Riding 2021, Jag repair

 I think it's been 3 years since we went for a real trail ride. The registration on the '98 Jag ran out last year anyway...

So a couple weeks ago when the snow was still good Angie and I got the two Jags out for a rip.

We had groomed the night before so the trails were really good. The snow wasn't great but what snow was was flat. We did about 20 miles just around the park, I had updated the registrations but as it was kind of late in the season I didn't get trail passes. As a board member I'm allowed a free trail pass but I've only taken one once. That was the year we rebuilt the track on the Pisten Bully and Ben wouldn't take my money. The club still has to pay for the pass and we're not exactly flush with cash.

Angie rode the old '91 the whole time, it was smooth enough that the lack of suspension wasn't a problem. I think I'll look for a Z or ZL machine with a blown engine and swap the suspension into it. The machine is a little lighter than the '98 and the dual carbs make a little more power.

The '98 ran like crap, it would spit and pop and fart and just had a terrible time. I had an inkling that the problem was the throttle safety switch. There are two little bushings where the pin that holds the throttle lever on are so I replaced them. I really miss having a shop just down the street to get parts like that.

Arctic Cat calls these "seals" and you can see that they're kind of chewed up. The new ones didn't make any difference though so I pulled the connection. Arctic Cat is interesting, they used 2 different electrical systems. Some are "normally open" which means there is an open circuit and to shut the sled off you close the circuit and ground the coil. Then a bunch of them are "normally closed" so the circuit powers the coil and you open the circuit to shut the machine off.

My '91 Jag is "normally closed", when the throttle switch failed on that and the previous owner wanted to jump around that switch he had to add a little jumper. The '98 is "normally open" and so I could just unplug the kill switch plug which includes the throttle switch. 

With the kill switch unplugged the sled ran perfectly. For the first time since I've owned it I could bomb around the yard. Used to be the sled ran great on the trail but poorly in the yard, now its fine all the time.

I had hoped I could just pull the throttle assembly apart and just jumper out the throttle switch but in doing I managed to break the kill switch. The sled still runs but I don't like not having a kill switch. Fortunately replacements are available. Unfortunately they cost about 15% of what the sled is worth...

The snow is gone now anyway, so I don't need to worry about it right away. I'll probably fix it, I like riding the sled. I'd thought about getting a brand new machine to replace both Jag's but they did so well...

Dead Sled Wrenching again!

 Ahh dear readers you must think I've abandoned you. Well maybe I had but here's some dead sled wrenching content.

The first big snow of 2021 is here so Saturday and Sunday I took some time to get things going.

I started with the two Arctic Cat Jags. Last year I had the '98 going although we never had any snow so I figured I'd start with the '91 this year. It was wicked cold when I dropped them off the trailer and I was disappointed when the '91 wouldn't crank at all. I stuck an electric heater under the hood and shifted my attention to the '98. It was simple enough to pull the plugs, squirt some gas down the plug holes and I was shocked when it fired up and ran on the very first pull. I did have to reprime before it would stay running on fuel from the tank and then the track really didn't want to spin but we got 'er going with relatively little fuss.

With that little accomplishment I moved to the '91, the recoil still wouldn't make the engine turn so I grabbed the clutch and broke it free with little trouble. I've seen this before where a little condensation gets into the jug and since it was so cold that ice held it a little. With the engine free I yanked the rope and, it stayed out... Blarg, a little Kroil fixed that and I shot a little more into the engine to lube it up. A little gas down the plug holes and this one also fired right up. I gotta say I love how the wedge Jag's go, they're lighter and snappier than the newer machines. I suspect the dual carbs on this one help too.

Flushed with success I moved on to the '79 Polaris Cobra. I haven't run this machine for several years, in fact I see my last post was working on that machine and it was very nearly 2 years ago. At that time it had no spark and I failed to fix that.

Well here is one of the culprits, this is the rear set of points. I don't remember which cylinder they're for, it doesn't really matter, they were both dirty. It was hard to get a picture but you can see how they're kind of greasy, what you can't see is that they were also kind of green. I tried my usual trick, Deoxit and a business card. While I could get the business card to come out dirty it didn't seem like things were really improving so I resorted to a file. Harbor Freight sells a nifty little file set that isn't marketed toward filing points but they're the right size and shape. I scraped on 'em a little bit, then sprayed off the residue with cheap contact cleaner, then repeated with Deoxit. Then got frustrated and quit for the day. Actually I shouldn't have been frustrated, we went from absolutely no spark to a little blip. It might not seem like much but thats improvement.

So yesterday I went back out, filed more, cleaned more, etc. The frustrating thing is that the recoil and inner cup have to come off to get to the points so you have to put it all back together to test it. Anyway after two more cycles I put it back together and YOWSA we've got spark!

At some point Saturday I did have the forethought to take the airbox off and have a look inside.

Mr. and Mrs Mouse got evicted...

The nice thing about having the airbox off was to make it easy to shoot gas into the carbs. And thats where we got stuck again, it would pop on premix but wouldn't stay running. So I pulled each carb out of its boot, flipped it over, popped off the bowl and cleaned it and the jets. I also make sure the needles were moving. Surprisingly nothing looked too bad, a little schmoo in the bowl maybe but nothing to write home about. 

Put it all back together and it STILL wouldn't run, I mean it'd run for a second on premix but wouldn't stay running. I figured it needed more gas so I got a couple fresh gallons mixed up and, well blarg...

Finally in desperation I took the torch and heated each plug until it glowed red, stabbed 'em in, shot in gas one more time and sonofagun she took right off. This machine has always idled high and it still does. Maybe when we get some snow and I can run it some more I'll try to adjust it, I do have a carb synchronizer I've never used...

So everybody is running and moving, I really like riding the Polaris, its light and geared low so its quick off the line although it runs out of snort pretty quick. The brake isn't working but thats just the fluid leaking out after sitting a couple years. I'll top it up and it should come right back.

If you've always wanted a Polaris Cobra (or one of the Jags) let me know, you could have this one. Its been a fun sled but I'm ready to play with something else for awhile. I'm open to trades even...

Odds and ends

I feel sorry for how few posts I put on here, there really hasn't been much to talk about.

So lets go back, during the short couple weeks we actually had snow I did get in a couple rides. First was the abortive ride when the '91 Jag was leaking gas. On that one we took a ride through an area where the trail passes through a deep cut in rock. Its old railroad line and a really cool spot. I got a picture there back in 2015:

What you can't really see in the picture is that right in front of the sled is a pipe or knee wall of some sort. When theres lots of snow you can ride right over and not know its there, with only 14" when we rode over there was a looong drop on the back side. I got the '91 up onto the bump and gently slid it over. I rode ahead a little and looked back, I saw the skis as Angie came over and thought she had it under control. In reality what happened is she grabbed a handful of throttle and stood the '98 Jag right up. When she landed she went over the windshield. She wasn't seriously hurt but got banged up and of course was really upset with me for "riding off without me". In reality I was gone for maybe 4-5 minutes, I looped around and back back behind her but she'd already ridden off. *sigh* lesson learned, look back more often.

There was enough snow for those two weeks that we groomed 3 times. I got more seat time than ever before but I don't think I did particularly well. I'm starting to tap the drag on posts as I go through and need to go slower and be more careful. I also haven't been utilizing the drag enough, I hadn't realized what an art there is to that. There needs to be enough snow in the drag to fill the bumps in the trail but not so much snow that the machine can't pull it. Also if theres too much snow in the drag it'll spill over the sides leaving boulders in the trail. The last time we groomed I rode with Chris, he works crazy hours and let me drive when he got tired. He promptly fell asleep and I made it my goal to run smoothly enough that he'd stay asleep. A goal like that helps me to become a better operator...

The last ride I took the 98 and went out on my own:

The '98 is a much more comfortable machine than the '91 at the cost of some speed. On the long straights the '91 maxes out at about 70mph, the '98 will only make around 60. Same 440 engine but the '91 is a little smaller/lighter and has dual carbs.
I think this summer I want to find a Z skid and track to put under the '91, with better suspension it'd be a sweet machine.

Gas tank welding

Went for a ride on Saturday and discovered that the repair I'd made to my '91 Jag's gas tank filler neck was insufficient. It leaked gas on my left foot the whole ride. Relatively safe, the exhaust is on the other side ;)

Anyway today I finally had a chance to attack the problem. I got a Harbor Freight plastic welding iron and began by cleaning the crack with the included wire brush. Then I repeatedly stabbed the iron into the plastic perpendicular to the crack. My idea here was to essentially stitch the crack back together:

That worked pretty well and when I was done I could no longer see a strong flashlight shining through the crack.

Then I took some of the filler material that comes with the iron and worked it into the repair. I'm hoping it'll add some strength. Fortunately theres a groove there anyway. Here I'm partway done:

I ran the filler material over all of the damaged part. I left the undamaged section alone, I may live to regret that...

Tested by putting in a few gallons of water, holding my hand over the filler hole and flipping the tank upside down. If I can manage to not screw it up during install it should be okay:

Right now its got a quart of denatured alcohol (all I had on hand) in it to absorb the water. I'll get more alcohol later today.

As a measure of safety I rinsed the tank with water yesterday. I'd tried to have the filler neck full of frozen water but couldn't get the water to stay in long enough to freeze. I did all the work outside, there was a good breeze and the ambient temp was below freezing. I wore a full face mask and had an extinguisher nearby. I sat in the middle of the driveway away from anything flammable and of course had lots of snow on hand.

Overall I consider this a success, I didn't get blowed up, in fact I never felt like I was really in any danger, no sizzling or fire of any kind...

A new season

After the washout that was the 2015-16 season I'm sure hoping for some snow this year. So far its been exciting and disappointing. Early season snow had things looking good and the Wednesday after Christmas I spent the morning putting up signs for the snowmobile club and the afternoon trying to get my old junk to run.
Right before Christmas I'd given it a shot and neither Jag would fire up. The '91 would pop a little but wouldn't stay running, the '98 wouldn't even pop unless I primed it with gas down the sparkplug holes. I figured dirty carbs.
The '98 has a single carb while the '91 has duals so I figured to try the single first. Access is tight but not impossible. The bowl had a soup of water and gas which was almost certainly the issue and although I did have to prime the engine with a shot of gas down the sparkplug holes it fired up and ran good. Its still got a weird bog but I *think* that might be because of how much sitting its done.

I ran out of light so the '91 waited until the next day. I pulled the carbs and found the filthiest bores I've ever seen...

See the schmoo down at the bottom of the bore? There should be a hole there, the carb on the left was totally plugged I ended up soaking it with carb cleaner and running a welding torch cleaning rod through it until I could get it to come out clean.

 The bowl from the left side carb. Both were gross but the left side was worse.

So knowing that the carbs were nasty I knew I'd need to do something about where the goo was coming from. I couldn't actually see anything in the airbox but I knew there had to be something in there. To remove the airbox the gas tank absolutely has to come out, then the steering column has to be loose. To get the gas tank out the seat has to come off leaving me with this:

Well that escalated quickly huh? I just wanted to clean the carbs and now...

While pulling the tank out of the way I realized the bottom of the filler neck was cracked. I wonder if this is why I was getting terrible gas mileage a couple winters ago.

So I got the airbox apart and evicted the mouse nest, and got it back together without breaking the old hardened plastic too badly. Then I ran some ThreeBond around the crack on the gas tank.

Threebond probably isn't the best stuff for fixing the crack but I cleaned the plastic good before I tried it and it seems to be holding well. The Threebond stays flexible and its strong against gasoline, we'll see how it lasts.

Finally probably the worst part of it all is that the seat wood is ruined and completely came apart. I'm kind of glad I found this now rather than bombing down the trail but I wish it hadn't happened at all. In retrospect the problem is I park my sleds pointed down hill which allows collected water to run under the seat rather than just running out.

A trip to the hardware store got a quarter sheet of 3/8" ACX plywood. The original stuff appeared to be 3/8" OSB but in retrospect (since the plastic trim doesn't fit) is probably 1/4"

The cut along the front is pretty important, it fits around the gas tank mount to hold the front of the seat down.

So I've got the seat base cut out and ready to go, the last step is to staple the base onto the seat and reinstall.

Meanwhile I got the carbs all cleaned and reinstalled and the sled fires up and runs nice.

Finally I wanted to at least try to prevent this from happening again or maybe mitigate the problem some. I got there by taping some hardware cloth over the opening to the airbox:

Thats quarter inch hardware cloth which is probably too big but its what I had. I usually use a couple yogurt cups of mothballs in the footwells. This spring I'll add more mothballs to the cup and I'll maybe add another cup under the hood.

No much happening but, the end of an era

So winter 2015-2016 is looking to be a washout. Probably to be expected really, we had 2 years of excellent snow, you can't count on greatness every year.

Obviously I haven't been doing much riding and having 7 sleds around doing nothing seems pretty absurd so last Saturday I finally said goodbye to an old friend, the 1995 Ski-Doo Grand Touring left the yard for the final time.

I accepted less money than I'd planned to but I still got better than 2/3 what I paid for the sled 7 years ago so I suppose I didn't come out too badly.

Friday I took the '91 Jag out for a spin, we'd gotten maybe 4" of snow and I just couldn't resist. The trails were rotten, the water holes had a skim of slush on them and were slippery as heck in the bottom, I had to keep hard on the gas to get through. The odo says I went 2.5 miles but I bet it was closer to 2 miles with half a mile of track slip. Still even a bad ride is better than no ride at all.

Finally I got the Wankel Panther going again. I'd gotten kind of disgusted with wrenching last winter and it was a challenge to get going again but I managed it. The change is nothing short of remarkable, the entire time I've owned it that sled was a challenge to run, I could never get it tuned well and it was just never happy. Once I got it back together and dealt with the fact that the gas line in the tank had melted it fired right up and ran pretty much perfectly. I think I could open the low needle just a little more but otherwise she's all set. I was so pleased I made a video:

Eventually I want to make a bunch of these where I show off the machine and take it for a ride, sort of like Jay Leno's garage but for snowmobiles.

Anyway, theres an update, we got another inch or two of snow last night so I reckon I'll get the '98 Jag out today and see what it can do. I've been fighting the carb on that one, it spits and dies. I think I had water in the gas so I finally bought an electric fuel siphon and drained the tank. With fresh gas it runs better but I think I need to go through the carb one more time. This summer I'll put a rubber glove on the gas cap in case its leaking...

Thats more like it

December when ones mind turns to snow. Sadly its not cold and theres no snow yet but whaddya gonna do?

Last weekend I tried firing up the '98 Jag but she was a no go. I farted around troubleshooting for awhile and finally found that the fuel pump was failing to chooch. This was a big setback, I'd intended to spend the day replacing the track but ended up troubleshooting the day away...
I guess this finally makes the '98 fit in around here, getting its chance to be a dead sled.

I was ordering Christmas presents on Amazon anyway so I added a Mikuni square, single output pump kit to the order. Tonight I finally had time to get the kit in place. Turns out the square single output pump is REALLY simple. There are 4 screws to take it apart, 2 gaskets and a diaphragm and that is it. I replaced a couple fuel lines while I was there, its amazing how long the original lines last. I put some tygon (yellow) lines on, we'll see how they last. The clear hose is usually the worst, it gets hard and doesn't seal. Blue is second best and yellow is supposed to be the best, we'll see. I need to get some clamps, they didn't come with them stock but you might remember a couple years ago on the trail with my El Tigre when the fuel line came off one carb. If I'd kept pressing on when that happened there could have been a nasty fire...

Anyway I got it all buttoned up and on the 15th crank just as I was about to lose hope it fired up. Ran rough for a little while but finally smoothed out. I think there might have been a hint of this problem last spring when I bought the sled, it would run but would occasionally stumble and the sled would about pitch me over the handlebars, now its much smoother. Next step is to put it on the trailer and get it over to buddy Chuck for a track replacement. I dunno what the previous owner did but the track is missing a bunch of lugs, looks like somebody got after it with a hot knife.

Earlier in the day I'd gotten the '91 Jag running, that one also needed about 15 pulls but no other real work. I think it needs some clutch work, it was awful hard on gas last winter. I'll ask Chuck to take a look at it too. Last Monday I got a SAM pass for it so that sled is ready and legal to ride. The '98 still needs to be registered, I'm hoping this Friday I'll get a chance to run down to Worcester...

Stuff is still going on

Yeah the season is over, the snow is gone, the rains have come, well the rains SHOULD have come but haven't. That doesn't mean the sleds get neglected, or it SHOULDN'T mean the sleds get neglected...

Saturday I got some time to start putting the machines into storage, step one was to pull the windshield off the '91 Jag, the windshield comes off that sled easily so I pull it, otherwise the tarp will pull on it all summer and fold it in effectively ruining it. Then I added a couple ounces of Seafoam gas additive to the tank. I've been adding Seafoam at every fill up so this dose wasn't all that important, I also managed to run the tank down pretty far the last time I rode the sled so I didn't use very much.

Then I scrubbed the sled:

I used normal carwash soap and my normal car scrubbing sponge. This is a chance to give the sled a good check over, look for anything broken or needing attention. I found some cracks in the fiberglass of the hood but nothing too bad. The I fired it up and ran it around the yard to its summertime spot. I was very pleased in that it started right up no problem. That got the engine warm and helped dry out the hook and engine compartment. Then I waxed the hood and put two yogurt cups with mothballs in the footwells to keep the mice away.

There are a couple more steps, I need to stop and get a tarp for it, the canvas cover I have will get killed by staying outside all summer. Then I'll start it one more time and turn off the gas so the carb bowls empty out some. I'll shut it off before they run out, 2 stroke engines really don't like running out of gas. The bowls will still have some gas in them, theres nothing I can do about that but having them half empty will help to keep varnish from building up on the jets and causing trouble.

Finally I'll hose down the whole engine compartment with WD40. This gets rid of any remaining water and puts a water resistant coating on the metal parts. I did this last year on this sled and I was very pleased with the results. Its especially important since I don't have covered storage for the sleds although even if I did I think I'd still go ahead with it. I wish I'd been doing this on the Pantera, if I had I wouldn't need to repaint the tinwork...

Its not a dead sled but...

Picked up a new-to-me sled yesterday,

Its a 1998 Jag 440 with just over 3100 miles.

Its in good shape although the hood is broken a little at the hinge:

The guy claims the wind caught the hood while it was open but he's repaired it with some tin on the inside and fiberglass on the outside. It looks like a decent repair although I'll keep my eyes open for a replacement hood. It'll also need a track in a year or two, I priced the sled with that in mind...

I bought this sled because my '91 Jag beat the snot out of me last winter. When the trails were nice and flat it was a nice sled to ride but when they were bumpy it wasn't. This '98 has at least twice as much suspension, this is the last generation of the Jag, they stopped making them in '99, its got the FastRack long travel rear suspension and should be a much more comfortable ride. Its got aftermarket plastic skis with good carbides so it turns great. Starts real easy, and with a single carb its easy on the thumb and should be pretty easy on gas.

Overall I'm excited, this sled should have all the good my '91 has plus be more comfortable to ride a win overall.

Call it

What a winter its been but as I write this the snow here in north central Massachusetts is about gone. They tell me theres still riding up north but sadly I have no time for that and honestly with such an epic winter I'm about all done. I did something like 300 miles this year which is a record for me. To get to that mileage we had at least two 50 mile rides which are also records never mind having just an epic amount of snowfall.

My last ride was actually several weeks ago, I went out by myself for another 50 miler. Angie was willing to go with me but the snow conditions were less than idea for a liquid cooled machine and I was worried the Ski-Doo would overheat. The Jag just ate up the miles no problem and most of the places I rode we nice and flat so its less than fantastic suspension wasn't a big issue. After a whole season of riding past it I finally found a spot lots of people had taken pics of and Ben had told me about:

Looks to me like some sort of railroad or maybe a trolley had run through here. This runs down through the Birch Hill recreation area by the parking lot and I think the tracks must have continued down into Lake Dennison park. I didn't realize it before but I can see them as tracks now.

The Jag seems to get about 10-12mpg limiting me to around a 50 mile run which is fine as thats about as far as I can stand. The sled has good front suspension but the rear end only has a few inches of travel. I've started looking around for something newer with more suspension. Randy tried to warn me about that last year but I didn't listen. My plan is to sell the Ski-Doo and Jag and get a pair of newer machines like a Z440 or newer Jag DLX, or maybe a Polaris with an Xtra 10 or Xtra 12 suspension. Something I can ride on the whoops without getting beaten to death.

A little light Jag repair

The Jag has been a great sled but theres a couple things bugging me about it. One was a spot on the windshield I managed to crack with just a tiny tap on a tree. Today I took the time to put some packing tape on the crack.

This was more challenging than I would have expected because the Windex I was trying to use to clean the windshield before I taped it kept freezing... Got it there eventually and now I'm thinking that it looks good enough I might leave it that way. I'd been thinking I'd buy a new windshield but they're kinda expensive and will just get broken eventually... Maybe when I take this one off in the spring I'll re-enforce a little where I couldn't get to with it mounted but I think its staying.

I've also noticed the sled getting a little louder. Theres a gasket where the manifold meets the muffler and surprisingly Troy Arctic Cat actually had one so I replaced it:

New gasket installed

The old one didn't look too bad and I didn't notice much difference in my test runs but it seemed like it didn't get loud until I'd been riding for awhile. I wonder if the old gasket was letting exhaust by when it got hot...

Finally the kill switch doesn't work. Arctic Cat used a kind of pain in the ass system to shut the sled down if the carbs get stuck open. When I bought the sled it was bypassed with a nice jumper but I've had a couple cases this year where the carbs have been a little sticky and I'd like to have the kill switch back so I spent some time looking at it.

The system is interesting there are switches in the carbs and two switches at the throttle lever. One of the throttle lever switches is activated when the lever is all the way back, when you move the lever that switch opens and the other closes. The sled won't run if one of the switches isn't closed all the time. The idea being if a carb was stuck open the cable would be slack and neither switch would be active thereby shutting the sled off.

I spent a bunch of time playing with adjusting carbs because I thought I was getting caught in the transition period between one switch opening and the other closing. It turns out the first switch is never closing:

If you look directly below where the cable mounts to the throttle lever theres a hole. That hole is directly against the first switch (visible to the right of the ferrule the cable goes into) so nothing ever pushes against that switch. I've asked about it over at vintagesleds.com but I think what I'm going to do is find a set screw that fits into that hole and wind it in so that it just pushes on that bottom switch. While I'm at it I should see if I can fix the thumb warmer, that'd be nice to have...

And sometimes this happens...

We got another 10.5" of the blessed white stuff last night which managed to wipe out all the tracks in the yard. That of course needed to be fixed so I fired up the '91 Jag for a good rip. 10.5" is good deep powder but the Jag just eats it up, no problem at all so full of confidence I hit the trails for one of my pirate runs.

Nobody had been through since I went last week and even then I'd only made one pass out and back which doesn't make much of a trail. About 200 yards in I found a 5 FOOT deep drift, fortunately it descended to only 3 feet at the left side of the trail, unfortunately that was right next to a tree. I split the difference and blasted through a 4 foot wall of snow, had no choice really, there was nowhere to turn around and I didn't dare stop for fear I wouldn't be able to get going again.

With that behind it was a hard but slow run to where I leave the railbed and cross to a parallel trail. I was nervous about this because its a tight area and wasn't sure if I could keep headway but the Jag just kept slogging along. Finally got to where I could turn around, decided I'd do a clockwise turn but suddenly realized there was a deep spot right where I was headed, reversed course and ended up foolishly getting off the power and hitting that deep spot heading the other way...

I commenced to digging. This was a learning experience, with older sleds that have no rear suspension travel you heave the back end over to the side, fill in the hole under the track, heave the sled back on top to pack the snow, then back off and repeat. With a sled like my Jag that has some rear suspension you dig out under the footboards the length of the sled, then sit way back on the seat and apply power, the track hopefully finds traction and you're out. I had to try the old method once before I realized the new method would work better.

Here's a look at how close I was to completing the turn:

I think my mistake is that I thought I was going to stay in the seat through the turn, I should have been standing on the left footboard. I also realize now that I should always plan on a counter clockwise reversing turn when I can manage it because it'll be easier to stay on the throttle through the turn. In a right turn it gets hard to pull the throttle since the right grip is now down by my right knee.

Ahh live and learn right? The good news here is that since the Jag is such a good powder sled I feel much more confident about trying to make it to our camp in Maine in the winter. The camp is 3/4 of a mile from the road with no trails kept in the winter so we'd have to break trail through what would probably be powder similar to this.

I took the Jag yesterday into the state park and rode the groomed trails, it rides good but fishtails something awful. I'd decided that it needed a new track but considering its powder performance it might just need studs. Actually if I could get a deeper lug track AND studs and slightly wider plastic skis this would be an amazing powder machine...

Progress!

Finally got my shipment from Dennis Kirk so work can progress.

The puller that I bought for the Pantera doesn't fit perfectly, the smaller 6mm holes don't line up perfectly with the holes in the magneto. Fortunately the larger holes line up well enough that the 6mm (grade 8) bolts would thread into the magneto. I added a little grease to the pulling bolt to reduce friction, then tightened it up. The puller has a cool little rod to keep the engine from turning. Or rather it USED to have a cool little rod to keep the engine from turning, that promptly broke off.

I barely put any torque on it at all. So I put the rope back in the cylinder and whacked the end of the puller a couple times. Then added a little more tension and "CLANG!" I thought I'd broken the puller but:

The magneto popped right off. While I was on a roll I bought a #3 phillips head driver, chucked it into a 1/4" socket and pulled the screws holding the PTO side plate on. I'd tried with a #2 phillips before but I couldn't apply enough torque to break the screws free.
Now I need to haul the engine back into the basement to replace the seals.

After taking the dog for a walk I went back to the Wankel Panther. I cleaned the mag side crank shaft really well and lubed it with axle grease, I also greased the shaft and held the o-ring in place with yet a little more grease.

I briefly considered some hylomar for holding the o-ring but was to lazy to go back into the house for it. The grease will melt out the first time the engine gets good and warm and won't cause any trouble. There was no o-ring there at all before so this has to be better...

The grease kept the o-ring in place perfectly allowing for easy installation which I strangely didn't get a picture of.

Getting the stator in place correctly took more time than I would have expected. I managed to get it not seated fully on one side which made the magneto hit, glad I rolled it over a few times before I buttoned everything back up. It turned out I had some wires trapped, once I got those aligned correctly everything went together easy.

I quit while I was ahead since I couldn't find my multi-meter. I want to check to be sure the points are opening before I button up the engine.

Not again!

Went to move the snowmobile trailer so I could plow around it and realized it was frozen to the ground. Similar to when I had the sleds frozen down a couple weeks ago the rain had gotten under the foot on the tongue jack and frozen. Worse the trailer sat all summer with nothing under the jack and the foot on the jack and sunk about an inch into the soft ground. I dug all around it and heated the foot with a torch but my puny propane torch was no match for the cold of the ground.

Today I dug around in the garage and found an old Mercedes screw type jack. This is the kind of jack that fits into a hole in the body and has a big crank to lift the car. I put the jack under the tongue to put some pressure on the foot, then boiled up a gallon of water. I poured the hot hot water on the foot and it popped right out no worries.

As usual I forgot before pictures but here's the rig:

and a close up on the foot:

With that done I fired up the Jag and headed out for a ride. This was a "pirate" run, I hadn't put the registration stickers on yet and went out on trails of dubious provenance. It was a good ride and I did about 15 miles in total before Angie got home.

Once Angie was with me we loaded up the Jag and the Grand Touring and headed to Lake Dennison State Park. We also added our registration stickers and trail passes to make it all nice and legal.

Old junk in the park:

The Jag performed fantastically, on the pirate run it was everything I could have asked for, it busts deep powder with no problem although I might consider putting some studs in it, I did climb a couple hills really slowly slipping and sliding. On the groomed trails Angie kept right up and said it was fun to ride.

As always that stupid Ski-Doo did its job with no real issues. It wouldn't start when I first went out, the battery was flat so I put the charger on and it drank an full 6 amps for awhile. I should probably pull it in the summer and put it on a desulfator, sitting is hard on them. It roars and bucks and darts a little, clearly I need to work on the alignment some more but it goes like stink. There are only two faults, the speedo doesn't work which is probably the drive gear, I need to pull it and see which type so I can order a replacement, and the thumb warmer which I should also take a look at, apparently these are known for wires pulling out...

We did 20 odd miles in the park, rode up and around Birch Hill Dam which was pretty cool. Overall a good day.

Ruined!

Finally got the clutch back for the Wankel Panther, the guy did a good job, we needed to get a new stationary sheave of eBay, the one he had wasn't that great and we wanted it to be right but realistically it didn't take all that long. Which reminds me I should send him some more money.

So I headed out to the garage to put it all back together. Sadly when I got the correct size o-ring for the magneto side I'd crammed the crank seal on. This was a big mistake because:

• I hadn't cleaned the crankshaft on that side yet
• I hadn't lubricated the shaft although I had lubed the seal itself
• It was 10 degrees and the seal had shrunk

So what I accomplished was to tear the seal.

I went back and tried cleaning the shaft and lubing it but the damage is already done, the seal had rolled and torn. Its hard to get a picture of but if you look over by where the wires are you might be able to spot it.

That seal MIGHT work okay but I don't want to chance it. So I headed to Dennis Kirk and found they had one of the seals left. Since I ordered it they say "Part unavailable". So I better not screw this one up.

Okay so I'm stuck on that sled, better get the Pantera engine done. I've got 6 or 7 different pullers but none for the magneto on that sled. I'd bought a harmonic balancer puller for the Panther which worked great but the Pantera magneto uses 6mm bolts and the holes are very close together. I bought some 6mm bolts but they're grade 5 and I just managed to pull the threads off them.

This was a stupid kid mistake, I should have known better. The good thing about using grade 5 bolts is I didn't break anything important. It turns out theres a special puller just for this kind of flywheel. Runs almost $30. At least I was already ordering from Dennis Kirk so the shipping won't cost much extra...

*sigh*

Then yesterday with plenty of snow the '79 Polaris Cobra starts running on only the mag side. No power, spits and pops. I automatically figure its spark so I strip it down and clean the points which look clean anyway. Then I test it and it tests fine, spark on both side but now it won't run at all and theres no fuel in the filter.

I dunno on that one, I've got a couple crazy theories but I need time to look at it. Time I should have taken today but I got lazy.

Not so bad as all that

Here's the finale from yesterday's debacle:

Its not much but that little charred end is what was holding the piston in place. I tried burning the end off but couldn't get enough heat to soften it enough. In the end I pulled the tinwork and the head. I put a block of wood on top of the piston and whacked it a couple times with a hammer.

I'm not too upset about this whole deal, the engine is filthy, the exhaust gaskets were leaking and I think the head gasket on the PTO side (the one with the rope in it incidentally) was leaking too. I ordered a gasket set this morning which Dennis Kirk claims will be here by Friday. In the mean time I have plenty of cleaning to do.

This is the PTO side head, its not too dirty now but when I started there was a lot of mouse fluff in the fins, there was also a bunch of acorns in the space between the jugs, another good reason to get the engine out.

Thats the tin work from behind the exhaust, you can see its greasy nasty. I think the last person who worked on it (this'd be pre-2001 when Ed bought the sled) put both exhaust gaskets on the same side of the tinwork. Looking at it now I think the gaskets are supposed to sandwich the tinwork. Obviously I'll correct that when I put it back together.

Finally I've taken the topside tin and stripped it for paint. I debated not doing that but figure I ought to do it right while I have the time. Got lucky and the "Arctic Cat Spirit Powered" sticker came off whole so I can reuse it.

Laugh at the idiot

As you know I've been fighting the clutch on my '78 Pantera for some time now. I finally got a new spring and pucks (Comet Duster) installed and then the dang engine was sticky, it'd only rock back and forth some. I thought it was maybe just from sitting although it'd only been a year, so I squirted a little oil in each side and worked it back and forth and it free'd up. So I put the plugs back in and tried to fire it up which is when it stuck SOLID.

Uh oh.

Today I finally got the engine out and found:

I'd been using a piece of recoil rope to keep the engine from turning while I worked on the clutch, I guess a piece got cut off on one of the ports and stayed inside. When I rocked it back and forth it must had slid out of the port but when I cranked it over it found the exhaust port. Now the thing is stuck hard so I think the only way to get it out will be to lift the jug. Guess I'll do a full gasket set while I'm there, it probably ought to have crank seals anyway.

The smart folks over at Vintagesleds.com along with the smart guys on the Okiebenz email list suggested I burn out the rope. with the exhaust manifold removed I can get right at the end of the rope. With it burned out I'd be able to crank the engine over and get the other piece out too. I've got a pencil torch so I can be precise about it. We'll see, I will of course take a picture and report.

While I've got the engine out I've got some work to do in the engine bay:

Years of accumulation in there, step one will be the vacuum cleaner. Because the engine sits so low its very hard to clean underneath it...

Also for once I managed to do a pretty good job packaging the pieces I took out:

It'd be all to easy to lose one of the bolts for the recoil or motor mount and then have to scab something in that would never be quite right...

Frozen down!

Its been cold this week, Wednesday night temps hit -11F which is pretty cold for us. Last week it was really warm and even rained so it wasn't a big surprise when I went out yesterday to move the Jag and found it frozen to the ground. The Grand Touring had the same problem. I went through this a couple years ago and screwed up the Pantera clutch getting that sled loose so I didn't want to do that again.

The Vintagesleds.com crowd suggested I pour some boiling water on 'em so I put some pots on the stove:

I swept off the skis as much as possible so I'd melt as little snow as I could get away with.

boiling water right off the stove works great and it wasn't long before the Jag was free.

I heated the pots again and got the Grand Touring free too although I forgot to take pictures. I got lucky and neither the Cobra nor Pantera had frozen down.

After that I got Angie to help me drag the Pantera next to the garage so I can pull the engine out. I forgot to tell you that I finally took some time to get the clutch back together only to find out that the engine has mysteriously gotten stuck. I think its just moisture inside and hopefully bringing it in will clear it up. While I've got it out of the sled I figure I'll put new crank seals in it and maybe repaint the tin, its suffered in the last couple years sitting outside.