450 top end rebuild

2008 High Lifter Edition Polaris Sportsman 800HO

450 top end rebuild

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450 top end rebuild - 7/25/2008 12:21:25 PM

bignick2508

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Joined: 9/11/2007
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hey guys i have a 2000 foreman 450 i cracked the rings, and i have decided that while in the top end i am going to put the big bore kit on it... i was also wandering if there are any type of after market cams for my bike... any suggestions tips or ideas will be appreciated

Post #: 1

RE: 450 top end rebuild - 7/25/2008 3:09:49 PM

mudfreak

Posts: 284
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From: The Show Me State
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highlifter makes a kit...

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(in reply to bignick2508)

Post #: 2

RE: 450 top end rebuild - 7/25/2008 3:42:06 PM

Flordia__redneck

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Also ****.

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Post #: 3

RE: 450 top end rebuild - 7/25/2008 4:43:20 PM

joshua99ta

Posts: 1327
Joined: 11/6/2007
From: Magee, MS
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call high lifter... add a big bore, camshaft and a clutch kit to the bike... it will make a big difference. I assume you have a pipe already?

where are you located? Some machine shops will not do it b/c ya have to cut the stock cylinder out a little to make the new sleeve fit but it comes with direction of how much needs to be cut out. With a little measuring any good machine shop can do it. I believe the clearances are .003-.004 between the cylinder and sleeve. When ya have the cylinder honed out make sure they check the piston size... mine was 3.672 and the specs said to put the bore @ 3.681... which would leave .009 between the piston and the sleeve... JE(maker of the piston) recommended .002-.003 so my machinist put the sleeve bore @ 3.675

I probably confused you by that but if you have any questions feel free to pm me

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Post #: 4

RE: 450 top end rebuild - 7/25/2008 5:08:35 PM

Flordia__redneck

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Joined: 5/22/2007
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quote:

ORIGINAL: joshua99ta

call high lifter... add a big bore, camshaft and a clutch kit to the bike... it will make a big difference. I assume you have a pipe already?

where are you located? Some machine shops will not do it b/c ya have to cut the stock cylinder out a little to make the new sleeve fit but it comes with direction of how much needs to be cut out. With a little measuring any good machine shop can do it. I believe the clearances are .003-.004 between the cylinder and sleeve. When ya have the cylinder honed out make sure they check the piston size... mine was 3.672 and the specs said to put the bore @ 3.681... which would leave .009 between the piston and the sleeve... JE(maker of the piston) recommended .002-.003 so my machinist put the sleeve bore @ 3.675

I probably confused you by that but if you have any questions feel free to pm me

Dosn't the stock sleave get pressed out. Then they bore the jug for a new sleave. But yeh all the .002-.003 is all right.

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quote:

ORIGINAL: M_R_M

somebody must of pee'd in his dew

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Post #: 5

RE: 450 top end rebuild - 7/25/2008 8:03:19 PM

machineman350

Posts: 434
Joined: 3/21/2008
From: Southeastern Ohio
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The stock sleeve is press fit. It does not have any clearance between the jug and the sleeve. And for the piston depending on what material it is made of the clearance can vary. For instance a honda piston will call for like .0006-.0018 as where a aftermarket forged piston could call for .002-.003 and possibly more.Press fit on the sleeve to jug depending on bore size is usually a ballpark figure of .002-.004. With a counterbored sleeve like on the hondas i do .003 but on the kawis where some of the aftermarket sleeves do not have counterbores i give them .0045 press fit so the sleeve doesn't try to slip in the jug when it warms up.

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Post #: 6

RE: 450 top end rebuild - 7/25/2008 9:53:22 PM

bignick2508

Posts: 55
Joined: 9/11/2007
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it has pipe jet kit clutch kit highlifter springs snorkel 28" swamplites...does the bbk come ith everything i need..and is there any type of aftermarket cam for my bike

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Post #: 7

RE: 450 top end rebuild - 7/25/2008 10:34:07 PM

muddin450

Posts: 322
Joined: 4/30/2008
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go to www.webcam.com

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Post #: 8

RE: 450 top end rebuild - 7/26/2008 2:27:24 AM

foremanten10

Posts: 42
Joined: 6/16/2008
Status: offline

hey man i got 2 buds with te 92 mm wiseco h/c piston and the web cam and they are pretty bad a$$. i had the big bore in my foreman and i think you would be well pleased with the wiseco. you can use the stock sleeve and save some $$$$

(in reply to muddin450)

Post #: 9

RE: 450 top end rebuild - 7/26/2008 6:47:59 PM

bignick2508

Posts: 55
Joined: 9/11/2007
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pm me and tell me more about the wiseco parts foremanten10

(in reply to foremanten10)

Post #: 10

RE: 450 top end rebuild - 7/26/2008 8:13:59 PM

joshua99ta

Posts: 1327
Joined: 11/6/2007
From: Magee, MS
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to remove the sleeve you can simply throw it in the oven for an hour @ 400* and the old sleeve will slide right out(changed 1 already and bout to have to do it again... water on piston gets trash in cylinder and not good for rings or cylinder)

Thats what it says to do on the paperwork that comes with it. It also says to cut the cylinder to a certain amount...which you will have to take the OD of the sleeve and add some.XXXX to it to get the size required. I may have been wrong on those numbers I stated... I'm offshore right now so I can't be for certain.

(in reply to bignick2508)

Post #: 11