[EZrider618]

I have been looking for a engine for my Wildcat 1000 x but only found trv 1000 engines available new. Could I use this engine for replacement. The crankcase and heads are the same. But appears that crank cylinders pistons are different. I am not concerned about power even though torque seems to be sufficient. Thanks so much for any help or opinions.

 

[Fortitude1]

I'm looking for an engine swap too, my starter and case just blew out., Boss is toast, maybe replace with a MC engine??

 

[izom]

i wouldnt worry about the motor itself - as i know was only the mild 80hp motor in the quads- BUT- as you have the wiring/ECU for the x-motor this could be the problem- btw dont know what you mean MC motor!?

 

[Fortitude1]

i wouldnt worry about the motor itself - as i know was only the mild 80hp motor in the quads- BUT- as you have the wiring/ECU for the x-motor this could be the problem- btw dont know what you mean MC motor!?

Motor Cycle engine, I really like the stance and look and handling of the wild cat and I think for 3 grand I could put a motorcycle engine in and really rip!!

 

[Sand-n-Sea]

You CAN repair the case/starter boss better than new. Your old engine can be saved.... ask me how i know LOL

 

[Fortitude1]

You CAN repair the case/starter boss better than new. Your old engine can be saved.... ask me how i know LOL

talk to me bro!!

 

[Sand-n-Sea]

My boss broke. I pulled the engine, drained the oil, and took off the stator cover/starter/gears. Then welded aluminum into the broken boss area and drilled it to fit the gear shaft. I also used a longer shaft. No issues since. If I were to do more I would make a cardboard template of the boss area, and then get some thick aluminum plate from the local metal yard. Use the template to make a reinforcement for the gear shaft.

 

[Sand-n-Sea]

Oh, and I did that without taking the engine apart

 

[Fortitude1]

My boss broke. I pulled the engine, drained the oil, and took off the stator cover/starter/gears. Then welded aluminum into the broken boss area and drilled it to fit the gear shaft. I also used a longer shaft. No issues since. If I were to do more I would make a cardboard template of the boss area, and then get some thick aluminum plate from the local metal yard. Use the template to make a reinforcement for the gear shaft.

Good to know, and I have seen the video of the reinforcement plate made for inside the starter case, I am not sure about the other issues that plague this engine as well, stator and such??

 

[Gord]

My boss and stator cover broke, my dealer had a used cover and fixed case. Without taking the engine out we welded the boss back on then added 1/4 " aluminum plates above and below the boss, its a bullet proof fix the boss cannot move in any direction regardless of kick back the plates are welded to the boss and case it took a couple hours but the boss is completely immobilized and could not possibly break in the future. The pin was a little sloppy in the boss so we applied a thin film of JB weld inserted it then put the stator cover on and let it set for 24 hours putting the cover back on ensures perfect pin alignment. We replaced the starter and gear with the upgrade and presto a bullet proof boss repair and Zero play in the shaft which will eliminate broken stator case issues

 

[Fortitude1]

My boss and stator cover broke, my dealer had a used cover and fixed case. Without taking the engine out we welded the boss back on then added 1/4 " aluminum plates above and below the boss, its a bullet proof fix the boss cannot move in any direction regardless of kick back the plates are welded to the boss and case it took a couple hours but the boss is completely immobilized and could not possibly break in the future. The pin was a little sloppy in the boss so we applied a thin film of JB weld inserted it then put the stator cover on and let it set for 24 hours putting the cover back on ensures perfect pin alignment. We replaced the starter and gear with the upgrade and presto a bullet proof boss repair and Zero play in the shaft which will eliminate broken stator case issues

Awesome, got any pic's sir.I may try that

 

[Gord]

Awesome, got any pic's sir.I may try that

Pic one shows the boss in place before welding , pic two shows the 1/4" thick upper plate also before welding, we made a bottom plate cut to fit the area below the boss them welded it all in, very strong permanent repair

 

[Gord]

View attachment 253148 View attachment 253149
Pic one shows the boss in place before welding , pic two shows the 1/4" thick upper plate also before welding, we made a bottom plate cut to fit the area below the boss them welded it all in, very strong permanent repair

This shows the top piece with the boss in place just before welding as you can see the boss will be fully supported after welding, we simply cut and welded in a bottom piece to support below the boss, once the boss is welded in place and to the plates and plates to the case the result is the boss becomes the strongest part of the case not the weakest. We used two support pieces but in hindsight and spending a little more time the plate could be one piece. Then using the JB weld to eliminate any shaft play the problem of the shaft moving and breaking the boss on the stator cover is also eliminated. Just make sure you put the stator cover back on while the Jb weld is setting up to ensure perfect alignment. I also cut the face of the boss down the width of a steel washer so the gear is riding on steel not aluminum. Once back together make sure your new gear spins freely before putting on the stator case.
Over all its not that big of job, the case boss that was the weakest link is now the strongest part of the case, the JB weld take all movement out of the shaft and the steel washer eliminated the gear wearing down the aluminum boss. All done by just removing the shock and exhaust.

If a person with a water jet table cut a plate to support the boss, they would get lots of orders, and all X owners would have a permanent bullet proof fix.

 

[faustr8832]

My boss broke. I pulled the engine, drained the oil, and took off the stator cover/starter/gears. Then welded aluminum into the broken boss area and drilled it to fit the gear shaft. I also used a longer shaft. No issues since. If I were to do more I would make a cardboard template of the boss area, and then get some thick aluminum plate from the local metal yard. Use the template to make a reinforcement for the gear shaft.

I would be willing to pay you for that plate