800 "fix"

GKR · Feb 15, 2012

Here is what I found on tear down. Interesting to note that both pistons looked marginal on the exhaust side but both had damage on the intake side. Beware, the Y pipe inspection method would not have revealed this.

PTO exhaust side

Mag exhaust side

PTO intake side

Mag intake side

After measuring I found both sides had 0.008" piston to cylinder clearance.

Cylinders were still nice and just under the recommended spec for the Fix kit of 3.347". With a light hone they came out perfect at this dimension.

New clearance is now right around 0.0040" to 0.0045"

One other thing I noticed is that my wrist pin bearings looked fairly "blued" from heat or possible limited lube so I will change them out as another precautionary step.

GKR · Feb 15, 2012

One question I have for PMSPOLARIS or others is when installing the kit, what is the target spec for wall clearance and ring end gap. As it stands now I have 0.0040" on wall clearance and spot on 0.019" ring end gap. This is right at the minimum spec on both. Ring end gap is recommended at 0.019-0.028" Am I better to be in the middle of the range or on the tight end? Some opinions please. I will leave it right at 0.019" if that is the best option.

gerrman · Feb 15, 2012

GKR...scoring on my pistons were on same side of pistons...both sides of skirt though, but worse. Similar mileage, 1250 miles. Just placing your new pistons in the cylinder for a test fit, you will notice a huge difference. Color on top of piston looks good, your PCV map is working for you. People that like these sleds should be doing this. Keep the update posts coming.

Joe57 · Feb 15, 2012

09 800 D

metallicat said:
I agree with you 100%. I am sitting here with a 2010 800 Dragon 155 with 1000 miles on it. Warranty about to runout. As much as i want a Pro, I really don't want to spend the money because this dragon is an awesome sled.I JUST DON'T TRUST IT!! i would rather spend the money though and get a new sled with warranty rather than have this one cost me $2000 down the road and still have a 3 or 4 year old sled. Do i want a Pro? Yes. just didn't want to feel like i HAVE to buy one. I do HAVE to buy one right??? at least that's what i'm gonna tell the wife!!!:behindsofa:

I was in the same boat as you I put in the Mtn tek kit ,Gary @ Buckies got mine warrentied jugs and pistons I bought the kit they installed it and kept the oem pistons for the price of the rebuild , I sold it for 5 grand and am holding the paper on it till it gets payed off.I'm riding a 2012 pro with 4 years of peace of mind......The Dragon runs waaaay better than it ever did new... But I didn't trust it....I was working with a guy that had his burn down sat.800 miles.

brokedragon · Mar 17, 2014

What's the verdict?

Just smoked my 2008 RMK 800 Dragon 163" for the second time. Can't afford another sled but I am sure not going to put OEM parts back in it. Which fix kit is better? MTNTK or Dragon Saver?

Snow Duck · Mar 18, 2014

MTNTK KIT BY FAR!

I have both...i am not afraid to ride my 09 with the MTNTK but everytime i get on my 10 with the no name kit i am running scared thats why i carry a tow rope with that sled!!

call and chat with them ....at least you can get the answers you are looking for...

SummitFox · Mar 19, 2014

Newbie question warning......I have an 08 800 as well and I'm wondering if my sled already has the MTNTK kit installed. When I bought the sled I didn't do much research, but I swear I remember the guy mentioning he had done something to the motor like this. How would I be able to tell? If it's not already done I'll definitely be doing it as well.

St0rm77 · Mar 19, 2014

if there is the MTNTK kit, there will be a 1/4" spacer between the case and cylinders of a different metal than the engine's aluminum.
other kits, i wouldn't know

Snow Duck · Mar 20, 2014

mtntk's spacer is a goldish steel plate and knock offs are usually alum..

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800 "fix"

GKR

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GKR

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gerrman

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Joe57

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brokedragon

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Snow Duck

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SummitFox

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St0rm77

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Snow Duck

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