Wyman Pond Racing

Pres · Tag Hgugr

RE: The rebirth of a WPR legend

Caboose · Bitch Rider

Correction,

Take your time, BC won 4-1.

#7

Caboose · Bitch Rider

Mr Critic,

I recommend that you pay those West Townsend leg breakers. Cause if BC doesn't win the National Championship tonight #4 is going ickybalookee on someone....

#7

Lame Member # 4

#5,

I think we will just take it back when you're done! You are not only a mechanic but a detective as well.

With the Poor Farm going out of business I think it's time for you and the Pres to make a charge at that business. Put the two of you behind the counter and the lines will soon be out the door again. What are you guys waiting for? This should be a no brainer.

#4

Johnny Rotten · WPR God

I should probably pay #3 for the sled here shouldn't I.

Need to get to the bank #3, will do it this week. Then I'll come pay you a visit.

#5

Johnny Rotten · WPR God

You all may be wondering why I am doing this work to a 17 year old 440 that has been "ridden hard and put away wet". The Prez has already posted how this sled is special, not only because of its rich WPR heritage, but also as a limited build factory race sled. He has challenged me to bring this sled back to its former glory. While you all know I like a clean machine, it is important to me that my machines function mechanically at 100%.

With the "X" designation model number, reading #1's media release materials describes this sled as having "composite" SLP skis as a factory option on the SP model. I laughed when I thought they were calling standard polaris steel skis with plastic ski skins composite. Ha! But alas, I was sorely mistaken.

The Prez sent me a post of the original skis. Tubular steel frame with a plastic ski beneath. Whoa, I had never seen anything like that on snow. This sled was meant to have these skis mounted under the IFS Extra front end... and now it will...

Johnny Rotten · WPR God

With the engine and front suspension out of the sled, it was time to degrease and inspect. I used an entire gallon of Purple Power and went through 6 toothbrushes (they get too gummed up to use after a while of heavy duty use). I have to say this ended up being a stroll down memory lane. As I continued to pull stuff out of the belly pan from every nook and cranny (like the English muffins), every time I thought I had it all more would come out where is this stuff coming from?!!?

Then, I started to recognize what some of these grease coated lumps were. They were organic. Plant material. I understood pulling the corn stalks wedged in, but this was different. Hmmm. As I pulled out what I could now make out as lily pads and seaweed, the memories of the nights of attempted pond crossings in the big field came flooding back! Some of the crossings were not full crossings, and I tried to recall ever having to pull the white 440 out of the drink.

I think I am at the farthest point of disassembly (except for the engine of course) at this point. The chassis is ready for cleaned, refurbished parts to be bolted back in place when they are ready. But Ill save the best parts for one last post here today.

Johnny Rotten · WPR God

Lots to report, but I'll start here. Upon contemplating that the top end of this engine was recently re-sleeved and yet no culprit, to my knowledge, was ever blamed for the problem. Combined with the fact that it is spring time and there are many months between now and when I will be able to ride this machine. I decided to borrow #2's leak down tester just because I know Polaris (Fuji) crank seals are suspect in older machines.

Fast forward - the clutch side crank seal makes a wonderful bubble machine. So out came the engine. Many hours of degreaser and toothbrush and it looks pretty good and is ready for disassembly. Onto the front suspension.

Johnny Rotten · WPR God

One side of the IFS came apart without too much issue, the other side however was a different story. In the end, the bottom shock bolt needed to be hack-sawed and the head ground off to remove it. Once I had the shocks off, the Prez tells me that when you push down on a shock it should slowly return to the extended position. One made a gurgling noise and need help at several points, and the other just sat there plunged in. Ok, so between a lack of lubrication of the pivot points and the condition of the shocks, I knew the rear suspension needed to come out.

I did feel like a geologist of sorts when disassembling the rear skid. Why a geologist? While I was thankful for the evidence that grease was used regularly on most of the grease points, it was interesting to see the different types and colors that were used year after year. I saw white, red, gray, black - all of differing states of hardness. The rear arm shock was covered with moist grime which is a tell-tale sign of a fluid leak and although the seal will need to be replaced, the shock itself seems to be in reasonably well working order. All of the shafts are pitted and will need to be replaced as well. (an ounce of prevention is worth a pound of cure boys! coat them with oil in the spring every time)

The time had come, the rubber sleeve that covers the front arm shock was cut/torn in a couple places, wasn't sure what could cause that, this is until I got it off the shock. When I hammered the bolt out of the mounts and pulled the shock from the frame I grabbled the cover and pulled, and when the cover came off the shock rod/piston assembly came with it, and a pile of dry red powder fell onto the floor. That would be what should have been fluid. Ugh.

Words cant describe so see the pic below. I fear the shock body ID is too corroded and they will not rebuild the shock. The shaft is also bent. I hope they will be able to rebuild this shock or I will be able to find a suitable replacement. This is the most important shock to the ride of the skid.

Finally, one of the skid rail mounting holes is hogged out (at the front arm lower mount) and the other has a crack at one of the cross member mounting points. I will see if the fab/snowmobiler guy will do some welding for me.

-- Edited by Johnny Rotten on Monday 2nd of April 2012 04:22:51 PM

Pres · Tag Hgugr

The snoGoer article below tell the whole story....the x signify the late release of the special edition race sled. They were reserved for qualified racers only. If you go to any parts diagram site like Ronnie's you will see 2 xcr440 and will notice the part # changes in the rear skid and front steering....... Also, this sled produce 85hp From the xcr history page 1995 XCR-440 SP Long travel was definitely needed, but handling and cornering were also a big factor in a snowmobiles use too, especially on the race circuits. With their latest SP, Polaris gave the best of both worlds to the sled buying public. Xtra-10 handled more like the nimble XC-101 of the old XCR, yet allowed the big bumps to be swallowed with ease. A massive engine overhaul [including Nicasil lined cylinders and 34mm carbs] also made this the fastest XCR-440 yet. Liquid cooled 432cc twin Fuji powerplant w/34mm carbs. Fox shocks all around with Xtra-10 front and rear suspensions. Nicasil cylinder coating, SLP plastic skis, and a new 3 piece exhaust system. Pictured above is the production 1996 XCR-440 which was visually the same as the limited release 1995 SP version. 1995 also produced two significant sleds from both Arctic Cat and Skidoo that would force Polaris to change the direction of the XCR, a change that many found to be in the wrong direction.

Johnny Rotten · WPR God

Although some light is being shed, we have a bit more research to do. Now equipped with the manual for all 85-95 Polaris sleds (thanks #2!) I was able to confirm the serial number that this is indeed a model year 1995. However, there is still an interesting twist. The model number designation chart in the manual starts with a "0" and this sled model number starts with an "X". So I wonder if this is a special build or something, here's why...

In the suspension section it says this sled has a suspension type "XC-101". Other sleds are listed in the same chart as having type "XTRA". When I look at the diagrams of the "XTRA" suspension it is the type where the front shock tilts to the rear of the sled and is connected to the rear arm and not the front arm. I believe they are referring to the "extra-12". It is listed for the XLT and the RXL which I seem to remember having this suspention. Didn't #4 have this sled?

The suspension in this sled has the traditional configuration with the front shock tilting forward and is attached to the front arm. No where in the chart is listed a type "Extra-10". In the text of the type "XC-100" suspension adjustments, they refer to ITS and XCR suspensions saying this type combines the best of both of those. No where does it mention type "XC-101" but perhaps they are basically the same. This sled does have the optional wheel kit assembly installed (2 additional bogies mounted toward the front of the skid rails).

This is fun homework.

#5

Pres · Tag Hgugr

If you have the rack then you have an extra 10.

# 2

Pres · Tag Hgugr

a Nice write up.....

-- Edited by Pres on Thursday 22nd of March 2012 06:10:07 PM

Caboose · Bitch Rider

Sweet ride. I'm sure the boys will enjoy the hell out of it.

Johnny Rotten · WPR God

I was sent an interesting post (thx #2) where the exact same model no. X951660 and date of mfg. 0101994 were used to describe a 1995 XCR440 Special. However, it was described as having rack steering, Extra 10 rear susp and stock plastic skis.

Do you know what year this sled is? I believe this has the rack steering but I have to do more research to know if this is the Extra 10 rear susp (there are no decals on the tunnel and does not have plastic skis.

I supose I can give a dealer the serial no. to find out. Just thought some input from the owner would be good, #3 couldn't really recall the year.

Was this sled raced by Poor Farm? I hope so! What a heritage!!

#5

Johnny Rotten · WPR God

Yes of course, a picture is worth a thousand words. So to save 2,000 words here's a couple pics.

Looks good don't it??!

#5

Pres · Tag Hgugr

How about some pictures.....Nice update...Keep them coming

Johnny Rotten · WPR God

Well the little white knight was cleaned up this weekend, this is a specialty of #5 as everyone knows, I can't help myself even when it is snow on the machine, I am always cleaning. I'm happy to report the sticky stuff washed away quite easily but I can't say the same for the CONCRETE SPLATTERED all over the machine! #3 or #4 you must be publicly reprimanded for this unwanton mistreatment of a snow machine. More care should have been taken to move a snowmobile away from the construction site. Shame shame. But the white hood came nice and clean and looks fantastic-I really like the decal design they did on this sled.

Anyway, moving on, the engine compartment was degreased, carbs removed, cleaned thoroughly and reinstalled. Fresh fuel was added to the tank. I was very pleased to HEAR THE 440 KICK INTO LIFE. Although started at the hottest point of a 70 degree day, I will assign the sluggish throttle response to the jetting being all wrong, and hopefully this will remedy itself for the colder temps the engine is calibrated to run in. What a nice sporty snap this engine produces.

The front suspension on the left side took the brunt of the neglect (this must have been the side facing the street or something). The sway bar link and steering arm tie rod ends are frozen solid on that side. They will most likely need to be replaced, but everything else looks to be in reasonably functioning order. There is some corrosion on the front left ski shock rod. I know it should really be replaced, I am undecided whether to have the shocks oil changed or not. If I do, then I will have the rod replaced. I snapped the bolts on the runners since they need to be replaced. I am undecided on leaving the ski skins on or not. I have 1 easy steer, would the installation of these make a significant difference for a kid to steer this sled?

I was elated to find that the track tensioning nuts and bolts spun free without any effort. The front most left rear suspension idler wheel mount is very loose, I am hoping simply tightening that back up won't be an issue. I will need to pull the rear suspension out in order to fully inspect the front skid shock. It will be good to fully lube the rear skid and check the slides.

The brake lever feels tight, maybe will become smoother with use, but may need a flush and piston cleaning. But overall the machine looks to be in perfectly workable order. The seat is not a mechanical issue, more of a cosmetic one, but it will absorb water if snowing or raining. If I do have the seat repaired, I will only replace the top/center panel because I love the crossed flags & Polaris XCR logo on the sides-adds so much to the look of the sled I think.

So that was the big news, hearing the little mill breath in and out. This was important to me so that I can work in peace throughout the off season. More diagnostics and fiddling to come, stay tuned!

#5

-- Edited by Johnny Rotten on Monday 19th of March 2012 01:26:34 PM

Johnny Rotten · WPR God

There is sits, in the corner of my garage, dirty, sticky (I have no idea what that is???), rusty, and in need of some significant TLC. The heart of the legendary sled I'm told is fresh and new - not even yet broken in. I can see the new sneaker fully studded and ready to throw some snow. I am giddy with excitement as I still love the look of the white hood on that classic Indy chassis. We have already had "the talk", and it will soon come to understand the meaning behind my commitment.

XCR440 Rejuvination Project

One-guy garage is back in business! Although this project will not come near the extent of the Indy 500 project, it will be undertaken with the same rigor and thoroughness for those aspects that require attention.

Check back often to see pictures and read the harrying accounts that this project will surely provide. I am energized by the idea that just as I passed on the fallen legendary Enticer on to the next generation of rider to be reconstituted and riden again - I wholeheartedly begin to restore this legend back to its former glory for my next generation riders.

It will be a great day to hear that mill roar to life again, and then I will properly put it into summer storage for that long awaited moment next season to rip down the trail!!! I can't wait for next year.

#5