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XCR 800 - Time to rebuild?
- 6500 Miles on 01 XCR 800 Runs great thinking of doing a rebuild
started by jasonmc98
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November 24th 2008 at 8:48 AM
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jasonmc98
New Member
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59 Posts 
Group: Members
Member Since: January 15th 2007
Location: Dexter, MI, USA
Current Sled: 2001 XCR 800
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2001 XCR 800 - 6500 miles on the stock motor. Sled runs great, with the exception of 3 sets of motor mounts and the water pump going out after about 1000 miles, this thing has been great. Just wondering if the amount of miles on the sled warrant a rebuild or should I take the "If it aint broke, don't fix it" approach. Haven't checked it this year yet but last year, beginning of season I checked compression and got 140psi accross all 3 holes. Let me know your thoughts!!
Ride Naked, Show the world yer NUTZ
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November 24th 2008 at 9:17 AM
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whitexc
Average Member
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946 Posts 
Group: Members
Member Since: February 19th 2006
Location: Pendleton, NY, USA
Current Sled: XC
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I said the same thing last season, with 6200 on my '99 XC700. About 500 miles into the season she let go, of course there were other factors, but I wish I would have caught it before it let go because it would have been about $500 cheaper. If it were me, and you don't have snow yet, I would tear it down and check it out. You can measure everything and see if it's in spec and maybe just do crank seals and gaskets, you never know. If you wait till it goes it gets expensive...of course this whole sport is expensive so....just my opinion and keep us posted.
Polaris...it IS the way out!
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November 24th 2008 at 9:22 AM
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Sledman74
CANDU is the right choice for Ontarios Power needs
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115 Posts 
Group: Members
Member Since: November 17th 2008
Location: Kitchener, ON, Canada
Current Sled: 2004 XC 800
2008-2009 Miles: 1100
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My experience has been any miles one puts one after 6000 is borrowed time. Most 2 stroke engines are needing a freshing up after that about of time.
I would invest in rebuilding it properly and you will get another 6000+ miles out of it.
Toys Own and Owned
1985 Indy Trail 440 - sold with 7500 miles
1987 Indy 600 - sold with 5800 miles
1997 XC 600 - sold with 6500 miles
2002 Edge X 700 - sold with 6000 miles
2004 XC 800
1995 Polaris SL 750 PWC
2000 Polaris Sportsman 500 ATV
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November 24th 2008 at 10:16 AM
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ACEXLT
THREE FOR ALL
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5668 Posts 
Group: Members
Member Since: September 17th 2002
Location: Greenfield, WI, USA
Current Sled: '01 XCR 800
2008-2009 Miles: 1326
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I'd say its time for a re-ring at the least. If it has the stock green carb slides those should be updated to the black ones. Green ones crack and break off and can enter engine and cause damage. A good engine tensioner or torque arm will eliminate the motor mount problem.
http://rpcracing.com/Catalog/page021.htm
'01 XCR 800
'00 Indy Triumph
TRIPLES RULE!!
TWINS HAVE NO BALLS!!
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November 24th 2008 at 11:05 AM
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sorenson10
Laid off
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64 Posts
Group: Members
Member Since: October 2nd 2007
Location: Brookfield, Wisconsin, USA
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If it was mine, I would rebuild it. That is a lot of miles and you don't want it to catch a ring and F your riding season up. Its not going to hurt and like said above your probably on borrowed time, time for a freshening up. Good luck!!
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November 24th 2008 at 11:14 AM
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gbaronet
Average Member
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841 Posts
Group: Members
Member Since: November 16th 2002
Location: Kitchener, Ontario, Canada
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12,600 miles still unopened. I was going to rebuild this year and got a freshen low mile XCR. Last year still see high teens on the GPS with the long track on.Know of two more over 10k.
Problally on borrowed time now..If time/money allows this year I'd like to peek in side and measure up the cly to see if new pistons are an option.
I say it depends, Last skidoo I had I was buying pistons by the 6 pack.
When in Doubt, gas it
01 XCR 136 Edge 12k stock
00 XCR 136 Edge Flannery/HTG
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November 24th 2008 at 11:34 AM
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BattleStorm
New Member
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91 Posts
Group: Members
Member Since: September 19th 2008
Current Sled: XCR 800, Storm
2008-2009 Miles: 0
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This is a tough question….. It has 140 on all three, then your rings are still good for sure. I wouldn’t really be worried about a piston failing. If your set on rebuilding it you may as well do a complete rebuild, new crank bearings, seals and all. Personally though, if it still has compression that good I wouldn’t touch it. This isn’t a twin cylinder engine, triples seem to last much longer. How many miles were on your sled the first time the water pump went out?
2000 XCR 800
1994 Storm
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November 24th 2008 at 12:13 PM
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jasonmc98
New Member
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59 Posts
Group: Members
Member Since: January 15th 2007
Location: Dexter, MI, USA
Current Sled: 2001 XCR 800
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I would have to say it had roughly 1000-1500 miles on it when the water pump went, it was at the end of its 2nd season, and when I first got it, I was just married and had no kids, so riding alot, needless to say, I've slowed down. I'm told, the water pump issue happnens alot to these. But, with the exception of that, the motor mounts, oh, and 2 out of 3 of the bellows were split on the VES last year, it has been a very good sled. I'll have the motor mount issue fixed here in the next few days with an aftermarket torque stop and High Perf Engineering mounts. Hence, the reason for the rebuild question as I'll have the motor out As for a rebuild, what should I be looking at, do I need to get into the crank or just a top end rebuild, such as gaskets and maybe rings? Like I said, it runs great, shows great compression I just don't want to be riding a ticking time bomb. Advice on easy, cheap maintenance is what I'm looking for for a little insurance.
Ride Naked, Show the world yer NUTZ
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November 24th 2008 at 12:40 PM
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myvertxcape
Bring It, Don't Sing It!
myvertxcape flu sucks azz.
Updated Thursday at 8:00 PM
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2640 Posts
Group: Members
Member Since: July 10th 2005
Location: Kotlik, AK, USA
Current Sled: '07/8 600RMK 144's
2008-2009 Miles: 6200
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I'd say if it ain't broke then leave it alone. These are one of the most reliable engines Polaris had made, 10k is easy to achieve. Get the updated bellows from Dennis Kirk, they are cheaper than the dealer's pricing.
'08 600RMK 144" 6565 miles
SLP single pipe/can, intake kit, footwell vents, Clutching
my own shockwell intake vent, VMI rack, backrest
'07 600RMK 144" 2725 miles
SLP can, VMI rack! Footwell vents
RAW chassis tunnel bag for sale, fits RMK's and Switchbacks. $80 new, $60 shipped within US(looks like new) http://www.snowmobilefanatics.com/forum/...splay.aspx
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November 24th 2008 at 12:40 PM
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whitexc
Average Member
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946 Posts
Group: Members
Member Since: February 19th 2006
Location: Pendleton, NY, USA
Current Sled: XC
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I forgot to add that mine was 135psi on both cyl's...before it went. There are many variables as to whether it will last or not. If the motor is out it is that much easier to take a look at some things. Have the crank checked, mine had 6800 miles and HTG said to run it. I had the wide bearing installed on the PTO end. That saved me some money there. I am also said to be "anal" about my stuff. Good luck with your decision.
Polaris...it IS the way out!
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November 24th 2008 at 5:57 PM
[ Modified November 24th 2008 at 6:02 PM
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CanadianXCR
New Ice Ripper!
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1642 Posts 
Group: Members
Member Since: December 18th 2004
Location: Barrie, ON, Canada
Current Sled: 1998 XCR 440
2008-2009 Miles: 0
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6500 miles is nothing assuming your anal about maintenance and don't use cheap oil and drive like a weapon. If you use cheap oil, drive it like its stolen 100% of the time and don't do any maintenance then you may have a time bomb. 
98 XCR 440 / Woodys / Hot Seat Performance / Shock Pros / Cobra / Sportech / Fox / TEAM / Camoplast Ice Ripper
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November 25th 2008 at 6:05 AM
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polaris1man
Average Member
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738 Posts
Group: Members
Member Since: December 22nd 2007
Location: Nashwauk, Minnesota, USA
Current Sled: Polaris SKS700
2008-2009 Miles: not many
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I would have to agree with WhiteXC, 6500 miles is pushing "original" equipment on a 2 stroke, especially 8000RPM's on a consistent basis. That 140 PSI's your pulling across those coffee can holes, is that Cold or a Warmed up engine? 140 is real good, using a good synthetic based oil helps, good maitanence is the key, and if you are good with a wrench in hand, and can afford a couple hundred bucks, I would go through the motor, it's about an hours worth of worth of time to have the motor on a bench, and inspecting the insides. Remember, rings of steel rubbing against walls of Nickasyl, pistons jumpin' up and down at 8000 Rev's. Yes, you have a motor still stock, very rare, most would agree. Might be worth your time versus a "tow" job this season
Three-1999 Polaris SKS700's
2000 Polaris SKS700
2000 Polaris Ranger 6x6
2007 Polaris Sportsman 800 EFI X2
2000 Yamaha YZ 250
1996 Yamaha WR250
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November 25th 2008 at 7:44 AM
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jasonmc98
New Member
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59 Posts
Group: Members
Member Since: January 15th 2007
Location: Dexter, MI, USA
Current Sled: 2001 XCR 800
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Well, I think at the very least I'll buy a top end gasket kit, couldn't hurt to at least see whats been going on in there. I am fairly decent with a wrench, I've done all the maintenance on this sled since it was new. I wouldn't go so far as to say I'm anal about it, but, greasing everything, cleaning the carbs and VES and generally checking everything over a couple times a season is just smart. By the way the 140 PSI was with a warm engine and I use Amsoil Dominator oil, I've used that oil since it was a year old, started out with the Polaris VES oil and switched the 2nd season.
Ride Naked, Show the world yer NUTZ
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November 25th 2008 at 10:28 AM
[ Modified November 25th 2008 at 10:28 AM
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BattleStorm
New Member
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91 Posts
Group: Members
Member Since: September 19th 2008
Current Sled: XCR 800, Storm
2008-2009 Miles: 0
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Ok, you run Amsoil? Don't touch it! LOL. Let her get up to 10,000+ miles then do another comp test. Your rings, pistons, and gaskets are still perfect with 140psi. That is the spec for when the sled was new. If you are going to do it you may as well rebuild the entire engine. Don't just replace pistons and rings (especially when there still good) put new bearings and seals in the bottom end. I'll bet your going to find the engine is perfect inside and as your scrapping base gasket material off you'll be wishing you never took it apart.
How often do you have to clean the valves using the Dominator oil? The Amsoil people say its not intended for VES sleds?
2000 XCR 800
1994 Storm
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November 25th 2008 at 11:22 AM
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CanadianXCR
New Ice Ripper!
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1642 Posts
Group: Members
Member Since: December 18th 2004
Location: Barrie, ON, Canada
Current Sled: 1998 XCR 440
2008-2009 Miles: 0
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I swear by Amsoil. I helped a friend rebuild an 89 650 Indy about 10 years ago, new crank, all 3 jugs .040" over, rest is stock. He drove the piss outta that thing for 2 seasons and racked up about 3500 miles, at which time we had to pull the motor due to a bearing locating pin that fell out. The inside of that motor was mint! The domes were clean and each piston had a very thin film of oil, I literally wiped it off with a paper towel and it looked new. All tolerances were great, this experience really sold me on this oil. Good oil does make a huge difference.
98 XCR 440 / Woodys / Hot Seat Performance / Shock Pros / Cobra / Sportech / Fox / TEAM / Camoplast Ice Ripper
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November 25th 2008 at 11:59 AM
[ Modified November 25th 2008 at 12:00 PM
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tdgbigfoot
Certified sledaholic
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1277 Posts
Group: Members
Member Since: September 12th 2008
Location: Albany, Vermont, USA
Current Sled: 99 SKS 700, 96 Mach Z 780
2008-2009 Miles: 500
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I have an 86 indy trail, with 7500 miles, and it ran alright last year, short of a bad fuel pump. Now i just can't get it started.
2000 Indy Trail Touring 550, 1999 Indy SKS 700, 1996 Mach Z 780, 1994 Wildcat 700, 1991 Formula Plus, 1990 Safari LX, 1989 Indy 400, 1988 Tundra Skandic, 1987 Citation, 1986 Indy Trail 488, 198? Bravo
1969 Corvette 350
2000 Cheroekee - 4 1/2" lift, & other goodies
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November 25th 2008 at 12:09 PM
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jasonmc98
New Member
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59 Posts
Group: Members
Member Since: January 15th 2007
Location: Dexter, MI, USA
Current Sled: 2001 XCR 800
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Quote originally posted by BattleStorm
How often do you have to clean the valves using the Dominator oil? The Amsoil people say its not intended for VES sleds?
That would make sence because I usually have to clean them every year, which I didn't think was that uncommon, but when I say I have to clean them, I mean it, they need it. I use the Dominator because before there was Dominator or Interceptor, there were still 2 different 2 stroke formulas, don't remember the names but I went with the one that closley matched what I had been using.
Ride Naked, Show the world yer NUTZ
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November 25th 2008 at 7:53 PM
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CanadianXCR
New Ice Ripper!
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1642 Posts
Group: Members
Member Since: December 18th 2004
Location: Barrie, ON, Canada
Current Sled: 1998 XCR 440
2008-2009 Miles: 0
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Dominator may be a bit overkill for a trail sled. Interceptor is geared more towards sleds with Power Valves to keep them clean.
98 XCR 440 / Woodys / Hot Seat Performance / Shock Pros / Cobra / Sportech / Fox / TEAM / Camoplast Ice Ripper
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November 26th 2008 at 6:16 AM
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polaris1man
Average Member
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738 Posts
Group: Members
Member Since: December 22nd 2007
Location: Nashwauk, Minnesota, USA
Current Sled: Polaris SKS700
2008-2009 Miles: not many
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Amsoil guy too, well then leave it, I rebuilt my motor at 3K, and now have over 10K on a '99 twin 700. As for the VES, you will snap the bolts for sure, get the replacement kit frmm an aftermarket company, I did a guys VES last year, and snapped the bolt/nuts on OEM's, and Poo gave us 2 new ones, the thread design is horrible
Three-1999 Polaris SKS700's
2000 Polaris SKS700
2000 Polaris Ranger 6x6
2007 Polaris Sportsman 800 EFI X2
2000 Yamaha YZ 250
1996 Yamaha WR250
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November 26th 2008 at 8:29 PM
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Dude, 140 psi is like brand new... I will not be affraid. If I was you, I will run it untill it dies. I'm pretty sure at this point you can't be affraid about a cold seizure, the clearance should be good enough to absorb a quick piston expansion. Winter is at the door, its not the time for a rebuilt, its time to makes your 3 holes sing  
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November 26th 2008 at 11:02 PM
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jbshocks
Shock Guru
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419 Posts
Group: Members
Member Since: December 20th 2005
Location: MI
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my riding buddy has 15000 on his. Personally I would never bother with the top end. I believe that getting into the crank case is just as important. The crank needs to be trued up more than rings if the compression is good.
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November 26th 2008 at 11:51 PM
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myvertxcape
Bring It, Don't Sing It!
myvertxcape flu sucks azz.
Updated Thursday at 8:00 PM
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2640 Posts
Group: Members
Member Since: July 10th 2005
Location: Kotlik, AK, USA
Current Sled: '07/8 600RMK 144's
2008-2009 Miles: 6200
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LMFAO, sorry to the guys that believe in Amsnotoil. Your choice though, if you only knew the whole story about it. I tried it before, never again. Can see all the hype in this thread how it turned around once you said you use it. Sorry again.
'08 600RMK 144" 6565 miles
SLP single pipe/can, intake kit, footwell vents, Clutching
my own shockwell intake vent, VMI rack, backrest
'07 600RMK 144" 2725 miles
SLP can, VMI rack! Footwell vents
RAW chassis tunnel bag for sale, fits RMK's and Switchbacks. $80 new, $60 shipped within US(looks like new) http://www.snowmobilefanatics.com/forum/...splay.aspx
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November 27th 2008 at 3:26 AM
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BattleStorm
New Member
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91 Posts
Group: Members
Member Since: September 19th 2008
Current Sled: XCR 800, Storm
2008-2009 Miles: 0
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Quote originally posted by myvertxcape
LMFAO, sorry to the guys that believe in Amsnotoil. Your choice though, if you only knew the whole story about it. I tried it before, never again. Can see all the hype in this thread how it turned around once you said you use it. Sorry again.
Amsoil is about the best oil out there and test prove it. The rule is 10 psi per 1,000 rpm in a small block chev engine. I drag raced/street raced a 406 for 6 years running only 55 psi at 7,000 rpm; standard oil pump with loose clearance bearings and 20/50 Racing Amsoil. I ran that engine the last 2 years with 5/30 Amsoil at 7,000 rpm with only 40psi plus water in the oil from a cracked block and it never missed a beat. I sold the short block to a guy and he said when he took it apart it had only slight main bearing wear, everything else was perfect.
2000 XCR 800
1994 Storm
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November 27th 2008 at 6:22 AM
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01ves800
Junior Member
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288 Posts
Group: Members
Member Since: October 23rd 2007
Location: Erie, pa, USA
Current Sled: 01 xcsp800 ves
2008-2009 Miles: 78
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i wouldnt fret a bit like a lot of ppl stated polaris uses very high quality parts they last a long time i wouldnt blink an eye at 12k miles on any polaris about that time i would tear it down to check tolerances and replace gaskets. I would run it by the time you will need a rebuild you will want a new sled and yours already wont be worth anything unfortunatly.
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November 27th 2008 at 8:22 AM
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polaris1man
Average Member
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738 Posts
Group: Members
Member Since: December 22nd 2007
Location: Nashwauk, Minnesota, USA
Current Sled: Polaris SKS700
2008-2009 Miles: not many
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Com'n Vert, you know better than to run that oil from your pickup after 6000 miles, and mix it up 40:1, and dump 'er in the tank, then let the Union Bay motor sing!!!
Three-1999 Polaris SKS700's
2000 Polaris SKS700
2000 Polaris Ranger 6x6
2007 Polaris Sportsman 800 EFI X2
2000 Yamaha YZ 250
1996 Yamaha WR250
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