Sled rebuild help.

[Andrew.L]

Hey there everyone.

so I have new pistons and such to install in my sled.
2012 Polaris RMK Pro 800.
I have never done a engine repair before. Only my dirt bikes and such.

Just wondering if anyone has a video for some help and guidance?
OR has a free afternoon and wants to come over and help a guy out.
The beer is cold and the pizza joint is around the corner haha.

Thanks everyone,

Andrew

 

[Vance Matheson]

Type "dragon saver" in youtube they make rebuild kits from 08 to 15. The video is not on a pro but the rebuild is very simular. Part 1 and 2

I found the rebuilds to be easier than a dirtbike just because you dont have to deal with the gearbox or wet clutch.

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[Vance Matheson]

Heres a link to my service manual if you dont already have one.

https://www.dropbox.com/s/9bi3p410tq671xj/polaris pro service manual 11-12.pdf?dl=0

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[Octanee]

Are you just doing pistons or a crank as well? It's pretty similar to a 2 stroke dirtbike just that you have 2 pistons as to 1, when putting it together it helps to have a buddy help support the cylinders as you both feed the pistons and rings in the cylinders. I just bought and overhauled a pro rmk engine, crank and pistons, To get the cylinders off you take the whole upper frame off and exhaust, leave the Y pipes on, Disconnect the fuel line hoses, (you will need a fuel injection hose disconnect tool) and disconnect the 1 main plug for the injectors, take off the coolant hose/s from the head and just work top down basically... however do drain coolant out from the bottom hose as you do need the coolant level down below the cylinders otherwise you'll get a big mess.

 

[kgb117]

i'll be rebuilding my 2012 rmk in the spring too! thanks for the service manual Vance. Octanee, do you have to remove the upper frame if you're only doing the pistons?

 

[Vance Matheson]

Theres a little trick to getting the fuel lines off. So you dont have to go buy a special tool. They changed this in 2013. I will look for the video and post it.

The over structure has to come off to lift the cylinders up.

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[Vance Matheson]

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[Octanee]

i'll be rebuilding my 2012 rmk in the spring too! thanks for the service manual Vance. Octanee, do you have to remove the upper frame if you're only doing the pistons?

Yes, It's really not that big of a deal to remove it and it lets you get at the engine from the top with room.

 

[Chrisco]

We never pull the upper frame off, and there is also no reason to remove the fuel lines as well. Just unbolt the fuel rail..... and remove the pto side exhaust valve and the cylinder will slide right off. We also remove the Y pipe.