Hello, i have found lots of useful info on this forum and have decided to join and hopefully continue to learn more as i go.
Recently i purchased a 2009 sportsman 850XP with a blown engine. The price was right and i have been looking for a semi long term project to keep me busy this winter.
a little bit of background:
I have a full factory service manual for this machine, very helpful. I have experience working on ATV's, cars etc. I have not fully rebuilt an engine like this one, but am confident that i will be able to do so, taking my time and having the help of a close friend who has done many engine rebuilds on dirt bikes/snowmobiles and is an auto mechanic by trade.
The machine has 2040 miles. Besides the engine, it is in good shape.The machine still has the original tires.
Where i am at right now:
the engine is pulled from the machine.
The engine is shot, the cases are broken and not usable. I believe something in the bottom end went out and caused catastrophic damage. I pulled the head and the cylinders are in good shape, no gouges or scoring. the very bottom of one cylinder is gouged from the piston rod and one piston is destroyed from the rod breaking free.
here is my plan so far:
-I have taken the engine apart and as i suspected there is nothing inside that is usable.
-Next i will be making a parts list and order the parts when needed. (this is where i would like some advise)
-find a good used set of engine cases. i would then have them honed. There is a nice set of 2017 cases for sale right now. from my research i believe these should work?
-rebuild. basically all new internals.
I am not looking to build this engine for more power than stock. this is already more power than i will likely need. My goal is to have an engine that is basically stock and reliable for normal trail riding ETC..
what i am interested in is:
- advice on what parts are recommended for this engine. factory OEM, aftermarket etc.. typically i like to go OEM but i know that inst always best
-what known issues does this engine have that i can upgrade while am doing the build. i know the crankshaft has been upgraded over the years, etc..
-while i have the engine out, what else is do you all recommend? tranny maintenance, etc..
as i get parts ordered ETC i will update, along with the questions i come up with along the way.
I know that i could buy a rebuilt/refurbished engine, however that would defeat the purpose of the project for me as i want to do the work myself, with help, learning along the way.
I am excited to be a part of these forums.