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So, I got this 07' Polaris Outlaw 90 in the shop to rebuild top end and transmission. Replaced all bearings and gears in the transmission. Replaced cylinder and piston with brand new parts. Put the engine back on the frame and fired it up. Started great, but had a taping sound in the lower crank case. pulled the flywheel cover off and found the flywheel was wobbling and hitting the stator. I then replaced the stator and flywheel with brand new parts. Timing is all set on the timing marks now, but when I turn it over it kicks back when it fires and ends up stripping the starter idler gear. I've replaced the starter gear once already and now have to replace it again. Is it possible that the timing marks on the flywheel are off or maybe this flywheel is not for this exact model? Thinking of advancing the timing to try it, but don't want to keep going through idler gears.
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The quad has done this off and on, almost since new, but it's gotten worse this year. Sometimes if I freshly charge the battery, it'll work fine, others times that won't matter. Turning the key to on it sounds like it's connecting as I go to the start position, slightly before the full turn, but it's not like there is just a sweet spot to find, it's totally erratic.
Now the battery is basically dead so I put a new, slightly bigger AGM battery in today to replace the factory one with all of 800 miles on it, but those have lots of plowing hours included.
I was able to get it started once, but it still went into limp mode after just a few moments of driving it (that's another topic), so I put it back in the garage and started probing around. Now it doesn't even try to turn over.
Is an ignition switch, the $18 shipped aftermarket variety on Amazon worth a shot? Or should I go straight for the starter? The new switch may not come for over a week, so I hate to just put my hopes in that if I'm missing something obvious. Fuses are good, so it's not something super obvious.
After purchasing a lightly used 2018 570SP (300 miles on it) I noticed that the display was flashing on and off. I remember reading awhile back that this was a common problem on the 18 model. I can't remember what the fix is. It also turns over slow even though the battery is charged. Anybody know what the fix is on this issue?
So this’ll be long I’ll give all the background first to see my issue skip to the ***
Hey I picked up a pit bike and a foreman for 800 the pit bike was running but the foreman was locked up. Sold the pit bike but when I took the top end off the piston I only found half a piston left. So knowing the rest of the piston was down in the crankcase I knew it had to be pulled and gone thru completely.
to pull the motor I went ahead and pulled the rear end off and unbolted the front diff to pull the drive shafts and pull the motor. Now I have the motor torn down completely and have all the parts of the piston removed. I know the rod and crankshaft is shot (heat discoloration and too much up and down play rod to crankshaft).
***so I’m wondering while I have the motor apart what should I check for? I know this motor died from heat as the oil in the head smelled like popcorn. So what should I check to make sure I fix the issue (overheating I assume) and not just the symptoms (blown up motor lol).
so put simply I don’t want to just rebuild the motor to have it overheat and repeat the process after 5mins of running
Here’s some pics
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