Quantcast
Jump to content

  • Do you own an ATV? Join our Forum!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.

Fyko

800 Outlander dropped valve

Recommended Posts

I have an Outlander 800 XT with 480 hours on it. Very recently the engine power dropped significantly while riding. Soon thereafter the engine created much noise and stopped.

On opening the rear cylinder I found one inlet valve stem bent and the other broken. The valve head caused considerable damage inside the cylinder.

My reading is that the timing chain to the rear cylinder jumped at least one sprocket tooth to reduce the engine power, thereby compromising engine power, and then shortly thereafter jumped one or more teeth to allow the rear piston to contact the intake valves. On disassembly I did not notice that the timing chain was particularly slack, but neither  was I looking for such things. The ATV has been serviced by agents according to requirements, in fact it was serviced very recently, by accredited agents.

Coincidently I met another 800 XT owner a couple of days ago who had had a similar incident a few years ago, which makes it likely that there are others out there who have had similar experiences. If there are I'd very much like to hear from you.

Share this post


Link to post
Share on other sites


Hey @Fyko welcome to Quadcrazy. That really stinks man about loosing the valve. Was the piston damaged? Also have you looked at the timing chain tensioner to see if anything was going on there ? Also maybe just a stretched timing chain? 

I would also check the other cylinder as well if your going to tare into it. Never know.  

Good luck brother 

 

Share this post


Link to post
Share on other sites

Hi Frank,

Good to hear from you. And good questions you have.

Right now I'm in the boonies of Mozambique, which is about as third-world as you'll find on the planet. So I haven't opened the front cylinder yet, but definitely will for the reasons you mentioned. Before we took the head off we didn't look too closely at the state of the tensioner because we didn't know what we were going to find under the cylinder head, and now it's a bit too late. But very good point. Thanks.

I spent the last 60 of my 69 years taking engines apart, but with this machine I gave it to the agents, so I have to trust they'd check such stuff - until proven otherwise. Having said that I must tell you the state of general workshop diligence here is so low that it's easy to picture them spending more time writing the invoice than doing the actual work.

Another thing I need to mention is that parts to fix this thing i.e. rear cylinder head, piston, and gaskets would cost US$564 from PartShark in the US. Plus postage. BRP hatched a plot with the local (South African) agents of BRP to disallow sales of parts outside of the US by US dealers. The same parts I detailed above cost well over US$2000 here. Now that really sucks.

The piston was pretty battered but not penetrated, the head was hammered from below, but can probably be rendered usable, the two intake valves are obviously shot. The minimum to repair will be a piston and 2 valves - and then most likely 2 timing chains, since it's hard to imagine them jumping sprocket teeth without being severely stretched.

Thanks again for your comments.

Best regards

Fyko

Share this post


Link to post
Share on other sites

Do you know anyone in the  US you  can trust to pick up  the  parts and  ship them  to  you?  I looked for Canadian dealers  but BRP  must have the same deal  with them . No shipping outside Canada  even to  the  US, and  I  didn't  find any  that  showed pistons or heads available online.

Share this post


Link to post
Share on other sites

Hi Dave, Sadly no. I should have distant relatives there, but too distant to lean on in this way.

I started this thread fully expecting others to have come up with this problem somewhere, on the basis that two near neighbors in South Africa have this disaster strike and not anybody else. But so far it's just the two of us - though the agent was heard to mutter darkly about how these Rotax engines regularly drop valves.

I'm now thinking that the front timing chain will probably turn out to be stretched as well. And it will come back to the servicemen not checking this when they ought to, this being Africa remember, where anything goes.

We won't know anything more until the ATV is trailered back home and we open up the front cylinder. But it's starting to look like shoddy local maintenance.

Thanks, and best regards,

 

Fyko

Share this post


Link to post
Share on other sites


Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


  • Similar Topics

    • By bren7176
      So honed out the cylinder and got most of it nice nice but left with this .. Might just have to have the things bored out now ..... some before and after..pics.
      1995 Polaris Sportsman 400 4x4 
       
       

       
       
      have to have the things bored out now ..... some before and after..pics..









    • By mikeexplorer
      PA Residents, please take a moment to send an email supporting this to [email protected]
      https://www.erienewsnow.com/story/41590987/proposed-changes-on-the-way-for-riding-atvs-on-state-forest-trails?fbclid=IwAR1EXkgtnRenBzFAKG5h1IOs7xDrNg6iedYSALckbjx2F5ZPjwdDFFij6Jc#.Xic-MeQ7aXY.facebook
      This week, the Department of Conservation and Natural Resources (DCNR) plans to outline proposed policy changes for ATV trails on state forest lands.  They will also be seeking public comment.
      Pennsylvania has more than 260 miles of ATV trails in state forests. The department is reviewing its policy to respond to increasing demands for riding opportunities and well as interest from local governments in expanding tourism.
      “The purpose of the policy is to provide guidance to DCNR when acquiring, developing and managing lands for ATV use by the public,” Secretary Cindy Adams Dunn said.
      There had been a moratorium on new trail development, but the policy revisions now authorize DCNR to consider new ATV trails and connectors on state forest lands.
      “New ATV trails will be considered, while still balancing the protection of natural resources as outlined in the Environmental Rights Amendment to the Pennsylvania Constitution, and the needs of all types of recreational users on DCNR lands,” Dunn said.
      In a 2016 survey of ATV users, more than 4,800 responded with many indicating a strong desire for more long-distance trails. Pennsylvania has around 285,000 registered ATVs. On state forest lands, ATV riding is allowed only on designated trails.
      Public comment will be taken at a meeting in Harrisburg Wednesday, January 22, from 10 a.m. to noon in Room 105 of the Rachel Carson State Office Building. Written comments can be submitted to [email protected]
      The deadline to submit comments is March 27.
      More information about ATV riding is on the DCNR website.

    • By David Miller
      Does anyone know how to access the check engine codes on a 2018 450 sportsman. Just changed battery and spark plug . It runs fine but the light is on and I need this to plow snow and need it reliable. Any ideas . Thanks
    • By Michael France
      I have a Kawasaki Bayou 220 KLF220A and I cannot get it to start using the starter button. I have replaced the starter solenoid and the starter relay. I have followed the wiring diagram in the repair manual and it looks like the switch is working well, the neutral and reverse relay have power running through them and appear tp be working correctly. However, I can not find a wire runnng the the starter button that has power on it. Anybody have any idea what the break down is?
    • By Johnnyhorsepower
      I finally found an awsome app for your phone that shows you on a map all the trails near your location. You can read or add reviews, look at picts...etc
      Its called: atv escape

      John
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...