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97 POLARIS SPORTSMAN 400L PROBLEMS!
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Posted: 07/27/07
12:07 AM
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I JUST BOUGHT A 97 SPORTSMAN (IM NOT MUCH OF A POLARIS GUY) BECAUSE I GOT IT PRETTY CHEAP BUT HERE IS MY PROBLEM...THE GUY I BOUGHT IT FROM JUST HAD THE TOP-END REBUILT AND BORED 40 OVER..BUT HE SAID WHEN HE PUT IT ALL BACK TOGETHER HE CRANKED IT AND IT FILLED THE CRANKCASE WITH WATER...SO SOMEWHERE THE WATER IS GETTING THROUGH THE CYLINDER..BUT ANY HELP WOULD BE APPRECIATED I'VE NEVER WORKED ON A POLARIS BETTER YET NEVER OWNED ONE..IM A HONDA GUY! ONE MORE QUESTION..HOW DO I GET THE PISTON CIRCLIPS OUT????? I NEED TO GET THE PISTON OFF THE ROD SO I CAN COMPRESS IT TO GO INTO THE CYLINDER...BUT I KNOW WITH IT OFF THE ROD I HAVE TO LEAVE ENUF OF THE PISTON OUT OF CYLINDER TO GET THE PISTON RETAINER BACK THROUGH THE ROD!! IS THEIR A EASIER WAY TO DO THIS???? PLEASE HELP
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Posted: 06/07/09
09:57 PM
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I just rebuilt the top end of my 97 sportsman 400 and I had a buddy hold the cylinder while I compressed the rings with my fingers. It only took a few seconds to get it in. You just have to make sure that the rings are in the right position with the little stopper in the middle of the gap. But to get the clips out you just use a small tool to rotate it so the end is in the gap where you can get some needle nose pliers to pry it out. Just make sure you put a clean rag in the crankcase because they have a tendancy to pop out. Hope that helps.
Travis
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