2004 Rev ..Rebuild or replace?

[BC Sno-Ghost]

I'm torn. Help me out. I've got a 2004 Rev Summit X 800. I've got about 4500 kms on it now and it's still running strong. Rest of the sled is in great shape. Had my mechanic take a look at the pistons prior to last years start and he said the pistons are showing some bluing but I should be OK for awhile, at least another season. Compression is about 140 each side. I'm trying to decide if I should do the top end, do the entire motor or sell it and buy a bit newer. I guess the other option is ride it until something lets go but I hate wrecking Chit and being stuck out in the boonies somewhere. What do you gear-heads think?

 

[imdoo'n]

replace the pistons and ride the beotch like ya stole it. do a rktech top end rebuild, you'll like it and real easy to do.

 

[BC Sno-Ghost]

Thanks Imdoo'n. I have sort of been leaning that way...to just do the top end with new double ring pistons. Lots of guys have told me it's easy to do but I've never torn into a sled engine. I have some mechanical knowledge but don't really have the proper tools so if I go this route I'll likely end up paying someone $1000 to do it for me.

 

[imdoo'n]

if i can doo it so can you, parts and supplies would cost less than a grand, ya can take your time and save a few $$ and put toward gas. real easy, drain antifreeze, pull exhaust, take off head, exhaust manifold flanges(can be a pain) take off cylinders, do an inspection, repair as necessary(140 psi you should be good to go) and start putting on new parts, watch for piston pin bearings, get caged bearings. 160 hp +/- you will love it. oh check crankrunout.

 

[BC Sno-Ghost]

You make it sound so Dam easy! I may have to take a closer look.

 

[imdoo'n]

just take your time get a manual online $10 and start. not that hard, just be carefull.

you can get parts direct from rktech. or ask around at shops for a price. but you can order and maybe leave some $ in your pocket.

 

[takethebounce]

Even with the good compression its still a good time to do the top end. As the rings wear you will get some piston slop and start to wear the sides a bit.

The only real specialty tools the average guy might not have is a torque wrench. Anyone who wrenches on a sled should have one though. Get yourself a copy of the shop manual (can be found online for free) and have a look at the process. Its fairly straight forward. You will need a new top end gasket kit to go with the piston/rings and caged bearings.

If the chassis is in good shape and you are happy with the sled, go for it. As imdoo'n said, also check the crank run out.(or have someone do it for you) If the crank run out is questionable might as well pick up a new short block which has everything except the head. Don't quote my on the price as I haven't priced out a HO block in awhile but I believe I saw prices as low as $2200-2400 with a core being thrown around on the forums last year.

If you have "Rowdy" take in the core and flash some cleavage they may even swap over the stator, head, oil pump and everything else for free!

I saw imadoo'n posted up thre $10 price for the manual while I was likely typing....here is the link to download the free manual.

http://chadt.us/manuals/index.php?option=com_docman&Itemid=57

 

[X-it]

We have 3 2004 revs, a lot more than 4500k's on them with no problems except for mine. A piece if the crank broke off and went through the block and toasted everything. I went with a rebuild and now on a second rebuild, lots of vibration on the second rebuild so far. All the other guys 800 are running great. I have seen some brand new 800 on kijiji for around 3500 dollars and that comes with new stator, rewinds, reeds....hell everything. I would just keep riding yours, more than likely your stator or reeds or rewind will go before your motor does and that is over a 1000 bucks. Pickup a new one, sell yours the end cost about 2000. But you will have to search around before you find one.

 

[BC Sno-Ghost]

Thanks Takethebounce and X-it. I'm gonna bring up the manual on-line and check it out. I have a torque wrench so now I'm gettin nervous!
I can get a fully rebuilt from Bombardier for about $2300 plus taxes. Installation is over and above that. Full rebuild I've been quoted $2000 plus taxes. That's with dual ring pistons and a rebuilt crank.

 

[X-it]

Here is close to one SKIDOO ROTAX 800R ENGINE/MOTOR BRAND NEW 2011 PTEC XP | eBay

 

[magnet]

Here is close to one SKIDOO ROTAX 800R ENGINE/MOTOR BRAND NEW 2011 PTEC XP | eBay

funny how your both in pg... lol
my recomendation to you fernie would unltimatly depend on what you would want to sell your 04 for?

 

[X-it]

Yep sure is....although i have never been at that place before. Although i should he has lots of atc parts. The ptec motor will not work in the 2004 though...i think.

 

[X-it]

I would be willing to bet his intake socket and reeds are gone though. 500 bucks in parts.

 

[X-it]

He has lots of engines. http://stores.ebay.ca/PG-Parts-RECR...b=12910261&_sid=8322196&_trksid=p4634.c0.m322

 

[imdoo'n]

hmm, not sure why bc ghost has to replace the motor, why not just put in a new topend, (brp pistons in an 04 where not the greatest). his motor is still good, just do a couple of checks for runout etc. if the motor goes south then i'd replace, otherwise freshen topend, put the money you guys want him tospend back in the pocket.


bc ghost ya can do what you like, but the 04 motor is a good one, freshin the topend, and ride the sled. you will be no further ahead with a new motor or a 800r. i tell it like it is(have an 04800 going strong) ya can do it yourself, just take your time, these other guys have no idea.

 

[tex78]

do what i did ..... i have a 04 rev chassis.... i put in a 800r with ecm and harness and track..... new style power and old style ride... I love it....


mine was a 04 600ho with a 144 before.... bought a bent up front sled and took everything i need out....
now its a 07 800r 151 x 2.33 track .... just with a 04 tunnel , front end....

 

[imdoo'n]

do what i did ..... i have a 04 rev chassis.... i put in a 800r with ecm and harness and track..... new style power and old style ride... I love it....

jeff get with the program!!! his motor right now is fine, i'm sure he doesn't want the change over head ache. he's still unsure if he can do it himself, and you already blew your F motor, give the guy a break.

he is better off just replacing the top end, instead of all the bs he is hearing so far.


you guys need to quit getting backed up as this is what causes shitty ideas.

 

[Veedy]

Love that REV chassis, I miss my hornet. If your selling it, I might be interested ... 4500k... that's it ??

 

[BC Sno-Ghost]

Thanks everyone for their advice. I do appreciate the different angles and each one is food for thought. I do have to agree however with Imdoo'n. If my pocket was bottomless then I'd probably replace the whole motor, but being a 2004 I don't think it's worth putting that kind of money into...even though the rest of the sled is in great shape. I'm kinda leaning towards a new set of Wiseco dual ring pistons and check the crank. Hoping to stay around $1000. I get out about 25 times a year but I don't ride like I stole the thing so the big HP increase is not an issue for me. I just want 800cc power and reliability.

 

[BC Sno-Ghost]

Thanks Veedy. I'll keep that in mind. Just out of interest, what are you running now that you don't like as well as the Rev Chassis?