Hello all, I am new to the Polaris world, but not ATVs or dirt bikes. So new to this site with my New to me Polaris.
So I just bought a 2002 Polaris Sportsman 700 Twin for cheap as it is in need of repair.
Has been blowing rad fluid out of holding tank. I figured it was a blow head gasket.
Bought it anyways, brought it home and tried to get the rad cap off but it was stuck which was strange. It would turn, but not pull out. I had to pry it out. It seemed to be baked into there. No fluid visible below rad cap. Wiped off the underside of the cap and it was black with what looked like exhaust residue. Wiped out the inside of the tube and was all black as well. So I can only assume it ran like this for a while.
With the cap off, I turned the key to start it to see if it would pump any rad fluid and all I could see was exhaust pumping through and out of the rad cap holder pipe.
So head gasket is blown. https://www.dropbox.com/s/gdbl9zl08t..._3616.MOV?dl=0
In hoping that the head is still ok, I am considering repairs. I cannot start taking it apart for 3-4 weeks, but just thinking about what needs to be done.
I do not know how long it was run like this, but had to be a while due to the black and baked rad cap. So damage could vary, but thinking
- new rad cap
- new thermostat
- gasket kit
Motor runs well, does not smoke oil and no water in oil, unless it was change after it failed, which I cannot verify. Guy said it smokes a bit of blue when first started but stops when warm. Now that could be a choke issue or warn rings.
I ran it for a very short period of time in my garage with the OH door closed and it did not smoke me out and it was a cold engine. So could not replicate the blue smoke when cold.
So I need to check the head and cylinder for warping.
Will check the jug and may do a light hone and new rings pending.
Check the valves, and replace the valve seals at a minimum.
Would the exhaust heat damage the impeller ? I can see it damaging seals, but does not appear to be leaking, but any exhaust heat damage might quickly show up once I start riding, so I will do those seals as well.
I cannot really think of anything else.
I have never worked on a twin cylinder, but have rebuilt dirt bike motors a carb motor for myself. I'm only a backyard mechanic... Haha
I will start going throught the service manual later this week.
Any thoughts ? Any thing else I am overlooking or that I should be paying attention to or replacing ?
Any comments are appreciated.
So I just bought a 2002 Polaris Sportsman 700 Twin for cheap as it is in need of repair.
Has been blowing rad fluid out of holding tank. I figured it was a blow head gasket.
Bought it anyways, brought it home and tried to get the rad cap off but it was stuck which was strange. It would turn, but not pull out. I had to pry it out. It seemed to be baked into there. No fluid visible below rad cap. Wiped off the underside of the cap and it was black with what looked like exhaust residue. Wiped out the inside of the tube and was all black as well. So I can only assume it ran like this for a while.
With the cap off, I turned the key to start it to see if it would pump any rad fluid and all I could see was exhaust pumping through and out of the rad cap holder pipe.
So head gasket is blown. https://www.dropbox.com/s/gdbl9zl08t..._3616.MOV?dl=0
In hoping that the head is still ok, I am considering repairs. I cannot start taking it apart for 3-4 weeks, but just thinking about what needs to be done.
I do not know how long it was run like this, but had to be a while due to the black and baked rad cap. So damage could vary, but thinking
- new rad cap
- new thermostat
- gasket kit
Motor runs well, does not smoke oil and no water in oil, unless it was change after it failed, which I cannot verify. Guy said it smokes a bit of blue when first started but stops when warm. Now that could be a choke issue or warn rings.
I ran it for a very short period of time in my garage with the OH door closed and it did not smoke me out and it was a cold engine. So could not replicate the blue smoke when cold.
So I need to check the head and cylinder for warping.
Will check the jug and may do a light hone and new rings pending.
Check the valves, and replace the valve seals at a minimum.
Would the exhaust heat damage the impeller ? I can see it damaging seals, but does not appear to be leaking, but any exhaust heat damage might quickly show up once I start riding, so I will do those seals as well.
I cannot really think of anything else.
I have never worked on a twin cylinder, but have rebuilt dirt bike motors a carb motor for myself. I'm only a backyard mechanic... Haha
I will start going throught the service manual later this week.
Any thoughts ? Any thing else I am overlooking or that I should be paying attention to or replacing ?
Any comments are appreciated.
