Did it again, bought another!!! '96 XLT RMK

[Nick_R_23]

Well now that Ive sold most of my stuff off to downsize a bit since I cant afford to ride everything, I was pretty set against buying anything else for a while. But Im sure you all know how that goes. Just a few days ago, I woke up, jumped on the computer, and started checking CL even though I had no intent on getting anything. I came across one of those ads that has very little description, titled "snowmachine projects", and expecting again one of those overpriced junkpiles that someone got bored with and became a lawn ornament.

Turned out it was a 1996 Polaris XLT RMK that the guy couldnt get to start, so he took the engine out and put it in his shed. It was about 95% complete, had 133.5x1.5" paddle track, Fox racing shocks, small riser, and plastic skis. The only things it was missing were the front shocks, windshield, and the ACCS parts. The guy wanted 150$ obo for it, so I thought Id be stupid not to go get it for that price. I ended up giving him 100$ for it and loaded it up later that night.

So far what it actually needs are the front shocks (know where a set is for 40$), key switch (missing the key), choke cable (lever was broke), few nuts/bolts/washers (pretty much a given on anything lol), seat cover (was a bit torn up), windshield (who knows where it went), and the ACCS parts (guy that works at the Polaris shop is giving me a deal on this).

The best part is that I cleaned out the carbs and kinda half-bolted the engine in place, sprayed some starting fluid in, gave it a pull and BAM!! fired right up first pull!!!!!! The end bearings on the crank are kinda worn, so the engine will be torn down, the crank have new bearings installed, the case drilled for another oil fitting, and a 4 line oil pump installed (which I also scored for free!! ). A common problem with these XLT engines was that the end bearing didnt get enough oil, so the 4 line pump and extra fitting help it get enough. Ill probably also re-ring it at least.

Id post pics but my camera is at the warranty place, I can get some cell phone pics if you all want.

-Nick

[Russell 350X]

Sounds sweet man, get us some pics.

[Nick_R_23]

Well I managed to get some cell phone pics. Right now it looks worse then it really is, since I took apart everything on it. I did get the rack welded (had a few cracks starting to form) and got it mounted.








Seat, tank, foam, exhaust


Engine cases


Crank


This is what was causing the rattle sounds


Bearing literally fell apart in my hands

The next 2 bearings in also feel a bit worn, so probably 4 bearings need to be replaced. Everything else looks really nice though. Polaris shop opens back up tomorrow so Ill be taking the engine up and having them take a look at it.

-Nick

[RedRider_AK]

Pretty sick. You will be able to spend the 600 dollars you saved to fill the machine up, oh, twice. Gas is getting insane nowadays.

[Russell 350X]

Same thing happened to my sled, bearing gave up, pricy fix.

[Nick_R_23]

Well almost 2 months later Ive gotten a lot done but still waiting on that effin crank, they havent even started working on it yet. But Ive fixed all the small things and except for putting the engine together again when I get the crank back, its ready to go!!

Things Ive done so far are:

Front shocks
'97 Carbs + Altitude compensator
New fuel/oil lines
New key switch
Throttle and choke cables
Unfroze rear clutch from shaft, cleaned and antiseized
Large style gauge conversion (still waiting on speedo)
Cleaned all the overspray that was on the cowling and rack off
Added a water temp gauge
Seat recovered
100W Xenon bulb -same one I run in my 250r, theyre insanely bright


Recovered seat


Larger gauges


Temp gauge, the mounting plate will be painted, it fits where the mesh usually goes on the left side of the cowling




gauge wiring


And finally the sensor for the gauge.

-Nick

[Russell 350X]

Lookin good man. How much is it gonna run you to get the motor fixed, and what mods are you doing?

[Nick_R_23]

Thanks!! The crank work is 400$, thats 4 bearings plus labor for splitting the crank and drilling the upper case for the oil line. I dont have any mods planned except what Ive already done (large gauges and temp gauge, and new style carbs), its pretty well set up right now. Maybe a bigger riser but I dont have anything I want to do engine wise.

-Nick

[honda250sx]

Next time send your crank to Northern Crankshaft. Best in the business. They can turn cranks around a hell of alot better than the joint your using. Been doing cranks 50 yrs. Good luck.

[Nick_R_23]

FINALLY!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! My crank got done today!!!!!! I have no idea what took so long since they usually get stuff done early, but I have it back now, it looks brand new again and Im more then ready to ride this thing!!

Biggest things I still need to get are spark plugs, gas cap, and exhaust gaskets, also still need a speedo and windshield but those arent as important. Other then those I can drop the engine in tomorrow and hopefully take it for a test ride soon. Im being lazy and assembling it in the basement since its way to cold outside.









Also the case drilled and fitting placed for the 4th oil line.

I did get the gauge panel painted and mounted but it was too dark for a pic. Looks exactly how I wanted it to come out though!!

-Nick

[Russell 350X]

Lookin good bro! Get some action pics when you test her out.

[Nick_R_23]

Last night I got the engine dropped in, hooked everything else up and BAM she runs!! Has a slight bog coming right off idle which I think is a mix between worn belt and one of the carbs is slighty off sync. Other then that it ripped across the yard pretty good. I need to find another expansion chamber, I dont know how I missed it before, but it has a crack going halfway around it!! Also has a small coolant leak due to the fact that I forgot to put some thread tape on the gauge sensor. Fires right up first pull every time, overall Im really happy with it. I just wish we had more snow so I could really go test it out!!!

Ill try for some pics tomorrow.

-Nick

[Russell 350X]

Sweet man, good to hear shes runnin. That oil line on the PTO side, is that fitted from the factory, or did you install it, or make it bigger than factory? I havent even looked at mine.

[edog]

Well now that Ive sold most of my stuff off to downsize a bit since I cant afford to ride everything, I was pretty set against buying anything else for a while. But Im sure you all know how that goes. Just a few days ago, I woke up, jumped on the computer, and started checking CL even though I had no intent on getting anything. I came across one of those ads that has very little description, titled "snowmachine projects", and expecting again one of those overpriced junkpiles that someone got bored with and became a lawn ornament.

Turned out it was a 1996 Polaris XLT RMK that the guy couldnt get to start, so he took the engine out and put it in his shed. It was about 95% complete, had 133.5x1.5" paddle track, Fox racing shocks, small riser, and plastic skis. The only things it was missing were the front shocks, windshield, and the ACCS parts. The guy wanted 150$ obo for it, so I thought Id be stupid not to go get it for that price. I ended up giving him 100$ for it and loaded it up later that night.

So far what it actually needs are the front shocks (know where a set is for 40$), key switch (missing the key), choke cable (lever was broke), few nuts/bolts/washers (pretty much a given on anything lol), seat cover (was a bit torn up), windshield (who knows where it went), and the ACCS parts (guy that works at the Polaris shop is giving me a deal on this).

The best part is that I cleaned out the carbs and kinda half-bolted the engine in place, sprayed some starting fluid in, gave it a pull and BAM!! fired right up first pull!!!!!! The end bearings on the crank are kinda worn, so the engine will be torn down, the crank have new bearings installed, the case drilled for another oil fitting, and a 4 line oil pump installed (which I also scored for free!! ). A common problem with these XLT engines was that the end bearing didnt get enough oil, so the 4 line pump and extra fitting help it get enough. Ill probably also re-ring it at least.

Id post pics but my camera is at the warranty place, I can get some cell phone pics if you all want.

-Nick

[Russell 350X]

I guess I missed that lol.