Blown engine - Polaris RZR Forum - RZR Forums.net
RZR Turbo Engine Discussions for the Polaris RZR XP 4-Stroke DOHC Twin Cylinder Turbocharged Engine/Drivetrain.

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post #1 of 80 Old July 29th, 2019, 06:55 PM Thread Starter
 
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Blown engine

Rzr has 970 miles on it with just a stage 5 trinity exhaust and canned Pvcx trinity tune. Iíve been working with Mike at Aftermarket Assassins to make a few improvements. Ended up purchasing 2018 head gasket, new head bolts, from OEM vendor, did DIY oil cooler mod, and RZRjoesí BOV done right mod. Purchased 2017 injectors, low temp spark plugs, and tunes 3, 3.5, 4 and s3 clutch kit with performance helix from Mike. 3 being safe pump gas tune, 3.5 being possible with good pump gas but on the edge and 4 98-100 octane.

Not looking to bash anyone with this thread but looking to find answers and see what failed. I have experience building motors for turboíd tuned import street cars. I have also rebuilt my old 2014 XP1000 at 1,900 mile with no problems. I donít take shortcuts and used OEM manual for head work and everything torques to spec. Before work began everything was cleaned and bed was removed. Any pause in work and everything was covered and protected form FOD and was reinspected before it went back together. Project went smooth nothing was rushed and no leftover parts.

Replaced head gasket, bolts, injectors, spark plugs, clutch kit. Installed oil cooler and BOV, verified timing twice. Loaded stage 3 (pump gas) tune (This is the only tune I have loaded so far). Put clutch kit to recommended weights for tune and 32s. Did vacuum test on BOV mine was .375 instead of rzrJoes' .400. Bled coolant and oil systems, verified BOV/diverter was working correctly, insured clutch was performing correctly at idle.

Did a couple of pulls to insure clutching was working properly and engine temps were stable. Clutching was close Ran it 20 miles on dirt and paved roads, then checking timing again along with coolant and oil levels. Clutch was still running a little hot but that was the case before work was done, it was staying cooler than before, just not where i thought it should be yet. Car was running good, felt a little slower then previous tune and clutch off the line but then would pull strong, figure this was due to not dialing in the clutch yet. Only did one Wide open pull on a road, rest of it was pretty tame between 20-50mph making sure everything was working properly.

Took the car out for another 20 mile run on dirt and paved roads. Driving about 40mph and boom pssssss and died. Wasnít sure what was wrong at this point, and called my wife for a tow. Got it home and have broken spark plug, ruined head, damaged cylinder walls, broken piston. I have not taken it apart yet as I was waiting to see what Mike wanted me to do, damage has been verified with a cheap borescope.

No leaks through this entire process, head bolts and gaskets are still fine with no leaks. No increase in temps at any point and no crazy boost spikes, no miss fires, no hard starting, no engine stumbling, verified timing again and still in.

Open to any ideas and requests for additional pictures to help determine cause.


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post #2 of 80 Old July 31st, 2019, 10:41 AM
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Re: Blown engine

Subscribing for pics. Forensics are impossible without data. You didn't possibly drop that plug before installing it did you? Did you notice any signs of detonation when scoping it?
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post #3 of 80 Old July 31st, 2019, 11:49 AM
 
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Re: Blown engine

Broken plug sounds about right, real bummer in any event.
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post #4 of 80 Old July 31st, 2019, 12:29 PM
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Re: Blown engine

This is terrible to hear. The carnage sounds exactly like detonation to me, but someone who clearly knows what they are doing, I just can't imagine you didn't hear it pinging if it was actually detonation.



You mention the car felt a little slower than the previous tune, but at the top you said you only had one tune loaded? Am I misunderstanding? I wonder if the damage was done previously and the piston let go later. Can you see any stress cracks in the piston leading away from the hole? I had a blown ranger blow a hole in a piston on a cold start, found out after the fact that it had been run with a tune way to lean previously, even though my tune was on the money. Engine builder said he was surprised it lasted as long as it did.


Good luck man.
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post #5 of 80 Old July 31st, 2019, 01:01 PM Thread Starter
 
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Re: Blown engine

Fordtruckman. The car was originally on trinity tune and felt good, then did head gasket injectors and the rest of the stuff. Then installed The new aa tune seemed good but clutching was not dialed in. No noise before blew just poofff and coasted to a stop. Plugs were put in with a spark plug socket to insure no closing of the gap. Iíll get more photos when I have the head off.


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post #6 of 80 Old July 31st, 2019, 06:49 PM
 
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Re: Blown engine

Helping add some pictures since he's having some technical difficulties.
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post #7 of 80 Old July 31st, 2019, 06:50 PM
 
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Re: Blown engine

and more
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post #8 of 80 Old July 31st, 2019, 06:52 PM
 
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Re: Blown engine

and last for now
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post #9 of 80 Old July 31st, 2019, 07:01 PM
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Re: Blown engine

looks like you dropped a valve, what does the top of valve look like?

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post #10 of 80 Old July 31st, 2019, 07:17 PM
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Re: Blown engine

I'll second the dropped valve. Is the spring damaged? Or the retaining clip? You didn't happen to check valve clearances when you were doing the gasket, injectors, etc.?
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post #11 of 80 Old July 31st, 2019, 07:29 PM Thread Starter
 
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Re: Blown engine

Quote:
Originally Posted by FordTruckMan View Post
I'll second the dropped valve. Is the spring damaged? Or the retaining clip? You didn't happen to check valve clearances when you were doing the gasket, injectors, etc.?


I did check them while I was in there. They were in tolerance, well extremely close


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post #12 of 80 Old July 31st, 2019, 08:09 PM
 
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Lean not damaged plug
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post #13 of 80 Old July 31st, 2019, 08:20 PM
 
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Re: Blown engine

I'll third the dropped valve, curious about the spring too.
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post #14 of 80 Old July 31st, 2019, 08:49 PM
 
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Re: Blown engine

My guess is detonation. Everything else came after.
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post #15 of 80 Old July 31st, 2019, 08:52 PM Thread Starter
 
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Re: Blown engine

Quote:
Originally Posted by RZR_Scott View Post
I'll third the dropped valve, curious about the spring too.


Would lean conditions cause valve drop ? Just curious because the plugs look brand new. No fuel on them.


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