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 Post subject: Polaris 2002 325 Magnum
PostPosted: Wed Dec 12, 2007 4:38 pm 
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I have a 2002 Polaris Magnum 325 4x4 that needs new crankshaft bearings. The previous owner let the oil run low from a leak in a oil cooler hose and fried them (heck that's what he said at least, wouldn't be surprised if the damn thing was empty of oil before he figured it out). It does run, but you can hear the banging inside and if you try to throttle it, it will lock up. I have been looking and looking for a replacement off of ebay, but no luck to date.

Couple questions. How hard would it be for me to repair? Also, should I not only replace the bearings, but also a new piston and rings to be on the safe side since it ran low on oil?


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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Wed Dec 12, 2007 5:58 pm 
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Rugger1 wrote:
I have a 2002 Polaris Magnum 325 4x4 that needs new crankshaft bearings. The previous owner let the oil run low from a leak in a oil cooler hose and fried them (heck that's what he said at least, wouldn't be surprised if the damn thing was empty of oil before he figured it out). It does run, but you can hear the banging inside and if you try to throttle it, it will lock up. I have been looking and looking for a replacement off of ebay, but no luck to date.

Couple questions. How hard would it be for me to repair? Also, should I not only replace the bearings, but also a new piston and rings to be on the safe side since it ran low on oil?



by replacement, i assume you mean motor?

how hard it would be to replace, well you'd have to pull the top end of the motor off, and i'm not sure if its a OHC motor or not. but after that you'd have to take both side covers off and split the case to reveal the crank tranny and god know what else.

your best bet would be to find a service manual or repair manual for it and see if you can do it or not.

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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Wed Dec 12, 2007 6:00 pm 
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Talk to Brian at Extreme Cycle. Maybe work is slow for him and he can cut you a deal??

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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Wed Dec 12, 2007 6:26 pm 
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You have to completely split the cases and pretty much disassemble the entire motor since the crank is the base of the motor. Depending on what you are doing with it and how much or little you have to spend, you could probably get away with no replacing the piston, just get the jug honed and get new rings.

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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Thu Dec 13, 2007 3:51 pm 
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Good idea about Extreme Cycle. He has calmed down some and is willing to work on it. From my research it's around $100.00 for parts, and then he said he's probably looking at $200 to $250 in labor. $350.00 bucks to get it up an running doesn't sound bad at all. Now I just need to get this motor out of the ATV, lol. Anybody up for a day of beer drinking and removing of an engine?


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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Thu Dec 13, 2007 5:58 pm 
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Rugger1 wrote:
Good idea about Extreme Cycle. He has calmed down some and is willing to work on it. From my research it's around $100.00 for parts, and then he said he's probably looking at $200 to $250 in labor. $350.00 bucks to get it up an running doesn't sound bad at all. Now I just need to get this motor out of the ATV, lol. Anybody up for a day of beer drinking and removing of an engine?


Phf a day?!?! i can have that bitch out in a couple hours. :thumright:

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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Fri Dec 14, 2007 10:49 am 
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LOL! I take it you've done a few of these then, hehe. This will be my first engine removal job. :) So I'll probably need to take pictures and mark stuff so when I put it back together 2 months down the road I don't have left over bolts and parts :scratch: lol.

2 hours to remove an engine, 8 hours to drink beer, like I said, a day of beer drinking and removing of an engine!


Last edited by Rugger1 on Fri Dec 14, 2007 10:56 am, edited 2 times in total.

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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Fri Dec 14, 2007 10:50 am 
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Left over bolts makes it lighter and faster!!

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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Fri Dec 14, 2007 8:43 pm 
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haha but polaris motors suck to tear down.

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 Post subject: Re: Polaris 2002 325 Magnum
PostPosted: Mon Dec 17, 2007 2:11 pm 
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Yea, I've heard that. But this is a 4-stroke which Bryan saids is a little easier to work with.


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