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700-800 crank failure info

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  #1  
Old 01-05-2009
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Default 700-800 crank failure info

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Polaris 700/800 Crankshaft Upgrade Kit

While the Polaris “big block” 700 & 800 twin engines have proven to be extremely powerful and dominant engines, a problem with premature failure of the PTO end of the crankshaft has surfaced, particularly on the 800 twins. The primary clutch and the PTO end of the crankshaft can snap off, rendering the vehicle unable to move under its own power.


What has been witnessed is the deformation of the crankcase line bore. The amount of bearing to crankcase bonding area on the PTO end appears to be less than perfect to be able to endure the tremendous load and thrust of the primary clutch. The crankcase line bore and PTO bearing mating areas can actually become warped, allowing an increasing amount of crankshaft wobble, eventually leading to PTO bearing and/or pin failure.


Allsport Polaris of Spokane, Washington, home of one of the largest Polaris parts inventories in the world, has developed an upgrade kit that greatly improves the longevity of the PTO end of the Polaris big block engines. The kit consists of increased bearing support area with a wider inner PTO pinned bearing and spacer, a new outer PTO end bearing, required crankcase modifications, improved oiling ability and a final crankshaft realignment. If the deformation to the crankcase line bore is sufficient, replacement could be necessary.


Total cost of the kit with crankcase modifications is $295 plus shipping. The crankshaft and crankcase must both be sent together for the work to be done. For engines that have already suffered a failure, the costs will be more to repair the damaged components, so why take the chance! This kit has been developed over the past few seasons and has all but eliminated the PTO end failures, and is virtually a must-do step in the modification of 800 twins for the best in long-term reliability.



The Allsport Polaris Crankshaft Upgrade Kit replaces the stock PTO bearings (lower) with a wider inner PTO bearing (upper) that is pinned, along with several detail changes to improve crankshaft reliability.




If you have the engine apart for any reason, this should be done to improve the reliability. Mountain riders who don’t want to take the risk of going down have started to do this during the off season as a preventative measure, but more casual riders seem to wait until the engine is apart or being serviced and then get it done. We’ve seen this twice in a matter of four years on our test sleds, so it is fairly common. Polaris seems to have improved the crankcase manufacturing since the introduction of the 800, but it was still occurring on some stock 2004s.



This cutaway of the PTO end of a stock crankcase shows the porosity (voids) in the aluminum that can lead to the deformation of the crankcase line bore and crankshaft failure.


Left as is, most failures occur within 2000-3500 miles on the engine. Allsport has found excessive crankshaft run out and out of balance primary clutches to accelerate the failure rate, as does modifications that increase the amount of stress to the PTO end of the crankshaft. Even bone-stock engines can and do experience PTO end failure, thus the need for an expertly developed fix to this growing problem. Having this service performed as a preventative measure is highly recommended, along with the precision balancing of the primary clutch. Allsport recommends Kinetic Balance and Machine of Spokane, Washington for expert clutch balancing (509-534-8722).
Even if your big block engine has experienced crankshaft PTO end failure, or some other crank related issue such as a broken rod, bad bearings, or something similar, don’t throw it away! Allsport offers expert crankshaft repair and can get you back up and running with their huge parts inventory when others can’t.


If you own a Polaris 800 twin and want to take steps to enhance the durability of your otherwise excellent engine package, give Allsport Polaris a call and talk to Bob at 800-359-4884 or e-mail them at allsport@sisna.com


©2004-2006 Snowtech Magazine. All Rights Reserved. Please see our Terms of Use policy.
Snowtech Magazine.com is powered by Podomani
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Last edited by captnhook1@hotmail.com : 01-05-2009 at 05:17 PM.
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  #2  
Old 01-05-2009
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Really well written ad for Allsports. Call and ask them what kind of guarantee is on their big bearing kit. Then go over to SnoWest, contact indydan and ask what his guarantee is. He is without a doubt higher priced, but you get what you pay for.

BTW, I have 2 of these BB 800 based motors, crankshaft trueness (runout in case) and clutch balancing go a long way towards long life on them. Polaris seemed pretty generous in tolerances for both on these motors. Well built motors, just piss-poor Quality Controls.
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  #3  
Old 01-05-2009
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he has talked to indy dan and is going with his crankshaft?
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  #4  
Old 01-05-2009
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Quote:
Originally Posted by Madcow View Post
he has talked to indy dan and is going with his crankshaft?
Don't know if he has or not, only know I'd talk to him before sending it anywhere......
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Liberty is a well-armed lamb contesting the vote.
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  #5  
Old 01-05-2009
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Quote:
Originally Posted by captnhook1@hotmail.com View Post
Article Archives
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http://snowtechmagazine.com/articles...lsprtcrank.php

Polaris 700/800 Crankshaft Upgrade Kit

While the Polaris ďbig blockĒ 700 & 800 twin engines have proven to be extremely powerful and dominant engines, a problem with premature failure of the PTO end of the crankshaft has surfaced, particularly on the 800 twins. The primary clutch and the PTO end of the crankshaft can snap off, rendering the vehicle unable to move under its own power.


What has been witnessed is the deformation of the crankcase line bore. The amount of bearing to crankcase bonding area on the PTO end appears to be less than perfect to be able to endure the tremendous load and thrust of the primary clutch. The crankcase line bore and PTO bearing mating areas can actually become warped, allowing an increasing amount of crankshaft wobble, eventually leading to PTO bearing and/or pin failure.


Allsport Polaris of Spokane, Washington, home of one of the largest Polaris parts inventories in the world, has developed an upgrade kit that greatly improves the longevity of the PTO end of the Polaris big block engines. The kit consists of increased bearing support area with a wider inner PTO pinned bearing and spacer, a new outer PTO end bearing, required crankcase modifications, improved oiling ability and a final crankshaft realignment. If the deformation to the crankcase line bore is sufficient, replacement could be necessary.


Total cost of the kit with crankcase modifications is $295 plus shipping. The crankshaft and crankcase must both be sent together for the work to be done. For engines that have already suffered a failure, the costs will be more to repair the damaged components, so why take the chance! This kit has been developed over the past few seasons and has all but eliminated the PTO end failures, and is virtually a must-do step in the modification of 800 twins for the best in long-term reliability.



The Allsport Polaris Crankshaft Upgrade Kit replaces the stock PTO bearings (lower) with a wider inner PTO bearing (upper) that is pinned, along with several detail changes to improve crankshaft reliability.




If you have the engine apart for any reason, this should be done to improve the reliability. Mountain riders who donít want to take the risk of going down have started to do this during the off season as a preventative measure, but more casual riders seem to wait until the engine is apart or being serviced and then get it done. Weíve seen this twice in a matter of four years on our test sleds, so it is fairly common. Polaris seems to have improved the crankcase manufacturing since the introduction of the 800, but it was still occurring on some stock 2004s.



This cutaway of the PTO end of a stock crankcase shows the porosity (voids) in the aluminum that can lead to the deformation of the crankcase line bore and crankshaft failure.


Left as is, most failures occur within 2000-3500 miles on the engine. Allsport has found excessive crankshaft run out and out of balance primary clutches to accelerate the failure rate, as does modifications that increase the amount of stress to the PTO end of the crankshaft. Even bone-stock engines can and do experience PTO end failure, thus the need for an expertly developed fix to this growing problem. Having this service performed as a preventative measure is highly recommended, along with the precision balancing of the primary clutch. Allsport recommends Kinetic Balance and Machine of Spokane, Washington for expert clutch balancing (509-534-8722).
Even if your big block engine has experienced crankshaft PTO end failure, or some other crank related issue such as a broken rod, bad bearings, or something similar, donít throw it away! Allsport offers expert crankshaft repair and can get you back up and running with their huge parts inventory when others canít.


If you own a Polaris 800 twin and want to take steps to enhance the durability of your otherwise excellent engine package, give Allsport Polaris a call and talk to Bob at 800-359-4884 or e-mail them at allsport@sisna.com


©2004-2006 Snowtech Magazine. All Rights Reserved. Please see our Terms of Use policy.
Snowtech Magazine.com is powered by Podomani


ps, if anyone is wondering i am sending my crank to indy dan for the billet end to be put on!

yeah see, right at the end of his article he put it there. dont know how you missed that earlier? need better glasses old timer!!
__________________
If the boner police are here I need a lawyer.

in a time of deciet telling the truth is a revolutionary act. george orwell.

aint no body ripin like me. M to the a-d-c-o-w. rock it hard for my fly ladies. I rock it yes in deed. homies still roll with me. money dont change me


nothing goes like 3 holes.

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  #6  
Old 01-06-2009
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I talked with dan today for an hour, great guy, wealth of knowledge, and very willing to discuss your issues, i think this is the only way to go.
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  #7  
Old 01-06-2009
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I thought you'd feel that way if you talked with him. ^^^
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BlueRibbon Coalition Preserving Our Natural Resource FOR The People Instead of FROM The People


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Liberty is a well-armed lamb contesting the vote.
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  #8  
Old 01-06-2009
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So WTF is my new toy a ticking time bomb or what??
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  #9  
Old 01-06-2009
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No more so than anything else. If clutch balance is out or crank runout is excessive, it will fail. Otherwise ride it like ya stole it.
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Liberty is a well-armed lamb contesting the vote.
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  #10  
Old 01-06-2009
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Quote:
Originally Posted by Ultrastud View Post
So WTF is my new toy a ticking time bomb or what??
pretty much, rubi got rid of it just in time. you are making more power at sea level than the mountain guys and turning the same track, it wont be long and BOOM. ha ha.
well, beings that you could probably get a grand for the motor, pipe, ignition and carbs, then you can pick up an xcr for about 1500 not a bad way to go.
__________________
If the boner police are here I need a lawyer.

in a time of deciet telling the truth is a revolutionary act. george orwell.

aint no body ripin like me. M to the a-d-c-o-w. rock it hard for my fly ladies. I rock it yes in deed. homies still roll with me. money dont change me


nothing goes like 3 holes.

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  #11  
Old 01-06-2009
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Quote:
Originally Posted by Ultrastud View Post
So WTF is my new toy a ticking time bomb or what??
Consider yourself warned! Check out post #26 in the following thread: http://www.slednutz.com/showthread.php?t=2286&page=2
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  #12  
Old 01-07-2009
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lol!
__________________
If the boner police are here I need a lawyer.

in a time of deciet telling the truth is a revolutionary act. george orwell.

aint no body ripin like me. M to the a-d-c-o-w. rock it hard for my fly ladies. I rock it yes in deed. homies still roll with me. money dont change me


nothing goes like 3 holes.

BRTECH HOODS
high performance engineering
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millennium technologies
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  #13  
Old 01-07-2009
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how prevelent is this for the 700's?

when should I unload the time bomb?
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then I'll be busy fingering myself on Saturday with my in-tact fingers, thank you.
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  #14  
Old 01-07-2009
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havent heard many if any of the 700's, the only ones i have heard are the 800's
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If the boner police are here I need a lawyer.

in a time of deciet telling the truth is a revolutionary act. george orwell.

aint no body ripin like me. M to the a-d-c-o-w. rock it hard for my fly ladies. I rock it yes in deed. homies still roll with me. money dont change me


nothing goes like 3 holes.

BRTECH HOODS
high performance engineering
aaen performance
millennium technologies
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  #15  
Old 01-07-2009
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not arguing with ya madcow, but wouldnt the 700-800 use the same crank?

Im will have too look at the fiche!!
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  #16  
Old 01-07-2009
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no the 700 has a shorter stroke than the 800.
__________________
If the boner police are here I need a lawyer.

in a time of deciet telling the truth is a revolutionary act. george orwell.

aint no body ripin like me. M to the a-d-c-o-w. rock it hard for my fly ladies. I rock it yes in deed. homies still roll with me. money dont change me


nothing goes like 3 holes.

BRTECH HOODS
high performance engineering
aaen performance
millennium technologies
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  #17  
Old 01-07-2009
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Hey thanks rubi!! LOL

After putting on a couple hundred miles on my time bomb I have come to the following conclusions!!

#1 Love the 151!! I find myself treking into new territory at half throttle that I wouldn't even dream of hitting WOT on a 121!!

#2 Madcow set the sled up beautiful, it has a nice steady pull from bottom to top!!

#3 I'd rather pull my Ultra over at -40 below than the RMK at 20 above!!

#4 I think madcow is right on the money, I think that chassis just screams "Give me an 800 XCR powerplant or give me death"!!

#5 I still find myself splitting my riding time about 50/50 with the Ultra/RMK, when I want deep I go RMK, when I want violent HP out comes the Ultra!
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  #18  
Old 01-07-2009
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Violent horsepower, you just got to love the sound of that,
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  #19  
Old 01-07-2009
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Oh its a lovely sound!!!
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