Cracked Cylinder on Sportsman

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Dear Motorhead,

I have a Polaris 500 Sportsman that is overheating and found a small crack in the block. What is the best way to fix it? What is the cheapest way? What would you do?




Thanks for your email!

You have a serious problem. I assume you mean the cylinder is cracked as there is a very small “block” on this engine.

Most of the coolant is – and I am assuming that’s where the crack is – in the waterjackets – and is carried in the cylinder and head on this engine. So, you should purchase a new cylinder as it is really the only way to fix the crack properly.

Yes, you can have it aluminum welded but this is often only a temporary and inadequate fix. It will require removal of the engine and disassembly so by the time you do this work, you should replace the cylinder – not weld it.

The other part of the problem is the labour required to completely rebuild the engine. I would look around for a used engine first and see what you can do with an engine swap rather than getting involved in a complete re-build.

You did not indicate how old and the mileage of your Sportsman so new parts and a rebuild may be prohibitive if the ATV is tired.

Hope this helps,

Motorhead Mark

Dirt Trax Online
Dirt Trax Online
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