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Has anyone heard of the sprocket bolt coming loose in the chain case of the Touring 550's causing major damage? I've heard of 4 incidents in the past couple of days. I was wondering if this is a common problem or if there is a service bulletin from Polaris.
 

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Quite common...no bulletin, but polaris recommends drilling and retapping the shaft for larger 3/8" bolt.
The problem is that when the bolt is tightened it squeezes together the shaft, bearing, and gear. When the parts get hot during use they expand making them a larger size and push outwards on the bolt with more force. End result is a broken bolt. A larger bolt will be stronger but the problem is getting the shaft redone. A viable solution is to use a longer bolt and not torque it hard tight....just enough to lightly compress the domed washer. Very important is to have clean threads and permanent Loctite applied. The longer bolt will give more threads for the thread-locker to work on while leaving it "loose" will give room for expansion as the parts heat up...the domed washer will act as a spring.
 

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Has anyone heard of the sprocket bolt coming loose in the chain case of the Touring 550's causing major damage? I've heard of 4 incidents in the past couple of days. I was wondering if this is a common problem or if there is a service bulletin from Polaris.[/b]
i know this was common on some of the older makes but the new ones have a grade 8 bolt or a bolt with six little lines on the head .this was suppose to do the trick,was this the case on yours
 

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I got to thinking about this problem - never seen it myself- but got to thinking that breaking due to heat makes no sense. Engines would break internal fasteners constantly if that was the case. There should be very little heat in a chain case anyway. The tougher grade eight bolt is the first fix I'd use followed by going larger and, perhaps, tougher.
 

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I had the same problem with my 2005 600 Classic in March. The repair bill was over $800. The service technician felt it was a defective bolt and that Polaris should cover the cost even though the machine is out of warranty. The service techs around here have seen this problem 5 or 6 times. Polaris should be looking into this. My Classic has less than 1400 miles on it!!!!

Soooooo....I sent a letter explaining the problem to Polaris Industries VP of Operations. If you would like to do the same here is the address:
Jeffery Bjorkman
VP Operations
Polaris Industries Inc.
2100 Highway 55
Medina, MN 53340-9770
 

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I had the same problem with my 2005 600 Classic in March. The repair bill was over $800. The service technician felt it was a defective bolt and that Polaris should cover the cost even though the machine is out of warranty. The service techs around here have seen this problem 5 or 6 times. Polaris should be looking into this. My Classic has less than 1400 miles on it!!!!

Soooooo....I sent a letter explaining the problem to Polaris Industries VP of Operations. If you would like to do the same here is the address:
Jeffery Bjorkman
VP Operations
Polaris Industries Inc.
2100 Highway 55
Medina, MN 53340-9770
 

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Lower sprocket bolt problems are seen frequently in Edge and Pro X chassis. A lot of guys believe the bolts were over torqued from the factory, but that doesn't explain the ones that back out nearly completely, then proceed to wear a hole in the cover where they rub until through.....

As mentioned previously, common cure for a broken bolt is to drill out/tap to 3/8". The other is to torque standard size bolt till snug only, use lots of loctite on clean components. Either way seems to work pretty well.

Heat explanation doesn't play well for me either. Have heard Polaris say it's from coming down off a jump with the track spinning when contacting ground. That explanation can play OK with performance sleds/aggressive riders but a trail sled.... ??

Best prevention program seems to be pulling the cover off the chain case annually, checking things out while you're in there cleaning/changing lube?
 

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Best prevention program seems to be pulling the cover off the chain case annually, checking things out while you're in there cleaning/changing lube?[/b]
+1, Ditto, and roger on that. That is such a simple way to prevent problems before they happen. I heartily recommend pulling the cover in the spring (before the machine is put up for the season.) The steps are few and simple.
 

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<<<< The steps are few and simple. >>>>

Unless you have a Gen II with reverse......... :eek:hmy:
 

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Use red there...and you'll remember to heat it up before trying to take it out.....about the time you twist the head off....

My vote would be blue...
 

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After what happened to both my 2004 550 fan cooled engines (you can read about them in another posting), and seeing & hearing the crap that other Polaris owners have to deal with regarding poor workmanship, not covering parts and/or labor after warranty, and making big bucks from all of us,,, I will never buy another Polaris again and have talked most of my friends into selling their Polaris's before the get screwed too.
 

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My technician told me that the damage to my machine was caused by the sprocket bolt shearing off and that he felt it was defective. Since the machine (600 Polaris Classic) has only 1400 miles and has been ridden gently (!!!) I would expect the manufacturer to cover the cost of repairs.

I contacted Polaris. Their response was that since the machine was out of warranty they would not cover the cost. Unfortunately for Polaris, the province of New Brunswick has consumer protection laws that supercede the warranties offered by manufacturers.

It is my belief that a consumer who pays BIG BUCKS for a snowmobile has a reasonable expectation that the machine will be free from poor workmanship and defects and that it will be reasonably durable.

I would also like to add that as a previously loyal owner of mulitple Polaris machines, I am absolutely appalled by the level of customer service they offer. Everything from the poorly planned toll-free customer service line which disconnected my call over 8 times, to the confused and impolite treatment from their customer service reps.

A claim will be filed with the Small Claims Court in New Brunswick. I hope this action will catch the attention of Polaris and prompt them to start treating these matters with a little more professionalism and respect. Only what the people who support thier company, their customers, deserve! If anyone else would like to share details of their stories with me please feel free. I will try to bring some of the stories to the attention of Polaris.
 

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<<<<It is my belief that a consumer who pays BIG BUCKS for a snowmobile has a reasonable expectation that the machine will be free from poor workmanship and defects and that it will be reasonably durable. >>>>

While I agree completely, there has to be a point in time where the manf. must say they've met this responsibility. Hopefully, you took the time to review when this warranty period ends prior to your purchase of the sled. You agreed to this condition by putting your money in the dealer's hands.

Now you have a problem with your machine, the warranty is expired, and you no longer agree the manufacturer's warranty period is long enough.

I'm sorry, but at this point with any further action on your part, I can't help but feel you are trying your darndest to take advantage of the system.

Good luck.....

I've had many Polaris sleds, and while my use generally can't be classified as 'gentle', it's darn sure not abusive. Anyone riding has to assume that sleds are used in an environment most would reasonablly call unfriendly. Stuff happens. You break parts. It doesn't make any difference what brand you are on. I would defy anyone to tell me that ANY of the manufacturers build sleds that will never break a part in use. In diagnosing what happened to cause one of these failures after the fact, most times there will be a part that is identified as "faulty" - the part that caused the problem. Holding the manf. responsible for this failure after the sled is out of warranty........well, that's why I wished you 'good luck' above.......

I'm sure I'm not the only one that's ever broken an Polaris 800 twin crankshaft while out of warranty (another common problem), and I love the concept that Polaris might pay for a new one, but at the same time, realize it just ain't going to happen. The sled is out of warranty. I will however, have that failure in mind when it's time to consider the next sled purchase...... -Al
 

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My goodness! You sound like you work for Polaris! Joking aside...I am fully aware of the difference between normal wear and tear and a manufacturer defect.

This is the first time that I have ever decided to take a manufacturer to small claims court. This is in spite of the fact that we own several motorcycles, sleds, boats etc (aren't we lucky!) and enjoy a variety of motorsports both on land and on sea.

As mentioned in my previous post: it is reasonable for consumers to expect a minimum level of quality and durability in products they purchase such as snowmobiles. Ask yourself what prompts a manufactuer to issue a recall? Is it for deficiencies affecting safety alone...no. Recalls can also address quality/durability issues.

As consumers, we have no control over the quality of component parts a manufacturer chooses to use, we have no control over the quality of workmanship and we have little little control over the warranty period a company decides to offer its customers. What rights we do have are articulated in the consumer protection legislation. If a manufacturer decides to use defective bolts or its workers over-torque bolts precipitating premature failure then the only recourse a consumer has is to wait for the manufacturer to issue a recall or to excercise their rights under the consumer protection legislation.

This is what I have chosen to do...excercise my rights. If the court decides I am wrong then so be it. If the court decides I am right then I hope that this situation will help other owners who have experienced the same problem and who have incurred the same expense and inconvenience.
 

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i was woundering where did you find the consumer protection laws and do you know if it applies to nl
My technician told me that the damage to my machine was caused by the sprocket bolt shearing off and that he felt it was defective. Since the machine (600 Polaris Classic) has only 1400 miles and has been ridden gently (!!!) I would expect the manufacturer to cover the cost of repairs.

I contacted Polaris. Their response was that since the machine was out of warranty they would not cover the cost. Unfortunately for Polaris, the province of New Brunswick has consumer protection laws that supercede the warranties offered by manufacturers.

It is my belief that a consumer who pays BIG BUCKS for a snowmobile has a reasonable expectation that the machine will be free from poor workmanship and defects and that it will be reasonably durable.

I would also like to add that as a previously loyal owner of mulitple Polaris machines, I am absolutely appalled by the level of customer service they offer. Everything from the poorly planned toll-free customer service line which disconnected my call over 8 times, to the confused and impolite treatment from their customer service reps.

A claim will be filed with the Small Claims Court in New Brunswick. I hope this action will catch the attention of Polaris and prompt them to start treating these matters with a little more professionalism and respect. Only what the people who support thier company, their customers, deserve! If anyone else would like to share details of their stories with me please feel free. I will try to bring some of the stories to the attention of Polaris.[/b]
 
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