Wyman Pond Racing

I would go -10 on the left side only,  aka enticer

2

the lower radius rods for this sled are out of production, so I ordered ones that are as close as I could find.  I also needed a new tie rod end for the torsion bar that broke (I transferred the steering arm one that matched and will replace with a new on the steering arm).

I am hoping they come in with time enough to test if the clutching problem was the cause of the bogging issue after all.  It is flurrying so I am hopeful.

#5

This post was bound to come at some point.  The XCR had a day to forget on the trails this weekend.  #19 learned first hand the price of riding old machinery.  The XCR chassis is showing it's age.  But first things first.  While it was widely believed that the bogging issue the 440 was experiencing was due to an overheating engine - the Pres has injected the possibility of clutching problems into the mix.  The primary was serviced by the dealership before the season so I am counting that out for now.  However, in a mind-boggling surprise in total un-5-like fashion, I did not disassemble, clean, inspect and refurb the secondary before popping back into the machine.

Adding to the calling into question what the problem actually going on is the fact that the TEMP light has been confirmed as working, which correlates to riding in low snow conditions and yet, no TEMP light coming on at all while this problem exists.  So, this began a riding-troubleshooting analysis to hunt for clutching possibility.  There were some inconsistencies in bogging from a stand still when we could stop and see that the belt was returned to the top in the secondary.  so that doesn't jive, but there were definately correlations between higher speeds and engine revving up when it would be assumed the clutch would be shifted out.  So the question became is this thing not back-shifting.

I have disassembled the secondary and there is a thick, sticky, old grease or something which is coating every sliding surface severely inhibiting motion between the sheaves.  This is very suspect!  From the effort it took to slide the sheaves relative to each other, I believe it is entirely possible the clutch would resist sliding while in operation.  This will be cleaned and reassembled to see if it makes any difference.  Remember the old law: 90% of carberator issues are clutching (so yes, we may need to expand the law to include suspected "overheating" issues).

Onto the chassis, the XCR actually left a rider stranded and needed to be abandoned trailside.  While trying to nurse the bogging engine, it occured to me that all of the engine problems started when I decided to get on the machine.  So I put #19 back on the machine and he seemed to be able to manage with less of a problem (we agreed it was related to the extra weight the little 440 needed to overcome with the full size WPR riders.

So while riding behind I noticed the left front suspension splayed out at a wicked angle.  This didn't look right.  I couldn't believe I had missed that kind of an adjustment.  The ski was on a severe angle to the snow.  Something was amis.  Just then, #19 looked down and pulled to the side of the trail.  As I pulled along side, I could see the torsion bar link was snapped and the trailing arm practically falling off.  Upon close inspection, the lower radius rod had, get this, pulled out of the (inner) tie rod end.  Ya, I know, I wouldn't believe me either if I was reading this!

Well, this write up is long enough.  We did a battle field dressing using a tow strap and limped the sled to the nearing road side and left it.  I doubled the kinder back through the studder bumps for about 10 miles or so.  That stunk.  But we retrieved the machine by trailer right where we left it.  I have pulled it apart and it is not pretty.  I am now on the lookout for replacement lower radius rods.  Rods, you say?  Plural?  Yes, this is where my disease takes it's toll.  So I figure hell if one side is rotted out the other is bound to be right behind it, and that lower radius arm was already bent anyway so why don't I just replace both while I'm disassembled right?  snap.  the right hand tie rod end snapped while trying to remove the bent rod.  I got the tie rod end off the original side but now can't get the "preventative" side off.  Used heat and penetrating oil.  So now the game of who is more stubborn, the answer is me.  So I'll update when I get it free.  While I order the new lower radius rods and tie rod ends, I will clean and reassemble the driven pulley.

Pres, while doing the work, I found I have the exact same problem you have when you "kicked the tire" on the rear trailing arm bolt of the yamaha at our break.  Every rivet is barely hanging on in the pivot bolt bracket.  So I will discuss procedure with you to remedy this.  It appears the misery of the 500 project has faded too much.  I am painfully reminded why I don't f around with old beat up chassis any more.  This is a young man's game.

As flurries gently fall outside as I write this, I wonder if the 440 will back together in time to test the clutch/engine issue before the season is done.  I'm sure it can be, just a matter of not sleeping.

#5

#5, I am a little disappointed with your last post.  Frankly, it lacks the enthusiasm that I have come to expect when discussing this particular project.  

The park across the street is still holding it's snow.  I would love to see the white sled zip across some very familiar terrian.  Any chance you could bring it by this evening and we could put it through a few test trails?  I know the moon will be at a waning crescent and that may not be ideal.  I would be happy to light up the area with my lamp.  You really need to get this sorted out.  What do you say?  Let's go.

Dr. 3

Happy to put up a ride report which includes a sled that hasn't been part of a ride report for some time.  Riding around in the yard at my house doesn't actually constitute an official ride report, but since over 10 miles were logged in the little riding area, and it seems appropriate that this post culminate with a story of the sled running, here it is.

Snow was finally on the ground, so the effort was put in to shovel off the trailer, and unload the XCR for its shakedown run.  I can't even write about how many pulls it took to get the engine running because my arms are still too tired.  I'm guessing close to 200 pulls.  I don't know why.  It wanted to start,  but wouldn't stay running.  Strong blue spark, smell of fuel, I'm writing it off as tight engine, stone cold with some condensation perhaps in the tank, extra oil in the fuel, old fuel mixed with 87.  I believe they said the standard fuel shim was in the head but I added premium to dilute the mix.

Anyway, it did start, took it around the house, it was night by this time and recall there is no headlight (still troubleshooting spiking voltage) so after a few laps we parked it in the backyard to wait for sunshine.  Sunday was just that and as you all know the snow has set up beautifully.  With about 30 laps on the sled is when the troubles began.  First I thought it was a combination of all of the suspect fuel issues listed previously combined with the low speed nature of riding in the yard.  but to lift the back the engine would clear,  but would not run above 5500rpm.  There was no TEMP light and I did not think this sled had the "safe mode" as early as 95.

After several plug inspections and belt swaps, there was nothing left to conclude, so I decided to let it cool completely.  Two hours later we got another 30 laps out of it until the same condition returned.  Another 2 hour rest and repeat.  I watched closely as the kids rode it around the yard and do believe that not enough snow (read: none) was being kicked up to cool the heat exchangers which, as any old Polaris guys know are outbound under the running boards where the feet go.  So I have concluded that this sled does in fact have the "safe mode" and since the TEMP light was not working, that fact saved the brand new engine. 

Steering was not heavy as expected with the aggressive carbides, the sled turned nice and easy.  Both 19 and 43 said the steering was good.  Notice from the pics this sled actually fits them both beautifully.  I didn't realize how much "bigger" the Edge chassis looked next to the older model.  The sleds were both trailered up again and I am ready to bring them somewhere we can open up the throttle a bit more.  19 was already applying throttle and looking for more room to get some speed - so this is very promising to bring him on a trail ride.  I think he is ready.  Even 43 is asking every day when he can ride the "white sled" again.  So I asked him if he is more interested in driving his own sled or still wants just to ride on the back.  With reservation, he says he wants to drive his own machine.  We'll see in time.

Enjoy the pics!

#5

Looks like I spoke to soon.  I went to load the XCR into the trailer ready for the season, and encountered two problems.  The first is that when I applied throttle to drive the sled into the trailer, it would not budge.  the clutch engaged and I could feel the chassis flex trying to move forward but it would not budge.  I smelled burning belt and backed off.  Back in the garage with the track up in the air I could rotate the driven clutch and track.  I had also done track alignment without trouble so I know the driveline is working.  There is a fair amount of resistence but this is normal for a snowmobile.  The only thing I can think of is the very sharp carbides were biting into the blacktop more than I would expect.  There is about 10" of an aggressive angle carbide on these SLP skis.  Maybe I will try again with wheels underneath the skis and see if that makes the difference.

The second issue was that when I revved up the engine it popped the headlamp.  The previous headlamp was popped as well.  #3, do you recall this happening?  Perhaps the voltage limiter is no good?  #2, would the tail lamps and dash lamps all pop if the voltage limiter was bad?  Or would it just be the high voltage that would be more susceptible?

The setbacks are disappointing but will be overcome, just to be sure, I pulled out the XC to do its pre-season prep (i.e. clean exhaust valves).  Came right to life.  Listening to the two sleds side by each, I couldn't believe how much snappier and louder the 440 was.  The super quiet exhaust on the 600 is heavy but it really works!

#5

#5,  Don't forget to get a new scratch free shield for the wedge helmet.  Dennis kirk sells them.  Classic.

I'm glad you asked!!!!!  Attached please find pictures of a RUNNING XCR 440 SP.  This machine is ready for the trail.  We need snow!!  I am so jacked up to ride this thing - in fact, #19 better show me superb grades or else I will have two sleds this year.

I'd like to get a pulse on how the attending members for the trip this year would feel about me using this sled instead of my '01?  It is a fresh motor and all mechanical parts are in A1 working order.  All fluids topped up.

Enjoy the pics.  Note the exhaust in the one of the front susp.  Also note the lit up headlight (new bulb btw) in the head on view.  #3, was the green ACC light in the dash ever hooked up?  I will need to run a wire from the hand warmers if I want this to light up.  I have nothing else to do so I just might!  Yeaahhahhh!!!

Also, I was advised to run premium fuel in this puppy as well.  Something was mentioned to me about a head shim installed and it was left in place so I'm interpreting that as high octane fuel is not a requirement but will enhance performance.  He kept telling me not to hold it open across a lake.  Which I never do anyway.

I am officially in the break-in period.  How long does that last?  One tank of fuel?

#5

A very important update: I have included two versions, one for those that do not have a lot of time, and one for those who find this stuff important.

Short version:  the 440 has been started and purrs like a star.

#5 version: Although I am still waiting for the final few parts to come in for the rear suspension, I could not wait another day to hear the engine which was ready to roll.  I waited patiently for #19 to get home, I would not rob him of this very anticipated moment.  When he arrived I didn't even allow him to go inside.  I was in the garage waiting.

I double checked everything to be sure all systems were in a ready state.  At the advice of the Pres and the dealer, the vent lever of the cooling pressure cap was in the lifted position.  Several pulls gave a sputter and a cough but no life.  This is only a 440cc engine but with all new top end parts, it is TIGHT, making a heavy pull start.  I like.

I don't want to wear myself out so we just confirm spark.  Blue and fat.  We can smell raw fuel and #19 notices a drop come from the exhaust port, it is fuel so we know fuel is entering the cylinder.  Long(er) story short, I had cleaned the carbs thoroughly in the spring when I took delivery of the sled before starting the engine.  But upon discovering the engine would be pulled I had removed the carbs and they had rested on their side all summer long.  By being on their side they should have been fully drained so I didn't bother taking them apart again, but gas is so crappy now, and I had not added new fuel to the machine, so I needed to be sure the pilot jet was not the culprit.

So apart came the carb bowls and a quick check and blast of gumout through each, they were clear but now my mind was at ease.  Reassemble with the same exact symptomps.  Cough sputter, nothing.  I said to #19 this is bad gas and we just need to move it through to let the fresh gas enter the system and she'll fire right up.  He looked at me and said you look like a mad man pulling this thing over as he held the machine in place with my violent pulling.

After about 50 pulls the coughing turned into an engine just dying to come to life.  A few more pulls and it was time to feather the throttle to get 5-10 seconds of run.  Each pull now lengthened the run time.  At last a pull had the machine smoking like the camel.  #19's face lit up.  Knuckle mash.  Priceless. 

We filled the garage with old fuel, extra oil, engine assembly oil and dust burning off as the little white 440 breathed in and out settling down and achieving a regular idle.  Could not rev the engine too much to engage the clutch as, again, there is no rear skid in.  That would be ugly.

I learned that I did not need to replace the key becuase the switch is disconnect as it is run parallel with the tether switch which is not in use.  Oh well, it's a visual deterrent now.

The sled looks even better in my eyes now that I know it runs.  Starts in half a pull when warm.  Same Polaris starting dance required of all their engines.  A pain but at least I know the dance.

Getting so close now..

#5

Seller's remorse is evident.  #5 will treat it right. These sites call that little white sled a classic.  

http://vintagesleds.com/bs/index.php?topic=59824.0

http://www.snowmobilefanatics.com/forum/topic/35845-xcr-440-owners

#7

#5,

I guess 800 horse power with a top speed of 220mph!  

#4

#7, you are correct - a BB Bold.  Why is there a defective camera in those?  The pics seem to be getting worse with time.

#388, you are incorrect - I don't own a single Apple product.  I am getting ready to purchase an MP3 player at a fraction of the cost of an iPod.  I can't stand Apple's stupid delivery method through iTunes.  If I buy a piece of music, it's mine, I should be able to keep the music on any computer I want.  I can't even use iTunes anymore because version 10 won't load for me.  Now they're on 11.  Forget it!

#5