[steveg_nh]

Thanks guys.

MachzKeith, I figured out what the deal was since I posted. Basically what I learned is the proper play allowed per the service manual. When you add the gasket, you also add play, so you need to take that out to ensure the cog or whatever you call it is in the block far enough...sounds like too, even without the bleed kit, the standard install from polaris doesn't even always meet the own spec/requirements.

From what northstarrick says, sounds like it may not even matter, but it's just one more small step (after taking a reading with a caliper) so might as well do it and be done with it.

I have my oil bleed kit in front of me. Just picked it up from the dealer yesterday. Haven't put it in yet.

 

[steveg_nh]

I this as much a problem on the older 550s I have a 02 bought it new for my wife, son rides it now. As he is only 11 he spends a lot of time at the 20-30 mph range. If he lets it idle for a few minutes it can bog down until you really brapp it. Sled has over 4000 miles on it never had a issue with it. I also ride with another family with 2 550s 03,and 04 4-5000 on those as well, only problem is starting or idling when hot. Any more info would be great hate spending $$ on older sled but better then big $ for a new one.

My understanding is that 02s are fine, as they are not in the Edge chassis. It is the edge chassis that changed ventilation and the problems started. I think you will be fine. 04s is when it really got going as an issue, with 03s mixed in there too. In 2003, early sleds had a smaller exhaust (single piece) and a heat shield between it and the recoil fan. In August 2002, they changed to a a much larger 2 piece exhaust, and deleted the exhaust shield. Go figure. That's really when things got crazy. At least that's my understanding.

I'm doing the oil kit on my 2003 just for some piece of mind. Oil is the blood of the engine. :thumbsup:

 

[MossyHorns]

My understanding is that 02s are fine, as they are not in the Edge chassis. It is the edge chassis that changed ventilation and the problems started. I think you will be fine. 04s is when it really got going as an issue, with 03s mixed in there too. In 2003, early sleds had a smaller exhaust (single piece) and a heat shield between it and the recoil fan. In August 2002, they changed to a a much larger 2 piece exhaust, and deleted the exhaust shield. Go figure. That's really when things got crazy. At least that's my understanding.

I'm doing the oil kit on my 2003 just for some piece of mind. Oil is the blood of the engine. :thumbsup:

2001 was the first year for the Edge Super Sport.

 

[SNOWMAN75]

My 02 550 Classic is an edge chassis and so is the 03 04 Super sports

 

[steveg_nh]

Thanks for clarifying. So it must be that really in the 03 model year, when they switched around the exhaust and deleting the heat shield, that things went crazy. I hate putting out bad info hence my "my understanding..." LOL

 

[SNOWMAN75]

Thanks for clarifying. So it must be that really in the 03 model year, when they switched around the exhaust and deleting the heat shield, that things went crazy. I hate putting out bad info hence my "my understanding..." LOL

No problem.

 

[machzkeith]

Just a heads up to anyone who was waiting for the fuel pump relocation update, it is done now and in the post. Hope this helps some folks out.

 

[steveg_nh]

I bought the oil tank kit, but still haven't put it in. Not sure I'm going to bother, but if not a waste of $50. I have the pre august 2002 models, with the smaller exhaust cans and heat shield, the ones before they started blowing up. Thoughts on doing it anyway? I thought about doing the fuel pump fix too, but I have the square fuel pump, and recall something different about that.

 

[pdiddy]

Shame on Polaris for not stepping up to make this right years ago! Hopefully they learned something.

Double shame for killing off the reliable 400.

 

[too slow]

Double shame for killing off the reliable 400.

Must of put the most miles of any sled owned on an old 87 400. Only real issues were the clutches needing rebuilding fairly often and the jackshaft/ chain case bearings failing. Good motor and fuel economy otherwise.

 

[Codger]

In 98, I snowchecked a 99 Trail RMK with the 550 in it. This (as I remember) was the 1st year for the 550. I was living and rinding in Colorado at the time. No issues as it had plenty of room to breath in the Gen II chassis. Gutty little engine. I adjusted the jetting and oil pump when breaking it in. It had the old ACCS altitude compensator which worked good up to around 9k'.

I sold it to a neighbor several years ago and it still running around the neighborhood and still in showroom condition. Still no issues.

.

 

[steveg_nh]

Just a heads up to anyone who was waiting for the fuel pump relocation update, it is done now and in the post. Hope this helps some folks out.

Is this in a tech section or something, I think I'm missing it, but would like to review it.

Thanks

 

[Ace60]

550 fan fixes - 2012 IQ LXT

Can someone tell me if the kits that Polaris have come up with for earlier (2004 - 2008) machines are standard on the the later machines? I am referring specifically to the fuel pump relocation kit # 2203890 and the 550 oil pump bleed kit #2203889. My wife has a 2012 which burned-down at 1100 miles. We replaced the pistons, cylinders, etc. and are trying to preserve the motor. We are now using premium gas and adding a pint of injection oil to each 5 gal gas (in addition to the injection system). We are wondering if there is any point in ordering these parts if these fixes have been made to the stock machines. We know that Polaris have made attempts to improve the air flow over the motor by making changes to the intake and routing the air flow over the motor, but alas it is still not enough. I heard today of a 2016 that went down with these same oil/heat issues that have plagued these machines since 2004. Thanks.

 

[M&N]

Hi. New to the thread. I own two Polaris 550 sleds, a 99 and 04. The 99 is a solid performer but the 04 has burned up twice in two weeks. The fixes posted are awesome and I appreciate the photos and explanations given. I asked -why does this keep happening and better yet- how does one sled perform perfectly (99) and the other not (04)? My observation is AIRFLOW. The 99 has cylinder baffles that channel the incoming air from the fan, through the cylinders, and right out the top vent. The 04 doesn’t have any air channeling. It’s like Polaris said goodbye to these critical air channeling parts. I’ve since ordered them from the 99 parts catalog and will installing on the 04. Right now, air just continues to circulate in the cavity. Great when you’re moving but horrible heat when at idle. If anyone is curious about the end result, I’ll share before and after photos.

 

[ThePartGuy]

Hi. New to the thread. I own two Polaris 550 sleds, a 99 and 04. The 99 is a solid performer but the 04 has burned up twice in two weeks. The fixes posted are awesome and I appreciate the photos and explanations given. I asked -why does this keep happening and better yet- how does one sled perform perfectly (99) and the other not (04)? My observation is AIRFLOW. The 99 has cylinder baffles that channel the incoming air from the fan, through the cylinders, and right out the top vent. The 04 doesn’t have any air channeling. It’s like Polaris said goodbye to these critical air channeling parts. I’ve since ordered them from the 99 parts catalog and will installing on the 04. Right now, air just continues to circulate in the cavity. Great when you’re moving but horrible heat when at idle. If anyone is curious about the end result, I’ll share before and after photos.

The '04 has the exact same air channel ducting on the recoil blower housing and around the cylinders as the '99. The outlet duct on the clutch gaurd is slightly different between the Gen 2 and the Edge because of different hood shapes/vent locations.

If your sled doesn't have it, sorry to say - but you were duped when you bought it. How long have you owned it? If you've owned the '04 longer than just this season, I'd be shocked it hadn't burned down sooner.

 

[M&N]

So far, 300 miles and counting! First year owned, second owner. Putting that cylinder cover to channel the air in from the fan and across the cylinders to the exit vent, seemed to help this. No more heat just swirling around in the engine compartment!

 

[wjt]

Gents great thread, my daughter has a 2014 same issues apply ? or did they make changes over the years ? tks

 

[1fastpolaris]

Gents great thread, my daughter has a 2014 same issues apply ? or did they make changes over the years ? tks

You are good. By then all the issues had been sorted out. Its still carbureted so keep the jets clean is still important.

 

[safetyjoe1]

If sled is running hot, try enlarging the vent holes at the rear of the engine compartment. I did this with my 07 Trail Touring Deluxe and it improved the air flow and reduced temperatures under the hood. Simple fix with keyhole saw and sharp knife.

 

[Arctic Donkey]

In addition to the fan duct kit some people have mentioned a carb needle kit from Polaris for certain years. Does anyone have a part number for this kit? I have a 2006 550 and was wondering if I should get the carb kit or just some .020 shims for the existing needles?