston kit with, of course, a carb cleaning, is all it needs to get it running he said. I brought it home after a two and a half hour round trip. I tried a compression test and I got, literally, zero compression. That can't be right I thought, so I tried again, nothing. I put my thumb over the spark plug hole but still nothing. I shine a flashlight down that cylinder and find myself staring at the crank. No piston? Nah, that can't be right. Off with the head! That revealed this.
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Holy crap! I pulled off the other head to see if there was any damage? Piston looked just fine.

I moved on to the brakes and found I needed a new cable. The rotor is free from the pads so it is not seized. Throttle cable works just fine, along with everything in the carb. The ski's look a little crooked but that will be addressed after I get the motor working.

I intend to use this snowmobile as a beater machine. I want something that I can crash into a tree and not care about. Don't get me wrong, this motor will be running like brand new as long as it doesn't cost me more than it is worth. I think its worth stands at tops, $250, that is being pretty generous too, or so I think. So look at this thread for more pictures and progress! I am sensing a new camera for Christmas too so a video of it running will be mandatory! Piston kit and gasket kit are on their way as we speak. Merry Christmas to all!

Eye candy: :P
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$250? Is that all older sleds are worth?

I figured anything that ran (regardless of seat cover condition) was worth like $500-$700.

It looks like it came apart due to a major lean condition. Considering it only has one carburetor, you need to assume that the side that came apart (notice it's the primary clutch side too) has a major air leak. Pull that primary clutch off and see if the bearing and seal are shot.

If you need, I have a polaris ATV primary clutch pulling tool....
 
Maybe they are worth more. Now that I take a look around at others they seems like mine might be worth around $500-$600. Then again I don't know for sure until I go to sell it.

I will have to take a look at that seal. I was wondering what in the world would cause one piston to be lean when the other was fine. A bad seal makes sense.

I might have to take you up on that kind offer for primary clutch tool. Were you looking to sell it or just let me borrow it? Thanks!
 
I figure you could borrow it. Pay for the ride both ways, cheaper than buying a clutch tool. If you need it a second time, you might as well buy your own clutch tool (not worth shipping the same one back and forth more than once, IS IT JonS?)
 
Alrighty, will the tool fit though? The threads are pretty specific right? Or maybe all polaris threads are the same.
 
The one I have is for the licensed Hoffco Industries polaris primary. It has 3/4" right hand (regular) NEF threads with a 3" extension off the front of it.

I figure polaris used the same one on every one of their products....
 
i have a 94 polaris 580 xlt and a 800 storm.both rip.i rebuilt the 580 i port and polished it and put new wiseco prolites in her.the 800 was done to the nuts.just need a swaybar,it likes to do the speed wobble at 70 mph.i have papers that says it did 117mph in 550ft.i know one thing there just isnt enuff runway around here to open her up lol
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too bad you couldnt fit a 500 rmk engine in your machine
 
Alright! I finally got the primary clutch off to take a look at the crank seal. Here it is,
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It looks fine to me, I should probably replace it anyway. But by the way it looks, could it cause an air leak?
 
Update time! I put the new piston and gaskets on. The cylinder that blew up now has 85 psi and the other cylinder has about 100psi. These are not very accurate because I could quite pull it very hard while still on the bench. New crank seal and brake line is one the way so I should be able to get it back on the snowmobile and running fairly soon. I will post some more pics and a video of it running when it gets there.