83' Trailfire LX Resto

[idMXLT]

I've decided it's time to start this project. When I picked up the Trailfire and Liquifire, I intended to wait until summer to start the restoration process. But every time I walk by them in the shop I get to thinking.... plotting..... planning......dreaming...

So let's get the party started!

The TF isn't missing any parts, so I'm going to bring it to life first. On that note, I need an airbox and throttle lever/kill switch for the Liquifire. PM if you have these parts and want to sell......

Resto Roadmap

• -Pull engine

• -Clean up engine compartment, assess paint/anti-corrosion needs

• -Pull/dry seat

• -Pull/clean fuel tank

• -Rebuild battery box

• -Teardown/reseal engine

• -Inspect/clean clutches

• -Pull/paint/lube ski's & steering gear

• -Pull/paint lube skid

• -Reassemble

• -New fuel/oil lines

• -Rain terror upon my WA brethren foolishly riding Skiroules and Arctic Cats

Sled History:
The previous owner indicated that this TF LX suffered a PTO side seizure in the early 2000's. They had a new top end put on it, only to have the PTO side stick again immediately (<20 miles). They parked the sled after that. It was sold to me with a "burnt" piston, and the engine would not turn.



Darn it, I just realized after typing all of this up that my exterior pics of the sled are on my other camera. Here is a placeholder. More pics to come!

[JDT]

Sounds like they did not replace the crankseals.....

[idMXLT]

They sure didn't!

So I put some Mystery Oil in the cylinders and started rocking the clutch back and forth. The engine freed up immediately. Apparently the second seizure wasn't too hard. I pulled it over several times, and tested the electric start. It winds over nicely with that feature! A compression test revealed 120psi on both sides.

Engine was pulled, and the teardown completed.





The Good:
The engine is weathered, but is in good overall shape. The pistons appear to be new, supporting the previous owners story. No scuffing on either one, but the PTO side looks like it was run lean and has "death ash" on the underside of the crown. All the crank/rod bearings feel great except for one on the PTO side. It's not bad, but it has some play and a little noise. I'll replace those 2 bearings.

The Expected:
Both crank seals are junk. The PTO side seal lip is completely gone, the garter spring was sitting on the crank! The MAG side seal was riddled with cracks and had no tension on the crankshaft. They didn't use new gaskets when reassembling this engine. Instead they used RTV for the intake and exhaust.

The Bad:
The PTO side cylinder has some scuffing. It's very light (pics make it look worse than it is, you can barely feel it with a finger), but given these are chrome bores it makes me hesitate. If they were iron liners I would lightly hone and reinstall, but these are chrome plated. What say you in the braintrust? Can I reuse the PTO cylinder, or is this thing going to flake on me?




Pics














"Death Ash"


Not so much sealing here

[smitfire]

Looks like that cylinder will need work before it can be used. Best to send them of to millennium and use the jd sleds discount.
I think they used the wrong head gaskets when they put this motor back together. It is an 83, so it has the late ignition and different cylinders. Theses take a copper head gasket.

[idMXLT]

Looks like that cylinder will need work before it can be used. Best to send them of to millennium and use the jd sleds discount.
I think they used the wrong head gaskets when they put this motor back together. It is an 83, so it has the late ignition and different cylinders. Theses take a copper head gasket.

Yep, they used the wrong head gaskets.I'm surprised it sealed, given that the fire rings had no support. Good thing it seized so fast! I assume the later Trailfire gasket kit from New Breed comes with the correct rings?

That's what I figured with the cylinder. I expect that most of the carnage is from the first seizure. I'll give eBay a look and see if I can find a good PTO cylinder. If not Millennium will be the next step.

[idMXLT]

Major setback today. I brought my crank to the local transmission shop today to get the noisy PTO bearings pulled off. The owner happens to be a sled guy as well. He took a quick look at it and condemned the whole thing. I've had lots of 2 strokes apart, and all of them with any miles have a little wiggle/noise in the bearings. I have also gotten many more miles on these engines after resealing without issue. But I'm not a professional in this field, and I'm not going to argue with one. He wouldn't pull the bearings for me since he said it's a lost cause. I felt the other 3 bearings and rods were fine, but that's water under the bridge now....


Super down about this, was really hoping to have this sled in the snow before spring.


So, now I'm on the lookout for a crank. Can I use any of the JD fan cooled 440 cranks, or is it specific to the later model trailfire?

[smitfire]

Major setback today. I brought my crank to the local transmission shop today to get the noisy PTO bearings pulled off. The owner happens to be a sled guy as well. He took a quick look at it and condemned the whole thing. I've had lots of 2 strokes apart, and all of them with any miles have a little wiggle/noise in the bearings. I have also gotten many more miles on these engines after resealing without issue. But I'm not a professional in this field, and I'm not going to argue with one. He wouldn't pull the bearings for me since he said it's a lost cause. I felt the other 3 bearings and rods were fine, but that's water under the bridge now....


Super down about this, was really hoping to have this sled in the snow before spring.


So, now I'm on the lookout for a crank. Can I use any of the JD fan cooled 440 cranks, or is it specific to the later model trailfire?

A trailfire 440 crank is different from the rest. I should have some good usable cranks yet.
If your interested pm me.

New breeds will have the correct gasket kit, but remember its aftermarket. Original heads gaskets were copper on this machine and aftermarket is now aluminum. If it were mine I would put in copper gaskets.

[fast823]

How many motors and what years used the copper gasket? Who stocks these?

[Matt]

Anyone nearby you could get a second opinion on for the crank? I believe the tech manual has run-out specs you can check on, if the rod bearings are smooth.

Sportfires and later Trailfires used the copper ring head gasket. However, for some reason none of the Winderosa Trailfire kits come with it. However the Sportfire kit comes with a set of rings, but they aren't copper, I'm not sure what they are. Tin? A couple years ago a guy at the Boonville summer show had tons of the copper rings NOS, I should have bought more then a set at that time.

[idMXLT]

Just found a set of NOS copper head gaskets on ebay, and they are on the way! I'll order the Winderosa Trailfire kit for the rest of the gaskets. Thanks for the info Matt.

I think my crankshaft dilemma may be resolved. Smitfire has graciously offered to sell me a good used one.

[smitfire]

Just found a set of NOS copper head gaskets on ebay, and they are on the way! I'll order the Winderosa Trailfire kit for the rest of the gaskets. Thanks for the info Matt.

I think my crankshaft dilemma may be resolved. Smitfire has graciously offered to sell me a good used one.

Are you sure you got trailfire head gaskets? I was searching eBay for you and only seen sportfire ones.

[idMXLT]

Are you sure you got trailfire head gaskets? I was searching eBay for you and only seen sportfire ones.

Not sure why but I thought they were the same. I just checked the Part #'s and they are in fact different. Live and learn! I've got Sportfire gaskets if someone needs them


Seat is off. As expected, very dirty underneath.



Tank is off. It had about 4 gallons of nasty, foul gas in it. My whole shop reeks of it now. I've restored many cars, motorcycles, ATV's, etc, but the old gas in this thing takes the cake! I've got some POR Marine Clean and hot water scouring the tank out now.




Kind of interesting. These holes were etched into the tunnel under just one spot of the seat. Not sure what got in there. I'll TIG weld them up.




Battery box removed and about 10lbs of spruce needles vacuumed out.




Corroded original battery box.




Laying out a replacement battery box

[JDT]

That will be nice when it is done.

Keep up the good work.

[idMXLT]

That will be nice when it is done.

Keep up the good work.

Thanks for the good words. I can't wait to try it out next season.

On another note, I was checking over the front end, and couldn't find any grease zerk fittings to lube the ski spindles. I guess removal is the only way to grease them? Seems strange to me, I grease the spindles on my other sleds several times a season, and almost always push some water out.........

[smitfire]

That will be nice when it is done.

Keep up the good work.

Thanks for the good words. I can't wait to try it out next season.

On another note, I was checking over the front end, and couldn't find any grease zerk fittings to lube the ski spindles. I guess removal is the only way to grease them? Seems strange to me, I grease the spindles on my other sleds several times a season, and almost always push some water out.........

I haven't ever added any zerks to the front spindles yet, I'm sure it can be done. I do add a lot of grease zerks to the rear suspension. The three main shafts like to freeze up and it's nice to be able to grease them with out taking the skid out and apart. I drill a hole and then weld a nut on a spin in a zerk.
World of difference when you have a working, free, suspension. You can do a lot of damage with a frozen suspension.