2005 Polaris 600 Classic - Burn Down

fredster

New member
Out riding with wife and son today. 1st trip for wife and her 600 Classic this year (other than fall prep and short ride). She was complaining of cold hands and my sled is a bit warmer so we swapped. We had already ridden 40+ miles at speeds of 35-60 and her sled was running fine. Stopped at an intersection and accelerated up to 55 or so and was just cruising along. Engine tone suddenly changed, got a lot louder. I was thinking maybe a spark plug had unscrewed itself or maybe an exhaust problem. Got out of the gas just as it lost all power and the engine seized just as I rolled to a stop.

Pulled the plugs and they were white and one showed signs of metal. Classic burndown. :-(

A little frustrating to say the least. It wasn't that cold out - temps around 12-14 degrees. Every spring I add seafoam to the gas and drain the carbs. Dry gas went in this morning along with a topping off of fresh gas. Wondering if I got a bunch of water in the gas or maybe just a fuel or oil delivery problem. Sled has 2500 easy miles all with the same jetting and setup. We have run it in temps down to -10 with no problems and the plugs are usually medium to dark brown.

One weird thing I noticed. While I could not rotate the engine foward with the rope or electric starter, I could rotate the engine backwards about 3/4 of a crankshaft revolution by rotating the clutch. The engine will not turn in either direction beyond 3/4 turn. I'm not sure what would keep the engine from turning over physically (once it was freed up) so I'm wondering just how expensive the repair will be.

The only good news, we were 4 miles from a trailhead, called the dealer (Peacock LTD) and they had a guy meet us there with a trailer. They even drove my wife back to our cabin. I was suddenly glad that I had that tow rope with me. It has sat in one sled or another unused for almost 10 years.

I'll post once they do the teardown and call me with the news....sometime next week.

If anyone has any ideas on why the engine won't rotate, I'd be curious to hear them.

I had a carb slide crack once on a 600 triple and about 1/4 of the slide entered the cylinder and took out a chunk of piston skirt, before shattering and making it's way out of the engine. In that case the engine pitch changed but the sled still ran fairly well, was just down on power due to the intake porting being screwed up. I ran it that way the rest of the day and then replaced the carb slide and had a new piston installed. So sometimes the unusual does happen.....
 

jim_golding

New member
Did you take off the carb and clean them this fall? I learned my lesson on my wifes Indy 500. I did not clean the carbs for two years (yes stupid) since it had very little miles each year. It ran great at normal speeds for her. However I get on it and go wide open across a long field and that was it- melted it down! Stupid me!! I found the a large spec a dirt on the main jet when i took it a part. For the issue of not rotating, I had friend who had his Indy 500 melt down and lock up like yours - 3/4 rotation only. Upon disassembly it was noted the piston skit had fractured and pieces of the skirts ended up on top of the piston via the transfer ports preventing it from rotating. Good luck
 

fredster

New member
You probably got me on the carb cleaning - nope I didn't clean them this year! We bought the sled in March 2007 with just 120 miles on it. Fall of 2007 I pulled both carbs and went through everything. They were really clean, so I put it back together and it ran great the first year. Did the seafoam at the end of the year. Ran great in it's second year, too. Thought I did the same steps this year (seafoam, drain carbs) but I'm wondering if I forget to do something when I got the sleds ready for summer storage.. Arrggghhh.

I've never considered carb cleaning a 'mandatory/annual' event but it's starting to look that way. Another reason for moving to fuel injection!
 

bouncer

Member
[QUOTE=fredster; Dry gas went in this morning along with a topping off of fresh gas. Wondering if I got a bunch of water in the .

Dry Gas?? What is meant by dry gas or am I just reading it wrong.
 

bouncer

Member
Just a thought but this could have contributed to the melt down. There is already 10% alcohol in the fuel. But its a long shot and I'm sure you did the same with your other sled and had no problem.
 
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bouncer

Member
As far as why the engine only rotates so far is because what ever came apart or melted down was trying to leave the engine through the exhaust. When you let off it must have lodged instead of getting chopped up and spit out. This never happens to me. I'm on her so hard all the time you can see a trail of aluminum from start to end. Good luck, You will get the bad news soon enough from the dealer.
 

blvette

New member
You got to clean the carbs every year, I hear so many stories like this. It takes probably a hour a year to clean and check carbs instead of burning them down. We clean all the sleds carbs in decemeber, we have had one go down on the trail a zrt 600 piston and cylinder but that was to fatigue not carbs. It just so easy to do. I think dealers probably don't charge that much to clean either hopefully it's something simple so you can get back out there. see ya on the trails
 

fredster

New member
Thanks for all the replies. Yes....I'll be doing annual cleanings from now on. Or trading for a cleanfire or other EFI sled. We have two PWC's with EFI and they are bulletproof......
 
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