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BACKCOUNTRY RIDES - BUILD THREADS We all like to see builds from the crate up. Bring us along for the creation.

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  #1  
Old 01-18-2015, 12:40 AM
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02zx800 02zx800 is offline
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Default Project pro rebuild

So here is a story...
In mid November I took a 2011 pro rmk 800 163
On trade for my 04 rev 800 turbo.
I was told it had allot of miles on the top end and it made me hesitate, but I decided to got out on a limb since the rest of the sled was pretty clean.
Met with the guy and talked shop for a bit then fired them up and shook hands and loaded up and went our separate ways.

Got back to my shop and went to pull the sled in and it started backfiring ....bad.
I got real nervous....

Pulled the head and found a scattered piston and a 1" chunk out of the mag side
Cylinder exhaust port....dug a big deeper and found a nice hole
In the case an a chunk of metal wedged in the rod bearing.
Dug a but deeper and found the case had 4 cracks and a dime sized hole.

That got expensive quick!
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  #2  
Old 01-18-2015, 12:48 AM
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02zx800 02zx800 is offline
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Default

The sled
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  #3  
Old 01-18-2015, 12:58 AM
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02zx800 02zx800 is offline
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Case
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Old 01-18-2015, 01:04 AM
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Lower case
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Old 01-18-2015, 01:08 AM
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Default

Crank
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Old 01-18-2015, 01:17 AM
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Default

I made the decision to just rebuild the sled from the ground up.
Not going over board with the motor but going to build it to be strong enough for boost but reliable. Everything on this build was done by me in my shop except for 3 key things.
Started by welding the case and sanding and polishing it down....
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  #7  
Old 01-18-2015, 01:19 AM
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More...I can only up load one pic per post apparently from my iPhone?
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  #8  
Old 01-18-2015, 01:22 AM
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02zx800 02zx800 is offline
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Default

Almost
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Last edited by 02zx800; 01-18-2015 at 01:24 AM.
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  #9  
Old 01-18-2015, 01:27 AM
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02zx800 02zx800 is offline
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Join Date: Oct 2012
Location: Conifer/Grand Lake,CO
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02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR
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Done
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  #10  
Old 01-18-2015, 01:48 AM
02zx800's Avatar
02zx800 02zx800 is offline
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Join Date: Oct 2012
Location: Conifer/Grand Lake,CO
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02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR02zx800 Has earned a rub and tug from AR
Default

Pulled a favor from a close friend and discussed motor options, after studying the motor we found some issues we wanted to address our way.
Fugi crank, billet 132mm rods,complete Polaris main/rod bearings,seals and gaskets, Rktek (wossner) piston kit, repair (weld) cylinder damage,bore,custom drop in port matched sleeves bored to spec, milled head. I ordered parts and as
I patiently waited I stripped the sled down and got to work sand blasting.
Only items I was not able to blast and powder coat myself was the skid rails and running board rails.
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