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post #1 of 11 Old 03-19-2017, 09:19 PM Thread Starter
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Sludge in engine question.

I recently purchased a 2003 400 manual 4x4. The guy I purchased it from said it stopped running and it wont start up. So I figured to was the flywheel. I pulled the side cover off where flywheel is and saw that It had already been replaced by the updated flywheel with the integrated magnet. That was good news but I noticed another potential problem. There was a thick layer of sludge coating the inside of the flywheel. I had to scrape it off with a razor blade to get all the sludge off. It had adhered to the magnets pretty tight. The bottom of the case also had this sludge on bottom. I can see that the stator would not work because of this and could be the problem with no spark. But im concerned about this sludge in the rest of the engine. The oil is drained out of it now. What should I do next before putting fresh oil back in?
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post #2 of 11 Old 03-19-2017, 09:56 PM
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Sludge in engine question.

Pull complete drain plug cover off and inspect screen. Clean if required. Let us know how much sludge is there and maybe take picture of it for us to see before you add oil.


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RTR Bushings & shock bushings


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
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2003 A/C 400 manual ACT 4x4
RTR Shock Bushings
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post #3 of 11 Old 03-19-2017, 10:24 PM Thread Starter
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Ok. Ill do that some time this week and post pic.
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post #4 of 11 Old 03-19-2017, 10:27 PM
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You could flush it with diesel.

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post #5 of 11 Old 03-20-2017, 09:09 AM
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I suspect they just drove it for short trips, never got it hot enough. I'd change the oil frequently until it comes out almost clean, after the diesel flush.

2008 AC 700 Diesel and 2002 AC 400FIS
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post #6 of 11 Old 03-20-2017, 09:49 AM
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ATV: 03 400 4x4 auto FIS, 05 300 4x4
I took my drain plate off my project 03 400. Screen not bad and a little sludge on bottom. Glad to see there wasn't any filings either.
Sludge in engine question.-img_0487.jpg


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Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt battery
26" Kenda Bearclaw HTR's


2003 A/C 400 manual ACT 4x4
RTR Shock Bushings
Rebuild Project started Mar 15 / 2017
Completed April 8 / 2017
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post #7 of 11 Old 03-20-2017, 07:40 PM Thread Starter
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I removed plate and screen today. The sludge wasn't too bad BUT there was metal shards and large sand sized metal pieces in the bottom. Here are some pics.
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post #8 of 11 Old 03-20-2017, 08:12 PM
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ATV: 03 400 4x4 auto FIS, 05 300 4x4
Those pieces don't look good.


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Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt battery
26" Kenda Bearclaw HTR's


2003 A/C 400 manual ACT 4x4
RTR Shock Bushings
Rebuild Project started Mar 15 / 2017
Completed April 8 / 2017
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post #9 of 11 Old 03-20-2017, 08:33 PM Thread Starter
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No they dont. Im not sure what I should do from here. I have rebuilt top ends before but Im not sure if this is the issue. The previous owner did tell me he replaced piston with larger one and had cylinder bored over. I do know if this isnt done correctly it could go bad. Maybe a compression check would reveal if piston or rings gone. Any suggestions?
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post #10 of 11 Old 03-20-2017, 08:51 PM
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Sled: 16 Bearcat XT, 06 T660 TT, 05 S/Cat 600
ATV: 03 400 4x4 auto FIS, 05 300 4x4
Did PO say why piston was changed and why a larger one? Maybe the piece you found is a piece of hopefully old piston??? You could take top end off again and if you find nothing, buy an aftermarket top end gasket set.

Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt battery
26" Kenda Bearclaw HTR's


2003 A/C 400 manual ACT 4x4
RTR Shock Bushings
Rebuild Project started Mar 15 / 2017
Completed April 8 / 2017
660catman is online now  
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