2005 Liberty 800 Engine Noise - HCS Snowmobile Forums

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Old 01-05-2012, 08:07 PM   #1 (permalink)
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Angry 2005 Liberty 800 Engine Noise

I just mistakenly purchased the beast & didn t notice the rattling noise until I dialed in the track & ran it 3-4 times and it reared its ugly head. Its coming from the right jug. I can actually feel the excess slop when rotating the crank back & forth. Get this,the sled has 1450 original miles. Its either rist pin or rod bearings. It seems Polaris has a problem with this motor from what i am reading. Any comments with info would be much appreciated.
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Old 01-05-2012, 09:24 PM   #2 (permalink)
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see Very good info on 800 crank failures
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Old 01-05-2012, 09:38 PM   #3 (permalink)
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Pull the cylinder and check it out before it becomes a HUGE problem.
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Old 01-06-2012, 10:06 PM   #4 (permalink)
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You should be glad it's coming from the rt cyl rather than looking at your clutch lying on it's side with the crank snout sheared. As long as you own one now, you should follow Ivar's link and read up on them.
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Old 01-06-2012, 11:19 PM   #5 (permalink)
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you could just be hearing the piston rocking back and forth in the bore . Does the piston actually stop moving when you rock the clutch back and forth in the "slop"
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Old 01-07-2012, 07:15 PM   #6 (permalink)
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1-7-12 Yea, tore down the top half & inspected. Can t believe the amount of piston to wall clearance, a tight .007. You would think that's to much & would make bucket noise,but both spec the same & everything looks real nice inside. I have to still mic everything to be certain
Definitely looser than the 500 I have. Polaris specs are .006 on 800 s & .0045 on 500 s. I ve got to dial the stub & go from there,I think ultimately the cranks going to get done. You can see the outer clutch wobbling,inner isn t perfect either. And I thought I got such a good deal?
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Old 01-07-2012, 07:27 PM   #7 (permalink)
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Yes the piston stops moving,but how much movement is acceptable? I would like to know the the bearing tolerance spec on that. If I had to estimate how much slop I would say .003 & thats enough to make the rattle noise I am hearing. Any recommendations on crank shops would be helpful. I want some one who knows whats best for situation.
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Old 01-07-2012, 07:35 PM   #8 (permalink)
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are you sure its in the motor not the primary clutch? the buttons on the spider will make a knocking knoise at idle and the exhaust valves make noise at idle. both knock and can give you a bad feeling thinking something has gone bad. Most of the the crank problems with the 800 are poor QC at the factory on case fit and bad ballance on the primary clutch that takes out the PTO bearing and cases if it no fixed early . Lack of summer fog oil can add to rusty crank or bad bearing problems .
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Old 01-08-2012, 08:42 AM   #9 (permalink)
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I can feel the slop in mine (crank) too by turning the clutch by hand. Been like that since I bought it.

I rebuilt and balanced my own clutch and I really think it made a difference in the smoothness of the motor. Drilled about 8 holes in it. Absolutely no vibration through the handlebars while riding. Could be just a primary in need of a rebuild. As stated, they start to rattle if worn considerably.

Email me if you are interested in clutch work:
Dman142@hotmail.com

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Last edited by dman400; 01-08-2012 at 08:49 AM.
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Old 01-12-2012, 11:12 PM   #10 (permalink)
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Current Sled(s): 05 Polaris 800 XC SP/ 02 Polaris 500 XC SP
Previous Sled(s): First sled- 72 340 Rupp Nitro,73 440 Nitro,75 440 FA Nitro
Location: Jackson,Wi.
Favorite Riding Area: North woods of Wi./UP Mi.
12-13 Mileage: 1900
11-12 Mileage: 1600
10-11 Mileage: 1400
Age: 53
Riding Since: 1968
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Finally figured it out. Loose rod bearing. Can t believe it with 1450 for miles. Very very difficult to locate,what a huge disappointment. Had to be bad from day 1. Polaris definitely had a QC problem. Pulled motor, can t get mag off with standard steer puller I hope the right puller will work because I used a Big freaking hammer & it wouldn t move, doing all the wrong stuff to a crank but whats the diff its going for rb, unbelievable how tight. Never ran across one that tight in 35 years of wrenching.
And I thought I got such a good deal.
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