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95 Polaris XLT rebuild


federline

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Bonzai and I are finally rebuilding Blaze's XLT 597cc triple right now, we've be planning it since fall. We're fairly seasoned shadetree mechanics, but just wanted to know if anyone else here has broken down and rebuilt one of these Polaris liteweight triples before. Just in case we needed some tips. We're about to split the case, the crank seal blew and spun the bearing. Thanks to anyone who is willing to speak up.

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grin.gif I'm a ditch pickle guy myself.

Say - this case is split now. PTO-side section of crankshaft is sheared in half, and PTO bearings toast. Amazingly, there is no other damage anywhere else, not the case, other crankshaft parts, arms, pistons, heads - all good.

We're considering using Recreational Engineering in Eden Valley, MN for crankshaft rebuild. Anyone have experience with them? They come recommended.

What about Straightline Performance in Forest Lake, MN? Anyone know them? They are listed in Snow Tech as crankshaft rebuilders. I know nothing about them.

Anyone have a favorite Polaris crankshaft rebuilder?

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That 600 triple from 95 and 96 is terrible...When mine was a year old I took it in for a cranshaft bearing meltdown and there were 6 others just like it with the same problem...Needless to say, no more Polaris....Cat only for me...No green on it anywhere..... grin.gif

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Quote:

That 600 triple from 95 and 96 is terrible...When mine was a year old I took it in for a cranshaft bearing meltdown and there were 6 others just like it with the same problem...Needless to say, no more Polaris....Cat only for me...No green on it anywhere.....
grin.gif


Statistically impossible........ confused.gif

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I'm a ditch pickle guy myself.


Yes, I'm an cat guy fixing an XLT for a buddy. I guess friendship *is* thicker than brand loyalty. smile.gif

1975 Arctic Cat Lynx. I've owned it for 19 of its 30 years, cost $40 to acquire (not a typo). One rebuild - bought it with blown head gasket. Free-air forever!

And there is indeed NO GREEN on my '75 Lynx! grin.gif

And still trolling for any input on those two crank refurb places above....

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Well, Federline and Bonzai have treated my XLT well, but unfortunately, the required $$ investment to fix the crank is more than I paid for the sled total. It's time to part this baby out and look for a newer sled.

Anyone looking for parts for a mid-90's XLT SKS? Let me know. Otherwise, hsolist here we come!

Mourning the loss of my sled,

Blaze frown.gif

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I just got the identical sled which according to the guy i got it from in a recent rebuild the shop bored the oil holes in the crank thats what they recomend I guess. I am looking for the front suspension bars and skis if you are set with parting it out, otherwise I have a 97 Xlt ran good but i am now using it for parts because of the body shape(the plastic skis on it also have cracks) . let me know either way. or what you want for your whole sled.

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  • Your Responses - Share & Have Fun :)

    • got this tackled today took about 3 hours to get both sides done. Didnt even get to use a torch....   Thought I was golden with just jacking it up and I could get to everything but no luck. Had to remove the entire axle hub and brake assembly to get to what I needed. Was a pain but still better then taking off the entire pivot arm.    Axle bearings were already greased and in great shape thankfully. Got both leaf springs installed and its ready for the road again.   Probably going to have my electric brakes checked, I am not touching anything with the brake drums. Based on what I saw it doesn't look like my electric brakes have been working anyway. Brakes are nice to have if its slippery out
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    • Chicken mine,  melded in Mccormick poultry seasoning for 24 hours.  Grill will get a break till the frigid temps go away!
    • we had some nice weather yesterday and this conundrum was driving me crazy  so I drove up to the house to take another look. I got a bunch of goodies via ups yesterday (cables,  winch ratchet parts, handles, leaf springs etc).   I wanted to make sure the new leaf springs I got fit. I got everything laid out and ready to go. Will be busy this weekend with kids stuff and too cold to fish anyway, but I will try to get back up there again next weekend and get it done. I don't think it will be bad once I get it lifted up.    For anyone in the google verse, the leaf springs are 4 leafs and measure 25 1/4" eye  to eye per Yetti. I didnt want to pay their markup so just got something else comparable rated for the same weight.   I am a first time wheel house owner, this is all new to me. My house didn't come with any handles for the rear cables? I was told this week by someone in the industry that cordless drills do not have enough brake to lower it slow enough and it can damage the cables and the ratchets in the winches.  I put on a handle last night and it is 100% better than using a drill, unfortatenly I found out the hard way lol and will only use the ICNutz to raise the house now.
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