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04-24-2012, 09:49 PM
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#1
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Member
Join Date: Feb 2003
Location: Cottage Grove, MN
Primary Sled: '03 700 XCSP; '02 INDY 500
Where I sled: Aitkin County, MN
Posts: 42
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'03 700 XCSP Broken Drive Shaft Bolt; Help
The bolt holding the lower sproket on the drive shaft broke. Lucky it didn't do more damage, but need to remove the rest of the bolt from the drive shaft. Can this be done with drive shaft in the machine or should I remove the drive shaft?
Thanks gentlemen.
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04-24-2012, 10:26 PM
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#2
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Member
Join Date: Feb 2003
Location: Cottage Grove, MN
Primary Sled: '03 700 XCSP; '02 INDY 500
Where I sled: Aitkin County, MN
Posts: 42
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Another question, do I have to remove the skid frame or can I get the drive shaft out without removing the entire skid?
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04-25-2012, 11:30 AM
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#3
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Senior Member
Join Date: Mar 2003
Location: Upstate, New York
Mileage: less than 200 (bad winter)
Primary Sled: '01 XCR800 / '06 Fusion 600
Where I sled: Upstate NY
Posts: 318
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I had that happened to me 2 years ago on my '01 XCR - not sure why the bolt just snapped off on mine but it did take my whole chaincase out. Your best bet is to take everything all apart - you need to inspect to make sure theres no cracks anywhere on the chaincase otherwise if you dont check it and theres a crack - youll be leaking oil all over the place. You should be able to use the EZ out to get the broken remainning bolt that is still in the driveshaft. WL.
PS - yes you have to remove the skid to get the driveshaft out.
__________________
'06 Polaris Fusion 600HO
'05 Polaris Sportsman 400 4x4
'01 Polaris XCR-800 (VF2, clutched and cut heads)
'00 Polaris XCR800 (VF2, dynoport pipes, HTG billetheads, clutched)
'99 Polaris XCR800 (shimkit with stock pipes)
'98 XC700 (reprogrammed CDI, powerpak, boost bottle, clutched - 824 version)
'98 XC700 (clutched, VF - 220 version)
'95 XCR600 (PSI heads, pipes and clutched)
'94 Indy Trail
'89 Indy 500 (PSI single pipes - clutched)
'89 Indy Sport
'88 Indy 400 (owned twice)
'88 Indy Sprint
'88 Indy Sport
'78 Polaris TX440
(and many more)
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04-25-2012, 09:14 PM
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#4
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Member
Join Date: Feb 2003
Location: Cottage Grove, MN
Primary Sled: '03 700 XCSP; '02 INDY 500
Where I sled: Aitkin County, MN
Posts: 42
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I figure I was pretty lucky not to be stranded. The bolt snapped off and I think it went around the outside of the chain twice. It made a horrible sound and slowed dramatically for about a second each time, then would run normal. I decided to take a peak in the chaincase just out of curiosity and found the trouble. The inside of the case shows wear around the outside of the chain.
Thanks for your reply, I will tear it down some more per your advice. I would hate to get it back together just to be leaking chain lube. At least I'm not missing out on riding, just missing out on fishing!
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04-26-2012, 05:24 PM
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#5
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Senior Member
Join Date: Nov 2002
Location: Oregon
Mileage: 0 miles
Primary Sled: 07 Dragon RMK 700 EFI
Where I sled: Oregon
Posts: 774
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That's a pretty common problem in Polaris sleds. When it comes time to replace the bolt, get a higher grade bolt, or drill/tap to a larger size to prevent it from happening again.
I also make sure to use blue loctite on clean surfaces to help keep the dang thing from loosening.
__________________
2007 RMK 700, 2008 RMK 600, 2006 RMK 600, 1990 Indy 650, 1995 AC Prowler 2-up
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04-29-2012, 08:45 PM
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#6
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Member
Join Date: Feb 2003
Location: Cottage Grove, MN
Primary Sled: '03 700 XCSP; '02 INDY 500
Where I sled: Aitkin County, MN
Posts: 42
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Thanks guys, there are a lot of this vintage Polaris in the family. We will be doing some re-engineering.
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04-30-2012, 03:40 PM
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#7
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Senior Member
Join Date: Mar 2003
Location: Upstate, New York
Mileage: less than 200 (bad winter)
Primary Sled: '01 XCR800 / '06 Fusion 600
Where I sled: Upstate NY
Posts: 318
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BC DAN - mine didnt loosen, the head of the bolt simply snapped right off ... which is why I am dumbfounded why this happen. So I made sure to buy a higher grade bolt and hopefully it wont failed like the other bolt did. WL.
__________________
'06 Polaris Fusion 600HO
'05 Polaris Sportsman 400 4x4
'01 Polaris XCR-800 (VF2, clutched and cut heads)
'00 Polaris XCR800 (VF2, dynoport pipes, HTG billetheads, clutched)
'99 Polaris XCR800 (shimkit with stock pipes)
'98 XC700 (reprogrammed CDI, powerpak, boost bottle, clutched - 824 version)
'98 XC700 (clutched, VF - 220 version)
'95 XCR600 (PSI heads, pipes and clutched)
'94 Indy Trail
'89 Indy 500 (PSI single pipes - clutched)
'89 Indy Sport
'88 Indy 400 (owned twice)
'88 Indy Sprint
'88 Indy Sport
'78 Polaris TX440
(and many more)
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04-30-2012, 06:14 PM
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#8
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Member
Join Date: Feb 2003
Location: Cottage Grove, MN
Primary Sled: '03 700 XCSP; '02 INDY 500
Where I sled: Aitkin County, MN
Posts: 42
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The bolt on mine snapped as well, can someone say "recall". Good luck with that, right?
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05-16-2012, 11:01 PM
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#9
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Member
Join Date: Feb 2003
Location: Cottage Grove, MN
Primary Sled: '03 700 XCSP; '02 INDY 500
Where I sled: Aitkin County, MN
Posts: 42
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Stock bolt is a grade 8. Grade eights can have a problem with vibration etc. Don't know if this is relateded or not, just information.
Got lucky removing the original bolt from the drive shaft. But here I am, rebuilding for next year, and wishing I was into fishing. 
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