04 REV 800 Crank ??????

[Yamadoo04]

I took my sled to the dealer and they said my crank is not within tolerance anymore. They said the tolerance is 3 thousants and mine is at 8 without the fixed part of the clutch on and with the clutch on it is at 15. They wanted close to $1700 to fix it. My friend said he can fix it but I just need to get the parts. So do any of you have suggestions as to what parts i may need to get to get my sled running again? THey said I need a crank, but do I need everything in the crank or could it be just the bearings? I am not a mechanic but my friend said he could do it. Oh and if I do need a crank does anyone have one for sale?

 

[Backcountrypro]

How many miles? It probably is a bearing that is getting loose, trouble is that you can't just replace a bearing with tearing the enging apart and splitting the crank. How mechanically inclined are you and your friend? You would have to pull cylinders, pistons, magneto, and split crankcase in half to get the crank out, all of this has to be done with the engine out of the machine. Yes it can be done in your garage but you had best do some research before you tear into it. I would get the crank out and put in a rebuilt, usually about $500 from Seadoo clinic.

 

[Yamadoo04]

He is pretty good at engines. He has built his from a wrecked sled he got for 900 bucks. So I guess I should try to get a rebuilt crank then???

 

[summit800]

your local skidoo dealer should be able to get you a rebuild one from slidoo for about 500.00 and they come with all new bearings, you'll also need Isiflex grease and 2 new crank seal, AND you will also need a upper end kit and Id also change the oil shaft seal while its all apart,$ 5.00 part

 

[hymark860]

Take the crank out and have it trued. Inspect bearings, if they check out repack outside bearings with isoflex and reinstall. No dealer can predict a crank is bad measuring runout. If the bearings are bad, youd be better off getting a reman or crank from seadoo clinic. If its a reman iwould still get it trued. I have seen remans out as much as .008.

Get your clutch balanced also.

 

[Tackbtch]

Take the crank out and have it trued. Inspect bearings, if they check out repack outside bearings with isoflex and reinstall. No dealer can predict a crank is bad measuring runout. If the bearings are bad, youd be better off getting a reman or crank from seadoo clinic. If its a reman iwould still get it trued. I have seen remans out as much as .008.

Get your clutch balanced also.

x2 on the clutch rebalanced. The crank is out on our 06, waiting for the reman from Sea Doo. It comes with sealed bearings that do not use the isoflex grease...gona give one a try. You will need a puller to remove the flywheel, can be difficult if its never been off.If your friend is good with engines I would tackle it your selfs. Dont buy a used crank, after all thats what you have now!!! .. buy a reman from Doo or Sea Doo Clinic. For around a 1000 frogskins you can have the reman crank and a set of double ring pistons and all the gaskets you will need ...enjoy...Dino

 

[team dirt]

drill out the case directly above the pto bearing to provide lubrication to the bearing. there is a spot that looks like it should be drilled out, you cant miss it. just order a rebuilt crank and save haedaches. deffinetly check new crank before install because it doesnt take much to knock them out of true.

 

[Red-eye]

drill out the case directly above the pto bearing to provide lubrication to the bearing. there is a spot that looks like it should be drilled out, you cant miss it. just order a rebuilt crank and save haedaches. deffinetly check new crank before install because it doesnt take much to knock them out of true.

Why would you drill the case out by the pto bearing for lube when its full of isoflex grease?

 

[team dirt]

Why would you drill the case out by the pto bearing for lube when its full of isoflex grease?

so you always have lubrication, isoflex will breakdown and cause failures. if you drill the case you will get runoff from the piston that will drain down into the bearing and back to the case.constant lubrication. some engines have the holes drilled already depending on year, i beleive it is the older 800's 01's mabey

 

[Tackbtch]

so you always have lubrication, isoflex will breakdown and cause failures. if you drill the case you will get runoff from the piston that will drain down into the bearing and back to the case.constant lubrication. some engines have the holes drilled already depending on year, i beleive it is the older 800's 01's maybe

Our 06 has a hole in the case that leads to a nipple on the outside that is plugged, but other than that no obvious drilling that I could make out. However the pto side had lots of oil in it and no grease or signs of grease, only had 1600 miles on it rod failed on the mag side. Dino

 

[Crasher]

Our 06 has a hole in the case that leads to a nipple on the outside that is plugged, but other than that no obvious drilling that I could make out. However the pto side had lots of oil in it and no grease or signs of grease, only had 1600 miles on it rod failed on the mag side. Dino

I just pulled my 05 down for a top end job. Yep, they changed the cases from 03 to 05. My buddies 03 summit HO has the cup area where you drill them out. My 05 does not. Guess I will not be drilling my cases either.

Sea Doo clinic drilled them out for my buddy but, from what I here, they don't do this anymore. Probably because Doo changed the case casting.

Pretty serious about going CAT pretty soon.

 

[NITROSKIDUDE]

Our 06 has a hole in the case that leads to a nipple on the outside that is plugged, but other than that no obvious drilling that I could make out. However the pto side had lots of oil in it and no grease or signs of grease, only had 1600 miles on it rod failed on the mag side. Dino

I also lost my rod bearig at about 1600 miles on my o6

I have had my cases drilled, and they are not where the nipples come out of the case, The cases get drilled where the older motors used to be drilled, if you look real close to the mag side you will notice a lil bump in the top section of the case if you use your imagination you can see where that bump would meet the cylinder, It sortta lays in there at an angle. That is where it would need to be driled, not much room for error. There is also the same type of said bump on the PTO side to.

I have an 05 motr now in my 06 with an 04 crank with all new bearings, and rods with the cases drilled. no problems. And a good piece of mind that those bearings are oiled.

 

[Tackbtch]

I also lost my rod bearig at about 1600 miles on my o6

I have had my cases drilled, and they are not where the nipples come out of the case, The cases get drilled where the older motors used to be drilled, if you look real close to the mag side you will notice a lil bump in the top section of the case if you use your imagination you can see where that bump would meet the cylinder, It sortta lays in there at an angle. That is where it would need to be driled, not much room for error. There is also the same type of said bump on the PTO side to.

I have an 05 motr now in my 06 with an 04 crank with all new bearings, and rods with the cases drilled. no problems. And a good piece of mind that those bearings are oiled.

Thanks for the info...going to try the crank from Sea Doo that runs sealed bearings Like said above "about to go to Cat I cant believe I said that Been running doos for the last twenty years...Dino

 

[JROD]

I definitely recommend the Sea-Doo clinic cranks. They are running a bigger PTO bearing and MIGHT be welded. Not positive on the welding though. Definitely get new upper rod bearings and new PTO, Mag seals, and water pump shaft seal. That one is a weird seal. I ruined the first one I tried to put in. Doesn't hurt to put a little loctite on your water pump impeller too.

Be careful with the Magneto pick-ups. They are very touchy and don't need a reason to go bad. I've seen engines come apart with no problems and re-assembled with the old pick-ups. NO SPARK. Also remember the pick-up with the green wire goes on top. DON'T GET THESE MIXED UP!!!

Damn! All my good advice comes from bad experiences. Thats not good.

 

[Tackbtch]

^^^^Yeah but its peeps like you that are willing to share that make it a good site... thanks Dino

 

[Crasher]

Tack,

I finally figured out my surging problem on my 05. Remember, I thought it was the spark plug caps.

Turns out I had a busted piston ring. The thin part of the ring that goes over the location pin on the piston broke off. Really screwed things up. Put several hundred miles on it trying to figure out the surging.
90 psi PTO side
145 psi Mag.

Junked the cylinder, piston, and head.

Gotta love a Doo.

 

[Tackbtch]

Tack,

I finally figured out my surging problem on my 05. Remember, I thought it was the spark plug caps.

Turns out I had a busted piston ring. The thin part of the ring that goes over the location pin on the piston broke off. Really screwed things up. Put several hundred miles on it trying to figure out the surging.
90 psi PTO side
145 psi Mag.

Junked the cylinder, piston, and head.

Gotta love a Doo.

Did you figure out what made the ring break ? Time for an SLP or RKTek head Dino

 

[Crasher]

Bad luck I guess.
It looks like a sharp corner on the end of the ring dug into the side of the cylinder and broke it off. Then tipped sidways and went up and down until it had a groove in the cylinder wall big enough for it to pass up into the squish band.
Once there, it tippy tap danced dents all over my head and piston until it went out the exhaust pipe.

Funny thing, it still ran pretty good other than the power surge at WOT.

 

[BIG JOHN]

ALL 800HO cranks are out of spec..that dealer could rebuild every sled that comes thru the door...

If you plan on keeping sled...and it has over 4000 miles...a fresh crank/pistons is smart...have the new crank trued too .000-.001"...the iso flex gease "IF" installed properly lasts forever...IMHO drilling cases is going backwards...rod bearing failure is due to oil quality or lack of it (1 qt oil per tank of fuel = 32-1)...you could ship me the motor, I could do a full rebuild for less than that (crank, trued, all seals/gaskets, iso-flex, 2 ring cast pistons and assembled to spec for about $1200 plus shipping)...BJ

 

[Red-eye]

so you always have lubrication, isoflex will breakdown and cause failures. if you drill the case you will get runoff from the piston that will drain down into the bearing and back to the case.constant lubrication. some engines have the holes drilled already depending on year, i beleive it is the older 800's 01's mabey

I have done the same engine two or three times and never seen ioflex break down. I'm not saying your wrong but ski-doo has been drilling cases for years and now they don't, they use isoflex, why? I often wondered but it seems to work and I have been doing engines since 1977.