Wyman Pond Racing

There should be 2 blocks in front and 2 in the rear....4 total.  If you have the rear ones missing you will have maximum transfer and the skis should point to the sky...didn't #3 like to wheely?

Great updates. The pictures are terribly out of focus. Blackberry bold... perhaps? 

Keep the updates coming. It's like snowmobile soap opera.  I realize it's just an old sled, but I need to know what happens next.

#7

I was a naughty boy last night, I blew off my school work to reassemble the rear skid.  I can't help it - getting so close now!!!  I had myself double convinced that although it has been a long time since I've put together a rear suspension from scratch, I thought it would come back.  It didn't.  I also didn't help that this is an "X" model and therefore this suspension is not in the standard manuals.  So with #19 at my side, we began on a long and strange journey.  I told not to get mad at me because we will almost undoubtedly need to take things apart more than once as we discover we assembled in the wrong order.  He promised.  And we did.  In fact, he had to go to bed before I actually figured out the correct way the coupling link worked.  The piece is actually reversed on this assembly compared ALL of the other models shown in the manual.

I think like the newer clutch model that they put on, they also put the newest (at the time) suspension in.  This skid is basically the same skid that's in my XC, essentially.  In fact, I think it's called XC-101 (the newest susp model in the manual is XC-100).  Which leads me to a question for #3.  When I did inventory and ordered all the little parts I needed I ordered to new stop blocks, these are the black plastic block that limit motion of the lower rear arm having to do with how much transfer is desired.  well the guy told me there are 4 in the schematic, but I only have two (and now I can't remember if they were in front or in back.  Use the photo below for reference, or take a peek at your XC and you'll see what I'm talking about.

So I used the age old method on looking for wear marks to determine where things where.  The puzzling thing to me was, and you can clearly see from the pic, that there are wear marks both in front and behind the arm.  So...  #3, were there front and rear blocks and you removed two?  If so, why?  Was the ride better?  Do you still have the others?  I am thinking I need to order two additional assemblies now (block, insert, bolt, nut) to get back to original.  Any feedback is appreciated.

The other odd thing was the lower rear shock both seems too short????  Only engages 2-3 threads, not good enough.  Weird because the upper bolt seems too long - AND NO THEY ARE NOT REVERSED!!

Almost ready to reinstall.  Then will come tensioning and alignment.  I added a quart of oil to the gas tank - which to answer your question requires no special fuel.  Standard pump grade 87 will be used.  One of the reasons Lee, the Polaris legend who has rebuilt one or two of these motors, guessed that the sled was run without the foam element intalled on the airbox and water injestion washed the front of the pistons which would result in the scoring seen right where the intake is exposed.  I had a hard time believing that until I remember #3 handed me a box separate from the sled and the foam element was in it.  Hmmmm.  A learning moment perhaps.

It was great to see snow on the ground as we worked on the sled.  I gave it a little pep talk.  Telling it "your time is coming.........."

#5

Please remind me.  Who is #10?  Do we really have that many members?

Fire it up!

#4

Nice work gentlemen. I hope the snow falls soon.

My buddy from work said he just got 3" of snow in the Burlington, VT area. Don't ask how he commutes 211 miles.

I'm curious about where there's snow right now and if the Diamond Pond area will be open Dec 15th.

My guess is that the new sled and fixed sleds will have the itch head north sometime in the next few weeks.

Here's hoping....

#7 

Next up is the rear skid.  All of the parts have been wiped down and some have been prepped with scotch brite and grease.  We have called up the schematic we will use to reassemble.  Shocks are fitted with bushings and staged up.

I have provided a picture of the step that will slow us down, the grinding flat, locating and drilling of 3 mounting holes in the skid rails.  I didn't show in the pic but some of the hardware must be reinstalled to the rail that was removed during the welding operation.

The rear susupension will be a fun final project because it is worked on out in the open.  Then the black art of reinstalling into the chassis.  Always tons of endless fun.  #19 will tell me he has figured it out at least 10 times during the process.  I look forward to his misplaced enthusiasm.  We all had to walk that path in our pasts.

I'd like to give a shout of thanks to the Pres for the use of his lift - it was a pleasure working at a comfortable standing height to do the front susp and engine compartment.  Excellent device.

Now I need to see the bets of the 1st snowfall pool so I can plan when I need to be finished to take the first test run on this machine.  What states do I need to register it for?  When is the first trip to #6's property?  I will be ready.  Actually, my sled could probably use some TLC...

#5

Day 2:

This was a big day.  The High Performance 440 Twin was mated back to its plate, new engine mounts installed and the mill was lovingly placed back into its cradle.  All necessary cooling hoses and electrical connections fitted.  Filled oil reservoir and bled oil pump.  Filled coolant but cannot find bleed screw - think it might be on water pump, but I'll have to remove cover to get back to that.  Do some homework to find this as this pump doesn't look like the one shown in the manuals.  

Next mounted carbs and air box.  Installed ignition switch and choke in dashboard.  Routed throttle and vent lines up to handle bars.  Installed driven clutch and belt.  Installed exhaust system.

Oh, and installed new amber and red reflectors, very important - safety first.

The engine compartment looks ready for a cover.

Stage pic attached.

Well if that's true - then I just got a HUUUUUGE blessing, just picked up the motor from the shop.  Ouch, still can't sit down.  The good news is I should have a little time over the T-day break to make some progress on this sled.

The bad part is they created another project for me.  They welded up the holes in the rails completely - both sides, so now I don't know where the hole belongs.  I don't know how to figure it out either.  ???  This is very regrettable.

Anyway, pics will soon return as assembly gets underway.  Can't wait to see those skis on this sled.

#5

Why does this keep happening to me?  Am I digging too deep?  I suppose it is why this year I will ride a 12 year old machine with confidence.

The 440 Special engine was dropped off at Performance Cycles in Shrewsbury.  After several hours of coaxing (and building a custom puller) the clutch was removed from the crankshaft.  The mag was also pulled using a special double-secret Polaris mag puller tool which is only available to authorized Polaris dealerships.  I have no idea if that's true, I'm just saying it to make myself feel better.  But I did see it and it was definately special, not like mine.

Case split.  Crank seals are replaced.  Crank main bearings passed inspection.  Case reassembled.  On to the top end.

I would advise that whomever did the last round of work not be used again for future machines that any of us will ride with.  If I understood the original story that was told to me, it was that the correct NiCaSil cylinder body that is used on the 440 Special motor could not be located so a standard 440 cylinder body was substituted.  This does not appear to be the case, further research is being conducted, but the standard 440 cylinder (which is a slightly smaller bore) was cast iron sleeve and not available in NiCaSil.

What appears to be the case, is that the oversize pistons for this motor could not be located by the previous repairman, and so...  get this... standard pistons were used.  Yep, you heard (read) me right, the wrong pistons appear to have been used.  That would explain their strange scoring on such new pistons.

Nothing more money won't fix.  So now new correct pistons, which according to the dealership, there are only a few in the country, were ordered and are on their way.  At this point, I have paid more for the engine repair than I did for the sled.  There was no alternative, this engine would have failed comprehensively.  The good news is, the engine will be brought back to its correct XCR 440 Special configuration.  When I pick it up, it will be in drop in condition.

The skid rails are also being weld repaired at the front arm lower mounting points (recall one side was badly enlongated and the other side was cracked).

If anyone but me, or someone specifically authorized by me crashes this sled into a tree, there will be hell to pay.

A costly update, but progress just the same.  Once the rails are returned reassembly of the rear skid will resume.  I need to find/use some assembly drawings on putting this back together since it's been apart so long.  I think I can handle the front end (the curved part of the ski goes in front right?!?!)

No pics this time, but reassembly will definately be heart warming.

#5

I will submit my installment a day early:  Nada.

Oh wait, yes that's right, there is a thick yellow coating of pollen on every part and chassis of the 440.  That's what's changed since my last post.

Jagger lied, Time is NOT on my side!

I haven't even opened up the box with the refurbished shocks.  It will happen, I have reverted to Just In Time (JIT) planning for this project.  So with this change - I am way ahead of schedule!

#5

#13,

Just waiting for these guys to start backing out of the Lime Rock trip now that they know you booked a site.  Should be just a matter of time.  It will be no big surprise when the old "something suddenly came up" starts to echo throughout the group.  You will have nobody to share that six pack of Keystone light you're planning on bringing, as well as,  the eight hot dogs you had such a hard time buying for the event.  Have a great time with yourself.

#4

Nope, not trapped under the sled (but thanks for thinking of me).  Been busy out securing new funding for the program.  That done, I can give an update:

The clutch is still a P-85 but evidently they made a revision to the hub of the fixed sheave to beef it up and this revised clutch was never meant to go on a 1995 sled, so there is no puller that will work with this clutch on this motor.  Fiddlesticks!  The clutch must come off in order to change the PTO side crank seal which if you will recall likes to blow bubbles (and top ends).  It does no good to fix, or believe this top end will last with this air leak.

So I have one of two choices at this point.  Find a local fabricator to modify the puller I purchased to work on this bastardized setup.  Or hand the motor and a credit card with a signed blank slip to the Polaris dealership and let them do it.  Given the lack of time I now have in my life, I think it will be the latter or this sled will be sitting right where it is throughout the summer months.  That will not do.

I also can't budge the magneto/flywheel and have mushroomed out the tip of my puller trying so that will become their problem too.  Anything is possible with time and money.  Forget that, it just takes money.

The pistons in the engine currently have scoring on the skirts which may indicate this engine has already been temperature seized or else the guy who did the work put in used pistons.  Huh??  However, the cylinder walls look perfect to me so that's the good news.

I have the shocks back from DeyCore, they were not able to salvage the front skid shock body, it was too badly deteriorated, so that is replaced with a newer style plated shock body.  It will be covered by the shock sleeve anyway and not noticed.  Also, all four shafts were replaced new along with seal kits.  The ride should be nice.

So there are no new photos to share.  But progress is being made.  Need to drop the engine off possibly this week for the work to be done.  Then reassembly can begin.  This is a great project to remain excited about snowmobiling in the off season months.  I work with a woman who lives north of Caribou, ME and she said the season got off to a slow start but finished strong and riding was good.  They had just above average snowfall this year.  We should never doubt the riding is good up north.

#5